Mitsubishi Diesel Forklift Truck Fd100nz Fd120nz Fd135nz Fd150anz Workshop Service Manual by www.heydownloads.com

Service Manual Chassis & Mast FD100NZ FD120NZ FD135NZ FD150ANZ

LC/FC

F15DE-60001-up F15DE-60001-up F15DE-60001-up F24BE-60001-up

For use with 6D16-TL Engine Service Manual.

99799-21000

FOREWORD This service manual is a guide for servicing Mitsubishi Forklift Trucks. The long productive life of your forklift 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 the forklift truck. The descriptions, illustrations and specifications contained in this manual are for forklift trucks with serial numbers in effect at the time of printing. Mitsubishi Forklift Trucks reserves the right to change specifications or designs without notice and without incurring obligations. For your convenience the instructions are grouped by systems as an easy reference. For engine servicing, please refer to the applicable engine service manual. 6D16-TL diesel engine

Safety related signs

Meanings

RWARNING

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

RCAUTION

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

NOTE

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

Unauthorized copying and lending are prohibited.

1. Safety R WARNING -

The proper and safe lubrication and maintenance for these forklift trucks, recommended by Mitsubishi Forklift Trucks, are outlined in the OPERATION & MAINTENANCE MANUAL. Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance on these trucks. Improper performance of lubrication or maintenance procedures is dangerous and could result in injury or death. The serviceman or mechanic may be unfamiliar with many of the systems on this truck. This makes it important to use caution when performing service work. Do not operate these trucks unless you have read and understood the instructions in the OPERATION & MAINTENANCE MANUAL. Improper truck operation is dangerous and could result in injury or death.

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 using a hammer or sledge 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. (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 (51 lb) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. (7) To avoid burns, be alert of the hot sections and hot fluids in lines, tubes and compartments, even when idle or off. (8) Be careful when removing cover plates. Gradually remove the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any springs or other pressures, 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. Be aware that the danger of being sprayed or splashed if the truck has just been stopped because fluids can be hot. (10) Use tools well maintained. And use the tools in proper way. (11) Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. (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) Before starting to work on truck, hang "Do not Operate" tag in the Operator Compartment. (14) Repairs, which require welding, should be performed only with the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine the type of metal and select the correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal. (15) Do not damage wiring during the removal process. Do not reuse the damaged wiring. Reinstall the wiring paying attention not to contact sharp corners or hot parts. Place wiring away from oil pipe. (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 could 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 could result in a high velocity oil stream that will be invisible close to the hose. This oil could penetrate the skin and cause personal injury. Use cardboard or paper to locate 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. Place blocks to prevent a device from falling if it is in the raised position. Release the residual pressure when removing a pressurized device. (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.

iii

2. How to Use This Manual 2.1 Truck Model LC (Lever Control System) Truck This model allows a very small operating effort, and is suitable for an operator who prefers the conventional operation movement.

500206

FC (Fingertip Control System) Truck This model allows a fingertip operation of lifting and tilting jobs, and may improve the job efficiency with less operation fatigue.

500207

3. Symbols and Abbreviations Symbol or abbreviation

Meanings

OP.

Option

R1/4

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

Rc1/8

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

G1/4A

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

Rp1/8

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

4. Units -

SI Units are used in this manual. The following table shows the conversion of SI unit and customary unit. Item

SI unit

Metric unit

Yard-pound unit

0.102 kgf

0.225 lbf

Pressure

1 MPa

10.1972 kgf/cm2

145.038 psi

Torque

1 N·m

0.102 kgf·m

0.7376 lbf·ft

1 mm

0.039 in.

3.281 feet

Weight

1 kg

2.205 lb

Temperature

1 °C

°F=1.8x°C+32

Volume

0.264 US.gal.

Force

Length

TABLE OF CONTENTS

Chapter 1 GENERAL INFORMATION 1. 2. 3. 4. 4.1 4.2

Model View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Applicable Truck Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Chapter 2 COOLING SYSTEM 1. 2. 3. 3.1 3.2 3.3

4. 4.1 4.2 4.3 4.4

5. 5.1

6. 6.1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Removing Radiator and Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Inspection and Adjustment of Radiator and Intercooler . . . . . . . . .2-5 Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Inspecting Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 Antifreeze and Cooling Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Installing Radiator and Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Chapter 3 ELECTRICAL SYSTEM 1. 2. 2.1

3. 3.1 3.2 3.3 3.4 3.5 3.6

4. 4.1 4.2

5. 6. 6.1 6.2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 Chassis Electrical Devices and Wiring Outline . . . . . . . . . . . . . . . . . . .3-2 Relay Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 Console Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 Function of Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5 Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7 Key Switch (Anti-Restart Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9 Combination Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10 Fuse Box Connection Table (Chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Disassembling Console Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

Reassembling Console Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14 Battery and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15 Electrolyte Specific Gravity (S.G.) and Charging Adjustment . . . . . . . . . . .3-15 Electrolyte Specific Gravity and State of Charge . . . . . . . . . . . . . . . . . . . . . . .3-15

TOC-1

TABLE OF CONTENTS

6.3 6.4

7. 7.1 7.2 7.3 7.4 7.5

Precautions for Charging Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Precautions to Handle Alternator Charging System . . . . . . . . . . . . . . . . . . 3-16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Starter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-17 3-17 3-18 3-19 3-19

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Chapter 4 CONTROLLERS 1. 1.1 1.2 1.3

2. 2.1 2.2 2.3 2.4

3. 4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23 4.24 4.25 4.26

TOC-2

Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Color coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Controller External View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Service Tool Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input Monitor and Output Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12 4-13 4-17 4-18

Error Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 VCM-3 Memory Check Error (F01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 VCM-3 Battery Voltage Error (F02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 VCM-3 Communication Error (F03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 MP Communication Error (F07) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Lift Lever Neutral Error (F10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Tilt Lever Neutral Error (F11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Attachment 1 Lever Neutral Error (F12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34 Attachment 2 Lever Neutral Error (F13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36 Attachment 3 Lever Neutral Error (F14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38 Shift Lever Error (F16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 Vehicle Speed Error (F17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41 Lift Lever Error (F20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42 Tilt Lever Error (F22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 Attachment 1 Lever Error (F24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 Attachment 2 Lever Error (F26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48 Attachment 3 Lever Error (F28) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50 Joystick Lever Error (F29) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52 VCM-3 Sensor Voltage Error (F31) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54 Vehicle Speed Sensor Error (F34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56 Output Unit Error (F41) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58 Output Unit Life Control Signal (F42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58 Output Unit Memory Check Error (F43) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59 Output Unit PWM Voltage Error (F44) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60 Output Unit Communication Error (F45) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62 Input Unit Error (F46) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64

TABLE OF CONTENTS

4.27 4.28 4.29 4.30 4.31 4.32 4.33 4.34 4.35 4.36 4.37 4.38 4.39 4.40 4.41 4.42 4.43 4.44 4.45 4.46 4.47 4.48 4.49 4.50 4.51 4.52 4.53 4.54 4.55 4.56

Input Unit Life Control Signal (F47) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-65 Input Unit Memory Check Error (F48) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-66 Input Unit Communication Error (F49) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-66 Lift Up Solenoid Error (F50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-68 Lift Down Solenoid Error (F52) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-70 Lift Solenoid Leak (F54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-72 Tilt Forward Solenoid Error (F55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-76 Tilt Backward Solenoid Error (F57) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-78 Tilt Solenoid Leak (F59) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-80 Attachment 1A Solenoid Error (F60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-84 Attachment 1B Solenoid Error (F62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-86 Attachment 1 Solenoid Leak (F64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-88 Attachment 2A Solenoid Error (F65) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-92 Attachment 2B Solenoid Error (F67) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-94 Attachment 2 Solenoid Leak (F69) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-96 Attachment 3A Solenoid Error (F70) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-100 Attachment 3B Solenoid Error (F72) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-102 Attachment 3 Solenoid Leak (F74) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-104 Unload Solenoid Error (F75) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-108 Unload Solenoid Leak (F79) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-110 Transmission Forward Solenoid Error (F85) . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-112 Transmission Backward Solenoid Error (F87) . . . . . . . . . . . . . . . . . . . . . . . . . .4-114 Transmission Solenoid Leak (F89) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-116 VCM3-OP Memory Check Error (F91) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-118 VCM3-OP Battery Voltage Error (F92) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-120 VCM3-OP Speed Change Solenoid 1 Error (F93) . . . . . . . . . . . . . . . . . . . . . . .4-122 VCM3-OP Speed Change Solenoid 2 Error (F94) . . . . . . . . . . . . . . . . . . . . . . .4-124 VCM3-OP Speed Change Solenoid Leak (F95) . . . . . . . . . . . . . . . . . . . . . . . . .4-126 VCM3-OP Setting Error (F96) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-128 VCM3-OP Communication Error (F97) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-130

Chapter 5 TILTABLE SYSTEM 1. 2. 2.1 2.2 2.3 2.4

3. 4. 5. 6. 6.1 6.2 6.3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2 Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3 Tiltable Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 Hydraulic Latch A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

Filling Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Bleeding Tiltable Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Hydraulic Circuit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 Tiltable Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 Cylinder bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 Pin A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

TOC-3

TABLE OF CONTENTS

Chapter 6 POWER TRAIN 1. 2. 3. 4. 4.1 4.2 4.3 4.4 4.5 4.6

5. 5.1 5.2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Removal and Installation of Engine and Transmission Unit . . . . . . 6-4 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Removing Covers and Engine Control Cables . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Removing Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Disconnecting Pipes and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Preparation for Removal of Engine and Transmission Unit . . . . . . . . . . . . 6-9 Removing Engine and Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Installing Engine and Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Capacity and Brand of Oils and Cooling Water . . . . . . . . . . . . . . . . . . . . . . . 6-13

Chapter 7 3-SPEED POWERSHIFT TRANSMISSION 1. 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

3. 3.1

4. 5. 5.1 5.2

6. 7. 7.1 7.2

8. 8.1 8.2 8.3 8.4 8.5 8.6

TOC-4

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Power Flow - Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Power Flow - Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Main Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 3-Speed Transmission Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7 Automatic 3-Speed Shift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Torque Converter Drive Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Removing Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Removing Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Installing Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Disassembling Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Inspecting and Correcting Torque Converter . . . . . . . . . . . . . . . . . . . 7-14 Reassembling Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Suggestions for Torque Converter Reassembly . . . . . . . . . . . . . . . . . . . . . . . 7-18

Disassembling Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Disassembly Sequence of Control Valve and External Parts . . . . . . . . . . . Disassembling Transmission Cover and Output, 1st/3rd Clutch, Forward Clutch, Reverse Clutch, and Input Shafts. . . . . . . . . . . . . . . . . . . . . Suggestions for Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Sequence of Stator Shaft and Oil Pump . . . . . . . . . . . . . . . . . Suggestions for Oil Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Sequence of Forward Clutch Shaft Assembly . . . . . . . . . . . .

7-19 7-20 7-21 7-23 7-24 7-26

TABLE OF CONTENTS

8.7 8.8 8.9 8.10 8.11

9. 10.

Suggestions for Disassembly of Forward Clutch Shaft Assembly . . . . . . .7-27 Disassembly Sequence of 1st/3rd Speed Clutch Shaft Assembly . . . . . . .7-28 Suggestions for Disassembly of 1st/3rd Clutch Shaft Assembly . . . . . . . .7-28 Disassembly Sequence of Reverser Clutch Shaft Assembly . . . . . . . . . . . .7-29 Suggestions for Disassembly of Reverse Clutch Shaft Assembly . . . . . . .7-29

Inspecting and Correcting Transmission . . . . . . . . . . . . . . . . . . . . . . . .7-30 Reassembling Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33

10.1 Reassembly Sequence of Forward Clutch Assembly (1st/3rd Clutch Shaft Assembly) (Reverse Clutch Shaft Assembly) . . . . . .7-33 10.2 Suggestions for Reassembly of Forward Clutch Assembly (1st/3rd Clutch Shaft Assembly) (Reverse Clutch Shaft Assembly) . . . . . .7-34 10.3 Reassembly Sequence of Stator Shaft and Oil Pump . . . . . . . . . . . . . . . . . .7-35 10.4 Suggestions for Stator Shaft and Oil Pump Reassembly . . . . . . . . . . . . . . .7-36 10.5 Reassembly Sequence of Input Shaft, Forward Clutch, 1st/3rd Speed Clutch, Reverse Clutch, Output Shafts and Transmission Cover . . . . . . . . . . . . . . . .7-37 10.6 Suggestions for Reassembly of Input Shaft, Forward Clutch, 1st/3rd Speed Clutch, Reverse Clutch, Output Shafts and Transmission Cover . . . . . . . . .7-38 10.7 Reassembly Sequence of Control Valve and External Parts . . . . . . . . . . . . .7-40

11.

Disassembling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41

11.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41

12. 13.

Inspecting and Correcting Control Valve . . . . . . . . . . . . . . . . . . . . . . . .7-42 Reassembling Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-43

13.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-43 13.2 Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-43 13.3 Suggestions for Control Valve Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-43

14.

Disassembling Main Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44

14.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44

15. 16.

Inspecting and Correcting of Main Regulator Valve . . . . . . . . . . . . .7-44 Reassembling Main Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44

16.1 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-44

17. 17.1 17.2 17.3 17.4 17.5

18. 19.

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45 Adjusting Brake Pedal and Inching Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-45 Measuring Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-47 Measuring Stall Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50 10 m (33 ft) Acceleration Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-50 Testing Automatic 3-Speed Transmission Functions . . . . . . . . . . . . . . . . . . .7-51

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-52 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-57

19.1 19.2 19.3 19.4 19.5 19.6 19.7 19.8

Stall Speed and Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-57 Pump Boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-57 Pilot Boss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-58 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-58 Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-59 Flexible Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-60 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-61 Input Shaft, Forward, Reverse, and 1st/ 3rd Speed Clutch Shafts, and Servo Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-62 19.9 Backlash of Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-63

TOC-5

TABLE OF CONTENTS

19.10 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-64 19.11 Main Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65 19.12 Inching Pedal Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65

Chapter 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 1. 2. 2.1 2.2

3. 3.1 3.2 3.3

4. 4.1

5. 5.1 5.2 5.3

6. 6.1

7. 7.1 7.2 7.3

8. 8.1

9. 9.1 9.2 9.3 9.4 9.5

10. 10.1 10.2 10.3 10.4

11. 11.1 11.2 11.3 11.4 11.5 11.6

12. TOC-6

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Reduction Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Removing Front Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Installing Front Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Removing Front Axle and Reduction Differential . . . . . . . . . . . . . . . 8-8 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Installing Front Axle and Reduction Differential . . . . . . . . . . . . . . . . 8-11 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Removing Reduction Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

Installing Reduction Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

Disassembling Hub Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Preparation (On-truck Condition) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Disassembly Sequence of Hub Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 Suggestions for Hub Reduction Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Disassembly Sequence of Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Suggestions for Wheel Brake Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

Inspecting and Correcting Hub Reduction . . . . . . . . . . . . . . . . . . . . . . 8-17 Reassembly Sequence of Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suggestions for Wheel Brake Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly Sequence of Hub Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suggestions for Reassembling of Hub Reduction . . . . . . . . . . . . . . . . . . . . .

8-18 8-18 8-19 8-20

Disassembling Reduction Differential . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22 Disassembly Sequence of Differential Gear Assembly . . . . . . . . . . . . . . . . 8-23 Suggestions for Disassembling of Differential Gear Assembly . . . . . . . . . 8-23 Disassembly Sequence of Reduction and Parking Brake Assembly . . . . 8-24 Suggestions for Disassembling of Reduction and Parking Brake Assembly 8-24 Inspecting and Correcting Reduction and Parking Brake Assembly . . . 8-25

Reassembling Reduction Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27

TABLE OF CONTENTS

12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8

13. 14.

Reassembly Sequence of Differential Gear Assembly . . . . . . . . . . . . . . . . .8-27 Suggestions for Reassembling Differential Gear Assembly . . . . . . . . . . . .8-28 Adjusting Preload of Reduction Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-30 Adjusting the Contact Between Gear and Pinion Teeth . . . . . . . . . . . . . . . .8-32 Reassembly Sequence of Reduction and Parking Brake Assembly . . . . .8-36 Reassembling Reduction and Parking Brake Assembly . . . . . . . . . . . . . . . .8-37 Assembly Sequence of Reduction Differential . . . . . . . . . . . . . . . . . . . . . . . .8-38 Suggestions for Reassembling of Reduction Differential . . . . . . . . . . . . . .8-38

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-39 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-40

14.1 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-40 14.2 Reduction Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-42

Chapter 9 REAR AXLE 1. 2. 2.1 2.2

3. 3.1 3.2 3.3

4. 4.1

5. 5.1 5.2

6. 6.1

7. 7.1 7.2

8. 8.1

9. 9.1 9.2

10. 11.

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2 Power Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-3

Removing Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5

Installing Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5

Removing Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6

Installing Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8

Disassembling Rear Axle Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9

Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10

Reassembling Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12 Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12

Disassembling Power Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . .9-17 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18

Inspecting and Adjusting Power Steering Cylinder . . . . . . . . . . . . . .9-19 Reassembling Power Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . .9-20

11.1 Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-20 11.2 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-20

12.

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-22

12.1 Measuring Minimum Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-22

13. 14.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-23 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-24 TOC-7

TABLE OF CONTENTS

14.1 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-24 14.2 Power Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25

Chapter 10 BRAKE SYSTEM 1. 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

3. 3.1 3.2 3.3

4. 4.1

5. 5.1 5.2

6. 7. 7.1 7.2

8. 8.1

9. 10.

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Outline of Wheel Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2 10-3 10-4 10-6 10-7 10-10 10-11 10-12 10-13

Removing Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

Installing Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

Disassembling Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19

Inspecting and Correcting Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Reassembling Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 Reassembly Sequence of Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22

Disassembling Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24 Disassembly Sequence of Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24

Inspecting and Correcting Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . 10-25 Reassembling Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25

10.1 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25

11.

Disassembling Air Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26

11.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26

12. 13.

Reassembling Air Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 Disassembling Air Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27

13.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27 13.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27

14.

Reassembling Air Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28

14.1 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28

15.

Disassembling Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29

15.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29

16. 17. TOC-8

Inspecting and Correcting Parking Brake . . . . . . . . . . . . . . . . . . . . . . . 10-30 Reassembling Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30

TABLE OF CONTENTS

17.1 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-30

18.

Disassembling Brake Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-31

18.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-31

19.

Reassembling Brake Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32

19.1 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32

20.

Disassembling Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-33

20.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-33

21.

Inspecting and Correcting Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-34

21.1 Scheduled Inspection of Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-34

22.

Reassembling Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-35

22.1 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-35

23. 23.1 23.2 23.3 23.4 23.5

24.

Adjustment and Operational Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-37 Inspecting Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-37 Bleeding Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-39 Bleeding Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-40 Inspecting Brake Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-40 Adjusting Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-41

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-42

24.1 Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-42 24.2 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-43 24.3 Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-43

25. 25.1 25.2 25.3 25.4 25.5 25.6 25.7 25.8

Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-44 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-44 Brake Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-44 Air Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-45 Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-47 Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-48 Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-48 Parking Brake Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-49 Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-50

Chapter 11 STEERING SYSTEM 1. 2.1 3.1 3.2 4.2 4.4 4.5 4.7 5.1 5.3 6.1 6.2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6 Suggestions for Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . .11-6 Installing Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8 Removing Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9 Installing Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9 Reassembling Tilt Lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-10 Disassembly Sequence of Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-11 Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-16 Reassembly Sequence of Steering Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-16

TOC-9

TABLE OF CONTENTS

Chapter 12 HYDRAULIC SYSTEM 1. 2. 2.1 2.2 2.3 2.4 2.5 2.6

3. 3.1 3.2 3.3

4. 4.1

5. 5.1

6. 6.1 6.2 6.3

7. 8. 8.1 8.2 8.3

9. 10.

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Hydraulic Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6 Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7

Removing Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8

Removing Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10

Installing Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-10

Removing Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11 Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-12

Removing Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13 Disassembling Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-14 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15

Inspecting and Correcting Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . 12-16 Reassembling Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18

10.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18 10.2 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-18

11. 12.

Installing Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-19 Disassembling Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20

12.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20 12.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20

13.

Reassembling Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20

13.1 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-20

14. 14.1 14.2 14.3 14.4 14.5 14.6 14.7 14.8 14.9

TOC-10

Disassembly and Reassembly of Control Valve . . . . . . . . . . . . . . . . . 12-21 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21 Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-21 Disassembling Inlet Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-22 Cleaning and Inspecting Inlet Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . 12-27 Reassembling Inlet Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-27 Disassembly and Reassembly of Tilt Valve Assembly . . . . . . . . . . . . . . . . . 12-31 Cleaning and Inspection of Tilt Valve Assembly . . . . . . . . . . . . . . . . . . . . . . 12-33 Reassembling Tilt Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-33

TABLE OF CONTENTS

14.10 Disassembly and Reassembly of Attachment Valve Assembly . . . . . . . . .12-35 14.11 Cleaning and Inspecting Attachment Valve Assembly . . . . . . . . . . . . . . . . .12-37 14.12 Reassembling Attachment Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .12-37

15.

Disassembling Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .12-39

15.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-39

16. 17. 18.

Inspecting and Correcting Flow Regulator Valve . . . . . . . . . . . . . . . .12-39 Reassembling Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .12-39 Disassembling Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-40

18.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-40 18.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-40

19. 20.

Inspecting Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-42 Reassembling Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-44

20.1 Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-44 20.2 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-44

21.

Disassembling Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-46

21.1 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-46 21.2 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-47

22. 23.

Inspecting and Correcting Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . .12-48 Reassembling Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-50

23.1 Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-50 23.2 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-50

24. 24.1 24.2 24.3 24.4 24.5

25.

Inspecting and Adjusting Hydraulic System . . . . . . . . . . . . . . . . . . . . .12-51 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-51 Test Operation of Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-51 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-52 Adjusting Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-53 Checking Priority Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-54

Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-55

25.1 Vertical Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-55 25.2 Tilt Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-55

26. 27. 27.1 27.2 27.3 27.4 27.5 27.6 27.7

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-56 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-59 Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-59 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-60 Priority Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-61 Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-62 Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-63 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-64 Tilt Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-65

Chapter 13 MASTS AND FORKS 1. 2. 3. 3.1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2 Removing Mast and Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-3 Removal Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-3

TOC-11

TABLE OF CONTENTS

3.2

4. 4.1 4.2

5. 6. 6.1

7. 8. 9.

Suggestions for Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4

Disassembling Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7

Inspecting and Correcting Mast Assembly . . . . . . . . . . . . . . . . . . . . . . 13-7 Reassembling Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-9

Adjusting Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-17 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-18

Chapter 14 FORK POSITIONER 1. 1.1 1.2

2. 2.1 2.2

3. 4. 4.1 4.2 4.3 4.4

5. 6. 6.1

7. 7.1 7.2

8. 9. 9.1 9.2

10. 11. 12.

TOC-12

Applicable Attachment Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 Simultaneous Move Fork Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1 Independent Move Fork Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2 Fork Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2 Applicable Fork Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-4 Removing Fork Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 Removal Sequence of Fork Positioner (Simultaneous Move Type) . . . . . 14-5 Removal Sequence of Fork Positioner (Independent Move Type) . . . . . 14-6 Suggestions for Removal of Fork Positioner . . . . . . . . . . . . . . . . . . . . . . . . . 14-7

Inspecting and Correcting Fork Positioner . . . . . . . . . . . . . . . . . . . . . 14-9 Installing Fork Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9 Suggestions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9

Disassembling Fork Positioner Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 14-10 Disassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10 Suggestions for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-11

Inspecting and Correcting Fork Positioner Cylinder . . . . . . . . . . . . 14-11 Reassembling Fork Positioner Cylinder . . . . . . . . . . . . . . . . . . . . . . . . 14-14 Reassembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14 Suggestions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-14

Inspection and Adjustment after Reassembly of Fork Positioner 14-15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-16

TABLE OF CONTENTS

Chapter 15 Service Data 1. 2. 2.1 2.2

3. 3.1

4. 4.1 4.2 4.3

5. 6.

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1 Tightening Torques for Standard Bolts and Nuts . . . . . . . . . . . . . . . .15-15 Metric fine thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-15 Metric coarse thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-17

Periodic Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-19 Location of Periodic Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-20

Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-21 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-21 Recommended Fuels and Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-22 Adjustment Value and Oil Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-25

Weight of Major Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-26 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-27

TOC-13

CHAPTER 1 GENERAL INFORMATION

Chapter 1 GENERAL INFORMATION 1.

Model View

500003

1-1

CHAPTER 1 GENERAL INFORMATION

Applicable Truck Model

This Service Manual provides service and maintenance information for the following trucks: Truck model

Transmission

FD100NZ FD120NZ FD135NZ FD150ANZ

1-2

Model code - Serial number

Mounted engine

F15DE-60001 Powershift transmission

F15DE-60001 F15DE-60001 F24BE-60001

Mitsubishi 6D16-TL diesel engine

CHAPTER 1 GENERAL INFORMATION

Serial Number Locations

500663

1. 2. 3.

Chassis number (frame right upper front position) Name plate Mast number

4. 5.

Transmission number Engine number

1-3

CHAPTER 1 GENERAL INFORMATION

Technical Data

13 4

16 25 3

14 7 500022

1-4

CHAPTER 1 GENERAL INFORMATION 4.1

Dimensions Unit: mm (in.)

Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Maximum lift

3300 (129.92)

Free lift height

Blade length

1220 (48.03)

Blade width

180 (7.09)

Blade thickness

72 (2.83)

79 (3.11)

88 (3.46)

Tilt angle (forward - backward) Deg

15-12째

Overall length

5515 (217.13)

5595 (220.28)

5750 (226.38)

6050 (238.19)

Overall width (tire outside-to-outside)

2515 (99.02)

2600 (102.36)

Overall height (with mast lowered)

3235 (127.36)

3235(127.36)

3480 (137.01)

Overall height (when mast extended)

5086 (200.24)

5083 (200.12)

5132 (202.05)

5225 (205.71)

Overall height (head guard height)

2915 (114.76)

2960 (116.54)

Tread (front wheels)

1900 (74.80)

1905 (75.00)

Tread (rear wheels)

1965 (77.36)

1925 (75.79)

Wheelbase

2800 (110.24)

2800 (100.24)

3100 (122.05)

Front overhang

756 (29.76)

763 (30.04)

791 (31.14)

792 (31.18)

Under clearance (at frame)

310 (12.20)

355 (13.98)

1-5

CHAPTER 1 GENERAL INFORMATION 4.2

Performance Truck model

Capacity

kg (lb)

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

10000 (22046)

12000 (26455)

13500 (29762)

15000 (33069)

Load center

mm (in.)

600 (23.62)

Lifting speed (no load/loaded)

mm/sec (in./sec)

500/460 (19.69/18.11)

500/410 (19.69/16.14)

420/350 (16.54/13.78)

420/330 (16.54/12.99)

Descending speed (no load/loaded)

mm/sec (in./sec)

500/460 (19.69/18.11)

420/480 (16.54/18.90)

Minimum turning radius

mm (in.)

4000 (157.48)

4060 (159.84)

4160 (163.78)

4550 (179.13)

Forward

Travel speed

Reverse

1st speed

km/h (mph)

8.0 (4.97)

8.5 (5.28)

2nd speed

km/h (mph)

18.5 (11.50)

19.5 (12.12)

3rd speed

km/h (mph)

29.5 (18.33)

30.0 (18.64)

29.5 (18.33)

1st speed

km/h (mph)

8.0 (4.97)

8.5 (5.28)

2nd speed

km/h (mph)

18.5 (11.50)

19.5 (12.12)

3rd speed

km/h (mph)

29.5 (18.33)

30.0 (18.64)

29.5 (18.33)

Mitsubishi 6D16TL diesel engine

7545 (460.42)

Model Total displacement Engine

cc (cu. in.)

Rated power/ Revolution speed

kW/rpm

100/2200

Maximum torque

N·m/rpm (kgf·m) [lbf·ft]

490/1200 (49.97/1200) [361.42/1200]

10.00-20-14PR

10.00-20-16PR

12.00-20-18PR

700 (7.14) [102]

800 (8.16) [116]

10.00-20-14PR

10.00-20-16PR

12.00-20-18PR

700 (7.14) [102]

800 (8.16) [116]

15070 (33224)

16340 (36023)

17980 (39639)

18330 (40411)

Size Front Tire Tire

kPa (kgf/cm2) [psi]

Size Rear Tire

Truck weight

1-6

Air pressure

kPa (kgf/cm2) [psi] kg (lb)

CHAPTER 2 COOLING SYSTEM

Chapter 2 COOLING SYSTEM 1.

Specifications Truck model Cooling method

Cooling system

FD100NZ

FD120NZ

FD135NZ

Water-cooled, forced circulation

Radiator type

Corrugate type, pressurized

Oil cooler type

Plate-fin

Total coolant amount

FD150ANZ

23 L (6.08 U.S. gal.)

Water pump type

Voltex driven by V-belt

Thermostat type

Wax type

2-1

CHAPTER 2 COOLING SYSTEM

Structure

10 4

12 3

8 9

4 7 5

500023

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

Universal joint Pulley boss Tension pulley Cooling fan Fan belt Radiator Transmission oil cooler

Inter cooler is installed as a standard equipment. The belt tension adjuster is provided for the fan belt.

2-2

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

Upper hose (radiator) Lower hose (radiator) Reserve tank Transmission oil cooler hose Intercooler Intercooler hose

CHAPTER 2 COOLING SYSTEM

3. 3.1

Removing Radiator and Intercooler Preparation

Drain the coolant from the radiator by loosening the drain cock.

R WARNING Check the cooling water temperature, lowered enough to open the drain cock.

3.2

Removal Sequence

6 9

8 4

7 5

10 500024

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

Engine cover, Radiator cover Fan guard Reserve tank hose Radiator hose Intercooler hose Grommet, Spacer, Washer , Bolt

7. 8. 9. 10. 11.

Radiator hose Radiator Intercooler Oil cooler pipe Oil cooler

2-3

CHAPTER 2 COOLING SYSTEM 3.3

Suggestions for Removal

Intercooler (1) Hitch hooks to the lifting holes in bracket. (2) Hitch ropes to the hooks and lift with a hoist to remove.

500025

Item Intercooler

Weight 9 kg (20 lb)

Radiator (1) Support the radiator with a hoist. (2) Remove radiator mountings (four places) and lift the radiator with a hoist.

500026

Item Radiator - dry

2-4

Weight 30 kg (66 lb) - dry condition

CHAPTER 2 COOLING SYSTEM

4. 4.1 -

Inspection and Adjustment of Radiator and Intercooler Intercooler Replace the radiator mount rubber if it is hardened and has no elasticity. If such obstacles as bugs and dust are deposited on the fin, wash off them by pressurized water in the reverse of air flow direction. Pay attention not to damage the fin.

R CAUTION Wear goggles for your safety. -

4.2

Replace the intercooler if corrosion or rust is significant, or the fin can not be repaired. Check the intercooler hoses (upper and lower) for the bulge and the damage at clamping position. If a hose is defective, replace the hose.

Inspecting Fan Belt

Adjusting fan belt tension (1) Verify the smooth rotation of fan after removing the fan belt. If the bearing makes noise, replace the bearing. (2) Install the fan belt and push the belt center position between pulleys. Adjust the deflection to the specified value with the tension pulley. Tighten the lock bolt firmly after the adjustment.

500028

Item Push load Belt deflection

4.3

Standard value 98.1 N (10 kgf) [22.05 lbf] 30 to 35 mm (1.18 to 1.38 in.)

Radiator

Radiator body Check the core for foreign substances such as dust. If foreign substances are deposited to the core surface, wash off them by pressurized water in the reverse of air flow direction.

R CAUTION Be careful not to damage the water pipe while cleaning. Radiator mount rubber (rubber cushion) Replace radiator mount rubber if it is hardened or not elastic. Radiator hose (upper, lower) Check the hoses for the bulge and the damage at clamping position. If a hose is defective, replace the hose.

2-5

CHAPTER 2 COOLING SYSTEM 4.4

Antifreeze and Cooling Water

(1) Mix the antifreeze and water to the specified concentration. Fill up the radiator with the mixture. (2) Fill the reserve tank to the specified level with the mixture. (3) Start the engine and warm up the engine paying attention to noise. (4) If the mixture level in reserve tank lowered, add the mixture to the level.

500029

500030

Installing Radiator and Intercooler

To install, follow the removal sequence in reverse.

5.1

Suggestions for Installation

Intercooler Support the radiator and align the lower mounting holes to the frame mounting pins.

Hose

1. Collar 2. Grommet 3. Washer

2-6

3 5

Insert the intercooler or radiator connectors as deep as possible into the hoses. Install the clamps firmly. Verify that the hoses can not be pulled-off being stopped by the flares.

4 2

3 500027 4. Bolt 5. Nut

CHAPTER 2 COOLING SYSTEM

Troubleshooting Situation

Coolant leaking from radiator

Engine overheated

Leaking oil from oil cooler hose

Possible causes

Action

Radiator is corroded by the prolonged usage or other reasons.

Repair the corrosion or replace the radiator when the corrosion is significant.

Aging of upper and lower hoses.

Replace.

Insufficient tightening torque of hose clamps

Retighten or replace.

Defective drain cock

Replace the drain cock.

Cracks in the engine cooling system and overheat

Check and repair the engine cooling system.

Clogged radiator fins

Clean the tube with cupper or steel wire paying attention not to damage the tube.

Excessively distorted fins

Repair the fins or replace the radiator.

Loose fan belt or water pump belt

Check the belt for tension, elongation, and cracks by aging. Replace the belt if such defects are found.

Thermostat malfunction

Inspect and repair, or replace.

Insufficient coolant amount

Refill.

Insufficient tightening torque of hose clamps

Retighten or replace.

Corroded radiator the prolonged usage or other reasons

Repair the corrosion or replace the radiator when the corrosion is significant.

2-7

CHAPTER 2 COOLING SYSTEM 6.1

Service Data

Ref.

Truck model

Tightening torque of drive pulley nut

Fan belt tension

FD100NZ

FD120NZ

FD150ANZ

67.0 to 82.0 N·m (6.83 to 8.36 kgf·m) [49.42 to 60.48 lbf·ft]

Push load Belt deflection

FD135NZ

98.1 N (10 kgf) [22.05 lbf] 30 to 35 mm (1.18 to 1.38 in.)

500640

2-8

CHAPTER 3 ELECTRICAL SYSTEM

Chapter 3 ELECTRICAL SYSTEM 1.

Specifications Truck model Type and quantity

Battery

FD135NZ

5HR capacity Ah

Automatic 3-speed transmission controller

FD150ANZ

95E41R x 2 12

Console box

Lamps

FD120NZ

Voltage V

Direction lever

Key switch

FD100NZ

Electrical With OK monitor VCM Anti-restart type (restart prohibition when running) See lamp and instrument table.

3-1

CHAPTER 3 ELECTRICAL SYSTEM

Chassis Electrical Devices and Wiring Outline

1) 19

11 20

21 17 1 22

2 23

29 31

24 27

3) 16

13 14

15 28 500209

3-2

CHAPTER 3 ELECTRICAL SYSTEM 1. Engine grounding cable 2. Battery cable 3. Harness A 4. VCM-3 5. Relay 6. Relay (a) 7. Relay (b) 8. Relay (c) 9. Relay (12d) 10. Engine thermo-unit 11. VCM3-OP 12. Fuel sensor 13. Lining wear detection switch 14. Horn 15. Front combination lamp 16. Harness B 17. Engine stop solenoid 18. Fuse Note: Fix the harnesses to avoid contact and abrasion with adjacent parts. Repair damages such as a tear and break with a plastic tape.

2.1

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 1) 2) 3)

Rear combination lamp DC-DC converter Power relay Transmission harness Tilt cab switch Low air pressure switch Output unit harness Output unit Harness C Mast harness S1 solenoid S2 solenoid SR solenoid SF solenoid To harness B To cabin harness To harness A

Relay Box

5 4 3 1 13

11 10

9 8 7 6 2 500610

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

Battery charging alarm relay (normal close) Parking brake alarm relay (Normal close) Glow lamp relay (normal open) Ignition relay (normal open) Small lamp relay (normal open) Starter No.1 relay (normal open) Right turn signal relay (normal open)

8. 9. 10. 11.

Left turn signal relay (normal open) Head lamp relay (normal open) Starter No.2 relay (normal open) Backup alarm (reverse traveling buzzer) relay (normal open) 12. Turn signal lamp relay 13. Head lamp Hi-Lo

3-3

CHAPTER 3 ELECTRICAL SYSTEM

3. 3.1

Structure Console Box

2 6

7 5

500031

1. 2. 3. 4.

3-4

Water temperature gauge Fuel gauge Hour meter, warning lamps Warning lamps

5. 6. 7.

Key switch Light switch, turn signal switch Direction lever

CHAPTER 3 ELECTRICAL SYSTEM 3.2

Function of Meter Panel

13 12

11 500044

Ref. 1

Name of indicator and warning lamp

OFF

ON or blink Parking brake is applied

Parking brake warning lamp Brake fluid level warning lamp

Remark

Normal level

Low level

Option

Turns on only when bulb checking.

Normal pressure

Low pressure

Fastened

Not fastened

Normal

Failure

Part shown by the printed symbol

Normal charging

Abnormality in charging system

Preheating completed

Preheating

(Void)

Engine oil pressure warning lamp

Seat belt warning lamp

Multi-purpose warning lamp (Turns on with the printed symbol warning or in a light failure.)

Charge warning lamp

Glow plug warning lamp

Mast interlock indicator lamp

Blinks when locked.

Interlock indicator

Blinks when locked.

Neutral indicator

Illuminates when in neutral position.

9 10

Fuel gauge

Water temperature gauge

Liquid crystal display (normally hour meter)

Indicates remaining fuel amount with key in "ON" position. Overheated when the indicator is in the red zone. Indicates accumulated service hours with key in "ON" position.

3-5

CHAPTER 3 ELECTRICAL SYSTEM Ref. Location and meaning of printed symbols

Name of indicator and warning lamp 13 Fuel filter water draining warning lamp 14 Low coolant level warning lamp 15 Clogged air cleaner element warning lamp

OFF

ON or blink

Remark

Normal

Drain water.

Normal level

low level

Option

Normal element

Clogged element

Option

Major failure Bulbs 1 2 3 4 5 6 7 8 blink simultaneously.

3-6

CHAPTER 3 ELECTRICAL SYSTEM 3.3

Side Panel

Ref.

11 8

Name

500611

Description

Hazard switch

Right and left turn signals blink when turned ON.

Front working lamp switch (option)

Front working lamp turns ON/OFF.

Rotary lamp switch (option)

Rotary lamp turns ON/OFF.

Temperature gauge of torque converter fluid.

Torque converter fluid temperature is shown.

Speed selector switch

Speed changes.

High-beam indicator (option)

High-beam and low-beam change.

Rear working lamp switch

Rear working lamp turns ON/OFF.

Operator compartment "OPEN" warning lamp

Turns on when the operator compartment is open.

Brake warning wear indicator (24V)

The lamp glows and buzzer sounds continuously when the brake lining is worn.

Brake air pressure warning lamp. (24V)

The buzzer sounds intermittently when the pressure in air tank becomes low.

Spare

3-7

CHAPTER 3 ELECTRICAL SYSTEM Speed selector switch Stop the truck whenever changing the selection of this switch.

2 1 1

3 3

250 2

251 252 250

251

252

500482

1. 2.

1 (1st-speed/fixed gear) 2 (speed 1 and 2 changed automatically)

Circuit No.

Wire diameter

Wire color

252

0.5

W/R

251

0.5

B/L

250

0.5

W/B

3-8

D (speed 1 to 3 changed automatically)

CHAPTER 3 ELECTRICAL SYSTEM 3.4

Key Switch (Anti-Restart Switch)

This key switch has an anti-restarting function. When the engine is running, the key switch is prohibited to move from "ON" to "START."

This prevents the engine and starter from troubles by wrong operations. Preheating is turned on at the "ON" position of the key switch when the weather is cod.

1) 2) S

1 2 3

500033

1) 2)

OFF ON

Circuit No.

Wire diameter

Wire color

0.5

Y/G

0.5

G/L

0.5

G/W

START

3-9

CHAPTER 3 ELECTRICAL SYSTEM 3.5

Combination Switch

500038

1. 2. 1) 2)

3-10

Direction lever Light switch and turn signal switch Forward (F) Neutral (N)

3) 4) 5) 6)

Reverse (R) Left turn (L) Neutral (N) Right turn (R)

CHAPTER 3 ELECTRICAL SYSTEM Direction lever

F1 F1 N R1

4 2

5 1

1 2 3 4 5

272 127 81 126 62

3 500040

Circuit No.

Wire diameter

Wire color

272

0.5

G/Y

127

0.5

B/L

0.5

G/R

126

0.5

B/L

0.5

L/G

3-11

CHAPTER 3 ELECTRICAL SYSTEM Light switch and turn signal switch

1 2

N L N R

T-2

T-1

L-1 L-3

T-3 L-2

L-1 L-2 L-3

2 3

116 93 92 100 91 90

T-1 T-2 T-3

500613

1. 2.

OFF Meter panel lamp Tail lamps Clearance lamps

3. Glows Glow Glow

Circuit No.

Wire diameter

Wire color

116

0.5

B/L

0.5

G/B

0.5

G/R

100

0.5

R/B

0.5

R/W

3-12

Meter panel lamp Tail lamps Clearance lamps Head lamps

Glows Glow Glow Glow

CHAPTER 3 ELECTRICAL SYSTEM 3.6

Fuse Box Connection Table (Chassis)

Symbol

Capacity

Main connected component

15A

Head lamp

10A

Horn

10A

Stop lamp

15A

Working lamp

10A

DC-DC converter

10A

Rotary lamp

20A

Room lamp

15A

Air conditioner, Heater

20A

Wet type brake

F10

10A

Air dryer

F11

15A

Back-up lamp

F12

15A

Fuel cut

F13

30A

Wiper

F14

10A

Warning lamp, Buzzer

F15

15A

Defroster

500210

1. Fuse box (chassis)

Table of lamps Lamp type

Quantity

Glass color

Bulb

Illustration

Transparent

60W

Transparent

62/62W

Option

Transparent

60W

Option

Turn signal lamp

Amber

25W

Clearance lamp

Amber

Tail lamp / Stop lamp

Red

21/5W

Turn signal lamp

Amber

21W

Back-up lamp

Transparent

21W

Rotary lamp

Red or amber

40W

Option

License plate lamp

Transparent

12W

Option

Alarm lamp

Red or amber

25W

Option

Head lamp Rear working lamp Front combination lamp Rear combination lamp

Remark

500043

3-13

CHAPTER 3 ELECTRICAL SYSTEM

4. 4.1

Disassembling Console Box Preparation

Place the key switch to the OFF position, and remove the cable from the ground side of the battery.

4.2

Disassembly Sequence

500047

1. 2. 3. 4.

Front cover Electric wiring connector Rear cover Key switch

Note: Spec. without the handle knob is available.

Reassembling Console Box

To reassemble, follow the disassembly sequence in reverse.

3-14

5. 6. 7.

Upper cover Steering wheel Combination switch

CHAPTER 3 ELECTRICAL SYSTEM

Battery and Maintenance

6.1

Electrolyte Specific Gravity (S.G.) and Charging Adjustment

Specific gravity reading at 20 째C (68 째F )

Condition

Adjustment procedure

1.280 to 1.260 or more

Good

If the difference in S.G. between any two cells is 0.04 or less, continue to use as is. If the difference is more than 0.04 , discharge the battery in an efficient manner. If the battery recovers, charge the battery to adjust the electrolyte S.G.

1.260 or lower to 1.220 or more

Half charged

Recharge battery to adjust electrolyte S.G. Check for any short-circuited cables or corroded cable connections in the electrical system.

1.220 or lower

Battery low (caution required)

Recharge battery. If the difference in S.G. is too much, charge the battery to adjust the electrolyte S.G.

If the difference in S.G. between cells is 0.040 or more.

A cell with a low S.G. may have a short circuit. Electrolyte leaked, or electrolyte rate is too high or too low.

Charge the battery until the voltage and S.G. of the cells become even. Charge to adjust the S.G. to be 1.280 to 1.260. If the difference in S.G. is more than 0.040 and a low S.G. is found in any of the cells, replace the battery with a new one. Conduct a high current discharge test after leaving the battery for 12 to 96 hours.

6.2

Electrolyte Specific Gravity and State of Charge

The fully charged condition can be checked with the electrolyte S.G. (1.280 to 1.260), and also the electrolyte decreasing rate shows a charging condition. If the electrolyte in the battery cell decreases to the level where the pole plates are exposed within one month, the battery may be overcharged. If the electrolyte amount remains sufficient for more than three months, the battery may be poorly charged.

6.3

Precautions for Charging Battery

(1) In a slow charging, the charging current should be about 1/10 of the capacity of battery. (2) In quick charging, the battery capacity in ampere (A) should not be exceeded. (3) During charging, adjust the charging current so that the electrolyte temperature does not exceed 45 째C (113 째F). (4) When connecting cables to battery terminals, always connect the positive (+) terminal first, and when disconnecting, remove the negative (-) terminal first.

R CAUTION Be sure to turn off the key switch and light switch before disconnecting or connecting the battery cables. (This prevents damage to the IC regulator.)

3-15

CHAPTER 3 ELECTRICAL SYSTEM 6.4

Precautions to Handle Alternator Charging System

The alternator is integrated with an IC voltage regulator. Pay attention to the followings to maintain and check the electrical system. -

3-16

Do not connect battery cables in reverse polarity. Do not disconnect any battery cable while the engine is running. Do not ground the terminal L. Do not make a short circuit between the terminal L and R. Do not apply a blast of steam cleaner directly to the alternator, or the IC regulator may be damaged.

L R B

500052

CHAPTER 3 ELECTRICAL SYSTEM

7. 7.1

Troubleshooting Starter System Situation

Starter won't crank the engine even if the key switch is turned ON. Key switch

Possible causes Battery discharged

Charge or replace battery.

Short or open circuit

Repair or replace.

Poor continuity in starter switch

Replace.

Defect in starter or starter relay

Replace.

Transmission shift lever not in the neutral position

Place the transmission shift lever to the neutral position.

Short or open circuit Engine won't stop even if the key switch is Stop solenoid defective turned OFF. Control linkage defective

7.2

Action

Repair or replace. Replace. Replace.

Gauges Situation

Will not work. Temperature gauges

Will not indicate correctly Indication is higher than the actual temperature.

Will not work.

Will not indicate correctly Fuel gauge

Indication is always "full."

Indication is always "empty."

Possible causes

Action

Short or open circuit

Repair or replace.

Gauge internal defect

Replace.

Defective gauge unit

Replace.

Improper gauge or gauge unit

Replace it with a specified one.

Loose terminal connection

Repair.

Wiring between gauge and gauge unit grounded

Repair.

Gauge internal defect

Replace.

Short or open circuit

Repair.

Gauge internal defect

Replace.

Defective gauge unit

Replace.

Improper gauge or gauge unit

Replace it with a specified one.

Loose terminal connection

Repair.

Wiring between gauge and gauge unit grounded

Repair.

Gauge internal defect

Replace.

Defective gauge unit

Replace.

Open or short circuit between gauge and gauge unit

Repair.

Gauge internal defect

Replace.

Defective gauge unit

Replace.

3-17

CHAPTER 3 ELECTRICAL SYSTEM 7.3

Lighting System Situation

Will not glow (blink) with the switch turned on

Lamps (in general)

Lamp glows (blinks) dimly.

Head lamp

Lamp does not glow.

Lamp does not blink. Will not turn off Turn signal lamp

Lamp blinks too slowly.

Lamp blinks too fast.

Back-up lamp does not glow. Other lamps Licence plate lamp does not glow.

3-18

Possible causes

Action

Battery discharged

Charge or replace battery.

Blown out fuse

Check and correct the cause, then replace the fuse.

Short or open circuit

Repair or replace.

Defective grounding wire

Remove corrosion from the terminal or retighten.

Burned-out bulb

Replace.

Weak battery

Check and charge.

Defective switch contact

Repair or replace.

Terminal contact failure

Repair.

Dirty lens

Clean.

Water drops inside of lens

Dry the lamp and replace the packings.

Bulb's service life expired

Replace.

Defective light switch conductivity

Replace.

Burned-out bulb

Replace.

Defective turn signal switch

Replace.

Defective turn signal relay

Replace.

Defective turn signal relay

Replace.

Bulb wattage is less than the specified value.

Replace it with a specified wattage bulb.

Defective turn signal relay

Replace.

Bulb wattage is more than the specified value.

Replace it with a specified wattage bulb.

Burned-out bulb

Replace.

Defective turn signal relay

Replace.

Defective back-up lamp switch

Correct if improperly installed, or replace if defective.

Burned-out bulb

Replace.

Defective light switch conductivity

Replace.

Burned-out bulb

Replace.

CHAPTER 3 ELECTRICAL SYSTEM 7.4

Alarm Unit Situation

Possible causes

Horn does not sound. Horn

Offensive sound

Vacuum buzzer

7.5

Buzzer does not sound.

Action

Blown out fuse

Check and correct the cause, then replace the fuse.

Short or open circuit

Repair or replace.

Defective horn button

Repair or replace.

Defective horn switch

Replace.

Defective horn

Replace.

Defective horn switch

Replace.

Defective horn

Replace.

Defective vacuum switch

Replace.

Defective buzzer

Replace.

Battery Situation

Possible causes Alternator belt slip

Alternator

Regulator

Weak battery

Battery

Wiring

Action Adjust the tension.

Stator coil open circuit

Repair or replace.

Rotor coil open circuit

Replace.

Poorly-seated brushes on slip rings

Replace brushes if worn-out, (clean the folder) and polish slip rings.

Diode short or open circuit

Replace.

Low output voltage

Adjustment

Electrolyte level low or inappropriate quality

Refill or adjust the S.G.

Defective cell plates (internal short-circuit)

Replace.

Loose connection of terminals

Clean and tighten.

Open circuit or loose connection between key switch and regulator IC terminal

Repair.

Blown out fuse in the circuit above or loose connection on the holder

Replace fuse or repair the holder contact part.

Open circuit or loose Repair. connection between regulator terminal and alternator terminal

Wiring Battery overcharge

Regulator

Incorrect connection or short Repair. circuit between regulator IC and terminal Defective grounding of regulator terminal F

Repair.

Pressure coil open circuit

Replace.

Output voltage too high

Readjust.

3-19

CHAPTER 3 ELECTRICAL SYSTEM

3-20

Electrical Schematic

CHAPTER 3 ELECTRICAL SYSTEM Replace this page and the next blank page with pages of file 99799-21000S.pdf

3-21

CHAPTER 4 CONTROLLERS

Chapter 4 CONTROLLERS 1.

Outline

1.1

System Configuration

The controller system consists of the vehicle control controllers (VCM-3 and VCM3-OP), meter panel, input unit and output unit.

Each controller is connected to the CAN (Controller Area Network) and controls the truck by exchanging information between controllers.

㧞

㧯㧺

㧯N

㨘㨑㨐

㨍㨄㨄㨘

㧿

㨑

㨞

㧹

㨕

㨛

㨄㨄 ‫ޓ‬

㧺㨄㨄㨛㧚

500664

1. 2. 3.

Output unit Meter panel Input unit

4. 5. 6.

VCM-3 VCM3-OP DC-DC converter

4-1

CHAPTER 4 CONTROLLERS CAN wiring diagram

Harness A

CAB harness

Harness B

Connector

201

200

Meter panel

Connector

201

200

396 396

395 395

396

395

Harness C

Connector

205

204

VCM3-OP

VCM-3 Input unit

286 285

288 287

VCM-3 GSE

Output unit

394 393

VCM3-OP GSE

500666

4-2

CHAPTER 4 CONTROLLERS 1.2

Color coding Coler

Mark

Black

White

Red

Green

Yellow

Blue

Broun

Light green

Orange

Purple

Gray

W/B, which means white with a black line

4-3

CHAPTER 4 CONTROLLERS 1.3

Controller External View

VCM-3

1) 1)

CN1

CN2

1 10

17 130 25

18 40 26 41

245

211

411 229 131

1 228 227 10 220 221 18 26

233 235 234 384

296 297 298 299 201 200

1) - 1)

4-4

17 25 34

500567

CHAPTER 4 CONTROLLERS CN1

CN2

Pin No.

Circ uit No.

Signal name

Wire diameter /color

Pin No.

228 Seat SW

227 Seat belt SW

0.5 L

245 Inching SW

Circ uit No.

Signal name

Wire diameter /color 0.5 B/G 0.5 W

220 Vehicle speed sensor

0.5 R/G

221 Vehicle speed sensor

0.5 G/B

233 Forward solenoid output

0.5 G/Y

235 Backward solenoid output

0.5 G/L

234 Forward/backward solenoid return

0.5 B/L

0.5 R/Y

12V power supply

384 Speedometer

0.5 W/L

130 GND

0.5 B/L

0.5 R/Y

296 Communication line for service tool

0.5 G

297 Communication line for service tool

0.5 G/W

298 Communication line for service tool

0.5 L/Y

0.5 Lg/R

299 Communication line for service tool

0.5 Lg/Y

201 CAN H

0.5 L/R

200 CAN L

0.5 B/W

30 31

12V power supply

211 Unload solenoid output -

411 Unload solenoid return

0.5 G/B

229 Warning buzzer

0.5 Lg/B

131 GND

0.5 B/L

4-5

CHAPTER 4 CONTROLLERS 1.2.2 VCM3-OP

1) 1)

CN1 1 10 18 42 26 43

CN2 9

17 135 25

250 252

257 136

281 279

17 258 25

253 273 254

18 292 293 294 295 205 204

1) - 1) 500568

4-6

CHAPTER 4 CONTROLLERS CN1

CN2

Pin Circu No. it No.

Signal name

Wire diameter/ color

Pin Circu No. it No.

Signal name

Wire diameter/ color

281

Coolant level

0.5 B/R

250

Speed selector SW

0.5 W/B

279

Air dust

0.5 R/Y

252

Speed selector SW

0.5 W/R

253

0.5 R/Y

Speed change solenoid 1 output

273

Speed change solenoid 2 output

0.5 G/Y

254

Speed change solenoid return

0.5 B/W

135

GND

0.5 B/L

12V power supply

0.5 R/Y

258

292

Connector for GSE

0.5 L

297

Connector for GSE

0.5 L/W

298

Connector for GSE

0.5 L/G

299

Connector for GSE

0.5 Y/B

201

CAN H

0.5 L/R

200

CAN L

0.5 B/W

12V power supply

257

Operator compartment open warning light

136

GND

0.5 R/Y

0.5 G/L 0.5 B/L

Cabin SW

0.5 Y/R -

4-7

CHAPTER 4 CONTROLLERS Meter panel

14 201 200 102 20

11 46 48 15 49

78 83 5 1 81 77 10 6 80 82 79

1 1.

CN1 (black)

500570

CN2 (white)

CN2 (white) Wire diameter/ color

Pin No.

Circuit No.

0.5 Lg

0.5 Br/R

Fuel gauge

0.5 W/Y

12V power supply

0.5 R/Y

Coolant temperature gauge

0.5 Y/R

24V lamp

0.5 G/R

Shift lever N

0.5 Y/L

Shift lever R

0.5 L/W

CAN H

0.5 L/R

Oil pressure gauge

0.5 Lg/W

200

CAN L

0.5 B/W

102

GND

0.5 B/L

Pin No.

Circuit No.

Charge lamp

Glow

201

19 20

4-8

Signal name

Signal name Shift lever F

Wire diameter/ color 0.5 G/R

Parking brake

0.5 L

CHAPTER 4 CONTROLLERS Input unit

1 937

396

2 397

395

477

460 468 470 472 474 31 464 469 471 473 475 32

476 479

500571

Pin Circuit No. No.

Signal name

Wire diameter /color

Pin Circuit No. No.

Signal name

937

GND

0.5 G

477

397

12V power supply

0.5 Y

396

CAN H

0.5 Br

460

5V power supply for lever

0.5 R

395

CAN L

0.5 L

464

GND for lever

0.5 B

468

Lift lever (main)

0.5 Y

469

Lift lever (sub)

0.5 G

470

Tilt lever (main)

0.5 Y

471

Tilt lever (sub)

0.5 L

472

Attachment 1 lever (main)

0.5 Y

476

0.5 B

473

Attachment 1 lever (sub)

0.5 Br

474

Attachment 2 lever (main)

0.5 Y

479

0.5 V

475

Attachment 2 lever (sub)

0.5 W

SW GND Speed changing SW

4/5 select SW

Wire diameter /color 0.5 O

4-9

CHAPTER 4 CONTROLLERS Output unit

1 933 390

394

935 19

21 480 482 484 486 488 490 492 494 35

2 934 391

393

392 20

22 481 483 485 487 489 491 493

36 500572

Pin Circuit No. No.

Signal name

Wire diameter/ color

933

GND

0.5 B

394

GND

0.5 B

390

12V power supply

0.5 R/Y

391

12V power supply

0.5 R/Y

394

393

935

GND

392

12V power supply

4-10

Pin Circuit No. No.

Signal name

Wire diameter /color

480

Lift up solenoid output

0.5 L

481

Lift down solenoid output

0.5 Br

482

Lift up/down solenoid return

0.5 W

483

Tilt backward solenoid output

0.5 R/W

484

Tilt forward solenoid output

0.5 L/W

485

Tilt backward/forward solenoid return

0.5 W/B

486

Attachment 1 solenoid A output

0.5 L/R

487

Attachment 1 solenoid B output

0.5 R

488

Attachment 1 solenoid A, B return

0.5 W/R

489

Attachment 2 solenoid A output

0.5 L/Y

CAN H

0.5 L/R

490

Attachment 2 solenoid B output

0.5 R/L

CAN L

0.5 B/W

491

Attachment 2 solenoid A, B return

0.5 W/L

492

Attachment 3 solenoid A output

0.5 B/W

493

Attachment 3 solenoid B output

0.5 Br/Y

494

Attachment 3 solenoid A, B return

0.5 L/R

0.5 B 0.5 R/Y

CHAPTER 4 CONTROLLERS DC-DC converter Although a 24V battery is used, there are 24V and 12V lines in the truck. The DC-DC converter is equipped to convert the 24V to 12V.

12V systematic

DC-DC converter 24 V->12 V

+ Battery 24V

Combination SW Meter panel VCM-3

24V systematic

VCM3-OP

Engine accessories

Input unit

Lamps such as head lamps

Output unit 500632E

40 107 104 8 301 62

95 49

500628

Circuit No.

Signal name

Wire diameter/ color

Circuit No.

0.5 G

24V lamp

0.5 Y

104

24V GND

1.25 B

107

12V GND

1.25 B/L

12V power supply

301

12V power supply

Power supply for ACC (accessories)

0.5 L/W

24V power supply

1.25 R/W

24V lamp

Signal name

Wire diameter/ color

0.5 G/R

4-11

CHAPTER 4 CONTROLLERS

2. 2.1

Service Tool Functions Menu structure Monitor menu

Description

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 error codes occurring.

Fault History

Indicates the fault data, such as the error codes and hour meter data, stored in the controller.

Tool menu

Description

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 a 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.

500573

4-12

CHAPTER 4 CONTROLLERS 2.2

Input Monitor and Output Monitor

These screens indicate the input and output values of each controller. VCM-3 input monitor

(InputUnit)

500574

4-13

CHAPTER 4 CONTROLLERS VCM-3 output monitor

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

500575

4-14

CHAPTER 4 CONTROLLERS VCM3-OP Input Monitor

500576

VCM3-OP Output Monitor

500630

4-15

CHAPTER 4 CONTROLLERS MP (Meter Panel) Input Monitor

500577

4-16

CHAPTER 4 CONTROLLERS 2.3

Fault Status

Indicates all error codes occurring.

OutputUnit Communication error InputUnit Communication error VCM3OP Communication error

500579

4-17

CHAPTER 4 CONTROLLERS 2.4

Fault History

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

500580

4-18

CHAPTER 4 CONTROLLERS

Error Code List

Error code

Description

Error code

Description

F01

VCM-3 Memory Check Error

F54

Lift Solenoid Leak

F02

VCM-3 Battery Voltage Error

F55

Tilt Forward Solenoid Error

F03

VCM-3 Communication Error

F57

Tilt Backward Solenoid Error

F07

MP Communication Error

F59

Tilt Solenoid Leak

F10

Lift Lever Neutral Error

F60

Attachment 1A Solenoid Error

F11

Tilt Lever Neutral Error

F62

Attachment 1B Solenoid Error

F12

Attachment 1 Lever Neutral Error

F64

Attachment 1 Solenoid Leak

F13

Attachment 2 Lever Neutral Error

F65

Attachment 2A Solenoid Error

F14

Attachment 3 Lever Neutral Error

F67

Attachment 2B Solenoid Error

F16

Shift Lever Error

F69

Attachment 2 Solenoid Error

F17

Vehicle Speed Error

F70

Attachment 3A Solenoid Error

F20

Lift Lever Error

F72

Attachment 3B Solenoid Error

F22

Tilt Lever Error

F74

Attachment 3 Solenoid Leak

F24

Attachment 1 Lever Error

F75

Unload Solenoid Error

F26

Attachment 2 Lever Error

F79

Unload Solenoid Leak

F28

Attachment 3 Lever Error

F85

Transmission Forward Solenoid Error

F29

Joystick Lever Error

F87

Transmission Backward Solenoid Error

F31

VCM-3 Sensor Voltage Error

F89

Transmission Solenoid Leak

F34

Vehicle Speed Sensor Error

F91

VCM3-OP Memory Check Error

F41

Output Unit Error

F92

VCM3-OP Battery Voltage Error

F42

Output Unit Life Control Signal

F93

VCM3-OP Speed Change Solenoid 1 Error

F43

Output Unit Memory Check Error

F94

VCM3-OP Speed Change Solenoid 2 Error

F44

Output Unit PWM Voltage Error

F95

VCM3-OP Speed Change Solenoid Leak

F45

Output Unit Communication Error

F96

VCM3-OP EAT Setting Error

F46

Input Unit Error

F97

VCM3-OP Communication Error

F47

Input Unit Life Control Signal

F48

Input Unit Memory Check Error

P03

VCM-3 Communication Error

F49

Input Unit Communication Error

P07

MP Communication Error

F50

Lift Up Solenoid Error

P22

Shift Lever Error Signal

F52

Lift Down Solenoid Error

4-19

CHAPTER 4 CONTROLLERS

4. 4.1

Troubleshooting General Precautions

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 the connectors are dirty, remove the connectors and clean them. See "How to clean harness connectors and system components" on the next page. - Make sure that the main harness is not short-circuited to the truck body. If any of items described above is a source of the trouble, the controller may be damaged even if it is replaced with a new one. Always check the above items first, and replace the controller carefully. Connecting Service Tool

(1) Turn off the truck power. (2) Find the service tool connector near the accelerator pedal. (3) Remove the connector cover. Connect to the personal computer (PC) through the cable. There are 2 connectors next to the accelerator pedal. Check the tag attached to the connectors and connect the PC to the connector for VCM. (4) Turn on the truck power. (5) Start the service tool software.

500581 1. GSE cable 2. VCM-3 GSE

4-20

3. VCM3-OP GSE 4. CAB harness

CHAPTER 4 CONTROLLERS 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 may penetrates electrical connections, results in loose metal-to-metal contact or electrical separation of surfaces in contact. For this reason, it is essential that the connectors and components be cleaned at every periodic inspection and at when servicing the truck. Instead of a commonly used solvent, use the electronic parts cleaner (ThreeBond 29D). (See the illustration.) Note: The cleaner liquid is volatile. All you have to do is just give a strong spray to wash off grim. No need to wipe off the sprayed liquid. (2) After cleaning the connector, remove the connector and spray the activator. Attach the connector and detach it again. Repeat this several times to wet the surfaces thoroughly with the activator liquid (ThreeBond 2501S aerosol). After coupling up the connector, check to be sure that the connector is in locked state. Note: -

Do not spray too much activator. Activators may adversely affect some plastics.

2 500583 1. Electronic parts cleaner

2. Activator (ThreeBond 2501S, aerosol)

4-21

CHAPTER 4 CONTROLLERS 4.2

VCM-3 Memory Check Error (F01)

Error code: F01 Situation

"F01" flickering. Drive and hydraulic operations disabled.

Possible causes

Faulty VCM-3, faulty truck type setting data in VCM-3

How the error code is triggered.

Software checks sum value of ROM and EEPROM (memory setting value) in CPU, and detects fault.

Checks

%JGEM VTWEM V[RG UGVVKPI FCVC 0QTOCN #DPQTOCN

'PVGT VTWEM V[RG UGVVKPI FCVC CICKP

'PVGT UJKROGPV FGHCWNV XCNWG KPVQ 8%/ 0QTOCN #DPQTOCN

2GTHQTO UVCPFCTF UGVVKPI VJGP GPVGT VTWEM V[RG UGVVKPI FCVC CICKP

9TKVG WRFCVGF UQHVYCTG KPVQ 8%/ 0QTOCN #DPQTOCN

(CWNV[ UQHVYCTG YTKVKPI

4GRNCEG 8%/ 500483E

4-22

CHAPTER 4 CONTROLLERS

1) 1)

CN1

CN2

1 10

17 130 25

18 40 26 41

245

211

411 229 131

1 228 227 10 220 221 18 26

233 235 234 384

296 297 298 299 201 200

1) - 1)

17 25 34

500567

4-23

CHAPTER 4 CONTROLLERS 4.3

VCM-3 Battery Voltage Error (F02)

Error code: F02 Situation

"F02" flickering. Drive and hydraulic operations disabled.

Possible causes

Poor battery charge, faulty battery, faulty VCM-3, faulty harness, or faulty DC-DC converter

How the error code is triggered.

When VCM-3 input voltage is 7V or less less or 21V or more.

Checks

0HDVXUH EDWWHU\ WHUPLQDO YROWDJH 1RUPDO 9 9 à &#x2030;à &#x2030;à &#x2030;à &#x2030; 9 RU OHVVà &#x2030;à &#x2030;à &#x2030;à &#x2030;à &#x2030;à &#x2030; à &#x2030; 9 RU PRUH

&KDUJH EDWWHU\

(UURU UHPDLQV

5HSODFH EDWWHU\

0HDVXUH RXWSXW YROWDJH DQG LQSXW YROWDJH RI '& '& FRQYHUWHU à£à£à£ 9 2XWSXW YROWDJH %HWZHHQ '& '& &RQYHUWHU 9 DQG '& '& FRQYHUWHU *1' ,QSXW YROWDJH %HWZHHQ '& '& &RQYHUWHU 9 DQG '& '& FRQYHUWHU *1' à£à£à£ 9 1RUPDO ,QSXW YROWDJH DEQRUPDO 2XWSXW YROWDJH DEQRUPDO

5HSODFH KDUQHVV

5HSODFH '& '& FRQYHUWHU

0HDVXUH LQSXW YROWDJH RI 9&0 %HWZHHQ 9&0 &1 DQG 9&0 &1 à£à£à£ 9 %HWZHHQ 9&0 &1 DQG 9&0 &1 à£à£à£ 9 9 RU OHVV 9 WR 9

5HSODFH KDUQHVV

5HSODFH 9&0 500484

4-24

CHAPTER 4 CONTROLLERS

DC-DC CONVERTER

VCM-3

CN1 131 130 P.SOURCE1 41 P.SOURCE2 40 GND1 GND2

0.5B/L

1.25B/L

0.5B/L

0.5R/Y

1.25B

0.5R/Y 1.25R/W

CN1

12V GND 12V MAIN 24V GND

24V BATT

245

17 25 130

40 18

10A

1.25R/W 8

104 107 40

62 301

105

41 26

211

34 131 229 411

100

107 40 104

BATTERY

500584

4-25

CHAPTER 4 CONTROLLERS 4.4

VCM-3 Communication Error (F03)

Error code: F03 Situation

"F03" flickering. Drive and hydraulic operations disabled.

Possible causes

Faulty VCM-3, faulty harness

How the error code is triggered.

When CAN communication of VCM-3 is interrupted.

Checks

&KHFN WR VHH LI RWKHU HUURUV KDYH RFFXUUHG ) RQO\ 2WKHU HUURUV KDYH RFFXUHG

6HH WURXEOHVKRRWLQJ IRU HUURUV RFFXUUHG

&KHFN FRQWLQXLW\ RI &$1 FRPPXQLFDWLRQ FDEOHV 9&0 WR PHWHU SDQHO %HWZHHQ 9&0 &1 DQG 03 DQG %HWZHHQ 9&0 &1 WR 03 à &#x2030; 9&0 WR 9&0 23 %HWZHHQ 9&0 &1 WR 9&0 23 &1 DQG %HWZHHQ 9&0 &1 DQG 9&0 23 &1 9&0 WR RXWSXW XQLW %HWZHHQ 9&0 &1 WR 2XWSXW XQLW DQG %HWZHHQ 9&0 &1 WR 2XWSXW XQLW 9&0 WR LQSXW XQLW %HWZHHQ 9&0 &1 WR ,QSXW XQLW DQG %HWZHHQ 9&0 &1 WR ,QSXW XQLW &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH 9&0

5HSODFH IDXOW\ KDUQHVV 500485E

4-26

CHAPTER 4 CONTROLLERS

CN2

VCM-3

254 273 253

258

CN2

279 281

205 204 295 294 293 292

VCM3-OP

CN2

0.5L/R

CAN H 201 0.5B/W CAN L 200

0.5B/W

204 205

0.5L/R

227 228 1 234 235 233

384

CAN H

METER PANEL

CN2

CAN L

221 220

200 201 299 298 297 296

0.5L/R

10 18

201

0.5B/W

200

CAN H CAN L

26 14 45 20 102 200 201

48 46 49

11 15

OUTPUT UNIT

BLACK

0.5L/R

394 CAN H 393 CAN L

0.5B/W

35 494 492 490 488 486 484 482 480 21

19 935

394

390 933 1

20 392

393

391 934 2

493 491 489 487 485 483 481 22

INPUT UNIT (HARNESS, IN FC) 0.5Br

396 CAN H 395 CAN L

0.5L

31 474 472 470 468 460 32 475 473 471 469 464

477 479 476

396

937 1

395

397 2

500667

4-27

CHAPTER 4 CONTROLLERS 4.5

MP Communication Error (F07)

Error code: F07 Situation

"F07" flickering. Drive operations disabled.

Possible causes

Faulty meter panel, faulty VCM-3, faulty harness

How the error code is triggered.

When CAN communication from meter panel to VCM-3 is interrupted.

Checks

&KHFN FRQWLQXLW\ RI &$1 FRPPXQLFDWLRQ FDEOHV 9&0 WR PHWHU SDQHO %HWZHHQ 9&0 &1 DQG 03 DQG %HWZHHQ 9&0 &1 WR 03 &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH PHWHU SDQHO

5HSODFH KDUQHVV

(UURU UHPDLQV 5HSODFH 9&0 500486E

4-28

CHAPTER 4 CONTROLLERS

METER PANEL VCM-3

CN2 0.5L/R

0.5L/R

CAN H 201 0.5B/W CAN L 200

0.5B/W

201 200

CAN H CAN L

CN2

227 228 1

9 17

234 235 233

384

221 220

200 201 299 298 297 296

10 18 26

14 45 20 102 200 201

48 46 49

11 15

BLACK 500586

4-29

CHAPTER 4 CONTROLLERS 4.6

Lift Lever Neutral Error (F10)

Error code: F10 Situation

"F10" flickering. Hydraulic operations disabled.

Possible causes

The load handling lever operated when turning on key switch. Faulty lift lever, faulty input unit, faulty harness

How the error code is triggered.

Lift lever is not in neutral when turning on key switch.

Checks

5JKHV NKHV NGXGT KP PGWVTCN VJGP VWTP QP MG[ UYKVEJ CICKP 0QTOCN 'TTQT TGOCKPU

(CKN UCHG QRGTCVKQP %JGEM EQPVKPWKV[ DGVYGGP NKHV NGXGT CPF KPRWV WPKV $GVYGGP +PRWV WPKV CPF .KHV NGXGT $GVYGGP +PRWV WPKV CPF .KHV NGXGT $GVYGGP +PRWV WPKV CPF .KHV NGXGT $GVYGGP +PRWV WPKV CPF .KHV NGXGT %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

4GRNCEG NKHV NGXGT YKVJ CPQVJGT UGEVKQP NGXGT 'TTQT VTCPUKVKQP 'TTQT TGOCKPU

4GRNCEG NKHV NGXGT

4GRNCEG KPRWV WPKV 500487E

4-30

CHAPTER 4 CONTROLLERS

INPUT UNIT (HARNESS, IN FC)

ARMREST ATT2/3 (OP)

CN1

0.5B

476 SW GND

0.5O

477 SW INPUT 3(4V/5V)

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 470 461 0.5B

0.5R

464 469 468 460 0.5B

ATT1 (OP)

TILT

0.5R

LIFT

4/5 SELECT SW (OP)

0.5R

460 464 0.5Y 468 0.5G 469 0.5Y 470 0.5L 471 0.5Y 472 0.5Br 473 0.5Y 474 0.5W 475

477

476

0.5B

460 469

468 464

461 471

470 465

462 473

472 466

463 475

5V GND LIFT 1 LIFT 2 TILT 1 TILT 2 ATT 1-1 ATT 1-2 ATT 2-1 ATT 2-2

474 467

31 474 472 470 468 460 32 475 473 471 469 464

477 479 476

396 395

937 1 397 2

500587

4-31

CHAPTER 4 CONTROLLERS 4.7

Tilt Lever Neutral Error (F11)

Error code: F11 Situation

"F11" flickering. Hydraulic operations disabled.

Possible causes

The load handling lever operated when turning on key switch. Faulty tilt lever, faulty input unit, faulty harness

How the error code is triggered.

Tilt lever is not in neutral when turning on key switch.

Checks

5JKHV VKNV NGXGT KP PGWVTCN VJGP VWTP QP MG[ UYKVEJ CICKP 0QTOCN 'TTQT TGOCKPU (CKN UCHG QRGTCVKQP %JGEM EQPVKPWKV[ DGVYGGP VKNV NGXGT CPF KPRWV WPKV $GVYGGP +PRWV WPKV CPF 6KNV NGXGT $GVYGGP +PRWV WPKV CPF 6KNV NGXGT $GVYGGP +PRWV WPKV CPF 6KNV NGXGT $GVYGGP +PRWV WPKV CPF 6KNV NGXGT %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

4GRNCEG VKNV NGXGT YKVJ CPQVJGT UGEVKQP NGXGT 'TTQT VTCPUKVKQP 'TTQT TGOCKPU

4GRNCEG VKNV NGXGT

4GRNCEG KPRWV WPKV 500488E

4-32

CHAPTER 4 CONTROLLERS

INPUT UNIT (HARNESS, IN FC)

ARMREST ATT2/3 (OP)

CN1

0.5B

476 SW GND

0.5O

477 SW INPUT 3(4V/5V)

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 470 461 0.5B

0.5R

464 469 468 460 0.5B

ATT1 (OP)

TILT

0.5R

LIFT

4/5 SELECT SW (OP)

0.5R

460 464 0.5Y 468 0.5G 469 0.5Y 470 0.5L 471 0.5Y 472 0.5Br 473 0.5Y 474 0.5W 475

477

476

0.5B

460 469

468 464

461 471

470 465

462 473

472 466

463 475

5V GND LIFT 1 LIFT 2 TILT 1 TILT 2 ATT 1-1 ATT 1-2 ATT 2-1 ATT 2-2

474 467

31 474 472 470 468 460 32 475 473 471 469 464

477 479 476

396 395

937 1 397 2

500587

4-33

CHAPTER 4 CONTROLLERS 4.8

Attachment 1 Lever Neutral Error (F12)

Error code: F12 Situation

"F12" flickering. Hydraulic operations disabled.

Possible causes

The load handling lever operated when turning on key switch. Faulty attachment 1 lever, faulty input unit, faulty harness

How the error code is triggered.

Attachment 1 lever is not in neutral when turning on key switch.

Checks

5JKHV CVVCEJOGPV NGXGT KP PGWVTCN VJGP VWTP QP MG[ UYKVEJ CICKP â&#x20AC;« Þ&#x201C;Þ&#x201C;â&#x20AC;¬0QTOCN 'TTQT TGOCKPU

(CKN UCHG QRGTCVKQP %JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV NGXGT CPF KPRWV WPKV $GVYGGP +PRWV WPKV CPF #66 NGXGT $GVYGGP +PRWV WPKV CPF #66 NGXGT $GVYGGP +PRWV WPKV CPF #66 NGXGT $GVYGGP +PRWV WPKV CPF #66 NGXGT %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

4GRNCEG CVVCEJOGPV NGXGT YKVJ CPQVJGT UGEVKQP NGXGT 'TTQT VTCPUKVKQP 'TTQT TGOCKPU

4GRNCEG CVVCEJOGPV NGXGT

4GRNCEG KPRWV WPKV 500489E

4-34

CHAPTER 4 CONTROLLERS

INPUT UNIT (HARNESS, IN FC)

ARMREST ATT2/3 (OP)

CN1

0.5B

476 SW GND

0.5O

477 SW INPUT 3(4V/5V)

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 470 461 0.5B

0.5R

464 469 468 460 0.5B

ATT1 (OP)

TILT

0.5R

LIFT

4/5 SELECT SW (OP)

0.5R

460 464 0.5Y 468 0.5G 469 0.5Y 470 0.5L 471 0.5Y 472 0.5Br 473 0.5Y 474 0.5W 475

477

476

0.5B

460 469

468 464

461 471

470 465

462 473

472 466

463 475

5V GND LIFT 1 LIFT 2 TILT 1 TILT 2 ATT 1-1 ATT 1-2 ATT 2-1 ATT 2-2

474 467

31 474 472 470 468 460 32 475 473 471 469 464

477 479 476

396 395

937 1 397 2

500587

4-35

CHAPTER 4 CONTROLLERS 4.9

Attachment 2 Lever Neutral Error (F13)

Error code: F13 Situation

"F13" flickering. Hydraulic operations disabled.

Possible causes

The load handling lever operated when turning on key switch. Faulty attachment 2 lever, faulty input unit, faulty harness

How the error code is triggered.

Attachment 2 lever is not in neutral when turning on key switch.

Checks

5JKHV CVVCEJOGPV NGXGT KP PGWVTCN VJGP VWTP QP MG[ UYKVEJ CICKP 0QTOCN 'TTQT TGOCKPU (CKN UCHG QRGTCVKQP %JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV NGXGT CPF KPRWV WPKV $GVYGGP +PRWV WPKV CPF #66 NGXGT $GVYGGP +PRWV WPKV CPF #66 NGXGT $GVYGGP +PRWV WPKV CPF #66 NGXGT $GVYGGP +PRWV WPKV CPF #66 NGXGT %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

4GRNCEG CVVCEJOGPV NGXGT YKVJ CPQVJGT UGEVKQP NGXGT 'TTQT VTCPUKVKQP 'TTQT TGOCKPU

4GRNCEG CVVCEJOGPV NGXGT

4GRNCEG KPRWV WPKV 500490E

4-36

CHAPTER 4 CONTROLLERS

INPUT UNIT (HARNESS, IN FC)

ARMREST ATT2/3 (OP)

CN1

0.5B

476 SW GND

0.5O

477 SW INPUT 3(4V/5V)

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 470 461 0.5B

0.5R

464 469 468 460 0.5B

ATT1 (OP)

TILT

0.5R

LIFT

4/5 SELECT SW (OP)

0.5R

460 464 0.5Y 468 0.5G 469 0.5Y 470 0.5L 471 0.5Y 472 0.5Br 473 0.5Y 474 0.5W 475

477

476

0.5B

460 469

468 464

461 471

470 465

462 473

472 466

463 475

5V GND LIFT 1 LIFT 2 TILT 1 TILT 2 ATT 1-1 ATT 1-2 ATT 2-1 ATT 2-2

474 467

31 474 472 470 468 460 32 475 473 471 469 464

477 479 476

396 395

937 1 397 2

500587

4-37

CHAPTER 4 CONTROLLERS 4.10 Attachment 3 Lever Neutral Error (F14) Error code: F14 Situation

"F14" flickering. Hydraulic operations disabled.

Possible causes

The load handling lever operated when turning on key switch. Faulty attachment 3 lever, faulty input unit, faulty harness

How the error code is triggered.

Attachment 3 lever is not in neutral when turning on key switch.

Checks

4GRNCEG JCTPGUU

4GRNCEG CVVCEJOGPV NGXGT YKVJ CPQVJGT UGEVKQP NGXGT 'TTQT VTCPUKVKQP 'TTQT TGOCKPU

4GRNCEG CVVCEJOGPV NGXGT

4GRNCEG KPRWV WPKV 500491E

4-38

CHAPTER 4 CONTROLLERS

INPUT UNIT (HARNESS, IN FC)

ARMREST ATT2/3 (OP)

CN1

0.5B

476 SW GND

0.5O

477 SW INPUT 3(4V/5V)

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 470 461 0.5B

0.5R

464 469 468 460 0.5B

ATT1 (OP)

TILT

0.5R

LIFT

4/5 SELECT SW (OP)

0.5R

460 464 0.5Y 468 0.5G 469 0.5Y 470 0.5L 471 0.5Y 472 0.5Br 473 0.5Y 474 0.5W 475

477

476

0.5B

460 469

468 464

461 471

470 465

462 473

472 466

463 475

5V GND LIFT 1 LIFT 2 TILT 1 TILT 2 ATT 1-1 ATT 1-2 ATT 2-1 ATT 2-2

474 467

31 474 472 470 468 460 32 475 473 471 469 464

477 479 476

396 395

937 1 397 2

500587

4-39

CHAPTER 4 CONTROLLERS 4.11 Shift Lever Error (F16) Error code: F16 Situation

"F16" flickering. Drive operations disabled.

Possible causes

Faulty meter panel, faulty VCM-3, faulty harness

How the error code is triggered.

When F, N and R signals of shift lever are input simultaneously.

Checks

&KHFN FRQWLQXLW\ EHWZHHQ PHWDO SDQHO DQG VKLIW OHYHU 1 %HWZHHQ 6KLIW OHYHU DQG 0HWHU 3DQHO ) %HWZHHQ 6KLIW OHYHU DQG 0HWHU 3DQHO 5 %HWZHHQ 6KLIW OHYHU DQG 0HWHU 3DQHO *1' %HWZHHQ 6KLIW OHYHU DQG 0HWHU SDQHO &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH PHWHU SDQHO

5HSODFH KDUQHVV

(UURU UHPDLQV 5HSODFH 9&0

%HFDXVH RI GLRGH DSSO\ HOHFWULFDO FXUUHQW WR PHWHU VLGH ZKHQ FKHFNLQJ FRQWLQXLW\ XVLQJ V FLUFXLW WHVWHU

500492E

DIODE

FNR LEVER 1 2 3 4 5

0.5L/G 0.5L/W

272 127 81 126 62 81 272 62

0.5L/W

0.5Y/L 0.5G/R

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

127 126

272

0.5G/Y 0.5Y/L

62 82

272 80

METER PANEL 62 82

F1 N R1

DIODE

0.5B/L

14 45 20 102 200 201

BLACK

4-40

48 46 11 49 15

82 80 81

102

R N F

GND

81 1 83 78 5 79 82 80 6 10 77

WHITE

500589

CHAPTER 4 CONTROLLERS 4.12 Vehicle Speed Error (F17) Error code: F17 Situation

"F17" flickering.

Possible causes

Vehicle speed over limit, faulty VCM-3, faulty harness

How the error code is triggered.

When vehicle speed is 35 km/h or more.

Checks

&KHFN FRQWLQXLW\ EHWZHHQ 9&0 DQG YHKLFOH VSHHG VHQVRU FRQQHFWRUV %HWZHHQ 9&0 &1 DQG 6SHHG VHQVRU %HWZHHQ 9&0 &1 DQG 6SHHG VHQVRU &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH 9&0

5HSODFH KDUQHVV 500493E

VCM-3

0.5R/G 0.5G/B

220 221

227 228 1

9 17

234 235 233

384

220 221

CN2

0.5G/B

220 221

0.5R/G

SPEED SENSOR SPEED SENSOR

221 220

200 201 299 298 297 296

10 18 26

SPEED SENSOR 500590

4-41

CHAPTER 4 CONTROLLERS 4.13 Lift Lever Error (F20) Error code: F20 Situation

"F20" flickering. Lift up and lift down operations disabled.

Possible causes

Faulty lift lever, faulty input unit, faulty harness

How the error code is triggered.

When lift lever signal voltage is out of 0.25V to 4.75V range.

Checks

&KHFN FRQWLQXLW\ EHWZHHQ OLIW OHYHU DQG LQSXW XQLW %HWZHHQ ,QSXW XQLW DQG /LIW OHYHU %HWZHHQ ,QSXW XQLW DQG /LIW OHYHU %HWZHHQ ,QSXW XQLW DQG /LIW OHYHU %HWZHHQ ,QSXW XQLW DQG /LIW OHYHU &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH KDUQHVV

5HSODFH OLIW OHYHU ZLWK DQRWKHU VHFWLRQ OHYHU (UURU WUDQVLWLRQ (UURU UHPDLQV

5HSODFH OLIW OHYHU

5HSODFH LQSXW XQLW 500494E

4-42

CHAPTER 4 CONTROLLERS

INPUT UNIT (HARNESS, IN FC)

ARMREST ATT2/3 (OP)

CN1

0.5B

476 SW GND

0.5O

477 SW INPUT 3(4V/5V)

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 470 461 0.5B

0.5R

464 469 468 460 0.5B

ATT1 (OP)

TILT

0.5R

LIFT

4/5 SELECT SW (OP)

0.5R

460 464 0.5Y 468 0.5G 469 0.5Y 470 0.5L 471 0.5Y 472 0.5Br 473 0.5Y 474 0.5W 475

477

476

0.5B

460 469

468 464

461 471

470 465

462 473

472 466

463 475

5V GND LIFT 1 LIFT 2 TILT 1 TILT 2 ATT 1-1 ATT 1-2 ATT 2-1 ATT 2-2

474 467

31 474 472 470 468 460 32 475 473 471 469 464

477 479 476

396 395

937 1 397 2

500587

4-43

CHAPTER 4 CONTROLLERS 4.14 Tilt Lever Error (F22) Error code: F22 Situation

"F22" flickering. Tilt forward and tilt backward operations disabled.

Possible causes

Faulty tilt lever, faulty input unit, faulty harness

How the error code is triggered.

When lift lever signal voltage is out of 0.25V to 4.75 range.

Checks

&KHFN FRQWLQXLW\ EHWZHHQ WLOW OHYHU DQG LQSXW XQLW %HWZHHQ ,QSXW XQLW DQG 7LOW OHYHU %HWZHHQ ,QSXW XQLW DQG 7LOW OHYHU %HWZHHQ ,QSXW XQLW DQG 7LOW OHYHU %HWZHHQ ,QSXW XQLW DQG 7LOW OHYHU &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH KDUQHVV

5HSODFH WLOW OHYHU ZLWK DQRWKHU VHFWLRQ OHYHU (UURU WUDQVLWLRQ (UURU UHPDLQV

5HSODFH WLOW OHYHU

5HSODFH LQSXW XQLW 500495E

4-44

CHAPTER 4 CONTROLLERS

INPUT UNIT (HARNESS, IN FC)

ARMREST ATT2/3 (OP)

CN1

0.5B

476 SW GND

0.5O

477 SW INPUT 3(4V/5V)

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 470 461 0.5B

0.5R

464 469 468 460 0.5B

ATT1 (OP)

TILT

0.5R

LIFT

4/5 SELECT SW (OP)

0.5R

460 464 0.5Y 468 0.5G 469 0.5Y 470 0.5L 471 0.5Y 472 0.5Br 473 0.5Y 474 0.5W 475

477

476

0.5B

460 469

468 464

461 471

470 465

462 473

472 466

463 475

5V GND LIFT 1 LIFT 2 TILT 1 TILT 2 ATT 1-1 ATT 1-2 ATT 2-1 ATT 2-2

474 467

31 474 472 470 468 460 32 475 473 471 469 464

477 479 476

396 395

937 1 397 2

500587

4-45

CHAPTER 4 CONTROLLERS 4.15 Attachment 1 Lever Error (F24) Error code: F24 Situation

"F24" flickering. Attachment 1 operation disabled.

Possible causes

Faulty attachment 1 lever, faulty input unit, faulty harness

How the error code is triggered.

When attachment 1 lever signal voltage is out of 0.25V to 4.75V range.

Checks

&KHFN FRQWLQXLW\ EHWZHHQ DWWDFKPHQW OHYHU DQG LQSXW XQLW %HWZHHQ ,QSXW XQLW DQG $77 OHYHU %HWZHHQ ,QSXW XQLW DQG $77 OHYHU %HWZHHQ ,QSXW XQLW DQG $77 OHYHU %HWZHHQ ,QSXW XQLW DQG $77 OHYHU &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH KDUQHVV

5HSODFH DWWDFKPHQW OHYHU ZLWK DQRWKHU VHFWLRQ OHYHU (UURU WUDQVLWLRQ (UURU UHPDLQV

5HSODFH DWWDFKPHQW OHYHU

5HSODFH LQSXW XQLW 500496E

4-46

CHAPTER 4 CONTROLLERS

INPUT UNIT (HARNESS, IN FC)

ARMREST ATT2/3 (OP)

CN1

0.5B

476 SW GND

0.5O

477 SW INPUT 3(4V/5V)

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 470 461 0.5B

0.5R

464 469 468 460 0.5B

ATT1 (OP)

TILT

0.5R

LIFT

4/5 SELECT SW (OP)

0.5R

460 464 0.5Y 468 0.5G 469 0.5Y 470 0.5L 471 0.5Y 472 0.5Br 473 0.5Y 474 0.5W 475

477

476

0.5B

460 469

468 464

461 471

470 465

462 473

472 466

463 475

5V GND LIFT 1 LIFT 2 TILT 1 TILT 2 ATT 1-1 ATT 1-2 ATT 2-1 ATT 2-2

474 467

31 474 472 470 468 460 32 475 473 471 469 464

477 479 476

396 395

937 1 397 2

500587

4-47

CHAPTER 4 CONTROLLERS 4.16 Attachment 2 Lever Error (F26) Error code: F26 Situation

"F26" flickering. Attachment 2 operation disabled.

Possible causes

Faulty attachment 2 lever, faulty input unit, faulty harness

How the error code is triggered.

When attachment 2 lever signal voltage is out of 0.25V to 4.75V range.

Checks

&KHFN FRQWLQXLW\ EHWZHHQ DWWDFKPHQW OHYHU DQG LQSXW XQLW

%HWZHHQ ,QSXW XQLW DQG $77 OHYHU %HWZHHQ ,QSXW XQLW DQG $77 OHYHU %HWZHHQ ,QSXW XQLW DQG $77 OHYHU %HWZHHQ ,QSXW XQLW DQG $77 OHYHU &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH KDUQHVV

5HSODFH DWWDFKPHQW OHYHU ZLWK DQRWKHU VHFWLRQ OHYHU (UURU WUDQVLWLRQ (UURU UHPDLQV

5HSODFH DWWDFKPHQW OHYHU

5HSODFH LQSXW XQLW 500497E

4-48

CHAPTER 4 CONTROLLERS

INPUT UNIT (HARNESS, IN FC)

ARMREST ATT2/3 (OP)

CN1

0.5B

476 SW GND

0.5O

477 SW INPUT 3(4V/5V)

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 470 461 0.5B

0.5R

464 469 468 460 0.5B

ATT1 (OP)

TILT

0.5R

LIFT

4/5 SELECT SW (OP)

0.5R

460 464 0.5Y 468 0.5G 469 0.5Y 470 0.5L 471 0.5Y 472 0.5Br 473 0.5Y 474 0.5W 475

477

476

0.5B

460 469

468 464

461 471

470 465

462 473

472 466

463 475

5V GND LIFT 1 LIFT 2 TILT 1 TILT 2 ATT 1-1 ATT 1-2 ATT 2-1 ATT 2-2

474 467

31 474 472 470 468 460 32 475 473 471 469 464

477 479 476

396 395

937 1 397 2

500587

4-49

CHAPTER 4 CONTROLLERS 4.17 Attachment 3 Lever Error (F28) Error code: F28 Situation

"F28" flickering. Attachment 3 operation disabled.

Possible causes

Faulty attachment 3 lever, faulty input unit, faulty harness

How the error code is triggered.

When attachment 3 lever signal voltage is out of 0.25V to 4.75V range.

Checks

5HSODFH KDUQHVV

5HSODFH DWWDFKPHQW OHYHU ZLWK DQRWKHU VHFWLRQ OHYHU (UURU WUDQVLWLRQ (UURU UHPDLQV

5HSODFH DWWDFKPHQW OHYHU

5HSODFH LQSXW XQLW 500498E

4-50

CHAPTER 4 CONTROLLERS

INPUT UNIT (HARNESS, IN FC)

ARMREST ATT2/3 (OP)

CN1

0.5B

476 SW GND

0.5O

477 SW INPUT 3(4V/5V)

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 470 461 0.5B

0.5R

464 469 468 460 0.5B

ATT1 (OP)

TILT

0.5R

LIFT

4/5 SELECT SW (OP)

0.5R

460 464 0.5Y 468 0.5G 469 0.5Y 470 0.5L 471 0.5Y 472 0.5Br 473 0.5Y 474 0.5W 475

477

476

0.5B

460 469

468 464

461 471

470 465

462 473

472 466

463 475

5V GND LIFT 1 LIFT 2 TILT 1 TILT 2 ATT 1-1 ATT 1-2 ATT 2-1 ATT 2-2

474 467

31 474 472 470 468 460 32 475 473 471 469 464

477 479 476

396 395

937 1 397 2

500587

4-51

CHAPTER 4 CONTROLLERS 4.18 Joystick Lever Error (F29) Error code: F29 Situation

"F29" flickering. Corresponding hydraulic operation disabled.

Possible causes

Faulty FC lever, faulty input unit, faulty harness

How the error code is triggered.

Voltage data between main signal and sub-signal is different when FC lever is not operated.

Checks

&KHFN WR VHH LI RWKHU HUURUV KDYH RFFXUUHG ) ) ) ) )

*R WR

5HSODFH OLIW OHYHU

5HSODFH WLOW OHYHU

5HSODFH DWWDFKPHQW OHYHU

5HSODFH DWWDFKPHQW OHYHU 500499E

4-52

CHAPTER 4 CONTROLLERS

INPUT UNIT (HARNESS, IN FC)

ARMREST ATT2/3 (OP)

CN1

0.5B

476 SW GND

0.5O

477 SW INPUT 3(4V/5V)

0.5R

467 475 474 463 0.5B

0.5B

0.5R

466 473 472 462

465 471 470 461 0.5B

0.5R

464 469 468 460 0.5B

ATT1 (OP)

TILT

0.5R

LIFT

4/5 SELECT SW (OP)

0.5R

460 464 0.5Y 468 0.5G 469 0.5Y 470 0.5L 471 0.5Y 472 0.5Br 473 0.5Y 474 0.5W 475

477

476

0.5B

460 469

468 464

461 471

470 465

462 473

472 466

463 475

5V GND LIFT 1 LIFT 2 TILT 1 TILT 2 ATT 1-1 ATT 1-2 ATT 2-1 ATT 2-2

474 467

31 474 472 470 468 460 32 475 473 471 469 464

477 479 476

396 395

937 1 397 2

500587

4-53

CHAPTER 4 CONTROLLERS 4.19 VCM-3 Sensor Voltage Error (F31) Error code: F31 Situation

"F31" flickering.

Possible causes

Faulty speed sensor, faulty VCM-3, faulty harness

How the error code is triggered.

When the sensor power voltage is 2.5V or less.

Checks

&KHFN FRQWLQXLW\ EHWZHHQ 9&0 DQG YHKLFOH VSHHG VHQVRU %HWZHHQ 9&0 &1 DQG 6SHHG VHQVRU %HWZHHQ 9&0 &1 DQG 6SHHG VHQVRU &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH KDUQHVV

&KHFN VKRUW FLUFXLW ZLWK YHKLFOH VSHHG VHQVRU 6KRUWHG 1RW VKRUWHG

5HSODFH VHQVRU

5HSODFH 9&0 500556E

4-54

CHAPTER 4 CONTROLLERS

VCM-3

0.5R/G 0.5G/B

220 221

227 228 1

9 17

234 235 233

384

220 221

CN2

0.5G/B

220 221

0.5R/G

SPEED SENSOR SPEED SENSOR

221 220

200 201 299 298 297 296

10 18 26

SPEED SENSOR 500590

4-55

CHAPTER 4 CONTROLLERS 4.20 Vehicle Speed Sensor Error (F34) Error code: F34 Situation

"F34" flickering. Drive speed change operation disabled.

Possible causes

Faulty vehicle speed sensor, faulty VCM-3, faulty harness

How the error code is triggered.

When vehicle speed sensor signal voltage is out of 1.3V to 4.9V range.

Checks

&KHFN FRQWLQXLW\ EHWZHHQ 9&0 DQG YHKLFOH VSHHG VHQVRU %HWZHHQ 9&0 &1 DQG 6SHHG VHQVRU %HWZHHQ 9&0 &1 DQG 6SHHG VHQVRU &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH KDUQHVV

0HDVXUH UHVLVWDQFH EHWZHHQ YHKLFOH VSHHG VHQVRU WHUPLQDOV %HWZHHQ 6SHHG VHQVRU DQG 6SHHG VHQVRU 1RUPDO > .Č? WR .Č? DW r & r ) @ $EQRUPDO

5HSODFH 9&0

5HSODFH YHKLFOH VSHHG VHQVRU 500500E

4-56

CHAPTER 4 CONTROLLERS

VCM-3

0.5R/G 0.5G/B

220 221

227 228 1

9 17

234 235 233

384

220 221

CN2

0.5G/B

220 221

0.5R/G

SPEED SENSOR SPEED SENSOR

221 220

200 201 299 298 297 296

10 18 26

SPEED SENSOR 500590

4-57

CHAPTER 4 CONTROLLERS 4.21 Output Unit Error (F41) Error code: F41 Situation

"F41" flickering. Hydraulic operations disabled.

Possible causes

Faulty output unit

How the error code is triggered.

Software checks sum value of ROM and EEPROM (memory setting value) in CPU, and detects fault.

Checks

:ULWH XSGDWHG VRIWZDUH LQWR RXWSXW XQLW 1RUPDO (UURU UHPDLQV

)DXOW\ VRIWZDUH ZULWLQJ

5HSODFH RXWSXW XQLW 500501E

4.22 Output Unit Life Control Signal (F42) Error code: F42 Situation

"F42" flickering. Hydraulic operations disabled.

Possible causes

Faulty output unit

How the error code is triggered.

When output unit is being initialized.

Checks

:ULWH XSGDWHG VRIWZDUH LQWR RXWSXW XQLW 1RUPDO (UURU UHPDLQV

)DXOW\ VRIWZDUH ZULWLQJ

5HSODFH RXWSXW XQLW 500502E

4-58

CHAPTER 4 CONTROLLERS 4.23 Output Unit Memory Check Error (F43) Error code: F43 Situation

"F43" flickering. Hydraulic operations disabled.

Possible causes

Faulty output unit

How the error code is triggered.

Software checks sum value of ROM and EEPROM (memory setting value) in CPU, and detects fault.

Checks

:ULWH XSGDWHG VRIWZDUH LQWR RXWSXW XQLW 1RUPDO (UURU UHPDLQV

)DXOW\ VRIWZDUH ZULWLQJ

5HSODFH RXWSXW XQLW 500503E

4-59

CHAPTER 4 CONTROLLERS 4.24 Output Unit PWM Voltage Error (F44) Error code: F44 Situation

"F44" flickering. Hydraulic operations disabled.

Possible causes

Poor battery charge or faulty battery, faulty output unit, faulty DC-DC converter, faulty harness

How the error code is triggered.

When output unit PWM voltage is 7V or less.

Checks

%JGEM VQ UGG KH GOGTIGPE[ DWVVQP KU RWUJGF 2WUJGF 0QV RWUJGF

4GNGCUG GOGTIGPE[ DWVVQP 0QTOCN #DPQTOCN

/GCUWTG DCVVGT[ VGTOKPCN XQNVCIG 0QTOCN 8 VQ 8 8 QT NGUU

%JCTIG DCVVGT[ 'TTQT TGOCKPU 4GRNCEG DCVVGT[

/GCUWTG QWVRWV XQNVCIG CPF KPRWV XQNVCIG QH &% &% EQPXGTVGT 1WVRWV XQNVCIG $GVYGGP &% &% %QPXGTVGT 8 CPF &% &% EQPXGTVGT )0& เกฎเกฎเกฎ 8 +PRWV XQNVCIG $GVYGGP &% &% %QPXGTVGT 8 CPF &% &% EQPXGTVGT )0& เกฎเกฎเกฎ 8 0QTOCN +PRWV XQNVCIG CDPQTOCN 1WVRWV XQNVCIG CDPQTOCN

4GRNCEG JCTPGUU

4GRNCEG &% &% EQPXGTVGT

/GCUWTG QWVRWV WPKV KPRWV XQNVCIG

$GVYGGP 1WVRWV WPKV 8 CPF 1WVRWV WPKV )0& เกฎเกฎเกฎ 8 $GVYGGP 1WVRWV WPKV 8 CPF 1WVRWV WPKV )0& เกฎเกฎเกฎ 8 8 QT NGUU 8 VQ 8

4GRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV 500504E

4-60

CHAPTER 4 CONTROLLERS

DC-DC CONVERTER

OUTPUT UNIT 0.5B

GND GND DC12V DC12V

1.25B/L

933 0.5B 935 0.5R/Y 390 0.5R/Y 392

2R 1.25B

1.25R/W

OUT

390 933 1

393

391 934 2

10A

24V BATT

1.25R/W

105

12V GND 12V MAIN 24V GND

104 107 40

62 301

394

100

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

107 40 104

BATTERY

500661

4-61

CHAPTER 4 CONTROLLERS 4.25 Output Unit Communication Error (F45) Error code: F45 Situation

"F45" flickering. Hydraulic operations disabled.

Possible causes

Faulty VCM-3, faulty harness, faulty output unit

How the error code is triggered.

When CAN communication from output unit to VCM-3 is interrupted.

Checks

&KHFN FRQWLQXLW\ RI &$1 FRPPXQLFDWLRQ FDEOHV 9&0 WR 2XWSXW XQLW %HWZHHQ 9&0 &1 WR 2XWSXW XQLW DQG %HWZHHQ 9&0 &1 WR 2XWSXW XQLW &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH RXWSXW XQLW

5HSODFH KDUQHVV

(UURU UHPDLQV 5HSODFH 9&0 500505E

4-62

CHAPTER 4 CONTROLLERS

OUTPUT UNIT

VCM-3

CN2 0.5L/R

0.5L/R

CAN H 201 0.5B/W CAN L 200

0.5B/W

394 CAN H 393 CAN L

CN2

227228 1

9 17

234 235 233

384

221 220

200 201 299 298 297 296

10 18 26

OUT 35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500597

4-63

CHAPTER 4 CONTROLLERS 4.26 Input Unit Error (F46) Error code: F46 Situation

"F46" flickering. Hydraulic operations disabled.

Possible causes

Faulty input unit

How the error code is triggered.

Software checks sum value of ROM in CPU, and defects fault.

Checks

:ULWH XSGDWHG VRIWZDUH LQWR LQSXW XQLW 1RUPDO (UURU UHPDLQV

)DXOW\ VRIWZDUH ZULWLQJ

5HSODFH LQSXW XQLW 500506E

4-64

CHAPTER 4 CONTROLLERS 4.27 Input Unit Life Control Signal (F47) Error code: F47 Situation

"F47" flickering. Hydraulic operations disabled.

Possible causes

Faulty input unit

How the error code is triggered.

When input unit is being initialized.

Checks

:ULWH XSGDWHG VRIWZDUH LQWR LQSXW XQLW ࠉࠉ1RUPDO (UURU UHPDLQV

)DXOW\ VRIWZDUH ZULWLQJ

5HSODFH LQSXW XQLW 500507E

4-65

CHAPTER 4 CONTROLLERS 4.28 Input Unit Memory Check Error (F48) Error code: F48 Situation

"F48" flickering. Hydraulic operations disabled.

Possible causes

Faulty input unit

How the error code is triggered.

Software checks sum value (memory setting value) of ROM in CPU, and detects fault.

Checks

:ULWH XSGDWHG VRIWZDUH LQWR LQSXW XQLW à &#x2030;à &#x2030;1RUPDO (UURU UHPDLQV

)DXOW\ VRIWZDUH ZULWLQJ

5HSODFH LQSXW XQLW 500508E

4.29 Input Unit Communication Error (F49) Error code: F49 Situation

"F49" flickering. Hydraulic operations disabled.

Possible causes

Faulty VCM-3, faulty harness, faulty input unit

How the error code is triggered.

When CAN communication from input unit to VCM-3 is interrupted.

Checks

&KHFN FRQWLQXLW\ RI &$1 FRPPXQLFDWLRQ FDEOHV 9&0 WR ,QSXW XQLW %HWZHHQ 9&0 &1 WR 2XWSXW XQLW DQG %HWZHHQ 9&0 &1 WR 2XWSXW XQLW &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH LQSXW XQLW

5HSODFH KDUQHVV

(UURU UHPDLQV 5HSODFH 9&0 500509E

4-66

CHAPTER 4 CONTROLLERS

INPUT UNIT

VCM-3

CN2 0.5L/R

0.5Br

CAN H 201 0.5B/W CAN L 200

0.5L

396 CAN H 395 CAN L

CN2

227228 1

9 17

234 235 233

384

221 220

200 201 299 298 297 296

10 18 26

IN 31 474 472 470 468 460 32 475 473 471 469 464

477 479 476

396

937 1

395

397 2 500665

4-67

CHAPTER 4 CONTROLLERS 4.30 Lift Up Solenoid Error (F50) Error code: F50 Situation

"F50" flickering. Lift operation disabled.

Possible causes

Faulty output unit, faulty lift up solenoid, faulty harness

How the error code is triggered.

Current is 0.16A or less, or 1.9A or more, when lift up solenoid signal is output.

Checks

%JGEM EQPVKPWKV[ DGVYGGP QWVRWV WPKV CPF NKHV WR UQNGPQKF .KHV WR $GVYGGP 1WVRWV WPKV CPF .KHV # UQNGPQKF .KHV TGVWTP $GVYGGP 1WVRWV WPKV CPF .KHV # UQNGPQKF %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

%JGEM TGUKUVCPEG QH NKHV WR UQNGPQKF .KHV WR $GVYGGP .KHV # UQNGPQKF CPF .KHV # UQNGPQKF 0QTOCN = วก VQ วก CV q % q ( ? #DPQTOCN

4GRNCEG QWVRWV WPKV

4GRNCEG NKHV # UQNGPQKF 500510E

4-68

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-69

CHAPTER 4 CONTROLLERS 4.31 Lift Down Solenoid Error (F52) Error code: F52 Situation

"F52" flickering. Lift operation disabled.

Possible causes

Faulty output unit, faulty lift down solenoid, faulty harness

How the error code is triggered.

Current is 0.16A or less, or 1.9A or more, when lift down solenoid signal is output.

Checks

%JGEM EQPVKPWKV[ DGVYGGP QWVRWV WPKV CPF NKHV FQYP UQNGPQKF .KHV FQYP $GVYGGP 1WVRWV WPKV CPF .KHV $ UQNGPQKF .KHV TGVWTP $GVYGGP 1WVRWV WPKV CPF .KHV $ UQNGPQKF %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

%JGEM TGUKUVCPEG QH NKHV FQYP UQNGPQKF .KHV FQYP $GVYGGP .KHV $ UQNGPQKF CPF .KHV $ UQNGPQKF 0QTOCN = วก VQ วก CV q % q ( ? #DPQTOCN

4GRNCEG QWVRWV WPKV

4GRNCEG NKHV $ UQNGPQKF 500511E

4-70

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-71

CHAPTER 4 CONTROLLERS 4.32 Lift Solenoid Leak (F54) Error code: F54 Situation

"F54" flickering. Hydraulic operations disabled.

Possible causes

Faulty output unit, faulty hydraulic operation device solenoid, faulty harness

How the error code is triggered.

Current is 0.18A or more when lift lever is not operated.

Checks

%JGEM J[FTCWNKE QRGTCVKQPU YJGP GTTQT QEEWTTGF

0QV QRGTCVG

6KNV QRGTCVKQP (QTYCTF $CEMYCTF

)Q VQ )Q VQ

#VVCEJOGPV QRGTCVKQP

#â&#x20AC;«Þ&#x201C;Þ&#x201C; Þ&#x201C;â&#x20AC;¬$

#â&#x20AC;«Þ&#x201C; Þ&#x201C;Þ&#x201C;â&#x20AC;¬$

)Q VQ )Q VQ

/GCUWTG TGUKUVCPEG QH EQTTGURQPFKPI UQNGPQKF 0QTOCN = Ç¡ VQ Ç¡ CV q % q ( ? #DPQTOCN

4GRNCEG QWVRWV WPKV

4GRNCEG HCWNV[ UQNGPQKF 500512E

4-72

CHAPTER 4 CONTROLLERS

%JGEM EQPVKPWKV[ DGVYGGP NKHV UGEVKQP CPF VKNV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN ǡ QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /ǡ

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP NKHV UGEVKQP CPF VKNV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN ǡ QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /ǡ

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP NKHV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN ǡ QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /ǡ

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP NKHV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN ǡ QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /ǡ

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

500513E

4-73

CHAPTER 4 CONTROLLERS

%JGEM EQPVKPWKV[ DGVYGGP NKHV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP NKHV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP NKHV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP NKHV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

500514E

4-74

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-75

CHAPTER 4 CONTROLLERS 4.33 Tilt Forward Solenoid Error (F55) Error code: F55 Situation

"F55" flickering. Tilt operation disabled.

Possible causes

Faulty output unit, faulty tilt forward solenoid, faulty harness

How the error code is triggered.

Current is 0.16A or less, or 1.9A or more, when tilt forward solenoid signal is output.

Checks

%JGEM EQPVKPWKV[ DGVYGGP QWVRWV WPKV CPF VKNV HQTYCTF UQNGPQKF 6KNV HQTYCTF $GVYGGP 1WVRWV WPKV CPF 6KNV # UQNGPQKF 6KNV TGVWTP $GVYGGP 1WVRWV WPKV CPF .KHV # UQNGPQKF %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

/GCUWTG TGUKUVCPEG QH VKNV HQTYCTF UQNGPQKF 6KNV HQTYCTF $GVYGGP 6KNV # UQNGPQKF CPF 6KNV # UQNGPQKF 0QTOCN = วก VQ วก CV q % q ( ? #DPQTOCN

4GRNCEG QWVRWV WPKV

4GRNCEG VKNV # UQNGPQKF 500515E

4-76

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-77

CHAPTER 4 CONTROLLERS 4.34 Tilt Backward Solenoid Error (F57) Error code: F57 Situation

"F57" flickering. Tilt operation disabled.

Possible causes

Faulty output unit, faulty tilt backward solenoid, faulty harness

How the error code is triggered.

Current is 0.16A or less, or 1.9A or more, when tilt backward solenoid signal is output.

Checks

%JGEM EQPVKPWKV[ DGVYGGP QWVRWV WPKV CPF VKNV DCEMYCTF UQNGPQKF 6KNV DCEMYCTF $GVYGGP 1WVRWV WPKV CPF 6KNV $ UQNGPQKF 6KNV TGVWTP $GVYGGP 1WVRWV WPKV CPF 6KNV $ UQNGPQKF %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

/GCUWTG TGUKUVCPEG QH VKNV DCEMYCTF UQNGPQKF 6KNV DCEMYCTF $GVYGGP 6KNV $ UQNGPQKF CPF 6KNV $ UQNGPQKF 0QTOCN = วก VQ วก CV q % q ( ? #DPQTOCN

4GRNCEG QWVRWV WPKV

4GRNCEG VKNV $ UQNGPQKF 500516E

4-78

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-79

CHAPTER 4 CONTROLLERS 4.35 Tilt Solenoid Leak (F59) Error code: F59 Situation

"F59" flickering. Hydraulic operations disabled.

Possible causes

Faulty output unit, faulty hydraulic operation device solenoid, faulty harness

How the error code is triggered.

Current is 0.18A or more when tilt lever is not operated.

Checks

%JGEM J[FTCWNKE QRGTCVKQPU YJGP GTTQT QEEWTTGF

.KHV QRGTCVKQP 0QV QRGTCVG 7R &QYP

)Q VQ

#VVCEJOGPV QRGTCVKQP

#â&#x20AC;«Þ&#x201C; Þ&#x201C;Þ&#x201C;â&#x20AC;¬$

#â&#x20AC;«Þ&#x201C;Þ&#x201C; Þ&#x201C;â&#x20AC;¬$

#â&#x20AC;«Þ&#x201C; Þ&#x201C;Þ&#x201C;â&#x20AC;¬$

)Q VQ

)Q VQ )Q VQ

/GCUWTG TGUKUVCPEG QH EQTTGURQPFKPI UQNGPQKF 0QTOCN = Ç¡ VQ Ç¡ CV q % q ( ? #DPQTOCN

4GRNCEG QWVRWV WPKV

4GRNCEG HCWNV[ UQNGPQKF 500517E

4-80

CHAPTER 4 CONTROLLERS

%JGEM EQPVKPWKV[ DGVYGGP VKNV UGEVKQP CPF NKHV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN ǡ QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /ǡ

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP VKNV UGEVKQP CPF NKHV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN ǡ QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /ǡ

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP VKNV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN ǡ QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /ǡ

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP VKNV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN ǡ QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /ǡ

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

500518E

4-81

CHAPTER 4 CONTROLLERS

&KHFN FRQWLQXLW\ EHWZHHQ WLOW VHFWLRQ DQG DWWDFKPHQW VHFWLRQ %HWZHHQ 2XWSXW XQLW DQG 2XWSXW XQLW &RQWLQXLW\ 6HYHUDO Ȑ RU OHVV 1R FRQWLQXLW\ 6HYHUDO 0Ȑ

,QVXODWH ZLUHV LQ KDUQHVV 2U UHSODFH KDUQHVV

5HSODFH RXWSXW XQLW

&KHFN FRQWLQXLW\ EHWZHHQ WLOW VHFWLRQ DQG DWWDFKPHQW VHFWLRQ %HWZHHQ 2XWSXW XQLW DQG 2XWSXW XQLW &RQWLQXLW\ 6HYHUDO Ȑ RU OHVV 1R FRQWLQXLW\ 6HYHUDO 0Ȑ

,QVXODWH ZLUHV LQ KDUQHVV 2U UHSODFH KDUQHVV

5HSODFH RXWSXW XQLW

&KHFN FRQWLQXLW\ EHWZHHQ WLOW VHFWLRQ DQG DWWDFKPHQW VHFWLRQ %HWZHHQ 2XWSXW XQLW DQG 2XWSXW XQLW &RQWLQXLW\ 6HYHUDO Ȑ RU OHVV 1R FRQWLQXLW\ 6HYHUDO 0Ȑ

,QVXODWH ZLUHV LQ KDUQHVV 2U UHSODFH KDUQHVV

5HSODFH RXWSXW XQLW

&KHFN FRQWLQXLW\ EHWZHHQ WLOW VHFWLRQ DQG DWWDFKPHQW VHFWLRQ %HWZHHQ 2XWSXW XQLW DQG 2XWSXW XQLW &RQWLQXLW\ 6HYHUDO Ȑ RU OHVV 1R FRQWLQXLW\ 6HYHUDO 0Ȑ

,QVXODWH ZLUHV LQ KDUQHVV 2U UHSODFH KDUQHVV

5HSODFH RXWSXW XQLW

500519E

4-82

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-83

CHAPTER 4 CONTROLLERS 4.36 Attachment 1A Solenoid Error (F60) Error code: F60 Situation

"F60" flickering. Attachment operation disabled.

Possible causes

Faulty output unit, faulty attachment 1A solenoid, faulty harness

How the error code is triggered.

Current is 0.16A or less, or 1.9A or more, when attachment 1A solenoid signal is output.

Checks

&KHFN FRQWLQXLW\ EHWZHHQ RXWSXW XQLW DQG DWWDFKPHQW $ VROHQRLG $WWDFKPHQW $ %HWZHHQ 2XWSXW XQLW DQG $77 $ VROHQRLG $WWDFKPHQW UHWXUQ %HWZHHQ 2XWSXW XQLW DQG $77 $ VROHQRLG &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH KDUQHVV

0HDVXUH UHVLVWDQFH RI DWWDFKPHQW $ VROHQRLG $WWDFKPHQW $ %HWZHHQ $77 $ VROHQRLG DQG $77 $ VROHQRLG 1RUPDO > Č? WR Č? DW r & r ) @ $EQRUPDO

5HSODFH RXWSXW XQLW

5HSODFH DWWDFKPHQW $ VROHQRLG 500520E

4-84

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-85

CHAPTER 4 CONTROLLERS 4.37 Attachment 1B Solenoid Error (F62) Error code: F62 Situation

"F62" flickering. Attachment operation disabled.

Possible causes

Faulty output unit, faulty attachment 1B solenoid, faulty harness

How the error code is triggered.

Current is 0.16A or less, or 1.9A or more, when attachment 1B solenoid signal is output.

Checks

&KHFN FRQWLQXLW\ EHWZHHQ RXWSXW XQLW DQG DWWDFKPHQW % VROHQRLG $WWDFKPHQW % %HWZHHQ 2XWSXW XQLW DQG $77 % VROHQRLG $WWDFKPHQW UHWXUQ %HWZHHQ 2XWSXW XQLW DQG $77 % VROHQRLG &RQWLQXLW\ 1R FRQWLQXLW\

5HSODFH KDUQHVV

0HDVXUH UHVLVWDQFH RI DWWDFKPHQW % VROHQRLG $WWDFKPHQW % %HWZHHQ $77 % VROHQRLG DQG $77 % VROHQRLG 1RUPDO > Č? WR Č? DW r & r ) @ $EQRUPDO

5HSODFH RXWSXW XQLW

5HSODFH DWWDFKPHQW % VROHQRLG 500521E

4-86

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-87

CHAPTER 4 CONTROLLERS 4.38 Attachment 1 Solenoid Leak (F64) Error code: F64 Situation

"F64" flickering. Hydraulic operations disabled.

Possible causes

Faulty output unit, faulty hydraulic operation device solenoid, faulty harness

How the error code is triggered.

Current is 0.18A or more when attachment 1 lever is not operated.

Checks

&KHFN K\GUDXOLF RSHUDWLRQV ZKHQ HUURU RFFXUUHG

/LIW RSHUDWLRQ

7LOW RSHUDWLRQ

8S 'RZQ

)RUZDUG %DFNZDUG

1RW RSHUDWH

*R WR

$WWDFKPHQW RSHUDWLRQ

$ŕ &#x2030; ŕ &#x2030;ŕ &#x2030;%

*R WR

0HDVXUH UHVLVWDQFH RI FRUUHVSRQGLQJ VROHQRLG 1RUPDO > Č? WR Č? DW r & r ) @ $EQRUPDO

5HSODFH RXWSXW XQLW

5HSODFH IDXOW\ VROHQRLG 500522E

4-88

CHAPTER 4 CONTROLLERS

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF NKHV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF NKHV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF VKNV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF VKNV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

500523E

4-89

CHAPTER 4 CONTROLLERS

&KHFN FRQWLQXLW\ EHWZHHQ DWWDFKPHQW VHFWLRQ DQG DWWDFKPHQW VHFWLRQ %HWZHHQ 2XWSXW XQLW DQG 2XWSXW XQLW &RQWLQXLW\ 6HYHUDO Ȑ RU OHVV 1R FRQWLQXLW\ 6HYHUDO 0Ȑ

,QVXODWH ZLUHV LQ KDUQHVV 2U UHSODFH KDUQHVV

5HSODFH RXWSXW XQLW

&KHFN FRQWLQXLW\ EHWZHHQ DWWDFKPHQW VHFWLRQ DQG DWWDFKPHQW VHFWLRQ %HWZHHQ 2XWSXW XQLW DQG 2XWSXW XQLW &RQWLQXLW\ 6HYHUDO Ȑ RU OHVV 1R FRQWLQXLW\ 6HYHUDO 0Ȑ

,QVXODWH ZLUHV LQ KDUQHVV 2U UHSODFH KDUQHVV

5HSODFH RXWSXW XQLW

&KHFN FRQWLQXLW\ EHWZHHQ DWWDFKPHQW VHFWLRQ DQG DWWDFKPHQW VHFWLRQ %HWZHHQ 2XWSXW XQLW DQG 2XWSXW XQLW &RQWLQXLW\ 6HYHUDO Ȑ RU OHVV 1R FRQWLQXLW\ 6HYHUDO 0Ȑ

,QVXODWH ZLUHV LQ KDUQHVV 2U UHSODFH KDUQHVV

5HSODFH RXWSXW XQLW

&KHFN FRQWLQXLW\ EHWZHHQ DWWDFKPHQW VHFWLRQ DQG DWWDFKPHQW VHFWLRQ %HWZHHQ 2XWSXW XQLW DQG 2XWSXW XQLW &RQWLQXLW\ 6HYHUDO Ȑ RU OHVV 1R FRQWLQXLW\ 6HYHUDO 0Ȑ

,QVXODWH ZLUHV LQ KDUQHVV 2U UHSODFH KDUQHVV

5HSODFH RXWSXW XQLW

500524E

4-90

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-91

CHAPTER 4 CONTROLLERS 4.39 Attachment 2A Solenoid Error (F65) Error code: F65 Situation

"F65" flickering. Attachment 2 operation disabled.

Possible causes

Faulty output unit, faulty attachment 2A solenoid, faulty harness

How the error code is triggered.

Current is 0.16A or less, or 1.9A or more, when attachment 2A solenoid signal is output.

Checks

%JGEM EQPVKPWKV[ DGVYGGP QWVRWV WPKV CPF CVVCEJOGPV # UQNGPQKF #VVCEJOGPV # $GVYGGP 1WVRWV WPKV CPF #66 # UQNGPQKF #VVCEJOGPV # TGVWTP $GVYGGP 1WVRWV WPKV CPF #66 # UQNGPQKF %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

/GCUWTG TGUKUVCPEG QH CVVCEJOGPV # UQNGPQKF #VVCEJOGPV # $GVYGGP #66 # UQNGPQKF CPF #66 # UQNGPQKF 0QTOCN = วก VQ วก CV q % q ( ? #DPQTOCN

4GRNCEG QWVRWV WPKV

4GRNCEG CVVCEJOGPV # UQNGPQKF 500525E

4-92

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-93

CHAPTER 4 CONTROLLERS 4.40 Attachment 2B Solenoid Error (F67) Error code: F67 Situation

"F67" flickering. Attachment 2 operation disabled.

Possible causes

Faulty output unit, faulty attachment 2B solenoid, faulty harness

How the error code is triggered.

Current is 0.16A or less, or 1.9A or more, when attachment 2B solenoid signal is output.

Checks

%JGEM EQPVKPWKV[ DGVYGGP QWVRWV WPKV CPF CVVCEJOGPV $ UQNGPQKF #VVCEJOGPV $ $GVYGGP 1WVRWV WPKV CPF #66 $ UQNGPQKF #VVCEJOGPV TGVWTP $GVYGGP 1WVRWV WPKV CPF #66 $ UQNGPQKF %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

/GCUWTG TGUKUVCPEG QH CVVCEJOGPV $ UQNGPQKF #VVCEJOGPV $ $GVYGGP #66 $ UQNGPQKF CPF #66 $ UQNGPQKF 0QTOCN = วก VQ วก CV q % q ( ? #DPQTOCN

4GRNCEG QWVRWV WPKV

4GRNCEG CVVCEJOGPV $ UQNGPQKF 500526E

4-94

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-95

CHAPTER 4 CONTROLLERS 4.41 Attachment 2 Solenoid Leak (F69) Error code: F69 Situation

"F69" flickering. Hydraulic operations disabled.

Possible causes

Faulty output unit, faulty hydraulic operation device solenoid, faulty harness

How the error code is triggered.

Current is 0.18A or more when attachment 2 lever is not operated.

Checks

%JGEM J[FTCWNKE QRGTCVKQPU YJGP GTTQT QEEWTTGF

.KHV QRGTCVKQP

6KNV QRGTCVKQP

7R &QYP

(QTYCTF $CEMYCTF

0QV QRGTCVG

)Q VQ

#VVCEJOGPV QRGTCVKQP

#â&#x20AC;«Þ&#x201C;Þ&#x201C; Þ&#x201C;â&#x20AC;¬$

)Q VQ

)Q VQ )Q VQ

/GCUWTG TGUKUVCPEG QH EQTTGURQPFKPI UQNGPQKF 0QTOCN = Ç¡ VQ Ç¡ CV q % q ( ? #DPQTOCN

4GRNCEG QWVRWV WPKV

4GRNCEG HCWNV[ UQNGPQKF 500527E

4-96

CHAPTER 4 CONTROLLERS

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF NKHV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF NKHV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF VKNV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF VKNV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

500528E

4-97

CHAPTER 4 CONTROLLERS

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

500529E

4-98

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-99

CHAPTER 4 CONTROLLERS 4.42 Attachment 3A Solenoid Error (F70) Error code: F70 Situation

"F70" flickering. Attachment 3 operation disabled.

Possible causes

Faulty output unit, faulty attachment 3A solenoid, faulty harness

How the error code is triggered.

Current is 0.16A or less, or 1.9A or more, when attachment 3A solenoid signal is output.

Checks

%JGEM EQPVKPWKV[ DGVYGGP QWVRWV WPKV CPF CVVCEJOGPV # UQNGPQKF #VVCEJOGPV # $GVYGGP 1WVRWV WPKV CPF #66 # UQNGPQKF #VVCEJOGPV TGVWTP $GVYGGP 1WVRWV WPKV CPF #66 # UQNGPQKF %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

/GCUWTG TGUKUVCPEG QH CVVCEJOGPV # UQNGPQKF #VVCEJOGPV # $GVYGGP #66 # UQNGPQKF CPF #66 # UQNGPQKF 0QTOCN = วก VQ วก CV q % q ( #DPQTOCN

4GRNCEG QWVRWV WPKV

4GRNCEG CVVCEJOGPV # UQNGPQKF 500530E

4-100

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-101

CHAPTER 4 CONTROLLERS 4.43 Attachment 3B Solenoid Error (F72) Error code: F72 Situation

"F72" flickering. Attachment 3 operation disabled.

Possible causes

Faulty output unit, faulty attachment 3B solenoid, faulty harness

How the error code is triggered.

Current is 0.16A or less, or 1.9A or more, when attachment 3B solenoid signal is output.

Checks

%JGEM EQPVKPWKV[ DGVYGGP QWVRWV WPKV CPF CVVCEJOGPV $ UQNGPQKF #VVCEJOGPV $ $GVYGGP 1WVRWV WPKV CPF #66 $ UQNGPQKF #VVCEJOGPV TGVWTP $GVYGGP 1WVRWV WPKV CPF #66 $ UQNGPQKF %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

/GCUWTG TGUKUVCPEG QH CVVCEJOGPV $ UQNGPQKF #VVCEJOGPV $ $GVYGGP #66 $ UQNGPQKF CPF #66 $ UQNGPQKF 0QTOCN = วก VQ วก CV q % q ( ? #DPQTOCN

4GRNCEG QWVRWV WPKV

4GRNCEG CVVCEJOGPV $ UQNGPQKF 500531E

4-102

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-103

CHAPTER 4 CONTROLLERS 4.44 Attachment 3 Solenoid Leak (F74) Error code: F74 Situation

"F74" flickering. Hydraulic operations disabled.

Possible causes

Faulty output unit, faulty hydraulic operation device solenoid, faulty harness

How the error code is triggered.

Current is 0.18A or more when lift lever is not operated.

Checks

%JGEM J[FTCWNKE QRGTCVKQPU YJGP GTTQT QEEWTTGF

.KHV QRGTCVKQP

7R &QYP

(QTYCTF $CEMYCTF

0QV QRGTCVG

)Q VQ

#VVCEJOGPV QRGTCVKQP

#â&#x20AC;«Þ&#x201C; Þ&#x201C;Þ&#x201C;â&#x20AC;¬$

)Q VQ

/GCUWTG TGUKUVCPEG QH EQTTGURQPFKPI UQNGPQKF 0QTOCN = Ç¡ VQ Ç¡ CV q % q ( ? #DPQTOCN

4GRNCEG QWVRWV WPKV

4GRNCEG HCWNV[ UQNGPQKF 500532E

4-104

CHAPTER 4 CONTROLLERS

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF NKHV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF NKHV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF VKNV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF VKNV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

500533E

4-105

CHAPTER 4 CONTROLLERS

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

%JGEM EQPVKPWKV[ DGVYGGP CVVCEJOGPV UGEVKQP CPF CVVCEJOGPV UGEVKQP $GVYGGP 1WVRWV WPKV CPF 1WVRWV WPKV %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG QWVRWV WPKV

500534E

4-106

CHAPTER 4 CONTROLLERS

0.5R 0.5W/R

480 482

481 495

483 485

484 496

486 488

487 497

(BLACK)

490 498

(BLACK)

ATT2 B

492 494

(BLACK)

ATT3 A

ATT1 A

480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 36

PWM 1+ PWM 2+ PWM 1-/PWM 2PWM 3+ PWM 4+ PWM 3-/PWM 4PWM5 + PWM 6+ PWM 5-/PWM 6PWM 7+ PWM 8+ PWM 7-/PWM 8PWM 9+ PWM 10+ PWM 9-/PWM 10-

ATT1 B

0.5Br/Y 0.5L/R

TILT B

493 499

492 494

490 498

489 491

(BLACK)

ATT2 A

TILT A

0.5B/W 0.5L/R

0.5R/L 0.5W/L

LIFT B

489 491

0.5L/Y 0.5W/L

LIFT A

0.5L 0.5Br 0.5W 0.5R/W 0.5L/W 0.5W/B 0.5L/R 0.5R 0.5W/R 0.5L/Y 0.5R/L 0.5W/L 0.5B/W 0.5Br/Y 0.5L/R

487 497

484 496

486 488

0.5L/R 0.5W/R

0.5L/W 0.5W/B

0.5R/W 0.5W

483 485

480 482

481 495

0.5L 0.5W

0.5Br 0.5G

OUTPUT UNIT

493 499

(BLACK)

ATT3 B

35 494 492 490 488 486 484 482 480 21 19 935 493 491 489 487 485 483 481 22 20 392 36

394 393

390 933 1 391 934 2

500599

4-107

CHAPTER 4 CONTROLLERS 4.45 Unload Solenoid Error (F75) Error code: F75 Situation

"F75" flickering. Hydraulic operations disabled.

Possible causes

Faulty VCM-3, faulty unload solenoid, faulty harness

How the error code is triggered.

Current is 0.16A or less, or 2.4A or more, when unload solenoid signal is output.

Checks

%JGEM VQ UGG KH GOGTIGPE[ DWVVQP KU RWUJGF 2WUJGF 0QV RWUJGF

4GNGCUG GOGTIGPE[ DWVVQP CPF TGUVCTV 'TTQT TGOCKPU %JGEM EQPVKPWKV[ DGVYGGP 8%/ CPF WPNQCF UQNGPQKF $GVYGGP 8%/ CPF 7PNQCF UQNGPQKF $GVYGGP 8%/ VQ 'OGTIGPE[ 59 $GVYGGP 'OGTIGPE[ 59 CPF 7PNQCF UQNGPQKF

%QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

/GCUWTG TGUKUVCPEG QH WPNQCF UQNGPQKF $GVYGGP 7PNQCF UQNGPQKF CPF 7PNQCF UQNGPQKF 0QTOCN = วก VQ วก CV q % q ( ? #DPQTOCN

4GRNCEG 8%/

4GRNCEG WPNQCF UQNGPQKF 500535E

4-108

CHAPTER 4 CONTROLLERS

VCM-3

UNLOAD SOL UNLOAD RETURN

211 411

0.50Lg/R 0.5G/B

130

34 131 229 411

40 211

0.5G/B

10 18

211 212

0.5Lg/R 0.5Br/B

212

245

411

9 17

212 411

Harness

CN1

0.5Br/B

EMERGENCY SW

41 26 211

212

(BLACK)

UNLOAD 500600

4-109

CHAPTER 4 CONTROLLERS 4.46 Unload Solenoid Leak (F79) Error code: F79 Situation

"F79" flickering. Drive and hydraulic operations disabled.

Possible causes

Faulty VCM-3, faulty relevant solenoid, faulty harness

How the error code is triggered.

Current is 0.18A or more when hydraulic operation signal is not outputted.

Checks

%JGEM J[FTCWNKE QRGTCVKQPU YJGP GTTQT QEEWTTGF

&WTKPI UVGGTKPI QRGTCVKQP YJGP MPQD RQUKVKQP EQPVTQN HWPEVKQP KU KPUVCNNGF

&TKXG QRGTCVKQP 0QV QRGTCVG (QTYCTF 4GXGTUG

)Q VQ

/GCUWTG TGUKUVCPEG QH WPNQCF UQNGPQKF 0QTOCN = วก VQ วก CV q % q ( #DPQTOCN

4GRNCEG 8%/

4GRNCEG WPNQCF UQNGPQKF

%JGEM EQPVKPWKV[ DGVYGGP VTCPUOKUUKQP UGEVKQP CPF WPNQCF UGEVKQP $GVYGGP 8%/ %0 CPF 8%/ %0 %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG 8%/

%JGEM EQPVKPWKV[ DGVYGGP VTCPUOKUUKQP UGEVKQP CPF WPNQCF UGEVKQP $GVYGGP 8%/ %0 CPF 8%/ %0 %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG 8%/ 500536E

4-110

CHAPTER 4 CONTROLLERS

VCM-3

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

0.5B/L

242

0.5G/L

233

233 234 235

235

T/M SOL. F T/M GND T/M SOL. R

234

SR SOLENOID (F - R)

UNLOAD SOL UNLOAD RETURN

0.5Lg/R

211 411

0.5G/B

245

34 131 229 411

41 26

211

212 411

212

411

10 130

211 212

17 25

0.5Lg/R 0.5Br/B

Harness 9

0.5G/B

CN1

0.5Lg/R

EMERGENCY SW

211

212

(BLACK)

CN2

227 228 1

234 235 233

384

221 220

200 201 299 298 297 296

UNLOAD

10 18 26

500601

4-111

CHAPTER 4 CONTROLLERS 4.47 Transmission Forward Solenoid Error (F85) Error code: F85 Situation

"F85" flickering. Drive operations disabled; forward movement disabled or both forward and backward movement disabled.

Possible causes

Faulty VCM-3, faulty transmission forward solenoid, faulty harness

How the error code is triggered.

Current is 0.25A or less, or 3.84A or more, when transmission forward solenoid signal is output.

Checks

%JGEM EQPVKPWKV[ DGVYGGP 8%/ CPF VTCPUOKUUKQP HQTYCTF UQNGPQKF $GVYGGP 8%/ %0 CPF 5QNGPQKF ( $GVYGGP 8%/ %0 CPF 5QNGPQKF ( %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

/GCUWTG TGUKUVCPEG QH VTCPUOKUUKQP HQTYCTF UQNGPQKF $GVYGGP 5QNGPQKF ( CPF 5QNGPQKF ( 0QTOCN = วก VQ วก CV q % q ( ? #DPQTOCN

4GRNCEG 8%/

4GRNCEG VTCPUOKUUKQP HQTYCTF UQNGPQKF 500537E

4-112

CHAPTER 4 CONTROLLERS

VCM-3

T/M SOL. F T/M GND T/M SOL. R

233 234 235

0.5G/Y

0.5G/Y 0.5B/L

0.5B/L

0.5G/L 0.5B/L

234 242

235

233

0.5G/L

SR SOLENOID(F - R) CN2

227 228 1

234 235 233

384

221 220

200 201 299 298 297 296

10 18 26

500603

4-113

CHAPTER 4 CONTROLLERS 4.48 Transmission Backward Solenoid Error (F87) Error code: F87 Situation

"F87" flickering. Drive operations disabled; backward movement disabled or both forward and backward movements disabled.

Possible causes

Faulty VCM-3, faulty transmission backward solenoid, faulty harness

How the error code is triggered.

Current is 0.25A or less, or 3.84A or more, when transmission backward solenoid signal is output.

Checks

%JGEM EQPVKPWKV[ DGVYGGP 8%/ CPF VTCPUOKUUKQP DCEMYCTF UQNGPQKF $GVYGGP 8%/ %0 CPF 5QNGPQKF 4 $GVYGGP 8%/ %0 CPF 5QNGPQKF 4 %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

/GCUWTG TGUKUVCPEG QH VTCPUOKUUKQP HQTYCTF UQNGPQKF $GVYGGP 5QNGPQKF 4 CPF 5QNGPQKF 4 0QTOCN = วก VQ วก CV q % q ( ? #DPQTOCN

4GRNCEG 8%/

4GRNCEG VTCPUOKUUKQP DCEMYCTF UQNGPQKF 500538E

4-114

CHAPTER 4 CONTROLLERS

VCM-3

T/M SOL. F T/M GND T/M SOL. R

233 234 235

0.5G/Y

0.5G/Y 0.5B/L

0.5B/L

0.5G/L 0.5B/L

234 242

235

233

0.5G/L

SR SOLENOID(F - R) CN2

227 228 1

234 235 233

384

221 220

200 201 299 298 297 296

10 18 26

500603

4-115

CHAPTER 4 CONTROLLERS 4.49 Transmission Solenoid Leak (F89) Error code: F89 Situation

"F89" flickering. Drive and hydraulic operations disabled.

Possible causes

Faulty VCM-3, faulty relevant solenoid, faulty harness

How the error code is triggered.

Current is 0.18A or more when transmission solenoid is in neutral position.

Checks

%JGEM J[FTCWNKE QRGTCVKQPU YJGP GTTQT QEEWTTGF

0QV QRGTCVG

&WTKPI J[FTCWNKE QRGTCVKQP

)Q VQ

/GCUWTG TGUKUVCPEG QH VTCPUOKUUKQP HQTYCTF DCEMYCTF UQNGPQKF 0QTOCN = วก VQ วก CV q % q ( ? #DPQTOCN

4GRNCEG 8%/

4GRNCEG HCWNV[ UQNGPQKF

%JGEM EQPVKPWKV[ DGVYGGP WPNQCF UGEVKQP CPF VTCPUOKUUKQP UGEVKQP $GVYGGP 8%/ %0 CPF 8%/ %0 %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU 1T TGRNCEG JCTPGUU

4GRNCEG 8%/ 500539E

4-116

CHAPTER 4 CONTROLLERS

VCM-3

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

0.5B/L

242

0.5G/L

233

233 234 235

235

T/M SOL. F T/M GND T/M SOL. R

234

SR SOLENOID (F - R)

UNLOAD SOL UNLOAD RETURN

0.5Lg/R

211 411

0.5G/B

245

34 131 229 411

41 26

211

212 411

212

411

10 130

211 212

17 25

0.5Lg/R 0.5Br/B

Harness 9

0.5G/B

CN1

0.5Lg/R

EMERGENCY SW

211

212

(BLACK)

CN2

227 228 1

234 235 233

384

221 220

200 201 299 298 297 296

UNLOAD

10 18 26

500601

4-117

CHAPTER 4 CONTROLLERS 4.50 VCM3-OP Memory Check Error (F91) Error code: F91 Situation

"F91" flickering. Driving speed change control disabled.

Possible causes

Faulty VCM3-OP, faulty truck model setting data in VCM3-OP

How the error code is triggered.

Software checks sum value of ROM and EEPROM (memory setting value) in CPU, and detects fault.

Checks

&KHFN WUXFN W\SH VHWWLQJ GDWD 1RUPDO $EQRUPDO

(QWHU WUXFN W\SH VHWWLQJ GDWD DJDLQ 6HW VKLSPHQW GHIDXOW YDOXH LQWR 9&0 23 1RUPDO $EQRUPDO

3HUIRUP VWDQGDUG VHWWLQJ WKHQ HQWHU WUXFN W\SH VHWWLQJ GDWD DJDLQ

:ULWH XSGDWHG VRIWZDUH LQWR 9&0 23 1RUPDO $EQRUPDO

)DXOW\ VRIWZDUH ZULWLQJ

5HSODFH 9&0 23 500540E

4-118

CHAPTER 4 CONTROLLERS

1) 1)

CN1 1 10 18 42 26 43

CN2 9

17 135 25

250 252

257 136

281 279

17 258 25

253 273 254

18 292 293 294 295 205 204

1) - 1) 500568

4-119

CHAPTER 4 CONTROLLERS 4.51 VCM3-OP Battery Voltage Error (F92) Error code: F92 Situation

"F92" flickering. Tilt horizontal control and speed change control disabled.

Possible causes

Poor battery charge, faulty battery, faulty VCM3-OP, faulty harness, or faulty DC-DC converter

How the error code is triggered.

When VCM3-OP input voltage is 7V or less or 21V or more.

Checks

/GCUWTG DCVVGT[ VGTOKPCN XQNVCIG 0QTOCN 8 8 â&#x20AC;« Þ&#x201C;â&#x20AC;¬8 QT NGUUâ&#x20AC;« Þ&#x201C; Þ&#x201C;Þ&#x201C;Þ&#x201C;Þ&#x201C;Þ&#x201C;Þ&#x201C;â&#x20AC;¬8 QT OQTG

%JCTIG DCVVGT[

'TTQT TGOCKPU

4GRNCEG DCVVGT[

/GCUWTG QWVRWV XQNVCIG CPF KPRWV XQNVCIG QH &% &% EQPXGTVGT 1WVRWV XQNVCIG $GVYGGP &% &% %QPXGTVGT 8 CPF &% &% EQPXGTVGT )0& 8 +PRWV XQNVCIG $GVYGGP &% &% %QPXGTVGT 8 CPF &% &% EQPXGTVGT )0& 8 0QTOCN +PRWV XQNVCIG CDPQTOCN 1WVRWV XQNVCIG CDPQTOCN

4GRNCEG JCTPGUU

4GRNCEG &% &% EQPXGTVGT

/GCUWTG KPRWV XQNVCIG QH 8%/ 12 $GVYGGP 8%/ 12 %0 CPF 8%/ 12 %0 8 $GVYGGP 8%/ 12 %0 CPF 8%/ 12 %0 8 8 QT NGUU 8 VQ 8

4GRNCEG JCTPGUU

4GRNCEG 8%/ 12 500541E

4-120

CHAPTER 4 CONTROLLERS

DC-DC CONVERTER

VCM3-OP GND2 GND1 P.SOURCE2 P.SOURCE1

CN1 136 135 43 42

0.5B/L

1.25B/L

0.5B/L

0.5R/Y

1.25B

0.5R/Y

F7 8 1

CN1

1.25R/W

12V GND 12V MAIN 24V GND

24V BATT

10A

BATTERY

104 107 40

62 301

5 㧙

105

1 10 42 18 43 26 100

9 252250 17 25 135 34 136 257

1.25R/W

107 40 104

㧗

㧙

BATTERY

㧗

500605

4-121

CHAPTER 4 CONTROLLERS 4.52 VCM3-OP Speed Change Solenoid 1 Error (F93) Error code: F93 Situation

"F93" flickering. Speed change control disabled (gear fixed and will not move to another gear).

Possible causes

Faulty VCM3-OP, faulty speed change solenoid 1, faulty harness

How the error code is triggered.

Current is 0.25A or less, or 3.84A or more, when speed change solenoid 1 signal is output.

Checks

%JGEM EQPVKPWKV[ DGVYGGP 8%/ 12 CPF URGGF EJCPIG UQNGPQKF $GVYGGP 8%/ 12 %0 CPF 5QNGPQKF 5* $GVYGGP 8%/ 12 %0 CPF 5QNGPQKF 5* %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

/GCUWTG TGUKUVCPEG QH URGGF EJCPIG UQNGPQKF $GVYGGP 5QNGPQKF 5* CPF 5QNGPQKF 5* 0QTOCN = วก VQ วก CV q % q ( #DPQTOCN

4GRNCEG 8%/ 12

4GRNCEG URGGF EJCPIG UQNGPQKF 500542E

4-122

CHAPTER 4 CONTROLLERS

VCM3-OP

CN2

SP SOL(SH) SP SOL (S1) SP SOL GND.

253 273 254

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

0.5R/Y 0.5G/Y

255

253

274

273

0.5R/Y 0.5G/Y

0.5G/Y

274

10 18 26

254

0.5R/Y

279 281

255

17 254 273 253 25 258 34 205 204 295 294 293 292

0.5B/W

CN2

246

SH SOLENOID (SPEED SELECT)

500606

4-123

CHAPTER 4 CONTROLLERS 4.53 VCM3-OP Speed Change Solenoid 2 Error (F94) Error code: F94 Situation

"F94" flickering. Speed change control disabled (gear fixed and will not move to another gear).

Possible causes

Faulty VCM3-OP, faulty speed change solenoid 2, faulty harness

How the error code is triggered.

Current is 0.25A or less, or 3.84A or more, when speed change solenoid 2 signal is output.

Checks

%JGEM EQPVKPWKV[ DGVYGGP 8%/ 12 CPF URGGF EJCPIG UQNGPQKF $GVYGGP 8%/ 12 %0 CPF 5QNGPQKF 5 $GVYGGP 8%/ 12 %0 CPF 5QNGPQKF 5 %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG JCTPGUU

/GCUWTG TGUKUVCPEG QH URGGF EJCPIG UQNGPQKF $GVYGGP 5QNGPQKF 5 CPF 5QNGPQKF 5 0QTOCN = วก VQ วก CV q % q ( ? # DPQTOCN

4GRNCEG 8%/ 12

4GRNCEG URGGF EJCPIG UQNGPQKF 500543E

4-124

CHAPTER 4 CONTROLLERS

VCM3-OP

CN2

SP SOL(SH) SP SOL (S1) SP SOL GND.

253 273 254

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

0.5R/Y 0.5G/Y

255

253

274

273

0.5R/Y 0.5G/Y

0.5G/Y

274

10 18 26

254

0.5R/Y

279 281

255

17 254 273 253 25 258 34 205 204 295 294 293 292

0.5B/W

CN2

246

SH SOLENOID (SPEED SELECT)

500606

4-125

CHAPTER 4 CONTROLLERS 4.54 VCM3-OP Speed Change Solenoid Leak (F95) Error code: F95 Situation

"F95" flickering. EAT control function disabled (gear fixed and will not move to another gear)

Possible causes

Faulty VCM3-OP, faulty relevant solenoid, faulty harness

How the error code is triggered.

Output signal current is 0.18A or more when truck is driven at 3rd speed.

Checks

/GCUWTG TGUKUVCPEG QH URGGF EJCPIG UQNGPQKF CPF 0QTOCN = วก VQ วก CV q % q ( ? #DPQTOCN

4GRNCEG HCWNV[ UQNGPQKF

%JGEM EQPVKPWKV[ DGVYGGP RQYGT UQWTEG 8 CPF URGGF EJCPIG UGEVKQP $GVYGGP 8%/ 12 %0 CPF 8%/ 12 %0 $GVYGGP 8%/ 12 %0 CPF 8%/ 12 %0 %QPVKPWKV[ 5GXGTCN วก QT NGUU 0Q EQPVKPWKV[ 5GXGTCN /วก

+PUWNCVG YKTGU KP JCTPGUU QT TGRNCEG JCTPGUU

4GRNCEG 8%/ 12 500544E

4-126

CHAPTER 4 CONTROLLERS

DC-DC CONVERTER

VCM3-OP

CN1 136 135 43 42

GND2 GND1 P.SOURCE2 P.SOURCE1

0.5B/L

1.25B/L

0.5B/L

0.5R/Y

12V GND 12V MAIN

0.5R/Y

CN2

SP SOL(SH) SP SOL (S1) SP SOL GND.

107 40

253 273 254

104 107 40

62 301

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

0.5R/Y 0.5G/Y

255

253

274

273

0.5R/Y 0.5G/Y

0.5G/Y

274

205 204 295 294 293 292

10 18

254

0.5R/Y

279 281

255

17 254 273 253 25 258

0.5B/W

CN2

246

SOLENOID (SPEED SELECT) 500607

4-127

CHAPTER 4 CONTROLLERS 4.55 VCM3-OP Setting Error (F96) Error code: F96 Situation

"F96" flickering. Speed change control disabled (gear fixed and will not move to another gear).

Possible causes

Faulty VCM3-OP controller, faulty truck model setting data in VCM3-OP

How the error code is triggered.

1. When setting value of speed shift point is not in the following relations. 2-speed specification truck: (from 1st-speed to 2nd-speed) (from 2nd-speed to 1st-speed) 3-speed specification truck: (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 selection is in the following conditions. Mode selection value is out of setting range (0 to 3). Mode selecting patter is repeated. Both mode selector SWs are not set. 3. When setting data for speed change solenoid is in the following conditions. Speed change solenoid output value is out of setting range (0 to 3). Speed change solenoid output patter is repeated. Both speed change solenoids are not set.

Checks

&KHFN WUXFN W\SH VHWWLQJ GDWD 1RUPDO $EQRUPDO

(QWHU WUXFN W\SH VHWWLQJ GDWD DJDLQ

6HW VKLSPHQW GHIDXOW YDOXH LQWR 9&0 23 1RUPDO $EQRUPDO

3HUIRUP VWDQGDUG VHWWLQJ WKHQ HQWHU WUXFN W\SH VHWWLQJ GDWD DJDLQ

5HSODFH 9&0 23 500545E

4-128

CHAPTER 4 CONTROLLERS

1) 1)

CN1 1 10 18 42 26 43

CN2 9

17 135 25

250 252

257 136

281 279

17 258 25

253 273 254

18 292 293 294 295 205 204

1) - 1) 500568

4-129

CHAPTER 4 CONTROLLERS 4.56 VCM3-OP Communication Error (F97) Error code: F97 Situation

"F97" flickering. Speed change control disabled (current gear held).

Possible causes

Faulty VCM3-OP, faulty VCM-3, faulty harness

How the error code is triggered.

When CAN communication from VCM3-OP to VCM-3 is interrupted.

Checks

%JGEM EQPVKPWKV[ QH %#0 EQOOWPKECVKQP ECDNGU 8%/ VQ 8%/ 12 $GVYGGP 8%/ %0 CPF 8%/ 12 %0 CPF $GVYGGP 8%/ %0 CPF 8%/ 12 %0 %QPVKPWKV[ 0Q EQPVKPWKV[

4GRNCEG 8%/ 12

4GRNCEG JCTPGUU

'TTQT TGOCKPU 4GRNCEG 8%/ 500546E

CN2

VCM3-OP

CN2

VCM-3

279 281

17 254 273 253 25 258 34 205 204 295 294 293 292

CN2

1 10 18 26

0.5L/R

CAN H 201 0.5B/W CAN L 200

0.5B/W 0.5L/R

204 205

CAN L CAN H

CN2 9 17 25 34

227228 1 221 220 234 235 233 384 200 201 299 298 297 296

10 18 26

500608

4-130

CHAPTER 5 TILTABLE SYSTEM

Chapter 5 TILTABLE SYSTEM 1.

Specifications Truck model

Hand pump

Tiltable cylinder

Hydraulic latch

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Maker / model

Power-Packer / DHP2-100417

Relief pressure

30.0 MPa (306 kgf/cm2) [4351 psi]

Discharge volume per one stroke

4 cm3 (0.001 U.S. gal.) Â±10%

Reservoir capacity

480 cm3 (0.13 U.S. gal.)

Control valve type

4 way / 2 POS

Maker / model Stroke Maker / model Latch working pressure

Power-Packer / DCD2-100416 330 mm (12.9921 in.) Power-Packer / KLH5000-01-98/3 (latch A) Power-Packer / KLH5000-01-99/3 (latch B) 1.38 to 2.07 MPa (14.1 to 21.1 kgf/cm2) [200 to 300 psi]

5-1

CHAPTER 5 TILTABLE SYSTEM

Structure

2.1

Outline

6 2) 1)

8 9

2 3

500057

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

Hand pump Pump lever connection Direction valve Pull cable Tiltable cylinder Stopper case Stopper pin Hydraulic latch A

9. 10. 11. 12. 1) 2) 3) 4)

Turn the direction valve clockwise then the hydraulic latch is released and the operator compartment rises to the maintenance position (50°). (The operator compartment tilt leftward seen from a truck rear position.) To raise the compartment to the full-open position (65°), operate the hand pump pulling the cable knob to release the stopper pin from the lock position. The full-open position is provided only for the dismounting of engine, transmission and torque converter.

Hydraulic latch B Cylinder bracket Pin A Pin B Full-lower position (0°) Partial stop position (25°) Maintenance position (50°) Full-open position (65°)

Turn the direction valve counterclockwise and operate the hand pump to lower the operator compartment to the partial stop position (25°). To lower the compartment to the full-lower position (0°), operate the hand pump pulling the cable knob to release the stopper pin from the lock position. The operator compartment is locked at the full-lower position with the hydraulic latch.

R CAUTION Tilt the mast fully forward to raise or lower the operator compartment, or the compartment will be damaged.

5-2

CHAPTER 5 TILTABLE SYSTEM 2.2

Hand Pump

6 2

7 1. 2. 3. 4.

Hand pump assembly Pump lever connection Direction valve Push port

500058

5. 6. 7.

Pull port Level plug (filler port) Electric pump (option) suction port

Direction pump and pumping 1) 2) 3)

To raise operator compartment To lower operator compartment Pumping to raise or lower the operator compartment

3) 2) 1) 500059

5-3

CHAPTER 5 TILTABLE SYSTEM 2.3

Tiltable Cylinder

500060

1. 2.

5-4

Tiltable cylinder assembly Push port

Pull port

CHAPTER 5 TILTABLE SYSTEM 2.4

Hydraulic Latch A and B

4 *1

*1 - *1 1. 2. 3.

Hydraulic latch assembly Latch Connector

500061

4. 5.

Connector (hydraulic latch A), Air bleeder (hydraulic latch B) Hydraulic pressure port

5-5

CHAPTER 5 TILTABLE SYSTEM

Filling Fluid

Lower the hand pump lever to fill the hydraulic fluid in the pump.

2 1)

1 1. Pump lever 2. Oil level

500062 1) 30 to 35 mm (1.18 to 1.37 in.)

Hydraulic fluid Hydraulic fluid ISO VG32

Bleeding Tiltable Cylinder

After repairing or replacing the cylinder and pipes, bleed air. (1) Support the operator compartment with a pillar at the full open position.

R CAUTION Secure the support paying attention for safety. (2) Attach the tiltable cylinder to the frame cylinder bracket and connect hydraulic hoses. (Retract the cylinder.) (3) Place the hand pump lever in a lowered position.

500458

5-6

CHAPTER 5 TILTABLE SYSTEM (4) Connect air bleeder tubes to the push and pull ports on the cylinder and to the hydraulic latch B. Place the other ends of the tubes in a drip pan. (Prepare a drip pan for the job.) (5) Turn the directional valve to the raise position. (6) Close the air bleeder on pull port. Open the air bleeders on push port and hydraulic latch B and operate the pump. Continue the pumping until air bubbles in the tube can not be seen and then close the air bleeder of hydraulic latch B. (7) Keep the push port air bleeder open for further bleeding of the cylinder.

2 500459

(8) Close the push port air bleeder after the cylinder rod is extended to the stroke end. (9) Turn the directional valve to the lower position. (10) Open the pull port air bleeder and continue pumping until the cylinder rod is retracted to the stroke end. Close the air bleeder after the rod is retracted to the stroke end. (11) Repeat the procedure (7) through (10) until no air bubble bleeds from the air bleeders. (12) Check the hydraulic pump fluid level. Add the fluid to the proper level if necessary. Note: Place the hand pump lever in a downward position.

1. Push port air bleeder 2. Pull port air bleeder 3. Hydraulic latch B air bleeder

(13) Extend the cylinder rod and connect the cylinder to the tiltable bracket of compartment. Then remove the support pillar. (14) Verify the movement of tiltable compartment. Note: -

During the bleeding job, check the hydraulic fluid level in the pump. Add the fluid if necessary. Place the operator compartment to the lowered position to check the hydraulic fluid level. Use ISO VG32 hydraulic fluid.

5-7

CHAPTER 5 TILTABLE SYSTEM

Hydraulic Circuit Schematic

5 4

500065

1. 2. 3.

Hand pump Tiltable cylinder Hydraulic latch A and B Item Relief pressure

Hand pump

Tiltable cylinder

5-8

4. 5.

Item

Value 30.0 MPa (306 kgf/ cm2) [4351 psi]

Discharge volume per 1 stroke

4 cm3 (0.001 U.S. gal.) Âą10%

Reservoir capacity

480 cm3 (0.13 U.S. gal.)

Stroke

Pull port Push port

330 mm (12.9921 in.)

Hydraulic latch A and B

Latch working pressure

Value 1.38 to 2.07 MPa (14.1 to 21.1 kgf/ cm2) [200 to 300 psi]

CHAPTER 5 TILTABLE SYSTEM

Service Data

6.1

Tiltable Cylinder

Ref.

Truck model

FD100NZ

FD135NZ

Standard value

20.1

+0.25 +0.0098 0 mm (0.791 0 in.)

Service limit value

20.1

+0.5 +0.0197 0 mm (0.791 0 in.)

Standard value

16.1

+0.25 +0.0098 0 mm (0.634 0 in.)

Service limit value

16.1

+0.5 +0.0197 0 mm (0.634 0 in.)

Pin A hole diameter

FD120NZ

Pin B hole diameter

FD150ANZ

500066

6.2

Cylinder bracket Truck model

FD100NZ Standard value

Pin A hole diameter Service limit value

FD120NZ 20

FD135NZ

FD150ANZ

+0.021 +0.0008 0 mm (0.79 0 in.)

+0.5 +0.0197 0 mm (0.79 0 in.)

500067

5-9

CHAPTER 5 TILTABLE SYSTEM 6.3

Pin A and B

Ref.

Truck model

FD100NZ Standard value

Pin A shaft diameter Service limit value Standard value

Pin B shaft diameter Service limit value

FD120NZ 0

FD135NZ

FD150ANZ

20 -0.021 mm (0.79 -0.0008 in.) 0

20 -0.5 mm (0.79 -0.0197 in.) 0

16 -0.018 mm (0.63 -0.0007 in.) 0

16 -0.5 mm (0.63 -0.0197 in.)

500068

5-10

CHAPTER 6 POWER TRAIN

Chapter 6 POWER TRAIN 1.

Specifications Truck model

FD100NZ

Model Torque converter

FD120NZ

FD135NZ

FD150ANZ

Three-element, 1-stage, 2-phase

Maker model

MN16

Stall torque ratio

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

Operation method

1st : 2.402 Forward Transmission

2nd : 1.010 3rd : 0.558

Gear ratio

1st : 2.402 Reverse

2nd : 1.010 3rd : 0.558

Reduction gear

Final drive

Differential

Front axle type Front axle suspension type

Gear type

Hypoid gear

Reduction ratio

5.571

Gear type

Planetary gear

Reduction ratio

4.167

Case type

Banjo

Gear type and number

Large

Straight bevel gear x 2

Small

Straight bevel gear x 2 Full-floating, tubular Rigid axle

6-1

CHAPTER 6 POWER TRAIN

Structure 12 17

7 8 18

14 15 1. 2. 3. 4. 5. 6. 7. 8. 9.

Engine Flywheel Torque converter Transmission Input shaft Forward clutch shaft Reverse clutch shaft 1st and 3rd speed clutch shaft Output shaft

9 10. 11. 12. 13. 14. 15. 16. 17. 18.

500196

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

The power transmission system, which serves to transmit power produced by the engine to the drive wheels, consists of the following devices: Ref.

Device

Description

Torque converter

The torque converter works as a clutch, and also increases the engine torque and transmits the torque to the transmission.

Transmission

This is a device to change and reverse the revolution from the engine and transmit the power to the universal joint.

Universal joint

This universal joint transmits the power from the transmission to the reduction differential.

Reduction differential

This devise reduces the speed and distributes the power to right and left drive wheels. When the right and left drive wheel speeds are different (on right/left turning), this device differentiate the speed of the two wheels to prevent the wheels from slipping.

Final drive

Final reduction device using planetary gears.

6-2

CHAPTER 6 POWER TRAIN

Reduction Ratio

(29)

(58) (54)

(18) (57)

(58)

(35) (34)

(58) (59)

(7)

(35) (24)

(46)

(58)

(39) (53)

(32)

(56)

500202

Note: Number of teeth is shown in the ( ).

Gear position

Forward

Reverse

Transmission

Reduction bevel gear

Final reduction

Total reduction ratio

1st speed

2.402 (35/34 x 58/58 x 58/58 x 56/24)

55.761

2nd speed

1.010 (35/34 x 53/54)

23.447

3rd speed

0.558 (35/34 x 58/58 x 58/58 x 32/59)

1st speed

2.402 (35/34 x 58/58 x 56/24)

2nd speed

1.010 (35/34 x 58/58 x 53/54)

23.447

3rd speed

0.558 (35/34 x 58/58 x 32/59)

12.954

5.571 (39/7)

4.167 (57/18+1)

12.954 55.761

PTO reduction ratio : 0.848

6-3

CHAPTER 6 POWER TRAIN

Removal and Installation of Engine and Transmission Unit

Remove the engine and the transmission as an assembly (one body).

4.1

Preparation

Removing battery cables Disconnect the body earth side of the battery cable. Draining oil and coolant Drain the engine oil, transmission oil and engine cooling water.

3 2

500076

1. 2.

Engine oil drain plug Transmission oil drain plug

Engine cooling water drain plug

R WARNING Obey the local rules and regulations for disposal of the oil and cooling water that has been drained. Removing residual pressure in pneumatic and hydraulic circuits (1) Open the drain cock of air tank and discharge air. (2) Operate the steering wheel and hydraulic system levers several times to the stroke ends to remove the residual pressure in the circuits. Tiltable operator compartment Raise the operator compartment to the full open position (65Â°).

6-4

CHAPTER 6 POWER TRAIN 4.2

Removing Covers and Engine Control Cables

3 1

500470

1. 2. 3.

Gas spring Engine cover Brake fluid reserve tank

4. 5. 6.

Cooling water reserve tank Middle cover Engine control cable

Suggestions for removal (1) Drain the brake fluid before removing the brake fluid reserve tank. (2) Drain the cooling water before removing the cooling water reserve tank. (3) Disconnect the engine control cables at the engine side, and round the cables below the operator compartment.

6-5

CHAPTER 6 POWER TRAIN 4.3

Removing Harnesses

Remove connectors and terminals.

1) 19

11 20

21 17 1 22

2 23

29 31

24 27

3) 16

13 14

15 28 500209

6-6

CHAPTER 6 POWER TRAIN 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Engine earth cable (frame side) Battery cable positive (+) side Harness A VCM-3 Relay Relay (a) Relay (b) Relay (c) Relay (12d) Engine thermo-unit VCM3-OP Fuel sensor Lining wear detection switch Horn Front combination lamp Harness B Engine stop solenoid Fuse

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 1) 2) 3)

Suggestions for removal Tack the disconnected harnesses to the main harness or the frame to prevent damage to them.

6-7

CHAPTER 6 POWER TRAIN 4.4

Disconnecting Pipes and Hoses

1 4 3 5

11 10

500303

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

Delivery hose of hydraulic pump Suction hose of hydraulic pump Inlet hose of intercooler Outlet hose of intercooler Upper hose of radiator Lower hose of radiator

Suggestions for removal (1) Disconnect the engine left side fuel hose. Keep other intermediate pipes and right side hoses as connected to the engine. (2) Disconnect the oil cooler hoses at transmission side and tack the hoses along the frame.

6-8

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

Exhaust pipe Air inlet hose Inlet hose of air compressor Outlet hose of air compressor Fuel hose Oil cooler hose

CHAPTER 6 POWER TRAIN 4.5

Preparation for Removal of Engine and Transmission Unit

Suggestions for the job (1) Prepare the crane or hoist that has capacity enough to lift the engine and transmission.

500203

Item Engine and transmission

Weight 900 kg (1984 lb)

(2) Attach a wire rope to the lifting eyes (2 places) on the engine. (3) Hitch a lever block to the transmission lifting eye (1 place) to adjust the wire length. (4) Lift a hoist to apply a little tension to wires.

6-9

CHAPTER 6 POWER TRAIN 4.6

Removing Engine and Transmission

6 4

500448

1. 2. 3.

Universal joint Propeller shaft Universal joint

Suggestions for removal (1) Disconnect the universal joint on the transmission side. (2) Remove the mountings of the engine and transmission assembly. Lift the assembly slowly with a hoist and check the center of gravity. If the center of gravity is being shifted, adjust it using the lever block. (3) Pay attention not to bump the engine and transmission assembly to the operator compartment when lifting up the assembly.

6-10

4. 5. 6.

Thrust rod (2 places) Cushion (2 places) Engine and transmission assembly

CHAPTER 6 POWER TRAIN

Installing Engine and Transmission

For installation, follow the removal sequence in reverse.

5.1

Suggestions for Installation

(1) Inspect the cushion rubber on engine and transmission mountings. If such defect as peeling or fatigue is found, replace with a new one. (2) When installing the engine and transmission assembly on the frame, position it on the mounting brackets while aligning the universal joint (front side) and the transmission output flange.

1 1. Output flange

500197

2. Universal joint

(3) Tighten the mounting bolts and nuts to the specified torque. Ref.

Tightening item

Tightening torque

Cushion rubber (upper side)

145 N·m (14.8 kgf·m) [107 lbf·ft]

Cushion rubber (lower side)

97 N·m (9.9 kgf·m) [72 lbf·ft]

Mounting bracket

60 N·m (6.1 kgf·m) [44 lbf·ft]

2 3 1) 2)

2 3

Engine side (Left and right side) Transmission right side

500198

Transmission left side

(4) Tighten the universal joint mounting bolt to the specified torque. Item Universal joint mounting bolt

Tightening torque 71±10 N·m (7.24±1.02 kgf·m) [52.37±7.38 lbf·ft]

(5) Replace the exhaust pipe gasket with a new one. (6) Connect electrical wirings, and before tightening the negative (-) terminal of the battery, check the connections of the electrical wiring to make sure that there is no error or miss connections.

6-11

CHAPTER 6 POWER TRAIN (7) Connect the engine control cables. - Adjust the control cable so that the injection pump lever is in the idling position when the accelerator pedal is free.

2) 1)

500304 1. Idling 2. Full throttle

Place the cable between pipes at the right front side of engine. Adjust the clip orientation to make the clearance between the pipe and cable to be 5 mm (0.20 in.) or more.

1) 19±5.0° 2) 21.5±5.0°

500373 1. Pipe 2. Cable

3. Clip

(8) Refill the engine oil, transmission oil and cooling water. Use antifreeze coolant of 30% concentration for the engine cooling water unless otherwise specified.

R CAUTION The manufacturer recommends the use of distilled water of deionized water to reduce the potential and severity of chemical insolubility. Acceptable water Water Content

Limit (ppm)

Chlorides (Cl)

50 ppm (maximum)

Sulfates (SO4)

50 ppm (maximum)

Total Hardness

80 mg/l

Total Solids

250 ppm (maximum)

6.0 to 8.0

ppm = parts par million

6-12

CHAPTER 6 POWER TRAIN (9) Bleed air from the fuel system. (Refer to the Operation and Maintenance Manual.) (10) After completing the tightening, start the engine to check the vibration. If there is too much vibration, tighten the mounting bolts further and verify that the vibration is reduced. (11) Make sure the safety around the truck, and verify the correct reassembly by performing the steering and handling operations. (12) Stop the engine and check the level of the oils and cooling water. Refill if required. (13) Check the transmission speeds and forward/reverse drive operation. Checking the transmission speeds and forward/ reverse drive operation.

R WARNING Because the front tires will rotate, provide a barrier around the lift truck to prevent the access of unauthorized people. (1) Tilt the mast fully backward, and place wood blocks under the outer mast. (2) Tilt the mast forward to raise the front wheels off the ground. (3) Place jack stands under the frame to support the truck. (4) Block the rear wheels. (5) Run the engine at low idling. Operate the transmission shift lever and check the direction of wheel rotation. (6) Operate the travel speed change switch to make sure the rotational speed of the front tires will change accordingly.

1 1. Wood block 1) Forward tilt

5.2

500201 2) Backward tilt

Capacity and Brand of Oils and Cooling Water

Refer to "CHAPTER 15 SERVICE DATA."

6-13

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

2. 2.1

Structure Torque converter

5 2

4 3

9 6 2)

500048

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

Pilot boss Flexible plate Drive cover Turbine assembly Stator Freewheel

7. 8. 9. 1) 2)

The pressurized oil in the torque converter flows to the outside of torque converter through the outlet port located inside of the stator shaft, then to the transmission lubrication system through the oil cooler. The oil flow created by the rotation of impeller rotates the turbine and input shaft. The freewheel, which is a kind of one-way clutch, allows the stator to rotate freely and the torque converter to work as a fluid coupling when the rotational speed of the engine and the input shaft are almost the same. The freewheel improves the efficiency of the torque converter in a high speed operation. Type

Model

3-element, 1-stage, 2-phase

MI16

7-2

Pump impeller Stator shaft Input shaft From oil pump To oil cooler

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 2.2

Transmission

10 9 2

4 1 8 2) 5

4) 5)

1) 3

500343

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

Flexible plate Torque converter assembly Input shaft Forward clutch shaft Reverse clutch shaft 1st/3rd speed clutch shaft PTO drive gear Output shaft

9. 10. 11. 1) 2) 3) 4) 5)

Pump idler Pump drive gear Pump case 1st speed 2nd speed 3rd speed Forward(F) Reverse(R)

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

7-3

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 2.3

Power Flow - Forward

Gear position

Gear engagement

Reduction ratio

1st speed

35/34x58/58x58/58x56/24

2.402

2nd speed

35/34x53/54

1.010

3rd speed

35/34x58/58x58/58x32/59

0.558

PTO

58/46x39/58

0.848

Forward 1st

Forward 2nd (39)

(58)

(54)

(35)

(58)

(34)

(24)

(35)

(46)

(58)

(56)

500548

Forward 3rd

(58) (35)

(58)

(34)

(59)

(58)

(32)

Note: Number of teeth is shown in the ( ).

7-4

500056

(53)

500549

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 2.4

Power Flow - Reverse

Gear position

Gear engagement

Reduction ratio

1st speed

35/34x58/58x56/24

2.402

2nd speed

35/34x58/58x53/54

1.010

3rd speed

35/34x58/58x32/59

0.558

PTO

58/46x39/58

0.848

Reverse 1st speed

Reverse 2nd speed (39)

(58) (58) (54)

(34)

(35) (24)

(58)

(46)

(58)

(35)

(58)

(56)

500550

(53)

500551

Reverse 3rd speed

(58)

(34)

(59)

(35)

(58) (32) 500063

Note: Number of teeth is shown in the ( ).

7-5

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 2.5

Control Valve

5 1 1. 2. 3.

2.6

500155

Accumulator valve Directional valve 1st speed valve

4. 5.

Main Regulator Valve

7 1. 2. 3. 4. 5.

7-6

Differential valve 2nd and 3rd speed valve

Bolt Cover O-ring Slug Spool

4 6. 7. 8. 9. 10.

3 2

Body Spring Drain port Main oil pressure port Torque converter inlet pressure port

500376

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 2.7

3-Speed Transmission Hydraulic Circuit

22 19 4

8 11 13

18 26

7 10 12 14

17 15

27 28

9 500398

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

Chassis area Oil cooler Torque converter Bypass orifice Oil filter Torque converter inlet relief valve Lubrication line Transmission oil reservoir Magnetic suction strainer 100 mesh C2 CF R C3 C1 Oil pump

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

Main regulator valve PM (Valve top marked "M") T/Cin (Valve top marked "T") Speed selector valve S2 (2nd/3rd speed) Last chance filter Main orifice Accumulator valve Differential valve Speed selector valve S1 (1st speed) Solenoid valve SR (direction selection) FR filter PS (Valve top is marked "S") Solenoid valve SF (direction selection) PD (Valve top is marked "D")

7-7

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Ref.

Part name

Bypass orifice

Torque converter inlet relief valve

Oil pump

Main regulator valve

Last chance filter

Main orifice

Accumulator valve

ø4 mm (0.16 in.) 0.15 to 0.69 MPa (1.53 to 7.04 kgf/cm2) [21.76 to 100.08 psi] 70 L/min [18.49 US gal/min] (at 2300 min-1) 0.88 to 1.08 MPa (9.0 to 11.0 kgf/cm2) [127.6 to 156.6 psi] 230 μ (Orifice: ø0.8 mm (0.032 in.)) ø1.8 mm (0.071 in.) Set pressure

0.3 MPa (3.06 kgf/cm2) [43.51 psi]

Closing pressure

0.34 MPa (3.47 kgf/cm2) [49.31 psi]

Opening pressure

0.71 MPa (7.24 kgf/cm2) [102.98 psi]

Final charge pressure

0.76 MPa (7.75 kgf/cm2) [110.23 psi]

Differential valve setting pressure

FR filter absolute filtration accuracy

7-8

Value

0.20 MPa (2.04 kgf/cm2) [29.01 psi] 95 μ

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 2.8

Automatic 3-Speed Shift Mechanism

Control system

2 3

1. 2. 3. 4. 5.

7 7

8 8 5

Output gear Transmission case Vehicle speed sensor VCM-3 Travel speed select switch

6. 7. 8. 1)

500547

VCM3-OP Forward solenoid Backward solenoid Travel speed solenoid 0.5 mm (0.020 in.)

7 10 4

8 3 1)

2 500462

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

Solenoid valve Vehicle speed sensor Power source Transmission shift lever VCM-3 VCM3-OP

7. 8. 9. 10. 1)

Travel speed select switch 1 (1st-speed/fixed gear) 2 (Automatic change between 1st and 2nd speeds) D (Automatic change between 3 speeds) To Meter panel

7-9

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Automatic 3-speed transmission system consists of the torque converter and 3-speed transmission. The speed control system consists of the vehicle 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. Thus, the travel speed can be changed depending on the working condition. Transmission signal table Forward Solenoid valve

Reverse

N 1

SF(F, R change )

OFF

SR(F, R change )

OFF

S1(1st speed )

OFF

S2 (2nd speed, 3rd speed )

OFF

2.9

Torque Converter Drive Control

6 9

3 8 2

4 1. 2. 3. 4. 5.

7-10

Transmission shift lever Control valve Solenoid valves (1st speed, 2nd/3rd speed) Solenoid valve (forward/reverse) VCM-3

500463

6. 7. 8. 9. 1)

VCM3-OP Inching pedal Cut-off switch Control relay To Meter panel

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

Removing Transmission

To remove the transmission assembly from the truck, remove it together with the engine. Refer to "Chapter 6 POWER LINE" for the procedure. (1) To separate the transmission from the engine, place the engine on a stable stand. Place wood blocks under the transmission to stabilize the transmission. (2) Remove the hydraulic gear pump from the transmission. (3) Hitch wire ropes to the transmission and support it with hoist. The transmission has lifting eyes, two on the differential side and one on the torque converter side. Hitch the wire ropes to these three point to lift. Use a lever block to lifting eye on the torque converter side to adjust the center of gravity. (4) Remove the flexible plate bolts through the access hole in the torque converter housing. (5) Lift the transmission and separate it from the engine.

3.1

500393

Removing Torque Converter

Slide out the torque converter assembly from the transmission stator shaft, PTO drive gear and input shaft, as the assembly is just inserted into the transmission. Note: Remove the drain plug of the torque converter and drain the remaining oil.

7-11

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

Installing Transmission

(1) Install torque converter into transmission. Make sure that the distance from the mating face of flexible plate to torque converter housing end is 25 mm [0.98 in.]. If the distance is more than 25 mm [0.98 in.], it indicates an improper engagement of the transmission stator shaft or the input shaft spline with the torque converter spline. Dismount and reinstall the torque converter. (2) Lift the transmission and couple it to the engine. (3) Check that the clearance between the flywheel and the flexible plate is somewhere from 0 to 1 mm (0 to 0.04 in.). (4) Tighten the flexible plate bolts to the flywheel through the access hole in the torque converter housing. Tighten the bolts evenly and progressively. To turn the torque converter, use a heavy-duty screwdriver through the access hole in the side face of the torque converter housing and apply it to the bolt. (5) Install the hydraulic gear pump to the transmission.

500394 1) Distance between the flexible plate mounting face and the torque converter housing end.

(6) Install the transmission harness. Connect the travel speed sensor at the connector side, and connect the torque converter thermo unit at the terminal. Connect the following wire color harness to each solenoid.

CHK

2 Ref. 1 2 3 4

7-12

Solenoid Travel speed solenoid Direction change solenoid

Harness wiring color S1

500374

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

5. 5.1

Disassembling Torque Converter Disassembly Sequence

5 6 7 7

1 2

4 1. 2. 3. 4.

5.2

Bolt, Spring washer, Plane washer Flexible plates, Pilot boss, O-ring, Bolt, Spring washer Bolt, Drive cover, Ball bearing, Drain plug, Seal washer Thrust washer, Turbine runner

500395

5. 6. 7.

Thrust washer, Thrust bearing Stator, Rollers, Hub, Springs, Spring caps, Thrust washers Ball bearing, O-ring, Pump boss, Pump impeller, Bolts, Toothed washers

Suggestions for Disassembly

To remove the stator assembly, slightly apply a force counterclockwise to the stator to prevent the rollers from falling, and pull the stator together with the hub by sliding the splines.

500396

7-13

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

Inspecting and Correcting Torque Converter

Pump impeller Check the pump impeller and make sure that the impeller is free of following defects. -

Cracks in pump impeller. Oil leak due to a loose pump boss bolt or a defective Oring. Wear of mating face on pump boss or oil seal. Wear of mating face on pump boss or seal ring.

2 1. O-ring 2. Oil seal

Stator Check the stator and make sure that the stator is free of following defects. -

7-14

Stator blade cracks or loose fitting with clutch cam. Flaws or wear of the clutch hub and cam. Distortion, wear or breakage of spring and spring cap. Scuff, distortion or wear of roller. Damage of clutch hub spline. Wear or damage of thrust washer.

1 3. Seal ring

500399

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Ref.

Item

Standard value

Service limit value

Outside diameter of clutch hub

67.951 to 67.97 mm (2.6752 to 2.6760 in.)

67.8 mm (2.669 in.)

Outside diameter of clutch roller

10.185 to 10.2 mm (0.4010 to 0.4016 in.)

10.1 mm (0.3976 in.)

Thickness of thrust washer

4.95 to 5 mm (0.1949 to 0.1969 in.)

4.8 mm (0.189 in.)

Thickness of thrust washer

3.95 to 4 mm (0.1555 to 0.1575 in.)

3.8 mm (0.150 in.)

Thickness of thrust washer

2.9 to 3 mm (0.114 to 0.118 in.)

2.8 mm (0.110 in.)

Thickness of thrust washer

4.9 to 5 mm (0.193 to 0.197 in.)

4.8 mm (0.189 in.)

Thickness of thrust washer

4.95 to 5 mm (0.195 to 0.197 in.)

4.8 mm (0.189 in.)

2 5

6 7

500400

Turbine runner Check the turbine runner and make sure that the turbine runner is free of following defects. -

Runner vane cracks. Loose fitting of turbine runner with turbine boss. Turbine boss spline damage.

7-15

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Pilot boss Check the pilot boss and make sure that the pilot boss is free of following defects. -

Wear or damage of pilot bearing.

500401

Item

Standard value

Diameter of portion in contact with flywheel

20 -0.020 mm -0.003 (0.7874 -0.008 in.)

Service limit value

-0.007

7-16

19.85 mm (0.7815 in.)

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

7. 7.1

Reassembling Torque Converter Reassembly Sequence

13 11

3 7

8 13

5 6

500402

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

Pump impeller Pump boss, O-ring, Bolts, Toothed washers Ball bearing Stator assembly Springs, Spring caps Rollers Hub

8. 9. 10. 11. 12.

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

7-17

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 7.2

Suggestions for Torque Converter Reassembly

Stator assembly

(1) Install the hub in the position as shown. (2) Put the spring and spring cap in the hole. Install the roller while pressing the spring cap with the roller. (3) After the eight rollers are installed, restore the hub to the center. (4) When the stator is reassembled, rotate the hub to verify for its one-way rotation.

500403

1. Hub 2. Spring

3. Spring cap 4. Rollers

Selection of spacer Measure the dimensions 1, 2 and 3 shown. Select a spacer which will fit to the space (Dimension 4) and insert it to the space.

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.)

Item

500404

Standard value 1

Standard dimension

26.4 mm (1.039 in.)

19 mm (0.748 in.)

0 0 4 -0.1 mm (0.158 -0.004 in.)

Flexible plate After installation of the flexible plate, measure face runout of the plate with a dial gauge, and adjust it if the measurement exceeds the service limit.

500405

Item

Standard value

Service limit value

Face runout of flexible plates (in a free state)

0.2 mm (0.008 in.)

0.5 mm (0.020 in.)

7-18

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

8. 8.1

Disassembling Transmission Disassembly Sequence of Control Valve and External Parts

12 14

8 16 8 500375

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

Breather Oil level gauge Oil pipe, Union bolt, Gasket Main regulator valve, Gasket, Bolts, Spring washers Oil pipe, O-rings, Bolts, Spring washers Control valve, Gasket, Bolts, Spring washers Oil pipe, Union bolt, Gasket Oil pipe, Union bolt, Gasket

9. 10. 11. 12. 13.

Oil filter Travel speed sensor, O-ring Thermo unit Drain plug, Gasket Suction pipe, O-rings, Bolts, Spring washers 14. Strainer, Cover, O-ring, Bolts, Spring washers 15. Bracket, Bolts, Spring washers 16. Bracket, Bolts, Spring washers

7-19

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 8.2

Disassembling Transmission Cover and Output, 1st/3rd Clutch, Forward Clutch, Reverse Clutch, and Input Shafts.

23 24

22 11

16 15

19 14

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

Servo case, O-ring, Bolts, Washers Servo case, O-ring, Bolts, Washers Servo case, O-ring, Bolts, Washers Transmission cover subassembly, Gasket, O-rings, Bolts, Washers 5. Oil seal 6. Ball bearing 7. Output gear (2nd speed) 8. Output gear (3rd speed) 9. Snap rings 10. Baffle plate, Bolts, Washers 11. 1st/3rd speed clutch shaft assembly 12. Forward cutch shaft assembly

7-20

1 ,2

3 500406

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Reverse clutch shaft assembly Baffle plate, Bolts, Washers Output shaft Travel speed sensor gear, Washers, Bolts Ball bearing Output gear (1st speed) Snap rings Lock nut Input gear Snap rings Input shaft, Ring seal Ball bearing

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 8.3

Suggestions for Transmission Disassembly

Removing transmission cover subassembly

Screw in the two special tool bolts evenly into the stator shaft jack bolt holes M10 X 1.25, and remove the stator shaft. Raise the cover by approx 25 mm [0.98 in.] to disengage the bearing fitting. Do not remove the plug installed on the cover.

500407

Ref. 1

Special tool name Bolt

Part name 67284-15400

Removing output gear (2nd speed, outside) Remove the output gear together with the ball bearing using a gear puller. Removing output shaft Install a sliding hammer to the thread M8x 1.25 at the end of output shaft, and remove the shaft together with the output gear, ball bearing and travel speed sensor gear.

2 1

3 500408 1. Sliding hammer 2. Output gear (1st speed)

3. Travel speed sensor gear

R CAUTION Be careful not to hit the travel speed sensor gear to other parts when removing the output shaft. It will be easily deformed. Removing ball bearing Place the output gear (1st speed) on a press bench and press the output shaft to remove the bearing together with the output gear (1st speed). Or using a gear puller, remove the bearing together with the gear.

1 500409 1. Press bench

7-21

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Removing lock nut Straighten the locking tab of lock nut, and remove the nut with a socket wrench and an impact wrench. Hold the spline on torque converter side with a pipe wrench to stop the shaft rotation. Or apply a bar to the input gear tooth to prevent the shaft from rotating counterclockwise.

7-22

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 8.4

Disassembly Sequence of Stator Shaft and Oil Pump

6 8

5 2

1 3 3

500415

1. 2. 3. 4. 5.

PTO cover, O-ring, Bolts, Spring washers Snap rings Pump drive gear, Seal rings Ball bearing Pump case, O-ring, Bolts, Spring washers 6. Pump plate, O-ring, Gasket 7. Internal gear 8. Pump drive gear 9. Ball bearing 10. Torque converter housing, Gasket, Flange bolts 11. Oil seal 12. Idler gear shaft

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.

Roller bearing PTO drive gear Ball bearing Ball bearing Stator shaft, Seal ring, Bolts, Spring washers Idler gear Roller bearing Roller bearing (outer race) Roller bearing (outer race) Roller bearing (outer race) Transmission case, Dowel pins

7-23

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 8.5

Suggestions for Oil Pump Disassembly

Removing Torque Converter Screw in the two special tool bolts evenly into the jack bolt holes M10 X 1.25 in the housing, and remove the housing. When the housing is approximately 18 mm (0.71 in.) raised, the PTO drive gear ball bearing will be disengaged. Then remove the housing with crane or hoist. Special tool name Bolt

Part number 67284-15400

Removing oil pump Remove the oil pump as a subassembly including pump case, pump plate, internal gear, pump gear and ball bearing. Removing idler shaft

2 1

Install the shaft puller, special tool (prepared by dealer), to the threaded hole M20 X 1.25 of the shaft. Screw in the sliding hammer used for the output shaft removal to the shaft puller, and remove the shaft.

500410 1. M8x1.25 2. M20x1.5

3. Idler gear shaft

Removing PTO dive gear Install a gear puller to the ball bearing. Place a plate at the end of stator shaft, and pull out the drive gear together with the two ball bearings.

500411 1. PTO drive gear

7-24

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Removing stator shaft Screw in the two special tool bolts evenly into the stator shaft jack bolt holes M10 X 1.25, and remove the stator shaft. Special tool name Bolt

Part number 67284-15400

Or place a metal piece and tap out. Roller bearing outer race Do not remove the roller bearing outer race installed in the transmission case, unless it is defective. Also maintain the roller bearing outer race of idler gear in the same way.

7-25

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 8.6

Disassembly Sequence of Forward Clutch Shaft Assembly

5 4 1

15 13

1513

11 10 11

8 10

11 500598

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

Seal ring Ball bearing Thrust washer Gear (2nd speed), Needle bearings Thrust washer Roller bearing Thrust washer Gear (forward), Needle bearings

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

Note: Do not remove the screw installed in the forward clutch shaft.

7-26

Thrust washer, Snap ring Snap ring, Pressure plate Friction plates, Mating plates Snap ring, Retainer Clutch springs Clutch piston, Piston seal Seal ring Forward clutch shaft

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 8.7

Suggestions for Disassembly of Forward Clutch Shaft Assembly

Removing ball bearing Install a gear puller to the 2nd speed gear, and pull out the gear together with the ball bearing and thrust washer. Removing roller bearing Install a gear puller to the forward drive gear, and pull out the gear together with the roller bearing and thrust washer. Disassembling forward clutch shaft Using the piston tool, special tool, or a press, compress the clutch spring and retainer, and remove the snap ring.

500413

Special tool name Piston tool

Part number 92267-00300

7-27

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 8.8

Disassembly Sequence of 1st/3rd Speed Clutch Shaft Assembly

5 4 1

15 13

13 15

11 10 11

8 10

11 500615

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

Seal ring Ball bearing Thrust washer Gear (3rd speed), Needle bearings Thrust washer Roller bearing Thrust washer Gear (1st speed), Needle bearings

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

Thrust washer Snap ring, Pressure plate Friction plates, Mating plates Snap ring, Retainer Clutch springs Clutch piston, Piston seal Seal ring 1st/3rd speed clutch shaft

Note: Do not remove the screw installed in the 1st/3rd speed clutch shaft.

8.9

Suggestions for Disassembly of 1st/3rd Clutch Shaft Assembly

The procedure to disassemble the 1st/3rd speed clutch is the same as that of the forward clutch shaft.

7-28

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 8.10 Disassembly Sequence of Reverser Clutch Shaft Assembly

11 13 1

8 7

8 500621

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

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

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

Friction plates, Mating plates Snap ring, Retainer Clutch springs Clutch piston, Piston seal Seal ring Reverse clutch shaft

Note: Do not remove the screw installed in the reverse clutch shaft.

8.11 Suggestions for Disassembly of Reverse Clutch Shaft Assembly The procedure to disassemble the reverse clutch is the same as that of the forward clutch shaft.

7-29

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

Inspecting and Correcting Transmission

Oil pump (1) Install the internal gear and pump gear to the pump case, and measure the top clearance. (2) Measure the side clearance between the gear and pump case with a dial gauge.

2 1

Ref.

Item

Standard value

Service limit value

Side clearance

0.040 to 0.078 mm (0.0016 to 0.0031 in.)

0.09 mm (0.0035 in.)

Top clearance

0.3 to 0.345 mm (0.0118 to 0.0136 in.)

0.35 mm (0.0138 in.)

Stator shaft Check the stator shaft and make sure that the stator shaft is free of following defects. -

Thread damage of spline Clutch passages clogged.

Friction plates and mating plates Check the friction plates and mating plates and make sure that they are free of following defects. -

Seizure, local contact, distortion and wear. Wear and damage of splines

Clutch drums of forward, reverse, and 1st/3rd speed clutches Check the shafts and clutch drums and make sure that they are free of following defects. -

7-30

Wear and damage of mating plate sliding surfaces. Wear and damage of clutch piston sliding surfaces.

500417

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Ref.

Item

Standard value

Service limit value

Thickness of mating plate

2.3 ± 0.07 mm (0.0906 ± 0.0028 in.)

2.1 mm (0.083 in.)

Thickness of friction plate

2.6 ± 0.1 mm (0.102 ± 0.004 in.)

2.2 mm (0.087 in.)

Backlash of friction plate and gear

0.1 ± 0.3 mm (0.0039 ± 0.0118 in.)

Width of piston seal ring

4 ± 0.5 mm (0.158 ± 0.020 in.)

3.5 mm (0.138 in.)

Width of piston seal ring groove

Clutch spring free length (k: Spring constant N/mm (kgf/mm) [lbf/in.])

Width of clutch piston seal ring

Width of clutch piston seal ring groove

+0.2

+0.008

4 +0.1 mm (0.158 +0.004 in.)

4.5 mm (0.177 in.)

68 ± 2 mm (2.68 ± 0.08 in.) k = 39.1 N/mm (3.99 kgf/mm) [223 lbf/in.]

65 mm (2.56 in.)

2.5 ± 0.05 mm (0.098 ± 0.0020 in.)

2.0 mm(0.079 in.)

+0.2

+0.008

2.5 +0.1 mm (0.098 +0.004 in.)

3.0 mm (0.118 in.)

7, 8

6 2 1

3 4

500418

7-31

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Forward, reverse, and 1st/3rd speed clutch shafts Check the shafts and make sure that they are free of following defects. -

Wear and damage of seal rings and sliding surfaces. Wear and damage of splines. Clutch passages clogged.

1, 2 3

500419

Ref. 1

Item Seal ring width of clutch shafts

Standard value

Service limit value

2.5 Âą 0.05 mm (0.098 Âą 0.0020 in.)

2.0 mm (0.079 in.)

+0.2

Seal ring groove width of clutch shafts

2.5 +0.1 mm +0.008 (0.098 +0.004 in.)

Inside diameter of sealing contact faces in servo cases

35 0 mm +0.0010 (1.378 0 in.)

3.0 mm (0.118 in.)

+0.025

Gears Check the gears and make sure that they are free of following defects. -

Wear and damage of teeth flank and splines. Wear and damage of siding surfaces of gear needle bearings.

Magnetic strainer assembly Disassemble and clean. Replace if damaged. Oil seals of transmission cover and torque converter housing Replace the oil seals with new ones.

7-32

35.2 mm (1.386 in.)

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

10. Reassembling Transmission 10.1 Reassembly Sequence of Forward Clutch Assembly (1st/3rd Clutch Shaft Assembly) (Reverse Clutch Shaft Assembly)

5 10 9 7

4 9 10 5 6 11

16 21

14 15

20 19 17 12 18

2 500624

Forward clutch shaft, 1st/3rd speed clutch shaft or Reverse clutch shaft 2. Seal rings, Piton seals 3. Clutch pistons 4. Clutch springs 5. Retainers 6. Snap rings 7. Mating plates 8. Friction plates 9. Pressure plates 10. Snap rings 11. Thrust washer

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

Needle bearings Gear (forward) Thrust washer Roller bearing Thrust washer Needle bearings Gear (2nd speed) Thrust washer Ball bearing Seal ring

Note: The reassembly sequence of the reverse clutch shaft and suggestions for the reassembly are the same as that of the forward clutch shaft, although the reverse clutch shaft does not have the seal ring side clutch.

7-33

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 10.2 Suggestions for Reassembly of Forward Clutch Assembly (1st/3rd Clutch Shaft Assembly) (Reverse Clutch Shaft Assembly) Installing clutch piston When inserting the clutch piston into the clutch drum, apply ATF (automatic transmission fluid) to the seal ring. Installing clutch spring Using the piston tool or a press, compress the clutch spring and retainer, and install the snap ring.

500413

Special tool name Piston tool

Part number 92267-00300

Assembling plates

Make sure that the position and number of the plates are correct. Apply ATF to assemble. When the friction plates are replaced, be sure to replace the mating plates at the same time.

500421 1. Friction plates

2. Mating plates

Installing thrust washer Install the thrust washers to the front and back of the gear with their oil grooves facing the gear.

500422

Testing clutch piston operation After the reassembly is completed, apply pressurized air of approx 690 kPa (7.04 kgf/cm2) [100.08 psi] to the oil hole to check for the piston smooth movement and air leak.

7-34

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 10.3 Reassembly Sequence of Stator Shaft and Oil Pump

12 18 19 14 13

17 20 3 9 8 2 10 4 6 7

11 500423

1. 2. 3. 4.

Transmission case, Dowel pins Roller bearing Idler gear Stator shaft, Seal ring, Bolts, Spring washers 5. Ball bearing 6. PTO drive gear 7. Ball bearing 8. Idler shaft 9. Roller bearing 10. Oil seal

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

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

Note: The dowel pins installed in the transmission case have not been removed. (Dowel pins are used to retain the pump case, torque converter housing, transmission cover subassembly and others.)

7-35

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 10.4 Suggestions for Stator Shaft and Oil Pump Reassembly Reassembling PTO drive gear Press in the ball bearing to the PTO drive gear, and tap in the gear to the stator shaft. Installing oil seal Replace the oil seals with new ones. Tap in the oil seal into the torque converter housing with the special tool installer before assembling.

2) 1)

1) ø98.5±0.1 mm (3.88±0.004 in.) 2) ø140 ± 0.2 mm (5.51±0.008 in.) 3) 13 mm (0.51 in.)

500424

4) 8 mm (0.31 in.) 5) 150 mm (5.90 in.) 6) ø40mm (1.57 in.)

Oil pump subassembly Assemble the pump case, internal gear, pump gear and pump plate together. Be sure to apply ATF to the internal gear and pump gear before assembling and install the O-ring without fail. Installing oil pump subassembly Be sure to install O-rings to the gasket and oil hole when installing the oil pump subassembly into the transmission case. Reassembling pump drive gear Install the ball bearing into the pump drive gear. Install two seal rings. Apply ATF and tap the pump drive gear into the transmission case. Align the pump gear splines to assemble. Installing ball bearing

When tapping the ball bearing, apply the pump drive gear pusher (to be made by the dealer) to prevent the pump drive gear from moving out. Or have someone press the gear with a copper bar or the like, to prevent the gear from moving out.

3) 2) 1)

5) 1) ø180 ± 0.2 (7.09±0.008)

5) ) 6 ) 7

500425

5) 10 mm (0.39 in.)

6) 8 mm (0.31 in.) 0 0 2) ø124.9 -0.12 mm (4.92-0.0047 in.) 7) 28 mm (1.10 in.)

3) ø40 ± 0.2 (1.57±0.008) 4) 2-ø3 (0.51)

7-36

8) 154±0.1 mm (6.06±0.004 in.)

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 10.5 Reassembly Sequence of Input Shaft, Forward Clutch, 1st/3rd Speed Clutch, Reverse Clutch, Output Shafts and Transmission Cover

1 25 17

6 8 19 26 27 4

23 22 21 20 14 16 9 15 10 11 12 13 500614

7-37

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Roller bearing (outer race) Roller bearing (outer race) Roller bearing (outer race) Ball bearing Input shaft Snap rings Input gear Lock nut Output shaft Snap rings Output gear (1st speed) Ball bearing Travel speed sensor gear, Spring washers, Bolts Snap rings Baffle plate, Bolts, Spring washers

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

Baffle plate, Bolts, Spring washers Forward cutch shaft assembly 1st/3rd speed clutch shaft assembly Reverse clutch shaft assembly Output gear (3rd speed) Output gear (2nd speed) Ball bearing Oil seal Transmission cover subassembly, Gasket, O-rings, Bolts, Spring washers 25. Servo case, O-ring, Bolts, Spring washers 26. Servo case, O-ring, Bolts, Spring washers 27. Servo case, O-ring, Bolts, Spring washers

10.6 Suggestions for Reassembly of Input Shaft, Forward Clutch, 1st/3rd Speed Clutch, Reverse Clutch, Output Shafts and Transmission Cover Input shaft Install the ball bearing to the input shaft, and install the input shaft to the transmission case. Tighten the lock nut to the specified torque. Bend the lock nut flange against the flat on the input shaft. When tightening the lock nut, hold the torque converter side of the shaft with a pipe wrench. Or apply a bar to the input gear tooth to prevent the shaft from rotating counterclockwise. Item

Standard value

Tightening torque for lock nut

389±38.9 N·m (39.67±3.97 kgf·m) [286.91±28.69 lbf·ft]

Output shaft Assemble the output shaft, snap ring, output gear, ball bearing and speed sensor gear as a sub-assembly. Then tap in the sub-assembly into the transmission case.

7-38

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Oil seal Replace the oil seals with new ones. Tap in the two oil seals with the installer (special tool). Place the main lips facing inside and apply grease to the lips.

500427

1) 2) 3)

9) 1) ø68.5±0.1 mm (2.697±0.004 in.) 2) ø94.5±0.1 mm (3.720±0.004 in.) 3) ø108±0.2 mm (4.25±0.008 in.) 4) 28 mm (1.10 in.) 5) 10 mm (0.39 in.)

5) 6)

4) 6) 7) 8) 9)

500428

1.5 mm (0.060 in.) ø40 mm (1.57 in.) C1 170 mm (6.69 in.)

Transmission cover Install lifting hooks to the jack bolt threads of transmission cover. Lift the cover with a hoist and install the cover. Place the gasket on the transmission case and place the Oring in the oil hole without fail.

500429

Servo case Apply ATF to the case inside and shaft seal ring. Install the O-ring to the servo case without fail.

7-39

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 10.7 Reassembly Sequence of Control Valve and External Parts

2 6 1

15 6 500430

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

7-40

Strainer, Cover, O-ring, Bolts, Spring washers Drain plug, Gasket Thermo unit Travel speed sensor, O-ring Suction pipe, O-rings, Bolts, Spring washers Oil pipe, Union bolt, Gasket Oil pipe, Union bolt, Gasket Oil filter

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

Control valve, Gasket, Bolts, Spring washers Oil pipe, O-rings, Bolts, Spring washers Main regulator valve, Gasket, Bolts, Spring washers Oil pipe, Union bolt, Gasket Oil level gauge Breather Bracket, Bolts, Spring washers Bracket, Bolts, Spring washers

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

11. Disassembling Control Valve 11.1 Disassembly Sequence

3 18

4 17

5 4 17 6

15 13

14 8 7 10

9 12 11 500431

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

Solenoid valve, O-ring Directional spring, Spring seat Directional valve Solenoid valve, O-ring 1st speed valve, Valve inner spring 2nd/3rd speed valve, Valve inner spring Snap ring, Plug, O-ring Inching dummy spool Snap ring, Plug, O-ring Differential valve spring, Differential valve

11. Plate, O-ring, Bolts, Spring washers 12. Accumulator piston, Accumulator valve springs (inner and outer) 13. Pin, Seat, O-ring 14. Filter, O-ring 15. Last chance filters (four pieces) 16. Roller bearing, Plug 17. Roller bearing, Plug 18. Plug, O-ring 19. Valve body, Gasket

R CAUTION Slowly loosen each bolt and solenoid valve so that the spring, spool, plunger and others do not suddenly fly off.

7-41

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

12. Inspecting and Correcting Control Valve -

Check oil holes of valve housing for clogging. Check the valves for wear or damage. Make sure the valve moves smoothly. Replace the oil seals with new ones. Replace the filters with new ones.

Ref.

Item

Standard value

Service limit value

1st speed, 2nd/3rd speed valves Free length of inner spring (k: Spring constant N/mm (kgf/mm) [lbf/in.])

36.5 mm (1.437 in.) k = 5.658 N/mm (0.58 kgf/mm) [32.31 lbf/in.]

35.5 mm (1.398 in.)

Differential Valve spring free length (k: Spring constant N/mm (kgf/mm) [lbf/in.])

59.5 mm (2.342 in.) k = 2.311 N/mm (0.24 kgf/mm) [13.20 lbf/in.]

57.5 mm (2.264 in.)

Accumulator valve Outer spring free length (k: Spring constant N/mm (kgf/mm) [lbf/in.])

125.5 mm (4.941 in.) k = 5.363 N/mm (0.55 kgf/mm) [30.62 lbf/in.]

123 mm (4.84 in.)

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

170.5 mm (6.713 in.) k = 4.129 N/mm (0.42 kgf/mm) [23.58 lbf/in.]

168 mm (6.61 in.)

Directional spring Free length (k: Spring constant N/mm (kgf/mm) [lbf/in.])

32.5 mm (1.279 in.) k = 4.23 N/mm (0.43 kgf/mm) [24.5 lbf/in.]

31.5 mm (1.240 in.)

500432

7-42

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

13. Reassembling Control Valve 13.1 Preparation Wash the oil passages of valve body thoroughly and make sure that they are not restricted.

13.2 Reassembly Sequence

17 18

5 13 12

11 10

15 9

15 14

6 2

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

Valve body Plug, Roller bearing Plug, Roller bearing Last chance filters (four pieces) Filter, O-ring Seat, O-ring, Pin Accumulator valve springs (inner and Accumulator piston Plate, O-ring, Bolts, Spring washers Differential valve, Differential valve spring

outer),

10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

500397

Plug, O-ring, Snap ring Inching dummy spool Plug, O-ring, Snap ring 1st speed valve, Valve inner spring 2nd/3rd speed valve, Valve inner spring Solenoid valve, O-rings (two pieces) Directional valve Spring seat, Directional spring Solenoid valve, O-rings (two pieces) Plug, O-ring

13.3 Suggestions for Control Valve Reassembly -

Replace the oil seals with new ones. Apply ATF to the valves and plungers before assembling.

7-43

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

14. Disassembling Main Regulator Valve 14.1 Disassembly Sequence

1 2

6 1. 2. 3. 4.

4 3

Cover, O-ring, Bolts, Spring washers Slug Main relief spool Spring

5. 6.

500433

Cover, O-ring, Bolts, Spring washers Body

R CAUTION Slowly loosen the cover bolts so that the slug, spool, spring and others do not suddenly fly off.

15. Inspecting and Correcting of Main Regulator Valve -

Check oil holes of valve body for clogging. Check the valves for wear or damage. Make sure the valve moves smoothly. Check the spring for damage or settling. Item

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

Standard value

Service limit value

112 mm (4.41 in.) k = 4.99 N/mm (0.51 kgf/mm) [28.49 lbf/in.]

109 mm (4.29 in.)

16. Reassembling Main Regulator Valve To reassemble, follow the disassembly sequence in reverse.

16.1 Suggestions for Reassembly Apply oil to the main relief spool, slug and others to assemble.

7-44

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

17. Adjustment 17.1 Adjusting Brake Pedal and Inching Pedal

(1) Set the inching pedal at an angle of 45° by adjusting the bolt and nut. (2) Set the height of the brake pedal equal to the height of the inching pedal by adjusting the bolt and nut. (3) Set the clearance between the inching pedal and the brake pedal to zero (0) by adjusting the bolt and nut.

5 4

6 2 3 500434 1. 2. 3. 4.

5. Nut 6. Nut 1) 45°±1.0° (Pedal set angle) 2) 22° (stroke)

Inching pedal Bolt Nut Bolt

5, 6 1. Inching pedal 2. Bolt 3. Nut

2, 3

500435

4. Brake pedal 5. Bolt 6. Nut

7-45

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION (4) Adjust the switch position so that the switch protrude by 1 mm (0.04 in.) from the end of the switch body.

1 2)

3) 4) 1. Cutoff point 0 0 1) 1 -0.3 mm (0.04 -0.012 in.)

(clearance) 2) 2 mm (0.08 in.) (ON)

7-46

3) 4 mm (0.16 in.) (OFF) 4) 6 mm (0.24 in.) (Stroke)

500436

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 17.2 Measuring Oil Pressure R WARNING Provide a barrier around the lift truck to prevent the access of unauthorized people, as the front wheels rotates during the oil pressure measurement. Close the operator compartment and measure the oil pressure. Extend the gauge kit with the extending hose to secure the job safety. Note: Adjust the pedals before measuring the oil pressure. Measuring main oil pressure (1) Connect a 2 MPa (20 kgf/cm2) [290 psi] oil pressure gauge to the oil pressure outlet of the regulator valve.

500437 1. Main oil pressure outlet (M) (G1/8)

Special tool name

Gauge kit (64309-17701)

Part number

Connector

64309-17733

Hose

64309-17722

Connector

64309-17731

Gauge

64309-17713

(2) After idling operation, stop the engine and measure the oil level after the elapse of a certain period of time (3 to 5 minutes) to make sure that the oil level is within the specified range. (3) Warm up the engine to raise the transmission oil temperature. (4) Run the engine at an idling speed between 1000 to 1500 rpm. (5) Keep the condition above and measure the main oil pressure. Item Main oil pressure (at 1500Âą100 rpm engine performance)

Standard value 1.26 to 1.38 MPa (12.85 to 14.07kgf/cm2) [182.7 to 200.15 psi]

Note: Measure the idling speed with the service tool.

7-47

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Measuring direction clutch oil pressure (1) Connect a 2 MPa (20.4 kgf/cm2) [290 psi] oil pressure gauge to the direction clutch oil pressure outlet of the selector valve. Note: Use the same special tool used for the main oil pressure measurement. (2) Raise the front wheels off the ground by either of the following methods: - Jack up the front axle housing. - Tilt the mast fully backward. Place wood blocks under the outer mast. Tilt the mast forward to raise the front wheels off the ground. After the wheels are raised, place jack stands or wood blocks to support the frame and prevent it from falling. (3) Block the rear wheels. (4) Perform steps 2 to 4 of "Measuring Main Oil Pressure." (5) Place the direction lever to the forward position, and release the parking brake. (6) Release the inching pedal from the fully pressed position, and measure the direction clutch oil pressure. Item

Standard value

Direction clutch oil pressure (at 1500Âą100 rpm engine performance)

1.04 to 1.20 MPa (10.61 to 12.24 kg/cm2) [150.84 to 174.05 psi]

7-48

500438 1. Direction clutch oil pressure (PD) (G1/8)

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Measuring torque converter inlet oil pressure (1) Install a 0.6 MPa (6 kgf/cm2) [87 psi] oil pressure gauge to the torque converter inlet oil pressure outlet of the regulator valve.

500439 1. Torque converter inlet oil pressure (T) (G1/8)

Special tool name

Part number

Connector

64309-17733

Hose

64309-17722

Connector

64309-17731

Gauge

64309-17714

Gauge kit (64309-17701)

(2) After idling operation, stop the engine and measure the oil level after the elapse of a certain period of time (3 to 5 minutes) to make sure that the oil level is within the specified range. (3) Warm up the engine to raise the transmission oil temperature. (4) Keep the engine at an idling speed between 1000 to 1500 rpm, and measure the inlet oil pressure of torque converter. Item Torque converter inlet oil pressure (at 1500Âą100 rpm engine performance)

Standard value 0.54 to 0.70 MPa (5.51 to 7.14 kg/cm2) [78.3 to 101.53 psi]

Note: Measure the idling speed with an engine tachometer.

7-49

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 17.3 Measuring Stall Speed (1) After idling operation, stop the engine and measure the oil level after the elapse of a certain period of time (3 to 5 minutes) to make sure that the oil level is within the specified range. (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 an idling speed. (5) Place the direction lever in the forward position and press the brake pedal by left foot. Gradually press the accelerator pedal to the full position. In this condition, measure the stall speed with the engine tachometer. Item Stall speed

Standard value 1810Âą100 rpm

R CAUTION Do not press the inching pedal. Do not continue the stall condition for 30 seconds or longer. It can break the torque converter. (6) Also measure the stall speed with the direction lever placed in the reverse position. Note: -

The stall speed within the Âą100 rpm tolerance is satisfactory. The stall speed is determined by a combination of the engine and torque converter. Thus, if the engine or torque converter is changed, also the stall speed will change.

17.4 10 m (33 ft) Acceleration Test (1) Place the direction lever in the N position, speed select switch in the D position, and run the engine at idling. (2) At the starting signal, place the direction lever in the forward position and fully press the accelerator pedal. (3) Measure the time required for the truck to travel 10 m (33 ft) with a stop watch. (4) Measure the time for both forward and reverse travels. Item

Standard value

Time required (empty load)

5 seconds or less

7-50

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 17.5 Testing Automatic 3-Speed Transmission Functions Operate the travel speed select switch to verify the speed change. When switching the speed, be sure to stop the truck.

3) 2) 1) 1 1. Travel speed select switch 1) 1 (1st-speed/fixed gear)

500440 2) 2 (Automatic change between 1st and 2nd speeds) 3) D (Automatic change between 3 speeds)

7-51

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

18. Troubleshooting Situation

Engine

Torque converter

Power output is low.

Transmission

Body

7-52

Possible causes

Action

Engine power output decrease (compression pressure decrease, oil consumption increase, oil pressure decrease, difficult start-up, etc.)

Adjust the engine.

Poor engine performance.

Adjust the engine.

Oil level is too low.

Refill.

Air sucking from the inlet port.

Retighten or replace the pipe or gasket.

Spool action in main regulator valve is faulty.

Repair or replace.

Settling of main regulator valve spring.

Replace the spring.

Oil pump wear (insufficient or decreased Disassemble to check, or replace the discharge amount) defective part. Clogged magnet strainer

Replace magnet strainer.

Seal rings or O-rings are worn.

Replace after measuring oil pressure.

Stator wheel seizure.

Replace stator assembly, hub and roller.

Stator damaged or rubbing.

Repair or replace stator and replace bearing.

Air sucking from the inlet port.

Retighten or replace.

Outlet pressure is too low to suppress internal forming.

Adjust pressure.

Water is mixed with oil.

Change oil.

Oil level is too low.

Refill.

Clutch slipping due to a low main oil pressure.

Adjust pressure after measuring oil pressure.

Seal rings or O-rings are worn.

Replace after measuring oil pressure.

Clutch piston is damaged.

Replace piston.

Friction plates seizure or dragging.

Replace plates.

High mechanical resistance.

Check and/or adjust brake system.

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Situation

Torque converter

No power flow Transmission

Body

Possible causes

Action

Broken flexible plate.

Replace.

Oil level is too low.

Refill.

Oil pump drive is defective.

Replace.

Broken turbine shaft.

Replace.

Main pressure is too low.

Check pump gears for wear. If worn, replace.

Oil level is too low.

Refill.

Worn seal rings in servo case.

Replace.

Worn O-rings in input shaft.

Replace.

Leaks due to loose plug in input shaft.

Repair.

Clutch seizure.

Replace.

Broken shafts.

Replace.

Broken clutch drum (snap ring groove).

Replace.

Broken spring in clutch drum.

Replace.

Clutch piston oil passages are clogged.

Wash or replace.

Worn shaft splines.

Replace.

Broken power transmission system (reduction and differential, and front axle)

Refer to the relevant section of this manual.

7-53

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Situation

Torque converter

Transmission

Abnormal noise Loud noise

Low noise

Oil leak

Action

Broken flexible plate.

Replace.

Bearings are damaged.

Replace.

Stator rubbing.

Replace.

Loose bolts.

Retighten or replace bolts.

Worn splines.

Replace.

Worn oil pump.

Disassemble for inspection. If defective, replace.

Dragging noise due to seized clutch.

Replace clutch plate.

Bearing is worn or seized.

Replace.

Broken gears.

Replace.

Loose bolts.

Retighten or replace bolts.

Worn splines.

Replace.

Clogged oil strainer.

Wash or replace.

Main regulator valve spool malfunction

Wash or replace.

Restriction in oil pipe.

Replace.

High oil viscosity in cold weather.

Refer to "Fuel and Lubricant Specifications" and replace.

Instrument malfunction.

Replace.

Improper oil.

Refer to "Fuel and Lubricant Specifications" and replace.

Clogged oil strainer.

Wash or replace.

Oil pump malfunction

Replace.

Main regulator spring Excessive oil malfunction. leak. Main regulator valve spool malfunction

Replace the spring. Repair or replace spool.

Air sucking

Retighten or replace packing.

Oil level is too low.

Refill.

Leaking from oil seals.

Check lips and sliding surfaces for wear. Replace seals if worn.

Leaking from case joint.

Retighten or replace packing.

Leaking in pipes and joints.

Repair or replace pipes, gaskets and Orings.

Leaking from drain plug.

Retighten and replace gasket.

Leaking from cracks.

Replace.

Oil flowing-out from transmission case. Oil level is too high.

7-54

Possible causes

Water is mixed with oil.

Change oil.

Air sucking from joint of inlet port.

Retighten or replace packing.

Oil leaking from air breather.

Repair. Drain oil to the specified level.

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Situation

Torque converter

Oil temperature is too high. Transmission

Body

Possible causes Improper oil level.

Add or drain.

Clogged oil strainer.

Wash or replace.

Stator rubbing.

Correct or replace stator.

Stator malfunction.

Replace stator assembly.

Air sucking

Retighten or replace O-ring.

Water mixed in oil.

Change oil.

Restriction in oil pipe.

Repair or replace.

Bearing is worn or seized.

Repair or replace.

Instrument malfunction.

Replace.

Clutches are dragging.

Replace clutch plate.

Bearing is worn or seized.

Repair or replace.

Improper operation of lift truck.

Operate properly.

Body malfunction

Main oil pressure is too high.

Main oil pressure is too low.

Clutch oil pressure is too low.

Action

Damaged fan belt

Replace.

Clogged oil cooler

Wash or replace.

Brake is dragging.

Check and adjust.

Damaged main regulator valve

Repair or replace valve assembly.

Cold climate

Refer to "Fuel and Lubricant Specifications" and replace oil.

Improper oil

Refer to "Fuel and Lubricant Specifications" and replace oil.

Clogged magnet strainer

Wash or replace.

Oil pump malfunction

Replace.

Main regulator valve spring malfunction

Replace the spring.

Main regulator valve spool malfunction

Repair or replace spool.

Air sucking

Retighten or replace packing.

Oil level is too low.

Refill.

Clutch valve malfunction

Repair or replace.

Clogged magnet strainer

Wash or replace.

Oil pump malfunction (worn)

Replace.

Main regulator valve spring malfunction

Replace the spring.

Main regulator valve spool malfunction

Repair or replace spool.

Air sucking

Retighten or replace packing.

Oil level is too low.

Refill.

Clutch valve malfunction

Repair or replace.

Broken seal ring in servo case.

Replace.

Broken clutch seal ring.

Replace.

7-55

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION Situation

Stall speed does not meet the specification.

No automatic speed shifting

Transmission shifts up even when travel speed select switch is in "Fixed 1st speed" position.

7-56

Possible causes

Action

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

Adjust the engine.

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

Replace stator assembly.

Clutch slipping if stall speed is higher than specification.

Repair or replace.

Travel speed select switch in "Fixed 1st speed" position

Place switch in "2" or "D" position.

Solenoid valve malfunction.

Replace.

Clogged orifice in solenoid valve inlet.

Wash or replace.

Solenoid valve spool malfunction.

Repair or replace spool.

Solenoid valve spring malfunction.

Replace the spring.

ECU internal malfunction.

Replace switch.

Disconnected switch harness. Switch malfunction.

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION

19. Service Data 19.1 Stall Speed and Oil Pressure Truck model

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Stall speed

Standard value

1810±100 rpm

Main oil pressure, Speed clutch oil pressure (at 1500±100 rpm engine performance)

Standard value

1.26 to 1.38 MPa (12.85 to 14.07 kg/cm2) [182.75 to 200.15 psi]

Direction clutch oil pressure (at 1500±100 rpm engine performance)

Standard value

1.04 to 1.20 MPa (10.61 to 12.24 kg/cm2) [150.84 to 174.05 psi]

Torque converter inlet oil pressure (at 1500±100 rpm engine performance)

Standard value

0.54 to 0.70 MPa (5.51 to 7.14 kg/cm2) [78.32 to 101.53 psi]

Lubrication oil pressure (at 1500±100 rpm engine performance)

Standard value

0.12 to 0.19 MPa (1.22 to 1.94 kgf/cm2) [17.40 to 27.56 psi]

10 m acceleration (empty load)

Standard value

5 seconds or less

19.2 Pump Boss Truck model Oil seal contact surface (outside diameter)

FD100NZ Standard value Service limit value

FD120NZ

FD135NZ

FD150ANZ

100 -0.035 mm (3.94 -0.0014 in.) 99.85 mm (3.9311 in.)

500441

7-57

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 19.3 Pilot Boss Truck model Diameter of portion in contact with flywheel

FD100NZ

FD120NZ -0.007

Standard value

FD135NZ

FD150ANZ

-0.0003

20.0 -0.020 mm (0.787 -0.0008 in.)

Service limit value

19.85 mm (0.7815 in.)

500442

19.4 Oil Pump Ref.

Truck model

Side clearance

Top clearance

FD100NZ Standard value

FD120NZ

FD135NZ

FD150ANZ

0.040 to 0.078 mm (0.0016 to 0.0031 in.)

Service limit value

0.09 mm (0.0035 in.)

Standard value

0.3 to 0.345 mm (0.012 to 0.0136 in.)

Service limit value

0.35 mm (0.0138 in.)

2 1 500443

7-58

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 19.5 Stator Ref.

Truck model

Outside diameter of clutch hub

Outside diameter of clutch roller

Thickness of thrust washer

FD100NZ Standard value

Standard value

FD150ANZ

67.8 mm (2.669 in.) 10.185 to 10.2 mm (0.4010 to 0.402 in.)

Service limit value Standard value

10.1 mm (0.398 in.) 4.95 to 5 mm (0.1949 to 0.20 in.)

Service limit value Standard value

4.8 mm (0.189 in.) 3.95 to 4 mm (0.1555 to 0.16 in.)

Service limit value Standard value

3.8 mm (0.150 in.) 2.9 to 3 mm (0.114 to 0.12 in.)

Service limit value Standard value

2.8 mm (0.110 in.) 4.9 to 5 mm (0.193 to 0.20 in.)

Service limit value Standard value

4.8 mm (0.189 in.) 4.95 to 5 mm (0.1949 to 0.20 in.)

Service limit value

FD135NZ

67.951 to 67.97 mm (2.6752 to 2.6760 in.)

Service limit value

FD120NZ

4.8 mm (0.189 in.)

1 2 5 6 7

500444

7-59

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 19.6 Flexible Plate Ref.

Truck model

Flexible plate face runout (in free state)

Distance between end face of transmission case and mating face of flexible plate

FD100NZ

FD120NZ

FD135NZ

Standard value

0.2 mm (0.008 in.)

Service limit value

0.5 mm (0.020 in.)

Standard value

14.5 mm (0.571 in.)

FD150ANZ

1 500446

7-60

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 19.7 Clutch Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

2.3±0.07 mm (0.091±0.0028 in.)

Thickness of mating plate Interchangeable

Standard value

Thickness of friction plate Interchangeable

Standard value

Backlash of friction plate and gear

Standard value

0.1 to 0.3 mm (0.004 to 0.012 in.)

Width of piston seal ring

Standard value

4±0.05 mm (0.16±0.0020 in.)

Width of piston seal ring groove

Service limit value

2.1 mm (0.083 in.) 2.6±0.1 mm (0.102±0.004 in.)

Service limit value

2.2 mm (0.087 in.)

Service limit value

3.5 mm (0.138 in.) +0.2 +0.008 4 +0.1 mm (0.16 +0.004 in.)

Standard value Service limit value

Clutch spring free length k: Spring constant N/mm (kgf/mm) [lbf/in.]

4.5 mm (0.177 in.) 68±2 mm (2.68±0.08 in.) k = 39.1 N/mm (3.99 kgf/mm) [233 lbf/in.]

Standard value Service limit value

6 2 1

FD150ANZ

65 mm (2.56 in.)

3 4

500445

7-61

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 19.8 Input Shaft, Forward, Reverse, and 1st/ 3rd Speed Clutch Shafts, and Servo Case Ref. 1

Truck model

FD100NZ

Service limit value

Seal ring groove width of clutch shafts Inside diameter of servo case contacting with clutch shaft seal rings

FD135NZ

2.0 mm (0.079 in.) -0.2 -0.008 2.5 -0.1 mm (0.098 -0.004 in.)

Standard value Service limit value

3.0 mm (0.118 in.) +0.025 +0.0010 35 0 mm (1.38 0 in.)

Standard value Service limit value

35.2 mm (1.386 in.)

Standard value Inside diameter of stator shaft contacting with input shaft seal ring Service limit value

+0.025 +0.0010 0 mm (1.38 0 in.)

35.2 mm (1.386 in.) 2.5±0.05 mm (0.098±0.0020 in.)

Seal ring width of each shaft clutch piston

Standard value

Seal ring groove width of each shaft clutch piston

Standard value

Seal ring width

Standard value

2.4 -0.1 mm (0.094 -0.004 in.)

Seal ring groove width

Standard value

2.5

Tightening torque for lock nut

Standard value

Service limit value

2.0 mm (0.079 in.) -0.2

-0.008

2.5 -0.1 mm (0.098 -0.004 in.)

Service limit value

1, 2

FD150ANZ

2.5±0.05 mm (0.098±0.0020 in.)

Standard value

Seal ring width of clutch shafts

FD120NZ

3.0 mm (0.118 in.) 0

-0.1 -0.004 0 mm (0.098 0 in.)

294 to 392 N·m (29.98 to 39.97 kgf·m) [216.84 to 289.12 lbf·ft]

5, 6

7, 8

500447

7-62

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 19.9 Backlash of Gears Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Input gear and forward/reverse gears

Standard value

0.12 to 0.28 mm (0.0047 to 0.0110 in.)

Forward and reverse gears, 1st/3rd speed gear Standard value

0.14 to 0.32 mm (0.0055 to 0.0126 in.)

2nd speed gear and output gear

Standard value

0.12 to 0.28 mm (0.0047 to 0.0110 in.)

1st speed gear and output gear

Standard value

0.13 to 0.30 mm (0.0051 to 0.0118 in.)

3rd speed gear and output gear

Standard value

0.13 to 0.30 mm (0.0051 to 0.0118 in.)

Pump drive gear and idler gear

Standard value

0.12 to 0.26 mm (0.0047 to 0.0102 in.)

PTO drive gear and idler gear

Standard value

0.12 to 0.26 mm (0.0047 to 0.0102 in.)

2 3

3 5 3)

500625

1) 2)

1st speed 2nd speed

3rd speed

7-63

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 19.10 Control Valve Ref.

Truck model Free length of 1st speed, and 2nd/ 3rd speed valve inner springs k: Spring constant N/mm (kgf/mm) [lbf/in.] Free length of differential valve spring k: Spring constant N/mm (kgf/mm) [lbf/in.] Free length of accumulator valve outer spring k: Spring constant N/mm (kgf/mm) [lbf/in.] Free length of accumulator valve inner spring k: Spring constant N/mm (kgf/mm) [lbf/in.] Free length of direction valve spring k: Spring constant N/mm (kgf/mm) [lbf/in.]

FD100NZ Standard value Service limit value Standard value Service limit value Standard value Service limit value Standard value Service limit value Standard value Service limit value

FD120NZ

FD135NZ

FD150ANZ

36.5 mm (1.437 in.) k = 5.658 N/mm (0.58 kgf/mm) [32.31 lbf/in.] 35.5 mm (1.398 in.) 59.5 mm (2.342 in. ) k = 2.311 N/mm (0.24 kgf/mm) [13.20 lbf/in.] 57.5 mm (2.264 in.) 125.5 mm (4.941 in.) k = 5.363 N/mm (0.55 kgf/mm) [30.62 lbf/in.] 123 mm (4.84 in.) 170.5 mm (6.713 in.) k = 4.129 N/mm (0.42 kgf/mm) [23.58 lbf/in.] 168 mm (6.61 in.) 32.5 mm (1.279 in.) k = 4.23 N/mm (0.43 kgf/mm) [24.15 lbf/in.] 31.5 mm (1.240 in.)

5 1

3 500451

7-64

CHAPTER 7 3-SPEED POWERSHIFT TRANSMISSION 19.11 Main Regulator Valve Truck model

FD100NZ

Main regulator valve Standard value Free length of inner spring Spring constant: k = N/m (kgf/mm) [lbf/in.] Service limit value

FD120NZ

FD135NZ

FD150ANZ

112 mm (4.41 in.) k = 4.99 (0.51 kgf/mm) [28.49 lbf/in.] 109 mm (4.29 in.)

500452

19.12 Inching Pedal Control Truck model Inching pedal height (from frame to top end of pedal pad)

FD100NZ Standard value

FD120NZ

FD135NZ

FD150ANZ

178 mm (7.01 in.)

500453

7-65

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

Chapter 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 1.

Specifications Truck model

Reduction gear

Final drive

Differential

Front axle type Suspension system

FD100NZ

Gear type

FD120NZ

FD135NZ

Hypoid gear

Reduction ratio

5.571

Gear type

Planet gear

Reduction ratio

4.167

Case type

Banjo

Gear type and quantity

FD150ANZ

Large

Straight bevel gear x 2

Small

Straight bevel gear x 4 Full floating tube type Rigid axle

8-1

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

Structure

2.1

Outline

16 11

2 8

10 9

6 5

7 500305

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

Front axle housing Differential case Input flange Parking brake bracket Parking brake assembly Parking brake drum Reduction pinion Reduction gear

This front axle is a banjo-shaped full floating type mounted on the front of the truck frame, and the final drive system is a planetary gear type.

8-2

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

Differential pinion Differential gear Axle shaft Hub reduction Planetary gear Ring gear Front wheel hub Dry type wheel brake

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL Hub reduction

10 11

13 15

17 18 19 16 20

7 6 9

4 3

14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Front axle housing Axle shaft Sun gear Cover Planet carrier Planet pin Steel ball Roller bearing Planetary gear Ring gear

500306

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

Nut Lock plate Tapered roller bearing Front wheel hub Tapered roller bearing Oil seal retainer Oil seal Brake drum Oil deflector Dry type wheel brake

The front axle housing is equipped with a dry type wheel brake.

8-3

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 2.2

Reduction Differential

23 21

25 24

24 22

16 17

1 13 2

4 5 10

3 6

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

Differential carrier Shim Bearing retainer Tapered roller bearing Tapered roller bearing Parking brake bracket Oil seal Input flange Parking brake assembly Lever Parking brake drum Adjuster Reduction pinion

The reduction differential is a single reduction type consisting of a reduction pinion and a reduction gear. The parking brake drum is mounted to the reduction pinion through the input flange, and the parking brake assembly is mounted to the parking brake bracket.

8-4

8 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Self-locking nut Roller bearing Differential case Differential case Reduction gear Spider Differential pinion Differential gear Tapered roller bearing Bearing cap Side bearing nut Lock plate

500311

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

3. 3.1

Removing Front Wheels Preparation

(1) Loosen each outer wheel nut about two turns. (2) Block the rear wheels. (3) Raise the front wheels off the ground by either method below: Method using a jack Position the jack under the frame near the mounting portions of right and left front axle, and jack up the right and left evenly. Method using a crane Hitch a hoist to the mast, and lift the mast to raise the front end of the truck.

500312

R WARNING After raising the wheels with either of the methods, place jack stands under the frame to prevent the truck falling.

3.2

Removal Sequence

6 5 4 7

2 3 500313

1. 2. 3. 4.

Extension bracket Wheel nut Clamp Wedge band

5. 6. 7. 8.

Outer wheels (tires) Spacer Extension valve Inner wheels (tires)

8-5

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 3.3

Suggestions for Removal

Outer wheels (tires) (1) Bring the extension valve to the top.

500314

R CAUTION Keep your face away from the tire, since the pressure is very high. (2) Attach a metal piece to the wedge band, and hit the metal piece to remove the wedge band. (3) Support the truck at the lower side of the outer tires either using a small forklift or applying the special tool tire hander there. Special tool Tire handler

Part number Banzai WD-5500 or equivalent

(4) Remove the wheel nuts to remove the outer wheels (tires). Inner wheels (tires) (1) Support the inner wheels (tires) in the same way as for the outer tires. (2) Remove the spacer. (3) Pull the inner wheels (tires) out to the end face of the brake hub, and disconnect the extension pipe from the air valve. (4) Remove the inner wheels (tires).

500315

8-6

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

Installing Front Wheels

For installation, follow the removal sequence in reverse.

4.1

Suggestions for Installation

Inner front wheels (tires) (1) Make sure that the air valve set groove of brake hub is aligned with the positioning boss on the rim. (2) After the inner front wheel is inserted all the way to the brake hub end face, mount the extension valve on the air valve. (3) After pressing-in the inner front wheel to the specified position, block the inner front wheel for fall prevention. Wheel nut

R CAUTION Tighten wheel nuts in the correct order by referring to the illustration on the right. (Numbers show the order of tightening.) Tighten wheel nuts to the specified torque evenly to prevent the wheel from wobbling.

6 9

-LE

VEL -

10 500316

Tightening torque 539.4±49 N·m (55.0±5.0 kgf·m) [397.83±36.14 lbf·ft] Retightening wheel nuts (1) Test-run the truck for about 10 minutes after completing the service work and check forward/reverse travel and braking. (2) Using a torque wrench, retighten all the wheel nuts to the specified torque.

8-7

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

5. 5.1

Removing Front Axle and Reduction Differential Preparation

(1) Block the rear wheels. (2) Remove the mast assembly by referring to the chapter "13 MASTS AND FORKS." (3) Remove the front wheels, referring to the section "Removing front wheels." (4) Place jack stands under the frame to prevent the truck from falling. (5) Drain the front axle oil as instructed below. Place drip pans large enough to catch oil beneath drain ports. Remove the drain plugs of the axle housing and wheel hub covers. To drain oil from the wheel hub cover, turn the wheel to bring a plug at the bottom, remove the plug, and remove the other plug of the wheel cover for air breathing.

500317

Capacity Approx 25 L (6.6 U.S. gal.)

8-8

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 5.2

Removal Sequence

4 1

500319

1. 2.

Wheel brake pipe Parking brake cable

3. 4.

Universal joint Front axle

8-9

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 5.3

Suggestions for Removal

Wheel brake pipes (right and left) After the wheel brake pipes are disconnected, cover the openings of the wheel cylinder and pipes to prevent dirt from getting inside them. Universal joint

(1) Fasten the universal joint to the transmission body with a rope, etc. Note: If the universal joint comes off from the transmission body, the transmission oil will flow out.

500320 1. Transmission

1) Disconnect here.

(2) Disconnect the universal joint at the input flange side of the reduction differential. Front axle (1) Use a forklift truck and firmly secure the lower part of the front axle with the right and left fork blades. Maximum load of forklift truck 1350 kg (2976 lb) As the differential is not located at the center of the right to left span of the front axle, firmly secure it for falling prevention upon removal. (2) Remove the mounting bolts, and operate the forklift truck to remove the front axle. If a forklift truck is not available, remove as instructed below. - Remove the mast assembly. (Refer to "13 MASTS AND FORKS.") - Always apply some protective cloth before hitching a hoist to and lifting the mast support bearings of the axle housing with a chain or wire rope. - Remove mounting bolts, and remove the front axle by lifting.

8-10

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

Installing Front Axle and Reduction Differential

For installation, follow the removal procedure in reverse.

6.1

Suggestions for Installation

Tightening torque Tighten the mounting bolts of the following parts to each specified torque. Item

Tightening torque

Front axle

640±96 N·m (65.26±9.79 kgf·m) [472.03±70.80 lbf·ft]

Universal joint

61 to 81 N·m (6.22 to 8.26 kgf·m) [44.99 to 59.74 lbf·ft]

Parking brake lever operating effort After installing the parking brake wire, make sure that the operating effort of the parking brake lever is within the range of standard values. Item

Standard value

Parking brake lever operating effort

245 to 294 N (24.98 to 29.98 kgf) [55.08 to 66.09 lbf]

Filling oil to the front axle (1) Position the level mark of either the right or left cover to be horizontal. (2) Remove the level plug located at the side of level mark. And remove the other plug. (3) Remove the oil supply hole plug and supply the gear oil through the hole.

500321

Recommended oil (API GL-5) Gear Oil SAE 90

Capacity Approx 25 L (6.6 U.S. gal.)

Bleeding brake fluid line When the assembly is completed, bleed air in the circuit, referring to the chapter "10 BRAKE SYSTEM." Also, check for oil leaks. Note: The air bleeding operation will be easier if it is performed before the front wheels and mast are installed.

8-11

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

Removing Reduction Differential

7.1

Preparation

(1) Remove the front wheels, referring to the section "Front Axle." (2) Lay the front axle housing with the reduction differential side facing upward using the frame mounting planes of the axle housing.

7.2

Removal Sequence

2 2

500322

1. 2.

7.3

Wheel hub cover (right and left) Axle shaft (pull it outward approx 150 mm (5.91 in.))

Suggestions for Removal

Axle shaft Remove the wheel hub cover and install the sliding hammer into the screw hole (M10 x 1.25) in the end of the axle shaft and pull it out approx 150 mm (5.91 in.). Reduction differential (1) Install the eye bolt into one of the universal joint mounting holes and attach a wire rope there, and apply light tension on the rope with a hoist. (2) Remove mounting bolts, and remove the reduction differential by lifting.

8-12

Reduction differential

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

Installing Reduction Differential

For installation, follow the removal sequence in reverse.

8.1

Suggestions for Installation

Reduction differential (1) Make sure that the reduction differential and axle housing mounting surfaces are free of dirt and damage. (2) Apply liquid gasket to the mounting surfaces. Liquid gasket ThreeBond #1215 (3) Lift the reduction differential and install it to the front axle housing, and then tighten the mounting bolts to the specified torque. Bolt length

Tightening torque

37 mm (1.46 in.)

117±11.8 N·m (11.93±1.20 kgf·m) [86.29±8.70 lbf·ft]

31 mm (1.22 in.)

127.5±12.7 N·m (13.00±1.30 kgf·m) [94.04±9.37 lbf·ft]

Bolt tightening torque varies depending on the length under the neck. Be sure to tighten to the specified torque. Wheel hub cover (1) Replace the gasket with new one. (2) Tighten the mounting bolts to the specified torque. Tightening torque 56.9±5.9 N·m (5.80±0.60 kgf·m) [41.97±4.35 lbf·ft]

8-13

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

Disassembling Hub Reduction

9.1

Preparation (On-truck Condition)

Hub reduction can be disassembled while it is installed on the truck. In this case, remove the front wheels according to the procedure of "Removing front wheels." (1) Remove the front wheels, referring to the section "Removing front wheels." (2) Drain the oil, referring to the section of "Removing front axle and reduction differential."

9.2

Disassembly Sequence of Hub Reduction

14 7

6 13

Wheel hub cover, Gasket Axle shaft Sun gear, Snap ring Sleeve Planet carrier, O-ring Planet pin, Steel ball Thrust washer Planetary gear, Needle roller bearing Lock plate

8-14

12 11

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

500323

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

Axle nut Ring gear Tapered roller bearing (inner race) Front wheel hub Oil deflector Brake hub Oil seal Tapered roller bearing (outer race) Tapered roller bearing (outer race)

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 9.3

Suggestions for Hub Reduction Disassembly

Axle shaft Install the sliding hammer into the screw hole (M10x1.25) on the edge face, and remove the axle shaft together with the sun gear and snap ring. Planet carrier Support the planet carrier by lifting. Install the bolts into the screw holes (M12x1.75) and equally tighten the bolts to remove the planet carrier.

500639

Axle nut Attach the socket wrench (special tool) and remove the nut using an impact wrench.

500324

Special tool name

Part number

Socket wrench (Width across flats: 144 mm (5.67 in.))

92267-00200

Ring gear Install jack bolts into the bolt holes (M16 x 1.5: 2 places) and equally tighten the bolts to remove the ring gear. Front wheel hub and brake hub (1) Support the hub drum assembly with a transmission jack. (2) Remove the assembly using a wheel hub puller.

8-15

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 9.4

Disassembly Sequence of Wheel Brake

3 2 1

500325

1. 2.

9.5

Tapered roller bearing (inner race) Oil seal retainer, O-ring

Wheel brake assembly

Suggestions for Wheel Brake Disassembly

Tapered roller bearing (inner race) Using the bearing puller, remove the bearing together with the seal retainer.

500326

Wheel brake assembly For disassembly, inspection and reassembly of the wheel brake assembly, refer to the chapter "10 BRAKE SYSTEM."

8-16

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

10. Inspecting and Correcting Hub Reduction Axle shaft Measure runout with a dial gauge positioned on the center of the axle shaft while rotating the shaft.

500638

Item

Service limit value

Runout of axle shaft

2.0 mm (0.08 in.)

Axle housing Check the axle housing for the following defects. -

Check the mast support bearing sliding surfaces for damage. Check the end-face oil seal for wear or damage. Check the axle housing for distortion, dents, or other defects. Also check the welds for cracks.

Front wheel hub Check the front wheel hub for the following defects. -

Check the oil seals for wear or damage. Check the tapered roller bearing (outer race) for wear or damage.

Brake drum Check the inner surface of drum for wear or damage.

Item Inside diameter of brake drum

Standard value

Service limit value

420 mm (16.54 in.)

424 mm (16.69 in.)

Planet carrier -

Check the inner surface of needle bearing and the outer surface of planet pin for wear or damage.

Item

Standard value

Service limit value

+0.029

+0.0011

57.96 mm (2.28 in.)

49.96 mm (1.9669 in.)

Needle bearing inside diameter

58 +0.010 mm (2.28 +0.0004 in.)

Planet pin outside diameter

58 -0.011 mm (2.28 -0.0004 in.)

8-17

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL -

Check the thrust washer for wear or damage.

Item Thickness of trust washer

Standard value

Service limit value

1.2±0.06 mm (0.047±0.0024 in.)

0.8 mm (0.031 in.)

Others -

Check the outer periphery of oil seal retainer for wear or damage. Check the tapered roller bearing (inner race) for wear or damage.

10.1 Reassembly Sequence of Wheel Brake

500327

1. 2.

Wheel brake assembly Oil seal retainer, O-ring

Tapered roller bearing (inner race)

10.2 Suggestions for Wheel Brake Reassembly Tapered roller bearing (inner race)

1 1) 2) 3) 4)

8-18

250 mm (9.84 in.) ø77 mm (ø3.03 in.) ø61 mm (ø2.40 in.) 8 mm (0.31 in.)

5 3 2

Using the installer (to be made by the dealer), install the tapered roller bearing together with the oil seal retainer.

500629 5) ø21 mm (ø0.83 in.) 6) ø60 h6 mm (ø2.36 in.) 7) ø20.071 mm (ø0.7902 in.)

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 10.3 Reassembly Sequence of Hub Reduction

7 9 8 2 3

6 5

12 17 16 11 15

15 10

4 500329

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

Front wheel hub Tapered roller bearing (outer race) Tapered roller bearing (outer race) Oil seal Brake hub Oil deflector Ring gear Tapered roller bearing (inner race) Nut

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

Lock plate Axle shaft, Sleeve Planetary gear Roller bearing, Thrust washer Planet pin, Steel ball Planet carrier, O-ring Sun gear Planetary gear cover, Gasket

8-19

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 10.4 Suggestions for Reassembling of Hub Reduction Front wheel hub

(1) Tighten the brake drum securing nuts to the specified torque. After tightening the nuts, caulk the nuts in the shape of a cross.

500330 1. Gasket

Tightening torque 358.9±36.3 N·m (36.60±3.70 kgf·m) [264.71±26.77 lbf·ft] (2) Apply a thin coat of liquid gasket to the mating surface of the oil deflector to drum brake. (3) Tighten the oil deflector mounting bolts to the specified torque. Tightening torque 33.3±2.9 N·m (3.40±0.30 kgf·m) [24.56±2.14 lbf·ft] Adjusting bearing preload (1) After hand tighten the nut, hook a spring scale to one of the hub bolts and measure the force applied in the tangential direction. (2) If the force applied in the tangential direction (preload) does not meet the standard value, re-adjust it by means of varying the tightening of the nut. (3) After completing the preload adjustment, assemble the lock plates into places and tighten the mounting bolts to the specified torque. 500331

Item

Preload (tangential force)

Wheel hub bearing

127.5 to 166.7 N (13.0 to 17.0 kgf) [28.66 to 37.48 lbf]

Note: However, it is advisable to aim the lower tolerance limit, if the bearing having been used for a prolonged period. Tightening torque 16.7±2.0 N·m (1.70±0.20 kgf·m) [12.32±1.48 lbf·ft]

8-20

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL Planet carrier (1) Before installing the planet pins into the carrier, coat the inside surfaces of the planetary gear bushings with the service oil. (2) Tighten the planet carrier mounting bolts to the specified torque. Tightening torque 93.2±9.8 N·m (9.50±1.0 kgf·m) [68.74±7.23 lbf·ft] Planetary gear cover Tighten the planetary gear cover mounting bolts to the specified torque. Tightening torque 56.9±5.9 N·m (5.80±0.60 kgf·m) [41.97±4.35 lbf·ft]

8-21

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

11. Disassembling Reduction Differential 11.1 Preparation Measuring backlash Before disassembling the reduction gear assembly, except for replacing the reduction gear set for a new one, measure the backlash between the reduction gear and the reduction pinion for their later reassembly. Note: When the reduction gear set is to be replaced with a new one, it is not necessary to measure the backlash.

500353

Item Backlash between reduction gear and pinion

Standard value 0.25 to 0.33 mm (0.010 to 0.0130 in.)

Matchmark Put a matchmark on the bearing cap, adjusting screw, and the carrier to ensure correct reassembly.

500354

8-22

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 11.2 Disassembly Sequence of Differential Gear Assembly

2 7 10 5 6 11

9 4 7

500355

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

Lock washer, Lock plate Side bearing nut Bearing cap, Lock washer Differential case R.H. Differential case L.H. Reduction gear

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

Tapered roller bearing Differential gear Thrust washer Spider Thrust washer Differential pinion

11.3 Suggestions for Disassembling of Differential Gear Assembly Tapered roller bearing Remove the inner race using a bearing puller.

8-23

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 11.4 Disassembly Sequence of Reduction and Parking Brake Assembly

3 4

7 6

8 12

13 14 500356

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

Parking brake drum Self-locking nut Input flange Parking brake assembly Parking brake bracket Oil separator Oil seal Bearing retainer Shim O-ring

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

O-ring Reduction pinion Snap rings Roller bearing Tapered roller bearing (inner race) Tapered roller bearing (inner race) Tapered roller bearing (outer race) Collar Tapered roller bearing (outer race)

11.5 Suggestions for Disassembling of Reduction and Parking Brake Assembly Bearing retainer (1) Utilize the bolt holes for separation (M14x1.5: 2 places) and drive-in jack bolts into them and turn the bolts evenly to pull out the bearing. (2) Check the thickness of shims which are removed at the same time and take care so as not to loose them. Tapered roller bearing Remove the inner race using a bearing puller.

8-24

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 11.6 Inspecting and Correcting Reduction and Parking Brake Assembly Inspecting wear or damage on each part Check for the following defects. -

Check the seat formed between the differential case and tapered roller bearing inner race to carry it to see whether the seat surface is galled or not. Check the differential case for crack, and check the sliding surfaces of differential gears and washers for wear or damage. Check the teeth of the differential pinions and bevel gears for wear, pitting, chipping, galling, etc. Also, check the washer supporting portions for wear or damage. Check the inside surface of the differential pinion and outside surface of pinion shaft for wear.

Item

Standard value

Clearance between differential bevel 0.169 to 0.278 mm pinion inner (0.0067 to 0.0109 in.) diameter and shaft outer diameter -

Service limit value

0.35 mm (0.0138 in.)

Check the differential gear and axle shaft spline for wear or looseness. (Insert the differential gear into the axle shaft to measure the clearance.)

Item Looseness of differential bevel gear on axle shaft (Looseness of spline)

Service limit value 0.5 mm (0.020 in.)

Differential gear and pinion Measure the backlash. If the backlash exceeds the service limit, replace the thrust washer with a new one.

Item Backlash between differential gear and pinion

Standard value

Service limit value

0.2 to 0.28 mm (0.008 to 0.0110 in.)

0.5 mm (0.020 in.)

Reduction gear and reduction pinion Check the gear teeth for uneven contact, wear, pitting, flaking or chipping. Minor flaws on the tooth surfaces that may not affect the service can be corrected by grinding with an oil stone or hand grinder. If the damage is excessive, replace the gear and pinion as a set.

8-25

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL Parking brake drum Check the drum inner surface for wear or damage. If the inside diameter of the drum exceeds the service limit, replace the drum with a new one. Item

Standard value

+0.5 +0.020 Drum inside 304.8 0 mm (12.0 0 in.) diameter

8-26

Service limit value 307 mm (12.09 in.)

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

12. Reassembling Reduction Differential 12.1 Reassembly Sequence of Differential Gear Assembly

10 9 2 3

14 4 5 6 8 7 9 12 11 13

500357

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

Differential case Thrust washer Differential gear Spider Differential pinion, Washer Differential gear Thrust washer

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

Differential case Tapered roller bearing Reduction gear Bearing cap Lock washer Side bearing nut Lock plate

8-27

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 12.2 Suggestions for Reassembling Differential Gear Assembly Differential case (1) Apply a thin coat of Locktite #271 to the mounting bolt surfaces. (2) Tighten the mounting bolts evenly to the specified torque to avoid uneven tightening. Tightening torque 196±29.4 N·m (19.99±3.0 kgf·m) [144.56±21.68 lbf·ft] Reduction gear (1) Apply a thin coat of Locktite #271 to the mounting bolt surfaces. (2) Tighten the mounting bolts evenly to the specified torque to avoid uneven tightening. Tightening torque 441±69 N·m (44.97±7.04 kgf·m) [325.26±50.89 lbf·ft] 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.

500358

Item

Standard value

Backlash between 0.2 to 0.28 mm differential gear and (0.008 to 0.0110 in.) pinion

Service limit value 0.5 mm (0.020 in.)

Hand tightening of bearing cap Install the bearing cap and install the lock washers and mounting bolts. Hand tighten the mounting 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.

8-28

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL Adjusting preload of tapered roller bearing (1) Check the preload of the differential alone before installing the reduction pinion. (2) Taking the tapered roller bearing backlash into account, tighten the side bearing nuts evenly between the right and left. (3) Tap the reduction gear on the back with a copper hammer while rotating the gear by hand for a snug fitting. (4) Attach a wire around the outer circumference of the differential case, and attach a spring scale to the wire. (5) Pull the spring scale in the tangential direction, and read a force (tangential force) just as the differential case begins to rotate.

1 1)

500359 1. Side bearing nut

Item

1) Outer circumference of the differential case

Standard value 23 to 32 N (2.35 to 3.26 kgf) [5.17 to 7.19 lbf.]

Tangential force Preload (reference)

2.45 to 3.43 N·m (0.25 to 0.35 kgf·m) [1.81 to 2.53 lbf·ft]

Tightening bearing caps (1) Tighten the mounting bolts evenly to the specified torque.

500637

Tightening torque 34.3±3.9 N·m (3.50±0.40 kgf·m) [25.30±2.88 lbf·ft] (2) Caulk the lock washer after tightening the bolt.

8-29

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 12.3 Adjusting Preload of Reduction Pinion (1) Tentatively assemble the reduction pinion in the order indicated below to check the preload of the tapered roller bearing.

3 5

500360

1. 2. 3. 4. 5.

Reduction pinion Tapered roller bearing (inner race) Bearing retainer Tapered roller bearing (outer race) Tapered roller bearing (outer race)

(2) Tighten the self-locking nut to the specified torque. Tightening torque 294.2±29.4 N·m (30.0±3.0 kgf·m) [216.99±21.68 lbf·ft]

8-30

6. 7. 8. 9. 10.

Collar Tapered roller bearing (inner race) Oil separator Input flange Self-locking nut

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL (3) Secure the input flange and apply a rated load on the top of the pinion. (4) Attach a thread around the outer circumference of the bearing retainer, and pull the thread attached to the spring balance, and read the force just as the bearing retainer begins to rotate.

1) 1) Fixing

500361

2) 5 ton

Force applied to bearing retainer in tangential direction 30.4 to 43.1 N (3.10 to 4.39 kgf) [6.83 to 9.69 lbf] (5) If the force applied in the tangential direction is within the specified range above, the preload also must be the specified value. (6) If the tangential force does not meet the specified value, re-adjust it by means of varying the thickness of collar(s). There are 25 different varieties of collar in thickness.

8-31

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 12.4 Adjusting the Contact Between Gear and Pinion Teeth With the tentatively assembled condition for "Adjusting preload of reduction pinion " above, install the reduction assembly into the differential. Note: The reassembly of the differential must have already been completed. Installing remaining parts

3 4

500362

1. 2. 3.

Roller bearing Snap rings Machining error adjustment shim

Note: -

8-32

The parts listed above are those needs to be installed to the tentatively assembly for "Adjusting preload of reduction pinion." Since the parking brake bracket is not installed, the removed bolts can not be used. Be sure to prepare the above mentioned bolts.

Bolt with spring washer (M14x5, length below neck 50 mm (1.97 in.))

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL Calculating the thickness of the machining error adjustment shim If the reduction pinion is reused, insert the shims that have been used. When the pinion is replaced, calculate the required amount (thickness) of shims as instructed below. (1) Check the preload first, and take an actual measured value "2" of the dimension "1." (2) Calculate the difference "3" between the actual measurement and nominal value (53.5 mm (2.106 in.) )of the dimension "1." "3"= 53.5 mm (2.106 in.) -"2" Note: -

Round off to the first decimal place. If the actual measurement "2" of dimension "1" is greater than the nominal value, "3" will be a negative value. (3) Calculate the shim thickness "4" from the following equation: Thickness of shim "4"= 0.5 mm (0.020 in.)+ "3" (Round off to the first decimal place.) (4) Install an appropriate number of shims to produce the calculated thickness. Part number

Thickness

92331-03500

0.2 mm (0.008 in.)

92335-03600

0.1 mm (0.004 in.)

4 1 500363

Installing reduction assembly (1) Lay the differential with its reduction and parking brake mounting side facing upward and secure it using wooden bars, etc. (2) Install the eye bolt to the universal joint mounting bolt hole of input flange. (3) Attach a wire rope to the eye bolt and lift the reduction assembly to install. Be careful not to allow the machining error adjustment shims to fall off. (4) Tighten the mounting bolts to the specified torque. Tightening torque 128.5±19.6 N·m (13.10±2.0 kgf·m) [94.78±14.46 lbf·ft]

8-33

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL Measuring and adjusting backlash (1) Lay the gear assembly with the differential facing upwards, and secure the assembly. (2) Set the dial indicator so that its tip is square to the reduction gear tooth face. (3) Move the reduction gear back and forth (in the rotating direction) and read deflection on the dial indicator (backlash).

500364

Item

Standard value

Backlash between reduction gear and pinion

0.25 to 0.33 mm (0.0098 to 0.0130 in.)

(4) If the backlash does not meet the standard value, turn both right and left side bearing nuts in or out exactly the same amount. Example: If you loosen the right side nut for one turn, tighten the left side nut for one turn. Note: The amount of turn in or out of the side bearing nuts must be the same for both the right and left side bearing nuts. If the amount of turn in or out is different between the right and left nuts, the preload of the differential case tapered roller bearing may vary and deviate from the specified value.

1) 2)

1) Increase

8-34

2) Decrease

500365

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL Adjusting reduction gear tooth contact (1) Apply a thin and even coat of marking blue to a few reduction gear teeth, on both drive and coast sides. (2) Rotate the reduction gear back and forth several times by hand. (3) Referring to the table below, check the tooth contact pattern. If the tooth contact is not appropriate, adjust it.

500366

No.

Tooth contact pattern

1 500471

Extends from toe to middle portion, covering 50% or more of tooth length.

Heavy contact at toe of tooth (Toe)

2 500472

Heavy contact at heel of tooth (Heel)

3 500473

4 500474

5 500475

Heavy contact on face or upper portion of tooth (Face)

Heavy contact on flank or lower portion of tooth (Flank)

Adjusting procedure

Good

1 2

Move gear away from pinion.

Move pinion toward gear by adding shim(s) to secure correct backlash.

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.

Slightly move pinion away from gear by removing shim(s).

Slightly move gear toward pinion to secure correct backlash.

500476

2 1

500477

2 1

500478

2 1

500477

Note: For toe contact or heel contact, observe contacts on the outside (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, check the backlash.

8-35

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 12.5 Reassembly Sequence of Reduction and Parking Brake Assembly

18 17

4 6 8

3 19 10 12 11

7 9

13 16 14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

8-36

Reduction pinion Tapered roller bearing (inner race) Collar Bearing retainer Tapered roller bearing (outer race) Tapered roller bearing (outer race) Tapered roller bearing (inner race) O-ring O-ring Oil separator

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

500367

Parking brake bracket Oil seal Parking brake assembly Input flange Self-locking nut Parking brake drum Roller bearing Snap rings Machining error adjustment shim

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 12.6 Reassembling Reduction and Parking Brake Assembly O-ring and oil separator for each part Apply the service oil before reassembly. Oil seal Prepare the following special tool. Installer: To be made by dealer (for the dimensions, refer to the illustration on the right.) -

2) 6)

Place the main lip of oil seal inward, and apply grease and service oil between the lips. Put the oil seal on the installer and insert it into the parking brake bracket.

4) 3)

1) 1

500368 1. 2. 1) 2)

Installer Oil seal 130 mm (5.12 in.) ø35 mm (1.38 in.)

3) 23 mm (0.91 in.) 4) 15 mm (0.59 in.) 0

5) ø95 -0.1 mm (3.74 -0.004 in.) 6) ø68.5±0.1 mm (2.697±0.004 in.)

Parking brake assembly (1) Exercise care for the direction of the parking brake lever when reassembling. (2) Tighten the mounting bolts to the specified torque. Tightening torque 145±22 N·m (14.79±2.24 kgf·m) [106.94±16.23 lbf·ft] Parking brake drum Tighten the mounting nuts to the specified torque. Tightening torque 96±15 N·m (9.79±1.53 kgf·m) [70.80±11.06 lbf·ft] Self-locking nut (1) Apply Locktite 271 to the self-locking nut and tighten it to the specified torque. Tightening torque 294.2±29.4 N·m (30.0±3.0 kgf·m) [216.99±21.68 lbf·ft] (2) Caulk the nut with a punch after tightening.

8-37

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 12.7 Assembly Sequence of Reduction Differential

1 2

500369

1. 2.

Reduction and parking brake assembly Reduction differential mounting bolt

3. 4.

Side bearing cap bolt (retighten to the specified torque) Lock washer, Lock plate

12.8 Suggestions for Reassembling of Reduction Differential (1) Lay the differential with its reduction and parking brake mounting side facing upward and support it using wooden bars, etc. (2) Install the eye bolt to the universal joint mounting bolt hole of input flange. (3) Attach a wire rope to the eye bolt and lift the reduction and parking brake assembly to install it into the differential. (4) Tighten the reduction differential mounting bolts to the specified torque. Ref.

Tightening torque

59.8±5.9 N·m (6.10±0.60 kgf·m) [44.11±4.35 lbf·ft]

(5) Retighten the side bearing cap bolt to the specified torque. Ref.

Tightening torque

379 to 512 N·m (38.65 to 52.21 kgf·m) [279.53 to 377.63 lbf·ft]

(6) Tighten the mounting bolts of the lock washers and lock plates to the specified torque. Ref.

Tightening torque

34.3±3.9 N·m (3.50±0.40 kgf·m) [25.30±2.88 lbf·ft]

8-38

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

13. Troubleshooting Situation

Gear noise comes out continuously during normal traveling.

Irregular noise comes out during normal traveling.

Abnormal noise comes out when turning a corner. Differential carrier overheats after traveling. Abnormal noise comes from hub reduction unit.

Possible causes

Action

Reduction bevel gear teeth badly worn

Replace reduction bevel gear.

Improper adjustment or excessive wear of reduction bevel gear bearing

Adjust or replace the bearing.

Hub bearings damaged

Replace the bearing.

Improper tooth contact between the reduction pinion and reduction gear of the output shaft

Adjust the tooth contact.

Reduction gear bearing or hub bearing broken

Replace the bearing.

Differential gear teeth broken or thrust washers worn

Replace differential gear or washer.

Metal chips in axle housing

Clean and change oil.

Bolts that secure the axle shaft or differential carrier loosened

Retighten.

Fit of differential gears in differential case out of specification due to wear

Replace.

Teeth of differential gear or pinion broken, seized on spider, or worn or damaged

Replace.

Bearing damaged due to excessive preload

Replace bearing and adjust preload.

Backlash between reduction pinion and reduction gear too small

Adjust tooth contact and backlash.

Low oil level or poor oil quality

Add or change oil.

Planetary gears worn or damaged

Replace the planetary gear.

Needle roller bearing worn

Replace the needle roller bearing.

8-39

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

14. Service Data 14.1 Front Axle Truck model

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Runout of axle shaft

Standard value

Preload of hub bearing (force applied to hub bolt in tangential direction)

Service limit value

Tightening torque of brake drum nuts

Standard value

358.9±36.3 N·m (36.6±3.70 kgf·m) [264.71±26.77 lbf·ft] After tightening the nuts, caulk the nuts in the shape of a cross.

Tightening torque of brake backing plate mounting nuts

Standard value

233.4±23 N·m (23.80±2.35 kgf·m) [172.14±16.96 lbf·ft]

Tightening torque of front axle housing mounting nuts

Standard value

640±96 N·m (65.26±9.79 kgf·m) [472.03±70.80 lbf·ft]

Tightening torque of wheel nuts

Standard value

539.4±49 N·m (55.0±5.0 kgf·m) [397.83±36.14 lbf·ft]

Tightening torque of wheel nuts

Standard value

93.2±9.8 N·m (9.50±1.0 kgf·m) [68.74±7.23 lbf·ft]

Standard value

50 -0.011 mm (1.97 -0.0004 in.)

Diameter of planet pin

Service limit value 9

Inside diameter of planetary gear bearing

Standard value Service limit value Standard value

2.0 mm (0.079 in.) 127.5 to 166.7 N (13.0 to 17.0 kgf) [28.66 to 37.48 lbf]

49.96 mm (1.9669 in.) +0.029

58 +0.010 mm (2.28

+0.0011 +0.0004 in.)

57.96 mm (2.2819 in.) 1.2±0.06 mm (0.047±0.0024 in.)

Thickness of trust washer

Tightening torque of cover bolts

Standard value

56.9±5.9 N·m (5.80±0.60 kgf·m) [41.97±4.35 lbf·ft]

Tightening torque of lock plate bolts

Standard value

16.7±2.0 N·m (1.70±0.20 kgf·m) [12.32±1.48 lbf·ft]

Tightening torque of deflector bolts Standard value

33.3±2.9 N·m (3.40±0.30 kgf·m) [24.56±2.14 lbf·ft]

Inside diameter of brake drum

8-40

Service limit value

0.8 mm (0.032 in.)

Standard value

420 mm (16.54 in.)

Service limit value

424 mm (16.69 in.)

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

9 10

10 8

12 11 6 13

7 6

500370

8-41

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL 14.2 Reduction Differential Truck model 1

Play of differential bevel gear on axle shaft (Looseness of spline)

Backlash between reduction gear and pinion

FD100NZ

FD120NZ

Standard value Service limit value

FD135NZ

FD150ANZ

0.5 mm (0.020 in.)

Standard value

0.25 to 0.33 mm (0.0098 to 0.0130 in.)

Backlash between differential gear and pinion

Standard value

0.2 to 0.28 mm (0.008 to 0.0110 in.)

Clearance between differential bevel pinion inner diameter and shaft outer diameter

Standard value

Preload of side bearing

Service limit value

0.5 mm (0.020 in.) 0.169 to 0.278 mm (0.0067 to 0.0109 in.) 0.35 mm (0.0138 in.)

Force applied to periphery A of differential case in tangential direction

Standard value

23 to 32 N (2.35 to 3.26 kgf) [5.17 to 7.19 lbf]

Preload (reference)

Standard value

2.45 to 3.43 N·m (0.25 to 0.35 kgf·m) [1.81 to 2.53 lbf·ft]

Tightening torque of differential case bolts

Standard value

196±29.4 N·m (19.99±3.0 kgf·m) [144.56±21.68 lbf·ft] (Apply Loctite 271.)

Tightening torque of nuts of reduction gear mounting bolts

Standard value

441±69 N·m (44.97±7.04 kgf·m) [325.26±50.89 lbf·ft] (Apply Loctite 271.)

Tightening torque of side bearing cap bolts

Standard value

379 to 512 N·m (38.65 to 52.21 kgf·m) [279.53 to 377.63 lbf·ft]

Preload of reduction pinion bearing (Force applied to bearing retainer in Standard value tangential direction)

Inside diameter of brake drum

Standard value Service limit value

30.4 to 43.1 N (3.10 to 4.39 kgf) [6.83 to 9.69 lbf] 304.8

+0.5 +0.020 0 mm (12.0 0 in.)

307 mm (12.09 in.)

Tightening torque of support plate nuts

Standard value

145±22 N·m (14.79±2.24 kgf·m) [106.95±16.23 lbf·ft]

Tightening torque of self-locking nuts

Standard value

294.2±29.4 N·m (30.0±3.0 kgf·m) [216.99±21.68 lbf·ft] (Apply Loctite 271.)

Tightening torque of brake drum nuts

Standard value

96±15 N·m (9.79±1.53 kgf·m) [70.80±11.06 lbf·ft]

Tightening torque of differential carrier mounting bolts

Bolt length: 31 Standard value mm (1.46 in.)

127.5±12.7 N·m (13.0±1.30 kgf·m) [94.04±9.37 lbf·ft]

Bolt length: 37 Standard value mm (1.46 in.)

117±11.8 N·m (11.93±1.20 kgf·m) [86.293±8.70 lbf·ft]

Tightening torque of reduction differential

Standard value

59.8±5.9 N·m (6.10±0.60 kgf·m) [44.11±4.35 lbf·ft]

Tightening torque of side bearing cap bolts

Standard value

34.3±3.9 N·m (3.50±0.40 kgf·m) [25.30±2.88 lbf·ft]

8-42

CHAPTER 8 FRONT AXLE AND REDUCTION DIFFERENTIAL

6 7 2 9 15 10

500372

8-43

CHAPTER 9 REAR AXLE

Chapter 9 REAR AXLE 1.

Specifications Truck model

Axis type

FD135NZ

FD150ANZ

Center pivot type Toe-in

Power steering cylinder

FD120NZ

Elliot type

Suspension system

Wheel alignment

FD100NZ

0 mm (0.00 in.)

Camber

+1°

Caster

0°

King pin inclination

0°

Inside diameter of cylinder

115 mm (4.53 in.)

Outside diameter of piston rod

80 mm (3.15 in.)

Stroke

182 mm (7.17 in.)

9-1

CHAPTER 9 REAR AXLE

Structure

2.1

Rear Axle

1 7

2 1)

2) 2) 3

1) - 1)

2) - 2) 500152

1. 2. 3. 4.

9-2

Rear axle housing Power steering cylinder Tie rod (right and left) Pins (2 for each right and left)

5. 6. 7. 8.

Steering knuckle (right and left) Wheel hub (right and left) Stopper bolt (right and left) Rear axle support (front and rear)

CHAPTER 9 REAR AXLE 2.2

Power Steering Cylinder

8 14 15

Cylinder Rod Snap rings O-ring Piston Wear ring Piston seal Cylinder head

10 4

6 7 6

13 12 11 1. 2. 3. 4. 5. 6. 7. 8.

500125

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

O-ring Bushing Seal Back-up ring Dust seal Bearing Stopper ring

9-3

CHAPTER 9 REAR AXLE

3. 3.1

Removing Rear Wheel Preparation

(1) Fully pull the parking brake lever to apply the parking brake securely. (2) Block the front wheels. (3) Loosen each rear wheel nut about two turns. (4) Place a jack under a concave at the bottom of the counterweight, and jack up the rear end of the truck. Jack capacity Truck model

Capacity

FD100NZ

7500 kg (16535 lb)

FD120NZ

9000 kg (19842 lb)

FD135NZ

10000 kg (19842 lb)

FD150ANZ

10000 kg (22046 lb)

Note: Counter weight lifting holes can also be used to lift the rear of truck.

R WARNING After raising the wheels with either of the methods, place jack stands under the frame to prevent the truck falling.

3.2

Removal Sequence

2 1 500126

1. 2.

9-4

Wheel nut Clamp

Rear wheels (tires)

CHAPTER 9 REAR AXLE 3.3

Suggestions for Removal

(1) Remove the wheel nuts. (2) Use either the tire handler or small forklift truck to remove the rear wheels. Weight of rear wheel Pneumatic tire

Item FD100NZ

10.00-20-14PR

85 kg (187 lb)

FD120NZ

10.00-20-16PR

90 kg (198 lb)

12.00-20-18PR

120 kg (265 lb)

FD135NZ FD150ANZ

Solid 190 kg (419 lb) 235 kg (518 lb)

Installing Rear Wheel

For installation, follow the removal procedure in reverse.

4.1

Suggestions for Installation

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 illustration evenly and finally to the specified torque.

7 6

2 500127

Tightening torque 490.3 to 588.4 N·m (50 to 60 kgf·m) [362 to 434 lbf·ft]

9-5

CHAPTER 9 REAR AXLE

5. 5.1

Removing Rear Axle Preparation

(1) Fully pull the parking brake lever to apply the parking brake securely. (2) Block the front wheels. (3) Remove the rear wheels (tires) while referencing the section of "Rear Wheels (Tires)." (4) Use a forklift truck with a duty load 10 tons or more and lift the rear end of truck until the bottom face of the weight is 400 to 500 mm (15.75 to 19.69 in.) above the ground. (5) Place solid stands under the both sides of the frame to prevent the truck from falling.

R WARNING Be sure to place solid stands to prevent the truck from falling down.

5.2

Removal Sequence

2 3

3 2

500454

1. 2.

9-6

Power steering cylinder hose Rear axle support

3. 4.

Thrust washer Rear axle assembly

CHAPTER 9 REAR AXLE Steering hose (1) Remove the hoses at the power steering cylinder sides. (2) Put a sealing plug to the mouthpiece of the disconnected hose to prevent oil from flowing out.

500128

Item Sealing plug

Part number 05330-30300 (G 3/8)

Rear axle assembly (1) Prepare such an engine jack, etc. that is provided with a wide supporting area. (2) From the rear of the truck, position the jack under the rear axle and fix it with a wire rope, etc. (3) Remove the rear axle supports of front and rear. (4) Operate the jack to lower the rear axle and pull it out diagonally backward.

500129

Item Rear axle

Weight Approx 790 kg (1742 lb)

R WARNING Carefully operate the jack so that the rear axle does not accidentally drop off. Rear axle support (1) Do not remove the bushings in the support unless any defect is found through inspection. (2) If any defect is found, either replace the rear axle support as a whole assembly or break the bushing to remove it.

500130

1) Seam of bushing

R CAUTION In the installation of a new bushing, note that the seam part of the bushing comes to the lower side (grease nipple side).

9-7

CHAPTER 9 REAR AXLE

Installing Rear Axle

For installation, follow the removal sequence in reverse.

6.1

Suggestions for Installation

Adjusting clearance on the rear axle support (1) Adjustment thrust washers are available in three different thicknesses.

500131

Item

Standard value 3.2 mm (0.126 in.)

Thrust washer type (thickness)

1.6 mm (0.063 in.) 0.8 mm (0.032 in.)

(2) Select optimal thrust washers for adjusting the clearance so that the total of front and rear clearance is 0.8 mm (0.032 in.) or less (0.4 mm (0.016 in.) or less for one side).

R CAUTION Put thrust washers evenly for the front and rear.

9-8

CHAPTER 9 REAR AXLE

7. 7.1

Disassembling Rear Axle Assembly Disassembly Sequence

45 6

46 47

5 4

21 22

23 2

24 48 42 41 40 43

26 25

44 49

35 39 34 33 32 31 38

30 12 29 11

28 27 8

25 26

500455

9-9

CHAPTER 9 REAR AXLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

7.2

Bolt Spring washer Clamp Cushion Hydraulic hose Hydraulic hose Bolt Spring washer Hub cap Gasket Bolt Spring washer Lock plate Lock nut Rear axle hub Tapered roller bearing Oil seal Tapered roller bearing (outer race) Tapered roller bearing (inner race) Oil seal retainer Bolt Collar Tie rod pin Tie rod Spacer

26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.

Dust seal Drain plug Gasket Bolt, Spring washer Cover Shim O-ring Tapered roller bearing (outer race) O-ring Oil seal Tapered roller bearing (inner race) Oil seal retainer Lower dust cover Steering knuckle Oil seal Oil seal retainer Tapered roller bearing Bolt Spring washer Power steering cylinder Snap rings Spherical bearing Nut Bolt Rear axle housing

Suggestions for Removal

Lock nut (1) Remove the mounting bolts, and remove the lock plate. (2) Remove the lock nuts using a socket wrench.

500132

Item

Standard value

Width across flats of lock nut

70 mm (2.76 in.)

9-10

CHAPTER 9 REAR AXLE Rear axle hub Using a puller, remove the rear axle hub from the steering knuckle.

500133

Tapered roller bearing Do not remove the outer race unless it is to be replaced with a new one.

R CAUTION When replacing the tapered roller bearing, the outer race and the inner race should be replaced as a set. Lower cover of the steering knuckle (1) Prepare a jack bolt.

1 1. Cover

Item

Jack bolt

500134 2. Jack bolt

Standard value

Nominal diameter

16 mm (0.63 in.)

Pitch

1.5 mm (0.06 in.)

Thread length

100 mm (3.94 in.) or more

(2) Remove the plug at the center of the cover. (3) Remove six (6) cover fixing bolts. (4) Drive-in the jack bolt into the plug hole to pull the cover out.

9-11

CHAPTER 9 REAR AXLE

Reassembling Rear Axle

8.1

Reassembly Sequence

35 1)

2) 2)

14 11 10 15 13 1

34 6

33 18

19 17 20

9 21 8

4 7 24 23 28 29

22 1) - 1)

26 26

2) - 2) 500153

9-12

CHAPTER 9 REAR AXLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Rear axle housing Tapered roller bearing (outer race) Oil seal Steering knuckle Oil seal retainer Tapered roller bearing (inner race) Oil seal retainer O-ring Tapered roller bearing (inner race) Oil seal retainer Tapered roller bearing (inner race) Rear axle hub Tapered roller bearing (outer race) Tapered roller bearing (outer race) Oil seal Tapered roller bearing (inner race) Lock nut Lock plate

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

Hub cap, Gasket Lower dust cover Cover Tapered roller bearing (outer race) O-ring Oil seal Shim Spherical bearing Stopper ring Spacer Dust seal Spacer Dust seal Tie rod Tie rod pin Power steering cylinder Clamp

Inside of rear axle hub (1) In order for the shaded area in the right-hand illustration to be successfully greased after the assembly is completed, coat the following grease on each part before assembly.

500135

Item Grease

Name Idemitsu Autolex A (NLGI No.2)

R CAUTION Do not forget to lubricate the inside of the roller supporter of the tapered roller bearing. (2) First install the oil seal retainer, then drive-in the tapered roller bearing (inner race) using the bearing installer. (3) Only lightly tighten the lock nuts (inside and outside), lock washer, and hub cap. (Tentative tightening)

500136

9-13

CHAPTER 9 REAR AXLE Upper and lower steering knuckle supports (1) In order for the shaded area in the right-hand illustration to be successfully greased after the assembly is completed, coat the following grease on each part before assembly.

500146

Item Grease

Name Idemitsu Autolex A (NLGI No.2)

R CAUTION Do not forget to lubricate the inside of the roller supporter of the tapered roller bearing. (2) For the upper and lower oil seals of the steering knuckle, coat the lips with the following grease. Item Grease

Name Idemitsu Autolex A (NLGI No.2)

R CAUTION Pay attention to the orientation of oil seal for reassembly. (See the illustration.)

9-14

CHAPTER 9 REAR AXLE Adjusting preload of knuckle bearing

(1) Install the cover without the shim. (2) Measure the clearance between the rear axle housing and cover without tightening the bolts. (3) Install a shim which is adjusted to 0.1 mm (0.004 in.) thinner than the measured clearance and evenly tighten the bolts. (4) Put 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.

1. Axle housing 2. Cover 3. Bolt

Item Tangential force

500147 1) Tie rod mounting hole 2) Clearance

Standard value 98 to 146 N (9.99 to 14.89 kgf) [22.03 to 32.82 lbf]

(5) If the force applied in the tangential direction does not meet the standard value, re-adjust it by means of varying the shim thickness. Adjusting preload of hub bearing (1) After all the parts are assembled, remove the hub cap and lock nut. (2) Tentatively tighten the lock nut. (3) Hook a spring scale to one of hub bolts and measure whether the force applied in the tangential direction meets the standard value.

500137

Item Tangential force

Standard value 88 to 127 N (8.97 to 12.95 kgf) [19.78 to 28.55 lbf]

(4) 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.

R CAUTION If the bearings are reused, aim a lower value in the tolerance range of tangential force.

9-15

CHAPTER 9 REAR AXLE (5) When the tangential force meets the standard value, gradually loosen the lock nut until each hole on the lock plate aligns with the threaded portion of the lock nut. (6) Tighten the lock plate with bolts and spring washers.

1 2

500138 1. Lock nut

9-16

2. Lock plate

CHAPTER 9 REAR AXLE

Disassembling Power Steering Cylinder

9.1

Disassembly Sequence

9 10

9 10 2

6 4 1

11 1. 2. 3. 4. 5. 6.

Cylinder head Dust seal Back-up ring Packing O-ring Piston rod

2 500139

7. 8. 9. 10. 11.

Wear ring Piston seal Stopper ring Bearing Cylinder

Note: -

Do not remove the bushing press-fit in the cylinder head. Do not remove the piston assembled with the piston rod.

9-17

CHAPTER 9 REAR AXLE 9.2

Suggestions for Disassembly

Cylinder head (1) Hold the cylinder which has been protected by copper plates in a vise. (2) Using the special tool, remove the cylinder head.

1 1. Hook wrench

Special tool name Hook wrench

9-18

Part number 05302-10800

500140

CHAPTER 9 REAR AXLE

10. Inspecting and Adjusting Power Steering Cylinder Deflection of piston rod (1) Support both ends of the piston rod with V-shaped blocks, and apply a dial gauge at the middle position. (2) Measure the deflection while rotating the piston rod one turn. If the measurement exceeds the service limit (refer to the table below), replace the piston rod together with the piston. Piston rod surfaces -

Check the piston rod surfaces for rust, damages, sliding marks, or dents. Replace if any excessive rust or damage is found. If the threaded portion is excessively damaged, replace the piston rod. Cylinder -

500141

Check the cylinder for any wear, damage or rust. Replace if any excessive rust or damage is found. Check the welded portion for cracks, damage or dent. Replace if any excessive damage is found.

Item

Standard value

Service limit value

Inside diameter of cylinder tube

115 mm (4.53 in.)

115.15 mm (4.53 in.)

Outside diameter of piston rod

80 mm (3.15 in.)

Clearance between rod and bushing

0.1 mm (0.004 in.)

0.2 mm (0.008 in.)

Runout of piston rod

0.6 mm (0.024 in.)

500149

9-19

CHAPTER 9 REAR AXLE

11. Reassembling Power Steering Cylinder 11.1 Reassembly Sequence

2 3

2 *

10 11

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

Piston rod Wear ring Piston seal Cylinder Cylinder head Packing

500150

7. 8. 9. 10. 11.

Back-up ring Dust seal O-ring Bearing Stopper ring

Note: The part marked with * is included in the seal kit.

11.2 Suggestions for Reassembly (1) Thoroughly clean all parts before reassembly making sure they are completely free from dirt or dust. (2) Replace the seal kit parts (* marked parts in the illustration above) whenever reassembling.

R CAUTION Seal Kit parts should always be new parts. Never re-install any part that has been once used. (3) Before reassembly coat each part with hydraulic oil. (4) Pay careful attention to the orientation of seals and rings when installing them to the cylinder head.

9-20

CHAPTER 9 REAR AXLE Installing piston seals (1) Hold the piston rod in a vise.

R CAUTION Be careful not to damage to the piston rod. (2) Lightly compress and release a piston seal 5 to 6 times by hand to make it soft. (3) Apply a thin coat of hydraulic oil to the piston seal. (4) Install the piston seal to the piston seal groove. (5) Check the entire circumference of the piston tube if the piston seals are firmly installed.

500142

(6) When the assembling of piston seal is completed, install the associated wearing.

500143

Cylinder head Tighten the cylinder head to the specified torque. Tightening torque 696 ± 70 N·m (71 ± 7 kgf·m) [513 ± 52 lbf·ft]

9-21

CHAPTER 9 REAR AXLE

12. Adjustment 12.1 Measuring Minimum Turning Radius (1) Secure a flat ground of 20 by 20 m (21.9 by 21.9 yd) or more.

R WARNING The area where the measurement to be taken must be surrounded by a fence, etc. or assigned with a watchman so that no unauthorized persons gain access to the area. (2) Put a piece of chalk to the end of a thread, and hang it down from a position of the counterweight shown in the illustration on 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).

500144

Truck model

Minimum turning radius

FD100NZ

4000

+300 +11.81 -50 mm (157.48 -1.97 in.)

FD120NZ

4060

+300 +11.81 -50 mm (159.84 -1.97 in.)

FD135NZ

4160

+300 +11.81 -50 mm (163.78 -1.97 in.)

FD150ANZ

4550

+300 +11.81 -50 mm (179.13 -1.97 in.)

Adjusting minimum turning radius (1) Make sure that the protrusion of the stopper bolt meets the standard value. Item Protrusion of bolt

Standard value 25 mm (0.98 in.)

(2) If the amount of protrusion of stopper bolt does not meet the standard value, adjust it as instructed blow. - Tentatively loosen the lock nut. - Adjust the stopper bolt protrusion to the standard value. - Measure the minimum turning radius again. - If the normal minimum turning radius cannot be obtained with the stopper bolt protrusion set to the standard value, re-adjust by varying the amount of protrusion properly. - When the minimum turning radius has met the specified value, tighten the lock nut to the specified torque.

Tightening torque 487 NÂˇm (50 kgfÂˇm) [359 lbfÂˇft]

9-22

500145 1. Lock nut

2. Stopper bolt (right and left)

CHAPTER 9 REAR AXLE

13. Troubleshooting Situation

Steering wheel is heavy.

Steering wheel pulls to one side.

Steering wheel swings.

Local or premature wear of rear wheel.

Possible causes

Action

Defective steering system.

Refer to the chapter of "11 STEERING SYSTEM" to proceed to inspection or adjustment.

Defective hydraulic system

Refer to the chapter of "12 HYDRAULIC SYSTEM" to proceed to inspection or adjustment.

Insufficient lubrication in the rear axle.

Greasing.

Low tire inflation pressure.

Adjust inflation pressure.

Difference in the outside diameter of tires between the right and left.

Change to the tire of normal outside diameter.

Tire inflation pressure differs between the right and left tires.

Adjust inflation pressure.

Wear or damage in the tapered roller bearing.

Replace the bearing.

Defective steering system.

Refer to the chapter of "11 STEERING SYSTEM" to proceed to inspection or adjustment.

Type or inflation pressure differs between the right and left wheels.

Replace wheels with specified ones and adjust inflation pressure.

9-23

CHAPTER 9 REAR AXLE

14. Service Data 14.1 Rear Axle Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

Oscillation angle (right and left)

Standard value

3°

Toe-in

Standard value

0°

Caster

Standard value

0°

Camber

Standard value

+1°

Inside (hub bolt)

Standard value

78°27’

Outside

Standard value

51°14’

Standard value

60 -0.010 mm (2.36 -0.0004 in.)

Steering angle

Outside diameter of knuckle pin

-0.029

Repair limit

FD150ANZ

-0.0011

59.9 mm (2.36 in.)

Tangential force of knuckle bearing (knuckle arm)

Standard value

98.1 to 145.8 N (10 to 15 kgf) [22 to 33 lbf]

Preload of hub bearing

Standard value

18.6 to 27.5 N·m (1.9 to 2.8 kgf·m) [14 to 20 lbf·ft]

Tangential force of hub bearing (hub bolt)

Standard value

88.3 to 127.5 N (9.0 to 13 kgf) [20 to 29 lbf]

Clearance of center pin in the front and Standard value rear directions Repair limit (total of front and rear)

Tightening torque for lock nut of knuckle stopper bolt

Standard value

487.4 N·m (49.7 kgf·m) [359.5 lbf·ft]

Tightening torque for wheel nuts

Standard value

490.3 to 588.4 N·m (50 to 60 kgf·m) [361.6 to 434.0 lbf·ft]

Tightening torque for rear axle support Standard value mounting bolts

Tightening torque of power steering bracket bolts

Standard value

290 to 350 N·m (30 to 36 kgf·m) [214 to 258 lbf·ft]

Tightening torque for hose

Standard value

49 ± 5 N·m (5 ± 0.5 kgf·m) [36 ± 4 lbf·ft]

0.8 mm (0.032 in.) or less 1.2 mm (0.047 in.)

209.9 N·m (21.4 kgf·m) [154.8 lbf·ft]

3 5

8 1)

9-24

2 1

1) - 1)

500154

CHAPTER 9 REAR AXLE 14.2 Power Steering Cylinder Ref.

Truck model

Inside diameter of cylinder

Outside diameter of piston rod

Clearance between rod and bushing

4 5

FD100NZ Standard value

FD120NZ

FD135NZ

115 mm (4.53 in.)

Repair limit

115.15 mm (4.5335 in.)

Standard value

80 mm (3.15 in.)

Standard value

0.1 mm (0.004 in.)

Repair limit

0.2 mm (0.008 in.)

Runout of piston rod

Repair limit

0.6 mm (0.024 in.)

Tightening torque for cylinder head

Standard value

FD150ANZ

696 ± 70 N·m (71 ± 7 kgf·m) [513 ± 52 lbf·ft]

500151

9-25

CHAPTER 10 BRAKE SYSTEM

Chapter 10 BRAKE SYSTEM 1.

Specifications Truck model Type Drum diameter

Wheel brake

Lining size (Length x Width x Thickness - Quantity) Wheel cylinder inner diameter Brake booster Type

Parking brake

Drum diameter Lining size (Length x Width x Thickness - Quantity)

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Hydraulic, internal shoe expanding drum, leading and trailing shoe type 420 mm (16.5354 in.) 401 mm x 190 mm x 16 mm - 4 pieces (15.7874 in. x 7.4803 in. x 0.6299 in.) 55.56 mm (2.1874 in.) Air Master (pneumatic booster) Center located, internal shoe expanding drum type 304.8 mm (12.0 in.) 353.2 mm x 75 mm x 6.2 mm - 2 pieces (13.9055 in. x 2.9528 in. x 0.2441 in.)

10-1

CHAPTER 10 BRAKE SYSTEM

2. 2.1

Structure Outline of Wheel Brake System

500250

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

Air compressor Air dryer Check valve Air tank Safety valve Air governor

Air compressed by the compressor is dehumidified with the air dryer, and filled in the air tank. The compressed air is open/closed and regulated with the brake control valve, and sent to the Air Master. The Air Master pressurize brake fluid with this compressed air, and activate the wheel brakes to bring the truck to stop.

10-2

7. 8. 9. 10. 11.

Relay valve Brake valve Air Master Reservoir tank Front axle

CHAPTER 10 BRAKE SYSTEM 2.2

Air Governor

2) 14

6 4

2 3 8

7 9

15 10 11 12

3) 4) 5)

500251

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

Valve body Cap Diaphragm assembly High pressure valve Low pressure valve Valve seat Sleeve Spring Spring guide Nut

When the air governor is not activated, compressed air from the air link equal to the set value is always applied to the bottom face of the high pressure valve in diaphragm assembly. As a result, the tank pressure and the spring tension are balanced so that the high pressure valve is in tight contact with the valve seat, and the connection between the tank side port and the unloader side port is blocked. When the tank pressure exceeds the set pressure, the compressed air prevails against the spring, and slightly pushes the high pressure valve up slightly off the valve seat.

11. 12. 13. 14. 15. 1) 2) 3) 4) 5)

Adjusting screw Nut Cover Tank side port Unloader side port Inactive State Active state Atmosphere Compressed air High compressed air

With the expansion of diaphragm effective area, the diaphragm is pushed up, and the low pressure valve is tightly pressed against the sleeve seat face. The compressed air activates the unloader valve flowing from the tank side port to the unloader side port, and block the supply of compressed air. When the tank pressure is reduced and becomes lower than the set pressure, the diaphragm is push down by the spring tension, and the compressor starts operation.

10-3

CHAPTER 10 BRAKE SYSTEM 2.3

Relay Valve

2) 9 3)

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

2 3 4)

Body Valve guide Inlet valve Spring Diaphragm Valve rod Spring

The relay valve controls the braking pressure corresponding to the pressure change in pipe line at the brake control valve side, which can extremely shorten the time required to increase the braking pressure.

10-4

500252

8. 9. 1) 2) 3) 4)

Cover Vent hole From brake control valve To Air Master From air tank To atmosphere

Compressed air in tank is directly sent to the Air Master to prevent the delay of brake application. When releasing the brake, the compressed air from the Air Master is discharged directly from here.

CHAPTER 10 BRAKE SYSTEM Generation of brake pressure

When the brake pedal is pressed down and the pipe line pressure from the brake control valve increases, the valve rod is lowered with the diaphragm to close the exhaust port, and the inlet valve is lowered to open the inlet port. The compressed air in air tank is led to Air Master from this inlet port.

3) 2) 500253 1) From brake control valve 2) From air tank

Stabilization of brake pressure

3) To Air Master

When the pressure of Air Master increases, the force acting on the underside of diaphragm increases by the pressure entered from vent hole. When this force becomes larger than the top face force supplied from the 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 of the brake control valve side.

500254 1) From brake control valve

Releasing of brake pressure

2) From Air Master

When the brake pedal is released, the air pressure from brake control valve decreases. The valve rod lifts further to open the exhaust port, and air in Air Master is discharged through the center of inlet valve.

3) 1) To brake control valve 2) From Air Master

500255 3) To atmosphere

10-5

CHAPTER 10 BRAKE SYSTEM 2.4

Brake Control Valve

9 8

4) 5)

1 13

14 15

3 4

6 7

17 18 19 20 500256

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

Valve cover Main spring assembly Valve case Return spring Spring Packing Cap Boot Pedal Push button Plunger Plunger guide Packing O-ring

By pressing down the pedal, a volume of compressed air in proportion to the pedal stroke is supplied to the cylinder shell in Air Master.

10-6

15. 16. 17. 18. 19. 20. 1) 2) 3) 4) 5) 6) 7)

Piston Feed valve assembly Spring sheet O-ring C-ring Dust seal Air tank side port Air Master side port Free play 4 ± 1.5° Normal braking 12 ± 1° Setting pedal angle 39 ± 1.5° Emergency braking 6 ± 1.5° 17°

When the pedal is released, the compressed air in the cylinder shell is discharged to the atmosphere.

CHAPTER 10 BRAKE SYSTEM 2.5

Air Master

1) 2)

14 500466

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

Piston packing Piston plate Cylinder shell Push rod Return spring End plate Air breather Hydraulic cylinder

9. 10. 11. 12. 13. 14. 1) 2)

Breather plug Cylinder cap Hydraulic piston assembly Switch assembly Rod and plate assembly Outlet valve From brake control valve (compressed air) To wheel brakes (high pressure fluid)

Blake fluid pressurized by the compressed air supplied from the brake control valve is used to activate the wheel cylinder.

10-7

CHAPTER 10 BRAKE SYSTEM Inactive state Since the brake control valve is closed, right and left of the piston plate is at the atmospheric pressure. The piston plate is pushed leftward by the return spring as shown in the illustration.

2 1. Piston plate

500257 2. Return spring

When brake pedal is pressed down When the brake control valve is opened, the compressed air flows into the inlet port of cylinder shell. The compressed air pushes the piston plate and return spring rightward as shown in the illustration, and also pushes the hydraulic piston through the push rod connected to the piston plate. When the hydraulic piston begins to move, the check valve yoke which contacted the stopper is pushed back by the spring. As a result, the ball is in tight contact with the seat face by the brake fluid in the cylinder, and closes the circuit to the reservoir tank. In this way, the brake fluid pressure in hydraulic cylinder is adjusted in proportion to the compressed air pressure by moving the piston, and applied to the wheel cylinder.

1 3 1. Push rod 2. Hydraulic piston 3. Check valve yoke

500258

4. Yoke spring 5. Ball

When brake pedal is released When the brake control valve closes, the compressed air in the cylinder is discharged through the bottom of 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 by the oil pressure from the wheel cylinder, as shown in the illustration. When the check valve yoke contacts the stopper, the ball is separated from the seat face, and the circuit is open to the reservoir tank. In this way, the brake fluid in the hydraulic cylinder is relieved and the brake is released.

1 500259 1. Stopper

10-8

CHAPTER 10 BRAKE SYSTEM Brake lining wear warning When the stroke of piston plate becomes longer, the 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 operator compartment illuminates, and the warning buzzer sounds. Since the elongated stroke of piston plate is caused by wear of brake linings, adjustment of the brake linings is required.

1 2 1. Piston plate 2. Rod and plate assembly

500260

3. Switch assembly

10-9

CHAPTER 10 BRAKE SYSTEM 2.6

Wheel Brake

9 8 5

1) - 1)

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

Brake shoe Anchor pin Lock plate Wheel cylinder Return spring

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 the 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 the adjusting cam. The adjusting cam is an eccentric cam, and the clearance adjustment of brake shoe is done by rotating the cam. The wheel cylinder is an opposed piston type, and its body is bolted on the anchor bracket.

10-10

10 6. 7. 8. 9. 10.

500261

Anchor bracket Adjusting cam Adjusting spring Lining wear indicator Dust cover

When the brake pedal is not pressed down, the brake shoe is retracted with the return spring, since the pressure of the brake fluid is not applied to the wheel cylinder. When the brake pedal is pressed down, the push rod of wheel cylinder is extended to right and left, and which results 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.

CHAPTER 10 BRAKE SYSTEM 2.7

Parking Brake System

500467

1. 2.

Parking brake lever Parking brake wire

Parking brake drum assembly

This parking brake is an internal expanding type, and the brake is applied with the parking brake lever and the flexible wire to the brake drum which is mounted to the input flange on the front axle. The main purpose of the parking brake system is preventing the truck from moving at the time of parking, it is also used as an auxiliary brake in case of brake system failure.

10-11

CHAPTER 10 BRAKE SYSTEM 2.8

Parking Brake Lever

4 500262

1. 2. 3.

Lever support pin Adjusting screw Parking brake lever assembly

4. 1) 2)

Inspection and repair (1) If the lever pin or lever pin hole is seriously damaged, replace the lever assembly. (2) If the parking brake cable is stretched, damaged or rusted, replace the cable. Reassembly Connect the wire to the lever, then inspect whether or not the operating effort is within the standard value. Item Lever operating effort

10-12

Standard value 245 to 295 N (24.98 to 30.08 kgf) [55.08 to 66.32 lbf]

Parking brake switch Released state Activated state

CHAPTER 10 BRAKE SYSTEM 2.9

Parking Brake

1) - 1) 3

5 6 7 1)

9 500270

1. 2. 3. 4. 5.

Dust shield Camshaft Parking brake drum Support plate Parking brake lining

6. 7. 8. 9. 10.

Parking brake shoe Spring Spring Adjuster assembly Lever

Parking brake is an internally expanding type, in which the brake shoes inside the drum is expanded by a cam operation, and has an adjuster assembly at the bottom to adjust a clearance between the lining and drum.

10-13

CHAPTER 10 BRAKE SYSTEM

Removing Wheel Brake

3.1

Preparation

Disassemble the front axle by referring to the disassembly sequence of front axle.

3.2

Removal Sequence

3 1

2 1. 2.

Bolts (2 places on the upper part) Bolt

10-14

Wheel brake assembly

500263

CHAPTER 10 BRAKE SYSTEM 3.3

Suggestions for Removal

Special tool

The removal of two mounting bolts on the upper part is difficult, because they are beneath the return spring. And the nuts on the back side is also difficult to remove. Use the special tools.

1 1. The bolt

500264 2. Return spring

1 2

3 Ref.

Special tool name

Part number

Bolt holding wrench

92367-02100

Torque wrench

92367-02200

Socket

92367-02300

500265

10-15

CHAPTER 10 BRAKE SYSTEM Removing upper bolts

(1) Use the "L" marked end to the left bolt and "R" to the right to hold the bolts when the wheel brake assembly is seen from the front.

1) 1. Bolt holding wrench

500266

1) Identification mark

(2) Remove the nut using the torque wrench and socket of the special tools.

500267 1. Torque wrench

2. Socket wrench

Removing other bolts Support other bolts using a normal tool, and loosen nuts using the torque wrench and the socket mentioned above.

2 500268 1. The bolt

10-16

2. Other bolt

CHAPTER 10 BRAKE SYSTEM

Installing Wheel Brake

For installation, follow the removal sequence in reverse.

4.1

Suggestions for Installation

Install the wheel brake assembly to the front axle and tighten the bolts to the specified torque.

500460

Item

Tightening torque M14

155.9 N·m (15.9 kgf·m) [115 lbf·ft]

M16

233.3 N·m (23.8 kgf·m) [172 lbf·ft]

Wheel brake assembly

10-17

CHAPTER 10 BRAKE SYSTEM

Disassembling Wheel Brake

5.1

Disassembly Sequence

6 5

7 1

8 11

12 3

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

Return spring Anchor pin Lock plate Shoe and lining assembly Cylinder plate Cylinder cover

10-18

500269

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

Wheel cylinder Pin, Indicator, Cover Boot, Spring, Washer Adjusting cam Dust cover Anchor bracket

CHAPTER 10 BRAKE SYSTEM 5.2

Suggestions for Disassembly

Removing return spring (1) Turn the adjusting cam and move the brake shoes to the fully inner side. (2) Remove the return spring from the brake shoe using the spring setter of the special tool.

500271

Special tool name Spring setter

Part number 03737-10001

Removing anchor pin -

Remove the anchor pin from the anchor bracket using the anchor pin puller of the special tool.

500272

Special tool name Anchor pin puller

Part number 03737-60000

10-19

CHAPTER 10 BRAKE SYSTEM

Inspecting and Correcting Wheel Brake

Dust cover -

Check the dust cover for cracks. When the dust cover is not removed, check the tightening torque of the bolts. Tightening torque 20 ± 4 N·m (2.0 ± 0.4 kgf·m) [14.8 ± 3 lbf·ft]

Shoe and lining assembly -

Check crack or breakage on lining and shoe. If the lining is significantly contaminated by oil, or glazed by heating or the like, replace the lining. Measure the thickness of the lining. If the thickness is less than the service limit, replace the lining.

500273

Item

Standard value Service limit value

Thickness of lining

16 mm (0.6299 in.)

10 mm (0.3937 in.)

Brake drum Grind the inside of the brake drum to repair if locally worn or scratched. Item

Standard value

+0.2 +0.0079 Inside diameter 420 0 mm (16.54 0 in.) of brake drum

Service limit value 424 mm (16.6929 in.)

Return spring -

If the return spring shows a clearance between coils when it is free, replace the spring. Measure the free length of return spring. Item

Free length of return spring

10-20

Standard value 203.5 mm (8.0118 in.)

CHAPTER 10 BRAKE SYSTEM

7. 7.1

Reassembling Wheel Brake Reassembly Sequence of Wheel Brake

8 1) - 1) 10

1 6

12 500461

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

Anchor bracket Adjusting cam Washer, Spring, Boot, Cover, Indicator, Pin Pin, E-ring Brake shoe Anchor pin, Bolt, Lock plate, Lock washer

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

Wheel cylinder, Cylinder plate, Bolt, Washer Cylinder cover, Bolt, Washer Return spring Air breather Connector, Bolt Dust cover, Bolt, Washer

10-21

CHAPTER 10 BRAKE SYSTEM 7.2

Suggestions for Reassembly

Greasing Apply a thin coat of the specified brake grease to the following parts. -

Apply grease to the fitting area of the adjusting cam and wheel cylinder to the anchor bracket before assembling. - Apply grease to the fitting area of the anchor pin to the anchor bracket, and the inside faces of shoe bushing before assembling. Note: Do not allow grease protruding into the drum. Installing wheel cylinder (1) Apply a thin coat of liquid gasket to the mounting surface of cylinder. (2) Align the oil filler port surface on the cylinder with the dust cover side face of anchor bracket, and tighten the bolt to the specified torque. Tightening torque 45 to 69 N·m (4.6 to 7.0 kgf·m) [33.2 to 50.9 lbf·ft] Installing brake shoe (1) Minimize the eccentricity of the right and left adjusting cams. (2) Verify that each push rod of the wheel cylinder is correctly inserted into the shoe web. Installing lock plate and lock washer (1) Tighten the mounting bolts to the specified torque. (2) After installing, bend the lock plate without fail.

500274

Tightening torque 15.7 to 23.6 N·m (1.6 to 2.4 kgf·m) [11.58 to 17.41 lbf·ft]

10-22

CHAPTER 10 BRAKE SYSTEM Installing return spring Hook the return spring to the brake shoe pin using the spring setter of the special tool.

500271

Special tool name Spring setter

Part number 03727-10001

Adjusting lining wear indicator Perform the adjustment of indicator only when the adjusting cam was disassembled. Turn the washer with a wrench, and set the indicator to the innermost position of the lining serve range. In this case, set the adjusting cam to place the shoes at the most retracted position, and hold the adjusting cam not to turn with another wrench. 500275

10-23

CHAPTER 10 BRAKE SYSTEM

Disassembling Wheel Cylinder

8.1

Disassembly Sequence of Wheel Cylinder

9 3

3 2

1 8

500276

1. 2. 3. 4. 5.

Push rod Dust cover Piston Piston cup Spring sheet

10-24

6. 7. 8. 9.

Return spring Bleeder screw Connector Cylinder body

CHAPTER 10 BRAKE SYSTEM

Inspecting and Correcting Wheel Cylinder

Cylinder body -

Check the inner surface of the cylinder bore for rust, erosion or scratches. Check the air bleeder, connector and threads of oil pipes for damage.

Piston -

Check the outer surface of piston for rust or scratches. Install the piston into the cylinder body and measure the clearance. Replace, if the clearance exceeds the service limit.

500277

Item

Standard value

Service limit value

Clearance between piston and cylinder body

0.13 to 0.24 mm (0.0051 to 0.0094 in.)

0.3 mm (0.0118 in.)

Piston cup -

Check bulge, damage and others. Replace, if there is any defect. Replace every year regardless of defects. Item

Standard value

Service limit value

Piston cup

1.94 mm (0.0764 in.)

0.2 to 0.3 mm (0.0079 to 0.0118 in.)

Dust cover -

Replace if damaged or deteriorated. Replace every year regardless of defects.

10. Reassembling Wheel Cylinder To reassemble, follow the disassembly sequence in reverse.

10.1 Suggestions for Reassembly (1) Apply an even coat of brake fluid to the cylinder inside face and piston cups. (2) Pay attention to the orientation of piston cups and not to damage the lips.

10-25

CHAPTER 10 BRAKE SYSTEM

11. Disassembling Air Governor 11.1 Disassembly Sequence

1 500278

1. 2.

Cover Adjusting screw, Nut, Spring guide, Spring, Sleeve, Oring

12. Reassembling Air Governor To reassemble, follow the disassembly sequence in reverse.

10-26

3. 4. 5.

Filter, Snap ring, Screen Valve seat, Bolt, Cap, Diaphragm Valve body

CHAPTER 10 BRAKE SYSTEM

13. Disassembling Air Master 13.1 Disassembly Sequence

6 7

8 *

* *

** *

* *

3 500281

1. 2. 3. 4.

Hydraulic cylinder, Outlet valve, Cylinder cap, Plug, Spring, O-ring, Washer, Ring, Gasket, Nut Hydraulic piston, Washer, Spring, Cup packing, Backup ring, Straight pin, Ring Cylinder shell, O-ring Piston plate, Rubber packing, Washer, Nut

5. 6. 7. 8. 9.

Push rod, Spring, Plate, Spring retainer, Gasket Rod and plate assy, Retainer, Spring Switch, Shims Exhaust cover End plate, Oil seal

Note: The part marked with * is included in the repair kit.

13.2 Suggestions for Disassembly Removing hydraulic piston (1) Apply compressed air of 588 kPa (6.0 kg/cm2) [85.3 psi] or lower to the inlet port at the cylinder shell rear face, and protrude the push rod from the end plate. (2) Remove the pin and remove the hydraulic piston.

500282

10-27

CHAPTER 10 BRAKE SYSTEM

14. Reassembling Air Master To reassemble, follow the disassembly sequence in reverse.

14.1 Suggestions for Reassembly Replacing parts in repair kit Replace the parts in repair kit whenever disassembled. Cleaning parts Clean the parts using cleaners written below to remove surface deposits. -

Wipe off surface deposits of rubber parts with alcohol or diesel oil soaked cloth. Never dip rubber parts in a cleaning fluid. Clean metal parts with a volatile metal cleaning fluid and blow off the fluid completely with compressed air.

Applying lubricant Apply lubricants to the parts written below before reassembling. -

Apply Air Master paste to the rod siding surface, cylinder shell (approx 20 g) [0.71 oz] and rubber packing (approx 10 g) [0.35 oz]. Fill silicone grease G40M to the position of oil seal as shown in the illustration. Apply silicone oil to the oil seal clearance installed in the end plate. Apply brake fluid to the sliding faces of hydraulic cylinder and hydraulic piston. Apply rubber grease to the sliding surfaces of the cup packing and push rod. Apply Air Master paste or silicone oil to the O-rings in air system.

Bleeding air After reassembly, bleed air.

10-28

500283 1. Fill silicone grease G40M.

CHAPTER 10 BRAKE SYSTEM

15. Disassembling Parking Brake 15.1 Disassembly Sequence

7 11 12

8 9

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

Parking brake drum Input flange Return spring Brace Spring Adjuster assembly

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

500284

Shoe and lining assembly Camshaft lever Spring Camshaft Support assembly Dust seal

10-29

CHAPTER 10 BRAKE SYSTEM

16. Inspecting and Correcting Parking Brake Shoe and lining assembly -

Check the lining and shoe for crack or damage. If the lining is significantly contaminated by oil, or glazed by heating or the like, replace the lining. Measure the thickness of the lining. If the wear exceeds the service limit, replace the lining. Item

Thickness of lining

Standard value

Service limit value

6.15 mm (0.2421 in.)

3.5 mm (0.1378 in.)

Brake drum Replace the brake drum if its inside face shows local wear or streak flaw. Item Inside diameter of brake drum

Standard value 304.8

+0.5 +0.0197 0 mm (12.0 0 in.)

Service limit value 307 mm (12.09 in.)

Adjuster assembly Check the wheel teeth for wear, and check that each part of the adjusting screw turns smoothly.

17. Reassembling Parking Brake To reassemble, follow the disassembly sequence in reverse.

17.1 Suggestions for Reassembly Brake drum Replace the brake drum if its inside face shows local wear or streak flaw. Adjuster assembly Check the wheel teeth for wear, and check that each part of the adjusting screw turns smoothly.

10-30

CHAPTER 10 BRAKE SYSTEM

18. Disassembling Brake Control Valve 18.1 Disassembly Sequence

3 4

* *

5 *

500285

1. Pedal, Pedal shaft, Pin, Push button, Shim 2. Valve cover, Boot, Plunger 3. Main spring 4. Piston, O-ring, Return spring Note: The part marked with * is included in the seal kit.

5. 6. 7.

Valve cap, Dust seal, Dust seal plate, C-ring, O-ring Feed valve, Spring seat, Spring Valve case

10-31

CHAPTER 10 BRAKE SYSTEM

19. Reassembling Brake Control Valve To reassemble, follow the disassembly sequence in reverse.

19.1 Suggestions for Reassembly Replacing parts in seal kit Replace the parts in seal kit whenever disassembled. Cleaning parts -

Clean metal parts with a clean metal cleaner. Wipe off surface deposits of rubber parts with alcohol or diesel oil soaked cloth.

R CAUTION Pay attention not to dip the rubber parts in a cleaning fluid. Applying grease Apply grease to O-rings and the sliding surfaces contacting with O-rings. Fill grease to grease grooves.

10-32

CHAPTER 10 BRAKE SYSTEM

20. Disassembling Air Dryer 20.1 Disassembly Sequence

7 8 9

16 *

15 14 1. 2. 3. 4. 5. 6. 7. 8.

Purge chamber Cartridge Filter O-ring Cover Check valve O-ring Set spring

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

500286

Filter plate Filter Desiccating agent Filter Filter plate Snap rings Exhaust cover Valve assembly

Note: The part marked with * is included in the seal kit.

10-33

CHAPTER 10 BRAKE SYSTEM

21. Inspecting and Correcting Air Dryer 21.1 Scheduled Inspection of Air Dryer Maintenance and inspection must be performed at the specified time or service hours as below. Every 3 month or every 500 hours, whichever comes first (1) Open the drain cock of air tank, and check the drain. When the air dryer works normally, the tank does not show drain discharge. (2) If a small amount of drain is discharged, check the discoloration of the desiccating agent. If one fifth of the agent is discolored to brown, replace the agent with new one. When the temperature drop around the air tank is more than 16Â°C (60.8Â°F), a small amount of water may accumulate.

500287 1) Desiccating agent

Every 1 year or 2000 hours, whichever comes first Disassemble the air dryer and replace the desiccating agent, oil filter and all rubber parts with new ones as the repair kit.

10-34

CHAPTER 10 BRAKE SYSTEM

22. Reassembling Air Dryer To reassemble, follow the disassembly sequence in reverse.

22.1 Suggestions for Reassembly Replacing parts in repair kit Replace repair kit parts with new ones. Cleaning parts Clean metal parts with a volatile metal cleaning fluid and blow off the fluid completely with compressed air. Applying grease Apply grease to the O-ring and piston sliding face. Cartridge assembly The standard weight of the desiccating agent is 200 g (7.05 oz). Use the whole one bag in the repair kit.

2 2

(1) Install the filter placing its soft side to the desiccating agent. (2) After placing the agent in the case, tap the whole circle of the case periphery with a plastic hammer to settle the agent.

3 1 1. Filter 2. Desiccating agent

500279 3. Case

10-35

CHAPTER 10 BRAKE SYSTEM (3) Place the soft side of filter to the desiccating agent, and place the filter plate on the case. (4) Tap the filter as below. - Wrap the case bottom with rag winding 2 to 3 rounds. - Hold the filter plate and raise the case approx 100 mm (3.94 in.) from the table and let the case fall to the table. - Repeat the tapping approx 30 times, and check the filter plate position lowered by 4 to 6 mm (0.1575 to 0.2362 in.) before the tapping.

3 1 2 4

1) 2 4 2) 5 1. 2. 3. 4.

Filter Desiccating agent Filter plate Case

500280 5. Rag 1) 4 to 6 mm (0.1575 to 0.2362 in.) 2) 100 mm (3.9370 in.)

R CAUTION Perform the tapping without fail, or the desiccating agent may flow out as powder and cause clogging in the brake system pipes, and result in malfunction of the braking system. Tightening torque Tighten to the specified torque. Item Heater

Tightening torque 19.6 to 29.4 N·m (2.0 to 3.0 kgf·m) [14.46 to 21.68 lbf·ft]

Valve assembly mounting bolt

3.9 to 6.9 N·m (0.4 to 0.7 kgf·m) [2.88 to 5.09 lbf·ft]

Cartridge, Cartridge mounting screw

2.0 to 3.9 N·m (0.2 to 0.4 kgf·m) [1.48 to 2.88 lbf·ft]

Purge chamber mounting bolt

8.8 to 13.7 N·m (0.9 to 1.4 kgf·m) [6.49 to 10.10 lbf·ft]

10-36

CHAPTER 10 BRAKE SYSTEM

23. Adjustment and Operational Test 23.1 Inspecting Wheel Brake Clearance between lining and drum (1) Remove the grommet covering the inspection hole of dust cover. (2) Insert a thickness gauge between the lining and drum through the inspection hole, and check the thickness of the gauge which feels a little drag to insert and pull out. (3) If the thickness is out of the standard value, adjust the clearance by turning the adjusting cam.

500288

Item

Standard value

Clearance between lining and drum

0.2 mm (0.0079 in.)

Check two places in a wheel. Replacing brake lining Replace the shoes as an assembly when the brake lining wear indicator shows the limit of service. And also replace the linings in the cases as below: -

If the lining and brake shoe are not properly assembled. If the lining is significantly contaminated by oil, or glazed by heating or the like. If the lining shows cracks or damage. 500289 1) Wear indicator

10-37

CHAPTER 10 BRAKE SYSTEM Adjusting lining wear indicator Perform the adjustment of indicator only when the adjusting cam was disassembled. To set the lining wear indicator, place the pointer to the inner most position of lining wear range by turning the washer with a wrench. In this case, set the adjusting cam to place the shoes at the most retracted position, and hold the adjusting cam not to turn with another wrench. 500290

Inspecting brake drum -

Check the streak flaw and local wear on the drum inside surface, and replace the drum if the flaw is significant or the local wear is 0.2 mm (0.0079 in.) deep or more. If the inside diameter of the brake drum comes to the service limit, replace the drum. Item

Inside diameter of brake drum

10-38

Standard value +0.2 +0.0079 0 mm (16.54 0 in.)

420

Service limit value 424 mm (16.6929 in.)

CHAPTER 10 BRAKE SYSTEM 23.2 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. (1) Air Master (2) Left side wheel cylinder (3) Right side wheel cylinder

R CAUTION -

Fill the brake fluid in the reserve tank before bleeding. During bleeding operation, refill the brake fluid as required to keep the fluid level to be half or more in the tank.

Bleeding air master The bleeding of Air Master must be performed by 2 persons. (1) Remove the air bleeder screw cap of Air Master, and insert one side of a clear plastic tube to the screw. Place the other side of the tube in a jar filled with the brake fluid. (2) Press down the brake pedal and loosen the bleeder screw to bleed air. (3) Repeat until no air bubbles are seen in the tube, then tighten the screw. 500291

Bleeding wheel cylinder (1) Connect a clear plastic tube onto the bleeder screw of the wheel cylinder. Place the other side of the tube in a jar filled with the brake fluid. (2) Press down the pedal several times, and loosen the bleeder screw while the pedal is pressed down. Then, tighten the screw while the brake fluid flows into the tube. (3) Repeat until no air bubbles are seen. Refill brake fluid to the specified level in the reserve tank. Note: -

Pay attention to the brake fluid level in the reserve tank during the bleeding. Use the specified brake fluid, and do not mix with another brand fluid.

500292

10-39

CHAPTER 10 BRAKE SYSTEM 23.3 Bleeding Brake Pedal Adjust the cam follower of brake control valve with the adjusting bolt to contact with the pedal.

500293 1) Adjusting bolt

R CAUTION Never change the pedal set angle (39 Âą 1.5Â°) of the brake valve.

23.4 Inspecting Brake Control Valve Air leak test (1) Check the air pressure in air tank to be the specified pressure. (2) Release the brake pedal. (3) Apply soap and water to the exhaust port of brake control valve, and check for bubbles. If bubbles are seen, the exhaust valve is leaking air. (4) Press the brake pedal fully, and check the bubbles for the valve air leak. (5) Remove the exhaust port plug and check the valve for damage.

500294

Functional check The functional check of brake control valve must be performed by 2 persons. (1) Attach a R(PT)3/8 connector to the outlet port of brake control valve and connect a pressure gauge. (2) Start the engine and raise the air pressure in the tank to the normal level, then stop the engine. (3) Has the brake pedal kept pressed down by the second person, and verify the readings of the pressure gauge and the gauge on the instrument panel indicating the same value. (4) Keep the pedal pressed down. If the pressure gauge indicator reading decreased, check the air line leak or adjust the governor.

10-40

500295

CHAPTER 10 BRAKE SYSTEM 23.5 Adjusting Parking Brake Adjusting clearance between drum and lining (1) Move the track little by little until the drum adjusting hole is brought to the 30 mm (1.1811 in.) position from the bottom. (2) Release the parking brake lever. (3) Remove the grommet from the adjusting hole and turn the adjuster assembly fully upward to close the clearance between drum and lining. (4) Then turn the adjuster assembly back about eight notches to get the correct clearance. (5) To measure the drum-to-lining clearance, remove the grommet from the dust cover and insert thickness gauges.

500296

1) Shoe expansion

500297

10-41

CHAPTER 10 BRAKE SYSTEM

24. Troubleshooting 24.1 Wheel Brake Situation

Brake can not be applied.

Brake chatters.

Unbalanced braking

Braking is too sensitive or drags.

Air brake drags.

One brake drags.

Possible causes

Action

Air line leak

Repair or replace.

Low air tank pressure

Increase air tank pressure.

Fluid line leak or low fluid level in reserve tank

Repair and add fluid.

Trapped air in hydraulic line

Bleed air from Air Master or wheel cylinder.

Faulty adjustment of drum-to lining clearance

Adjustment

Fluid leak caused by piston cup wear of Air Master or wheel cylinder

Replace. Change fluid with the recommended type if the cup is distorted.

Exposed rivet head caused by lining wear

Replace.

Deterioration of lining surface

Replace.

Local wear or loosening of brake drum

Replace or retighten.

Improper setting of lining to shoe

Replace.

Uneven air pressure of tires

Inflate correctly.

Faulty adjustment of drum-to lining clearance

Adjustment

Improper lining

Repair or replace.

Oil adhesion to lining or drum

Replace. Avoid over-lubrication.

Different size and material of lining

Replace.

Loose shoe or broken return spring

Retighten or replace anchor pin lock nut.

Defective wheel cylinder

Check cylinder piston and piston cup, and replace defective parts.

Small drum-to lining clearance

Adjustment

Activated Air Master with air leak from brake control valve to Air Master

Adjustment

Incomplete release of brake pedal

Lubricate and repair arm shaft. Replace return spring if necessary.

Small drum-to-lining clearance in one brake

Adjustment

Worn or damaged return spring.

Replace.

Incomplete shoe return with seized anchor pin

Replace.

Defective wheel cylinder and piston cup

Replace.

Failed fluid returning with clogging of brake pipe Clean. joint

Brake can not be released.

Brake pedal kicks back.

10-42

Swollen piston cup

Replace.

Distorted push rod

Replace.

Insufficient lubrication of power piston packings

Lubricate.

Defective hydraulic piston cup

Replace.

Incomplete contact of ball and seat in hydraulic piston check valve

Replace piston assembly.

CHAPTER 10 BRAKE SYSTEM 24.2 Parking Brake Situation Brake lever stroke is short. Noise

Brake can not be applied.

Possible causes

Action

Small drum-to lining clearance

Adjustment

Small drum-to lining clearance

Adjustment

Distorted brake drum

Replace.

Worn lining

Replace.

Small drum-to lining clearance

Adjustment

Improper adjustment of brake lever effort

Adjust to 245 to 249 N (24.98 to 25.39 kg) [55.08 to 55.98 lbf].

24.3 Air Dryer Situation

Possible causes

Action

Brake lever stroke is short.

Elongated time to dry saturated air

Drain daily at the end of operation until air line is completely dehydrated.

Noise

Excessive air consumption and continuous air compressor operation

Operate truck to allow compressor in loadedunloaded cycle operation. Or check air dryer installation.

Not periodical change of desiccant

Change desiccant kit periodically.

10-43

CHAPTER 10 BRAKE SYSTEM

25. Service Data 25.1 Brake Pedal Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

Height (from floor to pedal top)

Standard value

190 mm (7.4803 in.)

Free play

Standard value

15 mm (0.5906 in.)

FD150ANZ

500298

25.2 Brake Control Valve Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

Pedal set angle

Standard value

39 ± 1.5°

Free play

Standard value

4 ± 1.5°

Normal braking

Standard value

12 ± 1.0°

Emergency braking

Standard value

6 ± 1.0°

FD150ANZ

2 3 1

500299

10-44

CHAPTER 10 BRAKE SYSTEM 25.3 Air Master Ref.

Truck model Power piston return spring (set load / set length)

FD100NZ Standard value Service limit value

FD120NZ

FD135NZ

FD150ANZ

196 ± 20 N (20.0 ± 2.0 kgf) [44.06 ± 4.5 lbf]/179 mm (7.0472 in.) 157 N (16.0 kgf) [35.3 lbf]/179 mm (7.0472 in.)

Push rod bend

Standard value

0.05 mm (0.0020 in.) or less

Clearance between power piston and cylinder shell

Standard value

0.5 to 1.4 mm (0.02 to 0.0551 in.)

Clearance between hydraulic piston Standard value and cylinder Service limit value

Tightening torque of hydraulic cylinder lock nut

Standard value

98.1 to 147.1 N·m (10.0 to 15.0 kgf·m) [72.35 to 108.49 lbf·ft]

Tightening torque of power piston end nut

Standard value

19.6 to 29.4 N·m (2.0 to 3.0 kgf·m) [14.46 to 21.68 lbf·ft]

Tightening torque of plug nut

Standard value

6.9 to 12.7 N·m (0.7 to 1.3 kgf·m) [5.09 to 9.37 lbf·ft]

Tightening torque of cap

Standard value

176.5 to 343.2 N·m (18.0 to 35.0 kgf·m) [130.18 to 253.13 lbf·ft]

Tightening torque of end plate

Standard value

19.6 to 29.4 N·m (2.0 to 3.0 kgf·m) [14.46 to 21.68 lbf·ft]

Tightening torque of exhaust cover

Standard value

7.8 to 19.6 N·m (0.8 to 2.0 kgf·m) [5.75 to 14.46 lbf·ft]

Tightening torque of nut

Standard value

4.9 to 7.8 N·m (0.5 to 0.8 kgf·m) [3.61 to 5.75 lbf·ft]

Tightening torque of retainer

Standard value

7.8 to 19.6 N·m (0.8 to 2.0 kgf·m) [5.75 to 14.46 lbf·ft]

Tightening torque of switch

Standard value

24.5 to 34.3 N·m (2.5 to 3.5 kgf·m) [18.07 to 25.30 lbf·ft]

0.07 to 0.15 mm (0.003 to 0.0059 in.) 0.2 mm (0.0079 in.)

10-45

CHAPTER 10 BRAKE SYSTEM

8 500469

10-46

CHAPTER 10 BRAKE SYSTEM 25.4 Wheel Brake Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

Standard value

420 mm (16.5354 in.)

Service limit value

424 mm (16.6929 in.)

Inside diameter of brake drum

Thickness of lining

Clearance between lining and drum Standard value

Standard value

16 mm (0.6299 in.)

Service limit value

10 mm (0.3937 in.)

FD150ANZ

0.2 mm (0.0079 in.)

Free length

Standard value

203.5 mm (8.0118 in.)

Set force

Standard value

423 N (43.13 kgf) [95.09 lbf]

Set length

Standard value

251 mm (9.8819 in.)

Tightening torque of steering bracket bolt (M14)

Standard value

155.9 N·m (15.90 kgf·m) [114.98 lbf·ft]

Tightening torque of anchor bracket bolt (M16)

Standard value

233.3 N·m (23.79 kgf·m) [172.07 lbf·ft]

Tightening torque of lock plate bolt

Standard value

15.7 to 23.6 N·m (1.60 to 2.41 kgf·m) [11.58 to 17.41 lbf·ft]

Tightening torque of cylinder bolt

Standard value

45 to 69 N·m (4.59 to 7.04 kgf·m) [33.19 to 50.89 lbf·ft]

Tightening torque of cylinder plate

Standard value

45 to 69 N·m (4.59 to 7.04 kgf·m) [33.19 to 50.89 lbf·ft]

Return spring

1 2

3 500300

10-47

CHAPTER 10 BRAKE SYSTEM 25.5 Wheel Cylinder Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Inside diameter of cylinder body

Standard value

55.56 mm (2.1874 in.)

Clearance between piston and cylinder body

Standard value

0.13 to 0.24 mm (0.0051 to 0.0094 in.)

Service limit value

0.3 mm (0.0118 in.)

Piston cup (lip end) outside diameter

Standard value

56.2 mm (2.2126 in.)

Tightening torque of bleeder screw

Standard value

Service limit value

(Replace every one year) 9.8 to 13.7 N·m (1.0 to 1.4 kgf·m) [7.23 to 10.10 lbf·ft]

500302

25.6 Parking Brake Lever Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Free stroke

Standard value

60°

Lever lock position

Standard value

3 to 6°

Lever operating effort

Standard value

245 to 295 N (24.98 to 30.08 kgf) [55.08 to 66.32 lbf]

3 1

500301

10-48

CHAPTER 10 BRAKE SYSTEM 25.7 Parking Brake Drum Ref.

Truck model

Inside diameter of brake drum

Brake lining thickness

Clearance between lining and drum

Return spring

FD100NZ

FD120NZ

Standard value

FD135NZ

FD150ANZ

304.8 mm (12.0 in.)

Service limit value

307 mm (12.0866 in.)

Standard value

6.15 mm (0.2421 in.)

Service limit value

3.5 mm (0.1378 in.)

Standard value

0.1 to 0.25 mm (0.0039 to 0.0098 in.)

Free length

Standard value

77 ± 0.75 mm (3.0315 ± 0.0295 in.)

Test load (at 83 mm (3.27 in.))

Standard value

223 ± 23 N (22.7 ± 2.35 kgf) [50.13 ± 5.13 lbf]

Length subjected Standard value to test load

83 mm (3.27 in.)

Tightening torque of support plate nut

Standard value

145 ± 22 N·m (14.8 ± 2.2 kgf·m) [107 ± 16 lbf·ft]

Tightening torque for brake drum nuts

Standard value

96 ± 15 N·m (9.8 ± 1.5 kgf·m) [71 ± 11 lbf·ft]

Tightening torque of self-locking nut

Standard value

294 ± 29 N·m (30 ± 3.0 kgf·m) [217 ± 21 lbf·ft] (Including Locktite No.271)

Tightening torque of lever nut

Standard value

14.71 to 22.56 N·m (1.5 to 2.3 kgf·m) [10.85 to 16.64 lbf·ft]

5 6

4 8 500449

10-49

CHAPTER 10 BRAKE SYSTEM 25.8 Air Dryer Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Tightening torque of heater

Standard value

19.6 to 29.4 N·m (2.0 to 3.0 kgf·m) [14.46 to 21.68 lbf·ft]

Tightening torque of valve assembly

Standard value

3.9 to 6.9 N·m (0.4 to 0.7 kgf·m) [2.88 to 5.09 lbf·ft]

Tightening torque of cartridge and cartridge cover

Standard value

2.0 to 3.9 N·m (0.2 to 0.4 kgf·m) [1.48 to 2.88 lbf·ft]

Tightening torque of purge chamber

Standard value

8.8 to 13.7 N·m (0.9 to 1.4 kgf·m) [6.49 to 10.10 lbf·ft]

500468

10-50

CHAPTER 11 STEERING SYSTEM

Chapter 11 STEERING SYSTEM 1.

Specifications Truck model

Steering type Steering valve

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Full-hydraulic power steering Displacement volume

369 cm3/rev (22.52 cu. in./rev)

Rated flow

45.4 L/min (11.99 U.S. gal./min)

Max pressure Steering wheel outside diameter

17.2 MPa (175.4 kgf/cm2) [2495 psi] 320 mm (12.60 in.)

11-1

CHAPTER 11 STEERING SYSTEM

2.Structure 2.1

Steering System

8 7

4 9 1

3 500069

1. Hydraulic tank 2. Return filter 3. Suction strainer 4. Gear pump (oil pump) 5. Priority valve Note: Some truck models do not have the steering knob.

6. 7. 8. 9.

This truck employs a full-hydraulic system that consists of the steering valve, priority valve, power steering cylinder and others. Also with a load sensing mechanism the operator is provided with steering operations which are comfortable and lightly affected by the road condition. 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 steering cylinder on the rear axle. Hydraulic oil discharged from the oil pump is supplied to the steering valve. The flow rate required for the steering operation is determined at the priority valve.

When the steering system requires a small quantity of hydraulic oil, the rest of the hydraulic oil will be supplied to other operation devices. Except the time when the steering is operated, most of the hydraulic oil can be used for load handling devices.

11-2

Control valve for other operation devices Check valve Steering valve Power steering cylinder

CHAPTER 11 STEERING SYSTEM 2.2

Steering Valve

14 10 13 11

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

1 7

Spool Sleeve Outlet port( port T) Inlet port( port P) Rotor Rotor ring Drive shaft Centering spring Pin

The steering valve consists of two sections: rotary valve section and metering section. The rotary valve section consists of spool, sleeve and housing Spool is splined to connect with the steering shaft. When the spool is turned, the sleeve rotates, which causes the following passages to open. (1) The passage from inlet port to metering section. (2) The passage from metering section to port L or port R. (3) The passage that allows oil to flow from the steering cylinder to outlet port. Metering section is a small hydraulic pump consisting of rotor ring and rotor called gerotor. Spool and rotor are commonly connected to driveshaft. When the steering wheel is turned, the rotor 5 rotates in the same direction and at the same speed as the steering wheel does. When the steering wheel is not turned, the oil from inlet port P flows to outlet port T and returns to the hydraulic tank.

500073

10. 11. 12. 13. 14. 15. 1) 2)

Port L Port R Housing Check valve Rotary valve section Metering section Metering pump inlet port Metering pump outlet port

At this moment, the oil passage to metering section is blocked by spool and sleeve. When the steering wheel is turned clockwise, the oil from inlet port flows into areas. The rotor rotates as the steering wheel turns, and the oil in areas is forced into the steering cylinder through port. When the steering wheel is turned counterclockwise, oil flows in the direction reverse to the above. So the oil is forced into the steering cylinder through port L. As the pressure oil from inlet port applies a rotating force to rotor, the steering wheel can be turned with a little effort. Normally, check valve 13 blocks a bypass flow since it is pushed to the left by an oil pressure from the inlet port. When the oil supply from port of the hydraulic valve stops for some reason, the bypass passage opens to allow the oil from the hydraulic tank to flow into the metering section. When the steering wheel is turned, the metering section acts as a manually-operated pump, which pumps the oil into the steering cylinder.

11-3

CHAPTER 11 STEERING SYSTEM

R P

L T

3 1. 2. 3.

LEFT RIGHT OUT

4 500081

4. 5.

IN Load sensing

The steering valve is provided with a load sensing circuit. The load sensing circuit functions to balance the oil pressure between the downstream of variable orifice in the steering valve and the counter-side of spool in the priority valve. This offers a smooth steering operation that is not affected by the vibration in load conditions.

1 2 LS

3 OF

9 10

12 500083 1. 2. 3. 4. 5. 6.

11-4

Steering cylinder Input Load sensing steering valve Steering relief High pressure Filter

7. Main relief 8. Priority valve 9. Filter 10.Pump 11.Engine 12.Tank

CHAPTER 11 STEERING SYSTEM 2.3

Steering Column

6 7

9 10

8 11

1 2 2

1) 5

2) 14

3) 4

500086

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

Steering column Bracket (secured to lift truck body) Tilt lock lever Column lock lever Lock pin Column position when tilted fully forward Column position when lock is released. Combination switch mounting Column position when neutral (tilted 30 degree from the vertical line)

10. 11. 12. 13. 14. 1) 2) 3)

Column position when tilted fully rearward Steering column mounting plate (A) Tilt angle setting plate (B) Bolt Nut Fixing Loosen Lock release

Note: When the tilt lock lever is turned counter-clockwise, plate (A) and (B) are pinched with the bolt and nut and locked. Some truck models do not have the steering knob. The steering column tilt angle is adjustable in the range of 5Â° degrees forward and 7Â° backward as shown in the illustration. To adjust the tilt angle, lock the column lock lever first, and loosen the tilt lock lever by turning it clockwise. Then, tilt the steering column to the optimal angle and turn the tilt lock lever counterclockwise (pull upward) to lock.

The column lock lever is used to tilt the steering column forward for the operators easy access to the seat and for the maintenance job. Tilt the steering column forward by pushing down the tilt lock lever in 3) direction to disengage the column lock lever from the lock pin.

11-5

CHAPTER 11 STEERING SYSTEM

3.Removal and Installation of Steering Valve Pipings 3.1

Main Components

7 6 2

4 3 8 500090

Hose (from priority valve to steering valve P port) 2. Hose (from steering valve T port to main return pipe) 3. Hose (from steering valve L port to power steering cylinder L port) Note: Some truck models do not have the steering knob.

3.2

5. 6. 7. 8.

Hose (from steering valve R port to power steering cylinder R port) Hose (from load sensing LS port to priority valve LS port) Steering valve Priority valve Check valve

Suggestions for Disassembly and Reassembly

(1) Be sure to perform the maintenance work of the hydraulic system in a clean area and be careful not to allow abrasive foreign substances to enter the hydraulic system. (2) Replace the O-ring with a new one when assembling. (3) Hoses of the steering system (especially in the high pressure sections) are safety parts. These must be replaced with new ones disregarding with or without damage after they have been used for the specified period of time. For the replacement interval, refer to "15 SERVICE DATA." (4) When removing or installing hoses, use a counterhold spanner as needed in order to prevent excessive force from being applied to the mating fittings.

11-6

Ref.

Tightening torque of nut

44 to 54 N·m (4.49 to 5.51 kgf·m) [32.45 to 39.83 lbf·ft]

500092

CHAPTER 11 STEERING SYSTEM

4.Removal and Installation of Steering Wheel, Steering Valve and Tilt Lock Lever

2, 1) 3

8 7, 2) 4

5, 3)

500093

1. Steering wheel 2. Nut 3. Spring washer 4. Cover Note: Some truck models do not have the steering knob. Ref.

Tightening torque

54 to 59 N·m (5.51 to 6.02 kgf·m) [39.83 to 43.52 lbf·ft]

26.8 to 40.2 N·m (2.73 to 4.10 kgf·m) [19.77 to 29.65 lbf·ft]

29.4 N·m ( 3.0 kgf·m) [21.68 lbf·ft]

5. 6. 7. 8.

Steering valve mounting bolt Steering valve Steering column assembly mounting bolt Steering column assembly

11-7

CHAPTER 11 STEERING SYSTEM 4.1

Removing Steering Wheel

(1) Remove the horn button. (2) Remove steering wheel nut, and then remove steering wheel with the wheel puller.

2 3

4 500094 1. M12 bolt 2. M8 bolt

Special tool name Wheel puller

3. Wheel puller 4. Steering wheel

Part number 91268-10600

R CAUTION When removing the steering wheel, do not tap the top end of the steering shaft.

4.2

Installing Steering Wheel

(1) Turn the protrusion on the steering wheel angle sensor of combination switch by hand to orient the direction as shown in the illustration. (2) Apply a thin coat of grease to the sliding face of the horn contact under the steering wheel boss. (3) Orient the steering wheel to the straight forward traveling position. (The protrusions on the combination switch must fit to the dents on the steering wheel.) Rotate the steering wheel to both directions several times to make sure the snug fitting. (4) Before tightening the steering wheel nut, make sure that the automatic return of the combination switch functions properly. (5) If the automatic return does not function, repeat the step (3) and (4). (6) Tighten the steering wheel nut to the specified torque.

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

500095 1. Combination switch 1) Horn switch contact 2) Front

3) Protrusions form an isosceles triangle. 4) Forward 5) Protrusion

Note: Some truck models do not have the steering knob.

11-8

CHAPTER 11 STEERING SYSTEM 4.3

Inspection After Installation of Steering Wheel

Steering effort (1) Apply the parking brake. (2) Run the engine to warm the hydraulic oil temperature up to between 40 and 60 °C (104 and 140 °F). (3) Attach a spring scale to the rim or spoke of the steering wheel, and measure the steering effort required to turn the steering wheel clockwise or counterclockwise from the straight-ahead position. Steering effort must be the value specified below or lower.

500096

Note: Some truck models do not have the steering knob. Item

Standard value

Steering effort (at steering wheel rim)

28 N (2.86 kgf) [6.29 lbf]

4.4

Removing Steering Valve

(1) Remove the cover around the steering column. (2) Disconnect the five hoses from the steering valve. (3) Remove the steering wheel mounting bolts, and remove the steering valve.

500097

Ref.

Bolt tightening torque

29.4 N·m (3.0 kgf·m) [21.68 lbf·ft]

4.5

Installing Steering Wheel

(1) Apply grease to the serrated area on the lower part of the steering shaft. (2) Tighten the steering valve mounting bolts to the specified torque. (3) Tighten the hose nuts to the specified torque. (4) Bleed air after reassembly. Bleeding Steering system (1) Raise the rear tires and support with jack stands. (2) Start the engine and operate the accelerator pedal to vary the engine speed while turning the steering wheel fully to the right and left. This bleed air from the relief valve.

11-9

CHAPTER 11 STEERING SYSTEM 4.6

Disassembling Tilt Lock Lever

(1) Put alignment marks on the tilt lock lever and the nut (B) for the proper installation at reassembly. (2) Remove the bolt (A), and remove the tilt lock lever.

1 2

1 4 1. Tilt lock lever 2. Lever mounting bolt 3. Nut (B)

4.7

Reassembling Tilt Lock Lever

If the alignment marks have disappeared, or the lever is being replaced with a new lever, install the lever referring to the following steps. (The illustration right shows relative positionings of tiltneutral and column lock lever-lock) (1) Tighten the nut B to the tightening torque of 11 to 15 N·m (1.12 to 1.53 kgf·m) [8.11 to 11.06 lbf·ft]. (This represents a lever-locked condition.) (2) Select the optimal position for the tilt lock lever in a locked condition, and fit the tilt lock lever into the serration of nut (B). The optimal position is where the notch 2) section of the bracket intersects with the upper face of the lever. (3) Tighten the bolt (A). (4) Loosen the tilt lock lever and check that the bracket slides in the entire tilting area without interfering with other parts.

11-10

500098 4. Bolt (A) 1) Lever face

CHAPTER 11 STEERING SYSTEM

5.Disassembling Steering Valve 5.1

Disassembly Sequence of Steering Valve

4 6 5

11 7 9 8 10

500099

1. 2. 3. 4. 5.

End cap, Bolt, O-ring, Spacer Gerotor set, O-ring Drive shaft, Spacer plate, O-ring Retaining ring Seal gland bushing, O-ring Oil seal, Dust seal

6. 7. 8. 9. 10. 11.

Thrust needle, Race bearing Control sleeve Control spool Pin Centering spring Housing

11-11

CHAPTER 11 STEERING SYSTEM 5.2

Suggestions for Disassembly of Steering Valve

(1) Place the steering valve housing body in a vertical position with the end cap face upward. When using a vise, lightly clamp the mounting flange of the housing. Place copper plates between the housing and the jaws of vise to prevent the over tightening of housing.

500100

(2) Remove screw 7 and remove the end cap.

2 1

500101 1. O-ring 2. End cap

(3) Remove the O-ring from the end cap, and remove the spacer installed on the spline in the gerotor rotor. (4) Remove the gerotor. Pay attention not to drop the rotor from the rotor ring. (5) Remove the O-ring from the gerotor, oil seal retainer.

3. Screw

3 500102

1. O-ring 2. Spacer

11-12

3. Gerotor

CHAPTER 11 STEERING SYSTEM (6) Remove the drive shaft. (7) Remove the spacer plate. (8) Remove the O-ring from the housing.

3 500103 1. O-ring 2. Spacer plate

3. Drive

(9) Remove the adapter screw with a flat-tip screw driver. (10) Remove the housing from vise, and turn the housing upside down to remove the ball. (Pay attention not to drop or lose the ball. )

500104

(11) Place the housing on clean cloth facing the flange upward not to damage the finished surface. Remove the retaining ring from the housing with a flattip screw driver. Pay attention not to damage the machine finished surface.

500105

11-13

CHAPTER 11 STEERING SYSTEM (12) Place the pin in the horizontal position by turning the control spool and control sleeve, and push the spool and sleeve by thumb to remove the seal gland bushing from the housing. (13) Remove the seal gland bushing oil seal. (14) Remove the dust seal from the seal gland bushing with a flat-tip screw driver.

500106 1. Seal gland bushing

R CAUTION Pay attention not to damage the seal gland bushing. (15) Remove 2 race bearings and the thrust needle.

2 3

500109 1. Race bearing 2. Thrust needle

3. Race bearing

(16) Pull out the control sleeve and control spool as one body to the arrow direction in the illustration from the housing. Then, pull out the pin.

500107

R CAUTION Slightly rotate the sleeve to pull it out so that the sleeve does not bind inside the housing.

11-14

CHAPTER 11 STEERING SYSTEM R CAUTION Make mating marks on the control spool and control sleeve before disassembling. (17) Push the spool in sleeve slightly forward and remove the centering springs. Pull out the control sleeve to the rear by rotating the control spool slowly.

500108

5.3

Inspection after Disassembly

Check sliding faces between the sleeve and the housing and between the sleeve and the spool. (1) Check for sliding movement in the sub-assembly condition. (2) Check the sliding surfaces for any unusual sliding movement. If any defect such as wear, scratches, burrs, or rust is found, replace the assembly with a new one.

11-15

CHAPTER 11 STEERING SYSTEM

6.Reassembling Steering Valve 6.1

Preparation

Prepare new parts for the damaged parts. Clean surfaces of all metal parts, blow off foreign substances with compressed air and dry them. Replace parts included in the seal kit.

Apply a thin coat of oil to each part during reassembly. Apply grease to O-rings. Do not wear fabric gloves when assembling. Lint or fibers may enter the valve and cause failure.

R CAUTION

6.2

Reassembly Sequence of Steering Valve

9 86

7 11

4 2

1 10 500110

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

Long housing Control sleeve Control spool Centering spring Pin Thrust needle, Race bearing

11-16

7. 8. 9. 10. 11.

Seal gland bushing, oil seal, dust seal, O-ring Retaining ring Drive shaft, Spacer plate, O-ring Gerotor set, O-ring End cap, O-ring, Spacer, Bolt

CHAPTER 11 STEERING SYSTEM 6.3

Suggestions for Reassembly

Assembling control spool and sleeve Align the spring grooves in the spool and sleeve, then slide the spool into the sleeve while rotating the spool. Check the matching marks marked in the disassembling or marks marked by the manufacturer, if applicable.

2 1

3 1. Spring groove 2. Spring groove

500112

3. Matching mark

R CAUTION Be sure that the spool rotates smoothly in the sleeve without any restrictions. Installing centering spring (1) Align the spring grooves in the spool and sleeve assembly, and stand the spool and sleeve assembly on a flat workbench. (2) Use the spring insertion tool to install springs. Place three springs and three springs back to back and insert them into the spring insertion tool placing the notches on both ends downward. See the illustration on the right. (3) Hold one end of the springs with fingers and push the springs into the notches of the spool and sleeve assembly. If the spring insertion tool is not available, insert the springs one by one alternately from the right and left. Spring insertion tool Spring

500113

Number 97157-00100

Inserting control spool and sleeve assembly into housing (1) Insert the pin into the control spool and sleeve hole. Align the pin ends to the sleeve outside diameter. (2) Insert the spool and sleeve assembly from the back of housing (as shown in the illustration). Keep the pin in the horizontal position, slightly rotate the assembly clockwise and counter-clockwise to insert. Insert the spool and sleeve assembly until its rear end becomes flush with the housing end face. Do not insert farther.

500114

11-17

CHAPTER 11 STEERING SYSTEM Installing O-ring and thrust bearing

(1) Install the race bearing and thrust needle bearing to the control spool. (2) Install the O-ring to the housing.

500115 1. O-ring 2. Thrust needle

3. Race bearing

Installing seal (1) Install the dust seal to the seal gland bushing. The installing direction is as shown in the illustration. Install the oil seal. (2) Install the O-ring and install the seal gland bushing in the spool by rotating the bushing. Tap in the bushing to the specified position with a plastic hammer. (3) Check that the bushing is horizontally contacts on the race upper face of thrust bearing. (4) Install the retaining ring firmly in the housing groove. 500116

500117 1. Retaining ring

11-18

CHAPTER 11 STEERING SYSTEM Installing spacer plate (1) Use soft pads to hold the housing in a vise or wrap the housing with soft cloth before hold the housing with vise. Lightly hold the flange flat area. Never over-tighten with vise. Note: Check that the spool and sleeve is flush with the housing face or lower.

500118

(2) Install the ball in the hole of seven thread holes on the housing end face as shown in the illustration. (3) Install the adapter screw to the hole having the ball.

500119

(4) Install the O-ring to the housing. Place the spacer plate on the housing and align the bolt hole to the tap hole in housing.

500120

R CAUTION The bolt holes and oil holes are different in pitch diameters.

11-19

CHAPTER 11 STEERING SYSTEM Installing drive shaft

(1) Rotate the control spool and sleeve assembly to make the port surface of the housing parallel with the pin. (2) Insert the drive shaft, and fit the pin in the yoke of drive shaft. (3) Draw an alignment mark like the line B in the next illustration on the end face of drive shaft spline with a felt-tip pen to ensure the proper positioning during the following process.

1 2) 2 1. Drive shaft 2. Pin

1) Port face 2) Place the pin and port in a parallel position.

Installing gerotor set (1) Install the O-ring to the gerotor. Place the gerotor Oring side to the spacer plate side. Align the bottom of gerotor rotor (Line A) to the line B of drive shaft and assemble them. (2) Check the lines A, B, C, and D are in parallel with each other. (3) Keep the engagement of the drive shaft and gerotor rotor, and align the bolt holes of the gerotor set. Note: This procedure is important to determine the valve timing of this unit.

500121

1) 1 2

A B C

500122 1. Spacer plate 2. Drive shaft (with marked line)

11-20

1) Gerotor set, Bottom of rotor

CHAPTER 11 STEERING SYSTEM Installing end cap

Install the drive spacer in the spline of gerotor rotor. Install the O-ring to the end cap. Place the end cap on the gerotor set and align the bolt holes.

3 500123

1. End cap 2. Cap screw

3. Drive spacer 4. O-ring

Apply oil to the bolt threads, and tighten the bolts evenly in the sequence shown in the illustration. The tightening torque is shown in the table below. Install the steering shaft into the spool and make sure that the spool turns smoothly.

500124

Item End cap bolt

Tightening torque 28 N·m (2.86 kgf·m) [20.65 lbf·ft]

11-21

CHAPTER 11 STEERING SYSTEM

7.Troubleshooting Situation

Possible causes No steering flow

Flow priority valve failure

Spring settling.

Excessive steering effort

Disassemble and clean.

Spring in spool fatigued

Replace spring.

Low relief pressure

Adjust relief pressure.

Damaged valve seating surface

Replace valve assembly.

Spring settling.

Replace spring, and adjust relief pressure.

Damaged O-ring on the valve body

Replace O-ring. Disassemble and clean.

Sleeve and spool seizure due to foreign material

Replace.

Damaged bearing

Replace.

Overtightening of end cap bolts

Retighten.

Steering cylinder failure

Deflection of piston rod

Replace.

Damaged piston seal

Replace.

Misalignment

Faulty assembled steering valve and tilt column

Adjustment

Other defects

Flattened hose or pipe

Replace.

Spool or sleeve seizure

Replace.

Damaged center spring

Replace.

Air trapped

Bleed air.

Flattened hose or pipe

Replace.

Damaged piston seal of steering cylinder

Replace.

Steering valve failure

11-22

Foreign materials clogged in orifices of spool

Clogging in gerotor Steering valve failure

Unstable steering wheel operation

Malfunction of relief valve

Action

Other failures

CHAPTER 11 STEERING SYSTEM

8.Service Data Truck model

FD100NZ FD120NZ FD135NZ FD150ANZ

Steering effort at steering wheel periphery (at engine low-idling, steering wheel 1 turn/sec of stationary steering)

Standard value

28.0 N·m (2.86 kgf·m) [20.65 lbf·ft]

Steering wheel play

Standard value

70 mm (2.76 in.)

Inside

Standard value

78° 27’

Outside

Standard value

51° 14’

Tightening torque of steering wheel nuts

Standard value

54 to 59 N·m (5.51 to 6.02 kgf·m) [39.83 to 43.52 lbf·ft]

Tightening torque of steering bracket bolts

Standard value

26.8 to 40.2 N·m (2.73 to 4.10 kgf·m) [19.77 to 29.65 lbf·ft]

Displacement volume

Standard value

369 cm3/rev (22.52 cu. in./rev)

Rated flow

Standard value

45.4 L/min (11.99 U.S. gal./min)

Max pressure

Standard value

17.2 MPa (175.4 kgf/cm2) [2495 psi]

Tightening torque of mounting bolt

Standard value

29.4 N·m (3.0 kgf·m) [21.68 lbf·ft]

Rotating torque in normal operation

Standard value

1.5 N·m (0.15 kgf·m) [1.11 lbf·ft]

Tightening torque of cap bolt

Standard value

28 N·m (2.86 kgf·m) [20.65 lbf·ft]

Standard value

17.2 MPa (175.4 kgf/cm2) [2495 psi]

Steering angle

Steering valve

Steering system relief valve set pressure

500111

11-23

CHAPTER 12 HYDRAULIC SYSTEM

Chapter 12 HYDRAULIC SYSTEM 1.

Specifications Truck model

FD100NZ

FD120NZ

Type Gear pump

Priority valve

KFP51100CSMSM 205 (at 2200 rpm) L/min (54.2 U.S. gal./min)

Drive method

Directly coupled to torque converter

Maker model

VLE61C160PBB 15.7 MPa (160 kgf/cm2) [2277 psi]

Steering relief pressure Maker model

Control valve Hydraulic system

Flow regulator valve

Lift cylinder Tilt cylinder (Front and rear tilt angle15°-12°) Working fluid quantity (N level)

FD150ANZ

Gear type

Maker model Control flow rate

FD135NZ

Relief pressure Type Control flow rate Inner diameter Stroke Inner diameter Stroke Quantity of oil in circuit Tank capacity

MW(P)25 20.6

+0.5 +5.1 +72.52 2 0 MPa (210 0 kgf/cm ) [2987.8 0 psi]

Cylindrical valve type 120 L/min (31.7 U.S. gal./min)

143 L/min (37.8 U.S. gal./min)

105 mm (4.13 in.)

115 mm (4.53 in.)

1500 mm (59.1 in.) 120 mm (4.7 in.)

130 mm (5.12 in.) 270 mm (10.6 in.)

186 L (49.1 U.S. gal.)

195 L (51.5 U.S. gal.)

140 L (37.0 U.S. gal.)

223 L (58.9 U.S. gal.) 168 L (44.4 U.S. gal.)

12-1

CHAPTER 12 HYDRAULIC SYSTEM

2. 2.1

Structure Hydraulic Line

9, 10

9, 10 11 15

11 8

7 6

13 12

4 2

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

Hydraulic tank Return filter Suction strainer Gear pump (oil pump) Priority valve Control valve for work equipment Lift valve Tilt valve

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

Flow regulator valve Lift cylinder Tilt cylinder Check valve Steering control valve Power steering cylinder Emergency lift return valve

Note: Some truck models do not have the steering knob. The hydraulic system functions in such a way that it sucks up the working fluid from the hydraulic tank and distributes thus pressurized oil dividedly to the work equipment and steering system through an adjustment with the priority valve. Pressurized oil in the work equipment will be fed to each cylinder through the control valve. Note: Refer to "11 STEERING SYSTEM" for steering control valve. And refer to "9 REAR AXLE" for power steering.

12-2

500011

CHAPTER 12 HYDRAULIC SYSTEM 2.2

Hydraulic Tank

4 1

6 1. 2. 3. 4.

Cap Oil level gauge Strainer Breather

5. 6. 7. 8.

500005

Drain plug Suction strainer Return filter Oil level gauge

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 be merged to the return oil from the control valve and steering control valve and return to the hydraulic tank through the return filter (25 Îź).

12-3

CHAPTER 12 HYDRAULIC SYSTEM 2.3

Priority Valve

2 3 1

4 4)

1) 3)

5 6

6) 1. 2. 3. 4. 5. 6.

Relief valve Plug Housing Control spring Spool Plug

1) 2) 3) 4) 5) 6)

Of the working 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, and all the rest will be forwarded to circuits of other work equipment. Item Steering relief pressure

12-4

500004

Standard value 15.7 MPa (160.1 kgf/cm2) [2277.1 psi]

Pump port Tank port Control flow port Main flow port (control valve for work equipment) Load sensing port Port

When the steering is in neutral position, almost all of the work oil will be used for driving all the other work equipment.

CHAPTER 12 HYDRAULIC SYSTEM 2.4

Control Valve

1) 4

2) 3

500006

1. 2. 3. 4.

Inlet valve Block Main relief valve adjustment screw Tie bolt

1) 2) 3) 4) 5)

From priority valve To tank To lift cylinder To tilt cylinder From tilt cylinder

The control valve is an assembly of valve blocks which are tied by three tie bolts. The inlet valve has a pump port and tank port, and is mounted with a cartridge-type pilot-operate relief valve.

12-5

CHAPTER 12 HYDRAULIC SYSTEM 2.5

Lift and Tilt Cylinders

Lift cylinder

3 1. 2.

Flow regulator valve Bottom-side port

500007

Rod-side port

The lift cylinder is a single-action type of which the pressurized oil reacts only in one direction the piston is pressed. The bottom-side port has a built-in flow regulator valve, and the rod upper-side port is equipped with the oil return pipe. Tilt cylinder

500008

Socket

The tilt cylinder is a double-action 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.

12-6

Collar

CHAPTER 12 HYDRAULIC SYSTEM 2.6

Flow Regulator Valve

500009

1) 2) 3)

From control valve To cylinder From cylinder

4) 5)

To control valve Connected to the other flow regulator valve

The flow regulator valve will pass the entire amount of working 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 stopping 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 the both cylinders can be even.

3. 3.1

Removing Control Valve Preparation

(1) Raise the operator compartment to the maintenance position (65Â°). (2) Remove the front cover. (3) Before disconnecting each pipe, place the mast in the neutral position and lower the fork to the bottom in order to remove the residual pressure thoroughly from the pipe.

R WARNING Prepare a drip pan to catch remaining oil in the pipes and hoses before disconnecting each pipe. Further, take appropriate measures for the connections of pipes and control valves to prevent dust and dirt from entering in the opening.

12-7

CHAPTER 12 HYDRAULIC SYSTEM 3.2

Removal Sequence

7 12

9 10 1 11 10

6 4

8 500012

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

3.3

Pipe Hose Pipe, O-ring, Bolt, Washer Hose, Clamp, Pipe Hose Hose

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

Suggestions for Removal

Removing control valve When removing the control valve, support it by lifting it with a rope, etc. beforehand. Type

Weight

Two-way valve

35 kg (77 lb)

Three-way valve

45 kg (99 lb)

Four-way valve

55 kg (121 lb)

Five-way valve

65 kg (143 lb)

12-8

Pipe, O-ring, Bolt, Washer Pipe, O-ring, Bolt, Washer Pipe, O-ring, Connector Pipe, O-ring, Connector Connector, O-ring Control valve

CHAPTER 12 HYDRAULIC SYSTEM

Removing Lift Cylinders

8 4 3 7

500010

1. 2. 3. 4.

Lift bracket Return hose, Hose clamp High-pressure hose Synchronized pipe

5. 6. 7. 8.

Stopper bolt Cylinder clamp, Cushion, Collar, Shim Stopper bolt, Washer Lift cylinder

12-9

CHAPTER 12 HYDRAULIC SYSTEM 4.1

Suggestions for Removal R WARNING

Do not touch the lift lever while removing the return hose. (1) Remove the high pressure hose from the connector at the lower part of the lift cylinder. Note: Prepare a drip pan to catch remaining oil inside the hoses. Plug the hose openings to prevent from leaking. (2) Remove the synchronized pipe. (3) Remove the stopper bolt. (4) Remove the stopper bolt at the upper section of the lift cylinder, and lift the inner mast to separate the cylinder rod ends from the mast. Before lifting up the inner mast, wrap the inner mast with a protective cloth and hitch a wire rope winding a full turn.

500014

R WARNING Shims are inserted at the rod end section of the lift cylinders. Record how many shims are inserted in each cylinder before removal. (5) Place wood blocks under the chain wheel support of top cross member of inner mast to support the mast, and release the wire rope. Use wood blocks strong enough to support the mast. (6) Attach a wire rope to the lift cylinder from the rear of the mast, and slowly remove the lift cylinder. Attach a wire rope to the cylinder before removing the cylinder clamp.

500015

Installing Lift Cylinders

For installation, follow the removal procedure in reverse.

5.1

Suggestions for Installation

(1) Extend and retract the lift cylinders to the full stroke several times without load to bleed air out of the cylinders. Make sure that the cylinders move smoothly. (2) After making sure the cylinder smooth operation, check the working oil level with the oil level gauge. (Refer to "Specifications.") (3) Make sure that the lift height is correct. (4) When either the lift cylinder or piston rod has been replaced, always inspect the balance. (Refer to "13 MASTS AND FORKS" for inspection and adjustment.)

12-10

CHAPTER 12 HYDRAULIC SYSTEM

6. 6.1

Removing Tilt Cylinders 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) Tilt to open the operator compartment to remove the tilt pin on frame side. (Tilt up.)

6.2

Removal Sequence

2 1 1. 2. 3.

Tilt socket pin, Spacer, Washer, Spring washer, Bolt Spherical bushing, Snap ring, Spacer Hose

4. 5.

500013

Tilt cylinder pin, Spacer, Washer, Spring washer, Bolt Tilt cylinder

12-11

CHAPTER 12 HYDRAULIC SYSTEM 6.3

Suggestions for Removal

(1) Lift and support the right and left tilt cylinders as shown in the illustration. (Use two wire ropes.) (2) Remove the tilt socket pin mounting bolt, washer, and spacer. (3) Tap the tilt socket pin end to outside with a copper hummer or the like, and dislocate the socket. (4) Start the engine and retract the cylinder rod to minimum while lowering the crane, and stop the engine. (5) Lower the right and left cylinders to the ground, and remove the wire rope from the crane.

500016

1. Support position of tilt cylinder 3. Protective cloth 2. Tilt socket pin

(6) Disconnect the hose from the connector of the cylinder. (7) On this time, cap the connector end at the socket side of the tilt cylinder. Note: The cap confines the oil within the cylinder and by which prevents the cylinder rod from extending. Before lifting the tilt cylinders, be sure to attach both the right and left caps.

1) 1. Cap (G1/2) (Part number 05530-40400)

500017 1) Sealed oil

(8) Lift the tilt cylinder to be removed by a crane. (9) Remove the tilt cylinder pin mounting bolt.

(10) Screw in the jack bolt (M10 x 1.25) as shown in the illustration to remove the tilt cylinder pin. (11) While lifting the tilt cylinder by a crane, pull it out towards the front of the frame.

500018 1) Jack bolt hole

12-12

CHAPTER 12 HYDRAULIC SYSTEM

Removing Gear Pump

2 1

3 500205

1. 2. 3.

Split flange Delivery hose Suction hose

4. 5. 6.

Bolt Nut Gear pump

12-13

CHAPTER 12 HYDRAULIC SYSTEM

Disassembling Gear Pump

8.1

Preparation

(1) Clean the pump exterior. (2) Prepare paper or close to place disassembled parts.

8.2

Disassembly Sequence

16 15 14 5 16

3 2)

8 * *

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

Gear plate Drive gear Driven gear Cover A Cover B Pressure plates Plate seal Backup Isolation plate

Note: The part marked with * is included in the seal kit.

12-14

* 2) 10

Dowel O-ring Oil seal Snap rings Bolt Bolt Spring washer Washer

* 1) * 11 12 10

8 * 9

1) - 1) 10. 11. 12. 13. 14. 15. 16. 17.

500479

CHAPTER 12 HYDRAULIC SYSTEM 8.3

Suggestions for Disassembly

Do not forcibly remove the body, gear, etc. by tapping with a hammer or the like when disassembling. Before disassembling, mark the tooth engagement of the drive and driven gears so that the drive and driven gears are reassembled at the same point as they were engaged. Note: Assemble the gear plate, driven gear and pressure plate in the original position and orientation. On disassembling, put matching marks to ensure the correct reassembling. (1) Fix the flange with a vise to place the pump installing flange downward. (2) Remove the cover B. Remove the cover B straight along the axial direction. If the cover is stubborn, tap it out with a wooden hammer or the like. Do not pull out the dowel from the cover B unless it is necessary. (3) Remove plate seal, backup, isolation plate and O-ring. (4) Remove the pressure plate. Raise the drive end of the drive gear shaft a little to pull out. (5) Remove the drive gear and driven gear from the gear plate. (6) Remove the pressure plate at the bottom of gear plate. Do not tilt the pressure plate to pull out, or the plate will jam. If the plate is tilted and can not be removed, push in the raised position of the pressure plate with the dive shaft of gear to settle the plate. Then try to remove the plate. (7) Remove the plate seal at the bottom of gear plate, backup and isolation plate. (8) Remove the gear plate from cover A. Tap the periphery of gear plate to loosen. (9) Remove the O-ring on the cover mating face. Do not pull out the dowel from the cover unless it is necessary.

12-15

CHAPTER 12 HYDRAULIC SYSTEM

Inspecting and Correcting Gear Pump

Check the contamination and discoloring of the disassembled parts and clean with diesel fuel. Do not dip rubber parts in diesel fuel. Check the parts for the items below of the parts. If it is defective, repair or replace. Gear plate The pump gear is made with it tips lightly contact the gear plate and rotates snugly for the good efficiency. So, the pump, once it is operated, shows a contact mark near the suction chamber. The length of normal contact mark is 1/2 or less of the gear housing inner periphery. And the depth is 0.1 mm or less. If the mark exceed the service limit, replace the pump gear assembly with a new one. When the mark depth exceeds the service limit, wear of the shaft and bushing is suspected. Check these parts carefully.

1) 2)

3) 500642 1) Suction chamber 2) Discharge chamber

Ref.

Item

Service limit value

Gear plate contact mark depth

0.2 mm (0.008 in.)

3) Contact mark 4) Depth of contact mark

Drive gear and driven gear When the working fluid is normal, the surface roughness of the shaft and gear side face are not changed and show smooth contact surfaces. If the surface of the shaft or gear side face is rough to be felt by nail, the gear tip shows cracks, or the tooth are abnormally worn, replace with a new one. Or the shaft diameter at the specified positions becomes to the service limit or less, replace with a new one.

1) 2)

500643 1) 12.7 mm (0.5 in.)

Ref.

Item

Service limit value

Shaft diameter of drive gear and driven gears

31.627 mm (1.2452 in.)

12-16

2) Shaft diameter

CHAPTER 12 HYDRAULIC SYSTEM Pressure plates The normal pressure plate shows a glossy contacting mark on the copper metal side as shown in the illustration. If the copper metal surface is rough and shows many scratches which can be felt by nail, or the thickness is reduced to the service limit or less, replace with a new one.

500644

Item Thickness of pressure plate

Service limit value 6.656 mm (0.2620 in.)

Cover Check the cover at its bushing for the local wear. If the bluish gray teflon layer is worn and copper base metal is exposed to the area of 150Â° more in the bushing inside periphery, replace with a new one. Pay attention to the soft teflon layer.

2) 500645

1) Suction side 2) Discharge side

3) Shaft contact 4) Bushing

Oil seal

Oil seal stops oil leak with its inner seal lip and dust entering with its outer dust lip. Check the seal lip for flaw, deformation or lost of rubber elasticity. If it is defective, replace with a new one.

5) 2)

1) 6) 1) Pump inside 2) Pump outside 3) Seal lip

500646

4) Cover 5) Dust lip 6) Shaft

Dust seal, backup and O-ring Once disturbed, replace with a new one.

12-17

CHAPTER 12 HYDRAULIC SYSTEM

10. Reassembling Gear Pump 10.1 Preparation (1) Clean each part. (2) Apply a thin coat of grease to the seal lip and dust seal of oil seal. Do not apply excessively or it may seen as an oil leak.

10.2 Suggestions for Reassembly Note: Assemble the gear plate, driven gear and pressure plate in the original position and orientation. Assemble covers to the gear plate paying attention to the original mating faces. Place the driven gear to the original meshing position to the drive gear. On disassembling, put matching marks to ensure the correct reassembling. (1) Fix the cover A by holding its cast faces with vise. (2) Check 2 dowel pins installed on the cover A. If the pin is lost, install. (3) Install the O-ring to the cover groove. Pay attention to the small lips (4 places ) to install snugly in the groove. (4) Install the gear plate to the cover A. Position the gear plate with 2 dowel pins on the cover A. (5) Insert the isolation plate to the bottom of the gear plate. (6) Install the plate seal and backup to the bottom of the gear plate. (7) Install the pressure plate to the bottom of gear plate facing its copper metal side upward. Do not tilt the pressure plate, or the plate will jam. If the plate is tilted and can not be moved, push in the raised position of the pressure plate with the drive shaft of gear to install the plate at the bottom. (8) Install the drive gear and the driven gear. Apply hydraulic fluid of approx 5 cc (0.0013 U.S. gal.) to the gear tooth. (9) Install the pressure plate facing its copper metal side down. (10) Insert the isolation plate to the gear plate. (11) Install the plate seal and backup to the gear plate. (12) Check the positions of isolation plate, plate seal and backup. (13) Check 2 dowel pins installed on the cover B. If the pin is lost, install one. (14) Install the O-ring to the cover groove. Pay attention to the small lips (4 places ) to install snugly in the groove.

12-18

CHAPTER 12 HYDRAULIC SYSTEM (15) Place the cover B on the gear plate and press in lightly. If the cover B stops at the position about 3 mm (0.12 in.) from the gear plate, the positions of the isolation plate, plate seal and backup may be displaced. Check and reassemble. Do not forcibly tap in the cover, or the backup and other parts may break. (16) Install the washer to the bolt and tighten the bolt. Bolt tightening torque 132.4 to 137.2 N·m (13.5 to 13.99 kgf·m) [97.65 to 101.19 lbf·ft] [wet] (17) If the oil seal is disturbed, replace it with a new one, and fix with the snap ring. Pay attention not to tilt the oil seal to install. (18) Hand turn the drive gear shaft to check the effort. If the shaft rotate smoothly the pump is free from inclusion of seal, foreign matter and others. If not, the inclusion is suspected. Disassemble and reassemble. (19) Pay attention to the assembling sequence and the rotating direction.

11. Installing Gear Pump On installing, pay attention to the items blow: (1) Check flaw on the installing face for the proper centering. (2) Check flaw and dust on the cover mating face. Especially pay attention to the vise clamped positions. (3) Check flaw and dust on the piping flange faces.

12-19

CHAPTER 12 HYDRAULIC SYSTEM

12. Disassembling Priority Valve 12.1 Disassembly Sequence

1 3

2 500019

1. 2.

Spool, Plug, O-ring, Spring Plug, O-ring

12.2 Suggestions for Disassembly Do not disassemble the relief valve further than that shown in the illustration.

13. Reassembling Priority Valve To reassemble, follow the disassembly sequence in reverse.

13.1 Suggestions for Reassembly Ref.

Part name

1, 2

Plug

44 N·m (4.49 kgf·m) [32.45 lbf·ft]

Relief valve

21 N·m (2.14 kgf·m) [15.49 lbf·ft]

12-20

Tightening torque

3. 4.

Relief valve, O-ring Housing

CHAPTER 12 HYDRAULIC SYSTEM

14. Disassembly and Reassembly of Control Valve 14.1 Disassembly Sequence

1 1

2 3

4 3

4 5 1. 2. 3. 4.

Nut Block Valve assembly for attachments Tilt valve assembly

500377

5. 1) 2) 3)

Inlet valve assembly Three-way control valve Four-way control valve Five-way control valve

14.2 Reassembly Sequence To reassemble, follow the disassembly sequence in reverse.

14.3 Suggestions for Reassembly Tighten the tie bolt nuts to the specified torque. Tightening torque for nut 44.1 to 4.1 N·m (4.5 to 0.42 kgf·m) [32.53 to 3.02 lbf·ft] Note: Do not use liquid gasket.

12-21

CHAPTER 12 HYDRAULIC SYSTEM 14.4 Disassembling Inlet Valve Assembly Inlet valve assembly - disassembly sequence (part 1)

1 4 3 2 24 22 23

9 8 7

24 17

16 500378

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

O-ring Solenoid valve O-ring Orifice Plate Sleeve O-ring O-ring Bulb Spring Plug O-ring

Suggestions for disassembly Do not loosen the adjusting screw of plate 5. If the adjusting screw is loosened, readjustment of the relief pressure will be required.

12-22

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Spring Plug O-ring Plug O-ring Spool Plug O-ring Spring Bulb Strainer Orifice

CHAPTER 12 HYDRAULIC SYSTEM Inlet valve assembly - disassembly sequence (part 2)

22 23 25 26 26 28

5 6 7 8 9 11 12 13 14

10 4

21 20

18 17 16 15

1 500379

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

Cap O-ring Spring Spring sheet Cap O-ring Spacer Spring Spring sheet Lift spool Cap screw O-ring Spring Bulb

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

Cap screw O-ring Spring Bulb Plug O-ring Spring Plug O-ring Spool Plug O-ring Spring Bulb

Suggestions for disassembly (1) Do not loosen the adjuster of cap 5. (2) Pay attention not to drop the springs 13 and 17 and valves 14 and 18 when removing cap crews 11 and 15.

12-23

CHAPTER 12 HYDRAULIC SYSTEM Inlet valve assembly - disassembly sequence (part 3)

9 10 14 11

28 29 30

13 12

17 18 19 23 20 21 22 24 25 26 26

7 8 4 5 3 6

2 1

500380

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

Solenoid valve O-ring Sleeve O-ring O-ring O-ring Spring Spool Solenoid valve O-ring Sleeve O-ring O-ring O-ring Spring Spool

Suggestions for disassembly Arrange parts in the order of disassembling to ensure the correct combination of sleeves 3 and 11 to spools 8 and 16.

12-24

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

Tapered plug O-ring O-ring Plug O-ring O-ring Steel ball Plug O-ring Strainer Orifice Plug O-ring Spring Spool Slug

CHAPTER 12 HYDRAULIC SYSTEM Inlet valve assembly - disassembly sequence (part 4)

25 23 24 22 21 20 19

8 10

16 17

14 13 12 11

5 6 1

500381

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

Block O-ring O-ring O-ring O-ring Orifice Valve body Plug Shuttle Spring Steel ball O-ring O-ring

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

O-ring Plug O-ring Piston Spring Cap O-ring Spring Bulb Sleeve O-ring O-ring

12-25

CHAPTER 12 HYDRAULIC SYSTEM Inlet valve assembly - disassembly sequence (part 5)

500382

1. 2.

Tapered plug Plug

12-26

O-ring

CHAPTER 12 HYDRAULIC SYSTEM 14.5 Cleaning and Inspecting Inlet Valve Assembly (1) Wash all the parts except for rubber parts in a clean metal solution. (2) Thoroughly dry the parts that just washed using a compressed air. (3) Inspect each part for burrs, scratches, dents, or other surface damage. (4) Remove burrs with an oil stone or by lapping compound. If a part has excessive scratches that may cause oil leaks or malfunctions, replace the part or the section assembly.

R CAUTION -

Never change the original combinations of the valve housings and spools. Since the housings and spools are not interchangeable, if scratches and dents are minor, remove them with an oil stone or lapping compound. The replacement of spool only in not allowed, except lift spool. If the spool has any damage that can not be repaired, replace the valve assembly.

(5) Make sure the smooth movement of moving parts and sliding portions. Also make sure that grooves and oil passages are free of foreign matter. (6) Check orifices for clogs. (7) Replace broken or bent springs. (8) Replace all seals and O-rings with new ones.

14.6 Reassembling Inlet Valve Assembly To reassemble, follow the disassembly sequence in reverse. General precautions for reassembly (1) Most problems experienced by hydraulic devices are attributable to the following three causes: Contamination of hydraulic fluid Improper types of fluid Careless reassembling operation To prevent above mentioned problems, it is important to perform the daily maintenance properly and pay full attention when handling parts for reassembly. (2) Perform proper assembly and installation by following instructions below. Assembly work shall be accomplished in a clean dustfree area. Part shall be handled carefully. Avoid hitting a metal part against another, the parts may be dented or damaged. Be sure to understand the construction of each device before assembling its components. Especially, make sure the correct orientation of valves and spools when assembling. Assemble parts while lubricating them with clean hydraulic oil. Never fail to replace O-rings with new ones, and be careful not to damage them when installing. After installation, make sure they are properly installed in the seal grooves. Always observe all of the specified tightening torques.

12-27

CHAPTER 12 HYDRAULIC SYSTEM Suggestions for reassembly (1) Tightening torque for internal components

3 1

500383

Ref.

Part

Tightening torque

Plug

63.7±6.5 N·m (6.5±0.66 kgf·m) [47±4.8 lbf·ft]

Strainer

7.8 N·m (0.8 kgf·m) [5.75 lbf·ft] or less

Plug

12-28

19.6±2.0 N·m (2±0.2 kgf·m) [14.46±1.48 lbf·ft]

CHAPTER 12 HYDRAULIC SYSTEM (2) Tightening torque for exterior parts

10 6

1 8

17 2

9 11

500384

Ref.

Part

Tightening torque

Plug

24.5±2.5 N·m (2.5±0.25 kgf·m) [18±1.8 lbf·ft]

Mounting bolt

Plug

24.5±2.5 N·m (2.5±0.25 kgf·m) [18±1.8 lbf·ft]

Plug

24.5±2.5 N·m (2.5±0.25 kgf·m) [18±1.8 lbf·ft]

Tapered plug

14.7±1.5 N·m (1.5±0.15 kgf·m) [10.8±1.11 lbf·ft]

Mounting bolt

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

Mounting bolt

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

Plug

147±14.7 N·m (15±1.5 kgf·m) [108±10.8 lbf·ft]

Plug

147±14.7 N·m (15±1.5 kgf·m) [108±10.8 lbf·ft]

Mounting bolt

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

132±13.2 N·m (13.5±1.35 kgf·m) [97.4±9.74 lbf·ft]

12-29

CHAPTER 12 HYDRAULIC SYSTEM Ref.

Part

Tightening torque

Mounting bolt

Plug

215±21.6 N·m (21.9±2.2 kgf·m) [158.6±15.9 lbf·ft]

Plug

215±21.6 N·m (21.9±2.2 kgf·m) [158.6±15.9 lbf·ft]

Plug

147±14.7 N·m (15±1.5 kgf·m) [108±10.8 lbf·ft]

Plug

147±14.7 N·m (15±1.5 kgf·m) [108±10.8 lbf·ft]

Mounting bolt

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

Solenoid valve

36.3±3.9N·m (3.7±0.4 kgf·m) [26.8±2.88 lbf·ft]

12-30

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

CHAPTER 12 HYDRAULIC SYSTEM 14.7 Disassembly and Reassembly of Tilt Valve Assembly Tilt valve assembly - disassembly (part 1)

20 1

1 1

21 23 24 25 26 26 1

28 29 19

5 6 7 8 4 9 3

10 11 17 12 16 15 14 13

2 500386

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

O-ring Solenoid valve O-ring Sleeve Spring Spool O-ring O-ring O-ring Solenoid valve O-ring Sleeve Spring Spool O-ring

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

O-ring O-ring Cap O-ring Cap O-ring Tilt spool Cap screw O-ring Spring guide Spring Spring guide Spring Bulb

Suggestions for disassembly Arrange parts in the order of disassembling to ensure the correct combination of sleeves 4 and 12 to spools 6 and 14.

12-31

CHAPTER 12 HYDRAULIC SYSTEM Tilt valve assembly - disassembly (part 2)

18 14 15 10

9 7

4 17 16

13 12

500387

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

Plug O-ring Spring Bulb Plug O-ring O-ring Plug Steel ball O-ring

12-32

11. 12. 13. 14. 15. 16. 17. 18. 1)

O-ring Plug O-ring Plug O-ring Plug O-ring Plug Shuttle valve

CHAPTER 12 HYDRAULIC SYSTEM 14.8

Cleaning and Inspection of Tilt Valve Assembly

Refer to the section "Inlet Valve Assembly."

14.9 Reassembling Tilt Valve Assembly To reassemble, follow the disassembly sequence in reverse. General precautions for reassembly Refer to the section "Inlet Valve Assembly." Suggestions for reassembly (1) Shuttle valve Tighten plugs to the specified torque. Tightening torque 63.7±6.4 N·m (6.5±0.65 kgf·m) [47±4.72 lbf·ft] (2) Tilt spool Tighten the cap screw to the specified torque. Tightening torque 40.2±4.0 N·m (4.1±0.41 kgf·m) [29.65±2.95 lbf·ft]

12-33

CHAPTER 12 HYDRAULIC SYSTEM (3) Tightening torque for parts

2 5 4

1 9

6 500388

Ref.

Part

Tightening torque

Plug

34.3±3.4 N·m (3.5±0.35 kgf·m) [25.3±2.51 lbf·ft]

Plug

34.3±3.4 N·m (3.5±0.35 kgf·m) [25.3±2.51 lbf·ft]

Plug

34.3±3.4 N·m (3.5±0.35 kgf·m) [25.3±2.51 lbf·ft]

Plug

1.5±0.1 N·m (0.15±0.01 kgf·m) [1.1±0.07 lbf·ft]

Plug

14.7±1.5 N·m (1.5±0.15 kgf·m) [10.8±1.11 lbf·ft]

Mounting bolt

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

Mounting bolt

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

Mounting bolt

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

Mounting bolt

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

12-34

CHAPTER 12 HYDRAULIC SYSTEM 14.10 Disassembly and Reassembly of Attachment Valve Assembly Attachment valve assembly - disassembly (part 1)

20 21 23 24 25

26 1

26 22

5 19 18

6 7 8 4 9 3

10 11 17 12 16 15 14 13

500389

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

O-ring Solenoid valve O-ring Sleeve Spring Spool O-ring O-ring O-ring Solenoid valve O-ring Sleeve Spring Spool

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

O-ring O-ring O-ring Cap O-ring Cap O-ring Tilt spool Cap screw O-ring Spring guide Spring Spring guide

Suggestions for disassembly Arrange parts in the order of disassembling to ensure the correct combination of sleeves 4 and 12 to spools 6 and 14.

12-35

CHAPTER 12 HYDRAULIC SYSTEM Attachment valve assembly - disassembly (part 2)

9 7

4 13 12

500390

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

Plug O-ring Spring Bulb Plug O-ring O-ring Plug

12-36

9. 10. 11. 12. 13. 14. 1)

Steel ball O-ring O-ring Plug O-ring Plug Shuttle valve

CHAPTER 12 HYDRAULIC SYSTEM 14.11 Cleaning and Inspecting Attachment Valve Assembly Refer to the section "Inlet Valve Assembly."

14.12 Reassembling Attachment Valve Assembly To reassemble, follow the disassembly sequence in reverse. General Precautions for reassembly Refer to the section "Inlet Valve Assembly." Suggestions for reassembly (1) Shuttle valve Tighten plugs to the specified torque. Tightening torque 63.7±6.4 N·m (6.5±0.65 kgf·m) [47±4.72 lbf·ft] (2) Attachment spool Before installing the spool, make sure it is the correct spool for attachment. The attachment spool has a groove for identification. Tighten the cap screw to the specified torque.

500391

Tightening torque 40.2±4.0 N·m (4.1±0.41 kgf·m) [29.65±2.95 lbf·ft]

12-37

CHAPTER 12 HYDRAULIC SYSTEM (3) Tightening torque for parts

3 2

1 7

4 500392

Ref.

Part

Tightening torque

Plug

34.3±3.4 N·m (3.5±0.35 kgf·m) [25.3±2.51 lbf·ft]

Plug

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

Plug

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

Mounting bolt

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

Mounting bolt

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

Mounting bolt

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

Mounting bolt

15.7±1.6 N·m (1.6±0.16 kgf·m) [11.6±1.18 lbf·ft]

12-38

CHAPTER 12 HYDRAULIC SYSTEM

15. Disassembling Flow Regulator Valve 15.1 Disassembly Sequence

4 3 2 1

500020

1. 2. 3.

Plug, Ring, O-ring Snap rings Piston

4. 5.

Spring, Shim Sleeve, O-ring

16. Inspecting and Correcting Flow Regulator Valve If there is damage to any part of it, replace the assembly. (1) Check the fatigue of spring. (2) Check the sliding surfaces of piston and sleeve for damage.

17. Reassembling Flow Regulator Valve To reassemble, follow the disassembly sequence in reverse.

12-39

CHAPTER 12 HYDRAULIC SYSTEM

18. Disassembling Lift Cylinder 18.1 Disassembly Sequence

* * 3 *

* 1 *

* 4

* * 500034

1. 2. 3.

Wire Rod cover, Dust seal, Packing, Rod, Bushing, O-ring, Back-up ring Piston rod assembly

Note: The part marked with * is included in the seal kit.

18.2 Suggestions for Disassembly (1) Place the cylinder and horizontally. (2) Apply air pressure of 0.39 to 0.59 MPa (4.0 to 6.0 kgf/ cm2) [56.6 to 85.5 psi] to the extend port, and extend the rod to the stroke end. Then open the port to release the pressure in the cylinder.

12-40

4. 5.

Backup ring, Piston packing, Wear ring Cylinder

CHAPTER 12 HYDRAULIC SYSTEM (3) Remove the sealing compound from the rod cover stopper hole with tweezers.

500618

1) Stopper hole

(4) Turn the rod cover in the direction shown by arrow with the hook wrench (special tool), and remove the wire.

500619 1. O-ring (inside)

2. Wire

500616

Part name

Part number

1) Dimension

2) Dimension

3) Stamp

92367-00600

148 mm (5.82 in.)

400 mm (15.75 in.)

MHI148

92367-00700

160 mm (6.30 in.)

500 mm (19.68 in.)

MHI160

Hook wrench

Applicable truck model FD100NZ FD120NZ FD135NZ FD150ANZ

12-41

CHAPTER 12 HYDRAULIC SYSTEM

19. Inspecting Cylinder Cylinder Check the cylinder for the following defects. -

Check the cylinder bore for wear, damage or rust. Check the welded area for cracks, damage or dent.

Piston rod (1) Support the piston rod with V-shaped blocks placing in 1000 mm (39.4 in.), and measure the runout with a dial gauge applying to the center position. If the dial gauge reading exceeds the service limit, replace the piston rod. (2) Check the sliding surface for scratch, damage, rust and wear.

500617

Item Runout of piston rod

Service limit value 1.0 mm (0.039 in.)

Rings and seals Check the ring and seal for the following defects: -

Degrading of O-ring, backup ring, rod packing and dust seal. Damage and deformation on piston packing lip.

12-42

CHAPTER 12 HYDRAULIC SYSTEM Ref.

Truck model

Inside diameter of cylinder

Runout of piston rod

Outside diameter of piston rod

FD100NZ Standard value Service limit value

FD120NZ

FD135NZ

FD150ANZ

105 mm (4.13 in.)

115 mm (4.5 in.)

105.1 mm (4.138 in.)

115.1 mm (4.532 in.)

Service limit value

1.0 mm (0.039 in.)

Mast height 3000 to 4000 mm (118.11 to 157.48 in.)

Standard value

ø60 mm (2.36 in.)

Mast height 3000 to 4500 mm (118.11 to 177.16 in.)

Standard value

ø60 mm (2.36 in.)

Mast height 4500 to 5000 mm (177.16 to 196.85 in.)

Standard value

ø65 mm (2.56 in.)

Mast height 5000 to 5500 mm (196.85 to 216.54 in.)

Standard value

ø65 mm (2.56 in.)

Mast height 5500 to 6000 mm (216.54 to 236.22 in.)

Standard value

ø70 mm (2.76 in.)

Mast height 6000 mm (236.22 in.)

Standard value

ø70 mm (2.76 in.)

Mast height 6500 to 7000 mm (255.90 to 275.60 in.)

Standard value

ø75 mm (2.95 in.)

ø80 mm (3.15 in.)

3 1

500627

12-43

CHAPTER 12 HYDRAULIC SYSTEM

20. Reassembling Lift Cylinder 20.1 Reassembly Sequence

4 **

5 *

6 8 9 2 1 * * * * **

500626

1. 2. 3. 4. 5.

Rod cover, Rod packing, Dust seal Bushing Piston rod assembly Backup spring, Piston packing Wear ring

Note: The part marked with * is included in the seal kit.

20.2 Suggestions for Reassembly (1) Replace the * marked seal kit parts to new ones when assembling. (2) Thoroughly clean all parts before reassembly making sure they are completely free from dirt or dust. (3) Install the rod packing to the groove. (4) Apply Loctite 638 or equivalent to the dust seal groove in housing, then install the dust seal. (5) Install the Piston packing and backup ring to the groove. (6) Apply a thin coat of grease to the rod cover inside, then install to the rod. (7) Make V-shaped dents at the center of the wear ring gap ends on both sides with nipper for a stable seating of the ring. (8) Place the cylinder horizontally. (9) Set the backup spring, apply grease to the O-ring then install. (10) Apply working fluid to the inside face of cylinder bore and piston periphery. (11) Insert the rod aligning with the cylinder axle.

12-44

6. 7. 8. 9.

Backup ring, O-ring Cylinder O-ring Wire

CHAPTER 12 HYDRAULIC SYSTEM (12) Align the cylinder recess and rocker cover hole. (13) Insert the wire into the hole.

1 1)

2) 1. Wire 1) Cylinder recess

(14) Slowly rotate the rod cover clockwise with wrench until the end of wire enter the hole. Note: Pay attention not to damage the O-ring when installing the wire.

500620

2) Rod cover hole.

500622 1. O-ring (inside)

(15) After inserting the wire completely, fill the stopper hole with a sealing compound (silicone).

1) 2) 1 1. Wire 1) Stopper hole

500623

2) Sealing (silicone) compound.

12-45

CHAPTER 12 HYDRAULIC SYSTEM

21. Disassembling Tilt Cylinder 21.1 Disassembly Sequence

4 * 3

5 1

2 500042

1. 2. 3.

Socket, Nut Guide bushing, Dust seal, Rod packing, Buffer ring, Oring, Back-up ring Collar

Note: The part marked with * is included in the seal kit. Do not remove the bushing from the cylinder unless defective.

12-46

4. 5. 6.

Piston, Self-locking nut, Piston seal Piston rod Cylinder, Bushing

CHAPTER 12 HYDRAULIC SYSTEM 21.2 Suggestions for Disassembly Removing guide bushing (1) Wrap the tilt cylinder with a rag, and clamp it in a vise. Using the hook wrench, remove the guide bushing from the cylinder. (2) Before removing the guide bushing, wrap the threads of piston rod with a vinyl tape so that the buffer ring and packing, etc. do not get damaged.

1 Ref. 1

Special tool Hook wrench

500046

Part number 05312-11000

12-47

CHAPTER 12 HYDRAULIC SYSTEM

22. Inspecting and Correcting Tilt Cylinder Cylinder Check the cylinder for the following defects. - Check the cylinder bore for wear, damage or rust. - Check the welded area for cracks, damage or dent. Piston rod (1) Support both ends of the piston rod with V-shaped blocks, and measure the runout with a dial gauge applying to the center of rod. If the dial gauge reading exceeds the service limit, replace the piston rod. (2) Replace the rod if it shows surface rust, damage, sliding flaw, dent or severe thread damage. Rings and gaskets

500036

Check the rings and packings, and make sure that they are free of following defects. -

Damage or distortion of the lips of packing and buffer ring. Deterioration of rings

Ref. 1

Truck model Inside diameter of cylinder

FD100NZ Standard value Service limit value

Guide bushing

Clearance between rod and guide bushing

Inside diameter of bushing (under press-fit condition)

120.12 mm (4.73 in.)

130.12 mm (5.12 in.)

55 mm (2.16 in.) 0.1 mm (0.04 in.)

Service limit value

0.2 mm (0.008 in.) +0.100

Standard value

Tightening torque for socket nut

Standard value

Runout of piston rod

Service limit value

Tightening torque of self-locking nut

60.6 mm (2.386 in.) 637.7±64 N·m (65.03±6.53 kgf·m) [470.34±47.20 lbf·ft]

696.5±69 N·m (71.02±7.04 kgf·m) [513.70±50.89 lbf·ft]

1334 to 1468 N·m (136.03 to 149.69 kgf·m) [983.89 to 1082.72 lbf·ft]

1618 to 1780 N·m (164.99 to 181.51 kgf·m) [1193.36 to 1312.84 lbf·ft]

1.0 mm (0.039 in.) +147 0 N·m +14.99 (150 0 kgf·m) +108.42 [1084.94 0 lbf·ft]

1471

Standard value

+0.0039

60 +0.070 mm (2.36 +0.0028 in.)

Service limit value

Tightening torque of guide bushing Standard value

FD150ANZ

130 mm (5.12 in.)

Standard value

12-48

FD135NZ

120 mm (4.72 in.)

Outside diameter Standard value of piston rod 2

FD120NZ

+177 0 N·m +18.05 (179.98 0 kgf·m) +130.55 [1301.78 0 lbf·ft]

1765

CHAPTER 12 HYDRAULIC SYSTEM

1 6 3

7 500074

12-49

CHAPTER 12 HYDRAULIC SYSTEM

23. Reassembling Tilt Cylinder 23.1 Reassembly Sequence

4 1. 2.

Piston rod, Collar, Piston, Piston Seal, Self-locking nut Cylinder, Bushing

1 3. 4.

500075

Guide bushing, Rod packing, Buffer ring, Dust seal, Back-up ring, O-ring Socket, Nut

Note: The part marked with * is included in the seal kit.

23.2 Suggestions for Reassembly (1) Replace the * marked seal kit parts to new ones when assembling. (2) Thoroughly clean all parts before reassembly making sure they are completely free from dirt or dust. (3) Apply a coat of oil to inside surfaces of piston seals, Orings, packings, dust seals, and cylinder tube before reassembly. (4) When holding the cylinder's outer circumference in a vise, be careful not to over-tighten and distort the cylinder tube. 500142

(5) To install piston seals, lightly compress and release the piston seal 5 to 6 times by hand to make it soft. (6) Secure the piston rod in a vise, taking care not to cause damage to it, and apply a thin coat of the fluid to the piston seal. Fit half of the seal into the piston groove, and then press the other half into the groove. (7) Pay attention to the orientation of packings and dust seals when installing them into guide bushings.

500078

12-50

CHAPTER 12 HYDRAULIC SYSTEM

24. Inspecting and Adjusting Hydraulic System R WARNING Provide a fence around the lift truck to prevent the access of unauthorized people, as the front wheels rotates during the oil pressure measurement. Close the operator compartment and measure the oil pressure. Extend the gauge kit with the extending hose to secure the job safety.

24.1 Hydraulic Oil Replace cloudy oil as oil becomes cloudy when it is contaminated with water. Note: Be careful when checking oil immediately after the operation of control lever, as bubbles of oil is sometimes mistaken for water contamination. Suction strainer, return filter Check for damage or clogging, and clean or replace.

24.2 Test Operation of Gear Pump Test operation is to perform run-in of the pump and make sure the performance. It is desirable to perform the test operation on a dedicated test stand, however, the test stand is usually not available. Perform the test with the gear pump installed on the truck as instructed below. (1) Install an oil pressure gauge which can accommodate 25 MPa (254.9 kgf/cm2) [3626.3 psi] to the pressure measuring port on the upper right surface of the control valve. 500662

Part name

Part number

Connector

64309-17733 (R1/8 Thread)

Hose

64309-17722

Connector

64309-17731 (for gauge installation)

Gauge

64309-17712: 25 MPa (254.9 kgf/cm2) [3626.3 psi]

(2) Place the control lever in the neutral position and run the engine at 500 to 1000 rpm. The oil pressure gauge should read 1 MPa (10.2 kgf/cm2) [145.1 psi] or less when the lever is in the neutral position. Continue to run the engine in this condition for 10 minutes and listen for any abnormal noise coming from the pump. (3) When 10 minutes has elapsed, increase the engine speed to 1500 to 2000 rpm, and continue to run the engine under no load for another 10 minutes. (4) Loosen the adjusting screw of relief valve under the condition of above step (3) and shift the control lever to the active position. (5) 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.

500079

1. Adjusting screw

12-51

CHAPTER 12 HYDRAULIC SYSTEM (6) Then raise the pressure by 2 MPa (20.4 kgf/cm2) [290.1 psi] for 5 minutes progressively until relief valve set pressure is attained. Item Valve set pressure

Standard value 20.6

+0.5 +0.02 0 mm (0.811 0 in.)

(7) During the process of increasing the pressure, pay attention to the oil temperature, pump surface temperature, and listen for abnormal sound from the pump. 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. (8) After above steps (2) to (7) is completed, re-adjust the relief valve to the specified set pressure, and make sure that the operation speed is normal.

24.3 Control Valve Oil leak to the outside Check the oil leak at the positions below: -

Leak from O-ring between housing Leak from scraper and O-ring Leak from threaded connections

12-52

CHAPTER 12 HYDRAULIC SYSTEM 24.4 Adjusting Main Relief Valve (1) Install an oil pressure gauge (capacity 25 MPa) (254.9 kgf/cm2) [3626.3 psi] to the pressure measuring port on the upper right surface 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 increase the speed to the maximum. (3) When the relief valve is normal, the oil is relieved and the pointer of oil pressure gauge indicates the standard value when the tilt lever is tuned to the backward tilt position and the tilt cylinder reaches the backward tilt limit. (4) If the relief pressure is not satisfactory, loosen the lock nut of the relief valve, and adjust the pressure with the adjusting screw. Note: The change in pressure by a one full turn of the adjusting screw is approx 10.6 MPa (108.1 kgf/cm2) [1537 psi].

500662

(5) While holding the adjusting screw, tighten the lock nut to secure the adjusting screw. (6) After the adjusting screw is secured, check the relief valve set pressure again.

500079

1. Adjusting screw

Item

Standard value +0.5 0 MPa +5.1 (210.1 0 kgf/cm2) +72.52 [2987.8 0 psi]

20.6

Main relief valve set pressure

12-53

CHAPTER 12 HYDRAULIC SYSTEM 24.5 Checking Priority Valve Function (1) Install an oil pressure gauge (capacity 25 MPa (254.9 kgf/cm2) [3626.3 psi]) to the position shown in the illustration at the right. Note: In ordinary practice, the oil pressure gauge to be used has the capacity of twice as much as the oil pressure to be measured. In this case, the oil pressure gauge included in the gauge kit is to be used.

500080

Tool name Connector

Part number 91268-01700

Connector 64309-17733 (R1/8 Thread) Gauge kit (64309-17701)

Hose

64309-17722

Connector 64309-17731 (for gauge installation) Gauge

64309-17712: 25 MPa (254.9 kgf/cm2) [3626 psi]

(2) Start the engine and increase the speed to the maximum. (3) When the priority relief valve is normal, the oil is relieved and the pointer of oil pressure gauge indicates 15.7 MPa (160.1 kgf/cm2) [2277.1 psi] when the steering wheel is turned all the way to the left and the power steering cylinder stroke reaches its limit. 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 screw of the relief valve. Note: The change in pressure by a one full turn of the adjusting screw is approx 7.4 MPa (75.5 kgf/cm2) [1073 psi].

500082 1. Adjusting screw

12-54

CHAPTER 12 HYDRAULIC SYSTEM

25. Tests 25.1 Vertical Drift Test (1) Pick up a load equal to the rated capacity, place the mast in a vertical position, lift the forks about 1 to 1.5 m (3.9 to 5.9 in.), and stop the engine. (2) Mark a reference line on the mast, and measure the amount of descent (retraction of the piston rods) for 15 minutes.

500084

Item Rod retraction stroke in the vertical drift test (at the rated load) (Oil temperature: 40 to 50째C (104 to 122째F))

Standard value FD100NZ

68 mm (2.68 in.)/15 min

FD120NZ

78 mm (3.07 in.)/15 min

FD135NZ

61 mm (2.40 in.)/15 min

FD150ANZ

66 mm (2.60 in.)/15 min

25.2 Tilt Drift Test (1) Pick up a load equal to the rated capacity, place the mast to a vertical position, lift the fork about 500 mm (19.7 in.), and stop the engine. (2) Measure the extension of tilt cylinder piston rod for 15 minutes.

500085

Item Rod retraction stroke in the tilt drift test (at the rated load) (Oil temperature: 40 to 50째C (104 to 122째F))

Standard value FD100NZ

35 mm (1.38 in.)/15 min

FD120NZ

41 mm (1.61 in.)/15 min

FD135NZ

32 mm (1.26 in.)/15 min

FD150ANZ

35 mm (1.38 in.)/15 min

12-55

CHAPTER 12 HYDRAULIC SYSTEM

26. Troubleshooting Situation

Hydraulic tank heats excessively. Hydraulic tank

Possible causes

Action

Not enough oil.

Refill.

Oil viscosity is improper.

Refer to "Fuel and Lubricant Specifications" and replace.

Overloaded due to harsh operating conditions.

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

Line is clogged, which generates a restriction to oil line flow and causes local overheating.

Clean oil line.

Relief valve is improperly adjusted.

Adjust pressure setting.

Gear pump is worn.

Replace pump.

Clog due to flattened outlet pipe or tube, etc. Repair or replace.

Cylinders move too slow.

Gear pump

Clogged oil cooler.

Clean.

Shortage of oil due to a natural loss.

Refer to "Fuel and Lubricant Specifications" and refill oil.

Oil leaks due to damaged oil line, seals, etc.

Repair or replace.

Oil viscosity is too high.

Refer to "Fuel and Lubricant Specifications" and replace oil.

Gear pump does not suck 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 rises to an abnormal high level.

Check control valve spools for misalignment. Repair or replace.

Oil leaks inside of gear pump.

Replace pump.

Poor pumping of oil.

Refer to "Fuel and Lubricant Specifications" and refill oil. Check suction pipe for any flat portion or loose connection. Retighten or replace if necessary.

Pump is too noisy. Cavitation

Check shaft oil seal for air-tightness. Replace Pump. Check pump body for any outside interference. Repair.

Pressure exceeds the rating. Pump case, drive gear or pump port flange is damaged.

Replace pump. (Check to see if relief valve setting is correct.) Replace pump.

Distortion or damage due to external strain or stress.

Check if return line has been blocked or excessively restricted. Check if pipe connection has been externally strained or stressed.

12-56

CHAPTER 12 HYDRAULIC SYSTEM Situation

Gear pump

Possible causes

Action

Oil leaks from oil seal.

Replace seal.

Oil leaks through sliding surfaces of drive shaft.

Replace the whole pump assembly.

Pump mounting bolts loose.

Retighten. Replace parts if required.

Seal inside pump deteriorated.

Replace O-ring.

Valve opening pressure setting too low

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.

Short spool stroke with loose operation lever (in case of LC spec)

Adjustment

Lift drift

Lift lock valve failure

Replace lift lock valve.

Tilt forward drift

Control valve spool internal leaks.

Replace control valve assembly.

Leak between bodies

Replace control valve assembly.

Plug loose.

Retighten plug.

O-ring damaged

Replace O-ring.

Insufficient oil in hydraulic tank.

Refer to "Fuel and Lubricant Specifications" and refill oil.

Oil leaks from pump.

Slow or no motions of lift and tilt cylinders. Control valve

Oil leaks.

Mast will neither ascend nor tilt forward or backward.

Relief valve defects.

Main valve jamming.

Replace.

Valve spring fracture.

Replace.

Gear pump defects.

Unable to lift rated load. Lift and tilt cylinders

Lifting speed too slow.

Lowering speed of lift cylinder too slow.

Relief valve defects.

Replace.

Valve opening pressure setting too low

Adjust pressure.

Plunger or poppet seat defects.

Replace.

Spring settling.

Replace.

O-ring in valve case damaged.

Replace.

Gear pump defects.

Replace.

Piston seal worn or damaged.

Replace.

Engine speed too slow.

Adjust the engine.

Spool stroke is not enough due to loose control lever.

Adjustment

Clogging of tank strainer.

Wash or replace.

Gear pump delivery rate too low.

Repair or replace.

Sleeve seized in flow regulator valve.

Repair.

Excessive oil flow resistance in hydraulic line due to dirt clogged in the flow regulator valve, hydraulic hose fractured or locally clogged.

Clean or repair hydraulic circuit, or replace defective hose.

12-57

CHAPTER 12 HYDRAULIC SYSTEM Situation

Cylinder vibrates during operation.

Too much lift cylinder drift.

Lift and tilt cylinders

Too much tilt cylinder drift.

Lift cylinder or tilt cylinder will drift (descend or tilt forward) at a certain point.

Oil leaks from bushing.

12-58

Possible causes

Action

Deflection of piston rod

Repair or replace.

Air mixed in hydraulic line.

Bleed air by extending cylinder through its full stroke.

Insufficient oil in tank.

Refill.

Control valve spool internal leaks.

Replace each block assembly.

Scratches on sliding surface of cylinder that can be felt by finger nail.

Repair or replace.

Sliding surface of cylinder badly grooved

Replace cylinder assembly.

Piston seal damaged or distorted.

Replace seal.

Oil leaks from hydraulic line.

Repair or replace.

Control valve spool internal leaks.

Replace each block assembly.

Foreign matter stuck to packing.

Replace packing.

Piston seal damaged.

Replace seal.

Abnormal distortion or oil leaks from hydraulic line.

Repair or replace.

Inside surface of cylinder badly grooved.

Repair or replace.

Cylinder distortion.

Replace.

Foreign matter stuck to oil seal or dust seal.

Replace.

Inner or outer diameter of oil seal or dust seal Replace. damaged. O-ring damaged.

Replace O-ring.

Abnormal distortion

Repair or replace.

CHAPTER 12 HYDRAULIC SYSTEM

27. Service Data 27.1 Gear Pump Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Fork ascending speed (at the rated load) [Simplex mast] (at maximum engine speed)

Standard value

460 mm (18.11 in.)/sec

380 mm (14.96 in.)/sec

Fork ascending speed (no load) (at maximum engine speed)

Standard value

480 mm (18.90 in.)/sec

400 mm (15.75 in.)/sec

Fork descending speed (at the rated load) Standard value [Simplex Mast]

460 mm (18.11 in.)/sec

480 mm (18.90 in.)/sec

Forward tilt angle [Standard simplex mast truck]

Standard value

15°

Backward tilt angle [Standard simplex mast truck]

Standard value

12°

Lift cylinder vertical drift (at rated load) (Rod retraction stroke) (Oil temperature 40 to 50°C (104 to 122°F))

Standard value

68 mm (2.68 in.) (15 minutes)

78 mm (3.07 in.) (15 minutes)

61 mm (2.40 in.) (15 minutes)

66 mm (2.60 in.) (15 minutes)

Tilt cylinder drift (at rated load) (Rod extension stroke) (Oil temperature 40 to 50 °C (104 to 122 °F))

Standard value

35 mm (1.38 in.) (15 minutes)

41 mm (1.61 in.) (15 minutes)

32 mm (1.26 in.) (15 minutes)

35 mm (1.38 in.) (15 minutes)

Gear pump discharge rate

Standard value

205 L/min (54.2 U.S. gal./min) (at 2200 rpm)

Tightening torque for gear pump mounting bolts and nuts

Standard value

59.8 N·m (6.10 kgf·m) [44.11 lbf·ft]

Tightening torque for gear pump delivery hose mounting bolt

Standard value

56.8 N·m (5.79 kgf·m) [41.89 lbf·ft]

Tightening torque for gear pump cover mounting bolt

Standard value

132 to 137 N·m (13.46 to 13.97 kgf·m) [97.36 to 101.04 lbf·ft]

500204

12-59

CHAPTER 12 HYDRAULIC SYSTEM 27.2 Control Valve Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

+0.5 +5.1 +72.52 2 0 MPa (210.1 0 kgf/cm ) [2987.8 0 psi]

Main relief pressure

Standard value

20.6

Tie rod nuts tightening torque

Standard value

44.1 ± 4.4 N·m (4.5 ± 0.45 kgf·m) [32.5 ± 3.25 lbf·ft]

Tightening torque of plug nut

Standard value

147 ± 14.7 N·m (15.0 ± 1.5 kgf·m) [108.4 ± 10.8 lbf·ft]

Tightening torque for control valve mounting nut

Standard value

60 N·m (6.1 kgf·m) [44.3 lbf·ft]

Tightening torque for oil pipe

Standard value

58.8 ± 5.9 N·m (6.0 ± 0.6 kgf·m) [43.4 ± 4.4 lbf·ft]

Tightening torque for return pipe

Standard value

22 ± 2 N·m (2.2 ± 0.2 kgf·m) [16.2 ± 1.5 lbf·ft]

Tightening torque for delivery pipe

Standard value

83 ± 5 N·m (8.5 ± 0.5 kgf·m) [61.2 ± 3.7 lbf·ft]

5 2 3

7 4

2 1 500148

12-60

CHAPTER 12 HYDRAULIC SYSTEM 27.3 Priority Valve Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Steering relief pressure

Standard value

15.7 MPa (160 kgf/cm ) [2277 psi]

Tightening torque of plug nut

Standard value

44 N·m (4.5 kgf·m) [32.5 lbf·ft]

Tightening torque of relief valve assembly

Standard value

21 N·m (2.1 kgf·m) [15.5 lbf·ft]

500087

12-61

CHAPTER 12 HYDRAULIC SYSTEM 27.4 Hydraulic Tank Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Tightening torque of return filter

Standard value

49 N·m (5.0 kgf·m) [36.2 lbf·ft]

Tightening torque of suction strainer

Standard value

49 N·m (5.0 kgf·m) [36.2 lbf·ft]

Tightening torque of drain plug

Standard value

177 to 196 N·m (18.0 to 20.0 kgf·m) [130.6 to 144.6 lbf·ft]

Tightening torque of level gauge

Standard value

3 to 5 N·m (0.3 to 0.5 kgf·m) [2.2 to 3.7 lbf·ft]

3 2

12-62

500088

CHAPTER 12 HYDRAULIC SYSTEM 27.5 Flow Regulator Valve Ref.

Truck model

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

Flow control (Control pressure: 10 Standard value MPa (101.97 kgf/cm2) [1450.38 psi])

120 L/min (31.7 U.S. gal./min)

Tightening torque of plug nut

492±73.8 N·m (50.1±7.5 kgf·m) [362.9±54.4 lbf·ft]

Standard value

143 L/min (37.8 U.S. gal./min)

1 500089

12-63

CHAPTER 12 HYDRAULIC SYSTEM 27.6 Lift Cylinder Ref.

Truck model

Inside diameter of cylinder

Deflection of piston rod

Outside diameter of piston rod

FD100NZ

Standard value Service limit value

FD120NZ

FD150ANZ

105 mm (4.13 in.)

115 mm (4.5 in.)

105.1 mm (4.138 in.)

115.1 mm (4.532 in.)

Service limit value

Standard value

FD135NZ

1.0 mm (0.039 in.) Mast height 3000 to 4000 mm (118.11 to 157.48 in.)

ø60 mm (2.36 in.)

Mast height 3000 to 4500 mm (118.11 to 177.16 in.)

ø60 mm (2.36 in.)

Mast height 4500 to 5000 mm (177.16 to 196.85 in.)

ø65 mm (2.56 in.)

Mast height 5000 to 5500 mm (196.85 to 216.54 in.)

ø65 mm (2.56 in.)

Mast height 5500 to 6000 mm (216.54 to 236.22 in.)

ø70 mm (2.76 in.)

Mast height 6000 mm (236.22 in.)

ø70 mm (2.76 in.)

Mast height 6500 to 7000 mm (255.90 to 275.60 in.)

ø75 mm (2.95 in.)

ø80 mm (3.15 in.)

3 1

500627

12-64

CHAPTER 12 HYDRAULIC SYSTEM 27.7 Tilt Cylinder Ref. 1

Truck model

FD100NZ Standard value

Inside diameter of cylinder

Service limit value

FD120NZ

Guide bushing

Clearance between rod and guide bushing

Inside diameter of bushing (under press-fit condition)

130 mm (5.12 in.)

120.12 mm (4.73 in.)

130.12 mm (5.12 in.)

55 mm (2.16 in.)

Standard value

0.1 mm (0.04 in.)

Service limit value

0.2 mm (0.008 in.) +0.100

Standard value

Tightening torque of guide bushing Standard value

Tightening torque for socket nut

Outside diameter of tilt socket pin

60.6 mm (2.386 in.)

Standard value Standard value

637.7±64 N·m (65.03±6.53 kgf·m) [470.34±47.20 lbf·ft]

696.5±69 N·m (71.02±7.04 kgf·m) [513.70±50.89 lbf·ft]

1334 to 1468 N·m (136.03 to 149.69 kgf·m) [983.89 to 1082.72 lbf·ft]

1618 to 1780 N·m (164.99 to 181.51 kgf·m) [1193.36 to 1312.84 lbf·ft]

Service limit value 7

Tightening torque for tilt socket pin mounting bolt

Standard value

Runout of piston rod

Standard value

Tightening torque of self-locking nut

+0.010 +0.0004 -0.029 mm (2.36 -0.0011 in.)

59 mm (2.32 in.) 33 N·m (3.37 kgf·m) [24.34 lbf·ft] 1.0 mm (0.039 in.) +147 1471 0 N·m +14.99 (150 0 kgf·m) +108.42 [1084.94 0 lbf·ft]

Standard value

+0.0039

60 +0.070 mm (2.36 +0.0028 in.)

Service limit value

FD150ANZ

120 mm (4.72 in.)

Outside diameter Standard value of piston rod 2

FD135NZ

+177 0 N·m +18.05 (179.98 0 kgf·m) +130.55 [1301.78 0 lbf·ft]

1765

1 8 3

9 500091

12-65

CHAPTER 13 MASTS AND FORKS

Chapter 13 MASTS AND FORKS 1.

Specifications Truck model

FD100NZ

FD120NZ

Mast type

Mast dimension (Flange inside width x Flange thickness x Web thickness)

Main roller Loading equipment Side roller

FD135NZ

FD150ANZ

Simple x Mast

Outer

205 x 32 x 25 mm (8.07 x 1.26 x 0.98 in.)

205 x 36 x 28 mm (8.07 x 1.42 x 1.10 in.)

Inner

205 x 32 x 25 mm (8.07 x 1.26 x 0.98 in.)

205 x 36 x 28 mm (8.07 x 1.42 x 1.10 in.)

Type

Ball bearing

Dia. x W

205 x 52 mm (8.07 x 2.05 in.)

Type

Lubricated needle

Dia. x W

58 x 40 mm (2.28 x 1.57 in.)

Lift-chain type Fork blade (Length - Width x Thickness) Fork width adjustment (outside width)

EKBL-1434 1220-170 x 77 mm (48.036.69 x 3.03 in.)

1220-170 x 82 mm (48.036.69 x 3.23 in.)

410 to 2050 mm (16.14 to 80.71 in.)

EKBL-1634 1220-200 x 82 mm (48.03-7.87 x 3.23 in.) 470 to 2050 mm (18.50 to 80.71 in.)

Note: The dimensions are standard. The real dimensions differ depending on the specification.

13-1

CHAPTER 13 MASTS AND FORKS

Structure

1) - 1) 7

1) 3 1)

1 2

6 1. 2. 3. 4.

13-2

Inner mast Outer mast Lift chains Lift bracket

500157

5. 6. 7.

Mast support bearing cap Main roller, Side roller Mast strip

CHAPTER 13 MASTS AND FORKS

3. 3.1

Removing Mast and Lift Bracket Removal Sequence

500158

1. 2. 3.

Forks, Lift bracket Lift cylinder high-pressure hose Lift cylinder low-pressure return hose

4. 5.

Tilt cylinder pin Mast support bearing cap, Bushing

13-3

CHAPTER 13 MASTS AND FORKS 3.2

Suggestions for Removal

Removing lift bracket assembly (1) Remove the split pin from the lift chain. Remove the anchor nut and lock nut. (2) Connect a rope or the like to each chain end. The length of the rope is approx 3 m (9.8 ft.). (3) Start the engine and raise the inner mast. Raise the mast to the position where the main rollers of lift bracket come free from the mast. During this job, pull the rope to maintain the lift chain tension.

500159

(4) After raising the mast to the position where the main rollers come free from the mast, move the truck backward to separate the lift bracket from the truck. (5) Lower the inner mast and stop the engine.

500160

Removing low-pressure return hose and highpressure hose for the lift cylinder

(1) Disconnect the low-pressure return hose at the return connector. (2) Remove the high-pressure hose from the connector at the lower part of the lift cylinder. Note: Prepare a drip pan to catch remaining oil inside the hoses. Plug the hose openings to prevent from leaking.

2) 3) 500161 1) Low-pressure hose removing 2) Return connector

13-4

3) High-pressure hose removing

CHAPTER 13 MASTS AND FORKS Removing tilt cylinder (1) Hitch lifting jigs and wire ropes to the right and left lifting holes at the top of cross member and lift with hoist.

500164

R WARNING When removing and installing the mast assembly with a hoist, be sure to use a hoist with enough lifting capacity. Truck model

Mast weight

FD100NZ

1995 kg (4398 lb)

FD120NZ

1995 kg (4398 lb)

FD135NZ

2100 kg (4630 lb)

FD150ANZ

2320 kg (5115 lb)

(2) Remove the tilt pin and separate the tilt cylinder from the mast.

500163

Removing mast support bearing cap (1) Put the alignment mark on the cap. (2) Remove the cap mounting bolts and separate the whole mast assembly by lifting it up from the truck. (3) Place the mast on a level floor with the lift bracket side facing upward. Note: Lay the mast in a space large enough in the directions of sliding for the disassembly work.

500162

13-5

CHAPTER 13 MASTS AND FORKS

Disassembling Mast Assembly

4.1

Disassembly Sequence

2) 15

1) 18

16 12

11 2

20 20

13 2) 4

14 5

8 10

13-6

10 21

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

7 6

Handle Lift chain, Nuts, Split pin Lift bracket Screw bracket, Bolt, Washer Screw, Feed nuts, Thrust washers, Spacer Stopper plate, Guide bar, Shim, Bolt Fork blade Main roller, Side roller, Bolt, Nut, Snap ring, Pin Synchronized pipe, Elbow, O-ring Hose, Clamp bolt, Connector Cylinder bracket, Bolt, Shims, Cushion, Collar, Stopper bolt, Nut

500165

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

Bolt, Shims, Washer Lift cylinder, Flow regulator valve Main roller, Side roller, Snap ring, Shims, Pin Set screw, Nut Main roller, Side roller, Snap ring, Shims, Pin Mast strip, Shims Chain wheel support Inner mast Chain wheel, Pin, Spacer, Collar, Bearing, Bolt Outer mast

CHAPTER 13 MASTS AND FORKS 4.2

Suggestions for Disassembly

Removing inner mast (1) Lift cylinders, RH and LH are adjusted with shims at the cylinder rod end to adjust the imbalance. When cylinder rod installation bolts are removed, check how many shims are used on which side of the cylinders. (2) When the cylinder clamp bolts are removed, the lift cylinder becomes free. Retract the cylinder rod fully and cross the top end of 2 cylinders.

1 500167 1. Shim

(3) Slide the inner mast downward to remove main rollers, side rollers and mast strips of the outer mast, and main rollers and side rollers of the inner mast. (4) After removing the main rollers and side rollers, pull the inner mast upward from the outer mast to separate by ducking the main roller shafts with each other.

500168

Inspecting and Correcting Mast Assembly

Mast Check the mast for the following defects: -

Sticking, wear, and cracks of roller Wear, damage, or distortion on rolling surface Cracks in welded areas of mast members, cross beams, pin and support Wear or other defects of mast support bushings

500169

Lift bracket Check the lift bracket for the following defects. -

Sticking, wear, and cracks of main rollers and side rollers Cracks in the welded areas of lift bracket Bend and distortion of guide bar Fork shift screw damage damage of inside face of fork shift screw bushings Cracks in welded areas of fork bracket

500170

13-7

CHAPTER 13 MASTS AND FORKS Chain, Chain wheel support, and Chain wheel Check the chain for the following defects: -

Uneven length, wear, sticking and twist of chains Truck model

Standard value

Service limit value

889 mm (35.0 in.)

915 mm (36.02 in.)

1016 mm (40.0 in.)

1046 mm (41.18 in.)

FD100NZ FD120NZ

Length of the chain (mm/20 links)

FD135NZ FD150ANZ

Check the each chain anchor bolt for cracks or thread damage. Cracks, wear, and sticking of the chain wheel support and the chain wheel

Mast strip Check the mast strip for the following defects: -

Damage, wear or distortion Item

Standard value

Service limit value

Thickness of mast strip

9 mm (0.35 in.)

7 mm (0.28 in.)

Fork blade Check the fork blades for bend, cracks and uneven height of the blades ends.

500171

Item

Standard value

Difference of height at blade tips -

5 mm (0.2 in.) or less

Check the fork brades for wear. If it exceeds the service limit, replace with new ones. Truck model FD100NZ Blade thickness

Standard value

Service limit value

77 mm (3.03 in.)

67 mm (2.64 in.)

FD120NZ FD135NZ FD150ANZ

73 mm (2.87 in.) 82 mm (3.23 in.)

71 mm (2.80 in.) 75 mm (2.95 in.)

Note: The dimensions are standard. The real dimensions differ depending on the specification.

13-8

CHAPTER 13 MASTS AND FORKS

Reassembling Mast Assembly

To reassemble, follow the disassembly sequence in reverse, while observing the instructions below.

6.1

Suggestions for Reassembly

Front and rear clearance between mast and lift bracket

(1) Select the main rollers to make the standard clearance between the main roller and the rolling surface through the whole lifting stroke.

1) 500172

1. Inner mast 2. Lift bracket

Ref.

Item

Standard value

Fronr and rear clearance between mast and lift bracket

0.5 to 2.8 mm (0.020 to 0.110 in.)

3. Outer mast

(2) If the value exceeds the standard, replace the main rollers with a new ones. Item

Main roller size

Standard value S

203 mm (7.99 in.)

205 mm (8.07 in.)

207 mm (8.15 in.)

13-9

CHAPTER 13 MASTS AND FORKS Installing mast strip (1) Install the mast strip and shims to make the front and rear clearances between the outer and inner masts at the maximum height range.

500173

1. Mast strip

Ref. 1)

Item

Standard value

Forward and backward clearance between outer and inner masts

0.5 to 1.5 mm (0.02 to 0.06 in.)

(2) When the forward and backward clearance between the outer and inner masts is not with in the standard value, adjust the number of shims.

500174

Right and left clearances between outer and inner masts (1) Measure the dimension between the right and left side rollers of outer mast, and install the rollers so that the specified dimension is obtained. Note: Measure at the smallest inner width between the side rollers.

500175

Item

Truck model

Standard value

FD100NZ Dimension between the right and left side rollers

FD120NZ FD135NZ FD150ANZ

13-10

754±0.5 mm (29.69±0.02 in.)

748±0.5 mm (29.45±0.02 in.)

CHAPTER 13 MASTS AND FORKS (2) Measure the dimension between the right and left side rollers of inner mast, and install the rollers so that the specified dimension is obtained. Note: Measure at the largest outer width over the side rollers.

500176

Item

Truck model

Standard value

FD100NZ Dimension between the right and left side rollers of inner mast

FD120NZ

890±0.5 mm (35.04±0.02 in.)

FD135NZ FD150ANZ

884±0.5 mm (34.80±0.02 in.)

(3) Press the inner mast in a direction of right or left at the maximum height range, and measure the clearance made at the opposite side.

500177

Item

Standard value

Clearance at the opposite side

0.5 to 1.5 mm (0.02 to 0.06 in.)

(4) If the clearance is not within the specified value, adjust in accordance with the following procedure. To adjust the upper clearance, loosen the lock nut of side roller bracket and rotate the set screw. To adjust the lower clearance, remove the side roller and adjust the number of shims.

1 2 500178 1. Set screw

2. Shim

13-11

CHAPTER 13 MASTS AND FORKS Right and left clearances of lift bracket (1) Measure the dimension between the right and left side rollers of lift bracket mast, and install the rollers so that the specified dimension is obtained.

500180

Item

Truck model

Standard value

FD100NZ Dimension between the right and left side rollers of lift bracket

FD120NZ

754±0.5 mm (29.68±0.02 in.)

FD135NZ FD150ANZ

27.24±0.5 mm (27.24±0.02 in.)

(2) Press the inner mast in a direction of right or left at the whole lifting stroke, and measure the clearance made at the opposite side.

500181

Item

Standard value

Clearance at the opposite side

0.5 to 1.5 mm (0.02 to 0.06 in.)

To adjust the clearance, loosen the lock nut of side roller bracket and rotate the adjusting bolt.

1 1. Adjusting bolt

13-12

500182

CHAPTER 13 MASTS AND FORKS Cylinder bracket

Install the shims to make the cylinder in the aligned position, then assemble.

1 500183 1. Shim

Standard shim thickness 3.2 mm (0.126 in.) Mast support (1) Apply grease to the inner surface of the caps and the mast support groove. (2) Place the chamfered sides of the mast support bushing and the cap to face the center of truck, then assemble. For easier greasing, place wood blocks under the mast and tilt forward so that the mast support clearance is made.

1. Bushing 2. Mast cap

500184

1) Greasing 2) Bigger chamfering

Bolt tightening torque 490±49 N·m (49.97±5.0 kgf·m) [361.40±36.14 lbf·ft] Caution to assemble chain anchor kit Never install the center plate to the position of link plate.

4 1. Link plate (Marking on the face) 2. Center plate (No marking on the face)

1 1)

500185

3. Link 4. Stop pin 1) Marking

13-13

CHAPTER 13 MASTS AND FORKS

Adjusting Mast Assembly

Adjusting chain tension (1) Park the lift truck on a level ground, place the mast vertical and lower the fork to the ground. Check the lift cylinders are fully retracted. (2) Position the anchor bolt with the anchor nut and lock nut. (3) Raise the fork slightly from the ground and check the tension of the chains by pushing the midpoints between the chain wheel and the chain fixed end. Adjust the tension of two chains to be even. To adjust the chain tension with the anchor nut, tilt the mast forward to reduce the chain tension for the ease of adjustment.

500186

1 500187 1. Anchor bolt

(4) After adjusting the chain tension by turning the anchor nut, tighten the nut to the specified torque.

1 2 500188 1. Lock nut

Item

Standard value

Tightening torque of anchor bolt nuts

393±39.3 N·m (40.07±4.01 kgf·m) [289.86±28.99 lbf·ft]

(5) Place the mast in a vertical position to check the final adjustment.

13-14

2. Anchor nut

CHAPTER 13 MASTS AND FORKS Adjusting forward/backward and right/left clearances of lift bracket (1) Measure the forward/backward and right/left clearances of lift bracket. Adjust if the measured value exceeds the standard. (2) Use thickness gauges to measure the forward/ backward clearances of lift bracket. (3) Use a dial gauge to measure the right/left clearances of lift bracket. Set the dial gauge on the inner mast inside face, and apply the gauge head to the side face of lift bracket. Insert a bar between the lift bracket and the inner mast, and press the lift bracket to right and left directions alternately to measure the clearance. (4) When the clearance of the lift bracket is to be adjusted, remove the mast bracket from the mast referring to removal and assembly procedures, and adjust the roller. (5) If the forward/backward clearance exceeds the standard value, replace the main roller with an oversize one. (6) If the right/left clearance of side rollers exceeds the standard value, adjust the clearance referring to the procedure below. -

500189

To adjust the clearance, loosen the lock nut of side roller bracket and rotate the adjusting bolt.

500182

1. Adjusting bolt

Adjusting mast tilt angle (1) Adjust the tire air pressure and park the lift truck on a level ground. (2) Tilt the mast fully backward and stop the engine. (3) Measure the backward tilt angle of the right and left masts. (4) if the angle is out of the standard, loosen the locknut of tilt cylinder and turn the tilt cylinder rod to adjust. (5) Adjust the right and left masts to be in the same tilt angle. Note: Once the backward tilt angle has been properly adjusted, there is no need for forward tilt adjustment as it is determined by the tilt cylinder stroke. Item Tilt angle (forward -backward)

500191

Standard value 15Â°-12Â°

(6) Tighten the lock nuts to the specified torque after the adjustment.

13-15

CHAPTER 13 MASTS AND FORKS Truck model

Tightening torque for lock nut

FD100NZ FD120NZ FD135NZ FD150ANZ

1334 to 1468 N·m (136.03 to 149.69 kgf·m) [983.89 to 1082.72 lbf·ft] 1618 to 1780 N·m (164.99 to 181.51 kgf·m) [1193.36 to 1312.84 lbf·ft]

Adjusting right and left cylinder strokes (1) Install the lift cylinders without inserting shims. Raise the inner mast slowly. Check the right and left piston rods stopping at the moment of the stroke end. (2) Adjust shims to level the mast if necessary. Note: Shim adjust thickness is 8 mm (0.31 in.) or less. Abnormal condition can be detected by a little time lag in stopping between the piston rods, right and left, and the longer stroke cylinder shakes at the moment of the stopping. 500192

Adjustment procedure (1) Raise the mast, and place wood blocks below the inner mast end. Lower the mast until it rests on the wood blocks.

500193

(2) Remove the stopper bolt at the top of lift cylinder which showed earlier stroke end, retract the piston rod, and insert shims at the top of the piston rod end. (3) Raise the piston rod, and tighten the lift cylinder stopper bolt. Remove the wood blocks under the inner mast. (4) Check that the piston rods move smoothly throughout the stroke by slowly lowering the inner mast to the bottom.

500194 1. Shim

13-16

CHAPTER 13 MASTS AND FORKS

Troubleshooting Situation

Lift bracket, inner mast and outer masts do not move smoothly.

Lift bracket or inner mast are tilted.

Mast makes noise.

Possible causes

Action

Incorrect clearance between main rollers and side rollers

Readjust forward/backward and right/ left clearances.

Defective roller rotation

Lubricate or replace.

Sluggish chain movement

Lubricate or replace.

Incorrect clearance on mast strip

Adjust the number of shims

Excessive clearance on side roller

Increase the number of shims.

Uneven tension of lift chains

Adjust chain tension.

Shim adjustments are unequal between left and right lift cylinders (at the maximum height)

Adjust with shims.

Defective roller rotation

Adjust or replace rollers after inspection.

Damaged lift cylinder packing

Replace.

Drift (natural descent) of lift cylinders

Damaged sliding (inside) surface of lift cylinder

Replace.

Whole mast jolts.

Worn out mast support bushing

Retighten or replace bushing.

Mast is distorted.

Off-center load or overload

Replace mast assembly.

Distorted finger bar

Repair or replace.

Distorted fork blades

Repair or replace.

Mast distortion by off-center load

Repair or replace.

Fork blade tips are not aligned.

13-17

CHAPTER 13 MASTS AND FORKS

Service Data Truck model Difference of height at blade tips

FD100NZ Standard value

Chain length (mm/20 links) Tightening torque of chain anchor bolt nuts

Rollers

Main roller outside diameter

72 mm (2.83 in.)

79 mm (3.11 in.)

Service limit value

65 mm (2.56 in.)

71 mm (2.80 in.)

88 mm (3.46 in.) 76 mm (2.99 in.)

80 mm (3.15 in.)

Standard value

889 mm (35.0 in.)

1016 mm (40.0 in.)

Service limit value

915 mm (36.02 in.)

1046 mm (41.18 in.)

393±39.3 N·m (40.07±4.01 kgf·m) [289.86±28.99 lbf·ft]

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 -0.1 mm (2.28 -0.004 in.)

Standard value

+0.5 +0.020 890 -1.0 mm (35.04 -0.039 in.)

+0.5 -1.0 mm +0.020 (34.80 -0.039 in.)

Standard value

+1.0 +0.039 890 -0.5 mm (35.04 -0.020 in.)

+1.0 -0.5 mm +0.039 (34.80 -0.020 in.)

Standard value

754±0.5 mm (29.68±0.020 in.)

748±0.5 mm (29.45±0.020 in.)

Standard value

+0.5 +0.020 704 -1.0 mm (27.72 -0.039 in.)

+0.5 -1.0 mm +0.020 (27.24 -0.039 in.)

Standard value

+1.0 +0.039 704 -0.5 mm (27.72 -0.020 in.)

+1.0 -0.5 mm +0.039 (27.24 -0.020 in.)

6) Outer width of inner mast rollers

Standard value

890±0.5 mm (35.04±0.020 in.)

884±0.5 mm (34.80±0.020 in.)

7)Clearance between main roller and rolling face (whole lifting stroke)

Standard value

0.5 to 2.8 mm (0.020 to 0.110 in.)

8)Clearance between side roller and rolling face (at the Standard value maximum height)

0.5 to 1.5 mm (0.020 to 0.060 in.)

9) Clearance between mast strap and sliding face

0.5 to 1.5 mm (0.020 to 0.060 in.)

Smallest inner width of outer mast

2) 3) Inner width between outer mast rollers

13-18

FD150ANZ

Standard value

Side roller outside diameter

Outer mast and inner mast

FD135NZ

5 mm (0.20 in.) or less

Standard value Fork blade thickness Fork and chain

FD120NZ

Smallest inner width of inner mast

Standard value

884

692

CHAPTER 13 MASTS AND FORKS Truck model

FD100NZ

FD120NZ

FD135NZ

FD150ANZ

10) Outer most width of lift bracket

Standard value

11) Clearance between lift bracket main roller and rolling face (whole lifting stroke)

Standard value

0.5 to 2.8 mm (0.020 to 0.110 in.)

12) Clearance between lift bracket side roller and rolling surface (at the maximum height)

Standard value

0.5 to 1.5 mm (0.020 to 0.060 in.)

Tightening torque of mast cap mounting bolt

Standard value

490±49 N·m (49.97±5.0 kgf·m) [361.40±36.14 lbf·ft]

Lift bracket and inner mast

692±0.5 mm (27.24±0.020 in.)

704±0.5 mm (27.72±0.020 in.)

Note: The dimensions are standard. The real dimentions differ depending on the specification.

10) 1

3 9)

5) 6) 3

12)

1 12) 3)

11) 7)

8) 2) 3

500195

1. 2.

Inner mast Lift bracket

3. 4.

Outer mast Mast strip

13-19

CHAPTER 14 FORK POSITIONER

Chapter 14 FORK POSITIONER 1.

Applicable Attachment Model

This service manual is applicable to the attachment models and trucks below.

1.1

Simultaneous Move Fork Positioner

Attachment model

Applicable mast model

Mast piping

V120A dual-stage panoramic mast (Simplex)

Side pulley type

FD100NZ

F15DE-60001 up

FD120NZ

F15DE-60001 up

4FPS135AM

FD135NZ

F15DE-60001 up

4V135A dual-stage panoramic mast (Simplex)

Side pulley type

FPS160AM

FD150ANZ

F24BE-60001 up

4A150A dual-stage panoramic mast (Simplex)

Side pulley type

Applicable mast model

Mast piping

V120A dual-stage panoramic mast (Simplex)

Side pulley type

FPS120AM

1.2

Applicable truck model

Independent Move Fork Positioner

Attachment model

Applicable truck model FD100NZ

F15DE-60001 up

FD120NZ

F15DE-60001 up

4FP135AM

FD135NZ

F15DE-60001 up

4V135A dual-stage panoramic mast (Simplex)

Side pulley type

FP160AM

FD150ANZ

F24BE-60001 up

4A150A dual-stage panoramic mast (Simplex)

Side pulley type

FP120AM

14-1

CHAPTER 14 FORK POSITIONER

2. 2.1

Specifications Fork Positioner Simultaneous move

FPS120AM

4FPS135AM

FPS160AM

Independent move

FP120AM

4FP135AM

FP160AM

Attachment model

W2050 mm (80.71 in.) Stroke (each side)

W2200 mm (86.86 in.)

767 mm (30.20 in.) 842 mm (33.15 in.)

W2300 mm (90.55 in.) W2400 mm (94.49 in.)

W2200 mm (86.86 in.)

2012 mm (79.21 in.) 2162 mm (85.12 in.)

W2300 mm (90.55 in.) W2400 mm (94.49 in.)

2262 mm (89.05 in.) -

2362 mm (92.99 in.) 478 mm (18.82 in.)

W2200 mm (86.86 in.)

478 mm (18.82 in.)

W2300 mm (90.55 in.)

478 mm (18.82 in.) -

Mast tilt angle

578 mm (22.76 in.) 15° to -12°

Fork type

Heel free type FD100NZ

754 to 759 mm (29.69 to 29.88 in.)

FD120NZ

759 to 774 mm (29.88 to 30.47 in.)

FD100NZ

756 to 759 mm (29.76 to 29.88 in.)

FD120NZ

763 to 766 mm (30.04 to 30.16 in.)

1) Front overhang 2)

14-2

W2050 mm (80.71 in.)

W2400 mm (94.49 in.)

1) 2)

892 mm (35.12 in.) 600 mm (23.62 in.)

W2050 mm (80.71 in.)

Outside fork spread (minimum)

892 mm (35.12 in.)

Load center (standard fork blade spec)

Outside fork spread (maximum)

Forks manufactured by MSI. Forks manufactured by Huaxin.

793 mm (31.22 in.)

795 mm (31.30 in.)

791 to 795 mm (31.14 to 31.30 in.)

793 to 797 mm (31.22 to 31.38 in.)

CHAPTER 14 FORK POSITIONER 2.2

Applicable Fork Blade Truck model

FD100NZ

Fork type

FD135NZ

FD150ANZ

Heel free type

Length × Width

1220 to 2440 mm × 180 mm (48.03 to 96.06 in. × 7.09 in.)

Blade length 1220 mm (48.03 in.)

70 mm (2.76 in.)

75 mm (2.95 in.)

90 mm (3.54 in.)

72 mm (2.83 in.)

79 mm (3.11 in.)

88 mm (3.46 in.)

Blade length 1525 mm (60.04 in.)

70 mm (2.76 in.)

75 mm (2.95 in.)

90 mm (3.54 in.)

72 mm (2.83 in.)

79 mm (3.11 in.])

88 mm (3.46 in.)

Blade length 1830 mm (72.05 in.)

75 mm (2.95 in.)

90 mm (3.54 in.)

72 mm (2.83 in.)

79 mm (3.11 in.)

88 mm (3.46 in.)

Blade length 2440 mm (96.06 in.)

75 mm (2.95 in.)

90 mm (3.54 in.)

75 mm (2.95 in.)

82 mm (3.23 in.)

92 mm (3.62 in.)

Thickness

1) 2)

FD120NZ

Forks manufactured by MSI. Forks manufactured by Huaxin.

14-3

CHAPTER 14 FORK POSITIONER

Structure

5 3 2 1

500077

1. 2. 3. 4.

Lift bracket Side roller Main roller Fork blade

The fork positioner is an attachment that enables the outside fork spread to be adjusted steplessly from the minimum position to the maximum position. The spread of the forks must be changed depending on the sizes of loads to ensure the stability of load. In a big size truck equipped with heavy forks, the fork position can be smoothly adjusted using hydraulic cylinders. The fork positioner must be adjusted before picking up a load, as it cannot be adjusted while carrying the load on the fork.

14-4

5. 6. 7.

Mast Piping Fork positioner cylinder

The fork positioner cylinder is mounted between the fork bracket and the lift bracket, and the extending and retracting movement of the cylinder slides the fork blades side ways. The right and left blades are independently adjustable. In the case of simultaneous move type, one attachment lever operates the right and left blades simultaneously. In the case of independent move type, two attachment levers operate the right and left blades independently.

CHAPTER 14 FORK POSITIONER

4. 4.1

Removing Fork Positioner Preparation

(1) Park the truck on a flat, level and solid ground. (2) Start the engine and fully extend the fork positioner cylinder.

4.2

(3) Place the mast vertical, and lower the fork down to a pallet for easy removal. (4) Place wood blocks under the lift bracket.

Removal Sequence of Fork Positioner (Simultaneous Move Type)

2 7

1 4

1 1 5 1. 2. 3. 4.

Hose (4 pieces) Fork positioner cylinder, Pin Stopper plate, Shims Guide bar

500464

5. 6. 7. 8.

Fork blade Lift bracket Main roller (Do not disassemble unless defective) Side roller (Do not disassemble unless defective)

14-5

CHAPTER 14 FORK POSITIONER 4.3

Removal Sequence of Fork Positioner (Independent Move Type)

1 1 5 1. 2. 3. 4.

14-6

Hose (4 pieces) Fork positioner cylinder, Pin Stopper plate, Shims Guide bar

500465

5. 6. 7. 8.

Fork blade Lift bracket Main roller (Do not disassemble unless defective) Side roller (Do not disassemble unless defective)

CHAPTER 14 FORK POSITIONER 4.4

Suggestions for Removal of Fork Positioner

Removing fork positioner cylinder (1) Stop the engine, and attach a lifting sling to the fork positioner cylinder. (2) Remove the split pin, and remove slotted nuts and spherical nuts of rod. (3) Start the engine, and fully retract the fork positioner cylinder. (4) Stop the engine. (5) Disconnect the hydraulic hoses (4 pieces). (6) Disconnect the hydraulic hoses from the pulleys and attach the connectors of G 1/2B at each end to their open ends for securing the closed oil flow circuit. For independent move type, make sure the connections between hose 1) and 1) and hose 2) and 2) are secured as shown in the illustration on the right. (7) Remove the split pin, and remove the slotted nut and spherical nut of the tube. (8) Remove the fork positioner cylinder by lifting with a hoist. Be careful not to drop the space and spherical seat.

4 3

5 2)

500049 1. 2. 3. 4.

Fork positioner cylinder Split pin Slotted nut Spherical nut

5. Hydraulic hose 6. Spacer 7. Spherical seat

R CAUTION Slowly release pressure by opening gradually the connector of hydraulic hose. Removing fork blades (1) Attach two C-clamps to blade, hitch wire ropes and lift with a hoist. (2) Remove the stopper plate and shims, then pull out guide bar. Be careful not to drop shims. When about a half of guide bar is pulled out through the fork, support the fork bracket to prevent it from dropping. (3) Start the engine, and move the truck backward. (4) Combine the removed blades (two pieces) and tie them with a rope. Then carry the blades to a safe place. (5) Place wood blocks under the lift bracket to support.

500050

14-7

CHAPTER 14 FORK POSITIONER Removing lift bracket (1) Remove the split pin from the lift chain. Remove the anchor nut and lock nut. (2) Connect a rope to each end of the lift chain (two pieces). The length of the rope is approx 3 m (9.8 ft.). (3) Connect the ropes of 3 m (9.8 ft.) long to the hoses (2 pieces for simultaneous move type and 4 pieces for independent move type). (4) Start the engine and lift the inner mast to the position where main rolls on lift bracket are disengaged. At this time, pull the ropes to give the tension to the chains and hoses to prevent them from disengaging from the chain wheels and hose reels. (5) When the main rollers on the lift bracket come to the position where they disengage from the inner mast, move the lift truck backward to separate the lift bracket.

R CAUTION When the mast is rising, never touch any control levers except the lift lever.

14-8

500051

CHAPTER 14 FORK POSITIONER

Inspecting and Correcting Fork Positioner

Lift bracket Check the lift bracket for the following defects. -

Check the main rollers and the side rollers for binding, wear, and cracks. Check the welded areas of lift bracket for cracks. Check the guide bar for bend and distortion.

Fork blade Check the fork blade for bend, cracks and uneven height of the blade ends. Hose Replace the hoses every two years.

Installing Fork Positioner

For installation, follow the removal sequence in reverse.

6.1

Suggestions for Installation

Tapping-in main roller Use the tapping-in tool, and be careful not to hit the outer ring of roller. Installing lift chain Lift chains can be installed without change unless the positions of the upper lock nuts have been changed. Tighten the lock nuts and anchor nuts to the specified torque after the adjustment. Nut tightening torque 393 N·m (40.1 kgf·m) [290.0 lbf·ft] Adjusting hose tension The hose tension is 196 N (20 kgf) [44 lbf]. When the midpoint of 1 m (3.28 ft.) hose is pushed with a force of 9.8 N (1.0 kgf) [2.2 lbf], the hose tension should have approx 12.5 mm (0.49 in.) deflection. Adjust tension according to the length of hose which differs with the raised height of the mast. For example, if the hose length is 2 m (6.56 ft.) from the pulley to the bottom joint when the mast is raised to the highest position, the tension of the hose is acceptable with approx 25 mm (0.98 in.) deflection when the hose is pushed with a force of 9.8 N (1.0 kgf) [2.2 lbf].

500053

14-9

CHAPTER 14 FORK POSITIONER

Disassembling Fork Positioner Cylinder

7.1

Disassembly Sequence

5 2 1 3

7 9 8 6 500070

1. 2. 3. 4. 5.

Guide bushing O-ring Dust seal Rod packing Piston rod

14-10

6. 7. 8. 9. 10.

Collar Self-locking nut Piston Piston seal Cylinder

CHAPTER 14 FORK POSITIONER 7.2

Suggestions for Disassembly

Removing guide bushing (1) Release the caulking of cylinder. (2) Wrap the cylinder with a rag, and clamp it in a vise. Using the hook wrench, remove the guide bushing from the cylinder.

500046

1. Hook wrench

Special tool Hook wrench A

Part number 05312-20520

Inspecting and Correcting Fork Positioner Cylinder

Cylinder Check the cylinder for the following defects. -

Check the cylinder bore for wear, damage or rust. Check the welded area for cracks, damage or dent.

Piston rod -

Make sure the surface of rod is free of rust, damage, sliding marks, or dent. When the thread shows excessive damage, replace. Make sure that the piston rod does not bend. Support both ends of the piston rod with V-shaped blocks, and measure the runout with a dial gauge applying to the center of rod. If 1/2 of dial gauge reading exceeds the limit, replace the piston rod. 500036

Item Deflection of piston rod

Service limit value 2.0 mm (0.079 in.)

14-11

CHAPTER 14 FORK POSITIONER Seal Replace the following seal kit parts with new ones. -

Piston seal kit (1 thru 3) 96004-05010 Rod seal kit (4 thru 6) 96004-05020

6 1. O-ring 2. Back-up ring 3. O-ring

14-12

3 2 1 2 4. O-ring 5. Rod packing 6. Dust seal

500634

CHAPTER 14 FORK POSITIONER Ref.

FPS120AM, FP120AM

Attachment model

4FPS135AM, 4FP135AM

FPS160AM, FP160AM

Inside diameter of cylinder

Standard value

45 mm (1.77 in.)

Outside diameter of piston rod

Standard value

25 mm (0.98 in.)

Deflection of piston rod

Standard value

1.0 mm (0.039 in.) or less

Service limit value

2.0 mm (0.079 in.) or less

Length of collar

Stroke

W=2050 mm (80.71 in.)

Standard value

W=2200 mm (86.86 in.)

Standard value

W=2300/2400 mm (90.55/94.49 in.)

Standard value

W=2050 mm (80.71 in.)

Standard value

767 mm (30.20 in.)

W=2200 mm (86.86 in.)

Standard value

842 mm (33.15 in.)

W=2300/2400 mm (90.55/94.49 in.)

Standard value

892 mm (35.12 in.)

125 mm (4.92 in.) 50 mm (1.97 in.)

Overall length when retracted

Standard value

1115 mm (43.90 in.)

Tightening torque of self-locking nut

Standard value

200 N·m (20.4 kgf·m) [148 lbf·ft]

Tightening torque of guide bushing

Standard value

250 N·m (25.5 kgf·m) [184 lbf·ft]

Working pressure

Standard value

5.9 MPa (60.2 kg/cm2) [855.7 psi]

6 500072

14-13

CHAPTER 14 FORK POSITIONER

Reassembling Fork Positioner Cylinder

9.1

Reassembly Sequence

9 8 *

4 500071

1. 2. 3. 4. 5.

Piston Piston seal Piston rod Self-locking nut Collar

9.2

Suggestions for Reassembly

(1) Replace the * marked seal kit parts to new ones when assembling. (2) Before reassembly, thoroughly clean each part and make sure that they are free from foreign materials such as dust. Tightening self-locking nut Insert the piton into the piston rod and tighten self-locking nut to the specified torque. Note: Replace the self-locking nut every second or third reassembling. Tightening torque 200 N·m (20 kgf·m) [148 lbf·ft] Installing rod packing and dust seal (1) Insert the rod packing into the guide bushing with the main lip facing inside. (2) Insert the dust seal with the main lip facing outside.

14-14

6. 7. 8. 9. 10.

Cylinder Guide bushing Rod packing Dust seal O-ring

CHAPTER 14 FORK POSITIONER Tightening guide bushing (1) Tighten the guide bushing to the specified torque. Tightening torque 250 N·m (26 kgf·m) [184 lbf·ft] (2) Apply caulking to the cylinder.

500054

10. Inspection and Adjustment after Reassembly of Fork Positioner Checking right and left shift stroke After reassembly, verify that the right and left blades move across their full strokes within each frame.

11. Troubleshooting Situation

Shifting speed of right and left blades is slow or defective.

Possible causes Insufficient oil in hydraulic tank.

Add hydraulic oil.

Gear pump delivery rate low

Replace the whole pump assembly.

Overload relief valve malfunction.

Cylinder defects

Shift movement is not smooth (jamming or rattling).

Fork tips are different in height.

Action

Valve opening pressure setting too low

Adjust overload relief valve.

Pilot valve seat face defect or foreign matter inclusion

Replace overload relief valve assembly, or disassembly the valve and clean.

O-ring in valve case damaged

Replace O-ring.

Pilot valve spring fatigued

Replace overload relief valve assembly.

Foreign particles in packing

Replace rod packing.

Scratches on bore of rod packing

Replace rod packing.

Piston O-ring damaged

Replace piston O-ring.

Abnormal distortion

Replace.

Rust or scratches on guide bar

Repair and apply grease.

Scars on lift bracket surface to contact with fork blade

Repair and apply grease.

Scars on fork guide bar

Repair and apply grease.

Distorted fork blades

Replace.

Off-center loading

Instruct operator to handle loads within capacity.

14-15

CHAPTER 14 FORK POSITIONER

12. Service Data Ref.

FPS120AM, FP120AM

Attachment model

4FPS135AM, 4FP135AM

FPS160AM, FP160AM

Inside diameter of cylinder

Standard value

45 mm (1.77 in.)

Outside diameter of piston rod

Standard value

25 mm (0.98 in.)

Deflection of piston rod

Standard value

1.0 mm (0.039 in.) or less

Service limit value

2.0 mm (0.079 in.) or less

Length of collar

Stroke

W=2050 mm (80.71 in.)

Standard value

W=2200 mm (86.86 in.)

Standard value

W=2300/2400 mm (90.55/94.49 in.)

Standard value

W=2050 mm (80.71 in.)

Standard value

767 mm (30.20 in.)

W=2200 mm (86.86 in.)

Standard value

842 mm (33.15 in.)

W=2300/2400 mm (90.55/94.49 in.)

Standard value

892 mm (35.12 in.)

125 mm (4.92 in.) 50 mm (1.97 in.)

Overall length when retracted

Standard value

1115 mm (43.90 in.)

Tightening torque of self-locking nut

Standard value

200 N·m (20.4 kgf·m) [148 lbf·ft]

Tightening torque of guide bushing

Standard value

250 N·m (25.5 kgf·m) [184 lbf·ft]

Working pressure

Standard value

5.9 MPa (60.2 kg/cm2) [855.7 psi]

6 500072

14-16

CHAPTER 15 SERVICE DATA

Chapter 15 Service Data 1.

Maintenance Schedule

Note: Inspect the systems every specified period: week, month or service hour, whichever comes first.

Every 2000 hrs or 12 Months

Steering condition

Operation

Oil leak

Visual

Loose fit

Spanner

Cracks or damage on dust boot of ball joint

Visual

Rods and arms

Looseness, rattling and damage

Spanner

Wear and fitting condition of connections

Visual

Loose connections

Feeling

Knuckle

Cracks, distortion and damage

Visual

Wheel alignment

Visual, Feeling

Steering wheels

Distortion or damage of steeling axle

Visual

Power steering system

Oil leak and oil level

Visual

Loose fit

Spanner

Power steering cylinder

Visual

King pin lubrication

Lubrication

Steering axle

Tie-rod pin lubrication

Lubrication

Replacement of power steering cylinder hoses and rubber parts

Visual

FD150ANZ

Every 1000 hrs or 6 Months

FD135NZ

Every 500 hrs or 3 Months

FD120NZ

Every 200 hrs or monthly

Feeling, Scale

How to check

Remark

FD100NZ

Every 50 hrs or weekly

Steering valve

Steering System

Play, looseness, rattling

Inspection point

Steering wheel

Pre-start (daily/10 hours)

Division

Inspection and Maintenance Period

70 mm (2.76 in.) at engine idling.

z z

Every 4000 hrs or 24 months

15-1

CHAPTER 15 SERVICE DATA

Steering System

Steering axle

Brake System

Brake

Brake pedal

Parking brake mechanism

15-2

FD150ANZ

FD135NZ

FD120NZ

Remark

FD100NZ

Every 2000 hrs or 12 Months

Every 1000 hrs or 6 Months

Every 500 hrs or 3 Months

Every 200 hrs or monthly

How to check

Every 50 hrs or weekly

Inspection point

Pre-start (daily/10 hours)

Division

Inspection and Maintenance Period

Right and left wheel steering angle, knuckle, rod, arm and other steeling related parts

Visual, Feeling

Maneuvering gear

Visual, Feeling

Braking force, brake drum and shoe, and other brake devices

Operation, Visual, Feeling

Brake device

Operation, Visual, Feeling

Damage, looseness, rattle of links and cables and defective split pin

Visual, Feeling

Pedal stroke

Feeling

Play and clearance between floor and pedal with pedal pressed

Scale

Pedal play : 15 mm (0.59 in.) Pedal height(From floor to tip of pedal): 190 mm (7.48 in.)

Braking condition

Operation, Scale

10 m (33 ft) Acceleration Test: Within 5 m (16 ft) Pedal stroke when brake starts to work (angle after pedal play):12Âą0Â°

Pedal feeling (Air inclusion)

Feeling

Lubrication of brake, clutch and inching pedals

Lubrication

Lever stroke

Feeling

Damage or wear of ratchet

Visual

z z

CHAPTER 15 SERVICE DATA

Parking brake mechanism

Hoses and pipes

Brake System

Reservoir tank

Master cylinder, wheel cylinder and disk caliper

Air Master (booster)

Braking condition

Operation, Spring balance

Replacement of stop lamp switch (air type)

Visual

Leak, damage and fitting condition

Visual

FD150ANZ

FD135NZ

FD120NZ

FD100NZ

Lever position when locked: 63 to 66Â° Operating force: 245 to 295 N (24.98 to 30.08 kgf) [55.08 to 66.32 lbf]

z z

Replacement of hoses Visual z

Fluid level

Visual

Brake fluid change

Visual

Replacement of tubes

Visual

Function, wear and damage

Disassembly, Visual

Oil leak

Visual

Replacement of rubber parts

Visual

Rod stroke

Visual

Working condition

Operation

Function, wear and damage

Disassembly, Visual

240 cc (0.06 U.S. gal.)

z z

z z z

Function

Visual, Operation

Air pressure rise

Visual

Exhaust noise from brake valve

Spanner

Replacement of repair Visual kit

Remark

Replacement of repair Visual kit

Brake valve

Every 2000 hrs or 12 Months

Every 1000 hrs or 6 Months

Every 500 hrs or 3 Months

Every 200 hrs or monthly

How to check

Every 50 hrs or weekly

Inspection point

Pre-start (daily/10 hours)

Division

Inspection and Maintenance Period

15-3

CHAPTER 15 SERVICE DATA

Traveling System

Disassembly, Caliper

Service limit of thickness of lining: 10 mm (0.39 in.)

Anchor pin corrosion and spring settling

Visual

Replace if there is clearance between coils when not strained.

Wear and damage of drums

Visual, Scale

Service limit of drum inside diameter: 424 mm (16.69 in.)

Shoe working condition

Operation

Dye check

Distortion, cracks and damage

Wheel

FD150ANZ

Wear of shoe sliding portion and lining

FD135NZ

Standard value: 0.2 mm (0.008 in.)

FD120NZ

Every 2000 hrs or 12 Months z

FD100NZ

Every 1000 hrs or 6 Months z

Every 200 hrs or monthly

Every 50 hrs or weekly

Thickness gauge

How to check

Loose mounting bolts Spanner

Center brake drum and lining

15-4

Every 500 hrs or 3 Months

Brake System

Back plate

Remark

Clearance between wheel brake drum and lining (one side)

Inspection point

Brake drums and brake shoes

Pre-start (daily/10 hours)

Division

Inspection and Maintenance Period

Loose fitting of drum

Visual, Feeling

Clearance between parking brake drum and lining

Thickness gauge

Worn lining

Disassembly, Caliper

Wear and damage of drums

Visual, Scale

Tire pressure

Tire gauge

Standard: 0.1 to 0.25 mm (0.004 to 0.0098 in.)

z z

Cracks and damage of Visual tires

Abnormal wear of tires

Depth gauge

Tread groove depth of tires

Depth gauge

Damage of rims

Visual

Steering wheel mounting condition

Visual

Refer to Chapter "1 GENERAL INFORMATION."

CHAPTER 15 SERVICE DATA

Traveling System

Wheel

Power Transmission System

Steering axle

Looseness of wheel nuts and wheel bolts

Torque wrench

Damage of wheel nuts and wheel bolts

Visual

Backlash of front wheel bearing

Spring balance

Damage of rims, side rings and disk wheels

Visual

Backlash of rear wheel bearing

Spring balance, torque wrench

Front axle (cracks, damage and distortion)

Visual, Dye check

Rear axle (cracks, damage and distortion)

Visual, Dye check

Back-to-front looseness of rear axle

Operation

Lubrication of rear axle mount bushing

Visual

Loose fitting and damage

Visual

Dragging

Visual

Operation

Operation, Visual

FD150ANZ

FD135NZ

FD120NZ

Remark

FD100NZ

Every 2000 hrs or 12 Months

Every 1000 hrs or 6 Months

Every 500 hrs or 3 Months

Every 200 hrs or monthly

How to check

Every 50 hrs or weekly

Inspection point

Pre-start (daily/10 hours)

Division

Inspection and Maintenance Period

Front: 539.4±49 N·m (55.0±5.0 kgf·m) [397.54±36.14 lbf·ft]/ 93.2±9.8 N·m (9.50±1.0 kgf·m) [68.74±7.23 lbf·ft] Rear: 490.3 to 588.4 N·m (50.0 to 60.0 kgf·m) [361.62±433.97 lbf·ft]

Hub bearing preload (force applied to hub bolt in tangential direction): 127.5 to 166.7 N (13.0 to 17.0 kgf) [28.66 to 37.48 lbf]

Hub bearing preload (force applied to hub bolt in tangential direction): 883 to 127.5 N (90.04 to 13.0 kgf) [198.51 to 28.66 lbf] Lock nut (outside only)

Accelerator pedal

15-5

CHAPTER 15 SERVICE DATA

Power Transmission System

Transmission

Propeller shaft and drive shaft

Differential and final reduction

15-6

Change of hydraulic oil

Replace.

Gear and bearing

Visual

Clean or replacement of strainer

Visual, Replacement

Last change filter cleaning

Visual

Operation

Operation, Visual

Replacement of torque converter oil filter

Replace.

Inching pedal engagement/ disengagement condition

Scale, Operation

Loose connections

Spanner

Lubrication of connections

Visual

Cracks or damage on dust boot of universal joint

Visual

Loose joints

Spanner

Backlash of center bearing

Visual, Feeling

Operation

Operation, Visual

Oil leak and oil level

Visual

Change of hydraulic oil

Replace.

Operation

Operation, Visual

23 L (6.08 U.S. gal.)

z z

20 L (5.28 U.S. gal.)

FD150ANZ

Every 2000 hrs or 12 Months

FD135NZ

Every 1000 hrs or 6 Months

Visual

FD120NZ

Every 500 hrs or 3 Months

Oil leak and oil level

Remark

FD100NZ

Every 200 hrs or monthly

How to check

Every 50 hrs or weekly

Inspection point

Pre-start (daily/10 hours)

Division

Inspection and Maintenance Period

CHAPTER 15 SERVICE DATA

Replace.

Operation

Operation, Visual

Fluid level

Visual

Electrolyte specific gravity

Aerometer

Terminal connections

Visual, Feeling

Belt tension

Visual, Scale

Charging

FD150ANZ

FD135NZ

FD120NZ

FD100NZ

Every 50 hrs or weekly

Every 2000 hrs or 12 Months

Change of hydraulic oil

Every 1000 hrs or 6 Months

Visual

Every 500 hrs or 3 Months

Oil leak and oil level

Remark

PTO gear box

Battery

Electrical System

How to check

Pre-start (daily/10 hours)

Inspection point

Every 200 hrs or monthly

Power Transmission System

Division

Inspection and Maintenance Period

Alternator, starter

Meter panel

Electrical wiring

Operation, Visual

Operation

Operation, Visual

Pinion engagement

Operation

Display indication

Visual

Loose or damaged connections

Visual, Feeling

Voltage, current, other electrical system

Visual, Feeling

1.280 to 1.260

15-7

CHAPTER 15 SERVICE DATA

15-8

Every 1000 hrs or 6 Months

Every 2000 hrs or 12 Months

Driving interlock function

Operation, Visual, Feeling

Parking brake warning buzzer and warming lamp function

Operation, Visual, Feeling

Seat belt warning lamp function

Operation, Visual, Feeling

Starting condition and abnormal noise

Operation, Listen

Air cleaner element condition, cleaning

Visual

Replacement of air cleaner element

Replace.

Low speed and acceleration speed

Operation

Exhaust condition

Operation, Visual

Cylinder head and manifolds tightening condition

Torque wrench, spanner

Body

Valve clearance

Thickness gauge

When the engine is cold Intake: 4 mm (0.16 in.) Exhaust: 4 mm (0.16 in.)

Idle rotating speed 800Âą50 min-1 No-load maximum rotating speed 2400Âą40 min-1

Idle speed, no-load maximum speed

Tachometer

Rubber hoses

Visual, Feeling

Engine mount

Visual, Feeling

Glow function

Operation, Visual

FD150ANZ

Every 500 hrs or 3 Months

FD135NZ

Every 200 hrs or monthly

Operation, Visual, Feeling

FD120NZ

Every 50 hrs or weekly

Mast interlock function

FD100NZ

How to check

Inspection point

IPS

Remark

Pre-start (daily/10 hours)

Engine

Electrical System

Division

Inspection and Maintenance Period

CHAPTER 15 SERVICE DATA

Body

Lubrication system

Engine

Fuel system

Cooling system

FD150ANZ

FD135NZ

FD120NZ

Remark

FD100NZ

Every 2000 hrs or 12 Months

Every 1000 hrs or 6 Months

Every 500 hrs or 3 Months

Every 200 hrs or monthly

How to check

Every 50 hrs or weekly

Inspection point

Pre-start (daily/10 hours)

Division

Inspection and Maintenance Period

at 2.5 MPa (25.49 kgf/cm2) [362.60 psi.](200 min-1)

Hi: 12 L (3.17 U.S. gal.) / Low: 10 L (2.64 U.S. gal.) Oil filter, others: 4L (1.1 U.S. gal.)

Replace.

Replacement of oil filter element

Replace.

Fuel leak

Visual

Fuel level

Visual

Injection pressure, etc., and injection nozzle

Inspection

Fuel hose, pipe, joint

Visual

Replacement of fuel filter

Replace.

Replacement of fuel hose

Replace.

Injection timing

Operation

Feed pump function

Operation

Cooling water level

Visual

Replacement of cooling water

Replace.

Looseness, tension and damage of fan belt

Visual, Scale

Damage and fitting of fan

Visual, Feeling

Water leak

Visual

Radiator fin

Visual, Feeling

Radiator cap, hose

Visual, Feeling

Compression pressure

Compression gauge

Oil contamination and oil level

Visual, Feeling

Oil leak

Visual

Change oil.

17.6 MPa(179.47 kgf/cm2) [2552 psi.]

Every 4000 hrs or 24 months

BTDC 8Â°

13L (3.4 U.S. gal.) (Engine only)

Fan belt adjustment

15-9

CHAPTER 15 SERVICE DATA

Visual

Chain wheel

Chain elongation service limit (20 links)

Chain (elongation, tension, damage and distortion)

Visual, Scale

Lubrication of chain

Visual

Replacement of chain

Replace.

Wear, damage and distortion of chain wheel

Visual

Backlash of chain wheel bearing

Feeling

Damage and distortion of chain anchor bolt

Visual

Mounting bolts

Spanner

Cracks, damage, distortion

Visual

Oil leak

Visual

z 915 mm (36.02 in.)

Every 4000 hrs or 24 months z

z For fork lifting speed, refer to Chapter "1 GENERAL INFORMATION."

Function, wear

Stopwatch, Scale

Standard lowering speed: (mm (in.)/15 min) 68 (2.68)

15-10

1046 mm (41.18 in.)

Lift cylinder

Backrest

FD150ANZ

Piping damage

FD135NZ

FD120NZ

Remark

FD100NZ

Every 2000 hrs or 12 Months

Every 200 hrs or monthly

Inspection

How to check

Every 50 hrs or weekly

Every 1000 hrs or 6 Months

Crankcase emission control system

Pre-start (daily/10 hours)

Metering valve

Inspection point

Lift chains

Loading equipment

Every 500 hrs or 3 Months

Option

Division

Inspection and Maintenance Period

Load backrest extension

Visual

78 (3.07)

61 (2.40)

66 (2.60)

CHAPTER 15 SERVICE DATA

Damage and distortion of fork stopper pin

Visual

Loading equipment

Mast and Fork

Roller, mast strip sliding surfaces

Visual, Thickness gauge, Dial gauge

Looseness of mast support

Visual, Feeling

Lubrication of support

Lubrication

Socket bolts

Spanner

Lubrication of socket pins

Lubrication

Cracks, damage, distortion

Visual

Oil leak

Visual

Function, wear

Stopwatch, Scale

Tilt cylinder

Looseness and damage of mounting portion

Visual, Feeling

Loose socket nut

FD150ANZ

FD135NZ

FD120NZ

Remark

FD100NZ

Visual, Scale

Every 2000 hrs or 12 Months

Wear, damage and distortion of fork blades

Every 1000 hrs or 6 Months

Every 500 hrs or 3 Months

Visual, Dye check

Every 200 hrs or monthly

Mast (cracks, damage and distortion)

Inspection point

Every 50 hrs or weekly

How to check

Pre-start (daily/10 hours)

Division

Inspection and Maintenance Period

Fork blade thickness service limit

Spanner

65 mm 71 mm 76 mm 80 mm (2.56 (2.80 (2.99 (3.15 in.) in.) in.) in.)

Standard clearance between main roller and mating rolling surface: 0.5 to 2.8 mm (0.020 to 0110 in.) Standard clearance between side roller and mating rolling surface 0.5 to 1.5 mm (0.020 to 0.059 in.)

Standard forward (tilt) drift (mm(in.)/15 min) 35 (1.38)

41 (1.61)

32 (1.26)

35 (1.38)

1334 to 1468 N·m (136.03 to 149.69 kgf·m) [983.90 to 1082.72 lbf·ft]

1618 to 1780 N·m (164.99 to 181.51 kgf·m) [1193.36 to 1312.84 lbf·ft]

15-11

CHAPTER 15 SERVICE DATA

Every 1000 hrs or 6 Months

Every 2000 hrs or 12 Months

Attachments, others

Operation

Operation, Visual

Oil level and condition

Visual

Hydraulic oil Replacement of oil

Hydraulic system

Hydraulic hoses, pipes and joints

Hydraulic tank

Control valve

15-12

Replace.

Hose, pipes and joints Visual Replacement of hoses Replace. (High-pressure hoses)

FD150ANZ

Every 500 hrs or 3 Months

FD135NZ

Every 200 hrs or monthly

Operation, Visual

195 L (51.5 U.S. gal.)

225 L (59.4 U.S. gal.)

FD120NZ

Every 50 hrs or weekly

Mounting condition

Inspection point

Remark

FD100NZ

How to check

Pre-start (daily/10 hours)

Loading equipment

Division

Inspection and Maintenance Period

190 L (50.2 U.S. gal.)

Every 2000 hrs or 12 to 24 months Replace or clean every 12 months or 2000 hrs.

Cleaning of strainer

Visual

Replacement of return oil filter

Replace.

Valves

Visual

Priority relief oil pressure

Oil pressure gauge

Oil leak

Visual

Main relief oil pressure

Oil pressure gauge

20.6 0 MPa (210.06 +72.52 [2987.78 0 psi.]

Overload relief oil pressure

Oil pressure gauge

Option

z z

15.7 MPa (160.10 kgf/cm2) [2277 psi.]

z +0.5

+5.10 2 0 kgf/cm )

CHAPTER 15 SERVICE DATA

Stopwatch, Scale

Hydraulic system Others

Other hydraulic pressure devices

Visual

Hydraulic system operation

Visual

Operation, contamination, damage

Operation, Visual

Windshield cleaning fluid level and spray condition

Alarming horn, windshield wiper, windshield cleaning device, defroster and locking device

Operation, Visual

Wiper blade operation

Operation, Visual

Operation

Operation, Visual

Alarming horn sound

Operation, Listen

Rear view mirrors

Operation, Visual

Air dryer

Desiccating agent change

Replace.

Exhaust pipe and muffler

Loose fitting and damage

Visual, Feeling

Function

Inspection

Visual

Lowering speed

FD150ANZ

Oil leak

FD135NZ

Every 2000 hrs or 12 Months z

Visual, Listen

FD120NZ

Every 1000 hrs or 6 Months z

Pump (oil leak, abnormal noise)

Remark

FD100NZ

Every 500 hrs or 3 Months z

How to check

Every 50 hrs or weekly

Every 200 hrs or monthly

Hydraulic system

Flow regulator valve

Lighting system and direction indicator

Others

Inspection point

Hydraulic pump

Pre-start (daily/10 hours)

Division

Inspection and Maintenance Period

Fork lowering speed Refer to Chapter "1 GENERAL INFORMATION."

z z

15-13

CHAPTER 15 SERVICE DATA

Air compressor

Others

Truck frame and body

Visual

Operator compartment

Visual, Spanner

Seat belt

Others

15-14

Visual, Feeling

Seat adjustment

Visual, Feeling

Damage and looseness of operator seat

Visual

Malfunctions noticed during operation

Visual

Lubrication of chassis

Visual

Seat

Chassis

FD150ANZ

Assist grips

FD135NZ

Visual, Spanner

FD120NZ

Looseness and damage

Remark

FD100NZ

Operation

Every 2000 hrs or 12 Months

Compressor, pressure regulator and unloader valve function

Every 1000 hrs or 6 Months

Every 500 hrs or 3 Months

Operation, Visual

Every 200 hrs or monthly

Condensate water in air tank

Inspection point

Every 50 hrs or weekly

How to check

Pre-start (daily/10 hours)

Division

Inspection and Maintenance Period

CHAPTER 15 SERVICE DATA

Tightening Torques for Standard Bolts and Nuts

2.1

Metric fine thread With spring washer

Nominal size

Pitch 500244

500245

500246

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

7.4

0.75

5.46

9.6

0.98

7.08

12.7

1.30

9.37

1.25

16.7

1.70

12.32

22.6

2.30

16.67

30.4

3.10

22.42

1.25

34.3

3.50

25.30

45.1

4.60

33.26

69.6

7.10

51.33

1.25

63.7

6.50

46.98

82.4

8.40

60.77

122.6

12.50

90.42

1.5

102.0

10.40

75.23

132.4

13.50

97.65

192.2

19.60

141.76

1.5

157.9

16.10

116.46

202.0

20.60

148.99

287.3

29.30

211.90

1.5

224.6

22.90

165.65

292.2

29.80

215.51

413.8

42.20

305.20

1.5

310.9

31.70

229.30

404.0

41.20

297.97

573.8

58.51

423.21

1.5

413.8

42.20

305.20

537.5

54.81

396.43

763.0

77.80

562.75

1.5

547.2

55.80

403.59

711.0

72.50

524.40

1006.2

102.60

742.12

1.5

794.3

80.99

585.84

1032.6

105.29

761.59

1451.1

147.97

1072.47

1.5

1100.3

112.20

811.53

1430.8

145.90

1055.29

2012.3

205.19

1484.17

1.5

1467.1

149.60

1082.06

1907.4

194.50

1406.80

2680.2

273.30

1976.78

1.5

1918.2

195.70

1414.77

2493.8

254.29

1839.30

3497.1

356.60

2579.29

1.5

2461.5

251.00

1815.48

3198.8

326.18

2359.28

4469.9

455.80

3296.77

15-15

CHAPTER 15 SERVICE DATA Without spring washer Nominal size

Pitch 500244

500245

500246

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

8.6

0.88

6.34

10.8

1.10

7.97

14.7

1.50

10.84

1.25

19.6

2.00

14.46

26.5

2.70

19.55

36.6

3.73

26.99

1.25

41.2

4.20

30.39

53.0

5.40

39.09

81.4

8.30

60.04

1.25

74.5

7.60

54.95

97.1

9.90

71.62

144.2

14.70

106.35

1.5

119.6

12.20

88.21

155.9

15.90

114.98

226.5

23.10

167.06

1.5

182.4

18.60

134.53

237.3

24.20

175.02

338.3

34.50

249.51

1.5

263.8

26.90

194.57

343.2

35.00

253.13

487.4

49.70

359.48

1.5

365.8

37.30

269.80

475.6

48.50

350.78

674.7

68.80

497.63

1.5

486.4

49.60

358.74

632.5

64.50

466.50

897.3

91.50

661.80

1.5

643.3

65.60

474.47

836.5

85.30

616.96

1183.7

120.70

873.04

1.5

934.6

95.30

689.31

1216.0

124.00

896.86

1707.3

174.09

1259.22

1.5

1294.5

132.00

954.76

1682.8

171.60

1241.15

2367.3

241.39

1746.00

1.5

1726.0

176.00

1273.01

2243.8

228.80

1654.91

3153.8

321.59

2326.09

1.5

2256.5

230.10

1664.28

2934.1

299.19

2164.05

4114.0

419.50

3034.28

1.5

2896.0

295.31

2135.94

3763.8

383.79

2775.99

5258.3

536.19

3878.26

15-16

CHAPTER 15 SERVICE DATA 2.2

Metric coarse thread With spring washer

Nominal size

Pitch 500247

500248

500249

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

1.5

33.3

3.40

24.56

43.1

4.39

31.79

67.7

6.90

49.93

1.75

58.8

6.00

43.37

76.5

7.80

56.42

115.7

11.80

85.33

96.4

9.83

71.10

124.5

12.70

91.82

182.4

18.60

134.53

147.1

15.00

108.49

191.2

19.50

141.02

274.6

28.00

202.53

2.5

203.0

20.70

149.72

264.8

27.00

195.30

383.4

39.10

282.78

2.5

286.4

29.20

211.23

371.7

37.90

274.15

536.4

54.70

395.62

2.5

383.4

39.10

282.78

499.2

50.90

368.18

725.9

74.02

535.39

492.3

50.20

363.10

640.4

65.30

472.33

924.8

94.30

682.09

724.7

73.90

534.50

942.2

96.08

694.92

1350.4

137.70

995.99

3.5

969.9

98.90

715.35

1259.2

128.40

928.72

1843.7

188.00

1359.82

3.5

1328.8

135.50

980.06

1727.0

176.10

1273.75

2477.2

252.60

1827.06

1676.0

170.90

1236.13

2180.0

222.29

1607.86

3199.9

326.29

2360.09

2219.2

226.29

1636.77

2884.1

294.09

2127.17

4118.8

419.99

3037.82

4.5

2754.7

280.90

2031.73

3581.4

365.20

2641.46

5137.7

523.89

3789.31

15-17

CHAPTER 15 SERVICE DATA Without spring washer Nominal size

Pitch 500247

500248

500249

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

N·m

kgf·m

lbf·ft

1.5

39.2

4.00

28.91

51.0

5.20

37.62

79.4

8.10

58.56

1.75

69.6

7.10

51.33

90.2

9.20

66.53

135.3

13.80

99.79

112.8

11.50

83.20

146.1

14.90

107.76

215.7

21.99

159.09

172.6

17.60

127.30

224.6

22.90

165.65

323.6

33.00

238.67

2.5

239.3

24.40

176.50

311.9

31.80

230.04

451.1

46.00

332.71

2.5

336.4

34.30

248.11

437.4

44.60

322.60

630.6

64.30

465.10

2.5

392.3

40.00

289.34

587.4

59.90

433.24

842.4

85.90

621.31

578.6

59.00

426.75

753.2

76.80

555.52

1088.5

110.99

802.82

852.2

86.90

628.54

1108.2

113.00

817.35

1588.7

162.00

1171.75

3.5

1140.5

116.30

841.18

1481.8

151.10

1092.90

2168.3

221.10

1599.23

3.5

1563.2

159.40

1152.94

2031.9

207.19

1498.63

2915.5

297.29

2150.33

1972.1

201.10

1454.52

2564.4

261.49

1891.37

3765.8

384.00

2777.47

2610.5

266.19

1925.37

3393.1

345.99

2502.58

4845.5

494.10

3573.80

4.5

3241.1

330.49

2390.47

4212.9

429.59

3107.22

6044.8

616.39

4458.34

15-18

CHAPTER 15 SERVICE DATA

Periodic Replacement Parts

The important parts (marked with *) and elements for safe operation listed below must be replaced at each designated replacement period. If a malfunction is found on these parts, correct or replace immediately, regardless of scheduled replacement period. Replacement period No.

Periodic Replacement Parts

Year span (year)

Month span (month)

Service hours span (hour)

Rubber parts for brake master cylinder

2000

Rubber parts for brake wheel cylinder

2000

Brake valve repair kit

2000

Brake hose

2000

Rubber parts for spring chamber

2000

Stop lamp switch (air type)

4000

Tubes for brake reservoir tank

2000

High pressure hoses for loading operation

2000

Rubber parts for power steering cylinder

4000

Power steering hoses

4000

Lift chains

4000

Fuel hoses

4000

Remark

Engine oil filter element

500

Also 1 month after delivery

Fuel filter element

1000

Also 1 month after delivery

Torque converter oil filter

1000

Also 1 month after delivery

Transmission suction strainer

1000

Also 1 month after delivery

Hydraulic suction strainer

Hydraulic tank return filter

1000

Also 1 month after delivery

Air cleaner element

1000

Clean every 2 weeks.

Engine cooling water

2000

Air dryer desiccant

2000

PCV valve blow-by gas filter element

2000

200

Note: Replace the parts every specified period: year, month or service hour, whichever comes first. Time units are enclosed by parenthesis.

15-19

CHAPTER 15 SERVICE DATA 3.1

Location of Periodic Replacement Parts

4 6

5 10

1 11 8 2

Ref.

Part name

500660

Year

Rubber parts for brake master cylinder

Rubber parts for brake wheel cylinder

Brake valve rubber parts

Brake hoses

Stop lamp switch

Tubes for brake reservoir tank

High pressure hoses for loading operation

Rubber parts for power steering cylinder

Power steering hoses

Lift chains

Fuel hoses

15-20

CHAPTER 15 SERVICE DATA

4. 4.1

Lubrication Instructions Lubrication Chart

4 2 1

3 5

8 6 7

9 11

Ref.

Lubricating point

Mast support bushings (Each side)

Fork guide bar

Lift chain (Each side)

Mast and lift bracket side rollers (Each side)

Mast strips surfaces

Tilt socket pins (Each side)

Tilt cylinder pins (Each side)

Universal joint (2 places)

Fan belt pulleys (3 fittings)

Rear axle supports (Front and Rear)

Tire rod pins (4 places)

Lubricant/grease

500212

Period

Multipurpose-type grease Engine oil

Every 500 hour or 3 months Multipurpose-type grease

15-21

CHAPTER 15 SERVICE DATA 4.2

Recommended Fuels and Oils Recommendation for Ambient Temperatures 째C (째F) Fuel or Oil

-30 (-22)

Recommendation

Fuel

-20 (-4)

-10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

Consult your authorized Mitsubishi Forklift Truck dealer.

Engine oil

API service classification CD, min.

Gear oil (front axle)

API service classification multi-purpose type GL-4 or GL-5

Powershift Transmission Oil

Dexron II

Hydraulic Oil

ISO VG32

Brake Fruid

F.M.V.S.S. No. 116 - DOT3 or DOT4 (SAE J1703)

Grease

SAE10W

SAE30

SAE80W

SAE90

Consult your authorized Mitsubishi Forklift Truck dealer.

Wheel bearings

NLGI No.2 grade multipurpose type (lithium base), consistency: 265 - 295

Chassis

NLGI No.1 grade multipurpose type (lithium base), consistency: 310 - 340

Antifreeze solution

Ambient Temperature, 째C ( 째F)

-45 (-49)

-39 (-38.2)

-30 (-22)

-25 (-13)

-20 (-4)

-15 (5)

-10 (14)

Concentration (%)

Note: -

Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when mixed. It is best to stick with the same brand at successive service intervals. For refill capacities and measurements, see "Specifications" in this section.

15-22

CHAPTER 15 SERVICE DATA Engine Oils (Diesel) Specifications

Viscosity

SAE 10W30 API service classification CD or MIL-L-2104E equivalents SAE 30

Manufacturer

Brand name

Mobil

Mobil Delvac 1210

Shell

Shell Rotella T 10W

Exxon

XD-3 10W

Castrol

Castrol Syntec 10W-30

Mobil

Mobil Delvac 1230

Shell

Shell Rotella T 30

Exxon

XD-3 30

Castrol

Castrol Syntec 10W-30

Gear Oils (Front Axle) Specifications

API service classification GL-4 or GL-5

Viscosity

SAE 80W SAE 90

Manufacturer

Brand name

Mobil

Mobilube HD 80W-90

Shell

Shell Spirax HD 80W-90

Exxon

Gear Oil GX80W-90

Castrol

Castrol Hypoy 80W-90

Manufacturer

Brand name

Mobil

Mobil ATF

Shell

Shell Donax TG

Exxon

Exxtrans

Castrol

Castrol Dexron III/Mercon

Manufacturer

Brand name

Mobil

Mobil Universal Brake Fluid

Shell

Shell Advance Brake Fluid

Exxon

Brake Fluid DOT-3

Castrol

Castrol GT LMA Brake Fluid

Powershift Transmission Oils Specifications

Dexron II

Viscosity

---

Brake Fluids Specifications

F.M.V.S.S. No. 116 - DOT3 or DOT4 (SAE J1703)

Viscosity

---

15-23

CHAPTER 15 SERVICE DATA Antifreeze Summer Coolant Non-amin type Marcus Peak USI Chemical Hydraulic Oils Specifications

ISO VG32

Manufacturer

Brand name

Mobil

Mobiltrans HD 10W

Shell

Tellus T32

Exxon

Nuto H32

Castrol

15-24

Castrol Hyspin AWH-M32

CHAPTER 15 SERVICE DATA 4.3

Adjustment Value and Oil Quantities

Note: The values in the table below are for the standard model. Truck model Item FD100NZ Engine idling speed

FD120NZ

FD135NZ

800±50 min

Steering wheel free play (when measured at rim with engine idling)

70 mm (2.76 in.)

Brake pedal free play

15 mm (0.59 in.)

Tire size

Tire pressure

Tightening torque for wheel nuts Lift chain elongation limit

Front tire

10.00-20-14PR 10.00-20-16PR

12.00-20-18PR

Rear tires

10.00-20-14PR 10.00-20-16PR

12.00-20-18PR

Front tire

700 kPa

800 kPa

Rear tires

700 kPa

800 kPa

Front wheels Rear wheels (tires) (mm/20 links)

Fuel tank capacity Engine cooling system 0.65 L (0.17 U.S. gal.) reservoir tank included

Engine oil

539.4±49 N·m (55.0±5.0 kgf·m) [397.83±36.14 lbf·ft] 490.3 to 588.4 N·m (50.0 to 60.0 kgf·m) [361.62 to 433.97 lbf·ft] 915 mm (36.02 in.)

1,046 mm (41.18 in.)

155 L (41.0 U.S. gal.)

190 L (50.2 U.S. gal.)

24 L (6.3 U.S. gal.)

Engine

12 L (3.2 U.S. gal.)

Oil filter

4 L (1.1 U.S. gal.)

Total

16 L (4.2 U.S. gal.)

Transmission oil

23 L (6.1 U.S. gal.)

Transfer and differential gear oil level

20 L (5.3 U.S. gal.)

Hydraulic oil

FD150ANZ

-1

N level

Brake fluid Battery electrolyte specific gravity, corrected to 20°C (68°F)

190 L (50.2 U.S. gal.)

195 L (51.5 U.S. gal.)

225 L (59.4 U.S. gal.)

240 cc (0.063 U.S. gal.) 1.280 to 1.260

15-25

CHAPTER 15 SERVICE DATA

Weight of Major Devices Truck model Item FD100NZ

FD120NZ

Approx 4350 Approx 5560 kg (9590 lb) kg (12258 lb)

Counterweight

FD135NZ

Approx 6490 kg (14308 lb)

Engine only (service weight)

Approx 587 kg (1294 lb)

Power train Engine and transmission

Approx 900 kg (1984 lb)

Operator compartment

Approx 370 kg (816 lb)

Front axle (excluding tires and rims)

Approx 1210 kg (2668 lb)

Rear axle (excluding tires and rims)

Approx 790 kg (1742 lb)

Mast Dual-stage panoramic mast (3m) (Simplex.)

FD150ANZ

Outer mast

Approx 850.2 kg (1874 lb)

Approx 878.4 kg (1937 lb)

Approx 961.7 kg (2120 lb)

Inner mast

Approx 659.4 kg (1454 lb)

Approx 698.1 kg (1539 lb)

Approx 781.7 kg (1723 lb)

W2050

Approx 957.0 kg (2110 lb)

Approx 1,227.4 kg (2706 lb)

Approx 1,224.1 kg (2699 lb)

W2200

Approx 988.7 kg (2180 lb)

W2300

Approx 1,010.3 kg (2227 lb)

Approx 1,286.6 kg (2836 lb)

Approx 1,283.3 kg (2829 lb)

W2400

Approx 1,304.9 kg (2877 lb)

Approx 1301.3 kg (2869 lb)

Lift bracket

Forks (2 pieces)

Lift cylinder

1220 mm (48.03 in.) Others

HOLD

Approx 415.2 kg (915 lb)

Approx 439.3 kg (968 lb)

Approx 565.9 kg (1248 lb)

FREE

Approx 409.0 kg (902 lb)

Approx 433.0 kg (955 lb)

Approx 560.1 kg (1235 lb)

Approx 188 kg (414 lb)

Approx 226 kg (498 lb)

Note: The values listed in the table are for standard specification, therefore, they differ depending on the specification.

15-26

CHAPTER 15 SERVICE DATA

Special tools

Ref. No.

Part number

Name

Purpose

67284-15400

Bolt

Removal of torque converter, shaft, torque converter housing, torque converter stator shaft

92267-00300

Piston tool

Removal and installation of torque converter clutch spring

91268-00500

Ring puller

Removal and installation of torque converter clutch snap ring

64309-17713

Gauge kit

Measurement of torque converter main oil pressure

64309-17714

Gauge kit

Measurement of torque converter main oil pressure

64309-17722

Hose

Measurement of torque converter main oil pressure and control valve oil pressure

64309-17731

Connector

Measurement of torque converter main oil pressure and control valve oil pressure

64309-17733

Connector

Measurement of torque converter main oil pressure and control valve oil pressure

64309-17701

Gauge kit

Measurement of transmission hydraulic oil pressure

92267-00200

Socket wrench

Removal and installation of front axle lock nut

05312-11000

Hook wrench

Removal and installation of cylinder head

92367-02100

Bolt holding spanner

Removal and installation of wheel brake

92367-02200

Torque wrench

Removal and installation of wheel brake

03727-10001

Spring setter

Removal of wheel brake return spring

03727-60000

Anchor pin puller

Removal of wheel brake anchor pin

91268-10600

Puller

Removal of steering wheel

91268-03200

Puller

Removal of steering wheel needle bearing

05530-40400

Cap

Sealed lid for tilt cylinder oil

91268-01700

Connector

Measurement of control valve oil pressure

05312-20750

Hook wrench A

Removal and installation of fork positioner cylinder guide bushing

64309-17712

Gauge

Measurement of control valve oil pressure

64309-17734

Connector

Measurement of control valve oil pressure

15-27

CHAPTER 15 SERVICE DATA

M10 X 1.25

C 1.5

500217

500214

500218

500215

500219

500216

500220

Ã¸130

500213

03D

15-28

CHAPTER 15 SERVICE DATA

500221

500650

500223

500651

500648

500652

500649

500653

15-29

CHAPTER 15 SERVICE DATA

500654

500657

500655

500658

500656

500659

15-30

Mitsubishi Forklift Trucks

Service Manual

FD100NZ, FD120NZ, FD135NZ, FD150ANZ

99799-21000

Mitsubishi Caterpillar Forklift Europe B.V.

Mitsubishi Caterpillar Forklift Asia Pte. Ltd.

Hefbrugweg 77 1332 AM Almere The Netherlands

RCB No.: 199203169H No.1, Tuas West Street Singapore 637444

Printed in The Netherlands

Printed in U.S.A.

99799-21000

02/11