PDF Service Manual Caterpillar 2PD4000 Forklift - 4 MB
This service manual provides comprehensive information for the maintenance and repair of Caterpillar 2PD4000 series forklift trucks.
It is designed for professional mechanics, offering detailed guidance on troubleshooting, disassembly, and repair of all major systems.
With this manual, you can confidently tackle any service task, from routine maintenance to major overhauls, ensuring your forklift operates safely and efficiently.
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--- Page 1 ---
Service Manual
Chassis & Mast
MC/FC
2P3000 AT34-30121-49999 GP15NM AT34-T0100-T9999
2P3500 AT34-30121-49999 GP18NM AT34-W0100-W9999
2PC4000 AT34-80121-99999 GP20CNM AT34-P0100-P9999
2P4000 AT35-30121-49999 GP20NM AT17D-P0100-P9999
2P5000 AT35-30121-49999 GP25NM AT17D-T0100-T9999
2P5500 AT36-30121-49999 GP25NM-HP AT35-T0100-T9999
2P6000 AT13F-30121-49999 GP30NM AT13F-P0100-P9999
2P6500 AT13F-80121-99999 GP35NM AT13F-T0100-T9999
2P7000 AT13F-80121-99999
2PD4000 AT18C-30121-49999
2PD5000 AT18C-30121-49999
2PD5500 AT37-30121-49999
2PD6000 AT14E-30121-49999
2PD6500 AT14E-80121-99999
2PD7000 AT14E-80121-99999
For use with S4S and K21 / K25 Engine Service Manuals. 99719-8M110
--- Page 3 ---
TABLE OF CONTENTS
4.10 Error Codes and Troubleshootings..........................................................................................4 - 35
4.10.1 Error Code Display.........................................................................................................4 - 35
4.10.2 Diagnosis Table (F Code).............................................................................................. 4 - 36
4.10.3 Diagnostic Troubleshooting Codes (DTCs)....................................................................4 - 44
4.11 Locations of Sensors and Switches.........................................................................................4 - 64
4.11.1 Locations of Sensors and Switches............................................................................... 4 - 64
CHAPTER 5 POWER TRAIN
5.1 Removal and Installation (MC Models)........................................................................................5 - 1
5.1.1 Removal of Engine and Transmission Assembly (for Gasoline Engine Model)................. 5 - 1
5.1.2 Removal of Engine and Transmission Assembly (for Diesel Engine Model)..................... 5 - 7
5.2 Removal and Installation (FC Models)...................................................................................... 5 - 12
5.2.1 Removal of Engine and Transmission Assembly.............................................................5 - 12
CHAPTER 6 POWERSHIFT TRANSMISSION
6.1 Structure and Functions.............................................................................................................. 6 - 1
6.1.1 Transmission......................................................................................................................6 - 1
6.1.2 Torque Converter............................................................................................................... 6 - 3
6.1.3 Control System for Powershift Transmission..................................................................... 6 - 4
6.1.4 Hydraulic System Schematic of Powershift Transmission................................................. 6 - 5
6.2 Removal and Installation............................................................................................................. 6 - 7
6.2.1 Removal............................................................................................................................. 6 - 7
6.2.2 Installation.......................................................................................................................... 6 - 7
6.3 Outline......................................................................................................................................... 6 - 8
6.3.1 Overall View of Powershift Transmission...........................................................................6 - 8
6.3.2 Overall View of Control Valve.......................................................................................... 6 - 10
6.4 Powershift Transmission, Disassembly..................................................................................... 6 - 10
6.4.1 Preparation.......................................................................................................................6 - 10
6.4.2 Transmission External Parts, Removal............................................................................ 6 - 11
6.4.3 Oil Pump Assembly, Removal..........................................................................................6 - 13
6.4.4 Transmission Housing, Removal..................................................................................... 6 - 13
6.4.5 Input Shaft, Idler Shaft, and Output Gear, Removal........................................................ 6 - 15
6.4.6 Transmission Housing, Disassembly............................................................................... 6 - 16
6.4.7 Torque Converter Housing, Disassembly........................................................................ 6 - 17
6.4.8 Idler Shaft, Disassembly.................................................................................................. 6 - 18
6.4.9 Output Gear, Disassembly............................................................................................... 6 - 18
6.4.10 Forward Input Shaft Gear Assembly, Disassembly........................................................6 - 19
6.4.11 Reverse Input Shaft Gear Assembly, Disassembly....................................................... 6 - 22
6.4.12 Oil Pump Body, Disassembly.........................................................................................6 - 23
6.5 Powershift Transmission, Reassembly......................................................................................6 - 24
6.5.1 Transmission Housing, Assembly.................................................................................... 6 - 24
6.5.2 Torque Converter Housing, Assembly............................................................................. 6 - 25
6.5.3 Idler Shaft Assembly, Assembly.......................................................................................6 - 25
6.5.4 Output Gear Assembly, Assembly................................................................................... 6 - 26
6.5.5 Input Shaft Gear Assembly, Inspection............................................................................6 - 26
6.5.6 Forward Input Shaft Gear Assembly, Assembly.............................................................. 6 - 27
6.5.7 Reverse Input Shaft Gear Assembly, Assembly.............................................................. 6 - 32
6.5.8 Oil Pump Assembly, Assembly and Installation............................................................... 6 - 33
6.5.9 Torque Converter Housing, Assembly............................................................................. 6 - 37
6.5.10 Transmission Housing, Installation................................................................................ 6 - 39
xi
--- Page 4 ---
CHAPTER 1 GENERAL INFORMATION
1.4 DIMENSIONS
1-5
--- Page 5 ---
CHAPTER 2 COOLING SYSTEM
2.3.4 UNIT LAYOUT
2-5
--- Page 6 ---
CHAPTER 5 POWER TRAIN
5.1.2.2 CONTROLS
This section describes only removal and installation
procedures specific to mechanical controlled diesel
engine models. Follow the instructions for the
gasoline engine models in the preceding sections
for the common procedures.
Removal sequence (specific to diesel engine lift
trucks)
1. THROTTLE CABLE
5-9
--- Page 7 ---
CHAPTER 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
NOTE: 1) For removal of the front wheel, 7.2.2.2 INSTALLATION
see "Front Wheels, Page 7-4" IN
THE PREVIOUS SECTION. To install, follow the removal sequence in reverse.
Also follow the instructions listed below:
2) For removal of mast parts 2
through 8, see Ch 12. MAST AND (1) After connecting the parking brake cable,
FORKS make sure that the brake lever operating
effort is within the specification.
3) Before removing the front axle
and reduction differential, remove Truck type
the front axle drain plug and drain Items
transfer and differential oil. 1 ton class 2 ton class 3 ton class
150 to 200 200 to 250 230 to 250
Parking
7.2.2.1 REMOVAL (15.3 to (20.4 to (23.5 to
brake lever
20.4) 25.5) 25.5)
operating
Suggestions for Removal [33.7 to [45.0 to [51.7 to
effort
45.0] 56.2] 56.2]
Unit: N (kgf) [lbf]
(2) Before installing the mast, bleed trapped
air in the brake fluid circuits. For bleeding,
see Ch 9. BRAKE SYSTEM
(3) After installing the mast, make sure that tilt
angles, (forward and backward), are
correct and that the lift chains, (right and
left), are equal in tension. See Ch 12.
MAST AND FORKS
(4) Fill the front axle housing with oil up to the
1. BOLT plug hole level.
(1) Removing bolt 12 Truck type
Bolts 12 are coupling the transmission Items
1 ton class 2 ton class 3 ton class
with the differential. Before removing
these bolts, place a jack stand under the Refill
transmission to support it. capacity of
transfer 5.5 (1.5) 9.3 (2.5) 8.7 (2.3)
(2) Removing parking brake cable
and
To remove the parking brake cable,
differential
remove the parking brake lever assembly
from the dashboard and disconnect the Unit: liter (US gal.)
cable from the lever.
NOTE: To dismount the reduction differential
alone, remove the front axle as described
above. To dismount the reduction
differential, after removal of the engine and
transmission, the front axle does not need
to be removed from the lift truck
7-7
--- Page 8 ---
CHAPTER 7 FRONT AXLE AND REDUCTION DIFFERENTIAL
1) 1 TON CLASS 3) 3 TON CLASS
2) 2 TON CLASS
1. DIFFERENTIAL CASE 13. BALL BEARING
2. REDUCTION GEAR 14. INPUT FLANGE
3. BOLT 15. DRIVE GEAR
4. DIFFERENTIAL GEAR, THRUST WASHER 16. BALL BEARING
5. DIFFERENTIAL PINION, PINION THRUST 17. PLATE
WASHER (2, 3 TON CLASSES),
DIFFERENTIAL SHAFT, SPRINGPIN 18. REDUCTION PINION, SHIMS, TAPERED
ROLLER BEARING (INNER)
6. DIFFERENTIAL GEAR, THRUST WASHER
19. DRIVEN GEAR
7. TAPERED ROLLER BEARING
20. TAPERED ROLLER BEARING
8. DIFFERENTIAL CARRIER
21. SHIM
9. BEARING CAP
22. LOCKNUT, O-RING, COVER
10. ADJUSTING SCREW
23. LOCK PLATE
11. CARRIER COVER
12. CARRIER COVER
7-17
--- Page 9 ---
CHAPTER 8 REAR AXLE
Chapter 8 REAR AXLE
8.1 STRUCTURE AND FUNCTIONS
8.1.1 REAR AXLE IN GENERAL
Main Components
4) REAR AXLE VIEWED FROM FRONT
1) REAR AXLE VIEWED FROM REAR (WITH TIRES INSTALLED)
2) BOLT FOR SECURING AXLE TO TRUCK
5) FRONT OF VEHICLE
3) FRONT OF VEHICLE 6) CENTER OF TIRE
1. REAR AXLE MAIN UNIT
2. BUSHING SUPPORT (REAR AXLE 6. RIGHT-SIDE KING PIN
SUPPORT) 7. STEERING CYLINDER
3. WHEEL HUB 8. TIE ROD
4. KNUCKLE 9. WHEEL BOLT
5. LEFT-SIDE KING PIN
8-1
--- Page 10 ---
CHAPTER 8 REAR AXLE
(3) When replacing the dust seal and needle 4) 140.5 MM (5.5 IN.) (SEAL END FACE)
bearing, install them in the direction and 5) 12 MM (0.45 IN.) (BEARING END FACE)
dimensions shown in the illustration using
a driving tool. 6) REFERENCE SURFACE
Tightening torque of 31 to 42 (3.2 to 4.3) 8.3.3 STEERING CYLINDER,
locknut [22.9 to 31.0] DISASSEMBLY AND ASSEMBLY
Unit: N·m (kgf·m) [lbf·ft]
8.3.3.1 REMOVAL OF CYLINDER
(4) Place three tabs on plate 9 upward.
Align the notch to locating springpin (1) Remove cylinder mounting bolts (4 pieces)
position protruded from king pin. to remove the steering cylinder.
Install snugly to the full depth.
8.3.3.2 SUGGESTIONS FOR REMOVAL
(5) Apply a sufficient amount of grease after
assembly. Apply grease until it comes out Start by
of the boundary between the axle and the
knuckle. (1) Remove the rear axle assembly (with
cylinder) from the lift truck.
(6) Dimensions after assembly are shown
below: (2) Pull out the tie rod pins (right and left) on
the cylinder to disconnect the knuckle from
the cylinder.
1) TIGHTENING TORQUE: 265 TO 292 N·M
(27.0 TO 29.8 KGF·M) [195.5 TO 215.4
LBF·FT]
1) KING PIN
1. CYLINDER MOUNTING BOLT (TOTAL OF
2) 101 MM (4.0 IN.) (BEARING END FACE) 4)
3) 1 MM (0.04 IN.) (SEAL END FACE) 2. TIE ROD PIN
8-11
--- Page 11 ---
CHAPTER 9 BRAKE SYSTEM
(4) Disconnect the brake pipe from the wheel b. Replace the lining if it is heavily fouled
brake assembly. with grease, burnt, or otherwise
deteriorated.
Suggestions for Disassembly
c. Measure the thickness of the lining.
(1) Removing return springs Replace if it is worn to less than the
Use the spring remover to remove the service limit.
return springs from the shoe guide plates.
Truck type
Special tool needed
Items 2 ton class
Spring remover 64309-15411 1 ton class
3 ton class
Thickness of A 4.87 (0.19) 5.7 (0.22)
linings B 1.0 (0.04) 1.0 (0.04)
A: Standard value B: Service
limit
Unit: mm (in.)
(2) Removing hold-down springs
Use the spring retainer to remove the
hold-down springs from the backing plate.
Special tool needed
Spring retainer 64309-15412
(3) Brake drums
Check the inside (friction) surface of the
drum for abnormal wear, grooving and
other defects. Minor grooving can be
removed by grinding, provided that the
inside diameter does not exceed the
service limit.
Truck type
Items 2 ton class
1 ton class
3 ton class
Brake drums A 254 (10.0) 310 (12.2)
Inner
diameter B 256 (10.1) 312 (12.3)
Inspections after Disassembly
A: Standard value B: Service limit
(1) Backing plate
Unit: mm (in.)
a. Check the backing plate for cracks.
(2) Shoes and linings (4) Adjusting screw
Check the wheel teeth for wear. Turn the
a. Check each shoe and lining for screw by hand to see if its rotating parts
cracks. turn smoothly.
9-7
--- Page 12 ---
CHAPTER 9 BRAKE SYSTEM
9.3.7 PARKING BRAKE LEVER
1) RELEASED 2) APPLIED
1. LEVER SUPPORT PIN 3. PARKING BRAKE LEVER ASSEMBLY
2. ADJUSTING SCREW 4. PARKING BRAKE SWITCH
9.3.7.1 INSPECTION AND REPAIR 9.3.7.2 ASSEMBLY
(1) If the lever support pin and/or the pin hole With the parking brake cable and lever connected,
in the lever are badly worn, replace the the effort required to pull the lever should be
worn part(s). adjusted into the following range.:
(2) Replace the parking brake cable if it is
stretched, damaged, or rusted.
Truck type
Items
1 ton class 2 ton class 3 ton class
Parking brake 150 to 200 200 to 250 230 to 250
lever operating (15 to 20) (20 to 25) (23 to 25)
effort [34 to 45] [45 to 56] [52 to 56]
Unit: N (kgf) [lbf]
9-17
--- Page 13 ---
CHAPTER 10 STEERING SYSTEM
NOTE: When the tilt lock lever is turned counter-
clockwise, plate (A) and (B) are
sandwiched between bolt and nut, and
locked.
The steering column tilt angle is adjustable in the
range of 5 degrees forward and 7 degrees
backward as shown in the illustration.
To adjust the tilt angle, lock the column lock lever 4
first, and loosen the tilt lock lever 3 by turning it
clockwise. Then, tilt the steering column 1 to the
optimal angle and turn the tilt lock lever 3
counterclockwise (pulling upward) to lock.
The column lock lever 4 is used to tilt the steering
column forward for the convenience of the operator
to get on and off the lift truck and during
maintenance. Tilt the steering column forward by
pushing down the tilt lock lever 3 to disengage the
column lock lever 4 from the lock pin 5.
10-5
--- Page 14 ---
CHAPTER 10 STEERING SYSTEM
1. RETAINING RING
(4) Install O-ring and thrust bearing.
(6) Installing spacer plate
(5) Installing seal
a. Before holding the housing in a vise,
a. Install dust seal on seal gland use a soft pad or wrap a soft cloth
bushing. See the illustration in the around the housing. Hold the flat
"ASSEMBLY" in the previous page for section of flange in a vise. Do not hold
orientation. Then install the X-ring it in a vise too tight.
seal.
NOTE: Make sure that the spool and sleeve are
b. After installing the O-ring, fit the seal flush with or slightly lower than the surface
gland bushing into the spool while of housing.
turning the seal gland bushing. Drive
the bushing into the specified position
by a plastic hammer. Check that the
bushing contacts the top face of the
thrust bearing race evenly.
Securely fit the retaining ring into the
housing groove.
b. Install O-ring on the housing. Place
the spacer plate on the housing, and
align the bolt hole with the tap hole of
housing.
10-15
--- Page 15 ---
CHAPTER 11 HYDRAULIC SYSTEM
11.1.3 HYDRAULIC CIRCUIT DIAGRAM
(FOR MODELS WITH FC CONTROL
VALVE)
11-5
--- Page 16 ---
CHAPTER 11 HYDRAULIC SYSTEM
Cylinder Cylinder
Rod
inside outside
Model type Mast type Class Lift height diameter
diameter diameter
(d)
(ID) (OD)
Simplex 15 - 20C 3290 35 (1.38) 45 (1.77) 53 (2.07)
1 ton class
Triplex 15 - 20C 3290 35 (1.38) 45 (1.77) 53 (2.07)
20 - 25 3300 40 (1.57) 50 (1.97) 58 (2.28)
Simplex
28 - 30 3270 42 (1.65) 55 (2.17) 65 (2.56)
2 ton class
20 - 25 3300 40 (1.57) 50 (1.97) 58 (2.28)
Triplex
28 - 30 3270 42 (1.65) 55 (2.17) 65 (2.56)
Simplex 33 -35 3300 45 (1.77) 60 (2.36) 70 (2.76)
3 ton class
Triplex 33 - 35 3300 45 (1.77) 60 (2.36) 70 (2.76)
Unit: mm (in.)
Table 11-1. Cylinder dimensions (the length and stroke of cylinder vary depending on lift height.)
11-15
--- Page 17 ---
CHAPTER 11 HYDRAULIC SYSTEM
Main Components
7. WIPER RING
1. BOLT, NUT
8. NUT RING 13. PISTON SEAL
2. TILT SOCKET
9. BACK-UP RING 14. GUIDE RING
3. INNER RING
10. O-RING 15. SNAP RING
4. BEARING
11. PISTON ROD 16. CYLINDER ASSEMBLY
5. GREASE NIPPLE ASSEMBLY 17. BUSHING
6. ROD GUIDE 12. COLLER
The tilt cylinder is a double-acting type. To adjust Rod Cylinder Cylinder
right and left imbalance of tilt angles when the mast Model type
diameter I.D. O.D.
is attached, loosen the clamp bolt and turn the
piston rod with a spanner applied on area A. 1 ton class 25 (0.98) 63 (2.48) 73 (2.87)
2 ton class 30 (1.18) 70 (2.76) 82 (3.23)
Seal 11 helps extends the greasing intervals.
Installation of this seal has extended greasing 3 ton class 35 (1.38) 80 (3.15) 93 (3.66)
intervals up to 500 service hours. Unit: mm (in.)
Cylinder dimensions
Cylinder length and stroke vary depending on tilt
angles of forward and backward tilt.
11-25
--- Page 18 ---
CHAPTER 11 HYDRAULIC SYSTEM
Second lift cylinder for simplex mast and triplex mast
First, disassemble into the three main parts: I, II, and III.
Then disassemble each of the three main parts individually.
I HEAD SUB-ASSEMBLY (CONSISTING OF
THE FOLLOWING PARTS, 1 THRU 5.)
1. CYLINDER HEAD 3. X-RING
5. BUSHING
2. WIPER RING 4. O-RING
II PISTON ROD SUB-ASSEMBLY
(CONSISTING OF THE FOLLOWING PARTS,
6 THRU 13.)
6. PISTON ROD 9. BUSHING
ASSEMBLY 12. CHECK VALVE
10. SNAPRING
7. BACKUP RING 13. O-RING
11. CUSHION BEARING
8. U-RING
III CYLINDER TUBE ASSEMBLY (CONSISTING
OF THE FOLLOWING PARTS, 14 AND 15.)
14. CYLINDER TUBE SUB-ASSEMBLY 15. PLUG
Units: N·m (kgf·m) [lbf·ft]
1) APPLY LIQUID GASKET TO 3) APPLY GREASE WHEN ASSEMBLING.
CIRCUMFERENCE WHEN PRESSING IN. 4) APPLY THREEBOND ®1901 WHEN
2) TIGHTENING TORQUE SCREWING IN.
1 TON CLASS: 196±45.1 (20±4.6) [145±33] 5) SEAL IN GREASE. (ADHESION TO
(M49X1.5) BUSHING IS ACCEPTABLE.)
2 TON CLASS: 235±53.9 (24±5.5 ) [173±40]
(M54X1.5)
11-35
--- Page 19 ---
CHAPTER 11 HYDRAULIC SYSTEM
b. Hold the piston in a vise, making sure
care not to damage any part of the
piston. Apply a thin coat of hydraulic
oil on the seal. Fit a portion of the seal
to the groove, and push the other
portion into the groove as shown.
(5) Tighten the thread to the specified torque.
See "Figure 11-3, First, disassemble into
four main parts: I, II, III and IV.Then
disassemble each of the four main parts
individually., Page 11-43Figure 11-3, First,
disassemble into four main parts: I, II, III
and IV.Then disassemble each of the four
Inspections after Disassembly main parts individually., Page 11-43" for
(1) Cylinder tube the tightening torque.
a. Check the bore wall for wear,
grooving, scratches and rust.
b. Check the welds for cracks.
(2) Piston rod
a. Check for surface flaws such as
grooving, scratches, rust, and wear.
The rod must be replaced if its threads
show a sign of stripping or any other
damage.
(3) Rings and packings
a. Check each ring and packing for
damage or distortion.
b. Also check for deterioration due to
aging.
Suggestions for Assembly
To assemble, follow the disassembly sequence in
reverse, paying attention to the following points:
(1) Carefully clean all parts to remove any
foreign particle.
(2) Assemble the cylinder in the reverse
sequence of the disassembly, apply
hydraulic oil on the bore wall of the
cylinder tube, and also to sealing parts; O-
rings, piston seals, dust seals, and
packings. Pay attention to the orientation
of parts.
(3) When clamping the cylinder tube in the
vise, be careful not to distort the tube.
(4) Install the piston seal as follows:
a. Before fitting the piston seal, squeeze
it by hand five or six times to soften it.
11-45
--- Page 20 ---
CHAPTER 11 HYDRAULIC SYSTEM
Replace O-ring; check
Oil leakage from spool spool for flaws and if
ring cap any, repair or replace a
Oil leakage leaky block assembly
Loose plug Tighten plug
O-ring damaged Replace O-ring
Replenish oil by seeing
Not enough oil in
Chapter13.SERVICE
hydraulic tank
DATA
Mast will not lift or tilt forward Relief valve out of