Service Manual
99789-84120
For use with the GC35K-GC70K;
GP40 -GP50; GP40K-GP50K Chassis Service Manuals.
GM 4.3L, G6 Gasoline Engine
003103-up
Li ft
Tr u c k s
®
FOREWORD
This service manual covers the GM 4.3L Gasoline Engine installed in CAT
®
Lift Trucks and gives detailed mainte-
nance and repair information. For your convenience the instructions are grouped by systems as a ready reference.
The long productive life of your lift truck(s) depends on regular and proper servicing. Servicing consistent with what
you will learn from this service manual. Read the respective sections of this manual carefully and familiarize your-
self with all the components before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are for engines with serial numbers in
effect at the time of printing. CAT Lift Trucks reserves the right to change specifications or design without notice
and without incurring obligation.
Whenever a question arises regarding this engine, or this manual, consult your Cat lift truck dealer for the
latest available information.
For items pertaining to the chassis, refer to the Chassis Service Manual. This service manual covers the fuel system
for units built before 01/01/2004. See fuel system supplements for units built after 01/01/2004.
Notes, Cautions, and Warnings
NOTES, CAUTIONS, and WARNINGS are used in this manual to emphasize important and critical instructions. They
are used for the following conditions:
To highlight an essential operating procedure or condition.
Operating procedures or practices that will result in damage to or destruction of the
engine if not strictly observed.
Operating procedures or practices that will result in serious injury or
loss of life if not correctly followed.
NOTE
CAUTION
!
WARNING
!
-I-
Inspecting
Only the inspections to be performed by using special tools or measuring instruments are covered. General service procedures
not covered in this manual, such as visual inspections and cleaning of parts should always be performed during actual service
operations.
Scope of Explanation
This book describes the service procedures for the engine removed from a vehicle.
For procedures concerning the removal of the engine from the vehicle and on-vehicle inspection and servicing,
refer to the appropriate service manuals separately prepared for the individual models.
Classification of Major Maintenance/Service Points
When there are major points relative to maintenance and
servicing procedures (such as essential maintenance and
service points, maintenance and service standard values,
information regarding the use of special tools, etc.), these are
arranged together as major maintenance and service points
and explained in detail.
Indicates there are essential points for removal or
disassembly.
Indicates there are essential points for installation or
reassembly.
A
B
Grease
(multi-purpose grease unless there is a
brand or type specified)
Sealant or adhesive
Brake fluid, automatic transmission fluid
or air conditioner compressor oil
Engine oil or gear oil
Symbols for Lubrication, Sealants and
Adhesives
Information concerning the locations for lubrication
and application of sealants and adhesives is
provided, by using symbols, in the diagram of
component parts, or on the page following the
component parts page, and explained.
Maintenance and Servicing Procedures
(1) A diagram of the component parts is provided near
the front of each section in order to give the reader
a better understanding of the installed condition of
component parts.
(2) The numbers provided within the diagram indicate
the sequence for maintenance and servicing
procedures; the symbol indicates a non- reusable
part; the tightening torque is provided wher e
applicable.
• Removal Steps:
The part designation number corresponds to the number
in the illustration to indicate removal steps.
• Installation Steps:
Specified in case installation is impossible in reverse order
of removal steps. Omitted if installation is possible in reverse
order of removal steps.
• Disassembly Steps:
The part designation number corresponds to the number
in the illustration to indicate disassembly steps.
• Reassembly Steps:
Specified in case reassembly is impossible in reverse order
of disassembly steps. Omitted if reassembly is possible
in reverse order of disassembly steps.
N
How to Read This Manual
-II-
INSTALLATION OR REMOVAL SERVICE POINTS
Install the oil pump screen.
• If removed, replace the oil pump screen. The oil
pump screen must have a good press fit into the
oil pump body.
• Mount the oil pump in a soft jawed vise.
• Apply sealer to the end of the pipe.
• Use the (J 21882) and a soft-faced hammer to
tap the oil pump screen into the pump body. The
screen must align parallel with the bottom of the
oil pan when it is installed.
Removal steps
1. Plug
2. Nut
3. Bolt
4. Pan
5. Gasket
6. Bolt
7. Pin
8. Pump
9. Retainer
10. Shaft
11. Bolt
12. Pin
13. Cover
14. Screen
4
5
1
2
3
15. Plug
16. Valve
17. Spring
18. Filter
19. Fitting
20. Valve
21. Bolt
22. Adapter - Oil Filter
23. Gasket
24. Connector
25. Gasket
22
20
19
18
25
24
21
10
9
8
14
13
12
11
7
6
17
16
15
23
Lubricate all inter-
nal parts with
engine oil during
Unit: kgf-m (lb-ft) [N-m]
*kgf-m (lb-in.) [N-m]
T = 1.22 (106) [12]
Removal and Installation
➧
A
➧
➧
A
➧
Operating procedures, cautions, etc., on
removal, installation, disassembly and
reassembly are described.
Denotes tightening
torque.
This alphabetical letter corresponds to a part that is
indentified in the drawing on the first page of each
section. The letter appears during an explanation of
removal, installation, disassembly or reassembly steps.
Denotes
nonreusable part.
-III-
N
N
N
T = 9.14 (66) [90]
T = 2.08 (15) [20]
T = 2.49 (18) [25]
T = 2.49 (18) [25]
T = 2.49 (18) [25]
J 21882
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Caterpillar (CAT) GM 4.3L G6 Gasoline Forklifts (GP40/GPL40/DP40/DPL40/DP45/DP50) OEM Service & Repair Manual
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Description
If you are in need of a comprehensive OEM service repair manual for Caterpillar (CAT) GM 4.3L G6 Gasoline Forklifts, including models GP40, GPL40, DP40, DPL40, DP45, and DP50, look no further. This manual is an invaluable resource for both professional mechanics and DIY enthusiasts alike. Whether you are tackling routine maintenance or more complex repairs, this manual provides detailed guidance to help you get the job done right.
With the manual in .PDF format, you can easily access the information you need to troubleshoot and repair your Caterpillar (CAT) forklifts. Key technical details include:
- Engine specifications and performance data for the GM 4.3L G6 gasoline engine
- Electrical diagrams and wiring schematics
- Hydraulic systems and transmission details
- Step-by-step repair and maintenance instructions
For those looking for a .OVA file manual, rest assured that it provides the same level of detailed technical information and guidance as the .PDF version. Both formats offer a wealth of knowledge to support your maintenance and repair needs.
Investing in the OEM service repair manual for your Caterpillar (CAT) GM 4.3L G6 Gasoline Forklifts is a wise decision, as it serves as your go-to resource for all your repair and maintenance requirements.
