Cat DP150N Forklift Service Manual free download by engineparts2

Service Manual Chassis, Mast & Options DP100N DP120N DP135N DP150N DP160N

T36A-10011-up T37A-10011-up T38A-10011-up T39A-10011-up T40A-10011-up

Includes Mitsubishi 6M60-TL Engine Service Manual Pages 531 - 860

Cat DP150N Forklift Engine Parts Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 1 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com www.dp150.com/cat-dp150-engine-parts

99799-63100

FOREWORD This service manual is a guide for servicing CatÂŽ lift trucks. For your convenience the instructions are grouped by systems as a ready reference. The long productive life of your lift truck(s) depends on regular and proper servicing. Servicing consistent with what you will learn by reading this service manual. Read the respective sections of this manual carefully and familiarize yourself with all of the components before attempting to start a test, repair or rebuild job. The descriptions, illustrations and specifications contained in this manual are for trucks with serial numbers in effect at the time of printing. Cat Lift Trucks reserves the right to change specifications or design without notice and without incurring obligation. DP100N, DP120N, DP135N, DP150N and DP160N are powered by Mitsubishi 6M60-TL diesel engine. For engine servicing, please refer to the 6M60-TL diesel engine service manual Publication Number 99709-61100 included on pages 531 - 860 .

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

WARNING

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

CAUTION

Indicates a specific potential hazard resulting in bodily injury, or damage to, or destruction of, the lift truck.

NOTE

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

Pub. No. 99799-63100 1

SAFETY WARNING Do not operate this truck unless you have read and understand the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death. The proper and safe lubrication and maintenance for this lift truck, recommended by Cat Lift Trucks, are outlined in the OPERATION & MAINTENANCE MANUAL for these trucks. The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makes it important to use caution when performing service work. A knowledge of the system and/or components is important before the removal or disassembly of any component. Because of the size of some of the truck components, the serviceman or mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components. Following is a list of basic precautions that should always be observed. (1) Read and understand all warning plates and decals on the truck before operating, lubricating or repairing the product. (2) Always wear protective glasses and protective shoes when working around trucks. In particular, wear protective glasses when pounding on any part of the truck or its attachments with a hammer or sledge. Use welders gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery. (3) Do not work on any truck that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the truck before performing any disassembly.

WARNING 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.

(4) Lower the forks or other implements to the ground before performing any work on the truck. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly. (5) Use steps and grab handles (if applicable) when mounting or dismounting a truck. Clean any mud or debris from steps, walkways or work platforms before using. Always face truck when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations. (6) To avoid back injury, use a hoist when lifting components which weigh 23 kg (50 lb.) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. (7) To avoid burns, be alert for hot parts on trucks which have just been stopped and hot fluids in lines, tubes and compartments. (8) Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure, before removing the last two bolts or nuts completely. (9) Be careful when removing filler caps, breathers and plugs on the truck. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the truck has just been stopped because fluids can be hot. (10) Always use tools that are in good condition and be sure you understand how to use them before performing any service work. (11) Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. Do not mix metric fasteners with standard nuts and bolts. (12) If possible, make all repairs with the truck parked on a level, hard surface. Block truck so it does not roll while working on or under truck. (13) Disconnect battery and discharge any capacitors (electric trucks) before starting to work on truck. Hang “Do not Operate” tag in the Operator’s Compartment. (14) Repairs, which require welding, should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding proce-

dure 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 Disassembly diagram (example)

The suggestion for disassembly is shown below. 2 Index numbers show the sequence of 1 disassembly.

209603

Sequence 1 Cover, Bolt, Washer (part name) 2 Output shaft (part name)

Suggestion for disassembly (1) Output shaft removal

209604

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)

Clearance between cylinder and piston

Standard valve Repair service unit

0.020 to 0.105 mm (0.00079 to 0.00413 in.) 0.15 mm (0.059 in.)

GROUP INDEX GROUP INDEX

Items

GENERAL INFORMATION

Model View, Truck Models Covered, Serial Number Locations, Main Specifications, Chassis and Mast Model Identification, Dimensions, Technical Data

COOLING SYSTEM

Specifications, Structure, Suggestions for Removal and Installation, Troubleshooting

ELECTRICAL SYSTEM

Specifications, Location of Components, Structure, Disassembly and Reassembly, Batteries and Charging, Troubleshooting, Electrical Wiring Diagram

CONTROLLER

Outline, Service Tool Functions, Error Code List, Troubleshooting

TILTABLE SYSTEM

Specifications, Structure, Oil supply, Hydraulic circuit diagram, Service Data

POWER TRAIN

Specifications, Structure, Reduction ratio, Removal and Installation of Engine and Transmission Unit

POWERSHIFT TRANSMISSIONS

3-Speed Powershift Transmission Specifications, Description, Suggestions for Removal and Installation, Disassembly and Reassembly, Adjustment, Troubleshooting, Service Data

FRONT AXLE AND REDUCTION DIFFERENTIAL

Specifications, Structure, Suggestions for Removal and installation, Front Axle and Reduction Differential, Disassembly and Reassembly, Troubleshooting, Service Data

REAR AXLE

Specifications, Structure, Suggestions for Removal and Installation, Disassembly and Reassembly, Readjustment, Troubleshooting, Service Data

BRAKE SYSTEM

Specifications, Structure, Suggestions for Removal and Installation, Disassembly and Reassembly, Adjustment and Testing, Troubleshooting, Service Data

STEERING SYSTEM

Specifications, Structure, Procedure and Suggestions for Removal and Installation, Troubleshooting, Service Data

HYDRAULIC SYSTEM

Specifications, Structure, Suggestions for Removal and Installation, Priority valve, Lift cylinder, Tilt cylinder, Inspection and Adjustment, Tests, Troubleshooting, Service Data

MASTS AND FORKS

Specifications, Structure, Suggestions for Removal and Installation, Mast assembly, Troubleshooting, Service Data

FORK POSITIONER

Applicable Attachment Model, Specifications, Structure, Suggestions for Removal and installation, Fork positioner cylinder, Inspection and Adjustment, Troubleshooting, Service Data

SERVICE DATA

Maintenance Chart. Tightening torque of standard bolts, Lubrication Standards

GENERAL INFORMATION 1. Model View................................................................................................................... 1-2 2. Truck Models Covered ................................................................................................. 1-2 3. Serial Number Locations.............................................................................................. 1-3 4. Main specifications....................................................................................................... 1-4 5. Chassis and Mast Model Identification......................................................................... 1-5 6. Dimensions (Approximate)........................................................................................... 1-6

1-1

GENERAL INFORMATION

1. Model View

212161

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

Transmission

Model code - Serial number

Engine mounted

DP100N

Powershift

T36A-10011-up

Mitsubishi 6M60-TL diesel engine

DP120N

Powershift

T37A-10011-up

Mitsubishi 6M60-TL diesel engine

DP135N

Powershift

T38A-10011-up

Mitsubishi 6M60-TL diesel engine

DP150N

Powershift

T39A-10011-up

Mitsubishi 6M60-TL diesel engine

DP160N

Powershift

T40A-10011-up

Mitsubishi 6M60-TL diesel engine

Cat DP150N Forklift Mitsubishi 6M60TL Engine Parts Contact Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 1 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com www.dp150.com/cat-dp150-engine-parts

1-2

GENERAL INFORMATION

3. Serial Number Locations Chassis serial number

Mast serial number

Name plate

Transmission serial number

Engine model 216162

1-3

GENERAL INFORMATION

4. Main specifications Truck model Designation

DP100N

DP120N

DP135N

DP150N

DP160N

T36A

T37A

T38A

T39A

T40A

Type

Standard (with 3-speed powershift transmission)

Capacity/load center

10000/600 kgf/mm (17500/24 lbf/in.)

13500/600 kgf/mm (17500/24 lbf/in.)

12000/600 kgf/mm (20000/24 lbf/in.)

Lift

General

Lift speed (unloaded/ loaded)

480/360 mm/sec (104/98 fpm)

400/310 mm/sec (79/61 fpm)

370/310 mm/sec (73/61 fpm)

Lowering speed (unloaded/ loaded)

500/450 mm/sec (98/89 fpm)

510/380 mm/sec (100/75 fpm)

470/420 mm/sec (93/83 fpm)

15˚– 12˚

Free lift Travel speeds (unloaded/ loaded)

0 Forward 29/24.5 km/h (18/15 mph)

4060 mm (160 in.)

4160 mm (164 in.)

4550 mm (179 in.)

4815 mm (190 in.)

78˚27′

–

Outside

51˚14′

–

3550 mm (140 in.)

3590 mm (141 in.)

3680 mm (145 in.)

3830 mm (151 in.)

–

At 1.6 km/h (1 mph)

30%

27%

26%

27%

29%

At 2 km/h (1.2 mph)

21%

19%

15%

14%

10.00-20-14PR (I)

10.00-20-16PR (I)

12.00-20-18PR (I)

12.00-20-20PR (I)

700 kPa (7.0 kgf/cm2) [101 psi]

800 kPa (8.0 kgf/cm2) [116 psi]

800 kPa (7.7 kgf/cm2) [94 psi]

–

Weight

14800 kg (32630 lb)

16060 kg (28800 lb)

17700 kg (39020 lb)

18050 kg (39790 lb)

18950 kg (41780 lb)

Front axle loading

7450 kg (16420 lb)

7340 kg (16180 lb)

7850 kg (17310 lb)

8190 kg (18050 lb)

8910 kg (19640 lb)

Rear axle loading

7350 kg (16200 lb)

8720 kg (19250 lb)

9850 kg (21720 lb)

9860 kg (21730 lb)

10040 kg (22130 lb)

Gradeability (rated load)

Size of tires (front and rear) Inflation pressure of tires (front and rear)

1-4

4000 mm (157 in.)

Inside

Minimum intersecting aisle

Weight and axle loading (unload )

30/22.0 km/h (19/14 mph)

Reverse

Minimum turning radius Turning angle

Tires

16000/600 kgf/mm (17500/24 lbf/in.)

3300 mm (130 in.)

Tilt angle (forward-backward)

Performance

15000/600 kgf/mm (20000/24 lbf/in.)

GENERAL INFORMATION

5. Chassis and Mast Model Identification [Chassis] DP

100N

Maximum capacity DP100N: 10000 kg DP150N: 15000 kg DP120N: 12000 kg DP160N: 16000 kg DP135N: 13500 kg Engine type DP: Diesel engine type [Mast] 3

P 100

Maximum lifting height ["30" stand for 3000 mm] Order of the minor change ("A" for the original, "B" for the first change, "C" for the second change, and so on) Applicable truck model designation 100: 10.0 ton class 115: 11.5 ton class 135: 13.5 ton class 150: 15.0 ton class Kind of mast B: simplex mast (For DP150) P: triplex mast (For DP100, 115, 135) Major change ("2" for the original, "3" for the first change, and so on up to "9")

1-5

GENERAL INFORMATION

6. Dimensions (Approximate)

I C

D M L B

K F 212163

1-6

GENERAL INFORMATION

No.

Truck model

DP100N

DP120N

DP135N

DP150N

DP160N

88 mm (3.5 in.)

92 mm (3.6 in.)

Lift

3300 mm (130 in.)

Fork length

1220 mm (48 in.)

Fork width

Fork thickness

Tilt angle (forward-backward)

Overall length

Overall width (outside of tires)

2515 mm (99 in.)

2600 mm (102 in.)

5040 mm (198 in.)

Overall height (to top of mast lowered)

3235 mm (127 in.)

3480 mm (137 in.)

3680 mm (145 in.)

Tread (front)

1900 mm (75 in)

Tread (rear)

1765 mm (77 in)

Wheelbase

Front overhang

Ground clearance (at frame)

Minimum turning radius

180 mm (7.1 in.) 72 mm (2.8 in.)

79 mm (3.1 in.)

88 mm (3.5 in.) 15˚–12˚

4295 mm (169 in.) 4375 mm (172 in.) 4530 mm (178 in.) 4830 mm (190 in.) 5040 mm (198 in.)

1905 mm (75 in) 1925 mm (76 in)

2800 mm (110 in) 755 mm (29.7 in.)

765 mm (30 in.)

275 mm (10.8 in.)

795 mm (31.3 in.)

1890 mm (74 in)

3100 mm (122 in)

3300 mm (130 in)

795 mm (31.3 in.)

805 mm (31.7 in.)

320 mm (12.6 in.)

4000 mm (157 in.) 4060 mm (160 in.) 4160 mm (164 in.) 4550 mm (179 in.) 4815 mm (190 in.)

1-7

COOLING SYSTEM 1. Specifications ............................................................................................................... 2-2 2. Structure....................................................................................................................... 2-3 3. Suggestions for Removal and Installation.................................................................... 2-4 3.1 Removing radiator and intercooler........................................................................................................ 2-4 3.1.1 Preparation.................................................................................................................................................. 2-4 3.1.2 Removal sequence ..................................................................................................................................... 2-4 3.1.3 Suggestions for Removal and Installation................................................................................................... 2-5 3.1.4 Inspection and Repair ................................................................................................................................. 2-5 3.1.5 Installation ................................................................................................................................................... 2-6

4. Troubleshooting ........................................................................................................... 2-8

2-1

COOLING SYSTEM

1. Specifications Truck model Cooling method Cooling system

Radiator type Oil cooler type Coolant capacity

2-2

DP100N

DP120N

DP135N

DP150N

DP160N

Forced circulation of coolant Corrugated fins with pressure cap (oil cooler integral type) Plate fin type 23 Liters (4.7 U.S. gal.)

COOLING SYSTEM

2. Structure

Detail oil cooler

4 2

1 7 9

To torque converter From torque converter 212164

1 Intercooler

6 Drain cock

2 Intake hose

7 Upper hose

3 Outlet hose

8 Lower hose

4 Radiator

9 Reserve tank

5 Oil cooler

The cooling system has corrugated fins for the radiator and a cooling fan with eight blades which enhances the cooling efficiency.

The oil cooler for the torque converter, equipped in the lower tank of radiator, is a water-cooled type which utilizes the engine cooling water to enhance the cooling efficiency of torque converter fluid.

COOLING SYSTEM

3. Suggestions for Removal and Installation 3.1 Removing radiator and intercooler 3.1.1 Preparation Open the drain cock to drain coolant from radiator.

WARNING Make sure the coolant temperature is not hot and the radiator cap is removed before opening the drain cock.

3.1.2 Removal sequence

1 Engine cover, Gas spring

8 Radiator hose (lower)

2 Radiator cover

9 Clamp

3 Reservoir tank hose

10 Oil cooler pipe

4 Fan guard

11 Intercooler mount, Grommet, Collar, Washer

5 Intake hose of intercooler

12 Intercooler

6 Outlet hose of intercooler

13 Radiator mount, Grommet, Collar, Washer

7 Radiator hose (upper)

14 Radiator

2-4

COOLING SYSTEM

3.1.3 Suggestions for Removal and Installation

(1) Intercooler (a) Attach a lifting hook through the top mounting bolt holes on the left hand and right hand brackets of the intercooler.

(b) Hitch a rope to the hook and lift with a crane. Weight of intercooler

9 kg (20 lb.)

(2) Radiator (a) Support the radiator with crane. (b) Remove the radiator mount (four places) and lift the radiator. Weight of radiator

30 kg (66 lb.)

3.1.4 Inspection and Repair

(1) Intercooler (a) Replace any rubber mount which is inelastic or hardened.

(b) When foreign matters, such as insects and dust, have been adhered to the fins of the core, blow them out with compressed air from the opposite side and remove them, taking care not to damage the fins. Wear goggles for the sake of safety.

(d) Check the intercooler hoses (upper, lower) for bulge, damage to the hose clamp sections. Replace them if any abnormality is found.

2-5

COOLING SYSTEM

(2) Radiator (a) Replace any rubber mount which is inelastic or hardened.

(b) When foreign matters, such as insects and dust, have been adhered to the fin of the core, wash them out with pressurized water from the opposite side and remove remaining foreign matters carefully so as not to damage the water pipes.

(d) Check the radiator hoses (upper, lower) for bulge, damage to the hose clamp sections. Replace them if any abnormality is found. 3.1.5 Installation Follow the removal procedure in reverse while noting the following instructions.

(1) Intercooler (a) Lower and align the bottom bolt holes with the mounting pin of the frame mount. A

Collar

Washer

Bolt

Nut Washer

Washer

Grommet

Detail A

(2) Hose (a) Connect each hose to intercooler or radiator making sure the end of the hose reaches the base of the fitting. Tighten the clamp and make sure the hose end is stopped at the flare of the fitting and can not come off of the fitting.

2-6

212138

COOLING SYSTEM

(3) Antifreeze and coolant (a) Mix the coolant with antifreeze to specified concentration, and fill the radiator with it until the fluid level comes to the top of the inlet.

(b) In addition, fill the reserve tank with the mixed solution to the specified level.

(d) If coolant in reserve tank decreases, supply the mixed solution to the specified range. 101641

Fill within this range.

10465B

2-7

COOLING SYSTEM

4. Troubleshooting Radiator has been corroded due to prolonged activity or others Water leaks from radiator

Engine overheat

Oil leaks from oil cooler hose

2-8

Repair corroded part or replace if there is remarkable corrosion.

Deterioration of upper or lower hose

Replace.

Poor tightening of hose clamp

Retighten or replace.

Faulty drain cock

Replace drain cock.

Cracks occurred in engine cooling system, overheating

Inspect and repair engine cooling system.

Clogging of radiator fins

Clean tubes with copper or steel wire so as not to damage them.

Extreme deformation of fin

Repair or replace the fin.

Loosened fan belt and water pump belt

Check belts for tension, elongation and crack due to ageing, and replace if there is any defect.

Defective thermostat

Inspect and repair, or replace.

Insufficient coolant

Refill.

Poor tightening of hose clamp

Retighten or replace.

Oil cooler has been corroded due to prolonged activity or others

Repair corroded part or replace if there is remarkable corrosion.

ELECTRICAL SYSTEM 1. Specifications ............................................................................................................... 3-2 2. Location of Components .............................................................................................. 3-3 3. Structure....................................................................................................................... 3-4 3.1 Console box .......................................................................................................................................... 3-4 3.2 OK Monitor............................................................................................................................................ 3-5 3.3 Major Components................................................................................................................................ 3-6 3.3.1 ECU (Electronic Control Unit) ..................................................................................................................... 3-6 3.3.2 Starter Switch (Anti-restart Type)................................................................................................................ 3-7 3.3.3 Lighting switch............................................................................................................................................. 3-8 3.3.4 Fuse box ..................................................................................................................................................... 3-8 3.3.5 Spare terminal............................................................................................................................................. 3-9 3.3.6 Lamp Bulb Specifications............................................................................................................................ 3-9

4. Disassembly and Reassembly ................................................................................... 3-10 4.1 Disassembly of Console Box .............................................................................................................. 3-10 4.1.1 Disassembly sequence ............................................................................................................................. 3-10 4.1.2 Reassembly .............................................................................................................................................. 3-10

4.2 Combination Meter.............................................................................................................................. 3-11 4.2.1 Disassembly.............................................................................................................................................. 3-11 4.2.2 Reassembly .............................................................................................................................................. 3-11

4.3 Electrical Components in the Console Box......................................................................................... 3-12

5. Batteries and Charging .............................................................................................. 3-13 5.1 Battery Conditions and Adjustment Method Based on the Electrolyte Specific Gravity (S.G.) ........... 3-13 5.2 Relationship between Electrolyte S.G. and Charging Capacity .......................................................... 3-13 5.3 Precautions for Battery Charging........................................................................................................ 3-13 5.4 Precautions for Servicing the Charging System with Alternator ......................................................... 3-14

6. Troubleshooting ......................................................................................................... 3-15 6.1 Starter System .................................................................................................................................... 3-15 6.2 Gauges ............................................................................................................................................... 3-15 6.3 Lighting System .................................................................................................................................. 3-16 6.4 Alarm Unit ........................................................................................................................................... 3-17 6.5 Battery................................................................................................................................................. 3-18

7. Electrical Wiring Diagram........................................................................................... 3-19

3-1

ELECTRICAL SYSTEM

1. Specifications Truck model Model number and quantity Battery

DP150N

DP160N

65D23R × 2 12 52

3-speed automatic transmission controller

3-2

DP135N

Voltage (V)

Console box

Lamps

DP120N

Capacity (Ah) Direction lever

Starter switch

DP100N

Electric With OK monitor ECU (Electronic Control Unit) Anti-restart type (with the built-in mechanical lockout for preventing duplicated starting) 24V, Refer to “Lamp Bulb Specifications”.

ELECTRICAL SYSTEM

2. Location of Components Safety relay Engine stop control timer Horn

Turn signal switch Console box Forward-reverse switching solenoid

Stop lamp switch

Front combination lamp Electronic Control Unit (ECU)

Headlamp

Front combination lamp

Torque converter oil thermounit

Headlamp Fuel tank unit

Speed sensor

Battery

Engine stop solenoid

Brake oil sensor Glow plug Back-up buzzer (optional)

Starter relay Battery Engine oil pressure switch

Alternator

Rear combination lamp Rear combination lamp Engine thermounit 211305

NOTE Every harness should be properly retained to avoid it from being interfered or rubbed by other parts. Repair a damaged harnesses with vinyl tape.

3-3

ELECTRICAL SYSTEM

3. Structure 3.1 Console box

2 1

1 Engine coolant temperature gauge

2 Fuel gauge 3 Hourmeter, Indicator lamp

4 Meter panel 5 Starter switch 6 Lighting switch, Turn signal

7 Direction lever

7 5 212142

3-4

ELECTRICAL SYSTEM

3.2 OK Monitor

212143

No.

Indicator lamp

Brake fluid level indicator lamp ATM: Transmission oil temperature indicator lamp

MTM: Clutch wearing

OFF

ON or Flashing

Remark

Normal fluid level

Low fluid level

–

Normal temperature

Overheating

Automatic transmission model

Normal

Wearing

Manual transmission model

Normal oil pressure

Insufficient oil pressure

–

Properly attached

Unattached

–

Normal

Failure

Printed symbol part

Engine oil pressure indicator lamp

Seatbelt reminder lamp

Multi-purpose warning lamp (This turns on when any alarm regarding the printed symbols is issued or at a minor trouble.)

Charging indicator lamp

Normally charged

Charging system abnormal

–

Glow plug indicator lamp

Heating completed

Heating

Diesel engine truck

Mast interlock indicator

Blinks under interlocked condition

Fr, Re interlock indicator lamp

Blinks under interlocked condition

Neutral indicator lamp

Blinks when the gear is in neutral

I J

Fuel gauge

Engine coolant temperature gauge

LCD (typically used as an hour meter)

Shows the operation hours when the key is turned ON.

Fuel filter water drain warning lamp

Normal

Water drain

Diesel engine truck

Radiator coolant level warning lamp

Normal level

Low level

Option

Air cleaner element indicator lamp

Normal element condition

Clogged

Option

Location and meaning of printed symbols

Shows the remaining fuel quantity when the key is turned ON. Means overheat if the hand falls in the red zone.

When major failures occur: Bulbs A, C, D, E, and H simultaneously flash.

How to check indicator lamp bulbs Each bulb is normal if the indicator lamp check switch comes ON with the starter switch key turned to (ON) position. However, the charge condition indicator lamp and engine oil pressure indicator lamp will not be illuminated.

3-5

ELECTRICAL SYSTEM

3.3 Major Components 3.3.1 ECU (Electronic Control Unit)

Failure indicator lights

LED (green)

LED (red) Rear (mounting) face 205509 The Electronic Control Unit (ECU) has a built-in 1-chip microcomputer to process signals from the travel speed sensor for activating the 3-speed automatic transmission. This ECU has â&#x20AC;&#x153;self-diagnosticâ&#x20AC;? failure indicator lamps which allow the operator to understand the failure in the electrical system.

It is also provided with the fail-safe systems (that allow for a unit to be switched to the safer side should any malfunction occur on it) as shown in the table below.

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

Fail-safe Systems Failure

Function

Solenoid output signal circuit open

Turns OFF the power line and indicates the trouble content with the failure indicator lamp, if any open circuit is detected in the solenoid output signal circuit.

Travel speed sensor circuit open

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

Failure indicator lamp Failure

Failure indicator lamp flashing pattern

Travel speed sensor circuit open

3-speed automatic transmission solenoid circuit open

NOTE Each failure indicator lamp turns ON or turns OFF as shown below.

ON OFF 3-6

204668

ELECTRICAL SYSTEM

3.3.2 Starter Switch (Anti-restart Type) This switch has a built-in mechanical lockout to prevent restarting. Since this lockout mechanism restraints the starter switch (key) from moving from (ON) position to (START) position while the engine is running, it serves as to prevent

engine troubles or starter damages possibly caused by any operation mistake. The starter switch is wired in such a way to energize the glow plugs. The (ON) position of the switch is for energizing the glow plugs.

Terminal Component Fuse box, batteries, Fuse box, engine stop control timer, glow plug timer and relay alternator, Key glow plugs position

Transmission shift lever, glow plug timer

(OFF) (ON) (START) 203561A

3-7

ELECTRICAL SYSTEM

3.3.3 Lighting switch Connection Chart OFF 1st 2nd

Knob position

8 8 Stroke [Unit: mm (in.)] (0.3)(0.3)

Connection Chart Terminal Component Knob position

Batteries (fuses)

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

Headlamps

Front combination lamps

206481 3.3.4 Fuse box Connection Chart Symbol

Capacity

10A

F â&#x20AC;&#x201C; N â&#x20AC;&#x201C; R lever

10A

Instrument panel lamp, turn signal lamp

10A

Spare terminal

15A

Lamps

10A

Horn

10A

Spare fuse

10A

Transmission controller, vacuum buzzer, stop lamps

10A

Back-up lamps

15A

Spare fuse

3-8

Major components to be connected

101441F

ELECTRICAL SYSTEM

3.3.5 Spare terminal The spare supply 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 onto the harness protector with vinyl tape.

Spare terminal 207209

3.3.6 Lamp Bulb Specifications

Item Head lamps

Qty

Color of lens

Frosted

Bulb Remark

For 24V system

Schematic diagram

60W

60/60W, option Standard (mounted on the overhead guard)

Turn signal lamps

Amber

25W

Clearance lamps

Frosted

12W

Tail and stop lamps

Red

10/25W

Turn signal lamps

Amber

25W

Back-up lamps

Frosted

12W

Working lamps (front)

Frosted

60/60W

Option

Working lamps (rear)

Frosted

60/60W

Option

License plate lamp

Frosted

12W

Option

Instrument panel lamps

Frosted

For combination meter

OK monitor indicator lamps

Frosted

For combination meter

Combination lamps (front)

Combination lamps (rear)

205511

3-9

ELECTRICAL SYSTEM

4. Disassembly and Reassembly 4.1 Disassembly of Console Box

207175 4.1.1 Disassembly sequence

(1)Disconnect the electrical wires at connectors 1. (2)Remove screws 2 (four) securing the cover. (3)Remove screws 3 (six) and separate the front panel and rear panel. (4)Remove screws 4 (four) securing the combination meter panel.

NOTE Remove screws 3 and 4 to replace any bulb in the console box.

4.1.2 Reassembly Reassemble in the reverse order of disassembly sequence.

3-10

ELECTRICAL SYSTEM

4.2 Combination Meter 4.2.1 Disassembly

(1) Disassembly sequence 1 Meter panel 2 Meter cover 3 Engine coolant temperature gauge 4 Service hourmeter 5 Fuel gauge 6 Meter case 7 Printed circuit plate 8 Valve 9 Socket

NOTE Be careful not to damage the printed circuit plate.

(2) Indicator Bulb Replacement Turn the socket to the left to remove it from the printed circuit plate. Then, remove the bulb from the socket. For the location of each bulb, refer to â&#x20AC;&#x153;OK Monitor.â&#x20AC;?

206486

4.2.2 Reassembly Reassemble in the reverse order of disassembly sequence.

3-11

ELECTRICAL SYSTEM

4.3 Electrical Components in the Console Box

206423

1 Power relay

5 Glow plug timer

2 Power relay

6 Lighting switch

3 Turn signal relay

7 Starter switch

4 Glow plug relay

8 Fuse

3-12

ELECTRICAL SYSTEM

5. Batteries and Charging 5.1 Battery Conditions and Adjustment Method Based on the Electrolyte Specific Gravity (S.G.) Electrolyte S.G. reading at 20˚C (68˚F)

Battery condition

Adjustment

1.280 to 1.265

Battery is fully or well charged.

If difference in S.G. between any two cells is less than 0.04, continue to use the battery without additional charging. Where the difference in S.G. is greater than 0.04, discharge the battery with an efficiency-based manner. If the condition is improved, recharge the battery while adjusting the electrolyte specific gravity.

1.260 to 1.225

Battery is half charged.

Recharge the battery. Check for any short-circuited cord or corroded connection in the electrical system.

1.220 or less

battery is discharged, requiring cares.

When the difference in S.G. is greater than 0.040

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

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

5.2 Relationship between Electrolyte S.G. and Charging Capacity

Recharge until voltage and S.G. of each cell stabilize and are maintained 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. After leaving it for 12 to 96 hours, give it a high current discharge test.

over-charge the battery. If refilling is not required for over 3 months, it is likely that the system is inadequately charging.

Whether the battery is fully charged can be checked from the electrolyte S.G. (between 1.280 and 1.625) read with a hydrometer. However, it can also be judged theoretically from the reduction rate of the electrolyte quantity. If refilling is necessary every month or so, the system is tending to

5.3 Precautions for Battery Charging

CAUTION

(1) The charging current should be about 1/10 the capacity of the battery to be charged.

(2) For quick charging, the battery capacity in ampere should not be exceeded.

(3) During charging, adjust the charging current to prevent the electrolyte temperature from rising beyond 45˚C (113˚F). (4) When connecting cables to the battery terminal, begin with the cable for the positive (+) terminal. When disconnecting them from the battery, begin with a cable for the negative (-) terminal.

Be sure to turn off the starter switch and light switch before disconnecting or connecting the battery cables. (IC regulator may be damaged.)

3-13

ELECTRICAL SYSTEM

5.4 Precautions for Servicing the Charging System with Alternator The alternator is equipped with a built-in IC (integrated circuit) voltage regulator. When servicing the charging system, pay attention to the following precautions: (1) Do not reverse the polarity of the battery. (2) Do not disconnect any battery cable while the engine is running. (3) Do not ground the terminal L. (4) Do not short the terminals L and R. (5) Do not direct a blast of steam cleaner to the alternator. Remember, a blast of steam will damage the IC regulator.

3-14

Terminal L Terminal R Terminal B 202772

ELECTRICAL SYSTEM

6. Troubleshooting 6.1 Starter System

• Weak or dead battery

• Recharge or replace.

• Open or short circuit

• Repair or replace.

• Poor continuity in starter switch

• Replace.

• Starter of starter relay defective

• Replace.

• Transmission shift lever is not in neutral position.

• Move lever to neutral position.

• Open or short circuit

• Repair or replace.

• Engine stop solenoid defective

• Replace.

• Control timer defective

• Replace.

• Open or short circuit

• Repair or replace.

• Gauge internally defective

• Replace.

• Gauge unit defective

• Replace.

Will not indicate accurately

• Gauge or gauge unit is not of the specified type.

• Replace.

• Loose terminal connection

• Repair.

Will indicate higher than actual temperature

• Wiring between gauge and gauge unit grounded

• Repair.

• Gauge internally defective

• Replace.

• Open or short circuit

• Repair.

• Gauge internally defective

• Replace.

• Gauge unit defective

• Replace.

Will not indicate accurately

• Gauge or gauge unit is not of the specified type.

• Replace.

• Loose terminal connection

• Repair.

Will indicate “full” regardless of amount of fuel left in tank

• Wiring between gauge and gauge unit grounded

• Repair.

• Gauge internally defective

• Replace.

• Gauge unit defective

• Replace.

Starter will not crank engine Starter switch Turning off starter switch will not stop engine

6.2 Gauges

Will not indicate at all Temperature gauges

Will not indicate at all

Fuel gauge

Will indicate “empty” regardless of amount of fuel left in tank

• Open or short circuit between gauge and gauge • Repair. unit

• Gauge internally defective

• Replace.

• Gauge unit defective

• Replace.

3-15

ELECTRICAL SYSTEM

6.3 Lighting System

Will not light

• Weak or dead battery

• Recharge or replace.

• Fuses blown

• Check and replace.

• Open or short circuit

• Repair or replace.

• Poor grounding

• Remove stains from the terminal or retighten.

• Bulbs burnt out

• Replace.

• Weak or dead battery

• Check and recharge.

• Burned contact points in switches

• Repair or replace.

• Loose terminals

• Repair.

• Dirty lenses

• Clean.

• Water drops inside lenses

• Dry and replace the packings.

• Bulbs service life expired

• Replace.

• Lighting switch defective

• Replace.

• Bulbs burnt out

• Replace.

• Turn signal switch defective

• Replace.

• Turn signal relay defective

• Replace.

Will not go out

• Turn signal relay defective

• Replace.

Will flash too slow

• Bulb wattage less than the rating

• Replace it with specified bulb.

• Turn signal relay defective

• Replace.

Will flash too fast

• Bulb wattage greater than the rating

• Replace it with specified bulb.

• Turn signal relay defective

• Replace.

• Backup lamp switch defective

• Correct if improperly installed: replace if

• Bulbs burnt out

• Replace.

• Lighting switch defective

• Replace.

• Bulbs burnt out

• Replace.

Lamps general

Will light dimly

Head lamps

Will not light Will not flash

Turn signal lamps

Other lamps

3-16

Backup lamps will not light License number plate lamp will not light

internally defective.

ELECTRICAL SYSTEM

6.4 Alarm Unit

Will not sound Horn

Will give an offensive sound Vacuum buzzer

Will not sound

• Fuses blown

• Check and replace.

• Open or short circuit

• Repair or replace.

• Horn button defective

• Repair or replace.

• Horn switch defective

• Replace.

• Horn defective

• Replace.

• Horn switch defective

• Replace.

• Horn defective

• Replace.

• Vacuum switch defective

• Replace.

• Buzzer defective

• Replace.

3-17

ELECTRICAL SYSTEM

6.5 Battery

• Drive belt slipping

• Adjust the tension.

Alternator • Broken wire of stator coil

• Repair or replace.

• Rotor coil open

• Replace.

• Brushes poorly seating on slip rings

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

• Diode short or open

• Replace.

Regulator • Regulated voltage setting too low

• Readjust.

Battery Tends to run down rapidly

• Defective or inappropriate electrolyte

• Refill or adjust the S.G.

• Defective cell plates (internal short-circuit)

• Replace.

• Poor terminal connections due to insufficient • Clean and tighten. tightening torque

Battery

Wiring • Open or loose connection between the key switch • Repair. and regulator IC terminal • Fuse blown in the above mentioned circuit or poor • Replace fuse or repair the holder’s contact contact in the holder

part.

• Open or loose connection between the regulator • Repair. terminal and alternator terminal Wiring • Wrong connection or short circuit between the • Repair. regulator IC terminal and battery terminal. Battery overcharge

• Poor grounding of regulator terminal F

• Repair.

Regulator

3-18

• Pressure coil open-circuited

• Replace.

• Regulated voltage too high

• Readjust.

CONTROLLER 1. Outline.......................................................................................................................... 4-2 1.1 System Configuration............................................................................................................................ 4-2 1.2 External View ........................................................................................................................................ 4-4 1.2.1 VCM-3 ......................................................................................................................................................... 4-4 1.2.2 VCM-3OP.................................................................................................................................................... 4-5 1.2.3 ECU............................................................................................................................................................. 4-6 1.2.4 Meter panel ................................................................................................................................................. 4-7 1.2.5 Input unit ..................................................................................................................................................... 4-8 1.2.6 Output unit................................................................................................................................................... 4-9

2. Service Tool Functions............................................................................................... 4-10 2.1 Menu ................................................................................................................................................... 4-10 2.2 Input Monitor and Output Monitor ....................................................................................................... 4-11 2.2.1 VCM-3 input monitor and output monitor (VCM-3 → VCM-3)................................................................... 4-11 2.2.2 VCM-3OP input monitor and output monitor (VCM-3 → VCM-3OP) ........................................................ 4-13 2.2.3 MP input monitor (VCM-3 → MP) ............................................................................................................. 4-14 2.2.4 ECU input monitor and output monitor (VCM-3 → ECU) .......................................................................... 4-15

2.3 Fault Status......................................................................................................................................... 4-16 2.4 Fault History........................................................................................................................................ 4-17

3. Chassis Error Code List ............................................................................................. 4-18 4. Troubleshooting ......................................................................................................... 4-19 4.1 General Information ............................................................................................................................ 4-19 4.1.1 Before replacing controllers ...................................................................................................................... 4-19 4.1.2 Connection of service tool......................................................................................................................... 4-19 4.1.3 How to clean harness connectors and system components ..................................................................... 4-20

4.2 Troubleshooting .................................................................................................................................. 4-21

4-1

CONTROLLER

1. Outline 1.1 System Configuration The controller system consists of the vehicle control controllers (VCM-3 and VCM-3OP), engine control controller (ECU), meter panel, input unit and output unit.

The controllers are connected on the Controller Area Network (CAN) and communicate mutually to control the lift truck.

Gateway

ECU VCM-3OP

Input unit

Meter panel

N 1

VCM-3 Output unit

212331

4-2

CONTROLLER

CAN connection

Harness A

CAB harness

Harness B

Connector

201

Connector

Harness C

Connector

201

205

200

204

200

Meter panel

201

200

396 396

395 395

396

395

205

204

VCM-3OP

VCM-3 Input unit

286 285

288 287

VCM-3 GSE

VCM-3OP GSE

Output unit

Gateway

394 393

209 208 858 857

857

ECU 858

212332

4-3

CONTROLLER

1.2 External View 1.2.1 VCM-3

A A'

SECTION A ã§&#x2122; A'

Connector pin number (from view B')

Connector pin number (from view B) CN1

10 11 18

CN2

12 13 14

15 16 17

20 21 22 23 24

26 27 28 29 30 31 32 33 34

10 11 18

12 13 14

15 16 17

20 21 22 23 24

26 27 28 29 30 31 32 33 34

212333

4-4

CONTROLLER

1.2.2 VCM-3OP

A A'

SECTION A ã§&#x2122; A'

Connector pin number (from view B')

Connector pin number (from view B) CN1

10 11 18

CN2

12 13 14

15 16 17

20 21 22 23 24

26 27 28 29 30 31 32 33 34

10 11 18

12 13 14

15 16 17

20 21 22 23 24

26 27 28 29 30 31 32 33 34

212333

4-5

CONTROLLER

1.2.3 ECU

B C D

Connector pin number A: GF34A

B: GF35A

C: GF32A

D: GF35B

E: GF31A

212334

4-6

CONTROLLER

1.2.4 Meter panel

CN2

CN1

Connector pin number

13 14 11 12 15 16 17 18 19 20

CN2

1 6

2 7

9 10

CN1 212335

4-7

CONTROLLER

1.2.5 Input unit

Connector pin number (from view A)

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32

212336

4-8

CONTROLLER

1.2.6 Output unit

Connector pin number (from view A) 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

212337

4-9

CONTROLLER

2. Service Tool Functions 2.1 Menu Monitor menu

Tool menu

• Input Monitor

• Set-up Option

Indicates the input values of the controllers. • Output Monitor Indicates the output values of the controllers. • Custom Monitor Indicates the input/output values of the item selected. • Fault Status Indicates all error codes occurring. • Fault History Indicates the fault data, such as the error codes and hour meter data, stored in the controller.

Indicates or sets the Setup Option data. • Oscilloscope Graphs the input/output values. The oscillograph can be stored as data. • Active Test Outputs the signal forcibly to check the operation of the equipment selected. • Connection Change Designates the controller operated by the service tool and the controller connected to it. • Firmware Update Updates the firmware of the controller connected.

212338

4-10

CONTROLLER

2.2 Input Monitor and Output Monitor These screens indicate the input and output values of each controller. 2.2.1 VCM-3 input monitor and output monitor (VCM3 â&#x2020;&#x2019; VCM-3)

(InputUnit)

212339

4-11

CONTROLLER

(OutputUnit ) [ V ] (OutputUnit ) (OutputUnit )

212340

4-12

CONTROLLER

2.2.2 VCM-3OP input monitor and output monitor (VCM-3 â&#x2020;&#x2019; VCM-3OP)

212341

4-13

CONTROLLER

2.2.3 MP input monitor (VCM-3 â&#x2020;&#x2019; MP)

212342

4-14

CONTROLLER

2.2.4 ECU input monitor and output monitor (VCM-3

â&#x2020;&#x2019; ECU)

Accel pedal position (unfiltered) Accel pedal position (filtered)

Reference injection quantity

212343

4-15

CONTROLLER

2.3 Fault Status This screen indicates all error codes occurring.

OutputUnit Communication error InputUnit Communication error

212344

4-16

CONTROLLER

2.4 Fault History This screen indicates the fault data, such as the error codes and hour meter data, stored in the controller.

OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error OutputUnit Communication error InputUnit Communication error

212345

4-17

CONTROLLER

3. Chassis Error Code List Error Code

Description

Page No.

Error Code

Description

Page No.

F01

VCM-3 Memory Check Error

4-21

F54

Lift Solenoid Leak

4-90

F02

VCM-3 Battery Voltage Error

4-22

F55

Tilt Forward Solenoid Error

4-94

F03

VCM-3 Communication Error

4-24

F57

Tilt Backward Solenoid Error

4-96

F04

ECM Communication Error

4-26

F59

Tilt Solenoid Leak

4-98

F07

MP Communication Error

4-27

F60

Attachment 1A Solenoid Error

4-102

F10

Lift Lever Neutral Error

4-29

F62

Attachment 1B Solenoid Error

4-104

F11

Tilt Lever Neutral Error

4-31

F64

Attachment 1 Solenoid Leak

4-106

F12

Attachment 1 Lever Neutral Error

4-33

F65

Attachment 2A Solenoid Error

4-110

F13

Attachment 2 Lever Neutral Error

4-35

F67

Attachment 2B Solenoid Error

4-112

F14

Attachment 3 Lever Neutral Error

4-37

F69

Attachment 2 Solenoid Leak

4-114

F15

ECU Communication Error

4-39

F70

Attachment 3A Solenoid Error

4-118

F16

Shift Lever Error

4-41

F72

Attachment 3B Solenoid Error

4-120

F17

Vehicle Speed Error

4-43

F74

Attachment 3 Solenoid Leak

4-122

F18

ECU KWP2000 Communication Error

4-45

F75

Unload Solenoid Error

4-126

F19

ECU Speed Sensor Error

4-47

F79

Unload Solenoid Leak

4-128

F20

Lift Lever Error

4-49

F80

Knob Position Solenoid Error

4-131

F22

Tilt Lever Error

4-51

F84

Knob Position Solenoid Leak

4-133

F24

Attachment 1 Lever Neutral Error

4-53

F85

Transmission Forward Solenoid Error

4-136

F26

Attachment 2 Lever Neutral Error

4-55

F87

Transmission Backward Solenoid Error

4-138

F28

Attachment 3 Lever Neutral Error

4-57

F89

Transmission Solenoid Leak

4-140

F29

Joystick Lever Error

4-59

F90

VCM-3OP Sensor Voltage Error

4-143

F31

VCM-3 Sensor Voltage Error

4-61

F91

VCM-3OP Memory Check Error

4-146

F33

VCM-3OP Lift Oil Pressure Sensor Error

4-63

F92

VCM-3OP Battery Voltage Error

4-147

F34

Vehicle Speed Sensor Error

4-65

F93

VCM-3OP Speed Change Solenoid 1 Error

4-149

F36

Tire Angle Sensor Error

4-67

F94

VCM-3OP Speed Change Solenoid 2 Error

4-151

F39

VCM-3OP Tilt Angle Sensor Error

4-69

F95

VCM-3OP Speed Change Solenoid Leak

4-153

F40

Steering Error

4-71

F96

VCM-3OP EAT Setting Error

4-155

F41

Output Unit Error

4-73

F97

VCM-3OP Communication Error

4-156

F42

Output Unit Life Control Signal

4-74

L03

VCM3 Communication Error

F43

Output Unit Memory Check Error

4-75

L04

ECM/ECU Communication Error

F44

Output Unit PWM Voltage Error

4-76

L07

MP Communication Error

F45

Output Unit Communication Error

4-79

L08

TMS Communication Error

F46

Input Unit Error

4-81

P03

VCM3 Communication Error

F47

Input Unit Life Control Signal

4-82

P04

ECM/ECU Communication Error

F48

Input Unit Memory Check Error

4-83

P07

MP Communication Error

F49

Input Unit Communication Error

4-84

P08

TMS Communication Error

F50

Lift Up Solenoid Error

4-86

P22

Shift Lever Error Signal

F52

Lift Down Solenoid Error

4-88

4-18

CONTROLLER

4. Troubleshooting 4.1 General Information 4.1.1 Before replacing controllers Do not replace controllers casually even if replacement is required as a result of troubleshooting. Be sure to check the following items before replacing controllers. • Loose battery connectors • Abnormal wire harness connections • Loose connectors • Broken, bent or loose connector pins • Dirty connectors If connectors are dirty, remove the connector and clean connectors. See “How to clean harness connectors and system components” on the next page. • Ensure that the main harness is not short-circuited to the truck body. If any of these items (above items) is a source of the trouble, the controller will be damaged even if it is replaced with a new one. Be sure to check the above items and replace carefully. 4.1.2 Connection of service tool

(1) (2) (3) (4) (5)

Turn off the truck power. Find the service tool connector in the CAB harness. Remove the cover and connect the PC as shown. Turn on the truck power. Start the service tool software.

CAB harness VCM-3OP GSE

GSE cable

VCM-3 GSE

212346

4.1.3 Diagnostic Precautions

(4) When performing measurement with the tester, handle

(1) Before measuring voltage, check the battery for

the test bar carefully so that it does not damage internal circuit and other electrical parts of the electronic control unit to result in a short-circuit failure between terminals in connector or between connector and truck body. (5) Resistance is affected by temperature. Determine the necessity of resistance measurement following given temperature specification as a guide. Otherwise, use normal temperature (10 to 35°C) as the measuring condition.

charged condition and specific gravity. If system inspection is performed with the battery uncharged or reduced in specific gravity, accurate measurements cannot be achieved. (2) To avoid having electrical parts damaged, set the starter switch to OFF before disconnecting and reconnecting battery cables. (3) Before disconnecting connectors, set the starter switch to OFF then allow at least 20 seconds. Voltage may remain in electric parts or connected circuit.

4-19

CONTROLLER

4.1.4 How to clean harness connectors and system components

(1) Open-circuits are often caused by dirty harness connectors and components. Dust, together with greasy matter, forms grime which, in time, penetrates electrical connections, resulting in loose metal-to-metal contact or, for worse, electrical separation of surfaces in contact. For this reason, it is essential that the connectors and components be cleaned at each periodic inspection and when servicing the truck. Instead of a commonly used solvent, use the electronic parts cleaner (in the manner illustrated on the right). Electronic parts cleaner

Electronic parts cleaner

Three Bond 29D or Pow-R-Wash CZ*

212347

NOTE The cleaner liquid is volatile. All you have to do is just give a strong spray to wash off grime. No need to wipe off the sprayed liquid.

(2) After checking the connector for continuity, wash it as shown. Then, uncouple the connector and spray the contact surface activator onto contact surfaces. Install and remove the connector several times to wet the surfaces thoroughly with the activator liquid. After coupling up the connector, check to be sure that it is in locked state. Contact surface activator

Electronic parts cleaner

Three Bond 2501S (aerosol) or Nyogel 760G*

NOTE Do not spray too much liquid into the connector. Cleaner liquid reacts differently with some resins (plastic materials). *: Products contained in Terminal Maintenance kit (SE000003)

Contact surface activator 212348

4-20

CONTROLLER

4.2 Troubleshooting

Problem: VCM-3 Memory Check Error (F01) (1) Situation Indication: "F01" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty truck type setting data in VCM-3.

(3) How the error code is triggered Software checks sum value of ROM and EEPROM in CPU, and detects fault.

(4) Checks Check truck type setting data. Normal

Abnormal (5) Enter truck type setting data again.

(6) Enter shipment default value into VCM-3. Abnormal

Normal

(7) Perform standard setting, then enter truck type setting data again.

(8) Write updated software into VCM-3. Abnormal

Normal

(9) Faulty software writing.

(10) Replace VCM-3.

4-21

CONTROLLER

Problem: VCM-3 Battery Voltage Error (F02) (1) Situation Indication: "F02" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Poor battery charge, faulty battery, faulty VCM-3, faulty harness, faulty DC-DC converter.

(3) How the error code is triggered When VCM-3 input voltage is less than 7V or more than 21V.

(4) Checks Measure battery terminal voltage. Normal (18V to 32V)

32V or more

7V or less (5) Charge battery.

Error remains (6) Replace battery.

(7) Measure output voltage and input voltage of DC-DC converter. 1. Output voltage: Between 40(DC-DC converter: +12V) and 107 (DC-DC converter: GND). 2. Input voltage: Between 8(DC-DC converter: +24V) and 104 (DC-DC converter: GND). Normal

Input voltage abnormal

Output voltage abnormal

(9) Replace DC-DC converter.

(8) Replace harness.

(10) Measure input voltage of VCM-3. 1. Between 40(VCM-3: CN1-18) and 130(VCM-3: CN1-25). 2. Between 41(VCM-3: CN1-26) and 131(VCM-3: CN1-34). 7V or less

(11) Replace harness.

4-22

12V 24V

(12) Replace VCM-3.

7V to 21V

CONTROLLER

DC-DC CONVERTER

VCM-3 CN1 0.85B/L 131 0.85B/L 130 1.25R/Y 41 1.25R/Y 40

107 1.25B/L 2R/Y 40 1.25B 104

105 40

F7 8R

245

1 224 223

218 217 216132 215 40

10A

㧗

BATTERY

㧙

105

60B

2B/L

60B

㧙

2R/W

12V GND 12V MAIN 24V GND 12V LAMP 24V LAMP 24V BATT ACC IN 12V BATT

41 26

100

211

130

34 131 229 411

FLW 0.85R

2R/W

15R

CN1

107 40 104 94 49 8 62 301

㧗

BATTERY 212349

4-23

CONTROLLER

Problem: VCM-3 Communication Error (F03) (1) Situation Indication: "F03" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty harness.

(3) How the error code is triggered When CAN communication of VCM-3 is interrupted.

(4) Checks Check to see if other errors occur simultaneously. F03 only

Other errors occur (5) See troubleshooting for errors occurred.

(6) Check continuity of CAN communication cables. 1. VCM-3 to meter panel: Between 201(VCM-3: CN2-31) and 201(Meter panel: 18), and 200(VCM-3: CN2-32) and 200(Meter panel: 19) 2. VCM-3 to VCM-3OP: Between 201(VCM-3: CN2-31) and 205(VCM-3OP: CN2-32), and 200(VCM-3: CN2-32) and 204(VCM-3OP: CN2-31). 3. VCM-3 to output unit: Between 201(VCM-3: CN2-31) and 394(Output unit: 13), and 200(VCM-3: CN2-32) and 393(Output unit: 14). 4. VCM-3 to input unit: Between 201(VCM-3: CN2-31) and 396(Input unit: 7), and 200(VCM-3: CN2-32) and 395(Input unit: 8). In case of diesel engine 5. VCM-3 to gateway: Between 201(VCM-3: CN2-31) and 209(Gateway: A23), and 200(VCM-3: CN2-32) and 208(Gateway: A24). In case of asoline engine 6. VCM-3 to ECM: Between 201(VCM-3: CN2-31) and (ECM: 94), and 200(VCM-3: CN2-32) and (ECM: 86). Continuity

(7) Replace VCM-3.

4-24

No continuity

(8) Replace faulty harness.

CONTROLLER

CN2 9 277

VCM-3 CN2

254 273 253

258

0.85L/R

CAN H 201 0.85B/W CAN L 200

201 200

279 281

205 204 295 294 293 292

VCM-OP CN2

0.85B/W

204 205

CAN L

204 205

0.85L/R

CAN H

CN2

25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

METER PANEL

10 18 26

201 200

0.85L/R

CAN H

201

0.85B/W

CAN L

200

OUTPUT UNIT 0.85L/R 0.85B/W

393

394 13 CAN H 14 CAN L

INPUT UNIT (HARNESS, IN FC) 0.85L/R

0.85B/W

396 395

0.5B 0.5B/W

396 395

7 CAN H 8 CAN L

GATEWAY (Diesel engine)

208 209

9 17

0.85B/W 0.85L/R

94 86

ECM (Gasoline engine)

212350

4-25

CONTROLLER

Problem: ECM Communication Error (F04) (1) Situation Indication: "F04" flickering.

(2) Possible cause Faulty VCM-3, faulty harness, faulty ECM.

(3) How the error code is triggered When CAN communication from ECM to VCM-3 is interrupted.

(4) Checks Check continuity of CAN communication cables. VCM-3 to ECM: Between 201(VCM-3: CN2-31) and (ECM: 94), and 200(VCM-3: CN2-32) and (ECM:86).

Continuity

(6) Replace harness.

(5) Replace VCM-3. Error remains (7) Replace ECM.

4-26

No continuity

CONTROLLER

Problem: MP Communication Error (F07) (1) Situation Indication: "F07" flickering. Drive operations disabled.

(2) Possible cause Faulty meter panel, faulty VCM-3, faulty harness.

(3) How the error code is triggered When CAN communication from meter panel to VCM-3 is interrupted.

(4) Checks Check continuity of CAN communication cables. VCM-3 to meter panel: Between 201(VCM-3: CN2-31) and 201(Meter panel: 18), and 200(VCM-3: CN2-32) and 200(Meter panel: 19). Continuity

No continuity (6) Replace harness.

(5) Replace meter panel. Error remains (7) Replace VCM-3.

4-27

CONTROLLER

78 77 79 83 82 80 81

VCM-3

BRAKE F FUEL PKB OIL TEMP R N F

CN2 0.85L/R

201 0.85B/W 200

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

201 200

0.85L/R 0.85B/W

48 201 200 45 49 46 102

GLOW CAN H CAN L 12V LAMP ALT R ALT L GND

SIGNAL PROCESSOR

METER PANEL

FUEL GAGE WATER TEMP GAGE BRAKE LAMP OIL PRESSURE LAMP TORQ CONV OIL TEMP LAMP INTERLOCK LAMP MULTIPURPOSE WARNING LAMP GLOW LAMP (LPG) MAST INTERLOCK LAMP SEAT BELT LAMP

CHARGE LAMP

10 18 26

212351

4-28

CONTROLLER

Problem: Lift Lever Neutral Error (F10) (1) Situation Indication: "F10" flickering. Hydraulic operations disabled.

(2) Possible cause Lift lever operated when turning on key switch, faulty lift lever, faulty input unit, faulty harness.

(3) How the error code is triggered Lift lever is not in neutral when turning on key switch.

(4) Checks Shift lift lever in neutral, then turn on key switch. Normal

Error remains

Fail-safe operation (5) Check continuity between lift lever and input unit. 1. Between 468(Input unit: CN1-25) and 468(Lift lever). 2. Between 469(Input unit: CN1-26) and 468(Lift lever). 3. Between 460(Input unit: CN1-23) and 460(Lift lever). 4. Between 464(Input unit: CN1-24) and 464(Lift lever). Continuity

No continuity

(6) Replace harness.

(7) Replace lift lever with another section lever. Error transition

(8) Replace lift lever.

Error remains

(9) Replace input unit.

4-29

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

CN1 1 GND 2 Vcc 19V 3 FWE 4 RS-232 Tx 5 RS-232 Rx 6 RS-232 GND 7 CAN H 8 CAN L 9 CAN R+ 10 CAN R11 BOOT 12 SEL0 13 SEL1 476 14 SW GND 15 SW INPUT 1 16 SW INPUT 2(SPEED SEL) 477 17 SW INPUT 3(4V/5V) 18 SW INPUT 4(F) 19 SW INPUT 5(N) 20 SW INPUT 6(R) 21 SW INPUT 7 22 SW INPUT 8 460 23 5V 464 24 GND 468 25 LIFT 1 469 26 LIFT 2 470 27 TILT 1 471 28 TILT 2 472 29 ATT 1-1 473 30 ATT 1-2 474 31 ATT 2-1 475 32 ATT 2-2

474 467

0.5P 0.5B

212352

4-30

CONTROLLER

Problem: Tilt Lever Neutral Error (F11) (1) Situation Indication: "F11" flickering. Hydraulic operations disabled.

(2) Possible cause Tilt lever operated when turning on key switch, faulty tilt lever, faulty input unit, faulty harness.

(3) How the error code is triggered Tilt lever is not in neutral when turning on key switch.

(4) Checks Shift tilt lever in neutral, then turn on key switch. Normal

Error remains

Fail-safe operation (5) Check continuity between tilt lever and input unit. 1. Between 470(Input unit: CN1-27) and 470(Tilt lever). 2. Between 471(Input unit: CN1-28) and 471(Tilt lever). 3. Between 460(Input unit: CN1-23) and 461(Tilt lever). 4. Between 464(Input unit: CN1-24) and 465(Tilt lever). Continuity

No continuity

(6) Replace harness.

(7) Replace tilt lever with another section lever. Error transition

(8) Replace tilt lever.

Error remains

(9) Replace input unit.

4-31

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

474 467

0.5P 0.5B

212352

4-32

CONTROLLER

Problem: Attachment 1 Lever Neutral Error (F12) (1) Situation Indication: "F12" flickering. Hydraulic operations disabled.

(2) Possible cause Attachment 1 lever operated when turning on key switch, faulty attachment 1 lever, faulty input unit, faulty harness.

(3) How the error code is triggered Attachment 1 lever is not in neutral when turning on key switch.

(4) Checks Shift attachment 1 lever in neutral, then turn on key switch. Normal

Error remains

Fail-safe operation (5) Check continuity between attachment 1 lever and input unit. 1. Between 472(Input unit: CN1-29) and 472(ATT1 lever). 2. Between 473(Input unit: CN1-30) and 473(ATT1 lever). 3. Between 460(Input unit: CN1-23) and 462(ATT1 lever). 4. Between 464(Input unit: CN1-24) and 466(ATT1 lever). Continuity

No continuity (6) Replace harness.

(7) Replace attachment 1 lever with another section lever. Error transition

(8) Replace attachment 1 lever.

Error remains

(9) Replace input unit.

4-33

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

474 467

0.5P 0.5B

212352

4-34

CONTROLLER

Problem: Attachment 2 Lever Neutral Error (F13) (1) Situation Indication: "F13" flickering. Hydraulic operations disabled.

(2) Possible cause Attachment 2 lever operated when turning on key switch, faulty attachment 2 lever, faulty input unit, faulty harness.

(3) How the error code is triggered Attachment 2 lever is not in neutral when turning on key switch.

(4) Checks Shift attachment 2 lever in neutral, then turn on key switch. Normal

Error remains

Fail-safe operation (5) Check continuity between attachment 2 lever and input unit. 1. Between 474(Input unit: CN1-31) and 474(ATT2/3 lever). 2. Between 475(Input unit: CN1-32) and 475(ATT2/3 lever). 3. Between 460(Input unit: CN1-23) and 463(ATT2/3 lever). 4. Between 464(Input unit: CN1-24) and 467(ATT2/3 lever). No continuity

Continuity

(6) Replace harness.

(7) Replace attachment 2 lever with another section lever. Error transition

(8) Replace attachment 2 lever.

Error remains

(9) Replace input unit.

4-35

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

474 467

0.5P 0.5B

212352

4-36

CONTROLLER

Problem: Attachment 3 Lever Neutral Error (F14) (1) Situation Indication: "F14" flickering. Hydraulic operations disabled.

(2) Possible cause Attachment 3 lever operated when turning on key switch, faulty attachment 3 lever, faulty input unit, faulty harness.

(3) How the error code is triggered Attachment 3 lever is not in neutral when turning on key switch.

(4) Checks Shifts attachment 3 lever in neutral, then turn on key switch. Normal

Error remains

Fail-safe operation (5) Check continuity between attachment 3 lever and input unit. 1. Between 474(Input unit: CN1-31) and 474(ATT2/3 lever). 2. Between 475(Input unit: CN1-32) and 475(ATT2/3 lever). 3. Between 460(Input unit: CN1-23) and 463(ATT2/3 lever). 4. Between 464(Input unit: CN1-24) and 467(ATT2/3 lever). Continuity

No continuity

(6) Replace harness. (7) Replace attachment 3 lever with another section lever. Error remains

Error transition

(8) Replace attachment 3 lever.

(9) Replace input unit.

4-37

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

474 467

0.5P 0.5B

212352

4-38

CONTROLLER

Problem: ECU Communication Error (F15) (1) Situation Indication: "F15" flickering. Drive operations restricted.

(2) Possible cause Faulty ECU, faulty VCM-3, faulty gateway, faulty harness.

(3) How the error code is triggered When CAN communication from ECU(gateway) to VCM-3 is interrupted.

(4) Checks Check continuity of CAN communication cables. VCM-3 to gateway: Between 201(VCM-3: CN2-31) and 209(Gateway: A23), and 200(VCM-3: CN2-32) and 208(Gateway: A24). Gateway to ECU:

Between 857(Gateway: A26) and 857(ECU: 157), and 858(Gateway: A27) and 858(ECU: 158).

Continuity

No continuity (6) Replace harness.

(5) Replace gateway. Error remains (7) Replace VCM-3. Error remains (8) Replace ECU.

4-39

VCM-3 CN2

25 9

4-40 234 235 233 232 231 230 221 220

384 222 238

200 201 299 298 297 296 237

CAN H 201 0.85B/W CAN L 200 0.85L/R 0.85R

0.85W

0.85L/R

0.85B/W

0.85Lg

0.85V

0.85W

0.85R

0.85R/B

0.85G/W

0.85Y/B

SVC POWER - 1

WATER TEMP. SENSOR CAN - 1(H) 858 CAN - 1(L) 862 FUEL TEMP. SENSOR - 1(LEAK) 863 FUEL TEMP. SENSOR - 2

855 857

SVC POWER - 2 854 AIR TEMP. SENSOR

847

846

GATEWAY

0.85Or

858 857

208 209

162 163

158

157

154 155

146 147

CONTROLLER

CONTROL UNIT, ECG (e e)

201 200

CN2 227228 1

10 18

212353

CONTROLLER

Problem: Shift Lever Error (F16) (1) Situation Indication: "F16" flickering. Drive operations disabled.

(2) Possible cause Faulty meter panel, faulty VCM-3, faulty harness.

(3) How the error code is triggered When F, N and R signals of shift lever are inputted simultaneously.

(4) Checks Check continuity between meter panel and shift lever. 1. N: Between 272(Shift lever: 1) and 80 (Meter panel). 2. F: Between 81(Shift lever: 3) and 81(Meter panel). 3. R: Between 62(Shift lever: 5) and 82 (Meter panel). 4. GND: Between 126(Shift lever: 2) and 102(Meter panel), and 127(Shift lever: 4) and 102(Meter panel). Continuity

No continuity

(6) Replace harness.

(5) Replace meter panel. Error remains (7) Replace VCM-3.

4-41

CONTROLLER

METER PANEL

DIODE

127 126 81 272 62

0.85L/G 0.85L/W

0.85G/L 272 0.85B 127 0.85G/R 81 0.85B 126 0.85L/G

272

0.85G/L 0.85Y/L 272

62 82

1 2 34 5 F1 N R1

0.85L/W

0.85Y/L 0.85G/R

78 77 79 83 82 80 81 48 201 200 45 49

1.25B

46 102

BRAKE F FUEL PKB OIL TEMP R N F GLOW CAN H CAN L 12V LAMP ALT R ALT L GND

SIGNAL PROCESSOR

DIODE

FNR LEVER

FUEL GAGE WATER TEMP GAGE BRAKE LAMP OIL PRESSURE LAMP TORQ CONV OIL TEMP LAMP INTERLOCK LAMP MULTIPURPOSE WARNING LAMP GLOW LAMP (LPG) MAST INTERLOCK LAMP SEAT BELT LAMP

CHARGE LAMP

212354

4-42

CONTROLLER

Problem: Vehicle Speed Error (F17) (1) Situation Indication: "F17" flickering.

(2) Possible cause Vehicle speed over limit, Faulty VCM-3, faulty harness.

(3) How the error code is triggered When vehicle speed is 35 km/h or more.

(4) Checks Check continuity between VCM-3 and vehicle speed sensor connectors. 1. Between 220(VCM-3: CN2-10) and 220(Speed sensor: +). 2. Between 221(VCM-3: CN2-11) and 221(Speed sensor: -). Continuity

(5) Replace VCM-3.

No continuity (6) Replace harness.

4-43

CONTROLLER

VCM-3

Harness B

Harness A

SPEED METER

384

0.85R/G 0.85G/B 0.85Y/G

220 221

Harness C 220 221

0.85W/L

220 221

9 17 25 34

220 221

CN2

0.85G/B

220 221 222

0.85R/G

SPEED SENSOR SPEED SENSOR AUTO LIGHT OUT

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

SPEED SENSOR 212355

4-44

CONTROLLER

Problem: ECU KWP2000 Communication Error (F18) (1) Situation Indication: "F18" flickering. Drive operations disabled.

(2) Possible cause Faulty ECU, faulty gateway, faulty harness.

(3) How the error code is triggered When KWP2000 communication from ECU to gateway is interrupted.

(4) Checks Check continuity of KWP2000 communication cable. 1. Between 719(Gateway) and 719(ECU). Continuity

(5) Replace gateway.

No continuity

(6) Replace harness. Error remains

(7) Replace ECU.

4-45

4-46 2Y/R

0.85G/Y

PTO MAX. REV. SET (SIG) VEHICLE SPEED SENSOR (SIG) 730 IDLE VOLUME (SIG) 731 PTO ACCEL SENSOR (SIG) 734 EGR TEMP. SENSOR

726 727

0.85G/B

CASE GND MUT-3 (KWP2000) ACCEL SENSOR-1 (SIG) ACCEL SENSOR-2 (SIG)

TACHO OUT (SIG)

721 722

0.85G/L

0.85L/R

+VB-3(ECU POWER) 708 718 719

+VB-2(ECU POWER)

+VB-1(ECU POWER) 707

705 706

719

30 31

22 26

19 21

7 8

5 6

GATEWAY

1.25B

1.25Y/R

0.85L/R

CONTROLLER

CONTROL UNIT, ECG (ea)

212356

CONTROLLER

Problem: ECU Speed Sensor Error (F19) (1) Situation Indication: "F19" flickering. Drive operations restricted.

(2) Possible cause Faulty gateway, faulty VCM-3, faulty ECU, faulty harness.

(3) How the error code is triggered When vehicle speed pulse signal to ECU is interrupted. Abnormal signal is sent from ECU.

(4) Checks Check continuity between ECU and gateway. 1. Between 727(ECU) and 727(Gateway). Continuity

(5) Replace gateway.

No continuity

(6) Replace harness. Error remains

(7) Replace VCM-3. Error remains (8) Replace ECU.

4-47

4-48 2Y/R

0.85G/Y

0.85G/B

0.85G/L

CASE GND

31 731 PTO ACCEL SENSOR (SIG) 734 EGR TEMP. SENSOR

27 30

727 730

726

21 22

VEHICLE SPEED SENSOR (SIG) IDLE VOLUME (SIG)

MUT-3 (KWP2000) ACCEL SENSOR-1 (SIG) ACCEL SENSOR-2 (SIG) PTO MAX. REV. SET (SIG) 722

721

719

7 8 18

TACHO OUT (SIG) 708 718

5 6 +VB-3 (ECU POWER)

+VB-1 (ECU POWER) +VB-2 (ECU POWER) 707

705 706

727

GATEWAY

0.85L/R

1.25B

1.25Y/R

0.85G/Y

CONTROLLER

CONTROL UNIT, ECG

(ea)

212357

CONTROLLER

Problem: Lift Lever Error (F20) (1) Situation Indication: "F20" flickering. Lift up and lift down operations disabled.

(2) Possible cause Faulty lift lever, faulty input unit, faulty harness.

(3) How the error code is triggered When lift lever signal voltage is out of range of 0.25V to 4.75V.

(4) Checks Check continuity between lift lever and input unit. 1. Between 468(Input unit: CN1-25) and 468(Lift lever). 2. Between 469(Input unit: CN1-26) and 469(Lift lever). 3. Between 460(Input unit: CN1-23) and 460(Lift lever). 4. Between 464(Input unit: CN1-24) and 464(Lift lever). Continuity

No continuity

(5) Replace harness.

(6) Replace lift lever with another section lever. Error transition

(7) Replace lift lever.

Error remains

(8) Replace input unit.

4-49

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

474 467

0.5P 0.5B

212352

4-50

CONTROLLER

Problem: Tilt Lever Error (F22) (1) Situation Indication: "F22" flickering. Tilt forward and tilt backward operations disabled.

(2) Possible cause Faulty tilt lever, faulty input unit, faulty harness.

(3) How the error code is triggered When tilt lever signal voltage is out of range of 0.25V to 4.75V.

(4) Checks Check continuity between tilt lever and input unit. 1. Between 470(Input unit: CN1-27) and 470(Tilt lever). 2. Between 471(Input unit: CN1-28) and 471(Tilt lever). 3. Between 460(Input unit: CN1-23) and 461(Tilt lever). 4. Between 464(Input unit: CN1-24) and 465(Tilt lever). No continuity

Continuity

(5) Replace harness. (6) Replace tilt lever with another section lever. Error transition (7) Replace tilt lever.

Error remains (8) Replace input unit.

4-51

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

474 467

0.5P 0.5B

212352

4-52

CONTROLLER

Problem: Attachment 1 Lever Error (F24) (1) Situation Indication: "F24" flickering. Attachment 1 operation disabled.

(2) Possible cause Faulty attachment 1 lever, faulty input unit, faulty harness.

(3) How the error code is triggered When attachment 1 lever signal voltage is out of range of 0.25V to 4.75V.

(4) Checks Check continuity between attachment 1 lever and input unit. 1. Between 472(Input unit: CN1-29) and 472(ATT1 lever). 2. Between 473(Input unit: CN1-30) and 473(ATT1 lever). 3. Between 460(Input unit: CN1-23) and 462(ATT1 lever). 4. Between 464(Input unit: CN1-24) and 466(ATT1 lever). No continuity

Continuity

(5) Replace harness.

(6) Replace attachment 1 lever with another section lever. Error transition (7) Replace attachment 1 lever.

Error remains (8) Replace input unit.

4-53

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

474 467

0.5P 0.5B

212352

4-54

CONTROLLER

Problem: Attachment 2 Lever Error (F26) (1) Situation Indication: "F26" flickering. Attachment 2 operation disabled.

(2) Possible cause Faulty attachment 2 lever, faulty input unit, faulty harness.

(3) How the error code is triggered When attachment 2 lever signal voltage is out of range of 0.25V to 4.75V.

(4) Checks Check continuity between attachment 2 lever and input unit. 1. Between 474(Input unit: CN1-31) and 474(ATT2/3 lever). 2. Between 475(Input unit: CN1-32) and 475(ATT2/3 lever). 3. Between 460(Input unit: CN1-23) and 463(ATT2/3 lever). 4. Between 464(Input unit: CN1-24) and 467(ATT2/3 lever). Continuity

No continuity

(5) Replace harness.

(6) Replace attachment 2 lever with another section lever. Error transition

(7) Replace attachment 2 lever.

Error remains

(8) Replace input unit.

4-55

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

474 467

0.5P 0.5B

212352

4-56

CONTROLLER

Problem: Attachment 3 Lever Error (F28) (1) Situation Indication: "F28" flickering. Attachment 3 operation disabled.

(2) Possible cause Faulty attachment 3 lever, faulty input unit, faulty harness.

(3) How the error code is triggered When attachment 3 lever signal voltage is out of range of 0.25V to 4.75V.

(4) Checks Check continuity between attachment 3 lever and input unit. 1. Between 474(Input unit: CN1-31) and 474(ATT2/3 lever). 2. Between 475(Input unit: CN1-32) and 475(ATT2/3 lever). 3. Between 460(Input unit: CN1-23) and 463(ATT2/3 lever). 4. Between 464(Input unit: CN1-24) and 467(ATT2/3 lever). No continuity

Continuity

(5) Replace harness.

(6) Replace attachment 3 lever with another section lever. Error transition

(7) Replace attachment 3 lever.

Error remains

(8) Replace input unit.

4-57

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

474 467

0.5P 0.5B

212352

4-58

CONTROLLER

Problem: Joystick Lever Error (F29) (1) Situation Indication: "F29" flickering. Corresponding hydraulic operation disabled.

(2) Possible cause Faulty FC lever, faulty input unit, faulty harness.

(3) How the error code is triggered Voltage data between main signal and sub-signal is different when FC lever is not operated.

(4) Checks Check to see if other FC lever errors occur. F20

F22

F24

F26

F28

To (5)

To (6)

To (7)

To (8)

To (9)

(5) Replace lift lever.

(6) Replace tilt lever.

(7) Replace attachment 1 lever.

(8) Replace attachment 2 lever.

(9) Replace attachment 3 lever.

4-59

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

ARMREST LIFT

4/5 SELECT SW (OP)

ATT1 (OP)

TILT

ATT2/3 (OP)

0.5B

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 0.5R 470 461

0.5B

0.5R

0.5B

464 469 468 460

0.5O

0.5R

476

0.5B

477

0.5Y

460 469

0.5G 0.5Y

468 464

0.5L 461 471

0.5Y

470 465

462 473

0.5Br 0.5Y

472 466

0.5W 463 475

474 467

0.5P 0.5B

212352

4-60

CONTROLLER

Problem: VCM-3 Sensor Voltage Error (F31) (1) Situation Indication: "F31" flickering.

(2) Possible cause Faulty tire angle sensor, faulty VCM-3, faulty harness.

(3) How the error code is triggered When VCM-3 sensor power voltage is 3.85V or less.

(4) Checks Check continuity between sensor and VCM-3. 1. Between 231(Tire angle sensor: +5V) and 231(VCM-3: CN2-13: +5V). 2. Between 232(Tire angle sensor: GND) and 232(VCM-3: CN2-14: GND).

Continuity

No continuity

(5) Replace harness. (6) Check short circuit between sensor power and GND in sensor terminal. Not shorted

Shorted

(7) Replace tire angle sensor.

(8) Check short circuit between sensor and VCM-3 1. Between 231(Tire angle sensor: +5V) and 232(VCM-3: CN2-14: GND). 2. Between 232(Tire angle sensor: GND) and 231(VCM-3: CN2-13: +5V). Shorted

(9) Replace harness.

Not shorted

(10) Replace VCM-3.

4-61

CONTROLLER

VCM-3

0.85Y 1.25G/Y

230 231 232

9 17 25 34

231 232 230

232

CN2

0.85Br/Y

0.85Lg/R

231 230

230 231 232 233

Harness C

0.85Y

TIRE ANGLE SEN TIRE ANGLE SEN TIRE ANGLE SEN T/M SOL. F

Harness B 230 231 232

0.85Lg/R

Harness A 0.85Br/Y

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

TIRE ANGLE SENSOR 212358

4-62

CONTROLLER

Problem: VCM-3OP Lift Oil Pressure Sensor Error (F33) (1) Situation Indication: "F33" flickering. Tilt horizontal function operation disabled.

(2) Possible cause Faulty lift oil pressure sensor, faulty VCM-3OP, faulty harness.

(3) How the error code is triggered When lift oil pressure sensor signal voltage is out of range of 0.5V to 4.5V.

(4) Checks Check continuity between lift oil pressure sensor and VCM-3OP. 1. Between 267(VCM-3OP: CN1-14: +5V) and 267(Lift oil pressure sensor: Vcc). 2. Between 268(VCM-3OP: CN1-15: SIG) and 268(Lift oil pressure sensor: SIG). 3. Between 269(VCM-3OP: CN1-17: GND) and 269(Lift oil pressure sensor: GND). Continuity No continuity

(5) Replace harness. (6) Turn on key switch, then measure lift oil pressure sensor signal voltage between VCM-3OP connector terminals. 1. Between 268(Lift oil pressure sensor: SIG) and 269(Lift oil pressure sensor: GND). Normal (0.5V to 4.5V)

(7) Replace VCM-3OP.

Abnormal (out of 0.5V to 4.5V)

(8) Replace lift oil pressure sensor.

4-63

CONTROLLER

VCM-OP

250 252 267 268 269 264 265 266 290 257 42 43 135 136

0.85B/W

269 268 267

269

0.85Lg/B

0.85Lg

267

P. SOURCE 1 P. SOURCE 2 GND1 GND2

267 268 269

268

SP SEL. S/W 1 SP SEL. S/W 2 HYD PRESSURE HYD PRESSURE HYD PRESSURE TILT ANGLE SEN. TILT ANGLE SEN. TILT ANGLE SEN. SPEED PULSE CAB OPEN IND1

CN1 9

252 250

269

135

34 136 257

268 267

266 265 264 43 26

LIFT OIL PRESSURE SENSOR (OP) 212359

4-64

CONTROLLER

Problem: Vehicle Speed Sensor Error (F34) (1) Situation Indication: "F34" flickering. Drive speed change operation disabled.

(2) Possible cause Faulty vehicle speed sensor, faulty VCM-3, faulty harness.

(3) How the error code is triggered When vehicle speed sensor signal voltage is out of range of 1.3V to 4.9V.

(4) Checks Check continuity between VCM-3 and vehicle speed sensor. 1. Between 220(VCM-3: CN2-10) and 220(Speed sensor: +). 2. Between 221(VCM-3: CN2-11) and 221(Speed sensor: -).

Continuity

No continuity

(5) Replace harness. (6) Measure resistance between vehicle speed sensor terminals. 220(Speed sensor: +) and 221(Speed sensor: -). Normal [2kǡto 3kǡ at 25 °C (77 °F)]

(7) Replace VCM-3.

Abnormal

(8) Replace vehicle speed sensor.

4-65

CONTROLLER

VCM-3

Harness B

Harness A

SPEED METER

384

0.85R/G 0.85G/B 0.85Y/G

220 221

Harness C 220 221

0.85W/L

220 221

9 17 25 34

220 221

CN2

0.85G/B

220 221 222

0.85R/G

SPEED SENSOR SPEED SENSOR AUTO LIGHT OUT

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

SPEED SENSOR 212355

4-66

CONTROLLER

Problem: Tire Angle Sensor Error (F36) (1) Situation Indication: "F36" flickering. Knob position control disabled.

(2) Possible cause Faulty tire angle sensor, faulty VCM-3, faulty harness.

(3) How the error code is triggered When tire angle sensor signal voltage is out of range of 0.27V to 4.72V.

(4) Checks Check continuity between VCM-3 and tire angle sensor. 1. Between 231(VCM-3: CN2-13) and 231(Tire angle sensor: SIG). 2. Between 230(VCM-3: CN2-12) and 230(Tire angle sensor: Vcc). 3. Between 232(VCM-3: CN2-14) and 232(Tire angle sensor: GND). Normal

Abnormal

(5) Replace harness. (6) Measure resistance between tire angle sensor terminals. (Place tires in straight-ahead position.) 1. Between 230(Tire angle sensor: Vcc) and 231(Tire angle sensor: SIG). ࡮࡮࡮0.8kǡ to 1.2kǡ‫ޓ‬at 25͠ (77 ˚F) 2. Between 231(Tire angle sensor: SIG) and 232(Tire angle sensor: GND). ࡮࡮࡮0.8kǡ to 1.2kǡ‫ޓ‬at 25͠ (77 ˚F) 3. Between 230(Tire angle sensor: Vcc) and 232(Tire angle sensor: GND). ࡮࡮࡮1.6kǡ to 2.4kǡ‫ޓ‬at 25͠ (77 ˚F) Normal

(7) Replace VCM-3.

Abnormal (8) Replace tire angle sensor.

4-67

CONTROLLER

VCM-3

0.85Y 1.25G/Y

230 231 232

9 17 25 34

231 232 230

232

CN2

0.85Br/Y

0.85Lg/R

231 230

230 231 232 233

Harness C

0.85Y

TIRE ANGLE SEN TIRE ANGLE SEN TIRE ANGLE SEN T/M SOL. F

Harness B 230 231 232

0.85Lg/R

Harness A 0.85Br/Y

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

TIRE ANGLE SENSOR 212358

4-68

CONTROLLER

Problem: VCM-3OP Tilt Angle Sensor Error (F39) (1) Situation Indication: "F39" flickering. Tilt auto stop control function operation disabled.

(2) Possible cause Faulty tilt angle sensor, faulty VCM-3OP, faulty harness.

(3) How the error code is triggered When tilt angle sensor signal voltage is out of range of 0.1V to 4.9V.

(4) Checks Check continuity between VCM-3OP and tilt angle sensor. 1. Between 264(VCM-3OP: CN1-27: +5V) and 264(Tilt angle sensor: +5V). 2. Between 265(VCM-3OP: CN1-28: SIG) and 265(Tilt angle sensor: SIG). 3. Between 266(VCM-3OP: CN1-29: GND) and 266(Tilt angle sensor: GND). Continuity (6) Replace tilt angle sensor.

No continuity (5) Replace harness.

Error remains (8) Replace VCM-3OP.

4-69

CONTROLLER

VCM-OP

269 264

264 265 266

SPEED PULSE CAB OPEN IND1

0.85R/B

265 266 290 257 42 43 135

266 265 264

264 265

P. SOURCE 1 P. SOURCE 2 GND1 GND2

0.85B/Y

HYD PRESSURE TILT ANGLE SEN. TILT ANGLE SEN. TILT ANGLE SEN.

136

266

250 252 267 268

0.85Y/B

SP SEL. S/W 1 SP SEL. S/W 2 HYD PRESSURE HYD PRESSURE

CN1 9 17 25

252 250 269 135

34 136 257

268 267

266 265 264 43 26

TILT ANGLE SENSOR (OP) 212360

4-70

CONTROLLER

Problem: Steering Error (F40) (1) Situation Indication: "F40" flickering. Knob position control disabled.

(2) Possible cause Faulty steering sensor, faulty tire angle sensor, faulty VCM-3, faulty harness.

(3) How the error code is triggered Steering angle is changed when tire angle remains unchanged. Tire angle is changed when steering angle remains unchanged.

(4) Checks Check to see if tire angle sensor error (F36) occurs. F36 occurs

Not occurs

(5) See F36 troubleshooting. (6) Check continuity between VCM-3 and steering sensor. 1. Between 132(VCM-3: CN1-20: GND) and 132(Steering angle sensor: +5V). 2. Between 218(VCM-3: CN1-23: NT) and 218(Steering angle sensor: NT). 3. Between 217(VCM-3: CN1-22: ST2) and 217(Steering angle sensor: ST2). 4. Between 216(VCM-3: CN1-21: ST1) and 216(Steering angle sensor: ST1). 5. Between 215(VCM-3: CN1-19: +12V) and 215(Steering angle sensor: +12V). Continuity

No continuity

(7) Replace harness.

(8) Confirm tire angle with service tool when steering wheel is operated. Change

(9) Replace VCM-3.

Not change

(10) Replace steering sensor.

4-71

CONTROLLER

VCM-3

215 216 217 218 132

0.85Y 1.25G/Y

230 231 232

0.85Br 0.85Br/Y

CN2

9 25

10 18

41 26

245 224 223

17 130

218 217 216132 215 40

34 131 229 411

211

227228 1 234 235 233 232 231 230 221 220 384

222 238

0.85G/Y

0.85Br

217 215 218 216 132

237

200 201 299 298 297 296

132 218 217 216 215

CN1

0.85W/G

0.85B/G

0.85Br/Y

217 218 132

0.85W/G

0.85B/G

ST. ANGLE SEN ST. ANGLE SEN

231 232 230

215 216

232

Harness A 0.85G/Y

0.85Br/Y

ST. ANGLE SEN ST. ANGLE SEN ST. ANGLE SEN

0.85Lg/R

231 230

230 231 232 233

Harness C

0.85Y

TIRE ANGLE SEN TIRE ANGLE SEN TIRE ANGLE SEN T/M SOL. F

Harness B 230 231 232

0.85Lg/R

Harness A 0.85Br/Y

TIRE ANGLE SENSOR

18 26

R/E STEERING ANGLE SENSOR 212361

4-72

CONTROLLER

Problem: Output Unit Controller Error (F41) (1) Situation Indication: "F41" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit.

(3) How the error code is triggered Software checks sum value of ROM and EEPROM in CPU, and detects fault.

(4) Checks Write updated software into output unit. Normal Faulty software writing

Error remains

(5) Replace output unit.

4-73

CONTROLLER

Problem: Output Unit Life Control Signal (F42) (1) Situation Indication: "F42" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit.

(3) How the error code is triggered When output unit is being initialized.

(4) Checks Write updated software into output unit. Normal Faulty software writing

4-74

Error remains

(5) Replace output unit.

CONTROLLER

Problem: Output Unit Memory Error (F43) (1) Situation Indication: "F43" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit.

(3) How the error code is triggered Software checks sum value of ROM and EEPROM in CPU, and detects fault.

(4) Checks Write updated software into output unit. Normal Faulty software writing

Error remains

(5) Replace output unit.

4-75

CONTROLLER

Problem: Output Unit PWM Voltage Error (F44) (1) Situation Indication: "F44" flickering. Hydraulic operations disabled.

(2) Possible cause Poor battery charge, faulty VCM-3, faulty DC-DC converter, faulty harness.

(3) How the error code is triggered When output unit PWM voltage is 7V or less.

(4) Checks Measure battery terminal voltage. Normal (18V to 32V)

7V or less

(5) Charge battery. Error remains (6) Replace battery.

4-76

CONTROLLER

(7) Measure DC-DC converter output voltage and input voltage. 1. Output voltage: Between 40(DC-DC converter: +12V) and 107(DC-DC converter: GND). ࡮࡮࡮ (12V) 2. Input voltage: Between 8(DC-DC converter: +24V) and 104(DC-DC converter: GND). ࡮࡮࡮࡮ (24V) Normal Input voltage abnormal Output voltage abnormal (8) Replace harness.

(9) Replace DC-DC converter.

(10) Measure VCM-3 input voltage. 1. Between 40(VCM-3: CN1-18) and 130(VCM-3: CN1-25). 2. Between 41(VCM-3: CN1-26) and 131(VCM-3: CN1-34). 7V to 21V

7V or less (11) Replace harness.

(12) Replace VCM-3.

4-77

CONTROLLER

DC-DC CONVERTER

VCM-3 CN1 0.85B/L 131 0.85B/L 130 1.25R/Y 41 1.25R/Y 40

107 1.25B/L 2R/Y 40 1.25B 104

105 40

F7 8R

245

1 224 223

218 217 216132 215 40 211

10A

41 26

60B

5 㧙

2R/W

㧗

BATTERY

㧙

105

130

34 131 229 411

12V GND 12V MAIN 24V GND 12V LAMP 24V LAMP 24V BATT ACC IN 12V BATT

2B/L

2R/W

100

FLW 0.85R

15R

CN1

107 40 104 94 49 8 62 301

㧗

BATTERY 212349

4-78

CONTROLLER

Problem: Output Unit Communication Error (F45) (1) Situation Indication: "F45" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty harness, faulty output unit.

(3) How the error code is triggered When CAN communication from output unit to VCM-3 is interrupted.

(4) Checks Check continuity of CAN communication cables. VCM-3 to output unit: Between 201(VCM-3: CN2-31) and 394(Output unit: 13), and 200(VCM-3: CN2-32) and 393(Output unit: 14).

Continuity

No continuity (6) Replace harness.

(5) Replace output unit. Error remains (7) Replace VCM-3.

4-79

CONTROLLER

OUTPUT UNIT

VCM-3 CN2 0.85L/R

201 0.85B/W 200

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

201 200

0.85L/R 0.85B/W

1 2 3 4 5 6 7 8 9 10 11 12 394 13 393 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

GND GND +VE +VE N.C. N.C. SWITCH IN GND SWITCH IN GND SWITCH IN GND RS-232 Tx RS-232 Rx RS-232 GND CAN H CAN L N.C. N.C. BOOT FWE 0V DC 12V PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM4PWM 5+ PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

212362

4-80

CONTROLLER

Problem: Input Unit Controller Error (F46) (1) Situation Indication: "F46" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty input unit.

(3) How the error code is triggered Software checks sum value of ROM in CPU, and detects fault.

(4) Checks Write updated software into input unit. Normal Faulty software writing

Error remains

(5) Replace input unit.

4-81

CONTROLLER

Problem: Input Unit Life Control Signal (F47) (1) Situation Indication: "F47" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty input unit.

(3) How the error code is triggered When input unit is being initialized.

(4) Checks Write updated software into input unit. Normal Faulty software writing

4-82

Error remains

(5) Replace input unit.

CONTROLLER

Problem: Input Unit Memory Error (F48) (1) Situation Indication: "F48" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty input unit.

(3) How the error code is triggered Software checks sum value of ROM in CPU, and detects fault.

(4) Checks Write updated software into input unit. Normal Faulty software writing

Error remains

(5) Replace input unit.

4-83

CONTROLLER

Problem: Input Unit Communication Error (F49) (1) Situation Indication: "F49" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty harness, faulty input unit.

(3) How the error code is triggered When CAN communication from input unit to VCM-3 is interrupted.

(4) Checks Check continuity of CAN communication cables. VCM-3 to input unit: Between 201(VCM-3: CN2-31) and 396(Input unit: 7), and 200(VCM-3: CN2-32) and 395(Input unit: 8).

Continuity (5) Replace input unit.

(6) Replace harness. Error remains

(7) Replace VCM-3.

4-84

No continuity

CONTROLLER

INPUT UNIT (HARNESS, IN FC)

VCM-3 CN2 0.85L/R

201 0.85B/W 200

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

201 200

0.85L/R

0.85B/W

396 395

1 2 3 4 5 6 0.5B 396 7 0.5B/W 395 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

GND Vcc 19V FWE RS-232 Tx RS-232 Rx RS-232 GND CAN H CAN L CAN R+ CAN RBOOT SEL0 SEL1 SW GND SW INPUT 1 SW INPUT 2(SPEED SEL) SW INPUT 3(4V/5V) SW INPUT 4(F) SW INPUT 5(N) SW INPUT 6(R) SW INPUT 7 SW INPUT 8 5V GND LIFT 1 LIFT 2 TILT 1 TILT 2 ATT 1-1 ATT 1-2 ATT 2-1 ATT 2-2

212363

4-85

CONTROLLER

Problem: Lift Up Solenoid Error (F50) (1) Situation Indication: "F50" flickering. Lift operation disabled.

(2) Possible cause Faulty output unit, faulty lift up solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when lift up solenoid signal is outputted.

(4) Checks Check continuity between output unit and lift up solenoid. 1. Lift up: Between 480(Output unit: CN1-21) and 480(Lift A solenoid). 2. Lift return: Between 482(Output unit: CN1-23) and 482(Lift A solenoid). Continuity

No continuity

(5) Replace harness.

(6) Measure resistance of lift up solenoid. 1. Lift up: Between 480(Lift A solenoid) and 482(Lift A solenoid). Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)?

(7) Replace output unit.

4-86

Abnormal

(8) Replace lift up solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

480 21 PWM 1+ 22 PWM 2+ 482 23 PWM 1-/PWM 2483 24 PWM 3+ 484 25 PWM 4+ 26 PWM 3-/PWM 4485 486 27 PWM5 + 28 PWM 6+ 487 488 29 PWM 5-/PWM 630 PWM 7+ 489 490 31 PWM 8+ 32 PWM 7-/PWM 8491 492 33 PWM 9+ 493 34 PWM 10+ 494 35 PWM 9-/PWM 1036

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-87

CONTROLLER

Problem: Lift Down Solenoid Error (F52) (1) Situation Indication: "F52" flickering. Lift operation disabled.

(2) Possible cause Faulty output unit, faulty lift down solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when lift down solenoid signal is outputted.

(4) Checks Check continuity between output unit and lift down solenoid. 1. Lift down: Between 481(Output unit: CN1-22) and 481(Lift B solenoid). 2. Lift return: Between 482(Output unit: CN1-23) and 495(Lift B solenoid). Continuity

No continuity

(5) Replace harness.

(6) Measure resistance of lift down solenoid. 1. Lift down: Between 481(Lift B solenoid) and 495(Lift B solenoid). Normal [6.6

(7) Replace output unit.

4-88

to 9.8

at 25

(77Ë&#x161;F)]

Abnormal

(8) Replace lift down solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-89

CONTROLLER

Problem: Lift Solenoid Leak (F54) (1) Situation Indication: "F54" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit, faulty lift solenoids, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when lift lever is not operated.

(4) Checks Check hydraulic operations when error occurred.

(6) Tilt operation (5) Not operate

(7) Attachment 1 operation

(8) Attachment 2 operation

Forward

Backward

To (13)

To (16)

To (19)

To (22)

To (25)

To (28)

To (31)

To (34)

(10) Measure resistance of corresponding solenoid. Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(11) Replace output unit.

4-90

(9) Attachment 3 operation

Abnormal

(12) Replace faulty solenoid.

CONTROLLER

(13) Check continuity between lift section and tilt section. Between 483(Output unit: CN1-24) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less) (14) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (15) Replace output unit.

(16) Check continuity between lift section and tilt section. Between 484(Output unit: CN1-25) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less) (17) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (18) Replace output unit.

(19) Check continuity between lift section and attachment 1 section. Between 486(Output unit: CN1-27) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less) (20) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (21) Replace output unit.

(22) Check continuity between lift section and attachment 1 section. Between 487(Output unit: CN1-28) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less) (23) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (24) Replace output unit.

4-91

CONTROLLER

(25) Check continuity between lift section and attachment 2 section. Between 489(Output unit: CN1-30) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less) (26) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (27) Replace output unit.

(28) Check continuity between lift section and attachment 2 section. Between 490(Output unit: CN1-31) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less) (29) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (30) Replace output unit.

(31) Check continuity between lift section and attachment 3 section. Between 492(Output unit: CN1-33) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less) (32) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (33) Replace output unit.

(34) Check continuity between lift section and attachment 3 section. Between 493(Output unit: CN1-34) and 482(Output unit: CN1-23). Continuity (Several tenǡ or less) (35) Insulate wires in harness or replace harness.

4-92

No continuity (Several Mǡ) (15) Replace output unit.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-93

CONTROLLER

Problem: Tilt Forward Solenoid Error (F55) (1) Situation Indication: "F55" flickering. Tilt operation disabled.

(2) Possible cause Faulty output unit, faulty tilt forward solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when tilt forward solenoid signal is outputted.

(4) Checks Check continuity between output unit and tilt forward solenoid. 1. Tilt forward: Between 483(Output unit: CN1-24) and 483(Tilt A solenoid). 2. Tilt return: Between 485(Output unit: CN1-26) and 485(Tilt A solenoid). Continuity

No continuity

(5) Replace harness.

(6) Measure resistance of tilt forward solenoid. 1. Lift up: Between 483(Tilt A solenoid) and 485(Tilt A solenoid). Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(7) Replace output unit.

4-94

Abnormal

(8) Replace tilt forward solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-95

CONTROLLER

Problem: Tilt Backward Solenoid Error (F57) (1) Situation Indication: "F57" flickering. Tilt operation disabled.

(2) Possible cause Faulty output unit, faulty tilt backward solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when tilt backward solenoid signal is outputted.

(4) Checks Check continuity between output unit and tilt backward solenoid. 1. Tilt backward: Between 484(Output unit: CN1-25) and 484(Tilt B solenoid). 2. Tilt return: Between 485(Output unit: CN1-26) and 496(Tilt B solenoid). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of tilt backward solenoid. 1. Tilt backward: Between 484(Tilt B solenoid) and 496(Tilt B solenoid). Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] (7) Replace output unit.

4-96

Abnormal (8) Replace tilt backward solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-97

CONTROLLER

Problem: Tilt Solenoid Leak (F59) (1) Situation Indication: "F59" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit, faulty tilt solenoids, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when tilt lever is not operated.

(4) Checks Check hydraulic operations when error occurred.

(6) Lift operation (5) Not operate

(7) Attachment 1 operation

(8) Attachment 2 operation

Down

To (13)

To (16)

To (19)

To (22)

To (25)

To (28)

To (31)

To (34)

(10) Measure resistance of corresponding solenoid. Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(11) Replace output unit.

4-98

(9) Attachment 3 operation

Abnormal

(12) Replace faulty solenoid.

CONTROLLER

(13) Check continuity between tilt section and lift section. Between 480(Output unit: CN1-21) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less) (14) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (15) Replace output unit.

(16) Check continuity between tilt section and lift section. Between 481(Output unit: CN1-22) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less) (17) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (18) Replace output unit.

(19) Check continuity between tilt section and attachment 1 section. Between 486(Output unit: CN1-27) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less) (20) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (21) Replace output unit.

(22) Check continuity between tilt section and attachment 1 section. Between 487(Output unit: CN1-28) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less) (23) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (24) Replace output unit.

4-99

CONTROLLER

(25) Check continuity between tilt section and attachment 2 section. Between 489(Output unit: CN1-30) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less) (26) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (27) Replace output unit.

(28) Check continuity between tilt section and attachment 2 section. Between 490(Output unit: CN1-31) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less) (29) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (30) Replace output unit.

(31) Check continuity between tilt section and attachment 3 section. Between 492(Output unit: CN1-33) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less) (32) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (33) Replace output unit.

(34) Check continuity between tilt section and attachment 3 section. Between 493(Output unit: CN1-34) and 485(Output unit: CN1-26). Continuity (Several tenǡ or less) (35) Insulate wires in harness or replace harness.

4-100

No continuity (Several Mǡ) (36) Replace output unit.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-101

CONTROLLER

Problem: Attachment 1A Solenoid Error (F60) (1) Situation Indication: "F60" flickering. Attachment operation disabled.

(2) Possible cause Faulty output unit, faulty attachment 1A solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when attachment 1A solenoid signal is outputted.

(4) Checks Check continuity between output unit and attachment 1A solenoid. 1. Attachment 1 A: Between 486(Output unit: CN1-27) and 486(ATT1 A solenoid). 2. Attachment 1 return: Between 488(Output unit: CN1-29) and 488(ATT1 A solenoid). No continuity

Continuity

(5) Replace harness.

(6) Measure resistance of attachment 1A solenoid. 1. Attachment 1A: Between 486(ATT1 A solenoid) and 488(ATT1 A solenoid) Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] (9) Replace output unit.

4-102

Abnormal

(8) Replace attachment 1A solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-103

CONTROLLER

Problem: Attachment 1B Solenoid Error (F62) (1) Situation Indication: "F62" flickering. Attachment operation disabled.

(2) Possible cause Faulty output unit, faulty attachment 1B solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when attachment 1B solenoid signal is outputted.

(4) Checks Check continuity between output unit and attachment 1B solenoid. 1. Attachment 1B: Between 487(Output unit: CN1-28) and 486(ATT1 B solenoid). 2. Attachment 1 return: Between 488(Output unit: CN1-29) and 497(ATT1 B solenoid). No continuity

Continuity

(5) Replace harness.

(6) Measure resistance of attachment 1B solenoid. 1. Attachment 1B: Between 487(ATT1 B solenoid) and 497(ATT1 B solenoid) Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] (9) Replace output unit.

4-104

Abnormal

(8) Replace attachment 1B solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-105

CONTROLLER

Problem: Attachment 1 Solenoid Leak (F64) (1) Situation Indication: "F64" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit, faulty attachment 1 solenoids, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when attachment 1 lever is not operated.

(4) Checks Check hydraulic operations when error occurred.

(6) Lift operation

(7) Tilt operation

(5) Not operate

(8) Attachment 2 operation

Down

Forward

Backward

To (13)

To (16)

To (19)

To (22)

To (25)

To (28)

To (31)

To (34)

(10) Measure resistance of corresponding solenoid. Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(11) Replace output unit.

4-106

(9) Attachment 3 operation

Abnormal

(12) Replace faulty solenoid.

CONTROLLER

(13) Check continuity between attachment 1 section and lift section. Between 480(Output unit: CN1-21) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less) (14) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (15) Replace output unit.

(16) Check continuity between attachment 1 section and lift section. Between 481(Output unit: CN1-22) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less) (17) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (18) Replace output unit.

(19) Check continuity between attachment 1 section and tilt section. Between 483(Output unit: CN1-24) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less) (20) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (21) Replace output unit.

(22) Check continuity between attachment 1 section and tilt section. Between 484(Output unit: CN1-25) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less) (23) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (24) Replace output unit.

4-107

CONTROLLER

(25) Check continuity between attachment 1 section and attachment 2 section. Between 489(Output unit: CN1-30) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less) (26) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (27) Replace output unit.

(28) Check continuity between attachment 1 section and attachment 2 section. Between 490(Output unit: CN1-31) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less) (29) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (30) Replace output unit.

(31) Check continuity between attachment 1 section and attachment 3 section. Between 492(Output unit: CN1-33) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less) (32) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (33) Replace output unit.

(34) Check continuity between attachment 1 section and attachment 3 section. Between 493(Output unit: CN1-34) and 488(Output unit: CN1-29). Continuity (Several tenǡ or less) (35) Insulate wires in harness or replace harness.

4-108

No continuity (Several Mǡ) (36) Replace output unit.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-109

CONTROLLER

Problem: Attachment 2A Solenoid Error (F65) (1) Situation Indication: "F65" flickering. Attachment 2 operation disabled.

(2) Possible cause Faulty output unit, faulty attachment 2A solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when attachment 2A solenoid signal is outputted.

(4) Checks Check continuity between output unit and attachment 2A solenoid. 1. Attachment 2A: Between 489(Output unit: CN1-30) and 489(ATT2 A solenoid). 2. Attachment 2 return: Between 491(Output unit: CN1-32) and 491(ATT2 A solenoid). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of attachment 2A solenoid. 1. Attachment 2A: Between 489(ATT2 A solenoid) and 491(ATT2 A solenoid) Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] (7) Replace output unit.

4-110

Abnormal (8) Replace attachment 2A solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-111

CONTROLLER

Problem: Attachment 2B Solenoid Error (F67) (1) Situation Indication: "F67" flickering. Attachment 2 operation disabled.

(2) Possible cause Faulty output unit, faulty attachment 2B solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when attachment 2B solenoid signal is outputted.

(4) Checks Check continuity between output unit and attachment 2B solenoid. 1. Attachment 2B: Between 490(Output unit: CN1-31) and 490(ATT2 B solenoid). 2. Attachment 2 return: Between 491(Output unit: CN1-32) and 498(ATT2 B solenoid). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of attachment 2B solenoid. 1. Attachment 2B: Between 490(ATT2 B solenoid) and 498(ATT2 B solenoid) Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] (7) Replace output unit.

4-112

Abnormal (8) Replace attachment 2B solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-113

CONTROLLER

Problem: Attachment 2 Solenoid Leak (F69) (1) Situation Indication: "F69" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit, faulty attachment 2 solenoids, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when attachment 2 lever is not operated.

(4) Checks Check hydraulic operations when error occurred.

(6) Lift operation

(7) Tilt operation

(5) Not operate

(8) Attachment 1 operation

Down

Forward

Backward

To (13)

To (16)

To (19)

To (22)

To (25)

To (28)

To (31)

To (34)

(10) Measure resistance of corresponding solenoid. Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(11) Replace output unit.

4-114

(9) Attachment 3 operation

Abnormal

(12) Replace faulty solenoid.

CONTROLLER

(13) Check continuity between attachment 2 section and lift section. Between 480(Output unit: CN1-21) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less) (14) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (15) Replace output unit.

(16) Check continuity between attachment 2 section and lift section. Between 481(Output unit: CN1-22) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less) (17) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (18) Replace output unit.

(19) Check continuity between attachment 2 section and tilt section. Between 483(Output unit: CN1-24) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less) (20) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (21) Replace output unit.

(22) Check continuity between attachment 2 section and tilt section. Between 484(Output unit: CN1-25) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less) (23) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (24) Replace output unit.

4-115

CONTROLLER

(25) Check continuity between attachment 2 section and attachment 1 section. Between 486(Output unit: CN1-27) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less) (26) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (27) Replace output unit.

(28) Check continuity between attachment 2 section and attachment 1 section. Between 487(Output unit: CN1-28) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less) (29) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (30) Replace output unit.

(31) Check continuity between attachment 2 section and attachment 3 section. Between 492(Output unit: CN1-33) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less) (32) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (33) Replace output unit.

(34) Check continuity between attachment 2 section and attachment 3 section. Between 493(Output unit: CN1-34) and 491(Output unit: CN1-32). Continuity (Several tenǡ or less) (35) Insulate wires in harness or replace harness.

4-116

No continuity (Several Mǡ) (36) Replace output unit.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-117

CONTROLLER

Problem: Attachment 3A Solenoid Error (F70) (1) Situation Indication: "F70" flickering. Attachment 3 operation disabled.

(2) Possible cause Faulty output unit, faulty attachment 3A solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when attachment 3A solenoid signal is outputted.

(4) Checks Check continuity between output unit and attachment 3A solenoid. 1. Attachment 3A: Between 492(Output unit: CN1-33) and 492(ATT3 A solenoid). 2. Attachment 3 return: Between 494(Output unit: CN1-34) and 494(ATT3 A solenoid). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of attachment 3A solenoid. 1. Attachment 3A: Between 492(ATT3 A solenoid) and 494(ATT3 A solenoid) Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] (7) Replace output unit.

4-118

Abnormal (8) Replace attachment 3A solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-119

CONTROLLER

Problem: Attachment 3B Solenoid Error (F72) (1) Situation Indication: "F72" flickering. Attachment 3 operation disabled.

(2) Possible cause Faulty output unit, faulty attachment 3B solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 1.9A or more, when attachment 3B solenoid signal is outputted.

(4) Checks Check continuity between output unit and attachment 3B solenoid. 1. Attachment 3B: Between 493(Output unit: CN1-34) and 493(ATT3 B solenoid). 2. Attachment 3 return: Between 494(Output unit: CN1-32) and 499(ATT3 B solenoid). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of attachment 3B solenoid. 1. Attachment 3B: Between 493(ATT3 B solenoid) and 499(ATT3 B solenoid) Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] (7) Replace output unit.

4-120

Abnormal (8) Replace attachment 3B solenoid.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-121

CONTROLLER

Problem: Attachment 3 Solenoid Leak (F74) (1) Situation Indication: "F74" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty output unit, faulty attachment 3 solenoids, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when attachment 3 lever is not operated.

(4) Checks Check hydraulic operations when error occurred.

(6) Lift operation

(7) Tilt operation

(5) Not operate

(8) Attachment 1 operation

Down

Forward

Backward

To (13)

To (16)

To (19)

To (22)

To (25)

To (28)

To (31)

To (34)

(10) Measure resistance of corresponding solenoid. Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)]

(11) Replace output unit.

4-122

(9) Attachment 2 operation

Abnormal

(12) Replace faulty solenoid.

CONTROLLER

(13) Check continuity between attachment 3 section and lift section. Between 480(Output unit: CN1-21) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less) (14) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (15) Replace output unit.

(16) Check continuity between attachment 3 section and lift section. Between 481(Output unit: CN1-22) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less) (17) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (18) Replace output unit.

(19) Check continuity between attachment 3 section and tilt section. Between 483(Output unit: CN1-24) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less) (20) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (21) Replace output unit.

(22) Check continuity between attachment 3 section and tilt section. Between 484(Output unit: CN1-25) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less) (23) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (24) Replace output unit.

4-123

CONTROLLER

(25) Check continuity between attachment 3 section and attachment 1 section. Between 486(Output unit: CN1-27) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less) (26) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (27) Replace output unit.

(28) Check continuity between attachment 3 section and attachment 1 section. Between 487(Output unit: CN1-28) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less) (29) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (30) Replace output unit.

(31) Check continuity between attachment 3 section and attachment 2 section. Between 489(Output unit: CN1-30) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less) (32) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (33) Replace output unit.

(34) Check continuity between attachment 3 section and attachment 2 section. Between 490(Output unit: CN1-31) and 494(Output unit: CN1-35). Continuity (Several tenǡ or less) (35) Insulate wires in harness or replace harness.

4-124

No continuity (Several Mǡ) (36) Replace output unit.

CONTROLLER

OUTPUT UNIT

ATT1 A

ATT2 B

0.85Br/Y 0.85L/R

493 499

490 498 490 498

(BLACK)

493 499

492 494

(BLACK)

481

ATT1 B

492 0.85L/R 494

0.85R/L 0.85L/R

0.85L/Y 0.85W/L 489 491

(BLACK)

ATT2 A

0.85R 0.85W/R 487 497

(BLACK)

TILT B

0.85L 0.85Br 0.85W 0.85L/W 0.85R/W 0.85W/B 0.85L/R 0.85R 0.85W/R 0.85L/Y 0.85R/L 0.85W/L 0.85B/W 0.85Br/Y 0.85l/R

487 497

486 488

(BLACK)

TILT A

LIFT B

0.85L/R 0.85W/R

484 496

(BLACK)

0.85B/W

(BLACK)

489 491

LIFT A

484 496

483 485 483 485

481 495

(BLACK)

486 488

0.85L/W 0.85W/B

0.85W 0.85G

481 495

0.85L 0.85Br

480 482 480 482

(BLACK)

0.85R/W 0.85W

CN1

(BLACK)

ATT3 A

ATT3 B

212364

4-125

CONTROLLER

Problem: Unload Solenoid Error (F75) (1) Situation Indication: "F75" flickering. Hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty unload solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 2.4A or more, when unload solenoid signal is outputted.

(4) Checks Check to see if emergency button is pushed. Pushed

Not pushed

(5) Release emergency button and restart. Error remains

(6) Check continuity between VCM-3 and unload solenoid. 1. Between 211(VCM-3: CN1-30) and 211(Unload solenoid). 2. Between 411(VCM-3: CN1-32) and 411(Input unit). 3. Between 212(Input unit) and 212(Unload solenoid). No continuity

Continuity

(7) Replace harness.

(8) Measure resistance of unload solenoid. 1. Between 211(Unload solenoid) and 212(Unload solenoid). Normal [6.9 (9) Replace VCM-3.

4-126

to 10.3

at 25

(77Ë&#x161;F)]

Abnormal (10) Replace unload solenoid.

CONTROLLER

VCM-3

UNLOAD SOL UNLOAD RETURN CAN L CAN H PARK B P. SOURCE 1 P. SOURCE 2 GND 1 GND 2

0.85Lg/R

211 411 200 201 229 40 41

0.85G/B

Harness A 211

Harness B

Harness C 211

Harness B

0.85B/W

212

0.85L/R 0.85Lg/B 1.25R/Y 1.25R/Y

EMERGENCY SW Harness A

0.85B/L

130 131

212

0.85B/L

245

1 224 223

130

218 217 216132 215 40

34 131 229 411

211

10 18

41 26

212

937

396

397

395 411

0.85G/B

0.85Lg/R 0.85Br/B

211

211 212

9 17

937 397 396 395 212 411

INPUT UNIT

CN1

0.85Br/B

Harness C

212

(BLACK)

UNLOAD 212365

4-127

CONTROLLER

Problem: Unload Solenoid Leak (F79) (1) Situation Indication: "F79" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty unload solenoid, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when hydraulic operation signal is not outputted.

(4) Checks Check operating condition when error occurred.

(7) When knob position control function is installed

(6) Drive operation (5) Not operate. Forward

Reverse

To (11)

To (14)

During steering operation

To (17)

(8) Measure resistance of unload solenoid. Normal [6.9ǡ to 10.3ǡ at 25͠ (77˚F)]

(9) Replace VCM-3.

4-128

Abnormal

(10) Replace unload solenoid.

CONTROLLER

(11) Check continuity between transmission section and unload section. Between 233(VCM-3: CN2-15) and 411(VCM-3: CN1-32). Continuity (Several tenǡ or less) (12) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (13) Replace VCM-3.

(14) Check continuity between transmission section and unload section. Between 235(VCM-3: CN2-16) and 411(VCM-3: CN1-32). Continuity (Several tenǡ or less) (15) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (16) Replace VCM-3.

(17) Check continuity between knob position solenoid and unload section. Between 237(VCM-3: CN2-18) and 411(VCM-3: CN1-32). Continuity (Several tenǡ or less) (18) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (19) Replace VCM-3.

4-129

CONTROLLER

VCM-3

1.25G/Y

0.85Lg/R

1.25B/L

0.85Y 1.25G/Y

1.25B/L

234 242

1.25G/L

235

233

0.85Lg 0.85Lg/B 0.85W 0.85B/G

0.85Lg/B

SEAT S/W

0.85Br/Y

230 231 232 233 234 235 237 238 227 228

0.85Lg

TIRE ANGLE SEN. TIRE ANGLE SEN. TIRE ANGLE SEN. T/M SOL. F T/M GND T/M SOL. R P/S SOL P/S SOL SEAT S/W

SOLENOID (F - R)

238

237

(BLACK)

237 238

0.85G/B 0.85B/W 0.85L/R

PS CARIB (OP)

0.85Lg/B 1.25R/Y 1.25R/Y 0.85B/L 0.85B/L

245

1 224 223

17 25

130

218 217 216132 215 40

34 131 229 411

10 18

41 26

211

212

937

396

397

395 411

0.85Lg/R 0.85Br/B 211

211 212

INPUT UNIT

211 212

CN1

0.85G/B

EMERGENCY SW 0.85Br/B

UNLOAD RETURN CAN L CAN H PARK B P. SOURCE 1 P. SOURCE 2 GND 1 GND 2

0.85Lg/R

211 411 200 201 229 40 41 130 131

937 397 396 395 212 411

UNLOAD SOL

212

(BLACK)

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

UNLOAD 212366

4-130

CONTROLLER

Problem: Knob Position Solenoid Error (F80) (1) Situation Indication: "F80" flickering. Knob position control fuunction disabled.

(2) Possible cause Faulty VCM-3, faulty knob position solenoid, faulty harness.

(3) How the error code is triggered Current is 0.16A or less, or 3.54A or more, when knob position solenoid signal is outputted.

(4) Checks Check continuity between VCM-3 and knob position solenoid. 1. Between 237(VCM-3: CN2-18) and 237(PS CARIB solenoid). 2. Between 238(VCM-3: CN2-20) and 238(PS CARIB solenoid). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of knob position solenoid. 1. Between 237(PS CARIB solenoid) and 238(PS CARIB solenoid). Normal [6.9ǡ to 10.3ǡ at 25͠ (77˚F)] (7) Replace VCM-3.

Abnormal (8) Replace knob position solenoid.

4-131

CONTROLLER

VCM-3

0.85Br/Y

230 231 232 233 234 235 237 238 227 228

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

0.85W

Harness A

237 238

Harness B

237 238

237

0.85Lg

0.85B/G

0.85Lg/B

0.85Lg 0.85Lg/B

238

TIRE ANGLE SEN. TIRE ANGLE SEN. TIRE ANGLE SEN. T/M SOL. F T/M GND T/M SOL. R P/S SOL P/S SOL SEAT SW SEAT SW

(BLACK)

237 238

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

PS CARIB (OP) 212367

4-132

CONTROLLER

Problem: Knob Position Solenoid Leak (F84) (1) Situation Indication: "F84" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty knob position solenoid, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when steering wheel is not operated.

(4) Checks Check operating condition when error occurred.

(6) Drive operation (7) During hydraulic operation

(5) Not operate. Forward

Reverse

To (11)

To (14)

To (17)

(8) Measure resistance of knob position solenoid. Normal [6.9

(9) Replace VCM-3.

to 10.3

at 25

(77Ë&#x161;F)]

Abnormal

(10) Replace knob position solenoid.

4-133

CONTROLLER

(11) Check continuity between transmission section and knob position solenoid. Between 233(VCM-3: CN2-15) and 238(VCM-3: CN2-20). Continuity (Several tenǡ or less) (12) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (13) Replace VCM-3.

(14) Check continuity between transmission section and knob position solenoid. Between 235(VCM-3: CN2-16) and 238(VCM-3: CN2-20). Continuity (Several tenǡ or less) (15) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (16) Replace VCM-3.

(17) Check continuity between unload section and knob position solenoid. Between 211(VCM-3: CN1-30) and 238(VCM-3: CN2-20). Continuity (Several tenǡ or less) (18) Insulate wires in harness or replace harness.

4-134

No continuity (Several Mǡ) (19) Replace VCM-3.

CONTROLLER

VCM-3

1.25G/Y

0.85Lg/R

1.25B/L

0.85Y 1.25G/Y

1.25B/L

234 242

1.25G/L

235

233

0.85Lg 0.85Lg/B 0.85W 0.85B/G

0.85Lg/B

SEAT S/W

0.85Br/Y

230 231 232 233 234 235 237 238 227 228

0.85Lg

TIRE ANGLE SEN. TIRE ANGLE SEN. TIRE ANGLE SEN. T/M SOL. F T/M GND T/M SOL. R P/S SOL P/S SOL SEAT S/W

SOLENOID (F - R)

238

237

(BLACK)

237 238

0.85G/B 0.85B/W 0.85L/R

PS CARIB (OP)

0.85Lg/B 1.25R/Y 1.25R/Y 0.85B/L 0.85B/L

245

1 224 223

17 25

130

218 217 216132 215 40

34 131 229 411

10 18

41 26

211

212

937

396

397

395 411

0.85Lg/R 0.85Br/B 211

211 212

INPUT UNIT

211 212

CN1

0.85G/B

EMERGENCY SW 0.85Br/B

UNLOAD RETURN CAN L CAN H PARK B P. SOURCE 1 P. SOURCE 2 GND 1 GND 2

0.85Lg/R

211 411 200 201 229 40 41 130 131

937 397 396 395 212 411

UNLOAD SOL

212

(BLACK)

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

UNLOAD 212366

4-135

CONTROLLER

Problem: Transmission Forward Solenoid Error (F85) (1) Situation Indication: "F85" flickering. Drive operations disabled.

(2) Possible cause Faulty VCM-3, faulty transmission forward solenoid, faulty harness.

(3) How the error code is triggered Current is 0.25A or less, or 3.84A or more, when transmission forward solenoid signal is outputted.

(4) Checks Check continuity between VCM-3 and transmission forward solenoid. 1. Between 233(VCM-3: CN2-15) and 233(Solenoid F: +). 2. Between 234(VCM-3: CN2-17) and 234(Solenoid F: -). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of transmission forward solenoid. 1. Between 233(Solenoid F: +) and 234(Solenoid F: -). Normal [6.9ǡ to 14.9ǡ at 25͠ (77˚F)] (7) Replace VCM-3.

4-136

Abnormal (8) Replace transmission forward solenoid.

CONTROLLER

VCM-3

0.85Br/Y

230 231 232 233 234 235 237 238 227 228

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

Harness A

233 234 235

Harness B

233 234

Harness C 1.25B/L

1.25B/L

0.85Lg/B 0.85W 0.85B/G

235

1.25G/Y

234 242

1.25G/L

233

1.25G/Y

235

TIRE ANGLE SEN. TIRE ANGLE SEN. TIRE ANGLE SEN. T/M SOL. F T/M GND T/M SOL. R P/S SOL P/S SOL SEAT SW SEAT SW

SR SOLENOID(F - R)

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

212368

4-137

CONTROLLER

Problem: Transmission Backward Solenoid Error (F87) (1) Situation Indication: "F87" flickering. Drive operations disabled.

(2) Possible cause Faulty VCM-3, faulty transmission backward solenoid, faulty harness.

(3) How the error code is triggered Current is 0.25A or less, or 3.84A or more, when transmission backward solenoid signal is outputted.

(4) Checks Check continuity between VCM-3 and transmission backward solenoid. 1. Between 235(VCM-3: CN2-16) and 235(Solenoid R: +). 2. Between 234(VCM-3: CN2-17) and 242(Solenoid R: -). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of transmission backward solenoid. Between 235(Solenoid R: +) and 242(Solenoid R: -). Normal [6.9ǡ to 14.9ǡ at 25͠ (77˚F)] (7) Replace VCM-3.

4-138

Abnormal (8) Replace transmission backward solenoid.

CONTROLLER

VCM-3

0.85Br/Y

230 231 232 233 234 235 237 238 227 228

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

Harness A

233 234 235

Harness B

233 234

Harness C 1.25B/L

1.25B/L

0.85Lg/B 0.85W 0.85B/G

235

1.25G/Y

234 242

1.25G/L

233

1.25G/Y

235

TIRE ANGLE SEN. TIRE ANGLE SEN. TIRE ANGLE SEN. T/M SOL. F T/M GND T/M SOL. R P/S SOL P/S SOL SEAT SW SEAT SW

SR SOLENOID(F - R)

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

212368

4-139

CONTROLLER

Problem: Transmission Solenoid Leak (F89) (1) Situation Indication: "F89" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Faulty VCM-3, faulty transmission solenoids, faulty harness.

(3) How the error code is triggered Current is 0.18A or more when transmission solenoid is in neutral position.

(4) Checks Check operating condition when error occurred.

(5) Not operate.

(6) During hydraulic operation.

(7) When knob position control function is installed During steering operation

To (11)

To (14)

(10) Measure resistance of transmission forward/backward solenoid. Normal [9.9ǡ to 14.9ǡ at 25͠ (77˚F)]

(11) Replace VCM-3.

4-140

Abnormal

(12) Replace faulty solenoid.

CONTROLLER

(11) Check continuity between unload section and transmission section. Between 211(VCM-3: CN1-30) and 234(VCM-3: CN2-17). Continuity (Several tenǡ or less) (12) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (13) Replace VCM-3.

(14) Check continuity between knob position solenoid and transmission section. Between 237(VCM-3: CN2-18) and 234(VCM-3: CN2-17). Continuity (Several tenǡ or less) (15) Insulate wires in harness or replace harness.

No continuity (Several Mǡ) (16) Replace VCM-3.

4-141

CONTROLLER

VCM-3

1.25G/Y

0.85Lg/R

1.25B/L

0.85Y 1.25G/Y

1.25B/L

234 242

1.25G/L

235

233

0.85Lg 0.85Lg/B 0.85W 0.85B/G

0.85Lg/B

SEAT S/W

0.85Br/Y

230 231 232 233 234 235 237 238 227 228

0.85Lg

TIRE ANGLE SEN. TIRE ANGLE SEN. TIRE ANGLE SEN. T/M SOL. F T/M GND T/M SOL. R P/S SOL P/S SOL SEAT S/W

SOLENOID (F - R)

238

237

(BLACK)

237 238

0.85G/B 0.85B/W 0.85L/R

PS CARIB (OP)

0.85Lg/B 1.25R/Y 1.25R/Y 0.85B/L 0.85B/L

245

1 224 223

17 25

130

218 217 216132 215 40

34 131 229 411

10 18

41 26

211

212

937

396

397

395 411

0.85Lg/R 0.85Br/B 211

211 212

INPUT UNIT

211 212

CN1

0.85G/B

EMERGENCY SW 0.85Br/B

UNLOAD RETURN CAN L CAN H PARK B P. SOURCE 1 P. SOURCE 2 GND 1 GND 2

0.85Lg/R

211 411 200 201 229 40 41 130 131

937 397 396 395 212 411

UNLOAD SOL

212

(BLACK)

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

UNLOAD 212366

4-142

CONTROLLER

Problem: VCM-3OP Sensor Voltage Error (F90) (1) Situation Indication: "F90" flickering.

(2) Possible cause Faulty lift oil pressure/tilt angle sensor, faulty VCM-3OP, faulty harness.

(3) How the error code is triggered When VCM-3OP sensor 5V power voltage is 3.85V or less.

(4) Checks Check continuity between sensor and VCM-3OP. 1. Lift oil pressure sensor: Between 267(Lift oil pressure sensor: +5V) and 267(VCM-3OP: CN1-14: +5V), and 269(Lift oil pressure sensor: GND) and 269(VCM-3OP: CN1-17: GND). 2. Tilt angle sensor: Between 264(Tilt angle sensor: +5V) and 264(VCM-3OP: CN1-27: +5V), and 266(Tilt angle sensor: GND) and 266(VCM-3OP: CN1-29: GND). Continuity

No continuity

(5) Replace harness. (6) Check short circuit between sensor power and GND in sensor connector side. Shorted

Not shorted

(7) Replace faulty sensor(lift oil pressure/tilt angle).

4-143

CONTROLLER

(8) Check short circuit between sensor and VCM-3OP.

1. Lift oil pressure sensor: Between 267(Lift oil pressure sensor: +5V) and 269(VCM-3OP: CN1-17: GND), and 269(Lift oil pressure sensor: GND) and 267(VCM-3OP: CN1-14: +5V). 2. Tilt angle sensor: Between 264(Tilt angle sensor: +5V) and 266(VCM-3OP: CN1-29: GND), and 266(Tilt angle sensor: GND) and 264(VCM-3OP: CN1-27: +5V). Shorted

(9) Replace faulty harness.

4-144

Not shorted

(5) Replace VCM-3OP.

CONTROLLER

43 135

264 265

266 265 264

136

0.85B/W

0.85Lg 269 268 267

269

P. SOURCE 1 P. SOURCE 2 GND1 GND2

266

SPEED PULSE CAB OPEN IND1

0.85R/B

265 266 290 257 42

267

269 264

0.85B/Y

267 268 269 264 265 266

268

250 252 267 268

0.85Y/B

SP SEL. S/W 1 SP SEL. S/W 2 HYD PRESSURE HYD PRESSURE HYD PRESSURE TILT ANGLE SEN. TILT ANGLE SEN. TILT ANGLE SEN.

0.85Lg/B

VCM-OP

CN1 9 17 25

252 250 269 135

34 136 257

268 267

266 265 264 43 26

TILT ANGLE SENSOR (OP)

LIFT OIL PRESSURE SENSOR (OP) 212369

4-145

CONTROLLER

Problem: VCM-3OP Memory Check Error (F91) (1) Situation Indication: "F91" flickering. Drive and hydraulic operations disabled.

(2) Possible cause Faulty VCM-3OP, faulty truck type setting data in VCM-3OP.

(3) How the error code is triggered Software checks sum value of ROM and EEPROM in CPU, and detects fault.

(4) Checks Check truck type setting data. Normal

Abnormal (5) Enter truck type setting data again.

(6) Set shipment default value into VCM-3OP. Normal

Abnormal

(7) Perform standard setting, then enter truck type setting data again.

(8) Write updated software into VCM-3OP. Normal

(9) Faulty software writing.

4-146

Abnormal

(10) Replace VCM-3OP.

CONTROLLER

Problem: VCM-3OP Battery Voltage Error (F92) (1) Situation Indication: "F92" flickering. Tilt horizontal control and speed change control disabled.

(2) Possible cause Poor battery charge, faulty battery, faulty VCM-3OP, faulty harness, faulty DC-DC converter.

(3) How the error code is triggered When VCM-3OP input voltage is less than 7V or more than 21V.

(4) Checks Measure battery terminal voltage. Normal (18V to 32V)

More than 32V

Less than 7V (5) Charge battery.

Error remains (6) Replace battery.

Input voltage abnormal

Output voltage abnormal

(9) Replace DC-DC converter.

(8) Replace harness.

(10) Measure VCM-3OP input voltage. 1. Between 42(VCM-3OP: CN1-18) and 135(VCM-3OP: CN1-25). 2. Between 43(VCM-3OP: CN1-26) and 136(VCM-3OP: CN1-34). Less than 7V

(11) Replace harness.

12V 24V

7V to 21V

(12) Replace VCM-3OP.

4-147

CONTROLLER

DC-DC CONVERTER

VCM-3OP CN1 0.85B/L 136 0.85B/L 135 1.25R/Y 43 1.25R/Y 42

107 1.25B/L 2R/Y 40 1.25B 104

105 42

F7 8R

252 250 268 267

10A

2R/W

62 301

12V LAMP 24V LAMP 24V BATT ACC IN 12V BATT

266 265 264 43 26

60B

㧙

㧗

BATTERY

㧙

105

135

12V GND 12V MAIN 24V GND

2B/L

269

34 136 257

2R/W

100

FLW 0.85R

15R

CN1

107 40 104 94 49 8

㧗

BATTERY

212370

4-148

CONTROLLER

Problem: VCM-3OP Change Transmission Solenoid 1 Error (F93) (1) Situation Indication: "F93" flickering. EAT control function disabled (speed change step fixed).

(2) Possible cause Faulty VCM-3OP, faulty change transmission solenoid 1, faulty harness.

(3) How the error code is triggered Current is 0.25A or less, or 3.84A or more, when change transmission solenoid 1 signal is outputted.

(4) Checks Check continuity between VCM-3OP and change transmission solenoid 1. 1. Between 253(VCM-3OP: CN2-15) and 255(Solenoid SH: +). 2. Between 254(VCM-3OP: CN2-17) and 254(Solenoid SH: -). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of change transmission solenoid 1. 1. Between 255(Solenoid SH: +) and 254(Solenoid SH: -) Normal [9.9 (7) Replace VCM-3OP.

to 14.9

at 25

(77Ë&#x161;F)]

Abnormal (8) Replace change transmission solenoid 1.

4-149

CONTROLLER

VCM-OP

CN2

COOLANT AT OIL TEMP AIR DUST W/SEPA 2SP SOL 3SP SOL 2SP 3SP SOL TILT CAB TILT CAB TILT CAB TILT CAB TILT CAB CAN L CAN H

281 279 277 253 273 254 258

ECU FUSE 273 204 205

253 255

1.25R/Y

255

253

1.25L/Y 274

273

1.25R/Y 1.25L/Y

205 204 295 294 293 292

255

1.25L/Y

274

1 10

258

254

279 281

254 273 253

1.25R/Y

9 277 17

1.25B/W

CN2

246

SOLENOID (SPEED SELECT) 212371

4-150

CONTROLLER

Problem: VCM-3OP Change Transmission Solenoid 2 Error (F94) (1) Situation Indication: "F94" flickering. EAT control function disabled (speed change step fixed).

(2) Possible cause Faulty VCM-3OP, faulty change transmission solenoid 2, faulty harness.

(3) How the error code is triggered Current is 0.25A or less, or 3.84A or more, when change transmission solenoid 2 signal is outputted.

(4) Checks Check continuity between VCM-3OP and change transmission solenoid 2. 1. Between 273(VCM-3OP: CN2-16) and 274(Solenoid S2: +). 2. Between 254(VCM-3OP: CN2-17) and 246(Solenoid S2: -). Continuity

No continuity (5) Replace harness.

(6) Measure resistance of change transmission solenoid 2. 1. Between 274(Solenoid S2: +) and 246(Solenoid S2: -) Normal [9.9ǡ to 14.9ǡ at 25͠ (77˚F)] (7) Replace VCM-3OP.

Abnormal (8) Replace change transmission solenoid 2.

4-151

CONTROLLER

VCM-OP

CN2

COOLANT AT OIL TEMP AIR DUST W/SEPA 2SP SOL 3SP SOL 2SP 3SP SOL TILT CAB TILT CAB TILT CAB TILT CAB TILT CAB CAN L CAN H

281 279 277 253 273 254 258

ECU FUSE 273 204 205

253 255

1.25R/Y

255

253

1.25L/Y 274

273

1.25R/Y 1.25L/Y

205 204 295 294 293 292

255

1.25L/Y

274

1 10

258

254

279 281

254 273 253

1.25R/Y

9 277 17

1.25B/W

CN2

246

SOLENOID (SPEED SELECT) 212371

4-152

CONTROLLER

Problem: VCM-3OP Change Transmission Solenoid Leak (F95) (1) Situation Indication: "F95" flickering. EAT control function disabled.

(2) Possible cause Faulty VCM-3OP, faulty corresponding solenoid, faulty harness.

(3) How the error code is triggered Output signal current is 0.18A or more when vehicle is driving at 3rd speed.

(4) Checks Measure resistance of change transmission solenoid 1 and 2. Abnormal

Normal [9.9ǡ to 14.9ǡ at 25͠ (77˚F)]

(5) Replace faulty solenoid. (6) Check continuity between power source and change transmission section. 1. Between 42(VCM-3OP: CN1-18) and 253(VCM-3OP: CN2-15). 2. Between 42(VCM-3OP: CN1-18) and 273(VCM-3OP:CN2-16). Continuity (Several tenǡ or less)

(7) Insulate wires in harness or replace harness.

No continuity (Several Mǡ)

(8) Replace VCM-3OP.

4-153

CONTROLLER

DC-DC CONVERTER

VCM-3OP CN1 0.85B/L 136 0.85B/L 135 1.25R/Y 43 1.25R/Y 42

107 1.25B/L 2R/Y 40

105 42

CN2

ECU FUSE 273 204 205

253 255

CN2

205 204 295 294 293 292

1.25L/Y 274

273

1.25R/Y 1.25L/Y

CN1 252 250

34 136 257

269 135

268 267

266 265 264 43 26

1.25L/Y

258

253

255

279 281

254 273 253

255

274

1.25R/Y

1.25B/W

9 277 17

12V GND 12V MAIN 24V GND 12V LAMP 24V LAMP 24V BATT ACC IN 12V BATT

279 277 253 273 254 258

254

CAN H

281

1.25R/Y

COOLANT AT OIL TEMP AIR DUST W/SEPA 2SP SOL 3SP SOL 2SP 3SP SOL TILT CAB TILT CAB TILT CAB TILT CAB TILT CAB CAN L

107 40 104 94 49 8 62 301

246

SOLENOID (SPEED SELECT) 212372

4-154

CONTROLLER

Problem: VCM-3OP EAT Setting Error (F96) (1) Situation Indication: "F96" flickering. Speed change function disabled (speed change step fixed).

(2) Possible cause Faulty VCM-3OP, faulty truck type setting data in VCM-3OP

(3) How the error code is triggered 1 When setting value of speed shift point is not in following relations. 2- speed specification vehicle: (from 1st-speed to 2nd-speed) (from 2nd-speed to 1st-speed) 3- speed specification vehicle: (from 2nd-speed to 3rd-speed) (from 3rd-speed to 2nd-speed) (from 1st-speed to 2nd-speed) (from 2nd-speed to 1st-speed) 2 When setting data for mode selecting decision is in following conditions. Mode selecting decision value is out of setting range (0 to 3). Mode selecting pattern is repeated. Either of mode selector switch SW1 and SW2 is not set. 3 When setting data for speed change solenoid (SH and S2) is in following conditions. Speed change solenoid output decision value is out of setting range (0 to 3). Speed change solenoid output pattern is repeated. Either of SH and S2 is not set.

(4) Checks Check truck type setting data. Normal

Abnormal

(5) Enter truck type setting data again.

(6) Set shipment default value into VCM-3OP. Abnormal

Normal

(7) Perform standard setting, then enter truck type setting data again.

(8) Replace VCM-3OP.

4-155

CONTROLLER

Problem: VCM-3OP Communication Error (F97) (1) Situation Indication: "F97" flickering. Speed change function disabled (current step held).

(2) Possible cause Faulty VCM-3OP, faulty VCM-3, faulty harness.

(3) How the error code is triggered When CAN communication from VCM-3OP to VCM-3 is interrupted.

(4) Checks Check continuity of CAN communication cables. 1. VCM-3 to VCM-3OP: Between 201(VCM-3: CN2-31) and 205(VCM-3OP: CN2-32), and 200(VCM-3: CN2-32) and 204(VCM-3OP: CN2-31).

Continuity

No continuity (5) Replace harness.

(6) Replace VCM-3OP. Error remains (7) Replace VCM-3.

4-156

CONTROLLER

VCM-OP CN2 281

CN2 9 277

279 281

254 273 253

258

205 204 295 294 293 292

279 277 253 273 254 258

VCM-3 CN2 0.85L/R

201 0.85B/W 200

CN2 9 17 25 34

227228 1 234 235 233 232 231 230 221 220 384

222 238

237

200 201 299 298 297 296

10 18 26

201 200

204 205

0.85B/W 0.85L/R

204 205 CN1 250 252 267 268 269 264 265 266 290 257 42 43 135 136

COOLANT AT OIL TEMP AIR DUST W/SEPA 2SP SOL 3SP SOL 2SP 3SP SOL TILT CAB TILT CAB TILT CAB TILT CAB TILT CAB CAN L CAN H

SP SEL. S/W 1 SP SEL. S/W 2 HYD PRESSURE HYD PRESSURE HYD PRESSURE TILT ANGLE SEN. TILT ANGLE SEN. TILT ANGLE SEN. SPEED PULSE CAB OPEN IND1 P. SOURCE 1 P. SOURCE 2 GND1 GND2

212373

4-157

TILTABLE SYSTEM 1. Specifications ............................................................................................................... 5-2 2. Structure....................................................................................................................... 5-3 2.1 Outline................................................................................................................................................... 5-3 2.2 Hand pump ........................................................................................................................................... 5-4 2.3 Tiltable cylinder ..................................................................................................................................... 5-5 2.4 Hydraulic latch A, B............................................................................................................................... 5-6

3. Oil supply ..................................................................................................................... 5-7 4. Hydraulic circuit diagram.............................................................................................. 5-8 5. Service Data................................................................................................................. 5-9 5.1 Tiltable cylinder ..................................................................................................................................... 5-9 5.2 Cylinder bracket .................................................................................................................................. 5-10 5.3 Pin A, B ............................................................................................................................................... 5-11

5-1

TILTABLE SYSTEM

1. Specifications Truck model

DP100N

DP120N

Maker model

Hand pump

Tiltable cylinder

DP150N 2

30.0 MPa (306 kgf/cm ) [4352 psi]

Discharge quantity per stroke

4 cm ± 10% (0.244 cu. in. ±10%)

Reservoir capacity

480 cm (29.3 cu. in.)

Control valve type

4-way/2-POS

Maker model

DCD2-100416

Stroke Maker model Latch operating pressure

DP160N

DHP2-100417

Set relief pressure

Hydraulic latch

5-2

DP135N

330 mm (12.99 cu. in.) KLH5000-01-98/3 (latch A) KLH5000-01-99/3 (latch B) 2

1.38 to 2.07 MPa (14.1 to 21.1 kgf/cm ) [200 to 300 psi]

TILTABLE SYSTEM

2. Structure 2.1 Outline

Fully open position (65 ) Maintenance position (50 ) 7 Partially stopped position (25 ) Fully lowered position (0 ) 5

9 5

2 3

212004

1 Hand pump

5 Pull cable

9 Hydraulic latch A

2 Pump lever connection

6 Tiltable cylinder

10 Hydraulic latch B

3 Directional valve

7 Stopper case

4 Cable knob

8 Stopper pin

If you operate the hand pump with the direction valve turned clockwise, the hydraulic latch is released and the operator compartment rises up to the maintenance position (50˚) (the operator compartment tilts to the left if viewed from the rear of the vehicle). In order to raise it further to the full-open position (65˚), it is necessary to operate the hand pump while pulling the cable knob to release the stopper pin from the lock position. The full-open position must be used only for removing the engine. If you operate the hand pump with the direction valve turned counterclockwise, the operator compartment lowers down to the partial stop position (25˚).

In order to lower it further to the full-lower position (0˚), it is necessary to operate the hand pump while pulling the cable knob to release the stopper pin from the lock position. The operator compartment will be locked to the full-lower position by the hydraulic latch mechanism.

CAUTION If you attempt to raise or lower the operator compartment without tilting the mast fully forward beforehand, the operator compartment will be damaged.

5-3

TILTABLE SYSTEM

2.2 Hand pump

50 r5

23 r5

Clockwise: Operator compartment raised Counterclockwise: Operator compartment lowered

7 212005

1 Hand pump assembly

5 Pull port

2 Pump lever connection

6 level plug (oil supply mouth)

3 Directional valve

7 Suction port for power pump (option)

4 Push port

5-4

TILTABLE SYSTEM

2.3 Tiltable cylinder

212006

1 Tiltable cylinder assembly

3 Pull port

2 Push port

5-5

TILTABLE SYSTEM

2.4 Hydraulic latch A, B

SECTION A-A 212007

1 Hydraulic latch assembly

4 Connector (hydraulic latch A), Breather (hydraulic latch B)

2 Latch

5 Hydraulic port

3 Connector

5-6

TILTABLE SYSTEM

3. Oil supply

30 to 35 mm (1.18 to 1.38 in.)

Add oil to the hand pump with the pump lever pushed down.

Oil level

& 2

Pump lever

212008

5-7

TILTABLE SYSTEM

4. Hydraulic circuit diagram

Tiltable cylinder Stroke: 330 mm (12.99 in.)

Hydraulic latches A and B Operating pressure to open latch: 1.38 to 2.07 MPa (14.1 to 21.1 kgf/cm 2 ) [200 to 300 psi]

Hand pump Relief valve setting: 30.0 MPa (306 kgf/cm 2 ) [4352 psi] Flow per stroke: 4 cm3 10% (0.244 cu. in. 10%) Reservoir capacity: 480 cm3 (29.3 cu. in.)

Port thread size: UNF7/16-20

Push port (NPT1/8) Pull port (NPT1/8)

212009

5-8

TILTABLE SYSTEM

5. Service Data 5.1 Tiltable cylinder Truck model Inside diameter of pin A insertion part 1 Inside diameter of pin B insertion part 2

DP100N Standard value

Repair or service limit Standard value Repair or service limit

DP120N 20.1

DP135N + 0.25 0

20.1 16.1

+ 0.5

+ 0.25 0

16.1

+ 0.5

mm (0.791 mm (0.791 mm (0.634 mm (0.634

DP150N + 0.0098 0 + 0.020

in.)

+ 0.0098 0 + 0.020

DP160N

in.)

212010

5-9

TILTABLE SYSTEM

5.2 Cylinder bracket Truck model Inside diameter of pin A insertion part 1

DP100N Standard value

Repair or service limit

DP120N 20

DP135N

+ 0.221 0

+ 0.5

mm (0.79 mm (0.79

DP150N

+ 0.00083 0 + 0.020

DP160N

in.)

212011

5-10

TILTABLE SYSTEM

5.3 Pin A, B Truck model Outside diameter of Pin A shaft 1 Outside diameter of Pin B shaft 2

DP100N

DP120N

Standard value

mm (0.79

DP150N

0 -0.00083

20 -0.5 mm (0.79 -0.020 in.)

Standard value

16 -0.018 mm (0.63 -0.00071 in.)

Repair or service limit

16 -0.5 mm (0.63 -0.020 in.)

DP160N

in.)

Repair or service limit

Pin A

DP135N

0 -0.021

Pin B

212012

5-11

POWER TRAIN 1. Specifications ............................................................................................................... 6-2 2. Structure....................................................................................................................... 6-3 3. Reduction ratio ............................................................................................................. 6-5 4. Removal and Installation of Engine and Transmission Unit......................................... 6-6 4.1 Preparation ........................................................................................................................................... 6-6 4.1.1 Draining Oil and Coolant ............................................................................................................................. 6-6

4.2 Removing cover .................................................................................................................................... 6-7 4.2.1 Removal sequence ..................................................................................................................................... 6-7

4.3 Removing Harnesses............................................................................................................................ 6-8 4.3.1 Suggestions for Removal ............................................................................................................................ 6-8

4.4 Radiator (transmission oil cooler), Pipes and Hoses ............................................................................ 6-9 4.4.1 Removal sequence ..................................................................................................................................... 6-9

4.5 Other removing ................................................................................................................................... 6-10 4.5.1 Removal sequence ................................................................................................................................... 6-10

4.6 Removal of Engine and Transmission Unit......................................................................................... 6-11 4.6.1 Suggestions for Removal .......................................................................................................................... 6-11

4.7 Installation........................................................................................................................................... 6-12 4.7.1 Installation sequence ................................................................................................................................ 6-12 4.7.2 Suggestions for Removal .......................................................................................................................... 6-12

4.8 Capacity .............................................................................................................................................. 6-14

6-1

POWER TRAIN

1. Specifications Truck model

DP100N

Type Torque converter

Differential

DP160N

Stall torque ratio

2.51

Operation method

Forward/reverse switching electrical column shift, 1st, 2nd, 3rd, automatic drive Forward

1st: 2.402 2nd: 1.010 3rd: 0.558

Reverse

1st: 2.402 2nd: 1.010 3rd: 0.558

Gear type Reduction ratio Gear type

Hypoid gear 5.142 Planetary gear

Reduction ratio

4.235

Housing type

Banjo

Gear type and num- Large ber Small

Front axle type Front axle suspension method

6-2

DP150N

MN16

Gear ratio

Final drive

DP135N

3-element, 1-stage, 2-phase

Maker model

Transmission

Reduction gear

DP120N

Straight bevel gear × 2 Straight bevel gear × 2 Full-floating, tubular Fixed to frame

POWER TRAIN

2. Structure

12 6

4 3

14 15

10 205670A

1 Engine

10 Speed sensor gear

2 Flywheel

11 Pump drive gear

3 Torque converter

12 Hydraulic pump

4 Transmission

13 Universal joint

5 Input shaft

14 Parking brake

6 Forward clutch shaft

15 Front axle

7 Reverse clutch shaft

16 Reduction differential

8 1st and 3rd clutch shaft

17 Final drive

9 Output shaft

18 Wheel brake

The power transmission system, which serves to transmit power produced by the engine to the drive wheels, consists of the following components. (1) Torque converter 3 The torque converter itself not only works as a clutch but also transmits the increased engine torque to the transmission. (2) Transmission 4 This is a device to change the revolving speed and di-

rection of universal joint from those which are derived from the engine operation. (3) Universal joint 13 Transmits power from the transmission to the reduction differential. (4) Reduction differential 16 Not only reduces the speed but also distribute the power to right and left drive wheels. It also functions as to prevent slipping by differentiating

6-3

POWER TRAIN

two (right and left) drive wheels in terms of their number of rotation, when they have a difference in the rotating speed as the result of vehicleâ&#x20AC;&#x2122;s turning to the right or left. (5) Final drive 17 Final reduction system using planetary gears.

6-4

POWER TRAIN

3. Reduction ratio

(39)

(58) (58)

(54)

(17) (55)

(35) (34) (58)

(59)

(7)

(35) (24)

(46)

(58)

(36)

(32) (56)

(53)

205670B

( ) indicates number of teeth. Truck model

Forward

Reverse

Transmission

Reduction bevel gear

Final drive

Total gear ratio

1st

2.402 (35/34 × 58/58×58/58 × 56/24)

52.318

2nd

1.010 (35/34 × 53/54)

22.007

3rd

0.558 (35/34 × 58/58 × 58/58 × 32/59)

1st

2.402 (35/34 × 58/58 × 56/24)

2nd

1.010 (35/34 × 58/58 × 53/54)

22.007

3rd

0.558 (35/34 × 58/58 × 32/59)

12.161

5.142 (36/7)

4.235 (55/17 + 1)

12.161 52.318

PTO reduction ratio: 0.907

6-5

POWER TRAIN

4. Removal and Installation of Engine and Transmission Unit Both the engine and transmission should be removed as a unit.

4.1 Preparation 4.1.1 Draining Oil and Coolant

Engine coolant drain plug Transmission oil drain plug

Engine coolant drain plug

Engine oil drain plug

211787

Drain engine oil, transmission oil and engine coolant.

6-6

POWER TRAIN

4.2 Removing cover

3 2

211961

4.2.1 Removal sequence (Raise the tiltable cab.) 1 Gas-filled cylinder

4 Exhaust pipe

2 Engine cover

5 Radiator cover

3 Middle cover

6-7

POWER TRAIN

4.3 Removing Harnesses

Torgue converter oil thermo-unit Transmission solenoid

Travel speed sensor

Starter relay

Battery Oil by-pass alarm

Glow plug Alternator Engine oil pressure switch Engine thermo-unit

211789

4.3.1 Suggestions for Removal The harness connected to the engine and transmission should not be completely removed but partially disconnected at the sockets and terminals. Then, lay it along the main harness to which it is retained so as not to be damaged.

POWER TRAIN

4.4 Radiator (transmission oil cooler), Pipes and Hoses

2 4 3 5 1 6

10 8 11 9

211790

4.4.1 Removal sequence 1 Delivery hose

9 PCV valve hose

2 Suction hose

10 Air cleaner hose

3 Intercooler inlet hose

11 Compressor inlet hose

4 Intercooler outlet hose

12 Compressor outlet hose

5 Radiator upper hose

13 Fuel hose

6 Radiator lower hose

14 Oil cooler outlet hose

7 Exhaust pipe

15 Oil cooler inlet hose

8 Air inlet hose

6-9

POWER TRAIN

4.5 Other removing

3 2

211791

4.5.1 Removal sequence 1 Propeller shaft

3 Thrust rod (2 parts)

2 Universal joint

4 Cushion (4 parts)

6-10

POWER TRAIN

4.6 Removal of Engine and Transmission Unit

211792

4.6.1 Suggestions for Removal Fasten a hoist to the engine and transmission unit with wire ropes hitched to two lifting eyes on the engine and a sling chain hitched to one eye on the transmission while placing a levelling block under the unit. Adjust the length of the chain sling with the lever block so that the unit is horizontal. Then slowly lift the unit while moving it backward to remove in the upward direction. Weight of engine and transmission unit

900 kg (1.984 lb.)

6-11

POWER TRAIN

4.7 Installation 4.7.1 Installation sequence Install in the reverse sequence of the disassembly procedure. 4.7.2 Suggestions for Removal

Output shaft

(1) When mounting the engine and transmission unit on the frame, position it on the mounting brackets such that the universal joint in front of the unit is aligned with the transmission output flange.

Output flange

(2) Tighten the mounting bolt to the specified torque. Ref. No.

Item position

Tightening Torque

Cushion rubber and mounting bolt

145 N•m (14.8 kgf•m) [107 lbf•ft]

Mounting bracket bolt

60 N•m (6.1 kgf•m) [44 lbf•ft]

Cushion rubber bolt

97 N•m (9.9 kgf•m) [72 lbf•ft]

Mounting bracket bolt

60 N•m (6.1 kgf•m) [44 lbf•ft]

205457

Engine mount(left shown,right opposite) 4

206171

Transmission mount(right side)

1 2

206172

6-12

POWER TRAIN

Transmission mount(left side)

206173

(3) When installing the engine exhaust pipe, use a new gasket.

(4) Make sure that all wires have been connected properly, and then fasten the ground (negative) battery cable to the corresponding terminal. (5) Refill the engine oil, engine coolant, and transmission oil respectively and check for any water or oil leakage. For concentration of antifreeze in coolant, consult your Cat lift truck dealer. (6) Also bleed the engine fuel lines. (7) After checking every part, start the engine and observe its running condition. If the engine vibrates excessively, retighten the engine mounting bolts to see if this retightening has an effect. Additionally, operate the mast, forks and steering to check for the level of hydraulic oil, and refill it if necessary. Also check the engine oil, coolant and transmission oil levels, and refill each if necessary.

6-13

POWER TRAIN

4.8 Capacity Fuels and Oils

Oil Brand

Capacity

Antifreeze

M Lift long-life coolant (Genuine Mitsubishi Fuso Dia Queen) long-life coolant

23 Liters (4.7 U.S. gal.)

Torque converter oil

Diamond ATF DEXRON II

23 Liters (6.1 U.S. gal.)

Gear oil (differential gear, front axle final gear)

Diamond firm gear oil B API category, Multi-purpose type GL-5 SAE90, 80

20 Liters (5.3 U.S. gal.)

Brake oil

ENEOS brake fluid FMVSS DOT3 or DOT4

240 cc DP100N–135N 140 Liters (37.0 U.S. gal.)

Hydraulic oil

M Lift hydraulic oil (Genuine Mitsubishi Fuso hydraulic Oil) ISO VG32

Level gauge (N) mark

DP150N 168 Liters (44.4 U.S. gal.) DP160N 184 Liters (48.6 U.S. gal.)

Fuel

JIS Extra Grade 3 (-15˚C or lower) JIS Grade 3 (-5 to -15˚C) JIS Grade 2 (higher than -5˚C)

Engine oil

M Lift diesel engine oil (Genuine Mitsubishi Fuso Engine Oil Special) API category CD class or higher SAE 10W or SAE 10W30 (-10˚C or lower) SAE 20W (-10˚C to 10˚C) SAE 30 (higher than +10˚C)

6-14

175 Liters (46.2 U.S. gal.) Engine body: 12 Liters (3.2 U.S. gal.) Oil filter: 4 Liters (1.0 U.S. gal.) Total: 16 Liters (4.2 U.S. gal.)

3-SPEED POWERSHIFT TRANSMISSION 1. Specifications ............................................................................................................... 7-3 2. Description ................................................................................................................... 7-4 2.1 Torque Converter.................................................................................................................................. 7-4 2.2 Transmission......................................................................................................................................... 7-5 2.3 Power Flow ........................................................................................................................................... 7-6 2.4 Control Valve ........................................................................................................................................ 7-8

1 2

2.5 Main Regulator Valve............................................................................................................................ 7-8 2.6 Hydraulic Controls................................................................................................................................. 7-9 2.7 Speed Selector System ...................................................................................................................... 7-10 2.8 Control System ................................................................................................................................... 7-11

3 4

3. Suggestions for Removal and Installation.................................................................. 7-12 3.1 Removal.............................................................................................................................................. 7-12 3.1.1 Transmission removal ............................................................................................................................... 7-12

3.1.2 Torque converter removal ......................................................................................................................... 7-12

3.2 Torque converter installation............................................................................................................... 7-13

4. Disassembly and Reassembly ................................................................................... 7-14 4.1 Torque Converter................................................................................................................................ 7-14

6 7 7

4.1.1 Disassembly.............................................................................................................................................. 7-14 4.1.2 Inspection.................................................................................................................................................. 7-15 4.1.3 Reassembly .............................................................................................................................................. 7-18

4.2 Transmission....................................................................................................................................... 7-20 4.2.1 Disassembly.............................................................................................................................................. 7-20

8 9

4.2.2 Inspection.................................................................................................................................................. 7-30 4.2.3 Reassembly .............................................................................................................................................. 7-33

4.3 Control Valve ...................................................................................................................................... 7-41

4.3.1 Disassembly.............................................................................................................................................. 7-41 4.3.2 Inspection.................................................................................................................................................. 7-42 4.3.3 Reassembly .............................................................................................................................................. 7-43

4.4 Main Regulator Valve.......................................................................................................................... 7-44 4.4.1 Disassembly.............................................................................................................................................. 7-44

11 12

4.4.2 Inspection.................................................................................................................................................. 7-44 4.4.3 Reassembly .............................................................................................................................................. 7-44

5. Adjustment ................................................................................................................. 7-45 5.1 Brake pedal and inching pedal adjustment ......................................................................................... 7-45 5.2 Oil Pressure Measurement ................................................................................................................. 7-46

7-1

13 14

3-SPEED POWERSHIFT TRANSMISSION

5.2.1 Main oil pressure measurement................................................................................................................ 7-46 5.2.2 Direction clutch oil pressure measurement ............................................................................................... 7-47 5.2.3 Torque converter inlet oil pressure measurement..................................................................................... 7-48

5.3 Stall Speed Measurement................................................................................................................... 7-48 5.4 10 m (33 ft) Start Acceleration Test .................................................................................................... 7-49 5.5 Travel Speed Select Switch ................................................................................................................ 7-50

6. Troubleshooting ......................................................................................................... 7-51 7. Service Data............................................................................................................... 7-56 7.1 Stall Speed, Hydraulic......................................................................................................................... 7-56 7.2 Pump Boss.......................................................................................................................................... 7-56 7.3 Pilot Boss ............................................................................................................................................ 7-57 7.4 Oil Pump ............................................................................................................................................. 7-57 7.5 Stator .................................................................................................................................................. 7-58 7.6 Flexible Plates..................................................................................................................................... 7-58 7.7 Clutches .............................................................................................................................................. 7-60 7.8 Forward Clutch Shaft, Reverse Clutch Shaft, 1st-Speed/3rd-Speed Clutch Shaft and Servo Case... 7-61 7.9 Backlash of Gears............................................................................................................................... 7-62 7.10 Control Valve ...................................................................................................................................... 7-63 7.11 Main Regulator Valve.......................................................................................................................... 7-64 7.12 Inching Pedal Control.......................................................................................................................... 7-65

7-2

3-SPEED POWERSHIFT TRANSMISSION

1. Specifications Truck Model

DP100N

Type Torque converter

DP150N

DP160N

MN 16

Stall torque ratio

Transmission

DP135N

3-element, 1-stage, 2-phase

Model

Control

DP120N

2.51 Direction

Electric, column shift

Speed

Automatic

Forward

1st: 2.402 2nd: 1.010 3rd: 0.558

Reverse

1st: 2.402 2nd: 1.010 3rd: 0.558

Gear ratio

7-3

3-SPEED POWERSHIFT TRANSMISSION

2. Description 2.1 Torque Converter

5 2

From oil pump

1 8

6 To oil cooler

200550

1 Pilot boss

4 Turbine assembly

7 Pump (impeller)

2 Flexible plate

5 Stator

8 Stator shaft

3 Drive cover

6 Freewheel

9 Input shaft (transmission)

Oil pressurized in the torque converter flows from the outlet passage in the stator shaft to the lubrication circuit of transmission through the oil cooler. The oil flow generated by rotation of the impeller rotates the turbine and input shaft. The freewheel is a kind of one-way clutch. When the rotation speeds of the engine and input shaft are almost equal, the freewheel allows the stator to turn freely and causes the torque converter to act as a fluid coupling automatically. The torque converter is operated efficiently even in high speed rotation by the freewheel. Type

3-element, 1-stage, 2-phase

Model

MN 16

7-4

3-SPEED POWERSHIFT TRANSMISSION

2.2 Transmission

9 2 4 1 8

F R

1 3

212191

1 Flexible plate

5 Reverse clutch shaft

9 Pump idler gear

2 Torque converter assembly

6 1st-speed/3rd-speed clutch shaft

10 Pump drive gear

3 Input shaft

7 Output shaft

11 Pump case

4 Forward clutch shaft

8 PTO drive gear

The transmission is a 3-speed power shift transmission. The speed is changed by the hydraulic multi-disc clutch automatically at both forward and reverse operations.

7-5

3-SPEED POWERSHIFT TRANSMISSION

2.3 Power Flow

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

(39)

(58) (58) (35)

(58)

(34)

Forward 2nd (46)

(24)

(58)

(54)

(35)

(34)

(56)

Forward 3rd

(58) (35) (53)

(58)

(34)

(59)

(58)

(32)

212192

Speed

Gears engaged

Gear ratio

1st

35/34 × 58/58 × 58/58 × 56/24

2.402

2nd

35/34 × 53/54

1.010

3rd

35/34 × 58/58 × 58/58 × 32/59

0.558

58/46 × 39/58

0.848

PTO gear

7-6

3-SPEED POWERSHIFT TRANSMISSION

Reverse 1st

Figures in ( ) indicate number of gear teeth. (39)

(58)

(34)

Reverse 2nd

(35) (24)

(58)

(46)

(58) (58)

(54)

(56)

(34)

(58)

Reverse 3rd

(35)

(53)

(58)

(34)

(59)

(35)

(58)

(32)

212193

Speed

Gears engaged

Gear ratio

1st

35/34 × 58/58 × 56/24

2.402

2nd

35/34 × 58/58 × 53/54

1.010

3rd

35/34 × 58/58 × 32/59

0.558

58/46 × 39/58

0.848

PTO gear

7-7

3-SPEED POWERSHIFT TRANSMISSION

2.4 Control Valve 2

3 Section A - A A

B B

Section B - B 1 212194

1 Accumulator valve

3 1st-speed valve

2 Direction valve

4 Differential valve

5 2nd-speed/3rd-speed valve

2.5 Main Regulator Valve

1 212195

1 Bolts

5 Spool

9 Main pressure port

2 Cover

6 Body

10 Torque converter inlet pressure port

3 O-ring

7 Spring

4 Slug

8 Drain port

7-8

with magnet 100mesh

Suction strainer

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

Oil pump

Setting: 0.15 to 0.69 MPa (1.53 to 7.0 kgf/cm 2 ) [21.8 to 100 psi]

Torque converter inlet relief valve

Oil cooler

Chassis area

R C 3 C1

Transmission oil reservoir

C2 CF

Lubrication line

Oil filter

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

Torque converter

Transmission hydraulic circuit

Last chance filter

Orifice: Diam. 0.8 mm(0.031 in.)

Last chance filter

Main orifice: Diam. 2.2 mm(0.087 in.)

(marked D)

Orifice: Diam. 0.8 mm(0.031 in.)

Oil filter for forward/ reverse clutches (particle size )

Last chance filter

Solenoid valve (direction selection)

Setting: 0.88 to 1.08 MPa (9.0 to 11.0 kgf/cm ) [127.6 to 145 psi)

Main regulator valve

PM Tap (plug) for main pressure (marked "M")

Tap (plug) for torque converter inlet pressure (marked "T") T/C in

Speed selector valve S1 (1st speed)

(0.031 in.)

Orifice: Diam. 0.8 mm

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

Orifice: Diam. 0.8 mm(0.031 in.)

Solenoid valve (direction selection) Last chance filter

PS (marked S)

Setting: 0.2 MPa (2.0kgf/cm 2 ) [29 psi]

Differential valve

Pressure at start of charging 0.3 MPa (3.1kgf/cm 2 )[43.5 psi] Pressure at end of charging 0.76 MPa (7.8kgf/cm 2 )[110 psi]

Accumulator valve

3-SPEED POWERSHIFT TRANSMISSION

2.6 Hydraulic Controls

212196

7-9

3-SPEED POWERSHIFT TRANSMISSION

2.7 Speed Selector System

Travel speed select switch

Output gear

VCM

Travel speed sensor

Travel speed (solenoid) valve

1st speed clutch 2nd/3rd speed clutch

Electric signal Hydraulic pressure signal

0.5 mm Transmission case (0.02 in.) Control system

Power source To meter panel

Transmission shift lever

Travel speed select switch VCM

Solenoid valve

Travel speed sensor

212197

Location of components Automatic 3-speed transmission system consists of the torque converter and 3-speed transmission. The speed control system consists of the travel speed sensor, VCM (Vehicle Control Module) and solenoid valves. The truck speed can be changed from “automatic speed change” mode to “fixed 1st speed” mode by the travel speed selector switch to select the optimum truck speed according to the working condition.

7-10

3-SPEED POWERSHIFT TRANSMISSION

2.8 Control System

6 R 9

To meter panel 5 1

3 8

212198

1 Transmission shift lever

6 VCM-3OP

2 Control valve

7 Inching pedal

3 Travel speed (solenoid) valve

8 Cutoff switch

4 Direction (solenoid) valve

9 Control relay

5 VCM-3

7-11

3-SPEED POWERSHIFT TRANSMISSION

3. Suggestions for Removal and Installation To remove the transmission assembly from the truck, remove it together with the engine. Refer to â&#x20AC;&#x153;GROUP 6 POWER TRAIN.â&#x20AC;?

3.1 Removal 3.1.1 Transmission removal

(1) To separate the transmission from the engine, put the

(2) (3)

(4) (5)

engine on a stable stand, and support the transmission with wood blocks. Remove the hydraulic pump from the transmission. 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. Remove the bolts that hold the flexible plates through the access hole in the torque converter housing. Separate the transmission from the engine by lifting it with a hoist.

212199

3.1.2 Torque converter removal

(1) 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.

7-12

3-SPEED POWERSHIFT TRANSMISSION

3.2 Torque converter installation (1) Install the torque converter to the transmission. Make

(2) (3)

(4)

(5) (6)

sure that the distance between the end face of the torque converter housing and the mating face of the flexible plate is 14.5 mm (0.57 in.). If this distance is more than 14.5 mm (0.57 in.), it is an indication that spline engagement between the torque converter stator shaft and transmission input shaft is improper; reinstall the torque converter to the transmission. Lift the transmission, and bolt it to the engine. Make sure that the clearance between the flywheel and flexible plate is 0 to 2 mm (0 to 0.08 in.) when the transmission is bolted to the engine. Tighten the bolts that hold the flexible plate 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. Mount the hydraulic gear pump to the transmission. Install the transmission harness. Connect the travel speed sensor at the connector side, and connect the torque converter thermo unit at the terminal side. Connect the following wire color harness to each solenoid. Solenoid Valve

Travel speed Transmission shift lever

14.5 mm (0.57 in.)

200557

Harness Wire Color S1

F solenoid

(7) Pour in the torque converter oil.

R solenoid

S2 solenoid

S1 solenoid 212200

7-13

3-SPEED POWERSHIFT TRANSMISSION

4. Disassembly and Reassembly 4.1 Torque Converter 4.1.1 Disassembly

5 6

3 7

3 4 212201

(1) Sequence 1 Bolts, Spring washers, Plain washers

5 Thrust washers, Thrust bearing

2 Flexible plates, Pilot boss, O-ring, Bolts, Spring washers

6 Stator, Rollers, Hub, Springs, Spring caps, Thrust washers

3 Bolts, Drive cover, Ball bearing, Drain plug, Seal washers

7 Ball bearing, O-ring, Pump boss, Pump (impeller), Bolts, Toothed washers

4 Thrust washer, Turbine

7-14

3-SPEED POWERSHIFT TRANSMISSION

(2) 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

4.1.2 Inspection

(1) Pump (impeller) (a) Check for cracks. (b) Check for oil leaks due to looseness of the bolts holding the boss to the pump, or defective O-ring.

(d) Check the face of the pump boss in contact with the seal ring. Oil seal

Seal ring

O-ring 200561

7-15

3-SPEED POWERSHIFT TRANSMISSION

(2) Stator (a) Check the blades for cracks. Also check the fit of the stator on the clutch cam.

(b) Check the clutch hub and cam for wear or flaws. (c) Check the springs for damage. Also check the spring caps for wear or distortion.

(d) Check the rollers for flaws, distortion or flat spots due to wear.

(e) Check the clutch hub splines for defects. (f) Check the thrust washers for wear or other defects.

67.951 to 67.97 Outside diameter of Standard value (2.67523 to 2.6760) clutch hub 1 mm (in.) Service limit 67.8 (2.669) Diameter of clutch Standard value rollers 2 mm (in.) Service limit

10.185 to 10.2 (0.40098 to 0.402)

Thickness of thrust Standard value washer 3 mm (in.) Service limit

4.95 to 5 (0.1949 to 0.197)

Thickness of thrust Standard value washer 4 mm (in.) Service limit

3.95 to 4 (0.1555 to 0.157)

Thickness of thrust Standard value washer 5 mm (in.) Service limit

2.9 to 3 (0.114 to 0.118)

Thickness of thrust Standard value washer 6 mm (in.) Service limit

4.9 to 5 (0.193 to 0.197)

Thickness of thrust Standard value washer 7 mm (in.) Service limit

4.95 to 5 (0.1949 to 0.197)

7-16

10.1 (0.398)

1 2 5 6 7

4.8 (0.189)

3.8 (0.150)

2.8 (0.11)

4.8 (0.189)

200724

3-SPEED POWERSHIFT TRANSMISSION

(3) (a) (b) (c)

Turbine Check the vanes for cracks. Check the fit of the turbine boss in the turbine. 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. Standard Diameter of portion value in contact with engine flywheel 1 Service mm (in.) limit

-0.007

-0.00028

20 -0.020 (0.7874 -0.00079)

19.85 (0.7815)

200411

7-17

3-SPEED POWERSHIFT TRANSMISSION

4.1.3 Reassembly

13 11

4 2 9 3 7

5 6

212202

(1) Sequence 1 Pump (impeller)

8 Thrust washer

2 Pump boss, O-ring, Bolts, Toothed washers

9 Thrust bearing, Thrust washers

3 Ball bearing

10 Turbine

4 Stator assembly

11 Drive cover, O-ring, Bolts, Washers

5 Springs, Spring caps

12 Thrust washer, Ball bearing, Pilot boss, O-ring, Bolts, Washers

6 Rollers

13 Flexible plates, Bolts, Plain washers, Spring washers

7 Hub

7-18

3-SPEED POWERSHIFT TRANSMISSION

(2) Suggestions for Assembly (a) Stator assembly • 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. • Install a total of eight rollers, and restore the hub to its original position. • After having assembled the stator, turn the hub by hand, making sure that it rotates in only one direction.

5 5

202885A

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

Standard dimensions mm (in.)

26.4 (1.039)

19 (0.75)

4 -0.1 (0.16 -0.004 )

C 212203

(c) 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. Face runout of flexible Standard value plate (in free state) mm (in.) Service limit

0.2 (0.008) 0.5 (0.020)

205922

7-19

3-SPEED POWERSHIFT TRANSMISSION

4.2 Transmission 4.2.1 Disassembly (1)Control valve and external parts

7 4

1 13

16 10 9

15 17 14

11 8 12

212204

(a) Sequence 1 Air breather

9 Oil filter

2 Oil level gauge, Oil filler, O-ring, Stay, Clamp, Bolts, 10 Travel speed sensor, O-ring Spring washers, Plug, Gasket, Nuts 11 Thermo unit 3 Oil pipe, Eye bolt, Gaskets

12 Drain plug, Gasket

4 Main regulator valve, Gasket, Bolts, Washers

13 Suction pipe, O-rings, Bolts, Spring washers

5 Oil pipe, O-rings, Bolts, Spring washers

14 Cover, O-ring, Bolts, Spring washers

6 Control valve, Gasket, Bolts, Spring washers

15 Magnet strainer assembly

7 Oil pipes, Eye bolts, Gaskets

16 Bracket, Bolts, Spring washers

8 Oil pipes, Eye bolts, Gaskets

17 Bracket, Bolts, Spring washers

7-20

3-SPEED POWERSHIFT TRANSMISSION

(2)Transmission cover and shafts

13 23 24 22 21 20 11 4

16 17

14 15 9

8 7 6 10

4 5

3 1, 2 212205

1 Servo case, O-ring, Bolts, Washers

7 Output gear (2nd speed) 8 Output gear (3rd speed)

16 Travel speed sensor gear, Washers, Bolts

2 Servo case, O-ring, Bolts, Washers

9 Snap ring

17 Ball bearing

10 Baffle plate, Bolts, Washers

18 Output gear (1st speed)

3 Servo case, O-ring, Bolts, Washers

11 1st-speed/3rd-speed clutch shaft assembly

19 Snap ring

4 Transmission cover subassembly, Gasket, O-rings, Bolts, Washers

12 Forward clutch shaft assembly

21 Input gear

13 Reverse clutch shaft assembly

22 Snap ring

5 Oil seals

14 Baffle plate, Bolts, Washers

23 Input shaft, Ring seal

6 Ball bearing

15 Output shaft

24 Ball bearing

20 Lock nut

7-21

3-SPEED POWERSHIFT TRANSMISSION

(b) Suggestions for Disassembly • Transmission cover subassembly 4 removal Turn two Bolts (jack bolts) (special tool) in the M10 × 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 plug from the cover. Special tool needed

Jack bolt

Bolt 67284 - 15400 • Output gear (outside) 7 (2nd speed) removal Remove the output gear together with ball bearing 6 with a gear puller.

205629

• Output shaft 15 removal Turn a sliding hammer in the M8 × 1.25 hole in the end of the output shaft, and remove the shaft together with output gear 18, ball bearing 17 and travel speed sensor gear 16.

Output gear (1st speed) Sliding hammer

CAUTION Travel speed sensor gear

Be careful not to strike the travel speed sensor gear against the transmission case when removing the output shaft.

205480

The travel speed sensor gear will be deformed. • Ball bearing 17 removal Remove output shaft 15 with a press and a tooling as shown, or remove the gear with a puller, to remove the bearing.

Tooling 205630

• Lock nut 20 removal Straighten the locking tab of lock nut 20 away from flat of the input shaft 23 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 input gear 21 in such a manner as to prevent the shaft from turning counterclockwise.

7-22

3-SPEED POWERSHIFT TRANSMISSION

(3)Stator shaft and oil pump

6 7 8 5 13

9 2

18 12

3 19 4 3

15 14 16 17

23 21

212206

(a) Sequence 1 PTO cover, O-ring, Bolts, Spring washers

9 Ball bearing

17 Stator shaft, Seal ring, Bolts, Spring washers

2 Snap ring

10 Torque converter housing, Gasket, Flanged bolts

18 Pump idler gear

3 Pump drive gear, Seal rings

11 Oil seal

19 Roller bearing

4 Ball bearing

12 Idler gear shaft

20 Roller bearing (outer race)

5 Pump case, O-ring, Bolts, Spring washers

13 Roller bearing

21 Roller bearing (outer race)

6 Pump plate, O-ring, Gasket

14 PTO drive gear

22 Roller bearing (outer race)

7 Internal gear

15 Ball bearing

23 Transmission case, Dowels

8 Pump drive gear

16 Ball bearing

7-23

3-SPEED POWERSHIFT TRANSMISSION

(b) Suggestions for Disassembly • Torque converter housing 10 removal Turn two Bolts (jack bolts) (special tool) in the M10 ∞ 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 • Oil pump removal Remove the oil pump as a subassembly including pump case 5, pump plate 6, internal gear 7, pump gear 8 and ball bearing 9.

• Idler gear shaft 12 removal Turn the Shaft puller (special tool) in the shaft hole. Install the sliding hammer (used in removing the output shaft) to this puller and remove the shaft. Special tool needed Shaft puller (to be made by dealer)

M20 X 1.5 M8 X 1.25 12

210188

• PTO drive gear 14 removal Grip ball bearing 15 with a gear puller. Put a protective plate on the end of the stator shaft and remove the gear together with two ball bearings. 14

210193

7-24

3-SPEED POWERSHIFT TRANSMISSION

• Stator shaft 17 removal Turn two Bolts (jack bolts) (special tool) in the M10 × 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 • Roller bearing outer race removal Do not remove outer races 20, 21 and 22 of the roller bearings installed in the transmission case and the outer race of roller bearing 19 installed on idler gear shaft 18 unless they are defective.

7-25

3-SPEED POWERSHIFT TRANSMISSION

(4)Forward clutch shaft subassembly

5 15

6 11

8 9 10

212207

(a) Sequence 1 Seal rings

9 Thrust washer, Snap ring

2 Ball bearing

10 Snap rings, Pressure plates

3 Thrust washer

11 Friction plates, Mating plates

4 Gear (2nd-speed drive), Needle roller bearings

12 Snap rings, Retainers

5 Thrust washer

13 Clutch springs

6 Roller bearing

14 Clutch pistons, Piston seals

7 Thrust washer

15 Seal rings

8 Gear (forward drive), Needle roller bearings

16 Forward clutch shaft

NOTE Do not attempt to remove the screws from the forward clutch shaft

7-26

3-SPEED POWERSHIFT TRANSMISSION

(b) Suggestions for Disassembly • 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. • 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. • Forward clutch 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 92267 - 00300

207504

7-27

3-SPEED POWERSHIFT TRANSMISSION

(5)1st-speed/3rd-speed clutch shaft subassembly

12 15

4 2

3 16

1 14 12

10 6 11

11 8 9 10

212208

(a) Sequence 1 Seal rings

9 Thrust washer

2 Ball bearing

10 Snap rings, Pressure plates

3 Thrust washer

11 Friction plates, Mating plates

4 Gear (3rd-speed drive), Needle roller bearings

12 Snap rings, Retainers

5 Thrust washer

13 Clutch springs

6 Roller bearing

14 Clutch pistons, Piston seals

7 Thrust washer

15 Seal rings

8 Gear (1st-speed drive), Needle roller bearings

16 1st-speed/3rd-speed clutch shaft

(b) Suggestion for Disassembly

NOTE Do not attempt to remove the screws from the 1st-speed/ 3rd-speed clutch shaft.

7-28

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

3-SPEED POWERSHIFT TRANSMISSION

(6)Reverse clutch shaft subassembly

9 12

11 13

2 1

3 4 8

5 6 7

212209

(a) Sequence 1 Seal rings

8 Friction plates, Mating plates

2 Ball bearing

9 Snap ring, Retainer

3 Roller bearing

10 Clutch spring

4 Thrust washer

11 Clutch piston, Piston seal

5 Gear (reverse drive), Needle roller bearings

12 Seal ring

6 Thrust washer, Snap ring

13 Reverse clutch shaft

7 Snap ring, Pressure plate

(b) Suggestion for Disassembly

NOTE Do not attempt to remove the screws from the reverse clutch shaft.

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

7-29

3-SPEED POWERSHIFT TRANSMISSION

4.2.2 Inspection

(1) Oil pump (a) Put the internal gear and pump gear in the pump case, and measure top clearance 2.

(b) Using a dial indicator, measure side clearance 1 between the gears and pump case. 0.040 to 0.078 Standard value Side clearance 1 (0.00157 to 0.00307) mm (in.) Service limit 0.09 (0.0035) Standard value Top clearance 2 mm (in.) Service limit

(2) (a) (b) (3) (a)

0.3 to 0.345 (0.0118 to 0.0136) 0.35 (0.0138)

Stator shaft Check the splines for wear or damage. Check the oil passages for clogging. Friction plates and mating plates Check for sign of seizure, uneven contact, warpage or excessive wear.

(b) Check the splines for wear or damage. (4) Clutch drums (a) Check the mating plate sliding surfaces for wear or damage.

(b) Check the clutch piston sliding surfaces for wear or damage.

7-30

2 1

205486

3-SPEED POWERSHIFT TRANSMISSION

Standard Thickness of mating value plate 1 mm (in.) Service limit

2.3±0.07 (0.091±0.0028)

Standard Thickness of friction value plate 2 mm (in.) Service limit

2.6±0.1 (0.102±0.004)

Free movement of friction plate on gear 3 mm (in.)

Standard value

Standard Width of piston seal value ring 4 mm (in.) Service limit Standard value

Width of piston seal ring groove in piston 5 mm (in.) Service limit

2.2 (0.087) 0.10 to 0.30 (0.0039 to 0.0118) 4±0.05 (0.16±0.002) 3.5 (0.138) +0.2

2 1

3 4

+0.008

4 +0.1 (0.16 +0.004) 4.5 (0.177)

68 ± 2 (2.68 ± 0.08) Free length of clutch Standard k = 39.1(3.992) spring 6 value [223.5] mm (in.) k: Spring constant N/mm (kgf/mm) Service limit 65 (2.56) [lbf/in.] Standard Width of clutch piston value seal ring 7 mm (in.) Service limit

7, 8

2.1 (0.083)

5 212210

2.5±0.05 (0.098±0.0020) 2.0 (0.079)

Standard value

+0.2 +0.008 Width of clutch piston 2.5 +0.1 (0.098 +0.004) seal ring groove 8 mm (in.) Service limit 3.0 (0.118)

7-31

3-SPEED POWERSHIFT TRANSMISSION

(5) Forward clutch shaft, reverse clutch shaft and 1stspeed/3rd-speed clutch shaft (a) Check the seal rings and seal ring contact surfaces of the shaft and servo case for wear or damage. Standard Width of piston seal value ring for each clutch shaft 1 mm (in.) Service limit Standard Width of piston seal value ring groove in each clutch shaft 2 mm (in.) Service limit Standard Inside diameter of value each servo case in contact with seal ring 3 Service limit mm (in.)

2.5Âą0.05 (0.098Âą0.0020)

1, 2

2.0 (0.079) +0.2

+0.008

2.5 +0.1 (0.098 +0.004)

3.0 (0.118) 35

+0.025 0

(1.38

+0.00098 0 )

35.2 (1.386)

205635

(b) Check the splines for wear or damage. (c) Check the oil passages for clogging. (6) Gears (a) Check each gear for worn teeth or splines. (b) Check the needle bearing sliding surfaces of the gear for wear or damage.

(7) Magnet strainer assembly Disassemble and clean the strainer. Replace the strainer if defective. (8) Transmission cover and torque converter housing oil seals Replace the oil seals with new ones.

7-32

3-SPEED POWERSHIFT TRANSMISSION

4.2.3 Reassembly

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

5 10 9

9 10 5

11 6

14 15 6

19 17

12 18

2 212211

(a) Sequence 1 Forward clutch shaft, 1st-speed/3rd-speed clutch shaft, 11 Thrust washer or reverse clutch shaft 12 Needle roller bearings 2 Sealing rings, Piston seals

13 Gear (forward drive)

3 Clutch pistons

14 Thrust washer

4 Clutch springs

15 Roller bearing

5 Retainers

16 Thrust washer

6 Snap rings

17 Needle roller bearings

7 Mating plates

18 Gear (2nd-speed drive)

8 Friction plates

19 Thrust washer

9 Pressure plates

20 Ball bearing

10 Snap rings

21 Seal rings

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.

7-33

3-SPEED POWERSHIFT TRANSMISSION

(b) Suggestions for Reassembly • Piston installation When putting pistons 3 in the clutch drum, apply ATF (automatic transmission fluid) to their seal ring contact surfaces. • 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 92267 - 00300

207504

• Friction and mating plate installation 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.

Mating plate Friction plate

207516

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

203800

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

7-34

3-SPEED POWERSHIFT TRANSMISSION

(2)Stator shaft and oil pump

18 19 14 13

17 20 3 9

8 2

4 6

11 205638

(a) Sequence 1 Transmission case, Dowels

8 Idler gear shaft

15 Pump plate, O-ring, Gasket, Bolts, Spring washers

2 Roller bearing

9 Roller bearing

16 Ball bearing

3 Idler gear

10 Oil seal

17 Pump drive gear, Seal rings

4 Stator shaft, Seal ring, Bolts, Spring washers

11 Torque converter housing, Gasket, Flanged bolts

18 Ball bearing

5 Ball bearing

12 Pump case, O-ring, Bolts, Spring 19 Snap ring washers

6 PTO drive gear

13 Internal gear

7 Ball bearing

14 Pump gear

20 PTO cover, O-ring, Bolts, Spring washers

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.

7-35

3-SPEED POWERSHIFT TRANSMISSION

(b) Suggestions for Reassembly • PTO drive gear 6 installation Install ball bearings 5 and 7 to PTO drive gear 6. Install the gear to stator shaft 4. • Oil seal 10 installation Replace the oil seal with a new one. Install the oil seal to

Unit: mm (in.)

the torque converter housing by using the oil seal installer (special tool). Special tool needed Oil seal installer (to be made by dealer) • Oil pump reassembling Put internal gear 13, pump gear 14 and pump plate 15 in

13 (0.51)

8 (0.31) 150 (5.91)

pump case 12. Apply oil to the internal gear and pump gear. Do not forget to install the O-ring.

205491

• 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. • 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. • Ball bearing 18 installation When installing ball bearing 18 in pump case 12, hold the

Unit: mm (in.)

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. Special tool needed Pump drive gear holder (to be made by dealer) ) 39

(0.

10 )

(0.

0.3

8( )

(1.

205492

7-36

3-SPEED POWERSHIFT TRANSMISSION

(3)Shafts and transmission cover

6 5 8

19 26

3 24

20 14 16

9 15

12 13 212212

7-37

3-SPEED POWERSHIFT TRANSMISSION

(a) Sequence 1 Roller bearing (outer race)

15 Baffle plate, Bolts, Spring washers

2 Roller bearing (outer race)

16 Baffle plate, Bolts, Spring washers

3 Roller bearing (outer race)

17 Forward clutch shaft subassembly

4 Ball bearing

18 1st-speed/3rd-speed clutch shaft subassembly

5 Input shaft

19 Reverse clutch shaft subassembly

6 Snap ring

20 Output gear (3rd speed)

7 Input gear

21 Output gear (2nd speed)

8 Lock nut

22 Ball bearing

9 Output shaft

23 Oil seals

10 Snap ring 11 Output gear (1st speed)

24 Transmission cover subassembly, Gasket, Bolts, Spring washers, O-rings

12 Ball bearing

25 Servo case, O-ring, Bolts, Spring washers

13 Travel speed sensor gear, Spring washers, Bolts

26 Servo case, O-ring, Bolts, Spring washers

14 Snap ring

27 Servo case, O-ring, Bolts, Spring washers

(b) Suggestions for Reassembly • Input shaft 5 reassembling and installation Install ball bearing 4 on input shaft 5, then install the shaft in the transmission case. Tighten nut 8 to the specified torque and bend it against the flat of the input shaft for locking. Tightening torque for nut: 294 to 392 N•m (30 to 40 kgf•m) [217 to 289 lbf•ft] When tightening the nut, hold the torque converter side of the shaft with a pipe wrench, or put a bar to input gear 7 in such a manner as to prevent the shaft from turning clockwise. • Output shaft 9 reassembling and installation Reassemble output shaft 9, snap rings 10 and 14, output gear 11, ball bearing 12 and travel speed sensor gear 13 in a subassembly. Install the subassembly in the transmission case.

7-38

3-SPEED POWERSHIFT TRANSMISSION

• Oil seal 23 installation 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

Transmission cover

inside.

205494

Special tool needed Oil seal installer (to be made by dealer)

Unit: mm (in.)

1 (0.04)chamfer

10 (0.39) 1.5 (0.06)

28 (1.10)

170 (6.69)

205495

• 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

• Servo cases 25, 26 and 27 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.

7-39

3-SPEED POWERSHIFT TRANSMISSION

(4)Control valve and external parts

15 6

17 5 9

1 16 2

4 7 3

212213

(a) Sequence 1 Magnet strainer assembly

10 Control valve, Gasket, Bolts, Spring washers

2 Cover, O-ring, Bolts, Spring washers

11 Oil pipe, O-rings, Bolts, Spring washers

3 Plug, Gasket

12 Main regulator valve, Gasket, Bolts, Spring washers

4 Thermo unit

13 Oil pipe, Eye bolt, Gaskets

5 Travel speed sensor, O-ring

14 Oil level gauge, Oil filler, O-ring, Stay, Clump, Bolts, Spring washers, Plug, Nut

6 Suction pipe, O-rings, Bolts, Spring washers

15 Air breather

7 Oil pipe, Eye bolt, Gaskets

16 Bracket, Bolts, Spring washers

8 Oil pipe, Eye bolt, Gaskets

17 Bracket, Bolts, Spring washers

9 Oil filter

7-40

3-SPEED POWERSHIFT TRANSMISSION

4.3 Control Valve 4.3.1 Disassembly

1 2 3 4 5 18

17 19

17 6

1 15 13 14 8 7 16

10 9 12

212214

(1) Sequence 1 Solenoid valves, O-rings

7 Snap ring, Plug, O-ring

13 Pin, Seat, O-ring

2 Springs, Spring seats

8 Inching dummy spool

14 Oil filter, O-rings

3 Direction valve

9 Snap ring, Plug, O-ring

15 Last chance filters (four)

4 Solenoid valves, O-rings

10 Spring, Differential valve

16 Roller bearing, Plug

5 1st-speed valve, Spring

11 Plate, O-ring, Bolts, Washers

17 Roller bearing, Plug

6 2nd-speed/3rd-speed valve, Spring

12 Accumulator valve piston, Springs (inner and outer)

18 Plug, O-ring 19 Valve body, Gasket

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

7-41

3-SPEED POWERSHIFT TRANSMISSION

4.3.2 Inspection

(1) Check the oil holes in the valve body for restriction. (2) Check the valves for wear or damage. Make sure the valve moves freely.

(3) Replace all oil seals with new ones. (4) Replace oil filter 16 with a new one. (5) Wash oil filter 15, or replace it with a new one. Free length of selector valve springs 1 mm (in.) k: Spring constant N/mm (kgf/mm) [lbf/in.]

Standard value

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

Service limit

35.5 (1.40)

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

Standard value

60 (2.36) k = 1.677 (0.171) [9.58]

Service limit

58 (2.28)

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

Standard value

142.5 (5.61) k = 3.747 (0.3821) [21.3]

Service limit

140 (5.51)

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

Standard value

184.5 (7.26) k = 3.941 (0.4019) [22.50]

Service limit

182 (7.17)

Free length of direction valve springs 5 mm (in.) k: Spring constant N/mm (kgf/mm) [lbf/in.]

Standard value

32.5 (1.28) k = 4.23 (0.4313) [24.15]

Service limit

31.5 (1.24)

7-42

2 4

1 3 212215

3-SPEED POWERSHIFT TRANSMISSION

4.3.3 Reassembly

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

17 18

Section A - A

12 19

11 10 9

A 15

Section B - B

6 7

1 212216

(2) Sequence 1 Valve body

11 Inching dummy spool

2 Plug, Roller bearing

12 Plug, O-ring, Snap ring

3 Plug, Roller bearing

13 1st-speed valve, Spring

4 Last chance filters (four)

14 2nd-speed/3rd-speed valve, Spring

5 Oil filter, O-ring

15 Solenoid valves, O-rings (two)

6 Seat, O-ring, Pin

16 Direction valve

7 Springs (inner and outer), Accumulator piston

17 Spring seats, Springs

8 Plate, O-ring, Bolts, Spring washers

18 Solenoid valves, O-rings (two)

9 Differential valve, Spring

19 Plug, O-ring

10 Plug, O-ring, Snap ring

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

7-43

3-SPEED POWERSHIFT TRANSMISSION

4.4 Main Regulator Valve 4.4.1 Disassembly

1 2

3 212217

(1) Sequence 1 Cover, O-ring, Bolts, Sprig washers

4 Spring

2 Slug

5 Cover, O-ring, Bolts, Sprig washers

3 Spool

6 Body

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

4.4.2 Inspection

4.4.3 Reassembly

(1) Check the oil holes in the valve body for restriction. (2) Check the valve spool for wear or damage. Make sure

(1) Sequence

the spool moves freely. (3) Check the spring for damage or fatigue.

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

7-44

Standard value

107 (4.21) k = 4.99 (0.5087) [28.5]

Service limit

104 (4.09)

To reassemble, follow the reverse of disassembly sequence. (2) Suggestion for Reassembly Apply oil to the spool and slug when putting them in the body.

3-SPEED POWERSHIFT TRANSMISSION

5. Adjustment

ting

1 by using bolt 5 and nut 6.

set

(3) Eliminate the clearance between inching pedal 1 and

dal

brake pedal 4 by using bolt 7 and nut 8.

22 (S tro k

ang le)

(1) Set inching pedal 1 at 45Ë&#x161; by using bolt 2 and nut 3. (2) Place brake pedal 4 at the same height as inching pedal

5.1 Brake pedal and inching pedal adjustment

(Pe

9 2

3 212218

5, 6

2, 3 212219

(4) Adjust the switch position by using nut 9 so that the Clearance 1 mm (0.04 in.)

switch protrudes 1 mm (0.04 in.) from the end of the switch body.

Cutoff point 4 mm (0.16 in.) (OFF)

2 mm (0.08 in.) (ON)

Stroke 6 mm (0.24 in.) 212220

7-45

3-SPEED POWERSHIFT TRANSMISSION

5.2 Oil Pressure Measurement

CAUTION Front tires rotate during the measurement. Build a fence around the truck to prevent access to it.

NOTE Always perform pedal adjustments before oil pressure measurement.

5.2.1 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. Special tools needed *Connector 64309 - 17733 *Hose 64309 - 17722 *Connector 64309 - 17731 *Gauge 64309 - 17713

Main pressure tap (M)

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. Main oil pressure (with engine idling at 1500Âą100 rpm)

Standard value

0.88 to 1.08 MPa (9.0 to 11.0 kgf/cm2) [128 to 157 psi]

NOTE Monitor the idling speed through engine tachometer during measurement.

7-46

212221

3-SPEED POWERSHIFT TRANSMISSION

5.2.2 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. (b) The mast is tilted all the way backward first. With a

212222

wooden block applied under the outer mast, the mast is tilted forward to lift the front tires. Then, an appropriate stand 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.

(5) Place the direction lever into the forward position, then release the parking brake. (6) Release the inching pedal after fully depressing it, then measure the direction clutch oil pressure. Direction clutch oil pressure (with engine idling at 1500Âą100 rpm)

Standard value

0.73 to 0.93 MPa (7.44 to 9.48 kgf/cm2) [105.9 to 134.9 psi]

7-47

3-SPEED POWERSHIFT TRANSMISSION

5.2.3 Torque converter inlet oil pressure measure-

NOTE

ment

(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. Special tools needed *Connector 64309 - 17733 *Hose 64309 - 17722 *Connector 64309 - 17731 *Gauge 64309 - 17714

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

Torque converter inlet pressure tap (T)

(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), measure the torque converter inlet oil pressure. Torque converter inlet oil pressure (with engine idling at 1500Âą100 rpm)

Standard value

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.

5.3 Stall Speed Measurement (1) Idle the engine and check that the transmission oil is up to the specified level.

(2) Warm up the engine to raise the transmission oil temperature.

(3) Block the front and rear wheels, and apply the parking brake.

(4) Run the engine at low idle.

7-48

212223

3-SPEED POWERSHIFT TRANSMISSION

(5) Move the direction 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: Âą100 rpm)

1950 rpm

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

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

NOTE (a) Any stall speed within Âą10 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.

5.4 10 m (33 ft) Start Acceleration Test (1) Stand ready to start with the engine running at low idle, the direction lever in the neutral position and the travel speed select switch in D (automatic 3-speed) position. (2) At the signal, move the direction 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

7-49

3-SPEED POWERSHIFT TRANSMISSION

5.5 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.

Travel speed select switch 212224

7-50

3-SPEED POWERSHIFT TRANSMISSION

6. 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.

7-51

3-SPEED POWERSHIFT TRANSMISSION

Torque converter

No power flow

• 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.

• 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 • Repair. leaks Transmission

Power train

Torque converter

Transmission

Abnormal noise Loud noise

• 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 shaft.

• Broken parts in reduction and differential or front axle

• Refer to each section.

• Flexible plate 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.

• 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

7-52

• 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.

3-SPEED POWERSHIFT TRANSMISSION

Oil leaks

• 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 Orings.

• 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.

7-53

3-SPEED POWERSHIFT TRANSMISSION

Torque converter

• 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 • Repair or replace. flow)

Oil temperature is too high Transmission

• Bearings worn or seized

• Repair or replace.

• Instruments out of order

• Replace.

• Clutches dragging

• Replace clutch plates.

• Bearings worn or seized

• 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

7-54

• 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.

• 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.

• Inching valve out of order

• Repair or replace.

3-SPEED POWERSHIFT TRANSMISSION

Clutch pressure is too low

• Magnet strainer clogged

• Clean or replace.

• Oil pump worn or defective

• Replace.

• 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.

• 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 • Tune up engine. forward and reverse drive Stall speed out of specifica• Stator and freewheel defective if the speed is excessively • Replace stator assembly. tion low in both forward and reverse drive

No automatic shifting

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

• Clutch slipping if the speed is too high

• Repair or replace.

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

• Move switch to “2” or “D” 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.

7-55

3-SPEED POWERSHIFT TRANSMISSION

7. Service Data 7.1 Stall Speed, Hydraulic Truck Model

DP100N DP120N DP135N DP150N DP160N

Stall speed (tolerance: ±100 rpm) rpm Main pressure, Speed clutch pressure (engine at 1500±100 rpm)

Standard value

1950

Standard value

0.88 to 1.08 (9.0 to 11.0) [128 to 156]

MPa (kgf/cm2) [psi] Direction clutch pressure (engine at 1500±100 rpm) Standard value MPa (kgf/cm2) [psi]

0.73 to 0.93 (7.44 to 9.48) [105.9 to 134.9]

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

0.02 to 0.13 (0.2 to 1.3) [3 to 19]

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

Standard value

5 seconds, maximum

7.2 Pump Boss Truck Model

DP100N DP120N DP135N DP150N DP160N

Diameter of portion in contact with oil seal 1 mm (in.)

Standard value

100 -0.035 (3.94 -0.00138)

Service limit

99.85 (3.9311)

200721

7-56

3-SPEED POWERSHIFT TRANSMISSION

7.3 Pilot Boss Truck Model

DP100N DP120N DP135N DP150N DP160N

Diameter of portion in contact with engine flywheel 1 mm (in.)

-0.007

-0.00028

Standard value

20 -0.020 (0.79 -0.00079)

Service limit

19.85 (0.7815)

212225

7.4 Oil Pump

Truck Model

DP100N DP120N DP135N DP150N DP160N

Side clearance 1 mm (in.) Top clearance 2 mm (in.)

Standard value

0.040 to 0.078 (0.00157 to 0.00307)

Service limit

0.09 (0.0035)

Standard value

0.3 to 0.345 (0.0118 to 0.0136)

Service limit

0.35 (0.0138)

2 1 212226

7-57

3-SPEED POWERSHIFT TRANSMISSION

7.5 Stator Truck Model

DP100N DP120N DP135N DP150N DP160N Standard value

Outside diameter of clutch hub 1 mm (in.) Diameter of clutch rollers 2 mm (in.) Thickness of thrust washer 3 mm (in.) Thickness of thrust washer 4 mm (in.) Thickness of thrust washer 5 mm (in.) Thickness of thrust washer 6 mm (in.) Thickness of thrust washer 7 mm (in.)

67.951 to 67.97 (2.67523 to 2.6760)

Service limit

67.8 (2.669)

Standard value

10.185 to 10.2 (0.40098 to 0.402)

Service limit

10.1 (0.398)

Standard value

4.95 to 5 (0.1949 to 0.197)

Service limit

4.8 (0.189)

Standard value

3.95 to 4 (0.1555 to 0.157)

Service limit

3.8 (0.150)

Standard value

2.9 to 3 (0.114 to 0.118)

Service limit

2.8 (0.110)

Standard value

4.9 to 5 (0.193 to 0.197)

Service limit

4.8 (0.189)

Standard value

4.95 to 5 (0.1949 to 0.197)

Service limit

4.8 (0.189)

1 2 5 6 7

212227

7-58

3-SPEED POWERSHIFT TRANSMISSION

7.6 Flexible Plates Truck Model Face runout of flexible plates 1 (in free state)

DP100N DP120N DP135N DP150N DP160N mm (in.)

Distance between end face of torque converter housing and mating face of flexible plates 2 mm (in.)

Standard value

0.2 (0.008)

Service limit

0.5 (0.020)

Standard value

14.5 (0.57)

1 200725

7-59

3-SPEED POWERSHIFT TRANSMISSION

7.7 Clutches Truck Model

DP100N DP120N DP135N DP150N DP160N Standard value

Thickness of mating plate 1 mm (in.) Thickness of friction plate 2 mm (in.) Free movement of friction plate on gear 3 (looseness of mating splines)

mm (in.)

Width of piston seal ring 4 mm (in.)

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

Service limit

2.1 (0.083)

Standard value

2.6±0.1 (0.102±0.004)

Service limit

2.2 (0.087)

Standard value

0.10 to 0.30 (0.0039 to 0.0118)

Standard value

4±0.05 (0.16±0.002)

Service limit

3.5 (0.138)

Standard value

Width of seal ring groove in piston 5

mm (in.)

2 1

2.3±0.07 (0.091±0.0028)

+0.2 +0.1

+0.008

(0.16 +0.004)

Service limit

4.5 (0.177)

Standard value

68±2 (2.68±0.08) k = 39.1 (3.992) [223.5]

Service limit

65 (2.56)

3 4

5 212228

7-60

3-SPEED POWERSHIFT TRANSMISSION

7.8 Forward Clutch Shaft, Reverse Clutch Shaft, 1st-Speed/3rd-Speed Clutch Shaft and Servo Case

Truck Model

DP100N DP120N DP135N DP150N DP160N Standard value

Width of seal ring for each shaft 1 mm (in.)

Service limit Standard value

Width of seal ring groove in each shaft 2 mm (in.) Inside diameter of servo case and clutch shaft in contact with seal ring 3 mm (in.)

2.5±0.05 (0.098±0.0020) 2.0 (0.079) 2.5

Service limit Standard value

+0.2 +0.1

+0.008

(0.098 +0.004)

3.0 (0.118) 35

+0.025 0

Service limit

(1.38

+0.00098 0 )

35.2 (1.386) +0.00098 0 )

Inside diameter of stator shaft in contact with seal ring 4 mm (in.)

Standard value Service limit

35.2 (1.386)

Width of clutch piston seal ring for each shaft 5

Standard value

2.5±0.05 (0.098±0.0020)

mm (in.) Width of clutch piston seal ring groove in each shaft 6 mm (in.)

Service limit Standard value

2.0 (0.079) 2.5

+0.2 +0.1

(0.094 -0.0039) (0.098

Service limit

Width of seal ring 7

mm (in.)

Standard value

2.4

Width of seal ring groove 8

mm (in.)

Standard value

2.5

+0.1 0

N•m (kgf•m) [lbf•ft]

1, 2

Standard value

+0.008

(0.098 +0.004)

3.0 (0.118) 0 -0.1

Tightening torque for lock nut 9

(1.38

+0.0039 0 )

294 to 392 (30 to 40) [217 to 289]

5, 6

7, 8 9

212230

7-61

3-SPEED POWERSHIFT TRANSMISSION

7.9 Backlash of Gears Truck Model Input gear and forward and reverse gears 1

DP100N DP120N DP135N DP150N DP160N mm (in.)

Standard value

0.12 to 0.28 (0.0047 to 0.0110)

Forward gear and reverse and 1st-speed/3rd-speed gears 2 mm (in.)

Standard value

0.14 to 0.32 (0.0055 to 0.0126)

2nd-speed gear and output gear 3

mm (in.)

Standard value

0.12 to 0.28 (0.0047 to 0.0110)

1st-speed gear and output gear 4

mm (in.)

Standard value

0.13 to 0.30 (0.0051 to 0.0118)

3rd-speed gear and output gear 5

mm (in.)

Standard value

0.13 to 0.30 (0.0051 to 0.0118)

Pump drive gear and idler gear 6

mm (in.)

Standard value

0.12 to 0.26 (0.0047 to 0.0102)

PTO drive gear and idler gear 7

mm (in.)

Standard value

0.12 to 0.26 (0.0047 to 0.0102)

3 2

2 1 3 5 3

212229

7-62

3-SPEED POWERSHIFT TRANSMISSION

7.10 Control Valve

Truck Model

DP100N DP120N DP135N DP150N DP160N

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

mm (in.)

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

mm (in.)

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

mm (in.)

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

mm (in.)

Free length of direction valve springs 5 k: Spring constant N/mm (kgf/mm) [lbf/in.]

mm (in.)

Standard value

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

Service limit

35.5 (1.40)

Standard value

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

Service limit

57.5 (2.26)

Standard value

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

Service limit

123 (4.84)

Standard value

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

Service limit

168 (6.61)

Standard value

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

Service limit

31.5 (1.24)

2 4

1 3

212231

7-63

3-SPEED POWERSHIFT TRANSMISSION

7.11 Main Regulator Valve

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

DP100N DP120N DP135N DP150N DP160N m (in.)

Standard value

107 (4.21) k = 4.99 (0.5087) [28.5]

Service limit

104 (4.09)

1 212232

7-64

3-SPEED POWERSHIFT TRANSMISSION

7.12 Inching Pedal Control

Truck Model Inching pedal height (from frame to top end of pedal) 1 mm (in.)

DP100N DP120N DP135N DP150N DP160N Standard value

178 (7.01)

212233

7-65

FRONT AXLE AND REDUCTION DIFFERENTIAL 1. Specifications ............................................................................................................... 8-3 2. Structure....................................................................................................................... 8-4 2.1 Outline (DP100N to DP150N) ............................................................................................................... 8-4 2.1.1 Hub reduction.............................................................................................................................................. 8-5 2.1.2 Reduction differential .................................................................................................................................. 8-6

2.2 Outline (DP160N).................................................................................................................................. 8-7

1 2

2.2.1 Hub reduction.............................................................................................................................................. 8-8 2.2.2 Wet type wheel brake.................................................................................................................................. 8-9 2.2.3 Brake cooling system ................................................................................................................................ 8-10 2.2.4 Reduction differential ................................................................................................................................ 8-11

3 4

3. Suggestions for Removal and Installation.................................................................. 8-12 3.1 Front Wheels (Tires) ........................................................................................................................... 8-12 3.1.1 Preparation................................................................................................................................................ 8-12

3.1.2 Removal .................................................................................................................................................... 8-13 3.1.3 Installation ................................................................................................................................................. 8-14

3.2 Front Axle and Reduction Differential ................................................................................................. 8-15 3.2.1 Preparation................................................................................................................................................ 8-15 3.2.2 Removal .................................................................................................................................................... 8-16 3.2.3 Installation ................................................................................................................................................. 8-18

3.3 Reduction differential .......................................................................................................................... 8-19 3.3.1 Preparation................................................................................................................................................ 8-19 3.3.2 Removal .................................................................................................................................................... 8-19 3.3.3 Installation ................................................................................................................................................. 8-20

4. Disassembly and Reassembly ................................................................................... 8-21 4.1 Hub reduction (DP100N to DP150N) .................................................................................................. 8-21

6 7 8 8 9 10

4.1.1 Preparation (on-vehicle condition) ............................................................................................................ 8-21 4.1.2 Disassembling the hub reduction .............................................................................................................. 8-21 4.1.3 Removing the wheel brake........................................................................................................................ 8-23 4.1.4 Inspection and Repair ............................................................................................................................... 8-24 4.1.5 Installing the wheel brake.......................................................................................................................... 8-25

11 12

4.1.6 Reassembling the hub reduction............................................................................................................... 8-26

4.2 Hub reduction (DP160N)..................................................................................................................... 8-28 4.2.1 Disassembling the hub reduction .............................................................................................................. 8-28 4.2.2 Disassembling the wheel brake ................................................................................................................ 8-30 4.2.3 Inspection and Repair ............................................................................................................................... 8-31 4.2.4 Reassembling the wheel brake ................................................................................................................. 8-32

8-1

13 14

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.2.5 Reassembling the hub reduction............................................................................................................... 8-33

4.3 Reduction differential .......................................................................................................................... 8-38 4.3.1 Preparation................................................................................................................................................ 8-38 4.3.2 Disassembling the differential gear assembly........................................................................................... 8-39 4.3.3 Disassembling Reduction & Parking Brake Assembly .............................................................................. 8-40 4.3.4 Inspection and Repair ............................................................................................................................... 8-41 4.3.5 Reassembling the differential assembly.................................................................................................... 8-42 4.3.6 Adjustment of reduction pinion preload..................................................................................................... 8-45 4.3.7 Contact adjustment between the gear and pinion teeth............................................................................ 8-46 4.3.8 Reassembly of reduction & parking brake assembly ................................................................................ 8-50 4.3.9 Installing reduction differential................................................................................................................... 8-52

5. Troubleshooting ......................................................................................................... 8-53 6. Service Data............................................................................................................... 8-54 6.1 Front axle (DP100N to DP150N) ........................................................................................................ 8-54 6.2 Front axle (DP160N) ........................................................................................................................... 8-56 6.3 Reduction differential .......................................................................................................................... 8-58

8-2

FRONT AXLE AND REDUCTION DIFFERENTIAL

1. Specifications Truck model Reduction gear Final drive

Differential

DP100N

DP120N

DP135N

Gear type

Hypoid gear

Reduction ratio

5.571

Gear type

Planetary gear

Reduction ratio

4.167

Housing type

Banjo

Gear type and number

DP150N

Large

Straight bevel gear × 2

Small

Straight bevel gear × 4

Front axle type

Full floating tube type

Suspension method

Fixed to frame

Wheel brake

DP160N

Dry brake

Standard

Wet brake

Option

Standard

8-3

FRONT AXLE AND REDUCTION DIFFERENTIAL

2. Structure 2.1 Outline (DP100N to DP150N)

2 8 12

212286

1 Front axle housing

9 Differential pinion

2 Differential case

10 Differential gear

3 Input flange

11 Axle shaft

4 Parking brake bracket

12 Hub reduction

5 Parking brake assembly

13 Planetary gear

6 Parking brake drum

14 Ring gear

7 Reduction pinion

15 Front wheel hub

8 Reduction gear

16 Dry type wheel brake

This front axle is a banjo-shaped full floating type mounted to the front of the truck frame, and the final drive system is a planetary gear type.

8-4

FRONT AXLE AND REDUCTION DIFFERENTIAL

2.1.1 Hub reduction

17 18 19 16

7 6

4 3

212287

1 Front axle housing

11 Nut

2 Axle shaft

12 Lock plate

3 Sun gear

13 Tapered roller bearing

4 Cover

14 Front wheel hub

5 Planet carrier

15 Tapered roller bearing

6 Planet pin

16 Oil seal retainer

7 Steel ball

17 Oil seal

8 Roller bearing

18 Brake drum

9 Planetary gear

19 Oil deflector

10 Ring gear

20 Dry type wheel brake

The front axle housing has a dry type wheel brake mounted.

8-5

FRONT AXLE AND REDUCTION DIFFERENTIAL

2.1.2 Reduction differential 23 21

25 24

24 22

17 15

4 5 7

3 6

9 12

11 8

212288

1 Differential carrier

10 Lever

19 Spider

2 Shim

11 Parking brake drum

20 Differential pinion

3 Bearing retainer

12 Adjuster

21 Differential gear

4 Tapered roller bearing

13 Reduction pinion

22 Tapered roller bearing

5 Tapered roller bearing

14 Self-locking nut

23 Bearing cap

6 Parking brake bracket

15 Roller bearing

24 Side bearing nut

7 Oil seal

16 Differential case

25 Lock plate

8 Input flange

17 Differential case

9 Parking brake assembly

18 Reduction gear

The reduction differential is a single reduction type consisting of a reduction pinion and a reduction gear. The reduction pinion has a parking brake drum mounted via the input flange, and the parking brake bracket has a parking brake assembly mounted.

8-6

FRONT AXLE AND REDUCTION DIFFERENTIAL

2.2 Outline (DP160N)

2 8 10

12 6

212289

1 Front axle housing

9 Differential pinion

2 Differential case

10 Differential gear

3 Input flange

11 Axle shaft

4 Parking brake bracket

12 Spindle

5 Parking brake assembly

13 Planetary gear

6 Parking brake drum

14 Ring gear

7 Reduction pinion

15 Front wheel hub

8 Reduction gear

16 Wet type wheel brake

This front axle is a banjo-shaped full floating type mounted to the front of the vehicle frame, and the final drive system is a planetary gear type.

8-7

FRONT AXLE AND REDUCTION DIFFERENTIAL

2.2.1 Hub reduction

7 6

4 3

212290

1 Front axle housing

11 Nut

2 Axle shaft

12 Lock plate

3 Sun gear

13 Tapered roller bearing

4 Cover

14 Front wheel hub

5 Planet carrier

15 Tapered roller bearing

6 Planet pin

16 Seal retainer

7 Steel ball

17 Floating seal

8 Roller bearing

18 Brake hub

9 Planetary gear

19 Wet type wheel brake

10 Ring gear

The front axle housing has the wet type wheel brake mounted.

8-8

FRONT AXLE AND REDUCTION DIFFERENTIAL

2.2.2 Wet type wheel brake

14 11

Brake oil

212291

1 Spindle

6 End plate

11 Brake hub

2 Brake housing

7 Mating plate

12 Floating seal

3 Brake piston

8 Friction plate

13 Seal retainer

4 Bolt

9 Brake cover

14 Wheel hub

5 Return spring

10 Dust seal

The wet type wheel brake consists of brake housing, brake piston, plate and brake hub. The brake housing is bolted down to the spindle which has been mounted on the axle housing. Into the circular grooves provided on the brake housing and spindle, a piston is assembled and supported in position by the return spring. The brake hub is bolted down to the wheel hub so it can rotate together with the wheel hub.

The mating plate with outer teeth is supported by the housing as it engages with the inner teeth of the brake housing, while the friction plate with inner teeth engages with the outer teeth of the brake hub and rotates together with the wheel hub. The flange part of the spindle has a brake oil port provided and is attached with connectors and bleeder screws. Also, each part of sliding surfaces to seal the brake oil and mounting surfaces is attached with piston seals and O-rings.

8-9

FRONT AXLE AND REDUCTION DIFFERENTIAL

2.2.3 Brake cooling system

IN A A

B OUT B

212292

Brake disc is cooled by a forcible circulation of brake cooling oil. This spindle is provided with inlet and outlet ports for cooling oil.

8-10

FRONT AXLE AND REDUCTION DIFFERENTIAL

2.2.4 Reduction differential 23 21

25 24

24 22

17 15

4 5 7

3 6

9 12

11 8

212288

1 Differential carrier

10 Lever

19 Spider

2 Shim

11 Parking brake drum

20 Differential pinion

3 Bearing retainer

12 Adjuster

21 Differential gear

4 Tapered roller bearing

13 Reduction pinion

22 Tapered roller bearing

5 Tapered roller bearing

14 Self-locking nut

23 Bearing cap

6 Parking brake bracket

15 Roller bearing

24 Side bearing nut

7 Oil seal

16 Differential case

25 Lock plate

8 Input flange

17 Differential case

9 Parking brake assembly

18 Reduction gear

8-11

FRONT AXLE AND REDUCTION DIFFERENTIAL

3. Suggestions for Removal and Installation 3.1 Front Wheels (Tires) 3.1.1 Preparation

(1) Loosen each outer wheel nut about two turns. (2) Block the rear wheels. (3) Lift the vehicle from the ground at the front wheels using either of the following methods.

(a) Jacking Set the jack at the right and left front axle mounting parts of the frame to jack up the vehicle evenly for both the right and left sides. (b) Hoisting Fasten a hoist to the mast, and lift the mast to raise the front end of the truck.

WARNING After raising the front end with either of the methods, place jack stands under the frame to prevent the truck from falling.

8-12

212265

FRONT AXLE AND REDUCTION DIFFERENTIAL

3.1.2 Removal 6

1 Extension bracket

2 Wheel nut 3 Clamp 4 Wedge band

5 Outer wheels (tires)

6 Spacer

7 Extension valve 8 Inner wheels (tires)

8 3

210371

(1) Outer wheels (tires) (a) Have the extension valve come to the top. (b) Deflate the tire.

CAUTION Air is compressed. Keep your face away from the tire.

(d) Support the truck at the lower side of the outer tires

210373

either using a small-type lift truck or applying the special tool tire handler there. Special tool needed Tire handler

Banzai WD-5500

(e) Remove the wheel nuts to remove the outer wheels (tires).

(2) Inner wheels (tires) (a) Support the inner wheels (tires) in the same way as for the outer tires.

(b) Remove the spacer. (c) Pull the inner wheels (tires) out to the end face of the brake hub, and disconnect the extension pipe from the air valve.

(d) Remove the inner wheels (tires).

210375

8-13

FRONT AXLE AND REDUCTION DIFFERENTIAL

3.1.3 Installation Follow the removal procedure in reverse while noting the following instructions. (1) Inner front wheels (tires) (a) Make sure that the air valve set groove of brake hub is aligned with the positioning boss on the rim.

(b) When the inner front wheel goes all the way to the brake hub end face, mount the extension valve on the air valve.

(c) After pressing-in the inner front wheel to the specified position, take some measures to prevent the inner front wheel from falling down using stopper blocks, etc.

(2) Wheel nut Wheel nuts should be tightened to the specified torque evenly so that the runout of wheels can be avoided as much as possible. Tightening torque

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

CAUTION Wheel nuts should be tightened in the correct order as instructed by the right-hand side figure. (Numbers show the order of tightening.)

(3) Retightening of wheel nuts (a) Test-run the truck for about 10 minutes after complet-

ing the service work to check for forward/reverse drive and braking.

(b) Use a torque wrench to re-tighten all the wheel nuts to the specified torque.

3 8

210376

8-14

FRONT AXLE AND REDUCTION DIFFERENTIAL

3.2 Front Axle and Reduction Differential 3.2.1 Preparation

(1) Block the rear wheels. (2) Remove the mast assembly while referencing the chapter of “Mast and Fork”.

(3) Remove the front wheels while referencing the section of “Front Wheels”. (4) Insert solid stands under the frame to prevent the truck from falling.

(5) Drain the front axle oil with the following procedure. (a) Turn both the right and left wheel axles by hand to make the drain plug (right or left) of the wheel hub cover take the lowest position. On the other wheel hub cover, remove the plugs located at higher positions than the center for air bleeding.

(b) Place containers sufficient for the quantity of oil under each drain, then drain the oil by removing the drain plugs of the axle housings and wheel hub covers. Capacity (approximate)

25 liters (6.6 U.S. gal.)

212293

8-15

FRONT AXLE AND REDUCTION DIFFERENTIAL

3.2.2 Removal

A B C

3 C

The number shows removal sequence.

212294

1 Wheel brake pipe

4 Universal joint

2 Brake cooling pipe (DP160N)

5 Front axle

3 Parking brake wire

(1) Wheel brake pipes (right and left) After having disconnected the wheel brake pipes, cover the openings of the wheel cylinder and pipes to prevent dirt from getting inside them. (2) Brake cooling pipe (DP160N) After having disconnected the wheel brake pipes, cover the connector to prevent dirt from getting inside them.

8-16

FRONT AXLE AND REDUCTION DIFFERENTIAL

(3) Universal joint (a) Fasten the universal joint to the transmission body with

Transmission

a rope. Disconnect here.

NOTE If the universal joint is separated from the transmission body, the transmission oil will flow outside.

(b) Disconnect the universal joint at the input flange side of the reduction differential.

204585A

(4) Front axle (a) Use a service lift truck and firmly secure the lower part of the front axle with the right and left forks. Maximum load of service lift truck

Truck model DP100N to DP150N

1350 kg [3000 lb]

DP160N

1500 kg [3300 lb]

WARNING As the differential part is not at the center of the right to left span of the front axle, firmly secure it to prevent from falling on separation.

(b) Remove the mounting bolts, then operate the service lift truck to remove the front axle.

NOTE If any service lift truck is not available, use the following procedure for this removal. (a) Always apply some protective cloth before fastening a hoist and lifting the mast support bearings of the axle housing with a chain or wire rope. (b) Remove the mounting bolts, then lift the front axle to remove it.

8-17

FRONT AXLE AND REDUCTION DIFFERENTIAL

3.2.3 Installation Follow the removal procedure in reverse while noting the following instructions.

(1) Torque Tighten the mounting bolts of the following parts to each specified torque. (a) Front axle Tightening torque

640±96 N•m (65.3±9.8 kgf•m) [472±71 lbf•ft]

(b) Universal joint 61 to 81 N•m (6.2 to 8.3 kgf•m) [44.7 to 59.3 lbf•ft]

Tightening torque

(2) Operating effort of parking brake lever After installing the parking brake wire, make sure that the operating effort of the parking brake lever is the standard value. 245 to 294 N (25 to 30 kgf) [55 to 66 lbf]

Parking brake lever operating effort

(3) Add oil to the front axle (a) Position the level mark of either the right or left cover to be horizontal.

(b) Remove the level plug located at the side of the level mark. For the wheel hub cover at the opposite position, remove the level plug located in the higher positions than the center for air bleeding.

(c) Remove the level plug located at the differential side of the axle housing, then add oil through the plug hole. Recommended oil: (API service classification GL-4)

Gear oil SAE 90 25 liters (6.6 U.S. gal.

Capacity (approximate)

(4) Bleeding brake oil line (a) When the assembly is completed, bleed air in the circuit while referencing to the chapter of “Brake System”. Check also for oil leaks.

NOTE This air bleeding operation will be easier, if it is performed before installing the front wheels and mast.

8-18

212295

FRONT AXLE AND REDUCTION DIFFERENTIAL

3.3 Reduction differential 3.3.1 Preparation

(1) Remove the front axle while referencing the section of “Front Axle”. (2) Lay the front axle housing with the reduction differential side facing upward using the frame mounting part of the axle housing. 3.3.2 Removal

The number shows removal sequence.

212296 1 Wheel hub cover (right and left)

3 Reduction differential

2 Axle shaft (pull it outward approx. 150 mm [5.9 in.].)

(1) Axle shaft Remove the wheel hub cover and install the sliding hammer in the screw hole (M10 × 1.25) in the end of the axle shaft to pull it out approx. 150 mm (5.9 in.).

(2) Reduction differential (a) Install the anchor bolt in one of the universal joint mounting holes and put a wire rope there, and tension the rope with a crane.

(b) Remove the mounting bolts, then lift the reduction differential to remove it.

8-19

FRONT AXLE AND REDUCTION DIFFERENTIAL

3.3.3 Installation Follow the removal procedure in reverse while noting the following instructions.

(1) Reduction differential (a) Check for any soils or damages on the reduction differential and axle hosing mounting surfaces.

(b) Coat liquid packing on the mounting surfaces. Liquid packing

(Three Bond No. 1104)

(c) Lift the reduction differential to accommodate it in the front axle housing and tighten the mounting bolts to the specified torque. Bolt length

Tightening torque

37 mm (1.46 in.)

118±12 N•m (12±1.2 kgf•m) [87±9 lbf•ft]

31 mm (1.22 in.)

132±14 N•m (13.5±1.4 kgf•m) [98±10 lbf•ft]

CAUTION Bolt tightening torque varies depending on the length under the neck. Be sure to tighten to an appropriate torque.

(2) Wheel hub cover (a) Replace the gasket with new one. (b) Tighten the mounting bolts to the specified torque. Tightening torque

8-20

57±5.9 N•m (5.8±0.6 kgf•m) [42±4 lbf•ft]

FRONT AXLE AND REDUCTION DIFFERENTIAL

4. Disassembly and Reassembly 4.1 Hub reduction (DP100N to DP150N) (1) Remove the front wheels while referencing the section

4.1.1 Preparation (on-truck condition)

NOTE Hub reduction can be disassembled while it is installed on the truck. If this is the case, remove the front wheels (tires) according to the procedure of “Removing Front Wheels (Tires)”.

of “Removing Front Wheels”. (2) Drain the oil while referencing the section of “Removing Front Axle and Reduction Differential”.

4.1.2 Disassembling the hub reduction

The number shows disassembling sequence.

7 8

7 14

17 5 13 18 4

A 11

2 1

212297 1 Wheel hub cover, Gasket

10 Axle nut

2 Axle shaft,

11 Ring gear

3 Sun gear, Snap ring

12 Tapered roller bearing (inner race) [11]

4 Sleeve

13 Front wheel hub

5 Planet carrier, O-ring

14 Oil deflector [15]

6 Planet pin, Steel ball [5]

15 Brake hub [13]

7 Thrust washer [5]

16 Oil seal [13]

8 Planetary gear, Needle roller bearing [5]

17 Tapered roller bearing (outer race) [13]

9 Lock plate

18 Tapered roller bearing (outer race) [13]

NOTE [ ] shows the number of each place to remove from.

8-21

FRONT AXLE AND REDUCTION DIFFERENTIAL

(1) Axle shaft Install the sliding hammer into the screw hole (M10 ∞ 1.25) on the edge face, and turn it to remove the sun gear and snap ring as a whole.

(2) Planet carrier

Unit: mm (in.)

Attach the socket wrench (special tool) and remove the nut making use of an impact wrench. Special tool Socket wrench: 92267-00200 Width across flats: 144 mm (5.669 in)

65(2.56) 25(0.98)

(0 12. .5 7 0)

Ø75(Ø2.95)

Ø65 (Ø2.56)

3(0.12)

Ø155(Ø6.10)

15 Ø

(4) Ring gear (a) Utilize the bolt holes (M16 × 1.5: 2 places) and drive-in

3( Ø

)

19(0.75)

Ø162(Ø6.38)

(3) Axle nut

(Ø Ø2 0. 0 79 )

The planet carrier must be removed by lifting it with a crane.

two jack bolts into them and turn the bolts evenly to pull out the ring gear.

72(2.83) 144(5.67)

(5) Front Wheel Hub and Brake Hub (a) Support the hub drum assembly with a transmission jack.

(b) Remove the assembly using a wheel hub puller (special tool).

8-22

30(1.18)

60(2.36) 90(3.54)

212269

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.1.3 Removing the wheel brake The number shows removing sequence. 1 Tapered roller bearing (inner race) 2 Oil seal retainer, O-ring 3 Wheel brake assembly

3 2 1

212298

(1) Tapered roller bearing (inner race) Use the supplied bearing puller to remove the bearing together with the seal retainer.

(2) Wheel brake assembly For disassembly, inspection and reassembly of the wheel brake assembly, refer to the chapter of â&#x20AC;&#x153;BRAKE SYSTEMâ&#x20AC;?.

204590

8-23

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.1.4 Inspection and Repair

(1) Axle shaft Apply a dial indicator at the middle of the axle shaft, and rotate the shaft to measure the deflection. Deflection of axle shaft (1/2 of dial indicator reading)

Service limit

1.0 mm (0.039 in.)

(2) Axle housing (a) Check the mast support bearing contact surfaces for

(5) Planet carrier (a) Check the planetary gear roller inside surface and planet pin outside surface for wear or damage.

Planetary gear roller inside diameter

wear or damage.

(b) Check the oil seals for wear and damage. (c) Check the axle housing for distortion, dents, or other

Outside diameter of planet pins

defects. Also check the welds for cracks.

(3) Front wheel hub (a) Check the oil seals for wear and damage. (b) Check the tapered roller bearing (outer race) for wear or damage.

(4) Brake drum (a) Check the inside surface for wear or damage.

Brake drum inside diameter

8-24

Standard value

+0.2 0 mm +0.008 (16.535 0 in.)

Repair or service limit

424 mm (16.69 in.)

420

Standard value

+0.029 +0.010

(2.28

+0.0011 +0.0004

in.)

Service limit

57.96 mm (12.2819 in.)

Standard value

50-0.011 mm (1.97 -0.0004 in.)

Service limit

49.96 mm (1.967 in.)

(b) Check the thrust washers for wear or damage. Thrust washer thickness

Standard value

1.2Âą0.06 mm (0.047Âą0.002 in.)

Service limit

0.8 mm (0.031 in)

(6) Others (a) Check the outside surface of oil seal retainer for wear and damage.

(b) Check the tapered roller bearing (inner race) for wear or damage.

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.1.5 Installing the wheel brake

1 Wheel brake assembly 2 Oil seal retainer, O-ring 3 Tapered roller bearing (inner race)

The number shows installing sequence. 3

212299

(1) Tapered roller bearing (inner race) Use the installer to drive-in the brake assembly together with the oil seal retainer.

204592

8-25

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.1.6 Reassembling the hub reduction The number shows assembling sequence. 13

17 16 11 15

15 10

212300 1 Front wheel hub

10 Lock plate

2 Tapered roller bearing (outer race) [1]

11 Axle shaft, Sleeve

3 Tapered roller bearing (outer race) [1]

12 Planetary gear [15]

4 Oil seal [1]

13 Roller bearing, Thrust washer [15]

5 Brake hub [1]

14 Planet pin, Steel ball [15]

6 Oil deflector [5]

15 Planet carrier, O-ring [1]

7 Ring gear

16 Sun gear [11]

8 Tapered roller bearing (inner race) [7]

17 Planetary gear cover, Gasket

9 Nut

NOTE [ ] shows the number of each place to reassemble to.

(1) Front wheel hub (a) Tighten the brake drum fastening nuts to the specified

Liquid gascket

torque. Tightening torque

359±36.3 N•m (37±3.7 kgf•m) [263±26.5 lbf•ft]

(b) Apply a thin coat of liquid packing on the mating surface of the oil deflector before assembly.

210386

8-26

FRONT AXLE AND REDUCTION DIFFERENTIAL

(2) Preload adjustment (a) After temporarily tighten the nut, hook a spring scale to one of the hub bolts and measure the force applied in the tangential direction. 127.5 to 166.7 N (13 to 17 kg) [28.7 to 37.5 lbf]

Preload for wheel hub bearing (force applied in tangential direction)

NOTE However, it is advisable to aim at a value of tangential force (preload) in the lower tolerance limit, if the bearings are being reused.

212330

(b) If the force applied in the tangential direction (preload) does not meet the standard value, re-adjust it by means of varying the amount of turning-in the nut.

(c) After completing the preload adjustment, assemble the lock plates into places and tighten the mounting bolts to the specified torque. Tightening torque

16.7±2.0 N•m (1.7±0.2 kgf•m) [12.2±1.5 lbf•ft]

(3) Planet carrier (a) Before installing the planet pins into the carrier, coat the inside surfaces of the planetary gear bushings with oil to be used.

(b) Tighten the mounting bolts of the planet carrier to the specified torque. Tightening torque

93.2±9.8 N•m (9.5±1.0 kgf•m) [68.3±7.2 lbf•ft]

(4) Planetary gear cover (a) Tighten the mounting bolts of the planetary gear cover to the specified torque. Tightening torque

56.9±5.9 N•m (5.8±0.6 kgf•m) [41.7±4.3 lbf•ft]

8-27

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.2 Hub reduction (DP160N) 4.2.1 Disassembling the hub reduction

The number shows disassembling sequence. 14

B 15

17 16 18 19

8 7

21 6

22 13 4

2 3

212301 1 Wheel hub cover, Gasket

12 Ring gear

2 Axle shaft

13 Tapered roller bearing (inner race) [12]

3 Sun gear, Snap ring [3]

14 Brake hubs (including from 15 to 22)

4 Sleeve

15 Floating seal [14]

5 Planet carrier, O-ring

16 Seal retainer

6 Planet pin, Steel ball [5]

17 Floating seal [16]

7 Thrust washer [5]

18 O-ring [16]

8 Planetary gear, Needle roller bearing [5]

19 Tapered roller bearing (inner race)

9 Wheel brake (including from 10 to 22)

20 Wheel hub

10 Lock plate

21 Tapered roller bearing (outer race) [20]

11 Axle nut

22 Tapered roller bearing (outer race) [20]

NOTE [ ] shows the number of each place to remove from.

8-28

FRONT AXLE AND REDUCTION DIFFERENTIAL

(1) Axle shaft Install the sliding hammer into the screw hole (M10 × 1.25) on the edge face, and turn it to remove the sun gear and snap ring as a whole. (2) Planet carrier The planet carrier must be removed by lifting it with a crane.

(3) Wheel brake (a) Attach a wire rope to the wheel hub and brake housing and support them by lifting with a crane.

(b) Remove the spindle mounting bolts, and remove the spindle as an integral assembly including the wheel hub.

212302

Unit: mm (in.) 65(2.56) 25(0.98) 19(0.75)

72(2.83) 144(5.67)

30(1.18)

(0 12. .5 7 0)

Ø75(Ø2.95)

Ø65 (Ø2.56)

Ø155(Ø6.10)

3(0.12)

Ø162(Ø6.38)

3( Ø

)

Attach the socket wrench (special tool) and remove the nut making use of an impact wrench. Special tool Socket wrench: 92267-00200 Width across flats: 144 mm (5.669 in)

(Ø Ø2 0. 0 79 )

(4) Axle nut

60(2.36) 90(3.54)

212269

(5) Ring gear (a) Utilize the bolt holes (M16 × 1.5: 2 places) and install two jack bolts into them and turn the bolts evenly to pull out the ring gear.

(b) Remove the jack bolts and install the anchor bolts in the bolt holes (M16 × 1.5: 2 places).

212382

8-29

FRONT AXLE AND REDUCTION DIFFERENTIAL

(6) Wheel hub and brake hub (a) Prepare the special tool. Part No.

Part name

92E68-01000

Wheel hub puller

Bolt Spring washer

Adjusting plate

NOTE Use the following parts for this work. 92E68-00300: Wheel hub guide 92E68-00400: Adjusting plate 92E68-00600: Bolt stopper 45722-94700: Jack bolt F1035-12025: Bolt F2515-12000: Spring washer

Wheel hub guide Bolt stopper

(b) Install the bolt stopper on the top end of the spindle. (c) Install the adjusting plate on the wheel hub guide, and secure them with the bolts and spring washers.

(d) Install the wheel hub guide in the wheel hub, and secure them with the bolts and spring washers.

NOTE Secure the wheel hub guide with the bolts and spring washers used to secure the planet carrier.

212376

(e) Screw the eye bolts in the bolt holes of the wheel hub guide (M10 Ă&#x2014; 1.25: 2 places) and attach a wire rope,

Jack bolt

and then lift the wheel hub guide with a crane.

(f) Screw a jack bolt into the wheel hub guide. Screw the bolt to the bottom end and remove the tapered roller bearing inner race from the spindle.

(g) Lift the wheel hub and brake hub to remove them. Lay aside the removed assembly with the wheel hub side down.

(h) Remove the mounting bolts of the brake hub, and disassemble the wheel hub and brake hub.

212377

8-30

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.2.2 Disassembling the wheel brake

The number shows disassembling sequence.

8 2 9

12 3 4

11 13

212304 1 Brake cover

6 Snap ring

11 O-ring [10]

2 Dust seal [1]

7 Bolt, Spring

12 Spindle 13 O-ring [12]

3 Mating plate

8 Brake piston

4 Friction plate

9 Piston seal [8]

5 End plate

10 Brake housing

NOTE [ ] shows the number of each place to remove from.

8-31

FRONT AXLE AND REDUCTION DIFFERENTIAL

(5) Plates for wheel brake (a) Measure the thickness of each plate, and replace if any

4.2.3 Inspection and Repair

(1) Axle shaft Apply a dial indicator at the middle of the axle shaft, and rotate the shaft to measure the deflection. Deflection of axle shaft (1/2 of dial indicator reading)

Repair or service limit

0.2 mm (0.0039 in.)

(2) Axle housing (a) Check the mast support bearing sliding surfaces for wear or damage.

(b) Check the axle housing for distortion, dents, or other

has reached the service limit. Friction plate

Mating plate

End plate

Standard value

4.66±0.15 mm (0.184±0.006 in.)

Service limit

4.0 mm (0.157 in.)

Standard value

3.1±0.1 mm (0.122±0.004 in.)

Service limit

3.0 mm (0.118 in.)

Standard value

3.4±0.3 mm (0.134±0.012 in.)

Service limit

3.2 mm (0.126 in.)

defects. Also check the welds for cracks.

(3) Front wheel hub (a) Check the oil seals for wear and damage. (b) Check the tapered roller bearing (outer race) for wear or damage.

(b) Replace any gear whichever has deficiency in the number of teeth or pluck (chipping) in the tooth faces.

(d) Also replace any gear which has a crack, damage or (4) Planet carrier (a) Check the needle roller bearing inside surface and planet pin outside surface for wear or damage.

Needle roller bearing inside diameter

Outside diameter of planet pin

Standard value

+0.029 58 +0.010 mm +0.0011 (2.28 +0.0004 in.)

Service limit

57.96 mm (2.282 in.)

Standard value

50-0.011 mm (1.97 -0.0004 in.)

Service limit

49.96 mm (1.967 in.)

(b) Check the thrust washers for wear or damage. Thrust washer thickness

8-32

Standard value

1.2±0.06 mm (0.047±0.0024 in.)

Service limit

0.8 mm (0.031 in)

distortion.

(6) Brake housing, Brake hub (a) Replace any gear which has a wear or damage in the tooth faces.

(7) Floating seal (a) Replace any seal which has a fault or damage in the lip surfaces.

(8) Others (a) Check the outer circumference of oil seal retainer for wear and damage.

(b) Check the tapered roller bearing (inner race) for wear or damage.

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.2.4 Reassembling the wheel brake

9 8

6 3

7 4 2

1 The number shows assembling sequence.

212305

1 Spindle

7 End plate

2 Brake housing, O-ring

8 Mating plate

3 Brake piston, Piston seal

9 Friction plate

4 Spring

10 Brake cover

5 Bolt

11 Dust seal

6 Snap ring

(1) Brake housing Tighten the mounting bolts to the specified torque. Tightening torque

176±18 N•m (17.9±1.8 kgf•m) [129±13 lbf•ft]

(2) Brake piston (a) Coat the piston seal with service oil and re-assemble it with its round side facing outward.

(b) Install the brake piston taking care so as not to damage the piston seal.

8-33

FRONT AXLE AND REDUCTION DIFFERENTIAL

(3) Plates for wheel brake and brake cover Friction plate holder Dust seal Brake cover

Friction plate Mating plate End plate

Continue air supply (after installing brake cover)

(a) Prepare the special tool.

(g) Supply compressed air with the following specified

Part No.

Part name

92G68-00100

Friction plate holder

(b) Install the friction plate (special tool) to the spindle. (c) First install the end plate. (d) Continue to install the mating plate, then the friction plate.

NOTE

(e) Brake cover Tighten the mounting bolts to the specified torque. 112±10.8 N•m (11.4±1.1 kgf•m) [82.6±8.0 lbf•ft]

(f) Dust seal Tighten the mounting bolts for securing washers to the specified torque. Tightening torque

8-34

value from the connector of the brake oil supply mouth to prevent the friction plate from misalignment. 490 kPa (5 kgf/cm2) [71.1 psi]

Air pressure

(h) When these operations are completed, remove the friction plate holder (special tool).

Make sure to install the plates in the correct order.

Tightening torque

212378

16.7±2.0 N•m (1.7±0.2 kgf•m) [12.2±1.5 lbf•ft]

NOTE Do not stop supplying the compressed air until the installation of the hub reduction is completed. If the friction plate is misaligned, the brake hub can not be inserted.

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.2.5 Reassembling the hub reduction

The number shows assembling sequence. 16

20 19

17 13

13 18 11 14

1 10

2 9 4 3

6 6 5

212306 1 Wheel hub

11 Axle nut

2 Tapered roller bearing (outer race) [1]

12 Lock plate

3 Tapered roller bearing (outer race) [1]

13 Planetary gear, Needle roller bearing [16]

4 Tapered roller bearing (inner race) [1]

14 Thrust washer [16]

5 Floating seal [8]

15 Planet pin, Steel ball [16]

6 Floating seal [7]

16 Planet carrier, O-ring

7 Seal retainer [1]

17 Axle shaft

8 Brake hub

18 Sleeve

9 Tapered roller bearing (inner race) [10]

19 Sun gear, Snap ring [17]

10 Ring gear

20 Wheel hub cover, Gasket

NOTE [ ] shows the number of each place to reassemble to.

8-35

FRONT AXLE AND REDUCTION DIFFERENTIAL

(1) Floating seal (a) Mount a trick ring on the R portion of seal ring. (b) Make sure that the mold line(s) seen at the outer circumference of the trick ring is not twisted. If any twist is observed, separate several portions of the trick ring from the seal ring to remove the twist.

NOTE This is because twist in the trick ring may cause the seal performance to be degraded from the uneven bearing stress, resulting in oil leaks or undesirable suction of foreign matter.

212308

(c) Soak the trick ring in the cleaning agent as the entire surfaces under the level so that all oil films, dusts, and foreign matters can be washed out.

NOTE For this operation, always use a volatile cleaning agent suitable for cleaning a rubber trick ring and without producing any residue. Use of inappropriate cleaning agent may cause the sealing performance to be degraded due to twist or uneven bearing stress on the trick ring.

(d) Put the floating seal on the brake hub and seal retainer. (e) Apply a thin coat of service oil on the sealing surface of the seal ring using a cotton swab, gauze, or finger.

NOTE Check for any foreign matters adhered on the sealing surface of the seal ring. Note that even a fine piece of lint can cause the sealing surface to be separated, leading to oil leaks.

(2) Assembling wheel hub and brake hub (a) Tighten the mounting bolts of the brake hub to the specified torque. Tightening torque

8-36

366±3.7 N•m (358.9±36.3 kgf•m) [268±2.7 lbf•ft]

212314

FRONT AXLE AND REDUCTION DIFFERENTIAL

(3) Inserting wheel hub and brake hub (a) Prepare the special tool. Part No.

Part name

92E68-00000

Wheel hub pusher

Bolt Spring washer

Wheel nut

Adjusting plate

NOTE Use the following parts for this work. 92E68-00300: Wheel hub guide 92E68-00400: Adjusting plate 92E68-00500: Adjusting bolt MC810632 : Wheel nut F1035-12025: Bolt F2515-12000: Spring washer

(b) Install the adjusting plate on the wheel hub guide, and

Wheel hub guide

Adjusting bolt

secure them with the bolts and spring washers.

212379

NOTE Install the wheel nut until the threaded portion of the adjusting bolt appears a little.

(d) Install the wheel hub pusher (special tool) in the wheel hub, and secure them with the bolts and spring washers.

NOTE Secure the wheel hub pusher with the bolts and spring washers used to secure the planet carrier.

(e) Screw the eye bolts in the bolt holes of the wheel hub pusher (M10 Ă&#x2014; 1.25: 2 places) and attach a wire rope, and then lift the wheel hub guide with a crane.

(f) Lower the wheel hub and brake hub as an integral assembly to the wheel brake.

212380 8-37

FRONT AXLE AND REDUCTION DIFFERENTIAL

(g) Tighten the wheel nut while loosening the wire rope to lower integral assembly of wheel hub and brake hub,

Tighten

and install them to the wheel brake.

(h) When the assembly lowers to the bottom, check whether the dimension in the figure at the right is in the specified value.

(i) When these operations are completed, remove the wheel hub pusher (special tool).

8 mm [0.315 in]

(j) Stop the air supply to remove the air hose.

212381

(4) Ring gear (a) Install the tapered roller bearing (inner race). (b) Drive the anchor bolt in the jack bolt hole (M12 Ă&#x2014; 1.75) and put a wire rope.

(d) Temporarily tighten the axle nut to secure the ring gear, and remove the anchor bolt.

212382

8-38

FRONT AXLE AND REDUCTION DIFFERENTIAL

(5) Installing into the axle housing (a) When all the parts so far to the axle nut are assembled, lift the assembly of wheel hub and wheel brake to install it into the front axle.

(b) Tighten the mounting bolts of the spindle to the specified torque. 602±60 N•m (61.4±6.1 kgf•m) [135.3±13.5 lbf•ft]

Tightening torque

212302

(6) Preload adjustment (a) After temporarily tighten the nut, hook a spring scale to one of the hub bolts and measure the force applied in the tangential direction. Preload for wheel hub bearing (force applied in tangential direction)

117.7 to 156.9 N (12 to 16 kg) [26.5 to 35.3 lbf]

CAUTION However, it is advisable to aim at a value of preload in the lower tolerance limit, if the bearings are

212316

being reused.

(b) If the force applied in the tangential direction (preload) does not meet the standard value, re-adjust it by means of varying the amount of turning-in the nut.

(c) After completing the preload adjustment, assemble the lock plates into place and tighten the mounting bolts to the specified torque. Tightening torque

16.7±2.0 N•m (1.7±0.2 kgf•m) [12.2±1.5 lbf•ft]

(7) Planet carrier (a) Before installing the planet pins into the carrier, coat the needle roller bearing with service oil.

8-39

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.3 Reduction differential 4.3.1 Preparation

(1) Backlash measurement Before disassembling the differential gear assembly, except for replacing the reduction gear set for a new one, measure the backlash between the reduction gear and reduction pinion to help with reassembly. Backlash between reduction bevel gear and bevel pinion

Standard value

0.25 to 0.33 mm (0.010 to 0.012 in.)

CAUTION When the reduction gear set is to be replaced with

200247

a new one, it is not necessary to measure the backlash.

(2) Alignment marks (reference) Put alignment marks on one side of the bearing caps, adjustment screw and carrier to ensure correct refitting.

200241

(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.

8-40

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.3.2 Disassembling the differential gear assembly

The number shows disassembling sequence.

2 7 10 5

8 9

4 7 2

3 1

212317 1 Lock washer, Lock plate

7 Tapered roller bearing

2 Side bearing nut

8 Differential gear

3 Bearing cap, Lock washer

9 Thrust washer

4 Differential case R.H.

10 Spider

5 Differential case L.H.

11 Thrust washer

6 Reduction gear

12 Differential pinion

(1) Tapered roller bearing Remove the inner race using a bearing puller.

8-41

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.3.3 Disassembling Reduction & Parking Brake Assembly

The number shows disassembling sequence.

3 4

A 7

19 18

8 15

10 9

13 14

212318 1 Parking brake drum

11 O-ring

2 Self-locking nut

12 Reduction pinion

3 Input flange

13 Snap ring

4 Parking brake assembly

14 Roller bearing

5 Parking brake bracket

15 Tapered roller bearing (inner race)

6 Oil separator

16 Tapered roller bearing (inner race)

7 Oil seal

17 Tapered roller bearing (outer race)

8 Bearing retainer

18 Collar

9 Shim

19 Tapered roller bearing (outer race)

10 O-ring

(1) Bearing retainer (a) Utilize the bolt holes for separation (M14 Ă&#x2014; 1.5: 2 places) and install jack bolts into them and turn the bolts evenly to pull out the bearing.

(b) Make a record of the thickness of shims which are removed and take care so as not to lose them.

8-42

(2) Tapered roller bearing Remove the inner race using a bearing puller.

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.3.4 Inspection and Repair

(1) Check for any wear or damage on each part. (a) Check the seat formed between the differential case and tapered roller bearing inner race to carry it to see

(3) Reduction gear, Reduction pinion (a) Check the gear teeth for wear, pitting, flaking or chipping.

(b) Minor flaws on the tooth surfaces that may not affect the service can be repaired by grinding with an oil

whether the seat surface is galled or not.

(b) Check the differential case for crack, and check the sliding surfaces of differential gears and washers for

stone or hand grinder.

wear or damage.

(c) Check the teeth of the differential pinions and bevel gears for wear, pitting, chipping, galling, etc. Check also the washer supporting parts for wear or damage.

(d) Check the inside surface of the differential pinion and

damage.

(b) When the inside diameter of the drum exceeds the

outside surface of pinion shaft for wear. Play between differential bevel pinion inner diameter and shaft outer diameter

(4) Parking brake drum (a) Check the brake drum inside surfaces for wear and

Standard value

0.169 to 0.278 mm (0.007 to 0.011 in.)

Service limit

0.35 mm (0.014 in.)

repair or service limit, replace the drum with a new one.

Inside diameter of drum

(e) Check the differential gear and axle shaft spline for wear that may cause excessive play. (Measure this play

Standard value Service limit

+0.5 0 +0.020 0

304.8

(12

in.)

307 mm (12.09 in.)

with the differential gear temporarily put through the axle shaft.) Free movement of differential bevel gears on axle shafts (looseness of mating splines)

Service limit

0.5 mm (0.020 in)

(2) Differential gear and pinion (a) Measure the backlash. Backlash between differential gear and pinion

Standard value

0.1 to 0.3 mm (0.004 to 0.012 in.)

Service limit

0.5 mm (0.02 in)

(b) When the backlash exceeds the service limit, replace the thrust washer with a new one.

8-43

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.3.5 Reassembling the differential assembly

The number shows assembling sequence. 10 9

14 4

9 12

11 13

212319 1 Differential case

8 Differential case

2 Thrust washer

9 Tapered roller bearing

3 Differential gear

10 Reduction gear

4 Spider

11 Bearing cap

5 Differential pinion, Washer

12 Lock washer

6 Differential gear

13 Side bearing nut

7 Thrust washer

14 Lock plate

(1) Differential case (a) Lightly coat Loctite #271 to the mounting bolt surfaces.

(b) Tighten the mounting bolts evenly to the specified torque to avoid uneven tightening result. Tightening torque

8-44

196±29.4 N•m (20±3 kgf•m) [145±22 lbf•ft]

FRONT AXLE AND REDUCTION DIFFERENTIAL

(2) Reduction gear (a) Lightly coat Loctite #271 to the mounting bolt surfaces.

(b) Tighten the mounting bolts evenly to the specified torque to avoid uneven tightening result. Tightening torque

441±69 N•m (45±7 kgf•m) [325±51 lbf•ft]

(3) Backlash between differential gear and pinion Measure the backlash, and if the backlash exceeds the service limit, replace the thrust washer with a new one. Backlash between differential gear and pinion

Standard value

0.2 to 0.28 mm (0.008 to 0.011 in.)

Service limit

0.5 mm (0.020 in.)

212320

(4) Tentative tightening of bearing cap (a) Install the bearing cap and install the lock washers and mounting bolts.

(b) Only temporarily tighten the mountings bolts for the convenience of the subsequent adjustment.

NOTE The bearing caps are machined together with the differential carrier. Identify the right and left caps by referring to the alignment marks to avoid mistaking between them.

8-45

FRONT AXLE AND REDUCTION DIFFERENTIAL

(5) Adjustment of differential case tapered roller bearing preload Check the preload of the differential unit before installing the reduction pinion. (a) Taking the tapered roller bearing backlash into account, tighten the side bearing nuts evenly between the right and left.

(b) Tap the back of the reduction gear with a copper-face hammer while rotating the gear by hand for running-in.

(c) Wind a wire around the outer circumference of the differential case, and hook the wire by a spring scale. Side bearing

(d) Pull the spring scale outward to read a force (tangential force) just when the differential case begins to rotate. Tangential force

Preload (reference)

Standard value

23 to 32 N (25 to 35 kgf) [5.2 to 7.2 lbf]

Standard value

2.45 to 3.43 N•m (25 to 35 kgf•cm) [1.8 to 2.5 lbf•ft]

210395

(6) Tightening bearing cap (a) Tighten the mounting bolts evenly to the specified torque. Tightening torque

294.2±29.4 N•m (30±3 kgf•m) [217±21 lbf•ft]

(b) Calk the lock washer after tightening the bolt.

8-46

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.3.6 Adjustment of reduction pinion preload

(1) Tentatively assemble the reduction pinion in the following order to make sure the preload of the tapered roller bearing of the reduction pinion is correct. 1 Reduction pinion 2 Tapered roller bearing (inner race) 3 Bearing retainer

4 Tapered roller bearing (outer race) 6 Collar 7 Tapered roller bearing (inner race)

5 Tapered roller bearing (outer race)

3 5

8 Oil separator 9 Input flange 10 Self-locking nut

(2) Tighten the self-locking nut to the specified torque. Tightening torque

9 8

294.2±29.4 N•m (30±3 kgf•m) [217±21 lbf•ft]

212321

(3) Secure the input flange and apply a rated load from the top of the pinion.

5 ton (1124 lbf)

(4) Wind a thread around the outer circumference of the bearing retainer, and pull the end of the thread by spring scale to read the force just when the bearing retainer begins to rotate. Force applied to bearing retainer in tangential direction

30.4 to 43.1 N (3.1 to 4.4 kgf) [6.8 to 9.7 lbf]

(5) If the force applied in the tangential direction falls within the above mentioned range, the preload also must be the specified value. (6) If the force applied in the tangential direction does not meet the standard value, re-adjust it by means of varying the thickness of collar(s). There are 25 kinds of thickness prepared for collars.

Fixed 212322

8-47

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.3.7 Contact adjustment between the gear and pinion teeth Once assemble the reduction unit into the differential unit from the condition (tentative assembly) of above described “Preload adjustment of reduction pinion”.

NOTE You must have completed assembly of the differential unit.

(1) Installing additional parts 1 Roller bearing

2 Snap ring 3 Machining error adjustment shim 4 Bolt with spring washer (M12 × 1.25, length below neck: 35 mm [1.38 in.])

NOTE (1) The above mentioned parts are those which are installed more to the condition of “Preload adjustment of reduction pinion”. (2) As the parking brake bracket is not installed, the removed bolts can not be reused. Therefore, always

3 4

replace the above mentioned bolts.

212323

8-48

FRONT AXLE AND REDUCTION DIFFERENTIAL

(2) Calculating the thickness of the machining error adjustment shim If the removed reduction pinion can be reused, insert the shim that has been installed as-is. When the pinion is to be replaced with a new one, calculate the required amount (thickness) of shims with the following procedure.

(a) Once check the current preload, then take an actual measurement “b” of dimension B.

(b) Obtain difference “c” from the nominal dimension (53.5 mm [2.1063 in.]) of dimension B. c = 53.5 mm (2.1063 in.) – b

NOTE (a) Round off to the first digit below decimal point.

(b) If the actual measurement b of dimension B is greater than the nominal value, c will be a negative value.

210736

equation: Shim thickness A = 0.5 mm (0.0197 in.) + c (rounded off to the first digit below decimal point.) (d) Insert an appropriate number of shims as combined to produce the thickness calculated with the above equation. Part No.

Thickness

92331-03500

0.2 mm (0.0079 in.)

92335-03600

0.1 mm (0.0039 in.)

(3) Installing reduction unit (a) Lay the differential unit with its reduction and parking brake assembly mounting side facing upward and secure it to wooden bars, etc.

(b) Install the eyebolt into the universal joint mounting bolt hole of the input flange.

(c) Put a wire rope to the eye bolt and lift the reduction unit for assembling. Be careful not to allow the machining error adjustment shim to fall off.

(d) Tighten the mounting bolts to the specified torque. Tightening torque

128.5±19.6 N•m (13.1±2.0 kgf•m) [94.1±14.4 lbf•ft]

8-49

FRONT AXLE AND REDUCTION DIFFERENTIAL

(4) Measurement and adjustment of backlash (a) Lay the gear assembly with the differential unit comes to the top and secure it to the wooden bars, etc.

(b) Set the dial indicator so its tip is square to the reduction gear tooth face.

(c) Move the reduction gear back and forth (in the rotating direction) by hand to see how the dial indicator hand swings. Backlash between reduction gear and pinion

0.20 to 0.28 mm (0.008 to 0.011 in.)

210397

(d) If the backlash does not meet the standard value, readjust the same amount of turning-in of both the right

BACKLASH

and left side bearing nuts.

To increase.

To decrease.

Example: If you loosen the right side nut one turn, tighten the left side nut more one turn.

CAUTION The amount of turn in or out of the side bearing

To decrease.

nuts must be equal for both the right and left side To increase.

bearing nuts. Difference in the turn-in or -out amount between the right and left side bearing

To increase.

nuts will make the preload of the differential case tapered roller bearing vary from the standard value.

8-50

205611

To decrease.

BACKLASH

FRONT AXLE AND REDUCTION DIFFERENTIAL

(5) Contact adjustment of reduction gear (a) Coat a thin film of red lead uniformly on three to four reduction gear teeth (both sides).

(b) Rotate the reduction gear back and forth several times by hand.

210398

Tooth Contact Pattern

Tooth contact covers more than 1/2 of tooth length

Adjustment

Correct tooth contact

Heavy contact at toe of tooth

1. 2.

Move gear away from pinion. Move pinion toward gear by adding shim(s) to secure correct backlash.

1. 2.

Move gear toward pinion. Move pinion away from gear by removing shim(s) to secure correct backlash.

Slightly move pinion toward gear by adding shims. Slightly move gear away from pinion to secure correct backlash.

Heavy contact at heel of tooth

3 1

Heavy contact on face or upper portion of tooth

2. 1

Heavy contact on flank or lower portion of tooth

1. 2 1

Slightly more pinion away from gear by removing shim(s). Slightly move gear toward pinion to secure correct backlash.

NOTE For toe contact or heel contact, observe contacts on the outer side (convex face) of the reduction gear for judgement. For face contact or flank contact, repeat the steps above for adjustment until satisfactory tooth contact is obtained. After this adjustment is completed, make sure to check the backlash.

8-51

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.3.8 Reassembly of reduction and parking brake assembly

The number shows assembling sequence.

18 17

4 6 3

19 7

10 12

13 16 14

1 Reduction pinion

11 Parking brake bracket

2 Tapered roller bearing (inner race)

12 Oil seal

3 Collar

13 Parking brake assembly

4 Bearing retainer

14 Input flange

5 Tapered roller bearing (outer race)

15 Self-locking nut

6 Tapered roller bearing (outer race)

16 Parking brake drum

7 Tapered roller bearing (inner race)

17 Roller bearing

8 O-ring

18 Snap ring

9 O-ring

19 Machining error adjustment shim

10 Oil separator

8-52

212324

FRONT AXLE AND REDUCTION DIFFERENTIAL

(1) O-ring and oil separator for each part

grease and service oil between the lips.

0 [Ø3.74 - 0 . 0 0 4 ]

Unit: mm [in.]

Ø95 - 0 . 1

Special tool Installer: To be made by dealer (for the dimensions, refer to the figure at the right hand.) (b) Make the two main lips face the inside and apply

Ø68.5 ±0.1 [Ø2.7±0.004]

(2) Oil seal (a) Prepare the following special tools.

Ø35 [Ø1.38]

Before reassembly apply oil to the O-ring and oil separator.

15 [0.59] 130 [5.12]

23 [0.91]

Installer

Oil seal

212325 (3) Parking brake assembly (a) Exercise care for the direction of the parking brake lever for reassembly.

(b) Tighten the mounting bolts to the specified torque. Tightening torque

145±22 N•m (14.8±2.2 kgf•m) [107±16 lbf•ft]

(4) Parking brake drum Tighten the mounting nuts to the specified torque. Tightening torque

96±15 N•m (9.8±1.5 kgf•m) [71±11 lbf•ft]

(5) Self-locking nut (a) Tighten the self-locking nut to the specified torque. Tightening torque

249±29 N•m (30±3 kgf•m) [217±22 lbf•ft]

(b) After each tightening, calk each place with a punch.

8-53

FRONT AXLE AND REDUCTION DIFFERENTIAL

4.3.9 Installing reduction differential

212326 1 Reduction and parking brake assembly

3 Lock washer, Lock plate

2 Side bearing cap bolt (re-tighten to the specified torque.)

(1) Lay the differential unit with its reduction and parking brake assembly mounting side facing upward and secure it to wooden bars, etc. (2) Install the eyebolt into the universal joint mounting bolt hole of the input flange. (3) Attach a wire rope to the eye bolt and lift the reduction and parking brake assembly to assemble it into the differential unit. (4) Tighten the mounting bolts to the specified torque. Tightening torque

8-54

59.8±5.9 N•m (6.0±0.6 kgf•m) [43.8±4.3 lbf•ft]

(5) Re-tighten the side bearing cap bolt to the specified torque. Tightening torque

379 to 512 N•m (38.6 to 52.2 kgf•m) [279 to 378 lbf•ft]

(6) Tighten the mounting bolts of the lock washers and lock plates to each specified torque. Tightening torque

34.3±3.9 N•m (3.5±0.4 kgf•m) [25.1±2.9 lbf•ft]

FRONT AXLE AND REDUCTION DIFFERENTIAL

5. Troubleshooting • Reduction bevel gear teeth badly worn

• Replace reduction bevel gear.

• Improper adjustment or excessive wear of reduction • Readjust or replace the bearing. Gear noise comes out continuously during normal traveling

bevel gear bearing • Hub bearings damaged

• Replace the bearing

• Improper tooth contact between the reduction pinion • Readjust the tooth contact. and reduction gear of the output shaft • Reduction gear bearing or hub bearing broken. Irregular noise comes out during normal traveling

• Replace the bearing

• Differential gear teeth broken or thrust washers • Replace differential gear or washer. worn • Metal chips in axle housing

• Clean and change oil.

• Bolts securing axle shaft or differential carrier loose

• Retighten.

• Fit of differential gear in differential case out of • Replace. Abnormal noise specification due to wear comes out when turn• Teeth of differential gear or pinion broken, seized on • Replace. ing a corner. spiders, or worn or damaged • Bearing damaged due to excessive preload. • Replace bearing and readjust preload. Differential carrier overheats after travel- • Backlash between reduction pinion and reduction • Readjust tooth contact and backlash. ing. gear too small Abnormal noise comes from hub reduction unit.

• Shortage of oil or poor oil quality

• Add or change oil.

• Planetary gears worn or damaged

• Replace the planetary gear.

• Wear of needle roller bearing.

• Replace the needle roller bearing.

8-55

FRONT AXLE AND REDUCTION DIFFERENTIAL

6. Service Data 6.1 Front axle (DP100N to DP150N) Truck model

DP100N to DP150N

Deflection of axle shaft 1 (1/2 of dial indicator reading)

Standard value

1.0 mm (0.039 in.)

Preload for hub bearing 2 (force applied to hub bolt in tangential direction)

Standard value

118 to 157 N (12 to 16 kgf) [26 to 35 lbf]

Tightening torque for brake drum nuts 3

Standard value

359±36 N•m (36.6±3.7 kgf•m) [265±27 lbf•ft]

Tightening torque for brake backing plate mounting nuts 4

Standard value

156±16 N•m (15.9±1.6 kgf•m) [115±12 lbf•ft]

Tightening torque for front axle housing mounting nuts 5

Standard value

640±96 N•m (65.3±9.8 kgf•m) [472±71 lbf•ft]

Tightening torque for wheel nuts 6

Standard value

539±49 N•m (55±5.0 kgf•m) [398±36 lbf•ft]

Tightening torque for wheel nuts 7

Standard value

294±29 N•m (30±3.0 kgf•m) [217±21 lbf•ft]

Standard value

50 -0.011 mm (1.97 -0.00043 in.)

Diameter of planet pin 8

Service limit Inside diameter of planet gear bearing 9

Thickness of trust washer 10

Standard value

49.96 mm (1.967 in.) 58

+0.029 +0.010

+0.00114

mm (2.28 +0.00039 in.)

Service limit

57.96 mm (2.2819 in.)

Standard value

1.2±0.06 mm (0.05±0.002 in.)

Service limit

0.8 mm (0.03 in.)

Tightening torque for cover bolts 11

Standard value

57±6 N•m (5.8±0.6 kgf•m) [42±4.0 lbf•ft]

Tightening torque for lock plate bolts 12

Standard value

17.2±2 N•m (1.7±0.2 kgf•m) [12±1.0 lbf•ft]

Tightening torque for deflector bolts 13

Standard value

33±3 N•m (3.4±0.3 kgf•m) [25±2.0 lbf•ft]

Inside diameter of brake drum 14

Standard value Service limit

8-56

420

+0.2 0

mm [16.54

+0.008 0

424 mm (16.69 in.)

in.]

FRONT AXLE AND REDUCTION DIFFERENTIAL

9 10

10 8

7 6

212327

8-57

FRONT AXLE AND REDUCTION DIFFERENTIAL

6.2 Front axle (DP160N) Truck model

DP160N

Deflection of axle shaft 1 (1/2 of dial indicator reading)

Standard value

1.0 mm (0.039 in.)

Preload for hub bearing 2 (force applied to hub bolt in tangential direction)

Standard value

118 to 157 N (12 to 16 kgf) [26 to 35 lbf]

Standard value

3.4±0.3 mm (0.134±0.012 in.)

Service limit

3.2 mm (0.126 in.)

Standard value

3.1±0.1 mm (0.122±0.004 in.)

Thickness of end plate 3 Thickness of mating plate 4

Service limit

3.0 mm (0.118 in.)

Standard value

3.4±0.3 mm (0.134±0.012 in.)

Service limit

3.2 mm (0.126 in.)

Tightening torque for spindle mounting nuts 6

Standard value

602±60 N•m (61.4±6.1 kgf•m) [135.3±13.5 lbf•ft]

Tightening torque for brake housing mounting bolts 7

Standard value

176±18 N•m (17.9±1.8 kgf•m) [129±13 lbf•ft]

Tightening torque for brake cover mounting bolts 8

Standard value

112±10.8 N•m [11.4±1.1 kgf•m] [82±8 lbf•ft]

Tightening torque for seal washer mounting bolts 9

Standard value

16.7±2.0 N•m [1.7±0.2 kgf•m] [12.2±1.5 lbf•ft]

Tightening torque for brake hub mounting bolts 10

Standard value

358.9±36.3 N•m [36.6±3.7 kgf•m] [263±26.6 lbf•ft]

Standard value

50 -0.011 mm (1.97 -0.00043 in.)

Thickness of friction plate 5

Diameter of planet pin 11

Service limit Inside diameter of needle bearing 12

Standard value

49.96 mm (1.967 in.) 58

+0.029 +0.010

+0.00114

mm (2.28 +0.00039 in.)

Service limit

57.96 mm (2.2819 in.)

Standard value

1.2±0.06 mm (0.05±0.002 in.)

Service limit

0.8 mm (0.03 in.)

Tightening torque for lock plate bolts 14

Standard value

17.2±2 N•m (1.7±0.2 kgf•m) [12±1.0 lbf•ft]

Tightening torque for cover mounting bolts 15

Standard value

57±6 N•m (5.8±0.6 kgf•m) [42±4.0 lbf•ft]

Tightening torque for planet carrier mounting bolts 16

Standard value

539±49 N•m (55±5.0 kgf•m) [398±36 lbf•ft]

Tightening torque for wheel nuts 17

Standard value

294±29 N•m (30±3.0 kgf•m) [217±21 lbf•ft]

Tightening torque for front axle housing mounting nuts 18

Standard value

640±96 N•m (65.3±9.8 kgf•m) [472±71 lbf•ft]

Thickness of trust washer 13

8-58

FRONT AXLE AND REDUCTION DIFFERENTIAL

5 4 3

12 13

Section A

A 13 11

16 17

212328

8-59

FRONT AXLE AND REDUCTION DIFFERENTIAL

6.3 Reduction differential Truck model

DP100N to DP160N Standard value

——

Service limit

0.5 mm (0.020 in.)

Standard value

0.25 to 0.33 mm (0.010 to 0.013 in.)

Backlash between differential bevel gear and bevel pinion 3

Standard value

0.2 to 0.28 mm (0.008 to 0.011 in.)

Service limit

0.5 mm (0.02 in.)

Play between differential bevel pinion inner diameter and shaft outer diameter 4

Standard value

0.169 to 0.278 (0.007 to 0.011 in.)

Free movement of differential gear on axle shaft (looseness of mating splines) 1 Backlash between reduction bevel gear and bevel pinion 2

Service limit

0.35 mm (0.014 in.)

Force applied to periphery A of differential case in tangential direction

Standard value

23 to 32 N (15 to 30 kgf) [1.1 to 2.2 lbf]

Preload (reference)

Standard value

245 to 343 N•m (25 to 35 kgf•m) [180 to 253 lbf•ft]

Tightening torque for differential case bolts 6

Standard value

196±29 N•m (20±3 kgf•m) [145±22 lbf•ft] (Apply “LOCTITE No. 271.”)

Tightening torque for nuts 7 of reduction bevel gear mounting bolts

Standard value

441±69 N•m (45±7 kgf•m) [325±51 lbf•ft] (Apply “LOCTITE No. 271.”)

Tightening torque for side bearing cap bolts 8

Standard value

379 to 512 N•m (38.6 to 52.2 kgf•m) [279 to 378 lbf•ft]

Force applied to bearing retainer in tangential direction 9 (preload for reduction bevel pinion bearing)

Standard value

30 to 43 N•m (3.1 to 4.4 kgf•m) [6.8 to 9.7 lbf•ft]

Differential case bearing 5

Standard value

Inside diameter of brake drum 10

304.8

+0.5 0 mm

(12

+0.02 0

in.)

Service limit

307 mm (12.09 in.)

Tightening torque for support plate nuts 11

Standard value

145±22 N•m (14.8±2.2 kgf•m) [107±16 lbf•ft]

Tightening torque for self-locking nuts 12

Standard value

249±29 N•m (30±3 kgf•m) [217±22 lbf•ft]

Tightening torque for brake drum nuts 13

Standard value

96±15 N•m (9.8±1.5 kgf•m) [71±11 lbf•ft]

Bolt length 31 mm (1.22 in.)

Standard value

132±14 N•m (13.5±1.4 kgf•m) [98±10 lbf•ft]

Bolt length 37 mm (1.46 in.)

Service limit

118±12 N•m (12.0±1.2 kgf•m) [87±9 lbf•ft]

Tightening torque for differential carrier mounting bolts 14

8-60

FRONT AXLE AND REDUCTION DIFFERENTIAL

6 7 2 9

212329

8-61

REAR AXLE 1. Specifications ............................................................................................................... 9-2 2. Structure....................................................................................................................... 9-3 2.1 Rear axle............................................................................................................................................... 9-3 2.2 Power cylinder ...................................................................................................................................... 9-4

3. Suggestions for Removal and Installation.................................................................... 9-5 3.1 Rear wheels (tires)................................................................................................................................ 9-5 3.1.1 Preparation.................................................................................................................................................. 9-5 3.1.2 Removal ...................................................................................................................................................... 9-5 3.1.3 Installation ................................................................................................................................................... 9-6

3.2 Rear axle............................................................................................................................................... 9-7 3.2.1 Preparation.................................................................................................................................................. 9-7 3.2.2 Removal ...................................................................................................................................................... 9-7 3.2.3 Installation ................................................................................................................................................... 9-9

4. Disassembly and Reassembly ................................................................................... 9-10 4.1 Rear axle assembly ............................................................................................................................ 9-10 4.1.1 Disassembly.............................................................................................................................................. 9-10 4.1.2 Reassembly .............................................................................................................................................. 9-13

4.2 Power cylinder .................................................................................................................................... 9-17 4.2.1 Disassembly.............................................................................................................................................. 9-17 4.2.2 Inspection and Adjustment........................................................................................................................ 9-18 4.2.3 Reassembly .............................................................................................................................................. 9-19

5. Readjustment ............................................................................................................. 9-21 5.1 Measurement of minimum turning radius............................................................................................ 9-21 5.2 Adjustment of minimum turning radius................................................................................................ 9-21

6. Troubleshooting ......................................................................................................... 9-23 7. Service Data............................................................................................................... 9-24 7.1 Rear axle............................................................................................................................................. 9-24 7.2 Power cylinder .................................................................................................................................... 9-25

9-1

REAR AXLE

1. Specifications Truck model Axis type

9-2

DP135N

DP150N

Center pivot type Toe-in

0 mm

Camber

1˚

Caster

0˚

King pin inclination

Power cylinder

DP120N

Elliot type

Suspension method

Wheel alignment

DP100N

0˚

Cylinder inside diameter

115 mm (4.53 in.)

Piston rod outside diameter

80 mm (3.15 in.)

Stroke

182 mm (7.17 in.)

DP160N

REAR AXLE

2. Structure 2.1 Rear axle

3 8

4 6

4 5

Section A-A

Section B-B 212114

1 Rear axle housing

4 Pins (2 for each right and left)

7 Stopper bolt (right and left)

2 Power cylinder

5 Steering knuckle (right and left)

8 Rear axle support (front and rear)

3 Tie rod (right and left)

6 Wheel hub (right and left)

9-3

REAR AXLE

2.2 Power cylinder

6 7 6

2 14

12 11

212115

1 Cylinder tube

6 Wearing

11 Packing

2 Piston rod

7 Piston seal

12 Backup ring

3 Ring

8 Cylinder head

13 Dust seal

4 O-ring

9 O-ring

14 Bearings

5 Piston

10 Bushing

15 Stopper ring

9-4

REAR AXLE

3. Suggestions for Removal and Installation 3.1 Rear wheels (tires) 3.1.1 Preparation

(1) (2) (3) (4)

Set the parking brake. Block the front wheels. Loosen each rear wheel nut about two turns. Place a jack under the recess at the bottom of the counterweight, and jack up the rear end of the truck. Jack capacity DP100N

7500 kg (16500 lb)

DP120N

9000 kg (20000 lb)

DP135N

100000 kg (22000 lb)

DP150N

100000 kg (22000 lb)

DP160N

100000 kg (22000 lb)

NOTE You can also use the lifting holes of the counterweight to lift the rear end of the truck.

WARNING After raising the front end with either of the methods, place jack stands under the frame to prevent the truck from falling.

3.1.2 Removal

The number shows removal sequence.

(1) Removal sequence 1 Wheel nut

2 Clamp 3 Rear wheels (tires)

(2) Suggestions for Removal (a) Remove the wheel nuts. (b) Use either the tire handler or small lift truck to remove the rear wheels (tires). Weight of rear wheel (tire)

2 1

210406 Approx. 155 kg (342 lb)

9-5

REAR AXLE

3.1.3 Installation Follow the removal procedure in reverse while noting the following instructions. (1) Wheel nut In order to prevent the wheels from running-out, wheel nuts should be alternately tightened in the order shown in the right-hand side figure evenly and finally to the specified torque. Tightening Torque

539 ± 49 N•m (54.96 ± 5.0 kgf•m) [397.54 ± 36.14 lbf•ft]

7 6

210409

9-6

REAR AXLE

3.2 Rear axle (5) Insert solid stands under the both sides of the frame to

3.2.1 Preparation

(1) Set the parking brake. (2) Block the front wheels. (3) Remove the rear wheels (tires) while referencing the section of â&#x20AC;&#x153;Rear Wheels (Tires)â&#x20AC;?. (4) Use a lift truck with a duty load 10 tons or more and lift the rear end of the truck until the bottom of the weight is 400 to 500 mm (15.75 to 19.69 in.) above the ground.

prevent the truck from falling.

WARNING Never forget to place solid stands under both sides of the frame to prevent the truck from falling down.

3.2.2 Removal

The number shows removal sequence. 3 4

2 3

212116 1 Power cylinder hose

3 Thrust washer

2 Rear axle support

4 Rear axle assembly

9-7

REAR AXLE

(1) Steering hose (a) Remove hoses at the power cylinder side. (b) Install hose caps to the disconnected hose to prevent oil from flowing out. Hose cap

05330-30300 (G 3/8)

205558

(2) Rear axle assembly (a) Prepare an engine jack that has a wide supporting area. (b) From the rear of the truck, position the jack under the rear axle and tie it with a wire rope.

(c) Remove the front and rear axle supports. (d) Operate the jack to lower the rear axle and pull it out diagonally to the rear of the truck. Approx. 840 kg (1852 lb)

Weight of rear axle

WARNING Carefully operate the jack so that the rear axle

212117

does not accidentally drop off.

(3) Rear axle support (a) Do not remove the bushings in the support unless a defect is found through inspection.

(b) If any defect is found, either replace the rear axle support as a whole assembly or break the bushing to remove it.

CAUTION In the installation of a new bushing, note that the seam part of the bushing is installed to the lower side (grease nipple side).

9-8

Bushing joint

205431

REAR AXLE

3.2.3 Installation Follow the removal procedure in reverse while noting the following instructions. (1) Adjusting clearance on the rear axle support (a) There are 3 types of adjustment thrust washers available in different thicknesses. 3.2 mm (0.13 in.) Thrust washer type (thickness)

1.6 mm (0.063 in.) 0.8 mm (0.032 in.)

0.4mm (0.016 in.) (maximum)

(b) Select optimal thrust washers for adjusting the clearance so that the total of front and rear clearances is 0.8 mm (0.032 in.) or less (0.4 mm (0.018 in.) or less for

205555

one side).

CAUTION Install thrust washers evenly for the front and rear.

9-9

REAR AXLE

4. Disassembly and Reassembly 4.1 Rear axle assembly 4.1.1 Disassembly

12 26

16 15 17 18

32 33 35 34 27

13 14

21 6 8

7 5

3 2 1

212118

9-10

REAR AXLE

1 Hub cap, Gasket

19 Clamp

2 Lock plate

20 Power cylinder, Pipe

3 Lock nut

21 Cover

4 Rear axle hub

22 Shim [21]

5 Tapered roller bearing (inner race) [4]

23 O-ring [21]

6 Oil seal [4]

24 Oil seal [21]

7 Tapered roller bearing (outer race) [4]

25 Tapered roller bearing (outer race) [21]

8 Tapered roller bearing (outer race) [4]

26 Cap (O-ring)

9 Tapered roller bearing (inner race)

27 Steering knuckle

10 Oil seal retainer

28 Lower dust cover [27]

11 Tie rod pin

29 Tapered roller bearing (inner race) [27]

12 Tie rod

30 Oil seal retainer [27]

13 Spacer

31 O-ring [30]

14 Dust seal

32 Tapered roller bearing (inner race) [27]

15 Spacer

33 Oil seal retainer [27]

16 Dust seal

34 Oil seal [36]

17 Stopper ring [27]

35 Tapered roller bearing (outer race) [36]

18 Spherical bearing [27]

36 Rear axle housing

NOTE [ ] shows the number of each place to remove from.

(1) Lock nut (a) Remove the mounting bolts, and remove the lock plate. (b) Remove the lock nuts using a socket wrench. Width across flats of lock nut

70 mm (2.76 in.)

210413

(2) Rear axle hub Use a puller to remove the rear axle housing from the steering knuckle.

210414

9-11

REAR AXLE

(3) Tapered roller bearing Do not remove the outer race unless it is to be replaced with a new one.

CAUTION When replacing the tapered roller bearing, the outer race and the inner race should be replaced as a set.

(4) Lower cover of the steering knuckle (a) Prepare a jack bolt. Nominal diameter Jack bolt

Pitch

Thread length

16 mm (0.63 in.) 1.5 mm (0.059 in.) 100 mm or more (3.94 in. or more) Jack bolt

(b) Remove the plug at the center of the cover. (c) Remove six (6) cover fixing bolts. (d) Install the jack bolt into the plug hole to pull the cover out.

9-12

Cover

205430

REAR AXLE

4.1.2 Reassembly

The number shows assembling sequence.

35 1

20 6

15 13 10

2 3

12 14

29 30

Section A-A

24 23

Section B-B 212119

9-13

REAR AXLE

1 Rear axle housing

19 Hub cap, Gasket

2 Tapered roller bearing (outer race) [1]

20 Cap

3 Oil seal [1]

21 Lower dust cover

4 Steering knuckle

22 Cover

5 Oil seal retainer [4]

23 Tapered roller bearing (outer race)

6 Tapered roller bearing (inner race) [4]

24 O-ring

7 Oil seal retainer [4]

25 Oil seal

8 O-ring [7]

26 Shim

9 Tapered roller bearing (inner race) [4]

27 Spherical bearing

10 Oil seal retainer [4]

28 Stopper ring

11 Tapered roller bearing (inner race) [4]

29 Spacer

12 Rear axle hub

30 Dust seal

13 Tapered roller bearing (outer race) [12]

31 Spacer

14 Tapered roller bearing (outer race) [12]

32 Dust seal

15 Oil seal [12]

33 Tie rod

16 Tapered roller bearing (inner race)

34 Tie rod pin

17 Lock nut

35 Power cylinder

18 Lock plate

36 Clamp

(1) Inside of rear axle hub (a) In order for the shaded area in the right-hand side figure to be successfully greased after the assembly is completed, coat the following grease on each part before assembly. Grease

Idemitsu Autolex A

CAUTION Do not forget to lubricate the inside of the roller supporter of the tapered roller bearing.

212120

(b) First install the oil seal retainer, then drive-in the tapered roller bearing (inner race) using the bearing installer.

204664A

9-14

REAR AXLE

(2) Upper and lower steering knuckle supports (a) In order for the shaded area in the right-hand side figure to be successfully greased after the assembly is completed, coat the following grease on each part before assembly. Grease

Idemitsu Autolex A

CAUTION Do not forget to lubricate the inside of the roller supporter of the tapered roller bearing.

(b) For the upper and lower oil seals of the steering knuckle, coat the lips with the following grease. Grease

Idemitsu Autolex A

CAUTION Exercise care for the direction of the oil seal during reassembly. (See the figure at the right.)

212121

(3) Preload adjustment of knuckle bearing (a) Install the cover without the shims. (b) Use a thickness gauge to measure the clearance between the rear axle housing and cover.

(c) Install a shim which is 0.1 mm (0.0039 in.) thinner than the measured clearance and evenly tighten the cover mounting bolts.

(d) Hook a spring scale to the tie-rod mounting hole of the knuckle arm and measure whether the force applied in the tangential direction meets the specified value. Tangential force

98 to 146 N (9.993 to 14.888 kgf) [72.28 to 107.68 lbf]

(e) If the force applied in the tangential direction does not meet the standard value, re-adjust it by means of vary-

Clearance 210418

ing the shim thickness.

9-15

REAR AXLE

(4) Preload adjustment of hub bearing (a) After all the parts are assembled, remove the hub cap and lock nut.

(b) Temporarily tighten lock nuts. (c) Hook a spring scale to one of the hub bolts and measure whether the force applied in the tangential direction meets the specified value. Preload for hub bearing

88 to 127 N (8.97 to 12.95 kgf) [64.91 to 93.67 lbf]

210419

(d) If the force applied in the tangential direction does not meet the standard value, re-adjust it by means of varying the amount of turning-in of the lock nut.

CAUTION However, it is advisable to aim at a value somewhat lower than the tolerance limit, if the bearings are reused.

(e) If the tangential force meets the specified value, gradually loosen the lock nuts until each hole on the lock plate aligns with the threaded portion of the rock nut.

(f) Tighten the lock plate with bolts and spring washers.

Lock nut Lock plate

212122

9-16

REAR AXLE

4.2 Power cylinder 4.2.1 Disassembly

The number shows disassembling sequence. 7 8

9 10 2

6 3 4 1

1 4

212123 1 Cylinder head

5 O-ring

9 Stopper ring

2 Dust seal

6 Piston rod

10 Bearings

3 Backup ring

7 Wearing

11 Cylinder tube

4 Packing

8 Piston seal

NOTE (a) Do not remove the bushing press-fit in the cylinder head. (b) Do not remove the piston assembled with the piston rod.

(1) Cylinder head (a) Hold the cylinder tube which has been protected by copper plates in vise.

(b) Use the special tool to remove the cylinder head. Special tool Hook wrench

05302-10800 Hook wrench

205438

9-17

REAR AXLE

4.2.2 Inspection and Adjustment

(1) Piston rod bend (a) Support both ends of the piston rod with V-shaped blocks, and apply a dial gauge at the middle portion.

(b) Measure the deflection (runout) while rotating the piston rod one turn by hand. If this measurement exceeds the service limit (refer to the following table), replace the piston rod together with the piston.

(2) Piston rod surfaces (a) Check the piston rod surfaces for rust, damages, sliding

205439

marks, or dents. If any excessive rust or damage is found, replace the cylinder tube.

(b) When any of the thread parts are excessively damaged, replace the piston rod.

(3) Cylinder tube (a) Check the cylinder tube for any wear, damage or rust. If any excessive rust or damage is found, replace the cylinder tube.

(b) Check the welds for cracks, damage, and dent. If any excessive damage is found, replace the cylinder tube.

Item Inside diameter of cylinder tube

Piston rod outside diameter

Clearance between rod and bushing

Deflection of piston rod (1/2 of dial indicator reading)

Standard value

115 mm (4.528 in.)

Repair or service limit

115.15 mm (4.533 in.)

Standard value

80 mm (3.15 in.)

Standard value

0.1 mm (0.0039 in.)

Repair or service limit

0.2 mm (0.0079 in.)

Repair or service limit

0.3 mm (0.012 in.)

Service Data

212124

9-18

REAR AXLE

4.2.3 Reassembly

# 9

# # 2 3

# 2

The number shows assembling sequence. #: Seal kit parts.

1 10

# 8

# 7

# 6

212125

1 Piston rod

5 Cylinder head

9 O-ring [5]

2 Wearing [1]

6 Packing [5]

10 Bearings

3 Piston seal [1]

7 Backup ring [5]

11 Stopper ring

4 Cylinder tube

8 Dust seal [5]

NOTE [ ] shows the number of each part to reassemble to.

(1) Cleaning of each part (a) Thoroughly clean all parts before reassembly making sure they are completely free from dirt or dust.

(2) Seal Kit parts (marked with â&#x20AC;&#x2DC;#â&#x20AC;&#x2122; in the above figure) (a) Always prepare new parts.

CAUTION Seal Kit parts should always be new ones. Never re-install any part that has been once removed.

(b) Before reassembly coat each part with hydraulic oil. (c) Be aware of the direction to assemble the seals and rings to be inserted in the cylinder head.

9-19

REAR AXLE

(3) Installing piston seals (a) Hold the piston rod with a vise.

CAUTION Be careful not to damage the piston rod.

(b) Lightly compress and release a piston seal 5 to 6 times by hand to make it soft.

(d) First fit one of the piston seals in the mounting groove of the piston, then insert the other.

(e) Check the entire circumference of the piston tube to

200352

make sure the piston seals are firmly installed.

(f) When the assembling of piston seals is completed, install the associated wearing.

205552

(4) Cylinder head (a) Tighten the cylinder head to the specified torque. Tightening torque

9-20

539 ± 54 N•m (54.96 ± 5.506 kgf•m) [397.54 ± 39.83 lbf•ft]

REAR AXLE

5. Readjustment 5.1 Measurement of minimum turning radius (1) Secure an area of flat square ground which extends more than 20 m (65.6 ft.) in both directions of depth and width.

WARNING This measurement lot must be surrounded by a fence, etc. or assigned with watchman in order to prevent any persons unconcerned from entering the area.

Truck Model

Minimum turning radius

DP100N

4000 mm (157.5 in.)

DP120N

4060 mm (159.8 in.)

DP135N

4165 mm (163.8 in.)

DP150N

4555 mm (179.3 in.)

DP160N

4815 mm (189.6 in.)

di ra g in rn tu um im in M

down from a position of the counterweight as shown in the figure to the ground. (3) Turn the steering wheel fully and drive the truck at a low speed. At this time, make sure that the chalk draws a line (circle) on the ground. (4) Measure the diameter of the circle drawn on the ground. The radius of this circle is assumed to be the minimum turning radius (R).

(2) Put a piece of chalk to the end of a thread, and hang it

212256

9-21

REAR AXLE

5.2 Adjustment of minimum turning radius (1) Make sure that the protrusion of the stopper bolt meets the standard value. Standard value

25 mm (0.98 in.)

(2) If the amount of protrusion of the stopper bolt does not meet the standard value, re-adjust it with the following procedure. (a) Tentatively loosen the lock nut.

Stopper bolts (left and right)

25mm (0.984 in.)

Protrusion of bolt

Lock nut

(b) Adjust the stopper bolt protrusion to the specified value.

(c) Measure the minimum turning radius again. (d) If the normal minimum turning radius can not be obtained with the stopper bolt protrusion set to the standard value, re-adjust by varying the amount of pro-

212127

trusion properly.

(e) When the minimum turning radius has met the specified value, tighten the lock nut to the specified torque. Tightening torque

9-22

Standard value

233 Nâ&#x20AC;˘m (23.76 kgf/m) [171.85 lbfâ&#x20AC;˘ft]

REAR AXLE

6. Troubleshooting

Steering wheel is heavy Dull self-returning of steering wheel

• Insufficient lubrication in the rear axle

• Greasing

• Low tire inflation pressure

• Adjust inflation pressure

• Excessive tightening on each part of • Retighten to the specified torque the rear axle • Difference in the outside diameter of • Change to the tire of normal outside diam-

Steering operation is unexpectedly controlled to one side

tires between the right and left

eter

• Tire inflation pressure differs between • Adjust inflation pressure the right and left tires • Wear or damage in the tapered roller • Replace the bearing

Steering wheel swings

bearing • Defective steering system

• Refer to the chapter of Steering System to proceed inspection or adjustment

• Defective adjustment of wheel align- • Adjust alignment Rear tire’s uneven wear or early wear

ment • Type or inflation pressure differs • Replace wheels with specified ones and between the right and left wheels

adjust inflation pressure

9-23

REAR AXLE

7. Service Data 7.1 Rear axle Truck model

DP100N

DP120N

DP135N

Oscillation angle (right and left)

Standard value

3˚

Toe-in

Standard value

0˚

Caster

Standard value

0˚

Camber Steering angle

Standard value

1˚

Inside (hub bolt)

Standard value

75˚24′

Outside

Standard value 60

0 -0.019

mm (2.36 -0.00075 in.)

Repair limit

59.9 mm (2.358 in.)

Tangential force of knuckle bearing 2 (knuckle arm)

Standard value

98.1 to 145.8 N (10.0034 to 14.87 kgf) [72.35 to 107.54 lbf]

Preload of hub bearing

Standard value

18.6 to 27.5 N•m (1.8967 to 2.804 kgf•m) [13.72 to 20.283 lbf•ft]

Tangential force of hub bearing 3 (hub bolt)

Standard value

88.3 to 127.5 N (9.004 to 13.001 kgf) [65.13 to 94.039 lbf]

Standard value

0.8 mm or less (0.032 in.)

Clearance of center pin in the front and rear directions 4 (total of front and rear)

DP160N

49˚42′

Standard value

Outside diameter of knuckle pin 1

DP150N

Repair limit

1.2 mm (0.047 in.)

Locking of knuckle stopper bolt nut tightening torque 5

Standard value

487.4 N•m (49.7007 kgf•m) [359.486 lbf•ft]

Tightening torque of wheel nut 6

Standard value

490.3 to 588.4 N•m (49.996 to 59.9998 kgf•m) [361.62 to 433.98 lbf•ft]

Tightening torque of rear axle support mounting bolt 7

Standard value

209.9 N•m (21.404 kgf•m) [154.81 lbf•ft]

Tightening torque of power cylinder mounting bolts 8

Standard value

1136 N•m (115.84 kgf•m) [837.87 lbf•ft]

Tightening torque of hose 9

Standard value

49 ± 5 N•m (4.997 ± 0.51 kgf•m) [36.14 ± 3.69 lbf•ft]

2 9 5

1 3

A 6

9-24

Section A-A

212128

REAR AXLE

7.2 Power cylinder Truck model

DP100N

Outside diameter of piston rod 2

Clearance between rod and bushing 3 Deflection of piston rod 4 (1/2 of dial indicator reading) Tightening torque of cylinder head 5

DP150N

115 mm (4.527 in.)

Repair limit

115.15 mm (4.533 in.)

Standard value

80 mm (3.15 in.)

Standard value

0.1 mm (0.0039 in.)

Repair limit

0.2 mm (0.0079 in.)

Repair limit

0.3 mm (0.0118 in.)

Standard value

539 ± 54 N•m (54.96 ± 5.506 kgf•m) [397.54 ± 39.83 lbf•ft]

DP135N

DP160N

Inside diameter of cylinder tube 1

DP120N

Standard value

212129

9-25

BRAKE SYSTEM 1. Specifications ............................................................................................................. 10-4 1.1 Truck with dry brake............................................................................................................................ 10-4 1.2 Truck with wet brake ........................................................................................................................... 10-4

2. Structure..................................................................................................................... 10-5 2.1 Wheel brake system (DP100N to DP150N)........................................................................................ 10-5 2.1.1 Relay valve................................................................................................................................................ 10-6

1 2

2.1.2 Brake control valve.................................................................................................................................... 10-8 2.1.3 Air master.................................................................................................................................................. 10-9 2.1.4 Wheel brake ............................................................................................................................................ 10-12

2.2 Wheel brakes system (DP160N)....................................................................................................... 10-13 2.2.1 Brake booster.......................................................................................................................................... 10-14

3 4

2.3 Parking brake system ....................................................................................................................... 10-17 2.3.1 Parking brake lever ................................................................................................................................. 10-18 2.3.2 Parking brake .......................................................................................................................................... 10-19

3. Suggestions for Removal and Installation................................................................ 10-20 3.1 Wheel brake (DP100N to DP150N) .................................................................................................. 10-20 3.1.1 Preparation.............................................................................................................................................. 10-20 3.1.2 Removal .................................................................................................................................................. 10-20

5 6 7

3.1.3 Installation ............................................................................................................................................... 10-22

4. Disassembly and Reassembly ................................................................................. 10-23 4.1 Wheel brake (DP100N to DP150N) .................................................................................................. 10-23 4.1.1 Disassembly............................................................................................................................................ 10-23 4.1.2 Inspection and Repair ............................................................................................................................. 10-25 4.1.3 Reassembly ............................................................................................................................................ 10-26

4.2 Wheel cylinder (DP100N to DP150N)............................................................................................... 10-29

8 9 10 10

4.2.1 Disassembly............................................................................................................................................ 10-29 4.2.2 Inspection and Repair ............................................................................................................................. 10-30 4.2.3 Reassembly ............................................................................................................................................ 10-30

4.3 Air master (DP100N to DP150N) ...................................................................................................... 10-31 4.3.1 Disassembly............................................................................................................................................ 10-31

11 12

4.3.2 Reassembly ............................................................................................................................................ 10-32

4.4 Brake booster (DP160N)................................................................................................................... 10-33 4.4.1 Disassembly............................................................................................................................................ 10-33 4.4.2 Reassembly ............................................................................................................................................ 10-34

4.5 Parking brake.................................................................................................................................... 10-35 4.5.1 Disassembly............................................................................................................................................ 10-35

10-1

13 14

BRAKE SYSTEM

4.5.2 Inspection and Repair ............................................................................................................................. 10-35 4.5.3 Reassembly ............................................................................................................................................ 10-36

4.6 Brake control valve ........................................................................................................................... 10-37 4.6.1 Disassembly and Reassembly ................................................................................................................ 10-37

4.7 Replacing desiccating agent of air dryer........................................................................................... 10-39 4.7.1 Disassembly............................................................................................................................................ 10-39 4.7.2 Reassembly ............................................................................................................................................ 10-40

5. Adjustment and Testing ........................................................................................... 10-41 5.1 Inspecting wheel brake (DP100N to DP150N).................................................................................. 10-41 5.1.1 Clearance check between lining and drum ............................................................................................. 10-41 5.1.2 Replacing brake lining............................................................................................................................. 10-41 5.1.3 Adjusting lining wear indicator................................................................................................................. 10-41 5.1.4 Inspecting brake drum............................................................................................................................. 10-42

5.2 Bleeding brake system...................................................................................................................... 10-42 5.2.1 Bleeding air master ................................................................................................................................. 10-42 5.2.2 Bleeding wheel cylinder .......................................................................................................................... 10-43

5.3 Inspection of wheel brake (DP160N) ................................................................................................ 10-43 5.3.1 Replacing brake disc............................................................................................................................... 10-43 5.3.2 Brake oil line bleeding ............................................................................................................................. 10-44

5.4 Bleeding brake pedal ........................................................................................................................ 10-45 5.5 Inspecting brake control valve .......................................................................................................... 10-45 5.5.1 Air leakage check.................................................................................................................................... 10-45 5.5.2 Functional check ..................................................................................................................................... 10-45

5.6 Adjusting parking brake .................................................................................................................... 10-46 5.6.1 Clearance adjustment between drum and lining ..................................................................................... 10-46

5.7 Inspection of brake oil tank (DP160N) .............................................................................................. 10-46 5.7.1 Inspecting liquid level sensor .................................................................................................................. 10-46

6. Troubleshooting ....................................................................................................... 10-47 6.1 Wheel brake (DP100N to DP150N) .................................................................................................. 10-47 6.2 Wheel brake (DP160N)..................................................................................................................... 10-48 6.3 Parking brake.................................................................................................................................... 10-49 6.4 Air drier ............................................................................................................................................. 10-49

7. Service Data............................................................................................................. 10-50 7.1 Brake pedal....................................................................................................................................... 10-50 7.2 Brake control valve ........................................................................................................................... 10-50 7.3 Air master (DP100N to DP150N) ...................................................................................................... 10-51 7.4 Brake booster (DP160N)................................................................................................................... 10-52 7.5 Wheel brake (DP100N to DP150N) .................................................................................................. 10-53 7.6 Wheel cylinder (DP100N to DP150N)............................................................................................... 10-54 10-2

BRAKE SYSTEM

7.7 Parking brake lever ........................................................................................................................... 10-54 7.8 Parking brake drum........................................................................................................................... 10-55

10-3

BRAKE SYSTEM

1. Specifications 1.1 Truck with dry brake Truck model

Wheel brake

Parking brake

DP100N

DP120N

DP135N

DP150N

Type Drum diameter Brake shoe lining dimensions (length × width × thickness - number of shoes per brake) Wheel cylinder inside diameter Brake booster

Hydraulic drum internal expanding leading-trailing shoe type 420 mm 200 × 190 × 16 - 4 mm

Type Drum diameter Brake shoe lining dimensions (length × width × thickness - number of shoes per brake)

Center brake drum internal expanding type 304.8 mm 345 × 75 × 6.7 - 2 mm

55.56 mm Air master (air booster)

1.2 Truck with wet brake Truck model

Wheel brake

Parking brake

10-4

Type Disk diameter - number of disks in one side Brake booster Type Drum diameter Brake shoe lining dimensions (length × width × thickness - number of shoes per brake)

DP160N Hydraulic wet multiplate disc type 381 mm - 16 Brake booster Center brake drum internal expanding type 304.8 mm 345 × 75 × 6.7 - 2 mm

BRAKE SYSTEM

2. Structure 2.1 Wheel brake system (DP100N to DP150N)

From air compressor 6

212243

1 Air drier

5 Air master

2 Air tank

6 Reserve tank

3 Relay valve

7 Front axle

4 Brake control valve

Air compressed by the compressor is dehumidified by an air drier, and filled in the air tank. The compressed air is opened/closed by the brake control valve through a relay valve, and sent to air master. Since the air master compresses the brake fluid with this compressed air, the wheel brake activates to brake the truck.

10-5

BRAKE SYSTEM

2.1.1 Relay valve

B 9

D 212244

1 Body

6 Valve rod

2 Valve guide

7 Spring

3 Inlet valve

8 Cover

4 Spring

9 Ventilating hole

5 Diaphragm

A: From brake control valve B: To air master C: From air tank D: To atmosphere Relay valve controls the braking pressure corresponding to pressure change in pipeline at the brake control valve side, which can extremely shorten the time required to increase braking pressure.

10-6

Compressed air in the air tank is directly sent to the air master to prevent delay of brake application. When releasing the brake, the compressed air from air master is discharged directly from the relay valve.

BRAKE SYSTEM

(1) Operation (a) Generation of brake pressure When the brake pedal is depressed and the pipeline pressure from brake control valve increases, the valve rod is lowered along with diaphragm to close the exhaust port, moreover lower the inlet valve to open the inlet port. The compressed air in air tank is led to air master from this inlet port.

From brake control valve

To air master From air master

(b) Stabilization of brake pressure When the pressure of air master increases, the force acting on the underside of diaphragm increases by pressure entered from ventilating hole. When this force comes to be larger than the force acting on top face from brake control valve, the diaphragm and valve rod will be pushed up. Also, the inlet valve is closed by the spring, and the pressure of air master maintains a pressure which is equal to that at the brake control valve side.

Generation of brake pressure

From brake control valve

Releasing the brake pedal will drop the air pressure from brake control valve. Since the valve rod lifts further to open the exhaust port, air in the air master is discharged through the center of inlet valve.

Stabilization of brake pressure

To brake control valve

From air master

To atmosphere Releasing of brake pressure 212245

10-7

BRAKE SYSTEM

6±1° Emergency braking

r a k al ing

16 ° ± No 1° b rm

Applied position

17°

39± 1.5°

Fr 4±1 ee .5 pl ° ay

2.1.2 Brake control valve

B A

Released position

14 3 4

15 16 B

17 A

B 18

7 20

1 Valve cover

200629 11 Plunger

2 Main spring assembly

12 Plunger guide

3 Valve case

13 Packing

4 Return spring

14 O-ring

5 Spring

15 Piston

6 Packing

16 Feed valve assembly

7 Cap

17 Spring seat

8 Boot

18 O-ring

9 Pedal

19 C-ring

10 Push button

20 Dust seal

A: Air tank side port B: Air master side port By depressing the pedal, a volume of compressed air in proportion to the displacement of the pedal depressed, is supplied to the cylinder shell section in the air master. When releasing the foot from the pedal, the compressed air in the cylinder shell is discharged into the atmosphere.

10-8

BRAKE SYSTEM

2.1.3 Air master

From brake control valve (high pressure air)

To wheel brakes (high pressure fluid)

200632

1 Piston packing

8 Hydraulic cylinder

2 Piston plate

9 Breather plug

3 Cylinder shell

10 Cylinder cap

4 Pushrod

11 Hydraulic piston assembly

5 Return spring

12 Switch assembly

6 End plate

13 Rod and plate assembly

7 Air breather

14 Outlet valve

Brake fluid pressurized by the compressed air supplied from the brake control valve is used to activate the wheel cylinder.

10-9

BRAKE SYSTEM

(1) in the inactive condition Since the brake control valve has closed, right and left of the piston plate is at the atmospheric pressure. The piston plate is pushed by the return spring to the left as shown in the illustration.

Piston plate

Return spring

200633

(2) When depressing the brake pedal When the brake control valve opens, the compressed air flows into the inlet port of cylinder shell. This compressed air pushes the return spring to the right as shown in the illustration via the piston plate, and also pushes the hydraulic piston through the push rod connected to the piston plate. When the hydraulic piston begins to work, the check valve yoke which has touched to the stopper is returned by the spring. Therefore, the ball comes into close contact with the seat surface by the brake fluid in the cylinder, and closes the circuit to reservoir tank. In this way, the brake fluid in the hydraulic cylinder is adjusted to the pressure corresponding to compressed air pressure by moving the piston, and applied to the wheel cylinder.

Hydraulic piston

Push rod

Ball Yoke spring Check valve yoke 200634

(3) When releasing the brake pedal When the brake control valve closes, the compressed air in the cylinder shell is discharged from the bottom of air brake valve. Thus, the piston plate is pushed by the return spring and returns to the initial position. The hydraulic piston returns to the left in the illustration by the oil pressure from the wheel cylinder. At this time, when the check valve yoke touches the stopper, the ball will separate from seat surface, and circuit to the reservoir tank will be opened. In this way, the brake fluid in the hydraulic cylinder is depressurized and the brake is released.

10-10

Stopper 200635

BRAKE SYSTEM

(4) Warning of brake lining adjustment When the stroke of piston plate becomes longer, rod and plate assembly in the cylinder shell will be pushed by the piston plate, and the switch will be activated. Thus, the lamp in the operatorâ&#x20AC;&#x2122;s compartment illuminates, while the buzzer sounds to warn. Since the cause by which the stroke of piston plate becomes longer is wear of brake lining, adjustment of brake lining is needed.

Piston plate

Rod and plate assembly

Switch assembly

212235

10-11

BRAKE SYSTEM

2.1.4 Wheel brake

9 8

Section A â&#x20AC;&#x201C; A

A A

1 6

1 Brake shoe

6 Anchor bracket

2 Anchor pin

7 Adjusting cam

3 Lock plate

8 Adjusting spring

4 Wheel cylinder

9 Lining wear indicator

5 Return spring

10 Dust cover

The brake shoe has a T-shaped cross section, and the lining of non asbestos material is stuck on its outside as a friction surface. The support point at lower end of shoe is supported by the boss of anchor bracket, and the recess at the top is connected to the push rod of wheel cylinder. The intermediate rib section is also supported by the return spring and adjusting cam. The adjusting cam is a eccentric cam, and rotation of the cam is required when clearance adjustment of the brake shoe is performed. The wheel cylinder is the opposed piston type, and its body section is bolted to the anchor bracket.

10-12

205683

When the brake pedal is not depressed, the brake shoe is retracted with the return spring, since the pressure of brake fluid is not applied to the wheel cylinder. When the brake pedal is depressed, the push rod of wheel cylinder is extended to right and left, and which result in the linings of brake shoe pressed onto the brake drum, resisting the return spring force. In this way, the wheel brake is activated, and truck is slowed down and stopped.

BRAKE SYSTEM

2.2 Wheel brakes system (DP160N)

From air compressor

4 6 3

212246

1 Air drier

5 Brake booster

2 Air tank

6 Reserve tank

3 Relay valve

7 Front axle

4 Brake control valve

Air compressed by the compressor is dehumidified by an air drier, and fills the air tank. The compressed air is opened/ closed by the brake control valve, and sent to brake booster through the relay valve. Since the brake booster compresses the brake oil with this compressed air, the wheel brake activates to brake the truck.

NOTE (a) Relay valve and brake control valve are common to DP100N-DP150N. For structure description, refer to the section of DP100N-DP150N. (b) For structure description of wheel brake, refer to the chapter of â&#x20AC;&#x153;Front Axle and Reduction Differentialâ&#x20AC;?.

10-13

BRAKE SYSTEM

2.2.1 Brake booster

From brake oil tanks 7

From brake control valve (high pressure air)

To wheel brakes (high pressure brake oil)

1 Switch

212247

4 Pushrod

7 Piston

2 Load chamber body

5 Return spring

8 Check valve

3 Piston complete

6 Master cylinder

The brake booster converts energy of compressed air, which is supplied from brake control valve, into oil pressure force, and activates the wet disc brake installed to the front axle. Because the compressed air is used as source to increase the force, the force to depress the pedal is reduced with the braking effect improved.

10-14

When the switch built into the chamber is activated a warning buzzer sounds. This means the disk and plates in the wheel hub have reached the service limit.

BRAKE SYSTEM

(1) When depressing the brake pedal

Piston complete

From brake oil tanks

From brake control valve (high pressure air)

To wheel brakes (high pressure brake oil) Check valve

Push rod

Piston of master cylinder

212248 (a) Compressed air from the brake control valve pushes the piston complete and push rod. The push rod also pushes the piston of master cylinder.

(b) When the piston begins to move, check valve will be pressed on the seat surface and will close the oil passage from oil tank.

(c) In this way, the brake oil in master cylinder is adjusted to a pressure according to compressed air pressure by moving the piston, and applied to the wheel brake.

10-15

BRAKE SYSTEM

(2) When disk brake is worn

From brake control valve (high pressure air)

To wheel brakes (high pressure brake oil)

Head of switch

212249

(a) When the stroke of push rod becomes too long, the piston complete will push the head of switch in chamber. Thus, the switch is activated and the lamp in operatorâ&#x20AC;&#x2122;s compartment illuminates, while the buzzer sounds to warn.

(b) The stroke of push rod is too long because the brake disc and plates are worn and must be replaced.

10-16

BRAKE SYSTEM

2.3 Parking brake system

206098

1 Parking brake lever

3 Parking brake drum assembly

2 Parking brake cable

This parking brake is an internal expanding type, and brakes the brake drum mounted to the input flange part in the front axle with the parking brake lever and flexible wire. Even though the main purpose of parking brake system is preventing a motor movement at the time of parking, it is also used as an auxiliary brake if the wheel brake system is defective.

10-17

BRAKE SYSTEM

2.3.1 Parking brake lever

Released position

Applied position

3 2 1

212236

1 Lever support pin

3 Parking brake lever assembly

2 Adjusting screw

4 Parking brake lever switch

(1) Inspection and Repair (a) If there is serious damage to the lever support pin or the pin hole in the lever, replace the lever assembly.

(b) Replace the parking brake cable if it is stretched, damaged or rusty.

(2) Reassembly Connect the wire to the lever, then inspect whether or not the operating force is within the standard value. Lever operating effort

10-18

Standard value

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

BRAKE SYSTEM

2.3.2 Parking brake

10 Section A-A 1 2

5 6 7 A

210430

1 Dust shield

6 Parking brake shoe

2 Camshaft

7 Spring

3 Parking brake drum

8 Spring

4 Support plate

9 Adjuster assembly

5 Parking brake lining

10 Lever

The parking brake is of an internally expanding type that a cam operation expands the brake shoe inside the drum. It has an adjuster assembly installed at the bottom to adjust a clearance made between the lining and drum.

10-19

BRAKE SYSTEM

3. Suggestions for Removal and Installation 3.1 Wheel brake (DP100N to DP150N) 3.1.1 Preparation

(1) Disassemble the front axle according to the disassembly sequence of front axle. 3.1.2 Removal

3 1

The number shows removal sequence.

1 Bolts (two places on the upper part) 2 Bolt

10-20

212250

3 Wheel brake assembly

BRAKE SYSTEM

(1) Special tool It is hard to remove two attaching bolts at the upper portion, because they are under the return spring. In addition, since it is also difficult to loosen bolts on nut side, remove using the special tool.

Return spring

Bolts in awkward positions

206490

Special tool Tool name

Part No.

Bolt wrench

92367-02100

Torque wrench

92367-02200

Socket

92367-02300

15o A

S point

A 15o Bolt holding wrench S point

View A Torque wrench

Socket wrench

206491

10-21

BRAKE SYSTEM

(2) Removing upper bolt (a) Support bolt wrench as mark L contacts with the left Bolt holding wrench

side bolts while mark R contacts with the right bolts when the brake wheel assembly is shown from the front.

Identification marks

206493

(b) Remove the nut using the torque wrench and socket in the special tool. torque wrench Socket wrench

ard

rw Fo

206494

(3) Removing other bolts Support the other bolts using the normal tool, and remove the nut side bolts using the above mentioned torque wrench and socket. Bolt in awkward position

Other bolt

212251

3.1.3 Installation Follow the removal procedure in reverse while noting the following instructions. (1) Bolt tightening torque Tighten each bolt to the specified torque. Torque

10-22

156 Âą 16 Nâ&#x20AC;˘m

BRAKE SYSTEM

4. Disassembly and Reassembly 4.1 Wheel brake (DP100N to DP150N) 4.1.1 Disassembly

The number shows disassembly sequence.

7 1

4 9

12 3

212252 1 Return spring

7 Wheel cylinder

2 Anchor pin

8 Pin, Indicator, Cover

3 Lock plate

9 Boot, Spring, Washer

4 Shoe and lining assemblies

10 Adjusting cam

5 Cylinder plate

11 Dust cover

6 Cylinder cover

12 Anchor bracket

10-23

BRAKE SYSTEM

(1) Removing return spring (a) Turn the adjusting cam and move the brake shoe to the full inner side.

(b) Remove the return spring from the brake shoe using the spring setter in the special tool. Spring setter

Special tool Spring setter: 03737-10001

205687

(2) Removing anchor pin (a) Remove the anchor pin from the anchor bracket using the anchor pin puller (special tool). Special tool Anchor pin puller: 03737-60000

Anchor pin puller

205688

10-24

BRAKE SYSTEM

4.1.2 Inspection and Repair

(1) Dust cover (a) Check the dust cover for cracks. (b) When the dust cover is not removed, check whether the bolt has been tightened to the specified torque or not. Tightening torque

20±4 N•m (2.0±0.4 kgf•m) [14.5±3 lbf•ft]

(2) Shoe and lining assemblies (a) Check the linings or shoes for any cracks or fracture. (b) Replace the lining if it has been badly contaminated by oil or has been glazed or otherwise set or deteriorated from friction heat.

Thickness of lining

Standard value

16 mm (0.63 in.)

Service limit

10 mm (0.39 in.)

205689

(3) Brake drum Check the inside surface for any scoring and uneven wear. If necessary, repair the inside surface by grinding it.

Inside diameter of brake drum

Standard value

+0.2 0 mm +0.008 (16.54 0 in.)

Service limit

424 mm (16.69 in.)

420

(4) Return spring (a) Check the free length of return spring. Free length of return spring

Standard value

203.5 mm (8.01 in.)

(b) Replace if clearance exists between coils when no tension is applied to the return spring.

10-25

BRAKE SYSTEM

4.1.3 Reassembly

The number shows assembling sequence.

7 4

9 2

Section A-A 10 11

210433 1 Anchor bracket

8 Anchor pin

2 Dust cover

9 Lock plate, Lock washer

3 Adjusting cam

10 Wheel cylinder,

4 Washer, Spring, Boot

11 Cylinder cover

5 Cover, Indicator, Pin

12 Air breather

6 Pin, E-ring

13 Return spring

7 Shoe, Bush

(1) Installing wheel cylinder (a) Apply a thin coat of liquid packing on the cylinder mounting surfaces.

(b) Align the oil filler port surface on the cylinder with surface of the anchor bracket to be contacted with dust cover, and tighten the bolt to the specified torque. Tightening torque

10-26

135±22 N•m (13.8±2.3 kgf•m) [99±16 lbf•ft]

BRAKE SYSTEM

(2) Greasing Apply a thin coat of specified brake grease to the following parts: (a) Shoe bush inner surface

(b) Grease groove on anchor pin (c) Anchor bracket and adjusting cam contact surface (avoid over-lubrication or the linings will be soaked with grease)

(3) Installing brake shoe (a) Position the left and right adjusting cams so that the lobe lift or rise is minimum.

(b) Check that the push rod of wheel cylinder is correctly placed in the shoe web.

(4) Installing lock plate and lock washer (a) Tighten the mounting bolts to the specified torque. Tightening torque

15.7 to 23.5 N•m (1.6 to 2.4 kgf•m) [12 to 17 lbf•ft]

(b) After mounting, make sure to bend the lock plate.

205714

(5) Return spring installation Hang the return spring on the pin of brake shoe using the spring setter in the special tool. Special tool Spring setter: 03727-10001 Spring setter

205687

10-27

BRAKE SYSTEM

(6) Adjusting lining wear indicator

NOTE Perform adjustment of the indicator, only when the adjusting cam is disassembled.

(a) Turn the washer using the spanner, and set the indicator to the innermost part of the lining service range.

(b) In this case, set the adjusting cam with the shoe most retracted, and hold down with another spanner in order for the cam not to turn.

210435

(7) Installing wheel brake assembly Install the wheel brake assembly into the front axle, and tighten the bolt to the specified torque.

Tightening torque for wheel brake assembly bolts

10-28

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]

BRAKE SYSTEM

4.2 Wheel cylinder (DP100N to DP150N) 4.2.1 Disassembly

The number shows disassembling sequence.

6 1

2 3

3 2

1 8

212253 1 Pushrod

4 Piston cup

7 Bleeder screw

2 Dust cover

5 Spring seat

8 Connector

3 Piston

6 Return spring

9 Cylinder body

10-29

BRAKE SYSTEM

4.2.2 Inspection and Repair

(1) Cylinder body (a) Check the inner wall for rusting, corrosion and damage.

(b) Check each threaded part of air bleeder, connector, and oil pipe for damage.

(2) Piston (a) Check the outer surface for rusting and damage. (b) Install the piston into the cylinder body, and measure the clearance. Replace, if the clearance exceeds the service limit. Clearance between piston and cylinder body

Standard value

0.13 to 0.24 mm (0.005 to 0.009 in.)

Service limit

0.3 mm (0.012 in.)

205692

(3) Piston cup (a) Check for bulge, damage, hardened or otherwise deteriorated. Replace, if there is any defect. Fit of piston cups in cylinder body

Standard value

1.94 mm (0.076 in.)

Service limit

0.2 to 0.3 mm (0.008 to 0.012 in.)

(b) Replace the piston cups every year regardless of the existence of any abnormalities.

(4) Dust cover (a) Replace, if it is damaged or deteriorated. (b) Replace the piston cups every year regardless of the existence of any abnormalities. 4.2.3 Reassembly To reassemble, follow the disassembly sequence in reverse and observe the following. (1) Apply an even coat of brake fluid to the cylinderâ&#x20AC;&#x2122;s inside surface and piston cups. (2) Make sure the piston cups are correctly aligned, and install the lip of the piston cup being careful not to damage.

10-30

BRAKE SYSTEM

4.3 Air master (DP100N to DP150N) 4.3.1 Disassembly

The number shows disassembling sequence.

#: Seal kit parts. 8 9 7 6

# 2 ##

# #

# 3

# 4

200784 1 Hydraulic cylinder, Outlet valve, Cylinder cap, Plug, Spring, O-ring 2 Hydraulic piston, Washer, Spring, O-ring 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 and plate, Retainer, Spring 7 Switch, Shim 8 Air breather 9 End plate, Oil seal

(1) Removing hydraulic piston (a) Supply compressed air less than 588 kPa (85 psi) to the inlet port in the rear section of cylinder shell and make the push rod pull out from the end plate.

(b) Loosen the pin and remove the hydraulic piston.

200641

10-31

BRAKE SYSTEM

4.3.2 Reassembly To reassemble, follow the disassembly sequence in reverse and observe the following. (1) Always replace the repair kit parts with new ones, when reassembling. (2) Clean the removed parts with the following cleaning fluid to remove the surface deposit. (a) Handling of rubber parts Wipe off the surface deposit using a rag soaked with alcohol or light oil. Furthermore, don’t dip rubber parts into the cleaning fluid by any means. (b) Handling of metal parts Clean with volatile cleaning fluid, and remove the remaining cleaning fluid by blowing the parts with compressed air.

(3) When assembling, apply lubricant to the following parts. (a) Lightly coat air master paste to the power piston plate, leather packing, gasket, and inside of cylinder shell.

(b) Apply silicone grease to the clearance of oil seal installed in the end plate.

(4) Bleed after assembling. (Refer to the section of “Inspection and Adjustment”.)

Oil Seal

O-ring Cup

10-32

Hydraulic piston

200642

BRAKE SYSTEM

4.4 Brake booster (DP160N) 4.4.1 Disassembly

The number shows disassembling secuence.

10 11 3 4 7 5

6 8

9 1

19 18

2 17 16 15

210909

1 Switch

8 O-ring

15 Piston rod complete

2 Cylinder

9 SKY seal

16 O-ring

3 Push rod pin

10 Retaining ring

17 Sleeve

4 Piston

11 Oil filter

18 Packing 19 Air cylinder complete

5 O-ring

12 Collar

6 ST seal

13 Cover complete

7 O-ring

14 Return spring

(1) Piston O-ring, seals (a) Remove carefully so as not to damage the piston.

O-ring SKY seal

O-ring ST seal O-ring

210910

10-33

BRAKE SYSTEM

4.4.2 Reassembly

(1) Reassembly should be performed in the sequence reverse to that of disassembly, but the following precautions must be observed. (a) Rubber parts Wipe off the surface deposit using a rag soaked with light oil.

CAUTION Be careful not to dip the rubber parts into metal cleaning fluid.

(b) Metal parts Remove the surface deposit using clean metal cleaning fluid. (2) Repair kit parts Always replace with new ones before install. (3) Master cylinder (a) Apply lithium base grease (Remax 2) to seals of O-ring and seal grooves.

(b) Apply engine oil (10 W) to the sliding surfaces of cylinder inside surface and piston.

10-34

BRAKE SYSTEM

4.5 Parking brake 4.5.1 Disassembly

The number shows disassembling sequence. 2

3 7

10 1

12 5 8

6 7

212254 1 Parking brake drum

7 Shoe and lining assembly

2 Input flange

8 Camshaft lever

3 Return spring

9 Spring

4 Brace

10 Camshaft

5 Spring

11 Support assembly

6 Adjuster assembly

12 Dust seal

4.5.2 Inspection and Repair

(1) Shoe and lining assembly (a) Check the lining and shoe for cracks or damage. (b) Replace the lining if it has been badly contaminated by

(2) Brake drum Replace, if the brake drum inner surface has uneven wear or damage.

oil or has been glazed or deteriorated from friction heat.

Brake drum Inside diameter

worn beyond the service limit.

Lining thickness

Standard value

6.7 mm (0.264 in.)

Service limit

3.5 mm (0.138 in.)

Service limit

0.2 to 0.3 mm (0.008 to 0.012 in.)

Standard value Service limit

304.8 (12

+0.5 0 +0.02 0

mm in.)

307 mm (12.09 in.)

(3) Adjuster assembly Check the adjuster wheel teeth for wear, and check whether all rotating parts turn smoothly.

10-35

BRAKE SYSTEM

4.5.3 Reassembly To reassemble, follow the disassembly sequence in reverse and observe the following. (1) Brake drum Replace, if the brake drum inner surface has uneven wear or damage. (2) Adjuster assembly Check the adjuster wheel teeth for wear, and check whether all rotating parts turn smoothly.

10-36

BRAKE SYSTEM

4.6 Brake control valve 4.6.1 Disassembly and Reassembly

The number shows disassembling sequence.

# 4 1 2

# #

3 4

# 5 #

#: Seal kit parts.

200640

1 Pedal, Split pin, Pin, Push button, Shim 2 Valve cover, Boot, Plunger 3 Main spring 4 Piston, O-ring, Return spring 5 Valve cap, Dust seal, C-ring, O-ring 6 Feed valve, Spring seat, Spring 7 Valve case

NOTE Reassemble in the reverse order of disassembly sequence.

10-37

BRAKE SYSTEM

(1) Suggestion for Disassembly and Reassembly (a) Seal kit parts Always replace with new ones before install.

(b) Rubber parts Wipe off the surface deposit using a rag soaked with alcohol or light oil.

CAUTION Be careful not to dip the rubber parts into metal cleaning fluid.

(d) Applying grease Apply grease to sliding surfaces contacting with Orings.

10-38

BRAKE SYSTEM

4.7 Replacing desiccating agent of air dryer 4.7.1 Disassembly

The number shows assembling sequence.

1 6#

10# 11# 12#

7# 2

13# 8 9

#3 #4

#: Repair kit parts.

212240

1 Purge chamber

8 Set spring

2 Cartridge

9 Filter plate

3 Oil filter

10 Oil filter

4 O-ring

11 Desiccating agent

5 Cover

12 Oil filter

6 Check valve

13 Filter plate

7 O-ring

10-39

BRAKE SYSTEM

4.7.2 Reassembly Reassembly should be performed in the sequence reverse to that of disassembly, but the following precautions must be observed. (1) Wash all metal parts soaked in volatile cleaning solvent, and remove the remaining cleaning solvent by blowing the parts with compressed air. (2) Replace the Repair Kit parts with new ones. (3) Assemble cartridge assembly with the following procedure. (a) Standard amount of desiccating agent is 480 g (17 oz). However, use the complete bag if purchased for use in repair kits.

(b) Tap the case over its circumference with plastic hammer to make the desiccating agent properly seat.

2.0 to 3.9 N•m (0.2 to 0.4 kgf•m) [1.5 to 3.0 lbf•ft]

(d) Tighten the mounting bolts of the cartridge assembly to the specified torque. Tightening torque

2.0 to 3.9 N•m (0.2 to 0.4 kgf•m) [1.5 to 3.0 lbf•ft]

(e) Tighten the mounting bolts of the purge chamber to the specified torque. Tightening torque

10-40

8.8 to 13.7 N•m (0.9 to 1.4 kgf•m) [6 to 10 lbf•ft]

BRAKE SYSTEM

5. Adjustment and Testing 5.1 Inspecting wheel brake (DP100N to DP150N) 5.1.1 Clearance check between lining and drum

(1) Remove the grommet which plugs up the inspection hole on dust cover. (2) Insert thickness gauge between the lining and drum from the inspection hole, and check the thickness, when appropriate friction is felt by inserting/withdrawing the gauge. Standard value

0.2 mm (0.008 in.)

CAUTION

210441

Check the clearance at two places on each wheel.

(3) If it does not conform to the standard value, turn the adjusting cam to adjust.

5.1.2 Replacing brake lining When the wear indicator of brake lining reaches the service limit, replace the shoes as an assembly. The shoe assembly should also be replaced in the following cases: (1) When installation of lining and brake shoe is poor. (2) When it has been badly contaminated by oil or has been glazed or otherwise set or deteriorated from friction heat,. (3) When lining has cracks or damage.

Lining wear indicator

210442

5.1.3 Adjusting lining wear indicator

(1) In order to set the lining wear indicator, turn the washer using the wrench and set the indicator to the innermost part of the lining service limit range. (2) In this case, set the adjusting cam with the shoe most retracted, and hold down with another spanner in order for the cam not to turn.

NOTE Perform adjustment of the indicator, only when the adjusting cam is disassembled.

200651

10-41

BRAKE SYSTEM

5.1.4 Inspecting brake drum

(1) Replace, if the inside diameter of brake drum 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.

Inside diameter of brake drum

Standard value

+0.2 0 mm +0.008 (16.54 0 in.)

Service limit

424 mm (16.69 in.)

420

5.2 Bleeding brake system Be sure to bleed in the following sequence, if air is included in the circuit because of the lack of brake fluid in the brake cup, or if inspection and maintenance have been performed by removing any part in the circuit. (a) Air master

(b) Left hand wheel cylinder (c) Right hand wheel cylinder

CAUTION (a) Fill the brake fluid reserve tank full before bleeding. (b) During bleeding operation, refill the brake fluid reserve tank as required and do not allow the tank to go below half full.

5.2.1 Bleeding air master Bleeding air master must be performed by two persons.

(1) Remove the air bleeder screw cap of air master, and insert one side of a vinyl tube in it. Insert the other end of the vinyl tube into the container filled with brake fluid. (2) One person depresses the brake pedal, and the other person loosens the bleeder screw to bleed air. (3) Repeat the steps until no air bubble is seen, and tighten the bleeder screw.

200652

10-42

BRAKE SYSTEM

5.2.2 Bleeding wheel cylinder

(1) Connect one end of a vinyl tube to the bleeder screw of the wheel cylinder. Insert the other end of the vinyl tube into the container filled with the brake fluid. (2) After the one in the truck pumps the brake several times and then keeps it depressed, the other at the bleeder screw must loosen the bleeder screw to allow the brake fluid to flow into the container. The bleeder screw should be tightened after brake fluid flows as a solid stream without any bubbles. (3) Repeat the above steps until no air bubble is seen in the tube, and refill the reserve tank.

200285

NOTE (a) Exercise care so that the brake fluid level in the reserve tank does not become too low during this operation. (b) Be sure to use the specified brand of brake fluid, and never mix it with other brands.

5.3 Inspection of wheel brake (DP160N) 5.3.1 Replacing brake disc When the brake warning lamp is activated and warning buzzer sounds, check in the following order.

(1) Check the gauge of brake booster for wear. (2) Check that the amount of oil in the brake oil tank has decreased.

(3) If there is enough brake oil, disassemble the front axle and replace all brake discs. At this time, also replace the O-ring of brake piston, sleeve, and floating seal together.

NOTE For the removal of brake disc, refer to the chapter of â&#x20AC;&#x153;Front Axle and Reduction Differentialâ&#x20AC;?.

Gauge

208008

10-43

BRAKE SYSTEM

5.3.2 Brake oil line bleeding

(1) In the following cases, bleed the brake oil line. (a) When part of brake oil line is disassembled. (b) When the brake pedal feels spongy. (Air may be mixed in circuit.)

WARNING Observe the following precautions strictly before bleeding operation so that the truck does not move suddenly. (a) Ensure that the parking brake is applied. (b) Block all the wheels.

(2) Bleeding

NOTE Bleeding brake oil line must be performed by two persons.

(a) Fill up brake oil in the oil tank to the specified amount. (b) Start the engine, and increase the air pressure of air tank to the specified pressure.

(d) Another operator loosens the bleeder screw of axle housing flange. Tighten the bleeder screw, before the

Bleeder screw

flow of oil stops.

(e) Release foot from the accelerator pedal. (f) Repeat above mentioned (c) to (e) until no air bubbles appear in the oil flowing out.

NOTE During operations, refill oil as required so that the oil in the brake oil tank does not run short.

(g) When bleeding operation is completed, be sure to tighten the bleeder screw.

10-44

201504

BRAKE SYSTEM

5.4 Bleeding brake pedal Adjust the cam follower of brake pedal with adjusting bolt so that the pedal of brake control valve may be touched.

CAUTION

Adjusting bolt

Never change the pedal set angle (39 Âą 1.5 deg) of the brake valve.

206105

5.5 Inspecting brake control valve 5.5.1 Air leakage check

(1) Check the air pressure of the air tank is at the specified (2) (3)

(4)

(5)

pressure. Release the brake pedal. Apply soap and water solution to the exhaust side port on the brake control valve, and check for bubbles. If it bubbles, air has leaked from the exhaust valve. Perform the same test with the brake pedal fully depressed, and inspect the air leakage of the exhaust valve. Remove the plug of exhaust side port and check the valve for damage.

200654

5.5.2 Functional check Functional check of the brake control valve must be performed by two persons. (1) Mount the connector R (PT) 3/8 to outlet port on brake control valve, and connect pressure gauge. (2) Start the engine, and increase the air pressure in tank to the normal level before stopping the engine. (3) Second person continues to depress the brake pedal, and check that the pressure gauge reading and the indicator of air pressure gauge on instrument panel comes to the equal value. (4) Furthermore, continue to depress the brake pedal, and if it seems that the indicator of pressure gauge decreases, perform the leakage check of the air system or adjustment of the air governor.

200655

10-45

BRAKE SYSTEM

5.6 Adjusting parking brake 5.6.1 Clearance adjustment between drum and lining

(1) Move the truck a small distance at a time until the

(2) (3)

(4)

(5)

adjusting hole in the drum is approximately 30 mm (1.2 in.) right of the bottom point. Release the parking brake lever. Remove the grommet from the adjusting hole. Turn the adjuster assembly up all the way until the lining-todrum clearance is removed. From this position, turn the adjuster assembly back (down) about eight notches to obtain the correct liningto-drum clearance. To measure the lining-to-drum clearance, remove the grommet from the dust cover and insert a thickness gauge.

Turn adjuster to spreead shoes.

200658

200657

5.7 Inspection of brake oil tank (DP160N) 5.7.1 Inspecting liquid level sensor

(1) Check that the connector at the lower part of oil tank is connected.

NOTE There is another method of taking out the oil in accordance with â&#x20AC;&#x153;Bleeding brake oil lineâ&#x20AC;?.

High level Low level Alarm level 52 mm

brake oil with syringe or hand pump. With the brake oil, the float also falls gradually.

Float

(2.05 in.) 83 mm (3.27 in.) 103.5 mm (4.07 in.)

(2) Turn the starter switch to [ON] position. (3) Remove the cap and diaphragm, and gradually take out

(4) Check that the float turns on the brake oil quantity warning lamp when the oil level of brake oil falls down to approximately 52 mm (2.05 in.) height.

NOTE The brake oil quantity warning lamp is common to the brake disc wear warning lamp.

10-46

201507

BRAKE SYSTEM

6. Troubleshooting 6.1 Wheel brake (DP100N to DP150N) • Air line leaks

• Repair or replace.

• Air tank pressure too low

• Increase air tank pressure.

• Fluid line leaks, or fluid level too low in • Repair and add fluid. reserver Will not apply

• Air trapped in hydraulic line

• Bleed air out of air master or wheel cylinder

• Clearance between drum and linings out of • Readjust. adjustment • Air master or wheel cylinder piston cup worn, • Replace. Change fluid with recommended type resulting in fluid leaks

Brakes chatter

if caps are distorted.

• Linings worn to expose rivet heads

• Replace.

• Lining surface glazed

• Replace.

• Brake drum unevenly worn or loose

• Replace or retighten.

• Lining not seated on shoes

• Replace.

• Tires not uniformly inflated

• Inflate correctly.

• Clearance between drum and linings out of • Readjustment. adjustment Truck pulls to one side

• Mismatched linings

• Repair or replace.

• Linings or drum soaked with oil

• Replace, avoid over-lubrication.

• Linings not equal in size and material

• Replace.

• Shoes loosen 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.

• Brake control valve leaks air into line leading to • Readjust. Air brakes drag

air master, causing air master to operate • Brake pedal not returning properly

• Lubricate or repair arm shaft. Replace return spring if necessary.

• Clearance between drum and lining too small in • Readjust. one brake • Return spring wear or broken One brake drags

• Replace.

• Anchor pin seized, resulting in failure of shoe to • Replace. return • Wheel cylinder piston and piston cups defective • Replace. • Brake pipe restricted at joint, resulting in a fail- • Clean. ure of fluid to return properly

Will not release

• Piston cups swollen

• Replace.

• Push rods distorted

• Replace.

• Power piston packings lack lubrication

• Relubricate.

10-47

BRAKE SYSTEM

• Hydraulic piston cups defective Brake pedal kicks back

• Replace.

• Hydraulic piston check valve ball not seating • Replace piston assembly. tight

6.2 Wheel brake (DP160N) • Hydraulic line leaks, or oil level too low in res- • Repair and add Oil. ervoir Will not apply

Truck pulls to one side

Poor return of brake

Brake squeals

• Air trapped in hydraulic line

• Bleeding brake oil line

• Wear of brake piston seal

• Replace.

• Wear of friction plate, or damage to facing

• Replace.

• Wear of end plate and matching plate

• Replace.

• Tires not uniformly inflated

• Inflate correctly.

• Wear of friction plate, or damage to facing

• Replace.

• Wear of end plate and mating plate

• Replace.

• Deterioration of piston return spring

• Replace.

• Bend of spring guide

• Replace.

• Inappropriate lubrication oil is used

• Replace with specified lubrication oil

• Friction plate contact with end plate and mating • Perform brake break-in plate is poor

Poor return of brake

10-48

• Harness open-circuited

• Repair.

• Faulty sensor

• Replace.

BRAKE SYSTEM

6.3 Parking brake Brake lever stroke too small Noise

Will not apply

• Clearance between drum and linings too small

• Readjust.

• Clearance between drum and linings to small

• Readjust.

• Brake drum distorted

• Replace.

• Linings worn

• Replace.

• Clearance between drum and linings to small

• Replace.

• Brake lever lacks operating effort

• Readjusting to 245 to 249 N (25 to 30 kgf) [55 to 66 lbf].

6.4 Air drier Brake lever stroke too small

• Taking long time complete dehydration of satu- • Drain daily at end of operation until air line is rated air when air drier is equipped

completely dehydrated.

• Air consumption excessive and air compressor • Operate truck to allow compressor on load and Noise

not operating on load and unload cycles • Desiccant not changed periodically

unload cycles, or check drier installation. • Change desiccant kit periodically.

10-49

BRAKE SYSTEM

7. Service Data 7.1 Brake pedal Truck model

DP100N to DP160N

Height 1 (from floor to pedal top)

Standard value

190 mm (7.48 in.)

Free play 2

Standard value

15 mm (0.59 in.)

210444

7.2 Brake control valve Truck model

DP100N to DP160N Standard value

39±1.5˚

Standard value

4±1.5˚

Normal braking 3

Standard value

12±1.0˚

Emergency braking 4

Standard value

6±1.0˚

Pedal set angle 1 Free play 2

200629A

10-50

BRAKE SYSTEM

7.3 Air master (DP100N to DP150N) Truck model

DP100N to DP150N

Power piston return spring 1 (test force/length under test force)

Standard value

196±20 N (20±2 kgf) [44±4 lbf] /179 mm (7.05 in.)

Service limit

157 N (16 kgf) [35 lbf]/179 mm (7.05 in.)

Bend of push rod 2

Standard value

0.05 mm (0.002 in.), Maximum

Clearance between power piston and cylinder shell 3

Standard value

0.5 to 1.4 mm (0.020 to 0.055 in.)

Standard value

0.07 to 0.15 mm (0.003 to 0.006 in.)

Service limit

0.2 mm (0.008 in.)

Tightening torque for hydraulic cylinder lock nut 5

Standard value

98 to 147 N•m (10 to 15 kgf•m) [72 to 108 lbf•ft]

Tightening torque for power piston end nut 6

Standard value

20 to 29 N•m (2 to 3 kgf•m) [14 to 22 lbf•ft]

Clearance between hydraulic piston and cylinder tube 4

210182

10-51

BRAKE SYSTEM

7.4 Brake booster (DP160N) Truck model

DP160N Standard value

931 N (94.5 kgf) [209 lbf] /166 mm (6.54 in.)

Service limit

510 N (52 kgf) [114.7 lbf] /166 mm (6.54 in.)

Stroke of push rod 2

Standard value

77 mm (3 in.)

Clearance between hydraulic piston and cylinder tube 3

Standard value

0.06 to 0.18 mm (0.002 to 0.007 in.)

Tightening torque for load chamber mounting nut 4

Standard value

176 to 196 N•m (18 to 20 kgf•m) [129 to 144 lbf•ft]

Power piston return spring 1 (test force/length under test force)

4 2

212255

10-52

BRAKE SYSTEM

7.5 Wheel brake (DP100N to DP150N) Truck model

DP100N to DP150N Standard value

Inside diameter of brake drum 1

Thickness of lining 2 Clearance between drum and lining 3

420

+0.2 0

mm (16.54

+0.008 0

Service limit

424 mm (16.69 in.)

Standard value

16 mm (0.63 in.)

Service limit

10 mm (0.39 in.)

Standard value

0.2 mm (0.01 in.)

in.)

Free length

Standard value

203.5 mm (8.01 in.)

Test force

Standard value

423 N (43.1 kgf) [95 lbf]

Length under test force

Standard value

251 mm (9.88 in.)

Tightening torque for anchor bracket bolts (M14) 5

Standard value

156±16 N•m (15.9±1.6 kgf•m) [115±12 lbf•ft]

Tightening torque for anchor bracket bolts (M16) 6

Standard value

233±24 N•m (23.8±2.4 kgf•m) [172±17 lbf•ft]

Tightening torque for lock plate bolts 7

Standard value

17.5 to 23.5 N•m (1.6 to 2.4 kgf•m) [12 to 17 lbf•ft]

Return spring 4

1 2

210446

10-53

BRAKE SYSTEM

7.6 Wheel cylinder (DP100N to DP150N) Truck model Inside diameter of cylinder body 1

DP100N to DP150N Standard value

55.56 mm (2.19 in.)

Standard value

0.13 to 0.24 mm (0.005 to 0.009 in.)

Service limit

0.3 mm (0.012 in.)

Standard value

56.2 mm (2.21 in.)

Service limit

(To be replaced every year)

Tightening torque for cylinder mounting bolts

Standard value

45 to 69 N•m (4.6 to 7.0 kgf•m) [33 to 51 lbf•ft]

Tightening torque for bleeder screw

Standard value

22±3 N•m (2.25±0.35 kgf•m) [16±3 lbf•ft]

Clearance between piston and cylinder body Diameter of piston cup (lip side) 2

210445 7.7 Parking brake lever Truck model

DP100N to DP160N

Locked position of lever A

Standard value

63˚ to 66˚

Lever operating effort F

Standard value

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

F A

212242

10-54

BRAKE SYSTEM

7.8 Parking brake drum Truck model

DP100N to DP160N Standard value

Inside diameter of brake drum 1

304.8

+0.5 0

mm (12.0

+0.020 0

in.)

Service limit

307 mm (12.09 in.)

Standard value

6.7 mm (0.26 in.)

Service limit

3.5 mm (0.14 in.)

Standard value

0.25 mm (0.01 in.)

Free length

Standard value

77±0.75 mm (3.03±0.03 in.)

Test force

Standard value

223±23 N (22.7±2.3 kgf) [50±5 lbf]

Length under test force

Standard value

83 mm (3.27 in.)

Tightening torque for support plate nut 5

Standard value

145±22 N•m (14.8±2.2 kgf•m) [107±16 lbf•ft]

Tightening torque for brake drum nut 6

Standard value

96±15 N•m (9.8±1.5 kgf•m) [71±11 lbf•ft]

Thickness of brake lining 2 Clearance between drum and lining 3

Return spring 4

210447

10-55

STEERING SYSTEM 1. Specifications ............................................................................................................. 11-2 2. Structure..................................................................................................................... 11-3 2.1 Steering System.................................................................................................................................. 11-3 2.2 Steering valve ..................................................................................................................................... 11-4 2.3 Steering column .................................................................................................................................. 11-5

3. Procedure and Suggestions for Removal and Installation ......................................... 11-6 3.1 Removal and Installation of Steering Valve Piping ............................................................................. 11-6 3.2 Removal and Installation of Steering Wheel, Steering Valve and Tilt Lock Lever .............................. 11-7 3.2.1 Steering wheel .......................................................................................................................................... 11-8 3.2.2 Steering valve ........................................................................................................................................... 11-9 3.2.3 Tilt lock lever ........................................................................................................................................... 11-10

4. Troubleshooting ....................................................................................................... 11-11 5. Service Data............................................................................................................. 11-12

11-1

STEERING SYSTEM

1. Specifications Truck model

DP100N - DP160N

Steering type

Full-hydraulic power steering 3

Steering control valve

Displacement volume in cm /rev (cu in./rev)

369 (22.5)

Rated flow rate in l/min (qt/min)

45.4 (48)

Maximum pressure in MPa (PSI)

17.2 (2495)

Steering wheel outside diameter in mm (in.)

11-2

320 (12.6)

STEERING SYSTEM

2. Structure 2.1 Steering System

4 9 1

1 Hydraulic tank

6 Control valves for operation devices

2 Return filter

7 Check valve

3 Suction strainer

8 Steering valve

4 Gear pump (oil pump)

9 Power cylinder

212023

5 Priority valve

This truck has employed a full-hydraulic steering system that consists of steering valve, priority valve, power cylinder, and so on. Also with the load sensing mechanism the operator is provided with steering operations which are comfortable and hardly affected by the load conditions. The turning of the steering wheel is changed to a hydraulic pressure in the steering valve, then transformed to the steering force in the power cylinder on the rear axle. Hydraulic oil

discharged from the oil pump is supplied to the steering valve. Flow rate required for the steering operation is determined at the priority valve. If the steering system does not require a large quantity of hydraulic oil, the rest of the hydraulic oil will be supplied to other operation device lines. Except on the steering operation, most of the hydraulic oil can be used for other operation devices.

11-3

STEERING SYSTEM

2.2 Steering valve

LS (Load sensing) R (RIGHT) L (LEFT)

R P

L T

T T (OUT)

P (IN)

Hydraulic circuit

212027

The steering valve was designed with a load sensing circuit. This load sensing circuit functions as to balance between the downstream oil pressure of variable orifice in the steering valve and the counter-side oil pressure of the spool in the priority valve. This offers a smooth steering operation that is not affected by the variation in load conditions.

Steering cylinder

Input

Steering relief

Load sensing steering valve OF

High pressure EF

Filter Main relief

Priority valve

Filter Pump

Engine

Tank

212028

11-4

STEERING SYSTEM

2.3 Steering column

Column position when steering column is tilted fully forward Column position when lock is released

Column neutral tilt position (inclination of 30 degrees to vertical line)

Column position when steering column is tilted fully rearward

Combination switch mounting plate Steering column mounting plate A 1

Tilt angle setting plate B 2 Fix

Bolt

Loosen Nut

Lock release 4

When the tilt lever 3 is turned counterclockwise,the plates A and B are fixed between the bolt and nut.

212022 1 Steering column

4 Column lock lever

2 Bracket (fixed to truck body)

5 Locking pin

3 Tilt lock lever

The tilting angle of steering column is adjustable for the ranges of 5Â° forward and 7Â° rearward, respectively as shown in the figure. This adjustment can be achieved by turning the tilt lock lever clockwise to loosen it after locking the column lock lever. Then, tilt the steering column to an optimal angle and turn the tilt lock lever counterclockwise (i.e. pull it up) to

lock it. This column lock lever is useful for such cases where the entire column unit must be tilted forward (i.e. to the front) for ease of getting on and off or servicing. As shown in the figure, if you push the lock lever to the left, the lock lever can be disengaged from the lock pin, and the steering column can tilt to the front.

11-5

STEERING SYSTEM

3. Procedure and Suggestions for Removal and Installation 3.1 Removal and Installation of Steering Valve Piping Major components 1 Hose (from priority valve to steering valve P port) 2 Hose (from steering valve T port to control valve T2 port) 3 Hose (from steering valve L port to power cylinder L port)

4 Hose (from steering valve R port to power cylinder R port) 5 Hose (from load sensing LS port to priority valve LS port)

6 Steering valve

2 1

7 Priority valve

5 4 3

212029

Suggestions for disassembly and reassembly (1) The important point in servicing the hydraulic system is to proceed your operation in a clean environment and never allow any abrasive matters to enter inside the system. (2) On reassembly be sure to place a new replacement Oring in any section that has installed an O-ring before disassembly. (3) Hoses of the steering system (especially, in the highpressure section) are safety parts. These must be replaced with new ones disregarding with or without damage after they have been used for a specified period of time. For the replacement intervals, refer to the Operation & Maintenance Manual. (4) When any hose is removed or replaced, use double spanners (wrenches) as required for not applying an excessive force to the mating fitting.

11-6

Tightening torque of nut 44 to 54 N m

Check valve

212030

STEERING SYSTEM

3.2 Removal and Installation of Steering Wheel, Steering Valve and Tilt Lock Lever

Tightening torque : 18 to 22 N m

7 Tightening torque : 27 to 35 N m

5 Tightening torque : 29.4 N m

212024 1 Steering wheel

5 Steering valve mounting bolt

2 Nut

6 Steering valve

3 Spring washer

7 Steering column assembly mounting bolt

4 Cover

8 Steering column assembly

11-7

STEERING SYSTEM

3.2.1 Steering wheel Removal (1) Remove the horn button. (2) Remove steering wheel nut 2, then remove steering wheel 1 using a wheel puller (special tool).

M12 bolt M8 bolt

91268 - 10600 Wheel puller

Special tool Wheel puller

91268-10600 Steering wheel

CAUTION 209708

When removing the steering wheel, do not tap the Wheel puller setting

top end of the steering shaft.

Installation Follow the procedure shown below: (1) Turn the protrusion (a) of handling sensor on the combination switch by hand to the shown direction in the figure. (2) Apply a thin coat of grease on the horn contact sliding surface at the lower end of the steering wheel boss. (3) Assemble the steering wheel as it corresponds to straight ahead position. (The protrusion on the combination switch must fit with the concave provided on the steering wheel.) Turn this for several times clockwise and counterclockwise until it fits in completely. (4) Before tightening the steering wheel nut, make sure that the auto-return function of the combination switch normally operates. (5) If the auto-return function does not work satisfactorily, repeat the above steps (3) and (4). (6) Tighten the steering wheel nut to the specified torque.

Horn switch contact Front

(a) Protrusions form an isosceles triangle. Front Combination switch

Forward

209709

11-8

STEERING SYSTEM

Inspection after installation Inspection of the operation effort of steering wheel (1) Apply the parking brake. (2) Start the engine and wait until the hydraulic oil temperature rises to 40 to 60˚C (104 to 140˚F). (3) Run the engine at an idling speed, and hook a spring scale on either the outermost circumference of the steering wheel or spoke to measure steering effort when the steering wheel is turned to the right or left from the straight ahead position. The steering effort must be lower than the following value. Steering effort (at the outer circumference of steering wheel)

13 N (1.3 kgf) [2.87 lbf]

209710

3.2.2 Steering valve Removal (1) Remove the cover around the steering column. (2) Disconnect all five hoses from the steering valve. (3) Remove the steering valve mounting bolt and then, remove the steering valve. Installation Replacement must follow the reverse order of removal. (1) Apply grease on the serration provided at the lower part of the steering shaft. (2) Tighten the steering valve mounting bolt to the specified torque. (3) Tighten the hose nut to the specified torque. (4) After reassembly, be sure to perform air bleeding. • Lift the rear wheels from the ground using a support such

Tightening torque of bolt 29.4 N m

Check valve

212031

as a jack stand positioned under the truck body. • Start the engine and operate the acceleration pedal to vary the engine speed while turning the steering wheel fully to the right and left. This bleeds air from the relief valve.

11-9

STEERING SYSTEM

3.2.3 Tilt lock lever Top face of lever

Disassembly (1) Put an alignment mark on the tilt lock lever and nut (B) to ensure proper reassembly. (2) Remove bolt A, then remove the tilt lock lever. Reassembly When the alignment marks have faded out or the lever is to be replaced with new one, install it according to the following procedure. (The illustration on the right shows the relative positions of the consisting parts between tilt and neutral under the condition of the column lock lever being locked.) (1) Tighten nut B to the tightening toque of 11 to 15 N•m (1.1 to 1.5 kgf•m) [8.1 to 11.1 lbf•ft]. (This corresponds to the condition when the lever is locked.) (2) Select a position for the tilt lock lever to have the optimal position when it is locked, and engage the tilt lock lever in the serration of nut B. The optimal position corresponds to such a range where the cut ( part) of the fitting intersects the lever’s upper contour. (3) Tighten bolt A. (4) Release the tilt lock lever, and make sure that the bracket can slide over the entire tilting range without interfering with other parts.

11-10

★

Tilt lock lever

Lever mounting bolt

Nut B

Tilt lock lever Bolt A 209712

STEERING SYSTEM

4. Troubleshooting Insufficient service oil flow rate

Defect in flow priority valve

• Clean.

• Spool spring damaged

• Replace.

Defect in relief valve

• Unsatisfactory adjustment

• Readjust.

• Valve seat damaged

• Replace relief valve assembly.

• Spring damaged

• Adjust after replacement.

• Oil leak from relief valve due to damaged O-ring

• Replace.

• Clog at the measuring section

• Clean.

• Unsmooth movement of spool

• Clean.

• Bearing damaged

• Replace.

Defect in power cylinder

• Piston rod deformed

• Repair or replace.

• Piston seal damaged

• Replace.

Others

• Pipe or tube is flattened or the flow is obstructed

• Repair or replace.

Defect in steering valve

• Spool or sleeve stacks

• Repair or replace.

• Centering spring damaged

• Replace.

• Pipe or tube is flattened or the flow is obstructed

• Repair or replace.

• Power cylinder piston seal damaged

• Replace.

• Air trapped in hydraulic oil.

• Air-bleed.

• Power cylinder installation is loose

• Repair or replace.

Shift steering wheel operation Defect in steering valve

Abnormal vibration of steering wheel

• Spool orifice damaged

Others

Abnormal sound from steering system

11-11

STEERING SYSTEM

5. Service Data Truck model

DP100N - DP160N

Steering effort (at the outer circumference of steering wheel) (The standard value corresponds to a case where the engine is at low idle, steering wheel turning speed is 1 turn/second in stationary steering.)

Standard value

1.96 N•m (0.2 kgf•m) [1.45 lbf•ft]

Play in the steering wheel

Standard value

70 mm (2.75 in.)

Inside

Standard value

74˚

Outside

Standard value

48˚25′

Steering wheel mounting nut tightening toque

Standard value

18 to 22 N•m

Steering wheel bracket mounting nut tightening toque

Standard value

27 to 35 N •m

Discharge capacity

Standard value

369 cc (22.5 cu in.)

Rated flow rate

Standard value

45.4 cc (2777 cu in.)

Maximum pressure

Standard value

17.2 MPa (175 kgf•cm2) [2490 psi]

Tightening torque of mounting bolt

Standard value

29.4 N•m (3.0 kgf•m) [21.7 lbf•f]

Steering angle

Steering valve

11-12

HYDRAULIC SYSTEM 1. Specifications ............................................................................................................. 12-3 2. Structure..................................................................................................................... 12-4 2.1 Hydraulic line ...................................................................................................................................... 12-4 2.2 Hydraulic tank ..................................................................................................................................... 12-6 2.3 Priority valve ....................................................................................................................................... 12-7 2.4 Control Valve ...................................................................................................................................... 12-8 2.5 Lift and tilt cylinder .............................................................................................................................. 12-9

1 2

2.6 Flow regulator valve.......................................................................................................................... 12-10

3. Suggestions for Removal and Installation................................................................ 12-11

3.1 Control Valve .................................................................................................................................... 12-11 3.1.1 Removal .................................................................................................................................................. 12-11 3.1.2 Removal sequence ................................................................................................................................. 12-11

3.1.3 Preparation.............................................................................................................................................. 12-11 3.1.4 Suggestions for Removal ........................................................................................................................ 12-12

3.2 Lift cylinder........................................................................................................................................ 12-13 3.2.1 Removal .................................................................................................................................................. 12-13 3.2.2 Removal sequence ................................................................................................................................. 12-13 3.2.3 Suggestions for Removal ........................................................................................................................ 12-13 3.2.4 Installation ............................................................................................................................................... 12-15

6 7 8

3.3 Tilt cylinder........................................................................................................................................ 12-16 3.3.1 Removal .................................................................................................................................................. 12-16 3.3.2 Removal sequence ................................................................................................................................. 12-16 3.3.3 Preparation.............................................................................................................................................. 12-16

3.3.4 Suggestions for Removal ........................................................................................................................ 12-17

4. Priority valve............................................................................................................. 12-19

4.1 Disassembly and Reassembly.......................................................................................................... 12-19 4.1.1 Disassembly sequence ........................................................................................................................... 12-19 4.1.2 Suggestion for disassembly .................................................................................................................... 12-19

4.1.3 Suggestion for reassembly...................................................................................................................... 12-19

13 5. Flow regulator valve ................................................................................................. 12-20 5.1 Disassembly...................................................................................................................................... 12-20 5.1.1 Disassembly sequence ........................................................................................................................... 12-20

5.2 Inspection and Repair ....................................................................................................................... 12-20 5.3 Reassembly ...................................................................................................................................... 12-20

12-1

14 15

HYDRAULIC SYSTEM

6. Lift cylinder ............................................................................................................... 12-21 6.1 Disassembly...................................................................................................................................... 12-21 6.1.1 Disassembly sequence ........................................................................................................................... 12-21 6.1.2 Suggestion for disassembly .................................................................................................................... 12-21

6.2 Inspection and Repair ....................................................................................................................... 12-22 6.3 Reassembly ...................................................................................................................................... 12-24 6.3.1 Reassembly sequence............................................................................................................................ 12-24 6.3.2 Suggestion for reassembly...................................................................................................................... 12-24

7. Tilt cylinder ............................................................................................................... 12-25 7.1 Disassembly...................................................................................................................................... 12-25 7.1.1 Disassembly sequence ........................................................................................................................... 12-25 7.1.2 Suggestion for disassembly .................................................................................................................... 12-26

7.2 Inspection and Repair ....................................................................................................................... 12-27 7.3 Reassembly ...................................................................................................................................... 12-28 7.3.1 Reassembly sequence............................................................................................................................ 12-28 7.3.2 Suggestion for reassembly...................................................................................................................... 12-28

8. Inspection and Adjustment....................................................................................... 12-30 8.1 Hydraulic oil ...................................................................................................................................... 12-30 8.2 Test operation of gear pump............................................................................................................. 12-30 8.3 Control Valve .................................................................................................................................... 12-31 8.4 Adjusting main relief valve ................................................................................................................ 12-31 8.5 Functional inspection of priority relief valve ...................................................................................... 12-32

9. Tests ........................................................................................................................ 12-33 10.Troubleshooting....................................................................................................... 12-34 11.Service Data ............................................................................................................ 12-38

12-2

HYDRAULIC SYSTEM

1. Specifications Truck model

DP100N

DP120N

DP135N

Type Gear pump

Hydraulic system

Priority valve

KFP51100CSMSL 205 L/min (54.2 U.S. gal.) (at 2200 rpm)

Drive method

Directly coupled to torque converter

Maker model

VLH71C160B

Relief pressure

15.7 MPa (160 kgf/cm2) [2277.3 psi]

Maker model Control Valve Flow regulator valve Lift cylinder

Relief pressure

Inside diameter Stroke

Tilt cylinder

MW(P) 25 +0.5 20.6 0

MPa (210.1 kgf/cm2) [2988.1 psi]

Type Control flow rate

Cylindrical valve type 120 L/min (31.7 U.S. gal.)

150 L/min (39.6 U.S. gal.) Ď&#x2020;115 mm (4.5 in.)

105 mm (4.13 in.)

120 mm (4.7 in.)

1500 mm (59.1 in.)

Inside diameter

120 mm (4.7 in.)

Stroke

270 mm (10.6 in.)

Service oil quantity (tank level)

DP160N

Gear type

Maker model Control flow rate

DP150N

N level: 140 L (37.0 U.S. gal.)

N level: 168 L (44.4 U.S. gal.)

N level: 184 L (48.6 U.S. gal.)

12-3

HYDRAULIC SYSTEM

2. Structure 2.1 Hydraulic line

10,9

11 15 11

8 5

7 13 12

1 Hydraulic tank

9 Flow regulator valve

2 Return filter

10 Lift cylinder

3 Suction strainer

11 Tilt cylinder

4 Gear pump (oil pump)

12 Check valve

5 Priority valve

13 Steering valve

6 Control valves for work machines

14 Power cylinder

7 Lift valve

15 Lift return valve

8 Tilt valve

12-4

211967

HYDRAULIC SYSTEM

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 the control valve to the hydraulic cylinders.

NOTE The steering control valve is described in “11 STEERING SYSTEM”. Also for power cylinder, refer to “9 REAR AXLE”.

12-5

HYDRAULIC SYSTEM

2.2 Hydraulic tank

2 211968

1 Breather

3 Suction strainer

2 Drain plug

4 Return filter

The hydraulic tank is an integral structure with the frame and is provided with a strainer at the oil supply port, suction strainer, and return filter to keep the oil clean. Oil in the hydraulic tank will be drawn into the gear pump through the suction strainer (105 Îź ).The return oil from the lift cylinder will merge the return oil from the control valve and steering control valve and return to the hydraulic tank through the return filter (25 Îź ).

12-6

HYDRAULIC SYSTEM

2.3 Priority valve

3 1 4 EF

205648

1 Relief Valve

P: Pump port

2 Plug

T: Tank port

3 Housing

CF: Control flow port

4 Control spring

EF: Main flow port (control valve for service equipment)

5 Spool

LS: Load sensing port

6 Plug

Of the service oil discharged from the gear pump, only the amount required for steering operation will be supplied by the priority valve to the steering control valve, the remaining oil will be forwarded to circuits of other service equipment.

When the steering is in neutral position, almost all of the service oil will be used for operating all the other service equipment. Priority relief pressure

11.8 MPa (120.3 kgf/cm2) [2988.1 psi]

12-7

HYDRAULIC SYSTEM

2.4 Control Valve

T 3 A2

1 Inlet valve

P: From priority valve

2 Block

T: To tank

3 Main relief valve adjustment screw

A1: To lift cylinder

4 Tie bolt

A2: To tilt cylinder B2: From tilt cylinder

The control valve is an assembly of more than one valve block which are mounted together by three tie bolts. Each block has a pump port and tank port, and is mounted with a cartridge-type pilot-operate relief valve.

12-8

211932

HYDRAULIC SYSTEM

2.5 Lift and tilt cylinder

Bottom-side port

Flow regulator valve Rod-side port Lift cylinder

210468

The lift cylinder is a single working type of which the pressurized oil reacts only in one direction for pressing the piston. The bottom-side port has a flow regulator valve built in, and oil return pipe at the rod side port.

Collar

Socket

Tilt cylinder 211969

The tilt cylinder is a dual working type and has the rod end threaded for adjusting the balance between the right and left when the mast is mounted. The tilt angle setting can be modified through an optional adjustment of collar and socket.

12-9

HYDRAULIC SYSTEM

2.6 Flow regulator valve

To lift cylinder

From lift cylinder

From control valve

To control valve To other flow regulator valve

210470

The flow regulator valve will pass the entire amount of service oil fed from the pump as-is while the lift cylinder is raising the mast, but controls the flow rate passing through it by automatically closing down the orifice when the lift cylinder is lowering the mast. As the result, the descending speed of mast can be maintained constant irrespectively of whether the load is light or heavy. In addition, since the right and left flow regulator valves are linked together, the lowering speed of mast by both cylinders can be even.

12-10

210471

HYDRAULIC SYSTEM

3. Suggestions for Removal and Installation 3.1 Control Valve 3.1.1 Removal 4

8 9

1 10 10

7 2

3 211970

3.1.2 Removal sequence 1 Pipe

6 Pipe, O-ring, Bolt, Washer

2 Flow regulator valve, Pipe, O-ring, Bracket, Bolt, Wash- 7 Pipe, O-ring, Bolt, Washer er, Collar, 3 Hose, Clamp, Pipe

8 Pipe, O-ring

4 Hose

9 Pipe, O-ring

5 Hose

10 Connector

3.1.3 Preparation

(1) Remove the floor plate. (2) Before disconnecting each pipe, put the mast in neutral position and lower the fork to the bottom in order to purge the residual pressure in the pipe.

NOTE Before disconnecting each pipe, prepare oil receivers to catch oils remaining in the pipes and hoses. Further, take appropriate measures for the connections of pipes and control valves to prevent dust and dirt from entering in the openings.

12-11

HYDRAULIC SYSTEM

3.1.4 Suggestions for Removal Removing control valve When removing the control valve, support it by lifting it with a rope, etc. beforehand. Type

12-12

Weight

3-valve

45 kg (99.2 lb)

4-valve

55 kg (121.3 lb)

5-valve

65 kg (143.3 lb)

HYDRAULIC SYSTEM

3.2 Lift cylinder 3.2.1 Removal

Connector

1 2 8

211971 3.2.2 Removal sequence 1 Lift bracket

5 Stopper bolt

2 Return hose, Hose clamp

6 Cylinder clamp, Cushion, Collar, Shim

3 High-pressure hose

7 Stopper bolt

4 Constant descending hose

8 Lift cylinder

3.2.3 Suggestions for Removal

(1) Removing return hose Start the engine and raise the mast to the top, then stop the engine. Disconnect the return hose on the right and left lift cylinders at their connectors. (2) Lower the lift bracket.

Push the lift lever of the control valve forward slowly to lower the mast.

NOTE During this operation never touch the lift lever of the control valve. Push the lift lever of the control valve forward slowly to lower the mast.

12-13

HYDRAULIC SYSTEM

(3) Removing high-pressure hose and constant descending hose Remove the hose from the joint at the bottom of the lift cylinder. Prepare containers to catch oil, which should remain in the high-pressure hose.

(4) Removing stopper bolt (a) Remove the stopper bolt at the upper section of the lift cylinder, and lift the inner mast up to separate the cylinder rod end from the mast. Before lifting up the inner mast, wrap the inner mast channel with a protective cloth and attach a wire rope around the inner mast in such a way that includes an extra turn.

NOTE The rod end section of the lift cylinder has some shims inserted, record the number of shims inserted in each cylinder, right or left, before removal.

(b) Place wooden blocks with enough strength to support

210475

the weight of the inner mast under the mast, then remove the wire rope.

(5) Removing lift cylinder Hoist the lift cylinder from the rear of the mast with a rope to carefully remove it. Attach a wire rope on the lift cylinder before removing the cylinder clamp.

210476

3.2.4 Installation

(2) After making sure the operation is normal, inspect the

Follow the removal procedure in reverse while noting the following instructions. (1) Bleed air by repeating full upstroke and downstroke under no load, and make sure the operation is normal.

service oil level with an oil level gauge (Refer to the paragraph of â&#x20AC;&#x153;Service oil quantity and raised height of mastâ&#x20AC;?). (3) Check whether the raised height of mast is at the normal value.

12-14

HYDRAULIC SYSTEM

(4) When either the lift cylinder or piston rod has been replaced, always inspect the balance or racking (for the inspection and adjustment method, refer to â&#x20AC;&#x153;13 Mast and Forkâ&#x20AC;?).

12-15

HYDRAULIC SYSTEM

3.3 Tilt cylinder 3.3.1 Removal

211972 3.3.2 Removal sequence 1 Tilt socket pin, Collar, Washer, Spring washer, Bolt

4 Tilt cylinder pin, Collar, Washer, Spring washer, Bolt

2 Bearing, Snap ring, Spacer

5 Tilt cylinder

3 Hose

3.3.3 Preparation

(1) Block the front wheels. (2) Fully tilt the mast forward and slowly lower the lift bracket. When the fork tips reach the ground, stop the engine. (3) Open the overhead cover.

12-16

HYDRAULIC SYSTEM

3.3.4 Suggestions for Removal Remove the tilt cylinder in the following order. (1) Removing tilt socket pin (a) Lift and support the right and left cylinders at position A shown in the figure. (Use two pieces of wire rope.)

(b) Remove the socket pin mounting bolt, washer, and collar.

Tilt cylinder pin

(2) Retract the tilt cylinder rod. Start the engine and retract the cylinder rod to minimum while lowering the crane. Then, stop the engine. (3) Lower the right and left cylinder to the ground one at a time, and unhook the wire rope from the crane.

Protective cloth

(4) Disconnecting hose (a) Disconnect hose 2 from the connector of the cylinder. (b) At this time, cap the connector end at the socket side of

210479

Cap

the tilt cylinder. Cap (G1/2)

05530 - 40400

NOTE This cap serves as to confine the oil to within the cylinder and prevent the cylinder rod from extending. Before lifting the tilt cylinders, be sure to attach both the right and left caps.

Entrapped oil 211973

12-17

HYDRAULIC SYSTEM

(5) (a) (b) (c)

Removing tilt cylinder Lift the tilt cylinder to be removed by a crane. Remove the tilt cylinder pin mounting bolt. Screw in the jack bolt (M10 Ă&#x2014; 1.25) at section A shown

in the figure to remove the tilt cylinder pin.

(d) Pull out the seat frame in the forward direction while lifting the tilt cylinder by the crane.

211978

12-18

HYDRAULIC SYSTEM

4. Priority valve 4.1 Disassembly and Reassembly

2 205657

4.1.1 Disassembly sequence 1 Spool, Plug, O-ring, Spring

3 Relief valve, O-ring

2 Plug, O-ring

4 Housing

4.1.2 Suggestion for disassembly Do not disassemble relief valve 3 further than that shown in the figure. 4.1.3 Suggestion for reassembly Tightening torque of plugs 1 and 2

44.1 N•m (4.50 kgf•m) [32.55 lbf•ft]

Tightening torque of relief valve 3

20.6 N•m (2.10 kgf•m) [15.20 lbf•ft]

12-19

HYDRAULIC SYSTEM

5. Flow regulator valve 5.1 Disassembly

4 2

5 210492

5.1.1 Disassembly sequence 1 Plug, Ring, O-ring

4 Valve, Spring pin

2 Snap ring

5 Spring, Washer, Shim

3 Piston

6 Sleeve

5.2 Inspection and Repair (1) Check the spring for deterioration. (2) Check each contact surface and sliding surface of the check valve seat for damage. (3) Check each sliding surface of support and sleeve for damage.

NOTE When any of the parts are damaged, replace the whole assembly.

5.3 Reassembly Reassembly should be followed in the reverse order of disassembly.

12-20

HYDRAULIC SYSTEM

6. Lift cylinder 6.1 Disassembly

∗ ∗ 1

∗ ∗

∗

∗ ∗ Seal kit parts

210493

6.1.1 Disassembly sequence 1 Rod cover, Dash seal, Rod packing, O-ring, Bushing

3 Wear ring, Backup ring, Packing

2 Piston rod, Collar

4 Cylinder tube

6.1.2 Suggestion for disassembly Removing piston rod

(1) Wrap the lift cylinder with a piece of waste cloth, and hold it in a vise. Remove the cylinder head and rod cover with Hook Wrench A. Special tool Truck model Hook wrench A

DP100N, DP120N

DP135N, DP150N, DP160N

05312 - 11000

05312 - 11200

(2) When pulling out the piston rod from the cylinder, be careful not to damage the wear ring.

602303

12-21

HYDRAULIC SYSTEM

6.2 Inspection and Repair Cylinder tube

(1) Check the inside surface of the cylinder for wear, damage, or rust. (2) Check the welds for cracks, damage, and dents. Piston rod

(1) Check the piston rod if it may cause runout. Support both ends of the piston rod with V-shaped blocks, and measure its runout using a dial gauge at the center while turning the piston rod. If 1/2 of dial indicator reading exceeds the limit, replace the piston rod. (2) Check the rod surfaces for rust, damage, sliding trace, and dent.Replace the piston rod, if it is seriously damaged in the threaded part.

200319

Ring and packing

(1) Check the packing and wear ring for damage or distortion.

(2) Check each ring for deterioration.

Truck model

DP100N

Inside diameter of cylinder tube 1 Piston Deflection of piston rod 2 (1/2 of dial indicator reading)

Rod cover

Inside diameter of rod cover bushing 4 Rod cover tightening torque 5

DP135N

Standard value

115 mm (4.53 in.)

Repair or service limit

115.15 mm (4.534 in.)

Repair or service limit

0.5 mm (0.02 in.)

Standard value

Outside diameter of piston rod 3

DP120N

Standard value Standard value

-0.030

DP150N

-0.0012

60 -0.104 mm [2.36 -0.0041 in.] (Mast height 5500 to 7000 mm [18.04 to 22.97 ft]: 75 60

+0.11 0

mm [2.36

+0.0043 0

+0.035 -0.039

mm [2.95

+0.0014 -0.0015

in.]) Note 1

in.] (Mast height 5500 to 7000 mm +0.19

+0.0075

[18.04 to 22.97 ft]: 75 +0.06 mm [2.95 +0.0024 in.]) Note 1 1.18±0.1 kN•m (120.3 ± 10.2 kgf•m) [870.8 ± 73.8 lbf•ft]

Note 1: The mast height for DP135N and DP150N is from 5000 to 7000 mm.

12-22

HYDRAULIC SYSTEM

210494

12-23

HYDRAULIC SYSTEM

6.3 Reassembly

∗ Seal kit parts 1

∗

∗ 210495

6.3.1 Reassembly sequence 1 Piston rod, Collar

4 Rod cover, Bushing, O-ring, Packing, Dust seal

2 Wear ring, Backup ring, Packing 3 Cylinder tube

6.3.2 Suggestion for reassembly

(1) During reassembly, always replace the Seal Kit parts (2) (3) (4)

(5)

marked with an asterisk (*) in the figure. Thoroughly clean all parts before reassembly making sure they are completely free from dirt or dust. Apply a coat of oil to each inside surface of rings, bushings, and cylinder tube before reassembly. When holding the cylinder’s outer circumference on a vise, be careful not to tighten the vise excessively as to distort the cylinder. Before tightening the rod cover, apply Loctite #638 to the threaded part of the cylinder tube.

Rod cover tightening torque

12-24

1.18 ± 0.1 kN•m (120.3 ± 10.2 kgf•m) [870.8 ± 73.8 lbf•ft]

HYDRAULIC SYSTEM

7. Tilt cylinder 7.1 Disassembly

∗

5 1

∗

∗ Seal kit parts

211974

7.1.1 Disassembly sequence 1 Socket, Nut

4 Piston, Self-locking nut, Piston seal

2 Guide bushing, Dust seal, Packing, Buffer ring, O-ring, 5 Piston rod Backup ring 3 Collar

6 Cylinder tube, Bushing

NOTE The bushing press-fit in cylinder tube 6 does not have to be disassembled unless defective.

12-25

HYDRAULIC SYSTEM

7.1.2 Suggestion for disassembly Removing guide bushing

(1) Wrap the tilt cylinder with a piece of waste cloth, and hold it on a vise. Remove the guide bushing using Hook wrench A. Special tool Hook wrench A

05312 - 11000

(2) Before removing the guide bushing, wrap the threaded part of the piston rod with vinyl tape so that the thread edges do not damage the buffer ring and packing. 200351

12-26

HYDRAULIC SYSTEM

7.2 Inspection and Repair Cylinder tube

(1) Check the inside surface of the cylinder for wear, damage, or rust. (2) Check the welded area for cracks, damage, and dent. Piston rod

(1) Check the runout of piston rod. Support both ends of the piston rod with V-shaped blocks, and measure its runout using a dial gauge at the center while turning the piston rod. If 1/2 of dial indicator reading exceeds the limit, replace the piston rod. (2) Check the rod surfaces for rust, damage, sliding flaws, and dents. Replace the piston rod, if it is seriously damaged in the threaded part. Ring and packing 200319

(1) Check the lips of packing and buffer ring for damage or distortion.

(2) Check each ring for deterioration.

Truck model

DP100N

Inside diameter of cylinder tube 1

Guide bushing

DP120N

DP135N

120 mm (4.7 in.)

130 mm (5.1 in.)

Repair or service limit

120.12 mm (4.729 in.)

130.12 mm (5.123 in.)

Outside diameter of piston rod 2

Standard value

55 mm (2.17 in.)

Clearance between rod and guide bushing

Standard value

0.1 mm (0.004 in.)

Repair or service limit

0.2 mm (0.008 in.)

Standard value

Inside diameter of bushing 3 (under press-fit)

DP150N

Standard value

Repair or service limit

+0.100 +0.070

+0.0039

mm (2.36 +0.0028 in.)

60.6 mm (2.39 in.) 696.5±69 N•m (71.02±7.03 kgf•m) [514.0±50.9 lbf•ft]

637±63.7 N•m (64.95±6.5 kgf•m) [470.1±47.0 lbf•ft]

Tightening torque of guide bushing 4

Standard value

Tightening torque of socket nut 5

Standard value

1178 to 1472 N•m (120.1 to 150.1 kgf•m) [869.4 to 1086.3 lbf•ft]

Repair or service limit

0.5 mm (0.02 in.)

Deflection of piston rod 6 (1/2 of dial indicator reading)

6 3

211975

12-27

HYDRAULIC SYSTEM

7.3 Reassembly

∗ Seal kit parts

∗

211976

7.3.1 Reassembly sequence 1 Piston rod, Collar, Piston, Self-locking nut, Piston seal

3 Guide bushing, Packing, Buffer ring, Dust seal, Backup ring, O-ring

2 Cylinder tube, Bushing

4 Socket, Nut

7.3.2 Suggestion for reassembly

(1) During reassembly, always replace the Seal Kit parts marked with an asterisk (*) in the figure. (2) Thoroughly clean all parts before reassembly making sure they are completely free from dirt or dust. (3) Coat each inside surface of the piston seal, O-ring, packing, dust seal and cylinder with service oil before reassembly. (4) When holding the cylinder’s outer circumference in a vise, be careful not to tighten the vise excessively as to distort the cylinder.

200352

12-28

HYDRAULIC SYSTEM

(5) Procedure to install piston seal into tilt cylinder (a) Lightly compress and release a piston seal 5 to 6 times by hand to make it soft.

(b) Hold the piston with a vise while taking care so as not to damage the piston rod, and apply a thin coat of oil on the piston seal. First fit the one side of the piston seal into the mounting groove provided on the piston, then press-in the other side.

(6) Make sure each direction of the packing and dust seal to be inserted into the guide bushing.

204641

12-29

HYDRAULIC SYSTEM

8. Inspection and Adjustment 8.1 Hydraulic oil Cloudy oil should be changed, since water is suspected be mixed in. When the oil is checked immediately after operating the control lever, be careful not to mistake the bubbles of oil as a mixture with water. Suction strainer, Return filter Check for damage or clogging, and clean or replace.

8.2 Test operation of gear pump Test operation is to perform break-in of the pump and make check the performance. This test operation is desirable to be performed on the test stand, however, since the actual service is impossible, use the following method with the gear pump installed on the truck. (1) Connect an oil pressure gauge (gauge, 25 MPa (254.9 kgf/cm2) [3626.3 psi]) to the upper right surface of the control valve. Installing oil pressure indicator: Remove the plug from the connector of delivery hose and attach the following tool instead. Connector

64309 -17734(R (PT) 1/4 thread screw)

Hose

64309 - 17722

Connector

64309 - 17731 (for gauge installation)

Gauge

64309 - 17712 (25 MPa (254.9 kgf/cm2) [3626.3 psi])

NOTE Tools mentioned above are included in the Gauge Kit 64309-17701.

(2) Make the control lever to the neutral position and run the engine at 500 to 1000 rpm. At the neutral position the oil pressure meter must read 1 MPa (10.2 kgf/cm2) [145.1 psi] or less. Continue to run the engine in this condition for 10 minutes and listen to see if the pump generates abnormal sound. (3) After 10 minutes, raise the engine speed to 1500 to 2000 rpm, and continue to run the engine under no load for more 10 minutes. (4) Loosen the adjusting screws of the relief valve under the condition of paragraph (3) and shift the control lever to the active position. Then, adjust the adjusting screw to set the pressure to 3 MPa (30.6 kgf/cm2) [435.2 psi], and run the engine for 5 minutes. Continuously raise the pressure further by 2 MPa (20.4 kgf/ cm2) [290.1 psi] increments and run the engine for 5 minutes each time until the relief valve reaches the specified pressure setting.

12-30

Adjusting screw 211977

HYDRAULIC SYSTEM

(5) During the process of raising the pressure, watch the oil temperature, pump surface temperature, and listen for abnormal sound from the pump, etc. If the oil temperature or pump temperature abnormally rises, cancel the load and lower the temperature to continue the test operation, or disassemble the pump again to inspect the inside. (6) Complete the operations of (2) to (5), then re-adjust the relief valve to the specified pressure setting, and make sure that the operation speed is normal.

8.3 Control Valve Oil leak to the outside

(1) Oil leak from O-ring between housings (2) Oil leak from O-ring of the scraper (3) Oil leak at fastening screws 8.4 Adjusting main relief valve (1) Connect an oil pressure indicator (gauge, 25 MPa (254.9 kgf/cm2) [3626.3 psi]) on the left side of the control valve. The gauge, connector, hose, etc. to be used are same as with the gear pump test operation. (2) Start the engine and raise the speed to the maximum. (3) The relief valve is normal, if the oil pressure is relieved and the pressure meter hand points to 20.6

+0.5 0

MPa

(210.1 kgf/cm ) [2988.1 psi] when the tilt cylinder reaches the backward tilt limit as the result of turning the tilt lever to the backward tilt position. (4) If the relief pressure is not satisfactory, loosen the lock nut of the relief valve adjusting screw and adjust the pressure while observing the gauge reading.

Adjusting screw 211977

NOTE The reference amount of tightening-in of adjusting screw for relief valve is such that one turn varies the pressure for approx. 10.6 MPa (108.1 kgf/cm2) [1537.6 psi].

(5) Tighten the lock nut to secure the adjusting screw while holding it by hand.

(6) After securing the adjusting screw, recheck the relief valve pressure setting. Main relief valve pressure setting

20.6

+0.5 0

MPa

(210.1 kgf/cm2) [2988.1 psi]

12-31

HYDRAULIC SYSTEM

8.5 Functional inspection of priority relief valve (1) Set an oil pressure indicator (gauge, 25 MPa (254.9 kgf/cm2) [3626.3 psi]) to the shown position in the figure at the right.

Referenc e No.

211946 Tool name

Part No.

Connector

91268 - 01700

Connector

64309 - 17733(R (PT) 1/8 thread screw)

Hose

64309 - 17722

Connector

64309 - 17731 (for gauge installation)

Gauge

64309 - 17712 (25 MPa (254.9 kgf/ cm2) [3626.3 psi])

5 4 3

NOTE (a) Tools numbered as 2 to 5 are included in the Gauge Kit 64309-17701. (b) Oil pressure indicators (gauge) that are used can have twice the capacity of the oil pressure to be measured, however, in this case, use an appropriate device included in the Gauge Kit.

(2) Start the engine and raise the speed to the maximum. (3) The relief valve is turned to be normal, if the oil pres-

1 211947

Adjusting plug

sure is relieved and the pressure indicator hand shows +0.5

+5.1

+72.5

11.8 0 MPa (120.3 0 kgf/cm2) [1711.6 0 psi] when the steering wheel is turned all the way to the left and the steering cylinder stroke reaches the upper limit. (4) If the relief pressure is not satisfactory, disconnect the T-port piping of the priority valve and adjust the relief pressure by turning the adjusting plug of the relief valve.

NOTE The reference amount of tightening-in of adjusting plug is such that one turn produces a change of approx. 7.4 MPa (75.5 kgf/cm2) [1073.4 psi].

12-32

205668

HYDRAULIC SYSTEM

9. Tests Free descending amount test

(1) Using a capacity load, tilt the mast to vertical position and raise the forks 1 to 1.5 m (3 to 5 ft.) from the ground, and stop the engine. (2) Mark the mast with a reference line and measure the free descending amount after 15 minutes. Rod contraction length on free descending (with capacity load) (oil temperature 45˚C [113˚F])

DP100N: 40 mm (1.57 in.)/15 min DP120N: 45 mm (1.77 in.)/15 min DP135N: 38 mm (1.50 in.)/15 min DP150N: 42 mm (1.65 in.)/15 min

211951

Free forward tilt test

(1) Using a capacity load, tilt the mast to vertical position and raise the forks 50 cm (2.0 in.) from the ground, and stop the engine. (2) Measure the extension stroke of the tilt cylinder, and measure the extension stroke again after 15 minutes. Rod extension length on free descending (with capacity load) (oil temperature 45˚C [113˚F])

DP100N: 41 mm (1.61 in.)/15 min DP120N: 47 mm (1.85 in.)/15 min DP135N: 35 mm (1.38 in.)/15 min DP150N: 39 mm (1.54 in.)/15 min

211952

12-33

HYDRAULIC SYSTEM

10.Troubleshooting

Hydraulic tank heats excessively Hydraulic tank

Cylinders move too slow

12-34

• Not enough oil

• Refill.

• Inappropriate oil viscosity

• Refer to “List of Applicable Lubricant”, and replace oil.

• Operating conditions are hard and over-loaded.

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

• Local overheating of oil line due to a large restric- • Clean oil line. tion to flow • Relief valve adjustment improper

• Adjust pressure setting.

• Hydraulic pump worn

• Replace pump.

• Outlet-side line flattened or restriction to flow

• Repair or replace.

• Clogging of oil cooler

• Clean.

• Shortage of oil due to a natural loss

• Refer to “List of Applicable Lubricant”, and refill oil.

• Oil leakage due to damaged oil line, seal, etc.

• Repair or replace.

• Oil viscosity is too high

• Refer to “List of Applicable Lubricant”, and replace oil.

HYDRAULIC SYSTEM

Cylinders move too slow

• Gear pump does not pump-in oil

• Check pump and piping. Repair or replace if required.

• Oil leaks from part of the hydraulic line

• Check the oil level and contamination. Add or change oil if necessary.

• Oil level abnormally high

• Check the control valve spools for misalignment. Repair or replace.

• Oil leaks inside of gear pump

• Replace pump.

• Poor pumping of oil

• Refer to “List of Applicable Lubricant”, and refill oil.

• Cavitation

(1) Check suction pipe for any flat portion or loose connection. Retighten or replace. (2) Check shaft oil seal for air-tightness. Replace pump. (3) Check pump body for any outside interference. Repair.

Pump too noisy Gear pump

• Subjected to pressure greater than that rated Pump case, drive gear or pump port flange damaged

Oil leakage from pump

• Check if pressure control valve operates normally. Replace pump.

• Distortion or damage due to external strain or • Replace pump. stress (1) Check if return line has been blocked or restricted to flow. (2) Check if pipe connection has been externally strained or stressed. • Oil leakage from oil seal

• Replace seal.

• Oil leakage through sliding surfaces of drive shaft

• Replace pump assembly.

• Pump securing bolt loose

• Retighten, and replace parts if required.

• Sealing inside pump deteriorated

• Replace O-ring.

12-35

HYDRAULIC SYSTEM

Slow or no motions of lift and tilt cylinders Control Valve

Lift drops or tilts forward

Oil leakage

• Too low valve opening pressure setting

• Adjust pressure.

• Relief valve piston jamming

• Clean piston and check to see if it moves smoothly; or replace relief valve assembly.

• Outer O-ring on relief valve body damaged

• Replace O-ring.

• Control lever installed loose, resulting in not • Readjust. enough spool stroke • Control valve spool internal leakage

• Replace each block assembly.

• Oil leakage from spool ring cap

• Replace O-ring; check spool. If necessary, repair or replace each block assembly.

• Plug loose

• Retighten.

• O-ring damaged

• Replace O-ring.

• Insufficient oil in hydraulic tank

• Refer to “List of Applicable Lubricant”, and refill oil.

Mast will • Relief valve defects not ascend, (1) Main valve jamming tilt forward or backward. (2) Valve spring fracture

• Hydraulic pump defects

Lift and tilt cylinder

Unable to lift rated load

Lifting speed too slow

Lowering speed of lift cylinder too slow

12-36

• Relief valve defects (1) Too low valve opening pressure setting (2) Plunger or poppet seat defects (3) Spring fatigued (4) O-ring in valve case damaged

• Replace. • Replace. • Replace. • Adjust pressure. • Replace. • Replace. • Replace.

• Hydraulic pump defects

• Replace.

• Piston seal worn or damaged

• Replace.

• Engine speed too slow

• Adjust engine.

• Control lever installed loose, resulting in not • Readjust. enough spool stroke • Clogging of tank strainer

• Wash or replace.

• Gear pump delivery rate too low

• Repair or replace.

• Sleeve seized in flow regulator valve

• Repair.

• Hydraulic line extremely restricted from smooth • Clean or repair hydraulic system or replace defective hose. flowing due to dirt clogged in flow regulator valve, or hydraulic hose fractured or locally stopped.

HYDRAULIC SYSTEM

Cylinder vibrates during operation

Lift cylinder descend excessively

Lift and tilt cylinder

• Piston rod bend

• Repair or replace.

• Air mixed in hydraulic line

• Bleed air by operating cylinder across full stroke.

• Insufficient oil in tank

• Refill.

• Control valve spool internal leakage

• Replace each block assembly.

• Scratches on sliding surface of cylinder tube that • Repair or replace. can be felt by finger nail • Sliding surface of cylinder tube badly grooved

• Replace cylinder assembly.

• Piston seal damaged or distorted

• Replace seal.

• Oil leakage from hydraulic line

• Repair or replace.

• Control valve spool internal leakage

• Replace each block assembly.

Tilt cylinder tilt forward excessively

• Foreign matter lodged in packing

• Replace packing.

• Piston seal damaged

• Replace seal.

Lift cylinder or tilt cylinder will descend or tilt forward at a certain point

• Inside surface of cylinder badly grooved

• Repair or replace.

• Cylinder distortion

• Replace.

• Foreign matter lodged in oil seal or dust seal

• Replace.

Oil leakage from bushing

• Abnormal distortion or oil leakage from hydraulic • Repair or replace. line

• Inner or outer diameter of oil seal or dust seal • Replace. damaged • O-ring damaged

• Replace O-ring.

• Abnormal distortion

• Repair or replace.

12-37

HYDRAULIC SYSTEM

11.Service Data Truck model

DP100N

DP120N

DP135N

DP150N

330 mm (65.0 fpm)

340 mm (66.92 fpm)

290 mm (57.1 fpm)

280 mm (55.1 fpm)

Fork ascending speed (under the rated load) [Simplex mast] (at maximum engine speed)

Standard value

Fork ascending speed (under no load) (at maximum engine speed)

Standard value

360 mm (70.9 fpm)

310 mm (61.0 fpm)

Fork descending speed (under the rated load) [Simplex mast] (at maximum engine speed)

Standard value

450 mm (88.6 fpm)

380 mm (74.8 fpm)

Forward tilt angle [Standard simplex mast truck]

Standard value

6˚

Backward tilt angle [Standard simplex mast truck]

Standard value

12˚

Lift cylinder free fall (under the rated load) (rod contraction length) (oil temperature 45˚C [113˚F])

Standard value

40 mm (1.6 in.)

45 mm (1.8 in.)

38 mm (1.5 in.)

42 mm (1.7 in.)

Tilt cylinder free forward tilt amount (under the rated load) (rod contraction length) (oil temperature 45˚C [113˚F])

Standard value

45 mm (1.8 in.)

50 mm (2.0 in.)

40 mm (1.6 in.)

45 mm (1.8 in.)

Gear pump

Discharge capacity

Standard value

205 L/min (54.2 U.S. gal./min) (at 2200 rpm)

Mounting bolt and nut tightening torque 1

Standard value

59.8 N•m (6.1 kgf•m) [44.1 lbf•ft]

Delivery hose mounting bolt tightening torque 2

Standard value

76.5 N•m (7.8 kgf•m) [56.5 lbf•ft]

Cover mounting bolt tightening torque 3

Standard value

108.9 to 122.6 N•m (11.1 to 12.5 kgf•m) [80.4 to 90.5 lbf•ft]

1 210504

12-38

HYDRAULIC SYSTEM

Truck model Control Valve

DP100N +0.5 0

DP120N +5.1 0

DP135N

DP150N +72.5 0

Main relief pressure 1

Standard value

Tie bolt nut tightening torque 2

Standard value

98 to 118 N•m (10.0 kgf•m) [72.3 lbf•ft]

Control valve mounting bolt tightening torque 3

Standard value

60 N•m (6.1 kgf•m) [44.3 lbf•ft]

20.6

MPa (210.1

kgf/cm2) [2988.1

Front

psi]

Rear

212003

Truck model Priority valve

DP100N

DP120N

DP135N

DP150N

Set relief pressure 1

Standard value

11.8 MPa (120.3 kgf/cm ) [1711.6 psi]

Plug tightening torque 2

Standard value

44.1 N•m (4.5 kgf•m) [32.5 lbf•ft]

Relief valve tightening torque 3

Standard value

20.6 N•m (2.1 kgf•m) [15.2 lbf•ft]

2 1

3 210506

12-39

HYDRAULIC SYSTEM

Truck model Hydraulic tank

DP100N

DP120N

DP135N

DP150N

Return filter tightening torque 1

Standard value

49 N•m (5.0 kgf•m) [36.2 lbf•ft]

Suction strainer tightening torque 2

Standard value

49 N•m (5.0 kgf•m) [36.2 lbf•ft]

Drain plug tightening torque 3

Standard value

177 to 196 N•m (18.0 to 20.0 kgf•m) [130.6 to 144.6 lbf•ft]

Truck model Flow Control flow rate (under no load) regulator valve Plug tightening torque 1

DP100N Standard value Standard value

211980

DP120N

120 L/min (31.7 U.S. gal./min)

DP135N

DP150N

DP160N

150 L/min (39.6 U.S. gal./min)

343 (35.0 kgf•m) [253.1 lbf•ft]

1 210508

12-40

HYDRAULIC SYSTEM

Truck model

DP100N

DP120N

DP135N

Standard value

115 mm (4.53 in.)

120 mm (4.7 in.)

Inside diameter of cylinder tube 1

Repair or service limit

115.15 mm (4.534 in.)

125.15 mm (4.927 in.)

Deflection of piston rod 2 (1/2 of dial indicator reading)

Repair or service limit

0.5 mm (0.02 in.) -0.030

-0.0012

60 -0.104 mm (2.36 -0.0041 in.)

-0.030

Outside diameter of piston rod 3

+0.035 +0.0014 -0.039 mm (2.95 -0.0015 Mast height (5.5 to 7 m [18.0 to 23.0 ft])

Inside diameter of rod cover bushing 4

Standard value

Rod cover tightening torque 5

Standard value

Mast height

(3 to 5 m [9.8 to 16.4 ft])

Standard value

+0.11 0

Mast height (3 to 5 m [9.8 to 16.4 ft]) +0.19 +0.0075 +0.06 mm (2.95 +0.0024 Mast height (5.5 to 7 m [18.0 to 23.0 ft])

mm (2.36

+0.0043 0

-0.0012

65 -0.104 mm (2.56 -0.0041 in.)

Mast height

Lift cylinder

DP150N

(3 to 4.5 m [9.8 to 14.8 ft]) in.)

+0.035 -0.039

mm (3.15

+0.0014 -0.0015

in.)

Mast height (5 to 7 m [16.4 to 23.0 ft] )

in.) in.)

+0.11 0

+0.0043 0

in.)

Mast height (3 to 4.5 m [9.8 to 14.8 ft] ) +0.19 +0.0075 +0.06 mm (3.15 +0.0024 Mast height (5 to 7 m [16.4 to 23.0 ft])

in.)

mm (2.56

1.18±0.1 kN•m (120.3±10.2 kgf•m) [870.8±73.8 lbf•ft]

210509

12-41

HYDRAULIC SYSTEM

Truck model

Inside diameter of cylinder tube 1

Outside diameter of piston rod 2 (bushing) Guide bushing

Clearance between rod and guide bushing 2

Inside diameter of bushing 3 (under press-fit) Tilt cylinder

DP100N

DP120N

DP135N

DP150N

Standard value

120 mm (4.724 in.)

130 mm (5.118 in.)

Repair or service limit

120.12 mm (4.729 in.)

130.12 mm (5.123 in.)

Standard value

55 mm (2.1 in.)

Standard value

0.1 mm (0.0039 in.)

Repair or service limit

0.2 mm (0.0079 in.)

Standard value

+0.100 0.070

Repair or service limit

+0.0039

mm (2.36 +0.0028 in.)

60.6 mm (2.39 in.) 637±63.7 N•m (65.0±6.5 kgf•m) [470.1±47 lbf•ft]

696±68.6 N•m (71.0±7.0 kgf•m) [513.6±50.6 lbf•ft]

Tightening torque of guide bushing 4

Standard value

Tightening torque of socket nut 5

Standard value

1178 to 1472 N•m (120 to 150 kgf•m) [869.4 to 1086.3 lbf•ft]

Standard value

60-0.046 mm (2.36 -0.002 in.)

Repair or service limit

59 mm (2.3 in.)

Standard value

33 N•m (3.37 kgf•m) [24.35 lbf•ft]

Repair or service limit

0.5 mm (0.02 in.)

Outside diameter of tilt socket pin 6 Tilt socket pin mounting bolt tightening torque 7 Deflection of piston rod 8 (1/2 of dial indicator reading)

8 3

12-42

211981

MAST AND FORKS 1. Specifications ............................................................................................................. 13-2 2. Structure..................................................................................................................... 13-3 3. Suggestions for Removal and Installation.................................................................. 13-4 3.1 Removal sequence ............................................................................................................................. 13-4

3.2 Suggestions for Removal.................................................................................................................... 13-5

4. Mast assembly ........................................................................................................... 13-7

4.1 Disassembly........................................................................................................................................ 13-7 4.1.1 Disassembly sequence ............................................................................................................................. 13-7 4.1.2 Suggestion for disassembly ...................................................................................................................... 13-8

4.2 Inspection and Repair ......................................................................................................................... 13-8 4.3 Reassembly ...................................................................................................................................... 13-10

4 5

4.4 Readjust............................................................................................................................................ 13-14

5. Troubleshooting ....................................................................................................... 13-18 6. Service Data............................................................................................................. 13-19

6 7 8 9 10 11 12 13 14 15

13-1

MAST AND FORKS

1. Specifications Truck model

DP100N

DP120N

DP135N

Mast type

Mast dimensions (Flange inside width × Flange thickness × Web thickness)

Main roller Loading equipment Side roller

DP160N

CJ type

Outer

205 × 25 × 32 mm (8.07 × 0.98 × 1.26 in.)

205 × 28 × 36 mm (8.07 × 1.10 × 1.42 in.)

205 × 28 × 40 mm (8.07 × 1.10 × 1.57 in.)

Inner

205 × 25 × 32 mm (8.07 × 0.98 × 1.26 in.)

205 × 28 × 36 mm (8.07 × 1.10 × 1.42 in.)

205 × 28 × 40 mm (8.07 × 1.10 × 1.57 in.)

Type

Ball bearing

Diameter × Width

205 × 52 mm (8.07 × 2.05 in.)

Type

Lubricated needle

Diameter × Width

58 × 40 mm (2.28 × 1.57 in.)

Lift-chain type Fork length (width × thickness)

Fork width adjustment (outside width)

13-2

DP150N

EKBL-1434 1220 – 180 × 70 mm (48 – 7 × 2.8 in.)

1220 – 180 × 75 mm (48 – 7 × 3.0 in.)

410 to 2030 mm (16.1 to 79.9 in.)

EKBL-1634 1220 – 180 ∞ 90 mm (48 – 7 × 3.5 in.)

1220 – 180 × 89 mm (48 – 7 × 3.5 in.)

470 to 2030 mm (18.5 to 79.9 in.)

470 to 2020 mm (18.5 to 79.5 in.)

MAST AND FORKS

2. Structure

3 1 2

Section A - A

Section B - B

1 Inner mast

5 Mast support bearing cap

2 Outer mast

6 Main roller, Side roller

3 Lift chain

7 Mast strip

4 Lift bracket

8 Fork positioner screw

211990

13-3

MAST AND FORKS

3. Suggestions for Removal and Installation Mast and lift bracket assembly Removal

1 5

3 2

211991 3.1 Removal sequence 1 Fork, Lift bracket

4 Tilt cylinder pin

2 Lift cylinder low-pressure return hose

5 Mast support bearing cap, Bushing

3 Lift cylinder high-pressure hose

13-4

MAST AND FORKS

3.2 Suggestions for Removal 1. Removing lift bracket

(1) Remove the split pins from the lift chain, and remove (2)

(3) (4) (5)

(6)

the anchor nut and lock nut. Bind the end of the lift chain with a rope, etc. Leave an approximately 3 m (9.8 ft) long extras at the ends of the rope. Start the engine and raise the inner mast up to a position where the main rollers of the lift bracket come out. During this step, maintain the lift chain pulled downward. Lift the inner mast until it comes to a position where the main rollers of lift bracket can be removed, then reverse the truck to separate the lift bracket from the truck. Lower the inner mast and stop the engine.

211992

211993

2. Removing lift cylinder low-pressure return hose

Low-pressure hose removal

(1) Start the engine and raise the mast to the highest position. Then, stop the engine and disconnect the hose. Remove the hose at the return connector side. (2) Lower the mast. Return connector

3. Removing lift cylinder high-pressure hose

(1) Operate the lift lever to remove the remaining pressure in the lift cylinder hydraulic lines, and disconnect the high-pressure hose from the connection of lift cylinder.

High-pressure hose removal

211994

13-5

MAST AND FORKS

4. Removing tilt cylinder

(1) Hitch a sling to the upper cross-member at the top of the mast, then lift with a hoist.

NOTE For this operation be sure to use a hoist having a capacity enough to support the mast assembly.

Truck model

Mast weight

DP100N

1995 kg (4399 lb)

DP120N

1995 kg (4399 lb)

DP135N

2100 kg (4631 lb)

DP150N

2320 kg (5116 lb)

DP160N

2515 kg (5546 lb)

211995

(2) Remove the tilt pin and separate the tilt cylinder from the mast.

5. Removing mast support bearing cap

211962

(1) Put alignment marks on the caps. (2) Remove the cap mounting bolts and separate the whole mast assembly while lifting it up from the truck. Lay it down flat with the lift bracket side facing upward on level ground.

NOTE In order to avoid any obstruction in the subsequent disassembly, laying the removed mast assembly on a sufficient space in both directions of mast sliding (toward the top and bottom). 210519

13-6

MAST AND FORKS

4. Mast assembly 4.1 Disassembly

16 A

16 12 2 19

8 3

20 20

8 B

20 2 13

6 14

14 6

211997 4.1.1 Disassembly sequence 1 Handle

12 Bolt, Shim, Washer

2 Lift chain, Nut, Split pin

13 Lift cylinder, Flow regulator valve

3 Lift bracket

14 Main roller, Side roller, Snap ring, Side roller, shim, Pin

4 Screw bracket, Bolt, Washer

15 Bolt, Nut

5 Screw, Feed nut, Thrust washer, Spacer

16 Main roller, Side roller, Snap ring, Side roller, shim, Pin

6 Stopper plate, Guide bar, Shim

17 Mast strip, Shim

7 Fork, Fork bracket

18 Chain wheel support

8 Main roller, Side roller, Bolt, Nut, Snap ring, Pin

19 Inner mast

9 Pipe

20 Chain wheel, Pin, Spacer, Collar, Bearing

10 Hose, Clamp bolt, Connector

21 Outer mast

11 Cylinder clamp, Bolt, Seat, Shim, Cushion, Collar

13-7

MAST AND FORKS

4.1.2 Suggestion for disassembly Removing inner mast

(1) Lift cylinders LH and RH are shim adjusted at the cylinder rod ends to prevent racking. When cylinder rod installation bolts are removed, make record of how many shims are used and which side of cylinder the shims are installed to. (2) When the cylinder clamp bolts are removed, the lift cylinder becomes unfixed (free). Shorten the cylinder rods as much as possible to cross the top ends of two cylinders. (3) Slide the inner mast downward to remove main roller and side roller of outer mast and main roller and side roller of inner mast. (4) Remove main and side rollers, then withdraw the inner mast from the outer mast in an upward direction to separate them by sliding the shafts of main rollers of them each other.

Shims

210521

4.2 Inspection and Repair 1. Mast

(1) Check the rollers for wear, binding or crack. (2) Check the rolling surface of each roller for wear, dam-

210522

age or distortion. (3) Check the mast member and the welded joints of crossbeams, pins and supports for cracks. (4) Check the mast support bushings for wear or damage.

2. Lift bracket

(1) Check the main rollers and side rollers for sticking, (2) (3) (4) (5) (6)

210523

wear or cracks. Check the welded part of the lift bracket for cracks. Check the guide bars whether they are bent or deformed. Check threads of fork shift screw for damage. Check inside diameter of bush of fork shift screw for damage. Check the welded part of fork bracket for cracks. Guide bar Screw

210524

13-8

MAST AND FORKS

3. Chain, Chain wheel support, and Chain wheel

(1) Check right and left chains for uneven length, wear, adhesion, or distortion. DP100N, DP150N, DP120N, DP160N DP135N

Truck model

Length of lift chains (mm/20 links)

Standard value

889 mm (35 in.)

1016 mm (40 in.)

Service limit

915 mm (36 in.)

1046 mm (41 in.)

(2) Check the chain anchor bolt threads for cracks or defects.

(3) Check the chain wheel support and the chain wheel for crack or wear, or adhesion. 4. Mast strip

(1) Check for damage, chipping or distortion.

Thickness of mast strip

Standard value

9 mm (0.35 in.)

Service limit

7 mm (0.28 in.)

5. Fork

(1) Check the forks for bending, misalignment of tips, and cracks. Misaligned fork tips

Standard value

5 mm (0.2 in.) or less

(2) Check the forks for wear. If it exceeds the repair or service limit, replace. DP100N [DP120N]

DP135N [DP150N]

DP160N

Standard value

70 mm (2.8 in.) [75 mm] (3.0 in.)

90 mm (3.5 in.)

89 mm (3.5 in.)

Service limit

59 mm (2.3 in.) [65 mm] (2.6 in.)

69 mm (2.7 in.) [73 mm] (2.9 in.)

81 mm (3.2 in.)

Truck model

Fork thickness

211999

13-9

MAST AND FORKS

4.3 Reassembly To reassemble, follow the disassembly sequence in reverse and observe the following. 1. Front and rear clearance between mast and lift bracket

(1) Select and assemble the main roller in an appropriate manner in order that the clearances P and M are within the dimensions as shown below throughout the height range. P and M, clearances between main roller and rolling surface

0.5 to 2.8 mm (0.02 to 0.11 in.)

Inner mast

Outer mast

Lift bracket

If the specified value can not be achieved, replace the main roller.

Main roller size

203 mm (7.99 in.)

205 mm (8.07 in.)

207 mm (8.15 in.)

210526

2. Installing mast trip

(1) Install to make the front and rear clearance between outer and inner masts within the specified dimension at the maximum height range. Clearance L

0.5 to 1.5 mm (0.02 to 0.06 in.)

Mast strip 210527

(2) If the clearance of mast strip (L) is not within the specified value, adjust with the shims.

210528

13-10

MAST AND FORKS

3. Left and right clearance between outer and inner masts

(1) Measure the dimension between left and right side rollers of outer mast (A) and assemble them so that the specified dimension is obtained. Truck model

DP100N, DP120N, DP135N

DP150N, DP160N

Dimension A

754±0.5 mm (29.7±0.02 in.)

748±0.5 mm (29.4±0.02 in.)

NOTE

210529

Measurements shall be made at the smallest inner width. B

(2) Measure the dimension between left and right side rollers of inner mast (B) and assemble them so that the specified dimension is obtained. Truck model

DP100N, DP120N, DP135N

DP150N, DP160N

Dimension B

890±0.5 mm (35.0±0.02 in.)

884±0.5 mm (34.8±0.02 in.)

210530

NOTE Measurements shall be made at the largest outer width. K

(3) Press the inner mast in a direction of left or right at the maximum height range, and measure the clearance K produced at the opposite side. Clearance K

0.5 to 1.5 mm (0.02 to 0.06 in.)

K 210531

(4) If the clearance K is not within the specified value, adjust in accordance with the following procedure: • The adjustment of clearance K of upper side shall be made by loosening locknut of side roller bracket and by rotating the adjusting bolt.

Adjusting bolt

205585

13-11

MAST AND FORKS

• Clearance K at the lower side shall be made by removing side roller and by adding/subtracting shims.

Shims

210532

4. Left and right clearance of lift bracket C

(1) Measure the dimension of side roller (C) and assemble so that the specified dimension is obtained. Truck model

DP100N, DP120N, DP135N

DP150N, DP160N

Dimension C

704±0.5 mm (27.7±0.02 in.)

692±0.5 mm (27.2±0.02 in.)

210533

(2) Press in a direction of left or right throughout the height range and measure the clearance N produced at the opposite side with a thickness gauge. Clearance N

0.5 to 1.5 mm (0.02 to 0.06 in.)

• The adjustment of clearance N shall be made by loosening locknut of side roller bracket and by rotating the adjusting bolt.

210534 Adjusting bolt

Adjusting bolt

13-12

212000

MAST AND FORKS

5. Cylinder clamp

(1) Install shims to maintain the lift cylinder in the aligned

Shims

position, then assemble. Standard shim thickness

3.2 mm (0.13 in.)

210536

6. Mast support

(1) Apply grease to the cap inner surface and groove. (2) Install the mast support bushing and the cap with larger cut surface as they are directed to the center of truck. Note that placing blocks under the mast to make a clearance between mast and ground facilitates filling grease. Bolt tightening torque

Mast cap Bushing

490 N•m (49.97 kgf•m) [361.6 lbf•ft] Apply grease. Chamfered

7. Suggestion for assembling chain anchor kit

210537

(1) Never install the center plate to the position link plate should be installed. 1 Link plate (Mark on surface) 2 Center plate (No mark on surface) 3 Link 4 Split pin

1 4

Marking

200383

13-13

MAST AND FORKS

4.4 Readjust. 1. Adjusting chain tension

(1) Make the masts vertical on a flat place, lower the forks to the ground level, and check that lift cylinders are in the most retracted position. (2) Position the anchor bolt with anchor nut and locknut. (3) Lift the fork slightly from the ground and check the tension of chain as the two chains are stretched evenly, by pushing the midpoints between chain wheel and fixed end of chain of left and right chains alternately. Adjust if required. In the case of adjusting tensions of chains by anchor nut, it is recommended to tilt the mast forward to reduce chain tension for operational convenience.

102708

Anchor bolt

(4) When adjustment of chain tension is completed by

210538

rotating anchor nut, tighten the nut to the specified torque. Tightening torque of anchor bolt nut

393 Nâ&#x20AC;˘m (40.1 kgfâ&#x20AC;˘m) [290.0 lbfâ&#x20AC;˘ft]

Lock nut

(5) The mast must be checked in the vertical position, when it is finally adjusted.

Anchor nut

210539

13-14

MAST AND FORKS

2. Adjusting front and rear and left and right clearances of lift bracket

(1) Measure the front and rear and left and right clearances of lift bracket, and adjust, if any of them exceeds the specified value. (2) Use a thickness gauge for front and rear clearance of lift bracket. (3) Use a dial gauge for left and light clearance of lift bracket. Prepare a dial gauge for inner surface of inner mast and make the spindle of dial gauge contact with side wall of lift bracket. Insert a bar between lift bracket and inner mast, and press lift bracket in the left and right directions alternately to measure the travels. (4) If the clearance of lift bracket is adjusted, disconnect the lift bracket from the mast in accordance with removal/installation procedure, and adjust the rollers. (5) If the fro-to-aft clearance of main roller is not within the specified value, replace with an oversized main roller. (6) If left-to-right clearance of side roller is not within the specified value, adjust the clearance in accordance with the following procedure: â&#x20AC;˘ The adjustment clearance N shall be made by loosening locknut of side roller bracket and by rotating the adjusting bolt.

204691

Adjusting bolt

212000

13-15

MAST AND FORKS

3. Adjusting mast tilt angle

(1) Regulate the inflation pressure for all the wheels, then park the truck on a level floor. (2) Fully tilt the mast backward and stop the engine. (3) Measure the rear tilting angles of both left and right masts. (4) If required, perform the adjustment as follows: loosen the locknut of tilt cylinder rod, rotate the tilt cylinder rod and adjust the cylinder strokes to achieve an identical tilt angle for both left and right masts.

NOTE If the rear tilting angle is properly adjusted, the forward tilt angle is automatically determined by the stroke of tilt cylinder.

212002

(5) After adjustment, tighten the lock nuts to each specified torque. Lock nut tightening torque

1178 to 1472 N•m (120.1 to 150.1 kgf•m) [869.4 to 1086.3 lbf•ft]

4. Stroke adjustment of left and right lift cylinders

(1) Slowly lift inner masts to check the stopping condition of left and right piston rods at the maximum height. (2) If a top portion of inner mast vibrates at a moment that it stops, conduct shim adjustment.

NOTE Up to 8 shims (8 mm (0.32 in.) can be applied.

Abnormal condition—There is a slight difference in stop timing between left and right sides. A lift cylinder with a longer stroke vibrates when it stops.

13-16

210542

MAST AND FORKS

Adjusting method

(1) Raise the mast and place a block under the inner mast, then lower the mast until it rests on the block.

202983 (2) Remove the stop bolt at the top of lift cylinder that stopped first, lower the piston rod and insert shims to the top of the piston rod. (3) Extend the piston rod, and tighten the lift cylinder stopper bolt. Then, remove the block placed under the inner mast. (4) Slowly lower the inner mast until it comes to the lowermost position to check the piston rod for smooth operation.

Shims

210543

13-17

MAST AND FORKS

5. Troubleshooting • Improper clearance of main and/or side rollers

• Front and rear / left and right clearance adjustment

• Roller does not rotates smoothly

• Lubricate or replace.

• Chain operation too slow

• Lubricate or replace.

• Improper clearance of mast strip

• Adjust with shims.

• Large side roller clearance

• Adjust by adding shims.

Leaned lift bracket or inner mast

• Uneven chain tensions

• Adjust chain tension.

Abnormal noise from mast

• Roller does not rotates smoothly

• Check and perform adjustment or replace roller bearing.

• Damaged lift cylinder packing

• Replace.

• Damaged lift cylinder inner surface

• Replace.

Whole mast shakes

• Worn mast support bush

• Retighten or replace bushing.

Deformed mast

• Uneven loading or overload

• Replace assembly.

• Distortion of figer bar

• Repair or replace.

• Bent fork

• Repair or replace.

• Deformed mast due to uneven loading

• Repair or replace.

Lift bracket/inner mast does not lift/lower smoothly

Lift cylinder descends

Unevenness of fork tip height

13-18

• Uneven shim adjustment of left and right lift cyl- • Adjust with shims. inders (at the maximum height)

MAST AND FORKS

6. Service Data Truck model

DP100N Standard value

Misaligned fork tips

Fork thickness Fork and chain Length of lift chains (mm/20 links)

DP135N

DP150N

Standard value

70 mm (2.8 in.)

75 mm (3.0 in.)

Service limit

59 mm (2.3 in.)

65 mm (2.6 in.)

69 mm (2.7 in.)

73 mm (2.9 in.)

889 mm (35 in.)

1016 mm (40 in.)

Service limit

915 (36 in.)

1046 (41 in.)

S-size

Standard value

203 mm (7.99 in.)

M-size

Standard value

205 mm (8.07 in.)

L-size

Standard value

207 mm (8.15 in.)

Standard value

58 mm (2.3 in.)

X 1 Smallest inner width of outer mast

Standard value

890

+0.5 -1.0

mm (35.0

+0.020 -0.039

in.)

884 (34.8

890

Standard value

754±0.5 mm (29.7±0.02 in.)

Y 1

Standard value

704

+0.5 -1.0

X 2

Standard value

704

+1.0 -0.5

Outer width of inner mast roller B

Standard value

890±0.5 mm (35.0±0.02 in.)

Clearance between main roller and rolling surface P (Throughout height range)

Standard value

0.5 to 2.8 mm (0.02 to 0.11 in.)

Clearance between side roller and rolling surface K (at the maximum height)

Standard value

0.5 to 1.5 mm (0.02 to 0.06 in.)

Clearance between mast strip and sliding surface L

Standard value

0.5 to 1.5 mm (0.02 to 0.06 in.)

Inner width of outer mast roller A

Smallest inner width of inner mast

+1.0 -0.5

mm (35.0

+0.039 -0.020

mm (27.7

+0.020 -0.039

mm (27.7

+0.039 -0.020

in.)

+0.5 -1.0

+0.020 -0.039

in.)

+0.5 884 -1.0 mm +0.020 (34.8 -0.039 in.)

Standard value

X 2

81 mm (3.2 in.)

Standard value

392 N•m (40.0 kgf•m) [289.3 lbf•ft]

Side roller external diameter

89 mm (3.5 in.)

90 mm (3.5 in.)

Standard value

Roller

DP160N

5 mm (0.19 in.) or less

Tightening torque of chain anchor bolt nut N•m

Main roller outside diameter

Outer mast and inner mast

DP120N

748±0.5 mm (29.4±0.02 in.)

in.)

+0.5 -1.0 mm +0.020 (27.2 -0.039 in.)

in.)

+0.5 -1.0 mm +0.020 (27.2 -0.039 in.)

692

884±0.5 mm (34.8±0.02 in.)

13-19

MAST AND FORKS

Truck model

Lift bracket and inner mast

DP100N

DP120N

DP135N

DP150N

Largest outer width of lift bracket C

Standard value

Clearance between lift bracket main roller and rolling surface M (Throughout height range)

Standard value

0.5 to 2.8 mm (0.02 to 0.11 in.)

Clearance between lift bracket side roller and rolling surface N (at the maximum height)

Standard value

0.5 to 1.5 mm (0.02 to 0.06 in.)

Standard value

490 N•m (49.97 kgf•m) [361.6 lbf•ft]

Tightening torque of mast cap mounting bolts

Inner mast

DP160N

692±0.5 mm (27.2±0.02 in.)

704±0.5 mm (27.7±0.02 in.)

Lift bracket C

Inner mast Outer mast

L Y2 B Mast strip

N X1

Inner mast Outer mast N A

X2 Outer mast K

Lift bracket 210544

13-20

FORK POSITIONER 1. Applicable Attachment Model..................................................................................... 14-2 2. Specifications ............................................................................................................. 14-2 3. Structure..................................................................................................................... 14-3 4. Suggestions for Removal and Installation.................................................................. 14-4 4.1 Removal.............................................................................................................................................. 14-4 4.2 Suggestions for Removal.................................................................................................................... 14-5 4.3 Inspection and Repair ......................................................................................................................... 14-6 4.4 Installation........................................................................................................................................... 14-7 4.4.1 Suggestions for Installation ....................................................................................................................... 14-7

5. Fork positioner cylinder .............................................................................................. 14-8 5.1 Disassembly........................................................................................................................................ 14-8 5.2 Inspection and Repair ......................................................................................................................... 14-9 5.3 Reassembly ...................................................................................................................................... 14-11

6. Inspection and Adjustment....................................................................................... 14-12 7. Troubleshooting ....................................................................................................... 14-13 8. Service Data............................................................................................................. 14-14

14-1

FORK POSITIONER

1. Applicable Attachment Model

Attachment Model FP120AM 4FP135AM FP160AM

Applicable Truck

Applicable Mast Model

Mast Piping

V120A Simplex

Side pulley type

T38A – 10011

4V135A Simplex

Side pulley type

DP150N

T39A – 10011

4V150A Simplex

Side pulley type

DP160N

T40A – 10011

V160A Simplex

Side pulley type

Model

Designation – Serial No.

DP100N

T36A – 10011

DP120N

T37A – 10011

DP135N

2. Specifications Attachment Model Item

FP120AM

W2050 Stroke (each side)

W2200

842 mm (33.2 in.)

– 892 mm (35.1 in.)

–

Loading center

942 mm (37.1 in.) 0 mm (0 in.)

Outside fork spread (maximum)

Outside fork spread (minimum)

W2050

2008 mm (79.1 in.)

W2200

2258 mm (88.9 in.)

W2300

2258 mm (88.9 in.)

W2400

–

– 2358 mm (92.8 in.)

W2050

482 mm (19.0 in.)

W2200

482 mm (19.0 in.)

W2300

482 mm (19.0 in.)

W2400

–

– 582 mm (22.9 in.)

Mast tilt angle (forward - backward)

15˚ – 12˚

Type of forks

Heel free Length Width ∞ thickness

Front overhang (with standard fork)

14-2

892 mm (35.1 in.)

600 mm (23.6 in.)

Free lift

Fork

FP160AM

767 mm (30.20 in.)

W2300 W2400

4FP135AM

1220 mm (48.0 in.) 180 × 70 mm (7.1 × 2.8 in.) 754 mm (29.7 in.)

180 × 90 mm (7.1 × 3.5 in.) 793 mm (31.2 in.)

795 mm (31.3 in.)

FORK POSITIONER

3. Structure

5 3 2 1

4 210160

1 Lift bracket

5 Mast

2 Side roller

6 Piping

3 Main roller

7 Fork positioner cylinder

4 Fork

The fork positioner is an attachment that enables the outside fork spread to be adjusted steplessly from the maximum position to the minimum position and vice versa. When handling loads of different sizes, the spread of the fork must be change frequently to ensure stability of the load. The positioner for application to large trucks has a hydraulic cylinder which can change the spread of heavy forks smoothly. The fork positioner, which is intended for adjusting the fork spread before picking up a load, cannot shift the raised load from side to side. The forks are hanged from the guide bars and connected to the rod side of the fork positioner cylinder. The head side of fork positioner cylinder is attached to the corresponding fork prong and lift bracket, and slide the fork prong sideways by extending or retracting itself. The right and left fork prongs can shift independently.

14-3

FORK POSITIONER

4. Suggestions for Removal and Installation 4.1 Removal

3 6 8

2 2

1 1

210161

Removal procedure 1 Hose

5 Fork

2 Fork positioner cylinder

6 Fork bracket

3 Lift bracket

7 Main roller (If no abnormality is found, do not disassemble it.)

4 Guide bar

8 Side roller (If no abnormality is found, do not disassemble it.)

Preparation (1) Park the lift truck on a flat, level and solid ground. (2) Start the engine, and fully compress the fork positioner cylinder. (3) Raise the mast vertically and lower the forks down to the pallet for easy removal. (4) Place the wooden blocks under the lift bracket.

14-4

(5) Stop the engine, and move the fork positioner lever back and forth several times so that the remaining pressure in the lines is completely removed.

FORK POSITIONER

4.2 Suggestions for Removal 1. Removing hydraulic hoses

(1) Prepare containers to receive oil, which should remain in the cylinder and hydraulic hoses. (2) Disconnect the hydraulic hoses from the pulleys and attach the connectors sized to G 1/2B at each end to their open ends for securing the closed oil flow circuit. Be sure to mate hoses between Aâ&#x20AC;&#x2122;s and Bâ&#x20AC;&#x2122;s in the figure at the right.

210552

2. Removing fork positioner cylinder

(1) Remove the cylinder rod from its connector while exercising care not to damage the threaded part.

CAUTION This removal is recommended to be performed with the cylinder rod fully retracted.

3. Removing forks

(1) Connect to fork 5 a wire rope with a vise-type clamp

(2) (3)

(4)

(5)

attached on both ends to hold each prong, and tighten the rope using the crane. Remove the stopper plate and pull out the guide bar 4. Start the engine and raise the lift bracket to such a height (about 25 mm (0.98 in.) above the bottom) at which the heel hold part of fork 5 becomes free, then back the truck away. Combine the removed forks 5 (2 pieces) together and tie them with a rope, etc. to prevent from falling. Then, move it to a safe place. Place the supporting wooden blocks under the lift bracket.

210553

14-5

FORK POSITIONER

4. Removing lift bracket

(1) Remove the split pins from the lift chain, and remove the anchor nut and lock nut. (2) Remove the lift bracket with the following procedure. (a) Bind the ends of the two lift chains with a rope, etc. Leave an approximately 3 m (9.8 ft) long extras at the ends of the rope.

(b) Bind the four hoses in the same manner with a rope, leaving an approximately 3 m (9.8 ft) extras at the ends of the rope.

(c) Start the engine and raise the inner mast up to a position where the main rollers of the lift bracket come out. At this point, pull the lift chains and hoses taut by drawing the attached rope downward to prevent them from coming off from the chain wheels or hose reels.

(d) When the inner masts reach to the position where the main rollers of the lift bracket can be removed, reverse the truck, and separate the lift bracket from the truck.

CAUTION When raising the mast, never touch any control levers except the lift lever.

4.3 Inspection and Repair 1. Lift bracket

(1) Check the main rollers and side rollers for sticking, wear or cracks.

(2) Check the welds of the lift bracket for cracks. (3) Check the guide bars whether they are bent or deformed. 2. Fork

(1) Check the forks for bend, misalignment of tips, and cracks. 3. Hose

(1) Replace the hoses every two years.

14-6

210554

FORK POSITIONER

4.4 Installation Replacement must follow the reverse order of removal. 4.4.1 Suggestions for Installation 1. Driving in main roller

(1) For this operation use a driving jig and exercise care not to hit the outer ring of the roller. 2. Installing lift chains

(1) Lift chains can be replaced as-is unless the positions of the upper lock nuts are modified. Tighten the lock nuts and anchor nuts to the specified torque. Nut tightening torque

393 N•m (40.1 kgf•m) [290.0 lbf•ft]

3. Adjusting hose tension

(1) The tension of each hose should be 196 N (20.0 kgf) [44.1 lbf]. When the midpoint of a 1 m (3.28 ft) long hose is pushed with a force of 9.8 N (1.0 kgf) [2.2 lbf], its tension is appropriate when it deflects approx. 12.5 mm (0.49 in.). Adjust tension according to the length of hoses which differs with the raised height of the mast. For example, if the hose length is 2 m (78.7 in.) from the pulley to the bottom joint when the mast is raised to the highest position, the tension of the hose is acceptable if it deflects 25 mm (0.98 in.) when the hose is pushed with a force of 9.8 N (1.0 kg) [2.2 lbf].

12.5 mm (0.49 in.) 9.8 N (1.0 kgf) [2.2 lbf]

210555

14-7

FORK POSITIONER

5. Fork positioner cylinder 5.1 Disassembly

4 3

7 10 5

210165

Disassembly sequence 1 Guide bushing

7 Piston

2 O-ring

8 Backup ring

3 Dust seal

9 O-ring

4 Rod packing

10 O-ring

5 Collar

11 Piston rod

6 Self-locking nut

12 Cylinder tube

14-8

FORK POSITIONER

Suggestion for disassembly 1. Removing guide bushing

(1) Turn up the calking at the cylinder tube. (2) Wrap the cylinder tube with a piece of waste cloth, and hold it in a vise. Remove the guide bushing with Hook Wrench A. Special tool Hook wrench Ă&#x2021;`

05312 - 20520 A

210557

5.2 Inspection and Repair 1. Cylinder tube

(1) Check the inside surface of the cylinder for wear, damage, or rust.

(2) Check the welds for cracks, damage, and dent. 2. Piston rod

(1) Check the piston rod for runout. Support both ends of the piston rod with V-shaped blocks, and measure its runout using a dial gauge at the center while turning the piston rod. If 1/2 of dial indicator reading exceeds the limit, replace the piston rod. Deflection of piston rod (1/2 of dial indicator reading)

Repair service limit

1.0 mm (0.039 in.) 210558

(2) Check the rod surfaces for rust, damage, sliding flaws, and dent. (3) When any of the thread parts are excessively damaged, replace the piston rod. 3. Piston rod

(1) Replace the seal kit parts with new ones.

14-9

FORK POSITIONER

Attachment Model

FP120AM

4FP135AM

FP160AM

Bore diameter of cylinder tube 1

Standard value

45 mm (1.77 in.)

Outside diameter of piston rod 2

Standard value

25 mm (0.98 in.)

Standard value

0.5 mm (0.020 in.), maximum

Repair or service limit

1.0 mm (0.039 in.)

W2050

Standard value

767 mm (30.20 in.)

W2200

Standard value

842 mm (33.15 in.)

–

W2300

Standard value

892 mm (35.12 in.)

W2400

Standard value

–

942 mm (37.09 in.) 892 mm (35.12 in.)

W2050

Standard value

W2200

Standard value

50 mm (1.97 in.)

–

W2300

Standard value

–

W2400

Standard value

–

Overall length when fully contracted 6

Standard value

1115 mm (43.90 in.)

Self-locking nut tightening torque 7

Standard value

200 N•m (20.4 kgf•m) [148 lbf•ft]

Guide bushing tightening torque 8

Standard value

250 N•m (25.5 kgf•m) [184 lbf•ft]

Deflection of piston rod 3 (1/2 of dial indicator reading)

Stroke 4 Fork positioner cylinder

Length of collar 5

125 mm (4.92 in.)

7 4

5 6 210656

14-10

FORK POSITIONER

5.3 Reassembly

11 10

∗ Seal kit parts

∗ ∗

∗

∗ ∗ ∗

6 210168

Reassembly sequence 1 Piston

7 Collar

2 O-ring

8 Cylinder tube

3 O-ring

9 Guide bushing

4 Backup ring

10 Rod packing

5 Piston rod

11 Dust seal

6 Self-locking nut

12 O-ring

Suggestion for reassembly 1. Preparation

(1) During reassembly, do not forget to replace the Seal Kit parts marked with an asterisk (*) in the figure. (2) Thoroughly clean all parts before reassembly making sure they are completely free from dirt or dust. 2. Tightening of self-locking nut

(1) Insert piston 1 into piston rod 3, and tighten self-locking nut 4 to the specified torque. 200 N•m (20 kgf•m) [148 lbf•ft]

Torque

CAUTION If the self-locking nut has been used two or three times, replaced it with a new one.

14-11

FORK POSITIONER

3. Inserting rod packing and dust seal

(1) Insert rod packing 8 into guide bushing 7 with the main lip facing inward. (2) Insert dust seal 9 into the guide bushing with the main lip facing outward. 4. Tightening of guide bushing

(1) Tighten guide bushing 7 to the specified torque. Torque

250 N•m (25 kgf•m) [184 lbf•ft]

(2) Calk the cylinder tube at the guide bushing.

6. Inspection and Adjustment Inspecting right and left shift amounts

(1) After reassembly, make sure that both the right and left forks can move across their full stroke within the frame.

14-12

210561

FORK POSITIONER

7. Troubleshooting • Insufficient oil in hydraulic tank

• Add hydraulic oil.

• Too low gear pump delivery rate

• Replace pump assembly.

• Overload relief valve defects (1) Too low valve opening pressure setting • Adjust overload relief valve. (2) Defective pilot valve seat surface or foreign • Replace overload relief valve assembly matter in valve or disassemble and clean it. (3) O-ring in valve case damaged • Replace O-ring. Shifts of right and left fork (4) Pilot valve spring wearing prongs too slow or sluggish • Replace overload relief valve assembly. • Shift speed differs between the right and left • Cylinder defects (1) Foreign matter lodged in rod packing (2) Scratches on bore of rod packing (3) Piston O-ring damaged (4) Abnormal distortion

• Adjust with flow rate adjustment valve. • Replace rod packing. • Replace rod packing. • Replace piston O-ring. • Replace.

Unsmooth shifts of fork:

• Scratches or rust on guide bar

• Repair and apply grease.

(1) Jamming (2) Too large looseness

• Scars on lift bracket to fork contact surfaces

• Repair and apply grease.

• Scars on guide bar surface of forks

• Repair and apply grease.

• Bent fork

• Replace.

• Uneven loading

• Instruct operator to handle only loads within indicated capacity.

Misaligned fork tips

14-13

FORK POSITIONER

8. Service Data Attachment Model

FP120AM

4FP135AM

FP160AM

Bore diameter of cylinder tube 1

Standard value

45 mm (1.77 in.)

Outside diameter of piston rod 2

Standard value

25 mm (0.98 in.)

Standard value

0.5 mm (0.020 in.), maximum

Repair or service limit

1.0 mm (0.039 in.)

W2050

Standard value

767 mm (30.20 in.)

W2200

Standard value

842 mm (33.15 in.)

–

W2300

Standard value

892 mm (35.12 in.)

W2400

Standard value

–

942 mm (37.09 in.) 892 mm (35.12 in.)

W2050

Standard value

W2200

Standard value

50 mm (1.97 in.)

–

W2300

Standard value

–

W2400

Standard value

–

Overall length when fully contracted 6

Standard value

1115 mm (43.90 in.)

Self-locking nut tightening torque 7

Standard value

200 N•m (20.4 kgf•m) [148 lbf•ft]

Guide bushing tightening torque 8

Standard value

250 N•m (25.5 kgf•m) [184 lbf•ft]

Deflection of piston rod 3 (1/2 of dial indicator reading)

Stroke 4 Fork positioner cylinder

Length of collar 5

125 mm (4.92 in.)

7 4

5 6 210656

14-14

SERVICE DATA 1. Maintenance Chart..................................................................................................... 15-2 2. Tightening torque of standard bolts............................................................................ 15-7 2.1 Metric screw thread for automobiles ................................................................................................... 15-7 2.2 Metric Coarse Thread ......................................................................................................................... 15-8

3. Lubrication Standards ................................................................................................ 15-9 3.1 Fuel and Lubricant Specifications ....................................................................................................... 15-9 3.2 Capacity ............................................................................................................................................ 15-10

15 15-1

SERVICE DATA

1. Maintenance Chart

Brake

Others (See Note 1)

Yearly (2000 hrs)

Every 6 months (1000 hrs)

Every 3 months (500 hrs)

1st Month (200 hrs) Only

Inspection Point

Weekly (50 hrs)

System

Prestart (Daily/10 hrs)

: Check or Clean : Change or Adjust

Service Data

Check Brake Pipes & Joints

Check Brake Pedal (from floor to top of pedal)

Free Play: 15 mm (0.6 in.) Pedal height (to top of pedal pad): 190 mm (7.48 in.)

Check Service Brake Fluid Level Change Service Brake Fluid

240 cc (114.6 cu in.)

Check Brake Air Master Change Brake Master Cylinder Hoses & Rubber Parts Change Brake Wheel Cylinder Hoses & Rubber Parts Check Brake Control Valve

Check Parking Brake Lever

Operating effort: 245 to 294 N (25 to 30 kgf) [55 to 66 lbf]

Check Parking Brake Cable Check Center Brake Drum & Shoes Check Service Brake Drum & Shoes Check Brake System Check Wet Brake Change Wet Brake Fluid Check / Drain Water of Air Tank Check Air Drier Desiccant Change Air Drier Desiccant Cooling

Check & Clean Radiator Fins (See Note 2) Check Cooling Fan Check Fan Belt Tension Check Engine Coolant Level Change Engine Coolant Check Rubber Hose Condition Check Radiator Filler Cap Lubricate Water Pump

15-2

Change every 12 months or 1000 hours, 18 liters (4.7 U.S. gal.)

SERVICE DATA

Electrical

Others (See Note 1)

Yearly (2000 hrs)

Every 6 months (1000 hrs)

Every 3 months (500 hrs)

1st Month (200 hrs) Only

Inspection Point

Weekly (50 hrs)

System

Prestart (Daily/10 hrs)

: Check or Clean : Change or Adjust

Service Data

Check Alternator Check Battery (Electrolyte Level) Check Battery (Electrolyte Specific Gravity)

1.265 or above

Check Loosen & Damage of Battery Terminal Check Driving Interlock System Check Electrical Wires Check Horn Check Instrument Panel Lamp (Incl. Parking Brake, Seat Belt) Check Mast Interlock System Check Parking Brake Buzzer Check Starter Check Voltage, Current & Other Electric System Check Lights & Turn Signal Check Gauges Engine

Check Leaks (Damage & Wear of Hose) Check Cylinder Head Bolt & Manifold Nut Check Engine (Exhaust, Noise, Vibration) Check Engine Idle Speed Check Max. Speed Without Load & Hunting Check Compression Pressure

2940 kpa (30 kgf/cm2) [426 psi] at 200 rpm

Check Intake & Exhaust Valve Clearance

0.6 mm (0.023 in.) in cold state

Check Engine Oil Level Change Engine Oil

Change every 3 months or 500 hours 16 liters (4.2 U.S. gal.)

Change Engine Oil Filter

Change every 3 months or 500 hours

Check Turbocharger Check PCV Valve & Hose Change Element of PCV Valve Filter (See Note 3) Check Recycle System of Exhaust Gas Check Air Compressor Check Exhaust Pipe & Muffler

Cat DP150N Forklift Engine Parts Phone: 1 269 673 1638 Contact email: EngineParts@HeavyEquipmentRestorationParts.com www.dp150.com/cat-dp150-engine-parts

15-3

SERVICE DATA

Frame & Chassis

Others (See Note 1)

Yearly (2000 hrs)

Every 6 months (1000 hrs)

Every 3 months (500 hrs)

1st Month (200 hrs) Only

Inspection Point

Weekly (50 hrs)

System

Prestart (Daily/10 hrs)

: Check or Clean : Change or Adjust

Service Data

Check Overhead Guard & Assist Grip Check Loosen Bolts or Nuts Check Seat Adjustment Check Seat Belt Lubricate Each Part Check Horns, Wipers, Window Washer, Defroster & Key Check Rear View Mirror & Foot Step

Fuel

Check Fuel Leaks (Damage & Wear of Hose) Check Fuel Level Change Fuel Hose

175 liters (46.2 U. S. gal.) ***

Change every 6 months or 1000 hours

Change Fuel Filter (See Note 3) Check Water Separator (See Note 3) Change Water Separator Element Check Fuel Tank Check High Pressure Fuel Pipe Hydraulic

Check Oil Leaks & Function of Control Valve Check Control Valve Relief Pressure Check Hydraulic Hose, Pipes & Joints Change Hydraulic High Pressure Hose

Check Hydraulic Oil Level

Change Hydraulic Oil

Change Hydraulic Tank Strainer Change Hydraulic Tank Return Oil Filter Check Oil Leaks of Hydraulic Pump Check Hydraulic Motor, Cylinder, Safety Valve, Solenoid Valve etc. Check Mast & Fork, & Hydraulic System

15-4

Change oil every 12 months or 2000 hours, N Level: DP100N-135N 140 liters (37.0 U.S. gal) DP150N 168 Liters (44.4 U.S. gal) DP160N 48.6 Liters (48.6 U.S. gal)

SERVICE DATA

Intake

Clean Air Cleaner Element

Others (See Note 1)

Yearly (2000 hrs)

Every 6 months (1000 hrs)

Every 3 months (500 hrs)

1st Month (200 hrs) Only

Inspection Point

Weekly (50 hrs)

System

Prestart (Daily/10 hrs)

: Check or Clean : Change or Adjust

****

Change every 6 months or 1000 hours

Change Air Cleaner Element Front End

Service Data

Check Damage & Distortion of Chain Lubricate Lift Chains Service limit: DP100N-135N 915 mm (36 in.) DP150N-160N 1046 mm (41 in.)

Check Elongation of Chain (20 links)

Change Lift Chains

***

Check Lift Cylinder Check Lift Cylinder Mounting Bolts Check/ Lubricate Mast Support Lubricate Tilt Socket Pins Check Mast, Lift Bracket & Forks Check Lift Bracket Main Rollers & Side Rollers Check Mast Strip Sliding Surfaces Check Tilt Cylinder Socket Nuts Check Tilt Cylinder Function Check Chain Wheel & Anchor Bolt Check Oil Leaks of Flow Regulator Valve Check Fork Lowering Speed Steering & Axle

Check Oil Leaks & Damage of Piping Check Front Axle Check Power Steering Cylinder Change Power Steering Cylinder Hoses & Rubber Parts

Check Rear Axle Check Rear Wheel Bearing Check Steering Control Valve Check Priority Valve Check Steering Wheel Check Steering Column Check Steering Knuckle & Tie Rod King Pin Check Steering Knuckle Check Steering Angle, Knuckle, Rod & Arm

15-5

SERVICE DATA

Transmission & Drive

Others (See Note 1)

Yearly (2000 hrs)

Every 6 months (1000 hrs)

Every 3 months (500 hrs)

1st Month (200 hrs) Only

Inspection Point

Weekly (50 hrs)

System

Prestart (Daily/10 hrs)

: Check or Clean : Change or Adjust

Service Data

Check Differential Oil Level Change Differential Oil

Change every 6 months or 1000 hours 20 Liters (5.2 U. S. gal.)

Check Differential Mounting Bolts Check Differential Wheel Bearing Check Accelerator Pedal Check Inching Pedal Check Transmission Gear & Bearing Check Transmission Oil Level Change Transmission Oil

Change every 6 months or 1000 hours 23 liters (6.07 U.S. gal.)

Clean Transmission Strainer

Clean or change every 6 months or 1000 hours

Change Transmission Oil Filter

Change every 6 months or 1000 hours

Clean Last Chance Filter (Transmission Control Valve)

Clean or change every 6 months or 1000 hours

Lubricate Universal Joint Check Propeller Shaft Check Propeller Shaft Connections Check Tires & Rims Check Wheels & Wheel Nuts General

Oil, Fuel & Coolant Leak (Walk around) Damage Or Faulty Operation Found The Day Before Lubricate All Grease Nipples

Note 1

* Change every 1â&#x20AC;&#x201C;2 years ** Change every 2 years *** Change every 2â&#x20AC;&#x201C;4 years **** Every 2 weeks or 100 service hours

Note 2

In corrosive or abrasive environments check, clean, lubricate and change more frequently.

Note

When fuel with poor quality is used, check, drain, clean and change more frequently.

15-6

SERVICE DATA

2. Tightening torque of standard bolts 2.1 Metric screw thread for automobiles With spring washer

101656

Nominal size mm

Pitch mm

7.4 N·m

9.6 N·m

12.7 N·m

1.25

16.7 N·m

22.6 N·m

30.4 N·m

1.25

34.3 N·m

45.1 N·m

69.6 N·m

1.25

63.7 N·m

82.4 N·m

122.6 N·m

1.5

102.0 N·m

132.4 N·m

192.2 N·m

1.5

157.9 N·m

202.0 N·m

287.3 N·m

1.5

224.6 N·m

292.2 N·m

413.8 N·m

1.5

310.9 N·m

404.0 N·m

573.8 N·m

1.5

413.8 N·m

537.5 N·m

763.0 N·m

1.5

547.2 N·m

711.0 N·m

1006.2 N·m

1.5

794.3 N·m

1032.6 N·m

1451.1 N·m

1.5

1100.3 N·m

1430.8 N·m

2012.3 N·m

1.5

1467.1 N·m

1907.4 N·m

2680.2 N·m

1.5

1918.2 N·m

2493.8 N·m

3497.1 N·m

1.5

2461.5 N·m

3198.8 N·m

4469.9 N·m

Without spring washer

101656

Nominal size mm

Pitch mm

8.6 N·m

10.8 N·m

14.7 N·m

1.25

19.6 N·m

26.5 N·m

36.6 N·m

1.25

41.2 N·m

53.0 N·m

81.4 N·m

1.25

74.5 N·m

97.1 N·m

144.2 N·m

1.5

119.6 N·m

155.9 N·m

226.5 N·m

1.5

182.4 N·m

237.3 N·m

338.3 N·m

1.5

263.8 N·m

343.2 N·m

487.4 N·m

1.5

365.8 N·m

475.6 N·m

674.7 N·m

1.5

486.4 N·m

632.5 N·m

897.3 N·m

1.5

643.3 N·m

836.5 N·m

1183.7 N·m

1.5

934.6 N·m

1216.0 N·m

1707.3 N·m

1.5

1294.5 N·m

1682.8 N·m

2367.3 N·m

1.5

1726.0 N·m

2243.8 N·m

3153.8 N·m

1.5

2256.5 N·m

2934.1 N·m

4114.0 N·m

1.5

2896.0 N·m

3763.8 N·m

5258.3 N·m

15-7

SERVICE DATA

2.2 Metric Coarse Thread With spring washer

101657

Nominal size mm

Pitch mm

1.5

33.3 N·m

43.1 N·m

67.7 N·m

1.75

58.8 N·m

76.5 N·m

115.7 N·m

96.4 N·m

124.5 N·m

182.4 N·m

147.1 N·m

191.2 N·m

274.6 N·m

2.5

203.0 N·m

264.8 N·m

383.4 N·m

2.5

286.4 N·m

371.7 N·m

536.4 N·m

2.5

383.4 N·m

499.2 N·m

725.9 N·m

492.3 N·m

640.4 N·m

924.8 N·m

724.7 N·m

942.2 N·m

1350.4 N·m

3.5

969.9 N·m

1259.2 N·m

1843.7 N·m

3.5

1328.8 N·m

1727.0 N·m

2477.2 N·m

1676.0 N·m

2180.0 N·m

3199.9 N·m

2219.2 N·m

2884.1 N·m

4118.8 N·m

4.5

2754.7 N·m

3581.4 N·m

5137.7 N·m

Without spring washer

15-8

101657

Nominal size mm

Pitch mm

1.5

39.2 N·m

51.0 N·m

79.4 N·m

1.75

69.6 N·m

90.2 N·m

135.3 N·m

112.8 N·m

146.1 N·m

215.7 N·m

172.6 N·m

224.6 N·m

323.6 N·m

2.5

239.3 N·m

311.9 N·m

451.1 N·m

2.5

336.4 N·m

437.4 N·m

630.6 N·m

2.5

392.3 N·m

587.4 N·m

842.4 N·m

578.6 N·m

753.2 N·m

1088.5 N·m

852.2 N·m

1108.2 N·m

1588.7 N·m

3.5

1140.5 N·m

1481.8 N·m

2168.3 N·m

3.5

1563.2 N·m

2031.9 N·m

2915.5 N·m

1972.1 N·m

2564.4 N·m

3765.8 N·m

2610.5 N·m

3393.1 N·m

4845.5 N·m

4.5

3241.1 N·m

4212.9 N·m

6044.8 N·m

SERVICE DATA

3. Lubrication Standards 3.1 Fuel and Lubricant Specifications Fuels and Oils

Available lubricant/ fuel brand

Specification

-5˚C or higher: JIS Grade 2 -15 to -5˚C: JIS Grade 3 -15˚C or lower: IS Extra Grade 3

Fuel

Diesel oil

Engine oil

ENEOS Diesel Oil Touring

API service classification CF or better

Gear oil

ENEOS Super Hypoid Gear

GL-5

Torque converter oil

ENEOS ATF-II (N)

Hydraulic oil

ENEOS FBK RO32

ISO VG32

Brake fluid

ENEOS Brake Fluid

FMVSS DOT3 or DOT4

Wheel bearing

ENEOS Powerknock WB2

NLGI No. 2 (Lithium base consistency: 271)

Chassis

ENEOS Epiknock Grease AP1

NLGI No. 1 (Lithium base consistency: 315)

Grease

Anti-freeze (replace every two years)

Service range

-10˚C or higher: SAE90 -10˚C or lower: SAE80

GL-4

MHI Long Life Coolant

0˚C or higher: SAE30 -10 to 10˚C: SAE20W -10˚C or lower: SAE10W or SAE10W-30

-10˚C or higher: SAE10W -10˚C or lower: SAE5W

Ambient temperature (˚C)

-39

-30

-25

-20

-15

-10

Anti-freeze concentration (%)

WARNING The oil characteristics varies with each manufacturer. Do not mix different brands of oil for use.

15-9

SERVICE DATA

3.2 Capacity Truck model

DP100N

Fuel tank Engine coolant

DP135N

DP150N

Engine, radiator

17.35 Liters (4.6 U.S. gal.)

Reserve tank

0.65 Liters (0.17 U.S. gal.) 18 Liters (4.7 U.S. gal.)

Oil pan

12 Liters (3.2 U.S. gal.)

Oil Filter

4 Liters (1.0 U.S. gal.) Total

16 Liters (4.2 U.S. gal.)

Torque converter oil

23 Liters (6.1 U.S. gal.)

Differential gear oil Final drive gear oil

20 Liters (5.3 U.S. gal.)

Hydraulic oil

Brake fluid

15-10

DP160N

175 Liters (46.2 U.S. gal.)

Total Engine oil

DP120N

N Level: 140 Liters (37.0 U.S. gal.)

240 cc

N Level: 168 Liters (44.4 U.S. gal.)

N Level: 184 Liters (48.6 U.S. gal.)

Service Manual 6M60-TL Diesel Engine

For use with the P17500-P36000, DP80N-DP160N Service Manuals.

99709-61100

(for industrial use)

GROUP INDEX GENERAL........................................ ENGINE............................................ LUBRICATION ................................. FUEL AND ENGINE CONTROL...... ELECTRONICALLY CONTROLLED FUEL SYSTEM ..................................

FOREWORD This Shop Manual is published for the information and guidance of personnel responsible for maintenance of the Mitsubishi 6M60-TL series diesel engine, and includes procedures for adjustment and maintenance services.

COOLING......................................... INTAKE AND EXHAUST ................. EMISSION CONTROL .....................

We earnestly look forward to seeing that this manual is made full use of in order to perform correct services with no wastage.

ELECTRICAL...................................

For more details, please consult your nearest authorized CatÂ® lift truck dealer.

SPECIAL EQUIPMENT ...................

00 11 12 13A 13E 14 15 17 54 61

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.

SEPTEMBER 2006 Applicable models 6M60-TL

GROUP 00 GENERAL 00 HOW TO READ THIS MANUAL ......................................................... 00-2 ENGINE NUMBER ............................................................................ 00-7 PRECAUTIONS FOR MAINTENANCE OPERATION ....................... 00-8 DIAGNOSTIC CODES 1. 2. 3. 4.

Using Multi-Use Tester .............................................................. Use of Blinking Warning Lamp for Diagnostic Code .................... Diagnozer Service Tool Functions ................................................. Troubleshooting ...............................................................................

00-17 00-19 00-21 00-29

13A 13E

TABLE OF STANDARD TIGHTENING TORQUES .......................... 00-31

00-1

HOW TO READ THIS MANUAL This manual consists of the following parts: • Specifications • Structure and Operation • Troubleshooting • General Inspection and Adjustment • Service procedures General Inspection and Adjustment • Procedures for inspection and adjustment of individual parts and assemblies as mounted on the machine are described including specific items to check and adjust. Specified or otherwise, inspection should be performed for looseness, play, backlash, crack, damage, etc. Service procedure • Procedures for servicing components and parts off the machine are described centering on key points in their removal, installation, disassembly, reassembly, inspection, etc. Inspection • Check items subject to “acceptable/unacceptable” judgement on the basis of service standards are all given. • Some routine visual checks and cleaning of some reused parts are not described but must always be included in actual service work. Caution • 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, may result in damage to or destruction of equipment or parts.

NOTE

Suggestions or supplementary information for more efficient use of equipment or better understandings.

Terms and Units • Front and rear The forward running direction of the machine is referred to as the front and the reverse running direction is referred to as the rear. • Left and right Left hand side and right hand side, when facing the forward running direction of the machine, are respectively left and right. 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. 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.

00-2

00 Tightening torque • Values are directly specified for out-of-standard tightening torques for bolts and nuts. • 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. Units • Tightening torques and other parameters are given in SI* units with metric units added in brackets { }. Values in engine specifications, performance curves, and other items taken from official approval documents are given only in metric units. *SI: Le Système International d’Unités Example: 390 N·m {40 kgf·m} Metric unit SI unit Item

SI unit {metric unit}

Force Moment of force Positive pressure Pressure

Vacuum pressure

Volume Heat quantity

Conversion factor

N {kgf}

9.80665 N {1 kgf}

N·m {kgf·m}

9.80665 N·m {1 kgf·m}

kPa {kgf/cm2}

98.0665 kPa {1 kgf/cm2}

kPa {mmHg}

0.133322 kPa {1 mmHg}

Pa {mmH2O}

9.80665 Pa {1 mmH2O}

dm3 {L}

1 dm3 {1 L}

J {kcal}

4186.05 J {1 kcal}

W {kcal/h}

1.16279 W {1 kcal/h}

Power

kW {PS}

0.7355 kW {1 PS}

Angle

–

Temperature

˚C

–

Electric current

–

Voltage

–

Resistance

–

Electric power

–

Heat flow

Unit

SI unit

Foot-pound unit

Conversion rate

Force

N (Newton)

lbf

1 N = 0.2248 lbf

Moment of force

N·m

lbf.ft

1 N·m = 0.7375 lbf.ft

Pressure

kPa (kilopascal)

lbf/in.2

1 kPa = 0.145 lbf/in.2 1 kPa = 0.2953 in. Hg

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.

Volume

Power

kW (kilowatt)

1 kW = 1.34 HP

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

m mm

ft. in.

1 m = 3.2808 ft. 1 mm = 0.03937 in.

Stress

N/cm2

lbf/in.2

1 N/cm2 = 1.45 lbf/in.2

00-3

HOW TO READ THIS MANUAL Symbol

Denotation Tightening torque

00-4

Application Parts not tightened to standard torques (standard torques specified where necessary for servicing)

Remarks Specified values shown in table See Table of Standard Tightening Torques for parts for which no tightening torques are specified.

Locating pin

Parts to be positioned for installation

Non-reusable parts

Parts not to be reused

Lubricant and/or sealant

Parts to be coated with lubricant or sealant for assembly or installation

Special tool

Parts for which special tools are required for Tool name/shape and part number are shown in service operation table.

Associated part

Parts associated with those removed/disassembled for servicing

Necessary lubricant and/or sealant, quantity required, etc. are specified in table.

00-5

HOW TO READ THIS MANUAL How to Use Diagnostic Codes <Electronically Controlled Fuel System (Gr13E)>

TROUBLESHOOTING

This section suggests areas to inspect for each diagnostic code.

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

Diagnostic Procedure Diagnostic Precautions Inspections Based On Diagnostic Codes Multi-use Tester Service Data Actuator Tests Performed Using Multi-use Tester Inspections Performed At Electronic Control Unit Connectors

There are the diagnostic code and message displayed on Multi-Use Tester. Numerical values in parenthesis are added only when a diagnostic code indicated in the Multi-Use Tester display differs from the code indicated by the number of warning lamp flashes. P125A: Common Rail Pressure M/V1 (high) (warning lamp flashes: 63) Code generation criteria

MPROP1 (rail pressure control valve) voltage is above standard valve.

Resetability

System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON.

Electronic control unit control

• Engine is stopped. • Exhaust gas recirculation control is stopped.

Inspection item

Service data

0C: Difference Common Rail Pressure

Actuator test

B9: Fuel Leak Check

Electronic control unit connector Electrical part

08 : Resistance of MPROP (rail pressure control valve)

#574: MPROP1 (rail pressure control valve)

Refer to “Inspection of Electrical Equipment.”

The contents of this manual include functions and parts that are not used in your truck depending on the truck specifications. Please refer to the chassis service manual for the details.

00-6

ENGINE NUMBER

• Serial engine numbers are assigned to the engines in manufacturing sequence. Every engine has its own number. These numbers are required for registration and related inspection of the vehicle.

• An engine nameplate indicates the following item. • Engine model

00-7

PRECAUTIONS FOR MAINTENANCE OPERATION • Before performing service operations, inquire into the customer’s complaints and ascertain the conditions by checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors about the vehicle. And note the necessary information. This information will help you to service the truck efficiently. • Check the location of the fault, and identify its cause. Based on your findings, determine whether parts must be removed or disassembled. Then, follow the service procedure given in this manual. • Prepare all the general and special tools necessary for the job.

WARNING • Special tools must be used wherever specified in this manual. Do not attempt to use other tools since they could cause injuries and/or truck damage.

• Take extreme care when removing/installing heavy items such as engine, transmission and axle. When lifting heavy items using a cable etc., observe the following precautions. • Identify the weight of the item being lifted. Use a cable that is strong enough to support the weight.

• If lifting eyes are not provided on the item being lifted, tie a cable around the item taking into account the item’s center of gravity.

• Never work in shoes that have oily soles. When working with a partner or in a group, use pre-arranged signals and pay constant attention to safety. Be careful not to touch switches and levers unintentionally.

• Inspect for oil leakage etc. before washing the vehicle. If the order is reversed, any oil leakage or fault that may exist could go unnoticed during inspection.

00-8

00 • Prepare replacement parts ready for installation.

• Oil seals, packings, O-rings and other rubber parts, gaskets, and split pins must be replaced with new ones after removal. Use only genuine Cat replacement parts.

P00015

• When disassembling parts, visually check them for wear, cracks, damage, deformation, deterioration, rust, corrosion, defective rotation, fatigue, clogging and any other possible defect.

• To facilitate correct reassembly of parts, make alignment marks on them before disassembly and arrange disassembled parts neatly. Make punch marks and other alignment marks where they will not detract from parts’ functionality and appearance. • After removing parts from the vehicle, cover the area to keep it free of dust.

CAUTION • Be careful not to mix up identical parts, similar parts and parts that have left/right alignments. • Keep new replacement parts and original (removed) parts separately. • Apply the specified oil or grease to U-seals, oil seals, dust seals and bearings before reassembly. • Always use the specified oils and greases when performing inspection or replacement. Immediately wipe away any excess oil or grease with a rag.

00-9

PRECAUTIONS FOR MAINTENANCE OPERATION • Wear safety goggles when using a grinder or welder. Wear gloves when necessary, and watch out for sharp edges and other items that might wound your hands.

• Before working on the electrical system, disconnect the (–) battery cable to prevent short circuits.

CAUTION • Make sure the starter switch and lighting switches are OFF before disconnecting or connecting battery cable. Semiconductor components may otherwise be damaged.

• Carefully handle sensors relays, and other items that are sensitive to shock and heat. Do not remove or paint the cover of any control unit.

• When separating connectors, grasp the connectors themselves rather than the harnesses. • To separate locking connectors, first push them in the direction of the arrows. To reconnect locking connectors, push them together until they click.

• Before washing the vehicle, cover electrical parts to keep them dry. (Use plastic sheets or the like.) Keep water away from harness connectors and sensors and immediately wipe off any water that gets on them.

00-10

00 • When applying a voltage to a part for inspection purposes, check that the (+) and (–) cables are connected properly then gradually increase the voltage from zero. Do not exceed the specified voltage. Remember that control units and sensors do not necessarily operate on the battery voltage.

1. Handling Precautions for Electric Circuits CAUTION • Do not pierce wire insulation with test probes or alligator clips when performing electrical inspections. Piercing the wire harness will cause corrosion.

1.1 Inspection of harnesses (1) Inspections with connectors fitted together (1.1) Waterproof connectors • Connect an inspection harness and connector A between the connectors B of the circuit to be inspected. Perform the inspection by applying a test probe C to the connectors of the inspection harness. Do not insert the test probe C into the wire-entry sides of the waterproof connectors since this would damage their waterproof seals and lead to rust.

(1.2) Non-waterproof connectors • Perform the inspection by inserting a test probe C into the wireentry sides of the connectors. An extra-narrow probe is required for control unit connectors, which are smaller than other types of connector. Do not force a regular-size probe into control unit connectors since this would cause damage.

(2) Inspections with connectors separated (2.1) Inspections on female terminals • Perform the inspection by carefully inserting a test probe into the terminals. Do not force the test probe into the terminals since this could deform them and cause poor connections.

00-11

PRECAUTIONS FOR MAINTENANCE OPERATION (2.2) Inspections on male terminals • Perform the inspection by applying test probes directly to the pins. .

CAUTION • Be careful not to short-circuit pins together with the test probes. With control unit connectors, short-circuiting of pins can cause damage to the control unit’s internal circuitry.

• When using a multimeter to check continuity, do not allow the test probes to touch the wrong terminals.

1.2 Inspection of connectors (1) Visual inspection • Check that the connectors are fitted together securely.

• Check whether wires have been separated from their terminals due to pulling of the harness.

• Check that male and female terminals fit together tightly.

00-12

00 • Check for defective connections caused by loose terminals, by rust on terminals, or by contamination of terminals by foreign substances. (2) Checking for loose terminals • If connector terminal retainers become damaged, male and female terminals may not mate with each other when the connector bodies are fitted together. To check for such terminals, gently pull each wire and see whether any terminals slip out of their connector housings.

1.3 Inspections when a fuse blows • Remove the fuse, then measure the resistance between ground and the fuse’s load side. Next, close the switch of each circuit connected to the fuse. If the resistance measurement between any switch and ground is zero, there is a short circuit between the switch and the load. If the resistance measurement is not zero, the circuit is not currently short-circuited; the fuse probably blew due to a momentary short circuit. • The main causes of short circuits are as follows: • Harnesses trapped between chassis parts • Harness insulation damage due to friction or heat • Moisture in connectors or circuitry • Human error (accidental short-circuiting of components)

2. Service Precautions for Alternators • When servicing alternators, observe the following precautions: • Never reverse the polarity of battery connections. If the polarity of the battery connections were to be reversed, a large current would flow from the battery to the alternator, damaging the diodes and regulator.

00-13

PRECAUTIONS FOR MAINTENANCE OPERATION • Never disconnect the battery cables with the engine running. Disconnection of the battery cables during engine operation would cause a surge voltage, leading to deterioration of the diodes and regulator.

• Never perform inspections using a high-voltage multimeter. The use of a high-voltage multimeter could damage the diodes and regulator.

• Keep alternators dry. Water on alternators can cause internal short circuits and damage.

• Never operate an alternator with the B and L terminals short-circuited. Operation with the B and L terminals connected together would damage the diode trio.

• Disconnect the battery cables before quick-charging the battery with a quick charger. Unless the battery cables are disconnected, quick-charging can damage the diodes and regulator.

00-14

00 3. Intermittent Faults • An intermittent fault typically occurs only under certain operating conditions. Once these conditions have been identified, the cause of the intermittent fault can be ascertained easily. First, ask the customer about the vehicle operating conditions and weather conditions under which the fault occurs. Also ask about the frequency with which the fault occurs and about the fault symptoms. Then, reproduce the fault based on this information. In accordance with the conditions under which the fault occurs, determine whether the fault is caused by vibration, heat or other factors. if vibration is a possible factor, see if the fault can be reproduced by performing the following checks on individual connectors and other parts: • Gently move connectors up and down and to left and right. • Gently move wiring harnesses up and down and to left and right. • Gently wiggle sensors and other devices by hand. • Gently wiggle wiring harnesses on suspension systems and other moving parts. • Connectors and other parts to be checked are those included or given as likely fault locations in inspection procedures corresponding to diagnostic codes and/or fault symptoms.

00-15

PRECAUTIONS FOR MAINTENANCE OPERATION 4. Precautions for Arc Welding • When arc welding is performed, current from the welder flows to ground via the machine metal parts. Unless appropriate steps are taken, this current can damage control units, other electrical devices and wiring harnesses. And any electrical device near the point on the vehicle to which the (–) cable of the welder is connected, might be largely damaged.

• The current of the welder will flow backward through the battery’s (–) cable and damage the battery and electrical systems directly connected to the battery. Be sure to disconnect the battery’s (–) cable in the following procedure. • Turn the battery switch to the LOCK position. • Turn the starter switch to the LOCK position. • Disconnect the battery’s (–) cable. • Cover all parts of the machine that may be damaged by welding sparks. • Connect the welder’s (–) cable to the machine as close as possible to the area being welded. • Set the welding current in accordance with the part being welded.

00-16

DIAGNOSTIC CODES NOTE:

The Multi-Use tester tool will not be used to service the 6M60-TL diesel engine at this time. Please disregard the Multi-Use Tester information. Diagnozer 2.41 or later software must be used to service the 6M60-TL diesel engine.

1. Using Multi-Use Tester 1.1 Connecting Multi-Use Tester

Special tools Mark

Tool name and shape

Part No.

FMSi-E06-1 (Multi-Use Tester-III version)

Application

Data transmission to/from V.C.I.

N/A

Data transmission between electronic control unit and PC

MH062928

Power supply to V.C.I. and communication with electronic control unit

Multi-Use Tester test harness D (used for extension)

MH062931 (1 m) MH062951 (2 m)

Multi-Use Tester test harness A extension

USB cable

MB991827

Communication between V.C.I. and PC

V.C.I.

Multi-Use Tester harness A

• Move the starter switch to the LOCK position. • Connect , , and as illustrated. • Connect the Multi-Use Tester connector on the vehicle with the connector of .

00-17

DIAGNOSTIC CODES • Use to extend the cable if is not long enough such as when using Multi-Use Tester outside the vehicle.

1.2 Access and Clearing of Stored Diagnostic Code (1) Difference of diagnostic code • There are two types of diagnostic codes – present code and past code. (1.1) (1.2) Present diagnostic code • Fault developed in the machine after the starter switch is set to ON is indicated by corresponding diagnostic code. • The fault warning lamp is lit at the same time. (1.3) Past diagnostic code • Past fault developed in the machine is indicated by corresponding diagnostic code stored in the memory of the electronic control unit. • With the machine restored to its normal condition or the starter switch turned from OFF to ON after inspection or repair against present diagnostic codes, the present diagnostic code is stored as past diagnostic codes in the memory of the electronic control unit. • The warning lamp is not lit because the indicated fault is not present one. (2) Access of diagnostic code • Set the starter switch to ON. • Operate the Multi-Use Tester for a display of necessary diagnostic code stored in the memory of the electronic control unit and identify the location of the fault. (3) Clearing of diagnostic code • Set the starter switch to ON (the engine not to be started). • Operate the Multi-Use Tester to delete all the diagnostic codes stored in the memory of the electronic control unit.

00-18

00 2. Use of Blinking Warning Lamp for Diagnostic Code • Using the diagnostic and memory clear switches, display diagnostic codes.

CAUTION • Opening the memory clear switch followed by its reconnection will erase the stored diagnostic codes from the memory. To avoid inadvertently erasing necessary codes, be sure to read well the procedure described below before handling diagnostic codes.

2.1 Reading diagnostic codes • To read a diagnostic code, observe how may times the warning lamp flashes and how long each illumination lasts. • The duration of illumination differs between the first and second digits. • Second digit: 1.2 sec. • First digit: 0.4 sec. • A diagnostic code consists of the flashing of second digit and the flashing of first digit in that order. If a diagnostic code has “0” in the second digit, only the first digit will be displayed. • The same diagnostic code will be displayed 3 times in a row before moving to the display of the next code. • After the last diagnostic code is displayed, the first code will be displayed again 3 times in a row and then the subsequent codes. This will be repeated.

2.2 Present diagnostic codes • Turn the starter switch ON. • Remove the diagnostic switch. • Diagnostic codes will be displayed (flashing of the warning lamp). • When the diagnostic switch is connected, electronic control unit will immediately stop (terminate) displaying diagnostic codes.

2.3 Present and past diagnostic codes Turn the starter switch to the ON position. Open the diagnostic switch. Open the memory clear switch. The corresponding warning lamp will display diagnostic codes by flashing. • Turn the starter switch to the OFF position, connect the memory clear switch and then connect the diagnostic switch. The electronic control unit terminates (exits) the diagnostic code displaying mode. • • • •

00-19

DIAGNOSTIC CODES 2.4 Erasing diagnostic codes â&#x20AC;˘ Turn the starter switch to the ON position (do not start the engine). â&#x20AC;˘ Open the memory clear switch and reconnect it; all diagnostic codes stored in electronic control unit memory will be erased. To erase diagnostic code after opening the memory clear switch, turn the starter switch to the OFF position and then reconnect the memory clear switch.

00-20

00 3. Diagnozer Service Tool Functions 3.1 Menu Monitor menu • Input Monitor Indicates the input values of the controllers. • Output Monitor Indicates the output values of the controllers. • Custom Monitor Indicates the input/output values of the item selected. • Fault Status Indicates all error codes occurring. • Fault History Indicates the fault data, such as the error codes and hour meter data, stored in the controller.

Tool menu • Set-up Option Indicates or sets the Setup Option data. • Oscilloscope Graphs the input/output values. The oscillograph can be stored as data. • Active Test Outputs the signal forcibly to check the operation of the equipment selected. • Connection Change Designates the controller operated by the service tool and the controller connected to it. • Firmware Update Updates the firmware of the controller connected.

212338

00-21

DIAGNOSTIC CODES 3.2 Input Monitor and Output Monitor These screens indicate the input and output values of each controller. 3.2.1 VCM-3 input monitor and output monitor (VCM-3 â&#x2020;&#x2019; VCM-3)

(InputUnit)

212339

00-22

(OutputUnit ) [ V ] (OutputUnit ) (OutputUnit )

212340

00-23

DIAGNOSTIC CODES 3.2.2 VCM-3OP input monitor and output monitor (VCM-3 â&#x2020;&#x2019; VCM-3OP)

212341

00-24

00 3.2.3 MP input monitor (VCM-3â&#x2020;&#x2019; MP)

212342

00-25

DIAGNOSTIC CODES 3.2.4 ECU input monitor and output monitor (VCM-3 â&#x2020;&#x2019; ECU)

Accel pedal position (unfiltered) Accel pedal position (filtered)

Reference injection quantity

212343

00-26

00 3.3 Fault Status This screen indicates all error codes occurring.

OutputUnit Communication error InputUnit Communication error

212344

00-27

DIAGNOSTIC CODES 3.4 Fault History This screen indicates the fault data, such as the error codes and hour meter data, stored in the controller.

212345

00-28

00 4. Troubleshooting 4.1 General Information 4.1.1 Before replacing controllers Do not replace controllers casually even if replacement is required as a result of troubleshooting. Be sure to check the following items before replacing controllers. • Loose battery connectors • Abnormal wire harness connections • Loose connectors • Broken, bent or loose connector pins • Dirty connectors If connectors are dirty, remove the connector and clean connectors. See “How to clean harness connectors and system components” on the next page. • Ensure that the main harness is not short-circuited to the truck body. If any of these items (above items) is a source of the trouble, the controller will be damaged even if it is replaced with a new one. Be sure to check the above items and replace carefully.

4.1.2 Connection of service tool (1) Turn off the truck power. (2) Find the service tool connector in the CAB harness. (3) Remove the cover and connect the PC as shown. (4) Turn on the truck power. (5) Start the service tool software.

CAB harness VCM-3OP GSE

GSE cable

VCM-3 GSE 212346

4.1.3 Diagnostic Precautions (1) Before measuring voltage, check the battery for charged condition and specific gravity. If system inspection is performed with the battery uncharged or reduced in specific gravity, accurate measurements cannot be achieved. (2) To avoid having electrical parts damaged, set the starter switch to OFF before disconnecting and reconnecting battery cables. (3) Before disconnecting connectors, set the starter switch to OFF then allow at least 20 seconds. Voltage may remain in electric parts or connected circuit. (4) When performing measurement with the tester, handle the test bar carefully so that it does not damage internal circuit and other electrical parts of the electronic control unit to result in a short-circuit failure between terminals in connector or between connector and truck body.

(5) Resistance is affected by temperature. Determine the necessity of resistance measurement following given temperature specification as a guide. Otherwise, use normal temperature (10 to 35°C) as the measuring condition.

00-29

DIAGNOSTIC CODES 4.1.4 How to clean harness connectors and system components (1) Open-circuits are often caused by dirty harness connectors and components. Dust, together with greasy matter, forms grime which, in time, penetrates electrical connections, resulting in loose metal-to-metal contact or, for worse, electrical separation of surfaces in contact. For this reason, it is essential that the connectors and components be cleaned at each periodic inspection and when servicing the truck. Instead of a commonly used solvent, use the electronic parts cleaner (in the manner illustrated on the right). Electronic parts cleaner

Electronic parts cleaner 212347

Three Bond 29D or Pow-R-Wash CZ*

NOTE â&#x20AC;˘ The cleaner liquid is volatile. All you have to do is just give a strong spray to wash off grime. No need to wipe off the sprayed liquid.

Electronic parts cleaner

Three Bond 2501S (aerosol) or Nyogel 760G*

*: Products contained in Terminal Maintenance kit (SE000003)

NOTE â&#x20AC;˘ Do not spray too much liquid into the connector. Cleaner liquid reacts differently with some resins (plastic materials). Contact surface activator 212348

00-30

TABLE OF STANDARD TIGHTENING TORQUES

• Use specified bolts and nuts. Tighten them to the torques shown below as appropriate, unless otherwise specified. • Threads and bearing surfaces shall be dry. • If the mating nut and bolt (or stud bolt) are different in level of strength, tighten them to the torque specified for the bolt.

Hexagon Head Bolts and Stud Bolts (Unit: N·m {kgf·m}) Strength 4T 7T

Identification symbol Nominal diameter

(stud)

2 to 3 {0.2 to 0.3}

(stud) –

4 to 6 {0.4 to 0.6}

–

9 to 13 {0.9 to 1.3}

M10

(stud)

02154

–

5 to 7 {0.5 to 0.7}

–

7 to 10 {0.7 to 1.0}

–

8 to 12 {0.8 to 1.2}

–

16 to 24 {1.7 to 2.5}

–

19 to 28 {2.0 to 2.9}

–

18 to 27 {1.8 to 2.7}

17 to 25 {1.8 to 2.6}

34 to 50 {3.5 to 5.1}

32 to 48 {3.3 to 4.9}

45 to 60 {4.5 to 6.0}

37 to 55 {3.8 to 5.7}

M12

34 to 50 {3.4 to 5.1}

31 to 45 {3.1 to 4.6}

70 to 90 {7.0 to 9.5}

65 to 85 {6.5 to 8.5}

80 to 105 {8.5 to 11}

75 to 95 {7.5 to 10}

M14

60 to 80 {6.0 to 8.0}

55 to 75 {5.5 to 7.5}

110 to 150 {11 to 15}

100 to 140 {11 to 14}

130 to 170 {13 to 17}

120 to 160 {12 to 16}

M16

90 to 120 {9 to 12}

90 to 110 {9 to 11}

170 to 220 {17 to 23}

160 to 210 {16 to 21}

200 to 260 {20 to 27}

190 to 240 {19 to 25}

M18

130 to 170 {14 to 18}

120 to 150 {12 to 16}

250 to 330 {25 to 33}

220 to 290 {23 to 30}

290 to 380 {30 to 39}

250 to 340 {26 to 35}

M20

180 to 240 {19 to 25}

170 to 220 {17 to 22}

340 to 460 {35 to 47}

310 to 410 {32 to 42}

400 to 530 {41 to 55}

360 to 480 {37 to 49}

M22

250 to 330 {25 to 33}

230 to 300 {23 to 30}

460 to 620 {47 to 63}

420 to 560 {43 to 57}

540 to 720 {55 to 73}

490 to 650 {50 to 67}

M24

320 to 430 {33 to 44}

290 to 380 {29 to 39}

600 to 810 {62 to 83}

540 to 720 {55 to 73}

700 to 940 {72 to 96}

620 to 830 {63 to 85}

Hexagon Head Flange Bolts (Unit: N·m {kgf·m}) Strength 4T

Identification symbol Nominal diameter

02154

–

10 to 14 {1.0 to 1.4}

–

19 to 28 {2.0 to 2.9}

–

22 to 33 {2.3 to 3.3}

–

20 to 29 {2.0 to 3.0}

45 to 55 {4.5 to 5.5}

37 to 54 {3.8 to 5.6}

50 to 65 {5.0 to 6.5}

50 to 60 {5.0 to 6.5}

35 to 51 {3.5 to 5.2}

80 to 105 {8.0 to 10.5}

70 to 95 {7.5 to 9.5}

90 to 120 {9 to 12}

85 to 110 {8.5 to 11}

–

8 to 12 {0.8 to 1.2}

10 to 15 {1.0 to 1.5}

–

M10

21 to 31 {2.1 to 3.1}

M12

38 to 56 {3.8 to 5.5}

4 to 6 {0.4 to 0.6}

00-31

Hexagon Nuts (Unit: N·m {kgf·m}) 4T

Strength

Identification symbol

02155

Nominal diameter

Standard screw thread

Coarse screw thread

Standard screw thread

Coarse screw thread

2 to 3 {0.2 to 0.3}

–

4 to 6 {0.4 to 0.6}

–

4 to 6 {0.4 to 0.6}

–

7 to 10 {0.7 to 1.0}

–

9 to 13 {0.9 to 1.3}

–

16 to 24 {1.7 to 2.5}

–

M10

18 to 27 {1.8 to 2.7}

17 to 25 {1.8 to 2.6}

34 to 50 {3.5 to 5.1}

32 to 48 {3.3 to 4.9}

M12

34 to 50 {3.4 to 5.1}

31 to 45 {3.1 to 4.6}

70 to 90 {7.0 to 9.5}

65 to 85 {6.5 to 8.5}

M14

60 to 80 {6.0 to 8.0}

55 to 75 {5.5 to 7.5}

110 to 150 {11 to 15}

100 to 140 {11 to 14}

M16

90 to 120 {9 to 12}

90 to 110 {9 to 11}

170 to 220 {17 to 23}

160 to 210 {16 to 21}

M18

130 to 170 {14 to 18}

120 to 150 {12 to 16}

250 to 330 {25 to 33}

220 to 290 {23 to 30}

M20

180 to 240 {19 to 25}

170 to 220 {17 to 22}

340 to 460 {35 to 47}

310 to 410 {32 to 42}

M22

250 to 330 {25 to 33}

230 to 300 {23 to 30}

460 to 620 {47 to 63}

420 to 560 {43 to 57}

M24

320 to 430 {33 to 44}

290 to 380 {29 to 39}

600 to 810 {62 to 83}

540 to 720 {55 to 73}

Hexagon Flange Nuts (Unit: N·m {kgf·m}) 4T

Strength Identification symbol

02155

Nominal diameter

Standard screw thread

Coarse screw thread

4 to 6 {0.4 to 0.6}

–

10 to 15 {1.0 to 1.5}

–

M10

21 to 31 {2.1 to 3.1}

20 to 29 {2.0 to 3.0}

M12

38 to 56 {3.8 to 5.6}

35 to 51 {3.5 to 5.2}

00-32

00 Tightening Torque for General-Purpose Flare Nut (Unit: N·m {kgf·m}) Pipe diameter Tightening torque

φ4.76 mm

φ6.35 mm

φ8 mm

φ10 mm

φ12 mm

φ15 mm

17 {1.7}

25 {2.6}

39 {4.0}

59 {6.0}

88 {9.0}

98 {10}

Tightening Torque for General-Purpose Air Piping Nylon Tube (DIN Type) (Unit: N·m {kgf·m}) Nominal diameter × wall thickness Tightening torque

6 × 1 mm 20

+6 0

{2.0

+0.6 0

10 × 1.25 mm }

+10 0

{3.5

+1.0 0

}

12 × 1.5 mm 49

+10 0

{5.0

+1.0 0

15 × 1.5 mm }

+5 0

{5.5

+0.5 0

}

Tightening Torque for General-Purpose Air Piping Nylon Tube (SAE Type) (Unit: N·m {kgf·m}) Nominal diameter Tightening torque

1/4 in. +4 13 0

+0.4 {1.3 0

3/8 in. }

+5 29 0

+0.5 {3.0 0

1/2 in. }

+5 49 0

+0.5 {5.0 0

5/8 in. }

+5 64 0

{6.5

+0.5 0

}

00-33

GROUP 11 ENGINE SPECIFICATIONS ............................................................................. 11-2

STRUCTURE AND OPERATION 1. Engine Proper .................................................................................... 2. Rocker and Bracket Assembly, Camshaft, Rocker Case and Cylinder Head Gasket ........................................................................ 3. Valve Mechanism ............................................................................... 4. Connecting Rod ................................................................................. 5. Piston .................................................................................................. 6. Timing Gears ...................................................................................... 7. Flywheel ..............................................................................................

11-3 11-4 11-4 11-5 11-5 11-6 11-7

TROUBLESHOOTING ...................................................................... 11-8 GENERAL INSPECTION AND ADJUSTMENT 1. Measuring Compression Pressure ................................................ 11-10 2. Inspection and Adjustment of Valve Clearances .......................... 11-12

ROCKER COVER, ROCKER BRACKET AND CAMSHAFT ........... 11-16 CYLINDER HEAD AND VALVE MECHANISM ................................ 11-24 PISTON AND CONNECTING ROD, CYLINDER LINER .................. 11-40 FLYWHEEL ...................................................................................... 11-54 TIMING GEARS ............................................................................... 11-62 CRANKSHAFT AND CRANKCASE ................................................. 11-68

11-1

SPECIFICATIONS Item

Specifications

Engine mode

6M60-TL

Type

6-cylinder, in-line, water-cooled, 4-cycle diesel engine

Combustion chamber

Direct injection type

Valve mechanism

Overhead camshaft (OHC) system

Maximum output

kW {PS} /rpm

110 {150} / 2100

Maximum torque

N·m {kgf·m} /rpm

610 {62} / 1600

Bore × stroke Total displacement Compression ratio

11-2

mm 3

cm {L}

129 {175} / 2100

145 {195} / 2600

200 {270} / 2600

700 {71} / 1600

740 {75} / 1400

785 {80} / 1400

φ118 × 115 7545 {7.545} 17.5

STRUCTURE AND OPERATION

1. Engine Proper

â&#x20AC;¢ The 6M60-TL engine employs an overhead camshaft (OHC) system, with the valve mechanism and the timing gears arranged as shown above.

11-3

STRUCTURE AND OPERATION 2. Rocker and Bracket Assembly, Camshaft, Rocker Case and Cylinder Head Gasket • The camshaft is directly supported at its journals by the rocker case, and is held in place from above by the rocker and bracket assembly. • The camshaft journals are directly supported by the rocker case and the rocker and bracket assembly, without using any camshaft bearings. The rocker case and brackets have been machined together, meaning that they all need to be replaced with a new set when one of them becomes defective.

3. Valve Mechanism

• Each valve has a valve stem seal, which regulates the flow of lubricating oil to the contact surface between the valve and the valve guide. • The valve springs have a variable pitch to prevent abnormal vibration at high engine speed. The exhaust valves use a double spring, with the inner and outer springs coiled in different directions to prevent them from jamming each other.

11-4

11 4. Connecting Rod

5. Piston â&#x20AC;˘ The piston, the cylinder liner and the crankcase bore all must have the same size marks to ensure a good fit between them. â&#x20AC;˘ The pistons are made of special aluminum alloy, and are provided with a recess on each end of the piston pin boss to reduce weight.

11-5

STRUCTURE AND OPERATION 6. Timing Gears • The timing gears are provided with timing marks to help ensure correct assembly. • Timing marks are provided on the following gears. • Camshaft gear: stamped line • Crankshaft gear: “1” • Air compressor gear: “2” • No. 1 idler gear: “1”, “2”

6.1 No. 3 idler gear • The No. 3 idler gear consists of the sub-gear A, the sub-gear B and the main gear. • A spring is installed between the subgear A and the main gear, as well as between the sub-gear B and the main gear. The springs are locked in place with pins. • The sub-gears are installed as follows. The sub-gear A has been turned in such a way as to compress the spring before meshing with the camshaft gear. Likewise, the sub-gear B has been turned to compress the spring before meshing with the No. 2 idler gear.

11-6

11 (1) Non-backlash mechanism • Engine hunting during idling causes fluctuation in the speed of camshaft and No. 2 idler gears. • Without the non-backlash mechanism, the backlash changes between zero and the maximum, generating gear rattle noise.

• With the non-backlash mechanism equipped on the engine, the sub-gears A and B maintain the backlash to zero even when the engine hunts, eliminating gear rattle during idling.

7. Flywheel

11-7

TROUBLESHOOTING

Low power output

Abnormal engine noise

Symptoms

Incorrect valve clearance

Defective cylinder head gasket

Worn valve and valve seat; carbon deposits

Weakened valve spring

Possible causes

Cylinder head and valve mechanism

Timing gears Camshaft

Pistons and connecting rods

Crankshaft

Fuel system

Cooling system

Defective rocker shaft and bracket

Poor lubrication of rocker shaft bracket

Incorrect backlash in timing gears

Poor lubrication of timing gears and idler shaft

Excessive end play in camshaft

Worn camshaft

Worn/damaged piston ring groove(s)

Worn/damaged piston ring(s)

Worn piston pin and connecting rod small end

Excessive end play in crankshaft

Incorrectly fitted crankshaft pulley

Worn/damaged crankshaft pins and connecting rod bearings

Worn/damaged crankshaft journals and main bearings

Supply pump faulty

Defective injector

Air trapped in fuel system

Malfunctioning cooling system components

Loose/damaged V-belts Clogged air cleaner

Intake and exhaust system

Gr14

Clogged muffler

O Gr15

Malfunctioning turbochargers

Incorrect oil viscosity

Improper fuel

Gr12

Incorrectly fitted piping and hoses

Defective/incorrectly fitted alternator and other auxiliaries

11-8

Gr13E Gr13A

O O

Reference Gr

11 M E M O

11-9

GENERAL INSPECTION AND ADJUSTMENT 1. Measuring Compression Pressure Service standards Location

–

Maintenance item

Compression pressure

Standard value

Limit

Remedy

Each cylinder (at 200 rpm)

2,940 kPa {30 kgf/cm2}

1,960 kPa {20 kgf/cm2}

Inspect

Cylinder-to-cylinder pressure difference

–

390 kPa {4 kgf/cm2} or less

Inspect

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Compression gauge adapter

MH063384

Application

Measuring compression pressure

A M16 × 18

• A drop in compression pressure can be used as a guide to determine when the engine should be overhauled. • Measure the compression pressure at regular intervals. Keeping track of its transitions can provide a useful tool for troubleshooting. On new vehicles and vehicles with newly replaced parts, the compression pressure will be somewhat higher depending on the break-in condition of piston rings, valve seats, etc., but this will return to normal as the parts wear down. • Before inspection, confirm that the engine oil, starter, and battery are in normal condition, and satisfy the following conditions. • Warm up the engine until the coolant temperature reaches approximately 75 to 85°C. • Turn off the lights and auxiliaries. • Place the lever in neutral. • Remove the fuse for fuel cut to prevent fuel from being injected while the engine is cranked using the starter.

CAUTION • When cranking the engine, never shut off the power supplied to the engine electronic control unit by disconnecting the engine electronic control unit connector or other similar methods. If the engine is cranked with the power to the engine electronic control unit shut off, the supply pump will not be controlled by the electronic control unit, causing the supply pump to be malfunctioned.

11-10

11 • Remove all the injectors. (See Gr13A.)

• Cover the injector mounting holes with shop towels or other similar cloth. Crank the engine using the starter. Ensure that no foreign matter is attached on the shop towels.

CAUTION • If cracks or any other damage are evident in the cylinders, this means that the coolant, engine oil or fuel, or other substances, has entered the cylinders. If this is the case, it is extremely dangerous to crank the engine as these substances will gush out at high temperature from the injector mounting holes. Stay away from the engine when cranking it. • Attach the nozzle gasket and to one of the injection nozzle mounting holes. Then, connect a compression gauge to . • Crank the engine and measure the compression pressure. • Measure the compression pressure for all the cylinders one after another. Determine the compression pressure difference between the cylinders. • If the compression pressure is below the limit or the cylinder-tocylinder pressure differences is not within the limit, pour a small amount of engine oil into the corresponding injection nozzle mounting hole and remeasure the compression pressure. • If the compression pressure increases, the piston rings and cylinder surfaces may be badly worn or otherwise damaged. • If the compression pressure remains unchanged, there may be seizure in the valves, the valves may be incorrectly seated or the cylinder head gasket may be defective.

• Install the injectors. (See Gr13A.) • Install the rocker cover and gasket. (See later pages.)

11-11

GENERAL INSPECTION AND ADJUSTMENT 2. Inspection and Adjustment of Valve Clearances Service standards (Unit: mm) Location –

Maintenance item

Standard value

Limit

Remedy

0.6

–

Adjust

Valve clearance (when cold)

Tightening torque (Unit: N·m {kgf·m}) Mark

Tightening torque

Remarks

–

Lock nut (adjusting screw tightening)

Parts to be tightened

59 {6.0}

–

Lock nut (rocker arm adjusting screw tightening)

34 {3.5}

–

Special tools Mark

Tool name and shape

Part No.

Socket wrench

Application

MH063003

Tightening the lock nut

• Valve clearances should be checked and adjusted as follows while the engine is still cold. [Inspection] • Remove the rocker cover. • Bring the No. 1 or No. 6 cylinder piston to the top dead center (TDC) on the compression stroke according to the following procedure: • Rotate the crankshaft until the pointer is aligned with the “1 6” mark on the flywheel. • This will place either the No. 1 or No. 6 cylinder piston at TDC on the compression stroke. The cylinder in which the rocker arms for both the intake and exhaust valves can be pushed down by hand by the valve clearance amounts has its piston at TDC. Rotate the engine by one full turn to switch the TDCs of the No. 1 and No. 6 cylinder pistons. • With the No. 1 or No. 6 cylinder piston at TDC, measure the clearance of the valves (clearance between valve bridge and pad) marked with a circle in the table below. Cylinder No. Valve

No. 1 cylinder piston at TDC on O compression stroke

–

No. 6 cylinder piston at TDC on – compression stroke

–

11-12

IN EX IN EX IN EX IN EX IN EX IN EX

11 • Any attempt to insert a feeler gauge without first securing sufficient space, as described above, between the pad and the valve bridge will fail, as the pad will tilt as shown in the illustration, thus blocking the entry of a feeler gauge.

• Before inserting a feeler gauge, push the adjusting screw pad on the side opposite from where a feeler gauge is to be inserted, as shown in the illustration, using a flat-head screwdriver or other similar tool. This will create space necessary for the gauge to be inserted. • The measurement is correct when the feeler gauge feels slightly resisted as it is inserted. • The measurement is not yet correct if the feeler gauge can still be inserted smoothly. • If the measurement deviates from the standard value, adjust as follows. [Adjustment] • Loosen the lock nuts and adjusting screws on the valve bridge and rocker arm.

• While holding the valve bridge by hand, screw in the adjusting screw until it lightly contacts the valve stem end. • Then, further screw in the adjusting screw by 45°.

11-13

GENERAL INSPECTION AND ADJUSTMENT • While holding the adjusting screw in this position with a socket wrench and extension, tighten the lock nut to the specified torque using .

CAUTION • After adjusting the adjusting screw, be sure to tighten the lock nut to the specified torque. Insufficient torquing will compromise the parallelism of the valve bridge, damaging the valve mechanism.

• Screw in or out the adjusting screw on the rocker arm until the correct feeler gauge can be inserted with a slight resistance. • While holding the adjusting screw in this position with a screwdriver, tighten the lock nut to the specified torque using . • Recheck the valve clearance using the correct feeler gauge.

[Installation] • Install the rocker cover and gasket. (See later pages.)

11-14

11 M E M O

11-15

ROCKER COVER, ROCKER BRACKET AND CAMSHAFT

11-16

11 Disassembly sequence Oil filler cap Rubber Rocker cover Rocker cover gasket Baffle plate Cylinder recognition sensor Rocker case upper

1 2 3 4 5 6 7

8 Rocker case upper gasket 9 Packing 10 Rocker and bracket assembly (See later pages.) 11 Camshaft (See later pages.) 12 Rocker case

13 Rocker case gasket

*a: *b:

Cylinder head No. 3 idler gear

: Locating pin : Non-reusable parts

CAUTION • The rocker case and the brackets of the rocker and bracket assembly have been machined together, which means that they all must be replaced together. Never swap the locations of the brackets, either.

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location – 11, b

Standard value

Limit

Remedy

Camshaft end play

Maintenance item

0.05 to 0.20

0.4

Inspect

Backlash between camshaft gear and No. 3 idler gear

0.18 to 0.26

0.35

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (rocker cover mounting)

Tightening torque

Remarks

8.8 {0.9}

–

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Engine oil

As required

ThreeBond 1217H

As required

Rubber portion of oil filler cap Camshaft journal supports on rocker and bracket assembly Camshaft journals and cams Camshaft journal supports on rocker case Periphery and top surface of packing

Work before removal Inspection: Backlash between camshaft gear and No. 3 idler gear • Measure the backlash at least at three different locations. If the measurement exceeds the limit, replace the defective part(s).

11-17

ROCKER COVER, ROCKER BRACKET AND CAMSHAFT Inspection: Camshaft end play • If the measurement exceeds the limit, replace the defective part(s).

Releasing valve spring force • Before loosening the rocker and bracket assembly mounting bolts, check whether the valve springs are compressed by the rockers. If so, loosen the adjusting screws on the rockers to relieve the spring force. This will eliminate the possibility of compressed springs damaging parts when they are released.

Removal procedure Removal: Camshaft • Remove the plug at the rear end of the cylinder head. • Insert a sub-gear locking bolt (M8 × 1.25 mm, length 20 mm) into the dedicated hole in the No. 3 idler gear to lock the sub-gears. Remove the camshaft.

Installation procedure Installation: Rocker case • Tighten the rocker case bolts in the order shown in the illustration.

Installation: Camshaft • Make sure that the timing marks on the timing gears are aligned with each other. • Install the camshaft so that the stamped line on the camshaft gear is level with the top surface of the rocker case. • Install the plug at the rear end of the cylinder head. (See later pages.)

11-18

11 • • • •

Installation: Packing Apply sealant onto the peripheral surface of the packing. Immediately after the sealant application, install the packing to the rocker case. After installing it on the rocker case, apply sealant to the top surface of the packing. Immediately after the sealant application, install the rocker case upper and rocker case upper gasket in place.

CAUTION • Do not start the engine for one hour after installation. • When removing the rocker cover after installation, never fail to apply sealant again. Installation: Rocker case upper gasket • Make sure that the gasket fitting groove in the rocker case is clear of grease and dirt. Clean if necessary. • Before installation, make sure that the gasket is free of grease, etc. that could cause an oil leakage.

Installation: Rocker cover gasket • Make sure that the gasket fitting groove in the rocker cover is clear of grease and dirt. Clean if necessary. • Before installation, make sure that the gasket is free of grease, etc. that could cause an oil leakage.

11-19

ROCKER COVER, ROCKER BRACKET AND CAMSHAFT Rocker and Bracket Assembly

Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Front bracket Adjusting screw Rocker bushing Intake rocker Rocker shaft spring Adjusting screw Rocker bushing Exhaust rocker No. 1 center bracket No. 2 center bracket No. 3 center bracket No. 4 center bracket No. 5 center bracket Rear bracket Rocker shaft

CAUTION • The rocker and bracket assembly and the rocker case are assembled together with precise adjustment and therefore they cannot be replaced separately. If the rocker and bracket assembly is to be reused, be sure to reassemble the assembly with the same combinations of its parts as before.

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location 3, 7, 15 4, 8

Standard value

Limit

Remedy

Clearance between rocker shaft and bushing

Maintenance item

0.006 to 0.076

0.114

Replace

Radial clearance of rocker (roller)

0.035 to 0.078

–

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

34 {3.5}

–

Lock nut (adjusting screw tightening)

Lubricant and/or sealant Mark

Points of application Inside surface of rocker bushing

Specified lubricant and/or sealant

Quantity

Engine oil

As required

Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Rocker bushing puller

11-20

φ 25

φ 27.5

φ 25

MH062727

Application

Removal and installation of rocker bushing

11 Inspection procedure Inspection: Radial clearance of rocker (roller) • If the measurement deviates from the standard value, replace the defective part(s).

Inspection: Clearance between rocker shaft and bushing • If the measurement exceeds the limit, replace the bushing.

Replace of rocker bushing [Removal]

[Installation] • Assemble the bushing onto the rocker such that the oil holes are aligned as shown in the illustration. • After assembly, recheck the clearance. • If the measurement is less than the standard value, ream the bushing.

11-21

ROCKER COVER, ROCKER BRACKET AND CAMSHAFT Camshaft

Disassembly sequence 1 Camshaft gear 2 Key 3 Camshaft : Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location 1, 3

Maintenance item Interference between camshaft gear and camshaft

Standard value

Limit

Remedy

0.017 to 0.062

–

Replace Lobe diameter: 45.110

5.023

4.973 Replace

Intake Cam lift 3

Camshaft Exhaust

Bend Oil clearance at journal

7.084

Base circle diameter: 40.087 Lobe diameter: 47.370

7.034

Base circle diameter: 40.286

0.02 or less

0.04

Replace

0.075 to 0.12

0.25

Inspect

Removal procedure Removal: Camshaft gear • Remove the camshaft gear by pushing on the end of the camshaft with a press or other similar tool.

CAUTION • Do not attempt to remove the camshaft gear with a hammer as damage will result. Use a press or other similar tool.

11-22

11 Inspection procedure Inspection: Interference between camshaft gear and camshaft • If the measurement deviates from the standard value, replace the defective part(s).

Inspection: Camshaft (1) Cam lift • If the measurement (difference between lobe diameter and base circle diameter) is less than the limit, replace the camshaft.

(2) Bend • Measure the camshaft at the center journal for bend while supporting the shaft at the end journals. • A half of the dial gauge reading obtained as the camshaft is rotated by a full turn represents the bend of the camshaft. • If the measurement exceeds the limit, replace the camshaft.

(3) Oil clearance at journal • If the measurement exceeds the limit, replace the defective part(s).

CAUTION • The rocker case and the brackets of the rocker and bracket assembly have been machined together, which means that they all must be replaced together.

Installation procedure Installation: Camshaft gear • Heat the camshaft gear to approximately 150°C using a gas burner. • While facing the camshaft gear as shown in the illustration, press it onto the camshaft until it seats snugly on the camshaft.

WARNING • The camshaft is extremely hot. Be careful not to touch it.

11-23

CYLINDER HEAD AND VALVE MECHANISM

11-24

11 Disassembly sequence 1 2 3 4 5 6 7 8 9 10

Connecting plate Glow plug Nozzle bridge Injector (See Gr13A.) O-ring Nozzle tip gasket Cylinder head bolt Plug Collar O-ring

11 12 13 14 15 16 17 18 19

No. 3 idler bolt Thrust plate No. 3 idler shaft Snap ring Sub-gear Pin Spring No. 3 idler gear bushing No. 3 idler gear

20 Cylinder head (See later section.) 21 Cylinder head gasket a: *b: * c: *

No. 2 idler gear Flywheel housing Crankcase

: Locating pin : Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

CAUTION • After the No. 3 idler gear has been reassembled onto the cylinder head, remove the locking bolt from the sub-gears.

Service standards (Unit: mm) Location – 13, 18

Maintenance item

Standard value

Limit

Remedy

Backlash between No. 3 and No. 2 idler gears

0.17 to 0.25

0.35

Replace

No. 3 idler gear end play

0.05 to 0.15

0.3

Replace

Clearance between No. 3 idler shaft and No. 3 idler gear bushing

0.01 to 0.05

0.2

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (connecting plate mounting)

Tightening torque

Remarks

1.0 to 1.5 {0.1 to 0.15}

–

Glow plug

20 to 25 {2.0 to 2.5}

–

Bolt (nozzle bridge mounting)

33 to 38 {3.4 to 3.9}

–

78 {8} + 90° +5° + 90° +5° 0 0

Cylinder head bolt

• Wet • Reusable to 3 times

Plug

13 to 17 {1.3 to 1.7}

–

Nut (collar mounting)

39 to 59 {4.0 to 6.0}

–

No. 3 idler bolt

59 to 78 {6.0 to 8.0}

–

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Engine oil

As required

ThreeBond 1207F

As required

Threaded portion of cylinder head bolt O-ring Threaded portion of No. 3 idler bolt Periphery of No. 3 idler shaft Inside surface of No. 3 idler gear bushing Top mating surfaces of flywheel housing and crankcase

11-25

CYLINDER HEAD AND VALVE MECHANISM Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Socket wrench

MH063388

Installation of cylinder head

Pin wrench arm

MH063473

Assembly of No. 3 idler gear

MH061779

Removal and installation of No. 3 idler gear bushing

Idler gear push-puller A

φ 32

φ 35

φ 32

Work before removal Locking sub-gears • Before removing the No. 3 idler gear, install a locking bolt (M8 × 1.25 mm, length 20 mm) into the dedicated hole to lock the subgears.

Inspection: End play of No. 3 idler gear • If the measurement exceeds the limit, replace the defective part(s).

Inspection: Backlash between No. 2 and No. 3 idler gears • If the measurement exceeds the limit, replace the defective part(s).

11-26

11 Removal procedure Removal: Cylinder head • Remove the bolts (× 4). • Progressively loosen the cylinder head bolts in the order shown in the illustration, going over them several times, before eventually removing them.

Removal: Cylinder head gasket

CAUTION • Be careful not to scratch the cylinder head, crankcase and flywheel housing when removing the cylinder head gasket.

Inspection procedure Inspection: Clearance between No. 3 idler shaft and No. 3 idler gear bushing • If the measurement exceeds the limit, replace the bushing.

Replacement of No. 3 idler gear bushing [Removal]

[Installation] • Using , press in the bushing until contacts the No. 3 idler gear. • After installation, measure the clearance again. • If the measurement is lower than the standard value, ream the bushing.

11-27

CYLINDER HEAD AND VALVE MECHANISM Installation procedure Installation: Sub-gears • Install the No. 3 idler gear on a vice. Use shop towel to protect the gear from direct contact with the vice.

• Install a sub-gear, a spring and pins on one side of the No. 3 idler gear. • Hook each end A of the spring on a pin.

• Install a snap ring.

• Using , turn the sub-gear clockwise until the countermark on the sub-gear is aligned with the stamped line on the No. 3 idler gear. Then, install a locking bolt (M8 × 1.25 mm, 20 mm long) into the dedicated hole. • Turn over the No. 3 idler gear and repeat the same procedure on the other side of the No. 3 idler gear, installing another sub-gear, a spring, pins and a snap ring.

Installation: Cylinder head

CAUTION • Before fitting the cylinder head bolts, check the punch marks on each bolt’s head. Do not use the bolt if there are three punch marks. The punch marks indicate the number of times each bolt has been tightened using the torque-turn tightening method. Any bolt that already has three punch marks must be replaced.

11-28

11 • The cylinder head gasket is a part that needs to be selected for use. Choose the appropriate gasket in the following manner. • Measure the piston protrusion from each cylinder. (See Piston.) • Then, from the table below, choose the cylinder head gasket having a thickness appropriate to the average protrusion of the pistons. • If the cylinder head has even one cylinder that exceeds the largest of the measured piston protrusions by 0.05mm or more, use a gasket at least one size larger in thickness (A → B, B → C). Unit: mm Piston protrusion

Cylinder head gasket

Average piston protrusion

Type by size ( ): No. of notches

Tightened thickness

0.804 to 0.872

A(1)

1.70 ± 0.05

0.873 to 0.941

B(2)

1.75 ± 0.05

0.942 to 1.011

C(3)

1.80 ± 0.05

• Identify the appropriate type of cylinder head gasket according to the number of notches in its notched end.

• Remove oil and any other contamination from the surfaces where sealant is to be applied. • Apply sealant onto the surfaces of the flywheel housing and crankcase that will be fitted together. • Within three minutes following the sealant application, install the cylinder head onto the crankcase, with the cylinder head gasket in between them, using the cylinder head bolts. Take care so that the applied sealant is not displaced during installation. Be sure to install the gasket in the illustrated position.

CAUTION • Do not start the engine for at least an hour after installation. • Whenever cylinder head bolts are loosened or removed after installation, the cylinder head gasket must be replaced and sealant reapplied.

• Tighten the cylinder head bolts to a torque of 78N.m {8kgf.m} in the order shown in the illustration. • Further tighten the bolts in the illustrated order as follows.

11-29

CYLINDER HEAD AND VALVE MECHANISM • Turn the holder of nal spring.

counterclockwise to pretension the inter-

• Set the tool such that the rod (extension) is pressed against the rocker shaft bracket by the force of the spring. • Align any line on the holder scale with any line on the socket scale. (This will be used as the reference point = 0°.) • From the reference point, turn the socket by 90° +5° 0 in the direction shown. Each division on the holder scale represents 5°. • Further turn the socket by 90° +5° 0 . • After tightening the cylinder head bolts within the plastic region, punch a mark on the bolt heads to record the number of times that they have been tightened.

CAUTION • Cylinder head bolts that have been tightened using the torque-turn method must never be additionally tightened after the final angular tightening.

11-30

11 M E M O

11-31

CYLINDER HEAD AND VALVE MECHANISM Cylinder Head

Disassembly sequence 1 2 3 4 5 6

Adjusting screw Valve bridge Valve cotter Upper retainer Outer valve spring Inner valve spring <Only exhaust valve>

7 8 9 10 11 12 13

Valve stem seal Exhaust valve Intake valve Valve bridge guide Exhaust valve guide Intake valve guide Exhaust valve seat

14 Intake valve seat 15 Stud bolt 16 Cylinder head : Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

CAUTION â&#x20AC;˘ When an exhaust valve or intake valve has been removed, make sure to replace the valve stem seal.

11-32

11 Service standards (Unit: mm) Location 2, 10

Maintenance item

Standard value

Limit

Remedy

0.01 to 0.04

0.1

Replace

71.7

68.1

Replace

407 ± 20.6 N {42 ± 2.1 kgf}

367 N {37 kgf}

Replace

Squareness

–

2° or less

Replace

Free length

66.47

63.1

Replace

280 ± 14 N {29 ± 1.4 kgf}

252 N {26 kgf}

Replace

Valve bridge-to-valve bridge guide clearance Free length Intake side

Outer valve spring Exhaust side

Installed load (46.5 in installed length)

Installed load (46.5 in installed length) Squareness

Free length 6

Inner valve spring

Installed load (41.8 in installed length) Squareness

Exhaust valve

Replace

127 ± 6.3 N {12.9 ± 1.9 kgf}

121 N {12 kgf}

Replace

2° or less

Replace

Stem outside diameter

φ7.85

Replace

Sinkage from cylinder head bottom surface

1.3 ± 0.2

1.55

Inspect

1.5

1.2

Replace

45° ± 15’

–

Correct

0.07 to 0.10

0.2

Replace

Stem outside diameter

φ8 –0.025 –0.040

φ7.85

Replace

Sinkage from cylinder head bottom surface

1.3 ± 0.2

1.55

Inspect

1.5

1.2

Replace

Exhaust valve stem-to-valve guide clearance

Intake valve

Replace

57.6

–

Seat angle

2° or less

φ8 –0.060 –0.075

Valve margin 8, 11

– 60.61

Valve margin

45° ± 15’

–

Correct

Intake valve stem-to-valve guide clearance

Seat angle

0.06 to 0.09

0.2

Replace

Valve bridge guide in outside diameter

9.989 to 10

9.94

Replace

Exhaust valve seat width

2.3 to 2.7

3.3

Correct or replace

Intake valve seat width

1.8 to 2.2

2.8

Correct or replace

Bottom surface distortion

0.08 or less

0.2

Correct or replace

Height from top surface to bottom surface

94.9 to 95.1

94.5

Replace

9, 12

Cylinder head

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Lock nut (valve bridge adjusting screw tightening) Stud bolt

Tightening torque

Remarks

59 {6.0}

–

20 {2}

–

Lubricant and/or sealant Mark

Points of application Lip of valve stem seal Stem and end of valve

Specified lubricant and/or sealant

Quantity

Engine oil

As required

11-33

CYLINDER HEAD AND VALVE MECHANISM Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Valve lifter

MH061668

Valve lifter hook

MH061679

Application

Removal and installation of valve cotters

Valve lifter seat A

MH061772

φ 38

Valve stem seal installer A

φ 25

φ9

Valve lapper

Valve bridge guide installer A

φ 10

37.2

MH062689

Installation of valve stem seals

30091-07500

Lapping valves and valve seats

MH062724

Installation of valve bridge guides

Valve guide remover A

φ8

φ 12

31391-10500

Removal of valve guides

Valve guide installer A

φ 25.5

φ 13

MH062726

Caulking tool body

Installation of valve guides

31391-13100

Installation of valve seat

Installer ring

11-34

Intake valve

φ8

φ 42

Exhaust valve

φ8

φ 38

MH062725 <Intake valve> MH063605 <Exhaust valve>

11 Removal procedure Removal: Valve cotters • Using , and , remove the valve cotter while compressing the valve spring(s) evenly.

Inspection procedure Inspection: Valve bridge and valve bridge guide (1) Valve bridge-to-guide clearance • If the measurement exceeds the limit, replace the defective part(s). (2) Outside diameter of valve bridge guide • If the measurement is less than the limit or the valve bridge guide is worn extremely unevenly, replace the valve bridge guide.

Replacement of valve bridge guide [Installation] • Before installation, ensure that no water, oil or other foreign matter is in the installation hole. • Using , install the valve bridge guide until comes into positive contact with the cylinder head.

CAUTION • The valve bridge guide must be installed to the specified depth of the cylinder head. Correct installation can only be possible by using . Inspection: Intake and exhaust valve (1) Valve stem outside diameter • Replace the valve if the stem’s outside diameter is below the limit or is severely worn. • When the valve has been replaced with a new one, make sure to lap the valve and valve seat.

(2) Valve seat angle and valve margin • Reface or replace the valve if the valve seat angle or valve margin exceeds the specified limits. • After refacing or replacing the valve seat, make sure to lap the valve and valve seat.

11-35

CYLINDER HEAD AND VALVE MECHANISM Refacing • Limit grinding to a necessary minimum. • If the valve margin is below the limit after grinding, replace the valve. • After grinding, make sure to lap the valve and valve seat.

Inspection: Valve-to-valve guide clearance • If the clearance exceeds the specified limit, replace the defective part(s).

Replacement of valve guides [Removal]

[Installation] • Install the valve guide until head.

sits snugly on the cylinder

CAUTION • The valve guide must protrude from the cylinder head by the specified amount. Correct installation can only be possible by using . • The valve guides for the exhaust valves are longer than the valve guides for the inlet valves.

Inspection: Contact between valve and valve seat • Before starting inspection, check that the valve and valve guide are intact. • Apply an even coat of red lead to the valve contact surface of the valve seat. • Strike the valve once against the valve seat. Do not rotate the valve during this operation.

11-36

11 • If the red lead deposited on the valve indicates a poor contact pattern, take either of the following corrective actions. Contact pattern

Corrective action

Minor defect

Lapping

Serious defect

Reface or replace valve and valve seat

Lapping • Lap the valve in the following sequence. • Apply a thin coat of lapping compound to the seat contact surface of the valve. Adding a small amount of engine oil to the lapping compound can facilitate even application.

CAUTION • Do not put any compound on the stem. • Start with an intermediate-grit compound (120 to 150 grit) and finish with a fine-grit compound (200 grit or more). • Strike the valve several times against the valve seat while rotating the valve a little at a time. • Wash away the compound with diesel fuel. • Apply engine oil to the valve contact surface of the valve seat and rub in the valve and seat well. • Inspect the contact pattern of the valve and valve seat again. • If the contact pattern is still defective, replace the valve seat.

Inspection: Valve seats (1) Valve seat width • If the measurement exceeds the limit, reface or replace the valve seat. • After refacing or replacing the valve seat, make sure to lap the valve seat and valve.

(2) Valve sinkage from cylinder head bottom surface • Perform measurement keeping the valve in close contact with the valve seat. • If the measurement exceeds the limit, adjust or replace the defective part(s). • After refacing or replacing the valve seat, make sure to lap the valve seat and valve.

11-37

CYLINDER HEAD AND VALVE MECHANISM Refacing the valve seat • Grind the valve seat using a valve seat cutter or valve seat grinder. • Place a piece of sandpaper of approximately #400 between the cutter and valve seat and grind the valve seat lightly. • Use a 15° or 75° cutter to cut the valve seat to a width within the standard range.

CAUTION • Make sure that the valve seat refacing does not cause the valve sinkage to exceed the specified limit. • Lap the valve and valve seat. Replacement of valve seat [Removal] • The valve seats are installed by expansion fitting. To remove a valve seat, grind inside the metal stock to reduce the wall thickness, then remove the valve seat at room temperature.

[Installation] • Check that the diameters of the valve seat holes in the cylinder head conform with the values shown below. Diameters of the valve seat holes

Intake side

φ42 +0.025 mm 0

Exhaust side

φ38 +0.025 mm 0

• Replace the cylinder head if necessary.

• Chill the valve seat thoroughly by immersing in it in liquid nitrogen. • Install the valve seat in the cylinder head using and . • Lap the valve seat and valve.

Inspection: Cylinder head bottom surface distortion • If the distortion exceeds the specified limit, rectify it using a surface grinder.

CAUTION • Make sure that the height of the cylinder head from the top surface to the bottom surface is not reduced to a value below the specified limit.

11-38

11 Installation procedure Installation: Valve stem seal • Apply engine oil to the lip of the valve stem seal. • Install the valve stem seal until sits snugly on the cylinder head.

CAUTION • After installing the valve stem seal, check that its spring is not deformed or damaged.

Installation: Valve spring • Install the outer and inner valve springs onto the cylinder head while facing them as shown in the illustration.

Installation: Valve cotter • Using , and , install the valve cotter while compressing the valve spring(s) evenly.

CAUTION • Do not compress the valve spring(s) too much, or the upper retainer will contact the valve stem seal and damage will result.

11-39

PISTON AND CONNECTING ROD, CYLINDER LINER Disassembly sequence Lower connecting rod bearing Connecting rod cap Upper connecting rod bearing Piston and connecting rod (See later sections.) 5 Cylinder liner 1 2 3 4

: Locating pin

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

–

Piston projection from crankcase top surface

0.81 to 1.01

–

Inspect

–

Connecting rod end play

0.15 to 0.45

0.6

Inspect

1, 3

Connecting rod bearing

4, 5

Piston and connecting rod-to-cylinder liner clearance

Oil clearance Span when free

Flange projection 5

Cylinder liner

Bore Out of roundness

0.034 to 0.093

0.2

–

Less than 74.5

Replace

0.19 to 0.21

–

Replace

0.03 to 0.10

–

φ118 to 118.03

φ118.25

0.03 or less

–

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (connecting rod cap installation)

Tightening torque

Remarks

29 {3} + 90° (± 5°)

Wet

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Engine oil

As required

Threaded portion of connecting rod bolt Inside surface of connecting rod bearing Outside periphery of cylinder liner Outside periphery of piston

11-40

11 Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Piston guide clamp

MH061760

Piston guide lever

MH061658

Application

Installation of piston and connecting rod

Socket wrench

MH061560

Cylinder liner extractor A

MH061761

Removal of cylinder liner

MH061771

Installation of cylinder liner

φ117.5

Cylinder liner installer A φ117.5

Inspection before removal Retaining cylinder liners • The cylinder liners may move up when the crankcase is turned over, or the crankshaft is rotated after the pistons are installed. To prevent this, retain the cylinder liners by holding their flanges with bolts and washers.

11-41

PISTON AND CONNECTING ROD, CYLINDER LINER Inspection: Piston projection from crankcase top surface

CAUTION • The amount of piston projection affects engine performance and must therefore be inspected without fail. • Set the piston at the top dead center. • Mark reference points A (seven points in total) on the top surface of the crankcase as shown in the illustration. Using each of the marks as a zero point, measure the amount of piston projection relative to the zero point (height of measurement point B – height of reference point A). • Make the measurements at the two measurement points B for each cylinder (twelve points in total) using the reference point A nearest to each measurement point, and calculate the average value of all the measurements. • If the average value is out of the standard value range, check the clearances between all relevant parts.

Inspection: Connecting rod end play • Measure the end play for every connecting rod. • If any measurement exceeds the specified limit, replace the defective part(s).

Inspection: Cylinder liner flange projection • If the measurement deviates from the standard value, inspect the installation and replace the defective part(s).

CAUTION • If the cylinder liner flange protrusion is less than the specified value, the contact pressure of the cylinder head gasket against the bore of the cylinder will not be high enough to prevent gas leakage.

Inspection procedure Inspection: Connecting rod bearing span when free

CAUTION • Do not attempt to manually expand the bearings. • If the span is less than the specified limit, replace both the upper and lower bearings.

11-42

11 •

• • •

Inspection: Connecting rod bearing oil clearance Fit the lower bearing to the connecting rod cap and the upper bearing to the connecting rod, then tighten the nut to a torque of 29 N·m {3 kgf·m}. Measure the inside diameter of the bearing and the outside diameter of the crankshaft pin. If the clearance exceeds the limit, replace the defective part(s). If a bearing has to be replaced with an undersized one, machine the crankshaft pin to the specified undersize diameter. (See CRANKSHAFT AND CRANKCASE.)

Inspection: Clearance between piston and cylinder sleeve • If the measurement deviates from the standard value, replace the defective part(s). A: Measuring point on the crankcase (in direction of the crankcase axis). B: Measuring point on the crankcase (vertical to the crankcase axis). C: Measuring point on the piston outer diameter (vertical to the piston pin hole).

Replacement of cylinder liner [Removal] • If the cylinder liners will need to be reused for some reason or other, make countermarks to ensure correct reassembly.

11-43

PISTON AND CONNECTING ROD, CYLINDER LINER [Installation] • The cylinder liner being installed must have the same size mark as that on the crankcase as well as that on the piston. Size mark on crankcase “1”

Size mark on cylinder liner “1A” “1B”

“2”

“2A” “2B”

“3”

“3A” “3B”

Size mark on piston “A”

“B”

CAUTION • Using a piston with the size mark different from the size mark of the cylinder liner can lead to engine seizure. • Apply a thin coat of engine oil onto the outside periphery (hatched area) of the cylinder liner.

• While pushing the top surface of evenly with hands, gently insert the cylinder liner into the crankcase.

CAUTION • Cylinder liners are thinly structured. Therefore, they must be handled with extreme care.

Installation procedure Installation: Connecting rod bearings

CAUTION • Do not reverse the positions of the lower bearing and the upper bearing (with oil hole) when installing, as this may cause seizure in the engine.

11-44

11 Installation: Piston and connecting rod • Check that the piston ring end gaps are in their correct positions. A: 1st compression ring gap B: 2nd compression ring gap C: Oil ring gap D: Oil ring expander spring gap “

”: Front mark on piston

• Ensure that the size mark (“A”, “B”) on the piston is the same as that on the cylinder liner.

• Face the front mark “ ” of the piston toward the front of the engine. • With and installed around the piston skirt, tighten the adjusting bolt of until the inside diameter of matches the outside diameter of the piston skirt. • Remove and from the piston. Apply engine oil to the following areas. Then, install and over the rings of the piston. • Outside surface of piston • Inside surface of • Cylinder liner inside surface • Install the piston and connecting rod, taking care not to damage the inside surface of the cylinder liner or the crank pin with the connecting rod.

CAUTION • Be careful not to scratch or damage head of the piston (a part of the combustion chamber). • Make sure that the connecting rod does not hit oil jet.

11-45

PISTON AND CONNECTING ROD, CYLINDER LINER • After the piston and connecting rod have been installed, install the connecting rod cap onto the connecting rod, ensuring that the alignment marks are aligned. Tighten the bolts alternately as follows. • Tighten the bolts to a torque of 29 N·m {3 kgf·m}. • Further tighten the bolts in the following sequence.

• Turn the holder of spring.

counterclockwise to preload the built-in

• Set the tool such that the rod (extension) is pressed against the crankshaft by the force of the spring. • Align any line on the holder scale with any line on the socket scale. (This will be used as the reference point = 0°.) • From the reference point, turn the socket by 90° ± 5° in the direction shown. Each division on the socket scale represents 5°. • With the connecting rod cap installed, check the following items. • Connecting rod end play • Piston protrusion

11-46

11 M E M O

11-47

PISTON AND CONNECTING ROD, CYLINDER LINER Piston and Connecting Rod

Disassembly sequence 1 2 3 4 5 6 7 8

1st compression ring 2nd compression ring Oil ring Snap ring Piston pin Connecting rod bushing Connecting rod Piston

: Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location

Maintenance item 1st compression ring

1 to 3

Piston ring end gap

Piston ring side clear1 to 3, 9 ance in piston groove

2nd compression ring

Standard value 0.45 +0.05 –0.10

Oil ring

0.3 to 0.55

1st compression ring

0.13 to 0.18

2nd compression ring

0.065 to 0.105

Oil ring

0.025 to 0.065

Limit

Remedy

1.5

Replace

0.2 0.15

Replace

5, 6

Piston pin-to-connecting rod bushing clearance

0.02 to 0.055

0.1

Replace

5, 8

Piston pin-to-piston clearance

0.004 to 0.022

0.05

Replace

Bend

–

0.05

Twist

–

0.1

Connecting rod

Replace

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Engine oil

As required

Piston pin outside surface Connecting rod bushing outside surface Connecting rod bushing fitting surface of connecting rod

11-48

11 Special tools Mark

Tool name and shape

Piston ring tool

Connecting rod bushing puller kit

Part No.

30091-07100

MH062556

Application

Removal and installation of piston rings

Removal and installation of connecting rod bushings

Removal procedure Removal: Piston ring

Removal: Piston pin • Remove the piston pin by striking it with a rod and hammer. • If the piston pin is difficult to remove, first heat the piston in hot water or with a piston heater.

Inspection procedure Inspection: Piston ring end gap • Using the crown of a piston, push the piston ring horizontally into a cylinder in the crankcase until it reaches the lower part of the cylinder liner, where there is relatively small wear. • Taking care not to move the piston ring, measure the end gap. • If any of the rings has a gap exceeding the specified limit, replace all the piston rings as a set.

11-49

PISTON AND CONNECTING ROD, CYLINDER LINER • • •

•

Inspection: Piston ring side clearance in piston groove Remove any carbon deposits from the ring groove in the piston. Measure the side clearance of each ring around the piston’s entire periphery. If any of the measurements exceeds the specified limit, replace the defective part(s). If any of the piston rings is defective, replace all the rings on the piston as a set. The side clearance of the 1st compression ring must be measured using a feeler gauge while holding the ring against the piston ring groove with a straight edge.

Inspection: Piston pin-to-piston clearance • If the measurement exceeds the specified limit, replace the defective part(s).

Inspection: Piston pin-to-connecting rod bushing clearance • If any of the measurements exceeds the specified limit, replace the bushing.

11-50

11 Replacement of connecting rod bushing • Replace the connecting rod bushing using . [Removal] • Remove the upper bearing (if fitted) from the large end of the connecting rod. • Mount the connecting rod on the base and lock it in position with the bracket and plate. • Fit collar A over the puller with its ends facing in the illustrated directions. Then, slowly apply a pressure of approximately 49 kN {5,000 kgf} to the puller with a press to force out the connecting rod bushing.

[Installation] • Apply engine oil to the outside surface of the connecting rod bushing and the bushing fitting surface of the connecting rod. • Fit collar B, the bushing, and collar A over the puller in the illustrated directions and lock this arrangement together with the nut. • Align the oil holes in the connecting rod bushing and the connecting rod. Then, use a press to slowly apply a pressure of approximately 49 kN {5,000 kgf} to the puller until the bushing is forced into place. • After press-fitting the connecting rod bushing, measure the clearance between the piston pin and connecting rod bushing. • If the measurement is less than the standard clearance range, ream the bushing.

11-51

PISTON AND CONNECTING ROD, CYLINDER LINER Inspection: Connecting rod bend and twist • Mount the connecting rod on the connecting rod aligner. Also mount the connecting rod bearings, piston pin, and connecting rod cap to create the same conditions as are expected when the connecting rod is mounted on a crankshaft. Tighten the nuts of the connecting rod bearing cap to a torque of 29 N·m {3 kgf·m}. • Measure the extent of bend and twist in the connecting rod. • If either measurement exceeds the specified limit, replace the connecting rod.

Installation: Piston and connecting rod • If the piston and/or connecting rod have been replaced, assemble them while paying attention to the following: • The connecting rods on the same engine must all have the same mass mark (A to E). • Apply engine oil to the piston pin, and assemble the piston and connecting rod with their marks facing in the illustrated directions. “ ”: Front mark • If the piston pin is difficult to insert, heat the piston in hot water or with a piston heater.

Installation: Piston rings • With the manufacturer’s marks (found near the piston ring end gaps) facing up, install the piston rings so that the end gap of each ring is positioned as illustrated. A: 1st compression ring end gap B: 2nd compression ring end gap C: Oil ring end gap D: Oil ring’s expander spring end gap “ ”: Front mark on piston The manufacturer’s marks are present only on the 1st (“T”) and 2nd (“T1”) compression rings.

11-52

11 M E M O

11-53

FLYWHEEL

Disassembly sequence 1 Washer plate 2 Pilot bearing <Type A, Type B> 3 Ring gear 4 Flywheel 5 Engine speed sensor 6 Adapter <*a> 7 Plug 8 Eyebolt

11-54

9 10 11 12 13 14 15 16 17

Air outlet pipe Air suction pipe Eyebolt Water inlet pipe Eyebolt Oil pipe Eyebolt Water outlet pipe Air compressor (See Gr61.)

18 19 20 21

O-ring Rear oil seal Stiffener Flywheel housing

: Non-reusable parts *a: Varies depending on specifications

11 Assembly sequence Follow the disassembly sequence in reverse.

Service standards Location

Maintenance item Friction surface distortion Flywheel <Type A, Type B>

Friction surface height

Standard value

Limit

Remedy

0.05 or less

0.2

Correct or replace

Type A

Type B

44.5

43.5

–

0.2

Correct or replace

–

0.2

Inspect or replace

Friction surface runout (when fitted) Eccentricity of flywheel housing measured at spigot joint section (when fitted)

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Bolt (flywheel mounting)

98 {10} + 150°

+10° 0

Remarks • Wet • Can be reused up to 3 times

Plug

88 {9}

–

Eyebolt (air outlet pipe mounting)

98 {10}

–

19 to 28 {1.9 to 2.8}

–

50 {5.0}

–

21 {2.1}

–

Bolt (air suction pipe mounting) Eyebolt (water inlet pipe mounting) Eyebolt (water outlet pipe mounting) Eyebolt (oil pipe mounting)

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Engine oil

As required

ThreeBond 1207C

As required

Thread of bolts O-ring Rear oil seal lip Rear oil seal surface to be mated with flywheel housing Engine mounting surface of flywheel housing

11-55

FLYWHEEL Special tools Mark

Tool name and shape

Part No.

Socket wrench

Application

MH062354

Installation of flywheel

Magnet base

MH062356

Inspection before removal Inspection: Flywheel friction surface runout when fitted • If the measurement exceeds the limit, check if the bolts are correctly tightened as well as the crankshaft mounting surface. Correct or replace the flywheel as required.

Removal procedure Removal: Flywheel • To remove the flywheel, use bolts (M16 × 1.5 mm, Length 60 mm) inserted into the dedicated holes in the flywheel.

Removal: Ring gear • Heat the ring gear evenly with a gas burner or the like until it reaches approximately 200°C, then remove it from the flywheel.

WARNING • You may burn yourself if you touch the heated ring gear.

11-56

11 Inspection procedure Inspection: Flywheel (1) Friction surface height • If the height is less than the limit, replace the flywheel.

(2) Friction surface distortion • If the measurement exceeds the limit, rectify or replace the flywheel. • If the ring gear is evidently defective, replace the ring gear before inspecting the friction surface for distortion.

Rectification of friction surface • Rectify the friction surface so that its height is not below the specified limit, and it is parallel with surface A with an error not exceeding 0.1 mm.

11-57

FLYWHEEL Installation procedure Installation: Flywheel housing [Installation] • Clean the flywheel housing surface where sealant is to be applied. • Apply an even and continuous bead of sealant onto the flywheel housing surface where the crankcase is to be mounted. • Install the flywheel housing onto the crankcase within 3 minutes following the application. Be careful not to smear the sealant bead.

CAUTION • Do not start the engine at least for an hour after the flywheel housing has been installed. • If the flywheel housing mounting bolts are subsequently loosened, be sure to apply sealant again upon reassembly.

[Inspection] • While turning the crankshaft, measure the flywheel housing for any eccentricity at the location indicated in the illustration. • If the eccentricity exceeds the limit, reassemble the flywheel. • If the eccentricity still exceeds the limit after reassembly, replace the defective part(s).

Installation: Rear oil seal • Clean the rear oil seal surface where sealant is to be applied. • Apply an even and continuous bead of sealant on the rear oil seal as shown in the illustration. • Install the rear oil seal onto the flywheel housing within 3 minutes following the application. Be careful not to smear the sealant bead.

CAUTION • Do not start the engine at least for an hour after the rear oil seal has been installed. • If the rear oil seal mounting bolts are subsequently loosened, be sure to apply sealant again upon reassembly. • Apply engine oil to the rear oil seal lip. • Install the rear oil seal onto the flywheel housing ensuring that the seal is faced in the illustrated direction.

11-58

11 Installation: Air compressor • Bring the No. 1 cylinder of the engine to top dead center of the compression stroke. • After aligning inscribed lines with each other, install the air compressor to the flywheel housing.

• Remove the inspection plug and check if the inscribed line is aligned with the pointer. • If not aligned, remove and refit the air compressor.

Installation: Ring gear • Heat the ring gear evenly with a gas burner or the like until it reaches approximately 200°C.

WARNING • You may burn yourself if you touch the heated ring gear. • Fit the ring gear with the side having non-chamfered tooth edges toward the flywheel.

Installation: Flywheel

CAUTION • Before installing a bolt, check the number of punch marks on the bolt head. (Bolts with up to two punch marks can be reused.) The number of punch marks indicates the number of times the bolt has been tightened in the past within the plastic region. If there are three punch marks (tightened three times in the past), replace the bolt.

11-59

FLYWHEEL • Tighten the flywheel mounting bolts to a torque of 98 N·m {10 kgf·m}. • Further tighten the bolts in the following procedure. • Turn the holder of counterclockwise to preload the builtin spring. • Set such that the rod (extension) is pressed against by the force of the spring. • Align any line on the holder scale with any line on the socket scale. (This will be used as the reference point = 0°.) • From the reference point, turn the socket by 150° +10° 0° clockwise. Each division on the socket scale represents 5°. • After tightening the bolt within the plastic region, make a punch mark on the bolt head for subsequent identification.

CAUTION • The bolts should be tightened within the plastic region. Never tighten them further than the specified angle.

11-60

11 M E M O

11-61

TIMING GEARS

Disassembly sequence 1 2 3 4 5 6

No. 1 idler shaft No. 1 idler gear bushing No.1 idler gear O-ring Collar O-ring

7 8 9 10 11

No. 2 idler bolt Thrust plate No. 2 idler gear bushing No. 2 idler gear No. 2 idler shaft

Assembly sequence Follow the disassembly sequence in reverse.

11-62

a: *b: *

Air compressor gear Crankshaft gear

: Non-reusable parts

11 Service standards (Unit: mm) Location

–

Maintenance item

Backlash between gears

Standard value

Limit

Remedy

No. 1 idler gear and air compressor gear

0.08 to 0.15

0.35

Replace

No. 1 idler gear and No. 2 idler gear

0.08 to 0.15

0.35

Replace

No. 1 idler gear and crankshaft gear

0.08 to 0.14

0.35

Replace

1, 2

Clearance between No. 1 idler shaft and No. 1 idler gear bushing

0.01 to 0.05

0.2

Replace

3, 10

Idler gear end play

0.05 to 0.15

0.3

Replace

9, 11

Clearance between No. 2 idler gear bushing and No. 2 idler shaft

0.01 to 0.05

0.2

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

88 {9}

–

Nut (collar mounting)

82 {8.4}

–

No. 2 idler bolt

95 {9.7}

–

Bolt (No.1 idler gear mounting)

Lubricant and/or sealant Mark

Points of application O-ring

Specified lubricant and/or sealant

Quantity

Engine oil

As required

Special tools (Unit: mm) Mark

Tool name and shape

Gear puller

Part No.

Application

MH061326

Removal of No. 1 idler shaft and gear

MH062601

Removal and installation of No. 1 and No. 2 idler gear bushings

MH062562

Removal of No. 2 idler gear shaft

Idler gear push-puller A

φ 37

φ 40

No. 2 idler shaft puller A

M12 × 1.25 M10 × 1.5

11-63

TIMING GEARS Inspection before removal Inspection: Backlash between gears • For each pair of gears, measure the backlash at more than three teeth. • If any of the measurements exceeds the specified limit, replace the defective part(s).

Inspection: Idler gear end play • If the measurement exceeds the specified limit, replace the defective part(s).

Removal procedure Removal: No. 1 idler shaft and No. 1 idler gear • With the bolt loosened by approximately 15 mm, pull out the No. 1 idler shaft from the crankcase using . • Remove the bolt. Remove the No. 1 idler shaft and No. 1 idler gear.

Removal: No. 2 idler shaft

Inspection procedure Inspection: Clearance between No. 1 idler shaft and No. 1 idler gear bushing [Inspection] • If the measurement exceeds the limit, replace the bushing.

11-64

11 Replacement of No. 1 idler gear bushing [Removal]

[Installation] • Place the No. 1 idler gear as shown in the illustration. Using , insert the bushing until contacts the chamfered tooth edge of the gear. • After installation, measure the clearance again. • If the measurement is less than the standard value, ream the bushing.

Inspection: Clearance between No. 2 idler gear bushing and No. 2 idler shaft [Inspection] • If the measurement exceeds the limit, replace the bushing.

Replacement of No. 2 idler gear bushing [Removal]

[Installation] • Place the No. 2 idler gear as shown in the illustration. Using , insert the bushing until contacts the chamfered tooth edge of the gear. • After installation, measure the clearance again. • If the measurement is less than the standard value, ream the bushing.

11-65

TIMING GEARS Installation: No. 2 idler shaft • Install the No. 2 idler shaft onto the crankcase ensuring that the boss of the shaft faces down.

Installation: No. 1 idler gear • Install the No. 1 idler gear such that the alignment mark “2” on the gear is aligned with the alignment mark “2 2” on the air compressor gear. • When installing the No. 1 idler gear, also ensure that the alignment mark “1 1” on the gear is aligned with the alignment mark “1” on the crankshaft gear.

11-66

11 M E M O

11-67

CRANKSHAFT AND CRANKCASE

11-68

11 Disassembly sequence 1 2 3 4 5 6 7

Torsional damper Crankshaft pulley Front oil seal Front cover Main bearing cap Lower main bearing Thrust plate

8 9 10 11 12 13 14

Front oil seal slinger Rear oil seal slinger Crankshaft gear Crankshaft Rear plate Upper main bearing Check valve

15 Oil jet 16 Crankcase : Locating pin : Non-reusable parts

CAUTION • The check valve has been tightened using thread-locking compound and so, may deform during removal. Once removed, the check valve must not be reused. Do not remove it unless defects are evident.

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location 6, 13

Main bearing

Maintenance item

Standard value

Limit

Remedy

Oil clearance

0.039 to 0.101

0.15

Replace

–

Less than 89.5

Replace

Span when free End play

0.10 to 0.25

0.4

Replace

Bend

0.025 or less

0.05

Rectify or replace

0.01 or less

0.03

Rectify or replace

0.006 or less

–

Rectify or replace

0.07 or less

0.2

Replace

Crankshaft

Distortion of crankcase top surface

Out-of-roundPins and journals ness Taper

Tightening torque (Unit: N·m {kgf·m}) Mark

Tightening torque

Remarks

Bolt (crankshaft pulley installation)

Parts to be tightened

190 {19}

–

Bolt (torsional damper installation)

78 {8}

–

Bolt (main bearing cap installation)

+10° 78 + 90° +10° 0 {8 + 90° 0 }

Check valve

34 {3.5}

• Wet • Reusable up to 3 times –

Lubricant and/or sealant Mark

Points of application Front cover surface to be mated with crankcase

Specified lubricant and/or sealant

Quantity

ThreeBond 1207C

As required

Engine oil

As required

ThreeBond 1217H

As required

Front oil seal lip Thread of bolts Inside surface of main bearing Crankcase mounting surface of rear plate

11-69

CRANKSHAFT AND CRANKCASE Special tools (Unit: mm) Mark

Tool name and shape

Main bearing cap extractor A

M8 × 1.25

Socket wrench

Part No.

Application

MH061189

Removal of main bearing cap

MH061560

Installation of main bearing cap

MH062710

Installation of front oil seal slinger

MH061470

Installation of rear oil seal slinger

MH061326

Removal of crankshaft gear

Front oil seal slinger installer A φ 76

Rear oil seal slinger installer A

φ 104.5 φ 100

Gear puller

11-70

C φ 14

11 Inspection before removal Inspection: Crankshaft end play • If the measurement exceeds the specified limit, replace the thrust plates with oversized ones.

Removal procedure Removal: Main bearing caps

Removal: Front oil seal slinger • Taking care not to damage the crankshaft, split the rear oil seal slinger using a chisel or a similar tool. Removal: Rear oil seal slinger • Taking care not to damage the crankshaft, split the rear oil seal slinger using a chisel or a similar tool. Removal: Crankshaft gear

CAUTION • Do not tap off the crankshaft gear as this can damage it.

Inspection procedure Inspection: Main bearing (1) Main bearing span when free

CAUTION • Do not attempt to manually expand the bearings. • If the measurement exceeds the specified limit, replace the upper and lower bearings as a set.

11-71

CRANKSHAFT AND CRANKCASE (2) Main bearing-to-crankshaft clearance (oil clearance) • Fit the upper main bearing into the crankcase and the lower main bearing into the main bearing cap. • Tighten the main bearing cap bolts to a torque of 78 N·m {8 kgf·m}. • Measure the inside diameter of the main bearing and the diameter of the corresponding crankshaft journal. • If the difference between the measurements exceeds the specified limit, machine the crankshaft journal to one of the specified undersize dimensions.

Inspection: Crankshaft (1) Bend • Measure the crankshaft at the center journal for bend while supporting the shaft at the end journals. • A half of the dial gauge reading obtained as the crankshaft is rotated by a full turn represents the bend of the crankshaft. • If the measurement exceeds the specified limit, replace the crankshaft.

(2) Roundness and cylindricity of crankshaft journals and pins • If any of the measurements exceeds the specified limits, grind the crankshaft journal(s) and/or pin(s) to undersize(s) or replace the crankshaft.

11-72

11 Grinding of crankshaft

CAUTION • If the crankshaft pins and journals are ground to undersizes, be sure to use bearings of corresponding undersizes. • Do not change the center-to-center distance A between the journal and pin. A: 57.5 +0.0252 –0.075 mm • Do not change the journal width B and the pin width C. B: 37 +0.2 0 mm C: 42 +0.2 0 mm • Finish the fillets D smoothly. D: R4 ± 0.2 mm • Carry out a magnetic inspection to check for cracks possibly caused by grinding. Also, check that the hardness of the surface has not dropped below Shore hardness number (Hs) 75. • Replace the crankshaft if defects are evident.

Crankshaft undersize dimensions (Unit: mm) Undersizes Finished journal outside diameter Finished pin outside diameter

0.25

0.50

0.75

1.00

83.685 to 83.705

83.435 to 83.455

83.185 to 83.205

82.935 to 82.955

69.67 to 69.69

69.42 to 69.44

69.17 to 69.19

68.92 to 68.94

Out-of-roundness

0.01 or less

Taper

0.006 or less

• When grinding, turn both the crankshaft and the grinder counterclockwise as viewed from the crankshaft front end. • When finishing the crankshaft with whetstone or sandpaper, rotate the crankshaft clockwise.

Inspection: Distortion of crankcase top surface • If the measurement exceeds the limit, correct the crankcase top surface with a surface grinder.

CAUTION • Do not grind the crankcase top surface so much as to compromise the correct piston projection.

11-73

CRANKSHAFT AND CRANKCASE Installation procedure Installation: Rear plate • Clean the rear plate surface where sealant is to be applied. • Apply an even and continuous bead of sealant onto the rear plate surface where the crankcase is to be mounted. • Install the rear plate onto the crankcase within 3 minutes following the application. Be careful not to smear the sealant bead.

CAUTION • Do not start the engine at least for an hour after the rear plate has been installed. • If the rear plate mounting bolts are subsequently loosened, be sure to apply sealant again upon reassembly. Installation: Crankshaft gear • Heat the crankshaft gear to approximately 100°C with a burner or the like.

WARNING • Be careful not to get burned. • Align the key fitted in the crankshaft with the slot in the crankshaft gear. Drive the gear into position by lightly striking its end face with a plastic hammer. Installation: Rear oil seal slinger • Using , install the rear oil seal slinger onto the crankshaft until comes into positive contact with the end face of the crankshaft gear.

Installation: Front oil seal slinger • Using , install the front oil seal slinger onto the crankshaft until the end face of comes into positive contact with the guide.

11-74

11 Installation: Main bearing • Install the main bearings with their lugs aligned as shown in the illustration. When the crankshaft journals have been ground to an undersize, use undersized main bearings. Available main bearing undersizes: 0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm

CAUTION • The upper main bearing has an oil hole. The lower main bearing has no oil hole. Do not confuse the upper and lower bearings, as this can cause seizure in the engine. Installation: Thrust plate • Install trust plates on both sides of the main bearing cap and the rear end of the crankcase, ensuring that the oil grooves face outside. : Locating pin

NOTE • If oversized thrust plates are to be used, those with a mark must be the same in size. Oversized thrust plates are available in the following sizes: 2.6 mm, 2.75 mm and 2.9 mm.

CAUTION • If thrust plates are installed with the oil grooves facing inside, the engine may seize. Installation: Main bearing cap

CAUTION • Before installing the main bearing cap bolts, check the number of punch marks on the head of each bolt. (A bolt with two or less marks is reusable.) • The number of punch marks corresponds with the number of times the main cap bolt has been tightened using the torque-turn tightening method. Any bolt that has three marks (i.e. that has been used three times) must be replaced. • Starting at the front of the engine, fit the main bearing caps in the order of the embossed numbers facing the illustrated direction.

11-75

CRANKSHAFT AND CRANKCASE • Tighten all the bolts to 78 N·m {8 kgf·m}, then additionally tighten them according to the following procedure. • Turn the holder of counterclockwise to pretension the internal spring.

• Set the tool such that the rod (extension) is pressed against the crankshaft by the force of the spring. • Align a scale mark on the socket with a scale mark on the holder. (This point will be the point of reference, or the 0° point.) • Starting with this point of reference, turn the socket with a wrench in the illustrated direction until the scale on the socket indicates 90°. One graduation on the socket-side scale represents 5°. • After tightening the bolts using the above torque-turn tightening method, make a punch mark on the head of each bolt to indicate the number of times that it has been used.

CAUTION • The bolts that have been tightened using the torque-turn method must never be additionally tightened after the final angular tightening. • After installing the main bearing cap, rotate the crankshaft by hand. If it cannot be rotated smoothly, inspect the main bearing caps for correct installation. Installation: Front oil seal • Install the front oil seal onto the front cover while pressing the seal’s entire periphery evenly to prevent it from tilting. • Install the front oil seal until its flange comes into positive contact with the front cover.

Installation: Front cover • Clean the front cover surface where sealant is to be applied. • Apply an even and continuous bead of sealant onto the front cover surface where the crankcase is to be mounted. • Install the front cover onto the crankcase within 3 minutes following the application. Be careful not to smear the sealant bead.

CAUTION • Do not start the engine at least for an hour after the front cover has been installed. • If the front cover mounting bolts are subsequently loosened, be sure to apply sealant again upon reassembly.

11-76

GROUP 12 LUBRICATION SPECIFICATIONS .............................................................................. 12-2 STRUCTURE AND OPERATION 1. 2. 3. 4. 5.

Lubrication System ........................................................................... 12-3 Oil Pump ............................................................................................. 12-3 Oil Cooler ............................................................................................ 12-4 Oil Filter ....................................................................................... 12-5 Lubrication of Engine Components ................................................. 12-6

TROUBLESHOOTING ....................................................................... 12-9 GENERAL INSPECTION AND ADJUSTMENT 1. Oil Filter Replacement ..................................................................... 12-10 2. Engine Oil Replacement .................................................................. 12-12 3. Oil Pressure Measurement ............................................................. 12-13

OIL PAN, OIL JETS AND OIL LEVEL SENSOR .............................. 12-14 OIL PUMP, OIL STRAINER ............................................................. 12-16 OIL FILTER ...................................................................................... 12-18 OIL COOLER ................................................................................... 12-20 REGULATOR VALVE ....................................................................... 12-21

12-1

SPECIFICATIONS Item

Specifications

Method of lubrication

Oil pump type

Oil filter

Spin-on paper-filter type

Oil cooler

Shell and plate type (multiple-plate type) Grade

Engine oil

12-2

Quantity

API classification CD, CD/SF, CE, CE/SF, CF-4 dm3 {L}

Oil pan

Approx. 11 {11}, 12 {12}, 16 {16}, 28 {28},

Oil filter

Approx. 2.3 {2.3}

STRUCTURE AND OPERATION 1. Lubrication System

Engine oil pressure switch Main oil gallery Bypass valve Oil cooler Engine oil bypass alarm switch 6 Full-flow filter element 7 Bypass filter element 8 Relief valve (built into oil pump) 1 2 3 4 5

9 10 11 12 13 14 15 16 17 18

Oil pump Oil strainer Regulator valve Crankshaft main bearing Connecting rod bearing Connecting rod bushing Check valve for oil jet Piston Air compressor Timing gear

19 20 21 22 23 24 25 26 27

Camshaft bushing Rocker bushing Roller Valve bridge No.1 Idler shaft No.2 Idler shaft No.3 Idler shaft Turbocharger Oil pan

2. Oil Pump â&#x20AC;˘ This engine uses a gear-type oil pump driven by the rotation of the crankshaft transmitted through the engagement of the crankshaft gear and the oil pump gear. â&#x20AC;˘ The oil pump has a relief valve, which prevents excessive pressure from building up inside the lubricating system by allowing part of the engine oil to escape to the oil pan when the oil pressure exceeds a specified level.

12-3

STRUCTURE AND OPERATION 3. Oil Cooler

3.1 Bypass valve • When the engine oil is cool and its viscosity is high, or when the oil cooler element becomes clogged and restricts the flow of the engine oil, the bypass valve opens to let the engine oil bypass the oil cooler and flow directly to the oil filter.

3.2 Engine oil pressure switch and regulator valve • When the pressure of the engine oil to the main oil gallery drops below the specified level, an electrical contact inside the engine oil pressure switch closes. This causes a warning lamp on the meter cluster to illuminate and notify the operator of the excessive pressure drop. • When the oil pressure in the main oil gallery exceeds the specified level, the regulator valve opens to adjust the oil pressure by allowing part of the engine oil to escape to the oil pan.

12-4

12 4. Oil filter • This oil filter is a spin-on paper-filter type that incorporates both a full-flow filter and a bypass filter.

4.1 Engine oil bypass alarm switch • If the oil filter elements clog up, this will restrict the flow of engine oil, causing the engine to seize. To prevent this, the oil filter is provided with the engine oil bypass alarm switch. • If the oil filter clogs up, the engine oil bypass alarm switch trips in such a way as to direct the engine oil straight on to the oil cooler, bypassing the fullflow and bypass filter elements. When the switch trips, the relevant warning lamp illuminates to alert the operator to the clogged oil filter.

12-5

STRUCTURE AND OPERATION 5. Lubrication of Engine Components • The engine oil in the main oil gallery lubricates the engine components in the following ways.

5.1 Main bearing and connecting rod bearing

• Engine oil supplied through an oil passage in the crankshaft lubricates the big end (connecting rod bearing) of each connecting rod. Simultaneously, engine oil supplied through an oil passage in the connecting rod lubricates the connecting rod’s small end (connecting rod bushing).

5.2 Timing gears

• Engine oil in the main oil gallery is directed through the oil passages in the crankcase and cylinder head and is used to lubricate the various gear shafts. After lubricating the gear shafts, the oil is used to lubricate the gears before returning the oil pan.

12-6

12 5.3 Valve mechanism

• Engine oil in the main oil gallery is directed through the oil passages in the cylinder head, rocker case and front rocker bracket. The oil is then supplied through the camshaft and rocker shaft. The oil flowing through the camshaft also lubricates the camshaft journals. The oil flowing through the rocker shaft also lubricates the rockers. The oil flowing to the adjusting screws on the rockers also lubricates the valve bridges. After lubricating the various parts, the oil returns to the oil pan.

5.4 Check valves and oil jets • An oil jet is fitted in the lower part of the main oil gallery for each cylinder. • Engine oil is sprayed out of the oil jet into the piston to cool the piston. • Each oil jet is fitted with a check valve that opens and closes at predetermined oil pressure levels. At low engine speeds, the check valve closes to maintain the required volume of oil in the lubrication system and prevent reductions in oil pressure.

12-7

STRUCTURE AND OPERATION 5.5 Turbocharger • Engine oil in the main oil gallery is directed through a pipe to the bearing housing to lubricate the inner components. • A piston ring is provided on each end of the turbine wheel shaft. The rings function as oil sealing.

5.6 Air compressor • Engine oil in the main oil gallery is directed through a passage in the crankshaft to the supply pump coupling and also to the big ends of the connecting rods to lubricate these parts. At the same time, the pistons and the small ends of the connecting rods are splash-lubricated with engine oil by the rotating crankshaft.

12-8

TROUBLESHOOTING

Low oil pressure

Excessive oil consumption (oil leakage)

Incorrectly mounted element

Defective gasket

O O

Engine is difficult to start

Overheating

Symptoms

Possible causes

Oil cooler

Defective O-ring

Clogged element

Damaged element

Weakened bypass valve spring

Malfunctioning oil pump

Interference between oil pump gear and oil pump case and/or cover Oil pump

Incorrectly connected oil pipe

Clogged oil strainer

O O

Incorrect installation

Clogged element

Defective O-ring Front cover timing gear case Flywheel housing

Weakened relief valve spring Oil filter

O O

Defective front oil seal

Incorrectly mounted front cover

Defective rear oil seal

Incorrectly mounted gasket

Weakened regulator valve spring O

Oil working its way up into combustion chamber(s) through piston rings

Oil working its way down into combustion chamber(s) through valves

Gr11

Poor oil quality

Deterioration of oil

Excess of oil Fuel mixed with oil

Gr11

Defective piston cooling oil jet(s)

Too high oil viscosity

Reference Gr

O O

12-9

GENERAL INSPECTION AND ADJUSTMENT 1. Oil Filter Replacement Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Drain plug (oil filter)

Tightening torque

Remarks

7.8 ± 2.0 {0.8 ± 0.2}

–

Lubricant and/or sealant Mark –

Points of application Oil filter

Specified lubricant and/or sealant

Quantity

Engine oil API classification CD, CD/SF, CE, CE/SF, CF-4

Approx. 2.3 dm3 {2.3L}

Special tools Mark

Tool name and shape

Part No.

Oil filter wrench

MH061537

Application

Removal of oil filter

WARNING • Wipe up any spilled engine oil, as it can cause fires.

• Remove the oil filter using

12-10

12 [Installation] • Clean the surface of the oil filter head where the oil filter is to be mounted. • Apply a thin coat of engine oil onto the oil filter gasket. • Screw in the oil filter by hand until the gasket contacts the oil filter head. Tighten further by 1 1/8 to 1 3/8 of a turn. • Install the drain plug. • With the oil filter installed, start the engine and ensure that there is no oil leakage through the gasket. • If oil is leaking, remove and reinstall the oil filter. • Stop the engine and check the engine oil level. • Add engine oil if the engine oil level is low.

12-11

GENERAL INSPECTION AND ADJUSTMENT 2. Engine Oil Replacement Tightening torque (Unit: N·m {kgf·m}) Mark

Tightening torque

Remarks

–

Drain plug (oil filter)

Parts to be tightened

7.8 ± 2.0 {0.8 ± 0.2}

–

Drain plug (oil pan)

69 {7}

–

Lubricant and/or sealant Mark –

–

Points of application

Specified lubricant and/or sealant

Quantity Approx. 2.3 dm3 {2.3L}

Oil filter Engine oil API classification CD, CD/SF, CE, CE/SF, CF-4

Oil pan

Approx. 11 dm3 {11L}, 12 dm3 {12L}, 16 dm3 {16L}, 28 dm3 {28L}

WARNING • Wipe up any spilled engine oil, as it can cause fires.

CAUTION • Make sure not to put any engine oil on the V-belt when working on the oil filter. V-belts soiled with oil or grease may easily slip, resulting in deteriorated performance of the cooling system. [Draining] • Remove the filler cap. • Remove the drain plugs of the oil filter or oil pan to drain out the engine oil. [Refilling] • Tighten the drain plug to the specified torque, then pour a specified amount of new engine oil into the engine. • Stop the engine and check the engine oil level. • Add engine oil if the engine oil level is low.

CAUTION • Do not add engine oil too much. An excessive oil level can only lead to increased oil consumption or make the positive crankcase ventilation system less efficient.

12-12

12 3. Oil Pressure Measurement Service standards Location

–

Maintenance item

Oil pressure (oil temperature at 70 to 90°C)

Standard value

No-load minimum speed

145 to 295 kPa {1.5 to 3 kgf/cm2}

No-load maximum speed

295 to 490 kPa {3 to 5 kgf/cm2}

Limit

Remedy

49 kPa {0.5 kgf/ cm2}

Inspect

195 kPa {2 kgf/cm2}

Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Engine oil pressure switch

Tightening torque

Remarks

15 to 22 {1.5 to 2.2}

Sealant With cold engine

Lubricant and/or sealant Mark –

Points of application Engine oil pressure switch threads

Specified lubricant and/or sealant

Quantity

Teflon tape

3 1/2 turns

• Remove the engine oil pressure switch.

• Using an adapter, connect an oil pressure gauge to the engine oil pressure switch mounting hole. • Warm up the engine until the oil temperature reaches 70 to 90°C. • Measure the oil pressure while running the engine at a minimum speed and then at maximum speed, both under no load. • If the measurements are below the specified limits, overhaul the lubrication system. • After taking the measurements, wrap the threads of the engine oil pressure switch with teflon tape and then tighten the switch to the specified torque.

CAUTION • Reinstall the oil pressure switch only when the engine is cold.

12-13

OIL PAN, OIL JETS AND OIL LEVEL SENSOR Disassembly sequence 1 2 3 4

Drain plug Oil pan Check valve Oil jet : Locating pin : Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

CAUTION • If overtightened, the check valve will not operate properly, leading to engine seizure. Be sure to tighten the check valve to the specified torque.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Drain plug Check valve

Tightening torque

Remarks

69 {7}

–

34 {3.5}

–

Lubricant and/or sealant Mark

Points of application Crankcase mounting surface of oil pan

12-14

Specified lubricant and/or sealant

Quantity

ThreeBond 1207C

As required

12 Installation procedure • • • •

Installation: Oil pan Clean the mating surfaces of each part. Apply a bead of sealant to the mating surface of the oil pan evenly and without any breaks. Change the amount of application to A and B at four locations shown in the illustration. Mount the oil pan within three minutes of applying the sealant. Make sure that the sealant stays in place.

CAUTION • Do not start the engine for one hour after installation. If the oil pan mounting bolts were loosened or removed, be sure to reapply sealant.

12-15

OIL PUMP, OIL STRAINER

Disassembly sequence 1 2 3 4 5 6 7

Oil strainer Gasket Oil pipe Gasket Cover Driven gear Ring

8 9 10 11 12 13 14

Relief valve Relief valve spring Washer Gear and case Shim Shim Gasket

15 Oil deflector a: *b: *

Crankshaft gear Oil pump gear : Locating pin : Non-reusable parts

• The oil strainer, the oil pipe and the oil pump must all be removed together as an assembly. • Do not disassemble the oil pump unless defects are evident. • The gear and case assembly is not serviceable. If the gear and case assembly appears defective, replace it.

Assembly sequence Follow the disassembly procedure in reverse.

Service standards (Unit: mm) Location 5, 11 5, 6, 11 6, 11

Standard value

Limit

Remedy

Clearance between drive gear shaft and cover

Maintenance item

0.04 to 0.07

0.15

Replace

Clearance between driven gear shaft and case, and that between the shaft and cover

0.04 to 0.07

0.15

Replace

Clearance between case and tooth tips of each gear

0.10 to 0.19

0.2

Difference between case depth and height of each gear

0.06 to 0.11

0.15

1.1 ± 0.1 MPa {11 ± 1 kgf/cm2}

–

Replace

Relief valve opening pressure

Relief valve spring installed load (installed length: 30)

84N {8.6 kgf}

–

Replace

a, b Backlash between crankshaft gear and oil pump gear

0.08 to 0.15

0.35

Adjust

* *

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (oil pump cover mounting)

12-16

Tightening torque

Remarks

25 ± 4.9 {2.5 ± 0.5}

–

12 Inspection before removal Inspection: Backlash between oil pump gear and crankshaft gear • If the measurement exceeds the limit, adjust by shimming. Shim feeler

Change in backlash

0.1 mm

0.073 mm

0.2 mm

0.146 mm

CAUTION • Perform shimming such that the shim packs on both sides will have the same feeler.

Inspection procedure Inspection: Driven gear, Gear and case assembly • Perform the following inspections. Replace the defective part(s) as required. (1) Difference between case depth and height of each gear

(2) Clearance between case and tooth tips of each gear

(3) Clearance between drive gear shaft and cover (4) Clearance between driven gear shaft and case, and that between the shaft and cover

12-17

OIL FILTER Removal sequence 1 2 3 4 5 6

Drain plug Oil filter Engine oil bypass alarm switch O-ring Oil filter head Gasket : Non-reusable parts

Installation sequence Follow the removal sequence in reverse.

WARNING • Wipe up any spilled engine oil, as it can cause fires. • To avoid any risk of burns, take care not to touch the engine oil when the engine is hot.

CAUTION • When adding engine oil, be careful not to allow engine oil to smear the V-belt. A V-belt smeared with oil will slip, resulting in reduced cooling efficiency.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

Drain plug

7.8 ± 2 {0.8 ± 0.2}

–

Engine oil bypass alarm switch

49 ± 4.9 {5.0 ± 0.5}

–

Bolt (Oil filter head mounting)

37 to 53 {3.6 to 5.4}

–

Lubricant and/or sealant Mark

Points of application Oil filter gasket O-ring

12-18

Specified lubricant and/or sealant

Quantity

Engine oil

As required

12 [Removal] • Remove the drain plug and drain the oil out of the oil filter.

• Remove the oil filter using

[Installation] • Clean the surface of the oil filter head where the oil filter is to be mounted. • Apply a thin coat of engine oil onto the oil filter gasket. • Screw in the oil filter by hand until the gasket contacts the oil filter head. Tighten further by 1 1/8 to 1 3/8 of a turn. • Install the drain plug. • With the oil filter installed, start the engine and ensure that there is no oil leakage through the gasket. • If oil is leaking, remove and reinstall the oil filter. • Stop the engine and check the engine oil level. • Add engine oil if the engine oil level is low.

12-19

OIL COOLER Removal sequence Bypass valve O-ring Plug O-ring Plug O-ring Engine oil pressure switch Regulator valve (See later pages.) O-ring Plug O-ring Plug O-ring Oil cooler element Gasket Oil cooler cover Gasket O-ring

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

: Non-reusable parts

Installation sequence Follow the removal sequence in reverse.

Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

Air leakage from oil cooler element (air pressure: 1470 kPa {15 kgf/cm2})

0 cm3 {0 mL}

–

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bypass valve Nut (oil cooler element mounting) Engine oil pressure switch Regulator valve Plug

Tightening torque

Remarks

15 to 20 {1.5 to 2.0}

–

24.5 to 32.3 {2.5 to 3.3}

–

15 to 22 {1.5 to 2.2}

–

98 to 118 {10 to 12}

–

14.7 to 19.6 {1.5 to 2.0}

–

Lubricant and/or sealant Mark

Points of application

Lubricant and/or sealant

Quantity

Engine oil pressure switch threads

Teflon tape

3 1/2 turns

O-ring

Engine oil

As required

Inspection procedure Inspection: Oil cooler element • Plug the outlet of the oil cooler element and connect a hose to the engine oil inlet port. Then, immerse the oil cooler element in a tank of water. • Apply a specified air pressure for 15 seconds through the hose, and check for any air leaks. • Replace the element if it leaks air.

12-20

REGULATOR VALVE Disassembly sequence 1 2 3 4

Snap ring Valve Spring Body

Assembly sequence Follow the removal sequence in reverse.

Service standards (Unit: mm) Location

Maintenance item

–

Regulator valve opening pressure

Spring installed load (installed length 48.3)

Standard value

Limit

Remedy

392 ± 29 kPa {4.0 ± 0.3 kgf/cm2}

–

Replace

78.5 ± 1.96 N {8.0 ± 0.2 kgf}

–

Replace

12-21

GROUP 13A FUEL AND ENGINE CONTROL SPECIFICATIONS ............................................................................ 13A-2 STRUCTURE AND OPERATION 1. Fuel System (Flow of Fuel) ........................................................ 13A-3 2. Fuel Filter .................................................................................. 13A-4 3. Water separator ..........................................................................13A-5

13A

TROUBLESHOOTING ..................................................................... 13A-6 GENERAL INSPECTION AND ADJUSTMENT 1. Air-bleeding of Fuel System....................................................... 13A-8 2. Fuel Filter Replacement ................................................................ 13A-10 3. Water Separator Element Replacement ................................... 13A-12 FUEL FILTER ................................................................................. 13A-14 WATER SEPARATOR .................................................................... 13A-16 COMMON RAIL...............................................................................13A-20 SUPPLY PUMP ...............................................................................13A-22 INJECTOR.......................................................................................13A-24

13A-1

SPECIFICATIONS Item

Specifications

Manufacturer Supply pump

DENSO

Control system

Electronically-controlled pump

Type

HP-4

Feed pump type

Trochoid pump

Manufacturer

Common rail system

DENSO 3

Common rail capacity

cm {mL}

Pressure limiter valve opening pressure

MPa {kgf/cm2}

Common rail pressure sensor supply voltage

Manufacturer Injector

13A-2

221 Âą 9 {2253 Âą 91.8} 5 DENSO

Control system Maximum injection pressure

26 {26}

Electronically controlled MPa {kgf/cm2}

155 {1580}

STRUCTURE AND OPERATION

13A

1. Fuel System (Flow of Fuel)

• Fuel in the fuel tank is sucked up by the feed pump, which is driven by the pump camshaft within the supply pump, and is fed through the fuel filter where foreign matter is filtered out. • The filtered fuel is sent to the supply pump where it is pressurized, and then is accumulated in the common rail. The accumulated fuel is then delivered through the injectors into the combustion chambers. • If fuel leakage occurs through any of the fuel line connections between the common rail and injectors, the relevant flow damper(s) will close, shutting off fuel supply and thus preventing any further fuel leakage out of the system. • If the pressure of fuel in the common rail rises above the specified level, the pressure limiter valve opens to allow fuel to return to the fuel tank. • If the pressure of fuel in the supply pump rises above the specified limit, fuel is allowed to returned to the fuel tank.

13A-3

STRUCTURE AND OPERATION 2. Fuel Filter

• The fuel filter removes foreign matter from fuel via the filter element. The fuel filter also incorporates a water separator which separates any water from fuel. • Water separated from fuel accumulates at the bottom of the fuel filter assembly. When water has accumulated to a certain level, this is detected by the water separator sensor, provided on the fuel filter assembly, which then illuminates a warning lamp on the meter cluster. • The water which has collected in the water separator can be drained through the drain hole by loosening the water separator sensor. • To bleed air from the fuel system, a manually operated pump is provided on the fuel filter head.

13A-4

13A 3. Water separator â&#x20AC;˘ The water separator separates water in fuel. â&#x20AC;˘ The float provides visual indication of the level of the water separated from fuel. This enables the water to be drained at an appropriate timing through the drain hole by loosening the drain plug.

13A-5

TROUBLESHOOTING

Common rail system abnormal

Supply pump

Common rail

Incorrect injector fuel injection

O O

O O O

Incorrect pump output

O O

Defective pressurized-fuel delivery system

O O

Defective SCV; Defective base supply pump

O O

SCV open-circuited, short, or intermittent connection

O O

Defective sealing

Pressure limiter valve opening pressure too low

O O

Operation of flow damper

O O O

O O O O

Defective injector, injector magnetic valve, or injection nozzle

O O

O O O O O O

No fuel in fuel tank

O O O

O O O O O

Piping cracked

O O O

O O

Piping crushed and restricted

O O

Foreign matter stuck in piping

O O

Defective sealing or sealing surface

O O

O O O

Piping cracked or clogged

O O

O O O

O O O O

O O O

O O

Incorrectly adjusted accelerator pedal stopper bolt Defective accelerator position sensor

SCV: Suction Control Valve : Contact DENSO Service Station for repair.

O O O O

O Gr13E

O O

Poor quality fuel is used

O Gr13E or

Defective sealing or sealing surface

Air or water in fuel system

13A-6

O O

Injector magnetic valve open-circuited, short, or intermittent connection

O O

* * * *

O O

Fuel filter clogged

Engine control

O O

Clogged water separator

Low-pressure piping

O O O

Defective sealing

Orifice clogged

High-pressure piping

Reference Gr

O Gr13E

Defective feed pump

Common rail pressure sensor circuit open, short, or intermittent connection

Warning lamp illuminates

Fuel supply insufficient

Engine does not reach maximum speed

Engine stalls immediately after start

Engine idling unstable

Engine maximum speed too high

Engine output not sufficient

Excessive black smoke

Engine output unstable

Engine knocks

Possible causes

Engine hard to start

Engine does not start

Symptoms

O O Gr13E

13A

Oil viscosity unsuitable

Valve clearance incorrect

Defective cylinder head gasket

Valve and valve seat worn and carbon deposits

Valve spring fatigued

Piston ring worn and damaged

Piston ring groove worn and damaged

Piston and cylinder liner worn

Crankshaft incorrectly sized

O O O

Cooling system malfunction

Defective starter switch

O O

Defective glow relay

O O

Defective sensor; Sensor open-circuited, short, or intermitEngine speed sensor; Cylinder tent connection recognition Each sensor improperly mounted sensor

O O Gr14 O

O O O

O O

Dead battery Alternator malfunction Blown fuse

O O

Defective electronic control unit main power relay; Relay open-circuited, short O O or intermittent connection

Not yet initialized for supply pump unit difference

Gr13E

O O O O O

O O

Gr11

Defective idling speed adjustment knob; Idling speed adjustment knob opencircuited, short or intermittent connection

Defective electronic control unit

O Gr13E

Defective coolant temperature sensor; Coolant temperature sensor open-cirO O cuited, short, or intermittent connection

Engine electronic control unit

Warning lamp illuminates

Gr11

O O

Defective fuel injection volume adjusting resistor; Resistor open-circuited, short, or intermittent connection

Reference Gr

Gr12

O O O

Defective boost pressure sensor; Boost pressure sensor open-circuited, short or intermittent connection

Fuel supply insufficient

Engine does not reach maximum speed

Engine stalls immediately after start

Engine idling unstable

Engine maximum speed too high

Engine output not sufficient

Excessive black smoke

Possible causes

Engine hard to start

Engine does not start

Symptoms

O O

13A-7

GENERAL INSPECTION AND ADJUSTMENT 1. Air-bleeding of Fuel System Tightening torque (Unit: N·m {kgf·m}) Mark –

Parts to be tightened Plug

Tightening torque

Remarks

10 ± 2 {1 ± 0.2}

–

• Loosen one of the bleeder plugs on the fuel filter. • Feed the system with fuel by manually operating the pump up and down. • Continue pumping until fuel with no bubbles of air comes out of the bleeder plug. • With no air bubbles coming out with fuel, tighten the bleeder plug to the specified torque. • Continue operating the pump until there is strong pumping resistance.

CAUTION • If the fuel is cold, pumping resistance may not become strong. Even if this is the case, be sure to cycle the pump several times. • Wipe up all spilled fuel, then start the engine. • Check that no fuel leakage occurs.

WARNING • Fuel is highly flammable. Keep it away from flames and sources of heat. • Be sure to wipe up all spilled fuel. Unless it is wiped up, it could catch fire.

13A-8

13A M E M O

13A-9

GENERAL INSPECTION AND ADJUSTMENT 2. Fuel Filter Replacement Tightening torque (Unit: N·m {kgf·m}) Mark

Tightening torque

Remarks

–

Water separator sensor

Parts to be tightened

5 ± 1 {0.5 ± 0.1}

–

Case

30 ± 2 {3.1 ± 0.2}

–

Lubricant and/or sealant Location –

Points of application O-ring

Specified lubricant and/or sealant

Quantity

Engine oil

As required

Special tools Mark

Tool name and shape

Part No.

Filter wrench

MH063203

Application

Removal and installation of case

[Removal] • Drain fuel from the case by loosening the water separator sensor. • Using , remove the case.

WARNING • Fuel is highly flammable. Keep it away from flames and sources of heat. • Thoroughly wipe up any spilled fuel. Otherwise, it may catch fire.

CAUTION • Be careful not to damage the case.

13A-10

13A [Installation] • Clean the surface of the fuel filter head where the O-ring is to be mounted.

• Replace the filter element and O-rings with new parts. • Apply a thin coat of engine oil to the O-rings. Install the O-rings onto the case and water separator sensor.

CAUTION • The use of non-genuine filter elements will lead to engine problems. Be sure to use only genuine parts. • To help prevent fuel injection problems, keep the fuel filter and hoses free from contamination.

• Using , tighten the case to the specified torque. • Tighten the water separator sensor to the specified torque. With the sensor correctly installed, bleed air from the fuel system. • Start the engine and ensure that there is no fuel leakage. • If there is fuel leakage, remove and install the fuel filter correctly.

13A-11

GENERAL INSPECTION AND ADJUSTMENT 3. Water Separator Element Replacement Tightening Torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

1.47 ± 0.3 {0.15 ± 0.03}

–

Drain plug

–

Cover

19.6 ± 2.5 {2.0 ± 0.3}

–

Plug A

12.3 ± 2.5 {1.25 ± 0.3}

–

Plug B

17.2 ± 2.5 {1.75 ± 0.3}

–

Lubricant and/or sealant Mark –

Points of application O-ring

Specified lubricant and/or sealant

Quantity

Engine oil

As required

Special tools Mark

Tool name and shape

Part No.

Filter wrench

MH063201

Application

Removal and installation of cover

[Removal] • Loosen the plugs A and B, then loosen the drain plug to let out the fuel in the water separator. • Remove the cover using the .

WARNING • Fuel is highly inflammable. Keep open flame and heat source away from it. • Spilled fuel can easily catch a fire. Wipe it off completely.

CAUTION • Be careful not to damage the cover.

13A-12

13A [Installation] • Clean the O-ring contact surface of the water separator body and the O-ring fitting groove in the cover.

• Replace the element and O-ring with new ones. • Apply a thin coat of engine oil to the O-ring and fit the O-ring onto the cover.

CAUTION • The use of inappropriate element can lead to engine problems. Be sure to use a genuine element. • To prevent fuel injection problems, keep the water separator and fuel hoses clear of fine dirt and other foreign matter.

• Using the with a torque wrench attached to it, tighten the cover to the specified torque. • Tighten the drain plug, plug A and plug B to the specified torque. Then, bleed the fuel system of trapped air. • Start the engine and ensure that there is no fuel leakage. • If there is any fuel leakage, remove the water separator and reinstall it correctly.

13A-13

FUEL FILTER Disassembly sequence 1 2 3 4 5 6 7 8

Fuel hose Water separator sensor O-ring Case O-ring Element Plug Fuel filter head

: Non-reusable parts

WARNING • Fuel is highly flammable. Keep it away from flames and sources of heat. • Thoroughly wipe up any spilled fuel. Otherwise, it may catch fire.

Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

Water separator sensor

5 ± 1 {0.5 ± 0.1}

–

Case

30 ± 2 {3.1 ± 0.2}

–

Plug

10 ± 2 {1 ± 0.2}

–

Lubricant and/or sealant Mark

Points of application O-ring

Specified lubricant and/or sealant

Quantity

Engine oil

As required

Special tools Mark

Tool name and shape

Part No.

Filter wrench

MH063203

Application

Removal and installation of case

Removal procedure Removal: Case • Drain fuel from the case by loosening the water separator sensor. • Using , remove the case.

CAUTION • Be careful not to damage the case.

13A-14

13A Installation procedure Installation: Case • Clean the surface of the fuel filter head where the O-ring is to be mounted.

• Replace the filter element and O-rings with new parts. • Apply a thin coat of engine oil to the O-rings. Install the O-rings onto the case and water separator sensor.

• Using , tighten the case to the specified torque. • Tighten the water separator sensor to the specified torque. With the sensor correctly installed, bleed air from the fuel system. • If there is fuel leakage, remove and install the fuel filter correctly.

13A-15

WATER SEPARATOR Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12

Fuel hose Plug A O-ring Plug B O-ring Drain plug O-ring Cover O-ring Float Element Body

: Non-reusable parts

WARNING • Fuel is highly flammable. Keep it away from flames and sources of heat. • Thoroughly wipe up any spilled fuel, otherwise it may catch fire.

Assembly sequence Follow the disassembly sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

Plug A

12.3 ± 2.5 {1.3 ± 0.3}

–

Plug B

17.2 ± 2.5 {1.8 ± 0.3}

–

1.47 ± 0.3 {0.15 ± 0.03}

–

19.6 ± 2.5 {2.0 ± 0.3}

–

Drain plug Cover

Lubricant and/or sealant Mark

Points of application O-ring

Specified lubricant and/or sealant

Quantity

Engine oil

As required

Special tools (Unit: mm) Mark

Tool name and shape

Filter wrench

13A-16

Part No.

MH063201

Application

Removal and installation of cover

13A Removal procedure Removal: Fuel filter • Drain fuel from the cover by loosening the drain plug after loosening the plug A and B. • Remove the cover using .

CAUTION • Be careful not to damage the case.

Installation procedure Installation: Cover • Clean the O-ring contact surface of the water separator body and the O-ring fitting groove in the body.

• Replace the element and O-ring with new ones. • Apply a thin coat of engine oil to the O-ring and fit the O-ring onto the cover.

CAUTION • The use of an inappropriate element can lead to engine problems. Be sure to use a genuine element. • To prevent fuel injection problems, keep the water separator and fuel hoses clear of fine dirt and other foreign matter.

13A-17

WATER SEPARATOR • Using the with a torque wrench attached to it, tighten the cover to the specified torque. • Tighten the drain plug, plug A and plug B to the specified torque. Then, bleed the fuel system of trapped air. • Start the engine and ensure that there is no fuel leakage. • If there is any fuel leakage, remove the water separator and reinstall it correctly.

13A-18

13A M E M O

13A-19

COMMON RAIL

Disassembly sequence 1 2 3 4 5 6

Fuel temperature sensor O-ring Eyebolt Fuel return pipe Connector Eyebolt

7 8 9 10 11 12

Fuel overflow pipe Fuel pipe Injection pipe Flow damper Pressure limiter Common rail pressure sensor

13 Common rail Crankcase : Non-reusable parts

*a:

WARNING • Fuel is highly flammable. Do not handle it near flames or heat. • Spilled fuel may catch fire and therefore, must be wiped up completely. • Any contamination of the common rail, even if it is minor, will greatly affect the performance of the engine. After removing pipes or other parts, plug the openings with covers. Wash eye bolts and gaskets in light oil and keep them away from contaminants. • For the maintenance of the common rail, ask Denso Service Station.

Assembly sequence Follow the disassembly sequence in reverse.

13A-20

13A Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Fuel temperature sensor Eyebolt (for fuel return pipe mounting)

Tightening torque

Remarks

17.6 to 21.5 {1.8 to 2.2}

–

25 {2.6}

–

17.7 to 22.6 {1.8 to 2.3}

–

Fuel pipe

49 to 58.8 {5.0 to 6.0}

–

Injection pipe

39.2 to 49 {4.0 to 5.0}

–

160 to 190 {16 to 19}

–

98 {10}

–

Eyebolt (for fuel overflow pipe mounting)

Flow damper Pressure limiter Common rail pressure sensor

Lubricant and/or sealant Mark

Points of application Threads and end face of common rail pressure sensor

Specified lubricant and/or sealant

Quantity

DENSO Grease 5

As required

Installation procedure Installation: Common rail pressure sensor • Apply grease onto the threaded portion and end face of the sensor.

CAUTION • Do not touch the connector terminal of the common rail sensor.

Installation: Injection pipe and fuel pipe • Ensure that the pipe and mounting surfaces of the connector are flat and free from damage. • Bring the pipe into intimate contact with mounting surfaces of the connector evenly, and temporarily tighten it without applying an excessive force. • Tighten it to the specified torque after temporary tightening.

13A-21

SUPPLY PUMP

Disassembly sequence 1 2 3 4 5

Eyebolt Fuel return pipe Eyebolt Fuel suction pipe Fuel pipe

6 7 8 9 10

Supply pump bracket Supply pump Driving disc O-ring Key

*a: *b: *c:

Air compressor Fuel temperature sensor Suction control valve

: Non-reusable parts

WARNING • Fuel is highly flammable. Do not handle it near flames or heat. • Spilled fuel may catch fire and therefore, must be wiped up completely.

CAUTION • Any contamination of the supply pump, even if it is minor, will greatly affect the performance of the engine. After removing pipes, hoses, or other parts, plug the openings with covers. Wash eye bolts and gaskets in light oil and keep them away from contaminants. • For the maintenance of the supply pump, ask Denso Service Station.

Assembly sequence Follow the disassembly sequence in reverse.

13A-22

13A CAUTION • If the supply pump has been replaced, perform the “initialization of supply pump unit difference learning value” using Multi-Use Tester in order to clear the correction data (learned pump unit difference) from the engine electronic control unit. (See Gr13E.)

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Fuel pipe

Tightening torque

Remarks

39.2 to 49 {4.0 to 5.0}

–

Eyebolt (for fuel return pipe mounting)

7.9 to 12.7 {0.8 to 1.3}

–

Eyebolt (for fuel suction pipe mounting)

14.8 to 19.6 {1.5 to 2.0}

–

Lubricant and/or sealant Mark

Points of application O-ring

Specified lubricant and/or sealant

Quantity

Engine oil

As required

Installation procedure Installation: Supply pump • Position the No. 1 piston to the top dead center in the compression stroke in the following manner. • Crank the engine to align the pointer with the “1 6” mark on the flywheel. • This will bring either the No. 1 piston or the No. 6 piston to the top dead center in the compression stroke. If both the inlet and exhaust rockers can be moved by hand by the amount of valve clearance, that cylinder is at the top dead center in the compression stroke. From that position, every turn of the crankshaft will alternately bring the No.1 and No. 6 pistons to the top dead center in the compression stroke. (See Gr11.) • Install the supply pump while ensuring that the stamped line on the supply pump timing cover is aligned with the stamped line on the coupling block.

13A-23

INJECTOR Disassembly sequence 1 2 3 4 5 6 7 8 9 10

*a::

Injection pipe Injection pipe seal O-ring Nozzle bridge Injector O-ring O-ring Nozzle tip gasket Eye bolt Fuel return pipe Two-Way electromagnetic Valve Non-reusable parts

WARNING • Fuel is highly flammable. Keep it away from flames and sources of heat. • Be sure to wipe up all spilled fuel. Unless it is wiped up, it could catch fire.

CAUTION • To eliminate fuel injection and other problems, protect the injectors and pipes, that have been removed, from the ingress of contaminants. • For the maintenance of the injector, ask Denso Service Station.

Assembly sequence Follow the disassembly sequence in reverse.

CAUTION • Do not attempt to clean the nozzle hole with a wire brush or other similar tools, or the hole can be damaged. • Be sure to tighten the nozzle bridge bolts to the specified torque. Overtightening the bolts can deform the injectors, resulting in incorrect fuel injection.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (for mounting nozzle bridge) Injection pipe Eyebolt (for mounting fuel return pipe)

Tightening torque

Remarks

33 to 38 {3.4 to 3.9}

–

39.2 to 49 {4.0 to 5.0}

–

25 {2.6}

–

Lubricant and/or sealant Mark

Points of application O-ring

13A-24

Specified lubricant and/or sealant

Quantity

Engine oil

As required

13A Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Application

Injector extractor adapter

MH062560

Removing injector (use with MH061071)

Nozzle extractor A

MH061071

Removing injector

M8 ∞ 1.25

Removal procedure Removal: Injector • Using and and with the wire of groove on the injector, remove the injector.

engaged in the

13A-25

GROUP 13E ELECTRONICALLY CONTROLLED FUEL SYSTEM SPECIFICATIONS ............................................................................ 13E-2 STRUCTURE AND OPERATION 1. Overview .................................................................................. 13E-4 2. Electronic Control System ...................................................... 13E-12 3. Electronic Control Unit Connection Diagram .......................... 13E-18

13E

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

Diagnostic Procedure ................................................................... Diagnostic Precautions ................................................................ Inspections Based on Diagnostic Codes ................................... Multi-Use Tester Service Data ................................................. Reading and Erasing Diagnostic Trouble Codes ....................... Actuator Tests Performed Using Multi-Use Tester ..................... Initialization of Supply Pump Unit Difference Learning Value in Engine Electronic Control Unit ................................................ 8. Inspections Performed at Electronic Control Unit Connectors .............................................................................

13E-20 13E-21 13E-22 13E-37 13E-39 13E-41 13E-43 13E-44

INSPECTION OF ELECTRICAL EQUIPMENT ............................. 13E-47

13E-1

SPECIFICATIONS Item

Specification

Manufacturer

DENSO

Model Supply pump

HP-4

Control method

Electronic type

Feed pump type

Trochoid type

SCV (suction control valve)

Rated voltage V

Max. common rail pressure

MPa {kgf/cm2} [psi]

Manufacturer Common rail

DENSO 3

cm {mL}

Common rail volume Pressure limiter opening pressure

MPa {kgf/cm

Common rail pressure sensor supply voltage

Engine electronic control unit

221 Âą 9 {2250 Âą 92}

13E-2

DENSO

Control method

Electrical type {kgf/cm2}

Max. operating pressure

MPa

Min. operating pressure

MPa {kgf/cm2} [psi]

[psi]

Manufacturer Rated voltage

26 {26}

Manufacturer Injectors

24 155 {1580} [22473]

155 {1580} [22473] 24 {245} [3485] DENSO

13E M E M O

13E-3

STRUCTURE AND OPERATION 1. Overview • In the common rail system, an electronic control unit monitors various aspects of the engine (engine speed, throttle opening, coolant temperature, etc.) using information from sensors. In accordance with these data, the electronic control unit effects control over the fuel injection quantity, fuel injection timing, and fuel injection pressure in order to optimize the engine’s operation. • The electronic control unit has a diagnostic function that enables it to recognize abnormalities in the common rail system’s major components and alert the driver to them. • The common rail system consists mainly of an electronically controlled supply pump; injectors; a common rail; and the electronic control unit and sensors that are used to control the other components.

13E-4

13E • When the engine is cranked by means of the starter switch, the feed pump (this is located inside the supply pump) simultaneously draws fuel from the fuel tank and feeds it via the water separator and fuel filter to the SCV (suction control valve). A quantity of fuel metered by the SCV (suction control valve) is supplied via the inlet valves to the plunger chambers. • The fuel in the plunger chambers is pressurized. The outlet valves are then opened, and the fuel is fed under pressure to the common rail. • The pressurized fuel is held in the common rail and then uniformly fed to the injectors. • In response to signals from the engine electronic control unit, a solenoid valve in each injector causes the injector to inject fuel into the relevant combustion chamber at the optimal timing and in the optimal quantity.

13E-5

STRUCTURE AND OPERATION 1.1 Supply pump

13E-6

13E

CAUTION • Be sure to connect the SCV (suction control valve) connector to the engine harness before starting the engine. If the engine is started with the SCV (suction control valve) connector not connected, control of the supply pump by the engine electronic control unit would not be possible and a fault would ensue. • The supply pump pressurizes fuel and supplies it in a highly pressurized state. • Fuel drawn from the fuel tank by the feed pump is not supplied directly to the plungers. It is supplied first to the common rail pressure solenoid valve, which controls the amount of fuel reaching the plungers. • If the fuel pressure exceeds a certain level, the regulating valve returns fuel to the inlet side of the feed pump. This operation keeps the pressure of the fuel fed to SVC (suction control valve), constant. • Rotation of the camshaft causes (via the ring cam) up-down movement of the plungers. Fuel in the plunger chambers is thus highly pressurized. (1) SCV (suction control valve) • The SCV (suction control valve) receives fuel from the feed pump and feeds fuel toward the plungers of the supply pump in such a quantity that the fuel pressure corresponds to that required by the engine electronic control unit. • When the SCV (suction control valve) is not operating, i.e., when current is not flowing, fuel flows at its maximum rate. When current flows, the piston in the common rail pressure solenoid valve is pressed down such that fuel is not fed toward the plungers. • The engine electronic control unit controls the ratio of current-off time (duty ratio).

13E-7

STRUCTURE AND OPERATION 1.2 Common rail

• The common rail distributes to the injectors high-pressure fuel that has been fed from the supply pump. • Each flow damper prevents an abnormal outflow of fuel. It does so by blocking the fuel passage in the event of fuel leakage from the injection pipe or excessive injection of fuel from the injector. • The common rail pressure sensor is used in feedback control. It senses the fuel pressure inside the common rail and feeds a corresponding signal to the electronic control unit. • If the fuel pressure in the common rail exceeds a certain, set level, the piston in the pressure limiter pushes and compresses the spring such that fuel is able to escape. The pressure limiting valve thus prevents the fuel pressure from becoming higher than the set pressure.

CAUTION • When the pressure limiter is activated, the common rail system is faulty and needs an inspection. (1) Flow damper • During normal operation, the piston moves (thus pushing and compressing the spring) to the extent necessary for one injection quantity to pass through. The piston does not make contact with the seat at this time. When injection is complete, the piston is returned to its initial position by the spring. • If the amount of fuel passing through the flow damper becomes excessively great, the piston presses against the seat, thereby closing the fuel passage and preventing an abnormal outflow of fuel. When the piston has pressed against the seat, it does not return to its original position until the engine has been stopped and the pressure in the common rail has come down.

13E-8

13E 1.3 Injector

• In accordance with electrical signals from the engine electronic control unit, each injector supplies high-pressure fuel from the common rail to the relevant combustion chamber of the engine at the optimal timing and in the optimal quantity. • The injector is divided into the control section and the injector section. • The control section consists of the control chamber, magnet, spring, valve body, valve ball, pressure pin, command piston, and orifice plate. The pressure pin is located between the control section and the injection section. • The injection section consists of the nozzle body, nozzle needle, nozzle spring, and retaining nut.

13E-9

STRUCTURE AND OPERATION (1) Operation (1.1) Injection not taking place • With the magnet not energized, the valve body, is pushed up by the spring in the magnet such that the ball seat is closed. • The high-pressure fuel acts upon the control chamber via orifice plate. The same pressure acts upon the nozzle needle. • The fuel pressure acting on the nozzle needle cannot overcome the command piston and nozzle spring, so the nozzle needle stays in its downwardpushed position and injection does not take place.

(1.2) Start of injection • When the magnet is energized, the resulting electromagnetic force draws the valve body upward, causing the ball seat to open. • Fuel in the control chamber passes through the orifice plate and ball seat and flows to the fuel tank. • With the pressure in the control chamber reduced, the fuel acting on the nozzle needle overcomes the command piston and nozzle spring, pushing up the nozzle needle such that injection starts. • If the magnet remains energized, the injection rate reaches its maximum level.

13E-10

13E (1.3) End of injection â&#x20AC;˘ When energization of the magnet is stopped, the valve body is pushed downward by the spring in the magnet such that the ball seat closes. At this time, fuel flows into the control chamber via orifice plate, pushing down the command piston and nozzle needle such that injection finishes.

13E-11

STRUCTURE AND OPERATION 2. Electronic Control System 2.1 System block diagram

Engine

Input signals Engine speed sensor Cylinder recognition sensor Water temperature sensor Boost pressure sensor Common rail pressure sensor Fuel temperature sensor Intake air temperature sensor

Engine electronic control unit

Output signals

Fuel injection control

Injector magnetic valve supply pump (SCV: suction control valve)

Warm-up acceleration function

Fuel injection quantity control Fuel injection timing control Fuel injection pressure control

Electronic control unit main power relay

Exhaust gas recirculation valve control function (See Gr17.)

Engine warning lamp Tachometer

Vehicle

Glow drive relay

Starter switch Accelerator pedal position sensor Accelerator pedal switch Vehicle speed sensor Fuel injection rate adjustment resistor Memory clear switch (Connector) Diagnostic switch (Connector) Multi-Use Tester connector Transmission neutral switch

Starter continuous energization prevention function (See Gr54.)

Glow plugs

Pre-heat control function (See Gr54.)

Fault diagnostic function

Safety relay Exhaust gas recirculation solenoid valve

CAN communication

Truck VCM and other controls CAN: Controller Area Network

13E-12

13E Part

Main function/operation

Engine speed sensor

Sensing of engine speed

Cylinder recognition sensor

Cylinder recognition

Starter switch

Senses that the engine is in starting condition with the starter switch in START position.

Water temperature sensor

Sensing of coolant temperature

Accelerator pedal position sensor

Sensing of extent of accelerator pedal depression

Accelerator pedal switch

Sensing of released/depressed condition of accelerator pedal (OFF with pedal depressed)

Transmission neutral switch

Detecting of neutral position in the transmission (OFF with the transmission in neutral)

Vehicle speed sensor

Sensing of vehicle speed

Fuel temperature sensor

Sensing of fuel temperature

Diagnostic switch

Output of diagnostic codes

Memory clear switch

Deletion of diagnostic codes; output of past diagnostic codes

Fuel injection rate adjustment resistor

Correction of fuel injection rate

Boost pressure sensor

Sensing of boost pressure

Intake air temperature sensor

Sensing of intake air temperature

Multi-Use Tester connector

Communication between Multi-Use Tester and common rail system

Common rail pressure sensor

Sensing of common rail pressure

Injector magnetic valve

Control of fuel injection rate, fuel injection quantity, and fuel injection timing

SCV (suction control valve)

Control of fuel injection pressure

Electronic control unit main power relay

Power on/off of electronic control unit

Engine warning lamp

Indication of system abnormalities

Glow drive relay

ON/OFF control of glow plugs

(Tachometer)

(Indication of engine speed)

Exhaust gas recirculation solenoid valve

Exhaust gas recirculation switching control

Safety relay

Control of starter continuous energization prevention function

CAN communication (Truck VCM and other controls)

Engine data recognized by the engine electronic control unit are outputted to the CAN bus to enable Truck VCM and other controls system to obtain data needed for control. MVCU system issues signals to the engine electronic control unit via the CAN bus to enable it to effect engine control appropriate for each type of system control.

2.2 Fuel injection control (1) Pilot injection â&#x20AC;˘ Pilot injection entails the injection of an extremely small amount of fuel ahead of the main injection. â&#x20AC;˘ Pilot injection suppresses heat generation early in the injection cycle and thus suppresses NOx generation and noise at the start of combustion.

13E-13

STRUCTURE AND OPERATION 2.3 Fuel injection quantity control (1) Fuel injection quantity during engine startup • During engine startup, the fuel injection quantity is determined in accordance with the engine speed and coolant temperature.

(2) Basic fuel injection quantity • The basic fuel injection quantity is determined in accordance with the engine speed and throttle opening.

(3) Maximum injection quantity • The maximum injection quantity is calculated from the engine speed and boost pressure.

(4) Fuel injection rate adjustment resistor correction amount • To limit inconsistency in the injection quantity, the injection quantity is corrected by the fuel injection rate adjustment resistor.

13E-14

13E 2.4 Fuel injection timing control (1) Main injection timing • The main injection timing is calculated from the fuel injection quantity and engine speed.

(2) Pre injection timing • The pre injection timing is calculated from the fuel injection quantity and engine speed.

2.5 Fuel injection timing control • The fuel injection pressure is calculated from the fuel injection quantity and engine speed.

13E-15

STRUCTURE AND OPERATION 2.6 Warm-up acceleration function Input signals

Engine electronic control unit

Output signals

Comparison operations Water temperature sensor Accelerator pedal position sensor Idling speed adjustment potentiometer

Idling speed control Target injection quantity

• The warm-up acceleration function increases engine warm-up by varying the engine’s idling speed in accordance with the engine’s coolant temperature. It can operate either automatically or manually. Selection is made using the idling speed adjustment potentiometer.

2.7 Starter continuous energizing preventing function • This function is provided to prevent starter over-run. • If the starter operates for longer than a predetermined period following engine startup, the Engine electronic control unit deems that it has been energized continuously for too long. The Engine electronic control unit then stops the flow of current to the starter and starter relay, thereby preventing the starter from seizing. • If the engine electronic control unit determines, based on the engine speed signal it receives, that the engine has run at or above the specified speed for longer than the specified time period after start-up, the unit trips the safety relay open. (1) Operation mode

2.8 Preheating function • This preheating function aims to enhance the engine start up when the engine coolant is low in cold weather or temperature. (1) Pre-glow and After-glow The preheating is operated with a preglow before the engine starts and an after-glow after the engine starts. They are controlled by the starter switch (S terminal) signal, engine water temperature signal and the engine rotation signal.

13E-16

13E (2) Operation mode • When the engine coolant temperature is 60°C or more.

• When the engine coolant temperature is 0°C to 60°C.

• When the engine coolant temperature is 0°C or less.

2.9 Fault diagnostic function • When the starter switch is in the ON position, the system continuously monitors the sensors and other system components. If any fault is detected, the system warns the driver of this by illuminating the warning lamp and displaying the error code on the meter panel. At the same time, the system also stores a relevant diagnostic code in the memory and starts operation in the fault mode. • While the fault is taking place, the control limits the systems functionality to ensure vehicle and driver safety. It is possible to read the memorized diagnostic code using a Multi-Use Tester or from flashing of the warning lamp. • Diagnostic codes displayed on the meter panel, indicated by flashing of the warning lamp and shown by the MultiUse Tester are different. • The Multi-Use Tester is capable of showing more detailed diagnostic codes.

13E-17

STRUCTURE AND OPERATION 3. Electronic Control Unit Connection Diagram

13E-18

13E

13E-19

TROUBLESHOOTING 1. Diagnostic Procedure • The system can be efficiently inspected for faults using Diagnozer 2.41 or later software or a Multi-Use Tester III. System inspection can be accomplished basically in two ways according to trouble symptom and diagnostic code as shown below. • Check against each diagnostic code stored in memory by the electronic control unit • Response to transient fault Warning lamp lit

Vehicle in service shop

Read diagnostic code. (See Gr00.) Fault code output

Normal code output

Normal code output after cleared

Check against each diagnostic code

Response to transient fault (See Gr00.)

Clear stored diagnostic code. (See Gr00.)

Start the engine.

After starting the engine, check for diagnostic code and warning lamp lighting. If diagnostic code is issued and warning lamp is lit, check fault again.

Clear stored diagnostic code. (See Gr00.)

13E-20

13E 2. Diagnostic Precautions • Before measuring voltage, check the battery for charged condition and specific gravity. If system inspection is performed with the battery uncharged or reduced in specific gravity, accurate measurements cannot be achieved. • To avoid having electrical parts damaged, set the starter switch to LOCK or OFF before disconnecting and reconnecting battery cables. • Before disconnecting connectors, set the starter switch to LOCK or OFF, then allow at least 20 seconds. Voltage may remain in electric parts or connected circuit. • When performing measurement with the tester, handle the test bar carefully so that it does not damage internal circuit and other electrical parts of the electronic control unit to result in a short-circuit failure between terminals in connector or between connector and car body. • Resistance is affected by temperature. Determine the necessity of resistance measurement following given temperature specification as a guide. Otherwise, use normal temperature (10 to 35°C) as the measuring condition.

13E-21

TROUBLESHOOTING 3. Inspections Based on Diagnostic Codes 3.1 Diagnostic code list • Diagnostic codes displayed on the meter panel, indicated by flashing of the warning lamp and shown by the MultiUse Tester or Diagnozer 2.41 or later software are different. • The Multi-Use Tester or Diagnozer 2.41 or later software is capable of showing more detailed diagnostic codes.

Message

Code

GSE

Flashes

Accel Pedal Sensor 1

P0122

E-33

ECU Hardware (ROM)

Accel Pedal Sensor 1

P0123

E-33

ECU System (EEPROM)

P1605

Injector Circuit 1

P0200 P1200

GSE

Flashes

E-01 E-01

Message

Code P0605

E-02

Accel Pedal Sensor 2

P0222

E-34

E-02

Accel Pedal Sensor 2

P0223

E-34

Injector Circuit 2

E-03

Accel SW

P0510

E-34

Injector Circuit 3

P1210

E-04

Camshaft Position SNSR

P0340

E-35

Fuel Temp. Sensor (inlet) Low

P0182

E-05

Common Rail Pressure Defect

P0254

E-35

Fuel Temp. Sensor (inlet) High

P0183

E-05

Common Rail Pressure M/V 1

P0255

E-36

Fuel Temp. Sensor (outlet)

P0187

E-05

Common Rail Pressure M/V 1

P0256

E-36

Fuel Temp. Sensor (outlet)

P0188

P0257

E-37

INT Air Temp. SNSR (Low)

P0112

INT Air Temp. SNSR (High)

P0113 P1171

E-05

Common Rail Pressure M/V 1

E-06

Common Rail Pressure Defect

P0251

E-37

E-06

Common Rail Pressure Defect

P0252

E-39

Q Adjustment Resistor (Low)

E-07

CRS Pressure SNSR (Plausibility) P0191

E-39

Q Adjustment Resistor (High)

P1172

Vehicle Speed Sensor

P0500 P1255

E-07

CRS Pressure SNSR (Low)

P0192

E-41

E-07

CRS Pressure SNSR (High)

P0193

E-42

CRS Press M/V 1 (Low)

E-08

Accel Pedal Check (Plausibility)

P0121

E-42

CRS Press M/V 1 (High)

P1256

Common Rail Pressure M/V 1

P1257

E-09

Injector M/V-Cylinder1 (Load)

P0201

E-42

E-10

Injector M/V-Cylinder2 (Load)

P0202

E-43

EGR 1

P1267

E-11

Injector M/V-Cylinder3 (Load)

P0203

E-43

EGR 1

P1268

P0204

E-44

EGR 2

P1272

P0205

E-44

EGR 2

P1273 P1277

E-12

Injector M/V-Cylinder4 (Load)

E-13

Injector M/V-Cylinder5 (Load)

E-14

Injector M/V-Cylinder6 (Load)

P0206

E-45

EGR 3

E-15

Flow Limiter -Cylinder1

P1240

E-45

EGR 3

P1278

Relay for Glow Relay

P0380

E-16

Flow Limiter -Cylinder2

P1241

E-48

E-17

Flow Limiter -Cylinder3

P1242

E-49

Starter Safety Relay (Low)

P0616

E-18

Flow Limiter -Cylinder4

P1243

E-49

Starter Safety Relay (High)

P0617

E-19

Flow Limiter -Cylinder5

P1244

E-20

Flow Limiter -Cylinder6

P1245

E-24

Engine Revolution SNSR

P0335

E-25

Engine Overrunning

P0219

E-26

Boost Press SNSR (Low)

P0237

E-26

Boost Press SNSR (High)

P0238

E-28

Common Rail Pressure Defect

P0253

E-29

Atmospheric Pressure Sensor

P0107

E-29

Atmospheric Pressure Sensor

P0108

E-30

–

CAN Communication

P0600

E-32

Water Temp SNSR (Low)

P0117

E-32

Water Temp SNSR (High)

P0118

13E-22

13E 3.2 Diagnostic code generation conditions and inspection items E-01: Accel Pedal Sensor 1 (warning lamp flashes: 24) P0122 Generation condition

Accelerator pedal position sensor 1 voltage is below standard value.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Control is effected using accelerator pedal position sensor 2. • If both sensors 1 and 2 are faulty, control is effected on assumption that accelerator pedal is depressed 30% when accelerator switch is on and the pedal is not depressed when the switch is off.

Service data Inspection

Electronic control unit connector Electrical equipment

22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (filtered), 24: Accel Pedal Sensor Voltage 1 03 : Accelerator pedal position sensor

#324: Accelerator pedal position sensor

E-01: Accel Pedal Sensor 1 (warning lamp flashes: 24) P0123 Generation condition

Accelerator pedal position sensor 1 voltage is above standard value.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Service data Inspection

Electronic control unit connector Electrical equipment

22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (filtered), 24: Accel Pedal Sensor Voltage 1 03 : Accelerator pedal position sensor

#324: Accelerator pedal position sensor

E-02: Accel Pedal Sensor 2 (warning lamp flashes: 16) P0222 Generation condition

Accelerator pedal position sensor 2 voltage is below standard value.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Control is effected using accelerator pedal position sensor 1. • If both sensors 1 and 2 are faulty, control is effected on assumption that accelerator pedal is depressed 30% when accelerator switch is on and the pedal is not depressed when the switch is off.

Service data Inspection

Electronic control unit connector Electrical equipment

22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (filtered), 25: Accel Pedal Sensor Voltage 2 03 : Accelerator pedal position sensor

#324: Accelerator pedal position sensor

E-02: Accel Pedal Sensor 2 (warning lamp flashes: 16) P0223 Generation condition

Accelerator pedal position sensor 2 voltage is above standard value.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Service data Inspection

Electronic control unit connector Electrical equipment

22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (filtered), 25: Accel Pedal Sensor Voltage 2 03 : Accelerator pedal position sensor

#324: Accelerator pedal position sensor

13E-23

TROUBLESHOOTING E-03: Accel SW (warning lamp flashes: 65) P0510 Generation condition

Accelerator pedal switch signal is abnormal when compared with accelerator pedal position sensor outputs 1 and 2.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Normal control is effected using accelerator pedal position sensor signals.

Service data

73: Accel SW

Inspection Electronic control unit connector

10 : Accelerator pedal switch

Electrical equipment

#029: Accelerator pedal switch

E-04: Camshaft Position SNSR (warning lamp flashes: 12) P0340 Generation condition

Cylinder recognition sensor emits no pulses.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Control is effected using engine speed sensor. (If engine speed sensor also becomes faulty, engine is stopped.)

Service data

01: Engine Revolution

Inspection Electronic control unit connector

08 : Cylinder recognition sensor

Electrical equipment

#320: Cylinder recognition sensor

E-05: Common Rail Pressure Defect (warning lamp flashes: 23) P0254 Generation condition

Common rail pressure is slightly too high (lower than operating pressure of pressure limiter)

Recoverability

System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON.

Control effected by electronic control unit

• Main injections only enabled. • Common rail pressure upper limit provided. • Injection rate limited to predetermined value. • Exhaust gas recirculation control stopped. (Common rail pressure and injection quantity are limited.)

Inspection

Actuator test

B9: Fuel Leak Check

Other

• Inspection of fuel piping (See Gr13A.) • Inspection or replacement of supply pump. (Have work performed by DENSO Service Station.) • Pressure limiter (Have work performed by DENSO Service Station.), main body of common rail • Injectors (Have work performed by DENSO Service Station.)

E-05: Common Rail Pressure M/V 1 (warning lamp flashes: 23) P0255 Generation condition

Common rail pressure exceeds standard value for longer than standard period during low-speed use of supply pump.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Normal control

Inspection

13E-24

Actuator test

B9: Fuel Leak Check

Other

• Inspection or replacement of supply pump (Have work performed by DENSO Service Station.) • Pressure limiter (Have work performed by DENSO Service Station.), main body of common rail • Injectors (Have work performed by DENSO Service Station.)

13E E-05: Common Rail Pressure M/V 1 (warning lamp flashes: 23) P0256 Generation condition

Common rail pressure exceeds standard value for longer than standard period during mid-range-speed or high-speed use of supply pump.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Main injections only enabled. • Common rail pressure upper limit provided. • Injection rate limited to predetermined value. (Common rail pressure and injection quantity are limited.)

Inspection Other

E-05: Common Rail Pressure M/V 1 (warning lamp flashes: 23) P0257 Generation condition

Pressure-feed malfunction occurs because of fault in supply pump assembly (fault in one cylinder).

Recoverability

System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON.

Control effected by electronic control unit

• Main injections only enabled. • Common rail pressure upper limit provided. • Injection rate limited to predetermined value. (Common rail pressure and injection quantity are limited.)

Inspection Other

• Inspection or replacement of supply pump (Have work performed by DENSO Service Station.)

E-06: Common Rail Pressure Defect (warning lamp flashes: 36) P0251 Generation condition

Fuel is leaking from high-pressure part of system (calculated value).

Recoverability

System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON.

Control effected by electronic control unit

–

Inspection

Actuator test

B9: Fuel Leak Check

Other

• • • •

Air-bleeding of fuel system (See Gr13A.) Inspection of fuel piping (from supply pump to common rail) (See Gr13A.) Fuel filter (See Gr13A.) Supply pump (Have work performed by DENSO Service Station.), main body of common rail • Pressure limiter (Have work performed by DENSO Service Station.) • Injectors (Have work performed by DENSO Service Station.)

E-06: Common Rail Pressure Defect (warning lamp flashes: 36) P0252 Generation condition

Common rail pressure is too high and fuel leakage (calculated value) exceeds standard value.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

–

Inspection

Actuator test

B9: Fuel Leak Check

Other

• • • • • •

Air-bleeding of fuel system (See Gr13A.) Inspection of fuel piping (See Gr13A.) Fuel filter (See Gr13A.) Supply pump (Have work performed by DENSO Service Station.) Pressure limiter (Have work performed by DENSO Service Station.) Injectors (Have work performed by DENSO Service Station.)

13E-25

TROUBLESHOOTING E-07: CRS Pressure SNSR (Plausibility) (warning lamp flashes: 11) P0191

Generation condition

All three conditions listed below are satisfied simultaneously while engine is being cranked or while vehicle is being driven. • Engine speed, injection amount, common rail pressure and fuel type are within specification. • Difference between actual common rail pressure and target common rail pressure is greater than standard value. • Extent of changes in actual common rail pressure is smaller than standard value.

Recoverability

System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON.

Control effected by electronic control unit

• Common rail pressure open loop control is effected. • Exhaust gas recirculation control is stopped.

Inspection

Service data

07: Reference Common Rail Pressure, 09: Actual Common Rail Pressure, 0B: Difference Common Rail Pressure, 0C: Difference Common Rail Pressure

Electrical equipment

#319: Common rail pressure sensor

E-07: CRS Pressure SNSR (Low) (warning lamp flashes: 11) P0192 Generation condition

Common rail pressure sensor voltage is below standard value (0.7 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Common rail pressure open loop control is effected. • Exhaust gas recirculation control is stopped.

Inspection

Service data

07: Reference Common Rail Pressure, 09: Actual Common Rail Pressure, 0B: Difference Common Rail Pressure, 0C: Difference Common Rail Pressure

Electrical equipment

#319: Common rail pressure sensor

E-07: CRS Pressure SNSR (High) (warning lamp flashes: 11) P0193 Generation condition

Common rail pressure sensor voltage is above standard value (4.95 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Common rail pressure open loop control is effected. • Exhaust gas recirculation control is stopped.

Inspection

Service data

07: Reference Common Rail Pressure, 09: Actual Common Rail Pressure, 0B: Difference Common Rail Pressure, 0C: Difference Common Rail Pressure

Electrical equipment

#319: Common rail pressure sensor

E-08: Accel Pedal Check (Plausibility) (warning lamp flashes: 58) P0121 Generation condition

Output voltage difference of accelerator pedal position sensors 1 and 2 is outside standard range.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Control is effected using value of 30% with accelerator pedal depressed and using value of 0% with accelerator pedal not depressed. (Output is reduced.)

Service data Inspection

Electronic control unit connector Electrical equipment

22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (filtered), 24: Accel Pedal Sensor Voltage 1, 25: Accel Pedal Sensor Voltage 2 03 : Accelerator pedal position sensor

#324: Accelerator pedal position sensor

E-09: Injector M/V - Cylinder1 (Load) (warning lamp flashes: 37) P0201 Generation condition

Injector magnetic valve (No. 1 cylinder) is short-circuited or open-circuited.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Fuel injection stopped for faulty cylinder • Exhaust gas recirculation control stopped. • Inter-cylinder injection amount correction valve (FCCB) learning disabled.

Actuator test

BB: Injector Test 1

Inspection Electronic control unit connector

06 : Injector magnetic valve

Electrical equipment

#582: Injector magnetic valve

13E-26

13E E-10: Injector M/V - Cylinder2 (Load) (warning lamp flashes: 38) P0202 Generation condition

Injector magnetic valve (No. 2 cylinder) is short-circuited or open-circuited.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Fuel injection stopped for faulty cylinder • Exhaust gas recirculation control stopped. • Inter-cylinder injection amount correction valve (FCCB) learning disabled.

Actuator test

BF: Injector Test 5

Inspection Electronic control unit connector

06 : Injector magnetic valve

Electrical equipment

#582: Injector magnetic valve

E-11: Injector M/V - Cylinder3 (Load) (warning lamp flashes: 39) P0203 Generation condition

Injector magnetic valve (No. 3 cylinder) is short-circuited or open-circuited.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Fuel injection stopped for faulty cylinder • Exhaust gas recirculation control stopped. • Inter-cylinder injection amount correction valve (FCCB) learning disabled.

Actuator test

BD: Injector Test 3

Inspection Electronic control unit connector

06 : Injector magnetic valve

Electrical equipment

#582: Injector magnetic valve

E-12: Injector M/V - Cylinder4 (Load) (warning lamp flashes: 08) P0204 Generation condition

Injector magnetic valve (No. 4 cylinder) is short-circuited or open-circuited.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Fuel injection stopped for faulty cylinder • Exhaust gas recirculation control stopped. • Inter-cylinder injection amount correction valve (FCCB) learning disabled.

Actuator test

C0: Injector Test 6

Inspection Electronic control unit connector

06 : Injector magnetic valve

Electrical equipment

#582: Injector magnetic valve

E-13: Injector M/V - Cylinder5 (Load) (warning lamp flashes: 46) P0205 Generation condition

Injector magnetic valve (No. 5 cylinder) is short-circuited or open-circuited.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Fuel injection stopped for faulty cylinder • Exhaust gas recirculation control stopped. • Inter-cylinder injection amount correction valve (FCCB) learning disabled.

Actuator test

BC: Injector Test 2

Inspection Electronic control unit connector

06 : Injector magnetic valve

Electrical equipment

#582: Injector magnetic valve

E-14: Injector M/V - Cylinder6 (Load) (warning lamp flashes: 47) P0206 Generation condition

Injector magnetic valve (No. 6 cylinder) is short-circuited or open-circuited.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Fuel injection stopped for faulty cylinder • Exhaust gas recirculation control stopped. • Inter-cylinder injection amount correction valve (FCCB) learning disabled.

Actuator test

BE: Injector Test 4

Inspection Electronic control unit connector

06 : Injector magnetic valve

Electrical equipment

#582: Injector magnetic valve

13E-27

TROUBLESHOOTING E-15: Flow Limiter - Cylinder1 (warning lamp flashes: 71) P1240 Generation condition

Inter-cylinder injection amount correction value (FCCB) is higher than standard value and fluctuation in engine speed is greater than standard value.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

FCCB learning is disabled.

Inspection

Service data

43: Flow Limiter (#1)

Other

• Flow damper (Have work performed by DENSO Service Station.)

E-16: Flow Limiter - Cylinder2 (warning lamp flashes: 72) P1241 Generation condition

Inter-cylinder injection amount correction value (FCCB) is higher than standard value and fluctuation in engine speed is greater than standard value.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

FCCB learning is disabled.

Inspection

Service data

44: Flow Limiter (#2)

Other

• Flow damper (Have work performed by DENSO Service Station.)

E-17: Flow Limiter - Cylinder3 (warning lamp flashes: 73) P1242 Generation condition

Inter-cylinder injection amount correction value (FCCB) is higher than standard value and fluctuation in engine speed is greater than standard value.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

FCCB learning is disabled.

Inspection

Service data

45: Flow Limiter (#3)

Other

• Flow damper (Have work performed by DENSO Service Station.)

E-18: Flow Limiter - Cylinder4 (warning lamp flashes: 74) P1243 Generation condition

Inter-cylinder injection amount correction value (FCCB) is higher than standard value and fluctuation in engine speed is greater than standard value.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

FCCB learning is disabled.

Inspection

Service data

46: Flow Limiter (#4)

Other

• Flow damper (Have work performed by DENSO Service Station.)

E-19: Flow Limiter - Cylinder5 (warning lamp flashes: 75) P1244 Generation condition

Inter-cylinder injection amount correction value (FCCB) is higher than standard value and fluctuation in engine speed is greater than standard value.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

FCCB learning is disabled.

Inspection

Service data

47: Flow Limiter (#5)

Other

• Flow damper (Have work performed by DENSO Service Station.)

E-20: Flow Limiter - Cylinder6 (warning lamp flashes: 76) P1245 Generation condition

Inter-cylinder injection amount correction value (FCCB) is higher than standard value and fluctuation in engine speed is greater than standard value.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

FCCB learning is disabled.

Inspection

13E-28

Service data

48: Flow Limiter (#6)

Other

• Flow damper (Have work performed by DENSO Service Station.)

13E E-24: Engine Revolution SNSR (warning lamp flashes: 15) P0335 Generation condition

Engine speed sensor emits no pulses.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Control is effected using cylinder recognition sensor. (If cylinder recognition sensor also becomes faulty, engine is stopped.)

Service data

01: Engine Revolution

Inspection Electronic control unit connector

07 : Engine speed sensor

Electrical equipment

#263: Engine speed sensor

E-25: Engine Overrunning (warning lamp flashes: 07) P0219 Generation condition

Engine speed is higher than specified level.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Common rail system is deactivated (engine stopped immediately).

Inspection Electrical equipment

Engine electronic control unit

E-26: Boost Press SNSR (Low) (warning lamp flashes: 32) P0237 Generation condition

Boost pressure sensor voltage is below standard value (0.3 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Control is effected with boost pressure assumed as constant 101 kPa {1.03 kgf/ cm2}.

Inspection

Service data

26: Boost Pressure

Electrical equipment

#318: Boost pressure sensor

E-26: Boost Press SNSR (High) (warning lamp flashes: 32) P0238 Generation condition

Boost pressure sensor voltage is above standard value (4.7 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Control is effected with boost pressure assumed as constant 101 kPa {1.03 kgf/ cm2}.

Inspection

Service data

26: Boost Pressure

Electrical equipment

#318: Boost pressure sensor

E-28: Common Rail Pressure Defect (warning lamp flashes: 22) P0253 Generation condition

Common rail pressure is abnormally high (above 245 MPa (higher than operating pressure of pressure limiter))

Recoverability

System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON.

Control effected by electronic control unit

Common rail system is deactivated (engine stopped immediately).

Inspection Other

E-29: Atmospheric Pressure Sensor (warning lamp flashes: 19) P0107 Generation condition

Atmospheric pressure sensor (incorporated into engine electronic control unit) voltage is below standard value (1.9 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Control is effected with atmospheric pressure assumed as constant 101 kPa {1.03 kgf/cm2}. (Exhaust emissions worsen.) • Exhaust gas recirculation control is stopped.

Inspection

Service data

38: Atmospheric Pressure

Electrical equipment

Engine electronic control unit

13E-29

TROUBLESHOOTING E-29: Atmospheric Pressure Sensor (warning lamp flashes: 19) P0108 Generation condition

Atmospheric pressure sensor (incorporated into engine electronic control unit) voltage is above standard value (4.7 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Control is effected with atmospheric pressure assumed as constant 101 kPa {1.03 kgf/cm2}. (Exhaust emissions worsen.) • Exhaust gas recirculation control is stopped.

Inspection

Service data

38: Atmospheric Pressure

Electrical equipment

Engine electronic control unit

E-30: CAN Communication (warning lamp flashes: –) P0600 Generation condition

Error occurs in CAN communication with machinery side electronic control unit.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Engine speed is limited.

Inspection

Service data

4A: Speed Limiter Reference Speed

Other

• Combination of engine electronic control unit and machinery side electronic control unit is confirmed. • Vehicle speed sensor error is confirmed.

E-32: Water Temp SNSR (Low) (warning lamp flashes: 21) P0117 Generation condition

Water temperature sensor voltage is below standard value (0.1 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Water temperature is assumed as constant –20°C during engine startup and as constant 80°C while vehicle is being driven. (Exhaust emissions worsen.) • Exhaust gas recirculation control is stopped.

Service data

35: Water Temperature

Inspection Electronic control unit connector

02 : Water temperature sensor

Electrical equipment

#262: Water temperature sensor

E-32: Water Temp SNSR (High) (warning lamp flashes: 21) P0118 Generation condition

Water temperature sensor voltage is above standard value (4.8 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Service data

35: Water Temperature

Inspection Electronic control unit connector

02 : Water temperature sensor

Electrical equipment

#262: Water temperature sensor

E-33: ECU Hardware (ROM) (warning lamp flashes: 33) P0605 Generation condition

Main CPU in electronic control unit is abnormal.

Recoverability

System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON.

Control effected by electronic control unit

• Common rail system control is disabled (engine is stopped immediately) if mutual diagnoses of main CPU and sub CPU become impossible.

Inspection Other

Engine electronic control unit

13E-30

13E E-33: ECU System (EEPROM) (warning lamp flashes: 33) P1605 Generation condition

CPU in engine electronic control unit is faulty.

Recoverability

System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON.

Control effected by electronic control unit

Common rail system control is disabled (engine is stopped immediately) if mutual diagnoses of main CPU and sub CPU become impossible.

Inspection Other

Engine electronic control unit

E-34: Injector Circuit 1 (warning lamp flashes: 82) P0200 Generation condition

Either one of injector magnetic valves (No. 1, 2 or 3 cylinder) is short-circuited, or open-circuited.

Recoverability

• When short-circuited: System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON. • When open-circuited: System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

<When short-circuited> • Main injections only enabled. • Common rail pressure upper limit provided. • Injection rate limited to predetermined value. • Exhaust gas recirculation control stopped. • Inter-cylinder injection amount correction valve (FCCB) learning disabled. <When open-circuited> • Exhaust gas recirculation control stopped. • Inter-cylinder injection amount correction valve (FCCB) learning disabled.

Actuator test

BB: Injector Test 1, BD: Injector Test 3, BF: Injector Test 5

Inspection Electronic control unit connector

06 : Injector magnetic valve

Electrical equipment

#582: Injector magnetic valve

E-34: Injector Circuit 2 (warning lamp flashes: 82) P1200 Generation condition

Either one injector magnetic valves (No. 4, 5 or 6 cylinder) is short-circuited, or open-circuited.

Recoverability

Control effected by electronic control unit

<When short-circuited> • Main injections only enabled. • Common rail pressure upper limit provided. • Injection rate limited to predetermined value. • Exhaust gas recirculation control stopped. • FCCB learning disabled. <When open-circuited> • Auto cruise control stopped. • Exhaust gas recirculation control stopped. • FCCB learning disabled.

Actuator tests

BC: Injector Test 2, BE: Injector Test 4, C0: Injector Test 6

Inspection Electronic control unit connector

06 : Injector magnetic valve

Electrical equipment

#582: Injector magnetic valve

13E-31

TROUBLESHOOTING E-34: Injector Circuit 3 (warning lamp flashes: 82) P1210 Generation condition

Injector drive circuit voltage in engine electronic control unit is too low or too high.

Recoverability

System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON.

Control effected by electronic control unit

<Too low voltage> • Common rail pressure lower limit provided. • Idling speed is increased. • FCCB learning disabled. • Drive with the constant current. <Too high voltage> • Common rail system control is disabled (engine is stopped immediately).

Actuator tests

BB: Injector Test 1, BD: Injector Test 2, BD: Injector Test 3, BE: Injector Test 4, BF: Injector Test 5, C0: Injector Test 6

Inspection Electronic control unit connector

06 : Injector magnetic valve

Electrical equipment

#582: Injector magnetic valve

Other

Engine electronic control unit

E-35: Fuel Temp. Sensor (inlet) Low (warning lamp flashes: 41) P0182 Generation condition

Fuel temperature sensor (inlet) voltage is below standard value (0.1 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Fuel temperature is assumed to be constant 40°C.

Service data

36: Fuel Temperature (inlet)

Inspection Electronic control unit connector

04 : Fuel temperature sensor (inlet)

Electrical equipment

#323: Fuel temperature sensor (inlet)

E-35: Fuel Temp. Sensor (inlet) High (warning lamp flashes: 41) P0183 Generation condition

Fuel temperature sensor voltage is above standard value (4.8 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Fuel temperature is assumed to be constant 40°C.

Service data

36: Fuel Temperature (inlet)

Inspection Electronic control unit connector

04 : Fuel temperature sensor (inlet)

Electrical equipment

#323: Fuel temperature sensor (inlet)

E-36: Fuel Temp. Sensor (outlet) (warning lamp flashes: 56) P0187 Generation condition

Fuel temperature sensor (outlet) voltage is below standard value (0.1 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Fuel temperature is assumed as constant 40°C during engine startup and as constant 80°C while vehicle is being driven.

Service data

37: Fuel Temperature

Inspection Electronic control unit connector

05 : Fuel temperature sensor (outlet)

Electrical equipment

#323: Fuel temperature sensor (outlet)

E-36: Fuel Temp. Sensor (outlet) (warning lamp flashes: 56) P0188 Generation condition

Fuel temperature sensor (outlet) voltage is above standard value (4.8 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Fuel temperature is assumed as constant 40°C during engine startup and as constant 80°C while vehicle is being driven.

Service data

37: Fuel Temperature

Inspection Electronic control unit connector

05 : Fuel temperature sensor (outlet)

Electrical equipment

#323: Fuel temperature sensor (outlet)

13E-32

13E E-37: INT Air Temp. SNSR (Low) (warning lamp flashes: 44) P0112 Generation condition

Intake air temperature sensor voltage is below standard value (0.1 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Boost air temperature is assumed as constant –20°C during engine startup and as constant 25°C while vehicle is being driven.

Service data

27: Intake Air Temperature

Inspection Electronic control unit connector

01 : Intake air temperature sensor

Electrical equipment

#305: Intake air temperature sensor

E-37: INT Air Temp. SNSR (High) (warning lamp flashes: 44) P0113 Generation condition

Intake air temperature sensor voltage is above standard value (4.8 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Boost air temperature is assumed as constant –20°C during engine startup and as constant 25°C while vehicle is being driven.

Service data

27: Intake Air Temperature

Inspection Electronic control unit connector

01 : Intake air temperature sensor

Electrical equipment

#305: Intake air temperature sensor

E-39: Q Adjustment Resistor (Low) (warning lamp flashes: 34) P1171 Generation condition

Fuel injection rate adjustment resistor voltage is below standard value (0.6 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Control is effected using fuel injection rate adjustment resistor No. 1. (Output is slightly reduced.)

Service data

3E: Q Adjustment Resistor No.

Inspection Electronic control unit connector

11 : Fuel injection rate adjustment resistor

Electrical equipment

#828: Fuel injection rate adjustment resistor

E-39: Q Adjustment Resistor (High) (warning lamp flashes: 34) P1172 Generation condition

Fuel injection rate adjustment resistor voltage is above standard value (4.36 V).

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Control is effected using fuel injection rate adjustment resistor No. 1. (Output is slightly reduced.)

Service data

3E: Q Adjustment Resistor No.

Inspection Electronic control unit connector

11 : Fuel injection rate adjustment resistor

Electrical equipment

#828: Fuel injection rate adjustment resistor

E-41: Vehicle Speed Sensor (warning lamp flashes: 25) P0500 Generation condition

No vehicle speed sensor signal is received.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

• Engine speed is limited

Inspection Service data

3C: Vehicle Speed

13E-33

TROUBLESHOOTING E-42: CRS Press M/V 1 (Low) (warning lamp flashes: 63) P1255 Generation condition

SCV (suction control valve) is short-circuited to ground, or open circuited, or coil is broken.

Recoverability

System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON.

Control effected by electronic control unit

• • • •

Actuator test

Main injections only enabled. Common rail pressure upper limit provided. Injection rate limited to predetermined value. Exhaust gas recirculation control stopped.

B9: Fuel Leak Check

Inspection Electronic control unit connector

12 : SCV (suction control valve)

Electrical equipment

#574: SCV (suction control valve)

E-42: CRS Press M/V 1 (High) (warning lamp flashes: 63) P1256 Generation condition

SCV (suction control valve) is shorted to power supply circuit.

Recoverability

System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON.

Control effected by electronic control unit

• • • •

Actuator test

Main injections only enabled. Common rail pressure upper limit provided. Injection rate limited to predetermined value. Exhaust gas recirculation control stopped.

B9: Fuel Leak Check

Inspection Electronic control unit connector

12 : SCV (suction control valve) system

Electrical equipment

#574: SCV (suction control valve) system

E-42: Common Rail Pressure M/V 1 (warning lamp flashes: 63) P1257 Generation condition

SCV (suction control valve) binds and fails to operate.

Recoverability

System recovers (power is re-supplied to electronic control unit) if signal becomes normal when starter switch is turned OFF → ON.

Control effected by electronic control unit

• • • •

Actuator test

Main injections only enabled. Common rail pressure upper limit provided. Injection rate limited to predetermined value. Exhaust gas recirculation control stopped.

B9: Fuel Leak Check

Inspection Electronic control unit connector

12 : SCV (suction control valve)

Electrical equipment

#574: SCV (suction control valve)

E-43: EGR 1 (warning lamp flashes: 67) P1267 Generation condition

Exhaust gas recirculation solenoid valve (M/V-1) is shorted-circuited to ground, or open circuited.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Exhaust gas recirculation control is stopped.

Service data Inspection Actuator test Electrical equipment

1F: EGR Position A1: EGR 1 #530: Exhaust gas recirculation solenoid valve

E-43: EGR 1 (warning lamp flashes: 67) P1268 Generation condition

Exhaust gas recirculation solenoid valve (M/V-1) is shorted to power supply circuit.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Exhaust gas recirculation control is stopped.

Service data Inspection Actuator test Electrical equipment

13E-34

1F: EGR Position A1: EGR 1 #530: Exhaust gas recirculation solenoid valve

13E E-44: EGR 2 (warning lamp flashes: 68) P1272 Generation condition

Exhaust gas recirculation solenoid valve (M/V-2) is shorted-circuited to ground, or open circuited.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Exhaust gas recirculation control is stopped.

Service data Inspection Actuator test Electrical equipment

1F: EGR Position A2: EGR 2 #530: Exhaust gas recirculation solenoid valve

E-44: EGR 2 (warning lamp flashes: 68) P1273 Generation condition

Exhaust gas recirculation solenoid valve (M/V-2) is shorted to power supply circuit.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Exhaust gas recirculation control is stopped.

Service data Inspection Actuator test Electrical equipment

1F: EGR Position A2: EGR 2 #530: Exhaust gas recirculation solenoid valve

E-45: EGR 3 (warning lamp flashes: 69) P1277 Generation condition

Exhaust gas recirculation solenoid valve (M/V-3) is shorted-circuited to ground, or open circuited.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Exhaust gas recirculation control is stopped.

Service data Inspection Actuator test Electrical equipment

1F: EGR Position A3: EGR 3 #530: Exhaust gas recirculation solenoid valve

E-45: EGR 3 (warning lamp flashes: 69) P1278 Generation condition

Exhaust gas recirculation solenoid valve (M/V-3) is shorted to power supply circuit.

Recoverability

System recovers if signal becomes normal with starter switch in ON position.

Control effected by electronic control unit

Exhaust gas recirculation control is stopped.

Service data Inspection Actuator test Electrical equipment

1F: EGR Position A3: EGR 3 #530: Exhaust gas recirculation solenoid valve

E-48: Relay for Glow Relay (warning lamp flashes: 26) P0380 Generation condition

Glow drive relay is short-circuited or open circuited or overload.

Recoverability

System recovers if signal becomes normal with starter switch ON position.

Control effected by electronic control unit

â&#x20AC;˘ Suspend glow control

Inspection

Service data

8D: Glow relay

Actuator test

AF: Relay for glow relay

Electronic control unit connector Electrical equipment

13 : Glow drive relay

#201: Glow drive relay

13E-35

TROUBLESHOOTING E-49: Starter Safety Relay (Low) (warning lamp flashes: 48) P0616 Generation condition

Safety relay is shorted to power supply circuit.

Recoverability

System recovers if signal becomes with starter switch ON position.

Control effected by electronic control unit

â&#x20AC;˘ Continuous energization prevention function suspended.

Inspection

Service data

8F: Starter safety relay

Actuator test

B1: Starter safety relay

Electronic control unit connector Electrical equipment

14 : Safety relay

#201: Safety relay

E-49: Starter Safety Relay (High) (warning lamp flashes: 48) P0617 Generation condition

Safety relay is short-circuited to ground circuit, or open circuited.

Recoverability

System recovers if signal becomes with starter switch ON position.

Control effected by electronic control unit

Continuous energization prevention function suspended.

Inspection

Service data

8F: Starter safety relay

Actuator test

B1: Starter safety relay

Electronic control unit connector Electrical equipment

13E-36

14 : Safety relay

#201: Safety relay

13E 4. Multi-Use Tester Service Data • It is possible to see service data and actuator tests simultaneously. No.

Item

Data .rpm

Inspection condition

Engine Revolution

Reference Injection Quantity

Starter switch ON

Reference Common Rail Pressure Actual Common Rail Pressure Difference Common Rail Pressure Difference Common Rail Pressure

Starter switch ON

20 to 30%

Starter switch ON

MPa

Engine idling

0 MPa or lower

Engine idling

0% or lower

Idling [Actuator test] A1: EGR 1, A2: EGR 2, A3: EGR 3 Accelerator pedal not depressed Accelerator pedal gradually depressed Accelerator pedal fully depressed Accelerator pedal not depressed Accelerator pedal gradually depressed Accelerator pedal fully depressed Accelerator pedal gradually depressed from released position Accelerator pedal gradually depressed from released position Starter switch On (engine stopped) Press the accelerator pedal down after starting the engine

07 09 0B 0C

EGR Position

Accel Pedal Position (unfiltered)

Accel Pedal Position (filtered)

STEP

Accel Pedal Sensor Voltage 1

Accel Pedal Sensor Voltage 2

Boost Pressure

(

Intake Air Temperature (

KPa

inHg)

°C

°F)

Racing (engine running)

Requirement Value corresponds to tachometer indication.

Engine cold

0% Value gradually increases. 100% 0% Value gradually increases. 100% 0.85 to 4.15 V 0.85 to 4.15 V Equal to atmospheric pressure Gradual raise Value corresponds to ambient temperature.

°C

°F)

°C

°F)

°C

°F)

KPa

Value corresponds to ambient temperature. Engine in process of warming up Value gradually increases. Engine stopped after warming Value gradually decreases. up Value corresponds to ambient temEngine cold perature. Engine in process of warming up Value gradually increases. Engine stopped after warming Value gradually decreases. up Value corresponds to ambient temEngine cold perature. Engine in process of warming up Value gradually increases. Engine stopped after warming Value gradually decreases. up Altitude: 0 m 101 KPa (29.8 in.Hg)

inHg)

Altitude: 600 m

95 KPa (28.1 in.Hg)

Vehicle in motion

Value corresponds to speedometer indication.

Engine cold 35

Water Temperature (

Fuel Temperature (inlet) (

Fuel Temperature (

Atmospheric Pressure (

.km/h

Vehicle Speed (

.MPH)

13E-37

TROUBLESHOOTING No.

Item

Q Adjustment Resistor No.

Power Supply Voltage

Flow Limiter (#1)

Data

Inspection condition

1/2/3/4/5/6/7/8/ 9/10/11/NON

–

Requirement Number matches number marked on fuel injection rate adjustment resistor.

Starter switch ON

Value matches battery voltage.

Starter switch ON

Flow Limiter (#2)

Starter switch ON

Flow Limiter (#3)

Starter switch ON

Flow Limiter (#4)

Starter switch ON

Flow Limiter (#5)

Starter switch ON

Flow Limiter (#6)

Starter switch ON

Speed Limiter Reference Speed

Vehicle speed limited

Value is same as vehicle speed during vehicle speed restriction.

Engine idling

It is adjusting or Temporary end or Complete end.

4D 52 53

.km/h (

.MPH)

Pump Adjustment State Pump Adjustment Value (Last Time) Pump Adjustment Value (This Time)

. .

Engine idling

–100 to + 100 mA

Engine idling

–100 to + 100 mA

Starter SW (M)

ON/OFF

Accel SW

ON/OFF

Diagnostic SW

ON/OFF

Memory Clear SW

ON/OFF

Glow relay

ON/OFF

Glow relay indicator lamp

ON/OFF

Starter safety relay

ON/OFF

MIL Lamp

ON/OFF

Diagnostic Lamp

ON/OFF

13E-38

Starter Switch in ON position ON Starter switch in position except OFF ON Accelerator pedal not depressed ON Accelerator pedal depressed OFF Diagnostic switch OFF (fuse fitON ted) Diagnostic switch ON (fuse reOFF moved) Memory clear switch OFF (fuse ON fitted) Memory clear switch ON (fuse OFF removed) Actuator test is performed ON Actuator test is not performed OFF [Actuator test] AF: Relay for glow relay Actuator test is performed ON Actuator test is not performed OFF [Actuator test] B0: Glow indicator lamp Actuator test is performed ON Actuator test is not performed OFF [Actuator test] B1: Starter safety relay Starter switch ON (engine not ON started) No error after engine startup OFF [Actuator test] B3: MIL Lamp Starter switch ON (engine not ON started) No error after engine startup OFF [Actuator test] B4: Diagnostic Lamp

13E 5. Reading and Erasing Diagnostic Trouble Codes Diagnozer or Multi-Use Tester III is used to read or erase the diagnostic trouble code. And also, a method using the diagnostic switch and memory clear switch without these tools is available.

5.1 Method using Diagnozer or Multi-Use Tester III Refer to each service tool manual.

5.2 Method using diagnostic switch and memory clear switch (1) Current diagnostic trouble code • Set the starting switch to ON. • Disconnect the diagnostic switch connector. • The diagnostic trouble code is displayed by flashes of the warning lamp. (2) Reading diagnostic trouble code • Diagnostic trouble codes are indicated by the number of times the warning lamp flashes and their duration. • The flashing intervals also differ between the 10s digit and units digit. • 10s digit: 1.2 second interval • Units digit: 0.4 second interval • The display of diagnostic trouble codes starts from the 10s digit and next units digit. When the 10s digit of a diagnostic trouble code is 0, only the units code is displayed. • Some diagnostic trouble codes are displayed from the 10s unit in numeral followed by alphabet in place of the numeral for the units digit, in which case alphabetical letters are represented by the following numbers flashes. A: 10 times; B: 11 times; C: 12 times; D: 13 times; E: 14 times; F: 15 times Example) Diagnostic trouble code 8A. The lamp flashes 8 times for the 10s digit, followed by 10 times for A as the unit’s digit. • Each diagnostic trouble code is displayed three times in succession. • If there is no more code stored, the sequence is then repeated from the beginning with each code indicated three times. • When the diagnostic switch is connected, the engine control unit will immediately stop displaying codes. (3) Past diagnostic trouble codes • After reading the current diagnostic trouble codes (with the diagnostic switch disconnected), disconnect the memory clear switch. Then the warning lamp will restart flashing. • This time, the warning lamp displays the past diagnostic trouble codes. Determine the fault locations based on the indicated codes.

13E-39

TROUBLESHOOTING (4) Erasing diagnostic trouble codes Disconnect the memory clear switch connector and then reconnect. Then all the diagnostic trouble codes stored in the engine control unit will be cleared.

NOTE • Pay attention that the stored codes can be erased only by the operation of memory clear switch. • When you want to keep the memory contents after the indication of stored codes, leave the memory clear switch disconnected and turn the starter switch in the off position. Then connect the memory clear switch connector. • When you change the combination of the injection pump and engine control unit, you must rewrite the pump data stored in the engine control unit. For this purpose, be sure to perform the diagnostic trouble code erasing procedure.

13E-40

13E 6. Actuator Tests Performed Using Multi-Use Tester • It is possible to see service data and actuator tests simultaneously. No.

Item

EGR 1

EGR 2

EGR 3

Explanation

Confirmation method

Switch ON/OFF exhaust gas recirculation solenoid valve (automatic reset after six seconds) [Can be executed under the following conditions] • Vehicle: stopped (vehicle speed 0 km/h) • Starter switch: ON • Engine: Stopped

Operating sound of exhaust gas recirculation solenoid valve when turned ON/OFF [Service data] 1F: EGR Position

Relay for glow relay

Switch ON/OFF grow drive relay (automatic reset after six seconds) [Can be executed under the following conditions] • Vehicle: stopped (vehicle speed 0 km/h) • Starter switch: ON • Engine: Stopped

Operating sound of glow drive relay when turned ON/OFF [Service data] 8D: Glow Relay

Glow indicator lamp

Switch ON/OFF glow indicator lamp (automatic reset after six seconds) [Can be executed under the following conditions] • Vehicle: stopped (vehicle speed 0 km/h) • Starter switch: ON • Engine: Stopped

ON/OFF condition of indicator lamp [Service data] 8E: Glow Relay Indicator Lamp

Starter safety relay

Switch ON/OFF safety relay (automatic reset after six seconds) [Can be executed under the following conditions] • Vehicle: stopped (vehicle speed 0 km/h) • Starter switch: ON • Engine: Stopped

Operating sound of safety relay when turned ON/OFF [Service data] 8F: Starter Safety Relay

MIL Lamp

Switch ON/OFF engine warning lamp (orange) (automatic reset after six seconds) [Can be executed under the following conditions] • Vehicle: stopped (vehicle speed 0 km/h) • Starter switch: ON • Engine: Stopped

ON/OFF condition of warning lamp (orange) [Service data] 91: MIL Lamp

Diagnostic Lamp

Switch ON/OFF engine warning lamp (red) (automatic reset after six seconds) [Can be executed under the following conditions] • Vehicle: stopped (vehicle speed 0 km/h) • Starter switch: ON • Engine: stopped

ON/OFF condition of warning lamp (red) [Service data] 92: Diagnostic Lamp

13E-41

TROUBLESHOOTING No.

Item

Explanation Increase rail pressure for a specified six seconds [Can be executed under the following conditions] • Vehicle: stopped (vehicle speed 0 km/h) • Transmission: neutral • Diagnostic switch: OFF (removal of fuse)

Confirmation method

Check that no fuel leaks from fuel system (pipe, hose)

Fuel Leak Check

Injector Test 1

Injector Test 2

Injector Test 3

Injector Test 4

Injector magnetic valve (No.6 cylinder) should stop.

Injector Test 5

Injector magnetic valve (No.2 cylinder) should stop.

Injector Test 6

Injector magnetic valve (No.4 cylinder) should stop.

Pump Adjustment Value Clear

13E-42

Force the selected injector magnetic valve to be deactivated. [Can be executed under the following conditions] • Vehicle: stopped (vehicle speed 0 km/h) • Transmission: neutral • No present diagnostic codes generated

Delete the compensation information (pump learning condition) in engine electronic control unit

Injector magnetic valve (No.1 cylinder) should stop. Injector magnetic valve (No.5 cylinder) should stop. Injector magnetic valve (No.3 cylinder) should stop.

The service data “4D: Pump Adjustment State” displays “Unlearned”

13E 7. Initialization of Supply Pump Unit Difference Learning Value in Engine Electronic Control Unit • Following replacement of the engine electronic control unit or the supply pump, this item is used to program the current supply pump data into the engine electronic control unit.

7.1 After replacement of engine electronic unit with new one Replacement of engine electronic control unit with new one

Start engine. Allow it to warm up fully then run at low idle speed for 30 seconds. *

Check service data 4D: Pump Adjustment State. Learning, Temporal leaning completed or Learning completed will be shown. End of programming

* New engine electronic control unit starts auto learning when the truck is in a halt condition, engine lowidling, fuel temperature between 20 and 80˚C (68 and 176˚F) and water temperature 65˚C (149˚F) or higher without any defect.

7.2 After re-installing of other truck’s engine electronic control unit or replacement of supply pump without replacing engine electronic control unit. (This operation is available with MultiUse Tester III.) Replacement of supply pump or replacement (re-use) of engine electronic control unit

Erase the compensation information (pump learning condition) in the electronic control unit. Perform actuator test C2: Pump Adjustment Value Clear

Start engine. Allow it to warm up fully then run at low idle speed for 30 seconds.

Check service data 4D: Pump Adjustment State. Learning, Temporal leaning completed or Learning completed will be shown.

End of programming

7.3 Check after engine electronic control unit programming If the measurement values (which show the learning values) shown by service data 52: Pump Adjustment Value (Last Time) and 53: Pump Adjustment Value (This Time) are out of specification, a defect in the supply pump or in the engine electronic control unit is conceivable so you must replace the supply pump or engine electronic control unit. (Initialize the engine electronic control unit again after replacing the supply pump or engine electronic control unit.) • New engine electronic control unit starts automatic pump adjustment after engine warming-up and various conditions satisfied. To replace the supply pump and engine electronic control unit, complete all the replacement jobs other than the replacement of engine electronic control unit. Then replace the new unit.

13E-43

TROUBLESHOOTING 8. Inspections Performed at Electronic Control Unit Connectors • These inspections aid troubleshooting by enabling you to check whether electronic control unit signals are being correctly transmitted via the vehicle harness and connectors. The white-on-black numbers ( 01 , 02 , and so on) correspond to the similarly printed reference numbers in section “3. Inspections based on diagnostic codes”.

8.1 Electronic control unit connector terminal layout

8.2 Inspection instructions • Some inspections are performed with the connectors removed. Others are performed with the connectors fitted. Observe the following caution:

CAUTION • Do not touch any terminal except those specified for the inspection. Be particularly careful not to cause short circuits between terminals using the tester probes. • When the supply pump has been replaced, perform the “Initialization of supply pump unit difference learning value” using the MUT and erase the compensation information (pump learning condition) in the ECU.

Check item

Resistance of intake air temperature sensor

Resistance of water temperature sensor

13E-44

Measurement method [Conditions] • Starter switch OFF • Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: E25-B26 • 0°C: 5.88 ± 0.588 kΩ • 20°C: 2.45 ± 0.245 kΩ • 80°C: 0.322 ± 0.0483 kΩ [Conditions] • Starter switch OFF • Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: E24-B26 • 20°C: 2.45 ± 0.14 kΩ • 80°C: 0.32 kΩ (reference value) • 110°C: 147.1 ± 2 Ω (reference value)

13E Check item

Output voltage of accelerator pedal position sensor

Resistance of fuel temperature sensor (inlet)

Resistance of fuel temperature sensor (outlet)

Resistance of injector magnetic valve

Resistance of engine speed sensor

Output of cylinder recognition sensor

Continuity of accelerator pedal switch

Measurement method [Conditions] • Starter switch ON • Vehicle-side harness connected (Perform inspection on back of connector.) [Requirements] Terminals (+)-(–) A24-D30 (accelerator pedal position sensor 1) A23-D28 (accelerator pedal position sensor 2) • With accelerator pedal not depressed: 0.85 ± 0.1 V • With accelerator pedal depressed: 4.15 ± 0.1 V [Conditions] • Starter switch OFF • Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: E30-B27 • –20°C: 15.0 ± 1.5 kΩ • 20°C: 2.45 ± 0.24 kΩ • 80°C: 0.318 ± 0.008 kΩ [Conditions] • Starter switch OFF • Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: E31-B26 • 20°C: 2.45 +0.14 –0.13 kΩ • 80°C: 0.318 ± 0.01 kΩ • 110°C: 0.1417 ± 0.01 kΩ [Conditions] • Starter switch OFF • Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: D1 or D2-D5 (injector magnetic valve: No. 1 cylinder) D1 or D2-D3 (injector magnetic valve: No. 2 cylinder) D1 or D2-D4 (injector magnetic valve: No. 3 cylinder) E1 or E2-E5 (injector magnetic valve: No. 4 cylinder) E1 or E2-E7 (injector magnetic valve: No. 5 cylinder) E1 or E2-E6 (injector magnetic valve: No. 6 cylinder) • 0.45 ± 0.1 Ω (20°C) [Conditions] • Starter switch OFF • Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: B2-B1 • 125.5 ± 17 Ω (20°C) [Conditions] • Starter switch OFF • Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: D31-D33 (+5 V to GND) • 200 to 1800 Ω (Resistance serves as rough indication only. Pulse output monitor is needed for confirmation of functionality.) [Conditions] • Starter switch OFF • Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] • Terminals: B20 and chassis earth • With accelerator pedal depressed: no continuity is found. • With accelerator pedal not depressed: continuity is found.

13E-45

TROUBLESHOOTING Check item

Measurement method

[Conditions] • Starter switch OFF • Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: B35-B27 • No. 1 resistor: 270 ± 13.5 Ω • No. 2 resistor: 510 ± 25.5 Ω 10 • No. 3 resistor: 820 ± 41 Ω Resistance of fuel injection rate adjustment • No. 4 resistor: 1300 ± 65 Ω resistor • No. 5 resistor: 2000 ± 100 Ω • No. 6 resistor: 3300 ± 165 Ω • No. 7 resistor: 5600 ± 280 Ω • No. 8 resistor: 15000 ± 750 Ω • No. 9 resistor: 390 ± 19.5 Ω • No. 10 resistor: 4300 ± 215 Ω • No. 11 resistor: 9100 ± 455 Ω

Resistance of SCV (suction control valve)

Glow drive relay voltage

Safety relay voltage

13E-46

[Conditions] Starter switch OFF Disconnect connector. Perform inspection on vehicle-side connector. [Requirements] Terminals: E14-E16, E14-E17, E15-E16, E15-E17 • 7.9 ± 0.2 Ω [Conditions] • Keep the vehicle harnesses connected to the electronic control unit connector halves. (Inspection is made at the back of the vehicle connectors.) • Carry out the actuator test “AF-Relay for Glow Relay” using Multi-Use Tester. [Normal status] Terminals (+)-(–): C7 and body earth • Battery voltage [Conditions] • Keep the vehicle harnesses connected to the electronic control unit connector halves. (Inspection is made at the back of the vehicle connectors.) [Normal status] Terminals (+)-(–): B18 and body earth • Relay ON: 24 V • Relay OFF: 0 V

13E

INSPECTION OF ELECTRICAL EQUIPMENT #029 Inspection of accelerator pedal switch Switch position

Terminals with continuity

OFF

–

1–2

• If there is any abnormality, replace the switch.

#201 Inspection of relay (normally open type with 5 pins) • Test for continuity and proper operation. If there is any abnormality, replace the relay.

#262 Inspection of water temperature sensor • Place the water temperature sensor in a container filled with engine oil. • Heat the oil to each of the specified temperatures. Stir the oil well while doing so. • Measure the resistance between terminals 1 and 2.

Standard value

20°C

2.45 ± 0.14 kΩ

80°C

0.32 kΩ (reference value)

110°C

147.1 ± 2 Ω

• If either measurement is out of specification, replace the sensor. #263 Inspection of engine speed sensor • Measure the resistance between terminals 1 and 2. Standard value (at 20°C)

125.5 ± 17 Ω

• If the measurement is out of specification, replace the sensor.

13E-47

INSPECTION OF ELECTRICAL EQUIPMENT #305 Inspection of intake air temperature sensor • Clean the sensor as dirty sensor terminals may provide false output signals. (See Gr15.) • Place the boost air temperature sensor in a container filled with engine oil. • Heat the oil to each of the specified temperatures. Stir the oil well while doing so. • Measure the resistance between terminals 1 and 2. Standard value

0°C

5.88 ± 0.588 kΩ

20°C

2.45 ± 0.245 kΩ

80°C

0.322 ± 0.0483 kΩ

• If either measurement is out of specification, replace the sensor. #318 Inspection of boost pressure sensor • Apply 5 V DC to terminals 3 and 1. • Apply air pressure. Gradually increase it and, while doing so, measure the output voltage occurring at terminals 2 and 1 (see the diagram on the left). Air pressure (Gauge pressure)

Voltage

101.67 kPa {1.0 kgf/cm2}

Approx. 3.2 V

165.67 kPa {1.7 kgf/cm2}

Approx. 4.5 V

Standard value

• If any measurement is out of specification, replace the sensor. #319 Inspection of common rail pressure sensor • The sensor cannot easily be inspected in isolation, so you must evaluate it indirectly by inspection of system harnesses and related parts. • If there is no abnormality in any related part but the system is abnormal, replace the common rail pressure sensor. #320 Inspection of cylinder recognition sensor • Measure the resistance between terminals 1 and 2. (The resistance serves as a rough indication only. A pulse output monitor is needed for confirmation of functionality.) 200 to 1800 Ω

Standard value

• If the measurement is out of specification, replace the sensor.

#323 Inspection of fuel temperature sensor <Fuel temperature sensor (inlet)> • Measure the resistance between terminals 1 and 2. Standard value

–20°C

15.0 ± 1.5 kΩ

20°C

2.45 ± 0.24 kΩ

80°C

0.318 ± 0.008 kΩ

• If any measurement is out of specification, replace the supply pump.

13E-48

13E <Fuel temperature sensor (outlet)> • Measure the resistance between terminals 1 and 2. Standard value

20°C

2.45 +0.14 –0.13 kΩ

80°C

0.318 ± 0.01 kΩ

110°C

0.1417 ± 0.01 kΩ

• If any measurement is out of specification, replace the sensor.

#324 Inspection of accelerator pedal position sensor [Inspection] • Apply 5 V DC to terminals 4 and 6 and terminals 1 and 3 of the accelerator pedal position sensor connector. • Measure the output voltage at terminals 5 and 6 (sensor 1) and the output voltage at terminals 2 and 3 (sensor 2) with the lever in each specified position. Lever position Standard value

Output voltage

Idling position A

0.85 ± 0.1 V

Accelerator pedal switch operating position B

1.0 ± 0.2 V

Full load position C

4.15 ± 0.1 V

A: Position in which accelerator pedal switch is fully pushed in by lever B: Position at which continuity between terminals 1 and 2 of accelerator pedal switch connector disappears as accelerator pedal is pushed downward C: Position in which lever is touching stopper bolt • If any output voltage is out of specification, make an adjustment. • If any output voltage is still out of specification when you have made an adjustment, replace the sensor.

[Adjustment] • To adjust the output voltage for the accelerator pedal switch operating position A, use nut D. • To adjust the output voltage for the full load position C, loosen nut E and make the adjustment using the stopper bolt. • After making the adjustment, lock the stopper bolt in position with the nut.

13E-49

INSPECTION OF ELECTRICAL EQUIPMENT #530 Inspection of exhaust gas recirculation solenoid valve • Perform the following checks. If there is any abnormality, replace the exhaust gas recirculation solenoid valve. (1) Check of operation • Gradually increase from zero the voltage applied to terminals 1 and 4 (M/V-1), 2 and 5 (M/V-2), or 3 and 6 (M/V-3). • Observe the voltage when the exhaust gas recirculation solenoid valve operates. (Determine the solenoid valve’s OFF-ON operation from the operating sound.) Standard value (min. operating voltage)

18 V or lower

(2) Check of continuity and airtightness • Air pressure applied during check: 930 kPa {9.5 kgf/cm2}

#574 Inspection of SCV (suction control valve) • Measure the resistance between terminals 1 and 2. Standard value

7.9 ± 0.2 Ω

• If the measurement is out of specification, replace the supply pump.

#582 Inspection of injector • Measure the resistance between terminals 1 and 2. Standard value (at 20°C)

0.45 ± 0.1 Ω

• If the measurement is out of specification, replace the injector.

13E-50

13E #828 Inspection of fuel injection rate adjustment resistor • Measure the resistance of the resistor number marked on the fuel injection rate adjustment resistor.

Standard value (at 20°C)

Resistor No.

270 ± 13.5 Ω

510 ± 25.5 Ω

820 ± 41 Ω

1300 ± 65 Ω

2000 ± 100 Ω

3300 ± 165 Ω

5600 ± 280 Ω

15000 ± 750 Ω

390 ± 19.5 Ω

4300 ± 215 Ω

9100 ± 455 Ω

• If the measurement is out of specification, replace the fuel injection rate adjustment resistor with one that has the same resistor number and same specified resistance.

CAUTION • The fuel injection rate adjustment resistor is matched to the engine. If you replace it, be sure to replace it with one that has the same resistor number.

13E-51

GROUP 14 COOLING SPECIFICATIONS ............................................................................. 14-2 STRUCTURE AND OPERATION 1. Cooling System (Flow of Coolant) .............................................. 14-3 2. Thermostat ................................................................................. 14-4 3. Water Pump ................................................................................ 14-4

TROUBLESHOOTING ...................................................................... 14-5 GENERAL INSPECTION AND ADJUSTMENT 1. 2. 3. 4.

Coolant Replacement and Cleaning of Cooling System .............. Air Bleeding of Cooling System .................................................. Gas Leakage Test ........................................................................ Inspection of V-belts ...................................................................

14-6 14-8 14-8 14-9

DISCONNECTION AND CONNECTION OF HOSES AND PIPES .................................................................. 14-10 RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD ............................................. 14-12 COOLING FAN AND V-BELT ............................................................ 14-24 WATER PUMP................................................................................... 14-28 THERMOSTAT .................................................................................. 14-32 Cat DP150N Forklift Mitsubishi 6M60TL Engine Parts Contact Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 1 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com www.dp150.com/cat-dp150-engine-parts

14-1

SPECIFICATIONS Item Cooling system

Specifications Forced water circulation system

Water pump

Belt-driven type

Thermostat

Wax pellet, bottom bypass type (with jiggle valve)

14-2

STRUCTURE AND OPERATION

1. Cooling System (Flow of Coolant)

14-3

STRUCTURE AND OPERATION 2. Thermostat â&#x20AC;˘ The thermostat is a bottom bypass type that uses a wax-filled pellet as its flow-regulating element. When the wax is heated, it melts from solid to liquid, changing its total volume. This allows the valve to open or close in accordance with the coolant temperature, regulating and adjusting the flow of coolant to the radiator and to the water pump (bypassing the radiator).

3. Water Pump â&#x20AC;˘ The water pump has a drain hole to prevent coolant from entering the unit bearing in case of a defect in the unit seal.

14-4

TROUBLESHOOTING

Loose or damaged V-belt

Water pump

Thermostat

O O

Incorrectly mounted water pump

Defective gasket

Defective unit bearing

Defective impeller

O O O

Incorrectly mounted case

Defective gasket

Valve opening temperature too high (valve remains closed)

Cracked core and/or separation in welds

O O O

Defective gasket

Incorrectly mounted EGR cooler

Incorrectly mounted oil cooler

Defective gasket

Water leaking from water temperature sensor

Incorrectly mounted cylinder head

Defective gasket

Poorly airtight pressure cap

Gr17

Gr12

Gr11

Coolant quantity insufficient and/or coolant dirty

Coolant passages dirty and/or clogged

Hoses fitted poorly

Ambient temperature extremely low

Engine output insufficient

O O

Clogged core

Water leaking

Cylinder head

O O

Fit of unit bearing on flange and impeller too loose

Oil cooler <For machinery>

Oil cooler

Defective unit seal

Foreign matter adhered on the core

EGR system

Excessive coolant loss

Oil on belt

Intercooler

Reference Gr

Excessive tension

Valve opening temperature too low (valve remains open) Radiator

Abnormal noise

Possible causes

Overcooling

Overheating (poor cooling)

Symptoms

O O

14-5

GENERAL INSPECTION AND ADJUSTMENT 1. Coolant Replacement and Cleaning of Cooling System • Using the radiator for extended periods of time without cleaning can increase chance of rust and scale formation, which may cause engine overheating. The cooling system must be cleaned periodically.

Tightening torque (Unit: N·m {kgf·m}) Mark

Tightening torque

Remarks

–

Radiator drain cock

Parts to be tightened

2 {0.2}

–

Crank case drain cock

7 {0.7}

–

1.1 Draining of coolant • Before draining the coolant, loosen the pressure cap to reduce the pressure in the cooling system. Remember to drain the coolant out of the reservoir tank as well.

WARNING • Drain the coolant only after it has cooled sufficiently to avoid getting scalded. • Opening the pressure cap while the coolant temperature is still high can cause hot coolant to spray out. Cover the pressure cap with a cloth, and loosen it slowly to let the pressure out before opening it fully.

1.2 Cleaning procedure

CAUTION • Water used for flushing the cooling system must be soft water that has a property meeting the requirements indicated below. Using hard water will cause scale and rust to form in the system. Required properties of soft water Total hardness .......................... 300 ppm or less Sulfate SO 4 .............................. 100 ppm or less Chloride CI ............................. 100 ppm or less Total dissolved solids.............. 500 ppm or less pH .............................................. 6 to 8 • Keep the coolant temperature at approximately 90°C so that the thermostat valve remains open and coolant continues to circulate in the radiator. • For the sake of convenience you can raise the coolant temperature quickly by covering the front of the radiator with corrugated cardboard or something similar. • In cases where a great amount of rust has accumulated it is common for the radiator to leak as a result of cleaning. Conduct a through check for leakage after cleaning.

14-6

14 • Select an appropriate cleaning method according to the condition of the cooling system as shown below. Ordinary condition

•

Coolant extremely dirty

•

Radiator clogged

Cleaning using FUSO RADIATOR CLEANER (RADIPET-7) Flushing with water Drain out coolant Make water solution of FUSO RADIATOR CLEANER (RADIPET-7) at 5 to 10% concentration in volume. Pour solution into reservoir tank. Let the engine idle for 30 minutes with the water at approximately 90°C.

CAUTION •

Limit the engine idling period to one hour. Operating an engine containing the cleaning solution for longer time may lead to damage of the cooling system.

Drain out coolant Pour tap water (preferably hot) into the surge tank.

Let the engine idle for 10 minutes with the water at approximately 90°C. Drain out water Cleaning is complete if drained water is clear Repeat procedure if drained water is not clear

CAUTION •

•

After cleaning the cooling system using cleaning solution, fill it with coolant containing the specified additive as soon as possible. To prevent freezing of the coolant and corrosion of the cooling system, add the specified portion of FUSO DIESEL LONGLIFE COOLANT to the coolant. (See the Owner’s Handbook for instructions on the use of the additive.)

DANGER • If you accidentally splash FUSO DIESEL LONGLIFE COOLANT or RADIATOR ANTIRUST (RADIPET9) in your eyes, wash it out immediately with water and seek medical attention.

WARNING • FUSO DIESEL LONGLIFE COOLANT is flammable. Keep it away from heat and flames.

14-7

GENERAL INSPECTION AND ADJUSTMENT 2. Air Bleeding of Cooling System • With the pressure cap removed and the coolant temperature at 90°C, let the engine idle in order to bleed air completely out of the cooling system. • After air bleeding is completed, refill the reservoir tank with coolant as needed.

3. Gas Leakage Test • Presence of air or exhaust gas in coolant accelerates corrosion of the cooling system components. To prevent this, carry out air/ gas leakage tests in accordance with the following procedure. • Remove the pressure cap.

WARNING • If the engine is hot, boiling coolant may spurt out from the filler port when the pressure cap is loosened. To avoid burning yourself, make sure to remove the pressure cap only when the coolant is cold. • Run the engine until the coolant temperature rises to approximately 90°C. • If air bubbles appear continuously through the filler port, there is air or exhaust gas penetrating into the cooling system. • Presence of air in coolant can be an indication of loose cylinder head bolts, loose water pump mounting bolts, loose hose connections, and/or a damaged hose. • Presence of exhaust gas in coolant can be an indication of a damaged cylinder head gasket and/or cracks in the cylinder head.

14-8

14 4. Inspection of V-belts • Visually check the V-belts for possible cracks and damage. Vbelt replacement time varies depending on the severity of cracks and damage that may be found through the check. Study the table given below for the applicable replacement time. Belt condition

Remaining service life (reference) • The driving distance over the which the belt can still be used is at least as long as that over which the belt has been used since the vehicle was new or since the belt was replaced (whichever is more recent).

• The driving distance over the which the belt can still be used is about half of that over which the belt has been used since the vehicle was new or since the belt was replaced (whichever is more recent).

• The driving distance over the which the belt can still be used is about a quarter of that over which the belt has been used since the vehicle was new or since the belt was replaced (whichever is more recent).

• The belt has reached the end of its service life and must be replaced.

14-9

DISCONNECTION AND CONNECTION OF HOSES AND PIPES

Removal sequence 1 2 3 4

Water hose Eyebolt Joint pipe Water hose

5 6 7 8

Water hose EGR cooler water pipe Water hose Water hose

9 EGR cooler water pipe 10 Water hose EGR: Exhaust gas recirculation

Installation sequence Follow the removal sequence in reverse.

CAUTION • Install each hose clamp to the angle indicated in the illustration so that sufficient clearance is assured between the hose clamp and its surrounding parts.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Clamp

3.9 ± 0.6 {0.4 ± 0.06}

–

Clamp

4 to 5 {0.4 to 0.5}

–

25 {25}

–

Eyebolt (joint pipe mounting)

14-10

Remarks

14 M E M O

14-11

RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD Type A

Removal sequence 1 2 3 4

Intercooler Hose Drain cock Oil cooler

5 6 7 8

Pressure cap Filler Filler hose Radiator (See later pages.)

9 Shroud seal 10 Fan shroud

Installation sequence Follow the removal sequence in reverse.

Service standards Location

Maintenance item

Standard value

Limit

Remedy

0 cm3 {0 mL}

–

Replace

Coolant side (air pressure: 20 kPa {0.2 kgf/cm2})

0 cm3 {0 mL}

–

Replace

Oil side (air pressure: 150 kPa {1.5 kgf/cm2})

0 cm3 {0 mL}

–

Replace

49 ± 9.8 kPa {0.5 ± 0.1 kgf/cm2}

–

Replace

Air leaks from intercooler (air pressure: 150 kPa {1.5 kgf/cm2})

Air leaks from oil cooler

Pressure cap opening pressure

Tightening Torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Clamp

14-12

Tightening torque

Remarks

3.9 ± 0.6 {0.4 ± 0.06}

–

14 Special tools (Unit: mm) Mark

Tool name and shape Tip clearance spacer A

φ600

φ620

Part No.

<For φ600 fan> MC019470 <For φ620 fan> ME294842

Application

Adjusting clearance between fan shroud and cooling fan blades

Inspection procedure Inspection: Air leaking of intercooler • Plug an end of the intercooler and apply a specified air pressure from the other end with the intercooler immersed in water. • If any leakage is found, replace the intercooler.

Inspection: Air leaking of oil cooler • Plug an end of each coolant passage and oil passage of the oil cooler and apply a specified air pressure from the other end with the oil cooler immersed in water. • Be sure to check both the coolant passage and oil passage. • If any leakage is found, replace the oil cooler.

Inspection: Pressure cap (1) Pressure valve opening pressure • If the measurement does not conform to the standard value, replace the pressure cap.

14-13

RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD (2) Inspection of vent valve • Note the coolant level in the reservoir tank. • Start the engine and run it at high speed until the coolant level in the reservoir tank has risen to a certain degree. Stop the engine. • Allow the system to cool down. When the coolant temperature has dropped to the atmospheric temperature, check if the coolant level in the reservoir tank has subsided to the original level noted earlier. • If not, the vent valve is deemed faulty. Replace the pressure cap.

CAUTION • If the pressure cap is opened before the coolant temperature drops to the atmospheric temperature, the negative pressure in the radiator is canceled out. As a result, it is no longer possible for coolant to flow into the reservoir tank. Ensure that this does not happen.

Installation procedure Installation: Fan shroud • Using , adjust the clearance between the fan shroud and cooling fan blades to the dimension shown in the illustration.

14-14

14 Type B

Removal sequence 1 2 3 4 5 6 7 8

Plug Gasket Intercooler Protector Packing Packing Oil cooler Shroud

9 10 11 12 13 14 15 16

Packing Pressure cap Pressure cap Water hose Water hose Hose Cushion Bracket

17 18 19 20 21 22

Radiator Cushion Radiator Cushion Plate Frame

: Non-reusable parts

Installation sequence Follow the removal sequence in reverse.

Service standards Location

Maintenance item

Standard value

Limit

Remedy

Air leaks from intercooler (air pressure: 1.5 MPa {15 kgf/cm2})

0 cm3 {0 mL}

–

Replace

Air leaks from oil cooler (air pressure: 150 kPa {1.5 kgf/cm2})

0 cm3 {0 mL}

–

Replace

49 ± 9.8 kPa {0.5 ± 0.1 kgf/cm2}

–

Replace

0 cm3 {0 mL}

–

Replace

10, 11

Pressure cap opening pressure

17, 19

Air leaks from radiator (air pressure: 100 kPa {1.0 kgf/cm2})

14-15

RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD Inspection procedure Inspection: Air leaking of intercooler • Plug an end of the intercooler and apply a specified air pressure from the other end with the intercooler immersed in water. • If any leakage is found, replace the intercooler.

Inspection before removal • • • •

Inspection: Air leaking of radiator Install hose and radiator cap tester and plug to upper tank. Insert plug in lower tank, and immerse the entire body of the radiator in water. Apply a specified air pressure using radiator cap tester, and check for any air leakage. If any leakage is found, repair or replace radiator.

Inspection: Pressure cap (1) Pressure valve opening pressure • If the measurement does not conform to the standard value, replace the pressure cap.

14-16

14 (2) Inspection of vent valve • Note the coolant level in the reservoir tank. • Start the engine and run it at high speed until the coolant level in the reservoir tank has risen to a certain degree. Stop the engine. • Allow the system to cool down. When the coolant temperature has dropped to the atmospheric temperature, check if the coolant level in the reservoir tank has subsided to the original level noted earlier. • If not, the vent valve is deemed faulty. Replace the pressure cap.

14-17

RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD Radiator Assembly • Only the type A radiator can be disassembled.

Disassembly sequence 1 2 3 4

Radiator shroud Drain cock Side member Upper tank

5 6 7 8

Packing Lower tank Packing Core

: Non-reusable parts

CAUTION • Gently handle upper tank and lower tank, since they are made of a resin that can break on impact. • If there are two paint marks on the joint between the core and upper tank or on the joint between the core and lower tank (which indicates that the tank retaining tabs have been crimped twice before), replace the core with a new part.

Assembly sequence Follow the disassembly sequence in reverse.

Service standards Location 8

Maintenance item Air leakage from radiator (air pressure: 177 kPa {1.8 kgf/cm2})

Standard value

Limit

Remedy

0 cm3 {0 mL}

–

Repair or replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Drain cock Bolt (side member mounting)

14-18

Tightening torque

Remarks

2 {0.2}

–

13 {1.3}

–

14 Special tools Mark

Tool name and shape

Part No. J94-Z013 -10000

Lock-and-break tool

Application Removal of upper and lower tanks

The indicated part number is T. RAD’s part number.

Inspection before removal • • • •

• Replace the following parts according to the leakage location. Area of leakage Upper tank Lower tank

Cause

Tank

Cracked tank

Tank joint

Defective crimping Defective packing Cracked tank

Tube; Tube joint

Cracked tube

CAUTION • If there are two paint marks on the joint between the core and upper tank or on the joint between the core and lower tank (which indicates that the tank retaining tabs have been crimped twice before), replace the core with a new part. • The number of paint marks on the upper tank joint or the lower tank joint corresponds to the number of repairs performed on that joint.

Removal procedure Removal: Upper tank and lower tank • Use

for removal and reinstallation of the tanks.

14-19

RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD • Adjust the stopper bolt until the gap dimension shown in the illustration is obtained on the attachment of .

CAUTION • Before using , be sure to set the gap to the specified dimension by adjusting the stopper bolt. Otherwise, will become damaged.

• Use to bend open tabs of retain tank in place. • After tabs are bent open, squeeze the handle of to straighten tabs as illustrated. • After straightening all tabs in the perimeter, hold the pipes connected to the inlet/outlet, and remove tank.

• If it is difficult to remove tank lightly hit with rubber hammer (or plastic hammer) to remove.

CAUTION • Gently handle tanks, since they are made of a resin that can break on impact.

Inspection procedure Inspection: Tank surface where core is to be mounted • Check the tank surface where the core is to be mounted for cleanliness, damage, etc. Clean the surface. • If an abnormality is found on the surface, replace the tank.

CAUTION • To prevent adhesion of foreign substances on mounting surface, conduct work with bare hands.

14-20

14 Inspection: Core groove where tank is to be mounted • Check the groove on the core where the tank is to be mounted for adhesion of foreign substances or cracks. • If foreign substances are found, rub the area with #1000 sandpaper or a like gently so as to avoid scratching the surface, or use compressed air to remove them. • If there are cracks in the groove, repair or replace.

CAUTION • If the packing and tank are installed onto the core without removing foreign substances from the groove, coolant leakage will result. Be sure to inspect and clean the tank mounting groove along the entire periphery (even a hair can cause leakage). Repairing core

CAUTION • The core is repaired by means of tungsten inert-gas arc welding (TIG welding), which should only be performed by a skilled welder. • It is extremely dangerous to weld on a wet core. Before welding, ensure that the core is completely dry. • Using a stainless wire brush, brush both ends A of the leaky tube and the areas B around the tube ends until the base aluminum is exposed. • Before closing the tube at both ends by welding, drill a small breather hole in the tube.

CAUTION • If a breather hole is not provided, the tube may develop small pinholes due to escaping air.

• Ground the core at the support.

CAUTION • If welding is performed without the core properly grounded, this can lead to short-circuit where the base metal may melt.

14-21

RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD • Close both end of the tube by tungsten inert-gas arc welding (TIG welding). Welding conditions • Welding rod: A4043 (approx. φ2 mm) • Welding current: AC80A • After welding, check for the following problems. If any of them exist, repair again or replace the core. • Undercut • Bead crack • Base metal crack

CAUTION • Improper weld can lead to recurrence of coolant leakage.

Installation procedure Installation: Upper tank, Lower tank • With the tank installed, eliminate any clearance between the tank and core plate by tapping with a rubber (or plastic) hammer.

CAUTION • To prevent adhesion of foreign matter, use bare hands to install the packing and tank.

• Adjust the stopper bolt until the gap dimension shown in the illustration is obtained on the attachment of .

• Following the sequence shown in the diagram, bend tabs for caulking tank. To perform this work, since cannot be used to caulk sides 1 and 2, use pliers with the tips wrapped in vinyl tape. 1 to 4: Bend two tabs at the center. 5 to 8: Bend other tabs following the direction of the arrow. • After crimping the tabs onto the tank, check for coolant leakage.

14-22

14 â&#x20AC;˘ Paint a mark on the core where it can be easily noticed to indicate that the core has been crimped.

CAUTION â&#x20AC;˘ Paint a mark for each repair performed on either the upper or lower tank.

14-23

COOLING FAN AND V-BELT

Disassembly sequence 1 V-belt 2 Cooling fan <Type B and Type C> 3 Fan spacer <Type B> 4 Fan spacer <Type B and Type C>

5 6 7 8 9 10

Water pump pulley Inlet pipe Inlet hose Tube <Type C> Straight joint <Type C> Grease nipple <Type C>

11 Connector <Type C> 12 Grease nipple bracket <Type C> Water pump *a: b: Crankshaft pulley *

Assembly sequence Follow the disassembly sequence in reverse.

CAUTION â&#x20AC;¢ When replacing the V-belts, replace them as a set to prevent differences in tension between the belts.

14-24

14 Service standards (Units: mm) Location 1

Maintenance item V-belt tension

Service standard

Limit

Remedy

10 to 15

–

Adjust

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Grease nipple Straight joint Tube

Tightening torque

Remarks

12.5 ± 2.5 {1.3 ± 0.3}

–

2.25 ± 0.25 {0.2 ± 0.03}

Clamp

39 {0.4}

–

Lubricant and/or sealant Mark

Points of application Grease nipple

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

Special tools Mark

Tool name and shape

Belt tension gauge

Part No.

MH062345

Application

Measurement of tension of V-belt

Inspection procedure Inspection: Tension of V-belts • Press each V-belt at a central portion between pulleys with a force of approximately 98 N {10 kgf} as shown in the illustration and measure the amount of deflection of the belt. A: Alternator pulley B: Water pump pulley C: Crankshaft pulley

• Place the small O-ring on at the scale mark corresponding to 98N {10 kgf} (press force). • Place the large O-ring on at the scale mark corresponding to the maximum permissible deflection value specified for the belt.

14-25

COOLING FAN AND V-BELT • Place at a central portion between pulleys of the V-belt and push the handle (indicated by the arrow in the illustration) until the O-ring touches the flange.

• Measure the amount of deflection of the V-belt. • If the measured value deviates from the standard value range, adjust the tension of the belt as follows.

Adjustment of V-belt • Loosen alternator mounting bolts (2 locations), then adjust the tension of V-belts by moving the alternator from side to side. • When the adjustment is completed, tighten the bolts and nuts securely.

CAUTION • Excessive tension in V-belts may damage the belts and related bearings. • When replacing the V-belts, replace them as a set to prevent differences in tension between the two belts. • Keep the V-belts free of oil. If the belts become oily, they may slip, resulting in overheating of the engine and insufficient charging of the battery.

14-26

14 M E M O

14-27

WATER PUMP

Disassembly sequence 1 2 3 4 5 6

Impeller Flange Snap ring Bearing Spacer Bearing

7 8 9 10 11 12

Washer Water pump shaft Unit seal Grease nipple <If equipped> Water pump case Gasket

13 Cover 14 Gasket : Non-reusable parts

Assembly sequence For the sequence not mentioned below, follow the disassembly sequence in reverse. 12 → 8 → 7 → 6 → 5 → 4 → 11 → 3 → 9 → 10

Service standards (Unit: mm) Location

Maintenance item

Service standard

Limit

Remedy

1, 8

Flange-to-water pump shaft interference

0.03 to 0.06

–

Reassembly allowed only twice

2, 8

Impeller-to-water pump shaft interference

0.03 to 0.08

–

Reassembly allowed only twice

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (water pump mounting) Grease nipple

Tightening torque

Remarks

24 {2.4}

–

9.8 to 15 {1 to 1.5}

–

Lubricant and/or sealant Mark

Points of application Pack in bearing Fill through grease nipple Outer periphery of unit seal

14-28

Specified lubricant and/or sealant

Quantity

Wheel bearing grease [NLGI No. 2 (Li soap)]

As required

ThreeBond 1102

As required

60 g

14 Special tools (Unit: mm) Mark

Tool name and shape

Part No.

Impeller puller A B 49 ± 1

MH062192

φ 10

Application

Removal of impeller puller

Removal procedure Removal: Impeller

Removal: Flange

Inspection procedure Inspection: Impeller-to-water pump shaft interference • If the measurement does not comply with the standard value, replace the defective part(s).

CAUTION • Even if the measurement complies with the standard value, reassembly must not be carried out more than twice.

Inspection: Flange-to-water pump shaft interference • If the measurement does not comply with the standard value, replace the defective part(s).

CAUTION • Even if the measurement complies with the standard value, reassembly must not be carried out more than twice.

14-29

WATER PUMP Installation procedure Installation: Flange

CAUTION • Before installing flange, make sure that there is no or only one punch mark in the shown location on the flange. Make an additional punch mark on the flange to indicate that it undergoes the disassembly and reassembly process you are doing now. • Punch mark(s) indicate the number of times the flange was disassembled and reassembled in the past. If there are two marks, the flange must be replaced. • Place a fixture under the flange and apply the ram load of a press to the shaft of the bearing unit. • Ram the shaft of the bearing unit down into the flange until it contacts the fixture.

CAUTION • If the flange is installed without the fixture, the water pump case will be damaged.

Installation: Impeller

CAUTION • Before installing impeller, make sure that there is no or only one punch mark in the shown location on the impeller. Make an additional punch mark on the impeller to indicate that it undergoes the disassembly and reassembly process you are doing now. • Punch mark(s) indicate the number of times the impeller was disassembled and reassembled in the past. If there are two marks, the impeller must be replaced. • Place the water pump so that the flange side end of the water pump shaft becomes the load bearing surface. • Apply pressure to the impeller with a press and press-fit the impeller so that its end face is flush with the end of the water pump shaft.

14-30

14 Inspection after assembly Inspection: Flange rotation â&#x20AC;˘ Rotate the flange by hand. The flange should rotate smoothly without any binding. â&#x20AC;˘ If the flange does not rotate freely, disassemble and check.

14-31

THERMOSTAT Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11

Thermostat cover Gasket Thermostat Water temperature sensor Plug Cock Thermostat case Gasket O-ring Joint O-ring

: Non-reusable parts

CAUTION • Do not remove the thermostat case unless it has a water leak or any other defect.

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location 3

Maintenance item Thermostat

Standard value

Limit

Valve opening temperature

76.5 ± 2°C

–

Valve lift/temperature

10 or more/90°C

–

Remedy Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Water temperature sensor Cock

Tightening torque

Remarks

35 ± 7 {3.6 ± 0.7}

–

20 to 26 {2.0 to 2.7}

–

Lubricant and/or sealant Mark

Points of application O-ring Thread of plug

Specified lubricant and/or sealant

Quantity

Soapy water

As required

Loctite 575

As required

14-32

14 Inspection procedure Inspection: Thermostat • Stir the water using a stirring rod to maintain an even water temperature in the container, then conduct the tests indicated below. • If the measured values deviate from the standard value ranges, replace the thermostat. (1) Valve opening temperature • Hold the thermostat with wire to keep it away from the heat source. • Heat the water gradually to the valve opening temperature. • Maintain this temperature for five minutes and make sure that the valve is completely open. • Make sure that the valve closes completely when the water temperature drops below 65°C. (2) Valve lift • Heat the water to a temperature slightly higher than the valve opening temperature. Maintain this temperature for five minutes and measure the valve lift.

Installation procedure Installation: Gasket • Fit the gasket onto the thermostat case in the illustrated direction.

14-33

GROUP 15 INTAKE AND EXHAUST SPECIFICATIONS ............................................................................. 15-2 STRUCTURE AND OPERATION 1. Air Cleaner .................................................................................. 15-3 2. Turbocharger .............................................................................. 15-4 TROUBLESHOOTING ...................................................................... 15-5 AIR CLEANER .................................................................................. 15-6 TURBOCHARGER ............................................................................ 15-8

INTAKE MANIFOLD ........................................................................ 15-14 EXHAUST MANIFOLD .................................................................... 15-16

15-1

SPECIFICATIONS /

Item

Specifications

Air cleaner element

Cyclone filter paper type

Dust indicator type

Mechanical/electrical

Turbocharger

15-2

Model Manufacturer

TD06 Mitsubishi Heavy Industries

STRUCTURE AND OPERATION

1. Air Cleaner • The air cleaner utilizes single element. • The lower air duct incorporate a vacuator valve. • The vacuator valve automatically works in such a way that when the engine speed drops below a specified level, the valve’s rubber boot which is usually subdued by internal vacuum is allowed to spring back and accumulated dust and dirt are discharged as a result.

15-3

STRUCTURE AND OPERATION 2. Turbocharger

2.1 Waste gate mechanism • The waste gate mechanism, which is operated by an actuator, is designed to let excess exhaust gas bypass the turbocharger, thereby preventing the turbocharger from overrunning and the intake manifold pressure from rising excessively. This ensures that the boost pressure is properly controlled. • The boost pressure is led from the compressor cover into the actuator’s chamber A through rubber hose. When the boost pressure working on the chamber A is lower than the preset level, the actuator remains inactive, allowing exhaust gas to be blown against the turbine wheel with the waste gate valve closed. • When the boost pressure in the chamber A becomes higher than the preset level, it causes the waste gate valve to be opened, and the exhaust gas being blown against the turbine wheel is decreased. This reduces the revolution of the compressor wheel and the boost pressure returns below the preset level as a result.

15-4

Interference between turbine wheel and turbine housing

Turbocharger

Excess oil consumption

Clogged air cleaner element Cartridge assembly

Air cleaner

Poor engine power

Black exhaust gas

Carbon deposits on shaft

Possible causes

White exhaust gas

Engine hard to start

Symptoms

Abnormal noise or vibration in intake/exhaust system

TROUBLESHOOTING

Bent shaft

Damaged turbine wheel unit

Interference between compressor wheel and compressor cover

Damaged compressor wheel

Compressor cover fitted poorly Turbine housing fitted poorly Incorrect valve clearances

O O

Head gasket defective

Wear/carbon deposits on valves and valve seats

Valve spring weakened

Gr11

Piston rings worn/damaged

Piston ring grooves worn/damaged

Cooling system malfunctioning

Reference Gr

Engine oil quantity excessive

Gr14 O

Gr12

Major moving parts seized

Gr11

Uneven or excessive fuel injection

Gr13E

15-5

AIR CLEANER Removal sequence 1 2 3 4 5 6 7

Dust indicator Adaptor Vacuator valve Cover Element O-ring Case

: Non-reusable parts

Installation sequence Follow the removal sequence in reverse.

Service standards Location 1

Maintenance item Operation of dust indicator under specified negative pressure

Standard value

Limit

Remedy

6.2 ± 0.6 kPa {47 ± 4.3 mmHg}

–

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Dust indicator

15-6

Tightening torque

Remarks

3.0 to 3.5 {0.3 to 0.35}

–

15 Cleaning procedure Cleaning: Element • Blow a jet of compressed air at a pressure not higher than 685 kPa {7 kgf/cm2} against the inside surfaces of the element. • Move the compressed air jet up and down along all pleats of the filter paper element.

CAUTION • For the frequency and timing of cleaning, refer to the relevant instruction manual. More frequent cleaning than necessary could damage the element or cause dust and foreign matter to be sucked into the engine. • Do not strike the element or hit it against another object to remove dust. • Do not blow compressed air against outside surfaces of the element.

Inspection procedure Inspection: Element • Shine some electric light inside the element. • Replace the element if thin spots or broken parts are evident in the filter paper, or if the packing at the top of the element is damaged. Also replace the element if the dust on the element is damp with oily smoke or soot, regardless of the replacement schedule.

Inspection: Operation of dust indicator under specified negative pressure <Mechanical type> • Apply negative pressure to the dust indicator, and take the reading when the white signal appears in the dust indicator window. • Replace the dust indicator if found faulty.

<Electrical type> • Perform the following inspection and, if faulty, replace the dust indicator. • With no vacuum applied to the dust indicator, take measurement between the terminals 1 and 2. There should be no continuity. • Gradually apply vacuum to the dust indicator. Measure the vacuum when the continuity is made between the terminals 1 and 2.

15-7

TURBOCHARGER

Removal sequence 1 2 3 4 5 6

Air inlet pipe Rubber hose Eyebolt Oil feed pipe Oil return pipe Gasket

Turbocharger cover Exhaust pipe Gasket Turbocharger (See later section.) 11 Gasket 7 8 9 10

*a::

Exhaust manifold Non-reusable parts

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

Clamp (rubber hose mounting)

4.9 {0.5}

–

Eyebolt (oil feed pipe mounting)

21 {2.1}

–

41 {4.2}

–

Nut (exhaust pipe mounting) Nut (turbocharger mounting)

Lubricant and/or sealant Mark

Points of application Turbocharger (to be filled with engine oil)

Specified lubricant and/or sealant

Quantity

Engine oil

As required

15-8

15 Installation procedure Installation: Turbocharger â&#x20AC;˘ Before installing the turbocharger, pour engine oil into the oil hole to ensure smooth operation of the internal parts.

15-9

TURBOCHARGER Turbocharger

Disassembly sequence 1 2 3 4 5 6 7 8

Hose Actuator Coupling Turbine housing Snap ring Compressor cover O-ring Cartridge assembly

: Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

CAUTION • The cartridge assembly cannot be taken to pieces. Replace the whole assembly if the turbine wheel or compressor cover is damaged and when the cartridge does not rotate smoothly.

Service standards (Unit: mm) Location

Maintenance item Cartridge assembly

Standard value

Limit

Remedy

Play in axial direction of shaft

0.05 to 0.09

0.1

Replace

Play Turbine wheel end perpendicular to Compressor wheel end axis of shaft

0.40 to 0.53

0.58

Replace

0.55 to 0.66

0.72

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (coupling tightening)

Tightening torque

Remarks

3.9 to 4.9 {0.4 to 0.5}

Wet

Lubricant and/or sealant Mark

Points of application Thread of bolts O-ring

Specified lubricant and/or sealant

Quantity

Molybdenum disulfide grease [NLGI No. 2 (Li soap)]

As required

Engine oil

As required

Work before removal Alignment mark • Put alignment marks on the coupling, turbine housing, compressor cover and cartridge assembly.

15-10

15 Removal procedure Removal: Turbine housing • Lightly tap around the entire periphery of the turbine housing with a rubber-faced hammer, taking care not to cause damage.

CAUTION • The blades on the cartridge assembly are easily bent. Make sure that they do not strike the turbine housing.

Removal: Compressor cover • Lightly tap around the entire periphery of the compressor cover with a rubber-faced hammer, taking care not to cause damage.

CAUTION • The blades on the cartridge assembly are easily bent. Make sure that they do not strike the compressor cover.

Work after disassembly Cleaning • Before cleaning, visually check the disassembled parts for scorches, abrasion and other marks that may be difficult to see after cleaning. Replace any part that appears defective. • Immerse the disassembled parts in a non-flammable solvent (a 5 to 10 aqueous solution of Oil Clean from New Hope Co., Ltd.). Take out the parts and blow them dry with compressed air. Remove any hard deposits with a stiff brush or plastic scraper.

CAUTION • Do not immerse the cartridge assembly in the solvent. If the cartridge is immersed in the solvent, O-ring in the cartridge will swell, causing the turbocharger function to be impaired. • Again, immerse the parts in the solvent. • Blow them dry using compressed air.

Inspection procedure Inspection: Cartridge assembly • If the measurement exceeds the specified limit, replace the cartridge assembly. (1) Play in axial direction of shaft

15-11

TURBOCHARGER (2) Play perpendicular to axis of shaft

Installation procedure Installation: Snap ring • With the tapered surface facing up, install the snap ring into the compressor cover.

CAUTION • Fit the snap ring into place using hands not to let it spring away.

Work after installation Inspection: Free rotation of cartridge assembly • Turn the wheels of the cartridge assembly. They should turn freely without binding. • If not, disassemble again and correct.

15-12

15 M E M O

15-13

INTAKE MANIFOLD Removal sequence 1 Boost pressure sensor 2 Intake air temperature sensor 3 Exhaust gas recirculation valve adapter 4 Gasket 5 Plate 6 Reed valve 7 Intake manifold fitting 8 Gasket 9 Intake manifold

*a::

Cylinder head (See Gr11.) Non-reusable parts

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Bolt (boost pressure sensor mounting) Intake air temperature sensor Bolt (exhaust gas recirculation valve adapter mounting)

Tightening torque

Remarks

4 to 6 {0.4 to 0.6}

–

14.7 to 24.5 {1.5 to 2.5}

–

46 to 54 {4.7 to 5.5}

Lubricant and/or sealant Mark

Points of application Intake manifold to cylinder head mounting surface

Specified lubricant and/or sealant

Quantity

ThreeBond 1217H

As required

Inspection procedure • • •

•

Installation: Intake air temperature sensor Check that the sensor portion is free of soot, oily substance, etc. If not, clean the sensor portion as follows. Spray a cleaner on the sensor portion from 2 or 3 cm away. Recommended cleaners: Non-chlorinated Brake Parts Cleaner In 20 to 30 seconds after spraying, wipe the sensor portion clear of the sprayed cleaner using a soft waste cloth or the like.

CAUTION Cat DP150N Forklift Engine Parts Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 1 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com www.dp150.com/cat-dp150-engine-parts

15-14

• Be sure to wait for 20 to 30 seconds before wiping. It takes the cleaner that long to dissolve foreign matter. • If the sensor portion is fouled excessively, the positive crankcase ventilation (PCV) may be faulty. Inspect the PCV valve and filter to locate the cause and remove it. (See Gr17.)

15 Installation procedure Installation: Intake manifold • Clean the sealing surfaces of the intake manifold and cylinder head where they are to be mated with each other. • Apply an even and continuous bead of sealant onto the intake manifold surface where the cylinder head is to be mounted. • Install the intake manifold onto the cylinder head within 3 minutes following the application while taking care not to spread the sealant beyond the application area.

CAUTION • Do not start the engine at least for an hour after the intake manifold has been installed. • If the intake manifold mounting bolts are subsequently loosened or removed, be sure to apply sealant again upon reassembly.

15-15

EXHAUST MANIFOLD Removal sequence 1 2 3 4 5 6 7

Exhaust manifold insulator A Exhaust manifold insulator B Front exhaust manifold insulator Exhaust manifold bracket Distance piece Exhaust manifold Gasket

Cylinder head (See Gr11.) : Non-reusable parts

*a:

Installation sequence Follow the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (exhaust manifold mounting)

Tightening torque

Remarks

58 {5.9}

–

Installation procedure Installation: Gasket • Fit the gasket to the cylinder head in the illustrated direction.

15-16

GROUP 17 EMISSION CONTROL STRUCTURE AND OPERATION 1. Exhaust Gas Recirculation System ............................................... 17-2 2. Blowby Gas Return System .......................................................... 17-4

GENERAL INSPECTION AND ADJUSTMENT 1. Replacement of PCV Valve Element .............................................. 17-5 EGR VALVE, EGR SOLENOID VALVE, EGR PIPE AND EGR COOLER..................................................................................... 17-6 BLOWBY GAS RETURN SYSTEM .................................................... 17-9

17-1

STRUCTURE AND OPERATION 1. Exhaust Gas Recirculation System 1.1 Overview • EGR mixes inert gases contained in burned exhaust gases with the air on the inlet side (inlet manifold), thereby reducing the combustion temperature and thus reducing the amount of harmful NOx (nitrogen oxides) contained in the exhaust gases. The EGR cooler provides cooling to increase the density of the inert gases, thereby achieving a greater EGR effect. • The EGR system uses various sensors to detect engine operating conditions (engine speed, coolant temperature, accelerator opening) and, based on the information obtained, lets the engine ECU control operation of the EGR solenoid valve. (See Gr13E for the electronic control system and ECU connection diagram.) • If black smoke occurs or the engine speed becomes erratic under heavy or low load condition of the engine, the EGR valve control function is suspended.

17-2

17 (1) EGR solenoid valves

â&#x20AC;˘ The EGR solenoid valves are each turned ON/OFF by drive signals from the engine electronic control unit to realize a 7-stage supply of air to the EGR valve. (2) EGR valve

â&#x20AC;˘ The EGR valve realizes 7 stages of valve lift in accordance with the supply of air to its input ports from the EGR solenoid valves.

17-3

STRUCTURE AND OPERATION 2. Blowby Gas Return System

PCV: Positive Crankcase Ventilation • The blowby gas return system returns blowby gases to an air duct to prevent them from being released to the outside air. • The PCV valve keeps constant the pressure inside the crankcase. • The oil in the blowby gas is separated by the wire mesh and the element in the PCV valve and is returned to the oil pan. • When the element is clogged, the regulator valve opens and the blowby gas is returned to the breather hose.

17-4

GENERAL INSPECTION AND ADJUSTMENT

1. Replacement of PCV Valve Element Lubricant and/or sealant Mark –

Points of application O-ring

Specified lubricant and/or sealant

Quantity

Engine oil

As required

CAUTION • For information on the element replacement interval, refer to the element instruction manual. If the element is used beyond its replacement interval, it may become clogged, causing the pressure inside the engine to increase such that oil leakage occurs. • Be sure to remove and install the cap by hand. Using tools could result in damage. [Removal] • Loosen the cap by hand.

CAUTION • Do not use any tools to loosen the cap. Otherwise, the cap may become damaged.

[Installation] • Clean the thread on the cap. • Lightly smear the O-ring with engine oil and fit it on the cap. • Securely tighten the cap until it stops slightly above the PCV body.

CAUTION • Be sure to use a genuine Mitsubishi Fuso element. Using an inappropriate element could result in engine trouble. • When replacing the element, be sure to replace the O-ring also.

17-5

EGR VALVE, EGR SOLENOID VALVE, EGR PIPE AND EGR COOLER

Removal sequence 1 2 3 4 5 6 7 8 9

Water hose Water hose Water hose EGR adapter Gasket Gasket Plug EGR cooler Gasket

10 11 12 13 14 15 16 17 18

Upper EGR pipe clamp EGR pipe Gasket Eyebolt EGR air pipe Connector Connector EGR solenoid valve EGR valve

Installation sequence Perform installation by following the removal sequence in reverse.

17-6

19 Gasket

*a:

EGR valve adapter

: Non-reusable parts Arrows A to C indicate points to or from which pipes are connected. EGR: Exhaust Gas Recirculation

17 Service standards Location

Maintenance item

EGR valve lift

Operating stage

Standard value

Limit

–

1.3 ± 0.3

–

2.6 ± 0.3

–

4.6 ± 0.3

–

5.7 ± 0.3

–

7.7 ± 0.4

–

9.0 ± 0.3

–

11.0 ± 0.3

–

Remedy

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

Clamp (water hose mounting)

4 to 5 {0.4 to 0.5}

–

Connector (air pipe mounting)

15 to 29 {1.5 to 3.0}

–

Clamp (water hose mounting)

3.9 {0.4}

–

25 {2.6}

–

58 {5.9}

–

46 to 54 {4.7 to 5.5}

–

29 {3.9}

–

Eyebolt (water outlet pipe mounting) Eyebolt (EGR air pipe mounting) Nut (EGR adapter mounting) Bolt (EGR adapter mounting) Bolt (EGR pipe mounting) Bolt (EGR solenoid valve mounting) Plug

Inspection procedures Inspection: EGR valve lift • While applying air pressure of 637 to 932 kPa {6.5 to 9.5 kgf/ cm2} to the ports in accordance with the table below, measure the valve lift in operating steps 0 to 7 on each valve. • Replace the EGR valve if it does not conform to the standard value. Operating step

Input port M/V-1

M/V-2

M/V-3

–

O: Air applied –: Air not applied

17-7

EGR VALVE, EGR SOLENOID VALVE, EGR PIPE AND EGR COOLER Inspection procedures Inspection: EGR cooler (1) Exhaust gas passage side • Fit a cover over the exhaust gas outlet of the EGR cooler, and connect a hose to the exhaust gas inlet. Then, submerge the EGR cooler in a container of water. Make sure the coolant passage is full of water. • Apply air pressure of 390 kPa {4 kgf/cm2} through the hose. Check that air does not leak from any part of the EGR cooler. • If there is any abnormality, replace the EGR cooler.

(2) Coolant passage side • Fit covers over the EGR cooler’s exhaust gas inlet, exhaust gas outlet, and coolant outlet, and connect a hose to the coolant inlet. Then, submerge the EGR cooler in a container of water. • Apply air pressure of 294 kPa {3 kgf/cm2} through the hose. Check that air does not leak from any part of the EGR cooler. • If there is any abnormality, replace the EGR cooler.

17-8

BLOWBY GAS RETURN SYSTEM <Type A>

Removal sequence 1 2 3 4 5

Breather pipe Breather hose Breather hose Oil hose PCV valve bracket

6 7 8 9 10

Oil hose stay Cap O-ring Element PCV body

*a: *b:

Rocker cover Breather hose

: Non-reusable parts PCV: Positive crankcase ventilation

Installation sequence Perform installation by following the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Tightening torque

Remarks

Clamp

Parts to be tightened

4.9 {0.5}

–

Clamp

4.0 to 5.0 {0.4 to 0.5}

–

Lubricant and/or sealant Mark

Points of application O-ring

Specified lubricant and/or sealant

Quantity

Engine oil

As required

17-9

BLOWBY GAS RETURN SYSTEM <Type B>

Removal sequence 1 2 3 4 5

Breather hose Breather hose Oil hose PCV valve bracket Oil hose stay

6 7 8 9

Cap O-ring Element PCV body

*a: *b:

Rocker cover Air suction pipe

: Non-reusable parts PCV: Positive crankcase ventilation

Installation sequence Perform installation by following the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Clamp

Tightening torque

Remarks

4.9 {0.5}

–

Lubricant and/or sealant Mark

Points of application O-ring

17-10

Specified lubricant and/or sealant

Quantity

Engine oil

As required

17 <Type C>

Removal sequence 1 2 3 4 5 6

Breather hose Breather pipe Breather hose Breather hose Oil hose Cap

7 8 9 10 11

O-ring Element PCV body Oil hose stay PCV valve bracket

*a: *b:

Rocker cover Air suction pipe

: Non-reusable parts PCV: Positive crankcase ventilation

Installation sequence Perform installation by following the removal sequence in reverse.

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Clamp

Tightening torque

Remarks

4.9 {0.5}

–

Lubricant and/or sealant Mark

Points of application O-ring

Specified lubricant and/or sealant

Quantity

Engine oil

As required

17-11

GROUP 54 ELECTRICAL SPECIFICATIONS .............................................................................. 54-2 STRUCTURE AND OPERATION 1. Starter .................................................................................................. 54-3 2. Alternator ..................................................................................... 54-4 3. Circuit diagram ............................................................................. 54-7

TROUBLESHOOTING ....................................................................... 54-8 INSPECTION OF ELECTRICAL EQUIPMENT #001 to #179 SWITCH ...................................................................... 54-10 #180 to #249 RELAY ........................................................................ 54-11 #250 to #349 SENSOR ..................................................................... 54-12 #350 to #409 CONTROL UNIT .......................................................... 54-13 #750 to #859 OTHER ....................................................................... 54-14 #930 STARTER ................................................................................ 54-15 #940 ALTERNATOR ......................................................................... 54-28

GENERAL INSPECTION AND ADJUSTMENT #950 INSPECTION OF ALTERNATOR .............................................. 54-34 #951 INSPECTION OF REGULATOR ................................................ 54-35 #955 INSPECTION OF PREHEATING SYSTEM ................................. 54-36

54-1

SPECIFICATIONS Alternator Item

Specifications

Manufacturer

MITSUBISHI ELECTRIC Alternator with built-in regulator (without brush external fan)

Type Model

A4T40379

Output

V–A

A4T40399 24–50

Starter, Preheat Item Starter

Specifications

Manufacturer

MITSUBISHI ELECTRIC

Model Output Magnetic switch operating voltage

M008T62271 V–kW V

Model Excitation current Starter relay Closing voltage

Glow plug

24–2.3

16 or less

Opening voltage

4 or less

Allowable cutoff current

Model Rated voltage and current Excitation current

54-2

16 or less U001X33472

V–A

200 Sheathed type

V–A

Model

Glow relay

24–5.0

23–2.2 (reference) U001T41472

V–A

24–1.8

Closing voltage

16 or less

Opening voltage

4 or less

Allowable cutoff current

Temperature fuse capacity

127

A4TU7686

STRUCTURE AND OPERATION

1. Starter

â&#x20AC;¢ This starter uses planetary gears as its reduction gearing mechanism.

54-3

STRUCTURE AND OPERATION 2. Alternator <24Vâ&#x20AC;&#x201C;50A>

54-4

54 2.1 Alternator with neutral diodes (1) Features • The alternator with neutral diodes provides higher DC output during operation at high speeds than the alternator without neutral diodes.

(2) Variations of voltage at neutral point and operation of neutral diodes • The potential at the neutral point varies up and down with the neutral point DC voltage (1/2 of output voltage) as a center as shown. • When the alternator is operated at high speeds, the voltage at the neutral point can increase to exceed the output voltage (28 V) and decrease to become lower than the ground voltage (0 V), and these voltages are lost in conventional system. The neutral diodes rectifies these over-voltage and undervoltage (shaded portions of diagram) and adds them to the DC output. • When the voltage at neutral point is in the range from 0 to 28 V, the conventional diodes (other than neutral diodes) operate.

54-5

STRUCTURE AND OPERATION • When the voltage at neutral point exceeds 28 V, the positive diode operates and adds extra output to the DC output for supply to each electric equipment.

• When the voltage at neutral point drops below 0 V, the negative diode supplies the output from neutral point through other three diodes.

54-6

54 3. Circuit diagram

54-7

TROUBLESHOOTING

Alternator is normal but battery over-discharged.

Charge warning lamp does not light when starter switch is turned ON, with engine stopped.

Battery is normal but over-discharged.

Possible causes

Battery overheating.

Symptoms

Battery electrolyte decreases too early.

1. Power and Charging

Connector connection faulty, harness broken, grounding faulty

Fuse blown

V-belts loose

V-belts damaged

Battery faulty

Alternator

Stator coil short-circuited with core

Field coil broken

Rectifier faulty Wiring faulty

O O

Regulator faulty

54-8

O Stator coil broken

O O

Reference Gr

Gr14

54 2. Engine Starting, Preheating and Stopping

Battery insufficiently charged

Starter

Open circuit in magnetic switch coil

Overrunning clutch malfunctioning

Engine is hard to start.

Does not operate cold start function.

Pinion worn or damaged

O O

Starter switch defective

O O

Gr11

Engine electronic control unit defective

Supply pump defective

Water temperature sensor defective

Glow plugs defective

Glow relay defective

Connecting plate connection faulty

Electronically controlled fuel system

Reference Gr

Starter relay defective Flywheel ring gear worn or damaged

O Magnetic switch contacts stuck or fused together

Engine cannot be preheated.

Engine does not stop.

Fuse blown

Flywheel rotates but engine does not start.

Pinion engages with ring gear but does not rotate.

Possible causes Connector connection faulty, harness broken, grounding faulty

Pinion does not engage with ring gear.

Starter operates but engine does not start.

Starter does not operate.

Symptoms

Gr13E

Cold start switch defective Exhaust brake 3-way magnetic valve defective

Exhaust brake system defective

54-9

#001 to #179 SWITCH #024 Inspection of thermo switch • Dip the switch in a container filled with engine oil. • Raise the oil temperature to the specified one while stirring oil. • Measure the operating temperature between terminals 1 and 2 respectively. 105 ± 2°C

Standard value

• If the measured value deviates from the standard value, replace the sensor. (See Gr14.)

#044 Inspection of engine oil pressure switch • Perform the following checks, and if any fault is found, replace the switch. (See Gr12.) (1) Inspection by without applying air pressure • Make sure that there is continuity between terminal 1 and body. (2) Inspection by applying air pressure • Gradually apply air pressure 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 terminal 1 and body, and make sure to confirm if the value meets the standard. Standard value (operating pressure)

50 ± 10 kPa {0.5 ± 0.1 kgf/cm2}

#053 Inspection of engine oil bypass alarm switch • Perform the following checks, and if any fault is found, replace the switch. (See Gr12.) (1) Inspection by without applying air pressure • Make sure that there is no continuity between terminals 1 and body. (2) Inspection by applying air pressure • Gradually apply air pressure to the switch starting from 0 kPa {0 kgf/cm2}. • Measure the degree of air pressure at the moment when continuity is detected between terminals 1 and body, and make sure to confirm if the value meets the standard. Standard value (operating pressure)

185 +49 0 kPa {1.9

54-10

+0.5 0

kgf/cm2}

#180 to #249 RELAY

54 #187 Inspection of starter relay • Perform continuity check and operation check, and if any fault is found, replace the relay.

#188 Inspection of main power relay • Perform continuity check and operation check, and if any fault is found, replace the relay.

#195 Inspection of glow relay • Perform continuity check and operation check, and if any fault is found, replace the relay.

#201 Inspection of relay (normally open type 5 pin) • Perform continuity check and operation check, and if any fault is found, replace the relay.

54-11

#250 to #349 SENSOR #259 Inspection of water level sensor • Remove the water level sensor from the radiator. • Turn the starter switch ON. • Dip the water level sensor in a container filled with engine coolant, and check that the pilot lamp goes on and out under the following conditions. Condition

Pilot lamp

When water level sensor is out of the engine coolant

When water level sensor is in the engine coolant

OFF

• If any fault is found, replace the sensor. (See Gr14.) #262 Inspection of water temperature sensor <For water temperature gauge> • Dip the sensor in a container filled with engine oil. • Raise the oil temperature to the specified one while stirring oil. • Measure the resistance between terminals 1 and the body. 50 ± 0.2 °C

Standard value

80 ± 10 Ω

60 ± 0.2 °C

56.3 ± 5 Ω

80 ± 0.2 °C

29.5 ± 2.5 Ω

100 ± 0.3 °C

16.5 ± 0.9 Ω

106 ± 0.3 °C

14.3 ± 0.5 Ω

120 ± 0.3 °C

10 ± 0.3 Ω

• If the measured value deviates from the standard value, replace the sensor. (See Gr14.) <For water temperature gauge> • Dip the sensor in a container filled with engine oil. • Raise the oil temperature to the specified one while stirring oil. • Measure the resistance values between terminals 1 and the body.

Standard value

50 ± 0.2 °C

80 ± 10 Ω

60 °C

56.3 Ω (reference value)

80 °C

29.5 Ω (reference value)

100 °C

16.5 Ω (reference value)

106 ± 0.3 °C

14.3 ± 1.0 Ω

120 °C

10 Ω (reference value) • If the measured value deviates from the standard value, replace the sensor. (See Gr14.) <For engine control> • Dip the sensor in a container filled with engine oil. • Raise the oil temperature to the specified one while stirring oil. • Measure resistance values between terminals 1 and 2.

Standard value

20 °C

2.45 ± 0.14 kΩ

80 °C

0.32 kΩ (reference value)

110 °C

147.1 ± 2 Ω

• If the measured value deviates from the standard value, replace the sensor. (See Gr14.)

54-12

#250 to #349 SENSOR, #350 to #409 CONTROL UNIT

#263 Inspection of engine speed sensor • Measure the resistance values between terminals 1 and 2. 125.5 ± 17 Ω

Standard value (at 20°C)

• If the measured value deviates from the standard value, replace the sensor. (See Gr13E.)

#274 Inspection of water separator sensor Condition

Continuity terminal

ON (when coolant quantity is approx. 100 cm3 or more)

1–2

OFF

–

• If any fault is found, replace the sensor. (See Gr13A.)

#350 Inspection of control unit and other units • Since the units alone cannot be readily checked in the off–vehicle state, check the harness, switch and other related parts in each system. • If any fault is not found in the related parts, and the problem still remains in the system, replace the control units or other units.

54-13

#750 to #859 OTHER #757 Inspection of dust indicator • Perform the following checks, and if any fault is found, replace the dust indicator. • Make sure that there is no continuity between terminals 1 and 2 when air pressure is not applied to the dust indicator. • Make sure that there is no continuity between terminals 1 and 2 when negative pressure of 6.23 ± 0.57 kPa {635 ± 58 mmH2O} is applied to the dust indicator. (See Gr15.)

#758 Inspection of air dryer (1) Inspection of thermostat • Perform the following check. If any fault is found, replace the thermostat. • While varying the temperature around the thermostat, measure the temperatures when the continuity is established and is lost between terminals 1 and 2.

Standard value

Temperature when continuity is established (ON temperature)

4 ± 4°C

Temperature when Raising the tempercontinuity is lost ature (OFF temperature)

20°C or lower

Lowering the temperature

(2) Inspection of heater • Measure the resistance of heater as shown. Standard value

8.2 Ω or less

• If the measured value is out of the standard value, replace the heater.

#764 Inspection of glow plug • Measure resistance value of glow plug as shown. Standard value (cold resistance of glow plug)

Approx. 4 Ω

• If the measured value deviates from the standard value, replace the glow plug. (See Gr11.)

54-14

#930 STARTER Removal sequence 1 Starter relay 2 Starter

WARNING • Before removing the starter, disconnect the (–) battery cable and insulate the cable and the (–) battery terminal with tape. • It is dangerous to leave the (–) battery cable connected since the battery cable voltage is always present at terminal B.

Installation sequence Follow the removal sequence in reverse.

54-15

#930 STARTER

Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11

Stopper ring Pinion stopper Pinion Spring Magnetic switch Shim Rear bracket Packing Brush spring Brush (â&#x20AC;&#x201C;) Brush holder

12 13 14 15 16 17 18 19 20 21 22

Brush (+) Yoke Packing Rear bearing Washer Armature Ball Cover Rubber packing Planetary gear Rubber packing

23 24 25 26 27 28 29 30 31 32

Plate E-ring Gear shaft Washer Internal gear Overrunning clutch Lever Front bearing Oil seal Front bracket

: Non-reusable parts

54-16

54 CAUTION • When the armature is removed, the ball may come out with it. Take care not to lose the ball. • Do not remove the bearings and unless defects are evident. • The rubber packing is serviceable if any defect is not found in it during disassembly. • It is not necessary to remove the pinion when only the motor section needs to be disassembled for inspection, like when inspecting brushes and related parts. • Be sure to remove the pinion before disassembling any other parts.

Assembly sequence Follow the disassembly sequence in reverse.

CAUTION • Whenever the magnetic switch is replaced, the pinion gap must be adjusted.

Service standards (Unit: mm) Location –

Maintenance item Pinion gap

Remedy Adjust

0.5 to 2.0

– –

3300 rpm or higher

–

29.2 to 39.4 N {3 to 4 kgf}

13.7 N {1.4 kgf}

Replace

Brush length

Replace

Commutator outside diameter

31.4

Runout of commutator periphery

–

0.1 or higher

Mold depth between segments

–

0.2 or less

No-load characteristics

Brush spring pressure

Limit

85 A or less

–

10, 12

Standard value

With 23V applied

Current Rotation speed

Inspect

Replace Correct or replace

Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Multipurpose grease [NLGI No. 2 (Li soap)]

As required

Molykote AG650

As required

Multipurpose grease [NLGI No. 2 (Li soap)] or grease attached to oil seal

As required

Multemp OA-171 (Kyodo Yushi Co., Ltd.)

As required

Lever contact surface of magnetic switch Sliding surfaces of gear shaft and overrunning clutch Sliding surfaces of lever and overrunning clutch Sliding surfaces of armature and gear shaft Ball Teeth of planetary gear and internal gear Washer Oil seal Splines of overrunning clutch

Special tools Mark

Tool name and shape

Bearing puller and installer

Part No.

MH063597 A: MH063615 B: MH063629

Application

Removal and installation of front bearing

A: Bearing puller and installer B: Bearing installer

54-17

#930 STARTER Work before disassembly Mating mark: Rear bracket and yoke

Disassembly procedure Disassembly: Pinion • For removal of the pinion, current must be supplied to the starter such that the pinion springs out.

WARNING • When the starter is energized, the pinion will spring out and rotate. Be careful not to touch it with your hands. • The magnetic switch may become very hot during inspections. Be careful when touching it.

CAUTION • Do not energize the pull-in coil P for longer than 10 seconds, and do not energize the holding coil H for longer than 30 seconds. If these periods are exceeded, the coils may overheat and burn out. • To make the pinion spring out, be sure to energize the starter such that its parts are positioned correctly. If the starter is not energized and the lever is pulled to make the pinion come out, the front bracket and/or lever may be damaged by the shock inflicted upon them when the stopper ring is removed. • When current is supplied to the starter, a large current (100 A or higher) will flow. For inspection purposes, use booster cables or similarly thick cables. It is also important to ensure that all connections are secure.

54-18

54 • Connect the starter as illustrated. • The following operations are performed with current supplied to the starter. Thus, the entire procedure for removal of the pinion must be completed within 30 seconds. • Turn ON switches 1 and 2 to supply current to the starter. The pinion will spring out and rotate.

• After the pinion starts to rotate, quickly (within five seconds) turn OFF switch 2 to stop the pinion’s rotation.

CAUTION • When switches 1 and 2 are turned ON, the pull-in coil P and holding coil H are both energized. The circuit is connected such that no voltage is applied to starter terminal B, so current flows to the pull-in coil while the pinion rotates. To prevent the pull-in coil from burning out, it is essential to turn OFF switch 2 quickly (within five seconds) after the pinion starts to rotate. • Apply a pipe-shaped implement to the pinion stopper. • Using a hammer, lightly tap the pipe-shaped implement to remove the stopper ring from the ring groove of the pinion stopper. • Remove the stopper ring and pinion. • Turn OFF switch 1 to de-energize the starter.

CAUTION • When the starter is de-energized, the mechanism will attempt to pull in the pinion. Thus, the stopper ring may slip back into the ring groove of the pinion stopper. If this happens, energize the starter and go through the pinion removal procedure again.

54-19

#930 STARTER Disassembly: Yoke and brush holder • Use the following method to remove the yoke and brush holder in order to prevent the commutator of the armature from being damaged by the brushes. • Lift the brushes away from the commutator and hold them lifted by applying the brush springs against the sides of the brush springs.

• Pull part A of each brush spring and pull up the brushes. • Hold the brushes in position with the brush springs as illustrated. • Remove the yoke and brush holder.

Disassembly: Gear shaft and internal gear • Remove the E-rings and then the gear shaft and internal gear from the overrunning clutch. Proceed as follows if the gear shaft cannot be removed due to interference of the splined section of gear shaft with internal parts of the overrunning clutch. • Press the gear shaft against the overrunning clutch. • Turn the gear shaft approx. 1/8 of a turn to change the position of splined section.

Disassembly: Front bearing

54-20

54 Inspection procedure Inspection: Magnetic switch • Perform the following inspections. If any abnormality is found, replace the switch. (1) Test for coil open circuit • Check that continuity exists between terminals S and M.

• Check that continuity exists between terminal M and the body.

(2) Test for fused-together contacts • Check that continuity does not exist between terminals B and M.

(3) Test for contact-to-contact continuity • Push in the end of the magnetic switch to close the internal contacts. Then, check that continuity exists between terminals B and M.

54-21

#930 STARTER Inspection: Brush spring pressure • Using new brushes, measure the load required to separate each brush spring from its brush. • If either measurement is lower than the specified limit, replace the brush springs.

Inspection: Brush (–) (1) Brush length • If either brush (–) is shorter than the limit, it must be replaced.

CAUTION • The brush (–) and its brush holder should be replaced as a set. (2) Contact surface of armature’s commutator and brush • If the commutator contact surface of either brush is rough or unevenly worn, rectify it with emery paper (#300 to 500). Inspection: Brush holder • Thoroughly clean the (+) brush holder and the (–) holder plate, then, check that continuity does not exist between them. • If continuity exists, there is a short circuit and the brush holder must be replaced.

Inspection: Yoke (1) Test for coil open circuit • Check that continuity exists between the cable and the (+) brush. • If there is no continuity, there is an open circuit and the yoke or (+) brush must be replaced.

(2) Test for coil grounding • Check that continuity does not exist between the yoke and the (+) brush. • If continuity exists, the coil is grounded. Inspect the insulation, and replace the yoke and the (+) brush if the insulation cannot be rectified.

CAUTION • The coil may be grounded to the yoke due to the accumulation of worn-off metal particles from the brushes and/or armature.

54-22

54 Inspection: Brush (+) (1) Brush length • If either brush (+) is shorter than the limit, it must be replaced. (2) Contact surface of armature’s commutator and brush • If the commutator contact surface of either brush is rough or unevenly worn, rectify it with emery paper (#300 to 500).

Inspection: Armature (1) Test for coil short circuit • Hold an iron rod parallel with the armature. • Slowly rotate the armature by hand. • If the iron rod vibrates or is pulled toward the armature, the coil is short-circuited and the armature must be replaced.

(2) Test for coil grounding • Check that continuity does not exist between the commutator and the core (or shaft). • If continuity exists, the coil is grounded and the armature must be replaced.

(3) Commutator outside diameter • If the measurement is out of specification, replace the armature.

(4) Runout of commutator periphery • If the reading exceeds the specified limit, rectify the commutator of the armature, making sure the outside diameter stays within specification. (5) Condition of commutator surface • If the surface is rough or has stepped wear, rectify it with emery paper (#300 to 500). • After rectifying the surface, check the extent of commutator runout.

54-23

#930 STARTER (6) Mold depth between segments • If the measurement is lower than the specified limit, rectify or replace the armature. • To rectify the armature, grind the illustrated portions.

• If the mold is worn as illustrated, rectify or replace the armature. : Acceptable X : Unacceptable

Inspection: Overrunning clutch If the following inspections reveal any abnormality, replace the overrunning clutch. • Turn the shaft in direction B and check that it rotates smoothly. • Turn the shaft in direction A and check that it locks.

Assembly procedure Assembly: Front bearing • Press-fit the front bearing using

–A and

–B.

• After the press fitting, caulk the front bearing using the claws on –A.

CAUTION • Avoid re-caulking previously caulked points.

54-24

54 Assembly: Yoke and brush holder • To install the yoke and brush holder, follow the removal sequence in reverse. (See “ Disassembly: Yoke and brush holder”) Assembly: Magnetic switch • Fit the magnetic switch onto the lever with terminal S aligned as illustrated.

Assembly: Pinion • For installation of the pinion, it is not necessary to supply current to the starter. • Fit the pinion stopper and pinion onto the overrunning clutch, making sure they are oriented as illustrated. • Fit the stopper ring into the ring groove of the overrunning clutch.

• Pull the pinion hard and securely fit the stopper ring into the ring groove of the pinion stopper.

54-25

#930 STARTER Inspection after assembly Inspection: Performance and pinion gap • After assembling the starter, perform inspections with current supplied to it.

CAUTION • Do not energize the pull-in coil P for longer than 10 seconds, and do not energize the holding coil H for longer than 30 seconds. If these periods are exceeded, the coils may overheat and burn out. • When current is supplied to the starter, a large current (100 A or higher) will flow. For inspection purposes, booster cables or similarly thick cables must therefore be used. Also, it is important to ensure that all connections are secure.

(1) Performance test • Connect the starter as illustrated. • Set the voltage to 23 Volts DC.

CAUTION • The voltage applied must not exceed 24 V. • The following operations are performed with current supplied to the starter. Thus, the entire test (consisting of measurement of the current flowing through the starter and measurement of the starter’s rotational speed) must be completed within 30 seconds. • Turn ON the switch to supply current to the starter. The pinion will spring out and rotate.

CAUTION • When the switch is turned ON, the pull-in coil P and holding coil H are both energized. When the large current from the DC power supply flows from terminal B to terminal M, the supply of current to the pull-in coil P is cut; only the holding coil H remains energized. To prevent the holding coil from burning out, it is essential to complete all operations within 30 seconds. • Measure the current and the starter’s rotational speed. To measure the rotational speed, shine a stroboscope on the pinion. • Turn OFF the switch to de-energize the starter. • If either measurement is out of specification, disassemble and inspect the starter again.

54-26

54 (2) Pinion gap • Connect the starter as illustrated.

• The following operations are performed with current supplied to the starter. Thus, the entire procedure for measurement of the pinion gap must be completed within 30 seconds. • Turn ON switches 1 and 2 to supply current to the starter. The pinion will spring out and rotate.

• After the pinion starts to rotate, quickly (within five seconds) turn OFF switch 2 to stop the pinion’s rotation.

CAUTION • When switches 1 and 2 are turned ON, the pull-in coil P and holding coil H are both energized. The circuit is connected such that no voltage is applied to starter terminal B, so current flows to the pull-in coil while the pinion rotates. To prevent the pull-in coil from burning out, it is essential to turn OFF switch 2 quickly (within five seconds) after the pinion starts to rotate. • Pull out the end of the overrunning clutch and then lightly push in the end of the overrunning clutch and measure the amount of movement in the axial direction, i.e., the pinion gap. • Turn OFF switch 1 to de-energize the starter. • If the measurement is out of specification, replace the lever.

54-27

#940 ALTERNATOR

Removal sequence 1 Adjusting bolt 2 Adjusting shaft <With adjusting shaft> 3 V-belt

4 Alternator 5 Adjusting plate

*a:

Alternator bracket

WARNING • Before removing the alternator, disconnect the (–) battery cable and insulate the cable and the (–) battery terminal with tape. • It is dangerous to leave the (–) battery cable connected since the battery cable voltage is always present at terminal B.

Installation sequence Follow the removal sequence in reverse. • For adjustment of V-belt tension (See Gr14).

Service standards Location

Maintenance item Alternator output current (* when alternator is hot and producing 27 V)

4 Adjustment voltage of regulator (at 5000 rpm, 5 A is loaded)

Standard value

Limit

At 1500 rpm

24 A or more

–

At 2500 rpm

38 A or more

–

At 5000 rpm

45 A or more

–

28.5 ± 0.5 V

–

Remedy

Inspect

Replace

* The hot condition is that which occurs after the alternator has been running at normal ambient temperature at 5000 rpm and maximum output for 30 minutes.

54-28

54 Inspection procedure Inspection: Alternator (1) Alternator output current (bench test) • Connect the alternator as illustrated.

CAUTION • Wires with sufficient thickness should be used for wiring and each connection should be securely fastened. B: E: L: R:

Terminal B Terminal E Terminal L Terminal R

• Increase load resistance to the maximum (condition under which the load current hardly flows). • Turn switch A and B ON. • Run alternator at 5000 rpm for 30 minutes by adjusting load resistance so that electric current can conform to the following standard. Alternator nominal current Current Approx. 45 A

• Measure the current at each specified revolution of alternator. • If the measured value deviates from the standard value, disassemble and check alternator. (2) Adjustment voltage of regulator (bench test) • Connect the alternator as illustrated. B: E: L: R:

Terminal B Terminal E Terminal L Terminal R

• Turn switch ON. • Run alternator at low speeds. • Increase the speed of alternator to 5000 rpm and measure the voltage (adjustment voltage) at this speed. At the same time, make sure that the current is 5 amperes or less at 5000 rpm. • If the measured value deviates from the standard value, do as follows: • If higher than the standard value: Replace the regulator. • If lower than the standard value: Inspect the alternator related parts before replacing the regulator.

54-29

#940 ALTERNATOR

Disassembly sequence 1 2 3 4 5 6

Pulley & fan Spacer Rear bearing Rotor Cover Front bearing

7 8 9 10 11 12

Front bracket Field coil Stator Regulator Rectifier Rear bracket

• Do not remove the rear and front bearing, stator, or unless faulty.

Assembly sequence Follow the disassembly sequence in reverse.

Service standards Location 8

Maintenance item Field coil resistance (at 20°C)

Standard value

Limit

Remedy

6.1 to 7.1 Ω

–

Replace

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened Nut (pulley mounting)

54-30

Tightening torque

Remarks

143 to 181 {15 to 18}

–

54 Disassembly procedure Disassembly: Rotor and front bracket • Insert a screwdriver between front bracket and stator. • Use the screwdriver to pry rotor and front bracket away from stator and rear bracket.

CAUTION • Be careful not to insert the screwdriver too deep or it will damage coil of stator and may cause a short-circuit.

Disassembly: Pulley

CAUTION • Make sure to grip the root of the core claws when you hold the rotor in a vice. Gripping claws can damage them.

54-31

#940 ALTERNATOR Disassembly: Field coil • Remove screw A (2 places).

CAUTION • If screws B are removed first, the weight of field coil may be placed on the joining portion with regulator which is fixed with screw A, causing break of the joining portion. To avoid this, remove screw A first. • Remove screw B (3 places).

CAUTION • If screw B are removed, the field coil will fall under its own weight. Keep the field coil supported with your hand. • Remove field coil.

CAUTION • Do not remove the field coil forcibly. Otherwise the portion that joins with the regulator may be caught by the stator coil. Disassembly: Stator • Disconnect lead of stator from rectifier. The lead is soldered to the diode of the rectifier at 4 places.

CAUTION • Unsolder within as short a time period as possible (within 5 seconds), otherwise diode can be easily damaged by heat.

Inspection procedure Inspection: Field coil • Measure the resistance between the terminals of field coil. • If the measured value deviates from the standard value, replace field coil.

54-32

54 Inspection: Stator • Perform the following inspections. If any abnormality is found, replace the stator. (1) Continuity between each lead wire • Check that there is continuity between each stator lead. • If there is no continuity, the lead has broken.

(2) Continuity between each lead wires and the core • Check that there is no continuity between lead wires and the core. • If there is continuity, the lead wire has short-circuited.

Inspection: Rectifier • Check the function of diodes within rectifier properly. If any fault is found, replace the rectifier. If resistance is infinite in both cases, the diode has open. If resistance is close to 0 Ω in both cases, the diode has shorted. A, B, C, D: Lead connecting area of stator coil E, G: Heat sink area F: Regulator connecting area • Inspection should be conducted twice, changing over the positive probe and the negative probe of the tester.

CAUTION • When inspecting using a tester, the current flowing through the rectifier is smaller than usual. Therefore, an incorrect resistance value may be indicated on the tester. Additionally, incorrect indications become larger as the range of the tester gets smaller. Set the tester to the largest possible scale.

Assembly procedure Assembly: Stator • To install the stater, follow the disassembly sequence in reverse. (See ‘‘ Disassembly: Stator’’.)

54-33

#950 INSPECTION OF ALTERNATOR Performance test • Connect the meters to the alternator as shown.

WARNING • To prevent possible injury, be sure to disconnect the negative terminal of the battery and insulate it with tape before working on the wiring. With the negative terminal (–) of the battery connected, battery voltage is always applied to terminal B. • To connect to switch, use a lead wire with the same or larger diameter than that of the chassis harness connected to terminal B. • Turn on switch and make sure that voltmeter indicates battery voltage. • Start the engine. • Immediately turn on the switches for all lamps on the vehicle. • Immediately accelerate the engine to the speed indicated below and measure the alternator’s output current. Approx. 1400 rpm <A4T40399> Approx. 1900 rpm <A4T40379 (crankshaft pulley PCD 193mm)> Approx. 2100 rpm <A4TU7686> Approx. 2150 rpm <A4T40379 (crankshaft pulley PCD 168mm)> PCD: Pitch circle diameter • The alternator is considered to be good if the measured value is 70% or more of the nominal output current. Alternator nominal output Alternator Voltage Output current 50 A 24 V 50 A

CAUTION • The general inspection is only a simplified check. Use a test bench for accurate checking.

54-34

#951 INSPECTION OF REGULATOR Service standards Location –

Maintenance item Adjusting voltage

Standard value

Limit

Remedy

28.5 ± 0.5 V

–

Replace

• Connect the meters to the alternator as shown.

WARNING • To prevent possible injury, be sure to disconnect the negative terminal of the battery and insulate it with tape before working on the wiring. With the negative terminal (–) of the battery connected, battery voltage is always applied to terminal B. • To connect to switch, use a lead wire with the same or larger diameter than that of the chassis harness connected to terminal B. • Turn off the switches for lamps, heater, etc. so that electric loads may not be applied during the inspection. • Turn on switch and then start the engine. • If the output current is 5 amperes or less when the engine speed is raised to the appropriate speed indicated below, then measure the voltage at terminal B. Approx. 1400 rpm <A4T40399> Approx. 1900 rpm <A4T40379 (crankshaft pulley PCD 193mm)> Approx. 2100 rpm <A4TU7686> Approx. 2150 rpm <A4T40379 (crankshaft pull PCD 168mm)> PCD: Pitch circle diameter

CAUTION • If the output current is in the range from 5 to 10 amperes, the measured value (regulated voltage) will be slightly lower. 28 V – 0.2 to 0.3 V • If the output current is 5 amperes or more, do one of the following: • Run the engine for a while to charge the battery. • Replace the battery with a fully-charged one. • If the measured value deviates from the standard value, conduct checking again on the test bench.

54-35

#955 INSPECTION OF PREHEATING SYSTEM Service standards Location

Maintenance item

Standard value

Limit

No pre-glow operation

–

0 or 60°C

About 12 seconds

–

0°C or below

About 20 seconds

–

0°C or higher

No after-glow operation

–

0°C or below

About 168 seconds

–

60°C or higher –

Coolant temperature

Pre-glow time After-glow time

Remedy

Inspect

• Turn the starter switch to OFF. • Connect a check lamp to the glow plug.

• Remove the water temperature sensor from the engine, and close the sensor mounting hole with the plug (M16 × 1.5 mm).

• Connect the extension harness between the water temperature sensor and connector. • Place the water temperature sensor in a container of water. • Conduct the following test while changing the temperature of water in the container. If anything abnormal is found, check relevant components.

(1) Pre-glow time checking • Turn the starter switch to ON (without starting the engine) and confirm that the pre-glow time or check lamp ON time at each water temperature conform with standard values. (2) After-glow time checking • Start the engine and measure the check lamp ON time to ensure that the after-glow time conforms with the standard value.

54-36

GROUP 61 SPECIAL EQUIPMENT SPECIFICATION ................................................................................. 61-2 STRUCTURE AND OPERATION 1. Air Compressor ............................................................................ 61-4 2. Air Dryer ....................................................................................... 61-6 TROUBLESHOOTING ........................................................................ 61-9 GENERAL INSPECTION AND ADJUSTMENT 1. Maintenance and Inspection of Air Dryer .................................... 61-10 2. Inspection and Adjustment of Air Dryerâ&#x20AC;&#x2122;s Air Pressure Governor ................................................................ 61-11

AIR COMPRESSOR <154 cm3 {154 mL}> ........................................................................ 61-14 <319 cm3 {319 mL}> ........................................................................ 61-18

AIR DRYER ....................................................................................... 61-22

61-1

SPECIFICATIONS Air compressor Item

Specifications

Type

Water-cooled 1 cylinder

Cylinder bore × stroke

φ70 × 40

φ95 × 45

Cylinder displacement

cm3 {mL}

154 {154}

319 {319}

Manufacturer

Sanwa Seiki

Air dryer Item

Specifications

Model

DU-4

Heater capacity Thermostat operating temperature

V-W ON °C OFF

Purge chamber capacity Required time for recycling desiccant

4±4 16 ± 4 dm3 {L} sec.

Upper threshold Air pressure governor operating pressure pressure 2 kPa {kgf/cm } Lower threshold pressure Manufacturer

61-2

24-70

1.0 {1.0} 30 +0.3 890 +29 -20 {9.1 -0.2 }

760 ± 15 {7.8 ± 0.15} Nabtesco

61 M E M O

61-3

STRUCTURE AND OPERATION 1. Air Compressor

61-4

61 1.1 During suction • When the piston goes down during the suction stroke cycle, the vacuum causes the suction valve to open, allowing air to be drawn into the cylinder.

1.2 During compression and delivery • When the piston goes up during the compression and delivery stroke cycle, the suction valve is closed by air pressure. • Air pressure compressed by the piston forces open the delivery valve and makes its way to the air dryer and air tank.

61-5

STRUCTURE AND OPERATION 2. Air Dryer • The air dryer protects brake components by removing moisture and oil from air that has been compressed by the air compressor. • The air dryer incorporates an air pressure governor, which keeps the pressure in the air tank constant by releasing air compressed by the air compressor to the atmosphere when the pressure in the air tank makes such operation necessary.

2.1 Drying action • While the air tank is being charged, air from the air compressor enters the air dryer’s supply side. Moisture and oil are separated from the air inside the body and collect in the bottom. The air then passes through the oil filter, which removes smaller oil droplets and particles of dust. The air then flows into the case, where the desiccant removes any remaining moisture. • As the air flows upward in the case, it makes contact with increasingly dry desiccant and thus contains less and less moisture. When the air reaches the top of the case, it is dry. It flows through the check valve A, purge chamber, and check valve B, and it is then supplied from the delivery side to the air tank. Air pressure also acts upon the piston in the air pressure governor.

61-6

61 2.2 Regeneration of desiccant • When the air pressure in the air tank reaches the upper threshold level, signal pressure from the air pressure governor causes the valve in the air dryer’s control port to open. As a result, the pressure in the case cleans the oil filter and pushes the water and oil out into the atmosphere. • Following the rapid drop in pressure, dry air in the purge chamber flows through the orifice, expands, and becomes super-dry. As this super-dry air flows backward through the case, it carries moisture from the desiccant out into the atmosphere, thereby completing the desiccant’s regeneration. • During the regeneration process, the check valve is closed. Thus, the signal pressure from the air pressure governor continues to act upon the control port and the valve remains open. Air from the air compressor thus flows through the valve, through the silencer, and out into the atmosphere. • The regeneration process continues until air consumption causes the pressure in the air tank to decrease to the governor lower threshold level.

2.3 Operation when tank pressure reaches upper threshold level • Air pressure from the air tank continuously acts upon the piston. • When the tank pressure increases to such a level that it overcomes the spring, it pushes the piston upward such that the valve closes. • When the tank pressure increases further and exceeds the upper threshold level, the piston is pushed upward further such that the exhaust stem opens the inlet valve. Air pressure from the air tank thus flows out of the air pressure governor as signal pressure, causing the valve to open. Regeneration of the air dryer’s desiccant thus begins.

61-7

STRUCTURE AND OPERATION 2.4 Operation when tank pressure reaches lower threshold level â&#x20AC;˘ When the air pressure A from the air tank drops below the lower threshold level, the piston is pushed downward by the spring such that the inlet valve closes and the exhaust valve opens. As a result, air pressure flows through the exhaust stem and escapes to the atmosphere.

61-8

TROUBLESHOOTING Air dryer

Malfunctioning of valve due to adherence of foreign particles

Heater circuit open and therefore no heat retention

Heater malfunction due to thermostat malfunction

Extreme lowering of temperature of air dryer main body due to adherence of snow/ice

Heater malfunction due to disconnection with thermostat

Dry air in air tank flows out in reverse when check valve of air dryer fails to function as a non-return valve Rising of oil level in air compressor

Engine oil leaks from exhaust port

Air pressure in air tank decreases markedly

Inoperative heater causing air dryer to freeze

Freezing takes place within air dryer

Deterioration of desiccating agent

No deposits come out of exhaust port

Possible causes

Deposits come out of drain cock of air tank

Symptoms

Reference Gr

O O

61-9

GENERAL INSPECTION AND ADJUSTMENT 1. Maintenance and Inspection of Air Dryer Perform maintenance and inspections at each of the indicated intervals or service time. (1) Every three months or 500 hours • Check whether the air dryer is functioning properly by opening the drain cock on the air tank and checking whether water flows out. • If a small amount of water flows out, check whether the desiccant has changed color. If one fifth or more of the desiccant has changed in color from white to brown, replace the desiccant using repair kit B. (See “AIR DRYER”.)

NOTE • A small amount of moisture may collect whenever the temperature in the vicinity of the air tank drops by more than 16°C. • Place the desiccant in the case, then settle the desiccant by tapping gently and evenly around the case with a plastic hammer.

• Place the soft layer side of the filter on the desiccant, and place the filter plate on the case, then tap the desiccant down following the manners. • Before tapping the case against the work surface, lay two or three layers of shop towel on the work surface to protect the bottom of the case from scratches. • Holding down the filter plate with both hands, lift the case to a height of about 100 mm and tap it gently against the work surface. • Tap the case about 30 more times. Make sure the filter plate drops by 4 to 6 mm from its original position.

WARNING • Unless the tapping procedure is performed, particles of desiccant may escape and create blockages in brake lines, thus preventing normal brake operation. • Look carefully at the water that flows out of the air dryer’s exhaust port. If the water is contaminated with oil, inspect the air compressor. (See “AIR COMPRESSOR”.) (2) Every year or 2000 hours Disassemble the air dryer and replace the desiccant, oil filter, filter, and related rubber parts with the repair kit B. (See “AIR DRYER”.) (3) Every two years or 4000 hours Disassemble the air dryer and replace the desiccant, oil filter, and all rubber parts with repair kit A. (See “AIR DRYER”)

61-10

61 2. Inspection and Adjustment of Air Dryer’s Air Pressure Governor Service standards Location

–

Maintenance item

Standard value

Upper threshold pressure

Threshold pressure

Lower threshold pressure

Limit

Remedy

–

Adjust

–

Replace

Tightening torque

Remarks

890 +29 –20 kPa 2 {9.1 +0.3 –0.2 kgf/cm }

760 ± 15 kPa {7.8 ± 0.2 kgf/cm2}

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

–

Plug

14.7 to 24.5 {1.5 to 2.5}

–

Cap nut (seat and plate mounting)

4.9 to 5.9 {0.5 to 0.6}

–

Nut (for retention of adjusting screw)

6.9 to 7.8 {0.7 to 0.8}

–

Lubricant and/or sealant Mark –

Points of application Plug thread

Specified lubricant and/or sealant

Quantity

ThreeBond 1110B

As required

[Inspection] (1) Air leak • Install the air pressure gauge A between the air dryer and air tank (wet tank side). • Remove the plug from the air dryer at the location shown in the drawing. Connect air pressure gauge B at that point. • Start the engine to activate the air compressor such that the air pressure in the air tank gradually increases. Check that the pressures indicated by the pressure gauges A, B do not decrease when air is expelled from the exhaust cover. • If the pressure indicated by either of the pressure gauges A, B decreases, air is leaking from the check valve and air pressure governor in the air dryer, causing continuous charging and purging. Carry out disassembly and inspection.

61-11

GENERAL INSPECTION AND ADJUSTMENT (2) Operating pressure of air pressure governor • Remove the cap nut, plate, and seat. • Start the engine and gradually increase the air pressure in the air tank. • Turn the adjusting screw until the pressure indicated by air pressure gauge A when air is expelled from the exhaust cover is the standard value (the upper threshold pressure). • Reduce the air pressure to the lower threshold pressure or lower, then gradually increase it again. Check whether the pressure indicated by the air pressure gauge A is the standard value (the upper threshold pressure). If the indicated pressure deviates from the standard value, make further adjustments. • With the upper threshold pressure indicated, air from the air compressor is expelled from the exhaust cover continuously. With the equipment in this condition, open the drain cock to gradually reduce the air pressure. When air stops being expelled from the exhaust cover, check whether the pressure indicated by air pressure gauge B is the standard value (the lower threshold pressure). If the indicated pressure deviates from the standard value, replace relevant parts of the air compressor governor. • Tighten the nut to hold the adjusting screw in position.

61-12

61 M E M O

61-13

AIR COMPRESSOR <154 cm3 {154 mL}>

61-14

61 Disassembly sequence 1 2 3 4 5 6 7 8

Lock washer Compressor gear Cylinder head Gasket Valve seat O-ring Cylinder liner O-ring

9 10 11 12 13 14 15 16

1st compression ring 2nd compression ring 3rd compression ring Oil ring Snap ring Piston pin Piston Coupling

17 18 19 20 21

Bearing cover Bearing Connecting rod Crankshaft Crankcase

: Locating pin : Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

Clearance between cylinder liner and piston

Top

–

0.30

Skirt

–

0.20

Piston ring end gap (measured with ring placed in cylinder)

Compression ring

–

0.60

Oil ring

–

0.65

9 to 12, Clearance between piston ring Compression ring 15 and piston groove Oil ring

–

0.07

–

0.075

14, 15

Clearance between piston pin and piston

–

0.07

Replace

14, 19

Clearance between piston pin and connecting rod small end

–

0.07

Replace

7, 15

9 to 12

19 19, 20 20 20, 21

Replace

End play of connecting rod

–

1.5

Replace

Clearance between connecting rod big end and crankshaft

–

0.1

Replace

Crankshaft end play

–

0.7

Replace

Clearance between crankshaft and crankcase bushing inside diameter

–

0.2

Replace

Tightening torque (Unit: N·m {ft.lbs, kgf·m}) Mark

Tightening torque

Remarks

Nut (compressor gear mounting)

Parts to be tightened

167 to 186 {17 to 19}

–

Bolt (cylinder head mounting)

29 to 34 {3.0 to 3.5}

–

Bolt (cylinder liner mounting)

25 to 29 {2.5 to 3.0}

–

Bolt (coupling mounting) Nut (bearing cover mounting) Stud bolt

53 to 65 {5.4 to 6.6}

–

8.8 to 10.8 {0.9 to 1.1}

–

5.9 to 12 {0.6 to 1.2}

–

Special tools Mark

Tool name and shape

Piston ring tool

Part No.

Application

MH060014

Removal and installation of compression rings

61-15

AIR COMPRESSOR <154 cm3 {154 mL}> Removal procedure Removal: Compression rings

Installation procedure Installation: Compression rings • Install the compression rings, ensuring that their end gaps are located as shown in the illustration. • Install the compression rings by following the removal sequence in reverse. (See “ Removal: Compression rings”.)

Installation: Lock washer, compressor gear • Install the compressor gear onto the crankshaft, ensuring that “O” mark on the compressor gear is aligned with “O” mark on the crankshaft. • Insert the protrusion of the lock washer such that the “O” mark on the compressor gear remains exposed. • Tighten the nut to the specified torque. Bend one part at the bottom of the lock washer toward the nut to prevent the nut from loosening.

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61 M E M O

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AIR COMPRESSOR <319 cm3 {319 mL}>

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61 Disassembly sequence 1 2 3 4 5 6 7 8 9

Lock washer Compressor gear Cylinder head Gasket Valve seat O-ring Cylinder liner O-ring 1st compression ring

10 11 12 13 14 15 16 17 18

2nd compression ring 3rd compression ring Oil ring Snap ring Piston pin Piston Lock washer Connecting rod Connecting rod cap

19 20 21 22 23

Coupling Bearing cover Bearing Crankshaft Crankcase

: Locating pin : Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse.

Service standards (Unit: mm) Location

Maintenance item

Standard value

Limit

Remedy

Clearance between cylinder liner and piston

Top

–

0.335

Skirt

–

0.195

Piston ring end gap (measured with ring placed in cylinder)

Compression ring

–

1.0

Oil ring

–

0.8

9 to 12, Clearance between piston ring Compression ring 15 and piston groove Oil ring

–

0.08

–

0.07

14, 15

Clearance between piston pin and piston

–

0.08

Replace

14, 17

Clearance between piston pin and connecting rod small end

–

0.07

Replace

End play of connecting rod

–

0.5

Replace

Clearance between connecting rod big end and crankshaft

–

0.1

Replace

Crankshaft end play

–

1.0

Replace

Clearance between crankshaft and crankcase bushing inside diameter

–

0.12

Replace

7, 15

9 to 12

17 17, 18, 22 22 22, 23

Replace

Tightening torque (Unit: N·m {ft.lbs, kgf·m}) Mark

Tightening torque

Remarks

Nut (compressor gear mounting)

Parts to be tightened

167 to 186 {17 to 19}

–

Bolt (cylinder head mounting)

29 to 34 {3.0 to 3.5}

–

23 to 25 {2.3 to 2.6}

–

25 to 29 {2.5 to 3.0}

–

Nut (connecting rod cap mounting) Bolt (valve seat mounting) Nut (cylinder liner cap mounting) Bolt (coupling mounting) Nut (bearing cover mounting) Stud

53 to 65 {5.4 to 6.6}

–

8.8 to 10.8 {0.9 to 1.1}

–

5.9 to 12 {0.6 to 1.2}

–

Special tools Mark

Tool name and shape

Piston ring tool

Part No.

Application

MH060014

Removal and installation of compression rings

61-19

AIR COMPRESSOR <319 cm3 {319 mL}> Removal procedure Removal: Compression rings

Installation procedure Installation: Connecting rod cap and connecting rod • Assemble the connecting rod and cap while noting their alignment marks. • Install bolts in such a way that the notches in the bolt heads are directed toward the inside of the connecting rod cap.

Installation: Compression rings • Install the compression rings, ensuring that their end gaps are located as shown in the illustration. • Install the compression rings by following the removal sequence in reverse. (See “ Removal: Compression rings”.)

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61 M E M O Cat DP150N Forklift Mitsubishi 6M60TL Engine Parts Contact Email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 1 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com www.dp150.com/cat-dp150-engine-parts

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AIR DRYER

61-22

61 Disassembly sequence 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Purge chamber O-ring Check valve Case cover O-ring Set spring Filter plate Filter Desiccant Filter Filter plate Case Oil filter O-ring Cover Gasket ring Gasket ring Plate Seat

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

Retaining ring Upper spring seat Spring Lower spring seat Adjusting screw Exhaust stem Exhaust stem spring O-ring Piston Valve Valve spring Retaining ring O-ring Check valve guide Check valve spring Check valve Thermostat Heater Silencer

39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

Retaining ring Exhaust cover Retaining ring Silencer plate Silencer Silencer plate O-ring Silencer case O-ring Piston Valve spring Valve body O-ring Valve Plug Body

: Non-reusable parts

Assembly sequence Follow the disassembly sequence in reverse. • Check and adjust the air pressure governor after assembly. (See “GENERAL INSPECTION AND ADJUSTMENT”.) Repair kit: Air dryer kit A, B

Tightening torque (Unit: N·m {kgf·m}) Mark

Parts to be tightened

Tightening torque

Remarks

17.7 to 27.5 {1.8 to 2.8}

–

2.0 to 3.9 {0.2 to 0.4}

–

4.9 to 5.9 {0.5 to 0.6}

–

Nut (adjusting screw retaining)

6.9 to 7.8 {0.7 to 0.8}

–

Screw (clamp mounting)

1.0 to 1.5 {0.1 to 0.15}

–

Screw (thermostat mounting)

Bolt (purge chamber, cover and body mounting) Bolt (case mounting) Screw (case cover mounting) Cap nut (seat and plate mounting)

0.5 to 1.0 {0.05 to 0.10}

–

Heater

19.6 to 29.4 {2 to 3}

–

Bolt (valve, piston and valve body mounting)

3.9 to 6.9 {0.4 to 0.7}

–

Plug

14.7 to 24.5 {1.5 to 2.5}

–

Silencer

29.4 to 39.2 {3.0 to 4.0}

–

61-23

AIR DRYER Lubricant and/or sealant Mark

Points of application

Specified lubricant and/or sealant

Quantity

Multipurpose grease [NLGI No. 2 (Li soap)]

As required

Plug thread

ThreeBond 1110B

As required

Silencer thread

ThreeBond 1401B

Three threads from the end of thread

O-ring Adjusting screw (entire surface except thread) Outer periphery of piston and O-ring groove Body (inside surface)

Installation procedure Adjustment: Adjusting screw • Turn the adjusting screw to achieve the indicated dimension from the top of the upper spring seat to the bottom of the lower spring seat. Doing so will facilitate the threshold pressure adjustment to the specified value.

Installation: Filters, desiccant, and filter plate • Install the filters with their soft layers facing the desiccant.

• Place the desiccant in the case, then settle the desiccant by tapping gently and evenly around the case with a plastic hammer.

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61 • Place the soft layer side of the filter on the desiccant, and place the filter plate on the case, then tap the desiccant down following the manners. • Before tapping the case against the work surface, lay two or three layers of shop towel on the work surface to protect the bottom of the case from scratches. • Holding down the filter plate with both hands, lift the case to a height of about 100 mm and tap it gently against the work surface. • Tap the case about 30 more times. Make sure the filter plate drops by 4 to 6 mm from its original position.

WARNING • Unless the tapping procedure is performed, particles of desiccant may escape and create blockages in brake lines, thus preventing normal brake operation.

Inspection after installation Inspection: Air leakage • Completely plug the delivery side of the air dryer, then apply air pressure of 49 kPa {0.5 kgf/cm2} or 780 kPa {8 kgf/cm2} to the supply side and check that no air leaks from any joint. Leakage from the valve assembly must not exceed 20 cm3 per minute. • Increase the pressure applied to the supply side to 932 kPa {9.5 kgf/cm2} to cause purging (regeneration). Check that no air leaks from the check valve and from the air pressure governor (with the plug removed). • If there is air leakage from the air pressure governor or the check valves, charging (pressure filling) and purging (regeneration) will be performed continuously. Therefore, carry out the inspection of the air pressure governor and check valve.

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