SERVICE DATA

 SERVICE DATA
Fuel Information
Use only fuel recommended in this section.

 Gasoline (Gas) Specification

Your lift truck must use unleaded gasoline only.

Oxygenated gasoline
Some gasoline sold at service stations contain oxygenates such as ethanol, methanol, and MTBE (Methyl Tertiary Butyl Ether),
although they may not be so identified. The use of fuels containing oxygenates is not recommended.
Ethanol (Gasohol)
A mixture of 10% ethanol (grain alcohol) and 90% unleaded gasoline may be used in your lift truck, provided the octane rating
is at least as high as that recommended for unleaded gasoline.
Methanol
DO NOT operate your lift truck on gasoline containing methanol (wood alcohol). The use of this type of alcohol could result in
lift truck performance problems and could damage critical fuel system parts.
MTBE (Methyl Tertiary Butyl Ether)
A mixture of 15% or less MTBE and unleaded gasoline may be used in your lift truck provided the octane rating is at least as
high as that recommended for unleaded gasoline.
Note: If you experience driving problems which you suspect are fuel related, try switching to a different fuel.

 Diesel Fuel Specifications

Fuel types
The recommended fuels provide maximum engine service life and performance. They are distillate fuels. They are commonly
called diesel fuel, furnace oil, gas oil or kerosene (for cold weather operation).
The manufacturer strongly recommends the use of fuels that meet the recommended fuels specification.
Fuel sulfur content
- The percentage of sulfur in the fuel will affect the engine oil recommendations. Fuel sulfur is chemically changed during
combustion to form both sulfurous and sulfuric acid. These chemically attack metal surfaces and cause corrosive wear.
- Any API classification performance of oil should have sufficient TBN for fuels with less than 0. 5% sulfur. For fuels with 0.5%
to 1. 5% sulfur by weight, engine oil must have a TBN of 20 times the percentage of fuel sulfur as measured by the ASTM
(American Society of Testing Materials) D-2896 method. (ASTM D-2896 can normally be found at your local technological
society, library or college.)

 Liquefied Petroleum (LPG)

Specifications
Use grade HD5 LPB. LPG is a highly volatile fuel with an octane rating of 100 to 140. Follow local ordinances regarding storage
and/or filling of LPG tanks.

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SERVICE DATA
Coolant Information
The manufacturer recommends that the coolant mix contain 50% commercially available automotive antifreeze, and 50%
water.

- To reduce the risk of damage to your engine, DO NOT add coolant to an overheated engine.
Allow the engine to cool first.
- Dowtherm 209 full-fill coolant will lower the water pump cavitation temperature and boiling point. These lowered
temperatures will cause overheating at a lower ambient temperature than an ethylene glycol and water mix. If Dowtherm
is used, follow the instructions provided and use only the inhibitor package recommended by the supplier.
- If the lift truck is to be stored in, or shipped to, an area with freezing temperatures, the cooling system must be protected
to the lowest expected outside (ambient) temperature.
The engine cooling system is protected with a commercially available automotive antifreeze when shipped from the
factory. In cold weather, check the specific gravity of the coolant frequently to ensure adequate protection.
- Clean the cooling system if it is contaminated, the engine overheats or foaming is observed in the radiator.
Old coolant should be drained, the system cleaned and new coolant added—as recommended— using a commercially
available automotive antifreeze. Filling at over 20 liters per minute could cause air pockets in the cooling system.
- After draining and refilling the cooling system, run the engine with the radiator cap off. Run it until the coolant reaches its
normal operating temperatures and the coolant level stabilizes.
- Add coolant as necessary to fill the system to the proper level. Operate with a thermostat in the cooling system all year
round. Cooling system problems could arise without a thermostat.

 Coolant Water
- The manufacturer recommends the use of distilled water or deionized water to reduce the potential and severity of
chemical insolubility.
- Hard water, or water with high levels of calcium and magnesium ions, encourages the formation of insoluble chemical
compounds by combining with cooling system additives such as silicates and phosphates.
The tendency of silicates and phosphates to precipitate out-of-solution increases with increasing water hardness. Hard
water, or water with high levels of calcium and magnesium ions, encourages the formation of insoluble chemicals,
especially after a number of heating and cooling cycles.
- Using water that meets the minimum acceptable water requirement may not prevent dropout of these chemical
compounds completely but should control the dropout rate at acceptable levels.

Acceptable Water

Water Content Limits (ppm)

Chlorides (CI) 50 ppm (maximum)
Sulfates (SO4) 50 ppm (maximum)
Total Hardness 80 mg/l
Total Solids 250 ppm (maximum)
pH 6.0 to 8.0

ppm = parts per million

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 SERVICE DATA
 Antifreeze Solution
The manufacturer recommends that the coolant mix contain 50% commercially available automotive antifreeze, or equivalent,
and acceptable water to maintain an adequate water pump cavitation temperature for efficient water pump performance.
- Premix the coolant solution to provide protection to the lowest expected outside (ambient) temperature. Pure undiluted
antifreeze will freeze at -23°C (-10°F).
- Use a greater concentration (above 50%) of commercially available automotive antifreeze only as needed for anticipated
outside (ambient) temperatures.
- DO NOT exceed the coolant-to-water mix ratio recommendations provided with the commercially available automotive
antifreezes.
- Most commercial antifreezes are formulated for gasoline engine applications and will, therefore, have high silicate
content.
- DO NOT add pure (100%) antifreeze to the cooling system. Add antifreeze mixed with distilled water using the same freeze
protection ratio that is in your cooling system.

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SERVICE DATA
Recommended Fuels and Oils

Recommendation for Ambient Temperatures, °C (°F)

-30 -20 -10 0 10 20 30

Fuel or Oil Recommendation (-22) (-4) (14) (32) (50) (68) (86)

Contact your authorized Cat lift truck dealer

Fuel (For gasoline model: Use unleaded regular gasoline with an
octane rating of 91 or more.)
API service
Gasoline Models SAE10W-30
classification SL, min.
Engine Oil
API service
Diesel Models SAE10W-30
classification CF, min.
API service
classification multi-
Transfer and Differential Oil SAE80W SAE90
purpose type GL-4 or
GL-5
Powershift Transmission Oil Dexron II Contact your authorized Cat lift truck dealer
Hydraulic Oil ISO VG32
Wheel Bearings NLGI No.2 grade multipurpose type (lithium base), consistency: 271
Grease
Chassis NLGI No. 1 grade multipurpose type (lithium base), consistency: 315

-45 -39 -30 -25 -20 -15 -10

Ambient Temperature, °C (°F)
Antifreeze solution (-49) (-38) (-22) (-13) (-4) (5) (14)
Concentration (%) 60 55 50 45 40 35 30

Note:
- Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate
when mixed.
It is best to stick with the same brand at successive intervals
- For refill capacities and measurements, See 12-5 "Specifications (Standard Models)".

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 SERVICE DATA
Specifications (Standard Models)
Note: The values in the table below are for the standard model.

Gasoline model

Model
Item
GP40N GP45N GP50CN GP50N GP55N
Alternator drive belt deflection-when pushed
11 to 13 mm (0.43 to 0.51 in.)
inward with 98 N (10 kgf) [22 lbf] pressure
Spark plug type BPR4E
Spark plug gap 0.8 to 0.9 mm (0.032 to 0.035 in.)
Engine idling speed 700 ± 50 min-1
Steering wheel free play
15 to 30 mm (0.59 to 1.18 in.)
(when measured at rim with engine idling)
Inching pedal free play 3 to 6 mm (0.12 to 0.24 in.)
Brake pedal free play 5 mm (0.20 in.)
Single 8.25-15-14PR 300-15-18PR
Front tire Standard dual 7.50-16-12PR
Tire size
Special dual 8.25-15-12PR
Rear tire 7.00-12-12PR 7.00-12-14PR
Single 800 kPa (8.17 kgf/cm2) [116.04 psi]
Front tire Standard dual 700 kPa (7.14 kgf/cm2) [101.54 psi]

Tire pressure Special dual 700 kPa (7.14 kgf/cm2) [101.54 psi]
700 kPa 1000 kPa
Rear tire (7.14 kgf/cm2) 850 kPa (8.67 kgf/cm2) [123.30 psi] (10.20 kgf/cm2)
[101.54 psi] [145.05 psi]
Tightening Front tire 600 ± 60 N·m (61.18 ± 6.12 kgf·m) [442.80 ± 44.28 lbf·ft]
torque of wheel
nuts Rear tire 377.3 ± 37 N·m (38.47 ± 3.78 kgf·m) [278.45 ± 27.30 lbf·ft]

Lift chain (mm/20 links)

518 mm (20.39 in.) 648 mm (25.51 in.)
elongation limit
87 L
Fuel tank capacity 105 L (27.74 US gal.)
(22.99 US gal.)
Engine cooling system (0.65 liter [0.17 US gal.]
16 L (4.23 US gal.)
reservoir tank included)
Engine 8.1 L (2.14 US gal.)
Engine oil Oil filter 0.3 L (0.08 US gal.)
Total 8.4 L (2.22 US gal.)
Transmission oil 17 L (4.49 US gal.)
Transfer and differential gear oil level 7.9 L (2.09 US gal.)
Hydraulic oil N level 72 L (19.02 US gal.) 81 L (21.40 US gal.)
Cooling oil level inside wet disc brake 8.9 L (2.35 US gal.)

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SERVICE DATA

Model
Item
GP40N GP45N GP50CN GP50N GP55N
Battery electrolyte specific gravity, corrected to
1.26 to 1.28
20°C (68°F)

Diesel model

Model
Item
DP40N DP45N DP50CN DP50N DP55N
Alternator drive belt deflection-when pushed
11 to 13 mm (0.43 to 0.51 in.)
inward with 98 N (10 kgf) [22 lbf] pressure
Spark plug type BPR4E
Spark plug gap 0.8 to 0.9 mm (0.032 to 0.035 in.)
Engine idling speed 700 ± 50 min-1
Steering wheel free play
15 to 30 mm (0.59 to 1.18 in.)
(when measured at rim with engine idling)
Inching pedal free play 3 to 6 mm (0.12 to 0.24 in.)
Brake pedal free play 5 mm (0.20 in.)
Single 8.25-15-14PR 300-15-18PR
Front tire Standard dual 7.50-16-12PR
Tire size
Special dual 8.25-15-12PR
Rear tire 7.00-12-12PR 7.00-12-14PR
Single 800 kPa (8.17 kgf/cm2) [116.04 psi]
Front tire Standard dual 700 kPa (7.14 kgf/cm2) [101.54 psi]

Tire pressure Special dual 700 kPa (7.14 kgf/cm2) [101.54 psi]
700 kPa 1000 kPa
Rear tire (7.14 kgf/cm2) 2
850 kPa (8.67 kgf/cm ) [123.30 psi] (10.20 kgf/cm2)
[101.54 psi] [145.05 psi]
Tightening Front tire 600 ± 60 N·m (61.18 ± 6.12 kgf·m) [442.80 ± 44.28 lbf·ft]
torque of wheel
nuts Rear tire 377.3 ± 37 N·m (38.47 ± 3.78 kgf·m) [278.45 ± 27.30 lbf·ft]

Lift chain (mm/20 links)

518 mm (20.39 in.) 648 mm (25.51 in.)
elongation limit
87 L
Fuel tank capacity 105 L (27.74 US gal.)
(22.99 US gal.)
Engine cooling system (0.65 liter [0.17 US gal.]
12.9 L (3.41 US gal.)
reservoir tank included)
Engine 11.5 L (3.04 US gal.)
Engine oil Oil filter 1.0 L (0.26 US gal.)
Total 12.5 L (3.30 US gal.)
Transmission oil 17 L (4.49 US gal.)
Transfer and differential gear oil level 7.9 L (2.09 US gal.)
Hydraulic oil N level 72 L (19.02 US gal.) 81 L (21.40 US gal.)

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 SERVICE DATA

Model
Item
DP40N DP45N DP50CN DP50N DP55N
Cooling oil level inside wet disc brake 8.9 L (2.35 US gal.)
Battery electrolyte specific gravity, corrected to
1.26 to 1.28
20°C (68°F)

Note: The service data are subject to change without notice.

Capacities and Lift Truck Weight (Standard Models)

Truck model
Item
GP40N GP45N GP50CN GP50N GP55N
Rated Capacity, kg (lb)/500 mm (20 in.) 4000 (8820) 4500 (9920) 5000 (11030) 5000 (11030) 5500 (12130)
Single drive tires 5860 (12920) 6270 (13830) 6780 (14950) 7240 (15960) 7570 (16700)
Truck weight, unloaded kg (lb)
Dual drive tires 5980 (13190) 6350 (14000) 6870 (15150) 7320 (16140) 7660 (16890)

Truck model
Item
DP40N DP45N DP50CN DP50N DP55N
Rated Capacity, kg (lb)/500 mm (20 in.) 4000 (8820) 4500 (9920) 5000 (11030) 5000 (11030) 5500 (12130)
Single drive tires 5920 (13050) 6330 (13960) 6850 (15100) 7300 (16100) 7640 (16850)
Truck weight, unloaded kg (lb)
Dual drive tires 6050 (13340) 6420 (14160) 6930 (15280) 7390 (16300) 7720 (17020)

Note: Capacities shown apply to lift trucks with genuine Cat lift truck standard tires.

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