Service Manual - Truck

FOREWORD
This service manual is a guide to servicing of Cat® lift trucks. The instructions are grouped
by systems to serve the convenience of your ready reference.
Long productive life of your forklift trucks depends to a great extent on correct servicing
the servicing consistent with what you will learn from this service manual. We hope you
read the respective sections of this manual carefully and know all the components you will
work on before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual were of the
trucks of serial numbers in effect at the time it was approved for printing. Cat lift truck re-
serves the right to change specifications or design without notice and without incurring ob-
ligation.
DP100N, DP120N, DP135N, DP150N and DP160N are powered by Mitsubishi 6M60-TL
diesel engine.
6M60-TL Diesel Engine Service Manual Pub. No. 99709-61100
Safety Related Signs
The following safety related signs are used in this service
manual to emphasize important and critical instructions:
Indicates a specific potential hazard

WARNING resulting in serious bodily injury or
death.
Indicates a specific potential hazard
CAUTION resulting in bodily injury, or damage to,
or destruction of, the forklift truck.
Indicates a condition that can cause
damage to, or shorten service life of, the
NOTE
forklift truck.
Pub.No. 99799-63100
1
HOW TO READ THIS MANUAL)
Disassembly diagram (example)
The suggestion for

disassembly is shown
below.
2
Index numbers show
the sequence of
disassembly. 1
209603
Sequence
1 Cover, Bolt, Washer (part name)
2 Output shaft (part name)
Suggestion for disassembly

(1) Output shaft removal
209604
Symbols or abbreviations
OP Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)
Standard 0.020 to 0.105 mm

Cllearance valve (0.00079 to 0.00413 in.)
between cylinder
and piston Repair 0.15 mm
service unit (0.059 in.)
2
SAFETY
(5) Use steps and grab handles (if applicable) when mount-
WARNING ing or dismounting a truck. Clean any mud or debris
Do not operate this truck unless you have read and
from steps, walkways or work platforms before using.
understand the instructions in the OPERATION & Always face truck when using steps, ladders and walk-
MAINTENANCE MANUAL. Improper truck operation ways. When it is not possible to use the designed
is dangerous and could result in injury or death. access system, provide ladders, scaffolds, or work plat-
forms to perform safe repair operations.
The proper and safe lubrication and maintenance for
(6) To avoid back injury, use a hoist when lifting compo-
this forklift truck, recommended by Cat lift truck, are nents which weigh 23 kg (50 lb.) or more. Make sure
outlined in the OPERATION & MAINTENANCE MAN- all chains, hooks, slings, etc., are in good condition and
UAL for these trucks. are of the correct capacity. Be sure hooks are posi-
Improper performance of lubrication or maintenance tioned correctly. Lifting eyes are not to be side loaded
during a lifting operation.
procedures is dangerous and could result in injury or
(7) To avoid burns, be alert for hot parts on trucks which
death. Read and understand the OPERATION & have just been stopped and hot fluids in lines, tubes and
MAINTENANCE MANUAL before performing any compartments.
lubrication or maintenance. (8) Be careful when removing cover plates. Gradually
back off the last two bolts or nuts located at opposite
(1) Read and understand all warning plates and decals on
ends of the cover or device and pry cover loose to
the truck before operating, lubricating or repairing the
relieve any spring or other pressure, before removing
product.
the last two bolts or nuts completely.
(2) Always wear protective glasses and protective shoes
(9) Be careful when removing filler caps, breathers and
when working around trucks. In particular, wear pro-
plugs on the truck. Hold a rag over the cap or plug to
tective glasses when pounding on any part of the truck
prevent being sprayed or splashed by liquids under
or its attachments with a hammer or sledge. Use weld-
pressure. The danger is even greater if the truck has
ers gloves, hood/goggles, apron and other protective
just been stopped because fluids can be hot.
clothing appropriate to the welding job being per-
(10)Always use tools that are in good condition and be
formed. Do not wear loose-fitting or torn clothing.
sure you understand how to use them before perform-
Remove all rings from fingers when working on
ing any service work.
machinery.
(11)Reinstall all fasteners with same part number. Do not
(3) Do not work on any truck that is supported only by lift
use a lesser quality fastener if replacements are neces-
jacks or a hoist. Always use blocks or jack stands to
sary. Do not mix metric fasteners with standard nuts
support the truck before performing any disassembly.
and bolts.
(4) Lower the forks or other implements to the ground
(12)If possible, make all repairs with the truck parked on a
before performing any work on the truck. If this cannot
level, hard surface. Block truck so it does not roll while
be done, make sure the forks or other implements are
working on or under truck.
blocked correctly to prevent them from dropping unex-
pectedly. (13)Disconnect battery and discharge any capacitors (elec-
tric trucks) before starting to work on truck. Hang “Do
not Operate” tag in the Operator’s Compartment.
(14)Repairs, which require welding, should be performed
only with the benefit of the appropriate reference infor-
mation and by personnel adequately trained and knowl-
edgeable in welding procedures. Determine type of
metal being welded and select correct welding proce-
dure and electrodes, rods or wire to provide a weld
metal strength equivalent at least to that of parent
metal.
3
(15)Do not damage wiring during removal operations. The serviceman or mechanic may be unfamiliar with many
Reinstall the wiring so it is not damaged nor will it be of the systems on this truck. This makes it important to use
damaged in operation by contacting sharp corners, or caution when performing service work. A knowledge of the
by rubbing against some object or hot surface. Do not system and/or components is important before the removal
connect wiring to a line containing fluid. or disassembly of any component.
(16)Be sure all protective devices including guards and Because of the size of some of the truck components, the
shields are properly installed and functioning correctly serviceman or mechanic should check the weights noted in
before starting a repair. If a guard or shield must be this Manual. Use proper lifting procedures when removing
removed to perform the repair work, use extra caution. any components.
Following is a list of basic precautions that should always
(17)Always support the mast and carriage to keep carriage
be observed.
or attachments raised when maintenance or repair work
is performed, which requires the mast in the raised
position.
(18)Loose or damaged fuel, lubricant and hydraulic lines,
tubes and hoses can cause fires. Do not bend or strike
high pressure lines or install ones which have been bent
or damaged. Inspect lines, tubes and hoses carefully.
Do not check for leaks with your hands. Pin hole (very
small) leaks can result in a high velocity oil stream that
will be invisible close to the hose. This oil can penetrate
the skin and cause personal injury. Use cardboard or
paper to locate pin hole leaks..
(19)Tighten connections to the correct torque. Make sure
that all heat shields, clamps and guards are installed
correctly to avoid excessive heat, vibration or rubbing
against other parts during operation. Shields that pro-
tect against oil spray onto hot exhaust components in
event of a line, tube or seal failure, must be installed
correctly.
(20)Relieve all pressure in air, oil or water systems before
any lines, fittings or related items are disconnected or
removed. Always make sure all raised components are
blocked correctly and be alert for possible pressure
when disconnecting any device from a system that uti-
lizes pressure.
(21)Do not operate a truck if any rotating part is damaged
or contacts any other part during operation. Any high
speed rotating component that has been damaged or
altered should be checked for balance before reusing.
4
GROUP INDEX
GROUP INDEX Items
Model View, Truck Models Covered, Serial Number Locations,

GENERAL INFORMATION Chassis and Mast Model Identification, Dimensions, Technical Data
1
Specifications, Structure, Removal and Installation, Inspection and
COOLING SYSTEM Adjustment, Inspection of Fan belt, Fan Belt Tension Adjustment
2
Specifications, Location of Components, Description, Console Box, Major
ELECTRICAL SYSTEM Components, Lamp Bulb Specifications, Disassembly and Reassembly,
Console Box, Combination Meter, Components, Batteries, etc. 3
CONTROLLER Outline, Service Tool Functions, Error Code List, Troubleshooting
4
TILTABLE Specifications, Structure, Oil supply, Hydraulic circuit diagram, Service Data)
5
Specifications, Description, 2-speed Transmission, Gear Ratios,
POWER TRAIN Removal and Installation, Engine and Transmission Unit, Refill
Capacities (Approximate) 6
Specifications, Description, Torque Converter, Transmission, Power
POWERSHIFT TRANSMIS-
Flow, Control Valve, Main Regulator Valve, Hydraulic System
SIONS Schematic, Speed Selector System, Control System, etc. 7
Specifications, Description, Removal and Installation, Front Wheels
FRONT AXLE AND REDUC-
(Tires), Front Axle and Reduction Differential, Front Axle, Disassembly,
TION DIFFERENTIAL Inspection, Reassembly, Reduction Differential, etc. 8
Specifications, Description, Rear Axle, Power Cylinder, Removal and
REAR AXLE Installation, Rear Wheel (Tire), Rear Axle, Removal, Installation,
Disassembly, Reassembly, Power Cylinder, Disassembly, Inspection, etc. 9
Specifications, Structure, Brake System, Wheel Brakes, Brake Booster,
BRAKE SYSTEM Master Cylinder, Parking Brake, Wheel Brakes, Disassembly, Inspection
and Repair, Reassembly, Wheel Cylinders, Disassembly, etc. 10
Specifications, Structure and Functions, General, Steering Hydraulic
STEERING SYSTEM System, Steering Gear, Tilt Steering Assembly, Removal and Installation,
Removal, Installation, Steering Valve, Disassembly, Inspection, etc. 11
Specifications, Structure and Function, Hydraulic Line, Hydraulic Tank,
HYDRAULIC SYSTEM Hydraulic Pump (Gear Pump), Control Valve, Inlet Cover, Lift Valve, Tilt
Valve, Attachment Valve, Flow Regulator Valve, Down Safety Valve, etc. 12
Structure, Simplex Mast (4P70B, 4P70C), Triplex Mast (4M70A,
MASTS AND FORKS 4M70B), Removal and Installation, Mast and Lift Bracket Assembly,
Disassembly and Reassembly, Simplex Mast, Triplex Mast, etc. 13
Applicable Attachment Models, Specifications, Structure, Removal and
FORK POSITIONER Installation, Removal, Installation, Fork Positioner Assembly, Fork
Positioner Cylinder, Inspection and Adjustment, Troubleshooting, etc. 14
Tightening Torque for Standard Bolts and Nuts, Periodic Service Chart,
SERVICE DATA Periodic Replacement Parts, Lubrication Instructions, Lubrication Chart,
Location of Periodic Replacement Parts, etc. 15
5
GENERAL INFORMATION
1. Model View................................................................................................................... 1-2
2. Truck Models Covered ................................................................................................. 1-2
3. Serial Number Locations .............................................................................................. 1-3

1
4. Main specifications ....................................................................................................... 1-4
5. Chassis and Mast Model Identification......................................................................... 1-5
6. Dimensions (Approximate) ........................................................................................... 1-6
1-1
GENERAL INFORMATION
1. Model View
212161
2. Truck Models Covered

This Service Manual furnishes servicing and maintenance
information for the following trucks:
Model code - Serial
Truck model Transmission Engine mounted
number
DP100N Powershift T36A-10011-up Mitsubishi 6M60-TL diesel engine
1-2
GENERAL INFORMATION
3. Serial Number Locations
Chassis serial number Name plate
Mast serial number Transmission serial number Engine model
216162
1-3
GENERAL INFORMATION
4. Main specifications
Truck model DP100N DP120N DP135N DP150N DP160N

Designation T36A T37A T38A T39A T40A
Type Standard (with 3-speed powershift transmission)
10000/600 12000/600 13500/600 15000/600 16000/600
kgf/mm kgf/mm kgf/mm kgf/mm kgf/mm
Capacity/load center
(17500/24 (20000/24 (17500/24 (20000/24 (17500/24
lbf/in.) lbf/in.) lbf/in.) lbf/in.) lbf/in.)
Lift 3300 mm (130 in.)
370/310
Lift speed (unloaded/
480/360 mm/sec (104/98 fpm) 400/310 mm/sec (79/61 fpm) mm/sec
General loaded)
(73/61 fpm)
470/420
Lowering speed (unloaded/
500/450 mm/sec (98/89 fpm) 510/380 mm/sec (100/75 fpm) mm/sec
lloaded)
(93/83 fpm)
Tilt angle (forward-back-
15°– 12°
ward)
Free lift 0
Travel Forward
speeds
29/24.5 km/h (18/15 mph) 30/22.0 km/h (19/14 mph)
(unloaded/
Reverse
loaded)
Perfor- 4000 mm 4060 mm 4160 mm 4550 mm 4815 mm

Minimum turning radius
mance (157 in.) (160 in.) (164 in.) (179 in.) (190 in.)
Turning Inside 78.27’° –
angle Outside 51°14’ –
3550 mm 3590 mm 3680 mm 3830 mm
Minimum intersecting aisle –
(140 in.) (141 in.) (145 in.) (151 in.)
At 1.6 km/h
Gradeabil- 30% 27% 26% 27% 29%
(1 mph)
ity (rated
load) At 2 km/h
21% 19% 15% 14%
(1.2 mph)
Tires 10.00-20-14PR 10.00-20-16PR 12.00-20-20PR
Size of tires (front and rear) 12.00-20-18PR (I)
(I) (I) (I)
700 kPa 800 kPa 800 kPa
Inflation pressure of tires
(7.0 kgf/cm2) (8.0 kgf/cm2) (7.7 kgf/cm2) –
(front and rear)
[101 psi] [116 psi] [94 psi]
Weight 14800 kg 16060 kg 17700 kg 18050 kg 18950 kg

Weight
and (32630 lb) (28800 lb) (39020 lb) (39790 lb) (41780 lb)
axle 7450 kg 7340 kg 7850 kg 8190 kg 8910 kg
Front axle loading
loading (16420 lb) (16180 lb) (17310 lb) (18050 lb) (19640 lb)
(unload 7350 kg 8720 kg 9850 kg 9860 kg 10040 kg
) Rear axle loading
(16200 lb) (19250 lb) (21720 lb) (21730 lb) (22130 lb)
1-4
GENERAL INFORMATION
5. Chassis and Mast Model Identification

[Chassis]
DP 100N
Maximum capacity
DP100N: 10000 kg DP150N: 15000 kg
DP120N: 12000 kg DP160N: 16000 kg
DP135N: 13500 kg
Engine type
DP: Diesel engine type
[Mast]
3 P 100 C 30
Maximum lifting height

["30" stand for 3000 mm]
Order of the minor change
("A" for the original, "B" for the first change,
"C" for the second change, and so on)
Applicable truck model designation

100: 10.0 ton class
115: 11.5 ton class
135: 13.5 ton class
150: 15.0 ton class
Kind of mast
B: simplex mast (For DP150)
P: triplex mast (For DP100, 115, 135)
Major change
("2" for the original, "3" for the first change,
and so on up to "9")
1-5
GENERAL INFORMATION
6. Dimensions (Approximate)
J
G I
D
M
L K
B F
212163
1-6
GENERAL INFORMATION
No. Truck model DP100N DP120N DP135N DP150N DP160N

A Lift 3300 mm (130 in.)
B Fork length 1220 mm (48 in.)
C Fork width 180 mm (7.1 in.)
D Fork thickness 72 mm (2.8 in.) 79 mm (3.1 in.) 88 mm (3.5 in.) 88 mm (3.5 in.) 92 mm (3.6 in.)
Tilt angle (for-
E 15°–12°
ward-backward)
F Overall length 4295 mm (169 in.) 4375 mm (172 in.) 4530 mm (178 in.) 4830 mm (190 in.) 5040 mm (198 in.)
Overall width
G 2515 mm (99 in.) 2600 mm (102 in.) 5040 mm (198 in.)
(outside of tires)
Overall heght (to
H top of mast low- 3235 mm (127 in.) 3480 mm (137 in.) 3680 mm (145 in.)
ered)
I Tread (front) 1900 mm (75 in) 1905 mm (75 in)
J Tread (rear) 1765 mm (77 in) 1925 mm (76 in) 1890 mm (74 in)
K Wheelbase 2800 mm (110 in) 3100 mm (122 in) 3300 mm (130 in)
L Front overhang 755 mm (29.7 in.) 765 mm (30 in.) 795 mm (31.3 in.) 795 mm (31.3 in.) 805 mm (31.7 in.)
Ground clearance
M 275 mm (10.8 in.) 320 mm (12.6 in.)
(at frame)
Minimum turning
N 4000 mm (157 in.) 4060 mm (160 in.) 4160 mm (164 in.) 4550 mm (179 in.) 4815 mm (190 in.)
radius
1-7
COOLING SYSTEM
1. Specifications ............................................................................................................... 2-2
2. Structure....................................................................................................................... 2-3
3. Suggestions for Removal and Installation .................................................................... 2-4

3.1 Removing radiator and intercooler........................................................................................................ 2-4
3.1.1 Preparation.................................................................................................................................................. 2-4 2
3.1.2 Removal sequence ..................................................................................................................................... 2-4
3.1.3 Suggestions for Removal and Installation ................................................................................................... 2-5
3.1.4 Inspection and Repair ................................................................................................................................. 2-5
3.1.5 Installation ................................................................................................................................................... 2-6
4. Troubleshooting ........................................................................................................... 2-8
2-1
COOLING SYSTEM
1. Specifications

Cooling method Forced circulation of coolant
Cooling sys- Radiator type Corrugated fins with pressure cap (oil cooler integral type)
tem Oil cooler type Plate fin type
Coolant capacity 23 L
2-2
COOLING SYSTEM
2. Structure
Detail oil cooler
2 1
7
9 6
8 5
3
To torque converter
From torque converter
212164
1 Intercooler 6 Drain cock

2 Intake hose 7 Upper hose
3 Outlet hose 8 Lower hose
4 Radiator 9 Reserve tank
5 Oil cooler
The cooling system adopts corrugated fins for radiator fins The oil cooler for the torque converter, equipped in the
and a cooling fan which is made by extrusion and with eight lower tank of radiator, is a water-cooled type which utilizes
blades to enhances the cooling efficiency. the engine cooling water to enhance the cooling efficiency
of torque converter fluid.
2-3
COOLING SYSTEM
3. Suggestions for Removal and Installation

3.1 Removing radiator and intercooler
3.1.1 Preparation
Open the drain cock to drain coolant from radiator.
WARNING
Check that the coolant temperature has decreased
enough before opening the drain cock.
3.1.2 Removal sequence
1 Engine cover, Gas spring 8 Radiator hose (lower)

2 Radiator cover 9 Clamp
3 Reservoir tank hose 10 Oil cooler pipe
4 Fan guard 11 Intercooler mount, Grommet, Collar, Washer
5 Intake hose of intercooler 12 Intercooler
6 Outlet hose of intercooler 13 Radiator mount, Grommet, Collar, Washer
7 Radiator hose (upper) 14 Radiator
2-4
COOLING SYSTEM
3.1.3 Suggestions for Removal and Installation

(1) Intercooler
(a) Attach the sling to the hole of bolt securing the bracket.
(b) Put a rope to the sling and lift with a crane to remove.
Intercooler mass 9 kg
(2) Radiator
(a) Support the radiator with crane.
(b) Remove the radiator mount (four places) and lift the
radiator.
Radiator dry mass 30 kg
3.1.4 Inspection and Repair

(1) Intercooler
(a) Replace any mount rubber which is inelastic or hard-
ened.
(b) When foreign matters, such as insects and dust, have
been adhered to the fin of the core, blow out them with
compressed air from the opposite side and remove
carefully so as not to damage the fin.
Wear goggles for the sake of safety.
(c) Replace the intercooler, if the corrosion and rusting are
remarkable or the fin is not repairable.
(d) Check the intercooler hoses (upper, lower) for bulge,
damage to the hose clamp sections, and so on. Replace,
if abnormality is found.
2-5
COOLING SYSTEM
(2) Radiator
(a) Replace any mount rubber which is inelastic or hard-
ened.
(b) When foreign matters, such as insects and dust, have
been adhered to the fin of the core, wash out them with
pressurised water from the opposite side and remove
remaining foreign matters carefully so as not to dam-
age the water pipes.
(c) Replace the radiator, if the corrosion and rusting are
remarkable or the fin is not repairable.
(d) Check the radiator hoses (upper, lower) for bulge, dam-
age to the hose clamp sections, and so on. Replace, if
abnormality is found.
3.1.5 Installation
Follow the removal procedure in reverse while noting the
following instructions.
(1) Intercooler
(a) Lower the lower mount part with it aligning with the
mounting pin of the frame mount.
Collar
Washer
Nut Bolt
Washer Washer
Grommet
Detail A
212138
(2) Hose
(a) Connect each hose to intercooler or radiator making
sure that the end of the hose reaches the root of the fit-
ting. Tighten the clamp and make sure the hose end is
stopped at the flare of the fitting and can not be come
out.
2-6
COOLING SYSTEM
(3) Antifreeze and coolant

(a) Mix the coolant with antifreeze to specified concentra-
tion, and fill the radiator with it until the fluid level
comes to the top of the inlet.
(b) In addition, fill the reserve tank with the mixed solu-
tion to the specified level.
(c) Start and warm up the engine while checking for
abnormal sound.
(d) If coolant in reserve tank decreases, supply the mixed
solution to the specified amount of range.
101641
Fill within
this range.
10465B
2-7
COOLING SYSTEM
4. Troubleshooting
Radiator has been corroded due to prolonged activity Repair corroded part or replace if there is
or others remarkable corrosion.
Detarioration of upper or lower hose Replace.
Water leaks from radiator Poor tightening of hose clamp Retighten or replace.
Faulty drain cock Replace drain cock.
Cracks etc. occurred in engine cooling system, over-
Inspect and repair engine cooling system.
heating
Clean tubes with copper or steel wire so as
Clogging of radiator fins
not to damage them.
Extreme deformation of fin Repair or replace the fin.
Check belts for tension, elongation and crack
Engine overheat
Loosened fan belt and water pump belt due to ageing, and replace if there is any
defect.
Defective thermostat Inspect and repair, or replace.
Insufficient coolant Refill.
Poor tightening of hose clamp Retighten or replace.
Oil leaks from oil cooler
hose Oil cooler has been corroded due to prolonged activ- Repair corroded part or replace if there is
ity or others remarkable corrosion.
2-8
ELECTRICAL SYSTEM
1. Specifications ............................................................................................................... 3-2
2. Location of Components .............................................................................................. 3-3
3. Structure....................................................................................................................... 3-4
3.1 Console box .......................................................................................................................................... 3-4
3.2 OK Monitor............................................................................................................................................ 3-5
3.3 Major Components................................................................................................................................ 3-6
3.3.1 ECU (Electronic Control Unit) ..................................................................................................................... 3-6 3
3.3.2 Starter Switch (Anti-restart Type) ................................................................................................................ 3-7
3.3.3 Lighting switch............................................................................................................................................. 3-8
3.3.4 Fuse box ..................................................................................................................................................... 3-8
3.3.5 Spare terminal ............................................................................................................................................. 3-9
3.3.6 Lamp Bulb Specifications ............................................................................................................................ 3-9
4. Disassembly and Reassembly ................................................................................... 3-10

4.1 Disassembly of Console Box .............................................................................................................. 3-10
4.1.1 Disassembly sequence ............................................................................................................................. 3-10
4.1.2 Reassembly .............................................................................................................................................. 3-10
4.2 Combination Meter.............................................................................................................................. 3-11
4.2.1 Disassembly .............................................................................................................................................. 3-11
4.2.2 Reassembly .............................................................................................................................................. 3-11
4.3 Electrical Components in the Console Box......................................................................................... 3-12
5. Batteries and Charging .............................................................................................. 3-13

5.1 Battery Conditions and Adjustment Method Based on the Electrolyte Specific Gravity (S.G.) ........... 3-13
5.2 Relationship between Electrolyte S.G. and Charging Capacity .......................................................... 3-13
5.3 Precautions for Battery Charging........................................................................................................ 3-13
5.4 Precautions for Servicing the Charging System with Alternator ......................................................... 3-14
6. Troubleshooting ......................................................................................................... 3-15

6.1 Starter System .................................................................................................................................... 3-15
6.2 Gauges ............................................................................................................................................... 3-15
6.3 Lighting System .................................................................................................................................. 3-16
6.4 Alarm Unit ........................................................................................................................................... 3-17
6.5 Battery................................................................................................................................................. 3-18
7. Electrical Wiring Diagram ........................................................................................... 3-19
3-1
ELECTRICAL SYSTEM
1. Specifications

Model number and
65D23R × 2
quantity
Battery
Voltage (V) 12
Capacity (Ah) 52
Direction lever Electric
Console box With OK monitor
2-speed automatic transmission controller ECU (Electronic Control Unit)
Anti-restart type
Starter switch
(with the built-in mechanical lockout for preventing duplicated starting)
Lamps 24V, Refer to "Lamp Bulb Specifications".
3-2
ELECTRICAL SYSTEM
2. Location of Components
Safety relay
Engine stop control timer
Turn signal switch
Horn Console box Forward-reverse
switching solenoid
Stop lamp switch
Front combination
lamp
Electronic Control
Headlamp Unit (ECU)
Front combination
Torque converter lamp
oil thermounit
Headlamp
Fuel tank unit
Speed sensor
Battery
Engine stop
solenoid
Brake oil sensor
Glow plug
Starter relay Back-up buzzer

(optional)
Battery
Engine oil
pressure switch
Alternator
Rear combination lamp

Rear combination lamp
Engine thermounit
211305
NOTE
Every harness should be properly retained to avoid it from being interfered or rubbed by other parts. Repair a damaged har-
nesses with vinyl tape.
3-3
ELECTRICAL SYSTEM
3. Structure
3.1 Console box 2
1 Engine coolant temperature gauge 1
2 Fuel gauge 4
3 Hourmeter, Indicator lamp
4 Meter panel 6
5 Starter switch
6 Lighting switch, Turn signal 3
7 Direction lever
212142
3-4
ELECTRICAL SYSTEM
3.2 OK Monitor
A B C D E F G H
I K
L1 L2 L L3
212143
No. Indicator lamp OFF ON or Flashing Remark

A Brake fluid level indicator lamp Normal fluid level Low fluid level –
ATM: Transmission oil temperature Automatic transmis-
Normal temperature Overheating
indicator lamp sion model
B
Manual transmission
MTM: Clutch wearing Normal Wearing
model
Insufficient oil pres-
C Engine oil pressure indicator lamp Normal oil pressure –
sure
D Seatbelt reminder lamp Properly attached Unattached –
Multi-purpose warning lamp
(This turns on when any alarm regard-
E Normal Failure Printed symbol part
ing the printed symbols is issued or at a
minor trouble.)
Charging system
F Charging indicator lamp Normally charged –
abnormal
G Glow plug indicator lamp Heating completed Heating Diesel engine truck
H Mast interlock indicator Blinks under interlocked condition
Fr, Re interlock indicator lamp Blinks under interlocked condition
I
Neutral indicator lamp Blinks when the gear is in neutral
J Fuel gauge Shows the remaining fuel quantity when the key is turned ON.
K Engine coolant temperature gauge Means overheat if the hand falls in the red zone.
L LCD (typically used as an hour meter) Shows the operation hours when the key is turned ON.
Location L1 Fuel filter water drain warning lamp Normal Water drain Diesel engine truck
and mean- L2 Radiator coolant level warning lamp Normal level Low level Option
ing of
printed Normal element con-
L3 Air cleaner element indicator lamp Clogged Option
symbols dition
When major failures occur: Bulbs A, C, D, E, and H simultaneously flash.
3-5
ELECTRICAL SYSTEM
How to check indicator lamp bulbs

Each bulb is normal if the indicator lamp check switch comes ON with the starter switch key turned to (ON) position. However,
the charge condition indicator lamp and engine oil pressure indicator lamp will not be illuminated.
3.3 Major Components
3.3.1 ECU (Electronic Control Unit)
Failure indicator lights
LED (green)
LED (red)
Rear (mounting) face

205509
The Electronic Control Unit (ECU) has a built-in 1-chip It is also provided with the fail-safe systems (that allow for
microcomputer to process signals from the travel speed sen- a unit to be switched to the safer side should any malfunc-
sor for activating the 2-speed automatic transmission. tion occur on it) as shown in the table below.
This ECU has "self-diagnostic" failure indicator lamps
which allow the operator to understand the content of a NOTE
trouble, if occurs in the electrical system. The failure indicator lamps are located on the rear (mount-
ing) face of the ECU box. This makes it necessary to
remove the ECU from the truck to observe these lamps.
Fail-safe Systems
Name Function
Turns OFF the power line and indicates the trouble content with the failure indicator lamp, if
Solenoid output signal circuit open
any open circuit is detected in the solenoid output signal circuit.
Allows the truck to run at the present travel speed and indicates the trouble content with the
Travel speed sensor circuit open
failure indicator lamp.
Failure indicator lamp

Cause of trouble Failure indicator lamp flashing pattern
Travel speed sensor circuit open
2-speed automatic transmission

solenoid circuit open
3-6
ELECTRICAL SYSTEM
NOTE
Each failure indicator lamp turns ON or turns OFF in the
following situations.
ON
OFF
204668
3.3.2 Starter Switch (Anti-restart Type) serves as to prevent engine troubles or starter damages pos-
This switch has a built-in mechanical lockout to prevent a sibly caused by any operation mistake.
duplicated starting. The starter switch is wired in such a way to energize the
Since this lockout mechanism restraints the starter switch glow plugs, if it is set in the (ＯＮ) position for preheat-
(key) from moving from ( ＯＮ) position to ing.
( ＳＴＡＲＴ) position while the engine is running, it
Terminal
Component Fuse box, batteries, Fuse box, engine stop control Transmission
Key alternator, timer, glow plug timer and relay shift lever,
glow plug
position glow plugs timer
(OFF)
(ON)
(START)
203561A
3-7
ELECTRICAL SYSTEM
3.3.3 Lighting switch

Connection Chart
OFF 1st 2nd Knob position

8 8 Stroke [Unit: mm (in.)]
(0.3)(0.3)
Connection Chart
Terminal
Component Tail lamps, license Front

Batteries
Knob plate lamp (option), Headlamps combination
(fuses)
position instrument panel lamp lamps
206481
3.3.4 Fuse box

Connection Chart
Capac-
Symbol Major components to be connected
ity
A 10A F – N – R lever
Instrument panel lamp, turn signal
B 10A
lamp
C 10A Spare terminal
D 15A Lamps
E 10A Horn
F 10A Spare fuse
Transmission controller, vacuum
G 10A
buzzer, stop lamps 101441F
H 10A Back-up lamps
J 15A Spare fuse
3-8
ELECTRICAL SYSTEM
3.3.5 Spare terminal

The spare supply cord extends from the fuse box in the con-
sole box. (Another spare terminal is in the chassis-side main
harness.)
Color code Lg (light green)
Removing the console box rear panel will permit you to

gain access to this spare terminal, which is usually retained
onto the harness protector consisting of bundled harnesses
with vinyl tape.
Spare terminal
207209
3.3.6 Lamp Bulb Specifications
Bulb
Qua Color of
Item For 24V sys- Schematic dia- Remark
ntity lens
tem gram
Head lamps 2 Frosted 60W A 60/60W, option
Combination lamps Turn signal lamps 2 Amber 25W B Standard (mounted on the
(front) Clearance lamps 2 Frosted 12W C overhead guard)
Tail and stop
2 Red 10/25W B
Combination lamps lamps
(rear) Turn signal lamps 2 Amber 25W B
Back-up lamps 2 Frosted 12W B
Working lamps (front) 2 Frosted 60/60W A Option
Working lamps (rear) 2 Frosted 60/60W A Option
License plate lamp 1 Frosted 12W C Option
Instrument panel lamps 2 Frosted 3W D For combination meter
OK monitor indicator lamps 5 Frosted 3W E For combination meter
A B C D E
205511
3-9
ELECTRICAL SYSTEM
4. Disassembly and Reassembly

4.1 Disassembly of Console Box
207175
4.1.1 Disassembly sequence

(1)Disconnect the electrical wires at connectors 1.
(2)Remove screws 2 (four) securing the cover.
(3)Remove screws 3 (six) and separate the front panel and rear panel.
(4)Remove screws 4 (four) securing the combination meter panel.
NOTE
Remove screws 3 and 4 to replace any bulb in the console
box.
4.1.2 Reassembly
Reassemble in the reverse order of disassembly sequence.
3-10
ELECTRICAL SYSTEM
4.2 Combination Meter

4.2.1 Disassembly
(1) Disassembly sequence
1 Meter panel
2 Meter cover
3 Engine coolant temperature gauge
4 Service hourmeter
5 Fuel gauge
6 Meter case
7 Printed circuit plate
8 Valve
9 Socket
NOTE
Be careful not to damage the printed circuit plate.
(2) Indicator Bulb Replacement
Turn the socket to the left to remove it from the printed
circuit plate.
Then, remove the bulb from the socket.
For the location of each bulb, refer to "OK Monitor."
206486
4.2.2 Reassembly
3-11
ELECTRICAL SYSTEM
4.3 Electrical Components in the Console Box
206423
1 Power relay 5 Glow plug timer

2 Power relay 6 Lighting switch
3 Turn signal relay 7 Starter switch
4 Glow plug relay 8 Fuse
3-12
ELECTRICAL SYSTEM
5. Batteries and Charging

5.1 Battery Conditions and Adjustment Method Based on the Electrolyte Specific Gravity (S.G.)
Electrolyte S.G. reading
Battery condition Adjustment
at 20°C (68°F)
If difference in S.G. between any two cells is less than
0.04, continue to use the battery without additional
charging.Where the difference in S.G. is greater than
1.280 to 1.265 Battery is fully or well charged.
0.04, discharge the battery with an efficiency-based man-
ner. If the condition is improved, recharge the battery
while adjusting the electrolyte specific gravity.
Recharge the battery.Check for any short-circuited cord
1.260 to 1.225 Battery is half charged.
or corroded connection in the electrical system.
Recharge the battery.
1.220 or less battery is discharged, requiring cares. If difference in S.G. among the cell is large, adjust the
S.G. during recharging.
Recharge until voltage and S.G. of each cell stabilize and
are maintained constant for at least 2 hours.
A cell with a low S.G. is in shorted condi- During recharging, adjust the S.G. to anywhere between
When the difference in tion. 1.280 and 1.265.
S.G. is greater than 0.040 Some electrolyte has been lost. Too much If difference in S.G. among the cells is more than 0.040
electrolyte, or water in electrolyte. and a low S.G. is found in certain cells only, replace the
battery. After leaving it for 12 to 96 hours, give it a high
current discharge test.
5.2 Relationship between Electrolyte S.G. and over-charge the battery. If refilling is not required for over 3
Charging Capacity months, it is likely that the system is inadequately charging.
Whether the battey is fully charged can be checked from the

electrolyte S.G. (between 1.280 and 1.625) read with a
hydrometer. However, it can also be judged theoretically
from the reduction rate of the electrolyte quantity. If refill-
ing is necessary every month or so, the system is tending to
5.3 Precautions for Battery Charging

CAUTION
(1) The charging current should be about 1/10 the capacity
of the battery to be charged. Be sure to turn off the starter switch and lighting
(2) For quick charging, the battery capacity in ampere switch before disconnecting or connecting the
should not be exceeded. battery cables.
(3) During charging, adjust the charging current to prevent (IC regulator may be damaged.)
the electrolyte temperature from rising beyond 45°C
(113°F).
(4) When connecting cables to the battery terminal, begin
with the cable for the positive (+) terminal. When dis-
connecting them from the battery, begin with a cable
for the negative (-) terminal.
3-13
ELECTRICAL SYSTEM
5.4 Precautions for Servicing the Charging Sys-

tem with Alternator
The alternator is equipped with a built-in IC (integrated cir-
cuit) voltage regulator.
When servicing the charging system, pay attention to the
following precautions:
(1) Do not reverse the polarity of the battery. Terminal L
(2) Do not disconnect any battery cable while the engine is
running. Terminal R
(3) Do not ground the terminal L.
(4) Do not short the terminals L and R. Terminal B
(5) Do not direct a blast of steam cleaner to the alternator. 202772
Remember, a blast of steam will damage the IC regula-
tor.
3-14
ELECTRICAL SYSTEM
6. Troubleshooting
6.1 Starter System
• Weak or dead battery • Recharge or replace.

• Open or short circuit • Repair or replace.
Starter will not
• Poor continuity in starter switch • Replace.
crank engine
Starter • Starter of starter relay defective • Replace.
switch • Transmission shift lever is not in neutral position. • Move lever to neutral position.
Turning off • Open or short circuit • Repair or replace.
starter switch
• Engine stop solenoid defective • Replace.
will not stop
engine • Control timer defective • Replace.
6.2 Gauges

Will not indicate
• Gauge internally defective • Replace.
at all
• Gauge unit defective • Replace.
Tempera- • Gauge or gauge unit is not of the specified type. • Replace.
Will not indicate
ture
accurately • Loose terminal connection • Repair.
gauges
Will indicate • Wiring between gauge and gauge unit grounded • Repair.
higher than
actual tempera-
ture
• Open or short circuit • Repair.
Will not indicate
at all
Will not indicate • Gauge or gauge unit is not of the specified type. • Replace.
accurately • Loose terminal connection • Repair.
Fuel Will indicate • Wiring between gauge and gauge unit grounded • Repair.
gauge "full" regardless
of amount of fuel
left in tank • Gauge unit defective • Replace.
• Open or short circuit between gauge and gauge • Repair.
Will indicate
"empty" regard- unit
less of amount of • Gauge internally defective • Replace.
fuel left in tank
3-15
ELECTRICAL SYSTEM
6.3 Lighting System
• Weak or dead battery • Recharge or replace.

• Fuses blown • Check and replace.
Will not light
• Poor grounding • Remove stains from the terminal or
retighten.
Lamps - • Bulbs burnt out • Replace.
general • Weak or dead battery • Check and recharge.
• Burned contact points in switches • Repair or replace.
• Loose terminals • Repair.
Will light dimly
• Dirty lenses • Clean.
• Waterdrops inside lenses • Dry and replace the packings.
• Bulbs service life expired • Replace.
Head • Lighting switch defective • Replace.
Will not light
lamps • Bulbs burnt out • Replace.
• Turn signal switch defective • Replace.
Will not flash
• Turn signal relay defective • Replace.
Will not go out • Turn signal relay defective • Replace.
Turn sig-
Will flash too • Bulb wattage less than the rating • Replace it with specified bulb.
nal lamps
slow • Turn signal relay defective • Replace.
Will flash too • Bulb wattage greater than the rating • Replace it with specified bulb.
fast • Turn signal relay defective • Replace.
• Backup lamp switch defective • Correct if improperly installed: replace if
Backup lamps
internally defective.
will not light
Other • Bulbs burnt out • Replace.
lamps
License number • Lighting switch defective • Replace.
plate lamp will
• Bulbs burnt out • Replace.
not light
3-16
ELECTRICAL SYSTEM
6.4 Alarm Unit
• Fuses blown • Check and replace.

Will not sound • Horn button defective • Repair or replace.
Horn • Horn switch defective • Replace.
• Horn defective • Replace.
Will give an • Horn switch defective • Replace.
offensive sound • Horn defective • Replace.
Vacuum • Vacuum switch defective • Replace.
Will not sound
buzzer • Buzzer defective • Replace.
3-17
ELECTRICAL SYSTEM
6.5 Battery
• Drive belt slipping • Adjust the tension.

Alternator
• Broken wire of stator coil • Repair or replace.
• Rotor coil open • Replace.
• Brushes poorly seating on slip rings • Replace brushes if worn. Clean holder and
polish slip rings.
• Diode short or open • Replace.
Regulator
• Regulated voltage setting too low • Readjust.
Battery
Tends to run • Defective or inappropriate electrolyte • Refill or adjust the S.G.
down rapidly
• Defective cell plates (internal short-circuit) • Replace.
• Poor terminal connections due to insufficient • Clean and tighten.
tightening torque
Battery
Wiring
• Open or loose connection between the key switch • Repair.
and regulator IC terminal
• Fuse blown in the above mentioned circuit or poor • Replace fuse or repair the holder's contact
contact in the holder part.
• Open or loose connection between the regulator • Repair.
terminal and alternator terminal
Wiring
• Wrong connection or short circuit between the • Repair.
regulator IC terminal and battery terminal.
Battery over-
• Poor grounding of regulator terminal F • Repair.
charge
Regulator
• Pressure coil open-circuited • Replace.
• Regulated voltage too high • Readjust.
3-18
CONTROLLER
1. Outline.......................................................................................................................... 4-2
1.1 System Configuration............................................................................................................................ 4-2
1.2 External View ........................................................................................................................................ 4-4
1.2.1 VCM-3 ......................................................................................................................................................... 4-4
1.2.2 VCM-3OP .................................................................................................................................................... 4-5
1.2.3 ECU............................................................................................................................................................. 4-6
1.2.4 Meter panel ................................................................................................................................................. 4-7
1.2.5 Input unit ..................................................................................................................................................... 4-8
1.2.6 Output unit................................................................................................................................................... 4-9
2. Service Tool Functions............................................................................................... 4-10

2.1 Menu ................................................................................................................................................... 4-10
4
2.2 Input Monitor and Output Monitor ....................................................................................................... 4-11
2.2.1 VCM-3 input monitor and output monitor (VCM-3 → VCM-3)................................................................... 4-11
2.2.2 VCM-3OP input monitor and output monitor (VCM-3 → VCM-3OP) ........................................................ 4-13
2.2.3 MP input monitor (VCM-3 → MP) ............................................................................................................. 4-14
2.2.4 ECU input monitor and output monitor (VCM-3 → ECU) .......................................................................... 4-15
2.3 Fault Status......................................................................................................................................... 4-16
2.4 Fault History........................................................................................................................................ 4-17
3. Error Code List ........................................................................................................... 4-18

4.1 General Information ............................................................................................................................ 4-19
4.1.1 Before replacing controllers ...................................................................................................................... 4-19
4.1.2 Connection of service tool ......................................................................................................................... 4-19
4.1.3 How to clean harness connectors and system components ..................................................................... 4-20
4.2 Troubleshooting .................................................................................................................................. 4-21
4-1
CONTROLLER
1. Outline
1.1 System Configuration The controller are connected on the Controller Area Net-
The controller system consists of the vehicle control con- work (CAN) and communicate mutually to control the
trollers (VCM-3 and VCM-3OP), engine control controller vehicle.
(ECU), meter panel, input unit and output unit.
Gateway
ECU
VCM-3OP
Input unit
Meter panel
N
1
VCM-3
Output unit
212331
4-2
CONTROLLER
CAN connection
CAB harness Harness A Harness B Harness C

Connector Connector Connector
201 205 205
200 204 204
396 395
396 395
201 200 201 200 205 204
396 395
Meter
panel VCM-3 VCM-3OP
Input
unit
286 394
VCM-3 Output
285
GSE unit 393
209
288 208
VCM-3OP Gateway
GSE 858
287
857
857
ECU
858
212332
4-3
CONTROLLER
1.2 External View

1.2.1 VCM-3
A'
B B'
SECTION A 㧙 A'
Connector pin number Connector pin number

(from view B) (from view B')
CN1 CN2
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 18 19 20 21 22 23 24 25
26 27 28 29 30 31 32 33 34 26 27 28 29 30 31 32 33 34
212333
4-4
CONTROLLER
1.2.2 VCM-3OP
A'
B B'
SECTION A 㧙 A'
Connector pin number Connector pin number

(from view B) (from view B')
CN1 CN2
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 18 19 20 21 22 23 24 25
26 27 28 29 30 31 32 33 34 26 27 28 29 30 31 32 33 34
212333
4-5
CONTROLLER
1.2.3 ECU
A
B
C
D
E
Connector pin number
A: GF34A B: GF35A C: GF32A D: GF35B E: GF31A
212334
4-6
CONTROLLER
1.2.4 Meter panel
CN2 CN1
11 12 13 14 1 2 3 4 5
15 16 17 18 19 20 6 7 8 9 10
CN2 CN1
212335
4-7
CONTROLLER
1.2.5 Input unit

(from view A)
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
212336
4-8
CONTROLLER
1.2.6 Output unit

(from view A)
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
212337
4-9
CONTROLLER
2. Service Tool Functions

2.1 Menu
Monitor menu Tool menu
• Input Monitor • Set-up Option
Indicates the input values of the controllers. Indicates or sets the Setup Option data.
• Output Monitor • Oscilloscope
Indicates the output values of the controllers. Graphs the input/output values. The oscillograph
• Custom Monitor can be stored as data.
Indicates the input/output values of the item • Active Test
selected. Outputs the signal forcibly to check the operation of
• Fault Status the equipment selected.
Indicates all error codes occurring. • Connection Change
• Fault History Designates the controller operated by the service
Indicates the fault data, such as the error codes and tool and the controller connected to it.
hour meter data, stored in the controller. • Firmware Update
Updates the firmware of the controller connected.
212338
4-10
CONTROLLER
2.2 Input Monitor and Output Monitor

These screens indicate the input and output values of each controller.
2.2.1 VCM-3 input monitor and output monitor (VCM-
3 → VCM-3)
(InputUnit)
212339
4-11
CONTROLLER
(OutputUnit ) [ V ]
(OutputUnit )
(OutputUnit )
212340
4-12
CONTROLLER
2.2.2 VCM-3OP input monitor and output monitor

(VCM-3 → VCM-3OP)
212341
4-13
CONTROLLER
2.2.3 MP input monitor (VCM-3 → MP)
212342
4-14
CONTROLLER
2.2.4 ECU input monitor and output monitor (VCM-3

→ ECU)
Accel pedal position (unfiltered)

Accel pedal position (filtered)
Reference injection quantity
212343
4-15
CONTROLLER
2.3 Fault Status

This screen indicates all error codes occurring.
OutputUnit Communication error

InputUnit Communication error
212344
4-16
CONTROLLER
2.4 Fault History

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




212345
4-17
CONTROLLER
3. Error Code List

Error Error
Description Description
code code
F01 VCM-3 Memory Check Error F50 Lift Up Solenoid Error
F02 VCM-3 Battery Voltage Error F52 Lift Down Solenoid Error
F03 VCM-3 Communication Error F54 Lift Solenoid Leak
F04 ECM Communication Error F55 Tilt Forward Solenoid Error
F07 MP Communication Error F57 Tilt Backward Solenoid Error
F10 Lift Lever Neutral Error F59 Tilt Solenoid Leak
F11 Tilt Lever Neutral Error F60 Attachment 1A Solenoid Error
F12 Attachment 1 Lever Neutral Error F62 Attachment 1B Solenoid Error
F13 Attachment 2 Lever Neutral Error F64 Attachment 1 Solenoid Leak
F14 Attachment 3 Lever Neutral Error F65 Attachment 2A Solenoid Error
F15 ECU Communication Error F67 Attachment 2B Solenoid Error
F16 Shift Lever Error F69 Attachment 2 Solenoid Leak
F17 Vehicle Speed Error F70 Attachment 3A Solenoid Error
F18 ECU KWP2000 Communication Error F72 Attachment 3B Solenoid Error
F19 ECU Speed Sensor Error F74 Attachment 3 Solenoid Leak
F20 Lift Lever Error F75 Unload Solenoid Error
F22 Tilt Lever Error F79 Unload Solenoid Leak
F24 Attachment 1 Lever Neutral Error F80 Knob Position Solenoid Error
F26 Attachment 2 Lever Neutral Error F84 Knob Position Solenoid Leak
F28 Attachment 3 Lever Neutral 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
F33 VCM-3OP Lift Oil Pressure Sensor Error F90 VCM-3OP Sensor Voltage Error
F34 Vehicle Speed Sensor Error F91 VCM-3OP Memory Check Error
F36 Tire Angle Sensor Error F92 VCM-3OP Battery Voltage Error
F39 VCM-3OP Tilt Angle Sensor Error F93 VCM-3OP Speed Change Solenoid 1 Error
F40 Steering Error F94 VCM-3OP Speed Change Solenoid 2 Error
F41 Output Unit Error F95 VCM-3OP Speed Change Solenoid Leak
F42 Output Unit Life Control Signal F96 VCM-3OP EAT Setting Error
F43 Output Unit Memory Check Error F97 VCM-3OP Communication Error
F44 Output Unit PWM Voltage Error
F45 Output Unit Communication Error
F46 Input Unit Error
F47 Input Unit Life Control Signal
F48 Input Unit Memory Check Error
F49 Input Unit Communication Error
4-18
CONTROLLER
4. Troubleshooting
4.1 General Information
4.1.1 Before replacing controllers
Do not replace controllers casually even if replacement is
required as a result of troubleshooting. Be sure to check the
following items before replacing controllers.
• Loose battery connectors
• Abnormal wire harness connections
• Loose connectors
• Broken, bent or loose connector pins
• Dirty connectors
If connectors are dirty, remove the connector and
clean connectors. See "How to clean harness con-
nectors and system components" on the next page.
• Ensure that the main harness is not short-circuited to
the truck body.
If any of these items (above items) is a source of the trou-
ble, the controller will be damaged even if it is replaced
with a new one. be sure to check the above items and
replace carefully.
4.1.2 Connection of service tool

(1) Turn off the truck power.
(2) Find the service tool connector in the CAB harness. CAB harness
(3) Remove the cover and connect the PC as shown.
VCM-3OP
(4) Turn on the truck power. GSE
(5) Start the service tool software.
GSE cable VCM-3

GSE
212346
4-19
CONTROLLER
4.1.3 How to clean harness connectors and system

components
(1) Open-circuits are often caused by dirty harness connec-
tors and components. Dust, together with greasy mat-
ter, forms grime which, in time, penetrates electrical
connections, resulting in loose metal-to-metal contact
or, for worse, electrical separation of surfaces in con-
tact. For this reason, it is essential that the connectors
and components be cleaned at each periodic inspection
and at when servicing the truck. Instead of a commonly
used solvent, use the electronic parts cleaner (in the
manner illustrated on the right). Electronic parts cleaner
Electronic parts Three Bond 29D or 212347
cleaner Pow-R-Wash CZ*
NOTE
The cleaner liquid is volatile. All you have to do is just give
a strong spray to wash off grime.
No need to wipe off the sprayed liquid.
(2) After checking the connector for continuity, wash it as

shown. Then, uncouple the connector and spray the
contact surface activator onto contact surfaces.
Install and remove the connector several times to wet
the surfaces thoroughly with the activator liquid.
Electronic parts
After coupling up the connector, check to be sure that it cleaner
is in locked state.
Contact surface Three Bond 2501S (aerosol)

activator or Nyogel 760G*
NOTE
Do not spray too much liquid into the connector.
Cleaner liquid reacts differently with some resins (plastic
materials).
*: Products contained in Terminal Maintenance kit
(SE000003)
Contact surface
activator
212348
4-20
CONTROLLER
4.2 Troubleshooting
Problem: VCM-3 Memory Check Error (F01)
(1) Situation
Indication: "F01" flickering. Drive and hydraulic operations disabled.
(2) Possible cause
Faulty VCM-3, faulty truck type setting data in VCM-3.
(3) How the error code is triggered

Software checks sum value of ROM and EEPROM in CPU, and detects fault.
(4) Checks
Check truck type setting data.
Normal Abnormal
(5) Enter truck type setting data again.
(6) Enter shipment default value into VCM-3.

Normal Abnormal
(7) Perform standard setting, then enter truck type setting

data again.
(8) Write updated software into VCM-3.
Normal Abnormal
(9) Faulty software writing. (10) Replace VCM-3.
4-21
CONTROLLER
Problem: VCM-3 Battery Voltage Error (F02)
(1) Situation
(2) Possible cause
Poor battery charge, faulty battery, faulty VCM-3, faulty harness, faulty DC-DC converter.

When VCM-3 input voltage is less than 7V or more than 21V.
(4) Checks
Measure battery terminal voltage.
Normal (18V to 32V) 7V or less 32V or more
(5) Charge battery.
Error remains
(6) Replace battery.
(7) Measure output voltage and input voltage of DC-DC converter.

1. Output voltage: Between 40(DC-DC converter: +12V) and 107 (DC-DC converter: GND). 12V
2. Input voltage: Between 8(DC-DC converter: +24V) and 104 (DC-DC converter: GND). 24V
Normal Input voltage abnormal Output voltage abnormal
(8) Replace harness. (9) Replace DC-DC converter.
(10) Measure input voltage of VCM-3.

1. Between 40(VCM-3: CN1-18) and 130(VCM-3: CN1-25).
7V or less 7V to 21V
(11) Replace harness. (12) Replace VCM-3.
4-22
CONTROLLER
DC-DC
CONVERTER
VCM-3
CN1
0.85B/L 1.25B/L
131 105 107 107 12V GND
0.85B/L 2R/Y
130 40 40 12V MAIN
1.25R/Y 1.25B
41 40 104 104 24V GND
1.25R/Y
40 94 12V LAMP
F7 49 24V LAMP
8R 2R/W 2R/W
8 8 8 24V BATT
CN1
10A 62 ACC IN
1
301 12V BATT

15R
9 245 1
17 224 223 10
25 130 218 217 216132 215 40 18
34 131 229 411 211 41 26
FLW 0.85R
105
60B
100
60B
5
2B/L
2B
㧙㧗㧙㧗
BATTERY BATTERY
212349
4-23
CONTROLLER
Problem: VCM-3 Communication Error (F03)
(1) Situation
(2) Possible cause

Faulty VCM-3, faulty harness.

When CAN communication of VCM-3 is interrupted.
(4) Checks
Check to see if other errors occur simultaneously.
F03 only Other errors occur
(5) See troubleshooting for errors occurred.
(6) Check continuity of CAN communication cables.
1. VCM-3 to meter panel: Between 201(VCM-3: CN2-31) and 201(Meter panel: 18), and
200(VCM-3: CN2-32) and 200(Meter panel: 19)
2. VCM-3 to VCM-3OP: Between 201(VCM-3: CN2-31) and 205(VCM-3OP: CN2-32), and
200(VCM-3: CN2-32) and 204(VCM-3OP: CN2-31).
3. VCM-3 to output unit: Between 201(VCM-3: CN2-31) and 394(Output unit: 13), and
200(VCM-3: CN2-32) and 393(Output unit: 14).
4. VCM-3 to input unit: Between 201(VCM-3: CN2-31) and 396(Input unit: 7), and
200(VCM-3: CN2-32) and 395(Input unit: 8).
In case of diesel engine
5. VCM-3 to gateway: Between 201(VCM-3: CN2-31) and 209(Gateway: A23), and
200(VCM-3: CN2-32) and 208(Gateway: A24).
In case of asoline engine
6. VCM-3 to ECM: Between 201(VCM-3: CN2-31) and (ECM: 94), and
200(VCM-3: CN2-32) and (ECM: 86).
Continuity No continuity
(7) Replace VCM-3. (8) Replace faulty harness.
4-24
CONTROLLER
CN2
9 277 279 281 1

17 254 273 253 10
VCM-3 25 258 18 VCM-OP
CN2 34 205 204 295 294 293 292 26 CN2
0.85L/R
CAN H 201 201
0.85B/W 0.85B/W
CAN L 200 200 204 204 CAN L
0.85L/R
205 205 CAN H
CN2
9
17
227228 1
234 235 233 232 231 230 221 220 10
METER PANEL
25 384 222 238 237 18
34 200 201 299 298 297 296 26
0.85L/R CAN H
201 201
0.85B/W CAN L
200 200
OUTPUT UNIT
0.85L/R
394 13 CAN H
0.85B/W
393 14 CAN L
INPUT UNIT
(HARNESS, IN FC)
0.85L/R 0.5B
396 396 7 CAN H
0.85B/W 0.5B/W
395 395 8 CAN L
GATEWAY
(Diesel engine)
208
209
0.85B/W
0.85L/R
94 ECM
86 (Gasoline engine)
212350
4-25
CONTROLLER
Problem: ECM Communication Error (F04)
(1) Situation
Indication: "F04" flickering.
(2) Possible cause
Faulty VCM-3, faulty harness, faulty ECM.

When CAN communication from ECM to VCM-3 is interrupted.
(4) Checks
Check continuity of CAN communication cables.
VCM-3 to ECM: Between 201(VCM-3: CN2-31) and (ECM: 94), and 200(VCM-3: CN2-32) and (ECM:86).
(5) Replace VCM-3. (6) Replace harness.
Error remains
(7) Replace ECM.
4-26
CONTROLLER
Problem: MP Communication Error (F07)
(1) Situation
Indication: "F07" flickering. Drive operations disabled.
(2) Possible cause
Faulty meter panel, faulty VCM-3, faulty harness.

When CAN communication from meter panel to VCM-3 is interrupted.
(4) Checks
VCM-3 to meter panel: Between 201(VCM-3: CN2-31) and 201(Meter panel: 18), and 200(VCM-3: CN2-32)
and 200(Meter panel: 19).
(5) Replace meter panel. (6) Replace harness.
Error remains
(7) Replace VCM-3.
4-27
CONTROLLER
METER PANEL
BRAKE F
78 FUEL
PKB FUEL GAGE
SIGNAL PROCESSOR
77 WATER TEMP GAGE
OIL
79 BRAKE LAMP
TEMP
83 OIL PRESSURE LAMP
R
82 TORQ CONV OIL TEMP LAMP
N
80 INTERLOCK LAMP
81 F
VCM-3 MULTIPURPOSE WARNING LAMP
CN2
GLOW GLOW LAMP (LPG)
48
0.85L/R 0.85L/R CAN H MAST INTERLOCK LAMP
201 201 201 201
0.85B/W 0.85B/W CAN L SEAT BELT LAMP
200 200 200 200
12V
45
49 LAMP
ALT R
CN2 ALT L CHARGE LAMP
46
102 GND
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
212351
4-28
CONTROLLER
Problem: Lift Lever Neutral Error (F10)
(1) Situation
Indication: "F10" flickering. Hydraulic operations disabled.
(2) Possible cause

Lift lever operated when turning on key switch, faulty lift lever, faulty input unit, faulty harness.

Lift lever is not in neutral when turning on key switch.
(4) Checks
Shift lift lever in neutral, then turn on key switch.
Normal Error remains
Fail-safe operation
(5) Check continuity between lift lever and input unit.

1. Between 468(Input unit: CN1-25) and 468(Lift lever).
(6) Replace harness.
(7) Replace lift lever with another section lever.
Error transition Error remains
(8) Replace lift lever. (9) Replace input unit.
4-29
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
ATT1 ATT2/3 9 CAN R+
LIFT TILT (OP) (OP) 10 CAN R-
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
16 SW INPUT 2(SPEED SEL)
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
20 SW INPUT 6(R)
0.5B
0.5B
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
0.5G
477
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
0.5Y
461 471 470 465
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-30
CONTROLLER
Problem: Tilt Lever Neutral Error (F11)
(1) Situation
(2) Possible cause

Tilt lever operated when turning on key switch, faulty tilt lever, faulty input unit, faulty harness.

Tilt lever is not in neutral when turning on key switch.
(4) Checks
Shift tilt lever in neutral, then turn on key switch.
Fail-safe operation
(5) Check continuity between tilt lever and input unit.

1. Between 470(Input unit: CN1-27) and 470(Tilt lever).
(7) Replace tilt lever with another section lever.
(8) Replace tilt lever. (9) Replace input unit.
4-31
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
20 SW INPUT 6(R)
0.5B
0.5B
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
0.5G
477
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
0.5Y
461 471 470 465
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-32
CONTROLLER
Problem: Attachment 1 Lever Neutral Error (F12)
(1) Situation
(2) Possible cause

Attachment 1 lever operated when turning on key switch, faulty attachment 1 lever, faulty input unit, faulty harness.

Attachment 1 lever is not in neutral when turning on key switch.
(4) Checks
Shift attachment 1 lever in neutral, then turn on key switch.
Fail-safe operation
(5) Check continuity between attachment 1 lever and input unit.

1. Between 472(Input unit: CN1-29) and 472(ATT1 lever).
(7) Replace attachment 1 lever with another section lever.
(8) Replace attachment 1 lever. (9) Replace input unit.
4-33
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
20 SW INPUT 6(R)
0.5B
0.5B
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
0.5G
477
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
0.5Y
461 471 470 465
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-34
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks
Shift attachment 2 lever in neutral, then turn on key switch.
Fail-safe operation

1. Between 474(Input unit: CN1-31) and 474(ATT2/3 lever).
4-35
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
20 SW INPUT 6(R)
0.5B
0.5B
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
0.5G
477
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
0.5Y
461 471 470 465
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-36
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks
Shifts attachment 3 lever in neutral, then turn on key switch.
Fail-safe operation

4-37
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
20 SW INPUT 6(R)
0.5B
0.5B
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
0.5G
477
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
0.5Y
461 471 470 465
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-38
CONTROLLER
Problem: ECU Communication Error (F15)
(1) Situation
Indication: "F15" flickering. Drive operations restricted.
(2) Possible cause

Faulty ECU, faulty VCM-3, faulty gateway, faulty harness.

When CAN communication from ECU(gateway) to VCM-3 is interrupted.
(4) Checks
VCM-3 to gateway: Between 201(VCM-3: CN2-31) and 209(Gateway: A23), and

200(VCM-3: CN2-32) and 208(Gateway: A24).
Gateway to ECU: Between 857(Gateway: A26) and 857(ECU: 157), and
858(Gateway: A27) and 858(ECU: 158).
(5) Replace gateway. (6) Replace harness.
Error remains
(7) Replace VCM-3.
Error remains
(8) Replace ECU.
4-39
4-40
9
17
34
25
384
CONTROLLER
CN2
VCM-3
222 238
200 201 299 298 297 296
CN2
CAN L 200
CAN H 201
234 235 233 232 231 230 221 220

237
227228 1
18
10
26
0.85L/R
0.85B/W
201
200
0.85B/W
208
0.85L/R
209
0.85W
GATEWAY
858
0.85R
857
0.85Or
846 SVC POWER - 1 146
0.85Y/B
847 SVC POWER - 2 147
0.85G/W
854 AIR TEMP. SENSOR 154
0.85R/B
855 WATER TEMP. SENSOR 155
0.85R
(e e)
857 CAN - 1(H) 157

0.85W
858 CAN - 1(L) 158
0.85V
862 FUEL TEMP. SENSOR - 1(LEAK) 162
0.85Lg
CONTROL UNIT, ECG
863 FUEL TEMP. SENSOR - 2 163
212353
CONTROLLER
Problem: Shift Lever Error (F16)
(1) Situation
(2) Possible cause

Faulty meter panel, faulty VCM-3, faulty harness.

When F, N and R signals of shift lever are inputted simultaneously.
(4) Checks
Check continuity between meter panel and shift lever.
1. N: Between 272(Shift lever: 1) and 80 (Meter panel).
2. F: Between 81(Shift lever: 3) and 81(Meter panel).
3. R: Between 62(Shift lever: 5) and 82 (Meter panel).
4. GND: Between 126(Shift lever: 2) and 102(Meter panel), and 127(Shift lever: 4) and 102(Meter panel).
(5) Replace meter panel. (6) Replace harness.
Error remains
(7) Replace VCM-3.
4-41
CONTROLLER
FNR LEVER DIODE DIODE METER PANEL
1 2 34 5 BRAKE F
F1 FUEL
N 78 FUEL GAGE
R1 PKB
77 WATER TEMP GAGE
0.85Y/L 272
SIGNAL PROCESSOR
80
62
62 82 272 OIL
79 BRAKE LAMP
82 80 TEMP
83
0.85G/L
OIL PRESSURE LAMP
0.85L/W
0.85L/G
0.85L/W R
82 TORQ CONV OIL TEMP LAMP
0.85Y/L N
272
127
126
81
62
80 INTERLOCK LAMP
0.85G/R F
81
MULTIPURPOSE WARNING LAMP
0.85G/L
0.85G/R
0.85B
0.85L/G
0.85B
127 126 GLOW GLOW LAMP (LPG)

48
81 272 62
CAN H MAST INTERLOCK LAMP
201
CAN L SEAT BELT LAMP
200
12V
45
49 LAMP
ALT R
ALT L CHARGE LAMP
46
1.25B GND
102
212354
4-42
CONTROLLER
Problem: Vehicle Speed Error (F17)
(1) Situation
(2) Possible cause

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

When vehicle speed is 35 km/h or more.
(4) Checks
Check continuity between VCM-3 and vehicle speed sensor connectors.
1. Between 220(VCM-3: CN2-10) and 220(Speed sensor: +).
2. Between 221(VCM-3: CN2-11) and 221(Speed sensor: -).
(5) Replace VCM-3. (6) Replace harness.
4-43
CONTROLLER
VCM-3
Harness A Harness B Harness C

0.85R/G
SPEED SENSOR 220 220 220
0.85G/B
0.85Y/G
AUTO LIGHT OUT 222
0.85W/L
SPEED METER 384
0.85G/B
0.85R/G
220 221
CN2
221
220
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
SPEED
SENSOR
212355
4-44
CONTROLLER
Problem: ECU KWP2000 Communication Error (F18)
(1) Situation
(2) Possible cause

Faulty ECU, faulty gateway, faulty harness.

When KWP2000 communication from ECU to gateway is interrupted.
(4) Checks
Check continuity of KWP2000 communication cable.
1. Between 719(Gateway) and 719(ECU).
Error remains
(7) Replace ECU.
4-45
4-46
CONTROLLER
GATEWAY
0.85L/R
719
2Y/R
705 +VB-1(ECU POWER) 5
1.25Y/R
1.25Y/R
708 TACHO OUT (SIG) 8
1.25B
718 CASE GND 18
0.85L/R
719 MUT-3 (KWP2000) 19
0.85G/L
ACCEL SENSOR-1 (SIG) 21
(ea)
721
0.85G/B
722 ACCEL SENSOR-2 (SIG) 22
726 PTO MAX. REV. SET (SIG) 26
0.85G/Y
727 VEHICLE SPEED SENSOR (SIG) 27
CONTROL UNIT, ECG
730 IDLE VOLUME (SIG) 30

731 PTO ACCEL SENSOR (SIG) 31
734 EGR TEMP. SENSOR 34
212356
CONTROLLER
Problem: ECU Speed Sensor Error (F19)
(1) Situation
Indication: "F19" flickering. Drive operations restricted.
(2) Possible cause

Faulty gateway, faulty VCM-3, faulty ECU, faulty harness.

When vehicle speed pulse signal to ECU is interrupted.
Abnormal signal is sent from ECU.
(4) Checks
Check continuity between ECU and gateway.
1. Between 727(ECU) and 727(Gateway).
Error remains
(7) Replace VCM-3.
Error remains
(8) Replace ECU.
4-47
4-48
CONTROLLER
GATEWAY
0.85G/Y
727
2Y/R
705 +VB-1 (ECU POWER) 5
1.25Y/R
1.25Y/R
708 TACHO OUT (SIG) 8
1.25B
718 CASE GND 18
0.85L/R
719 MUT-3 (KWP2000) 19
(ea)
0.85G/L
0.85G/B
726 PTO MAX. REV. SET (SIG) 26
0.85G/Y
CONTROL UNIT, ECG
727 VEHICLE SPEED SENSOR (SIG) 27

730 IDLE VOLUME (SIG) 30
731 PTO ACCEL SENSOR (SIG) 31
734 EGR TEMP. SENSOR 34
212357
CONTROLLER
Problem: Lift Lever Error (F20)
(1) Situation
Indication: "F20" flickering. Lift up and lift down operations disabled.
(2) Possible cause

Faulty lift lever, faulty input unit, faulty harness.

When lift lever signal voltage is out of range of 0.25V to 4.75V.
(4) Checks
Check continuity between lift lever and input unit.
(6) Replace lift lever with another section lever.
(7) Replace lift lever. (8) Replace input unit.
4-49
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
20 SW INPUT 6(R)
0.5B
0.5B
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
0.5G
477
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
0.5Y
461 471 470 465
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-50
CONTROLLER
Problem: Tilt Lever Error (F22)
(1) Situation
Indication: "F22" flickering. Tilt forward and tilt backward operations disabled.
(2) Possible cause

Faulty tilt lever, faulty input unit, faulty harness.

When tilt lever signal voltage is out of range of 0.25V to 4.75V.
(4) Checks
Check continuity between tilt lever and input unit.
(6) Replace tilt lever with another section lever.
(7) Replace tilt lever. (8) Replace input unit.
4-51
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
20 SW INPUT 6(R)
0.5B
0.5B
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
0.5G
477
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
0.5Y
461 471 470 465
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-52
CONTROLLER
Problem: Attachment 1 Lever Error (F24)
(1) Situation
Indication: "F24" flickering. Attachment 1 operation disabled.
(2) Possible cause

Faulty attachment 1 lever, faulty input unit, faulty harness.

When attachment 1 lever signal voltage is out of range of 0.25V to 4.75V.
(4) Checks
Check continuity between attachment 1 lever and input unit.
4-53
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
20 SW INPUT 6(R)
0.5B
0.5B
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
0.5G
477
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
0.5Y
461 471 470 465
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-54
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks
4-55
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
20 SW INPUT 6(R)
0.5B
0.5B
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
0.5G
477
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
0.5Y
461 471 470 465
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-56
CONTROLLER
(1) Situation
(2) Possible cause


(4) Checks
4-57
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
20 SW INPUT 6(R)
0.5B
0.5B
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
0.5G
477
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
0.5Y
461 471 470 465
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-58
CONTROLLER
Problem: Joystick Lever Error (F29)
(1) Situation
Indication: "F29" flickering. Corresponding hydraulic operation disabled.
(2) Possible cause

Faulty FC lever, faulty input unit, faulty harness.

Voltage data between main signal and sub-signal is different when FC lever is not operated.
(4) Checks
Check to see if other FC lever errors occur.
F20 F22 F24 F26 F28
To (5) To (6) To (7) To (8) To (9)
(5) Replace lift lever. (6) Replace tilt lever.
(7) Replace attachment 1 lever. (8) Replace attachment 2 lever.
(9) Replace attachment 3 lever.
4-59
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
CN1
1 GND
2 Vcc 19V
3 FWE
4 RS-232 Tx
5 RS-232 Rx
6 RS-232 GND
7 CAN H
ARMREST 8 CAN L
4/5 11 BOOT
SELECT SW
(OP) 12 SEL0
13 SEL1
0.5B
476 14 SW GND
15 SW INPUT 1
0.5O
477 17 SW INPUT 3(4V/5V)
471
0.5R 470
461
473
472
467
475
474
462
463
465
469
468
466
464
460
18 SW INPUT 4(F)
19 SW INPUT 5(N)
0.5R
0.5R
0.5R
0.5B
0.5B
20 SW INPUT 6(R)
0.5B
0.5B
21 SW INPUT 7
22 SW INPUT 8
0.5R
460 23 5V
0.5B
476
464 24 GND
0.5Y
468 25 LIFT 1
0.5G
477
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
0.5Y
461 471 470 465
472 29 ATT 1-1
0.5Br
473 30 ATT 1-2
0.5Y
462 473 472 466 474 31 ATT 2-1
0.5W
475 32 ATT 2-2
463 475 474 467
0.5P
0.5B
212352
4-60
CONTROLLER
Problem: VCM-3 Sensor Voltage Error (F31)
(1) Situation
(2) Possible cause

Faulty tire angle sensor, faulty VCM-3, faulty harness.

When VCM-3 sensor power voltage is 3.85V or less.
(4) Checks
Check continuity between sensor and VCM-3.
1. Between 231(Tire angle sensor: +5V) and 231(VCM-3: CN2-13: +5V).

2. Between 232(Tire angle sensor: GND) and 232(VCM-3: CN2-14: GND).
(6) Check short circuit between sensor power and GND in sensor terminal.
Shorted Not shorted
(7) Replace tire angle sensor.
(8) Check short circuit between sensor and VCM-3

1. Between 231(Tire angle sensor: +5V) and 232(VCM-3: CN2-14: GND).
2. Between 232(Tire angle sensor: GND) and 231(VCM-3: CN2-13: +5V).
Shorted Not shorted
4-61
CONTROLLER
VCM-3

0.85Br/Y
TIRE ANGLE SEN 230 230 230 230
0.85Lg/R
0.85Y
1.25G/Y
T/M SOL. F 233
0.85Lg/R
0.85Br/Y
0.85Y
CN2 231 232 230
231
232
230
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
TIRE ANGLE
SENSOR
212358
4-62
CONTROLLER
Problem: VCM-3OP Lift Oil Pressure Sensor Error (F33)
(1) Situation
Indication: "F33" flickering. Tilt horizontal function operation disabled.
(2) Possible cause

Faulty lift oil pressure sensor, faulty VCM-3OP, faulty harness.

When lift oil pressure sensor signal voltage is out of range of 0.5V to 4.5V.
(4) Checks
Check continuity between lift oil pressure sensor and VCM-3OP.
1. Between 267(VCM-3OP: CN1-14: +5V) and 267(Lift oil pressure sensor: Vcc).
2. Between 268(VCM-3OP: CN1-15: SIG) and 268(Lift oil pressure sensor: SIG).
3. Between 269(VCM-3OP: CN1-17: GND) and 269(Lift oil pressure sensor: GND).
(6) Turn on key switch, then measure lift oil pressure sensor signal voltage between VCM-3OP connector terminals.
1. Between 268(Lift oil pressure sensor: SIG) and 269(Lift oil pressure sensor: GND).
Normal (0.5V to 4.5V) Abnormal (out of 0.5V to 4.5V)
(7) Replace VCM-3OP. (8) Replace lift oil pressure sensor.
4-63
CONTROLLER
VCM-OP
SP SEL. S/W 1 250

SP SEL. S/W 2 252
HYD PRESSURE 267 267
TILT ANGLE SEN. 264
TILT ANGLE SEN. 265
TILT ANGLE SEN. 266
0.85Lg/B
0.85B/W
0.85Lg
SPEED PULSE 290
269 268 267
CAB OPEN IND1 257
P. SOURCE 1 42
P. SOURCE 2 43
267
269
268
GND1 135
GND2 136
CN1
9 252 250 1
17 269 268 267 10
25 135 42 18
34 136 257 266 265 264 43 26
LIFT OIL PRESSURE

SENSOR (OP)
212359
4-64
CONTROLLER
Problem: Vehicle Speed Sensor Error (F34)
(1) Situation
Indication: "F34" flickering. Drive speed change operation disabled.
(2) Possible cause

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

When vehicle speed sensor signal voltage is out of range of 1.3V to 4.9V.
(4) Checks
Check continuity between VCM-3 and vehicle speed sensor.
1. Between 220(VCM-3: CN2-10) and 220(Speed sensor: +).
2. Between 221(VCM-3: CN2-11) and 221(Speed sensor: -).
(6) Measure resistance between vehicle speed sensor terminals.

220(Speed sensor: +) and 221(Speed sensor: -).
Normal [2kǡto 3kǡ at 25 °C (77 °F)] Abnormal
(7) Replace VCM-3. (8) Replace vehicle speed sensor.
4-65
CONTROLLER
VCM-3

0.85R/G
0.85G/B
0.85Y/G
AUTO LIGHT OUT 222
0.85W/L
SPEED METER 384
0.85G/B
0.85R/G
220 221
CN2
221
220
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
SPEED
SENSOR
212355
4-66
CONTROLLER
Problem: Tire Angle Sensor Error (F36)
(1) Situation
Indication: "F36" flickering. Knob position control disabled.
(2) Possible cause

Faulty tire angle sensor, faulty VCM-3, faulty harness.

When tire angle sensor signal voltage is out of range of 0.27V to 4.72V.
(4) Checks
Check continuity between VCM-3 and tire angle sensor.
1. Between 231(VCM-3: CN2-13) and 231(Tire angle sensor: SIG).
2. Between 230(VCM-3: CN2-12) and 230(Tire angle sensor: Vcc).
3. Between 232(VCM-3: CN2-14) and 232(Tire angle sensor: GND).
Normal Abnormal
(6) Measure resistance between tire angle sensor terminals. (Place tires in straight-ahead position.)
1. Between 230(Tire angle sensor: Vcc) and 231(Tire angle sensor: SIG). ࡮࡮࡮0.8kǡ to 1.2kǡ‫ޓ‬at 25͠ (77 ˚F)
2. Between 231(Tire angle sensor: SIG) and 232(Tire angle sensor: GND). ࡮࡮࡮0.8kǡ to 1.2kǡ‫ޓ‬at 25͠ (77 ˚F)
3. Between 230(Tire angle sensor: Vcc) and 232(Tire angle sensor: GND). ࡮࡮࡮1.6kǡ to 2.4kǡ‫ޓ‬at 25͠ (77 ˚F)
Normal Abnormal
(7) Replace VCM-3. (8) Replace tire angle sensor.
4-67
CONTROLLER
VCM-3

0.85Br/Y
0.85Lg/R
0.85Y
1.25G/Y
T/M SOL. F 233
0.85Lg/R
0.85Br/Y
0.85Y
CN2 231 232 230
231
232
230
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
TIRE ANGLE
SENSOR
212358
4-68
CONTROLLER
Problem: VCM-3OP Tilt Angle Sensor Error (F39)
(1) Situation
Indication: "F39" flickering. Tilt auto stop control function operation disabled.
(2) Possible cause

Faulty tilt angle sensor, faulty VCM-3OP, faulty harness.

When tilt angle sensor signal voltage is out of range of 0.1V to 4.9V.
(4) Checks
Check continuity between VCM-3OP and tilt angle sensor.
1. Between 264(VCM-3OP: CN1-27: +5V) and 264(Tilt angle sensor: +5V).
2. Between 265(VCM-3OP: CN1-28: SIG) and 265(Tilt angle sensor: SIG).
3. Between 266(VCM-3OP: CN1-29: GND) and 266(Tilt angle sensor: GND).
(6) Replace tilt angle sensor. (5) Replace harness.
Error remains
(8) Replace VCM-3OP.
4-69
CONTROLLER
VCM-OP
SP SEL. S/W 1 250

SP SEL. S/W 2 252
HYD PRESSURE 267
HYD PRESSURE 268
HYD PRESSURE 269
TILT ANGLE SEN. 264 264
SPEED PULSE 290
CAB OPEN IND1 257
0.85B/Y
0.85R/B
0.85Y/B
P. SOURCE 1 42
P. SOURCE 2 43
266 265 264
GND1 135
264
265
266
GND2 136
CN1
9 252 250 1
17 269 268 267 10
25 135 42 18
34 136 257 266 265 264 43 26
TILT ANGLE
SENSOR (OP)
212360
4-70
CONTROLLER
Problem: Steering Error (F40)
(1) Situation
Indication: "F40" flickering. Knob position control disabled.
(2) Possible cause

Faulty steering sensor, faulty tire angle sensor, faulty VCM-3, faulty harness.

Steering angle is changed when tire angle remains unchanged.
Tire angle is changed when steering angle remains unchanged.
(4) Checks
Check to see if tire angle sensor error (F36) occurs.
F36 occurs Not occurs
(5) See F36 troubleshooting.
(6) Check continuity between VCM-3 and steering sensor.

1. Between 132(VCM-3: CN1-20: GND) and 132(Steering angle sensor: +5V).
2. Between 218(VCM-3: CN1-23: NT) and 218(Steering angle sensor: NT).
3. Between 217(VCM-3: CN1-22: ST2) and 217(Steering angle sensor: ST2).
4. Between 216(VCM-3: CN1-21: ST1) and 216(Steering angle sensor: ST1).
5. Between 215(VCM-3: CN1-19: +12V) and 215(Steering angle sensor: +12V).
(8) Confirm tire angle with service tool when steering wheel is operated.
Change Not change
(9) Replace VCM-3. (10) Replace steering sensor.
4-71
CONTROLLER
VCM-3

0.85Br/Y
0.85Lg/R
0.85Y
1.25G/Y
T/M SOL. F 233
0.85Lg/R
0.85Br/Y
0.85Y
Harness A
0.85G/Y 231 232 230
ST. ANGLE SEN 215 215
231
232
230
0.85Br
0.85Br/Y
0.85W/G
0.85B/G
0.85W/G
0.85Br/Y
0.85G/Y
0.85B/G
0.85Br
CN1 CN2 217 215 218

216 132
218
217
216
215
132
9 245 1 9 227228 1
224 223 17 234 235 233 232 231 230 221 220 10
TIRE ANGLE
17 10
25 130 218 217 216132 215 40 18 25 384 222 238 237 18
34 131 229 411 211 41 26 34 200 201 299 298 297 296 26 SENSOR
R/E
STEERING ANGLE
SENSOR
212361
4-72
CONTROLLER
Problem: Output Unit Controller Error (F41)
(1) Situation
(2) Possible cause
Faulty output unit.

(4) Checks
Write updated software into output unit.
Faulty software writing (5) Replace output unit.
4-73
CONTROLLER
Problem: Output Unit Life Control Signal (F42)
(1) Situation
(2) Possible cause
Faulty output unit.

When output unit is being initialized.
(4) Checks
4-74
CONTROLLER
Problem: Output Unit Memory Error (F43)
(1) Situation
(2) Possible cause
Faulty output unit.

(4) Checks
4-75
CONTROLLER
Problem: Output Unit PWM Voltage Error (F44)
(1) Situation
(2) Possible cause
Poor battery charge, faulty VCM-3, faulty DC-DC converter, faulty harness.

When output unit PWM voltage is 7V or less.
(4) Checks
Normal (18V to 32V) 7V or less
(5) Charge battery.
Error remains
4-76
CONTROLLER
(7) Measure DC-DC converter output voltage and input voltage.

1. Output voltage: Between 40(DC-DC converter: +12V) and 107(DC-DC converter: GND). ࡮࡮࡮ (12V)
2. Input voltage: Between 8(DC-DC converter: +24V) and 104(DC-DC converter: GND). ࡮࡮࡮࡮ (24V)
(10) Measure VCM-3 input voltage.

7V or less 7V to 21V
4-77
CONTROLLER
DC-DC
CONVERTER
VCM-3
CN1
0.85B/L 1.25B/L
131 105 107 107 12V GND
0.85B/L 2R/Y
130 40 40 12V MAIN
1.25R/Y 1.25B
41 40 104 104 24V GND
1.25R/Y
40 94 12V LAMP
F7 49 24V LAMP
8R 2R/W 2R/W
8 8 8 24V BATT
CN1
10A 62 ACC IN
1
301 12V BATT

15R
9 245 1
17 224 223 10
25 130 218 217 216132 215 40 18
34 131 229 411 211 41 26
FLW 0.85R
105
60B
100
60B
5
2B/L
2B
㧙㧗㧙㧗
BATTERY BATTERY
212349
4-78
CONTROLLER
Problem: Output Unit Communication Error (F45)
(1) Situation
(2) Possible cause
Faulty VCM-3, faulty harness, faulty output unit.

When CAN communication from output unit to VCM-3 is interrupted.
(4) Checks
VCM-3 to output unit: Between 201(VCM-3: CN2-31) and 394(Output unit: 13), and 200(VCM-3: CN2-32)
and 393(Output unit: 14).
(5) Replace output unit. (6) Replace harness.
Error remains
(7) Replace VCM-3.
4-79
CONTROLLER
OUTPUT UNIT
1 GND
2 GND
3 +VE
4 +VE
5 N.C.
6 N.C.
7 SWITCH IN GND
8 SWITCH IN GND
9 SWITCH IN GND
VCM-3 10 RS-232 Tx
CN2 11 RS-232 Rx
12 RS-232 GND
0.85L/R 0.85L/R
201 201 394 13 CAN H
0.85B/W 0.85B/W
200 200 393 14 CAN L
15 N.C.
16 N.C.
17 BOOT
CN2
18 FWE
9 227228 1
19 0V
17 234 235 233 232 231 230 221 220 10 20 DC 12V
25 384 222 238 237 18
34 200 201 299 298 297 296 26 21 PWM 1+
22 PWM 2+
23 PWM 1-/PWM 2-
24 PWM 3+
25 PWM 4+
26 PWM 3-/PWM4-
27 PWM 5+
28 PWM 6+
29 PWM 5-/PWM 6-
30 PWM 7+
31 PWM 8+
32 PWM 7-/PWM 8-
33 PWM 9+
34 PWM 10+
35 PWM 9-/PWM 10-
36
212362
4-80
CONTROLLER
Problem: Input Unit Controller Error (F46)
(1) Situation
(2) Possible cause
Faulty input unit.

Software checks sum value of ROM in CPU, and detects fault.
(4) Checks
Write updated software into input unit.
Faulty software writing (5) Replace input unit.
4-81
CONTROLLER
Problem: Input Unit Life Control Signal (F47)
(1) Situation
(2) Possible cause
Faulty input unit.

When input unit is being initialized.
(4) Checks
4-82
CONTROLLER
Problem: Input Unit Memory Error (F48)
(1) Situation
(2) Possible cause
Faulty input unit.

Software checks sum value of ROM in CPU, and detects fault.
(4) Checks
4-83
CONTROLLER
Problem: Input Unit Communication Error (F49)
(1) Situation
(2) Possible cause
Faulty VCM-3, faulty harness, faulty input unit.

When CAN communication from input unit to VCM-3 is interrupted.
(4) Checks
VCM-3 to input unit: Between 201(VCM-3: CN2-31) and 396(Input unit: 7), and 200(VCM-3: CN2-32)
and 395(Input unit: 8).
(5) Replace input unit. (6) Replace harness.
Error remains
(7) Replace VCM-3.
4-84
CONTROLLER
INPUT UNIT
(HARNESS, IN FC)
1 GND
2 Vcc 19V
3 FWE
VCM-3 4 RS-232 Tx
CN2 5 RS-232 Rx
6 RS-232 GND
0.85L/R 0.85L/R 0.5B
201 201 396 396 7 CAN H
0.85B/W 0.85B/W 0.5B/W
200 200 395 395 8 CAN L
9 CAN R+
10 CAN R-
11 BOOT
CN2
12 SEL0
13 SEL1
9 227228 1
17 234 235 233 232 231 230 221 220 10 14 SW GND
25 384 222 238 237 18
34 200 201 299 298 297 296 26 15 SW INPUT 1
17 SW INPUT 3(4V/5V)
18 SW INPUT 4(F)
19 SW INPUT 5(N)
20 SW INPUT 6(R)
21 SW INPUT 7
22 SW INPUT 8
23 5V
24 GND
25 LIFT 1
26 LIFT 2
27 TILT 1
28 TILT 2
29 ATT 1-1
30 ATT 1-2
31 ATT 2-1
32 ATT 2-2
212363
4-85
CONTROLLER
Problem: Lift Up Solenoid Error (F50)
(1) Situation
Indication: "F50" flickering. Lift operation disabled.
(2) Possible cause
Faulty output unit, faulty lift up solenoid, faulty harness.

Current is 0.16A or less, or 1.9A or more, when lift up solenoid signal is outputted.
(4) Checks
Check continuity between output unit and lift up solenoid.
1. Lift up: Between 480(Output unit: CN1-21) and 480(Lift A solenoid).
2. Lift return: Between 482(Output unit: CN1-23) and 482(Lift A solenoid).
(6) Measure resistance of lift up solenoid.

1. Lift up: Between 480(Lift A solenoid) and 482(Lift A solenoid).
Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)? Abnormal
(7) Replace output unit. (8) Replace lift up solenoid.
4-86
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497
(BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK)
LIFT A LIFT B TILT A TILT B ATT1 A ATT1 B

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499

(BLACK) (BLACK) (BLACK) (BLACK)
ATT2 A ATT2 B ATT3 A ATT3 B

212364
4-87
CONTROLLER
Problem: Lift Down Solenoid Error (F52)
(1) Situation
Indication: "F52" flickering. Lift operation disabled.
(2) Possible cause

Faulty output unit, faulty lift down solenoid, faulty harness.

Current is 0.16A or less, or 1.9A or more, when lift down solenoid signal is outputted.
(4) Checks
Check continuity between output unit and lift down solenoid.
1. Lift down: Between 481(Output unit: CN1-22) and 481(Lift B solenoid).
2. Lift return: Between 482(Output unit: CN1-23) and 495(Lift B solenoid).
(6) Measure resistance of lift down solenoid.

1. Lift down: Between 481(Lift B solenoid) and 495(Lift B solenoid).
Normal [6.6 to 9.8 at 25 (77˚F)] Abnormal
(7) Replace output unit. (8) Replace lift down solenoid.
4-88
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-89
CONTROLLER
Problem: Lift Solenoid Leak (F54)
(1) Situation
(2) Possible cause
Faulty output unit, faulty lift solenoids, faulty harness.

Current is 0.18A or more when lift lever is not operated.
(4) Checks
Check hydraulic operations when error occurred.
(6) Tilt operation (7) Attachment 1 (8) Attachment 2 (9) Attachment 3

(5) Not operate operation operation operation
Forward Backward A B A B A B
To (13) To (16) To (19) To (22) To (25) To (28) To (31) To (34)
(10) Measure resistance of corresponding solenoid.
Normal [6.6ǡ to 9.8ǡ at 25͠ (77˚F)] Abnormal
(11) Replace output unit. (12) Replace faulty solenoid.
4-90
CONTROLLER
(13) Check continuity between lift section and tilt section.

Between 483(Output unit: CN1-24) and 482(Output unit: CN1-23).
Continuity (Several tenǡ or less) No continuity (Several Mǡ)
(14) Insulate wires in harness or replace harness. (15) Replace output unit.
(16) Check continuity between lift section and tilt section.

(19) Check continuity between lift section and attachment 1 section.


4-91
CONTROLLER




4-92
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-93
CONTROLLER
Problem: Tilt Forward Solenoid Error (F55)
(1) Situation
Indication: "F55" flickering. Tilt operation disabled.
(2) Possible cause
Faulty output unit, faulty tilt forward solenoid, faulty harness.

Current is 0.16A or less, or 1.9A or more, when tilt forward solenoid signal is outputted.
(4) Checks
Check continuity between output unit and tilt forward solenoid.
1. Tilt forward: Between 483(Output unit: CN1-24) and 483(Tilt A solenoid).
2. Tilt return: Between 485(Output unit: CN1-26) and 485(Tilt A solenoid).
(6) Measure resistance of tilt forward solenoid.

1. Lift up: Between 483(Tilt A solenoid) and 485(Tilt A solenoid).
(7) Replace output unit. (8) Replace tilt forward solenoid.
4-94
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-95
CONTROLLER
Problem: Tilt Backward Solenoid Error (F57)
(1) Situation
Indication: "F57" flickering. Tilt operation disabled.
(2) Possible cause
Faulty output unit, faulty tilt backward solenoid, faulty harness.

Current is 0.16A or less, or 1.9A or more, when tilt backward solenoid signal is outputted.
(4) Checks
Check continuity between output unit and tilt backward solenoid.
1. Tilt backward: Between 484(Output unit: CN1-25) and 484(Tilt B solenoid).
2. Tilt return: Between 485(Output unit: CN1-26) and 496(Tilt B solenoid).
(6) Measure resistance of tilt backward solenoid.

1. Tilt backward: Between 484(Tilt B solenoid) and 496(Tilt B solenoid).
(7) Replace output unit. (8) Replace tilt backward solenoid.
4-96
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-97
CONTROLLER
Problem: Tilt Solenoid Leak (F59)
(1) Situation
(2) Possible cause
Faulty output unit, faulty tilt solenoids, faulty harness.

Current is 0.18A or more when tilt lever is not operated.
(4) Checks
(6) Lift operation (7) Attachment 1 (8) Attachment 2 (9) Attachment 3

(5) Not operate operation operation operation
Up Down A B A B A B
4-98
CONTROLLER
(13) Check continuity between tilt section and lift section.

(16) Check continuity between tilt section and lift section.

(19) Check continuity between tilt section and attachment 1 section.


4-99
CONTROLLER




4-100
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-101
CONTROLLER
Problem: Attachment 1A Solenoid Error (F60)
(1) Situation
Indication: "F60" flickering. Attachment operation disabled.
(2) Possible cause
Faulty output unit, faulty attachment 1A solenoid, faulty harness.

Current is 0.16A or less, or 1.9A or more, when attachment 1A solenoid signal is outputted.
(4) Checks
Check continuity between output unit and attachment 1A solenoid.
1. Attachment 1 A: Between 486(Output unit: CN1-27) and 486(ATT1 A solenoid).
2. Attachment 1 return: Between 488(Output unit: CN1-29) and 488(ATT1 A solenoid).
(6) Measure resistance of attachment 1A solenoid.

1. Attachment 1A: Between 486(ATT1 A solenoid) and 488(ATT1 A solenoid)
(9) Replace output unit. (8) Replace attachment 1A solenoid.
4-102
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-103
CONTROLLER
Problem: Attachment 1B Solenoid Error (F62)
(1) Situation
Indication: "F62" flickering. Attachment operation disabled.
(2) Possible cause
Faulty output unit, faulty attachment 1B solenoid, faulty harness.

Current is 0.16A or less, or 1.9A or more, when attachment 1B solenoid signal is outputted.
(4) Checks
Check continuity between output unit and attachment 1B solenoid.
1. Attachment 1B: Between 487(Output unit: CN1-28) and 486(ATT1 B solenoid).
2. Attachment 1 return: Between 488(Output unit: CN1-29) and 497(ATT1 B solenoid).
(6) Measure resistance of attachment 1B solenoid.

1. Attachment 1B: Between 487(ATT1 B solenoid) and 497(ATT1 B solenoid)
(9) Replace output unit. (8) Replace attachment 1B solenoid.
4-104
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-105
CONTROLLER
Problem: Attachment 1 Solenoid Leak (F64)
(1) Situation
(2) Possible cause
Faulty output unit, faulty attachment 1 solenoids, faulty harness.

Current is 0.18A or more when attachment 1 lever is not operated.
(4) Checks
(6) Lift operation (7) Tilt operation (8) Attachment 2 (9) Attachment 3
(5) Not operate operation operation
Up Down Forward Backward A B A B
4-106
CONTROLLER
(13) Check continuity between attachment 1 section and lift section.


(19) Check continuity between attachment 1 section and tilt section.


4-107
CONTROLLER
(25) Check continuity between attachment 1 section and attachment 2 section.




4-108
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-109
CONTROLLER
(1) Situation
(2) Possible cause

(4) Checks
1. Attachment 2A: Between 489(Output unit: CN1-30) and 489(ATT2 A solenoid).

4-110
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-111
CONTROLLER
(1) Situation
(2) Possible cause

(4) Checks

4-112
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-113
CONTROLLER
(1) Situation
(2) Possible cause

(4) Checks
4-114
CONTROLLER




4-115
CONTROLLER




4-116
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-117
CONTROLLER
(1) Situation
(2) Possible cause

(4) Checks
1. Attachment 3A: Between 492(Output unit: CN1-33) and 492(ATT3 A solenoid).

4-118
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-119
CONTROLLER
(1) Situation
(2) Possible cause

(4) Checks

4-120
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-121
CONTROLLER
(1) Situation
(2) Possible cause

(4) Checks
4-122
CONTROLLER




4-123
CONTROLLER




4-124
CONTROLLER
OUTPUT UNIT
CN1
0.85L
480 21 PWM 1+
0.85Br 22 PWM 2+
481
0.85W
482 23 PWM 1-/PWM 2-
0.85L/W
483 24 PWM 3+
0.85R/W
484 25 PWM 4+
0.85W/B
485 26 PWM 3-/PWM 4-
0.85L/R
486 27 PWM5 +
0.85R
487 28 PWM 6+
0.85W/R
488 29 PWM 5-/PWM 6-
0.85L/Y
489 30 PWM 7+
0.85R/L
490 31 PWM 8+
0.85W/L
491 32 PWM 7-/PWM 8-
0.85B/W
492 33 PWM 9+
0.85Br/Y
493 34 PWM 10+
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
494 35 PWM 9-/PWM 10-

0.85G
0.85R
0.85L
36
495
481
497
488
486
482
487
480
485
483
496
484
480 482 481 495 483 485 484 496 486 488 487 497

0.85W/L
0.85B/W
0.85Br/Y
0.85L/Y
0.85R/L
0.85L/R
0.85L/R
493 0.85L/R
491
498
494
490
489
499
492
489 491 490 498 492 494 493 499


212364
4-125
CONTROLLER
Problem: Unload Solenoid Error (F75)
(1) Situation
(2) Possible cause

Faulty VCM-3, faulty unload solenoid, faulty harness.

Current is 0.16A or less, or 2.4A or more, when unload solenoid signal is outputted.
(4) Checks
Check to see if emergency button is pushed.
Pushed Not pushed
(5) Release emergency button and restart.
Error remains
(6) Check continuity between VCM-3 and unload solenoid.

1. Between 211(VCM-3: CN1-30) and 211(Unload solenoid).
2. Between 411(VCM-3: CN1-32) and 411(Input unit).
3. Between 212(Input unit) and 212(Unload solenoid).
(8) Measure resistance of unload solenoid.

1. Between 211(Unload solenoid) and 212(Unload solenoid).
(9) Replace VCM-3. (10) Replace unload solenoid.
4-126
CONTROLLER
VCM-3
0.85Lg/R Harness A Harness B Harness C

UNLOAD SOL 211 211 211
0.85G/B
UNLOAD RETURN 411
0.85B/W Harness B
CAN L 200
0.85L/R 212 212
CAN H 201
0.85Lg/B
PARK B 229
1.25R/Y
P. SOURCE 1 40 EMERGENCY SW
1.25R/Y
P. SOURCE 2 41 Harness A
0.85B/L
GND 1 130
0.85B/L
GND 2 131
Harness C
0.85Br/B
0.85G/B
INPUT UNIT
CN1
0.85Br/B
0.85Lg/R
9 245 1
937
395
212
411
397
396
17 224 223 937 396 212
10
25 130 218 217 216132 215 40 18
34 131 229 411 211 41 26 397 395 411
211
212
212
211
211 212
(BLACK)
UNLOAD
212365
4-127
CONTROLLER
Problem: Unload Solenoid Leak (F79)
(1) Situation
(2) Possible cause
Faulty VCM-3, faulty unload solenoid, faulty harness.

Current is 0.18A or more when hydraulic operation signal is not outputted.
(4) Checks
Check operating condition when error occurred.
(6) Drive operation (7) When knob position control

function is installed
(5) Not operate.
Forward Reverse During steering operation
To (11) To (14) To (17)
(8) Measure resistance of unload solenoid.
(9) Replace VCM-3. (10) Replace unload solenoid.
4-128
CONTROLLER
(11) Check continuity between transmission section and unload section.

Between 233(VCM-3: CN2-15) and 411(VCM-3: CN1-32).
(12) Insulate wires in harness or replace harness. (13) Replace VCM-3.
(14) Check continuity between transmission section and unload section.

(17) Check continuity between knob position solenoid and unload section.
4-129
CONTROLLER
VCM-3
0.85Br/Y 1.25G/Y
TIRE ANGLE SEN. 230
0.85Lg/R 1.25B/L
TIRE ANGLE SEN. 231 234
0.85Y
TIRE ANGLE SEN. 232
1.25G/Y
T/M SOL. F 233 1.25B/L
1.25B/L 242
T/M GND 234
1.25G/L 1.25G/L
T/M SOL. R 235
0.85Lg
P/S SOL 237
233
235
0.85Lg/B
P/S SOL 238
0.85Lg/B
0.85W
SEAT S/W 227
0.85Lg
0.85B/G
SEAT S/W 228
SR SF
(BLACK)
237 SOLENOID (F - R)
238
237 238
0.85Lg/R
UNLOAD SOL 211
0.85G/B
UNLOAD RETURN 411
CAN L 200
0.85B/W PS CARIB
0.85L/R (OP)
CAN H 201
0.85Lg/B
PARK B 229
1.25R/Y
P. SOURCE 1 40
1.25R/Y
P. SOURCE 2 41
0.85B/L
GND 1 130
0.85B/L
GND 2 131
EMERGENCY SW
0.85Br/B
0.85G/B
0.85Br/B
0.85Lg/R
CN1 INPUT UNIT

212
211
9 245 1
212
211
937 396 212

937
395
212
411
397
396
17 224 223 10
25 130 218 217 216132 215 40 18
397 395 411
34 131 229 411 211 41 26
211 212
(BLACK)
CN2
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237
200 201 299 298 297 296
18
26
UNLOAD
34
212366
4-130
CONTROLLER
Problem: Knob Position Solenoid Error (F80)
(1) Situation
Indication: "F80" flickering. Knob position control fuunction disabled.
(2) Possible cause
Faulty VCM-3, faulty knob position solenoid, faulty harness.

Current is 0.16A or less, or 3.54A or more, when knob position solenoid signal is outputted.
(4) Checks
Check continuity between VCM-3 and knob position solenoid.
1. Between 237(VCM-3: CN2-18) and 237(PS CARIB solenoid).
2. Between 238(VCM-3: CN2-20) and 238(PS CARIB solenoid).
(6) Measure resistance of knob position solenoid.

1. Between 237(PS CARIB solenoid) and 238(PS CARIB solenoid).
(7) Replace VCM-3. (8) Replace knob position solenoid.
4-131
CONTROLLER
VCM-3
0.85Br/Y
TIRE ANGLE SEN. 230
0.85Lg/R
TIRE ANGLE SEN. 231
0.85Y
TIRE ANGLE SEN. 232
1.25G/Y
T/M SOL. F 233
1.25B/L
T/M GND 234
1.25G/L
T/M SOL. R 235
0.85Lg Harness A Harness B
P/S SOL 237 237 237
0.85Lg/B
P/S SOL 238 238 238
0.85W
SEAT SW 227
0.85B/G
SEAT SW 228
0.85Lg/B
0.85Lg
237
238
(BLACK)
237 238
CN2
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
PS CARIB
(OP)
212367
4-132
CONTROLLER
Problem: Knob Position Solenoid Leak (F84)
(1) Situation
(2) Possible cause
Faulty VCM-3, faulty knob position solenoid, faulty harness.

Current is 0.18A or more when steering wheel is not operated.
(4) Checks
(6) Drive operation

(5) Not operate. (7) During hydraulic operation
Forward Reverse
To (11) To (14) To (17)
(8) Measure resistance of knob position solenoid.
(9) Replace VCM-3. (10) Replace knob position solenoid.
4-133
CONTROLLER
(11) Check continuity between transmission section and knob position solenoid.
(14) Check continuity between transmission section and knob position solenoid.
(17) Check continuity between unload section and knob position solenoid.
4-134
CONTROLLER
VCM-3
0.85Br/Y 1.25G/Y
TIRE ANGLE SEN. 230
0.85Lg/R 1.25B/L
0.85Y
TIRE ANGLE SEN. 232
1.25G/Y
T/M SOL. F 233 1.25B/L
1.25B/L 242
T/M GND 234
1.25G/L 1.25G/L
T/M SOL. R 235
0.85Lg
P/S SOL 237
233
235
0.85Lg/B
P/S SOL 238
0.85Lg/B
0.85W
SEAT S/W 227
0.85Lg
0.85B/G
SEAT S/W 228
SR SF
(BLACK)
238
237 238
0.85Lg/R
UNLOAD SOL 211
0.85G/B
UNLOAD RETURN 411
CAN L 200
0.85B/W PS CARIB
0.85L/R (OP)
CAN H 201
0.85Lg/B
PARK B 229
1.25R/Y
P. SOURCE 1 40
1.25R/Y
P. SOURCE 2 41
0.85B/L
GND 1 130
0.85B/L
GND 2 131
EMERGENCY SW
0.85Br/B
0.85G/B
0.85Br/B
0.85Lg/R
CN1 INPUT UNIT

212
211
9 245 1
212
211
937 396 212

937
395
212
411
397
396
17 224 223 10
25 130 218 217 216132 215 40 18
397 395 411
34 131 229 411 211 41 26
211 212
(BLACK)
CN2
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237
200 201 299 298 297 296
18
26
UNLOAD
34
212366
4-135
CONTROLLER
Problem: Transmission Forward Solenoid Error (F85)
(1) Situation
(2) Possible cause
Faulty VCM-3, faulty transmission forward solenoid, faulty harness.

Current is 0.25A or less, or 3.84A or more, when transmission forward solenoid signal is outputted.
(4) Checks
Check continuity between VCM-3 and transmission forward solenoid.
1. Between 233(VCM-3: CN2-15) and 233(Solenoid F: +).
2. Between 234(VCM-3: CN2-17) and 234(Solenoid F: -).
(6) Measure resistance of transmission forward solenoid.

1. Between 233(Solenoid F: +) and 234(Solenoid F: -).
(7) Replace VCM-3. (8) Replace transmission forward solenoid.
4-136
CONTROLLER
VCM-3
0.85Br/Y
TIRE ANGLE SEN. 230
0.85Lg/R
TIRE ANGLE SEN. 231
0.85Y
TIRE ANGLE SEN. 232
1.25G/Y Harness A Harness B Harness C 1.25G/Y
T/M SOL. F 233 233 233
1.25B/L 1.25B/L
T/M GND 234 234 234 234
1.25G/L
T/M SOL. R 235 235
0.85Lg 1.25B/L
P/S SOL 237 242
0.85Lg/B
P/S SOL 238
0.85W
SEAT SW 227 1.25G/L
0.85B/G 235
233
SEAT SW 228
235
SR SF
SOLENOID(F - R)
CN2
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
212368
4-137
CONTROLLER
Problem: Transmission Backward Solenoid Error (F87)
(1) Situation
(2) Possible cause
Faulty VCM-3, faulty transmission backward solenoid, faulty harness.

Current is 0.25A or less, or 3.84A or more, when transmission backward solenoid signal is outputted.
(4) Checks
Check continuity between VCM-3 and transmission backward solenoid.
1. Between 235(VCM-3: CN2-16) and 235(Solenoid R: +).
2. Between 234(VCM-3: CN2-17) and 242(Solenoid R: -).
(6) Measure resistance of transmission backward solenoid.

Between 235(Solenoid R: +) and 242(Solenoid R: -).
(7) Replace VCM-3. (8) Replace transmission backward solenoid.
4-138
CONTROLLER
VCM-3
0.85Br/Y
TIRE ANGLE SEN. 230
0.85Lg/R
TIRE ANGLE SEN. 231
0.85Y
TIRE ANGLE SEN. 232
1.25G/Y Harness A Harness B Harness C 1.25G/Y
T/M SOL. F 233 233 233
1.25B/L 1.25B/L
T/M GND 234 234 234 234
1.25G/L
T/M SOL. R 235 235
0.85Lg 1.25B/L
P/S SOL 237 242
0.85Lg/B
P/S SOL 238
0.85W
SEAT SW 227 1.25G/L
0.85B/G 235
233
SEAT SW 228
235
SR SF
SOLENOID(F - R)
CN2
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237 18
34 200 201 299 298 297 296 26
212368
4-139
CONTROLLER
Problem: Transmission Solenoid Leak (F89)
(1) Situation
(2) Possible cause
Faulty VCM-3, faulty transmission solenoids, faulty harness.

Current is 0.18A or more when transmission solenoid is in neutral position.
(4) Checks
(7) When knob position control

(6) During hydraulic operation. function is installed
(5) Not operate.
During steering operation
To (11) To (14)
(10) Measure resistance of transmission forward/backward solenoid.
(11) Replace VCM-3. (12) Replace faulty solenoid.
4-140
CONTROLLER
(11) Check continuity between unload section and transmission section.

(14) Check continuity between knob position solenoid and transmission section.
4-141
CONTROLLER
VCM-3
0.85Br/Y 1.25G/Y
TIRE ANGLE SEN. 230
0.85Lg/R 1.25B/L
0.85Y
TIRE ANGLE SEN. 232
1.25G/Y
T/M SOL. F 233 1.25B/L
1.25B/L 242
T/M GND 234
1.25G/L 1.25G/L
T/M SOL. R 235
0.85Lg
P/S SOL 237
233
235
0.85Lg/B
P/S SOL 238
0.85Lg/B
0.85W
SEAT S/W 227
0.85Lg
0.85B/G
SEAT S/W 228
SR SF
(BLACK)
238
237 238
0.85Lg/R
UNLOAD SOL 211
0.85G/B
UNLOAD RETURN 411
CAN L 200
0.85B/W PS CARIB
0.85L/R (OP)
CAN H 201
0.85Lg/B
PARK B 229
1.25R/Y
P. SOURCE 1 40
1.25R/Y
P. SOURCE 2 41
0.85B/L
GND 1 130
0.85B/L
GND 2 131
EMERGENCY SW
0.85Br/B
0.85G/B
0.85Br/B
0.85Lg/R
CN1 INPUT UNIT

212
211
9 245 1
212
211
937 396 212

937
395
212
411
397
396
17 224 223 10
25 130 218 217 216132 215 40 18
397 395 411
34 131 229 411 211 41 26
211 212
(BLACK)
CN2
9 227228 1
17 234 235 233 232 231 230 221 220 10
25 384 222 238 237
200 201 299 298 297 296
18
26
UNLOAD
34
212366
4-142
CONTROLLER
Problem: VCM-3OP Sensor Voltage Error (F90)
(1) Situation
(2) Possible cause

Faulty lift oil pressure/tilt angle sensor, faulty VCM-3OP, faulty harness.

When VCM-3OP sensor 5V power voltage is 3.85V or less.
(4) Checks
Check continuity between sensor and VCM-3OP.
1. Lift oil pressure sensor: Between 267(Lift oil pressure sensor: +5V) and 267(VCM-3OP: CN1-14: +5V), and
269(Lift oil pressure sensor: GND) and 269(VCM-3OP: CN1-17: GND).
2. Tilt angle sensor: Between 264(Tilt angle sensor: +5V) and 264(VCM-3OP: CN1-27: +5V), and
266(Tilt angle sensor: GND) and 266(VCM-3OP: CN1-29: GND).
(6) Check short circuit between sensor power and GND in sensor connector side.
Shorted Not shorted
(7) Replace faulty sensor(lift oil pressure/tilt angle).
4-143
CONTROLLER
(8) Check short circuit between sensor and VCM-3OP.
1. Lift oil pressure sensor: Between 267(Lift oil pressure sensor: +5V) and 269(VCM-3OP: CN1-17: GND), and
269(Lift oil pressure sensor: GND) and 267(VCM-3OP: CN1-14: +5V).
2. Tilt angle sensor: Between 264(Tilt angle sensor: +5V) and 266(VCM-3OP: CN1-29: GND), and
266(Tilt angle sensor: GND) and 264(VCM-3OP: CN1-27: +5V).
Shorted Not shorted
(9) Replace faulty harness. (5) Replace VCM-3OP.
4-144
CONTROLLER
VCM-OP
SP SEL. S/W 1 250

SP SEL. S/W 2 252
0.85Lg/B
0.85B/W
0.85Lg
SPEED PULSE 290
CAB OPEN IND1 257
0.85B/Y
0.85R/B
0.85Y/B
P. SOURCE 1 42 269 268 267
P. SOURCE 2 43
267
269
268
266 265 264
GND1 135
264
265
266
GND2 136
CN1
9 252 250 1
17 269 268 267 10
25 135 42 18
34 136 257 266 265 264 43 26
TILT
ANGLE
SENSOR LIFT OIL PRESSURE
(OP) SENSOR (OP)
212369
4-145
CONTROLLER
Problem: VCM-3OP Memory Check Error (F91)
(1) Situation
(2) Possible cause
Faulty VCM-3OP, faulty truck type setting data in VCM-3OP.

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

Normal Abnormal
(7) Perform standard setting, then enter truck type setting

data again.
(8) Write updated software into VCM-3OP.
Normal Abnormal
(9) Faulty software writing. (10) Replace VCM-3OP.
4-146
CONTROLLER
Problem: VCM-3OP Battery Voltage Error (F92)
(1) Situation
Indication: "F92" flickering. Tilt horizontal control and speed change control disabled.
(2) Possible cause
Poor battery charge, faulty battery, faulty VCM-3OP, faulty harness, faulty DC-DC converter.

When VCM-3OP input voltage is less than 7V or more than 21V.
(4) Checks
Normal (18V to 32V) Less than 7V More than 32V
(5) Charge battery.
Error remains
(7) Measure output voltage and input voltage of DC-DC converter.

1. Output voltage: Between 40(DC-DC converter: +12V) and 107 (DC-DC converter: GND). 12V
2. Input voltage: Between 8(DC-DC converter: +24V) and 104 (DC-DC converter: GND). 24V
(10) Measure VCM-3OP input voltage.

1. Between 42(VCM-3OP: CN1-18) and 135(VCM-3OP: CN1-25).
Less than 7V 7V to 21V
(11) Replace harness. (12) Replace VCM-3OP.
4-147
CONTROLLER
DC-DC
CONVERTER
VCM-3OP
CN1
0.85B/L 1.25B/L
136 105 107 107 12V GND
0.85B/L 2R/Y
135 40 40 12V MAIN
1.25R/Y 1.25B
43 42 104 104 24V GND
1.25R/Y
42 94 12V LAMP
F7 49 24V LAMP
8R 2R/W 2R/W
8 8 8 24V BATT
CN1
10A 62 ACC IN
1
301 12V BATT

15R
9 252 250 1
17 269 268 267 10
25 135 42 18
34 136 257 266 265 264 43 26

FLW 0.85R
105
60B 60B 100
5
2B/L
2B
㧙㧗㧙㧗
BATTERY BATTERY
212370
4-148
CONTROLLER
Problem: VCM-3OP Change Transmission Solenoid 1 Error (F93)
(1) Situation
Indication: "F93" flickering. EAT control function disabled (speed change step fixed).
(2) Possible cause

Faulty VCM-3OP, faulty change transmission solenoid 1, faulty harness.

Current is 0.25A or less, or 3.84A or more, when change transmission solenoid 1 signal is outputted.
(4) Checks
Check continuity between VCM-3OP and change transmission solenoid 1.
1. Between 253(VCM-3OP: CN2-15) and 255(Solenoid SH: +).
2. Between 254(VCM-3OP: CN2-17) and 254(Solenoid SH: -).
(6) Measure resistance of change transmission solenoid 1.

1. Between 255(Solenoid SH: +) and 254(Solenoid SH: -)
(7) Replace VCM-3OP. (8) Replace change transmission solenoid 1.
4-149
CONTROLLER
VCM-OP CN2
COOLANT 281
AT OIL TEMP
AIR DUST 279
W/SEPA 277
2SP SOL 253
3SP SOL 273
2SP 3SP SOL 254
TILT CAB 258
TILT CAB
TILT CAB
TILT CAB ECU FUSE
TILT CAB 273
CAN L 204 253
1.25R/Y 1.25R/Y
CAN H 205 255 255 253
1.25L/Y 274 1.25L/Y
273
CN2
9 277 279 281 1 1.25B/W

1.25R/Y
1.25L/Y
17 254 273 253 10
25 258 18
34 205 204 295 294 293 292 26
274
254
255
246
SH S2
SOLENOID
(SPEED SELECT)
212371
4-150
CONTROLLER
Problem: VCM-3OP Change Transmission Solenoid 2 Error (F94)
(1) Situation
Indication: "F94" flickering. EAT control function disabled (speed change step fixed).
(2) Possible cause
Faulty VCM-3OP, faulty change transmission solenoid 2, faulty harness.

Current is 0.25A or less, or 3.84A or more, when change transmission solenoid 2 signal is outputted.
(4) Checks
Check continuity between VCM-3OP and change transmission solenoid 2.
1. Between 273(VCM-3OP: CN2-16) and 274(Solenoid S2: +).
2. Between 254(VCM-3OP: CN2-17) and 246(Solenoid S2: -).
(6) Measure resistance of change transmission solenoid 2.

1. Between 274(Solenoid S2: +) and 246(Solenoid S2: -)
(7) Replace VCM-3OP. (8) Replace change transmission solenoid 2.
4-151
CONTROLLER
VCM-OP CN2
COOLANT 281
AT OIL TEMP
AIR DUST 279
W/SEPA 277
2SP SOL 253
3SP SOL 273
2SP 3SP SOL 254
TILT CAB 258
TILT CAB
TILT CAB
TILT CAB ECU FUSE
TILT CAB 273
CAN L 204 253
1.25R/Y 1.25R/Y
CAN H 205 255 255 253
1.25L/Y 274 1.25L/Y
273
CN2
9 277 279 281 1 1.25B/W

1.25R/Y
1.25L/Y
17 254 273 253 10
25 258 18
34 205 204 295 294 293 292 26
274
254
255
246
SH S2
SOLENOID
(SPEED SELECT)
212371
4-152
CONTROLLER
Problem: VCM-3OP Change Transmission Solenoid Leak (F95)
(1) Situation
Indication: "F95" flickering. EAT control function disabled.
(2) Possible cause
Faulty VCM-3OP, faulty corresponding solenoid, faulty harness.

Output signal current is 0.18A or more when vehicle is driving at 3rd speed.
(4) Checks
Measure resistance of change transmission solenoid 1 and 2.
(5) Replace faulty solenoid.
(6) Check continuity between power source and change transmission section.
2. Between 42(VCM-3OP: CN1-18) and 273(VCM-3OP:CN2-16).
(7) Insulate wires in harness or replace harness. (8) Replace VCM-3OP.
4-153
CONTROLLER
DC-DC
CONVERTER
VCM-3OP
CN1
0.85B/L
136 105 107 1.25B/L 107 12V GND
0.85B/L 2R/Y
135 40 40 12V MAIN
1.25R/Y
43 42 104 24V GND
1.25R/Y
42 94 12V LAMP
49 24V LAMP
8 24V BATT
CN2
62 ACC IN
281 301 12V BATT
COOLANT
AT OIL TEMP
AIR DUST 279
W/SEPA 277
2SP SOL 253
3SP SOL 273
2SP 3SP SOL 254
TILT CAB 258
TILT CAB
TILT CAB
TILT CAB ECU FUSE
TILT CAB 273
CAN L 204 253
1.25R/Y 1.25R/Y
CAN H 205 255 255 253
1.25L/Y 274 1.25L/Y
273
CN2 CN1
9 277 279 281 1 9 252 250 1

1.25B/W
1.25R/Y
1.25L/Y
17 254 273 253 10 17 269 268 267 10
25 258 18 25 135 42 18
205 204 295 294 293 292 26 34 136 257 266 265 264 43 26
34
274
254
255
246
SH S2
SOLENOID
(SPEED SELECT)
212372
4-154
CONTROLLER
Problem: VCM-3OP EAT Setting Error (F96)
(1) Situation
Indication: "F96" flickering. Speed change function disabled (speed change step fixed).
(2) Possible cause

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

1 When setting value of speed shift point is not in following relations.
2- speed specification vehicle: (from 1st-speed to 2nd-speed) (from 2nd-speed to 1st-speed)
3- speed specification vehicle: (from 2nd-speed to 3rd-speed) (from 3rd-speed to 2nd-speed)
(from 1st-speed to 2nd-speed) (from 2nd-speed to 1st-speed)
2 When setting data for mode selecting decision is in following conditions.
Mode selecting decision value is out of setting range (0 to 3).
Mode selecting pattern is repeated.
Either of mode selector switch SW1 and SW2 is not set.
3 When setting data for speed change solenoid (SH and S2) is in following conditions.
Speed change solenoid output decision value is out of setting range (0 to 3).
Speed change solenoid output pattern is repeated.
Either of SH and S2 is not set.
(4) Checks
Normal Abnormal
(6) Set shipment default value into VCM-3OP.

Normal Abnormal
(7) Perform standard setting, then enter truck type setting (8) Replace VCM-3OP.
data again.
4-155
CONTROLLER
Problem: VCM-3OP Communication Error (F97)
(1) Situation
Indication: "F97" flickering. Speed change function disabled (current step held).
(2) Possible cause
Faulty VCM-3OP, faulty VCM-3, faulty harness.

When CAN communication from VCM-3OP to VCM-3 is interrupted.
(4) Checks
1. VCM-3 to VCM-3OP: Between 201(VCM-3: CN2-31) and 205(VCM-3OP: CN2-32), and

200(VCM-3: CN2-32) and 204(VCM-3OP: CN2-31).
(6) Replace VCM-3OP.
Error remains
(7) Replace VCM-3.
4-156
CONTROLLER
VCM-OP
CN2
281 COOLANT
AT OIL TEMP
279 AIR DUST
277 W/SEPA
CN2 253 2SP SOL
273 3SP SOL
9 277 279 281 1
254 2SP 3SP SOL
17 254 273 253 10
25 258 18 258 TILT CAB
34 205 204 295 294 293 292 26
VCM-3 TILT CAB
CN2 TILT CAB
TILT CAB
0.85L/R
201 201 TILT CAB
0.85B/W 0.85B/W
200 200 204 204 CAN L
0.85L/R
205 205 CAN H
CN1
CN2
250 SP SEL. S/W 1
9 227228 1
252 SP SEL. S/W 2
17 234 235 233 232 231 230 221 220 10 267 HYD PRESSURE
25 384 222 238 237 18
34 200 201 299 298 297 296 26 268 HYD PRESSURE
269 HYD PRESSURE
264 TILT ANGLE SEN.
265 TILT ANGLE SEN.
266 TILT ANGLE SEN.
290 SPEED PULSE
257 CAB OPEN IND1
42 P. SOURCE 1
43 P. SOURCE 2
135 GND1
136 GND2
212373
4-157
TILTABLE SYSTEM
1. Specifications ............................................................................................................... 5-2
2. Structure....................................................................................................................... 5-3
2.1 Outline................................................................................................................................................... 5-3
2.2 Hand pump ........................................................................................................................................... 5-4
2.3 Tiltable cylinder ..................................................................................................................................... 5-5
2.4 Hydraulic latch A, B............................................................................................................................... 5-6
3. Oil supply ..................................................................................................................... 5-7
4. Hydraulic circuit diagram .............................................................................................. 5-8
5. Service Data................................................................................................................. 5-9

5.1 Tiltable cylinder ..................................................................................................................................... 5-9 5
5.2 Cylinder bracket .................................................................................................................................. 5-10
5.3 Pin A, B ............................................................................................................................................... 5-11
5-1
TILTABLE SYSTEM
1. Specifications

Maker model DHP2-100417
2
Set relief pressure 30.0 MPa (306 kgf/cm ) [4352 psi]
3
Hand pump Discharge quantity per stroke 4 cm ± 10% (0.244 cu. in. ±10%)
3
Reservoir capacity 480 cm (29.3 cu. in.)
Control valve type 4-way/2-POS
Maker model DCD2-100416
Tiltable cylinder
Stroke 330 mm (12.99 cu. in.)
KLH5000-01-98/3 (latch A)
Maker model
Hydraulic latch KLH5000-01-99/3 (latch B)
2
Latch operating pressure 1.38 to 2.07 MPa (14.1 to 21.1 kgf/cm ) [200 to 300 psi]
5-2
TILTABLE SYSTEM
2. Structure
2.1 Outline
Fully open position (65 )
Maintenance position (50 )
Partially stopped position (25 )
Fully lowered
position (0 )
6 5
8 1 4
5
10 2
212004
1 Hand pump 5 Pull cable 9 Hydraulic latch A

2 Pump lever connection 6 Tiltable cylinder 10 Hydraulic latch B
3 Directional valve 7 Stopper case
4 Cable knob 8 Stopper pin
If you operate the hand pump with the direction valve In order to lower it further to the full-lower position (0°), it
turned clockwise, the hydraulic latch is released and the is necessary to operate the hand pump while pulling the
operator compartment rises up to the maintenance position cable knob to relase the stopper pin from the lock position.
(50°) (the operator compartment tilts to the left if viewed The operator compartment will be locked to the full-lower
from the rear of the vehicle). position by the hydralic latch mechanism.
In order to raise it further to the full-open position (65°), it
is necessary to operate the hand pump while pulling the CAUTION
cable knob to relase the stopper pin from the lock position. If you attempt to raise or fall the operator compart-
The full-open position must be used only for unloading the ment without fully tilting the mast to the front
engine.
beforehand, the operator compartment will be
If you operate the hand pump with the direction valve
turned counterclockwise, the operator compartment falls damaged.
down to the partial stop position (25°).
5-3
TILTABLE SYSTEM
2.2 Hand pump
6 6 1
2 50 r5
2
23 r5
3 3
Clockwise:
Operator compartment raised
5 4 Counterclockwise:
Operator compartment lowered
5 4
7
212005
1 Hand pump assembly 5 Pull port

2 Pump lever connection 6 level plug (oil supply mouth)
3 Directional valve 7 Suction port for power pump (option)
4 Push port
5-4
TILTABLE SYSTEM
2.3 Tiltable cylinder
2 3
1
2 3
212006
1 Tiltable cylinder assembly 3 Pull port

2 Push port
5-5
TILTABLE SYSTEM
2.4 Hydraulic latch A, B
4 1
A A
3
2
SECTION A-A
212007
1 Hydraulic latch assembly 4 Connector (hydraulic latch A),

Breather (hydraulic latch B)
2 Latch 5 Hydraulic port
3 Connector
5-6
TILTABLE SYSTEM
3. Oil supply
Pour working oil in the hand pump with the pump lever
pushed down.
(1.18 to 1.38 in.)

Oil level
30 to 35 mm
&2
Pump lever
212008
5-7
TILTABLE SYSTEM
4. Hydraulic circuit diagram
Tiltable cylinder
Stroke: 330 mm (12.99 in.)
Hydraulic latches A and B

Operating pressure to open latch:
1.38 to 2.07 MPa (14.1 to 21.1 kgf/cm 2 )
Hand pump [200 to 300 psi]
Relief valve setting: 30.0 MPa (306 kgf/cm 2 ) Port thread size: UNF7/16-20
[4352 psi]
Flow per stroke: 4 cm3 10%
(0.244 cu. in. 10%)
Reservoir capacity: 480 cm3 (29.3 cu. in.)
Push port (NPT1/8)
Pull port (NPT1/8)
Push port (NPT1/8)
Pull port (NPT1/8)
212009
5-8
TILTABLE SYSTEM
5. Service Data
5.1 Tiltable cylinder
＋ 0.25 ＋ 0.0098
Inside diameter of pin A Standard value 20.1 0 mm (0.791 0 in.)
insertion part 1 Repair or service limit ＋ 0.5 ＋ 0.020
20.1 mm (0.791 in.)
＋ 0.25 ＋ 0.0098
Inside diameter of pin B Standard value 16.1 0 mm (0.634 0 in.)
16.1 mm (0.634 in.)
2 1
212010
5-9
TILTABLE SYSTEM
5.2 Cylinder bracket

＋ 0.221 ＋ 0.00083
Inside diameter of pin A Standard value 20 0 mm (0.79 0 in.)
20 mm (0.79 in.)
212011
5-10
TILTABLE SYSTEM
5.3 Pin A, B
0 0
Outside diameter of Pin A Standard value 20 -0.021 mm (0.79 -0.00083 in.)
shaft 1 Repair or service limit 20 -0.5 mm (0.79 -0.020 in.)
0 0
Outside diameter of Pin B Standard value 16 -0.018 mm (0.63 -0.00071 in.)
shaft 2 Repair or service limit 16 -0.5 mm (0.63 -0.020 in.)
Pin A Pin B
1 2
212012
5-11
POWER TRAIN
1. Specifications ............................................................................................................... 6-2
2. Structure....................................................................................................................... 6-3
3. Reduction ratio ............................................................................................................. 6-5
4. Removal and Installation of Engine and Transmission Unit ......................................... 6-6

4.1 Preparation ........................................................................................................................................... 6-6
4.1.1 Draining Oil and Coolant ............................................................................................................................. 6-6
4.2 Removing cover .................................................................................................................................... 6-7
4.3 Removing Harnesses............................................................................................................................ 6-8
4.3.1 Suggestions for Removal ............................................................................................................................ 6-8
4.4 Removing wiring ................................................................................................................................... 6-9
4.5 Other removing ................................................................................................................................... 6-10
4.5.1 Removal sequence ................................................................................................................................... 6-10
6
4.6 Removal of Engine and Transmission Unit......................................................................................... 6-11
4.6.1 Suggestions for Removal .......................................................................................................................... 6-11
4.7 Installation........................................................................................................................................... 6-12
4.7.1 Installation sequence ................................................................................................................................ 6-12
4.7.2 Suggestions for Removal .......................................................................................................................... 6-12
4.8 Capacity .............................................................................................................................................. 6-14
6-1
POWER TRAIN
1. Specifications

Type 3-element, 1-stage, 2-phase
Torque converter Maker model MN16
Stall torque ratio 2.51
Forward/reverse switching electrical column shift, 1st, 2nd, 3rd,
Operation method
automatic drive
1st: 2.402
Forward 2nd: 1.010
Transmission
3rd: 0.558
Gear ratio
1st: 2.402
Reverse 2nd: 1.010
3rd: 0.558
Gear type Hypoid gear
Reduction gear
Reduction ratio 5.142
Gear type Planetary gear
Final drive
Housing type Banjo
Differential Gear type and num- Large Straight bevel gear × 2
ber Small Straight bevel gear × 2
Front axle type Full-floating, tubular
Front axle suspension method Fixed to frame
6-2
POWER TRAIN
2. Structure
12
11
17 6 4
3 2 1
5
18
14
15 13 9 10
16
205670A
1 Engine 10 Speed sensor gear

2 Flywheel 11 Pump drive gear
3 Torque converter 12 Hydraulic pump
4 Transmission 13 Universal joint
5 Input shaft 14 Parking brake
6 Forward clutch shaft 15 Front axle
7 Reverse clutch shaft 16 Reduction differential
8 1st and 3rd clutch shaft 17 Final drive
9 Output shaft 18 Wheel brake
The power transmission system, which serves to transmit rection of universal joint from those which are derived
power produced by the engine to the drive wheels, consists from the engine operation.
of the following components. (3) Universal joint 13
(1) Torque converter 3 Transmits power from the transmission to the reduction
The torque converter itself not only works as a clutch differential.
but also transmits the increased engine torque to the (4) Reduction differential 16
transmission. Not only reduces the speed but also distribute the power
(2) Transmission 4 to right and left drive wheels.
This is a device to change the revolving speed and di- It also functions as to prevent slipping by differentiating
6-3
POWER TRAIN
two (right and left) drive wheels in terms of their num-

ber of rotation, when they have a difference in the rotat-
ing speed as the result of vehicle's turning to the right or
left.
(5) Final drive 17
Final reduction system using planetary gears.
6-4
POWER TRAIN
3. Reduction ratio
(39)
(58)
(58)
(17) (55) (54) (35)
(34)
(58)
(59) (46)
(35)
(24)
(7) (58)
(36) (32)
(53) (56)
205670B
( ) indicates number of teeth.
Reduction bevel
Truck model Transmission Final drive Total gear ratio
gear
1st 2.402 ( 35/34 × 58/58×58/58 × 56/24 ) 52.318
Forward 2nd 1.010 ( 35/34 × 53/54 ) 22.007
3rd 0.558 ( 35/34 × 58/58×58/58 × 32/59 ) 5.142 4.235 12.161
1st 2.402 ( 35/34 × 58/58 × 56/24 ) ( 36/7 ) ( 55/17 + 1 ) 52.318
Reverse 2nd 1.010 ( 35/34 × 58/58 × 53/54 ) 22.007
3rd 0.558 ( 35/34 × 58/58 × 32/59 ) 12.161
PTO reduction ratio: 0.907
6-5
POWER TRAIN
4. Removal and Installation of Engine and Transmission Unit

Both the engine and transmission should be removed as a
unit.
4.1 Preparation
4.1.1 Draining Oil and Coolant
Engine coolant Engine coolant

drain plug drain plug
Transmission oil Engine oil drain plug

drain plug
211787
Drain engine oil, transmission oil and engine coolant.
6-6
POWER TRAIN
4.2 Removing cover
1
5
211961

(Raise the tiltable cab.)
1 Gas-filled cylinder 4 Exhaust pipe
2 Engine cover 5 Radiator cover
3 Middle cover
6-7
POWER TRAIN
4.3 Removing Harnesses
Torgue converter oil

thermo-unit
Transmission
solenoid
Travel speed sensor

Starter relay
Battery
Oil by-pass alarm
Glow plug
Alternator
Engine oil pressure

switch
Engine thermo-unit
211789
4.3.1 Suggestions for Removal

The harness connected to the engine and transmission
should not be completely removed but partially discon-
nected at the sockets and terminals. Then, lay it along the
main harness to which it is retained so as not to be dam-
aged.
6-8
POWER TRAIN
4.4 Removing wiring
2
4
5
1
10 6
8
11
9 7
12
8
15 14
13
211790
1 Delivery hose 9 PCV valve hose
2 Suction hose 10 Air cleaner hose
3 Intercooler inlet hose 11 Compressor inlet hose
4 Intercooler outlet hose 12 Compressor outlet hose
5 Radiator upper hose 13 Fuel hose
6 Radiator lower hose 14 Oil cooler outlet hose
7 Exhaust pipe 15 Oil cooler inlet hose
8 Air inlet hose
6-9
POWER TRAIN
4.5 Other removing
3
2
211791

1 Propeller shaft 3 Thrust rod (2 parts)
2 Universal joint 4 Cushion (4 parts)
6-10
POWER TRAIN
4.6 Removal of Engine and Transmission Unit
211792

Fasten a hoist to the engine and transmission unit with wire
ropes hitched to two lifting eyes on the engine and a sling
chain hitched to one eye on the transmission while placing a
levelling block under the unit. Adjust the length of the chain
sling with the lever block so that the unit is horizontal. Then
slowly lift the unit while moving it backward to remove in
the upward direction.
Weight of engine and transmission unit 900 kg
6-11
POWER TRAIN
4.7 Installation
4.7.1 Installation sequence
Install in the reverse sequence of the disassembly proce-
dure.
Output shaft
(1) When mounting the engine and transmission unit on
the frame, position it on the mounting brackets such
that the universal joint in front of the unit is aligned
with the transmission output flange.
Output flange
205457
(2) Tighten the mounting bolt to the specified torque. Engine mount(left shown,right opposite)
Refer-
ence Tightening position Torque 4 1
No.
145 N•m
Cushion rubber and mounting
1 (14.8 kgf•m)
bolt 3
[107 lbf•ft]
60 N•m
2 Mounting bracket bolt (6.1 kgf•m)
[44 lbf•ft]
206171
97 N•m
3 Cushion rubber bolt (9.9 kgf•m)
[72 lbf•ft] Transmission mount(right side) 1
60 N•m
4 Mounting bracket bolt (6.1 kgf•m) 2
[44 lbf•ft]
3
206172
6-12
POWER TRAIN
Transmission mount(left side) 1
206173
(3) When installing the engine exhaust pipe, use a new

gasket.
(4) Make sure that all wires have been connected properly,
and then fasten the ground (negative) battery cable to
the corresponding terminal.
(5) Refill the engine oil, engine coolant, and transmission
oil respectively and check for any water or oil leakage.
For concentration of antifreeze in coolant, consult your
Mitsubishi forklift truck dealer.
(6) Also bleed the engine fuel lines.
(7) After checking every part, start the engine and observe
its running condition. If the engine vibrates exces-
sively, retighten the engine mounting bolts to see if this
retightening has an effect. Additionally, operate the
mast, forks and steering to check for the level of
hydraulic oil, and refill it if necessary. Also check the
engine oil, coolant and transmission oil levels, and
refill each if necessary.
6-13
POWER TRAIN
4.8 Capacity
Fuels and Oils Oil Brand Capacity

M Lift long-life coolant
Antifreeze (Genuine Mitsubishi Fuso Dia Queen) 23 L
long-life coolant
Torque converter Diamond ATF
23 L
oil DEXRON II
Gear oil Diamond firm gear oil Ｂ
(differential gear，front API category，Multi-purpose type GL-5 20 L
axle final gear) SAE90，80
ENEOS brake fluid
Brake oil 240 cc
FMVSS DOT3 or DOT4
M Lift hydraulic oil
Level gauge
Hydraulic oil (Genuine Mitsubishi Fuso hydraulic Oil) 130 L
(N) mark
ISO VG32
JIS Extra Grade 3 (-15°C or lower)
Fuel JIS Grade 3 (-5 to -15°C) 220 L
JIS Grade 2 (higher than -5°C)
M Lift diesel engine oil
(Genuine Mitsubish Fuso Engine Oil Special)
API category CD class or higher Engine body: 14 L
Engine oil SAE 10W or SAE 10W30 (-10°C or lower) Oil filter: 1 L
Total: 15 L
SAE 20W (-10°C to 10°C)
SAE 30 (higher than +10°C)
6-14
3-SPEED POWERSHIFT TRANSMISSION
1. Specifications ............................................................................................................... 7-3
2. Description ................................................................................................................... 7-4

2.1 Torque Converter.................................................................................................................................. 7-4
2.2 Transmission......................................................................................................................................... 7-5
1
2.3 Power Flow ........................................................................................................................................... 7-6
2.4 Control Valve ........................................................................................................................................ 7-8 2
2.5 Main Regulator Valve............................................................................................................................ 7-8
2.6 Hydraulic Controls................................................................................................................................. 7-9
2.7 Speed Selector System ...................................................................................................................... 7-10
3
2.8 Control System ................................................................................................................................... 7-11
4
3. Suggestions for Removal and Installation .................................................................. 7-12
3.1 Removal.............................................................................................................................................. 7-12
3.1.1 Transmission removal ............................................................................................................................... 7-12 5
3.1.2 Torque converter removal ......................................................................................................................... 7-12
3.2 Torque converter installation............................................................................................................... 7-13
6
4. Disassembly and Reassembly ................................................................................... 7-14 7
4.1 Torque Converter................................................................................................................................ 7-14 7
4.1.1 Disassembly .............................................................................................................................................. 7-14
4.1.2 Inspection .................................................................................................................................................. 7-15
4.1.3 Reassembly .............................................................................................................................................. 7-18
8
4.2 Transmission....................................................................................................................................... 7-20
4.2.1 Disassembly .............................................................................................................................................. 7-20
9
4.2.2 Inspection .................................................................................................................................................. 7-30
4.2.3 Reassembly .............................................................................................................................................. 7-33
4.3 Control Valve ...................................................................................................................................... 7-41 10
4.3.1 Disassembly .............................................................................................................................................. 7-41
4.3.2 Inspection .................................................................................................................................................. 7-42
4.3.3 Reassembly .............................................................................................................................................. 7-43
11
4.4 Main Regulator Valve.......................................................................................................................... 7-44
4.4.1 Disassembly .............................................................................................................................................. 7-44 12
4.4.2 Inspection .................................................................................................................................................. 7-44
4.4.3 Reassembly .............................................................................................................................................. 7-44
13
5. Adjustment ................................................................................................................. 7-45
5.1 Brake pedal and inching pedal adjustment ......................................................................................... 7-45 14
5.2 Oil Pressure Measurement ................................................................................................................. 7-46
7-1
5.2.1 Main oil pressure measurement ................................................................................................................ 7-46

5.2.2 Direction clutch oil pressure measurement ............................................................................................... 7-47
5.2.3 Torque converter inlet oil pressure measurement..................................................................................... 7-48
5.3 Stall Speed Measurement................................................................................................................... 7-48
5.4 10 m (33 ft) Start Acceleration Test .................................................................................................... 7-49
5.5 Travel Speed Select Switch ................................................................................................................ 7-50
7. Service Data............................................................................................................... 7-56

7.1 Stall Speed, Hydraulic......................................................................................................................... 7-56
7.2 Pump Boss.......................................................................................................................................... 7-56
7.3 Pilot Boss ............................................................................................................................................ 7-57
7.4 Oil Pump ............................................................................................................................................. 7-57
7.5 Stator .................................................................................................................................................. 7-58
7.6 Flexible Plates..................................................................................................................................... 7-58
7.7 Clutches .............................................................................................................................................. 7-60
7.8 Forward Clutch Shaft, Reverse Clutch Shaft, 1st-Speed/3rd-Speed Clutch Shaft and Servo Case... 7-61
7.9 Backlash of Gears............................................................................................................................... 7-62
7.10 Control Valve ...................................................................................................................................... 7-63
7.11 Main Regulator Valve.......................................................................................................................... 7-64
7.12 Inching Pedal Control.......................................................................................................................... 7-65
7-2
1. Specifications
Truck Model DP100N DP120N DP135N DP150N DP160N

Torque converter Model MN 16
Stall torque ratio 2.51
Direction Electric, column shift
Control
Speed Automatic
1st: 2.402
Forward 2nd: 1.010
Transmission
3rd: 0.558
Gear ratio
1st: 2.402
Reverse 2nd: 1.010
3rd: 0.558
7-3
2. Description
2.1 Torque Converter
7 5
2
From oil pump

4
1
8
To oil cooler
200550
1 Pilot boss 4 Turbine assembly 7 Pump (impeller)

2 Flexible plate 5 Stator 8 Stator shaft
3 Drive cover 6 Freewheel 9 Input shaft (transmission)
Oil pressurized in the torque converter flows from the outlet

passage in the stator shaft to the lubrication circuit of trans-
mission through the oil cooler.
The oil flow generated by rotation of the impeller rotates
the turbine and input shaft.
The freewheel is a kind of one-way clutch. When the rota-
tion speeds of the engine and input shaft are almost equal,
the freewheel allows the stator to turn freely and causes the
torque converter to act as a fluid coupling automatically.
The torque converter is operated efficiently even in high
speed rotation by the freewheel.
Model MN 16
7-4
2.2 Transmission
11
10
2 F
R
5
3 1
6
212191
1 Flexible plate 5 Reverse clutch shaft 9 Pump idler gear

2 Torque converter assembly 6 1st-speed/3rd-speed clutch shaft 10 Pump drive gear
3 Input shaft 7 Output shaft 11 Pump case
4 Forward clutch shaft 8 PTO drive gear
The transmission is a 3-speed power shift transmission. The

speed is changed by the hydraulic multi-disc clutch auto-
matically at both forward and reverse operations.
7-5
2.3 Power Flow
Figures in ( ) indicate number of gear teeth.

Forward 1st (39)
(58)
(58)
(35)
(34) Forward 2nd

(58)
(46)
(24)
(58) (54) (35)
(56) (34)
Forward 3rd
(58)
(35)
(53)
(34)
(58)
(59)
(58)
(32)
212192
Speed Gears engaged Gear ratio

1st 35/34 × 58/58 × 58/58 × 56/24 2.402
2nd 35/34 × 53/54 1.010
3rd 35/34 × 58/58 × 58/58 × 32/59 0.558
PTO gear 58/46 × 39/58 0.848
7-6
Figures in ( ) indicate number of gear teeth.

Reverse 1st (39)
(58)
(34)
Reverse 2nd
(35) (46)
(58)
(24)
(58)
(58)
(54)
(56) (34)
(58)
Reverse 3rd (35)
(53)
(34)
(58)
(59)
(35)
(58)
(32)
212193
Speed Gears engaged Gear ratio

1st 35/34 × 58/58 × 56/24 2.402
2nd 35/34 × 58/58 × 53/54 1.010
3rd 35/34 × 58/58 × 32/59 0.558
PTO gear 58/46 × 39/58 0.848
7-7
2.4 Control Valve
Section A - A
A A
4
B
B 5
Section B - B
1
212194
1 Accumulator valve 3 1st-speed valve 5 2nd-speed/3rd-speed valve

2 Direction valve 4 Differential valve
2.5 Main Regulator Valve
10 9 8
7 6 5 4 3 2 1
212195
1 Bolts 5 Spool 9 Main pressure port

2 Cover 6 Body 10 Torque converter inlet pressure port
3 O-ring 7 Spring
4 Slug 8 Drain port
7-8
Transmission hydraulic circuit
2.6 Hydraulic Controls
Accumulator valve
Torque converter Pressure at start of
charging 0.3 MPa
Speed selector valve (3.1kgf/cm 2 )[43.5 psi]
Chassis area Last chance filter Pressure at end of
S2 (2nd /3rd speed)
charging 0.76 MPa
(7.8kgf/cm 2 )[110 psi]
Orifice: Diam. 0.8 mm
(0.031 in.) Main orifice: Diam. 2.2 mm(0.087 in.)
Torque converter Orifice: Diam. 0.8 mm(0.031 in.) Differential valve
Oil cooler bypass orifice: Setting: 0.2 MPa
Diam. 4.0mm (0.157 in.) (2.0kgf/cm 2 )
Speed selector valve [29 psi]
S1 (1st speed)
Last chance
filter 2 3
Torque converter
inlet relief valve Oil filter
Setting: 0.15 to 0.69 MPa
(1.53 to 7.0 kgf/cm 2 )
[21.8 to 100 psi] Tap (plug) for
torque converter
inlet pressure 1
Oil pump (marked "T")
Capacity: 70liters T/C in Oil filter for forward/ PS
(18.5 US gal.)/min reverse clutches
at 2300rpm (marked S)
PM (particle size )
Tap (plug) for
main pressure
Lubrication (marked "M") PD
line (marked D)
Main regulator valve
Suction strainer Setting: 0.88 to 1.08 MPa
C2 CF R C 3 C1 (9.0 to 11.0 kgf/cm )
with magnet 100mesh
[127.6 to 145 psi)
F R
Transmission oil reservoir
Solenoid valve Solenoid valve
(direction selection) (direction selection)
Last chance filter Last chance filter
Orifice: Diam. 0.8 mm(0.031 in.) Orifice: Diam. 0.8 mm(0.031 in.)
212196
7-9
2.7 Speed Selector System
Travel speed select switch
Travel speed 1st speed clutch

Output
VCM (solenoid)
gear 2nd/3rd speed
valve
clutch
Travel speed sensor Electric signal
Hydraulic pressure
0.5 mm Transmission case signal
(0.02 in.)
Control system
Power
source Transmission Travel speed select switch
shift lever
To meter panel VCM
Solenoid valve
Travel speed sensor
212197
Location of components
Automatic 3-speed transmission system consists of the
torque converter and 3-speed transmission. The speed con-
trol system consists of the travel speed sensor, VCM (Vehi-
cle Control Module) and solenoid valves.
The truck speed can be changed from "automatic speed
change" mode to "fixed 1st speed" mode by the travel speed
selector switch to select the optimum truck speed according
to the working condition.
7-10
2.8 Control System
N 9
F To meter panel
5
1
4 7
3
8
4 2
212198
1 Transmission shift lever 6 VCM-3OP

2 Control valve 7 Inching pedal
3 Travel speed (solenoid) valve 8 Cutoff switch
4 Direction (solenoid) valve 9 Control relay
5 VCM-3
7-11

To remove the transmission assembly from the truck,
remove it together with the engine. Refer to “GROUP 6
POWER TRAIN.”
3.1 Removal
3.1.1 Transmission removal
(1) To separate the transmission from the engine, put the
engine on a stable stand, and support the transmission
with wood blocks.
(2) Remove the hydraulic pump from the transmission.
(3) The transmission has three lifting eyes, two eyes on the
differential side and one eye on the torque converter
side.
To lift the transmission, fasten two slings to the differ-
ential side eyes and one sling (chain with lever block) to
the torque converter side eye. Balance the transmission
with the lever block and lift it at three points just enough
to take the weight of the transmission.
(4) Remove the bolts that hold the flexible plates through
the access hole in the torque converter housing.
(5) Separate the transmission from the engine by lifting it
with a hoist.
212199
3.1.2 Torque converter removal

(1) To remove the torque converter assembly from the
transmission, slide the splines of the stator shaft, PTO
drive gear and input shaft away from the mating
splines.
NOTE
Remove the drain plug of the torque converter and drain the
oil.
7-12
3.2 Torque converter installation

(1) Couple the torque converter to the transmission. Make
sure that the distance between the end face of the
14.5 mm (0.57 in.)
torque converter housing and the mating face of the
flexible plates is 14.5 mm (0.57 in.). If this distance is
more than 14.5 mm (0.57 in.), it is an indication that
spline engagement between the torque converter stator
shaft and transmission input shaft is improper; recouple
the torque converter to the transmission.
(2) Lift the transmission, and couple it to the engine.
(3) Make sure that the clearance between the flywheel and
flexible plates is 0 to 2 mm (0 to 0.08 in.) when the
transmission is coupled to the engine.
(4) Tighten the bolts that hold the flexible plates to the fly-
wheel through the access hole in the torque converter
housing. The bolts should be tightened evenly in a
crisscross pattern. When tightening those bolts, turn the 200557
torque converter with a heavy-duty screwdriver put to
the bolts.
(5) Mount the hydraulic gear pump to the transmission.
(6) Install the transmission harness.
Connect the travel speed sensor at the connector side,
and connect the torque converter thermo unit at the ter-
minal side.
Connect the following wire color harness to each sole-
noid.
Solenoid Valve Harness Wire Color F solenoid
S1 RY
Travel speed
S2 LY
F GY
Transmission shift lever
R GL
(7) Pour in the torque converter oil.
R solenoid
S2 solenoid S1 solenoid
212200
7-13

4.1 Torque Converter
4.1.1 Disassembly
3 6
7
3
4
212201
(1) Sequence
1 Bolts, Spring washers, Plain washers 5 Thrust washers, Thrust bearing
2 Flexible plates, Pilot boss, O-ring, Bolts, 6 Stator, Rollers, Hub, Springs, Spring caps,
Spring washers Thrust washers
3 Bolts, Drive cover, Ball bearing, Drain plug, 7 Ball bearing, O-ring, Pump boss, Pump(impeller), Bolts,
Seal washers Toothed washers
4 Thrust washer, Turbine
7-14
(2) Suggestion for Disassembly

To remove the stator assembly, slightly force the stator
just like turning it counterclockwise to prevent the roll-
ers from falling and pull the stator together with the hub
by sliding the splines.
204530
4.1.2 Inspection
(1) Pump (impeller)
(a) Check for cracks.
(b) Check for oil leaks due to looseness of the bolts hold-
ing the boss to the pump, or defective O-ring.
(c) Check the face of the pump boss in contact with the oil
seal for wear.
(d) Check the face of the pump boss in contact with the
seal ring.
Oil seal O-ring

Seal ring
200561
7-15
(2) Stator
(a) Check the blades for cracks. Also check the fit of the
stator on the clutch cam.
(b) Check the clutch hub and cam for wear or flaws.
(c) Check the springs for damage. Also check the spring
caps for wear or distortion.
(d) Check the rollers for flaws, distortion or flat spots due
to wear.
(e) Check the clutch hub splines for defects.
(f) Check the thrust washers for wear or other defects.
Outside diameter of Standard value 67.951 to 67.97

clutch hub 1 (2.67523 to 2.6760)
mm (in.) Service limit 67.8 (2.669)
Diameter of clutch 10.185 to 10.2
Standard value
rollers 2 (0.40098 to 0.402)
3 4 1 2 5 6 7
Thickness of thrust 4.95 to 5
Standard value
washer 3 (0.1949 to 0.197)
Standard value
washer 4 (0.1555 to 0.157)
mm (in.) Service limit 3.8 (0.150) 200724
Standard value
washer 5 (0.114 to 0.118)
Standard value
washer 6 (0.193 to 0.197)
Standard value
washer 7 (0.1949 to 0.197)
7-16
(3) Turbine
(a) Check the vanes for cracks.
(b) Check the fit of the turbine boss in the turbine.
(c) Check the turbine boss splines for wear or other
defects.
(4) Pilot boss

Check the surface in contact with the pilot bearing for
wear or other defects.
Diameter of portion Standard -0.007 -0.00028

value 20 -0.020 (0.7874 -0.00079) 1
in contact with
engine flywheel 1 Service
mm (in.) 19.85 (0.7815)
limit
200411
7-17
4.1.3 Reassembly
10 1
13
11
4
2
9
3
12 7
13 5
212202
(1) Sequence
1 Pump (impeller) 8 Thrust washer
2 Pump boss, O-ring, Bolts, Toothed washers 9 Thrust bearing, Thrust washers
3 Ball bearing 10 Turbine
4 Stator assembly 11 Drive cover, O-ring, Bolts, Washers
5 Springs, Spring caps 12 Thrust washer, Ball bearing, Pilot boss, O-ring, Bolts,
Washers
6 Rollers 13 Flexible plates, Bolts, Plain washers,
Spring washers
7 Hub
7-18
(2) Suggestions for Assembly

(a) Stator assembly
• Put hub 7 in the stator as shown. Put spring 5 and spring 5 5
cap 5 in each hole, and press in roller 6 while pushing the
spring cap.
• Install a total of eight rollers, and restore the hub to its 6
original position.
• After having assembled the stator, turn the hub by hand,
making sure that it rotates in only one direction.
7 202885A
(b) Selection of spacer

Measure the dimensions A, B and C. Select a spacer
equal to the clearance (dimension D) and put it in posi-
tion.
Part number Thickness of spacer
A
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.)
B
92322 - 06700 3.5 mm (0.138 in.) D C
A 26.4 (1.039) 212203

Standard dimensions B 19 (0.75)
mm (in.)
0 0
C 4 -0.1 (0.16 -0.004 )
(c) Flexible plate

After having installed the flexible plate, measure the
face runout of the plates with a dial indicator. Replace
the plates if the runout has exceeded the service limit.
Face runout of flexible Standard value 0.2 (0.008)

plate (in free state)
205922
7-19
4.2 Transmission
4.2.1 Disassembly
(1)Control valve and external parts
7
4 3
5
7
6 2
1
13
16
10
15
17
14
8 11
8
12
212204
(a) Sequence
1 Air breather 9 Oil filter
2 Oil level gauge, Oil filler, O-ring, Stay, Clamp, Bolts, 10 Travel speed sensor, O-ring
Spring washers, Plug, Gasket, Nuts 11 Thermo unit
3 Oil pipe, Eye bolt, Gaskets 12 Drain plug, Gasket
4 Main regulator valve, Gasket, Bolts, Washers 13 Suction pipe, O-rings, Bolts, Spring washers
5 Oil pipe, O-rings, Bolts, Spring washers 14 Cover, O-ring, Bolts, Spring washers
6 Control valve, Gasket, Bolts, Spring washers 15 Magnet strainer assembly
7 Oil pipes, Eye bolts, Gaskets 16 Bracket, Bolts, Spring washers
8 Oil pipes, Eye bolts, Gaskets 17 Bracket, Bolts, Spring washers
7-20
(2)Transmission cover and shafts
12
13
23
24
22
21
20
11
4
16 19
17 14
15
18 9
8
6
10
4
3
5
1, 2
212205
1 Servo case, O-ring, Bolts, 7 Output gear (2nd speed) 16 Travel speed sensor gear,
Washers 8 Output gear (3rd speed) Washers, Bolts
2 Servo case, O-ring, Bolts, 9 Snap ring 17 Ball bearing

Washers 10 Baffle plate, Bolts, Washers 18 Output gear (1st speed)
3 Servo case, O-ring, Bolts, 11 1st-speed/3rd-speed clutch 19 Snap ring
Washers shaft assembly 20 Lock nut
4 Transmission cover subassembly, 12 Forward clutch shaft assembly 21 Input gear
Gasket, O-rings, Bolts, Washers 13 Reverse clutch shaft assembly 22 Snap ring
5 Oil seals 14 Baffle plate, Bolts, Washers 23 Input shaft, Ring seal
6 Ball bearing 15 Output shaft 24 Ball bearing
7-21
(b) Suggestions for Disassembly

• Transmission cover subassembly 4 removal
Turn two Bolts (jack bolts) (special tool) in the M10 × Jack bolt
1.25 holes in the cover evenly until the cover is approxi-
mately 25 mm (1 in.) apart (the bearings get out of place).
Then remove the cover. Do not attempt to remove the
lubrication line plug from the cover.
Special tool needed
Bolt 67284 - 15400
• Output gear (outside) 7 (2nd sppeed) removal
Remove the output gear together with ball bearing 6 with
a gear puller.
205629
• Output shaft 15 removal
Turn a sliding hammer in the M8 × 1.25 hole in the end of
the output shaft, and remove the shaft together with out- Output gear (1st speed)
put gear 18, ball bearing 17 and travel speed sensor gear Sliding hammer
16.
CAUTION
Be careful not to strike the travel speed sensor Travel speed
sensor gear
gear against the transmission case when remov-
ing the output shaft.
205480
The travel speed sensor gear will be deformed.
• Ball bearing 17 removal

Remove output shaft 15 with a press and a tooling as
shown, or remove the gear with a puller, to remove the
bearing.
Tooling
205630
• Lock nut 20 removal

Straighten the locking tab of lock nut 20 away from flat of
the input shaft 23 and remove the nut with a socket
wrench and an impact wrench. When removing the nut,
hold the splined end of the input shaft with a pipe wrench,
or put a bar to input gear 21 in such a manner as to pre-
vent the shaft from turning counterclockwise.
7-22
(3)Stator shaft and oil pump
7
8
9 13
2 1 18
3 12
19
4
3
15
14
16
17
11
20 23
21
10
22
212206
(a) Sequence
1 PTO cover, O-ring, Bolts, 9 Ball bearing 17 Stator shaft, Seal ring, Bolts,
Spring washers Spring washers
2 Snap ring 10 Torque converter housing, 18 Pump idler gear
Gasket, Flanged bolts
3 Pump drive gear, Seal rings 11 Oil seal 19 Roller bearing
4 Ball bearing 12 Idler gear shaft 20 Roller bearing (outer race)
5 Pump case, O-ring, Bolts, 13 Roller bearing 21 Roller bearing (outer race)
Spring washers
6 Pump plate, O-ring, Gasket 14 PTO drive gear 22 Roller bearing (outer race)
7 Internal gear 15 Ball bearing 23 Transmission case, Dowels
8 Pump drive gear 16 Ball bearing
7-23

• Torque converter housing 10 removal
Turn two Bolts (jack bolts) (special tool) in the M10 ×
1.25 holes in the housing evenly until the housing is
approximately 18 mm (0.7 in.) apart (the PTO drive gear
ball bearing gets out of place). Fasten a hoist to the hous-
ing and remove the housing.
Special tool needed
Bolt 67284 - 15400
• Oil pump removal

Remove the oil pump as a subassembly including pump
case 5, pump plate 6, internal gear 7, pump gear 8 and ball
bearing 9.
• Idler gear shaft 12 removal

Turn the Shaft puller (special tool) in the shaft hole.
M20 X 1.5
Install the sliding hammer (used in removing the output
shaft) to this puller and remove the shaft. M8 X 1.25
Special tool needed
12
Shaft puller (to be made by dealer)
210188
• PTO drive gear 14 removal

Grip ball bearing 15 with a gear puller. Put a protective
plate on the end of the stator shaft and remove the gear
together with two ball bearings.
14
210193
7-24
• Stator shaft 17 removal

Turn two Bolts (jack bolts) (special tool) in the M10 ×
1.25 holes in one end of the shaft evenly, or hit the other
end by using a protective plate.
Special tool needed
Bolt 67284 - 15400
• Roller bearing outer race removal

Do not remove outer races 20, 21 and 22 of the roller
bearings installed in the transmission case and the outer
race of roller bearing 19 installed on idler gear shaft 18
unless they are defective.
7-25
(4)Forward clutch shaft subassembly
5 12
13
15
4
14
3
2 16
1
14
15
13
12
11
10
6
7
11
11 8
9
10
11
212207
(a) Sequence
1 Seal rings 9 Thrust washer, Snap ring
2 Ball bearing 10 Snap rings, Pressure plates
3 Thrust washer 11 Friction plates, Mating plates
4 Gear (2nd-speed drive), Needle roller bearings 12 Snap rings, Retainers
5 Thrust washer 13 Clutch springs
6 Roller bearing 14 Clutch pistons, Piston seals
7 Thrust washer 15 Seal rings
8 Gear (forward drive), Needle roller bearings 16 Forward clutch shaft
NOTE
Do not attempt to remove the screws from the forward
clutch shaft
7-26

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

Grip forward drive gear 8 with a gear puller and remove
the bearing together with the gear and thrust washer 7.
• Forward clutch shaft disassembling

Using the Piston tool A (special tool) or an arbor press,
compress clutch spring 13 and retainer 12, and remove
snap ring 12.
Special tool needed A
Piston tool 92267 - 00300
207504
7-27
(5)1st-speed/3rd-speed clutch shaft subassembly
5 12
13
4 15
14
3
2 16
1
14
15
13
12
11
10
6
11 11 7
8
9
10
11
212208
(a) Sequence
1 Seal rings 9 Thrust washer
2 Ball bearing 10 Snap rings, Pressure plates
3 Thrust washer 11 Friction plates, Mating plates
4 Gear (3rd-speed drive), Needle roller bearings 12 Snap rings, Retainers
5 Thrust washer 13 Clutch springs
6 Roller bearing 14 Clutch pistons, Piston seals
7 Thrust washer 15 Seal rings
8 Gear (1st-speed drive), Needle roller bearings 16 1st-speed/3rd-speed clutch shaft
(b) Suggestion for Disassembly

NOTE
For disassembly, make reference to the disassembly of
Do not attempt to remove the screws from the 1st-speed/
the forward clutch shaft.
3rd-speed clutch shaft.
7-28
(6)Reverse clutch shaft subassembly
9
10
12
11
13
2
1
3
4
8
5
6
7
212209
(a) Sequence
1 Seal rings 8 Friction plates, Mating plates
2 Ball bearing 9 Snap ring, Retainer
3 Roller bearing 10 Clutch spring
4 Thrust washer 11 Clutch piston, Piston seal
5 Gear (reverse drive), Needle roller bearings 12 Seal ring
6 Thrust washer, Snap ring 13 Reverse clutch shaft
7 Snap ring, Pressure plate
(b) Suggestion for Disassembly

NOTE
For disassembly, make reference to the disassembly of
Do not attempt to remove the screws from the reverse
the forward clutch shaft.
clutch shaft.
7-29
4.2.2 Inspection
(1) Oil pump
(a) Put the internal gear and pump gear in the pump case,
and measure top clearance 2.
(b) Using a dial indicator, measure side clearance 1
between the gears and pump case.
0.040 to 0.078
Side clearance 1 Standard value
(0.00157 to 0.00307)
mm (in.)
Service limit 0.09 (0.0035) 2
0.3 to 0.345
Top clearance 2 Standard value
(0.0118 to 0.0136) 1
mm (in.) 205486
Service limit 0.35 (0.0138)
(2) Stator shaft

(a) Check the splines for wear or damage.
(b) Check the oil passages for clogging.
(3) Friction plates and mating plates
(a) Check for sign of seizure, uneven contact, warpage or
excessive wear.
(b) Check the splines for wear or damage.
(4) Clutch drums
(a) Check the mating plate sliding surfaces for wear or
damage.
(b) Check the clutch piston sliding surfaces for wear or
damage.
7-30
Thickness of mating Standard 2.3±0.07

plate 1 value (0.091±0.0028) 7, 8
Thickness of friction Standard 2.6±0.1
plate 2 value (0.102±0.004)
Free movement of
Standard 0.10 to 0.30
friction plate on gear 3
value (0.0039 to 0.0118)
mm (in.)
Width of piston seal Standard 4±0.05 6 2 1 3
ring 4 value (0.16±0.002 )
mm (in.) Service limit 3.5 (0.138) 4
Width of piston seal Standard +0.2 +0.008
value 4 +0.1 (0.16 +0.004 )
ring groove in piston 5
Free length of clutch 68 ± 2 (2.68 ± 0.08)
Standard
spring 6 k = 39.1(3.992) 5
value
mm (in.) [223.5] 212210
k: Spring constant
N/mm (kgf/mm) Service limit 65 (2.56)
[lbf/in.]
Width of clutch piston Standard 2.5±0.05
seal ring 7 value (0.098±0.0020)
Width of clutch piston Standard +0.2 +0.008
value 2.5 +0.1 (0.098 +0.004 )
seal ring groove 8
7-31
(5) Forward clutch shaft, reverse clutch shaft and 1st-

speed/3rd-speed clutch shaft
(a) Check the seal rings and seal ring contact surfaces of
the shaft and servo case for wear or damage.
Width of piston seal Standard 2.5±0.05
ring for each clutch value (0.098±0.0020)
shaft 1 1, 2
Width of piston seal Standard +0.2 +0.008

ring groove in each value 2.5 +0.1 (0.098 +0.004)
3
clutch shaft 2
Inside diameter of Standard +0.025 +0.00098

each servo case in value 35 0 (1.38 0 )
contact with seal
ring 3 Service limit 35.2 (1.386)
mm (in.)
205635
(b) Check the splines for wear or damage.

(c) Check the oil passages for clogging.
(6) Gears
(a) Check each gear for worn teeth or splines.
(b) Check the needle bearing sliding surfaces of the gear
for wear or damage.
(7) Magnet strainer assembly
Disassemble and clean the strainer. Replace the strainer
if defective.
(8) Transmission cover and torque converter housing oil
seals
Replace the oil seals with new ones.
7-32
4.2.3 Reassembly
(1) Forward clutch shaft subassembly
(1st-speed/3rd-speed clutch shaft subassembly/reverse clutch shaft subassembly)
5 10 9 7 8 4 7 8 4 9 10 5 11
16 6
14 15
6
21
20 19 17
12 13
18 2 3 2
212211
(a) Sequence
1 Forward clutch shaft, 1st-speed/3rd-speed clutch shaft, 11 Thrust washer
or reverse clutch shaft 12 Needle roller bearings
2 Sealing rings, Piston seals 13 Gear (forward drive)
3 Clutch pistons 14 Thrust washer
4 Clutch springs 15 Roller bearing
5 Retainers 16 Thrust washer
6 Snap rings 17 Needle roller bearings
7 Mating plates 18 Gear (2nd-speed drive)
8 Friction plates 19 Thrust washer
9 Pressure plates 20 Ball bearing
10 Snap rings 21 Seal rings
NOTE
The reassembly sequence and suggestions for the reverse
clutch shaft subassembly are similar to the forward clutch
shaft subassembly as far as the clutch is concerned
7-33
(b) Suggestions for Reassembly
• Piston installation
When putting pistons 3 in the clutch drum, apply ATF
(automatic transmission fluid) to their seal ring contact
surfaces.
• Return spring installation

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

6.
Special tool needed
Piston tool 92267 - 00300
207504
• Friction and mating plate installation
Make sure that the position and number of the plates are Mating plate
correct. Install the plates while applying ATF to them. Friction plate
When replacing the friction plates, replace the mating
plates, too.
207516
Thrust washer installation
Install thrust washers 11, 14, 16 and 19 with the side that
has oil grooves toward the gear.
203800
• Piston testing
After reassembling the clutch, apply pressure air of
approximately 690 kPa(7 kgf/cm2) [100 psi] to the oil
hole to make sure that the piston move freely without any
sign of air leaks.
7-34
(2)Stator shaft and oil pump
15 16
12
18
17
19
14 20
1 13
3
9
10
4
6
5 11
205638
(a) Sequence
1 Transmission case, Dowels 8 Idler gear shaft 15 Pump plate, O-ring, Gasket,
Bolts, Spring washers
2 Roller bearing 9 Roller bearing 16 Ball bearing
3 Idler gear 10 Oil seal 17 Pump drive gear, Seal rings
4 Stator shaft, Seal ring, Bolts, 11 Torque converter housing, 18 Ball bearing
Spring washers Gasket, Flanged bolts
5 Ball bearing 12 Pump case, O-ring, Bolts, Spring 19 Snap ring
washers
6 PTO drive gear 13 Internal gear 20 PTO cover, O-ring, Bolts,
7 Ball bearing 14 Pump gear Spring washers
NOTE
The dowels fitted into the transmission case should not
been removed. These dowels are for locating the pump
case, torque converter housing and transmission cover sub-
assembly for installation.
7-35
• PTO drive gear 6 installation

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

Unit: mm (in.)
Replace the oil seal with a new one. Install the oil seal to
the torque converter housing by using the oil seal installer
(special tool).
Special tool needed
Oil seal installer (to be made by dealer)
• Oil pump reassembling

13 (0.51) 8 (0.31)
Put internal gear 13, pump gear 14 and pump plate 15 in
150 (5.91)
pump case 12. Apply oil to the internal gear and pump
gear. Do not forget to install the O-ring. 205491
• Oil pump subassembly installation

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

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

Unit: mm (in.)
When installing ball bearing 18 in pump case 12, hold the
pump drive gear with the Pump drive gear holder (special
tool), or have someone press the gear with a copper bar or
the like, in order to prevent the gear from coming off.
Special tool needed
Pump drive gear holder (to be made by dealer)
)
39
(0. 1)
10 (0.
3
8
)
39 10
)
(0. (1.
10 28
205492
7-36
(3)Shafts and transmission cover
25 1
17
19 4
26
7
27
2
18
24
23 22 21 20 14 16 9 15 10 11 12 13
212212
7-37
(a) Sequence
1 Roller bearing (outer race) 15 Baffle plate, Bolts, Spring washers
2 Roller bearing (outer race) 16 Baffle plate, Bolts, Spring washers
3 Roller bearing (outer race) 17 Forward clutch shaft subassembly
4 Ball bearing 18 1st-speed/3rd-speed clutch shaft subassemblly
5 Input shaft 19 Reverse clutch shaft subassembly
6 Snap ring 20 Output gear (3rd speed)
7 Input gear 21 Output gear (2nd speed)
8 Lock nut 22 Ball bearing
9 Output shaft 23 Oil seals
10 Snap ring 24 Transmission cover subassembly, Gasket, Bolts,
11 Output gear (1st speed) Spring washers, O-rings
12 Ball bearing 25 Servo case, O-ring, Bolts, Spring washers

13 Travel speed sensor gear, Spring washers, Bolts 26 Servo case, O-ring, Bolts, Spring washers
14 Snap ring 27 Servo case, O-ring, Bolts, Spring washers
• Input shaft 5 reassembling and installation

Install ball bearing 4 on input shaft 5, then install the shaft
in the transmission case.
Tighten nut 8 to the specified torque and bend it against
the flat of the input shaft for locking.
Tightening torque for nut:

294 to 392 N•m (30 to 40 kgf•m) [217 to 289 lbf•ft]
When tightening the nut, hold the torque converter side of

the shaft with a pipe wrench, or put a bar to input gear 7 in
such a manner as to prevent the shaft from turning clock-
wise.
• Output shaft 9 reassembling and installation

Reassemble output shaft 9, snap rings 10 and 14, output
gear 11, ball bearing 12 and travel speed sensor gear 13 in
a subassembly. Install the subassembly in the transmis-
sion case.
7-38
• Oil seal 23 installation

Replace two oil seals with new ones. Apply grease to the
lips of the oil seals and, using the Oil seal installer (spe-
Transmission cover
cial tool), install the seals in position with the lips toward
inside.
205494
Special tool needed

Oil seal installer (to be made by dealer) Unit: mm (in.) 1 (0.04)chamfer
10 (0.39) 28 (1.10)
170 (6.69) 1.5 (0.06)
205495
• Transmission cover installation

Install hooks in the jack bolt holes in the transmission
cover and hitch slings to these hooks. Put the gasket on
the transmission case. Hoist the cover and install it in
position. Do not forget to put the O-rings in the oil holes.
205640
• Servo cases 25, 26 and 27 installation

When installing the servo cases, apply oil to the inside
surfaces of the cases and the seal rings of the shafts. Do
not forget to install the O-rings to the cases.
7-39
(4)Control valve and external parts
8
12 13
11
8
10 14
15
6
17
1
16
2
7 4
7
3
212213
(a) Sequence
1 Magnet strainer assembly 10 Control valve, Gasket, Bolts, Spring washers
2 Cover, O-ring, Bolts, Spring washers 11 Oil pipe, O-rings, Bolts, Spring washers
3 Plug, Gasket 12 Main regulator valve, Gasket, Bolts, Spring washers
4 Thermo unit 13 Oil pipe, Eye bolt, Gaskets
5 Travel speed sensor, O-ring 14 Oil level gauge, Oil filler, O-ring, Stay, Clump, Bolts,
Spring washers, Plug, Nut
6 Suction pipe, O-rings, Bolts, Spring washers 15 Air breather
7 Oil pipe, Eye bolt, Gaskets 16 Bracket, Bolts, Spring washers
8 Oil pipe, Eye bolt, Gaskets 17 Bracket, Bolts, Spring washers
9 Oil filter
7-40
4.3 Control Valve

4.3.1 Disassembly
1
2
3
4
5
18 17
19 4
A
17 6
2 A
1
15
13
14
7
16 13
10
9
12
11
212214
(1) Sequence
1 Solenoid valves, O-rings 7 Snap ring, Plug, O-ring 13 Pin, Seat, O-ring
2 Springs, Spring seats 8 Inching dummy spool 14 Oil filter, O-rings
3 Direction valve 9 Snap ring, Plug, O-ring 15 Last chance filters (four)
4 Solenoid valves, O-rings 10 Spring, Differential valve 16 Roller bearing, Plug
5 1st-speed valve, Spring 11 Plate, O-ring, Bolts, Washers 17 Roller bearing, Plug
6 2nd-speed/3rd-speed valve, 12 Accumulator valve piston, 18 Plug, O-ring
Spring Springs (inner and outer) 19 Valve body, Gasket
CAUTION
Slowly loosen each bolt and solenoid valve so
that the spring and plunger do not suddenly jump
out.
7-41
4.3.2 Inspection
(1) Check the oil holes in the valve body for restriction.
(2) Check the valves for wear or damage. Make sure the
valve moves freely.
(3) Replace all oil seals with new ones.
(4) Replace oil filter 16 with a new one.
(5) Wash oil filter 15, or replace it with a new one.
Free length of selector 36.5 (1.44)

Standard
valve springs 1 k = 5.658 (0.577) 5 5
value
mm (in.) [32.3]
k: Spring constant Service
N/mm (kgf/mm) [lbf/in.] 35.5 (1.40)
limit
1
Free length of differential 60 (2.36)
Standard
valve spring 2 k = 1.677 (0.171)
value
mm (in.) [9.58]
N/mm (kgf/mm) [lbf/in.] 58 (2.28)
limit
Free length of accumulator 142.5 (5.61)
Standard
valve outer spring 3 k = 3.747 (0.3821)
value 2
mm (in.) [21.3] 1
N/mm (kgf/mm) [lbf/in.] 140 (5.51) 4
limit 3
Free length of accumulator 184.5 (7.26)
Standard 212215
valve inner spring 4 k = 3.941 (0.4019)
value
mm (in.) [22.50]
N/mm (kgf/mm) [lbf/in.] 182 (7.17)
limit
Free length of direction 32.5 (1.28)
Standard
valve springs 5 k = 4.23 (0.4313)
value
mm (in.) [24.15]
N/mm (kgf/mm) [lbf/in.] 31.5 (1.24)
limit
7-42
4.3.3 Reassembly
(1) Preparation
Wash the oil passages in the control valve thoroughly
and make sure they are not restricted.
17 3 16 17
18
18
4 5 13
Section A - A
12
A A
19
11
15
10
9 B 15
B
8
14
Section B - B
6
7
2 1
212216
(2) Sequence
1 Valve body 11 Inching dummy spool
2 Plug, Roller bearing 12 Plug, O-ring, Snap ring
3 Plug, Roller bearing 13 1st-speed valve, Spring
4 Last chance filters (four) 14 2nd-speed/3rd-speed valve, Spring
5 Oil filter, O-ring 15 Solenoid valves, O-rings (two)
6 Seat, O-ring, Pin 16 Direction valve
7 Springs (inner and outer), Accumulator piston 17 Spring seats, Springs
8 Plate, O-ring, Bolts, Spring washers 18 Solenoid valves, O-rings (two)
9 Differential valve, Spring 19 Plug, O-ring
10 Plug, O-ring, Snap ring
(3) Suggestions for Reassembly

(a) Replace oil seal 2 with a new one.
(b) Apply ATF (automatic transmission fluid) to the valves
and plungers when installing them in the valve body.
7-43

4.4.1 Disassembly
2
5
6 4 3
212217
(1) Sequence
1 Cover, O-ring, Bolts, Sprig washers 4 Spring
2 Slug 5 Cover, O-ring, Bolts, Sprig washers
3 Spool 6 Body
CAUTION
Slowly loosen bolts 1 so that the spring, spool and
slug do not suddenly jump out.
4.4.2 Inspection 4.4.3 Reassembly

(1) Check the oil holes in the valve body for restriction. (1) Sequence
(2) Check the valve spool for wear or damage. Make sure To reassemble, follow the reverse of disassembly se-
the spool moves freely. quence.
(3) Check the spring for damage or fatigue. (2) Suggestion for Reassembly
Apply oil to the spool and slug when putting them in the
body.
Free length of main 107 (4.21)
Standard
regulator valve spring k = 4.99 (0.5087)
value
mm (in.) [28.5]
N/mm (kgf/mm) [lbf/in.] 104 (4.09)
limit
7-44
5. Adjustment
5.1 Brake pedal and inching pedal adjustment
(1) Set inching pedal 1 at 45° by using bolt 2 and nut 3.
le)
)
ke
(2) Place brake pedal 4 in the same height as inching pedal
ang
tro
1 by using bolt 5 and nut 6.
(S
ngti
22
(3) Eliminate the clearance between inching pedal 1 and
set
brake pedal 4 by using bolt 7 and nut 8.
dal
8 1
(Pe
45
7
2 3
212218
4 1
5, 6 2, 3
212219
(4) Adjust the switch position by using nut 9 so that the

switch protrudes 1 mm (0.04 in.) from the end of the Clearance
1 mm (0.04 in.)
switch body.
Cutoff point
4 mm (0.16 in.) 2 mm (0.08 in.)

(OFF) (ON)
Stroke
6 mm (0.24 in.)
212220
7-45
5.2 Oil Pressure Measurement
CAUTION
Front tires rotate during the measurement. Build a
fence around the vehicle to prevent access to it.
NOTE
Always perform pedal adjustments before oil pressure mea-
surement.
5.2.1 Main oil pressure measurement

(1) Connect a 2 MPa (20 kgf/cm2) [290 psi] oil pressure
gauge to the main oil pressure outlet of the regulator Main pressure tap (M)
valve.
Special tools needed
*Connector 64309 - 17733
*Hose 64309 - 17722
*Connector 64309 - 17731
*Gauge 64309 - 17713
NOTE
Parts marked with an asterisk (*) are included in the gauge
kit 64309 - 17701. 212221
(2) Idle the engine and check that the transmission oil is up
to the specified level.
(3) Warm up the engine to raise the transmission oil tem-
perature.
(4) Keep the engine idling (at between 1000 and 1500
rpm).
(5) Under the above condition, perform the oil pressure
measurement.
Main oil pressure Stan- 0.88 to 1.08 MPa
(with engine idling at dard (9.0 to 11.0 kgf/cm2)
1500±100 rpm) value [128 to 157 psi]
NOTE
Monitor the idling speed through engine tachometer during
measurement.
7-46
5.2.2 Direction clutch oil pressure measurement

(1) Connect a 2 MPa (20 kgf/cm2) [290 psi] oil pressure
gauge to the direction clutch oil pressure outlet port of
the selector valve. Direction clutch pressure tap (PD)
NOTE
Use the same special tools as used for main oil pressure
measurement.
(2) Lift the front tires off the floor by either of the follow-
ing methods.
(a) The front axle housing is jacked up.
(b) The mast is tilted all the way backward first. With a 212222
wooden block applied under the outer mast, the mast is
tilted forward to lift the front tires. Then, an appropri-
ate stand or square timber is placed under the frame to
keep the front tires lifted.
(3) Put scotch blocks under the rear tires.
(4) Implement the steps (2) through (4) of main oil pres-
sure measurement.
(5) Place the direction lever into the forward position, then
release the parking brake.
(6) Release the inching pedal after fully depressing it, then
measure the direction clutch oil pressure.
Direction clutch oil
Stan- 0.73 to 0.93 MPa
pressure
dard (7.44 to 9.48 kgf/cm2)
(with engine idling at
value [105.9 to 134.9 psi]
1500±100rpm)
7-47
5.2.3 Torque converter inlet oil pressure measure-

ment
Torque converter
(1) Connect a 0.6 MPa (6 kgf/cm2) [87 psi] oil pressure inlet pressure tap (T)
gauge to the torque converter inlet oil pressure inlet
port of the regulator valve.
Special tools needed
*Connector 64309 - 17733
*Hose 64309 - 17722
*Connector 64309 - 17731
*Gauge 64309 - 17714
NOTE
The parts marked with an asterisk (*) are included in the 212223
gauge kit 64309 - 17701.
perature.
(4) Keep the engine idling (at between 1000 and 1500
rpm), measure the torque converter inlet oil pressure.
Torque converter inlet
Stan- 0.15 to 0.69 MPa
oil pressure
dard (1.5 to 7.0 kgf/cm2)
(with engine idling at
value [22 to 100 psi]
1500±100 rpm)
NOTE
Monitor the idling speed through engine tachometer during
measurement.
5.3 Stall Speed Measurement

perature.
(3) Block the front and rear wheels, and apply the parking
brake.
(4) Run the engine at low idle.
7-48
(5) Move the direction lever to the forward position, and

gradually depress the accelerator pedal fully. Under
this condition, measure the stall speed with an engine
tachometer.
Stall speed
1950 rpm
(tolerance: ±100 rpm)
CAUTION
Do not attempt to depress the inching pedal. Do
not continue operation in stall condition for more
than 30 seconds. A failure to follow this precau-
tion would result in destruction of the torque con-
verter.
(6) Similarly measure the stall speed for reverse drive.
NOTE
(a) Any stall speed within ±10 rpm tolerance of the speci-
fication is satisfactory.
(b) If the engine or torque converter is changed, the stall
speed will vary since the stall speed is determined by
the combination of engine and torque converter.
5.4 10 m (33 ft) Start Acceleration Test

(1) Stand ready to start with the engine running at low idle,
the direction lever in the neutral position and the travel
speed select switch in D (automatic 3-speed) position.
(2) At the signal, move the direction lever to the forward
position and, at the same time, depress the accelerator
pedal all the way.
(3) Measure the time required for the truck to travel 10 m
(33 ft) with a stopwatch.
(4) Conduct the same test for reverse travel, too.
Travel time (no load) 5 seconds, maximum
7-49
5.5 Travel Speed Select Switch

Move the travel speed select switch mounted on the console
box to each position, and make sure that the speed selector D
system functions properly. Move the switch when the truck
is at standstill.
Travel speed select switch
212224
7-50
6. Troubleshooting
Engine • Poor performance • Tune up engine.

• Oil level too low • Refill.
• Air being sucked in on suction side • Retighten or replace gasket.
• Main regulator valve not operating properly • Repair or replace.
• Main regulator valve spring fatigued • Replace.
• Oil pump gears worn, resulting in reduced capacity • Overhaul and check or replace defec-
Torque con- tive parts.
verter • Magnet strainer clogged • Replace.
• Seal rings or O-rings worn • Replace after measuring oil pressure.
• Stator freewheel seized • Replace stator assembly, hub and
Not
enough roller.
output • Blades of running members damaged or rubbing • Repair or replace.
power • Replace bearing.
• Air being sucked in on suction side • Retighten or replace.
• Outlet pressure too low to suppress internal foaming • Readjust.
• Water in oil • Replace oil.
Transmission
• Main pressure too low, resulting in slipping clutches • Readjust after measuring oil pressure.
• Seal rings or O-rings worn • Replace after measuring oil pressure.
• Clutch piston damaged • Replace.
• Friction plate seized or dragging • Replace.
Wheels • High mechanical resistance • Check and adjust brake system.
7-51
• Flexible plates broken • Replace.

Torque con- • Oil pump drive defective • Replace.
verter • Turbine shaft broken • Replace.
• Main pressure too low • Check pump gears for wear or
replace.
• Seal rings worn in servo case • Replace.
No power • O-rings on input shaft worn • Replace.
flow • Plug on input shaft loose or slipped off, resulting in oil • Repair.
leaks
Transmission • Clutch seized • Replace.
• Shafts broken • Replace.
• Clutch drum, particularly snap ring groove, defective • Replace.
• Snap ring fitted to clutch drum broken • Replace.
• Oil line to clutch piston clogged • Clean or replace.
• Shaft splines worn • Replace shaft.
Power train • Broken parts in reduction and differential or front axle • Refer to each section.
7-52
• Flexible plate broken • Replace.

• Bearings damaged • Replace.
Torque con- • Rubbing vanes of running members • Replace.
verter • Bolts loose • Retighten or replace.
• Splines worn • Replace.
• Oil pump worn • Inspection or replace.
• Clutch seized and dragging • Replace clutch plate.
• Bearings worn or seized • Replace.
Transmission • Gears broken • Replace.
• Bolts loose • Retighten or replace.
• Splines worn • Replace.
Abnormal • Oil strainer clogged • Clean or replace.
noise • Main regulator valve spool defective • Wash or replace.
• Restriction in oil pipe • Replace.
Loud noise
• Oil too viscous in cold weather • Replace oil.
• Instruments out of order • Replace.
• Improper oil used • Replace oil.
• Oil strainer clogged • Clean or replace.
• Oil pump defective • Replace.
Excessive oil leaks
Low noise • Main regulator valve spring defective • Replace.
• Main regulator valve spool defective • Repair or replace.
• Air being sucked in • Retighten or replace packing.
• Leaking oil seals • Check lips and sliding surfaces for

wear.
• Replace seals.
• Leaking joint of case • Retighten or replace packing.
• Leaking pipe connection or joint • Repair or replace pipe, gasket and O-
rings.
Oil leaks • Leaking drain plug • Retighten or replace gasket.

• Cracks or blowholes in case • Replace.
Oil blowing out of transmission case
• Water in oil • Replace oil.
• Air being sucked in on suction side • Replace packing and retighten.
• Oil leaks from air breather • Repair.
• Oil level too high • Lower oil level.
7-53
• Oil level too high or too low • Keep correct oil level.
• Oil strainer clogged • Clean or replace.
• Rubbing vanes of running members • Repair or replace.
• Stator freewheel defective • Replace stator assembly.
Torque con- • Air being sucked in • Retighten or replace O-ring.
verter • Water in oil • Replace oil.
• Restriction in oil pipe (resulting in reduced circulation • Repair or replace.
flow)
Oil tem-
perature is • Bearings worn or seized • Repair or replace.
too high • Instruments out of order • Replace.
• Clutches dragging • Replace clutch plates.
Transmission
• Bearings worn or seized • Repair or replace.
• Truck not operated properly • Advice user to drive truck properly.
Others
Others • Cooling fan belt damaged • Replace.
• Oil cooler clogged • Clean or replace.
• Brakes grabbing • Check and readjust.
• Main regulator valve defective • Repair or replace valve assembly.

Main pressure is too high • Oil viscosity too high in cold weather • Replace oil.
• Improper oil used • Replace oil.
• Magnet strainer clogged • Clean or replace.

• Oil pump defective • Replace.
• Spring defective in main regulator valve. • Replace.
Main pressure is too low • Main regulator valve spool defective • Repair or replace.
• Air being sucked in • Retighten or replace packing.
• Inching valve out of order • Repair or replace.
7-54
• Magnet strainer clogged • Clean or replace.

• Oil pump worn or defective • Replace.
• Spring defective in main regulator valve. • Replace.
• Main regulator valve spool defective • Repair or replace.
Clutch pressure is too low • Air being sucked in • Retighten or replace packing.
• Inching valve defective • Repair or replace.
• Seal ring broken in servo case • Replace.
• Clutch seal rings broken • Replace.
• Lack of engine power if the speed is slightly low in both • Tune up engine.
forward and reverse drive
Stall speed out of specifi-
• Stator and freewheel defective if the speed is excessively • Replace stator assembly.
cation
low in both forward and reverse drive
• Clutch slipping if the speed is too high • Repair or replace.
• Travel speed select switch in "Fixed 1st speed" position • Move switch to "2"or "D" position.
• Solenoid valve defective • Replace.
No automatic shifting • Solenoid valve inlet orifice clogged • Clean or replace.
• Solenoid valve spool or spring defective • Repair or replace.
• ECU control box internally defective • Check or replace.
Transmission shifts up • Harness open • Repair.

when travel speed select
• Travel speed select switch defective • Replace.
switch is in “Fixed 1st
speed” position
7-55
7. Service Data
7.1 Stall Speed, Hydraulic
DP100 DP120 DP135 DP150 DP160

Truck Model
N N N N N
Stall speed (tolerance: ±100 rpm)
Standard value 1950
rpm
Main pressure, Speed clutch pressure
(engine at 1500±100 rpm) Standard value 0.88 to 1.08 (9.0 to 11.0) [128 to 156]
MPa (kgf/cm2) [psi]
Direction clutch pressure (engine at 1500±100 rpm)
Standard value 0.73 to 0.93 (7.44 to 9.48) [105.9 to 134.9]
MPa (kgf/cm2) [psi]
Torque converter inlet pressure (engine at 1500±100 rpm)
Standard value 0.15 to 0.69 (1.5 to 7.0) [21 to 100]
MPa (kgf/cm2) [psi]
Lubrication line pressure (engine at 1500±100 rpm)
Standard value 0.02 to 0.13 (0.2 to 1.3) [3 to 19]
MPa (kgf/cm2) [psi]
10 m (33 ft) start acceleration (no load) Standard value 5 seconds, maximum
7.2 Pump Boss
DP100 DP120 DP135 DP150 DP160

Truck Model
N N N N N
0 0
Diameter of portion in contact with oil seal 1 Standard value 100 -0.035 (3.94 -0.00138)
200721
7-56
7.3 Pilot Boss
DP100 DP120 DP135 DP150 DP160

Truck Model
N N N N N
-0.007 -0.00028
Diameter of portion in contact with engine flywheel 1 Standard value 20 -0.020 (0.79 -0.00079)
212225
7.4 Oil Pump
DP100 DP120 DP135 DP150 DP160

Truck Model
N N N N N
Side clearance 1 Standard value 0.040 to 0.078 (0.00157 to 0.00307)
Top clearance 2 Standard value 0.3 to 0.345 (0.0118 to 0.0136)
1
212226
7-57
7.5 Stator
DP100 DP120 DP135 DP150 DP160

Truck Model
N N N N N
Outside diameter of clutch hub 1 Standard value 67.951 to 67.97 (2.67523 to 2.6760)
Diameter of clutch rollers 2 Standard value 10.185 to 10.2 (0.40098 to 0.402)
Thickness of thrust washer 3 Standard value 4.95 to 5 (0.1949 to 0.197)
3 4 1 2 5 6 7
212227
7.6 Flexible Plates
DP100 DP120 DP135 DP150 DP160

Truck Model
N N N N N
Face runout of flexible plates 1 Standard value 0.2 (0.008)
(in free state) mm (in.) Service limit 0.5 (0.020)
Distance between end face of torque coverter housing and
Standard value 14.5 (0.57)
mating face of flexible plates 2 mm (in.)
7-58
200725
7-59
7.7 Clutches
DP100 DP120 DP135 DP150 DP160

Truck Model
N N N N N
Thickness of mating plate 1 Standard value 2.3±0.07 (0.091±0.0028)
Thickness of friction plate 2 Standard value 2.6±0.1 (0.102±0.004)
Free movement of friction plate on gear 3
Standard value 0.10 to 0.30 (0.0039 to 0.0118)
(looseness of mating splines) mm (in.)
Width of piston seal ring 4 Standard value 4±0.05 (0.16±0.002)
+0.2 +0.008
Width of seal ring groove in piston 5 Standard value 4 +0.1 (0.16 +0.004 )
68±2 (2.68±0.08)
Free length of clutch spring 6 mm (in.) Standard value
k = 39.1 (3.992) [223.5]
k: Spring constant N/mm (kgf/mm) [lbf/in.]
Service limit 65 (2.56)
6 2 1 3
212228
7-60
7.8 Forward Clutch Shaft, Reverse Clutch Shaft, 1st-Speed/3rd-Speed Clutch Shaft and Servo Case
DP100 DP120 DP135 DP150 DP160

Truck Model
N N N N N
Width of seal ring for each shaft 1 Standard value 2.5±0.05 (0.098±0.0020)
+0.2 +0.008
Width of seal ring groove in each shaft 2 Standard value 2.5 +0.1 (0.098 +0.004)
+0.025 +0.00098
Inside diameter of servo case and clutch shaft in contact with Standard value 35 0 (1.38 0 )
seal ring 3 mm (in.) Service limit 35.2 (1.386)
+0.025 +0.00098
Inside diameter of stator shaft in contact with seal ring 4 Standard value 35 0 (1.38 0 )
Width of clutch piston seal ring for each shaft 5 Standard value 2.5±0.05 (0.098±0.0020)
+0.2 +0.008
Width of clutch piston seal ring groove in each shaft 6 Standard value 2.5 +0.1 (0.098 +0.004)
0 0
Width of seal ring 7 mm (in.) Standard value 2.4 -0.1 (0.094 -0.0039)
+0.1 +0.0039
Width of seal ring groove 8 mm (in.) Standard value 2.5 0 (0.098 0 )
Tightening torque for lock nut 9
Standard value 294 to 392 (30 to 40) [217 to 289]
N•m (kgf•m) [lbf•ft]
1, 2 3 5, 6
7, 8
9 4
212230
7-61
7.9 Backlash of Gears
DP100 DP120 DP135 DP150 DP160

Truck Model
N N N N N
Input gear and forward and reverse gears 1 mm (in.) Standard value 0.12 to 0.28 (0.0047 to 0.0110)
Forward gear and reverse and 1st-speed/3rd-speed gears 2
Standard value 0.14 to 0.32 (0.0055 to 0.0126)
mm (in.)
2nd-speed gear and output gear 3 mm (in.) Standard value 0.12 to 0.28 (0.0047 to 0.0110)
1st-speed gear and output gear 4 mm (in.) Standard value 0.13 to 0.30 (0.0051 to 0.0118)
3rd-speed gear and output gear 5 mm (in.) Standard value 0.13 to 0.30 (0.0051 to 0.0118)
Pump drive gear and idler gear 6 mm (in.) Standard value 0.12 to 0.26 (0.0047 to 0.0102)
PTO drive gear and idler gear 7 mm (in.) Standard value 0.12 to 0.26 (0.0047 to 0.0102)
1 6
2 7
3
2
2
1
3
5
4
3 1
212229
7-62
7.10 Control Valve
DP100 DP120 DP135 DP150 DP160

Truck Model
N N N N N
36.5 (1.44)
Free length of selector valve spring 1 mm (in.) Standard value
k = 5.658 (0.577) [32.3]
59.5 (2.34)
Free length of differential valve spring 2 mm (in.) Standard value
k = 2.311 (0.2357) [13.2]
125.5 (4.94)
Free length of accumulator valve outer spring 3 mm (in.) Standard value
k = 5.363 (0.5469) [30.6]
170.5 (6.71)
Free length of accumulator valve inner spring 4 mm (in.) Standard value
k = 4.128 (0.4210) [23.5]
32.5 (1.28)
Free length of direction valve springs 5 mm (in.) Standard value
k = 8.616 (0.8786) [49.2]
5 5
2 1
4
3
212231
7-63
DP100 DP120 DP135 DP150 DP160

Truck Model
N N N N N
107 (4.21)
Free length of main regulator valve spring 1 m (in.) Standard value
k = 4.99 (0.5087) [28.5]
212232
7-64
7.12 Inching Pedal Control
DP100 DP120 DP135 DP150 DP160

Truck Model
N N N N N
Inching pedal height (from frame to top end of pedal) 1
Standard value 178 (7.01)
mm (in.)
212233
7-65
FRONT AXLE AND REDUCTION DIFFERENTIAL
1. Specifications ............................................................................................................... 8-3
2. Structure....................................................................................................................... 8-4
2.1 Outline (DP100N to DP150N) ............................................................................................................... 8-4
2.1.1 Hub reduction .............................................................................................................................................. 8-5
1
2.1.2 Reduction differential .................................................................................................................................. 8-6
2.2 Outline (DP160N).................................................................................................................................. 8-7 2
2.2.1 Hub reduction .............................................................................................................................................. 8-8
2.2.2 Wet type wheel brake.................................................................................................................................. 8-9
2.2.3 Brake cooling system ................................................................................................................................ 8-10
3
2.2.4 Reduction differential ................................................................................................................................ 8-11
4
3.1 Front Wheels (Tires) ........................................................................................................................... 8-12
3.1.1 Preparation................................................................................................................................................ 8-12 5
3.1.2 Removal .................................................................................................................................................... 8-13
3.1.3 Installation ................................................................................................................................................. 8-14
3.2 FRONT AXLE AND REDUCTION DIFFERENTIAL............................................................................ 8-15
6
3.2.1 Preparation................................................................................................................................................ 8-15
3.2.2 Removal .................................................................................................................................................... 8-16 7
3.2.3 Installation ................................................................................................................................................. 8-18
8
3.3 Reduction differential .......................................................................................................................... 8-19
3.3.1 Preparation................................................................................................................................................ 8-19
8
3.3.2 Removal .................................................................................................................................................... 8-19
3.3.3 Installation ................................................................................................................................................. 8-20
9
4.1 Hub reduction (DP100N to DP150N) .................................................................................................. 8-21 10
4.1.1 Preparation (on-vehicle condition) ............................................................................................................ 8-21
4.1.2 Disassembling the hub reduction .............................................................................................................. 8-21
4.1.3 Removing the wheel brake........................................................................................................................ 8-23
11
4.1.4 Inspection and Repair ............................................................................................................................... 8-24
4.1.5 Installing the wheel brake.......................................................................................................................... 8-25 12
4.1.6 Reassembling the hub reduction............................................................................................................... 8-26
4.2 Hub reduction (DP160N)..................................................................................................................... 8-28
4.2.1 Disassembling the hub reduction .............................................................................................................. 8-28 13
4.2.2 Disassembling the wheel brake ................................................................................................................ 8-30
4.2.4 Reassembling the wheel brake ................................................................................................................. 8-32
14
8-1
4.2.5 Reassembling the hub reduction............................................................................................................... 8-33

4.3.1 Preparation................................................................................................................................................ 8-38
4.3.2 Disassembling the differential gear assembly ........................................................................................... 8-39
4.3.3 Disassembling Reduction & Parking Brake Assembly .............................................................................. 8-40
4.3.5 Reassembling the differential assembly.................................................................................................... 8-42
4.3.6 Adjustment of reduction pinion preload ..................................................................................................... 8-45
4.3.7 Contact adjustment between the gear and pinion teeth ............................................................................ 8-46
4.3.8 Reassembly of reduction & parking brake assembly ................................................................................ 8-50
4.3.9 Installing reduction differential................................................................................................................... 8-52
6. Service Data............................................................................................................... 8-54

6.1 Front axle (DP100N to DP150N) ........................................................................................................ 8-54
6.2 Front axle (DP160N) ........................................................................................................................... 8-56
8-2
1. Specifications

Gear type Hypoid gear
Reduction gear
Gear type Planetary gear
Final drive
Housing type Banjo
Differential Gear type and Large Straight bevel gear × 2
number Small Straight bevel gear × 4
Front axle type Full floating tube type
Suspension method Fixed to frame
Dry brake Standard -
Wheel brake
Wet brake Option Standard
8-3
2. Structure
2.1 Outline (DP100N to DP150N)
13 14 15 16
11 1
8
12 10 9 4
5 3 7
212286
1 Front axle housing 9 Differential pinion

2 Differential case 10 Differential gear
3 Input flange 11 Axle shaft
4 Parking brake bracket 12 Hub reduction
5 Parking brake assembly 13 Planetary gear
6 Parking brake drum 14 Ring gear
7 Reduction pinion 15 Front wheel hub
8 Reduction gear 16 Dry type wheel brake
This front axle is a banjo-shaped full floating type mounted

to the front of the vehicle frame, and the final drive system
is a planetary gear type.
8-4
2.1.1 Hub reduction
8 10 11 13 15 17 18 19 16 20
4
3
14 12 2 1
212287
1 Front axle housing 11 Nut

2 Axle shaft 12 Lock plate
3 Sun gear 13 Tapered roller bearing
4 Cover 14 Front wheel hub
5 Planet carrier 15 Tapered roller bearing
6 Planet pin 16 Oil seal retainer
7 Steel ball 17 Oil seal
8 Roller bearing 18 Brake drum
9 Planetary gear 19 Oil deflector
10 Ring gear 20 Dry type wheel brake
The front axle housing has a dry type wheel brake mounted.
8-5
2.1.2 Reduction differential
23 21 19 20 22
21
23
25 25
24
24
22
16
17 1
15 13
18
2
4
3
5
6
7
10
11 12
8 14 212288
1 Differential carrier 10 Lever 19 Spider

2 Shim 11 Parking brake drum 20 Differential pinion
3 Bearing retainer 12 Adjuster 21 Differential gear
4 Tapered roller bearing 13 Reduction pinion 22 Tapered roller bearing
5 Tapered roller bearing 14 Self-locking nut 23 Bearing cap
6 Parking brake bracket 15 Roller bearing 24 Side bearing nut
7 Oil seal 16 Differential case 25 Lock plate
8 Input flange 17 Differential case
9 Parking brake assembly 18 Reduction gear
The reduction differential is a single reduction type consist-

ing of a reduction pinion and a reduction gear.
The reduction pinion has a parking brake drum mounted via
the input flange, and the parking brake bracket has a park-
ing brake assembly mounted.
8-6
2.2 Outline (DP160N)
13 14 15 16
11 1
8
10 9 4
12
5 3 7
212289
1 Front axle housing 9 Differential pinion

2 Differential case 10 Differential gear
3 Input flange 11 Axle shaft
4 Parking brake bracket 12 Spindle
5 Parking brake assembly 13 Planetary gear
6 Parking brake drum 14 Ring gear
7 Reduction pinion 15 Front wheel hub
8 Reduction gear 16 Wet type wheel brake
This front axle is a banjo-shaped full floating type mounted

to the front of the vehicle frame, and the final drive system
is a planetary gear type.
8-7
2.2.1 Hub reduction
8 10 11 13 15 18 17 16 19
4
3
14 12 2 1
212290
1 Front axle housing 11 Nut

2 Axle shaft 12 Lock plate
3 Sun gear 13 Tapered roller bearing
4 Cover 14 Front wheel hub
5 Planet carrier 15 Tapered roller bearing
6 Planet pin 16 Seal retainer
7 Steel ball 17 Floating seal
8 Roller bearing 18 Brake hub
9 Planetary gear 19 Wet type wheel brake
10 Ring gear
The front axle housing has the wet type wheel brake
mounted.
8-8
2.2.2 Wet type wheel brake
14
11 10 9 2 8 7 6 3 4 1
Brake oil
13 12
212291
1 Spindle 6 End plate 11 Brake hub

2 Brake housing 7 Mating plate 12 Floating seal
3 Brake piston 8 Friction plate 13 Seal retainer
4 Bolt 9 Brake cover 14 Wheel hub
5 Return spring 10 Dust seal
The wet type wheel brake consists of brake housing, brake The mating plate with outer teeth is supported by the hous-
piston, plate and brake hub. ing as it engages with the inner teeth of the brake housing,
The brake housing is bolted down to the spindle which has while the friction plate with inner teeth engages with the
been mounted on the axle housing. outer teeth of the brake hub and rotates together with the
Into the circular grooves provided on the brake housing and wheel hub.
spindle, a piston is assembled and supported in position by The flange part of the spindle has a brake oil port provided
the return spring. and is attached with connectors and bleeder screws. Also,
The brake hub is bolted down to the wheel hub so it can each part of sliding surfaces to seal the brake oil and mount-
rotate together with the wheel hub. ing surfaces is attached with piston seals and O-rings.
8-9
2.2.3 Brake cooling system
IN
A
B
OUT
B
212292
Brake disc is cooled by a forcible circulation of brake cool-

ing oil.
This spindle is provided with inlet and outlet ports for cool-
ing oil.
8-10
2.2.4 Reduction differential
23 21 19 20 22
21
23
25 25
24
24
22
16
17 1
15 13
18
2
4
3
5
6
7
10
11 12
8 14 212288
1 Differential carrier 10 Lever 19 Spider

2 Shim 11 Parking brake drum 20 Differential pinion
3 Bearing retainer 12 Adjuster 21 Differential gear
4 Tapered roller bearing 13 Reduction pinion 22 Tapered roller bearing
5 Tapered roller bearing 14 Self-locking nut 23 Bearing cap
6 Parking brake bracket 15 Roller bearing 24 Side bearing nut
7 Oil seal 16 Differential case 25 Lock plate
8 Input flange 17 Differential case
9 Parking brake assembly 18 Reduction gear
The reduction differential is a single reduction type consist-

ing of a reduction pinion and a reduction gear.
The reduction pinion has a parking brake drum mounted via
the input flange, and the parking brake bracket has a park-
ing brake assembly mounted.
8-11

3.1 Front Wheels (Tires)
3.1.1 Preparation
(1) Loosen each outer wheel nut about two turns.
(2) Block the rear wheels.
(3) Lift the vehicle from the ground at the front wheels
using either of the following methods.
(a) Jacking
Set the jack at the right and left front axle mounting
parts of the frame to jack up the vehicle evenly for both
the right and left sides.
(b) Hoisting
Fasten a hoist to the mast, and lift the mast to raise the
front end of the truck.
WARNING
After raising the front end with either of the meth-
ods, place jack stands under the frame to prevent
212265
the truck from falling.
8-12
3.1.2 Removal
1 Extension bracket 6
5
2 Wheel nut
3 Clamp
4 Wedge band
5 Outer wheels (tires) 4
7
6 Spacer 1
7 Extension valve
8 Inner wheels (tires) 8
2
3 210371
(1) Outer wheels (tires)

(a) Have the extension valve come to the top.
(b) Deflate the tire.
CAUTION
Never close your face to the tire, since it is high-
pressured.
(c) The wedge band should be removed while being

impacted with a hammer via a protective patch.
210373
(d) Support the vehicle at the lower side of the outer tires
either using a small-type fork lift or applying the spe-
cial tool tire handler there.
Special tool needed
Tire handler Banzai WD-5500
(e) Remove the wheel nuts to remove the outer wheels

(tires).
(2) Inner wheels (tires)

(a) Support the inner wheels (tires) in the same way as for
the outer tires.
(b) Remove the spacer.
(c) Pull the inner wheels (tires) out to the end face of the
brake hub, and disconnect the extension pipe from the
air valve.
(d) Remove the inner wheels (tires).
210375
8-13
3.1.3 Installation
(1) Inner front wheels (tires)
(a) Make sure that the air valve set groove of brake hub is
aligned with the positioning boss on the rim.
(b) When the inner front wheel goes all the way to the
brake hub end face, mount the extension valve on the
air valve.
(c) After pressing-in the inner front wheel to the specified
position, take some measures to prevent the inner front
wheel from falling down using stopper blocks, etc.
(2) Wheel nut
Wheel nuts should be tightened to the specified torque
evenly so that the runout of wheels can be avoided as
1 4
much as possible.
6 7
539±49 N•m (55±5 kgf•m)
Tightening torque
[398±36 lbf•ft]
9 2
CAUTION 10
3
Wheel nuts should be tightened in the correct 8 5
order as instructed by the right-hand side figure.
210376
(Numbers show the order of tightening.)
(3) Retightening of wheel nuts

(a) Test-run the truck for about 10 minutes after complet-
ing the service work to check for forward/reverse drive
and braking.
(b) Use a torque wrench to re-tighten all the wheel nuts to
the specified torque.
8-14
3.2 FRONT AXLE AND REDUCTION DIFFEREN-

TIAL
3.2.1 Preparation
(1) Block the rear wheels.
(2) Remove the mast assembly while referencing the chap-
ter of "Mast and Fork".
(3) Remove the front wheels while referencing the section
of "Front Wheels".
(4) Insert solid stands under the frame to prevent the truck
from falling.
(5) Drain the front axle oil with the following procedure.
(a) Turn both the right and left wheel axles by hand to
make the drain plug (right or left) of the wheel hub
cover take the lowest position. On the other wheel hub
cover, remove the plugs located at higher positions
than the center for air bleeding.
(b) Place containers sufficient for the quantity of oil under
each drain, then drain the oil by removing the drain
plugs of the axle housings and wheel hub covers.
25 liters
Capacity (approximate) 212293
(6.6 U.S. gal.)
8-15
3.2.2 Removal
1 2 4
A
B
B A
3
C
The number shows removal sequence.

212294
1 Wheel brake pipe 4 Universal joint

2 Brake cooling pipe (DP160N) 5 Front axle
3 Parking brake wire
(1) Wheel brake pipes (right and left)

After having disconnected the wheel brake pipes, cover
the openings of the wheel cylinder and pipes to prevent
dirt from getting inside them.
(2) Brake cooling pipe (DP160N)
After having disconnected the wheel brake pipes, cover
the connector to prevent dirt from getting inside them.
8-16
(3) Universal joint

(a) Fasten the universal joint to the transmission body with Transmission
a rope, etc.
Disconnect here.
NOTE
If the universal joint is separated from the transmission
body, the transmission oil will flow outside.
(b) Disconnect the universal joint at the input flange side

of the reduction differential.
204585A
(4) Front axle

(a) Use a service lift truck and firmly secure the lower part
of the front axle with the right and left forks.
Maximum load of service
Truck model
lift truck.
DP100N to DP150N 1350 kg [3000 lb]
DP160N 1500 kg [3300 lb]
WARNING
As the differential part is not at the center of the
right to left span of the front axle, firmly secure it
to prevent from falling on separation.
(b) Remove the mounting bolts, then operate the service

lift truck to remove the front axle.
NOTE
If any service lift truck is not available, use the following
procedure for this removal.
(a) Always apply some protective cloth before fastening a
hoist to and lifting the mast support bearings of the
axle housing with a chain or wire rope.
(b) Remove the mounting bolts, then lift the front axle to
remove it.
8-17
3.2.3 Installation
(1) Torque
Tighten the mounting bolts of the following parts to
each specified torque.
(a) Front axle
640±96 N•m (65.3±9.8 kgf•m)
Tightening torque
[472±71 lbf•ft]
(b) Universal joint

61 to 81 N•m (6.2 to 8.3 kgf•m)
Tightening torque
[44.7 to 59.3 lbf•ft]
(2) Operating effort of parking brake lever

After installing the parking brake wire, make sure that
the operating effort of the parking brake lever is the
standard value.
Parking brake lever　 245 to 294 N (25 to 30 kgf)

operating effort [55 to 66 lbf]
(3) Oil supply to the front axle

(a) Position the level mark of either the right or left cover
to be horizontal.
(b) Remove the level plug located at the side of the level
mark. For the wheel hub cover at the opposite position,
remove the level plug located in the higher positions
than the center for air bleeding.
(c) Remove the level plug located at the differential side of
the axle housing, then supply oil through the plug hole.
Recommended oil: Gear oil
212295
(API service classification GL-4) SAE 90
25 liters
Capacity (approximate)
(6.6 U.S. gal.
(4) Bleeding brake oil line

(a) When the assembly is completed, bleed air in the cir-
cuit while referencing to the chapter of "Brake Sys-
tem".Check also for oil leaks.
NOTE
This air bleeding operation will be easier, if it is performed
before installing the front wheels and mast.
8-18
3.3 Reduction differential

3.3.1 Preparation
(1) Remove the front axle while referencing the section of
"Front Axle".
(2) Lay the front axle housing with the reduction differen-
tial side facing upward using the frame mounting part
of the axle housing.
3.3.2 Removal
2 3
212296
1 Wheel hub cover (right and left) 3 Reduction differential

2 Axle shaft (pull it outward approx. 150 mm [5.9 in.].)
(1) Axle shaft (2) Reduction differential

Remove the wheel hub cover and drive the sliding ham- (a) Drive the anchor bolt in one of the universal joint
mer in the screw hole (M10 × 1.25) in the end of the axle mounting holes and put a wire rope there, and tension
shaft to pull it out approx. 150 mm (5.9 in.). the rope with a crane.
(b) Remove the mounting bolts, then lift the reduction dif-
ferential to remove it.
8-19
3.3.3 Installation
(1) Reduction differential

(a) Check for any soils or damages on the reduction differ-
ential and axle hosing mounting surfaces.
(b) Coat liquid packing on the mounting surfaces.
Liquid packing (Three Bond No.1104)
(c) Lift the reduction differential to accommodate it in the

front axle housing and tighten the mounting bolts to the
specified torque.
Bolt length Tightening torque
118±12 N•m (12±1.2 kgf•m)
37 mm (1.46 in.)
[87±9 lbf•ft]
132±14 N•m (13.5±1.4 kgf•m)
31 mm (1.22 in.)
[98±10 lbf•ft]
CAUTION
Bolt tightening torque varies depending on the
length under the neck. Be sure to tighten to an
appropriate torque.
(2) Wheel hub cover

(a) Replace the gasket with new one.
(b) Tighten the mounting bolts to the specified torque.
57±5.9 N•m (5.8±0.6 kgf•m)
Tightening torque
[42±4 lbf•ft]
8-20

4.1 Hub reduction (DP100N to DP150N)
4.1.1 Preparation (on-vehicle condition) (1) Remove the front wheels while referencing the section
of "Removing Front Wheels".
NOTE (2) Drain the oil while referencing the section of "Remov-
Hub reduction can be disassembled while it is installed on ing Front Axle and Reduction Differential".
the vehicle. If this is the case, remove the front wheels
(tires) according to the procedure of "Removing Front
Wheels (Tires)".
4.1.2 Disassembling the hub reduction
The number shows disassembling sequence.
7
8
7
14
A 6 15
16
17 B
5
13
18 10
4 12
A
2 11
9
1
3
212297
1 Wheel hub cover, Gasket 10 Axle nut

2 Axle shaft, 11 Ring gear
3 Sun gear, Snap ring 12 Tapered roller bearing (inner race) [11]
4 Sleeve 13 Front wheel hub
5 Planet carrier, O-ring 14 Oil deflector [15]
6 Planet pin, Steel ball [5] 15 Brake hub [13]
7 Thrust washer [5] 16 Oil seal [13]
8 Planetary gear, Needle roller bearing [5] 17 Tapered roller bearing (outer race) [13]
9 Lock plate 18 Tapered roller bearing (outer race) [13]
NOTE
[ ] shows the number of each place to remove from.
8-21
(1) Axle shaft

Drive the sliding hammer into the screw hole (M10 ×
1.25) on the edge face, and turn it to remove the sun gear
and snap ring as a whole.
(2) Planet carrier

The planet carrier must be removed by lifting it with a
crane.
(3) Axle nut Unit: mm (in.)
0. 0
)
(Ø Ø2
79
Attach the socket wrench (special tool) and remove the 65(2.56)
nut making use of an impact wrench. 25(0.98)
Special tool 19(0.75) 3(0.12)
.5 7
0)
(0 12.
Socket wrench: 92267-00200
Width across flats: 144 mm (5.669 in)
Ø162(Ø6.38)
Ø155(Ø6.10)
Ø75(Ø2.95)
)
02
(Ø2.56)
6.
Ø
Ø65
3(
(4) Ring gear
15
Ø
(a) Utilize the bolt holes (M16 × 1.5: 2 places) and drive-
in two jack bolts into them and turn the bolts evenly to
pull out the ring gear. 72(2.83) 30(1.18) 60(2.36)
144(5.67) 90(3.54)
212269
(5) Front Wheel Hub and Brake Hub
(a) Support the hub drum assembly with a transmission
jack.
(b) Remove the assembly using a wheel hub puller (special
tool).
8-22
4.1.3 Removing the wheel brake

The number shows removing sequence.
1 Tapered roller bearing (inner race)
2 Oil seal retainer, O-ring
3 Wheel brake assembly
3
2
212298
(1) Tapered roller bearing (inner race)

Use the supplied bearing puller to remove the bearing
together with the seal retainer.
(2) Wheel brake assembly

For disassembly, inspection and reassembly of the
wheel brake assembly, refer to the chapter of "BRAKE
SYSTEM".
204590
8-23

(1) Axle shaft (5) Planet carrier
Apply a dial indicator at the middle of the axle shaft, (a) Check the planetary gear roller inside surface and
and rotate the shaft to measure the deflection. planet pin outside surface for wear or damage.
Deflection of axle shaft Service 1.0 mm Standard 58
+0.029
+0.010 mm
(1/2 of dial indicator reading) limit (0.039 in.) value +0.0011
Planetary gear (2.28 +0.0004 in.)
roller inside diameter
(2) Axle housing Service 57.96 mm
(a) Check the mast support bearing contact surfaces for limit (12.2819 in.)
0
wear or damage. Standard 50-0.011 mm
(b) Check the oil seals for wear and damage. Outside diameter of value 0
(1.97 -0.0004 in.)
(c) Check the axle housing for distortion, dents, or other planet pins
Service 49.96 mm
defects. Also check the welds for cracks. limit (1.967 in.)
(b) Check the thrust washers for wear or damage.

(3) Front wheel hub
(a) Check the oil seals for wear and damage. Standard 1.2±0.06 mm
Thrust washer value (0.047±0.002 in.)
(b) Check the tapered roller bearing (outer race) for wear
thickness Service 0.8 mm
or damage.
limit (0.031 in)
(4) Brake drum (6) Others

(a) Check the inside surface for wear or damage. (a) Check the outside surface of oil seal retainer for wear
+0.2 and damage.
Standard 420 0 mm
value +0.008 (b) Check the tapered roller bearing (inner race) for wear
Brake drum inside (16.535 0 in.)
diameter or damage.
Repair or 424 mm
service limit (16.69 in.)
8-24
4.1.5 Installing the wheel brake
1 Wheel brake assembly

2 Oil seal retainer, O-ring The number shows installing sequence.
3 Tapered roller bearing (inner race) 1
3 2
212299
(1) Tapered roller bearing (inner race)

Use the installer to drive-in the brake assembly together
with the oil seal retainer.
204592
8-25
4.1.6 Reassembling the hub reduction
The number shows assembling sequence.
13 7 9 8 2 3 1 6 5
14
12
17
16
11
15
15 10 11 4
212300
1 Front wheel hub 10 Lock plate
2 Tapered roller bearing (outer race) [1] 11 Axle shaft, Sleeve
3 Tapered roller bearing (outer race) [1] 12 Planetary gear [15]
4 Oil seal [1] 13 Roller bearing, Thrust washer [15]
5 Brake hub [1] 14 Planet pin, Steel ball [15]
6 Oil deflector [5] 15 Planet carrier, O-ring [1]
7 Ring gear 16 Sun gear [11]
8 Tapered roller bearing (inner race) [7] 17 Planetary gear cover, Gasket
9 Nut
NOTE
[ ] shows the number of each place to reassemble to.
(1) Front wheel hub

(a) Tighten the brake drum fastening nuts to the specified Liquid gascket
torque.
359±36.3 N•m (37±3.7 kgf•m)
Tightening torque
[263±26.5 lbf•ft]
(b) Apply a thin coat of liquid packing on the mating sur-

face of the oil deflector before assembly.
210386
8-26
(2) Preload adjustment

(a) After temporarily tighten the nut, hook a spring scale to
one of the hub bolts and measure the force applied in
the tangential direction.
Preload for wheel hub
127.5 to 166.7 N (13 to 17 kg)
bearing (force applied in
[28.7 to 37.5 lbf]
tangential direction)
NOTE
However, it is advisable to aim at a value of tangential force
(preload) in the lower tolerance limit, if the bearings having 212330
been used long are re-assembled.
(b) If the force applied in the tangential direction (preload)

does not meet the standard value, re-adjust it by means
of varying the amount of turning-in the nut.
(c) After completing the preload adjustment, assemble the
lock plates into places and tighten the mounting bolts
to the specified torque.
16.7±2.0 N•m (1.7±0.2 kgf•m)
Tightening torque
[12.2±1.5 lbf•ft]
(3) Planet carrier

(a) Before installing the planet pins into the carrier, coat
the inside surfaces of the planetary gear bushings with
oil to be used.
(b) Tighten the mounting bolts of the planet carrier to the
specified torque.
93.2±9.8 N•m (9.5±1.0 kgf•m)
Tightening torque
[68.3±7.2 lbf•ft]
(4) Planetary gear cover

(a) Tighten the mounting bolts of the planetary gear cover
56.9±5.9 N•m (5.8±0.6 kgf•m)
Tightening torque
[41.7±4.3 lbf•ft]
8-27
4.2 Hub reduction (DP160N)

4.2.1 Disassembling the hub reduction

14
B
15
17
16
18
19
7
8
7
B
21 9
A 6
5 20
22
13
4
A
12 11
10
2
1
3
212301
1 Wheel hub cover, Gasket 12 Ring gear

2 Axle shaft 13 Tapered roller bearing (inner race) [12]
3 Sun gear, Snap ring [3] 14 Brake hubs (including from 15 to 22)
4 Sleeve 15 Floating seal [14]
5 Planet carrier, O-ring 16 Seal retainer
6 Planet pin, Steel ball [5] 17 Floating seal [16]
7 Thrust washer [5] 18 O-ring [16]
8 Planetary gear, Needle roller bearing [5] 19 Tapered roller bearing (inner race)
9 Wheel brake (including from 10 to 22) 20 Wheel hub
10 Lock plate 21 Tapered roller bearing (outer race) [20]
11 Axle nut 22 Tapered roller bearing (outer race) [20]
NOTE
8-28
(1) Axle shaft

Drive the sliding hammer into the screw hole (M10 ×
1.25) on the edge face, and turn it to remove the sun gear
and snap ring as a whole.
(2) Planet carrier
The planet carrier must be removed by lifting it with a
crane.
(3) Wheel brake
(a) Put a wire rope to the wheel hub and brake housing and
support them by lifting with a crane.
(b) Remove the spindle mounting bolts, and remove the
spindle as an integral assembly including the wheel
hub.
(c) Lay aside the removed assembly with the spindle side
down.
212302
(4) Axle nut

Attach the socket wrench (special tool) and remove the
Unit: mm (in.)
0. 0
nut making use of an impact wrench.
)
(Ø Ø2
79
65(2.56)
Special tool
25(0.98)
Socket wrench: 92267-00200
19(0.75) 3(0.12)
.5 7
Width across flats: 144 mm (5.669 in)
0)
(0 12.
Ø162(Ø6.38)
Ø155(Ø6.10)
Ø75(Ø2.95)
)
02
(Ø2.56)
6.
Ø
Ø65
3(
15
Ø
72(2.83) 30(1.18) 60(2.36)

144(5.67) 90(3.54)
212269
(5) Ring gear

(a) Utilize the bolt holes (M16 × 1.5: 2 places) and drive-
in two jack bolts into them and turn the bolts evenly to
pull out the ring gear.
(b) Remove the jack bolts to drive the anchor bolts in the
bolt holes (M16 × 1.5: 2 places).
(c) Put a wire rope to the anchor bolts and lift the ring gear
to remove.
212382
8-29
(6) Wheel hub and brake hub

(a) Prepare the special tool.
Bolt
Part No. Part name Adjusting plate
92E68-01000 Wheel hub puller Spring washer
NOTE
Use the following parts for this work.
92E68-00300: Wheel hub guide
92E68-00400: Adjusting plate
92E68-00600: Bolt stopper
45722-94700: Jack bolt
F1035-12025: Bolt
F2515-12000: Spring washer Wheel hub guide
Bolt stopper
(b) Install the bolt stopper on the top end of the spindle.
(c) Install the adjusting plate on the wheel hub guide, and
secure them with the bolts and spring washers.
(d) Install the wheel hub guide in the wheel hub, and
NOTE
Secure the wheel hub guide with the bolts and spring wash-
ers used to secure the planet carrier.
212376
(e) Drive the eye bolts in the bolt holes of the wheel hub
guide (M10 × 1.25: 2 places) and put a wire rope, and
Juck bolt
then lift the wheel hub guide with a crane.
(f) Screw a jack bolt into the wheel hub guide. Screw the
bolt to the bottom end and remove the tapered roller
bearing inner race from the spindle.
(g) Lift the wheel hub and brake hub to remove them. Lay
aside the removed assembly with the wheel hub side
down.
(h) Remove the mounting bolts of the brake hub, and dis-
assemble the wheel hub and brake hub.
212377
8-30
4.2.2 Disassembling the wheel brake
The number shows disassembling sequence. 6
9
1
12
4
11
13 7
3 10
5
11
212304
1 Brake cover 6 Snap ring 11 O-ring [10]

2 Dust seal [1] 7 Bolt, Spring 12 Spindle
3 Mating plate 8 Brake piston 13 O-ring [12]
4 Friction plate 9 Piston seal [8]
5 End plate 10 Brake housing
NOTE
8-31
4.2.3 Inspection and Repair (5) Plates for wheel brake

(1) Axle shaft (a) Measure the thickness of each plate, and replace if any
Apply a dial indicator at the middle of the axle shaft, has reached the service limit.
and rotate the shaft to measure the deflection. 4.66±0.15 mm
Standard value
Repair or Friction plate (0.184±0.006 in.)
Deflection of axle shaft (1/2 0.2 mm
service Service limit 4.0 mm (0.157 in.)
of dial indicator reading) (0.0039 in.)
limit
3.1±0.1 mm
Standard value
Mating plate (0.122±0.004 in.)
(2) Axle housing
Service limit 3.0 mm (0.118 in.)
(a) Check the mast support bearing sliding surfaces for
3.4±0.3 mm
wear or damage. Standard value
End plate (0.134±0.012 in.)
(b) Check the axle housing for distortion, dents, or other
defects. Also check the welds for cracks.
(3) Front wheel hub (b) Replace any gear whichever has deficiency in the num-
(a) Check the oil seals for wear and damage. ber of teeth or pluck (chipping) in the tooth faces.
(b) Check the tapered roller bearing (outer race) for wear (c) Replace any gear which has a flaking or damage in the
or damage. facing surfaces.
(d) Also replace any gear which has a crack, damage or
(4) Planet carrier distortion.
(a) Check the needle roller bearing inside surface and
planet pin outside surface for wear or damage. (6) Brake housing, Brake hub
+0.029
(a) Replace any gear which has a wear or damage in the
Standard +0.010 mm
58
tooth faces.
Needle roller bearing value +0.0011
(2.28 +0.0004 in.)
inside diameter
Service 57.96 mm
(7) Floating seal
limit (2.282 in.)
(a) Replace any seal which has a fault or damage in the lip
0
Standard 50-0.011 mm surfaces.
Outside diameter of value 0
(1.97 -0.0004 in.)
planet pin
Service 49.96 mm (8) Others
limit (1.967 in.)
(a) Check the outer circumference of oil seal retainer for
(b) Check the thrust washers for wear or damage. wear and damage.
(b) Check the tapered roller bearing (inner race) for wear
Standard 1.2±0.06 mm
value (0.047±0.0024 in.) or damage.
Thrust washer
thickness Service 0.8 mm
limit (0.031 in)
8-32
4.2.4 Reassembling the wheel brake
11
10
9 6
8
3
7
4
2
5
1

212305
1 Spindle 7 End plate

2 Brake housing, O-ring 8 Mating plate
3 Brake piston, Piston seal 9 Friction plate
4 Spring 10 Brake cover
5 Bolt 11 Dust seal
6 Snap ring
(1) Brake housing

Tighten the mounting bolts to the specified torque.
176±18 N•m (17.9±1.8 kgf•m)
Tightening torque
[129±13 lbf•ft]
(2) Brake piston

(a) Coat the piston seal with service oil and re-assemble it
with its round side facing outward.
(b) Install the brake piston taking care so as not to damage
the piston seal.
8-33
(3) Plates for wheel brake and brake cover
Friction plate holder

Dust seal
Brake cover
Friction plate
Meating plate
End plate
Continue air supply (after installing brake cover) 212378
(a) Prepare the special tool. (h) When these operations are completed, remove the fric-
Part No. Part name tion plate holder (special tool).
92G68-00100 Friction plate holder
NOTE
Do not stop supplying the compressed air until the installa-
(b) Install the friction plate (special tool) to the spindle.
tion of the hub reduction is completed. If the friction plate is
(c) First install the end plate.
misaligned, the brake hub can not be inserted.
(d) Continue to install the mating plate, then the friction
plate.
NOTE
Make sure to install the plates in the correct order.
(e) Brake cover

Tighten the mounting bolts to the specified torque.
112±10.8 N•m (11.4±1.1 kgf•m)
Tightening torque
[82.6±8.0 lbf•ft]
(f) Dust seal

Tighten the mounting bolts for securing washers to the
specified torque.
16.7±2.0 N•m (1.7±0.2 kgf•m)
Tightening torque
[12.2±1.5 lbf•ft]
(g) Supply the air compressed with the following specified

value from the connector of the brake oil supply mouth
to prevent the friction plate from misalignment.
Air pressure 490 kPa (5 kgf/cm2) [71.1 psi]
8-34
4.2.5 Reassembling the hub reduction

16 20 19 17 13 15 14
13
18
11
14
12
1
10
3 8
6
6
5
212306
1 Wheel hub 11 Axle nut

2 Tapered roller bearing (outer race) [1] 12 Lock plate
3 Tapered roller bearing (outer race) [1] 13 Planetary gear, Needle roller bearing [16]
4 Tapered roller bearing (inner race) [1] 14 Thrust washer [16]
5 Floating seal [8] 15 Planet pin, Steel ball [16]
6 Floating seal [7] 16 Planet carrier, O-ring
7 Seal retainer [1] 17 Axle shaft
8 Brake hub 18 Sleeve
9 Tapered roller bearing (inner race) [10] 19 Sun gear, Snap ring [17]
10 Ring gear 20 Wheel hub cover, Gasket
NOTE
[ ] shows the number of each place to reassemble to.
8-35
(1) Floating seal

(a) Mount a trick ring on the R portion of seal ring.
(b) Make sure that the mold line(s) seen at the outer cir-
cumference of the trick ring is not twisted. If any twist
is observed, separate several portions of the trick ring
from the seal ring to remove the twist.
NOTE
This is because twist in any on the trick ring my cause the
seal performance to be degraded from the uneven bearing
stress, resulting in oil leaks or undesirable suction of for-
212308
eign matters.
(c) Soak the trick ring in the cleaning agent as the entire
surfaces under the level so that all oil films, dusts, and
foreign matters can be washed out.
NOTE
For this operation, always use a volatile cleaning agent suit-
able for cleaning a rubber trick ring and without producing
any residue. Use of inappropriate cleaning agent may cause
the sealing performance to be degraded due to twist or
uneven bearing stress on the trick ring.
(d) Put the floating seal on the brake hub and seal retainer.
(e) Apply a thin coat of service oil on the sealing surface
of the seal ring using a cotton swab, gauze, or finger.
NOTE
Check for any foreign matters adhered on the sealing sur-
face of the seal ring. Note that even a fine piece of lint can
cause the sealing surface to be separated, leading to oil
leaks.
212314
(2) Assembling wheel hub and brake hub

(a) Tighten the mounting bolts of the brake hub to the
specified torque.
366±3.7 N•m (358.9±36.3 kgf•m)
Tightening torque
[268±2.7 lbf•ft]
8-36
(3) Inserting wheel hub and brake hub

(a) Prepare the special tool. Bolt
Part No. Part name Wheel nut
Spring washer
92E68-00000 Wheel hub pusher
Adjusting plate
NOTE
Use the following parts for this work.
92E68-00300: Wheel hub guide
92E68-00400: Adjusting plate
92E68-00500: Adjusting bolt
MC810632 : Wheel nut
F1035-12025: Bolt
F2515-12000: Spring washer Wheel hub guide
(b) Install the adjusting plate on the wheel hub guide, and
Adjusting bolt
(c) Install the adjusting bolt in the wheel hub guide, and
then install the wheel nut.
212379
NOTE
Install the wheel nut until the threaded portion of the adjust-
ing bolt appears a little.
(d) Install the wheel hub pusher (special tool) in the wheel
hub, and secure them with the bolts and spring wash-
ers.
NOTE
Secure the wheel hub pusher with the bolts and spring
washers used to secure the planet carrier.
(e) Drive the eye bolts in the bolt holes of the wheel hub
pusher (M10 × 1.25: 2 places) and put a wire rope, and
then lift the wheel hub guide with a crane.
(f) Lower the wheel hub and brake hub as an integral
assembly to the wheel brake.
212380
8-37
(g) Tighten the wheel nut while loosening the wire rope to
lower integral assembly of wheel hub and brake hub,
Tighten
and install them to the wheel brake.
(h) When the assembly lowers to the bottom, check
whether the dimension in the figure at the right is in the
specified value.
(i) When these operations are completed, remove the
wheel hub pusher (special tool).
(j) Stop the air supply to remove the air hose.
8 mm [0.315 in]
212381
(4) Ring gear

(a) Install the tapered roller bearing (inner race).
(b) Drive the anchor bolt in the jack bolt hole (M12 × 1.75)
and put a wire rope.
(c) Operate the crane to lower the ring gear into the wheel
hub.
(d) Temporarily tighten the axle nut to secure the ring gear,
and remove the anchor bolt.
212382
8-38
(5) Installing into the axle housing

(a) When all the parts so far to the axle nut are assembled,
lift the assembly of wheel hub and wheel brake to
install it into the front axle.
(b) Tighten the mounting bolts of the spindle to the speci-
fied torque.
602±60 N•m (61.4±6.1 kgf•m)
Tightening torque
[135.3±13.5 lbf•ft]
212302
(6) Preload adjustment

(a) After temporarily tighten the nut, hook a spring scale to
one of the hub bolts and measure the force applied in
the tangential direction.
Preload for wheel hub
117.7 to 156.9 N (12 to 16 kg)
bearing (force applied in
[26.5 to 35.3 lbf]
tangential direction)
CAUTION
However, it is advisable to aim at a value of pre-
212316
load in the lower tolerance limit, if the bearings
have long been in service.
(b) If the force applied in the tangential direction (preload)

does not meet the standard value, re-adjust it by means
of varying the amount of turning-in the nut.
(c) After completing the preload adjustment, assemble the
lock plates into places and tighten the mounting bolts
16.7±2.0 N•m (1.7±0.2 kgf•m)
Tightening torque
[12.2±1.5 lbf•ft]
(7) Planet carrier

(a) Before installing the planet pins into the carrier, coat
the needle roller bearing with service oil.
8-39

4.3.1 Preparation
(1) Backlash measurement
Before disassembling the differential gear assembly, ex-
cept for replacing the reduction gear set for a new one,
measure the backlash between the reduction gear and
reduction pinion to help their later reassembly.
Backlash between
reduction bevel gear
value (0.010 to 0.012 in.)
and bevel pinion
CAUTION
200247
When the reduction gear set is to be replaced with
a new one, it is not necessary to measure the
backlash.
(2) Alignment marks (reference)

Put alignment marks on either of the bearing caps, ad-
justment screw and carrier to be useful for subsequent
reassembly.
200241
8-40
4.3.2 Disassembling the differential gear assembly
10
12 8
11 9
3 2
1
212317
1 Lock washer, Lock plate 7 Tapered roller bearing

2 Side bearing nut 8 Differential gear
3 Bearing cap, Lock washer 9 Thrust washer
4 Differential case R.H. 10 Spider
5 Differential case L.H. 11 Thrust washer
6 Reduction gear 12 Differential pinion
(1) Tapered roller bearing

Remove the inner race using a bearing puller.
8-41
4.3.3 Disassembling Reduction & Parking Brake

Assembly
3 2
A 7
B
5 11
6
16
19
18 8
15
B 17 12
10
9 13 14
212318
1 Parking brake drum 11 O-ring

2 Self-locking nut 12 Reduction pinion
3 Input flange 13 Snap ring
4 Parking brake assembly 14 Roller bearing
5 Parking brake bracket 15 Tapered roller bearing (inner race)
6 Oil separator 16 Tapered roller bearing (inner race)
7 Oil seal 17 Tapered roller bearing (outer race)
8 Bearing retainer 18 Collar
9 Shim 19 Tapered roller bearing (outer race)
10 O-ring
(1) Bearing retainer (2) Tapered roller bearing

(a) Utilize the bolt holes for separation (M14 × 1.5: 2 Remove the inner race using a bearing puller.
places) and drive-in jack bolts into them and turn the
bolts evenly to pull out the bearing.
(b) Make sure the thickness of shims which are removed at
the same time and take care so as not to lose them.
8-42
4.3.4 Inspection and Repair (3) Reduction gear, Reduction pinion

(1) Check for any wear or damage on each part. (a) Check the gear teeth for wear, pitting, flaking or chip-
(a) Check the seat formed between the differential case ping.
and tapered roller bearing inner race to carry it to see (b) Minor flaws on the tooth surfaces that may not affect
whether the seat surface is galled or not. the service can be repaired by grinding with an oil
(b) Check the differential case for crack, and check the stone or hand grinder.
sliding surfaces of differential gears and washers for (c) If the damage is excessive, replace the gear and pinion
wear or damage. as one set.
(c) Check the teeth of the differential pinions and bevel
gears for wear, pitting, chipping, galling, etc. Check (4) Parking brake drum
also the washer supporting parts for wear or damage. (a) Check the brake drum inside surfaces for wear and
(d) Check the inside surface of the differential pinion and damage.
outside surface of pinion shaft for wear. (b) When the inside diameter of the drum exceeds the
repair or service limit, replace the drum with a new
Play between differen- Standard 0.169 to 0.278 mm
tial bevel pinion inner value (0.007 to 0.011 in.) one.
diameter and shaft outer Service +0.5
diameter 0.35 mm (0.014 in.) Standard 304.8 0 mm
limit
value (12
+0.020
0 in.)
Inside diameter of drum
(e) Check the differential gear and axle shaft spline for Service 307 mm
wear that may cause excessive play.(Measure this play limit (12.09 in.)
with the differential gear temporarily put through the
axle shaft.)
Free movement of differential
Service 0.5 mm
bevel gears on axle shafts
limit (0.020 in)
(looseness of mating splines)
(2) Differential gear and pinion

(a) Measure the backlash.
Backlash between differ- value (0.004 to 0.012 in.)
ential gear and pinion Service
0.5 mm (0.02 in)
limit
(b) When the backlash exceeds the service limit, replace

the thrust washer with a new one.
8-43
4.3.5 Reassembling the differential assembly

10 14
9 1 3 2 4 5 6 8 7 9
12
11
13
212319
1 Differential case 8 Differential case

2 Thrust washer 9 Tapered roller bearing
3 Differential gear 10 Reduction gear
4 Spider 11 Bearing cap
5 Differential pinion, Washer 12 Lock washer
6 Differential gear 13 Side bearing nut
7 Thrust washer 14 Lock plate
(1) Differential case

(a) Lightly coat Loctite #271 to the mounting bolt sur-
faces.
(b) Tighten the mounting bolts evenly to the specified
torque to avoid uneven tightening result.
196±29.4 N•m (20±3 kgf•m)
Tightening torque
[145±22 lbf•ft]
8-44
(2) Reduction gear

(a) Lightly coat Loctite #271 to the mounting bolt sur-
faces.
(b) Tighten the mounting bolts evenly to the specified
torque to avoid uneven tightening result.
441±69 N•m (45±7 kgf•m)
Tightening torque
[325±51 lbf•ft]
(3) Backlash between differential gear and pinion

Measure the backlash, and if the backlash exceeds the
service limit, replace the thrust washer with a new one.
Backlash between differ- value (0.008 to 0.011 in.)
ential gear and pinion Service 0.5 mm
limit (0.020 in.)
212320
(4) Tentative tightening of bearing cap

(a) Install the bearing cap and install the lock washers and
mounting bolts.
(b) Only temporarily tighten the mountings bolts for the
convenience of the subsequent adjustment.
NOTE
The bearing caps are machined together with the differen-
tial carrier. Identify the right and left caps by referring to the
alignment marks to avoid mistaking between them.
8-45
(5) Adjustment of differential case tapered roller bearing

preload
Check the preload of the sole differential unit before in-
stalling the reduction pinion.
(a) Taking the tapered roller bearing backlash into account,
tighten the side bearing nuts evenly between the right
and left.
(b) Tap the back of the reduction gear with a copper-face
hammer while rotating the gear by hand for running-in.
(c) Wind a wire around the outer circumference of the dif-
ferential case, and hook the wire by a spring scale.
(d) Pull the spring scale outward to read a force (tangential Side bearing
force) just when the differential case begins to rotate.
23 to 32 N
Standard
Tangential force (25 to 35 kgf)
value
[5.2 to 7.2 lbf] A
2.45 to 3.43 N•m
Preload Standard
(25 to 35 kgf•cm )
(reference) value
[1.8 to 2.5 lbf•ft]
210395
(6) Tightening bearing cap
(a) Tighten the mounting bolts evenly to the specified
torque.
294.2±29.4 N•m (30±3 kgf•m)
Tightening torque
[217±21 lbf•ft]
(b) Calk the lock washer after tightening the bolt.
8-46
4.3.6 Adjustment of reduction pinion preload

(1) Tentatively assemble the reduction pinion with the fol-
lowing procedure in order to make sure the preload of
the tapered roller bearing of the reduction pinion.
1 Reduction pinion
3 Bearing retainer 1
4 Tapered roller bearing (outer race) 4
2
5 Tapered roller bearing (outer race)
6 Collar 3
6 5
8 Oil separator
9 Input flange
10 Self-locking nut
9
7 8
(2) Tighten the self-locking nut to the specified torque.
294.2±29.4 N•m (30±3 kgf•m) 10
Tightening torque
[217±21 lbf•ft]
212321
(3) Secure the input flange and apply a rated load from the
top of the pinion.
5 ton (1124 lbf)
(4) Wind a thread around the outer circumference of the
bearing retainer, and pull the end of the thread by
spring scale to read the force just when the bearing
retainer begins to rotate.
30.4 to 43.1 N
Force applied to bearing retainer
(3.1 to 4.4 kgf)
in tangential direction
[6.8 to 9.7 lbf]
(5) If the force applied in the tangential direction falls

within the above mentioned range, the preload also
must be the specified value.
(6) If the force applied in the tangential direction does not
meet the standard value, re-adjust it by means of vary-
ing the thickness of collar(s). There are 25 kinds of
thickness prepared for collars.
Fixed
212322
8-47
4.3.7 Contact adjustment between the gear and pin-

ion teeth
Once assemble the reduction unit into the differential unit
from the condition (tentative assembly) of above described
"Preload adjustment of reduction pinion".
NOTE
You must have completed assembly of the differential unit.
(1) Installing additional parts

1 Roller bearing 1 2
2 Snap ring
3 Machining error adjustment shim
4 Bolt with spring washer
(M12 × 1.25，length below neck: 35 mm [1.38 in.])
NOTE
(1) The above mentioned parts are those which are
installed more to the condition of "Preload adjustment
of reduction pinion".
(2) As the parking brake bracket is not installed, the 3
removed bolts can not be reused. Therefore, always 4

prepare the above mentioned bolts.
212323
8-48
(2) Calculating the thickness of the machining error adjust-

ment shim
If the removed reduction pinion can be reused, insert the
shim that has been installed as-is. When the pinion is to
be replaced with a new one, calculate the required
amount (thickness) of shims with the following proce-
dure.
(a) Once check the current preload, then take an actual
measurement "b" of dimension B.
(b) Obtain difference "c" from the nominal dimension
(53.5mm [2.1063 in.]) of dimension B.
　　　ｃ = 53.5 mm (2.1063 in.) – ｂ
NOTE
(a) Round off to the first digit below decimal point.
A B
(b) If the actual measurement b of dimension B is greater
than the nominal value, c will be a negative value.
(c) Calculate the shim thickness "A" from the following
210736
equation:
Shim thickness A = 0.5 mm (0.0197 in.) + ｃ
(rounded off to the first digit below decimal point.)
(d) Insert an appropriate number of shims as combined to
produce the thickness calculated with the above equa-
tion.
Part No. Thickness
92331-03500 0.2 mm (0.0079 in.)
92335-03600 0.1 mm (0.0039in.)
(3) Installing reduction unit

(a) Lay the differential unit with its reduction & parking
brake assembly mounting side facing upward and
secure it to wooden bars, etc.
(b) Drive-in to set the eyebolt into the universal joint
mounting bolt hole of the input flange.
(c) Put a wire rope to the eye bolt and lift the reduction
unit for assembling. Be careful not to allow the
machining error adjustment shim to fall off.
(d) Tighten the mounting bolts to the specified torque.
128.5±19.6 N•m (13.1±2.0 kgf•m)
Tightening torque
[94.1±14.4 lbf•ft]
8-49
(4) Measurement and adjustment of backlash

(a) Lay the gear assembly with the differential unit comes
to the top and secure it to the wooden bars, etc.
(b) Set the dial indicator so its tip is square to the reduction
gear tooth face.
(c) Move the reduction gear back and forth (in the rotating
direction) by hand to see how the dial indicator hand
swings.
Backlash between reduction 0.20 to 0.28 mm
gear and pinion (0.008 to 0.011 in.)
210397
(d) If the backlash does not meet the standard value, re-
adjust the same amount of turning-in of both the right
BACKLASH To
and left side bearing nuts. increase.
Example: If you loosen the right side nut for one turn, To decrease.
tighten the left side nut more one turn.
CAUTION
To
The amount of turn in or out of the side bearing decrease.
nuts must be equal for both the right and left side
bearing nuts. Difference in the turn-in or -out To increase.
amount between the right and left side bearing To increase.

nuts will make the preload of the differential case
tapered roller bearing vary to come away from the BACKLASH
To decrease.
205611
standard value.
8-50
(5) Contact adjustment of reduction gear

(a) Coat a thin film of red lead uniformly on three to four
reduction gear teeth (both sides).
(b) Rotate the reduction gear back and forth several times
by hand.
(c) Make sure the tooth contact against the table shown
below. If the tooth contact is not appropriate, adjust it.
210398
Tooth Contact Pattern Adjustment

Tooth contact
covers more than
1 1/2 of tooth length Correct tooth contact
Heavy contact at 1. Move gear away from pinion.

toe of tooth 1 2. Move pinion toward gear by
2 2 adding shim(s) to secure correct
backlash.
Heavy contact at 1. Move gear toward pinion.

heel of tooth 2 2. Move pinion away from gear by
3 removing shim(s) to secure correct
backlash.
1
Heavy contact on 1. Slightly move pinion toward gear

face or upper 2 by adding shims.
4 portion of tooth 2. Slightly move gear away from
pinion to secure correct backlash.
1
Heavy contact on 1. Slightly more pinion away from

flank or lower 2 gear by removing shim(s).
5 portion of tooth 1 2. Slightly move gear toward pinion
to secure correct backlash.
NOTE
For toe contact or heel contact, observe contacts on the outer side (convex face) of the reduction gear for judgement. For face
contact or flank contact, repeat the steps above for adjustment until satisfactory tooth contact is obtained.After this adjustment
is completed, make sure the backlash.
8-51
4.3.8 Reassembly of reduction & parking brake

assembly

18
17 1
5 2
4
6
3
8
19
7
10
9 12
11
13
16
14 15 212324
1 Reduction pinion 11 Parking brake bracket

2 Tapered roller bearing (inner race) 12 Oil seal
3 Collar 13 Parking brake assembly
4 Bearing retainer 14 Input flange
5 Tapered roller bearing (outer race) 15 Self-locking nut
6 Tapered roller bearing (outer race) 16 Parking brake drum
7 Tapered roller bearing (inner race) 17 Roller bearing
8 O-ring 18 Snap ring
9 O-ring 19 Machining error adjustment shim
10 Oil separator
8-52
(1) O-ring and oil separator for each part

Before reassembly coat service oil in places.
(2) Oil seal

(a) Prepare the following special tools.
Unit: mm [in.]
[Ø1.38]
Ø35
Special tool
Installer: To be made by dealer (for the dimensions, re-
[Ø3.74 - 0 . 0 0 4 ]
[Ø2.7±0.004]
Ø68.5 ±0.1
Ø95 - 0 . 1
fer to the figure at the right hand.)
0
(b) Make the both two main lips face the inside and apply
grease and service oil between the lips.
(c) Put the oil seal on the installer and insert it into the
parking brake bracket. 15 [0.59]
130 [5.12] 23 [0.91]
Installer
Oil seal
212325
(3) Parking brake assembly

(a) Exercise care for the direction of the parking brake
lever for reassembly.
(b) Tighten the mounting bolts to the specified torque.
145±22 N•m (14.8±2.2 kgf•m)
Tightening torque
[107±16 lbf•ft]
(4) Parking brake drum

Tighten the mounting nuts to the specified torque.
96±15 N•m (9.8±1.5 kgf•m)
Tightening torque
[71±11 lbf•ft]
(5) Self-locking nut

(a) Tighten the self-locking nut to the specified torque.
249±29 N•m (30±3 kgf•m)
Tightening torque
[217±22 lbf•ft]
(b) After each tightening, calk each place with a punch.
8-53
4.3.9 Installing reduction differential
2 3
212326
1 Reduction & parking brake assembly 3 Lock washer, Lock plate

2 Side bearing cap bolt
(re-tighten to the specified torque.)
(1) Lay the differential unit with its reduction & parking (5) Re-tighten the side bearing cap bolt to the specified
brake assembly mounting side facing upward and torque.
secure it to wooden bars, etc.
379 to 512 N•m (38.6 to 52.2 kgf•m)
(2) Drive-in to set the eyebolt into the universal joint Tightening torque
[279 to 378 lbf•ft]
mounting bolt hole of the input flange.
(3) Put a wire rope to the eye bolt and lift the reduction and (6) Tighten the mounting bolts of the lock washers and
parking brake assembly to assemble it into the differen- lock plates to each specified torque.
tial unit. 34.3±3.9 N•m (3.5±0.4 kgf•m)
Tightening torque
(4) Tighten the mounting bolts to the specified torque. [25.1±2.9 lbf•ft]
59.8±5.9 N•m (6.0±0.6 kgf•m)
Tightening torque
[43.8±4.3 lbf•ft]
8-54
5. Troubleshooting
• Reduction bevel gear teeth badly worn • Replace reduction bevel gear.
• Improper adjustment or excessive wear of reduc- • Readjust or replace the bearing.
Gear noise cones out tion bevel gear bearing
continuously during
normal traveling • Hub bearings damaged • Replace the bearing
• Improper tooth contact between the reduction pin- • Readjust the tooth contact.
ion and reduction gear of the output shaft
• Reduction gear bearing or hub bearing broken. • Replace the bearing
• Differential gear teeth broken or thrust washers • Replace differential gear or washer.
Irregular noise comes worn
out during normal
traveling • Metal chips in axle housing • Clean and change oil.
• Bolts securing axle shaft or differential carrier • Retighten.
loose
• Fit of differential gear in differential case out of • Replace.
Abnormal noise specification due to wear
comes out when turn-
ing a corner. • Teeth of differential gear or pinion broken, seized • Replace.
on spiders, or worn or damaged
Differential carrier
• Bearing damaged due to excessive preload. • Replace bearing and readjust preload.
overheats after travel- • Backlash between reduction pinion and reduction • Readjust tooth contact and backlash.
ing.
gear too small
Abnormal noise • Shortage of oil or poor oil quality • Add or change oil.
comes from hub • Planetary gears worn or damaged • Replace the planetary gear.
reduction unit.
• Wear of needle roller bearing. • Replace the needle roller bearing.
8-55
6. Service Data
6.1 Front axle (DP100N to DP150N)
Truck model DP100N to DP150N
Defrection of axle shaft 1
Standard value 1.0 mm (0.039 in.)
(1/2 of dial indicator reading)
Preload for hub bearing 2 118 to 157 N (12 to 16 kgf)
Standard value
(force applied to hub bolt in tangential direction) [26 to 35 lbf]
359±36 N•m (36.6±3.7 kgf•m)
Tightening torque for brake drum nuts 3 Standard value
[265±27 lbf•ft]
Tightening torque for brake backing plate 156±16 N•m (15.9±1.6 kgf•m)
Standard value
mounting nuts 4 [115±12 lbf•ft]
Tightening torque for front axle housing 640±96 N•m (65.3±9.8 kgf•m)
Standard value
mounting nuts 5 [472±71 lbf•ft]
539±49 N•m (55±5.0 kgf•m)
Tightening torque for wheel nuts 6 Standard value
[398±36 lbf•ft]
294±29 N•m (30±3.0 kgf•m)
[217±21 lbf•ft]
0 0
Standard value 50 -0.011 mm (1.97 -0.00043 in.)
Diameter of planet pin 8
+0.029 +0.00114
Standard value 58 +0.010 mm (2.28 +0.00039 in.)
Inside diameter of planet gear bearing 9
Standard value 1.2±0.06 mm (0.05±0.002 in.)
Thickness of trust washer 10
57±6 N•m (5.8±0.6 kgf•m)
Tightening torque for cover bolts 11 Standard value
[42±4.0 lbf•ft]
17.2±2 N•m (1.7±0.2 kgf•m)
Tightening torque for lock plate bolts 12 Standard value
[12±1.0 lbf•ft]
33±3 N•m (3.4±0.3 kgf•m)
Tightening torque for defrector bolts 13 Standard value
[25±2.0 lbf•ft]
+0.2 +0.008
Standard value 420 0 mm [16.54 0 in.]
Inside diameter of brake drum 14
Service limit 424 mm (16.69 in.)
8-56
9 10 2 3 14 4 1 5
10
12
11
13
212327
8-57
6.2 Front axle (DP160N)

Truck model DP160N
Defrection of axle shaft 1
Preload for hub bearing 2 118 to 157 N (12 to 16 kgf)
Standard value
(force applied to hub bolt in tangential direction) [26 to 35 lbf]
Thickness of end plate 3
Thickness of mating plate 4
Thickness of friction plate 5
602±60 N•m (61.4±6.1 kgf•m)
Tightening torque for spindle mounting nuts 6 Standard value
[135.3±13.5 lbf•ft]
176±18 N•m (17.9±1.8 kgf•m)
Tightening torque for brake housing mounting bolts 7 Standard value
[129±13 lbf•ft]
Tightening torque for brake cover mounting bolts 112±10.8 N•m [11.4±1.1 kgf•m]
Standard value
8 [82±8 lbf•ft]
Tightening torque for seal washer mounting bolts 16.7±2.0 N•m [1.7±0.2 kgf•m]
Standard value
9 [12.2±1.5 lbf•ft]
Tightening torque for brake hub mounting bolts 358.9±36.3 N•m [36.6±3.7 kgf•m]
Standard value
10 [263±26.6 lbf•ft]
0 0
Diameter of planet pin 11
+0.029 +0.00114
Inside diameter of needle bearing 12
Thickness of trust washer 13
17.2±2 N•m (1.7±0.2 kgf•m)
[12±1.0 lbf•ft]
57±6 N•m (5.8±0.6 kgf•m)
Tightening torque for cover mounting bolts 15 Standard value
[42±4.0 lbf•ft]
539±49 N•m (55±5.0 kgf•m)
Tightening torque for planet carrier mounting bolts 16 Standard value
[398±36 lbf•ft]
294±29 N•m (30±3.0 kgf•m)
[217±21 lbf・ft]
Tightening torque for front axle housing mounting nuts 640±96 N•m (65.3±9.8 kgf•m)
Standard value
18 [472±71 lbf•ft]
8-58
5 4 3
12 13 10 9 Section A 1 18
13
11
14
15
17
2 8 7 6
16
17
212328
8-59

Free movement of differential gear on axle shaft (loose- Standard value ──
ness of mating splines) 1 Service limit 0.5 mm (0.020 in.)
Backlash between reduction bevel gear and bevel pinion
Standard value 0.25 to 0.33 mm (0.010 to 0.013 in.)
2
Backlash between differential bevel gear and bevel pin- Standard value 0.2 to 0.28 mm (0.008 to 0.011 in.)
ion 3 Service limit 0.5 mm (0.02 in.)
Play between differential bevel pinion inner diameter Standard value 0.169 to 0.278 (0.007 to 0.011 in.)
and shaft outer diameter 4 Service limit 0.35 mm (0.014 in.)
Force applied to periphery A of dif- 23 to 32 N (15 to 30 kgf)
Standard value
Differential case ferential case in tangential direction [1.1 to 2.2 lbf]
bearing 5 245 to 343 N•m (25 to 35 kgf•m)
Preload (reference) Standard value
[180 to 253 lbf•ft]
196±29 N•m (20±3 kgf•m) [145±22 lbf•ft]
Tightening torque for differential case bolts 6 Standard value
(Apply "LOCTITE No. 271.")
Tightening torque for nuts 7 of reduction bevelgear 441±69 N•m (45±7 kgf•m) [325±51 lbf•ft]
Standard value
mounting bolts (Apply "LOCTITE No. 271.")
379 to 512 N•m (38.6 to 52.2 kgf•m)
Tightening torque for side bearing cap bolts 8 Standard value
[279 to 378 lbf•ft]
Force applied to bearing retainer in tangential direction 9 30 to 43 N•m (3.1 to 4.4 kgf•m)
Standard value
(preload for reduction bevel pinion bearing) [6.8 to 9.7 lbf•ft]
+0.5 +0.02
Standard value 304.8 0 mm (12 0 in.)
145±22 N•m (14.8±2.2 kgf•m)
Tightening torque for support plate nuts 11 Standard value
[107±16 lbf•ft]
249±29 N•m (30±3 kgf•m)
Tightening torque for self-locking nuts 12 Standard value
[217±22 lbf•ft]
96±15 N•m (9.8±1.5 kgf•m)
Tightening torque for brake drum nuts 13 Standard value
[71±11 lbf•ft]
Bolt length 132±14 N•m (13.5±1.4 kgf•m)
Standard value
Tightening torque for differential 31 mm (1.22 in.) [98±10 lbf•ft]
carrier mounting bolts 14 Bolt length 118±12 N•m (12.0±1.2 kgf•m)
Service limit
37 mm (1.46 in.) [87±9 lbf•ft]
8-60
8 1 3 4 5
14
7
2
10
11
12 13
212329
8-61
REAR AXLE
1. Specifications ............................................................................................................... 9-2
2. Structure....................................................................................................................... 9-3
2.1 Rear axle............................................................................................................................................... 9-3
2.2 Power cylinder ...................................................................................................................................... 9-4
3. Suggestions for Removal and Installation .................................................................... 9-5

3.1 Rear wheels (tires)................................................................................................................................ 9-5
3.1.1 Preparation.................................................................................................................................................. 9-5
3.1.2 Removal ...................................................................................................................................................... 9-5
3.1.3 Installation ................................................................................................................................................... 9-6
3.2 Rear axle............................................................................................................................................... 9-7
3.2.1 Preparation.................................................................................................................................................. 9-7
3.2.2 Removal ...................................................................................................................................................... 9-7
3.2.3 Installation ................................................................................................................................................... 9-9

4.1 Rear axle assembly ............................................................................................................................ 9-10
4.1.1 Disassembly .............................................................................................................................................. 9-10
4.1.2 Reassembly .............................................................................................................................................. 9-13
4.2 Power cylinder .................................................................................................................................... 9-17
4.2.1 Disassembly .............................................................................................................................................. 9-17
4.2.2 Inspection and Adjustment ........................................................................................................................ 9-18
4.2.3 Reassembly .............................................................................................................................................. 9-19 9
5. Readjustment ............................................................................................................. 9-21
5.1 Measurement of minimum turning radius............................................................................................ 9-21
5.2 Adjustment of minimum turning radius................................................................................................ 9-21
7. Service Data............................................................................................................... 9-24

7.1 Rear axle............................................................................................................................................. 9-24
7.2 Power cylinder .................................................................................................................................... 9-25
9-1
REAR AXLE
1. Specifications

Axis type Elliot type
Suspension method Center pivot type
Toe-in 0 mm
Camber 1°
Wheel alignment
Caster 0°
King pin inclination 0°
Cylinder inside diameter 115 mm (4.53 in.)
Piston rod outside diam-
Power cylinder 80 mm (3.15 in.)
eter
Stroke 182 mm (7.17 in.)
9-2
REAR AXLE
2. Structure
2.1 Rear axle
1 8 2
7 6
B B
3 A 3
8
4
6
2 3 4
Section A-A Section B-B

212114
1 Rear axle housing 4 Pins (2 for each right and left) 7 Stopper bolt (right and left)
2 Power cylinder 5 Steering knuckle (right and left) 8 Rear axle support (front and rear)
3 Tie rod (right and left) 6 Wheel hub (right and left)
9-3
REAR AXLE
2.2 Power cylinder
8 9 10 4 6 7 6 3
2
14 15
13 12 11 1 5
212115
1 Cylinder tube 6 Wearing 11 Packing

2 Piston rod 7 Piston seal 12 Backup ring
3 Ring 8 Cylinder head 13 Dust seal
4 O-ring 9 O-ring 14 Bearings
5 Piston 10 Bushing 15 Stopper ring
9-4
REAR AXLE

3.1 Rear wheels (tires)
3.1.1 Preparation
(1) Fully pull the parking brake lever to have the parking
brake substantially work.
(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 coun-
terweight, and jack up the rear end of the truck.
Jack capacity
DP100N 7500 kg (16500 lb)

DP120N 9000 kg (20000 lb)
DP135N 100000 kg (22000 lb)
DP150N 100000 kg (22000 lb)
DP160N 100000 kg (22000 lb)
NOTE
You can otherwise use the lifting hole of the counterweight
to lift the rear end of the truck.
WARNING
After raising the front end with either of the meth-
ods, place jack stands under the frame to prevent
the truck from falling.
3.1.2 Removal
(1) Removal sequence The number shows removal sequence.
1 Wheel nut
2 Clamp 3
3 Rear wheels (tires)
(2) Suggestions for Removal 2

(a) Remove the wheel nuts.
1
(b) Use either the tire handler or small forklift truck to
remove the rear wheels (tires). 210406
Weight of rear wheel (tire) Approx. 155 kg (342 lb)
9-5
REAR AXLE
3.1.3 Installation
(1) Wheel nut
In order to prevent the wheels from running-out, wheel
1 5
nuts should be alternately tightened in the order shown
in the right-hand side figure evenly and finally to the
8 3
specified torque.
539 ± 49 N•m
Torque (54.96 ± 5.0 kgf•m) 4 7
[397.54 ± 36.14 lbf•ft]
6 2
210409
9-6
REAR AXLE
3.2 Rear axle

3.2.1 Preparation the weight is 400 to 500 mm (15.75 to 19.69 in.) above
(1) Fully pull the parking brake lever to have the parking the ground.
brake substantially work. (5) Insert solid stands under the both sides of the frame to
(2) Block the front wheels. prevent the truck from falling.
(3) Remove the rear wheels (tires) while referencing the WARNING
section of "Rear Wheels (Tires)". Never forget to place solid stands to prevent truck
(4) Use a forklift truck with a duty load 10 tons or more from falling down.
and lift the rear end of the truck until the bottom face of
3.2.2 Removal

3
4 2
3
1
212116
1 Power cylinder hose 3 Thrust washer

2 Rear axle support 4 Rear axle assembly
9-7
REAR AXLE
(1) Steering hose

(a) Remove hoses at the power cylinder side.
(b) Put a sealing plug to the mouth piece of the discon-
nected hose to prevent oil from flowing out.
Sealing plug 05330-30300 (G 3/8)
205558
(2) Rear axle assembly

(a) Prepare such an engine jack, etc. that is provided with a
wide supporting area.
(b) From the rear of the truck, position the jack under the
rear axle and fix it with a wire rope, etc.
(c) Remove the front and rear rear axle supports.
(d) Operate the jack to lower the rear axle and pull it out
diagonally backward.
Approx. 840 kg
Weight of rear axle
(1852 lb)
WARNING
212117
Carefully operate the jack so that the rear axle
does not accidentally drop off.
(3) Rear axle support

(a) Do not remove the bushings in the support unless any
defect is found through inspection.
(b) If any defect is found, either replace the rear axle sup-
port as a whole assembly or break the bushing to
remove it.
CAUTION
In the installation of a new bushing, note that the
seam part of the bushing comes to the lower side
(grease nipple side).
Bushing joint
205431
9-8
REAR AXLE
3.2.3 Installation
(1) Adjusting clearance on the rear axle support
(a) There are 3 types of adjustment thrust washers pre-
pared in different thicknesses.
3.2 mm (0.13 in.)
Thrust washer type 0.4mm
1.6 mm (0.063 in.)
(thickness) (0.016 in.)
0.8 mm (0.032 in.) (maximum)
(b) Select optimal thrust washers for adjusting the clear-

ance so that the total of front and rear clearances is
0.8mm (0.032 in.) or less (0.4mm (0.018 in.) or less for 205555
one side).
CAUTION
Put thrust washers evenly for the front and rear.
9-9
REAR AXLE

4.1 Rear axle assembly
4.1.1 Disassembly
20
36 19 11
12
26 16
15
32
17
33 18
35
34 27 13
14
22 31
23 30
10
24 29 9
25 28
21
6
8
7
4 5
3
2
1
212118
9-10
REAR AXLE
1 Hub cap, Gasket 19 Clamp

2 Lock plate 20 Power cylinder, Pipe
3 Lock nut 21 Cover
4 Rear axle hub 22 Shim [21]
5 Tapered roller bearing (inner race) [4] 23 O-ring [21]
6 Oil seal [4] 24 Oil seal [21]
7 Tapered roller bearing (outer race) [4] 25 Tapered roller bearing (outer race) [21]
8 Tapered roller bearing (outer race) [4] 26 Cap (O-ring)
9 Tapered roller bearing (inner race) 27 Steering knuckle
10 Oil seal retainer 28 Lower dust cover [27]
11 Tie rod pin 29 Tapered roller bearing (inner race) [27]
12 Tie rod 30 Oil seal retainer [27]
13 Spacer 31 O-ring [30]
14 Dust seal 32 Tapered roller bearing (inner race) [27]
15 Spacer 33 Oil seal retainer [27]
16 Dust seal 34 Oil seal [36]
17 Stopper ring [27] 35 Tapered roller bearing (outer race) [36]
18 Spherical bearing [27] 36 Rear axle housing
NOTE
(1) Lock nut

(a) Remove the mounting bolts, and remove the lock plate.
(b) Remove the lock nuts using a socket wrench.
Width across flats of lock
70 mm (2.76 in.)
nut
210413
(2) Rear axle hub
Use a puller to remove the rear axle housing from the
steering knuckle.
210414
9-11
REAR AXLE
(3) Tapered roller bearing

Do not remove the outer race unless it is to be replaced
with a new one.
CAUTION
When replacing the tapered roller bearing, the
outer race and the inner lace should be replaced
as a set.
(4) Lower cover of the steering knuckle

(a) Prepare a jack bolt.
Nominal diame-
16 mm (0.63 in.)
ter
1.5 mm
Pitch
Jack bolt (0.059 in.)
100 mm or more
Thread length (3.94 in. or
more)
Jack bolt
(b) Remove the plug at the center of the cover. Cover
(c) Remove six (6) cover fixing bolts. 205430
(d) Drive-in the jack bolt into the plug hole to pull the
cover out.
9-12
REAR AXLE
4.1.2 Reassembly
36
A
B B
A
35
1 20 6 15 13 10 11
2
3 12
34 31 32 33
14
5 16
4 18
7 19
28 17
25
27
21
29 30 24 23 9 8 22 26
Section A-A Section B-B

212119
9-13
REAR AXLE
1 Rear axle housing 19 Hub cap, Gasket

2 Tapered roller bearing (outer race) [1] 20 Cap
3 Oil seal [1] 21 Lower dust cover
4 Steering knuckle 22 Cover
5 Oil seal retainer [4] 23 Tapered roller bearing (outer race)
6 Tapered roller bearing (inner race) [4] 24 O-ring
7 Oil seal retainer [4] 25 Oil seal
8 O-ring [7] 26 Shim
9 Tapered roller bearing (inner race) [4] 27 Spherical bearing
10 Oil seal retainer [4] 28 Stopper ring
11 Tapered roller bearing (inner race) [4] 29 Spacer
12 Rear axle hub 30 Dust seal
13 Tapered roller bearing (outer race) [12] 31 Spacer
14 Tapered roller bearing (outer race) [12] 32 Dust seal
15 Oil seal [12] 33 Tie rod
16 Tapered roller bearing (inner race) 34 Tie rod pin
17 Lock nut 35 Power cylinder
18 Lock plate 36 Clamp
(1) Inside of rear axle hub

(a) In order for the shaded area in the right-hand side fig-
ure to be successfully greased after the assembly is
completed, coat the following grease on each part
before assembly.
Grease Idemitsu Autolex A
CAUTION
Do not forget to lubricate the inside of the roller
supporter of the tapered roller bearing. 212120
(b) First install the oil seal retainer, then drive-in the
tapered roller bearing (inner race) using the bearing
installer.
(c) Only lightly tighten the lock nuts (inside and outside),
lock washer, and hub cap.
204664A
9-14
REAR AXLE
(2) Upper and lower steering knuckle supports

(a) In order for the shaded area in the right-hand side fig-
ure to be successfully greased after the assembly is
completed, coat the following grease on each part
before assembly.
CAUTION
Do not forget to lubricate the inside of the roller
supporter of the tapered roller bearing.
(b) For the upper and lower oil seals of the steering
knuckle, coat the lips with the following grease.
CAUTION
Exercise care for the direction of the oil seal for
reassembly.
(See the figure at the right.)
212121
(3) Preload adjustment of knuckle bearing

(a) Drive in the cover with the shim being removed.
(b) Use a thickness gauge to measure the clearance
between the rear axle housing and cover.
(c) Install a shim which is adjusted to 0.1 mm (0.0039 in.)
thinner than the measured clearance and evenly tighten
the cover mounting bolts.
(d) 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.
98 to 146 Ｎ
Tangential force (9.993 to 14.888 kgf)
[72.28 to 107.68 lbf]
Clearance
(e) If the force applied in the tangential direction does not 210418
ing the shim thickness.
9-15
REAR AXLE
(4) Preload adjustment of hub bearing

(a) After all the parts are assembled, remove once the hub
cap and lock nut.
(b) Temporarily tighten lock nuts.
(c) Hook a spring scale to one of the hub bolts and mea-
sure whether the force applied in the tangential direc-
tion meets the specified value.
88 to 127 Ｎ
Tangential force (8.97 to 12.95 kgf)
[64.91 to 93.67 lbf]
210419
(d) If the force applied in the tangential direction does not
ing the amount of turning-in of the lock nut.
CAUTION
However, it is advisable to aim at a value some-
what lower than the tolerance limit, if the bearings
are reused.
(e) If the tangential force meets the specified value, gradu-

ally loosen the lock nuts until each hole on the lock
plate aligns with the threaded portion of the rock nut.
(f) Tighten the lock plate with bolts and spring washers. Lock nut
Lock plate
212122
9-16
REAR AXLE
4.2 Power cylinder

4.2.1 Disassembly
7
9 8
10 7
9
10
6
2
3
4
1
5
5
1
4
3
2
11
212123
1 Cylinder head 5 O-ring 9 Stopper ring

2 Dust seal 6 Piston rod 10 Bearings
3 Backup ring 7 Wearing 11 Cylinder tube
4 Packing 8 Piston seal
NOTE
(a) Do not remove the bushing press-fit in the cylinder
head.
(b) Do not remove the piston assembled with the piston
rod.
(1) Cylinder head

(a) Hold the cylinder tube which has been protected by
copper plates by a vise.
(b) Use the special tool to remove the cylinder head.
Special tool
Hook wrench 05302-10800
Hook wrench 205438
9-17
REAR AXLE
4.2.2 Inspection and Adjustment

(1) Piston rod bend
(a) Support both ends of the piston rod with V-shaped
blocks, and apply a dial gauge at the middle portion.
(b) Measure the deflection (runout) while rotating the pis-
ton rod one turn by hand. If this measurement exceeds
the service limit (refer to the following table), replace
the piston rod together with the piston.
(2) Piston rod surfaces

205439
(a) Check the piston rod surfaces for rust, damages, sliding
marks, or dents. If any excessive rust or damage is
found, replace the cylinder tube.
(b) When any of the thread parts are excessively damaged,
replace the piston rod.
(3) Cylinder tube

(a) Check the cylinder tube for any wear, damage or rust.
If any excessive rust or damage is found, replace the
cylinder tube.
(b) Check the welded part for cracks, damage, and dent. If
any excessive damage is found, replace the cylinder
tube.
Item Service Data

Standard value 115 mm (4.528 in.)
１ Inside diameter of cylinder tube
Repair or service limit 115.15 mm (4.533 in.)
２ Piston rod outside diameter Standard value 80 mm (3.15 in.)
３ Clearance between rod and bushing
Deflection of piston rod
４ Repair or service limit 0.3 mm (0.012 in.)
3 4
1
212124
9-18
REAR AXLE
4.2.3 Reassembly
# # # # The number shows assembling sequence.

5 9 2 3 2
#: Seal kit parts.
1
10 11
# # # 4
8 7 6
212125
1 Piston rod 5 Cylinder head 9 O-ring [5]

2 Wearing [1] 6 Packing [5] 10 Bearings
3 Piston seal [1] 7 Backup ring [5] 11 Stopper ring
4 Cylinder tube 8 Dust seal [5]
NOTE
[ ] shows the number of each part to reassemble to.
(1) Cleaning of each part

(a) Thoroughly clean all parts before reassembly making
sure they are completely free from dirt or dust.
(2) Seal Kit parts (marked with '#' in the above figure)
(a) Always prepare new parts.
CAUTION
Seal Kit parts should be always new ones. Never
re-install any part that has been once removed.
(b) Before reassembly coat each part with hydraulic oil.
(c) Be aware of the direction to assemble the seals and
rings to be inserted in the cylinder head.
9-19
REAR AXLE
(3) Installing piston seals

(a) Hold the piston rod with a vise.
CAUTION
Be careful not to damage the piston rod.
(b) Lightly compress and release a piston seal 5 to 6 times
by hand to make it soft.
(c) Coat a small quantity of hydraulic oil on the piston
seal.
(d) First fit one of the piston seals in the mounting groove
of the piston, then insert the other.
(e) Check the entire circumference of the piston tube if the 200352
piston seals are firmly installed.
(f) When the assembling of piston seals is completed,

install the associated wearing.
205552
(4) Cylinder head

(a) Tighten the cylinder head to the specified torque.
539 ± 54 N•m
Torque (54.96 ± 5.506 kgf•m)
[397.54 ± 39.83 lbf•ft]
9-20
REAR AXLE
5. Readjustment
5.1 Measurement of minimum turning radius
(1) Secure an flat square ground which extends more than
20 m (65.6 ft.) in the both directions of depth and
width.
WARNING
This measurement lot must be surrounded by a
fence, etc. or assigned with watchman in order to
prevent any persons unconcerned from entering
there.
(2) Put a piece of chalk to the end of a thread, and hang it

down from a position of the counterweight as shown in
the figure to the ground.
(3) Turn the steering wheel fully and drive the truck at a
s
low speed. At this time, make sure that the chalk draws
iu
d
ra
a line (circle) on the ground.
ngi
rn
(4) Measure the diameter of the circle drawn on the
tu
ground. The radius of this circle is assumed to be the
um
minimum turning radius (R). im
in
M
Truck Model Minimum turning radius

DP100N 4000 mm (157.5 in.) 212256
DP120N 4060 mm (159.8 in.)
DP135N 4165 mm (163.8 in.)
DP150N 4555 mm (179.3 in.)
DP160N 4815 mm (189.6 in.)
9-21
REAR AXLE
5.2 Adjustment of minimum turning radius

(1) Make sure that the protrusion of the stopper bolt meets
the standard value. Lock nut
Stopper bolts
Protrusion of bolt Standard value 25 mm (0.98 in.) (left and right)
(0.984 in.)
25mm
(2) If the amount of protrusion of the stopper bolt does not
meet the standard value, re-adjust it with the following
procedure.
(a) Tentatively loosen the lock nut.
(b) Adjust the stopper bolt protrusion to the specified
value.
(c) Measure the minimum turning radius again.
(d) If the normal minimum turning radius can not be
obtained with the stopper bolt protrusion set to the
standard value, re-adjust by varying the amount of pro-
trusion properly. 212127
(e) When the minimum turning radius have met the speci-
fied value, tighten the lock nut to the specified torque.
233 N•m
Torque Standard value (23.76 kgf/m)
[171.85 lbf•ft]
9-22
REAR AXLE
6. Troubleshooting
• Insufficient lubrication in the rear axle • Greasing

Steering wheel is heavy
• Low tire inflation pressure • Adjust inflation pressure
• Excessive tightening on each part of • Retighten to the specified torque
Dull self-returning of steering wheel
the rear axle
• Difference in the outside diameter of • Change to the tire of normal outside diam-
Steering operation is unexpectedly tires between the right and left eter
controlled to one side • Tire inflation pressure differs between • Adjust inflation pressure
the right and left tires
• Wear or damage in the tapered roller • Replace the bearing
bearing
Steering wheel swings
• Defective steering system • Refer to the chapter of Steering System to
proceed inspection or adjustment
• Defective adjustment of wheel align- • Adjust alignment
Rear tire's uneven wear or ment
early wear • Type or inflation pressure differs • Replace wheels with specified ones and
between the right and left wheels adjust inflation pressure
9-23
REAR AXLE
7. Service Data
7.1 Rear axle
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 75°24′
Steering angle
Outside Standard value 49°42′
0 0
Outside diameter of knuckle pin 1
Repair limit 59.9 mm (2.358 in.)
Tangential force of knuckle bearing 2 98.1 to 145.8 N (10.0034 to 14.87 kgf)
Standard value
(knuckle arm) [72.35 to 107.54 lbf]
18.6 to 27.5 N•m (1.8967 to 2.804 kgf•m)
Preload of hub bearing Standard value
[13.72 to 20.283 lbf•ft]
Tangential force of hub bearing 3 88.3 to 127.5 N (9.004 to 13.001 kgf)
Standard value
(hub bolt) [65.13 to 94.039 lbf]
Clearance of center pin in the front and rear Standard value 0.8 mm or less (0.032 in.)
directions 4 (total of front and rear) Repair limit 1.2 mm (0.047 in.)
Locking of knuckle stopper bolt 487.4 N•m (49.7007 kgf•m)
Standard value
nut tightening torque 5 [359.486 lbf•ft]
490.3 to 588.4 N•m (49.996 to 59.9998 kgf•m)
Tightening torque of wheel nut 6 Standard value
[361.62 to 433.98 lbf•ft]
Tightening torque of rear axle support mount- 209.9 N•m (21.404 kgf•m)
Standard value
ing bolt 7 [154.81 lbf•ft]
Tightening torque of power cylinder mounting 1136 N•m (115.84 kgf•m)
Standard value
bolts 8 [837.87 lbf•ft]
49 ± 5 N•m (4.997 ± 0.51 kgf•m)
Tightening torque of hose 9 Standard value
[36.14 ± 3.69 lbf•ft]
2 1
9 7 3
5 8 8
4
A A
7
Section A-A 212128
9-24
REAR AXLE
7.2 Power cylinder

Standard
115 mm (4.527 in.)
Inside diameter of cylinder tube 1 value
Standard
Outside diameter of piston rod 2 80 mm (3.15 in.)
value
Standard
0.1 mm (0.0039 in.)
Clearance between rod and bushing 3 value
Deflection of piston rod 4
Standard 539 ± 54 N•m (54.96 ± 5.506 kgf•m)
Tightening torque of cylinder head 5
value [397.54 ± 39.83 lbf•ft]
5 3 4
1
212129
9-25
BRAKE SYSTEM
1. Specifications ............................................................................................................. 10-4
1.1 Truck with dry brake............................................................................................................................ 10-4
1.2 Truck with wet brake ........................................................................................................................... 10-4
2. Structure..................................................................................................................... 10-5
1
2.1 Wheel brake system (DP100N to DP150N)........................................................................................ 10-5
2.1.1 Relay valve................................................................................................................................................ 10-6 2
2.1.2 Brake control valve.................................................................................................................................... 10-8
2.1.3 Air master .................................................................................................................................................. 10-9
2.1.4 Wheel brake ............................................................................................................................................ 10-12
3
2.2 Wheel brakes system (DP160N)....................................................................................................... 10-13
2.2.1 Brake booster .......................................................................................................................................... 10-14 4
2.3 Parking brake system ....................................................................................................................... 10-17
2.3.1 Parking brake lever ................................................................................................................................. 10-18
2.3.2 Parking brake .......................................................................................................................................... 10-19 5
3. Suggestions for Removal and Installation ................................................................ 10-20
3.1 Wheel brake (DP100N to DP150N) .................................................................................................. 10-20
6
3.1.1 Preparation.............................................................................................................................................. 10-20
3.1.2 Removal .................................................................................................................................................. 10-20 7
3.1.3 Installation ............................................................................................................................................... 10-22
4. Disassembly and Reassembly ................................................................................. 10-23

8
4.1.1 Disassembly ............................................................................................................................................ 10-23
9
4.1.2 Inspection and Repair ............................................................................................................................. 10-25 10
4.1.3 Reassembly ............................................................................................................................................ 10-26
4.2 Wheel cylinder (DP100N to DP150N)............................................................................................... 10-29 10
4.2.1 Disassembly ............................................................................................................................................ 10-29
4.2.2 Inspection and Repair ............................................................................................................................. 10-30
4.2.3 Reassembly ............................................................................................................................................ 10-30
11
4.3 Air master (DP100N to DP150N) ...................................................................................................... 10-31
4.3.1 Disassembly ............................................................................................................................................ 10-31 12
4.3.2 Reassembly ............................................................................................................................................ 10-32
4.4 Brake booster (DP160N)................................................................................................................... 10-33
4.4.1 Disassembly ............................................................................................................................................ 10-33 13
4.4.2 Reassembly ............................................................................................................................................ 10-34
4.5 Parking brake.................................................................................................................................... 10-35
4.5.1 Disassembly ............................................................................................................................................ 10-35
14
10-1
BRAKE SYSTEM
4.5.2 Inspection and Repair ............................................................................................................................. 10-35

4.5.3 Reassembly ............................................................................................................................................ 10-36
4.6 Brake control valve ........................................................................................................................... 10-37
4.6.1 Disassembly and Reassembly ................................................................................................................ 10-37
4.7 Replacing desiccating agent of air dryer........................................................................................... 10-39
4.7.1 Disassembly ............................................................................................................................................ 10-39
4.7.2 Reassembly ............................................................................................................................................ 10-40
5. Adjustment and Testing ........................................................................................... 10-41

5.1 Inspecting wheel brake (DP100N to DP150N).................................................................................. 10-41
5.1.1 Clearance check between lining and drum ............................................................................................. 10-41
5.1.2 Replacing brake lining ............................................................................................................................. 10-41
5.1.3 Adjusting lining wear indicator................................................................................................................. 10-41
5.1.4 Inspecting brake drum............................................................................................................................. 10-42
5.2 Bleeding brake system...................................................................................................................... 10-42
5.2.1 Bleeding air master ................................................................................................................................. 10-42
5.2.2 Bleeding wheel cylinder .......................................................................................................................... 10-43
5.3 Inspection of wheel brake (DP160N) ................................................................................................ 10-43
5.3.1 Replacing brake disc ............................................................................................................................... 10-43
5.3.2 Brake oil line bleeding ............................................................................................................................. 10-44
5.4 Bleeding brake pedal ........................................................................................................................ 10-45
5.5 Inspecting brake control valve .......................................................................................................... 10-45
5.5.1 Air leakage check .................................................................................................................................... 10-45
5.5.2 Functional check ..................................................................................................................................... 10-45
5.6 Adjusting parking brake .................................................................................................................... 10-46
5.6.1 Clearance adjustment between drum and lining ..................................................................................... 10-46
5.7 Inspection of brake oil tank (DP160N) .............................................................................................. 10-46
5.7.1 Inspecting liquid level sensor .................................................................................................................. 10-46
6. Troubleshooting ....................................................................................................... 10-47

6.2 Wheel brake (DP160N)..................................................................................................................... 10-48
6.3 Parking brake.................................................................................................................................... 10-49
6.4 Air drier ............................................................................................................................................. 10-49
7. Service Data............................................................................................................. 10-50

7.1 Brake pedal....................................................................................................................................... 10-50
7.2 Brake control valve ........................................................................................................................... 10-50
7.3 Air master (DP100N to DP150N) ...................................................................................................... 10-51
7.4 Brake booster (DP160N)................................................................................................................... 10-52
7.6 Wheel cylinder (DP100N to DP150N)............................................................................................... 10-54
10-2
BRAKE SYSTEM
7.7 Parking brake lever ........................................................................................................................... 10-54

7.8 Parking brake drum........................................................................................................................... 10-55
10-3
BRAKE SYSTEM
1. Specifications
1.1 Truck with dry brake
Truck model DP100N DP120N DP135N DP150N

Type Hydraulic drum internal expanding leading-trailing shoe type
Drum diameter 420 mm
Brake shoe lining dimensions 200 × 190 × 16 - 4 mm
Wheel brake (length × width × thickness - number
of shoes per brake)
Wheel cylinder inside diameter 55.56 mm
Brake booster Air master (air booster)
Type Center brake drum internal expanding type
Drum diameter 304.8 mm
Parking brake Brake shoe lining dimensions 345 × 75 × 6.7 - 2 mm
(length × width × thickness - number
of shoes per brake)
1.2 Truck with wet brake
Truck model DP160N

Type Hydraulic wet multiplate disc type
Disk diameter - number of disks in 381 mm - 16
Wheel brake
one side
Brake booster Brake booster
Type Center brake drum internal expanding type
Drum diameter 304.8 mm
Parking brake Brake shoe lining dimensions 345 × 75 × 6.7 - 2 mm
(length × width × thickness - number
of shoes per brake)
10-4
BRAKE SYSTEM
2. Structure
2.1 Wheel brake system (DP100N to DP150N)
1
From air compressor
212243
1 Air drier 5 Air master

2 Air tank 6 Reserve tank
3 Relay valve 7 Front axle
4 Brake control valve
Air compressed by the compressor is dehumidified with air

drier, and filled in the air tank. The compressed air is
opened/closed by the brake control valve through relay
valve, and sent to air master. Since the air master com-
presses the brake fluid with this compressed air, the wheel
brake activates to brake the truck.
10-5
BRAKE SYSTEM
2.1.1 Relay valve
5 7 6 A 8
D
4 2 3
212244
1 Body 6 Valve rod

2 Valve guide 7 Spring
3 Inlet valve 8 Cover
4 Spring 9 Ventilating hole
5 Diaphragm
A: From brake control valve

B: To air master
C: From air tank
D: To atmosphere
Relay valve controls the braking pressure corresponding to Compressed air in air tank is directly sent to the air master
pressure change in pipeline at brake control valve side, to prevent delay of brake application.
which can extremely shorten the time required to increase When releasing the brake, the compressed air from air mas-
braking pressure. ter is discharged directly from here.
10-6
BRAKE SYSTEM
(1) Operation
(a) Generation of brake pressure
When the brake pedal is depressed and the pipeline From brake control valve
pressure from brake control valve increases, the valve
rod is lowered along with diaphragm to close the ex-
haust port, moreover lower the inlet valve to open the
inlet port. The compressed air in air tank is led to air
master from this inlet port. To air master
(b) Stabilization of brake pressure From air master

When the pressure of air master increases, the force act-
ing on the underside of diaphragm increases by pressure
entered from ventilating hole. When this force comes to
Generation of brake pressure
be larger than the force acting on top face from brake
control valve, the diaphragm and valve rod will be
pushed up. Also, the inlet valve is closed by the spring,
From brake control valve
and the pressure of air master maintains a pressure
which is equal to that at the brake control valve side.
(c) Releasing of brake pressure

Releasing the brake pedal will drop the air pressure From air master
from brake control valve. Since the valve rod lifts fur-
ther to open the exhaust port, air in the air master is dis-
charged through the center of inlet valve.
Stabilization of brake pressure
To brake control valve
From air master
To atmosphere
Releasing of brake pressure
212245
10-7
BRAKE SYSTEM
2.1.2 Brake control valve
pl °
ay
ee .5
Applied position
Fr 4±1
°
16
N ±1°
1.5°
kin l
braorma
g
12
39±
8 9 10 11
6±1°
Emergency
braking
17°
B
A
1 12 Released position
2 13
14
3 15
16
4 B
17
5 A B
18
6
7 19
20 200629
1 Valve cover 11 Plunger

2 Main spring assembly 12 Plunger guide
3 Valve case 13 Packing
4 Return spring 14 O-ring
5 Spring 15 Piston
6 Packing 16 Feed valve assembly
7 Cap 17 Spring seat
8 Boot 18 O-ring
9 Pedal 19 C-ring
10 Push button 20 Dust seal
A: Air tank side port

B: Air master side port
By depressing the pedal, a volume of compressed air in pro-

portion to the displacement of the pedal depressed, is sup-
plied to the cylinder shell section in the air master. When
releasing the foot from the pedal, the compressed air in the
cylinder shell is discharged into the atmosphere.
10-8
BRAKE SYSTEM
2.1.3 Air master
1 2 3 4 5 6 7 11 8 9 10
From brake
control valve
(high pressure To wheel
air) brakes
(high pressure
fluid)
13 12 14
200632
1 Piston packing 8 Hydraulic cylinder

2 Piston plate 9 Breather plug
3 Cylinder shell 10 Cylinder cap
4 Pushrod 11 Hydraulic piston assembly
5 Return spring 12 Switch assembly
6 End plate 13 Rod and plate assembly
7 Air breather 14 Outlet valve
Brake fluid pressurized by the compressed air supplied

from the brake control valve is used to activate the wheel
cylinder.
10-9
BRAKE SYSTEM
(1) in the inactive condition

Since the brake control valve has closed, right and left
of the piston plate is at the atmospheric pressure.
Piston plate
The piston plate is pushed by the return spring to the left
as shown in the illustration.
Return spring 200633
(2) When depressing the brake pedal

When the brake control valve opens, the compressed air
flows into the inlet port of cylinder shell. This com- Hydraulic piston
pressed air pushes the return spring to the right as shown
in the illustration via the piston plate, and also pushes
the hydraulic piston through the push rod connected to
the piston plate.
When the hydraulic piston begins to work, the check
valve yoke which has touched to the stopper is returned Ball
by the spring.Therefore, the ball comes into close con- Yoke spring
tact with the seat surface by the brake fluid in the cylin- Push rod Check valve yoke
der, and closes the circuit to reservoir tank. In this way,
the brake fluid in the hydraulic cylinder is adjusted to 200634
the pressure corresponding to compressed air pressure
by moving the piston, and applied to the wheel cylinder.
(3) When releasing the brake pedal

When the brake control valve closes, the compressed air
in the cylinder shell is discharged from the bottom of air
brake valve. Thus, the piston plate is pushed by the re-
turn spring and returns to the initial position.
The hydraulic piston returns to the left in the illustration
by the oil pressure from the wheel cylinder. At this time,
when the check valve yoke touches the stopper, the ball
will separate from seat surface, and circuit to the reser-
Stopper
voir tank will be opened. In this way, the brake fluid in
the hydraulic cylinder is depressurized and the brake is
released. 200635
10-10
BRAKE SYSTEM
(4) Warning of brake lining adjustment

When the stroke of piston plate becomes longer, rod and
plate assembly in the cylinder shell will be pushed by
the piston plate, and the switch will be activated. Thus,
the lamp in the operator's compartment illuminates,
while the buzzer sounds to warn.
Since the cause by which the stroke of piston plate be- Piston plate
comes longer is wear of brake lining, adjustment of
brake lining is needed.
Rod and plate assembly Switch assembly
212235
10-11
BRAKE SYSTEM
2.1.4 Wheel brake
9
8
7
5 4
Section A – A
A
A
6 3 10 2
205683
1 Brake shoe 6 Anchor bracket

2 Anchor pin 7 Adjusting cam
3 Lock plate 8 Adjusting spring
4 Wheel cylinder 9 Lining wear indicator
5 Return spring 10 Dust cover
The brake shoe has a T-shaped cross section, and the lining When the brake pedal is not depressed, the brake shoe is
of non asbestos material is stuck on its outside as a friction retracted with the return spring, since the pressure of brake
surface. fluid is not applied to the wheel cylinder.
The support point at lower end of shoe is supported by the When the brake pedal is depressed, the push rod of wheel
boss of anchor bracket, and the recess at the top is con- cylinder is extended to right and left, and which result in the
nected to the push rod of wheel cylinder. The intermediate linings of brake shoe pressed onto the brake drum, resisting
rib section is also supported by the return spring and adjust- the return spring force.
ing cam. In this way, the wheel brake is activated, and truck is
The adjusting cam is a eccentric cam, and rotation of the slowed down and stopped.
cam is required when clearance adjustment of the brake
shoe is performed.
The wheel cylinder is the opposed piston type, and its body
section is bolted to the anchor bracket.
10-12
BRAKE SYSTEM
2.2 Wheel brakes system (DP160N)
1
From air compressor
212246
1 Air drier 5 Brake booster

2 Air tank 6 Reserve tank
3 Relay valve 7 Front axle
4 Brake control valve
Air compressed by the compressor is dehumidified with air

drier, and filled in the air tank. The compressed air is NOTE
opened/closed by the brake control valve, and sent to brake (a) Relay valve and brake control valve are common to
booster through relay valve. Since the brake booster com- DP100N-DP150N. For structure description, refer to
presses the brake oil with this compressed air, the wheel the section of DP100N-DP150N.
brake activates to brake the truck.
(b) For structure description of wheel brake, refer to the
chapter of "Front Axle and Reduction Differential".
10-13
BRAKE SYSTEM
2.2.1 Brake booster
4 5
3 From brake
oil tanks
7 8 6
From brake
control valve To wheel brakes
(high pressure (high pressure
air) brake oil)
2 1
212247
1 Switch 4 Pushrod 7 Piston

2 Load chamber body 5 Return spring 8 Check valve
3 Piston complete 6 Master cylinder
The brake booster converts energy of compressed air, which When the switch built into chamber is activated, warning
is supplied from brake control valve, into oil pressure force, buzzer sounds. This means the disk and plate, etc. in the
and activates the wet disc brake installed to the front axle. disk brake reaches the service limit.
Because the compressed air is used as source to increase the
force, the force to depress the pedal is reduced with the
braking effect improved.
10-14
BRAKE SYSTEM
(1) When depressing the brake pedal
Piston complete
From brake
oil tanks
From brake
control valve To wheel brakes
(high pressure (high pressure
air) brake oil)
Check valve
Piston of master cylinder

Push rod
212248
(a) Compressed air from the brake control valve pushes

the piston complete and push rod. The push rod also
pushes the piston of master cylinder.
(b) When the piston begins to move, check valve will be
pressed on the seat surface and will close the oil pas-
sage from oil tank.
(c) In this way, the brake oil in master cylinder is adjusted
to a pressure according to compressed air pressure by
moving the piston, and applied to the wheel brake.
10-15
BRAKE SYSTEM
(2) When disk brake is worn
From brake
control valve
(high pressure To wheel brakes
air) (high pressure
brake oil)
Head of switch
212249
(a) When the stroke of push rod becomes too long, the pis-
ton complete will push the head of switch in chamber.
Thus, the switch is activated and the lamp in operator's
compartment illuminates, while the buzzer sounds to
warn.
(b) Because the cause by which the stroke of push rod
becomes long is wear of brake disc, a plate, etc., these
parts must be replaced.
10-16
BRAKE SYSTEM
2.3 Parking brake system
206098
1 Parking brake lever 3 Parking brake drum assembly

2 Parking brake cable
This parking brake is an internal expanding type, and

brakes the brake drum mounted to the input flange part in
the front axle with the parking brake lever and flexible wire.
Even though the main purpose of parking brake system is
preventing a motor movement at the time of parking, it is
also used as an auxiliary brake if the wheel brake system is
defective.
10-17
BRAKE SYSTEM
2.3.1 Parking brake lever
Released position
Applied position
3
2
1
212236
1 Lever support pin 3 Parking brake lever assembly

2 Adjusting screw 4 Parking brake lever switch
(1) Inspection and Repair

(a) If there is a serious damage on the lever support pin
and the pin hole in the lever, replace the lever assem-
bly.
(b) Replace the parking brake cable if it is stretched, dam-
aged or rusty.
(2) Reassembly
Connect the wire to the lever, then inspect whether or
not the operating force is within the standard value.
245 to 294 N
Standard
Lever operating effort (25 to 30 kgf)
value
[55 to 66 lbf]
10-18
BRAKE SYSTEM
2.3.2 Parking brake
10
Section A-A
1 2 3
5
6
7
A A
9
210430
1 Dust shield 6 Parking brake shoe

2 Camshaft 7 Spring
3 Parking brake drum 8 Spring
4 Support plate 9 Adjuster assembly
5 Parking brake lining 10 Lever
The parking brake is of an internally expanding type that a

cam operation expands the brake shoe inside the drum. It
has an adjuster assembly installed at the bottom to adjust a
clearance made between the lining and drum.
10-19
BRAKE SYSTEM

3.1 Wheel brake (DP100N to DP150N)
3.1.1 Preparation
(1) Disassemble the front axle according to the disassem-
bly sequence of front axle.
3.1.2 Removal
2
212250
1 Bolts (two places on the upper part) 3 Wheel brake assembly

2 Bolt
10-20
BRAKE SYSTEM
(1) Special tool

It is hard to remove two attaching bolts at the upper por-
tion, because they are under the return spring. In addi- Return spring
tion, since it is also difficult to loosen bolts on nut side,
remove using the special tool.
Bolts in awkward positions
206490
Special tool
Tool name Part No.
Bolt wrench 92367-02100 15o
Torque wrench 92367-02200 A

S point
Socket 92367-02300 R L
A
15o
Bolt holding wrench
R
S point
View A
Torque wrench
Socket wrench
206491
10-21
BRAKE SYSTEM
(2) Removing upper bolt

(a) Support bolt wrench as mark L contacts with the left
Bolt holding wrench
side bolts while mark R contacts with the right bolts
when the brake wheel assembly is shown from the
front.
L R
Identification marks
206493
(b) Remove the nut using the torque wrench and socket in
the special tool.
torque wrench
Socket wrench
ard
rw
Fo
206494
(3) Removing other bolts

Support the other bolts using the normal tool, and re-
move the nut side bolts using the above mentioned
torque wrench and socket.
Bolt in awkward
position
Other bolt
212251
3.1.3 Installation
(1) Bolt tightening torque
Tighten each bolt to the specified torque.
Torque 156 ± 16 N•m
10-22
BRAKE SYSTEM

4.1.1 Disassembly
The number shows disassembly sequence.
7 5
4 8
9
10
11
12
2
212252
1 Return spring 7 Wheel cylinder

2 Anchor pin 8 Pin, Indicator, Cover
3 Lock plate 9 Boot, Spring, Washer
4 Shoe and lining assemblies 10 Adjusting cam
5 Cylinder plate 11 Dust cover
6 Cylinder cover 12 Anchor bracket
10-23
BRAKE SYSTEM
(1) Removing return spring

(a) Turn the adjusting cam and move the brake shoe to the
full inner side.
(b) Remove the return spring from the brake shoe using the
spring setter in the special tool.
Spring setter
Special tool
　　Spring setter: 03737-10001
205687
(2) Removing anchor pin

(a) Remove the anchor pin from the anchor bracket using
the anchor pin puller (special tool).
Special tool
　　Anchor pin puller: 03737-60000 Anchor pin puller
205688
10-24
BRAKE SYSTEM

(1) Dust cover
(a) Check the dust cover for cracks.
(b) When the dust cover is not removed, check whether the
bolt has been tightened to the specified torque or not.
20±4 N•m (2.0±0.4 kgf•m)
Tightening torque
[14.5±3 lbf•ft]
(2) Shoe and lining assemblies

(a) Check the linings or shoes for any crack or fracture.
(b) Replace the lining if it has been badly contaminated by
oil or has been glazed or otherwise set or deteriorated
from friction heat, etc.
(c) Check the thickness of the lining, and replace if it is
worn beyond the service limit.
Standard 16 mm
value (0.63 in.)
Thickness of lining
Service 10 mm
limit (0.39 in.) 205689
(3) Brake drum

Check the inside surface for any scoring and uneven
wear. If necessary, rectify the inside surface by grinding
it.
+0.2
Standard 4200 mm
Inside diameter of brake value +0.008

(16.54 0 in.)
drum
Service 424 mm
limit (16.69 in.)
(4) Return spring

(a) Check the free length of return spring.
Free length of return Standard 203.5 mm
spring value (8.01 in.)
(b) Replace if clearance exists between coils when no ten-

sion is applied to the return spring.
10-25
BRAKE SYSTEM
4.1.3 Reassembly
The number shows assembling sequence. 3
7 9 8
4 2
Section A-A
10
11
6 5 12
210433
1 Anchor bracket 8 Anchor pin

2 Dust cover 9 Lock plate, Lock washer
3 Adjusting cam 10 Wheel cylinder,
4 Washer, Spring, Boot 11 Cylinder cover
5 Cover, Indicator, Pin 12 Air breather
6 Pin, E-ring 13 Return spring
7 Shoe, Bush
(1) Installing wheel cylinder

(a) Lightly coat liquid packing on the cylinder mounting
surfaces.
(b) Align the oil filler port surface on the cylinder with sur-
face of the anchor bracket to be contacted with dust
cover, and tighten the bolt to the specified torque.
135±22 N•m (13.8±2.3 kgf•m)
Tightening torque
[99±16 lbf•ft]
10-26
BRAKE SYSTEM
(2) Greasing
Apply a thin coat of specified brake grease to the fol-
lowing parts:
(a) Shoe bush inner surface
(b) Grease groove on anchor pin
(c) Anchor bracket and adjusting cam contact surface
(don't protruded to the shoe side)
(3) Installing brake shoe

(a) Minimize the eccentricity of the right and left adjusting
cam.
(b) Check that the push rod of wheel cylinder is correctly
placed in the shoe web.
(4) Installing lock plate and lock washer

(a) Tighten the mounting bolts to the specified torque.
15.7 to 23.5 N•m (1.6 to 2.4 kgf•m)
Tightening torque
[12 to 17 lbf•ft]
(b) After mounting, make sure to bend the lock plate.
205714
(5) Return spring installation

Hang the return spring on the pin of brake shoe using
the spring setter in the special tool.
Special tool
　　Spring setter: 03727-10001
Spring setter
205687
10-27
BRAKE SYSTEM
(6) Adjusting lining wear indicator
NOTE
Perform adjustment of the indicator, only when the adjust-
ing cam is disassembled.
(a) Turn the washer using the spanner, and set the indicator
to the innermost part of the lining service range.
(b) In this case, set the adjusting cam with the shoe most
retracted, and hold down with another spanner in order
for the cum not to turn.
210435
(7) Installing wheel brake assembly

Install the wheel brake assembly into the front axle, and
tighten the bolt to the specified torque.
156±16 N•m
M14 (15.9±1.6 kgf•m)
Tightening torque for [115±12 lbf•ft]
wheel brake assembly
bolts 233±24N•m
M16 (23.8±2.4 kgf•m)
[172±17 lbf•ft]
10-28
BRAKE SYSTEM
4.2 Wheel cylinder (DP100N to DP150N)

4.2.1 Disassembly
6
5
1
9 2
3
4
4
3
2
7
212253
1 Pushrod 4 Piston cup 7 Bleeder screw

2 Dust cover 5 Spring seat 8 Connector
3 Piston 6 Return spring 9 Cylinder body
10-29
BRAKE SYSTEM
(1) Cylinder body

(a) Check the inwall for rusting, corrosion and the damage.
(b) Check each threaded part of air bleeder, connector, and
oil pipe for damage.
(2) Piston
(a) Check the outer surface for rusting and the damage.
(b) Install the piston into the cylinder body, and measure
the clearance.Replace, if the clearance exceeds the ser-
vice limit.
Clearance between pis- value (0.005 to 0.009 in.)
ton and cylinder body Service 0.3 mm
limit (0.012 in.)
205692
(3) Piston cup
(a) Check for bulge, damage, and so on.Replace, if there is
any defect.
Standard 1.94 mm
Fit of piston cups in value (0.076 in.)
cylinder body Service 0.2 to 0.3 mm
limit (0.008 to 0.012 in.)
(b) Replace the piston cups every year regardless of the

existence of any abnormalities.
(4) Dust cover

(a) Replace, if it is damaged or deteriorated.
(b) Replace the piston cups every year regardless of the
existence of any abnormalities.
4.2.3 Reassembly
To reassemble, follow the disassembly sequence in reverse
and observe the following.
(1) Apply an even coat of brake fluid to the cylinder's
inside surface and piston cups.
(2) Make sure the piston cups are correctly aligned, and
install the lip part so as not to be damaged.
10-30
BRAKE SYSTEM
4.3 Air master (DP100N to DP150N)

4.3.1 Disassembly
The number shows disassembling sequence. 5

6
#: Seal kit parts. #
8
9
7
6 #
2
##
1
#
#
# #
#
#
# #
#
# 3
#
2
#
4
200784
1 Hydraulic cylinder, Outlet valve, Cylinder cap, Plug, Spring, O-ring

2 Hydraulic piston, Washer, Spring, O-ring
3 Cylinder shell, O-ring
4 Piston plate, Nut, Retainer plate, Expander, Wick, Leather packing
5 Push rod, Spring, Plate, Spring retainer, Gasket
6 Rod and plate, Retainer, Spring
7 Switch, Shim
8 Air breather
9 End plate, Oil seal
(1) Removing hydraulic piston

(a) Supply compressed air less than 588 kPa from the inlet
port of cylinder shell rear, and make the push rod pull
out from the end plate.
(b) Loosen the pin and remove the hydraulic piston.
200641
10-31
BRAKE SYSTEM
4.3.2 Reassembly
(1) Always replace the repair kit parts with new ones,
when reassembling.
(2) Clean the removed parts with the following cleaning
fluid to remove the surface deposit.
(a) Handling of rubber parts
Wipe off the surface deposit using the rag soaked with
alcohol or light oil. Furthermore, don't dip rubber parts
into the cleaning fluid by any means.
(b) Handling of metal parts
Clean with the volatile cleaning fluid, and remove the
remaining cleaning fluid by exposing the parts to com-
pressed air.
(3) When assembling, apply lubricant to the following
parts.
(a) Lightly coat air master paste to the power piston plate,
leather packing, gasket, and inside of cylinder shell.
(b) Apply silicone grease to the clearance of oil seal
installed in the end plate.
(c) Apply the brake fluid throughout the O-ring, cup, and
hydraulic piston.
(4) Bleed after assembling. (Refer to the section of
"Inspection and Adjustment")
Oil Seal O-ring

Cup Hydraulic
piston 200642
10-32
BRAKE SYSTEM
4.4 Brake booster (DP160N)

4.4.1 Disassembly
The number shows disassembling secuence. 13
10 11
3
4
7
6
5
8
9
19
2 18
17
16
15
14
210909
1 Switch 8 O-ring 15 Piston rod complete

2 Cylinder 9 SKY seal 16 O-ring
3 Push rod pin 10 Retaining ring 17 Sleeve
4 Piston 11 Oil filter 18 Packing
5 O-ring 12 Collar 19 Air cylinder complete
6 ST seal 13 Cover complete
7 O-ring 14 Return spring
(1) Piston O-ring, seals

(a) Remove carefully so as not to damage the piston.
O-ring
SKY seal
O-ring
ST seal
O-ring
210910
10-33
BRAKE SYSTEM
4.4.2 Reassembly
(1) Reassembly should be performed in the sequence
reverse to that of disassembly, but the following pre-
cautions must be observed.
(a) Rubber parts
light oil.
CAUTION
Be careful not to dip the rubber parts into metal
cleaning fluid.
(b) Metal parts
Remove the surface deposit using clean metal cleaning
fluid.
(2) Repair kit parts
Always replace with new ones before install.
(3) Master cylinder
(a) Apply lithium base grease (Remax 2) to seals of O-ring
and seal grooves.
(b) Apply engine oil (10 W) to the sliding surfaces of cyl-
inder inside surface and piston.
(c) When assembling the master cylinder, apply grease
including molybdenum at the head of push rod.
10-34
BRAKE SYSTEM
4.5 Parking brake

4.5.1 Disassembly
3
7 4
11 10
12 1
5
8 9
7
212254
1 Parking brake drum 7 Shoe and lining assembly

2 Input flange 8 Camshaft lever
3 Return spring 9 Spring
4 Brace 10 Camshaft
5 Spring 11 Support assembly
6 Adjuster assembly 12 Dust seal

(1) Shoe and lining assembly (2) Brake drum
(a) Check the lining and shoe for crack and damage. Replace, if the brake drum inner surface has uneven
(b) Replace the lining if it has been badly contaminated by wear or damage.
oil or has been glazed or otherwise set or deteriorated +0.5
Standard 304.8 0 mm
from friction heat, etc. Brake drum value +0.02
(12 0 in.)
(c) Check the thickness of the lining, and replace if it is Inside diameter
Service 307 mm
worn beyond the service limit. limit (12.09 in.)
Standard 6.7 mm
value (0.264 in.) (3) Adjuster assembly
Service 3.5 mm Check the adjuster wheel teeth for wear, and check
Lining thickness whether all rotating parts turn smoothly.
limit (0.138 in.)
Service 0.2 to 0.3 mm
limit (0.008 to 0.012 in.)
10-35
BRAKE SYSTEM
4.5.3 Reassembly
(1) Brake drum
Replace, if the brake drum inner surface has uneven
wear or damage.
(2) Adjuster assembly
Check the adjuster wheel teeth for wear, and check
whether all rotating parts turn smoothly.
10-36
BRAKE SYSTEM
4.6 Brake control valve

4.6.1 Disassembly and Reassembly
#
4
1
2
7
3 #
# 6
#
4 #
#: Seal kit parts.

200640
1 Pedal, Split pin, Pin, Push button, Shim

2 Valve cover, Boot, Plunger
3 Main spring
4 Piston, O-ring, Return spring
5 Valve cap, Dust seal, C-ring, O-ring
6 Feed valve, Spring seat, Spring
7 Valve case
NOTE
10-37
BRAKE SYSTEM
(1) Suggestion for Disassembly and Reassembly

(a) Seal kit parts
Always replace with new ones before install.
(b) Rubber parts
alcohol or light oil.
CAUTION
Be careful not to dip the rubber parts into metal
cleaning fluid.
(c) Metal parts
Wash with clean metal cleaning fluid.
(d) Applying grease
Apply grease to sliding surfaces contacting with O-
rings.
10-38
BRAKE SYSTEM
4.7 Replacing desiccating agent of air dryer

4.7.1 Disassembly
6# 10#
11#
5
12#
7#
2 13#
8
#3
#4
#: Repair kit parts. 212240
1 Purge chamber 8 Set spring

2 Cartridge 9 Filter plate
3 Oil filter 10 Oil filter
4 O-ring 11 Desiccating agent
5 Cover 12 Oil filter
6 Check valve 13 Filter plate
7 O-ring
10-39
BRAKE SYSTEM
4.7.2 Reassembly
Reassembly should be performed in the sequence reverse to
that of disassembly, but the following precautions must be
observed.
(1) Wash all metal parts soaked in volatile cleaning sol-
vent, and remove the remaining cleaning solvent by
exposing the parts to compressed air.
(2) Replace the Repair Kit parts with new ones.
(3) Assemble cartridge assembly with the following proce-
dure.
(a) Standard amount of desiccating agent is 480 g (17
oz).However, put in all of one bag if purchased for use
in repair kits.
(b) Tap the case over its circumference with plastic ham-
mer to make desiccating agant seated properly.
(c) Tighten screw of cover to the specified torque.
2.0 to 3.9 N•m
Tightening torque (0.2 to 0.4 kgf•m)
[1.5 to 3.0 lbf•ft]
(d) Tighten the mounting bolts of the cartridge assembly to

the specified torque.
2.0 to 3.9 N•m
[1.5 to 3.0 lbf•ft]
(e) Tighten the mounting bolts of the purge chamber to the

specified torque.
8.8 to 13.7 N•m
[6 to 10 lbf•ft]
10-40
BRAKE SYSTEM
5. Adjustment and Testing

5.1 Inspecting wheel brake (DP100N to DP150N)
5.1.1 Clearance check between lining and drum
(1) Remove the grommet which plugs up the inspection
hole on dust cover.
(2) Insert thickness gauge between the lining and drum
from the inspection hole, and check the thickness,
when appropriate friction is felt by inserting/withdraw-
ing the gauge.
CAUTION 210441
Check both two places for each wheel.
(3) If it does not conform to the standard value, turn the

adjusting cam to adjust.
5.1.2 Replacing brake lining

When the wear indicator of brake lining reaches the service Lining wear indicator
limit, replace the shoes as an assembly. Perform as same as
this if following cases take place.
(1) When installation of lining and brake shoe is poor.
(2) When it has been badly contaminated by oil or has
been glazed or otherwise set or deteriorated from fric-
tion heat, etc.
(3) When lining has crack, damage, and so on.
210442
5.1.3 Adjusting lining wear indicator

(1) In order to set the lining wear indicator, turn the washer
using the wrench and set the indicator to the innermost
part of the lining service limit range.
(2) In this case, set the adjusting cam with the shoe most
retracted, and hold down with another spanner in order
for the cum not to turn.
NOTE
Perform adjustment of the indicator, only when the adjust-
ing cam is disassembled.
200651
10-41
BRAKE SYSTEM
5.1.4 Inspecting brake drum

(1) Replace, if the inside diameter of brake drum reaches
the service limit.
(2) Check the streak of the brake drum inner surface and
the conditions of uneven wear, replace if the degree of
the streak is large, or if uneven wear is more than 0.2
mm (0.008 in).
+0.2
Standard 420 0 mm
Inside diameter of brake value +0.008
(16.54 0 in.)
drum
Service 424 mm
limit (16.69 in.)
5.2 Bleeding brake system

Be sure to bleed in the following sequence, if air is included
in the circuit because of the lack of brake fluid in the brake
cup, or if inspection and maintenance have been performed
by removing any part in the circuit.
(a) Air master
(b) Left hand wheel cylinder
(c) Right hand wheel cylinder
CAUTION
(a) Make the brake fluid of reserve tank full before bleed-
ing.
(b) During bleeding operation, refill the brake fluid as
required in order for the fluid not to come to less than
the half.
5.2.1 Bleeding air master

Bleeding air master must be performed by two persons.
(1) Remove the air bleeder screw cap of air master, and
insert one side of a vinyl tube to it. Insert the other end
of the vinyl tube into the container filled with the brake
fluid.
(2) Depress the brake pedal, and loosen bleeder screw and
bleed air.
(3) Repeat the steps until no air bubble is seen, and tighten
the bleeder screw.
200652
10-42
BRAKE SYSTEM
5.2.2 Bleeding wheel cylinder

(1) Connect one end of a vinyl tube to the bleeder screw of
the wheel cylinder. Insert the other end of the vinyl
tube into the container filled with the brake fluid.
(2) After the one in the truck pumps the brake several
times and then keeps it depressed, the other at the
bleeder screw must loosen the bleeder screw to allow
the brake fluid to flow into the container. The latter
should be tighten the bleeder screw while the brake
fluid flows as a solid stream without any bubbles.
(3) Repeat the above steps until no air bubble is seen in the
tube, and supply a given quantity of brake fluid in the
200285
reserve tank at last.
NOTE
(a) Exercise care so that the brake fluid level in the reserve
tank becomes too low during this operation.
(b) Be sure to use the specified brand of brake fluid, and
never mix it with other brand.
5.3 Inspection of wheel brake (DP160N)

5.3.1 Replacing brake disc
When the brake warning lamp is activated and warning
buzzer sounds, check in the following order.
(1) Check that the gauge of brake booster shows wear.
(2) Check that amount of oil in the brake oil tank
decreases.
(3) If there is enough brake oil, disassemble the front axle
and replace all brake discs. At this time, also replace
the O-ring of brake piston, sleeve, and floating seal
together.
NOTE
For the clearing work of brake disc, refer to the chapter of
"Front Axle and Reduction Differential". Gauge
208008
10-43
BRAKE SYSTEM
5.3.2 Brake oil line bleeding

(1) In the following cases, bleeding the brake oil line.
(a) When part of brake oil line is disassembled
(b) When efficacy of brake is poor
(Air may be mixed in circuit)
WARNING
Observe the following precautions strictly before
bleeding operation so that vehicles do not move sud-
denly.
(a) Ensure that the parking brake is applied.
(b) Block all the wheels.
(2) Bleeding
NOTE
Bleeding brake oil line must be performed by two persons.
(a) Fill up brake oil in the oil tank to the specified amount.
(b) Start the engine, and increase the air pressure of air
tank to the specified pressure.
(c) Depress the brake pedal several times, finally keep it
depressed.
(d) Another operator loosens the bleeder screw of axle

housing flange. Tighten the bleeder screw, before the
flow of oil stops. Breather screw
(e) Release foot from the accelerator pedal.
(f) Repeat above mentioned (c) to (e) until no air bubbles
appear in the oil flowing out.
NOTE
During operations, refill oil as required so that the oil in a
brake oil tank does not run short.
(g) When bleeding operation is completed, be sure to 201504
tighten the bleeder screw.
10-44
BRAKE SYSTEM
5.4 Bleeding brake pedal

Adjust the cam follower of brake pedal with adjusting bolt
so that the pedal of brake control valve may be touched.
Adjusting
CAUTION bolt
Never change the pedal set angle (39±1.5deg) of
the brake valve.
206105
5.5 Inspecting brake control valve

5.5.1 Air leakage check
(1) Check whether the air pressure of air tank is in the
specified pressure.
(2) Release the brake pedal.
(3) Apply soap and water solution to the exhaust side port
on the brake control valve, and check for bubbles. If it
bubbles, air has leaked from the exhaust valve.
(4) Perform the same test with the brake pedal fully
depressed, and inspect the air leakage of the exhaust
valve.
(5) Remove the plug of exhaust side port and check the 200654
valve for damage.
5.5.2 Functional check

Functional check of the brake control valve must be per-
formed by two persons.
(1) Mount the connector R (PT) 3/8 to outlet port on brake
control valve, and connect pressure gauge.
(2) Start the engine, and increase the air pressure in tank to
the normal level before stopping the engine.
(3) Second person continues to depress the brake pedal,
and check that the pressure gauge reading and the indi-
cator of air pressure gauge on instrument panel come to
the equal value. 200655
(4) Furthermore, continue to depress the brake pedal, and
if it seems that the indicator of pressure gauge
decreases, perform the leakage check of the air system
or adjustment of the air governor.
10-45
BRAKE SYSTEM
5.6 Adjusting parking brake

5.6.1 Clearance adjustment between drum and lining
(1) Move the truck to a small distance at a time until the
adjusting hole in the drum is approximately 30 mm
(1.2 in.) right of the bottom point.
(2) Release the parking brake lever.
(3) Remove the grommet from the adjusting hole. Turn the
adjuster assembly up all the way until the lining-to-
drum clearance is removed.
(4) From this position, turn the adjuster assembly back
(down) for about eight notches to obtain the correct lin- Turn adjuster
ing-to-drum clearance. to spreead shoes. 200658
(5) To measure the lining-to-drum clearance, remove the
grommet from the dust cover and insert a thickness
gauge.
200657
5.7 Inspection of brake oil tank (DP160N)

5.7.1 Inspecting liquid level sensor
(1) Check that the connector at the lower part of oil tank is
connected certainly.
Float
(2) Turn the starter switch to [ON] position.
(3) Remove the cap and diaphragm, and gradually take out
brake oil with syringe or hand pump. With the brake High level
oil, the float also falls gradually. Low level
103.5 mm
(4.07 in.)
NOTE Alarm level

(3.27 in.)
83 mm
(2.05 in.)
There is another method of taking out the oil in accordance

52 mm
with "Bleeding brake oil line".

(4) Check that the float turns on and remaining brake oil
quantity warning lamp illuminates, when the oil level
201507
of brake oil falls down to approximately 52mm height.
NOTE
The brake oil quantity warning lamp is common to the
brake disc wear warning lamp.
10-46
BRAKE SYSTEM
6. Troubleshooting
• Air line leaks • Repair or replace.

• Air tank pressure too low • Increase air tank pressure.
• Fluid line leaks, or fluid level too low in • Repair and add fluid.
reserver
Will not apply • Air trapped in hydraulic line • Bleed air out of air master or wheel cylinder
• Clearance between drum and linings out of • Readjust.
adjustment
• Air master or wheel cylinder piston cup worn, • Replace. Change fluid with recommended type
resulting in fluid leaks if caps are distorted.
• Linings worn to expose rivet heads • Replace.
• Lining surface glazed • Replace.
Brakes chatter
• Brake drum unevenly worn or loose • Replace or retighten.
• Lining not seated on shoes • Replace.
• Tires not uniformly inflated • Inflate correctly.
• Clearance between drum and linings out of • Readjustment.
adjustment
• Mismatched linings • Repair or replace.
Truck pulls to one
• Linings or drum soaked with oil • Replace, avoid over-lubrication.
side
• Linings not equal in size and material • Replace.
• Shoes loosen or return springs broken • Retighten anchor pin lock nut or replace.
• Wheel cylinder defective. • Check cylinder piston and piston cups, and
replace defective parts.
Brakes too sensitive • Clearance between drum and linings too small • Readjust.
or drag
• Brake control valve leaks air into line leading to • Readjust.
air master, causing air master to operate
Air brakes drag
• Brake pedal not returning properly • Lubricate or repair arm shaft.
Replace return spring if necessary.
• Clearance between drum and lining too small in • Readjust.
one brake
• Return spring wear or broken • Replace.
• Anchor pin seized, resulting in failure of shoe to • Replace.
One brake drags
return
• Wheel cylinder piston and piston cups defective • Replace.
• Brake pipe restricted at joint, resulting in a fail- • Clean.
ure of fluid to return properly
• Piston cups swollen • Replace.
Will not release • Push rods distorted • Replace.
• Power piston packings lack lubrication • Relubricate.
10-47
BRAKE SYSTEM
• Hydraulic piston cups defective • Replace.

Brake pedal kicks
• Hydraulic piston check valve ball not seating • Replace piston assembly.
back
tight
6.2 Wheel brake (DP160N)

• Hydraulic line leaks, or oil level too low in • Repair and add Oil.
reserver
• Air trapped in hydraulic line • Bleeding brake oil line
Will not apply
• Wear of brake piston seal • Replace.
• Wear of friction plate, or damage to facing • Replace.
• Wear of end plate and matching plate • Replace.
• Tires not uniformly inflated • Inflate correctly.
Truck pulls to one
• Wear of friction plate, or damage to facing • Replace.
side
• Wear of end plate and meating plate • Replace.
• Deterioration of piston return spring • Replace.
Poor return of brake
• Bend of spring guide • Replace.
• Inappropriate lubrication oil is used • Replace with specified lubrication oil
Brake squeals • Friction plate contact with end plate and meat- • Perform brake break-in
ing plate is poor
• Harness open-circuited • Repair.
Poor return of brake
• Faulty sensor • Replace.
10-48
BRAKE SYSTEM
6.3 Parking brake
Brake lever stroke • Clearance between drum and linings too small • Readjust.
too small
• Clearance between drum and linings to small • Readjust.
Noise
• Brake drum distorted • Replace.
• Linings worn • Replace.
• Clearance between drum and linings to small • Replace.
Will not apply
• Brake lever lacks operating effort • Readjusting to 245 to 249 N
(25 to 30 kgf)[55 to 66 lbf].
6.4 Air drier
Brake lever stroke • Taking long time complete dehydration of satu- • Drain daily at end of operation until air line is
too small rated air when air drier is equipped completely dehydrated.
• Air consumption excessive and air compressor • Operate truck to allow compressor on load and
Noise not operating on load and unload cycles unload cycles, or check drier installation.
• Desiccant not changed periodically • Change desiccant kit periodically.
10-49
BRAKE SYSTEM
7. Service Data
7.1 Brake pedal

Height 1
(from floor to pedal top)
Free play 2 Standard value 15 mm (0.59 in.)
2
1
210444
7.2 Brake control valve

Pedal set angle 1 Standard value 39±1.5°
Free play 2 Standard value 4±1.5°
Normal braking 3 Standard value 12±1.0°
Emergency braking 4 Standard value 6±1.0°
2
3
1
200629A
10-50
BRAKE SYSTEM
7.3 Air master (DP100N to DP150N)

196±20 N (20±2 kgf) [44±4 lbf]
Power piston return spring 1 Standard value
/179mm (7.05 in.)
(test force/length under test force)
Service limit 157 N (16 kgf) [35 lbf]/179 mm (7.05 in.)
Bend of push rod 2 Standard value 0.05 mm (0.002 in.), Maximum
Clearance between power piston and cylinder shell 3 Standard value 0.5 to 1.4 mm (0.020 to 0.055 in.)
Clearance between hydraulic piston and cylinder tube 4
98 to 147 N•m (10 to 15 kgf•m)
Tightening torque for hydraulic cylinder lock nut 5 Standard value
[72 to 108 lbf•ft]
20 to 29 N•m (2 to 3 kgf•m)
Tightening torque for power piston end nut 6 Standard value
[14 to 22 lbf•ft]
3 2 1 4 5
210182
10-51
BRAKE SYSTEM
7.4 Brake booster (DP160N)
Truck model DP160N

931 N (94.5 kgf) [209 lbf]
Standard value
Power piston return spring 1 /166 mm (6.54 in.)
(test force/length under test force) 510 N (52 kgf) [114.7 lbf]
Service limit
/166 mm (6.54 in.)
Stroke of push rod 2 Standard value 77 mm (3 in.)
Clearance between hydraulic piston and cylinder tube 3 Standard value 0.06 to 0.18 mm (0.002 to 0.007 in.)
176 to 196 N•m (18 to 20 kgf•m)
Tightening torque for load chamber mounting nut 4 Standard value
[129 to 144 lbf•ft]
4
2
212255
10-52
BRAKE SYSTEM

+0.2 +0.008
Standard value 420 0 mm (16.54 0 in.)
Thickness of lining 2
Clearance between drum and lining 3 Standard value 0.2 mm (0.01 in.)
Free length Standard value 203.5 mm (8.01 in.)
Return spring 4 Test force Standard value 423 N (43.1 kgf) [95 lbf]
Length under test force Standard value 251 mm (9.88 in.)
Tightening torque for anchor bracket bolts 156±16 N•m (15.9±1.6 kgf•m)
Standard value
(M14) 5 [115±12 lbf•ft]
Tightening torque for anchor bracket bolts 233±24 N•m (23.8±2.4 kgf•m)
Standard value
(M16) 6 [172±17 lbf•ft]
17.5 to 23.5 N•m (1.6 to 2.4 kgf•m)
[12 to 17 lbf•ft]
6 7 5
3
210446
10-53
BRAKE SYSTEM
7.6 Wheel cylinder (DP100N to DP150N)

Inside diameter of cylinder body 1 Standard value 55.56 mm (2.19 in.)
Clearance between piston and cylinder body
Diameter of piston cup (lip side) 2
Service limit (To be replaced every year)
45 to 69 N•m (4.6 to 7.0 kgf•m)
Tightening torque for cylinder mounting bolts Standard value
[33 to 51 lbf•ft]
22±3 N•m (2.25±0.35 kgf•m)
Tightening torque for bleeder screw Standard value
[16±3 lbf•ft]
1 2
210445
7.7 Parking brake lever

Locked position of lever A Standard value 63° to 66°
245 to 294 N (25 to 30 kgf)
Lever operating effort F Standard value
[55 to 66 lbf]
F
A
212242
10-54
BRAKE SYSTEM
7.8 Parking brake drum

+0.5 +0.020
Standard value 304.8 0 mm (12.0 0 in.)
Thickness of brake lining 2
Clearance between drum and lining 3 Standard value 0.25 mm (0.01 in.)
Free length Standard value 77±0.75 mm (3.03±0.03 in.)
223±23 N (22.7±2.3 kgf)
Return spring 4 Test force Standard value
[50±5 lbf]
Length under test force Standard value 83 mm (3.27 in.)
145±22 N•m (14.8±2.2 kgf•m)
Tightening torque for support plate nut 5 Standard value
[107±16 lbf•ft]
96±15 N•m (9.8±1.5 kgf•m)
Tightening torque for brake drum nut 6 Standard value
[71±11 lbf•ft]
1 3 2
210447
10-55
STEERING SYSTEM
1. Specifications ............................................................................................................. 11-2
2. Structure..................................................................................................................... 11-3
2.1 Steering System.................................................................................................................................. 11-3
2.2 Steering valve ..................................................................................................................................... 11-4
2.3 Steering column .................................................................................................................................. 11-5
3. Procedure and Suggestions for Removal and Installation ......................................... 11-6

3.1 Removal and Installation of Steering Valve Piping ............................................................................. 11-6
3.2 Removal and Installation of Steering Wheel, Steering Valve and Tilt Lock Lever .............................. 11-7
3.2.1 Steering wheel .......................................................................................................................................... 11-8
3.2.2 Steering valve ........................................................................................................................................... 11-9
3.2.3 Tilt lock lever ........................................................................................................................................... 11-10
5. Service Data............................................................................................................. 11-12
11
11-1
STEERING SYSTEM
1. Specifications
Truck model DP100N - DP160N

Steering type Full-hydraulic power steering
3
Displacement volume in cm /rev 369
(cu in./rev) (22.5)
Rated flow rate in l/min 45.4
Steering control valve
(qt/min) (48)
Maximum pressure in MPa 17.2
(PSI) (2495)
320
Steering wheel outside diameter in mm (in.)
(12.6)
11-2
STEERING SYSTEM
2. Structure
2.1 Steering System
8 6
4
9
1 2 3
212023
1 Hydraulic tank 6 Control valves for operation devices

2 Return filter 7 Check valve
3 Suction strainer 8 Steering valve
4 Gear pump (oil pump) 9 Power cylinder
5 Priority valve
This truck has employed a full-hydraulic steering system discharged from the oil pump is supplied to the steering
that consists of steering valve, priority valve, power cylin- valve. Flow rate required for the steering operation is deter-
der, and so on. Also with the load sensing mechanism the mined at the priority valve. If the steering system does not
operator is provided with steering operations which are require a large quantity of hydraulic oil, the rest of the
comfortable and hardly affected by the load conditions. The hydraulic oil will be supplied to other operation device
turning of the steering wheel is changed to a hydraulic pres- lines. Except on the steering operation, most of the hydrau-
sure in the steering valve, then transformed to the steering lic oil can be used for other operation devices.
force in the power cylinder on the rear axle. Hydraulic oil
11-3
STEERING SYSTEM
2.2 Steering valve
LS (Load sensing)
R (RIGHT)
L (LEFT)
L R
L T
R P
T LS P
T (OUT) P (IN)
Hydraulic circuit
212027
The steering valve is provided with a load sensing circuit. Steering cylinder
This load sensing circuit functions as to balance between
the downstream oil pressure of variable orifice in the steer-
ing valve and the counter-side oil pressure of the spool in Load sensing
Input L R
the priority valve. This offers a smooth steering operation steering valve
that is not affected by the variation in load conditions. T P
LS
High
OF
pressure
Steering
relief EF
LS DS PP
T
Filter
Main P Priority valve

relief
Filter
Pump Engine
Tank
212028
11-4
STEERING SYSTEM
2.3 Steering column
Column position when steering column

is tilted fully forward
Column position when lock is released Column neutral tilt position
13 (inclination of 30 degrees to vertical line)
5 Column position when steering column is
7 tilted fully rearward
Combination switch
mounting plate
Steering column
mounting plate A
1
2
Tilt angle
setting plate B
2
Bolt
Fix 3
Loosen
5 Nut
Lock release
4
When the tilt lever 3 is turned counterclockwise,the

plates A and B are fixed between the bolt and nut.
212022
1 Steering column 4 Column lock lever

2 Bracket (fixed to truck body) 5 Locking pin
3 Tilt lock lever
The tilting angle of steering column is adjustable for the lock it.
ranges of 5° forward and 7° rearward, respectively as This column lock lever is useful for such cases where the
shown in the figure. entire column unit must be tilted forward (i.e. to the front)
This adjustment can be achieved by turning the tilt lock for ease of getting on and off or servicing. As shown in the
lever clockwise to loosen it after locking the column lock figure, if you push the lock lever to the left, the lock lever
lever. Then, tilt the steering column to an optimal angle and can be disengaged from the lock pin, and the steering col-
turn the tilt lock lever counterclockwise (i.e. pull it up) to umn can tilt to the front.
11-5
STEERING SYSTEM
3. Procedure and Suggestions for Removal and Installation

3.1 Removal and Installation of Steering Valve Piping
Major components
1 Hose (from priority valve to steering valve P port)
2 Hose (from steering valve T port to control valve T2
port)
3 Hose (from steering valve L port to power cylinder L
port) 7
4 Hose (from steering valve R port to power cylinder
R port)
5 Hose (from load sensing LS port to priority valve LS 6
port)
6 Steering valve 2
1 5
7 Priority valve
4
3
212029
Suggestions for disassembly and reassembly

(1) The important point in servicing the hydraulic system
is to proceed your operation in a clean environment and
never allow any abrasive matters entering inside the Tightening torque of nut
system. 44 to 54 N m
(2) On reassembly be sure to place a new replacement O-
ring in any section that has installed an O-ring before
disassembly.
(3) Hoses of the steering system (especially, in the high-
pressure section) are safety parts. These must be
replaced with new ones disregarding with or without
damage after they have been used for a specified period
of time. For the replacement intervals, refer to the
Operation & Maintenance Manual. Check valve
(4) When any hose is removed or replaced, use double 212030
spanners (wrenches) as required for not applying an
excessive force to the mating fitting.
11-6
STEERING SYSTEM
3.2 Removal and Installation of Steering Wheel, Steering Valve and Tilt Lock Lever
Tightening torque :
2 18 to 22 N m 1
7
Tightening torque : 4
27 to 35 N m
5 Tightening torque :
29.4 N m
212024
1 Steering wheel 5 Steering valve mounting bolt

2 Nut 6 Steering valve
3 Spring washer 7 Steering column assembly mounting bolt
4 Cover 8 Steering column assembly
11-7
STEERING SYSTEM
3.2.1 Steering wheel

Removal M12 bolt
(1) Remove the horn button.
M8 bolt
(2) Remove steering wheel nut 2, then remove steering
wheel 1 using a wheel puller (special tool).
91268 - 10600
Wheel puller
Special tool
Wheel puller 91268-10600
Steering wheel
CAUTION
209708
When removing the steering wheel, do not tap the
top end of the steering shaft. Wheel puller setting
Installation
Follow the procedure shown below: Horn switch contact
(1) Turn the protrusion (a) of handling sensor provided on

the combination switch by hand to the shown direction Front
in the figure.
(2) Apply a thin coat of grease on the horn contact sliding
surface at the lower end of the steering wheel boss. (a)
(3) Assemble the steering wheel as it corresponds to
Protrusions form an
straight ahead position. (The protrusion on the combi- isosceles triangle.
nation switch must fit with the concave provided on the
steering wheel.) Front
Turn this for several times clockwise and counterclock- Combination switch
wise until it fits in completely.
(4) Before tightening the steering wheel nut, make sure
that the auto-return function of the combination switch Forward
normally operates.
(5) If the auto-return function does not work satisfactorily,
repeat the above steps (3) and (4).
(6) Tighten the steering wheel nut to the specified torque.
209709
11-8
STEERING SYSTEM
Inspection after installation

Inspection of the operation effort of steering wheel
(1) Activate the parking brake.
(2) Start the engine and wait until the hydraulic oil temper-
ature rises to 40 to 60°C (104 to 140°F).
(3) Run the engine at an idling speed, and hook a spring
scale on either the outermost circumference of the
steering wheel or spoke to measure steering effort
when the steering wheel is turned to the right or left
from the straight ahead position. The steering effort
must be smaller than the following value.
Steering effort
(at the outer circumference 13 N (1.3 kgf) [2.87 lbf]
of steering wheel)
209710
3.2.2 Steering valve

Removal
(1) Remove the cover around the steering column.
(2) Disconnect five pieces of hoses from the steering Tightening torque of bolt
29.4 N m
valve.
(3) Remove the steering valve mounting bolt and then,
remove the steering valve.
Installation
Replacement must follow the reverse order of removal.
(1) Apply grease on the serration provided at the lower
part of the steering shaft.
(2) Tighten the steering valve mounting bolt to the speci-
Check valve
fied torque.
212031
(3) Tighten the hose nut to the specified torque.
(4) After reassembly, be sure to perform air bleeding.
• Lift the rear wheels from the ground using a support such
as a jack stand positioned under the truck body.
• Start the engine and operate the acceleration pedal to vary
the engine speed while turning the steering wheel fully to
the right and left. This bleeds air from the relief valve.
11-9
STEERING SYSTEM
3.2.3 Tilt lock lever

Top face of
Disassembly
lever
(1) Put each alignment mark on the tilt lock lever and nut
(B) to ensure proper reassembly.
(2) Remove bolt A, then remove the tilt lock lever.
★
Reassembly
When the alignment marks have faded out or the lever is to
be replaced with new one, install it according to the follow-
ing procedure. (The illustration on the right shows the rela- Tilt lock lever
tive positions of the consisting parts between tilt and neutral
under the condition of the column lock lever being locked.)
Lever mounting bolt
(1) Tighten nut B to the tightening toque of 11 to 15 N•m
(1.1 to 1.5 kgf•m) [8.1 to 11.1 lbf•ft]. (This corre-
sponds to the condition when the lever is locked.)
(2) Select a position for the tilt lock lever to have the opti- Nut B
mal position when it is locked, and engage the tilt lock
lever in the serration of nut B.
The optimal position corresponds to such a range where
the cut ( part) of the fitting intersects the lever's upper Tilt lock lever
contour.
(3) Tighten bolt A. Bolt A
209712
(4) Release the tilt lock lever, and make sure that the
bracket can slide over the entire tilting range without
interfering with other parts.
11-10
STEERING SYSTEM
4. Troubleshooting
Insufficient service oil flow rate

• Spool orifice damaged • Clean.
• Spool spring damaged • Replace.
Defect in flow pri- Defect in relief valve
ority valve • Unsatisfactory adjustment • Readjust.
• Valve seat damaged • Replace relief valve assembly.
Shift steer- • Spring damaged • Adjust after replacement.
ing wheel
operation • Oil leak from relief valve due to damaged O-ring • Replace.
• Clog at the measuring section • Clean.
Defect in steering
• Unsmooth movement of spool • Clean.
valve
• Bearing damaged • Replace.
Defect in power • Piston rod deformed • Repair or replace.
cylinder • Piston seal damaged • Replace.
Others • Pipe or tube is flattened or the flow is obstructed • Repair or replace.
Defect in steering • Spool or sleeve stacks • Repair or replace.
Abnormal
valve • Centering spring damaged • Replace.
vibration of
steering • Pipe or tube is flattened or the flow is obstructed • Repair or replace.
wheel Others
• Power cylinder piston seal damaged • Replace.
Abnormal sound from steering • Air trapped in hydraulic oil. • Air-bleed.
system • Power cylinder installation is loose • Repair or replace.
11-11
STEERING SYSTEM
5. Service Data
Truck model DP100N - DP160N
Steering effort (at the outer circumference of steering
wheel) 1.96 N•m
(The standard value corresponds to a case where the Standard value (0.2 kgf•m)
engine is at low idle，steering wheel turning speed is 1 [1.45 lbf•ft]
turn/second in stationary steering. )
Play in the steering wheel Standard value 70 mm ( 2.75 in.)
Inside Standard value 74°
Steering angle
Outside Standard value 48°25′
Steering wheel mounting nut
Standard value 18 to 22 N•m
tightening toque
Steering wheel bracket mounting nut
Standard value 27 to 35 N •m
tightening toque
Discharge capacity Standard value 369 cc (22.5 cu in.)
Rated flow rate Standard value 45.4 cc (2777 cu in.)
17.2 MPa
Steering valve Maximum pressure Standard value (175 kgf•cm2)
[2490 psi]
29.4 N•m
Tightening torque of mounting bolt Standard value (3.0 kgf•m)
[21.7 lbf•f]
11-12
HYDRAULIC SYSTEM
1. Specifications ............................................................................................................. 12-3
2. Structure..................................................................................................................... 12-4
2.1 Hydraulic line ...................................................................................................................................... 12-4
2.2 Hydraulic tank ..................................................................................................................................... 12-6
1
2.3 Priority valve ....................................................................................................................................... 12-7
2.4 Control Valve ...................................................................................................................................... 12-8 2
2.5 Lift and tilt cylinder .............................................................................................................................. 12-9
2.6 Flow regulator valve.......................................................................................................................... 12-10 3
3. Suggestions for Removal and Installation ................................................................ 12-11
3.1 Control Valve .................................................................................................................................... 12-11
4
3.1.1 Removal .................................................................................................................................................. 12-11
3.1.2 Removal sequence ................................................................................................................................. 12-11 5
3.1.3 Preparation.............................................................................................................................................. 12-11
3.1.4 Suggestions for Removal ........................................................................................................................ 12-12
3.2 Lift cylinder........................................................................................................................................ 12-13
6
3.2.1 Removal .................................................................................................................................................. 12-13
3.2.3 Suggestions for Removal ........................................................................................................................ 12-13
3.2.4 Installation ............................................................................................................................................... 12-15
8
3.3 Tilt cylinder........................................................................................................................................ 12-16
3.3.1 Removal .................................................................................................................................................. 12-16
3.3.3 Preparation.............................................................................................................................................. 12-16
3.3.4 Suggestions for Removal ........................................................................................................................ 12-17 10
4. Priority valve............................................................................................................. 12-19
4.1 Disassembly and Reassembly.......................................................................................................... 12-19
11
4.1.1 Disassembly sequence ........................................................................................................................... 12-19
4.1.2 Suggestion for disassembly .................................................................................................................... 12-19 12
4.1.3 Suggestion for reassembly...................................................................................................................... 12-19
13
5. Flow regulator valve ................................................................................................. 12-20
5.1 Disassembly...................................................................................................................................... 12-20
5.1.1 Disassembly sequence ........................................................................................................................... 12-20 14
5.2 Inspection and Repair ....................................................................................................................... 12-20
5.3 Reassembly ...................................................................................................................................... 12-20 15
12-1
HYDRAULIC SYSTEM
6. Lift cylinder ............................................................................................................... 12-21

6.1 Disassembly...................................................................................................................................... 12-21
6.1.2 Suggestion for disassembly .................................................................................................................... 12-21
6.3 Reassembly ...................................................................................................................................... 12-24
6.3.1 Reassembly sequence ............................................................................................................................ 12-24
7. Tilt cylinder ............................................................................................................... 12-25

7.1 Disassembly...................................................................................................................................... 12-25
7.1.2 Suggestion for disassembly .................................................................................................................... 12-26
7.3 Reassembly ...................................................................................................................................... 12-28
7.3.1 Reassembly sequence ............................................................................................................................ 12-28
8. Inspection and Adjustment ....................................................................................... 12-30

8.1 Hydraulic oil ...................................................................................................................................... 12-30
8.2 Test operation of gear pump............................................................................................................. 12-30
8.3 Control Valve .................................................................................................................................... 12-31
8.4 Adjusting main relief valve ................................................................................................................ 12-31
8.5 Functional inspection of priority relief valve ...................................................................................... 12-32
9. Tests ........................................................................................................................ 12-33
10.Troubleshooting....................................................................................................... 12-34
11.Service Data ............................................................................................................ 12-38
12-2
HYDRAULIC SYSTEM
1. Specifications

Type Gear type
Maker model KFP51100CSMSL
Gear pump
Control flow rate 205 L/min (54.2 U.S. gal.) (at 2200 rpm)
Drive method Directly coupled to torque converter
Maker model VLH71C160B
Priority valve
Relief pressure 15.7 MPa (160 kgf/cm2) [2277.3 psi]
Maker model MW(P) 25
Control Valve +0.5
Hydr Relief pressure 20.6 0 MPa (210.1 kgf/cm2) [2988.1 psi]
aulic
sys- Flow regulator Type Cylindrical valve type
tem valve Control flow rate 120 L/min (31.7 U.S. gal.) 150 L/min (39.6 U.S. gal.)
120 mm
Inside diameter 105 mm (4.13 in.) φ115 mm (4.5 in.)
Lift cylinder (4.7 in.)
Inside diameter 120 mm (4.7 in.)
Tilt cylinder
N level: 184
N level: 168 L
Service oil quantity (tank level) N level: 140 L (37.0 U.S. gal.) L (48.6 U.S.
(44.4 U.S. gal.)
gal.)
12-3
HYDRAULIC SYSTEM
2. Structure
2.1 Hydraulic line
10,9 10,9
11
15
11
8
5
7
13
12
14 4
1 2 3
211967
1 Hydraulic tank 9 Flow regulator valve

2 Return filter 10 Lift cylinder
3 Suction strainer 11 Tilt cylinder
4 Gear pump (oil pump) 12 Check valve
5 Priority valve 13 Steering valve
6 Control valves for work machines 14 Power cylinder
7 Lift valve 15 Lift return valve
8 Tilt valve
12-4
HYDRAULIC SYSTEM
The hydraulic system functions in such a way that it sucks

up the service oil from the hydraulic tank and distributes
thus pressurized oil dividedly to the service equipment and
steering system through an adjustment with the priority
valve.
Pressurized oil at the service equipment will be fed to each
cylinder through the control valve.
NOTE
The steering control valve is described in “11 STEERING
SYSTEM”. Also for power cylinder, refer to “9 REAR
AXLE”.
12-5
HYDRAULIC SYSTEM
2.2 Hydraulic tank
4 3 2
211968
1 Breather 3 Suction strainer

2 Drain plug 4 Return filter
The hydraulic tank is an integral structure with the frame

and is provided with a strainer at the oil supply port, suction
strainer, and return filter to keep the oil clean.
Oil in the hydraulic tank will be drawn into the gear pump
through the suction strainer (105 μ).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 μ).
12-6
HYDRAULIC SYSTEM
2.3 Priority valve
LS
T
1
4
EF
CF
6
205648
1 Relief Valve P: Pump port

2 Plug T: Tank port
3 Housing CF: Control flow port
4 Control spring EF: Main flow port (control valve for service equipment)
5 Spool LS: Load sensing port
6 Plug
Of the service oil discharged from the gear pump, only the When the steering is in neutral position, almost all of the
amount required for steering operation will be supplied by service oil will be used for driving all the other service
the priority valve to the steering control valve, and all the equipment.
rest will be forwarded to circuits of other service equip-
11.8 MPa
ment. Priority relief pressure (120.3 kgf/cm2)
[2988.1 psi]
12-7
HYDRAULIC SYSTEM
2.4 Control Valve
B2
2 T
A2 A1 1
211932
1 Inlet valve P: From priority valve

2 Block T: To tank
3 Main relief valve adjustment screw A1: To lift cylinder
4 Tie bolt A2: To tilt cylinder
B2: From tilt cylinder
The control valve is an assembly of more than one valve

block which are tied by three tie bolts.
Each block has a pump port and tank port provided, and is
mounted with a cartridge-type pilot-operate relief valve.
12-8
HYDRAULIC SYSTEM
2.5 Lift and tilt cylinder
Bottom-side port
Flow regulator valve

Rod-side port
Lift cylinder
210468
The lift cylinder is a single working type of which the pres-
surized oil reacts only in one direction for pressing the pis-
ton.
The bottom-side port has a flow regulator valve built in, and
oil return pipe at the rod side port.
Socket Collar
211969
The tilt cylinder is a dual working type and has the rod end
threaded for adjusting the balance between the right and left
when the mast is mounted.
The tilt angle setting can be modified through an optional
adjustment of collar and socket.
12-9
HYDRAULIC SYSTEM
2.6 Flow regulator valve
To lift cylinder
From lift cylinder
From control
valve To control valve
To other
flow regulator
valve
210470 210471
The flow regulator valve will pass the entire amount of ser-
vice 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 main-
tained 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 cyl-
inders can be even.
12-10
HYDRAULIC SYSTEM

3.1 Control Valve
3.1.1 Removal
10
10
7
2 3
211970

1 Pipe 6 Pipe, O-ring, Bolt, Washer
2 Flow regulator valve, Pipe, O-ring, Bracket, Bolt, Wash- 7 Pipe, O-ring, Bolt, Washer
er, Collar,
3 Hose, Clamp, Pipe 8 Pipe, O-ring
4 Hose 9 Pipe, O-ring
5 Hose 10 Connector
3.1.3 Preparation
NOTE
Before disconnecting each pipe, prepare oil receivers to
(1) Remove the floor plate. catch oils remaining in the pipes and hoses. Further, take
(2) Before disconnecting each pipe, make the mast in neu- appropriate measures for the connections of pipes and con-
tral position and lower the fork to the bottom in order trol valves to prevent dust and dirt from entering in the
to purge the residual pressure in the pipe. openings.
12-11
HYDRAULIC SYSTEM

Removing control valve
When removing the control valve, support it by lifting it
with a rope, etc. beforehand.
Type Weight
Triplet valve 45 kg (99.2 lb)
Quadruplet valve 55 kg (121.3 lb)
Quintuplet valve 65 kg (143.3 lb)
12-12
HYDRAULIC SYSTEM
3.2 Lift cylinder

3.2.1 Removal
Connector
5
1
2
4
3
211971
1 Lift bracket 5 Stopper bolt
2 Return hose, Hose clamp 6 Cylinder clamp, Cushion, Collar, Shim
3 High-pressure hose 7 Stopper bolt
4 Constant descending hose 8 Lift cylinder
Push the lift lever of the control valve forward slowly to

3.2.3 Suggestions for Removal lower the mast.
(1) Removing return hose NOTE
Start the engine and raise the mast to the top, then stop During this operation never touch the lift lever of the con-
the engine. Disconnect each return hose for the right and trol valve.Push the lift lever of the control valve forward
left lift cylinders at their connectors. slowly to lower the mast.
(2) Lower the lift bracket.
12-13
HYDRAULIC SYSTEM
(3) Removing high-pressure hose and constant descending

hose
Remove the hose from the joint at the lower part of the
lift cylinder.Prepare containers to catch oil, which
should remain in the high-pressure hose.
(4) Removing stopper bolt

(a) Remove the stopper bolt at the upper section of the lift
cylinder, and lift the inner mast up to separate the cyl-
inder rod end from the mast.
Before lifting up the inner mast, wrap the inner mast
with a protective cloth and put the wire rope over there
in such a way that includes an extra turn.
NOTE
As the rod end section of the lift cylinder has some shims
inserted, record how many number of shims inserted in
which cylinder, right or left, before removal.
(b) Place wooden blocks with enough strength to support

210475
the weight of the inner mast under the mast, then
remove the wire rope.
(5) Removing lift cylinder

Hoist the lift cylinder from the rear of the mast with a
rope to carefully remove it. Put a wire rope on the lift
cylinder before removing the cylinder clamp.
210476
12-14
HYDRAULIC SYSTEM
3.2.4 Installation
(1) Bleed air by repeating full upstroke and downstroke
under no load, and make sure whether the operation is
normal.
(2) After making sure the operation, inspect the service oil
level with an oil level gauge (Refer to the paragraph of
“Service oil quantity and raised height of mast”).
(3) Check whether the raised height of mast is at the nor-
mal value.
(4) When either the lift cylinder or piston rod has been
replaced, always inspect the balance (for the inspection
and adjustment method, refer to “13 Mast and Fork”).
12-15
HYDRAULIC SYSTEM
3.3 Tilt cylinder

3.3.1 Removal
3 4
1
211972

1 Tilt socket pin, Collar, Washer, Spring washer, Bolt 4 Tilt cylinder pin, Collar, Washer, Spring washer, Bolt
2 Bearing, Snapring, Spacer 5 Tilt cylinder
3 Hose
3.3.3 Preparation
(1) Block the front wheels.
(2) Fully tilt the mast forward and slowly lower the lift
bracket.
When the forks tips reach the ground, stop the engine.
(3) Open the overhead cover.
12-16
HYDRAULIC SYSTEM

Remove the tilt cylinder in the following order.
(1) Removing tilt socket pin
(a) Lift and support the right and left cylinders at position
A shown in the figure. (Use two pieces of wire rope.)
(b) Remove the socket pin mounting bolt, washer, and col- Tilt
A
lar. cylinder
pin
(c) Drive in the jack bolt (M10 × 1.25) at section B shown
in the figure to remove the tilt socket pin.
(2) Retract the tilt cylinder rod.
B
Start the engine and retract the cylinder rod to minimum
while lowering the crane. Then, stop the engine.
(3) Lower once the right and left cylinder to the ground, Protective cloth 210479
and unhook the wire rope from the crane.
(4) Disconnecting hose

(a) Disconnect hose 2 from the connector of the cylinder.
(b) On this time, cap the connector end at the socket side Cap
of the tilt cylinder.
Cap (G1/2) 05530 - 40400
NOTE
This cap serves as to confine the oil to within the cylinder
and prevent the cylinder rod from extending. Before lifting Entrapped oil
211973
the tilt cylinders, be sure to attach both the right and left
caps.
12-17
HYDRAULIC SYSTEM
(5) Removing tilt cylinder

(a) Lift the tilt cylinder to be removed by a crane.
(b) Remove the tilt cylinder pin mounting bolt.
(c) Drive in the jack bolt (M10 × 1.25) at section A shown A
in the figure to remove the tilt cylinder pin.
(d) Pull out the seat frame in the forward direction while
lifting the tilt cylinder by the crane.
211978
12-18
HYDRAULIC SYSTEM
4. Priority valve
4.1 Disassembly and Reassembly
205657

1 Spool, Plug, O-ring, Spring 3 Relief valve, O-ring
2 Plug, O-ring 4 Housing
4.1.2 Suggestion for disassembly

Do not disassemble relief valve 3 further than that shown in
the figure.
4.1.3 Suggestion for reassembly

44.1 N•m
Tightening torque of plugs 1 and 2 (4.50 kgf•m)
[32.55 lbf•ft]
20.6 N•m
Tightening torque of relief valve 3 (2.10 kgf•m)
[15.20 lbf•ft]
12-19
HYDRAULIC SYSTEM
5. Flow regulator valve

5.1 Disassembly
4 3
210492

1 Plug, Ring, O-ring 4 Valve, Spring pin
2 Snap ring 5 Spring, Washer, Shim
3 Piston 6 Sleeve
5.2 Inspection and Repair

(1) Check the spring for deterioration.
(2) Check each contact surface and sliding surface of the
check valve seat for damage.
(3) Check each sliding surface of support and sleeve for
damage.
NOTE
When any of the parts are damaged, replace the whole
assembly.
5.3 Reassembly
Reassembly should be followed in the reverse order of dis-
assembly.
12-20
HYDRAULIC SYSTEM
6. Lift cylinder
6.1 Disassembly
∗
∗
2 ∗
∗
3
∗
∗ Seal kit parts 210493

1 Rod cover, Dash seal, Rod packing, O-ring, Bushing 3 Wear ring, Backup ring, Packing
2 Piston rod, Collar 4 Cylinder tube
Removing piston rod

(1) Wrap the lift cylinder with a piece of waste cloth, and
hold it in a vise. Remove the cylinder head and rod
cover with Hook Wrench A.
Special tool
DP135N,
DP100N,
Truck model DP150N,
DP120N
DP160N
Hook wrench A 05312 - 11000 05312 - 11200 A
(2) When pulling out the piston rod from the cylinder, be 602303
careful not to damage the wear ring.
12-21
HYDRAULIC SYSTEM

Cylinder tube
(1) Check the inside surface of the cylinder for wear, dam-
age, or rust.
(2) Check the welded part for cracks, damage, and dent.
Piston rod
(1) Check the piston rod if it may cause runout.
Support both ends of the piston rod with V-shaped
blocks, and measure its runout using a dial gauge at the
center while turning the piston rod. If 1/2 of dial indica-
tor reading exceeds the limit, replace the piston rod. 200319
(2) Check the rod surfaces for rust, damage, sliding trace,
and dent.Replace the piston rod, if it is seriously dam-
aged in the threaded part.
Ring and packing

(1) Check the packing and wear ring for damage or distor-
tion.
(2) Check each ring for deterioration.

Standard
115 mm (4.53 in.)
value
Inside diameter of cylinder tube 1
Repair or
Piston 115.15 mm (4.534 in.)
service limit
Deflection of piston rod 2 (1/2 of dial Repair or
0.5 mm (0.02 in.)
indicator reading) service limit
-0.030 -0.0012
Standard 60 -0.104 mm [2.36 -0.0041 in.] (Mast height 5500 to 7000 mm
Outside diameter of piston rod 3
value [18.04 to 22.97 ft]: 75
+0.035
-0.039 mm [2.95
+0.0014
-0.0015 in.])Note 1
+0.11 +0.0043
Rod cover Standard 60 0 mm [2.36 0 in.] (Mast height 5500 to 7000 mm
Inside diameter of rod cover bushing 4
value +0.19 +0.0075
[18.04 to 22.97 ft]: 75 +0.06 mm [2.95 +0.0024 in.])Note 1
Standard
Rod cover tightening torque 5 1.18±0.1 kN•m (120.3 ± 10.2 kgf•m) [870.8 ± 73.8 lbf•ft]
value
Note 1: The mast height for DP135N and DP150N is from 5000 to 7000 mm.
12-22
HYDRAULIC SYSTEM
5 2
4 3 1
210494
12-23
HYDRAULIC SYSTEM
6.3 Reassembly
∗ Seal kit parts
4 1 3 2
∗ ∗ ∗ ∗ ∗ ∗
210495
6.3.1 Reassembly sequence

1 Piston rod, Collar 4 Rod cover, Bushing, O-ring, Packing, Dust seal
2 Wear ring, Backup ring, Packing
3 Cylinder tube

(1) During reassembly, do not forget to replace the Seal Kit
parts marked with an asterisk (*) in the figure.
(2) Thoroughly clean all parts before reassembly making
(3) Apply a coat of oil to each inside surface of rings,
bushings, and cylinder tube before reassembly.
(4) When holding the cylinder’s outer circumference on a
vise, be careful not to tighten the vise excessively as to
distort the cylinder.
(5) Before tightening the rod cover, apply Loctite #638 to
the threaded part of the cylinder tube.
1.18 ± 0.1 kN•m
Rod cover tightening torque (120.3 ± 10.2 kgf•m)
[870.8 ± 73.8 lbf•ft]
12-24
HYDRAULIC SYSTEM
7. Tilt cylinder
7.1 Disassembly
4
∗
∗ 3
∗
∗ 2
∗
∗

1 Socket, Nut 4 Piston, Self-locking nut, Piston seal
2 Guide bushing, Dust seal, Packing, Buffer ring, O-ring, 5 Piston rod
Backup ring
3 Collar 6 Cylinder tube, Bushing
NOTE
The bushing press-fit in cylinder tube 6 does not have to be
disassembled unless defective.
12-25
HYDRAULIC SYSTEM

Removing guide bushing
(1) Wrap the tilt cylinder with a piece of waste cloth, and
hold it on a vise. Remove the guide bushing using
Hook wrench A.
Special tool
Hook wrench A 05312 - 11000
(2) Before removing the guide bushing, wrap the threaded

part of the piston rod with a vinyl tape so that the
thread edges may not damage the buffer ring and pack-
ing. 200351
12-26
HYDRAULIC SYSTEM

Cylinder tube
age, or rust.
Piston rod
center while turning the piston rod. If 1/2 of dial indica-
tor reading exceeds the limit, replace the piston rod.
and dent.Replace the piston rod, if it is seriously dam-
aged in the threaded part.
Ring and packing
200319
(1) Check the lips of packing and buffer ring for damage or
distortion.
(2) Check each ring for deterioration.

Standard value 120 mm (4.7 in.) 130 mm (5.1 in.)
Inside diameter of cylinder tube 1 120.12 mm
(4.729 in.)
Outside diameter of piston rod 2 Standard value 55 mm (2.17 in.)
Guide bushing Clearance between rod and guide Standard value 0.1 mm (0.004 in.)
bushing Repair or service limit 0.2 mm (0.008 in.)
+0.100 +0.0039
Inside diameter of bushing 3 (under press-fit)
637±63.7 N•m 696.5±69 N•m
Tightening torque of guide bushing 4 Standard value (64.95±6.5 kgf•m) (71.02±7.03 kgf•m)
[470.1±47.0 lbf•ft] [514.0±50.9 lbf•ft]
1178 to 1472 N•m (120.1 to 150.1 kgf•m)
Tightening torque of socket nut 5 Standard value
[869.4 to 1086.3 lbf•ft]
Deflection of piston rod 6 (1/2 of dial indicator
reading)
5 4 2 1 6
211975
12-27
HYDRAULIC SYSTEM
7.3 Reassembly
∗ Seal kit parts

∗ ∗
4 3 1 2
211976
7.3.1 Reassembly sequence

1 Piston rod, Collar, Piston, Self-locking nut, Piston seal 3 Guide bushing, Packing, Buffer ring, Dust seal, Backup
ring, O-ring
2 Cylinder tube, Bushing 4 Socket, Nut

(3) Coat each inside surface of the piston seal, O-ring,
packing, dust seal and cylinder with service oil before
reassembly.
(4) When holding the cylinder’s outer circumference on a
vise, be careful not to tighten the vise excessively as to
distort the cylinder.
200352
12-28
HYDRAULIC SYSTEM
(5) Procedure to install piston seal into tilt cylinder

(a) Lightly compress and release a piston seal 5 to 6 times
by hand to make it soft.
(b) Hold the piston with a vise while taking care so as not
to damage the piston rod, and apply a thin coat of oil on
the piston seal. First fit the one side of the piston seal
into the mounting groove provided on the piston, then
press-in the other side.
(6) Make sure each direction of the packing and dust seal
to be inserted into the guide bushing. 204641
12-29
HYDRAULIC SYSTEM
8. Inspection and Adjustment

8.1 Hydraulic oil
Cloudy oil should be changed, since any water is suspected
to mix in. When the oil is checked immediately after operat-
ing the control lever, be careful not to mistake the bubbles
of oil as a mixture with water.
Suction strainer, Return filter
Check for damage or clogging, and clean or replace.
8.2 Test operation of gear pump
Test operation is to perform run-in of the pump and make
sure the performance. This test operation is desirable to be
performed on the test stand, however, since the actual ser-
vice is impossible, use the following method with the gear
pump installed on the truck.
(1) Connect an oil pressure gauge (gauge, 25 MPa (254.9
kgf/cm2) [3626.3 psi]) on the upper right surface of the
control valve.
Installing oil pressure indicator:
Remove the plug from the connector of delivery hose
and attach the following tool instead.
Connector 64309 -17734(R (PT) 1/4 thread screw)

Hose 64309 - 17722
Connector 64309 - 17731 (for gauge installation)
64309 - 17712 (25 MPa (254.9 kgf/cm2)

Gauge
[3626.3 psi])
Adjusting screw
NOTE 211977
Tools mentioned above are included in the Gauge Kit
64309-17701.
(2) Make the control lever to the neutral position and run
the engine at 500 to 1000 rpm. At the neutral position
the oil pressure meter must read 1 MPa (10.2 kgf/cm2)
[145.1 psi] or less.
Continue to run the engine in this condition for 10 min-
utes and hear if the pump generates abnormal sound.
(3) When 10 minutes elapses, raise the engine speed to
1500 to 2000 rpm, and continue to run the engine under
no load for more 10 minutes.
(4) Loosen the adjusting screws of the relief valve under
the condition of paragraph (3) and shift the control
lever to the active position. Then, adjust the adjusting
screw to set the pressure to 3 MPa (30.6 kgf/cm2)
[435.2 psi], and run the engine for 5 minutes. Continu-
ously raise the pressure further at 2 MPa (20.4 kgf/cm2)
[290.1 psi] increments and run the engine for 5 minutes
each time until the relief valve reaches the specified
pressure setting.
12-30
HYDRAULIC SYSTEM
(5) During the process of raising the pressure, watch the

oil temperature, pump surface temperature, and abnor-
mal sound from the pump, etc. If the oil temperature or
pump temperature abnormally rises, cancel the load
and lower the temperature to continue the test opera-
tion, or disassemble the pump again to inspect the
inside.
(6) Complete the operations of (2) to (5), then re-adjust the
relief valve to the specified pressure setting, and make
sure that the operation speed is normal.
8.3 Control Valve

Oil leak to the outside
(1) Oil leak from O-ring between housings
(2) Oil leak from O-ring of the scraper
(3) Oil leak at fastening screws
8.4 Adjusting main relief valve

(1) Connect an oil pressure indicator (gauge, 25 MPa
(254.9 kgf/cm2) [3626.3 psi]) on the left side of the
control valve.
The gauge, connector, hose, etc. to be used are same as
with the gear pump test operation.
(2) Start the engine and raise the speed to the maximum.
(3) The relief valve is turned to be normal, if the oil pres-
sure is relieved and the pressure meter hand points to
+0.5
20.6 0 MPa (210.1 kgf/cm2) [2988.1 psi] when the tilt
cylinder reaches the backward tilt limit as the result of
turning the tilt lever to the backward tilt position.
(4) If the relief pressure is not satisfactory, loosen the lock
nut of the relief valve adjusting screw and adjust the Adjusting screw
pressure while observing the gauge reading. 211977
NOTE
The reference amount of tightening-in of adjusting screw
for relief valve is such that one turn varies the pressure for
approx. 10.6 MPa (108.1 kgf/cm2) [1537.6 psi].
(5) Tighten the lock nut to secure the adjusting screw while
holding it by hand.
(6) After securing the adjusting screw, recheck the relief
valve pressure setting.
+0.5
20.6 0 MPa
Main relief valve pressure set-
ting (210.1 kgf/cm2)
[2988.1 psi]
12-31
HYDRAULIC SYSTEM
8.5 Functional inspection of priority relief valve

(1) Set an oil pressure indicator (gauge, 25 MPa (254.9
kgf/cm2) [3626.3 psi]) to the shown position in the fig-
ure at the right.
Ref- 211946
erenc Tool name Part No.
e No.
1 Connector 91268 - 01700 5
64309 - 17733(R (PT) 1/8 thread
2 Connector
screw) 4
3 Hose 64309 - 17722
4 Connector 64309 - 17731 (for gauge installation) 3
64309 - 17712 (25 MPa (254.9 kgf/

5 Gauge
cm2) [3626.3 psi]) 2
NOTE
(a) Tools numbered as 2 to 5 are included in the Gauge Kit
64309-17701. 1
(b) Oil pressure indicator (gauge) to be mounted can be 211947
such that has a twice capacity of the oil pressure to be mea-
sured, however, in this case, use an appropriate device
included in the Gauge Kit.
(2) Start the engine and raise the speed to the maximum.
(3) The relief valve is turned to be normal, if the oil pres- Adjusting plug
sure is relieved and the pressure indicator hand shows
+0.5 +5.1 +72.5
11.8 0 MPa (120.3 0 kgf/cm2) [1711.6 0 psi] when
the steering wheel is turned all the way to the left and
the steering cylinder stroke reaches the upper limit.
(4) If the relief pressure is not satisfactory, disconnect the
T-port piping of the priority valve and adjust the relief
pressure by turning the adjusting plug of the relief
valve.
NOTE
The reference amount of tightening-in of adjusting plug is 205668
such that one turn produces a change of approx. 7.4 MPa
(75.5 kgf/cm2) [1073.4 psi].
12-32
HYDRAULIC SYSTEM
10.Troubleshooting
• Not enough oil • Refill.

• Inappropriate oil viscosity • Refer to "List of Applicable Lubricant",
and replace oil.
• Operating conditions are hard and over-loaded. • Check the working conditions, and if over-
loaded, urge the operator to stay within the
Hydraulic load limit.
tank heats
• Local overheating of oil line due to a large restric- • Clean oil line.
excessively
tion to flow
Hydrau- • Relief valve adjustment improper • Adjust pressure setting.
lic tank
• Hydraulic pump worn • Replace pump.
• Outlet-side line flattened or restriction to flow • Repair or replace.
• Clogging of oil cooler • Clean.
• Shortage of oil due to a natural loss • Refer to "List of Applicable Lubricant",
Cylinders and refill oil.
move too • Oil leakage due to damaged oil line, seal, etc. • Repair or replace.
slow
• Oil viscosity is too high • Refer to "List of Applicable Lubricant",
and replace oil.
12-34
HYDRAULIC SYSTEM
• Gear pump does not pump-in oil • Check pump and piping. Repair or replace
if required.
Cylinders • Oil leaks from part of the hydraulic line • Check the oil level and contamination. Add
move too or change oil if necessary.
slow • Oil level abnormally high • Check the control valve spools for mis-
alignment. Repair or replace.
• Oil leaks inside of gear pump • Replace pump.
• Poor pumping of oil • Refer to "List of Applicable Lubricant",
and refill oil.
• Cavitation (1) Check suction pipe for any flat portion
or loose connection. Retighten or
Pump too
replace.
noisy
(2) Check shaft oil seal for air-tightness.
Gear Replace pump.
pump
(3) Check pump body for any outside inter-
ference. Repair.
• Subjected to pressure greater than that rated • Check if pressure control valve operates
normally. Replace pump.
Pump case,
drive gear or • Distortion or damage due to external strain or • Replace pump.
pump port stress (1) Check if return line has been blocked or
flange dam- restricted to flow.
aged
(2) Check if pipe connection has been exter-
nally strained or stressed.
• Oil leakage from oil seal • Replace seal.
Oil leakage • Oil leakage through sliding surfaces of drive shaft • Replace pump assembly.
from pump • Pump securing bolt loose • Retighten, and replace parts if required.
• Sealing inside pump deteriorated • Replace O-ring.
12-35
HYDRAULIC SYSTEM
• Too low valve opening pressure setting • Adjust pressure.
Slow or no • Relief valve piston jamming • Clean piston and check to see if it moves
motions of smoothly; or replace relief valve assembly.
lift and tilt • Outer O-ring on relief valve body damaged • Replace O-ring.
cylinders
• Control lever installed loose, resulting in not • Readjust.
Control enough spool stroke
Valve Lift drops or • Control valve spool internal leakage • Replace each block assembly.
tilts forward
• Oil leakage from spool ring cap • Replace O-ring; check spool. If necessary,
repair or replace each block assembly.
Oil leakage
• Plug loose • Retighten.
• O-ring damaged • Replace O-ring.
• Insufficient oil in hydraulic tank • Refer to "List of Applicable Lubricant",

and refill oil.
Mast will
not ascend, • Relief valve defects
tilt forward (1) Main valve jamming • Replace.
or backward. (2) Valve spring fracture
• Replace.
• Hydraulic pump defects • Replace.
• Relief valve defects
(1) Too low valve opening pressure setting • Adjust pressure.
(2) Plunger or poppet seat defects • Replace.
Unable to
lift rated (3) Spring fatigued • Replace.
load (4) O-ring in valve case damaged • Replace.
Lift and
tilt cylin- • Hydraulic pump defects • Replace.
der
• Piston seal worn or damaged • Replace.
• Engine speed too slow • Adjust engine.
Lifting • Control lever installed loose, resulting in not • Readjust.
speed too enough spool stroke
slow • Clogging of tank strainer • Wash or replace.
• Gear pump delivery rate too low • Repair or replace.
• Sleeve seized in flow regulator valve • Repair.
Lowering
• Hydraulic line extremely restricted from smooth • Clean or repair hydraulic system or replace
speed of lift
cylinder too flowing due to dirt clogged in flow regulator defective hose.
slow valve, or hydraulic hose fractured or locally
stopped.
12-36
HYDRAULIC SYSTEM
• Piston rod bend • Repair or replace.

Cylinder
vibrates dur- • Air mixed in hydraulic line • Bleed air by operating cylinder across full
ing opera- stroke.
tion
• Insufficient oil in tank • Refill.
• Control valve spool internal leakage • Replace each block assembly.
• Scratches on sliding surface of cylinder tube that • Repair or replace.
Lift cylinder can be felt by finger nail
descend
excessively • Sliding surface of cylinder tube badly grooved • Replace cylinder assembly.
• Piston seal damaged or distorted • Replace seal.
• Oil leakage from hydraulic line • Repair or replace.
• Control valve spool internal leakage • Replace each block assembly.
Tilt cylinder • Foreign matter lodged in packing • Replace packing.
Lift and
tilt cylin- tilt forward • Piston seal damaged • Replace seal.
der excessively
• Abnormal distortion or oil leakage from hydraulic • Repair or replace.
line
Lift cylinder • Inside surface of cylinder badly grooved • Repair or replace.
or tilt cylin-
• Cylinder distortion • Replace.
der will
descend or
tilt forward
at a certain
point
• Foreign matter lodged in oil seal or dust seal • Replace.
Oil leakage • Inner or outer diameter of oil seal or dust seal • Replace.
from bush- damaged
ing • O-ring damaged • Replace O-ring.
• Abnormal destortion • Repair or replace.
12-37
HYDRAULIC SYSTEM

+0.5 +5.1 +72.5
Main relief pressure 1 Standard value 20.6 0 MPa (210.1 0 kgf/cm2) [2988.1 0 psi]
Control
Valve Tie bolt nut tightening torque 2 Standard value 98 to 118 N•m (10.0 kgf•m) [72.3 lbf•ft]
Control valve mounting bolt tightening torque 3 Standard value 60 N•m (6.1 kgf•m) [44.3 lbf•ft]
3
2 3
Front 1 Rear
212003

Set relief pressure 1 Standard value 2
11.8 MPa (120.3 kgf/cm ) [1711.6 psi]
Priority
Plug tightening torque 2 Standard value 44.1 N•m (4.5 kgf•m) [32.5 lbf•ft]
valve
Relief valve tightening torque 3 Standard value 20.6 N•m (2.1 kgf•m) [15.2 lbf•ft]
2
2
210506
12-39
HYDRAULIC SYSTEM

Return filter tightening torque 1 Standard value 49 N•m (5.0 kgf•m) [36.2 lbf•ft]
Hydrau- Suction strainer tightening torque 2 Standard value 49 N•m (5.0 kgf•m) [36.2 lbf•ft]
lic tank 177 to 196 N•m (18.0 to 20.0 kgf•m)
Drain plug tightening torque 3 Standard value
[130.6 to 144.6 lbf•ft]
1 2 3
211980

Flow 120 L/min (31.7
Control flow rate (under no load) Standard value 150 L/min (39.6 U.S.gal./min)
regula- U.S.gal./min)
tor valve Plug tightening torque 1 Standard value 343 (35.0 kgf•m) [253.1 lbf•ft]
1
210508
12-40
HYDRAULIC SYSTEM

Standard value 115 mm (4.53 in.) 120 mm (4.7 in.)
Inside diameter of cylinder tube 1 Repair or service
115.15 mm (4.534 in.) 125.15 mm (4.927 in.)
limit
Deflection of piston rod 2 Repair or service
0.5 mm (0.02 in.)
(1/2 of dial indicator reading) limit
-0.030 -0.0012 -0.030 -0.0012
60 -0.104 mm (2.36 -0.0041 in.) 65 -0.104 mm (2.56 -0.0041 in.)
Mast height Mast height
(3 to 5 m [9.8 to 16.4 ft]) (3 to 4.5 m [9.8 to 14.8 ft])
Lift Outside diameter of piston rod 3 Standard value +0.035 +0.0014 +0.035 +0.0014
cylinder 75 -0.039 mm (2.95 -0.0015 in.) 80 -0.039 mm (3.15 -0.0015 in.)
(5.5 to 7 m [18.0 to 23.0 ft]) (5 to 7 m [16.4 to 23.0 ft] )
+0.11 +0.0043 +0.11 +0.0043
60 0 mm (2.36 0 in.) 65 0 mm (2.56 0 in.)
Inside diameter of rod cover bush- (3 to 5 m [9.8 to 16.4 ft]) (3 to 4.5 m [9.8 to 14.8 ft] )
Standard value
ing 4 75
+0.19 +0.0075
+0.06 mm (2.95 +0.0024 in.) 80
+0.19
+0.06 mm (3.15 +0.0024
+0.0075
in.)
(5.5 to 7 m [18.0 to 23.0 ft]) (5 to 7 m [16.4 to 23.0 ft])
Rod cover tightening torque 5 Standard value 1.18±0.1 kN•m (120.3±10.2 kgf•m) [870.8±73.8 lbf•ft]
5 2
4 3 1
210509
12-41
HYDRAULIC SYSTEM

120 mm
(4.724 in.)
Inside diameter of cylinder tube 1
Repair or service
120.12 mm (4.729 in.) 130.12 mm (5.123 in.)
limit
Outside diameter of
piston rod 2 Standard value 55 mm (2.1 in.)
(bushing)
Guide bushing
Clearance between Standard value 0.1 mm (0.0039 in.)
rod and guide bushing Repair or service
2 0.2 mm (0.0079 in.)
limit
+0.100 +0.0039
Standard value 60 0.070 mm (2.36 +0.0028 in.)
Inside diameter of bushing 3 (under
press-fit) Repair or service
60.6 mm (2.39 in.)
Tilt cylinder limit
637±63.7 N•m 696±68.6 N•m
Tightening torque of guide bushing 4 Standard value (65.0±6.5 kgf•m) (71.0±7.0 kgf•m)
[470.1±47 lbf•ft] [513.6±50.6 lbf•ft]
1178 to 1472 N•m (120 to 150 kgf•m)
Tightening torque of socket nut 5 Standard value
[869.4 to 1086.3 lbf•ft]
0 0
Standard value 60-0.046 mm (2.36 -0.002 in.)
Outside diameter of tilt socket pin 6 Repair or service
59 mm (2.3 in.)
limit
Tilt socket pin mounting bolt tightening
Standard value 33 N•m (3.37 kgf•m) [24.35 lbf•ft]
torque 7
Deflection of piston rod 8 (1/2 of dial Repair or service
0.5 mm (0.02 in.)
indicator reading) limit
5 2
4 8
3
6
7
211981
12-42
MAST AND FORKS
1. Specifications ............................................................................................................. 13-2
2. Structure..................................................................................................................... 13-3

1
3.1 Removal sequence ............................................................................................................................. 13-4
3.2 Suggestions for Removal.................................................................................................................... 13-5 2
4. Mast assembly ........................................................................................................... 13-7 3
4.1 Disassembly........................................................................................................................................ 13-7
4.1.1 Disassembly sequence ............................................................................................................................. 13-7
4.1.2 Suggestion for disassembly ...................................................................................................................... 13-8
4
4.2 Inspection and Repair ......................................................................................................................... 13-8
4.3 Reassembly ...................................................................................................................................... 13-10 5
4.4 Readjust............................................................................................................................................ 13-14

6
6. Service Data............................................................................................................. 13-19 7
8
9
10
11
12
13
14
15
13-1
MAST AND FORKS
1. Specifications

Mast type CJ type
205 × 28 ×
205 × 25 × 32 mm 205 × 28 × 36 mm 40 mm
Outer
Mast dimensions (8.07 × 0.98 × 1.26 in.) (8.07 × 1.10 × 1.42 in.) (8.07 × 1.10
(Flange inside width x × 1.57 in.)
Flange thickness x 205 × 28 ×
Web thickness) 205 × 25 × 32 mm 205 × 28 × 36 mm 40 mm
Inner
(8.07 × 0.98 × 1.26 in.) (8.07 × 1.10 × 1.42 in.) (8.07 × 1.10
× 1.57 in.)
Type Ball bearing
Main roller
Loading Diameter x Width 205 × 52 mm (8.07 × 2.05 in.)
equipment Type Lubricated needle
Side roller
Diameter x Width 58 × 40 mm (2.28 × 1.57 in.)
Lift-chain type EKBL-1434 EKBL-1634
1220 – 180 1220 – 180 1220 – 180
× 70 mm × 75 mm 1220 – 180 × 90 mm × 89 mm
Fork length (width x thickness)
(48 – 7 × (48 – 7 × (48 – 7 × 3.5 in.) (48 – 7 ×
2.8 in.) 3.0 in.) 3.5 in.)
470 to 2020
410 to 2030 mm 470 to 2030 mm mm
Fork width adjustment (outside width)
(16.1 to 79.9 in.) (18.5 to 79.9 in.) (18.5 to
79.5 in.)
13-2
MAST AND FORKS
2. Structure
3
1
2
8 4
6
6 6
Section A - A Section B - B
211990
1 Inner mast 5 Mast support bearing cap

2 Outer mast 6 Main roller, Side roller
3 Lift chain 7 Mast strip
4 Lift bracket 8 Fork positioner screw
13-3
MAST AND FORKS

Mast and lift bracket assembly
Removal
1
5
3
2
211991
3.1 Removal sequence

1 Fork, Lift bracket 4 Tilt cylinder pin
2 Lift cylinder low-pressure return hose 5 Mast support bearing cap, Bushing
3 Lift cylinder high-pressure hose
13-4
MAST AND FORKS
3.2 Suggestions for Removal

1. Removing lift bracket
(1) Remove the split pins from the lift chain, and remove
the anchor nut and lock nut.
(2) Bind the end of the lift chain with a rope, etc.Leave an
approximately 3m (9.8 ft) long extras at the ends of the
rope.
(3) Start the engine and raise the inner mast up to a posi-
tion where the main rollers of the lift bracket come off.
(4) During this step, maintain the lift chain pulled down-
ward.
(5) Lift the inner mast until it comes to a position where
the main rollers of lift bracket can be removed, then
reverse the truck to separate the lift bracket from the
211992
truck.
(6) Lower the inner mast and stop the engine.
211993
2. Removing lift cylinder low-pressure return hose Low-pressure hose removal
(1) Start the engine and raise the mast to the highest posi-
tion. Then, stop the engine and disconnect the hose.
Remove the hose at the return connector side.
(2) Lower the mast.
Return connector
3. Removing lift cylinder high-pressure hose

(1) Operate the lift lever to remove the remaining pressure
in the lift cylinder hydraulic lines, and disconnect the
high-pressure hose from the connection of lift cylinder.
High-pressure hose removal

211994
13-5
MAST AND FORKS
4. Removing tilt cylinder

(1) Hitch a sling to the upper cross-member at the top of
the mast, then lift with a hoist.
NOTE
For this operation be sure to use a hoist having a capacity
enough to support the mast assmbly.
Truck model Mast weight

DP100N 1995 kg (4399 lb)
DP120N 1995 kg (4399 lb)
DP135N 2100 kg (4631 lb)
DP150N 2320 kg (5116 lb) 211995
DP160N 2515 kg (5546 lb)
(2) Remove the tilt pin and separate the tilt cylinder from
the mast.
5. Removing mast support bearing cap 211962
(1) Put alignment marks on the caps.

(2) Remove the cap mounting bolts and separate the whole
mast assembly while lifting it up from the turck. Lay it
down flat with the lift braket side facing upward on a
level ground.
NOTE
In order to avoid any obstruction in the subsequent disas-
sembly, laying the removed mast assembly on a sufficient
space in the both directions of mast sliding. (toward the top
and bottom).
210519
13-6
MAST AND FORKS
4. Mast assembly
4.1 Disassembly
15 B
17 16 11
18 12
A
16 12
2
19 20 11
8 20 13
5 3 8 8 12
A 10
B 20
2
13
1 6
14 9
5 21
10
14
7 6
7
211997

1 Handle 12 Bolt, Shim, Washer
2 Lift chain, Nut, Split pin 13 Lift cylinder, Flow regulator valve
3 Lift bracket 14 Main roller, Side roller, Snap ring, Side roller, shim, Pin
4 Screw bracket, Bolt, Washer 15 Bolt, Nut
5 Screw, Feed nut, Thrust washer, Spacer 16 Main roller, Side roller, Snap ring, Side roller, shim, Pin
6 Stopper plate, Guide bar, Shim 17 Mast strip, Shim
7 Fork, Fork bracket 18 Chain wheel support
8 Main roller, Side roller, Bolt, Nut, Snap ring, Pin 19 Inner mast
9 Pipe 20 Chain wheel, Pin, Spacer, Collar, Bearing
10 Hose, Clamp bolt, Connector 21 Outer mast
11 Cylinder clamp, Bolt, Seat, Shim, Cushion, Collar
13-7
MAST AND FORKS

Removing inner mast
(1) Lift cylinders LH and RH are shim adjusted at the cyl-
inder rod ends to prevent limping. When cylinder rod
installation bolts are removed, check how many shims
are used and which side of cylinder the shims are
installed to.
(2) When the cylinder clamp bolts are removed, the lift
cylinder become unfixed (free). Shorten the cylinder Shims
rods as much as possible to cross the top ends of two
cylinders.
210521
(3) Slide the inner mast downward to remove main roller
and side roller of outer mast and main roller and side
roller of inner mast.
(4) Remove main and side rollers, then withdraw the inner
mast from the outer mast in an upward direction to sep-
arate them by sliding the shafts of main rollers of them
each other.

1. Mast
(1) Check the roller for wear, binding or crack. 210522
(2) Check the rolling surface of each roller for wear, dam-
age or distortion.
(3) Check the mast member and the welded joints of cross-
beams, pins and supports for cracks.
(4) Check the mast support bushings for wear or damage.
2. Lift bracket
(1) Check the main rollers and side rollers for sticking, 210523
wear or cracks.
(2) Check the welded part of the lift bracket for cracks.
(3) Check the guide bars whether they are bent or
deformed.
(4) Check threads of fork shift screw for damage.
(5) Check inside diameter of bush of fork shift screw for
damage.
Guide bar
(6) Check the welded part of fork bracket for cracks.
Screw
210524
13-8
MAST AND FORKS
3. Chain, Chain wheel support, and Chain wheel

(1) Check right and left chains for uneven length, wear,
adhesion, or distortion.
DP100N,
DP150N,
Truck model DP120N,
DP160N
DP135N
Stan-
889 mm 1016 mm
dard
Length of lift chains (35 in.) (40 in.)
value
(mm/20 links)
Service 915 mm 1046 mm
limit (36 in.) (41 in.)
(2) Check the chain anchor bolt for cracks or defects on

thread.
(3) Check the chain wheel support and the chain wheel for
crack or wear, or adhesion.
4. Mast strip
(1) Check for damage, chipping or distortion.
Stan-
dard 9 mm (0.35 in.)
Thickness of mast strip value
Service
7 mm (0.28 in.)
limit
5. Fork
(1) Check the fork for bend, misalignment of tips, and
cracks.
Stan-
Misaligned fork tips dard 5 mm (0.2in.) or less
value
(2) Check the forks for wear. If it exceeds the repair or ser-
vice limit, replace.
DP100N DP135N
Truck model DP160N
[DP120N] [DP150N]
70 mm
Standard (2.8 in.) 90 mm 89 mm
value [75 mm] (3.5 in.) (3.5 in.)
Fork (3.0 in.)
thickness 59 mm 69 mm
Service (2.3 in.) (2.7 in.) 81 mm
limit [65 mm] [73 mm] (3.2 in.) 211999
(2.6 in.) (2.9 in.)
13-9
MAST AND FORKS
4.3 Reassembly
To reassemble, follow the disassembly sequence in reverse and observe the following.
1. Front and rear clearance between mast and lift bracket
(1) Select and assemble the main roller in an appropriate Inner mast Outer mast
manner in order that the clearances P and M are within
the dimensions as shown below throughout the height
range. M
P and M, clearances between main 0.5 to 2.8 mm

roller and rolling surface (0.02 to 0.11 in.) Lift bracket
If the specified value can not be achieved, replace the P

main roller.
S 203 mm (7.99 in.)
210526
Main roller size M 205 mm (8.07 in.)
L 207 mm (8.15 in.)
2. Installing mast trip

(1) Install to make the front and rear clearance between
outer and inner masts within the specified dimension at
the maximum height range.
0.5 to 1.5 mm
Clearance L
(0.02 to 0.06 in.)
L
Mast strip
210527
(2) If the clearance of mast strip (L) is not within the spec-
ified value, adjust with the shims.
210528
13-10
MAST AND FORKS
3. Left and right clearance between outer and inner masts

(1) Measure the dimension between left and right side roll-
ers of outer mast (A) and assemble them so that the
A
specified dimension is obtained.
DP100N,
DP150N,
Truck model DP120N,
DP160N
DP135N
754±0.5 mm 748±0.5 mm
Dimension A
(29.7±0.02 in.) (29.4±0.02 in.)
NOTE
210529
Measurements shall be made at the smallest inner width.
B
(2) Measure the dimension between left and right side roll-
ers of inner mast (B) and assemble them so that the
specified dimension is obtained.
DP100N,
DP150N,
Truck model DP120N,
DP160N
DP135N
890±0.5 mm 884±0.5 mm 210530
Dimension B
(35.0±0.02 in.) (34.8±0.02 in.)
NOTE
Measurements shall be made at the largest outer width.
(3) Press the inner mast in a direction of left or right at the

maximum height range, and measure the clearance K
produced at the opposite side.
0.5 to 1.5 mm
Clearance K K
(0.02 to 0.06 in.)
210531
(4) If the clearance K is not within the specified value,

adjust in accordance with the following procedure:
• The adjustment of clearance K of upper side shall be Adjusting
made by loosening locknut of side roller bracket and by bolt
rotating the adjusting bolt.
205585
13-11
MAST AND FORKS
• Clearance K at the lower side shall be made by removing

side roller and by adding/subtracting shims.
Shims
210532
4. Left and right clearance of lift bracket
(1) Measure the dimension of side roller (C) and assemble C
so that the specified dimension is obtained.
DP100N,
DP150N,
Truck model DP120N,
DP160N
DP135N
704±0.5 mm 692±0.5 mm
Dimension C
(27.7±0.02 in.) (27.2±0.02 in.)
210533
(2) Press in a direction of left or right throughout the

height range and measure the clearance N produced at
the opposite side with a thickness gauge.
0.5 to 1.5 mm
Clearance N N
(0.02 to 0.06 in.)
N
• The adjustment of clearance N shall be made by loosen- 210534
ing locknut of side roller bracket and by rotating the
adjusting bolt. Adjusting bolt
Adjusting bolt
212000
13-12
MAST AND FORKS
5. Cylinder clamp
(1) Install shims to maintain the lift cylinder in the aligned Shims
position, then assemble.
Standard shim thickness 3.2 mm (0.13 in.)
210536
6. Mast support
(1) Apply grease to the cap inner surface and groove.
(2) Install the mast support bush and the cap with larger
cut surface as they are directed to the center of truck. Mast cap
Note that placing blocks under the mast to make a clear- Bushing
ance between mast and ground facilitates filling grease.
490 N•m
Bolt tightening torque (49.97 kgf•m)
[361.6 lbf•ft]
Apply grease.
Chamfered
7. Suggestion for assembling chain anchor kit 210537
(1) Never install the center plate to the position link plate
should be installed.
1 Link plate (Mark on surface)
2 Center plate (No mark on surface)
2
3 Link 3
4 Split pin
1
4 Marking
200383
13-13
MAST AND FORKS
4.4 Readjust.
1. Adjusting chain tension
(1) Make the masts vertical on a flat place, lower the fork
to the ground level, and check that lift cylinders are in
the most retracted position.
(2) Position the anchor bolt with anchor nut and locknut.
(3) Lift the fork slightly from the ground and check the
tension of chain as the two chains are stretched evenly,
by pushing the midpoints between chain wheel and
fixed end of chain of left and right chains alternately.
Adjust if required.
In the case of adjusting tensions of chains by anchor nut,
it is recommended to tilt the mast forward to reduce
102708
chain tension for operational convenience.
Anchor bolt
(4) When adjustment of chain tension is completed by 210538

rotating anchor nut, tighten the nut to the specified
torque.
393 N•m
Tightening torque of anchor
(40.1 kgf•m)
bolt nut
[290.0 lbf•ft]
Lock nut
(5) The mast must be checked in the vertical position,

Anchor nut
when it is finally adjusted.
210539
13-14
MAST AND FORKS
2. Adjusting front and rear and left and right clearances of

lift bracket
(1) Measure the front and rear and left and right clearances
of lift bracket, and adjust, if any of them exceeds the
specified value.
(2) Use a thickness gauge for front and rear clearance of
lift bracket.
(3) Use a dial gauge for left and light clearance of lift
bracketPrepare a dial gauge for inner surface of inner
mast and make the spindle of dial gauge contact with
side wall of lift bracket.
Insert a bar between lift bracket and inner mast, and
press lift bracket in the left and right directions alter-
nately to measure the travels.
(4) If the clearance of lift bracket is adjusted, disconnect 204691
the lift bracket from the mast in accordance with
removal/installation procedure, and adjust the rollers.
(5) If the fro-to-aft clearance of main roller is not within
the specified value, replace with an oversized main
roller.
(6) If left-to-right clearance of side roller is not within the
specified value, adjust the clearance in accordance with
the following procedure:
• The adjustment of FD80 clearance N shall be made by
loosening locknut of side roller bracket and by rotating
the adjusting bolt. Adjusting bolt
Adjusting bolt
212000
13-15
MAST AND FORKS
3. Adjusting mast tilt angle

(1) Regulate the inflation pressure for all the wheels, then
park the truck on a level floor.
(2) Fully tilt the mast backward and stop the engine.
(3) Measure the rear tilting angles of both left and right
masts.
(4) If required, perform the adjustment as follows: loosen
the locknut of tilt cylinder rod, rotate the tilt cylinder
rod and adjust the cylinder strokes to achieve an identi-
cal tilt angle for both left and right masts.
NOTE
If the rear tilting angle is properly adjusted, the forward tilt
angle is automatically determined by the stroke of tilt cylin-
der. 212002
(5) After adjustment, tighten the lock nuts to each speci-
fied torque.
1178 to 1472 N•m
Lock nut tightening torque (120.1 to 150.1 kgf•m)
[869.4 to 1086.3 lbf•ft]
4. Stroke adjustment of left and right lift cylinders

(1) Slowly lift inner masts to check the stopping condition
of left and right piston rods at the maximum height.
(2) If a top portion of inner mast vibrates at a moment that
it stops, conduct shim adjustment.
NOTE
Up to 8 shims (8 mm (0.32 in.)) can be applied.
Abnormal condition - There is a slight difference in stop 210542

timing between left and right sides. A lift cylinder with
a longer stroke vibrates when it stops.
13-16
MAST AND FORKS
Adjusting method
(1) Once raise the mast and place a block under the inner
mast, then lower the mast until it rests on the block.
202983
(2) Remove the stop bolt at the top of lift cylinder which
stops earlier than the other, lower the piston rod to
insert shims to the upper portion of the piston rod end.
(3) Extend the piston rod, and tighten the lift cylinder stop-
per bolt.Then, remove the block placed under the inner
mast.
(4) Slowly lower the inner mast until it comes to the lower-
most position to check the piston rod for smooth opera- Shims
tion.
210543
13-17
MAST AND FORKS
5. Troubleshooting
• Improper clearance of main and/or side rollers • Front and rear / left and right clearance
adjustment
Lift bracket/inner mast
does not lift/lower • Roller does not rotates smoothly • Lubricate or replace.
smoothly • Chain operation too slow • Lubricate or replace.
• Improper clearance of mast strip • Adjust with shims.
• Large side roller clearance • Adjust by adding shims.
Leaned lift bracket or • Uneven chain tensions • Adjust chain tension.
inner mast • Uneven shim adjustment of left and right lift cyl- • Adjust with shims.
inders (at the maximum height)
Abnormal noise from • Roller does not rotates smoothly • Check and perform adjustment or replace
mast roller bearing.
• Damaged lift cylinder packing • Replace.
Lift cylinder descends
• Damaged lift cylinder inner surface • Replace.
Whole mast shakes • Worn mast support bush • Retighten or replace bushing.
Deformed mast • Uneven loading or overload • Replace assembly.
• Distortion of figer bar • Repair or replace.
Unevenness of fork tip
• Bent fork • Repair or replace.
height
• Deformed mast due to uneven loading • Repair or replace.
13-18
MAST AND FORKS
6. Service Data

Standard
Misaligned fork tips 5 mm (0.19 in.) or less
value
Standard 70 mm 75 mm 89 mm
90 mm (3.5 in.)
value (2.8 in.) (3.0 in.) (3.5 in.)
Fork thickness
Service 59 mm 65 mm 69 mm 73 mm 81 mm
limit (2.3 in.) (2.6 in.) (2.7 in.) (2.9 in.) (3.2 in.)
Fork and chain
Standard
889 mm (35 in.) 1016 mm (40 in.)
value
Length of lift chains (mm/20 links)
Service
915 (36 in.) 1046 (41 in.)
limit
Tightening torque of chain anchor bolt Standard 392 N•m (40.0 kgf•m)
nut N•m value [289.3 lbf•ft]
Standard
S-size 203 mm (7.99 in.)
value
Standard
Main roller outside diameter M-size 205 mm (8.07 in.)
value
Roller
Standard
L-size 207 mm (8.15 in.)
value
Standard
Side roller external diameter 58 mm (2.3 in.)
value
+0.5
Standard +0.5 +0.020 884 -1.0 mm
Ｘ１ 890 -1.0 mm (35.0 -0.039 in.)
value +0.020
(34.8 -0.039 in.)
Smallest inner width of outer
mast +0.5
Standard +1.0 +0.039 884 -1.0 mm
Ｘ２ 890 -0.5 mm (35.0 -0.020 in.)
value +0.020
(34.8 -0.039 in.)
Standard 748±0.5 mm
Inner width of outer mast roller A 754±0.5 mm (29.7±0.02 in.)
value (29.4±0.02 in.)
+0.5
Standard +0.5 +0.020 692 -1.0 mm
Ｙ１ 704 -1.0 mm (27.7 -0.039 in.)
value +0.020
(27.2 -0.039 in.)
Smallest inner width of inner
Outer mast mast +0.5
Standard +1.0 +0.039 692 -1.0 mm
and inner mast Ｙ２ 704 -0.5 mm (27.7 -0.020 in.)
value +0.020
(27.2 -0.039 in.)
Outer width of inner mast roller B 890±0.5 mm (35.0±0.02 in.)
value (34.8±0.02 in.)
Clearance between main roller and
Standard
rolling surface P (Throughout height 0.5 to 2.8 mm (0.02 to 0.11 in.)
value
range)
Clearance between side roller and roll- Standard
0.5 to 1.5 mm (0.02 to 0.06 in.)
ing surface K (at the maximum height) value
Clearance between mast strip and slid- Standard
0.5 to 1.5 mm (0.02 to 0.06 in.)
ing surface L value
13-19
MAST AND FORKS

Largest outer width of lift bracket C 704±0.5 mm (27.7±0.02 in.)
value (27.2±0.02 in.)
Clearance between lift bracket main
Standard
Lift bracket roller and rolling surface M (Through- 0.5 to 2.8 mm (0.02 to 0.11 in.)
value
and inner mast out height range)
Clearance between lift bracket side
Standard
roller and rolling surface N (at the 0.5 to 1.5 mm (0.02 to 0.06 in.)
value
maximum height)
Standard 490 N•m (49.97 kgf•m)
Tightening torque of mast cap mounting bolts
value [361.6 lbf•ft]
Inner mast Lift bracket

Y1 C
Inner mast
Outer mast
Y2
B
Mast strip
N
X1
Inner mast
Outer mast
N
A M
K P
X2
Outer mast Lift bracket
K
210544
13-20
FORK POSITIONER
1. Applicable Attachment Model..................................................................................... 14-2
2. Specifications ............................................................................................................. 14-2
3. Structure..................................................................................................................... 14-3

4.1 Removal.............................................................................................................................................. 14-4
4.2 Suggestions for Removal.................................................................................................................... 14-5
4.4 Installation........................................................................................................................................... 14-7
4.4.1 Suggestions for Installation ....................................................................................................................... 14-7
5. Fork positioner cylinder .............................................................................................. 14-8

5.1 Disassembly........................................................................................................................................ 14-8
5.3 Reassembly ...................................................................................................................................... 14-11
6. Inspection and Adjustment ....................................................................................... 14-12
8. Service Data............................................................................................................. 14-14
14
14-1
FORK POSITIONER
1. Applicable Attachment Model
Applicable Truck
Attachment Model Applicable Mast Model Mast Piping
Model Designation – Serial No.
DP100N T36A – 10011
FP120AM V120A Simplex Side pulley type
DP120N T37A – 10011
4FP135AM DP135N T38A – 10011 4V135A Simplex Side pulley type
DP150N T39A – 10011 4V150A Simplex Side pulley type
FP160AM
DP160N T40A – 10011 V160A Simplex Side pulley type
2. Specifications
Attachment Model
FP120AM 4FP135AM FP160AM
Item
W2050 767 mm (30.20 in.)
W2200 842 mm (33.2 in.) –
Stroke (each side)
W2300 892 mm (35.1 in.)
W2400 – 942 mm (37.1 in.) 892 mm (35.1 in.)
Loading center 600 mm (23.6 in.)
Free lift 0 mm (0 in.)
W2050 2008 mm (79.1 in.)
Outside fork spread W2200 2258 mm (88.9 in.)
(maximum) W2300 2258 mm (88.9 in.) –
W2400 – 2358 mm (92.8 in.)
W2050 482 mm (19.0 in.)
Outside fork spread W2200 482 mm (19.0 in.)
(minimum) W2300 482 mm (19.0 in.) –
W2400 – 582 mm (22.9 in.)
Mast tilt angle (forward - backward) 15° – 12°
Type of forks Heel free
Length 1220 mm (48.0 in.)
Fork 180 × 70 mm
Width × thickness 180 × 90 mm (7.1 × 3.5 in.)
(7.1 × 2.8 in.)
Front overhang (with standard fork) 754 mm (29.7 in.) 793 mm (31.2 in.) 795 mm (31.3 in.)
14-2
FORK POSITIONER
3. Structure
5
7
2
1
7 6 4
210160
1 Lift bracket 5 Mast

2 Side roller 6 Piping
3 Main roller 7 Fork positioner cylinder
4 Fork
The fork positioner is an attachment that enables the outside

fork spread to be adjusted steplessly from the maximum
position to the minimum position and vice versa.
When handling loads of different sizes, the spread of the
fork must be change frequently to ensure stability of the
load.
The positioner for application to large trucks has a hydrau-
lic cylinder which can change the spread of heavy forks
smoothly.
The fork positioner, which is intended for adjusting the fork
spread before picking up a load, cannot shift the raised load
from side to side.
The forks are hanged from the guide bars and connected to
the rod side of the fork positioner cylinder.
The head side of fork positioner cylinder is attached to the
corresponding fork prong and lift bracket, and slide the fork
prong sideways by extending or retracting itself.
The right and left fork prongs can shift independently.
14-3
FORK POSITIONER

4.1 Removal
3
6
8 7
5 1 2
2
6
1
1
210161
Removal procedure
1 Hose 5 Fork
2 Fork positioner cylinder 6 Fork bracket
3 Lift bracket 7 Main roller (If no abnormality is found, do not disassem-
ble it.)
4 Guide bar 8 Side roller (If no abnormality is found, do not disassem-
ble it.)
Preparation
(1) Park the fork lift truck on a flat, level and solid ground. (5) Stop the engine, and move the fork positioner lever
(2) Start the engine, and fully compress the fork positioner back and forth several times so that the remaining pres-
cylinder. sure in the lines is completely removed.
(3) Raise the mast vertically and lower the fork down to
the pallet for easy removal.
(4) Place the wooden blocks under the lift bracket.
14-4
FORK POSITIONER
4.2 Suggestions for Removal

1. Removing hydraulic hoses A
(1) Prepare containers to receive oil, which should remain
in the cylinder and hydraulic hoses.
B
(2) Disconnect the hydraulic hoses from the pulleys and
attach the connectors sized to G 1/2B at each end to
their open ends for securing the closed oil flow circuit.
Be sure to mate hoses between A's and B’s in the figure
at the right.
210552
2. Removing fork positioner cylinder

(1) Remove the cylinder rod from its connector while exer-
cising care not to damage the threaded part.
CAUTION
This removal is recommended to be performed
with the cylinder rod fully retracted.
3. Removing forks
(1) Connect to fork 5 a wire rope with a vise-type clamp
attached on both ends to hold each prong, and strain the
rope using the crane.
(2) Remove the stopper plate and pull out the guide bar 4.
(3) Start the engine and raise the lift bracket to such a
height (about 25 mm (0.98 in.) above the bottom) at
which the heel hold part of fork 5 becomes free, then
back the truck away.
(4) Combine the removed forks 5 (2 pieces) together and 210553
tie them with a rope, etc. to prevent their fall. Then,
move it to a safe place.
(5) Place the supporting wooden blocks under the lift
bracket.
14-5
FORK POSITIONER
4. Removing lift bracket

(1) Remove the split pins from the lift chain, and remove
the anchor nut and lock nut.
(2) Remove the lift bracket with the following procedure.
(a) Bind the ends of the two lift chains with a rope,
etc.Leave an approximately 3 m (9.8 ft) long extras at
the ends of the rope.
(b) Bind the four hoses in the same manner withy a rope,
leaving an approximately 3 m (9.8 ft) extras at the ends
of the rope.
(c) Start the engine and raise the inner mast up to a posi-
tion where the main rollers of the lift bracket come
off.At this point, pull the lift chains and hoses taut by
drawing the attached rope downward to prevent them
from coming off from the chain wheels or hose reels.
(d) When the inner masts reach to the position where the
main rollers of the lift bracket can be removed, reverse
the truck, and separate the lift bracket from the truck.
CAUTION
When the masts are rising, never touch any con-
210554
trol levers except the lift lever.

1. Lift bracket
(1) Check the main rollers and side rollers for sticking,
wear or cracks.
(2) Check the welded part of the lift bracket for cracks.
(3) Check the guide bars whether they are bent or
deformed.
2. Fork
(1) Check the fork for bend, misalignment of tips, and
cracks.
3. Hose
(1) Replace the hoses every two years.
14-6
FORK POSITIONER
4.4 Installation
Replacement must follow the reverse order of removal.
4.4.1 Suggestions for Installation

1. Driving in main roller
(1) For this operation use a driving jig and exercise care
not to hit the outer ring of the roller.
2. Installing lift chains

(1) Lift chains can be replaced as-is unless the positions of
the upper lock nuts are modified.Tighten the lock nuts
and anchor nuts to each specified torque.
393 N•m (40.1 kgf•m)
Nut tightening torque
[290.0 lbf•ft]
3. Adjusting hose tension

(1) The tension of each hose should be 196 N (20.0 kgf)
12.5 mm
[44.1 lbf]. (0.49 in.)
When the midpoint of a 1 m (3.28 ft) long hose is
9.8 N
pushed with a force of 9.8 N (1.0 kgf) [2.2 lbf], its ten-
(1.0 kgf)
sion is appropriate it deflects approx. 12.5 mm (0.49 [2.2 lbf]
in.).
Adjust tension according to the length of hoses which
differs with the raised height of the mast.
For example, if the hose length is 2 m (78.7 in.) from the

pulley to the bottom joint when the mast is raised to the
highest position, the tension of the hose is acceptable if 210555
it deflects 25 mm (0.98 in.) when the hose is pushed
with a force of 9.8 N (1.0 kg) [2.2 lbf].
14-7
FORK POSITIONER
5. Fork positioner cylinder

5.1 Disassembly
11 12
2 8
1 9
8
4 6
3 7
10
5
210165
Disassembly sequence
1 Guide bushing 7 Piston
2 O-ring 8 Backup ring
3 Dust seal 9 O-ring
4 Rod packing 10 O-ring
5 Collar 11 Piston rod
6 Self-locking nut 12 Cylinder tube
14-8
FORK POSITIONER
Suggestion for disassembly

1. Removing guide bushing
(1) Turn up the calking at the cylinder tube.
(2) Wrap the cylinder tube with a piece of waste cloth, and
hold it in a vise. Remove the guide bushing with Hook
Wrench A.
Special tool
Hook wrench Ａ 05312 - 20520

A
210557
1. Cylinder tube
age, or rust.
2. Piston rod
center while turning the piston rod.
If 1/2 of dial indicator reading exceeds the limit, replace
the piston rod.
Deflection of piston rod Repair service 1.0 mm
(1/2 of dial indicator reading) limit (0.039 in.) 210558
and dent.
(3) When any of the thread parts are excessively damaged,
replace the piston rod.
3. Piston rod
(1) Replace the seal kit parts with new ones.
14-9
FORK POSITIONER
Attachment Model FP120AM 4FP135AM FP160AM

Standard
Bore diameter of cylinder tube 1 45 mm (1.77 in.)
value
Standard
value
Standard
0.5 mm (0.020 in.), maximum
value
(1/2 of dial indicator reading) Repair or
service 1.0 mm (0.039 in.)
limit
Standard
W2050 767 mm (30.20 in.)
value
Standard
W2200 842 mm (33.15 in.) –
value
Stroke 4
Standard
W2300 892 mm (35.12 in.) 892 mm (35.12 in.)
Fork value
positioner Standard
W2400 – 942 mm (37.09 in.) 892 mm (35.12 in.)
cylinder value
Standard
W2050 125 mm (4.92 in.)
value
Standard
W2200 50 mm (1.97 in.) –
value
Length of collar 5
Standard
W2300 – –
value
Standard
W2400 – –
value
Standard
Overall length when fully contracted 6 1115 mm (43.90 in.)
value
Standard
Self-locking nut tightening torque 7 200 N•m (20.4 kgf•m) [148 lbf•ft]
value
Standard
Guide bushing tightening torque 8 250 N•m (25.5 kgf•m) [184 lbf•ft]
value
8 3
2 1
4 5
6
210656
14-10
FORK POSITIONER
5.3 Reassembly
∗
9 5 7 2
11 10 12 8 4 3 4 1 6
∗ ∗ ∗ ∗ ∗ ∗
Reassembly sequence
1 Piston 7 Collar
2 O-ring 8 Cylinder tube
3 O-ring 9 Guide bushing
4 Backup ring 10 Rod packing
5 Piston rod 11 Dust seal
6 Self-locking nut 12 O-ring
Suggestion for reassembly
1. Preparation
2. Tightening of self-locking nut

(1) Insert piston 1 into piston rod 3, and tighten self-lock-
ing nut 4 to the specified torque.
200 N•m
Torque (20 kgf•m)
[148 lbf•ft]
CAUTION
If the self-locking nut has been used two or three
times, replaced it with a new one.
14-11
FORK POSITIONER
3. Inserting rod packing and dust seal

(1) Insert rod packing 8 into guide bushing 7 with the main
lip facing inward.
(2) Insert dust seal 9 into the guide bushing with the main
lip facing outward.
4. Tightening of guide bushing

(1) Tighten guide bushing 7 to the specified torque.
250 N•m
Torque (25 kgf•m)
[184 lbf•ft]
210561
(2) Calk the cylinder tube at the guide bushing.
6. Inspection and Adjustment

Inspecting right and left shift amounts
(1) After reassembly, make sure that both the right and left
forks can move across their full stroke within each
frame.
14-12
FORK POSITIONER
7. Troubleshooting
• Insufficient oil in hydraulic tank • Add hydraulic oil.

• Too low gear pump delivery rate • Replace pump assembly.
• Overload relief valve defects
(1) Too low valve opening pressure setting • Adjust overload relief valve.
(2) Defective pilot valve seat surface or foreign • Replace overload relief valve assembly
matter in valve or disassemble and clean it.
(3) O-ring in valve case damaged • Replace O-ring.
Shifts of right and left fork
prongs too slow or sluggish (4) Pilot valve spring wearing • Replace overload relief valve assembly.
• Shift speed differs between the right and left • Adjust with flow rate adjustment valve.
• Cylinder defects
(1) Foreign matter lodged in rod packing • Replace rod packing.
(2) Scratches on bore of rod packing • Replace rod packing.
(3) Piston O-ring damaged • Replace piston O-ring.
(4) Abnormal destortion • Replace.
Unsmooth shifts of fork: • Scratches or rust on guide bar • Repair and apply grease.
(1) Jamming • Scars on lift bracket to fork contact surfaces • Repair and apply grease.
(2) Too large looseness • Scars on guide bar surface of forks • Repair and apply grease.
• Bent fork • Replace.
Misaligned fork tips • Uneven loading • Instruct operator to handle only loads
within indicated capacity.
14-13
FORK POSITIONER
8. Service Data
Attachment Model FP120AM 4FP135AM FP160AM
Standard
Bore diameter of cylinder tube 1 45 mm (1.77 in.)
value
Standard
value
Standard
0.5 mm (0.020 in.), maximum
value
(1/2 of dial indicator reading) Repair or
service 1.0 mm (0.039 in.)
limit
Standard
W2050 767 mm (30.20 in.)
value
Standard
W2200 842 mm (33.15 in.) –
value
Stroke 4
Standard
W2300 892 mm (35.12 in.) 892 mm (35.12 in.)
Fork value
positioner Standard
W2400 – 942 mm (37.09 in.) 892 mm (35.12 in.)
cylinder value
Standard
W2050 125 mm (4.92 in.)
value
Standard
W2200 50 mm (1.97 in.) –
value
Length of collar 5
Standard
W2300 – –
value
Standard
W2400 – –
value
Standard
Overall length when fully contracted 6 1115 mm (43.90 in.)
value
Standard
Self-locking nut tightening torque 7 200 N•m (20.4 kgf•m) [148 lbf•ft]
value
Standard
Guide bushing tightening torque 8 250 N•m (25.5 kgf•m) [184 lbf•ft]
value
8 3
2 1
4 5
6
210656
14-14
Service Data
1. Tightening torque of standard bolts............................................................................ 15-2
1.1 Metric screw thread for automobiles ................................................................................................... 15-2
1.2 Metric Coarse Thread ......................................................................................................................... 15-3
2. Lubrication Standards ................................................................................................ 15-4

2.1 Fuel and Lubricant Specifications ....................................................................................................... 15-4
2.2 Capacity .............................................................................................................................................. 15-5
15
15-1
Service Data
1. Tightening torque of standard bolts

1.1 Metric screw thread for automobiles
With spring washer 101656
Nominal size Pitch

mm mm
7 8 10
6 1 7.4 N·m 9.6 N·m 12.7 N·m

8 1.25 16.7 N·m 22.6 N·m 30.4 N·m
10 1.25 34.3 N·m 45.1 N·m 69.6 N·m
12 1.25 63.7 N·m 82.4 N·m 122.6 N·m
14 1.5 102.0 N·m 132.4 N·m 192.2 N·m
16 1.5 157.9 N·m 202.0 N·m 287.3 N·m
18 1.5 224.6 N·m 292.2 N·m 413.8 N·m
20 1.5 310.9 N·m 404.0 N·m 573.8 N·m
22 1.5 413.8 N·m 537.5 N·m 763.0 N·m
24 1.5 547.2 N·m 711.0 N·m 1006.2 N·m
27 1.5 794.3 N·m 1032.6 N·m 1451.1 N·m
30 1.5 1100.3 N·m 1430.8 N·m 2012.3 N·m
33 1.5 1467.1 N·m 1907.4 N·m 2680.2 N·m
36 1.5 1918.2 N·m 2493.8 N·m 3497.1 N·m
39 1.5 2461.5 N·m 3198.8 N·m 4469.9 N·m
Without spring washer 101656
Nominal size Pitch

mm mm
7 8 10
6 1 8.6 N·m 10.8 N·m 14.7 N·m

8 1.25 19.6 N·m 26.5 N·m 36.6 N·m
10 1.25 41.2 N·m 53.0 N·m 81.4 N·m
12 1.25 74.5 N·m 97.1 N·m 144.2 N·m
14 1.5 119.6 N·m 155.9 N·m 226.5 N·m
16 1.5 182.4 N·m 237.3 N·m 338.3 N·m
18 1.5 263.8 N·m 343.2 N·m 487.4 N·m
20 1.5 365.8 N·m 475.6 N·m 674.7 N·m
22 1.5 486.4 N·m 632.5 N·m 897.3 N·m
24 1.5 643.3 N·m 836.5 N·m 1183.7 N·m
27 1.5 934.6 N·m 1216.0 N·m 1707.3 N·m
30 1.5 1294.5 N·m 1682.8 N·m 2367.3 N·m
33 1.5 1726.0 N·m 2243.8 N·m 3153.8 N·m
36 1.5 2256.5 N·m 2934.1 N·m 4114.0 N·m
39 1.5 2896.0 N·m 3763.8 N·m 5258.3 N·m
15-2
Service Data
1.2 Metric Coarse Thread
With spring washer 101657
Nominal size Pitch

mm mm
10 1.5 33.3 N·m 43.1 N·m 67.7 N·m

12 1.75 58.8 N·m 76.5 N·m 115.7 N·m
14 2 96.4 N·m 124.5 N·m 182.4 N·m
16 2 147.1 N·m 191.2 N·m 274.6 N·m
18 2.5 203.0 N·m 264.8 N·m 383.4 N·m
20 2.5 286.4 N·m 371.7 N·m 536.4 N·m
22 2.5 383.4 N·m 499.2 N·m 725.9 N·m
24 3 492.3 N·m 640.4 N·m 924.8 N·m
27 3 724.7 N·m 942.2 N·m 1350.4 N·m
30 3.5 969.9 N·m 1259.2 N·m 1843.7 N·m
33 3.5 1328.8 N·m 1727.0 N·m 2477.2 N·m
36 4 1676.0 N·m 2180.0 N·m 3199.9 N·m
39 4 2219.2 N·m 2884.1 N·m 4118.8 N·m
42 4.5 2754.7 N·m 3581.4 N·m 5137.7 N·m
Without spring washer 101657
Nominal size Pitch

mm mm
10 1.5 39.2 N·m 51.0 N·m 79.4 N·m

12 1.75 69.6 N·m 90.2 N·m 135.3 N·m
14 2 112.8 N·m 146.1 N·m 215.7 N·m
16 2 172.6 N·m 224.6 N·m 323.6 N·m
18 2.5 239.3 N·m 311.9 N·m 451.1 N·m
20 2.5 336.4 N·m 437.4 N·m 630.6 N·m
22 2.5 392.3 N·m 587.4 N·m 842.4 N·m
24 3 578.6 N·m 753.2 N·m 1088.5 N·m
27 3 852.2 N·m 1108.2 N·m 1588.7 N·m
30 3.5 1140.5 N·m 1481.8 N·m 2168.3 N·m
33 3.5 1563.2 N·m 2031.9 N·m 2915.5 N·m
36 4 1972.1 N·m 2564.4 N·m 3765.8 N·m
39 4 2610.5 N·m 3393.1 N·m 4845.5 N·m
42 4.5 3241.1 N·m 4212.9 N·m 6044.8 N·m
15-3
Service Data
2. Lubrication Standards
2.1 Fuel and Lubricant Specifications
Available lubricant/
Fuels and Oils Specification Service range
fuel brand
-5°C or higher: JIS Grade 2
Fuel Diesel oil -15 to -5°C: JIS Grade 3
-15°C or lower: IS Extra Grade 3
0°C or higher: SAE30
ENEOS Diesel Oil API service classifica-
Engine oil -10 to 10°C: SAE20W
Touring tion CF or better
-10°C or lower: SAE10W or SAE10W-30
ENEOS Super Hypoid GL-5 -10°C or higher: SAE90
Gear oil
Gear GL-4 -10°C or lower: SAE80
Torque converter oil ENEOS ATF-II (N)
-10°C or higher: SAE10W
Hydraulic oil ENEOS FBK RO32 ISO VG32
-10°C or lower: SAE5W
FMVSS DOT3 or
Brake fluid ENEOS Brake Fluid
DOT4
Wheel ENEOS Powerknock NLGI No.2 (Lithium
bearing WB2 base consistency: 271)
Grease
ENEOS Epiknock NLGI No.1 (Lithium
Chassis
Grease AP1 base consistency: 315)
Ambient tempera-
Anti-freeze -39 -30 -25 -20 -15 -10
ture (°C)
(replace every two MHI Long Life Coolant
years) Anti-freeze concen-
55 50 45 40 35 30
tration (%)
WARNING
The oil characteristics varies with each manufac-
turer. Do not mix different brands of oil for use.
15-4
Service Data
2.2 Capacity

Fuel tank 175 L
Engine, radiator 17.35 L
Engine coolant Reserve tank 0.65 L
Total 18 L
Oil pan 12 L
Engine oil Oil Filter 4L
Total 16 L
Torque converter oil 23 L
Differential gear oil
20 L
Final drive gear oil
Hydraulic oil N Level: 131 L
Brake fluid 240 cc
15-5

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FOREWORD

Indicates a specific potential hazard

The suggestion for

Suggestion for disassembly

Standard 0.020 to 0.105 mm

GROUP INDEX Items

Model View, Truck Models Covered, Serial Number Locations,

2. Truck Models Covered ................................................................................................. 1-2

3. Serial Number Locations .............................................................................................. 1-3

5. Chassis and Mast Model Identification......................................................................... 1-5

6. Dimensions (Approximate) ........................................................................................... 1-6

2. Truck Models Covered

3. Serial Number Locations

Chassis serial number Name plate

Mast serial number Transmission serial number Engine model

Truck model DP100N DP120N DP135N DP150N DP160N

Perfor- 4000 mm 4060 mm 4160 mm 4550 mm 4815 mm

Weight 14800 kg 16060 kg 17700 kg 18050 kg 18950 kg

5. Chassis and Mast Model Identification

Maximum lifting height

Applicable truck model designation

No. Truck model DP100N DP120N DP135N DP150N DP160N

3. Suggestions for Removal and Installation .................................................................... 2-4

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

Truck model DP100N DP120N DP135N DP150N DP160N

Detail oil cooler

1 Intercooler 6 Drain cock

3. Suggestions for Removal and Installation

3.1.2 Removal sequence

1 Engine cover, Gas spring 8 Radiator hose (lower)

3.1.3 Suggestions for Removal and Installation

3.1.4 Inspection and Repair

(3) Antifreeze and coolant

2. Location of Components .............................................................................................. 3-3

4. Disassembly and Reassembly ................................................................................... 3-10

5. Batteries and Charging .............................................................................................. 3-13

6. Troubleshooting ......................................................................................................... 3-15

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

Truck model DP100N DP120N DP135N DP150N DP160N

Stop lamp switch

Starter relay Back-up buzzer

Rear combination lamp

No. Indicator lamp OFF ON or Flashing Remark

How to check indicator lamp bulbs

Failure indicator lights

Rear (mounting) face

Failure indicator lamp

Travel speed sensor circuit open

2-speed automatic transmission

3.3.3 Lighting switch

OFF 1st 2nd Knob position

Component Tail lamps, license Front

3.3.4 Fuse box

3.3.5 Spare terminal

Removing the console box rear panel will permit you to

3.3.6 Lamp Bulb Specifications

4. Disassembly and Reassembly

4.1.1 Disassembly sequence

4.2 Combination Meter

4.3 Electrical Components in the Console Box

1 Power relay 5 Glow plug timer

5. Batteries and Charging

Whether the battey is fully charged can be checked from the

5.3 Precautions for Battery Charging