Cat DP135 Forklift Service Manual free download by engineparts2

Service Manual Chassis & Mast DP100 DP115 DP135 DP150

3DP-10011-up 4DP-10011-up 5DP-10011-up 6DP-10011-up

Includes Mitsubishi 6D16 and 6D16TL Engine Service Manual - Begins on Page 476

Cat DP135 Forklift Diesel Engine Parts Contact phone: 1 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Website: www.HeavyEquipmentRestorationParts.com www.dp150.com/cat-dp135-engine-parts

99799-80120

FOREWORD

This service manual is a guide to servicing of Cat® Lift Truck’s 10 ton to 15 ton pneumatic models. 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. These lift trucks are powered by Mitsubishi 6D16TL diesel engine. For the items of the engine, refer to the following service manual: 6D16 6D16TL Diesel Engine Service Manual (Pub. No. 99709-68130) - Begins on page 476

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

CAUTION

NOTE

Indicates a specific potential hazard resulting in serious bodily injury or death. Indicates 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. 99799-80120

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.

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. WARNING

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.

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.

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.

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.

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.

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.

HOW TO READ THIS MANUAL 1. Service data in the text

Example: A: Standard value

Clearance between cylinder and piston

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

0.020 to 0.105 (0.00079 to 0.00413)

0.15 (0.0059)

2. Symbols or abbreviations

OP ....................... Option R1/4 .................... Taper pipe thread (external) 1/4 inch (formerly PT1/4) Rc1/8................... Taper pipe thread (internal) 1/8 inch (formerly PT1/8) G1/4A ................. Straight pipe thread (external) 1/4 inch (formerly PF1/4-A) Rp1/8 .................. Straight pipe thread (internal) 1/8 inch (formerly PS1/8)

GROUP INDEX GROUP INDEX

Items

GENERAL INFORMATION

Model View, Truck Models Covered, Serial Number Locations, Technical Data, Dimensions

COOLING SYSTEM

Removal and Installation, Fan Belt Adjustment

ELECTRICAL SYSTEM

Console Box, Major Components, Lamp Bulb Specifications, Batteries, Electrical System Schematic

POWER TRAIN

2-speed Transmission, 3-speed Transmission, Gear Ratios, Removal and Installation, Engine and Transmission Unit

2-SPEED POWERSHIFT TRANSMISSION

Torque Converter, Transmission, Power Flow, Control Valve, Main Regulator Valve, Hydraulic Controls, Speed Selector System, Control System

3-SPEED POWERSHIFT TRANSMISSION

Torque Converter, Transmission, Power Flow, Control Valve, Main Regulator Valve, Hydraulic Controls, Speed Selector System, Control System

FRONT AXLE AND REDUCTION DIFFERENTIAL

Front Wheels (Tires), Front Axle and Reduction Differential

REAR AXLE

Rear Axle, Power Cylinder, Minimum Turning Radius

BRAKE SYSTEM

Wheel Brake System, Brake Control Valve, Air Master, Air Governor, Air Dryer, Parking Brake, Testing and Adjusting

STEERING SYSTEM

Steering Control Valve, Tilt Steering Assembly

HYDRAULIC SYSTEM

Hydraulic System, Hydraulic Tank, Gear Pump, Priority Valve, Control Valve, Flow Regulator Valve, Down Safety Valve, Lift and Tilt Cylinders

MASTS AND FORKS

Simplex Mast

HYDRAULIC FORK POSITIONER

Applicable Attachment Models, Specifications, Structure, Removal and Installation, Removal, Installation, Fork Positioner Assembly, Fork Positioner Cylinder, Inspection and Adjustment, Troubleshooting, etc.

HYDRAULIC SIDE SHIFTERS

Side Shifter Assembly, Hydraulic Cylinder

SERVICE DATA

Maintenance Chart, Tightening Torque for Standard Bolts and Nuts, Periodic Replacement Parts, Lubrication Instructions, Weight of Major Components, Special Tools

GENERAL INFORMATION 1 Model View ................................................................................................ Truck Models Covered ........................................................................... Serial Number Locations ....................................................................... Technical Data .......................................................................................... Dimensions (Approximate) ....................................................................

1–1 1–1 1–2 1–3 1–4

GENERAL INFORMATION

Model View

210310

Truck Models Covered This Service Manual furnishes servicing and maintenance information for the following trucks: Truck model

Transmission

Designation – Serial number

Engine mounted

DP100

Powershift

3DP – 10011- up

Mitsubishi 6D16TL diesel engine

DP115

Powershift

4DP – 10011- up

Mitsubishi 6D16TL diesel engine

DP135

Powershift

5DP – 10011- up

Mitsubishi 6D16TL diesel engine

DP150

Powershift

6DP – 10011- up

Mitsubishi 6D16TL diesel engine

Cat Forklift Mitsubishi Diesel Engine Parts Contact phone: 1 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Website: www.HeavyEquipmentRestorationParts.com www.dp150.com/cat-dp135-engine-parts 1-1

GENERAL INFORMATION

Serial Number Locations

Name plate

Mast serial number

Chassis serial number

Transmission serial number

Diesel engine serial number 210311

1-2

GENERAL INFORMATION

Technical Data Truck Model DP100

DP115

DP135

DP150

Designation

3DP

4DP

5DP

6DP

Type

Standard (with 3-speed powershift transmission)

Item

Capacity/load center kgf/mm (lbf/in.) Lift General

mm (in.)

Lift speed (unloaded/loaded) mm/sec (fpm) Lowering speed (unloaded/loaded) mm/sec (fpm)

10000/600 (22000/24)

11500/600 (25000/24)

3000 (120) 360/300 (71/65)

500/450 (98/89)

Minimum turning radius mm (in.)

31.5/24.5 (20/15)

33.0/22.0 (20/14)

4000 (157)

4160 (164)

4550 (179)

3680 (145)

3830 (151)

4060 (160) 78°27’

Outside

51°14’

mm (in.)

Weight and axle loading (unloaded)

Inside

Minimum intersecting aisle

Tires

310/280 (61/55)

420/380 (83/75)

mm (in.)

Turning angle

310/290 (61/57)

15° – 12°

Travel speeds (unloaded/ Forward loaded) km/h (mph) Reverse

Performance

15000/600 (33000/24)

3300 (130)

360/340 (71/67)

Tilt angle (forward – backward) Free lift

13500/600 (30000/24)

3550 (140)

3590 (141)

Gradeability

At 1.6 km/h (1 mph)

32%

29%

(rated load)

At 2 km/h (1.2 mph)

21%

19%

Size of tires (front and rear)

10.00-2014PR (I)

10.00-2016PR (I)

12.00-20-18PR (I)

Inflation pressure of tires (front and rear) kPa (kgf/cm2) [psi]

700 (7.0) [101]

800 (8.0) [116]

Weight kg (lb)

14450 (31860)

15330 (33800)

17320 (38190)

17760 (39160)

kg (lb)

7090 (15630)

6950 (15320)

7460 (16450)

7940 (17510)

kg (lb)

7360 (16230)

8380 (18480)

9860 (21740)

9820 (21650)

Front axle loading Rear axle loading

1-3

23% 15%

14%

GENERAL INFORMATION

Dimensions (Approximate)

C G

E E

A H

D M

F 210312

1-4

GENERAL INFORMATION

Unit: mm (in.) Truck Model

Ref. No.

Item

Lift

3300 (130)

Fork length

1220 (48)

Fork width

180 (7.1)

Fork thickness

Tilt angle (forward – backward)

Overall length

Overall width (outside of tires)

2514 (99)

2599 (102)

Overall height (to top of mast lowered)

3137 (124)

3483 (137)

Tread (front)

1900 (75)

1906 (75)

Tread (rear)

1930 (76)

1890 (74)

Wheelbase

Front overhang

Ground clearance (at frame)

Minimum turning radius

DP100

DP115

DP135

70 (2.8)

DP150

90 (3.5) 15° – 12°

4293 (169)

4371 (172)

4528 (178)

2800 (110) 754 (29.7)

759 (29.9)

340 (13.4) 4000 (157)

1-5

4060 (160)

4830 (190)

3100 (122) 792 (31.2)

794 (31.3)

380 (15.0) 4160 (164)

4550 (179)

COOLING SYSTEM Specifications .......................................................................................... 2 – 1 Description ............................................................................................... 2 – 2 Removal and Installation ...................................................................... 2 – 3 Radiator and Intercooler ........................................................................... 2 – 3

Troubleshooting ...................................................................................... 2 – 6

COOLING SYSTEM

Specifications Truck Model DP100

DP115

DP135

Item Type

Forced circulation

Radiator type

Corrugated fin with pressure cap (with built-in transmission oil cooler)

Oil cooler type

Plate fin type

Capacity (complete system)

23 (6.1)

liter (U.S. gal.)

2-1

DP150

COOLING SYSTEM

Description

Detail of transmission oil cooler

7 6

9 1 3

8 5 To torque converter From torque converter

1. 2. 3. 4. 5.

Intercooler Intake hose (intercooler) Outlet hose (intercooler) Radiator Transmission oil cooler

6. 7. 8. 9.

The radiator with a tube-and-fin type core comes standard. The fins are corrugated. The cooling fan is of pusher type and has eight blades to provide high cooling efficiency. The lower tank has a built-in transmission oil cooler which, in operation, is constantly removing heat from the transmission oil returning from the torque converter.

2-2

210313

Drain cock Upper hose (radiator) Lower hose (radiator) Reserve tank

COOLING SYSTEM

Removal and Installation Radiator and Intercooler Removal 11 2 1

12 13 9

1 4

3 10

13 8

9 210314

Sequence 1. 2. 3. 4. 5. 6. 7.

Engine cover, Gas spring Radiator cover Reserve tank hose Fan guard Intercooler intake hose Intercooler outlet hose Radiator hoses (upper)

8. 9. 10. 11. 12. 13. 14.

Start by:

Loosen the radiator drain cock to drain coolant from the radiator.

WARNING Make sure the coolant temperature is cool before opening the drain cock.

2-3

Radiator hose (lower) Clamp Oil cooler pipe Intercooler mount, Grommet, Collar, Washers Intercooler Radiator mount, Grommet, Collar, Washers Radiator

COOLING SYSTEM

Suggestions for Removal 1. Intercooler

(1) Install eyebolts in the bracket mounting bolt holes. (2) Hitch a sling into the eyebolts and lift the intercooler with a crane to remove. Weight of intercooler

9 kg (20 lb)

210139

2. Radiator

(1) Hitch a sling to the radiator and support the radiator. Weight of radiator

30 kg (66 lb)

(2) Remove the radiator mounts (at 4 places) and lift off the radiator.

206547

Inspection 1. Intercooler

(1) Replace the mounting rubber if it lacks elasticity or if it is hardened. (2) If foreign substances such as insects or dust adhere to the core fins, blow compressed air from the opposite direction to remove them, taking care not to damage the fins. (3) Replace the intercooler if corrosion and rusting are remarkable or if the fins are unrepairable. (4) Check the intercooler hoses (upper and lower) for expansion and damage to the hose clamp. Replace them if any abnormality is found. 2. Radiator

(1) Blow dirt and bugs, if any, from the radiator fins with compressed air. Be careful not to bend the fins because this will decrease cooling efficiency.

2-4

COOLING SYSTEM

(2) Replace the radiator if the fins are damaged beyond repair. (3) Check the rubber cushions of the radiator mounts and replace them if damaged or deteriorated. (4) Check the radiator hoses, upper and lower, and replace them if damaged or deteriorated.

Installation To install, follow the reverse of removal sequence and do the following steps: 1. Intercooler

Lower the intercooler, aligning the lower mount with the mounting pin of the frame mount.

Mount

210315

2. Hose

When connecting a hose to the intercooler or radiator, insert it fully to the base. Securely tighten the clamp and make sure that it stops at the flair of the base and that it does not come out. 3. Antifreeze and Coolant

(1) Mix antifreeze with distilled water to the specified concentration and fill the mixed solution to the radiator neck. (2) Likewise, fill the mixed solution to the specified level in the reserve tank.

101641

(3) Start the engine and warm it up with attention to noise. (4) If coolant in the reserve tank decreases, fill the mixed solution to the specified level.

Fill within this range.

101465B

2-5

COOLING SYSTEM

Troubleshooting

Coolant leaks from radiator

Cooling system overheats

Oil leaks from oil cooler hose

Radiator corroded

Repair or replace.

Hose clamps loose

Retighten or replace.

Upper or lower hose deteriorated due to aging

Replace.

Drain cock defective

Replace.

Cracks in coolant passage in engine

Check and repair.

Debris in radiator fin

Clean.

Radiator fins distorted

Repair or replace.

Water pump belt loose

Readjust. Check for elongation or cracks due to aging and replace if necessary.

Thermostat defective

Repair or replace.

Hose clamps loose

Retighten or replace.

Oil cooler corroded

Repair or replace.

2-6

ELECTRICAL SYSTEM Specifications .......................................................................................... 3 – 1 Location of Components ..................................................................... 3 – 2 Harness A.................................................................................................. 3 – 4 Harness B.................................................................................................. 3 – 8 Harness C.................................................................................................. 3 – 10

Description ............................................................................................... 3 – 12 Console Box ............................................................................................. 3 – 12 Major Components ................................................................................... 3 – 15 Lamp Bulb Specifications .......................................................................... 3 – 18

Removal and Installation ...................................................................... 3 – 19 Console Box ............................................................................................. 3 – 19

Disassembly and Reassembly ............................................................ 3 – 20 Console Box ............................................................................................. 3 – 20 Components in Console Box .................................................................... 3 – 21 Combination Meter ................................................................................... 3 – 22 Sub-Meter ................................................................................................. 3 – 23

Batteries ................................................................................................... 3 – 26 Troubleshooting ...................................................................................... 3 – 27 Starter System .......................................................................................... 3 – 27 Gauges ..................................................................................................... 3 – 27 Lighting System ........................................................................................ 3 – 28 Alarm Unit ................................................................................................. 3 – 28 Batteries ................................................................................................... 3 – 29

Electrical System Schematic .............................................................. 3 – 31

ELECTRICAL SYSTEM

Specifications Truck Model DP100

DP115

DP135

Item Model nomenclature – No. of batteries Battery

95E41R – 2

Voltage

Capacity

Transmission shift lever

Electric

Console box

With OK monitor

Automatic transmission controller

Electronic Control Unit (ECU)

Starter switch

Anti-restart type

Lamps

See “Lamp Bulb Specifications.”

3-1

DP150

ELECTRICAL SYSTEM

Location of Components

Front combination light

Harnass A

Right side

Seat frame

Heater cable

To air heater relay

Engine

Left side To battery relay

To engine coolant temperature gauge unit Harness C

Rear combination light

Harness B 210316

For the components to which harnesses A, B and C are connected, see the pages which follow.

CAUTION Clamp the harnesses away from moving parts or sharp edges. Repair a frayed harnesses with vinyl tape.

3-2

ELECTRICAL SYSTEM

Memo

3-3

ELECTRICAL SYSTEM

Harness A (located under the seat frame) Part 1

2 13

4 1

12 5

10 9

11 18

15 22 14

14 See page 3-6. 14 210317

3-4

ELECTRICAL SYSTEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Console box Sub-meter Steering column Horn switch Transmission shift lever Turn signal switch Stop lamp switch RH front combination lamp RH high beam LH front combination lamp LH high beam Diode Ground point To harness B To transmission harness Junction connector RH working lamp (option) LH working lamp (option) Cab power supply (option) Front revolving light (option) High beam (option) Air conditioner/car heater power supply (option) 23. Option terminal

3-5

ELECTRICAL SYSTEM

Harness A (located under the seat frame) Part 2

4 5

7 8 6

11 10

210318

3-6

ELECTRICAL SYSTEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

ECU Relay for battery relay Relay for air dryer F signal relay R signal relay Battery fuse Fuse holder A Fuse holder B Speedometer power supply (option) Speedometer signal (option) Option terminal

3-7

ELECTRICAL SYSTEM

Harness B (located at the left of engine compartment)

16 8 2 9

10 2

3 7 12

210319

3-8

ELECTRICAL SYSTEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

To harness A To harness C Glow plug Electronic horn Lining wear detection switch Fuel tank unit Battery relay M5 terminal Battery side terminal Frame side terminal Battery Starter relay Alternator Engine coolant temperature gauge unit Ground point Earphone switch (option)

3-9

ELECTRICAL SYSTEM

Harness C (located at the right of engine compartment)

1 2

3 5

4 5

12 11

13 14

210320

3-10

ELECTRICAL SYSTEM 1. 2 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

To harness B Low air pressure switch Air dryer Air pressure gauge unit Engine stop control timer Engine stop solenoid Oil bypass alarm switch Engine oil pressure switch RH rear combination lamp LH rear combination lamp Ground point Air cleaner dust indicator (option) Working and license plate lamp (option) Back-up buzzer (option)

3-11

ELECTRICAL SYSTEM

Description Console Box 1. 2. 3. 4. 5. 6. 7. 8.

Engine coolant temperature gauge Travel speed select switch Fuel gauge Service hourmeter OK monitor Starter switch Lighting switch Fuse box

7 6 8 2 207464

OK Monitor

207465

Function

No.

Indicator light

OFF

ON or flickering

Remarks

Powershift transmission oil temp. indicator light Normal

Overheating

Air cleaner element indicator light

Normal

Clogged

Brake fluid level indicator light

Normal

Low

Engine oil pressure indicator light

Normal

Low

Alternator not charging indicator light

Normal

Abnormal

Glow plug indicator light

Heating completed Heating

Turn signal indicator light

Turn signal OFF

Turn signal ON

Engine coolant level indicator light

Normal

Low

Option

Headlamp beam indicator light

Low

High

Option

How to check indicator light bulbs

The bulbs are normal if the indicator lights 1, 2, 3 and 8 come ON when the starter switch key is turned to (ON) position. (The indicator lights will go OFF when the engine starts.) 3-12

ELECTRICAL SYSTEM

Components

9 6 5

4 3 2 1

207176

1. Power relay 2. Power relay 3. Turn signal relay

4. Glow plug relay 5. Glow plug timer 6. Lighting switch

7. Starter switch 8. Fuses 9. Travel speed select switch

Spare Terminals The spare terminal cord extends from the fuse box in the console box. (Another spare terminal is in the chassis-side main harness.) Color code

Lg (light green)

Removing the console box rear panel will permit you to gain access to this spare terminal which is taped to the harness protector.

Spare terminal

3-13

207209

ELECTRICAL SYSTEM

Side Instrument Panels

3 210321

1. 2. 3. 4.

Working lamp switches (option) Working lamp indicators (option) Windshield wiper switches (option) Brake lining wear indicator

5. 6. 7. 8.

3-14

Brake air pressure gauge Battery switch Powershift transmission oil temperature gauge Speedometer (option)

ELECTRICAL SYSTEM

Major Components Electronic Control Unit (ECU)

Failure indicator lights

LED (green)

LED (red)

Rear (mounting) face

205509

The Electronic Control Unit (ECU) has a built-in 1chip microcomputer. This computer processes signals from the travel speed sensor for actuating the 2-speed automatic transmission.

systems so that failure of power, control circuit, or other components will not endanger the operator.

The ECU has “self-diagnostic” failure indicator lights which come on when any problem occurs in the electrical system, thereby allowing the operator to locate the problem. It has the following fail-safe

The failure indicator lights are located on the rear (mounting) face of the ECU. This makes it necessary to remove the ECU from the truck to observe these lights.

NOTE

Fail-safe Systems

Failure

Function

Solenoid output signal circuit open

Turns OFF the power line and causes an indicator light to come on when the solenoid output signal circuit is open.

Travel speed sensor circuit open

Allows the truck to run at the present travel speed but causes an indicator light to come on.

Failure Indicator Light Flashing Patterns

Failure

Flashing pattern

Travel speed sensor circuit open 2-speed automatic transmission control circuit open

204697

NOTE: The failure indicator lights come ON and go OFF as shown below: ON 204668

OFF

3-15

ELECTRICAL SYSTEM

running) to help prevent damage to the starter pinion or flywheel ring gear. The (ON) position of the switch is for energizing the glow plugs.

Starter Switch (Anti-restart Type) This switch has a built-in mechanical lockout. This lockout restrains the key from turning to (START) position from (ON) position (as when the engine is (OFF) (ON)

(START)

203561A

Connection Chart

Key position

Terminal

Component

Fuse box, batteries, alternator, glow plugs

Fuse box, engine stop control timer, glow plug timer and relay

Transmission shift lever, glow plug timer

(OFF)

{

(ON)

{

(START)

{

Lighting Switch OFF 1st 2nd

Knob position

8 8 (0.3) (0.3)

Stroke [Unit: mm (in.)]

206481

Connection Chart

Terminal

Component

Batteries (fuses)

Tail lamps, license plate lamp (option), instrument panel lamp

Headlamps

Front combination lamps

1st position

{

2nd position

{

Knob position (OFF)

3-16

{ {

{

ELECTRICAL SYSTEM

Fuse Box

Symbol Capacity

10 A

Transmission shift lever

10 A

Instrument panel lamp, turn signals

10 A

Spare terminal

15 A

Lamps

10 A

Horn

10 A

Spare

10 A

Transmission controller, vacuum buzzer, stop lamps

10 A

Back-up lamps

15 A

Spare

B C D E F G H

Circuit

101441F

Optional fuses Fuse

Capacity

Battery fuse

15 A

Fuse holder A

Fuse holder B

Circuit

15 A

Working lamps

10 A

Revolving lamp

10 A

Air dryer relay

15 A

Air conditioner

Car heater

20 A

Windshield wiper

10 A

Cab

Fuse holder B Fuse holder A

Battery fuse

210322

3-17

ELECTRICAL SYSTEM

Lamp Bulb Specifications Item

Bulb Quantity of bulbs

Color of lens

Frosted

60W

Amber

25W

For 24V system

Type of lamp

Headlamps

Turn signal lamps

Remarks Schematic drawing

60/60W (option)

Standard (mounted on overhead guard)

Combination lamps (front) Clearance lamps

Frosted

12W

Stop and tail lamps

Red

10W/25W

Turn signal lamps

Amber

25W

Back-up lamps

Frosted

25W

Working lamps (front)

Frosted

60W/60W

Option

Working lamps (rear)

Frosted

60W/60W

Option

License plate lamp

Frosted

12W

Option

Instrument panel lamps

Frosted

Combination lamps (rear)

For combination meter OK monitor indicator lamps

Frosted

207466

3-18

ELECTRICAL SYSTEM

Removal and Installation Console Box Removal 6

5 2

207539A

(a) Turn off the starter switch, and disconnect the negative (grounding) cable from the battery.

5. Disconnect the electrical wires at connectors, and remove transmission shift lever and turn signal lever 5.

(b) Remove nut and washer on steering wheel, and remove the steering wheel.

6. Remove bolts on console box assembly 6, and remove the console box assembly.

Suggestions for Removal

Installation

1. Disconnect the electrical wires at connectors 1.

To install, follow the reverse of removal sequence.

Start by:

2. Remove screws on cover 2 using a flat-tip screwdriver, and remove the cover. 3. Remove screws on cover (U-RE) 3, and remove the cover. 4. Remove screws on cover (U-FR) 4, and remove the cover. 3-19

ELECTRICAL SYSTEM

Disassembly and Reassembly Console Box Disassembly

207175

Suggestions for Disassembly

Reassembly

1. Remove two screws 1 securing the cover. (Use a flat-tip screwdriver.)

To reassemble the console box, follow the reverse of disassembly sequence.

2. Remove six screws 2 and separate the front and rear panels. 3. Remove four screws 3 securing the instrument panel.

NOTE To replace the instrument panel bulbs, remove screws 2 and 3.

3-20

ELECTRICAL SYSTEM

Components in Console Box Disassembly

10 7 6

5 4 3 2 8

9 1

207558

Sequence 1. 2. 3. 4. 5.

6. 7. 8. 9. 10.

Harness Power relay Power relay Turn signal relay Glow plug relay

Reassembly To reassemble the console box, follow the reverse of disassembly sequence.

3-21

Glow plug timer Lighting switch Starter switch Fuses Travel speed select switch

ELECTRICAL SYSTEM

Combination Meter Disassembly

2 3 4 5

7 8 9 206480

Sequence 1. 2. 3. 4. 5.

6. 7. 8. 9.

Instrument panel Dial Engine coolant temperature gauge Service hourmeter Fuel gauge

Meter case Printed circuit plate Bulb Socket

Bulb replacement

CAUTION

For bulb replacement, remove the socket from the printed circuit plate by turning it counterclockwise. For configuration of the indicator lights, refer to “OK Monitor.”

Be careful not to damage the printed circuit plate when disassembling the combination meter.

Reassembly To reassemble the combination meter, follow the reverse of disassembly sequence.

3-22

ELECTRICAL SYSTEM

Sub-Meter Disassembly

6 7 4

8 5

3 10

12 1

210323

Sequence

1. Disconnect the harness at connectors 1. 2. Remove three bolts 2 that hold the side instrument panel, and remove the instrument panel from the seat frame. 3. Remove four screws 3 and separate panel 4 from cover 5. 4. Remove the following components: 6. 7. 8. 9. 10. 11. 12.

Brake air pressure gauge Battery switch Brake lining wear indicator Powershift transmission temperature gauge Low air pressure buzzer Power relay Brake lining wear buzzer

3-23

ELECTRICAL SYSTEM

Reassembly Follow the reverse of disassembly sequence.

NOTE Connect the air pressure gauge harness to the correct terminal.

(Green/red) (Black)

Air pressure gauge terminal (Green) (Blue)

To brake lining wear indicator

To battery switch

To low air pressure buzzer

To power relay To brake lining wear buzzer

210324

3-24

ELECTRICAL SYSTEM

Precautions for installing other parts 1. Engine stop solenoid installation

(1) Before installing the solenoid, push the plunger all the way into it to make sure that the plunger stroke coincides with the standard value. 0

Stroke L

0 0 L=26-1.5 mm (1.02 -0.063 in.)

26 – 1.6 mm (1.02 – 0.063 in.)

Note: Record the measured value of plunger stroke. 210325

(2) After installing the solenoid, connect a lamp (or tester) and power supply to it.

V Testa

(3) Energize the solenoid to see if the lamp is lit. (Check voltage when the tester is used.)

Lamp

NOTE When testing the solenoid DC24V

(1) Do not energize any longer than 5 seconds. (2) Do not energize any more than 5 times.

AUX

3-25

210326

ELECTRICAL SYSTEM

Batteries 1. Electrolyte specific gravity (S.G.) reading and battery condition Electrolyte S.G. reading at 20°C (68°F)

Battery condition

Adjustment

1.280 to 1.265

Battery is fully or well charged.

Check each cell for S.G.

1.260 to 1.225

Battery is half charged.

Recharge the battery. Make sure there is neither faulty component, short-circuited cord nor corroded connection in the system.

1.220 or lower

Battery is discharged.

Recharge the battery. If difference in S.G. among the cell is large, adjust the S.G. during recharging.

When S.G. difference among cells is more than 0.040

A cell with a low S.G. is in shorted condition. Some electrolyte has been lost. Too much electrolyte, or water in electrolyte, too.

Recharge until voltage and S.G. stabilize and have remained constant for at least 2 hours. During recharging, adjust the S.G. to anywhere between 1.280 and 1.265. If difference in S.G. among the cells is more than 0.040 and a low S.G. is found in certain cells only, replace the battery.

2. Relationship between electrolyte specific gravity and charging rate

(3) During charging, adjust the charging current to prevent the battery electrolyte temperature from rising beyond 45°C (113°F).

To check the battery for charging, take hydrometer readings on its electrolyte: the battery may be deemed to be fully charged if the readings are between 1.280 and 1.265 at normal temperature. The tendency of the charging system can be told from the way the electrolyte level goes down to expose cell plates. If refilling (with distilled water) is necessary every month or so, the system is tending to over-charge the battery. If refilling is not required for over 3 months, it is likely that the system is inadequately charging.

(4) When connecting the cables to the battery, begin with the cable for the positive (+) terminal. When disconnecting them from the battery, begin with the cable for the negative (-) terminal.

CAUTION Be sure to turn off the starter switch and lighting switch before disconnecting or connecting the battery cables to prevent the IC regulator from suffering damage.

3. Precautions for battery charging (1) In slow-charging a dead battery, the charging current should be about 1/10 the capacity of the battery to be charged. (2) In quick-charging the battery, the battery capacity in ampere should not be exceeded.

3-26

ELECTRICAL SYSTEM

Troubleshooting Starter System Dead or weak battery Starter circuit defective Poor continuity in starter switch Starter or starter relay defective Transmission shift lever not in neutral position

Recharge or replace. Repair or replace. Replace. Replace. Move the lever to neutral position.

Turning off starter switch will not stop engine

Open or short circuit Engine stop solenoid defective Control timer defective

Repair or replace. Replace or readjust. Replace.

Will not indicate at all

Open or short circuit Gauge internally defective Gauge unit defective

Repair or replace. Replace. Replace.

Will not indicate accurately

Wrong type of gauge or gauge unit Loose terminal connection

Replace. Repair.

Will indicate higher than actual temperature

Circuit between gauge and gauge unit grounded Gauge internally defective

Repair. Replace.

Will not indicate at all

Open or short circuit Gauge internally defective Gauge unit defective

Repair or replace. Replace. Replace.

Will not indicate accurately

Gauge or gauge unit not of the type called for Loose terminal connection

Replace.

Will indicate “Full” regardless of fuel level in tank

Circuit between gauge and gauge unit grounded Gauge internally defective Gauge unit defective

Repair.

Will indicate “Empty” regardless of fuel level in tank

Circuit between gauge and gauge unit open or short Gauge unit defective Gauge internally defective

Replace. Replace.

Will not indicate (even if air pressure is acting on gauge unit)

Open or short circuit Gauge defective Gauge unit defective

Repair or replace. Replace. Replace.

Indication will not return to 0 (when air pressure is 0 kPa (0 kgf/cm2) [0 psi])

Circuit between gauge and gauge unit grounded Gauge defective Gauge unit defective

Repair.

Starter will not crank engine Starter switch

Gauges

Temperature gauges

Fuel gauge

Air pressure gauge

3-27

Repair.

Replace. Replace. Repair.

Replace. Replace.

ELECTRICAL SYSTEM

Lighting System

Bulbs burnt out

Recharge or replace. Check and replace. Repair or replace. Clean ground spot and re-make connection. Replace.

Will light dimly

Dead or weak battery Burned contact points in switches Loose terminals Dirty lenses Waterdrops inside lenses Bulbs expired in service life

Check and recharge. Repair or replace. Repair. Clean. Dry and replace packings. Replace.

Will not light

Light switch defective Bulbs burnt out

Replace. Replace.

Will not flash

Bulbs burnt out Turn signal relay defective

Replace. Replace.

Will not go out

Turn signal relay defective Turn signal switch defective

Replace. Replace.

Will flash too slow

Wrong wattage of bulbs Weak battery Turn signal relay detective

Replace. Recharge or replace. Replace.

Will flash too fast

Wrong wattage of bulbs Turn signal relay defective

Replace. Replace.

Back-up lamp switch defective Bulbs burnt out

Correct if improperly installed: replace if internally defective. Replace.

Lighting switch defective Bulb burnt out

Replace. Replace.

Will not give blast of sound

Fuse blown out Open or short circuit Horn switch defective Horn defective Horn button defective

Check and replace. Repair or replace. Repair or replace. Replace. Replace.

Will give abnormal blast of sound

Horn switch defective Horn defective

Replace. Replace.

Will not light

Lamps – general

Headlamps

Turn signal lamps

Back-up lamps will not lights

Dead or weak battery Fuses blown out Open or short circuit Poor grounding

Other lamps License plate lamp will not lights

Alarm Unit

Horn

3-28

ELECTRICAL SYSTEM

Batteries Alternator belt slipping

Readjust.

* Alternator

Stator coil grounded or open-circuited

Repair or replace.

Rotor coil open

Replace.

Brushes poorly seating on slip rings

Replace brushes if worn. Clean holder and polish slip rings.

Diode ruptured

Replace.

* Regulator

Regulated voltage setting too low

Readjust.

Tends to run down rapidly * Batteries

Not enough electrolyte or wrong proportion of acid to water

Refill and check specific gravity: 1.280

Battery cell plates deteriorated (possibly internal short-circuit)

Replace.

Terminal connections loose

Clean and retighten.

* Wiring

Open or loose connection between starter switch and regulator IC terminal

Repair.

Fuse blown, or loosely set in holder

Replace and repair.

Open or loose connection between F terminals of regulator and alternator

Repair.

* Wiring

Circuit between regulator IC and F terminals shorted or miswired

Repair.

Poor grounding of regulator F terminal

Repair.

Tends to get overcharged * Regulator

Pressure coil open-circuited

Replace.

Regulated voltage too high

Readjust.

3-29

ELECTRICAL SYSTEM

Memo

3-30

ELECTRICAL SYSTEM

Electrical System Schematic

3-31

Br R LgR F BW N BR B1 L B2

HORN SWITCH

LEVER FORWARD NEUTRAL REVERSE

GY GL 17 19 GR

224 223

Y B G

GY GL 17

74 4

121

228

21 20 22 15

YR 61 62 72 36 26 50 51 218 217 219 36 3 74 200

37 68 95

119

LOW AIR PRESSURE SWITCH

LR G Y R 2R BY

LR B

85 66 85 70

228

230

228

230

REAR COMBINATION LAMP (24V) 22 101

51 340

OIL BYPASS ALARM (ENGINE GROUP)

OIL PRESSURE SWITCH (ENGINE GROUP)

101

119

182 77

5BW

182

ENGINE STOP SOLENOID

CODE SOLENOIDO

18 92 75

GY B G GR GL

341

BACK BUZZER (OP.)(24V)

HARNESS, I

WORKING LAMP (OP.)(24V)

CORD 341

TURN SIGNAL LAMP LEVER CHART 15 21 313 121

RELAY FOR BATTERY RELAY FUSE HOLDER 22

95 15A

228

2R BY

312

R GR GL

316

13 11

316 317 336

R GR RW GY GL

317 2LW 2L 315 2WR

305

WL 2WB 2WR

308

220

79 RB

POWER SOURCE FOR REAR WORKING LAMP (OP.)

INPUT FOR WORKING LAMP (OP.)

322

STOP LAMP SWITCH WR

336

213

315 213

FORWARD-REVERSE SOLENOID (TRANSMISSION GROUP) TRAVEL SPEED SENSOR (TRANSMISSION GROUP)

214

2WR

225

HARNESS, A

225

TRAVEL SPEED SOLENOID (2 SPEED) (TRANSMISSION GROUP)

TRAVEL SPEED SOLENOID (3 SPEED) (TRANSMISSION GROUP)

230

228

301

230

WORKING LAMP (OP.)(24V)

230

228

301

SEAT FRAME SIDE

FRAME SIDE (R.H.) 60B

M10

CORD

228

10A 15A

15A

82 91

18 51

20 75

REAR COMBINATION LAMP (24V) 5

230

52 20 34 43

HARNESS, ECU FUSE

77 91 99

GB GR G GL B

BACKUP LAMP (12W) TAIL & STOP LAMP (10/25W) TURN SIGNAL LAMP (25W)

130 98

(3) Termimal of marks show arrangemant of electrical apparatus side.

116

(2) Phenomenon line show circuits for optional parts.

219 218

216 214

340 341

HEATER SWITCH (OP.)

44 60B B

341 340 215 217 112 211 327 214 216 218 219 116 210

CABLE,STARTER 60B

ECU FUSE

CABLE,BATTERY 31 90

213 214 212 216 215 218 217 219 112 116 211 210 327 4 15 3 14 13 7 6 8 10 11 2 1 16

TRANSMISSION CONTROLLER

CABLE,BATTERY

60B 60B

225

HORN (24V)

BRAKE LINING WEAR DETECTING SWITCH (AIRMASTER)

CABLE,BATTERY

BATTERY RELAY

M L

M10 ENGINE

CABLE,BATTERY 4

FUEL TANK UNIT (FUEL SYSTEM)

NOTES

(1) Unless otherwise specified. wire size shall be 1.25mm2.

2 212 213

HEATER (OP.)

210

15A

39 212

LW YB 2B RL GY GL G GR GL 5BW LW

GB RW

214

8BW 8B

212

SPEED METER SIGNAL (OP.)

213

c FRONT & REAR WORKING LAMP d ROOM LAMP(OP.) e WIPER POWER SOURSE FOR AIR CONDITIONER f POWER SOURSE FOR CAR HEATER

POWER SOURCE FOR SPEED METER (OP.)

CORD,HEATER

TERMINAL MUST BE TIGHTEN WITH BOLT FOR VALVE COVER.

5BW

215 216

CORD

WORNING LAMP(OP.)

212

214

2B Y G R RL

CORD

316

216

RG BR

222

215

LW LR YB BY

TORQUE-CONVERTER OIL THERMO UNIT (TRANSMISSION GROUP) SR

213

327 327

217

GL GY GB BW YG YW YW GR GL RW G GR GL 2BY

317

206

212

328

112

BY B

HARNESS,T/M

216

335 317

R G

WORKING LAMP(OP.)(24V)

215

208

207

209

GY BW

335

GR GL B

215

323

211 25

FRONT COMBINATION LAMP

222

91 222

HEAD LAMP(24V)

FRONT WORKING LAMP (OP.)

REAR WORKING LAMP (OP.) BACK SIGNAL (OP.)

YR GL GY RG BR RY B RB

307

327

FUSE CAPACITY CIRCUIT a AIR DRYER(STD.) 10A b WORNING LAMP

8BW

334

336

LW GL B B

301 309

335

304

335

R GR GL

306

335

324 11

2LW 2L 2LW

d e f

2BR 2BY 2BW

82 RL

HARNESS,HEAD LAMP

POWER SOURCE FOR CAB

a b c

332

334

M10 20

FUSE HOLDER

332

2BY

RW RW

115

GL B

116

RB B RY BR RG WR BW WB RL LW B RW W

HARNESS,B 114

FUSE HOLDER B 338

24V-60W

111

HARNESS,HEAD LAMP

20 316

5BW

BR 314 2BY 313 2BW

312

60B

317

60B

18 17

X 112

FUSE HOLDER A

8 313

110

FLW 0.5R

8BW 8B

127

338 R

182

82 RL B

230

126

FLW 0.85R

314

116 117 114 115

2B G G R RL

112 111 110 113

LW LR YB BY

314 127 126 85

225

226

HEAD LAMP(24V) 24V-60W

GL GY GB BW YG YW YW GR GL RW G BR GL 2BY

GL GR

RL GY B B

203 226 95 225

FRONT COMBINATION LAMP

BR L B R

338

CORD GW BR B GR

2BY

WORKING LAMP(OP.)(24V)

60B

130

43 130 L R

CAT Schematic No.

Used for

ES099 - 80120

99799 - 80120

YW YR

STARTER(24V-5kW) (ENGINE GROUP)

IC REGULATOR

126

114

218 219 217

FLW 0.85R

M6 STEERING COLUMN

R SIGNAL RELAY

339 B

F SIGNAL RELAY

83 RL B

0.5

121

AIR DRYER RELAY

BW B

336

L N R

RW GB LR G

TERMIMAL F L R

LEVER LEFT NEUTRAL RIGHT

TURN SIGNAL LAMP (25W) TAIL & STOP LAMP (10/25W) BACKUP LAMP (12W)

GROW PLUG 36

352

230 229

F N R

228

HARNESS,C 24

TERMINAL B1 B2 F N R

222

230 352

230 22

HARNESS, INDICATOR RADIATOR

229

YB 2B 46 22 RL GY 82 18 GL G 20 92 GR GL 51

HARNESS,SUBMETER

AIR PRESSURE GAGE UNIT

2B Y L GR GW BR L GL G BW

228

67 LW B

YB L

LG L

GW BW B BR

G L

GW B L R

15B

200

WORK LAMP SWITCH (OP.)(24V)

218 219 3 200 217 36 74

(GREEN)

65 51 50 26 72 36 62 61

119

230

(WHITE)

WR BW WB BL WL GL GW

15 16 17 18 19 20 21 22 23 15 50 8 52 79 57 55 70 75

18 19 16 17 23

WR BW WB BW BR GL L

G R RW GB RB RL GW BY GL

GR GR R GR RB RW R BY GL

LW LR

9 10 230 228 LW LR

W YB YR L B YL RY GR B YW

6 5 3 8 7 13 12 83 14 90

SHIFT LEVER CHART

121

121 221

TURN SIGNAL LEVER R L

GR GB

GL GY BW BR L

6 7 8 12 13 14 83 90 43 46 72 31 121

F-N-R LEVER

3 34

YW YB

GROW RELAY

2B G L GR R BR L LG YB BW

357

AIR HORN SWITCH (OP.) (BRAKE LINE)

201

106

B R

0.75fB

3 SPEED

201

2 5

202

B RL GR

2 SPEED

202

1 2

SPEED SELECT SWITCH 2

106

B GL G GR GB

24 119

GLOW TIMER

356

312

332

5BW

320

2BW

2RW

2BY

WL 1 5

357

10A 10A 15A

355

5BW

110

334

15A 10A 10A

BACK LAMP POWER RELAY

313

T B

10A 10A 10A

COOLANT LEVEL SENSOR (OP.) (COOLING SYSTEM)

HARNESS, INDICATOR DUST

2R 2R BAT BY 0.75fG ON 2L 2L SOL

FUEL

336

AIR DRAYER (BRAKE LINE)

HOUR METER

WATER TEMP

110

T B

SUBMETER ASSY

B RL GR

3BY

BATTERY SWITCH

DUST INDICATOR SWITCH (OP.) (INTAKE SYSTEM)

ENGINE STOP CONTROL TIMER

LR B

POWER RERAY

LOW AIR PRESSURE BUZZER

AV1.25B

BRAKE LINING WEAR WARNING BUZZER

T P H

P H T

BRAKE LINING WEAR WARNING LAMP

FRONT WORKING SWITCH (OP.)

TORQUE-CONVERTER AIR PRESSURE OIL THERMO GAGE GAGE

REAR WORKING SWITCH (OP.)

B G1 G2 M S

OFF ON START

YR L

WORNING SWITCH (OP.)

CORD,AIR DRYER

STARTING SWITCH CONNECTION CHART

LITING SWITCH CONNECTION CHART TURN SIGNAL RELAY LIGHTING TERMINAL NO. CORD OFF 1 2 B AV1.25B SWITCH

CONSOLE BOX

Truck Model

Serial No.

DP 100

3DP10011-up

DP 115

4DP10011-up

DP 135

5DP10011-up

DP 150

6DP10011-up

M10

INSIDE OF FRAME (LH.)

ALTERNATOR(24V-40A) (ENGINE GROUP)

ENGINE THERMO UNIT

Pub. No. 99799 - 80120 3 - 31

POWER TRAIN Specifications .......................................................................................... 4 – 1 Description ............................................................................................... 4 – 2 2-speed Transmission ............................................................................... 4 – 2 3-speed Transmission ............................................................................... 4 – 3 Gear Ratios (2-speed Transmission) ........................................................ 4 – 4 Gear Ratios (3-speed Transmission) ........................................................ 4 – 5

Removal and Installation ...................................................................... 4 – 6 Engine and Transmission Unit Removal .................................................... 4 – 6 Installation ................................................................................................ 4 – 16 Refill Capacities (Approximate) ................................................................. 4 – 19

Service Data ............................................................................................ 4 – 20

POWER TRAIN

Specifications Truck Model DP100

DP115

DP135

Item

Torque converter

Type

3-element, 1-stage, 2-phase

Model

MI 16

Stall torque ratio

2.88 Direction control

Electric, column shift

Speed control

Automatic

Control

Transmission

2-speed transmission 1st: 1.556 2nd: 0.685 3-speed transmission 1st: 2.402 2nd: 1.010 3rd: 0.532

Forward Gear ratio Reverse

Reduction bevel gear

Gear type

Hypoid

Gear ratio

5.571

Type

Planetary gear

Final drive

Differential

Gear ratio

4.167

Housing type

Banjo

Differential bevel gear, type – No. of gears

Straight bevel – 2

Differential bevel pinion, type – No. of pinions

Straight bevel – 4

Type

Full-floating, tubular

Front axle Mounting method

Fixed

4-1

DP150

POWER TRAIN

Description 2-speed Transmission 10 9 15 4

6 16

8 205488A

1. 2. 3. 4. 5. 6. 7. 8.

Diesel engine Flywheel Torque converter Transmission Input shaft Countershaft Output shaft Travel speed sensor gear

9. 10. 11. 12. 13. 14. 15. 16.

Power from the diesel engine is sent through the following components to the front wheels:

Pump drive gear Hydraulic pump Universal joint Parking brake Front axle Reduction and differential Final drive Wheel brake

(4) Reduction and differential 14 Receives power from the universal joint and splits it through two rear axles to the final drive. The differential allows the front wheels to turn different amounts when the truck goes around a curve.

(1) Torque converter 3 Is a hydrokinetic device serving as a variable torque amplifier. (2) Transmission 4

(5) Final drive 15

Has two forward and two reverse speeds. It has four hydraulic multi-disc clutches.

Has a planetary gear and drives the front wheels.

(3) Universal joint (propeller shaft) 11 Transmits power from the transmission to the reduction and differential.

4-2

POWER TRAIN

3-speed Transmission 11 12 3 17

8 18

1. 2. 3. 4. 5. 6. 7. 8. 9.

Diesel engine Flywheel Torque converter Transmission Input shaft FORWARD clutch shaft REVERSE clutch shaft 1ST-SPEED/3RD-SPEED clutch shaft Output shaft

10. 11. 12. 13. 14. 15. 16. 17. 18.

Power from the diesel engine is sent through the following components to the front wheels:

205670A

Travel speed sensor gear Pump drive gear Hydraulic pump Universal joint Parking brake Front axle Reduction and differential Final drive Wheel brake

(3) Universal joint (propeller shaft) 13 Transmits power from the transmission to the reduction and differential.

(1) Torque converter 3 Is a hydrokinetic device serving as a variable torque amplifier. It is one of two related devices, hydraulic coupling and converter.

(4) Reduction and differential 16 Receives power from the universal joint and splits it through two rear axles to the final drive. The differential allows the front wheels to turn different amounts when the truck goes around a curve.

(2) Transmission 4 Has three forward and three reverse speeds. It has five hydraulic multi-disc clutches.

(5) Final drive 17 Has a planetary gear and drives the front wheels.

4-3

POWER TRAIN

Gear Ratios (2-speed Transmission) Figures in ( ) indicate number of gear teeth. (39)

(60)

(18) (57)

(54)

(52)

(36)

(54) (36) (42)

(52)

(7)

(39)

(37) (56)

210327

Speed

Transmission 52

1st

1.556 ( 52 x 36 )

2nd

0.685 ( 52 x 54 )

1st

1.556 ( 36 )

2nd

0.685 ( 54 )

Forward

Reverse

Reduction bevel gear

Total gear ratio 36.111

5.571 (

36 ) 7

Final drive

(

4.167

15.906

57 +1) 18

36.111 15.906

PTO gear ratio: 0.929 ( 42 x 60 ) PTO: For driving hydraulic pump (standard) Above + For driving air conditioner compressor (option)

4-4

POWER TRAIN

Gear Ratios (3-speed Transmission) Figures in ( ) indicate number of gear teeth. (39)

(60) (58) (18)

(54)

(57)

(35)

(34) (58)

(60)

(7)

(42)

(35) (24)

(58)

(39) (31) (53)

(56)

210328

Speed

Transmission 1st

Forward

Reduction bevel gear 56

2.402 ( 34 x 58 x 58 x 24 )

1st

Total gear ratio 55.760

2nd 1.010 ( 34 x 54 )

23.455 58

3rd 0.532 ( 34 x 58 x 58 x 60 )

Reverse

Final drive

2.402 ( 34 x 58 x 24 )

5.571 (

2nd 1.010 ( 34 x 58 x 54 )

39 ) 7

(

4.167

12.347

57 + 1) 18

55.760 23.455

3rd 0.532 ( 34 x 58 x 60 )

12.347

PTO gear ratio: 0.929 ( 42 x 60 ) PTO: For driving hydraulic pump (standard) Above + For driving air conditioner compressor (option)

4-5

POWER TRAIN

Removal and Installation Engine and Transmission Unit Removal Start by:

(a) Disconnect the negative (ground) battery cable. (b) Drain the coolant [approximately 23 liters (6 U.S. gal.)] from the radiator and from the engine. (c) Open the air tank drain plug to release air from the tank.

Overhead guard or cab

Suggestions for Removal A. Overhead guard

1. Disconnect the harnesses of the head lamps and combination lamps from the connectors. 2. Remove the four bolts (M16) that hold the overhead guard. 3. Hitch a sling to the overhead guard and remove the guard.

NOTE

210329

Hitch slings with balancing at the center-of-gravity position duly in mind.

B. Cab (when so equipped)

1. Disconnect the harness of the head lamps, combination lamps, warning lamps, windshield wiper and washer and pump from the connectors.

Seat frame

2. Remove the covers at the four lower corners of the cab. Remove the four bolts (M16) that hold the cab. 3. Hitch a sling to the cab and remove the cab. Frame

NOTE (1) For head guard-equipped or cab-equipped truck, the subsequent steps of work are the same when removal has been done this far. (2) If the truck is equipped with a cab and a car heater, disconnect the engine coolant hose and the heater harness.

4-6

210330

POWER TRAIN

Removal of Covers and Plates

3 1

11 6 12

2 4 8 5

7 10

Seat frame 9 210331

Sequence 1. 2. 3. 4. 5. 6.

Gas spring (LH, RH) Engine cover Radiator cover Front cover B, Air cleaner Front cover A Floor plate A (RH)

7. 8. 9. 10. 11. 12.

Suggestions for Removal

(1) Leave the seat bracket attached to the seat frame. (2) Leave the accelerator pedal, brake pedal, inching pedal, brake control valve, etc. attached to the seat frame. (3) Disconnect the air cleaner hose at the engine side, then remove the hose and air cleaner attached to the front cover B.

4-7

Floor plate A (LH) Cover (brake pedal) Cover (front) Toe board Floor plate D Floor plate C

POWER TRAIN

Removal of Seat Frame and Associated Parts

5 4 7 3

6 8

10 To transmission 2 To harness B

210332

Sequence 1. 2. 3. 4. 5.

Engine control cable Seat frame harness A Inching pedal cable Brake control valve hose Parking brake lever

6. 7. 8. 9. 10.

4-8

Brake reserve tank Hydraulic control cable Steering control valve Body grounding cable Seat frame

POWER TRAIN Suggestions for Removal (1) Engine control cable

Disconnect the cable at the engine side. Coil it up at the front side of the seat frame. (2) Inching pedal cable

Disconnect the cable from the clevis pin of the inching lever under the seat frame. (3) Parking brake lever

Remove the lever mounting bolt with the lever in the brake applied position.

210333

(4) Hydraulic control cable

Remove the cable from the clevis pin at the foot of the control lever. (5) Brake reserve tank

Remove the mounting bolt and drain oil from the tank. (6) Seat frame harness A

Disconnect the harness at the following connectors. (a) Connectors (3 places) to harness B 210334

(b) Connector of transmission harness (7) Body grounding cable

Disconnect the cable at the seat frame side.

4-9

POWER TRAIN (8) Brake control valve hose

Disconnect the two hoses from the valve at connectors.

210335

(9) Steering control valve

Disconnect the five hoses from the valve at connectors.

210336

Seat frame

(10)Seat frame

(a) Remove the mounting bolts from the seat frame. This must be done by at least two persons.

Bolt Cushions

(b) Hitch slings to the bolt holes located at four corners of the NOTE Hitch the slings with balancing at the center-of-gravity position duly in mind.

seat frame and hoist the seat frame to move out of place.

4-10

Frame Nut

210337

POWER TRAIN

Electrical Parts Removal

Suggestions for Removal (1) Harness B disconnecting points (see page 3-8.) 1. 2. 3. 4. 5.

Note:

Glow plug terminal Joint with harness C Lining wear detection switch connector Alternator connector Engine coolant temperature gauge unit terminal

Disconnect the harness B from the right-hand side of the truck. Then, unclip the harness at two midpoints and put it aside to the left-hand side of the truck.

(2) Harness C disconnecting points (see page 3-10.) 1. Engine stop solenoid connector 2. Oil bypass alarm switch terminal 3. Engine oil pressure switch terminal

(3) Starter cable

Disconnect the cable at the starter relay side connector.

(4) Engine grounding cable

Remove the bolt securing the cable to the frame.

210338

4-11

POWER TRAIN

Pipes and Hoses Removal

8 6

3 10

10 12

2 1

1 1 210339

Sequence 1. 2 3 4 5. 6.

Fuel hose Cross member Air compressor hose Exhaust pipe Air master Hydraulic high pressure hose

7. 8. 9. 10. 11. 12.

Hydraulic suction hose Fan guard Intercooler hose Radiator hose Intercooler Transmission cooler hose

4-12

POWER TRAIN Suggestions for Removal (1) Fuel hose

Two pipes remain attached to the underside of the cross member. Disconnect the hoses to the engine and truck body at pipe connectors. (2) Air compressor hoses

Leave the two hoses connected at the suction side. (3) Air master

(a) Disconnect the pipe between the air master and wheel brake. (b) With the brake reserve tank and pipe behind left connected, remove the air master together with bracket. (4) Hydraulic high pressure hose

Disconnect the hose at the oil pump and priority valve sides. (5) Hydraulic suction hose

Disconnect the hose from the suction pipe on the underside of the oil pump and the suction hose connector. (Place a dip pan to receive the oil that flows out.) (6) Intercooler

(a) Unclip the harness C (at three points) ahead of the intercooler and slacken it forward to prevent breaking. (b) Remove the bolts securing the intercooler and lift the intercooler off the frame. Intercooler weight

Approx. 9 kg (19.8 lb)

210340

(7) Transmission cooler hose

Disconnect the hose at the transmission side and leave it lying along the frame.

4-13

POWER TRAIN

Engine Mounts, Thrust Rods and Associated Parts Removal

1 3

1 4

210341

Sequence 3. Transmission mounting bracket fitting nut 4. Universal joint

1. Thrust rod bracket 2. Engine mounting bracket fitting nut

Suggestions for Removal (1) Thrust rod bracket

Remove the bolts attaching the bracket, then remove the bracket with the thrust rod left attached to the transmission mounting bracket. (2) Universal joint

Remove the universal joint at the transmission side.

4-14

POWER TRAIN

Engine and Transmission Unit

210342

Fasten a hoist to the engine and transmission unit by hitching slings to the eyes of the engine at two places and a chain sling with lever block to the transmission at one place as shown. Adjust the length of the chain sling with the lever block so that the unit is horizontal. Slowly lift the unit while moving it backward.

Weight of engine and transmission unit (3-speed transmission)

910 kg (2010 lb)

4-15

POWER TRAIN

Installation To install, follow the reverse of removal sequence. Suggestions for Installation Output shaft

(1) Check the cushions of the engine and transmission mounting brackets and replace them if damaged or deteriorated. (2) Mount the engine and transmission combination on the mounting bracket while fitting the universal joint to the transmission output flange.

Output flange

(3) Tighten the mounting bolts to the specified torque. Ref. No.

205457

Engine mount (left shown, right opposite) 4

Item

Tightening torque

Rubber cushion bolts

145 N·m (14.8 kgf·m) [107 lbf·ft]

Mounting bracket bolts

60 N·m (6.1 kgf·m) [44 lbf·ft]

Rubber cushion bolts

97 N·m (9.9 kgf·m) [72 lbf·ft]

206171

Transmission mount (right side)

Mounting bracket bolts

1 2

60 N·m (6.1 kgf·m) [44 lbf·ft]

206172

Transmission mount (left side) 1 2

206173

4-16

POWER TRAIN

(4) Tighten the universal joint to the specified torque. Tightening torque for universal joint

71±10 N·m (7.2±1.0 kgf·m) [52±7 lbf·ft]

(5) Install the exhaust pipe with a new gasket. (6) Install the harnesses, making sure their connectors and terminals are tightened properly. (7) Install the seat frame in position. When the selflocking nuts contact the plain washers, tighten 2 turns [3 mm (0.12 in.)] more. (8) Install the overhead guard or cab in position and tighten the mounting bolts to the specified torque. Tightening torque for overhead guard or cab bolts

Seat frame Bolt Cushions

145 N·m (14.8 kgf·m) [107 lbf·ft]

Frame Nut

(9) Install the parking brake wire with ball and nut. Then test the operating effort of the lever. 245 to 294 N (25 to 30 kgf) [55 to 66 lbf]

(10) Install the brake pedal and inching pedal rods and cables, and check the height of the pedals and the stroke of the inching valve plunger.

Unit: mm (in.) 190 mm (7.48 in.)

Operating effort of parking brake lever

210337

Unit: mm (in.) Height of pedal

190 (7.48)

Stroke of inching valve plunger with inching pedal released

9 (0.35) 9 mm (0.35 in.)

(11) Connect the engine control cable to the injection pump lever, and make sure that the lever is in full throttle position when the pedal is depressed all the way. (12) Connect piping between the hydraulic pump and steering control valve. (13) Make sure that all wires have been connected properly, and then connect the ground (negative) cables to the batteries.

4-17

210343

POWER TRAIN

(14) Refill the engine oil pan, radiator and transmission, and check for leakage. For concentration of antifreeze in coolant, consult your Cat lift truck dealer. (15) Fill the brake fluid reservoir, and bleed the brake lines. (16) Prime the fuel system. (17) After having checked the various parts, start the engine, and observe its running condition. If the engine vibrates excessively, retighten the mounting bolts to see if this retightening has any effect. Operate the mast, forks and steering, and check the oil level in the hydraulic tank, adding oil if necessary. Recheck the engine oil, coolant and transmission oil levels, and refill if necessary. (18) Test the transmission as follows: (a)

Tilt the mast fully backward. Position wood blocks under the mast and tilt the mast forward to raise the front wheels until they clear the ground. After raising the wheels, support the frame with stands. Block the rear wheels.

(b)

Start the engine and operate it at low idle. Move the transmission shift lever to FORWARD position to make sure the front wheels rotate in the correct direction. Move the transmission shift lever to REVERSE position and do the same step.

(c)

Move the travel speed select switch on the console box to each position to make sure the front wheels rotate at the correct speed in each position.

CAUTION During testing, the front wheels rotate. Set up a fence around the truck to prevent anyone from entering into the testing area.

4-18

201143A

POWER TRAIN

Refill Capacities (Approximate) Unit: liter (U.S. gal.) Truck Model DP100

DP115

DP135

DP150

Item Radiator

23 (6.1) 2-speed: 22 (5.8) 3-speed: 23 (6.1)

Transmission Differential Front axle

25 (7) Final drive

Brake fluid reservoir

200 cc (12.2 cu in.)

Hydraulic tank

172 (45)

204 (54)

Fuel tank

230 (61)

280 (74)

Engine oil

Engine

12 (3.2)

Oil filter

4 (1.0)

Total

16 (4.2)

NOTE: For recommended oil brands, etc., see the “GROUP 15 SERVICE DATA.”

4-19

POWER TRAIN

Service Data A: Standard value Truck Model DP100

DP115

DP135

DP150

Item Tightening torque for rubber cushion bolts 1 A N·m (kgf·m) [lbf·ft]

145 (14.8) [107]

Tightening torque for mounting bracket bolts 2 A N·m (kgf·m) [lbf·ft]

60 (6.1) [44]

Tightening torque for rubber cushion bolts 3 A N·m (kgf·m) [lbf·ft]

97 (9.9) [72]

Tightening torque for mounting bracket bolts 4 A N·m (kgf·m) [lbf·ft]

60 (6.1) [44]

Engine mount (left side shown, right side opposite) 4

210344 Transmission mount (left side)

Transmission mount (right side) 1

1 2 2

3 3

210345

4-20

210346

POWER TRAIN

A: Standard value Truck Model DP100

DP115

DP135

DP150

Item Tightening torque for overhead guard or cab bolts 1 A N·m (kgf·m) [lbf·ft] Tightening torque for seat frame 2 N·m (kgf·m) [lbf·ft]

145 (14.8) [107] When self-locking nuts contact plain washers, tighten 2 turns [3 mm (0.12 in.)] more.

210347

Tightening torque for universal joint 1 N·m (kgf·m) [lbf·ft]

70±10 (7.2±1.0) [52±7]

210348

4-21

2-SPEED POWERSHIFT TRANSMISSION Specifications .......................................................................................... 5 – 1 Description ............................................................................................... 5 – 2 Torque Converter ...................................................................................... 5 – 2 Transmission ............................................................................................ 5 – 3 Power Flow ............................................................................................... 5 – 4 Control Valve ............................................................................................ 5 – 5 Main Regulator Valve ................................................................................ 5 – 5 Hydraulic Controls .................................................................................... 5 – 6 Speed Selector System ............................................................................ 5 – 8 Control System ......................................................................................... 5 – 9

Removal and Installation ...................................................................... 5 – 10 Torque Converter .................................................................................... 5 – 12 Disassembly ............................................................................................. 5 – 12 Inspection ................................................................................................. 5 – 13 Reassembly .............................................................................................. 5 – 16

Transmission ............................................................................................ 5 – 18 Disassembly ............................................................................................. 5 – 18 Inspection ................................................................................................. 5 – 27 Reassembly .............................................................................................. 5 – 31

Control Valve ............................................................................................ 5 – 39 Disassembly ............................................................................................. 5 – 39 Inspection ................................................................................................. 5 – 40 Reassembly .............................................................................................. 5 – 41

Main Regulator Valve ............................................................................. 5 – 42 Disassembly ............................................................................................. 5 – 42 Inspection ................................................................................................. 5 – 42 Reassembly .............................................................................................. 5 – 42

Adjustment ............................................................................................... 5 – 43 Stall Speed Measurement ......................................................................... 5 – 47 10 m (33 ft) Start Acceleration Test ........................................................... 5 – 48 “Automatic 2-speed”/“Fixed 1st Speed” Test ............................................. 5 – 49

Troubleshooting ...................................................................................... 5 – 50 Service Data ............................................................................................. 5 – 55

2-SPEED POWERSHIFT TRANSMISSION

Specifications Truck Model DP100

DP115

DP135

Item

Torque converter

Type

3-element, 1-stage, 2-phase

Model

MI 16

Stall torque ratio

2.88 Direction control: Electric, column shift Speed control: Automatic

Control

Transmission

Forward

1st: 1.556 2nd: 0.685

Reverse

1st: 1.556 2nd: 0.685

Gear ratio

5-1

DP150

2-SPEED POWERSHIFT TRANSMISSION

Description Torque Converter 7

5 2

From oil pump

1 8

6 To oil cooler

200550

1. Pilot boss 2. Flexible plate 3. Drive cover

4. Turbine assembly 5. Stator 6. Freewheel

7. Pump (impeller) 8. Stator shaft 9. Input shaft (transmission)

They allow the engine to turn fast while the truck wheels are turning slowly. Thus, a high torque can be applied, and the truck can accelerate. As the truck comes up to speed, the turbine begins to “catch up” the pump (to cause the torque converter to act as a fluid coupling). When this happens, the oil leaving the trailing edges of the turbine vanes is moving at about the same speed as the pump. Now, the oil could pass directly into the pump in a “helping” direction, without being given an assist by the stator. Under these conditions, the stator vanes are in the way. The oil begins to hit the back sides of the stator vanes. To allow the stator vanes to move out of the way, the stator is mounted on a freewheeling mechanism (one-way clutch) that allows the stator to turn freely, or “freewheel”, in only one direction.

Oil for the operation of the torque converter is from the oil pump. It goes through outlet passage in the stator shaft to the oil cooler, from which it goes to the transmission lubrication circuit. The torque converter consists essentially of three fundamental members: namely, the pump, turbine and stator (reaction member). The pump is attached to the drive cover which in turn is driven by the engine through flexible plates. The turbine is splined to the input shaft (of the transmission). The stator is attached to the stator shaft, with freewheel in between. The purpose of the stator is to cause the torque converter to multiply torque when the pump is turning faster than the turbine. This speed difference and increase in torque have the same effect as a low gear in the manual transmission. 5-2

2-SPEED POWERSHIFT TRANSMISSION

Transmission

9 8

1 R2

207500

1. Flexible plate 2. Torque converter assembly 3. Input shaft

4. Countershaft 5. Output shaft 6. PTO drive gear

The transmission is the powershift type and has two speeds forward and two speeds reverse. It has four hydraulic clutches of the disc type. 5-3

7. Pump idler gear 8. Pump drive gear 9. Pump case

2-SPEED POWERSHIFT TRANSMISSION

Power Flow Figures in ( ) indicate number of gear teeth. Forward 1st

Reverse 1st

(39)

(60)

(52)

(36)

(29) (42) (36) (52)

(50)

(56)

Forward 2nd

Reverse 2nd

(54)

(52)

(54)

(52)

(37)

205460B

Speed

Gears engaged 1st

Forward 2nd 1st Reverse 2nd PTO gear

52 56 x 52 36 52 37 x 52 54 56 36 37 54 60 39 x 42 60

Gear ratio 1.556 0.685 1.556 0.685 0.929 5-4

2-SPEED POWERSHIFT TRANSMISSION

Control Valve 2

Section A – A

Section B – B

B C

1 Section C – C 205461

1. Accumulator valve 2. Direction valve

3. Inching valve plunger 4. Inching valve

5. Travel speed (1st/2nd) valve

Main Regulator Valve

1 200554A

1. 2. 3. 4.

Bolts Cover O-ring Slug

5. 6. 7. 8.

Spool Body Spring Drain port

9. Main pressure port 10. Torque converter inlet pressure port

5-5

5-6

Capacity: 70 liters (18.5 U.S. gal.)/min at 2300 rpm

Oil pump

Setting: 0.02 to 0.15 MPa (0.2 to 1.5 kgf/cm 2) [3 to 21 psi]

Lubrication relief valve

Setting: 0.05 to 0.49 MPa (0.5 to 5.0 kgf/cm 2) [7 to 71 psi]

Torque converter inlet relief valve

Torque converter bypass orifice: Diam. 4.0 mm (0.157 in.)

Oil cooler

Chassis area

Transmission oil reservoir

Lubrication line

Oil filter

Diam. 6 mm (0.24 in.)

Torque converter

Tap (plug) for main pressure (marked “M”)

Tap (plug) for torque converter inlet pressure (marked “T”)

Suction strainer with magnet 100 mesh (particle size 220 µ)

Setting: 1.08 to 1.37 MPa (11.0 to 14 kgf/cm 2) [156 to 199 psi]

Main regulator valve

Last chance filter 230 µ

Orifice: Diam. 0.8 mm (0.031 in.)

Solenoid valve (speed selection)

Last chance filter 230 µ

Orifice: Diam. 0.8 mm (0.031 in.)

Pressure at end of charging: 0.71 MPa (7.2 kgf/cm 2) [102 psi]

Pressure at start of charging: 0.21 MPa (2.1 kgf/cm 2) [30 psi]

Accumulator valve

Oil filter for forward/ reverse clutches (particle size 95 µ) Response (inching) valve Setting: 0 to 0.22 MPa (0 to 2.2 kgf/cm 2) [0 to 31.3 psi]

Solenoid valve (direction selection)

Main orifice: Diam. 2.0 mm (0.079 in.)

Solenoid valve (direction selection)

Last chance filter 230 µ

Orifice: Diam. 0.8 mm (0.031 in.)

2-SPEED POWERSHIFT TRANSMISSION

Hydraulic Controls

205923

2-SPEED POWERSHIFT TRANSMISSION

Oil Pressure Taps

PC PP

210658

PM: Main pressure tap PT: Torque converter inlet pressure tap

PP: Solenoid valve pilot pressure tap PC: Clutch pressure tap

5-7

2-SPEED POWERSHIFT TRANSMISSION

Speed Selector System

Travel speed select switch 1st speed clutch

Electronic Control Unit (ECU)

Output gear

Travel speed (solenoid) valve 2st speed clutch

Electric signal

Travel speed sensor 0.5 mm (0.02 in.)

Hydraulic pressure signal Transmission case

Control system Electronic Control Unit (ECU)

Travel speed select switch

Solenoid valves

Travel speed sensor

210351

Location of components

The speed selector system is made up of an Electronic Control Unit (ECU), a travel speed sensor and a travel speed (solenoid) valve. The selection of two modes “Automatic 2-speed” and “Fixed 1st speed” is done manually by means of the travel speed select switch.

Unit: km/h (mph) Select switch position (mode)

Automatic 2-speed

Fixed 1st speed 5-8

Travel speed DP100, DP115

DP135, DP150

1st

0 to 10 (0 to 6.2)

0 to 9 (0. to 5.6)

2nd

10 to 26 (6.2 to 16.1)

9 to 27 (5.6 to 16.8)

0 to 12 (0 to 7.5)

0 to 13 (0 to 8.1)

2-SPEED POWERSHIFT TRANSMISSION

Control System

R N

F 1

7 4 5

5 6

210352

1. 2. 3. 4. 5.

Transmission shift lever Inching bracket Control valve Travel speed (solenoid) valve Direction (solenoid) valve

6. 7. 8. 9. 10.

5-9

Inching valve plunger Inching lever Inching cable Electronic Control Unit (ECU) Inching pedal

2-SPEED POWERSHIFT TRANSMISSION

Removal and Installation To remove the transmission assembly from the truck, remove it together with the engine. Refer to “GROUP 4 POWER TRAIN.”

Transmission removal (1) To separate the transmission from the engine, put the engine on a stable stand, and support the transmission with wood blocks. (2) Remove the hydraulic pump from the transmission. (3) Fasten a hoist to the transmission and lift the transmission just enough to take the weight of the transmission. To lift the transmission, tie a sling around the torque converter housing and install an eye bolt to the transmission cover, hitching a chain with lever block to the eye bolt as shown. (4) Remove the bolts that hold the flexible plates through the access hole in the torque converter housing. (5) Separate the transmission from the engine by lifting it with a hoist.

205464

Torque converter removal Remove the torque converter as an assembly from the transmission by separating the stator shaft from the transmission input shaft

NOTE Remove the drain plug of the torque converter and drain the oil.

5-10

2-SPEED POWERSHIFT TRANSMISSION

Torque converter installation (1) Couple the torque converter to the transmission. Make sure that the distance between the end face of the torque converter housing and the mating face of the flexible plate is 25 mm (0.984 in.). If this distance is more than 25 mm (0.984 in.), it is an indication that spline engagement between the torque converter stator shaft and transmission input shaft is improper; recouple the torque converter to the transmission.

25 mm (0.984 in.)

(2) Lift the transmission, and couple it to the engine. (3) Make sure that the clearance between the flywheel and flexible plates is 0 to 2 mm (0 to 0.08 in.) when the transmission is coupled to the engine. (4) Tighten the bolts that hold the flexible plates to the flywheel through the access hole in the torque converter housing. The bolts should be tightened evenly in a crisscross pattern. When tightening those bolts, turn the torque converter with a heavy-duty screwdriver put to the bolts.

200557

(5) Install the hydraulic pump to the transmission. (6) Mount the transmission harness.

Travel speed solenoid valve (S1)

Connect the travel speed sensor at the connector side, and connect the thermounit at the terminal side. Connect the F and R changeover solenoid valves respectively to the terminals with F and R identification marks at their roots. Connect the travel speed solenoid valve to the terminal which has no mark. The remaining terminal is for grounding. Solenoid Valve Travel speed

Harness Wire Color S1

LgR

R solenoid valve

F solenoid valve

206064

Transmission shift lever PVC-R tape

NOTE The transmission harness is common for the 2nd and 3rd speed transmissions. When the transmission harness is used for the 2nd speed transmission, ensure that the terminal marked 2 is not covered. (Refer to the illustration shown at right.) (7) Pour in the torque converter oil. 5-11

Travel speed sensor side Tie branch wire onto truck cable.

Harness A side Cover the terminal portions fully. 206250

2-SPEED POWERSHIFT TRANSMISSION

Torque Converter Disassembly 5 6

3 7

3 4 205626

Sequence 1. Bolts, Washers, Plate 2. Flexible plates, Pilot boss, O-ring, Bolts, Washers 3. Bolts, Drive cover, Ball bearing, Plug, Gasket, Washers 4. Spacer, Turbine

5. Thrust washers, Thrust bearing 6. Stator, Rollers, Hub, Springs, Spring caps, Thrust washers 7. Ball bearing, O-ring, Pump boss, Pump (impeller), Snap ring, Bolts, Washers

5-12

2-SPEED POWERSHIFT TRANSMISSION

Suggestion for Disassembly To remove the stator assembly, slightly force the stator just like turning it counterclockwise to prevent the rollers from falling and pull the stator together with the hub by sliding the splines.

204530

Inspection 1. Pump (impeller)

(1) Check for cracks. (2) Check for oil leaks due to looseness of the bolts holding the boss to the pump, or defective O-ring. (3) Check the face of the pump boss in contact with the oil seal for wear. (4) Check the face of the pump boss in contact with the seal ring for wear.

Oil seal

5-13

Seal ring

O-ring 200561

2-SPEED POWERSHIFT TRANSMISSION 2. Stator

(1) Check the blades for cracks. Also check the fit of the stator on the clutch cam. (2) Check the clutch hub and cam for wear or flaws. (3) Check the springs for damage. Also check the spring caps for wear or distortion. (4) Check the rollers for flaws, distortion or flat spots due to wear. (5) Check the clutch hub splines for defects. (6) Check the thrust washers for wear or other defects. A: Standard value

Outside diameter of clutch hub 1

Diameter of clutch rollers 2

Thickness of thrust washer 3

Thickness of thrust washer 4

Thickness of thrust washer 5

Thickness of thrust washer 6

Thickness of thrust washer 7

B: Repair or service limit Unit: mm (in.)

67.97 to 67.951 (2.6760 to 2.67523)

67.8 (2.669)

10.185 to 10.2 (0.40098 to 0.402)

10.1 (0.398)

4.95 to 5 (0.1949 to 0.197)

4.8 (0.189)

3.95 to 4 (0.1555 to 0.157)

3.8 (0.150)

2.9 to 3 (0.114 to 0.118)

2.8 (0.11)

4.9 to 5 (0.193 to 0.197)

4.8 (0.189)

4.95 to 5 (0.1949 to 0.197)

4.8 (0.189)

1 2 5 6 7

200724

5-14

2-SPEED POWERSHIFT TRANSMISSION 3. Turbine

(1) Check the vanes for cracks. (2) Check the fit of the turbine boss in the turbine. (3) Check the turbine boss splines for wear or other defects. 4. Pilot boss

Check the surface in contact with the pilot bearing for wear or other defects. A: Standard value Diameter of portion in contact with engine flywheel 1

B: Repair or service limit Unit: mm (in.) − 0.007

− 0.00028

20 − 0.020 (0.79 − 0.00079 )

19.85 (0.7815) 200411

5-15

2-SPEED POWERSHIFT TRANSMISSION

Reassembly

4 2

9 3

5 6

205643

Sequence 1. 2. 3. 4. 5. 6. 7.

Pump (impeller) Pump boss, O-ring, Bolts, Washers Ball bearing, Snap ring Stator assembly Springs, Spring caps Rollers Hub

8. 9. 10. 11. 12.

Thrust washer Thrust bearing, Thrust washers Turbine Drive cover, O-ring, Bolts, Washers Spacer, Ball bearing, Pilot boss, O-ring, Bolts, Washers 13. Flexible plates, Plate, Bolts, Washers

5-16

2-SPEED POWERSHIFT TRANSMISSION

Suggestions for Reassembly 1. Stator assembly

5 5

(1) Put hub 7 in the stator as shown. Put spring 5 and spring cap 5 in each hole, and press in roller 6 while pushing the spring cap.

(2) Install a total of ten rollers, and restore the hub to its original position. (3) After having assembled the stator, turn the hub by hand, making sure that it rotates in only one direction. 7

202885A

2. Selection of spacer

Measure the dimensions A, B and C. Select a spacer equal to the clearance (dimension D) and put it in position. A

Part number

Thickness of spacer

92322 - 14700

2.9 mm (0.114 in.)

92322 - 14800

3.0 mm (0.118 in.)

92322 - 14900

3.2 mm (0.126 in.)

92322 - 06600

3.4 mm (0.134 in.)

92322 - 06700

3.5 mm (0.138 in.) A

Standard dimensions mm (in.)

204534

26.3 (1.035)

B C

19 (0.75) 4

0 − 0.1

(0.16 − 0.004 )

3. Flexible plate

After having installed the flexible plate, measure the face runout of the plates with a dial indicator. Replace the plates if the runout has exceeded the service limit. A: Standard value

Face runout of flexible plate (in free state)

B: Repair or service limit Unit: mm (in.)

0.2 (0.008)

0.5 (0.020)

205922

5-17

2-SPEED POWERSHIFT TRANSMISSION

Transmission Disassembly 1. Control valve and external parts

1 6

2 5 12

11 18

15 8

210353

Sequence 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Inching bracket, Spring, Bolts, Washers Breather Oil level gauge, Plug Oil pipe, Eye bolt, Gaskets Oil pipe, Eye bolts, Gaskets Oil pipe, O-rings, Bolts, Washers Oil pipe, O-rings, Bolts, Washers Oil pipe, Eye bolt, Gaskets Control valve, Gasket, Bolts, Washers Main regulator valve, Gasket, Bolts, Washers

11. Bracket, Bolts, Washers 12. Bracket, Bolts, Washers 13. Travel speed sensor cover, Travel speed sensor, Bolts, Washers 14. Thermounit 15. Drain plug, Gasket 16. Oil filter 17. Cover, O-ring, Bolts, Washers 18. Magnet strainer assembly

5-18

2-SPEED POWERSHIFT TRANSMISSION

2. Transmission cover and shafts

12 13

7 11 14 10 5 9

6 4 3

1 2 207501

Sequence 1. Transmission cover subassembly, Gasket, O-rings, Bolts, Washers 2. Oil seals 3. Ball bearing 4. Output gear 5. Snap ring 6. Baffle plate, Bolts, Washers 7. Countershaft subassembly

8. 9. 10. 11. 12. 13. 14.

5-19

Input shaft subassembly Baffle plate, Bolts, Washers Output shaft Travel speed sensor gear, Lock plate, Bolts Ball bearing Output gear Snap ring

2-SPEED POWERSHIFT TRANSMISSION

Suggestions for Disassembly 1. Transmission cover subassembly 1 removal

Turn two Bolts (jack bolts) (special tool) in the M10 x 1.25 holes in the cover evenly until the cover is approximately 25 mm (1 in.) apart (the bearings get out of place). Then remove the cover, taking care not to damage the seal rings of the input shaft and countershaft. Do not attempt to remove the lubrication line relief valve from the cover.

Bolts (jack bolts)

Special tool needed Bolt

67284 - 15400

205479

2. Output gear (outside) 4 removal

Remove the output gear together with ball bearing 3 with a gear puller.

Output gear Sliding hammer

3. Input shaft subassembly 8 and countershaft subassembly 7 removal

Tap the rear end of the input shaft subassembly 8 to push it forward. This will also cause the countershaft subassembly to come off. Remove the countershaft subassembly by turning it aside the input shaft subassembly. Then remove the input shaft subassembly. 4. Output shaft 10 removal

Turn a sliding hammer in the M10 x 1.25 hole in the end of the output shaft, and remove the shaft together with the output gear, ball bearing and travel speed sensor gear.

5-20

205480

2-SPEED POWERSHIFT TRANSMISSION

3. Stator shaft and oil pump

21 22 19 27 23 16

15 26

18 17 29 28 30 31

205679

Sequence 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

PTO cover, O-ring, Bolts, Washers Snap ring Pump drive gear, Seal rings Ball bearing Pump case, O-ring, Bolts, Washers Pump plate, O-ring, Gasket, Bolts, Washers Internal gear Pump gear Ball bearing Torque converter housing, Gasket, Bolts, Washers

25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

5-21

Oil seal Idler gear shaft Roller bearing PTO drive gear Ball bearing Ball bearing Stator shaft, Seal ring, Bolts, Washers Pump idler gear Roller bearing Transmission case, Dowels

2-SPEED POWERSHIFT TRANSMISSION

Suggestions for Disassembly 1. Torque converter housing 24 removal

Turn two Bolts (jack bolts) (special tool) in the M10 x 1.25 holes in the housing evenly until the housing is approximately 18 mm (0.7 in.) apart (the PTO drive gear ball bearing gets out of place). Fasten a hoist to the housing and remove the housing. Special tool needed Bolt

67284 - 15400

2. Oil pump removal

Remove the oil pump as a subassembly including pump case 19, pump plate 20, internal gear 21 and pump gear 22. 3. Idler gear shaft 26 removal

Turn the Shaft Puller (special tool) in the shaft hole. Install the sliding hammer (used in removing output shaft 10) to this Puller and remove the shaft.

M20 × 1.5 M10 × 1.25

Special tool needed Shaft puller

To be made by dealer

204852

4. PTO drive gear 28 removal

Grip ball bearing 29 with a gear puller. Put a protective plate on the end of the stator shaft and remove the gear together with two ball bearings

205483

5-22

2-SPEED POWERSHIFT TRANSMISSION 5. Stator shaft 31 removal

Turn two Bolts (jack bolts) (special tool) in the M10 x 1.25 holes in one end of the shaft evenly or hit the other end by using a protective plate. Special tool needed Bolt

67284 - 15400

6. Roller bearing outer race removal

Do not remove the outer race of roller bearing 33 for idler gear 32 unless it has a defect.

5-23

2-SPEED POWERSHIFT TRANSMISSION

4. Input shaft subassembly

5 15

4 1

14 16 14 13

10 6 11

8 9 10

11 207502

Sequence 1. 2. 3. 4. 5. 6. 7. 8. 9.

Seal rings Ball bearing Thrust washer Gear (R2 drive), Needle roller bearing Thrust washer, Snap ring Ball bearing Thrust washer Gear (R1 drive), Needle roller bearing Thrust washer, Snap ring

10. 11. 12. 13. 14.

Snap rings, Pressure plates Friction plates, Mating plates Snap rings, Retainers Clutch springs Clutch pistons, Steel balls, Screws, Piston seals 15. Seal rings 16. Input shaft

NOTE Do not attempt to remove the screws from the input shaft. It is not necessary to disassemble clutch pistons 14 if the balls move freely in the pistons when the pistons are shaken.

5-24

2-SPEED POWERSHIFT TRANSMISSION

Suggestions for Disassembly 1. Input shaft ball bearing 6 removal

Use the special tools to remove ball bearing 6 from the input shaft.

Special tools needed Ref. No.

Part No.

Q'ty

Puller

91268 - 13810

Plate

91268 - 13820

Bolt

F1035 - 10020

Gear puller T-24 [BANZAI make]

—

Tool name

207503

Unit: mm (in.) 4

200

2 ) 08 (0.

21 (0.83)

1 (0. 2 47 )

ø11 (0.43) 87)

(7.

6 (0.24)

55 ) 17 (2. 320

2 (0. 5 98 )

) .60 (12 ) 54 (3. 44) 90 (2. 62

6 (0.24) 1

M10 × 1.25 203541

2. Input shaft disassembling

Using the Piston Tool A (special tool) or an arbor press, compress clutch spring 13 and retainer 12, and remove snap ring 12.

Special tool needed Piston tool A

92267 - 00300

207504

5-25

2-SPEED POWERSHIFT TRANSMISSION

5. Countershaft subassembly

5 15

14 1

16 14 13

10 7

11 9 10

207505

Sequence 1. 2. 3. 4. 5. 6. 7. 8. 9.

Seal rings Ball bearing Thrust washer Gear (F2 drive), Needle roller bearing, Spacer Thrust washer, Snap ring Ball bearing Thrust washer Gear (F1 drive), Needle roller bearing Thrust washer, Snap ring

10. 11. 12. 13. 14.

Snap rings, Pressure plates Friction plates, Mating plates Snap ring, Retainer Clutch springs Clutch pistons, Steel balls, Screws, Piston seals 15. Seal rings 16. Countershaft

Suggestion for Disassembly

NOTE

For disassembly, make reference to the disassembly of the input shaft.

Do not attempt to remove the screws from the countershaft. It is not necessary to disassemble clutch pistons 14 if the balls move freely in the pistons when the pistons are shaken.

5-26

2-SPEED POWERSHIFT TRANSMISSION

Inspection 1. Oil pump

(1) Put the internal gear and pump gear in the pump case, and measure top clearance 2. (2) Using a dial indicator, measure side clearance 1 between the gears and pump case. A: Standard value

B: Repair or service limit Unit: mm (in.)

0.040 to 0.078 (0.00157 to 0.00307)

0.09 (0.0035)

0.3 to 0.345 (0.0118 to 0.0136)

0.35 (0.0138)

Side clearance 1

Top clearance 2

2. Stator shaft

(1) Check the splines for wear or damage. (2) Check the oil passages for clogging. 3. Friction plates and mating plates

(1) Check for sign of seizure, uneven contact, warpage or excessive wear. (2) Check the splines for wear or damage. 4. Clutch drums

(1) Check the mating plate sliding surfaces for wear or damage. (2) Check the clutch piston sliding surfaces for wear or damage.

5-27

205486

2-SPEED POWERSHIFT TRANSMISSION 5. Gears

7,8

(1) Check the gear and splines for wear or damage. (2) Check the gear surface in contact with the needle roller bearings for wear or damage. A: Standard value

Thickness of mating plate 1

Thickness of friction plate 2

Free movement of friction plate on gear 3 Width of piston seal ring 4

Width of piston seal ring groove in piston 5 Free length of clutch spring 6 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

Width of clutch piston seal ring 7

Width of clutch piston seal ring groove 8

B: Repair or service limit Unit: mm (in.) 2.3±0.07 (0.091±0.0028)

2.1 (0.083)

2.6±0.1 (0.102±0.004)

2.2 (0.087)

0.10 to 0.30 (0.0039 to 0.0118)

4 − 0.03 (0.16 − 0.0012 )

3.5 (0.138)

4 + 0.1 (0.16 + 0.004 )

4.5 (0.177)

62.9 (2.48) k = 39.1 (3.992) [223.5]

60 (2.36)

2.5±0.05 (0.098±0.0020)

2.0 (0.079)

2.5 + 0.1 (0.098 + 0.004 )

3.0 (0.118)

− 0.01

+ 0.2

2 1

3 4

5 207514

− 0.0004

+ 0.008

5-28

2-SPEED POWERSHIFT TRANSMISSION 6. Input shaft and countershaft

(1) Check the seal rings, shaft and case for wear or damage. A: Standard value

Width of piston seal ring for input shaft 1

Width of piston seal ring groove in input shaft 2

B: Repair or service limit Unit: mm (in.)

2.5±0.05 (0.098±0.0020)

2.0 (0.079)

2.5 + 0.1 (0.098 + 0.004 )

3.0 (0.118)

+ 0.2

+ 0.025 0

+ 0.008

(1.38

+ 0.00098 0

Inside diameter of stator shaft in contact with seal ring 3

A B

35.2 (1.386)

Width of seal ring for input shaft and countershaft 4

2.5±0.05 (0.098±0.0020)

2.0 (0.079)

Width of seal ring groove in input shaft and countershaft 5

2.5 + 0.1 (0.098 + 0.004 )

3.0 (0.118)

Inside diameter of transmission cover in contact with seal ring 6

+ 0.2

+ 0.025 0

)

+ 0.008

(1.38

+ 0.00098 0

)

35.2 (1.386)

4,5 1,2

207506

Remarks: The input shaft is shown. Items other than 1, 2 and 3 are common to the input shaft and countershaft. (2) Check the splines for wear or damage. (3) Check oil passages for clogging.

5-29

2-SPEED POWERSHIFT TRANSMISSION 7. Gears

Check each gear for worn teeth or splines. 8. Magnet strainer assembly

Disassemble and clean the strainer. Replace the strainer if defective. 9. Transmission cover and torque converter housing oil seals

Replace the oil seals with new ones.

5-30

2-SPEED POWERSHIFT TRANSMISSION

Reassembly 1. Input shaft subassembly (countershaft subassembly)

9 8 7

7 8

4 9 10

5 13

14 15

21 20

11 12

1 207507

Sequence 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Input shaft or countershaft Sealing rings, Piston seals Pistons Springs Retainers Snap rings Mating plates Friction plates Pressure plates Snap rings Thrust washer, Snap ring

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

NOTE The countershaft subassembly is similar in reassembly sequence and suggestions to the input shaft, the only difference being that the portion carrying the F2 drive gear is long and has needle roller bearing and spacer and that the torque converter side does not extend beyond the ball bearing.

5-31

Needle roller bearing Gear (R1 drive) Thrust washer Ball bearing Thrust washer, Snap ring Needle roller bearing Gear (R2 drive) Thrust washer Ball bearing Seal rings

2-SPEED POWERSHIFT TRANSMISSION

Suggestions for Reassembly 1. Piston installation

When putting pistons 3 in the clutch drum, apply ATF (automatic transmission fluid) to their seal ring contact surfaces. 2. Return spring installation

Using the Piston Tool A (special tool) or an arbor press, compress springs 4 and retainers 5, and install snap rings 6. Special tool needed Piston tool A

92267 - 00300

207504

3. Friction and mating plate installation

Mating plate

(1) Make sure that the position and number of the plates are correct. Install the plates while applying ATF to them. When replacing the friction plates, replace the mating plates as a set.

Friction plate

207516

(2) Thrust washer installation Install thrust washers 11, 14, 16 and 19 with the side that has oil grooves toward the gear.

203800

4. Piston testing

After having assembled the clutch, apply air pressure of approximately 690 kPa (7 kgf/cm2) [100 psi] to the oil hole to make sure that the piston moves freely without any sign of air leaks.

5-32

2-SPEED POWERSHIFT TRANSMISSION

2. Stator shaft and oil pump 15

18 19

1 8 2

4 6 7

205680

Sequence 1. 2. 3. 4.

Transmission case, Dowels Roller bearing Idler gear Stator shaft, Seal ring, Bolts, Washers 5. Ball bearing 6. PTO drive gear 7. Ball bearing

8. 9. 10. 11.

Idler gear shaft Roller bearing Oil seal Torque converter housing, Gasket, Bolts, Washers 12. Pump case, O-ring, Bolts, Washers 13. Internal gear 14. Pump gear

NOTE The dowels fitted into the transmission case have not been removed. These dowels are for locating the pump case, torque converter housing and transmission cover subassembly for installation. 5-33

15. Pump plate, O-ring, Gasket, Bolts, Washers 16. Ball bearing 17. Pump drive gear, Seal rings 18. Ball bearing 19. Snap ring 20. PTO cover, O-ring, Bolts, Washers

2-SPEED POWERSHIFT TRANSMISSION

Suggestions for Reassembly 1. PTO drive gear 6 installation

Install ball bearings 5 and 7 to PTO drive gear 6. Install the gear to stator shaft 4. 2. Oil seal 10 installation

Unit: mm (in.)

Oil seal installer

To be made by dealer

13 (0.51)

ø40 (1.57)

Special tool needed

ø98.5 (3.88)

ø140 (5.51)

Replace the oil seal with a new one. To install the new oil seal, use the Installer (special tool).

8 (0.31) 150 (5.91)

205491

3. Oil pump assembling

Put internal gear 13, pump gear 14 and pump plate 15 in pump case 12. Apply oil to the internal gear and pump gear. Do not forget to install the O-ring. 4. Oil pump subassembly installation

Be sure to place the gasket and the O-ring for the oil hole when installing the oil pump subassembly. 5. Pump drive gear 17 installation

Install ball bearing 16 on pump drive gear 17. Install two seal rings in position and apply oil to these seal rings. Then drive the gear assembly into the transmission case with the splines in alignment with those of pump gear 14. 6. Ball bearing 18 installation

Unit: mm (in.)

2 − ø13 (0.51)

6.0

When installing ball bearing 18 in pump case 12, hold the pump drive gear with the Pump Drive Gear Holder (special tool), or have someone press the gear with a copper bar or the like, in order to prevent the gear from coming off. 0(

ø4 7)

1.5

9) 0.3 1) ( 10 (0.3 8

)

(7.

(4.

To be made by dealer

ø1

Pump drive gear holder

ø1

Special tool needed

5-34

)

0. 0(

28 0) 1 (1.

205492

2-SPEED POWERSHIFT TRANSMISSION

3. Shafts and transmission cover

34 25

32 31 26 28 21 22

27 23

24 207508

Sequence 21. 22. 23. 24. 25. 26. 27. 28.

Output shaft Snap ring Output gear Ball bearing Travel speed sensor gear, Lock plate, Bolts Snap ring Baffle plate, Bolts, Washers Baffle plate, Bolts, Washers

29. 30. 31. 32. 33. 34.

5-35

Input shaft subassembly Countershaft subassembly Output gear Ball bearing Oil seals Transmission cover subassembly, Gasket, O-rings, Bolts, Washers

2-SPEED POWERSHIFT TRANSMISSION

Suggestions for Reassembly 1. Output shaft 21 assembling and installation

Assemble output shaft 21, snap rings 22 and 26, output gear 23, ball bearing 24 and travel speed sensor gear 25 in a subassembly. Install the subassembly in the transmission case. Use a new lock plate for the bolts that hold the travel speed sensor gear. 2. Input shaft subassembly installation

Install a total of four seal rings, one on the front side and three on the rear side. Apply oil to these rings when installing them. 3. Oil seal 33 installation

Replace two oil seals with new ones. To install these seals, apply grease to their lips and install them with the Oil Seal Installer (special tool) with their main lips toward inside.

Transmission cover

205494

Special tool needed

1 (0.04) chamfer

10 (0.39) 170 (6.69)

ø108 (4.25)

28 (1.10) 1.5 (0.06)

5-36

ø94.5 (3.72)

ø68.5 (2.70)

To be made by dealer

ø40 (1.57)

Oil seal installer

Unit: mm (in.)

205495

2-SPEED POWERSHIFT TRANSMISSION 4. Transmission cover installation

Install hooks in the jack bolt holes in the transmission cover and hitch slings to these hooks. Put the gasket on the transmission case. Hoist the cover and install it in position. Apply oil to the servo cases formed of the cover when installing the cover. Do not forget to put the O-rings in the oil holes

205496

5-37

2-SPEED POWERSHIFT TRANSMISSION

4. Control valve and external parts

18 13

17 14 7 16 12

8 5

1 4

11 3

210354

Sequence 1. 2. 3. 4. 5. 6.

Magnet strainer assembly Cover, O-ring, Bolts, Washers Oil filter Plug, Gasket Thermounit Travel speed sensor cover, Travel speed sensor, Bolts, Washers 7. Bracket, Bolts, Washers 8. Bracket, Bolts, Washers 9. Main regulator valve, Gasket, Bolts, Washers

10. 11. 12. 13. 14. 15. 16. 17. 18.

5-38

Control valve, Gasket, Bolts, Washers Oil pipe, Eye bolt, Gaskets Oil pipe, O-rings, Bolts, Washers Oil pipe, O-rings, Bolts, Washers Oil pipe, Eye bolts, Gaskets Oil pipe, Eye bolt, Gaskets Plug, Oil level gauge Breather Inching bracket, Spring, Bolts, Washers

2-SPEED POWERSHIFT TRANSMISSION

Control Valve Disassembly 1 1 2

5 9 8

2 10

4 11

15 6

7 12 11 11

205473

Sequence 1. 2. 3. 4. 5. 6. 7.

Solenoid valves, O-rings Speed valve, Solenoid spring Springs, Direction valve Plug, O-ring, Roller bearing Oil filter, O-rings Stopper pin, O-ring Inching valve plunger, Spring

8. 9. 10. 11.

Inching valve, Spring, Slug Roller bearing, Plug, O-ring Plate, O-ring, Bolts, Washers Accumulator piston, Spring guide, Springs (outer and inner)

CAUTION Slowly loosen each bolt and solenoid valve so that the spring and plunger do not suddenly jump out.

5-39

12. 13. 14. 15.

Oil seal Oil filter Plugs, O-rings Valve body, Gasket

2-SPEED POWERSHIFT TRANSMISSION

Suggestion for Disassembly Stopper pin 6 removal

Turn a screw in the M4 x 0.7 hole in the stopper pin 6 and carefully remove the pin because removal of the stopper pin will cause inching valve plunger 7 to fly out.

Inspection (1) Check the oil holes in the valve body for restriction. (2) Check each plunger for wear or damage. Make sure the plunger moves freely. (3) Check the orifice in the inching valve for restriction. Also check the inching valve spring for damage. Measure free length. (4) Replace oil seal 12 with a new one. 200220

(5) Replace filter 13 with a new one. (6) Wash filter 5, or replace it with a new one. A: Standard value

Free length of speed valve spring 1 Spring constant: k = N/mm (kgf/mm) [lbf/in.] Free length of direction valve springs 2 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

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

87.5 (3.44) k = 3.88 (0.396) [22.1]

85 (3.35)

32.5 (1.26) k = 8.61 (0.8786) [49.2]

31.5 (1.24)

3 Free length of inching valve spring 3 Spring constant: k = N/mm (kgf/mm) [lbf/in.] Free length of return spring 4 Spring constant: k = N/mm (kgf/mm) [lbf/in.] Free length of accumulator valve outer spring 5 Spring constant: k = N/mm (kgf/mm) [lbf/in.] Free length of accumulator valve inner spring 6 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

39 (1.53) k = 2.12 (0.217) [12.1]

4 6

38 (1.49)

28 (1.10) k = 0.478 (0.0488) [2.73]

26.5 (1.04)

109.5 [4.31] k = 6.38 (0.651) [36.4]

107.5 [4.23]

154 (6.06) k = 6.86 (0.6998) [38.6]

152 (5.98)

5 205699

5-40

2-SPEED POWERSHIFT TRANSMISSION

Reassembly

2 14 13

Section A – A 13 12 10

Section B – B

9 16

8 7 B

B C

C 4

Section C – C

5 210192

Sequence 1. 2. 3. 4. 5.

Valve body Oil filter Oil seal Plate, O-ring Accumulator piston, Springs (inner and outer), Spring seat 6. Plate, O-ring 7. Plug, O-ring, Roller bearing 8. Inching valve, Spring, Slug

9. 10. 11. 12. 13. 14. 15. 16.

Start by:

Clean the oil passages in the control valve thoroughly and make sure they are not restricted.

Suggestions for Reassembly (1) Replace oil seal 3 with a new one. (2) Apply ATF (automatic transmission fluid) to the valves and plungers when installing them in the valve body.

5-41

Spring, Inching valve plunger Stopper pin, O-ring Oil filter, O-ring Spring, Direction valve Solenoid valves Plug, O-ring, Roller bearing Spring, Travel speed valve, Solenoid valve Plug, O-ring

2-SPEED POWERSHIFT TRANSMISSION

Main Regulator Valve Disassembly

1 5 2

3 210180

Sequence 1. Cover, O-ring, Bolts, Washers 2. Slug 3. Spool

4. Spring 5. Cover, O-ring, Bolts, Washers 6. Body

CAUTION Slowly loosen bolts 1 so that the spring, spool and slug do not suddenly jump out.

Inspection

Reassembly

(1) Check the oil holes in the valve body for restriction.

To reassemble, follow the reverse of disassembly sequence.

(2) Check the valve spool for wear or damage. Make sure the spool moves freely.

Suggestion for Reassembly

(3) Check the spring for damage. Measure the free length of the spring. A: Standard value

Apply oil to the spool and slug when putting them in the body.

B: Repair or service limit Unit: mm (in.)

Free length of main 112 (4.41) A regulator valve spring k = 4.99 (0.5087) [28.5] Spring constant: k = N/mm (kgf/mm) B 109 (4.29) [lbf/in.]

5-42

2-SPEED POWERSHIFT TRANSMISSION

Adjustment Brake pedal and inching pedal adjustment Adjust the brake pedal before adjusting the inching pedal.

Bring the roller 1 of the brake pedal into contact with the pedal 2 of the brake control valve 2 by means of the adjusting bolt 4. Under this condition, the top height of the pedal from the floor level will be approximately 190 mm (7.5 in.).

1 4 3

NOTE: The set angle (39±1.5°) of the brake valve must be kept unchanged.

2. Inching pedal adjustment

(1) With the clutch valve plunger 1 pushed in all the way [6 mm (0.24 in.) allowed for protrusion], attach the transmission side return spring 2 to the inching lever 3 and inching bracket 4.

190 mm (7.5 in.)

1. Brake pedal adjustment

2 210611

6 mm (0.24 in.)

4 2

3 1

(2) Connect the inching cable 5 to the inching bracket 4, then attach the clevis 6 to the inching lever 3.

(4) Attach the return spring 10 between the vehicle body side inching lever 9 and seat frame. (5) Tilting the inching pedal 11, adjust the clearance A between cam follower 12 and brake pedal valve 13 to 14.5 mm (0.571 in.), then hold the inching pedal 11 in that position with the adjusting bolt 14. Under this condition, the top height of the inching pedal 11 from the floor level will be approximately 190 mm (7.5 in.).

12 11 A 13 8

190 mm (7.5 in.)

(3) Attach the pedal side turnbuckle 7 to the inching pedal arm 8 and vehicle body side inching lever 9. Be sure that turnbuckle clevis pin holes are approximately 272 mm (10.7 in.) apart center to center.

210612

272 mm (10.7 in.) 210613

5-43

2-SPEED POWERSHIFT TRANSMISSION

(6) Attach the inching cable 15 to the vehicle body side inching lever 9 and bracket 16. (7) With the clearance A set at 14.5 mm (0.571 in.) between cam follower 12 and brake valve pedal 13, adjust the protrusion of clutch valve plunger 1 to 9 mm (0.35 in.) with the turnbuckle 7.

9 mm (0.35 in.) 12

9 16 15

210614

(8) Depress the inching pedal 11 and make sure that the protrusion of clutch valve plunger 1 is 11.5±0.5 mm (0.453±0.020 in.) when the cam follower 12 touches the brake valve pedal 13. If the 11.5±0.5 mm (0.453±0.020 in.) cannot be obtained, adjust the length of the turnbuckle 7.

11.5±0.5 mm (0.453±0.020 in.) 1

11 12

13 7

210615

(9) Depress the inching pedal 11 all the way and make sure that the protrusion of clutch valve plunger 1 is 19.5±1 mm (0.768±0.039 in.). Then, tighten the lock nut of the turnbuckle 7 and adjusting bolt 14.

19.5±1 mm (0.768±0.039 in.) 1 11

210616

5-44

2-SPEED POWERSHIFT TRANSMISSION

Oil Pressure Measurement NOTE Front tires rotate during the measurement. Build a fence around the vehicle to prevent access to it.

NOTE: Always perform pedal adjustments before oil pressure measurement.

1. Main oil pressure measurement

(1) Connect a 2 MPa (20 kgf/cm2) [290 psi] oil pressure gauge to the main oil pressure outlet of the regulator valve.

Main pressure tap (M)

Special tools needed *Connector

64309 - 17733

*Hose

64309 - 17722

*Connector

64309 - 17731

*Gauge

64309 - 17713

210617

NOTE: Parts marked with an asterisk (*) are included in the gauge kit 64309 - 17701.

(2) Idle the engine and check that the transmission oil is up to the specified level. (3) Warm up the engine to raise the transmission oil temperature. (4) Keep the engine idling (at between 1000 and 1500 rpm). (5) Under the above condition, perform the oil pressure measurement. A: Standard value Main oil pressure (with engine idling at 1500±100 rpm)

1.08 to 1.37 MPa (11 to 14 kgf/cm2) [157 to 199 psi]

NOTE: Monitor the idling speed through engine tachometer during measurement.

5-45

2-SPEED POWERSHIFT TRANSMISSION 2. Clutch Oil Pressure Measurement

(1) Connect a 2 MPa (20 kgf/cm2) [290 psi] oil pressure gauge to the clutch oil pressure outlet port of the selector valve.

Clutch pressure tap (Pc)

NOTE: Use the same special tools as used for main oil pressure measurement. (2) Lift the front tires off the floor by either of the following methods. 210618

(a) The front axle housing is jacked up. (b) The mast is tilted all the way backward first. With a wooden block applied under the outer mast, the mast is tilted forward to lift the front tires. Then, an appropriate stand or square timber is placed under the frame to keep the front tires lifted. (3) Put scotch blocks under the rear tires. (4) Implement the steps (2) through (4) of main oil pressure measurement.

End face of control valve body

(5) Place the transmission shift lever into the FORWARD position, then release the parking brake. (6) Depress the inching pedal gradually to pull out the clutch (inching) valve plunger pushed all the way in. Record pressure fluctuations with plunger stroke in the meantime and make sure that the oil pressure change patterns as shown at the left. B

Reference data

Clearance between inching cam follower and brake valve

1.23 (12.5) [178]

190 mm (7.5 in.) 14.5 mm (0.571 in.)

Plunger protrusion A when inching pedal is not depressed

9 mm (0.35 in.)

Plunger protrusion B when brake begins to work

14 mm (0.55 in.)

0.22 (2.2) [31]

7 10.5 (0.41) (0.28) 15 (0.59)

10 (0.39)

2 5 (0.20) (0.08)

Clutch pressure, MPa (kgf/cm2) [psi]

Pedal height (from frame top surface to uppermost end of pedal)

Clutch valve plunger stroke, mm (in.) 210619

5-46

2-SPEED POWERSHIFT TRANSMISSION 3. Torque converter inlet oil pressure measurement

(1) Connect a 0.6 MPa (6 kgf/cm2) [87 psi] oil pressure gauge to the torque converter inlet oil pressure inlet port of the regulator valve.

Torque converter inlet pressure tap (T)

Special tools needed *Connector

64309 - 17733

*Hose

64309 - 17722

*Connector

64309 - 17731

*Gauge

64309 - 17713

210620

NOTE: The parts marked with an asterisk (*) are included in the gauge kit 64309 - 17701.

(2) Idle the engine and check that transmission oil is up to the specified level. (3) Warm up the engine to raise the transmission oil temperature. (4) Keep the engine idling (at between 1000 and 1500 rpm), measure the torque converter inlet oil pressure. A: Standard value Torque converter inlet oil pressure (with engine idling at 1500±100 rpm)

0.05 to 0.49 MPa (0.5 to 5 kgf/cm2) [7 to 71 psi]

NOTE: Monitor the idling speed through engine tachometer during measurement.

Stall Speed Measurement (1) With the engine running at low idle, check to make sure that the oil level is correct in the transmission case. (2) Warm up transmission oil. (3) Block the front and rear wheels, and apply the parking brake. (4) Run the engine at low idle.

5-47

2-SPEED POWERSHIFT TRANSMISSION

(5) Move the transmission shift lever to the forward position, and gradually depress the accelerator pedal all the way. Under this condition, measure the stall speed with an engine tachometer. Stall speed (tolerance: ±100 rpm)

1760 rpm

CAUTION Do not attempt to depress the inching pedal. Do not continue operation in stall condition for more than 30 seconds. A failure to follow this precaution would result in destruction of the torque converter.

(6) Similarly measure the stall speed for reverse drive.

NOTE (a) Any stall speed within ±100 rpm tolerance of the specification is satisfactory. (b) If the engine or torque converter is changed, the stall speed will vary since the stall speed is determined by the combination of engine and torque converter.

10 m (33 ft) Start Acceleration Test (1) Stand ready to start with the engine running at low idle, the transmission shift lever in the neutral position and the travel speed select switch in “Automatic 2-speed” position. (2) At the signal, move the transmission shift lever to the forward position and, at the same time, depress the accelerator pedal fully. (3) Measure the time required for the truck to travel 10 m (33 ft) with a stopwatch. (4) Conduct the same test for reverse travel, too.

Travel time (no load)

5 seconds, maximum

5-48

2-SPEED POWERSHIFT TRANSMISSION

“Automatic 2-speed”/“Fixed 1st Speed” Test Move the travel speed select switch mounted on the console box to each position, and make sure that the speed selector system functions properly. Move the switch when the truck is at standstill. DP100, DP115

(1) In the “Fixed 1st speed” position, the truck runs at a maximum speed of 12 km/hr (7.5 mph) and a greater torque is available. (2) In the “Automatic 2-speed” position, the transmission automatically shifts from the 1st to the 2nd speed when the travel speed reaches 10 km/hr (6.2 mph) to allow the truck to run at a maximum speed of 26 km/hr (16.1 mph). DP135, DP150

(1) In the “Fixed 1st speed” position, the truck runs at a maximum speed of 13 km/hr (8.1 mph) and a greater torque is available. (2) In the “Automatic 2-speed” position, the transmission automatically shifts from the 1st to the 2nd speed when the travel speed reaches 9 km/hr (5.6 mph) to allow the truck to run at a maximum speed of 26 km/hr (16.1 mph).

5-49

Travel speed select switch 205698A

2-SPEED POWERSHIFT TRANSMISSION

Troubleshooting

Engine

Torque converter

Not enough output power

Transmission

Wheels

Poor performance

Tune up engine.

Oil level too low

Refill.

Air being sucked in on suction side

Retighten or replace gasket.

Main regulator valve not operating properly

Repair or replace.

Main regulator valve spring fatigued

Replace.

Oil pump gears worn, resulting in reduced capacity

Overhaul and check or replace defective parts.

Magnet strainer clogged

Replace.

Seal rings or O-rings worn

Replace after measuring oil pressure.

Stator freewheel seized

Replace stator assembly, hub and roller.

Blades of running members damaged or rubbing

Repair or replace. Replace bearing.

Air being sucked in on suction side

Retighten or replace.

Outlet pressure too low to suppress internal foaming

Readjust.

Water in oil

Replace oil.

Oil level too low

Refill.

Main pressure too low, resulting in slipping clutches

Readjust after measuring oil pressure.

Seal rings or O-rings worn

Replace after measuring oil pressure.

Clutch piston damaged

Replace.

Friction plate seized or dragging

Replace.

High mechanical resistance

Check and adjust brake system.

5-50

2-SPEED POWERSHIFT TRANSMISSION

Torque converter

No power flow Transmission

Power train

Torque converter

Abnormal noise

Transmission

Flexible plate broken

Replace.

Oil level too low

Refill.

Oil pump drive defective

Replace.

Turbine shaft broken

Replace.

Main pressure too low

Check pump gears for wear or replace.

Oil level too low

Refill.

Inching pedal link maladjusted

Readjust.

Seal rings worn in servo case

Replace.

O-rings on input shaft worn

Replace.

Plug on input shaft loose or slipped off, resulting in oil leaks

Repair.

Clutch seized

Replace.

Shafts broken

Replace.

Clutch drum, particularly snap ring groove, defective

Replace.

Snap ring fitted to clutch drum broken

Replace.

Oil line to clutch piston clogged

Clean or replace.

Shaft splines worn

Replace shafts.

Broken parts in reduction and differential or front axle

Refer to each section.

Flexible plates broken

Replace.

Bearings damaged

Replace.

Rubbing vanes of running members

Replace.

Bolts loose

Retighten or replace.

Splines worn

Replace.

Oil pump worn

Inspect or replace.

Clutch seized and dragging

Replace clutch plate.

Bearings worn or seized

Replace.

Gears broken

Replace.

Bolts loose

Retighten or replace.

Splines worn

Replace.

5-51

2-SPEED POWERSHIFT TRANSMISSION

Loud noise

Abnormal noise

Oil strainer clogged

Clean or replace.

Main regulator valve spool defective

Wash or replace.

Restriction in oil pipe

Replace.

Oil too viscous in cold weather

Replace oil. *

Instruments out of order

Replace.

Improper oil used

Replace oil. *

Oil strainer clogged

Clean or replace.

Oil pump defective

Replace.

Excessive oil leaks Low noise

Oil leaks

• Main regulator valve spring defective

Replace.

• Main regulator valve spool defective

Repair or replace.

Air being sucked in

Retighten or replace packing.

Oil level too low

Refill.

Leaking oil seals

Check lips and sliding surfaces for wear. Replace seals.

Leaking joint of case

Retighten or replace packing.

Leaking pipe connection or joint

Repair or replace pipe, gasket and O-rings.

Leaking drain plug

Retighten or replace gasket.

Cracks or blowholes in case

Replace.

Oil blowing out of transmission case • Water in oil

Replace oil.

• Air being sucked in on suction side

Replace packing and retighten.

• Oil leaks from air breather

Repair.

Oil level too high

Lower oil level.

* (Refer to “Recommended Brands of Lubricants.”)

5-52

2-SPEED POWERSHIFT TRANSMISSION

Torque converter

Oil temperature is too high Transmission

Oil level too high or too low

Keep correct oil level.

Oil strainer clogged

Clean or replace.

Rubbing vanes of running members

Repair or replace.

Stator freewheel defective

Replace stator assembly.

Air being sucked in

Retighten or replace O-ring.

Water in oil

Replace oil.

Restriction in oil pipe (resulting in reduced circulation flow)

Repair or replace.

Bearings worn or seized

Repair or replace.

Instruments out of order

Replace.

Clutches dragging

Replace clutch plates.

Bearings worn or seized

Repair or replace.

Control linkage defective

Repair or replace.

Truck not operated properly

Advice user to drive truck properly.

Others Others

Main pressure is too high

Main pressure is too low

• Cooling fan belt damaged

Replace.

• Oil cooler clogged

Clean or replace.

• Brakes grabbing

Check and readjust.

Main regulator valve defective

Repair or replace valve assembly.

Oil viscosity too high in cold weather

Replace oil. *

Improper oil used

Replace oil. *

Magnet strainer clogged

Clean or replace.

Oil pump defective

Replace.

Coil spring defective in main regulator valve

Replace.

Main regulator valve spool defective

Repair or replace.

Air being sucked in

Retighten or replace packing.

Oil level too low

Refill.

Control linkage defective

Repair or replace.

Inching valve out of order

Repair or replace.

* (Refer to “Recommended Brands of Lubricants.”)

5-53

2-SPEED POWERSHIFT TRANSMISSION

Clutch pressure is too low

Stall speed out of specification

No automatic shifting

Transmission shifts up when travel speed select switch is in “Fixed 1st speed” position

Magnet strainer clogged

Clean or replace.

Oil pump worn or defective

Replace.

Coil spring defective in main regulator valve

Replace.

Main regulator valve spool defective

Repair or replace.

Air being sucked in

Retighten or replace packing.

Oil level too low

Refill.

Control linkage out of order

Repair or replace.

Inching valve defective

Repair or replace.

Seal ring broken in servo case

Replace.

Clutch seal rings broken

Replace.

Lack of engine power if the speed is slightly low in both forward and reverse drive

Tune up engine.

Stator and freewheel defective if the speed is excessively low in both forward and reverse drive

Replace stator assembly.

Inching pedal linkage defective, or clutch slipping if the speed is too high

Repair or replace.

Travel speed select switch in “Fixed 1st speed” position

Move switch to “Automatic 2-speed” position.

Solenoid valve defective

Replace.

Solenoid valve inlet orifice clogged

Clean or replace.

Solenoid valve spool or spring defective

Repair or replace.

ECU control box internally defective

Check or replace.

Harness open

Repair.

Travel speed select switch defective

Replace.

5-54

2-SPEED POWERSHIFT TRANSMISSION

Service Data A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item Stall speed (tolerance: ±100 rpm)

rpm A

Main pressure (engine at 1500±100 rpm)

MPa (kgf/cm2) [psi] A

Clutch pressure (engine at 1500±100 rpm)

MPa (kgf/cm2) [psi] A

1760

1.08 to 1.37 (11 to 14) [156.4 to 199]

Torque converter inlet pressure (engine at 1500±100 rpm) A MPa (kgf/cm2) [psi]

0.05 to 0.49 (0.5 to 5.0) [7 to 71]

Lubrication line pressure (engine at 1500±100 rpm) A MPa (kgf/cm2) [psi]

0.02 to 0.15 (0.2 to 1.5) [3 to 21]

10 m (33 ft) start acceleration (no load)

5 seconds, maximum

100 − 0.035 (3.94 − 0.00138 )

99.85 (3.9311)

Diameter of portion in contact with oil seal 1

Pump boss 1

200721 − 0.007

− 0.00028

20 − 0.020 (0.79 − 0.00079 )

19.85 (0.7815)

Diameter of portion in contact with engine flywheel 1

Pilot boss 1

200411

5-55

2-SPEED POWERSHIFT TRANSMISSION

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item Side clearance 1 Top clearance 2

0.040 to 0.078 (0.00157 to 0.00307)

0.09 (0.0035)

0.3 to 0.345 (0.0118 to 0.0136)

0.35 (0.0138)

Oil pump

2 205486

Outside diameter of clutch hub 1 Diameter of clutch rollers 2 Thickness of thrust washer 3 Thickness of thrust washer 4 Thickness of thrust washer 5 Thickness of thrust washer 6 Stator Thickness of thrust washer 7

67.97 to 67.951 (2.6760 to 2.67523)

67.8 (2.669)

10.185 to 10.2 (0.40098 to 0.402)

10.1 (0.398)

4.95 to 5 (0.1949 to 0.197)

4.8 (0.189)

3.95 to 4 (0.1555 to 0.157)

3.8 (0.150)

2.9 to 3 (0.114 to 0.118)

2.8 (0.110)

4.9 to 5 (0.193 to 0.197)

4.8 (0.189)

4.95 to 5 (0.1949 to 0.197)

4.8 (0.189)

1 2 5 6 7

200724

5-56

2-SPEED POWERSHIFT TRANSMISSION

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item Face runout of flexible plates 1 (in free state) Distance between end face of torque converter housing and mating face of flexible plate 2

0.2 (0.008)

0.5 (0.020)

25 (0.984)

Flexible plates

1 200725

Thickness of mating plate 1 Thickness of friction plate 2 Free movement of friction plate on gear 3 Width of piston seal ring 4

2.3±0.07 (0.091±0.0028)

2.1 (0.083)

2.6±0.1 (0.102±0.004)

2.2 (0.087)

0.10 to 0.30 (0.0039 to 0.0118)

4 − 0.03 (0.16 − 0.0012 )

− 0.01

B A

Width of seal ring groove in piston 5

Clutches

A Free length of clutch spring 6 Spring constant: k = N/mm (kgf/mm) [lbf/in.] B

− 0.0004

3.5 (0.138) 4

+ 0.2 + 0.1

+ 0.008

(0.16 + 0.004 )

4.5 (0.177) 62.9 (2.48) k = 39.1 (3.992) [223.5] 60 (2.36)

4 6

2 1

3 5

5-57

210220

2-SPEED POWERSHIFT TRANSMISSION

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item A

2.5±0.05 (0.098±0.0020)

2.0 (0.079)

2.5 + 0.1 (0.098 + 0.004 )

3.0 (0.118)

Width of piston seal ring for input shaft 1

Width of piston seal ring groove in input shaft 2 Inside diameter of stator shaft in contact with seal ring 3

+ 0.2

+ 0.025 0

+ 0.008

(1.38

+ 0.00098 0

)

35.2 (1.386)

2.5±0.05 (0.098±0.0020)

2.0 (0.079)

Width of seal ring groove in input shaft and countershaft 5

2.5 + 0.1 (0.098 + 0.004 )

3.0 (0.118)

Inside diameter of transmission cover in contact with seal ring 6

A B

35.2 (1.386)

Width of clutch piston seal ring for input shaft and countershaft 7

2.5±0.05 (0.098±0.0020)

2.0 (0.079)

Width of clutch piston seal ring groove in input shaft and countershaft 8

2.5 + 0.1 (0.098 + 0.004 )

3.0 (0.118)

Width of seal ring for input shaft and countershaft 4

Input shaft, countershaft and transmission cover

4,5

+ 0.2

+ 0.025 0

+ 0.2

+ 0.008

(1.38

+ 0.00098 0

)

+ 0.008

1,2

7,8

3 210218

Remarks: The input shaft is shown. Items other than 1, 2 and 3 are common to the input shaft and countershaft.

5-58

2-SPEED POWERSHIFT TRANSMISSION

A: Standard value Unit: mm (in.) Truck Model DP100

DP115

DP135

DP150

Item Input gear and counter gear 1

Forward 1st speed gear and reverse 1st speed gear 2

0.12 to 0.28 (0.0047 to 0.0110)

0.13 to 0.32 (0.0051 to 0.0126) Forward 2nd speed gear and reverse 2nd speed gear 3

Pump drive gear and idler gear 4

PTO drive gear and idler gear 5

0.12 to 0.26 (0.0047 to 0.0102)

4 3

Backlash of gears

3 2

210217

5-59

2-SPEED POWERSHIFT TRANSMISSION

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item Free length of speed valve spring 1 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

Free length of direction valve springs 2 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

Free length of inching valve spring 3 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

Free length of return spring 4 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

Free length of accumulator valve outer spring 5 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

Control valve

Free length of accumulator valve inner spring 6 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

87.5 (3.44) k = 3.88 (0.396) [22.1]

85 (3.35)

32.5 (1.28) k = 8.61 (0.8786) [49.2]

31.5 (1.24)

39 (1.53) k = 2.12 (0.217) [12.1]

38 (1.49)

28 (1.10) k = 0.478 (0.0488) [2.73]

26.5 (1.04)

109.5 (4.31) k = 6.38 (0.651) [36.4]

107.5 (4.23)

154 (6.06) k = 6.86 (0.6998) [38.6]

152 (5.98)

4 6

210208

5-60

2-SPEED POWERSHIFT TRANSMISSION

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item Free length of main regulator valve spring 1 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

112 (4.41) k = 4.99 (0.5087) [28.5]

109 (4.29)

Main regulator valve

1 210181

Inching pedal height (from frame to top end of pedal) 1

190 (7.48)

Clearance between inching pedal cam follower and brake control valve pedal 2

14.5 (0.57)

Protrusion of inching plunger with inching pedal released 3

9 (0.35)

Protrusion of inching plunger when brake starts to be applied 4

14 (0.55), minimum

Inching pedal control 2 1

3 4

210358

5-61

3-SPEED POWERSHIFT TRANSMISSION Specifications .......................................................................................... 6 – 1 Description ............................................................................................... 6 – 2 Torque Converter ...................................................................................... 6 – 2 Transmission ............................................................................................ 6 – 3 Power Flow ............................................................................................... 6 – 4 Control Valve ............................................................................................ 6 – 6 Main Regulator Valve ................................................................................ 6 – 6 Hydraulic Controls .................................................................................... 6 – 7 Speed Selector System ............................................................................ 6 – 8 Control System ......................................................................................... 6 – 9

Removal and Installation ...................................................................... 6 – 10 Torque Converter .................................................................................... 6 – 12 Disassembly ............................................................................................. 6 – 12 Inspection ................................................................................................. 6 – 13 Reassembly .............................................................................................. 6 – 16

Transmission ............................................................................................ 6 – 18 Disassembly ............................................................................................. 6 – 18 Inspection ................................................................................................. 6 – 28 Reassembly .............................................................................................. 6 – 31

Control Valve ............................................................................................ 6 – 39 Disassembly ............................................................................................. 6 – 39 Inspection ................................................................................................. 6 – 40 Reassembly .............................................................................................. 6 – 41

Main Regulator Valve ............................................................................. 6 – 42 Disassembly ............................................................................................. 6 – 42 Inspection ................................................................................................. 6 – 42 Reassembly .............................................................................................. 6 – 42

Adjustment ............................................................................................... 6 – 43 Stall Speed Measurement ......................................................................... 6 – 47 10 m (33 ft) Start Acceleration Test ........................................................... 6 – 48 Travel Speed Select Switch ...................................................................... 6 – 49

Troubleshooting ...................................................................................... 6 – 50 Service Data ............................................................................................. 6 – 55

3-SPEED POWERSHIFT TRANSMISSION

Specifications Truck Model DP100

DP115

DP135

Item

Torque converter

Type

3-element, 1-stage, 2-phase

Model

MI 16

Stall torque ratio

2.88 Direction control: Electric, column shift Speed control: Automatic

Control Transmission

Forward

1st: 2.402 2nd: 1.010 3rd: 0.532

Gear ratio Reverse

6-1

DP150

3-SPEED POWERSHIFT TRANSMISSION

Description Torque Converter 7

5 2

From oil pump

1 8

6 To oil cooler

200550

1. Pilot boss 2. Flexible plate 3. Drive cover

4. Turbine assembly 5. Stator 6. Freewheel

7. Pump (impeller) 8. Stator shaft 9. Input shaft (transmission)

3-SPEED POWERSHIFT TRANSMISSION

Transmission

9 F

4 1 8

6 3

207509

1. 2. 3. 4.

Flexible plate Torque converter assembly Input shaft Forward clutch shaft

5. Reverse clutch shaft 6. 1st-speed/3rd-speed clutch shaft 7. Output shaft

The transmission is the powershift type and has three speeds forward and three speeds reverse. It has five hydraulic clutches of the disc type.

6-3

8. 9. 10. 11.

PTO drive gear Pump idler gear Pump drive gear Pump case

3-SPEED POWERSHIFT TRANSMISSION

Power Flow Forward 1st

Figures in ( ) indicate number of gear teeth.

(39)

(60) (58) (35)

(34)

(58)

Forward 3rd

(42) (24)

(58) (58) (35) (56) (58)

(34)

Forward 2nd (60)

(58)

(54)

(31)

(35)

(34)

(53)

Speed 1st 2nd 3rd PTO gear

205618B

Gears engaged 35 58 58 56 x x x 34 58 58 24 35 53 x 34 54 35 58 58 31 x x x 34 58 58 60 60 39 x 42 60

Gear ratio 2.402 1.010 0.532 0.929 6-4

3-SPEED POWERSHIFT TRANSMISSION

Figures in ( ) indicate number of gear teeth.

Reverse 1st (39)

(60)

(34)

Reverse 3rd

(58) (35)

(42)

(58)

(56)

(34) (58)

(60)

(35)

Reverse 2nd

(58)

(31)

(54)

(34) (58)

(35)

(53)

205619B

Speed 1st 2nd 3rd PTO gear

Gears engaged 35 58 56 x x 34 58 24 35 58 53 x x 34 58 54 35 58 31 x x 34 58 60 60 39 x 42 60

Gear ratio 2.402 1.010 0.532 0.929

6-5

3-SPEED POWERSHIFT TRANSMISSION

Control Valve 2

Section A – A 3

A Section B – B

Section C – C

1 205620

1. Accumulator valve 2. Direction valve

3. Inching valve plunger 4. 1st-speed valve

5. Differential valve 6. 2nd-speed/3rd-speed valve

Main Regulator Valve

1 200554A

1. 2. 3. 4.

Bolts Cover O-ring Slug

5. 6. 7. 8.

Spool Body Spring Drain port

9. Main pressure port 10. Torque converter inlet pressure port

6-6

6-7

Suction strainer with magnet 100 mesh (particle size 220 µ)

Transmission oil reservoir

C3 C1

Oil filter

Diam. 6 mm (0.24 in.) Torque converter bypass orifice: Diam. 4.0 mm (0.157 in.)

Oil pump Lubrication Capacity: 70 liters (18.5 line U.S. gal.)/min at 2300 rpm C2 CF R

Lubrication relief valve Setting: 0.02 to 0.10 MPa (0.2 to 1.0 kgf/cm2) [3 to 14 psi]

Torque converter inlet relief valve Setting: 0.15 to 0.69 MPa (1.5 to 7.0 kgf/cm2) [21 to 100 psi]

Oil cooler

Chassis area

Torque converter

Solenoid valve (direction selection)

Last chance filter 230 µ

Orifice: Diam. 0.8 mm (0.031 in.)

PD (marked “D”)

Orifice: Diam. 0.8 mm (0.031 in.)

Oil filter for forward/ reverse clutches (particle size 95 µ)

Last chance filter 230 µ

Main regulator valve Setting: 1.08 to 1.27 MPa (11.0 to 13.0 kgf/cm2) [156 to 185 psi]

Tap (plug) for main pressure (marked “M”)

Tap (plug) for torque converter inlet pressure (marked “T”)

Speed selector valve S1 (1st speed)

Orifice:Diam.0.8 mm (0.031 in.)

Speed selector valve S2 (2nd/3rd speed)

Solenoid valve (direction selection)

Orifice: Diam. 0.8 mm (0.031 in.)

Last chance filter 230 µ

PS (marked “S”)

Response (inching) valve Setting: 0 to 0.22 MPa (0 to 2.2 kgf/cm2) [0 to 31.3 psi]

Main orifice: Diam. 1.8 mm (0.071 in.) Differential valve Setting: 0.20 MPa (2.0 kgf/cm2) [28 psi]

Accumulator valve Pressure at start of charging: 0.34 MPa (3.5 kgf/cm2) [50 psi] Pressure at end of charging: 0.71 MPa (7.2 kgf/cm2) [102 psi]

3-SPEED POWERSHIFT TRANSMISSION

Hydraulic Controls

205924

3-SPEED POWERSHIFT TRANSMISSION

Speed Selector System

Travel speed select switch 1st speed clutch

Electronic Control Unit (ECU)

Output gear

0.5 mm (0.02 in.)

Travel speed (solenoid) valve

2nd/3rd speed clutch

Electric signal

Travel speed sensor

Hydraulic pressure signal Transmission case Control system Electronic Control Unit (ECU)

D Travel speed select switch

2 Power source

Solenoid valves

Travel speed sensor

210360

Location of components

Unit: km/h (mph)

The speed selector system is made up of an Electronic Control Unit (ECU), a travel speed sensor and two speed selector valves, one for 2nd and 3rd speeds and the other for 1st speed.

Select switch position (mode)

The selection of three modes “Fixed 1st speed”, “Automatic 2-speed” and “Automatic 3-speed” is done manually by means of the travel speed select switch.

Automatic 2nd 3-speed D

1st

3rd Automatic 2-speed 2

1st 2nd

Fixed 1st speed 1 6-8

Travel speed DP100, DP115 DP135, DP150 0 to 6.5 0 to 6 (0 to 4.0) (0 to 3.7) 6.5 to 15 6 to 12.5 (4.0 to 9.3) (3.7 to 7.8) 15 to 31.5 12.5 to 33 (9.3 to 20.5) (7.8 to 20.5) 0 to 6.5 0 to 6 (0 to 4.0) (0 to 3.7) 6.5 to 18.5 6 to 19 (4.0 to 11.5) (3.7 to 11.8) 0 to 8 0 to 8.5 (0 to 5.0) (0 to 5.3)

3-SPEED POWERSHIFT TRANSMISSION

Control System

8 R 2

N F 1

7 5

4 10 5

3 206579

1. 2. 3. 4. 5.

Transmission shift lever Inching bracket Control valve Travel speed (solenoid) valve Direction (solenoid) valve

6. 7. 8. 9. 10.

6-9

Inching valve plunger Inching lever Inching cable Electronic Control Unit (ECU) Inching pedal

3-SPEED POWERSHIFT TRANSMISSION

Removal and Installation To remove the transmission assembly from the truck, remove it together with the engine. Refer to “GROUP 4 POWER TRAIN.”

Transmission removal (1) To separate the transmission from the engine, put the engine on a stable stand, and support the transmission with wood blocks. (2) Remove the hydraulic pump from the transmission. (3) The transmission has three lifting eyes, two eyes on the differential side and one eye on the torque converter side. To lift the transmission, fasten two slings to the differential side eyes and one sling (chain with lever block) to the torque converter side eye. Balance the transmission with the lever block and lift it at three points just enough to take the weight of the transmission. (4) Remove the bolts that hold the flexible plates through the access hole in the torque converter housing. (5) Separate the transmission from the engine by lifting it with a hoist.

210361

Torque converter removal To remove the torque converter assembly from the transmission, slide the splines of the stator shaft, PTO drive gear and input shaft away from the mating splines.

NOTE Remove the drain plug of the torque converter and drain the oil.

6-10

3-SPEED POWERSHIFT TRANSMISSION

Torque converter installation (1) Couple the torque converter to the transmission. Make sure that the distance between the end face of the torque converter housing and the mating face of the flexible plates is 25 mm (0.984 in.). If this distance is more than 25 mm (0.984 in.), it is an indication that spline engagement between the torque converter stator shaft and transmission input shaft is improper; recouple the torque converter to the transmission.

25 mm (0.984 in.)

200557

(5) Mount the transmission harness. Connect the travel speed sensor at the connector side, and connect the torque converter thermounit at the terminal side.

F solenoid

Connect the F and R changeover solenoid valves respectively to the terminals with F and R identification marks at their roots. There are two kinds of the travel speed solenoid valve, S1 and S2. Connect the S2 solenoid to the terminal marked 2, and the S1 solenoid to the terminal which has no mark. The remaining terminal is for grounding. Solenoid Valve

Harness Wire Color S1

LgR

R solenoid

Travel speed

Transmission shift lever S2 solenoid

(6) Pour in the torque converter oil.

6-11

S1 solenoid

206070

3-SPEED POWERSHIFT TRANSMISSION

Torque Converter Disassembly 5 6

3 7

3 4 205626

Sequence 1. Bolts, Washers, Plate 2. Flexible plates, Pilot boss, O-ring, Bolts, Washers 3. Bolts, Drive cover, Ball bearing, Plug, Gasket, Washers 4. Spacer, Turbine

5. Thrust washers, Thrust bearing 6. Stator, Rollers, Hub, Springs, Spring caps, Thrust washers 7. Ball bearing, O-ring, Pump boss, Pump (impeller), Snap ring, Bolts, Washers

6-12

3-SPEED POWERSHIFT TRANSMISSION

204530

Inspection 1. Pump (impeller)

Oil seal

6-13

Seal ring

O-ring 200561

3-SPEED POWERSHIFT TRANSMISSION 2. Stator

Outside diameter of clutch hub 1

Diameter of clutch rollers 2

Thickness of thrust washer 3

Thickness of thrust washer 4

Thickness of thrust washer 5

Thickness of thrust washer 6

Thickness of thrust washer 7

B: Repair or service limit Unit: mm (in.)

67.951 to 67.97 (2.67523 to 2.6760)

67.8 (2.669)

10.185 to 10.2 (0.40098 to 0.402)

10.1 (0.398)

4.95 to 5 (0.1949 to 0.197)

4.8 (0.189)

3.95 to 4 (0.1555 to 0.157)

3.8 (0.150)

2.9 to 3 (0.114 to 0.118)

2.8 (0.11)

4.9 to 5 (0.193 to 0.197)

4.8 (0.189)

4.95 to 5 (0.1949 to 0.197)

4.8 (0.189)

1 2 5 6 7

200724

6-14

3-SPEED POWERSHIFT TRANSMISSION 3. Turbine

(1) Check the vanes for cracks. (2) Check the fit of the turbine boss in the turbine. (3) Check the turbine boss splines for wear or other defects. 4. Pilot boss

Check the surface in contact with the pilot bearing for wear or other defects. A: Standard value Diameter of portion in contact with engine flywheel 1

B: Repair or service limit Unit: mm (in.) − 0.007

− 0.00028

20 − 0.020 (0.79 − 0.00079 )

19.85 (0.7815) 200411

6-15

3-SPEED POWERSHIFT TRANSMISSION

Reassembly

4 2

9 3

5 6

205643

Sequence 1. 2. 3. 4. 5. 6. 7.

Pump (impeller) Pump boss, O-ring, Bolts, Washers Ball bearing, Snap ring Stator assembly Springs, Spring caps Rollers Hub

8. 9. 10. 11. 12.

Thrust washer Thrust bearing, Thrust washers Turbine Drive cover, O-ring, Bolts, Washers Spacer, Ball bearing, Pilot boss, O-ring, Bolts, Washers 13. Flexible plates, Plate, Bolts, Washers

6-16

3-SPEED POWERSHIFT TRANSMISSION

Suggestions for Reassembly 1. Stator assembly

(1) Put hub 7 in the stator as shown. Put spring 5 and spring cap 5 in each hole, and press in roller 6 while pushing the spring cap. (2) Install a total of ten rollers, and restore the hub to its original position.

5 5

(3) After having assembled the stator, turn the hub by hand, making sure that it rotates in only one direction. 202885A

2. Selection of spacer

Measure the dimensions A, B and C. Select a spacer equal to the clearance (dimension D) and put it in position. A

Part number

Thickness of spacer

92322 - 14700

2.9 mm (0.114 in.)

92322 - 14800

3.0 mm (0.118 in.)

92322 - 14900

3.2 mm (0.126 in.) D

92322 - 06600

3.4 mm (0.134 in.)

92322 - 06700

3.5 mm (0.138 in.) A

Standard dimensions mm (in.)

204534

26.3 (1.035)

B C

19 (0.75) 4

0 − 0.1

(0.16 − 0.004 )

3. Flexible plate

After having installed the flexible plate, measure the face runout of the plates with a dial indicator. Replace the plates if the runout has exceeded the service limit. A: Standard value

Face runout of flexible plate (in free state)

B: Repair or service limit Unit: mm (in.)

0.2 (0.008)

0.5 (0.020)

205922

6-17

3-SPEED POWERSHIFT TRANSMISSION

Transmission Disassembly 1. Control valve and external parts

4 8 5

7 2 1 14 17 11 10

16 18

15 9

12 9 13

210362

Sequence 1. 2. 3. 4. 5. 6. 7.

Air breather Oil level gauge, Plug, Gasket Oil pipe, Eye bolt, Gaskets Inching bracket, Spring Main regulator valve, Gasket, Bolts, Washers Oil pipe, O-rings, Bolts, Washers Control valve, Gasket, O-rings, Bolts, Washers 8. Oil pipes, Eye bolts, Gaskets 9. Oil pipes, Eye bolts, Gaskets

10. Oil filter 11. Travel speed sensor cover, Travel speed sensor, Bolts, Washers 12. Thermounit 13. Drain plug, Gasket 14. Suction pipe, O-rings, Bolts, Washers 15. Cover, O-ring, Bolts, Washers 16. Magnet strainer assembly 17. Bracket, Bolts, Washers 18. Bracket, Bolts, Washers

6-18

3-SPEED POWERSHIFT TRANSMISSION

2. Transmission cover and shafts

13 23 24 22 21 20 11 4

16 17 15

8 7 6

4 5

1,2

207510

Sequence 1. Servo case, O-ring, Bolts, Washers 2. Servo case, O-ring, Bolts, Washers 3. Servo case, O-ring, Bolts, Washers 4. Transmission cover subassembly, Gasket, O-rings, Bolts, Washers 5. Oil seals 6. Ball bearing

7. 8. 9. 10. 11.

Output gear (53 teeth) Output gear (31 teeth) Snap ring Baffle plate, Bolts, Washers 1st-speed/3rd-speed clutch shaft assembly 12. Forward clutch shaft assembly 13. Reverse clutch shaft assembly 14. Baffle plate, Bolts, Washers

6-19

15. Output shaft 16. Travel speed sensor gear, Lock plate, Bolts 17. Ball bearing 18. Output gear (56 teeth) 19. Snap ring 20. Nut 21. Input gear 22. Snap ring 23. Input shaft 24. Ball bearing

3-SPEED POWERSHIFT TRANSMISSION

Suggestions for Disassembly 1. Transmission cover subassembly 4 removal

Turn two Bolts (jack bolts) (special tool) in the M10 x 1.25 holes in the cover evenly until the cover is approximately 25 mm (1 in.) apart (the bearings get out of place). Then remove the cover. Do not attempt to remove the lubrication line relief valve from the cover. Special tool needed Bolt

67284 - 15400

205629

2. Output gear (outside) 7 removal

Remove the output gear together with ball bearing 6 with a gear puller.

Output gear Sliding hammer

3. Output shaft 15 removal

Turn a sliding hammer in the M10 x 1.25 hole in the end of the output shaft, and remove the shaft together with the output gear, ball bearing and travel speed sensor gear. 205480

4. Ball bearing 17 removal

Remove the output shaft with a press and a tooling as shown, or remove the gear with a puller, to remove the bearing.

Tooling 205630

5. Nut 20 removal

Straighten the locking tab of the nut away from the flat of the input shaft and remove the nut with a socket wrench and an impact wrench. When removing the nut, hold the splined end of the input shaft with a pipe wrench, or put a bar to the input gear in such a manner as to prevent the shaft from turning counterclockwise. 6-20

3-SPEED POWERSHIFT TRANSMISSION

3. Stator shaft and oil pump 30

31 32 29 37

33 26

36 43

28 27 39 38 40 41

47 45

34 46

205631

Sequence 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47.

6-21

Idler gear shaft Roller bearing PTO drive gear Ball bearing Ball bearing Stator shaft, Seal ring, Bolts, Washers Pump idler gear Roller bearing Roller bearing (outer race) Roller bearing (outer race) Roller bearing (outer race) Transmission case, Dowels

3-SPEED POWERSHIFT TRANSMISSION

Suggestions for Disassembly 1. Torque converter housing 34 removal

67284 - 15400

2. Oil pump removal

Remove the oil pump as a subassembly including pump case 29, pump plate 30, internal gear 31 and pump gear 32. 3. Idler gear shaft 36 removal

Turn the Shaft Puller (special tool) in the shaft hole. Install the sliding hammer (used in removing output shaft 15) to this Puller and remove the shaft. Special tool needed Shaft puller

M20 × 1.5 M10 × 1.25 36

To be made by dealer

210188

4. PTO drive gear 38 removal

Grip ball bearing 39 with a gear puller. Put a protective plate on the end of the stator shaft and remove the gear together with two ball bearings.

210193

6-22

3-SPEED POWERSHIFT TRANSMISSION 5. Stator shaft 41 removal

Turn two Bolts (jack bolts) (special tool) in the M10 x 1.25 holes in one end of the shaft evenly, or hit the other end by using a protective plate. Special tool needed Bolt

67284 - 15400

6. Roller bearing outer race removal

Do not remove the outer races 44, 45 and 46 of the roller bearings installed in the transmission case and the outer race of roller bearing 43 installed on idler gear shaft 36 unless they are defective.

6-23

3-SPEED POWERSHIFT TRANSMISSION

4. Forward clutch shaft subassembly

5 15

2 1 14 13

10 6 11

8 9 10

207511

Sequence 1. 2. 3. 4. 5. 6. 7. 8. 9.

Seal rings Ball bearing Thrust washer Gear (2nd-speed drive), Needle roller bearings Thrust washer Roller bearing Thrust washer Gear (forward drive), Needle roller bearings Thrust washer, Snap ring

10. 11. 12. 13. 14.

Snap rings, Pressure plates Friction plates, Mating plates Snap rings, Retainers Clutch springs Clutch pistons, Steel balls, Screws, Piston seals 15. Seal rings 16. Forward clutch shaft

NOTE Do not attempt to remove the screws from the forward clutch shaft. It is not necessary to disassemble clutch pistons 14 if the balls move freely in the pistons when the pistons are shaken.

6-24

3-SPEED POWERSHIFT TRANSMISSION

Suggestions for Disassembly 1. Ball bearing 2 removal

Grip 2nd-speed drive gear 4 with a gear puller and remove the bearing together with the gear and thrust washer 3. 2. Roller bearing 6 removal

Grip forward drive gear 8 with a gear puller and remove the bearing together with the gear and thrust washer 7. 3. Input shaft disassembling

Using the Piston Tool A (special tool) or an arbor press, compress clutch spring 13 and retainer 12, and remove snap ring 12.

Special tool needed Piston tool A

92267 - 00300

207504

6-25

3-SPEED POWERSHIFT TRANSMISSION

5. 1st-speed/3rd-speed clutch shaft subassembly

12 15

4 2

3 16

1 14 13

10 6 7

11 11

8 9 10

11 207512

Sequence 1. 2. 3. 4. 5. 6. 7. 8. 9.

Seal rings Ball bearing Thrust washer Gear (3rd-speed drive), Needle roller bearings Thrust washer Roller bearing Thrust washer Gear (1st-speed drive), Needle roller bearings Thrust washer, Snap ring

10. 11. 12. 13. 14.

Snap rings, Pressure plates Friction plates, Mating plates Snap rings, Retainers Clutch springs Clutch pistons, Steel balls, Screws, Piston seals 15. Seal rings 16. 1st-speed/3rd-speed clutch shaft

Suggestion for Disassembly

NOTE

For disassembly, make reference to the disassembly of the forward clutch shaft.

Do not attempt to remove the screws from the 1stspeed/3rd-speed clutch shaft. It is not necessary to disassemble clutch pistons 14 if the balls move freely in the pistons when the pistons are shaken.

6-26

3-SPEED POWERSHIFT TRANSMISSION

6. Reverse clutch shaft subassembly

9 10 12 11 13

2 1

3 4 8

6 7

8 207513

Sequence 1. 2. 3. 4. 5. 6. 7.

Seal rings Ball bearing Roller bearing Thrust washer Gear (reverse drive), Needle roller bearings Thrust washer Snap ring, Pressure plate

8. 9. 10. 11. 12. 13.

Friction plates, Mating plates Snap ring, Retainer Clutch spring Clutch piston, Steel balls, Screws, Piston seal Seal ring Reverse clutch shaft

Suggestion for Disassembly

NOTE

For disassembly, make reference to the disassembly of the forward clutch shaft.

Do not attempt to remove the screws from the reverse clutch shaft. It is not necessary to disassemble clutch piston 11 if the balls move freely in the piston when the piston is shaken.

6-27

3-SPEED POWERSHIFT TRANSMISSION

Inspection 1. Oil pump

(1) Put the internal gear and pump gear in the pump case, and measure top clearance 2. (2) Using a dial indicator, measure side clearance 1 between the gears and pump case. A: Standard value

B: Repair or service limit Unit: mm (in.)

0.040 to 0.078 (0.00157 to 0.00307)

0.09 (0.0035)

0.3 to 0.345 (0.0118 to 0.0136)

0.35 (0.0138)

Side clearance 1

Top clearance 2

2. Stator shaft

(1) Check the splines for wear or damage. (2) Check the oil passages for clogging. 3. Friction plates and mating plates

(1) Check for sign of seizure, uneven contact, warpage or excessive wear. (2) Check the splines for wear or damage. 4. Clutch drums

(1) Check the mating plate sliding surfaces for wear or damage. (2) Check the clutch piston sliding surfaces for wear or damage.

6-28

205486

3-SPEED POWERSHIFT TRANSMISSION 5. Gears 7,8

(1) Check the gear and splines for wear or damage. (2) Check the gear surface in contact with the needle roller bearings for wear or damage. A: Standard value

Thickness of mating plate 1

B: Repair or service limit Unit: mm (in.)

2.3±0.07 (0.091±0.0028)

2.1 (0.083)

2.6±0.1 (0.102±0.004)

2.2 (0.087)

0.10 to 0.30 (0.0039 to 0.0118)

4 − 0.03 (0.16 − 0.0012 )

3.5 (0.138)

4 + 0.1 (0.16 + 0.004 )

4.5 (0.177)

62.9 (2.48) k = 39.1 (3.992) [223.5]

60 (2.36)

2.5±0.05 (0.098±0.0020)

2.0 (0.079)

2.5 + 0.1 (0.098 + 0.004 )

3.0 (0.118)

2 1

3 4

Thickness of friction plate 2

Free movement of friction plate on gear 3 Width of piston seal ring 4

Width of piston seal ring groove in piston 5 Free length of clutch spring 6 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

Width of clutch piston seal ring 7

Width of clutch piston seal ring groove 8

− 0.01

+ 0.2

207514

− 0.0004

+ 0.008

6-29

3-SPEED POWERSHIFT TRANSMISSION 6. Forward clutch shaft, reverse clutch shaft and 1stspeed/3rd-speed clutch shaft

(1) Check the seal rings and seal ring contact surfaces of the shaft and servo cases for wear or damage. A: Standard value

Width of piston seal ring for each clutch shaft 1

Width of piston seal ring groove in each clutch shaft 2

B: Repair or service limit Unit: mm (in.)

2.5±0.05 (0.098±0.0020)

2.0 (0.079)

2.5 + 0.1 (0.098 + 0.004 )

3.0 (0.118)

Inside diameter of each A servo case in contact with seal ring 3 B

+ 0.2

+ 0.025 0

1,2

+ 0.008

(1.38

+ 0.00098 0

) 205635

35.2 (1.386)

(2) Check the splines for wear or damage. (3) Check oil passages for clogging. 7. Gears

Check each gear for worn teeth or splines. 8. Magnet strainer assembly

Disassemble and clean the strainer. Replace the strainer if defective. 9. Transmission cover and torque converter housing oil seals

Replace the oil seals with new ones.

6-30

3-SPEED POWERSHIFT TRANSMISSION

Reassembly 1. Forward clutch shaft subassembly (1st-speed/3rd-speed clutch shaft subassembly/reverse clutch shaft subassembly)

9 78

11 6

6 14 15 21

12 207515

Sequence 1. Forward clutch shaft (1st-speed/3rd-speed clutch shaft or reverse clutch shaft) 2. Sealing rings, Piston seals 3. Pistons 4. Springs 5. Retainers 6. Snap rings 7. Mating plates 8. Friction plates 9. Pressure plates 10. Snap rings

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

NOTE The reassembly sequence and suggestions for the reverse clutch shaft subassembly are similar to the forward clutch shaft subassembly as far as the clutch is concerned.

6-31

Thrust washer, Snap ring Needle roller bearings Gear (forward drive) Thrust washer Roller bearing Thrust washer Needle roller bearings Gear (2nd-speed drive) Thrust washer Ball bearing Seal rings

3-SPEED POWERSHIFT TRANSMISSION

Suggestions for Reassembly 1. Piston installation

When putting pistons 3 in the clutch drum, apply ATF (automatic transmission fluid) to their seal ring contact surfaces. 2. Return spring installation

Using the Piston Tool A (special tool) or an arbor press, compress springs 4 and retainers 5, and install snap rings 6. Special tool needed Piston tool A

92267 - 00300

207504

3. Friction and mating plate installation

Mating plate

(1) Make sure that the position and number of the plates are correct. Install the plates while applying ATF to them. When replacing the friction plates, replace the mating plates, too.

Friction plate

207516

(2) Thrust washer installation Install thrust washers 11, 14, 16 and 19 with the side that has oil grooves toward the gear.

203800

4. Piston testing

After having assembled the clutch, apply air pressure of approximately 690 kPa (7 kgf/cm2) [100 psi] to the oil hole to make sure that the piston moves freely without any sign of air leaks.

6-32

3-SPEED POWERSHIFT TRANSMISSION

2. Stator shaft and oil pump

18 19 14 13

17 20

3 9

8 2

4 6

11 205638

Sequence 1. 2. 3. 4.

Transmission case, Dowels Roller bearing Idler gear Stator shaft, Seal ring, Bolts, Washers 5. Ball bearing 6. PTO drive gear 7. Ball bearing

8. 9. 10. 11.

Idler gear shaft Roller bearing Oil seal Torque converter housing, Gasket, Bolts, Washers 12. Pump case, O-ring, Bolts, Washers 13. Internal gear 14. Pump gear

NOTE The dowels fitted into the transmission case should not been removed. These dowels are for locating the pump case, torque converter housing and transmission cover subassembly for installation. 6-33

15. Pump plate, O-ring, Gasket, Bolts, Washers 16. Ball bearing 17. Pump drive gear, Seal rings 18. Ball bearing 19. Snap ring 20. PTO cover, O-ring, Bolts, Washers

3-SPEED POWERSHIFT TRANSMISSION

Suggestions for Reassembly 1. PTO drive gear 6 installation

Install ball bearings 5 and 7 to PTO drive gear 6. Install the gear to stator shaft 4. 2. Oil seal 10 installation

Unit: mm (in.)

Oil seal installer

To be made by dealer

13 (0.51)

8 (0.31) 150 (5.91)

ø40 (1.57)

Special tool needed

ø98.5 (3.88)

ø140 (5.51)

Replace the oil seal with a new one. To install the new oil seal, use the Installer (special tool).

205491

3. Oil pump assembling

Put internal gear 13, pump gear 14 and pump plate 15 in pump case 12. Apply oil to the internal gear and pump gear. Do not forget to install the O-ring. 4. Oil pump subassembly installation

Do not forget to put the gasket and the O-ring for the oil hole when installing the oil pump subassembly. 5. Pump drive gear 17 installation

Unit: mm (in.)

2 − ø13 (0.51)

6.0

ø4 7)

1.5

9) 0.3 1) ( 10 (0.3 8

)

(7.

(4.

To be made by dealer

ø1

Pump drive gear holder

ø1

Special tool needed

6-34

)

0. 0(

28 0) 1 (1.

205492

3-SPEED POWERSHIFT TRANSMISSION

3. Shafts and transmission cover

26 25 28

39 46

23 44

40 34 36

29 35 30 31

32 33

207517

6-35

3-SPEED POWERSHIFT TRANSMISSION Sequence 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

Roller bearing (outer race) Roller bearing (outer race) Roller bearing (outer race) Ball bearing Input shaft Snap ring Input gear Nut Output shaft Snap ring Output gear (56 teeth) Ball bearing Travel speed sensor gear, Lock plate, Bolts Snap ring

35. 36. 37. 38. 39. 40. 41. 42. 43. 44.

Baffle plate, Bolts, Washers Baffle plate, Bolts, Washers Forward clutch shaft subassembly 1st-speed/3rd-speed clutch shaft subassembly Reverse clutch shaft subassembly Output gear (31 teeth) Output gear (53 teeth) Ball bearing Oil seals Transmission cover subassembly, Gasket, Bolts, Washers, O-rings 45. Servo case, O-ring, Bolts, Washers 46. Servo case, O-ring, Bolts, Washers 47. Servo case, O-ring, Bolts, Washers

Suggestions for Reassembly 1. Input shaft 25 assembling and installation

(1) Install ball bearing 24 on the input shaft, then install the shaft in the transmission case. (2) Tighten nut 28 to the specified torque and bend it against the flat of the input shaft for locking. When tightening the nut, hold the torque converter side of the shaft with a pipe wrench, or put a bar to input gear 27 in such a manner as to prevent the shaft from turning clockwise.

Tightening torque for nut

294 to 392 N·m (30 to 40 kgf·m) [217 to 289 lbf·ft]

2. Output shaft 29 assembling and installation

Assemble output shaft 29, snap rings 30 and 34, output gear 31, ball bearing 32 and travel speed sensor gear 33 in a subassembly. Install the subassembly in the transmission case. Use a new lock plate for the bolts that hold the travel speed sensor gear.

6-36

3-SPEED POWERSHIFT TRANSMISSION 3. Oil seal 43 installation Transmission cover

Replace two oil seals with new ones. Apply grease to the lips of the oil seals and, using the Oil Seal Installer (special tool), install the seals in position with the lips toward inside.

205494

Special tool needed

Unit: mm (in.) 1 (0.04) chamfer

10 (0.39) 170 (6.69)

ø108 (4.25)

ø94.5 (3.72)

ø68.5 (2.70)

To be made by dealer

ø40 (1.57)

Oil seal installer

28 (1.10) 1.5 (0.06)

205495

4. Transmission cover installation

Install hooks in the jack bolt holes in the transmission cover and hitch slings to these hooks. Put the gasket on the transmission case. Hoist the cover and install it in position. Do not forget to put the O-rings in the oil holes.

205640

5. Servo cases 45, 46 and 47 installation

When installing the servo cases, apply oil to the inside surfaces of the cases and the seal rings of the shafts. Do not forget to install the O-rings to the cases.

6-37

3-SPEED POWERSHIFT TRANSMISSION

4. Control valve and external parts

13 8 12

16 6 18 5 9

2 7

4 7

210363

Sequence 1. 2. 3. 4. 5. 6. 7. 8. 9.

Magnet strainer assembly Cover, O-ring, Bolts, Washers Plug, Gasket Thermounit Travel speed sensor cover, Travel speed sensor, Bolts, Washers Suction pipe, O-rings, Bolts, Washers Oil pipe, Eye bolt, Gaskets Oil pipe, Eye bolt, Gaskets Oil filter

10. 11. 12. 13. 14. 15. 16. 17. 18.

6-38

Control valve, Gasket, O-rings, Bolts, Washers Oil pipe, O-rings, Bolts, Washers Main regulator valve, Gasket, Bolts, Washers Inching bracket, Spring Oil pipe, Eye bolt, Gaskets Oil level gauge, Plug, Gasket Air breather Bracket, Bolts, Washers Bracket, Bolts, Washers

3-SPEED POWERSHIFT TRANSMISSION

Control Valve Disassembly 1 2 3 4 5 19 9

4 18 6

1 16

14 15

7 9

8 20

11 10 13

205641

Sequence 1. Solenoid valves, O-rings (two) 2. Springs, Spring seats 3. Direction valve 4. Solenoid valves, O-rings (two) 5. 2nd-speed/3rd-speed valve, Spring 6. 1st-speed valve, Spring

7. 8. 9. 10. 11. 12. 13.

Stopper pin, O-ring Inching valve plunger, Spring Inching valve, Slug, Spring Roller bearing, Plug, O-ring Spring, Differential valve Plate, O-ring, Bolts, Washers Accumulator valve piston, Springs (inner and outer)

CAUTION Slowly loosen each bolt and solenoid valve so that the spring and plunger do not suddenly jump out.

6-39

14. 15. 16. 17. 18. 19. 20. 21.

Pin, Seat, O-ring Oil filter, O-rings Last chance filters (four) Roller bearing, Plug Roller bearing, Plug Plug, O-ring Oil seal Valve body, Gasket

3-SPEED POWERSHIFT TRANSMISSION

Suggestion for Disassembly Stopper pin 7 removal

Turn a screw in the M4 x 0.7 hole in the stopper pin and carefully remove the pin because removal of the stopper pin will cause inching valve plunger 8 to fly out.

Inspection (1) Check the oil holes in the valve body for restriction. (2) Replace all oil seals with new ones. (3) Check the orifices in the inching valve for restriction. Also check the inching valve springs for fatigue or damage. (4) Replace oil filter 16 with a new one. (5) Wash oil filter 15, or replace it with a new one. A: Standard value Free length of selector valve springs 1 Spring constant: k = N/mm (kgf/mm) [lbf/in.] Free length of return spring 2 Spring constant: k = N/mm (kgf/mm) [lbf/in.] Free length of differential valve spring 3 Spring constant: k = N/mm (kgf/mm) [lbf/in.] Free length of inching valve spring 4 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

200220

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

36.5 (1.44) k = 5.658 (0.577) [32.3]

35.5 (1.40)

28 (1.10) k = 0.478 (0.0488) [2.73]

1 4

26.5 (1.04)

59.5 (2.34) k = 2.311 (0.2357) [13.2]

57.5 (2.26)

39 (1.53) k = 2.128 (0.217) [12.1]

38 (1.49)

125.5 (4.94) k = 5.363 (0.5469) [30.6]

123 (4.84)

170.5 (6.71) k = 4.128 (0.4210) [23.5]

168 (6.61)

32.5 (1.28) k = 8.616 (0.8786) [49.2]

31.5 (1.24)

5 205707

Free length of accumulator valve outer spring 5 Spring constant: k = N/mm (kgf/mm) [lbf/in.] Free length of accumulator valve inner spring 6 Spring constant: k = N/mm (kgf/mm) [lbf/in.] Free length of direction valve springs 7 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

6-40

3-SPEED POWERSHIFT TRANSMISSION

Reassembly 19

20 20

15 6

Section A – A

2 A Section B – B

17 13 11 10

17 C

16 7

Section C – C 8

Sequence 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Valve body Oil seal Plug, Roller bearing Plug, Roller bearing Last chance filters (four) Oil filter, O-ring Seat, O-ring, Pin Springs (inner and outer), Accumulator piston Plate, O-ring, Bolts, Washers Differential valve, Spring Plug, O-ring, Roller bearing

12. 13. 14. 15. 16. 17 18. 19. 20. 21.

Start by:

Wash the oil passages in the control valve thoroughly and make sure they are not restricted.

Suggestions for Reassembly (1) Replace oil seal 2 with a new one. (2) Apply ATF (automatic transmission fluid) to the valves and plungers when installing them in the valve body.

6-41

Spring, Inching valve, Slug Spring, inching valve plunger Stopper pin, O-ring 1st-speed valve, Spring 2nd-speed/3rd-speed valve, Spring Solenoid valves, O-rings (two) Direction valve Spring seats, Springs Solenoid valves, O-rings (two) Plug, O-ring

210196

3-SPEED POWERSHIFT TRANSMISSION

Main Regulator Valve Disassembly

1 5 2

3 210180

Sequence 1. Cover, O-ring, Bolts, Washers 2. Slug 3. Spool

4. Spring 5. Cover, O-ring, Bolts, Washers 6. Body

CAUTION Slowly loosen bolts 1 so that the spring, spool and slug do not suddenly jump out.

Inspection

Reassembly

(1) Check the oil holes in the valve body for restriction.

To reassemble, follow the reverse of disassembly sequence.

(2) Check the valve spool for wear or damage. Make sure the spool moves freely.

Suggestion for Reassembly

(3) Check the spring for damage. Measure the free length of the spring. A: Standard value

Apply oil to the spool and slug when putting them in the body.

B: Repair or service limit Unit: mm (in.)

Free length of main 112 (4.41) A regulator valve spring k = 4.99 (0.5087) [28.5] Spring constant: k = N/mm (kgf/mm) B 109 (4.29) [lbf/in.]

6-42

3-SPEED POWERSHIFT TRANSMISSION

Adjustment Brake pedal and inching pedal adjustment Adjust the brake pedal before adjusting the inching pedal.

190 mm (7.5 in.)

1. Brake pedal adjustment 1 4 3

NOTE: The set angle (39±1.5°) of the brake valve must be kept unchanged.

2 210611

6 mm (0.24 in.)

2. Inching pedal adjustment

3 1

(1) With the clutch valve plunger 1 pushed in all the way [6 mm (0.24 in.) allowed for protrusion], attach the transmission side return spring 2 to the inching lever 3 and inching bracket 4.

(2) Connect the inching cable 5 to the inching bracket 4, then attach the clevis 6 to the inching lever 3. 6

12 11 A 13 8

190 mm (7.5 in.)

210612

272 mm (10.7 in.) 210613

6-43

3-SPEED POWERSHIFT TRANSMISSION

9 mm (0.35 in.) 12

9 16 15

210614

(8) Depress the inching pedal 11 and make sure that the protrusion of clutch valve plunger 1 is 11.5±0.5 mm (0.453±0.02 in.) when the cam follower 12 touches the brake valve pedal 13. If the 11.5±0.5 mm (0.453±0.02 in.) cannot be obtained, adjust the length of the turnbuckle 7.

11.5±0.5 mm (0.453±0.020 in.) 1

11 12

13 7

210615

19.5±1 mm (0.768±0.039 in.) 1 11

210616

6-44

3-SPEED POWERSHIFT TRANSMISSION

Oil Pressure Measurement NOTE Front tires rotate during the measurement. Build a fence around the vehicle to prevent access to it.

NOTE: Always perform pedal adjustments before oil pressure measurement.

1. Main oil pressure measurement

(1) Connect a 2 MPa (20 kgf/cm2) [290 psi] oil pressure gauge to the main oil pressure outlet of the regulator valve.

Main pressure tap (M)

Special tools needed *Connector

64309 - 17733

*Hose

64309 - 17722

*Connector

64309 - 17731

*Gauge

64309 - 17713

210621

NOTE: Parts marked with an asterisk (*) are included in the gauge kit 64309 - 17701.

1.08 to 1.27 MPa (11 to 13 kgf/cm2) [157 to 184 psi]

NOTE: Monitor the idling speed through engine tachometer during measurement.

6-45

3-SPEED POWERSHIFT TRANSMISSION 2. Direction clutch oil pressure measurement

(1) Connect a 2 MPa (20 kgf/cm2) [290 psi] oil pressure gauge to the direction clutch oil pressure outlet port of the selector valve.

Direction clutch pressure tap (PD)

NOTE: Use the same special tools as used for main oil pressure measurement. (2) Lift the front tires off the floor by either of the following methods. (a) The front axle housing is jacked up.

210622

(b) The mast is tilted all the way backward first. With a wooden block applied under the outer mast, the mast is tilted forward to lift the front tires. Then, an appropriate stand or square timber is placed under the frame to keep the front tires lifted. (3) Put scotch blocks under the rear tires. (4) Implement the steps (2) through (4) of main oil pressure measurement.

End face of control valve body

Pedal height (from frame top surface to uppermost end of pedal)

0.98 (10) [142]

190 mm (7.5 in.)

Clearance between inching cam follower and brake valve

14.5 mm (0.571 in.)

Plunger protrusion A when inching pedal is not depressed

9 mm (0.35 in.)

Plunger protrusion B when brake begins to work

14 mm (0.55 in.)

0.22 (2.2) [31]

7 10.5 (0.41) (0.28) 15 (0.59)

10 (0.39)

2 5 (0.20) (0.08)

Clutch pressure, MPa (kgf/cm2) [psi]

Reference data

Clutch valve plunger stroke, mm (in.) 210623

6-46

3-SPEED POWERSHIFT TRANSMISSION 3. Torque converter inlet oil pressure measurement

(1) Connect a 0.6 MPa (6 kgf/cm2) [87 psi] oil pressure gauge to the torque converter inlet oil pressure inlet port of the regulator valve.

Torque converter inlet pressure tap (T)

Special tools needed *Connector

64309 - 17733

*Hose

64309 - 17722

*Connector

64309 - 17731

*Gauge

64309 - 17713

210624

NOTE: The parts marked with an asterisk (*) are included in the gauge kit 64309 - 17701.

0.15 to 0.69 MPa (1.5 to 7.0 kgf/cm2) [22 to 100 psi]

NOTE: Monitor the idling speed through engine tachometer during measurement.

6-47

3-SPEED POWERSHIFT TRANSMISSION

(5) Move the transmission shift lever to the forward position, and gradually depress the accelerator pedal fully. Under this condition, measure the stall speed with an engine tachometer. Stall speed (tolerance: ±100 rpm)

1760 rpm

(6) Similarly measure the stall speed for reverse drive.

10 m (33 ft) Start Acceleration Test (1) Stand ready to start with the engine running at low idle, the transmission shift lever in the neutral position and the travel speed select switch in D (automatic 3-speed) position. (2) At the signal, move the transmission shift lever to the forward position and, at the same time, depress the accelerator pedal all the way. (3) Measure the time required for the truck to travel 10 m (33 ft) with a stopwatch. (4) Conduct the same test for reverse travel, too.

Travel time (no load)

5 seconds, maximum

6-48

3-SPEED POWERSHIFT TRANSMISSION

Travel Speed Select Switch Move the travel speed select switch mounted on the console box to each position, and make sure that the speed selector system functions properly. Move the switch when the truck is at standstill. DP100, DP115

(1) In the “Fixed 1st speed” position, the truck runs at a maximum speed of 8 km/hr (5.0 mph) and a greater torque is available. (2) In the “Automatic 2-speed” position, the transmission automatically shifts from the 1st to the 2nd speed when the travel speed reaches 6.5 km/hr (4.0 mph) to allow the truck to run at a maximum speed of 18.5 km/hr (11.5 mph). (3) In the “Automatic 3-speed” position, the transmission automatically shifts from the 1st to the 2nd speed when the travel speed reaches 6.5 km/h (4.0 mph). It automatically shifts from the 2nd to the 3rd speed when the travel speed reaches 15 km/h (9.3 mph) to allow the truck to run at a maximum speed of 27 km/h (16.5 mph). DP135, DP150

(1) In the “Fixed 1st speed” position, the truck runs at a maximum speed of 8.5 km/hr (5.3 mph) and a greater torque is available. (2) In the “Automatic 2-speed” position, the transmission automatically shifts from the 1st to the 2nd speed when the travel speed reaches 6.5 km/hr (4.0 mph) to allow the truck to run at a maximum speed of 19 km/hr (11.8 mph). (3) In the “Automatic 3-speed” position, the transmission automatically shifts from the 1st to the 2nd speed when the travel speed reaches 6 km/h (3.7 mph). It automatically shifts from the 2nd to the 3rd speed when the travel speed reaches 12.5 km/h (7.8 mph) to allow the truck to run at a maximum speed of 32 km/h (19.6 mph).

6-49

Travel speed select switch

207499

3-SPEED POWERSHIFT TRANSMISSION

Troubleshooting

Engine

Torque converter

Not enough output power

Transmission

Wheels

Poor performance

Tune up engine.

Oil level too low

Refill.

Air being sucked in on suction side

Retighten or replace gasket.

Main regulator valve not operating properly

Repair or replace.

Main regulator valve spring fatigued

Replace.

Oil pump gears worn, resulting in reduced capacity

Overhaul and check or replace defective parts.

Magnet strainer clogged

Replace.

Seal rings or O-rings worn

Replace after measuring oil pressure.

Stator freewheel seized

Replace stator assembly, hub and roller.

Blades of running members damaged or rubbing

Repair or replace. Replace bearing.

Air being sucked in on suction side

Retighten or replace.

Outlet pressure too low to suppress internal foaming

Readjust.

Water in oil

Replace oil.

Oil level too low

Refill.

Main pressure too low, resulting in slipping clutches

Readjust after measuring oil pressure.

Seal rings or O-rings worn

Replace after measuring oil pressure.

Clutch piston damaged

Replace.

Friction plate seized or dragging

Replace.

High mechanical resistance

Check and adjust brake system.

6-50

3-SPEED POWERSHIFT TRANSMISSION

Torque converter

No power flow Transmission

Power train

Torque converter

Abnormal noise

Transmission

Flexible plates broken

Replace.

Oil level too low

Refill.

Oil pump drive defective

Replace.

Turbine shaft broken

Replace.

Main pressure too low

Check pump gears for wear or replace.

Oil level too low

Refill.

Inching pedal link maladjusted

Readjust.

Seal rings worn in servo case

Replace.

O-rings on input shaft worn

Replace.

Plug on input shaft loose or slipped off, resulting in oil leaks

Repair.

Clutch seized

Replace.

Shafts broken

Replace.

Clutch drum, particularly snap ring groove, defective

Replace.

Snap ring fitted to clutch drum broken

Replace.

Oil line to clutch piston clogged

Clean or replace.

Shaft splines worn

Replace shafts.

Broken parts in reduction and differential or front axle

Refer to each section.

Flexible plates broken

Replace.

Bearings damaged

Replace.

Rubbing vanes of running members

Replace.

Bolts loose

Retighten or replace.

Splines worn

Replace.

Oil pump worn

Inspection or replace.

Clutch seized and dragging

Replace clutch plate.

Bearings worn or seized

Replace.

Gears broken

Replace.

Bolts loose

Retighten or replace.

Splines worn

Replace.

6-51

3-SPEED POWERSHIFT TRANSMISSION

Loud noise

Abnormal noise

Oil strainer clogged

Clean or replace.

Main regulator valve spool defective

Wash or replace.

Restriction in oil pipe

Replace.

Oil too viscous in cold weather

Replace oil. *

Instruments out of order

Replace.

Improper oil used

Replace oil. *

Oil strainer clogged

Clean or replace.

Oil pump defective

Replace.

Excessive oil leaks Low noise

Oil leaks

• Main regulator valve spring defective

Replace.

• Main regulator valve spool defective

Repair or replace.

Air being sucked in

Retighten or replace packing.

Oil level too low

Refill.

Leaking oil seals

Check lips and sliding surfaces for wear. Replace seals.

Leaking joint of case

Retighten or replace packing.

Leaking pipe connection or joint

Repair or replace pipe, gasket and O-rings.

Leaking drain plug

Retighten or replace gasket.

Cracks or blowholes in case

Replace.

Oil blowing out of transmission case • Water in oil

Replace oil.

• Air being sucked in on suction side

Replace packing and retighten.

• Oil leaks from air breather

Repair.

Oil level too high

Lower oil level.

* (Refer to “Recommended Brands of Lubricants.”)

6-52

3-SPEED POWERSHIFT TRANSMISSION

Torque converter

Oil temperature is too high Transmission

Oil level too high or too low

Keep correct oil level.

Oil strainer clogged

Clean or replace.

Rubbing vanes of running members

Repair or replace.

Stator freewheel defective

Replace stator assembly.

Air being sucked in

Retighten or replace O-ring.

Water in oil

Replace oil.

Restriction in oil pipe (resulting in reduced circulation flow)

Repair or replace.

Bearings worn or seized

Repair or replace.

Instruments out of order

Replace.

Clutches dragging

Replace clutch plates.

Bearings worn or seized

Repair or replace.

Control linkage defective

Repair or replace.

Truck not operated properly

Advice user to drive truck properly.

Others Others

Main pressure is too high

Main pressure is too low

• Cooling fan belt damaged

Replace.

• Oil cooler clogged

Clean or replace.

• Brakes grabbing

Check and readjust.

Main regulator valve defective

Repair or replace valve assembly.

Oil viscosity too high in cold weather

Replace oil. *

Improper oil used

Replace oil. *

Magnet strainer clogged

Clean or replace.

Oil pump defective

Replace.

Coil spring defective in main regulator valve

Replace.

Main regulator valve spool defective

Repair or replace.

Air being sucked in

Retighten or replace packing.

Oil level too low

Refill.

Control linkage defective

Repair or replace.

Inching valve out of order

Repair or replace.

* (Refer to “Recommended Brands of Lubricants.”)

6-53

3-SPEED POWERSHIFT TRANSMISSION

Clutch pressure is too low

Stall speed out of specification

No automatic shifting

Transmission shifts up when travel speed select switch is in “Fixed 1st speed” position

Magnet strainer clogged

Clean or replace.

Oil pump worn or defective

Replace.

Coil spring defective in main regulator valve

Replace.

Main regulator valve spool defective

Repair or replace.

Air being sucked in

Retighten or replace packing.

Oil level too low

Refill.

Control linkage out of order

Repair or replace.

Inching valve defective

Repair or replace.

Seal ring broken in servo case

Replace.

Clutch seal rings broken

Replace.

Lack of engine power if the speed is slightly low in both forward and reverse drive

Tune up engine.

Stator and freewheel defective if the speed is excessively low in both forward and reverse drive

Replace stator assembly.

Inching pedal linkage defective, or clutch slipping if the speed is too high

Repair or replace.

Travel speed select switch in “Fixed 1st speed” position

Move switch to “Automatic” position.

Solenoid valve defective

Replace.

Solenoid valve inlet orifice clogged

Clean or replace.

Solenoid valve spool or spring defective

Repair or replace.

ECU control box internally defective

Check or replace.

Harness open

Repair.

Travel speed select switch defective

Replace.

6-54

3-SPEED POWERSHIFT TRANSMISSION

Service Data A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item Stall speed (tolerance: ±100 rpm) Main pressure (engine at 1500±100 rpm)

rpm A

1760

MPa (kgf/cm2) [psi] A

Speed clutch pressure (engine at 1500±100 rpm) A MPa (kgf/cm2) [psi]

1.08 to 1.27 (11 to 13) [156 to 185]

Direction clutch pressure (engine at 1500±100 rpm) A MPa (kgf/cm2) [psi] Torque converter inlet pressure (engine at 1500±100 rpm) A MPa (kgf/cm2) [psi]

0.15 to 0.69 (1.5 to 7.0) [21 to 100]

Lubrication line pressure (engine at 1500±100 rpm) A MPa (kgf/cm2) [psi]

0.02 to 0.10 (0.2 to 1.0) [3 to 14]

10 m (33 ft) start acceleration (no load)

5 seconds, maximum

100 − 0.035 (3.94 − 0.00138 )

99.85 (3.9311)

Diameter of portion in contact with oil seal 1

Pump boss 1

200721 − 0.007

20 − 0.020 (0.79 − 0.00079 )

19.85 (0.7815)

Diameter of portion in contact with engine flywheel 1

Pilot boss

− 0.00028

200411

6-55

3-SPEED POWERSHIFT TRANSMISSION

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item Side clearance 1 Top clearance 2

0.040 to 0.078 (0.00157 to 0.00307)

0.09 (0.0035)

0.3 to 0.345 (0.0118 to 0.0136)

0.35 (0.0138)

Oil pump

2 1

205486

67.951 to 67.97 (2.67523 to 2.6760)

67.8 (2.669)

10.185 to 10.2 (0.40098 to 0.402)

10.1 (0.398)

4.95 to 5 (0.1949 to 0.197)

4.8 (0.189)

3.95 to 4 (0.1555 to 0.157)

3.8 (0.150)

2.9 to 3 (0.114 to 0.118)

2.8 (0.110)

4.9 to 5 (0.193 to 0.197)

4.8 (0.189)

4.95 to 5 (0.1949 to 0.197)

4.8 (0.189)

1 2 5 6 7

200724

6-56

3-SPEED POWERSHIFT TRANSMISSION

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item Face runout of flexible plates 1 (in free state) Distance between end face of torque converter housing and mating face of flexible plates 2

0.2 (0.008)

0.5 (0.020)

25 (0.984)

Flexible plates

1 200725

Thickness of mating plate 1 Thickness of friction plate 2 Free movement of friction plate on gear 3 (looseness of mating splines) Width of piston seal ring 4

2.3±0.07 (0.091±0.0028)

2.1 (0.083)

2.6±0.1 (0.102±0.004)

2.2 (0.087)

0.10 to 0.30 (0.0039 to 0.0118)

4 − 0.03 (0.16 − 0.0012 )

− 0.01

B A

Width of seal ring groove in piston 5

Clutches

A Free length of clutch spring 6 Spring constant: k = N/mm (kgf/mm) [lbf/in.] B

− 0.0004

3.5 (0.138) 4

+ 0.2 + 0.1

+ 0.008

(0.16 + 0.004 )

4.5 (0.177) 62.9 (2.48) k = 39.1 (3.992) [223.5] 60 (2.36)

4 6

2 1

3 5

6-57

210220

3-SPEED POWERSHIFT TRANSMISSION

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item A

2.5±0.05 (0.098±0.0020)

2.0 (0.079)

2.5 + 0.1 (0.098 + 0.004 )

3.0 (0.118)

Width of piston seal ring for each shaft 1

Width of piston seal ring groove in each shaft 2 Inside diameter of servo case and clutch shaft in contact with seal ring 3

Inside diameter of stator shaft in contact with seal ring 4

+ 0.2

+ 0.025 0

+ 0.008

(1.38

+ 0.00098 0

)

35.2 (1.386) 35

+ 0.025 0

(1.38

+ 0.00098 0

)

35.2 (1.386)

2.5±0.05 (0.098±0.0020)

2.0 (0.079)

Width of clutch piston seal ring for each shaft 5 Width of clutch piston seal ring groove in each shaft A 6 B

+ 0.2

+ 0.008

2.5 + 0.1 (0.098 + 0.004 ) 3.0 (0.118)

Forward clutch shaft, reverse clutch shaft, 1st-speed/ 3rd-speed clutch shaft and servo cases

1 ,2

5,6

207518

1,2 4

207519

6-58

3-SPEED POWERSHIFT TRANSMISSION

A: Standard value Unit: mm (in.) Truck Model DP100

DP115

DP135

DP150

Item Input gear and forward and reverse gears 1

0.12 to 0.28 (0.0047 to 0.0118)

Forward gear and reverse and 1st-speed/3rd-speed gears 2

0.14 to 0.32 (0.0055 to 0.0126)

2nd-speed gear and output gear 3

0.12 to 0.28 (0.0047 to 0.0110)

1st-speed gear and output gear 4

3rd-speed gear and output gear 5

Pump drive gear and idler gear 6

PTO drive gear and idler gear 7

0.13 to 0.30 (0.0051 to 0.0118)

0.12 to 0.26 (0.0047 to 0.0102)

Backlash of gears

3 2

2 1 3 5 3

210219

6-59

3-SPEED POWERSHIFT TRANSMISSION

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item

Control valve

A Free length of selector valve spring 1 Spring constant: k = N/mm (kgf/mm) [lbf/in.] B

36.5 (1.44) k = 5.658 (0.577) [32.3]

A Free length of return spring 2 Spring constant: k = N/mm (kgf/mm) [lbf/in.] B

28 (1.10) k = 0.478 (0.0488) [2.73]

A Free length of differential valve spring 3 Spring constant: k = N/mm (kgf/mm) [lbf/in.] B

59.5 (2.34) k = 2.311 (0.2357) [13.2]

A Free length of inching valve spring 4 Spring constant: k = N/mm (kgf/mm) [lbf/in.] B

39 (1.53) k = 2.128 (0.217) [12.1]

A Free length of accumulator valve outer spring 5 Spring constant: k = N/mm (kgf/mm) [lbf/in.] B

125.5 (4.94) k = 5.363 (0.5469) [30.6]

A Free length of accumulator valve inner spring 6 Spring constant: k = N/mm (kgf/mm) [lbf/in.] B

170.5 (6.71) k = 4.128 (0.4210) [23.5]

A Free length of direction valve springs 7 Spring constant: k = N/mm (kgf/mm) [lbf/in.] B

32.5 (1.28) k = 8.616 (0.8786) [49.2]

35.5 (1.40)

26.5 (1.04)

57.5 (2.26)

38 (1.49)

123 (4.84)

168 (6.61)

31.5 (1.24) 7

1 4

2 3

1 5

6-60

210209

3-SPEED POWERSHIFT TRANSMISSION

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item A

112 (4.41) k = 4.99 (0.5087) [28.5]

109 (4.29)

Free length of main regulator valve spring 1 Spring constant: k = N/mm (kgf/mm) [lbf/in.]

Main regulator valve

1 210181

Inching pedal height (from frame to top end of pedal) 1

190 (7.48)

Clearance between inching pedal cam follower and brake control valve pedal 2

14.5 (0.571)

Protrusion of inching plunger with inching pedal released 3

9 (0.35)

Protrusion of inching plunger when brake starts to be applied 4

14 (0.55), minimum

Inching pedal control 2 1

3 4

210358

6-61

FRONT AXLE AND REDUCTION DIFFERENTIAL Specifications .......................................................................................... 7 – 1 Description ............................................................................................... 7 – 2 Removal and Installation ...................................................................... 7 – 3 Front Wheels (Tires) .................................................................................. 7 – 3 Front Axle and Reduction Differential Assembly ........................................ 7 – 5 Reduction Differential Assembly ................................................................ 7 – 7

Front Axle ................................................................................................. 7 – 9 Disassembly .............................................................................................. 7 – 9 Inspection .................................................................................................. 7 – 12 Reassembly ............................................................................................... 7 – 14

Reduction Differential ........................................................................... 7 – 17 Disassembly .............................................................................................. 7 – 17 Inspection .................................................................................................. 7 – 19 Reassembly ............................................................................................... 7 – 21

Troubleshooting ...................................................................................... 7 – 28 Service Data ............................................................................................ 7 – 29

FRONT AXLE AND REDUCTION DIFFERENTIAL

Specifications Truck Model DP100

DP115

DP135

Item Type

Full-floating, tubular

Front axle

Reduction bevel gear

Final drives

Housing type

Banjo

Gear type

Hypoid

Gear ratio

5.571

Type

Planetary gear

Gear ratio

4.167

Differential bevel gear, type – No. of gears

Straight bevel – 2

Differential bevel pinion, type – No. of pinions

Straight bevel – 4

Differential

7-1

DP150

FRONT AXLE AND REDUCTION DIFFERENTIAL

Description

15 7

13 210370

1. 2. 3. 4. 5. 6. 7. 8.

Front wheel hub Front axle housing Axle shaft Ring gear Planet gear Wheel brake assembly Reduction and differential assembly Differential case

9. 10. 11. 12. 13. 14. 15. 16.

The front axle is of full-floating type with banjo-type axle housing of all-welded construction. It is bolted to the front side of the frame. The final drives are of planetary gear type. The wheel brake assemblies are mounted on the axle housing. The parking brake assembly is mounted on the input flange fitted to the reduction bevel pinion.

7-2

Differential bevel gear Differential bevel pinion Reduction bevel gear Reduction bevel pinion Input flange Parking brake drum Parking brake bracket Parking brake assembly

FRONT AXLE AND REDUCTION DIFFERENTIAL

Removal and Installation Front Wheels (Tires) Removal 6

Sequence 1. 2. 3. 4. 5. 6. 7. 8.

Extension bracket Wheel nuts Clamp Wedge band Front wheel (Tire) (outer) Spacer Extension valve Front wheel (Tire) (inner)

4 7

2 3 210371

Start by:

Loosen the outer wheel nuts about two full turns, and block the rear wheels. Truck lifting

(1) Lifting with lift equipment Tilt the mast fully backward, place wood blocks under the mast, and tilt the mast forward.

Tilt backward

Tilt forward

WARNING After raising the front end of the truck, securely support the truck by putting wood blocks under the frame. Block the rear wheels. Wood block

210372

(2) Tire removal (a) Position the extension valve at top center. (b) Release air from the tire.

NOTE Air is compressed. Keep your face away. bar applied to it. 210373

7-3

FRONT AXLE AND REDUCTION DIFFERENTIAL

(d) Front tire removal Support the front tires with the fork of a lift truck or the Tire Handler (special tool). Remove outer wheel nuts and detach the front tire. Special tool needed Tire handler

Banzai WD-5500

210374

(e) Extension valve removal Draw out the inner tire as far as the end of the brake hub, and remove the extension valve of the air valve.

210375

Installation Follow the reverse of removal sequence and do the following steps. (1) Install the inner tire into place. (a) Make sure that the air valve set groove in the hub and the positioning boss on the rim meet. (b) After the tire goes in as far as the end of the brake hub, fit the extension valve to the air valve.

(2) Tighten wheel nuts evenly to specified torque in the numerical order shown at the right.

7 -LE

L-

3 8

5 210376

Tightening torque

539±49 N·m (55±5 kgf·m) [398±36 lbf·ft]

(3) After installing the tires, retighten wheel nuts. After about 10 minutes of advancing, reversing and braking, check wheel nuts for the specified torque using a torque wrench.

7-4

FRONT AXLE AND REDUCTION DIFFERENTIAL

Front Axle and Reduction Differential Assembly Removal

2 4 210378

Sequence 1. Wheel brake pipes (left and right) 2. Parking brake cable, Nut 3. Universal joint

4. Front axle and reduction differential assembly, Bolts, Nuts, Washers

Start by:

(1) Mast assembly removal (a) Disconnect piping and electrical wiring from the mast assembly. (b) Hitch a shackle and a sling to the hanger on top of the outer mast, and hoist the front of the frame to lift the front tires off the floor. (c) Place an appropriate stand or square timber under the front of the frame to prevent falling. (d) Put scotch blocks under the rear tires. (e) With the outer mast lifted off the floor, disconnect the tilt cylinder at the rod side. (f) Remove the mast assembly. (For details, refer to “GROUP 12 MASTS AND FORKS.”) (2) Removing front tires Refer to “(d) Front tire removal on page 7-4.” 7-5

210377

FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Removal (1) After disconnecting the wheel brake pipes, cover the openings to prevent dirt from getting inside the brake lines. (2) Disconnect the universal joint at the input flange side. Before disconnecting the joint, fasten it to the transmission with rope to prevent it from falling. Remember that the oil will flow out of the transmission case when the joint is removed.

Transmission Disconnect here.

(3) To remove the front axle and reduction and differential assembly, fasten a hoist to the axle housing by hitching chains or wires to the mast supports. When hitching such slings, be sure to use a protective rag to prevent damage to these supports. 204585A

Installation Follow the reverse of removal sequence and do the following steps: (1) Tighten the bolts to the specified torque. Tightening torque for front axle housing mounting bolts

640±96 N·m (65.3±9.8 kgf·m) [472±71 lbf·ft]

(2) After having installed the parking brake wire, check to make sure that the lever operating effort is within the specified range. Parking brake lever operating effort

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

(3) After having installed the wheel brake pipes, bleed the brake lines, and check them for leakage. It is advisable that this work be performed before the front wheels and mast are installed.

NOTE: For the procedure to bleed the brake lines, refer to “GROUP 9 BRAKE SYSTEM.”

7-6

FRONT AXLE AND REDUCTION DIFFERENTIAL

Reduction Differential Assembly Removal Remove the front axle and reduction differential assembly from the frame, then remove the parking brake and reduction differential assembly from the front axle.

210379

Sequence 1. Wheel hub cover, Gasket, Bolts, Washers 2. Axle shafts, Sun gear, Snap ring

3. Reduction differential assembly, Bolts, Washers

Start by:

Remove the drain plugs from the axle housing and the planet carrier and drain the oil

Suggestions for Removal (1) Axle shaft removal Remove each axle shaft with the sun gear. (2) Lay the axle housing with the differential side up. (3) To remove the differential assembly, install two eye bolts to the universal joint mounting bolt holes and fasten a hoist to these eye bolts.

7-7

FRONT AXLE AND REDUCTION DIFFERENTIAL

Installation Follow the reverse of removal sequence.

Suggestions for Installation (1) When installing the differential assembly, check to make sure the mounting surfaces of the differential assembly and the front axle housing are clean and free from any defect. Apply ThreeBond No. 1215 to these surfaces.

Tightening torque for reduction differential bolts

Bolt length 37 mm (1.46 in.)

118±12 N·m (12.0±1.2 kgf·m) [87±9 lbf·ft]

Bolt length 31 mm (1.22 in.)

132±14 N·m (13.5±1.4 kgf·m) [98±10 lbf·ft]

(2) Install the wheel hub cover with new gasket. Tighten the bolts to the specified torque. Tightening torque for wheel hub cover bolts

57±6 N·m (5.8±0.6 kgf·m) [42±4 lbf·ft]

(3) Install the front axle to the frame and fill the axle with oil. On one side of the axle, position the wheel hub so that -LEVEL- mark on the wheel hub cover is horizontal. Remove the level plug from a cover on which it is horizontal. On the other cover, remove the drain or the level plug whichever is above horizontal. Then remove the level plug on the differential side of the axle housing and fill the housing through this plug hole. The oil used in the axle housing is high in viscosity and will not flow out soon even if leakage occurs. With this kept in mind, tighten all the plugs securely. Recommended oil

Hypoid gear oil SAE #90

Refill capacity

25 liters (6.6 U.S. gal.)

7-8

210380

FRONT AXLE AND REDUCTION DIFFERENTIAL

Front Axle Disassembly

4 3

3 2

1 210381

Sequence 6. Ring gear, Taper roller bearing (inner race) 7. Hub drum assembly, Front wheel hub, Stud, Brake drum, Stud bolts, Washers, Nuts, Taper roller bearing (outer race), Oil seal, Oil deflector, Bolts, Washers 8. Taper roller bearing (inner race), Oil seal retainer, O-ring

1. Plug, Gasket 2. Cover, Gasket, Bolts, Washers 3. Planet carrier assembly, Planet carrier, O-rings, Planet pins, Steel balls, Thrust washers, Planet gears, Bushings 4. Axle shaft, Sun gear, Sleeve, Snap ring 5. Lock plates, Bolts, Washers, Nuts

NOTE The oil can be drained with the axle housing on the truck. 7-9

FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Disassembly 1. Oil draining

Place a dip pan to catch the oil that flows from the axle housing when the plug is removed and when the planet carrier assembly is removed. 2. Planet carrier assembly removal

Remove the bolts holding the planet carrier assembly. Screw two wheel hub cover bolts into the removal holes in the carrier evenly to force out the planet carrier assembly.

210382

3. Planet gear removal

Remove the pins to remove the planet gears. Be careful not to lose the steel balls.

210383

72 (2.83)

25 (0.98) 3 (0.12)

92267 - 00200

15 3

Socket wrench

.0 2

)

ø162 (6.38)

Special tool needed

19 (0.75)

5. Axle shaft removal

30 (1.18)

Turn a sliding hammer in the M10 x 1.25 hole at the end of the axle shaft to remove the axle shaft.

7-10

Unit: mm (in.)

(0 ø20 .7 9)

65 (2.56)

1 (0 2.7 .5 0)

144 (5.67)

(6.10) ø155 ø65 (2.56)

Use the Socket Wrench (special tool) and an impact wrench to remove the nut.

ø75 (2.95)

4. Nut removal

60 (2.36) 90 (3.54)

205603A

FRONT AXLE AND REDUCTION DIFFERENTIAL 6. Hub drum assembly removal

Support the hub drum assembly with a transmission jack. Remove the front wheel hub with a wheel hub puller.

210384

7. Bearing removal

Using a bearing puller, remove the inner race of the taper roller bearing from the axle housing, along with the seal retainer.

204590

NOTE For disassembly, inspection and assembly of the wheel brakes mounted on the axle housing, refer to “GROUP 9 BRAKE SYSTEM.”

7-11

FRONT AXLE AND REDUCTION DIFFERENTIAL

Inspection 1. Axle shafts

Set a dial indicator at the middle part of the axle shaft, and rotate the shaft to measure the deflection. B: Repair or service limit Unit: mm (in.) Deflection of axle shaft (1/2 of dial indicator reading)

1.0 (0.039) 200860

2. Axle housing

(1) Check the mast support bearing contact surfaces for wear or damage. (2) Check the outer and inner oil seals for wear or damage. (3) Check the axle housing for distortion, dents or other defects. Also check the welds for cracks.

3. Hub and drum assemblies

(1) Check the oil seal for wear or damage. (2) Check the inside surface of the brake drum for wear or damage. A: Standard value

Inside diameter of wheel brake drum

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

420 + 00.2 (16.54 + 00.008 )

424 (16.69)

(3) Check the taper roller bearings (outer races) for wear or damage.

7-12

FRONT AXLE AND REDUCTION DIFFERENTIAL 4. Planet carriers

(1) Measure the inside diameter of the planet gear rollers and the diameter of the planet pins. A: Standard value

Inside diameter of planet gear rollers

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

0.010 58 ++ 0.029 0.00039 ) (2.28 ++ 0.00114

57.96 (2.2819)

0 50 – 0.011 0 (1.97 – 0.00043 )

49.96 (1.9669)

Diameter of planet pins

(2) Check the thrust washers for wear or damage. A: Standard value

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

1.2±0.06 (0.047±0.0024)

0.8 (0.031)

Thickness of thrust washer

5. Others

(1) Check the outer surface of oil seal retainer for wear or damage. (2) Check the taper roller bearings (inner races) for wear or damage.

7-13

FRONT AXLE AND REDUCTION DIFFERENTIAL

Reassembly

2 210385

Sequence 6. 7. 8. 9.

Nut Lock plate, Bolts, Washers Sleeve, Axle shaft Planet carrier assembly, Planet carrier, Planet gears, Bushings, Thrust washers, Planet pins, Steel balls, O-ring, Bolt, Washers 10. Sun gear, Snap ring 11. Cover, Gasket, Bolts, Washers

1. 2. 3. 4.

Front axle housing Oil seal retainer, O-ring Taper roller bearing (inner race) Hub and drum assembly, Front wheel hub, Studs, Brake Drum, Studs, Washers, Nuts, Taper roller bearing (outer race), Oil seal, Oil deflector, Bolts, Washers 5. Ring gear, Taper roller bearing (inner race)

7-14

FRONT AXLE AND REDUCTION DIFFERENTIAL Start by:

(a) Assemble the planet carrier. (b) When assembling the hub and drum assembly after replacing the parts, align the extension valve grooves in the brake drum and wheel hub.

Liquid gasket

Tightening torque for brake drum nuts

359±36 N·m (36.6±3.7 kgf·m) [265±27 lbf·ft] 210386

NOTE Replace the oil seals of the front axle housing.

Suggestions for Reassembly 1. Taper roller bearing (inner race) installation

Using an installer, install the taper roller bearing inner race in position, along with the oil seal retainer.

204592

7-15

FRONT AXLE AND REDUCTION DIFFERENTIAL 2. Wheel hub bearing preload adjustment

Hook a spring scale to one of the hub bolts. Pull the scale in tangential direction and take a reading on the scale just when the hub begins to rotate. Adjust the preload by means of the nut that holds the ring gear. The preload decreases after a period of months, it is advisable to aim at a value of preload in the lower half of the range. Preload for wheel hub bearing (force applied in tangential direction)

118 to 157 N (12 to 16 kgf) [26 to 35 lbf]

210387

NOTE Adjust the hub bearing preload every 2400 hours or 1 year.

3. Planet gear installation

(1) Put the needle roller bearing in position in each planet gear. Put the thrust washers on both sides of each gear and install the gears with the pin in the carrier. Lock the gear in position with a steel ball.

210388

(2) Install the planet carrier to the wheel hub and, after making sure the hub rotates freely, tighten its mounting bolts to the specified torque. Tightening torque for planet carrier bolts

93±10 N·m (9.5±1.0 kgf·m) [69±7 lbf·ft]

210389

7-16

FRONT AXLE AND REDUCTION DIFFERENTIAL

Reduction Differential Disassembly

9 7

3 4

1 4

4 210390

Sequence 6. Nut, Washer, O-ring 7. Input flange, Parking brake drum, Reamer bolts, Washers, Nuts, Dust plug 8. Parking brake assembly, Bolts, Nuts, Washers 9. Parking brake bracket, Oil seal, O-ring, Bolts, Washers 10. Reduction bevel pinion, Oil separator, Taper roller bearings, Collar, Bearing retainer, Shim(s), O-ring, Roller bearings, Stopper

1. Bolts, Washers, Lock plates 2. Side bearing nuts 3. Differential carrier, Cap set, Bolts, Lock washers, Bearing caps, Differential carrier 4. Differential bevel gear assembly, Reduction bevel gear, Spider, Differential bevel pinions, Differential bevel gears, Washers, Differential case, Bolts, Nut 5. Taper roller bearings

7-17

FRONT AXLE AND REDUCTION DIFFERENTIAL

NOTE (1) For disassembly, inspection and assembly of the parking brake assembly, refer to “GROUP 9 BRAKE SYSTEM.” (2) Replace the oil seal of the parking brake bracket.

Suggestions for Disassembly NOTE (1) Before disassembling the differential, measure the gear backlash to aid in assembling the differential correctly. Backlash between reduction bevel gear and bevel pinion

0.25 to 0.33 mm (0.0098 to 0.0130 in.)

(2) Put a mark across the bearing cap and carrier on one side to ensure correct refitting.

210391

(3) When removing the bearing retainer from the differential carrier, make a record of the thickness or amount of shim(s) between the retainer and carrier.

210392

7-18

FRONT AXLE AND REDUCTION DIFFERENTIAL

Inspection 1. Reduction bevel gear and reduction bevel pinion

Check the reduction bevel gear and reduction bevel pinion for tooth contact. Check the gear teeth for wear, pitting, flaking or chipping. Minor flaws on the tooth surfaces can be repaired by grinding with an oil stone or a sand paper. If the gear is badly damaged to require replacement, replace the gear and pinion as a set. 2. Differential

(1) Check the differential case for damage. Check, in particular, the seat formed of each case for carrying the taper roller bearing inner race to see whether the seat surface is fretted or not. (2) Check the sliding surfaces of the washers and gears for wear or damage. (3) Check the teeth of the differential bevel pinions and bevel gears for wear, pitting, chipping, galling, etc. (4) Check the play of each pinion on the shaft. A: Standard value

Play between differential bevel pinion inner diameter and shaft outer diameter

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

0.169 to 0.278 (0.00665 to 0.01094)

0.35 (0.0138)

(5) Check the free movement of the differential bevel gears on the axle shafts (looseness of mating splines). B: Repair or service limit Unit: mm (in.) Free movement of differential bevel gears on axle shafts (looseness of mating splines)

0.5 (0.020)

7-19

FRONT AXLE AND REDUCTION DIFFERENTIAL 3. Parking brake drum

(1) Check the inside surface of the drum for wear or damage. (2) Replace the drum if its inside diameter is in excess of the service limit. A: Standard value

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

304.8 + 00.5 (12.000 + 00.020 )

307 (12.09)

Inside diameter of brake drum

7-20

FRONT AXLE AND REDUCTION DIFFERENTIAL

Reassembly

11 10 12 9 9 7

8 6

2 4

13 5 3 1 210393

Sequence 7. Bearing retainer, Taper roller bearing (outer race), O-ring, Shim(s) 8. Taper roller bearing (inner race), Oil separator 9. Parking brake bracket, Oil seal, O-ring, Bolts, Washers 10. Parking brake assembly, Bolts, Washers 11. Input flange, Parking brake drum, Reamer bolts, Washers, Nuts, Plug 12. Self-locking nut, Washers, O-ring 13. Lock plates, Bolts, Washers

1. Differential case, Washers, Differential bevel gears, Differential bevel pinions, Pinion shafts, Washers , Bolts 2. Reduction bevel gear, Bolts, Nuts 3. Taper roller bearings 4. Differential carrier, Bearing caps, Lock washers, Bolts 5. Side bearing nuts 6. Reduction bevel pinion, Taper roller bearing (inner race), Collar

7-21

FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Reassembly 1. Differential case assembling

The backlash between the differential bevel gear and bevel pinion is to be adjusted by means of the washers of the differential bevel gear. If the backlash is in excess of the service limit, replace the washers. A: Standard value

Backlash between differential bevel gear and bevel pinion

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

0.2 to 0.28 (0.008 to 0.0110)

0.5 (0.020)

210394

2. Differential case installation

Apply LOCTITE No. 271 to the bolts that hold the differential case and tighten the bolts to the specified torque. 196±29 N·m (20±3 kgf·m) [145±22 lbf·ft]

Tightening torque for differential case bolts

3. Reduction bevel gear installation

To install the reduction bevel gear, put LOCTITE No. 271 on the threads of the mounting bolts, and tighten the bolts evenly to the specified torque. Tightening torque for reduction bevel gear mounting bolts

441±69 N·m (45±7 kgf·m) [325±51 lbf·ft]

4. Side bearing cap installation

The bearing caps are machined together with the differential carrier. Identify the left and right caps by referring to the marks. Fit the caps tentatively by tightening the cap bolts finger tight. The caps are to be secured tight after the preload for the differential case taper roller bearing and the tooth contact of the reduction bevel gear and bevel pinion have been adjusted. Tightening torque for side bearing cap bolts

379 to 512 N·m (38.6 to 52.2 kgf·m) [279 to 378 lbf·ft]

7-22

FRONT AXLE AND REDUCTION DIFFERENTIAL 5. Differential case side bearing preload adjustment Side bearing

(1) Check the preload for the taper roller bearing with the differential case off the truck before installing the reduction bevel pinion. Tie a wire around the periphery A of the differential case, and hook a spring scale to the wire. Pull the scale in tangential direction and take a reading on the spring scale just when the case begins to rotate. The preload can be adjusted by means of the left and right bearing nuts.

NOTE 210395

Tighten the side bearing nuts equally so as not to disturb the backlash. Before measuring the preload, tap the back of the reduction bevel gear with a copperface hammer while rotating the gear by hand for running-in.

Preload for differential case side bearing

6. Reduction adjustment

bevel

245 to 343 N·m (25 to 35 kgf·cm) [180 to 253 lbf·ft] 23 to 32 N (2.3 to 3.3 kgf) [5.2 to 7.2 lbf] as force applied to periphery A of differential case in tangential direction

pinion

bearing

preload Fixed

(1) Tentatively assemble the reduction bevel pinion by installing the parts 6, 7, 8, 11 and 12 in that order. (2) Tighten the self-locking nut to the specified torque.

Tightening torque for selflocking nut

294±29 N·m (30±3.0 kgf·m) [217±21 lbf·ft)

294±29 N·m (30±3.0 kgf·m) [217±21 lbf·ft]

Fixed 210396

7-23

FRONT AXLE AND REDUCTION DIFFERENTIAL

(3) Hold the input flange in a vise. Hook a spring scale to the bolt hole of the bearing retainer. Pull the spring scale in tangential direction and take a reading on the spring scale just when the retainer begins to turn.

Preload for reduction bevel pinion bearing

Collar

30 to 43 N (3.1 to 4.4 kgf) [6.8 to 9.7 lbf] as force applied to bearing retainer in tangential direction

204602

The preload can be adjusted by means of the collar. The collars are available in twenty-five different thicknesses. When assembling the reduction bevel pinion without replacing any parts, adjust the preload to 80% of the standard value. 7. How to determine the required thickness of shim(s) when the reduction bevel gear and reduction bevel pinion are replaced

(1) Temporarily assemble the reduction bevel pinion. (2) After checking the preload, measure actual value b of dimension B. (3) Find difference c between the standard value of dimension B [53.5 mm (2.1063 in.)] and the actual measurement. c = 53.5 mm (2.1063 in.) – b

210736

Note: (a) Round the thickness to the nearest tenth in case of mm unit, and to the nearest tenthousandth in case of in. unit. (b) When actual value b of dimension B is larger than the standard value, c becomes a negative value. (4) Determine the required thickness A of shim(s) by the following formula. A = 0.5 mm (0.0197 in.) + c Note: Round the thickness to the nearest tenth in case of mm unit, and to the nearest ten-thousandth in case of in. unit. (5) Combine shims to install so that the thickness determined above will be achieved. Shims

Unit: mm Part No. 92331 – 03500

Thickness 0.2 (0.0079)

92331 – 03600

0.1(0.0039) 7-24

FRONT AXLE AND REDUCTION DIFFERENTIAL 8. Reduction bevel gear and bevel pinion tooth contact and backlash adjustment

(1) Tentatively install the reduction bevel pinion in the differential carrier as outlined in the preceding item “5. Reduction bevel pinion bearing preload adjustment.” (2) Put the original amount of the shim(s) in position, and tentatively secure the bearing retainer. (3) Move the reduction bevel gear toward the bevel pinion to obtain the correct backlash. Backlash between reduction bevel gear and bevel pinion

BACKLASH To increase.

0.25 to 0.33 mm (0.0098 to 0.0130 in.)

To decrease.

NOTE Turn in or out the left and right side bearing nuts equally, or the preload will vary.

To increase.

BACKLASH To increase.

To decrease.

205611

(4) Set up a dial indicator with its spindle pointing squarely to the tooth face of reduction bevel gear. With the bevel pinion held, move the gear back and forth to observe the indicator.

210397

(5) Put a small amount of coloring paste on three or four reduction bevel gear teeth on both concave and convex faces. Press forward on the bevel pinion, and rotate the reduction bevel gear back and forth until a contact pattern is noted on both the concave and convex faces of the gear teeth. To adjust the tooth contact, refer to the following chart.

210398

7-25

FRONT AXLE AND REDUCTION DIFFERENTIAL

Tooth Contact Patterns and Adjustment Tooth Contact

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

Adjustment

Correct tooth contact

Short contact at top of tooth

1. 2.

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

1. 2.

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

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

Short contact at bottom of tooth 3

Heavy contact on top half (addendum) of tooth

2. 1

Heavy contact on bottom half (dedendum) of tooth

1. 2 1

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

204606

NOTE For top contact or bottom contact, observe contacts on the outer side (convex face) of the reduction bevel gear for judgment. For top half contact or bottom half contact, repeat the steps above for adjustment until satisfactory tooth contact is obtained.

7-26

FRONT AXLE AND REDUCTION DIFFERENTIAL

φ 35 (φ 1.38) 0 0 φ 95 -0.1 (φ 3.74 -0.004 )

15 (0.59)

(To be made by dealer)

φ 68.5±0.1 (φ 2.70±0.004)

10. Reduction and differential assembly installation

Apply retaining compound (ThreeBond No. 1215) to the mounting face of the reduction and differential assembly, and install the assembly to the front axle housing.

7-27

23 (0.91)

Special tool needed Oil seal installer

Unit: mm (in.)

Installer

Using an installer, put the oil seal in the parking brake bracket with the main lip toward the inside. Apply grease and oil to the lips of the seal.

130 (5.12)

9. Oil seal installation

210399

FRONT AXLE AND REDUCTION DIFFERENTIAL

Troubleshooting

Gear noise comes out continuously during driving

Irregular noise comes out during normal driving

Abnormal noise comes out when turning a corner

Reduction bevel gear teeth badly worn

Replace.

Bearing preload incorrect, or bearings worn excessively

Readjust or replace.

Hub bearings damaged

Replace.

Reduction bevel pinion and reduction bevel gear tooth contact incorrect

Readjust.

Reduction bevel gear bearing or hub bearings broken

Replace.

Differential bevel gear teeth broken, or thrust washers worn

Replace gears or washers.

Metal piece in axle housing

Clean and replace oil.

Axle shaft or differential carrier bolts loose

Retighten.

Fit of differential bevel gears in differential case out of specification due to wear

Replace worn parts.

Differential bevel pinion or side gear teeth broken, or pinions seized on spider

Replace defective parts.

Bearings damaged due to incorrect preload

Replace bearings and readjust preload.

Backlash between bevel pinion gear and reduction bevel gear incorrect

Readjust tooth contact and backlash.

Oil level too low or bad quality of oil

Replace. (Refer to “Recommended Brands of Lubricants.”)

Planet gear teeth badly worn or chipping

Replace.

Planet gear pin bushings abnormally worn

Replace.

Differential overheats

Abnormal noise from final drive

7-28

FRONT AXLE AND REDUCTION DIFFERENTIAL

Service Data Front Axle A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

Item Deflection of axle shaft 1 (1/2 of dial indicator reading)

1.0 (0.039)

Preload for hub bearings 2 (force applied to hub bolt in tangential direction) N (kgf) [lbf]

118 to 157 (12 to 16) [26 to 35]

Tightening torque for brake drum nuts 3 N·m (kgf·m) [lbf·ft]

359±36 (36.6±3.7) [265±27]

Tightening torque for brake backing plate mounting nuts 4 N·m (kgf·m) [lbf·ft]

156±16 (15.9±1.6) [115±12]

Tightening torque for front axle housing mounting nuts 5 N·m (kgf·m) [lbf·ft]

640±96 (65.3±9.8) [472±71]

Tightening torque for wheel nuts 6 N·m (kgf·m) [lbf·ft]

539±49 (55±5.0) [398±36]

Tightening torque for wheel nuts 7 N·m (kgf·m) [lbf·ft]

294±29 (30±3) [217±21]

0 0 50 – 0.011 (1.97 – 0.00043 )

49.96 (1.9669)

+ 0.00114 0.010 (2.28 + 0.00039 ) 58 ++ 0.029

57.96 (2.2819)

1.2±0.06 (0.047±0.0024)

0.8 (0.031)

Tightening torque for cover bolts 11 N·m (kgf·m) [lbf·ft]

57±6 (5.8±0.6) [42±4]

Tightening torque for lock plate bolts 12 N·m (kgf·m) [lbf·ft]

17±2 (1.7±0.2) [12±1]

Tightening torque for deflector bolts 13 N·m (kgf·m) [lbf·ft]]

33±3 (3.4±0.3) [25±2]

420 + 00.2 (16.54 + 00.008 )

424 (16.69)

Diameter of planet pin 8

Inside diameter of planet gear bearing 9

Thickness of thrust washer 10

Inside diameter of brake drum 14

7-29

DP150

FRONT AXLE AND REDUCTION DIFFERENTIAL

Truck Model DP100

DP115

DP135

DP150

Item

Front axle

7 6

LEVEL

210402

7-30

FRONT AXLE AND REDUCTION DIFFERENTIAL

Reduction Differential A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item Backlash between differential bevel gear and bevel pinion 1

0.2 to 0.28 (0.008 to 0.0110)

0.5 (0.020)

Play between differential bevel pinion inner diameter and shaft outer diameter 2

0.169 to 0.278 (0.00665 to 0.01094)

0.35 (0.0138)

N·m (kgf·m) [lbf·ft]

245 to 343 (25 to 35) [180 to 253]

Differential Force applied to periphery A of case bearing 3 differential case in tangential direction N (kgf) [lbf]

23 to 32 (15 to 30) [1.1 to 2.2]

Backlash between reduction bevel gear and bevel pinion 4

0.25 to 0.33 (0.0098 to 0.0130)

Free movement of differential gear on axle shaft (looseness of mating splines) 5

—

0.5 (0.020)

Tightening torque for nuts 6 of reduction bevel gear mounting bolts N·m (kgf·m) [lbf·ft]

441±69 (45±7) [325±51] (Apply “LOCTITE No. 271.”)

Tightening torque for side bearing cap bolts 7 N·m (kgf·m) [lbf·ft]

379 to 512 (38.6 to 52.2) [279 to 378]

Bolt length 37 mm (1.46 in.)

118±12 (12.0±1.2) [87±9]

Bolt length 31 mm (1.22 in.)

132±14 (13.5±1.4) [98±10]

Tightening torque for self-locking nut 9 N·m (kgf·m) [lbf·ft]

294±29 (30±3) [217±22]

Force applied to bearing retainer in tangential direction 10 (preload for reduction bevel pinion bearing) N (kgf) [lbf]

30 to 43 (3.1 to 4.4) [6.8 to 9.7]

Tightening torque for differential case bolts 11 N·m (kgf·m) [lbf·ft]

196±29 (20±3) [145±22] (Apply LOCTITE No. 271.)

Tightening torque for brake drum nuts 12 N·m (kgf·m) [lbf·ft]

96±15 (9.8±1.5) [71±11]

Tightening torque for support plate nuts 13 N·m (kgf·m) [lbf·ft]

145±22 (14.8±2.2) [107±16]

304.8 + 00.5 (12.000 + 00.020 )

307 (12.09)

Preload

Tightening torque for differential carrier mounting bolts 8 N·m (kgf·m) [lbf·ft]

Inside diameter of brake drum 14

7-31

FRONT AXLE AND REDUCTION DIFFERENTIAL

Truck Model DP100

DP115

DP135

DP150

Item

12 13 14 4 10 6 11

Reduction differential

5 3

210403

7-32

REAR AXLE Specifications .......................................................................................... 8 – 1 Description ............................................................................................... 8 – 2 Rear Axle .................................................................................................. 8 – 2 Power Cylinder ......................................................................................... 8 – 3

Removal and Installation ...................................................................... 8 – 4 Rear Wheel (Tire) ..................................................................................... 8 – 4

Rear Axle .................................................................................................. 8 – 6 Removal ................................................................................................... 8 – 6 Installation ................................................................................................ 8 – 7 Disassembly ............................................................................................. 8 – 8 Reassembly .............................................................................................. 8 – 11

Power Cylinder ........................................................................................ 8 – 14 Disassembly ............................................................................................. 8 – 14 Inspection ................................................................................................. 8 – 15 Reassembly .............................................................................................. 8 – 16

Adjusting ................................................................................................... 8 – 17 Minimum Turning Radius .......................................................................... 8 – 17

Troubleshooting ...................................................................................... 8 – 18 Service Data ............................................................................................ 8 – 19

REAR AXLE

Specifications Truck Model DP100

DP115

DP135

Item Steering knuckle arrangement

Elliott

Mounting method

Wheel alignment

Power cylinder

Center pin

Toe-in

mm (in.)

Camber

deg.

1.0

Caster

deg.

Kingpin inclination

deg.

Inside diameter x piston rod diameter mm (in.) Stroke

115 x 80 (4.53 x 3.15)

mm (in.)

182 (7.17)

8-1

DP150

REAR AXLE

Description Rear Axle

4 A 3

3 8

7 4 3 4

5 Section B-B

Section A-A

210405

1. 2. 3. 4.

Rear axle housing Power cylinder Tie rods (left and right) Steering knuckles (left and right)

5. 6. 7. 8.

8-2

Wheel hubs (left and right) Stopper bolts (left and right) Pins (two on each side) Rear axle supports (front and rear)

REAR AXLE

Power Cylinder

15 14

7 8 9

12 11 205425

1. 2. 3. 4. 5. 6.

Bearing Stopper ring Piston rod Cylinder head O-ring Bushing

7. 8. 9. 10. 11.

Wear ring Piston seal Wear ring Cylinder tube Ring

8-3

12. 13. 14. 15. 16.

O-ring Piston Packing Back-up ring Dust seal

REAR AXLE

Removal and Installation Rear Wheel (Tire) Removal Sequence 1. Wheel nuts, Clamp 2. Rear wheel (tire)

Suggestions for Removal

(1) Set the parking brake and block the front wheels.

210406

(2) Loosen the wheel nuts two turns and raise the rear end of the truck with a jack or a hoist until the tire clears the ground. [Jacking instructions]

Position the jack under the counterweight at the slotted point as shown. Truck Model Item Capacity of jack kg (lb)

DP100

DP115

DP135, DP150

7000 (16000)

8000 (18000)

10000 (23000) 210407

[Hoisting instructions]

Fasten three slings to the holes in the counterweight as shown.

CAUTION Place appropriate stands or square logs under the both sides of the body frame. 204657

CAUTION The air is compressed. Keep your face away.

8-4

REAR AXLE

(e) Apply the forks of a lift truck or tire handler under the tire. Then, remove wheel nuts and detach the tire. Wheel weight

140 kg (310 lb)

210408

Installation Follow the reverse of removal sequence, and do the following steps. (1) Before installing the wheel onto the hub, make sure that the air valve set groove in the hub and the positioning boss on the rim meet at top position. (2) Snug up the wheel nuts evenly in the illustrated numerical order. Then, tighten them to the specified torque in the same sequence.

1 8

7 6

Tightening torque for wheel nuts

539±54 N·m (55±5.5 kgf·m) [398±40 lbf·ft]

2 210409

(3) After installing the tires, retighten wheel nuts. After about 10 minutes of advancing, reversing and braking, check that wheel nuts for the specific torque using a torque wrench.

8-5

REAR AXLE

Rear Axle Removal 4

1 2

210410

Sequence 3. Rear axle supports 4. Rear axle assembly, Thrust washers

1. Rear wheel (tire), Wheel nuts, Clamps 2. Steering hoses

Start by:

(a) Set the parking brake and block the front wheels. (b) Raise the rear end of the truck with a jack and put supporting stands or blocks of wood under the frame on both sides so the bottom of the counterweight is 400 to 500 mm (16 to 20 in.) from the ground. Unit: kg (lb) Truck Model Item Capacity of jack

DP100

DP115

DP135, DP150

7000 (16000)

8000 (18000)

10000 (23000)

8-6

210407

REAR AXLE

Suggestions for Removal (1) Disconnect the steering hoses from the power cylinder pipes. Install the Hose caps to all openings to prevent the oil from flowing out. Hose cap

05530 - 30300 (G 3/8)

205558

(2) Position a wide-saddle jack under the rear axle from the rear end of the truck to support the axle. Weight of rear axle

840 kg (1850 lb)

(3) Remove the rear axle supports, front and rear. Carefully lower the rear axle by operating the jack and pull it out diagonally to the rear of the truck.

210411

Installation Follow the reverse of removal sequence and do the following step:

Rear axle support clearance adjustment Adjust the total clearance of the front and rear supports with thrust washer(s) so that it is less than 0.8 mm (0.031 in.).

NOTE Install the same amount of thrust washer(s) on the front and rear supports.

Unit: mm (in.) 3.2 (0.126) Thickness of thrust washers available

1.6 (0.063) 0.8 (0.031)

8-7

0.8 mm (0.031 in.) maximum

205555

REAR AXLE

Disassembly

4 8

7 8

7 2

4 7 5

1 210412

Sequence 5. Cover, Shims, O-ring, Taper roller bearing (outer race), Oil seal, Lower dust cover 6. Cover, O-ring 7. Steering knuckle, Taper roller bearing (inner race), Oil seal retainer, O-ring 8. Rear axle housing, Taper roller bearing (outer race), Oil seal

1. Wheel hub cap, Gasket, Nuts, Lock washer, Taper roller bearing (inner race) 2. Wheel hub, Taper roller bearing, Oil seal, Oil seal retainer 3. Tie rod, Pin, Spacer, Dust seal, Stopper ring, Spherical roller bearing 4. Power cylinder, Clamp, Pipes

8-8

REAR AXLE

Suggestions for Disassembly 1. Lock nut removal

After removing the wheel hub cap, remove the lock nut with a socket wrench. Width across flats

70 mm (2.76 in.)

210413

2. Wheel hub removal

Fasten a hoist to the wheel hub and remove the hub from the axle.

210414

3. Taper roller bearing (outer race) removal

Do not remove the outer race unless it is defective. Replace the outer and inner races at the same time. 4. Cover removal

(1) Remove the six bolts that hold the cover in position. (2) Remove the plug from the cover. (3) Install a jack bolt, 20 mm (0.79 in.) in diameter, 1.5 mm (0.059 in.) in pitch and 100 mm (3.94 in.) long, in the hole for the plug. Turn the jack bolt in until the cover becomes free.

Jack bolt Cover

8-9

210415

REAR AXLE 5. Rear axle support bushing removal

Do not remove the bushing from the support unless it is defective. If the bushing is defective, remove it by breaking. Install a new bushing with the joint in alignment with the grease nipple.

Bushing joint 205431

8-10

REAR AXLE

Reassembly

9 10

B A A 6

9 1

3 2 7

Section A-A

Section B-B

210416

Sequence 6. Tie rod, Pin, Spacer, Dust seal, Stopper ring, Spherical roller bearing 7. Wheel hub, Taper roller bearings, Oil seal, Oil seal retainer 8. Wheel hub cap, Nuts, Lock washer, Taper roller bearing (inner race) 9. Rear axle supports, Bushings 10. Power cylinder hoses

1. Rear axle, Taper roller bearing (outer race), Oil seal 2. Steering knuckle, Taper roller bearings (inner races), Oil seal retainer, O-ring 3. Cover, O-ring 4. Cover, Shims, O-ring, Taper roller bearing (outer race), Oil seal, Lower dust cover 5. Power cylinder, Pipes, Clamp

8-11

REAR AXLE

Suggestions for Reassembly 1. Wheel hub installation

(1) Install the oil seal retainer and the inner race of the inner bearing in position with a bearing installer.

204664A

(2) Fill the pocket (hatched portion) with grease. Apply grease to the roller retainers and oil seal lip grooves.

210417

2. Steering knuckle bearing preload adjustment

Install the cover to the axle housing without putting shims. Measure the clearance between the cover and the housing. Remove the cover. Put shim(s) which is 0.1 mm (0.004 in.) smaller in thickness than the clearance measured. Install the cover and tighten the bolts that hold the cover. Hook a spring scale to the arm of the steering knuckle. Pull the spring scale in tangential direction and read the spring scale to find the preload. If the preload is not correct, make a shim adjustment again.

98 to 146 N (10 to 14.87 kgf) [22 to 33 lbf]

spring scale reading (preload)

Clearance 210418

NOTE Adjusting shims are 2-piece type.

8-12

REAR AXLE 3. Hub bearing preload adjustment

(1) Tighten the inner nut. Hook a spring scale to the hub bolt. Pull the spring scale in tangential direction and read the spring scale to find the preload. If the preload is not correct, make an adjustment by turning the inner nut in either direction.

88 to 127.5 N (9 to 13 kgf) [20 to 29 lbf]

spring scale reading (preload)

210419

NOTE If the hub bearings are reused, aim at a value of preload in the lower half of the range.

(2) After having adjusted the hub bearing preload, install the outer nut and lock washer, and tighten the outer nut to the specified torque. Inner nut

Tightening torque for outer nut

Outer nut

196 N·m (20 kgf·m) [145 lbf·ft]

210420

(3) Bend the lock washer against the flats of the inner and outer nuts.

Wrong

Right

210421

8-13

REAR AXLE

Power Cylinder Disassembly 3 2

1 1

205437

Sequence 1. Cylinder head, Dust seal, Back-up ring, Packing, O-ring 2. Piston rod, Wear rings, Piston seal

3. Stopper rings, Bearings 4. Cylinder tube

NOTE (1) Do not remove bushing from cylinder head 1, if not necessary. (2) Do not remove piston from piston rod 2, if not necessary.

Suggestion for Disassembly Cylinder head removal

Wrap up the cylinder tube with rag or cloth, and hold it in a vise. Remove the cylinder head with the the Hook Wrench A (special tool). Special tool needed Hook wrench A

05312 - 11000

8-14

205438

REAR AXLE

Inspection 1. Cylinder tube

(1) Check the bore surface for wear, scuffs, scratches or rust. (2) Check the welds for cracks. 2. Piston rod

(1) Using V-blocks and a dial indicator, check runout at the center. (2) Check the rod surface for rust, scratches or dents. Replace the rod if the threads are stripped or badly damaged.

205439

3. Rings and packings

(1) Check the packings and rings for damage or distortion. (2) Also check for deterioration due to aging. A: Standard value

B: Repair or service limit Unit: mm (in.)

Item

Service data

Inside diameter of cylinder tube 1

155 (4.53)

115.15 (4.5335)

Diameter of piston rod 2

80 (3.15)

Clearance between piston rod and bushing 3

0.1 (0.004)

0.2 (0.008)

0.3 (0.012)

Deflection of piston rod 4 (1/2 of dial indicator reading)

210422

8-15

REAR AXLE

Reassembly ❋: Seal kit parts.

❋

210190

Sequence 3. Cylinder head, Dust seal, Back-up ring, Rod seal, O-ring 4. Stopper ring, Bearing

1. Piston rod, Wear rings, Piston seal 2. Cylinder tube

Suggestions for Reassembly (1) Replace the seal kit parts. (2) Thoroughly wash all parts and components. (3) Apply hydraulic oil to the sealing parts and the inside surfaces of the cylinder. (4) Wrap the cylinder tube with rag or cloth, and hold it in a vise. Pay attention not to deform the cylinder. (5) Install the piston seal to the piston as follows: (a) Squeeze the piston seal by hand five or six times to soften it. Hold the piston rod in vise. Apply a small amount of hydraulic oil to the piston seal. Fit a portion of the seal in the groove of the piston, then push the other portions into the groove. 200352

(b) Install the wear rings in position.

NOTE Install the seals and rings on the cylinder head correctly.

(6) Tighten the cylinder head to the specified torque. Tightening torque for cylinder head

539±54 N·m (55±5.5 kgf·m) [398±40 lbf·ft] 205552

8-16

REAR AXLE

Adjusting Minimum Turning Radius (1) Measure the turning angle of the rear wheels, inside and outside, with a turning radius gauge. (2) If the turning angle is not correct, adjust it with knuckle stopper bolts.

Stopper bolts (left and right) Lock nut

Inside wheel

78°27’

Outside wheel

51°14’

Turning angle

Tightening torque for knuckle stopper bolt lock nut

487 N·m (49.7 kgf·m) [359 lbf·ft]

(3) Drive the truck at low speeds and make the sharpest practicable turn to both sides. After making a turn to each side, measure the distance from the turning center to the center of tire contact with the ground of the outermost rear wheel. (4) The minimum turning radius R is the distance from the turning center to the center of tire contact with the ground of the outermost rear wheel plus the rear overhang (the distance from the center of rear tire to the outermost end of the counterweight). Item Truck Model

210423

Minimum turning radius

DP100

4000 mm (157 in.)

DP115

4060 mm (160 in.)

DP135

4160 mm (164 in.)

DP150

4550 mm (179 in.)

202800

8-17

REAR AXLE

Troubleshooting

Heavy steering

Steering – poor centering (or recovery from turns)

Truck pulls to one side during normal driving

Shimmy

Rear wheel tires wear rapidly or unevenly

Incorrect toe-in

Readjust.

Excessive friction in steering or rear axle linkage due to poor lubrication

Lubricate.

Low tire pressure

Inflate properly.

Joints and connections in steering or rear axle linkage too tight

Retighten to specified torque.

Tire diameter differs between left and right

Replace tire.

Uneven tire pressure

Inflate properly.

Taper roller bearings badly worn or damaged in hub

Replace.

Steering system maladjusted

Check and adjust. (Refer to “GROUP 10 STEERING SYSTEM.”)

Wheel alignment maladjusted

Readjust.

Different tires are mixed, or uneven tire pressure

Replace tires and reinflate.

8-18

REAR AXLE

Service Data A: Standard value Truck Model

DP100

Item

B: Repair or service limit Unit: mm (in.)

DP115

DP135

Oscillating angle (left or right)

2°

Toe-in

Caster

0°

Camber

1°

Inside wheel

78°27’

Outside wheel

Turning angle

51°14’

Diameter of knuckle 1

DP150

0 – 0.019

0 (2.36 – 0.00075 )

59.9 (2.358)

98 to 146 (10 to 14.87) [22 to 33]

88 to 127.5 (9 to 13) [20 to 29]

0.8 (0.031)

1.2 (0.047)

487 (49.7) [359]

539±54 (55±5.5) [398±40]

196 (20) [145]

Tightening torque for rear axle support bolts 8 N·m (kgf·m) [lbf·ft]

210 (21.4) [155]

Tightening torque for power cylinder bolts 9 N·m (kgf·m) [lbf·ft]

1138 (116) [839]

Tightening torque of hoses 10

49±5 (5±0.5) [36±4]

Preload (spring scale reading) of steering knuckle bearing 2

N (kgf) [lbf]

Preload (spring scale reading) of hub bearing 3 N (kgf) [lbf] Longitudinal play of axle at center pin (total) 4 Tightening torque of knuckle stopper bolt lock nuts 5 N·m (kgf·m) [lbf·ft] Tightening torque of wheel nuts 6 N·m (kgf·m) [lbf·ft] Tightening torque of outer nuts 7 N·m (kgf·m) [lbf·ft]

N·m (kgf·m) [lbf·ft] 8 4

3 7

9 8

8-19

210424

REAR AXLE

A: Standard value Truck Model

DP100

Item

DP115

DP135

115 (4.53)

115.15 (4.5335)

80 (3.15)

0.1 (0.004)

0.2 (0.008)

Deflection of piston rod 4 (1/2 of dial indicator reading)

0.3 (0.012)

Tightening torque for cylinder head 5 N·m (kgf·m) [lbf·ft]

539±54 (55±5.5) [398±40]

Inside diameter of cylinder tube 1 Diameter of piston rod 2 Power cylinder

B: Repair or service limit Unit: mm (in.)

Clearance between piston rod and bushing 3

DP150

210191

8-20

BRAKE SYSTEM Specifications .......................................................................................... 9 – 1 Description ............................................................................................... 9 – 2 Wheel Brake System ................................................................................ 9 – 2 Brake control valve ................................................................................ 9 – 4 Air master .............................................................................................. 9 – 5 Air governor ........................................................................................... 9 – 7 Safety valve ........................................................................................... 9 – 8 Wheel brakes ........................................................................................ 9 – 9 Air dryer ................................................................................................ 9 – 10 Parking Brake System .............................................................................. 9 – 13 Parking brake lever ............................................................................... 9 – 14 Parking brake ........................................................................................ 9 – 15

Wheel Brakes .......................................................................................... 9 – 16 Disassembly ............................................................................................. 9 – 16 Inspection ................................................................................................. 9 – 17 Reassembly .............................................................................................. 9 – 19

Wheel Cylinders ...................................................................................... 9 – 22 Disassembly ............................................................................................. 9 – 22 Inspection ................................................................................................. 9 – 23 Reassembly .............................................................................................. 9 – 23

Air Master ................................................................................................. 9 – 24 Disassembly ............................................................................................. 9 – 24 Reassembly .............................................................................................. 9 – 25

Brake Control Valve ............................................................................... 9 – 26 Disassembly and Reassembly .................................................................. 9 – 26

Air Governor ............................................................................................. 9 – 27 Disassembly and Reassembly .................................................................. 9 – 27

Air Dryer .................................................................................................... 9 – 28 Disassembly ............................................................................................. 9 – 28 Reassembly .............................................................................................. 9 – 30

Parking Brake .......................................................................................... 9 – 32 Disassembly ............................................................................................. 9 – 32 Inspection ................................................................................................. 9 – 32 Reassembly .............................................................................................. 9 – 33

Testing and Adjusting ............................................................................ 9 – 35 Wheel Brakes ........................................................................................... 9 – 35 Air Bleeding .............................................................................................. 9 – 36 Brake Pedal .............................................................................................. 9 – 37 Brake Control Valve .................................................................................. 9 – 38 Air Governor Adjustment ........................................................................... 9 – 39 Parking Brake Clearance .......................................................................... 9 – 39

Troubleshooting ...................................................................................... 9 – 41 Service Data ............................................................................................. 9 – 44

BRAKE SYSTEM

Specifications Truck Model DP100

DP115

DP135

DP150

Item Hydraulically actuated, internal-expanding, with leading and trailing shoes, effective on front wheels

Type Drum diameter

Wheel brake

mm (in.)

420 (16.54)

Lining dimensions (length x width x thickness) – number mm (in.)

200 x 190 x 16 (7.9 x 7.5 x 0.63) – 4

Wheel cylinder inside diameter mm (in.)

55.56 (2.187)

Brake booster

Air master (pneumatic booster) Mechanically actuated, internal-expanding, effective on reduction bevel pinion

Type

Parking brake

Drum diameter

mm (in.)

304.8 (12.00)

Lining dimensions (length x width x thickness) – number mm (in.)

345 x 75 x 6.7 (13.6 x 3.0 x 0.26) – 2

9-1

BRAKE SYSTEM

Description Wheel Brake System

11 8 12

7 15

4 16

13 14

210426

1. 2. 3. 4. 5. 6. 7. 8.

Brake control valve Brake fluid reservoir Air master Air compressor Wheel cylinder (left) Wheel cylinder (right) Air horn (option) Safety valve

9. 10. 11. 12. 13. 14. 15. 16.

Air supply valve (option) Air tank Air governor Air dryer Air horn switch (option) Stop lamp switch Air pressure gauge unit Low air pressure switch

9-2

BRAKE SYSTEM

11 9

6 1

14 15 16

2 5

3 210427

1. 2. 3. 4. 5. 6. 7. 8.

Brake control valve Brake fluid reservoir Air master Air compressor Wheel cylinder (left) Wheel cylinder (right) Air horn (option) Safety valve

9. 10. 11. 12. 13. 14. 15. 16.

The air from the air compressor is sent through the air dryer to the air tank and is stored in it for actuating the wheel brake system. This air is being applied to the brake control valve (controlled by the brake pedal). When the pedal is depressed to apply the brakes, the air is allowed to flow into the air master. The air entering the air master pushes its power piston to move the hydraulic cylinder piston. The movement of the latter piston forces brake fluid out of that cylinder into the line leading to the wheel cylinders. Now each brake piston is actuated to produce braking action. As the protective devise for the air line, the safety valve and air governor are provided in this system. Compressed air of this system is also used to blast air horn and switch stop lamp. 9-3

Air supply valve (option) Air tank Air governor Air dryer Air horn switch (option) Stop lamp switch Air pressure gauge unit Low air pressure switch

BRAKE SYSTEM

Brake control valve

6±1° Emergency braking

Fr 4 ee ± 1 pl .5° ay

1 12 6° ±

1° No bra rma kin l g

11 B

17°

39± 1.5°

Applied position

14 15 16

3 4

200630

Released position

17 A

7 20

200629

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Valve cover Main spring assembly Valve case Return spring Spring Packing Cap Boot Pedal Push button

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Plunger Plunger guide Packing O-ring Piston Feed valve assembly Spring seat O-ring C-ring Dust seal

The brake control valve is constructed as shown. Depressing the brake pedal causes this valve to open to introduce the air, proportional to the pedal position, into the line leading to the air master. As the pedal is released, it lets out the air to the atmosphere. 9-4

200631

A: Air tank side port B: Air master side port

BRAKE SYSTEM

Air master

A B

200632

1. 2. 3. 4. 5. 6. 7.

Piston packing Piston plate Cylinder shell Push rod Return spring End plate Air breather

8. 9. 10. 11. 12. 13. 14.

Hydraulic cylinder Breather plug Cylinder cap Hydraulic piston assembly Switch assembly Rod and plate assembly Outlet valve

The air master is an air-actuated hydraulic booster. The air from the control valve enters the piston shell to push the piston plate against the force of the return spring, thereby pressing the push rod into the hydraulic cylinder. This forces the fluid in the cylinder to actuate the wheel cylinders.

9-5

A: From brake control valve (high air pressure) B: To wheel brakes (high pressure fluid)

BRAKE SYSTEM 1. Air master operation – released position

The control valve is kept closed and no air pressure is applied to the air master. Under this condition, the piston plate is being pushed to the left (in the illustration) by the force of the return spring.

Piston plate

2. Air master operation – applied position

(1) As the brake pedal is depressed, the air (high pressure) from the control valve enters the piston shell, and pushes the piston plate and, in turn, the hydraulic piston through the push rod.

200633

(2) When the hydraulic piston is so moved, the check valve yoke (which has been blocked by the stopper) is returned by the yoke spring to cause the ball to cover the fluid port. Now the fluid in the hydraulic cylinder is trapped and forced out into the line leading to the wheel cylinders through the outlet valve. The outlet valve is provided to maintain the pressure of fluid applied to the wheel cylinders in proportion to the air pressure.

Hydraulic piston

3 200634

1. Check valve yoke 2. Yoke spring

3. Ball

3. Air master operation – transition from applied position to released position

(1) When the brake pedal is released, the control valve is closed, and the air is let out to the atmosphere from this valve. As a result, the pressure acting on the piston plate drops, causing the return spring to move the plate to the left (original position). (2) Now the hydraulic piston moves back, drawing the fluid from the line leading to the wheel cylinders. As the check valve yoke touches the stopper, the ball unseats to allow the fluid to flow back.

Stopper 200635

4. Brake lining wear alarm

The piston stroke increases as the linings are worn. If this stroke increases beyond the prescribed limit due to excessive lining wear, the piston plate comes in contact with the alarm switch built in the cylinder shell to close it, allowing the current to flow to the alarm lamp and buzzer. Now the lamp glows and the buzzer sounds to warn the operator of excessive lining wear. 9-6

BRAKE SYSTEM

Air governor

Closed position

Open position A

4 a

3 1 6

B 8

9 10

Atmosphere Low pressure air High pressure air

210428

1. Valve body 2. Cap 3. Diaphragm assembly (a: High pressure valve, b: Low pressure valve) 4. Valve seat 5. Sleeve

6. 7. 8. 9. 10. 11.

Spring Spring guide Nut Adjusting screw Nut Cover

A: Tank side port B: Unloader side port

As the pressure in the tank drops, because of this bleeding action, to a level slightly below the setting, the force of the spring overcomes the force acting on the underside of the diaphragm and unseats the low pressure valve to admit the high air pressure into the sleeve. This increases the force acting on the top of the diaphragm, which adds to the spring force to press the diaphragm down all the way and thereby seats the high pressure valve. The closing and opening actions are rather abrupt. The governor operates on and off to keep the air tank pressure at the set level.

The air governor is a spring-loaded diaphragm valve and limits the pressure built up in the air tank. The pressure in the tank is acting on the high pressure valve. The spring, seated on the low pressure valve, keeps the high pressure valve pressed against its seat to isolate the unloader line from the tank line. As the air tank pressure rises above the setting, the force created by this pressure overcomes the force of the spring and unseats the high pressure valve to admit the high air pressure into the chamber below the diaphragm. When this occurs, the diaphragm deflects upward to press the low pressure valve against its seat provided on the sleeve and lift the high pressure valve fully so that the high air pressure flows through the unloader side port to the unloader valve in the compressor and shuts off the air pressure supply.

9-7

BRAKE SYSTEM

Safety valve

8 7

2 5 1 3 4 Atmosphere Low pressure air High pressure air Closed position

Open position

200637

1. 2. 3. 4.

Valve ball Spring Valve case Valve body

5. 6. 7. 8.

The safety valve is a spring-loaded ball valve. Normally, the ball is being pushed down against its seat of the valve body by the force of the spring seated on the retainer. As the air tank pressure, acting on the bottom side of the ball, rises abnormally, the force created by this pressure overcomes the spring force to lift the ball off its seat and thus bleed the pressure out to the atmosphere.

9-8

Spring retainer Adjusting screw Nut Dust cover

BRAKE SYSTEM

Wheel brakes

13 9

12 210429

1. 2. 3. 4. 5. 6. 7.

Adjusting cam Push rod Cover Wheel cylinder Spring Piston cup, Spring seat Piston

8. 9. 10. 11. 12. 13.

Return spring Anchor pin Brake shoes Brake drum Dust cover Anchor bracket

clearance.

The brake shoe is of T-cross-sectional construction, and has a non-asbestos lining bonded onto its outside surface. The lower end of the shoe (pivoting point) is supported at the boss of the dust cover through the anchor bracket. The concave portion at the upper end is coupled with the push rod of the wheel cylinder. The intermediate rib portion is supported by the return spring and adjusting cam. The adjusting cam, an eccentric cam, rotates to adjust the brake shoe

9-9

BRAKE SYSTEM

Air dryer

22 21

20 28 12

13 11

18 17

27 29

15 16

26 25

6 5 34 33 31 32

4 3

10 2

7 8 9

206583

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Body O-ring Valve body Valve spring Piston O-ring Valve component Bolt and washer Exhaust cover Retaining ring Cover Case

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

O-ring Oil separator filter Hexagon socket head bolt Spring washer Filter plate (1) Filter Desiccant Filter plate (2) Set spring Case cover Check valve

9-10

24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

Screw and washer Gasket ring Gasket ring O-ring Purge chamber Bolt and washer Heater Thermostat component (A) FT screw Cord clamp Rolling screw

BRAKE SYSTEM Air dryer operation – dehydrating cycle

Check valve

Purge chamber Check valve

Desiccant

Oil filter

Air tank

Inlet

Outlet

Air governor

Air compressor Safety valve

To brake valve 206584

The air (moisture-laden) from the compressor enters the air dryer from its inlet port and is cooled while it flows outside the tube containing desiccant. Then the air passes through the filter with a built-in oil mist separator. The air, now cool and free from particles of dirt and oil mist, passes through the desiccant and flows through the check valve into the purge chamber, from which it is flows into the air tank through the check valve.

9-11

BRAKE SYSTEM Air dryer operation – reconditioning cycle

Check valve

Orifice

Purge chamber Desiccant Oil filter

Outlet

Inlet

Air tank

Air governor

Purge valve Control port

Exhaust Air compressor

Safety valve To brake valve 206585

When the air pressure in the system rises to the upper limit, the pressure signal from the air governor unloads the air compressor. This signal also goes to the control port of the air dryer to open the purge valve. When the purge valve is so opened, it lets out the air in the desiccant tube to the atmosphere quickly, thereby cleaning the filter and exhausting moisture and oil mist to the atmosphere. This sudden drop of the pressure causes the air (dry) in the purge chamber to expand through the orifice and flow through the desiccant in the reverse direction to remove moisture from the desiccant. At the end of reconditioning cycle, the purge valve is closed by the signal from the air governor to cause the air dryer to start a new cycle for dehydrating.

9-12

BRAKE SYSTEM

Parking Brake System

206098

1. Parking brake lever 2. Flexible wire 3. Parking brake drum assembly

The parking brake (also used as an emergency brake in the event of wheel brake failure) is of internally expanding type, mounted on the front axle side of the propeller shaft. The brake shoes are mechanically actuated from the parking brake lever (toggle type) through flexible cable.

9-13

BRAKE SYSTEM

Parking brake lever

Released position

Applied position 1 2 3 4

5 7 6

205504

1. 2. 3. 4.

Grip Stud Lever assembly Rod assembly

5. Bracket 6. Parking brake wire 7. Clevis pins

9-14

BRAKE SYSTEM

Parking brake

3 Section A-A

5 6 7 A A

210430

1. 2. 3. 4. 5.

Dust seal Camshaft Parking brake drum Support plate Parking brake lining

6. 7. 8. 9. 10.

In the parking brake, the brake shoes are attached at one point to the backing plate and expanded by the cam against the friction (inside) surface of the drum. At the bottom of this brake is located a brake adjuster for self-adjusting of the clearance between the drum and linings.

9-15

Parking brake shoe Spring Spring Adjuster assembly Lever

BRAKE SYSTEM

Wheel Brakes Disassembly

5 7 5

2 210431

Sequence 1. 2. 3. 4.

Return springs Anchor pin, Lock plate Shoes and lining assembly Wheel cylinder, Cylinder plate, Cylinder cover

5. Adjusting cam, Pin, Indicator, Washers, Cover, Spring, Shims 6. Dust cover, Bolts, Grommets 7. Anchor bracket

Start by:

(a) Remove the front wheels. (b) Disassemble the front axle. (c) Disconnect the brake pipe from the wheel brake assembly.

9-16

BRAKE SYSTEM

Suggestions for Disassembly 1. Return spring removal

Turn the adjusting cams to move the shoes fully inward and away from the drum. Using the Spring Setter (special tool), remove the return springs from the shoes. Special tool needed Spring setter

Special tool

03727 - 10001

210432

2. Anchor pin removal

Using the Anchor Pin Puller (special tool), remove the anchor pins from the shoes.

Special tool

Special tool needed Anchor pin puller

03727 - 60000 205688

Inspection 1. Dust cover

(1) Check for cracks. (2) Check to make sure the bolts have been tightened to the specified torque before removing the dust cover. Tightening torque for dust cover bolts

20±4 N·m (2.0±0.4 kgf·m) [14.5±3 lbf·ft]

2. Anchor bracket

Check for cracks.

9-17

BRAKE SYSTEM 3. Shoe and lining assemblies

(1) Check the shoes and linings for cracks. (2) Replace the linings if they are badly soaked with oil, hardened or defective. (3) Measure the thickness of the linings, and replace the linings if it is in excess of the service limit. A: Standard value

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

16 (0.63)

10 (0.39)

Thickness of lining

205689

4. Brake drums

Check the inside surface for grooving or abnormal wear. Repair a grooved or otherwise defective drum by grinding, provided the service limit on the inside diameter is not exceeded. A: Standard value

Inside diameter of brake drum

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

420 (16.54)

424 (16.69)

5. Return springs

Measure the free length of the springs and, if it is in excess of the service limit, replace the springs. A: Standard value

Free length of return springs

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

203.5 (8.01)

Distorted coils

9-18

BRAKE SYSTEM

Reassembly

7 4

9 2

Section A-A 10 11

12 210433

Sequence 1. 2. 3. 4. 5. 6.

Anchor brackets Adjusting cam Washer, Spring, Boot, Cover, Indicator, Pin Pins, E-rings Brake shoes Anchor pin, Bolt, Lock plate, Lock washer

7. 8. 9. 10. 11. 12.

9-19

Wheel cylinder, Cylinder plate, Bolts, Washers Cylinder cover, Bolts, Washers Return spring Air bleeder Connector, Bolt Dust cover, Bolts, Washers

BRAKE SYSTEM

Suggestions for Reassembly 1. Wheel cylinder installation

Apply liquid packing to the mounting face of the wheel cylinder. Put the cylinder in position on the bracket with the inlet port side face of the cylinder even with the bracket (in contact with the dust cover) and tighten the bolts to the specified torque.

Tightening torque for wheel cylinder bolts

45 to 69 N·m (4.6 to 7.0 kgf·m) [33 to 51 lbf·ft]

2. Initial lubrication

Apply a thin coat of the recommended grease to the following parts: (1) Inside surface of shoe bushings (2) Grooves of anchor pins (3) Anchor bracket surfaces in contact with adjusting cams (Avoid over-lubrication or the linings would be soaked with grease.) 3. Shoe installation

(1) Position the left and right adjusting cams so that the lobe lift or rise is minimum. (2) Install the shoes, making sure the push rods of the wheel cylinder are in the holes of the shoe webs. 4. Lock washer installation

Tighten the bolt that holds the anchor pin lock plate to the specified torque and bend the lock washer properly.

Tightening torque for anchor pin lock plate bolt

15.7 to 23.5 N·m (1.6 to 2.4 kgf·m) [12 to 17 lbf·ft]

205714

9-20

BRAKE SYSTEM 5. Return spring installation

Using the Spring Setter (special tool), hook the ends of the return springs to the pins of the shoes. Special tool needed Spring setter

03727 - 10001 Special tool

210432

6. Lining wear indicator installation

(1) Using a wrench, turn the washer to set the pointer as far at inside of the service range scale as possible. (2) In setting the indicator, set the adjusting cam with the shoes contracted all the way, and hold the adjusting cam with another wrench to prevent it from rotating when turning the washer.

NOTE Reset the indicator at minimum value only after the adjusting cam has been reassembled.

7. Wheel brake assembly installation

Tighten the bolts that hold the wheel brake assembly to the front axle to the specified torque.

M14

156±16 N·m (15.9±1.6 kgf·m) [115±12 lbf·ft]

M16

233±24 N·m (23.8±2.4 kgf·m) [172±17 lbf·ft]

Tightening torque for wheel brake assembly bolts

9-21

210435

BRAKE SYSTEM

Wheel Cylinders Disassembly

5 7 4 3 2 1

210436

Sequence 1. 2. 3. 4.

Push rods Dust cover Pistons Piston cups

5. 6. 7. 8.

9-22

Spring seat Return spring Cylinder body Bleeder screw

BRAKE SYSTEM

Inspection 1. Cylinder bodies

(1) Check the bore surface for rusting, corrosion or scoring. (2) Check the threads of the air bleeders and oil pipes for damage. 2. Pistons

(1) Check the sliding surfaces for rusting or scoring. (2) Insert the piston into the cylinder body, and measure the clearance between the two. Replace the wheel cylinder assembly if the clearance exceeds the service limit. A: Standard value

Clearance between piston and cylinder body

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

0.13 to 0.24 (0.0051 to 0.0094)

0.3 (0.0118)

205692

3. Piston cups

Check each cup for swelling or other defects, and replace it even if its defect is minor. A: Standard value

Fit of piston cups in cylinder body

B: Repair or service limit Unit: mm (in.)

56.2 (2.213)

(To be replaced every year)

4. Boots

Replace the boots if they are hardened, damaged or otherwise deteriorated. Replace it every year.

Reassembly Follow the reverse of disassembly sequence and do the following steps: (1) Apply a uniform coat of brake fluid to the cylinder bore and piston cups. (2) Be careful not to damage the lip of piston cup. (3) Position the cups correctly in the cylinder body.

9-23

BRAKE SYSTEM

Air Master Disassembly ❋: Seal kit parts. 5

❋

8 9 7 ❋

2 ❋❋ 1

❋

❋ 3

❋ 4

200784

Sequence 1. Hydraulic cylinder, Outlet valve, Cylinder cap, Plug, Spring, O-ring 2. Hydraulic piston, Washer, Spring, Retainer, Cup packing, Thrust pin 3. Cylinder shell, O-ring 4. Piston plate, Nut, Retainer plate, Expander, Wick, Leather packing

5. Push rod, Spring, Plate, Spring retainer, Gasket 6. Rod, Plate, Retainer, Spring 7. Switch, Shim 8. Air breather 9. End plate, Oil seal

9-24

BRAKE SYSTEM

Suggestion for Disassembly Hydraulic piston removal

Apply air pressure (not higher than 588 kPa (6 kgf/cm2) [85 psi]) to the inlet port in the rear section of the cylinder shell to push the push rod out of the end plate. Remove the push rod pin and take out the hydraulic piston.

200641

Reassembly Follow the reverse of disassembly sequence and do the following steps: 1. Clean the disassembled parts. (1) Rubber parts Wipe the surface of each rubber part with a cloth saturated with alcohol. Never use solvent. (2) Metal parts Wash metal parts with washing fluid. 2. Be sure to replace the parts for which the repair kits are available at the time of assembly. 3. Apply lubricant to the following parts: (1) Apply a thin coat of AIR MASTER PASTE to the power piston plate, leather packing, gasket and the inside surface of the cylinder shell. (2) Fill the pocket of oil seal 1 (which is to be fitted to the hub bore of the end plate) with silicone grease. (3) Apply brake fluid to the entire surfaces of O-ring 2, cup 3 and hydraulic piston 4. 4. After assembling and installing the air master, bleed air out of the brake line. (See “Testing and Adjusting” section as follow.)

9-25

200642

BRAKE SYSTEM

Brake Control Valve Disassembly and Reassembly ❋: Seal kit parts.

❋ 4 1 2

❋ ❋

3 4

❋

❋ 5 ❋

200640

Sequence 1. 2. 3. 4.

Pedal, Split pin, Pin, Push button, Shim Valve cover, Boot, Plunger Main spring Piston, O-ring, Return spring

5. Valve cap, Dust seal, C-ring, O-ring 6. Feed valve, Spring seat, Spring 7. Valve case

Suggestions for Disassembly and Reassembly 1. Be sure to replace the parts for which the repair kits are available at the time of assembly.

3. Apply grease to the O-rings and the surfaces coming in contact with the rings.

2. Clean the disassembled parts. (1) Rubber parts Wipe the surface of each rubber part with a cloth saturated with alcohol. Never use solvent. (2) Metal parts Wash metal parts with washing fluid.

9-26

BRAKE SYSTEM

Air Governor Disassembly and Reassembly Disassembly

200646

Sequence 1. Cover 2. Adjusting screw, Nut, Spring guide, Spring, Sleeve, O-ring

3. Filter, Snap ring, Screen 4. Valve seat, Bolts, Cap, Diaphragm 5. Valve body

Reassembly To reassemble, follow the reverse of disassembly sequence.

9-27

BRAKE SYSTEM

Air Dryer Disassembly 1. Air dryer disassembly

1 6❋

7❋ 8❋ 14

11 ❋4 10

❋5 9 2

Note: Parts marked with ❋ are repair kit parts.

210437

Sequence 1. 2. 3 4. 5. 6. 7.

Purge chamber Cover Cartridge Filter O-ring O-ring Gasket ring

8. 9. 10. 11. 12. 13. 14.

Start by:

(1) Before disassembling the air dryer, hold its body 14 with a vise.

9-28

O-ring Retaining ring Exhaust cover Valve assembly Thermostat assembly Heater assembly Body

BRAKE SYSTEM 2

Cartridge disassembly

Sequence 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Cover Check valve O-ring Set spring Filter plate Filter Desiccant Filter Filter plate Case

2❋ 6❋ 7❋ 1

8❋

❋3 9 4 10

210438

NOTE: Parts marked with ❋ are repair kit 3. Valve disassembly Sequence 1. 2. 3. 4. 5. 6.

Valve Piston O-ring Valve spring O-ring Valve body

3❋ 2 4 5 6 1❋

210439

NOTE: Parts marked with ❋ are repair kit parts.

9-29

BRAKE SYSTEM

Reassembly To reassemble, follow the reverse of disassembly sequence and do the following steps. (1) Clean metal parts with appropriate washing fluid. Dry up cleaned surfaces with compressed air. (2) Replace the parts for which the repair kits are available. (3) Apply an even coat of grease to each O-ring and install into place. (4) Complete the valve assembly by the following procedure. (a) Tighten bolt to the specified torque. Tightening torque

3.9 to 6.9 N·m (0.4 to 0.7kgf·m) [3 to 5 lbf·ft]

(b) Apply an even coat of grease to the piston contact surface of the valve body. (4) Tighten the heater assembly to the specified torque. Tightening torque

19.6 to 29.4 N·m (2.0 to 3.0 kgf·m) [14 to 22 lbf·ft]

(5) Complete the cartridge assembly by the following procedure. (a) The standard quantity of desiccant is 480g (17 oz). (Use one whole bag of desiccant if it is in the repair kit.) (b) To make the desiccant stable, tap lightly on the periphery of the case with a plastic hammer. (c) Secure the cover by tightening screws to the specified torque. 2.0 to 3.9 N·m Tightening torque (0.2 to 0.4 kgf·m) [1.5 to 3 lbf·ft]

9-30

BRAKE SYSTEM

(6) Secure the cartridge assembly by tightening mounting bolts to the specified torque.

Tightening torque

2.0 to 3.9 N·m (0.2 to 0.4 kgf·m) [1.5 to 3 lbf·ft]

(7) Secure the purge chamber by tightening mounting bolts to the specified torque.

Tightening torque

8.8 to 13.7 N·m (0.9 to 1.4 kgf·m) [6 to 10 lbf·ft]

9-31

BRAKE SYSTEM

Parking Brake Disassembly 2 3 3 4 5 7 8 1 7

210440

Sequence 1. Nut 2. Parking brake drum, Nuts, Washers, Grommet 3. Input flange, Bolts, O-ring

4. Return springs 5. Brace 6. Shoe-and-lining assemblies, Adjuster assembly, Spring

Inspection 1. Shoe-and-lining assemblies

B: Repair or service limit Unit: mm (in.)

6.7 (0.264)

3.5 (0.138)

Thickness of lining 9-32

7. Camshaft, Camshaft lever, Spring 8. Support plate assembly, Dust seal, Bolts, Washers

BRAKE SYSTEM 2. Brake drum

Check the friction surface of the drum for uneven wear or groovy marks. Repair the drum by grinding. A: Standard value

Inside diameter of brake drum

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

304.8 + 00.5 (12.000 + 00.020 )

307 (12.09)

3. Adjuster assembly

Check the wheel teeth for wear. Turn the screw by hand to see if it turns freely.

Reassembly Follow the reverse of disassembly sequence, and do the following steps: 1. Keep the brake linings free of oil or grease. 2. Before assembling the brake, apply grease to the following parts: (1) The contact faces of the anchor pins and shoe webs. (2) The end faces of the shoe webs fitted to the slots on both sides of the adjuster assembly. (3) The end and threaded portions of the adjuster assembly. (4) Shoe guide ledges formed of the support plate at six places. 3. Align the matching marks when installing the lever to the camshaft.

9-33

BRAKE SYSTEM

Parking brake lever Disassembly

Released position

Applied position 1 2 3 4

5 7 6

205504

Sequence 1. 2. 3. 4.

Grip Stud Lever assembly Rod assembly

5. Bracket 6. Parking brake wire 7. Clevis pins

Inspection (1) Replace the lever if the clevis pins or pin holes in the lever are badly worn. (2) Replace the wire if it is stretched, rusted or damaged.

Reassembly After connecting the brake wire, make sure that the operating effort of the brake lever is 245 to 294 N (25 to 30 kgf) [55 to 66 lbf].

9-34

BRAKE SYSTEM

Testing and Adjusting Wheel Brakes 1. Clearance adjustment

(1) Remove the grommet from the inspection hole in the dust cover. (2) Insert different feeler gauges one by one into between the drum and lining through the inspection hole to find a gauge that gives a slight resistance when it is inserted. Check to see if the thickness of this gauge coincides with the standard value.

Standard value

0.2 mm (0.008 in.) 210441

CAUTION Check the clearance at two places on each wheel.

(3) If the clearance is incorrect, adjust it by turning the adjusting cam. 2. Lining (shoe assembly) replacement

Lining wear indicator

If the lining wear indicator shows that the linings have reached the service limit, replace lining alone or the shoe assembly. The shoe assembly should also be replaced: (1) If the linings are improperly installed (riveted) to the shoes. (2) If the linings are badly soaked with oil or grease, burnt or deteriorated (hardened). (3) If the linings are cracked or broken. NOTE: For brake lining replacement procedure, see page 9-40.

210442

3. Lining wear indicator setting

9-35

BRAKE SYSTEM

NOTE Reset the indicator at minimum value only after the adjusting cam has been reassembled.

4. Brake drum

(1) Replace the drum if its inside diameter reaches the service limit. (2) Check the friction (inside) surface of the drum for uneven wear or scratches. Replace the drum if uneven wear exceeds 0.2 mm (0.008 in.), or if the friction surface is badly scratched. A: Standard value

Inside diameter of brake drum

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

420 (16.54)

424 (16.69)

Air Bleeding When any part of the brake fluid line has been serviced by disconnecting, or if the brake pedal feels spongy because of trapped air, bleed air out of the line. Bleed the components in this sequence: air master – left-hand wheel cylinder – right-hand wheel cylinder. Fill the brake fluid reservoir to the normal level before starting bleeding operation. During bleeding operation, check the fluid level in the reservoir from time to time and add fluid as necessary to keep it above 1/2 level at all times. For bleeding operation, use two men – one at the brake pedal, the other at the bleeder screw of the wheel cylinder. 1. Air master

(1) Start the engine and allow it to run at low idle. (2) Remove the cap from the air bleeder screw of the air master. Connect a transparent vinyl tube to this screw with the free end of the tube put in a jar filled with brake fluid. Pour sufficient amount of clean brake fluid into the jar so that the end of tube can be submerged. (3) Have someone get into the truck and pump the brake pedal, allowing it to return slowly, then keep the pedal depressed and loosen the bleeder screw to allow the fluid to flow into the jar.

9-36

200652

BRAKE SYSTEM

(4) Do Step (3) until the fluid flows from the vinyl tube into the jar in a solid stream that is free of air bubbles, and tighten the bleeder screw. 2. Wheel cylinders

(1) Start the engine and allow it to run at low idle. (2) Connect a transparent vinyl tube to the bleeder screw of the wheel cylinder with the free end of the tube put in a jar filled with brake fluid. (3) Have someone get into the truck and pump the brake pedal, allowing it to return slowly, then keep the pedal depressed and loosen the bleeder screw to allow the fluid to flow into the jar. Tighten the bleeder screw while the fluid is flowing into the jar.

200285

(4) Do Step (3) until the fluid free of air bubbles flows from the vinyl tube into the jar, and fill the reservoir with the fluid up to the specified level.

NOTE (1) Maintain proper fluid level in the reservoir during bleeding operation. (2) Avoid mixing different types or brands of fluids.

Brake Pedal Set the brake pedal with bolt 1 so that the roller may come in contact with the brake control valve pedal.

NOTE Do not tamper with the brake valve pedal set angle (39±1.5°).

206105

9-37

BRAKE SYSTEM

Brake Control Valve 1. Air leak test

(1) Make sure the air tank pressure is correct. (2) Release the brake pedal. Apply soapy water to the exhaust port of the control valve to see if any air bubble forms there. Air bubbles mean that the exhaust valve inside is not seated tight. (3) Depress the brake pedal fully, and conduct the same test on the exhaust valve to check for air leaks. (4) If air leaks, remove the plug from the exhaust port and take out the exhaust valve for inspection.

200654

2. Function test

(1) Connect a test pressure gauge with R (PT) 3/8 connector to the outlet port of the brake control valve. (2) Start the engine and raise the tank pressure to the normal level, then stop the engine. (3) Have someone get into the truck and keep on depressing the brake pedal. Compare the reading of the test pressure gauge with the indication of the pressure gauge on the instrument panel, making sure these pressure gauge readings are coincide with each other. (4) If the pressure gauge indicate pressure drop when the pedal is kept depressed, check the air system for leakage, or adjust the air governor.

9-38

200655

BRAKE SYSTEM

Air Governor Adjustment Adjust the air governor after making sure the air pressure gauge is not defective. (1) Wrong setting of the governor is evidenced by the air compressor remaining idle even when the air tank pressure drops to and below 745 kPa (7.6 kgf/cm2) [108 psi]. In such a case, remove the cover and reposition the adjusting screw. (2) Turning the adjusting screw clockwise will raise the pressure, and vice versa. 200656

Parking Brake Clearance (1) Move the truck until the access hole in the drum is approximately 30 mm (1.2 in.) to the right from the bottom point. (2) Release the brake. (3) Remove the grommet from the access hole. Turn the adjuster up all the way until the shoes get in touch with the drum. From that position of the adjuster, turn it back about 8 clicks to obtain a correct clearance [0.23 mm (0.0091 in.)] between the shoes and drum. Turn adjuster to spread shoes.

200658

(4) To check the clearance, remove the grommet from the dust cover, and measure it with a feeler gauge.

200657

9-39

BRAKE SYSTEM

Brake lining replacement (1) Using a drilling machine 3, remove rivets 2 by drilling off their brake shoe 1 side heads, then detach the lining 4. (2) Align the rivet holes in the brake shoe to the spot faced holes in the brake lining center to center. Then, rivet the brake shoe and lining together using a riveting machine. (3) When the riveting is done by hand, hold the brake lining closely to the brake shoe using a squill vise or the like and tighten the riveting block against the vise. Then, place the lining-side heads of rivets parallel on the riveting block and stamp them with a punch to head the rivets' other end to fasten the lining to the brake shoe.

NOTE: (1) After replacing the brake linings, always check for their contact with the brake inside surface and repair where the contact is poor. (2) After adjusting the shoe clearance to 0.2 mm (0.008 in.) at each side, be sure to break fresh linings in to ensure proper contact with the brake drum by the following procedure. (a) Depress the accelerator pedal all the way and fill up the air tank. (b) With the brake pedal depressed with a leg power of about 245 N (25 kgf) [55 lbf], place the forward/reverse lever into the forward position. Depress the accelerator lever all the way little by little and run the truck a distance of 200 m (220 yd). (c) After the above is done, let the brake cool down to normal temperature. Before using, make sure that the brake feels normally.

9-40

3 2

4 210443

BRAKE SYSTEM

Troubleshooting Wheel Brakes Air line leaks

Repair or replace.

Air tank pressure too low

Increase air tank pressure.

Fluid line leaks, or fluid level too low in reservoir

Repair and add fluid.

Air trapped in hydraulic line

Bleed air out of air master or wheel cylinders.

Clearance between drum and linings out of adjustment

Readjust.

Air master or wheel cylinder piston cup worn, resulting in fluid leaks

Replace. Change fluid with recommended type if cups are distorted.

Linings worn to expose rivet heads

Replace.

Lining surface glazed

Replace.

Brake drum unevenly worn or loose

Replace or retighten.

Linings not seated on shoes

Replace.

Tires not uniformly inflated

Inflate correctly.

Clearance between drum and linings out of adjustment

Readjust.

Mismatched linings

Repair or replace.

Linings or drum soaked with oil

Replace; avoid over-lubrication.

Linings not equal in size and material

Replace.

Shoes loose or return springs broken

Retighten anchor pin lock nut or replace.

Wheel cylinder defective

Check cylinder piston and piston cups, and replace defective parts.

Brakes too sensitive or drag

Clearance between drum and linings too small

Readjust.

Repair or replace.

All brakes drag

Brake control valve leaks air into line leading to air master, causing air master to operate Brake pedal not returning properly

Lubricate or repair arm shaft. Replace return spring if necessary.

Will not apply

Brakes chatter

Truck pulls to one side

9-41

BRAKE SYSTEM

One brake drags

Will not release

Brake pedal kicks back

Clearance between drum and linings too small in one brake

Readjust.

Return spring weak or broken

Replace.

Anchor pin seized, resulting in a failure of shoe to return

Replace.

Wheel cylinder piston and piston cups defective

Replace.

Brake pipe restricted at joint, resulting in a failure of fluid to return properly

Clean.

Piston cups swollen

Replace.

Push rods distorted

Replace.

Power piston packings lack lubrication

Relubricate.

Hydraulic piston cups defective

Replace.

Hydraulic piston check valve ball not seating tight

Replace piston assembly.

Clearance between drum and linings too small

Readjust.

Clearance between drum and linings too small

Readjust.

Brake drum distorted

Repair or replace.

Linings worn

Replace.

Clearance between drum and linings too small

Readjust.

Brake lever lacks operating effort

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

Parking Brake Brake lever stroke too small

Noise

Will not apply

9-42

BRAKE SYSTEM

Air Dryer

Air dryer drains moisture during operation

Purge valve will not drain

Taking long time to complete dehydration of saturated air when air dryer is equipped

Drain daily at end of operation until air line is completely dehydrated.

Air consumption excessive and air compressor not operating on load and unload cycles

Operate truck to allow compressor on load and unload cycles, or check dryer installation.

Air governor (pressure regulator) operating pressure set too low (lower than 490 kPa (5 kgf/cm2) [71 psi]) and purge valve kept closed

Reset air governor.

Air dryer located too close to air compressor

Install air dryer more than 1.5 m (5 ft) apart from air compressor.

Desiccant not changed periodically

Change desiccant kit periodically.

No purging action

Check air governor operating pressure and relief valve closing pressure.

Desiccant not changed periodically

Change desiccant kit periodically.

Air governor (pressure regulator) operating pressure set too low (lower than 490 kPa (5 kgf/cm2) [71 psi]) and purge valve kept closed

Reset air governor.

Purge valve jammed with foreign particles

Disassemble and replace valve kit.

Air dryer exposed at low temperature [−30°C (−22°F)]

Change location.

Thermostat defective and heater not operating properly

Test thermostat as follows: (a) Expose thermostat at a temperature below 0°C (32°F) and check for continuity with a tester. (b) Wrap thermostat in the palms by cloths to see if it turns off. Replace thermostat if defective.

Air dryer covered with ice

Remove ice.

Foreign particles lodged between purge valve and seat

Disassemble and check purge valve. Replace valve kit or valve body assembly.

Dry air flows out of air tank during air compressor operation on unload cycle

Replace check valve in line between air tank and purge chamber.

Air dryer internally frozen

Air leaks from purge valve

Air tank pressure drops abnormally

9-43

BRAKE SYSTEM

Service Data A: Standard value Unit: mm (in.) Truck Model DP100

DP115

DP135

DP150

Item Height 1 (from floor to pedal top)

190 (7.48)

Free play 2

15 (0.59)

Brake pedal 1

210444

39±1.5°

Free play 2

4±1.5°

Normal braking 3

12±1°

Emergency braking 4

6±1°

Pedal set angle 1

Brake control valve

200629A

9-44

BRAKE SYSTEM

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item Power piston return spring 1 (Test force/length under test force)

196±20 (20±2) [44±4] / 179 (7.05)

N (kgf) [lbf] B

157 (16) [35] / 179 (7.05)

0.05 (0.0020), maximum

0.5 to 1.4 (0.020 to 0.055)

1.8 (0.071)

0.07 to 0.15 (0.0028 to 0.0059)

0.2 (0.008)

Bend of push rod 2 Clearance between power piston and cylinder shell 3

Clearance between hydraulic piston and cylinder tube 4

Tightening torque for hydraulic cylinder lock nut 5 A N·m (kgf·m) [lbf·ft]

98 to 147 (10 to 15) [72 to 108]

Tightening torque for power piston end nut 6 A N·m (kgf·m) [lbf·ft]

20 to 29 (2 to 3) [14 to 22]

Air master

6 210182

9-45

BRAKE SYSTEM

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item Inside diameter of cylinder body 1

55.56 (2.187)

0.13 to 0.24 (0.0051 to 0.0094)

0.3 (0.0118)

56.2 (2.213)

(To be replaced every year)

Tightening torque for cylinder mounting bolts A N·m (kgf·m) [lbf·ft]

45 to 69 (4.6 to 7.0) [33 to 51]

Tightening torque for bleeder screw A N·m (kgf·m) [lbf·ft]

22±3 (2.25±0.35) [16±3]

Clearance between piston and cylinder body

Diameter of piston cup (lip side) 2

Wheel cylinders

210445

9-46

BRAKE SYSTEM

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item A

420 + 00.2 (16.54 + 00.008 )

424 (16.69)

16 (0.63)

10 (0.39)

0.2 (0.01)

Free length

203.5 (8.01)

Test force

N (kgf) [lbf] A

423 (43.1) [95]

Inside diameter of brake drum 1

Thickness of lining 2 Clearance between drum and lining 3

Return spring 4

Length under test force

Wheel brakes

251 (9.88)

Tightening torque for anchor bracket bolts (M14) 5 A N·m (kgf·m) [lbf·ft]

156±16 (15.9±1.6) [115±12]

Tightening torque for anchor bracket bolts (M16) 6 A N·m (kgf·m) [lbf·ft]

233±24 (23.8±2.4) [172±17]

Tightening torque for lock plate bolts 7 A N·m (kgf·m) [lbf·ft]

15.7 to 23.5 (1.6 to 2.4) [12 to 17]

1 2

210446

9-47

BRAKE SYSTEM

A: Standard value Unit: mm (in.) Truck Model DP100

DP115

DP135

DP150

Item Locked position of lever A Lever operating effort F

71 to 76°

N (kgf) [lbf] A

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

F A

Parking brake lever

205505

9-48

BRAKE SYSTEM

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item A

304.8 + 00.5 (12.000 + 00.020 )

307 (12.09)

6.7 (0.26)

3.5 (0.14)

0.25 (0.0098)

Free length

77±0.75 (3.03±0.03)

Test force

N (kgf) [lbf] A

Inside diameter of brake drum 1

Thickness of brake lining 2 Clearance between drum and lining 3

Return spring 4

Length under test force

223±23 (22.7±2.3) [50±5]

83 (3.27)

Tightening torque for support plate nut 5 A N·m (kgf·m) [lbf·ft]

145±22 (14.8±2.2) [107±16]

Tightening torque for brake drum nut 6 A N·m (kgf·m) [lbf·ft]

96±15 (9.8±1.5) [71±11]

Parking brake drum

210447

9-49

STEERING SYSTEM Specifications ..........................................................................................10 – 1 Description ...............................................................................................10 – 2 General .....................................................................................................10 – 2 Steering Control Valve ..............................................................................10 – 3

Removal and Installation ......................................................................10 – 4 Steering Control Valve Assembly ..............................................................10 – 4 Inspection .................................................................................................10 – 5

Steering Control Valve ..........................................................................10 – 6 Disassembly .............................................................................................10 – 6 Inspection .................................................................................................10 – 9 Reassembly .............................................................................................. 10 – 10

Troubleshooting ...................................................................................... 10 – 15 Service Data ............................................................................................ 10 – 16

STEERING SYSTEM

Specifications Truck Model DP100

DP115

DP135

Item Type

All hydraulic power steering

Diameter of steering wheel Steering control valve

mm (in.)

330 (13)

Flow rate

45.4 (2771)

liter (cu in.)/min

Inside

78°27’

Outside

51°14’

Turning angle

10-1

DP150

STEERING SYSTEM

Description General 2 1

1. 2. 3. 4. 5.

210450

Steering wheel Hydraulic tank Steering control valve Priority valve Oil pump

6. Power cylinder 7. Check valve A: To hydraulic tank B: To hydraulic control valve

When the steering wheel is at standstill, the greater part of the oil flows through this priority valve to the hydraulic system control valve.

The steering system features a load sensing system. This system consists essentially of a steering control valve (“Orbitrol”), a priority valve, and other components to provide the operator with quick steering response and effortless control. When the steering wheel is turned, the control valve is actuated to send the oil pressure to the power cylinder for turning the rear wheels. The priority valve is a metering valve and controls the volume of the oil to the steering control valve at a rate required for steering action. The excess of the oil flows to the hydraulic system control valve.

10-2

STEERING SYSTEM

Steering Control Valve

Detail B

Section A – A

8 7

13 T.L

R.P

1 9 10

11 4 207241

1. 2. 3. 4. 5. 6. 7.

Housing Wear plate Gerotor set (Rotor) End cap Thrust needle bearing Centering spring Pin

8. 9. 10. 11. 12. 13.

Drive Control sleeve Control spool Spacer Seal gland bushing assembly Ball

10-3

P: T: L: R:

Pump port Tank port Cylinder port (left) Cylinder port (right)

STEERING SYSTEM

Removal and Installation Steering Control Valve Assembly Removal

6 7 5

8 3 7

1 2

210451

Sequence 1. 2. 3. 4.

Cover Toe board Hydraulic hoses, Connectors Steering wheel, Nut

5. 6. 7. 8.

10-4

Console box cover Transmission shift lever, Turn signal lever Clamp, Rubber, Bolts, Washer, Cushion, Collar Steering column assembly

STEERING SYSTEM

Suggestion for Removal Steering wheel removal

Use the Steering Wheel Puller (special tool).

Wheel puller

Special tool needed Steering wheel puller

91268 - 10600

CAUTION Do not hit the end of steering shaft when the steering wheel is removed.

205770

Inspection 1. Steering wheel free play

Check the free play with the engine running at low idle. 2. Steering effort

(1) Set the parking brake. Run the engine until the hydraulic oil temperature reaches 40 to 60°C (104 to 140°F). (2) Hook a spring scale to the rim of the steering wheel. Pull the spring scale in tangential direction and look at the reading on the spring scale just when the wheel begins to turn.

Steering effort N·m (kgf·m) [lbf·ft]

16 (1.65) [12]

Tangential force N (kgf) [lbf]

98 (10) [22] 205771A

3. Air bleeding

If any air is in the steering system, the system could have noise or vibration. To bleed air from the steering system, do the following procedure: (1) Raise the rear wheels with a jack. Refer to “GROUP 8 REAR AXLE.” (2) Depress and release the accelerator pedal several times while turning the steering wheel from lock to lock of steering cylinder. 10-5

STEERING SYSTEM

Steering Control Valve Disassembly

5 7 6 8

A 2

4 1

A 207559

Sequence 1. 2. 3. 4. 5.

6. 7. 8. 9.

End cap, Screws, O-ring Gerotor set, O-ring, Spacer Wear plate, Drive, O-ring Ball, Adapter Retaining ring

10-6

Seal gland bushing assembly Thrust needle bearing, Bearing race Spool and sleeve assembly Housing

STEERING SYSTEM

Suggestions for Disassembly Disassembly on gerotor side 1. Removing the end cap

(1) 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.

207180

(2) Remove the cap screws and the end cap. Remove the O-ring from the end cap.

Cap screw End cap O-ring

207181

2. Removing the gerotor set

Remove the gerotor set, taking care not to let the star drop. Remove the O-ring from the gerotor set. Remove the drive spacer.

O-ring

Gerotor set Spacer 207182

3. Removing the drive

Remove the drive and wear plate. Remove the O-ring from the housing.

Wear plate

Drive O-ring 207183

10-7

STEERING SYSTEM Disassembly on control side 1. Removing the seal gland bushing

(1) Use a thin-bladed screwdriver to pry the retaining ring from the housing.

200665

(2) Turn 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 bushing assembly from the housing.

Seal gland bushing assembly

200666

(3) 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.

Quad ring seal Seal gland bushing Dust seal 207184

2. Removing the thrust needle bearing

Remove the two bearing races and the thrust needle bearing from the spool and sleeve assembly.

Bearing race

Thrust needle bearing

Bearing race 207185

10-8

STEERING SYSTEM 3. Removing spool and sleeve assembly

(1) Remove the spool and sleeve assembly from the end of the housing. Do not jam the spool and sleeve assembly. Rotate it slowly when removing it from the housing. Pull the pin from the spool and sleeve assembly. Pin

200667

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

Spring package

Identification mark

Inspection (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 materials in the hydraulic system cause damage. Do not use a coarse grit or try to file or grind these parts.

10-9

200668

STEERING SYSTEM

Reassembly

5 3 4 2

A 8

6 9

A 210221

Sequence 1. 2. 3. 4. 5.

6. 7. 8. 9.

Housing Spool and sleeve assembly Thrust needle bearing, Bearing race Seal gland bushing assembly Retaining ring

NOTE Replace all seals with new ones once disturbed. Lubricate all seals with clean petroleum jelly such as Vaseline.

10-10

Ball, Adapter Wear plate, Drive, O-ring Gerotor set, O-ring, Spacer End cap, Screw, O-ring

STEERING SYSTEM

Suggestion for Reassembly Reassembly on gerotor side 1. Reassembly the spool and sleeve

(1) Reassemble the spool and sleeves so that the spring slots line up. Rotate the spool while sliding into the parts together. Some sets have identification marks. Align these marks. Test for free rotation.

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

Spring slot Control sleeve Spring slot Control spool Identification marks 207191

Special tool needed Spring installation tool

97157 - 00100

(3) Center the spring set in parts so that they push down evenly and flush with the upper surfaces of the spool and sleeve.

200671

(4) Install the pin through the spool and sleeve to the point where pin ends are flush with the sleeve. Insert the spool and sleeve assembly, placing the splined end to enter the housing first.

NOTE Be extremely careful that the parts do not jam. Push the parts into place with a slight rotating action. Keep the pin nearly horizontal and check for free rotation without allowing the pin to drop into the discharge groove in the housing.

207192

10-11

STEERING SYSTEM 2. Reassembling the needle bearing

Install the O-ring in the housing. Install the two races and the thrust needle bearing as shown.

Thrust needle bearing

Bearing race (two)

O-ring

207193

3. Reassembling the seal gland bushing

(1) Install the dust seal in the bushing with the flat side facing towards the bushing.

Dust seal Seal gland bushing

(2) Install the quad ring seal in the bushing by smoothing it into place with your finger. (3) Install the bushing assembly over the spool end with a twisting motion. Tap it into place with a rubber head hammer. Make sure the bushing is mush against with the bearing race. (4) Install the retaining ring in the housing and tap on the ring end or pry it with a screwdriver around the entire circumference to ensure a good sitting.

Quad ring seal 210215

Screwdriver Dust seal Retaining ring Seal gland bushing Quad ring seal O-ring

207195

Reassembly on gerotor side 1. Reassembling the wear plate

(1) Clamp the housing in a vise, equipped with soft jaws or softened with rag clamping lightly over the edges of the mounting area. Do not overtighten the vise jaws.

NOTE Check that the spool and sleeve are flush with or slightly below the surface of the housing. 10-12

207196

STEERING SYSTEM

(2) Install the O-ring in the housing. Place the wear plate on the housing and align the bolt holes with the tapped holes in the housing.

207169

2. Reassembling the driver

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

Port surface Drive

(2) Rotate the spool and sleeve assembly until the pin is parallel with the port surface. Install the drive and make sure that it engages the pin. This mark should be parallel to the port surface.

Pin parallel with port surface

200675

3. Reassembling the gerotor set

(1) Install O-ring in the gerotor set.

Gerotor set

O-ring

207198

(2) With the O-ring side of the gerotor set towards the wear plate, align the star valleys A on the drive B. Noting the parallelism of reference lines A, B, C, and D, align the bolt holes without disengaging the gerotor set from the drive.

Gerotor set star valley

B Drive (marked) C D

207199

10-13

Port surface

STEERING SYSTEM 4. Reassembling the end cap End cap

(1) Install the drive spacer in the gerotor set. Install the Oring in the end cap. Install the end cap in the gerotor set and align the holes.

Cap screw

O-ring Drive spacer 207200

(2) Install dry cap screw with new seal washers. Tighten all screws snug, then tighten them progressively to the specified torque in the sequence as shown.

Initial torque for screws

14.7 N·m (1.5 kgf·m) [10.8 lbf·ft]

Finishing torque for screws

23.5 N·m (2.4 kgf·m) [17.3 lbf·ft]

7 5 200677

After installing the end cap, install the steering wheel to the spool and make sure the spool rotates smoothly.

10-14

STEERING SYSTEM

Troubleshooting No steering flow due to: • Clogged spool orifice

Clean.

• Damage to spool spring

Replace.

Relief valve defective due to: Priority valve has a defect

Hard steering Control valve has a defect

Power cylinder has a defect

Other

Control valve has a defect

• Maladjustment

Readjust.

• Damage to valve seat

Replace relief valve assembly.

• Damage to spring

Replace and readjust setting.

Oil leakage from relief valve due to damage to O-ring

Replace.

Metering section clogged

Clean.

Spool movement erratic

Clean.

Damage to bearing

Replace.

Piston rod distorted

Repair or replace.

Damage to piston seals

Replace.

Pipes or tubes flattened, or restriction to flow

Repair or replace.

Spool or sleeve sticking

Repair or replace.

Damage to centering spring

Replace.

Pipes or tubes flattened, or restriction to flow

Repair or replace.

Damage to power cylinder piston seals

Replace.

Air trapped in hydraulic fluid

Bleed air.

Power cylinder installation loose

Repair.

Shimmy Others

Steering system has noise

10-15

STEERING SYSTEM

Service Data A: Standard value Unit: mm (in.) Truck Model DP100

DP115

DP135

DP150

Item Steering effort (at steering wheel rim) (While engine is running at low idle, rotate wheel at a A rate of on full turn per second, keeping standstill.) N·m (kgf·m) [lbf·ft]

16 (1.65) [12]

Inside

78°27’

Outside

51°14’

Steering wheel free play

70 (2.75)

Tightening torque for steering wheel nut N·m (kgf·m) [lbf·ft]

54 to 59 (5.5 to 6.0) [40 to 43]

Tightening torque for steering bracket bolts N·m (kgf·m) [lbf·ft]

29.4 (3) [21.7]

Displacement

cc (cu in.)/rev.

277 (16.9)

Rated flow rate

liter (cu in.)/min.

45.4 (2777)

17162 (175) [2489]

23.5 (2.4) [17.3]

Turning angle Steering wheel

Maximum operating pressure kPa (kgf/cm2) [psi] Tightening torque for end cap screws 1 N·m (kgf·m) [lbf·ft]

Steering control valve

210216

10-16

HYDRAULIC SYSTEM Specifications .......................................................................................... 11 – 1 Description ............................................................................................... 11 – 2 Hydraulic System ...................................................................................... 11 – 2 Hydraulic Tank .......................................................................................... 11 – 3 Gear Pump ............................................................................................... 11 – 4 Priority Valve ............................................................................................. 11 – 6 Control Valve ............................................................................................ 11 – 7 Lift and Tilt Cylinders ................................................................................ 11 – 12 Flow Regulator Valve ................................................................................ 11 – 13 Removal and Installation ...................................................................... 11 – 14 Gear Pump ............................................................................................... 11 – 14 Control Valve ............................................................................................ 11 – 15 Lift Cylinders ............................................................................................. 11 – 16 Tilt Cylinders ............................................................................................. 11 – 19 Gear Pump ............................................................................................... 11 – 22 Disassembly ............................................................................................. 11 – 22 Reassembly .............................................................................................. 11 – 23 Inspection ................................................................................................. 11 – 24 Priority Valve ............................................................................................ 11 – 25 Disassembly ............................................................................................ 11 – 25 Reassembly ............................................................................................... 11 – 25 Control Valve ........................................................................................... 11 – 26 Disassembly ............................................................................................. 11 – 26 Reassembly .............................................................................................. 11 – 26 Flow Regulator Valve ............................................................................. 11 – 35 Disassembly ............................................................................................. 11 – 35 Inspection ................................................................................................. 11 – 35 Reassembly .............................................................................................. 11 – 35 Lift Cylinders ............................................................................................. 11 – 36 Disassembly ............................................................................................. 11 – 36 Inspection ................................................................................................. 11 – 38 Reassembly .............................................................................................. 11 – 40

Tilt Cylinders ............................................................................................ 11 – 42 Disassembly ............................................................................................. 11 – 42 Inspection ................................................................................................. 11 – 43 Reassembly .............................................................................................. 11 – 45 Testing and Adjusting ........................................................................... 11 – 46 Hydraulic Oil ............................................................................................. 11 – 46 Gear Pump ............................................................................................... 11 – 46 Control Valve ............................................................................................ 11 – 47 Main Relief Valve ...................................................................................... 11 – 48 Priority Relief Valve ................................................................................... 11 – 49 Overload Relief Valve (Option) ................................................................. 11 – 50 Lift Cylinder Drift ....................................................................................... 11 – 51 Tilt Cylinder Drift ....................................................................................... 11 – 51 Troubleshooting ...................................................................................... 11 – 52 Service Data ............................................................................................ 11 – 55

HYDRAULIC SYSTEM

Specifications Truck Model DP100

DP115

DP135

DP150

Item

Gear pump

Type

Gear

Model

P20300C

Rated output

205 (54)/2200

liter (U.S. gal.)/rpm

Priority valve

Drive

Directly driven by torque converter

Model

VLE61C120B

Relief valve setting MPa (kgf/cm2) [psi]

11.8 (120) [1707]

Model Control valve

Flow regulator valve

Lift cylinders

Tilt cylinders

KVML-200-3

Relief valve setting MPa (kgf/cm2) [psi]

17.2 + 00.5 (175 + 05 ) [2489 + 071 ]

Type

Variable (adjustable)

Flow rate

150 (40)

liter (U.S. gal.)/min Inside diameter

mm (in.)

Stroke

mm (in.)

Inside diameter

mm (in.)

Stroke

mm (in.)

115 (4.53)

125 (4.92) 1650 (64.96)

120 (4.72)

130 (5.12) 395 (15.55)

H level: 186 (49) N level: 172 (45) L level: 141 (37)

Hydraulic tank capacity liter (U.S. gal.)

11-1

H level: 218 (58) N level: 204 (54) L level: 173 (46)

HYDRAULIC SYSTEM

Description Hydraulic System 1 4 9

2 8

7 5 6 8 210455

4. Power cylinder 5. Tilt cylinders 6. Lift cylinders

1. Hydraulic tank 2. Priority valve 3. Gear pump

The gear pump draws oil from the hydraulic tank and sends it to the priority valve. The oil pressure is metered and divided by this priority valve into two systems, one for the hydraulic system and the other for the steering system. The oil that goes to the hydraulic system is sent through control valve to the hydraulic cylinders.

NOTE The steering control valve is described in “GROUP 10 STEERING SYSTEM.” The power cylinder is described in “GROUP 8 REAR AXLE.”

11-2

7. Control valve 8. Flow regulator valve 9. Steering control valve (Orbitrol)

HYDRAULIC SYSTEM

Hydraulic Tank

From control valve

To hydraulic pump

2 3 1

5 210456

1. 2. 3. 4.

Strainer Breather Cap Oil level gage

5. Drain plug 6. Suction strainer 7. Return filter

The hydraulic tank is integral with the frame and contains an oil inlet strainer, a suction strainer and a return filter to keep the oil clean. Oil is drawn from the tank through suction strainer (105 µ) by the gear pump. The oil returning from the lift cylinders joins the oil returning from the hydraulic and steering control valves, and returns to the tank through return filter (25 µ).

11-3

HYDRAULIC SYSTEM

Gear Pump

8 210457

1. Steel ring 2. Isolation plate B, Back-up ring, O-ring, Retainer 3. O-ring 4. Dowel pin 5. Pressure plate 6. Body 7. Driven gear

8. Isolation plate A, Back-up ring, O-ring, Retainer 9. Pressure plate 10. Drive gear 11. Cover 12. Oil seal 13. Snap ring

11-4

HYDRAULIC SYSTEM

Operation 2

The pump is a single section external gear type pump. It consists essentially of two gears, drive gear 1 and driven gear 2 closely fitted inside the body. As the gears rotate and come out of mesh, they trap inlet oil between the gear teeth and the body. The trapped oil is carried around to the outlet. As the gears mesh again, they form a seal which prevents the oil from backing up to the inlet. The oil is forced out at the outlet and sent through the system. 1

210458

Pressure loading mechanism This pump features pressure-loading design of the pressure plates. During operation, a small amount of oil pressure is fed under the pressure plates, pressing them against the gears and keeping the end clearance (between the pressure plates and the gears) at the desired fluid-film thickness to provide high volumetric efficiency.

End clearance

Outlet

11-5

210459

HYDRAULIC SYSTEM

Priority Valve LS T

3 1 4 EF

6 205648

1. 2. 3. 4. 5. 6.

Relief valve Plug Housing Control spring Spool Plug

P: Pump port T: Tank port CF: Control flow port EF: Main flow port (to hydraulic control valve) LS: Load sensing port

The priority valve, as its name implies, gives priority over the flow of oil that is sent to the steering control valve when both steering and hydraulic systems are in operation. The remainder or excess of the oil goes to the hydraulic control valve. When the steering control valve is in the neutral position and only the hydraulic system is in operation (the lift and tilt cylinders are actuated), most of the oil goes to the hydraulic control valve. 11-6

Priority relief valve pressure

11.8 MPa (120 kgf/cm2) [1707 psi]

HYDRAULIC SYSTEM

Control Valve

P (on this side)

T (on backside) 12 210460

1. 2. 3. 4. 5.

Inlet cover Main relief valve Lift valve block Tilt valve block Tilt lock valve

6. 7. 8. 9. 10.

Attachment valve blocks End cover Load check valve Tie rod High-pressure port

11. Center bypass port 12. Low-pressure port 13. Plug P: Pump port (inlet port) T: Tank port (outlet port)

The spools and valve blocks are selectively machined by lapping.

The control valve is made up of inlet cover, lift valve block, tilt valve block, attachment valve blocks and end cover. These blocks and covers are put together with four tie rods.

Each valve block has a built-in load check valve. The tilt vale spool has a built-in tilt lock valve.

The inlet cover has pump port and tank port and, on the top, a cartridge type pilot-operated relief valve. The spools are connected through linkage to the control levers in the operator’s compartment and are held in neutral by the springs located on the top of the spools.

11-7

HYDRAULIC SYSTEM

Operation

6 Neutral position 210461

1. Inlet cover 2. Lift valve block 3. Tilt valve block

4. Attachment valve blocks 5. End cover 6. Tilt cylinder

When the control valve is in neutral, the oil from the pump flows from the pump port through the center bypass ports in the valve blocks and covers to the tank port. There is a continuous flow of oil through this circuit as long as the engine is running.

11-8

7. Lift cylinder T: Tank port P: Pump port

HYDRAULIC SYSTEM 1. Tilt lock valve operation

Non-locking position

Locking position

(Engine is running and hydraulic pressure is available at pump port.)

(Engine stops and hydraulic pressure is lost at pump port.)

1 2 3 a

Tank port Pump port

High pressure oil Return oil Trapped oil

210462

1. Plug 2. Spring

3. Poppet a: Damper chamber

passage for the tank port. Under this condition, the oil in the head end of the tilt cylinder is forced out of the cylinder by the piston and returns through the tank port to the tank.

The tilt lock valve operates when the hydraulic pressure is lost at the pump port, that is, in the line extending from the pump, with the mast tilted forward. If the engine stops when the mast is tilted back, the load check valve operates to close the return line and prevents the mast from tilting forward.

(b) When the engine stops

The hydraulic pressure is no longer available at the pump port. This means that the pressure is lost in the damper chamber, causing the poppet to be pushed down by its spring to shut off the return oil passage. Under this condition, the pressure in the line leading to the tilt cylinder becomes trapped to lock its piston there. Thus the mast remains in its current tilted position.

(a) When the engine is running

As the tilt control lever is moved to “forward tilt” position, the oil pressure flows to the cap end of the tilt cylinder and, at the same time, flows into the damper chamber. The oil in the damper chamber pushes the poppet, against the force of its spring, to uncover the

11-9

HYDRAULIC SYSTEM 2. Main relief valve operation

The main relief valve limits the highest pressure that occurs in the hydraulic line, in order to avoid overstressing of the components and pipe lines. It functions as a safety valve. An adjusting screw is provided for adjustment of relieving pressure.

10 210463

1. 2. 3. 4. 5. 6.

Body Plunger Spring Spring seat Filter Plug

7. Poppet 8. Poppet spring 9. Spring seat 10. Adjusting screw P: Pump port T: Tank port

(a) Initial relieving

If the pressure in the pump port rises high enough to overcome the force of the poppet spring, it pushes the poppet off its seat, allowing the oil to flow around the poppet to the tank port.

210464

(b) Full relieving

Opening of the poppet drops the pressure inside the plunger lower than that in the pump port to move the plunger off its seat. Now the oil directly flows to the tank port.

210465

11-10

HYDRAULIC SYSTEM 3. Port relief valve operation

The port relief valve, built in the attachment valve block, protects the attachment components.

NOTE This valve has been properly set at the factory and should not be readjusted in field unless absolutely necessary. If the valve has to be readjusted, be sure to use a pressure gauge to obtain the correct setting.

8 210466

1. 2. 3. 4.

Adjusting screw Plug Spring Body

5. 6. 7. 8.

Poppet Seat Spring Plunger

4. Load check valve operation P

The load check valve allows the oil to flow only in one direction — that is, to prevent the reverse flow of oil to the pump port.

2 210467

1. Check valve 2. Spring

11-11

P: Pump port A: Cylinder port

HYDRAULIC SYSTEM

Lift and Tilt Cylinders

Head-end port Flow regulator valve

210631

Cap-end port

Lift cylinder

Socket

Collar

Tilt cylinder 210632

The lift cylinder is of single-acting type. The cap-end port is equipped with a flow regulator valve. A return pipe is connected to the head-end port to admit the oil from the tank when the piston goes down. By this feature, the top portion of the cylinder bore wall is protected against rusting.

rod carries a screw-on socket. This socket can be repositioned by turning when the cylinder is connected to the outer mast. By this feature, the tilt cylinders, left and right, can move in unison. The tilt angle can be increased or decreased by means of collar and socket of each cylinder.

The tilt cylinder is of double-acting type. The piston

11-12

HYDRAULIC SYSTEM

Flow Regulator Valve

To lift cylinder

From lift cylinder

From control valve

To control valve To other flow regulator valve

210470

210471

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 forks are lowered to keep a constant safe lowering speed regardless of load. The flow regulator valves on both sides are communicated to each other to equalize the actuating speeds of both cylinders.

11-13

HYDRAULIC SYSTEM

Removal and Installation Gear Pump Removal

4 2

3 210472

Sequence 4. Nuts, Spring washers, Washers 5. Bolts, Spring washers 6. Gear pump, O-rings

1. Split flange, Bolts, Washers 2. Delivery hose, O-ring 3. Suction elbow, O-ring, Bolts, Washers

Start by:

Remove floor mat and floor plates.

Suggestion for Removal To remove the gear pump, lift it with hoist and sling. Weight of gear pump

9.6 kg (21 lb)

11-14

HYDRAULIC SYSTEM

Control Valve Removal 7

210473

Sequence 1. 2. 3. 4.

Clevis pins Delivery hose, O-ring Lift pipe, O-ring Tilt pipes, O-rings

5. Return pipe, O-ring 6. Stud 7. Control valve

Start by:

Suggestion for Removal

(a) Remove floor plates.

Fasten a hoist to the control valve and support it with a sling.

(b) Tilt the mast to vertical position, lower the forks all the way, and relieve the pressure from the hydraulic lines.

NOTE

Weight

When disconnecting the pipes and hoses, place a dip pan. Cover the openings of the control valve and connectors to prevent entrance of dirt.

11-15

3-valve type control valve 4-valve type control valve 5-valve type control valve

62 kg (137 lb) 76 kg (168 lb) 90 kg (198 lb)

HYDRAULIC SYSTEM

Lift Cylinders Removal 6

Connector

1 2 8

3 4

210474

Sequence 1. 2. 3. 4.

Lift bracket Return hoses, Clamps High-pressure hoses Flow regulator valve hose

5. 6. 7. 8.

Suggestions for Removal 1. Return hoses removal

Start the engine. Raise the inner mast all the way and stop the engine. Disconnect the return hoses from the left and right lift cylinders at their connectors.

CAUTION Be careful not to touch the lift control lever.

11-16

Stopper bolt, Washer, Spring washer Cylinder clamp, Cushions, Collars, Shims Stopper bolt Lift cylinder

HYDRAULIC SYSTEM 2. Lift bracket removal

Slowly push the lift control lever to lower the inner mast. 3. High-pressure hoses removal

Disconnect the high-pressure hose from the connector at the bottom of each lift cylinder. Direct the oil flow into a container. 4. Stopper bolt removal

(1) Remove the stopper bolt at the top of each lift cylinder. Lift the inner mast to separate it from the lift cylinders. To lift the inner mast, hitch a sling to the mast with protective rag as shown.

NOTE The rod end of either lift cylinder is shim-adjusted. Before removing the stopper bolts, make a record of the amount of shims on each cylinder.

210475

(2) Put wood blocks under the inner mast and detach the sling. Use the blocks strong enough to support the mast. 5. Lift cylinder removal

Fasten a hoist to the lift cylinder from the rear side of the mast, and remove the cylinder. Fasten the hoist to the cylinder before removing the cylinder clamp.

210476

11-17

HYDRAULIC SYSTEM

Installation To install, follow the reverse of removal sequence and do the following steps: (1) Extend and retract the lift cylinder rods several times under no load condition to remove air out of the cylinder circuits and to make sure that the cylinder rods moves freely. (2) Check the oil level in the hydraulic tank with an oil level gauge. (Refer to “Hydraulic tank refill capacities” in the “Testing and Adjusting” section as follows.) (3) Check to make sure that the lift height is correct. (4) After the lift cylinders or piston rods have been replaced, check for difference in stroke between the two cylinders. (Refer to “Group 12 MASTS AND FORKS.”)

11-18

HYDRAULIC SYSTEM

Tilt Cylinders Removal 3

1 210477

Sequence 3. Tilt cylinder pin, Collars, Washers, Spring washers, Bolts 4. Tilt cylinder

1. Tilt cylinder pin, Collars, Washers, Spring washers, Bolts 2. Hoses

Start by:

(a) Remove floor plates. (b) Remove cover from the front side of seat frame.

Front cover

11-19

210478

HYDRAULIC SYSTEM

(c) Start the engine, tilt the mast all the way forward, stop the engine and apply the parking brake. (d) Put a 3000 kg (6600 lb) weight on the forks to prevent the mast from falling when the tilt cylinders are disconnected from the mast. (e) Block the front wheels.

210454

Suggestions for Removal Tilt cylinder removal

(1) Fasten a hoist to the rods A of the left and right tilt cylinders. (2) Remove the bolts, washers and collars holding tilt cylinder pin 1 (of a tilt cylinder to be removed). Turn forcing screws (M10 × 1.25) in the holes B evenly until the pin is free. Remove the pin.

Tilt cylinder pin

(3) Start the engine and retract the cylinders all the way while operating with the hoist, then stop the engine. (4) Lower the cylinders and unfasten the hoist from a tilt cylinder to be left unremoved.

Protective cloth

210479

(5) Disconnect hoses 2 from the cylinder connectors. (6) Install Caps (special tool) to the front connector of the right and left cylinders. Cap

Special tool needed Cap (G 1/2)

05530 - 40400

NOTE

Entrapped oil

Be sure to install the caps before lifting the cylinders. This cap entraps the oil in the cylinder to prevent its rod from extending when the cylinder is lifted.

11-20

210480

HYDRAULIC SYSTEM

(7) Remove the bolts that hold tilt cylinder pin 3. Remove tilt cylinder pin 3 with a hammer through the hole in the frame as shown. Use a hollow pipe tooling to prevent damage to the grease fitting of the pin.

Hollow pipe

NOTE Have someone support the pin to prevent it from falling.

(8) Remove the cylinder from the front side of the seat frame.

11-21

210481

HYDRAULIC SYSTEM

Gear Pump Disassembly 3

7 6 5 4 210482

Sequence 1. 2. 3. 4.

Cover, Snap ring, Oil seal, Plug, O-ring Steel ring, Plate, Ring, O-ring, Ring retainer Pressure plate Drive gear, Driven gear

5. Pressure plate 6. Plate, Ring, O-ring, Ring retainer 7. Body

NOTE The gear pump is to be repaired by the pump manufacturer. Disassembly of the pump in field will release the manufacturer from any guarantee against the pump performance.

Suggestions for Disassembly

Do not attempt to loosen or force out any part of the pump with a hammer or similar tooling.

11-22

HYDRAULIC SYSTEM

Reassembly Suggestions for Reassembly

(1) Before reassembling the pump, visually check all parts to be sure they are clean, and apply hydraulic oil to the inside surfaces of the body. (2) Apply a thin coat of grease to the oil seal. (3) When installing the drive and driven gears, be sure to engage their teeth in such a way as to re-create the original engagement. (4) Tighten the cover bolts to the specified torque.

Tightening torque for cover bolts

109 to 123 N·m (11.1 to 12.5 kgf·m) [80 to 90 lbf·ft]

(5) The fit of the pump gears in the reassembled pump may be deemed satisfactory if the pump shaft rotates smoothly and freely when turned by hand with a 10 mm (0.4 in.) adjustable wrench. (6) If the cover, drive gear and/or driven gear has to be replaced, replace the pump assembly.

11-23

HYDRAULIC SYSTEM

Inspection 1. Drive and driven gears

(1) Check the teeth of each gear for wear or damage. (2) Check the end faces of the gears for wear or damage. (3) Check the shaft portion of each gear for wear or damage.

210483

2. Cover, body and pressure plate

Check for wear or damage.

210484

3. Oil seal and O-rings

Check for wear, cuts or hardening due to deterioration.

210485

11-24

HYDRAULIC SYSTEM

Priority Valve Disassembly Sequence 1. 2. 3. 4.

Spool, Plug, O-ring, Spring Plug, O-ring Relief valve, O-ring Housing

2 205657

Suggestion for Disassembly Do not disassemble relief valve 3.

Reassembly To reassemble, follow the reverse of disassembly sequence.

Suggestion for Reassembly Tightening torque for plugs 1 and 2

44.1 N·m (4.5 kgf·m) [32.5 lbf·ft]

Tightening torque for relief valve 3

20.6 N·m (2.1 kgf·m) [15.2 lbf·ft]

11-25

HYDRAULIC SYSTEM

Control Valve Disassembly 1. Valve Components Disassembly

6 4

5 3

2 2 2-valve type control valve

3-valve type control valve

6 6

5 5

5 1

4 3

3 2

4-valve type control valve

5-valve type control valve

210486

Sequence 1. Tie bolt, Nut, Washer 2. Inlet cover assembly 3. Lift valve assembly

4. Tilt valve assembly 5. Attachment valve assembly 6. End cover

Reassembly

NOTE

Follow the disassembly sequence in reverse.

Do not use liquid packing.

Suggestions for Reassembly

(1) Tighten the tie bolt nut to the specified torque.

Nut tightening torque

98 to 118 N·m (10 to 12 kgf·m) [72 to 87 lbf·ft]

11-26

HYDRAULIC SYSTEM

2. Inlet Cover Disassembly 1

Sequence 1. Relief valve assembly 2. O-ring 3. Inlet cover

2❋ 3

Suggestions for Disassembly

(1) Do not disassemble the relief valve unless pressure adjustment is impossible to make. 210487

NOTE: Parts marked with ❋ are repair kit

Inspection and Repair (1) Check the inlet cover for cracks. Check the relief valve for worn seat surface. Repair if necessary.

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

Suggestions for Reassembly

(1) Replace the part marked with an asterisk (❋) in the illustration with appropriate replacement part in the repair kit. (2) Take extreme care that foreign matter like dust is not trapped in the assembly. (3) Tighten the relief valve assembly to the specified torque.

Relief valve tightening torque

127±10 N·m (13±1 kgf·m) [94±7 lbf·ft]

11-27

HYDRAULIC SYSTEM

3. Lift Valve Disassembly Sequence 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

O-ring O-ring Plug Spring Load check valve O-ring End cover, Bolt Spacer bolt Spring seat Spring Washer Spring seat Washer Packing Pin Cover, Bolt Packing Spool Flange, Bolt O-ring Valve body

8 9 10 11

20❋

12 13 ❋14 19

1❋

6❋

1❋

2❋ 1❋

18 ❋17 16 15

210488

NOTE: Parts marked with ❋ are repair kit

Inspection and Repair (1) Check the valve body for cracks and damaged sliding contract surface. Check the load check valve for worn seat surface. Repair if necessary. (2) Check the spool for damage, seizure or bend. Repair if necessary. (3) Check the spring for damage in fatigue.

11-28

HYDRAULIC SYSTEM

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

Suggestions for Reassembly

(1) Replace the parts marked with an asterisk (❋) in the illustration with appropriate replacement parts in the repair kit. (2) Take extreme care that foreign matter like dust is not trapped in the assembly. (3) Apply an even coat of oil to the spool before fitting it into the valve body. (4) Tighten the following parts to the appropriate specified torques. Unit: N·m (kgf·m) [lbf·ft] Plug 3

196±10 (20±1) [145±7]

End cover 7 attaching bolt

12±1 (1.2±0.1) [9±0.07]

Spacer bolt 8

12±1 (1.2±0.1) [9±0.07 ]

Pin 15

19.6±2 (2±0.2) [14±0.15]

Cover 16 attaching bolt

12±1 (1.2±0.1) [9±0.07]

Flange 19 attaching bolt

56.8±9 (5.8±0.9) [42±6.6]

CAUTION Overtightening these parts may bulge the spool to prevent its smooth movement.

NOTE Do not use liquid packing.

11-29

HYDRAULIC SYSTEM

4. Tilt Valve Disassembly Sequence 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

O-ring O-ring Plug Spring Load check valve O-ring End cover, Bolt Spacer bolt Spring seat Spring Washer Spring seat Plug O-ring Spring Spool Spring Spring seat Steel ball Plunger Washer Packing Pin Cover, Bolt Packing Spool Valve body

8 9 10 11 12 13 ❋14 15 16 17 20

18 19

21 ❋22 27 5

1❋

6❋

1❋ 2❋ 1❋

4 3 26 ❋25 24 23

210489

NOTE: Parts marked with ❋ are repair kit

Inspection and Repair (1) Check the valve body for cracks and damaged sliding contact surface. Check the load check valve for worn seat surface. Repair if necessary. (2) Check the spools for damage, seizure or bend. Repair if necessary. (3) Check the springs for damage in fatigue.

11-30

HYDRAULIC SYSTEM

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

Suggestions for Reassembly

(1) Replace the parts marked with an asterisk (❋) in the illustration with appropriate replacement parts in the repair kit. (2) Take extreme care that foreign matter like dust is not trapped in the assembly. (3) Apply an even coat of oil to the spools before fitting them into the valve body. (4) Install the spool 16 correctly into place. (5) Tighten the following parts to the appropriate specified torques. Unit: N·m (kgf·m) [lbf·ft] Plug 3

196±10 (20±1) [145±7]

End cover 7 attaching bolt

12±1 (1.2±0.1) [9±0.07]

Spacer bolt 8

12±1 (1.2±0.1) [9±0.07 ]

Plug 13

44±5 (4±0.5) [32±3.7]

Pin 23

19.6±2 (2±0.2) [14±0.15]

Cover 24 attaching bolt

12±1 (1.2±0.1) [9±0.07]

CAUTION Overtightening these parts may bulge the spools to prevent their smooth movement.

NOTE Do not use liquid packing.

11-31

HYDRAULIC SYSTEM

5. Attachment Valve Disassembly Sequence 1. O-ring 2 . O-ring 3. Plug 4 . Spring 5. Load check valve 6. O-ring 7. End cover, Bolt 8. Spacer bolt 9. Spring seat 10. Spring 11. Washer 12. Spring seat 13. Washer 14. Packing 15. Pin 16. Cover, Bolt 17. Packing 18. Spool 19. Plug 20. O-ring 21. O-ring 22. Valve body

7 8 19 20❋ 21❋

9 10 11 12 13 ❋14 22

1❋

6❋

1❋

5 4 3

2❋ 1❋

18 ❋17

21❋ 20❋ 19

15 210490

NOTE: Parts marked with ❋ are repair kit

Inspection and Repair (1) Check the valve body for cracks and damaged sliding contact surface. Check the load check valve for worn seat surface. Repair if necessary. (2) Check the spool for damage, seizure or bend. Repair if necessary. (3) Check the spring for damage in fatigue.

11-32

HYDRAULIC SYSTEM

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

Suggestions for Reassembly

196±10 (20±1) [145±7]

End cover 7 attaching bolt

12±1 (1.2±0.1) [9±0.07]

Spacer bolt 8

12±1 (1.2±0.1) [9±0.07 ]

Pin 15

19.6±2 (2±0.2) [14±0.15]

Cover 16 attaching bolt

12±1 (1.2±0.1) [9±0.07]

Plug 19

108±10 (11±1) [80±7]

CAUTION Overtightening these parts may bulge the spool to prevent its smooth movement.

NOTE Do not use liquid packing.

11-33

HYDRAULIC SYSTEM

6. End Cover Disassembly 3

Sequence 1. O-ring 2. O-ring 3. End cover

1❋ 1❋ 2❋ 1❋ 210491

NOTE: Parts marked with ❋ are repair kit

Inspection and Repair (1) Check the end cover for cracks. Repair if necessary.

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

Suggestions for Reassembly

NOTE Do not use liquid packing.

11-34

HYDRAULIC SYSTEM

Flow Regulator Valve Disassembly 3

4 2

5 210492

Sequence 1. Plug, Ring, O-ring 2. Snap ring

3. Piston 4. Valve, Spring pin

Inspection (1) Check the spring for fatigue or damage. (2) Check the sliding and contact surfaces of the valve for damage. (3) Check the sliding surfaces of the sleeve for damage.

NOTE Replace the valve assembly if any part is defective.

Reassembly To reassemble, follow the reverse of disassembly sequence.

11-35

5. Spring, Washers, Shims 6. Sleeve

HYDRAULIC SYSTEM

Lift Cylinders Disassembly

4 2

5 1

210453

Sequence 4. Piston rod 5. Piston, Bushings, Piston seal 6. Cylinder tube

1. Stopper 2. Cylinder head, Wiper ring, Bushing, U-ring, Bushing, O-ring, Back-up ring, O-ring 3. Spacer

11-36

HYDRAULIC SYSTEM

Suggestions for Disassembly 1. Stopper removal

Wrap the cylinder tube with a rag or cloth, and hold it in a vise. Using a fine tip tool, remove the sealing compound from the stopper hole in the cylinder head.

Stopper hole 206521

Using the Hook Wrench (special tool), turn the head slowly in the direction of the arrow to remove the stopper.

O-ring (inside)

Stopper

Special tool needed Truck Model Tool Name

DP100, DP115

DP135, DP150

Hook wrench

92367 - 00600

92367 - 00700

φA mm (in.)

L mm (in.)

Maker No.

92367 - 00600

148 (5.83)

400 (15.75)

MH148

92367 - 00700

160 (6.30)

500 (19.69)

MH160 φA

Part No.

φ10 mm (0.39 in.)

206522

Maker No.

210452

11-37

HYDRAULIC SYSTEM 2. Piston rod removal

Pull out the piston rod as straight as possible from the cylinder tube so the inside surface of the cylinder tube is not damaged by the spacer (if so equipped) or the bushings.

Cylinder tube

Piston rod

206523

Inspection 1. Cylinder tube

(1) Check the inside surfaces of the cylinder tube for wear, scratches or rusting. (2) Check the welds for cracks or dents. 2. Piston rod

(1) Check the piston rod for deflection on V-blocks, 1000 mm (39 in.) apart, with a dial indicator as shown. Replace the piston rod if 1/2 of the gauge reading exceeds the service limit. B: Repair or service limit Unit: mm (in.) Deflection of piston rod (1/2 of dial indicator reading)

0.25 (0.0098)

(

210214

(2) Check the surface of the rod for surface flaws such as grooving, scratching, rusting or wear. 3. Rings and seals

(1) Check each O-ring, back-up ring, U-ring and wiper ring for deterioration due to aging. (2) Check the piston seal lip for damage or distortion.

11-38

HYDRAULIC SYSTEM

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item A

115 (4.53)

125 (4.92)

115.14 (4.53331)

125.16 (4.9275)

Inside diameter of cylinder tube 1 Deflection of piston rod 2 (1/2 of dial indicator reading) Lift height 3000 to 5000 (118 to 197) Diameter of piston rod 3 Lift height 5500 to 7000 (217 to 276)

0.5 (0.020)

60 (2.36)

59.84 (2.3559)

75 (2.95)

74.84 (2.9465)

210633

11-39

HYDRAULIC SYSTEM

Reassembly ❋ Seal kit parts.

❋

❋❋ ❋ ❋

❋

❋❋

❋

3 210634

Sequence 1. 2. 3. 4.

5. Cylinder head, Wiper ring, Bushing, U-ring, Bushing, O-ring, Back-up ring, O-ring 6. Stopper

Piston rod Piston, Bushings, Piston seal Spacer Cylinder tube

Suggestions for Reassembly (1) Replace the seal kit parts. (2) Clean the parts thoroughly before installing them. (3) When installing the wiper ring, apply LOCTITE 242 to the ring. (4) Apply hydraulic oil to the bushings, piston seals, spacer, piston rod and the inside surface of cylinder tube. (5) Install the piston seal as follows: (a) Before fitting the piston seal, squeeze it by hand 5 or 6 times to soften it.

200352

(b) Wrap the piston rod with rag or cloth, and hold it in a vise. Pay attention not to deform the piston. Apply a small amount of hydraulic oil to the seal. Fit a portion of the seal to the groove, and push the other portion into the groove as shown.

204641

11-40

HYDRAULIC SYSTEM

(6) Stopper installation

Stopper

Align the stopper holes in the cylinder tube and head. Put the part A of the stopper in the holes. Part A

Hole in cylinder tube

Hole in cylinder head

Using a hook wrench, turn the head slowly clockwise to install the stopper until its outer end sinks into the hole.

206525

O-ring (inside)

NOTE Do not damage the O-rings when installing the stopper.

206526

After the stopper has been installed properly, fill the stopper hole with sealing (silicone) compound.

Stopper hole

Sealing (silicone) compound Stopper

11-41

206527

HYDRAULIC SYSTEM

Tilt Cylinders Disassembly ❋ Seal kit parts. 4 ❋

5 1

❋

2 210496

Sequence 1. Socket, Nut 2. Guide bushing, Dust seal, Packing, Buffer ring, O-ring, Back-up ring 3. Collar

4. Piston, Self-locking nut, Piston seal 5. Piston rod 6. Cylinder tube, Bushing

NOTE Do not remove the bushings from cylinder tube 6 unless it is defective to require replacement.

11-42

HYDRAULIC SYSTEM

Suggestion for Disassembly Guide bushing removal

(1) Wrap the cylinder tube with a wad or cloth, and hold it in a vise. Pay attention not to deform the cylinder. Using the Hook Wrench A (special tool), remove the guide bushing from the tube. Special tool needed Hook wrench A

05312 - 11000

(2) When removing the guide bushing from the piston rod, cover the threads of the piston rod with vinyl tape to prevent damage to buffer ring, packing, etc.

A 200351

Inspection 1. Cylinder tube

(1) Check the bore wall for wear, grooving, scratching or rusting. (2) Check the welds for cracks or other defects. 2. Piston rod

(1) Check the rod for deflection on V-blocks with a dial indicator as shown. If the 1/2 of dial indicator reading is more than 0.25 mm (0.0098 in.), replace the rod. (2) Check the surface of the rod for surface flaws such as grooving, scratching, rusting or wear. Replace the rod if its threads are badly damaged.

200319

3. Rings and packing

(1) Check each ring and packing for damage or distortion. (2) Also check for deterioration due to aging.

11-43

HYDRAULIC SYSTEM

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item A

120 (4.72)

130 (5.12)

120.12 (4.7291)

130.12 (5.1228)

Inside diameter of cylinder tube 1 Diameter of piston rod (guide bushing side) 2

55 (2.17)

0.1 (0.004)

0.2 (0.008)

60 + 0.070 (2.36 + 0.00276 )

60.6 (2.386)

Clearance between rod and bushing

Inside diameter of bushing 3 (as installed) Tightening torque for guide bushing 4 N·m (kgf·m) [lbf·ft]

+ 0.100

637 ± 64 (65 ± 6.5) [470 ± 47]

1275 0 (130 + 05 )

+ 0.00394

696 ± 69 (71 ± 7) [514 ± 51]

+ 49

Tightening torque for self-locking nut 5 N·m (kgf·m) [lbf·ft]

[940

+ 36 0

+ 98

1520 0 (155 + 010 )

]

[1121

+ 72 0

]

Tightening torque for socket nut 6 N·m (kgf·m) [lbf·ft]

1177 to 1471 (120 to 150) [868 to 1085]

Deflection of piston rod 7 (1/2 of dial indicator reading)

0.5 (0.020)

5 3

1 210497

11-44

HYDRAULIC SYSTEM

Reassembly ❋ Seal kit parts. ❋

❋

4 210498

Sequence 3. Guide bushing, Packing, Buffer ring, Dust seal, Back-up ring, O-ring 4. Socket, Nut

1. Piston rod, Collar, Piston, Self-locking nut, Piston seal 2. Cylinder tube, Bushing

Suggestions for Reassembly (1) Replace the seal kit parts. (2) Clean all parts, making sure that each part is free from any dust. (3) Apply hydraulic oil to the cylinder bore, piston seal, Oring, packing and dust seal. (4) Wrap the cylinder tube with a wad or cloth, and hold it in a vise. Pay attention not to deform the cylinder. (5) Install the piston seal as follows: (a) Before fitting the piston seal, squeeze it by hand 5 or 6 times to soften it. (b) Wrap the piston rod with rag or cloth, and hold it in a vise. Pay attention not to deform the piston. Apply a small amount of hydraulic oil to the seal. Fit a portion of the seal to the groove, and push the other portion into the groove as shown.

200352

(6) Install the packing and dust seal to the bushing correctly.

204641

11-45

HYDRAULIC SYSTEM

Testing and Adjusting Hydraulic Oil Check the hydraulic oil in the tank for water-in-oil emulsion, and change the oil if its color has changed to as milky appearance. Remember, the oil appears as if it was emulsified with bubbles, when the oil is checked immediately after the hydraulic control levers were operated. • Suction strainer and return filter

Check for clogging or damage, and clean or replace the strainer and filter.

Gear Pump The purpose of test run is to break-in the overhauled pump and verify its performance. The use of a pump testing equipment, specially designed as such and commonly used in the service shop, is recommended but is not mandatory. The following procedure, however, assumes that the pump is installed on the truck: (1) Install a pressure gauge capable of measuring up to 25 MPa (250 kgf/cm2) [3626 psi] to the tap on the left side of the control valve. To install the pressure gauge, remove the plug from the delivery hose connector and attach the following tools:

Connector

64309 - 17734 (R (PT) 1/8 thread)

Hose

64309 - 17722

Connector

64309 - 17731 (for gauge) Pressure tap

Gauge

64309 - 17712 {25 MPa (250 kgf/cm2) [3626 psi])}

NOTE These tools are contained in the Gauge Kit 64309 17701.

(2) With the transmission shift levers in neutral, run the engine at 500 to 1000 rpm. The discharge pressure will not be higher than 981 kPa (10 kgf/cm2) [142 psi]. Run the pump under this condition for 10 minutes for breakin, listening for noise. 11-46

210499

HYDRAULIC SYSTEM

(3) Increase the engine speed to 1500 to 2000 rpm, and run the engine for another 10 minutes in the no-load condition. (4) With the pump being so run, loosen the adjusting screw, and shift the transmission shift levers into operating positions. Next, set the pressure to 3 MPa (30 kgf/cm2) [427 psi], and run the pump for 5 minutes at this pressure. Following this, increase the pressure by changing the setting of adjusting screw in increments of 2 MPa (20 kgf/cm2) [284 psi] and run the pump for 5 minutes at each increased pressure until, finally, the prescribed set pressure of the relief valve is reached. (5) Pay attention to the temperatures of oil and pump surfaces and to the running noise while increasing the pressure. If any abnormal condition is noticed, bring the pump to no-load condition to cool the oil or pump or, as necessary, discontinue the test run, and overhaul the pump once again. Do not keep on increasing the pressure when an abnormal condition is noticed. (6) After doing Steps (2) thru (5) above, reset the relief valve as specified and operate the forks and mast to see if the tilt and lift cylinders work with the specified speeds.

Control Valve • External leakage

(1) Check for oil leaks from the joint between adjacent valve housings sealed by O-ring. (2) Check for oil leaks from the scrapers sealed by Orings. (3) Check for oil leaks from the screw connections.

11-47

Adjusting screw

210500

HYDRAULIC SYSTEM

Main Relief Valve (1) Attach a pressure gauge capable of measuring up to 25 MPa (250 kgf/cm2) [3626 psi] to the tap on the left side of the control valve. Use the gauge, connectors and hose used for testing the gear pump.

Adjusting screw

(2) Start the engine and run it at the maximum speed. Move the tilt control lever to the backward tilt position. + 0.5 +5 If the pressure is relieved at 17.2 0 MPa (185 0 + 71 kgf/cm2) [2631 0 psi] when the tilt cylinders reach the end of their stroke, the main relief valve setting is correct. (3) If the setting is incorrect, loosen the lock nut of the adjusting screw and, while observing the pressure gauge reading, slowly run in the adjusting screw until the gauge indicates the prescribed set value.

NOTE One rotation of the adjusting screw changes the pressure by approximately 10.6 MPa (108 kgf/cm 2) [1536 psi].

(4) While holding the adjusting screw, tighten the lock nut to secure the adjusting screw. (5) After securing the adjusting screw, recheck the setting.

+ 0.5

Main relief valve setting

17.2 0 MPa +5 (185 0 kgf/cm2) + 71 [2631 0 psi]

11-48

210500

HYDRAULIC SYSTEM

Priority Relief Valve (1) Set up a pressure gauge capable of measuring up to 25 MPa (250 kgf/cm2) [3626 psi] as shown.

205542

Ref. Tool Name No.

Part No.

Connector

91268 - 01700

Connector

64309 - 17733 [R(PT) 1/8 thread]

Hose

64309 - 17722

Connector

64309 - 17731 (for gauge)

Gauge

64309 - 17712 {25 MPa (250 kgf/cm2) [3626 psi]}

3 2 1

205543

NOTE (1) The tools 2 thru 5 are contained in the Gauge Kit 64309 - 17701. (2) Use the gauge contained in this gauge kit.

(2) Start the engine. With the engine running at the maximum speed, turn the steering wheel counterclockwise to the + 0.5 +5 lock. If the pressure is relieved at 11.8 0 MPa (120 0 + 71 kgf/cm2) [1707 0 psi], the priority relief valve setting is correct.

Adjusting plug

(3) If the setting is incorrect, disconnect the line from the T port of the priority valve and turn the adjusting plug of the relief valve in either direction.

NOTE One rotation of the adjusting plug changes the pressure by 7.4 MPa (75 kgf/cm2) [1067 psi]. 11-49

210205

HYDRAULIC SYSTEM

Overload Relief Valve (Option) (1) Attach a pressure gauge capable of measuring up to 25 MPa (250 kgf/cm2) [3626 psi] to the tap on the left side of control valve.

Overlord relief valve

NOTE Use the same tools as used for adjusting the main relief valve.

(2) Start the engine. With the engine running at the maximum speed, move the auxiliary control lever forward or backward. If the pressure is relieved when the actuator moves to the end of its stroke, the overload relief valve setting is correct. (3) If the setting is incorrect, loosen the lock nut of the adjusting screw and, while observing the pressure gauge reading, turn the adjusting screw. (4) While holding the adjusting screw, tighten the lock nut to secure the adjusting screw. (5) After securing the adjusting screw, recheck the setting.

11-50

210501

HYDRAULIC SYSTEM

Lift Cylinder Drift (1) Pick up a load equal to the rated capacity, tilt the mast to vertical position, lift the forks 1 to 1.5 m (3.3 to 4.9 ft) from the floor, and stop the engine. (2) Mark a reference line on the mast, and measure the amount of lift cylinder drift (retraction of the piston rods) for 15 minutes. Unit: mm (in.) Maximum amount of lift cylinder drift (retraction of piston rods) with rated load for 15 minutes

DP100 DP115 DP135 DP150

: 40 (1.6) : 45 (1.8) : 38 (1.5) : 42 (1.7)

210502

Tilt Cylinder Drift (1) Pick up a load equal to the rated capacity, tilt the mast to vertical position, lift the forks about 50 cm (20 in.) from the floor, and stop the engine. (2) Measure the amount of tilt cylinder drift (extension of the piston rods) for 15 minutes. Unit: mm (in.) Maximum amount of tilt cylinder drift (extension of piston rods) with rated load for 15 minutes

DP100 DP115 DP135 DP150

: 41 (1.6) : 47 (1.9) : 35 (1.4) : 39 (1.5) 210503

11-51

HYDRAULIC SYSTEM

Troubleshooting Not enough oil in hydraulic tank Oil viscosity improper Overload

Hydraulic tank heats excessively

Hydraulic tank

Cylinders move too slow

Local overheating of oil line due to a large restriction to flow Relief valve adjustment improper Gear pump worn Discharge-side pipe or tube flattened, or restriction to flow Clogged oil cooler Shortage of oil due to a natural loss Oil leakage due to damaged oil line and seals Oil viscosity too high Gear pump not pulling oil Oil leakage from oil line

Cylinders move too slow

Noisy

Abnormal oil temperature rise

Gear pump internally leaking Poor pumping Cavitation

Gear pump

Pump case, drive gear or pump port flange damaged

Oil leakage from pump

Pressure too high Distortion or damage due to external strain or stress

Oil leakage past oil seal Oil leakage past sliding surfaces of drive shaft Pump securing bolts loose Excessive internal leakage

Refill. Change oil. * Check working conditions and, if overloaded, urge the operator to stay within the load limit. Clean. Readjust pressure setting. Replace. Repair or replace. Clean Refill. * Repair or replace. Change oil. * Check pump and piping; repair or replace. Check oil level and condition; add or change oil. Check control valve spools for misalignment; repair or replace. Replace pump. Refill. * 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. Replace pump. (Check to see if relief valve setting is correct.) Replace pump. 1) Check to see if return line is restricted. 2) Check to see if pipe connections have been externally strained or stressed. Replace seal. Replace pump assembly. Retighten. Replace O-ring.

* (Refer to “Recommended Brands of Lubricants.”) 11-52

HYDRAULIC SYSTEM

Slow or no motion of lift and tilt cylinders

Control valve

Excessive drift of lift or tilt cylinders with transmission shift lever in neutral

Relief valve setting too low Relief valve piston sticking

O-ring in relief valve body damaged Control lever installed loose, resulting in not enough spool stroke

Readjust. Wash piston and check to see if it moves freely; or replace relief valve assembly. Replace O-ring. Readjust.

Control valve internally leaking

Replace a leaky block assembly.

Oil leakage from spool ring cap

Replace O-ring; check spool for flaws and if any, repair or replace a leaky block assembly. Retighten. Replace.

Oil leakage Loose plugs O-ring damaged

Will not lift nor tilt

Not enough oil in hydraulic tank Relief valve out of order, because of: • Stuck main relief valve • Broken valve spring Gear pump defective

Replace. Replace. Replace.

Will not lift rated load

Relief valve out of order, because of: • Too low a relief valve setting • Defective plunger or poppet seat • Weak spring • Damaged O-ring in valve case Gear pump defective Piston seals worn or damaged

Readjust. Replace. Replace. Replace O-ring. Replace. Replace.

Lifting speed is too low

Engine speed too low Control lever installed loose, resulting in not enough spool stroke Tank strainer clogged Pump not delivering enough oil

Tune up. Adjust.

Sleeve stuck in flow regulator valve Dirt in flow regulator valve, abnormal hose or resistance to flow due to flattened local clogging

Repair. Clean, repair system and replace defective hose.

Piston rod distorted Air in oil circuit

Repair or replace. Bleed air by operating cylinder through full stroke. Refill.

Lift and tilt cylinders

Lowering speed is too low

Cylinder vibrates when actuated

Not enough oil in hydraulic tank

Refill. *

Clean or replace. Repair or replace.

* (Refer to “Recommended Brands of Lubricants.”) 11-53

HYDRAULIC SYSTEM

Control valve spool internally leaking Sliding (inside) surface of cylinder tube slightly grooved Sliding (inside) surface of cylinder tube badly grooved Piston seals broken or distorted Oil leakage from piping

Replace a leaky block assembly. Repair or replace.

Control valve spool internally leaking Foreign particles lodged between packing and mating surface Piston seals damaged Cylinder distorted or oil leakage from hydraulic pipes

Replace a leaky block assembly. Replace packing.

Lift cylinders or tilt cylinders drift excessively at a certain point of stroke

Sliding surface of cylinder tube badly grooved or rusted at one point Cylinder tube distorted

Repair or replace.

Bushing leaks

Foreign particles lodged between sealing members such as oil seals and dust seals Oil seals and dust seals defective O-rings damaged Cylinder distorted

Excessive drift of lift cylinder

Excessive drift of tilt cylinders Lift and tilt cylinders

11-54

Replace cylinder assembly. Replace seal kit. Repair or replace.

Replace. Repair or replace.

Replace. Replace.

Replace. Replace. Repair or replace.

HYDRAULIC SYSTEM

Service Data A: Standard value Unit: mm (in.) Truck Model DP100

DP115

DP135

DP150

330 (65)

340 (67)

290 (57)

280 (55)

Item Lift speed (rated load) [simplex mast] (with engine at maximum speed)

mm/sec (fpm)

Lift speed (no load) (with engine at maximum speed)

mm/sec (fpm)

Lowering speed (rated load) [simplex mast] (with engine at maximum speed)

mm/sec (fpm)

A A

360 (71)

310 (61)

450 (89)

380 (75)

Forward tilt angle [standard model with simplex mast]

15°

Backward tilt angle [standard model with simplex mast]

12°

Amount of lift cylinder drift (rated load) for 15 minutes [Oil temperature: 50°C (122°F)]

40 (1.6)

45 (1.8)

38 (1.5)

42 (1.7)

Amount of tilt cylinder drift (rated load) for 15 minutes [Oil temperature: 50°C (122°F)]

41 (1.6)

47 (1.9)

35 (1.4)

39 (1.5)

Priority relief valve setting

MPa (kgf/cm2) [psi]

11.8 (120) [1707]

Output

liter (U.S. gal.)/rpm

205 (54)/2200

Tightening torque for bolts and nuts 1 N·m (kgf·m) [lbf·ft]

60 (6.1) [44]

Tightening torque for delivery hose flange bolts 2 N·m (kgf·m) [lbf·ft]

76 (7.8) [56]

Tightening torque for cover bolt 3 N·m (kgf·m) [lbf·ft]

109 to 123 (11.1 to 12.5) [80 to 90]

Gear pump

1 210504

11-55

HYDRAULIC SYSTEM

A: Standard value Unit: mm (in.) Truck Model DP100

DP115

DP135

DP150

Item Main relief valve setting 1 MPa (kgf/cm2) [psi] Spool operating effort 2

17.2

+ 0.5 0

(175

+5 0

) [2489

+ 71 0

]

294 (30) [66], maximum

Tightening torque for tie bolts 3 N·m (kgf·m) [lbf·ft]

98 to 118 (10 to 12) [72 to 87]

Tightening torque for control valve bolt 4 N·m (kgf·m) [lbf·ft]

60 (6.1) [44]

N (kgf) [lbf]

Control valve

1 4

210505

Relief valve pressure 1 MPa (kgf/cm2) [psi] Tightening torque for plug 2 N·m (kgf·m) [lbf·ft] Tightening torque for relief valve 3 N·m (kgf·m) [lbf·ft]

11.8 (120) [1707]

44.1 (4.5) [33]

21 (2.1) [15]

Priority valve 2

2 1

3 210506

11-56

HYDRAULIC SYSTEM

A: Standard value Unit: mm (in.) Truck Model DP100

DP115

DP135

DP150

Item Tightening torque for return filter 1 N·m (kgf·m) [lbf·ft]

49 (5) [36]

Tightening torque for suction strainer 2 N·m (kgf·m) [lbf·ft]

49 (5) [36]

Tightening torque for drain plug 3 N·m (kgf·m) [lbf·ft]

177 to 196 (18 to 20) [131 to 145]

Hydraulic tank

1 2

210507

Control flow (no load)

liter [U.S. gal.]/min

Tightening torque for plug 1 N·m (kgf·m) [lbf·ft]

150 (40)

343 (35) [253]

Flow regulator valve

210508

11-57

HYDRAULIC SYSTEM

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item A

115 (4.53)

125 (4.92)

115.14 (4.53331)

125.16 (4.9275)

Inside diameter of cylinder tube 1 Deflection of piston rod 2 (1/2 of dial indicator reading) Lift height 3000 to 5000 (118 to 197) Diameter of piston rod 3 Lift cylinders

Lift height 5500 to 7000 (217 to 276)

0.5 (0.020)

60 (2.36)

59.84 (2.3559)

75 (2.95)

74.84 (2.9465)

210633

11-58

HYDRAULIC SYSTEM

A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item A

120 (4.72)

130 (5.12)

120.12 (4.7291)

130.12 (5.1228)

Inside diameter of cylinder tube 1 Diameter of piston rod 2 (guide bushing side)

55 (2.17)

0.1 (0.004)

0.2 (0.008)

+ 0.00394 60 ++ 0.100 0.070 (2.36 + 0.00276 )

60.6 (2.386)

Clearance between rod and guide bushing Inside diameter of bushing 3 (as installed)

Tilt cylinders

Tightening torque for guide busing 4 N·m (kgf·m) [lbf·ft]

637±64 (65±6.5) [470±47]

696±69 (71±7) [514±51]

1275 + 049

1520 + 098

Tightening torque for self-locking nut 5 N·m (kgf·m) [lbf·ft]

Tightening torque for socket nut 6

1177 to 1471 (120 to 150) [868 to 1085]

60 − 00.046 (2.36 − 00.00181 )

59 (2.32)

Tightening torque for tilt cylinder pin mounting bolts 8 N·m (kgf·m) [lbf·ft]

33 (3.4) [25]

Deflection of piston rod 9 (1/2 of dial indicator reading)

0.5 (0.020)

Diameter of tilt cylinder pin 7

(130

+5 0

[940

+ 36 0

) ]

(155

+ 10 0

[1121

+ 72 0

) ]

8 210510

11-59

MASTS AND FORKS Specifications ........................................................................................12 – 1 Description .............................................................................................12 – 2 Removal and Installation ......................................................................12 – 3 Removal ................................................................................................12 – 3 Installation .............................................................................................12 – 6 Mast Assembly ........................................................................................12 – 7 Disassembly...........................................................................................12 – 7 Inspection ..............................................................................................12 – 9 Reassembly .......................................................................................... 12 – 11 Adjusting ............................................................................................... 12 – 15

Troubleshooting ..................................................................................... 12 – 19 Service Data ........................................................................................... 12 – 20

MASTS AND FORKS

Specifications Truck Model DP100

DP115

DP135

DP150

Item Mast type

Mast dimensions (flange width x thickness x web thickness) mm (in.)

Outer

205 x 32 x 25 (8.07 x 1.26 x 0.98)

Inner

Bearing type Main rollers

Diameter x width

Ball 205 x 52 (8.07 x 2.05)

mm (in.)

Bearing type Side rollers

Lift chains

Diameter x width

Needle roller (lubricating) 58 x 40 (2.28 x 1.57)

mm (in.)

Model

EKBL-1434

Fork dimensions (length x width x thickness) mm (in.) Fork spacing (outside)

205 x 36 x 28 (8.07 x 1.42 x 1.10)

1220 x 180 x 70 (48 x 7 x 3.5)

mm (in.)

EKBL-1634 1220 x 180 x 90 (48 x 7 x 3.5)

770 to 2030 (30 to 80)

12-1

MASTS AND FORKS

Description

A 7

7 3 1

6 6

Section A-A

Section B-B

210730

1. 2. 3. 4.

Inner mast Outer mast Lift chain Lift bracket

5. Mast support bearing cap 6. Cross rollers 7. Mast strip

12-2

MASTS AND FORKS

Removal and Installation Removal Mast and Lift Bracket Assembly 4

1 2

3 5

Sequence 4. Tilt cylinder pin 5. Mast support bearing cap, Bushing

1. Forks, Lift bracket 2. Low-pressure (return) hose for lift cylinders 3. High-pressure hose for lift cylinders

12-3

210731

MASTS AND FORKS

Suggestions for Removal 1. Lift bracket removal

(1) Pull the split pin and remove the anchor nut and lock nut from the lift chain on each side. (2) Fasten an approximate 3 meter (10 ft) long rope to the ends of the lift chains. (3) Start the engine and raise the inner mast by operating the lift control lever until the lift bracket main rollers are free, with the lift chains pulled down. (4) Move the truck backward to separate the lift bracket (fork positioner) from the truck. 210514

210515

2. Lift cylinder low-pressure (return) hose removal

(1) Start the engine and extend the mast fully. Stop the engine and disconnect the hoses at the return connectors.

Low-pressure hose removal

(2) Lower the mast. 3. Lift cylinder high-pressure hose removal

Return connector

Relieve the pressure in the lift cylinder circuits by moving the lift control lever back and forth. Disconnect the highpressure hoses from the lift cylinder.

High-pressure hose removal 210516

12-4

MASTS AND FORKS 4. Tilt cylinder removal

(1) Attach lifting hooks to the top crossmember of the outer mast. Fasten a hoist to these hooks and support the mast assembly.

NOTE Be sure to use a hoist of the correct capacity to lift the mast assembly.

Unit: kg (lb) Truck Model

210517

Weight — approximate

DP100

1950 (4300)

DP115

1950 (4300)

DP135

2170 (4800)

DP150

2410 (5300)

(2) Remove the tilt pin, and separate each tilt cylinder from the mast. (3) Start the engine and place the tilt lever in the tilt rearward position to retract the tilt cylinder rod. Then stop the engine.

210518

5. Mast support bearing cap removal

(1) Put marks across the supports and bearing caps. (2) Remove the bolts that hold the caps and remove the caps. Then remove the mast from the truck.

NOTE Lay the mast assembly on a level floor large enough to permit free sliding of the mast for disassembly. 210519

12-5

MASTS AND FORKS

Installation For installation, follow the reverse of removal sequence and do the following steps. Mast cap

1. Mast support bushing 5 and cap 5 mounting procedures

Bushing

(1) Apply grease to the inside surfaces of the cap and the mast support bushing. (2) Install mast support bushing 5 and cap 5 with their larger chamfered sides toward the center of the truck.

Apply grease. Chamfered

(3) Firmly tighten the support tightening bolts.

210537

Tightening torque for bolts

490 N·m (50 kgf·m) [362 lbf·ft]

2. Adjustment of chain tension

Adjust the tension of the chain. (Refer to the section on “Adjusting and Checking” as follows.) Tighten the nuts to the specified torque.

Anchor bolt

2 Upper nut

Tightening torque of upper nut and double nut (lower)

392 N·m (40 kgf·m) [289 lbf·ft]

102709

3. Bleeding lift cylinder

Start the engine and bleed the lift cylinder by lifting it up to the maximum height and then down to the floor repeatedly several times. 4. Oil level check

After confirmation of operation, check the oil level.

12-6

Double nut (upper)

Double nut (lower)

MASTS AND FORKS

Mast Assembly Disassembly

B 9

13 9

1 4

A B

6 18

4 11 210732

Sequence 1. 2. 3. 4. 5. 6. 7. 8. 9.

Lift chains, Nuts, Split pins Lift bracket Stopper plates, Guide bars Forks, Fork retainer Main rollers, Side rollers, Bolts, Nuts, Snap rings, Pins Hoses, Elbow, O-rings Hoses, Clamps, Bolts, Connectors Cylinder clamps, Bolts, Seats, Shims, Cushions, Collars Bolts, Shims, Washers

10. Lift cylinders, Flow regulator valve 11. Main rollers, Side rollers, Snap rings, Side roller shims, Pins 12. Bolts, Nuts 13. Main rollers, Side rollers, Snap rings, Side roller shims, Pins 14. Chain wheel supports 15. Inner mast 16. Chain wheels, Pins, Spacers, Collars, Bearings 17. Mast strips, Shims 18. Outer mast

12-7

MASTS AND FORKS

Suggestion for Disassembly Inner mast removal

(1) The cylinder stroke is adjusted by means of the shims fitted to the rod end. Before disassembling, write down a cylinder on which shim adjustment has been made and the amount of shims used. (2) Remove the bolts that holds the cylinder clamp to free each cylinder. Retract the piston rods fully and cross the top ends of the cylinders. Shims

210521

(3) Slide the inner mast toward the bottom of the outer mast. Remove the main rollers, side rollers and mast strips from the outer mast and the main and side rollers from the inner mast. (4) After removing the main rollers and the side rollers, slide the inner mast out the top of the outer mast.

210522

12-8

MASTS AND FORKS

Inspection 1. Mast

(1) Check each roller for binding, wear or cracks. (2) Check each roller for flat spots on rolling surface. (3) Check the mast member and the welds of crossmembers, pins and supports for cracks. (4) Check the mast support bushings for wear or other defects.

210523

2. Lift bracket

(1) Check the main and side rollers for binding, wear or cracks. (2) Check the welds for cracks. (3) Check the guide bars for distortion.

Guide bar

210733

3. Chains, chain wheels and chain wheel supports

(1) Measure the length of each chain to make sure that two chains are equal in length. Also check the chains for wear, breakage, link binding or twist. A: Standard value Truck Model

DP100, DP115, DP135

DP150

889 (35)

1016 (40)

915 (36)

1046 (41)

Item Length of lift chain (20 links)

B: Repair or service limit Unit: mm (in.)

(2) Check the chain anchor bolts for cracks or damaged threads. (3) Check the chain wheel supports and chain wheels for cracks or wear. Also check the wheels for binding.

12-9

MASTS AND FORKS 4. Mast strips

Check the mast strips for damage, scratching or distortion. A: Standard value

Thickness of mast strips

B: Repair or service limit Unit: mm (in.)

9 (0.35)

7 (0.28)

5. Forks

(1) Carefully inspect the forks for cracks. Special attention should be given to the heel section A, all weld areas and mounting brackets B. Forks with cracks should be removed from service. The magnetic particle inspection is generally preferred due to its sensitivity and the ease of interpreting the results.

A 101628

(2) Check the difference in height of one fork tip to the other when mounted on the fork carrier. A difference in fork tip height can result in uneven support of the load and cause problems when loaded. The maximum allowable difference in fork tip elevation C is 5 mm (0.20 in.) for pallet forks. Replace one or both forks when the difference in fork tip height exceeds the maximum allowable difference.

101629

(3) Check the fork blade D. The fork should be withdrawn from service if the thickness is reduced to less than the allowable thickness. Fork blade length may also be reduced by wear, especially on tapered forks and platens. Withdraw the forks from service when the blade length is no longer adequate for the load size. A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model

DP100, DP115

DP135, DP150

70 (2.76)

90 (3.54)

56 (2.20)

79 (3.11)

Item Thickness of blade D

12-10

101630

MASTS AND FORKS

Reassembly Follow the reverse of disassembly sequence and do the following steps: 1. Longitudinal clearance between lift bracket and inner mast and between inner mast and outer mast

Select main rollers of the size that will provide the specified clearance at M and P over the whole lift range of the mast.

Inner mast

Outer mast

Lift bracket

Unit: mm (in.)

0.5 to 2.8 (0.020 to 0.110)

Clearance at M, P

210526

If the clearance is out of the specification, replace the main roller referring to the sizes below. Unit: mm (in.) Size S

203 (7.99)

Main roller sizes Size M

205 (8.07)

Size L

207 (8.15)

2. Mast strip installation

(1) Mast strips are used to limit the longitudinal clearance between the inner and outer masts. L

Unit: mm (in.) Clearance L

0.5 to 1.5 (0.020 to 0.059) Mast strip

210527

(2) If the clearance L exceeds the specification, adjust it by means of shim(s).

210528

12-11

MASTS AND FORKS 3. Lateral clearance between outer and inner masts

(1) Measure the distance A between the side rollers, left and right, of the outer mast, and adjust this distance to the specification.

Unit: mm (in.) Truck Model Item Distance A

DP100, DP115, DP135

DP150

754±0.5 (29.69±0.020)

748±5 (29.45±0.020)

210529

NOTE Measure the distance A between the innermost points of the rollers.

(2) Measure the distance B between the side rollers, left and right, of the inner mast, and adjust this distance to the specification.

Unit: mm (in.) Truck Model Item Distance B

DP100, DP115, DP135

DP150

890±0.5 (35.04±0.020)

884±0.5 (34.80±0.020)

210530

NOTE Measure the distance B between the outermost points of the rollers.

(3) At the maximum fork height, push the inner mast to one side of the outer mast and check clearance K with feeler gauges on the other side. Unit: mm (in.) Clearance K

0.5 to 1.5 (0.020 to 0.059)

K 210531

12-12

MASTS AND FORKS

• To adjust the clearance K on the upper side of the mast, loosen the lock nut for the side roller bracket adjusting bolt and turn the adjusting bolt.

Adjusting bolt

205585

• To adjust the clearance K on the lower side of the mast, remove the side roller and increase or decrease the amount of the shims.

Shims

210532

4. Lateral clearance between lift bracket and inner mast

(1) Measure the distance C between the side rollers. Unit: mm (in.) Truck Model Item Distance C

DP100, DP115, DP135

DP150

704±0.5 (27.72±0.020)

692±0.5 (27.24±0.020) 210533

12-13

MASTS AND FORKS

(2) At the maximum fork height, push the bracket to one side of the inner mast and check clearance N with a feeler gauge on the other side. Unit: mm (in.) Clearance N

0.5 to 1.5 (0.020 to 0.059)

N 210534

• To adjust the clearance N, loosen the lock nut for the side roller bracket adjusting bolt and turn the adjusting bolt.

Adjusting bolts

Adjusting bolts 210734

5. Cylinder clamps

Shim each lift cylinder so that it is in vertical position in the mast. Unit: mm (in.) Thickness of shim(s)

Shims

3.2 (0.126)

210536

6. Mast supports

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

Mast cap

(2) Install the mast support bushings and caps with beveled side toward the center of the truck. Greasing will be facilitated if the mast is kept lifted from the floor with wood blocks.

Tightening torque for cap bolts

490 N·m (50 kgf·m) [362 lbf·ft]

Bushing

Apply grease. Chamfered

12-14

210537

MASTS AND FORKS 7. Precautions for installing chain anchor kit

Take care not to install the center plate in the position for the link plate.

1 4

Marking 200383

1. 2. 3. 4.

Link plate (marked) Center plate (not marked) Link Split pin

Adjusting 1. Adjusting tension of chain Anchor bolt

(1) On a flat ground surface, place the mast in the upright position and lower the fork down to the ground surface, and check that the lift cylinder is in its shortest position. (2) Loosen double nut (lower)

and upper nut

(3) Position the anchor bolt with double nut (upper)

2 Upper nut

. ! .

(4) Raise the fork slightly above the ground surface and adjust the chain tension so that the two chains will be about equally tight when checked by alternately pressing the right and left ones at the mid point between the chain wheel and chain fixed end.

102709

To adjust the chain tension by double nut (upper) ! , tilt the mast forward to slacken the chain. By so doing, the chain tension will be easier to adjust.

102708

12-15

Double nut (upper)

Double nut (lower)

MASTS AND FORKS

(5) After adjustment of the chain tension by double nut (upper) ! , set a spanner on upper nut and tighten it to the specified torque. (6) Set a spanner on double nut (upper) ! and tighten double nut (lower) to the specified torque.

Tightening torque for nuts of anchor bolts

392 N·m (40 kgf·m) [289 lbf·ft]

Anchor bolt

210538

(7) Check to ensure that when the lift cylinder is in its shortest position, the protrusion of the lift bracket main roller is less than 40% of the roller diameter.

40 % or less 207652

(8) After final adjustment, check the tension with the mast in vertical position.

2. Longitudinal and lateral clearances between lift bracket and inner mast

(1) Check these clearances and adjust them if necessary. (2) Check the longitudinal clearance with a feeler gauge. (3) Check the lateral clearance with a dial indicator. Set the dial indicator on the inside face of the inner mast, with its spindle put to the side face of the lift bracket. Insert a bar into between the lift bracket and inner mast and pry the lift bracket laterally to check the clearance. (4) To adjust the clearance, remove the lift bracket and adjust the rollers. (5) If the longitudinal clearance of the main rollers exceeds the limit, replace the rollers with oversize main rollers.

12-16

204691

MASTS AND FORKS

(6) If the lateral clearance of the side rollers is incorrect, make an adjustment. • To adjust the clearance N, loosen the lock nut for the side roller bracket adjusting bolt and turn the adjusting bolt. Adjusting bolts

Adjusting bolts 210735

3. Tilt angle

(1) Adjust the tire pressure correctly, and park the truck on a level floor. (2) Tilt the mast fully backward, and stop the engine. (3) Measure the backward tilt angle of the mast at both sides. (4) To adjust the tilt angle, loosen the lock nut of the tilt cylinder rod, and turn the rod so that there is no difference in stroke tilt angle between the left and right cylinders. 210541

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

Forward – backward tilt angle

15° – 12° (standard)

12-17

MASTS AND FORKS

(5) After having adjusted the tilt angle, tighten the lock nuts to the specified torque.

Tightening torque for tilt cylinder lock nuts

1177 to 1471 N·m (120 to 150 kgf·m) [868 to 1085 lbf·ft]

5. Lift cylinder stroke

(1) Slowly raise the inner mast, and observe how the piston rods, left and right, stop at the moment the inner mast reaches its maximum height. (2) If the top of the inner mast jolts at that moment, make a shim adjustment. Abnormal condition can be detected by a little time lag in stopping between the piston rods, left and right, and jolting of the rod with a longer cylinder stroke.

NOTE

210542

The maximum permissible amount (thickness) of the shims is eight [8 mm (0.31 in.)].

Adjusting method

(1) Raise the inner mast, put wood blocks under the left and right sides of the mast, and lower the mast until it rests on the blocks. Use the blocks strong enough to support the inner mast.

202983

(2) Remove the stopper bolt at the top of a lift cylinder which stopped first, retract the piston rod, and insert shim(s) at the top of the piston rod of that cylinder. (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 to the bottom to ensure the piston rods move freely.

Shims

210543

12-18

MASTS AND FORKS

Troubleshooting

Lift bracket and inner mast will not move freely

Lift bracket or inner mast binds

Mast makes noise

Excessive lift cylinder piston rod drift

Mast shakes entirely

Mast is distorted

Fork tips uneven in height

Lateral and longitudinal clearances of main rollers and side rollers incorrect

Readjust.

Rollers binding on their shafts

Relubricate or replace.

Lift chains jerky in movement

Relubricate or replace.

Mast strip clearance incorrect

Shim adjust.

Too much clearance on side rollers

Shim adjust.

Lift chains unequally tensioned

Readjust.

Shim adjustments unequally made on between left and right lift cylinders (at maximum height)

Readjust.

Rollers not rotating freely on their shafts

Readjust or replace.

Lift cylinder packing damaged

Replace.

Sliding (inside) surface of lift cylinder tube damaged

Replace.

Mast-support bushings worn

Retighten or replace.

Off-center loading or overloading

Replace mast assembly.

Guide bar bent

Repair or replace.

Forks bent

Repair or replace.

Mast distorted

Repair or replace.

12-19

MASTS AND FORKS

Service Data A: Standard value

B: Repair or service limit Unit: mm (in.)

Truck Model DP100

DP115

DP135

DP150

Item Unevenness of two fork tips

5 (0.20), maximum

70 (2.76)

90 (3.5)

56 (2.20)

79 (3.1)

Thickness of forks Forks and chains

Rollers

889 (35)

1016 (40)

915 (36)

1046 (41)

Tightening torque for nuts of lift chain anchor bolt N·m (kgf·m) [lbf·ft]

392 (40) [289]

Size S

203 (7.99)

Size M

205 (8.07)

Size L

207 (8.15)

58 (2.28)

Diameter of main roller

Diameter of side rollers

Outer mast

Inner mast

Lift bracket and inner mast

A Length of lift chain (20 links)

890 +− 0.5 1.0 (35.04 +− 0.020 0.039 )

884 +− 0.5 1.0 (34.80 +− 0.020 0.039 )

890 +− 1.0 0.5 (35.04 +− 0.039 0.020 )

884 +− 0.5 1.0 (34.80 +− 0.020 0.039 )

754±0.5 (29.69±0.020)

748±0.5 (29.45±0.020)

704 +− 0.5 1.0 (27.72 +− 0.020 0.039 )

692 +− 0.5 1.0 (27.24 +− 0.020 0.039 )

704 +− 1.0 0.5 (27.72 +− 0.039 0.020 )

692 +− 0.5 1.0 (27.24 +− 0.020 0.039 )

890±0.5 (35.04±0.020)

884±0.5 (34.80±0.020)

Clearance P (over the whole lift range)

0.5 to 2.8 (0.020 to 0.110)

Clearance K (at minimum lift height)

0.5 to 1.5 (0.020 to 0.059)

Mast strip clearance L

0.5 to 1.5 (0.020 to 0.059)

Lift bracket C

704±0.5 (27.72±0.020)

Clearance M (over the whole lift range) A

0.5 to 2.8 (0.020 to 0.1102)

Clearance N (at maximum lift height)

0.5 to 1.5 (0.020 to 0.059)

Tightening torque for mast cap bolts N·m (kgf·m) [lbf·ft]

490 (50) [362]

12-20

692±0.5 (27.24±0.020)

MASTS AND FORKS

Truck Model DP100

DP115

DP135

DP150

Item

Inner mast

Lift bracket

Inner mast Outer mast

L Y2 B Mast strip

N X1

Inner mast Outer mast N A

Outer mast

Lift bracket

210544

12-21

HYDRAULIC FORK POSITIONER Applicable Attachment Model .............................................................13 – Specifications ...........................................................................................13 – Structure ....................................................................................................13 – Removal and Installation .......................................................................13 –

1 1 2 3

Fork Positioner Assembly ..........................................................................13 – 3 Removal................................................................................................13 – 3 Inspection and Correction .....................................................................13 – 6 Installation.............................................................................................13 – 6 Fork Positioner Cylinder ............................................................................13 – 7 Disassembly..........................................................................................13 – 7 Inspection and Correction .....................................................................13 – 8 Reassembly .......................................................................................... 13 – 10

Inspection and Adjustment................................................................... 13 – 11 Troubleshooting ....................................................................................... 13 – 12 Service Data.............................................................................................. 13 – 13

HYDRAULIC FORK POSITIONER

Applicable Attachment Model Applicable Truck Attachment Model

Model

Designation – Serial No.

Applicable Mast Model

Mast Piping

3P115C Simplex

Side pulley type

DP100

3DP – 10011-up

DP115

4DP – 10011-up

3FP135CM

DP135

5DP – 10011-up

3P135C Simplex

Side pulley type

3FP150CM

DP150

6DP – 10011-up

3B150C Simplex

Side pulley type

3FP115CM

Specifications Unit: mm (in.) Attachment Model 3FP115CM

3FP135CM

3FP150CM

Item W2050 Stroke (each side)

W2200

767 (30.20) 842 (33.2)

W2300 W2400

— 892 (35.1)

—

Load center

942 (37.1) 600 (23.6)

Free lift

Outside fork spread (maximum)

Outside fork spread (minimum)

W2050

2008 (79.1)

W2200

2258 (88.9)

W2300

2258 (88.9)

—

W2400

—

2358 (92.8)

W2050

482 (19.0)

W2200

482 (19.0)

W2300

482 (19.0)

—

W2400

—

582 (22.9)

Mast tilt angle (forward – backward)

15° – 12°

Type of forks

Heel free

Length Forks

892 (35.1)

Width x thickness

Front overhang (with standard fork)

1220 (48.0) 180 x 70 (7.1 x 2.8) 754 (29.7)

13-1

180 x 90 (7.1 x 3.5) 793 (31.2)

795 (31.3)

HYDRAULIC FORK POSITIONER

Structure

5 3 2 1

210160

1. 2. 3. 4.

Lift bracket Side roller Main roller Fork

5. Mast 6. Piping 7. Fork positioner cylinder

A fork positioner is a device that can adjust steplessly the spacing between the maximum position and minimum position of outer width of two forks. It is necessary to change the spacing between the forks to safely transport loads of varying sizes. For large trucks using heavy forks, a hydraulic cylinder is used for changing the position of the forks, allowing the forks to be smoothly adjusted. The positioner, which adjusts the spacing before picking up a load, cannot shift the raised load from side to side. Fork positioner cylinders are installed between the fork bracket and the lift bracket, and slide the forks side to side by expansion and contraction of the cylinders. The right and left forks can be adjusted independently. 13-2

HYDRAULIC FORK POSITIONER

Removal and Installation Fork Positioner Assembly Removal

3 6 8

2 2

1 1

210161

Sequence 1. 2. 3. 4. 5.

Hose Fork positioner cylinder Lift bracket Guide bar Fork

6. Fork bracket 7. Main roller (If no abnormality is found, do not disassemble it.) 8. Side roller (If no abnormality is found, do not disassemble it.)

Start by:

(a) Start the engine and extend the spacing of the forks to the full adjustable width. (b) Place forks on a flat place with the mast vertically positioned, and put a wood block under the lift bracket.

13-3

HYDRAULIC FORK POSITIONER Removal of fork positioner cylinder

1. Stop the engine and hang a sling on the fork positioner cylinder 1 to keep it suspended with a crane. 1

2. Remove the split pin 2, and then, remove the slotted nut 3 and spherical nut 4 on the rod. 3. Start the engine and fully contract the fork positioner cylinder 1.

4. Stop the engine and move the fork positioner lever back and forth several times to remove residual pressure in the circuit.

5. Disconnect the hydraulic hoses 5 (four hoses).

5 6

6. Disconnect the hydraulic hoses from the pulley and connect the connector whose both ends are G1/2B to secure the oil closed circuit. Be sure to connect hoses A and A, and B and B, as shown in the illustration on the right. 7. Remove the split pin 2, and then, remove the slotted nut 3 and spherical nut 4 on the tube. 8. Suspend the fork positioner cylinder with a crane to remove. Be careful not to lose the spacer 6 and the spherical seat 7, as these may fall off.

13-4

210162

HYDRAULIC FORK POSITIONER Removal of Lift Bracket

1. Remove the split pin of the lift chain, and then, remove anchor nuts and locknuts. 2. Bind the end of the lift chain with a rope. Make allowance of approx. 1 m (3.3 ft) at the end of the rope. 3. Bind four hoses in the same manner. Make allowance of approx. 1 m (3.3 ft) at the end of the rope. 4. Start the engine, and raise up the inner mast to the position where the main roller of the lift bracket is removed. At this point, pull the attached rope downward to stretch the lift chain and hoses taut so that they will not come off the chain wheel and hose reels. 5. When raising the inner mast to the position where the main roller of the lift bracket can be removed from the inner mast, back up the truck, and separate the lift bracket from the truck. WARNING While the mast is rising, never touch any operating levers except for the lift lever.

210655

Removal of Fork

1. As the fork 1 becomes unstable when removed, place blocks to prevent it from falling down. 2. Remove the stopper plate 2 and pull out the guide bar 3 from the lift bracket 4. Be careful not to lose the shim 5, as it may fall off.

5 2 3

3. When pulling out the guide bar 3 halfway through the fork 1, support the fork bracket 6 to prevent it from falling off.

1 210164

13-5

HYDRAULIC FORK POSITIONER

Inspection and Correction 1. Lift bracket

(1) Check the main roller and side roller for sticking, wear, and cracks. If any abnormality is found, replace with a new one. (2) Check the welded part of the lift bracket for cracks. 2. Fork

Check the forks for bend, irregular tips, and cracks. 3. Hose

Replace hoses every two years.

Installation To install, follow the reverse of removal sequence.

Suggestions for Installation 1. Adjustment of lift chain tension

Refer to page 12-15. 2. Adjustment of fore-and-aft and side-to-side clearance of the lift bracket

Refer to page 12-16. 3. Guide bar

When making the clearance between the guide bar 1 and the stopper plate 2 on one side 0, adjust with a shim so that the clearance A between the guide bar 1 and the stopper plate 2 on the opposite side becomes 1.0 mm (0.039 in.) or less. Part No.

Thickness

94632 - 01800

3.2 mm (0.126 in.)

94632 - 01700

2.3 mm (0.091 in.)

94632 - 01600

1.0 mm (0.039 in.)

3 A

210152

13-6

1 2

HYDRAULIC FORK POSITIONER

Fork Positioner Cylinder Disassembly

8 9

8 6

4 3

7 10 5

210165

Sequence 1. 2. 3. 4. 5. 6.

Guide bushing O-ring Dust seal Rod packing Collar Self-locking nut

7. 8. 9. 10. 11. 12.

Piston Backup ring O-ring O-ring Piston rod Cylinder tube

Suggestions for Disassembly 1. Removal of guide bushing

Wrap the cylinder tube with rag, and secure it onto the vise. Then, remove the guide bushing with a Hook Wrench (special tool). Special tool needed Hook wrench A

05312 - 20520

A 200351

13-7

HYDRAULIC FORK POSITIONER

Inspection and Correction 1. Cylinder tube

(1) Check the inside surface of the cylinder for wear, damage, and rust. (2) Check the welded part for cracks, damage, and dent. 2. Piston rod

(1) Check the piston rod for deflection. Support both ends of the piston rod on V-blocks, and measure the deflection by putting a dial gauge to the center of the piston rod. Replace the piston rod if 1/2 of the gauge reading exceeds the service limit. B: Repair or service limit Unit: mm (in.) Deflection of piston rod (1/2 of dial indicator reading)

200319

1.0 (0.039)

(2) Check the rod surface for rust, damage, sliding scratches, and dent. If threads are severely damaged, replace it. 3. Seals

Replace the following parts as a seal kit. (1) Piston seal kit Piston seal kit

96004 - 05010

1. O-ring 2. Backup ring 3. O-ring

(2) Rod seal kit Rod seal kit

96004 - 05020

4. Dust seal 5. Rod packing 6. O-ring

13-8

2 210166

HYDRAULIC FORK POSITIONER

A: Standard value

B: Repair or service limit Unit: mm (in.)

Attachment Model 3FP115CM

3FP135CM

3FP150CM

Item Bore diameter of cylinder tube 1

45 (1.77)

Outside diameter of piston rod 2

25 (0.98)

0.5 (0.020), maximum

1.0 (0.039)

W2050

767 (30.20)

W2200

842 (33.15)

—

W2300

892 (35.12)

W2400

—

W2050

W2200

50 (1.97)

—

W2300

—

W2400

—

Deflection of piston rod 3 (1/2 of dial indicator reading)

Stroke 4 942 (37.09)

892 (35.12)

125 (4.92)

Length of collar 5

Fork positioner cylinder

Overall length when fully contracted 6

1115 (43.90)

Self-locking nut tightening torque 7 N·m (kgf·m) [lbf·ft]

200 (20.4) [148]

Guide bushing tightening torque 8 N·m (kgf·m) [lbf·ft]

250 (25.5) [184]

7 4

5 6 210656

13-9

HYDRAULIC FORK POSITIONER

Reassembly

11 10

210168

Sequence 1. 2. 3. 4. 5. 6.

Piston O-ring O-ring Backup ring Piston rod Self-locking nut

7. 8. 9. 10. 11. 12.

Suggestions for Reassembly 1. Cleaning of each part

Thoroughly clean each part before reassembly to prevent dust from adhering. 2. Insertion of piston seal

Insert the piston seal into the piston 1. 3. Tightening of self-locking nut

Insert the piston into the piston rod and tighten the selflocking nut to the specified torque.

Tightening torque for self-locking nut

200 N·m (20 kgf·m) [148 lbf·ft]

Replace the self-locking nut with a new one after it has been used two to three times.

13-10

Collar Cylinder tube Guide bushing Rod packing Dust seal O-ring

HYDRAULIC FORK POSITIONER 4. Insertion of rod packing and dust seal

Insert the rod packing 10 into the guide bushing with the main lip facing inward.

Insert the dust seal 11 into the guide bushing with the main lip facing outward. 5. Tightening of guide bushing

Tighten the guide bushing to the specified torque.

Tightening torque for guide bushing

210169

250 N·m (25 kgf·m) [184 lbf·ft]

Inspection and Adjustment Inspection of right and left shift amounts

After reassembly, make sure that stroke of the forks on the right and left works fully within each limit.

13-11

HYDRAULIC FORK POSITIONER

Troubleshooting Insufficient oil in hydraulic tank

Add hydraulic oil.

Too low gear pump delivery rate

Replace pump assembly.

Port relief valve problems Shifts of right and left fork prongs too slow or sluggish

(1) Too low valve opening pressure setting

Adjust port relief valve.

(2) Defective pilot valve seat surface or foreign matter in valve

Replace port relief valve assembly or disassemble and clean it.

(3) Damaged valve housing O-ring

Replace O-ring.

Cylinder problems:

Unsmooth shifts of fork: (1) Jamming (2) Too large looseness

Misaligned fork tips

(1) Foreign matter lodged in rod packing

Replace rod packing.

(2) Scratches on bore of rod packing

Replace rod packing.

(3) Damaged piston seal

Replace piston seal.

(4) Deformation

Replace cylinder.

Scratches or other damage on lift bracket to fork contact surfaces

Repair and apply grease.

Scratches or other damage on guide surface of forks

Repair and apply grease.

Bent fork

Replace.

Uneven loading

Instruct operator to handle only loads within indicated capacity.

13-12

HYDRAULIC FORK POSITIONER

Service Data A: Standard value

B: Repair or service limit Unit: mm (in.)

Attachment Model 3FP115CM

3FP135CM

3FP150CM

Item Bore diameter of cylinder tube 1

45 (1.77)

Outside diameter of piston rod 2

25 (0.98)

0.5 (0.020), maximum

1.0 (0.039)

W2050

767 (30.20)

W2200

842 (33.15)

—

W2300

892 (35.12)

W2400

—

W2050

W2200

50 (1.97)

—

W2300

—

W2400

—

Deflection of piston rod 3 (1/2 of dial indicator reading)

Stroke 4 942 (37.09)

892 (35.12)

125 (4.92)

Length of collar 5

Fork positioner cylinder

Overall length when fully contracted 6

1115 (43.90)

Self-locking nut tightening torque 7 N·m (kgf·m) [lbf·ft]

200 (20.4) [148]

Guide bushing tightening torque 8 N·m (kgf·m) [lbf·ft]

250 (25.5) [184]

7 4

5 6 210656

13-13

HYDRAULIC SIDE SHIFTERS Applicable Attachment Models ...........................................................14 – Specifications ..........................................................................................14 – Structure ...................................................................................................14 – Removal and Installation ......................................................................14 –

1 1 2 3

Removal ...................................................................................................14 – 3 Installation ................................................................................................14 – 4

Side Shifter Assembly ...........................................................................14 – 5 Disassembly .............................................................................................14 – 5 Inspection and Correction .........................................................................14 – 7 Reassembly ..............................................................................................14 – 7

Side Shift Cylinder .................................................................................14 – 8 Disassembly .............................................................................................14 – 8 Inspection and Correction .........................................................................14 – 9 Reassembly .............................................................................................. 14 – 11

Inspection and Adjustment ................................................................. 14 – 12 Troubleshooting ...................................................................................... 14 – 13 Service Data ............................................................................................ 14 – 14

HYDRAULIC SIDE SHIFTER

Applicable Attachment Model Applicable Truck Attachment Model

Model

Designation – Serial No.

Applicable Mast Model

Mast Piping

3P115C Simplex

Side pulley type

DP100

3DP – 10011-up

DP115

4DP – 10011-up

3SS135BM

DP135

5DP – 10011-up

3P135C Simplex

Side pulley type

3SS150BM

DP150

6DP – 10011-up

3P150C Simplex

Side pulley type

3SS115BM

Specifications

Unit: mm (in.) Attachment Model 3FP115BM

3FP135BM

3FP150BM

Item Side shift (each side)

230 (9.1)

Load center

228.5 (9.0) 600 (24)

Free lift

0 W2050

Outside fork spread (maximum)

W2200

2020 (79.5) 2170 (85.4)

W2300

— 2270 (89.4)

W2400

—

2370 (93.3)

W2050

480 (18.9)

470 (18.5)

W2200

480 (18.9)

—

W2300

480 (18.9)

470 (18.5)

W2400

—

570 (22.4)

Mast tilt angle (forward – backward)

15° – 12°

Type of forks

Heel free

Forks

Length

1220 (48.0)

Width

180 (7.1)

Thickness

DP100: 70 (2.8) DP115: 75 (3.0)

90 (3.5)

Front overhang (with standard fork)

DP100: 841.5 (33.2) DP115: 847.5 (33.4)

901 (35.5)

14-1

HYDRAULIC SIDE SHIFTER

Structure

8 210640

1. 2. 3. 4.

Lift bracket Carriage Side shifter cylinder Fork

5. 6. 7. 8.

A carriage, provided in front of the lift bracket, can be slid from side to side (side shift) by hydraulic force of the cylinder. In case of a large truck, it is difficult to move the truck to a proper position during picking-up and loading operation. Installation of a side shifter to the truck enables forks to slide from side to side while carrying a load without moving the truck, leading to increased efficiency in cargo handling operation.

14-2

Guide bar Support Slider block Slider block

HYDRAULIC SIDE SHIFTER

Removal and installation Removal 1. Removal of fork

(1) Position the mast vertically, and move forks 1 on the right and left to the center.

4 3

(2) Install two C clamps and a wire rope on forks 1, and hang the forks with a crane.

(3) Remove plate 2 and shim 3, and pull out guide bar 4. (4) Bring removed two forks 1 near to each other, bind them with a rope to prevent them from falling down, and transport them to a safe place. (5) Support the lift bracket and carriage by placing wood blocks under them. 1

210642

2. Removal of side shifter assembly

(1) Remove two hoses from the pulley. (2) Remove the split pin of the lift chain, and then remove anchor nuts and lock nuts. (3) Remove the lift bracket in the following procedure. (a) Bind the ends of the two lift chains with a rope. Make allowance of approx. 3 m (9.8 ft) at the end of the rope. (b) Bind four hoses in the same manner. Make allowance of approx. 3 m (9.8 ft) at the end of the rope. 210643

(c) Start the engine, and raise the inner mast to the position where the main roller of the lift bracket can be removed. At this point, pull the attached rope downward to stretch the lift chains and hoses to prevent the main roller from coming off the chain wheel and hose reel. (d) When the inner mast is raised to the position where the main roller of the lift bracket can be removed from the inner mast, back up the truck, and separate the lift bracket from the truck. WARNING While the mast is rising, never touch any operating levers except for the lift lever. 14-3

210644

HYDRAULIC SIDE SHIFTER

Installation To install, follow the reverse of removal sequence.

Suggestions for Installation 1. Installation of lift chains

(1) Install the lift chains as they are if the position of the lock nut on the upper side remains unchanged. Tighten the lock nuts and anchor nuts to the specified torque. Tightening torque

392 N·m (40 kgf·m) [289 lbf·ft]

(2) Raise the forks a little above the ground, and push the midpoint of chains alternately to make sure that tension of the two chains is equal.

2. Adjustment of hose tension

(1) Specified hose tension is 196 N (20 kgf) [44 lbf]. When the center of a hose 1 m (39.4 in.) long is pushed with a force of 9.8 N (1.0 kgf) [2.2 lbf], slack of approx. 12.5 mm (0.492 in.) serves as a guide for tension. Adjust tension according to length of hoses which differs with raised height of the mast.

12.5 mm (0.492 in.) 9.8 N (1.0 kgf) [2.2 lbf]

Example: If a hose is 2 m (78.7 in.) long from the pulley when raised to the highest position to the bottom joint, slack of 25 mm (0.98 in.) is acceptable when the hose is pushed with a force of 9.8 N (1.0 kgf) [2.2 lbf].

210555

3. Guide bar

Part No.

Thickness

94632 - 01800

3.2 mm (0.126 in.)

94632 - 01700

2.3 mm (0.091 in.)

94632 - 01600

1.0 mm (0.039 in.)

1 2

210152

14-4

HYDRAULIC SIDE SHIFTER

Side Shifter Assembly Disassembly Start by:

(a) Place the side shifter separated from the truck on a wood block with the lift bracket facing downward. (b) Prepare an oil receiver, as oil is left in the cylinder and hoses.

6 2

10 3

3 2 9 3

1 2

7 5

210645

Sequence 1. 2. 3. 4. 5.

Hose Self-locking Nut, Bolt, Washers Side shift cylinder, Bushing Support, Shims, Bolts, Washers Carriage

6. 7. 8. 9. 10.

14-5

Slider block Slider block Main roller, Snap ring Side roller, Pin Lift bracket

HYDRAULIC SIDE SHIFTER

Suggestions for Disassembly 1. Removal of hose

Remove hoses 1 from the connector of side shift cylinder 3. 2. Removal of side shift cylinder

(1) When removing, be careful not to damage threads of the cylinder rod and connector. (2) It is advisable to remove the side shift cylinder with the cylinder rod fully contracted. 3. Removal of carriage

(1) Hang a wire rope on the carriage, utilizing three locations (two guide bar mounting holes on the right and left and plate on the center bottom), and support it with a crane. (2) Remove support 4. (3) Slide carriage 5 sideways until slider block 6 is disengaged. After disengagement, lift it up as it is.

210646

14-6

HYDRAULIC SIDE SHIFTER

Inspection and correction 1. Lift bracket

(1) Check the roller for sticking, wear and cracks. (2) Check the main roller and side roller for sticking, wear and cracks. (3) Check the welded part of the lift bracket for cracks. (4) Check the side shift bar for bend and cracks. 2. Carriage

(1) Check the welded part for cracks. (2) Check the sliding surface for scratches. 3. Hose

Replace hoses every two years. 4. Slider block

Check for a wear condition and thickness within the service limit. A: Standard value

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

19.1±1 (0.75±0.04)

12 (0.47)

15.8±0.3 (0.622±0.012)

8.8 (0.346)

Slider block 6

Slider block 7

Reassembly To reassembly, follow the reverse of disassembly sequence.

Suggestions for Reassembly 1. Driving of main roller

Using a driving jig, drive the main roller. Be careful not to tap outer rings of the roller. 2. Assembly of slider block

After assembling the slider block, never apply grease to the sliding surface.

14-7

210647

HYDRAULIC SIDE SHIFTER

Side Shift Cylinder Disassembly ❋8 4 ❋10 ❋9 11 2 3

2 3 1 12

5 ❋7 6

Note: Parts marked with ❋ are seal kit parts.

210648

Sequence 1. 2. 3. 4. 5. 6.

Grease nipple Snap ring Spherical bushing Guide bushing Self-locking nut Piston

7. 8. 9. 10. 11. 12.

14-8

Piston seal O-ring Dust seal Rod packing Piston rod Cylinder tube

HYDRAULIC SIDE SHIFTER

Suggestions for Disassembly 1. Removal of guide bushing

(1) Wrap the cylinder tube with waste cloth, and secure it onto the vise. Then, remove the guide bushing with Hook Wrench A. Special tool needed Truck Model Tool Name Hook wrench A

DP100, DP115

DP135, DP150

05312 - 20980

05312 - 21100

A 210557

Inspection and Correction 1. Cylinder tube

(1) Check the inside surface of the cylinder for wear, damage and rust. (2) Check the welded part for cracks, damage and dent. 2. Piston rod

(1) Check the piston rod for bend. Support both ends of the piston rod with a V-shaped block, and measure bend by putting a dial gauge to the center of the piston rod. Replace the piston rod if 1/2 of the gauge reading exceeds the service limit. B: Repair or service limit Unit: mm (in.) Deflection of piston rod (1/2 of dial indicator reading)

210558

1.0 (0.039)

(2) Check the rod surface for rust, damage, sliding scratches and dent. (3) Replace the piston rod if excessive damage is found on the thread. 3. Rings and packing

Replace seal kit parts with new ones.

14-9

HYDRAULIC SIDE SHIFTER

A: Standard value

B: Repair or service limit Unit: mm (in.)

Attachment Model 3SS115BM

3SS135BM

3SS150BM

Item Bore diameter of cylinder tube 1

90 (3.54)

100 (3.94)

Outside diameter of piston rod 2

40 (1.57)

45 (1.77)

Deflection of piston rod 3 (1/2 of dial indicator reading)

0.5 (0.020), maximum

1.0 (0.039)

Stroke 4

460 (18.1)

457 (18.0)

Overall length when fully contracted 5

769 (30.3)

772 (30.4)

Guide bushing tightening torque 6 N·m (kgf·m) [lbf·ft]

491 to 638 (57 to 65) [412 to 456]

Self-locking nut tightening torque 7 N·m (kgf·m) [lbf·ft]

559 to 618 (50 to 65) [362 to 470]

17.2 (175) [2489]

Working pressure Mpa (kgf/cm2) [psi]

210649

14-10

HYDRAULIC SIDE SHIFTER

Reassembly

3 12

1 10

❋4 ❋5

❋6

210650

Sequence Piston Piston seal Guide bushing Rod packing Dust seal O-ring

7. 8. 9. 10. 11. 12.

Suggestions for Reassembly Start by:

(a) During reassembly, replace seal kit parts marked with ❋ in the illustration. (b) Sufficiently clean each part before reassembly to prevent dust from adhering. 1. Insertion of piston seal

The piston seal consists of an O-ring and a seal. Insert the O-ring into the groove of piston 1 before inserting the seal. 2. Tightening of self-locking nut

Tighten self-locking nut 8 to the specified torque. Tightening torque for self-locking nut

Note: Parts marked with ❋ are seal kit parts.

1. 2. 3. 4. 5. 6.

559 to 618 N·m (57 to 63 kgf·m) [362 to 470 lbf·ft]

14-11

Piston rod Self-locking nut Cylinder tube Spherical bushing Snap ring Grease nipple

HYDRAULIC SIDE SHIFTER 3. Insertion of rod packing and dust seal

(1) Insert rod packing 4 into guide bushing 3 with the main lip facing inward.

(2) Insert dust seal 5 with the main lip facing outward. 4 5

210651

4. Tightening of guide bushing

Tighten guide bushing 3 to the specified torque.

Tightening torque for guide bushing

491 to 638 N·m (50 to 65 kgf·m) [412 to 456 lbf·ft]

Inspection and Adjustment Inspection of right and left shift amount After reassembly, make sure that the carriage moves smoothly and that the side shift amount is equal for the right and left.

14-12

HYDRAULIC SIDE SHIFTER

Troubleshooting Not enough oil in hydraulic tank

Refill.

Pump not delivering enough oil

Replace pump assembly.

Main relief valve defective because of:

Slow shift speed

(1) Too low a setting

Readjust. 5.9 MPa (60 kgf/cm2) [853 psi]

(2) Defective pilot valve seat or foreign particles lodged between valve and valve seat

Clean or replace main relief valve assembly.

(3) Valve case O-ring damaged

Replace.

(4) Pilot valve spring weak

Replace main relief valve assembly.

Cylinder defective because of:

Abnormal shift movement (1) Binding (2) Rattling

Fork tips uneven

(1) Defective piston seal or foreign particles lodged between piston rod and packing

Replace seal kit.

(2) Structural warpage

Replace.

Slider blocks worn

Replace.

Sliding surfaces of carriage worn

Replace.

Carriage distorted

Repair or replace.

Guide bar distorted

Repair or replace.

Forks distorted

Replace.

Off-center loading

Urge operator to load properly.

14-13

HYDRAULIC SIDE SHIFTER

A: Standard value

B: Repair or service limit Unit: mm (in.)

Attachment Model 3SS115BM

3SS135BM

3SS150BM

Item Bore diameter of cylinder tube 1

90 (3.54)

100 (3.94)

Outside diameter of piston rod 2

40 (1.57)

45 (1.77)

Deflection of piston rod 3 (1/2 of dial indicator reading)

0.5 (0.020), maximum

1.0 (0.039)

Stroke 4

460 (18.1)

457 (18.0)

Overall length when fully contracted 5

769 (30.3)

772 (30.4)

Guide bushing tightening torque 6 N·m (kgf·m) [lbf·ft]

491 to 638 (50 to 65) [412 to 456]

Self-locking nut tightening torque 7 N·m (kgf·m) [lbf·ft]

559 to 618 (57 to 63) [362 to 470]

Side shift Working pressure cylinder Mpa (kgf/cm2) [psi]

17.2 (175) [2489]

5 210649

Thickness of slider block 8 Thickness of slider block 9

19±1 (0.75±0.04)

12 (0.47)

15.8±0.3 (0.622±0.012)

8.8 (0.346)

Side shifter 8 9

210652

14-14

SERVICE DATA Maintenance Chart ................................................................................15 – 1 Tightening Torque for Standard Bolts and Nuts ............................ 15 – 10 Periodic Replacement Parts ............................................................... 15 – 12 Location of Periodic Replacement Parts ................................................... 15 – 13

Lubrication Instructions ....................................................................... 15 – 14 Lubrication Chart ...................................................................................... 15 – 14 Fuel and Lubricant Specifications ............................................................. 15 – 15 Recommended Brands of Lubricants ........................................................ 15 – 16 Refill Capacities (Approximate) ................................................................. 15 – 17

Weight of Major Components (Approximate) ................................. 15 – 18 Special Tools ........................................................................................... 15 – 19

SERVICE DATA

Maintenance Chart {: Check or clean : Change or adjust

DP150

DP135

DP115

Service data

DP100

How to check

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Item

Daily (pre-start)

Intervals

Coolant leaks

Visual

Radiator filler cap – function

Visual/feel

Coolant level

Visual

Fan belt – tension and condition

Visual/ measure

Cooling fan – condition

Visual/feel

Hoses – condition

Visual/feel

Starting and noise

Test/listen

Low idle and acceleration

Tachometer/ test

Exhaust smoke

Visual

Valves

Clearance for intake and exhaust valves

Feeler gauge

0.4 mm (0.016 in.) in cold state

Air cleaner

Element – clogging or damage

Visual

Change every 1200 hours or 6 months.

Oil leaks

Visual

Cooling system

Engine

Low idle: 650±20 rpm

Visual/feel

Change every 200 hours or monthly. 16 liters (4.2 U.S. gal.)

Oil filter element – clogging

Check

Change every 200 hours or monthly.

No-load maximum speed

Tachometer

2400 − 50 rpm

Oil – level and Lubrication contamination system

Governor

23 liters (6.1 U.S. gal.)

15-1

SERVICE DATA

Fuel system

Check

Change every 1200 hours or 6 months.

Injection nozzles – injection pressure and discharge pattern

Nozzle tester

17652 kPa (180 kgf/cm2) [2560 psi]

Injection timing

Test

16° BTDC

Feed pump – function

Test

Pinion – meshing action

Test

Alternator

Charge rate

Test/visual

Level of electrolyte

Visual

Specific gravity of electrolyte

Hydrometer

2550 kPa (26 kgf/cm2) [370 psi] at 300 rpm

1.265 or above

Insulators, connectors and battery terminals – Visual/feel looseness, damage or corrosion Free play, looseness, rattle

Feel/ measure

Response

Test

Oil leaks

Visual

Installation

Wrench

Steering knuckles

Kingpins – rattle

Feel

Rear axle

Distortion, damage

Visual/feel

Steering power cylinder

Oil leaks

Visual

Installation

Wrench

Steering control valve

DP150

Fuel filter – clogging

Starter

Steering wheel

DP135

Visual

Compression gauge

Electrical system

DP115

Fuel leaks

Compression All cylinders pressure

Battery

Service data

DP100

How to check

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Item

Daily (pre-start)

Intervals

70 mm (2.8 in.) with engine at low idle

15-2

SERVICE DATA

DP150

DP135

DP115

Free play and height above floor plate with pedal Measure depressed

Free play: 15 mm (0.6 in.) Pedal height (to top of pedal pad): 190 mm (7.5 in.)

Test/ measure

5 m (16 ft), maximum with rated load Effective stroke (after free play): 12±1° Lever position when brake applied: 4° to 5° Operating effort: 245 to 294 N (25 to 30 kgf) [55 to 66 lbf]

Brake pedal Truck stopping distance

Parking brake

Application (holding)

Test/spring scale

Brake hoses and pipes

Fluid leaks, damage or installation

Visual

Brake fluid

Level in reservoir

Visual

Brake booster

Operation

Test

Wheel brakes

Master cylinder and wheel Overhaul/ cylinders – operation, visual wear and damage

Brake drums and shoes

Service data

DP100

How to check

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Item

Daily (pre-start)

Intervals

200 cc (12.2 cu in.)

Clearance between drum and linings

Feeler gauge

0.2 mm (0.008 in.)

Sliding surfaces of shoes and lining – wear

Overhaul/ calipers

10 mm (0.39 in.), maximum

Drum – wear or damage

Visual/scale

ID: 424 mm (16.69 in.)

Return springs – free length

Measure

260.5 mm (10.26 in.), maximum

Shoes – operation

Test

Anchor pins – seizure

Visual

15-3

SERVICE DATA

Backing plates

Distortion, cracks or damage

Dye check

Fittings cables – damage

Visual

DP150

DP135

DP115

DP100

How to check

Service data

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Item

Daily (pre-start)

Intervals

Ratchet – wear or damage Visual

Visual

Strainer – clogging

Visual

Control valve filter

Visual

Inching pedal – adjustment

Powershift transmission

Change oil every 1200 hours or 6 months. 22 liters (5.8 U.S. gal.)

Oil level and oil leaks

Pressure (engine at 1500 ± 100 rpm)

Clean or change every 1200 hours or 6 months. Inching pedal height (above floor): 190 mm (7.5 in.) Valve plunger protrusion: 9 mm (0.354 in.) with inching pedal released 14 mm (0.55 in.) when inching pedal is fully depressed

Measure/ test

Specification, MPa (kgf/cm2) [psi] 2-speed transmission

3-speed transmission

Main

1.08 to 1.37 (11 to 14) [156 to 199]

1.08 to 1.27 (11 to 13) [156 to 185]

Clutch

1.08 to 1.37 (11 to 14) [156 to 199]

Speed Direction

1.08 to 1.27 (11 to 13) [156 to 185]

Torque converter inlet

0.05 to 0.49 (0.5 to 5.0) [7 to 71]

0.15 to 0.69 (1.5 to 7.0) [21 to 100]

Lubrication line

0.02 to 0.15 (0.2 to 1.5) [3 to 21]

0.02 to 0.10 (0.2 to 1.0) [3 to 14]

Stall speed

1760 rpm

10 m (33 ft) start acceleration (no load)

5 seconds, maximum

15-4

SERVICE DATA

Front axle

Front axle and differential

DP150

DP135

DP115

Service data

DP100

How to check

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Item

Daily (pre-start)

Intervals

Cracks, distortion or other Dye check/ defects visual Oil level and oil leaks

Visual

Mounting bolts – tightness

Torque wrench

Front wheel bearings – preload

Spring balancer

Longitudinal play at center pin

Test

25 liters (6.6 U.S. gal.)

118 to 157 N (12 to 16 kgf) [27 to 35 lbf] (as tangential force applied to hub bolt)

Cracks, distortion or other Visual defects Rear axle

Rear wheel bearings – preload

Spring balancer/ torque wrench

88 to 127 N (9 to 13 kgf) [20 to 29 lbf] (as tangential force applied to hub bolt) Torque for lock nut (outer only): 196 N·m (20 kgf·m) [145 lbf·ft]

Tire gauge

DP100: 686 kPa (7.0 kgf/cm2) [99 psi] DP115, DP135, DP150: 785 kPa (8.0 kgf/cm2) [114 psi]

Front Front and rear axles

Tire pressure Rear

Tires – cuts or gouges

Visual

Tires – tread wear

Depth gauge

Tires – imbedded stone, etc. Visual Wheels 539±49 N·m (55±5.0 kgf·m) [398±36 lbf·ft]

Front and rear wheel nuts Torque – tightening torque wrench

15-5

SERVICE DATA

Wheels

Wheel discs – damage

DP150

DP135

DP115

Visual

Oil level and contamination Visual

Change every 2400 hours or 12 months. N level: N level: 172 liters 204 liters (45 U.S. gal.) (54 U.S. gal.)

Strainer – clogging

Clean or change every 2400 hours or 12 months.

Hydraulic tank Visual

Change every 1200 hours or 6 months.

Return filter – clogging Gear pump

Oil leaks or abnormal noise Visual/listen

Priority valve

Relief valve setting (for power cylinder)

Pressure gauge

Oil leaks

Visual

Main relief valve setting

Pressure gauge

Overload relief valve setting (optional)

Pressure gauge

Control valve

11.8 + 00.5 MPa (120 + 05 kgf/cm2) [1706 + 071 psi]

17.2 + 00.5 MPa (185 + 05 kgf/cm2) [2631 + 071 psi]

Control levers and links – Test/feel rattle Lift cylinders

Service data

DP100

How to check

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Item

Daily (pre-start)

Intervals

Cracks, distortion or other Visual defects

15-6

SERVICE DATA

Function, wear and internal leakage Lift cylinders

DP150

DP135

DP115

Service data

DP100

How to check

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Item

Daily (pre-start)

Intervals

Lift speed (rated load) mm/sec (fpm) 330 340 290 280 (65) (67) (57) (55)

Visual/ watch/ measure

Drift (rated load) mm (in.)/15 min 40 45 38 42 (1.6) (1.8) (1.5) (1.7)

Auxiliary equipment Mounting bolts – tightness Wrench Flow regulator valve

Oil leaks

Visual

Lowering speed (rated load)

Watch/ measure

450 mm/sec (89 fpm)

380 mm/sec (75 fpm)

Cracks, distortion or other Visual defects External oil leaks

Tilt cylinders

Function and wear

Visual Drift (forward) (rated load) mm (in.)/15 min 41 47 35 39 (1.6) (1.9) (1.4) (1.5)

Watch/scale

Mounts – rattle or damage Visual/feel

Piping

Sockets – tightening torque

Torque wrench

Oil leaks

Visual

Hoses – damage

Visual

1177 to 1471 N·m (120 to 150 kgf·m) [868 to 1085 lbf·ft]

Hose reels and swivel joint – Visual distortion or other defects

15-7

SERVICE DATA

DP150

DP135

DP115

Service data

DP100

How to check

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Item

Daily (pre-start)

Intervals

Cracks, distortion or other Visual/dye defects check Mast supports – rattle or damage Mast and lift bracket

Lift chains and chain wheels

Main and side rollers – clearance

Feeler gauge/ dial indicator

Length of lift chains (20 links)

Scale

Tension (deflection) of lift chains

Scale

Clearance between roller and mast (over the whole lift range) Main rollers: 0.5 to 2.8 mm (0.020 to 0.110 in.) Side rollers: 0.5 to 1.5 mm (0.020 to 0.059 in.) 915 mm (36 in.), maximum

1046 mm (41 in.), maximum

Both chains to be equal in tension

Chains – damage or rusting Visual Chain wheels – wear, Visual distortion or other defects Chain wheel bearings – rattle

Feel

Chain anchor bolts – distortion or damage

Visual Fork thickness 69 mm (2.7 in.), minimum

Visual/ Forks – wear and distortion measure Forks Fork stopper pins – damage or distortion

Visual

Lamps

Operating condition

Test/visual

Horn

Operating condition

Test/listen

15-8

79 mm (3.1 in.), minimum

SERVICE DATA

Turn signals Operating condition

Test/visual

Rear view mirrors (option)

Rear vision

Visual

Overhead guard

Installation and damage

Visual/ wrench

Loosen bolts or nuts

Wrench/ visual

Operator seat – damage and installation

Visual

Lubrication points

Lubricate

Change of lubricants and fluids

Inspect

Chassis Lubricate mast supports weekly.

15-9

DP150

DP135

DP115

Service data

DP100

How to check

Every 50 hours or weekly Every 200 hours or monthly Every 1200 hours or 6 months Every 2400 hours or 1 year

Item

Daily (pre-start)

Intervals

SERVICE DATA

Tightening Torque for Standard Bolts and Nuts 101656

With spring washer Nominal size

Pitch

Metric fine thread

in.

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

0.24

0.04

7.4

0.75

5.4

9.6

0.98

7.1

12.7

1.3

9.4

0.32

1.25

0.05

16.7

1.7

12.3

22.6

2.3

16.6

30.4

3.1

22.4

0.39

1.25

0.05

34.3

3.5

25.3

45.1

4.6

33.3

69.6

7.1

51.4

0.47

1.25

0.05

63.7

6.5

47.0

82.4

8.4

60.8

122.6

12.5

90.4

0.55

1.5

0.06

102.0

10.4

75.2

132.4

13.5

97.6

192.2

19.5

141.8

0.63

1.5

0.06

154.9

15.8

114.3

202.0

20.6

149.0

287.3

29.3

211.9

0.71

1.5

0.06

224.6

22.9

165.6

292.2

29.8

215.5

413.8

42.2

305.2

0.79

1.5

0.06

310.9

31.7

229.3

404.0

41.2

298.0

573.7

58.5

423.1

0.87

1.5

0.06

413.8

42.2

305.2

537.4

54.8

396.4

763.0

77.8

562.7

0.95

1.5

0.06

547.2

55.8

403.6

711.0

72.5

524.4

1006.2

102.6

742.1

1.06

1.5

0.06

794.3

81.0

585.9

1032.6

105.3

761.6

1451.1

148.0

1070.5

1.18

1.5

0.06

1100.3

112.2

811.5

1430.8

145.9

1055.3 2012.3

205.2

1484.2

1.30

1.5

0.06

1467.1

149.6

1082.1 1907.4

194.5

1406.8 2680.2

273.3

1976.8

1.42

1.5

0.06

1918.2

195.6

1414.8 2493.8

254.3

1839.4 3497.1

356.6

2579.3

1.54

1.5

0.06

2461.5

251.0

1815.5 3198.8

326.2

2359.4 4469.9

455.8

3296.8

101656

Without spring washer Nominal size

Pitch

0.24

0.04

8.6

0.88

6.4

10.8

1.1

8.0

14.7

1.5

10.8

0.32

1.25

0.05

19.6

2.0

14.5

26.5

2.7

19.5

36.6

3.7

26.8

0.39

1.25

0.05

41.2

4.2

30.4

53.0

5.4

29.1

81.4

8.3

60.0

0.47

1.25

0.05

74.5

7.6

55.0

97.1

9.9

71.6

144.2

14.7

106.3

0.55

1.5

0.06

119.6

12.2

88.2

155.9

15.9

115.0

226.5

23.1

167.1

0.63

1.5

0.06

182.4

18.6

134.5

237.3

24.2

175.0

338.3

34.5

249.5

0.71

1.5

0.06

263.8

26.9

194.6

343.2

35.0

253.2

487.4

49.7

359.5

0.79

1.5

0.06

365.8

37.3

269.8

475.6

48.5

350.8

674.7

68.8

497.6

0.87

1.5

0.06

486.4

49.6

358.8

632.5

64.5

466.5

897.3

91.5

661.8

0.95

1.5

0.06

643.3

65.6

474.5

836.5

85.3

617.0

1183.7

120.7

873.0

1.06

1.5

0.06

934.6

95.3

689.3

1216.0

123.9

894.2

1707.3

174.1

1259.3

1.18

1.5

0.06

1294.5

132.0

954.8

1682.8

171.6

1241.2 2367.3

241.4

1746.0

1.30

1.5

0.06

1726.0

176.0

1273.0 2243.8

228.8

1654.9 3153.8

321.6

2326.1

1.42

1.5

0.06

2256.5

230.1

1664.3 2934.1

299.2

2164.1 4114.0

419.6

3035.0

1.54

1.5

0.06

2896.0

295.3

2135.9 3763.8

383.8

2776.0 5258.3

536.2

3878.3

15-10

SERVICE DATA 101656

With spring washer Nominal size

Metric coarse thread

Pitch

in.

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

0.39

1.5

0.06

33.3

3.4

24.6

43.1

4.4

31.8

67.7

6.9

49.9

0.47

1.75

0.07

58.8

6.0

43.4

76.5

7.8

56.4

115.7

11.8

85.3

0.55

0.08

96.4

9.8

70.9

124.5

12.7

91.9

182.4

18.6

134.5

0.63

0.08

147.14

15.0

108.5

191.2

19.5

141.0

274.6

28.0

202.5

0.71

2.5

0.10

203.0

20.7

149.7

264.8

27.0

195.3

383.4

39.1

282.8

0.79

2.5

0.10

286.4

29.2

211.2

371.7

37.9

274.1

536.4

54.7

395.6

0.87

2.5

0.10

383.4

39.1

282.8

499.2

50.9

368.2

715.9

73.0

528.0

0.95

0.12

492.3

50.2

363.1

640.4

65.3

472.3

924.8

94.3

682.1

1.06

0.12

724.7

73.9

534.5

942.2

96.1

695.1

1350.4

137.7

996.0

1.18

3.5

0.14

969.9

98.9

715.3

1259.2

128.4

928.7

1843.7

188.0

1359.8

1.30

3.5

0.14

1328.8

135.5

980.1

1727.0

176.1

1273.7 2477.2

252.6

1827.1

1.42

0.16

1676.0

170.9

1236.1 2180.0

222.3

1607.9 3199.9

326.3

2360.1

1.54

0.16

2219.2

226.3

1636.8 2884.1

294.1

2127.2 4118.8

420.0

3037.9

1.65

4.5

0.18

2754.7

280.9

2031.8 3581.4

365.2

2641.5 5137.7

523.9

3789.4

101656

Without spring washer Nominal size

Pitch

0.39

1.5

0.06

39.2

4.0

28.9

51.0

5.2

37.6

79.4

8.1

58.6

0.47

1.75

0.07

69.6

7.1

51.4

90.2

9.2

66.5

135.3

13.8

99.8

0.55

0.08

112.8

11.5

83.2

146.1

14.9

107.8

215.7

22.0

159.1

0.63

0.08

172.6

17.6

127.3

224.6

22.9

165.6

323.6

33.0

238.7

0.71

2.5

0.10

239.3

24.4

176.5

311.9

31.8

230.0

451.1

46.0

332.7

0.79

2.5

0.10

336.4

34.3

248.1

437.4

44.6

322.6

630.6

64.3

465.1

0.87

2.5

0.10

392.3

40.0

289.3

587.4

59.9

433.3

842.4

85.9

621.3

0.95

0.12

578.6

59.0

426.7

753.2

76.8

555.5

1088.5

111.0

802.9

1.06

0.12

852.2

86.9

628.5

1108.2

113.0

817.3

1588.7

162.0

1171.7

1.18

3.5

0.14

1140.5

116.3

841.2

1481.8

151.1

1092.9 2168.3

221.1

1599.2

1.30

3.5

0.14

1563.2

159.4

1153.0 2031.9

207.2

1498.7 2915.5

297.3

2150.4

1.42

0.16

1972.1

201.1

1454.6 2564.4

261.5

1891.4 3765.8

384.0

2777.5

1.54

0.16

2610.5

266.2

1925.4 3393.1

346.0

2502.6 4845.5

494.1

3573.8

1.65

4.5

0.18

3241.1

330.5

2390.5 4212.9

429.6

3107.3 6044.8

616.4

4458.4

Remarks: 1. The tolerance on these torque is ±10%. 2. These torques are for “dry” condition.

15-11

SERVICE DATA

Periodic Replacement Parts The parts listed below are important for the safe working of the truck, and are specially designated as the parts to be replaced at specified periods. Each service shop is requested to adhere to the replacement schedule given here. Intervals Ref. No.

Periodic replacement parts

Service

* Repair kit parts for air master (oil seals, gaskets, O-rings, cups, packings, valve assembly, etc.)

Replace

* Repair kit parts for brake control valve (valves, O-rings, packing, dust seals, boot, O-rings, etc.)

Replace

* Rubber parts for wheel cylinders (cups, dust seals, etc.)

Replace

* Brake hoses

Replace

* High-pressure hoses for hydraulic system

Replace

* Rubber parts for power cylinder

Replace

* Hoses for power cylinder

Replace

* Stop light switch (air-actuated type)

Replace

* Fuel hoses

Replace

10 * Lift chains

Replace

11 * Tube for brake fluid reservoir

Replace

12 Hydraulic suction strainer

Replace

13 Hydraulic tank return filter

Replace

14 Desiccant for air dryer

Replace

oil filter suction 15 Transmission strainer

Replace

{

16 Engine oil filter element

Replace

{

17 Fuel filter element

Replace

{

Clean

{

1 month after delivery

Every 200 hours or monthly

Every 1200 hours or 6 months

Every 2400 hours or 1 year

Every 4800 hours or 2 years

Every 5600 service hours

{

18 Air cleaner element Replace Footnotes: (1) * (asterisk) indicates critical safety related parts. (2) For item 15, refer to “GROUP 5 2-SPEED POWERSHIFT TRANSMISSION” and “GROUP 6 3SPEED POWERSHIFT TRANSMISSION.” (3) For items 16 and 17, refer to the SERVICE MANUAL for 6D16 Diesel Engine. (4) For item 18, refer to “GROUP 4 POWER TRAIN.”

15-12

SERVICE DATA

Location of Periodic Replacement Parts 12 13 6

5 5 210580

1 11 8 3

210581

15-13

15-14

❋

Every 50 hours or weekly

Hydraulic oil

Every 2400 hours or 12 months

Every 1200 hours or 6 months

Gear oil Engine oil Brake fluid

MPG Multipurpose grease

Every 200 hours or monthly

MPG

ATF Torque converter oil

MPG

Rear axle support (back)

ATF

MPG

ATF

MPG

MPG MPG

❋

210582

❋ Lubricate points on both sides

Change

Check and refill

Tie rod pin

Fun belt pully (3 places)

Engine oil

Hydraulic oil

Tilt cylinder pin

MPG

Differential/final oil Universal joint

Tilt socket pin

Forkshift screw guide bar Lift chain

MPG

❋

MPG MPG

❋ EO

MPG

❋ MPG ❋

Rear axle support (front)

Brake fluid

Torque converter oil

Mast support

Mast strip (sliding surface)

Lift bracket side roller (4 places) Mast and lift bracket side roller (4 places)

SERVICE DATA

Lubrication Instructions

Lubrication Chart

SERVICE DATA

Fuel and Lubricant Specifications Recommendation for ambient temperature, °C (°F) Fuel or lubricant

Recommendation

-30 (-22)

-20 (-4)

Fuel

-10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

Consult your Cat lift truck dealer.

Engine oil

API service classification CD or higher

Front axle oil

API service classification multipurpose type GL-4 (gear oil)

Powershift transmission oil

Dexron

Hydraulic oil

Brake fluid

SAE 10W

SAE 30

SAE 80W

SAE 90

See “Recommended Brands of Lubricants.” —

SAE 5W

F.M.V.S.S. No. 116 – DOT 3 or DOT 4 (SAE J1703)

SAE 10W

See “Recommended Brands of Lubricants.”

Wheel bearings

NLGI No. 2 grade multipurpose type (lithium base) Consistency: 265 – 295

Chassis

NLGI No. 1 grade multipurpose type (lithium base) Consistency: 310 – 340

Grease

See “Recommended Brands of Lubricants.”

Antifreeze solution (Long Life Coolant)

Ambient temperature Concentration

°C (°F)

-45 (-49)

-39 (-38)

-30 (-22)

-25 (-13)

-20 (-4)

-15 (5)

-10 (14)

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 stick with one and the same brand at successive service intervals.

15-15

SERVICE DATA

Recommended Brands of Lubricants Engine oils (gasoline) Spe cific ation Vis cos ity

API service classification CD or MIL-L-2104E equivalents SAE 10W

SAE 30

Mobil

Mobil Delvac 1210

Mobil Delvac 1230

Shell

Shell Rotella T10W

Shell Rotella T30

Exxon

XD-3 10W

XD-3 30

Manufacturer

Castrol

Castrol Syntec 10W-30

Front axle oils (gear oils) Spe cific ation Vis cos ity Manufacturer

Hydraulic oils (powershift)

API service classification GL-4or GL-5 SAE 80

ISO VG32 —

SAE 90

Mobil

Mobilube HD 80W-90

Mobiltrans HD 10W

Shell

Shell Spirax HD 80W-90

Tellus oil 32

Exxon

Gear Oil GX80W-90

Nuto H32

Castrol

Castrol Hypoy 80W-90

Castrol Hyspin AWH-M32

Powershift transmission oils Spe cific ation Vis cos ity

Brake fluids

Dexron

—

SAE J1703

Mobil

Mobil ATF

Mobil Universal Brake Fluid

Shell

Shell Donax TC

Shell Advance Brake Fluid

Exxon

Exxtrans

Castrol

Castrol Dexron III/Mercon

Manufacturer

Brake Fluid DOT-3 ®

Castrol GT LMA Brake Fluid

Greases Spe cific ation Vis cos ity

Antifreeze/Summer Coolant NLGI No.1

NLGI No.2

Consistency 310 to 340

Consistency 265 to 295

Mobil

Mobilux EP 1

Mobilux EP 2

Marcus

Shell

Retinax HD NLGI 1

Retinax HD NLGI 2

Peak

Exxon

Ronex Extra Duty 1

Ronex Extra Duty 2

Castrol

Castrol EPL 1

Castrol EPL 2

Manufacturer

Full Force USI Chemical

Remarks: Brands of oils are subject to change without notice. When you buy oils, select recommended brands and check specification (for example API service classification CD, SAE 10W). 15-16

SERVICE DATA

Refill Capacities (Approximate)

Unit: liter (U.S. gal.)

Truck Model DP100

DP115

DP135

DP150

Item Fuel tank

Engine cooling system

230 (61) Engine, radiator

22.35 (5.9)

Reserve tank

0.65 (0.2) Total

Engine lubrication system

280 (74)

23 (6.1)

Oil pan

12 (3.2)

Oil filter

4 (1.1) Total

16 (4.2)

Transmission

22 (5.8)

Differential and final drive

20 (5.3)

Hydraulic tank (N level) Brake fluid reservoir

172 (45) cc (cu in.)

200 (12.2)

15-17

204 (54)

SERVICE DATA

Weight of Major Components (Approximate)

Unit: kg (lb)

Truck Model DP100

DP115

DP135

DP150

4530 (9990)

5400 (11900)

6620 (14590)

6620 (14595)

Item Counterweight Engine (service weight)

540 (1190)

Power train (engine and transmission)

905 (1995)

Overhead guard

100 (220)

Front axle (excl. wheels and rims)

1255 (2770)

Rear axle (excl. wheels and rims)

810 (1790)

Simplex mast [3.3 m (10.8 ft)]

Outer mast

845 (1860)

890 (1960)

990 (2180)

Inner mast

830 (1830)

885 (1950)

1000 (2000)

Lift bracket

945 (2080)

Forks (two)

390 (860)

Lift cylinders, etc. Total

415 (915)

225 (496) 14500 (32000)

15-18

15400 (33950)

1200 (2645) 570 (1260) 330 (730) 17500 (38580)

17900 (39460)

SERVICE DATA

Special Tools Ref. No.

Part number

67284 - 15400

Bolt

92267 - 00300

DP100, DP115

DP135, DP150

Powershift transmission cover and shifter shaft removal

{

Piston tool

Powershift transmission clutch return spring removal/installation

{

91268 - 00500

Ring puller

Powershift transmission snap ring removal/ installation

{

64309 - 17701

Gauge kit

Powershift transmission hydraulic pressure testing

{

03727 - 60000

Anchor pin puller

Wheel brake anchor pin removal

{

03727 - 10001

Spring setter

Wheel brake return spring removal/installation

{

91268 - 10600

Puller

Steering wheel removal

{

91268 - 03200

Puller

Steering column needle roller bearing removal

{

91268 - 01700

Connector

Power steering main pressure testing (to be used in combination with 64309 - 17701 gauge kit)

{

05312 - 20520

Hook wrench

Fork positioner guide bushing removal/ installation

{

05312 - 20980

Hook wrench

Side shift cylinder guide bushing removal/ installation

{

—

05312 - 21100

Hook wrench

Side shift cylinder guide bushing removal/ installation

—

{

05312 - 11000

Hook wrench

Tilt cylinder guide bushing removal/installation

{

05312 - 12000

Hook wrench

Power cylinder head removal/installation

{

05530 - 40400

Cap

Tilt cylinder removal

{

91268 - 13810 91268 - 13820 F1035 - 10020 T-24

1) Puller (two) 2) Plate (one) 3) Bolt (two) 4) Gear puller (one) [Banzai make]

2-speed transmission input shaft ball bearing removal/installation

{

92267 - 00200

Socket

Front axle lock nut removal/installation

{

Part name

Application

15-19

SERVICE DATA

Unit: mm (in.)

M10 × 1.25

1.5 C (0.06 C)

75 (2.95)

200465

210206

ø130 (ø5.12)

203847 !

210204 7

M12 × 1.25

M8 × 1.25

5 (2. 5 17 )

200438 "

(1. 30 18 )

203551 8

203544

15-20

203552

SERVICE DATA

Unit: mm (in.) 9

G-B1/2 27 (1.06)

G (PF) 3/8-A

G (PF) 3/8-B

RP (PS) 1/8-A 203849

210584 1 Puller

φ11 (0.43)

0 20 8) 0.0 2(

) 87 (7.

) 17 (2. 5 5

6 (0.24)

)

.60

( 20

Flame hardened Hv>500, depth:2 (0.08)

12 (0.47)

[25(0.98)]

) 54 (3.62 )

21 (0.83)

44 (2.

6 (0.24) M10 x 1.25

2) .0 (6 3 15

19 (0.75) 30 (1.18)

600328

15-21

(0 ø20 .7 9)

25 (0.98) 3 (0.12) ø75 (2.95)

65 (2.56)

72 (2.83)

(6.10) ø155 ø65 (2.56)

144 (5.67)

ø162 (6.38)

210585

2 Plate

1 (0 2.7 .5 0)

210583

60 (2.36) 90 (3.54)

210586

Service Manual 6D16 Diesel Engine DP80 DP90 DP100 DP115 DP135 DP150

T32B-00011-up T32B-50001-up 3DP-00001-up 4DP-00001-up 5DP-00001-up 6DP-00011-up

For use with Chassis Service Manual.

99709-68130

diesel engine

Shop Manual (for industrial use)

GROUP INDEX HOW TO READ THIS MANUAL GENERAL ........................................... 00 ENGINE............................................... 11

FOREWORD

LUBRICATION .................................... 12 FUEL AND ENGINE CONTROL .......... 13

This Shop Manual is published for the information and guidance of personnel responsible for maintenance of 6D16 diesel engine, and includes procedures for adjustment and maintenance services. We earnestly look forward to seeing that this manual is made full use of in order to perform correct service with no wastage. For more details, please consult your nearest authorized CatTM dealer or distributor. Kindly note that the specifications and maintenance service figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future. Applicable models 6D16 6D16-TLE

COOLING............................................ 14 INTAKE AND EXHAUST ...................... 15 ELECTRICAL SYSTEM ....................... 54 SPECIAL EQUIPMENT ....................... 61

Cat Forklift Mitsubishi 6D16, Mitsubishi 6D16-TLE Diesel Engine Parts Contact phone: 1 269 673 1638 Email: EngineParts@HeavyEquipmentRestorationParts.com Website: www.HeavyEquipmentRestorationParts.com www.dp150.com/cat-dp135-engine-parts

Pub. No. 99709-68130

HOW TO READ THIS MANUAL HOW THIS MANUAL IS COMPILED

GENERAL EXPLANATION OF THIS MANUAL

iii

TERMS AND UNITS

vii

HOW TO READ THIS MANUAL How This Manual Is Compiled • This manual is compiled by classifying various systems into certain groups. • Each group contains specifications; troubleshooting; maintenance service standards; lubricant, fluid and sealant; special tools; and service procedure.

tightening torque;

• Page enumeration is independent by every group where first page is always 1.

Group No.

Group denomination

Contents

General

General specifications, engine No. and name plate, precautions for maintenance operations, table of standard tightening torques

Engine

Engine body

Lubrication

Lubrication system

Fuel and engine control

Fuel system

Cooling

Cooling system

Intake and exhaust

Intake and exhaust system, intercooler

Electrical system

Alternator, starter, preheating system, engine start system, automatic stop system

Special equipment

Air compressor

General Explanation of This Manual ● Specifications Particulars relative to maintenance service are made. ● Structure and operation (1) Regarding conventional equipment, descriptions are made in brief. (2) Regarding new equipment, descriptions of system and operating condition are made in detail. ● Troubleshooting Symptoms of troubles and possible causes are described comparatively. ● Inspection and adjustment mounted in vehicle Descriptions are made regarding inspection and adjustment of units mounted in vehicle. ● Service procedure In principle, an explanation is given at the spread title page so that the service procedure can be understood. Servicing points are explained as a supplementary explanation.

Regarding the design of this manual

1a 1 5 1b 6 2 3

1. ............... Illustration for disassembly and assembly or removal and installation: 3-D exploded view of component parts is displayed. 1a. ........ Names of parts show an example of the disassembly (removal) sequence. 1b. ........ When the assembly (installation) sequence differs from the disassembly (removal) sequence, an example of the assembly (installation) sequence is shown. 2. ............... Service standards are shown collectively, classified by location. 3. ............... Tightening torques are shown collectively, classified by location. 4. ............... Points of lubricant, fluid and sealant application are shown collectively, classified by location. 5. ............... Special tools to be used are shown collectively, classified by location. 6. ............... When it is considered hard to understand the service procedure, just by the foregoing description, a supplementary description of the service procedure is given.

iii

HOW TO READ THIS MANUAL 1. Illustration for disassembly and assembly or removal and installation This shows that the appropriate service procedure is described in the text.

This shows the key No. of the part. In the text, this No. is referred to uniformly throughout.

This shows an example of the disassembly (removal) sequence.

This shows that the service procedure is described in another section. P. : shows reference page within the same group. Gr : shows reference group within the same book.

Meaning of symbols : shows that the tightening torque is specified. : shows that application of lubricant, fluid or sealant is required. : shows that the part should not be reused.

No service procedure is referred to in this section, but the item can be an objective of various procedures. This is shown when the assembly (installation) sequence is not the reverse of the disassembly (removal) sequence. This shows that a repair kit is available.

2. Service standards table Only the relevant service standards are shown.

Service standards Location 1, 11 7

Unit: mm (in.) Maintenance item

Clearance between strap bolt and strap plate Pressure spring

Standard value

Limit

Remedy

0.01 to 0.16 (0.0039 to 0.0629)

0.3 (0.0118)

Replace

835 N (85 kgf) [187.7 lbf]

710 N (72.3 kgf) [159.6 lbf]

Replace

2.9 (1.1417) or less

5.0 (0.197)

Replace

Installed load (Installed length 49.1) Tilt

This shows the key No. of the relevant part.

3. Tightening torque table This shows specified tightening torque.

Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Strap bolts (Strap bolt mounting)

Bolt (Lock plate mounting)

Tightening torque

Remarks

39 to 59 (4 to 6) [28.8 to 43.5]

–

5.9 to 7.8 (0.6 to 0.8) [4.3 to 10.5]

Wet

This shows the key No. of the relevant part.

This shows that the item is to be tightened wet.

4. Lubricants and sealant table Only the relevant lubricants and sealant are shown. This shows the application point.

Lubricants and sealant Location 1 10, 16

Points of application

Kinds

Quantity

Thread area of bolt

LOCTITE 272

As required

Friction surfaces of release lever plate and release lever

Molybdenum disulfide grease [NLGI No. 2 (Li soap)]

As required

This shows the key No. of the relevant part.

This shows the specified brand.

HOW TO READ THIS MANUAL 5. Special tools table Only the relevant special tools are shown.

Purpose of special tools is shown.

Special tools Location

Unit: mm (in.)

Tool name and shape

Clutch installer

Part No.

Application

MH061051

Removal and installation of clutch cover

MH062291

Adjust release lever heights

01277

Master plate

01278

This shows the key No. of the relevant part.

Quote this number when placing an order for the part.

6. Service procedure This indicates a special service tool.

This shows the key No. of the relevant part.

11 Removal and installation of clutch cover • Depress pressure spring 7 using clutch installer, then remove the following parts: Strap bolt 1, washer 2, washer 3, bolt 4, lock plate 5, support nut 6 • Loosen the clutch installer gradually, then remove clutch cover 11 when the pressure spring is fully released. • For installation, follow the removal sequence in reverse. 01281

The key No. referred to in the text is always the same as the key No. shown in the illustration.

Servicing procedures of disassembly (removal), assembly (installation), inspection, adjustment, etc. are shown collectively.

Terms and Units The terms and units in this manual are defined as follows. ● This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information:

DANGER

Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives.

WARNING

Precautionary instructions, which, if not observed, could result in serious injury or death.

CAUTION

Precautionary instructions, which, if not observed, could result in damage to or destruction of equipment or parts.

NOTE

Suggestions or supplementary information for more efficient use of equipment or a better understanding.

● Front and rear The terms “front” is the fan side and “rear” the flywheels side of the engine. ● Left and right The terms “right” and “left” shall be used to indicate the side as viewed from the flywheel side of the engine. ● Terms of service standards (1) Standard value Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance between two parts when assembled, and the standard value for an assembly part, as the case may be. The figure in [ ] is the basic diameter. (2) Limit When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must be replaced or repaired. ● Tightening torque Excessive or insufficient tightening torque has particular importance in respect of performance. Accordingly, tightening torque is specified in locations that are to be tightened. Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. When the item is to be tightened in a wet state, wet is indicated. Where there is no indication, read it as dry, and tighten at specified torque. ● Unit Length, weight, surface area and capacity are in SI units with foot-pound units are given in brackets. Tightening torques and other parameters are given in SI units with metric and foot-pound units added in brackets ( ) and [ ]. Example: 390 N·m (40 kgf·m) [289 lbf·ft] Foot-pound unit Metric unit SI unit Temperatures are given in degrees Celsius with degrees Fahrenheit given brackets. For the conversion into the foot-pound system, refer to the following conversion table.

vii

HOW TO READ THIS MANUAL Unit Force Moment of force

SI unit {metric unit}

Conversion factor

N {kgf}

9.80665 N {1 kgf}

N·m {kgf·m}

9.80665 N·m {1 kgf·m}

kPa {kgf/cm }

98.0665 kPa {1 kgf/cm2}

kPa {mmHg}

0.133322 kPa {1 mmHg}

Pa {mmH2O}

9.80665 Pa {1 mmH2O}

Volume

dm3 {L}

1 dm3 {1 L}

Power

kW {PS}

0.7355 kW {1 PS}

Heat quantity

J {kcal}

4186.05 J {1 kcal}

Heat flow

W {kcal/h}

1.16279 W {1 kcal/h}

Angle

–

Temperature

°C

–

Electric current

–

Voltage

–

Resistance

Ω

–

Electric power

–

Foot-pound unit

Conversion rate

Positive pressure Pressure

Vacuum pressure

Unit

SI unit

Force

N (Newton)

lbf

1 N = 0.2248 lbf

Moment of force

N·m

ft.lbs

1 N·m = 0.7375 ft.lbs

Pressure

kPa (kilopascal)

psi

1 kPa = 0.145 psi 1 kPa = 0.2953 in. Hg

Volume

gal.

cm3

cu.in.

1 L = 0.2642 gal. (U.S.) 1 L = 0.220 gal. (Imp.) 1 cm3 = 0.033814 oz (U.S.) 1 cm3 = 0.035195 oz (Imp.) 1 cm3 = 0.061023 cu.in.

Power

kW (kilowatt)

1 kW = 1.3596 PS

Temperature

°C

°F

t°C = (1.8t°C + 32)°F

Mass quantity of matter kg g

lb oz

1 kg = 2.2046 lb 1 g = 0.035274 oz

Dimension

ft. in.

1 m = 3.2808 ft. 1 mm = 0.03937 in.

viii

m mm

GROUP 00 GENERAL GENERAL SPECIFICATIONS ..................................................................

00-2

ENGINE NUMBER AND NAME PLATE ...................................................

00-3

PRECAUTIONS FOR MAINTENANCE OPERATION ...............................

00-4

TABLE OF STANDARD TIGHTENING TORQUES.................................... 00-12

00-1

GENERAL SPECIFICATIONS Item

Specifications

Engine model

6D16

Type

6D16-TLE

6-cylinder in-line, water-cooled 4-cycle diesel

Combustion chamber type

Direct injection type

Valve mechanism

Overhead valve (OHV) type

Bore × Stroke Total displacement

mm (in.)

118 × 115 (4.65 × 4.53)

cc (cu. in.)

7545 (460.4)

Compression ratio

17.5

Empty mass

kg (lb)*

500 (1.102)

560

* Empty mass as measured according to Mitsubishi Motors Corporation standard.

Engine Outputs Classified By Application Engine model

6D16

Application

6D16-TLE Middle-speed specification

High-speed specification

Intermittent rated output

kW (HP)

71 (95)/1500 85 (114)/1800 93 (125)/2000 101 (135)/2200 111 (149)/2500 120 (161)/2800

106 (142)/1500 123 (165)/1800 131 (176)/2000 140 (188)/2200

101 (136)/1500 121 (163)/1800 131 (175)/2000 139 (186)/2200 147 (197)/2500 151 (203)/2800

Coutinuous rated output

kW (HP)

65 (87)/1500 77 (103)/1800 84 (113)/2000 93 (125)/2200 101 (135)/2500 110 (147)/2800

96 (129)/1500 111 (149)/1800 119 (160)/2000 127 (170)/2200

92 (123)/1500 110 (148)/1800 118 (158)/2000 125 (168)/2200 133 (178)/2500 137 (184)/2800

NOTE 1. The output (SAE, gross) is corrected to standard ambient conditions based on SAE J1349. 2. The continuous rated output allows 10% (one hour) overload operation.

00-2

ENGINE NUMBER AND NAME PLATE

The serial number for engine is assigned to the respective engine in manufacturing sequence: every engine has its own number. This number is required for incidental inspection of the engine. Please do not fail to mention this number to the dealers when ordering spare parts.

Engine Number Engine number 1 is punch-marked on the left of the crankcase. Example: 6D16–

Engine model

Engine number

18769

Name Plate The name plate is attached to the portion shown in the illustration, and indicate the following items.

18779

1 2 3 4 5 6

Engine model Total displacement Maximum output Valve clearance Firing order Fuel injection timing

18780

00-3

PRECAUTIONS FOR MAINTENANCE OPERATION In order to determine the condition of the vehicle adequately, attend the vehicle beforehand to find and keep record of the accumulated mileage, operating condition, what the customer's demand is, and other information that may be necessary. Prepare the steps to be taken and perform efficient and wasteless maintenance procedure. Determine where the fault exists and check for the cause to see whether removal or disassembly of the part is necessary. Then follow the procedure specified by this manual.

18770

Perform maintenance work at a level area. Prepare the following. • Prepare general and special tools necessary for the maintenance work.

WARNING

00009

Do not attempt to use tools other than special tools where use of special tools is specified in this manual. This will avoid injury or damage.

Pay special attention to safety when removing or installing heavy items such as engines, transmissions. When lifting up heavy items using cables, pay special attention to the following points: • Check the mass of the item to be lifted and use a cable capable of lifting that mass. 14194

• If you do not have the specified lifting hanger, secure the item using cable taking the point-of-balance of the item into consideration.

14195

• You must work in a position where you will not be injured even if the cable comes undone and the lifted item falls.

00-4

00 Be particularly careful not to work in shoes that have oily soles and are slippery. When working as a team of two or more, arrange signals in advance and keep confirming safety. Be careful not to accidentally bump switches or levers.

00012

Check for oil leakage before cleaning the area having the fault otherwise you might miss detecting the leakage. Prepare replacement part(s) beforehand.

00014

Replace oil seals, packing, O-rings and other rubber parts; gaskets and split pins with new parts whenever any of them has been removed. Use only genuine MITSUBISHI replacement parts.

00015

On disassembly, visually inspect all parts for wear and tear, cracks, damage, deformation, degradation, rust, corrosion, smoothness in rotation, fatigue, clogging and any other possible defect.

00016

00-5

PRECAUTIONS FOR MAINTENANCE OPERATION Put alignment marks on part combinations before disassembly and arrange the disassembled parts neatly. This will help avoid mismating of the parts later. Put the alignment marks, punch marks, etc. where performance and appearance will not be affected. Cover the area left open after removal of parts to keep it free from dust.

CAUTION 00017

• Take care to avoid mixing up numerous parts, similar parts, left and right, etc. • Keep new parts for replacement and original (removed) parts separate.

Apply the specified oil or grease to U-packings, oil seals, dust seals and bearings during assembly. Use only the specified oil, grease, etc. for lubricant, remove the excess immediately after application with a piece of waste, etc.

CAUTION When the specified lubricant, fluid and sealant is not available, you may use an equivalent. 00018

Wear goggles when using a grinder or welder. Pay full attention to safety by wearing gloves when necessary. Watch out for sharp edges, etc. that might injure your hands or fingers.

00019

Before carrying out maintenance work on the electric system, disconnect the negative terminals of the batteries to prevent them from short-circuiting and burning-out.

CAUTION

14184

00-6

Be sure to turn starter and lighting switches, etc. off before disconnecting or connecting battery terminals, because the semiconductors can be damaged.

00 Take care when handling sensors, relays, etc. which are vulnerable to shock and heat. Do not attempt to remove the cover from, or apply paint to, the electronic control unit.

00021

Pull the connector, and not the harness lead, to separate connectors. To separate a lock-type connector, first push toward arrow mark. To reconnect a lock-type connector, press the separated parts until they click together.

00022

When washing the vehicle, cover the electric system parts and instruments with waterproof material beforehand (Cover with vinyl sheet or the like). Keep water away from harness wire connectors and sensors. If any of them should get wet, wipe them off immediately.

00023

When using an electric welder, such electronic parts that are directly connected to the batteries might be damaged due to the flow of current from the welder that flows through the negative circuit. Parts that have switches might be subject to the same danger if the switches are left on. Therefore, do not fail to observe the following. • Connect the negative terminal of the welder as near as possible to the area that is to be welded. • Disconnect the negative terminals of batteries. To apply voltage for testing, check that the positive and negative cables are connected properly, then increase voltage gradually from 0 volt. Do not apply voltage higher than the specified value. In particular, pay close attention to the electronic control unit and sensors, since they are not always fed the battery voltage.

14185

00-7

PRECAUTIONS FOR MAINTENANCE OPERATION When using testers or the like for continuity tests, be careful not to allow test probes to touch the wrong terminals.

00027

Measurement Procedures Using Connectors Test with connectors engaged (continuity through circuit obtained) <Waterproof connector> Prepare a test harness and connectors A, then connect if between the two parts of harness B that is to be tested. Check the circuit by touching test probe C to the test connector. Never insert the test probe from the harness side of the waterproof connection, or waterproof performance might be diminished causing corrosion of the connector. 02587

<Non-waterproof connector> Insert test probe C from the harness side of the connector. Where control units, etc. have connectors that are too small to accept the test probe, do not force the test probe into them.

02588

Test with connectors disengaged Using female pins Insert a test probe into a terminal. However, do not force the probe into the terminal, or it will cause a poor contact.

02589

00-8

00 Using male pins Touch the pins directly using test probes.

CAUTION Be sure that you do not short circuit the connector pins when you use the test probe because this could damage the internal circuit of the electronic control unit. 02590

Connector Inspection Procedures Visual inspection Check for loose connection and poor engagement.

02591

Check if harnesses are broken by pulling gently around the terminals.

02592

Check for a decrease in contact pressure between the male and female terminals.

02593

Check for poor contact caused by connector pins having fallen out, rusted terminals or foreign particles.

00-9

PRECAUTIONS FOR MAINTENANCE OPERATION Connector pin fall out inspection Damaged connector pin stoppers can cause poor engagement of the terminals (male and female pins) even if the connector body is secured, and might cause some pins to fall out. Check if the pins have fallen out from the connector by pulling each harness gently.

02594

Inspection Procedures for Blown Fuses Remove fuse B and measure resistance between the loaded side of the fuse and ground. Turn on all circuit switches (connected to the fuse). If the resistance value reading is approximately 0, a short has occurred between the switch and the loaded point. A value of other than zero may indicate that the fuse was blown by a temporary short but the short is no longer present. The major causes of a short circuit are as follows: • Harness stuck onto the vehicle body. • Harness sheath damaged by friction or heat. • Water in connectors or circuits. • Mistakes (accidental short circuits) A: Battery B: Fuse C: Loaded switch D: Load E: Short circuit 02596

Precautions for Handling Alternator When servicing the alternator, pay attention to the following: • Do not connect the alternator with battery polarities reversed. If the alternator is connected with reversed polarities, a large current flow from the battery to the alternator occurs, and the diode or regulator might be damaged.

04746

00-10

00 • While the engine is running, do not remove the battery terminals. If the battery terminals are removed at that time, a surge voltage is generated and the diode or regulator might be weakened.

04747

• Do not use a high-voltage tester such as a megger for inspection. If a high-voltage tester is used, the diode or regulator might be destroyed.

02371

• Do not splash water over the alternator. If water is directly splashed over the alternator, individual components will be short-circuited and might be destroyed.

05165

• Do not short-circuit terminal B and terminal L while running the alternator. If the terminals are short-circuited while the alternator is running, the diode trio might be destroyed.

04749

• Disconnect the battery terminals before quick-charging the battery. Quick-charging without disconnecting the battery terminals might damage the diode or regulator.

05166

00-11

TABLE OF STANDARD TIGHTENING TORQUES • Use specified bolts and nuts and tighten them at specified torques according to the following table, unless otherwise specified. • Threads and contact seats shall be dry. • Where there is a difference in strength classification between the nut and bolt (or stud bolt), the torque specified for the bolt shall apply.

Hex-head Bolt and Stud Bolt Strength classification

Diameter symbol

00-12

Unit: N·m (kgf·m) [lbf·ft]

Representation (Stud)

(Stud)

02154

(Stud)

2 to 3 (0.2 to 0.3) [1.48 to 2.21]

–

4 to 6 (0.4 to 0.6) [2.95 to 4.43]

–

5 to 7 (0.5 to 0.7) [3.69 to 5.16]

–

4 to 6 (0.4 to 0.6) [2.95 to 4.43]

–

7 to 11 (0.7 to 1.1) [5.16 to 8.11]

–

8 to 12 (0.8 to 1.2) [5.90 to 8.85]

–

9 to 14 (0.9 to 1.4) [6.64 to 10.3]

–

17 to 26 (1.7 to 2.6) [12.5 to 19.2]

–

20 to 29 (2.0 to 3.0) [14.8 to 21.4]

–

M10

19 to 28 (1.9 to 2.8) [14.0 to 20.6]

18 to 26 (1.8 to 2.7) [13.3 to 19.2]

36 to 52 (3.5 to 5.5) [26.6 to 38.4]

33 to 49 (3.5 to 5.0) [24.3 to 36.1]

45 to 60 (4.5 to 6.0) [33.2 to 44.3]

41 to 59 (4.3 to 6.9) [30.2 to 43.5]

M12

35 to 50 (3.4 to 5.0) [25.8 to 36.9]

31 to 46 (3.1 to 4.7) [22.9 to 33.9]

70 to 95 (7.0 to 9.5) [51.6 to 70.1]

65 to 85 (6.5 to 8.5) [47.9 to 62.7]

85 to 110 (8.5 to 11) [62.7 to 81.1]

75 to 100 (7.5 to 10) [55.3 to 73.8]

M14

60 to 85 (6.0 to 8.5) [44.3 to 62.7]

55 to 75 (5.5 to 7.5) [40.6 to 55.3]

120 to 160 (12 to 16) [88.5 to 118]

110 to 140 (11 to 14) [81.1 to 103]

130 to 180 (13 to 18) [95.9 to 133]

120 to 160 (12 to 17) [88.5 to 118]

M16

90 to 130 (9.5 to 13) [66.4 to 95.9]

90 to 120 (9.0 to 12) [66.4 to 88.5]

180 to 240 (18 to 24) [133 to 177]

160 to 220 (16 to 22) [118 to 162]

200 to 270 (20 to 27) [148 to 199]

190 to 260 (19 to 26) [140 to 192]

M18

140 to 190 (14 to 19) [103 to 140]

120 to 160 (12 to 16) [88.5 to 118]

260 to 340 (25 to 35) [192 to 251]

220 to 290 (22 to 30) [162 to 214]

290 to 390 (30 to 40) [214 to 288]

260 to 340 (26 to 35) [192 to 251]

M20

190 to 260 (19 to 26) [140 to 192]

170 to 230 (17 to 23) [125 to 170]

350 to 470 (36 to 48) [251 to 347]

320 to 420 (32 to 43) [236 to 310]

410 to 550 (41 to 56) [302 to 406]

370 to 490 (37 to 50) [273 to 361]

M22

260 to 340 (26 to 35) [192 to 251]

230 to 300 (23 to 31) [170 to 221]

470 to 640 (48 to 65) [347 to 472]

430 to 570 (43 to 58) [317 to 420]

550 to 740 (56 to 75) [406 to 546]

490 to 670 (50 to 68) [361 to 494]

M24

340 to 450 (34 to 46) [251 to 332]

290 to 390 (29 to 40) [214 to 288]

630 to 840 (63 to 86) [465 to 620]

540 to 730 (55 to 74) [398 to 538]

730 to 980 (74 to 100) [538 to 723]

630 to 840 (64 to 86) [465 to 620]

00 Hex-head Flange Bolt Strength classification

Diameter symbol

Unit: N·m (kgf·m) [lbf·ft]

Representation 02154

4 to 6 (0.4 to 0.6) [2.95 to 4.43]

–

8 to 12 (0.8 to 1.2) [5.90 to 8.85]

–

9 to 14 (0.9 to 1.4) [6.64 to 10.3]

–

10 to 15 (1.0 to 1.5) [7.38 to 11.1]

–

19 to 28 (1.9 to 2.8) [14.0 to 20.6]

–

22 to 32 (2.2 to 3.3) [16.2 to 23.6]

–

M10

21 to 30 (2.1 to 3.1) [15.5 to 22.1]

20 to 28 (1.9 to 2.9) [14.8 to 20.6]

39 to 58 (3.9 to 6.0) [28.8 to 42.8]

37 to 53 (3.6 to 5.4) [27.3 to 39.1]

50 to 65 (5.0 to 6.5) [66.8 to 47.9]

45 to 65 (4.5 to 6.5) [33.2 to 47.9]

M12

38 to 54 (3.8 to 5.5) [28.0 to 39.8]

35 to 51 (3.4 to 5.2) [25.8 to 37.6]

80 to 110 (8.0 to 11) [59.0 to 81.1]

70 to 95 (7.0 to 9.5) [51.6 to 70.1]

90 to 120 (9.0 to 12) [66.4 to 88.5]

85 to 110 (8.5 to 11) [62.7 to 81.1]

00-13

TABLE OF STANDARD TIGHTENING TORQUES Hex-head Nut

Unit: N·m (kgf·m) [lbf·ft]

Strength classification

Representation Diameter symbol

00-14

02155

Standard screw Coarse screw

Standard screw

Coarse screw

2 to 3 (0.2 to 0.3) [1.48 to 2.21]

–

4 to 6 (0.4 to 0.6) [2.95 to 4.43]

–

4 to 6 (0.4 to 0.6) [2.95 to 4.43]

–

7 to 11 (0.7 to 1.1) [5.16 to 8.11]

–

9 to 14 (0.9 to 1.4) [6.64 to 10.3]

–

17 to 26 (1.7 to 2.6) [12.5 to 19.2]

–

M10

19 to 28 (1.9 to 2.8) [14.0 to 20.6]

18 to 26 (1.8 to 2.7) [13.3 to 19.2]

36 to 52 (3.5 to 5.5) [26.6 to 38.4]

33 to 49 (3.5 to 5.0) [24.3 to 36.1]

M12

35 to 50 (3.4 to 5.0) [25.8 to 36.9]

31 to 46 (3.1 to 4.7) [22.9 to 33.9]

70 to 95 (7.0 to 9.5) [51.6 to 70.1]

65 to 85 (6.5 to 8.5) [47.9 to 62.7]

M14

60 to 85 (6.0 to 8.5) [44.3 to 62.7]

55 to 75 (5.5 to 7.5) [40.6 to 55.3]

120 to 160 (12 to 16) [88.5 to 118]

110 to 140 (11 to 14) [81.1 to 103]

M16

90 to 130 (9.5 to 13) [66.4 to 95.9]

90 to 120 (9.0 to 12) [66.4 to 88.5]

180 to 240 (18 to 24) [133 to 177]

160 to 220 (16 to 22) [118 to 162]

M18

140 to 190 (14 to 19) [103 to 140]

120 to 160 (12 to 16) [88.5 to 118]

260 to 340 (25 to 35) [192 to 251]

220 to 290 (22 to 30) [162 to 214]

M20

190 to 260 (19 to 26) [140 to 192]

170 to 230 (17 to 23) [125 to 170]

350 to 470 (36 to 48) [251 to 347]

320 to 420 (32 to 43) [236 to 310]

M22

260 to 340 (26 to 35) [192 to 251]

230 to 300 (23 to 31) [170 to 221]

470 to 640 (48 to 65) [347 to 472]

430 to 570 (43 to 58) [317 to 420]

M24

340 to 450 (34 to 46) [251 to 332]

290 to 390 (29 to 40) [214 to 288]

630 to 840 (63 to 86) [465 to 620]

540 to 730 (55 to 74) [398 to 538]

00 Hex-head Flange Nut Strength classification

Unit: N·m (kgf·m) [lbf·ft]

Representation Diameter symbol

02155

Standard screw Coarse screw

4 to 6 (0.4 to 0.6) [3.69 to 5.16]

–

10 to 15 (1.0 to 1.5) [2.95 to 4.43]

–

M10

21 to 30 (2.1 to 3.1) [7.38 to 11.1]

20 to 28 (1.9 to 2.9) [28.0 to 39.8]

M12

38 to 54 (3.8 to 5.5) [15.5 to 22.1]

35 to 51 (3.4 to 5.2) [14.8 to 20.6]

00-15

TABLE OF STANDARD TIGHTENING TORQUES Tightening torque for flare nut for general purpose Pipe diameter Tightening torque

Unit: N·m (kgf·m) [lbf·ft]

φ4.76 mm (φ0.187 in.)

φ6.35 mm (φ0.250 in.)

φ8 mm (φ0.315 in.)

φ10 mm (φ0.394 in.)

φ12 mm (φ0.472 in.)

φ15 mm (φ0.591 in.)

17 (1.7) [12.5]

25 (2.6) [18.4]

39 (4.0) [28.8]

59 (6.0) [43.5]

88 (9.0) [64.9]

98 (10.0) [72.3]

Tightening torque for air piping nylon tube for general purpose {DIN type} Standard diameter Tightening torque

Unit: N·m (kgf·m) [lbf·ft]

6 × 1 mm (0.236 × 0.0394 in.)

10 × 1.25 mm (0.394 × 0.0492 in.)

12 × 1.5 mm (0.472 × 0.0591 in.)

15 × 1.5 mm (0.591 × 0.0591 in.)

+6 −0 +0.6 2.0 −0 +0.4 14.8 −0

+10 −0 +1.0 3.0 −0 +0.7 21.4 −0

+10 −0 +1.0 5.0 −0 +0.7 36.1 −0

+5 −0 +1.0 5.5 −0 +0.7 39.8 −0

Tightening torque for air piping nylon tube for general purpose {SAE type}

Unit: N·m (kgf·m) [lbf·ft]

Standard diameter

1/4 in.

3/8 in.

1/2 in.

5/8 in.

Tightening torque

+4 −0 +0.4 1.3 −0 +0.30 9.59 −0

+5 −0 +0.5 3.0 −0 +0.4 21.4 −0

+5 −0 +0.5 5.0 −0 +0.4 36.1 −0

+5 −0 +0.5 6.5 −0 +0.4 47.2 −0

00-16

GROUP 11 ENGINE SPECIFICATIONS....................................................................................

11-2

STRUCTURE AND OPERATION.............................................................. 1. Cylinder Head and Crankcase.............................................................................. 2. Valve Mechanism.................................................................................................. 3. Connecting Rods .................................................................................................. 4. Pistons .................................................................................................................. 5. Timing Gears ........................................................................................................ 6. Flywheel ................................................................................................................

11-3 11-3 11-4 11-4 11-5 11-5 11-5

TROUBLESHOOTING .............................................................................

11-6

ON-VEHICLE INSPECTION AND ADJUSTMENT....................................

11-8 1. Measuring Compression Pressure ....................................................................... 11-8 2. Inspecting and Adjusing Valve Clearances.......................................................... 11-10

CYLINDER HEAD AND VALVE MECHANISM.......................................... 11-12 PISTONS, CONNECTING RODS, AND CYLINDER LINERS ................... 11-30 FLYWHEEL .............................................................................................. 11-46 TIMING GEARS ....................................................................................... 11-52 CAMSHAFT ............................................................................................. 11-58 CRANKSHAFT AND CRANKCASE.......................................................... 11-66

11-1

SPECIFICATIONS Item

Specifications

Engine model

6D16

Type

6D16-TLE

6-cylinder, in-line, water-cooled, 4-cycle diesel

Combustion chamber type

Direct injection

Valve mechanism

Overhead valve

Cylinder bore × stroke Total displacement

mm (in.)

φ118 × 115 (φ4.65 × 4.53)

cc (cu. in.)

7545 (460.4)

Compression ratio

11-2

17.5

STRUCTURE AND OPERATION 1. Cylinder Head and Crankcase 1 2 3 4 5 6 7 8

Connecting plate Glow plug Cylinder liner Crankcase Water jacket Piston Injection nozzle Cylinder head

A: Cylinder liner size mark Outer diameter mark: 1, 2, 3 Inner diameter mark: A, B • The cylinder liners 3 are a dry type liners that are easier to remove than wet liners. Liners are press-fitted into the crankcase 4. • The cylinder liners 3, crankcase 4, and pistons 6 have size marks. They should be combined as specified according to the size marks. P.11-36 01925

11-3

STRUCTURE AND OPERATION 2. Valve Mechanism 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

01926

Exhaust valve Inlet valve Camshaft Tappet Push rod Rocker shaft Rocker shaft spring Rocker Rocker shaft bracket Valve cap Valve cotter Upper retainer Outer valve spring Inner valve spring Valve stem seal Valve guide

• The valve stem seals 15 are fitted onto the valves 1, 2 to control the amount of lubricant flowing onto the sliding surfaces of the valves 1, 2 and valve guides 16. • The valve springs 13, 14 are unevenly pitched to prevent abnormal vibration at high speeds. To prevent the inner and outer springs from meshing with each other, the springs are wound in opposite directions. • To facilitate removal and reinstallation of the camshaft from the rear end of the crankcase, the diameter of each bushing is smaller toward the front of the engine.

3. Connecting Rods <6D16>

1 2 3 4 5

<6D16-TLE>

Connecting rod bushing Connecting rod Connecting rod bearing Connecting rod cap Connecting rod bolt

A: Alignment mark B: Weight mark stamp (A, B, C, D, E, F, G, H, I, V, W, X, Y, Z: <6D16>) (A, B, C, D, E, F: <6D16-TLE>)

13622

11-4

11 4. Pistons A: Part number B: “T” mark <6D16-TLE> C: Size mark (A, B: <6D16, 6D16-TLE>) D: Weight mark : Front mark

16936

5. Timing Gears Camshaft gear No. 2 idler gear No. 1 idler gear Oil pump gear Crankshaft gear Air compressor drive gear or injection pump drive gear 7 No. 1 idler gear 1 2 3 4 5 6

Each gear is stamped with a timing gear alignment mark (“1”, “2”, “3”, or “4”) to facilitate reassembly.

16937

6. Flywheel 1 Flywheel 2 Pilot bearing 3 Ring gear A: Angle scale, cylinder number

01934

11-5

TROUBLESHOOTING

Abnormal engine noise

Possible causes

Low power output

Symptoms

Remarks

Incorrect oil viscosity

Gr 11

Incorrect/defective fuel

Gr 13

Incorrect valve clearance Defective cylinder head gasket Worn valve/valve seat, and carbon deposits Weakened valve spring Worn/damaged piston ring(s) Worn/damaged piston ring groove(s) Incorrect injection timing

Gr 13

Defective injection pump

Gr 13

Defective cooling system

Gr 14

Defective injection nozzle(s)

Gr 13

Air trapped in fuel system

Gr 13

Clogged air cleaner

Gr 15

Clogged muffler

Gr 15

Defective turbocharger

Gr 15

Incorrectly fitted pipe(s)/hose(s)

Gr 13

Injection pump, alternator, or other auxiliary device(s) defective/incorrectly fitted

Gr 13, 54

Loose/damaged V-belt

Gr 14

Incorrectly fitted crankshaft pulley Defective air cleaner or muffler Defective valve spring(s) Defective rocker shaft and bracket Incorrect lubrication of rocker shaft bracket Incorrect backlash in timing gears Incorrect lubrication of timing gear peripheries and idler shafts Worn connecting rod small end bushing and piston pin Worn/damaged crankshaft pin and connecting rod big end bearing Worn/damaged crankshaft journal and main bearing Excessive end play in crankshaft and camshaft Worn tappet(s) and camshaft

11-6

Gr 15

MEMO

11-7

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Measuring Compression Pressure Service standards Location –

Maintenance item Compression pressure

Each cylinder (at 200 rpm)

Standard value

Limit

Remedy

2550 kPa (26 kgf/cm2) [370 psi]

1960 kPa (20 kgf/cm2) [284 psi]

Inspect

–

390 kPa (4 kgf/cm2) [56.6 psi]

Inspect

Cylinder-to-cylinder pressure difference

Special tools Location

–

Unit: mm (in.)

Tool name and shape

Part No.

Compression Gauge Adapter

MH061461

Application

Measuring compression pressure

01942

Reductions in compression pressure should be used as a guide in determining the timing of engine overhauls. Take measurements regularly and keep track of changes; an overview of pressure variations can be useful in fault diagnosis. During the engine's run-in period and after parts have been replaced, the compression pressure will increase slightly as piston rings, valve seats, and other parts fit snugly in position. The pressure will then normalize as parts wear. • Before inspections, check that the engine oil, starter, and battery are normal. • Warm up the engine until the coolant temperature reaches 75 to 85°C (167 to 185°F). • Turn off all lights and auxiliary devices. • To prevent injection of fuel while cranking the engine by the starter, perform the following steps. • Set the stop lever of the injection pump governor to the stop position. <Mechanical governor> • Remove fuse 1 shown in the diagram below. For the terminal arrangement of the engine ECU, refer to Gr 13E. <Electronic governor>

P 47396

11-8

11 • Remove the injection nozzle A. Gr 13

CAUTION Cover the mounting holes and injection pipes to prevent the entry of dust and dirt.

01938

• Cover the injection nozzle mounting hole B with a cloth C. Then, turn the engine over with the starter and check that no foreign matter adheres to the cloth.

WARNING

11735

01939

If any cylinder is cracked, coolant, engine oil, and fuel will enter the cylinder through the crack. When the engine is turned over, these substances will spray out of the nozzle mounting hole B at a high temperature. For safety, move away from the nozzle mounting hole before turning over the engine.

• Fit the Compression Gauge Adapter onto an injection nozzle mounting hole B together with a nozzle gasket. Then, connect the compression gauge 1. • Turn the engine over and measure the compression pressure. • Measure the compression pressure in every cylinder and determine the pressure differences between cylinders. • If any compression pressure or cylinder-to-cylinder pressure difference exceeds the specified limit, pour a little engine oil into the cylinder via the injection nozzle mounting hole B then take the measurement again. • If the compression pressure increases, there may be wear or damage on piston rings and inner surfaces of cylinders. • If the compression pressure does not increase, valves may be seized or incorrectly seated, or the cylinder head gasket may be defective.

11-9

ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Inspecting and Adjusting Valve Clearances Service standards Location –

Unit: mm (in.)

Maintenance item Valve clearance (when cold)

Standard value

Limit

Remedy

0.4 (0.0158)

–

Adjust

Tightening torques Location 2, 3

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened Rocker arm adjusting screw lock nut

Tightening torque

Remarks

34 (3.5) [25.1]

–

Valve clearances should be checked and adjusted when the engine is cold. [Inspection] • Bring piston No. 1 or piston No. 6 to the top-dead-centre (TDC) position of its compression stroke. To do this, crank the engine until the “1.6” mark inscribed on the flywheel is aligned with the pointer A in the flywheel housing inspection window.

NOTE Pistons whose push rods are not pushing up their rockers are at top-dead-centre (TDC) of their compression strokes. 01940

• When piston No. 1 or piston No. 6 is at the TDC position of its compression stroke, measure the clearance B of every valve marked “ ” in the following table. Piston No. Valve arrangement

In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.

No. 1 piston at TDC of compression stroke 11620

No. 6 piston at TDC of compression stroke

NOTE To measure the clearance, insert a feeler gauge 1. The gauge should be able to move in the gap, albeit not loosely. Accurate measurements cannot be taken if the gauge moves loosely in the gap.

11-10

11 • If any measurement is out of specification, make adjustments as follows: [Adjustment] • To adjust the valve clearance B, loosen the lock nut 2 and turn the adjusting screw 3 until the feeler gauge 1 moves more stiffly in the gap. • After adjusting the clearance, tighten the lock nut 2. At this time, use a screwdriver C to stop the adjusting screw 3 from turning. Next, insert the feeler gauge 1 once more to confirm that the clearance B is correct. 11621

11-11

CYLINDER HEAD AND VALVE MECHANISM

04134

● Disassembly sequence 1 Joint 2 Oil filler cap 3 Bolt 4 Plate 5 Rubber 6 Rocker cover gasket 7 Rocker cover

8 Cylinder head bolt 9 Rocker and bracket assembly P.11-16 10 Cylinder head and valve assembly P.11-20 11 Cylinder head gasket

● Assembly sequence Follow the disassembly sequence in reverse.

11-12

12 Push rod 13 Tappet

*: Crankcase

P.11-66 A: Locating pin : Non-reusable part

11 Service standards Location

Maintenance item

Standard value

Limit

Remedy

–

0.4 (0.0157)

Replace

0.06 to 0.10 (0.00237 to 0.00394)

0.2 (0.00787)

Replace tappet

0.03 to 0.07 (0.00118 to 0.00276)

0.1 (0.00394)

Push rod runout

12 13,

Unit: mm (in.)

Tappet-to-crankcase clearance 6D16 [Basic diameter: 31 mm (1.220 in.)] 6D16-TLE

Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

Joint

29 (3.0) [21.4]

–

Rocker cover bolt

3.9 (0.4) [2.88]

–

Cylinder head bolt M14 bolt (installation of rocker and bracket assembly and cylinder head and valve assembly) M10 bolt

78 (8) [57.5] + 180°

• Wet • Can be reused up to 3 times

17 (1.75) [12.5] + 34 (3.5) [25.1]

–

Lubricant Location

Points of application

Specified lubricant

Quantity

Rubber seal of oil filler cap

Engine oil

As required

Threads of cylinder head bolts

Engine oil

As required

Both ends of push rods

Engine oil

As required

Outer surfaces of tappets

Engine oil

As required

Special tools Location

Tool name and shape

Socket Wrench

Part No.

Application

MH063388

Tightening cylinder head bolts (M14 bolt only)

01984

◆ Service procedure 10 Cylinder head and valve assembly [Removal] • Before loosening the cylinder head bolts 8, loosen the adjusting screw C on every rocker A that is compressing its valve spring B.

13021

11-13

CYLINDER HEAD AND VALVE MECHANISM • Loosen and remove the cylinder head bolts 8 in the sequence shown. Each cylinder head bolt should be loosened a little at a time.

01945

[Installation]

CAUTION

P 21229

Before fitting any cylinder head bolt 8, check the punch marks A on its head. Do not use the bolt if there are more than two punch marks. The punch marks indicate the number of times each bolt has been tightened using the plastic area tightening method. Any bolt that already has three punch marks must be replaced. • Tighten the cylinder head bolts 8 to the specified torque {M14 bolts: 78 N·m (8 kgf·m) [57.5 lbf·ft]; M10 bolts: 17 N·m (1.75 kgf·m) [12.5 lbf·ft]} in the sequence shown. Then, turn the bolts further in accordance with the following procedure.

*: Tighten together with rocker and bracket assembly

➀ to

: M14 bolt (wet) : M10 bolt

01945

<M14 Bolts> • Before fitting the Socket Wrench over a cylinder head bolt, turn the holder D counter-clockwise to tension the built-in spring. E: Socket F: Rod G: Rod (extension) 01991

• Set the socket such that the built-in spring force forces the rod G against the rocker shaft bracket, an injection pipe, or another nearby part. • On the holder D, select the inscribed line H that is easiest to see. • Using the selected line as a reference, turn the socket E 180° clockwise. (One gradation on the scale J represents 5°.)

CAUTION 12825

11-14

Since the M14 cylinder head bolts 8 utilize the plastic region tightening method, they must not be tightened further after this procedure.

11 <M10 Bolts> • After fitting the M14 cylinder head bolts 8, tighten the M10 bolts to the specified torque {34 N·m (3.5 kgf·m) [25.1 lbf·ft]} in the sequence shown.

01945

11 Cylinder head gasket [Removal]

CAUTION When removing the cylinder head gasket 11, be careful not to scratch the cylinder head and valve assembly 10 and the crankcase .

[Fitting] • Fit the cylinder head gasket 11 onto the crankcase

* as shown.

13582

12 Push rod runout If any measurement exceeds the specified limit, replace the defective part(s).

01948

13 * Tappet-to-crankcase clearance If any measurement exceeds the specified limit, replace the defective part(s).

01949

11-15

CYLINDER HEAD AND VALVE MECHANISM Rocker and Bracket Assembly ● Disassembly sequence 1 Rocker assembly 2 Rocker bushing 3 Lock nut 4 Adjusting screw 5 Rocker 6 No. 6 rocker shaft bracket 7 Set screw 8 No. 5 rocker shaft bracket 9 No. 4 rocker shaft bracket 10 No. 3 rocker shaft bracket 11 No. 2 rocker shaft bracket 12 No. 1 rocker shaft bracket 13 Rocker shaft spring 14 Rocker shaft ● Assembly sequence Reverse the order of disassembly. 13022

Service standards

Unit: mm (in.)

Location

Maintenance item

Standard value

Limit

Remedy

2, 14

Rocker bushing-to-rocker shaft clearance [Basic diameter: 24 mm (0.945 in.)]

0.01 to 0.08 (0.000394 to 0.00315)

0.12 (0.00472)

Replace

Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

Adjusting screw lock nut

34 (3.5) [25.1]

–

Rocker shaft set screw

3.9 (0.4) [2.88]

–

Lubricant Location 2

Points of application Rocker bushing inner surface

Specified lubricant Engine oil

Special tools Location

As required

Unit: mm (in.)

Tool name and shape

Rocker Bushing Puller

01951

11-16

Quantity

Part No.

Application

MH061777

Removing and installing rocker bushings

11 ◆ Service procedure 2 14 Rocker bushing and rocker shaft [Inspection] If any clearance exceeds the specified limit, replace the defective part(s).

01952

Rocker bushing [Removal]

12994

[Installation] • Align the oil hole A in the rocker bushing 2 with the oil hole B in the rocker 5. • Position the notch C and seam D on the rocker bushing 2 as shown. • Install the rocker bushing 2 into the rocker 5 from the chamfered side F.

12995

6 8 to 12 14 Installing rocker shaft brackets and rocker shaft Rocker shaft brackets Be sure to fit the rocker shaft brackets 6, 8, 12 in their correct positions. A: Oil hole B: Threaded hole (for M8 rocker cover bolt) C: Threaded hole (for M6 set screw) D: No threaded hole

13023

11-17

CYLINDER HEAD AND VALVE MECHANISM Rocker shaft Align the oil hole G in the No. 6 rocker shaft bracket 6 with the oil hole H in the rocker shaft 14.

13024

11-18

MEMO

11-19

CYLINDER HEAD AND VALVE MECHANISM Cylinder Head and Valve Mechanism

01955

● Disassembly sequence 1 Valve cap 2 Valve cotter 3 Upper retainer 4 Outer valve spring 5 Inner valve spring 6 Valve stem seal 7 Exhaust valve 8 Inlet valve

Injection nozzle Gr 13 Dust seal Nozzle tip gasket Nut Connecting plate Glow plug Gr 54 15 Exhaust valve guide 9 10 11 12 13 14

16 17 18 19 20

Inlet valve guide Exhaust valve seat Inlet valve seat Stud Cylinder head : Non-reusable part

CAUTION The injection nozzles 9 and glow plugs 14 project from the bottom surface of cylinder head 20. Take care not to damage them.

● Assembly sequence Follow the disassembly sequence in reverse.

NOTE Any valve stem seal 6 removed from an exhaust valve 7 or inlet valve 8 must be replaced.

11-20

11 Service standards Location

Unit: mm (in.)

Maintenance item

Standard value

Limit

Remedy

6D16

67.0 (2.64)

64.0 (2.52)

Replace

6D16-TLE

68.3 (2.689)

65.3 (2.571)

330 N (33.5 kgf) [74.5 lbf]

290 N (29.7 kgf) [65.2 lbf]

390 N (40.0 kgf) [87.7 lbf]

350 N (35.5 kgf) [65.2 lbf]

–

2.5 (0.0984)

Replace

6D16

55.1 (2.17)

52.1 (2.05)

Replace

6D16-TLE

65.1 (2.563)

61.5 (2.421)

92 N (94 kgf) [20.7 lbf]

78 N (8.0 kgf) [17.5 lbf]

155 N (15.8 kgf) [34.9 lbf]

130 N (13.4 kgf) [29.3 lbf]

6D16

–

2.0 (0.0787)

Replace

6D16-TLE

–

2.5 (0.0984)

Replace

Stem outside diameter

φ8.93 to 8.94 (φ0.3516 to 0.3520)

φ8.85 (φ0.348)

Replace

Sinkage from cylinder head bottom surface

1.3 to 1.7 (0.0512 to 0.0670)

2.0 (0.0787)

Inspect every location

Valve margin

1.5 (0.0591)

1.2 (0.0472)

Reface or replace

Seat angle

45°

–

Correct

Stem outside diameter

φ8.96 to 8.97 (φ0.3528 to 0.3531)

φ8.85 (φ0.348)

Replace

Sinkage from cylinder head bottom surface

1.1 to 1.5 (0.0433 to 0.0591)

1.8 (0.0709)

Inspect every location

Valve margin

1.5 (0.0591)

1.2 (0.0472)

Reface or replace

Seat angle

45° ± 15’

–

Correct

Exhaust valve stem-to valve guide clearance [Basic diameter: 9 mm (0.354 in.)]

0.07 to 0.10 (0.00276 to 0.00394)

0.2 (0.00787)

Replace

7, 15 8, 16

Inlet valve stem-to-valve guide clearance [Basic diameter: 9 mm (0.354 in.)]

0.04 to 0.06 (0.00157 to 0.00236)

0.15 (0.00591)

Replace

Exhaust valve seat width

1.8 to 2.2 (0.0709 to 0.0866)

2.8 (0.110)

Correct or replace

Inlet valve seat width

1.8 to 2.2 (0.0709 to 0.0866)

2.8 (0.110)

Correct or replace

Bottom surface distortion

0.08 (0.00315) or less

0.2 (0.00787)

Correct or replace

Height from top to bottom surface

94.9 to 95.1 (3.736 to 3.744)

94.5 (3.72)

Replace

Outer valve spring 4

Free length

Installed load 6D16 [at 47.8 mm (1.88 in.) installed length] 6D16-TLE

Squareness Inner valve spring

Free length

Installed load 6D16 [at 40.5 mm (1.59 in.) installed length] 6D16-TLE

Squareness Exhaust valve 7

Inlet valve

17 18

Cylinder head

Replace

11-21

CYLINDER HEAD AND VALVE MECHANISM Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Glow plug

Exhaust manifold mounting stud

Tightening torque

Remarks

15 to 20 (1.5 to 2.0) [11.1 to 14.8]

–

29 (3) [21.4]

–

Lubricant Location

Points of application

Specified lubricant

Quantity

Rocker contact surface on valve cap top

Engine oil

As required

Lip of valve stem seal

Engine oil

As required

7, 8

Valve stem

Engine oil

As required

Special tools Location

Unit: mm (in.)

Tool name and shape

Part No. A: MH061668 [with φ42 (φ1.65) valve lifter seat] B: MH061679

A: Valve Lifter B: Valve Lifter Hook

Application

Removing and installing valve cotters

01956

Valve Stem Seal Installer

MH061293

Installing valve stem seals

01957

7, 8

30091-07500 Lapping valves and valve seats (inlet, exhaust)

Valve Lapper

01958

11-22

11 Special tools Location

Unit: mm (in.)

Tool name and shape

Part No.

Valve Guide Remover

Application

MH061066 Removing valve guides (inlet, exhaust)

01959

15, 16

Valve Guide Remover

MH061998

Installing inlet and exhaust valve guides

01960

A: Caulking Tool Body B: Installer Ring

A: MH061067 B: MH061695 <6D16-TLE> (Inlet)

C dimension

MH061696 <6D16-TLE> (Exhaust) Installing valve seats

MH061695 φ49 (φ1.93) 17, 18

MH061696 φ42 (φ1.65)

MH061693 <6D16> (Inlet)

MH061693 φ51 (φ2.01) MH061694 φ44 (φ1.73) 01961

MH061694 <6D16> (Exhaust)

11-23

CYLINDER HEAD AND VALVE MECHANISM ◆ Service procedure 2 Valve cotters [Removal] To remove the valve cotter 2, use the compress the valve springs 4, 5.

Valve Lifter to evenly

[Installation] To install valve cotters, follow the removal instructions in reverse. 01962

CAUTION Do not compress the valve springs 4, 5 more than is necessary. If the valve springs are compressed excessively, the upper retainer 3 can touch the valve stem seal 6 and be damaged. 4 5 Installing outer and inner valve springs Fit the outer and inner valve springs 4, 5 onto the cylinder head 20 with their painted ends downward. A: Painted end

11641

6 Installing valve stem seals • Apply engine oil to the lip A of the valve stem seal 6. • Install the valve stem seal 6 using the Valve Stem Seal Installer. Strike the Valve Stem Seal Installer until it sits snugly on the cylinder head 20.

01964

11-24

11 7 8 Valves [Inspection] (1) Valve stem outside diameter Replace the valves 7, 8 if its stem's outside diameter is below specification or severely worn.

CAUTION 01965

Whenever the valves 7, 8 are replaced, be sure to lap the valves and valve seats 17, 18. P.11-26 (2) Valve seat angle and valve margin Reface or replace the valves 7, 8 if the valve seat angle or valve margin exceeds the specified limits. A: Valve seat angle B: Valve margin

02264

[Rectification]

NOTE • Keep grinding to a minimum. • If the valve margin is below specification after grinding, replace the valves 7, 8. • After grinding, be sure to lap the valves 7,8 and valve seats 17, 18. P.11-26 01966

7 8 15 16 Valves and valve guides [Inspection] If any clearance exceeds the specified limit, replace the defective part(s).

01967

Valve guides [Removal]

01972

11-25

CYLINDER HEAD AND VALVE MECHANISM [Installation] Install the valve guides 15, 16 using the Valve Guide Installer. Strike the Valve Guide Installer until it sits snugly on the cylinder head 20.

CAUTION

02220

• The valve guides 15, 16 must be pressed in to the specified depth. Be sure to use the Valve Guide Installer for this operation. • Exhaust valve guides 15 are longer than inlet valve guides 16. Be sure to install the correct type of guide in each location.

7 8 17 18 Valves and valve seats [Inspection] • Apply an even coat of minium to the valve seats 17, 18 surface A that makes contact with the valves 7, 8. • Using the Valve Lapper, strike the valves 7, 8 against the valve seats 17, 18 once. Do not rotate the valve during this operation.

NOTE 01968

Carry out these inspections after inspecting the valves and valve guides. • If the minium deposited on the valves 7, 8 indicate a poor contact pattern, rectify the contact pattern as follows: Contact

Corrective action

Minor defect

Lapping

Serious defect

Reface or replace valve and valve seat

01969

[Refacing] Lap the valve in accordance with the following procedure: • Apply a thin, even coat of lapping compound to the surface A of the valves 7, 8 that makes contact with the valve seats 17, 18.

CAUTION Ensure that no compound adheres to the stem B of the valves 7, 8. 01970

NOTE • Start with intermediate-mesh compound (120 to 150 mesh) and finish with fine-mesh compound (200 mesh or more). • The addition of a small amount of engine oil makes lapping compound easier to apply.

11-26

01971

• Using the Valve Lapper, lightly strike the valves 7, 8 against the valve seats 17, 18 while turning it little by little. • Wash away the compound with gas oil or a similar fluid. • Apply engine oil to the contact surfaces of the valve seats 17, 18 and rub it in so that the contact surfaces are lubricated and mate together snugly. • Inspect the contact pattern of the valves 7, 8 and valve seats 17, 18 once more. • If the contact pattern is still defective, replace the valve seats 17, 18.

17 18 Valve seats [Inspection] (1) Valve seat width If the measurement exceeds the specified limit, rectify or replace the valve seats 17, 18. A: Valve seat width 01975

NOTE Whenever the valve seats 17, 18 are rectified or replaced, be sure to lap the valve seats 17, 18 and valves 7, 8. P.11-26 (2) Valve sinkage from cylinder head bottom surface If any measurement exceeds the specified limit, rectify or replace the defective part(s). B: Valve sinkage

02265

[Rectification] • Grind the valve seats 17, 18 using a valve seat cutter or valve seat grinder. • After grinding, put some sandpaper of around #400 grade between the cutter and valve seat and grind the valve seat lightly. • Use a 15° or 17° cutter to achieve the specified valve seat width A. C: Valve seat angle 01977

CAUTION Ensure that grinding does not cause the valve sinkage B to exceed the specified limit. • After rectification, lap the valves 7, 8 and valve seats 17, 18. P.11-26

11-27

CYLINDER HEAD AND VALVE MECHANISM [Removal] Valve seats 17, 18 are installed by expansion fitting. To remove a valve seat, grind the inside surface to reduce its thickness, then remove the valve seat at room temperature. D: Material to remove

01973

[Installation] • Check that the valve seat hole diameters E, F in the cylinder head 20 conform with the values shown below. Unit: mm (in.) 6D16

01976

+0.03 0

Inlet valve seat hole (E)

φ51

Exhaust valve seat hole (F)

φ44 0

+0.025

(φ2.01

6D16-TLE +0.0012 0

+0.00098

(φ1.73 0

)

φ49

+0.025 0

+0.025

) φ42 0

+0.00098

(φ1.93 0

+0.00098

(φ1.65 0

) )

• Cool the valve seats 17, 18 by immersing it in liquid nitrogen. • Install the valve seats 17, 18 in the cylinder head 20 using the Caulking Tool Body and Installer Ring. • After installing the valve seats 17, 18, lap the valve seats and valves 7, 8. P.11-26

01974

20 Inspecting cylinder head • Measure the extent of distortion in the cylinder head's bottom surface. • If the degree of distortion exceeds the specified limit, rectify the distortion with a surface grinder.

CAUTION 01978

11-28

Ensure that grinding does not cause the cylinder head's top surface-to-bottom surface distance to fall below the specified limit.

MEMO

11-29

PISTONS, CONNECTING RODS, AND CYLINDER LINERS ● Pre-disassembly inspection P.11-32 ● Removal sequence 1 Bolt 2 Lower connecting rod bearing 3 Connecting rod cap 4 Upper connecting rod bearing 5 Piston and connecting rod assembly P.11-38 6 Cylinder liner

*a: Oil pan Oil pan gasket *b: Crankshaft P.11-66 ● Installation sequence Reverse the order of removal. 16914

Service standards Location –

2, 4, *b

Unit: mm (in.)

Maintenance item

Standard value

Limit

Remedy

Piston projection

0.85 to 1.06 (0.0335 to 0.0417)

–

Inspect each location

Connecting rod end play

0.15 to 0.45 (0.00591 to 0.0177)

0.6 (0.0236)

Replace

6D16

[65] 0.04 to 0.09 (0.00157 to 0.00354)

0.2 (0.00787)

Replace

6D16-TLE

[70] 0.04 to 0.09 (0.00157 to 0.00354)

Connecting rod bearing

Oil clearance

Span when free

5, 6

6D16

–

Less than 69.5 (2.736)

6D16-TLE

–

Less than 74.5 (2.933)

[118] 0.075 to 0.105 (0.00295 to 0.00413)

–

Replace

Piston and connecting rod 6D16 assembly-to-cylinder liner clearance 6D16-TLE

Cylinder liner

Flange projection

0.03 to 0.10 (0.00118 to 0.00394)

–

Replace

Inside diameter

φ118 to 118.03 (φ4.646 to 4.647)

φ118.25 (φ4.656)

Replace

0.03 (0.00118) or less

–

Replace or grind to oversize

Cylindricity

11-30

[118] 0.136 to 0.165 (0.00535 to 0.00650)

11 Tightening torques Location 1

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened Bolt (connecting rod installation)

Tightening torque

Remarks

29 (3) [21.4] + 90° ± 5°

Wet

Lubricant Location

Points of application

Specified lubricant

Quantity

Both threads

Engine oil

As required

2, 4

Connecting rod bearing inside surface

Engine oil

As required

Cylinder liner outside surface

Engine oil

As required

Special tools Location

Unit: mm (in.)

Tool name and shape

Socket Wrench

Part No.

Application

MH061560

Installing piston and connecting rod assembly

A: MH061760 B: MH061658

Installing piston and connecting rod assembly

MH061761

Removing cylinder liners

MH061771

Installing cylinder liners (dry type)

01984

A: Piston Guide Clamp B: Piston Guide Lever

01981

Cylinder Liner Extractor

01982

Cylinder Liner Installer

01983

11-31

PISTONS, CONNECTING RODS, AND CYLINDER LINERS ◆ Service procedure ● Pre-disassembly inspection (1) Piston projection from crankcase top surface

NOTE The piston projections affect engine performance and must therefore be checked.

WARNING 01985

The cylinder liners may rise out of position when the crankcase is turned over or the crankshaft is turned. Hold their flanges down using bolts and washers A.

• Measure the projection of each piston at two points and calculate the average of the two values. A: Front of engine • If the average value is out of specification, check the clearances between all relevant parts. 01986

(2) Connecting rod end play • Measure the end play of every connecting rod. • If any measurement exceeds the specified limit, replace the defective part(s).

01987

(3) Cylinder liner flange projection • If any measurement is out of specification, replace the defective part(s). B: Flange projection

CAUTION

01988

11-32

If the cylinder liner 6 flange projection is insufficient, bearing pressure on the cylinder head gasket will be too low in the region of the bore, possibly causing gas to leak.

11 2 4 Connecting rod bearings [Installation] Install the connecting rod bearings 2, 4 by fitting the lugs A into their respective grooves.

CAUTION The upper connecting rod bearing has an oil hole B. The lower connecting rod bearing has no oil hole. Take care not to confuse the upper and lower parts.

01994

[Inspection]

CAUTION • Do not attempt to manually expand a connecting rod bearings 2, 4 if its span is insufficient. • Upper and lower connecting rod bearings 2, 4 must be replaced as a set. 01995

(1) Span when free If the span is less than the specified requirement, replace the upper and lower connecting rod bearings 2, 4 as a set. (2) Connecting rod bearing-to-crankshaft pin clearance If the connecting rod bearing-to-crankshaft pin clearance exceeds the specified limit, replace the defective part(s).

01995

01997

Installing piston and connecting rod assembly

CAUTION

01985

• Ensure that the piston ring gaps A remain in their correct positions. P.11-43 • Take care not to damage the piston crown B (the area that forms part of the combustion chamber). • Ensure that the connecting rod does not touch the oil jet C.

11-33

PISTONS, CONNECTING RODS, AND CYLINDER LINERS • With the piston’s “ ” front mark facing the front of the engine, install the piston and connecting rod assembly in accordance with the following procedure. D: Front of engine

03384

• Fit the Piston Guide Clamp over the piston skirt. Using the bolt E of the Piston Guide Lever, adjust the clamp's inside diameter such that it matches the piston's outside diameter. • Once the Piston Guide Clamp is adjusted properly, remove it from the piston and smear engine oil over the following items: • Outside of piston • Inside of the Piston Guide Clamp • Cylinder liner 11651

Piston Guide Clamp tightening direction

02011

• With the piston installed, align the mating marks F on the connecting rod and connecting rod cap 3 and tighten the bolts to the specified torque. Then, tighten the bolts 1 further in accordance with the following procedure.

01990

• Before fitting the Socket Wrench over a bolt, turn the holder G counter-clockwise to tension the built-in spring. H: Socket J: Rod K: Rod (extension)

01991

11-34

11 • Set the socket wrench such that the built-in spring force forces the rod K against the crankshaft. • On the holder G, select the inscribed line L that is easiest to see. • Using the selected line as a reference, turn the socket H 90° ± 5° clockwise. (One gradation on the scale M represents 5°.)

NOTE

11652

After fitting the connecting rod caps 3, inspect the following items: • Connecting rod end play ( P.11-32) • Piston projections ( P.11-32) 5 6 Piston-and-onnecting rod assembly and cylinder liners [Inspection] If any clearance is out of specification, replace the defective part(s). A: Outside diameter measurement position B: Direction of crankshaft axis C: Perpendicular to crankshaft axis

NOTE

03375

The cylinder liners are of a thin design and cannot be bored to oversize dimensions. To prevent deformation of the cylinder liners, do not remove them except for replacement.

02003

Cylinder liners [Removal]

NOTE If any cylinder liner 6 must be reused after removal, make an alignment mark with paint and use this mark to reinstall the cylinder liner in its original position.

02004

11-35

PISTONS, CONNECTING RODS, AND CYLINDER LINERS [Installation] • Apply engine oil to the outside surface of the cylinder liner 6. • Insert the cylinder liner into the crankcase and press it into position using the Cylinder Liner Installer. Push down evenly on the entire upper surface of the Cylinder Liner Installer.

11-36

MEMO

11-37

PISTONS, CONNECTING RODS, AND CYLINDER LINERS Piston and Connecting Rod Assembly ● Disassembly sequence 1 Snap ring 2 Piston pin 3 Connecting rod bushing 4 Connecting rod 5 1st compression ring 6 2nd compression ring 7 Oil ring 8 Piston ● Assembly sequence Reverse the order of disassembly.

02012

Service standards Location 2, 3

2, 8

4 5 to 7

Unit: mm (in.)

Maintenance item Piston pin-to-connecting rod small end bushing clearance

Piston pin-to-piston clearance

Standard value

Limit

Remedy

6D16

[38] 0.02 to 0.05 (0.000787 to 0.00197)

0.1 (0.00394)

Replace

6D16-TLE

[42] 0.02 to 0.05 (0.000787 to 0.00197)

6D16

[38] 0.004 to 0.02 (0.000157 to 0.000787)

0.05 (0.00197)

Replace

6D16-TLE

[42] 0.004 to 0.02 (0.000157 to 0.000787) –

0.05 (0.00197)

Correct or replace

0.35 to 0.55 (0.0138 to 0.0217)

1.5 (0.0591)

Replace

1.5 (0.0591)

Replace

0.35 to 0.55 (0.0138 to 0.0217)

1.5 (0.0591)

Replace

0.11 to 0.15 (0.00433 to 0.00591)

0.2 (0.00787)

Replace

0.15 (0.00591)

Replace

0.15 (0.00591)

Replace

Connecting rod bend and torsion Piston ring end gap

1st compression 6D16 ring 6D16-TLE 2nd compression 6D16 ring 6D16-TLE Oil ring

5 to 8

Piston ring1st compression 6D16 to-piston ring ring groove 6D16-TLE clearance 2nd compression 6D16 ring 6D16-TLE Oil ring

11-38

0.35 to 0.55 (0.0138 to 0.0217) 0.35 to 0.55 (0.0138 to 0.0217) 0.45 to 0.6 (0.0177 to 0.0236)

0.13 to 0.18 (0.0512 to 0.00709) 0.05 to 0.08 (0.00197 to 0.00315) 0.07 to 0.10 (0.00276 to 0.00394) 0.03 to 0.06 (0.00118 to 0.00236)

11 Lubricant Location

Points of application

Specified lubricant

Quantity

Piston pin outer surface

Engine oil

As required

Connecting rod bushing outer surface

Engine oil

As required

Bushing installation surface of connecting rod

Engine oil

As required

Special tools Location

Unit: mm (in.)

Tool name and shape

Part No.

Connecting Rod Bushing Puller

Application

<6D16> MH061778

02014

Removing and installing connecting rod bushings

Connecting Rod Bushing Puller Kit

<6D16-TLE> MH062556

02015

5 to 7

Piston Ring Tool

30091-07100

Removing and installing piston rings

02013

◆ Service procedure 2 3 Piston and connecting rod If the clearance exceeds the specified limit, replace the defective part(s).

02017

11-39

PISTONS, CONNECTING RODS, AND CYLINDER LINERS Connecting rod bushing <6D16> [Removal] Apply the Connecting Rod Bushing Puller to the connecting rod bushing 3. Using a press, apply pressure of approximately 49 kN (5,000 kgf) [11,015 lbf] such that the bushing is pressed out of the connecting rod 4.

13616

[Installation] • Align oil hole A in the connecting rod bushing 3 with oil hole B in the connecting rod 4. • Apply the Connecting Rod Bushing Puller to the connecting rod bushing 3. Using a press, apply pressure of approximately 49 kN (5,000 kgf) [11,015 lbf] such that the bushing is pressed into the connecting rod 4 from the chamfered side C.

NOTE 13617

After installing the connecting rod bushing 3, insert the piston pin 2 and check that it turns smoothly and without play. <6D16-TLE> Replace the connecting rod bushing 3 using the Connecting Rod Bushing Puller Kit. This consists of the following parts:

02019

02020

11-40

D: Base E: Bracket F: Puller G: Collar H: Plate J: Collar K: Nut [Removal] • Remove the bearing (if fitted) from the big end of the connecting rod 4. • Mount the connecting rod 4 on the base D and lock it in position with the bracket E and plate H. • Position the puller F and collar G as shown in the illustration. Then, slowly apply pressure of approximately 49 kN (5,000 kgf) until the connecting rod bushing 3 is pressed out.

11507

[Installation] • Apply engine oil to the small end of the connecting rod 4 and to the outer surface of the connecting rod bushing 3. • Fit the collar J over the puller F, position the connecting rod bushing 3 and collar G as shown in the illustration, and lock this arrangement together with the nut K. • Align the oil holes L in the small end of the connecting rod bushing 3 and connecting rod 4. Then, use a press to slowly apply pressure of approximately 49 kN (5,000 kgf) until the bushing is pressed into place. • After press-fitting the connecting rod bushing 3, ream it to achieve the specified nominal clearance between the bushing and piston pin 2.

NOTE After installing the connecting rod bushing 3, insert the piston pin 2 and check that it turns smoothly and without play. 2 4 8 Piston pin, connecting rod, and piston [Removal] • Tap out the piston pin 2 using a rod and hammer. • If the piston pin 2 is difficult to remove, heat the piston 8 in hot water or using a piston heater.

02022

[Installation] • Apply engine oil to the piston pin 2. With the connecting rod 4 and piston 8 aligned as illustrated, insert the piston pin to hold these components together.

02023

A: Weight mark B: Weight mark (A, B, C, D, E, F, G, H, I, V, W, X, Y, Z) C: Alignment mark for connecting rod cap : Front mark • If the piston pin 2 is difficult to insert, heat the piston 4 in hot water or using a piston heater.

CAUTION • No piston should differ from any other piston by a weight of more than log. • The connecting rods must all have the same weight mark. • After inserting the piston pin 2, check that it turns smoothly and without play.

11-41

PISTONS, CONNECTING RODS, AND CYLINDER LINERS 2 8 Piston pin-to-piston clearance If the clearance exceeds the specified limit, replace the defective part(s).

02016

4 Connecting rod bend and twist • Fit the connecting rod bushing 3 and piston 2 in their respective positions of the connecting rod 4. • Measure the extent of bending A and twisting B in the connecting rod 4. • If either measurement exceeds the specified limit, replace the connecting rod 4 or rectify it. C: Connecting rod 4 aligner (measurement device) 02039

NOTE • Before mounting the connecting rod 4 on the connecting rod aligner C, install the upper and lower connecting rod bearings in their respective positions. • Measurements must be made with the connecting rod cap mounting nuts tightened to their specified torque. P.11-31 02040

11-42

11 5 to 8 Piston rings and piston Piston rings [Removal]

02024

[Installation] • Fit the oil ring 7 onto the piston 8 with its side rail gaps A and the expander spring gap B in the positions illustrated. • Fit the compression rings 5, 6 onto the piston such that the manufacturer's marks C near the gaps face upward. • Align the compression ring gaps D, E as illustrated.

02028

D: 1st compression ring gap E: 2nd compression ring gap : Front mark [Inspection] (1) Piston ring end gap • Using the crown of a piston 8, push the piston ring 5, 6 or 7 horizontally into a cylinder liner F for measurement. • Taking care not to move the piston ring 5, 6 or 7, measure the end gap. Replace all the rings of a piston if any gap exceeds the specified limit.

NOTE 02027

• To keep the piston ring 5, 6 or 7 horizontal, be sure to insert them into the cylinder liner F using a piston 8. • Push the piston ring 5, 6 or 7 down to the bottom of cylinder liner F; the bottom should be less worn than the top. • Piston ring 5, 6 or 7 must be replaced as a set. Never replace piston rings individually.

11-43

PISTONS, CONNECTING RODS, AND CYLINDER LINERS (2) Piston ring-to-piston ring groove clearance • If any measurement exceeds the specified limit, replace the defective part(s). • Measure the 1st compression ring 5 clearance with a thickness gauge H while pressing the ring against the piston 8 with a straight edge G.

NOTE

02025

02026

11-44

• Remove any carbon deposits from the ring groove of the piston 8 and measure the clearance around the piston's entire periphery. • Piston rings 5, 6, 7 must be replaced as a set. Never replace piston rings individually.

MEMO

11-45

FLYWHEEL

16923

● Disassembly sequence 1 Spacer 2 Bolt 3 Washer plate 4 Flywheel assembly 5 Pilot bearing 6 Ring gear 7 Flywheel

8 Rear oil seal 9 Plug 10 Flywheel housing - Flywheel housing gasket

*: Crankcase

A: Locating pin : Non-reusable part

● Assembly sequence Reverse the order of disassembly.

11-46

P.11-66

11 Service standards Location 4

Unit: mm (in.)

Maintenance item Flywheel assembly

Standard value

Limit

Remedy

Friction surface distortion

0.05 (0.00197) or less

0.2 (0.00787)

Correct or replace

Height of friction surface

20 (0.787)

19 (0.748)

Replace

Friction surface runout (when fitted)

–

0.2 (0.00787)

Correct or replace

–

0.2 (0.00787)

Inspect or replace

Eccentricity of joint

Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Flywheel mounting bolt

Plug

Location

Tightening torque

Remarks

98 (10) [72.3] + 150°

• Wet • Can be reused up to 3 times

88 (9) [64.9]

–

Points of application

Quantity

Bolt threads

Engine oil

As required

Rear oil seal lip

Engine oil

As required

Engine mounting surface of flywheel housing

Flywheel housing gasket

Special tools Location

Unit: mm (in.)

Tool name and shape

Part No.

Socket Wrench

MH062354

01984

Application

Magnetic Base

Fitting flywheel

MH062356

00471

11-47

FLYWHEEL ◆ Service procedure 4 Flywheel assembly [Removal] To remove the flywheel assembly 4, screw the mounting bolts 2 into the removal holes A.

02052

[Installation]

CAUTION Before installing the bolt 2, check the number of punch marks K on its head. (If there are two or less, the bolt is reusable.) The number of punch marks corresponds with the number of times a bolt has been tightened by the plastic region tightening method. If there are three (which means that the bolt has been tightened 3 times), replace the bolt. P 36164

• Tighten the bolts 2 to their specified torque, then tighten them further in accordance with the following procedure: • Turn the holder B of the Socket Wrench counter-clockwise to tension the built-in spring. C: Socket D: Rod E: Rod (extension) 01991

• Set the Socket Wrench such that the built-in spring forces the rod E against the Magnetic Base. • On the holder B, select the inscribed line F that is easiest to see. • Using the selected line as a reference, turn the socket 150° clockwise. (One gradation on the scale G represents 5°.)

CAUTION Since the bolts 2 utilize the plastic region tightening method, they must not be tightened further after this procedure. 14312

[Inspection] (1) Runout • Tighten the bolts 2 to their specified torque. • If runout exceeds the specified limit, check that the bolts 2 are tightened correctly and inspect the crankshaft * mounting surface. Then, rectify or replace the flywheel assembly 4 as required.

02055

11-48

11 (2) Height of friction surface If the measurement is below the specified value, rectify or replace the flywheel assembly 4. H: Height of friction surface

03349

(3) Distortion of friction surface If distortion exceeds the specified limit, rectify or replace the flywheel assembly 4.

NOTE If any abnormality is evident on the ring gear 6, replace the ring gear before making inspections.

02054

[Rectification] Grind the friction surface such that its height H remains greater than the specified minimum. The friction surface must remain parallel with surface J with a tolerance of 0.1 mm (0.00394 in.).

03351

6 Ring gear [Inspection] Inspect the ring gear 6 for damage and abnormal wear. If any defect is evident, the ring gear must be replaced. [Removal] • Heat the ring gear 6 evenly with an acetylene torch or the like.

CAUTION Be careful not to get burned.

02057

• Remove the ring gear 6 from the flywheel 7 by tapping around its entire periphery.

11-49

FLYWHEEL [Installation] • Using a piston heater or the like, heat the ring gear 6 to approximately 100°C (212°F) for 3 minutes.

CAUTION Be careful not to get burned.

03353

• Fit the ring gear 6 with the non-chamfered side of its teeth toward the flywheel 7. A: Chamfered side of ring gear

• Apply engine oil to the lip of the rear oil seal 8. • Fit the rear oil seal 8 onto the flywheel housing 10 in the direction illustrated.

02059

11-50

[Inspection] • Rotate the crankshaft and check the extent of eccentricity at the joint A of the flywheel housing 10. • If eccentricity exceeds the specified limit, carry out reassembly. • If eccentricity still exceeds the specified limit after reassembly, replace the defective part(s).

02062

11-51

TIMING GEARS Timing plate gasket

16939

● Pre-disassembly inspection P.11-54 ● Disassembly sequence 1 Bolt 2 No. 1 idler shaft 3 No. 1 idler gear bushing 4 No. 1 idler gear 5 Nut 6 O-ring 7 Collar 8 O-ring 9 Bolt ● Assembly sequence Reverse the order of disassembly.

11-52

10 11 12 13

Thrust washer No. 2 idler gear bushing No. 2 idler gear No. 2 idler shaft

*1: Drive gear *2: Camshaft gear *3: Crankshaft gear

P.11-58 P.11-66

: Non-reusable part

CAUTION Since the No. 1 idler gear 4 is supported by the No. 1 idler shaft 2, these parts must be removed as a single unit.

11 Service standards Location

Maintenance item Gear backlash

–

Unit: mm (in.)

Standard value

Limit

Remedy

Between No. 1 idler gear and crankshaft gear

0.08 to 0.15 (0.00315 to 0.00591)

0.35 (0.0138)

Replace

Between No. 1 idler gear and No. 2 idler gear

0.07 to 0.15 (0.00276 to 0.00591)

0.35 (0.0138)

Replace

Between No. 1 idler gear and drive gear

0.07 to 0.15 (0.00276 to 0.00591)

0.35 (0.0138)

Replace

Between No. 2 idler gear and camshaft gear

0.08 to 0.16 (0.00315 to 0.00630)

0.35 (0.0138)

Replace

2. 3

No. 1 idler shaft-to-gear bushing clearance [Basic diameter: 37 mm (1.46 in.)]

0.01 to 0.05 (0.000394 to 0.00197)

0.2 (0.00787)

Replace

4, 12

Idler gear end play

0.05 to 0.15 (0.00197 to 0.00591)

0.3 (0.0118)

Replace

11, 13

No. 2 idler gear bushing-to-shaft clearance [Basic diameter: 32 mm (1.26 in.)]

0.01 to 0.05 (0.000394 to 0.00197)

0.2 (0.00787)

Replace

Tightening torques Location

Parts to be tightened

Unit: N·m (kgf·m) [lbf·ft]

Tightening torque

Remarks

No. 1 idler gear mounting bolt

88 (9) [64.9]

–

Collar mounting nut

82 (8.4) [60.5]

–

No. 2 idler gear mounting bolt

95 (9.7) [70.1]

–

Lubricant Location 6, 8

Points of application O-ring

Specified lubricant Engine oil

Quantity As required

11-53

TIMING GEARS Special tools Location

2, 4

Unit: mm (in.)

Tool name and shape

Part No.

Gear Puller

Application

MH061326

Removing No. 1 idler shaft and gear

<No. 1> MH062601 <No. 2> MH061779

Removing and fitting idler gear bushings

MH062405

Removing No. 2 idler gear shaft

02065

Idler Gear Bushing Puller A 3, 11

No. 1 idler φ37 φ40 gear bushing (φ1.46) (φ1.57) No. 2 idler φ32 φ35 gear bushing (φ1.26) (φ1.38)

02066

Idler Shaft Puller

02067

◆ Service procedure ● Pre-disassembly inspection (1) Gear backlash For each gear pair, measure backlash at three or more points. If any measurement exceeds the specified limit, replace the defective part(s).

02284

(2) Idler gear end play If the measurement exceeds the specified value, replace the defective part(s).

02069

11-54

11 2 3 No. 1 idler shaft and No. 1 idler gear bushing [Inspection] If the clearance exceeds the specified limit, replace the defective part(s).

02576

No. 1 idler gear bushing [Removal] A: Press

02577

[Installation] • Using the Idler Gear Bushing Puller, press the No. 1 idler gear bushing 3 into the No. 1 idler gear 4 from the side of the gear whose internal diameter is chamfered B. A: Press

02578

• After installation, measure the clearance again. If the measurement is below the nominal value range, ream the bushing 3.

2 4 Removing No. 1 idler shaft and No. 1 idler gear Loosen the bolt 1 by approximately 15 mm (0.591 in.), then remove the No. 1 idler shaft 2 and No. 1 idler gear 4 as a single unit.

02070

4 12 Installing No. 1 and No. 2 idler gears Fit the No. 1 and No. 2 idler gears 4, 12 such that their alignment marks (“1”, “2”, “3”, “4”) are aligned with those on the gears with which they mate.

02074

*1: Drive gear *2: Camshaft gear *3: Crankshaft gear

11-55

TIMING GEARS 11 13 No. 2 idler gear bushing and No. 2 idler shaft [Inspection] If the clearance exceeds the specified limit, replace the defective part(s).

02579

No. 2 idler gear bushing [Removal] A: Press

02580

[Installation] • Using the Idler Gear Bushing Puller, press the No. 2 idler gear bushing 11 into the No. 2 idler gear 12 from the side of the gear whose internal diameter is chamfered B. A: Press

02581

• After installation, measure the clearance again. If the measurement is below the nominal value range, ream the bushing 11.

02075

11-56

Removing No. 2 idler shaft

MEMO

11-57

CAMSHAFT

18061

● Pre-disassembly inspection P.11-60 ● Disassembly sequence 1 Engine speed sensor <models with electric speed sensor> 2 Adapter <models with electric speed sensor> Tachometer drive case <models with mechanical tachometer> 3 O-ring 4 Pulse rotor <models with electric speed sensor> Tachometer drive coupling <models with mechanical tachometer> 5 Side cover 6 Camshaft assembly 7 Bolt

8 9 10 11 12 13 14 15

Camshaft gear Thrust plate Key Camshaft No. 4 camshaft bushing No. 3 camshaft bushing No. 2 camshaft bushing No. 1 camshaft bushing

*: Crankcase

P.11-66 : Non-reusable part

NOTE • Do not remove the engine speed sensor 1 unless defects are evident. • Do not remove the camshaft gear 8 unless defects are evident. ● Assembly sequence Reverse the order of disassembly.

11-58

11 Service standards

Unit: mm (in.)

Location

Maintenance item

Standard value

Limit

Remedy

2.3 ± 0.2 kΩ

–

Replace

0.05 to 0.22 (0.00197 to 0.00866)

0.4 (0.0157)

Inspect each part

Inlet

6.901 (0.272)

6.40 (0.252)

Lobe height: 49.011 (1.930) Base circle diameter: 42.110 (1.658)

Exhaust

7.680 (0.302)

7.18 (0.283)

Lobe height: 49.307 (1.941) Base circle diameter: 41.627 (1.659)

0.02 (0.000787) or less

0.04 (0.00157)

Replace

No. 1 journal [Basic diameter: 57.75 mm (2.27 in.)]

0.05 to 0.10 (0.00197 to 0.00394)

0.25 (0.00984)

Replace

No. 2 journal [Basic diameter: 58.00 mm (2.28 in.)]

0.05 to 0.10 (0.00197 to 0.00394)

No. 3 journal [Basic diameter: 58.25 mm (2.29 in.)]

0.13 to 0.18 (0.00512 to 0.00709)

No. 4 journal [Basic diameter: 58.50 mm (2.28 in.)]

0.05 to 0.10 (0.00197 to 0.00394)

Resistance of engine speed sensor [at 25°C (77°F)]

Camshaft assembly end play

Camshaft

Cam lift

Bend 11, 12 to 15

Camshaft journal-tocamshaft bushing clearance

Tightening torques Location

Parts to be tightened

Unit: N·m (kgf·m) [lbf·ft]

Tightening torque

Remarks

Engine speed sensor <models with electric speed sensor>

29 ± 5.9 (3.0 ± 0.6) [21.4 ± 4.4]

–

Pulse rotor <models with electric speed sensor>

98 (10) [72.3]

–

Camshaft gear mounting bolt

175 (18) [129]

–

Lubricant and/or sealant Location

Points of application

Specified lubricant and/or sealant

Quantity

Engine speed sensor threads <models with electric speed sensor>

Threebond 1104J

As required

Camshaft journals

Engine oil

As required

Inside surfaces of camshaft bushings

Engine oil

As required

12 to 15

11-59

CAMSHAFT Special tools Location

Unit: mm (in.)

Tool name and shape

Plug

Part No.

Application

MF665007

Blanking plug for use when removing camshaft gear

MH061326

Removing camshaft gear

MH062025

Removing and installing camshaft bushings

02082

Gear Puller

02065

Camshaft Bushing Installer and Extractor

12 to 15

A, C dimension B dimension No. 1 φ62.00 (φ2.44) φ57.75 (φ2.27) No. 2 φ62.25 (φ2.45) φ58.00 (φ2.28) No. 3 φ62.50 (φ2.46) φ58.25 (φ2.29) No. 4 φ62.75 (φ2.47) φ58.50 (φ2.30)

02083

◆ Service procedure ● Pre-disassembly inspection Camshaft end play If the end play measurement exceeds the specified limit, replace the defective part(s).

02084

1 Inspecting engine speed sensor <Models with electric speed sensor> • Measure the electrical resistance between terminals ➀ and ➁. • If the measurement is out of specification, replace the speed sensor 1. P.11-59

CAUTION 03674

11-60

Check the tightening torque of the engine speed sensor 1. If the sensor is insufficiently tightened, it may not produce signals.

6 Camshaft assembly [Removal] • When removing the camshaft assembly 6, take off the side cover 5 and support the camshaft by hand. • Remove the bolts A from the camshaft gear holes, then slowly remove the camshaft assembly 6.

02086

CAUTION Take care not to damage the camshaft bushings 12 to 15 when removing the camshaft assembly 6.

[Installation] • Before installing the camshaft assembly 6, measure the end play between the thrust plate 9 and camshaft 11. • If the measurement exceeds the specified limit, replace the defective part(s). • With the alignment marks lined up on the camshaft gear 8 and No. 2 idler gear, fit the camshaft assembly. 02092

8 Camshaft gear [Removal]

CAUTION The camshaft gear 8 must be removed with the appropriate special tools. Do not tap off the camshaft gear since this would damage it. 02088

: Gear Puller : Plug

11-61

CAMSHAFT [Installation] • Fit the camshaft gear 8 onto the camshaft 11 in the direction illustrated. • Do not forget to fit the key 10.

11714

11 Inspecting camshaft (1) Cam lift If any base circle-to-lobe height difference is less than the required value, replace the camshaft 11.

NOTE Since the cams are tapered, they must be measured at the position A shown in the diagram. 02090

B: Lobe height C: Base circle diameter D: Front of engine (2) Camshaft bend Support the camshaft 11 at its No. 1 journal E and No. 4 journal F, then take measurements at the No. 2 journal G and No. 3 journal H. If either measurement exceeds the specified limit, replace the camshaft.

NOTE Turn the camshaft 11 through one revolution. One-half of the dial indicator reading represents the camshaft's bend. 04108

11 to 15 Camshaft and camshaft bushings [Inspection] If any clearance exceeds the specified limit, replace the defective part(s).

NOTE Measure the camshaft bushings 12 to 15 with the camshaft installed in the crankcase *. 02093

11-62

11 Camshaft bushings Removal and installation of camshaft bushings should be carried out using the Camshaft Bushing Installer and Extractor. Each guide of the tool is stamped with an identification mark (“1”, “2”, “3”, “4”) in the position shown. Use correct adapter and/or guide piece to remove and install a bushing according to the table below.

13020

Bushing No. (from front of engine)

Identification mark

No. 1

No. 2

No. 3

No. 4

<Components of Camshaft Bushing Installer and Extractor> A: Rod B: Camshaft bushing adapter C: Guide piece D: Nut [Removal] Remove the No. 4 and No. 3 camshaft bushings 12, 13 from the rear of the engine. Remove the No. 2 and No. 1 camshaft bushings 14, 15 from the front of the engine. : Camshaft Bushing Installer and Extractor

02094

[Installation] • Identify the No. 1 to No. 4 camshaft bushings 12 to 15 from their identification marks (“1”, “2”, “3”, “4”) in accordance with the table below. If any bushing's identification mark is unclear, identify the bushing from its internal diameter E.

11741

Bushing No. (from front of engine)

Identification mark

Internal diameter [mm (in.)]

No. 1

φ57.75 (φ2.27)

No. 2

φ58.00 (φ2.28)

No. 3

φ58.25 (φ2.29)

No. 4

φ58.50 (φ2.30)

11-63

CAMSHAFT • Install the bushings 12 to 15 by using all components of the Camshaft Bushing Installer and Extractor (rod A, camshaft bushing adapter B, guide piece C and nut D). • Install the camshaft bushings 12 to 15 in the following order: No. 3, No. 4, No. 2 and No. 1.

NOTE 06225

Install the No. 3 and No. 4 camshaft bushings 12, 13 from the rear of the engine. Install the No. 1 and No. 2 camshaft bushings 14, 15 from the front of the engine. • Ensure that the oil holes F in the No. 1 and No. 4 camshaft bushings 15, 12 are aligned with the oil holes G in the crankcase. With the No. 4 camshaft bushing, ensure also that the longer oil hole H is toward the rear of the engine. J: Bushing clinch joint : Camshaft Bushing Installer and Extractor

04109

11-64

MEMO

11-65

CRANKSHAFT AND CRANKCASE

18070

● Pre-disassembly inspection P.11-69 ● Disassembly sequence 1 Bolt 2 Crankshaft pulley 3 Bolt 4 Torsional damper 5 Front cover assembly 6 Front oil seal 7 Front cover Front cover gasket ● Assembly sequence Reverse the order of disassembly.

11-66

8 9 10 11 12 13 14

Bolt Lower main bearing Main bearing cap Thrust plate Crankshaft assembly Front oil seal slinger Rear oil seal slinger

15 16 17 18

Crankshaft gear Crankshaft Upper main bearing Crankcase : Non-reusable part

11 Service standards

Unit: mm (in.)

Location

Maintenance item Main bearing

9, 17

Standard value

Limit

Remedy

0.05 to 0.10 (0.00197 to 0.00394)

0.15 (0.00591)

Replace

–

Less than 85.5 (3.37)

Replace

End play

0.10 to 0.25 (0.00394 to 0.00984)

0.4 (0.0157)

Replace

Bend

0.05 (0.00197) or less

0.1 (0.00394)

Correct or replace

Roundness

0.01 (0.000394) or less

0.03 (0.00118)

Correct or replace

Cylindricity

0.006 (0.000236) or less

–

Correct or replace

0.07 (0.000276) or less

0.2 (0.00787)

Replace

Oil clearance [Basic diameter: 84 mm (3.307 in.)] Span when free

Crankshaft bearing

Pin and journal

Distortion of crankcase top surface

Tightening torques Location

Parts to be tightened

Unit: N·m (kgf·m) [lbf·ft]

Tightening torque

Remarks

Crankshaft pulley mounting bolt

185 (19) [136]

–

Torsional damper mounting bolt

67 (8) [49.4]

–

Main bearing cap mounting bolt

67 (8) [49.4] + 90°

• Wet • Can be reused up to 3 times

Lubricant and/or sealant Location

Points of application

Specified lubricant and/or sealant

Quantity

Front oil seal lip

Engine oil

As required

Bolt threads

Engine oil

As required

Main bearing inside surfaces

Engine oil

As required

9, 17

11-67

CRANKSHAFT AND CRANKCASE Special tools Location

Unit: mm (in.)

Tool name and shape

Main Bearing Cap Extractor

Part No.

Application

MH061189

Removing main bearing caps

MH061560

Fitting main bearing caps

MH062710

Installing front oil seal

MH061470

Installing rear oil seal slinger

MH061326

Removing crankshaf gear

02097

Socket Wrench

01984

Front Oil Seal Slinger Installer

13625

Rear Oil Seal Slinger Installer

02051

Gear Puller

02065

11-68

11 ◆ Service procedure ● Pre-disassembly inspection Crankshaft assembly end play If the measurement exceeds the specified limit, replace the defective part(s).

02098

Torsional damper <Viscous type>

CAUTION

14933

Leakage of silicon oil from the caulked seam A can cause the viscous-type torsional damper to stop functioning. Note the following points: • Check that the caulked seam is free of gouges and other damage. • Do not submit the torsional damper to shock by striking it with a hammer or dropping it. • Do not roll the torsional damper or stack it with other units.

9 17 Main bearings [Installation] Install the main bearings 9, 17 such that their lugs A fit into the corresponding grooves.

CAUTION 11730

The upper main bearing 17 has an oil hole B. The lower main bearing 9 has no oil hole. Take care not to confuse the upper and lower parts.

11-69

CRANKSHAFT AND CRANKCASE [Inspection]

CAUTION • Do not attempt to manually expand either bearing 9, 17 if its span is insufficient. • Upper and lower bearings 9, 17 must be replaced as a set.

01995

(1) Span when free If either bearing's span when free exceeds the specified limit, the bearings 9, 17 must be replaced. (2) Main bearing-to-crankshaft clearance • Fit the upper main bearing 17 into the crankcase 18 and the lower main bearing 9 into the main bearing cap 10. Then, tighten the bolts 8 to their specified torque. • Measure the internal diameters of the main bearings 9, 17 and the outside diameter A of the crankshaft journal. If the clearance exceeds the specified limit, replace the defective part(s).

02104

10 Main bearing caps [Removal]

02100

[Installation] • Starting at the front of the engine B, fit the main bearing caps 10 in the order of the numbers A embossed on them and such that the numbers are in the positions illustrated. • The bolts 8 can be reused only three times. Before fitting the bolts, make a punch mark on the head of each bolt to indicate times of reuse.

CAUTION 02103

11-70

If any bolt already has three punch marks, it must not be reused any more; replace it with a new one.

11 • Tighten the bolts 8 to the specified torque. Then, turn the bolts further in accordance with the following procedure: • Turn the holder C of the Socket Wrench counter-clockwise to tension the built-in spring. D: Socket E: Rod F: Rod (extension) 01991

• Set the socket wrench such that the built-in spring force forces the rod F against the crankshaft assembly 12. • On the holder C, select the inscribed line G that is easiest to see. • Using the selected line as a reference, turn the socket D 90° clockwise. (One gradation on the scale H represents 5°.)

CAUTION 12829

Since the bolts utilize the plastic region tightening method, they must not be tightened further after this procedure.

11 Installing thrust plates Fit a thrust plate 11 on each side of the main bearing caps 10 and at the rear end of the crankcase 18 such that the oil grooves A are on the outside. B: Locating pin

NOTE 11731

If oversize thrust plates 11 are used, they must be fitted on both sides of the bearing caps 10. Ensure that the bearing cap rear thrust plates and the rearmost thrust plate in the crankcase 18 are the same size. Note, however, that the front and rear thrust plates on each bearing cap may be of different sizes.

13 Installing front oil seal slinger Using the Front Oil Seal Slinger Installer, drive the front oil seal slinger 13 onto the crankshaft 16 until the tool's end face A is pressed firmly against the guide B.

11969

11-71

CRANKSHAFT AND CRANKCASE 14 Installing rear oil seal slinger Using the Rear Oil Seal Slinger Installer, drive the rear oil seal slinger 14 onto the crankshaft 16 until it is pressed firmly against the end face A of the crankshaft gear 15.

02063

15 Removing and fitting crankshaft gear [Removal]

CAUTION Do not tap off the crankshaft gear 15 since this could damage it. 02110

: Gear Puller [Installation] • Using a piston heater or the like, heat the crankshaft gear 15 to a temperature of approximately 100°C (212°F). • Align the locating pin A on the crankshaft 16 with the notch B in the crankshaft gear 15. Then, drive the gear into position by striking its end face with a plastic mallet.

02111

16 Crankshaft [Inspection] (1) Roundness and cylindricity of crankshaft journal and pin If either measurement exceeds the specified limit, replace the crankshaft 16 or grind it to undersize. A: Roundness B: Cylindricity 21871

(2) Bend • Support the crankshaft 16 at its No. 1 journal A and No. 7 journal B. Measure the extent of bending in the crankshaft at the centre of the No. 4 journal C. • If the measurement exceeds the specified limit, replace the crankshaft.

NOTE 04110

11-72

With the dial indicator applied to the centre journal, turn the crankshaft 16 through one revolution. One-half of the dial indicator reading represents the extent of bending.

11 [Rectification]

NOTE If the crankshaft 16 is rectified by grinding, the main bearings 9, 17 must be replaced with undersized ones.

02107

• Grind such that the centre-to-centre distance F between the journal D and pin E does not change. +0.001 F: 57.5 +0.025 −0.075 mm (2.26 −0.003 in.) • Grind such that the journal width G and pin width H do not change. G: 37 mm (1.46 in.) H: 42 +0.2 mm (1.65 +0.008 in.) 0 0 • Finish the corner fillet smoothly and to the specified radius J. J: Radius 4 ± 0.2 mm (Radius 0.157 ± 0.008 in.) • Carry out a magnetic inspection to check for cracks caused by grinding. Also, check that the Shore hardness of the surface has not dropped below Hs 75.

Crankshaft undersize dimensions

Unit: mm (in.)

Degree of undersize 0.25 (0.00984)

0.50 (0.0197)

0.75 (0.0295)

1.00 (0.0394)

Finished journal diameter

83.685 to 83.705 (3.295 to 3.296)

83.435 to 83.455 (3.285 to 3.286)

83.185 to 83.205 (3.275 to 3.276)

82.935 to 82.955 (3.265 to 3.266)

Finished pin diameter 6D16

64.67 to 64.69 (2.546 to 2.547)

64.42 to 64.44 (2.536 to 2.537)

64.17 to 64.19 (2.526 to 2.527)

63.92 to 63.94 (2.517 to 2.518)

69.67 to 69.69 (2.743 to 2.744)

69.42 to 69.44 (2.733 to 2.734)

69.17 to 69.19 (2.723 to 2.724)

68.92 to 68.94 (2.713 to 2.714)

6D16-TLE Roundness

0.01 (0.000394) or less

Cylindricity

0.006 (0.000236) or less

• When grinding K, turn the crankshaft 16 counter-clockwise as viewed from its front end. The grinder L should rotate in the same direction. • When finishing N the crankshaft 16 with sandpaper or a whetstone M, rotate the crankshaft clockwise.

02108

18 Distortion of crankcase top surface If distortion exceeds the specified limit, correct it with a surface grinder. A: Measurement positions

CAUTION 02114

When grinding the crankcase 18, take care that the piston projections stay within specification.

11-73

GROUP 12 LUBRICATION SPECIFICATIONS....................................................................................

12-2

STRUCTURE AND OPERATION..............................................................

12-3 12-3 12-4 12-4 12-5 12-6 12-7

1. Lubrication System (Oil Flow) .............................................................................. 2. Oil Pump ............................................................................................................... 3. Oil Filter................................................................................................................. 4. Oil Cooler .............................................................................................................. 5. Engine Oil Pressure Switch, Regulator Valve ...................................................... 6. Lubrication of Related Parts ................................................................................

TROUBLESHOOTING ............................................................................. 12-11 ON-VEHICLE INSPECTION AND ADJUSTMENT.................................... 12-12 1. Oil Filter Replacement .......................................................................................... 12-12 2. Engine Oil Replacement ....................................................................................... 12-15 3. Oil Pressure Measurement ................................................................................... 12-16 OIL PAN, OIL JET, AND OIL LEVEL SENSOR ......................................... 12-18 OIL PUMP AND OIL STRAINER.............................................................. 12-20 OIL FILTER .............................................................................................. 12-24 <Spin-on Type> ......................................................................................................... 12-24 OIL COOLER ........................................................................................... 12-28 <6D16>....................................................................................................................... 12-28 <6D16-TLE> ............................................................................................................... 12-30 REGULATOR VALVE................................................................................ 12-32

12-1

SPECIFICATIONS Item Mode of lubrication

Specifications Oil pump type

Oil filter type

Spin-on paper-filter type or replaceable-element type

Oil cooler type

Shell and plate type (multi-plate type)

Engine oil

Turbocharged engine: API CD or above Nom-turbocharged engine: API CC or above Oil pan

Oil quantity L (U.S.gal.)

Oil filter

General power applications

Approx. 9.5 (2.51)

Construction machinery applications

Approx. 16 (4.23)

Spin-on type: A, B type

2.1 (0.555)

Spin-on type: C type

12-2

2.3 (0.608)

STRUCTURE AND OPERATION 1. Lubrication System (Oil Flow)

16887

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Engine oil pressure gauge unit Main oil gallery Bypass valve Oil cooler Engine oil bypass alarm switch Full-flow filter element Bypass filter element Check valve (built into oil filter) Bypass check valve (built into oil filter) Relief valve (built into oil pump) Oil pump Oil strainer Regulator valve Crankshaft main bearing Connecting rod bearing

16 17 18 19 20 21 22 23 24 25 26 27 28 29

Connecting rod bushing Check valve for oil jet Piston Injection pump Injection pump drive (or air compressor) Timing gears Camshaft bushing Rocker bushing Push rod Tappet Idler gear shaft No. 1 Idler gear shaft No. 2 Turbocharger <6D16-TLE> Oil pan

12-3

STRUCTURE AND OPERATION 2. Oil Pump 1 2 3 4 5

Crankshaft gear Oil pump gear Oil pump Oil strainer Relief valve

A: To oil filter B: From oil pan C: To oil pan

01476

Oil pump 3 is a gear type. It is driven by rotation of the crankshaft via crankshaft gear 1 and oil pump gear 2. Relief valve 5 is fitted to the oil pump. When the oil pump discharge pressure exceeds a specified level, the relief valve returns some of the engine oil to the oil pan, thus protecting the lubrication system from excessive oil pressure.

3. Oil Filter <Spin-on type (A, B type)> 1 2 3 4 5

Full-flow filter element Bypass filter element Engine oil bypass alarm switch Check valve Bypass check valve

A: To oil cooler B: From oil pump C: To oil pan

P 47027

12-4

This oil filter is a spin-on paper-filter type incorporating fullflow filter element 1 and bypass filter element 2. Engine oil bypass alarm switch 3 is fitted to the oil filter bracket. If clogging causes the pressure difference before and after the element to exceed a specified level, a valve inside the switch opens to allow oil to flow directly to the oil cooler. Check valve 4 is fitted to the inlet to prevent a reverse flow of oil out of the filter when the engine is stationary. In conjunction with this, bypass check valve 5 opens only when oil pressure in the bypass arrangement exceeds a specified level. As a result, the oil level in the filter is kept constant and oil reaches all parts of the lubrication system quickly when the engine is started.

12 <Spin-on type (C type)> 1 Engine oil bypass alarm switch 2 Bypass filter element 3 Full-flow filter element A: To oil pan B: To oil cooler C: From oil pump This oil filter is a paper-filter type incorporating full-flow filter element 3 and bypass filter element 2.

P 34244

P 34247

● Engine oil bypass alarm switch • If the oil filter element becomes clogged, the flow of engine oil is restricted, causing engine parts to seize. To prevent this, engine oil bypass alarm switch 1 is fitted to the spin-on filter. • When the oil filter element becomes clogged, engine oil bypass alarm switch 1 is activated. As a result, engine oil is allowed to flow directly to the oil cooler, bypassing full-flow filter element 3. When the engine oil bypass alarm switch is activated, a warning lamp illuminates to notify the operator of the clogged oil filter element.

4. Oil Cooler <6D16>

<6D16-TLE>

P 34273

01478

1 Oil cooler cover 2 Oil cooler element 3 Bypass valve

A: To main oil gallery B: From oil filter

12-5

STRUCTURE AND OPERATION ● Bypass valve Bypass valve 3 is fitted to the oil cooler. When engine oil is cool and its viscosity is high, or when the oil cooler element becomes clogged and restricts the flow of engine oil, this valve opens. As a result, engine oil is allowed to flow directly to the main oil gallery, bypassing the oil cooler.

<6D16>

A: To main oil gallery B: From oil filter 01479

<6D16-TLE>

P 34275

5. Engine Oil Pressure Switch, Regulator Valve 1 Crankcase 2 Engine oil pressure switch 3 Regulator valve

<6D16>

A: To oil pan B: Main oil gallery

16888

<6D16-TLE>

P 44719

● Engine oil pressure switch If the pressure of engine oil to the main oil gallery drops below a specified level, an electrical contact incorporated in engine oil pressure switch 2 closes. This causes a relevant warning lamp on the meter cluster to illuminate, notifying the operator of the excessive pressure drop. ● Regulator valve If the oil pressure in the main oil gallery exceeds a specified level, regulator valve 3 opens to allow some of the engine oil to return to the oil pan, thereby regulating the oil pressure to specification.

12-6

12 6. Lubrication of Related Parts Engine oil fed to the main oil gallery lubricates the following related parts: ● Main Bearing and Connecting Rod Bearing 1 Connecting rod bushing 2 Connecting rod bearing 3 Crankshaft 4 Main bearing

01481

A: Oil jet B: Connecting rod oil passage C: Main oil gallery Oil supplied via the oil passage in crankshaft 3 flows through connecting rod oil passage B to lubricate the connecting rod's small end. The oil then sprays out of oil jet A at the top of the connecting rod to cool the piston. ● Timing gear and camshaft 1 Camshaft bushing No. 4 2 Camshaft 3 Idler gear No. 2 4 Idler gear bushing 5 Idler shaft No. 2 6 Idler gear No. 1 7 Idler gear bushing 8 Idler gear shaft No. 1 A: To rocker bushing B: From main oil gallery Engine oil flows through the inside of camshaft 2 and lubricates each camshaft bushing.

01482

12-7

STRUCTURE AND OPERATION ● Valve mechanism 1 Rocker shaft bracket 2 Rocker 3 Rocker shaft 4 Rocker bushing 5 Crankcase 6 Cylinder head 7 Cylinder head bolt 8 Push rod 9 Tappet 10 Camshaft A: From camshaft bushing No. 4 B: Oil reservoir C: To oil pan 01484

After lubricating rocker 2, the camshaft bushings, and other components, oil enters oil reservoir B to lubricate the cams.

01485

● Check valve and oil jet 1 Piston 2 Oil jet 3 Check valve A: Main oil gallery

01487

12-8

An oil jet 2 is fitted in the lower part of the main oil gallery A for each piston. These oil jets cool the pistons 1 by injecting oil into them. Each oil jet is fitted with a check valve that opens and closes at specified oil pressure levels. At low engine speeds, these check valves 3 close to maintain the required volume of oil in the lubrication system and prevent reductions in oil pressure.

12 ● Turbocharger <6D16-TLE> 1 Bearing housing 2 Snap ring 3 Piston ring 4 Bearing A: From main oil gallery B: To oil pan Via an oil pipe, engine oil is delivered from the main oil gallery to the bearing housing 1 to lubricate the inside of the bearing housing. At each end of the turbine wheel shaft, piston ring 3 acts as an oil seal. 01488

● Injection pump 1 Injection pump 2 Governor 3 Air compressor (or injection pump drive) A: From main oil gallery B: To oil pan

01489

Engine oil that has lubricated injection pump 1 and governor 2 returns to the oil pan via the timer case, air compressor 3 (or injection pump drive), and timing gear train. ● Air compressor 1 Piston 2 Connecting rod 3 Crankshaft 4 Connecting rod bushing 5 Crankcase A: From main oil gallery B: To oil pan Engine oil from the main oil gallery splashes onto connecting rod 2 and lubricates connecting rod bushing 4. Piston 1 and the connecting rod's small end are lubricated by oil that is splashed onto them by the rotation of the crankshaft 3.

11107

12-9

STRUCTURE AND OPERATION ● Vacuum pump Some of the oil used to lubricate the camshaft bushings is fed to the vacuum pump housing via a flexible hose. After lubricating the vacuum pump vanes, this oil leaves via an outlet at the bottom of the housing and returns to the oil pan.

01491

12-10

Low oil pressure

Possible causes

Overheating

Engine hard to start

Symptoms

Excessive oil consumption (oil leakage)

TROUBLESHOOTING

Remarks

Oil cooler element installed poorly Gasket defective Oil cooler

O-ring defective Oil cooler element clogged Oil cooler element damaged Fatigue in bypass valve spring Oil pump malfunctioning Interference between oil pump gear and oil pump case or cover

Oil pump

Oil pipe poorly fitted Oil strainer clogged Fatigue in relief valve spring Oil filter fitted poorly Element clogged

Oil filter

Fatigue in check valve and bypass check valve springs <A, B type> O-ring defective

Front cover assembly timing gear case Flywheel housing

Front oil seal defective

Gr 11

Front cover assembly fitted poorly

Gr 11

Rear oil seal defective

Gr 11

Gasket fitted poorly

Gr 11

Fatigue in regulator valve spring Piston cooling oil jet(s) defective Oil working its way up into combustion chamber(s)

Gr 11

Oil working its way down into combustion chamber(s)

Gr 11

Oil viscosity too high Unsuitable oil quality Deterioration in oil Fuel mixed with oil

12-11

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Oil Filter Replacement <Spin-on type> Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

Oil filter drain valve <A type>

29 ± 4.9 (3 ± 0.5) [22.1 ± 3.6]

–

Oil filter drain valve <B, C type>

7.8 ± 2.0 (0.8 ± 0.2) [5.89 ± 1.44]

–

Special tools Location

Unit: mm (in.)

Tool name and shape

Part No.

Oil Filter Wrench

MH061537

Application

Oil filter removal

01503

WARNING

• Wipe up any spilled engine oil since it can cause a fire. • Do not touch oil when the engine is hot since it can inflict severe burns.

CAUTION

P 47028

When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip, rendering the cooling system less effective.

For type A or type B oil filter, loosen drain plug 1 or oil filter drain plug 2 and air plug 3 in that order, then drain the oil out of filter 4.

P 47029

P 11108

12-12

12 [Removal]

: Oil Filter Wrench

P 47030

P 47031

P 11109

12-13

ON-VEHICLE INSPECTION AND ADJUSTMENT <A type>

P 47032

P 47033

P 11110

12-14

[Installation] • Clean the surface on oil filter head 5 that makes contact with oil filter 4. • Apply a film of engine oil to gasket area A of filter 4. • Screw oil filter 4 into oil filter head 5 until gasket area A touches the oil filter head. • From this position, tighten filter 3 by a further 1 1/8 to 1 3/8 of a turn. • Fit oil filter drain valve 1 or oil filter drain plug 2. • Start the engine and check that no oil leaks from gasket area A. • Check the engine oil level and add oil if necessary.

12 2. Engine Oil Replacement Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

Oil pan drain plug

69 (7) [50.9]

–

Oil filter drain valve

29 ± 4.9 (3 ± 0.5) [22.1 ± 3.6]

–

Oil filter drain plug

7.8 ± 2.0 (0.8 ± 0.2) [5.89 ± 1.44]

–

Lubricants

Unit: L (U.S.gal.)

Location –

Points of application Oil pan

General power applications Construction machinery applications

–

Oil filter

Spin-on type: A, B type Spin-on type: C type

Kinds

Quantity

Non-turbocharged engines: API CC or above Turbocharged engines: API CD or above

Approx. 9.5 (2.51)

Non-turbocharged engines: API CC or above Turbocharged engines: API CD or above

Approx. 2.1 (0.555)

Approx. 16 (4.23)

Approx. 2.3 (0.608)

WARNING

<Spin-on type: A type>

• Wipe up any spilled engine oil since it can cause a fire. • Do not touch oil when the engine is hot since it can inflict severe burns.

CAUTION <Spin-on type: B type>

P 16770

When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip, rendering the cooling system less effective.

[Draining] • Warm up the engine, then remove oil filler cap 1. • Remove oil pan drain plug 2, oil filter drain valve 3, and air plug 4. Then, drain the engine oil. P 47034

[Filling] Tighten oil pan drain plug 2 and oil filter drain valve 3 or oil filter drain plug 4 to their specified torques, then pour the specified quantity of engine oil into the engine.

<Spin-on type: C type>

P 47096

12-15

ON-VEHICLE INSPECTION AND ADJUSTMENT 3. Oil Pressure Measurement <6D16> Service standards Location –

Unit: MPa (kgf/cm2) [psi] Maintenance item

Oil pressure [at oil temperature 70 to 90 °C (158 to 194 °F)]

Standard value

Limit

Remedy

At no-load minimum speed

0.1 (1.0) [14.5] or higher

Up to 0.1 (1.0) [14.5]

Adjust

At no-load maximum speed

0.2 to 0.6 (2.0 to 6.1) [29.0 to 87.0]

Up to 0.2 (2.0) [29.0]

Tightening torque

Unit: N·m (kgf·m) [lbf·ft]

Location

Parts to be tightened

Tightening torque

Remarks

Engine oil pressure gauge unit

15 to 22 (1.5 to 2.2) [11.1 to 16.2]

Check with engine cold

Sealant Location 1

Points of application Wrap around thread of engine oil pressure gauge unit

Specified sealant Teflon tape

Quantity 3 1/2 turns

• Remove engine oil pressure gauge unit 1.

16773

• Fit adapter 3 onto the engine oil pressure gauge unit mounting, then fit the oil pressure gauge onto the adapter. • Warm up the engine until the oil temperature reaches 70 to 90°C (158 to 194°F). • Measure the oil pressure at no-load minimum speed and at no-load maximum speed. If the measured values are below the specified standard values, overhaul the lubrication system. • After taking measurements, fit oil pressure gauge unit 1 and tighten it to the specified torque. 16774

NOTE Oil pressure gauge unit 1 must be fitted with the engine cold.

12-16

12 <6D16-TLE> Service standards Location –

Unit: MPa (kgf/cm2) [psi] Maintenance item

Oil pressure [at oil temperature 70 to 90 °C (158 to 194 °F)]

Standard value

Limit

Remedy

At no-load minimum speed

0.1 (1.0) [14.5] or higher

Up to 0.1 (1.0) [14.5]

Adjust

At no-load maximum speed

0.2 to 0.6 (2.0 to 6.1) [29.0 to 87.0]

Up to 0.2 (2.0) [29.0]

Tightening torque Location 1

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened Engine oil pressure switch

Tightening torque

Remarks

15 to 22 (1.5 to 2.2) [11.1 to 16.2]

Check with engine cold

Sealant Location 1

Points of application Wrap around thread of engine oil pressure switch

Specified sealant Teflon tape

Quantity 3 1/2 turns

• Remove engine oil pressure gauge unit 1. 2: Oil cooler

P 11112

• Fit adapter 3 into the opening from which the engine oil pressure switch has been removed. Install an oil pressure gauge onto the adapter. • Run the engine until oil temperature reaches 70 to 90°C. (158 to 194°F). • Measure the oil pressure at both no-load minimum and maximum speeds. If either of the measured values is below the limit pressures, overhaul the lubrication system. • Fit engine oil pressure switch 1 and tighten it to the specified torque. P 11113

NOTE Installation of engine oil pressure switch 1 must be performed while the engine is cold.

12-17

OIL PAN, OIL JET, AND OIL LEVEL SENSOR ● Disassembly sequence 1 Drain plug 2 Oil pan - Oil pan gasket 3 Engine oil temperature sensor 4 Check valve 5 Oil jet

*: Crankcase

Gr 11

A: Locating pin : Non-reusable part ● Assembly sequence Reverse the order of disassembly.

CAUTION Do not tighten check valve 4 in excess of the specified torque. Excessive tightness can cause defective operation, resulting in scorching of the engine. 16775

Service standards Location

Maintenance item

Standard value

Limit

Remedy

Resistance of engine oil temperature sensor 50°C (122°F) (between ternimal ➀ and body) 80°C (176°F)

(136 V)

–

Replace

48 ± 5 V

–

100°C (212°F)

27.2 ± 2 V

–

Figures in parentheses are approximate.

Tightening torques Location

Parts to be tightened

Drain plug

Engine oil temperature sensor

Check valve

12-18

Unit: N·m (kgf·m) [lbf·ft]

Tightening torque

Remarks

69 (7) [50.9]

–

34 ± 6.9 (3.5 ± 0.7) [25.1 ± 5.1]

–

34 (3.5) [25.1]

–

03868

3 Engine oil temperature sensor • Place engine oil temperature sensor 3 in a container of engine oil. • Heat the engine oil until it reaches each of the temperatures in the service standards table. • At each of the given temperatures, measure the electrical resistance between the engine oil temperature sensor's terminal ➀ and body ➁. • If the resistance values do not match those in the service standards table, replace the engine oil temperature sensor 3.

12-19

OIL PUMP AND OIL STRAINER

01497

● Inspection before disassembly P.12-21 ● Disassembly sequence 1 Oil strainer 2 Oil pipe 3 Oil pump assembly 4 Bolt 5 Cover 6 Driven gear assembly 7 Ring

8 9 10 11 12

Relief valve Relief valve spring Washer Gear and case assembly Shim

*1: Crankcase Gr 11 *2: Crankshaft gear Gr 11 A: Oil pump gear B: Locating pin : Non-reusable part

NOTE • Do not remove parts #7 to 10 unless they are defective. • Gear and case assembly 11 is an integrated unit and cannot be disassembled. If any defect is apparent, replace the whole unit. • Do not remove oil strainer 1 and oil pipe 2 from oil pump assembly 3 unless they are defective. Remove those three as a unit. ● Assembly sequence Reverse the order of disassembly.

12-20

12 Service standards

Unit: mm (in.)

Location

Maintenance item

Standard value

Limit

Remedy

5, 11

Clearance between drive gear shaft and inner diameter of cover [Basic diameter: 20 mm (0.787 in.)]

0.04 to 0.07 (0.00157 to 0.00276)

0.15 (0.00591)

Replace

5, 6, 11

Clearance between drive gear shaft and inner diameter of case and cover [Basic diameter: 20 mm (0.787 in.)]

0.04 to 0.07 (0.00157 to 0.00276)

0.15 (0.00591)

Replace

6, 11

Clearance between case and tooth tips of each gear

0.10 to 0.19 (0.00394 to 0.00748)

0.2 (0.00787)

Replace

Difference between height of each gear and depth of case

0.06 to 0.11 (0.00236 to 0.00433)

0.15 (0.00591)

980 to 1175 kPa (10 to 12 kgf/cm2) [142 to 170 psi]

–

Replace

Relief valve opening pressure

Relief valve spring load [Installed length = 30 mm (1.18 in.)]

84 N (8.6 kgf) [18.9 lbf]

–

Replace

*2, A

Backlash between oil pump gear and crankshaft gear

0.08 to 0.18 (0.00315 to 0.00709)

0.35 (0.0138)

Adjust with shims

Tightening torque Location 4

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened Oil pump cover mounting bolt

Tightening torque

Remarks

25 ± 4.9 (2.5 ± 0.5) [18.4 ± 3.6]

–

◆ Service procedure ● Inspection before disassembly Measure the backlash between oil pump gear A and crankshaft gear *2. If the amount of backlash exceeds the specified limit, adjust it with shims 12. Unit: mm (in.)

Shim thickness

Change in amount of backlash

0.1 (0.00394)

0.073 (0.00287)

0.2 (0.00787)

0.146 (0.00575)

01498

NOTE Shim 12 must have the same thickness on the left and right sides.

12-21

OIL PUMP AND OIL STRAINER 5

Inspection of driven gear assembly and of gear and case assembly

(1)

Differences between gear heights and case depth Replace any component whose measurement is out of specification.

(2)

Clearance between gear teeth and case Replace any component whose measurement is out of specification.

Inspection of cover, driven gear assembly, and gear and case assembly Measure the clearance between each gear shaft and the internal diameters of the cover and case.

01499

01500

01501

12-22

MEMO

12-23

OIL FILTER <Spin-on Type> ● Disassembly sequence 1 Oil filter drain valve <A, B type> 2 Oil filter drain plug 3 Oil filter P.12-12 4 Engine oil bypass alarm switch 5 O-ring 6 Air plug <A, B type> 7 Oil filter head 8 Spacer 9 O-ring

*a: Oil cooler P.12-28 *b: Crankcase assembly

Gr 11

: Non-reusable part P 47035

P 47036

P 34249

12-24

● Assembly sequence Reverse the order of disassembly.

12 WARNING • Wipe up any spilled engine oil since it can cause a fire. • Do not touch oil when the engine is hot since it can inflict severe burns.

CAUTION When pouring oil into the engine, take care not to spill any on the V-belts. Contact with oil could make the V-belts slip, rendering the cooling system less effective.

Service standards

Unit: MPa (kgf/cm2) [psi]

Location 4

Maintenance item

Standard value

Engine oil bypass alarm switch valve opening pressure

0.19

+ 0.05 −0

(1.9

+ 0.5 −0

) [27.6

+ 7.3 −0

Tightening torques Location

Limit

Remedy

–

Replace

]

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

Oil filter drain valve <A, B type>

29 ± 4.9 (3.0 ± 0.5) [22.1 ± 3.6]

–

Oil filter drain plug

7.8 ± 2.0 (0.8 ± 0.2) [5.89 ± 1.44]

–

Engine oil bypass alarm switch

49 ± 4.9 (5.0 ± 0.5) [36.1 ± 3.6]

–

Lubricant Location

Points of application

Apply thin film to oil filter gasket area

Apply to O-rings

P.12-12

Specified lubricant

Quantity

Engine oil

As required

Engine oil

As required

◆ Service procedure

11312

4 Inspection of engine oil bypass alarm switch Carry out the following inspections and replace the engine oil bypass alarm switch 4 if the results are unsatisfactory: • With no air pressure A applied to engine oil bypass alarm switch 4, check that there is no electrical continuity between the terminal ➀ and body ➁ of the engine oil bypass alarm switch. • Starting with pressure of 0 kPa (0 kgf/cm 2) [0 lbf/in. 2], gradually increase the air pressure A on engine oil bypass alarm switch 4. Note the air pressure when electrical continuity appears between the terminal ➀ and body ➁. Verify that this pressure conforms with the specified standard value. B: Air pressure gauge

12-25

OIL COOLER <6D16> ● Disassembly sequence 1 Bypass valve 2 O-ring 3 Oil cooler plug 4 O-ring 5 Nut 6 Oil cooler element 7 O-ring 8 Oil cooler cover 9 Gasket 10 O-ring 11 O-ring 12 Regulator valve P.12-32 13 Engine oil pressure gauge unit 14 Engine oil pressure switch

*: Crankcase assembly

Gr 11

: Non-reusable part ● Assembly sequence Reverse the order of disassembly.

16779

Service standards Location

Unit: kPa (kgf/cm2) [psi] Maintenance item

Standard value

Limit

Remedy

Oil cooler bypass valve opening pressure

295 ± 20 (3.0 ± 0.2) [42.8 ± 2.9]

–

Oil cooler element air leakage (air pressure of 980 kPa (10 kgf/cm2) [142 psi] for 15 seconds)

0 cc (0 cu.in.)

–

Replace

Operating pressure of engine oil pressure switch

49 ± 9.8 (0.5 ± 0.1) [7.11 ± 1.42]

–

Replace

Tightening torques Location

Parts to be tightened

Unit: N·m (kgf·m) [lbf·ft]

Tightening torque

Remarks

Bypass valve

20 ± 4.9 (2.0 ± 0.5) [14.8 ± 3.6]

–

Oil cooler plug

25 ± 4.9 (2.5 ± 0.5) [18.4 ± 3.6]

–

Nut (oil cooler element mounting)

20 ± 4.9 (2.0 ± 0.5) [14.8 ± 3.6]

–

Regulator valve

105 ± 9.8 (11 ± 1) [77.4 ± 7.2]

–

Engine oil pressure gauge unit

15 ± 22 (1.5 ± 2.2) [11.1 ± 16.2]

–

Engine oil pressure switch

15 ± 22 (1.5 ± 2.2) [11.1 ± 16.2]

–

12-26

12 Lubricant and/or sealant Location

Points of application

Specified lubricant and/or sealant

Quantity

2, 4, 11

Apply to O-rings

Engine oil

As required

13, 14

Wrap around thread of engine oil pressure gauge unit and engine oil pressure switch

Teflon tape

3 1/2 turns

◆ Service procedure ● Cleaning • Check whether carbon deposits or sludge have accumulated in the oil passages of oil cooler element 6 and oil cooler cover 8 or in the oil cooler's bypass arrangement. Remove any deposits with cleaning sealant. • Clean out any water scale or fur that has accumulated in the oil cooler element 6 or oil cooler cover 8. Gr 14 6 Inspection of oil cooler element Plug outlet A of oil cooler element 6 and connect a hose to the oil inlet. Then, immerse the oil cooler element in a tank of water. Apply the specified air pressure via the hose and check that no air leaks from the oil cooler element. If any air leaks, replace the oil cooler element.

01505

13 Engine oil pressure gauge unit If the engine oil pressure gauge unit 13 is installed horizontally, it must be fitted with its arrow pointing upward.

16886

12-27

OIL COOLER <6D16>

16202

14 Inspection of engine oil pressure switch Perform the following checks, and if any fault is found, replace the engine oil pressure switch 14. • Inspection by not applying air pressure Make sure that there is continuity between terminals ➀ and ➁ (body). • Inspection by applying air pressure • Gradually apply air pressure A to the switch starting from 0 kPa (0 kgf/cm2) {0 lbf/in2}. • Measure the degree of air pressure at the moment when continuity is not detected between terminals ➀ and ➁ (body), and make sure to confirm if the value meets the standard. B: Air pressure gauge

12-28

MEMO

12-29

OIL COOLER <6D16-TLE> ● Disassembly sequence 1 Bypass valve plug 2 O-ring 3 Bypass valve spring 4 Bypass valve 5 Engine oil pressure switch 6 Regulator valve P.12-32 7 O-ring 8 Nut 9 Oil cooler element 10 Gasket 11 Oil cooler plug 12 O-ring 13 Oil cooler plug 14 O-ring 15 Oil cooler cover 16 O-ring 17 Gasket P 34270

*: Crankcase assembly

Gr 11

: Non-reusable part ● Assembly sequence Reverse the order of disassembly.

Service standards Location 3

Maintenance item Bypass valve spring

Free length Spring load (installed length)

Operating pressure of engine oil pressure switch

Oil cooler element air leakage [Apply air pressure of 1000 kPa (10.2 kgf/cm2) [145 psi] for 15 seconds.]

Standard value

Limit

Remedy

104.3 ± 1 mm (4.12 ± 0.04 in.)

–

84 ± 3 N (8.6 ± 0.3 kgf) [18.9 ± 0.7 lbf]

–

Replace

49 ± 9.8 kPa (0.5 ± 0.1 kgf/cm2) [7.11 ± 1.42 psi]

–

Replace

0 cm3 (0 mL)

–

Replace

Tightening torques Location

Parts to be tightened

Unit: N·m (kgf·m) [lbf·ft]

Tightening torque

Remarks

Bypass valve plug

34.5 ± 4.9 (3.5 ± 0.5) [25.4 ± 3.6]

–

Engine oil pressure switch

15 to 22 (1.5 to 2.2) [11.1 to 16.2]

–

Regulator valve

98 to 118 (10 to 12) [72.3 to 87.0]

–

Nut (for fixing oil cooler element)

20 ± 4.9 (2.0 ± 0.5) [14.8 ± 3.6]

–

Oil cooler plug

25 ± 4.9 (2.5 ± 0.5) [18.4 ± 3.6]

–

Oil cooler plug

34.5 ± 4.9 (3.5 ± 0.5) [25.4 ± 3.6]

–

12-30

12 Lubricant and/or sealant Location 5 7, 12, 14, 16

Points of application

Specified lubricant and/or sealant

Quantity

Thread of engine oil pressure switch

Teflon tape

Wrap around 3 1/2 turns

O-rings on oil cooler

Engine oil

As required

◆ Service procedure ● Cleaning • Check whether carbon deposits or sludge have accumulated in the oil passages of oil cooler element 9 and in the oil cooler’s bypass arrangement. Remove any deposits with cleaning sealant. • Clean out any water scale or fur that has accumulated in the oil cooler element 9 or oil cooler cover 15. Gr 14

16202

5 Inspection of engine oil pressure switch Perform the following checks, and if any fault is found, replace the engine oil pressure switch 5. • Inspection by not applying air pressure Make sure that there is continuity between terminals ➀ and ➁ (body). • Inspection by applying air pressure • Gradually apply air pressure A to the switch starting from 0 kPa {0 kgf/cm2}. • Measure the degree of air pressure at the moment when continuity is not detected between terminals ➀ and ➁ (body) and make sure to confirm if the value meets the standard. B: Air pressure gauge 9 Inspection of oil cooler element Plug outlet A of oil cooler element 9 and connect a hose to the oil inlet. Then, immerse the oil cooler element in a tank of water. Apply the specified air pressure B via the hose and check that no air leaks from the oil cooler element. If any air leaks, replace the oil cooler element.

01505

12-31

REGULATOR VALVE ● Disassembly sequence 1 Snap ring 2 Valve 3 Spring 4 Body ● Assembly sequence Reverse the order of disassembly. [Installation] P.12-26, 30

09189

Service standards Location

Maintenance item

Standard value

Limit

Remedy

Regulator valve spring load [Installed length = 48.3 mm (1.90 in.)]

76 to 80 N (7.8 to 8.2 kgf) [17.1 to 18.0 lbf]

–

Regulator valve opening pressure

390 ± 29 kPa (4.0 ± 0.3 kgf/cm2) [56.6 ± 4.2 psi]

–

12-32

GROUP 13 FUEL AND ENGINE CONTROL SPECIFICATIONS....................................................................................

13-2

STRUCTURE AND OPERATION..............................................................

13-4 1. Fuel System .......................................................................................................... 13-4 2. Fuel Filter .............................................................................................................. 13-5 3. Injection Pump...................................................................................................... 13-5 4. Governor ............................................................................................................... 13-8 5. Feed Pump ........................................................................................................... 13-9 6. Automatic Timer ................................................................................................... 13-10 7. Boost Compensator ............................................................................................. 13-11 8. Injection Pump Drive ............................................................................................ 13-12 9. Injection Nozzles .................................................................................................. 13-12

TROUBLESHOOTING ............................................................................. 13-14 ON-VEHICLE INSPECTION AND ADJUSTMENT.................................... 13-18 1. Checking and Adjusting Injection Timing ............................................................ 13-18 2. Checking and Adjusting Minimum and Maximum No-load Speeds.................... 13-22 3. Cleaning Fuel Feed Pump Gauze Filter................................................................ 13-23 FUEL FILTER ........................................................................................... 13-24 INJECTION PUMP .................................................................................. 13-26 <Oldham’s Coupling Type> ....................................................................................... 13-26 <Laminated Coupling Type> ..................................................................................... 13-28 INJECTION PUMP DRIVE ....................................................................... 13-34 <Oldham’s Coupling Type> ....................................................................................... 13-34 <Laminated Coupling Type> ..................................................................................... 13-38 INJECTION NOZZLE ............................................................................... 13-42

13-1

SPECIFICATIONS Injection Pump Engine model Item

6D16

Model

6D16-TLE Bosch AD

Governor type

RSV-type all-speed mechanical governor

Feed pump type

Automatic timer type

–

SPG mechanical timer

Manufacturer

BOSCH AUTOMOTIVE SYSTEMS

Injection Nozzle Engine model Item

6D16

Model

6D16-TLE Hole-type (1-spring)

No. of holes

Hole diameter

mm (in.)

Manufacturer

0.31 (0.0122)

0.29 (0.0114)

BOSCH AUTOMOTIVE SYSTEMS

Other Items Item Fuel filter type

13-2

Specifications Spin-on type (paper filter)

0.275 (0.0108)

MEMO

13-3

STRUCTURE AND OPERATION 1. Fuel System

12574

1 2 3 4

Injection nozzle Fuel filter Automatic timer Fuel tank

5 6 7 8

Feed pump Injection pump Overflow valve Governor

• Fuel from the fuel tank 4 is drawn up by the feed pump 5 and strained by the fuel filter 2. The feed pump is driven by a cam in the injection pump 6. • After filtration, fuel is fed to the injection pump 6. From there, it is fed under high pressure to the injection nozzles 1. The injection nozzles spray the fuel into the combustion chambers. • If the fuel pressure in the injection pump 6 exceeds a preset level, the overflow valve 7 opens to allow excess fuel to return to the fuel tank 4.

13-4

13 2. Fuel Filter 1 Fuel filter 2 Fuel filter head A: From feed pump B: To injection pump The fuel filter separates any water content out of fuel fed from the injection pump's feed pump, and its element removes any impurities.

01822

3. Injection Pump 1 2 3 4 5 6 7 8 9 10 11

Delivery valve holder Delivery valve spring Delivery valve Plunger barrel Control pinion Plunger Control rack Control sleeve Plunger spring Tappet Camshaft

The injection pump feeds fuel to the injection nozzles under high pressure and incorporates a mechanism for increasing and decreasing the fuel flow.

01823

13-5

STRUCTURE AND OPERATION ● Fuel feed action A: Fuel drawn in B: Start of pressure feed C: End of pressure feed D: Inlet/outlet hole E: Lead

01824

As the plunger 6 rises and its lead E meets the fuel inlet/outlet hole D, fuel flows through the center of the plunger and is expelled from the inlet/outlet hole. Regardless of how much further the plunger rises, no fuel feed takes place thereafter. The stroke length F of the plunger 6 during which pressure feed takes place is known as the “effective stroke.”

01825

● Injection volume adjustment mechanism To match changes in engine loading, an adjustment mechanism controls the amount of fuel injected. This mechanism turns the plunger 6 by a given angle, thereby altering the point at which the fuel inlet/outlet hole D meets the lead E. Simply stated, the effective stroke is made longer or shorter. A single control rack 7 is used to rotate every plunger in the engine, so the plungers rotate simultaneously and by the same angle. 01826

13-6

13 ● Delivery valve G: Pressurization starts H:: Injection J: Pressurization ends (Starting suction) K: Suction ends L: Suction stroke

01827

Fuel highly pressurized by plunger pushes up delivery valve 3 for injection, and when delivery of pressurized fuel ends, delivery valve returns by the force of delivery valve spring to close fuel passage, thus avoiding reverse flow of fuel. Delivery valve lowers further to rest at its seat, and for this stroke L, residual pressure between delivery valve and injection nozzle is for an instant lowered. This return suction makes fuel-cutting at nozzles effective and avoids post-injection dripping. ● Overflow valve When the fuel pressure in the injection pump exceeds a preset level, the steel ball R is pushed up, allowing fuel to flow out from the injection pump and return to the fuel tank. This stabilizes the fuel temperature and temperature distribution in the injection pump and keeps the injection rate constant in each cylinder.

01830

13-7

STRUCTURE AND OPERATION 4. Governor

18225

1 2 3 4 5 6 7 8 9

13-8

Tension lever Guide lever Supporting lever shaft Governor housing Control rack Adjusting lever Swivel lever Camshaft Flyweight

10 11 12 13 14 15 16 17

Stop lever Full-load stopper bolt Ungleich spring or idling spring Idling subspring Governor spring Control lever Shackle Start spring

13 5. Feed Pump 1 2 3 4 5

Priming pump Inlet check valve Gauze filter Outlet check valve Feed pump housing

A: From fuel tank B: To fuel filter

14431

The feed pump is driven by the camshaft in the injection pump. The priming pump 1 enables fuel to be drawn up manually when the injection pump is stationary. It is particularly useful for air bleeding. The gauze filter 3 removes large impurities from fuel drawn up from the fuel tank and thus prevents clogging of the feed pump. It must be washed regularly in gas oil.

● Suction stroke When the injection pump camshaft 6 forces up the push rod 7, fuel in the suction chamber C is compressed and opens the outlet check valve 4. Most of the fuel forced out is drawn into the pressure chamber D below the piston.

13912

● Pressure feed stroke As the camshaft 6 turns and the cam loses its lift, the piston 9 is pushed down by the piston spring 8. The fuel in the pressure chamber D is thus forced out and fed toward the fuel filter. At the same time, the outlet check valve 4 closes and the inlet check valve 2 opens. As a result, fuel is again drawn into the suction chamber C. 13913

● Stoppage When pressure in the pressure chamber D exceeds a preset level, the piston spring 8 cannot push back the piston 9. The pump therefore stops operating, preventing pressure in the fuel filter from rising more than necessary.

13914

13-9

STRUCTURE AND OPERATION 6. Automatic Timer The automatic timer utilizes a mechanical arrangement to adjust the injection timing in accordance with the engine speed. The automatic timer is mounted on the injection pump camshaft using a round nut. Via a driving disk, it is driven by the air compressor crankshaft or pump drive shaft. 1 2 3 4 5 6 7 8

Timer housing Eccentric cam (small) Eccentric cam (large) Timer holder Flyweight Timer spring Pilot pin Cover

P 47183

● With engine stationary With the engine stationary, flyweight 5 is held against timer holder 4 by the force of timer spring 6.

P 47184

P 47185

13-10

● With engine running As the engine speed increases, the centrifugal force exerted on flyweight 5 matches the force of timer spring 6. As the engine speed increases further, the centrifugal force overcomes the force of spring, causing the flyweight to move outwards. As the flyweight moves outwards, eccentric cam (small) 2 rotates in the reverse direction of the shaft rotation about pin A of the timer housing. Also, center B of eccentric cam (large) 3 rotates in the reverse direction of the shaft rotation about center C of the timer. The eccentric cam (large) has been fit into timer holder 4. Therefore, the movement of the eccentric cam (large) is transmitted to the timer holder. The maximum retard is achieved when the back of the flyweight bottoms against the inner surface of timer housing 1.

13 7. Boost Compensator

P 47186

1 2 3 4 5 6

Inlet manifold Turbo charger Turbine Boost compensator spring Boost compensator Hose

7 8 9 10 11 12

Diaphragm Push rod Compensator lever Governor Floating lever Control rod

A: Boost pressure B: Intake air C: Exhaust D: More fuel E, F: Pivot

• The boost compensator is designed to ensure that a greater amount of fuel is injected as the turbo charger feeds more air into the engine so that the engine output increases accordingly. • As boost pressure A in inlet manifold 1 overcomes the force of boost compensator spring 4 of boost compensator 5, diaphragm 7 and push rod 8 are pushed to the left. • As push rod 8 is pushed to the left, compensator lever 9 moves counterclockwise about pivot F to the position shown by the dotted line. This causes floating lever 11 to move counterclockwise about pivot E, which in turn moves control rod 12 in the direction of D (more fuel). As a result, a greater amount of fuel is injected irrespective of the operations of governor 10.

13-11

STRUCTURE AND OPERATION 8. Injection Pump Drive 1 2 3 4 5

Pump drive case Bearing Pump drive gear Pump drive shaft Coupling

A: Timing gear side B: Timer side The injection pump drive is fitted onto the flywheel housing on the left of the engine. It is driven by the engine timing gear at half the engine speed. The pump drive shaft 4 drives the injection pump via the coupling 5 on its timer side.

01844

9. Injection Nozzles 1 2 3 4 5

Nozzle spring Needle valve Nozzle Adjusting screw Nozzle holder

A: To leak-off pipe B: From injection pump Fuel fed from the injection pump enters the nozzle holder 5. When the fuel pressure in the nozzle holder exceeds a preset pressure, it overcomes the nozzle spring 1, pushes up the needle valve 2, and the fuel is sprayed into the cylinder from the orifice at the end of the nozzle 3. Some of the high-pressure fuel lubricates the needle valve 2 and returns to the fuel tank via the leak-off pipe.

04538

13-12

MEMO

13-13

Sticky plunger Sticky control rack Sticky delivery valve Worn tappet Worn camshaft Poorly adjusted injection timing Worn plunger Defective delivery valve seat Excessively advanced injection timing Injection pump proper

Insufficient plunger slide stroke Broken plunger spring Defective sliding action in control rack Tappet worn or not sliding correctly Broken delivery valve spring Poor airtightness due to loose delivery valve holder Defective delivery valve operation Loose control pinion Plunger spring not seating correctly Delivery valve holder too tight Uneven injection volume to cylinders Gauze filter clogged Check valve not operating Sticky piston

Fuel feed pump

Sticky push rod Worn tappet Defective check valve operation Piston worn

13-14

Defective fuel supply

Accelerator pedal too stiff

Engine will not stop

Engine stops soon after starting

Unstable engine idling

Engine maximum speed too high

Insufficient engine output

Unstable engine output

Engine knocks

Possible causes

Engine difficult to start

Engine will not start

Symptoms

Engine does not reach maximum speed

TROUBLESHOOTING

Defective fuel supply

Accelerator pedal too stiff

Engine will not stop

Engine stops soon after starting

Unstable engine idling

Engine maximum speed too high

Insufficient engine output

Unstable engine output

Engine knocks

Possible causes

Engine difficult to start

Engine will not start

Symptoms

Engine does not reach maximum speed

Insufficient full-load stopper position Weak governor spring Incorrectly adjusted control lever Flyweights not operating effectively Weak idling spring Governor

Bent links Excessive friction or play in links Loose round nut Poorly adjusted idling set bolt Defective sliding action in control lever Stop mechanism damaged

Automatic timer

Defective advancing action Sticky needle valve Valve opening pressure too low Blocked injection orifice Poor airtightness in nozzle

Injection nozzles

Valve opening pressure too high Broken spring Defective sliding action in needle valve Defective valve opening pressure Weakness/deterioration in spring

Fuel filter

Filter (and/or secondary filter) clogged

Fuel tank empty Fuel pipes blocked and/or fuel leaking from connections Air or water in fuel system Low-quality fuel in use Cracked fuel pipe Leaky fuel tank

13-15

Incorrect oil viscosity

Gr 12

Incorrect valve clearance

Gr 11

Defective head gasket

Gr 11

Wear and/or carbon deposits on valve and valve seat

Gr 11

Weakness/deterioration in valve spring

Gr 11

Worn/damaged piston ring(s)

Gr 11

Worn/damaged piston ring groove(s)

Gr 11

Worn piston and cylinder liner

Gr 11

Cooling system malfunctioning

Gr 14

Defective starter switch

Gr 54

Defective glow relay

Gr 54

13-16

Defective fuel supply

Accelerator pedal too stiff

Engine will not stop

Engine stops soon after starting

Unstable engine idling

Engine maximum speed too high

Insufficient engine output

Unstable engine output

Engine knocks

Possible causes

Engine difficult to start

Engine will not start

Symptoms

Engine does not reach maximum speed

TROUBLESHOOTING

MEMO

13-17

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Checking and Adjusting Injection Timing <6D16> Service standards Location –

Maintenance item Fuel injection timing (BTDC)

Standard value

Limit

Remedy

6D16-EA

11°

–

Adjust

6D16-UA

13°

–

Adjust

Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

25 (2.5) [18.4]

–

Union nut (injection pipe mounting)

Bolt (injection pipe lock plate)

BOSCH AUTOMOTIVE SYSTEMS, AD-type

3.4 to 4.9 (0.35 to 0.5) [2.88 to 3.61]

–

Delivery valve holder

BOSCH AUTOMOTIVE SYSTEMS, AD-type

49 to 54 (5 to 5.5) [36.1 to 39.8]

–

[Inspection] • From the injection pump's No. 1 cylinder, remove the injection pipe 1, lock plate 2, delivery valve holder 3, stopper 4, delivery valve spring 5, and delivery valve 6. • Fit the delivery valve holder 3.

CAUTION Place all parts in gas oil after removal to keep them free of dust. 18934

• Fit an injection pipe 7 onto cylinder No. 1. Point the pipe's other end downward such that fuel flowing out can be seen clearly. • Rotate the crankshaft pulley clockwise (as seen from the front of engine) by at least 180° and bring cylinder No. 1 to approximately 30° BTDC on its compression stroke.

NOTE 18935

If the engine is turned in its reverse direction (when stopping the engine or by cranking), the automatic timer may stay in an advanced condition. This may not be cancelled by a slight forward rotation of the engine. Be sure to crank the engine forward manually by at least 180°.

13-18

13 • Feed fuel into the injection pump using the priming pump 8. With fuel flowing out of the injection pipe 7, crank the engine slowly clockwise (as seen from the front of engine).

NOTE Ensure that the stop lever 9 at the side of the governor is not in its STOP position.

18936

• When the flow of fuel from the injection pipe 7 diminishes, crank the engine more slowly. When the flow of fuel stops completely, stop cranking the engine.

18937

• Check that the pointer 10 on the flywheel housing or torsional damper B indicates the value 1° earlier than the correct fuel injection timing. A: Flywheel

NOTE

14814

• The injection timing in this measurement becomes 1° earlier than the correct injection timing due to the inactivation of the delivery valve spring. • The correct injection timing is indicated on the plate attached on the rocker cover. • If the injection timing should be measured in a dusty location, perform as follows: • Rotate the crankshaft pulley clockwise (as seen from the front of engine) and bring the No. 1 cylinder to 30° BTDC on its compression stroke. • Disconnect the injection pipe 1 with a little amount of fuel remained at the top of the delivery valve holder 3. • Slowly rotate the crankshaft pulley clockwise. When the injection timing is reached, the fuel at the top of the delivery valve holder 3 starts to move. • If the injection timing is out of the specification, adjust as follows:

13-19

ON-VEHICLE INSPECTION AND ADJUSTMENT [Adjustment] • Loosen the nuts 12 that hold the timer case 11 onto the pump drive or air compressor 13. • If the fuel injection timing is overly retarded, incline the injection pump toward the crankcase. • If the fuel injection timing is overly advanced, incline the injection pump away from the crankcase.

NOTE 01852

Turning the injection pump by one of the gradations inscribed on the timer case flange C causes a 6° change in the injection timing. • Tighten the nuts 12, then check the fuel injection timing again.

NOTE If the fuel injection timing is so far out of specification that adjustment with the injection pump is not possible, the engine timing gear and injection pump drive gear may not be meshing correctly. If this occurs, remove and refit the air compressor or injection pump drive. • Air compressor: Gr 61 • Injection pump drive: P.13-34, 36 • After checking that the fuel injection timing is up to specification, fit the delivery valve 6, delivery valve spring 5, and stopper 4. • Tighten each part to its specified torque.

01853

13-20

13 <6D16-TLE> Service standards Location

Maintenance item

Standard value

Limit

Remedy

8°

–

Adjust

–

Fuel injection timing (BTDC)

–

No-load minimum speed

700 ± 50 rpm

–

Adjust

–

No-load maximum speed

2400 ± 40 rpm

–

Adjust

Tightening torques Location 2

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened Bolt

Tightening torque

Remarks

59 to 64 (6 to 6.5) [43.5 to 47.2]

–

[Inspection] • Turn the crankshaft by 180° or more in the forward direction to bring cylinder No. 1 to TDC on its compression stroke. Set the injection timing by aligning the specified value shown on scale A stamped on the periphery of the flywheel with pointer 1 on the flywheel housing.

CAUTION 14814

If the engine is turned in reverse while the engine is stationary, the automatic timer can move to an advanced position. To return the automatic timer to a normal position, it may be necessary to manually rotate the engine forward by 180° or more. • The injection timing is correct if line B inscribed in the injection pump aligns with line C inscribed in the automatic timer. • If out of alignment, adjust using the following procedures.

P46823

[Adjustment] • Loosen adjusting bolt 2. Turn the automatic timer to align line B with line C. • Tighten adjusting bolt 2 to the specified torque. • Repeat the injection timing inspection.

CAUTION Only adjusting bolt 2 should be loosened. P47366

13-21

ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Checking and Adjusting Minimum and Maximum No-load Speeds Service standards Location – –

Maintenance item

Standard value

No-load minimum speed

700 ± 10 rpm (690

No-load maximum speed

2350

Limit

Remedy

rpm: on truck)

–

Adjust

rpm

–

Adjust

+ 30 0

+ 100 0

Start the engine and allow it to warm up before carrying out the following inspections.

<RSV-type governor> ● No-load minimum speed [Inspection] Confirm that the control lever 1 is touching the idling set bolt 3. Then check that the minimum speed is up to specification. A: Idling position

18231

[Adjustment] If the minimum speed is out of specification, adjust it using the idling set bolt 3. ● No-load maximum speed [Inspection] Confirm that the control lever 1 is touching the full-speed set bolt 2. Then, check that the maximum speed is up to specification. B: Full-speed position [Adjustment] If the maximum speed is out of specification, adjust it using the fullspeed set bolt 2.

NOTE Check that the engine does not stall and that no hunting occurs when the control lever 1 is moved quickly from the full-speed position to the idling position. If any abnormality is apparent, make adjustments within the specified range.

13-22

13 ● No-load minimum speed [Inspection] Confirm that the control lever 7 is touching the idling set bolt 6. Then check that the minimum speed is up to specification. A: Idling position

18233

[Adjustment] If the minimum speed is out of specification, adjust it using the idling set bolt 6. ● No-load maximum speed [Inspection] Move the load control lever 7 to the full-load position B. Then, check that the maximum speed is up to specification. [Adjustment] If the maximum speed is out of specification, adjust position of the speed control lever 8 using the maximum speed stopper bolt 9 and stopper bolt 10.

NOTE • Do not alter the position of the full-load stopper bolt 11. • Check that the engine does not stall and that no hunting occurs when the load control lever 7 is moved quickly from the full-load position to the idling position. If any abnormality is apparent, make adjustments within the specified range.

3. Cleaning Fuel Feed Pump Gauze Filter Tightening torques Location 1

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened Eyebolt

BOSCH AUTOMOTIVE SYSTEMS

Tightening torque

Remarks

20 to 25 (2 to 2.5) [14.8 to 18.4]

–

• Remove the eyebolt 1 from the suction port side of the fuel feed pump. • Remove the gauze filter 2 from the eyebolt 1. • Clean the gauze filter 2. • Refit the gauze filter 2 and eyebolt 1 in the opposite order to their removal. • Bleed all air out of the fuel system. • Start the engine and check for fuel leaks. 18234

13-23

FUEL FILTER

P 47191

● Disassembly sequence 1 Eyebolt 2 Fuel pipe 3 Air vent plug

4 Fuel filter 5 Fuel filter head

● Assembly sequence Reverse the order of disassembly.

Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Eyebolt

Air vent plug

Tightening torque

Remarks

34 (3.5) [25.1]

–

9.8 ± 2.0 (1 ± 0.2) [7.23 ± 1.48]

–

Lubricant Location 2

Points of application Gasket between fuel filter and fuel filter head

Specified lubricant

Quantity

Engine oil

As required

Special tools Location

Unit: mm (in.)

Tool name and shape

Part No.

Application

MH061509

Removing fuel filter

Filter Wrench

Part No.

MH061509

90.2 (3.55) 01882

13-24

13 ◆ Service procedure 4 Fuel filter [Removal]

WARNING • Fuel is highly flammable; keep it away from flames and sources of heat. • To minimize the risk of fire, wipe up any spilled fuel. 01883

[Installation]

WARNING Use of an unsuitable fuel filter 4 can lead to fuel leaks and fires. Be sure to use a genuine Mitsubishi filter.

13220

• To fit the fuel filter 4, turn it until the gasket C touches surface B of the fuel filter head 5. Then, tighten the filter by 3/4 to 1 turn. Be sure to turn the filter by hand. • Start the engine and check for fuel leaks.

13-25

INJECTION PUMP <Oldham’s Coupling Type>

P 18238

● Disassembly sequence 1 Eyebolt 2 Fuel feed hose 3 Eyebolt 4 Fuel suction pipe 5 Eyebolt 6 Fuel feed hose 7 Eyebolt

8 9 10 11 12 13 14

Fuel return pipe Injection pipe Eyebolt Eyebolt Connector Oil pipe Injection pump stay

15 Injection pump assembly 16 Driving disk 17 O-ring *: Injection pump drive P.13-34, or air compressor Gr 61 : Non-reusable part

● Assembly sequence Reverse the order of disassembly.

WARNING • Fuel is highly flammable; keep it away from flames and sources of heat. • To minimize the risk of fire, wipe up any spilled fuel.

CAUTION Dirt particles in the injection pump assembly 15 can seriously detract from engine performance. To prevent the ingress of dirt, cover all pipes, hoses, and other parts after removal.

NOTE For maintenance of the injection pump assembly 15, please contact a BOSCH AUTOMOTIVE SYSTEMS service station.

13-26

13 Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

1, 7

Eyebolt (fuel feed hose, fuel return pipe)

BOSCH AUTOMOTIVE SYSTEMS

20 to 29 (2 to 3) [14.8 to 21.4]

–

3, 5

Eyebolt (fuel suction pipe, BOSCH AUTOMOTIVE fuel feed hose) SYSTEMS

20 to 25 (2 to 2.5) [14.8 to 18.4]

–

Injection pipe union nut

25 (2.5) [18.4]

–

Eyebolt (oil pipe; air compressor or pump drive side)

21 (2.1) [15.5]

–

Eyebolt (oil pipe; injection BOSCH AUTOMOTIVE pump side) SYSTEMS

10 to 13 (1 to 1.3) [7.38 to 9.59]

–

Connecter (oil pipe)

21 (2.1) [15.5]

–

◆ Service procedure 15 Installing injection pump assembly • Bring cylinder No. 1 of the engine to the TDC position of its compression stroke.

01885

• Align the inscribed lines C on the timer case A and timer B. Then, fit the injection pump assembly 15 onto the air compressor or injection pump drive.

01886

13-27

INJECTION PUMP <Laminated Coupling Type>

P46821

● Disassembly sequence 1 Eyebolt 2 Fuel feed hose 3 Eyebolt 4 Fuel suction pipe 5 Eyebolt 6 Fuel feed hose 7 Eyebolt 8 Fuel return pipe 9 Injection pipe 10 Eyebolt 11 Eyebolt 12 Eyebolt 13 Oil pipe 14 Eyebolt 15 Oil return pipe 16 Eyebolt (mechanical governor)

17 18 19 20 21 22 23 24 25 26

Boost hose Eyebolt Oil pipe Bolt Cotter bolt Driving coupling Injection pump assembly Bolt Injection pump bracket Key

*a: Injection pump drive

P.13-36 or air

compressor Gr 61 : Non-reusable part

● Assembly sequence Reverse the order of disassembly.

13-28

13 CAUTION • Fuel is highly flammable; keep it away from flames and sources of heat. • To minimize the risk of fire, wipe up any spilled fuel. • For maintenance of the injection pump assembly 23, please contact a Bosch Automotive Systems service station or Denso service station. • Dirt particles in the injection pump assembly 23 can seriously detract from engine performance. To prevent the ingress of dirt, cover all pipes, hoses, and other parts after removal. • Never carry around the injection pump assembly 23 by holding it at the lever or the engine speed sensor *b. Removing the lever may result in deteriorated pump performance. • Do not remove the injection pump bracket 25 unless it is faulty.

13-29

INJECTION PUMP <Laminated Coupling Type> Service standards Location

Unit: mm (in.) Maintenance item

–

Fuel injection timing (BTDC)

Injection pump bracket (eccentricity between injection pump centering tool and injection pump drive or air compressor crankshaft)

Standard value

Limit

Remedy

Depends on specifications

–

Adjust

0.2 (0.0079)

–

Adjust

Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

1, 7

Eyebolt (for fitting fuel feed hose and fuel return pipe)

20 to 29 (2 to 3) [14.8 to 21.4]

–

3, 5

Eyebolt (for fitting fuel suction pipe and fuel feed hose)

20 to 25 (2 to 2.5) [14.8 to 18.4]

–

Injection pipe (for fitting union nut)

25 (2.5) [18.4]

–

Eyebolt (for fitting oil pipe on either injecion pump drive or air compressor side)

20.6 (2.1) [15.19]

–

Eyebolt (for fitting oil pipe on injecion pump side)

10 to 13 (1 to 1.3) [7.38 to 9.59]

–

Eyebolt (for fitting oil pipe on crankcase side)

20.6 (2.1) [15.19]

–

Eyebolt (for fitting oil return pipe)

20 to 25 (2 to 2.5) [14.8 to 18.4]

–

Eyebolt (for fitting boost hose)

10 to 13 (1 to 1.3) [7.38 to 9.59]

–

Oil pipe

25 (2.5) [18.4]

–

Bolt (for fitting driving coupling)

59 to 64 (6 to 6.5) [43.5 to 47.2]

–

Cotter bolt

83 to 93 (8.5 to 9.5) [61.2 to 68.6]

–

Special tools Location

Tool name and shape

Injection Pump Centering Tool

Part No.

Application

MH063393

Locating injection pump bracket

P 13221

◆ Service procedure 23 Installing injection pump assembly • Crank the engine to set cylinder No. 1 at the specified injection timing position.

14821

13-30

13 • Ensure that the key way A on the injection pump drive or air compressor (*a) crankshaft is facing upwards. • If key way A is not facing upwards, rotate the engine crankshaft by one turn.

13222

• Align line B inscribed on the injection pump and line C inscribed on the automatic timer.

P 46823

• Fit driving coupling 22 to the injection pump drive or air compressor *a crankshaft D. Push the driving coupling against the injection pump drive or air compressor crankshaft D. • Fit injection pump assembly 23 to injection pump bracket 25.

13223

• Set driving coupling 22 apart from coupling plate E by 0.5 mm (0.020 in.) as shown in the illustration. Tighten cotter bolt 21 to the specified torque.

13185

• Using bolts 20, fit driving coupling 22 and coupling plate E.

13186

13-31

INJECTION PUMP <Laminated Coupling Type> 25 Injection pump bracket [Inspection] • Set dial gauge B at rod A of zero-point correction.

Injection Pump Centering Tool for

13224

• Slide dial gauge B against the injection pump drive or the air compressor *a and measure the eccentricity between rod A and the crankshaft C of the injection pump drive or the air compressor at D, E and F. • If one of the measurements exceeds the specified value, adjust as follows.

13225

[Adjustmentn] • When the measured value at point E is higher than the standard value: Insert shims G into four points equally. • When the measured value at point D is higher than the standard value: Insert shims G into lower side H. • When the measured value at point F is higher than the standard value: Insert shims G into upper side J.

CAUTION 13226

Insert shims G observing the following conditions: • Number of shims per point is three or less. • The same number of shims should be used for the front and the rear. • The difference in number of shims used for bottom and top is none or one. • Tighten bolts 24 to the specified torque and repeat the inspection.

13-32

MEMO

13-33

INJECTION PUMP DRIVE <Oldham’s Coupling Type> ● Disassembly sequence 1 Injection pump drive assembly 2 Nut 3 Lock washer 4 Drive gear 5 Collar 6 Bolt 7 Pin 8 Coupling 9 Bolt 10 Cover 11 Bolt 12 Bearing 13 Bearing holder 14 Shaft 15 Pump drive case 16 O-ring

*a: Injection pump assembly *b: Oil pipe P.13-26

P.13-26

● Assembly sequence Reverse the order of disassembly.

P 47199

Service standards

Unit: mm (in.)

Location 14 14, 15

Maintenance item

Standard value

Limit

Remedy

Shaft end play

–

0.59 (0.0232)

Replace

Shaft-to-pump drive case clearance

–

0.12 (0.00474)

Replace pump drive case

Tightening torques Location

Parts to be tightened

Unit: N·m (kgf·m) [lbf·ft]

Tightening torque

Remarks

21 (2.1) [15.5]

–

Eyebolt

Nut (drive gear mounting)

167 to 211 (17 to 21.5) [123 to 156]

–

Bolt (coupling mounting)

30 to 36 (3.1 to 3.7) [22.1 to 26.6]

–

Bolt (cover mounting)

25 to 29 (2.5 to 3) [18.4 to 21.4]

–

Bolt (bearing holder mounting)

5.9 to 6.9 (0.6 to 0.75) [4.35 to 5.09]

–

13-34

13 Lubricant Location 16

Points of application O-ring

Specified lubricant Engine oil

Quantity As required

◆ Service procedure 1 Installing injection pump drive assembly • Bring cylinder No. 1 of the engine to the TDC position of its compression stroke. Gr 11 • Align the inscribed line A on the drive gear 4 of the injection pump drive assembly 1 with the inscribed line A on the pump drive case 15.

01919

• Remove the plug C from the flywheel housing B, then check that the inscribed line A on the drive gear 4 is aligned with the pointer D. If the line and pointer are not aligned, remove and refit the injection pump drive assembly.

01920

4 Installing drive gear • Fit the drive gear 4 such that its “0” alignment mark is aligned with the “0” alignment mark on the pump drive shaft 14. Then, fit the lock washer 3 such that its notch A is aligned with the drive gear alignment mark, and tighten the nut 2 to the specified torque.

01921

• When the assembly is complete, bend the lock washer 3 down onto the nut 2.

P46828

13-35

INJECTION PUMP DRIVE <Oldham’s Coupling Type> 14 15 Pump drive shaft-to-pump drive case clearance If the clearance exceeds the specified limit, replace the pump drive case 15. A: Bushing B: Measurement directions C: Measurement positions 01923

02116

13-36

MEMO

13-37

INJECTION PUMP DRIVE <Laminated Coupling Type> ● Disassembly sequence 1 Injection pump drive assembly 2 Nut 3 Lock washer 4 Drive gear 5 Collar 6 Bolt 7 Oil seal 8 Bearing holder 9 O-ring 10 Sleeve 11 Bearing 12 Shaft 13 Pump drive case 14 O-ring

*a: Injection pump assembly *b: Oil pipe P.13-28

P.13-28

● Assembly sequence Reverse the order of disassembly.

P 46824

Service standards

Unit: mm (in.)

Location 12

Maintenance item Shaft end play

Standard value

Limit

Remedy

–

0.59 (0.0232)

Replace

Tightening torques Location

Parts to be tightened

Nut (drive gear mounting)

Bolt (bearing holder mounting)

Unit: N·m (kgf·m) [lbf·ft]

Tightening torque

Remarks

167 to 211 (17 to 21.5) [123 to 156]

–

13.7 to 17.7 (1.4 to 1.8) [10.10 to 13.05]

–

Specified lubricant

Quantity

Lubricant Location 14

13-38

Points of application O-ring

Engine oil

As required

13 ◆ Service procedure 1 Installing injection pump drive assembly • Set cylinder No. 1 of the engine at TDC on the compression stroke. Gr 11 • Align line A inscribed on drive gear 4 of injection pump drive assembly 1 with line A inscribed on pump drive case 13.

P 46825

• Remove plug C from flywheel housing B. Check if line A inscribed on drive gear 4 is aligned with pointer D. If not, remove and refit injection pump drive assembly 1 to obtain the alignment.

P 46826

4 Installing drive gear • Install drive gear 4 such that its “0” alignment mark is aligned with the “0” alignment mark on shaft 12. • Fit lock washer 3 such that its notch A is aligned with the "0" alignment mark on drive gear 4. Tighten nut 2 to the specified torque.

P 46827

• After the drive gear is installed, bend lock washer 3 over nut 2.

P46828

13-39

INJECTION PUMP DRIVE <Laminated Coupling Type> 7 Installing oil seal Face oil seal 7 as shown in the illustration. Then, fit it in bearing holder 8 by pressing evenly until it is flush with the end face A of the holder.

P 46829

13-40

MEMO

13-41

INJECTION NOZZLE ● Inspection before disassembly P.13-43 ● Disassembly sequence 1 Eyebolt 2 Fuel leak-off pipe 3 Injection pipe 4 Bolt 5 Injection nozzle assembly 6 Connector 7 Cap nut 8 Adjusting screw 9 Spring 10 Push rod 11 Retaining nut 12 Nozzle 13 Needle valve 14 Pin 15 Nozzle holder 16 Dust seal 17 Gasket : Non-reusable part Repair kit: Nozzle Service Kit (for BOSCH AUTOMOTIVE SYSTEMS nozzles only)

04555

● Assembly sequence Reverse the order of disassembly.

WARNING To minimize the risk of fire, wipe up any spilled fuel.

CAUTION Under no circumstances change the needle valve 13 and nozzle 12 combination used in each injection nozzle assembly 5.

NOTE • Clean off any carbon deposits before disassembling, reassembling, or adjusting the injection nozzle assembly 5. Before disassembly, check the pressure and shape of the spray and inspect the assembly for fuel leaks. If no abnormality is apparent, do not commence disassembly. • When fitting the injection nozzle assembly 5, tighten each of the two bolts 4 a little at a time.

13-42

13 Service standards Location 5

Maintenance item Injection pressure

Standard value

Limit

Remedy

17.7 MPa (180 kg/cm2) [2,567 psi]

–

Adjust

Tightening torques

Unit: N·m (kgf·m) [lbf·ft]

Location

Parts to be tightened

Tightening torque

Remarks

Eyebolt (fuel leak-off pipe mounting) BOSCH

9.8 to 15 (1.0 to 1.5) [7.23 to 11.1]

–

Injection pipe union nut

25 (2.5) [18.4]

–

Bolt (injection nozzle mounting)

BOSCH

15 (1.5) [11.1]

–

Connector

BOSCH

69 to 78 (7 to 8) [50.9 to 57.5]

–

Cap nut

29 to 39 (3 to 4) [21.4 to 28.8]

–

Retaining nut

59 to 78 (6 to 8) [43.3 to 57.5]

–

Special tools Location –

Tool name and shape Nozzle Cleaning Tool

Part No. *105789-0010

Application Cleaning nozzles

*BOSCH AUTOMOTIVE SYSTEMS part number

◆ Service procedure ● Pre-disassembly inspection Fit the injection nozzle assembly 5 onto the nozzle tester A ready for inspection.

NOTE Before commencing inspection, operate the lever on the nozzle tester A two or three times to bleed all air out of the arrangement.

01910

(1) Checking valve opening pressure • Push down the lever on the nozzle tester A at a rate of 1-2 seconds per stroke. The pressure gauge reading will gradually rise, then the needle will suddenly deflect. Note the pressure when the needle starts to deflect. • If the measurement is out of specification, disassemble the nozzle, clean it, and make adjustments using the adjusting screw 8. • If the measurement is still out of specification after adjustment, replace the injection nozzle assembly 5.

WARNING Do not touch the spray that comes out of the nozzle.

13-43

INJECTION NOZZLE (2) Inspecting spray condition • Pump the lever on the nozzle tester A at a rate of about 1-2 seconds per stroke, and maintain a continuous spray. B: Even spray from all five injection orifices (Good) C: Even and symmetrical spray (Good) D: Asymmetrical spray (Bad) E: Branched spray (Bad) F: Thin spray (Bad) G: Irregular spray (Bad) 06931

• If the spray is unsatisfactory, disassemble and clean the injection nozzle assembly 5, then inspect the spray again. If the spray is still unsatisfactory, replace the injection nozzle assembly 5. • Check that no fuel drips from the nozzle after the spray is complete.

WARNING Do not touch the spray that comes out of the nozzle.

(3) Inspecting for leaks • Slowly increase the nozzle pressure to 1.96 MPa (20 kgf/cm2) [284.3 psi] below the specified valve opening pressure. Maintain this pressure for 10 seconds and check that no fuel drips from the end of the nozzle. • If the injection nozzle assembly 5 appears defective, disassemble and clean it, then inspect it again. If the injection nozzle assembly 5 still appears defective, it must be replaced. 05388

5 Injection nozzle assembly [Disassembly]

CAUTION • Do not touch the sliding parts A of the needle valve 7. • Do not change the needle valve 13 and nozzle 12 combination on each cylinder. 04744

[Cleaning] Wash the needle valve 13 and nozzle 12 in gas oil, then use the Cleaning Tool Set to remove any carbon deposits in accordance with the following procedure. • Remove carbon from the end of the needle valve 13 using the Cleaning Bar of the Cleaning Tool Set.

CAUTION 04556

13-44

Do not use a wire brush or any hard metallic object for cleaning.

13 • Remove carbon from the injection orifice of the nozzle 12 using the Needle Cleaner of the Cleaning Tool Set. Insert the Needle Cleaner and rotate it to dislodge the carbon.

01893

• Clean the seat of the nozzle 12 using the Cleaning Scraper of the Cleaning Tool Set. • To remove burned and hardened carbon, use FUSO Carbon Remover.

01894

[Inspection] • Wash the needle valve 13 and nozzle 12 in gas oil, then fit them together. • Pull up the needle valve 13 by approximately 1/3 of its entire stroke, then check that it drops under its own weight. Repeat this test several times, turning the needle valve each time. • If the needle valve 13 does not drop as required, wash it in gas oil and carry out this test again. If the needle valve is still defective, replace the needle valve and nozzle 12 as a set. 01911

NOTE Whenever a nozzle 12 is replaced, the nozzle and needle valve 13 must be replaced as a set using Nozzle Service Kit. (This applies to BOSCH AUTOMOTIVE SYSTEMS products only.)

13-45

GROUP 14 COOLING SPECIFICATIONS....................................................................................

14-2

STRUCTURE AND OPERATION.............................................................. 1. Cooling System (Water Flow) ............................................................................... 2. Water Pump .......................................................................................................... 3. Thermostat............................................................................................................

14-3 14-3 14-3 14-4

TROUBLESHOOTING .............................................................................

14-5

ON-VEHICLE INSPECTION AND ADJUSTMENT....................................

14-6 14-6 14-8 14-8

1. Replacing Coolant and Cleaning Coolant System............................................... 2. Air Bleeding of Cooling System ........................................................................... 3. Gas Leak Testing..................................................................................................

RADIATOR............................................................................................... 14-10 COOLING FAN AND V-BELT ................................................................... 14-12 WATER PUMP ......................................................................................... 14-14 THERMOSTAT ......................................................................................... 14-18

14-1

SPECIFICATIONS Item

Specifications

Cooling system

Forced water circulation type

Water pump type

Belt-driven involute type

Thermostat type

Wax pellet, bottom bypass type (with jiggle valve)

Automatic cooling fan coupling type

Constant control type

Radiator type Coolant capacity (engine main body only)

14-2

Tube and corrugated fin type L (U.S.gal.)

13 (3.43)

STRUCTURE AND OPERATION 1. Cooling System (Water Flow) 1 2 3 4 5 6 7 8 9

Reservoir tank Thermostat Cylinder head Drain plug Oil cooler Water pump Drain cock Radiator Bypass hose

16951

2. Water Pump 1 2 3 4 5 6 7 8 9 10

Water pump shaft Flange Snap ring Bearing Spacer Bearing Water pump case Washer Impeller Unit seal

A: Drain hole

16934

14-3

STRUCTURE AND OPERATION 3. Thermostat 1 Thermostat cover 2 Thermostat 3 Thermostat case A: To radiator B: With low coolant temperature C: With high coolant temperature D: From cylinder head E: To water pump

06361

14-4

Thermostat 2 is a bottom bypass type that uses waxcharged pellets as its regulating element. As the wax changes from solid to liquid in line with temperature increases, the total wax volume changes. As a result, the position of the valve, changed by the coolant temperature, regulates the flow of coolant to the radiator and water pump (bypass side) and controls the coolant temperature.

TROUBLESHOOTING

Loose or damaged Excessive tension Oil on belt Water pump fitted poorly Water pump Gasket defective Bearing defective Impeller defective Unit seal defective Loose fit between shaft and flange and/or shaft and impeller Case fitted poorly Thermostat Gasket defective Valve opening temperature too high; valve remains closed Valve opening temperature too low; valve remains open Water leaking from water temperature sensor Space between core and fins clogged Radiator Core cracked and/or separation of soldered joints Pressure cap not sufficiently airtight Cooling fan Fan shroud fitted poorly Automatic cooling Bearing defective fan coupling Bimetal damaged Bimetal contaminated with foreign particles Silicon oil leaking Oil cooler fitted poorly Oil cooler Gasket defective Cylinder head fitted poorly Cylinder head Gasket defective Coolant quantity insufficient and/or coolant dirty Coolant passages dirty and/or clogged Hoses fitted poorly Ambient temperature extremely low

Excessive coolant loss

Abnormal noise

Overcooling

Possible causes

Overheating (insufficient cooling)

Symptoms

Remarks

V-belt

Gr 12 Gr 11

14-5

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Replacing Coolant and Cleaning Coolant System 1 Pressure cap 2 Crankcase drain plug 3 Radiator drain cock

16941

16942

Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened Crankcase drain plug

Tightening torque

Remarks

115 (12) [84.8]

–

Using the radiator for extended periods without cleaning the cooling system will cause overheating since rust and scale deposits will accumulate. The cooling system must be cleaned periodically. ● Draining coolant Before draining the coolant, loosen pressure cap 1 to reduce the pressure in the cooling system.

WARNING • To avoid being scalded, ensure that the coolant has cooled sufficiently before draining it out. • Unless care is exercised, opening pressure cap 1 when the coolant is hot can cause the coolant to spray out. Cover the pressure cap with a cloth, and loosen the cap slowly to bleed off the pressure before opening it fully. ● Cleaning procedure • Run the engine and keep the coolant at a temperature of approximately 90°C (194°F) so that the thermostat valve remains open and the coolant continues to circulate in the radiator. • To increase the coolant temperature quickly, cover the front of the radiator with cardboard or a similar material. • If cleaning is carried out after a large amount of rust has accumulated, the radiator may start to leak. Carefully examine the radiator for leaks after cleaning the cooling system. • Soft water to be used should have the following properties.

CAUTION Do not use hard water as it causes scale and rust.

Required propertiies of soft water Total hardness Sulfate SO

300 ppm or less

Total dissolved solids

500 ppm or less

− 4

100 ppm or less

6 to 8

−

100 ppm or less

–

Chloride Cl

14-6

14 Method of cleaning the cooling system depends on its condition. ● Ordinary condition

● Extremely dirty coolant

Cleaning using water

● Clogged radiator

Cleaning using Radipet 7 or equivalent.

Drain the coolant. (Work procedure)

Make a solution of FUSO Radiator Cleaner (Radipet 7 or equivalent) at a rate of 5 to 10% to the total volume of coolant.

Fill the radiator with the solution.

Keep the solution temperature at 90°C (194°F) and let the engine idle for 30 minutes. CAUTION Be sure to allow the engine to idle for 30 minutes only. Circulating the solution in the system for more than an hour might cause the system to breakdown.

Drain the water and the solution.

Fill with soft water (boiled preferably). Keep the water temperature at 90°C (194°F) and let engine idle for 10 minutes. Drain the water. If the drained water is clear, cleaning has been successful. If it is still muddy, repeat the procedure.

DANGER If you accidentally splash FUSO Diesel Long Life Coolant, Fuso Antifreeze, or Radiator Antirust (Radipet 9) in your eyes, wash it out immediately with water and seek medical attention.

WARNING FUSO Diesel Long Life Coolant is flammable. Keep them away from heat and flames.

NOTE • After cleaning the cooling system with cleaning fluid, fill it with coolant as soon as possible. • To prevent freezing of the coolant and corrosion of the cooling system, add to the coolant the specified proportion of FUSO Diesel Long Life Coolant. (See the Maintenance Manual for instructions on the use of these products).

14-7

ON-VEHICLE INSPECTION AND ADJUSTMENT 2. Air Bleeding of Cooling System • Remove the pressure cap. Keeping the coolant temperature at 90°C (194°F), let the engine idle until the cooling system is completely bled of air. While the engine is idling, keep the heater controller's adjustment lever at its maximum-temperature position so that coolant flows freely in the heater piping. • After bleeding the cooling system of air, add coolant to the radiator and reservoir tank as required.

3. Gas Leak Testing The presence of air or exhaust gas in the coolant increases corrosion and rust in the cooling system. Check for air or exhaust gas in the coolant using the following procedure: • Remove pressure cap 1.

WARNING Make sure the coolant is sufficiently cool before loosening the pressure cap. If the coolant is hot, it will spray out.

• Run the engine until the coolant temperature reaches approximately 90°C (194°F). • If bubbles A appear continuously, there is air or exhaust gas in the coolant. • If the coolant contains air, the cylinder head bolts, water pump mounting bolts, or hose connections may be loose. Alternatively, the hoses may be damaged. • If the coolant contains exhaust gas, it is possible that the cylinder head gasket is damaged or that the cylinder head is cracked.

00187

14-8

MEMO

14-9

RADIATOR ● Disassembly sequence 1 Wire net 2 Shroud 3 Frame 4 Drain cock 5 Drain hose 6 Pressure cap 7 Radiator ● Assembly sequence Reverse the order of disassembly.

16943

Service standards Location

Maintenance item

Pressure valve opening pressure

Radiator air leakage {with air pressure of 150 kPa (1.5 kgf/cm2) [21.8 psi]}

Standard value

Limit

Remedy

69 ± 15 kPa (0.7 ± 0.15 kg/cm2) [10.0 ± 2.2 psi]

–

Replace

0 cc (0 cu.in.)

–

Correct or replace

◆ Service procedure 6 Pressure cap inspection Measure the pressure valve's opening pressure. If the measurement does not conform with the standard value, replace pressure cap 6.

00194

7 Radiator inspection • Fit hose A and radiator cap tester B to the radiator upper tank. • Fit plug C to the lower tank, then immerse the radiator in a tank of water. • Using radiator cap tester B, apply the specified air pressure of 150 kPa (1.5 kgf/cm2) [21.8 psi], and check for air leakage. • If air leakage is apparent, correct or replace radiator 7. 07386

14-10

MEMO

14-11

COOLING FAN AND V-BELT ● Disassembly sequence 1 V-belt 2 Cooling fan 3 Spacer 4 Water pump pulley

*: Water pump assembly P.14-14 ● Assembly sequence Reverse the order of disassembly.

CAUTION

16947

• Automatic cooling fan coupling 2 is an integrated unit and cannot be disassembled. If any fault is apparent, replace the whole assembly. • When replacing V-belts 1, be sure to replace them as a set to maintain even tension between them.

Service standards Location 1

Unit: mm (in.) Maintenance item

V-belt tension

Standard value

Limit

Remedy

10 to 15 (0.394 to 0.591)

–

Adjust

Special tools Location

Tool name and shape

Part No.

Belt Tension Gauge

MH062345

Application

V-belt tension measurement

03612

◆ Service procedure 1 V-belt [Inspection] Apply force of approximately 98 N (10 kgf) [22.0 lbf] to the center of the V-belt 1 and measure the extent of V-belt deflection A. B: Alternator pulley C: Water pump pulley D: Crankshaft pulley 16948

14-12

14 ● Use of belt tension gauge • Set upper O-ring E of Belt Tension Gauge to 8 N (10 kgf) [1.80 lbf] (push load) on scale F. • Set lower O-ring G of Belt Tension Gauge to the V-belt's correct maximum deflection value on scale

03613

• Apply the Belt Tension Gauge to the center of V-belt 1 and push until O-ring E reaches the flange K.

03614

• Measure the extent of V-belt 1 deflection A. If the measurement does not conform with the standard value, adjust the V-belt as shown below.

03615

[Adjustment]

CAUTION • Excessive tension in V-belt 1 may damage the belt and related bearings. • Be sure to replace the V-belts 1 as a set to maintain even tension between them. • Keep V-belt 1 free of oil. If the belt becomes oily, it will slip, resulting in overheating of the engine and insufficient charging of the battery. 00203

• Loosen alternator mounting bolts L (2 places) and adjust the V-belt tension by moving alternator M to the left or right. • When the adjustment is complete, tighten the bolts and nuts securely.

14-13

WATER PUMP ● Disassembly sequence 1 Bolt 2 Water pump assembly 3 Impeller 4 Flange 5 Snap ring 6 Bearing 7 Spacer 8 Bearing 9 Washer 10 Water pump shaft 11 Unit seal 12 Grease nipple 13 Water pump case 14 Gasket

: Non-reusable part ● Assembly sequence 14 ➞ 2 ➞ 1 2:

16925

5 8

● Inspection after assembly P.14-15

Service standards

Unit: mm (in.)

Location

Maintenance item

Standard value

Limit

Remedy

3, 10

Impeller-to-water pump shaft interference [Basic diameter: 13 mm (0.512 in.)]

0.03 to 0.06 (0.00118 to 0.00236)

–

Reassembly allowed only twice

4, 10

Flange-to-water pump shaft interference [Basic diameter: 26 mm (1.02 in.)]

0.05 to 0.08 (0.00197 to 0.00315)

–

Reassembly allowed only twice

Tightening torques Location 1

Parts to be tightened Bolt (water pump assembly mounting)

Unit: N·m (kgf·m) [lbf·ft]

Tightening torque

Remarks

9.8 (1.0) [7.23]

–

14-14

14 Lubricants and/or sealant Location

Points of application

Specified lubricant and/or sealant

Quantity

6, 8

Bearings

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Unit seal outer periphery

THREEBOND 1102

As required

Grease nipple

Wheel bearing grease [NLGI No. 2 (Li soap)]

60 g (2.12 oz)

Special tools Location

Unit: mm (in.)

Tool name and shape

Impeller Puller

Part No.

Application

MH061417

Removing impeller

16927

◆ Service procedure ● Inspection after assembly • After assembly, rotate flange 4 by hand and check that it turns smoothly without hindrance. • If the flange does not turn smoothly, disassemble and inspect the water pump again.

16928

3 Impeller [Removal]

16929

14-15

WATER PUMP [Installation]

CAUTION

P 46285

• Before refitting impeller 3, check the number of punch marks in location A shown in the illustration. If there is no or only one punch mark in location A, the impeller can be refitted. Ensure to punch a mark in location A for future reference before refitting the impeller. • The punch mark is used to show how many times in the past impeller 3 is removed and refit. If there are two punch marks (i.e. removed and refit twice in the past), do not refit the impeller again. Replace it with a new impeller. [Press-fitting] Press-fit impeller 3 until its end face B is in line with end face A of water pump shaft 10. C: Press NOTE Press-fit the impeller such that flange side D of water pump shaft 10 is the load receiving surface.

16930

3 10 Impeller-to-water pump shaft interference If the measurement does not conform with the standard value, replace the defective part(s).

CAUTION Even if the standard value is satisfied, reassembly must not be carried out more than twice.

16931

4 Flange [Removal] A: Gear puller

16932

14-16

14 [Installation]

CAUTION

P 46284

• Before refitting flange 4, check the number of punch marks in location A shown in the illustration. If there is no or only one punch mark in location A, the flange can be refitted. Ensure to punch a mark in location A for future reference before refitting the flange. • The punch mark is used to show how many times in the past flange 4 is removed and refit. If there are two punch marks (i.e. removed and refit twice in the past), do not refit the flange again. Replace it with a new flange.

[Press-fitting] With a load of 9,810 N (4,000 kgf) [2,205 lbf], press-fit flange 4 until it touches bearing 6. B: Press C: Cylindrical jig

16933

4 10 Flange-to-water pump shaft interference If the measurement does not conform with the standard value, replace the defective part(s).

CAUTION Even if the standard value is satisfied, reassembly must not be carried out more than twice. 00212

14-17

THERMOSTAT

16944

● Disassembly sequence 1 Water temperature sensor 2 Thermostat cover 3 Gasket 4 Thermostat 5 Bolt 6 Thermostat case 7 Gasket

16945

8 9 10 11

Front hanger Bypass hose O-ring Joint : Non-reusable part

NOTE Do not remove thermostat case 6 and front hanger 8 unless they are leaking water or otherwise defective. ● Assembly sequence Reverse the order of disassembly.

Service standards Location 1

Maintenance item Water temperature sensor resistance (Between terminal ➀ and body) Thermostat

Standard value

Limit

Remedy

50°C (122°F)

(136 V)

–

Replace

80°C (176°F)

48 ± 5 V

–

100°C (212°F)

27.2 ± 2 V

–

Valve opening temperature

76.5 ± 2°C (170 ± 36°F)

–

10 mm (0.394 in.) or more at 90°C (194°F)

–

Valve lift/temperature

14-18

Replace

14 Tightening torques Location 1

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened Water temperature sensor

Tightening torque

Remarks

34 ± 6.9 (3.5 ± 0.7) [25.1 ± 5.1]

–

Lubricant and/or sealant Location

Points of application

Specified lubricant and/or sealant

Quantity

Threads of bolts (thermostat case mounting)

THREEBOND 2302

As required

Periphery of O-ring

Soapy water

As required

◆ Service procedure 1 Water temperature sensor inspection • Place water temperature sensor 1 in a container of engine oil. • Heat the oil until it reaches the specified temperatures. Stir the oil to ensure that it heats up evenly. • Measure the resistance between terminal ➀ and body ➁ of the water temperature sensor. • If the measurements do not conform with the specified values, replace the water temperature sensor 1. 03868

00218

4 Thermostat inspection Place the thermostat in a container of water. While stirring the water with a rod A to ensure that it is heated evenly, carry out the following inspection procedure. If the measurements do not conform with the standard values, replace the thermostat 4. (1) Valve opening temperature • Support thermostat 4 with wire E to keep it away from heat source D. • Gradually heat the water until it reaches the valve opening temperature. • Maintain this temperature for 5 minutes and check that valve B is open. • When the water temperature drops below 65°C (149°F), check that valve B is completely closed. C: Thermometer (2) Valve lift Heat the water to slightly higher than the valve opening temperature. With valve B fully open, maintain this water temperature for 5 minutes. Measure the extent of valve lift F.

14-19

GROUP 15 INTAKE AND EXHAUST SPECIFICATIONS....................................................................................

15-2

STRUCTURE AND OPERATION.............................................................. Turbocharger .............................................................................................................

15-4 15-4

TROUBLESHOOTING .............................................................................

15-6

TURBOCHARGER...................................................................................

15-8 15-8

<T04E (6D16-TLE)>....................................................................................................

INTERCOOLER ....................................................................................... 15-20 <6D16-TLE> ............................................................................................................... 15-20 INTAKE MANIFOLD................................................................................. 15-22 <6D16>....................................................................................................................... 15-22 <6D16-TLE> ............................................................................................................... 15-24 EXHAUST MANIFOLD............................................................................. 15-26 <6D16>....................................................................................................................... 15-26 <6D16-TLE> ............................................................................................................... 15-27

15-1

SPECIFICATIONS Turbocharger <6D16-TLE> Item Type

Specifications T04E

Manufacturer

Honeywell

Intercooler Item Type

15-2

Specifications Tube & corrugated fin air cooled type

MEMO

15-3

STRUCTURE AND OPERATION Turbocharger <T04E (6D16-TLE)> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

18273

15-4

Compressor housing Piston ring Thrust collar Thrust bearing Center housing Wheel shroud Exhaust coupler Actuator assembly Turbine housing Turbine wheel Piston ring Retaining ring Bearing Seal ring Back plate Compressor wheel

15 ● Waste gate mechanism <T04E (6D16-TLE)> • The waste gate mechanism has the actuator assembly 8 to let extra exhaust gas escape. By so doing, the boost pressure is properly controlled to prevent the turbine wheel from overrunning and prevent an excessive pressure produced in the intake manifold. • The boost pressure is led from the compressor housing 1 through a rubber hose to the chamber A of the actuator assembly 8. When the boost pressure that acts on the chamber A is below the setting, the actuator assembly does not operate, and the waste gate valve remains closed, and the exhaust gas D is blown against the turbine wheel 10.

01510

• When the boost pressure that acts on the chamber A exceeds the setting, the waste gate valve is opened. As a result, the amount of exhaust gas blown against the turbine wheel 10 decreases, and the rotating speed of the compressor wheel 16 also decreases, and the boost pressure falls.

01511

● Operation of overboost valve • The overboost valve E operates when the boost pressure becomes abnormally high due to the failure of the waste gate mechanism.

01512

• When the boost pressure F of the overboost valve E exceeds the setting, the valve releases the boost pressure into the atmosphere to make sure that a boost pressure more than necessary is not applied to the engine. The valve whistles when it is in operation.

01513

15-5

Air cleaner

Strange sound or vibration in intake and exhaust system

Insufficient engine output

White exhaust gas

Back exhaust gas

Possible causes

Engine hard to start

Symptoms

Excessive oil consumption

TROUBLESHOOTING

Remarks

Clogged air cleaner element

Turbocharger Defective bearing Carbon deposited on turbine wheel Turbine wheel interfering with wheel shroud and turbine back plate Turbine wheel interfering with turbine housing Bent turbine wheel Damaged turbine wheel Compressor wheel interfering with compressor housing Thrust sleeve, thrust collar and thrust bearing seizure Damaged compressor wheel Oil leaks due to worn piston ring and insert Improperly mounted piston ring Unsmooth sliding of internal parts due to clogged lubrication oil pipe and eyebolt Damaged oil seals due to clogged oil return pipe Improperly mounted compressor housing Improperly mounted turbine housing Intercooler

Foreign substances deposited on front core of intercooler

Deformed front pipe, muffler, tail pipe Improperly mounted front pipe, muffler, tail pipe Incorrect valve clearance

Gr 11

Defective head gasket

Gr 11

Worn valve and valve seat and deposited carbon

Gr 11

Sagging valve spring

Gr 11

Worn or damaged piston ring

Gr 11

Worn or damaged piston ring groove of piston

Gr 11

Malfunctioning cooling equipment

Gr 14

Excessive engine oil

Gr 12

Seizure of major moving parts

Gr 11

Uneven or excessive fuel injection

Gr 13

15-6

MEMO

15-7

TURBOCHARGER <T04E (6D16-TLE)> ● Removal sequence 1 Eyebolt 2 Oil inlet pipe 3 Oil return pipe 4 Nut 5 Turbocharger assembly 6 Gasket

*: Exhaust manifold

P.15-10

P.15-26, 27

: Non-reusable part ● Installation sequence Reverse the order of removal.

18387

Tightening torque Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

Eyebolt (for mounting oil inlet pipe)

21 (2.1) [15.0]

–

Nut (for mounting turbocharger assembly)

41 (4.2) [30.2]

–

Lubricant Location

Points of application

Supply when installing turbocharger assembly

Specified lubricant Engine oil

Quantity As required

◆ Service procedure 5 Installation of turbocharger assembly When the turbocharger assembly 5 is installed, supply engine oil from the oil hole A to make sure that all the parts operate smoothly.

18388

15-8

MEMO

15-9

TURBOCHARGER <T04E (6D16-TLE)> Turbocharger Assembly

18315

● Operations before disassembly P.15-12 ● Disassembly sequence 1 Hose clamp 2 Hose 3 Retaining ring 4 Nut 5 Nut 6 Actuator assembly 7 Rod end 8 Bolt 9 Bracket 10 Bolt 11 Exhaust coupler 12 Gasket 13 Bolt

14 15 16 17 18 19 20 21 22 23 24 25

Clamp Turbine housing Bolt Clamp Compressor housing O-ring Center housing & rotating assembly Lock nut Compressor wheel Turbine wheel Piston ring Wheel shroud

CAUTION Carefully remove the piston rings 24 and 31, as they are readily broken.

15-10

26 27 28 29 30 31 32 33 34 35

Bolt Back plate Seal ring Thrust collar Thrust bearing Piston ring Retaining ring Bearing Retaining ring Center housing : Non-reusable part

15 ● Cleaning after disassembly P.15-13 ● Reassembly sequence

CAUTION Do not widen the piston rings 24 and 31 more than necessary, as they are readily broken. ● Inspection after reassembly P.15-13

Service standards Location

Unit: mm (in.)

Maintenance item

Standard value (Basic diameter in [ ])

Limit

Remedy

Actuator assembly set pressure

83 to 90 kPa (625 to 675 mmHg) [12.04 to 13.05 psi]

–

Adjust

Turbine wheel

[10.156 (0.39984)]

10.152 (0.39969) or more

Replace

Shaft bend

–

0.01 (0.000394) or less

Hub diameter

[17.31 (0.6815)]

17.25 (0.6791) or more

Groove width

1.69 (0.0665)

1.74 (0.0685) or less

Groove diameter

[14.46 (0.5693)]

14.40 (0.5669) or more

Play in radial direction

0.076 to 0.150 (0.0030 to 0.0060)

–

Play in thrust direction

0.025 to 0.076 (0.0010 to 0.0030)

–

Seal land height

11.672 (0.45953)

11.658 (0.45898) or less

Seal bore inside diameter

[12.687 (0.49949)]

12.712 (0.50047) or less

Piston ring mounting portion

Groove width

1.640 (0.064567)

1.659 (0.065315) or less

Groove diameter

[10.35 (0.40748)]

10.29 (0.40512) or more

Thrust bearing mounting portion

Groove width

4.43 (0.1744)

4.44 (0.1748) or less

Groove diameter

[9.53 (0.3752)]

9.40 (0.3701) or more

Inside diameter

[6.358 (0.250315)]

6.363 (0.250511) or less

Bearing inserting portion inside diameter

[15.800 (0.622046)]

15.806 (0.622282) or less

Seal bore inside diameter

[18.03 (0.70984)]

18.06 (0.71102) or less

Bearing journal outside diameter

Piston ring mounting portion

Back plate

Thrust collar

Center housing

Check

Replace

15-11

TURBOCHARGER <T04E (6D16-TLE)> Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

Nut (for mounting actuator assembly)

5.6 to 7.8 (0.57 to 0.80) [4.13 to 5.75]

–

Nut (for mounting rod end)

5.6 to 6.8 (0.57 to 0.70) [4.13 to 5.02]

–

Bolt (for mounting bracket)

20 to 22 (2.07 to 2.29) [14.8 to 16.2]

–

Bolt (for mounting exhaust coupler)

20 to 22 (2.07 to 2.29) [14.8 to 16.2]

–

Bolt (for mounting clamp)

20 to 22 (2.07 to 2.29) [14.8 to 16.2]

–

Bolt (for mounting clamp)

16 to 19 (1.67 to 1.89) [11.8 to 14.0]

–

Lock nut (for mounting compressor wheel)

2.1 to 2.3 (0.21 to 0.23) [1.55 to 1.70]

After tightening, turn down 90°C to 110°C further from that position.

Bolt (for mounting back plate)

12 to 14 (1.26 to 1.45) [8.9 to 10.3]

–

Lubricant Location

Points of application

Specified lubricant

Quantity

Apply to threads and bearing surface of bolt

MOLYKOTE

As required

16, 26

Apply to threaded portion of bolt

LOCTITE

As required

19, 23 24, 29 to 34

Apply to all of the parts.

Engine oil

As required

Special tools Location

Tool name and shape

Part No.

Application

T-handle

801059-0

Holding fixture

801053-0

Measuring element

801098-0

Inspection of play of turbine wheel in radial direction

Piston ring inserter

801050-0

Installation of piston ring

Retaining ring remover

801058-0

Removal and installation of retaining ring

32, 34

Removal and installation of compressor wheel

Part numbers listed above are Honeywell part numbers.

◆ Service procedure ● Operations before disassembly Make alignment mark A on the turbine housing 15, compressor housing 18 and center housing & rotating assembly 20.

18316

15-12

15 ● Cleaning after disassembly • Before cleaning, visually check the individual parts for burns, rubbed stains, etc. which might disappear after cleaning. If there is anything wrong, replace.

CAUTION Do not immerse the actuator assembly 6 in the solvent. Clean it with a cloth dipped in kerosene. • Immerse the disassembled parts in a non-combustible solvent (DAIDO CHEMICAL INDUSTRY CO., LTD. DAI CLEANER T-30).

13628

• Take out the parts from the solvent and blow compressed air A against them.

18293

• Scrape off deposits. B: Plastic scraper or stiff brush • Re-immerse in the solvent. • Blow compressed air A.

13630

● Inspection after reassembly (1) Manually rotate the compressor wheel 22 and turbine wheel 23 to check whether they rotate smoothly.

18358

15-13

TURBOCHARGER <T04E (6D16-TLE)> (2) Play of turbine wheel in radial direction • Mount the Measuring Element to the dial gauge A and insert it from the oil outlet and press it against the shaft of the turbine wheel 23 at right angles. • Move the shaft of the turbine wheel 23 up and down by both hands to measure the play in the radial direction. • If the reading exceeds the limit, replace the bearing 33.

18317

(3) Play of turbine wheel in thrust direction • Set the dial gauge A on the end of the turbine wheel 23 and move the shaft of the turbine wheel in the axial direction to measure the play. • If the reading exceeds the limit, worn or defective back plate 27, thrust collar 29 and thrust bearing 30 are suspected. Replace.

18318

(4) Measurement of operating pressure of actuator assembly • Set the dial indicator A on the end of the rod end 7. (In this case, set the scale of the dial indicator to 0.) • Extend the rod end 0.38 mm by use of the external air B.) [The scale of the dial indicator A is 0.38 mm (0.0150 in.).] • With the scale of the dial indicator A at 0.38 mm (0.0150 in.), read the value of the pressure gauge C, and check to ensure that the reading is between 83 and 90 kPa (625 to 675 mmHg) [12.04 to 13.05 psi]. (5) Adjustment of operating pressure of actuator assembly • If the reading of the pressure gauge C is not between 83 and 90 kPa (625 to 675 mmHg) [12.04 to 13.05 psi], remove the retaining ring 3, loosen the nut 5, and adjust the length of the rod end 7. Rod end length adjusting direction Rod end extending direction → Reduces the pressure. Rod end retracting direction → Increases the pressure.

CAUTION

18325

15-14

When the rod end length is adjusted, if the piston assembly D is rotated, damage to the diaphragm in the actuator assembly 6 will result. Secure the piston assembly through use of a vice, pliers, etc. to make sure that it is not rotated.

15 6 Air-tightness check on actuator assembly Slowly apply the air pressure A to the actuator assembly 6 to check that there are no air leaks when the air pressure is 87 kPa (650 mmHg) [12.62 psi]. If there are air leaks, replace the actuator assembly. B: Pressure gauge 18366

15 Turbine housing [Removal] A: Rubber hammer

CAUTION

18319

• While using care to prevent damage to the turbine housing 15, lightly strike its entire circumference with a rubber hammer or similar tool. • Since the blades of the turbine wheel 23 are readily bent, use care to make sure that they do not hit the turbine housing 15. [Installation] Apply MOLYKOTE to the threads and bearing surface of bolt 13, partially tighten the bolt, line up the alignment marks made before disassembly, and then tighten the bolt to the specified torque.

CAUTION Use care to prevent damage to the blades of the turbine wheel 23. 18320

18 Compressor housing [Removal] A: Rubber hammer

CAUTION

18321

• While using care to prevent damage to the compressor 18, lightly strike its entire circumference with a rubber hammer A or similar tool. • Since the blades of the compressor wheel 22 are readily bent, use care to make sure that they do not hit the compressor housing 18. [Installation] • Place the center housing & rotating assembly 20 on the compressor housing 18, line up the alignment marks made before disassembly, and tighten the bolt 16 to the specified torque.

18322

15-15

TURBOCHARGER <T04E (6D16-TLE)> 22 Compressor wheel [Removal] • Hold the Holding Fixture in a vice, and slowly insert the center housing & rotating assembly 20. • Using the T-handle, remove the lock nut 21 and slowly withdraw the compressor wheel 22 upward. 18300

CAUTION Use care to prevent bending the shaft of the turbine wheel 23. [Installation] • Hold the shaft of the turbine wheel 23 and center housing 35 by hand, and slowly insert them into the Holding Fixture.

CAUTION

18301

• When they are inserted, use care to prevent damage to the blades of the turbine wheel 23. • Do not release the shaft before insertion, as the turbine wheel 23 falls down. • Hold the Holding Fixture in a vice and slowly insert the compressor wheel 22. • Using the T-handle, tighten the lock nut 21 to the specified torque, and then turn it down 90 to 110°C (194 to 230°F) further from that position.

CAUTION Use care to prevent bending the shaft of the turbine wheel 23. 18302

23 25 Compressor housing [Removal] Place the back plate 27 of the center housing 35 on the compressor housing 18 removed beforehand, and remove the turbine wheel 23 and wheel shroud 25.

18303

[Installation] After installation, lightly rotate the turbine wheel 23 by hand to check whether it continues to rotate. If it does not rotate lightly, re-perform the disassembly and reassembly procedures.

18304

15-16

15 [Inspection] (1) Bend of shaft • Using the dial indicator, measure at the illustrated position. • If the reading exceeds the limit, replace the turbine wheel 23.

13655

(2) Outside diameters of journal and hub If any reading exceeds the limit, replace the turbine wheel 23. A: Journal B: Hub

18305

(3) Width and outside diameter of piston ring groove If any reading exceeds the limit, replace the turbine wheel 23. A: Width B: Outside diameter

18306

24 Installation of piston ring Insert the Piston Ring Inserter into the turbine wheel 23 and install the piston ring 24.

18307

27 Back plate [Installation] Slowly install the back plate 27 on the center housing 35, while lining up the alignment marks made before disassembly, and tighten the bolt 26 to the specified torque.

18308

15-17

TURBOCHARGER <T04E (6D16-TLE)> [Inspection] • Measure the seal land height A and seal bore inside diameter B of the back plate 27. • If any reading exceeds the limit, replace the back plate 27.

18309

Piston ring groove and groove diameter of thrust collar and thrust bearing groove width, groove diameter and bore inside diameter If any reading exceeds the limit, replace the thrust collar 29.

18311

A: Piston ring groove B: Thrust bearing groove C: Groove width D: Groove diameter E: Bore inside diameter 30 Installation of thrust bearing Install the thrust bearing 30 on the thrust collar 29 with the oil groove A toward the center housing 35, and insert it onto the positioning pins B of the center housing.

18312

32 34 Retaining ring [Removal] : Retaining Ring Remover

CAUTION When the retaining rings 32 and 34 are removed, hold your hand over the rings to make sure that they do not bounce out. 18313

[Installation] Install the retaining rings 32 and 34 securely in the groove of the center housing.

CAUTION When the retaining rings 32 and 34 are installed, hold your hand over the rings to make sure that they do not bounce out. 18313

15-18

15 35

Check the bearing inserting portion inside diameter and seal bore diameter of the center housing. If any reading exceeds the limit, replace the center housing 35. A: Bearing inserting portion inside diameter B: Seal bore diameter 18314

15-19

INTERCOOLER <6D16-TLE> ● Disassembly sequence 1 Clamp 2 Rubber hose 3 Intercooler ● Reassembly sequence Reverse the order of disassembly.

18348

Service standards Location

Maintenance item

Standard value

Limit

Remedy

Intercooler {air leak at the air pressure of 150 kPa (1.5 kgf/cm2) [21.75 psi]}

0 cm {0 mL}

–

Replace

Tightening torque Location 1

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened Clamp (for mounting rubber hose)

Tightening torque

Remarks

4.9 to 9.8 (0.5 to 1.0) [3.61 to 7.23]

–

◆ Service procedure 3 Inspection of intercooler Put a cap A on either of the air ports of the intercooler 3 and connect a hose to the other, immerse the intercooler 3 in a water tank, and apply the standard pressure from the hose side to check for air leaks. If there are air leaks, replace the intercooler.

Cat Forklift Mitsubishi Diesel Engine Parts Contact phone: 1 269 673 1638 18349 Email: EngineParts@HeavyEquipmentRestorationParts.com Website: www.HeavyEquipmentRestorationParts.com www.dp150.com/cat-dp135-engine-parts

15-20

MEMO

15-21

INTAKE MANIFOLD <6D16> ● Disassembly sequence 1 Earth plate 2 Coupler 3 Gasket 4 Air heater 5 Gasket 6 Bolt 7 Intake manifold : Non-reusable part ● Reassembly sequence Reverse the order of removal.

18337

Tightening torque Location 6

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened Bolt (for mounting intake manifold)

Tightening torque

Remarks

23 (2.37) [17.0]

–

Sealant Location

Points of application

Apply to cylinder head mounting surface of the intake manifold

Specified sealant

Quantity

THREE BOND 1207B

As required

15-22

15 ◆ Service procedure 4 Installation of air heater The air heater 4 should be installed with its arrow mark A directed toward the intake manifold 7.

18698

7 Installation of intake manifold • The intake manifold is installed by use of either a seat gasket or sealant. This section describes the procedures for installation by use of a sealant. • Apply sealant A evenly without a break to the cylinder head mounting surface of the intake manifold 7. • Install the intake manifold on the cylinder head in less than three minutes after application of sealant A. 18339

CAUTION • Thoroughly clean the sealant applying surface of the intake manifold 7 beforehand. • When the intake manifold 7 is installed, make sure that it is not out of alignment. • When the manifold mounting bolt 6 was loosened, be sure to re-apply sealant A to the intake manifold 7. • Do not start the engine in less than an hour after installation.

15-23

INTAKE MANIFOLD <6D16-TLE>

P 47071

● Disassembly sequence 1 Rubber hose 2 Overboost valve 3 Air inlet pipe 4 Air inlet pipe 5 Gasket

*: Turbocharger assembly

6 Bolt 7 Intake manifold

P.15-10 : Non-reusable part

● Reassembly sequence Reverse the order of disassembly.

Tightening torque Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

Overboost valve

31 (3.2) [22.9]

–

Bolt (for fitting intake manifold)

23 (2.37) [17.0]

–

Sealant Location

Points of application

Specified sealant

Quantity

Apply to cylinder head mounting surface of intake manifold

THREE BOND 1207B

As required

15-24

15 ◆ Service procedure 7 Installation of intake manifold • Apply sealant A evenly without a break to the cylinder head mounting surface of the intake manifold 7. • Install the intake manifold 7 on the cylinder head in less than three minutes after application of sealant A.

CAUTION 12256

• Thoroughly clean the sealant applying surface of the intake manifold 7 beforehand. • When the intake manifold 7 is installed, make sure that it is not out of alignment. • When the manifold mounting bolt 6 was loosened, be sure to re-apply sealant A to the intake manifold 7. • Do not start the engine in less than an hour after installation.

15-25

EXHAUST MANIFOLD <6D16>

18343

● Disassembly sequence 1 Nut 2 Gasket 3 Nut 4 Exhaust manifold 5 Gasket

18344

*: Cylinder head

Gr 11

: Non-reusable part

● Reassembly sequence Reverse the order of disassembly.

Tightening torque Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

Nut (for mounting exhaust pipe)

41 (4.2) [30.2]

–

Nut (for mounting exhaust manifold)

58 (5.9) [42.4]

–

◆ Service procedure 5 Installation of gasket Install the gasket 5 with the grommet fold-back portion A toward the cylinder head.

12259

15-26

EXHAUST MANIFOLD <6D16-TLE> ● Disassembly sequence 1 Cover 2 Nut 3 Exhaust manifold 4 Gasket

*: Cylinder head

Gr 11

: Non-reusable part ● Reassembly sequence Reverse the order of disassembly.

18346

Tightening torque Location 2

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

58 (5.9) [42.4]

–

Nut (for mounting exhaust manifold)

◆ Service procedure 4 Installation of gasket Install the gasket 4 with the grommet fold-back portion A toward the cylinder head.

12259

15-27

GROUP 54 ELECTRICAL SYSTEM SPECIFICATIONS....................................................................................

54-2

STRUCTURE AND OPERATION..............................................................

54-3 1. Circuit Diagram..................................................................................................... 54-3 2. Alternator .............................................................................................................. 54-5 3. Charging Circuit.................................................................................................... 54-10 4. Starter ................................................................................................................... 54-12 5. Preheating Circuit................................................................................................. 54-13 6. Engine Starter Circuit ........................................................................................... 54-14 7. Safety Relay.......................................................................................................... 54-15

TROUBLESHOOTING ............................................................................. 54-16 ON-VEHICLE INSPECTION AND ADJUSTMENT.................................... 54-18 1. Inspection of Preheater System........................................................................... 54-18 2. Inspection of Safety Relay ................................................................................... 54-18 ALTERNATOR.......................................................................................... 54-24 <24V–40A> (with vacuum pump) ............................................................................... 54-24 <24V–40A> (without vacuum pump).......................................................................... 54-32 <24V–50A> ................................................................................................................. 54-38 STARTER................................................................................................. 54-44 <24V–5kW> ................................................................................................................ 54-44 PREHEATER CIRCUIT ............................................................................ 54-56 ENGINE STARTER CIRCUIT ................................................................... 54-59

54-1

SPECIFICATIONS Item Alternator

Specifications

Manufacturer

MITSUBISHI ELECTRIC CORP.

Type

Alternator with built-in regulator, fan externally mounted type Brushless

Vacuum pump

Provided

Model

A4TU 3186

Output Starter

V–A

Manufacturer

V–kW (HP)

16 or less U001T35383 24–2.3

Closed magnetic voltage

16 or less

Opened magnetic voltage

4 or less

Allowable breaking voltage

200

Manufacturer Voltage – capacity

Hiyoshi Denso V–kW A

Manufacturer

Voltage – current Fuse capacity

Fuse capacity

54-2

127

U1T31383 V–A

24–2.3

127 Sheathed type

V–A

Model Voltage – current

22–2.9

MITSUBISHI ELECTRIC CORP.

Type Voltage – current

Glow relay

U1X15076

V–A

Model

Glow plug

24–5 (6.7)

Model

Fuse capacity Heater relay

24–50

M8T60071

Exciting current

Intake air heater

A4T4 0386

MITSUBISHI ELECTRIC CORP.

Magnet switch operating voltage Starter relay

A4T4 0286

24–40

Model Output

Not provided

23–3 U1T06670

V–A

24–2.3

127

STRUCTURE AND OPERATION 1. Circuit Diagram <24V (Air Heater) Specification> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Starter switch Heater relay Air heater Heater indicator Battery Battery relay Tachometer sensor Ammeter Lamp switch Tachometer Fuse box Safety relay Alternator Starter relay Starter Thermometer (for oil) Thermo sending unit Thermometer (for coolant) Thermo sending unit Oil pressure gauge Oil pressure gauge unit Warning lamp Oil bypass alarm switch

B: Terminal B E: Terminal E L: Terminal L M: Terminal M P: Terminal P R: Terminal R S: Terminal S SW: Terminal SW

18458

54-3

STRUCTURE AND OPERATION <24V (Glow Plug) Specification> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Starter switch Glow relay Glow plug Glow indicator Battery Battery relay Tachometer sensor Ammeter Lamp switch Tachometer Fuse box Safety relay Alternator Starter relay Starter Thermometer (for oil) Thermo sending unit Thermometer (for coolant) Thermo sending unit Oil pressure gauge Oil pressure gauge unit Warning lamp Oil bypass alarm switch

B: Terminal B E: Terminal E L: Terminal L M: Terminal M P: Terminal P R: Terminal R S: Terminal S SW: Terminal SW

18459

54-4

54 2. Alternator <24V–40A (with vacuum pump)>

09431

1 2 3 4 5 6

Rectifier Rotor assembly Stator assembly Fan Pulley Front bearing

7 8 9 10 11 12

Front bracket Field coil Rear bracket Regulator Vacuum pump Rear bearing

B: Terminal B E: Terminal E L: Terminal L P: Terminal P R: Terminal R

54-5

STRUCTURE AND OPERATION <24V–40A (without vacuum pump), 12V–80A>

08644

1 2 3 4 5 6

54-6

Rectifier Rotor assembly Stator assembly Fan Pulley Front bearing

7 8 9 10 11

Front bracket Field coil Rear bracket Regulator Rear bearing

B: Terminal B E: Terminal E L: Terminal L P: Terminal P R: Terminal R

54 <24V–50A>

P 34192

1 2 3 4 5 6

Rectifier Rotor assembly Stator assembly Fan Pulley Front bearing

7 8 9 10 11

Front bracket Field coil Rear bracket Regulator Rear bearing

A: Neutral point diode B: Terminal B E: Terminal E L: Terminal L R: Terminal R

54-7

STRUCTURE AND OPERATION ● Alternator with neutral point diode Effectiveness of alternator with neutral point diode The point where three stator coils A are coupled is called the neutral point C. Addition of two diodes D to the current alternator which uses six diodes makes it possible to provide a higher DC output than an alternator without neutral point diodes. B: Alternator terminal B E: Alternator terminal E F: IC regulator L: Alternator terminal L R: Alternator terminal R 07033

Variations in potential at neutral point, and operation of neutral point diode • The potential at the neutral point C varies up and down as shown with the neutral point DC voltage (one half of the output voltage) as the center. When the alternator rotates at a very high speed, the peak values of the potential by far exceed the output voltage. (28V or more, 0V or less)

07400

G: During high speed rotation H: During low speed rotation J: Neutral point voltage waveform K: Output voltage L: Mean voltage at neutral point M: Ground potential In each of the voltage and potential conditions, the neutral point diode operates as described below. • When the neutral point voltage is more than 0V and less than 28V, the six conventional diodes operate.

54-8

54 ● When the neutral point voltage is more than 28V The positive side diode N conducts to add to the conventional DC output, so a higher DC voltage is output to each equipment.

07034

● When the neutral point voltage is less than 0V The negative side diode P conducts, and the neutral point output is supplied via the three conventional diodes.

07035

54-9

STRUCTURE AND OPERATION 3. Charging Circuit

16739

1 2 3 4 5 6 7 8

54-10

Battery Battery relay Ammeter Fuse box Alternator Safety relay <Circuit without charge lamp> Charge lamp <Circuit with charge lamp> Starter switch

A: To starter relay terminal B B: Terminal B E: Terminal E L: Terminal L R: Terminal R

54 When engine is stationary Position of starter switch 8: ON • To improve the performance of the alternator 5 in starting power generation at a low speed immediately after the engine has been started, current is set flowing to terminal R. 1

5 (R

Ground

6 (R

5 (L

Ground 16740

• In the circuit with A charge lamp 7, current flows as shown below. 1

5 (R

5 (L

Ground E)

Ground

After engine has been started Position of starter switch 8: ON • The alternator 5 starts generating power. • The output voltage at terminal B of the alternator 5 becomes higher than the voltage of the battery 1. • The alternator 5 starts charging the battery 1. 5 (B)

16741

• In the case of the circuit with the charge lamp 7, the charge lamp goes out, as there is no potential difference between the voltage at terminal L of the alternator 5 and the battery voltage.

54-11

STRUCTURE AND OPERATION 4. Starter <24V–5kW (6.7 HP)>

10739

1 2 3 4 5 6 7 8 9

Rear bracket Brush Brush spring Brush holder assembly Magnet switch Ball Lever Front bracket Spring

10 11 12 13 14 15 16 17 18

Pinion stopper Pinion Front bearing Overrunning clutch Washer Gear shaft assembly Internal gear assembly Planetary gear Packing

19 20 21 22

Yoke assembly Armature assembly Packing Rear bearing

B: Terminal B M: Terminal M S: Terminal S

This starter uses planetary gear 17 in the reduction gear mechanism.

13501

54-12

54 5. Preheating Circuit <Intake Air Heater> 1 2 3 4 5 6

Starter switch Battery relay Battery Heater relay Heater indicator Heater plug

1 2 3 4 5 6

Starter switch Battery relay Battery Heater relay Glow indicator Glow plug

18461

18462

54-13

STRUCTURE AND OPERATION 6. Engine Starter Circuit

16757

1 2 3 4 5 6

54-14

Battery Battery relay Starter relay Starter Safety relay Starter switch

54 7. Safety Relay The safety relay detects the rotating speed of the alternator. When the rotating speed exceeds the reference value, the safety relay keeps the starter inoperative even if the starter switch is accidentally set to ON while the engine is running.

17530

P: Terminal P R: Terminal R L: Terminal L S: Terminal S E: Terminal E

17531

1 2 3 4 5

Alternator Starter switch Battery switch Battery Starter relay

6 Safety relay 7 IC regulator A: To starter terminal B

• When the starter switch 2 is set to ON, current flows from the starter relay 5 through terminal S of the safety relay 6 to terminal E, and contact P1 closes. • When rotation of the starter causes the engine to start running, pulses with a frequency of a tenth of the alternator speed are generated at terminal P of the alternator 1. • When the pulse frequency at terminal P of the alternator 1 exceeds the reference value, the continuity between terminals S and E is lost, and the starter remains inoperative even if the starter switch 2 is set to ON while the engine is running.

54-15

TROUBLESHOOTING

Alternator is in order but battery is over-discharged

With the engine stationary (the starter seitch at ON), the charge lamp does not come on.

Battery is normal but is overdischarged.

Possible causes

Battery temperature high

Defective conditions

Battery fluid decreases in a short time

Alternator

Remarks

Connector incorrectly connected, harness opencircuited, defective grounding Blown fuse Weak tension of V-belt

Gr 14

Broken V-belt

Gr 14

Defective battery Alternator

Stator coil open-circuited Stator coil and core short-circuited Field coil defective Rectifier defective Regulator defective Brush worn (if brush is provided) Sagging brush spring (if brush is provided) Defective wiring

54-16

54 Starter

Engine is hard to start

Engine cannot be preheated

Engine does not stop

Flywheel rotates but engine does not start

Pinion comes in mesh with ring gear but does not rotate

Starter does not start

Possible causes

Pinion does not come in mesh with ring gear

Starter starts but engine does not start

Defective condition

Remarks

Connector incorrectly connected, harness opencircuited, defective grounding Blown fuse Insufficient capacity of battery Starter

Contact of magnet switch binding or deposited Coil of magnet switch open-circuited Overrunning clutch in defective operation Worn or damaged pinion

Defective starter relay Defective starter switch Worn or damaged ring gear of flywheel

Gr 11

Possible causes

Engine is hard to start

Defective condition

Engine cannot be preheated

Starter, Preheater

Remarks

Defective heater relay or glow relay wiring Defective battery wiring Defective glow plug wiring Defective glow plug Defective coolant temperature sensor

Gr 14

Defective coolant temperature sensor wiring

54-17

ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection of Preheater System <Glow Plug Specification> • Set the starter switch to OFF. • Connect the inspection lamp 2 (24V–1.8W or thereabouts) to the glow plug 1. • Set the starter switch to the HEAT position. • If the inspection lamp 2 does not come on, check the glow plug or heater relay.

08718

2. Inspection of Safety Relay Service standards Location 6

Maintenance item

Standard value

Limit

When engine is stationary

1V or less

–

Replace alternator or wiring.

While engine is running (at idle, 600 rpm or more)

12 – 16V

–

Check and replace wiring.

Output voltage at terminal R

When engine is running

Approx. 24V

–

Check and replace wiring.

Output voltage at terminal S

When engine is started (in cranking state)

1V or less

–

• If the output voltage is close to the battery voltage, replace the safety relay. • If the output voltage is 0V, check and replace parts.

Output voltage at terminal L

When engine is running

5V or less (but not 0V)

–

• Replace. • If the output voltage is close to the battery voltage, inspect the alternator and herness and replace if necessary.

Output voltage at terminal P

54-18

Remedy

54 (1) Checking output voltage at terminal P • Connect the voltmeter (point type) 7 as shown. 1 2 3 4 5 6 7

18469

17534

17535

Battery Battery relay Starter switch Fuse Alternator Safery relay Voltmeter (pointer type)

A: To terminal B of starter relay D: To terminal L of starter relay E: Terminal E L: Terminal L P: Terminal P R: Terminal R S: Terminal S • Measure the voltage between terminal P in the illustration and the ground. • If the reading is out of the standard value, the alternator 5 or wiring is defective. Check all the parts and replace defective ones. • Start the engine and let it run at idle (600 rpm or more) and measure the voltage. • If the reading is 0V, the wiring to terminal P is shortcircuited. Check the wiring and connector connections. Replace if defective.

54-19

ON-VEHICLE INSPECTION AND ADJUSTMENT (2) Checking output voltage at terminal R • Connect the voltmeter 7 as shown. • Place the starter switch 3 in the ON position and measure the voltage. • When the reading is out of the standard value, check the wiring. Replace if defective.

18471

17534

54-20

17535

54 (3) Checking output voltage at terminal S • Connect the voltmeter 7 and lamp 8 as shown. • Set the starter switch 3 to the START position and measure the voltage between the safety relay 6 (terminal S) and the earth in the cranking state. • If the reading is out of the standard value, the following points are likely to be defective. Check all the parts and replace if defective. • When the reading is close to the battery voltage, the safety relay 6 is defective. • When the reading is 0V, the following problems are suspected. Defective wiring Incorrectly connected connector Defective starter relay Defective starter switch

18470

17534

• Start the engine and let it run at idle (600 rpm or more). • Measure the voltage at terminal P. • If the reading is out of the standard value, replace the alternator 5. • In the idling state, check to ensure that the lamp 8 does not come on. When the voltage at terminal P is normal and the lamp comes on, replace the safery relay 6.

17535

54-21

ON-VEHICLE INSPECTION AND ADJUSTMENT (4) Checking output voltage at terminal L (where no charge lamp is provided) • Connect the voltmeter 7 as shown. • Place the starter switch 3 in the ON position and measure the voltage. • If the reading is out of the standard value, replace the safety relay 6. If the reading is close to the battery voltage, check the alternator 5 and wiring, and replace if defective.

18472

17534

54-22

17535

MEMO

54-23

ALTERNATOR <24V–40A (with vacuum pump)> ● Removal sequence 1 Vacuum pipe 2 Oil return hose 3 Oil inlet hose 4 Adjust plate 5 V-belt 6 Alternator assembly 7 Adjust plate

P.54-26

*: Alternator bracket

16752

WARNING Before removing the alternator 6, be sure to disconnect the negative terminal of the battery and insulate it with a tape or something else. If the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous.

● Installation sequence Reverse the order of removal. ● Adjustment after installation Adjust the tension of the V-belt 5.

Gr 14

Service standards Location 6

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Standard value

Limit

Remedy

1500 rpm

24A or more

–

Check

2500 rpm

33A or more

–

5000 rpm

37A or more

–

28.5 ± 0.5V

–

Regulator regulated voltage (5000 rpm, loads 5A or less)

Replace

*: “When hot” refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-24

54 ◆ Service procedure 6 Inspection of alternator (1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 6 as shown.

NOTE

P 16753

• • •

• •

P 16755

Each wire must be adequately thick and each connection must be properly secured. A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter Increase the load resistance F to a maximum (where practically no load current flows). Set the switch C and switch D to ON. Operate the alternator 6 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in “Service standard”. Nominal value of alternator current 24V–40A Measure the current with the alternator 6 at each of the specified speeds. If the reading is out of the standard value, disassemble and check the alternator 6. P.54-26

(2) Inspection of performance of regulator (Inspection by test bench) • Wire the alternator 6 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 6 rotate at a low speed. • Increase the rotating speed of the alternator 6 to 5000 rpm and measure the voltage (regulated voltage). At the same time, check to ensure that the current value is 5A or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-25

ALTERNATOR <24V–40A (with vacuum pump)> Alternator Assembly

10114

● Disassembly sequence 1 Vacuum pump assembly P.54-30 2 O-ring 3 Rotor & front bracket assembly 4 Nut 5 Pulley 6 Fan 7 Spacer 8 Rear bearing 9 Rotor assembly 10 Cover

11 12 13 14 15 16 17 18 19

Front bearing Front bracket Stator & rear bracket assembly Stator assembly Field coil Regulator Rectifier Oil seal Rear bracket : Non-reusable part

NOTE Do not remove parts 8, 11 and 14 unless they are found to be defective. ● Reassembly sequence 13

13:

18 16

54-26

54 Service standards Location 15

Maintenance item

Standard value

Limit

Remedy

Field coil resistance [at 20°C (68°F)]

Approx. 6.2 V

–

Replace

Tightening torques Location 4

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened Nut (to mount pulley)

Tightening torque

Remarks

132 to 162 (13.5 to 16.5) [97.4 to 119]

–

◆ Service procedure 3 Rotor & front bracket assembly [Removal]

CAUTION Wind a tape around the spline portion A of the shaft of the rotor & front bracket assembly 3 to prevent damage to the oil seal 18 at the time of removal.

10116

• Insert a plain screwdriver A between the front bracket 12 and stator assembly 14. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 3 from the stator & rear bracket assembly 13.

CAUTION If the plain screwdriver A is inserted too far, the coil B of the stator assembly 14 might be damaged and short-circuited.

10701

54-27

ALTERNATOR <24V–40A (with vacuum pump)> [Disassembly]

CAUTION When the rotor assembly 9 is held in a vice, make sure that the base B of the lugs of the core is held. If the lugs C of the core are held, they will be broken or damaged.

10819

14 Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 14 from the rectifier 17. The leads are soldered to the diode leads B of the rectifier. (Three places)

CAUTION P 02335

De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time. • For installation, reverse the order of removal. [Inspection] (1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 14.

P 02336

(2) Continuity between each lead and core • Check to ensure that there is no continuity between each lead and the core. • If there is continuity, it means a short circuit. Replace the stator assembly 14.

P 02337

54-28

54 15 Field coil [Removal] • Remove the two screws A.

CAUTION If the screws B are removed first, the weight of the field coil 15 will act on the lead portion secured by the screws A, and damage to the lead portion may result. Therefore, make sure that the screws A are removed first. 16118

• Remove the three screws B.

CAUTION When the screws B are removed, the field coil 15 will fall under its own weight. Therefore, hold the field coil by hand beforehand. • Remove the field coil 15.

CAUTION When the field coil 15 is taken out, the coil lead portion may be caught by the stator coil. Don't pull it out with undue force. [Inspection] • Measure the resistance between the terminals of the field coil 15. • If the reading is out of the standard value, replace the field coil 15.

02325

17 Inspection of rectifier • Check the rectifier 17 to see if the internal diodes function properly, and replace if defective. Resistance infinite in both cases....Open Resistance close to V in both cases...Short A, B, C: Leads of stator coil connected D, F: Heat sink portion E: Regulator connected P 13084

• Exchange the both cases.

and

sides of the tester and perform checks in

CAUTION When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 17, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range. P 13083

54-29

ALTERNATOR <24V–40A (with vacuum pump)> Vacuum Pump Assembly ● Disassembly sequence 1 Vacuum housing 2 O-ring 3 Vane 4 Rotor 5 Plate 6 O-ring

*: Alternator

P.54-26 : Non-reusable part

● Reassembly sequence Reverse the order of removal.

00359

Service standards Location –

54-30

Maintenance item Attainable vacuum pressure (when alternator speed is 1500 rpm)

Standard value

Limit

Remedy

93 kPa (0.95 kgf/cm2) [13 psi]

–

MEMO

54-31

ALTERNATOR <24V–40A (without vacuum pump)> ● Removal sequence 1 Adjust bolt 2 V-belt 3 Alternator assembly 4 Adjust plate

P.54-34

*: Alternator bracket

16752

WARNING Before removing the alternator 3, be sure to disconnect the negative terminal of the battery and insulate it with a tape or something else. If the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous.

● Installation sequence Reverse the order of removal. ● Adjustment after installation Adjust the tension of the V-belt 2.

Gr 14

Service standards Location 3

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Standard value

Limit

Remedy

1500 rpm

24A or more

–

Check

2500 rpm

33A or more

–

5000 rpm

37A or more

–

28.5 ± 0.5V

–

Regulator regulated voltage (5000 rpm, loads 5A or less)

Replace

*: “When hot” refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-32

54 ◆ Service procedure 3 Inspection of alternator (1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 3 as shown.

NOTE

P 16753

• • •

• •

P 16755

Each wire must be adequately thick and each connection must be properly secured. A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter Increase the load resistance F to a maximum (where practically no load current flows). Set the switch C and switch D to ON. Operate the alternator 3 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in “Service standard”. Nominal value of alternator current 24V–40A Measure the current with the alternator 3 at each of the specified speeds. If the reading is out of the standard value, disassemble and check the alternator 3. P.54-34

(2) Inspection of performance of regulator (Inspection by test bench) • Wire the alternator 3 as shown. A: Ammeter B: Alternator terminal B C: Switch E: Alternator terminal E G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter • Set the switch C to ON. • Let the alternator 3 rotate at a low speed. • Increase the rotating speed of the alternator 3 to 5000 rpm and measure the voltage (regulated voltage). At the same time, check to ensure that the current value is 5A or less. • If the readings are out of the standard values, proceed as described below. • If the readings exceed the standard values, replace the regulator. • If the readings are below the standard values, check all the parts of the alternator before replacing the regulator.

54-33

ALTERNATOR <24V–40A (without vacuum pump)> Alternator Assembly <Triple pulley>

16754

● Disassembly sequence 1 Rotor & front bracket assembly 2 Nut 3 Pulley 4 Fan 5 Spacer 6 Rear bearing 7 Rotor assembly 8 Cover 9 Front bearing 10 Oil seal

11 12 13 14 15 16 17

Front bracket Stator & rear bracket assembly Stator assembly Field coil Regulator Rectifier Rear bracket : Non-reusable part

NOTE Do not remove parts 6, 9 and 13 unless they are found to be defective. ● Reassembly sequence 12

12:

16 15

54-34

54 Service standards Location 14

Maintenance item Field coil resistance [at 20°C (68°F)]

Standard value

Limit

Remedy

5.8 to 6.6 V

–

Replace

Tightening torques Location 2

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened Nut (to mount pulley)

Tightening torque

Remarks

132 to 162 (13.5 to 16.5) [97.4 to 119]

–

◆ Service procedure 1 Rotor & front bracket assembly [Removal] • Insert a plain screwdriver A between the front bracket 11 and stator assembly 13. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 12.

CAUTION If the plain screwdriver A is inserted too far, the coil B of the stator assembly 13 might be damaged and short-circuited.

09525

[Disassembly]

CAUTION When the rotor assembly 7 is held in a vice, make sure that the base E of the lugs of the core is held. If the lugs D of the core are held, they will be broken or damaged.

02319

54-35

ALTERNATOR <24V–40A (without vacuum pump)> 13 Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 13 from the rectifier 16. The leads are soldered to the diode leads B of the rectifier. (Three places)

CAUTION P 02335

P 02336

P 02337

54-36

54 14 Field coil [Removal] • Remove the two screws A.

CAUTION If the screws B are removed first, the weight of the field coil 14 will act on the lead portion secured by the screws A, and damage to the lead portion may result. Therefore, make sure that the screws A are removed first. 16118

• Remove the three screws B.

CAUTION When the screws B are removed, the field coil will fall under its own weight. Therefore, hold the field coil by hand beforehand. • Remove the field coil 14.

CAUTION When the field coil is taken out, the coil lead portion may be caught by the stator coil. Don't pull it out with undue force. [Inspection] • Measure the resistance between the terminals of the field coil 14. • If the reading is out of the standard value, replace the field coil 14.

02325

16 Inspection of rectifier • Check the rectifier 16 to see if the internal diodes function properly, and replace if defective. Resistance infinite in both cases....Open Resistance close to V in both cases...Short A, B, C: Leads of stator coil connected D, F: Heat sink portion E: Regulator connected P 13084

• Exchange the both cases.

and

sides of the tester and perform checks in

CAUTION When a tester is used for the checks, the current that flows out from the tester is feebler than the current that normally flows through the rectifier 16, so the tester may indicate a questionable resistance value. In a low range, this tendency will be stronger. Therefore, it is advisable to use the highest possible range. P 13083

54-37

ALTERNATOR <24V–50A> ● Removal sequence 1 Adjust bolt 2 V-belt 3 Alternator assembly 4 Adjust plate

P.54-40

*: Alternator bracket

P 46896

● Installation sequence Reverse the order of removal. ● Adjustment after installation Adjust the tension of the V-belt 2.

Gr 14

Service standards Location 3

Maintenance item Alternator output current (* When hot, when 27V is generated)

Alternator speed

Standard value

Limit

Remedy

1500 rpm

24A or more

–

Check

2500 rpm

38A or more

–

5000 rpm

45A or more

–

28.5 ± 0.5V

–

Regulator regulated voltage (5000 rpm, loads 5A or less)

Replace

*: “When hot” refers to the state of the engine after 30 minutes of maximum output operation at 5000 rpm at a normal ambient temperature.

54-38

54 ◆ Service procedure 3 Inspection of alternator (1) Inspection of performance of alternator (Inspection by test bench) • Wire the alternator 3 as shown.

NOTE

P 16753

• • •

• •

P 16755

Each wire must be adequately thick and each connection must be properly secured. A: Ammeter B: Alternator terminal B C: Switch D: Switch E: Alternator terminal E F: Load resistance (variable resistance) G: Alternator drive motor L: Alternator terminal L R: Alternator terminal R V: Voltmeter Increase the load resistance F to a maximum (where practically no load current flows). Set the switch C and switch D to ON. Operate the alternator 3 at 5000 rpm for 30 minutes with the load resistance F adjusted such that the output current is as specified in “Service standard”. Nominal value of alternator current 24V–50A Measure the current with the alternator 3 at each of the specified speeds. If the reading is out of the standard value, disassemble and check the alternator 3. P.54-40

54-39

ALTERNATOR <24V–50A> Alternator Assembly

P 42355

● Disassembly sequence 1 Rotor & front bracket assembly 2 Nut 3 Pulley 4 Fan 5 Spacer 6 Rear bearing

7 8 9 10 11 12

Rotor assembly Cover Front bearing Front bracket Stator & rear bracket assembly Screw

13 14 15 16 17 18

Screw Field coil Stator assembly Regulator P.54-39 Rectifier Rear bracket

NOTE Do not remove parts 6, 9 and 15 unless they are found to be defective. ● Reassembly sequence 11

11:

17 16

54-40

54 Service standards Location 14

Maintenance item Field coil resistance [at 20°C (68°F)]

Standard value

Limit

Remedy

5.1 to 6.0 V

–

Replace

Tightening torques Location 2

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened Nut (to mount pulley)

Tightening torque

Remarks

132 to 162 (13.5 to 16.5) [97.4 to 119]

–

◆ Service procedure 1 Rotor & front bracket assembly [Removal] • Insert a plain screwdriver A between the front bracket 10 and stator assembly 15. • While wrenching the plain screwdriver A, remove the rotor & front bracket assembly 1 from the stator & rear bracket assembly 11.

CAUTION If the plain screwdriver A is inserted too far, the coil B of the stator assembly 15 might be damaged and short-circuited.

P 42356

[Disassembly]

CAUTION When the rotor assembly 7 is held in a vice, make sure that the base C of the lugs of the core is held. If the lugs D of the core are held, they will be broken or damaged.

P 42410

54-41

ALTERNATOR <24V–50A> 14 Field coil [Removal] • Remove the two screws 12.

CAUTION If the screws 13 are removed first, the weight of the field coil 14 will act on the portion connected to the regulator 16 and secured by the screws 12, and damage to the connected portion may result. Therefore, make sure that the screws 13 are removed first. P 19134

• Remove the three screws 13.

CAUTION When the screws 13 are removed, the field coil 14 will fall under its own weight. Therefore, hold the field coil by hand beforehand. • Remove the field coil 14.

CAUTION P 30765

When the field coil 14 is taken out, the portion connected to the regulator 16 may be caught by the stator coil. Don't pull it out with undue force.

[Inspection] • Measure the resistance between the terminals of the field coil 14. • If the reading is out of the standard value, replace the field coil 14.

P 16636

15 Stator assembly [Removal] • Disconnect the leads A and remove the stator assembly 15 from the rectifier 17. The leads are soldered to the diode B of the rectifier. (four places)

CAUTION P 02335

De-soldering should be done quickly (in about 5 seconds or less). The diodes will be damaged if heated for a longer time. • For installation, reverse the order of removal.

54-42

54 [Inspection] (1) Continuity between leads • Check to ensure that there is continuity between each lead. • If there is no continuity, the leads are open-circuited. Replace the stator assembly 15.

P 02336

P 02337

17 Inspection of rectifier • Check the rectifier 17 to see if the internal diodes function properly, and replace if defective. Resistance infinite in both cases....Open Resistance close to V in both cases...Short A, B, C, D: Leads of stator coil connected E, G: Heat sink portion F: Regulator connected P 15270

• Exchange the both cases.

and

sides of the tester and perform checks in

54-43

STARTER <24V–5kW> ● Removal sequence 1 Earth strap 2 Starter relay 3 Battery cable 4 Starter assembly

P.54-45

B: Terminal B S: Terminal S

WARNING Before removing the starter 4, be sure to disconnect the negative terminal of the battery and insulate it with a tape or something else. If the negative terminal is not disconnected, the battery voltage is always available at terminal B and is dangerous.

● Installation sequence Reverse the order of removal.

16759

54-44

54 Starter Assembly

P 47262

● Disassembly sequence 1 Stopper ring 2 Pinion stopper 3 Pinion 4 Spring 5 Magnet switch 6 Shim 7 Rear bracket 8 Packing 9 Yoke & brush holder assembly 10 Brush spring 11 Brush 12 Brush holder assembly 13 Yoke assembly 14 Brush

Yoke Armature assembly Rear bearing Armature Ball Front bracket assembly Cover Packing Planetary gear Packing Plate Gear shaft & overrunning clutch assembly 27 E-ring 15 16 17 18 19 20 21 22 23 24 25 26

28 Gear shaft & internal gear assembly 29 Gear shaft assembly 30 Washer 31 Internal gear 32 Overrunning clutch 33 Lever assembly 34 Front bearing 35 Oil seal 36 Front bracket : Non-reusable part

54-45

STARTER <24V–5kW> CAUTION • Do not remove the bearings 17 and 34 unless defects are evident. • When the armature assembly 16 is removed, the ball 19 might come out with it. Take care not to lose the ball. • It is not necessary to remove the pinion 3 when only the motor should be removed and inspected for inspection of the brushes and the related parts. • Be sure to remove the pinion 3 before disassembling any other parts. ● Assembly sequence Follow the disassembly sequence in reverse.

CAUTION Whenever the magnetic switch 5 is replaced, the pinion gap must be adjusted. ● Inspection after reassembly P.54-47

Service standards Location – – 10

11, 14 16

Unit: mm (in.) Maintenance item

Standard value Limit Remedy Pinion gap 0.5 to 2.0 (0.0197 to 0.0787) – Adjust No-load During 23V Current 85A or less – Check characteristics supply Rotating speed 3300 rpm or more – Spring pressure of brush spring 29 to 39 N 20 N Replace (3 to 4 kgf) (2 kgf) [6.52 to 8.77 lbf] [4.50 lbf] Brush length 18 (0.709) 11 (0.433) Replace Outside diameter of commutator 32 (1.26) 31.4 (1.24) Replace Commutator outer circumferential runout – 0.05 (0.00197) or more Depth of mica between segments – 0.2 (0.00787) Repair or or less replace

Lubricant Location 5 16 16, 29 19 23, 31 29, 32

Points of application Lever contact surface of magnetic switch Teeth of armature assembly gear Sliding surfaces of armature assembly and gear shaft assembly Ball Teeth of planetary gear and internal gear Sliding surfaces of gear shaft assembly and overrunning clutch

30 32

Washer Splines of overrunning clutch

Sliding surfaces of lever assembly and overrunning clutch

54-46

Specified lubricant

Quantity

Multipurpose grease [NLGI No.2 (Li soap)] MOLYKOTE ® AG650 MOLYKOTE ® AG650 MOLYKOTE ® AG650 MOLYKOTE ® AG650 Multipurpose grease [NLGI No.2 (Li soap)] MOLYKOTE ® AG650 Multipurpose grease [NLGI No.2 (Li soap)] Multipurpose grease [NLGI No.2 (Li soap)]

As required As required As required As required As required As required As required As required As required

54 ◆ Service procedure ● Inspection after reassembly After reassembly, check the starter by supplying current.

WARNING • When current is supplied to the starter, the pinion 3 will spring out and rotate. Be careful not to touch it by hand. • The magnet switch 5 may be very hot after the end of inspection. Be careful when you touch it. P 14266

CAUTION

P 14257

(1) Performance test • Wire the starter as shown. A: Ammeter B: Starter terminal B C: Switch

D: DC power supply S: Starter terminal S V: Voltmeter

• Set the voltage at 23V DC. P 10767

CAUTION The voltage that is applied should be limited to 24V maximum. • The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations ranging from measuring the current that flows through the starter to measuring the rotating speed are completed in less than 30 seconds. • Set the switch C to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate.

P 14258

CAUTION When the switch C is set to ON, current is supplied to both the pull-in coil P and holding coil H. When the large current from the DC power supply D is supplied from terminal B of the starter to terminal M, the current to the pull-in coil is interrupted, and current flows to the holding coil only. To prevent baking the holding coil, therefore, all the operations must be completed in less than 30 seconds. • Measure the current and rotating speed of the starter. Measure the rotating speed of the starter by illuminating the pinion 3 with a stroboscope. • Set the switch C to OFF to stop supplying current to the starter. • If the reading is out of the standard value, disassemble and check the starter.

54-47

STARTER <24V–5kW> (2) Pinion gap [Inspection] • Wire the starter as shown.

10768

P 14259

C: Switch D: Switch E: Cable M: Starter terminal M S: Starter terminal S • The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations up to completion of measurement of the pinion gap is completed in less than 30 seconds. • Set the switch C and switch D to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate.

• Immediately (in less than 5 seconds) after the pinion has started rotation, set the switch D to OFF stop rotation of the pinion.

CAUTION

P 14260

P 10769

54-48

When the switch C and switch D are set to ON, current is supplied to both the pull-in coil P and holding coil H. Since wiring is such that no voltage is applied to terminal B of the starter, current flows to the pull-in coil during rotation of the pinion 3. To prevent baking the pull-in coil, therefore, it is necessary that the switch E is set to OFF immediately (in less than 5 seconds) after the pinion has started rotating. • Pull out the overrunning clutch 32 by hand, then push back its end lightly and measure the amount F the clutch moves in the axial direction (pinion gap). • Set the switch C to OFF to stop supplying current to the starter. • If the reading is out of the standard value, replace the lever assembly 33.

54 3 Pinion [Removal] To remove the pinion 3, it is necessary to supply current to the starter and let the pinion spring out.

WARNING P 14267

• When current is supplied to the starter, the pinion 3 will spring out and rotate. Be careful not to touch it by hand. • The magnet switch assembly 5 may be very hot after the end of inspection. Be careful when you touch it.

CAUTION

P 14257

• The time during which current is supplied to the starter should be limited to 10 seconds or less on the pull-in coil P side and 30 seconds or less on the holding coil H side. If current is supplied to the coils for a longer period, the coils will be overheated and baked. • Make sure that the pinion 3 is made to spring out by supplying current to the starter. If the pinion is forced out by pulling the lever assembly 33 without supplying current to the starter, the front bracket 36 and lever could be damaged by the impact produced when the stopper ring 1 is removed. • When current is supplied to the starter, a large current that exceeds 100A will flow. When the starter is inspected, therefore, use thick cables like booster cables. Check to ensure that all the connections are tight and secure. • Wire the starter as shown.

10768

A: Switch C: Switch D: Cable M: Starter terminal M S: Starter terminal S • The following operations are performed by supplying current to the starter. It is therefore necessary that the series of operations up to removal of the pinion 3 is completed in less than 30 seconds. • Set the switch A and switch C to ON to supply current to the starter. At the time, the pinion 3 will spring out and rotate.

P 14259

54-49

STARTER <24V–5kW> • Immediately (in less than 5 seconds) after the pinion 3 has started rotating, set the switch C to OFF to stop rotation of the pinion.

CAUTION

P 14260

When the switch A and switch C are set to ON, current is supplied to both the pull-in coil P and holding coil H. Since wiring is such that no voltage is applied to terminal B of the starter, current flows to the pull-in coil during rotation of the pinion 3. To prevent baking the pull-in coil, therefore, it is necessary that the switch C is set to OFF immediately (in less than 5 seconds) after the pinion has started rotating. • Set the pipe-like tool E on the pinion stopper 2. • Lightly strike the tool E with a hammer to remove the stopper ring 1 from the ring groove F of the pinion stopper 2. • Remove the stopper ring 1 and remove the pinion 3. • Set the switch A to OFF to stop supplying current to the starter.

P 10779

CAUTION When the power supply to the starter is stopped, the pinion 3 may move in and the stopper ring 1 may fit in the ring groove F of the pinion stopper 2 again. In this case, repeat the operations by supplying current to the starter.

[Installation] To install the pinion 3, it is not necessary to supply current to the starter. • Install the pinion stopper 2 and pinion 3 on the overrunning clutch 32 in the direction shown. • Set the stopper ring 1 in the ring groove F of the overrunning clutch 32. P 10781

• Pull the pinion 3 strongly to make sure that the stopper ring 1 securely fits in the ring groove F of the pinion stopper 2.

P 10782

54-50

54 5 Magnet switch [Installation] Install the magnet switch 5 on the lever assembly 33 with terminal S in the direction shown.

P 10771

[Inspection] (1) Open circuit test on coil • Check to ensure that there is continuity between terminals S and M. • If there is no continuity, replace the magnet switch 5.

P 10773

• Check to ensure that there is continuity between terminal M and body A. • If there is no continuity, replace the magnet switch 5.

P 10774

(2) Contact fusion check • Check to ensure that there is no continuity between terminals B and M. • If there is continuity, replace the magnet switch 5.

P 10775

(3) Contact contacting check • Push the end of the magnet switch 5 in to close the internal contact. In this state, check to ensure that there is continuity between terminals B and M. • If there is no continuity, replace the magnet switch 5.

P 10776

54-51

STARTER <24V–5kW> 9 Removal of yoke & brush holder assembly To remove the yoke & brush holder assembly 9, proceed as described below, while using care to prevent damage to the commutator A of the armature assembly 16 by the brushes 11 and 14. • Keep the brushes 11 and 14 apart from the commutator A and hold the brush spring 10 alongside the brushes.

P 16083

• Remove the yoke & brush holder assembly 9 from the front bracket assembly 20.

CAUTION When the yoke & brush holder assembly 9 is removed, do not tilt it downward. Otherwise, the armature assembly 16 may fall down. 20017

• For installation, reverse the order of removal. 10 Inspection of brush spring • Use new brushes 11 and 14 and measure the load at the moment the brush spring 10 leaves the brushes as shown. • If the reading is less than the limit, replace the brush spring 10.

02466

11 14 Inspection of brush (1) Length of brush If the reading is less than the limit, replace the brushes 11 and 14.

CAUTION To replace the brush 02465

11, replace the brush holder assembly 12.

(2) Commutator contacting surfaces If the contacting surfaces are rough or unevenly worn, repair with emery paper (#300 to 500). 12 Inspection of brush holder assembly • Check to ensure that there is no continuity between the side brush holder and side holder plate. • If there is continuity, it means a short circuit. Replace the brush holder assembly 12.

P 02467

54-52

54 13 Inspection of yoke assembly (1) Open circuit test on coil • Check to ensure that there is continuity between cable A and brush 14. • If there is no continuity, it means an open circuit. Replace the brush 14 or yoke assembly 13.

P 02477

(2) Earth test on coil • Check to ensure that there is no continuity between the yoke assembly 13 and brush 14. • If there is continuity, it means a short circuit. Check the insulation. If repair is impossible, replace the brush 14 or yoke assembly 13.

CAUTION P 02478

The coil may be short-circuited to the yoke assembly 13 due to the accumulation of worn-off metal particles from the brushes and/or armature. 16 Inspection of armature assembly (1) Short circuit test on coil • Bring the iron piece A close to the armature assembly 16, keeping it in parallel. B: Armature tester

P 02471

• Slowly rotate the armature assembly 16 by hand. • If the iron piece A is attracted or vibrates, it means a short circuit. Replace the armature assembly 16. (2) Ground test on coil • Check to ensure that there is no continuity between the commutator C and core D (or shaft portion E). • If there is continuity, it means a short circuit. Replace the armature assembly 16.

P 13329

P 13330

(3) Runout of commutator If the reading is more than the limit, repair the outside diameter of the commutator portion C of the armature assembly 16 within the limit. (4) Condition of commutator surface • If the surface is rough or unevenly worn, repair with emery paper (#300 to 500). • After the repair, be sure to check the runout of the commutator portion C.

54-53

STARTER <24V–5kW> (5) Outside diameter of commutator If the reading is more than the limit, replace the armature assembly 16.

P 02474

(6) Depth of mold between segments Before inspection, clean the mold portions. • If the reading is less than the limit, repair or replace the armature assembly 16. F: Depth of mold • Make repairs by grinding the illustrated portion G. P 16078

• If the mold portion is as shown, repair or replace the armature assembly 16.

P 02476

28 Removal of gear shaft and internal gear assembly Remove the E-rings 27 and then the gear shaft and internal gear assembly 28 from the overrunning clutch 32. Proceed as follows if the assembly 28 cannot be removed due to interference of the splined section A of gear shaft assembly 29 with internal parts of the overrunning clutch. • Press the gear shaft assembly 29 against the overrunning clutch 32. • Turn the gear shaft assembly 29 approx. 1/8 of a turn to change the position of splined section A. P 16917

P 16915

54-54

54 32 Inspection of overrunning clutch Perform the following checks. If there is anything wrong, replace the overrunning clutch 32. • Check to ensure that when the shaft A is made to rotate in the direction B, it rotates smoothly. • Check to ensure that when the shaft A is made to rotate in the direction C, it is locked. P 13328

33 Installation of lever assembly Install the lever assembly 33 in the illustrated direction on the overrunning clutch 32.

P 10778

34 Inspection of front bearing • Before the front bearing 34 is press-fitted, install the oil seal 35. • Press-fit the front bearing 34 in the front bracket 36 with a press, using the pipe-like tool A.

P 13325

• Stake the front bracket 36 side.

CAUTION Avoid staking the previously staked points B. C: Staking points (4 places) P 13326

54-55

PREHEATER CIRCUIT 1 Starter switch 2 Heater relay (or glow relay) 3 Heater indicator (vehicles with air heater) Glow plug indicator (vehicles with glow plugs) 4 Intake air heater 5 Glow plug 6 Battery relay (24V specification) Battery switch (12V specification) 7 Battery

<24V (air heater) specification>

18461

<24V (glow plug) specification>

18462

54-56

54 Service standards Location 5

Maintenance item

Standard value

Limit

Remedy

3.8 V

–

Replace

Resistance of glow plug at normal temperature

◆ Service procedure 2

Inspection of heater relay (or glow relay)

(1) Inspection of heater If the fuse A is blown, replace it with one having the same amperage stamped on the fuse.

(2) Inspection of main body • Perform continuity checks according to the following table.

➀

➁

➂

➃

➄ (Body ground)

When no current is supplied When current is supplied P 29090

−

There is continuity between terminals. − Terminals to which battery voltage is applied: DC24V <24V system> DC12V <12V system>

A: Fuse • If there is anything wrong, replace the heater relay (or glow relay) 2.

54-57

PREHEATER CIRCUIT 4

Inspection of intake air heater

(1) Inspection of fuse If there is anything wrong, replace the fuse A (127A). A: Fuse (127A)

18465

(2) Inspection of main body Check the terminals for looseness, and the heater element for damage and loose contact with the glass. • If there is anything wrong, replace the intake air heater 4.

Inspection of glow plug

• Measure the resistance of the glow plug 5 as shown. • If the reading is out of the standard value, replace the glow plug 7. Gr 11

02513

54-58

ENGINE STARTER CIRCUIT 1 2 3 4 5 6 7

Alternator Starter relay Starter Battery relay (24V) Battery Starter switch Safety relay

18466

Service standards Location 7

Maintenance item Safety relay

Standard value

Limit

Remedy

Approx. 200 V

–

Replace

◆ Service procedure 2 Inspection of starter relay • Perform continuity checks according to the following table.

−

When no current is supplied 18017

When current is supplied +

There is continuity between terminals. − Terminals to which 24V DC is applied

• If there is anything wrong, replace the starter relay 2. 7 Inspection of safety relay Measure the resistance value between terminals R-L. If the reading is out of the standard value, replace the safety relay 7.

17530

54-59

GROUP 61 SPECIAL EQUIPMENT SPECIFICATIONS....................................................................................

61-2

STRUCTURE AND OPERATION..............................................................

61-3 61-3

Air Compressor ..........................................................................................................

AIR COMPRESSOR ................................................................................

61-8 <AIR-COOLED (Oldham’s Coupling Type)> .............................................................. 61-8 <AIR-COOLED (Laminated Coupling Type)> ............................................................ 61-16

AIR PRESSURE GOVERNOR.................................................................. 61-23

61-1

SPECIFICATIONS Item Air compressor

Specifications

Type

Air-cooled, single-cylinder

Cylinder bore × stroke mm (in.) Cylinder displacement L (U.S.gal.) Manufacturer

61-2

φ80 × 40 (φ3.15 × 1.57) 201 (0.0531) SANWA SEIKI MFG. CO., LTD

STRUCTURE AND OPERATION Air Compressor <Air-cooled type> <Oldham’s coupling type>

P 18392

1 2 3 4 5 6 7 8 9 10

Delivery valve Cylinder head Unloader valve Unloader valve spring Suction valve Suction valve spring Cylinder liner Compressor gear Crankshaft Crankcase

P 47000

11 12 13 14 15

Bearing holder <Laminated coupling type> Coupling <Oldham’s coupling type> Connecting rod Piston Delivery valve spring

A: From air cleaner B: To air tank C: From air pressure governor

• The air compressor is driven by compressor gear 8 which is in mesh with the timing gear of the engine. • Cylinder head 2 is provided with fins that prevent it from being overheated by the compression heat generated by the air compressor. When air is taken in • When compressor gear 8 is turned, crankshaft 9 in mesh with the compressor gear lowers piston 14. • The vacuum generated at this time opens suction valve 5, allowing air A from the air cleaner to be drawn into cylinder liner 7.

12791

61-3

STRUCTURE AND OPERATION When air is sent under pressure • When piston 14 goes up on the compression stroke, suction valve spring 6 closes suction valve 5. • The compressed-air pressure overcomes the force of delivery valve spring 15, pushing to open delivery valve 1, which results in the air B being sent under pressure to the air tank.

12792

12793

When the unloader valve operates • When the pressure of the air in the air tank builds up to exceed the predetermined level, the air pressure governor operates and compressed air C is sent to unloader valve 3, pushing down the unloader valve. At the same time, the air keeps suction valve 5 open, which means that the air in cylinder liner 7 is not compressed and the air compressor runs under no load. • As the air pressure of the air tank drops below the predetermined level, the air pressure governor is operated again to discharge compressed air C above unloader valve 3. As a result, the unloader valve is returned to its original position by unloader valve spring 4.

<Water-cooled type (Oldham’s coupling type)> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

P18393

Delivery valve Cylinder head Unloader valve Unloader valve spring Suction valve Suction valve spring Piston Cylinder liner Crankcase Compressor gear Bearing Crankshaft Coupling Connecting rod Delivery valve spring

A: From air cleaner B: To air tank C: From air pressure governor

• The air compressor is driven by compressor gear 10 which is in mesh with the timing gear of the engine. • To prevent cylinder head 2 from being overheated by the compression heat generated by the air compressor, coolant is introduced from the oil cooler to cool down each valve of the cylinder head. It is then returned to the rear end of the engine cylinder head.

61-4

61 When air is taken in • When compressor gear 10 is turned, crankshaft 12 in mesh with the compressor gear lowers piston 7. • The vacuum generated at this time opens suction valve 5, allowing air A from the air cleaner to be drawn into cylinder liner 8.

18394

When air is sent under pressure • When piston 7 goes up on the compression stroke, suction valve spring 6 closes suction valve 5. • The compressed-air pressure overcomes the force of delivery valve spring 15, pushing to open delivery valve 1, which results in the air B being sent under pressure to the air tank.

18395

18396

When the unloader valve operates When the pressure of the air in the air tank builds up to exceed the predetermined level, the air pressure governor operates and compressed air C is sent to unloader valve 3, pushing down the unloader valve. At the same time, the air keeps suction valve 5 open, which means that the air in cylinder liner 8 is not compressed and the air compressor runs under no load. As the air pressure of the air tank drops below the predetermined level, the air pressure governor is operated again to discharge compressed air C above unloader valve 3. As a result, the unloader valve is returned to its original position by unloader valve spring 4.

61-5

STRUCTURE AND OPERATION <Water-cooled type (Laminated coupling type)> 1 2 3 4 5 6 7 8 9 10 11

Delivery valve Suction valve Compressor gear Crankshaft Crankcase Bearing holder Connecting rod Piston Cylinder liner Valve seat assembly Cylinder head assembly

A: From air cleaner B: To air tank

P 47001

When air is taken in • As compressor gear 3 is driven, crankshaft 4 which is meshed with the compressor gear is also driven. As a result, piston 8 moves down. • This creates vacuum which then opens suction valve 2. As a result, air A is sucked from the air cleaner and flows into cylinder liner 9.

22282

When air is sent out under pressure • As piston 8 moves up in the compression stroke, suction valve 2 is closed by compressed air B. • Air B compressed by piston 8 opens delivery valve 1 and flows to the air tank.

22283

61-6

MEMO

61-7

AIR COMPRESSOR <AIR-COOLED (OLDHAM’S COUPLING TYPE)> ● Removal sequence 1 Unloader pipe 2 Connector 3 Eyebolt 4 Air outlet pipe 5 Eyebolt 6 Air inlet pipe 7 Air compressor assembly 8 O-ring

P.61-10

*a: Injection pump assembly Gr 13 *b: Oil pipe Gr 13 *c: Flywheel housing Gr 11 : Non-reusable part

P 46992

● Installation sequence Reverse the order of removal.

Tightening torques Location

Parts to be tightened

Unit: N·m (kgf·m) [lbf·ft]

Tightening torque

Remarks

20 to 25 (2.0 to 2.5) [14.8 to 18.4]

–

14.7 to 21.5 (1.5 to 2.2) [10.8 to 15.9]

–

Unloader pipe

Connector

Eyebolt (for air outlet pipe installation)

130 (13) [96.0]

–

Eyebolt (for air inlet pipe installation)

110 (11) [81.1]

–

Lubricant Location 8

Points of application O-ring

Specified lubricant Engine oil

61-8

Quantity As required

61 ◆ Service procedure 7 Installation of air compressor assembly • Set cylinder No. 1 of the engine at TDC in the compression stroke. Gr 11 • After aligning inscribed lines A with each other, install air compressor assembly 7 to flywheel housing *c.

35653

• Remove inspection plug B and check if inscribed line A is aligned with pointer C. • If not aligned, remove and refit air compressor assembly 7.

35654

61-9

AIR COMPRESSOR <AIR-COOLED (OLDHAM’S COUPLING TYPE)> Air Compressor Assembly

P 46993

61-10

61 ● Disassembly sequence 1 Nut 2 Lock washer 3 Compressor gear 4 Spacer 5 Bolt 6 Coupling 7 Bolt 8 Connector 9 Gasket 10 Snap ring 11 Unloader valve 12 Unloader valve spring 13 Unloader valve guide 14 Suction valve holder 15 Suction valve spring 16 Suction valve 17 Suction valve seat

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Suction valve gasket Nut Delivery valve holder Suction valve gasket Delivery valve Delivery valve spring Spring holder Gasket Cylinder head Bolt Cylinder liner O-ring 1st compression ring 2nd compression ring 3rd compression ring Oil ring Snap ring

35 36 37 38 39 40 41 42 43 44 45 46 47

Piston pin Piston Nut Lock washer Connecting rod Bearing Bolt Connecting-rod cap Crankshaft Bolt Plate Bearing Crankcase : Non-reusable parts

P : Locating pin

● Reassembly sequence Reverse the order of disassembly.

Service standards Location

Unit: mm (in.)

Maintenance item

Suction valve spring load [Installed length: 9 mm (0.354 in.)]

Suction valve spring load

29, 36

30 to 33

30 to 33, 36

35, 36 35, 39 39 42, 43 43 43, 47

Clearance between piston and cylinder liner

Top

Skirt [Basic diameter: 80 mm (3.15 in.)] Piston ring gap (as measured inside Compression cylinder liner) ring Oil ring Clearance between piston ring and Compression piston groove ring Oil ring Clearance between piston pin and piston [Basic diameter: 16 mm (0.630 in.)] Clearance between piston pin and connecting-rod small end [Basic diameter: 16 mm (0.630 in.)] Connecting rod end play

Standard value

Limit

Remedy

2.3 N (0.23 kgf) [0.52 lbf] 3.2 N (0.33 kgf) [0.72 lbf] 0.27 to 0.33 (0.016 to 0.0130) 0.11 to 0.17 (0.00433 to 0.00670) –

1.3 N (0.13 kgf) [0.29 lbf] 2.4 N (0.24 kgf) [0.54 lbf] 0.35 (0.0138) 0.19 (0.00748) 1.0 (0.0394) 1.0 (0.0394) 0.08 (0.00315) 0.08 (0.00315) 0.08 (0.00315) 0.07 (0.00276)

Replace

– – – – – –

0.5 (0.0197)

Clearance between connecting-rod bearing and crankshaft [Basic diameter: 34 mm (1.34 in.)] Crankshaft end play

–

0.1 (0.0394)

–

Clearance between crankshaft and crankcase bushing I.D. [Basic diameter: 76.5 mm (3.01 in.)]

–

1.0 (0.0394) 0.12 (0.00472)

Replace Replace cylinder liner Replace

Replace

Replace piston pin Replace connecting rod Replace connecting rod Replace Replace crankshaft Replace crankshaft

61-11

AIR COMPRESSOR <AIR-COOLED (OLDHAM’S COUPLING TYPE)> Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

Nut (for compressor gear installation)

165 to 211 (17 to 21.5) [122 to 156]

–

Bolt (for coupling installation)

30 to 36 (3.1 to 3.7) [22.1 to 26.6]

–

Bolt (for cylinder head installation)

25 to 29 (2.5 to 3.0) [18.4 to 21.4]

–

Connector

29 to 34 (3.0 to 3.5) [21.4 to 25.1]

–

Unloader valve guide

98 to 118 (10 to 12) [72.3 to 87.0]

–

Suction valve holder

98 to 118 (10 to 12) [72.3 to 87.0]

–

Nut

44 to 58 (4.5 to 6.0) [32.5 to 42.8]

–

Delivery valve holder

98 to 118 (10 to 12) [72.3 to 87.0]

–

Bolt (for installation of cylinder liner and crankcase)

25 to 29 (2.5 to 3.0) [18.4 to 21.4]

–

Nut (for installation of connecting rod and connecting-rod cap)

23 to 25 (2.3 to 2.6) [17.0 to 18.4]

–

Bolt (for plate installation)

14 to 18 (1.4 to 1.8) [10.3 to 13.3]

–

Special tools Location

Unit: mm (in.)

Tool name and shape

Suction Valve Tool

Part No.

Application

MH062013

For removal and installation of suction valve holder

MH062014

For removal and installation of delivery valve holder

MH060014

For removal and installation of piston rings

01730

Delivery Valve Tool

04813

30 to 33

Piston Ring Tool

01732

61-12

61 ◆ Service procedure 3 Installation of compressor gear • Install compressor gear 3 to crankshaft 43, ensuring that the “0” mark on the gear is aligned with the “0” mark on the crankshaft. • Insert tab A of lock washer 2 such that the “0” mark on compressor gear 3 remains exposed.

35656

• Tighten nut 1 to the specified torque. Lock the nut by bending bottom portion B of lock washer 2 over the nut.

04894

14 Suction valve holder [Removal and Installation]

04814

[Staking] Stake cylinder head 26 at points not corresponding to O-ring’s sealing surface A. B: Punch

01736

Removal and installation of delivery valve holder

04815

61-13

AIR COMPRESSOR <AIR-COOLED (OLDHAM’S COUPLING TYPE)> 30 to 33 Piston rings [Removal and Installation] : Piston Ring Tool

01738

[Installation positions] A: Inscription of letters B: Gap in 2nd compression ring 31 C: Gap in 1st compression ring 30 D: Side rail gap in oil ring 33 E: Spacer gap in oil ring 33 F: Gap in 3rd compression ring 32

P 46994

39 Assembling connecting rod • Assemble connecting rod cap 42 onto connecting rod 39 such that inscribed numerical figures A are located on the same side. • Install bolts 41 in such a way that the notches in the bolt heads are directed toward the inside of connecting rod cap 42. • After tightening the nuts, bend lock washers 38.

09645

61-14

MEMO

61-15

AIR COMPRESSOR <AIR-COOLED (LAMINATED COUPLING TYPE)> ● Removal sequence 1 Unloader pipe 2 Connector 3 Eyebolt 4 Air outlet pipe 5 Eyebolt 6 Air inlet pipe 7 Air compressor assembly 8 O-ring

P.61-18

*a: Injection pump assembly Gr 13 *b: Oil pipe Gr 13 *c: Flywheel housing Gr 11 : Non-reusable part

P 46966

● Installation sequence Reverse the order of removal.

Tightening torques Location

Parts to be tightened

Unit: N·m (kgf·m) [lbf·ft]

Tightening torque

Remarks

20 to 25 (2.0 to 2.5) [14.8 to 18.4]

–

14.7 to 21.5 (1.5 to 2.2) [10.8 to 15.9]

–

Unloader pipe

Connector

Eyebolt (for air outlet pipe installation)

130 (13) [96.0]

–

Eyebolt (for air inlet pipe installation)

110 (11) [81.1]

–

Lubricant Location 8

Points of application O-ring

Specified lubricant Engine oil

61-16

Quantity As required

35653

• Remove inspection plug B and check if inscribed line A is aligned with pointer C. • If not aligned, remove and refit air compressor assembly 7.

35654

61-17

AIR COMPRESSOR <AIR-COOLED (LAMINATED COUPLING TYPE)> Air Compressor Assembly

P46967

61-18

61 ● Disassembly sequence 1 Nut 2 Lock washer 3 Compressor gear 4 Collar 5 Bolt 6 Connector 7 Gasket 8 Snap ring 9 Unloader valve 10 Unloader valve spring 11 Unloader valve guide 12 Suction valve holder 13 Suction valve spring 14 Suction valve 15 Suction valve seat 16 Suction valve gasket

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Nut Delivery valve holder Suction valve gasket Delivery valve Delivery valve spring Spring holder Gasket Cylinder head Bolt Cylinder liner O-ring 1st compression ring 2nd compression ring 3rd compression ring Oil ring Snap ring

Piston pin Piston Nut Lock washer Connecting rod Bolt Connecting-rod cap Bolt Oil seal Bearing holder O-ring Bearing Crankshaft Crankcase

33 34 35 36 37 38 39 40 41 42 43 44 45 46

: Non-reusable part

● Reassembly sequence Reverse the order of disassembly.

Service standards Location

Unit: mm (in.)

Maintenance item

Suction valve spring load [Installed length: 9 mm (0.354 in.)]

Suction valve spring load [Installed length: 5 mm (0.197 in.)]

26, 34

28 to 31

28 to 30, 34

33, 37 37 37, 45 45

Clearance between piston and cylinder liner

Top

Skirt [Basic diameter: 80 mm (3.15 in.)] Piston ring gap (as measured inside Compression cylinder liner) ring Oil ring

Standard value

Limit

Remedy

2.3 N (0.23 kgf) [0.52 lbf] 3.2 N (0.33 kgf) [0.72 lbf] 0.27 to 0.33 (0.016 to 0.0130) 0.11 to 0.17 (0.00433 o 0.00670) –

1.3 N (0.13 kgf) [0.29 lbf] 2.4 N (0.24 kgf) [0.54 lbf] 0.35 (0.0138) 0.19 (0.00748) 1.0 (0.0394) 1.0 (0.0394) 0.08 (0.00315) 0.08 (0.00315) 0.07 (0.00276)

Replace

–

Piston ring to piston groove Compression clearance ring Piston pin to piston clearance [Basic diameter: 16 mm (0.630 in.)] Piston pin to connecting rod small end clearance

–

[Basic diameter: 16 mm (0.630 in.)] Connecting rod end play

–

0.5 (0.0197)

Connecting rod big end to crankshaft clearance

–

0.1 (0.0394)

[Basic diameter: 34 mm (1.34 in.)] Crankshaft end play

–

1.0 (0.0394)

–

Replace Replace cylinder liner Replace

Replace Replace piston pin Replace connecting rod Replace connecting rod Replace connecting rod Replace bearing and/or crankshaft

61-19

AIR COMPRESSOR <AIR-COOLED (LAMINATED COUPLING TYPE)> Tightening torques Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

Nut (for compressor gear installation)

165 to 211 (17 to 21.5) [122 to 156]

–

Bolt (for cylinder head assembly installation)

29 to 34 (3.0 to 3.5) [21.4 to 25.1]

–

Connector

29 to 34 (3.0 to 3.5) [21.4 to 25.1]

–

Unloader valve guide

98 to 118 (10 to 12) [72.3 to 87.0]

–

Suction valve holder

98 to 118 (10 to 12) [72.3 to 87.0]

–

Nut

44 to 58 (4.5 to 6.0) [32.5 to 42.8]

–

Delivery valve holder

98 to 118 (10 to 12) [72.3 to 87.0]

–

Bolt (for cylinder liner installation)

25 to 29 (2.5 to 3.0) [18.4 to 21.4]

–

Nut (for installation of connecting rod cap and connecting rod )

23 to 26 (2.3 to 2.6) [17.0 to 19.2]

–

Bolt (for bearing holder installation)

14 to 18 (1.4 to 1.8) [10.3 to 13.3]

–

Special tools Location

Unit: mm (in.)

Tool name and shape

Suction Valve Tool

Part No.

Application

MH062013

For removal and installation of suction valve holder

MH062014

For removal and installation of delivery valve holder

MH060014

For removal and installation of piston rings

01730

Delivery Valve Tool

04813

28 to 31

Piston Ring Tool

01732

61-20

61 ◆ Service procedure 3 Installation of compressor gear • Install compressor gear 3 to crankshaft 45, ensuring that the “0” mark on the gear is aligned with the “0” mark on the crankshaft. • Insert tab A of lock washer 2 such that the “0” mark on compressor gear 3 remains exposed.

35656

• Tighten nut 1 to the specified torque. Lock the nut by bending bottom portion B of lock washer 2 over the nut.

04894

12 Suction valve holder [Removal and Installation] : Suction Valve Tool

04814

[Staking] Stake cylinder head 24 at points not corresponding to O-ring’s sealing surface A. B: Punch

01736

Removal and installation of delivery valve holder : Delivery Valve Tool

04815

61-21

AIR COMPRESSOR <AIR-COOLED (LAMINATED COUPLING TYPE)> 28 to 31 Piston rings [Removal and Installation] : Piston Ring Tool

09643

[Installation positions] A: Inscription of letters B: Side rail C: Spacer D: Gap in 2nd compression ring 29 E: Gap in 1st compression ring 28 F: Side rail gap in oil ring 31 G: Spacer gap in oil ring 31 H: Gap in 3rd compression ring 30

P 36519

37 Assembling connecting rod • Assemble connecting rod cap 39 onto connecting rod 37 such that inscribed numerical figures A are located on the same side. • Install bolts 38 in such a way that the notches in the bolt heads are directed toward the inside of connecting rod cap 39. • After tightening the nuts, bend lock washers 36.

09645

41 Installing oil seal Face oil seal 41 as shown in the illustration. Then, fit it in bearing holder 42 by pressing evenly until it is flush with end face A of the holder.

P 46829

61-22

AIR PRESSURE GOVERNOR ● Disassembly sequence 1 Cover 2 Nut 3 Adjusting screw 4 Spring 5 Nut 6 Sleeve 7 O-ring 8 Snap ring 9 Filter 10 Screen 11 Cap 12 Diaphragm : Non-reusable parts ● Reassembly sequence Reverse the order of disassembly. ● Adjustment after reassembly P.61-8

18426

Tightening torque Location

Unit: N·m (kgf·m) [lbf·ft]

Parts to be tightened

Tightening torque

Remarks

Nut (for tightening of adjusting screw)

9.8 to 15 (1 to 1.5) [7.2 to 11.1]

–

Nut (for tightening of sleeve)

15 to 20 (1.5 to 2) [11.1 to 14.8]

–

61-23