Cat E3000 E3500 EC4000 E4000 E5000 EX5000 E5500 E6000 E6500 Chassis & Mast Service Manual - DOWNLOAD

Service Manual Chassis & Mast E3000, E3500, EC4000 A4EC1-10200-up A4EC1-20200-up A4EC1-30200-up

E4000, E5000 A4EC2-10200-up A4EC2-20200-up

EX5000, E5500, E6000 A4EC3-20200-up A4EC3-30200-up A4EC3-40200-up

E6500 A4EC4-10200-up

99759-8B110

TABLE OF CONTENTS Chapter 1: General Information Scope ........................................................................................................................................... 1.1 Truck Models Covered ................................................................................................................. 1.1 Nameplate and Serial Number Locations .................................................................................... 1.2 Dimensions................................................................................................................................... 1.3 Dimensions Chart .................................................................................................................... 1.4 General Information (Standard Models)....................................................................................... 1.5

Chapter 2: Front Axle & Reduction Differential Front Axle Description ................................................................................................................................... 2.1 General Information ................................................................................................................. 2.1 Removal .......................................................................................................................................

Front Wheels ............................................................................................................................

Method 1..............................................................................................................................

Method 2..............................................................................................................................

Method 3..............................................................................................................................

2.2 2.2 2.3 2.3 2.3

Installation .................................................................................................................................... 2.4 Disassembly ................................................................................................................................. 2.5 Removing Front Wheel Hub ..................................................................................................... 2.6 Inspection after Disassembly ....................................................................................................... 2.7 Reassembly..................................................................................................................................

Axle Housing ............................................................................................................................

Front Wheel Hub ......................................................................................................................

Hub Bearing Preload................................................................................................................

Installation and Setting Preload...........................................................................................

2.8 2.8 2.8 2.10 2.10

Reduction Differential Description ................................................................................................................................... 2.11 Disassembly ................................................................................................................................. 2.12 Inspection after Disassembly ....................................................................................................... 2.13 Reduction Gear ........................................................................................................................ 2.13 Differential ................................................................................................................................ 2.13 Reassembly.................................................................................................................................. 2.14 Inspection and Adjustment...........................................................................................................

Side Bearing Preload ...............................................................................................................

Reduction Gear Backlash ........................................................................................................

Reduction Gear Face Runout ..................................................................................................

Tooth Contact ...........................................................................................................................

Tooth Contact Adjustment ........................................................................................................

Transfer Assembly....................................................................................................................

Front Axle .................................................................................................................................

99759-8B110

2.16 2.16 2.16 2.17 2.17 2.18 2.21 2.23 i

TABLE OF CONTENTS Chapter 3: Transfer Assembly Description ................................................................................................................................... 3.1 Disassembly ................................................................................................................................. 3.2 Disassembly Sequence................................................................................................................ 3.2 Inspection after Disassembly ....................................................................................................... 3.4 Reassembly.................................................................................................................................. 3.5

Chapter 4: Rear Axle Description ................................................................................................................................... 4.1 Rear Wheels................................................................................................................................. 4.2 Removal ................................................................................................................................... 4.2 Steering Cylinder.......................................................................................................................... 4.3 Installation ................................................................................................................................ 4.4 Rear Axle .....................................................................................................................................

Removal ...................................................................................................................................

Installation ................................................................................................................................

Disassembly .............................................................................................................................

Inspection after Disassembly ...................................................................................................

Reassembly..............................................................................................................................

4.7 4.7 4.8 4.9 4.11 4.12

Inspection and Adjustment........................................................................................................... 4.17 Minimum Turning Radius Adjustment....................................................................................... 4.17

Chapter 5: Brake System Description ................................................................................................................................... 5.1 Automatic Adjusting Device ..................................................................................................... 5.1 General Information ................................................................................................................. 5.1 Master Cylinder Disassembly ............................................................................................................................. 5.2 Inspection after Disassembly ................................................................................................... 5.3 Reassembly.............................................................................................................................. 5.3 Service Brakes Disassembly (E3000 - EC4000) ...............................................................................................................

(E4000 - E6500) ..................................................................................................................

Inspection after Disassembly ...................................................................................................

Reassembly (E3000 - EC4000) ...............................................................................................................

(E4000 - E6500) ..................................................................................................................

Wheel Cylinders Disassembly .............................................................................................................................

Inspection after Disassembly ...................................................................................................

Reassembly..............................................................................................................................

Inspection and Adjustment.......................................................................................................

ii

5.4 5.5 5.7 5.8 5.9 5.12 5.13 5.13 5.14

99759-8B110

TABLE OF CONTENTS Chapter 6: Steering System Steering System Description ...................................................................................................................................

Steering System ......................................................................................................................

Oil Flow Sequence ..............................................................................................................

General Information.............................................................................................................

6.1 6.1 6.1 6.1

Steering Gear Steering Wheel Removal ................................................................................................................................... 6.2 Installation ................................................................................................................................ 6.2 Steering Gear............................................................................................................................... 6.3 Inspection after Removal ............................................................................................................. 6.4 Disassembly .................................................................................................................................

Working Rules and Tips ...........................................................................................................

Suggestions .............................................................................................................................

Inspection after Disassembly ...................................................................................................

6.5 6.6 6.6 6.6

Reassembly.................................................................................................................................. 6.7 Steer Pump Removal ....................................................................................................................................... 6.8 Installation .................................................................................................................................... 6.9 Disassembly .................................................................................................................................

Sequence .................................................................................................................................

Working Rules and Tips ...........................................................................................................

Suggestions .............................................................................................................................

Inspection after Disassembly ...................................................................................................

6.10 6.10 6.11 6.11 6.13

Reassembly..................................................................................................................................

Sequence .................................................................................................................................

Suggestions .............................................................................................................................

Inspection after Reassembly....................................................................................................

6.14 6.14 6.15 6.17

Chapter 7: Hydraulic System Hydraulic System Description ...................................................................................................................................

Schematics ..............................................................................................................................

Hydraulic Tank..........................................................................................................................

Hydraulic Pump .......................................................................................................................

Control Valve ............................................................................................................................

Lift and Tilt Cylinders................................................................................................................

Down Safety Valve ...................................................................................................................

7.1 7.1 7.5 7.6 7.8 7.9 7.10

Removal and Installation Warning................................................................................................ 7.11

99759-8B110

iii

TABLE OF CONTENTS Hydraulic Pump Removal ....................................................................................................................................... 7.12 Installation .................................................................................................................................... 7.13 Disassembly ................................................................................................................................. 7.14 Working Rules and Tips ........................................................................................................... 7.14 Suggestions ............................................................................................................................. 7.16 Inspection after Disassembly .......................................................................................................

Body .........................................................................................................................................

Mounting Flange Face .............................................................................................................

Bushes and Balance Plate.......................................................................................................

Gears .......................................................................................................................................

7.18 7.18 7.18 7.18 7.18

Reassembly.................................................................................................................................. 7.19 Inspection after Reassembly........................................................................................................ 7.23 Control Valve Removal ....................................................................................................................................... 7.24 Installation .................................................................................................................................... 7.25 Disassembly ................................................................................................................................. 7.26 Suggestions ................................................................................................................................. 7.27 Reassembly.................................................................................................................................. 7.27 Lift and Tilt Cylinders Removal Lift Cylinders ............................................................................................................................ 7.28 Tilt Cylinders ............................................................................................................................ 7.31 Disassembly Lift Cylinders ............................................................................................................................ 7.33 Tilt Cylinders ............................................................................................................................ 7.34 Inspection after Disassembly ................................................................................................... 7.35 Precautions for Reassembly ........................................................................................................ 7.35 Inspection and Adjustment Hydraulic Tank.............................................................................................................................. 7.36 Control Valve ................................................................................................................................ 7.37 Lift and Tilt Cylinders.................................................................................................................... 7.40 Adjusting Method ..................................................................................................................... 7.41 Testing ...................................................................................................................................... 7.42

Chapter 8: Mast and Forks Description ................................................................................................................................... 8.1 Removal and Installation.............................................................................................................. 8.2

iv

99759-8B110

TABLE OF CONTENTS Disassembly ................................................................................................................................ 8.4 Inspection after Disassembly ....................................................................................................... 8.6 Reassembly.................................................................................................................................. 8.7 Inspection and Adjustment...........................................................................................................

Forks ........................................................................................................................................

Chain Tension Adjustment .......................................................................................................

Clearance Adjustment on Lift Bracket......................................................................................

Mast Clearance Adjustment .....................................................................................................

Main Roller Shim Replacement ...............................................................................................

Mast Strip Adjustment..............................................................................................................

Tilt Angle Adjustment ...............................................................................................................

Lift Cylinder Stroke Adjustment................................................................................................

Bleeding Lift Cylinders .............................................................................................................

8.8 8.8 8.9 8.10 8.13 8.15 8.15 8.16 8.17 8.17

Service Data ................................................................................................................................ 8.18 Troubleshooting ............................................................................................................................ 8.20

Chapter 9: Troubleshooting Front Axle and Reduction Differential .......................................................................................... 9.1 Brake System ............................................................................................................................... 9.2 Steering System........................................................................................................................... 9.4 Hydraulic System ......................................................................................................................... 9.6 Rear Axle ..................................................................................................................................... 9.8 Mast and Forks ............................................................................................................................ 9.9

Chapter 10: Maintenance Service Data Maintenance Service Data...........................................................................................................

Front Axle and Reduction Differential ......................................................................................

Transfer Case ...........................................................................................................................

Rear Axle .................................................................................................................................

Brake System ...........................................................................................................................

Steering System,......................................................................................................................

Hydraulic System .....................................................................................................................

Mast and Forks (Simplex Mast) ...............................................................................................

Mast and Forks ........................................................................................................................

10.1 10.1 10.3 10.4 10.6 10.11 10.13 10.16 10.17

Tightening Torques for Standard Bolts and Nuts .........................................................................

Fine Thread—With Spring Washer ..........................................................................................

Fine Thread—Without Spring Washer .....................................................................................

Coarse Thread—With Spring Washer......................................................................................

Coarse Thread—With Spring Washer......................................................................................

10.18 10.18 10.18 10.18 10.18

Tightening Torques for Standard Bolts and Nuts with Standard Threads .................................... 10.19 Coarse Thread—Inches ........................................................................................................... 10.19 99759-8B110

v

TABLE OF CONTENTS Tightening Torques for Taperlock Studs ....................................................................................... 10.19 Coarse Thread—Inches ........................................................................................................... 10.19 Maintenance Chart....................................................................................................................... 10.20 Planned Replacement Parts ........................................................................................................ 10.26 Lubrication Information.................................................................................................................

Chart ........................................................................................................................................

Fuel and Lubricant Specifications ............................................................................................

Recommended Brands of Lubricants.......................................................................................

10.27 10.27 10.28 10.28

Weight of Major Components (Approximate) ............................................................................... 10.29 Special Service Tools ................................................................................................................... 10.30 Special Tool Illustrations........................................................................................................... 10.31 Inspection Guide .......................................................................................................................... 10.34

vi

99759-8B110

TABLE OF CONTENTS Chapter 1: General Information Scope ........................................................................................................................................... 1.1 Truck Models Covered ................................................................................................................. 1.1 Nameplate and Serial Number Locations .................................................................................... 1.2 Dimensions................................................................................................................................... 1.3 Dimensions Chart .................................................................................................................... 1.4 General Information (Standard Models)....................................................................................... 1.5

TABLE OF CONTENTS Chapter 1: General Information Scope ........................................................................................................................................... 1.1 Truck Models Covered ................................................................................................................. 1.1 Nameplate and Serial Number Locations .................................................................................... 1.2 Dimensions................................................................................................................................... 1.3 Dimensions Chart .................................................................................................................... 1.4 General Information (Standard Models)....................................................................................... 1.5

NOTES

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GENERAL INFORMATION

Scope This service manual deals with all components or systems of the Cat lift trucks, except for the electrical system, which is covered in a separate manual.

8609141A

Truck Models Covered This service manual furnishes service and maintenance information for the following trucks.

Truck Model

Serial Number

E3000, E3500, EC4000

A4EC1-10200-up A4EC1-20200-up A4EC1-30200-up A4EC2-10200-up A4EC2-20200-up A4EC3-20200-up A4EC3-30200-up A4EC3-40200-up A4EC4-10200-up

E4000, E5000 EX5000, E5500, E6000

E6500

99759-8B110

1.1

GENERAL INFORMATION

Nameplate and Serial Number Locations

Mast serial number

Chassis serial number Power steering motor serial number

Traction motor serial number Hydraulic motor serial number

Nameplate 8609141

1.2

99759-8B110

GENERAL INFORMATION

Dimensions

8609142

8609143

99759-8B110

1.3

GENERAL INFORMATION

Dimensions Chart Ref#

Truck Model

E3000, E3500

EC4000

E4000, E5000

EX5000

E5500

E6000

E6500

3320 (130)

3320 (130)

3340 (131)

3340 (131)

3340 (131)

3310 (130)

3045 (119)

A

Maximum Lift

B

Free Lift

115 (4.5)

115 (4.5)

130 (5.1)

130 (5.1)

130 (5.1)

135 (5.3)

135 (5.3)

C

Maximum Fork Spacing (outside to outside)

818 (32.0)

818 (32.0)

818 (32.0)

818 (32.0)

818 (32.0)

818 (32.0)

818 (32.0)

D

Fork Length

1070 (42)

1070 (42)

1070 (42)

1070 (42)

1070 (42)

1070 (42)

1070 (42)

E

Tilt Angle (forward/backward)

5°/6°

5°/6°

5°/6°

5°/6°

5°/6°

5°/6°

5°/6°

F

Overall Length

3050 (120)

3125 (123)

3155 (124)

3255 (128)

3255 (128)

3325 (131)

3325 (131)

G

Overall Width (outside of tires)

945 (37)

970 (38)

1055 (41.5)

1055 (41.5)

1103 (43.5)

1103 (43.5)

1103 (43.5)

H

Overall Height (to top of mast, lowered)

2105 (83)

2105 (83)

2110 (83.5)

2110 (83.5)

2110 (83.5)

2110 (83.5)

2110 (83.5)

I

Overall Height (to top of overhead guard)

2180 (86)

2180 (86)

2210 (87)

2210 (87)

2210 (87)

2210 (87)

2210 (87)

J

Overall Height (to top of mast, extended)

4570 (180)

4570 (180)

4570 (180)

4570 (180)

4570 (180)

4550 (179)

4550 (179)

K

Tread (front)

793 (31)

818 (32)

875 (34.5)

875 (34.5)

900 (35.5)

900 (35.5)

900 (35.5)

L

Tread (rear)

826 (32.5)

826 (32.5)

900 (35.5)

900 (35.5)

900 (35.5)

900 (35.5)

900 (35.5)

M

Wheelbase

1170 (46)

1170 (46)

1280 (50.5)

1380 (54.5)

1380 (54.5)

1380 (54.5)

1380 (54.5)

N

Front Overhang

376 (14.8)

376 (14.8)

394 (15.5)

394 (15.5)

394 (15.5)

406 (16)

406 (16)

O

Rear Overhang

434 (17.2)

509 (20.2)

411 (16)

411 (16)

411 (16)

469 (18.5)

469 (18.5)

P

Underclearance (at center of wheelbase)

118 (4.6)

118 (4.6)

124 (4.9)

124 (4.9)

124 (4.9)

124 (4.9)

124 (4.9)

Unit: mm (in.)

1.4

99759-8B110

GENERAL INFORMATION

General Information (Standard Models) Truck Model Units

E3000

E3500

EC4000

meters

3.3

3.3

3.3

3.3

3.3

3.3

3.3

3.3

3.3

2095

2335

2595

2685

2870

2695

2865

3335

3530

(4620)

(5140)

(5720)

(5920)

(6330)

(5940)

(6320)

(7353)

(7770)

3295

3535

3795

4285

4420

4495

4665

5135

5330

(7270)

(7790)

(8370)

(9470)

(9880)

(9940)

(10320)

(11353)

(11770)

Standard Controller Standard Simplex Mast Size Battery

(standard axle)

With Max.

kg (lb)

Work Performance

Battery

Traveling Performance

E5500

E6000

E6500

kg/mm

1350/600 1600/600

Load Center

(lb/in.)

(3000/24) (3500/24) (4000/24) (4000/24) (5000/24) (5500/24) (5000/24) (6000/24) (6500/24)

Maximum Fork Height Lift Speed (Rated Load)

mm (in.)

1800/600 1800/600

33235 (131)

2275/600 2275/600 2500/600

3340 (131)

2725/600 2950/600

3315 (131) 3345 (131)

36V

m/sec.

.38 (75)

.36 (71)

.34 (67)

.32 (63)

.28 (55)

.25 (49)

.23 (45)

48V

(fph)

.53 (104)

.49 (96)

.47 (93)

.45 (89)

.38 (75)

.36 (71)

.31 (61)

Lowering Speed (rated load)

Free Lift

.50 (98) degrees

5° / 6°

mm (in.)

Travel Speed

36V

km/h

(Without Load)

48V

(mph)

115 (4.5) 18 (11.2)

130 (5.1)

17.3 (10.8)

17.4 (10.8)

135 (5.3) 17.0 (10.6)

17.1 (10.6)

18.2 (11.3)

Minimum Turning

mm

1790

1840

1990

2045

Radius

(in.)

(70.5)

(72.5)

(78.5)

(80.5)

36V

60min.

Output

48V

HP(kW)

Transfer

Type

Gear

Ratio

Reduction

Type

Gear

Ratio

Traction Motor

Power Train

EX5000

Rated Capacity/

Tilt Angle (forward/backward)

Differential

8.3 (6.2) 9.2 (6.8)

12.1 (9.0)

13.7 (10.2)

14.2 (10.6)

17.2 (12.8)

Spur 3.538

3.067 Bevel

4.571

Axle Housing

99759-8B110

E5000

MHI SX Controller

Without Service Weight

E4000

5.0 Banjo

Gear Type/

Gears

Straight Bevel/2

Number

Pinions

Straight Bevel/2

1.5

GENERAL INFORMATION Truck Model

Power Steering System

Units

E3000

E3500

EC4000

Type

E4000

E5000

EX5000

E5500

E6000

E6500

Dynamic Load Sense Inside

83°

83°

54°

56°

Degrees

Turning Angle Outside Steering Wheel Diameter

mm (in.) kgf/cm2 (psi) [kPa]

Cylinder Minimum Test Pressure

328 (13) 107 (1522) [10,500]

Type

163 (2320) [16,000]

Self-Adjusting Duo-Servo

Inside Drum mm (in.)

Diameter

254

+0 0.13(10.00 +0 0.0051)

Service Brake Brake System

Lining Thickness

mm (in.)

Master mm (in.)

Cylinder ID Wheel Cylinder ID

Traveling System

Park Brake

Lever Operating Effort

6 (0.24) 22.22 (0.8748)

22.22 (0.8748)

Type

1.6

4.87 (0.19)

28.58 (1.1252)

Mechanical, Mounted on Front Wheels kgf (lbf) [N]

25 to 30 (55 to 66) [245 to 295]

Front Wheels

Fixed Type

Rear Wheels

Center Pivot Type

Mounting

Wheel Alignment

Oscillation Angle Camber

3° Degrees 1°

99759-8B110

GENERAL INFORMATION Truck Model Units

E3000

E3500

EC4000

Type Hydraulic Pump

Make Model

Hydraulic System

Valve

E6000

E6500

25 (1.526)

29 (1.77) Husco International 9510 Sectional Valve

Relief

kgf /cm2

Pressure

(psi) [kPa]

AUX

158 (2250) [15513]

Lift Tilt

185 (2630) [18133}

Type

Variable

Regulated liter Flow Rate (cu.in.) / min

Lift Cylinders

E5500

Parker Hydraulics, Inc. 25R029

Model

Flow Regulator

EX5000

Casappa KP20–24.5

Make

Interval

E5000

Gear

Displacement cc (cu in.)

Control Valve

E4000

ID

45 (2746)

60 (3661)

68 (4150)

45 (1.77)

50 (1.97)

55 (2.17)

63 (2.48)

70 (2.75)

80 (3.15)

8 (4.8)

24 (6.3)

30 (7.9)

mm (in.)

Tilt Cylinders

ID

Hydraulic Tank Capacity liter (Approx)

1 (US gal.)

Mast and Forks

Mast Mast Dimensions (Flange Inside Width x THK x WEB THK) Main Rollers

Roller type CL 100 x 42 x 11 (3.94 x 0.59 x 0.47)

Outer mm (in.)

100 x 60 x 10 (3.94 x 0.67 x 0.47)

Inner Type

Side Rollers

mm (in.)

mm (in.)

115 x 30 (3.94 x 1.18)

42 x 36 (1.65 x 1.42)

1070x100x35 (36x4x1.3) 240 / 818 (9.4/32)

BL634

BL834

1070 x100 x40 (42 x 3.9 x 1.6)

1070 x 125 x 45 (42 x 5 x 1.8)

240 / 920

285 / 960

min/max

Voltage

36/48

Amp Hours (6 hr. rate)

Battery

115 x 30 (4.53 x 1.58)

BL534

Forks (Lgth x Wdth x Thk)

Compartment

Height-Center

Dimensions

Height-Edges

99759-8B110

#6309 Ball Bearing

Lubricating type needle roller bearing

Lift Chains

Weight (Min/Max)

100 x 27 (3.94 x 1.18)

Type Diameter x Width

115 x 45 x 11 (4.53 x 0.83 x 0.51)

#6308 Ball Bearing

Diameter x Width

Fork Spacing (out to out)

115 x 46 x 12 4.53 x 0.79 x 0.51)

36/48

36/48

36/48

36/48

36V

900

1400

48V

700

1100

36/48

598 (23.6) 589 (23.2)

mm (in.)

Length

705 (27.8)

Width

903 (35.5) kg (lb)

750/1200 (1650/2650)

772 (30.4)

872 (34.3) 1000 (39.4)

1000/1600 1315/1600 (2200/3550) (2900/3550)

1400/1800 (3100/4000)

1.7

NOTES

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TABLE OF CONTENTS Chapter 2: Front Axle & Reduction Differential Front Axle Description ................................................................................................................................... 2.1 General Information ................................................................................................................. 2.1 Removal .......................................................................................................................................

Front Wheels ............................................................................................................................

Method 1..............................................................................................................................

Method 2..............................................................................................................................

Method 3..............................................................................................................................

2.2 2.2 2.3 2.3 2.3

Installation .................................................................................................................................... 2.4 Disassembly ................................................................................................................................. 2.5 Removing Front Wheel Hub ..................................................................................................... 2.6 Inspection after Disassembly ....................................................................................................... 2.7 Reassembly..................................................................................................................................

Axle Housing ............................................................................................................................

Front Wheel Hub ......................................................................................................................

Hub Bearing Preload................................................................................................................

Installation and Setting Preload...........................................................................................

2.8 2.8 2.8 2.10 2.10

Reduction Differential Description ................................................................................................................................... 2.11 Disassembly ................................................................................................................................. 2.12 Inspection after Disassembly ....................................................................................................... 2.13 Reduction Gear ........................................................................................................................ 2.13 Differential ................................................................................................................................ 2.13 Reassembly.................................................................................................................................. 2.14 Inspection and Adjustment...........................................................................................................

Side Bearing Preload ...............................................................................................................

Reduction Gear Backlash ........................................................................................................

Reduction Gear Face Runout ..................................................................................................

Tooth Contact ...........................................................................................................................

Tooth Contact Adjustment ........................................................................................................

Transfer Assembly....................................................................................................................

Front Axle .................................................................................................................................

2.16 2.16 2.16 2.17 2.17 2.18 2.21 2.23

NOTES

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FRONT AXLE & REDUCTION DIFFERENTIAL

Front Axle Description

6

8

5 7

4

1

3 2

203658

1. Front wheel hub

5. Reduction pinion

2. Frame support

6. Reduction gear

3. Axle shaft

7. Differential case

4. Axle housing

8. Differential carrier

General Information The frame supports hold the front axle housing in such a manner as to allow a limited amount of rotary motion of the housing, the rotary sliding surfaces being lubricated with grease.

The cushion tire is press-fitted to the outer ring of the wheel hub.

99759-8B110

2.1

FRONT AXLE & REDUCTION DIFFERENTIAL

Removal Front Wheels

Suggestions

!

WARNING

Be sure to use the same size and brand tire for replacement.

1. Park the truck on level floor with the parking brake applied, the direction lever in neutral, the forks lowered, and the key switch off.

2. Prepare tools, jacks, and wheel blocks.

3. Block the rear wheels.

4. Loosen the wheel nuts about two turns.

Removal Sequence 2 Wheel nut

1 205952

100902B

1. Wheel Nuts

NOTE

2. Front Wheel

Loosen, but do not remove, the wheel nuts.

5. Raise the front end of the truck. Use one of the methods shown.

!

WARNING

To prevent possible injury, do not replace the tire when the truck is loaded.

Dismount the truck before raising the front tire.

To prevent possible personal injury, raise the truck only until the tire just clears the ground.

Do not put any portion of your body under the truck. Securely support the truck on blocks after raising it.

2.2

99759-8B110

FRONT AXLE & REDUCTION DIFFERENTIAL Method 1

Method 3

Position the jack under the frame and raise the truck until the tire clears the floor.

Fasten a hoist to the mast and lift the front end of the truck as shown.

100828

Jack Capacities

202778A

6. Remove the wheel nuts (loosened in Step 4.)

E3000 - EC4000

3000 kgf (6700 lbf)

E4000 - E6500

5000 kgf (12,000 lbf)

!

CAUTION

Be careful not to damage the bolt threads when removing the wheel.

Method 2 Tilt the mast all the way back, place wood blocks under the mast, and tilt the mast forward.

!

7. Remove the wheel.

CAUTION

After raising the front end, securely support it by blocks.

NOTE Service Limit For Cushion Tires Replace the tire if the height of the solid rubber portion is 25.4 mm (1 in. or less). For tire replacement, consult your Cat lift dealer.

200227

25.4 mm (1 inch)

100880

99759-8B110

2.3

FRONT AXLE & REDUCTION DIFFERENTIAL

Installation To install, reverse the removal sequence and do the following steps.

!

2. Lower the truck until the tire touches the floor. Then tighten the wheel nuts in numbered sequence shown below, in two or three steps, to the specified torque.

CAUTION 1

Use the same size and brand of tire.

6 3

Make sure the clamping surfaces of the wheel nuts and counterbores in the rim are free of dirt.

4 5

1. Install the tire and tighten the wheel nuts.

Tighten each nut until its tapered portion is in full-face contact with the counterbore in the rim.

2 205953

Tightening Torque For Wheel Nuts Wheel Nut Counterbore

E3000 - EC4000

E4000 - E6500

16 kgf•m

38.5 kgf•m

(116 lbf•ft)

(278 lbf•ft)

[157 N•m]

[378 N•m]

100835A

2.4

99759-8B110

FRONT AXLE & REDUCTION DIFFERENTIAL

Disassembly 6

7

1

2

3

4

5

205954

Sequence 1. Axle shaft 2. Lock nut, lock washer, oil seal, and tapered roller bearing (inner bearing) 3. Hub & drum assembly [Front wheel hub, brake drum, wheel bolts, drum nuts, and tapered roller bearing (outer bearing)]

4. Tapered roller bearing (outer bearing), oil seal, and oil deflector 5. Tapered roller bearing (inner bearing), and seal retainer 6. Brake assembly 7. Frame support and axle housing

Start By: 1. Remove the mast. (For replacement of the front axle housing and disassembly of the differential, refer to section, MAST AND FORKS.)

3. Support the front end of the truck at both sides with blocks or stands to keep the truck in a horizontal position.

2. Jack up the truck.

4. Remove the front wheels.

NOTE It is not necessary to remove the axle housing or drain the oil for removal of the shaft only.

99759-8B110

2.5

FRONT AXLE & REDUCTION DIFFERENTIAL Suggestions

Removing Front Wheel Hub

Removing the Lock Nut

Use a wheel hub puller (Special Tool).

Use a lock nut wrench (Special Tool).

Tool Lock Nut Wrench

Tool

E3000 - EC4000 E4000 - E6500 91268-00800

03703-59001

E3000 - EC4000

Wheel Hub Puller 64309-40100 (Puller seat) (64309-10601)

E4000 - E6500 MH061017

NOTE It is not necessary to remove the oil seal from the hub or to disassemble the oil deflector unless the seal is defective.

Special Tool

Any wear or grooves in oil seal deflector would require replacement.

200232

It has been standard practice to replace the oil seal every time the hub is removed to reduce the possibility of oil leaks.

Special Tool

200233

Removing Bearings The inner race of the tapered roller bearing remains in the axle housing when the hub is drawn out. Remove this race together with the seal retainer with a bearing puller.

203651

2.6

99759-8B110

FRONT AXLE & REDUCTION DIFFERENTIAL

Inspection after Disassembly Axle Shafts Looseness of Mating Splines

Runout

Mount the differential bevel gear on the splined end of the shaft and set a dial indicator as shown below. Turn the bevel gear and read the indicator.

Set a dial indicator at the middle part of the axle shaft. Turn the shaft and read the indicator to find runout.

Runout of shaft

200235

Free movement (looseness of splines)

A

0.07 to 0.17 (0.0028 to 0.0067)

B

0.5 (0.020)

Unit: mm (in.)

A = Assembly Standard B = Repair or Service Limit

Axle Housing 1. Check the surfaces of axle housing in contact with the mast bearing for damage.

2. Check the entire axle housing for distortion, dents, and other defects, paying particular attention to the welds to see if any weld is cracked.

Oil Seals and Retainers 1. Check the outer surface of the oil seal retainer for wear or damage.

Face runout of flange

200236

E3000 -EC4000

Runout of axle shaft (1/2 of dial indicator reading

E4000 E6500

A

0.5 (0.020) maximum

1.0 (0.039) maximum

B

1.0 (0.039)

2.0 (0.079)

Unit: mm (in.)

A = Assembly Standard B = Repair or Service Limit

Set a dial indicator against the flange of the axle shaft as shown. Turn the shaft and read the indicator to find face runout.

Face runout of axle shaft flange

A

0.05 (0.0020)

B

0.5 (0.020)

Unit: mm (in.)

A = Assembly Standard B = Repair or Service Limit

2. Check the outer and inner oil seals for wear and damage.

99759-8B110

2.7

FRONT AXLE & REDUCTION DIFFERENTIAL

Reassembly

Front Wheel Hub

To reassemble, reverse the steps of the disassembly sequence and do the following steps.

1. Fill the front wheel hub, especially the roller holder and oil seal lip groove, with grease.

Pack both bearings with grease.

Axle Housing 1. Install the O-ring in the outer groove (of the two grooves in the bore of each frame support).

2. Apply grease to the surfaces A of the support and axle housing.

O-ring

Frame support A

205954a

NOTE

200237

Be careful not to apply grease to the brake drum.

Check for excessive movement between frame support and axle housing.

200238

2.8

99759-8B110

FRONT AXLE & REDUCTION DIFFERENTIAL 2. Install the inner race and oil seal retainer of the wheel hub bearing with an installer (Special Tool).

Special tool

203569

Tool Installer

E3000 - EC4000 64309-12300

E4000E6500 91468-00300

3. Apply retaining compound to the flange surfaces of the axle shafts.

99759-8B110

2.9

FRONT AXLE & REDUCTION DIFFERENTIAL Hub Bearing Preload

Installation and Setting Preload

Tighten the inner nut to produce the required preload. Tighten the outer nut to the specified torque and check the preload. Be sure that the preload noted after tightening the outer nut still meets the specification. This step is for new bearings. Where the bearings removed in disassembly are reused, try to produce the preload at the lower side of the range.

1. Fill the hub with the recommended grease as listed in the service manual.

Preload for hub bearing

5 to 50 kgf•cm (0.4 to 3.6 lbf•ft) [0.5 to 4.9 N•m]

Tightening torque for lock nuts

20 kgf•m (145 lbf•ft) [196 N•m]

2. Pack the inner and outer bearing with the recommended grease.

3. Install the inner bearing to the back side of the hub.

4. Install the inner seal.

5. Clean the lining surface of the drum.

6. Install the hub onto the axle.

7. Install the outer bearing, grease seal and preload nut.

8. If the bearings are being reused, try to produce the lower side of the applied force in tangential direction.

9. For new bearings, tighten the preload nut to 14 kgf•m (101 lbf•ft) [137 N•m]. Slowly rotate the hub slightly more than 3 turns, back the nut off 80°, and set the applied force in tangential direction.

Inner nut

Outer nut

200468

10. For models with an outer lock nut, torque the nut to 20 kgf•cm (145 lbf•ft) [196 N•m]. After torquing the lock nut, check the force applied in tangential direction again to insure the preload did not change.

Bar

Spring balancer

101653

2.10

99759-8B110

FRONT AXLE & REDUCTION DIFFERENTIAL

Reduction Differential Description 3

4

5 2

1 200240

Sequence 1. Lock plates 2. Side bearing nuts 3. Differential carrier assembly (lock washers, side bearing caps, and differential carrier)

4. Reduction gear and differential gear assembly (spring pins, pinion shafts, differential pinions, differential bevel gear, washers, and differential case) 5. Tapered roller bearings

Start By: 1. Remove the differential carrier from the transmission case.

2. Check the pattern of gears at time of removal.

This step is important when assembly has been completed and checking pattern of gears to match.

99759-8B110

2.11

FRONT AXLE & REDUCTION DIFFERENTIAL

Disassembly Suggestions

Removing Bearing Inner Races

1. Before removing the differential carrier from the transmission case, measure the gear backlash to aid in obtaining correct backlash at the time of reassembly.

Use a bearing puller to remove the inner races from the differential case.

Backlash between reduction gear 0.15 to 0.25 and pinion (0.0059 to 0.0098) Unit: mm (in.)

200242

200247

2. Put a mark across the bearing cap, adjusting screw and carrier on each side.

The caps are not interchangeable.

200241

2.12

99759-8B110

FRONT AXLE & REDUCTION DIFFERENTIAL

Inspection after Disassembly Reduction Gear

Differential

Check the teeth for wear, pitting, flaking, or chipping. Minor flaws on the tooth surface can be repaired by grinding with an oil stone or a hand grinder. Check the teeth for contact. If the gear is badly damaged and requires replacement, replace the pinion too. Reduction gear and pinion are a matched set and must be changed at the same time.

1. Check the differential cases for damage.

Check in particular the seat formed of each case for carrying the side bearing inner race to see whether the seat surface is galled or not.

2. Check the sliding surfaces of the thrust washers and gears for wear or damage.

3. Check the teeth of the differential pinions and bevel gears for wear, pitting, chipping, or galling.

4. Check the fit of each pinion on the spider.

Fit of differential pinions on spider

A

0.02 to 0.07 (0.0008 to 0.0028)

B

0.35 (0.0138)

Unit: mm (in.)

A = Assembly Standard B = Repair or service limit

99759-8B110

2.13

FRONT AXLE & REDUCTION DIFFERENTIAL

Reassembly 4

1

5

3

2

200243

Sequence 1. Tapered roller bearings

3. Spring pin

2. Differential gear assembly [differential case, thrust washers, bevel gears, pinions, and pinion shaft]

4. Reduction gear

2.14

5. Differential carrier assembly [carrier, side bearing caps, side bearing nuts, and lock washers]

99759-8B110

FRONT AXLE & REDUCTION DIFFERENTIAL Suggestions Reassembling Differential Pinions

Reassembling Differential Case

The thrust washers of the differential gears are to be used for adjusting the backlash between the differential gears and pinions. Measure the backlash and, if it exceeds the limit, replace the thrust washers.

After putting the case assembly in place on the carrier, install the bearing caps tentatively by making the cap bolts snug tight. The caps are to be secured tight after the bearing preload has been adjusted.

Backlash between differential gears and pinions

A

0.18 to 0.23 (0.0071 to 0.0091)

B

0.5 (0.020)

Unit: mm (in.)

A = Assembly Standard B = Repair or service limit

Installing Bearing Caps Be sure to know which are the left and right caps and to put each cap in place correctly.

Tightening torque for bearing cap bolts

12.8 kgf•m (93 lbf•ft) [126 N•m]

200244 200241

Installing Reduction Gear Apply LOCTITE No. 271 to the bolts for holding the reduction gear to the case. Be sure to tighten these bolts evenly so as not to strain the gear.

Tightening torque for reduction gear bolts

99759-8B110

12.0 kgf•m (87 lbf•ft) [118 N•m]

2.15

FRONT AXLE & REDUCTION DIFFERENTIAL

Inspection and Adjustment Side Bearing Preload

Reduction Gear Backlash

Tie a wire on the reduction gear tooth and hook a spring scale to the wire. Tighten the side bearing nuts while reading the spring scale until the specified preload is obtained.

Adjust the backlash between the reduction gear and pinion after installing the differential carrier assembly to the transmission case. To measure the backlash, set a dial indicator with its spindle pointing squarely to the tooth face of the reduction gear. With the pinion held, move the gear back and forth to read the indicator. Adjust the backlash using the left and right side bearing nuts and pinion shims.

NOTE Before measuring the preload, tap the back of the reduction gear with a copper hammer while rotating the gear to center between bearing.

Preload for differential case side bearings

Min.

15 to 30 kgf (1.1 to 2.2 lbf) [1.5 to 2.9 N]

Max.

1.32 to 2.5 kgf•cm (2.9 to 5.5 lbf•ft) [13 to 25 N•m]

Backlash between reduction gear and pinion

0.15 to 0.25 (0.0059 to 0.0098) Unit: mm (in.)

As force applied to reduction gear in tangential direction.

200247

Backlash Increase Decrease Decrease

200246

Increase Increase Backlash

Decrease 200248

2.16

99759-8B110

FRONT AXLE & REDUCTION DIFFERENTIAL Reduction Gear Face Runout

Tooth Contact

Using a dial indicator, check the reduction gear for face runout at the maximum radius position in back of the gear. If the runout exceeds the limit, check the reduction gear bolts for tightness; retighten if necessary. Check the tapered roller bearings for condition. Readjust or replace them if necessary.

Check the gear reduction tooth contact. To check, apply a thin coat of bluing to several gear teeth on both drive and coast sides. Press forward on the reduction pinion and rotate the reduction gear back and forth until a contact pattern is noted on both concave and convex faces of the gear teeth.

To adjust the tooth contact, refer to the chart.

Face runout of reduction gear

A

0.05 (0.0020) maximum

B

0.05 (0.0020) maximum

Unit: mm (in.)

A = Assembly Standard B = Repair or Service Limit

200250

200249

99759-8B110

2.17

FRONT AXLE & REDUCTION DIFFERENTIAL Tooth Contact Adjustment (E3000 - EC4000) Tooth Contact

Adjustment

Extends from toe to middle portion, covering not less than 50% of tooth length.

1

Correct tooth contact

203669-1

1. Move gear away from pinion.

Short contact at toe of tooth.

2. Move pinion toward gear by increasing shim thickness to secure correct backlash.

2 203669-2A

203669-2

1. Move gear toward pinion.

Short contact at heel of tooth.

2. Move pinion away from gear by decreasing shim thickness to secure correct backlash.

3 203669-3A

203669-3

1. Move pinion toward gear by increasing shim thickness.

Heavy contact on face or upper portion of tooth.

4

2. Move gear away from pinion to secure correct backlash.

203670-4A

203669-4

1. Move pinion away from gear by decreasing shim thickness.

Heavy contact on flank or lower portion of tooth.

5 203669-5

2. Move gear toward pinion to secure correct backlash.

203670-5A

Repeat the above adjustment until the correct tooth contact is obtained.

2.18

99759-8B110

FRONT AXLE & REDUCTION DIFFERENTIAL Tooth Contact Adjustment (E4000 - E6500) Tooth Contact

Adjustment

Extends from toe to middle portion, covering not less than 50% of tooth length.

1

Correct tooth contact

203670-1

1. Move pinion toward gear by increasing shim thickness.

Short contact at toe of tooth.

2. Move gear away from pinion to secure correct backlash.

2 203670-2A

203670-2

1. Move pinion away from gear by decreasing shim thickness.

Short contact at heel of tooth.

2. Move gear toward pinion to secure correct backlash.

3 203670-3A

203670-3

1. Move pinion toward gear by increasing shim thickness.

Heavy contact on face or upper portion of tooth.

4

2. Move gear away from pinion to secure correct backlash.

203670-4A

203670-4

1. Move pinion away from gear by decreasing shim thickness.

Heavy contact on flank or lower portion of tooth.

5 203670-5

2. Move gear toward pinion to secure correct backlash.

203670-5A

Repeat the above adjustment until the correct tooth contact is obtained.

99759-8B110

2.19

NOTES

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TRANSFER ASSEMBLY

FRONT AXLE ASSEMBLY

TABLE OF CONTENTS Chapter 3: Transfer Assembly Description ................................................................................................................................... 3.1 Disassembly ................................................................................................................................. 3.2 Disassembly Sequence................................................................................................................ 3.2 Inspection after Disassembly ....................................................................................................... 3.4 Reassembly.................................................................................................................................. 3.5

NOTES

____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________

TRANSFER ASSEMBLY

Front axle center

Description 1

8

2

3

8

Traction motor

6

7 5

9

4

6

209002

Main component 1 2 3 4 5

Transfer case Transfer cover Input gear (13T) Output gear (48T) Bevel gear set

6 7 8 9

Taper roller bearing Lock nut Ball bearing Plug (standard) or pulse generator (option)

The transfer assemblies of all the 1 ton, 2 ton, and 3 ton class trucks share completely identical components except the different bevel gear sets as shown below.

No. of teeth on bevel pinion

No. of teeth on bevel gear

1 ton class trucks

7

32

2 and 3 ton class trucks

7

35

99759-8B110

3.1

TRANSFER ASSEMBLY

Disassembly Start by: (1) Remove the drain plug on the front axle housing to let the oil drain out.

(3) Remove the traction motor, reduction and differential assembly and transfer assembly as one unit, from the front axle housing.

(2) Disconnect the connectors of the traction motor harnesses and pulse generator harness.

(4) Separate the three assemblies removed in step (3) from each other.

3

Liquid gasket

15

2

1

18

14 17 Plug (standard) or Pluse generator (option)

16

Staked 7

5

4 6

8

9 13

11

10

12 209002A

Disassembly sequence 1 Bolt 2 Transfer cover 3 Side cover with pulse generator, or plug 4 Nut 5 Shim Remove parts 6 and 8 as a unit.

6 Bevel pinion shaft 7 Shim 8 Bearing cone 9 Bearing cone

3.2

10 Output gear 11 Spacer 12 Bearing cup 13 Bearing cup 14 Snap ring Remove parts 15 to 17 as a unit.

15 Input gear 16 Ball bearing 17 Ball bearing 18 Transfer case

99759-8B110

TRANSFER ASSEMBLY Suggestions for Disassembly 1. Remove the bevel pinion shaft 6 as follows: (1) Using a chisel, cut the staked portion of the nut 4, taking care not to damage the bevel pinion shaft.

(2) Hold the input gear 15 with the special tool to prevent the bevel pinion 6 from rotating, then remove the nut 4 and shims 5.

Shaft locking bar fixing bolt

15

Shaft locking bar Special tool

18

6 Staked

Special tool needed Transfer bearing tool

97E67 - 00100

(3) Using the bevel pinion puller (special tool), pull the bevel pinion 6 out of the bearing cone 9 (See the drawing on the right).

4 5 9 8

13

10

12 209003

Special tool needed Bevel pinion puller

91268 - 00300

(4) If the bearing cone 8 needs to be removed, use a bearing puller and a press to pull it from the bevel pinion 6.

(5) If the bearing cups 12 and 13 need to be removed, use a bearing cup puller to pull them out of the transfer case 18.

205829

NOTE (1) The taper roller bearing cup and cone are an exclusive pair. If either the cup or cone of a pair is faulty, replace them as a set.

(2) The removed shims should be kept together until they are reinstalled.

(This only applies when the bevel pinion and/or taper roller bearing are/is reused.)

205830

(3) The bevel pinion and bevel gear are an exclusive pair. If either of them is defective, replace them as a set.

99759-8B110

3.3

TRANSFER ASSEMBLY 2. Remove the input gear as follows: (1) Remove the snap ring 14.

(2) Using a sliding hammer, pull the input gear 15, complete with the ball bearings out of the case 18.

(3) If the ball bearings 16 and 17 need to be removed, use a puller to pull them out.

Do not attempt to tap them out.

17

M14 × 1.5 18 Thread

14 15 Rod of sliding hammer

16 209004

Inspection after disassembly (1) Check the output gear 10 and the input gear 15 for damaged/worn teeth and worn splines.

(2) Check the bearings for wear or damage.

Make sure that they rotate freely without making noise.

(3) Check the transfer case for cracks or other damage.

(4) Check the bevel pinion and the bevel gear for incorrect tooth contact, damage and wear.

3.4

99759-8B110

TRANSFER ASSEMBLY

Reassembly Follow the disassembly sequence in reverse.

2

1

4

5 17

3

18

19

16

13 10

Staked

8

14

9 15

6

11

12

7

209002B

Reassembly sequence 1 Transfer case Assemble the parts 2 to 4 first, then install the assembly into the case 1.

2 Input gear 3 Ball bearing 4 Ball bearing 5 Snap ring Press-fit the parts 6 and 7 into the case 1.

6 Bearing cup 7 Bearing cup Assemble the parts 8, 9 and 10.

8 Bevel pinion shaft 9 Shim 10 Bearing cone

99759-8B110

11 12 13 14 15 16 17 18 19

Spacer Output gear Bearing cone Shim Nut Side cover with pulse generator (option) Liquid gasket Transfer cover Bolt

3.5

TRANSFER ASSEMBLY Suggestions for Reassembly

CAUTION

Ball bearings and taper roller bearings can be fitted onto shafts more easily when they are warmed in hot oil. However, do not increase the oil temperature above 120°C (250°F).

Axle center

Mark “b” is indicated here.

!

1. Install the input gear 2 as follows: (1) Press-fit the ball bearings 3 and 4 into the input gear 2. Force the assembly into the transfer case 1.

B

(2) Install the snap ring 5.

A

2. Sub-assemble the bevel pinion shaft 8 as follows:

Mark “a” is indicated here.

(1) Place shim stock 9 and bearing cone 10 on the bevel pinion 8, then install these into place using a press. The thickness C of shims 9 can be calculated using the following equation.

209005

C = 1.8 + a/100 - b (unit: mm) a: Machining error in the differential carrier dimension A b: Machining error in the bevel pinion dimension B The machining error “a” is stamped on the top surface of the differential carrier.

(No stamping is present if the error is within ± 0.05 mm.)

The machining error “b” is marked on the end surface of the bevel pinion using electric marking pen. No mark is present if the error “b” is ± 0.

1.0 mm (0.04 in.) thick shim C

Standard shim stock thickness 1.8 mm (0.071 in.)

209006

NOTE When installing shim stock 9, be sure to locate the 1.0 mm (0.04 in.) thick shim closest to the bevel pinion.

3.6

99759-8B110

TRANSFER ASSEMBLY (2) While inserting the bevel pinion shaft sub-assembly into the case, install the spacer 11, output gear 12, bearing cone 13, and shim stock 14. Reuse the originally installed shim stock 14.

Preload adjustment of taper roller bearing

Attach spring scale hook here to measure the tangential force.

2

Special tool 8

(3) Hold the input gear 2 to prevent the bevel pinion shaft 8 from rotating.

Special tool needed Transfer bearing tool

(4) Install a new nut 15 on the bevel pinion shaft 8. Tighten and loosen the nut several times, each time after rotating the shaft a little, so that the bearing cups and cones settle completely on each other. Finally, tighten the nut to the torque shown below. Do not give the bearings too much preload.

Tightening torque of nut 15

13 12 11 209007

(1) Stake the nut completely against the bottom of the groove on the bevel pinion.

(2) The staked portion should have a flat of φ 4 mm (φ 0.16 in.) or more.

54 to 81 N (5.5 to 8.3 kgf) [12.1 to 18.26 lbf]

(6) Adjust the preload as required by increasing or decreasing the thickness of the shim stock 14. The greater the shim stock thickness, the smaller the preload. The smaller the shim stock thickness, the greater the preload. Repeat the steps (4) and (5) until the specified preload is obtained.

(7) After the specified preload is obtained, lock the nut 15 on the bevel pinion shaft 8 by staking to prevent it from loosening.

(See the drawing shown on the right.)

99759-8B110

15

294 ± 20 N·m (30.0 ± 2.0 kgf·m) [217 ± 14.5 lbf·ft]

(5) With the special tool installed on the input gear 2, measure the preload of the taper roller bearing on the bevel pinion gear shaft 8. The preload is measured in terms of the tangential force required to start the input gear 2 rotating. The measurement should meet the following specified value.

Tangential force required to start input gear 2 rotating

14

97E67 - 00100

Staking tool needed

R

A screwdriver is not appropriate for staking.

R φ 4 to 6 mm (φ 0.16 to 0.24 in.)

209008

3.7

TRANSFER ASSEMBLY 3. Bolts to be tightened to special torques

Supply liquid gasket onto the face of flange.

4 2

3

1 5 209009

Tightening torque

3.8

N·m

kgf·m

lbf·ft

33 ± 2

3.4 ± 0.2

24.6 ± 1.4

1

Cover-to-traction motor

2

Side cover

39.2 ± 3.9

4.0 ± 0.4

29.0 ± 2.9

3

Plug or pulse generator

54.0 ± 4.9

5.5 ± 0.5

39.7 ± 3.6

4

Case-to-cover

39.2 ± 3.9

4.0 ± 0.4

29.0 ± 2.9

5

Lock nut

294 ± 20

30.0 ± 2.0

217 ± 14.5

99759-8B110

TABLE OF CONTENTS Chapter 4: Rear Axle Description ................................................................................................................................... 4.1 Rear Wheels................................................................................................................................. 4.2 Removal ................................................................................................................................... 4.2 Steering Cylinder.......................................................................................................................... 4.3 Installation ................................................................................................................................ 4.4 Rear Axle .....................................................................................................................................

Removal ...................................................................................................................................

Installation ................................................................................................................................

Disassembly .............................................................................................................................

Inspection after Disassembly ...................................................................................................

Reassembly..............................................................................................................................

4.7 4.7 4.8 4.9 4.11 4.12

Inspection and Adjustment........................................................................................................... 4.17 Minimum Turning Radius Adjustment....................................................................................... 4.17

NOTES

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REAR AXLE

Rear Axle Description

3

2 1

5

7 3 6 B

4

8609001

1. Rear axle

5. Tie rods

2. Steering cylinder

6. Wheel rims

3. Steer knuckles

7. Shims

4. King pins

The truck is steered by the rear wheels. The rear axle is connected to the frame by its center pivot shaft. Because of the center pivoting feature, the rear axle can oscillate up to 3° in each direction.

99759-8B110

4.1

REAR AXLE

Rear Wheels Removal

Suggestions

!

CAUTION

Use the same size and brand of tire for replacement.

1. Park the truck on level floor with the parking brake applied, the direction lever in neutral, the forks lowered, and the key switch off.

2. Prepare the tools, parts, jack, and wheel blocks.

Tools Needed: Spring scale, bearing installer, and puller.

Parts Needed: Lock washer 3; oil seal 7; cap 1 (when required); bearings 5, 8, 9, and 10 (when required); wheel assembly 6.

10 7 A

8

6

A 954 3 2

1

3. Cap 1 is press-fitted to the rim. Pry it off using a chisel and hammer as shown. Discard the removed cap. Use a new cap when installing a replacement wheel.

207030

Removal Sequence 1. Cap 2. Outer nut 3. Lock washer 203614

4. Inner nut 5. Inner race bearing

4. Bend down lock washer 3.

6. Wheel assembly

5. Loosen nut 2.

7. Oil seal

6. Raise the wheels.

8. Outer race bearing 9. Outer race bearing

Hoist Capacities E3000/EC4000

10. Inner race bearing E4000/E6500

4.2

3000 kgf (6700 lbf) 5000 kgf (12,000 lbf)

99759-8B110

REAR AXLE

Steering Cylinder *: Parts contained in seal kit 12 * 14 13 * *

17

6

▲

11 *

▲

▲

▲

▲

▲

9 8

16 * ▲

7 ▲

▲

10

▲

▲

•▲

• ▲

5 ▲

3

2

▲

* 15

• 1

▲

4 207168

1 2 3 4 5 6 7 8 9

Cylinder tube Piston rod Cylinder head Cylinder head Pivot joint Snap ring Tie rod Nut Spring washer

10 11 12 13 14 15 16 17

Stopper ring Wiper U-seal O-ring O-ring Guide ring Piston seal Bushing

Double-action cylinder is used.

99759-8B110

4.3

REAR AXLE Suggestions, continued 7. Block the front wheels.

8. Fasten a hoist to the counterweight and lift the rear end of the truck.

9. Place the wood blocks under the side frames to support the truck (with the left and right rear wheels slightly clearing the floor).

Inspection 1. Oil seal Check the oil seal of the rim for excessive wear or damage.

2. Tires Check the height of the solid rubber portion and, if worn down to 25.4 mm (1 in.), replace the tire.

NOTE Replace all tires if one tire is damaged. If new and used tires are mixed, rapid tire wear will result.

Installation

Blocks

100393B

To install, follow the reverse the removal sequence: 1. Using a puller, install bearings (outer) 8 and 9 to the new wheel assembly 6.

2. Install oil seal 7 to the new wheel assembly 6.

10. Remove nut 2, lock washer 3 and nut 4.

11. Remove wheel assembly 6 from the rear axle. Be careful not to cause damage to the oil seal fitted to the rim. After removing the assembly, raise the counterweight to a position 400 to 500 mm (16 to 20 in.) from the floor.

10 7 A

8

12. Using a puller, remove outer race bearings 8 and oil seal 7 from the wheel assembly.

6

A 954 3 2

NOTE

1

207030

Replace the cap and bearings (inner and outer) if defective.

25.4 mm (1 inch)

207029

4.4

99759-8B110

REAR AXLE 3. Fill the rim and oil seal with grease. Do not overfill the oil seal to prevent leakage.

Oil seal ▲

4. Tighten nut 4 to 137 N·m (14 kgf·m) [101 lbf·ft] torque and back it off 80°, then put lock washer 3. Install nut 2, tightening it to 157 N·m (16 kgf·m) [116 lbf·ft] torque. Check the hub bearing preload, making sure it is 2.5 to 6.4 N·m (25 to 65 kgf·cm) [1.8 to 4.7 lbf·ft]. If the preload is correct, bend lock washer 3.

• Fill with grease

207024

5. Check to make sure the preload is correct.

Insert a 24mm round bar into the cast hole of the rim. Attach a spring balance to the round bar, and measure the tangential force.

Tangential force N (kgf) [lbf]

E3000 EC4000

E4000 E6500

33.1 to 86 (3.38 to 8.78) [7.4 to 19.3]

26.7 to 69.6 (2.73 to 7.10) [6.0 to 15.6]

▲

Bar

207025

Tighten the inner nut to achieve the specified value.

Reference value Preload for hub bearings

2.5 to 6.4 N·m (25 to 65 kgf·cm) [1.8 to 4.7 lbf·ft]

Bar

Spring scale

207026

99759-8B110

4.5

REAR AXLE 6. After adjusting the preload, tighten a new lock washer 3 and an outer nut 2 to the specified torque.

Tightening torque for outer (lock) nut

157N·m (16 kgf·m) [116 lbf·ft]

Inside nut ••

Outside nut

207024

7. Bend the lock washer to both sides (inward and outward).

205436

8. Fill the cap with grease, and install the cap 1.

9. Raise the rear end of the truck and remove the blocking from the side frames.

10 Lower the truck until the rear wheels just touch the floor.

4.6

99759-8B110

REAR AXLE

Rear Axle Removal

6 7 6

2

1

5 4 3 203613

Sequence 1. Cap

4. Rim and tire

2. Nut and washer

5. Drag link

3. Bearing

6. Bearing support and bolts

7. Rear axle assembly

Start By: 1. Apply the parking brake and block the front wheels.

2. Raise the rear end of the truck with a jack and place wood blocks under the side frames (with the left and right rear wheels slightly clearing the floor).

3. A hoist can be used instead of the jack to raise the rear end (counterweight).

203622

99759-8B110

4.7

REAR AXLE Suggestions

Installation

Removing Rear Axle Assembly

To install, reverse the removal sequence and do the following steps.

!

WARNING

Be sure the pressure in the hydraulic system is released before any lines or hoses are disconnected.

1. Put identification marks on the hoses, then disconnect them.

2. Support the rear axle at its center with a garage jack.

Adjusting Bearing Support Clearance Adjust the longitudinal clearance to 0.8 mm (0.031 in.) with the thrust washer and tighten the bolts holding the bearing support to the specified torque.

Tightening torque for bearing support bolts

14.8 kgf•m (107 lbf•ft) [145 N•m]

3. Loosen and remove the axle mounting bolts.

Clearance: 0.8 mm (0.031 in.)

200257 203615

Weight of Rear Axle E3000-EC4000

60kg [132 lb]

E4000-E6500

85kg [187 lb]

4.8

99759-8B110

REAR AXLE

Disassembly REAR AXLE ASSEMBLY

17 16

15

14

15

4

2

17 19 13 11 2 10 9

3

8 7 6

18

9 5

10

1

12 207028

Disassembly Disassembly sequence 1 Taper roller bearing (inner), Retainer 2 Tie rod pin, Bolt, Spring washer, Plain washer, Collar, Grease nipple 3 Spherical bushing, Ring, Retainer, Dust seal 4 Tie rod 5 Kingpin plate, Shim 6 Kingpin, O-ring Remove parts 7 through 12 as an assembly.

7 Knuckle 8 O-ring 99759-8B110

9 10 11 12 13 14 15 16 17 18 19

Taper roller bearing Oil seal Cover, Retainer Boot Cover Clamp, Bolt, Spring washer Pipe (L.H., R.H.) Steering cylinder [Bolt, Spring washer, Nut] Elbow, O-ring Stopper bolt, Lock nut Rear axle housing 4.9

REAR AXLE Suggestions Removing Retainer and Bearing

Mark Cylinder End Caps

Use a puller to remove the retainer and inner bearing from the knuckle.

Mark the cylinder end caps for proper alignment before they are disassembled from the cylinder.

Mark

203618

4.10

Mark

8609004

99759-8B110

REAR AXLE

Inspection after Disassembly Tie Rods and Pins

Seals and O-rings

1. Make sure that the pins are free of any surface flaws such as grooving or stepped wear.

Examine the keeper plate weld for cracking.

Examine all seals and O-rings for damage such as cuts and tears. Replace seals which show signs of aging.

2. Examine the bearings for wear or damage.

3. Examine the tie rods for damage and alignment. Inspect the welds for signs of cracks.

NOTE If a pin must be replaced, replace its bearing as well.

Hydraulic Pipes Inspect the hydraulic pipes for cracks, especially at the joints with the end fittings. Check for leaks.

Tires Check the height of the solid rubber portion and, if worn down to 25.4 mm (1 in.), replace the tire.

NOTE

Kingpins Check the kingpins for any surface flaws such as grooving or stepped wear. Inspect the pins for cracks at the bearing shoulder.

Replace all tires even if only one tire is damaged. If new and used tires are mixed, rapid tire wear will result.

Kingpin Bearings Examine the rollers and bearing races for grooving, abrasive wear, pitting, bruising, or corrosion.

Replace both the cup and cone of damaged bearings.

Knuckles Inspect the inside of each knuckle for wear or damage. Be sure to examine for casting cracks.

Check the tie rod pin hole. Examine the wheel nut threads for damage.

25.4 mm (1 inch)

100880

Cylinder Rod Examine the rod for surface or plating damage.

Inspect the rod for straightness. Examine the piston for damage. Check the tie rod pin hole for damage or wear.

99759-8B110

4.11

REAR AXLE

Reassembly 3 2

4

5

4

16

17

3 1 15 11 17 10 9

7

8 6 13

18

9 14

10

19

12 207028

Assembly sequence 1 2 3 4 5 6 7 8 9 10

4.12

Rear axle housing Steering cylinder [bolt, spring washer, nut] Elbow, O-ring Pipe (L.H., R.H.) Clamp, bolt, spring washer Knuckle Spherical bushing, ring, retainer, dust seal O-ring Taper roller bearing Oil seal

11 12 13 14 15 16 17 18 19

Cover, retainer Boot Kingpin, O-ring, bolt, spring washer Kingpin plate, shim, bolt, spring washer Cover Tie rod Tie rod pin, bolt, spring washer, plain washer, collar, grease nipple Stopper bolt, lock nut Retainer, taper roller bearing

99759-8B110

REAR AXLE Suggestions Reassembling Steer Cylinder 1. Replace all seals and O-rings when reassembling the steer cylinder. Lubricate seals and Orings lightly with hydraulic fluid.

4. Pressure test cylinder reassembly for leaks.

E3000-EC4000

2. Assemble wiper seal and U-seal as shown.

Minimum test pressure

107 (1522) [10,500]

E4000-E6500 163 (2320) [16,000]

Unit: kgf/cm2 (psi) [kPa]

5. Use an alternating tightening pattern to tighten the mounting bolts when attaching the cylinder assembly to the axle beam.

Wiper seal

E3000-EC4000

U-Seal 8609006

Tightening torque for bolts

3. Align marks on the end caps to marks on the cylinder body. Tighten nuts.

Tightening torque for cylinder nuts

2.1 ± 0.2 kgf•m (15.5 ± 1.5 lbf•ft) [21 ± 2 N•m]

Mark

17.9 kgf•m (130 lbf•ft) [176 N•m]

1. Insert bearing cups into knuckles. Adequately fill bearing cages with “AUTOLEX A” grease.

Apply a coat of grease to the oil seal groove.

Insert the bearing cages in the knuckles and apply additional grease as required to meet the recommended amount.

Quantity of grease

8609004

26.7 kgf•m (193 lbf•ft) [262 N•m]

Reassembling Knuckles

E3000-EC4000

Mark

E4000-E6500

40cc (2.44 in3)

E4000-E6500 80 cc (4.88 in3)

2. Reassemble remaining components (seals, O-rings, covers, and boots).

3. Assemble parts, knuckle 6 through Boot 12, and insert this sub-assembly into the rear axle housing.

99759-8B110

4.13

REAR AXLE Reassembling Kingpins 1. Install the kingpins and measure the distances “A” on both the left and right kingpins.

3. Measure the tangential force at point “C”.

When the tangential force is larger than the values shown in the table below, add shims.

When the tangential force is smaller than the values shown in the table below, remove shims. Repeat this procedure until the values in the table are attained.

Tangential force A

E3000-EC4000

E4000-E6500

1.6 to 2.6 kgf (3.5 to 5.7 lb.)

15.7 to 25.5 N

2.5 to 4.5 kgf (5.5 to 9.9 lb.)

24.5 to 44.1 N

8609007

2. Add shims to each side to within 0.1 mm (0.004 in.) of the measured distance “A” and tighten bolt “B”.

C

8609009

4. Tighten kingpin keeper plate bolts.

Tightening torque for bolts

Kingpin Bolt

Keeper Plate Bolts

1.7 kgf•m (12.3 lbf•ft) [16.7 N•m]

3.4 kgf•m (24.6 lbf•ft) [33.4 N•m]

Shims

Bolt B

8609008

4.14

99759-8B110

REAR AXLE Reassembling Tie Rods Replace dust seals. Tighten tie rod pin bolts to the specified torque. Grease the joints using the grease zerks.

3. Reassemble rear axle hubs. The inner race of the inner bearing must be driven onto the shaft using a special tool as shown below.

0.7 kgf•m (5 lbf•ft) [6.9 N•m]

Tightening torque for bolts

Zerk

205022

Dust seals

Rod pin bolt 8609010

4. There is space between the two tapered roller bearings inside the rear axle hub. Be sure to fill this space with grease. Grease the oil seal lip groove and roller retainers, too. Do not overfill the oil seal lip groove as this can cause leakage.

Reassembling Rear Axle Hub 1. Using Installation Tool #91268-01500 or #64309-40400 install inner bearing races.

Using Tool #91268-01400 or 91268-00400 install outer bearing races.

Bearing installer

E3000-EC4000

E4000-E6500

91268-01500

64309-40400

Oil seal

Fill with grease

8609002A

2. Pack bearing cones.

5. Install wheel assembly carefully so as not to damage the bearing or seal.

10 7 A

8

6

A 9 54 3 2 1

101744

99759-8B110

4.15

REAR AXLE 6. Install outer bearing and nut 4.

7. Tighten nut 4 to 14 kgf•m (101 lbf•ft) [137 N•m] torque and back it off to 80°, then place lock washer 3.

Install nut 2, tightening it to 16 kgf•m (116 lbf•ft) [157 N•m] torque.

Check the hub bearing preload, making sure it is 25 to 65 kgf•cm (1.8 to 4.7 lbf•ft) [2.5 to 6.4 N•m].

NOTE Preload for bearing is given in tangential force measurement and must be measured with a spring scale. Apply force to spring scale as shown in graphic #101653, read scale. Adjust nut 4 to achieve correct preload.

If the preload is correct, bend lock washer 3.

8. Check to make sure the preload is correct.

Preload for hub bearings Inside nut Outside nut

25 to 65 kgf•cm (1.8 to 4.7 lbf•ft) [2.5 to 6.4 N•m]

Bar

8609002B

Preload for hub bearings Tangential Force

25 to 65 kgf•cm (1.8 to 4.7 lbf•ft) [2.5 to 6.4 N•m]

Tightening torque for outer lock nut

16 kgf•m (116 lbf•ft) [157 N•m]

8609002

Bar

Spring scale

101653

9. Install cap 1.

10. Raise the rear end of the truck and remove the blocking from the side frames.

11. Lower the truck until the rear wheels are on the floor.

4.16

99759-8B110

REAR AXLE

Inspection and Adjustment Minimum Turning Radius Adjustment 1. Using a turning radius gauge, measure the angular swing of rear wheels.

2. Setting the turning angle of each rear wheel to the specification is not enough. The truck must be driven to make the sharpest possible turn to either side, and the radius of the track left behind by the outer wheel must be measured for confirmation. The standard minimum turning radius is indicated below.

E3000-EC4000 Steering Angle Inside Outside Tightening torque for knuckle stopper bolt lock nut

E4000-E6500

83° 54°

83° 56° 6.8 kgf•m (49 lbf•ft) [67 N•m]

3. Drive the machine at low speeds in such a way as to make the sharpest possible turn to either side. Measure the radius of the track left by the outer wheel.

4. The minimum turning radius, R, is the distance from the turning center to the center of tire contact with the surface while the truck is executing its sharpest turn, plus the rear overhang (distance from center of rear tire to the outermost end of the counterweight).

E3000

1787 (70.4)

E3500

1787 (70.4)

EC4000

1841 (72.5)

E4000

1890 (74.4)

E5000

1890 (74.4)

EX5000

1991 (78.4)

E5500

1991 (78.4)

E6000

2045 (80.5)

E6500

2045 (80.5)

R

202800

Turning radius [Unit: mm (in.)]

99759-8B110

4.17

REAR AXLE STEERING CYLINDER Disassembly *: Parts contained in repair kit

10 *

11 9

A

11 3 * 4 5

* 6

2

1

* 7

7 * 6 *

A 2

5 4 * 3

1

8

1 207036

Disassembly sequence 1 2 3 4 5

Nut, Spring washer, Tie rod Remove parts 7 through 12 as assembly.

Cylinder head O-ring Snap ring Bushing

6 7 8 9 10 11

Wiper U-seal Cylinder tube Piston rod Guide ring, Piston seal Stopper ring

NOTE (1) Do not remove bushing 5 from the cylinder head 2 if acceptable.

(2) Do not remove bearing 11 from piston rod 9 if acceptable.

4.18

99759-8B110

REAR AXLE Suggestions Mark Cylinder End Caps Mark the cylinder end caps for proper alignment before they are disassembled from the cylinder.

Mark

Mark 207035

Inspection and Repair 1

2

3

Cylinder tube 8: Check for wear, damage or rust inside the cylinder.

Piston rod 9: Check for rust, damage, scratches or impact marks on the rod surface.

Rings and gaskets: Replace the entire seal kit.

A: Standard value Unit: mm (in.)

205439

E3000-EC4000 E4000-E6500 Internal diameter of cylinder tube 1

A

63(2.480)

75(2.953)

External diameter of piston rod 2

A

40(1.575)

50(1.968)

2

1

207034

99759-8B110

4.19

REAR AXLE Reassembly 5

5 1

2

13 4

14

16

12 •

•

•

9 8 6

15

7

10

3

11

207034

Assembly sequence 1 2 3 4 5 6

Piston rod Piston seal Guide ring Cylinder tube Cylinder head Bushing

7 8 9 10 11 12

Snap ring U-seal Wiper O-ring O-ring Tie rod

13 14 15 16

Spring washer Nut Pivot joint Stopper ring

Suggestions 1. Replace all seals and O-rings whenever reassembling steer cylinder. Lubricate seals and O-rings lightly with hydraulic fluid.

2. Assemble wiper seal and U-seal as shown.

3. Align marks on the end caps to marks on the cylinder body. Tighten nuts.

Wiper

U-seal

207042

Unit: N·m (kgf·m) [lbf·ft] Tightening torque for cylinder nuts N·m (kgf·m) [lbf·ft]

21±2 (2.1±0.2) [15.5±1.5]

Mark

4. Pressure test cylinder reassembly for leaks.

Unit: kPa (kgf/cm2) [psi]

Minimum test pressure

4.20

E3000-EC4000

E4000-E6500

10500 (107) [1522]

16000 (163) [2320]

Mark 207035

99759-8B110

TABLE OF CONTENTS Chapter 5: Brake System Description ................................................................................................................................... 5.1 Automatic Adjusting Device ..................................................................................................... 5.1 General Information ................................................................................................................. 5.1 Master Cylinder Disassembly ............................................................................................................................. 5.2 Inspection after Disassembly ................................................................................................... 5.3 Reassembly.............................................................................................................................. 5.3 Service Brakes Disassembly (E3000 - EC4000) ...............................................................................................................

(E4000 - E6500) ..................................................................................................................

Inspection after Disassembly ...................................................................................................

Reassembly (E3000 - EC4000) ...............................................................................................................

(E4000 - E6500) ..................................................................................................................

Wheel Cylinders Disassembly .............................................................................................................................

Inspection after Disassembly ...................................................................................................

Reassembly..............................................................................................................................

Inspection and Adjustment.......................................................................................................

5.4 5.5 5.7 5.8 5.9 5.12 5.13 5.13 5.14

NOTES

____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________

BRAKE SYSTEM

Description Automatic Adjusting Device

205955

General Information This device adjusts the drum-to-lining clearance automatically. As the clearance increases due to lining wear, the lever mechanism of this device turns the adjusting screw by one notch or tooth to reposition the shoes closer to the drum. This corresponds to 1/24 of one rotation or 15°. In the course of usage, the adjusting process repeats itself at long intervals.

99759-8B110

5.1

BRAKE SYSTEM

Master Cylinder Disassembly

9 8 7

4

10

6 5

*3

91484-37100 E3000 - EC4000 91246-65300 E4000 - E6500

1 2

97146-10000A

1. Taper plug

6. Oil tank assembly

2. Master cylinder body

7. Push rod

3. Repair kit

8. Jam nut

4. Cap assembly

9. Clevis

5. Level sensor

10. Push rod assembly

NOTE The parts* to be changed periodically are included in the Repair Kit.

5.2

99759-8B110

BRAKE SYSTEM

Inspection after Disassembly Brake Fluid Level Sensor

Piston

1. Fill the reservoir with brake fluid. Connect the level sensor connector at the bottom of the fluid reservoir and turn the key to ON.

Replace the piston if it is damaged. Check the piston clearance in the cylinder body. Replace the cylinder body and piston if the clearance is in excess of the service limit.

Clearance between piston and cylinder

A

0.020 to 0.105 (0.00079 to 0.00413)

B

0.2 (0.008)

Unit: mm (in.)

A = Assembly Standard B = Repair or Service Limit DOWN = ON

Return Spring

UP = OFF

Replace the return spring every year.

200270

Primary Cup, Secondary Cup, and Valve 2. The sensor is satisfactory if the brake fluid level warning lamp on the monitor flashes when the reservoir filler is in the DOWN position and goes off when it is in the UP position.

Check these rubber parts for swelling, tearing, and deterioration from aging. Replace them every year.

Cylinder Body

Reassembly

1. Check the bore of the cylinder for rust, corrosion, and scoring.

2. Check the inlet port and relief ports for cleanliness. Also check the threads in the screw connection of each joint for damage. Make sure the boot is free from defects.

To reassemble, reverse the procedure for disassembly and do the following steps.

1. Clean all metal parts with a volatile cleaning solvent. Dry them with pressure air.

2. Apply a thin coat of rubber grease (Metal Rubber #20) or brake fluid to the piston cups and the cylinder bore.

Master Cylinder Adjustment: Adjust master cylinder only after pedal height adjustment has been made (See pg. 5.18). With master cylinder installed and push rod connected to brake pedal, use the clevis pin to adjust the master cylinder push rod so there is 0.5 to 2.8mm of free play between the end of the push rod and cylinder position contact. Tighten jam nut on push rod clevis assembly.

99759-8B110

5.3

BRAKE SYSTEM

Service Brakes Disassembly (E3000 - EC4000) 1

2 16

23

24

3

13

9

21

9

5

20 19 7

22 6 26 27

10

4

17 15

11 14 25

18 12

8

97146-11800A

Components 1. Service Brake Assembly

15. Spring

2. Wheel cylinder assembly

16. Pin

3. Backing plate

17. Spring

4. Primary shoe and lining assembly

18. Strut

5. Secondary shoe and lining assembly

19. Spring washer

6. Parking Lever

20. Retainer

7. Adjusting screw

21. Bolt with washer

8. Adjusting lever

22. Snap ring

9. Spring

23. Cover

10. Cable guide

24. Parking cable assembly

11. Fitting cable

25. Spring

12. Spring

26. Spring washer

13. Shoe guide plate

27. Bolt

14. Cup 5.4

99759-8B110

BRAKE SYSTEM

Disassembly (E4000 - E6500) 1

2 16

23

24

3

10

13

28

27

21

29

5 26 9 20 19 7

22 6

31 30

4 17

14 15 14 18

11 12

8

25

97246-10900A

Components 1. Service Brake Assembly

10. Self-locking nut

21. Bolt with washer

2. Wheel cylinder assembly

11. Fitting cable

22. Snap ring

3. Backing plate

12. Spring

23. Cover

4. Primary shoe and lining assembly

13. Shoe guide plate

24. Parking cable assembly

14. Cup

25. Spring

5. Secondary shoe and lining assembly

15. Spring

26. Spring

16. Pin

27. Pin

17. Spring

28. Sheave

18. Strut

29. Plain washer

19. Spring washer

30. Bolt

20. Retainer

31. Spring washer

6. Parking Lever 7. Adjusting screw 8. Adjusting lever 9. Spring

99759-8B110

5.5

BRAKE SYSTEM Start By: 1. Remove the front wheel.

2. Remove the wheel hub and brake drum.

4. Disconnect the brake pipe from the wheel brake assembly.

3. Separate the parking brake lever and cable at the bottom of the wheel brake.

Suggestions Removing Return Springs

Removing Hold-Down Springs

Use a special tool to remove the return springs.

Use a special tool to remove the hold-down springs.

Special Tool

Part Number

Special Tool

Part Number

Spring remover

64309-15411

Spring remover

64309-15412

200271

5.6

200272

99759-8B110

BRAKE SYSTEM

Inspection after Disassembly Backing Plate

Brake Drums

1. Check the backing plate for cracks.

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 service limit on the inside diameter is not exceeded.

2. Tighten the backing plate mounting bolts to the specified torque.

Tightening torque for backing plate mounting bolts

16 kgf•m (116 lbf•ft) [157 N•m]

E3000 - EC4000 Inside diameter of brake drum

Shoes and Linings 1. Check each shoe and lining for cracks.

2. Replace the lining if it is dirty, greasy, burnt, or glazed.

3. Check the thickness of the lining. Replace the lining if it exceeds the service limit.

A

254 + (10.0 +

B

0.13 0 0.0051 0)

256 (10.08)

E4000-E6500 310 + 0.15 0 (12.2 + 0.0059 0) 312 (12.28)

Unit: mm (in.)

A = Assembly standard B = Repair or service limit

Adjusting Screws Check the wheel teeth for wear. Turn the screw by hand to ensure its rotating parts turn freely.

203005

200274

E3000 - EC4000 Lining thickness

E4000-E6500

A

4.87 (0.19)

6 (0.24)

B

2.5 (0.10) maximum

3 (0.12) maximum

Unit: mm (in.)

A = Assembly standard B = Repair or service limit

Parking Brake Cable Replace a cable if it is permanently stretched, rusted, or damaged.

Other: 1. Check the return springs for cracks or fatigue.

2. Check the adjusting springs for cracks or fatigue.

3. Check the fitting cables for stretching.

99759-8B110

5.7

BRAKE SYSTEM

Reassembly (E3000 - EC4000) 6

A

10

3

12

1

8

12 13

5 8 4 7

1

11 9 9

14 16 15

A

Section A-A

2

205960

Sequence 1. Backing plate

9. Pin, hold-down spring, and cup

2. Parking brake cable

10. Shoe guide plate

3. Wheel cylinder

11. Fitting cable

4. Parking brake lever

12. Return spring

5. Shoe and primary lining

13. Cable guide

6. Retainer and washer

14. Adjusting lever and adjusting spring

7. Shoe and secondary lining

15. Adjusting screw

8. Strut and anti-rattle spring

16. Return spring

5.8

99759-8B110

BRAKE SYSTEM

Reassembly (E4000 - E6500) A

3

11 9

6

1

13

7 4 8

10 10

12 5

16

14 15

2

Section A-A

A 205961

Sequence 1. Backing plate

9. Strut and anti-rattle spring

2. Parking brake cable

10. Pin, hold-down spring, and cup

3. Wheel cylinder

11. Shoe guide plate

4. Parking brake lever

12. Fitting cable

5. Shoe and primary lining

13. Return spring

6. Retainer and washer

14. Adjusting lever and adjusting spring

7. Pin, sheave, and washer

15. Adjusting screw

8. Shoe and secondary lining

16. Return spring

99759-8B110

5.9

BRAKE SYSTEM Suggestions Installing Wheel Cylinder

Greasing

Apply 3 Bond to the mounting face of the wheel cylinder before positioning the cylinder in place.

Secure it by tightening to the specified torque:

Apply a thin coat of the specified brake grease to each of the following parts.

E3000 - EC4000 Tightening torque for wheel cylinder

0.8 to 1.2 (6 to 9) [8 to 12]

E4000-E6500 1.8 to 2.7 (13 to 20) [18 to 26]

Unit: kgf•m (lbf•ft) [N•m]

1. Shoe ledges (6 places): The ledges are the portions of the backing plate in contact with the shoe.

2. Anchor pin surface in contact with the shoe ends.

Installing Shoes Make sure that each push rod of the wheel cylinder is snugly fitted to its shoe web.

Installing Return Springs Use a special tool to install the return springs to the backing plate pins Special Tool

Part Number

Spring installer

65309-15413

200275

200276

5.10

99759-8B110

BRAKE SYSTEM Installing Automatic Adjusting Device 1. Clean the adjusting screw and associated parts, then grease the screw threads and screw socket. Be sure the screw turns freely when rotated by hand. If the screw is hard to turn, replace it.

2. The right and left adjusting screws are colorcoded.

• Right-hand adjusting screw and lever (lefthand thread) is yellow.

• Left-hand adjusting screw and lever (righthand thread) is white.

200277

NOTE After reassembly, bleed air out of the brake fluid lines. (Refer to INSPECTION AND ADJUSTMENT, p. 5.15).

99759-8B110

5.11

BRAKE SYSTEM

Wheel Cylinders Disassembly 10 7 6

12 11

5 9

3

8

1

4 2

*

97246-10900B

Sequence 1. Connecting link

8. Spring

2. Boot

9. Cup

3. Piston

10. Piston

4. Piston cup

11. Boot

5. Body

12. Connecting Link

6. Bleeder screw 7. Cap

NOTE The parts (*) to be changed annually are included in the repair kit.

5.12

99759-8B110

BRAKE SYSTEM

Inspection after Disassembly Cylinder Bodies

Piston Cups

1. Check the bore for rusting, corrosion, and scoring.

Check for swelling or other defects. Replace the cups at the time of overhaul and every year.

2. Check the threads of the bleeder screw and oil pipe for damage.

Boots Replace the boots if they are hardened, damaged, or otherwise deteriorated.

Pistons 1. Check the sliding surface for rusting or scratching. Cylinders with any rust, corrosion or scoring should be replaced 2. Check the piston clearance in the cylinder body. Replace the cylinder body and piston if the clearance exceeds the service limit.

Reassembly To reassemble, reverse the procedure for disassembly and do the following: 1. Coat the piston cups and the cylinder bore with brake fluid.

2. Be careful not to damage the lips of the cups.

200280

Clearance between piston and cylinder

A B

E3000 - EC4000

E4000-E6500

0.040 to 0.125 (0.00157 to 0.00492)

0.020 to 0.105 (0.00079 to 0.00413)

0.15 (0.0059)

Unit: mm (in.)

A = Assembly standard B = Repair or service limit

It is recommended that the brake cylinder kit be replaced any time it is disassembled.

99759-8B110

5.13

BRAKE SYSTEM

Inspection and Adjustment Automatic Adjusting Device 1. Have the service brake properly set with the drum-to-lining clearance adjusted to specification. Pull the adjusting lever by giving a push to the cable, as shown, to see if the lever turns the adjusting screw by one tooth and, as the push is released, returns to its original position. If it does, the device is in satisfactory condition.

3. When the automatic adjusting device is suspected of malfunctioning during normal use of the machine, check for the following causes: a. Adjusting spring is not correctly hooked to the primary shoe. b. Any one of these parts is in bad condition and needs replacing: 1) fitting cable 2) adjusting lever 3) adjusting screw

Manual Adjustment The drum-to-lining clearance can be adjusted by rotating the adjusting screw with a screwdriver on to the toothed wheel. The hole through which the screwdriver tip can be inserted is in the backing plate.

200281

2. If the lever fails or is sluggish to turn the adjusting screw in the above test, the likely cause is that the lever is not properly positioned relative to the toothed wheel. Be sure that the lever is positioned so that its actuating tip touches the toothed wheel at about 9 mm (0.35 in.) under the center line of the screw, as shown below.

200283

9 mm (0.35 inch) 200282

5.14

99759-8B110

BRAKE SYSTEM Brake Pedal Adjustment

Bleeding Air Out of Brake Fluid Line

Set the dimensions A, B, and C to the specified values.

Whenever any part of the brake fluid line is disconnected in servicing work, an air bleeding operation must be performed to complete the job. Air trapped in any part of the fluid line will cause the brake pedal to feel spongy.

After the shoe linings have been replaced, turn the adjusting screw as far as it will go (until the clearance becomes zero) and back it off by the amount of rotation shown below.

E3000 - EC4000:

19 clicks

E4000 - E6500:

16 clicks

Height from floor to pedal (A) Stroke (to a point where brakes start to apply) (B)

120mm ± 3 mm 3 to 10 (0.12 to 0.4)

Clearance between piston 0.5 to 2.7 (0.02 to 0.11) and push rod (C) Unit: mm (in.)

Air Bleeding Operation Procedure: 1. Tie a flexible tube, such as a vinyl pipe, to the bleeder screw on the wheel cylinder. Insert the free end of the tube into a vessel filled with brake fluid.

2. Pump the brake pedal and depress it all the way. While keeping the pedal depressed, loosen the bleeder screw. When air bubbles cease to come out, tighten the screw. Repeat this process until nothing but brake fluid flows into the vessel.

3. Repeat procedure at each wheel brake, and fill up the brake fluid reservoir to level.

B A

Push rod

200285

C

NOTE

Stop bolt 8609011

Be sure that the reservoir never becomes empty of fluid at any time during the procedure.

Use specified brake fluid. Avoid mixing different brands of brake fluid before and after filling up the reservoir.

Brake Test After completion of necessary adjustments, test the brake force by operating the truck at a slow speed of 2.0 km/h (1.2 mph). Test brakes—then increase speed up to 10 km/h (6.2 mph). Refer to Manual Adjustment for necessary readjustment.

99759-8B110

5.15

NOTES

____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________

TABLE OF CONTENTS Chapter 6: Steering System Steering System Description ...................................................................................................................................

Steering System ......................................................................................................................

Oil Flow Sequence ..............................................................................................................

General Information.............................................................................................................

6.1 6.1 6.1 6.1

Steering Gear Steering Wheel Removal ................................................................................................................................... 6.2 Installation ................................................................................................................................ 6.2 Steering Gear............................................................................................................................... 6.3 Inspection after Removal ............................................................................................................. 6.4 Disassembly .................................................................................................................................

Working Rules and Tips ...........................................................................................................

Suggestions .............................................................................................................................

Inspection after Disassembly ...................................................................................................

6.5 6.6 6.6 6.6

Reassembly.................................................................................................................................. 6.7 Steer Pump Removal ....................................................................................................................................... 6.8 Installation .................................................................................................................................... 6.9 Disassembly .................................................................................................................................

Sequence .................................................................................................................................

Working Rules and Tips ...........................................................................................................

Suggestions .............................................................................................................................

Inspection after Disassembly ...................................................................................................

6.10 6.10 6.11 6.11 6.13

Reassembly..................................................................................................................................

Sequence .................................................................................................................................

Suggestions .............................................................................................................................

Inspection after Reassembly....................................................................................................

6.14 6.14 6.15 6.17

NOTES

____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________

STEERING SYSTEM

Steering System Description Steering System

6

4

3 2

5

1

8609044

Oil Flow Sequence 1. From hydraulic tank

4. Steering cylinder

2. Steering pump

5. Mast operating valve

3. Steer gear

6. To hydraulic tank

General Information This steering system is an open-center type, where the steering fluid is provided by a dedicated steering pump. The oil is constantly available and flows through the steer gear and back to the tank via the mast operating valve.

In this type of steering system, only the small dedicated steer pump is pressurized, providing an efficient, energy-conservation system.

99759-8B110

6.1

STEERING SYSTEM

Steering Gear Removal Steering Wheel

1

2

8609016

Sequence 1. Nut, washer 2. Wheel

Removal

Installation

Use a special tool.

To install, follow the reverse of the removal sequence.

Special Tool

Part Number

Wheel puller

91268-10600

Wheel puller

203466A

6.2

99759-8B110

STEERING SYSTEM Steering Gear

Sequence 1. Column & Kick cover mounting hardware 2. Column & Kick covers 3. Hoses, connectors and o-rings 4. Steer column mounting bolts 5. Steer column 6. Steer gear

!

WARNING

Hydraulic pressure can cause personal injury. Before any steering system hydraulic lines or components are disconnected, make sure all hydraulic pressure is released in the steering system. Move the steer wheels to the left and right, then straight.

NOTE For servicing the steer cylinder, see REAR AXLE section.

99759-8B110

6.3

STEERING SYSTEM

Inspection after Removal 1. Inspect the grommets for cracks or tears in the rubber or for signs of aging. Check the O-rings for damage.

Installation To install, follow the reverse order of the removal sequence. Tighten bolts to the specified torque Tightening torque for bolts

6.4

2.9 ± 0.3 kgf•m (20.9 ± 2.1 lbf•ft) [28.4 ± 2.9 N•m]

99759-8B110

STEERING SYSTEM

Steering Gear Disassembly

99759-8B110

6.5

STEERING SYSTEM

Steering Gear Disassembly Working Rules and Tips The steering gear is a precision-machined component, so it must be handled with extreme care.

Cleanliness is Imperative: work in a clean place and use clean tools.

1. Before disconnecting the hydraulic lines, clean the port area of the steer gear unit.

2. Before disassembly, drain the oil and then plug the ports and thoroughly clean the exterior of the steer gear unit.

3. Clean the disassembled parts with a volatile solvent such as trichlene or chlorobenzene, and dry them with compressed air. This does not apply to rubber parts.

4. Oil seals, O-rings, and the like are rubber parts. Never clean them with solvents. Blow dirt off rubber parts with compressed air and keep them immersed in a pool of hydraulic oil until they are ready for reassembly. A rubber part showing even slight wear and tear must be replaced. Rubber parts are expendable components that should be replaced once a year.

5. Parts that need to be installed by pressing or forcing need special treatment. a. Oil Seals Oil seals, once removed, must not be reused. After disassembly, examine the oil seals in place. If they are in good condition, leave them in place. When installing a replacement oil seal, be careful not to score or scratch the lip area.

Suggestions: The steer gear is designed with very few serviceable components. Only disassemble the steer gear if you plan to replace one of the following: 1. Dust Seal 2. Pressure Seal 3. O-rings 4. Thrust Race and/or Bearings If replacing these parts does not improve performance, you must replace the entire steer gear assembly. Refer to your parts manual for ordering information.

6.6

1. Remove the plug and inlet relief valve.

NOTE The manual steering check is part of the inlet relief valve. If inlet relief valve is not present, the manual steering check is in the housing.

2. Remove the four cap screws and the end cap and disassemble the the steer gear.

3. Slide the spool and sleeve from the housing.

4. Remove the thrust bearing and bearing races.

5. Remove the seal.

6. Using a small blade screwdriver, carefully pry the dust seal from the housing.

7. Remove the pin that holds the spool and sleeve together.

8. Carefully slide the spool out of the sleeve. The springs and retaining ring will stay with the spool as it’s removed.

9. Remove the retaining ring and springs.

!

CAUTION

The centering springs are under tension; remove the retaining ring carefully.

Inspection after Disassembly 1. Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leaks.

2. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe dry with cloth or paper towels because lint or other matter can get into the hydraulic system and cause damage. Do not use a coarse grit or try to file or grind these parts.

99759-8B110

STEERING SYSTEM

Steering Gear Reassembly Suggestions

NOTE DO NOT disassemble the steer gear further than required to replace serviceable components. Doing do may result in replacing entire gear.

NOTE Always use new seals when reassembling hydraulic steer gear units.

NOTE During reassembly lubricate the new seals with petroleum jelly. Lubricate machined surfaces and bearings with clean hydraulic fluid.

1. Install the quad seal • Put one of the bearing races and sleeve into the housing.

• Together, the housing and bearing race create a groove into which the quad seal will be installed.

• Hold the bearing race tightly against the input end of the housing by pushing on the gerotor end of the sleeve.

• Fit the quad seal into its seat through the input end of the housing. Be sure the seal is not twisted.

• Remove the sleeve and the bearing race.

2. Lubricate and install the dust seal.

3. Install the centering springs in the spool. It is best to install the two flat pieces first. Next, install the curve pieces, three at a time.

4. Fit the retaining ring over the centering springs.

5. Apply a light coating of clean hydraulic fluid to the spool and slide it into the sleeve. Be sure the centering springs fit into the notches in the sleeve.

6. Install the pin.

7. Apply a light coat of petroleum jelly to the inner edge of the dust and quad seals.

8. Put the thrust bearing and races into the housing. The thrust bearing goes between the two races.

99759-8B110

9. Apply a light coating of clean hydraulic fluid to the spool and sleeve assembly and slide it into the housing. Important: Do not damage the dust or quad seals.

10. Clamp the housing in a vise. Use just enough clamping force to hold the housing securely.

11. Install manual steering check ball and pin into housing, if no relief valve is present.

12. Lubricate and install a new o-ring seal in the groove in the housing.

13. Install the wear plate and align the timing groove on plate with the timing groove on the housing.

14. Install the drive, be sure the slot in the drive engages the pin.

NOTE The holes in the wear plate are not symmetrical.

15. Lubricate and install a new o-ring and seal ring in the groove in the wear plate.

16. Install the gerotor and align the timing groove with the timing groove in the wear plate.

17. Lubricate and install a new o-ring seal in the groove in gerotor ring.

18. Lubricate and install a new o-ring and seal ring in the groove in the gerotor star.

19. Install the spacer.

20. Install end cap and four cap screws. Align timing groove on end cap with timing groove on gerotor. Tighten cap screws in a criss cross pattern, to 16 – 18 Nm [250 lb-in].

21. Install the relief valve/check if present. Use a new o-ring and tighten the plug to 17 Nm [150 lb-in].

22. Remove the steering gear from the vise.

23. Check the steering gear and confirm that all timing grooves are in line.

NOTE If timing grooves are not aligned properly, steering gear will not operate properly.

6.7

STEERING SYSTEM

Steer Pump Removal

5

4

Sequence 1. Motor mounting bracket

3. Motor

2. Motor mounting hardware

4. Pump mounting hardware

5. Pump

Start By: 1. Remove the battery.

2. Remove the acid tray.

3. Disconnect the cables and wires from the steer pump motor. Mark the wire leads and cables so they can be correctly reconnected.

4. Disconnect the hydraulic lines from the pump.

6.8

99759-8B110

STEERING SYSTEM Suggestions

Installation

Removing the Motor and Pump Assembly

1. To install, reverse removal sequence.

After disconnecting the steer pump hoses, motor cables, and harness leads, remove the pump and motor assembly by removing the motor bracket mounting hardware where the bracket is bolted to the frame.

Removing the Pump Remove the pump from the motor.

99759-8B110

6.9

STEERING SYSTEM

Disassembly 8

4 2 6

7

3 5 1

Sequence 1. Cover and mounting bolts

5. Rotor and vanes

2. O-ring

6. Retaining ring

3. Spring and Pressure plate

7. Shaft and bearing

4. Ring and locating pins

8. Body, O-ring, and seal

6.10

99759-8B110

STEERING SYSTEM Working Rules and Tips

Suggestions

The steer pump is a precision-machined component and must be handled with extreme care.

Cleanliness is imperative: use clean tools and work in a clean place.

Removing the Motor and Pump Assembly

1. Clean the disassembled parts with a volatile solvent such as trichlene or chlorobenzene and dry them with compressed air. This does not apply to rubber parts.

2. Oil seal, O-rings, and the like are rubber parts.

Never wash them with solvent. Blow dirt off rubber parts with compressed air and keep immersed in a pool of hydraulic oil until they are ready for reassembly. A rubber part showing even slight wear and tear must be replaced. Rubber parts are expendable components and should be replaced yearly.

Disconnect the steer pump hoses, motor cables, and harness leads. Remove the pump and motor assembly by removing the motor bracket mounting hardware where the bracket is bolted to the frame.

Removing the Pump Remove the pump from the motor.

Removing The Pump Cover Remove the four bolts holding the rear cover on the pump. Remove the cover. Remove the O-ring located in the groove of the cover.

3. Parts to be installed by pressing or forcing need special treatment.

Oil Seals An oil seal, once removed, must not be reused. After disassembly, examine the oil seal in place (in the housing) and, if in sound condition, leave it in place. When installing a replacement oil seal, be careful not to score or scratch its lip portion.

8609075

Removing the Spring Lift the spring off the pressure plate.

8609076

99759-8B110

6.11

STEERING SYSTEM Removing the Pressure Plate

Removing the Retaining Ring

Lift the pressure plate off of the ring and remove the two locating pins from the ring.

The shaft and bearing assembly is held in place by an internal retaining ring on the driven end of the pump. Remove the retaining ring using a standard retaining ring tool.

8609077

Retaining Ring

Removing the Rotor and Vanes Remove the rotor and the vanes. Take care not to lose any of the vanes.

8609080

8609078

Removing the Ring Lift the ring off of the pump body.

8609079

6.12

99759-8B110

STEERING SYSTEM Removing the Shaft and Bearing

Removing the Seal and O-ring

1. Tap the end of the shaft very lightly to remove it from the pump body. Take extreme care not to damage the end of the shaft.

1. Examine the shaft seal in place in the housing.

If it is in sound condition, do not attempt to remove it. Instead, use it as part of the rebuilt unit. If there is any damage to the seal, remove it and do not reuse it.

2. Remove the external retaining ring from the shaft to allow removal of the bearing. Tap the end of the shaft very lightly to separate the bearing from the shaft. Take extreme care not to damage the end of the shaft.

2. Remove the O-ring from the slot in the body.

8609082 8609081

Inspection after Disassembly 1. Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leaks.

2. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe dry with cloth or paper towels because lint or other matter can get into the hydraulic system and cause damage. Do not use a coarse grit or try to file or grind these parts.

99759-8B110

6.13

STEERING SYSTEM

Reassembly

3

6

2 1 4 5 7 8

8609083

Sequence 1. Body and seal

5. Rotor and vanes

2. Shaft and bearing

6. Pressure plate

3. Retaining ring

7. Spring

4. Ring

8. Cover

6.14

99759-8B110

STEERING SYSTEM Suggestions

Reassembling the Shaft and Bearing Press the bearing onto the shaft and secure it with the external retaining ring.

NOTE Replace all old seals with new seals.

Lubricate all seals with clean petroleum jelly such as Vaseline.

Reassembling the Shaft Seal 1. Install the seal in the housing, orienting the seal lip as shown. Take care not to damage the seal during installation.

8609085

2. The seal must be bottomed against the shoulder when installed.

Reassembling the Shaft and Body Install the shaft and bearing assembly into the body, taking care not to damage the shaft seal during installation. Secure the shaft by installing the retainer ring.

8609084

Retaining ring

8609086

99759-8B110

6.15

STEERING SYSTEM Reassembling the Ring

Reassembling the Pressure Plate

Press the O-ring into the groove in the body. Place the ring on the body, aligning the bolt holes and the pin holes. Install the two pins through the ring and into the body.

Install the pressure plate by slipping it over the two pins

8609089 8609087

Reassembling the Spring Slip the spring over the spring seat of the pressure plate.

Reassembling the Rotor and Vanes Slip the rotor over the splined portion of the shaft.

Insert a vane in each of the slots in the rotor.

8609090 8609088

6.16

99759-8B110

STEERING SYSTEM Inspection after Reassembly

Reassembling the Cover 1. Press the O-ring into the groove in the cover.

Place the cover on the ring and align the four bolt holes. Take care to properly orient the discharge port to its original position prior to assembly.

Check the pump for smooth, free rotation. Check for leaks after reinstallation in the truck.

2. Install and tighten the cover bolts.

8609091

Tightening torque for cover bolts

99759-8B110

4.8 to 6.2 kgf•m (35 to 45 lbf•ft) [47 to 61 N•m]

6.17

NOTES

____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________

TABLE OF CONTENTS Chapter 7: Hydraulic System Hydraulic System Description ...................................................................................................................................

Schematics ..............................................................................................................................

Hydraulic Tank..........................................................................................................................

Hydraulic Pump .......................................................................................................................

Control Valve ............................................................................................................................

Lift and Tilt Cylinders................................................................................................................

Down Safety Valve ...................................................................................................................

7.1 7.1 7.5 7.6 7.8 7.9 7.10

Removal and Installation Warning................................................................................................ 7.11 Hydraulic Pump Removal ....................................................................................................................................... 7.12 Installation .................................................................................................................................... 7.13 Disassembly ................................................................................................................................. 7.14 Working Rules and Tips ........................................................................................................... 7.14 Suggestions ............................................................................................................................. 7.16 Inspection after Disassembly .......................................................................................................

Body .........................................................................................................................................

Mounting Flange Face .............................................................................................................

Bushes and Balance Plate.......................................................................................................

Gears .......................................................................................................................................

7.18 7.18 7.18 7.18 7.18

Reassembly.................................................................................................................................. 7.19 Inspection after Reassembly........................................................................................................ 7.23 Control Valve Removal ....................................................................................................................................... 7.24 Installation .................................................................................................................................... 7.25 Disassembly ................................................................................................................................. 7.26 Suggestions ................................................................................................................................. 7.27 Reassembly.................................................................................................................................. 7.27 Lift and Tilt Cylinders Removal Lift Cylinders ............................................................................................................................ 7.28 Tilt Cylinders ............................................................................................................................ 7.31 Disassembly Lift Cylinders ............................................................................................................................ 7.33 Tilt Cylinders ............................................................................................................................ 7.34 Inspection after Disassembly ................................................................................................... 7.35 Precautions for Reassembly ........................................................................................................ 7.35 Inspection and Adjustment Hydraulic Tank.............................................................................................................................. 7.36

TABLE OF CONTENTS Control Valve ................................................................................................................................ 7.37 Lift and Tilt Cylinders.................................................................................................................... 7.40 Adjusting Method ..................................................................................................................... 7.41 Testing ...................................................................................................................................... 7.42

HYDRAULIC SYSTEM

Hydraulic System Description Schematic for Trucks

1. Hydraulic tank

4. Steer gear

7. Down safety valve

2. Hydraulic lift pump

5. Main control valve

8. Lift cylinder

3. Steer pump

6. Flow regulator valve

9. Tilt cylinder

10. Steering cylinder

General Information The hydraulic pump draws oil from the oil tank and delivers it to the main control valve, which dispenses it for lift and tilt functions.

The steer gear and steer pump are covered in the STEERING SYSTEM section and the steering cylinder is covered in the REAR AXLE section.

99759-8B110

7.1

NOTES

____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ 7.2

99759-7B110

SCHEMATIC(S) INSERTION Schematic(s) name/number

Replace this page with page 3 of 3 99759-8B110i.pdf

99759-7B110

7.3

HYDRAULIC SYSTEM Hydraulic Tank 1

2

6

5

4 3

8609093

1. Cap

3. Drain plug

5. Suction line strainer

2. Oil level gauge

4. Return line filter

6. Lift cylinder pipe

General Information The tank contains internal filtering means including a strainer on the suction line and a filter on the return line.

The lift cylinder return pipe allows the cylinders to draw fluid when they retract, providing the bore walls with oil which inhibits corrosion.

99759-8B110

7.5

HYDRAULIC SYSTEM Hydraulic Pump

8609094A

General Information This gear pump is capable of developing very high pressure on its discharge side. A special arrangement is incorporated in the pump construction for the purpose of keeping the side clearances minimized between bushings on the one side and pump gears on the other. Note, in illustration 203585 (page 7.6), that discharge pressure is applied to the back of each bushing through internal oilways.

7.6

99759-8B110

HYDRAULIC SYSTEM Hydraulic Pump Operation

Pressure Loading Principle

Essentially the pump consists of two gears—the drive gear and the driven gear—closely fitted in the housing. The oil is carried around the periphery of the revolving gears from the suction to the discharge side. The teeth meshing between the two gears prevents the return of oil from the discharge to the suction side.

This pump is a self-balanced type based on the principle of pressure loading, balancing for equal pressure on all sides of the revolving gear. This reduces bushing and gear wear. In operation, the high-pressure oil on the discharge side is fed back to the suction side. On the suction side, pressure is exerted equally on both sides of the gears and shafts, thereby cancelling out unequal pressure to balance the pump.

Driven Gear

Clearance

Drive Gear 203585

Discharge side

99759-8B110

200333

7.7

HYDRAULIC SYSTEM Control Valve 8

9

7

10 14

1 6

2

6

3

6

4 5

11 12

13

Sequence 1. Inlet / Unloader Spool

8. From Hydraulic Pump

2. Tilt Spool

9. To Tank

3. Auxiliary Spool

10. Main Relief Valve, Auxiliary Valve (back)

4. Auxiliary Attachment Spool

11. Auxiliary Relief Valve (front)

5. Outlet Spool

12. Tie bolt

6. Flow Control Screws

13. Nut

7. Lift Port

14. Switches

General Information The control valve consists of three valve blocks, all spool-type. The spools are finished by lapping for their respective blocks and their combination should not be changed. The lift valve assembly has a built-in load check valve. The tilt valve spool has a built-in tilt lock valve. The attachment valve assembly has a built-in overload relief valve.

7.8

99759-8B110

HYDRAULIC SYSTEM Lift and Tilt Cylinders

200345

205979

General Information The left and right lift cylinders are single-acting type.

The left and right tilt cylinders are double-acting type. The piston rod carries a screw-on socket.

The socket is repositioned as necessary by turning when the cylinder is connected to the outer mast. This feature allows the tilt cylinders to move in unison.

The tilt angle is increased or decreased with the spacer and shim of each cylinder.

99759-8B110

7.9

HYDRAULIC SYSTEM Down Safety Valve

Burst

When hose burst

Normal

204971

General Information The down safety valve is built in the oil pipe joint at the bottom end of the lift cylinder. This valve is internally provided with an orifice to prevent shock when the valve is closed. In the valve having no orifice, the oil leaks around the valve to prevent shock.

Valve Types Down safety valves are available in six types differing in terms of shutoff flow and identified by the number punched on the flat (indicated as “a” on illustration 201731A). The numbers are: 50, 70, 90, 100, 120, and 150. No. 90 and No. 120 valves each come in two kinds differing in screw thread size.

Truck

E3000 EC4000 E4000 EX5000 E5500 E6500

Dual stage Dual-stage full panoramic free-lift panoramic

a

a

Triple-stage full free-lift panoramic

1st lift cylinder

2nd lift cylinder

1st lift cylinder

2nd lift cylinder

70

90

70

90

70

70

120

70

120

70

• Dual-stage full free-lift panoramic, 1st and 2nd cylinders

90

90

120

120

90

• Triple-stage full free-lift panoramic, 2nd lift cylinder

201731A

Top View:

• Dual-stage panoramic lift cylinder

Bottom View: • Triple-stage full free-lift panoramic 1st lift cylinder 7.10

99759-8B110

HYDRAULIC SYSTEM

Removal and Installation Warning

!

WARNING

Hydraulic oil under pressure can remain in the hydraulic system after the truck and pump have been stopped. To avoid personal injury, this pressure must be released before any work is done on the hydraulic system.

To prevent possible injury, lower the lift bracket to the ground, turn the truck off, and move the control levers to make sure all hydraulic pressure is released before any fitting, plug, or hose is loosened, tightened, removed, or adjusted.

Always move the lift truck to a clean and level location away from the path of other machines.

Be sure that no personnel are near the machine when the truck is running and tests or adjustments are being made.

99759-8B110

7.11

HYDRAULIC SYSTEM

Hydraulic Pump Removal

2

1

Sequence 1. Hardware 2. Pump

Start By: 1. Disconnect the battery from the truck.

2. Disconnect the hoses attached to the pump fittings.

3. Disconnect the power cables and wire leads from the pump motor.

4. Raise the truck enough to allow the pump and motor assembly to be removed from below the truck. Make sure that the truck is stable and secure in the raised position.

7.12

5. Secure the motor from above with a crane, hoist, or other adequate device, or support it at its center with a garage jack.

6. Remove the motor and pump assembly from the truck.

7. Remove the hydraulic fittings from the pump.

99759-8B110

HYDRAULIC SYSTEM

Installation 1. To install, follow the reverse sequence of the disassembly procedure. Before installing hydraulic fittings in the pump, inspect all O-rings for damage or aging and replace them as required.

2. Tighten hose to the following specifications.

Tightening Torque for Hose E3000-EC4000 Supply hose from pump to mast operating valve

E4000-E6500

6.5 ± 0.7 kgf•m 10.3 to 11.7 kgf•m (48 ± 5 lbf•ft) (74 to 85 lbf•ft) [65 ± 7 N•m] [101 to 115 N•m]

3. Lube pump splines before installing into pump motor. Use molybdenum disulfide grease.

HYDRAULIC PUMP APPLICATIONS

Market

Models E3000-EC4000 No. Am. E4000-E6500 EC15N-EC18N Europe EC20N-EC30N E3000-EC4000 E4000-E6500 No. Am. E4000, E5000, EX5000 E5500, E6000, E6500

99759-8B110

Pump UL Motor E & ES 8" DC & AC E & ES 9" DC & AC N/A 8" AC N/A 9" AC EE 8" DC & AC EE 9" AC EE 9" DC EE 9" DC

Voltage 36/48 36/48 36/48 36/48 36/48 36/48 36/48 36/48

97E71-00030 23cc

97E71-00040 25cc

97271-00700 29cc

Cast-Iron Gear

Cast-Iron Gear

Cast-Iron Gear

w/ bronze wear pl. w/ bronze wear pl.

split gear (quiet)

7.13

HYDRAULIC SYSTEM

Disassembly Standard Pump (1 ton) 2

8

5 3 1 4 7 9 6

Sequence 1. End cover

4. Shaft seal and retainer ring

7. Drive shaft

2. O-ring, bush seal, and back-up seal

5. O-ring, bush seal, and back-up seal

8. Gear pack

3. Flange

6. Front bushes

9. Body and rear bushes

Working Rules and Tips The hydraulic pump is a precision-machined component and as such must be handled with extreme care. Cleanliness is imperative: use clean tools and work in a clean place.

1. Clean the disassembled parts with a volatile solvent such as trichlene or chlorobenzene and dry them with compressed air. This does not apply to rubber parts.

Oil Seal An oil seal, once removed, must not be reused.

After disassembly, examine the oil seal in place (in the pump flange) and, if in good condition, leave it in place. When installing a replacement oil seal, be careful not to score or scratch its lip portion.

2. Oil seals, O-rings, and the like are rubber parts. Never clean them with solvent. Blow dirt off rubber parts with compressed air, and keep them immersed in hydraulic oil until they are ready for reassembly. A rubber part showing even slight wear and tear must be replaced. Rubber parts are expendable items that should be replaced once a year.

3. Parts that are installed by pressing or forcing need special treatment.

7.14

99759-8B110

HYDRAULIC SYSTEM

Disassembly Standard Pump (2/3.3 ton) 2

8

5

1

3 9 4

7 6

Sequence 1. End cover

4. Shaft seal and retainer ring

7. Drive shaft

2. O-ring, bush seal, and back-up seal

5. O-ring, bush seal, and back-up seal

8. Gear pack

3. Flange

6. Front bushes

9. Body and rear bushes

Start By: Externally clean the pump to make sure that it is free of all matter that may contaminate the pump parts during disassembly, inspection, or reassembly.

99759-8B110

7.15

HYDRAULIC SYSTEM Suggestions

Removing the Flange

Removing the End Cover

Turn the unit over and lightly tap the mounting flange to disengage it from the locating dowels.

Slide the flange squarely off the shaft.

1. Lightly mark the end cover, pump body, and mounting flange to ensure proper reassembly.

2. Remove the rear bolts, spring washers, and the end cover.

Removing the Seals Remove the O-ring from the pump body. Remove the bush seal and the backup seal from the rear bushings.

8609101

Removing the Shaft Seal Remove the internal retaining clip in the front of the flange. Push the shaft seal squarely out of the mounting flange.

8609100

8609102

7.16

99759-8B110

HYDRAULIC SYSTEM Removing the O-ring and Seals

Separating the Gear Pack

Remove the O-ring from the groove in the body of the pump. Remove the bush seal and the backup seal from the front bushings.

1. Separate the gears, key, and balance plate from the drive shaft and driven idler shaft.

2. Note the position of the balance plate to ensure proper location during reassembly.

Removing the Rear Bushes Remove the remaining rear bushes from the body bore.

8609103

Removing the Bushings Before removing the internal components, mark the bushings to denote the location in the body on a plain area away from the seal location mark.

8609105

FD = Bush on flange end of the drive shaft FI = Bush on flange end of idler shaft CD = Bush on the cover of priority valve end of the drive shaft CI = Bush on the cover end of the idler shaft

Removing the Drive Shaft With the unit lying on its side, hold the drive shaft and pull it squarely out of the body, bringing with it the bushings and the complete gear pack.

8609104

99759-8B110

7.17

HYDRAULIC SYSTEM

Inspection after Disassembly Body 1. Inspect the body bore cut-in where gears wipe into the body.

2. The body can only be reused if the cut-in is bright and polished in appearance and the depth does not exceed .08 mm.

3. The body should be replaced if the surface is scored, has a matte appearance, or shows signs that the tips of the gears have dug in and torn away the surface material.

4. The body should be inspected to ensure that there is no superficial damage which may adversely affect performance or sealing. Pay particular attention to the port threads and body O-ring seal recesses.

Mounting Flange Face 1. The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the regions where the body O-rings and bush seals contact, which could result in external leakage.

2. Check the shaft seal recess for scoring or damage that could result in oil leakage around the outer diameter of the shaft seal. A replacement shaft seal can be refitted with Loctite hydraulic sealant to overcome slight damage in this area.

Bushes and Balance Plate 1. The side faces which abut the gears should be perfectly flat and show no signs of scoring.

Characteristically there are bright polished areas on this surface caused by loading against the gear side faces. This is often more pronounced on the low-pressure side. These should be replaced if there is any general scoring or fine scoring with a matte appearance or tearing of the surface material.

3. The bush bearing liners are acceptable if they are not scored or do not show other damage.

The general outside area of the bush should not show any prominent signs of wear.

Gears 1. The gear side faces should be examined for bushing or scoring. Often operation on contaminated fluid shows scoring between the root of the gear and the journal, which leaves a wear step. If a wear step can be felt, coincidental with the root diameter, by drawing a sharp-pointed tool across the surface from the journal outward towards the tip of the gear, then the gear must be replaced.

2. The gear teeth should be carefully examined to ensure that there are no signs of bruising or pitting.

3. The journal bearing surfaces should be completely free from scoring or bruising. The surface should be highly polished and smooth to the touch.

4. Examine the area where the shaft seal lips run on the drive shaft. This shows up as polished ring or rings. If a noticeable groove can be felt, or if there is scoring, the shaft should be replaced.

5. Examine drive keyway in driveshaft journal extension to ensure it is not damaged or chipped.

6. If the driveshaft is not damaged from the drive coupling and the gears have not been harmed as described above, then the gears can be reused. If the gears are damaged, they must be replaced as a matched set.

7. As a matter of good practice, when pumps have been dismantled, all the seals should be replaced.

2. Often, the tips of the opposing gears have wiped an overlap in a half-moon shape. There must be no noticeable wear step as it is critical that the bush side face and balance plate are completely flat to the gear side face.

7.18

99759-8B110

HYDRAULIC SYSTEM

Reassembly Trucks with Standard Hydraulic Pump

2

8

5 3 1 4 7 9 6

Sequence 1. End cover

4. Shaft seal and retainer ring

7. Drive shaft

2. O-ring, bush seal, and back-up seal

5. O-ring, bush seal, and back-up seal

8. Gear pack

3. Flange

6. Front bushes

9. Body and rear bushes

Start By: Ensure that all parts are perfectly clean. Lubricate the bushes and gears with clean hydraulic fluid.

Ensure that the O-ring recess and end faces of the body remain dry. This will assist the assembly of the components with the body bores.

99759-8B110

7.19

HYDRAULIC SYSTEM Reassembling the Rear Bushes

Fixturing with the End Cover

1. Install the rear bushes (marked CD and CI) into the undowelled end of the body.

Use the end cover to temporarily fixture the parts as they are reassembled. Place the end cover on its back and set the undowelled end of the body against it so that the dowels are pointing up.

Reassembling the Balance Plate 1. Hold the driveshaft and driven gear of the idler shaft together and refit the balance plate in its original position.

8609107

2. The C-shaped cutout in the bushes must be to the side of the body with the cusp removal flat.

2. The two grooves in the plate must be to the low-pressure side of the pump (the side where the body bores meet in a point). With the drive shaft nearest to you, these grooves will be on the left-hand side as shown for the counterclockwise rotation.

3. The diagram below shows the location of the driveshaft and the front bushes and seals installed.

Location dowels

Flange end

Cusp Removal Inlet

8609109

Position of driveshaft Counterclockwise Rotation

7.20

8609108

99759-8B110

HYDRAULIC SYSTEM Reassembling the Gear Pack

Reassembling the O-ring and Seals

1. Fit the key into the keyway in the driveshaft and then carefully fit the gear over the key. Fit the second gear on the idler shaft.

Fit a new O-ring, bush seal and backup seal, ensuring that the seals locate correctly in the seal grooves.

2. Keeping the gear pack together, carefully feed the assembly into the body bores with the driveshaft positioned as previously shown.

8609112

8609110

Reassembling the Shaft Seal 1. Fit a new shaft seal into the recess in the mounting flange with the “garter” spring facing into the pump.

Premium pump configuration

2. If the seal recess was scored, then Loctite hydraulic sealant must be applied to the outer diameter of the seal.

3. Apply a coat of high-melting-point grease to the shaft seal lips.

4. Reinstall the retaining ring. Ensure that it is located in its groove.

Standard pump configuration

Reassembling the Front Bushes Refit the front bushes (FD and FI) into their original bores, remembering that the C-cutout must be to the side of the body with the cusp removal flat.

They must match the rear end bushes.

8609102

8609111 99759-8B110

7.21

HYDRAULIC SYSTEM Reassembling the Flange

Reassembling the End Cover:

Slip the shaft seal and flange assembly over the driveshaft and carefully refit the mounting flange, ensuring that it is positioned squarely onto the dowels in the body.

Replace end cover and refit the bolts and washers. Tighten the bolts.

End cover

8609115A 8609113

Reassembling the Rear O-ring and Seals 1. Hold the whole unit together and carefully turn it over. Ensure that it is supported on the mounting flange, not the driveshaft.

E3000 - EC4000 4.7 to 5.2 kgf•m Tightening torque (34 to 38 lbf•ft) for bolts [46 to 51 N•m]

E4000 - E6500 9.0 to 10.4 kgf•m (65 to 75 lbf•ft) [88 to 102 N•m]

2. Remove the end cover and install a new Oring, bush seal, and backup seal.

NOTE Lube splines before installing in pump motor. Use molybdenum disulfide grease.

8609114

7.22

99759-8B110

HYDRAULIC SYSTEM Inspection after Reassembly Pour a small amount of clean hydraulic fluid into a port and check that the shaft can be rotated without undue force using a smooth-jawed vise.

Running In After Reassembly A unit which has been reassembled with either new gears, bushes, or body, must be carefully run in before it is subjected to full working conditions.

Ideally, this should be done on a test rig, where pressure can be applied gradually and any wipings from the body cut-in can be arrested by filters.

Test unit

Tank

It is recommended that, initially, the unit is run in at 1500 rpm at zero pressure for one minute. The pressure should then be increased in intervals of 35 bars a minute until maximum pressure is reached. Check the system temperature frequently, ensuring that it does not exceed the maximum permissible temperature of 80°C. If the temperature exceeds the system or unit specification, the test must be delayed and operated off-load until the temperature is lowered to an acceptable range.

Typical pump ratings are shown in the table below.

Pressure gauge Micronic filter

Relief valve

Strainer

Variable restrictor

Flow meter

Typical pump test circuit

8609116

Typical performance applicable when using ISOVG 32 at 40°C (104°F) Pump Part Number

Max. Continuous Pressure

Flow Rate

97L71-00030 1500 rpm

[180 bar] (2683 psi) 204 kg/cm2

9.11 GPM 32.1 L/min

97L71-00040 1500 rpm

[180 bar] (2683 psi) 209 kg/cm2

9.91 GPM 34.2 L/min

97271-00700

[185 bar] 11.49 GPM (2683 psi) 43.5 L/min 204 kg/cm2

99759-8B110

Test Speed

1500 rpm

7.23

HYDRAULIC SYSTEM

Control Valve Removal

Sequence 1. Auxiliary lines 2. Tilt lines, connectors, and O-rings 3. Delivery hose, connector, and O-ring 4. Return Hose 5. Lift hose and connector 6. Steering return hose 7. Solenoid 8. Lower Switch 9. Control Valve 10. Steering Return Connector 11. Switches

Start By: 1. Remove the floorplates and the front dashboard cover.

2. Tilt the mast to vertical position, lower the forks all the way, and relieve the pressure in the hydraulic lines.

3. Disconnect the battery.

4. Disconnect the wire leads to the valve switches.

5. Disconnect the hydraulic lines per the listed sequence solenoid, and lower switch.

6. Remove the 3 mounting bolts from the front of the dash.

7. Remove the valve from the truck.

7.24

99759-8B110

HYDRAULIC SYSTEM

Control Valve Installation

1. To install, follow the reverse of the disassembly sequence. Before installing hydraulic fittings, inspect all O-rings for damage or aging and replace them as required.

2. Tighten hoses to the specifications shown in the chart.

99759-8B110

Tightening Torque for Hoses A

Tilt hoses

B

Delivery hose

C

Lift Hose

D

Aux Hoses

E

Steer Gear Return Connector

F

Return Connector

25 ± 0.5 N•m 2.5 ± 0.5 kgf•m 18 ± 3.6 lbf•ft 65 ± 7 N•m 6.5 ± 0.7 kgf•m 47 ± 5 lbf•ft 82 ± 8 N•m 6.5 ± 0.7 kgf•m 47 ± 5 lbf•ft 82 ± 8 N•m 5.0 ± 0.5 kgf•m 36.2 ± 3.6 lbf•ft 48 ± 5 N•m 5 ± 0.5 kgf•m 36.2 ± 3.6 lbf•ft 98 ± 10 N•m 10 ± 1.0 kgf•m 72 ± 7.2 lbf•ft

7.25

HYDRAULIC SYSTEM

Disassembly

7.26

99759-8B110

HYDRAULIC SYSTEM

Suggestions

Reassembly

Main Relief Valve

Before Reassembly: 1. Wash all parts except for O-rings with solvent.

NOTE To remove main relief valve for cleaning or inspection, loosen its plug. Loosening the lock nut will disturb the pressure setting.

Do not remove the main relief valve unless it is defective. This also applies to shut-off valve assembly.

Plug

2. Apply hydraulic oil to O-rings when installing them.

3. Make sure that each spool moves freely.

1. Lay out valve components on a clean, flat working surface. The inlet assembly will include an o-ring, and the spool sections include an o-ring, a load check poppet and a load check spring. Tools required for basic valve assembly include 1/2” and 9/16” open or box end wrenches and a torque wrench with thin wall sockets.

2. Assemble tie rod nuts to one end of each tie rod with one or two threads showing. Insert rods through tie rod holes of inlet (larger tie rod at top). Lay inlet on end with tie rods up, place o-ring into position.

Lock nut

205025

Auxiliary Relief Valve NOTE To remove auxiliary relief valve for cleaning or inspection, loosen its plug.

Loosening the lock nut will disturb the pressure setting.

Do not remove the auxiliary relief valve unless it is defective. This also applies to shut-off valve assembly.

Plug

3. Place first spool section (o-ring side up) on inlet section, position o-ring and insert load check poppet (nose down) and spring (behind poppet) into load check cavity as shown.

Repeat this procedure for each spool section; the load check springs are compressed by the following sections during assembly.

4. Position end section on last spool section and hand tighten tie rod nuts. The end section is a “turn around” section without ports. Universal outlet / power beyond section and power beyond and closed center sections are also used as end sections. These end sections do not have o-ring grooves.

5. Position valve assembly with the mounting pads of the end sections on a flat surface. To obtain proper alignment of end sections relative to the spool sections apply downward pressure to the end sections; snug tie rod nuts to about 10 ft-lb.

Final torque the two 1.2” nuts to 14 ft-lb; final torque the 9/16” nut to 33 ft-lb. check for proper spool movement.

Lock nut

6. Install auxiliary valves and plugs and torque to proper specifications 205025 99759-8B110

7.27

HYDRAULIC SYSTEM

Lift and Tilt Cylinders Removal Lift Cylinders

3 5

4

5

2

1 207068

Sequence 1. Hose guard

4. Cylinder clamp (cushion, collar, and shims)

2. High-pressure hose

5. Lift cylinder and bracket

3. Set bolt and shims

7.28

99759-8B110

HYDRAULIC SYSTEM Suggestions 1. Removing hose guard: With the lift bracket raised to the maximum height, remove each hose guard from the front side of the mast.

!

CAUTION

Be careful not to touch the lift control lever.

2. Lowering lift bracket: Lower the lift bracket by carefully operating the lift control lever.

3. Disconnecting high-pressure hoses: Disconnect the high-pressure hoses at the joints indicated by arrows. Use a container to catch oil flowing out of the hoses.

Right-hand cylinder Left-hand cylinder

204933

99759-8B110

7.29

HYDRAULIC SYSTEM Removing Set Bolts

Removing Lift Cylinders

1. Remove the set bolt at the top of each lift cylinder. Lift the inner mast to separate the cylinder rod ends. To lift the inner mast, clove-hitch a sling to the mast with protective wad.

Attach a lift sling to the lift cylinder from the rear side of the mast and remove the cylinder. Attach the sling before removing the cylinder clamp.

204935 204934

Installation

NOTE The rod end of either lift cylinder is shimadjusted to eliminate the difference in stroke between the cylinders. Before removing the stopper bolts, make a record of the number of shims and the cylinder to which the shims are fitted.

2. Place wood blocks under the inner mast and detach the sling. Use blocks strong enough to support the mast.

Lift Cylinders To install, reverse the removal sequence and do the following steps.

1. Extend and retract the lift cylinders several times under no-load conditions to expel air from the cylinder circuits and to make sure the cylinders move smoothly.

2. Check the oil level in the hydraulic tank with the oil level gauge.

3. Check that the lift height is correct.

4. After the lift cylinders or piston rods have been replaced, check for difference in stroke between the two cylinders (refer to MAST AND FORKS).

202983

7.30

99759-8B110

HYDRAULIC SYSTEM

Removal Tilt Cylinders

2 4

3 1 206883

Sequence 1. Tilt socket pin (spacer)

3. Cylinder pin (spacer)

2. Rubber hose (O-ring)

4. Tilt cylinder

Start By: 1. Lower the forks all the way and tilt the mast fully forward.

2. Hitch lifting slings to the top crossmember of the outer mast by passing them through the round holes. Take up the weight of the mast with a hoist.

Suggestions 1. Retracting piston rod: Remove tilt cylinder pin (item 1), and retract the piston rod all the way.

207085

2. Disconnecting hoses: Disconnect hoses (item 2) from the cylinder at the connectors. Use a container to catch oil from flowing out of the cylinder. Attach caps to the connectors of the cylinder to protect the threads of the connectors and to prevent oil from flowing out of the cylinder when the cylinder is removed.

99759-8B110

7.31

HYDRAULIC SYSTEM Suggestions Removing Tilt Socket Later Version

!

WARNING

If both tilt cylinders are to be removed at the same time, make sure that the mast is held either by a hoist or is securely supported and held in place by blocks.

1 4

2

3

206883

1. Rubber hose 2. Tilt socket pin, bolt, washer 3. Tilt cylinder pin, bolt, washer 4. Tilt cylinder

NOTE When the tilt cylinders are to be replaced, it is necessary to adjust the cylinder stroke and tilt.

7.32

99759-8B110

HYDRAULIC SYSTEM

Disassembly Lift Cylinders 1

2

5 4 3

204948

Sequence 1. Bracket assembly 2. Holder, wiper ring, U-ring and O-ring 3. Bushing and bearing

4. Piston rod, snap ring, holder, U-ring, nylon heel, and piston ring 5. Cylinder tube

Suggestions Removing Piston Rod Draw the piston rod out gently, taking care not to damage the sealing members fitted to the piston.

200349

99759-8B110

7.33

HYDRAULIC SYSTEM

Disassembly Tilt Cylinders ✱ Parts contained in seal kit 4

3 ✱

2

1 ✱

✱

✱

1

207050

Sequence 1. Tilt socket, bushing, bolt, washer, nut, and grease fitting

3. Piston rod, piston seal, and nut 4. Cylinder tube and bushing

2. Bushing, O-ring, dust seal, packing and buffer ring

NOTE Do not remove the tilt socket and cylinder tube bushing unless they are defective.

Suggestions Removing Bushing 1. Wrap the cylinder with a wad of cloth and hold it in a vise. Using a wrench, remove the bushing from the cylinder.

2. When removing the bushing from the piston rod, be careful not to rub the buffer ring, packing, etc., against the threads of the piston rod.

200351

7.34

99759-8B110

HYDRAULIC SYSTEM

Inspection after Disassembly

Precautions for Reassembly

Lift and Tilt Cylinders

1. Wash all parts clean, making sure that each part is clear of any gritty particles.

Cylinder Tube

2. Before inserting the piston rod complete with the piston, apply hydraulic oil to the bore wall of the cylinder tube and to the sealing parts: O-rings, U-rings, wiper rings, nylon heels, piston seals, dust seals, and packings—so they will slide smoothly into the bore.

1. Check the bore wall for wear, grooving, scratch marks, and rusting.

2. Check the welds for cracks.

Piston Rod 1. Check for deflection in the manner shown.

200319

2. Check for surface flaws such as grooving, scratch marks, rusting, and wear. The rod must be replaced if its threads show signs of stripping or any other damage.

3. When clamping the cylinder tube in the vise in order to run the head into the cylinder tube, be careful not to distort the tube #4 and #117.

Before fitting the piston seal to the tilt cylinder piston, squeeze the seal by hand 5 or 6 times to soften it. Hold the piston steady by clamping the rod in a vise and apply a small amount of hydraulic oil to the seal. Fit a portion of the seal to the groove and push the rest of the seal into place a little at a time until the seal is in the groove.

4. Be sure to torque the nut, not the bolt when re-installing the tilt cylinder.

Torque to 108 to 118 N•m; 11 to 12 kgf•m.

Packings and Rings 1. Check the packings and the lips of dust seals for damage, distortion, and deterioration due to aging.

2. Check each ring for deterioration due to aging.

200352

200353

99759-8B110

7.35

HYDRAULIC SYSTEM

Inspection and Adjustment Hydraulic Tank

NOTE

Hydraulic Oil 1. Check the hydraulic oil in the tank for cleanliness. Oil appearing dirty or whitish (showing more or less emulsification) must be changed.

2. Refill capacities in the amount of oil required.

!

A general rule: in any machine, regardless of the mast-and-attachment combination, the oil level should not be above the “H” mark on the level gauge when the mast is all the way down.

Suction Strainer

WARNING

Check the suction strainer for clogging or damage.

Remove the hydraulic tank filler cap only after the truck has been stopped and the fill cap is cool enough to remove with your bare hand.

Return Filter Check the return filter for clogging or damage.

Hydraulic Tank Refill Capacities E3000 - EC4000

E4000 - E5000

EX5000 - E6500

18 (4.8)

24 (6.3)

30 (7.9) Unit: liter (U.S. gal)

7.36

99759-8B110

HYDRAULIC SYSTEM

Control Valve External Leakage 1. Check for oil leaks from the joint between adjacent valve housings sealed by O-ring.

2. Check for oil leaks from the scrapers sealed

by O-rings.

2. Quickly disconnect the oil return hose and start collecting the oil coming out of the valve from the oil return port A.

3. Check for oil leaks from the screw connections.

Internal Leakage It is not practical to check the control valve alone for internal leakage. The correct way to check the control valve in place under normal operating conditions follows.

The internal leakage to be checked includes leakage occurring at the lift spool, tilt spool, tilt lock valve, and check valves.

A

[Test oil temperature: approx. 50°C (122°F)] 1. Pick up a load equal to the rated capacity. Lift it approximately 1 meter (3 ft) high. Tilt the mast forward 3° - 4° and turn off key.

Amount of oil collected for 15 minutes

500 cc (30.5 cu. in.) maximum

3. If the tilt cylinders or lift cylinders drift (the mast tilts forward or the fork lowers) excessively even though the amount of oil collected in 15 minutes is less than 500 cc (30.5 cu. in.), measure the internal leakage of each cylinder. (The measurement is the assembly standard and not the service limit.)

3° - 4°

approx.

1 meter (3 feet)

203521A

99759-8B110

7.37

HYDRAULIC SYSTEM Main Relief Valve Adjustment

Auxiliary Relief Valve Adjustment

1. Screw in special tool (6V3965) pressure port with o-ring into gauge port on valve (B).

1. Screw in special tool (6V3965) pressure port with o-ring into delivery hose port on valve(B).

2. Attach a pressure gauge capable of measuring up to 250 kgf•cm2 (3555 psi) [25,000 kPa] to the pressure port.

2. Attach a pressure gauge capable of measuring up to 250 kgf•cm2 (3555 psi) [25,000 kPa] to the pressure port.

3. Start the truck and move the control lever to the backward tilt position and hold. If the relief pressure reading is

3. Start the truck and move the Auxiliary 1 control lever to the far right position and hold. If the relief pressure reading is

197 ± 3 kgf/cm2 (2630 ± 50 psi) [19,650 ± 34 kPa]

158 ± 5 kgf/cm2 (2250 ± 71 psi) [15,513 ± 490 kPa]

when the tilt cylinders reach the end of their stroke, the main relief valve setting is correct.

the auxiliary relief valve setting is correct.

B A C

4. If the setting is incorrect, loosen the lock (C) nut of the adjusting screw and, while observing the pressure gauge reading, slowly turn the adjusting screw in either direction until the gauge indicates the prescribed set value.

5. While holding the adjusting screw, tighten the lock nut to secure the adjusting screw.

6. After securing the adjusting screw, recheck the setting.

Main relief valve setting

7.38

197 ± 3 kgf/cm2 (2630 ± 50 psi) [19,650 ± 34 kPa]

4. If the setting is incorrect, loosen the lock nut of the adjusting screw and, while observing the pressure gauge reading, slowly turn the adjusting screw in either direction until the gauge indicates the prescribed set value.

5. While holding the adjusting screw, tighten the lock nut to secure the adjusting screw.

6. After securing the adjusting screw, recheck the setting.

Auxiliary relief valve setting

158 ± 5 kgf/cm2 (2250 ± 71 psi) [15,513 ± 490 kPa]

99759-8B110

HYDRAULIC SYSTEM Basic Hydraulic Switch Adjustments Install switch on Lift spool per Photo 1. Adjust and torque bolts on switches to 7 ± 1 in-lbs [0.79 N•m ± 0.11 N•m] (0.08 kgf•m ± 0.01 kgf•m).

Switch 1

A

Install switch on Tilt spool or Auxiliary spool per Photo 3 centered on spool lobe. Adjust and torque bolts on switches to 7 ± 1 in-lbs [0.79 N•m ± 0.11 N•m] (0.08 kgf•m ± 0.01 kgf•m).

Switch has to activate before reaching point A (the top of the cam).

Switch 3

Switch activates once leaving point C (the spool Groove).

C

Photo 1

Photo 3

Install switch 2 on Lift spool per Photo 2 centered on identification groove. Adjust and torque bolts on the switches to 7 ± 1 in-lbs [0.79 N•m ± 0.11 N•m] (0.08 kgf•m ± 0.01 kgf•m).

Switch 2

Switch has to activate before reaching point B (the top of the cam).

B

Switch 2

Photo 2

99759-8B110

7.39

HYDRAULIC SYSTEM Lift and Tilt Cylinders

NOTE

Mast Tilt Angle Adjustment 1. Place machine in a horizontal position.

2. Tilt the mast all the way backward, and stop the truck.

It is not necessary to adjust the forward tilt angle, provided that the backward tilt angle is properly adjusted.

3. Measure the tilt angle of the mast at both sides.

4. To adjust the tilt angle, loosen bolt A of the tilt cylinder socket, and adjust the cylinder stroke by turning the rod on either cylinder so that there is no difference in stroke between the cylinders.

Forward/backward tilt angle

5° – 6°

Lift Cylinder Stroke Adjustment 1. Slowly raise the inner mast and check the stopping manner of the left and right piston rods at the moment the inner mast reaches its maximum lift height.

207054

Tightening torque for tilt cylinder socket bolt

127 to 152 (13 to 15.5) [94 to 112]

204698

2. If the top of the mast rocks at that moment, it should be adjusted with shims. Abnormal conditions will appear as a time lag in stopping between right- and left-hand piston rods and rocking of the rod with a longer cylinder stroke.

7.40

99759-8B110

HYDRAULIC SYSTEM Adjusting Method 1. Raise the inner mast, place blocks under the right and left sides of the mast, and lower the mast until it rests on the blocks.

3. Extend the piston rod and tighten the cylinder stopper bolt. Remove the blocks from under the inner mast.

4. Slowly lower the inner mast all the way to make sure that the piston rods move smoothly.

202983

1. Remove the stopper bolt at the top of the lift cylinder which stopped first, retract the piston rod, and insert the shims at the top of the piston rod end.

Stopper bolt

Shims

200365

NOTE To retract the piston rod, move the lift control lever to the lowering position to let the oil escape from the lift cylinder.

99759-8B110

7.41

HYDRAULIC SYSTEM Testing Lift Cylinder Drift Test

Tilt Cylinder Drift Test

1. Pick up a load equal to the rated value, tilt the mast to the vertical position, raise the forks 1 to 1.5 m (3.3 to 4.9 ft) and stop the truck.

1. Pick up a load equal to the rated value, tilt the mast to the vertical position, raise the forks about 50 cm (20 in.) and stop the truck.

2. Scribe a line on the mast column and measure the drift of the lift cylinder (drop for 15 minutes)

2. Measure the drift extension of the tilt cylinder for (extension) 15 minutes.

206891

E3000 - EX5000

Lift cylinder drift (rated load)

50 (2.0) maximum

207056

E5500 - E6500

40 (1.6)

E3000 - EC4000

Tilt cylinder drift 22 (0.9) (rated load) maximum

E4000 - EX5000

E5500 - E6500

20 (0.8)

15 (0.6)

Unit: mm (in.)/15 min

Unit: mm (in.)/15 min

Piping 1. Check each hydraulic circuit for leaks.

2. Check to make sure that each hose is free from twisting or excessive loops.

7.42

99759-8B110

GAUGE GAGE

3000-6500 lb Capacity Four Section Hydraulic Schematic

TABLE OF CONTENTS Chapter 8: Mast and Forks Description ................................................................................................................................... 8.1 Removal and Installation.............................................................................................................. 8.2 Disassembly ................................................................................................................................ 8.4 Inspection after Disassembly ....................................................................................................... 8.6 Reassembly.................................................................................................................................. 8.7 Inspection and Adjustment...........................................................................................................

Forks ........................................................................................................................................

Chain Tension Adjustment .......................................................................................................

Clearance Adjustment on Lift Bracket......................................................................................

Mast Clearance Adjustment .....................................................................................................

Main Roller Shim Replacement ...............................................................................................

Mast Strip Adjustment..............................................................................................................

Tilt Angle Adjustment ...............................................................................................................

Lift Cylinder Stroke Adjustment................................................................................................

Bleeding Lift Cylinders .............................................................................................................

8.8 8.8 8.9 8.10 8.13 8.15 8.15 8.16 8.17 8.17

Service Data ................................................................................................................................ 8.18 Troubleshooting ............................................................................................................................ 8.20

NOTES

____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________

MAST AND FORKS

Mast and Forks Description G 1 A

2 3

Forward

Detail of A

B

Forward

Detail of F

D Forward

Forward

C Detail of B, C

E

4

Detail of D

Forward

F

Detail of E

5

Detail of G 207082

207081

Components 1. Inner mast

A. Main roller

E. Main roller

2. Outer mast

B. Main roller

F. Main roller

3. Lift chain

C. Main roller

G. Mast strip

4. Lift bracket

D. Side roller

5. Mast support bearing cap The simplex mast features two lift cylinders placed behind the mast columns, right and left, to provide maximum forward visibility.

Mast strips are fitted to the top end parts of outer mast. These strips are for backing up the inner mast when the mast is tilted backward.

Diam. of main roller

E3000 - EC4000

E4000 - E6500

S

99 (3.90)

113.8 (4.48)

M

100 (3.94)

115 (4.53)

L

101 (3.98)

116 (4.57)

LL

102 (4.016)

117 (4.606) Unit: mm (in.)

99759-8B110

8.1

MAST AND FORKS

Removal and Installation Mast and Lift Bracket Assembly

5

2

4

3

6 1

207083

Sequence 1. Nut

4. Tilt socket pins

2. Forks and lift bracket

5. Tilt cylinders

3. High-pressure hose for lift cylinders

6. Mast-support bearing caps and bushing

Suggestions Removing Lift Bracket 1. Tilt the mast forward, and lower the inner mast all the way. Slacken the lift chains, and remove the nuts from the anchor bolts.

2. Tilt the mast back to vertical position. Secure the lift bracket to prevent it from falling over.

Raise the inner mast until the lift bracket becomes free. Then, back the truck away, leaving the lift bracket and fork assembly standing on the floor.

207084

8.2

99759-8B110

MAST AND FORKS Removing Lift Cylinder High-Pressure Hoses With the mast in the lowest position, disconnect the hoses at the flow regulator valve.

Removing Mast Support Bearing Caps 1. Scribe marks on the bearing caps before removing them.

Removing Tilt Cylinders 1. Attach a sling to the holes, left and right in the top cross member of the mast, and lift the mast with a hoist.

Marks

207087

2. Remove the cap bolts and lift off the mast assembly, laying it down flat on a level floor.

207085

NOTE Lay the mast assembly on a floor large enough for disassembly.

NOTE Be sure to use a hoist having a capacity enough to carry the weight of the mast assembly.

Weight of Components

Gross (Simplex 3.3 m mast)

E3000 EC4000

E4000 E5500

E6000 E6500

520 (1150)

725 (1600)

830 (1830)

Unit: kg (lb)

2. Remove the tilt socket pins, and separate the masts from the tilt cylinders.

Tilt socket pin 207086 99759-8B110

8.3

MAST AND FORKS

Disassembly 10

12 15

3

11

10

13

9 2

16

17

8 2 6 6 7 6

14

1 5

4 207088

Sequence 1. Nut 2. Forks and lift bracket 3. Backrest 4. Main roller and shims 5. Main roller and shims 6. Side roller, bracket, and shims 7. Hose guard 8. Lift hose (high pressure) (Rubber hose, T-joint and down safety valve)

10. Cylinder clamp, seat, shims, cushion, collar and bolts 11. Bolt and shims 12. Mast strip and shims 13. Main roller and shims 14. Main roller and shims 15. Inner mast 16. Lift cylinders 17. Outer mast

9. Snap ring and chain wheel

8.4

99759-8B110

MAST AND FORKS Suggestions Removing Mast Strips and Main Rollers Remove bolts 10, 11 to free lift cylinder 16. Cross the tops of the two lift cylinders. Slide inner mast 15 toward the bottom of outer mast 17, and remove main rollers 13, 14 and mast strips 12.

Removing Inner Mast After removing the main rollers, attach a sling to the inner mast crossmember and slide the inner mast toward the top of the outer mast until it gets clear of the outer mast roller shafts. Sling the inner mast again and remove it from the outer mast.

207089

99759-8B110

8.5

MAST AND FORKS

Inspection after Disassembly Lift Chains, Chain Wheels and Chain Wheel Supports

Mast 1. Check each roller for wear, binding or other defects.

2. Check each roller for flat spots on rolling surface.

1. Measure the length of each chain to be sure that two chains are equal in length. Also check the chains for wear, evidence of breakage, link binding and twist.

3. Check the mast member and the welds of crossmembers, shafts and supports for cracks.

2. Check each chain anchor bolt for cracks or damaged thread.

4. Check the mast support bushings for wear or other damage.

3. Check each chain wheel support and chain wheel for crack or wear. Check to be sure that the wheels are capable of smooth rotation.

4. Measure sections of chain that travel over the chain wheel.

Length of Chain (Per 20 Links)

207090

Lift Bracket 1. Check the main rollers and side rollers for smoothness of rotation. Inspect each roller for wear and cracks.

E3000 EC4000

E4000 E5500

E6000 E6500

A

318 (12.52)

381 (15.00)

508 (20.00)

B

327 (12.87)

392 (15.43)

523 (20.59)

Unit: mm (in.)

A = Assembly standard B = Repair or service limit

Mast Strips Check the mast strips for damage, wear or distortion.

2. Check the welds of the bracket for cracks.

3. Check the finger bar for bend or distortion.

Finger bar

207091

Distortion of finger bar

A

5 mm (0.2 in.) maximum A = Assembly standard

8.6

99759-8B110

MAST AND FORKS

Reassembly To reassemble, follow the reverse of disassembly sequence and do the following steps:

Adjusting Mast and Lift Bracket Clearance Rollers for mast and lift bracket are available in three sizes (diameters) for selective use. Select the size that will provide a longitudinal clearances of 1 mm (0.04 in.) and less.

Clearance

Mast Supports 1. Check mast support bushing for wear. Replace if worn.

2. Apply a grease to the inside surfaces and grooves of the caps.

3. Install mast support bushings and caps with beveling toward the center of truck respectively. Greasing will be facilitated if the mast is lifted by placing wooden blocks under it.

Mast cap Bushing

Clearance

Upper/middle roller

Lower roller

Apply grease

207096

Side with wider cut 203712

Roller Sizes Diameter of main roller

E3000 - EC4000

E4000 - E6500

S

99 (3.90)

113.8 (4.48)

M

100 (3.94)

115 (4.53)

L

101 (3.98)

116 (4.57)

LL

102 (4.016)

117 (4.606)

Precautions for Installing Chain Anchor Kit Be careful not to install the center plate in the position for link plate.

2 3

Unit: mm (in.)

Cylinder Clamps Install each lift cylinder in place (in vertical position) by fitting to the support, and see if there is any clearance between the outer mast and cylinder.

Reduce the clearance, if any, to zero by shimming.

1 4

Stamped mark 207094

1. Link plate (marked) 2. Center plate (not marked) 3. Link 4. Split pin

Shims

207093 99759-8B110

8.7

MAST AND FORKS

Inspection and Adjustment Forks 1. Carefully inspect the forks for cracks. Special attention should be given to the heel section A, all weld areas and B mounting brackets.

Forks with cracks should be removed from service.

“Wet Test” magnetic particle inspection is generally preferred due to its sensitivity and the ease of interpreting the results.

3. Check the fork blade D. The fork should be withdrawn from service if the thickness is reduced to less than the tolerant thickness.

Check the heel of fork. Fork blade length may also be reduced by wear, especially on tapered forks and platens. Remove the forks from service when the blade length is no longer adequate for the intended loads.

B D

A

Toe

Heel

101628

2. Check the difference in height of one fork tip to the other when mounted on the fork carrier.

A difference in fork tip height can result in uneven support of the load and cause problems when entering loads.

The maximum allowable difference in fork tip elevation C is 5 mm (0.20 in.) for pallet forks.

Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference.

101630

Tolerant Thickness

Standard

Limit

E3000

40 (1.6)

31 (1.2)

E3500 - EC4000

40 (1.6)

33 (1.3)

E4000

45 (1.8)

36 (1.4)

E5000, EX5000, E5500

45 (1.8)

39 (1.5)

E6000, E6500

45 (1.8)

40 (1.57) Unit: mm (in.)

C

101629

8.8

99759-8B110

MAST AND FORKS Chain Tension Adjustment

!

Tightening Torque

WARNING

Personal injury can be caused by sudden movement of the mast and lift bracket.

Blocks must be used to prevent the mast and lift bracket from any movement while the adjustments are made. Keep hands and feet clear of any parts that can move.

Nut 2 Nut 3

Nut 1

E3000 - E5500

E6000 - E6500

57 (5.8) [42.0] 98 (10) [72.3]

84 (8.6) [62.2] 147 (15.0) [108.5] Unit: N•m (kgf•m) [lbf•ft]

1. Have the truck standing on a level floor, with the mast vertical and the forks lowered to the floor. Check to be sure that the lift cylinders are fully retracted.

6. Adjust until tension is equal on both chains.

2. Set the anchor bolts with nut 3.

3. Raise the forks slightly and push the chains inward midway between the chain wheel and anchor alternately to check the tension. When adjusting the chains by means of the nut 3, tilt the mast forward to slacken the chains to facilitate adjustment.

4. Turn nut 3 to adjust the chain tension. Then, hold the anchor bolt in place with a wrench and tighten nut 2 to the specified torque.

5. Hold nut 3 in place with a wrench, and tighten nut 1 to the specified torque.

Anchor bolt

2 nut

3 nut 1 nut 102709

99759-8B110

8.9

MAST AND FORKS Clearance Adjustment on Lift Bracket Longitudinal Clearance Adjustment on Lift Bracket Main Rollers 1. Raise the forks a little from the floor.

Roller Sizes

2. Insert a bar between the upper part of lift bracket and the inner mast, and push the inner mast to one side. Using a feeler gauge, measure the clearance F between the main roller and inner mast on the opposite side.

F

Diameter of main roller

E3000 - EC4000

E4000 - E6500

S

99 (3.90)

113.8 (4.48)

M

100 (3.94)

115 (4.53)

L

101 (3.98)

116 (4.57)

LL

102 (4.016)

117 (4.606) Unit: mm (in.)

4. Lift bracket main rollers (upper and center rollers).

The upper rollers should be the same in size or 1-rank larger than the center rollers.

F

207095

0.1 to 1.0 mm (0.004 to 0.039 in.)

Clearance F

3. If the clearance F is out of specification, use oversize rollers.

F

F

Lower roller

8.10

Upper/middle roller

207096

99759-8B110

MAST AND FORKS Lateral Clearance Adjustment on Lift Bracket Main Rollers and Side Rollers 1. Raise the mast all the way.

2. Set a dial indicator on the inner mast with its contact point rested on the side of the lift bracket.

3. Go over to the opposite side of the mast, and push the lift bracket to one side with a bar. Set the indicator to zero.

4. Insert a bar between the inner mast and lift bracket on the indicator side, and push the lift bracket to the opposite side.

For the lift bracket upper main roller or center main roller, to extend 0.5 mm (0.02 in.), insert a 0.5 mm (0.02 in.) shim (a) on the inside and remove the 0.5 mm (0.02 in.) shim (b) from the lower stopper, then tighten the bolts.

Inner mast

Shims (b)

Shims (a)

207156

203818

5. Read the indicator.

Clearance G

0.1 to 0.5 mm (0.004 to 0.020 in.)

6. Adjust clearance G1 between the middle main roller and weld plate 2 at the maximum lift position by increasing or decreasing the thickness of the shim.

1

1 G1

2

2

202276

99759-8B110

8.11

MAST AND FORKS Lateral Clearance Adjustment on Lift Bracket Main Rollers and Side Rollers, continued 7. Lower the lift bracket slightly below its maximum lift position, then adjust clearance G2 between the side roller and mast by increasing or decreasing the thickness of the shim.

8. With the lift bracket at the maximum lift position, adjust clearance G3 with shims.

G2

Side roller

Side Roller

G3

207158

202277

Adjust the side roller clearance by adding shims under the roller bracket.

Shims

Shims Roller

Bracket

8.12

207157

207098

99759-8B110

MAST AND FORKS Mast Clearance Adjustment Longitudinal Clearance Adjustment on Mast Main Rollers

Lateral Clearance Adjustment on Inner Mast Main Rollers

1. Tilt the mast all the way backward.

1. Raise the mast all the way.

2. Using a feeler gauge, measure the clearance H between the inner mast lower roller and the outer mast.

2. Set a dial indicator on the inside of the outer mast with its contact point rested on the inner mast.

Clearance H

0.1 to 1.0 mm (0.004 to 0.039 in.)

3. Go over to the opposite side of the mast, and push the inner mast against the outer mast.

Set the indicator to zero.

3. If the clearance H is out of specification, use oversize rollers.

Roller Sizes Diameter of main roller

E3000 - EC4000

E4000 - E6500

S

99 (3.90)

113.8 (4.48)

M

100 (3.94)

115 (4.53)

L

101 (3.98)

116 (4.57)

LL

102 (4.016)

117 (4.606) Unit: mm (in.)

J 204886

4. Insert a bar between the outer and inner masts on the indicator side, and push the inner mast to the opposite side.

5. Read the indicator.

H

0.1 to 0.5 mm (0.004 to 0.020 in.)

Clearance J

207099

J 207101

99759-8B110

8.13

MAST AND FORKS 6. If the clearance J is out of specification, adjust it by using shims.

K

Shims 207103

207102

6. If the clearance K is out of specification, adjust it by using shims.

NOTE Refer to Main Roller Shim Replacement.

Lateral Clearance Adjustment on Outer Mast Main Rollers

Shims

1. Raise the mast all the way.

207104

2. Set a dial indicator on the outer mast with its contact point rested on the inner mast.

3. Go over to the opposite side of the mast, and push the outer mast against the inner mast with a bar. Set the indicator to zero.

4. Insert a bar between the outer and inner masts, and push the inner mast to the opposite side.

NOTE Refer to Main Roller Shim Replacement.

5. Read the indicator.

Clearance K

0.1 to 0.5 mm (0.004 to 0.020 in.)

K

204889

8.14

99759-8B110

MAST AND FORKS Main Roller Shim Replacement

Mast Strip Adjustment

1. Remove the lift bracket from the mast.

1. Check the clearance L with the clearance between the outer mast rollers and inner mast set to zero (0) in maximum lift position.

NOTE L

Refer to REMOVAL AND INSTALLATION, 1. Lift Bracket Removal.

2. Lower the inner mast below the outer mast as follows: a. Raise the front end of the machine, and block that end with a jack stand or the like. b. Remove the upper set of bolts from the lift cylinders, and lift the inner mast with a hoist. Remove the hose guard. c. Remove the clamps from the lift cylinders.

Pull the bottom ends of the cylinders from the outer mast, tilt the cylinders to the center of the mast, and tie them to the crossmember of outer mast with rope. d. Slowly lower the inner mast until it comes in contact with the lift cylinders. e. Now the main rollers can be removed from the inner and outer masts. Remove the mast strips and shims in advance because they are apt to come off under this condition.

200391

0.1 to 0.5 mm (0.004 to 0.020 in.)

Clearance L

2. If the clearance L is out of specification, adjust it by means of shims.

NOTE Refer to Main Roller Shim Replacement.

3. After adjusting the all clearance, move the mast and lift bracket slowly to make sure that they move smoothly through their full stroke.

Shims

202961

200392

99759-8B110

8.15

MAST AND FORKS Tilt Angle Adjustment 1. Adjust the tire pressure correctly and keep the truck level.

2. Tilt the mast all the way backward and stop the engine 3. Measure the backward tilt angle of the mast at both sides.

5. After adjusting the tilt angle, tighten the socket bolts to the specified torque.

Tightening torque for tilt cylinder socket bolt

127 to 152 (13 to 15.5) [94 to 112] Unit: N•m (kgf•m) [lbf•ft]

3. To adjust the tilt angle, loosen the bolt of tilt cylinder socket, and adjust the cylinder stroke by turning the rod on either cylinder so that there is no difference in stroke between the cylinders, left and right.

Bolt 207105

NOTE It is not necessary to adjust the forward tilt angle if the backward tilt angle is properly adjusted.

Forward/backward tilt angle

8.16

5° to 6° (standard)

99759-8B110

MAST AND FORKS Lift Cylinder Stroke Adjustment 1. Slowly raise the inner mast, and check how the piston rods, left and right, stop at the moment the inner mast reaches its maximum height.

2. If the top of the inner mast rocks at that moment, make a shim adjustment. Abnormal condition can be told by a little time lag in stopping between the piston rods, left and right, and rocking of the rod with a longer cylinder stroke.

2. Remove the set bolt at the top of lift cylinder which stopped first, retract the piston rod, and insert shims at the top of piston rod end.

3. Extend the piston rod, and tighten the cylinder set bolt. Remove the blocks from under the inner mast.

Set bolt Shims

200365

204698

4. Slowly lower the inner mast all the way to make sure that the piston rods move smoothly and that the left and right lift cylinders come to the end of stroke simultaneously.

Adjusting Method 1. Raise the inner mast, place blocks under the left and right sides of the inner mast, and lower the mast until it rests on the blocks.

Bleeding Lift Cylinders When air and oil remaining inside the air chamber of the rod and inside the rod chamber between the tubes are compressed, they open the check valve and flow out of the cylinder. Therefore, there is no need to bleed the lift cylinders.

202983

99759-8B110

8.17

MAST AND FORKS

Service Data Inner mast F

L G1

G3 G2 B

F

Lift Bracket A K H

C1

E J

Outer mast

C2

D

207106

8.18

99759-8B110

MAST AND FORKS

Service Data Truck Model

Item Difference in height between fork tips

A

Forks Chains Rollers

5 (0.20) 125 x 45 (4.92 x 1.8)

E3000 100 x 31 (3.9 x 1.2) E3500 100 x 33 (3.9 x 1.3)

E4000 100 x 38 (3.9 x 1.5) E5000-EX5000 100 x 40 (3.9 x 1.57)

125 x 39 (4.92 x 1.53)

A

318 (12.52)

381 (15.00)

508 (20.00)

B

327 (12.87)

392 (15.43)

523 (20.59)

S

A

99 (3.90)

113.8 (4.48)

M

A

101 (3.94)

115 (4.53)

L

A

101 (3.98)

116 (4.57)

LL

A

102 (4.016)

117 (4.606)

B

(width x thickness) Length of tilt chains (per 20 links)

Mast and Lift Bracket

E6000-E6500

100 x 40 (3.9 x 1.6)

Thickness of forks

Diameter of main roller

E4000-E5500

100 x 40 (3.9 x 1.6)

A

99759-8B110

E3000-EC4000

Diameter of side roller

A

Distance between outer mast main rollers (inside to inside) A

42 (1.65)

A

523 (20.59)

575 (22.64)

Distance between inner mast main rollers (outside to outside) B

A

581 (22.87)

639 (25.16)

Distance between lift bracket main rollers (outside to outside) C1

A

485 (19.09)

535 (21.06)

Distance between lift bracket main rollers (outside to outside) C2

A

487 (19.17)

537 (21.14)

Distance between lift bracket main rollers (outside to outside) D

A

491 (19.33)

539 (21.22)

Distance between lift bracket side rollers (outside to outside) E

A

496 (19.53)

546 (21.50)

Longitudinal clearance of lift bracket middle rollers (with forks slightly lifted) F

A

0.1 to 1.0 (0.004 to 0.039)

Lateral clearance of lift bracket middle main rollers (fully raised) G1

A

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of lift bracket side rollers (fully raised) G2

A

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of lift bracket lower main rollers (fully raised) G3

A

0.1 to 0.5 (0.004 to 0.020)

Longitudinal clearance of mast main rollers (in the whole lift range) H

A

0.1 to 1.0 (0.004 to 0.039)

Lateral clearance of inner mast main rollers (fully raised) J

A

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of outer mast main rollers (fully raised) K

A

0.1 to 0.5 (0.004 to 0.020)

Mast strip clearance (fully raised) L

A

0.1 to 0.5 (0.004 to 0.020)

8.19

MAST AND FORKS

Troubleshooting Complaint

Possible Cause

Lift bracket and inner mast will not move smoothly

a) Main rollers and side rollers having no proper clearance b) Rollers involved binding on their shafts c) Rollers damaged d) Improper mast-to-strip clearance

Lift bracket or inner mast cocks

a) Too much clearance on side rollers, or side rollers damaged b) Lift chains unequally tensioned c) Shim adjustments unequally made on left and right lift cylinders (at maximum height)

Mast makes noise

Rollers not rotating smoothly on their shafts, or damaged

Load drops (drifts)

a) Lift cylinder packing damaged b) Lift cylinder bore grooved c) Control valve defective

Mast shakes entirely

Mast-support bushing worn

Mast is distorted

Improper loading or overload

Fork tips differ in height

a) Finger bar bent b) Forks bent c) Distortion of mast due to off-center loading

8.20

99759-8B110

TABLE OF CONTENTS Chapter 9: Troubleshooting Front Axle and Reduction Differential .......................................................................................... 9.1 Brake System ............................................................................................................................... 9.2 Steering System........................................................................................................................... 9.4 Hydraulic System ......................................................................................................................... 9.6 Rear Axle ..................................................................................................................................... 9.8 Mast and Forks ............................................................................................................................ 9.9

NOTES

____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________ ____________________________________________________________________________

TROUBLESHOOTING

Troubleshooting Front Axle and Reduction Differential Complaint Gear noise comes out continuously during normal cruising run

Irregular noise comes out during normal travel

Abnormal noise comes out when turning a corner

Differential overheats

99759-8B110

Possible Cause

Remedy

Teeth worn excessively or tooth contact out of adjustment in spiral bevel drive

Readjust or replace

Bearing preloads too much or too little, or bearings are worn excessively

Readjust or replace

Hub bearings broken

Replace

Improper tooth contact between reduction pinion (on output shaft) and reduction gear

Readjust

Bearings associated with spiral bevel drive or hub bearings broken

Replace

Differential side gears have broken teeth, or thrust washers worn

Replace gears or washer

Metal piece in axle housing

Clean and replace oil

Bolts securing axle shaft or differential carrier are loose

Retighten

Fit differential gears in differential case are out of specification due to wear

Replace worn parts

Broken teeth on differential pinions or side gears, or pinions seized on spiders

Replace defective parts

Bearings broken due to too large a preload

Replace bearing and readjust preload

Backlash between reduction pinion (on output shaft) and reduction gear too small

Replace bearings and readjust preload and backlash

9.1

TROUBLESHOOTING

Brake System Complaint Lack of braking force

Service Brakes

Pedal stroke is too large

Uneven braking (machine pulls to one side)

Brake squeals

Brake chatters or clatters

9.2

Possible Cause

Remedy

Oil leaking past primary cup in master cylinder

Replace piston cup if cylinder is worn.

Replace cup and fluid if the cup is distorted.

Oil leaking past cups in wheel cylinders

Replace pipe and connector and retighten

Oil leaking from oil pipe connection

Retighten

Shoe linings excessively worn

Replace

Linings dirty with oil or grease

Clean or replace

Air trapped in brake oil line

Bleed air at master cylinder and wheel cylinder

Piston cup defective in master cylinder

Replace

Not enough fluid in reservoir

Refill

Push rod-to-piston clearance too large in master cylinder

Readjust

Brake fluid leakage

Replace piston cup if cylinder is worn.

Replace the cup and fluid if the cup is distorted.

Automatic adjusting device out of order

Check cable guide and adjusting spring installation. If they are defective, replace fitting cable, lever and adjusting screw.

Lining or drum dirty with oil or grease in less effective brake

Clean or replace

Wobbly or loose-mounted drum in less effective brake

Replace drum. Readjust and retighten.

Linings glazed

Replace shoe & lining assembly

Linings badly worn

Replace

Backing-plate securing bolts loose

Retighten

Wheel bearings loose

Readjust preload and retighten

Brake drum dirty

Clean

Anchored ends of shoes rattling on anchor

Repair or replace

Shoe ledges badly worn

Replace backing plate

Piston badly worn in wheel cylinder

Replace

99759-8B110

TROUBLESHOOTING

Parking Brake

Complaint

Remedy

Lever stroke is too small

Lining-to-drum clearance too small

Readjust

Squeals during traveling

Lining-to-drum clearance too small

Readjust

Brake drum badly distorted

Repair or replace

Parking brake cable longer than specified

Check drum-to-lining clearance and, if brake will not apply, turn adjusting knob clockwise

Linings worn to service limit

Replace shoe & lining assembly

Lining-to-drum clearance too small

Readjust

Lack of brake lever operating effort

Readjust to 25 to 30 kgf (55 to 66 lbf) [245 to 294 N]

Will not apply

Complaint Hard steering

Steering System

Possible Cause

Possible Cause

Remedy

a) Overloaded steer axle

Reduce load

b) Damaged mechanical linkage

Replace

c) Dry mechanical linkage joints

Lubricate

d) Mechanical joints too tight

Readjust

e) Kingpin bearings improperly preloaded

Readjust

f) Low pump pressure

Replace pump

a) Damaged or worn mechanical linkage

Replace

b) Loose cylinder piston

Replace cylinder rod

a) Damaged or worn mechanical linkage

Replace

b) Tire diameter differs between right and left

Replace tire

Erratic steering

Loose cylinder piston

Replace cylinder rod

Excessive free play

Damaged or worn linkage between cylinder

Replace

at steered wheels

and steered wheels

Axle shimmy

a) Excessive clearance between the kingpin

Truck wanders

Truck drifts

Repair or replace

and its bearings b) Worn or damaged hub bearing

Replace

Rear tires wear

Tire on one side differs in kind or brand

Replace tires

prematurely

from that on the other side.

or unevenly

99759-8B110

9.3

TROUBLESHOOTING

Steering System Complaint Slow steering, hard steering or loss of steering

Truck wanders

Possible Cause

Remedy

Worn or malfunctioning pump

Replace

Malfunctioning relief valve

Readjust or replace

Worn or malfunctioning steer gear

Replace

Pipe or tube flattened, or restriction in an oil line

Clean or replace

Air in system

Low level of oil

Fill as required

Leaking joint

Tighten joint

Pinched pipe or hose

Straighten or replace

Worn steer gear

Replace

Worn steer gear

Replace

Leakage of cylinder seals or at lines between steer gear and cylinder

Repair

Temporary hang-up in steering

Thermal shock—caused by actuation of hydraulic lift and tilt for long periods of time without actuation of steering system, creating more than a 28°C (50° F) temperature differential between the oil in the tank and the oil in the steer gear.

Correct operating procedure

Erratic steering

Air in system

Low level of oil

Fill as required

Leaking joint

Tighten joint

Pinched pipe or hose

Straighten or replace

Steering slip

Spongy or soft steering

9.4

Thermal shock damage to steer gear

Replace

Motor not operating at correct speed

Repair/replace

Air in system

Low level of oil

Fill as required

Leaking joint

Tighten joint

Pinched pipe or hose

Straighten or replace

Air trapped in cylinder

Bleed air

99759-8B110

TROUBLESHOOTING Complaint Steering wheel turns with no axle response

Possible Cause Problem with steering column

Air in steer gear

No flow to steer gear

Remedy

Column loose or damaged

Repair or replace

Column splines damaged or disengaged from steer gear

Repair or replace

Starved at startup

Temporary

Starved from long period of non-use

Temporary

Low oil level

Fill as required

Ruptured hose

Replace

Thermal shock damage to steer gear Replace Blown piston seal Steering instability or oscillation

Air in lines

Replace Pump sucking air at inlet

Check joints

Components or lines contain air

Bleed circuit

Improper relief setting

Readjust

Steering wheel turns in wrong direction

Lines connected to wrong cylinder ports

Correct connections

Excessive freeplay

At steering wheel

Loose steering wheel nut

Tighten

Damaged or worn column shaft

Replace

Leaky cylinder seals

Replace

At steered wheels Binding or poor centering of steering wheel

Steer gear locks up

Binding or misalignment between column and steer gear

Readjust steer gear mounting bracket or replace rubber mounting grommets

High back pressure in tank return line

Clear blockages

Contamination in steer gear unit

Clean unit

Contamination in steer gear unit

Clean unit

Insufficient hydraulic power Check pump and power supply Worn or damaged steer gear or steer gear pin

99759-8B110

Replace

9.5

TROUBLESHOOTING

Hydraulic System Complaint Will not lift or tilt

Will not lift rated load

Lift and Tilt Cylinders

Lift speed is too low

Lowering speed is too low

Cylinder vibrates when actuated

Load will not hold

Possible Cause

Remedy

Not enough oil in hydraulic tank

Refill

Relief valve out of order because of: 1) Seized main valve 2) Broken valve spring

Replace Replace relief valve

Oil pump defective

Replace

Control valve switch misaligned or defective

Readjust or replace

Relief valve out or order because of: 1) Too low a relief valve setting 2) Defective plunger and poppet seat 3) Weakened spring 4) Damaged O-ring in valve case

Readjust Replace relief valve Replace relief valve Replace O-ring

Oil pump defective

Replace

Piston seals worn or damaged

Replace

Rpm too low

Adjust

Control lever installed loose, resulting in not enough spool stroke

Repair or replace

Tank strainer clogged

Clean or replace

Pump not delivering enough oil

Repair or replace

Sleeve seized in flow regulator valve

Repair

Dirt in flow regulator valve

Clean, repair system and replace defective hose

Abnormal resistance to flow due to flattened hose or local clogging

Replace hose

Piston rod distorted Control lever installed loose, resulting in not enough spool stroke

Repair or replace Repair or replace

Air in oil circuit

Bleed air by operation cylinder through full stroke

Not enough oil in hydraulic tank

Refill

Control valve spool leaking internally

Replace

Lift connector on bottom of control valve

Torque to 33 ± 3.5 ft•lbs

not tight

9.6

Sliding (inside) surface of cylinder tube slightly grooved

Repair or replace cylinder assembly

Sliding (inside) surface of tube badly grooved

Replace

Piston seals broken or distorted

Replace seal kit

Oil leakage from piping

Repair or replace 99759-8B110

TROUBLESHOOTING

Lift and Tilt Cylinders, continued

Complaint Mast tilts forward (drifts)

Bushing leaks

Hydraulic Tank

Hydraulic tank heats excessively

Cylinders move too slowly

Hydraulic Pump

Cylinders move too slowly

Noisy

Possible Cause

Remedy

Control valve spool leaking internally

Replace

Foreign particles lodged between packing and mating surface

Replace packing

Piston seal damaged

Repair

Cylinder distorted

Repair or replace

Foreign particles lodged between sealing members such as oil seals and dust seals

Replace

Oil seals and dust seals defective

Replace

O-rings damaged

Replace

Cylinder distorted

Repair or replace

Oil viscosity improper

Change oil

Overload

Check working conditions and, if overloaded, urge the operator to stay within the load limit

Local overheating of oil line due to a large restriction flow

Repair or replace

Relief valve adjustment improper

Readjust pressure setting

Pressure drop due to weakened or broken springs

Repair or replace and readjust

Hydraulic pump worn

Replace

Outlet pipe or tube flattened, or restriction to flow

Repair or replace

Shortage of oil due to a natural loss

Refill

Oil leakage due to damaged oil line seals

Repair or replace

Oil viscosity too high

Change oil

Hydraulic pump defective

Check pump and piping; repair or replace

Oil leakage from oil line and/or change oil

Check oil for level and condition;

Abnormal rise in oil temperature

Check control valve spools for misalignment: repair or replace

Hydraulic pump leaking internally

Replace pump

Poor pumping

Refill

Cavitation

1. Check suction pipe for any flat portion or loose connection; retighten or replace 2. Check shaft oil seal for airtightness; replace pump

Hyd. Cont.

Valve

3. Check pump body for any outside interference; repair Forks will not lower

99759-8B110

Control Valve Solenoid

Check positive and negative to solenoid.

Check wire #25 positive or wire #26 negative to the solenoid.

Repair wiring or replace solenoid.

9.7

TROUBLESHOOTING

Rear Axle Complaint Hard steering

Possible Cause

Remedy

Low pump pressure

Check pressure, replace pump as needed

Damaged mechanical linkage

Replace

Dry mechanical linkage joints

Lubricate

Mechanical joints too tight

Readjust

Kingpin bearings improperly preloaded

Readjust

Damaged or worn mechanical linkage

Replace

Loose cylinder piston

Replace cylinder rod

Damaged or worn mechanical linkage

Replace

Tire diameter differs between right and left

Replace tire

Erratic steering

Loose cylinder piston

Replace cylinder rod

Excessive freeplay at steered wheels

Damaged or worn linkage between cylinder and steered wheels

Replace

Axle shimmy

Excessive clearance between the kingpin and its bearings

Repair or replace

Worn or damaged hub bearing

Replace

Tire on one side differs in kind or brand from that on the other side

Replace tires

Truck wanders

Truck drifts

Rear tires wear prematurely or unevenly

9.8

99759-8B110

TROUBLESHOOTING

Mast and Forks Complaint Lift bracket and inner mast do not move smoothly

Possible Cause Main rollers and side rollers have proper clearance Rollers involved are binding on their shafts Rollers damaged Improper mast-to-strip clearance

Lift bracket or inner mast cocks

Too much clearance on side rollers, or side rollers are damaged Lift chains unequally tensioned Shim adjustments unequally made on left and right lift cylinders (at maximum height)

Mast makes noise

Rollers not rotating smoothly on their shafts or are damaged

Load drops (drifts)

Lift cylinder packing damaged Lift cylinder bore grooved Control valve defective

Entire mast shakes

Mast-support bushing worn

Mast is distorted

Improper loading or overload

Fork tips differ in height

Finger bar bent Forks bent Distortion of mast due to off-center loading

99759-8B110

9.9

NOTES

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TABLE OF CONTENTS Chapter 10: Maintenance Service Data Maintenance Service Data...........................................................................................................

Front Axle and Reduction Differential ......................................................................................

Transfer Case ...........................................................................................................................

Rear Axle .................................................................................................................................

Brake System ...........................................................................................................................

Steering System,......................................................................................................................

Hydraulic System .....................................................................................................................

Mast and Forks (Simplex Mast) ...............................................................................................

Mast and Forks ........................................................................................................................

10.1 10.1 10.3 10.4 10.6 10.11 10.13 10.16 10.17

Tightening Torques for Standard Bolts and Nuts .........................................................................

Fine Thread—With Spring Washer ..........................................................................................

Fine Thread—Without Spring Washer .....................................................................................

Coarse Thread—With Spring Washer......................................................................................

Coarse Thread—With Spring Washer......................................................................................

10.18 10.18 10.18 10.18 10.18

Tightening Torques for Standard Bolts and Nuts with Standard Threads .................................... 10.19 Coarse Thread—Inches ........................................................................................................... 10.19 Tightening Torques for Taperlock Studs ....................................................................................... 10.19 Coarse Thread—Inches ........................................................................................................... 10.19 Maintenance Chart....................................................................................................................... 10.20 Planned Replacement Parts ........................................................................................................ 10.26 Lubrication Information.................................................................................................................

Chart ........................................................................................................................................

Fuel and Lubricant Specifications ............................................................................................

Recommended Brands of Lubricants.......................................................................................

10.27 10.27 10.28 10.28

Weight of Major Components (Approximate) ............................................................................... 10.29 Special Service Tools ................................................................................................................... 10.30 Special Tool Illustrations........................................................................................................... 10.31 Inspection Guide .......................................................................................................................... 10.34

NOTES

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MAINTENANCE SERVICE DATA

Maintenance Service Data Front Axle and Reduction Differential Truck Model

Item

Face runout of axle shaft flange Runout of axle shaft (1/2 of dial indicator reading)

Hubs and Wheels

Preload for hub bearing 1, kgf•cm (lb•ft) [N•m] Tightening torque kgf•cm (lbf•ft) [N•m]

E3000 - EC4000

E4000 - E6500

A

0.05 (0.0020)

B

0.5 (0.020)

A

0.5 (0.020) max

1.0 (0.039) max

B

1.0 (0.039) max

2.0 (0.079)

A

5 to 50 (0.4 to 3.6) [0.5 to 4.9]

Hub bearing lock nuts (outer) (2)

A

20 (145) [196]

Axle shaft bolts (3)

A

8.8 (64) [86]

Backing plate bolts (4)

A

6 (43) [59]

18.5 (134) [181]

Hub bolt lock nuts (5)

A

6 (43) [59]

18.5 (134) [181]

Frame support bolts (6)

A

Wheel nuts (7)

A

6

22.9 (166) [225] 16 (116) [157]

38.5 (278) [378]

1

3

2

4

7

5

203665

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

99759-8B110

10.1

MAINTENANCE SERVICE DATA Item

Truck Model

Gear backlash (1)

E3000 - E6500

A

0.18 to 0.23 (0.0071 to 0.0091)

B

0.5 (0.020)

A

0.02 to 0.07 (0.0008 to 0.0028)

B

0.35 (0.0138)

Fit of bevel pinion on spider (2)

15 to 30 (1.1 to 2.2) [1.5 to 2.9] Preload for differential case side bearings (3) kgf•cm (lbf•ft) [N•m]

A 1.3 to 2.5 kgf (2.9 to 5.5 lbf) [13 to 25 N]

Hubs and Wheels

as force applied to reduction gear in tangential direction

Face runout of reduction gear (4)

A

0.05 (0.0020) max

B

0.05 (0.0020)

A

0.15 to 0.25 (0.0059 to 0.0098)

A

0.07 to 0.17 (0.0028 to 0.0067)

B

0.5 (0.020)

Reduction gear bolts (7)

A

12 (87) [118]

Side bearing cap bolts (8)

A

12.8 (93) [126]

Carrier bolts (9)

A

6.1 (44) [60]

Differential carrier cover bolts (10)

A

3.4 (25) [33]

Backlash between reduction gear and pinion (5) Free movement (looseness) of axle shaft splines (6)

Tightening torque kgf•cm (lbf•ft) [N•m]

6

5

4

7

10 9

3 8 2

1 203664

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.2

99759-8B110

MAINTENANCE SERVICE DATA

Transfer Case N•m

kgf•m

lbf•ft

33±2

3.4±0.2

24.6±1.4

1

Cover-to-traction motor

2

Side cover

39.2±3.9 4.0±0.4

29.0±2.9

3

Plug or pulse generator

54.0±4.9 5.5±0.5

39.7±3.6

4

case-to-cover

39.2±3.9 4.0±0.4

29.0±2.9

5

Lock nut

292±20 30.0±2.0 217±14.5

Transfer Case

Supply liquid gasket onto the face of flange.

4 2

3

1 5 209009

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

99759-8B110

10.3

MAINTENANCE SERVICE DATA

Rear Axle Item

E3000 - EC4000

E4000 - E6500

Oscillating angle

A

3°

Toe-in

A

0°

Caster

A

0°

Camber

A

1°

Total fore-aft play of axle at center pin (1)

A

0.8 (0.031)

B

1.2 (0.047)

Turning Angle

Tightening torque, kgf•m (lbf•ft) [N•m] Rear Axle

Truck Model

Inside (2)

A

83°

83°

Outside (3)

A

54°

56°

Support bolts (4)

A

14.8 (107) [145]

Stopper bolt nuts (5)

A

6.8 (49) [67]

Cylinder minimum test pressure,

A

107 (1522) [10,500]

163 (2320) [16,000]

2

kgf•cm (psi) [kPa]

8609145

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.4

99759-8B110

MAINTENANCE SERVICE DATA

Rear Axle, continued Item

Tightening torque kgf•m (lbf•ft) [N•m]

Truck Model

E3000 - EC4000

E4000 - E6500

Outer locknut (6)

A

16 (116) [157]

Cylinder nuts (7)

A

1.9 to 2.3 (14 to 17) [19 to 23]

Cylinder bolts (8)

A

17.9 (130) [176]

26.7 (193) [262]

Kingpin bolts (9)

A

1.7 (12.3) [16.7]

3.4 (24.6) [33.4]

Tie rod bolts (10)

A

0.7 (5) [6.9]

A

25 to 65 (1.8 to 4.7) [2.5 to 6.4]

Preload for hub bearing (11) kgf•m (lbf•ft) [N•m]

Rear Axle

8

7 10

9

11 6 8609146

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

99759-8B110

10.5

MAINTENANCE SERVICE DATA

Brake System Truck

E3000 - E6500

Height of pedal (1)

A

120 ± 3 (3.5 ± 0.12)

Stroke (to point where brakes start to apply) (2)

A

3 to 10 (0.12 to 0.40)

Clearance between piston and push rod (3)

A

0.5 to 2.7 (0.02 to 0.11)

Item Model

B Brake Pedal

A

Push rod

C

Stop bolt

8609011

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.6

99759-8B110

MAINTENANCE SERVICE DATA

Brake System, continued Truck Model

Item

E4000 - E6500

Inside diameter of cylinder body (1)

A

19.05 + 0 0.052 (0.7500 + 0 0.00205)

22.22 + 0 0.052 (0.8748 +0 0.00205)

Diameter of piston (2)

A

19.05 -0.020 -0.053 (0.7500 -0.0079 -0.00209)

22.22 -0.020 -0.053 (0.8748 -0.0079 -0.00209)

Clearance between cylinder and piston

A

0.020 to 0.105 (0.00079 to 0.00413)

0.020 to 0.105 (0.00079 to 0.00413)

B

0.2 (0.008)

0.2 (0.008)

A

20 0 -0.3 (0.79 0 -0.012)

23.2 ± 0.25 (0.913 ± 0.0098)

B

replace every year

replace every year

A

20.2 ± 0.2 (0.795 ± 0.008)

23.2 ± 0.25 (0.913 ± 0.0098)

B

replace every year

replace every year

A

46.8 (1.843)

85 (3.35)

B

replace every year

replace every year

Diameter of primary cup (lip side) (3)

Diameter of secondary cup (lip side) (4)

Free length of return spring (5) Master Cylinder

E3000 - EC4000

Earlier Version

204936

Later Version

2 4

1

3

5 91246-07200

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

99759-8B110

10.7

MAINTENANCE SERVICE DATA

Brake System, continued Truck Model

Item

E3000 - EC4000

Inside diameter of cylinder body (1)

A

22.22 + 0 0.052 (0.8748 - 0 0.00205)

28.58 + 0 0.052 (1.1252 + 0 0.00205)

Diameter of piston (2)

A

22.22 - 0.040 - 0.073 (0.8748 - 0.00157 - 0.00287)

28.58 - 0.020 - 0.058 (1.1252 - 0.00079- 0.00228)

A

0.040 to 0.125 (0.00157 to 0.00492)

0.020 to 0.105 (0.00079 to 0.00413)

Clearance between cylinder and piston

B Diameter of piston cup (lip side) (3)

0.15 (0.0059) 23.7 ± 0.2 (0.933 ± 0.0079)

A B

Return Spring (4)

Wheel Cylinder

E4000 - E6500

replace every year

Free length

A

49.5 (1.95)

58 (2.28)

Length under test force

A

20 (0.79)

23 (0.91)

A

1.2 ± 0.1 (2.6 ± 0.2) [12 ± 1]

1.3 ± 0.1 (2.9 ± 0.2) [13 ± 1]

Test force kgf (lbf) [N]

B Tightening torque, kgf•m (lbf•ft) [N•m]

30.5 ± 0.25 (1.201 ± 0.0098)

Wheel cylinder bolts (5)

A

Bleeder screw (6)

A

replace every year 0.8 to 1.2 (6 to 9) [8 to 12]

0.6 to 0.9 (4 to 7) [6 to 9]

6

1

4

3

1.8 to 2.7 (13 to 20) [18 to 26]

5

2 200426

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.8

99759-8B110

MAINTENANCE SERVICE DATA

Brake System, continued Truck Model

Item

E4000 - E6500

A

254 + 0 1.3 (10.00 + 0 0.0051)

310 + 0 0.15 (12.20 + 0 0.0059)

B

256 (10.08)

312 (12.28)

A

4.87 (0.19)

6 (0.24)

B

2.5 (0.098) max

3 (0.118) max

Clearance between drum and lining (3) (one side)

A

0.2 to 0.5 (0.0079 to 0.0197)

0.2 to 0.6 (0.0079 to 0.0236)

Return spring (4)

Free length

A

102 (4.02)

Primary:120 (4.72) Secondary: 139.3 (5.48)

Length under test force

A

111 (4.37)

Primary: 134 (5.28) Secondary: 145.4 (5.72)

Test force, kgf (lbf) [N]

A

16 ± 1.6 (35 ± 3.5) [157 ± 16]

23 ± 2.3 (51 ± 5.1) [226 ± 23]

Inside diameter of brake drum (1)

Thickness of lining (2)

Wheel Brakes

E3000 - EC4000

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

99759-8B110

10.9

MAINTENANCE SERVICE DATA

Brake System, continued Truck Model

Item Adjusting spring (5)

E3000 - EC4000

E4000 - E6500

Free length

A

79 (3.11)

104 (4.11)

Length under test force

A

98.5 (3.88)

122 (4.80)

Test force, kgf (lbf) [N]

A

14 ± 1.4 (31 ± 3) [137 ± 14]

8 ± 0.8 (18 ± 2) [78 ± 8]

Service Brakes

Tightening torque for backing plate bolts (6) kgf•m (lbf•ft) [N•m]

A

16 (116) [157]

1 4

2

6

3 Secondary spring 4 5 Free length 203588

Lever operating effort (F)

245–294N (20–30 kgf) [55–66 lbf] Applied

Parking Brake

F

Released

209790

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.10

99759-8B110

MAINTENANCE SERVICE DATA

Steering System Truck Model

Item Steering effort (at rim with truck on) kgf (lbf) [N]

E4000 - E6500

A

1.3 (2.9) [12.8]

Tank Plug (1)

A

4.8 (35) [47.5]

Body cap screws (2)

A

2.3 (17) [23]

Steering Gear

Tightening torque kgf•cm, (lbf•ft) [N•m]

E3000 - EC4000

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

99759-8B110

10.11

MAINTENANCE SERVICE DATA

Steering System Truck Model

Steering Cylinder

Item

E3000 - EC4000

E4000 - E6500

Inside diameter

A

63 (2.48)

75 (2.95)

Diameter of piston rod

A

40 (1.57)

50 (1.97)

Minimum test pressure for leaks, kgf•cm2 (psi) [kPa]

A

107 (1522) [10,500]

163 (2320) [16,000]

Tightening torque, kgf•cm, (lbf•ft) [N•m]

Cylinder nuts (1)

A

Mounting bolts (2)

A

2.1 ± 0.2 (15.5 ± 1.5) [21 ± 2] 17.9 (130) [176]

26.7 (193) [262]

8609149

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.12

99759-8B110

MAINTENANCE SERVICE DATA

Hydraulic System

Simplex Mast

Item

Truck E3000 E3500 EC4000 E4000 Model

48 volt lift speed (rated load) mm/sec (fpm)

A

Lowering speed (rated load) mm/sec (fpm)

A

Forward tilt angle

A

5°

Backward tilt angle

A

6°

Lift cylinder drift (rated load) mm (in.) / 15 min.

[Oil temperature 45°C (113°F)]

A

50 (2.0) max

Tilt cylinder drift (forward) rated load mm(in.) / 15 min.

[Oil temperature 45°C (113°F)]

A

A

Power steering relief valve setting kgf•cm2, (psi) [kPa]

A

Hydraulic Pump

Main relief valve setting, kgf•cm2, (psi) [kPa]

Control Valve

E5000 EX5000

Output, liter (cu. in.) / min

Standard

Premium Tightening torque for oil pump bolts kgf•m (lbf•ft) [N•m] Tightening torque kgf•m (lbf•ft) [N•m]

A A A

.34 (67) .32 (64) .47 (93) .40 (78) .58 (115)

.57 (113)

22 (0.9)

E5500

E6000 E6500

.38 (74)

.32 (64)

.59 (116)

.52 (102)

40 (1.6)

20 (0.8)

15 (0.6)

197±kgf/cm2 (2630 ± 50 psi) [19650 ± 34 kPa] 51 (725)[5000] 55.2(3360) 2400 rpm

81.5 (1160) [8000]

60(3913) 2400 rpm

60(3913)2400rpm 69.6 (4549) 2400 rpm

60(3913)2400rpm DNA

69.6 (4539) 2400 rpm

4.7 to 5.2 (34 to 38) [46 to 51]

Tie bolts (1/2 in.)

A

1.9 (14) [19]

Tie bolts (9/16 in.)

A

4.5 (33) [45]

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

99759-8B110

10.13

MAINTENANCE SERVICE DATA

Hydraulic System, continued Truck Model

Item

E3000 - EC4000 45

+0.2 0

E4000 - EX5000 50

E5500 - E6500

+0.2 0

55

+0.2 0 +0.008) 0

[Piston] Inside diameter of cylinder tube (1)

A

Diameter of piston ring (2)

A

35 (1.38)

40 (1.57)

45 (1.77)

Thread diameter (3)

A

M49 x 1.5

M54 x 1.5

M59 x 1.5

A

170 to 240 (17.3 to 24.5) [125 to 175]

200 to 270 (20.4 to 27.5) [150 to 200]

270 to 304 (27.5 to 31.0) [200 to 225]

(1.77

Lift Cylinder

Tightening torque (4) N•m (kgf•m) [lbf•ft] 3

2

+0.008) 0

(1.97

+0.008) 0

(2.17

1

4

Return Filter

207073

Tightening torque N•m (kgf•m) [lbf•ft]

A

49 ± 10 (5 ± 1) [36 ± 7.2]

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.14

99759-8B110

MAINTENANCE SERVICE DATA

Hydraulic System, continued Truck Model

Item

E3000 - EC4000

63

A Inside diameter of cylinder tube (1)

(2.48 B

[Guide bushing] Diameter of piston rod (2)

A

Inside diameter of mast-side socket bushing (fitted) (3)

A

Inside diameter of frame-side head bushing (fitted) (4)

A

[Guide bushing] thread diameter (5)

70

+0.004) 0

(2.76

-0.02 -0.05 -0.000 8) -0.002 0

25

+0.1 0

80

+0.004) 0

(3.15

70.12 (2.760 6) 30 (1.18

E5500 - E6500 +0.1 0 +0.004) 0

80.12 (3.154 3)

-0.02 -0.05 -0.000 8) -0.002 0

-0.025 35 -0.064

(1.38

-0.000 98) -0.002 52

0 0 35 -0.012 (1.38-0.0005 )

32

+0.085 0

(1.26

+0.003) 0

32.6 (1.283)

B A

M68 x 2

M75 x 2

M85 x 2

A

265 ± 29 (27 ± 3) [195 ± 22]

314 ± 31 (32 ± 3.2) [231 ± 23]

373 ± 37 (38 ± 3.8) [275 ± 27]

[Socket] thread diameter (6)

A

M24 x 1.5

M27 x 1.5

M30 x 1.5

Tightening torque, N•m (kgf•m) [lbf•ft]

A

Tightening torque Tilt Cylinders

+0.1 0

63.12 (2.485 0)

(1.0

E4000 - EX5000

N•m (kgf•m) [lbf•ft]

Socket bolt (7) Self-locking nut (8)

Clearance between rod and guide bushing (9)

127 to 152 (13 to 15.5) [94 to 112]

A

127 ± 9.8 (13 ± 1.0) [94 ± 7.2]

A

0.06 to 0.111 (0.002 4 to 0.004 4)

B

235 ± 19.6 (24 ± 2.0) [174 ± 14.5]

39.2 ± 25 (40 ± 2.5) [289 ± 18.1]

0.075 to 0.139 (0.003 0 to 0.005 5) 0.35 (0.013 8)

9 3

4

6

7

5

1

2

8

207033

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

99759-8B110

10.15

MAINTENANCE SERVICE DATA

Mast and Forks (Simplex Mast) Truck Model

Item Difference in height between fork tips

Forks Chains

Thickness of forks

Rollers Mast and Lift Bracket

A

Diameter of main roller

E4000 - EX5000

E5500 - E6500

5 (0.20)

A

100 x 40 (3.9 x 1.6)

100 x 45 (3.9 x 1.8)

B

E3000 100 x 31 (3.9 x 1.2)

E4000 100 x 38 (3.9 x 1.5)

E3500 - EC4000 100 x 33 (3.9 x 1.3)

E5000/EX5000/E5500 100 x 40 (3.9 X 1.57)

A

318 (12.52)

381 (15.00)

508 (20.00)

B

327 (12.87)

392 (15.43)

523 (20.59)

(width x thickness) Length of tilt chains (per 20 links)

E3000 - EC4000

125 x45 (4.92 x 1.8)

125 X 39 (4.92 x 1.53)

S

A

99 (3.90)

113.8 (4.48)

M

A

100 (3.94)

115 (4.53)

L

A

101 (3.98)

116 (4.57)

LL

A

102 (4.016)

117 (4.606)

Diameter of side roller

A

42 (1.65)

Distance between outer mast main rollers (inside to inside) A

A

523 (20.59)

575 (22.64)

Distance between inner mast main rollers (outside to outside) B

A

581 (22.87)

639 (25.16)

Distance between lift bracket main rollers (outside to outside) C1

A

485 (19.09)

535 (21.06)

Distance between lift bracket main rollers (outside to outside) C2

A

487 (19.17)

537 (21.14)

Distance between lift bracket main rollers (outside to outside) D

A

491 (19.33)

539 (21.22)

Distance between lift bracket side rollers (outside to outside) E

A

496 (19.53)

546 (21.50)

Longitudinal clearance of lift bracket middle rollers (with forks slightly lifted) F

A

0.1 to 1.0 (0.004 to 0.039)

Lateral clearance of lift bracket middle main rollers (fully raised) G1

A

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of lift bracket side rollers (fully raised) G2

A

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of lift bracket lower main rollers (fully raised) G2

A

0.1 to 0.5 (0.004 to 0.020)

Longitudinal clearance of mast main rollers (in the whole lift range) H

A

0.1 to 1.0 (0.004 to 0.039)

Lateral clearance of inner mast main rollers (fully raised) J

A

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of outer mast main rollers (fully raised) K

A

0.1 to 0.5 (0.004 to 0.020)

Mast strip clearance (fully raised) L

A

0.1 to 0.5 (0.004 to 0.020)

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

10.16

99759-8B110

MAINTENANCE SERVICE DATA

Mast and Forks Truck Model

Item

E3000

E3500 EC4000

E4000 E5000 EX5000 E5500

Inner mast

F

E6000 E6500

L G1

G3

Mast and Lift Bracket/Later Version

G2 B

F

Lift Bracket A

C1

K H

E J

C2

D Outer mast 207106

Tightening torque, kgf•m (lbf•ft) [N•m]

Distortion of finger bar

Mast support bolts

A

7.5 (54) [74]

18.2 (132) [178]

Chain wheel support bolts

A

9.9 (72) [97]

A

5 (0.2)

A = Assembly Standard B = Repair or service limit Unit: mm (in.)

99759-8B110

10.17

MAINTENANCE SERVICE DATA

Tightening Torques for Standard Bolts and Nuts Fine Thread – Without Spring Washer

Fine Thread – With Spring Washer

Without Spring Washer

With Spring Washer

Nominal Size

Pitch

mm

in.

mm

6

0.24

1

in.

0.04

kgf·m (lbf·ft) [N·m] 0.6

4.3

Pitch

mm

in.

mm

6

0.24

1

5.9

in.

0.04

kgf·m (lbf·ft) [N·m] 0.7

5.1

6.9

8

0.32

1.25

0.05

1.7

12.3

16.7

10

0.39

1.25

0.05

3.4

24.6

33.3

12

0.47

1.25

0.05

6.1

44.1

59.8

14

0.55

1.5

0.06

9.9

71.6

97.1

16

0.63

1.5

0.06

14.8

107.0

145.1

18

0.71

1.5

0.06

21.4

154.8

209.9

20

0.79

1.5

0.06

29.7

214.8

291.3

327.5

22

0.87

1.5

0.06

39.3

284.3

385.4

413.8

24

0.95

1.5

0.06

49.7

359.5

487.4

8

0.32

1.25

0.05

1.4

10.1

13.7

10

0.39

1.25

0.05

2.9

21.0

28.4

12

0.47

1.25

0.05

5.2

37.6

51.0

14

0.55

1.5

0.06

8.4

60.8

82.4

16

0.63

1.5

0.06

12.6

91.1

123.6

18

0.71

1.5

0.06

18.2

131.6

178.5

20

0.79

1.5

0.06

25.2

182.3

247.1

22

0.87

1.5

0.06

33.4

241.6

24

0.95

1.5

0.06

42.2

305.2

Metric Fine Thread

Metric Fine Thread

Nominal Size

Note 1. These charts give the torques for standard bolts and nuts.

2. The tolerance for these torques is ± 10%.

3. Unless otherwise specified, use these torques.

4. These torques are for “dry” conditions.

Coarse Thread – With Spring Washer

Coarse Thread – Without Spring Washer

With Spring Washer

10.18

Pitch

Nominal Size

mm

in.

mm

in.

10

0.39

1.5

0.06

kgf·m (lbf·ft) [N·m] 2.8

20.3

27.5

12

0.47

1.75

0.07

4.9

35.4

48.1

14

0.55

2.0

0.08

8.1

58.6

79.4

16

0.63

2.0

0.08

12.1

87.5

118.7

18

0.71

2.5

0.10

16.8

121.5

164.8

20

0.79

2.5

0.10

23.5

170.0

230.5

22

0.87

2.5

0.10

31.5

227.8

308.9

24

0.95

3.0

0.12

40.5

292.9

397.2

Metric Coarse Thread

Metric Coarse Thread

Nominal Size

Without Spring Washer

Pitch

mm

in.

mm

in.

10

0.39

1.5

0.06

kgf·m (lbf·ft) [N·m] 3.3

23.9

32.4

12

0.47

1.75

0.07

5.8

42.0

56.9

14

0.55

2.0

0.08

9.5

68.7

93.2

16

0.63

2.0

0.08

14.2

102.7

139.3

18

0.71

2.5

0.10

19.8

143.2

194.2

20

0.79

2.5

0.10

27.7

200.4

271.6

22

0.87

2.5

0.10

37.0

267.6

362.8

24

0.95

3.0

0.12

47.7

345.0

467.8

99759-8B110

MAINTENANCE SERVICE DATA

Tightening Torques for Standard Bolts and Nuts with Standard Threads Coarse Thread – Inches

Inch Coarse Thread

Nominal Size Threads per inch

Standard Bolt & Nut Torque

mm

in.

kgf·m

(lbf·ft)

[N·m]

6.35

1/4

20

1.2±0.4

9±3

12±4

7.94

5/16

28

2.5±0.7

18±5

25±7

9.52

3/8

16

4.6±0.7

33±5

45±7

11.11

7/16

14

7.0±1.5

50±11

70±15

12.7

1/2

13

10.4±1.5

75±11

100±15

14.29

9/16

18

15.0±2.0

110±15

150±20

15.88

5/8

11

20±3

150±18

200±25

19.05

3/4

10

37±5

270±37

360±50

22.22

7/8

9

58±8

420±60

570±80

25.40

1

8

88±10

640±75

875±100

28.58

1 1/8

7

113±15

820±110 1100±150

31.75

1 1/4

7

138±18

1000±130 1350±175

34.92

1 3/8

6

163±20

1180±150 1600±200

38.10

1 1/2

6

205±28

1480±200 2000±275

Tightening Torques for Taperlock Studs Coarse Thread – Inches Nominal Size Threads per inch

Inch Coarse Thread

mm

in.

Standard Bolt & Nut Torque

kgf·m

(lbf·ft)

[N·m]

6.35

1/4

20

0.8±0.3

6±2

8±3

7.94

5/16

28

1.8±0.6

13±4

17±5

9.52

3/8

16

3.6±0.6

26±4

35±5

11.11

7/16

14

4.6±1.0

33±7

45±10

12.7

1/2

13

6.6±1.0

48±7

65±10

14.29

9/16

18

9.0±1.5

65±11

90±15

15.88

5/8

11

11±1.5

80±11

110±15

19.05

3/4

10

17±2

125±15

170±20

22.22

7/8

9

26±3

190±22

260±30

25.40

1

8

41±4

300±30

400±40

28.58

1 1/8

7

51±4

370±30

500±40

31.75

1 1/4

7

66±5

480±37

650±50

34.92

1 3/8

6

76±5

550±37

750±50

38.10

1 1/2

6

88±5

640±37

870±50

99759-8B110

10.19

MAINTENANCE SERVICE DATA

Maintenance Chart Use the service chart to determine servicing intervals. Calendar intervals shown (weekly, monthly, etc.) may be used instead of service meter intervals if they provide more convenient servicing schedules and approximate the indicated service meter reading. Recommended service should always be performed at the interval that occurs first.

Perform service on items at multiples of the original requirement. For example, at every 1200 hours or 6 months, also service those items listed under every 200 hours or monthly, every 50 hours or weekly and daily (pre-start). ● = Check or clean ★ = Change or adjust R = Replace

Motors

Steering linkage

10.20

Service Data

Bearing lubrication, damage

Visual

●

●

Lubricate

Winding to case resistance

Test

●

●

Resistance to be > 1

Armature to case resistance

Test

●

●

Brush contact area

Visual

●

●

Change brush

Brush length

Visual

●

●

Change brush

Brush spring force

Test

●

●

Change spring

Commutator surface condition

Visual

●

●

Commutator discoloration

Visual

●

●

Interior, exterior cleanliness

Visual

●

●

●

Test

●

●

●

●

●

Operation

Test

●

●

●

●

●

Oil leaks

Visual

●

●

●

●

●

Mounting bolts, tightness

Wrench

●

●

●

Beam structural damage

Visual

Cylinder leaks

Visual

Cylinder mounting bolts

Wrench

●

Tie rod bearings and pins

Visual

●

Kingpin looseness

Test

●

Trunnion fore-aft looseness

Test

●

Steering wheel Free-play, looseness, rattling

Steering gear

How to Check

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Inspection Point

Daily (pre-start)

Maintenance Intervals

Mega Ω

Clean

● ●

●

●

●

●

Nominal 0.8 mm (0.031 in.) clearance 99759-8B110

MAINTENANCE SERVICE DATA

Brake pedal

Every 1200 hours or 6 months Every 2400 hours or 1 year

How to Check Daily (pre-start)

Inspection Point

Every 50 hours or weekly Every 200 hours or monthly

Maintenance Intervals

Height of pedal above floor

Scale

●

●

●

●

●

Stroke to point where brakes start applying

Scale

●

●

●

●

●

Performance

Test/spring balancer

●

●

●

●

●

Visual

●

●

●

●

●

Visual Overhaul/ Replace

●

●

●

●

★

Parking brake

Brake hoses and pipes Brake fluid Wheel brakes

Fluid leaks, damage or installation Level in reservoir Master cylinder and wheel cylinders—operation, wear and damage Brake clutch/inching pedal rod Brake master cylinder hoses & rubber parts Service brake fluid Brake wheel cylinder rubber parts

89 ± 3 mm (3.5 ± 0.12 in.)

3 to 10 mm (0.12 to 0.4 in.)

Lever lock position: 4° - 5° Operating effort: 55–66 kgf (25–30 lbf) [245–294 N]

103cc (7.9 cu. in.)

★ ●

Visual/wrench

R R R

Brakes drums and shoes Drum-to-lining clearance

Service Data

Feeler gauge

●

●

●

E3000-EC4000 0.2 to 0.5mm (0.01 to 0.02) E4000-E6500 0.2 to 0.6mm (0.01 to 0.02)

Sliding surfaces of shoes and wear of lining

Disassemble/ calipers

●

E3000-EC4000 2.5mm (0.10 in.)

E4000-E6500 3.0mm (0.12 in.)

Drum—wear or damage

Visual scale

●

Service Limit: E3000 - EC4000 254 + 0 0.13 mm (10.00 + 0 0.0051 in.)

E4000-E6500 310 + 0 0.13 mm (12.20 + 0 0.0051 in.)

99759-8B110

Free length of return springs

Scale

●

Operation of shoes

Test

●

Anchor pins—seizure

Visual

●

10.21

MAINTENANCE SERVICE DATA

How to Check Daily (pre-start)

Inspection Point

Dye check

●

Fitting cables– damage and length

Visual/scale

●

Ratchet–wear or damage

Visual

●

Cracks, distortion, or other defects

Dye check/ visual

●

Front wheel bearings–preload

Spring balancer

●

Backing plates Distortion, cracks, or damage

Front axle

Differential

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Maintenance Intervals

Fore-aft play

Test

●

Cracks, distortion, or other defects

Visual

●

Oil level and oil leaks

Visual

●

●

●

Service Data

Hub bearing preload

5 to 50 kgf (0.4 to 3.6 lbf•ft) [0.5 to 4.9 N•m]

E3000 - EX5000 5.7 liters (1.5 U.S. gal)

E5500 - E6500 6.1 liters (1.6 U.S. gal)

Rear axle

Mounting bolts

Torque wrench

●

Front wheel bearings–preload

Spring balancer Torque wrench

●

Hub bearing preload

25 to 65 kgf (1.8 to 4.7 lbf•ft) [2.5 to 6.4 N•m] Lock Nut (outside)

16 kgf•cm (116 lbf•ft) [157 N•m] Wheels

Tires–cuts or gouges

Visual

●

●

●

●

●

Tires–wear

Depth gauge

●

●

●

●

●

Tires–imbedded objects

Visual

●

●

●

●

●

Wheel nuts–tightness

Torque wrench

●

●

●

●

●

Front Wheel Nuts: E3000 - EC4000 16 kgf•cm (116 lbf•ft) [157 N•m] E4000 - E6500 38.5 kgf•cm (278 lbf•ft) [378 N•m] Rims–damage

10.22

Visual

●

●

●

99759-8B110

MAINTENANCE SERVICE DATA

Hydraulic tank

How to Check

●

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Inspection Point

Daily (pre-start)

Maintenance Intervals

●

●

●

Service Data

★

Oil level and contamination

Visual

Strainer—clogging

Visual

★

Return filter—clogging

Visual

★ ●

●

●

●

●

●

Hydraulic pump Oil leaks or abnormal noise

Visual / listen

Control valve

Oil leaks

Visual

Main relief valve setting

Pressure gauge

●

185 kgf/cm2 (2631 psi) [18,142 kPa]

Auxiliary relief valve setting

Pressure gauge

●

158±5 kgf/cm2

●

●

2250±71psi 15,513 ± 490 kpa ●

Overload relief setting (optional) Pressure gauge

Lift cylinders

Control levers and links—rattle

Test

●

●

●

●

●

Cracks, distortion, or other defects

Visual

●

●

●

●

●

Rod drift (rated load)

Visual/watch/ scale

●

●

●

●

●

E3000 - EX5000 50 mm (2.0 in.)/15 min

E5500 - E6500 40 mm (1.6 in.)/15 min

●

Attachment

99759-8B110

Mounting bolts—tightness

Wrench

Oil Leaks

Visual

●

● ●

●

●

●

●

●

●

●

●

●

10.23

MAINTENANCE SERVICE DATA

Tilt cylinders

How to Check

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Inspection Point

Daily (pre-start)

Maintenance Intervals

Cracks, distortion, or other defects

Visual

●

●

Oil leaks

Visual

●

●

Forward rod drift (rated load)

Watch/scale

Service Data

●

●

●

●

●

●

●

●

● E3000 - EC4000 22 mm (0.9 in.)/15 min E4000 - E5500 20 mm (0.8 in.)/15 min E6000 - E6500 15 mm (0.6 in.)/15 min

Mounts—rattle or damage

Visual/free

●

●

●

●

●

Rod socket nut—tightness

Torque wrench

●

●

●

●

● E3000 - EC4000 15 kgf·m (108 lbf•ft) [147 N•m] E4000 - E6500 40 kgf·m (289 lbf·ft) [392 N·m]

Piping

Mast and lift bracket

●

●

●

Visual

●

●

●

Hose reels and swivel joint— distortion or other defects

Visual

●

●

●

Cracks, distortion, or other defects

Visual/ dye check

●

●

●

●

●

●

●

●

● Each roller to mast clearance (at max. height): 0.1 to 0.5 mm (0.004 to 0.020 in.)

Oil leaks

Visual

Rubber hoses: damage

Mast supports—rattle or damage Main rollers—clearance, damage

10.24

Feeler gauge/ dial gauge

●

●

●

●

99759-8B110

MAINTENANCE SERVICE DATA

Lift chains and chain wheels

How to Check

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Inspection Point

Daily (pre-start)

Maintenance Intervals

Length of lift chains (20 links) Scale

●

E3000 - EC4000 318 mm (12.5 in.)

E4000 - E5500 381 mm (15.0 in.)

E6000 - E6500 508 mm (20.0 in.)

Both chains to equal in tension

Tension deflection of lift chains Scale

●

●

●

●

●

Chains—damaged or rusting

Visual

●

●

●

●

●

Chains wheels—wear, distortion, or other defects

Visual

●

●

●

Chain wheel bearings—rattle

Feel

●

●

●

●

●

●

Chain anchor bolts—distortion Visual or damage Forks—wear and distortion

Visual/scale

●

●

●

●

●

Forks stopper pins— damage or distortion

Visual

●

●

●

●

●

Backrest mounting bolts— tightness

Torque wrench

●

●

●

●

●

Backrest—distortion or damage Visual

●

●

●

●

●

Lights

Operation

Test/visual

●

●

●

●

●

Turn signals (optional)

Operation

Test

●

●

●

●

●

Rear view Rear vision mirrors (optional)

Visual

●

●

●

●

●

Overhead guard Installation and damage

Visual/wrench

●

●

●

●

●

Chassis

Loosen bolts or nuts

Wrench

Operator’s seat— damage and installation

Visual

●

●

●

Lubrication points

Lubricate

●

●

●

Oil change

Inspect

●

●

●

Forks and backrest

99759-8B110

Service Data

Fork thickness— refer to Service Data

●

Lubricate mast supports every 50 hours or weekly

10.25

MAINTENANCE SERVICE DATA

Periodic Replacement Parts The parts listed below are important for the safe operation of the truck, and especially designed to be replaced at specified periods. Each service shop is requested to adhere to the replacement schedule given here on all trucks brought into its care.

Periodic Replacement Parts

Service

Period 1 month after delivery

1 month 6 months 1 year 2 years (200 hours) (1200 hours) (2400 hours) (4800 hours)

1

★

Replace

●

●

2

★

Replace

●

●

3

★

Replace

●

●

4

★

Replace

●

5

★

Replace

●

6

★

Replace

●

7

Hydraulic tank return filter

Replace

8

Drum to lining clearance

9

Motor brushes

Rubber parts for brake master cylinder Rubber parts for brake wheel cylinders Hydraulic hoses Hoses for power steering

Rubber parts for steering cylinder Lift chains

●

●

●

●

Check or replace

●

●

Check or replace

●

●

★

10.26

Indicates important safety-related parts

99759-8B110

99759-8B110

TRANSFER AND DIFFERENTIAL OIL HYDRAULIC TANK OIL FILTER

PARKING BRAKE

HYDRAULIC OIL BRAKE FLUID

DASH MONITOR

NOTE: REDUCE SERVICING INTERVALS IN DUSTY OR SEVERE CONDITIONS. REFER TO OPERATION MANUAL

EVERY 2400 HR. OR 1 YEAR

HORN

ACCELERATOR PEDAL

EVERY 1200 HR. OR 6 MONTHS

OIL FLUID FILTER,

SERVICE BRAKES

STEERING

SEAT BELT AND RAILS

(FRONT/REAR)

AXLE CENTER PIN

97182-12900

TIE ROD ENDS (4 FITTINGS) REAR

BRAKE PEDAL

TILT CYLINDER (EACH SIDE)

FRONT AXLE SUPPORT (EACH SIDE)

TILT SOCKET (EACH SIDE)

MAST, FORKS, LIFT CHAINS

CHANGE

LIFT CHAIN (EACH SIDE)

BATTERY RESTRAINT

CONTACTORS MOTOR BRUSHES

BATTERY ELECTROLYTE LEVEL

MAST STRIPS, ROLLER SURFACES (EACH SIDE) LIFT BRACKET SIDE ROLLERS (EACH SIDE)

EVERY 500 HR. OR 3 MONTHS

DIFFERENTIAL OIL LEVEL

EVERY 500 HR. OR 3 MONTHS

MAST SUPPORTS

EVERY 50 HR. OR WEEKLY

MULTIPURPOSE-TYPE GREASE ENGINE OIL

LUBRICATE

BE SURE TO PERFORM SERVICE ITEMS QUOTED BELOW

EVERY 500 HR. OR 3 MONTHS

SPECIFIC GRAVITY OF BATTERY BOLTS, NUTS

EVERY 50 HR. OR WEEKLY

HYDRAULIC OIL LEVEL

BRAKE FLUID LEVEL

TIRES, WHEEL NUTS

OIL LEAKS

EVERY 10 HR. OR DAILY

CHECK

LUBRICATION AND MAINTENANCE CHART

MAINTENANCE SERVICE DATA

Lubrication Chart

10.27

10.28

Grease

Brake fluid

Hydraulic oil

Gear oil

|

(50) 10 |

SAE 10W

|

(32) 0 |

SAE 5W -30 to -10

|

(14) -10 | ISO Grade 68 SAE 80W AGMA-2EP

|

(-4) -20 |

ISO Grade 32 SAE 75W AGMA-1EP

(-22) -30 |

NLGI No. 2 grade multipurpose type (lithium base), consistency: 265 - 295 NLGI No. 1 grade multipurpose type (lithium base), consistency: 310 - 340

Chassis

F.M.V.S.S. No. 116—DOT 3 or DOT4 (SAE J1703)

API service classification multipurpose type GL-5 (hypoid gear oil)

Recommendation

Wheel bearings

Oil |

(68) 20 |

Recommendation for ambient temperatures [°C (°F)]

|

(86) 30 |

Gear Oil GX 80W90

Castrol Hypoy

Exxon

Castrol

Castrol LM Grease

----

Retinax A No. 1

Mobil Grease JL 77 No. 1

Consistency 310-340

NLGI No. 1

Greases

Brands of oil are subject to change without notice.

■ When you buy oil, select recommended brands and check specifications.

■

Shell Spirax EP90

90 Pegasus Gear Oil

SAE90W

API service classification GL-5

Shell

Visc osit y Manufacturer Mobil

Specifications

Gear Oil

EP 68 Gear oil with borate additives are not recommended.

Castrol Spheerol API

Ronex MP

Retinax A No. 2

Mobil Grease JL 77 No. 2

Consistency 265-295

NLGI No. 2

Tellus oil T-32 Nuto H32 Castrol Hyspin AWS68

UNIVISN 22 Castrol Hyspin AWS32

Hydraulic oil 28 LP

SAE10W

Tellus oil 22

—

SAE5W

Hydraulic oils

• 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 service intervals.

◆

MAINTENANCE SERVICE DATA

Fuel and Lubricant Specifications

99759-8B110

MAINTENANCE SERVICE DATA

Weight of Major Components (Approximate) Component / Model

Counterweight Power train (Motor, transfer box, reduction gear and differential)

E3000

E3500

EC4000

470(1036)

625(1378)

910(2006)

E4000

E5000

540(1190) 730(1609)

200 (441)

EX5000

540(1190)

E5500

E6000E6500

730(1609) 1060(2337)

215 (474)

Overhead guard

62.7 (138)

67.4 (149)

66.0 (146)

Rear axle

150 (331)

Mast (3.3 m simplex mast)

520 (1146)

725 (1598)

830 (1830)

Outer mast

140 (309)

190 (419)

205 (452)

Inner mast

135 (298)

180 (397)

190 (419)

Lift bracket (including backrest)

105 (231)

150 (331)

175 (386)

Forks (two)

80 (176)

130 (287)

165 (364)

Lift cylinder and related parts

60 (132)

75 (165)

95 (209)

Hydraulic motor

45 (99)

50 (110)

Traction motor

80 (176)

100 (220)

220 (485)

Unit: kg (lb)

99759-8B110

10.29

MAINTENANCE SERVICE DATA

Special Service Tools Truck Models Ref. No.

Part No.

Part Name

Application

FBC15N -

FBC20N -

FBC30N -

FBC18LN

FBC25LN

FBC30LN

Removal and installation of rear wheel nuts

●

●

●

91268-00300 Bevel pinion (or 91268-02100) puller

Removal of bevel pinion assembly

●

●

●

3

64309-17700

Gauge kit

Measurement of hydraulic pressure

●

●

●

4

91268-00800

Socket wrench (70 mm)

Removal/installation of front wheel hub nuts

●

●

●

5

MH061108

Socket wrench (90 mm)

Removal/installation of front wheel hub nuts

●

—

—

6

91468-00300

Installer

Installation of front axle wheel bearing inner races

—

●

●

7

64309-40400

Installer

Installation of rear axle inner bearing inner races

—

●

●

8

64309-15411

Spring remover

Removal of return spring

●

●

●

9

64309-15412

Spring remover

Removal/installation of brake shoes

●

●

●

10

64309-15413

Spring hook

Installation of return spring

●

●

●

11

91268-10600

Steering wheel

Removal of steering wheel puller

●

●

●

12

91268-01600

Installer

Installation of tilt cylinder tube bushing

●

●

●

13

05312-20650

●

—

—

—

●

—

—

—

●

1

91268-00700

2

05312-20750

Socket wrench

Hook wrench

Remove / install tilt cylinder guide bushing

05312-20850 14

F4540-06300

Pipe connector

Measurement of control valve main relief pressure & overload relief pressure (to be used with 64309-17701 gauge kit)

●

●

●

15

97157-00100

Spring installer

Install centering spring in steer gear

●

●

●

16

64309-40100

Wheel puller

Removal of drive wheel hub

●

—

—

17

MH061108

Wheel puller

Removal of drive wheel hub

—

●

●

18

K8000-02921

Nipple Assy

Main Relief Valve Pressure Check

●

●

●

19

97E67-00100

Transfer Bearing Tool

Removal of Bevel Pinion Shaft

●

●

●

20

97E67-00200

Plug Assy Tool

Torque or Steer Gear Tank

●

●

●

21

97E67-00500

Tool - STC

Steer Gear Hose Removal (STC)

●

●

●

10.30

99759-8B110

MAINTENANCE SERVICE DATA

Special Tool Illustrations 2

1

M10 x 1.5

46 M14 x 1.5

164 95 250

17 10 22 155

91268-00701

3

91268-00300 91868-02100

4

91268-00800

64309-17701

6

5 90

03703-59001

7

8

64309-40400

99759-8B110

91648-00300

64309-15411

10.31

MAINTENANCE SERVICE DATA 9

10

64309-15413

64309-15412

11

12 M12 X 1.25

ø35 ø32

M8 X 1.25

30

45

45

55

91268-01600

91268-10600

14

13

Flame-hardened Hv >500, depth 2mm (0.08 in.)

05312-20650 05312-20750 05312-20850

16

15

97157-00100

10.32

F4540-06300

64309-40100

99759-8B110

MAINTENANCE SERVICE DATA 17

18

6V3965

MH061017

19

20

97E67-00100

97E67-00200

21

Rubber Coated Handle 97E67-00500

99759-8B110

10.33

MAINTENANCE SERVICE DATA

Inspection Guide Check Antifriction bearings

For (item or defect)

How

ITEMS

Measure inside diameter with an indicator hole gauge and shaft outside diameter with an indicating micrometer

a) Fit on shaft b) Fit in housing

Measure outside diameter with an indicating micrometer and housing inside diameter with an indicator hole gauge

c) Preload (small initial load applied to absorb initial bearing deformation)

As stated in service manual

DEFECTS a) High running temperature (caused by over lubrication)

As shown

b) Noise (humming), vibration, or rough running

Radial bearing

c) Creep (marks of circumferential slip on inner ring’s surface in contact with shaft or on outer ring’s surface in contact with housing due to loose fit of bearing) d) Corrosion

Thrust bearing 8609153

Visually

Visually

8609151

e) True brineling (caused by careless installation or removal)

8609152

10.34

99759-8B110

MAINTENANCE SERVICE DATA Check Antifriction bearings

For (item or defect)

How

f) False brinelling (caused by a constant vibration or oscillation of non-rotating bearings through small arc)

Visually

8609154

g) Cracked race (caused by forcing bearing or oversize shaft or by cooking race when installing or removing)

Visually

8609155

h) Broken separator (caused by dirt, metal chips, or lack of lubricant)

Visually

8609156

i) Damaged seal (caused by improper use of tools)

Visually

8609157

j) Spalled race (caused by too loose a fit)

Visually

8609158

99759-8B110

10.35

MAINTENANCE SERVICE DATA Check Antifriction bearings

For (item or defect)

How

k) Bad discoloration (caused by overheating due to poor lubrication)

Visually

8609159

i) Craters (caused by passage of electric current)

Visually

8609160

Bushings or sleeve bearings

ITEM Fit on shaft

DEFECTS Nicks, burrs, or other flaws on bearing surface

Fasteners

Gears

Determine by measuring inside diameter of bushing and outside diameter of shaft

Hold bushing toward a light and look through bore

DEFECTS a) Striped or otherwise damaged threads (bolts, nuts, screws, etc.)

Visually

b) Distortion or loss of tension (spring lock washers, snap rings, etc.)

Examine by compressing

ITEMS a) Fit on bearing, bushing, spline or key

As stated in service manual

b) Backlash

As stated in service manual

DEFECTS

10.36

a) Excessive wear on teeth, thrust faces, and end faces on hub

Visually

b) Scratching wear (caused by large particles other than associated with abrasive wear)

Visually

99759-8B110

MAINTENANCE SERVICE DATA Check Gears

99759-8B110

For (item or defect)

How

c) Abrasive wear (caused by fine particles carried in lubricant)

Visually

d) Overload wear

Visually

e) Pitting

Visually

f) Spalling

Visually

g) Overload breakage

Visually

h) Fatigue breakage

Visually

i) Corrosive wear

Visually

10.37

MAINTENANCE SERVICE DATA Check Keys and keyways Oil seals Roller chains and sprockets

How

For (item or defect) Wear on sides making parts not fit tightly

Examine by placing

Damage to lip

Visually

a) Wear on pins, bushings, rollers, and plates in each link tending to increase in pitch.

Visually

b) Wear on sprocket teeth

Visually

Chain load

Sprocket rotation New

Old 8609189

Rubber parts

Splines and serrations

Hardening or softening, swelling, tackiness, tearing, and deterioration due to aging

Visually

ITEM Fit DEFECTS a) Nicks, burrs, chips, etc.

Visually

b) Free movement (looseness) of mating splines

Examine

c) Excessive wear polish on sides (sliding fit splines)

Visually

d) Ridge or edge left between worn and unworn areas (sliding fit spline)

Visually

8609170

10.38

99759-8B110

MAINTENANCE SERVICE DATA Check Springs

For (item or defect)

How

ITEMS

See specification

a) Type called for

Use a square

b) Squareness

8609171

c) Free length test

Examine

d) Test force DEFECTS a) Excessive clearance space between coils (compression springs) in free state

Visually

b) Any clearance space between coils (tension springs) in free state

8609172 8609173

99759-8B110

c) Condition or ends or hooks

Visually

d) Cracks or breakage

Visually

10.39

Cat Lift Trucks

Service Manual

E3000, E3500, EC4000, E4000, E5000, EX5000, E5500, E6000, E6500 Lift Trucks

99759-8B110

Mitsubishi Caterpillar Forklift America Inc. 2121 W. Sam Houston Parkway N. Houston, TX 77043-2305

99759-8B110

Copyright © 2008 by MCFA. All Rights Reserved.

CATERPILLAR and CAT are registered trademarks of Caterpillar Inc.

Printed in the U.S.A.