CAT 2PD4000, 2PD5000, 2PD5500, 2P6000, 2PD7000 Lift Truck Service Manual

CAT 2PD4000 Service Manual

CAT 2P5000, 2P5500, 2P6000, 2P6500, 2P7000 Lift Truck Service Manual

2PD4000, 2PD5000, 2PD5500, 2P6000, 2PD7000 Lift Truck

Complete CAT 2PD4000, 2PD5000, 2PD5500, 2P6000, 2PD7000 Lift Truck Service Manual & Maintenance Guide



2P3000 AT34-30121-49999
2P3500 AT34-30121-49999
2PC4000 AT34-80121-99999
2P4000 AT35-30121-49999
2P5000 AT35-30121-49999
2P5500 AT36-30121-49999
2P6000 AT13F-30121-49999
2P6500 AT13F-80121-99999
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
GP15NM AT34-T0100-T9999
GP18NM AT34-W0100-W9999
GP20CNM AT34-P0100-P9999
GP20NM AT17D-P0100-P9999
GP25NM AT17D-T0100-T9999
GP25NM-HP AT35-T0100-T9999
GP30NM AT13F-P0100-P9999
GP35NM AT13F-T0100-T9999

In the demanding world of material handling, the efficiency and reliability of lift trucks are crucial. The CAT 2PD4000, 2PD5000, 2PD5500, 2P6000, 2PD7000 lift trucks are renowned for their robust performance and durability.

This comprehensive CAT 2PD4000 Repair Manual to provide detailed guidance on maintaining and servicing these models to ensure optimal operation and longevity.

Table of Contents: CAT 2PD4000, 2PD5000, 2PD5500, 2P6000, 2PD7000

  1. Introduction
  2. Safety Precautions
  3. Technical Specifications
  4. Regular Maintenance Procedures
  5. Engine Service and Repair
  6. Transmission Service and Repair
  7. Hydraulic System Maintenance
  8. Electrical System Overview
  9. Troubleshooting Common Issues
  10. Conclusion

Safety Precautions

Importance of Safety in Lift Truck Maintenance

Safety is paramount when servicing lift trucks. Always ensure the lift truck is on a level surface and the parking brake is engaged. Disconnect the battery before performing any electrical work to prevent accidental shocks or short circuits.

Personal Protective Equipment (PPE)

  • Gloves: To protect hands from sharp edges and hot surfaces.
  • Safety Glasses: To protect eyes from debris and splashes.
  • Steel-Toed Boots: To protect feet from heavy objects.
  • Coveralls: To keep clothing clean and provide some protection from splashes.

Ultimate CAT 2PD4000, 2PD5000, 2PD5500, 2P6000, 2PD7000 Lift Truck Service Manual for Optimal Performance

Regular Maintenance Procedures

Daily Checks

  • Fluid Levels: Check engine oil, hydraulic fluid, and coolant levels.
  • Tire Condition: Inspect tires for wear and proper inflation.
  • Fork Condition: Ensure forks are not bent or cracked.
  • Operational Test: Check all controls for proper function.

Weekly Checks

  • Battery: Inspect for corrosion and secure connections.
  • Brake System: Check brake fluid level and test brakes for proper function.
  • Hydraulic Hoses: Inspect for leaks and wear.

Monthly Checks

  • Engine Air Filter: Inspect and clean or replace if necessary.
  • Drive Belts: Check for wear and proper tension.
  • Lubrication: Grease all fittings and moving parts.

Engine Service and Repair

Oil Change Procedure

  1. Warm Up Engine: Run the engine for a few minutes to warm the oil.
  2. Drain Oil: Remove the drain plug and allow the oil to drain completely.
  3. Replace Filter: Remove the old oil filter and install a new one.
  4. Refill Oil: Replace the drain plug and refill with the recommended oil type and quantity.

Spark Plug Replacement

  1. Remove Spark Plug Wires: Carefully disconnect the spark plug wires.
  2. Remove Old Spark Plugs: Use a spark plug socket to remove the old plugs.
  3. Install New Spark Plugs: Gap the new plugs as per specifications and install them.
  4. Reconnect Wires: Reattach the spark plug wires.

Transmission Service and Repair

Fluid Change

  1. Drain Old Fluid: Remove the transmission drain plug and drain the old fluid.
  2. Replace Filter: Install a new transmission filter if applicable.
  3. Refill Fluid: Refill with the recommended transmission fluid to the correct level.


  • Shift Linkage: Ensure the shift linkage is properly adjusted for smooth gear changes.
  • Clutch: Adjust the clutch pedal free play as per manufacturer specifications.

Hydraulic System Maintenance

Fluid Level Check

  • Reservoir: Ensure the hydraulic fluid reservoir is at the correct level.
  • Hoses and Fittings: Inspect for leaks and damage.

Cylinder Maintenance

  1. Inspect Seals: Check hydraulic cylinder seals for leaks.
  2. Replace if Necessary: Replace seals or cylinders if they are worn or damaged.

Electrical System Overview

Battery Maintenance

  • Clean Terminals: Ensure battery terminals are clean and tight.
  • Charge: Maintain a full charge to prevent starting issues.

Detailed CAT 2P3000, 2P3500, 2PC4000, 2P4000 Lift Truck Maintenance

Wiring Inspection

  • Visual Check: Inspect wiring for signs of wear, fraying, or damage.
  • Connections: Ensure all electrical connections are secure.

Troubleshooting Common Issues

Engine Won’t Start

  • Check Battery: Ensure the battery is charged and connections are secure.
  • Fuel Supply: Ensure there is sufficient fuel and that the fuel pump is operational.
  • Ignition System: Inspect spark plugs and ignition coils.

Hydraulic System Failure

  • Fluid Level: Check hydraulic fluid level.
  • Pump Operation: Ensure the hydraulic pump is functioning properly.
  • Cylinder Condition: Inspect hydraulic cylinders for leaks.

CAT 2PD4000, 2PD5000, 2PD5500, 2P6000, 2PD7000 Lift Truck Service Manual
CAT 2PD4000, 2PD5000, 2PD5500, 2P6000, 2PD7000 Lift Truck Service Manual
Price: $39.99

Detailed CAT 2PD4000, 2PD5000, 2PD5500, 2P6000, 2PD7000 Lift Truck Maintenance and Repair Manual