Caterpillar EP16 EP18 EP20 EP25 EP30 Chassis with MicroCommand II™ Controller Service Manual - PDF

SENB8637

EP16, EP18, EP20, EP25, EP30 Chassis with MicroCommand II™ Controller For 36/48V Trucks EP16 & EP18 EP20 & EP25 EP30

E1EP1-60001 & up E1EP2-60001 & up E1EP3-60001 & up

For 72/80V Trucks EP16 & EP18 EP20 & EP25 EP30

E1EP1-80001 & up E1EP2-80001 & up E1EP3-80001 & up

Foreword This service manual has instructions and procedures for the subject on the front cover. The information, specifications, and illustrations used in this manual are based on information that was current at the time this issue was written.

Correct servicing will give these lift trucks a long, productive life. Before attempting to start a test, repair or rebuild job, be sure you have studied the respective sections of this manual, and know all the components you will work on.

Safety is not only your concern but everybody’s concern. Safe working habits cannot be bought or manufactured; they must be learned through the job you do. By learning what CAUTION or WARNING symbol emphasizes, know what is safe — what is not safe. Consult your foreman, if necessary, for specific instructions on a job, and the safety equipment required.

NOTES, CAUTIONS and WARNINGS NOTES, CAUTIONS and WARNINGS are used in this manual to emphasize important and critical instructions. They are used for the following conditions.

!

!

NOTE

An operating procedure, condition, etc., essential to highlight.

CAUTION

Operating procedures, practices, etc. which, if not strictly observed, will result in damage to or destruction of the engine.

Operating procedures, practices, etc., which, if not correctly followed, will result in serious injury or loss of life.

WARNING

i

!

!

WARNING

!

WARNING

WARNING

Do not operate this machine unless you have read and understand the instructions in the OPERATOR’S MANUAL. Improper machine operation is dangerous and could result in injury or death.

The proper and safe lubrication and maintenance for this machine, recommended by Catapillar, are outlined in the OPERATION & MAINTENANCE MANUAL for these machines.

Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance.

5. Use steps and grab handles (if applicable) when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

The service mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component.

6. To reduce the risk of back injury, use a hoist when lifting components which weigh 23 kg (50lb.) 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. Lifting eyes are not to be side loaded during a lifting operation.

Because of the size of some of the machine components, the service mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components.

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

7. To reduce the risk of burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments.

1. Read and understand all warning plates and decals on the machine before operating, lubricating or repairing the product.

8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure before removing the last two bolts or nuts completely.

2. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when pounding on any part of the machine or its attachments with a hammer or sledge. Use welder’s gloves, hood goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loosefitting or torn clothing. Remove all rings from fingers when working on machinery.

9. Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.

3. Do not work on any machine that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the machine before performing any disassembly.

10. Always use tools that are in good condition and be sure you understand how to use them before performing any service work.

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

11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. Do not mix metric fasteners with standard nuts and bolts.

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12. If possible, make all repairs with the machine parked on a level, hard surface. Block machine so it does not roll while working on or under machine.

13. Disconnect battery and discharge any capacitors before starting to work on machine. Hang “Do Not Operate” tag in the Operator’s Compartment.

14. Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal.

15. Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will it be damaged in operation by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid.

16. Be sure all protective devices, including guards and shields, are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution.

20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

21. Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.

22. Caution should be used to avoid breathing dust that may be generated when handling components containing asbestos fibers. If this dust is inhaled, it can be hazardous to your health.

If dust which may contain asbestos is present, there are several common sense guidelines that should be followed.

Never use compressed air for cleaning.

b.

Avoid brushing or grinding of asbestos containing materials.

c.

For clean up, use wet methods or a vacuum equipped with a high efficiency particu(HEPA) filter.

late air

17. Always support the mast and carriage to keep carriage or attachments raised when maintenance or repair work is performed, which requires the mast in the raised position.

18. Loose or damaged hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands.

Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause serious injury. Use cardboard or paper to locate pin hole leaks.

a.

d.

Use exhaust ventilation on permanent machining jobs.

e.

Wear an approved respirator if there is no other way to control the dust.

f.

Comply with applicable rules and regulafor the work place.

g.

Follow environmental rules and regulations disposal of asbestos.

h.

Avoid areas where asbestos particles may in the air.

tions

for

be

19. Tighten connections to the correct torque. Make sure all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot components in event of a line, tube or seal failure must be installed correctly.

iii

TABLE OF CONTENTS

Chapter 1: General Information Scope

1.1

Truck Models Covered

1.1

Nameplate and Serial Number Locations

1.2

Dimensions

1.3

Dimensions Chart

1.4

General Information (Standard Models)

1.5

Chapter 2: Rear Axle Description

2.1

Removal and Installation of Rear Wheels

2.2

Removal and Installation of Rear Axle

2.6

Disassembly

2.8

Inspection after Disassembly

2.10

Reassembly

2.11

Inspection and Adjustment

2.16

Chapter 3: Transfer Case Differential Assembly

3.1

Transfer Case

3.2

Disassembly

3.3

Reassembly

3.4

Chapter 4: Steering System Description

4.1

Removal & Installation of Steering Wheel

4.2

Steering Gear Removal

4.3

Steering Gear Installation

4.4

Steering Gear Disassembly

4.5

Inspection after Disassembly

4.9

Steering Gear Reassembly

4.10

Inspection after Reassembly

4.15

Chapter 5: Front Axle Description

5.1

Front Axle & Reduction Differential Description

5.2

Removal & Installation

5.3

Removal

5.7

Installation

5.8

TABLE OF CONTENTS

Chapter 6: Brake System Description

6.1

Master Cylinder Disassembly

6.2

Inspection after Disassembly

6.3

Reassembly

6.3

Wheel Brakes Disassembly

6.4

Inspection after Disassembly

6.6

Brake System Reassembly

6.8

Wheel Cylinder Disassembly

6.11

Inspection after Disassembly

6.12

Reassembly

6.12

Inspection & Adjustment

6.13

Chapter 7: Hydraulic System Description

7.1

Hydraulic Tank

7.2

Hydraulic Pump

7.3

Control Valve

7.5

Tilt & Lift Cylinder

7.6

Flow Regulator Valve

7.7

Down Safety Valve

7.8

Removal & Installation Warning

7.9

Pump Removal

7.10

Pump Installation

7.11

Pump Disassembly

7.12

Inspection after Disassembly

7.16

Pump Reassembly

7.18

Inspection after Assembly

7.24

Priority Valve Disassembly

7.25

Priority Valve Reassembly

7.28

Control Valve Removal

7.32

Control Valve Installation

7.33

Control Valve Disassembly

7.34

Control Valve Inspection and Reassembly

7.36

Hydraulic System Disassembly

7.37

Hydraulic System Installation

7.39

Tilt & Lift Cylinder Disassembly

7.41

Tilt & Lift Cylinder Inspection after Disassembly

7.43

Flow Regulator Valve Disassembly

7.44

TABLE OF CONTENTS Hydraulic System Inspection & Adjustment

7.45

Control Valve Inspection & Adjustment

7.46

Tilt & Lift Cylinder Inspection & Adjustment

7.48

Adjustment Method

7.49

Testing

7.50

Chapter 8: Mast and Forks Description

8.1

Removal & Installation

8.3

Disassembly

8.6

Inspection after Disassembly

8.8

Reassembly

8.9

Inspection and Adjustment

8.10

Chain Tension Adjustment

8.11

Lift Bracket Adjustment

8.12

Mast Clearance Adjustment

8.14

Mast Adjustment Chart

8.20

Chapter 9: Troubleshooting Front Axle & Reduction Differential

9.1

Brake System

9.2

Steering System

9.4

Hydraulic System

9.6

Rear Axle

9.8

Mast & Forks

9.9

Chapter 10: Maintenance Service Data System Service Charts Front Axle and Reduction Differential

10.1

Transfer Case

10.3

Rear Axle

10.4

Brake System

10.6

Steering System

10.10

Hydraulic System

10.12

Mast and Forks (Simplex Mast)

10.15

Tightening Torques for Standard Bolts and Nuts Fine Thread—With Spring Washer

10.17

Fine Thread—Without Spring Washer

10.18

TABLE OF CONTENTS Coarse Thread—With Spring Washer

10.19

Coarse Thread—Without Spring Washer

10.20

Maintenance Chart

10.21

Periodic Replacement Parts

10.26

Lubrication Data

10.27

Chart

10.27

Fuel and Lubricant Specifications

10.28

Recommended Brands of Lubricants

10.29

Weight of Major Components (Approximate)

10.30

Special Service Tools

10.31

Special Tool Illustrations

10.32

Inspection Guide

10.35

Chapter 1: General Information Scope

1.1

Truck Models Covered

1.1

Nameplate and Serial Number Locations

1.2

Dimensions

1.3

Dimensions Chart

1.4

General Information (Standard Models)

1.5

GENERAL INFORMATION: SCOPE

Scope This service manual deals with all components or systems of the Caterpillar® Lift Trucks, except for the electrical system, which is covered in a separate manual.

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

Truck Model

Serial Number

Serial Numbers for Trucks with Voltages 36V or 48V EP16, EP18

E1EP1–60001 & UP

EP20, EP25

E1EP2–60001 & UP

EP30

E1EP3-60001 & UP

Serial Numbers for Trucks with Voltages 72V or 80V EP16, EP18

E1EP1–80001 & UP

EP20, EP25

E1EP2–80001 & UP

EP30

E1EP3–80001 & UP 1.1

GENERAL INFORMATION: PLATES

Nameplate and Serial Number Locations

1.2

GENERAL INFORMATION: DIMENSIONS

Dimensions

860142

8609143

1.3

GENERAL INFORMATION: DIMENSIONS

Dimensions Chart Ref# Truck Model A B C D E F G H I J K L M N O P

Maximum Lift Free Lift Maximum Fork Spacing (outside to outside) Fork Length Tilt Angle (forward / backward) Overall Length Overall Width (fenders) Overall Height (to top of mast,lowered) Overall Height (to top of overhead guard) Overall Height (to top of mast, extended) Tread (front) Tread (rear) Wheelbase Front Overhang Rear Overhang Underclearance (at center of wheelbase)

EP16

EP18

EP20

EP25

EP30

3335 (131.3) 3335 (131.3) 3340 (131.5) 3340 (131.5) 3245 (127.8) 115 (4.5) 115 (4.5) 142 (5.6) 142 (5.6) 150 (5.9) 918 (36.1) 918 (36.1) 920 (36.2) 920 (36.2) 6° / 9°

983 (38.7) 1070 (42.1)

983 (38.7) 1070 (42.1) 6° / 8°

998 (39.3) 1070 (42.1)

3018 (118.8) 3018 (118.8) 3433 (135.2) 3433 (135.2) 3641 (143.3) 1160 (45.7) 1160 (45.7) 1190 (46.8) 1190 (46.8) 1230 (48.4) 2128 (83.8)

2128 (83.8)

2191 (86.3)

2191 (86.3)

2200 (86.6)

2180 (85.8)

2180 (85.8)

2200 (86.6)

2200 (86.6)

2250 (88.6)

4327 (170.4) 4327 (170.4) 4327 (170.4) 4327 (170.4) 4435 (174.6) 950 (37.4) 898 (35.4) 1400 (55.1) 392 (15.4) 306 (12.0)

950 (37.4) 898 35.4) 1400 (55.1) 392 (15.4) 306 (12.0)

980 (38.6) 985 (38.8) 1585 (62.4) 417 (16.4) 361 (14.2)

980 (38.6) 985 (38.8) 1585 (62.4) 417 (16.4) 361 (14.2)

990 (39.0) 985 (38.8) 1730 (68.1) 480 (18.9) 361 (14.2)

105 (4.1)

105 (4.1)

122 (4.8)

122 (4.8)

123 (4.8) Unit: mm (in.)

1.4

GENERAL INFORMATION: STANDARD MODELS

General Information (Standard Models) Truck Model Units

EP16

Standard Controller

EP18

EP20

EP25

EP30

MicroCommand

Standard Simplex Mast Size Service Weight Without (standard axle) Battery

meters

3.3 2355 (5190)

3.3 2415 (5325)

3.3 2940 (6485)

3.3 3095 (6825)

3.2 3495 (7710)

3705 (8170)

3765 (8300)

4705 (10,375)

4860 (10,715)

5585 (12,315)

2500/500 5000/24)

3000/500 (6000/24)

kg(lb) With Max. Battery Rated Capacity / Load Center

kg/mm (lb/in.)

1600/500 1800/500 (3000/24) 3500/24)

2000/500 (4000/24)

Maximum Fork Height Lift Speed (rated 36V load) 48V

mm(in.)

3335(131) 0.29(57) 0.29(57)

3340(132) 3345(132) 0.29(57) 0.27(53) —

0.39(77)

0.38(75)

0.38(75)

0.36(71)

—

0.40(79)

0.39(77)

0.40(79)

0.38(75)

0.34(67)

0.59(116)

0.52(102)

m/sec. (fpm)

80V Lowering Speed (rated load) Tilt Angle (forward/backward) Free Lift Travel Speed (without load)

degrees mm (in)

6°/9° 115(4.5)

km/h (mph)

12.2(7.6)

36V

Reduction Gear

Differential

12.0(7.4)

15.0(9.3)

150(5.9) 14.3(8.9)

— —

16.3(10.1) 16.0(9.9)

20.0(12.4) 19.0(11.8)

80V

16.7(10.4)

16.7(10.4)

20.0(12.4)

19.0(11.8)

19.5(12.1)

1885 (74.2)

1885 (74.2)

2125 (83.7)

2125 (83.7)

2260 (89.0)

mm (in)

36V 48V

KW—1 hr (hp)

80V Transfer Gear

6°/8° 142(5.6)

48V Minimum Turning Radius

Traction Motor Output (60 min duty)

0.58(114)

5.5(7.4)

9.1(12.2)

—

7.6(10.2)

12.5(16.8)

—

9.4(12.6)

11.0(14.8)

—

Type

Spur

Ratio

3.983

Type

Skew Bevel

Ratio

3.769

Axle Housing Gear Type/ Number

Banjo Gears

Straight Bevel /2

Pinions

Straight Bevel / 2

1.5

GENERAL INFORMATION: STANDARD MODELS Truck Model Units

EP16

EP18

Type

EP20

EP25

EP30

Dynamic Load Sense

Turning Angle

Inside

Degrees

Outside Steering Wheel Diameter

83° 56.5°

mm (in.)

Cylinder Minimum Test Pressure

kgf/cm2 (psi) [kPa]

328 (13) 163 (2320) [16,000]

Type

Self-Adjusting Duo Servo

Inside Drum Diameter

mm (in.)

254 +00.13

279.4+00.13 (11.00+00.0051)

Lining Thickness

mm (in.)

4.87 (.19)

5.1(0.20)

Master Cylinder ID

mm (in.)

19.05+0.052 (0.7500+0.00205)

19.05+0.052 (0.7500+0.00205)

Wheel Cylinder ID

mm (in.)

22.22+0.052 (0.8748+0.0020)

22.22+0.052 (0.8748+0.00205)

310.0+00.13 (12.20+00.0051)

Service Brake

Type Lever Operating Effort

Mounting

Front Wheels

Fixed Type

Rear Wheels

Center Pivot Type

Oscillation Angle Camber

1.6

28.58+0.052 (1.1252+0.0020)

Mechanical, Mounted on Front Wheels

Park Brake

Wheel Alignment

5.67(0.22)

kgf (lbf) [N]

25 to 30 (55 to 66) [245 to 294]

3° Degrees 1°

GENERAL INFORMATION: STANDARD MODELS Truck Model Units

Hydraulic Pump

EP16

EP18

EP20

Type

Gear

Make

Ultra Hydraulics, Inc.

Model cc (cu in.)

Displacement

1SX230

2SR029

23.0 (1.40)/rev.

29.0 (1.77)/rev.

Make

Kayaba

Model

KVSF65

EP25

EP30

Control Valve Relief Pressure Flow Regulator Valve

Variable liter

50±3 (3051± 183)

65 ± 3 (3967 ± 183)

45 (1.77)

50 (1.97)

75 ± 3 4577 ± 183

(cu.in.) / min

ID Stroke

Tilt Cylinders

185+05 (2631+071) [18142+0490]

Type Regulated Flow Rate

Lift Cylinders

kgf /cm2 (psi) [kPa]

mm (in.)

1650 (64.96)

55 (2.17) 1600 (62.99)

ID

63 (2.48)

70(2.75)

80 (3.15)

Stroke

96 (3.78)

98 (38.6)

124 (4.88)

25(6.6)

25 (6.6)

30 (7.9)

Hydraulic Tank Capacity (Approx)

liter (US gal.)

Mast

Roller type CL

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

Outer

Inner

100 x 17 x 12 (3.94 x 0.67 x 0.47)

Main Rollers

Type

# 6308 Ball Bearing

#6309 Ball Bearing

100 x 30 (3.94 x 1.18)

115 x 35 (4.53 x 1.58)

mm (in.)

Diameter x Width Side Rollers

Type Diameter x Width

115 x 20 x 13 (4.53 x 0.79 x 0.51)

115 x 21 x 13 (4.53 x 0.83 x 0.51)

115 x 21 x 13 (4.53 x 0.83 x 0.51)

Lubricating type needle roller bearing mm (in.)

Lift Chains

42 x 36 (1.65 X 1.42) BL534

Forks (Lgth x wdth x Thk) mm (in.)

Fork Spacing (out to out)

100 x 15 x 12 (3.94 x 0.59 x 0.47)

920 x 100 x 35 (36 x 4 x 1.4)

920 x 100 x 35 (36 x 4 x 1.4)

200 to 918 (7.9 to 36.1)

BL634 1070 x 125 x 40 (42 x 5 x 1.6)

BL834 1070 x 125 x 45 (42 x 5 x 1.8)

250 to 983 250 to 998 (9.8 to 38.7) (9.8 to 39.3)

1.7

GENERAL INFORMATION Truck Model Units

Voltage

EP20

Heights-Edges

EP25

36/48/72/80

EP30

36/48/72/80 72/80

36V

1050

1350

—

48V

750

1050

—

72V

500

600

800

80V

450

600

750

Height-Center

794 (31.3) mm (in.)

788 (31.0)

Length

580

725

870

Width

1040

1040

1040

Weight (Min/Max)

1.8

EP18

36/48/72/80 36/48/72/80

Amp Hours (5hr. rate) max.

Compartment Dimensions

EP16

kg (lb)

995/1350

1215/1350

930/1765

(2194/2977) (2679/2977)

(2050/3892)

1385/1765

1710/2090

(3054/3892)

(3770/4608)

Chapter 2: Rear Axle Description

2.1

Removal and Installation of Rear Wheels

2.2

Removal and Installation of Rear Axle

2.6

Disassembly

2.8

Inspection after Disassembly

2.10

Reassembly

2.11

Inspection and Adjustment

2.16

REAR AXLE: DESCRIPTION

Description 3 1

2 5 7

3

6

4

1. Rear axle 2. Steering cylinder 3. Steering knuckles 4. King pins

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

5. Tie rods 6. Wheel rims 7. Shims

2.1

REAR AXLE: REAR WHEELS

Removal and Installation of Rear Wheels !!

NOTE

WARNING WARNING

Servicing and changing tires and rims can be dangerous and should be done only by trained personnel using proper tools and procedures. If correct procedures are not followed while servicing tires and rims, the assemblies could burst with explosive force and cause serious physical injury or death. Carefully follow the specific information provided by your tire servicing company or dealer.

When changing tires, change them in sets, even if only one of the tires is damaged. If new and used tires are on the same axle, tilting of the mast and rapid tire wear will result.

The mounting faces of the hub, wheel nuts and wheels must be free of any foreign material and lubricants of any kind. Tighten wheel nuts again after 24 hours of operation.

Use a tire inflation gauge and stand behind the tread when inflating a tire and checking tire pressure.

Proper inflation equipment and training in using the equipment are necessary to reduce the risk of overinflation. A tire blowout or rim failure can result from improper or misused equipment.

!

2.2

Removal 1. Wheel nuts 2. Rear wheel

CAUTION

●

Always deflate tires before changing them to reduce the risk of a tire explosion.

●

Make sure the replacement tire is of the same size, type and load range.

●

Make sure the replacement tire is properly inflated.

204897

REAR AXLE: REAR WHEELS Suggestions

Jack Capacities

1. Block the front wheels.

2. Pull the parking brake lever, and loosen the wheel nuts one to two turns.

EP16, EP18 EP20, EP25, EP30

3 ton (6700 #lb) minimum 5 tons (12000 #lb) minimum

3. Slightly deflate tires to be removed.

4. Raise the rear end of the machine with a jack.

!

WARNING

● To avoid the possibility of serious injury DO NOT attempt to change the tire with the truck loaded. ● BE SURE to get off the truck when raising the rear tire. ● Stop raising the truck when the tire clears the ground. To avoid the possibility of serious injury, DO NOT raise the truck more than is necessary. ● DO NOT put any portion of your body under the truck. SECURELY SUPPORT with blocks after jacking.

Method Using a Jack Position the jack under the side of the frame or beneath the center of the steer axle beam.

After lifting, securely support by blocks.

2.3

REAR AXLE: REAR WHEELS 5. Remove the wheel nuts (loosened in step 2).

!

NOTE

CAUTION

Be careful NOT to strip the bolt threads when removing the wheel.

The tire pressure is indicated on the nameplate attached to the top of the battery hood.

6. Firmly grip the wheel with both hands and remove it from the truck.

Installation To install, follow the reverse of the removal sequence, including the following steps.

!

CAUTION

Use the same size and brand tire.

1. Install the tire and tighten the wheel nuts so the the tire will not rattle.

2. Jack the truck and remove supporting blocks.

Lower the truck by operating the jack until the tire just touches the ground. Then tighten the wheel nuts in the sequence shown in two or three steps, to the specified torque.

Tighten torque for wheel nuts

16 kgf·m (116 lbf·ft) [157 N·m]

3. Lower the truck fully, inflate tires and restore the jack.

4. Check to make sure the tire pressure is correct.

2.4

200229A

REAR AXLE: REAR WHEELS 5. After tire replacement, drive the truck for a while and check the wheel nuts for tightness.

!

WARNING

When adding air to the tire or when checking tire pressure, BE SURE to keep your body away from the side. The use of an inflation cage, or some other safety device helps reduce the risk of serious injury.

When adding air to the tire using an air compressor, make sure the compressor valve is correctly set. Failure to follow this precaution may cause serious injury or may damage the tire. Always maintain correct tire pressure.

100904A

2.5

REAR AXLE: REMOVAL & INSTALLATION

Removal and Installation of Rear Axle

Sequence 1. Rear wheel, wheel nuts 2. Bearing support 3. Rear axle assembly [thrust washer]

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

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

203622

2.6

REAR AXLE: REMOVAL & INSTALLATION Removal

Installation

Removing Rear Axle Assembly

To install, reverse the removal sequence including the following.

Adjusting Bearing Support Clearance

!!

WARNING WARNING

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

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

Adjust the longitudinal clearance to 0.8mm (0.031 in.) with the thrust washer, and tighten the bolts holding the bearing support to the specific torque.

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

3. Loosen and remove the axle mounting bolts.

Tightening torque for bearing support bolts

14.8 kgf·m (107 lbf·t) [145 N·m]

200257

204900

2.7

REAR AXLE: DISASSEMBLY

Disassembly

10 7

5 9 4 6

8 1 3 2

Sequence 6. Oil seal 1. Cap 2. Nuts and washer 3. Bearing 4. Wheel rim 5. Bearing and retainer

2.8

7. Tie rods 8. King pins 9. Knuckles 10. Cylinder assembly

REAR AXLE: DISASSEMBLY Suggestions

Removing Bearing Races from the Knuckles

Removing Retainer and Bearing

Use a puller to remove the bearing races from the inside of the knuckle.

Use a puller to remove the hub.

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

203618

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

8609004

205021

2.9

REAR AXLE: INSPECTION

Inspection after Disassembly Tie Rods and Pins 1. Make sure the pins are free of any surface flaws, such as grooving or stepped wear.

Examine the keeper plate weld for cracking.

Cylinder Rod Examine the rod for surface or plating damage.

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

2. Examine the bearings for wear or damage.

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

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

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

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

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

Replace both the cup and cone of damaged bearings.

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

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

2.10

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

REAR AXLE : REASSEMBLY

Reassembly

1

4

5 2 7 6 3

8

10 9 8609005

Sequence 6. Bearing and retainer 1. Cylinder assembly 2. Knuckles 3. King pins 4. Tie rods

7. Wheel rim 8. Bearing 9. Nuts and washer 10. Cap

5. Oil seal

2.11

REAR AXLE: REASSEMBLY Reassembling Steer Cylinder 1. Replace all seals and O-rings whenever reassembling steer cylinder. Lubricate seals and O-rings lightly with hydraulic fluid.

4. Pressure test cylinder reassembly for leaks.

All

2. Assemble wiper and U-seal as shown.

163 (2320) [16,000]

Minimum test pressure

Unit:kgf/ cm2 (psi) [kPa] 5. Use an alternating tightening pattern to tighten the mounting bolts when attaching the cylinder assembly to the axle beam.

All 8609006 Tightening torque for bolts 3. Align marks on the end caps to mark on the cylinder body. Tighten nuts.

Tightening torque for cylinder nuts

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

26.7 (193) [262]

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

Apply a coat of grease to the oil seal groove.

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

All Quantity of grease

80cc (4.88)

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

8609004

2.12

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

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

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

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

All Tangential force

A

2.5 to 4.5 kgf 24.5 to 44.1 N

8609007

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

8609009

4. Tighten kingpin keeper plate bolts.

Tightening torque for bolts

Kingpin bolt

Keeper plate bolts

1.7 kgf·m (12.3 lbf·ft) {16.7 N·m]

3.4 kgf·m (24.6 lbf·ft) [33.4 N·m]

8609008

2.13

REAR AXLE: REASSEMBLY Reassembling Rear Axle Hub

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

Tightening torque for bolts

0.7 kgf·m (5 lbf·ft) [6.9 N·m]

1. The inner race of the inner bearing must be driven onto the shaft using a special tool as shown below.

All Bearing installer

64309-40400

Zerk

Dust seals

Rod Pin Bolt

8609010 205022

2.14

REAR AXLE: REASSEMBLY 2. Rear Axle Hub Reassembly There is a space between two tapered roller bearings inside the rear axle hub. Be sure to fill up this space with grease. Grease the oil seal lip groove and roller retainers, too. Do not overfill the oil seal lip groove as this can cause leakage.

3. Preload adjustment on hub bearings Bearing preload is specified. Tighten the inside nut first to secure the prescribed preload; after this tightening, tighten the outside nut (lock nut) to the specified torque value; and then re-check the preload. If the hub bearings (tapered roller bearings) have long been in service, it is advisable to aim at a value of preload in the lower half of the specified range.

Preload for hub bearing

Fill up with grease 205365

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

Tightening torque for lock nut

16kgf·m (115.7 lbf·ft) [157 N·m] Outside nut (lock nut) Inside nut 200469

2.15

REAR AXLE: INSPECTION

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

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

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

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

All Turning radius [unit: mm (in.)]

Steering angle Inside Outside

83° 56°

Tightening torque for knuckle stopper bolt lock nut

6.8 kgf·m (49 lbf·ft) [67 N·m]

EP16

1875 (73.8)

EP18

1875 (73.8)

EP20

2125 (83.7)

EP25

2125 (83.7)

EP30

2260 (89.0)

202800 2.16

Chapter 3: Transfer Case Differential Assembly

3.1

Transfer Case

3.2

Disassembly

3.3

Reassembly

3.4

TRANSFER CASE: DIFFERENTIAL

Differential Assembly

8 7 3 5

6

4 10

1

9

2 Description 1. Bearing cap

6. Output shaft

2. Output gear and Differential Assy.

7. Roller bearing

3. Cover (R.H.)

8. Plate

4. Cover (L.H.)

9. Gear

5. Plate

10. Nut, washer, taper roller bearing

3.1

TRANSFER CASE

Transfer Case

20

16

19 17 13

18

14 15 12

11

Description (2) 11. Bolts, lock plate

16. Snap ring

12. Idler shaft

17. Ball bearing

13. Gear

18. Input gear

14. Ball bearing

19. Ball bearing

15. Ball bearing

20. Transfer case

3.2

TRANSFER CASE

Disassembly Removal Sequence To remove, follow the sequence of description (1) and (2).

Remove Bearing Use a press to remove the bearing from the output shaft.

Remove Input Gear 1. Snap ring.

2. Input gear and ball bearing.

200091

NOTE Do not remove taper roller bearing (10) unless it is defective.

3.3

TRANSFER CASE: REASSEMBLY

Reassembly Installation To install, follow the reverse of removal sequence.

Suggestions Sub-Assemble as follows.

(1) Output shaft 6 and Nut, Washer, Taper roller bearing 10.

(2) Bolts, Lockplate 11 and Idler shaft 12.

(3) Gear 13 to Ball bearing 14 and Ball bearing 15.

3.4

Chapter 4: Steering System Description

4.1

Removal & Installation of Steering Wheel

4.2

Steering Gear Removal

4.3

Steering Gear Installation

4.4

Steering Gear Disassembly

4.5

Inspection after Disassembly

4.9

Steering Gear Reassembly

4.10

Inspection after Reassembly

4.15

STEERING SYSTEM: DESCRIPTION

Description

7 5

4

8

1

6

3 2

8609014

Oil Flow Sequence 5. Steering cylinder 1. From hydraulic tank 2. Hydraulic pump 3. Integral priority valve

6. Mast operating valve 7. To hydraulic tank 8. Pressure switch

4. Steer gear

General Information This steering system is a closed-center, loadsense circuit with a dynamic signal. The integral priority valve on the pump provides steering flow on demand, diverting the excess flow to the mast operating valve. The pressure switch increases the motor RPM for steering when the wheel is turned.

Load sense steering, with the ability to control flow and pressure, will react the same regardless of flow, this means smooth pressure-compensated steering. Standby losses are low because of low pump pressures. The dynamic signal provides fast response.

4.1

STEERING SYSTEM: REMOVAL & INSTALLATION

Removal and Installation of Steering Wheel

8609016

Sequence 1. Nut, washer 2. Wheel

Removal Use a special tool.

Special Tool

Part Number

Wheel puller

91268-10600

203466A

Installation To install, follow the reverse of the removal sequence.

4.2

STEERING SYSTEM: REMOVAL & INSTALLATION

Steering Gear Removal

Sequence 1. Hose connectors, O-rings 2. Mounting hardware 3. Steer gear 4. Spacer

!

WARNING

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

5. Grommet

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

For servicing the pump and valve, see HYDRAULIC SYSTEM section.

4.3

STEERING SYSTEM: REMOVAL & INSTALLATION

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

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

Tightening torque for bolts

4.4

3.4 kgf·m (24.6 lbf·ft) [33.4 N·m]

STEERING SYSTEM: STEERING GEAR DISASSEMBLY

Steering Gear Disassembly 1 2 6 7

3

4

5

8609017

Sequence 5. Needle thrust bearing 1. End cap, screws, seal 2. Meter, seal, spacer

6. Spool and sleeve assembly 7. Check valve

3. Spacer plate, drive, seal 4. Seal gland bushing assembly

4.5

STEERING SYSTEM: STEERING GEAR DISASSEMBLY Working Rules and Tips

Suggestions

The steering gear, complete with the control valve, is a precision-machined component. As such, it must be handled with extreme care. Cleanliness is imperative: work in a clean place and use clean tools.

Removing the End Cap Clamp the unit in a vise with the meter end up.

Clamp lightly on the edges of the mounting area, using protective material on the vise jaws. Housing distortion can result if the jaws are overtightened.

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

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

8609018

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

Oil seals Oil seals, once removed, must not be reused. After disassembly, examine the oil seals in place (in the gear box and side cover). If they are in good condition, leave them in place. When installing a replacement oil seal, be careful not to score or scratch the lip area.

Remove the cap screws and the end cap. Remove the seal from the end cap.

8609019

4.6

STEERING SYSTEM: STEERING GEAR DISASSEMBLY Removing the Meter Remove the meter, being careful not to drop the star. Remove the seal from the meter. Remove the drive spacer(s).

8609020

Removing the Drive Remove the drive and spacer plate. Remove the seal from the housing.

Rotate the spool and sleeve assembly until the pin is horizontal. Push the spool and sleeve assembly forward with your thumbs just far enough to free the gland from the housing.

8609023

Remove the quad ring seal from the seal gland bushing. Use a thin bladed screwdriver to pry the dust seal from the bushing. Do not damage the bushing.

8609021

8609024

Removing the Seal Gland Bushing Use a thin-bladed screwdriver to pry the retaining ring from the housing.

8609022

4.7

STEERING SYSTEM: STEERING GEAR DISASSEMBLY Removing the Needle Thrust Bearing Remove the two bearing races and the needle thrust bearing from the spool and sleeve assembly.

Push the spool partially from the control end of the sleeve and carefully remove the centering springs from the spool by hand. Push the spool back through and out of the sleeve. Rotate the spool slowly when removing it from the sleeve.

8609025

Removing Spool And Sleeve Assembly Remove the spool and sleeve assembly from the end of the housing. Do not bind the spool and sleeve assembly. Rotate it slowly when removing it from the housing. Push the pin from the spool and sleeve assembly.

8609027

Removing the Check Valve Remove the seal from the housing. Remove the set screw. Screw a #10-24 machine screw into the end of the check ball seat. Then, by pulling on the screw with the pliers, lift the seat out of the housing. Remove the two seals from the seat. Tip the housing to remove the check ball and check ball retainer.

8609026

8609028

4.8

STEERING SYSTEM: INSPECTION AFTER DISASSEMBLY

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

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

4.9

STEERING SYSTEM: STEERING GEAR REASSEMBLY

Steering Gear Reassembly 8 7 2 1

6

4 5

8609029

3 Sequence 1. Check valve

5. Spacer plate and seal

2. Spool and sleeve assembly

6. Drive

3. Needle thrust bearing

7. Meter and seal

4. Seal gland bushing assembly

8. End cap, screws, seal

4.10

STEERING SYSTEM: STEERING GEAR REASSEMBLY Reassembling the Spool and Sleeve

NOTE Replace all old seals with new seals. Lubricate all seals with clean petroleum jelly, such as, Vaseline.

Assemble the spool and sleeve so the spring slots line up. Rotate the spool while sliding the parts together.

Some sets have identification marks. Align these marks. Test for free rotation.

Suggestions Reassembling the Check Valve Use needlenose pliers to lower the check ball retainer into the housing. Make sure it is straight.

Install the ball into the housing.

Control sleeve

Spring slot

Spring slot

Lubricate the seals and install them on the check ball seat. Lubricate the seat and lower it into the housing. Do not twist or damage the seals. Push the seat to the shoulder of the housing.

Install the set screw. Use a 1/4” allen wrench to tighten the set screw. Make sure the top of the set screw is slightly below the housing mounting surface.

Tightening torque for set screw

Control spool Identification marks

8609031

Bring spring slots of both parts in line. Position one end of the centering springs in Spring Installation Tool and compress the other end. Push the spring set into the spool sleeve assembly while withdrawing the installation tool at the same time.

1.2 kgf·m (8.3 lbf·ft [11.3 N·m]

Special Tool

Part Number

Spring installation tool

97157-00100

Set screw

Seal

Check ball seat

Seal Check ball Check ball retainer 8609030

4.11

STEERING SYSTEM: STEERING GEAR REASSEMBLY Center the spring set in parts so they push down evenly and flush with the upper surfaces of the spool and sleeve.

Reassembling the Needle Bearing Install the seal in the housing. Install the two races and the needle thrust bearing as shown.

8609032

Install the pin through the spool and sleeve until it is flush at both sides of the sleeve.

Position the spool and sleeve assembly so the splined end of the spool enters the housing first.

8609033

NOTE Be extremely careful that the parts do not cock.

Push the parts gently into place with a slight rotation action. Keep the pin nearly horizontal and check for free rotation without allowing the pin to drop into the discharge groove in the housing.

4.12

8609034

STEERING SYSTEM: STEERING GEAR REASSEMBLY Reassembling the Seal Gland Bushing 1. Install the dust seal in the bushing with the flat or smooth side facing towards the bushing.

2. Install the quad ring seal in the bushing by smoothing it into place with your finger. Do not use any seal that falls freely into the pocket of the bushing.

Reassembling the Spacer Plate 1. Clamp the housing in a vise, clamping lightly over the edges of the mounting area. Do not overtighten the vise jaws.

NOTE Check to ensure that the spool and sleeve are flush or slightly below the surface of the housing.

3. Install the bushing assembly over the spool end with a twisting motion. Tap it into place with a rubber hammer. Make sure the bushing is flush against a bearing race.

8609037

8609035

4. Install the retaining ring in the housing and tap on the ring end, or pry it with a screw driver around the entire circumference, to properly seat it in the groove.

NOTE Clean the mounting surface of the housing by wiping with the palm of a clean hand. Clean each of the flat surfaces of the spacer and meter in a similar way prior to reassembly.

Do not use a cloth or paper towel to clean these surfaces.

2. Install the seal in the housing. Place the spacer plate on the housing and align the bolt holes with the tapped holes in the housing.

8609036

8609038 4.13

STEERING SYSTEM: STEERING GEAR REASSEMBLY Reassembling the Driver

Reassembling the Meter

1. Place a mark across the splined end of the drive to indicate the direction of the slot at the opposite end of the drive.

2. Rotate the spool and sleeve assembly until the pin is parallel with the port face. Install the drive and make sure it engages the pin.

This mark should be parallel to the port face.

1. Install seal in the meter.

Meter (Gerotor)

Seal 8609040

Port face Drive

Pin parallel with port face Pin 8609039

2. With the seal side of the meter towards the spacer plate, align the star valleys (A) on the drive (B). Note the parallel relationship of reference lines A,B,C, and D. Align the bolt holes without disengaging the meter from the drive.

Meter (Gerotor) star valley

Drive (marked)

Pin

4.14

Port face 8609041

STEERING SYSTEM: INSPECTION AFTER REASSEMBLY Reassembling the End Cap

Inspection after Reassembly

1. Install the drive spacer(s) in the meter. Install the seal in the end cap. Install the end cap on the meter and align the holes.

Drive spacers(s)

Cap screw

End cap

Seal

Check the steer gear for smooth, free rotation in both directions.

Seal washer

8609042

2. Install dry cap screw(s) with new washers.

Pretighten all of the screws, then torque them in the sequence shown below.

4

6

2

1

3

7 5

8609043

Pretightening torque for bolts

1.7 kgf·m (12.5 lbf·ft) [17N·m]

Final tightening torque

3.2 kgf·m (23 lbf·ft) [31.2 N·m]

4.15

Chapter 5: Front Axle Description

5.1

Front Axle & Reduction Differential Description

5.2

Removal & Installation

5.3

Removal

5.7

Installation

5.8

FRONT AXLE: DESCRIPTION

Description 4

6

8

3 1

7 2 5

203658

1. Front wheel hub

5. Reduction pinion

2. Frame support

6. Reduction gear

3. Axle shaft

7. Differential case

4. Axle housing

8. Differential carrier

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

5.1

FRONT AXLE AND REDUCTION DIFFERENTIAL

Description

11

10 12 2

9 13

3 5

14

1

6

7

11.

12.

13.

14.

Drive gear Driven gear Differential case Backing plate

8 4

1.

2.

3.

4.

5.

Front wheel hub Frame support Axle shaft Axle housing Differential pinion

6.

7.

8.

9.

10.

Differential gear Differential carrier Reduction gear Reduction pinion Input flange

The frame support is bolted to the front axle housing, together with the backing plate of wheel brake.

The hub carries a single tire. The reduction

5.2

differential is mounted on the axle housing. The input flange carries a drive gear which is in mesh with the driven gear mounted on the reduction pinion.

FRONT AXLE AND REDUCTION DIFFERENTIAL

Removal and Installation Front Wheels NOTE

!

WARNING

Servicing and changing tires and rims can be dangerous and should be done only by trained personnel using proper tools and procedures. If correct procedures are not followed while servicing tires and rims, the assemblies could burst with explosive force and cause serious physical injury or death. Follow carefully the specific information provided by your tire servicing company or dealer.

Use a tire inflation gauge and stand behind the tread when inflating a tire and checking tire pressure.

Proper inflation equipment and training in using the equipment are necessary to reduce the risk of overinflation. A tire blowout or rim failure can result from improper or misused equipment.

!

CAUTION

● Always deflate tires before changing

them, to prevent a tire explosion.

When changing tires, change them in sets, even if only one of the tires is damaged. If new and used tires are used on the same axle, tilting of the mast and rapid tire wear will result.

The mounting faces of the hub, wheel nuts and wheels must be free of any foreign material and lubricants of any kind. Tighten wheel nuts again after 24 hours of operation.

Do not reinflate a tire mounted on a split type rim that has been driven on while flat, or underinflated without inspecting the rim for damage and checking the lock ring for proper installation.

2 1

● Make sure the replacement tire is

the same size, type and load range. ● Make sure the replacement tire is

properly inflated.

200225

Removal 1. Wheel nuts 2. Front Wheel

5.3

FRONT AXLE AND REDUCTION DIFFERENTIAL Suggestions

Wheel nut

1. Block the rear wheels.

2. Pull the parking brake lever, and loosen the wheel nuts one to two turns.

!

WARNING Rim nut

DO NOT LOOSEN RIM NUTS. 100902 3. Slightly deflate tires to be removed.

4. Raise the front end of the truck by jacking or hoisting.

!

Jack Capacities

WARNING

1) To avoid the possibility of personal injury, DO NOT attempt to change the tire with the truck loaded .

2) BE SURE to get off the truck when raising the front or rear tire.

EP16, EP18

3 tons (6700 lb) minimum

EP20 thru 30

5 tons (12000 lb) minimum

3) Stop raising the truck when the tire clears the ground. To avoid the possibility of personal injury, DO NOT raise the truck more than is necessary.

4) DO NOT put any portion of your body under the truck. SECURELY SUPPORT with blocks after jacking.

Method Using a Hoist Attach a sling to the round holes in the top crossmember and lift the front end with a hoist.

5.4

204845A

FRONT AXLE AND REDUCTION DIFFERENTIAL Method Using Hydraulic System Tilt the mast all the way back. Put wood blocks under the mast, and tilt the mast forward to raise the front end.

NOTE After raising the front end, securely support it by blocking properly.

5. Remove the wheel nuts (loosened in step 2).

!

200227

CAUTION

Be careful NOT to strip the bolt threads when removing the wheel.

6. Firmly grip the wheel with both hands and remove it from the truck.

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

!

CAUTION

Use the same size and brand tire.

Wheel Nut

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

1. Install the tire and tighten the wheel nuts so the tire will not rattle. Tighten each wheel nut until its tapered portion comes into full-face contact with the counterbore in the rim.

Counterbore

100835

5.5

FRONT AXLE AND REDUCTION DIFFERENTIAL 2. Lower the truck by operating the jack until the tire just touches the ground. Then tighten the wheel nuts in the sequence shown, in two or three steps, to the specified torque.

3. Lower the truck fully, inflate tires and restore the jack and tire.

Tightening torque for wheel nuts

EP 16-25

EP30

16kfg·m (116 lbf·ft) [157 N·m]

38.5 kgf·m (278 lbf·ft) [378 N·m]

4. Check to make sure the tire pressure is correct. For tire pressure, see SERVICE DATA.

100836

Tightening Sequence

NOTE The tire pressure is indicated on the nameplate attached on the left top side of the battery hood.

5. After tire replacement, drive the truck for a while and check the wheel nuts for tightness.

!

200230

WARNING

When adding air to the tire or when checking tire pressure, BE SURE to keep your body away from the the side. The use of an inflation cage, or some other safety device helps reduce the risk of injury.

When adding air to the tire using an air compressor, make sure the compressor valve is correctly set. Failure to follow this precaution may cause serious injury or may damage the tire. Always maintain correct tire pressure.

100904A

5.6

FRONT AXLE AND REDUCTION DIFFERENTIAL

Removal

11 9

4 5 10

12

2 3

6 7

13

14

8 1

DRAIN PLUG

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

NOTE 1) For removal of front wheel 1, refer to Removal, Front Wheels.

2) For removal of mast parts 2 thru 8, refer to MAST AND FORKS.

8.

9.

10.

11.

12.

13.

14.

Mast Brake pipe Parking brake cable Motor Bolt, nut Bolt Front axle and reduction differential

!

WARNING

Hot oil and components can cause serious injury. DO NOT allow hot oil or components to contact skin.

3) Before removing the front axle and reduction differential, drain differential oil by removing the front axle drain plug.

5.7

FRONT AXLE AND REDUCTION DIFFERENTIAL Removing parking brake To remove the parking brake cable, remove the parking brake lever from the dashboard, and disconnect the cable from the lever.

Parking brake lever operating effort

20 to 30 kgf (55 to 66 lbf) [245 to 294 N]

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

1. After installing the parking brake cable, make sure the brake lever operating effort is within the specification.

2. Before installing the mast, bleed the brake fluid circuits. For bleeding, refer to BRAKE SYSTEM. 3. After installing the mast, make sure the tilt angles, forward and backward, are correct and the lift chains, right and left, are equal in tension. Refer to MAST AND FORKS. 4. Fill the front axle housing with oil up to the plug hole.

5.8

Refill capacity of front axle housing

1-ton models 2-ton and 3-ton models

5.7 liters (1.5 U.S. gal) 6.1 liters (1.6 U.S. gal)

Chapter 6: Brake System Description

6.1

Master Cylinder Disassembly

6.2

Inspection after Disassembly

6.3

Reassembly

6.3

Wheel Brakes Disassembly

6.4

Inspection after Disassembly

6.6

Brake System Reassembly

6.8

Wheel Cylinder Disassembly

6.11

Inspection after Disassembly

6.12

Reassembly

6.12

Inspection & Adjustment

6.13

BRAKE SYSTEM: DESCRIPTION

Description Automatic Adjusting Device

205955

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

6.1

BRAKE SYSTEM: MASTER CYLINDER

Master Cylinder

8

(★) 5 23

7

6

4

1 204924

Disassembly Sequence 1. Clevis, lock nut, push rod

5. Spring seat, primary cup, cup spacer

2. Boot

6. Return spring

3. Stopper ring

7. Cylinder body

4. Secondary cup, piston

8. Fluid reservoir, wire band

NOTE The parts (*) to be changed periodically are involved in the Repair Kit.

6.2

BRAKE SYSTEM: MASTER CYLINDER

Inspection after Disassembly 1. Brake fluid level sensor (1) Fill the reservoir with brake fluid.

Connect the level sensor connector at the bottom of fluid reservoir, and turn the key switch to ON. (2) The sensor is satisfactory if the brake fluid level warning light on the monitor flashes when the filler of the reservoir is positioned downward and goes out when it is positioned upward.

OFF

ON 200270

2. Cylinder body (1) Check the bore of the cylinder for rusting, erosion and scoring.

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

A= Assembly Standard B= Repair or service limit Unit: mm (in.)

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

Clearance between piston and cylinder

A B

0.020 to 0.105 (0.00079 to 0.00413) 0.2 (0.008)

4. Return spring Replace the return spring every year.

5. Primary cup, secondary cup and valve Check these rubber parts for swelling, tearing and deterioration due to aging. Replace them every year.

Reassembly To reassemble, follow the reverse of disassembly procedure including the following.

(1) Wash all metal parts with a volatile cleaning solvent, and dry them with pressure air.

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

6.3

BRAKE SYSTEM: WHEEL BRAKES

Wheel Brakes Disassembly 10 9

9

6 3 1

11

5 8

7 2

3

5

*

4 200100

Sequence 1. Return spring

7. Strap, anti-rattle spring

2. Fitting cable

8. Shoe and lining (primary), parking brake lever, retainer, spring washer

3. Hold-down spring, cup, pin 4. Adjusting lever, adjusting spring, return spring 5. Cable guide, sheave, adjusting screw, pin, washer 6. Shoe guide plate, shoe and lining, secondary

NOTE The parts (*) to be changed periodically are involved in the Repair Kit.

6.4

9. Wheel cylinder 10. Parking brake cable 11. Backing plate

BRAKE SYSTEM: WHEEL BRAKES To Start:

!

WARNING

Wood blocks or jack stands of the correct capacity must be used under the machine to reduce the risk of the machine unexpectedly falling. Failure to do so can result in injury or death.

1. Remove the front wheel.

2. Remove the wheel hub and brake drum.

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

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

6.5

BRAKE SYSTEM: WHEEL BRAKES Suggestions 1. Return spring removal Use a special tool to remove the return springs.

Special tool needed Spring remover

1022755 200271

2. Hold-down spring removal Use a special tool to remove the hold-down springs.

Special tool needed Spring retainer

1022754

Inspection after Disassembly 200272

1. Backing plate (1) Check the backing plate for cracks.

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

Tightening torque for backing plate mounting bolts

16 kgf·m (116 lbf·ft) [157 N·m]

2. Shoes and linings (1) See pg. 6-7. Check each shoe and lining for cracks.

(2) Replace the lining if it is dirty with grease matter, burnt or glazed.

(3) Check the thickness of the lining and replace the lining if it is in excess of the service limit.

A Thickness of linings B

EP16/18

EP20-30

4.87 (0.19) 2.5 (0.10), maximum

6 (0.24) 3 (0.12), maximum

A=Assembly standard B=Repair or service limit

6.6

203005

BRAKE SYSTEM: WHEEL BRAKES 3. Brake drums Check the inside (friction) surface of the drum for abnormal wear, grooving and other defects. Minor grooving can be removed by grinding, provided the service limit on the inside diameter is not exceeded.

4. Adjusting screws Check the wheel teeth for wear. Turn the screw by hand to see if its rotating parts turn smoothly.

Inside diameter of brake drum

A B

EP 16/18

EP 20-30

254 +0.13 0 (10 +0.0051) 0

310 +0.15

256 (10.08)

0

(12.2 + 0.0059) 0

312 (12.28)

A=Assembly standard B=Repair or service limit Unit: mm (in.)

5. Parking brake cable Replace a cable found permanently stretched, rusted or damaged.

6. Others (1) Check the return springs for cracks or fatigue.

(2) Check the adjusting springs for cracks or fatigue.

200074 (3) Check the fitting cables for stretching.

6.7

BRAKE SYSTEM: WHEEL BRAKES

Brake System Reassembly

203586

Sequence 1. Wheel cylinder

9. Hold down spring, cup, pin

2. Backing plate

10. Shoe guide plate

3. Shoe and lining (primary)

11. Fitting cable

4. Parking brake lever

12. Return spring

5. Retainer, washer

13. Cable guide, sheave, pin, washer

6. Shoe and lining (secondary)

14. Adjusting lever, adjusting screw, adjusting

7. Strap 8. Anti-rattle spring

6.8

spring

BRAKE SYSTEM: WHEEL BRAKES Suggestions 1. Wheel cylinder installation Apply the liquid packing to the mounting face of the wheel cylinder before positioning the cylinder in place; secure it by tightening to the specified torque.

Tightening torque for wheel cylinder

EP 16/18

EP 20-30

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

1.8 to 2.7 (13 to 20) [18 to 26]

200275

Unit: kgf•m(lbf•ft)[N•m] 2. Greasing Apply the specified brake grease to the following parts, forming a thin coat of grease at each.

(1) Shoe ledges (6 places) The ledges are those portions of the backing plate in contact with the shoe (2) Anchor pin surface in contact with the shoe ends 3. Shoe and lining installation Be sure each push rod of the wheel cylinder is snugly fitted to its shoe web.

4. Return spring installation Use a special tool to install the return springs to the backing plate pins.

Special tool needed Spring installer

1022756

200276

6.9

BRAKE SYSTEM: WHEEL BRAKES 5. Automatic adjusting device installation (1) Have the adjusting screw and associated parts washed clean, and grease the screw threads and screw socket. Check to be sure the screw turns smoothly when rotated by hand. If the screw is hard to turn, replace it with a new one.

(2) Distinguish the right-hand adjusting screw and lever from the left-hand one by the color: Right-hand adjusting screw and lever (left-hand thread) Yellowish color Left-hand adjusting screw and lever (right-hand thread) Whitish color

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

6.10

299266

BRAKE SYSTEM: WHEEL CYLINDERS

Wheel Cylinder Disassembly

200278

200279

Sequence 1. Connector link

5. Return spring

2. Boot

6. Bleeder screw, cap

3. Piston

7. Cylinder body

4. Piston cup

NOTE The parts (*) to be changed periodically are involved in the Repair Kit.

6.11

BRAKE SYSTEM: WHEEL CYLINDERS

Inspection after Disassembly 1. Cylinder bodies (1) Check the bore for rusting, erosion and scoring.

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

2. Pistons 200280

(1) Check the sliding surface for rusting and scratching.

(2) Check the piston clearance in the cylinder body. Replace the cylinder body and piston if the clearance is in excess of the service limit.

Clearance between A piston and cylinder B

EP 16/18

EP 20-30

0.040 to 0.125 (0.00157 to 0.00492)

0.020 to 0.105 (0.00079 to 0.00413)

To reassemble, follow the reverse of disassembly.

Include the following steps.

0.15 (0.0059)

(1)

A=Assembly standard B=Repair or service limit Unit: mm (in.)

Coat the piston cups and the cylinder bore with brake fluid.

(2)

Be careful not to damage the lips of the cups.

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

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

6.12

Reassembly

BRAKE SYSTEM: WHEEL CYLINDER

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

200281

2. If the lever fails or is sluggish to turning the adjusting screw in the above test, the likely cause is the lever is not properly positioned relative to the toothed wheel. Be sure the lever is so positioned that its actuating tip touches the toothed wheel at a level about 9mm (0.36 in.) under the center line of the screw, as shown.

3. Where the automatic adjusting device is suspected of malfunctioning during normal use of the machine, the following possible causes must be considered.

(1) Adjusting spring is not correctly hooked to primary shoe.

(2) One of these parts is in bad condition and requires replacement: a) fitting cable, b) adjusting lever, and c) adjusting screw.

200282

Adjusting toothed wheel and lever positions

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

200283

6.13

BRAKE SYSTEM: WHEEL CYLINDER Brake Pedal Adjustment 1. Set the height A (from the toe plate to the bottom of pad) of the pedal to the specified value.

Toe Plate

2. Set the freeplay of push rod to 3mm.

Pedal height A

EP 16/18

EP 20-30

125 (4.9)

135 (5.3)

Free play

Unit: mm(in.)

Bleeding Air Out of the Brake Fluid Line Whenever any part of the brake fluid line is disconnected in servicing work, an air bleeding operation must be carried out to complete the work. With air trapped in any part of the fluid line, the pedal will “feel” spongy.

The procedure for air bleeding operation is as follows.

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

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

200285

NOTE 1) Be sure that, at no time during the bleeding operation, the reservoir becomes empty of fluid.

2) Use the specified brake fluid. Avoid different brands of brake fluid getting mixed before and after filling up the reservoir.

3. Carry out the above steps with each wheel brake, and fill up the brake fluid reservoir to level.

Brake Test After completion of necessary adjustments, test the brake force by operating the truck at a speed of 10 km/h (6.2 mph).

Refer to Manual Adjustment for necessary re-adjustment.

6.14

Chapter 7: Hydraulic System Description

7.1

Hydraulic Tank

7.2

Hydraulic Pump

7.3

Control Valve

7.5

Tilt & Lift Cylinder

7.6

Flow Regulator Valve

7.7

Down Safety Valve

7.8

Removal & Installation Warning

7.9

Pump Removal

7.10

Pump Installation

7.11

Pump Disassembly

7.12

Inspection after Disassembly

7.16

Pump Reassembly

7.18

Inspection after Assembly

7.24

Priority Valve Disassembly

7.25

Priority Valve Reassembly

7.28

Control Valve Removal

7.32

Control Valve Installation

7.33

Control Valve Disassembly

7.34

Control Valve Inspection and Reassembly

7.36

Hydraulic System Disassembly

7.37

Hydraulic System Installation

7.39

Tilt & Lift Cylinder Disassembly

7.41

Tilt & Lift Cylinder Inspection after Disassembly

7.43

Flow Regulator Valve Disassembly

7.44

Hydraulic System Inspection & Adjustment

7.45

Control Valve Inspection & Adjustment

7.46

Tilt & Lift Cylinder Inspection & Adjustment

7.48

Adjustment Method

7.49

Testing

7.50

HYDRAULIC SYSTEM: DESCRIPTION

Description 10

9

9

4 1

5 3 2

8

8 1 6

8609092

Schematic 1. Hydraulic tank

8. Lift cylinder

2. Hydraulic pump

9. Tilt cylinder

3. Integral priority valve

10. Steering cylinder

4. Steer gear

11. Steering pressure switch

5. Mast operating valve

General Information

6. Flow regulator valve

The hydraulic pump draws oil from the oil tank via an integral priority valve. Priority flow, if directed to the steer gear and excess flow, is diverted to the mast operating valve. The steer gear is covered in the STEERING SYSTEM section and the cylinder is covered in the REAR AXLE section.

7. Down safety valve

7.1

HYDRAULIC SYSTEM: DESCRIPTION

Hydraulic Tank 1

2

6

4

3 5

8609093

1. Cap

4. Return line filter

2. Oil level gauge

5. Suction line strainer

3. Drain plug

6. Lift cylinder return pipe

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

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

7.2

HYDRAULIC SYSTEM: DESCRIPTION

Hydraulic Pump

8609094

General Information This gear pump is capable of developing very high pressure on its discharge side. A special arrangement is incorporated in the pump construction for the purpose of keeping the side clearances minimized between bushings on the one side and pump gears on the other. Note, in illustration 203585 (page 7.4), that discharge pressure is applied to the back of each bushing through internal oilways.

7.3

HYDRAULIC SYSTEM: DESCRIPTION Hydraulic Pump Operation

Pressure Loading Principle

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

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

203585

200333

Integral Priority Valve The pump is equipped with an integral priority valve, which provides oil flow on demand to the steering system based on an external pilot signal.

Excess flow is diverted to the mast operating valve for the lift, tilt, and auxiliary functions.

7.4

HYDRAULIC SYSTEM: DESCRIPTION

Control Valve

203486 1. Inlet cover

7. From steering control valve

2. Lift valve assembly

8. To tank

3. Tilt valve assembly

9. Main relief valve

4. Attachment valve assembly

10. Tie bolt

5. End cover

11. Nut

6. Pump port

12. Shutoff valve

General Information The control valve consists of three valve blocks, all spool-type. The spools are finished by lapping for their respective blocks and their combination should not be changed. The lift valve assembly has a built-in tilt lock valve. When necessary, the attachment valve assembly has a built-in overload relief valve. If the overload relief valve is not used, a shut-off valve is installed.

7.5

HYDRAULIC SYSTEM: DESCRIPTION

Tilt and Lift Cylinders

200345

205979

General Information The left and right lift cylinders are single-acting types. A return pipe is tied into its rod-side port in order to admit hydraulic oil from the oil tank when the piston goes down. By this feature, the top portion of the cylinder wall is protected against rusting.

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

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

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

7.6

HYDRAULIC SYSTEM: DESCRIPTION

Flow Regulator Valve

203558

General Information The flow regulator valve is located between each lift cylinder and control valve. It limits the flow of oil forced out of the cylinder when the loaded forks are lowered to keep a safe constant lowering speed regardless of load.

7.7

HYDRAULIC SYSTEM: DESCRIPTION

Down Safety Valve

204971

General Information The down safety valve is located at the bottom side of the right-hand lift cylinder. This valve provides a means of preventing the load from unsafely lowering rapidly when the hose bursts.

7.8

HYDRAULIC SYSTEM: GENERAL WARNING

Removal and Installation Warning !

WARNING

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

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

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

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

7.9

HYDRAULIC SYSTEM: PUMP REMOVAL

Pump Removal

8609095

Sequence 1. Hardware 2. Pump

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

5. Separate the pump from the motor.

2. Disconnect the hoses attached to the pump fittings.

6. Remove the hydraulic fittings from the pump.

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

4. Remove side sheet metal. Loosen pump motor bracket bolts so the pump and motor assembly can slide out.

7.10

HYDRAULIC PUMP: INSTALLATION

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

2. Lubricate the pump and motor shaft spline joint with Multipurpose Molybdenum Grease prior to bolting the pump to the motor.

3. Tighten hoses to the following specifications.

Tightening Torque for Hoses A

Supply hose from pump to mast operating valve

10.3 to 11.7 kgfm (74 to 85 lbf·ft) [101 to 115 N·m]

B

Supply hose from pump to steer gear

5.6 to 6.0 kgf·m (40 to 43 lbf·ft) [55 to 59 N·m]

C

Load sense feedback hose from steer gear

1.7 to 2.2 kgf·m (12 to 16 lbf·ft) [17 to 22 N·m]

8609096

7.11

HYDRAULIC SYSTEM: PUMP DISASSEMBLY

Pump Disassembly

8609099

Sequence 1. Priority valve

6. Front bushes

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

7. Drive shaft

3. Flange

8. Gear pack

4. Shaft seal and retainer ring

9. Body and rear bushes

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

7.12

HYDRAULIC SYSTEM: PUMP DISASSEMBLY Working Rules and Tips

Oil Seal

The hydraulic pump, complete with the priority valve, is a precision-machined component and as such, must be handled with extreme care.

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

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

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

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

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

Never clean them with solvent. Blow dirt off rubber parts with compressed air and keep them immersed in hydraulic oil until they are ready for reassembly. A rubber part showing even slight wear and tear must be replaced.

Rubber parts are expendable items that should be replaced once a year.

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

7.13

HYDRAULIC SYSTEM: PUMP DISASSEMBLY Suggestions

Removing the Flange

Removing the Priority Valve

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

Slide the flange squarely off the shaft.

1. Lightly mark the priority valve body, pump body, and mounting flange to ensure proper reassembly.

2. Remove the rear bolts, spring washers, and the priority valve.

NOTE Set the priority valve assembly aside or go on to page no. 7.25 which discusses the disassembly and the reassembly of the priority valve.

8609101

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

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

8609102 8609100

7.14

HYDRAULIC SYSTEM: PUMP DISASSEMBLY Removing the O-ring and Seals

Removing the Drive Shaft

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

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

8609104

8609103

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

FD = Bush on flange end of the drive shaft

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

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

FI = Bush on flange end of idler shaft

Removing the Rear Bushes CD = Bush on the cover of priority valve end of the drive shaft

Remove the remaining rear bushes from the body bore.

CI = Bush on the cover end of the idler shaft

8609105

7.15

HYDRAULIC SYSTEM: INSPECTION AFTER DISASSEMBLY

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

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

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

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

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

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

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

Characteristically, there are bright polished areas on this surface caused by loading against the 7.16

gear side faces. This is often more pronounced on the low-pressure side. These should be replaced if there is any general scoring or fine scoring with a matte appearance or tearing of the surface material.

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

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

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

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

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

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

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

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

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

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

7.17

HYDRAULIC SYSTEM: PUMP REASSEMBLY

Pump Reassembly

8609106

Sequence 6. O-ring, bush seal, and backup seal 1. Body and rear bushes 2. Priority valve 3. Driveshaft and idler shaft 4. Gear pack

7. Shaft seal 8. Flange 9. O-ring, bush seal, and backup seal 10. Bolts

5. Front bushes

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

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

7.18

HYDRAULIC SYSTEM: PUMP REASSEMBLY Reassembling the Rear Bushes

Fixturing with the Priority Valve

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

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

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

8609107

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

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

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

8609109

8609108

7.19

HYDRAULIC SYSTEM: PUMP REASSEMBLY Reassembling the Gear Pack

Reassembling the Front Bushes

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

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

They must match the rear end bushes.

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

8609111 8609110

7.20

HYDRAULIC SYSTEM: PUMP REASSEMBLY Reassembling the O-ring and Seals

Reassembling the Shaft Seal

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

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

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

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

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

8609112

8609102

7.21

HYDRAULIC SYSTEM: PUMP REASSEMBLY Reassembling the Flange

Reassembling the Rear O-ring and Seals

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

1. Hold the whole unit together and carefully turn it over. Ensure it is supported on the mounting flange, not the driveshaft.

2. Remove the priority valve and install a new O-ring, bush seal, and backup seal.

8609113

8609114

7.22

HYDRAULIC SYSTEM: PUMP REASSEMBLY Reassembly the Priority Valve Replace the priority valve and refit the bolts and washers. Tighten the bolts.

8609115

Tightening torque for bolts

EP16 / 18

EP20 - 30

4.7 to 5.2 kgf·m (34 to 38 lbf·ft) [46 to 51 N·m]

9.0 to 10.4 kgf·m (65 to 75 lbf·ft) [88 to 102 N·m]

7.23

HYDRAULIC SYSTEM: INSPECTION AFTER ASSEMBLY

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

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

pressure should then be increased in intervals of 35 bars a minute until maximum pressure is reached. Check the system temperature frequently, ensuring it does not exceed the maximum permissible temperature of 80°C (176°). If the temperature exceeds the system or unit specification, the test must be delayed and operated off-load until the temperature is lowered to an acceptable range.

Typical pump ratings are shown in the table below.

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

It is recommended that initially, the unit is run in at 1500 rpm at zero pressure for one minute. The

Pressure gauge

Test unit

Micronic filter

Relief valve

Strainer Tank

Variable restrictor

Flow meter

Typical pump test circuit 8609116

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

Test Speed

Max. Continuous Pressure

Flow Rate

97171-13200

1500 rpm

253 kg/cm2 (3335 psi) [227 bar]

33.8 I/min (7.44 gpm)

97271-00800

1500 rpm

255 kg/cm2 (3625 psi) [247 bar]

42.88 I/min (9.43 gpm)

7.24

HYDRAULIC SYSTEM: PRIORITY VALVE DISASSEMBLY

Priority Valve Disassembly

8609117

Sequence 7. Core plug 1. Body plug 2. Spring seat 3. Spring and spacer 4. Spool

8. Relief valve seat 9. Relief valve 10. Spring 11. Valve body

5. Spool plug 6. Filter

NOTE For information on removing the pump from the truck and the priority valve from the pump, see page 7.10

7.25

HYDRAULIC SYSTEM: PRIORITY VALVE DISASSEMBLY Removing the Body Plug

Removing the Spool

Remove the body plug from the valve body.

Remove the O-ring from the plug.

Remove the spool from the valve body.

8609121 8609118

Removing the Spring Seat

Removing the Spool Plug

Remove the spring seat from the valve body.

Remove the O-ring from the seat.

To prevent damage, unscrew the spool plug (damping orifice) from the end of the spool by holding the spool on the unground surfaces.

8609122 8609119

Removing the Spring

Removing the Internal Filter

Remove the spacer (if present) and the spring from the valve body through the opening created by the removal of the spring seat.

Remove the filter from the inside of the spool.

8609123

8609120

NOTE The relief valve is preset for optimum operation of the steering system and should not be removed unless absolutely necessary.

7.26

HYDRAULIC SYSTEM: PRIORITY VALVE DISASSEMBLY Removing the Core Plug

Removing the Valve

Remove the core plug to gain access to the relief valve seat.

Remove the filter valve from the valve body.

8609126 8609124

Removing the Spring Removing the Valve Seat Remove the spring from the valve body.

Unscrew the valve seat. This item is peened in position as part of the setting process and it may be necessary to locally drill to ease removal.

8609127

8609125

Priority Valve Inspection After Disassembly Examine the spool and bore for signs of damage.

Check the orifices in the spring seat, the spool plug, and the spool to make sure they are free and clear of contaminants.

Inspect the relief valve seat for wear or damage.

7.27

HYDRAULIC SYSTEM: PRIORITY VALVE REASSEMBLY

Priority Valve Reassembly

8609128

Sequence 1. Relief valve

4. Spring

2. Filter

5. Body plug

3. Spool and plug

6. Spring seat

7.28

HYDRAULIC SYSTEM: PRIORITY VALVE REASSEMBLY Reassembling the Relief Valve

Reassembling the Spring

1. Replace the relief valve components. Ensure the valve remains properly located in the valve seat.

Replace the spring in the valve body. Insert the spacer if the valve had one originally.

2. Screw the valve seat in just far enough to take up the spring load. The relief valve pressure will require setting on the truck or on a test rig.

8609132

8609129

Reassembling the Internal Filter Reassembling the Body Plug

Insert a new filter into the spool.

Install the new O-ring on the body and screw the plug into the valve body. Tighten the plug.

8609130

Tightening torque for plug

7.6 to 8.2 kgf·m (55 to 59 lbf·ft) [75 to 80 N·m]

Reassembling the Spool 1. Apply a small amount of Loctite 542 to the threads of the plug (dampening orifice) and screw into the spool to hold the filter in place.

Tighten the plug.

Tightening torque for plug

1.4 kgf°m (10lbf·ft) [14 N·m]

2. Reinstall the spool in the valve body.

8609133

8609131

7.29

HYDRAULIC SYSTEM: PRIORITY VALVE REASSEMBLY Reassembling the Spring Seat

Reassembling the Pump Valve

1. Install a new O-ring on the spring seat. Screw the spring seat into the valve and tighten.

1. Replace the priority valve on the pump. Ensure the inlet to the valve in the near face is over the high pressure-side of the pump (semicircular cutout in the bushes).

Tightening torque for spring seat

9.8 to 10.7 kgf·m (74 to 78 lbf·ft) [100 to 105 N·m]

2. Tighten the bolts.

EP16/18 4.7 to 5.2 kgf·m Tightening torque (34 to 38 lbf·ft) for bolts [46 to 51 N·m]

EP20-30 9.0 to 10.4 kgf·m (65 to 75 lbf·ft) [88 to 102 N·m]

8609134

8609115

7.30

HYDRAULIC SYSTEM: PRIORITY VALVE REASSEMBLY Running in Priority Valve after Reassembly

Resetting the Relief Valve

1. If new components have been fitted to the pump, in addition to disassembly of the priority valve, the pump must be run in before it is subjected to full working pressures. See the requirements for running in the pump, in the pump section.

1. Install the pump and priority valve in the test rig or in the application.

2. To do this after changes have been made to the priority valve, make sure the relief valve is screwed in solidly and the main valve spool and spring are removed, but the cap is replaced.

3. Blank port P and the load sense connection and fit the test rig loading circuit to port EF.

2. Fit a pressure gauge and variable restrictor to the line from valve port P. The gauge should be between the port and the restrictor. Connect the LS port between the valve and the variable restrictor to ensure that flow is demanded from port P. 3. Run the pump at normal operating speed, close restrictor, and adjust the relief pressure by screwing the valve seat in or out until the correct level is reached.

4. Run the pump in at up to: 15.3 kg/cm2 (218 psi) [15 bar]

EP16/18

below the maximum pressure quoted in the pump run-in section table. Refit the main spool and spring and unscrew the relief valve for resetting.

51 kg.cm2 (725 psi) [50 bar]

Relief pressure setting

EP20-30 81.5 kg.cm2 (1160 psi) [80 bar]

4. Peen the valve seat in position using a center punch to prevent movement during operation. Fit a new core plug.

7.31

HYDRAULIC SYSTEM: CONTROL VALVE REMOVAL

Control Valve Removal

8

1

2

3

4 9

8

7 6 5

Sequence

8609097 5. Lift pipe

1. Clevis pins and rods

6. Steering return hose and connector

2. Tilt lines, connectors, and O-rings

7. Return hose

3. Auxiliary line plugs

8. Switches

4. Delivery hose, connector, and O-ring

9. Control valve

To Start: 1. Remove the floorplates and control valve switch cover.

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

7.32

3. Disconnect the battery.

4. Disconnect the wire leads to the valve switches.

HYDRAULIC SYSTEM: CONTROL VALVE INSTALLATION

Control Valve Installation

8609098

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

Tightening Torque for Hoses

2.5 to 3.5 kgf·m (1.8 to 25 lbf·ft) [24 to 24 N·m]

A

Tilt hoses

B

Delivery hose EP16/18

8.9 to 9.7 kgf·m (64 to 70 lbf·ft) [87 to 95 N·m]

C

Delivery hose EP20-30

10.3 to 11.7 kgf·m (74 to 85 lbf·ft) [101 to 115 N·m]

2. Tighten hoses to the following specifications.

7.33

HYDRAULIC SYSTEM: CONTROL VALVE DISASSEMBLY

Control Valve Disassembly

8609135

7.34

HYDRAULIC SYSTEM: CONTROL VALVE DISASSEMBLY Sequence 19. Elbow and O-ring 1. Tie rod nuts 2. End cover 3. Spring and poppet 4. O-ring 5. Attachment section 6. Spring and poppet 7. O-ring 8. Tilt section 9. O-ring 10. Lift section 11. O-ring 12. Inlet section 13. Main relief valve 14. Cap

20. Plug and O-ring 21. Plug, O-ring, poppet, and spring 22. Cap 23. Spool 24. Screw, seat, O-ring, and spring 25. Plate, wiper, and O-ring 26. Tilt lock valve and spring 27. Plate, wiper, O-ring, and screw 28. Cap 29. Spool 30. Screw, seat, and spring 31. Plate, wiper, and O-ring 32. Plate, wiper, O-ring, and screw 33. Shut-off valve assembly

15. Spool 16. Screw, seat, and spring 17. Plate, wiper, and O-ring 18. Plate, wiper, O-ring, and screw

7.35

HYDRAULIC SYSTEM: CONTROL VALVE INSPECTION & REASSEMBLY Suggestions

Inspection after Disassembly

Main Relief Valve

Sections, Spools, and Return Springs

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

1. Check each section for cracks and defective sliding surfaces. Also, inspect the check valve seat for wear.

2. Check the spools for burns or distortions. Also, check for operating force.

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

203517

205025

Lift, Tilt and Attachment Sections Spool operating force

1. Remove the spool from the section, together with the screw and plate, when disassembling the tilt or attachment spools.

2. Hold the spool in a vise with protective jaw caps and remove the screw with an Allen wrench.

18 to 22 kgf (40 to 49 lbf) [177 to 216 N]

3. Check the tilt lock valve for damage and seizure.

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

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

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

3. Make sure each spool moves freely.

205028

7.36

HYDRAULIC SYSTEM: DISASSEMBLY

Hydraulic System Disassembly 4 5

6

1

6

3 2 204931

Sequence 1. Return hose

4. Set bolt, shims

2. Hose guard

5. Cylinder clamp [cushion, collar, shims]

3. High-pressure hose

6. Lift cylinder, bracket

Suggestions 1. Disconnecting return hoses Start the truck. Raise the lift bracket to the maximum height and stop the truck. Disconnect the return hoses of left-hand and right-hand lift cylinders at their connectors.

2. Removing hose guard With the lift bracket raised to the maximum height, remove each hose guard from the front side of the mast.

204932

7.37

HYDRAULIC SYSTEM: DISASSEMBLY NOTE Be careful not to touch the lift control lever.

3. Lowering lift bracket Lower the lift bracket by carefully operating the lift control lever.

4. Disconnecting high-pressure hoses Disconnect the high-pressure hoses at the joints, which are indicated by arrows. Use a container to catch oil flowing out of the hoses.

204933

5. Removing set bolts (1)

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

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

(2)

204934

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

202983

7.38

HYDRAULIC SYSTEM: INSTALLATION 6. Removing lift cylinders Attach lift sling to the lift cylinder from the rear side of the mast, and remove the cylinder. Attach the sling before removing the cylinder clamp.

Hydraulic System Installation To install, follow the reverse of removal sequence including the following steps.

204935

1. Extend and retract the lift cylinders several times under no load condition: to remove air out of the cylinder circuits, and to make sure the cylinders move smoothly.

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

3. Check to make sure the lift height is correct.

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

7.39

HYDRAULIC SYSTEM: TILT CYLINDERS

Tilt Cylinders

(3)

Retract the tilt cylinders and disconnect them from the tilt sockets.

1. Tilt socket 2. Rubber hose [O-ring] 3. Cylinder pin [spacer] 4. Tilt cylinder

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

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

204974

Suggestions Removing tilt sockets

!

WARNING

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

(1)

Mark the tilt cylinder sockets and nuts.

NOTE

204845A

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

(2)

Using a wrench, turn the piston rods to disconnect the tilt cylinders from the tilt sockets.

NOTE Loosen the nut just enough to permit turning of the piston rod. Do not change the position of the nut.

201737 7.40

HYDRAULIC SYSTEM: TILT & LIFT CYLINDERS DISASSEMBLY

Tilt Cylinders Disassembly

205971

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

3. Piston rod, piston seal, and nut

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

4. Cylinder tube and bushing

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

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

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

200351

7.41

HYDRAULIC SYSTEM: TILT & LIFT CYLINDERS DISASSEMBLY

Lift Cylinders Disassembly

204948

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

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

3. Bushing and bearing

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

200349

7.42

HYDRAULIC SYSTEM: TILT & LIFT CYLINDERS INSPECTION

Inspection after Disassembly

Precautions for Reassembly

Cylinder Tube

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

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

2. Check the welds for cracks.

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

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

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

2. Check for surface flaws such as grooving, 4. Before fitting the piston seal to the tilt cylinder piston, squeeze the seal by hand five or six times to soften it. Hold the piston steady by clamping the rod in a vise and apply a small amount of hydraulic oil to the seal. Fit a portion of the seal to the groove and push the rest of the seal into place a little at a time.

200319 scratch marks, rusting, and wear. The rod must be replaced if its threads show signs of stripping or any other damage.

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

200352

2. Check each ring for deterioration due to aging.

200353

7.43

TILT & LIFT CYLINDERS: FLOW REGULATOR VALVE

Flow Regulator Valve Disassembly

2

1 5 3

4

203559

Sequence 1. Lock nut

Inspection after Disassembly

2. Plug and O-ring

1. Check the springs for fatigue.

3. Spring and shims

2. Check the valve seats for damage. Check the sliding surfaces for evidence of binding and repair as necessary.

4. Piston, pin, washer, spring, and valve 5. Valve body

3. Check the sliding surfaces of the piston and valve body for damages.

NOTE Replace the flow regulator valve as an assembly if any part is defective.

7.44

HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT

Hydraulic System Inspection and Adjustment Hydraulic Tank

NOTE

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

2. Refill capacities in the amount of oil required.

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

Suction Strainer Check the suction strainer for clogging or damage.

!

WARNING

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

Return Filter Check the return filter for clogging or damage.

Hydraulic Tank Refill Capacities EP16-18

EP20-30

24.9 (6.6)

27.6 (7.3) Unit: liter (U.S. gal)

7.45

HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT Control Valve Inspection and Adjustment External Leakage 1. Check for oil leak from the joint between adjacent valve housings sealed by O-ring.

2. Quickly disconnect the oil return hose and start collecting the oil coming out of this hose as shown.

2. Check for oil leaks from the scrapers sealed by O-rings.

3. Check for oil leaks from the screw connections.

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

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

203522

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

203521A

7.46

Amount of oil collected 500cc (30.5 cu.in.) maximum for 15 minutes

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

HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT Main Relief Valve Adjustment 1. Attach a pressure gauge capable of measuring up to 250 kgf·cm2 (3555 psi) [25000kPa] to the delivery hose connector.

2. Start the truck and move the control lever to the backward tilt position and hold. If the relief pressure reading is 185±5 kgf/cm2 (2631 ± 71 psi) [18,142 ± 490 kPa]

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

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

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

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

Main relief valve setting

185±5 kgf/cm2 (2631 ± 71 psi) [18,142 ± 490 kPa]

203523

7.47

HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT

Tilt and Lift Cylinders Inspection & Adjustment Lift Cylinder Stroke Adjustment Mast Tilt Angle Adjustment 1. Slowly raise the inner mast and check the stopping manner of the left and right piston rods at the moment the inner mast reaches its maximum lift height.

1. Place machine in a horizontal position.

2. Tilt the mast all the way back.

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

4. To adjust the tilt angle, loosen the lock nut of the tilt cylinder rod and adjust the cylinder stroke by turning the rod on either cylinder so there is no difference in stroke between the cylinders.

204698

204893

2. If the top of the mast rocks at that moment, it should be adjusted with shims. Abnormal conditions will appear as a time lag in stopping between right- and left-hand piston rods and rocking of the rod with a longer cylinder stroke.

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

Forward/ backward tilt angle

7.48

Simplex

EP16/18 6°-9° EP20-30 6°-8°

HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT

Adjustment Method 1. Raise the inner mast, place blocks under the right and left sides of the mast, and lower the mast until it rests on the blocks.

3. Extend the piston rod and tighten the cylinder stopper bolt. Remove the blocks from under the inner mast.

4. Slowly lower the inner mast all the way to make sure the piston rods move smoothly.

Flow Regulator Valve Measure the lowering speed with rated load. If the speed is out of specification, repair or replace the flow regulator valve. For the specification of lowering speed, refer to SERVICE DATA. 202983

2. Remove the stopper bolt at the top of the lift cylinder which stopped first, retract the piston rod, and insert the shims at the top of the piston rod end.

205972

200365

NOTE To retract the piston rod, move the lift control lever to the lowering position to let the oil escape from the lift cylinder.

7.49

HYDRAULIC SYSTEM: INSPECTION & ADJUSTMENT Testing Lift Cylinder Drift Test

Tilt Cylinder Drift Test

1. Pick up a load equal to the rated value, tilt the mast to the vertical position, raise the forks 1 to 1.5m (3.3 to 4.9 ft) and stop the truck.

1. Pick up a load equal to the rated value, tilt the mast to the vertical position, raise the forks about 50 cm (20 in.) and stop the truck.

2. Scribe a line on the mast column and measure the drift of the cylinder (drop for 15 minutes).

2. Measure the drift extension of the tilt cylinder for 15 minutes.

200366

Lift cylinder drift (rated load)

EP16-25

EP30

50 (2.0) maximum

40 (1.6)

200367

Tilt cylinder drift (rated load)

Unit: mm (in.) / 15 min

EP16-18

EP20-25

EP30

22 (0.9) maximum

20 (0.8)

15 (0.6)

Unit: mm (in.) / 15 min

Piping 1. Check each hydraulic circuit for leaks.

2. Make sure each hose is free from twisting or excessive loops.

7.50

Chapter 8: Mast and Forks Description

8.1

Removal & Installation

8.3

Disassembly

8.6

Inspection after Disassembly

8.8

Reassembly

8.9

Inspection and Adjustment

8.10

Chain Tension Adjustment

8.11

Lift Bracket Adjustment

8.12

Mast Clearance Adjustment

8.14

Mast Adjustment Chart

8.20

MAST AND FORKS: DESCRIPTION

Description

205020 205973

Components 1. Inner mast 2. Outer mast 3. Lift chain 4. Lift bracket 5. Mast support bearing cap Diam. of main roller

EP16/18

EP20/25/30

S

99 (3.90)

114 (4.49)

D. Side roller

M

100 (3.94)

115 (4.93)

E. Main roller

L

101 (3.98)

116 (4.57)

A. Main roller B. Main roller C. Main roller

F. Main roller G. Mast strip

8.1

MAST AND FORKS: DESCRIPTION General Information The simplex mast features two lift cylinders placed behind the mast columns, left and right, to provide maximum forward visibility.

Each main roller is a declining type and takes up thrust forces acting in two directions, front-back and sideways. The roller shaft is slightly tilted to orient the roller in such a way, as to provide the two-directional counteraction.

It is ideal that the roller end face should be in light contact with the mast. However, in actual mast operation, some clearance inevitably occurs between the roller and mast as the mast extends (for lifting) or contracts (for lowering) The Caterpillar® mast is designed to minimize the clearance when the mast is fully extended—a condition for which stability assumes greater importance.

Mast strips are fitted near the top of the outer mast. These strips help support the inner mast during back-tilting.

8.2

MAST AND FORKS: REMOVAL & INSTALLATION

Removal and Installation Mast and Lift Bracket Assembly

2 1

6

5

3

4

205974

Sequence 1. Nut 2. Forks and lift bracket 3. Low-pressure hose for lift cylinders 4. High-pressure hose for lift cylinders 5. Tilt cylinder 6. Mast-support bearing caps and bushing

8.3

MAST AND FORKS: REMOVAL & INSTALLATION Suggestions Removing Lift Cylinder Low-Pressure Hoses

Removing Lift Bracket 1. Tilt the mast forward and lower the inner mast all the way. Slacken the lift chains and remove the nuts from the anchor bolts.

1. Power up the truck. Extend the mast all the way and turn the truck off. Disconnect the hoses at the return connector.

2. Lower the mast.

205975

2. Tilt the mast back to vertical position. Raise the inner mast until the lift bracket becomes free. Back the truck away, leaving the lift bracket and fork assembly standing on the floor.

205976

Removing Lift Cylinder High Pressure Hoses With the mast in the lowest position, disconnect the hoses at the flow regulator valve.

8.4

MAST AND FORKS: REMOVAL & INSTALLATION Removing Tilt Cylinders 1. Attach a sling to the left and right holes in the top crossmember of the mast and lift the mast with a hoist.

2. Mark the rod end of each tilt cylinder. Marking is not necessary when the cylinders are being replaced. In such a case, adjust the tilt angle and the stroke of both cylinders to eliminate the difference

201737

205970

in stroke between the two.

Note Be sure to use a hoist with enough capacity to carry the weight of the mast assembly.

3. Using a wrench, turn each rod to disconnect it from the mast.

Removing Mast Support Bearing Caps Weight of components

Unit: kg (lb)

EP16 and 18

EP20 and 25

EP30

Outermast

160 (350)

230 (510)

250 (550)

Inner mast

140 (310)

180 (400)

190 (420)

Lift bracket (with backrest)

90 (200)

130 (290)

165 (360)

Forks (2 pcs)

80 (180)

130 (290)

155 (340)

Lift cylinders and others

60 (120)

60 (120)

90 (195)

Gross (Simplex 3.3m mast)

530 (1160)

730 (1610)

850 (1870)

1. Scribe marks on the bearing caps before

200372 removing them.

2. Remove the cap bolts and lift off the mast

NOTE Lay the mast assembly on a floor large enough for disassembly.

8.5

MAST AND FORKS: DISASSEMBLY

Disassembly

13

3

10

12

16

9

11

6

4

14

18

17 7

5 2

15 8

1

Sequence

205977

9. Low-pressure rubber hose

1. Nut

10. Snap ring and chain wheel

2, Forks and lift bracket

11. Cylinder clamp, seat, shims, cushion, collar and bolts

3. Backrest 4. Main roller and shims 5. Snap ring and main roller 6. Side roller, bracket, and shims 7. Hose guard 8. High-pressure lift hose (Rubber hose, T-joint and down valve)

8.6

12. Bolt and shims 13. Mast strip and shims 14. Main roller and shims 15. Main roller and shims 16. Inner mast 17. Lift cylinder 18. Outer mast

MAST AND FORKS: DISASSEMBLY Suggestions Removing Mast Strips and Main Rollers Removing bolts 11,12 to free lift cylinder 17. Cross the tops of the two lift cylinders. Slide inner mast 16 toward the bottom of outer mast 18, and remove main rollers 14,15 and mast strips 13.

Removing Inner Mast After removing the main rollers, attach sling to the inner mast cross member and slide the inner mast toward the top of the outer mast until it gets clear of the outer mast roller shafts. Sling the inner mast again and remove it from the outer mast.

204876

8.7

MAST AND FORKS: INSPECTION

Inspection after Disassembly Mast 1. Check each roller for wear, binding or other defects.

2. Check each roller for flat spots on rolling surface.

3. Check the mast member and the welds of crossmembers, shafts and supports for cracks.

Lift Chains, Chain Wheels and Chain Wheel Supports 1. Measure the length of each chain to be sure that two chains are equal in length. Also check the chains for wear, evidence of breakage, link binding and twist.

Length of Chain (Per 20 Links)

4. Check the mast supports bushings for wear or other damage.

EP16/18

EP20/25

EP30

A

318 (12.52)

381 (15.00)

508 (20.00)

B

327 (12.87)

392 (15.43)

523 (20.59)

Unit: mm (in.)

A = Assembly standard B= Repair or service limit 204877

Lift Bracket 1. Check the main rollers and side rollers for smoothness of rotation. Inspect each roller for wear and cracks.

2. Check the welds of the bracket for cracks.

3. Check the finger bar for bend or distortion.

204878 Distortion of finger bar 8.8

A

5mm (0.2in.) maximum

2. Check each chain anchor bolt for cracks or damaged thread.

3. Check each chain wheel support and chain wheel for crack or wear. Check to be sure the wheels are capable of smooth rotation.

Mast Strips Check the mast strips for damage, wear or distortion.

MAST AND FORKS: REASSEMBLY Mast Supports

Reassembly To reassemble, follow the reverse of disassembly sequence including the following steps.

1. Apply grease to the inside surfaces and grooves of the caps.

Mast cap

Adjusting Mast and Lift Bracket Clearance

Bushing

Roller for mast and lift bracket are available in three sizes (diameters) for selective use. Select the size that will provide a longitudinal clearance of 1mm (0.04 in.) and less.

Outer mast

Inner mast

Apply grease Side with wider cut

Clearance

203712

Lift bracket

Clearance

2. Install mast support bushings and caps with beveling toward the center of truck respectively.

Greasing will be facilitated if the mast is lifted by placing wooden blocks under it.

203529

Precautions for Installing Chain Anchor Kit

Roller Sizes Diameter of main roller

EP16/18

EP20/25/30

S

99 (3.90)

114 (4.49)

M

100 (3.94)

115 (4.53)

Be careful not to install the center plate in the position for link plate.

2 3

L

101 (3.98)

116 (4.57) Unit: mm (in.)

Cylinder Clamps Install each lift cylinder in place (in vertical position) by fitting to the support, and see if there is any clearance between the outer mast and cylinder.

Reduce the clearance, if any, to zero by shimming.

1 4

Stamped mark 200383

1. Link plate (marked) Shims

2. Center plate (not marked) 3. Link

204879

4. Split pin 8.9

MAST AND FORKS: INSPECTION & ADJUSTMENT

Inspection and Adjustment Forks 1. Carefully inspect the forks for cracks. Special attention should be given to the heel section A, all weld areas and B mounting brackets.

Forks with cracks should be removed from service.

3. Check the fork blade D. The fork should be withdrawn from service if the thickness is reduced to less than the tolerant thickness.

Fork blade length may also be reduced by wear, especially on tapered forks and platens.

Remove the forks from service when the blade length is no longer adequate for the intended loads.

“Wet Test” magnetic particle inspection is generally preferred due to its sensitivity and the ease of interpreting the results.

101630 101630 2. Check the difference in height of one fork tip to the other when mounted on the fork carrier.

A difference in fork tip height can result in uneven support of the load and cause problems when entering loads.

The maximum allowable difference in fork tip elevation C is 5mm (0.20 in.) for pallet forks.

Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference.

101629 8.10

Tolerant thickness

Standard

Limit

EP16/18

35 (1.4)

33 (1.3)

EP20/25

40 (1.6)

38 (1.5)

EP30

45 (1.8)

43 (`1.7) Unit: mm (in.)

MAST AND FORKS: INSPECTION & ADJUSTMENT Chain Tension Adjustment

!

WARNING

Serious injury can be caused by sudden movement of the mast and lift bracket.

Blocks must be used to prevent the mast and lift bracket from any movement while adjustments are made. Keep hands and feet clear of any parts that can move.

4. After adjusting the chains by means of the lock nuts, tighten the anchor nuts to the specified torque. Check each chain for twist.

1. Have the truck standing on a level floor with the mast vertical and the forks lowered to the floor. Check to be sure the lift cylinders are fully retracted.

204880

2. Set the anchor bolts with lock nuts.

3. Raise the forks a little and push the chains inward, midway between the chain wheel and anchor alternately, to check the tension. When adjusting the chains by means of the anchor bolt lock nuts, tilt the mast forward to slacken the chains to facilitate adjustment.

EP16/18/20/25

Tightening torque for anchor bolt lock nut

EP30

Min

Max

Min

Max

10

15

15

20

(72)

(108)

(108)

(144)

[98]

[147]

[147]

[196]

Unit: kgf•m (lbf•ft) [N•m] 5. Make sure the chain tension is correct with the mast in vertical (0°) position.

8.11

MAST AND FORKS: INSPECTION & ADJUSTMENT Clearance Adjustment on Lift Bracket Longitudinal Clearance Adjustment on Lift Bracket Main Rollers 1. Raise the forks a little from the floor.

3. If the clearance F is out of specification, use oversize rollers.

2. Insert a bar between the upper part of lift bracket and the inner mast, and push the inner mast to one side. Using a feeler gauge, measure the clearance F between the main roller and inner mast on the opposite side.

204883

204882

Roller Sizes Diameter of main roller

Clearance F

0.1 to 1.0 mm (0.004 to 0.039 in.)

EP16/18

EP20/25/30

S

99 (3.90)

114 (4.49)

M

100 (3.94)

115 (4.53)

L

101 (3.98)

116 (4.57) Unit: mm (in.)

8.12

MAST AND FORKS: INSPECTION & ADJUSTMENT Lateral Clearance Adjustment on Lift Bracket Main Rollers and Side Rollers 1. Raise the mast all the way.

5. Read the indicator.

2. Set a dial indicator on the inner mast with its contact point rested on the side of the lift bracket.

6. If the clearance G is out of specification, use oversize rollers. Adjust the side roller clearance by adding shims under the roller bracket.

3. Go over to the opposite side of the mast, and push the lift bracket to one side with a bar. Set the indicator to zero.

4. Insert a bar between the inner mast and lift bracket on the indicator side, and push the lift bracket to the opposite side.

204884

Clearance G

0.1 to 0.5 mm (0.004 to 0.020 in.)

203818

7. After adjusting the clearance, move the mast and lift bracket slowly to make sure they move smoothly through their full stroke.

8.13

MAST AND FORKS: INSPECTION & ADJUSTMENT Mast Clearance Adjustment Longitudinal Clearance Adjustment on Mast Main Rollers 1. Tilt the mast all the way backward.

3. If the clearance H is out of specification, use oversize rollers.

2. Using a feeler gauge, measure the clearance H between the inner mast lower roller and outer mast.

Roller Sizes Diameter of main roller

Clearance H

0.1 to 1.0 mm (0.004 to 0.039 in.)

EP16/18

EP20/25/30

S

99 (3.90)

114 (4.49)

M

100 (3.94)

115 (4.53)

L

101 (3.98)

116 (4.57) Unit: mm (in.)

204885

8.14

MAST AND FORKS: INSPECTION & ADJUSTMENT Lateral Clearance Adjustment on Inner Mast Main Rollers 1. Raise the mast all the way.

5. Read the indicator.

2. Set a dial indicator on the inside of the outer mast, with its contact point rested on the inner mast.

3. Go over to the opposite side of the mast, and push the inner mast against the outer mast.

Set the indicator to zero.

4. Insert a bar between the outer and inner masts on the indicator side, and push the inner mast to the opposite side.

204887

Clearance J

0.1 to 0.5 mm (0.004 to 0.020 in.)

6. If the clearance J is out of specification, adjust it by using shims.

204886

204888

NOTE Refer to Main Roller Shim Replacement.

8.15

MAST AND FORKS: INSPECTION & ADJUSTMENT Lateral Clearance Adjustment on Outer Mast Main Rollers 1. Raise the mast all the way.

5. Read the indicator.

2. Set a dial indicator on the outer mast with its contact point rested on the inner mast.

3. Go over to the opposite side of the mast, and push the outer mast against the inner mast with a bar. Set the indicator to zero.

4. Insert a bar between the outer and inner masts, and push the inner mast to the opposite side.

Clearance K

0.1 to 0.5 mm (0.004 to 0.020 in.)

6. If the clearance K is out of specification, adjust it by means of shims.

204890 204889

NOTE Refer to Main Roller Shim Replacement.

8.16

MAST AND FORKS: INSPECTION & ADJUSTMENT Main Roller Shim Replacement Remove the lift bracket from the mast.

Mast Strip Adjustment 1. Check the clearance L with the clearance between the outer mast rollers and inner mast set to zero (0) in maximum lift position.

NOTE Refer to REMOVAL AND INSTALLATION, Lift bracket Removal.

Lower the inner mast below the outer mast as follows.

1. Raise the front end of the machine, and block that end with a jack stand or the like.

200391

2. Remove the upper set of bolts from the lift cylinders, and lift the inner mast with a hoist.

Remove the hose guard.

3. Remove the clamps from the lift cylinders. Pull the bottom ends of the cylinders from the outer mast, tilt the cylinders to the center of the mast, and tie them to the crossmember of outer mast with rope.

4. Slowly lower the inner mast until it comes in contact with the lift cylinders.

5. Now the main rollers can be removed from the inner and outer masts. Remove the mast strips and shims in advance, because they are apt to come off under this condition.

200392

Clearance L

0.1 to 0.5 mm (0.004 to 0.020 in.)

2. If the clearance L is out of specification, adjust if by means of shims.

NOTE Refer to Main Roller Shim Replacement.

202961

8.17

MAST AND FORKS: INSPECTION & ADJUSTMENT Lift Cylinder Stroke Adjustment

Tilt Angle Adjustment

1. Slowly raise the inner mast, and check how the piston rods, left and right, stop at the moment the inner mast reaches its maximum height.

1. Adjust the tire pressure correctly and keep the truck level.

2. Tilt the mast all the way back and turn off the truck.

2. If the top of the inner mast rocks at that moment, make a shim adjustment. Abnormal condition can be told by a little time lag in stopping between the piston rods, left and right, and rocking of the rod with a longer cylinder stroke.

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

4. To adjust the tilt angle, loosen the lock nut of tilt cylinder socket, and adjust the cylinder stroke by turning the rod on either cylinder so there is no difference in stroke between the left and right cylinders.

204893 204968

NOTE It is not necessary to adjust the forward tilt angle if the backward tilt angle is properly adjusted.

Forward/backward tilt angle

Simplex

EP16/18 EP20-30

5. After adjusting the tilt angle, tighten the lock nuts to the specified torque.

Tightening torque for tilt cylinder lock nuts

EP16/18

EP20/25/30

28 (203) [275]

40 (289) [392]

Unit: kgf•m (Ibf•ft) [N•m] 8.18

6°/9° 6°/8°

MAST AND FORKS: INSPECTION & ADJUSTMENT Adjusting Method 1. Raise the inner mast, place blocks under the left and right sides of the inner mast, and lower the mast until it rests on the blocks.

202983 2. Remove the set bolt at the top of the lift cylinder that stopped first, retract the piston rod, and inset shims at the top of piston rod end.

3. Extend the piston rod and tighten the cylinder set bolt. Remove the blocks from under the inner mast.

200365 4. Slowly lower the inner mast all the way, to make sure the piston rods move smoothly and the left and right lift cylinders come to the end of stroke, simultaneously.

8.19

MAST AND FORKS: INSPECTION & ADJUSTMENT

Mast Adjustment Chart

204894A

EP16/18

EP20/25/30

Distance between outer mast main rollers (inside to inside) A

511 (20.12)

559 (22.01)

Distance between inner mast main rollers (outside to outside) B

581 (22.87)

639 (25.16)

Distance between lift bracket main rollers (outside to outside) C, D

477 (18.78)

523 (20.59)

Distance between lift bracket side rollers (outside to outside) E

482 (18.98)

528 (20.79)

Longitudinal clearance of lift bracket main rollers (with forks slightly lifted) F

0.1 to 1.0 (0.004 to 0.039)

Lateral clearance of lift bracket main rollers (fully raised) G1

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of lift bracket side rollers (fully raised) G2

0.1 to 0.5 (0.004 to 0.020)

Longitudinal clearance of mast main rollers (in the whole lift range) H

0.1 to 1.0 (0.004 to 0.039)

Lateral clearance of the inner mast main rollers (fully raised) J

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of the outer mast main rollers (fully raised) K

0.1 to 0.5 (0.004 to 0.020)

Mast strip clearance (fully raised) L

0.1 to 0.5 (0.004 to 0.020)

Unit: mm (in.)

8.20

Chapter 9: Troubleshooting Front Axle & Reduction Differential

9.1

Brake System

9.2

Steering System

9.4

Hydraulic System

9.6

Rear Axle

9.8

Mast & Forks

9.9

TROUBLESHOOTING: FRONT AXLE & REDUCTION DIFFERENTIAL

Front Axle and Reduction Differential

Complaint Gear noise continuously during normal cruising run

Irregular noise during normal travel

Abnormal noise when turning a corner

Differential overheats

Possible Cause

Remedy

Gear teeth worn or broken.

Replace.

Bearing preloads too much or too little, or bearings are worn excessively.

Readjust or replace.

Hub bearings broken.

Replace.

Improper tooth contact between gears.

Readjust.

Bearings damaged.

Replace.

Differential side gears have broken, or thrust washers worn.

Replace gears or washer.

Metal piece in axle housing.

Clean and replace oil.

Bolts securing axle shaft or differential carrier are loose.

Retighten.

Fit of differential gears in differential case Replace worn parts. are out of specification due to wear.

Broken teeth on differential pinions or side gears, or pinions seized on spiders.

Replace defective parts.

Bearings damaged due to too much preload.

Replace bearing and readjust preload.

Improper gear backlash.

Inspect bearings and readjust preload and backlash.

9.1

TROUBLESHOOTING: BRAKE SYSTEM

Brake System Complaint Lack of braking force

Pedal stroke is too large

Uneven braking (machine pulls to one side)

Brake squeals

Brake chatters or clatters

Possible Cause Oil leaking past primary cup in master cylinder.

Replace piston cup if cylinder is worn.

Replace cup and fluid if the cup is distorted.

Oil leaking past cups in wheel cylinders.

Replace pipe and connector and retighten.

Oil leaking from oil pipe connection.

Shoe linings excessively worn.

Linings dirty with oil or grease.

Retighten.

Replace.

Clean or replace.

Air trapped in brake oil.

Bleed air at master cylinder and wheel cylinder.

Piston cup defective in master cylinder.

Replace.

Not enough fluid in reservoir.

Refill.

Push rod-to-piston clearance too large in master cylinder.

Readjust.

Brake fluid leakage.

Replace piston cup if cylinder is worn.

Replace the cup and fluid if the cup is distorted.

Automatic adjusting device out of order.

Check cable guide and adjusting spring installation. If they are defective, replace fitting cable, lever and adjusting screw.

Lining or drum dirty with oil or grease in less effective brake.

Clean or replace.

Wobbly or loose-mounted drum in less effective brake.

Replace drum. Readjust and retighten.

Linings glazed.

Replace shoe & lining assembly.

Linings badly worn.

Replace.

Backing-plate securing bolts loose.

Retighten.

Wheel bearings loose.

Readjust preload and retighten.

Brake drum dirty.

Clean.

Anchored ends of shoes rattling on anchor.

Repair or replace.

Shoe ledges badly worn.

Replace backing plate.

Piston badly worn in wheel cylinder.

9.2

Remedy

Replace.

TROUBLESHOOTING: BRAKE SYSTEM Complaint

Possible Cause

Remedy

Lever stroke is too small

Lining-to-drum clearance too small.

Readjust.

Squeals during traveling

Lining-to-drum clearance too small.

Readjust.

Brake drum badly distorted.

Repair or replace.

Parking brake cable longer than specified.

Check drum-to-lining clearance and turn adjusting knob clockwise.

Linings worn to service limit.

Replace shoe & lining assembly.

Lining-to-drum clearance too small.

Readjust.

Lack of brake lever operating effort.

Readjust to 25 to 30 kgf (55 to 66 lbf) [245 to 294 N].

Will not apply

9.3

TROUBLESHOOTING: STEERING SYSTEM

Steering System Complaint Slow steering, hard steering or loss of steering

Possible Cause If pump is defective

Remedy

Worn or malfunctioning pump

Replace.

Malfunctioning relief valve

Readjust or replace.

Malfunctioning priority valve · Sticking spool or spring · Clogged orifices · Damaged valve seat

Truck wanders

Clean or replace.

Clean.

Replace.

Worn or malfunctioning steer gear

Replace.

Pipe or tube flattened, or restriction in an oil line

Clean or replace.

Air in system

Low level of oil

Fill as required.

Leaking joint

Tighten joint.

Pinched pipe or hose

Straighten or replace.

Worn steer gear

Replace.

Worn steer gear

Replace.

Leakage of cylinder seals or at lines between steer gear and cylinder

Repair.

Temporary hang-up in steering

Thermal shock– caused by actuation of hydraulic lift and tilt for long periods of time without actuation of steering system, creating more than a 28°C (50° F) temperature differential between the oil in the tank and the oil in the steer gear

Correct operating procedure.

Erratic steering

Air in system

Low level of oil

Fill as required.

Leaking joint

Tighten joint.

Pinched pipe or hose

Straighten or replace.

Steering slip

Spongy or soft steering

9.4

Thermal shock damage to steer gear

Replace.

Sticky spool in priority valve

Clean or replace.

Air in system

Low level of oil

Fill as required.

Leaking joint

Tighten joint.

Pinched pipe or hose

Straighten or replace.

Air trapped in cylinder

Bleed air.

TROUBLESHOOTING: STEERING SYSTEM Complaint Free wheeling

Possible Cause Problem with steering column

Air in steer gear

No flow to steer gear

Remedy

Column loose or damaged

Repair or replace.

Column splines damaged or disengaged from steer gear

Repair or replace.

Starved at startup

Temporary.

Starved from long period of non-use

Temporary.

Low oil level

Fill as required.

Ruptured hose

Replace.

Thermal shock damage to steer gear Replace.

Blown piston seal Steering instability or oscillation

Air in lines

Replace.

Pump sucking air at inlet

Check joints.

Components or lines contain air

Bleed circuit.

Improper relief setting

Readjust.

Damaged or broken priority valve spring

Replace.

Sticky spool in priority valve

Clean or replace.

Steering wheel turns in wrong direction

Lines connected to wrong cylinder ports

Correct connections.

Excessive freeplay

At steering wheel

Loose steering wheel nut

Tighten.

Damaged or worn column shaft

Replace.

Leaky cylinder seals

Replace.

At steered wheels Binding or poor centering of steering wheel

Steer gear locks up

Binding or misalignment between column and steer gear

Readjust steer gear mounting bracket or replace rubber mounting grommets.

High back pressure in tank return line

Clear blockages.

Contamination in steer gear unit

Clean unit.

Contamination in steer gear unit

Clean unit.

Insufficient hydraulic powerCheck pump and power. supply.

Worn or damaged steer gear or steer gear pin Momentary kick or steer- Damaged check valve ing wheel at start of steering

Replace.

Replace.

9.5

TROUBLESHOOTING: HYDRAULIC SYSTEM

Hydraulic System Complaint Will not lift or tilt

Possible Cause Not enough oil in hydraulic tank

Remedy Refill.

Relief valve out of order because of: 1) Seized main valve

Replace.

2) Broken valve spring

Replace.

Oil pump defective Will not lift rated load

Lift speed is too low

Lowering speed is too low

Cylinder vibrates when actuated

Load will not hold

9.6

Replace.

Relief valve out of order because of: 1) Too low a relief setting

Readjust.

2) Defective plunger and poppet seat

Replace.

3) Weakened spring

Replace.

4) Damaged O-ring in valve case

Replace O-ring.

Oil pump defective

Replace.

Piston seals worn or damaged

Replace.

Motor rpm too low

Adjust.

Control lever installed loose, resulting in not enough spool stroke

Repair or replace.

Tank strainer clogged

Clean or replace.

Pump not delivering enough oil

Repair or replace.

Sleeve seized in flow regulator valve

Repair.

Dirt in flow regulator valve

Clean, repair system and replace defective hose.

Abnormal resistance to flow due to flattened hose or local clogging

Replace hose.

Piston rod distorted

Repair or replace.

Air in oil circuit

Bleed air by operation cylinder through full stroke.

Not enough oil in hydraulic tank

Refill.

Control valve spool leaking internally

Replace.

Sliding (inside) surface of cylinder tube slightly grooved

Repair or replace cylinder assembly.

Sliding (inside) surface of tube badly grooved

Replace.

Piston seals broken or distorted

Replace seal kit.

Oil leakage from piping

Repair or replace.

TROUBLESHOOTING: HYDRAULIC SYSTEM Complaint Mast tilts forward (drifts)

Bushing leaks

Possible Cause Control valve spool leaking internally

Replace.

Foreign particles lodged between packing and mating surface

Replace packing.

Piston seal damaged

Repair.

Cylinder distorted

Repair or replace.

Foreign particles lodged between sealing members such as oil seals and dust seals

Replace.

Oil seals and dust seals defective

Replace.

O-rings damaged

Replace.

Cylinder distorted

Repair or replace.

Hydraulic tank heats Oil viscosity improper excessively Overload

Cylinders move too slowly

Cylinders move too slowly

Noisy

Remedy

Change oil.

Check working conditions and, if overloaded, urge the operator to stay within the load limit.

Local overheating of oil due to a large flow restriction

Repair or replace.

Relief valve adjustment improper

Readjust pressure setting.

Pressure drop due to weakened or broken springs

Repair or replace and readjust.

Hydraulic pump worn

Replace.

Outlet pipe or tube flattened, or restriction to flow

Repair or replace.

Shortage of oil due to a natural loss

Refill.

Oil leakage due to damaged oil line seals

Repair or replace.

Oil viscosity too high

Change oil.

Hydraulic pump defective

Check pump and piping; repair or replace.

Oil leakage from oil line

Check oil for level and condition; and/or change oil.

Abnormal rise in oil temperature

Check control valve spools for misalignment: repair or replace.

Hydraulic pump leaking internally

Replace pump.

Poor pumping

Refill.

Cavitation

1. Check suction pipe for any flat portion or loose connection; retighten or replace 2. Check shaft oil seal for airtightness; replace pump 3. Check pump body for any outside interference; repair.

9.7

TROUBLESHOOTING: REAR AXLE

Rear Axle Complaint Hard steering

Possible Cause

Remedy

Overloaded steer axle

Reduce load.

Damaged mechanical linkage

Replace.

Dry mechanical linkage joints

Lubricate.

Mechanical joints too tight

Readjust.

Kingpin bearings improperly preloaded

Readjust.

Damaged or worn mechanical linkage

Replace.

Loose cylinder piston

Replace cylinder rod.

Damaged or worn mechanical linkage

Replace.

Tire diameter differs between right and left

Replace tire.

Erratic steering

Loose cylinder piston

Replace cylinder rod.

Excessive freeplay at steered wheels

Damaged or worn linkage between cylinder and steered wheels

Replace.

Axle shimmy

Excessive clearance between the kingpin and its bearings

Repair or replace.

Worn or damaged hub bearing

Replace.

Tire on one side differs in kind or brand from that on the other side

Replace tires.

Truck wanders

Truck drifts

Rear tires wear prematurely or unevenly

9.8

TROUBLESHOOTING: MAST & FORKS

Mast and Forks Complaint Lift bracket and inner mast will not move smoothly

Possible Cause Main rollers and side rollers do not have proper clearance Rollers are binding on their shafts Rollers damaged Improper mast-to-strip clearance

Lift bracket or inner mast cocks

Too much clearance on side rollers, or side rollers are damaged Lift chains unequally tensioned Shim adjustments unequally made on left and right lift cylinders (at maximum height)

Mast makes noise

Roller not rotating smoothly on their shafts or are damaged

Load drops (drifts)

Lifts cylinder packing damaged Lift cylinder bore grooved Control valve defective

Entire mast shakes

Mast-support bushing worn

Mast is distorted

Improper loading or overload

Fork tips differ in height

Finger bar bent Forks bent Distortion of mast due to off-center loading

9.9

Chapter 10: Maintenance Service Data System Service Charts Front Axle and Reduction Differential

10.1

Transfer Case

10.3

Rear Axle

10.4

Brake System

10.6

Steering System

10.10

Hydraulic System

10.12

Mast and Forks (Simplex Mast)

10.15

Tightening Torques for Standard Bolts and Nuts Fine Thread—With Spring Washer

10.17

Fine Thread—Without Spring Washer

10.18

Coarse Thread—With Spring Washer

10.19

Coarse Thread—Without Spring Washer

10.20

Maintenance Chart

10.21

Periodic Replacement Parts

10.26

Lubrication Data

10.27

Chart

10.27

Fuel and Lubricant Specifications

10.28

Recommended Brands of Lubricants

10.29

Weight of Major Components (Approximate)

10.30

Special Service Tools

10.31

Special Tool Illustrations

10.32

Inspection Guide

10.35

MAINTENANCE SERVICE DATA: FRONT AXLE

Front Axle and Reduction Differential Item

Truck

Preload for hub bearing 1, kgf·cm (lb·ft) [N·m]

A

Tightening torque kgf·cm (lbf·ft) [N·m]

Hub bearing lock nuts (outer) (2)

A

Axle shaft bolts (3)

A

Backing plate bolts (4)

A

Hub bolt lock nuts (5)

A

Frame support bolts (6)

A

Wheel nuts (7)

A

EP16/18/20/25

3.1-5.6 (22 - 41) [30 - 56]

EP30

2.3 — 4.1 (17 - 30) [23 - 41]

20 (145) [196] — EP 16 thru 25 Install nut keeper & bolt EP30 4.5 (33) [44] EP16/18 8.8 (64) [86] EP20/25/30 21.9 (158) [215] 6 (43) [59]

18.5 (134) [181]

22.9 (166) [225] 16 (116) [157]

38.5 (278) [379]

1

6

4 3

2 5 1

A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.1

MAINTENANCE SERVICE DATA: FRONT AXLE

Front Axle and Reduction Differential, continued Item

Truck Model

Gear backlash (1)

Fit of bevel pinion on spider (2)

EP16/18/20/25/30

A

0.18 to 0.23 (0.0071 to 0.0091)

B

0.5 (0.020)

A

0.02 to 0.07 (0.008 to 0.0028)

B

0.35 (0.0138)

Preload for differential case kgf·cm (lbf·ft) [N·m]

A

Free movement (looseness) of axle shaft splines (6)

A

0.07 to 0.17 (0.0028 to 0.0067)

B

0.5 (0.020)

Reduction gear bolts (7)

A

12 (87) [118]

Side bearing cap bolts (8)

A

1.7 (125) [17]

Carrier bolts (9)

A

6.1 (44) [60]

Gear Box Reduction Shaft Beg. nut (11)

A

30 (216) [294]

A

4.1 (29.5) [40]

A

3.4 (25) [33]

Tightening torque kgf·cm (lbf·ft) [N·m]

Gear Box Reduction Shaft Brg Plt retainer bolts (12) Gear Box Cover Bolts (10)

4.5 to 6.0 kgf (33 to 44 lbf) [45 to 60N] as force applied to reduction gear in tangential direction

A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.2

MAINTENANCE SERVICE DATA: TRANSFER CASE

Transfer Case Item

Truck Model

Gear backlash (1)

A

EP16 EP18

EP20, EP25, EP30

0.09 to 0.22 (0.003 to 0.009)

(1) B A

0.5 (0.020) 0.10 to 0.24 (0.004 to 0.009)

(2) B A

0.5(0.20) 0.12 to 0.28 (0.005 to 0.011)

(3) B Tightening torque, kgf·m (lbf·ft) [N·m] lockplate

(4)

A

0.5 to 0.020)

3.4 ±0.3 (24.6±2.2) [33 ±3]

A = Assembly Standard B= Repair or service limit Unit:mm (in.)

10.3

MAINTENANCE SERVICE DATA: REAR AXLE

Rear Axle Item

Truck Model

EP16/18/20/25/30

Oscillating angle

A

3°

Toe-in

A

0°

Caster

A

0°

Camber

A

1°

Total fore-aft play of axle at center pin (1)

A

0.8 (0.031)

B

1.2 (0.047)

Inside (2)

A

83°

Outside (3)

A

56.5°

Support bolts (4)

A

14.8 (107) [145]

Stopper bolt nuts (5)

A

6.8 (49) [67]

A

163 (2320) [16,000]

Turning Angle

Tightening torque, kgf·m (lbf·ft) [N·m]

Cylinder minimum test pressure, kgf·cm2 (psi) [kPa]

8609145

A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.4

MAINTENANCE SERVICE DATA: REAR AXLE

Rear Axle, continued Item Tightening torque kgf·m (lbf·ft) [N·m]

Truck Model

EP16/18/20/25/30

Outer locknut (6)

A

16 (116) [157]

Cylinder nuts (7)

A

1.9 to 2.3 (14 to 17) [19 to 23]

Cylinder bolts (8)

A

26.7 (193) [262]

Kingpin bolts (9)

A

1.7 (12.3) [16.7]

Tie rod bolts (10)

A

0.7 (5) [6.9]

Lug Nuts (11)

A

16 (116) [157]

Keeper Plate Bolts (12)

A

3.4 (24.6) [33.4]

A

5 to 50 (0.4 to 3.6) [0.5 to 4.9]

Preload for hub bearing (13) kgf·m (lbf·ft) [N·m]

8

7

10

1

12 9

13

6

A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.5

MAINTENANCE SERVICE DATA: BRAKE SYSTEM

Brake System Item

Truck Model

Height of pedal (1)

A

Clearance between piston and push rod (2)

A

EP16/18

EP20/25/30

125 (4.9)

135 (5.3) 3 (0.12)

1

Toe Plate

2 A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.6

MAINTENANCE SERVICE DATA: BRAKE SYSTEM

Brake System, continued Item Inside diameter of cylinder body (1)

Truck Model A

EP16/18/20/25/30 19.05 (0.7500

+

0.052

+

0.00205

0 0

)

Diameter of piston (2)

A

19.05 -0.020 -0.053 (0.7500 -0.0079 -0.00209)

Clearance between cylinder and piston

A

0.020 to 0.105 (0.00079 to 0.00413)

B

0.2 (0.08)

A

20 0 -0.3 (0.79 0 -0.012)

B

replace every year

A

20.2 ± 0.2 (0.795 ± 0.008)

B

replace every year

A

46.8 (1.843)

B

replace every year

Diameter of primary cup (lip side) (3)

Diameter of secondary cup (lip side) (4)

Free length of return spring (5)

204936

A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.7

MAINTENANCE SERVICE DATA: BRAKE SYSTEM

Brake System, continued Item

Truck Model

Inside diameter of cylinder body (1)

A

EP16/18/20/25 22.22+00.052 (0.8748 - 0 0.00205)

EP30 28.58 (1.1252

+ +

0 0

0.052

)

0.00205

Diameter of piston (2)

A

22.22 -0.040 -0.073 (0.8748 - 0.00157 -0.00287)

Clearance between cylinder and piston

A

0.040 to 0.125 0.020 to 0.105 (0.00157 to 0.00492) (0.00079 to 0.00413)

B

0.15 (0.0059)

Diameter of piston cup (lip side) (3)

A

23.7 ± 0.2 (0.933 ± 0.0079)

B Return Spring (4) Free length

30.5 ± 0.25 (1.201 ± 0.0098)

replace every year

A

49.5 (1.95)

58 (2.28)

Length under test force

A

20 (0.79)

23 (0.91)

Test force kgf (lbf) [N]

A

1.2 ± 0.1 (2.6 ± 0.2) [12 ± 1]

1.3 ± 0.1 (2.9 ± 0.2) [13 ± 1]

B Tightening torque, kgf·m (lbf·ft) [N·m]

28.58 -0.020 -0.058 (1.1252 -0.00079-0.00228)

Wheel cylinder bolts (5)

A

Bleeder screw (6)

A

replace every year 0.8 to 1.2 (6 to 9) [8 to 12]

1.8 to 2.7 (13 to 20) [18 to 26]

0.6 to 0.9 (4 to 7) [6 to 9]

200426 A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.8

MAINTENANCE SERVICE DATA: BRAKE SYSTEM

Brake System, continued Item

Inside diameter of brake drum (1)

Thickness of lining (2)

Truck Model

EP16/18

EP20/25

A

254 +0 1.0 (10.00+00.0051)

279.4 +0 0.13 (11.00+00.0051)

310 +0 0.15 (12.20+00.0059)

B

256(10.08)

281.4(11.08)

312(12.28)

A

4.87(0.19)

5.1(0.20)

6 (0.24)

B

2.5(0.098) max

2.5(0.098) max

3(0.118) max

Clearance between drum and lining (3) (one side)

A

Return spring (4)

A

Free length

Length under test force

Test force, kgf (lbf) [N]

A

A

EP30

0.2 to 0.5

0.2 to 0.5

0.2 to 0.6

(0.0079 to 0.0197)

(0.0079 to 0.0197)

(0.0079 to 0.0236)

102(4.02)

111(4.37)

16 ± 1.6 (35 ± 3.5) [157 ± 16]

Primary:110(4.33)

Primary:120(4.72)

Secondary:107(4.21)

Secondary: 139.3(5.48)

Primary:118(4.65)

Primary: 134(5.28)

Secondary:199(4.69)

Secondary: 145.4(5.72)

p.26±2.6 s.18.5±1.9

23 ± 2.3 (51 ± 5.1) [226 ± 23]

(57 ±5.7) (41±4.2) [255±26] [181±19]

A= Assembly Standard B= Repair or service limi Unit: mm (in.

10.9

MAINTENANCE SERVICE DATA: STEERING SYSTEM

Steering System Item

Adjusting spring (5)

Truck Model

EP16/18

EP20/25

EP30

Free length

A

79(3.11)

99.8 (3.93)

104(4.11)

Length under test force

A

98.5 (3.88)

126 (4.96)

122(4.80)

Test force, kgf (lbf) [N]

A

Tightening torque for backing plate bolts (6) kgf·m (lbf·ft) [N·m]

14±1.4(31±3) [137±14] 6±0.6(13.7±1.3) [59±6] 8±0.8(18±2[78±8]

A

16(116) [157]

203588

Locked position of lever A

A

4° to 5°

Lever operating effort (F)

A

25 to 30 (55 to 66) [245 to 294]

204967

A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.10

MAINTENANCE SERVICE DATA: STEERING SYSTEM

Steering System, continued Item

Truck Model

EP16/18/20/25/30

Steering effort (at rim with truck on) kgf (lbf) [N]

A

1.3 (9.0) [12.8]

Tightening torque kgf·cm, (lbf·ft) [N·m]

Relief set screw (1)

A

1.2 (8.3) [11.3]

Body cap screws (2)

A

3.2 (23) [31.2]

2

1 8609048 Inside diameter

A

75 (2.95)

Diameter of piston rod

A

50 (1.97)

Minimum test pressure for leaks, kgf·cm2 (psi) [kPa]

A

163 (2320) [16,000]

Tightening torque, kgf·cm, (lbf·ft) [N·m]

Cylinder nuts (1)

A

2.1 ± 0.2 (15.5 ± 1.5) [21 ± 2]

Mounting bolts (2)

A

26.7 (193) [262]

8609149 A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.11

MAINTENANCE SERVICE DATA: HYDRAULIC SYSTEM

Hydraulic System Item

Truck Model

48 volt lift speed (rated load) mm/sec (fpm)

A

80 volt lift speed (rated load) m/sec(fpm) Lowering speed (rated load ) mm/sec (fpm)

A

Forward tilt angle

A

Backward tilt angle

A

Lift cylinder drift (rated load) mm (in.)/ 15min.

[Oil temperature 45°C(113°F)]

A

Tilt cylinder drift (forward) rated load) mm(in.)/ 15min.

EP16/18

EP20

EP25

EP30

360(71)

—

390 (77)

380 (75)

0.39 (77)

0.40 (79)0.38 (75)

0.34 (67)

580 (114)

590 (116)

520 (102)

6° 9°

8° 50 (2.0) max

A

40 (1.6)

20 (8.0) + 5

71

Power steering relief valve setting kgf·cm2, (psi) [kPa]

A

51 (725) [5000]

Output, liter (cu. in.) / min

A

55.2 (3360) 2400 rpm

69.6 (4248) 2400 rpm

Tightening torque for oil pump bolts kgf·m (lbf·ft) [N·m]

A

4.7 to 5.2 (34 to 38) [46 to 51]

9.0 to 10.4 (65 to 75) [88 to 102]

Tightening torque kgf·m (lbf·ft) [N·m]

Tie bolts (1/2 in.)

A

4.7 (34) [46]

Tie bolts (3/8 in.)

A

1.9 (14) [19]

A

45 + 0 0.2 (1.77 + 0 0.008)

B

45.25 (1.7815)

0

) [18142

+

A

[Piston] inside diameter of cylinder head (1)

185 0 (2631

+

Main relief valve setting, kgf·cm2, (psi) [kPa]

0

490

]

81.5 (1160) [8000]

50 + 0 0.2 (1.97 + 0 0.008)

55 +0 0.2 (2.17 + 0 0.008)

50.25 (1.9783)

55.25 (2.1752)

A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.12

MAINTENANCE SERVICE DATA: HYDRAULIC SYSTEM

Hydraulic System, continued Item

Truck Model

EP16/18

EP20/25

EP30

Diameter of piston 3

A

35

40

45

Thread diameter 5

A

M48 X 1.5

M53 X 1.5

M58 X 1.5

Width across flats 6

A

60 (2.36)

64 (2.52)

70 (2.76)

Tightening torque, kgf·m (lbf·ft) [N·m]

A

27 ± 4 (195 ± 29) [265 ± 39]

31 ± 4 (224 ± 29) [304 ± 39]

35 ± 5 (253 ± 36) [343 ± 49]

200431

Tightening torque, kgf·m (lbf·ft) [N·m]

A

5 ± 1 (36 ± 7.2) [49 ± 10]

63 +0 1.0

70 +00.1

80 +00.1

(2.48+0.039)

(2.76+0.004)

0

0

0

63.12 (2.4850)

70.12 (2.7606)

80.12 (3.1543)

A (3.15

)

+0.004

Inside diameter of cylinder tube 1 B

[Guide bushing] Diameter of piston rod 2

A

35

-0.02 30 -0.05

(1.18

-0.0008 -0.0020

)

(1.38

-0.025 -0.064 -0.00098 -0.00252

)

A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.13

MAINTENANCE SERVICE DATA: HYDRAULIC SYSTEM

Hydraulic System, continued Item

Truck Model

Clearance between rod and guide bushing

EP16/18

0.075 to 0.139 (0.0030 to 0.0055)

B

0.35 (0.0138) 40 +0.140 -0.020

(1.57

+0.0033 (1.26-0.0000 )

+0.085 32 0.000

B

Tightening torque kgf·m (lbf·ft) [N·m] [Socket] Thread diameter 6

)

40.6 (1.598)

A

[Guide bushing] Thread diameter 5

+0.0055

-0.0008

B

Inside diameter of frame-side head bushing (fitted) 4

EP30

A

A Inside diameter of mast-side socket bushing (fitted) 3

EP20/25

32.6 (1.283)

A

M68 X 2

M75 X 2

M85 X 2

A

27 ± 2.7 (195 ± 20) [265 ± 26]

32 ± 3.2 (231 ± 23) [314 ± 31]

38 ± 3.8 (275 ± 27) [373 ± 37]

A

M27 x 1.5

M30 x 1.5

15+08 (108 +058) [147+078]

40+08 (289+058) [392 +078]

Tightening torque, kgf·m (lbf·ft) [N·m] Tightening torque for rod socket nut 7, kgf·m (lbf·ft) [N·m]

A

28 (203) [275]

40 (289) [392]

Tightening torque for self-locking nut 8, kgf·m (lbf·ft) [N·m]

A

2 ± 3 (195 ± 22) [265 ± 29]

40 ± 2 (289 ± 18) [392 ± 25]

3

7

6

Flow rate (no load), liter (cu in.)/ min

4

5

1

A

2

50 (3051)

204946

8

65 (3967)

75 (4577)

A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.14

MAINTENANCE SERVICE DATA: MASTS & FORKS

Masts and Forks Item

Truck Model

Difference in height between fork tips

A

EP16/18

EP20/25

EP30

5(0.20)

A

35 (1.4)

40 (1.6)

45 (1.75)

B

33 (1.3)

38 (1.5)

43 (1.7)

A

318 (12.52)

381 (15.00)

508 (20.00)

B

327 (12.87)

392 (15.43)

523 (20.59)

A A A

100 (3.94) 101 (3.98) 99 (3.90)

Thickness of forks

Length of lift chains (per 20 links)

Main roller size

M L S

115 (4.53) 116 (4.57) 114 (4.49)

Diameter of side rollers

A

Distance between outer mast main rollers (outside to outside) A

A

511 (20.12)

559 (22.01)

A

581 (22.87)

639 (25.16)

Distance between lift bracket main rollers (outside to outside) C,D

A

477 (18.78)

523 (20.59)

Distance between lift bracket side rollers (outside to outside) E

A

482 (18.98)

528 (20.79)

Longitudinal clearance of lift bracket main rollers (with forks slightly lifted) F

A

0.1 to 1.0 (0.004 to 0.039)

Lateral clearance of lift bracket main rollers (fully raised) G1

A

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of lift bracket side rollers (fully raised) G2

A

0.1 to 0.5 (0.004 to 0.020)

Lateral clearance of inner mast main rollers (fully raised ) K

A

0.1 to 0.5 (0.004 to 0.020)

Mast strip clearance (fully raised) L

A

0.1 to 0.5 (0.004 to 0.020)

Distance between inner mast main rollers (outside to outside) B

42 (1.65)

A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.15

MAINTENANCE SERVICE DATA: MAST AND FORKS

Mast and Forks, continued Item

Truck Model

EP16

EP18

EP20 EP25

EP30

204894A

Tightening torque, kgf·m (lbf·ft) [N·m]

Mast support bolts

A

Chain wheel support bolts

A

9.9 (72) [97]

A

5 (0.2)

Distortion of finger bar

7.5 (54) [74]

18.2 (132) [178]

A= Assembly Standard B= Repair or service limit Unit: mm (in.)

10.16

MAINTENANCE SERVICE DATA: GENERAL

Tightening Torques for Standard Bolts and Nuts Fine Thread—With Spring Washer With Spring Washer Nominal Size

mm

in.

Pitch

mm

in.

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

6

0.24

1

0.04

0.75

5.4

7.4

0.98

7.1

9.6

1.3

9.4

12.7

8

0.32

1.25

0.05

1.7

12.3

16.7

2.3

16.6

22.6

3.1

22.4

30.4

10

0.39

1.25

0.05

3.5

25.3

34.3

4.6

33.3

45.1

7.1

51.4

69.6

12

.047

1.25

0.05

6.5

47.0

63.7

8.4

60.8

82.4

12.5

90.4

122.6

14

0.55

1.5

0.06

10.4

75.2

102.0

13.5

97.6

132.4

19.5

141.8

192.2

16

0.63

1.5

0.06

15.8

114.3

154.9

20.6

149.0

202.0

29.3

211.9

287.9

18

0.71

1.5

0.06

22.9

165.6

224.6

29.8

215.5

292.2

42.2

305.2

413.8

20

0.79

1.5

0.06

31.7

229.3

310.9

41.2

298.0

404.0

58.5

423.1

573.7

22

0.87

1.5

0.06

42.2

305.2

413.8

54.8

396.4

537.4

77.8

562.7

763.0

24

0.95

1.5

0.06

55.8

403.6

547.2

72.5

524.4

711.0

102.6

742.1

1006.2

27

1.06

1.5

0.06

81.0

585.9

794.3

105.3

761.6

1032.6

148.0

1070.5 1451.4

30

1.18

1.5

0.06

112.2

811.5

1100.3

145.9

1055.3 1430.8

205.2

1484.2 2012.3

33

1.30

1.5

0.06

149.6

1082.1 1467.1

194.5

1406.8 1907.4

273.3

1976.8 2680.2

36

1.42

1.5

0.06

195.6

1414.8 1918.2

254.3

1839.4 2493.8

356.6

2579.3 3497.1

39

1.54

1.5

0.06

251.0

1815.5 2461.5

326.2

2359.4 3198.9

455.8

3296.8 4469.9

Note 1. The tolerance on these torques is ± 10%.

2. These torques are for “dry” conditions.

10.17

MAINTENANCE SERVICE DATA: GENERAL

Tightening Torques for Standard Bolts and Nuts Fine Thread—Without Spring Washer Without Spring Washer Nominal Size

mm

in.

Pitch

mm

in.

kgf·m

lbf·ft

N·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

6

0.24

1

0.04

0.88

6.4

8.6

1.1

8.0

10.8

1.5

10.8

14.7

8

0.32

1.25

0.05

2.0

14.5

19.6

2.7

19.5

26.5

3.7

26.8

36.3

10

0.39

1.25

0.05

4.2

30.4

41.2

5.4

39.1

53.0

8.3

60.0

81.4

12

.047

1.25

0.05

7.6

55.0

74.5

9.9

71.6

97.1

14.7

106.3

144.2

14

0.55

1.5

0.06

12.2

88.2

119.6

15.9

115.0

155.9

23.1

167.1

226.5

16

0.63

1.5

0.06

18.6

134.5

182.4

24.2

175.0

237.3

34.5

249.5

338.3

18

0.71

1.5

0.06

26.9

194.6

263.8

35.0

253.2

343.2

49.7

359.5

487.4

20

0.79

1.5

0.06

37.3

269.8

365.8

48.5

350.8

475.6

68.8

497.6

674.7

22

0.87

1.5

0.06

49.6

358.8

486.4

64.5

466.5

632.5

91.5

661.8

897.3

24

0.95

1.5

0.06

65.6

474.5

643.3

85.3

617.0

836.5

120.7

873.0

1183.7

27

1.06

1.5

0.06

95.3

689.3

934.6

123.9

896.2

1216.0

174.1

1259.3 1707.3

30

1.18

1.5

0.06

132.0

954.8

1294.5

171.6

1241.2 1682.8

241.4

1746.0 2367.3

33

1.30

1.5

0.06

176.0

1273.0 1726.0

228.8

1654.9 2243.8

321.6

2326.1 3153.8

36

1.42

1.5

0.06

230.1

1664.3 2256.5

299.2

2164.1 2934.1

419.6

3035.0 4114.0

39

1.54

1.5

0.06

295.3

2135.9 2896.0

383.8

2776.0 3763.8

536.2

3878.3 5258.3

Note 1. The tolerance on these torques is ± 10%.

2. These torques are for “dry” conditions.

10.18

kgf·m

MAINTENANCE SERVICE DATA: GENERAL

Tightening Torques for Standard Bolts and Nuts Coarse Thread—With Spring Washer With Spring Washer Nominal Size

mm

in.

Pitch

mm

in.

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

10

0.39

1.5

0.06

3.4

24.6

33.3

4.4

31.8

43.1

6.9

49.9

67.7

12

.047

1.75

0.07

6.0

43.4

58.8

7.8

56.4

76.5

11.8

85.3

115.7

14

0.55

2

0.08

9.8

70.9

96.1

12.7

91.9

124.5

18.6

134.5

182.4

16

0.63

2

0.08

15.0

108.5

147.1

19.5

141.0

191.2

28.0

202.5

274.6

18

0.71

2.5

0.10

20.7

149.7

203.0

27.0

195.3

264.8

39.1

282.8

383.4

20

0.79

2.5

0.10

29.2

211.2

286.4

37.9

274.1

371.7

54.7

395.6

536.4

22

0.87

2.5

0.10

39.1

282.8

383.4

50.9

368.2

499.2

73.0

528.0

715.9

24

0.95

3

0.12

50.2

363.1

492.3

65.3

472.3

640.4

94.3

682.1

924.8

27

1.06

3

0.12

73.9

534.5

724.7

96.1

695.1

942.2

137.7

996.0

1350.4

30

1.18

3.5

0.14

98.9

715.3

969.9

128.4

928.7

1259.2

188.0

1359.8 1843.7

33

1.30

3.5

0.14

135.5

980.12 1328.8

176.1

1273.7 1727.0

252.6

1827.1 2477.2

36

1.42

4

0.16

170.9

1236.1 1676.0

222.3

1607.9 2180.0

326.3

2360.1 3199.9

39

1.54

4

0.16

226.3

1636.8 2219.2

294.1

2127.2 2884.1

420.0

3037.9 4118.8

42

1.65

4.5

0.18

280.9

2031.8 2754.7

365.2

2641.5 3581.4

523.9

3789.4 5137.7

Note 1. The tolerance on these torques is ± 10%.

2. These torques are for “dry” conditions.

10.19

MAINTENANCE SERVICE DATA: GENERAL

Tightening Torques for Standard Bolts and Nuts Coarse Thread—Without Spring Washer Without Spring Washer Nominal Size

mm

in.

Pitch

mm

in.

kgf·m

lbf·ft

N·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

10

0.39

1.5

0.06

4.0

28.9

39.2

5.2

37.6

51.0

8.1

58.6

79.4

12

.047

1.75

0.07

7.1

51.4

69.6

9.2

66.5

90.2

13.8

99.8

135.3

14

0.55

2

0.08

11.5

83.2

112.8

14.9

107.8

146.1

22.0

159.1

215.7

16

0.63

2

0.08

17.6

127.3

172.6

22.9

165.6

224.6

33.0

238.7

323.6

18

0.71

2.5

0.10

24.4

176.5

239.3

31.8

230.0

311.9

46.0

332.7

451.1

20

0.79

2.5

0.10

34.3

248.1

336.4

44.6

322.6

437.4

64.3

465.1

630.6

22

0.87

2.5

0.10

40.0

289.3

392.3

59.9

433.3

587.4

85.9

621.3

842.2

24

0.95

3

0.12

59.0

426.7

578.6

76.8

555.5

753.2

111.0

802.9

1088.5

27

1.06

3

0.12

86.9

628.5

852.2

113.0

817.3

1108.2

162.0

1171.7 1588.7

30

1.18

3.5

0.14

116.3

841.2

1140.5

151.1

1092.9 1481.8

221.1

1599.2 2168.3

33

1.30

3.5

0.14

159.4

1153.0 1563.2

207.2

1498.7 2031.9

297.3

2150.4 2915.5

36

1.42

4

0.16

201.1

1454.6 1972.1

261.5

1891.4 2564.4

384.0

2777.5 3765.8

39

1.54

4

0.16

266.2

1925.4 2610.5

346.0

2502.6 3393.1

494.1

3573.8 4845.5

42

1.65

4.5

0.18

330.5

2390.5 3241.1

429.5

3107.3 4212.9

616.4

4458.4 6044.8

Note 1. The tolerance on these torques is ± 10%.

2. These torques are for “dry” conditions.

10.20

kgf·m

MAINTENANCE SERVICE DATA GENERAL

Maintenance Chart Use the service chart to determine servicing intervals. Calendar intervals shown (weekly, monthly, etc.) may be used instead of service meter intervals, if they provide more convenient servicing schedules and approximate the indicated service meter reading. Recommended service should always be performed at the interval that occurs first.

Perform service on items at multiples of the original requirement. For example, at every 1200 hours or 6 months, also service those items listed under every 200 hours or monthly, every 50 hours or weekly and daily (pre-start). ● = Check or clean ★ = Change or adjust Maintenance Intervals

Inspection Point

Service Data

How to check

Bearing lubrication, damage

Visual

●

●

Winding to case resistance

Test

●

● Resistance to be > 1

Armature to case resistance

Test

●

●

Brush contact area

Visual

●

●

Change brush

Brush length

Visual

●

●

Change brush

Test

●

●

Change spring

Commutator surface condition

Visual

●

●

Commutator discoloration

Visual

●

●

Interior, exterior cleanliness

Visual

●

●

●

Motors Brush spring force

Test

●

●

●

●

●

Operation

Test

●

●

●

●

●

Oil leaks

Visual

●

●

●

●

●

●

●

●

Steering Wheel Free-play, looseness, rattling

Steering gear

Mounting bolts, tightness

Wrench

Beam structural damage

Visual

Cylinder leaks

Visual

Steering linkage

●

●

●

●

● ●

Visual

●

Kingpin looseness

Test

●

Trutnion fore-aft looseness

Test

●

Tie rod bearings and pins

Clean

●

Wrench

Cylinder mounting bolts

Lubricate

Nominal 0.8mm (0.031 in.) clearance

10.21

MAINTENANCE SERVICE DATA: GENERAL Maintenance Intervals

Inspection Point

How to check Service Data

Brake pedal

Parking brake

Height of pedal above floor

Scale

●

●

●

●

●

Stroke to point where brakes start applying

Scale

●

●

●

●

●

Performance

Test/spring balancer

●

●

●

●

●

3 to 10 mm (0.12 to 0.4 in.)

Lever lock position: 4° - 5° Operating effort: 25 to 30 kgf (55 to 66 lb) [245 to 294 N]

Brake hoses and pipes Brake fluid Wheel brakes

Fluid leaks, damage or installation

Visual

●

●

●

●

●

Level in reservoir

Visual

●

●

●

●

★

Master cylinder and wheel Overhaul/Visual cylinders—operation, wear and damage

Drum-to- lining clearance

Feeler gauge

Sliding surfaces of shoes and wear of lining

Disassemble/ calipers

★

●

●

●

●

Brakes drums and shoes

10.22

130cc(7.9 cu. in.)

Drum—wear or damage

Visual scale

●

Free length of return springs

Scale

●

Operation of shoes

Test

●

Anchor pins—seizure

Visual

●

EP16/18 0.2 to 0.5mm (0.01 to 0.02) EP 20/25/30 0.2 to 0.6mm (0.01 to 0.02) EP16/18 2.5mm (0.10 in.)

EP20/25/30 3.0mm (0.12 in.)

Service Limit: EP16/18 256mm (10.08 in.)

EP20/25 281.4mm (11.08 in) EP30 312mm (12.28 in.)

MAINTENANCE SERVICE DATA: GENERAL Maintenance Intervals

Inspection Point

Hydraulic tank

Lift cylinders

●

●

●

★

Visual

Strainer—clogging

Visual

★

Return filter—clogging

Visual

★

Visual / listen ●

●

●

●

●

●

●

●

Oil leaks

Visual

Main relief valve setting

Pressure gauge

●

Overload relief setting (optional) Pressure gauge

●

Control levers and links—rattle

Test

●

●

●

●

●

Cracks, distortion, or other defects

Visual

●

●

●

●

●

●

●

●

●

●

Rod drift (rated load)

Visual-watch/ scale ●

●

●

●

●

●

●

●

●

●

●

●

●

●

Attachment

Flow regulator valve

●

Oil level and contamination

Hydraulic pump Oil leaks or abnormal noise

Control valve

Service Data

How to check

Mounting bolts—tightness

Wrench

Oil leaks

Visual

Lowering speed

Watch/scale

●

●

185kgf.cm2 (2631 psi) [18142 kPa]

EP16-25 50mm (2.0 in.)/15min EP30 40mm (1.6in.)/15min

Lowering speed (rated load) EP16/18 580mm.sec (114 fpm) EP20/25 590 mm/sec (116 fpm EP30 520 mm/sec (102fpm)

10.23

MAINTENANCE SERVICE DATA Maintenance Intervals

Inspection Point

Tilt cylinders

Service Data

How to check

Cracks, distortion, or other defects

Visual

●

●

●

●

●

Oil leaks

Visual

●

●

●

●

●

Forward rod drift (rated load)

Watch/scale

●

●

●

Mounts—rattle or damage

Visual/free

●

●

●

●

●

Rod socket nut — tightness

Torque wrench

●

●

●

●

●

Oil leaks

Visual

●

●

●

●

●

Rubber hoses: damage

Visual

●

●

●

Hose reels and swivel joint— distortion or other defects

Visual

●

●

●

Cracks, distortion, or other defects

Visual/dye check ●

●

●

●

●

●

●

●

●

●

Piping

Mast and lift bracket

Mast supports—rattle or damage Main rollers—clearance, damage

10.24

Feeler gauge/ dial gauge

●

EP16/18 22mm (0.9 in.)/15 min EP20/25 20mm (0.8 in.)/15 min EP30 15 mm(0.6in.)/15 min

EP16/18 28kgf·m (203) lbf·ft) [275 N·m] EP20-30 40kgf·m (289) lbf·ft) [392 N·m]

Each roller to mast clearance (at max. height) 0.1 to 0.5mm (0.004 to 0.020 in.)

MAINTENANCE SERVICE DATA: GENERAL Maintenance Intervals

Inspection Point

How to check

Service Data

Length of lift chains (20 links)

Scale

Tension deflection of lift chains

Scale

●

●

●

●

●

Chains—damaged or rusting

Visual

●

●

●

●

●

Chain wheels—wear, distortion, or other defects

Visual

●

●

●

Chain wheel bearings—rattle

Feel

●

●

●

Chain anchor bolts—distortion or damage

Visual

●

●

●

Forks—wear and distortion

Visual/scale

●

●

●

●

●

Forks stopper pins— damage or distortion

Visual

●

●

●

●

●

Backrest mounting bolts— tightness

Torque wrench

●

●

●

●

●

Backrest—distortion or damage

Visual

●

●

●

●

●

Lights

Operation

Test/visual

●

●

●

●

●

Turn signals (optional)

Operation

Test/visual

●

●

●

●

●

Rear view Rear vision mirrors (optional)

Visual

●

●

●

●

●

Overhead guard Installation and damage

Visual/wrench

●

●

●

●

●

Lift chains and chain wheels

Forks and backrest

●

Both chains to be equal in tension

Fork thickness—refer to Service Data

●

Loosen bolts or nuts

Wrench

Operator’s seat— damage and installation

Visual

●

●

●

Lubrication points

Lubricate

●

●

●

Oil change

Inspect

●

●

●

Chassis

EP16/18 318mm (12.5 in.)

EP20/25 381mm (15.0 in.)

EP30 508mm(20.0in.)

Lubricate mast supports every 50 hours or weekly

10.25

SERVICE DATA GENERAL

Periodic Replacement Parts The parts listed below are important for the safe operation of the truck, and especially designed to be replaced at specified periods. Each service shop is requested to adhere to the replacement schedule given here on all trucks brought into its care.

Periodic Replacement Parts

Service

Period 1 month 1 month 6 months after (200 hours) (1200 hours) delivery

1 year 2 years (2400 hours) (4800 hours)

1

★

Rubber parts for brake master cylinder

Replace

●

●

2

★

Rubber parts for brake wheel cylinders

Replace

●

●

3

★

Replace

●

●

4

★

Replace

●

5

★

Rubber parts for steering cylinder

Replace

●

6

★

Replace

●

7

Hydraulic tank return filter

Replace

8

Drum to lining clearance

9

Motor brushes

Hydraulic hoses Hoses for power steering

Lift chains

●

●

●

●

Check or replace

●

●

Check or replace

●

●

✶

10.26

Indicates important safety-related parts.

MAINTENANCE SERVICE DATA: GENERAL

Lubrication Chart

8609151

10.27

MAINTENANCE SERVICE DATA: GENERAL

Fuel and Lubricant Specifications Fuel or Lubricant

Differential oil

Recommendation

Recommendation for Ambient Temperature °C, (°F) -30 -20 -10 0 10 20 30 (-22) (-4) (14) (32) (50) (68) (86)

API service classification GL-4 (Hypoid gear oil)

Hydraulic oil Brake fluid

Grease

ISO GRADE 32 SAE 75W AGMA-1EP SAE 5W

SAE 10W

F.M.V.S.S. No. 116: DOT 3 or DOT 4 (SAEJ1703) Wheel bearings

Chassis

NLGI #2 grade multipurpose type (lithium base) Consistency: 265 - 295

See RECOMMENDED BRANDS OF LUBRICANTS

N:GI #1 grade Multipurpose type (lithium base) Consistency: 310 - 340

Remarks: Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when mixed. It is best to use the same brand at successive service intervals.

▲ EP68 gear oil with borate additives are not recommended.

10.28

ISO GRADE 68 ▲ SAE80W AGMA-2EP

MAINTENANCE SERVICE DATA: GENERAL

Recommended Brands of Lubricants Transfer and Differential Oils Manufacturer

Hydraulic Oils

Specifications

Viscosity

SAE 80W

Mobil

Mobil Lub HD80W-90

Shell

Spirax HD80W90

Exxon

Spartan EP68

Specifications: Viscosity Manufacturer SAE 5W

SAE 10W

Mobil

—

Hydraulic oil 29 LP

Shell

Tellus Oil 22

Tellus Oil T-32

Exxon Castrol

Castrol

Castrol Hypoy 80W-90 GL-5

Nuto H32 Castrol Hyspin AWS32

Castrol Hyspin AWS68

Remarks:

Greases NLGI No.1

NLGI No.2

Consistency 310 to 340

Consistency 245 to 295

Mobil Grease JL77 No. 1

Mobil Grease JL77 No.2

Retinax A No.1

Retinax A No. 2

Brands of oil are subject to change without notice.

When you buy oils, select recommended brands and check specification ( for example API service classification SC, SAE 10W).

Refill Capacities (Approximate)

Exxon Ronex MP Castrol LM Grease

Castrol Spheerol API

Item & Mode Differential Hydraulic system

Brake Fluids

Brake fluid reservoir

EP16/18

EP20/25

5.3 (1.4)

EP30

6.0 (1.6)

25 (6.6)

30 (7.9)

100cc (6.2 cu. in)

SAE J1703f Unit: liter (U.S. gal) Mobil Super Heavy Duty Brake Fluid Shell Brake Fluid 250 Brake Fluid DOT-3 Castrol Brake Fluid Crimson

10.29

MAINTENANCE SERVICE DATA: GENERAL

Weight of Major Components (Approximate) Component / Model Counterweight Power train (Motor, transfer box, reduction gear and differential)

EP16

EP18

EP20

EP25

302 (666)

360(794)

420(926)

583(1286)

210 (463)

EP30 731(1612)

225 (496)

Overhead guard

60 (132)

65 (143)

70 (154)

Rear axle

220(485)

250(551)

Mast (3.3 m simplex mast)

530(1160)

730(1610)

850(1870)

Outer mast

160(350)

230(510)

250(555)

Inner mast

140(310)

180(400)

190(419)

Lift bracket (including backrest)

90(200)

130(290)

165(360)

Forks (two)

80(176)

130(287)

165(364)

Lift cylinder and related parts

60(132)

60(132)

90(198)

Hydraulic motor

45(99)

50(110)

Traction motor

80(176)

100(220) Unit:kg (lb)

10.30

MAINTENANCE SERVICE DATA: SPECIAL TOOLS

Special Service Tools Truck Models Ref. No.

Part No.

Part Name

Application

EP16/18

EP20/25

EP30

Removal and installation of rear wheel nuts

●

●

●

91268-00300 Bevel pinion (or 91868-02100) puller

Removal of bevel pinion assembly

●

●

●

3

64309-17701

Gauge kit

Measurement of hydraulic pressure

●

●

●

4

91268-00800

Socket wrench

Removal/installation of front wheel hub nuts

●

●

●

5

03703-59001

Socket wrench

Removal/installation of front wheel hub nuts

●

—

—

6

91468-00300

Installer

Installation of front axle wheel bearing inner races

—

●

●

●

—

—

1

91268-00701

2

Socket wrench

64309-12300 7

91268-01500

Installer

Installation of rear axle inner bearing inner races

●

—

—

8

64309-40400

Installer

Installation of rear axle inner bearing inner races

—

●

●

9

91268-01400

Installer

Install rear axle outer bearing inner races

●

—

—

10

91468-00400

Installer

Install rear axle outer bearing outer races

—

●

●

11

64309-15411

Spring remover

Removal f return spring

●

●

●

12

64309-15412

Spring retainer

Removal/installation of brake shoes

●

●

●

13

64309-15413

Spring hook

Installation of return spring

●

●

●

14

91268-10600

Steering wheel puller

Removal of steering wheel

●

●

●

15

91268-01600

Installer

Installation of tilt cylinder tube bushing

●

●

●

●

—

—

Hook wrench

Remove / install tilt cylinder guide bushing

09305-00750

—

●

—

09305-00800

—

—

●

09305-00680 16

17

18

64309-16300 or F4540-06300

Pipe connector

Measurement of control valve main relief pressure & overload relief pressure (to be used with 64309-17701 gauge kit)

●

●

●

97157-00100

Spring installer

Install centering spring in steer gear

●

●

●

10.31

MAINTENANCE SERVICE DATA: SPECIAL TOOLS

Special Tool Illustrations

91268-00701

64309-17701

03703-59001

91268-01500

10.32

91268-00300 91868-02100

91268-00800

91468-00300 64309-12300

64309-40400

MAINTENANCE SERVICE DATA:SPECIAL TOOLS

91268-01400

61468-00400

64309-15412 64309M12 X 1.25 M8 X 1.25

64309-15413

91268-10600

10.33

MAINTENANCE SERVICE DATA: SPECIAL TOOLS

91268-01600

Flame-hardened Hv >500, depth 2mm (0.08 in.)

09305-00680 09305-00750 09305-00800

64309-16300 F4540-06300

97157-00100

10.34

MAINTENANCE SERVICE DATA: GENERAL

Inspection Guide Check Antifriction bearings

For (item or defect)

How

ITEMS

Measure inside diameter with an indicator hole gauge and shaft outside diameter with an indicating micrometer

a) Fit on shaft b) Fit in housing

Measure outside diameter with an indicating micrometer and housing inside diameter with an indicator hole gauge

c) Preload (small initial load applied to absorb initial bearing deformation)

As stated in service manual

DEFECTS a) High running temperature (caused by overlubrication)

As shown

b) Noise (humming), vibration, or rough running

8609153

c) Creep (marks of circumferential slip on inner ring’s surface in contact with Visually shaft or on outer ring’s surface in contact with housing due to loose fir of bearing) d) Corrosion

Visually

8609151

e) True brineling (caused by careless installation or removal)

8609152

10.35

MAINTENANCE SERVICE DATA GENERAL Check Antifrication bearings

For (item or defect)

How

f) False brinelling (caused by a constant vibration or oscillation of non-rotating bearings through small arc)

Visually

g)Cracked race (caused by forcing bearing or oversize shaft or by cooking race when installing or removing)

Visually

8609155

h)Broken separator (caused by dirt, metal chips, or lack of lubricant)

Visually

8609156

i) Damaged seal (caused by improper use of tools)

Visually

8609157

j) Spalled race (caused by too loose a fit)

8609158

10.36

Visually

MAINTENANCE SERVICE DATA: GENERAL Check Antifrication bearings

For (item or defect)

How

k) Bad discoloration (caused by overheating due to poor lubrication)

Visually

8609159 i) Craters (caused by passage of electric current)

Visually

8609160 Bushings or sleeve bearings

ITEM Fit on shaft

Determine by measuring inside diameter of bushing and outside diameter of shaft

DEFECTS

Fasteners

Nicks, burrs, or other flaws on bearing surface

Hold bushing toward a light and look through bore

DEFECTS

Visually

a) Striped or otherwise damaged threads (bolts, nuts, screws, etc.) b) Distortion or loss of tension (spring lock washers, snap rings, etc.)

Gears

Examine by compressing

ITEMS a) fit on bearing, bushing, spline or key

As stated in service manual

b) Backlash

As stated in service manual

DEFECTS a) Excessive wear on teeth, thrust faces, and end faces on hub

Visually

b) Scratching wear (caused by large particles other than associated with abrasive wear)

Visually

10.37

MAINTENANCE SERVICE DATA: GENERAL Check

For (item or defect)

How

Gears

c) Abrasive wear (caused by fine particles carried in lubricant)

Visually

8609162 d) Overload wear

Visually

8609163 e) Pitting

Visually

8609164 f) Spalling

Visually

8609165 g) Overload breakage

Visually

8609166 h) Fatigue breakage

Visually

8609167 i) Corrosive wear

Visually

8609168

10.38

MAINTENANCE SERVICE DATA: GENERAL Check Keys and keyways Oil seals Roller chains and sprockets

For (item or defect)

How

Wear on sides making parts not fit tightly

Examine by placing

Damage to lip

Visually

a) Wear on pins, bushings, rollers, and plates in each link tending to increase in pitch.

Visually

b) Wear on sprocket teeth

Visually

8609189 Rubber parts

Splines and serrations

Hardening or softening, swelling, tackiness, tearing, and deterioration due to aging

Visually

ITEM Fit DEFECTS a) Nicks, burrs, chips, etc.

Visually

b) Free movement (looseness) of mating splines

Examine

c) Excessive wear polish on sides (sliding fit splines)

Visually

d) Ridge or edge left between worn and unworn areas (sliding fit spline)

Visually

8609170

10.39

MAINTENANCE SERVICE DATA: GENERAL Check

For (item or defect)

How

Springs

ITEMS

See specification

a) Type called for

Use a square

b) Squareness

8609171 c) Free length test

Examine

d) Test force DEFECTS a) Excessive clearance space between coils (compression springs) in free state

Visually

b) Any clearance space between coils (tension springs) in free state

8609172 8609173

10.40

c) Condition or ends or hooks

Visually

d) Cracks or breakage

Visually

SENB8637

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