Cat GPE15N GPE18N GPE20CN GPE20N GPE20ZN GPE25N GPE25ZN GPE30N GPE35N Chassis & Mast Service Manual

Cat Lift Trucks

Service Manual Service Manual GP/GPE 15N-35N, DP15N-35N Lift Trucks

Mitsubishi Logisnext Asia Pacific Pte. Ltd. RCB No.: 199203169H No.1, Tuas West Street Singapore 637444

GP15N GP15ZN GP18N GP18ZN GP20CN GP20N GP20ZN GP25N GP25ZN GP30N GP35N

CT25C-55001-59999 CT34-52001-59999 CT25C-75001-79999 CT34-72001-79999 CT34-22001-29999 CT17D-10001-19999 CT35-10001-19999 CT17D-60001-69999 CT35-60001-69999

GPE15N GPE18N GPE20CN GPE20N GPE20ZN GPE25N GPE25ZN GPE30N GPE35N

CT34-00001-09999 CT34-40001-49999 CT34-30001-39999 CT17D-20001-29999 CT35-20001-29999 CT17D-70001-79999 CT35-70001-79999

DP15N DP18N DP20CN DP20N DP25N DP30N DP35N

CT16D-54001-59999 CT16D-74001-79999 CT16D-24001-29999 CT18C-20001-29999 CT18C-70001-79999 CT14E-10001-19999 CT14E-80001-89999

CT13F-10001-19999 CT13F-80001-89999

CT13F-40001-49999 CT13F-60001-69999

99719-3F120

© 2017. All rights reserved. CAT, CATERPILLAR, their respective logos, "Caterpillar Yellow", the "Power Edge" trade dress as well as corporate and product identity used herein are trademarks of Caterpillar and may not be used without permission. All registered trademarks are the property of their respective owners. Some products may be shown with optional equipment.

99719-3F120

MC

Chassis & Mast

11/17

For use with GK15, GK21, GK25, S4Q2 and S4S Engine Service Manuals.

99719-3F120

Service Manual MC

Chassis & Mast GP15N GP15ZN GP18N GP18ZN GP20CN GP20N GP20ZN GP25N GP25ZN GP30N GP35N

CT25C-55001-59999 CT34-52001-59999 CT25C-75001-79999 CT34-72001-79999 CT34-22001-29999 CT17D-10001-19999 CT35-10001-19999 CT17D-60001-69999 CT35-60001-69999

GPE15N GPE18N GPE20CN GPE20N GPE20ZN GPE25N GPE25ZN GPE30N GPE35N

CT34-00001-09999 CT34-40001-49999 CT34-30001-39999 CT17D-20001-29999 CT35-20001-29999 CT17D-70001-79999 CT35-70001-79999

DP15N DP18N DP20CN DP20N DP25N DP30N DP35N

CT16D-54001-59999 CT16D-74001-79999 CT16D-24001-29999 CT18C-20001-29999 CT18C-70001-79999 CT14E-10001-19999 CT14E-80001-89999

CT13F-10001-19999 CT13F-80001-89999

CT13F-40001-49999 CT13F-60001-69999

For use with GK15, GK21, GK25, S4Q2 and S4S Engine Service Manuals.

99719-3F120

FOREWORD This service manual is a guide for servicing Cat Lift Trucks.

The long productive life of your truck(s) depends on regular and proper servicing, servicing consistent with what you will learn by reading this service manual.

Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting to start a test, repair, or rebuild job.

The descriptions, illustrations and specifications contained in this manual are for Lift Trucks with serial numbers in effect at the time of printing.

Cat Lift Trucks reserves the right to change specifications or designs without notice and without incurring obligations. For your convenience the instructions are grouped by systems as an easy reference.

For engine servicing, please refer to the applicable engine service manual.

GK15, GK21, or GK25 Gasoline engine S4Q2 or S4S Diesel engine

Safety Related Signs

Meanings

RWARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

RCAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or damage to your machine.

NOTE

NOTE indicates a condition that can cause damage to or shorten service life of the machine.

Unauthorized copying and lending of this material are prohibited.

i

1. SAFETY PRECAUTIONS R WARNING -

-

This service manual contains the proper and safe lubrication and maintenance information recommended by Cat® Lift Trucks. Please read this service manual carefully and fully understand the procedures before proceeding with any maintenance work. Improper lubrication, or maintenance work is dangerous and could result in injury or death.

Be sure to read this service manual and understand the contents before proceeding with the work. Improper truck operation is dangerous and could result in injury or death.

Be sure to familiarize yourself with the systems and components described herein before proceeding with removal or disassembly work.

For heavyweight components, BE SURE to check the weight of each component beforehand by referring to this service manual.

Also, for safety, use proper lifting equipment for removal/ installation work.

Following is a list of basic precautions that should always be observed.

(1) Read and understand all warning plates and decals on the truck before proceeding with operation, lubrication, or repair work.

(2) Always wear safety glasses and protective shoes when working around trucks. Be sure to wear safety glasses to prevent any type of metal from getting into your eyes when using a hammer or sledge.

Use welders gloves, hood/goggles, apron, and other protective clothing appropriate to the welding operation. Do not wear loose clothing or accessories that can be caught in moving parts. Do not wear rings when you work.

(3) Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before proceeding with the work.

(4) Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly.

(5) Use steps and assist grips (if equipped) when you mount or dismount the truck. Clean the steps, hand rails, and floor of operator seat beforehand. Always face the truck when using steps, ladders, and walkways. If you cannot use the designed access system, use ladders, scaffolds, or work platforms to ensure the safety at the workplace.

(6) To avoid back injury, use a hoist when lifting components which weigh 23 kg (51 lb) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Make sure the load is well balanced prior to lifting.

(7) To prevent burns, DO NOT touch hot sections of the truck immediately after stopping the truck.

(8) Remove covers carefully. When removing the last two bolts or nuts, loosen gradually to release spring force or pressure.

(9) Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. Use extreme care immediately after stopping.

(10) Use well maintained tools in a proper way.

ii

(11) Use bolts and nuts of the same part number when replacing. Do not use poor quality parts for replacement.

(12) Park the truck on level and hard ground for maintenance work. Block the wheels when working on or under the truck to prevent it from moving unexpectedly.

(13) Before starting work on the truck, hang "Do not Operate" tag in the operator compartment.

(14) Welding work must be performed only by qualified personnel. Determine the type of metal and select the correct welding procedure and electrodes, rods or wire to ensure a weld metal strength equivalent at least to that of parent metal.

(15) Do not damage electrical wiring during the removal process. Do not reuse the wiring if damaged. Be careful not to touch hot parts or sharp edges when installing wires. Also, route wire harnesses away from oil pipe.

(16) Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting the work.

If protective devices have to be removed for maintenance work, be sure to install them as they were after the work.

(17) When working with the mast in the raised position, BE SURE to block the mast and bracket to prevent them falling unexpectedly.

(18) Loose or damaged fuel, lubricant, hydraulic lines, tubes, and hoses could cause fires. Do not bend high pressure lines or do not apply strong force. Inspect lines, tubes, and hoses carefully. DO NOT check oil leaks with your hands. Pin hole (very small) leaks could result in a high velocity oil stream that will be invisible close to the hose. This oil could penetrate the skin and cause personal injury. Use cardboard or paper to locate leaks from a minute pinhole.

(19) Tighten pipe connections to the correct torque. Make sure that all heat shields, clamps, and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. For protective covers, which purpose is to prevent hot oil from splashing over exhaust system, make sure they are properly installed.

(20) Release all pressure in air, oil, or water systems before any lines, fittings, or related items are disconnected or removed.

Use blocks to prevent the implement from falling if it is in the raised position. Be careful of residual pressure when removing implements that are operated at a pressure.

(21) Do not operate the truck if any rotating part is damaged or if they have come in contact with other part.

When a high speed rotating component is replaced, be sure to check its balance before operation.

2. HOW TO USE THIS MANUAL 2.1 Truck Models MC (Mechanical Control System) model The truck equipped with mechanically controlled hydraulic system (conventional lever system)

1 2

504506

1.

Implement lever

2.

Control valve

FC (Fingertip Control System) model The truck equipped with electronically controlled hydraulic system (fingertip control system)

1 4 2 3 5

6

7 504507

1.

2.

3.

4.

FC lever box Input unit VCM Controller Output unit

5.

6.

7.

Electric wiring Electromagnetic control valve Flow regulator valve

iii

Gasoline models Equipped with GK15, GK21, or GK25 gasoline engine Diesel models Equipped with S4Q2 or S4S diesel engine Powershift trucks Trucks equipped with powershift transmission Manual transmission trucks Trucks equipped with manual transmission (2 types of clutch; dry and wet)

3. Symbols and Abbreviations Symbol or abbreviation

Meanings

OP.

Option

R1/4

Taper pipe thread (external) 1/4 inch (formerly PT1/4)

Rc1/8

Taper pipe thread (internal) 1/8 inch (formerly PT1/8)

G1/4A

Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)

Rp1/8

Straight pipe thread (internal) 1/8 inch (formerly PS1/8)

4. Units -

SI Units are used in this manual.

The following table shows the conversion of SI unit and customary unit: Item

SI unit

Metric unit

Yard-pound unit

1N

0.102 kgf

0.225 lbf

Pressure

1 MPa

10.1972 kgf/cm2

145.038 psi

Torque

1 N·m

0.102 kgf·m

0.7376 lbf·ft

1 mm

-

0.039 in.

1m

-

3.281 feet

Weight

1 kg

-

2.205 lb

Temperature

1 °C

-

°F = 1.8 x °C + 32

Volume

1L

-

0.264 US.gal.

Force

Length

iv

TABLE OF CONTENTS

Chapter 1 GENERAL INFORMATION 1.

2.

3.

4.

5.

6.

Model View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Applicable Truck Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Chapter 2 COOLING SYSTEM 1.

2.

3.

3.1 3.2 3.3

4.

4.1

5.

5.1 5.2 5.3 5.4 5.5

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Fan Belt, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Fan Belt, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Cooling System, Inspecting and Adjusting . . . . . . . . . . . . . . . . . . . . . .2-4 Fan Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Fan Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Hoses, Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Cooling Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Chapter 3 ELECTRICAL SYSTEM 1.

2.

2.1 2.2 2.3

3.

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13

Chassis Electrical Components and Wiring Outline . . . . . . . . . . . . . .3-1 Console Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 Console Box Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 Meter Panel, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 Meter Panel, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Main Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 Meter panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 Direction (FNR) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Light Switch and Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11 Key Switch (Anti-Restart Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12 Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13 Steering Angle Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 Backup Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 QGS Controller (Diesel Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16 VCM (Vehicle Control Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17 ECM (Gasoline Engine Control Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18 Relay Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19 Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22 Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23

TOC-1

TABLE OF CONTENTS

3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24

4.

4.1 4.2 4.3

5.

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9

6.

6.1

7.

7.1 7.2 7.3 7.4 7.5

8.

Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Rear Combination Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Rear Combination Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Front Combination Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Front Combination Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Stop Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 Backup Light Switch (Manual T/M Truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Neutral Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Thermoswitch (Engine Coolant Temperature) . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Thermoswitch (T/C Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 List of Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Battery and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 State of Charge in Specific Gravity and Adjustment . . . . . . . . . . . . . . . . . . . 3-32 Relationship Between Electrolyte Specific Gravity and State of Charge 3-32 Precautions for Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Meter Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Basic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39 When A Warning Occurs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 Diagnostic Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 Warning Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 Optional Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Wire Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 List of Wire Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 Engine Startup Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 Gauge-related Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 Lightning-related Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 Warning System Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 Battery-related problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63

Electrical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64

Chapter 4 CONTROLLER 1.

2.

2.1 2.2 2.3 2.4

3.

3.1 3.2

4.

4.1

TOC-2

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Main Functions of Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Meter panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VCM -1M (Vehicle Control Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ECM (Gasoline Engine Control Module) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GSE Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3 4-3 4-3 4-4

Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Service Tool Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Toolbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Mast Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Mast Interlock Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

TABLE OF CONTENTS

4.2 4.3

5.

5.1 5.2 5.3

6.

6.1 6.2

7.

7.1 7.2 7.3

8.

9.

9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12

10.

10.1 10.2 10.3 10.4

VCM-1M Controller, Mast Interlock System Checking Procedure . . . . . . .4-21 Active Test Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24

Driving Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 Controller Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27 Driving Interlock Function, Checking the Operation . . . . . . . . . . . . . . . . . . .4-28 Active Test Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31

Seat Belt Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-32 Seat Belt Warning Light, Checking the Operation . . . . . . . . . . . . . . . . . . . . . .4-32 Seat Belt Warning Light, Checking the Operation . . . . . . . . . . . . . . . . . . . . .4-33

Parking Brake Warning Buzzer and Light . . . . . . . . . . . . . . . . . . . . . . . .4-34 Parking Brake Warning Buzzer and Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34 Parking Brake Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 Parking Brake Warning Buzzer/Light, Checking the Operation with Key in OFF Position . . . . . . . . . . . . . . . . . . . . .4-37

Harness Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38 Controller Output Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40 VCM-1M Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-40 Seat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44 Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44 Direction Lever Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45 T/M Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45 Unload Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45 Lift Lock Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-46 Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47 Warning Buzzer Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-47 Warning Buzzer Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48 Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-49

Truck Status Display and Troubleshooting . . . . . . . . . . . . . . . . . . . . . .4-51 Truck Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-51 Diagnosis Table (F Code) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-52 LED Blink Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-60 Probable Warning Cause on Diagnostic Code and Troubleshooting . . . .4-61

Chapter 5 POWER TRAIN 1.

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11

Installation of Engine and Transmission Assembly (for Gasoline Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Removal Sequence of Overhead Guard, Air Cleaner and Others . . . . . . .5-1 Suggestions for Removal of Overhead Guard, Air Cleaner and Others . .5-2 Removal Sequence of Controls (Manual T/M Truck) . . . . . . . . . . . . . . . . . . .5-3 Suggestions for Removal of Controls (Manual T/M Truck) . . . . . . . . . . . . .5-3 Suggestions for Installing Controls (Manual T/M Truck) . . . . . . . . . . . . . . .5-4 Removal Sequence of Controls (Power Shift T/M Truck) . . . . . . . . . . . . . . .5-4 Suggestions for Removing Controls (Power Shift T/M Truck) . . . . . . . . . .5-4 Suggestions for Installing Controls (Power Shift T/M Truck) . . . . . . . . . . .5-4 Preparation for Removing Pipes and Radiator (Manual T/M Truck) . . . . .5-5 Removal Sequence of Pipes and Radiator (Manual T/M Truck) . . . . . . . . .5-5 Suggestions for Installing of Pipes and Radiator (Manual T/M Truck) . . .5-5

TOC-3

TABLE OF CONTENTS

1.12 1.13 1.14 1.15 1.16 1.17 1.18

Preparation for Removing Pipes and Radiator (Power Shift T/M Truck) 5-6 Removal Sequence of Pipes and Radiator (Manual T/M Truck) . . . . . . . . 5-6 Suggestions for Installing Pipes and Radiator (Powershift T/M Truck) . 5-6 Preparation for Removing Engine and Transmission Assembly . . . . . . . 5-7 Removal Sequence of Engine and Transmission Assembly . . . . . . . . . . . . 5-7 Suggestions for Removing Engine and Transmission Assembly . . . . . . . 5-7 Suggestions for Installing Engine and Transmission Assembly (Manual T/M truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 1.19 Suggestions for Installing Engine and Transmission Assembly (Power Shift T/M Truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

2.

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15

Installation of Engine and Transmission Assembly (for Diesel Truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Removal Sequence of Overhead Guard, Air Cleaner and Others . . . . . . . 5-10 Suggestions for Removing Overhead Guard, Air Cleaner and Others . . 5-11 Removal Sequence of Controls (Manual T/M Truck) . . . . . . . . . . . . . . . . . . 5-11 Removal Sequence of Controls (Power Shift T/M Truck) . . . . . . . . . . . . . . 5-11 Preparation for Removing Pipes and Radiator (Manual T/M Truck) . . . . 5-12 Removal Sequence of Pipes and Radiator (Manual T/M Truck) . . . . . . . . 5-12 Suggestions for Installing Pipes and Radiator (Manual T/M Truck) . . . . . 5-12 Preparation for Removing Pipes and Radiator (Power Shift T/M Truck) 5-13 Removal Sequence of Pipes and Radiator (Power Shift T/M Truck) . . . . 5-13 Suggestions for Removing Pipes and Radiator (Power Shift T/M Truck) 5-13 Suggestions for Installing Pipes and Radiator (Power Shift T/M Truck) . 5-13 Preparation for Removing Engine and Transmission Assembly . . . . . . . 5-14 Removal Sequence of Engine and Transmission Assembly . . . . . . . . . . . . 5-14 Suggestions for Removing Engine and Transmission Assembly . . . . . . . 5-14 Suggestions for Installing Engine and Transmission Assembly . . . . . . . . 5-14

Chapter 6 CLUTCHES 1.

1.1 1.2 1.3

2.

2.1 2.2

3.

3.1

4.

4.1 4.2

5.

5.1

6.

7.

7.1

8.

TOC-4

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Advantages and Disadvantages of Clutches by Type of Drive System . . 6-1 Main Differences Between Dry-Type and Wet-Type Clutches . . . . . . . . . . 6-2 Structure and Function of Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Clutch Assembly, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Clutch Assembly, Inspection and Repair After Disassembly . . . . . 6-11 Clutch Disc Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Clutch Assembly, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Pressure Plate Assembly, Disassembling . . . . . . . . . . . . . . . . . . . . . . . 6-16 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Pressure Assembly, Inspection and Repair After Disassembly . . . 6-17 Pressure Assembly, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Clutch Master Cylinder (Dry Type Clutch), Disassembling . . . . . . . 6-20

TABLE OF CONTENTS

8.1 8.2

9.

10.

Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

Clutch Master Cylinder (Dry Type Clutch), Inspection and Repair 6-21 Clutch Master Cylinder (Dry Type Clutch), Assembling . . . . . . . . . .6-22

10.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

11.

Clutch Release Cylinder, Disassembling . . . . . . . . . . . . . . . . . . . . . . . .6-22

11.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22 11.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23

12.

13.

Clutch Release Cylinder, Inspection and Repair After Disassembly6-23 Clutch Release Cylinder, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

13.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

14.

14.1 14.2 14.3 14.4

15.

16.

17.

Clutch System, Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25 Bleeding Clutch Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25 Clutch Pedal (Dry Type), Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26 Clutch Pedal (Wet Type), Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-27

Checking Clutch Disc for Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31

17.1 Dry Type Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31 17.2 Wet Type Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

Chapter 7 MANUAL TRANSMISSION 1.

1.1

2.

2.1

3.

3.1

4.

4.1

5.

5.1

6.

6.1 6.2

7.

7.1 7.2

8.

8.1

9.

9.1

10.

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Components of Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Transmission, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

Transmission, Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4

Transmission External Parts, Disassembly . . . . . . . . . . . . . . . . . . . . . . .7-5 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

Control Covers, Shift Rails and Forks, Disassembly . . . . . . . . . . . . . .7-6 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

Shifter Case and Input Shaft, Disassembly . . . . . . . . . . . . . . . . . . . . . .7-7 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8

Transmission Housing and Shaft Assemblies, Disassembly . . . . . .7-9 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9

Synchro-shaft Assembly, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10

Input Gear Assembly, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11

Output Gear, Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 TOC-5

TABLE OF CONTENTS

10.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

11.

Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

11.1 Synchromesh Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

12.

12.1 12.2 12.3 12.4 12.5 12.6

13.

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Shifter Case, Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Output Gear, Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 Input Gear and Idler Gear, Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . 7-15 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Main Shaft Assembly, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

13.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 13.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 13.3 Selection of Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

14.

Transmission Housing, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

14.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

15.

Fork and Shift Rails and Control Cover, Assembly . . . . . . . . . . . . . . . 7-21

15.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 15.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

16.

17.

17.1 17.2 17.3 17.4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Shift Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Input Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-24 7-24 7-25 7-27

Chapter 8 POWERSHIFT TRANSMISSION 1.

1.1 1.2 1.3 1.4 1.5 1.6

2.

2.1

3.

3.1

4.

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8

TOC-6

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 External View of Torque Converter Transmission . . . . . . . . . . . . . . . . . . . . . 8-1 External View of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Transmission Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 Torque Converter Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Torque Converter Drive Control Components . . . . . . . . . . . . . . . . . . . . . . . . 8-6 Schematic Diagram of Powershift Transmission Hydraulic System . . . . . 8-7

Transmission, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Transmission, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Torque Converter Transmission, Disassembling . . . . . . . . . . . . . . . . 8-9 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Transmission Accessories, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Oil Pump, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Transmission Housing, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Input Shaft, Idler Shaft and Output Gear, Removing . . . . . . . . . . . . . . . . . . 8-17 Transmission Housing, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20 Torque Converter Housing, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21 Idler Shaft, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-21

TABLE OF CONTENTS

4.9 4.10 4.11 4.12

5.

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11

6.

6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8

7.

7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11

8.

8.1 8.2 8.3

9.

10.

10.1 10.2 10.3 10.4 10.5 10.6

Output Gear, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-22 Forward Side Input Shaft Gear Assembly, Disassembling . . . . . . . . . . . . . .8-23 Reverse Side Input Shaft Gear, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . .8-28 Oil Pump, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-30

Torque Converter Transmission, Assembling . . . . . . . . . . . . . . . . . . .8-32 Transmission Housing, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-32 Idler Shaft Assembly, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-33 Output Gear Assembly, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-33 Input Shaft Gear Assembly, Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-34 Forward Side Input Shaft Gear Assembly, Assembling . . . . . . . . . . . . . . . . .8-36 Reverse Side Input Shaft Gear Assembly, Assembling . . . . . . . . . . . . . . . . .8-43 Oil Pump Assembly, Assembling and Installing . . . . . . . . . . . . . . . . . . . . . . .8-44 Torque Converter Housing, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-49 Transmission Housing, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-52 Servo Case Assembly, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-53 Transmission Accessories, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-54

Control Valve, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-60 Control Valve Accessories, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-60 Valve Body Plate, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-60 Plugs, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-61 Strainer, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-62 Regulator Valve Section, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-62 Accumulator Valve Section, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . .8-63 Inching Valve Section, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-64 Oil Seal and Plug, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-66

Control Valve, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-67 Control Valve, Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-67 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-68 Washing and Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-68 Valve Plug and Oil Seal, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-69 Inching Valve Section, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-70 Accumulator Valve Section, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-72 Regulator Valve Section, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-73 Strainer, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-75 Plug, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-75 Valve Body Plate and Breather Cover, Installing . . . . . . . . . . . . . . . . . . . . . . .8-77 Control Valve Accessories, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-77

Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-79 Oil Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-79 Brake (Inching) Pedal, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-81 Inching Cable, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-83

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-84 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-89 Pump Boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-89 Pilot Boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-90 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-90 Flexible Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-91 Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-91 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-92

TOC-7

TABLE OF CONTENTS

Chapter 9 FRONT AXLE AND REDUCTION DIFFERENTIAL 1.

2.

2.1 2.2 2.3

3.

3.1 3.2 3.3

4.

5.

5.1 5.2

6.

7.

7.1 7.2 7.3

8.

9.

10.

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 1 Ton Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 2 Ton Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 3 Ton Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

Front Wheel, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

Front Wheels, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 Front Axle and Reduction Differential, Removing . . . . . . . . . . . . . . . 9-7 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

Front Axle and Reduction Differential, Installing . . . . . . . . . . . . . . . . 9-8 Front Axle, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

Front Axle, Inspection and Repair After Disassembly . . . . . . . . . . . . 9-11 Front Axle, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12 Reduction Differential, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15

10.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15 10.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

11.

12.

Reduction Differential, Inspection and Repair After Disassembly 9-18 Reduction Differential, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19

12.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 12.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20

13.

Reduction Differential, Inspecting and Adjusting After Assembly 9-25

13.1 Reduction Gear Tooth Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25

14.

15.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-26 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-27

Chapter 10 REAR AXLE 1.

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

2.

TOC-8

Rear Axle Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Specifications for Wheel Alignment and Steering Angle . . . . . . . . . . . . . . 10-2 Wheel Hub Section, Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Left Side Kingpin Section, Main Components . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Right Side Kingpin Section, Main Components . . . . . . . . . . . . . . . . . . . . . . . 10-3 Main Components of Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Tie Rod Section, Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Steering Cylinder, Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

Rear wheels, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

TABLE OF CONTENTS

2.1

3.

4.

4.1 4.2

5.

6.

7.

7.1 7.2

8.

9.

9.1 9.2

10.

Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6

Rear Wheels, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-6 Rear Axle Assembly, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7

Axle Assembly, Inspection and Repair After Disassembly . . . . . . . .10-7 Axle Assembly, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8 Wheel Hub, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-9

Wheel Hub Section, Inspection and Repair After Disassembly . . .10-9 Wheel Hub Section, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-9 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-9 Wheel Bearing, Assembling and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-9

Knuckle Section (Kingpin), Disassembling . . . . . . . . . . . . . . . . . . . . . . .10-11

10.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11 10.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11

11.

12.

Knuckle Section (Kingpin), Inspection After Disassembly . . . . . . . .10-12 Knuckle Section (Kingpin), Assembling . . . . . . . . . . . . . . . . . . . . . . . . .10-13

12.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13

13.

Steering Cylinder, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14

13.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14 13.2 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14

14.

Steering Cylinder, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15

14.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15 14.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15

15.

Steering Cylinder, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-16

15.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-16

16.

Tie Rod, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-16

16.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-16 16.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-16

17.

Tie Rod, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-16

17.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-16

Chapter 11 BRAKE SYSTEM 1.

2.

2.1

3.

4.

4.1

5.

5.1 5.2

Structure of Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1 Master Cylinder, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2

Master Cylinder, Inspection and Repair after Disassembly . . . . . . .11-3 Master Cylinder, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3

Structure of Wheel Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4 1 Ton Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-4 2, 3 Ton Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-5

TOC-9

TABLE OF CONTENTS

6.

6.1 6.2 6.3

7.

8.

8.1 8.2 8.3

9.

9.1

10.

11.

12.

12.1 12.2 12.3 12.4 12.5 12.6 12.7

13.

14.

Wheel Brakes, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7

Wheel Brakes, Inspection and Repair After Disassembly . . . . . . . . . 11-8 Wheel Brakes, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9 Assembly Sequence (1 Ton Class) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9 Assembly Sequence (2, 3 Ton Class) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11

Wheel Cylinder, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

Wheel Cylinder, Inspection and Repair After Disassembly . . . . . . . 11-13 Wheel Cylinder, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13 Brake System, Inspecting and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . 11-14 Automatic Adjuster, Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-14 Manual Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15 Parking Brake Cable, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-16 Brake Pedal, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17 Brake Oil Line, Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18 Braking Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18 Parking Brake Lever, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22

Chapter 12 STEERING SYSTEM 1.

1.1 1.2 1.3 1.4

2.

2.1

3.

3.1 3.2

4.

5.

5.1

6.

7.

8.

9.

10.

Structure and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Knob Deviation Correction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5

Pipes and Hoses, Disassembling and Assembling . . . . . . . . . . . . . . . 12-6 Suggestions for Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

Steering Wheel and Steering Valve, Disassembling . . . . . . . . . . . . . 12-7 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

Steering Wheel and Steering Valve, Installing . . . . . . . . . . . . . . . . . . . 12-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9 Inspection After Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9

Steering Valve, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10 Steering Valve, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10 Tilt Lock Lever, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10 Tilt Lock Lever, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11 Steering Valve, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12

10.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12 10.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13

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11.

12.

Inspection After Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-14 Steering Valve, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-15

12.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-15

13.

14.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-20 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-21

Chapter 13 HYDRAULIC SYSTEM 1.

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10

2.

2.1 2.2

3.

3.1

4.

4.1 4.2

5.

6.

6.1 6.2

7.

7.1 7.2

8.

8.1

9.

9.1 9.2 9.3 9.4

10.

Structure and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1 Hydraulic Lines Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-4 Hydraulic Pump (Gear Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-5 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-6 Down Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-7 Lift Cylinder (First Cylinder for Duplex and Triplex Masts) . . . . . . . . . . . . . .13-8 Lift Cylinder (Second Lift Cylinder for Simplex Mast and Triplex Mast) . .13-9 Lift Cylinder (Second Lift Cylinder for Duplex Mast) . . . . . . . . . . . . . . . . . . .13-12 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-15

Hydraulic Pump, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-16 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-16 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-16

Hydraulic Pump, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-16 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-16

Hydraulic Pump, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-17 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-17 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-17

Hydraulic Pump, Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . .13-18 Hydraulic Pump, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-18 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-18 Operation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-18

Lift Cylinders (Simplex Mast), Removing . . . . . . . . . . . . . . . . . . . . . . . .13-19 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-19 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-19

Lift Cylinders (Simplex Mast), Installing . . . . . . . . . . . . . . . . . . . . . . . . .13-21 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-21

Lift Cylinders (Duplex and Triplex Masts), Removing . . . . . . . . . . . .13-21 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-21 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-22 Removing First Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-22 Removing Second Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-23

Lift Cylinders (Duplex and Triplex Masts), Installing . . . . . . . . . . . . .13-24

10.1 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-24

11.

Lift Cylinder, Disassembling (First Cylinder for Duplex and Triplex Masts) . . . . . . . . . . . . . . . . . . . .13-24

11.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-24 11.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-25

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TABLE OF CONTENTS

12.

13.

Lift Cylinder, Inspecting (First Cylinder for Duplex and Triplex Masts) . . . . . . . . . . . . . . . . . . . . 13-25 Lift Cylinders, Assembling (First Cylinder for Duplex and Triplex Masts) . . . . . . . . . . . . . . . . . . . . 13-26

13.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-26

14.

Lift Cylinder, Disassembling (Second Cylinder for Simplex Mast and Triplex Mast) . . . . . . . . . . . 13-27

14.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-27 14.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-28

15.

16.

Lift Cylinder, Inspecting (Second Cylinder for Simplex Mast and Triplex Mast) 13-29 Lift Cylinders, Assembling (Second Cylinder for Simplex Mast and Triplex Mast) . . . . . . . . . . . 13-30

16.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-30

17.

Lift cylinders, Removing (Second Cylinder for Duplex Mast) . . . . . 13-31

17.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-31 17.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-31

18.

19.

Lift Cylinder (Second for Duplex Mast), Inspecting . . . . . . . . . . . . . . 13-31 Lift Cylinders, Assembling (Second Cylinder for Duplex Mast) . . . 13-32

19.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-32

20.

Removing tilt cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-33

20.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-33 20.2 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-33 20.3 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-33

21.

Tilt Cylinders, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-33

21.1 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-33

22.

Tilt Cylinder, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-34

22.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-34 22.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-34

23.

24.

Tilt Cylinder, Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-35 Tilt Cylinder, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-35

24.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-35 24.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-36

25.

Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-37

25.1 Piping for Control Valve on Diesel Engine Models . . . . . . . . . . . . . . . . . . . . 13-37

26.

Suction Strainer and Return Filter, Removing . . . . . . . . . . . . . . . . . . . 13-38

26.1 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-38 26.2 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-38

27.

28.

Suction Strainer and Return Filter, Inspecting . . . . . . . . . . . . . . . . . . 13-38 Suction Strainer and Return Filter, Installing . . . . . . . . . . . . . . . . . . . . 13-38

28.1 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-38

29.

Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-39

29.1 Hydraulic Tank, Inspecting and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-39 29.2 Control Valve, Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-39 29.3 Vertical Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-41

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29.4 Tilt Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-42

30.

30.1 30.2 30.3 30.4

31.

31.1 31.2 31.3 31.4

32.

32.1 32.2 32.3 32.4 32.5

33.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-42 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-42 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-43 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-43 Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-44

Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-45 First Cylinder for Duplex and Triplex Masts . . . . . . . . . . . . . . . . . . . . . . . . . . .13-46 Second Cylinder for Simplex and Triplex Masts . . . . . . . . . . . . . . . . . . . . . . .13-47 Second Cylinder for Duplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-48 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-49

Control Valve, Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-50 Hydraulic Lines Diagram of Hydraulic Control Valve . . . . . . . . . . . . . . . . . . .13-51 Inlet Cover Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-52 Lift Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-54 Tilt Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-57 Unload Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-59

Control Valve, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-60

33.1 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-60

34.

Control Valve, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-60

34.1 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-60

35.

Control Valve - Inlet Cover Section, Disassembling . . . . . . . . . . . . . .13-61

35.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-61 35.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-61

36.

Control Valve - Lift Valve, Disassembling . . . . . . . . . . . . . . . . . . . . . . . .13-62

36.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-62 36.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-62

37.

Control Valve - Tilt Valve, Disassembling . . . . . . . . . . . . . . . . . . . . . . . .13-63

37.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-63 37.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-63

38.

Control Valve - End Cover Section, Disassembling . . . . . . . . . . . . . . .13-64

38.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-64

39.

40.

Control Valve - End Cover Section, Disassembling . . . . . . . . . . . . . . .13-64 Control Valve - End Cover Section, Assembling . . . . . . . . . . . . . . . . .13-65

40.1 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-65

41.

Attachment Valves, Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-66

41.1 Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-66 41.2 Suggestions for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-67

TOC-13

TABLE OF CONTENTS

Chapter 14 MAST AND FORKS 1.

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24 1.25 1.26 1.27

2.

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17

TOC-14

Simplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 Mast System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 Structure and Functions (5V15D to 5V35D) . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2 Mast and Lift Bracket Assembly, Removal Sequence . . . . . . . . . . . . . . . . . . 14-4 Suggestions for Removing of Mast and Lift Bracket Assembly . . . . . . . . 14-4 Suggestions for Installing of Mast and Lift Bracket Assembly . . . . . . . . . 14-6 Mast and Lift Bracket, Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7 Suggestions for Disassembly of Mast and Lift Bracket . . . . . . . . . . . . . . . . 14-7 Mast and Lift Bracket, Inspection (All Mast Models) . . . . . . . . . . . . . . . . . . . 14-8 Lift Bracket Roller, Assembly Sequence (All Mast Models) . . . . . . . . . . . . . 14-9 Lift Bracket Clearance Adjustment (All Mast Models) . . . . . . . . . . . . . . . . . 14-10 Installing Mast Rollers (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-12 Installing Mast Strips (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13 Installing Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14 Connecting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 Installing Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16 Mast Rollers and Strips, Removal and Installation Without Removing Mast from Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-18 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19 Inspecting Forks (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-19 Chain Tension, Inspection and Adjustment (All Mast Models) . . . . . . . . . 14-21 Measuring Chain Elongation (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . 14-22 Adjusting Clearance Between Lift Bracket Roller and Inner Mast (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-23 Adjusting Mast Roller Clearance (All Mast Models) . . . . . . . . . . . . . . . . . . . 14-25 Inspecting and Adjusting Mast Strip Clearance (All Mast Models) . . . . . 14-26 Adjusting Mast Tilt Angle (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . 14-27 Inspecting and Adjusting Right and Left Lift Cylinder Stroke (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-27 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-29

Duplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-32 Mast System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-32 Structure and Functions (5F15C to 5F35CF) . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-33 Mast and Lift Bracket Assembly, Removal Sequence . . . . . . . . . . . . . . . . . . 14-35 Suggestions for Removing of Mast and Lift Bracket Assembly . . . . . . . . 14-35 Suggestions for Installing Mast and Lift Bracket Assembly . . . . . . . . . . . . 14-37 Mast and Lift Bracket, Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . 14-38 Preparation for Disassembly of Mast and Lift Bracket . . . . . . . . . . . . . . . . . 14-38 Suggestions for Disassembly of Mast and Lift Bracket . . . . . . . . . . . . . . . . 14-39 Mast and Lift Bracket, Inspection (All Mast Models) . . . . . . . . . . . . . . . . . . . 14-40 Lift Bracket Roller, Assembly Sequence (All Mast Models) . . . . . . . . . . . . . 14-41 Lift Bracket Clearance Adjustment (All Mast Models) . . . . . . . . . . . . . . . . . 14-42 Installing Mast Rollers (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-44 Installing Mast Strips (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-45 Installing Second Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-46 Installing First Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47 Connecting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47 Installing Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-48

TABLE OF CONTENTS

2.18 Mast Rollers and Strips, Removal and Installation Without Removing Mast from Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-50 2.19 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-51 2.20 Inspecting Forks (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-51 2.21 Chain Tension, Inspection and Adjustment (All Mast Models) . . . . . . . . . .14-53 2.22 Measuring Chain Elongation (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . .14-54 2.23 Adjusting Clearance Between Lift Bracket Roller and Inner Mast (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-55 2.24 Adjusting Mast Roller Clearance (All Mast Models) . . . . . . . . . . . . . . . . . . . .14-56 2.25 Inspecting and Adjusting Mast Strip Clearance (All Mast Models) . . . . . .14-58 2.26 Adjusting Mast Tilt Angle (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . .14-59 2.27 Inspecting and Adjusting Right and Left Lift Cylinder Stroke (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-59 2.28 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-60 2.29 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-61

3.

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3.27 3.28 3.29

Triplex Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-64 Mast System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-64 Structure and Functions (5M15D to 5M35D) . . . . . . . . . . . . . . . . . . . . . . . . . .14-65 Mast and Lift Bracket Assembly, Removal Sequence . . . . . . . . . . . . . . . . . .14-67 Suggestions for Removing Mast and Lift Bracket Assembly . . . . . . . . . . . .14-67 Suggestions for Installing of Mast and Lift Bracket Assembly . . . . . . . . . .14-69 Mast and Lift Bracket, Disassembly Sequence (All Mast Models) . . . . . . .14-70 Preparation for Disassembly of Mast and Lift Bracket . . . . . . . . . . . . . . . . . .14-70 Suggestions for Disassembly of Mast and Lift Bracket . . . . . . . . . . . . . . . . .14-71 Mast and Lift Bracket, Inspection (All Mast Models) . . . . . . . . . . . . . . . . . . .14-72 Lift Bracket Roller, Assembly Sequence (All Mast Models) . . . . . . . . . . . . .14-73 Lift Bracket Clearance Adjustment (All Mast Models) . . . . . . . . . . . . . . . . . .14-74 Installing Mast Rollers (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-76 Installing Mast Strips (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-77 Installing Second Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-78 Installing First Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-79 Connecting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-80 Installing Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-81 Mast Rollers and Strips, Removal and Installation Without Removing Mast from Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-83 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-84 Inspecting Forks (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-84 Chain Tension, Inspection and Adjustment (All Mast Models) . . . . . . . . . .14-86 Measuring Chain Elongation (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . .14-87 Adjusting Clearance Between Lift Bracket Roller and Inner Mast (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-88 Adjusting Mast Roller Clearance (All Mast Models) . . . . . . . . . . . . . . . . . . . .14-89 Inspecting and Adjusting Mast Strip Clearance (All Mast Models) . . . . . .14-91 Adjusting Mast Tilt Angle (All Mast Models) . . . . . . . . . . . . . . . . . . . . . . . . . . .14-92 Inspecting and Adjusting Right and Left Lift Cylinder Stroke (All Mast Models) 14-92 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-93 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-94

TOC-15

TABLE OF CONTENTS

Chapter 15 SERVICE DATA 1.

2.

2.1 2.2

3.

3.1

4.

4.1 4.2 4.3

5.

5.1 5.2

TOC-16

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 Tightening Torques for Standard Bolts and Nuts . . . . . . . . . . . . . . . . 15-6 Metric Fine Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6 Metric Coarse Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8

Periodic Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-9 Safety Critical Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-10

Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-11 Fuel and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-13 Adjustment Value and Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-14

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-20 Special Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-20 Special Service Tools (For Powershift Transmission) . . . . . . . . . . . . . . . . . . . 15-23

Chapter 1 GENERAL 1.

Overview .................................................................................................. 1-1

1

GENERAL Chapter 1 GENERAL

1. Overview The following figure shows the major components of the wet disc brake system.

Main tank Gear pump

OCM (controller for options) (for wet disc brake specification models only)

Auto-deceleration valve (optional)

Oil filter

Parking brake switch

Pedal assembly

Parking brake valve

Connector Shuttle valve (optional) Wet disc brake assembly

Brake valve 215997

The brake oil sucked up from the tank by the gear pump passes through the parking brake valve and flows into the brake valve.

Brake oil, corresponding in amount to how far the brake pedal is pressed, will flow into the wet disc brake assembly, which presses the internal multi-disc brake to produce a braking force.

At the time of parking, if the parking brake switch is operated, the parking brake valve is electrically operated and the brake oil in the wet disc brake assembly is discharged into the tank. As a result, the multi-disc brake is mechanically pressed by the internal spring force to produce a braking force for parking.

1-1

Chapter 3 ELECTRICAL SYSTEM 1.

Outline of the Electrical System ............................................................ 3-1

2.

Outline of Vehicle Electronic System Wiring ....................................... 3-2

3.

Instrument Panel ..................................................................................... 3-3 3.1

4.

Optional Functions................................................................................................... 3-3

Electrical Schematic ............................................................................... 3-5

3

ELECTRICAL SYSTEM

1. Outline of the Electrical System

Chapter 3 ELECTRICAL SYSTEM

The following components described in this service manual are for a wet brake specification forklift truck, but are not installed on a standard specification model.

Brake oil sensor Back lamp switch Neutral switch Brake oil level warning lamp

3-1

ELECTRICAL SYSTEM

2. Outline of Vehicle Electronic System Wiring Starter switch

Main harness

Key

QGS controller Harness rear combination Input unit Back-up buzzer

Selector switch Warning buzzer Harness front combination VCM (Vehicle control module)

OCM (optional control module) (for wet disc brake specification models only) GSE connector

Clip GLE connector Harness front combination

Connector bracket

Battery seat ECM (Gasoline engine control module)

DCM (Diesel engine control module)

Horn Output unit Fuse box, Fuse Relay box, Relay Hi-speed sensor (pulse generator)

Transmission

215998

3-2

ELECTRICAL SYSTEM

3. Instrument Panel 3.1 Optional Functions For wet disc brake models, the automatic deceleration function, the controlled rollback function, and the proshift function have been added.

3.1.1 Automatic deceleration function (1) This function will automatically activate the service brakes if the accelerator pedal is released while the lift truck is traveling faster than a set-up speed by the manufacturer, and the deceleration function will continue until the lift truck slows down to the pre-set speed.

Normally ON

(2) Once the automatic deceleration function is set up, the automatic deceleration icon on the LCD will remain ON. (3) Use the service tools to set up the automatic deceleration function.

215999

3.1.2 Controlled rollback function (1) This function helps to prevent undesired backward movement of the lift truck when the operator changes from pressing the brake pedal to the accelerator pedal during the start on a grade.

ON only during operation

(2) Once the controlled rollback function is set up, the corresponding icon will turn on while it is activated.

(3) Use the service tools to set up the controlled rollback function.

Note: a) The service brake is applied only after the lift truck has stopped without pressing the accelerator pedal.

216000

b) The controlled rollback function will be released if the accelerator pedal is pressed with the direction lever placed in the F or R position. Therefore, the lift truck will slide backward when starting on a grade by pressing the inching pedal as the clutch is disengaged.

3-3

ELECTRICAL SYSTEM

3.1.3 Pro-shift function (1) This function prevents the power train from being damaged due to a mistake by the operator. (a) Jack-rabbit-start prevention function This function allows the lift truck to start if the accelerator pedal is pressed after placing the forward/reverse lever to either F or R position. (b) Forward/reverse shifting mistake prevention function This function disables the actual forward/ reverse shifting operation, if the operator moves the forward/reverse lever while the lift truck is traveling faster than the pre-set speed.

(2) Once the pro-shift function is set up, either the neutral lamp or the pro-shift lamp will glow. The neutral glows when the jack-rabbit-start prevention function is activated. The pro-shift lamp glows when the forward/reverse switching mistake prevention function is activated.

(3) Use the service tools to set up the pro-shift function and automatic deceleration function.

3-4

(a) Blinks when jack-rabbit-start prevention is active.

(b) Glows when forward/reverse switching operation mistake prevention is activated.

216018

ELECTRICAL SYSTEM

4. Electrical Schematic

3-5

ELECTRICAL SYSTEM Replace this page with page 1 of 2 from 99719-6W110_CAT_Gasoline.pdf

3-6

ELECTRICAL SYSTEM Replace this page with page 2 of 2 from 99719-6W110_CAT_Diesel.pdf

3-7

WIRING DIAGRAM （GASOLINE）

G004 S001 S002 A006 G042

OCM GSE

S001 S002 G004 G042 A006

0.5Y/B 0.5Y/L 0.5G/R 0.5G/R 0.5G/B

1.25Y/R 0.5Y/B 0.5Y/L 0.5G/R 0.5W/B 0.5L/R 0.5Y 0.5R 1.25W 1.25W/L 0.5G/B

S001 S002 G004

A006

CONNECTOR A

CONNECTOR B

G009 S008 G008 A101 S007 A102

ECM AVC1 ECM AVC2 ECM GND ECM APS1 ECM APS2 ECM GND

A104 S005 S006 G003 A103 G010 A102 A101 G009 S007 S008 G008

0.5Y/W 0.5L/W 0.5G/W 0.5B/R 0.5R/W 0.5L/Y 0.5Y 0.5R 0.5B/W 0.5L 0.5G 0.5B/Y

0.5Y/W 0.5L/W 0.5G/W 0.5B/R 1.25G 1.25R

A104 S005 S006 G003 A101 S003

S004

A102

A001

0.5L 0.5G 1.25B 1.25R/B 0.85R/Y

S007 S008

A012

G009 G008

S007 S008 G001 A016 A112

0.5B/W G009 0.5W/R A010 0.5B/Y G008 G001 A016

1.25B

G002

G002

1 SERVICE BRAKE SOL. + 2 RS232-Tx 3 RS232-Rx 4 RS232-GND 5 CAN H 6 CAN L 7 AVcc1 5V + 8 AVcc2 5V + 9 PARKING BRAKE SOL. + 10 SERVICE BRAKE SOL. 11 BOOT 12 13 APS 5V + 14 APS1 15 APS2 16 APS GND 17 PARKING BRAKE SOL. 18 12V + 19 20 21 22 23 APS1 OUT 24 APS2 OUT 25 GND 26 12V + 27 PRESSURE SW 28 29 AVcc2 GND 30 PARKING BRAKE SW 31 AVcc1 GND 32 33 34 GND

9

1

A004 A101 A102 S004 S003 G004 S002 S001 A001 17 A011 G003 S006 S005 A104 25 G001 S008 S007 G002 34

A006 A005 10 A012 18

G008 A010 G009

A112 A016 26

TABLE - 1 COMPARISON TABLE OF WIRE SIZE 5 3 2

10 12 14

1.25

16

0.85 0.5

18 20

mm 2 AWG

0.85R/Y 0.85B A112 G047

A010

1.25Y/R 1.25W/L

0.5W/B 0.5L/R 1.25R 1.25B 1.25R/B 1.25B 0.5W/R

A001 A005

G002 S003 A016 A010 G001 S004 A012

S003 S004 A012 G001 A016 G002 A010

1.25W 1.25G

CONNECTOR C

CAN H CAN L 12V + GND 12V + GND PKB SW

A104 S005 S006 G003 A011 A012

A005

A011 A004

A004 A011

TO HARNESS B

G003 S006 G010 A104 S005 A103

AWU AVC1 AWU APS1 AWU APS2 AWU GND AWU AVC2 AWU GND

A001 S001 S002 G004 S003 S004 A102 A101 A004 A005 A006

CONTROLLER(OCM)

HARNESS,WDB G

A005 A001

HARNESS, S/B SOL G

3）REFER TO TABLE-1 FOR COMPARISON BETWEEN AWG SIZE AND NOMINAL CROSS-SECTIONAL AREA. 2）THE FIGURE OF THE CONNECTOR SHOWN IN THIS DRAWING MEANS HARNESS, WDB G SIDE. NOTES 1）THIS DRAWING SHOWS THE WIRING DIAGRAM OF WET DISC BRAKE FOR GASOLINE TRUCK. BLACK WHITE RED GREEN YELLOW BLUE BROWN Light green ORENGE PURPLE GRAY B W R G Y L BR LG OR PU GY CAT

PARKING BRAKE SOL.

PRESSURE SWITCH

A004 A011

SERVICE BRAKE SOL.

Schematic No.

Used for

ES019-6W110

99719-6W110

A112 G047

Pub.No.99719-6W110

54 48

57 74

G004 S001 S002 A006 G042

39 45

STEPPING MOTOR MOTOR LEVER SWITCH 9 54

48

35

GND CAN L CAN H PKB SW

9

25 G006

S012

50 57 A021 S034 936 A111 S033

45 722

1.25Y/R 0.5Y/B 0.5Y/L 0.5G/R 0.5W/B 0.5L/R 0.5W/Y

A001 S001 S002 G004 S010 S012 A021

1.25W 1.25W/L 0.5G/B 0.85R 0.5R/W 0.5Y/R

A004 A005 A006 A022 A111 S033

0.5B/W G029 1.25G A011 1.25G/W A034 0.85R/L A023

G029

A034

723

40 41

0.5L/W

S034 1.25B/R 1.25Y G006 A033 0.85R/Y A112

58 51

0.5W/B 0.5L/R

A033

725 74 71

007

1.25Y 1.25Y 1.25B 1.25B

A011

A005

0.5W/R A010 0.5B 936

59 60

1.25B/R

G007

G007

A023 A034 18

936 A010

A112 A033 26

1 SERVICE BRAKE SOL.+ 2 RS232-Tx 3 RS232-Rx 4 RS232-GND 5 CAN H 6 CAN L 7 AVcc 5V + 8 9 PARKING BRAKE SOL.+ 10 SERVICE BRAKE SOL.11 BOOT 12 ACCEL SW 13 APS 5V + 14 APS1 15 16 APS GND 17 PARKING BRAKE SOL.18 12V + 19 ACCEL OUT 20 21 22 23 APS1 OUT 24 25 GND 26 12V + 27 PRESSURE SW 28 29 30 PARKING BRAKE SW 31 AVcc1 GND 32 33 34 GND

1.25Y/R A001 1.25W/L A005

0.5R/W A111 S033 0.5Y/R G029 0.5B/W

997

0.85R/Y A112 G047 0.85B

999

A005 A001

ACCEL PEDAL SWITCH ACCEL PEDAL SENSOR

A022 007

HARNESS, S/B SOL D

A004 A011

POWER SELECT SWITCH 722 751 721 721 983 981 720 751 999

L

SOFT

A111 S033

PRESSURE SWITCH

PARKING BRAKE SOL.

G029

POWER

40 41 59 60

A001

A004 A022

1.25W A004 1.25G A011

58 51

G006

720

S033 A111 A022 A006 A005 10 S034

G007 34

A023

39

A021 S012 S010 G004 S002 S001 A001

17 A011 G029

S010

A023 0.85R/L 50 0.85G 57 0.85W 0.5W/Y A021 S034 0.5L/W 0.5B 936 0.5R 39 0.5L 45

1

A004

1.25B/R G006 0.5L/R S012 0.5W/B S010 0.5W/R A010

A033 12V + 1.25Y

0.85B 0.85G 0.85B 0.85W

1.25W 1.25BR 1.25R 1.25OR 1.25Y

1.25W 1.25BR 1.25R 1.25OR 1.25Y

35 48 54 36 43

0.5B 0.5B 0.5B 0.5G 0.5G 0.5W/L 0.5R/Y 0.5R/Y 0.5BR/Y

1 2 3 4 5 6 IDOL SW 7 CLOSE SW 8 OPEN SW 9 ACC 5V +10 ACC SIG 11 ACC - 12 SENSOR +13 SENSOR -14 15 16 17 18 19 20 21 22 23 24 25 CAN H 26 CAN L 27 28 29 30 Vcc 12V +31 Vcc 12V +32 GND 33 GND 34

999 983 981 751 751 722 721 721 720

CONTROLLER (DCM)

COM 12V + MOTOR A1 MOTOR A2 MOTOR B1 MOTOR B2

0.5W/L 722 VCM 0.5W 723 VCM

58 26

39 45

51

0.5R 0.5L

40

35 48 54 36 43

41

M

HARNESS,WDB D

OCM GSE

TO HARNESS B

936 S034 A021 10 18

59

P/S S/S CONNECTOR

CONNECTOR E CONNECTOR D

007 0.85B A022 0.85R

36 39

H

45

25 60 34

SPEED SENSOR

0.5B 997 0.5B 990 0.5B 984 0.5G 750 0.5G 750 724 0.5R/Y 0.5R/Y 724 0.5BR/Y 725 0.5W 723

43

50 A023

71 50 74 57

57 17

A033

723 722

1

G006 S010 S012 A010

CONTROLLER (OCM)

50 71

G042 A006 G004 S002 S001

43 36 35

0.5G/R 0.5G/B 0.5G/R 0.5Y/L 0.5Y/B

WIRING DIAGRAM （DIESEL）

SERVICE BRAKE SOL.

A112 G047

TABLE - 1 COMPARISON TABLE OF WIRE SIZE 5 10 3 12 2 14 1.25 0.85 0.5

16 18 20

mm2 AWG 3）REFER TO TABLE-1 FOR COMPARISON BETWEEN AWG SIZE AND NOMINAL CROSS-SECTIONAL AREA. 2）THE FIGURE OF THE CONNECTOR SHOWN IN THIS DRAWING MEANS HARNESS, WDB G SIDE. NOTES 1）THIS DRAWING SHOWS THE WIRING DIAGRAM OF WET DISC BRAKE FOR DIESEL TRUCK.

BLACK WHITE RED GREEN YELLOW BLUE BROWN Light green ORENGE PURPLE GRAY B W R G Y L BR LG OR PU GY CAT

SPEED SELECT SWITCH

Schematic No.

Used for

723 750 724 724 984 725 750 997 990

ES019-6W110

99719-6W110

Pub.No.99719-6W110

Chapter 4 CONTROLLER 1.

Outline...................................................................................................... 4-1

2.

Main Functions of Each Controller........................................................ 4-2

3.

Traveling Control Interlock Function .................................................... 4-3

4.

Warning Buzzer and Warning Lamp for Parking Brake....................... 4-4 4.1 4.2 4.3 4.4

5.

Function................................................................................................................... 4-4 How to Check the Parking Brake Warning Buzzer and Warning Lamp Operations....................................................................................... 4-5 How to Check the Parking Brake Warning Buzzer and Warning Lamp Operations When the Key is OFF ................................................... 4-7 Parking Brake Dragging Warning Buzzer................................................................ 4-8

List of Diagnosis Contents (D-code) ..................................................... 4-9 5.1 5.2

DCM ........................................................................................................................ 4-9 OCM ...................................................................................................................... 4-12

4

CONTROLLER Chapter 4 CONTROLLER

1. Outline The controllers control both the lift truck body and the engine.

A wet disc brake-specification truck is fitted with the OCM (Optional Control Module).

Instrument panel Input unit VCM-1M (Vehicle control module)

OCM (Optional control module) (for wet disc brake models only)

GSE connector

GLE connector

Output unit QGS controller

ECM (Gasoline engine control module)

DCM (Disel engine control module)

216001

4-1

CONTROLLER

2. Main Functions of Each Controller Each controller connects into a CAN network, and information is exchanged between controllers via the CAN network. The VCM (vehicle control module) controller controls the whole lift truck system, and the other controllers control relevant components.

FC specification Arm rest

Instrument panel

Input unit

FC valve

Output unit

OCM

FNR lever Loading

ECM / DCM

Steering Drive

VCM-1M Lamp

Service solenoid Parking SW Parking solenoid

Instruments Warning Seat

Engine

For wet disc brake specification models only

216002

OCM (Optional control module) The OCM controller is located on the left side of the lift truck, and controls the service solenoid and the parking solenoid.

For other functions, refer to "3. Electrical System."

4-2

CONTROLLER

3. Traveling Control Interlock Function In addition to the driving interlock function for standard models, the models with wet disc brake system feature the following function. If an operator leaves the operator's seat without applying the parking brake, the driving interlock function automatically actuates the parking brake.

Note: 1. The parking brake will work when the lift truck is on level ground, synchronizing with the driving interlock. However, when the lift truck is on a grade, the lift truck will start to move downward.

2. Even if the driving interlock system is activated, the lift truck may move downward when the lift truck is on a grade. In this case, apply the parking brake switch and sit securely in the operator's seat.

4-3

CONTROLLER

4. Warning Buzzer and Warning Lamp for Parking Brake 4.1 Function Warning Buzzer and Warning Lamp for Parking Brake Whether the engine is stopped or running, leaving the operator's seat with the parking brake released activates the operator presence switch which causes the warning buzzer to activate and the warning lamp to blink.

(1) Before operating the lift truck, make sure the parking brake warning buzzer and the warning lamp function properly.

(2) The warning buzzer and warning lamp remind the operator to apply the parking brake switch before leaving the lift truck. Be sure to maintain the warning buzzer and the warning lamp so that they function properly.

(3) How to park the lift truck: Park the lift truck on level and hard ground.

Place the direction lever to the neutral position Lower the forks until the fork tips touch the floor.

Apply the parking brake switch.

Stop the engine and remove the key.

(4) When replacing the operator's seat with a new one, be sure to use the Cat genuine seat with an operator presence switch.

Outline of Controller Functions The controller turns the warning buzzer output ON when the operator is not seated and leaves the parking brake switch released while the key switch is in the ON position. (The warning buzzer activates.)

Also when the key switch is OFF, and the parking brake switch is not applied, the controller will activate the warning buzzer as the power normally flows in the electric circuit.

4-4

Parking brake warning lamp

Parking brake switch P

216106

CONTROLLER

4.2 How to Check the Parking Brake Warning Buzzer and Warning Lamp Operations (1) Connect the service tool to the VCM-1M controller.

(2) Turn the key switch ON to start the engine.

(Leave the parking brake applied.)

(3) Display the service tool input monitor screen.

(4) Use the service tool while sitting in the seat of the lift truck to check the seating condition (the seat switch is ON, the seating flag is ON). (Fig. 4-1)

Fig. 4-1 Input monitor screen

214155

(5) With the service tool, check that the parking brake switch is ON (Fig. 4-2) and that the parking brake warning lamp glows. (Fig. 4-3) (6) Release the parking brake switch, then leave the seat.

Fig. 4-2 Input monitor screen

214191

Glow

Fig. 4-3 Instrument panel screen

215108

4-5

CONTROLLER (7) With the service tool, check that the seat switch is OFF and the parking brake switch is OFF. (Fig. 44, 4-5) Also make sure that the parking brake warning lamp in the instrument panel turns off and the warning buzzer activates. (Fig. 4-6) (8) Apply the parking brake switch. Make sure that the parking brake warning lamp in the instrument panel glows and the warning buzzer deactivates.

Fig. 4-4 Input monitor screen

Fig. 4-5 Input monitor screen

214158

214194

Turn off

Fig. 4-6 Instrument panel screen

4-6

215109

CONTROLLER

4.3 How to Check the Parking Brake Warning Buzzer and Warning Lamp Operations When the Key is OFF (1) Keep the parking brake switch locked. Place the forward/reverse lever in the neutral position. Turn the key switch OFF to stop the engine. This deactivates both the VCM-1M controller and instrument panel because the power to them is turned off.

Release Apply

(2) Make sure that the parking brake warning buzzer activates when the parking brake switch is released. (This operation is not affected by the seat switch conditions.)

(3) Make sure that the parking brake warning buzzer stops if the parking brake switch is in the locked condition.

215335

This function must be checked on flat and solid pavement.

If the seat switch does not turn on Refer to "8. List of Harness Wire Numbers", "9.1 VCM-1M Controller", and "9.2 Seat Switch and Seat Belt Switch", and perform the seat switch operation and wiring checks, etc.

If the parking brake switch does not turn on Refer to "8. List of Harness Wire Numbers", "9.1 VCM-1M Controller", and "9.3 Parking Brake Switch", and perform the parking brake switch operation and wiring checks, etc.

If the warning buzzer does not turn on Refer to "4.3 Inspection Method with an Active Test", and check the warning buzzer output with any applicable active test. If the warning buzzer does not activate after checking with the active test, perform wiring checks while referring to "8. List of Harness Wire Numbers", "9.1 VCM-1M Controller", "9.9 Warning Buzzer", "9.10 Relay for Warning Buzzers", and "9.11 Warning Buzzer Circuit."

Note: For the references shown above, refer to the Service Manual for standard lift trucks.

214197

4-7

CONTROLLER

4.4 Parking Brake Dragging Warning Buzzer This buzzer will activate if an operator drives the lift truck without releasing the parking brake.

4-8

CONTROLLER

5. List of Diagnosis Contents (D-code) 5.1 DCM Diagnosis

DCM memory check error (D-51)

Logic conditions EEPROM sum check value ROM error, RAM error Recovery

Power reset

Control action

Controller operation stops (executing only GSE, CAN communication)

LED blink pattern

B

Diagnosis

Abnormal DCM power supply voltage (D-52)

Logic conditions

Power supply voltage ≤ 7 V Power supply voltage ≥ 21V (400 ms continuity)

Recovery

Self recovery

Control action

Throttle full close

LED blink pattern

B

Diagnosis

VCM communication error (D-53)

D-51

D-52

Logic conditions Cannot receive CAN from VCM-1 (2 seconds' continuity) Recovery

Self recovery

Control action

Operates with the received data from VCM as default.

LED blink pattern

B

Diagnosis

DCM communication error (D-55)

D-53

Logic conditions Cannot send CAN from DCM (2 seconds' continuity) Recovery

Self recovery

Control action

Continues operation disregarding the notified error.

LED blink pattern

B

Diagnosis

MP communication error (D-57)

D-55

Logic conditions Cannot receive CAN from instrument panel (2 seconds' continuity) Recovery

Self recovery

Control action

Operates with the received data from instrument panel as default.

LED blink pattern

B

D-57

4-9

CONTROLLER

Diagnosis

Overrun error (D-61)

Logic conditions After initialization, engine speed is 3000 rpm or more. (300 ms continuity) Recovery

Self recovery

Control action

Throttle full close

LED blink pattern

C

Diagnosis

Abnormal engine speed pulse (D-62)

Logic conditions

After detecting engine start (400 rpm or more), engine speed pulse disappears (200 ms continuity)

Recovery

Self recovery

Control action

Throttle full close

LED blink pattern

C

Diagnosis

Overheat (Step1) (D-63)

Logic conditions

Engine cooling water temperature is equal to or higher than 115°C (239°F) and lower than 125°C (257°F).

Recovery

Self recovery

Control action

Limit the engine speed to 1500 rpm.

LED blink pattern

C

Diagnosis

Overheat (Step 2) (D-64)

Logic conditions

Engine cooling water temperature is equal to or higher than 125°C (257°F) and lower than 127°C (260°F).

Recovery

Power reset

Control action

Limit the engine speed to 800 rpm.

LED blink pattern

C

Diagnosis

Acceleration sensor error (D-71)

Logic conditions

Acceleration input signal ≤ 0.15 V Acceleration input signal ≥ 4.37 V (300 ms continuity)

Recovery

Power reset

Control action

Throttle full close

LED blink pattern

D

4-10

D-61

D-62

D-63

D-64

D-71

CONTROLLER

Diagnosis Logic conditions

Engine speed sensor error (D-73) Engine speed sensor input signal ≤ 1.00 V Engine speed sensor input signal ≥ 4.37 V (300 ms continuity.)

Recovery

Power reset

Control action

Throttle full close

LED blink pattern

D

Diagnosis

Idling SW error (D-75)

D-73

Logic conditions Acceleration input is equal to or more than 50% and Idling SW is ON. (1 ms continuity) Recovery

Power reset

Control action

Throttle full close

LED blink pattern

D

Diagnosis

Throttle close SW error (D-76)

Logic conditions

During initialization, Close SW will not be ON even if the motor is operated at 120% in the full-close direction.

During initialization, Close SW will not be OFF even if the motor is operated at 120% in the fullopen direction.

Recovery

Power reset

Control action

Throttle full close

LED blink pattern

D

Diagnosis

Throttle open SW error (D-77)

Logic conditions

When learning the maximum lever position, Open SW will not be ON even if the motor is operated at 120% in the full-open direction.

When learning the maximum lever position, the Open SW is already ON.

Recovery

Power reset

Control action

Throttle full close

LED blink pattern

D

Diagnosis

Stepping motor error (D-91)

D-75

D-76

D-77

Logic conditions Current value ≤ 160 mA (1800 ms continuity) Current value ≥ 8 A (200 ms continuity) Recovery

Power reset

Control action

Throttle full close

LED blink pattern

E

D-91

4-11

CONTROLLER

5.2 OCM Diagnosis

OCM memory check error (S-01)

Logic conditions EEPROM sum check value ROM error, RAM error Recovery

Power reset

Control action

Controller operation stops (executing only GSE, CAN communication)

LED blink pattern

B

Diagnosis

OCM power supply, abnormal voltage (S-02)

Logic conditions

Power supply voltage ≤ 70 V Power supply voltage ≥ 21V (1 second's continuity)

Recovery

Self recovery

Control action

Set all the solenoid outputs to OFF.

LED blink pattern

B

Diagnosis

Abnormal VCM communication signal (S-03)

S-01

S-02

Logic conditions Cannot receive CAN from VCM-1M (2 seconds' continuity) Recovery

Self recovery

Control action

Operates with the received data from VCM as default.

LED blink pattern

B

Diagnosis

Abnormal OCM communication signal (S-06)

S-03

Logic conditions Cannot send CAN from OCM (2 seconds' continuity) Recovery

Self recovery

Control action

Continues operation disregarding the notified error.

LED blink pattern

B

Diagnosis

Abnormal APS1 input signal (S-10)

Logic conditions

APS1 input signal ≤ 0.1 V APS1 input signal ≥ 4.95 V (300 ms continuity)

Recovery

Power reset

Control action

Throttle full close

LED blink pattern

D

4-12

S-06

S-10

CONTROLLER

Diagnosis Logic conditions

Abnormal APS2 input signal (S-11) APS2 input signal ≤ 0.1 V APS2 input signal ≥ 4.95 V (300 ms continuity)

Recovery

Power reset

Control action

Throttle full close

LED blink pattern

D

Diagnosis

APS1/APS2 correlation error signal (S-13)

S-11

Logic conditions Difference between APS1 and APS2 input signals are greater than 0.085 V. Recovery

Power reset

Control action

Throttle full close

LED blink pattern

D

Diagnosis

Abnormal idling SW input signal (S-14)

S-13

Logic conditions Acceleration input is equal to or more than 50% and Idling SW is ON. Recovery

Power reset

Control action

Throttle full close

LED blink pattern

D

Diagnosis

Abnormal service brake solenoid (S-40)

S-14

Logic conditions Current value ≤ 160 mA (1800 ms continuity) Current value ≥ 1.6 A (200 ms continuity) Recovery

Power reset

Control action

Set the parking brake solenoid outputs to OFF.

LED blink pattern

E

Diagnosis

Abnormal service brake solenoid leakage (S-41)

S-40

Logic conditions Current value at output OFF ≥ 180 mA (600 ms continuity) Recovery

Power reset

Control action

Set all the solenoid outputs to OFF.

LED blink pattern

E

S-41

4-13

CONTROLLER

Diagnosis

Abnormal service brake solenoid (S-42)

Logic conditions Current value ≤ 160 mA (1800 ms continuity) Current value ≥ 1.6 A (200 ms continuity) Recovery

Power reset

Control action

Set the parking brake solenoid outputs to OFF.

LED blink pattern

E

Diagnosis

Abnormal service brake solenoid leakage (S-43)

S-42

Logic conditions Current value at output OFF ≥ 180 mA (600 ms continuity) Recovery

Power reset

Control action

Set all the solenoid outputs to OFF.

LED blink pattern

E

4-14

S-43

Chapter 5 POWER TRAIN 1.

Removal and installation Procedure and Points (MC models) ........... 5-1 1.1 1.2

Removal of Engine and Transmission Assembly (Gasolin-engine models) ............ 5-1 Removal of Engine and Transmission Assembly (Diesel-engine models) ............ 5-10

5

POWER TRAIN

1. Removal and installation Procedure and Points (MC models)

Chapter 5 POWER TRAIN

1.1 Removal of Engine and Transmission Assembly (Gasoline-engine models) The engine and transmission are installed as an assembled unit. The engine may be removed independently of the transmission, but the transmission can only be removed together with the engine.

1.1.1 Overhead guard, covers, air cleaner, etc.

5

6 1

3

10 4

9

7 11 2

8 12

215874

Sequence 1 2 3 4 5

Overhead guard Battery Steering wheel Gas spring Engine cover, Seat

6 7 8 9 10

Radiator cover Floor mat Floor plate Tank cover Air hose, Air cleaner

11 Exhaust pipe 12 Fuel hose 13 Under cover

5-1

POWER TRAIN Procedure for removal (1) Be sure to disconnect the ground (negative) cable first when removing a battery.

(2) Remove the tank cover 9, floor mat 7, and floor plate 8.

Tank cover

Floor mat Floor plate

215777

(3) Disconnect the exhaust pipe 11 on the engine side.

(4) Before removing the fuel hose 12, be sure to close the petcock on the fuel tank.

(5) When disconnecting individual harnesses from the sockets and terminals, which are interconnected to the engine and transmission, temporarily attach the harnesses along the main harness to prevent damage to them.

Before removing the fuel hose from the electroniccontrolled engine model, be sure to follow the procedure below to relieve the internal pressure of the fuel tank.

(1) Remove the fuel pump fuse.

(2) Turn the key switch to (START), and run the engine for several seconds to relieve the internal pressure of the fuel line.

(3) Turn the key switch to (OFF) and reinstall the fuel pump fuse.

(4) To relieve the internal pressure of the fuel tank, remove the fuel tank cap and then reinstall it after relieving the pressure.

5-2

POWER TRAIN

1.1.2 Control-related (Gasoline-engine trucks)

5

4 6 1

7 Electronic-controlled engine trucks

8

3 2 215966

Sequence 1 2 3 4

Brake pipes Rubber hose Rubber hose Inching cable

5 6 7 8

Stop lamp switch Accelerator pedal position sensor assembly Pedal assembly Brake valves

Procedure for removal Disconnect the inching cables 4 on both sides of the inching pedal and transmission, and loosen the lock nuts to remove them.

Reinstallation Follow the sequence of reinstallation in the reverse order of removal. For adjusting the brake pedal, refer to Chapter 8, "8.2 Adjusting the Brake Pedal (inching)", and Chapter 11, "3.4 Adjusting the Brake Pedal."

For adjusting the inching cable, refer to Chapter 8, "8.3 Adjusting the Inching Cable."

5-3

POWER TRAIN

1.1.3 Piping, radiator-related (Gasoline-engine trucks)

4

5

7 3

6

8

2

1

14 10

13 12

9

15

16 11

215967

Sequence 1 2 3 4 5 6 7

Reservoir tank Hose (upper) Hose (lower) Hose (between hydraulic tank and control valve) Hose (between hydraulic tank and oil pump) Hose (between oil pump and steering control valve) Cooler hose (between radiator and torque converter transmission) 8 Cooling fan 9 Fan belt

5-4

10 Fan guard 11 Universal joint (between transmission and reduction differential) 12 Hose (between auto-deceleration valve and parking brake valve) 13 Return hose 14 Suction hose 15 Hose (between parking brake valve and gear pump) 16 Suction hose

POWER TRAIN Preparation (1) Loosen the petcook at the lower part of the radiator to drain the cooling water.

(2) Drain the cooling water by removing the engine case drain plug. (Note that the position of the drain plug depends on the engine type.)

(3) Drain the oil from the main tank for the wet disc brakes.

Procedure for removal (1) Remove the cooler hose 7 on the transmission side and place it along the right side of the frame.

(2) Piping for wet disc brakes (a) Remove the suction hose located between the gear pump and main tank at the main tank side.

Parking brake valve

(b) Remove the delivery hose located between the gear pump and parking brake valve at the parking brake valve side.

Gear pump

Auto-deceleration valve

(c) Remove the delivery hose located between the parking brake valve and auto-deceleration valve. (optional)

Main tank 215968

Procedure for reinstallation Follow the sequence of reinstallation in the reverse order of removal.

Carefully check the angle of each connector as shown in the figure on the right when reinstalling the delivery hose to the hydraulic gear pump and control valve.

B A °)

(10

30°

A

45 ± 5

°

B

215755

5-5

POWER TRAIN

1.1.4 Engine and transmission assembly

*

*

3

*

2

1

* :Lifting hook 215969

1 Transmission mounting bolt 2 Engine mounting bolt Preparation Before lifting the engine and transmission assembly 3, hook the lifting wire at the three lifting hooks and tension the wire rope in advance using a crane.

Weight

Approx. 250 kg (Approx. 551.15 lb)

Procedure for removal (1) Before removing the mounting bolts 1 and 2, tension the wire rope for lifting the engine and transmission assembly just enough to remove the load from the mounting cushions.

(2) After confirming its center of gravity, slowly lift the engine and transmission assembly in an upward and backward direction to remove it.

Note: Drain the transmission oil while the engine and transmission assembly is being lifted up.

5-6

3 Engine and transmission assembly

POWER TRAIN (3) Reinstallation Follow the sequence of reinstallation in the reverse order of removal.

Procedure for reinstallation (1) Engine and transmission assembly (a) Slowly lift the engine and transmission assembly. (b) Align the right and left transmission mounting bolts to the screw holes of the differential carrier cover, then temporarily tighten these bolts.

Bolt

Transmission mount

Carrier cover 215970

(c) Align the right and left engine mounting bracket mounting bolts to the screw holes of the frameside mounting bracket screw holes, then temporarily tighten these bolts.

Bolt

Engine mount Frame-side engine mounting bracket 215971

(d) Finally tighten these bolts to the specified tightening torque.

Tightening torque

59.8 ± 6 N·m (6.1 ± 0.6 kgf·m) [44.1 ± 4.4 lbf·ft]

(2) After the cable between the inching pedal and transmission is joined at both ends, check that the extra length of the inching rod fully projects.

Inching rod protrusion

215972

5-7

POWER TRAIN (3) Connect the brake pipe.

(4) When reattaching the exhaust pipe, replace the old gasket with a new one.

(5) First make sure that the battery cables are properly connected and there are no connection mistakes, then tighten the (–) battery terminal.

(6) Add engine oil, engine cooling water and transmission oil, then check for any water leaks or oil leaks. For the cooling water, unless otherwise specified, use soft tap water mixed with 35% antifreeze solution. Replace the cooling water in the reservoir tank during an engine overhaul.

(7) Relieve air from the engine fuel circuit.

(8) When the inspection of each component is complete, check the amount of hydraulic oil available after operating the mast, tilt and steering wheel, etc. Also, check the engine oil, cooling water, and transmission oil.

(9) Relieve air from the wet disc brakes.

Note: For the procedure, refer to section "1.1.5 Wet disc brake air relief procedure."

5-8

POWER TRAIN

1.1.5 Wet disc brake air relief procedure (1) Supply 4.5 L (274.6 cu.in) of brake oil to the main tank.

Main tank High (3.9 L) [237.99 cu.in]

Manufacturer's recommendation oil

Oil for use

(2) Start the engine. (Keep the engine idling.)

(3) Make sure that the oil level is lowered in the tank.

Then, add oil to keep the oil level in between the High and Low marks of the level gauge.

Low (3.5 L) [213.58 cu.in] 215774

(4)

2 ton

(a) Service brake: Connect a hose to the service bleeder. And keep pressing brake pedal until the internal air is completely removed.

Parking

Service

Parking Cooler

Cooler

(b) Parking brake: Connect a hose to the parking bleeder. And keep releasing parking brake switch until the internal air is completely removed. (c) Cooler: Connect a hose to the cooler bleeder. And keep it attached until the internal air is completely removed.

Service

Front of truck Right side

Left side 215776

3 ton Parking Service

Parking Service Cooler

Cooler

Front of truck Right side

Left side 215775

(5) Check the amount of oil in the tank. The oil level should be between the High and Low levels of the level gauge.

Note: If the oil level goes higher than the High level of the level gauge, the oil may blow out at a high temperature. Therefore, the oil level should always be kept between the High and Low levels of the level gauge.

Gasoline-engine models

Amount of oil

2 ton class

3 ton class

10.9 L (665.16 cu.in)

12.8 L (781.10 cu.in)

5-9

POWER TRAIN

1.2 Removal of Engine and Transmission Assembly (Diesel-engine models) The engine and transmission are installed as an assembled unit. The engine may be removed independently of the transmission, but the transmission can only be removed together with the engine.

1.2.1 Overhead guard, covers, air cleaner, etc.

5 6

3

1

4

9

10

11

7

2 8 12

215973

Sequence 1 2 3 4 5

Overhead guard Battery Steering wheel Gas spring Engine cover, Seat

5-10

6 7 8 9 10

Radiator cover Floor mat Floor plate Tank cover Air hose, Air cleaner

11 Exhaust pipe 12 Fuel hoses 13 Under cover

POWER TRAIN Procedure for removal (1) Be sure to disconnect the ground (negative) cable first when removing a battery.

(2) Remove the tank cover 9, floor mat 7, and floor plate 8.

Tank cover

Floor mat Floor plate

215777

(3) Disconnect the exhaust pipe 11 on the engine side.

(4) Before removing the fuel hose 12, be sure to close the petcock on the fuel tank.

(5) When disconnecting individual harnesses from the sockets and terminals, which are interconnected to the engine and transmission, temporarily attach the harnesses along the main harness to prevent damage to them.

5-11

POWER TRAIN

1.2.2 Control-related (Diesel-engine models) Procedures where the places of removal/installation differ from gasoline-engine models are described below. However, for the items which are not described here, perform the operation in the same way as for a gasoline-engine model.

Sequence (different from gasoline models) Non-electronically controlled model 1 Throttle cable

1

213539

Electronically-controlled model 1 Throttle cable 2 Accelerator control assembly 3 Accelerator assembly 1 2 3

5-12

216032

POWER TRAIN

1.2.3 Control-related (Diesel-engine trucks) 4 5

7

3 10

6

8

5

2 1

14

16 13 9

11

15 12 215974

Sequence 1 2 3 4 5 6 7

Reservoir tank Hose (upper) Hose (lower) Hose (between hydraulic tank and control valve) Hose (between hydraulic tank and oil pump) Hose (between oil pump and steering control valve) Cooler hose (between radiator and torque converter transmission) 8 Cooling fan 9 Fan belt 10 Fan guard

11 Universal joint (between transmission and reduction differential) 12 Hose (between auto-deceleration valve and parking brake valve) 13 Return hose 14 Suction hose 15 Hose (between parking brake valve and gear pump) 16 Pipe (between parking brake valve and gear pump)

5-13

POWER TRAIN Preparation (1) Loosen the petcook at the lower part of the radiator to drain the cooling water.

(2) Discharge the cooling water by removing the engine case drain plug. (Note that the position of the drain plug varies depending on the engine type.)

(3) Drain the oil from the main tank for the wet disc brakes.

Procedure for removal (1) Remove the cooler hose 7 on the transmission side and place it along the right side of the frame.

(2) Piping for wet disc brakes

Parking brake valve

(a) Remove the suction hose located between the gear pump and main tank on the main tank side.

Auto-deceleration valve

(b) Remove the delivery hose located between the gear pump and parking brake valve at the parking brake valve side.

Main tank

(c) Remove the delivery hose located between the parking brake valve and auto-deceleration valve. (optional)

Gear pump 215975

Procedure for reinstallation Follow the sequence of reinstallation in the reverse order of removal.

Carefully check the angle of each connector as shown in the figure on the right when reinstalling the delivery hose to the hydraulic gear pump and control valve.

B

A A 30 ± 5°

B

5-14

215757

POWER TRAIN

1.2.4 Engine and transmission assembly

3

2

1

213542

Sequence 1 Transmission mounting bolt 2 Engine mounting bolt

3 Engine and transmission assembly

Preparation Before lifting the engine and transmission assembly 3, hook the lifting wire at the three lifting hooks and tension the wire rope in advance using a hoist.

Weight

Approx. 350 kg (Approx. 771.60 lb)

Procedure for removal (1) Before removing the mounting bolts 1 and 2, tension the wire rope for lifting the engine and transmission assembly just enough to remove the load from the mounting cushions. Remove the support mounting bolts before removing the engine side bolts.

(2) After confirming its center of gravity, slowly lift the engine and transmission assembly in a upward and backward direction to remove it.

Note: Drain the transmission oil while the engine and transmission assembly is being lifted.

5-15

POWER TRAIN Reinstallation Follow the sequence of reinstallation in the reverse order of removal.

Procedure for reinstallation (1) Engine and transmission assembly (a) Slowly lift the engine and transmission assembly. (b) Align the right and left transmission mounting bolts to the screw holes of the differential carrier cover, then temporarily tighten these bolts.

Bolt

Transmission mount

Carrier cover 215970

(c) Align the right and left of the engine mount bracket mounting bolts to the screw holes of the frame-side mounting bracket screw holes, then temporarily tighten these bolts. (d) Finally tighten these bolts to the given tightening torque.

Tightening torque

59.8 ± 6 N·m (6.1 ± 0.6 kgf·m) [44.1 ± 4.4 lbf·ft]

Bolt Engine mount Frame-side engine mounting bracket

215976

(2) After the cable between the inching pedal and transmission is joined at both ends, check that the extra length of the inching rod fully projects.

Inching rod protrusion

215972

5-16

POWER TRAIN (3) On a non-electronically controlled diesel model, make sure that the throttle lever is in the full-open position when the accelerator pedal is fully pressed after the accelerator pedal link of the floor plate and throttle cable is joined.

(4) Connect the brake pipe.

(5) When reattaching the exhaust pipe, replace the old gasket with a new one.

(6) First make sure that the battery cables are properly connected and there are no connection mistakes, then tighten the (–) battery terminal.

(7) Add engine oil, engine cooling water for any water leaks or oil leaks. For the cooling water, unless otherwise specified, use soft tap water mixed with 35% antifreeze solution. Replace the cooling water in the reservoir tank during an engine overhaul.

(8) Relieve air from the engine fuel circuit.

(9) When the inspection of each component is complete, check the amount of hydraulic oil available after operating the mast, tilt and steering wheel, etc. Check also the engine oil, cooling water, and transmission oil.

(10)Relieve air from the wet disc brakes.

Note: For the procedure, refer to section "1.2.5 Wet disc brake air relief procedure."

5-17

POWER TRAIN

1.2.5 Wet disc brake air relief procedure (1) Supply 4.5 L (274.6 cu.in) of brake oil to the main tank.

Main tank High (3.9 L) [237.99 cu.in]

Manufacturer's recommended oil

Oil for use

(2) Start the engine. (Keep the engine idling.)

(3) Make sure that the oil level is lowered in the tank.

Then, add oil to keep the oil level in between the High and Low marks of the level gauge.

Low (3.5 L) [213.58 cu.in] 215774

(4)

2 ton

(a) Service brake: Connect a hose to the service bleeder. And keep pressing brake pedal until the internal air is completely removed.

Parking

Service

Parking Cooler

Cooler

(b) Parking brake: Connect a hose to the parking bleeder. And keep releasing parking brake switch until the internal air is completely removed. (c) Cooler: Connect a hose to the cooler bleeder. And keep it attached until the internal air is completely removed.

Service

Front of truck Right side

Left side 215776

3 ton Parking Service

Parking Service Cooler

Cooler

Front of truck Right side

Left side 215775

(5) Check the amount of oil in the tank. The oil level should be between the High and Low levels of the level gauge.

Note: If the oil level goes higher than the High level of the level gauge, the oil may blow out at a high temperature. Therefore, the oil level should always be kept between the High and Low levels of the level gauge.

Diesel-engine models

Amount of oil

5-18

2-ton class

3-ton class

10.4 L (634.65 cu.in)

12.3 L (750.59 cu.in)

Chapter 8 TORQUE CONVERTER DRIVE TRANSMISSION 1.

Brake Pedal (Inching Pedal) Adjustment .............................................. 8-1

8

TORQUE CONVERTER DRIVE TRANSMISSION Chapter 8 TORQUE CONVERTER DRIVE TRANSMISSION

1. Brake Pedal (Inching Pedal) Adjustment The clutch (inching) mechanism is linked to the brake pedal. Pressing the brake pedal cuts the pressure acting on the transmission before the brakes take effect, bringing the transmission to a neutral condition. If the inching mechanism is poorly adjusted, it may create such problems as failure in clutch disengagement and partial clutch engagement. This in turn may cause an abnormal increase in the transmission temperature, as well as braking malfunctions and clutch plate seizures.

(1) Adjusting the brake pedal (a) Adjust the brake pedal height A (from the floor plate top surface to the brake pedal top surface) to the following standard value by turning the stopper bolt 1 and then lock it with the lock nut.

Brake pedal height A

1

3

189.5 − 193.4 mm (7.460 − 7.614 in)

(b) Turn the push rod clockwise to reduce the clearance between the push rod and piston of the brake valve 2 to 1.0 mm (0.079 to 0.039 in.), and when it touches the piston, turn it counterclockwise about 0.8 of one turn, then lock the clevis with the lock nut. After completing this adjustment, check the brake pedal for the amount of play.

Amount of brake pedal play

A

2

(a) Adjust the height A of the inching pedal (from the floor plate top surface to the inching pedal top surface) to the following standard value by turning the stopper bolt 3 and then lock it with the lock nut.

189.5 − 193.4 mm (7.460 − 7.614 in)

(b) In part B, adjust the clearance between the bolt top surface and brake link to the following value and lock it firmly with the nut.

Clearance between bolt top and brake link

216050

Approx. 5 mm (Approx. 0.19 in)

(2) Adjusting the inching pedal

Inching pedal height A

2

11.6 − 12.1 mm (0.45 − 0.47 in)

216051

Bolt, Pedal stopper Jam,Nut

11.6 - 12.1 mm [0.45 - 0.47 in]

216052

8-1

TORQUE CONVERTER DRIVE TRANSMISSION (3) Adjusting the stop lamp switch Adjust the stop lamp switch position so that the stop lamp glows when the brake pedal is pressed and then secure the switch into the correct position.

Stop lamp clearance after installation

0.5 − 1.0 mm (0.019 − 0.039 in)

0.5 - 1.0 mm [0.019 - 0.039 in] 216053

8-2

Chapter 9 FRONT AXLE AND REDUCTION DIFFERENTIAL 1.

Structure .................................................................................................. 9-1 1.1 1.2

2.

Front Axle Assembly................................................................................................ 9-1 Wet Disc Brake Assembly (2-ton class) .................................................................. 9-2

Removal and Installation Procedure ..................................................... 9-3 2.1 2.2

Front Wheel ............................................................................................................. 9-3 Front Axle and Reduction Differential...................................................................... 9-3

3.

Disassembly and Reassembly Procedure ............................................ 9-8

4.

Reassembly ........................................................................................... 9-13

5.

Procedure for Flushing and Air Bleeding after Assembly ................ 9-21 5.1 5.2

Procedure for Flushing .......................................................................................... 9-21 Procedure for Bleeding Air from the Wet Disc Brake ............................................ 9-21

6.

Wear Gauge for Wet Disc Brakes ........................................................ 9-23

7.

Forcible Release of Parking Brake ...................................................... 9-23

8.

Reduction Differential........................................................................... 9-23

9.

Troubleshooting.................................................................................... 9-23

10. Service Data........................................................................................... 9-24

9

FRONT AXLE AND REDUCTION DIFFERENTIAL Chapter 9 FRONT AXLE AND REDUCTION DIFFERENTIAL

1. Structure 1.1 Front Axle Assembly 3

4

2

5 6 7

8

9

10

11

12 1 13 14 216064

1 2 3 4 5

Front axle housing Front axle shaft Wet disc brake assembly Floating seal Floating seal retainer

6 7 8 9 10

Wheel nut Front wheel hub Tapered roller bearing Lock ring Lock nut

11 12 13 14

Oil seal Tapered roller bearing Oil seal retainer Oil seal

The wet disc brake is part of an integral structure, with the frame support and wet disc brake assembly forming one unit. The whole structure is fastened and locked to the front axle housing. The front wheel hub is linked to the wet disc brake assembly by means of a floating seal.

9-1

FRONT AXLE AND REDUCTION DIFFERENTIAL

1.2 Wet Disc Brake Assembly (2-ton class) 2 1

A-A

A

3 4 B

5

B

6

A 8

7

11

B-B

9

1 2 3 4

Brake cover Air bleeding screw Parking brake piston Service brake piston

5 6 7 8

Piston housing Rod gauge Brake housing Mating plate, Friction plate, Wave spring

This wet multiple-disc brake is a combination of service brake and negative-type parking brake.

The mating plate having outer teeth is supported by the brake housing by means of engagement with the inner teeth of the brake housing, while the friction plate having inner teeth is engaged with the outer teeth of the brake hub, which rotates together with the wheel hub.

9-2

10

216024

9 Outer spring 10 Inner spring 11 Pressure plate

This service brake is structured, so when the brake pedal is pressed, the service brake piston is applied with hydraulic pressure so the piston presses on the pressure plate which causes the mating plate to come into contact with friction plate, which results in braking.

In the case of the parking brake, pressing the parking brake switch in the operator's seat applies hydraulic pressure to the parking brake piston, therefore releasing the parking brake.

FRONT AXLE AND REDUCTION DIFFERENTIAL

2. Removal and Installation Procedure 2.1 Front Wheel Refer to the service manual for standard models.

2.2 Front Axle and Reduction Differential 2.2.1 Removal

9

11

4

13 10 9 5 12 6 2

14 8

7

3

1

214804

Sequence 1 2 3 4 5 6 7

Front wheel Nuts Forks, lift bracket Return hose for lift cylinder High-pressure hose for lift cylinder Tilt cylinder socket Mast support bearing cap

8 9 10 11 12 13 14

Mast Brake pipe Return hose for oil filter Universal joint Bolt, nut Bolt, nut Front axle and reduction differential

9-3

FRONT AXLE AND REDUCTION DIFFERENTIAL Removing brake pipes Remove the brake pipes in the sequence shown in the following figure. (a) Standard model 5

STANDARD

4

1 6

2 3

Front 215740

1 Service pipe R.H 2 Parking pipe R.H 3 Cooler pipe R.H

9-4

4 Service pipe L.H 5 Parking pipe L.H 6 Cooler pipe L.H

FRONT AXLE AND REDUCTION DIFFERENTIAL (b) Option model 2

OPTION 8

1 3

7

4

5

9

6

Front 215741

1 2 3 4 5

Brake pipe Brake pipe Shuttle valve Service pipe R.H Parking pipe R.H

6 7 8 9

Cooler pipe R.H Service pipe L.H Parking pipe L.H Cooler pipe L.H

9-5

FRONT AXLE AND REDUCTION DIFFERENTIAL Procedure for removal (1) For details on removing the front wheel and mast, refer to the service manual for standard models.

(2) Before removing the front axle and reduction differential, remove the front axle drain plug and drain the transfer and differential oil.

(3) Before removing the wet disc brake main unit remove the return hose at the main unit side to drain the brake oil.

2 ton

Return hose placing area 216036

3 ton

Return hose placing area 216037

(4) Disconnect the brake pipe on the wet disc brake assembly side. Follow the sequence shown in the figure STANDARD or OPTION of "2.2.1.

Removal" for proper disconnection of this pipe.

(5) After disconnecting the brake pipe, seal the connector section using tape, etc. to prevent dust, etc. from entering.

(6) Disconnect the return hose that is connected to the oil filter on the front axle side.

9-6

FRONT AXLE AND REDUCTION DIFFERENTIAL Procedure for reinstallation (1) Connect the brake pipe to the wet disc brake assembly at the specified torque.

Tightening torque Service brake, Parking brake

13 − 18 N·m (1.3 − 1.8 kgf·m) [9.59 − 13.28 lbf·ft]

Cooler

16 − 23 N·m (1.6 − 2.3 kgf·m) [11.80 − 16.97 lbf·ft]

(2) After connecting the return hose to the connector on the front axle side, tighten the hose clamp to the specified torque.

Tightening torque

5.0 − 6.8 N·m (0.5 − 0.7 kgf·m) [3.69 − 5.01 lbf·ft]

9-7

FRONT AXLE AND REDUCTION DIFFERENTIAL

3. Disassembly and Reassembly Procedure Disassembly (2 ton class) 11 10

6 7 16

9 15 10 5

9

4 3 22 9

11 12 1

21 2 20 19 12

14 13 18

17 8 22

20 214802

Sequence 1 2 3 4 5 6 7 8 9

Elbow, O-ring, connector, return pipe, return hose Flange bolt, front axle shaft Bolt, lock ring Lock nut Tapered roller bearing (inner race) Oil seal retainer, O-ring Tapered roller bearing (inner race) Flange bolt, washer, seal washer Front wheel hub, tapered roller bearing (outer race), oil seal, O-ring 10 Hexagon socket bolt, floating seal retainer, floating seal 11 Floating seal, O-ring

9-8

12 13 14 15 16 17 18 19 20 21 22

Air bleeder screw, plug Gauge plug, rod gauge, O-ring Taper plug Hexagon socket bolt, brake cover O-ring Mating plate, friction plate, wave spring, pressure plate Flange bolt Parking brake piston, O-ring Brake housing, O-ring Eye bolt, pipe, O-ring Piston, brake spring (outer, inner)

FRONT AXLE AND REDUCTION DIFFERENTIAL Disassembly (3 ton class) 6

10

7

9 11 10 12

5 4

9

3

21

14

9 20 2

22

19

13 18 17 8 22

16 15 20

1 8 11

214803

Sequence 1 2 3 4 5 6 7 8 9

Elbow, O-ring, connector, return pipe, return hose Flange bolt, front axle shaft Bolt, lock ring Lock nut Tapered roller bearing (inner race) Oil seal retainer, O-ring Tapered roller bearing (inner race) Flange bolt, washer, seal washer, front axle support Front wheel hub, tapered roller bearing (outer race), oil seal, O-ring 10 Hexagon socket bolt, floating seal retainer, floating seal 11 Floating seal, O-ring

12 13 14 15 16 17 18 19 20 21 22

Air bleeder screw, plug Gauge plug, rod gauge, O-ring Taper plug Hexagon socket bolt, brake cover O-ring Mating plate, friction plate, wave spring, pressure plate Flange bolt Parking brake piston, O-ring Brake housing, O-ring Eye bolt, pipe, O-ring Piston, brake spring (outer, inner)

9-9

FRONT AXLE AND REDUCTION DIFFERENTIAL Procedure for disassembly (common to both 2- and 3ton classes) (1) Removing the lock nut Remove these lock nuts using the lock nut wrench (special tool).

Special tool

Special tool Lock nut wrench

03703-59001

214805

(2) Removing the front wheel hub Remove the front wheel hub using the wheel hub puller (special tool).

Special tool Wheel hub puller

Special tool

MH061017

Note: The oil seal press-fitted into the hub does not need to be removed unless a fault is found during inspection.

214806

(3) Remove two tapered plugs located at opposing diagonal positions on the piston housing. Replace them with two special bolts and screw them into the piston housing evenly.

Special tool Bolt Plain washer

Part No.

Qty

2 ton models

F1035-10050

2

3 ton models

F1035-08055

2

92071-01300

2

Tapered plug

Tapered plug

(4) Record the order in which the pressure plate, mating plate, friction plate and wave spring were removed from the brake housing.

215965

Brake piston side Pressure plate Mating plate

2 ton models

3 ton models

9-10

Pressure plate

1 piece

Mating plate

4 pieces

Friction plate

4 pieces

Wave spring

4 pieces

Pressure plate

1 piece

Mating plate

6 pieces

Friction plate

6 pieces

Wave spring

6 pieces

Friction plate Brake cover side

215616

FRONT AXLE AND REDUCTION DIFFERENTIAL (5) Disassembly of brake housing and piston housing Parking brake piston

If the two bolts attached in step (3) are carelessly loosened, they may suddenly fly out due to the brake spring force between the brake housing and piston housing.

Install two special tool bolts into the forcible cancellation bolt holes.

Loosen the bolts evenly until the spring force disappears, then disassemble the brake housing and piston housing.

Special tool Bolt Plain washer

Part No.

Qty

2 ton models

F1035-10065

2

3 ton models

F1035-08070

2

92071-01300

2

Plain washer

Bolt 216033

9-11

FRONT AXLE AND REDUCTION DIFFERENTIAL Inspection after disassembly Use the same procedure as for standard models except the following inspection items: (1) Wet disc brake assembly (a) Piston Check the sliding areas for any wear or damage. If there is any surface flaw, grind the surface, then wash the surface. (b) Brake housing and hub Check the teeth surfaces for any wear or damage. (c) Piston housing Check the sliding areas of the piston for any wear or damage. (d) Friction plate and mating plate 1) Check for any burns, traces of uneven contact, deformations or damages.

2) Check the mating plate for any heat spots.

3) Check the inner teeth and outer teeth surfaces for any wear or damage.

4) Measure the thickness of each plate.

Note: A complete replacement is required if any of the above checks reveal a problem. Upon replacement, perform flushing.

Unit: mm (in.)

Friction plate

Mating plate

A

3.80 ± 0.1 (0.149 ± 0.004 in)

B

3.43 (0.135 in)

A

2.00 ± 0.07 (0.078 ± 0.002 in)

B

1.9 (0.074 in)

A: Standard value B: Service limit

215622

(e) Brake spring Measure the free length of brake spring.

Unit: mm (in.)

Free length of brake spring (inner)

A

52 (2.04 in)

B

50 (1.96 in)

Free length of brake spring (outer)

A

51 (2.00 in)

B

49 (1.92 in)

A: Standard value B: Service limit

214807

(f) Floating seal Check the floating seal lip surface for any damage, and replace the lip if damaged. (g) Wave spring The wave spring should be replaced at the same time the seals are replaced.

9-12

FRONT AXLE AND REDUCTION DIFFERENTIAL

4. Reassembly Reassembling procedure The following operations (1) and (2) apply to only the 2 ton class.

(1) Connect the service brake pipe to the piston housing.

Eye Bolt 13.7N·m （1.4kgf·m） [10.1lbf·ft]

Service Breake Pipe

(2) Tighten the eye bolt to the specified torque.

13.7 N·m (1.4 kgf·m) [10.1 lbf·ft]

Tightening torque

Piston Housing

O-ring 215880

(3) Fit the D-ring into the piston.

Note: Apply oil (SAE10W-30 engine oil CD class) to the piston seal area and sliding surfaces.

Service Brake Piston Brake Spring

(4) Install the piston in the piston housing.

(5) Install the brake spring (inner, outer) in the piston housing.

Brake Spring

D-ring 215881

(6) Fit the O-ring in the parking brake piston.

(7) Fit the O-ring in the brake housing.

Note: Apply oil (SAE10W-30 engine oil, CD class) to the piston seal area and sliding surfaces.

Brake Housing Parking Brake Piston

O-ring

(8) Insert the parking brake piston into the brake housing.

(9) Use the special tool to install the piston housing to the parking brake piston.

Note: Place two special tool bolts in diagonal positions and screw them in evenly until the piston housing touches the end surface of the parking brake piston.

Special tool Bolt Plain washer

Part No.

Qty

2 ton models

F1035-10065

2

3 ton models

F1035-10070

2

92071-01300

2

Plain Washer (9207-01300) Bolt (2ton models:F1035-10065) (3ton models:F1035-10070)

O-ring 215882

9-13

FRONT AXLE AND REDUCTION DIFFERENTIAL (10)Install the following special tool to the piston housing.

Note: Place two special tool bolts in diagonal positions and fully screw them in evenly.

Special tool Bolt

Part No.

Qty

2 ton models

F1035-10050

2

3 ton models

F1035-08055

2

92071-01300

2

Plain washer

2.Remove

1.Fully Install

Plain Washer

Bolt 215883

(11)Remove the special tool installed in step (9).

(12)Install the flange bolt to the piston housing at the specified torque.

Special tool

Part No.

Qty Tightening torque 9

44.1 ± 8.8 N·m (4.47 ± 0.9 kgf·m) [32.55 ± 6.49 lbf·ft]

91A24-07600

3

44.1 ± 8.8 N·m (4.47 ± 0.9 kgf·m) [32.55 ± 6.49 lbf·ft]

3 ton 91524-02700 models

12

44.1 ± 8.8 N·m (4.47 ± 0.9 kgf·m) [32.55 ± 6.49 lbf·ft]

91524-02600 Flange bolt

2 ton models

Flange Bolt 44.1±8.8Ｎ･m （4.47±0.9kgf･m） [32.55±6.49lbf･ft]

Flange Bolt 44.1±8.8Ｎ･m （4.47±0.9kgf･m） [32.55±6.49lbf･ft] 215884

(13)Fit the O-ring in the brake housing.

(14)Using a special tool, assemble the mating plate, friction plate and wave spring to the brake housing in the same order they were removed.

2 ton models

3 ton models

Pressure plate

1 piece

Mating plate

4 pieces

Friction plate

4 pieces

Wave spring

4 pieces

Pressure plate

1 piece

Mating plate

6 pieces

Friction plate

6 pieces

Wave spring

6 pieces

Special tool Holder, friction plate

O-ring

Wave Spring Friction Plate

Special tool

Mating Plate

Pressure Plate 218885

Part No. 91E68-01200

Note: Align each chipped part of the friction plate in the same directions.

216027

9-14

FRONT AXLE AND REDUCTION DIFFERENTIAL (15)Install the brake cover to the brake housing.

Tightening torque Hexagon socket bolt

38.1 ± 7.6 N·m (3.89 ± 0.76 kgf·m) [28.12 ± 5.61 lbf·ft]

Brake Cover

Hexagon Soket Bolt 38.1±7.6N･m （3.89±0.76kgf･m） [28.12±5.61lbf･ft]

218886

(16)Install the taper plug to the piston housing.

Tightening torque Taper plug

29.4 ± 2.9 N·m (3.0 ± 0.3 kgf·m) [21.7 ± 2.1 lbf·ft]

Taper Plug 29.4±2.9N･m (3.0±0.3kgf･m) [21.7±2.1lbf･ft]

215887

9-15

FRONT AXLE AND REDUCTION DIFFERENTIAL (17)2-ton model Install the rod gauge, air bleeder screw and plug to the wet disc brake assembly at the specified torque.

Plug 13to18N･m （1.33to1.84kgf･m） [9.59to13.28lbf･ft]

Tightening torque Rod gauge plug

39.2 ± 3.9 N·m (4.0 ± 0.4 kgf·m) [28.9 ± 2.9 lbf·ft]

Air bleeder screw

6.86 − 11.78 N·m (0.7 − 1.2 kgf·m) [5.06 − 8.69 lbf·ft] 13 − 18 N·m (1.33 − 1.84 kgf·m) [9.59 − 13.28 lbf·ft]

Plug 1

13 − 18 N·m (1.33 − 1.84 kgf·m) [9.59 − 13.28 lbf·ft]

Plug 2

Cap

Rod Gauge

O-ring Rod Gauge 39.2±3.9N･m （4.0±0.4kgf･m） [28.9±2.9lbf･ft]

Screw 13to18N･m （1.33to1.84kgf･m） [9.59to13.28lbf･ft]

O-ring

Plug 13to18N･m （1.33to1.84kgf･m） [9.59to13.28lbf･ft] 215888

3-ton models Install the rod gauge, air bleeder screw, taper plug and brake pipe to the wet disc brake assembly at the specified torque.

Tightening torque Rod gauge plug

39.2 ± 3.9 N·m (4.0 ± 0.4 kgf·m) [28.9 ± 2.9 lbf·ft]

Air bleeder screw

6.86 − 11.78 N·m (0.7 − 1.2 kgf·m) [5.06 − 8.69 lbf·ft]

Taper plug

12.8 ± 1.3 N·m (1.3 ± 0.1 kgf·m) [9.5 ± 1.0 lbf·ft]

Eye bolt

13.7 N·m (1.4 kgf·m) [10.1 lbf·ft]

Taper Plug 12.8±1.3N･m （1.3±0.1kgf･m） [9.5±1.0lbf･ft]

Rod Gauge

O-ring

Service Brake Pipe

Cap

Screw Plug Gauge O-ring 13to18N･m Eye Bolt 39.2±3.9N･m 13.7N･m （1.33to1.84kgf･m） （4.0±0.4kgf･m） （1.4kgf･m）[9.59to13.28lbf･ft] [28.9±2.9lbf･ft] [10.1lbf･ft] 215889

(18)Fit the O-ring in the wet disc brake assembly.

(19)Use the special tool to install the floating seal to the wet disc brake assembly.

Special tool

Special tool

Floating Seal

Part No.

Inserter, floating seal

91E68-01300

Guide, inserter

91E68-01400

O-ring

Wet Brake Assembly 215890

9-16

FRONT AXLE AND REDUCTION DIFFERENTIAL (20)Use the special tool to install the floating seal to the floating seal retainer.

Special tool

Part No.

Inserter, floating seal

91E68-01300

Guide, inserter

91E68-01400

Ring, guide

91E68-01500

Special tool

Floating Seal

Floating Seal Retainer 215891

(21)Fit the O-ring into the hub & bolt assembly.

(22)Use the special tool installer to tap the oil seal and tapered roller bearing (outer race) into the hub & bolt assembly.

Special tool (installer) Part to be installed

Special tool part number

Oil seal (91E33-01800)

91E68-00700

Oil seal (91E33-17500)

-

Tapered roller bearing (F8140-30213)

91E68-00900

Tapered roller bearing (F8143-32215)

91E68-00800

(23)Install the floating seal retainer to the hub & bolt assembly.

Tightening torque Hexagon socket bolt

Oil Seal

38.1 ± 7.6 N·m (3.89 ± 0.76 kgf·m) [28.12 ± 5.61 lbf·ft]

Hexagon Soket Bolt 38.1±7.6N･m （3.89±0.76kgf･m） [28.12±5.61lbf･ft]

O-ring

(24)Fill the inside of the hub & bolt assembly with grease. (shaded area in the right figure)

Teperd Roller Bearing

Tightening torque Grease brand

Oil Seal Autolex A

Hab & Bolt Assembly

Teperd Roller Bearing

215892

9-17

FRONT AXLE AND REDUCTION DIFFERENTIAL (25)Install the front axle support (only for 3 ton models), and wet disc brake assembly to the front axle housing.

Washer

Note: Apply sealant on the flange bolt surface.

Brand of seal agent

Loctite #271

Tightening torque Flange bolt

Flange Bolt 212.7±21.3N･m (21.7±2.2kgf･m) [157.0±15.7lbf･ft]

212.7 ± 21.3 N·m (21.7 ± 2.2 kgf·m) [157.0 ± 15.7 lbf·ft]

Seal Washer

215893

(26)Fit the O-ring in the oil seal retainer.

(27)Install the oil seal retainer and tapered roller bearing (inner race) in this order in the front axle housing.

Oil Seal Retainer O-ring

Taperd Roller Bearing

215894

9-18

FRONT AXLE AND REDUCTION DIFFERENTIAL (28)Insert the hub & bolt assembly into the wet disc brake assembly.

215895

(29)Tap the tapered roller bearing (inner race) into the hub & bolt assembly.

(30)Install the nut and hand-tighten it with a socket wrench (special tool) in the hub & bolt assembly.

Socket Wrench

03703-59001

Tangential force of

Wheel Bolt Nut

(31)Rotate the hub & bolt assembly and tap its periphery with a soft-head mallet for snug assembling.

(32)Adjust the degree of tightening using the nut so that the tapered roller bearing preload is within the standard value.

Note: To check the preload, hook a spring scale on the wheel bolt, then pull it to measure the tangential force of the wheel bolt.

Taperd Roller Bearing Tangential force of wheel bolt

4.5 − 44.5 N (0.45 − 4.53 kgf) [1.01 − 10.00 lbf]

Release Parking Brake 215896

Add the tangential force before tightening.

Example: When the tangential force before tightening is 5 N 5 + 4.5 to 44.5 = 9.5 to 49.5 N (0.50 + 0.45 to 4.53 = 0.95 to 4.53 kgf) [1.12 + 1.01 to 10.00 = 2.13 to 10.00 lbf]

9-19

FRONT AXLE AND REDUCTION DIFFERENTIAL (33)When the tangential force reaches the specified value, insert the lock ring in the front axle housing.

(34)Use a loosening-preventive bolt applied with sealant to secure the lock ring.

Lock Ring

Bolt Front Axle Housing

Specified sealant

Loctite #271

(35)Measure the tangential force again to confirm that it is within the specified range.

Flange Bolt 98.1±9.8N･m (10.0±1.0kgf･m) [72.4±7.2lbf･ft]

Taper Plug

Apply liquid Packing

215897

(36)Apply liquid packing on the contact surfaces of hub & bolt assembly and front axle shaft.

Liquid packing

ThreeBond #1194 or the equivalent

(37)Install the front axle shaft to the hub & bolt assembly.

Tightening torque Flange bolt

98.1 ± 9.8 N·m (10.0 ± 1.0 kgf·m) [72.4 ± 7.2 lbf·ft]

216023

(38)Install the return hose to the front axle housing at the specified torque.

At this time, the angle of the return hose must be as shown in the figure on the right.

70

°

J Tightening Torque 58.8±5.9N･m （6±0.6kgf･m） [43.4±4.4lbf･ft]

J

G Tightening Torque 58.8±5.9N･m （6±0.6kgf･m） [43.4±4.4lbf･ft]

H 30°

45°

G

H

215735

9-20

FRONT AXLE AND REDUCTION DIFFERENTIAL

5. Procedure for Flushing and Air Bleeding after Assembly When the wet disc brake assembly has been disassembled, perform flushing to remove any foreign matter remaining in the hydraulic circuit. Also, carry out air bleeding after flushing.

5.1 Procedure for Flushing (1) Operation method Flushing can be conducted either by releasing the parking brake switch with the front wheels lifted off the ground, or by traveling the lift truck. (a) Lift the front wheels off the ground, and then place the jack stands under the frames and block the rear wheels with wood blocks. (b) With the front wheels lifted off the ground, release the parking brake, and press the accelerator pedal. (c) Flushing oil: 10 W (d) Vehicle speed: 12 km/h (7.5 MPH) (when the brake is operated) (e) Timing to operate the brake: Repeat 10-sec ON and 5-sec OFF for 1 minute in the forward direction.

Repeat 10-sec ON and 5-sec OFF for 1 minute in the reverse direction. (f) After the operation described above, replace with the specified brake cooling oil. Carry out air bleeding.

5.2 Procedure for Bleeding Air from the Wet Disc Brake (1) Supply 4.5 L (274.6 cu.in.) of brake oil to the main tank.

Oil for use

Manufacturerrecommended oil

Main tank High (3.9 L) [237.99 cu.in]

(2) Start the engine. (Keep the engine idling.)

(3) Make sure that the oil level is lowered in the tank.

Then, add oil to keep the oil level in between the High and Low marks of the level gauge.

Low (3.5 L) [213.58 cu.in] 215774

9-21

FRONT AXLE AND REDUCTION DIFFERENTIAL (4)

2 ton

(a) Service brake: Connect a hose to the service bleeder. And keep pressing brake pedal until the internal air is completely removed.

Parking

Service

Parking Cooler

Cooler

(b) Parking brake: Connect a hose to the parking bleeder. And keep releasing parking brake switch until the internal air is completely removed. (c) Cooler: Connect a hose to the cooler bleeder. And keep it attached until the internal air is completely removed.

Service

Front of truck Right side

Left side 215776

3 ton Parking Service

Parking Service Cooler

Cooler

Front of truck Right side

Left side 215775

(5) Check the amount of oil in the tank. The oil level should be between the High and Low levels of the level gauge.

Note: If the oil level goes higher than the High level of the level gauge, the oil may blow out at a high temperature. Therefore, the oil level should always remain between the High and Low levels of the level gauge. For the required amount of oil in this brake system, refer to the following table.

Amount of oil

2 ton class

3 ton class

Gasoline engine model

10.9 L (665.16 cu.in)

12.8 L (781.10 cu.in)

Diesel engine model

10.4 L (634.65 cu.in)

12.3 L (750.59 cu.in)

9-22

FRONT AXLE AND REDUCTION DIFFERENTIAL

6. Wear Gauge for Wet Disc Brakes Standard for replacing the plate of a wet disc brake

Replace the plate when the bolt has been driven in up to the groove after pushing the bolt.

216049

7. Forcible Release of Parking Brake For the method of forcibly releasing the parking brake, refer to the chapter "Brake System."

8. Reduction Differential Refer to the service manual for standard models.

9. Troubleshooting Refer to the service manual for standard models.

9-23

FRONT AXLE AND REDUCTION DIFFERENTIAL

10.Service Data Refer to the service manual for the standard models except for the following data.

Unit: mm (in.)

Truck models

Item

2 ton class

Mating plate thickness 1 Friction plate thickness 2 Inner spring free length 3 Outer spring free length 4

3 ton class

A

2.00 ± 0.07 (0.078 ± 0.002)

B

1.9 (0.074)

A

3.8 ± 0.1 (0.149 ± 0.004)

B

3.43 (0.135)

A

52 (2.04)

B

50 (1.96)

A

51 (2.00)

B

49 (1.92)

A-A

Wet disc brake assembly

A

B

B

3

A 1,2 B-B

6

7

216030

A: Standard value B: Repair limit or Service limit

9-24

Chapter 11 BRAKE SYSTEM 1.

Structure ................................................................................................ 11-1 1.1 1.2 1.3

2.

Brake System ........................................................................................................ 11-1 Hydraulic Circuit Diagram (Standard).................................................................... 11-2 Hydraulic Circuit Diagram (Optional) ..................................................................... 11-3

Disassembly and Reassembly............................................................. 11-4 2.1 2.2 2.3 2.4 2.5 2.6

Main Tank.............................................................................................................. 11-4 Gear Pump-related ................................................................................................ 11-5 Brake Valves ....................................................................................................... 11-11 Parking Brake Valve ............................................................................................ 11-18 Shuttle Valve, Connector..................................................................................... 11-21 Oil Filter ............................................................................................................... 11-22

3.

Measurement of Hydraulic Pressure................................................. 11-23

4.

Forcible Release of Parking Brake .................................................... 11-24 4.1 4.2

5.

Release by Turning Bolt ...................................................................................... 11-24 Release by the External Hydraulic Pressure ....................................................... 11-25

Troubleshooting.................................................................................. 11-26

11

BRAKE SYSTEM Chapter 11 BRAKE SYSTEM

1. Structure 1.1 Brake System

Main tank Gear pump Auto-deceleration valve (optional)

Oil filter Pedal assembly

Parking brake valve

Connector Shuttle valve (optional) Wet disc brake assembly Brake valve 215946

The wheel brake structure has one set of multi-disc brake (negative brake) installed on each side of the front axle.

The parking brake is operated mechanically by the spring force in the wet disc brake assembly. Hydraulic pressure from the brake valve is used to release it.

The brake oil used has different specifications from conventional brake fluid and is stored in a dedicated tank.

If hydraulic pressure is not generated, the parking brake is held by the spring force of the wet disc brake assembly. The lift truck will not move.

The brake system gear pump applies pressure to the brake oil which operates the wheel brake.

To release the parking brake, one port for forcible cancellation is provided on the parking brake valve and one bolt for forcible cancellation is provided on the wet disc brake assembly.

This foot brake will operate the multi-disc brake with hydraulic pressure from the brake valve or auto-deceleration valve.

11-1

11-2

BRAKE UNIT (LH)

BRAKE UNIT (RH)

CONNECTOR

COOLER

PARKING

SERVICE

SERVICE

PARKING

COOLER

T

P

CONNECTOR

BRAKE VALVE

A

BR

PKB

6 MPa T

P

Φ0.8 mm [0.031 in]

PARKING BRAKE VALVE ASSY

PARKING BRAKE VALVE EMERGENCY PORT

IN LINE FILTER

GEAR PUMP

ENGINE

OIL TANK (MAX 3.9 L) [MAX 237.99 cu·in]

LEVEL GAUGE

BRAKE SYSTEM

1.2 Hydraulic Circuit Diagram (Standard)

215795

BRAKE UNIT (LH)

BRAKE UNIT (RH)

CONNECTOR

PROPORTIONAL SOLENOID VALVE (OPTIONAL)

T

A2

COOLER

PARKING

SERVICE

SERVICE

PARKING

COOLER

SHUTTLE VALVE (OPTIONAL)

B

P

B

A T

P

CONNECTOR

PRESSURE SWITCH (OPTIONAL)

ONLY CONTROLLED ROLLBACK

BRAKE VALVE

2.3 MPa

A1

BR

PKB

6 MPa T

LEVEL GAUGE

ENGINE

OIL TANK (MAX 3.9 L) [MAX 237.99 cu·in]

P GEAR PUMP

Φ0.8 mm [0.031 in]

PARKING BRAKE VALVE EMERGENCY PORT PARKING BRAKE VALVE ASSY

IN LINE FILTER

BRAKE SYSTEM

1.3 Hydraulic Circuit Diagram (Optional)

215796

11-3

BRAKE SYSTEM

2. Disassembly and Reassembly 2.1 Main Tank 2 3

A

4 A 5

2 1

Front of truck

6 5

3

Gauge,Oil level Valve,auto decelaration 215737

Sequence 1 2 3 4

Drain plug Connector Hose Brake pipe

5 Hose 6 Main tank mounting bolt 7 Main tank

Procedure for removal Before starting the removal, loosen the drain plug 1 to drain oil from the main tank.

Procedure for reinstallation Reinstall in the reverse order of removal.

After reinstalling the main tank, carry out air bleeding and flushing.

Note: For the procedure, refer to the section of "1.2.5 Air bleeding of wet disc brake" in "Chapter 5 Power Train."

Oil for use: Manufacturer's recommended oil Amount of oil

2 ton class

3 ton class

Gasoline engine model

10.9 L (665.16 cu.·in.)

12.8 L (781.10 cu.·in.)

Diesel engine model

10.4 L (634.65 cu.·in.)

12.3 L (750.59 cu.·in.)

11-4

BRAKE SYSTEM

2.2 Gear Pump-related 2.2.1 Removal (Gasoline-engine models)

2

Tightening torque 33.3 ± 3.3 N·m (3.4 ± 0.3 kgf·m) [24.6 ± 2.4 lbf·ft]

10

7

3 Tightening torque 49 ± 4.9 N·m (5.0 ± 0.5 kgf·m) [36.1 ± 3.6 lbf·ft]

Tightening torque 6.9 ± 0.7 N·m (0.7 ± 0.07 kgf·m) [5.1 ± 0.5 lbf·ft] 9 8 5 6

4 1

11 16

Tightening torque 33.3 ± 3.3 N·m (3.4 ± 0.3 kgf·m) [24.6 ± 2.4 lbf·ft] 15

14 17 12

Tightening torque 59.8 ± 6 N·m (6.1 ± 0.6 kgf·m) [44.1 ± 4.4 lbf·ft]

13

215727

Sequence 1 2 3 4 5 6

V-belt Suction hose Delivery pipe Wheel mounting bolt Wheel Snap ring

7 8 9 10 11 12

Driven pulley Snap ring Ball bearing Gear pump mounting bolt Gear pump Tensioner assembly mounting bolt

13 14 15 16 17

Tensioner assembly Engine mount mounting bolt Engine mount bracket mounting bolt Engine mount bracket Engine mount

Procedure for removal (1) Remove the under cover and left-side rear cover.

(2) Loosen the adjustment bolt of the tensioner assembly 13 to remove the V-belt 1.

(5) Remove the snap ring 6, then remove the driven pulley 7, snap ring 8, and ball bearing 9 together.

(3) Disconnect the suction hose 2 and delivery pipe 3.

(6) Remove the snap ring 8 from the driven pulley 7, then remove the ball bearing 9.

(4) Remove the wheel mounting bolt 4 (3 places), then remove the wheel 5.

(7) Remove the gear pump mounting bolt 10 to remove the gear pump 11.

11-5

BRAKE SYSTEM

2.2.2 Removal (Diesel-engine models) Tightening torque 33.3 ± 3.3 N·m (3.4 ± 0.3 kgf·m) 10 [24.6 ± 2.4 lbf·ft] Tightening torque 49 ± 4.9 N·m 3 (5.0 ± 0.5 kgf·m) [36.1 ± 3.6 lbf·ft]

11

2 12

Tightening torque 6.9 ± 0.7 N·m (0.7 ± 0.07 kgf·m) [5.1 ± 0.5 lbf·ft]

1

Tightening torque 59.8 ± 6 N·m (6.1 ± 0.6 kgf·m) 15 [44.1 ± 4.4 lbf·ft]

4

14 6

8

9

7 Tightening torque 59.8 ± 6 N·m (6.1 ± 0.6 kgf·m) [44.1 ± 4.4 lbf·ft]

5

13

215730

Sequence 1 2 3 4 5

V-belt Suction hose Delivery pipe Wheel mounting bolt Wheel

6 7 8 9 10

Snap ring Driven pulley Snap ring Ball bearing Gear pump mounting bolt

11 12 13 14 15

Gear pump Engine mount mounting bolt Engine mount bracket mounting bolt Engine mount bracket Engine mount

Procedure for removal (1) Remove the under cover and right-side rear cover.

(5) Remove the snap ring 6, then remove the driven pulley 7, snap ring 8, and ball bearing 9 together.

(2) Loosen the adjustment bolt of the tensioner assembly to remove the V-belt 1.

(6) Remove the snap ring 8 from the driven pulley 7, then remove the ball bearing 9.

(3) Disconnect the suction hose 2 and delivery pipe 3.

(7) Remove the gear pump mounting bolt 10 to remove the gear pump 11.

(4) Remove the wheel mounting bolt 4 (3 places), then remove the wheel 5.

11-6

BRAKE SYSTEM

2.2.3 Reinstallation (Gasoline-engine models) Reinstall in the reverse order of removal, noting the following points.

Deflection amount

Tightening torque 26.5 ± 2.65 N·m (2.7 ± 0.27 kgf·m) [19.5 ± 1.95 lbf·ft]

215728

(1) Check the following points before reinstalling the V-belt: (a) Check the belt for contamination with oil, grease and dust, etc., and replace it, if necessary. If the contamination is not significant, clean with a rag or paper towel. Do not use gasoline, oil or any other solvent to clean the belt. (b) If the belt is damaged, replace it with a new one.

(2) During the inspection of bearings, confirm that each bearing rotates smoothly and generates no abnormal noises.

(3) Make sure that the V-belt is not twisted. Adjust it, to obtain the deflection shown in the table. Use the tension adjustment belt and nut on the tension assembly.

Deflection amount New part

0 14-2 mm 0 (0.55-0.08 in.)

0

Reinstalled part

16-2 mm

Pressing force 98 N (10 kgf) [22 lbf]

0

(0.62-0.08 in.)

(4) After reinstalling the gear pump, make sure there are no oil leaks.

11-7

BRAKE SYSTEM

2.2.4 Reinstallation (Diesel-engine models) Reinstall in the reverse order of removal, noting the following points.

Tightening torque 26.5 ± 2.65 N·m (2.7 ± 0.27 kgf·m) [19.5 ± 1.95 lbf·ft]

Deflection amount

215731

(1) Check the following points before reinstalling the V-belt: (a) Check the belt for contamination with oil, grease and dust, etc., and replace it, if necessary. If the contamination is not significant, clean with a rag or paper towel. Do not use gasoline, oil or any other solvent to clean the belt. (b) If the belt is damaged, replace it with a new one.

(2) During the inspection of bearings, confirm that each bearing rotates smoothly and generates no abnormal noises.

(3) Make sure that the V-belt is not twisted. Adjust it, to obtain the deflection shown in the table. Use the tension adjustment bolt and nut on the tension assembly.

Deflection amount New part

0 14-2

mm

0 (0.55-0.08

in.)

0

Reinstalled part

Pressing force

16-2 mm

98 N (10 kgf) [22 lbf]

0

(0.62-0.08 in.)

(4) After reinstalling the gear pump, make sure there are no oil leaks.

11-8

BRAKE SYSTEM

2.2.5 Disassembling the gear pump 9 8 10 7 6

2

1

5

12

11 4

5

3

7 8

216006

1 2 3 4

Bolt Front cover Retainer ring Oil seal

5 6 7 8

Bushing Gasket Gasket (3-shaped) Side plate

9 10 11 12

Gear drive Gear driven Steel ball Body

Note: a) The gear pump should be disassembled, repaired and assembled by the manufacturer. If this has to be done in the field, carefully note the following points. Remember, doing this procedure in the field will invalidate the manufacturer's guarantee b) The oil seal 4 and bushing 5 do not need to be disassembled, unless a fault is found.

Procedure for disassembly As the front cover 2 is made of aluminum alloy and is easily scratched, do not forcibly tap them with a hammer, etc. Use a wooden hammer or plastic hammer.

When disassembling, do not remove the body, gear and bushing, etc. by forcibly tapping them with a hammer etc.

Place the disassembled parts in an orderly sequence on a clean workbench.

Do not mix up the relative position of the gear and bushing side plate.

11-9

BRAKE SYSTEM

2.2.6 Reassembling the gear pump ※ RETAINER RING ※ GASKET ※ OIL SEAL

※ GASKET

(3-SHAPED)

215964

Procedure for reassembly To reassemble, follow the sequence of disassembly in the reverse order while noting the following points.

(1) Replace the seal kit parts, marked by a * in the figure, with new ones.

Seal kit

91K46-00018

(2) Completely remove oil or grease on the mating surfaces of the front cover, body, etc.

(3) Wash all parts, visually check all parts for cleanliness, wear and damage. Apply brake oil to the inside surface of the body before reassembly.

(4) Apply grease to the lip of the oil seal.

(5) Be careful not to damage the lip of the shaft seal by the spline edges of the drive gear.

(6) Tighten the bolts evenly and progressively.

(7) After reassembly, check that the pump shaft can be easily rotated by hand with a pipe wrench fitted on the pump shaft.

(8) After reinstalling the pump, bleed the air from the brake system and check that it operates normally.

Note: For the procedure, refer to section "1.1.5 Wet disc brake air bleeding procedure."

11-10

BRAKE SYSTEM

2.3 Brake Valves 2.3.1 Removal

3

Brake pedal assembly 1 4

2 3 215947

Sequence 1 Snap pin, washer 2 Clevis pin

3 Brake valve mounting bolt 4 Brake valve

2.3.2 Reinstallation Reinstall in the reverse order of removal.

After reinstallation, carry out air bleeding of the brake system.

Note: For the procedure, refer to the section "1.1.5 Wet disc brake air bleeding procedure.

11-11

BRAKE SYSTEM

2.3.3 Disassembly Precautions on this operation (1) Since the performance of the brake valve assembly will greatly deteriorate if foreign matter such as dirt and dust gets inside, it cannot be disassembled except for the boot and push rod.

(3) Since the cylinder and spool are combined so as to have the optimum clearance, do not replace the cylinder unit by itself, nor attempt to modify the combination of parts.

(2) Perform disassembly and reassembly in a clean place.

(4) For cleaning parts and O-rings, use mineral-oil type hydraulic fluid.

Note: There must be only a small clearance between the cylinder and spool. If any matter becomes trapped between them, the clearance may become too large, interfering with spool operation.

(5) Do not reuse the R-cup once it has been removed from the piston.

10

18 19

13

14 16 17 20

8

15

9

7

3

6

5

11

12

4

14.7 – 34.3 N·m (1.5 – 3.5 kgf·m) [10.8 – 25.3 lbf·ft]

14.7 – 34.3 N·m (1.5 – 3.5 kgf·m) [10.8 – 25.3 lbf·ft] 2

1

58.8 – 78.4 N·m (6.0 – 8.0 kgf·m) [43.4 – 57.9 lbf·ft] 215948

Sequence 1 2 3 4 5 6 7

End plug O-ring Bolt S cylinder O-ring Holder Rod

11-12

8 9 10 11 12 13 14

Spring spring Retainer Spool Spring Push rod Boot

15 16 17 18 19 20

Stop wire Piston R-cup Clevis pin Lock nut Flange

BRAKE SYSTEM Procedure for disassembly (1) Remove the end plug from the S cylinder.

Do not let the spool fall off.

Tightening bolt

(2) Unfasten each tightening bolt of the flange and S cylinder to remove them, then remove the S cylinder. Do not allow the spool to fall off while doing this.

End plug Flange

S cylinder 215949

(3) Pull out the spool from the S cylinder.

Take care not to let this fall.

215950

(4) Remove the holder, rod, spring, and retainer together from the flange.

Flange 215951

(5) Disassemble the holder, rod, spring, and retainer which have been removed. When drawing out the rod through the oval hole of the holder, do not allow the spring to fly out.

Retainer

Spring

Holder

Rod

Be careful. The springs will jump off when the rod is released.

215952

11-13

BRAKE SYSTEM (6) Remove the push rod from the flange.

(7) Remove the boot.

Boot

Push rod 215953

(8) Remove the stop wire from the piston, then remove the piston.

(9) Remove the R-cup from the piston.

Pull out.

R-cup

Stop wire

215954

11-14

BRAKE SYSTEM

2.3.4 Inspection after disassembly (1) S cylinder and spool Check whether the spool slides smoothly by hand, and if you can feel any interference, replace it as a set.

(2) Flange Check the piston sliding area of the flange for any fault, wear, or other damage. If there is any, replace the flange.

(3) Piston Check the flange sliding area of the piston for any fault, wear, or other damage. If there is any, replace the piston.

Unit: mm (in.)

Clearance between flange and piston

A

0.016 – 0.095 (0.0006 – 0.0037)

B

0.15 (0.0059)

(6) Push rod Replace the push rod if it is bent or deformed.

(7) Boot (a) Check for any cracks, damages, or crevices, and replace the boot if it appears to be abnormal. (b) Check the interference area of the cylinder and rod, and replace any part whose interference size is too small or none.

(8) Bolt, Nut, End plug Check for any damage and wear, and confirm its smooth operation.

A: Standard value B: Repair/Service limit

(4) R-cup (a) Replace the R-cup, even if it has a minimal fault in the lip area. (b) Check the interference of the R-cup, and replace the cup if the size is smaller than the service limit using the repair kit.

Unit: mm (in.)

Cup interference size

A

-

B

0.4 (0.015)

A: Standard value B: Repair/Service limit

(5) Spring (a) Check for any fault, wear, or fatigue. Replace any spring that has a severe fault, etc. (b) Measure the free length of the spring, and replace any which exceeds the service limit.

Unit: mm (in.)

Major diameter of control spool Spring free length

A

48.0 (1.89)

B

47.5 (1.87)

Minor diameter of control spool Spring free length

A

50.5 (1.99)

Spool return spring free length

B

-

A

24.8 (0.98)

B

-

A: Standard value B: Repair/Service limit

11-15

BRAKE SYSTEM

2.3.5 Reassembly Procedure for reassembly To reassemble, follow the sequence of disassembly in the reverse order while noting the following points.

(1) Install the R-cup to the piston without damaging it.

(2) Install the piston to the flange.

Note: a) Apply lithium grease to the piston circumference area and R-cup.

Flange Piston

b) When installing the piston to the flange, do not damage the R-cup.

R-cup 215955

(3) Install the stop wire to the piston.

Piston

Stop wire

215956

(4) Assemble the holder, rod, spring and retainer together.

Retainer Spring

Holder

Rod

Hook in the oval hole.

215957

(5) Attach the holder, rod, spring, and retainer which have been assembled together to the flange in the direction shown in the figure on the right.

(6) Install the O-ring to the S cylinder.

O-ring Flange

S cylinder 215958

11-16

BRAKE SYSTEM (7) While aligning the direction of each port, install the S cylinder and the flange.

T

P

A

Tightening torque 14.7 – 34.3 N·m (1.5 – 3.5 kgf·m) [10.8 – 25.3 lbf·ft] 215959

Direction of port

(8) Apply oil to the cylinder's inside surfaces and install the spool and spring in the direction shown in the figure on the right.

Spring Spool

(9) Install the O-ring to the end plug.

O-ring

(10) Install the end plug to the S cylinder.

Tightening torque 58.8 – 78.4 N·m (6.0 – 8.0 kgf·m) [43.4 – 57.9 lbf·ft]

End plug 216035

(11) Install the boot and push rod to the flange.

Note: a) Install the boot with the hole facing the T-port side.

Boot hole

T

P

b) Apply lithium grease to the tip of the push rod. c) When replacing the end plug, take a note of serial number engraved on the original end plug.

A 215960

11-17

BRAKE SYSTEM

2.4 Parking Brake Valve 2.4.1 Removal (Gasoline-engine models) Tightening torque 49 ± 4.9 N·m (5.0 ± 0.5 kgf·m) [36.1 ± 3.6 lbf·ft]

4

7 Port for forcible release

Port for forcible release Front side

6

4

1

Tightening torque 15.5 ± 2.5 N·m (1.6 ± 0.2 kgf·m) [11.4 ± 1.8 lbf·ft]

5 3

5

Tightening torque 49 ± 4.9 N·m (5.0 ± 0.5 kgf·m) [36.1 ± 3.6 lbf·ft]

2

Front side

Tightening torque 49 ± 4.9 N·m (5.0 ± 0.5 kgf·m) [36.1 ± 3.6 lbf·ft] 215872

Sequence 1 2 3 4

Brake pipes Hose (between parking brake valve and connector) Hose (between parking brake valve and brake valve) Hose (between gear pump and parking brake valve)

2.4.2 Reinstallation (Gasoline-engine models) Reinstall in the reverse order of removal.

11-18

5 Connector 6 Bolt 7 Parking brake valve

BRAKE SYSTEM

2.4.3 Removal (Diesel-engine models) Tightening torque 49 ± 4.9 N·m (5.0 ± 0.5 kgf·m) [36.1 ± 3.6 lbf·ft]

7 4

Port for forcible release

Front side

6

Port for forcible release

5

1

4

Tightening torque 15.5 ± 2.5 N·m (1.6 ± 0.2 kgf·m) [11.4 ± 1.8 lbf·ft]

3 2

5

Tightening torque 49 ± 4.9 N·m (5.0 ± 0.5 kgf·m) [36.1 ± 3.6 lbf·ft]

Tightening torque 49 ± 4.9 N·m (5.0 ± 0.5 kgf·m) [36.1 ± 3.6 lbf·ft] Front side

215873

Sequence 1 2 3 4

Brake pipes Hose (between parking brake valve and connector) Hose (between parking brake valve and brake valve) Hose (between gear pump and parking brake valve)

5 Connector 6 Bolt 7 Parking brake valve

2.4.4 Reinstallation (Diesel-engine models) Reinstall in the reverse order of removal.

11-19

BRAKE SYSTEM

2.4.5 Disassembling parking brake valve Tightening torque 19.6 N·m (2.0 kgf·m) [14.4 lbf·ft]

Tightening torque 39.2 ± 3.9 N·m (4.0 ± 0.4 kgf·m) [28.9 ± 2.8 lbf·ft]

9

5

10

MG

BE

6

PK

T

3

Tightening torque 39.2 ± 3.9 N·m (4.0 ± 0.4 kgf·m) [28.9 ± 2.8 lbf·ft]

4

Tightening torque 39.2 ± 3.9 N·m (4.0 ± 0.4 kgf·m) [28.9 ± 2.8 lbf·ft]

P BR

Tightening torque 39.2 N·m (4.0 kgf·m) [29.0 lbf·ft]

11

12

2 Tightening torque 19.6 N·m (2.0 kgf·m) [14.4 lbf·ft]

Tightening torque 20.3 N·m (2.1 kgf·m) [15.0 lbf·ft]

7

8

1

Tightening torque 19.6 N·m (2.0 kgf·m) [14.4 lbf·ft]

Tightening torque 34 N·m (3.5 kgf·m) [25.1 lbf·ft]

215961

Sequence 1 2 3 4 5 6 7

Valve, solenoid Orifice Elbow Elbow Valve, relief Connector Plug, O-ring type

8 9 10 11 12 13

Plug, O-ring type Plug, O-ring type Plug, O-ring type Plug, O-ring type Strainer Plug, O-ring type

Procedure for reinstallation When reinstalling the elbow, pay attention to the position of the angle as shown in the figure on the right.

45 °

10°

10°

215742

11-20

BRAKE SYSTEM

2.5 Shuttle Valve, Connector

Connector

90

°

A Front of truck Front of truck View A Option Auto-decelerate & Controlled-rollback

STD

Pro-shift & Auto-decelerate & Controlled-rollback

Pro-shift & Auto-decelerate Valve,Shuttle

Valve,Shuttle

Switch,Pressure Valve,Shuttle Connector Connector

Elbow Tightening torque: 39.2 ± 3.9 N·m (4.0 ± 0.4 kgf·m) [28.9 ± 2.8 lbf·ft]

Elbow Tightening torque: 39.2 ± 3.9 N·m (4.0 ± 0.4 kgf·m) [28.9 ± 2.8 lbf·ft]

Elbow Tightening torque: 39.2 ± 3.9 N·m (4.0 ± 0.4 kgf·m) [28.9 ± 2.8 lbf·ft] 215736

11-21

BRAKE SYSTEM

2.6 Oil Filter

Elbow Screw

Oil filter assy

20° A IN OUT

Oil filter cover

Elbow Oil filter bracket Front of truck

A

215749

Procedure for reinstallation After thoroughly cleaning the mounting surface at the filter bracket side, apply a thin coat of brake oil to the O-ring of the filter, then fully hand-tighten the filter.

Bracket side

Note: Do not tighten the filter using a wrench, etc.

Apply oil.

216004

11-22

BRAKE SYSTEM

3. Measurement of Hydraulic Pressure (1) Block the wheels with wood blocks.

(2) Attach a hydraulic pressure gauge to the specific port of the parking brake valve.

(3) Use the hydraulic pressure measuring tool in the table shown below.

Relief valve

Hydraulic pressure gauge

Front side

G1/8

(4) Hydraulic pressure measurement Start the engine and set all the levers in the neutral position, pull the parking brake switch, measure the hydraulic pressure required to open the valve using a hydraulic pressure gauge.

Engine speed

Low idling

Hydraulic pressure

6.0 – 7.0 MPa (61.18 – 71.38 kgf/cm2) [870.32 – 1015.37 psi]

216003

(5) If the hydraulic pressure at the relief valve is different from the standard value, stop the engine, loosen the lock nut of the relief valve, then turn the screw with a screwdriver to tighten the lock nut.

Start the engine again and measure the hydraulic pressure.

When the hydraulic pressure reaches the standard value, firmly tighten the lock nut.

11-23

BRAKE SYSTEM

4. Forcible Release of Parking Brake (1) If the parking brake can not be released for some reason, perform the required operation as follows.

(2) Block the wheel with wood blocks.

4.1 Release by Turning Bolt (1) Remove the tapered plug (4 places) attached to the back of the wet disc brake assembly, then screw in each bolt with a washer (for both right and left).

Bolt

92071-01300

Washer

F1035-10050

Tapered plug

Tapered plug

215965

(2) The required amount of turning in is approximately one turn after the bolt and washer come into light contact with the seat surface. Do not overtighten.

Bolt for forcibly releasing parking brake 216005

11-24

BRAKE SYSTEM

4.2 Release by the External Hydraulic Pressure (1) Remove the plug (G 1/8) for forcible release of the parking brake valve.

(2) Install the connector attached with the nut, washer and O-ring to the respective port.

Connector for forcible release

91K67-00200

Nut

91K67-00300

Washer

F2500-10000

O-ring

05500-24014

Port plug for forcible release O-ring

Connector Nut Washer O-ring

Port for forcible release

215962

(3) Screw in the connector for forcible release until it is completely in contact with the sealing surface of the parking brake valve. At that position tighten the nut to the specified torque.

Tightening torque

19.6 N·m (2.0 kgf·m) [14.5 lbf·ft]

(4) Connect an external hydraulic source to the connector (G 1/4) for forcible release, and generate a sufficient hydraulic pressure to release the parking brake.

Allowable range of hydraulic pressure

External hydraulic pressure source

6 – 7 MPa (61.18 – 71.38 kgf/cm2) [870.32 – 1015.37 psi]

215963

11-25

BRAKE SYSTEM

5. Troubleshooting Unit

Situation

Description

Service brake Brake does not func- Leak from the hydraulic system, or tion. main tank oil level is too low.

Uneven brake effect

Brake return failure Brake squeaks

11-26

Repair leak and add brake oil.

Air mixed in the hydraulic system

Bleeding air from brake oil line.

Brake piston seal worn or damaged

Replace

Friction plate worn or facing damaged

Replace

Mating plate worn

Replace

Uneven tire pneumatic pressures

Adjust to the correct pneumatic pressure.

Friction plate worn or facing damaged

Replace

Mating plate worn

Replace

Piston return spring deteriorated

Replace

Spring guide bent

Replace

Inappropriate brake oil

Replace with the specified brake oil.

Poor contact between friction plate and mating plate

Replace

Parking brake Brake does not func- Brake spring deteriorated tion.

Oil line is sealed up.

Brake can not be released.

Remedy

Replace After draining oil from the port to forcibly release the parking brake valve, disassemble and check the parking brake valve.

Insufficient oil line pressure

Measure the hydraulic pressure of the relief valve in the parking brake valve, and adjust it.

Parking brake valve failure

Replace

Electric wiring damaged

Check the wiring continuity.

Chapter 15 SERVICE DATA 1.

Maintenance Schedule ......................................................................... 15-1

2.

Periodically Inspected Parts ................................................................ 15-2

3.

Supply Oil Standard.............................................................................. 15-3 3.1

4.

Supply Oil Table and Oil Quantity ......................................................................... 15-3

List of Special Tools ............................................................................. 15-4 4.1

List of Special Tools .............................................................................................. 15-4

15

SERVICE DATA Chapter 15 SERVICE DATA

Inspection point

Front axle Friction plate

Visual

X

Brake hose, pipes & joints

Visual

Brake pedal clearance between pedal and floor when pressed

Scale

X

Operation / visual

X

Visual

X

Parking brake system Brake

How to check

Pre-start (daily/10 hours) Weekly (50 hours) 1 month (200 hours) only 3 months (500 hours) 6 months (1000 hours) 12 months (2000 hours) Others (see Note 1)

1. Maintenance Schedule

Brake oil level

Service data

SEE PAGE 9-24

X Brake pedal height: 189.5 – 193.4 mm (7.460 – 7.614 in) Brake pedal play: Approx. 5 mm (Approx. 0.196 in)

Brake valve rubber parts

R

Brake hydraulic line-filter

R 0

Brake pump drive belt

Scale

Replaced part: Brake oil

0

New Part: 14-2mm(0.55-0.08in.)

X

0 0 16-2mm(0.62-0.08in.)

R Abbreviation…X:Check, C:Clean, D:Drain, L:Lubricate, R:Replace

15-1

SERVICE DATA

2. Periodically Inspected Parts The following safety parts and elements must be replaced at the specified intervals.

Note: * mark shows a safety part.

Time for replacement No.

Periodically replaced parts

Every year

Every month

Remark

After each unit of operation hours

1

*Brake valve rubber parts

1

2000

2

*Brake hose rubber parts

1

2000

3

Replacement of brake line filter

1

2000

4

Brake oil

1

2000

5

O-ring, Oil seal, Floating seal, Wave spring

5 years (10000 hours)

6

*Brake pump bearing

5 years (10000 hours)

Main tank 4

2 Gear pump

3

6 2

5

2 Parking brake valve

1 5

2 216031

15-2

SERVICE DATA

3. Supply Oil Standard 3.1 Supply Oil Table and Oil Quantity Oil type Brake oil

Oil quantity

Oil brand for use Manufacturer-recommended oil

2 ton class

3 ton class

Gasoline-engine model

10.9 L 12.8 L (665.16 cu.·in.) (781.10 cu.·in.)

Diesel-engine model

10.4 L 12.3 L (634.65 cu.·in.) (750.59 cu.·in.)

Oil properties vary for each manufacturer. Do not mix more than one brand of oil.

15-3

SERVICE DATA

4. List of Special Tools 4.1 List of Special Tools Part No.

Description

Use

1

91E68-01200

Holder, friction plate

For assembling wet disc brake

2

91E68-01300

Inserter, floating seal

For assembling wet disc brake

3

91E68-01400

Guide, inserter

For assembling wet disc brake

4

91E68-01500

Ring, guide

For assembling wet disc brake

5

92071-01300

Bolt for forcible release

For emergency release of parking brake

6

F1035-10050

Washer

For emergency release of parking brake

7

91K67-00200

Connector for forcible release

For emergency release of parking brake

8

91K67-00300

Nut

For emergency release of parking brake

9

F2500-10000

Washer

For emergency release of parking brake

O-ring

For emergency release of parking brake

10 05500-24014

15-4

CAT Lift Trucks Service Manual

GP20N-35N, DP20N-35N Lift Trucks

99719-6W110

Mitsubishi Caterpillar Forklift Europe B.V. Hefbrugweg 77 1332 AM Almere, The Netherlands

99719-6W110

© 2015 MCFA. All rights reserved. CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow,” the “Power Edge” trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. All registered trademarks are the property of their respective owners. Some products may be shown with optional equipment.

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