POWER TRAIN

Specifications .......................................................................................... 4 1
Description ............................................................................................... 4 2
2-speed Transmission ............................................................................... 4 2
3-speed Transmission ............................................................................... 4 3
Gear Ratios (2-speed Transmission) ........................................................ 4 4
Gear Ratios (3-speed Transmission) ........................................................ 4 5 4
Removal and Installation ...................................................................... 4 6
Engine and Transmission Unit Removal .................................................... 4 6
Installation ................................................................................................ 4 16
Refill Capacities (Approximate) ................................................................. 4 19
Service Data ............................................................................................ 4 20
 POWER TRAIN

Specifications

Truck Model
DP100 DP115 DP135 DP150
Item
Type 3-element, 1-stage, 2-phase
Torque
Model MI 16
converter
Stall torque ratio 2.88

Direction control Electric, column shift

Control
Speed control Automatic

2-speed transmission
Transmission Forward 1st: 1.556
2nd: 0.685
Gear ratio 3-speed transmission
1st: 2.402
Reverse 2nd: 1.010
3rd: 0.532

Gear type Hypoid

Reduction
bevel gear
Gear ratio 5.571

Type Planetary gear

Final drive
Gear ratio 4.167

Housing type Banjo

Differential bevel gear, type

Straight bevel 2
Differential No. of gears

Differential bevel pinion, type

Straight bevel 4
No. of pinions

Type Full-floating, tubular

Front axle
Mounting method Fixed

4-1
POWER TRAIN

Description

2-speed Transmission

10

9
15
4 3 2 1

16

13 14 12 11 7 8
205488A

1. Diesel engine 9. Pump drive gear

2. Flywheel 10. Hydraulic pump
3. Torque converter 11. Universal joint
4. Transmission 12. Parking brake
5. Input shaft 13. Front axle
6. Countershaft 14. Reduction and differential
7. Output shaft 15. Final drive
8. Travel speed sensor gear 16. Wheel brake

Power from the diesel engine is sent through the
following components to the front wheels:
(1) Torque converter 3
Is a hydrokinetic device serving as a variable
torque amplifier.
(2) Transmission 4
Has two forward and two reverse speeds. It has
four hydraulic multi-disc clutches.
(4) Reduction and differential 14
Receives power from the universal joint and splits
it through two rear axles to the final drive. The
differential allows the front wheels to turn
different amounts when the truck goes around a
curve.
(5) Final drive 15
Has a planetary gear and drives the front wheels.

(3) Universal joint (propeller shaft) 11

Transmits power from the transmission to the
reduction and differential.

4-2
 POWER TRAIN

3-speed Transmission

11

12
3 2 1
17 4 5

8
18

15 16 14 13 9 10
205670A

1. Diesel engine 10. Travel speed sensor gear

2. Flywheel 11. Pump drive gear
3. Torque converter 12. Hydraulic pump
4. Transmission 13. Universal joint
5. Input shaft 14. Parking brake
6. FORWARD clutch shaft 15. Front axle
7. REVERSE clutch shaft 16. Reduction and differential
8. 1ST-SPEED/3RD-SPEED clutch shaft 17. Final drive
9. Output shaft 18. Wheel brake

Power from the diesel engine is sent through the
following components to the front wheels:
(1) Torque converter 3
Is a hydrokinetic device serving as a variable
torque amplifier. It is one of two related devices,
hydraulic coupling and converter.
(2) Transmission 4
Has three forward and three reverse speeds. It has
five hydraulic multi-disc clutches.
(3) Universal joint (propeller shaft) 13
Transmits power from the transmission to the
reduction and differential.
(4) Reduction and differential 16
Receives power from the universal joint and splits
it through two rear axles to the final drive. The
differential allows the front wheels to turn
different amounts when the truck goes around a
curve.
(5) Final drive 17
Has a planetary gear and drives the front wheels.

4-3
POWER TRAIN

Gear Ratios (2-speed Transmission)

Figures in ( ) indicate number of gear teeth.

(39)

(60)
(18) (57)

(54)
(52)
(36)

(54)
(36)
(42)

(7) (52)

(39)
(37)
(56)

210327

Speed Transmission Reduction bevel gear Final drive Total gear ratio
52 56
1st 1.556 ( 52 x 36 ) 36.111
Forward
52 37
2nd 0.685 ( 52 x 54 ) 5.571 4.167 15.906
56 36 57
1st 1.556 ( 36 ) ( ) ( +1) 36.111
7 18
Reverse
37
2nd 0.685 ( 54 ) 15.906

60 39
PTO gear ratio: 0.929 ( 42 x 60 )
PTO: For driving hydraulic pump (standard)
Above + For driving air conditioner compressor
(option)

4-4
 POWER TRAIN

Gear Ratios (3-speed Transmission)

Figures in ( ) indicate number of gear teeth.

(39)

(60)

(58)
(18) (57) (54) (35)

(34)

(58)

(42)
(60) (35)
(24)

(7) (58)

(39)
(31)
(53) (56)

210328

Speed Transmission Reduction bevel gear Final drive Total gear ratio
35 58 58 56
1st 2.402 ( 34 x 58 x 58 x 24 ) 55.760
35 53
Forward 2nd 1.010 ( 34 x 54 ) 23.455
35 58 58 31
3rd 0.532 ( 34 x 58 x 58 x 60 ) 5.571 4.167 12.347
35 58 56 39 57
1st 2.402 ( 34 x 58 x 24 ) ( ) ( + 1) 55.760
7 18
35 58 53
Reverse 2nd 1.010 ( 34 x 58 x 54 ) 23.455
35 58 31
3rd 0.532 ( 34 x 58 x 60 ) 12.347

60 39
PTO gear ratio: 0.929 ( 42 x 60 )
PTO: For driving hydraulic pump (standard)
Above + For driving air conditioner compressor
(option)

4-5
POWER TRAIN

Removal and Installation

Engine and Transmission Unit Removal

Start by:
(a) Disconnect the negative (ground) battery cable.
(b) Drain the coolant [approximately 23 liters (6 U.S. gal.)]
from the radiator and from the engine.
(c) Open the air tank drain plug to release air from the
tank.

1. Overhead guard or cab

Suggestions for Removal

A. Overhead guard
1. Disconnect the harnesses of the head lamps and
combination lamps from the connectors.
2. Remove the four bolts (M16) that hold the overhead
guard.
3. Hitch a sling to the overhead guard and remove the
guard.

NOTE 210329

Hitch slings with balancing at the center-of-gravity

position duly in mind.

B. Cab (when so equipped)

1. Disconnect the harness of the head lamps, combination Seat frame
lamps, warning lamps, windshield wiper and washer
and pump from the connectors.
2. Remove the covers at the four lower corners of the cab.
Remove the four bolts (M16) that hold the cab.
3. Hitch a sling to the cab and remove the cab.

NOTE Frame

(1) For head guard-equipped or cab-equipped truck, 210330

the subsequent steps of work are the same when

removal has been done this far.
(2) If the truck is equipped with a cab and a car heater,
disconnect the engine coolant hose and the heater
harness.

4-6
 POWER TRAIN

2. Removal of Covers and Plates

3
1

11
6

2 12
4

8
5

7
10

Seat frame

9
210331

Sequence
1. Gas spring (LH, RH) 7. Floor plate A (LH)
2. Engine cover 8. Cover (brake pedal)
3. Radiator cover 9. Cover (front)
4. Front cover B, Air cleaner 10. Toe board
5. Front cover A 11. Floor plate D
6. Floor plate A (RH) 12. Floor plate C

Suggestions for Removal

(1) Leave the seat bracket attached to the seat frame.
(2) Leave the accelerator pedal, brake pedal, inching pedal,
brake control valve, etc. attached to the seat frame.
(3) Disconnect the air cleaner hose at the engine side, then
remove the hose and air cleaner attached to the front
cover B.

4-7
POWER TRAIN

3. Removal of Seat Frame and Associated Parts

4
7
3

10

To transmission
2

To harness B 9

210332

Sequence
1. Engine control cable 6. Brake reserve tank
2. Seat frame harness A 7. Hydraulic control cable
3. Inching pedal cable 8. Steering control valve
4. Brake control valve hose 9. Body grounding cable
5. Parking brake lever 10. Seat frame

4-8
 POWER TRAIN

Suggestions for Removal

(1) Engine control cable

Disconnect the cable at the engine side. Coil it up at
the front side of the seat frame.

(2) Inching pedal cable

Disconnect the cable from the clevis pin of the inching
lever under the seat frame.

(3) Parking brake lever

Remove the lever mounting bolt with the lever in the
brake applied position.

210333

(4) Hydraulic control cable

Remove the cable from the clevis pin at the foot of the
control lever.

(5) Brake reserve tank

Remove the mounting bolt and drain oil from the tank.

(6) Seat frame harness A

Disconnect the harness at the following connectors.
(a) Connectors (3 places) to harness B
(b) Connector of transmission harness 210334

(7) Body grounding cable

Disconnect the cable at the seat frame side.

4-9
POWER TRAIN

(8) Brake control valve hose

Disconnect the two hoses from the valve at
connectors.

210335

(9) Steering control valve

Disconnect the five hoses from the valve at
connectors.

210336

Seat frame
(10)Seat frame
Bolt
(a) Remove the mounting bolts from the seat frame.
This must be done by at least two persons. Cushions

(b) Hitch slings to the bolt holes located at four

corners of the
NOTE Frame
Hitch the slings with balancing at the center-of-gravity
position duly in mind. Nut
210337

seat frame and hoist the seat frame to move out of

place.

4-10
 POWER TRAIN

4. Electrical Parts Removal

Suggestions for Removal

(1) Harness B disconnecting points (see page 3-8.)

1. Glow plug terminal
2. Joint with harness C
3. Lining wear detection switch connector
4. Alternator connector
5. Engine coolant temperature gauge unit terminal

Note: Disconnect the harness B from the right-hand side

of the truck. Then, unclip the harness at two mid-
points and put it aside to the left-hand side of the
truck.

(2) Harness C disconnecting points (see page 3-10.)

1. Engine stop solenoid connector
2. Oil bypass alarm switch terminal
3. Engine oil pressure switch terminal

(3) Starter cable

Disconnect the cable at the starter relay side connector.

(4) Engine grounding cable

Remove the bolt securing the cable to the frame.

210338

4-11
POWER TRAIN

5. Pipes and Hoses Removal

8
6
7 11

3 9

3
5
10
9

10

12

2
4
1 12
1

1
1

210339

Sequence
1. Fuel hose 7. Hydraulic suction hose
2 Cross member 8. Fan guard
3 Air compressor hose 9. Intercooler hose
4 Exhaust pipe 10. Radiator hose
5. Air master 11. Intercooler
6. Hydraulic high pressure hose 12. Transmission cooler hose

4-12
 POWER TRAIN

Suggestions for Removal

(1) Fuel hose

Two pipes remain attached to the underside of the
cross member. Disconnect the hoses to the engine and
truck body at pipe connectors.

(2) Air compressor hoses

Leave the two hoses connected at the suction side.

(3) Air master

(a) Disconnect the pipe between the air master and
wheel brake.
(b) With the brake reserve tank and pipe behind left
connected, remove the air master together with
bracket.

(4) Hydraulic high pressure hose

Disconnect the hose at the oil pump and priority valve
sides.

(5) Hydraulic suction hose

Disconnect the hose from the suction pipe on the
underside of the oil pump and the suction hose
connector. (Place a dip pan to receive the oil that flows
out.)

(6) Intercooler
(a) Unclip the harness C (at three points) ahead of the
intercooler and slacken it forward to prevent
breaking.
(b) Remove the bolts securing the intercooler and lift
the intercooler off the frame.

Intercooler weight Approx. 9 kg (19.8 lb)

210340

(7) Transmission cooler hose

Disconnect the hose at the transmission side and leave
it lying along the frame.

4-13
POWER TRAIN

6. Engine Mounts, Thrust Rods and Associated Parts Removal

2
1

1
4

210341

Sequence
1. Thrust rod bracket 3. Transmission mounting bracket fitting nut
2. Engine mounting bracket fitting nut 4. Universal joint

Suggestions for Removal

(1) Thrust rod bracket

Remove the bolts attaching the bracket, then remove
the bracket with the thrust rod left attached to the
transmission mounting bracket.

(2) Universal joint

Remove the universal joint at the transmission side.

4-14
 POWER TRAIN

7. Engine and Transmission Unit

210342

Fasten a hoist to the engine and transmission unit by

hitching slings to the eyes of the engine at two places and a
chain sling with lever block to the transmission at one place
as shown. Adjust the length of the chain sling with the
lever block so that the unit is horizontal. Slowly lift the
unit while moving it backward.

Weight of engine and

transmission unit 910 kg (2010 lb)
(3-speed transmission)

4-15
POWER TRAIN

Installation
To install, follow the reverse of removal sequence.

Suggestions for Installation

Output shaft
(1) Check the cushions of the engine and transmission
mounting brackets and replace them if damaged or
deteriorated.
(2) Mount the engine and transmission combination on the
mounting bracket while fitting the universal joint to the
transmission output flange.

Output flange
205457

(3) Tighten the mounting bolts to the specified torque. Engine mount (left shown, right opposite)

4 1
Ref. Item Tightening torque
No.

145 Nm
1 Rubber cushion bolts (14.8 kgfm) 3
[107 lbfft]

60 Nm
2 Mounting bracket bolts (6.1 kgfm) 206171
[44 lbfft]
Transmission mount (right side)
97 Nm 1
3 Rubber cushion bolts (9.9 kgfm)
[72 lbfft] 2

60 Nm
3
4 Mounting bracket bolts (6.1 kgfm)
[44 lbfft]

206172

Transmission mount (left side)

1

206173
4-16
 POWER TRAIN

(4) Tighten the universal joint to the specified torque.

7110 Nm
Tightening torque for
(7.21.0 kgfm)
universal joint
[527 lbfft]

(5) Install the exhaust pipe with a new gasket.

(6) Install the harnesses, making sure their connectors and
terminals are tightened properly.
(7) Install the seat frame in position. When the self-
Seat frame
locking nuts contact the plain washers, tighten 2 turns
[3 mm (0.12 in.)] more.
Bolt
(8) Install the overhead guard or cab in position and tighten
the mounting bolts to the specified torque. Cushions

145 Nm
Tightening torque for
(14.8 kgfm)
overhead guard or cab bolts Frame
[107 lbfft]

Nut 210337
(9) Install the parking brake wire with ball and nut. Then
test the operating effort of the lever.

245 to 294 N
Operating effort of parking
(25 to 30 kgf)
brake lever
[55 to 66 lbf]

(10) Install the brake pedal and inching pedal rods and
Unit: mm (in.)
cables, and check the height of the pedals and the
stroke of the inching valve plunger.

(7.48 in.)
190 mm
Unit: mm (in.)
Height of pedal 190 (7.48)

Stroke of inching valve plunger

9 (0.35)
with inching pedal released
9 mm
(0.35 in.)
(11) Connect the engine control cable to the injection pump 210343
lever, and make sure that the lever is in full throttle
position when the pedal is depressed all the way.
(12) Connect piping between the hydraulic pump and
steering control valve.
(13) Make sure that all wires have been connected properly,
and then connect the ground (negative) cables to the
batteries.

4-17
POWER TRAIN

(14) Refill the engine oil pan, radiator and transmission,

and check for leakage. For concentration of
antifreeze in coolant, consult your Cat lift truck
dealer.
(15) Fill the brake fluid reservoir, and bleed the brake
lines.
(16) Prime the fuel system.
(17) After having checked the various parts, start the
engine, and observe its running condition. If the
engine vibrates excessively, retighten the mounting
bolts to see if this retightening has any effect.
Operate the mast, forks and steering, and check the oil
level in the hydraulic tank, adding oil if necessary.
Recheck the engine oil, coolant and transmission oil
levels, and refill if necessary.
(18) Test the transmission as follows:
d
(a) Tilt the mast fully backward. Position wood
blocks under the mast and tilt the mast forward
to raise the front wheels until they clear the
ground. After raising the wheels, support the
frame with stands. Block the rear wheels.
(b) Start the engine and operate it at low idle. Move
the transmission shift lever to FORWARD
position to make sure the front wheels rotate in
the correct direction. Move the transmission
shift lever to REVERSE position and do the
201143A
same step.
(c) Move the travel speed select switch on the
console box to each position to make sure the
front wheels rotate at the correct speed in each
position.
CAUTION
During testing, the front wheels rotate. Set up a
fence around the truck to prevent anyone from
entering into the testing area.

4-18
 POWER TRAIN

Refill Capacities (Approximate)

Unit: liter (U.S. gal.)
Truck Model
DP100 DP115 DP135 DP150
Item
Radiator 23 (6.1)

2-speed: 22 (5.8)
Transmission
3-speed: 23 (6.1)

Differential
Front axle 25 (7)
Final drive

Brake fluid reservoir 200 cc (12.2 cu in.)

Hydraulic tank 172 (45) 204 (54)

Fuel tank 230 (61) 280 (74)

Engine 12 (3.2)

Engine oil Oil filter 4 (1.0)

Total 16 (4.2)

NOTE: For recommended oil brands, etc., see the GROUP 15 SERVICE DATA.

4-19
POWER TRAIN

Service Data

A: Standard value
Truck Model
DP100 DP115 DP135 DP150
Item

Tightening torque for rubber cushion bolts 1

A 145 (14.8) [107]
Nm (kgfm) [lbfft]

Tightening torque for mounting bracket bolts 2

A 60 (6.1) [44]
Nm (kgfm) [lbfft]

Tightening torque for rubber cushion bolts 3

A 97 (9.9) [72]
Nm (kgfm) [lbfft]

Tightening torque for mounting bracket bolts 4

A 60 (6.1) [44]
Nm (kgfm) [lbfft]

Engine mount (left side shown, right side opposite)

210344

Transmission mount (right side) Transmission mount (left side)

1 1

2
2

3
3

210345 210346

4-20
 POWER TRAIN

A: Standard value
Truck Model
DP100 DP115 DP135 DP150
Item

Tightening torque for overhead guard or cab bolts 1

A 145 (14.8) [107]
Nm (kgfm) [lbfft]

Tightening torque for seat frame 2 When self-locking nuts contact plain washers,
A
Nm (kgfm) [lbfft] tighten 2 turns [3 mm (0.12 in.)] more.

210347

Tightening torque for universal joint 1

A 7010 (7.21.0) [527]
Nm (kgfm) [lbfft]

1 1

210348

4-21