Caterpillar Cat EP20CN 48V Forklift Lift Trucks Service Repair Manual SN ETB17-20011 and up

Service Manual MC/FC

Chassis, Mast & Options EP16N-48v EP18N-48v EP20CN-48v

ETB15-20011-up ETB15-70001-up ETB17-20011-up

For use with EP16N-EP20CN Controller Service Manual.

99759-67100

FOREWORD

This service manual is a guide to servicing of CatÂŽ lift truck of 1.6 ton, 1.8 ton and 2.0 ton classes. The instructions are grouped by systems to serve the convenience of your ready reference.

Long productive life of your lift trucks depends to a great extent on correct servicing — the servicing consistent with what you will learn from this service manual. We hope you read the respective sections of this manual carefully and know all the components you will work on before attempting to start a test, repair or rebuild job.

The descriptions, illustrations and specifications contained in this manual were of the trucks of serial numbers in effect at the time it was approved for printing. Cat lift truck reserves the right to change specifications or design without notice and without incurring obligation.

Safety Related Signs The following safety related signs are used in this service manual to emphasize important and critical instructions:

!

WARNING

!

CAUTION

NOTE

Indicate a specific potential hazard resulting in serious bodily injury or death.

Indicate a specific potential hazard resulting in bodily injury, or damage to, or destruction of, the machine.

Indicates a condition that can cause damage to, or shorten service life of, the machine.

Pub. No. 99759-67100

HOW TO READ THIS MANUAL Disassembly diagram (example)

Each disassembly diagram is followed by Disassembly sequence and Suggestion for disassembly.

Disassembly sequence

1 2

Cover, Bolt, Washer (part name) Output shaft (part name)

Suggestion for disassembly (1) Output shaft removal

Clearance between cylinder and piston

A

Unit: mm (in.)

0.020 to 0.105 (0.00079 to 0.00413)

B

A: Standard value B: Repair or service limit

0.15 (0.0059)

!

WARNING

SAFETY

!

WARNING

The proper and safe lubrication and maintenance for this lift truck, recommended

by Cat lift truck, are outlined in the OPERATION & MAINTENANCE MANUAL for these trucks.

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.

The serviceman or mechanic may be unfamiliar with many of the systems on this truck. 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.

Because of the size of some of the truck components, the serviceman or 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.

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

2. Always wear protective glasses and protective shoes when working around trucks. In particular, wear protective glasses when pounding on any part of the truck or its attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery.

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

!

WARNING

Do not operate this truck unless you have read and understand the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death.

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

5. Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from steps, walkways or work platforms before using. Always face truck 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.

6. To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or more.

Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

7. To avoid burns, be alert for hot parts on trucks which have just been stopped and hot fluids in lines, tubes and compartments.

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.

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

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

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.

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

13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck.

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.

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 fuel, lubricant and 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 personal injury. Use cardboard or paper to locate pin hole leaks.

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

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 truck 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.

GENERAL INFORMATION

Vehicle Exterior

Control lever (MC models)

Joystick box (FC models)

211146

Models This manual applies to EP16N, EP18N and EP20CN.

Truck Model

Serial Number

EP16N

ETB15-20011-up

EP18N

ETB15-70001-up

EP20CN

ETB17-20011-up

1-1

GENERAL INFORMATION

Serial Number Locations

Mast number

Chassis number

Nameplate

211270

1-2

GENERAL INFORMATION

Chassis and Mast Model Identification

[Chassis] EP

16

N

Generation designator

Maximum capacity 16: 1600 kg (3500 lb) 18: 1800 kg (4000 lb) 20: 2000 kg (4400 lb) Battery type

[Mast] 4

G

15

A

30

Maximum lifting height [“30” stands for 3000 mm (118 in.)]

Order of the minor change (“A” for the original, “B” for the first change, “C” for the second change, and so on) Applicable truck model designation 15: 1 ton class 20: 2 ton class Kind of mast G: simplex mast H: duplex mast J: triplex mast Major change (“1” for the original, “2” for the first change, and so on up to “9”)

1-3

GENERAL INFORMATION

Dimensions

B

F

E

C

D A

211271

1-4

GENERAL INFORMATION

Technical Data Truck Models

EP16N

EP18N

EP20CN

Class

1.6 ton

1.8 ton

2.0 ton

15690 (1600)/500 [3530/20]

17650 (1800)/500 [3970/20]

19610 (2000)/500 [4410/20]

Load Capacity/Load Center

N (kgf)/mm [lbf/in.]

Truck size Length to Fork Face A

mm (in.)

2074 (81.7)

2074 (81.7)

2188 (86.1)

B

mm (in.)

1070 (42.1)

1070 (42.1)

1130 (44.5)

Height of Overhead C Guard

mm (in.)

2048 (80.6)

2048 (80.6)

2048 (80.6)

D

mm (in.)

1360 (53.5)

1360 (53.5)

1463 (57.6)

kg (lb)

3190 (7033)

3280 (7231)

3470 (7650)

mm (in.)

913/898 (35.9/35.4)

913/898 (35.9/35.4)

935/898 (36.8/35.4)

Tires Size Front

18 × 7-8

18 × 7-8

200/50-10

Rear

16 × 6-8

16 × 6-8

16 × 6-8

1810 (71.3)

1810 (71.3)

1910 (75.2)

17/17 (10.6/10.6)

17/17 (10.6/10.6)

17/17 (10.6/10.6)

35/27

35/25

35/24

Width

Wheelbase Truck weight, without load/ including battery Tread Front/Rear

E/F

Turning Radius Travel Speeds Unloaded/Loaded

mm (in.) km/h (mph)

Maximum Gradeability Unloaded/Loaded

%

Lift Speeds Unloaded/Loaded

m (in.)/sec

0.60/0.50 (23.6/19.7) 0.60/0.44 (23.6/17.3) 0.60/0.40 (23.6/15.7)

Lowering Speed Unloaded/Loaded

m (in.)/sec

0.5/0.52 (19.7/20.5)

0.5/0.52 (19.7/20.5)

0.5/0.52 (19.7/20.5)

V

48

48

48

Ah

600

600

720

Battery Voltage Battery Rated Capacity (5 hrs.) MAX Battery Compartment Size Battery Weight

mm (in.) kg (lb)

Tilt Angle (forwards-backwards)

1006 × 521 × 650 1006 × 624 × 650 1006 × 624 × 650 (39.6 × 20.5 × 25.6) (39.6 × 24.6 × 25.6) (39.6 × 24.6 × 25.6) 865 (1907)

865 (1907)

1000 (2205)

6°-7°

6°-7°

6°-7°

Drive Motor, 60 min rating

kW

2 × 6.3

2 × 6.3

2 × 6.3

Hydraulic Motor (15% duty)

kW

14

14

14

Drive Motor Control Method

MOSFET

MOSFET

MOSFET

Hydraulic Motor Control Method

MOSFET

MOSFET

MOSFET

1-5

VEHICLE ELECTRICAL COMPONENTS

Console Box 1 2 3 4 5 6

1 6

Central vehicle monitoring system (CVMS) Mode selector button Steering tilt lever Key switch Lighting switch Mode check button

2

5 3 4

NOTE 103043

For setting the clock and selection of KPH or MPH, refer to “Selection of KPH or MPH” and “Setting the clock”.

Functions of Central Vehicle Monitor System (CVMS)

8

9

10

1

2

3

4

5

6

7

211131

Operations

No. 1

Monitor name

When OFF

When ON or flashing

Remarks

Service indicator

Starts flashing 20 hours before set time. Remains ON when set time is reached.

Seat belt warning light

Seat belt is fastened.

Seat belt is not fastened when operator sits on seat (seat switch is turned on).

2

2-1

VEHICLE ELECTRICAL COMPONENTS

No.

Monitor name

When OFF

When ON or flashing

Controller/motor overheat indicator

Controller, drive motors and Overheating pump motor in normal temperature

Remaining battery charge warning light

Normal battery condition

3

Remarks Overheating causes a significant output loss. When component temperature returns to normal levels, output power returns.

Flashing indicates battery needs to be recharged soon.

ON indicates battery needs to be recharged and lifting function inoperable.

4

5

Brake fluid level indicator Normal fluid level

Low fluid level

6

Parking brake warning light

Parking brake disengaged

Parking brake engaged

Fault detection indicator

Normal

Vehicle malfunction

Vehicle speed and error code display

Displays the vehicle speed during normal operation and displays an error code in the event of a malfunction.

Battery discharge indicator (BDI)

The battery charge status is indicated by the ten element indicator. When fully charged, all elements are lit through to the right side. As the battery discharges, the indicator elements decrease toward the left side. When only one element is on, the remaining battery charge warning light 4 in the LED section will flash. When the indicator completely goes off, the remaining battery charge warning light 4 will be continuously lit and the vehicle enters power reduction mode.

Hourmeter, time display

It normally displays the time.

When the key switch is set to the I (ON) position, the drive motor, pump motor, and vehicle service hours are indicated sequentially.

7

8

9

10

2-2

Error codes appear on the error code display.

The vehicle speed display can be switched between KPH and MPH. Follow the steps in “Selection of KPH or MPH” below.

The time of clock can be adjusted. Follow the steps in “Setting the clock” below.

VEHICLE ELECTRICAL COMPONENTS Selection of KPH or MPH

1. Apply the parking brake.

2. Place the direction lever in NEUTRAL. Button 1

3. Turn the key switch to the I (ON) position.

Button 2

4. Push and hold button 1 for one to two seconds.

NOTICE: Display will show KPH and a 24-hour clock until it is changed. When MPH is selected, the clock will change to a 12-hour clock.

Setting the clock

103043

1. Apply the parking brake.

2. Place the direction lever in NEUTRAL. 3. Turn the key switch to the I (ON) position.

4. Push and hold button 1 until the minutes’ display flashes.

5. Release button 1.

6. Adjust the minutes with button 2.

7. Push button 1 and release when the hours’ display flashes.

8. Adjust the hour with button 2.

9. Push button 1 to lock in the time.

2-3

VEHICLE ELECTRICAL COMPONENTS Error code display

Indication E

Condition Indicator flickers if seat switch is turned off during driving operation. Then, indicator turns on when seat switch is turned on again. Indicator turns off when direction lever and accelerator pedal are returned.

(E) 0

ON

Right traction motor overheated

E 1

ON

Left traction motor overheated

E 2

ON

Pump motor overheated

E 5

ON

Right traction inverter overheated

E 6

ON

Left traction inverter overheated

E 7

ON

Pump inverter overheated

H 1

ON

Faulty setting of lift lever

H 2

ON

Faulty setting of tilt lever

H 3

ON

Faulty setting of attachment 1 lever

H 4

ON

Faulty setting of attachment 2 lever

H 5

ON

Faulty setting of attachment 3 lever

(L)

Indicator flickers if seat switch is turned off during lifting operation.

Then, H1 to H5 turn on when seat switch is turned on again. Indicator turns off when lifting operation is suspended.

(E) means flickering.

2-4

VEHICLE ELECTRICAL COMPONENTS

Electrical Components in Console Box

Horn cable

Monitor cable 2 Direction lever switch cable 1

211148

1 2

Key switch Lighting switch

2-5

VEHICLE ELECTRICAL COMPONENTS

Disassembly and Reassembly Disassembly 2

3 1

5 4 211149

Sequence 1 2 3

4 5

Console box (front panel) Central vehicle monitor panel Direction lever

Steering tilt lever Console box (rear panel)

Disassembly procedure (1) Remove the front panel and monitor panel from the console box.

(2) Disconnect the harness connectors from the horn and direction lever.

(3) Remove the screw from the steering tilt lever, and remove the lever from the rear panel of the console box.

T-nut

Steering tilt lever Screw

(4) Remove the rear panel.

208079

Reassembly Follow the disassembly procedure in reverse.

2-6

VEHICLE ELECTRICAL COMPONENTS

Direction Lever Structure

4 1

2 3

208080

1 2

Lever Harness

3 4

2-7

Connector Screw

VEHICLE ELECTRICAL COMPONENTS

Accelerator Control Accelerator pedal

Initial position

Stopper bolt 1.5 to 2.5 Lock nut

Switching position of idle switch Floor plate 30 to 32 mm (1.18 to 1.26 in.)

Accelerator lever Accelerator

Adjusting screw Position meter

211136

Adjustment procedure (1) Disconnect the battery plug.

(2) Set the stopper bolt to 30 to 32 mm (1.18 to 1.26 in.) from the floor to the upper face of bolt.

(3) Adjust the mounting angle of the position meter using the adjusting screw so the switch inside the position meter turns on when the accelerator lever is moved 1.5° to 2.5° from the initial position.

Make sure the inside switch turns ON by checking the continuity between the two terminals (indicated by arrows) by using an ohmmeter.

(4) Perform the accelerator self-diagnostics according to the self-diagnosis table (See Controller Service Manual). The display shows OFF and Speed 0 without the accelerator depressed. Depress the accelerator a little. The display shows ON before the speed changes from 0 to 1. If not, then readjust accelerator switch.

(5) Make sure the display shows Speed 16 when the accelerator is fully depressed. If not, readjust the stop bolt.

2-8

Connector CN7

208081

VEHICLE ELECTRICAL COMPONENTS

Key Switch Terminal

B

M

Connection destination

Main fuse Battery

Logic card

●

●

● (OFF) I (ON)

206806

Lighting Switch Terminal

2, 5

3

6

Connection destination

Battery

Head lamps

Working lamps

1st position (Circuit 1)

●

●

2nd position (Circuit 1 & 2)

●

●

Push

OFF 1st (cir. 1) 2nd (cir. 1 & 2)

● BAT

2 3

Cir. 1

5 6 Cir. 2

211150

2-9

VEHICLE ELECTRICAL COMPONENTS

Fuses Capacity (A)

Location

Main connecting device

500 500

Traction motor Contactor assembly

15 10

Pump motor Key switch, Lighting switch

Fuse holder

Power relay

NOTE Refer to Parts Manual for proper replacement fuses.

Lamp Specification Chart Item Lamp

Quantity Bulb color

Bulb 48 V

Head lamps

2

Clear

45 W

Working lamp

1

Clear

45 W

External diagram

Remarks

205833

2-10

VEHICLE ELECTRICAL COMPONENTS

Troubleshooting of Lighting and Horn Systems Complaint

a) Dead or weak battery b) Fuses blown out c) Open or short in circuit d) Poor grounding

Remedy

e) Bulbs burnt out

Recharge or replace.

Check and replace.

Repair or replace.

Clean ground spot and re-make connection.

Replace.

Will light dimly

a) Dead or weak battery b) Burned contact points in switches c) Loose terminals d) Dirty lenses e) Waterdrops inside lenses f) Bulbs expired service life

Check and recharge.

Repair or replace.

Retighten.

Clean.

Dry and replace packings.

Replace.

Will not light

a) Lighting switch defective b) Bulbs burnt out

Replace.

Replace.

Backup lamps will not light

a) Backup lamp switch defective

b) Bulbs burnt out

Correct if improperly installed: replace if internally defective.

Replace.

Will not give blast of sound

a) Fuse blown out b) Open or short in circuit c) Horn switch defective d) Horn defective e) Horn button defective

Check and replace.

Repair or replace.

Replace.

Replace.

Repair or replace.

Will give ugly blast of sound

a) Horn switch defective b) Horn defective

Replace.

Replace.

Horn

Other lamps

Head lamps

Lamps-general

Will not light

Possible cause

2-11

VEHICLE ELECTRICAL COMPONENTS

Joystick Box Description

This system, unlike the conventional mechanical control, is electronically actuated to reduce the effort required of the operator in moving the control levers for lift, tilt and attachment functions.

(1) In the duplex and triplex full free masts, more oil returns from the 1st lift cylinder than from the 2nd lift cylinders to allow the 1st lift cylinder to retract faster for better maneuverability.

Tilt control lever Lift control lever Backward Raise Neutral Neutral Forward

Lower

211138

2-12

VEHICLE ELECTRICAL COMPONENTS

(2) This system provides the following safety functions: (a) When the pump motor is not running, the lift, tilt and attachment functions will not work even if the control levers are moved. (b) When the emergency switch is in the ON (pushed) position, the lift, tilt and attachments functions will not work even if the control levers are moved. (c) When the seat switch is not ON (the operator is not seated), the lift, tilt and attachments

2-13

functions will not work even if the control levers are moved. (d) The fault detection indicator in the LED alerts the operator to malfunctions involving the electrical system and also an inoperable status. (If any problem occurs in the lift system, for example, the system becomes inoperative.)

POWER TRAIN

Procedures and Suggestions for Removal and Installation Removal 1. Remove the masts.

(Refer to MASTS AND FORKS section.)

2. Removing batteries (1) Disconnect the battery plug.

(2) Open the battery cover, and lock it in the open position.

(3) Remove the side covers (L.H., R.H.) and front covers (L.H., R.H.).

Lock/unlock lever

211152

(4) Attach suspending ropes or adequate lifting device to the batteries.

Unit: kg (lb) Truck Model Item Battery weight (maximum)

1 ton class

2 ton class

1090 (2403)

1225 (2701)

(5) Remove the battery retaining plate and pin, and then remove the batteries.

3-1

208075

POWER TRAIN

3. Removing front wheels (1) Pull the parking brake lever and block the rear wheels.

(2) Loosen the wheel nuts by two turns. Then, raise the front end of the truck using a hoist or the hydraulic system. (a) Hoisting Using a sling and eye-bolts at both ends of the cross member at the top of the outer mast, lift the front end of the truck with a hoist. (b) Using hydraulic system Tilt the mast fully backward and place wood blocks under the mast. Tilt the mast forward to raise the front end.

!

CAUTION

After raising the front end, place wood blocks under the frame to prevent the truck from falling.

210757

(3) Remove the wheel nuts.

(4) Remove the wheel.

Truck Model Item

1 ton class

2 ton class

18 Ă— 7 - 8

200/50-10

Tire size of front wheels

Solid pneumatic tire

Solid tire

206920

4. Removing steps and floor plates (1) Steps (L.H., R.H.) (2) Step plates (L.H., R.H.) (3) Floor plate

(3) Floor plate B (1)

(1) (2)

Remove floor plate B.

Floor plate A

Disconnect the accelerator connector mounted on the back side of the floor plate, then remove floor plate A.

(2) 211153

3-2

POWER TRAIN

5. Removing steering hoses Disconnect the steering hoses and pipes at the connectors.

206922

6. Removing delivery pipe and drive motor harness (1) Remove the drive motor harness at the connector.

Disconnect the harnesses of the brush wear sensors and temperature sensors located on the right and left sides.

(2) The harnesses are secured to the delivery pipe with clamps. Loosen the clamps, and remove the delivery pipe.

208076

3-3

POWER TRAIN

7. Removing brake components

(i)

(ii)

(iii) (v)

(iv) (vi)

206824

(1) Loosen the parking brake lever, and remove parking brake cable assemblies (i) (L.H.) and (ii) (R.H.).

Disconnect the parking brake cables at the calipers, and keep the cables together on the frame near the center brake.

(2) Position a drip pan, and disconnect brake fluid tube (iii) at the master cylinder.

(3) Disconnect brake pipes (iv, v) (L.H., R.H.) at the master cylinder. Disconnect the branch brake hoses (L.H., R.H.) from the brake pipes.

(4) Remove brake pedal assembly (vi).

3-4

POWER TRAIN

8. Removing return hoses Remove return hose (1) from the control valve, and return hose (2) from the lift cylinder.

(1)

(2) 206925

9. Remove drive motors cables (L.H., R.H.).

Remove the generators (speed sensors) of the transfers (L.H., R.H.).

10. Removing tension rods and brackets Loosen right and left nuts (1) by approximately 6 mm (0.24 in.).

Remove bolts (2), and take out bracket (3) and tension bolt (4) together from each side of the vehicle.

(3)

Left transfer

(3)

(2)

(2) (4)

Right transfer

(1) 206926

3-5

POWER TRAIN

11. Removing transfer assemblies, drive motors and calipers

Left transfer

Right transfer (iii) Gravity center (ii)

(ii)

(i) (i) Frame Frame (iv)

Gravity center

(iii)

(iv) 206927

Remove the transfer assemblies with the drive motors and calipers mounted.

First, dismount the left transfer, lower it, then pull it out from the front of the vehicle. Then, dismount the right transfer, lower it, then pull it out from the front.

Cow hitch

(1) When suspending the assembly, position the wire rope at the gravity center.

The suspending wire rope must be cow hitched.

When using a textile sling, make two loops to prevent slipping.

(2) Remove bolt (i) from the lower part of the step and remove bolt (ii) from the frame, then remove the assembly.

(3) Remove bolt (iii), and dismount the caliper assembly.

(4) Remove bolt (iv) and dismount the drive motor.

3-6

206928

Total weight of transfer, drive motor and caliper

115 kg (253.5 lb)

POWER TRAIN

Installation Follow the removal sequence in reverse. For installation, follow the instructions below.

!

CAUTION

When mounting the transfer assembly on the frame, do not insert a finger into the bolt hole to check hole alignment.

1. Be sure to tighten bolts to the specified torque.

Front of vehicle 3

4

4

3

5

5 2 2

1

1

206785

A: Standard value

Tightening torque

Unit: N·m (kgf·m) [lbf·ft] Drive motor mounting bolt 1

A

60 ± 12 (6.1 ± 1.2) [44.25 ± 8.85]

Transfer assembly mounting bolt 2

A

508 ± 51 (51.8 ± 5.2) [375 ± 38]

Bracket mounting bolt 3

A

176 ± 18 (17.9 ± 1.8) [129.5 ± 13.0]

Bolt nut 4

A

231 ± 24 (23.6 ± 2.4) [170.7 ± 17.4]

Hub nut 5

A

156.9 ± 15.7 (16.0 ± 1.6) [115.7 ± 11.6]

2. Bleed the brake oil line.

(Refer to BRAKE SYSTEM section.)

3-7

POWER TRAIN

3. After installing the parking brake cable, be sure to adjust.

(Refer to BRAKE SYSTEM section.)

4. Pour oil into the transfer cases: Left transfer

Remove oil level plug (1).

Remove oil inlet plug (2).

Pour appropriate oil in the oil inlet. Make sure the oil level reaches the level plug location.

(2)

Unit: liter (U.S. gal) (1)

Left transfer

Right transfer

1.09 (0.29)

1.86 (0.49)

Oil quantity

Front of vehicle

Right transfer

(2)

(1)

206786

5. Bleeding hydraulic oil line and inspecting oil level Operate the tilt cylinders in the forward and backward directions to bleed the tilt cylinders. Operate the lift cylinders in the vertical directions to fill the cylinders with oil.

Lower the lift cylinders to the lowest position, and check the oil level gauge. If the oil level is low, add oil to the specified level.

6. Checking steering oil line Operate the steering wheel to make sure that it operates smoothly.

3-8

POWER TRAIN

Service Data A : Standard value Truck Models

Item Tightening torque

1 ton class

2 ton class

Drive motor mounting bolt 1

A

60 ± 12 (6.1 ± 1.2) [44.25 ± 8.85]

Transfer assembly mounting bolt 2

A

508 ± 51 (51.8 ± 5.2) [375 ± 38]

A

176 ± 18 (17.9 ± 1.8) [129.5 ± 13.0]

A

231 ± 24 (23.6 ± 2.4) [170.7 ± 17.4]

A

156.9 ± 15.7 (16.0 ± 1.6) [115.7 ± 11.6]

N·m Bracket mounting bolt 3 (kgf·m) [lbf·ft] Bolt nut 4 Hub nut 5

4

4

3

Power Line

3

5

5 2 2

1

1

206785

3-9

TRANSFER UNITS

Specifications Truck Model Item

1 ton class

Gear type Transfer

2 ton class

Constant-mesh type, 3 stages (helical gears) 58 x 83 x 45 =20.151 24 16 28

Reducing gear ratio

4-1

TRANSFER UNITS

Structure and Functions (Part 1)

Front of vehicle 7

7

A

8

8

A

9

6

6

3

1

5 5 2

4

206785

1 2 3 4 5

Transfer (left) Drive motor (left) Transfer (right) Drive motor (right) Frame

6 Wheel hub 7 Front tire 8 Bracket 9 Tension rod Section A: Mast support mounting section

Since two drive motors are installed in a limited space, the drive motors are offset in position.

Tension rod 9 connects brackets 8, and includes a turnbuckle to serve as a thrust rod for the left and right transfer units.

4-2

TRANSFER UNITS

Structure and Functions (Part 2)

18

3

4 5

2

17 18

2 3

17 4 5

211058

1 2 3 4 5 6 7

Drive motor Input gear Second gear Third gear Output shaft Wheel hub Cover

8 9 10 11 12 13 14

Main case Nut Retainer (Oil seal) Oil seal O-ring Spacer Taper roller bearing

15 16

Ball bearing Pulse generator (DC motor models only) 17 Oil level plug 18 Air breather Bolts marked with Ă— : Bolts for mounting transfer units to frame

The pulse generator detects rotating speed.

The left and right transfer units are identical, and are mounted on the frame with bolts marked with an Ă— in the illustration.

Helical gears are used for reduced operating noise.

The output shaft is provided with two taper roller bearings to withstand heavy loads.

The left and right transfer units are installed to the drive motors. The motor shafts are jointed to the involute splines of the input gears.

Transfer reducing gear ratio

Driving force is transmitted via the input gear, second gear, third gear, then to the output shaft that rotates the wheel hub.

4-3

20.151

TRANSFER UNITS

Procedures and Suggestions for Disassembly and Reassembly Start by:

3. Remove the drive motor and caliper.

1. Remove the power train consisting of the transfer, drive motor and caliper. (Refer to Removal and Installation of POWER TRAIN section.)

2. Drain oil from the transfer.

Disassembly

1

211059

Sequence 1 Bolt Remove parts 2 to 12 as sub-assembly.

2 Cover 3 Cap 4 Nut 5 Spacer, O-ring 6 Wheel hub, Hub bolt

7 8 9 10 11 12 13

Taper roller bearing Retainer O-ring Output shaft, O-ring Taper roller bearing Oil seal Input gear

4-4

14 15 16 17 18 19

Ball bearing Second gear Ball bearing Third gear Ball bearing Main case, Dowel pin

TRANSFER UNITS Suggestions for Disassembly 1. Removing nut 4

Nut 4 is secured to output shaft 10 by punching.

Use a chisel to scrape punched section carefully. Do not scratch output shaft 10.

Nut 4 is not reusable.

206789

2. Cover 2

Outer laces of taper roller bearings 7 and 11 that are pressfit into cover 2 do not have to be disassembled if inspection finds no abnormality.

Remove oil seal 12, and use a new seal.

Inspection after Disassembly 1. Inspect the gear teeth and splines for wear and damage.

2. Inspect the bearings for wear, damage, rotating resistance and noise.

3. Inspect main case 19 and cover 2 for cracking and damage.

4. Inspect the oil seal contact surface of retainer 8 for damage.

4-5

TRANSFER UNITS

Reassembly

211060

Sequence Assemble parts 1 to 4 prior to final assembly.

1 Cover 2 Taper roller bearing (outer race) 3 Taper roller bearing (outer race) 4 Oil seal 5 Output shaft, Inner race of taper roller bearing 2, O-ring Assemble parts 6 and 7, and inner race of taper roller bearing 3 prior to final assembly.

6 Wheel hub, Hub bolt 7 Retainer, O-ring, Inner race of taper roller bearing 3 Install sub-assemblies 5 and 6 in cover 1.

8 9 10 11 12 13 14 15 16 17 18

4-6

Spacer, O-ring Nut Cap Main case Third gear Ball bearing Second gear Ball bearing Input gear Ball bearing Bolt

Thank you very much for your reading.

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