Cat DP160 DP160N Forklift Service Manual Free Download PDF

Service Manual
Chassis, Mast & Options

DP100N T36A-10011-up
DP120N T37A-10011-up
DP135N T38A-10011-up
DP150N T39A-10011-up
DP160N T40A-10011-up
Includes Mitsubishi 6M60-TL Engine Service Manual Pages 531 - 860
Cat DP160 DP160N Forklift Engine Parts

Contact email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 1 269 673 1638
Website: www.HeavyEquipmentRestorationParts.com
www.dp150.com/cat-dp160-engine-parts
99799-63100
FOREWORD
This service manual is a guide for servicing Cat® lift trucks. For your convenience the in-
structions are grouped by systems as a ready reference.
The long productive life of your lift truck(s) depends on regular and proper servicing. Ser-
vicing consistent with what you will learn by reading this service manual. Read the respec-
tive sections of this manual carefully and familiarize yourself with all of the components
before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are for trucks
with serial numbers in effect at the time of printing. Cat Lift Trucks reserves the right to
change specifications or design without notice and without incurring obligation.
DP100N, DP120N, DP135N, DP150N and DP160N are powered by Mitsubishi 6M60-TL
diesel engine. For engine servicing, please refer to the 6M60-TL diesel engine service man-
ual Publication Number 99709-61100 included on pages 531 - 860 .
Safety Related Signs

The following safety related signs are used in this service
manual to emphasize important and critical instructions:
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 lift truck.
Indicates a condition that can cause
damage to, or shorten service life of, the
NOTE
lift truck.
Pub. No. 99799-63100

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

Clearance valve (0.00079 to 0.00413 in.)
between cylinder
and piston Repair 0.15 mm
service unit (0.059 in.)
4
GROUP INDEX
GROUP INDEX Items
Model View, Truck Models Covered, Serial Number Locations, Main Specifications,
GENERAL INFORMATION
Chassis and Mast Model Identification, Dimensions, Technical Data 1
COOLING SYSTEM Specifications, Structure, Suggestions for Removal and Installation, Troubleshooting
2
Specifications, Location of Components, Structure, Disassembly and Reassembly, Batter-
ELECTRICAL SYSTEM ies and Charging, Troubleshooting, Electrical Wiring Diagram 3
CONTROLLER Outline, Service Tool Functions, Error Code List, Troubleshooting
4
TILTABLE SYSTEM Specifications, Structure, Oil supply, Hydraulic circuit diagram, Service Data
5
Specifications, Structure, Reduction ratio, Removal and Installation of Engine and Trans-
POWER TRAIN mission Unit 6
3-Speed Powershift Transmission Specifications, Description, Suggestions for Removal
POWERSHIFT
TRANSMISSIONS
and Installation, Disassembly and Reassembly, Adjustment, Troubleshooting, Service
Data 7
FRONT AXLE AND REDUC- Specifications, Structure, Suggestions for Removal and installation, Front Axle and
TION DIFFERENTIAL Reduction Differential, Disassembly and Reassembly, Troubleshooting, Service Data 8
Specifications, Structure, Suggestions for Removal and Installation, Disassembly and
REAR AXLE Reassembly, Readjustment, Troubleshooting, Service Data 9
Specifications, Structure, Suggestions for Removal and Installation, Disassembly and
BRAKE SYSTEM Reassembly, Adjustment and Testing, Troubleshooting, Service Data 10
Specifications, Structure, Procedure and Suggestions for Removal and Installation, Trou-
STEERING SYSTEM bleshooting, Service Data 11
Specifications, Structure, Suggestions for Removal and Installation, Priority valve, Lift
HYDRAULIC SYSTEM cylinder, Tilt cylinder, Inspection and Adjustment, Tests, Troubleshooting, Service Data 12
Specifications, Structure, Suggestions for Removal and Installation, Mast assembly, Trou-
MASTS AND FORKS bleshooting, Service Data 13
Applicable Attachment Model, Specifications, Structure, Suggestions for Removal and
FORK POSITIONER installation, Fork positioner cylinder, Inspection and Adjustment, Troubleshooting, Ser-
vice Data
14
SERVICE DATA Maintenance Chart. Tightening torque of standard bolts, Lubrication Standards 15
5
GENERAL INFORMATION
1. Model View................................................................................................................... 1-2
2. Truck Models Covered ................................................................................................. 1-2

1
3. Serial Number Locations.............................................................................................. 1-3
4. Main specifications....................................................................................................... 1-4
5. Chassis and Mast Model Identification......................................................................... 1-5
6. Dimensions (Approximate)........................................................................................... 1-6
1-1
GENERAL INFORMATION
1. Model View
212161
2. Truck Models Covered

This Service Manual furnishes servicing and maintenance
information for the following trucks:
Model code - Serial
Truck model Transmission Engine mounted
number
DP100N Powershift T36A-10011-up Mitsubishi 6M60-TL diesel engine
Cat DP160 DP160N Forklift Mitsubishi 6M60TL Engine Parts

Phone: 1 269 673 1638
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
loaded)
(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 height (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

Phone: 1 269 673 1638
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 Liters (4.7 U.S. gal.)
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 has corrugated fins for the radiator and The oil cooler for the torque converter, equipped in the
a cooling fan with eight blades which enhances the cooling lower tank of radiator, is a water-cooled type which utilizes
efficiency. the engine cooling water to enhance the cooling efficiency
of torque converter fluid.

Phone: 1 269 673 1638
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
Make sure the coolant temperature is not hot and
the radiator cap is removed before opening the
drain cock.
3.1.2 Removal sequence
1 Engine cover, Gas spring 8 Radiator hose (lower)

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

Phone: 1 269 673 1638
2-4 www.dp150.com/cat-dp160-engine-parts
COOLING SYSTEM
3.1.3 Suggestions for Removal and Installation

(1) Intercooler
(a) Attach a lifting hook through the top mounting bolt
holes on the left hand and right hand brackets of the
intercooler.
(b) Hitch a rope to the hook and lift with a crane.
Weight of intercooler 9 kg (20 lb.)
(2) Radiator
(a) Support the radiator with crane.
(b) Remove the radiator mount (four places) and lift the
radiator.
Weight of radiator 30 kg (66 lb.)
3.1.4 Inspection and Repair

(1) Intercooler
(a) Replace any rubber mount which is inelastic or hard-
ened.
(b) When foreign matters, such as insects and dust, have
been adhered to the fins of the core, blow them out with
compressed air from the opposite side and remove
them, taking care not to damage the fins.
Wear goggles for the sake of safety.
(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. Replace them if
any abnormality is found.
2-5
COOLING SYSTEM
(2) Radiator
(a) Replace any rubber mount 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 them out with
pressurized 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. Replace them if any
abnormality is found.
3.1.5 Installation
Follow the removal procedure in reverse while noting the
following instructions.
(1) Intercooler
(a) Lower and align the bottom bolt holes with the mount-
ing 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 the end of the hose reaches the base of the fitting.
Tighten the clamp and make sure the hose end is
stopped at the flare of the fitting and can not come off
of the fitting.
2-6
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 solution
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 range.
101641
Fill within
this range.
10465B
2-7
COOLING SYSTEM
4. Troubleshooting
Radiator has been corroded due to prolonged Repair corroded part or replace if there is
activity or others remarkable corrosion.
Deterioration 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 occurred in engine cooling system, over-
Inspect and repair engine cooling system.
heating
Clean tubes with copper or steel wire so as not to
Clogging of radiator fins
damage them.
Extreme deformation of fin Repair or replace the fin.
Engine overheat Check belts for tension, elongation and crack due
Loosened fan belt and water pump belt
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 Repair corroded part or replace if there is
activity 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
3-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

Phone: 1 269 673 1638
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
C Engine oil pressure indicator lamp Normal oil pressure –
pressure
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.
How to check indicator lamp bulbs

Each bulb is normal if the indicator lamp check switch comes ON with the starter switch key turned to (ON) position. However,
the charge condition indicator lamp and engine oil pressure indicator lamp will not be illuminated.
3-5
ELECTRICAL SYSTEM
3.3 Major Components

3.3.1 ECU (Electronic Control Unit)
Failure indicator lights
LED (green)
LED (red)
Rear (mounting) face

205509
The Electronic Control Unit (ECU) has a built-in 1-chip 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 3-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 failure in the NOTE
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
Failure 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.
Travel speed sensor circuit open Allows the truck to run at the present travel speed but cause an indicator light to come on.
Failure indicator lamp

Failure Failure indicator lamp flashing pattern
Travel speed sensor circuit open
3-speed automatic transmission

solenoid circuit open
NOTE
Each failure indicator lamp turns ON or turns OFF as
shown below.
ON
OFF
204668
3-6
ELECTRICAL SYSTEM
3.3.2 Starter Switch (Anti-restart Type) engine troubles or starter damages possibly caused by any
This switch has a built-in mechanical lockout to prevent operation mistake.
restarting. The starter switch is wired in such a way to energize the
Since this lockout mechanism restraints the starter switch glow plugs. The (ON) position of the switch is for ener-
(key) from moving from (ON) position to (START) gizing the glow plugs.
position while the engine is running, it serves as to prevent
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 taped onto the
harness protector with vinyl tape.
Spare terminal
207209
3.3.6 Lamp Bulb Specifications
Bulb
Color of
Item Qty For 24V Schematic Remark
lens
system diagram
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 battery is fully charged can be checked from

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

(1) The charging current should be about 1/10 the capacity CAUTION
of the battery to be charged. Be sure to turn off the starter switch and light
(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.
• Water drops 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. Chassis 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 controllers are connected on the Controller Area Net-
The controller system consists of the vehicle control con- work (CAN) and communicate mutually to control the lift
trollers (VCM-3 and VCM-3OP), engine control controller truck.
(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 can
• Custom Monitor 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. Chassis Error Code List

Error Page Error Page
Description Description
Code No. Code No.
F01 VCM-3 Memory Check Error 4-21 F54 Lift Solenoid Leak 4-90
F02 VCM-3 Battery Voltage Error 4-22 F55 Tilt Forward Solenoid Error 4-94
F03 VCM-3 Communication Error 4-24 F57 Tilt Backward Solenoid Error 4-96
F04 ECM Communication Error 4-26 F59 Tilt Solenoid Leak 4-98
F07 MP Communication Error 4-27 F60 Attachment 1A Solenoid Error 4-102
F10 Lift Lever Neutral Error 4-29 F62 Attachment 1B Solenoid Error 4-104
F11 Tilt Lever Neutral Error 4-31 F64 Attachment 1 Solenoid Leak 4-106
F12 Attachment 1 Lever Neutral Error 4-33 F65 Attachment 2A Solenoid Error 4-110
F13 Attachment 2 Lever Neutral Error 4-35 F67 Attachment 2B Solenoid Error 4-112
F14 Attachment 3 Lever Neutral Error 4-37 F69 Attachment 2 Solenoid Leak 4-114
F15 ECU Communication Error 4-39 F70 Attachment 3A Solenoid Error 4-118
F16 Shift Lever Error 4-41 F72 Attachment 3B Solenoid Error 4-120
F17 Vehicle Speed Error 4-43 F74 Attachment 3 Solenoid Leak 4-122
F18 ECU KWP2000 Communication Error 4-45 F75 Unload Solenoid Error 4-126
F19 ECU Speed Sensor Error 4-47 F79 Unload Solenoid Leak 4-128
F20 Lift Lever Error 4-49 F80 Knob Position Solenoid Error 4-131
F22 Tilt Lever Error 4-51 F84 Knob Position Solenoid Leak 4-133
F24 Attachment 1 Lever Neutral Error 4-53 F85 Transmission Forward Solenoid Error 4-136
F26 Attachment 2 Lever Neutral Error 4-55 F87 Transmission Backward Solenoid Error 4-138
F28 Attachment 3 Lever Neutral Error 4-57 F89 Transmission Solenoid Leak 4-140
F29 Joystick Lever Error 4-59 F90 VCM-3OP Sensor Voltage Error 4-143
F31 VCM-3 Sensor Voltage Error 4-61 F91 VCM-3OP Memory Check Error 4-146
F33 VCM-3OP Lift Oil Pressure Sensor Error 4-63 F92 VCM-3OP Battery Voltage Error 4-147
F34 Vehicle Speed Sensor Error 4-65 F93 VCM-3OP Speed Change Solenoid 1 Error 4-149
F36 Tire Angle Sensor Error 4-67 F94 VCM-3OP Speed Change Solenoid 2 Error 4-151
F39 VCM-3OP Tilt Angle Sensor Error 4-69 F95 VCM-3OP Speed Change Solenoid Leak 4-153
F40 Steering Error 4-71 F96 VCM-3OP EAT Setting Error 4-155
F41 Output Unit Error 4-73 F97 VCM-3OP Communication Error 4-156
F42 Output Unit Life Control Signal 4-74 L03 VCM3 Communication Error
F43 Output Unit Memory Check Error 4-75 L04 ECM/ECU Communication Error
F44 Output Unit PWM Voltage Error 4-76 L07 MP Communication Error
F45 Output Unit Communication Error 4-79 L08 TMS Communication Error
F46 Input Unit Error 4-81 P03 VCM3 Communication Error
F47 Input Unit Life Control Signal 4-82 P04 ECM/ECU Communication Error
F48 Input Unit Memory Check Error 4-83 P07 MP Communication Error
F49 Input Unit Communication Error 4-84 P08 TMS Communication Error
F50 Lift Up Solenoid Error 4-86 P22 Shift Lever Error Signal
F52 Lift Down Solenoid Error 4-88
4-18
CONTROLLER
4. Troubleshooting
4.1 General Information
4.1.1 Before replacing controllers
Do not replace controllers casually even if replacement is
required as a result of troubleshooting. Be sure to check the
following items before replacing controllers.
• Loose battery connectors
• Abnormal wire harness connections
• Loose connectors
• Broken, bent or loose connector pins
• Dirty connectors
If connectors are dirty, remove the connector and
clean connectors. See “How to clean harness 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.
(4) Turn on the truck power. VCM-3OP
GSE
(5) Start the service tool software.
GSE cable VCM-3

GSE
212346
4.1.3 Diagnostic Precautions (4) When performing measurement with the tester, handle
(1) Before measuring voltage, check the battery for the test bar carefully so that it does not damage internal
charged condition and specific gravity. If system circuit and other electrical parts of the electronic con-
inspection is performed with the battery uncharged or trol unit to result in a short-circuit failure between ter-
reduced in specific gravity, accurate measurements minals in connector or between connector and truck
cannot be achieved. body.
(2) To avoid having electrical parts damaged, set the starter (5) Resistance is affected by temperature. Determine the
switch to OFF before disconnecting and reconnecting necessity of resistance measurement following given
battery cables. temperature specification as a guide. Otherwise, use
(3) Before disconnecting connectors, set the starter switch normal temperature (10 to 35°C) as the measuring con-
to OFF then allow at least 20 seconds. Voltage may dition.
remain in electric parts or connected circuit.
4-19
CONTROLLER
4.1.4 How to clean harness connectors and system

components
(1) Open-circuits are often caused by dirty harness 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 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.
After coupling up the connector, check to be sure that it Electronic parts
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
131 105 107 1.25B/L 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
100
60B 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 227228 1
17 234 235 233 232 231 230 221 220 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
FUEL
78 FUEL GAGE
PKB
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
0.5B
0.5B
20 SW INPUT 6(R)
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
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
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
0.5B
0.5B
20 SW INPUT 6(R)
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
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
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
0.5B
0.5B
20 SW INPUT 6(R)
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
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
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
0.5B
0.5B
20 SW INPUT 6(R)
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
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
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
0.5B
0.5B
20 SW INPUT 6(R)
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
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
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
0.85Y/L 272
SIGNAL PROCESSOR
80
WATER TEMP GAGE
62
82
62 272 OIL
79 BRAKE LAMP
82 80 TEMP
0.85G/L
83 OIL PRESSURE LAMP
0.85L/W
0.85L/G
0.85L/W R
82 TORQ CONV OIL TEMP LAMP
272
N
127
0.85Y/L
126
81
62
80 INTERLOCK LAMP
0.85G/R F
81
0.85G/L
0.85G/R
MULTIPURPOSE WARNING LAMP

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
212357 734 EGR TEMP. SENSOR 34
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
0.5B
0.5B
20 SW INPUT 6(R)
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
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
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
0.5B
0.5B
20 SW INPUT 6(R)
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
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
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
0.5B
0.5B
20 SW INPUT 6(R)
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
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
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
0.5B
0.5B
20 SW INPUT 6(R)
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
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
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
0.5B
0.5B
20 SW INPUT 6(R)
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
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
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
0.5B
0.5B
20 SW INPUT 6(R)
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
477
0.5G
469 26 LIFT 2
0.5Y
460 469 468 464 470 27 TILT 1
0.5L
471 28 TILT 2
461 471 470 465 0.5Y
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
0.85B/Y
CAB OPEN IND1 257
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
231
232
230
ST. ANGLE SEN 215 215
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
218
217
216
215
216 132
132
9 245 1 9 227228 1
17 224 223 10 17 234 235 233 232 231 230 221 220 10
25 130 218 217 216132 215 40 18 25 384 222 238 237 18 TIRE ANGLE
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
131 105 107 1.25B/L 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
100
60B 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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
0.85R/W
0.85W/R
0.85W/R
0.85W/B
0.85L/W
493 34 PWM 10+
0.85L/R
0.85l/R
0.85W
0.85Br
0.85W
0.85G
0.85R
494 35 PWM 9-/PWM 10-
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
0.85L/R
491
498
494
490
489
499
492
493
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
937
395
212
411
245
397
396
9 1
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
233
P/S SOL 237
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)
SOLENOID (F - R)
237
238
237 238
0.85Lg/R
UNLOAD SOL 211
0.85G/B
UNLOAD RETURN 411
0.85B/W PS CARIB
CAN L 200
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
0.85Lg/B
228
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
233
P/S SOL 237
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)
SOLENOID (F - R)
237
238
237 238
0.85Lg/R
UNLOAD SOL 211
0.85G/B
UNLOAD RETURN 411
0.85B/W PS CARIB
CAN L 200
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
233
P/S SOL 237
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)
SOLENOID (F - R)
237
238
237 238
0.85Lg/R
UNLOAD SOL 211
0.85G/B
UNLOAD RETURN 411
0.85B/W PS CARIB
CAN L 200
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
0.85B/Y
CAB OPEN IND1 257
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
136 105 107 1.25B/L 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
100
60B 60B
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 release 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 hydraulic 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 release the stopper pin from the lock position. If you attempt to raise or lower the operator com-
The full-open position must be used only for removing the partment without tilting the mast fully forward
engine.
beforehand, the operator compartment will be
If you operate the hand pump with the direction valve
turned counterclockwise, the operator compartment lowers damaged.
down to the partial stop position (25˚).
5-3
TILTABLE SYSTEM
2.2 Hand pump
6 6 1
2 2
50 r5
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
Add oil to 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 Radiator (transmission oil cooler), Pipes and Hoses ............................................................................ 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.
Phone: 1 269 673 1638
6-8
POWER TRAIN
4.4 Radiator (transmission oil cooler), Pipes and Hoses
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 Cat DP160 DP160N Forklift Engine Parts
Phone: 1 269 673 1638
Website: www.HeavyEquipmentRestorationParts.com 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.
900 kg
Weight of engine and transmission unit
(1.984 lb.)
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)
Ref. Tightening
Item position
No. Torque 4 1
145 N•m
Cushion rubber and mounting
1 (14.8 kgf•m)
bolt
[107 lbf•ft]
3
60 N•m
2 Mounting bracket bolt (6.1 kgf•m)
[44 lbf•ft]
97 N•m
206171
3 Cushion rubber bolt (9.9 kgf•m)
[72 lbf•ft]
60 N•m Transmission mount(right side) 1
4 Mounting bracket bolt (6.1 kgf•m)
[44 lbf•ft] 2
206172

Phone: 1 269 673 1638
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
Cat lift truck dealer.
(6) Also bleed the engine fuel lines.
(7) After checking every part, start the engine and observe
its running condition. If the engine vibrates 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
23 Liters
Antifreeze (Genuine Mitsubishi Fuso Dia Queen)
(4.7 U.S. gal.)
long-life coolant
Torque converter Diamond ATF 23 Liters
oil DEXRON II (6.1 U.S. gal.)
Gear oil Diamond firm gear oil B
20 Liters
(differential gear, front API category, Multi-purpose type GL-5
(5.3 U.S. gal.)
axle final gear) SAE90, 80
ENEOS brake fluid
Brake oil 240 cc
FMVSS DOT3 or DOT4
DP100N–135N
140 Liters
(37.0 U.S. gal.)
M Lift hydraulic oil DP150N

Level gauge
Hydraulic oil (Genuine Mitsubishi Fuso hydraulic Oil) 168 Liters
(N) mark
ISO VG32 (44.4 U.S. gal.)
DP160N
184 Liters
(48.6 U.S. gal.)
JIS Extra Grade 3 (-15˚C or lower)
175 Liters
Fuel JIS Grade 3 (-5 to -15˚C)
(46.2 U.S. gal.)
JIS Grade 2 (higher than -5˚C)
M Lift diesel engine oil Engine body: 12 Liters
(Genuine Mitsubishi Fuso Engine Oil Special) (3.2 U.S. gal.)
API category CD class or higher Oil filter: 4 Liters
Engine oil SAE 10W or SAE 10W30 (-10˚C or lower) (1.0 U.S. gal.)
SAE 20W (-10˚C to 10˚C) Total: 16 Liters
SAE 30 (higher than +10˚C) (4.2 U.S. gal.)
6-14
3-SPEED POWERSHIFT TRANSMISSION
1. Specifications ............................................................................................................... 7-3
2. Description ................................................................................................................... 7-4

2.1 Torque Converter.................................................................................................................................. 7-4 1
2.2 Transmission......................................................................................................................................... 7-5
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
Transmission Forward 2nd: 1.010
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 valve 2nd/3rd speed
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) Install 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 plate is 14.5 mm (0.57 in.). If this distance is
more than 14.5 mm (0.57 in.), it is an indication that
spline engagement between the torque converter stator
shaft and transmission input shaft is improper; reinstall
the torque converter to the transmission.
(2) Lift the transmission, and bolt it to the engine.
(3) Make sure that the clearance between the flywheel and
flexible plate is 0 to 2 mm (0 to 0.08 in.) when the
transmission is bolted to the engine.
(4) Tighten the bolts that hold the flexible plate 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 67.951 to 67.97

Standard value
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 speed) removal
Remove the output gear together with ball bearing 6 with
a gear puller.
205629
• Output shaft 15 removal
Turn a sliding hammer in the M8 × 1.25 hole in the end of
the output shaft, and remove the shaft together with 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 clutch the forward clutch shaft.
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)
mm (in.) 1
Service limit 0.35 (0.0138) 205486
(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 subassem-
bly 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

Replace the oil seal with a new one. Install the oil seal to Unit: mm (in.)
the torque converter housing by using the oil seal installer

(special tool).
Special tool needed
Oil seal installer (to be made by dealer)
• Oil pump reassembling

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

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

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

When installing ball bearing 18 in pump case 12, hold the Unit: mm (in.)
pump drive gear with the Pump drive gear holder (special
tool), or have someone press the gear with a copper bar or
the like, in order to prevent the gear from coming off.
Special tool needed
Pump drive gear holder (to be made by dealer)
)
39
(0. 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 subassembly
5 Input shaft 19 Reverse clutch shaft subassembly
6 Snap ring 20 Output gear (3rd speed)
7 Input gear 21 Output gear (2nd speed)
8 Lock nut 22 Ball bearing
9 Output shaft 23 Oil seals
10 Snap ring 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 valve 36.5 (1.44)

Standard
springs 1 k = 5.658 (0.577)
value 5 5
mm (in.) [32.3]
k: Spring constant Service
N/mm (kgf/mm) [lbf/in.] 35.5 (1.40)
limit
Free length of differential 60 (2.36) 1
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
mm (in.) [21.3] 2 1
N/mm (kgf/mm) [lbf/in.] 140 (5.51)
limit 4
3
Free length of accumulator 184.5 (7.26)
Standard
valve inner spring 4 k = 3.941 (0.4019) 212215
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)
e)
(2) Place brake pedal 4 at the same height as inching pedal
ang
k
tro
1 by using bolt 5 and nut 6.
(S
ting
(3) Eliminate the clearance between inching pedal 1 and
22
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 truck 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
(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 0.88 to 1.08 MPa
Standard
(with engine idling at (9.0 to 11.0 kgf/cm2)
value
1500±100 rpm) [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 appropriate
stand is placed under the frame to keep the front tires
lifted.
(3) Put scotch blocks under the rear tires.
(4) Implement the steps (2) through (4) of main oil 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
0.73 to 0.93 MPa
pressure Standard
(7.44 to 9.48 kgf/cm2)
(with engine idling at value
[105.9 to 134.9 psi]
1500±100 rpm)
7-47
5.2.3 Torque converter inlet oil pressure measure-

NOTE
ment
The parts marked with an asterisk (*) are included in the
(1) Connect a 0.6 MPa (6 kgf/cm2) [87 psi] oil pressure
gauge kit 64309 - 17701.
gauge to the torque converter inlet oil pressure inlet
port of the regulator valve.
Special tools needed
*Connector 64309 - 17733 Torque converter
inlet pressure tap (T)
*Hose 64309 - 17722
*Connector 64309 - 17731
*Gauge 64309 - 17714
perature.
(4) Keep the engine idling (at between 1000 and 1500
rpm), measure the torque converter inlet oil pressure. 212223
Torque converter inlet

0.15 to 0.69 MPa
oil pressure Standard
(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. Failure to follow this precaution
may result in destruction of the torque converter.
(6) Similarly measure the stall speed for reverse drive.
NOTE
(a) Any stall speed within ±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.
Not • Stator freewheel seized • Replace stator assembly, hub and

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.
• 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.
7-52
• Leaking oil seals • Check lips and sliding surfaces for

wear.
• Replace seals.
• Leaking joint of case • Retighten or replace packing.
• Leaking pipe connection or joint • Repair or replace pipe, gasket and O-
rings.
• Leaking drain plug • Retighten or replace gasket.
Oil leaks
• 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 specifica-
• Stator and freewheel defective if the speed is excessively • Replace stator assembly.
tion
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

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

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

-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

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

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
7-58
7.6 Flexible Plates

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 converter housing and
Standard value 14.5 (0.57)
mating face of flexible plates 2 mm (in.)
200725
7-59
7.7 Clutches

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

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 Standard value 35 0 (1.38 0 )
with 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

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

36.5 (1.44)
Free length of selector valve spring 1 mm (in.) Standard value
k = 5.658 (0.577) [32.3]
Service limit 35.5 (1.40)
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

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

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 1
2.1.1 Hub reduction.............................................................................................................................................. 8-5
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
6
3.2 Front Axle and Reduction Differential ................................................................................................. 8-15
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
4.2.3 Inspection and Repair ............................................................................................................................... 8-31 14
4.2.4 Reassembling the wheel brake ................................................................................................................. 8-32
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
4.3.4 Inspection and Repair ............................................................................................................................... 8-41
4.3.5 Reassembling the differential assembly.................................................................................................... 8-42
4.3.6 Adjustment of reduction pinion preload..................................................................................................... 8-45
4.3.7 Contact adjustment between the gear and pinion teeth............................................................................ 8-46
4.3.8 Reassembly of reduction & parking brake assembly ................................................................................ 8-50
4.3.9 Installing reduction differential................................................................................................................... 8-52
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 truck 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
Air is compressed. Keep your face away from the
tire.
(c) The wedge band should be removed while being

impacted with a hammer via a protective patch.
210373
(d) Support the truck at the lower side of the outer tires
either using a small-type lift truck 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 CAUTION
evenly so that the runout of wheels can be avoided as Wheel nuts should be tightened in the correct
much as possible. order as instructed by the right-hand side figure.
539±49 N•m (Numbers show the order of tightening.)
Tightening torque (55±5 kgf•m)
[398±36 lbf•ft]
(3) Retightening of wheel nuts 1 4

(a) Test-run the truck for about 10 minutes after complet- 6 7
ing the service work to check for forward/reverse drive
and braking. 9 2
(b) Use a torque wrench to re-tighten all the wheel nuts to
the specified torque. 3 10
8 5
210376
8-14
3.2 Front Axle and Reduction Differential

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.
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 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
Tightening torque (6.2 to 8.3 kgf•m)
[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.
245 to 294 N
Parking brake lever
(25 to 30 kgf)
operating effort
[55 to 66 lbf]
(3) Add oil to the front axle

(a) Position the level mark of either the right or left cover
to be horizontal.
(b) Remove the level plug located at the side of the level
mark. For the wheel hub cover at the opposite position,
remove the level plug located in the higher positions
than the center for air bleeding.
(c) Remove the level plug located at the differential side of
the axle housing, then add oil through the plug hole.
Recommended oil: Gear oil
(API service classification GL-4) SAE 90 212295
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 install the sliding (a) Install the anchor bolt in one of the universal joint
hammer in the screw hole (M10 × 1.25) in the end of the mounting holes and put a wire rope there, and tension
axle 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
37 mm (1.46 in.) (12±1.2 kgf•m)
[87±9 lbf•ft]
132±14 N•m
31 mm (1.22 in.) (13.5±1.4 kgf•m)
[98±10 lbf•ft]
CAUTION
Bolt tightening torque varies depending on the
length under the neck. Be sure to tighten to an
appropriate torque.
(2) Wheel hub cover

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

4.1 Hub reduction (DP100N to DP150N)
4.1.1 Preparation (on-truck 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 truck. 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

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

The planet carrier must be removed by lifting it with a
crane.
(3) 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 +0.029
Standard 58 +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
(b) Check the tapered roller bearing (outer race) for wear Thrust washer value (0.047±0.002 in.)
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
Brake drum inside value +0.008 (b) Check the tapered roller bearing (inner race) for wear
(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
Tightening torque (37±3.7 kgf•m)
[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
bearing (force applied in (13 to 17 kg)
tangential direction) [28.7 to 37.5 lbf]
NOTE
However, it is advisable to aim at a value of tangential force
(preload) in the lower tolerance limit, if the bearings are 212330
being reused.
(b) If the force applied in the tangential direction (preload)

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

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

(a) Tighten the mounting bolts of the planetary gear cover
to the specified torque.
56.9±5.9 N•m
[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

Install the sliding hammer into the screw hole (M10 ×
1.25) on the edge face, and turn it to remove the sun gear
and snap ring as a whole.
(2) Planet carrier
The planet carrier must be removed by lifting it with a
crane.
(3) Wheel brake
(a) Attach a wire rope to the wheel hub and brake housing
and support them by lifting with a crane.
(b) Remove the spindle mounting bolts, and remove the
spindle as an integral assembly including the wheel
hub.
(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
Special tool 65(2.56)
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 install
two jack bolts into them and turn the bolts evenly to
pull out the ring gear.
(b) Remove the jack bolts and install the anchor bolts in
the bolt holes (M16 × 1.5: 2 places).
(c) Attach 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) Screw the eye bolts in the bolt holes of the wheel hub
guide (M10 × 1.25: 2 places) and attach a wire rope,
Jack bolt
and then lift the wheel hub guide with a crane.
(f) Screw a jack bolt into the wheel hub guide. Screw the
bolt to the bottom end and remove the tapered roller
bearing inner race from the spindle.
(g) Lift the wheel hub and brake hub to remove them. Lay
aside the removed assembly with the wheel hub side
down.
(h) Remove the mounting bolts of the brake hub, and 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
wear or damage. 3.4±0.3 mm
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 58 +0.010 mm
value +0.0011 tooth faces.
Needle roller bearing (2.28 +0.0004 in.)
inside diameter
Service 57.96 mm
limit (2.282 in.)
(7) Floating seal
0
(a) Replace any seal which has a fault or damage in the lip
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
[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
Mating plate
End plate
Continue air supply (after installing brake cover) 212378
(a) Prepare the special tool. (g) Supply compressed air with the following specified
Part No. Part name value from the connector of the brake oil supply mouth
92G68-00100 Friction plate holder to prevent the friction plate from misalignment.
490 kPa
(b) Install the friction plate (special tool) to the spindle. Air pressure (5 kgf/cm2)
(c) First install the end plate. [71.1 psi]
(d) Continue to install the mating plate, then the friction
(h) When these operations are completed, remove the fric-
plate.
tion plate holder (special tool).
NOTE
NOTE
Make sure to install the plates in the correct order.
Do not stop supplying the compressed air until the installa-
tion of the hub reduction is completed. If the friction plate is
(e) Brake cover misaligned, the brake hub can not be inserted.
Tighten the mounting bolts to the specified torque.
112±10.8 N•m
[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
[12.2±1.5 lbf•ft]
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 the trick ring may cause the seal per-
formance to be degraded from the uneven bearing stress,
resulting in oil leaks or undesirable suction of foreign matter.
212308
(c) Soak the trick ring in the cleaning agent as the entire
surfaces under the level so that all oil films, dusts, and
foreign matters can be washed out.
NOTE
For this operation, always use a volatile cleaning agent 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.
(2) Assembling wheel hub and brake hub
212314
(a) Tighten the mounting bolts of the brake hub to the
specified torque.
366±3.7 N•m
[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) Screw the eye bolts in the bolt holes of the wheel hub
pusher (M10 × 1.25: 2 places) and attach a wire rope,
and then lift the wheel hub guide with a crane.
(f) Lower the wheel hub and brake hub as an integral
assembly to the wheel brake.
212380
8-37
(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
[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
bearing (force applied in (12 to 16 kg)
tangential direction) [26.5 to 35.3 lbf]
CAUTION
However, it is advisable to aim at a value of pre-
212316
load in the lower tolerance limit, if the bearings are
being reused.
(b) If the force applied in the tangential direction (preload)

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

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

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 with reassembly.
Backlash between
reduction bevel gear
value (0.010 to 0.012 in.)
and bevel pinion
CAUTION
When the reduction gear set is to be replaced with 200247
a new one, it is not necessary to measure the

backlash.
(2) Alignment marks (reference)

Put alignment marks on one side of the bearing caps, ad-
justment screw and carrier to ensure correct refitting.
200241
(3) When removing the bearing retainer from the differen-

tial carrier, make a record of the thickness or amount of
shim (s) between the retainer and carrier.
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 install jack bolts into them and turn the
bolts evenly to pull out the bearing.
(b) Make a record of the thickness of shims which are
removed and take care so as not to lose them.
8-42
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
value (0.007 to 0.011 in.) one.
tial bevel pinion inner
diameter and shaft outer Service +0.5
0.35 mm (0.014 in.) Standard 304.8 0 mm
diameter 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
[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
[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 differential unit before install-
ing 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 in the fol-
lowing order to make sure the preload of the tapered
roller bearing of the reduction pinion is correct.
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
10
[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”.
3
(2) As the parking brake bracket is not installed, the
removed bolts can not be reused. Therefore, always 4
replace 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
(53.5 mm [2.1063 in.]) of dimension B.
c = 53.5 mm (2.1063 in.) – b
NOTE
(a) Round off to the first digit below decimal point. 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 (0.0039 in.)
(3) Installing reduction unit

(a) Lay the differential unit with its reduction and parking
brake assembly mounting side facing upward and
secure it to wooden bars, etc.
(b) Install the eyebolt into the universal joint mounting bolt
hole of the input flange.
(c) Put a wire rope to the eye bolt and lift the reduction
unit for assembling. Be careful not to allow the
machining error adjustment shim to fall off.
(d) Tighten the mounting bolts to the specified torque.
128.5±19.6 N•m
[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 one turn, tight- To decrease.
en 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 from the standard BACKLASH
To decrease.
205611
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) Refer to 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 to check the backlash.
8-51
4.3.8 Reassembly of reduction and 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 apply oil to the O-ring and oil sepa-
rator.
(2) Oil seal
(a) Prepare the following special tools.
Unit: mm [in.]
[Ø1.38]
Ø35
Special tool
[Ø3.74 - 0 . 0 0 4 ]
Installer: To be made by dealer (for the dimensions, re-
[Ø2.7±0.004]
Ø68.5 ±0.1
Ø95 - 0 . 1
fer to the figure at the right hand.)
0
(b) Make the 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
[107±16 lbf•ft]
(4) Parking brake drum

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

(a) Tighten the self-locking nut to the specified torque.
249±29 N•m
[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 and parking brake assembly 3 Lock washer, Lock plate

2 Side bearing cap bolt
(re-tighten to the specified torque.)
(1) Lay the differential unit with its reduction and parking (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
(2) Install the eyebolt into the universal joint mounting bolt Tightening torque (38.6 to 52.2 kgf•m)
hole of the input flange. [279 to 378 lbf•ft]
(3) Attach a wire rope to the eye bolt and lift the reduction
and parking brake assembly to assemble it into the dif- (6) Tighten the mounting bolts of the lock washers and
ferential unit. lock plates to each specified torque.
(4) Tighten the mounting bolts to the specified torque. 34.3±3.9 N•m
59.8±5.9 N•m Tightening torque (3.5±0.4 kgf•m)
Tightening torque (6.0±0.6 kgf•m) [25.1±2.9 lbf•ft]
[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 reduction • Readjust or replace the bearing.
Gear noise comes out bevel gear bearing
continuously during
normal traveling • Hub bearings damaged • Replace the bearing
• Improper tooth contact between the reduction pinion • Readjust the tooth contact.
and reduction gear of the output shaft
• Reduction gear bearing or hub bearing broken. • Replace the bearing
Irregular noise comes • Differential gear teeth broken or thrust washers • Replace differential gear or washer.
out during normal worn
traveling • Metal chips in axle housing • Clean and change oil.
• Bolts securing axle shaft or differential carrier loose • Retighten.
• Fit of differential gear in differential case out of • Replace.
Abnormal noise specification due to wear
comes out when turn-
ing a corner. • Teeth of differential gear or pinion broken, seized on • Replace.
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
Deflection 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 deflector 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
Deflection 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 bevel gear 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
A
B B
A
3 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) Set the parking brake.
(2) Block the front wheels.
(3) Loosen each rear wheel nut about two turns.
(4) Place a jack under the recess 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 also use the lifting holes of the counterweight to
lift the rear end of the truck.
WARNING
After raising the front end with either of the 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 lift 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
Tightening 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 (5) Insert solid stands under the both sides of the frame to
(1) Set the parking brake. prevent the truck from falling.
WARNING
(3) Remove the rear wheels (tires) while referencing the
section of “Rear Wheels (Tires)”. Never forget to place solid stands under both
(4) Use a lift truck with a duty load 10 tons or more and lift sides of the frame to prevent the truck from falling
the rear end of the truck until the bottom of the weight down.
is 400 to 500 mm (15.75 to 19.69 in.) above the
ground.
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) Install hose caps to the disconnected hose to prevent oil
from flowing out.
Hose cap 05330-30300 (G 3/8)
205558
(2) Rear axle assembly

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

(a) Do not remove the bushings in the support unless a
defect is found through inspection.
(b) If any defect is found, either replace the rear axle 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 is installed 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 avail-
able in different thicknesses.
3.2 mm (0.13 in.)
Thrust washer type
1.6 mm (0.063 in.) 0.4mm
(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 0.8
mm (0.032 in.) or less (0.4 mm (0.018 in.) or less for 205555
one side).
CAUTION
Install thrust washers evenly for the front and rear.
9-9
REAR AXLE

4.1 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 race 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) Install 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 dur-
ing reassembly.
(See the figure at the right.)
212121
(3) Preload adjustment of knuckle bearing

(a) Install the cover without the shims.
(b) Use a thickness gauge to measure the clearance
between the rear axle housing and cover.
(c) Install a shim which is 0.1 mm (0.0039 in.) thinner than
the measured clearance and evenly tighten the cover
mounting bolts.
(d) Hook a spring scale to the tie-rod mounting hole of the
knuckle arm and measure whether the force applied in
the tangential direction meets the specified value.
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 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
Preload for
(8.97 to 12.95 kgf)
hub bearing
[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 in vise.
(b) Use the special tool to remove the cylinder head.
Special tool
Hook wrench 05302-10800
Hook wrench 205438
9-17
REAR AXLE
4.2.2 Inspection and Adjustment

(1) Piston rod bend
(a) Support both ends of the piston rod with V-shaped
blocks, and apply a dial gauge at the middle portion.
(b) Measure the deflection (runout) while rotating the 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

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

(a) Check the cylinder tube for any wear, damage or rust.
If any excessive rust or damage is found, replace the
cylinder tube.
(b) Check the welds for cracks, damage, and dent. If any
excessive damage is found, replace the cylinder tube.
Item 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 always be new ones. Never
re-install any part that has been once removed.
(b) Before reassembly coat each part with hydraulic oil.

(c) Be aware of the direction to assemble the seals and
rings to be inserted in the cylinder head.
9-19
REAR AXLE
(3) Installing piston seals

(a) Hold the piston rod with a vise.
CAUTION
Be careful not to damage the piston rod.
(b) Lightly compress and release a piston seal 5 to 6 times

by hand to make it soft.
(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 to 200352
make sure the piston seals are firmly installed.
(f) When the assembling of piston seals is completed,

install the associated wearing.
205552
(4) Cylinder head

(a) Tighten the cylinder head to the specified torque.
539 ± 54 N•m
Tightening 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 area of flat square ground which extends
more than 20 m (65.6 ft.) in both directions of depth
and width.
WARNING
This measurement lot must be surrounded by a
fence, etc. or assigned with watchman in order to
prevent any persons unconcerned from entering
the area.
(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.
us
(3) Turn the steering wheel fully and drive the truck at a
di
ra
low speed. At this time, make sure that the chalk draws
g
in
a line (circle) on the ground.
rn
tu
(4) Measure the diameter of the circle drawn on the
um
im
ground. The radius of this circle is assumed to be the
in
M
minimum turning radius (R).
Truck Model Minimum turning radius
212256
DP100N 4000 mm (157.5 in.)
DP120N 4060 mm (159.8 in.)
DP135N 4165 mm (163.8 in.)
DP150N 4555 mm (179.3 in.)
DP160N 4815 mm (189.6 in.)
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 has met the speci-
fied value, tighten the lock nut to the specified torque.
233 N•m
Tightening 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
Dull self-returning of steering • Excessive tightening on each part of • Retighten to the specified torque
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
1
2. Structure..................................................................................................................... 10-5
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 6
3.1 Wheel brake (DP100N to DP150N) .................................................................................................. 10-20
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 14
4.5.1 Disassembly............................................................................................................................................ 10-35
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 by an air

drier, and filled in the air tank. The compressed air is
opened/closed by the brake control valve through a relay
valve, and sent to air master. Since the air master 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 the air tank is directly sent to the air mas-
pressure change in pipeline at the brake control valve side, ter 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 the relay valve.
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 in-
let 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
No 1°
1.5°
r a k al
±
ing
b rm
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 slowed
The adjusting cam is a eccentric cam, and rotation of the 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 by an air

drier, and fills the air tank. The compressed air is opened/ NOTE
closed by the brake control valve, and sent to brake booster (a) Relay valve and brake control valve are common to
through the relay valve. Since the brake booster compresses DP100N-DP150N. For structure description, refer to
the brake oil with this compressed air, the wheel brake acti-
the section of DP100N-DP150N.
vates 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 the chamber is activated a warn-
is supplied from brake control valve, into oil pressure force, ing buzzer sounds. This means the disk and plates in the
and activates the wet disc brake installed to the front axle. wheel hub have reached 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) The stroke of push rod is too long because the brake
disc and plates are worn and must be replaced.
10-16
BRAKE SYSTEM
2.3 Parking brake system
206098
1 Parking brake lever 3 Parking brake drum assembly

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

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

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

(a) If there is serious damage to the lever support pin or the
pin hole in the lever, replace the lever assembly.
(b) Replace the parking brake cable if it is stretched, 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
[14.5±3 lbf•ft]
(2) Shoe and lining assemblies

(a) Check the linings or shoes for any cracks or fracture.
(b) Replace the lining if it has been badly contaminated by
oil or has been glazed or otherwise set or deteriorated
from friction heat.
(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, repair the inside surface by grinding
it.
+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.)
(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) Apply a thin coat of 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
[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
(avoid over-lubrication or the linings will be soaked
with grease)
(3) Installing brake shoe

(a) Position the left and right adjusting cams so that the
lobe lift or rise is minimum.
(b) Check that the push rod of wheel cylinder is correctly
placed in the shoe web.
(4) Installing lock plate and lock washer

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

Hang the return spring on the pin of brake shoe using
the spring setter in the special tool.
Special tool
Spring setter: 03727-10001
Spring setter
205687
10-27
BRAKE SYSTEM
(6) Adjusting lining wear indicator
NOTE
Perform adjustment of the indicator, only when the 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 cam not to turn.
210435
(7) Installing wheel brake assembly

Install the wheel brake assembly into the front axle, and
tighten the bolt to the specified torque.
156±16 N•m
M14 (15.9±1.6 kgf•m)
Tightening torque for [115±12 lbf•ft]
wheel brake assembly
bolts 233±24 N•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 inner wall for rusting, corrosion and dam-
age.
(b) Check each threaded part of air bleeder, connector, and
oil pipe for damage.
(2) Piston
(a) Check the outer surface for rusting and damage.
(b) Install the piston into the cylinder body, and measure
the clearance. Replace, if the clearance exceeds the 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, hardened or otherwise dete-
riorated. 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 of the piston cup being careful not to
damage.
10-30
BRAKE SYSTEM
4.3 Air master (DP100N to DP150N)

4.3.1 Disassembly
The number shows disassembling sequence. 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 (85 psi) to the
inlet port in the rear section of cylinder shell and make
the push rod pull out from the end plate.
(b) Loosen the pin and remove the hydraulic piston.
200641
10-31
BRAKE SYSTEM
4.3.2 Reassembly
(1) Always replace the repair kit parts with new ones,
when reassembling.
(2) Clean the removed parts with the following cleaning
fluid to remove the surface deposit.
(a) Handling of rubber parts
Wipe off the surface deposit using a rag soaked with al-
cohol or light oil. Furthermore, don’t dip rubber parts
into the cleaning fluid by any means.
(b) Handling of metal parts
Clean with volatile cleaning fluid, and remove the re-
maining cleaning fluid by blowing the parts with 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 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
Wipe off the surface deposit using a rag soaked with
light oil.
CAUTION
Be careful not to dip the rubber parts into metal
cleaning fluid.
(b) Metal parts

Remove the surface deposit using clean metal cleaning
fluid.
(2) Repair kit parts
Always replace with new ones before install.
(3) Master cylinder
(a) Apply lithium base grease (Remax 2) to seals of O-ring
and seal grooves.
(b) Apply engine oil (10 W) to the sliding surfaces of 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 cracks or 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 deteriorated from friction +0.5
Standard 304.8 0 mm
heat. 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
Check the adjuster wheel teeth for wear, and check
Service 3.5 mm
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
Wipe off the surface deposit using a rag soaked with al-
cohol 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
blowing the parts with 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, use the complete bag if purchased for use in
repair kits.
(b) Tap the case over its circumference with plastic ham-
mer to make the desiccating agent properly seat.
(c) Tighten screw of cover to the specified torque.
2.0 to 3.9 N•m
[1.5 to 3.0 lbf•ft]
(d) Tighten the mounting bolts of the cartridge assembly to

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 the clearance at two places on each wheel.
(3) If it does not conform to the standard value, turn the

adjusting cam to adjust.
5.1.2 Replacing brake lining

When the wear indicator of brake lining reaches the service Lining wear indicator
limit, replace the shoes as an assembly. The shoe assembly
should also be replaced in the following cases:
(1) When installation of lining and brake shoe is poor.
(2) When it has been badly contaminated by oil or has
been glazed or otherwise set or deteriorated from fric-
tion heat,.
(3) When lining has cracks or damage.
210442
5.1.3 Adjusting lining wear indicator

(1) In order to set the lining wear indicator, turn the washer
using the wrench and set the indicator to the innermost
part of the lining service limit range.
(2) In this case, set the adjusting cam with the shoe most
retracted, and hold down with another spanner in order
for the cam not to turn.
NOTE
Perform adjustment of the indicator, only when the 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 friction (inside) surface of the drum for
uneven wear or scratches. Replace the drum if uneven
wear exceeds 0.2 mm (0.008 in.), or if the friction sur-
face is badly scratched.
+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) Fill the brake fluid reserve tank full before bleeding.
(b) During bleeding operation, refill the brake fluid reserve
tank as required and do not allow the tank to go below
half full.
5.2.1 Bleeding air master

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

(1) Connect one end of a vinyl tube to the bleeder screw of
the wheel cylinder. Insert the other end of the vinyl
tube into the container filled with the brake fluid.
(2) After the one in the truck pumps the brake several
times and then keeps it depressed, the other at the
bleeder screw must loosen the bleeder screw to allow
the brake fluid to flow into the container. The bleeder
screw should be tightened after brake fluid flows as a
solid stream without any bubbles.
(3) Repeat the above steps until no air bubble is seen in the
tube, and refill the reserve tank.
200285
NOTE
(a) Exercise care so that the brake fluid level in the reserve
tank does not become too low during this operation.
(b) Be sure to use the specified brand of brake fluid, and
never mix it with other brands.
5.3 Inspection of wheel brake (DP160N)

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

(1) In the following cases, bleed the brake oil line.
(a) When part of brake oil line is disassembled.
(b) When the brake pedal feels spongy.
(Air may be mixed in circuit.)
WARNING
Observe the following precautions strictly before
bleeding operation so that the truck does not move
suddenly.
(a) Ensure that the parking brake is applied.
(b) Block all the wheels.
(2) Bleeding
NOTE
Bleeding brake oil line must be performed by two persons.
(a) Fill up brake oil in the oil tank to the specified amount.
(b) Start the engine, and increase the air pressure of air
tank to the specified pressure.
(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. Bleeder 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 the
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 ± 1.5 deg) of
the brake valve.
206105
5.5 Inspecting brake control valve

5.5.1 Air leakage check
(1) Check the air pressure of the air tank is at the specified
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 comes
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 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) about eight notches to obtain the correct lining-
to-drum clearance. Turn adjuster
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.
(2) Turn the starter switch to [ON] position. Float
(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 the brake oil quantity
warning lamp when the oil level of brake oil falls down
201507
to approximately 52 mm (2.05 in.) height.
NOTE
The brake oil quantity warning lamp is common to the
brake disc wear warning lamp.
10-46
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 res- • Repair and add Oil.
ervoir
• 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 mating 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 mating • Perform brake break-in
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
/179 mm (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 was designed 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 to enter 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
When removing the steering wheel, do not tap the 209708
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 on the com-
bination switch by hand to the shown direction in the Front
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
straight ahead position. (The protrusion on the combi- Protrusions form an
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) Apply 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 lower 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 all five hoses from the steering valve. Tightening torque of bolt
(3) Remove the steering valve mounting bolt and then, 29.4 N m
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-
fied torque.
(3) Tighten the hose nut to the specified torque. Check valve
(4) After reassembly, be sure to perform air bleeding. 212031
• 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 an alignment mark on the tilt lock lever and nut (B)
to ensure proper reassembly.
(2) Remove bolt A, then remove the tilt lock lever.
★
Reassembly
When the alignment marks have faded out or the lever is to
be replaced with new one, install it according to the 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.)
(1) Tighten nut B to the tightening toque of 11 to 15 N•m Lever mounting bolt
(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
contour. Tilt lock lever
(3) Tighten bolt A. Bolt A
(4) Release the tilt lock lever, and make sure that the 209712
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 1
2.2 Hydraulic tank ..................................................................................................................................... 12-6
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
6
3.2 Lift cylinder........................................................................................................................................ 12-13
3.2.1 Removal .................................................................................................................................................. 12-13
3.2.2 Removal sequence ................................................................................................................................. 12-13 7
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
3.3.2 Removal sequence ................................................................................................................................. 12-16
9
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
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
Hydraulic system
Control Valve +0.5

Relief pressure 20.6 0 MPa (210.1 kgf/cm2) [2988.1 psi]
Flow regulator Type Cylindrical valve type
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 gear pump draws oil from the hydraulic tank and sends
it to the priority valve. The oil pressure is metered and
divided by this priority valve into two systems, one for the
hydraulic system and the other for the steering system. The
oil that goes to the hydraulic system is sent through the con-
trol valve to the hydraulic cylinders.
NOTE
The steering control valve is described in “11 STEERING
SYSTEM”. Also for power cylinder, refer to “9 REAR
AXLE”.
12-5
HYDRAULIC SYSTEM
2.2 Hydraulic tank
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 merge 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 operating all the other service
the priority valve to the steering control valve, the remain- equipment.
ing oil 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 mounted together by three tie bolts.
Each block has a pump port and tank port, and is mounted
with a cartridge-type pilot-operate relief valve.
12-8
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
Tilt cylinder
211969
The tilt cylinder is a dual working type and has the rod end
threaded for adjusting the balance between the right and left
when the mast is mounted.
The tilt angle setting can be modified through an optional
adjustment of collar and socket.
12-9
HYDRAULIC SYSTEM
2.6 Flow regulator valve
To lift cylinder
From lift cylinder
From control
valve To control valve
To other
flow regulator
valve
210470 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 closing 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 both cylin-
ders 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, put the mast in neutral
appropriate measures for the connections of pipes and con-
position and lower the fork to the bottom in order to
trol valves to prevent dust and dirt from entering in the
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
3-valve 45 kg (99.2 lb)
4-valve 55 kg (121.3 lb)
5-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 the return hose on 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 bottom of the lift
cylinder. Prepare containers to catch oil, which should
remain in the high-pressure hose.
(4) Removing stopper bolt

(a) Remove the stopper bolt at the upper section of the lift
cylinder, and lift the inner mast up to separate the cylin-
der rod end from the mast.
Before lifting up the inner mast, wrap the inner mast
channel with a protective cloth and attach a wire rope
around the inner mast in such a way that includes an ex-
tra turn.
NOTE
The rod end section of the lift cylinder has some shims
inserted, record the number of shims inserted in each cylin-
der, right or left, before removal.
210475
(b) Place wooden blocks with enough strength to support
the weight of the inner mast under the mast, then
remove the wire rope.
(5) Removing lift cylinder

Hoist the lift cylinder from the rear of the mast with a
rope to carefully remove it. Attach a wire rope on the lift
cylinder before removing the cylinder clamp.
210476
3.2.4 Installation (2) After making sure the operation is normal, inspect the
Follow the removal procedure in reverse while noting the service oil level with an oil level gauge (Refer to the
following instructions. paragraph of “Service oil quantity and raised height of
(1) Bleed air by repeating full upstroke and downstroke mast”).
under no load, and make sure the operation is normal. (3) Check whether the raised height of mast is at the nor-
mal value.
12-14
HYDRAULIC SYSTEM
(4) When either the lift cylinder or piston rod has been
replaced, always inspect the balance or racking (for the
inspection and adjustment method, refer to “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, Snap ring, Spacer 5 Tilt cylinder
3 Hose
3.3.3 Preparation
(2) Fully tilt the mast forward and slowly lower the lift
bracket.
When the fork tips reach the ground, stop the engine.
(3) Open the overhead cover.
12-16
HYDRAULIC SYSTEM

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) Screw 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.
Start the engine and retract the cylinder rod to minimum B
while lowering the crane. Then, stop the engine.
(3) Lower the right and left cylinder to the ground one at a Protective cloth 210479
time, and unhook the wire rope from the crane.
(4) Disconnecting hose

(a) Disconnect hose 2 from the connector of the cylinder.
(b) At this time, cap the connector end at the socket side of Cap
the tilt cylinder.
Cap (G1/2) 05530 - 40400
NOTE
This cap serves as to confine the oil to within the cylinder
and prevent the cylinder rod from extending. Before lifting 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) Screw 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 welds for cracks, damage, and dents.
Piston rod
(1) Check the piston rod if it may cause runout.
Support both ends of the piston rod with V-shaped
blocks, and measure its runout using a dial gauge at the
center while turning the piston rod. If 1/2 of dial 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, always 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 vinyl tape so that the thread
edges do not damage the buffer ring and packing.
200351
12-26
HYDRAULIC SYSTEM

Cylinder tube
age, or rust.
(2) Check the welded area for cracks, damage, and dent.
Piston rod
(1) Check the runout of piston rod.
center while turning the piston rod. If 1/2 of dial indica-
tor reading exceeds the limit, replace the piston rod.
(2) Check the rod surfaces for rust, damage, sliding flaws,
and dents. Replace the piston rod, if it is seriously 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

(1) During reassembly, always replace the Seal Kit parts
marked with an asterisk (*) in the figure.
(3) Coat each inside surface of the piston seal, O-ring,
packing, dust seal and cylinder with service oil before
reassembly.
(4) When holding the cylinder’s outer circumference in a
vise, be careful not to tighten the vise excessively as to
distort the cylinder.
200352
12-28
HYDRAULIC SYSTEM
(5) Procedure to install piston seal into tilt cylinder

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

8.1 Hydraulic oil
Cloudy oil should be changed, since water is suspected be
mixed in. When the oil is checked immediately after 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 break-in of the pump and make
check the performance. This test operation is desirable to be
performed on the test stand, however, since the actual 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]) to the upper right surface of the
control valve.
Installing oil pressure indicator:
Remove the plug from the connector of delivery hose
and attach the following tool instead.
Connector 64309 -17734(R (PT) 1/4 thread screw)

Hose 64309 - 17722
Connector 64309 - 17731 (for gauge installation)
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 listen to see if the pump generates abnormal
sound.
(3) After 10 minutes, raise the engine speed to 1500 to
2000 rpm, and continue to run the engine under no load
for more 10 minutes.
(4) Loosen the adjusting screws of the relief valve under
the condition of paragraph (3) and shift the control
lever to the active position. Then, adjust the adjusting
screw to set the pressure to 3 MPa (30.6 kgf/cm2)
[435.2 psi], and run the engine for 5 minutes. Continu-
ously raise the pressure further by 2 MPa (20.4 kgf/
cm2) [290.1 psi] increments and run the engine for 5
minutes each time until the relief valve reaches the
specified pressure setting.
12-30
HYDRAULIC SYSTEM
(5) During the process of raising the pressure, watch the oil
temperature, pump surface temperature, and listen for
abnormal sound from the pump, etc. If the oil tempera-
ture or pump temperature abnormally rises, cancel the
load and lower the temperature to continue the test
operation, or disassemble the pump again to inspect the
inside.
(6) Complete the operations of (2) to (5), then re-adjust the
relief valve to the specified pressure setting, and make
sure that the operation speed is normal.
8.3 Control Valve

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

(1) Connect an oil pressure indicator (gauge, 25 MPa
(254.9 kgf/cm2) [3626.3 psi]) on the left side of the
control valve.
The gauge, connector, hose, etc. to be used are same as
with the gear pump test operation.
(2) Start the engine and raise the speed to the maximum.
(3) The relief valve is normal, if the oil pressure is relieved
+0.5
and the pressure meter hand points to 20.6 0 MPa
2
(210.1 kgf/cm ) [2988.1 psi] when the tilt cylinder
reaches the backward tilt limit as the result of turning
the tilt lever to the backward tilt position.
(4) If the relief pressure is not satisfactory, loosen the lock
nut of the relief valve adjusting screw and adjust the
pressure while observing the gauge reading. Adjusting screw
211977
NOTE
The reference amount of tightening-in of adjusting screw
for relief valve is such that one turn varies the pressure for
approx. 10.6 MPa (108.1 kgf/cm2) [1537.6 psi].
(5) Tighten the lock nut to secure the adjusting screw while
holding it by hand.
(6) After securing the adjusting screw, recheck the relief
valve pressure setting.
+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 indicators (gauge) that are used can have 211947
twice the capacity of the oil pressure to be measured, how-
ever, 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
9. Tests
Free descending amount test

(1) Using a capacity load, tilt the mast to vertical position
and raise the forks 1 to 1.5 m (3 to 5 ft.) from the
ground, and stop the engine.
(2) Mark the mast with a reference line and measure the
free descending amount after 15 minutes.
DP100N: 40 mm (1.57 in.)/15
Rod contraction length
min
on free descending
DP120N: 45 mm (1.77 in.)/15
(with capacity load)
min
(oil temperature 45˚C
DP135N: 38 mm (1.50 in.)/15 min
[113˚F])
DP150N: 42 mm (1.65 in.)/15 min
211951
Free forward tilt test

(1) Using a capacity load, tilt the mast to vertical position
and raise the forks 50 cm (2.0 in.) from the ground, and
stop the engine.
(2) Measure the extension stroke of the tilt cylinder, and
measure the extension stroke again after 15 minutes.
DP100N: 41 mm (1.61 in.)/15
Rod extension length min
on free descending DP120N: 47 mm (1.85 in.)/15
(with capacity load) min
(oil temperature 45˚C DP135N: 35 mm (1.38 in.)/15
[113˚F]) min
DP150N: 39 mm (1.54 in.)/15 min
211952
12-33
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
noisy replace.
(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
(3) Spring fatigued
lift rated • Replace.
load (4) O-ring in valve case damaged
Lift and • Replace.
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 distortion • Repair or replace.
12-37
HYDRAULIC SYSTEM
11.Service Data
Fork ascending speed (under the rated load) 330 mm 340 mm 290 mm 280 mm
Standard value
[Simplex mast] (at maximum engine speed) (65.0 fpm) (66.92 fpm) (57.1 fpm) (55.1 fpm)
Fork ascending speed (under no load)
Standard value 360 mm (70.9 fpm) 310 mm (61.0 fpm)
(at maximum engine speed)
Fork descending speed (under the rated load)
Standard value 450 mm (88.6 fpm) 380 mm (74.8 fpm)
[Simplex mast] (at maximum engine speed)
Forward tilt angle [Standard simplex mast truck] Standard value 6˚
Backward tilt angle [Standard simplex mast
Standard value 12˚
truck]
Lift cylinder free fall (under the rated load)
40 mm 45 mm 38 mm 42 mm
(rod contraction length) (oil temperature 45˚C Standard value
(1.6 in.) (1.8 in.) (1.5 in.) (1.7 in.)
[113˚F])
Tilt cylinder free forward tilt amount (under the
rated load) 45 mm 50 mm 40 mm 45 mm
Standard value
(rod contraction length) (oil temperature 45˚C (1.8 in.) (2.0 in.) (1.6 in.) (1.8 in.)
[113˚F])
Discharge capacity Standard value 205 L/min (54.2 U.S. gal./min) (at 2200 rpm)
Mounting bolt and nut tightening
Standard value 59.8 N•m (6.1 kgf•m) [44.1 lbf•ft]
torque 1
Gear
pump Delivery hose mounting bolt tight-
Standard value 76.5 N•m (7.8 kgf•m) [56.5 lbf•ft]
ening torque 2
Cover mounting bolt tightening
Standard value 108.9 to 122.6 N•m (11.1 to 12.5 kgf•m) [80.4 to 90.5 lbf•ft]
torque 3
1
210504
12-38
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

2
Set relief pressure 1 Standard value 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
+0.06 mm (2.95 +0.0024
+0.0075
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 × × 1.57 in.)
Flange thickness × 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 × Width 205 × 52 mm (8.07 × 2.05 in.)
equipment Type Lubricated needle
Side roller
Diameter × 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 × 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 3 m (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 out.
(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
truck. 211992
(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 assembly.
Truck model Mast weight

DP100N 1995 kg (4399 lb)
DP120N 1995 kg (4399 lb)
DP135N 2100 kg (4631 lb)
DP150N 2320 kg (5116 lb) 211995
DP160N 2515 kg (5546 lb)
(2) Remove the tilt pin and separate the tilt cylinder from
the mast.
211962
5. Removing mast support bearing cap
(1) Put alignment marks on the caps.
(2) Remove the cap mounting bolts and separate the whole
mast assembly while lifting it up from the truck. Lay it
down flat with the lift bracket side facing upward on
level ground.
NOTE
In order to avoid any obstruction in the subsequent disas-
sembly, laying the removed mast assembly on a sufficient
space in both directions of mast sliding (toward the top and
bottom).
210519
13-6
MAST AND FORKS
4. Mast assembly
4.1 Disassembly
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 racking. When cylinder rod
installation bolts are removed, make record of how
many shims are used and which side of cylinder the
shims are installed to.
(2) When the cylinder clamp bolts are removed, the lift
cylinder becomes unfixed (free). Shorten the cylinder Shims
rods as much as possible to cross the top ends of two
cylinders.
(3) Slide the inner mast downward to remove main roller 210521
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 rollers 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,
wear or cracks. 210523
(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.
(6) Check the welded part of fork bracket for cracks.
Guide bar
Screw
210524
13-8
MAST AND FORKS
3. Chain, Chain wheel support, and Chain wheel

(1) Check right and left chains for uneven length, wear,
adhesion, or distortion.
DP100N,
DP150N,
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 threads for cracks or

defects.
(3) Check the chain wheel support and the chain wheel for
crack or wear, or adhesion.
4. Mast strip
(1) Check for damage, chipping or distortion.
Stan-
dard 9 mm (0.35 in.)
Thickness of mast strip value
Service
7 mm (0.28 in.)
limit
5. Fork
(1) Check the forks for bending, misalignment of tips, and
cracks.
Stan-
5 mm (0.2 in.) or
Misaligned fork tips dard
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.)
(2.6 in.) (2.9 in.) 211999
13-9
MAST AND FORKS
4.3 Reassembly
To reassemble, follow the disassembly sequence in reverse and observe the following.
1. Front and rear clearance between mast and lift bracket
(1) Select and assemble the main roller in an appropriate 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.
(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.
K
(3) Press the inner mast in a direction of left or right at the

maximum height range, and measure the clearance K
produced at the opposite side.
0.5 to 1.5 mm K
Clearance 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
bolt
made by loosening locknut of side roller bracket and by
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 bushing 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)
3 Link 2
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 forks
to the ground level, and check that lift cylinders are in
the most retracted position.
(2) Position the anchor bolt with anchor nut and locknut.
(3) Lift the fork slightly from the ground and check the
tension of chain as the two chains are stretched evenly,
by pushing the midpoints between chain wheel and
fixed end of chain of left and right chains alternately.
Adjust if required.
In the case of adjusting tensions of chains by anchor nut,
it is recommended to tilt the mast forward to reduce
chain tension for operational convenience. 102708
Anchor bolt
(4) When adjustment of chain tension is completed by 210538

rotating anchor nut, tighten the nut to the specified
torque.
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,

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

lift bracket
(1) Measure the front and rear and left and right clearances
of lift bracket, and adjust, if any of them exceeds the
specified value.
(2) Use a thickness gauge for front and rear clearance of
lift bracket.
(3) Use a dial gauge for left and light clearance of lift
bracket. Prepare a dial gauge for inner surface of inner
mast and make the spindle of dial gauge contact with
side wall of lift bracket.
Insert a bar between lift bracket and inner mast, and
press lift bracket in the left and right directions 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 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 specified
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 210542

stop 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) Raise the mast and place a block under the inner mast,
then lower the mast until it rests on the block.
202983
(2) Remove the stop bolt at the top of lift cylinder that
stopped first, lower the piston rod and insert shims to
the top of the piston rod.
(3) Extend the piston rod, and tighten the lift cylinder 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
X 1 890 -1.0 mm (35.0 -0.039 in.)
value (34.8
+0.020
in.)
Smallest inner width of outer -0.039
mast +0.5
Standard +1.0 +0.039 884 -1.0 mm
X 2 890 -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
Y 1 704 -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 X 2 704 -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 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 forks 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 tighten
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
tie them with a rope, etc. to prevent from falling. Then, 210553
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 with a rope,
leaving an approximately 3 m (9.8 ft) extras at the ends
of the rope.
(c) Start the engine and raise the inner mast up to a posi-
tion where the main rollers of the lift bracket come out.
At this point, pull the lift chains and hoses taut by
drawing the attached rope downward to prevent them
from coming off from the chain wheels or hose reels.
(d) When the inner masts reach to the position where the
main rollers of the lift bracket can be removed, reverse
the truck, and separate the lift bracket from the truck.
CAUTION
When raising the mast, never touch any control
210554
levers except the lift lever.

1. Lift bracket
(1) Check the main rollers and side rollers for sticking,
wear or cracks.
(2) Check the welds of the lift bracket for cracks.
(3) Check the guide bars whether they are bent or
deformed.
2. Fork
(1) Check the forks for bend, misalignment of tips, and
cracks.
3. Hose
(1) Replace the hoses every two years.
14-6
FORK POSITIONER
4.4 Installation
Replacement must follow the reverse order of removal.
4.4.1 Suggestions for Installation

1. Driving in main roller
(1) For this operation use a driving jig and exercise care
not to hit the outer ring of the roller.
2. Installing lift chains

(1) Lift chains can be replaced as-is unless the positions of
the upper lock nuts are modified. Tighten the lock nuts
and anchor nuts to the specified torque.
393 N•m
Nut tightening torque (40.1 kgf•m)
[290.0 lbf•ft]
3. Adjusting hose tension

(1) The tension of each hose should be 196 N (20.0 kgf) 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 when it deflects approx. 12.5 mm [2.2 lbf]
(0.49 in.).
Adjust tension according to the length of hoses which
differs with the raised height of the mast.
For example, if the hose length is 2 m (78.7 in.) from the

pulley to the bottom joint when the mast is raised to the
210555
highest position, the tension of the hose is acceptable if
it deflects 25 mm (0.98 in.) when the hose is pushed
with a force of 9.8 N (1.0 kg) [2.2 lbf].
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 Ç` 05312 - 20520

A
210557
1. Cylinder tube
age, or rust.
(2) Check the welds for cracks, damage, and dent.
2. Piston rod
(1) Check the piston rod for runout.
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
(2) Check the rod surfaces for rust, damage, sliding flaws,
and dent.
(3) When any of the thread parts are excessively damaged,
replace the piston rod.
3. Piston rod
(1) Replace the seal kit parts with new ones.
14-9
FORK POSITIONER
Attachment Model FP120AM 4FP135AM FP160AM

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
(1) During reassembly, do not forget to replace the Seal Kit
parts marked with an asterisk (*) in the figure.
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 the
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
Shifts of right and left fork (4) Pilot valve spring wearing • Replace O-ring.
prongs too slow or sluggish • 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 distortion
• 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. Maintenance Chart..................................................................................................... 15-2
2. Tightening torque of standard bolts............................................................................ 15-7

2.1 Metric screw thread for automobiles ................................................................................................... 15-7
2.2 Metric Coarse Thread ......................................................................................................................... 15-8
3. Lubrication Standards ................................................................................................ 15-9

3.1 Fuel and Lubricant Specifications ....................................................................................................... 15-9
3.2 Capacity ............................................................................................................................................ 15-10
15
15-1
SERVICE DATA
1. Maintenance Chart
: Check or Clean
: Change or Adjust
Every 6 months (1000 hrs)

1st Month (200 hrs) Only
Prestart (Daily/10 hrs)
Others (See Note 1)

Yearly (2000 hrs)
Weekly (50 hrs)
System Inspection Point Service Data
Brake Check Brake Pipes & Joints

Free Play: 15 mm (0.6 in.)
Pedal height (to top of
Check Brake Pedal (from floor to top of pedal)
pedal pad): 190 mm (7.48
in.)
Check Service Brake Fluid Level
Change Service Brake Fluid 240 cc (114.6 cu in.)
Check Brake Air Master
Change Brake Master Cylinder Hoses & Rubber Parts
Change Brake Wheel Cylinder Hoses & Rubber Parts
Check Brake Control Valve
Operating effort:
245 to 294 N
Check Parking Brake Lever
(25 to 30 kgf)
[55 to 66 lbf]
Check Parking Brake Cable
Check Center Brake Drum & Shoes
Check Service Brake Drum & Shoes
Check Brake System
Check Wet Brake
Change Wet Brake Fluid
Check / Drain Water of Air Tank
Check Air Drier Desiccant
Change Air Drier Desiccant
Cooling Check & Clean Radiator Fins (See Note 2)
Check Cooling Fan
Check Fan Belt Tension
Check Engine Coolant Level
Change every 12 months or
Change Engine Coolant 1000 hours,
18 liters (4.7 U.S. gal.)
Check Rubber Hose Condition
Check Radiator Filler Cap
Lubricate Water Pump
15-2
SERVICE DATA
: Check or Clean
: Change or Adjust

Others (See Note 1)

Yearly (2000 hrs)
Weekly (50 hrs)
Electrical Check Alternator

Check Battery (Electrolyte Level)
Check Battery (Electrolyte Specific Gravity) 1.265 or above
Check Loosen & Damage of Battery Terminal
Check Driving Interlock System
Check Electrical Wires
Check Horn
Check Instrument Panel Lamp (Incl. Parking Brake, Seat
Belt)
Check Mast Interlock System
Check Parking Brake Buzzer
Check Starter
Check Voltage, Current & Other Electric System
Check Lights & Turn Signal
Check Gauges
Engine Check Leaks (Damage & Wear of Hose)
Check Cylinder Head Bolt & Manifold Nut
Check Engine (Exhaust, Noise, Vibration)
Check Engine Idle Speed
Check Max. Speed Without Load & Hunting
2940 kpa (30 kgf/cm2)
Check Compression Pressure
[426 psi] at 200 rpm
0.6 mm (0.023 in.) in cold
Check Intake & Exhaust Valve Clearance
state
Check Engine Oil Level
Change Engine Oil 500 hours
Change Engine Oil Filter
500 hours
Check Turbocharger
Check PCV Valve & Hose
Change Element of PCV Valve Filter (See Note 3)
Check Recycle System of Exhaust Gas
Check Air Compressor
Check Exhaust Pipe & Muffler
Cat DP160 DP160N Forklift Engine Parts Phone: 1 269 673 1638
Contact email: EngineParts@HeavyEquipmentRestorationParts.com 15-3
SERVICE DATA
: Check or Clean
: Change or Adjust

Others (See Note 1)

Yearly (2000 hrs)
Weekly (50 hrs)
Frame & Check Overhead Guard & Assist Grip

Chassis Check Loosen Bolts or Nuts
Check Seat Adjustment
Check Seat Belt
Lubricate Each Part
Check Horns, Wipers, Window Washer, Defroster & Key
Check Rear View Mirror & Foot Step
Fuel Check Fuel Leaks (Damage & Wear of Hose)
Check Fuel Level 175 liters (46.2 U. S. gal.)
Change Fuel Hose ***
Change Fuel Filter (See Note 3)
1000 hours
Check Water Separator (See Note 3)
Change Water Separator Element
Check Fuel Tank
Check High Pressure Fuel Pipe
Hydraulic Check Oil Leaks & Function of Control Valve
Check Control Valve Relief Pressure
Check Hydraulic Hose, Pipes & Joints
Change Hydraulic High Pressure Hose *
Check Hydraulic Oil Level
Change oil every 12 months
or 2000 hours,
N Level:
DP100N-135N
Change Hydraulic Oil 140 liters (37.0 U.S. gal)
DP150N
168 Liters (44.4 U.S. gal)
DP160N
48.6 Liters (48.6 U.S. gal)
Change Hydraulic Tank Strainer
Change Hydraulic Tank Return Oil Filter
Check Oil Leaks of Hydraulic Pump
Check Hydraulic Motor, Cylinder, Safety Valve, Sole-
noid Valve etc.
Check Mast & Fork, & Hydraulic System
15-4
SERVICE DATA
: Check or Clean
: Change or Adjust

Others (See Note 1)

Yearly (2000 hrs)
Weekly (50 hrs)
Intake Clean Air Cleaner Element ****

Change Air Cleaner Element
1000 hours
Front End Check Damage & Distortion of Chain
Lubricate Lift Chains
Service limit:
DP100N-135N
Check Elongation of Chain (20 links) 915 mm (36 in.)
DP150N-160N
1046 mm (41 in.)
Change Lift Chains ***
Check Lift Cylinder
Check Lift Cylinder Mounting Bolts
Check/ Lubricate Mast Support
Lubricate Tilt Socket Pins
Check Mast, Lift Bracket & Forks
Check Lift Bracket Main Rollers & Side Rollers
Check Mast Strip Sliding Surfaces
Check Tilt Cylinder Socket Nuts
Check Tilt Cylinder Function
Check Chain Wheel & Anchor Bolt
Check Oil Leaks of Flow Regulator Valve
Check Fork Lowering Speed
Steering & Check Oil Leaks & Damage of Piping
Axle Check Front Axle
Check Power Steering Cylinder
Change Power Steering Cylinder Hoses & Rubber Parts **
Check Rear Axle
Check Rear Wheel Bearing
Check Steering Control Valve
Check Priority Valve
Check Steering Wheel
Check Steering Column
Check Steering Knuckle & Tie Rod King Pin
Check Steering Knuckle
Check Steering Angle, Knuckle, Rod & Arm
15-5
SERVICE DATA
: Check or Clean
: Change or Adjust

Others (See Note 1)

Yearly (2000 hrs)
Weekly (50 hrs)
Transmis- Check Differential Oil Level

sion & Change every 6 months or
Drive Change Differential Oil 1000 hours
20 Liters (5.2 U. S. gal.)
Check Differential Mounting Bolts
Check Differential Wheel Bearing
Check Accelerator Pedal
Check Inching Pedal
Check Transmission Gear & Bearing
Check Transmission Oil Level
Change Transmission Oil 1000 hours
Clean or change every
Clean Transmission Strainer
6 months or 1000 hours
Change Transmission Oil Filter
1000 hours
Clean or change every
Clean Last Chance Filter (Transmission Control Valve)
6 months or 1000 hours
Lubricate Universal Joint
Check Propeller Shaft
Check Propeller Shaft Connections
Check Tires & Rims
Check Wheels & Wheel Nuts
General Oil, Fuel & Coolant Leak (Walk around)
Damage Or Faulty Operation Found The Day Before
Lubricate All Grease Nipples
Note 1 * Change every 1–2 years
** Change every 2 years
*** Change every 2–4 years
**** Every 2 weeks or 100 service hours
Note 2 In corrosive or abrasive environments check, clean, lubricate and change more frequently.
Note When fuel with poor quality is used, check, drain, clean and change more frequently.
15-6
SERVICE DATA
2. Tightening torque of standard bolts

2.1 Metric screw thread for automobiles
With spring washer 101656
Nominal size 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
15-7
SERVICE DATA
2.2 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
15-8
SERVICE DATA
3. Lubrication Standards
3.1 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.
15-9
SERVICE DATA
3.2 Capacity

Fuel tank 175 Liters (46.2 U.S. gal.)
Engine, radiator 17.35 Liters (4.6 U.S. gal.)
Engine coolant Reserve tank 0.65 Liters (0.17 U.S. gal.)
Total 18 Liters (4.7 U.S. gal.)
Oil pan 12 Liters (3.2 U.S. gal.)
Engine oil Oil Filter 4 Liters (1.0 U.S. gal.)
Total 16 Liters (4.2 U.S. gal.)
Torque converter oil 23 Liters (6.1 U.S. gal.)
Differential gear oil
20 Liters (5.3 U.S. gal.)
Final drive gear oil
N Level: N Level:
168 Liters 184 Liters
Hydraulic oil N Level: 140 Liters (37.0 U.S. gal.)
(44.4 U.S. (48.6 U.S.
gal.) gal.)
Brake fluid 240 cc
15-10
Service Manual
6M60-TL Diesel Engine

Phone: 1 269 673 1638
For use with the P17500-P36000,

DP80N-DP160N Service Manuals. 99709-61100
GROUP INDEX
(for industrial use)
GENERAL........................................
00
ENGINE............................................
11
LUBRICATION .................................
12
FUEL AND ENGINE CONTROL......
13A
ELECTRONICALLY CONTROLLED
FUEL SYSTEM .................................. 13E
FOREWORD COOLING......................................... 14
This Shop Manual is published for the information and
guidance of personnel responsible for maintenance of the
INTAKE AND EXHAUST ................. 15
Mitsubishi 6M60-TL series diesel engine, and includes
procedures for adjustment and maintenance services.
We earnestly look forward to seeing that this manual is
EMISSION CONTROL ..................... 17
made full use of in order to perform correct services with
no wastage.
ELECTRICAL................................... 54
For more details, please consult your nearest authorized
Cat® lift truck dealer.
SPECIAL EQUIPMENT ................... 61
Kindly note that the specifications and maintenance
service figures are subject to change without prior notice
in line with improvement which will be effected from time
to time in the future.
SEPTEMBER 2006
Applicable models Cat DP160 DP160N Forklift Engine Parts

6M60-TL Contact email: EngineParts@HeavyEquipmentRestorationParts.com
Phone: 1 269 673 1638
GROUP 00 GENERAL
00
HOW TO READ THIS MANUAL ......................................................... 00-2
ENGINE NUMBER ............................................................................ 00-7
PRECAUTIONS FOR MAINTENANCE OPERATION ....................... 00-8
DIAGNOSTIC CODES
13A
1. Using Multi-Use Tester .............................................................. 00-17
2. Use of Blinking Warning Lamp for Diagnostic Code .................... 00-19 13E
3. Diagnozer Service Tool Functions ................................................. 00-21
4. Troubleshooting ............................................................................... 00-29
TABLE OF STANDARD TIGHTENING TORQUES .......................... 00-31
00-1
This manual consists of the following parts:
• Specifications
• Structure and Operation
• Troubleshooting
• General Inspection and Adjustment
• Service procedures
General Inspection and Adjustment

• Procedures for inspection and adjustment of individual parts and assemblies as mounted on the machine are de-
scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for
looseness, play, backlash, crack, damage, etc.
Service procedure
• Procedures for servicing components and parts off the machine are described centering on key points in their re-
moval, installation, disassembly, reassembly, inspection, etc.
Inspection
• Check items subject to “acceptable/unacceptable” judgement on the basis of service standards are all given.
• Some routine visual checks and cleaning of some reused parts are not described but must always be included in
actual service work.
Caution
• This service manual contains important cautionary instructions and supplementary information under the follow-
ing four headings which identify the nature of the instructions and information:
DANGER Precautions that should be taken in handling potentially dangerous substances

such as battery fluid and coolant additives.
WARNING Precautionary instructions, which, if not observed, could result in serious injury or
death.
CAUTION Precautionary instructions, which, if not observed, may result in damage to or de-
struction of equipment or parts.
Suggestions or supplementary information for more efficient use of equipment or

NOTE better understandings.
Terms and Units

• Front and rear
The forward running direction of the machine is referred to as the front and the reverse running direction is re-
ferred to as the rear.
• Left and right

Left hand side and right hand side, when facing the forward running direction of the machine, are respectively left
and right.
Standard value
• Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clear-
ance between two parts when assembled, and the standard value for an assembly part, as the case may be.
Limit
• When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must
be replaced or repaired.
00-2
00
Tightening torque
• Values are directly specified for out-of-standard tightening torques for bolts and nuts.
• Where there is no specified figure for tightening torque, follow the table covering standard tightening torques.
• When the item is to be tightened in a wet state, “wet” is indicated. Where there is no indication, read it as dry.
Units
• Tightening torques and other parameters are given in SI* units with metric units added in brackets { }. Values in
engine specifications, performance curves, and other items taken from official approval documents are given only
in metric units.
*SI: Le Système International d’Unités
Example: 390 N·m {40 kgf·m}
Metric unit
SI unit
Item SI unit {metric unit} Conversion factor

Force N {kgf} 9.80665 N {1 kgf}
Moment of force N·m {kgf·m} 9.80665 N·m {1 kgf·m}
Positive pressure kPa {kgf/cm2} 98.0665 kPa {1 kgf/cm2}
Pressure kPa {mmHg} 0.133322 kPa {1 mmHg}
Vacuum pressure
Pa {mmH2O} 9.80665 Pa {1 mmH2O}
Volume dm3 {L} 1 dm3 {1 L}
Heat quantity J {kcal} 4186.05 J {1 kcal}
Heat flow W {kcal/h} 1.16279 W {1 kcal/h}
Power kW {PS} 0.7355 kW {1 PS}
Angle ˚ –
Temperature ˚C –
Electric current A –
Voltage V –
Resistance Ω –
Electric power W –
Unit SI unit Foot-pound unit Conversion rate

Force N (Newton) lbf 1 N = 0.2248 lbf
Moment of force N·m lbf.ft 1 N·m = 0.7375 lbf.ft
1 kPa = 0.145 lbf/in.2
Pressure kPa (kilopascal) lbf/in.2
1 kPa = 0.2953 in. Hg
L gal. 1 L = 0.2642 gal. (U.S.)
1 L = 0.220 gal. (Imp.)
Volume cm3 oz 1 cm3 = 0.033814 oz (U.S.)
1 cm3 = 0.035195 oz (Imp.)
cm3 cu.in. 1 cm3 = 0.061023 cu.in.
Power kW (kilowatt) HP 1 kW = 1.34 HP
Temperature ˚C ˚F t˚C = (1.8t˚C + 32)˚F
Mass quantity of kg lb 1 kg = 2.2046 lb
matter g oz 1 g = 0.035274 oz
m ft. 1 m = 3.2808 ft.
Dimension
mm in. 1 mm = 0.03937 in.
Stress N/cm2 lbf/in.2 1 N/cm2 = 1.45 lbf/in.2
00-3
Symbol Denotation Application Remarks
Specified values shown in table
Parts not tightened to standard torques
See Table of Standard Tightening Torques for
Tightening torque (standard torques specified where neces-
parts for which no tightening torques are speci-
sary for servicing)
fied.
Locating pin Parts to be positioned for installation
Non-reusable parts Parts not to be reused
Lubricant and/or Parts to be coated with lubricant or sealant Necessary lubricant and/or sealant, quantity re-
sealant for assembly or installation quired, etc. are specified in table.
Parts for which special tools are required for Tool name/shape and part number are shown in
Special tool
service operation table.
Parts associated with those removed/disas-
*a Associated part
sembled for servicing
00-4
00
00-5
How to Use Diagnostic Codes <Electronically Controlled Fuel System (Gr13E)>
TROUBLESHOOTING
1. Diagnostic Procedure
2. Diagnostic Precautions
This section suggests areas to in-
spect for each diagnostic code. 3. Inspections Based On Diagnostic Codes
4. Multi-use Tester Service Data
5. Actuator Tests Performed Using Multi-use Tester
6. Inspections Performed At Electronic Control
Unit Connectors
There are the diagnostic code and message displayed on Multi-Use Tester.
Numerical values in parenthesis are added only when a diagnostic code indicated in
the Multi-Use Tester display differs from the code indicated by the number of warning
lamp flashes.
P125A: Common Rail Pressure M/V1 (high) (warning lamp flashes: 63)
Code generation criteria MPROP1 (rail pressure control valve) voltage is above standard valve.
System recovers (power is re-supplied to electronic control unit) if signal
Resetability
becomes normal when starter switch is turned OFF → ON.
• Engine is stopped.
Electronic control unit control
• Exhaust gas recirculation control is stopped.
Service data 0C: Difference Common Rail Pressure
In- Actuator test B9: Fuel Leak Check
spec-
tion Electronic control unit
08 : Resistance of MPROP (rail pressure control valve)
item connector
Electrical part #574: MPROP1 (rail pressure control valve)
Refer to “Inspection of Electrical

Equipment.”
The contents of this manual include functions and parts that are not used in your truck depending on
the truck specifications. Please refer to the chassis service manual for the details.
00-6
ENGINE NUMBER 00
• Serial engine numbers are assigned to the engines in manufac-
turing sequence. Every engine has its own number. These num-
bers are required for registration and related inspection of the
vehicle.
• An engine nameplate indicates the following item.

• Engine model
00-7
PRECAUTIONS FOR MAINTENANCE OPERATION
• Before performing service operations, inquire into the customer’s complaints and ascertain the conditions by
checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors
about the vehicle. And note the necessary information. This information will help you to service the truck efficiently.
• Check the location of the fault, and identify its cause. Based on your findings, determine whether parts must be
removed or disassembled. Then, follow the service procedure given in this manual.
• Prepare all the general and special tools necessary for the job.
WARNING
• Special tools must be used wherever specified in this man-
ual. Do not attempt to use other tools since they could
cause injuries and/or truck damage.
• Take extreme care when removing/installing heavy items such

as engine, transmission and axle. When lifting heavy items us-
ing a cable etc., observe the following precautions.
• Identify the weight of the item being lifted. Use a cable that is
strong enough to support the weight.
• If lifting eyes are not provided on the item being lifted, tie a ca-
ble around the item taking into account the item’s center of
gravity.
• Never work in shoes that have oily soles.

When working with a partner or in a group, use pre-arranged
signals and pay constant attention to safety. Be careful not to
touch switches and levers unintentionally.
• Inspect for oil leakage etc. before washing the vehicle. If the or-
der is reversed, any oil leakage or fault that may exist could go
unnoticed during inspection.
00-8
00
• Prepare replacement parts ready for installation.
• Oil seals, packings, O-rings and other rubber parts, gaskets, and
split pins must be replaced with new ones after removal. Use
only genuine Cat replacement parts.
P00015
• When disassembling parts, visually check them for wear, cracks,

damage, deformation, deterioration, rust, corrosion, defective
rotation, fatigue, clogging and any other possible defect.
• To facilitate correct reassembly of parts, make alignment marks

on them before disassembly and arrange disassembled parts
neatly. Make punch marks and other alignment marks where
they will not detract from parts’ functionality and appearance.
• After removing parts from the vehicle, cover the area to keep it
free of dust.
CAUTION
• Be careful not to mix up identical parts, similar parts and
parts that have left/right alignments.
• Keep new replacement parts and original (removed) parts
separately.
• Apply the specified oil or grease to U-seals, oil seals, dust seals
and bearings before reassembly.
• Always use the specified oils and greases when performing in-
spection or replacement. Immediately wipe away any excess oil
or grease with a rag.
00-9
• Wear safety goggles when using a grinder or welder. Wear
gloves when necessary, and watch out for sharp edges and oth-
er items that might wound your hands.
• Before working on the electrical system, disconnect the (–) bat-

tery cable to prevent short circuits.
CAUTION
• Make sure the starter switch and lighting switches are OFF
before disconnecting or connecting battery cable.
Semiconductor components may otherwise be damaged.
• Carefully handle sensors relays, and other items that are sensi-
tive to shock and heat. Do not remove or paint the cover of any
control unit.
• When separating connectors, grasp the connectors themselves

rather than the harnesses.
• To separate locking connectors, first push them in the direction
of the arrows. To reconnect locking connectors, push them to-
gether until they click.
• Before washing the vehicle, cover electrical parts to keep them

dry. (Use plastic sheets or the like.) Keep water away from har-
ness connectors and sensors and immediately wipe off any wa-
ter that gets on them.
00-10
00
• When applying a voltage to a part for inspection purposes,
check that the (+) and (–) cables are connected properly then
gradually increase the voltage from zero. Do not exceed the
specified voltage.
Remember that control units and sensors do not necessarily op-
erate on the battery voltage.
1. Handling Precautions for Electric Circuits

CAUTION
• Do not pierce wire insulation with test probes or alligator
clips when performing electrical inspections. Piercing the
wire harness will cause corrosion.
1.1 Inspection of harnesses

(1) Inspections with connectors fitted together
(1.1) Waterproof connectors
• Connect an inspection harness and connector A between the
connectors B of the circuit to be inspected. Perform the inspec-
tion by applying a test probe C to the connectors of the inspec-
tion harness. Do not insert the test probe C into the wire-entry
sides of the waterproof connectors since this would damage
their waterproof seals and lead to rust.
(1.2) Non-waterproof connectors

• Perform the inspection by inserting a test probe C into the wire-
entry sides of the connectors. An extra-narrow probe is required
for control unit connectors, which are smaller than other types of
connector. Do not force a regular-size probe into control unit
connectors since this would cause damage.
(2) Inspections with connectors separated

(2.1) Inspections on female terminals
• Perform the inspection by carefully inserting a test probe into the
terminals. Do not force the test probe into the terminals since
this could deform them and cause poor connections.
00-11
(2.2) Inspections on male terminals
• Perform the inspection by applying test probes directly to the
pins.
.
CAUTION
• Be careful not to short-circuit pins together with the test
probes. With control unit connectors, short-circuiting of
pins can cause damage to the control unit’s internal circuit-
ry.
• When using a multimeter to check continuity, do not allow the

test probes to touch the wrong terminals.
1.2 Inspection of connectors

(1) Visual inspection
• Check that the connectors are fitted together securely.
• Check whether wires have been separated from their terminals

due to pulling of the harness.
• Check that male and female terminals fit together tightly.
00-12
00
• Check for defective connections caused by loose terminals, by
rust on terminals, or by contamination of terminals by foreign
substances.
(2) Checking for loose terminals

• If connector terminal retainers become damaged, male and fe-
male terminals may not mate with each other when the connec-
tor bodies are fitted together. To check for such terminals, gently
pull each wire and see whether any terminals slip out of their
connector housings.
1.3 Inspections when a fuse blows

• Remove the fuse, then measure the resistance between ground
and the fuse’s load side.
Next, close the switch of each circuit connected to the fuse. If
the resistance measurement between any switch and ground is
zero, there is a short circuit between the switch and the load. If
the resistance measurement is not zero, the circuit is not cur-
rently short-circuited; the fuse probably blew due to a momen-
tary short circuit.
• The main causes of short circuits are as follows:

• Harnesses trapped between chassis parts
• Harness insulation damage due to friction or heat
• Moisture in connectors or circuitry
• Human error (accidental short-circuiting of components)
2. Service Precautions for Alternators

• When servicing alternators, observe the following precautions:
• Never reverse the polarity of battery connections.
If the polarity of the battery connections were to be reversed,
a large current would flow from the battery to the alternator,
damaging the diodes and regulator.
00-13
• Never disconnect the battery cables with the engine running.
Disconnection of the battery cables during engine operation
would cause a surge voltage, leading to deterioration of the di-
odes and regulator.
• Never perform inspections using a high-voltage multimeter.

The use of a high-voltage multimeter could damage the diodes
and regulator.
• Keep alternators dry.

Water on alternators can cause internal short circuits and dam-
age.
• Never operate an alternator with the B and L terminals short-cir-

cuited. Operation with the B and L terminals connected together
would damage the diode trio.
• Disconnect the battery cables before quick-charging the battery

with a quick charger.
Unless the battery cables are disconnected, quick-charging can
damage the diodes and regulator.
00-14
00
3. Intermittent Faults
• An intermittent fault typically occurs only under certain operating
conditions. Once these conditions have been identified, the
cause of the intermittent fault can be ascertained easily. First,
ask the customer about the vehicle operating conditions and
weather conditions under which the fault occurs. Also ask about
the frequency with which the fault occurs and about the fault
symptoms. Then, reproduce the fault based on this information.
In accordance with the conditions under which the fault occurs,
determine whether the fault is caused by vibration, heat or other
factors. if vibration is a possible factor, see if the fault can be re-
produced by performing the following checks on individual con-
nectors and other parts:
• Gently move connectors up and down and to left and right.
• Gently move wiring harnesses up and down and to left and
right.
• Gently wiggle sensors and other devices by hand.
• Gently wiggle wiring harnesses on suspension systems and
other moving parts.
• Connectors and other parts to be checked are those included or

given as likely fault locations in inspection procedures corre-
sponding to diagnostic codes and/or fault symptoms.
00-15
4. Precautions for Arc Welding
• When arc welding is performed, current from the welder flows to ground via the machine metal parts. Unless ap-
propriate steps are taken, this current can damage control units, other electrical devices and wiring harnesses.
And any electrical device near the point on the vehicle to which the (–) cable of the welder is connected, might be
largely damaged.
• The current of the welder will flow backward through the bat-
tery’s (–) cable and damage the battery and electrical systems
directly connected to the battery. Be sure to disconnect the bat-
tery’s (–) cable in the following procedure.
• Turn the battery switch to the LOCK position.
• Turn the starter switch to the LOCK position.
• Disconnect the battery’s (–) cable.
• Cover all parts of the machine that may be damaged by welding
sparks.
• Connect the welder’s (–) cable to the machine as close as possi-
ble to the area being welded.
• Set the welding current in accordance with the part being weld-
ed.
00-16
DIAGNOSTIC CODES 00
NOTE:
The Multi-Use tester tool will not be used to service the 6M60-TL diesel engine at this time. Please disregard
the Multi-Use Tester information. Diagnozer 2.41 or later software must be used to service the 6M60-TL
diesel engine.
1. Using Multi-Use Tester

1.1 Connecting Multi-Use Tester
Special tools
Mark Tool name and shape Part No. Application
FMSi-E06-1
(Multi-Use
PC Data transmission to/from V.C.I.
Tester-III ver-
sion)
Data transmission between electronic

V.C.I. N/A
control unit and PC
Power supply to V.C.I. and communi-

Multi-Use Tester har- MH062928
cation with electronic control unit
ness A
MH062931
Multi-Use Tester test
(1 m) Multi-Use Tester test harness A
harness D
MH062951 extension
(used for extension)
(2 m)
Communication between V.C.I. and

USB cable MB991827
PC
• Move the starter switch to the LOCK position.

• Connect , , and as illustrated.
• Connect the Multi-Use Tester connector on the vehicle with the
connector of .
00-17
DIAGNOSTIC CODES
• Use to extend the cable if is not long enough such as
when using Multi-Use Tester outside the vehicle.
1.2 Access and Clearing of Stored Diagnostic Code

(1) Difference of diagnostic code
• There are two types of diagnostic codes – present code and past code.
(1.1)
(1.2) Present diagnostic code
• Fault developed in the machine after the starter switch is set to ON is indicated by corresponding diagnostic code.
• The fault warning lamp is lit at the same time.
(1.3) Past diagnostic code

• Past fault developed in the machine is indicated by corresponding diagnostic code stored in the memory of the
electronic control unit.
• With the machine restored to its normal condition or the starter switch turned from OFF to ON after inspection or
repair against present diagnostic codes, the present diagnostic code is stored as past diagnostic codes in the
memory of the electronic control unit.
• The warning lamp is not lit because the indicated fault is not present one.
(2) Access of diagnostic code

• Set the starter switch to ON.
• Operate the Multi-Use Tester for a display of necessary diagnostic code stored in the memory of the electronic
control unit and identify the location of the fault.
(3) Clearing of diagnostic code

• Set the starter switch to ON (the engine not to be started).
• Operate the Multi-Use Tester to delete all the diagnostic codes stored in the memory of the electronic control unit.
00-18
00
2. Use of Blinking Warning Lamp for Diagnostic Code
• Using the diagnostic and memory clear switches, display diagnostic codes.
CAUTION
• Opening the memory clear switch followed by its reconnection will erase the stored diagnostic codes
from the memory. To avoid inadvertently erasing necessary codes, be sure to read well the procedure de-
scribed below before handling diagnostic codes.
2.1 Reading diagnostic codes

• To read a diagnostic code, observe how may times the warning
lamp flashes and how long each illumination lasts.
• The duration of illumination differs between the first and second
digits.
• Second digit: 1.2 sec.
• First digit: 0.4 sec.
• A diagnostic code consists of the flashing of second digit and the
flashing of first digit in that order. If a diagnostic code has “0” in
the second digit, only the first digit will be displayed.
• The same diagnostic code will be displayed 3 times in a row be-
fore moving to the display of the next code.
• After the last diagnostic code is displayed, the first code will be
displayed again 3 times in a row and then the subsequent
codes. This will be repeated.
2.2 Present diagnostic codes

• Turn the starter switch ON.
• Remove the diagnostic switch.
• Diagnostic codes will be displayed (flashing of the warning
lamp).
• When the diagnostic switch is connected, electronic control unit
will immediately stop (terminate) displaying diagnostic codes.
2.3 Present and past diagnostic codes

• Turn the starter switch to the ON position.
• Open the diagnostic switch.
• Open the memory clear switch.
• The corresponding warning lamp will display diagnostic codes
by flashing.
• Turn the starter switch to the OFF position, connect the memory
clear switch and then connect the diagnostic switch. The elec-
tronic control unit terminates (exits) the diagnostic code display-
ing mode.
00-19
DIAGNOSTIC CODES
2.4 Erasing diagnostic codes
• Turn the starter switch to the ON position (do not start the en-
gine).
• Open the memory clear switch and reconnect it; all diagnostic
codes stored in electronic control unit memory will be erased. To
erase diagnostic code after opening the memory clear switch,
turn the starter switch to the OFF position and then reconnect
the memory clear switch.
00-20
00
3. Diagnozer Service Tool Functions
3.1 Menu
Monitor menu 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 select- • Active Test
ed. 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
00-21
DIAGNOSTIC CODES
3.2 Input Monitor and Output Monitor
These screens indicate the input and output values of each controller.
3.2.1 VCM-3 input monitor and output monitor (VCM-3 → VCM-3)
(InputUnit)
212339
00-22
00
(OutputUnit ) [ V ]
(OutputUnit )
(OutputUnit )
212340
00-23
DIAGNOSTIC CODES
3.2.2 VCM-3OP input monitor and output monitor (VCM-3 → VCM-3OP)
212341
00-24
00
3.2.3 MP input monitor (VCM-3→ MP)
212342
00-25
DIAGNOSTIC CODES
3.2.4 ECU input monitor and output monitor (VCM-3 → ECU)
Accel pedal position (unfiltered)

Accel pedal position (filtered)
Reference injection quantity
212343
00-26
00
3.3 Fault Status
This screen indicates all error codes occurring.

212344
00-27
DIAGNOSTIC CODES
3.4 Fault History
This screen indicates the fault data, such as the error codes and hour meter data, stored in the controller.




212345
00-28
00
4. Troubleshooting
4.1 General Information
4.1.1 Before replacing controllers
Do not replace controllers casually even if replace-
ment is required as a result of troubleshooting. Be sure
to check the following items before replacing control-
lers.
• 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
trouble, the controller will be damaged even if it is re-
placed 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 har- CAB harness
ness.
(3) Remove the cover and connect the PC as shown. VCM-3OP
GSE
(4) Turn on the truck power.
(5) Start the service tool software.
GSE cable VCM-3

GSE
212346
4.1.3 Diagnostic Precautions (5) Resistance is affected by temperature. Determine

(1) Before measuring voltage, check the battery for the necessity of resistance measurement following
charged condition and specific gravity. If system given temperature specification as a guide. Other-
inspection is performed with the battery uncharged wise, use normal temperature (10 to 35°C) as the
or reduced in specific gravity, accurate measure- measuring condition.
ments cannot be achieved.
(2) To avoid having electrical parts damaged, set the
starter switch to OFF before disconnecting and re-
connecting battery cables.
(3) Before disconnecting connectors, set the starter
switch to OFF then allow at least 20 seconds. Volt-
age may remain in electric parts or connected cir-
cuit.
(4) When performing measurement with the tester,
handle the test bar carefully so that it does not
damage internal circuit and other electrical parts of
the electronic control unit to result in a short-circuit
failure between terminals in connector or between
connector and truck body.
00-29
DIAGNOSTIC CODES
4.1.4 How to clean harness connectors and sys-
tem components
(1) Open-circuits are often caused by dirty harness
connectors and components. Dust, together with
greasy matter, forms grime which, in time, pene-
trates electrical connections, resulting in loose
metal-to-metal contact or, for worse, electrical sep-
aration of surfaces in contact. For this reason, it is
essential that the connectors and components be
cleaned at each periodic inspection and when ser-
vicing the truck. Instead of a commonly used sol-
vent, use the electronic parts cleaner (in the
manner illustrated on the right). Electronic parts cleaner
212347
Electronic parts Three Bond 29D or
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 Electronic parts
cleaner
liquid.
After coupling up the connector, check to be sure
that it is in locked state.
Contact surface Three Bond 2501S (aerosol)
activator or Nyogel 760G*
*: Products contained in Terminal Maintenance kit

(SE000003)
NOTE
• Do not spray too much liquid into the connector.
Cleaner liquid reacts differently with some res-
ins (plastic materials).
Contact surface
activator
212348
00-30
TABLE OF STANDARD TIGHTENING TORQUES 00
• Use specified bolts and nuts. Tighten them to the torques shown below as appropriate, unless otherwise speci-
fied.
• Threads and bearing surfaces shall be dry.
• If the mating nut and bolt (or stud bolt) are different in level of strength, tighten them to the torque specified for the
bolt.
Hexagon Head Bolts and Stud Bolts (Unit: N·m {kgf·m})

Strength 4T 7T 8T
Identification
symbol
Nominal
diameter (stud) (stud) (stud) 02154
2 to 3 4 to 6 5 to 7
M5 {0.2 to 0.3}
–
{0.4 to 0.6}
–
{0.5 to 0.7}
–
4 to 6 7 to 10 8 to 12
M6 {0.4 to 0.6}
–
{0.7 to 1.0}
–
{0.8 to 1.2}
–
9 to 13 16 to 24 19 to 28
M8 {0.9 to 1.3}
–
{1.7 to 2.5}
–
{2.0 to 2.9}
–
18 to 27 17 to 25 34 to 50 32 to 48 45 to 60 37 to 55
M10 {1.8 to 2.7} {1.8 to 2.6} {3.5 to 5.1} {3.3 to 4.9} {4.5 to 6.0} {3.8 to 5.7}
34 to 50 31 to 45 70 to 90 65 to 85 80 to 105 75 to 95
M12 {3.4 to 5.1} {3.1 to 4.6} {7.0 to 9.5} {6.5 to 8.5} {8.5 to 11} {7.5 to 10}
60 to 80 55 to 75 110 to 150 100 to 140 130 to 170 120 to 160
M14 {6.0 to 8.0} {5.5 to 7.5} {11 to 15} {11 to 14} {13 to 17} {12 to 16}
90 to 120 90 to 110 170 to 220 160 to 210 200 to 260 190 to 240
M16 {9 to 12} {9 to 11} {17 to 23} {16 to 21} {20 to 27} {19 to 25}
130 to 170 120 to 150 250 to 330 220 to 290 290 to 380 250 to 340
M18 {14 to 18} {12 to 16} {25 to 33} {23 to 30} {30 to 39} {26 to 35}
180 to 240 170 to 220 340 to 460 310 to 410 400 to 530 360 to 480
M20 {19 to 25} {17 to 22} {35 to 47} {32 to 42} {41 to 55} {37 to 49}
250 to 330 230 to 300 460 to 620 420 to 560 540 to 720 490 to 650
M22 {25 to 33} {23 to 30} {47 to 63} {43 to 57} {55 to 73} {50 to 67}
320 to 430 290 to 380 600 to 810 540 to 720 700 to 940 620 to 830
M24 {33 to 44} {29 to 39} {62 to 83} {55 to 73} {72 to 96} {63 to 85}
Hexagon Head Flange Bolts (Unit: N·m {kgf·m})

Strength 4T 7T 8T
Identification
symbol
Nominal
diameter 02154
4 to 6 8 to 12 10 to 14
M6 {0.4 to 0.6}
–
{0.8 to 1.2}
–
{1.0 to 1.4}
–
10 to 15 19 to 28 22 to 33
M8 {1.0 to 1.5}
–
{2.0 to 2.9}
–
{2.3 to 3.3}
–
21 to 31 20 to 29 45 to 55 37 to 54 50 to 65 50 to 60
M10 {2.1 to 3.1} {2.0 to 3.0} {4.5 to 5.5} {3.8 to 5.6} {5.0 to 6.5} {5.0 to 6.5}
38 to 56 35 to 51 80 to 105 70 to 95 90 to 120 85 to 110
M12 {3.8 to 5.5} {3.5 to 5.2} {8.0 to 10.5} {7.5 to 9.5} {9 to 12} {8.5 to 11}
00-31
Hexagon Nuts (Unit: N·m {kgf·m})
Strength 4T 6T
Identification
symbol
02155
Nominal Standard screw Coarse screw
Standard screw thread Coarse screw thread
diameter thread thread
2 to 3 4 to 6
M5 {0.2 to 0.3}
–
{0.4 to 0.6}
–
4 to 6 7 to 10
M6 {0.4 to 0.6}
–
{0.7 to 1.0}
–
9 to 13 16 to 24
M8 {0.9 to 1.3}
–
{1.7 to 2.5}
–
18 to 27 17 to 25 34 to 50 32 to 48
M10 {1.8 to 2.7} {1.8 to 2.6} {3.5 to 5.1} {3.3 to 4.9}
34 to 50 31 to 45 70 to 90 65 to 85
M12 {3.4 to 5.1} {3.1 to 4.6} {7.0 to 9.5} {6.5 to 8.5}
60 to 80 55 to 75 110 to 150 100 to 140
M14 {6.0 to 8.0} {5.5 to 7.5} {11 to 15} {11 to 14}
90 to 120 90 to 110 170 to 220 160 to 210
M16 {9 to 12} {9 to 11} {17 to 23} {16 to 21}
130 to 170 120 to 150 250 to 330 220 to 290
M18 {14 to 18} {12 to 16} {25 to 33} {23 to 30}
180 to 240 170 to 220 340 to 460 310 to 410
M20 {19 to 25} {17 to 22} {35 to 47} {32 to 42}
250 to 330 230 to 300 460 to 620 420 to 560
M22 {25 to 33} {23 to 30} {47 to 63} {43 to 57}
320 to 430 290 to 380 600 to 810 540 to 720
M24 {33 to 44} {29 to 39} {62 to 83} {55 to 73}
Hexagon Flange Nuts (Unit: N·m {kgf·m})

Strength 4T
Identification
symbol
02155
Nominal Standard screw Coarse screw
diameter thread thread
4 to 6
M6 {0.4 to 0.6}
–
10 to 15
M8 {1.0 to 1.5}
–
21 to 31 20 to 29
M10 {2.1 to 3.1} {2.0 to 3.0}
38 to 56 35 to 51
M12 {3.8 to 5.6} {3.5 to 5.2}
00-32
00
Tightening Torque for General-Purpose Flare Nut (Unit: N·m {kgf·m})
Pipe diameter φ4.76 mm φ6.35 mm φ8 mm φ10 mm φ12 mm φ15 mm
Tightening torque 17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0} 98 {10}
Tightening Torque for General-Purpose Air Piping Nylon Tube (DIN Type) (Unit: N·m
{kgf·m})
Nominal diameter
6 × 1 mm 10 × 1.25 mm 12 × 1.5 mm 15 × 1.5 mm
× wall thickness
+6 +0.6 +10 +1.0 +10 +1.0 +5 +0.5
Tightening torque 20 0 {2.0 0 } 34 0 {3.5 0 } 49 0 {5.0 0 } 54 0 {5.5 0 }
Tightening Torque for General-Purpose Air Piping Nylon Tube (SAE Type) (Unit: N·m
{kgf·m})
Nominal diameter 1/4 in. 3/8 in. 1/2 in. 5/8 in.
+4 +0.4 +5 +0.5 +5 +0.5 +5 +0.5
Tightening torque 13 0 {1.3 0 } 29 0 {3.0 0 } 49 0 {5.0 0 } 64 0 {6.5 0 }
00-33
GROUP 11 ENGINE
SPECIFICATIONS ............................................................................. 11-2

11
STRUCTURE AND OPERATION
1. Engine Proper .................................................................................... 11-3
2. Rocker and Bracket Assembly, Camshaft, Rocker Case and
Cylinder Head Gasket ........................................................................ 11-4
3. Valve Mechanism ............................................................................... 11-4
4. Connecting Rod ................................................................................. 11-5
5. Piston .................................................................................................. 11-5
6. Timing Gears ...................................................................................... 11-6
7. Flywheel .............................................................................................. 11-7
TROUBLESHOOTING ...................................................................... 11-8
GENERAL INSPECTION AND ADJUSTMENT

1. Measuring Compression Pressure ................................................ 11-10
2. Inspection and Adjustment of Valve Clearances .......................... 11-12
ROCKER COVER, ROCKER BRACKET AND CAMSHAFT ........... 11-16
CYLINDER HEAD AND VALVE MECHANISM ................................ 11-24
PISTON AND CONNECTING ROD, CYLINDER LINER .................. 11-40
FLYWHEEL ...................................................................................... 11-54
TIMING GEARS ............................................................................... 11-62
CRANKSHAFT AND CRANKCASE ................................................. 11-68

Phone: 1 269 673 1638
11-1
SPECIFICATIONS
Item Specifications
Engine mode 6M60-TL
Type 6-cylinder, in-line, water-cooled, 4-cycle diesel engine
Combustion chamber Direct injection type
Valve mechanism Overhead camshaft (OHC) system
110 {150} / 129 {175} / 145 {195} / 200 {270} /
Maximum output kW {PS} /rpm
2100 2100 2600 2600
610 {62} / 700 {71} / 740 {75} / 785 {80} /
Maximum torque N·m {kgf·m} /rpm
1600 1600 1400 1400
Bore × stroke mm φ118 × 115
3
Total displacement cm {L} 7545 {7.545}
Compression ratio 17.5
11-2
STRUCTURE AND OPERATION 11
1. Engine Proper
• The 6M60-TL engine employs an overhead camshaft (OHC) system, with the valve mechanism and the timing
gears arranged as shown above.
11-3
2. Rocker and Bracket Assembly, Camshaft, Rocker Case and
Cylinder Head Gasket
• The camshaft is directly supported at
its journals by the rocker case, and is
held in place from above by the rocker
and bracket assembly.
• The camshaft journals are directly
supported by the rocker case and the
rocker and bracket assembly, without
using any camshaft bearings. The
rocker case and brackets have been
machined together, meaning that they
all need to be replaced with a new set
when one of them becomes defective.
3. Valve Mechanism
• Each valve has a valve stem seal, which regulates the flow of lubricating oil to the contact surface between the
valve and the valve guide.
• The valve springs have a variable pitch to prevent abnormal vibration at high engine speed. The exhaust valves
use a double spring, with the inner and outer springs coiled in different directions to prevent them from jamming
each other.
11-4
11
4. Connecting Rod
5. Piston
• The piston, the cylinder liner and the
crankcase bore all must have the
same size marks to ensure a good fit
between them.
• The pistons are made of special alu-
minum alloy, and are provided with a
recess on each end of the piston pin
boss to reduce weight.
11-5
6. Timing Gears
• The timing gears are provided with
timing marks to help ensure correct
assembly.
• Timing marks are provided on the fol-
lowing gears.
• Camshaft gear: stamped line
• Crankshaft gear: “1”
• Air compressor gear: “2”
• No. 1 idler gear: “1”, “2”
6.1 No. 3 idler gear

• The No. 3 idler gear consists of the
sub-gear A, the sub-gear B and the
main gear.
• A spring is installed between the sub-
gear A and the main gear, as well as
between the sub-gear B and the main
gear. The springs are locked in place
with pins.
• The sub-gears are installed as follows.
The sub-gear A has been turned in
such a way as to compress the spring
before meshing with the camshaft
gear. Likewise, the sub-gear B has
been turned to compress the spring
before meshing with the No. 2 idler
gear.
11-6
11
(1) Non-backlash mechanism
• Engine hunting during idling causes
fluctuation in the speed of camshaft
and No. 2 idler gears.
• Without the non-backlash mechanism,
the backlash changes between zero
and the maximum, generating gear
rattle noise.
• With the non-backlash mechanism

equipped on the engine, the sub-gears
A and B maintain the backlash to zero
even when the engine hunts, eliminat-
ing gear rattle during idling.
7. Flywheel
11-7
TROUBLESHOOTING
Symptoms
Abnormal engine noise

Reference Gr
Low power output

Possible causes
Incorrect valve clearance O O
Defective cylinder head gasket O O
Cylinder head and valve Worn valve and valve seat; carbon deposits O O
mechanism Weakened valve spring O O
Defective rocker shaft and bracket O
Poor lubrication of rocker shaft bracket O
Incorrect backlash in timing gears O
Timing gears
Poor lubrication of timing gears and idler shaft O
Excessive end play in camshaft O
Camshaft
Worn camshaft O
Worn/damaged piston ring groove(s) O O
Pistons and connecting
Worn/damaged piston ring(s) O O
rods
Worn piston pin and connecting rod small end O
Excessive end play in crankshaft O
Incorrectly fitted crankshaft pulley O
Crankshaft Worn/damaged crankshaft pins and connecting rod bear-
O
ings
Worn/damaged crankshaft journals and main bearings O
Supply pump faulty O O
Gr13E
Fuel system Defective injector O O
Air trapped in fuel system O Gr13A
Malfunctioning cooling system components O
Cooling system Gr14
Loose/damaged V-belts O
Clogged air cleaner O O
Intake and exhaust
Clogged muffler O O Gr15
system
Malfunctioning turbochargers O O
Incorrect oil viscosity O Gr12
Improper fuel O
Incorrectly fitted piping and hoses O
Defective/incorrectly fitted alternator and other auxiliaries O
11-8
11
M E M O
11-9
1. Measuring Compression Pressure
Service standards
Location Maintenance item Standard value Limit Remedy
2,940 kPa 1,960 kPa
Each cylinder (at 200 rpm) Inspect
{30 kgf/cm2} {20 kgf/cm2}
– Compression pressure 390 kPa
Cylinder-to-cylinder pres-
– {4 kgf/cm2} Inspect
sure difference
or less
Special tools (Unit: mm)

Compression gauge
adapter MH063384 Measuring compression pressure
A
M16 × 18
• A drop in compression pressure can be used as a guide to determine when the engine should be overhauled.
• Measure the compression pressure at regular intervals. Keeping track of its transitions can provide a useful tool
for troubleshooting. On new vehicles and vehicles with newly replaced parts, the compression pressure will be
somewhat higher depending on the break-in condition of piston rings, valve seats, etc., but this will return to nor-
mal as the parts wear down.
• Before inspection, confirm that the engine oil, starter, and battery are in normal condition, and satisfy the following
conditions.
• Warm up the engine until the coolant temperature reaches approximately 75 to 85°C.
• Turn off the lights and auxiliaries.
• Place the lever in neutral.
• Remove the fuse for fuel cut to prevent fuel from being injected
while the engine is cranked using the starter.
CAUTION
• When cranking the engine, never shut off the power sup-
plied to the engine electronic control unit by disconnecting
the engine electronic control unit connector or other similar
methods. If the engine is cranked with the power to the en-
gine electronic control unit shut off, the supply pump will
not be controlled by the electronic control unit, causing the
supply pump to be malfunctioned.
11-10
11
• Remove all the injectors. (See Gr13A.)
• Cover the injector mounting holes with shop towels or other sim-
ilar cloth. Crank the engine using the starter. Ensure that no for-
eign matter is attached on the shop towels.
CAUTION
• If cracks or any other damage are evident in the cylinders,
this means that the coolant, engine oil or fuel, or other sub-
stances, has entered the cylinders. If this is the case, it is
extremely dangerous to crank the engine as these sub-
stances will gush out at high temperature from the injector
mounting holes. Stay away from the engine when cranking
it.
• Attach the nozzle gasket and to one of the injection nozzle

mounting holes. Then, connect a compression gauge to .
• Crank the engine and measure the compression pressure.
• Measure the compression pressure for all the cylinders one after
another. Determine the compression pressure difference be-
tween the cylinders.
• If the compression pressure is below the limit or the cylinder-to-
cylinder pressure differences is not within the limit, pour a small
amount of engine oil into the corresponding injection nozzle
mounting hole and remeasure the compression pressure.
• If the compression pressure increases, the piston rings and
cylinder surfaces may be badly worn or otherwise damaged.
• If the compression pressure remains unchanged, there may
be seizure in the valves, the valves may be incorrectly seated
or the cylinder head gasket may be defective.
• Install the injectors. (See Gr13A.)

• Install the rocker cover and gasket. (See later pages.)
11-11
2. Inspection and Adjustment of Valve Clearances
Service standards (Unit: mm)

– Valve clearance (when cold) 0.6 – Adjust
Tightening torque (Unit: N·m {kgf·m})

Mark Parts to be tightened Tightening torque Remarks
– Lock nut (adjusting screw tightening) 59 {6.0} –
– Lock nut (rocker arm adjusting screw tightening) 34 {3.5} –
Special tools
Socket wrench MH063003 Tightening the lock nut
• Valve clearances should be checked and adjusted as follows

while the engine is still cold.
[Inspection]
• Remove the rocker cover.
• Bring the No. 1 or No. 6 cylinder piston to the top dead center
(TDC) on the compression stroke according to the following pro-
cedure:
• Rotate the crankshaft until the pointer is aligned with the “1 6”
mark on the flywheel.
• This will place either the No. 1 or No. 6 cylinder piston at TDC
on the compression stroke. The cylinder in which the rocker
arms for both the intake and exhaust valves can be pushed
down by hand by the valve clearance amounts has its piston
at TDC. Rotate the engine by one full turn to switch the TDCs
of the No. 1 and No. 6 cylinder pistons.
• With the No. 1 or No. 6 cylinder piston at TDC, measure the

clearance of the valves (clearance between valve bridge and
pad) marked with a circle in the table below.
Cylinder No. 1 2 3 4 5 6
Valve IN EX IN EX IN EX IN EX IN EX IN EX
No. 1 cylinder
piston at TDC on O O O – – O O – – O – –
compression stroke
No. 6 cylinder
piston at TDC on – – – O O – – O O – O O
compression stroke
Phone: 1 269 673 1638
11-12
11
• Any attempt to insert a feeler gauge without first securing suffi-
cient space, as described above, between the pad and the valve
bridge will fail, as the pad will tilt as shown in the illustration, thus
blocking the entry of a feeler gauge.
• Before inserting a feeler gauge, push the adjusting screw pad on

the side opposite from where a feeler gauge is to be inserted, as
shown in the illustration, using a flat-head screwdriver or other
similar tool. This will create space necessary for the gauge to be
inserted.
• The measurement is correct when the feeler gauge feels slightly
resisted as it is inserted.
• The measurement is not yet correct if the feeler gauge can still
be inserted smoothly.
• If the measurement deviates from the standard value, adjust as
follows.
[Adjustment]
• Loosen the lock nuts and adjusting screws on the valve bridge
and rocker arm.
• While holding the valve bridge by hand, screw in the adjusting

screw until it lightly contacts the valve stem end.
• Then, further screw in the adjusting screw by 45°.
11-13
• While holding the adjusting screw in this position with a socket
wrench and extension, tighten the lock nut to the specified
torque using .
CAUTION
• After adjusting the adjusting screw, be sure to tighten the
lock nut to the specified torque. Insufficient torquing will
compromise the parallelism of the valve bridge, damaging
the valve mechanism.
• Screw in or out the adjusting screw on the rocker arm until the
correct feeler gauge can be inserted with a slight resistance.
• While holding the adjusting screw in this position with a screw-
driver, tighten the lock nut to the specified torque using .
• Recheck the valve clearance using the correct feeler gauge.
[Installation]
• Install the rocker cover and gasket. (See later pages.)
11-14
11
M E M O
11-15
ROCKER COVER, ROCKER BRACKET AND CAMSHAFT
11-16
11
1 Oil filler cap 8 Rocker case upper gasket 13 Rocker case gasket
2 Rubber 9 Packing
3 Rocker cover 10 Rocker and bracket assembly *a: Cylinder head
4 Rocker cover gasket (See later pages.) No. 3 idler gear
5 Baffle plate 11 Camshaft
*b:
6 Cylinder recognition sensor (See later pages.) : Locating pin
7 Rocker case upper 12 Rocker case : Non-reusable parts
CAUTION
• The rocker case and the brackets of the rocker and bracket assembly have been machined together,
which means that they all must be replaced together. Never swap the locations of the brackets, either.
Assembly sequence
Follow the disassembly sequence in reverse.

– Camshaft end play 0.05 to 0.20 0.4 Inspect
11, b Backlash between camshaft gear and No. 3 idler gear 0.18 to 0.26 0.35 Replace
*
Bolt (rocker cover mounting) 8.8 {0.9} –
Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
Rubber portion of oil filler cap
Camshaft journal supports on rocker and bracket assem-
bly Engine oil As required
Camshaft journals and cams
Camshaft journal supports on rocker case
Periphery and top surface of packing ThreeBond 1217H As required
Work before removal

Inspection: Backlash between camshaft gear and No. 3 idler
gear
• Measure the backlash at least at three different locations. If the
measurement exceeds the limit, replace the defective part(s).
11-17
Inspection: Camshaft end play
• If the measurement exceeds the limit, replace the defective
part(s).
Releasing valve spring force

• Before loosening the rocker and bracket assembly mounting
bolts, check whether the valve springs are compressed by the
rockers. If so, loosen the adjusting screws on the rockers to re-
lieve the spring force. This will eliminate the possibility of com-
pressed springs damaging parts when they are released.
Removal procedure
Removal: Camshaft
• Remove the plug at the rear end of the cylinder head.
• Insert a sub-gear locking bolt (M8 × 1.25 mm, length 20 mm) into
the dedicated hole in the No. 3 idler gear to lock the sub-gears.
Remove the camshaft.
Installation procedure
Installation: Rocker case
• Tighten the rocker case bolts in the order shown in the illustra-
tion.
Installation: Camshaft
• Make sure that the timing marks on the timing gears are aligned
with each other.
• Install the camshaft so that the stamped line on the camshaft
gear is level with the top surface of the rocker case.
• Install the plug at the rear end of the cylinder head. (See later
pages.)
11-18
11
Installation: Packing
• Apply sealant onto the peripheral surface of the packing.
• Immediately after the sealant application, install the packing to
the rocker case.
• After installing it on the rocker case, apply sealant to the top sur-
face of the packing.
• Immediately after the sealant application, install the rocker case
upper and rocker case upper gasket in place.
CAUTION
• Do not start the engine for one hour after installation.
• When removing the rocker cover after installation, never fail
to apply sealant again.
Installation: Rocker case upper gasket

• Make sure that the gasket fitting groove in the rocker case is
clear of grease and dirt. Clean if necessary.
• Before installation, make sure that the gasket is free of grease,
etc. that could cause an oil leakage.
Installation: Rocker cover gasket

• Make sure that the gasket fitting groove in the rocker cover is
clear of grease and dirt. Clean if necessary.
• Before installation, make sure that the gasket is free of grease,
etc. that could cause an oil leakage.
11-19
Rocker and Bracket Assembly
1 Front bracket
2 Adjusting screw
3 Rocker bushing
4 Intake rocker
5 Rocker shaft spring
6 Adjusting screw
7 Rocker bushing
8 Exhaust rocker
9 No. 1 center bracket
14 Rear bracket
15 Rocker shaft
CAUTION
• The rocker and bracket assembly
and the rocker case are assembled
together with precise adjustment
and therefore they cannot be re-
placed separately.
If the rocker and bracket assembly
is to be reused, be sure to reassem-
ble the assembly with the same
combinations of its parts as before.
Assembly sequence

3, 7, 15 Clearance between rocker shaft and bushing 0.006 to 0.076 0.114 Replace
4, 8 Radial clearance of rocker (roller) 0.035 to 0.078 – Replace

Lock nut (adjusting screw tightening) 34 {3.5} –

Inside surface of rocker bushing Engine oil As required

Rocker bushing puller Removal and installation of rocker

MH062727
A B C bushing
φ 25 φ 27.5 φ 25
11-20
11
Inspection procedure
Inspection: Radial clearance of rocker (roller)
• If the measurement deviates from the standard value, replace
the defective part(s).
Inspection: Clearance between rocker shaft and bushing

• If the measurement exceeds the limit, replace the bushing.
Replace of rocker bushing

[Removal]
[Installation]
• Assemble the bushing onto the rocker such that the oil holes are
aligned as shown in the illustration.
• After assembly, recheck the clearance.
• If the measurement is less than the standard value, ream the
bushing.
11-21
Camshaft
1 Camshaft gear
2 Key
3 Camshaft
: Non-reusable parts
Assembly sequence
Follow the disassembly sequence in re-
verse.

1, 3 Interference between camshaft gear and camshaft 0.017 to 0.062 – Replace
Lobe diame-
ter: 45.110
Intake 5.023 4.973 Base circle
diameter:
Replace
40.087
Cam lift
Lobe diame-
3 Camshaft ter: 47.370
Exhaust 7.084 7.034 Base circle
diameter:
40.286
Bend 0.02 or less 0.04 Replace
Oil clearance at journal 0.075 to 0.12 0.25 Inspect
Removal procedure
Removal: Camshaft gear
• Remove the camshaft gear by pushing on the end of the cam-
shaft with a press or other similar tool.
CAUTION
• Do not attempt to remove the camshaft gear with a hammer
as damage will result. Use a press or other similar tool.

Phone: 1 269 673 1638
11-22
11
Inspection: Interference between camshaft gear and cam-
shaft
Inspection: Camshaft
(1) Cam lift
• If the measurement (difference between lobe diameter and base
circle diameter) is less than the limit, replace the camshaft.
(2) Bend
• Measure the camshaft at the center journal for bend while sup-
porting the shaft at the end journals.
• A half of the dial gauge reading obtained as the camshaft is ro-
tated by a full turn represents the bend of the camshaft.
• If the measurement exceeds the limit, replace the camshaft.
(3) Oil clearance at journal

part(s).
CAUTION
• The rocker case and the brackets of the rocker and bracket
assembly have been machined together, which means that
they all must be replaced together.
Installation: Camshaft gear
• Heat the camshaft gear to approximately 150°C using a gas
burner.
• While facing the camshaft gear as shown in the illustration,
press it onto the camshaft until it seats snugly on the camshaft.
WARNING
• The camshaft is extremely hot. Be careful not to touch it.
11-23
CYLINDER HEAD AND VALVE MECHANISM
11-24
11
1 Connecting plate 11 No. 3 idler bolt 20 Cylinder head
2 Glow plug 12 Thrust plate (See later section.)
3 Nozzle bridge 13 No. 3 idler shaft 21 Cylinder head gasket
4 Injector (See Gr13A.) 14 Snap ring
5 O-ring 15 Sub-gear a: No. 2 idler gear
6 Nozzle tip gasket 16 Pin
*b: Flywheel housing
7 Cylinder head bolt 17 Spring
* c: Crankcase
8 Plug 18 No. 3 idler gear bushing
*
9 Collar 19 No. 3 idler gear : Locating pin
10 O-ring : Non-reusable parts
Assembly sequence
CAUTION
• After the No. 3 idler gear has been reassembled onto the cylinder head, remove the locking bolt from the
sub-gears.

Backlash between No. 3 and No. 2 idler gears 0.17 to 0.25 0.35 Replace
–
No. 3 idler gear end play 0.05 to 0.15 0.3 Replace
Clearance between No. 3 idler shaft and No. 3 idler
13, 18 0.01 to 0.05 0.2 Replace
gear bushing

Nut (connecting plate mounting) 1.0 to 1.5 {0.1 to 0.15} –
Glow plug 20 to 25 {2.0 to 2.5} –
Bolt (nozzle bridge mounting) 33 to 38 {3.4 to 3.9} –
• Wet
Cylinder head bolt 78 {8} + 90° +5°
0 + 90° +5°
0 • Reusable up
to 3 times
Plug 13 to 17 {1.3 to 1.7} –
Nut (collar mounting) 39 to 59 {4.0 to 6.0} –
No. 3 idler bolt 59 to 78 {6.0 to 8.0} –

Threaded portion of cylinder head bolt
O-ring
Threaded portion of No. 3 idler bolt Engine oil As required
Periphery of No. 3 idler shaft
Inside surface of No. 3 idler gear bushing
Top mating surfaces of flywheel housing and crankcase ThreeBond 1207F As required
11-25
Socket wrench MH063388 Installation of cylinder head
Pin wrench arm MH063473 Assembly of No. 3 idler gear
Idler gear push-puller Removal and installation of No. 3 idler

MH061779
A B C gear bushing
φ 32 φ 35 φ 32
Work before removal

Locking sub-gears
• Before removing the No. 3 idler gear, install a locking bolt (M8 ×
1.25 mm, length 20 mm) into the dedicated hole to lock the sub-
gears.
Inspection: End play of No. 3 idler gear

part(s).
Inspection: Backlash between No. 2 and No. 3 idler gears

part(s).
11-26
11
Removal procedure
Removal: Cylinder head
• Remove the bolts (× 4).
• Progressively loosen the cylinder head bolts in the order shown
in the illustration, going over them several times, before eventu-
ally removing them.
Removal: Cylinder head gasket

CAUTION
• Be careful not to scratch the cylinder head, crankcase and
flywheel housing when removing the cylinder head gasket.
Inspection: Clearance between No. 3 idler shaft and No. 3
idler gear bushing
Replacement of No. 3 idler gear bushing

[Removal]
[Installation]
• Using , press in the bushing until contacts the No. 3
idler gear.
• After installation, measure the clearance again.
• If the measurement is lower than the standard value, ream the
bushing.
11-27
Installation: Sub-gears
• Install the No. 3 idler gear on a vice. Use shop towel to protect
the gear from direct contact with the vice.
• Install a sub-gear, a spring and pins on one side of the No. 3

idler gear.
• Hook each end A of the spring on a pin.
• Install a snap ring.
• Using , turn the sub-gear clockwise until the countermark

on the sub-gear is aligned with the stamped line on the No. 3
idler gear. Then, install a locking bolt (M8 × 1.25 mm, 20 mm
long) into the dedicated hole.
• Turn over the No. 3 idler gear and repeat the same procedure on
the other side of the No. 3 idler gear, installing another sub-gear,
a spring, pins and a snap ring.
Installation: Cylinder head

CAUTION
• Before fitting the cylinder head bolts, check the punch
marks on each bolt’s head. Do not use the bolt if there are
three punch marks.
The punch marks indicate the number of times each bolt
has been tightened using the torque-turn tightening meth-
od. Any bolt that already has three punch marks must be re-
placed.
11-28
11
• The cylinder head gasket is a part that needs to be selected for
use. Choose the appropriate gasket in the following manner.
• Measure the piston protrusion from each cylinder. (See Piston.)
• Then, from the table below, choose the cylinder head gasket
having a thickness appropriate to the average protrusion of the
pistons.
• If the cylinder head has even one cylinder that exceeds the larg-
est of the measured piston protrusions by 0.05mm or more, use
a gasket at least one size larger in thickness
(A → B, B → C).
Unit: mm
Piston protrusion Cylinder head gasket
Average piston Type by size Tightened
protrusion ( ): No. of notches thickness
0.804 to 0.872 A(1) 1.70 ± 0.05
0.873 to 0.941 B(2) 1.75 ± 0.05
0.942 to 1.011 C(3) 1.80 ± 0.05
• Identify the appropriate type of cylinder head gasket according
to the number of notches in its notched end.
• Remove oil and any other contamination from the surfaces

where sealant is to be applied.
• Apply sealant onto the surfaces of the flywheel housing and
crankcase that will be fitted together.
• Within three minutes following the sealant application, install the
cylinder head onto the crankcase, with the cylinder head gasket
in between them, using the cylinder head bolts. Take care so
that the applied sealant is not displaced during installation.
Be sure to install the gasket in the illustrated position.
CAUTION
• Do not start the engine for at least an hour after installation.
• Whenever cylinder head bolts are loosened or removed af-
ter installation, the cylinder head gasket must be replaced
and sealant reapplied.
• Tighten the cylinder head bolts to a torque of 78N.m {8kgf.m} in

the order shown in the illustration.
3
• Further tighten the bolts in the illustrated order as follows.
19 11 6 14 22
25 17 9 1 8 16 24
23 15 7 2 10 18 26
21 13 5
4 12 20
Phone: 1 269 673 1638

11-29
• Turn the holder of counterclockwise to pretension the inter-
nal spring.
• Set the tool such that the rod (extension) is pressed against the
rocker shaft bracket by the force of the spring.
• Align any line on the holder scale with any line on the socket
scale. (This will be used as the reference point = 0°.)
• From the reference point, turn the socket by 90° +5°
0 in the direc-
tion shown. Each division on the holder scale represents 5°.
• Further turn the socket by 90° +5°
0 .
• After tightening the cylinder head bolts within the plastic region,
punch a mark on the bolt heads to record the number of times
that they have been tightened.
CAUTION
• Cylinder head bolts that have been tightened using the
torque-turn method must never be additionally tightened af-
ter the final angular tightening.
11-30
11
M E M O
11-31
Cylinder Head
1 Adjusting screw 7 Valve stem seal 14 Intake valve seat
2 Valve bridge 8 Exhaust valve 15 Stud bolt
3 Valve cotter 9 Intake valve 16 Cylinder head
4 Upper retainer 10 Valve bridge guide
5 Outer valve spring 11 Exhaust valve guide : Non-reusable parts
6 Inner valve spring 12 Intake valve guide
<Only exhaust valve> 13 Exhaust valve seat
Assembly sequence
CAUTION
• When an exhaust valve or intake valve has been removed, make sure to replace the valve stem seal.

Phone: 1 269 673 1638
11-32
11
2, 10 Valve bridge-to-valve bridge guide clearance 0.01 to 0.04 0.1 Replace
Free length 71.7 68.1 Replace
Installed load
407 ± 20.6 N 367 N
Intake side (46.5 in installed Replace
{42 ± 2.1 kgf} {37 kgf}
length)
Outer valve Squareness – 2° or less Replace
5
spring Free length 66.47 63.1 Replace
Installed load
280 ± 14 N 252 N
Exhaust side (46.5 in installed Replace
{29 ± 1.4 kgf} {26 kgf}
length)
Squareness – 2° or less Replace
Free length 60.61 57.6 Replace
Inner valve Installed load 127 ± 6.3 N 121 N
6 Replace
spring (41.8 in installed length) {12.9 ± 1.9 kgf} {12 kgf}
Squareness – 2° or less Replace
Stem outside diameter φ8 –0.060
–0.075 φ7.85 Replace
Sinkage from cylinder head
1.3 ± 0.2 1.55 Inspect
8 Exhaust valve bottom surface
Valve margin 1.5 1.2 Replace
Seat angle 45° ± 15’ – Correct
8, 11 Exhaust valve stem-to-valve guide clearance 0.07 to 0.10 0.2 Replace
Stem outside diameter φ8 –0.025
–0.040 φ7.85 Replace
Sinkage from cylinder head bottom
1.3 ± 0.2 1.55 Inspect
9 Intake valve surface
Valve margin 1.5 1.2 Replace
Seat angle 45° ± 15’ – Correct
9, 12 Intake valve stem-to-valve guide clearance 0.06 to 0.09 0.2 Replace
10 Valve bridge guide in outside diameter 9.989 to 10 9.94 Replace
Correct or
13 Exhaust valve seat width 2.3 to 2.7 3.3
replace
Correct or
14 Intake valve seat width 1.8 to 2.2 2.8
replace
Correct or
Bottom surface distortion 0.08 or less 0.2
replace
16 Cylinder head
Height from top surface to
94.9 to 95.1 94.5 Replace
bottom surface

Lock nut (valve bridge adjusting screw tightening) 59 {6.0} –
Stud bolt 20 {2} –

Lip of valve stem seal
Engine oil As required
Stem and end of valve
11-33
Valve lifter MH061668
Valve lifter hook MH061679
Valve lifter seat Removal and installation of valve cot-

ters
A MH061772
φ 38
Valve stem seal installer

MH062689 Installation of valve stem seals
A B
φ 25 φ9
Valve lapper 30091-07500 Lapping valves and valve seats
Valve bridge guide

installer MH062724 Installation of valve bridge guides
A B
φ 10 37.2
Valve guide remover

31391-10500 Removal of valve guides
A B
φ8 φ 12
Valve guide installer

MH062726 Installation of valve guides
A B C
φ 25.5 φ 13 17
Caulking tool body 31391-13100
Installation of valve seat
A B
MH062725
Intake <Intake valve>
Installer ring φ8 φ 42
valve MH063605
<Exhaust valve>
Exhaust
φ8 φ 38
valve
11-34
11
Removal procedure
Removal: Valve cotters
• Using , and , remove the valve cotter while com-
pressing the valve spring(s) evenly.
Inspection: Valve bridge and valve bridge guide
(1) Valve bridge-to-guide clearance
part(s).
(2) Outside diameter of valve bridge guide
• If the measurement is less than the limit or the valve bridge
guide is worn extremely unevenly, replace the valve bridge
guide.
Replacement of valve bridge guide

[Installation]
• Before installation, ensure that no water, oil or other foreign mat-
ter is in the installation hole.
• Using , install the valve bridge guide until comes into
positive contact with the cylinder head.
CAUTION
• The valve bridge guide must be installed to the specified
depth of the cylinder head. Correct installation can only be
possible by using .
Inspection: Intake and exhaust valve

(1) Valve stem outside diameter
• Replace the valve if the stem’s outside diameter is below the
limit or is severely worn.
• When the valve has been replaced with a new one, make sure
to lap the valve and valve seat.
(2) Valve seat angle and valve margin

• Reface or replace the valve if the valve seat angle or valve mar-
gin exceeds the specified limits.
• After refacing or replacing the valve seat, make sure to lap the
valve and valve seat.
11-35
Refacing
• Limit grinding to a necessary minimum.
• If the valve margin is below the limit after grinding, replace the
valve.
• After grinding, make sure to lap the valve and valve seat.
Inspection: Valve-to-valve guide clearance

• If the clearance exceeds the specified limit, replace the defective
part(s).
Replacement of valve guides

[Removal]
[Installation]
• Install the valve guide until sits snugly on the cylinder
head.
CAUTION
• The valve guide must protrude from the cylinder head by
the specified amount. Correct installation can only be pos-
sible by using .
• The valve guides for the exhaust valves are longer than the
valve guides for the inlet valves.
Inspection: Contact between valve and valve seat

• Before starting inspection, check that the valve and valve guide
are intact.
• Apply an even coat of red lead to the valve contact surface of
the valve seat.
• Strike the valve once against the valve seat. Do not rotate the
valve during this operation.
11-36
11
• If the red lead deposited on the valve indicates a poor contact
pattern, take either of the following corrective actions.
Contact pattern Corrective action
Minor defect Lapping
Serious defect Reface or replace valve and valve seat
Lapping
• Lap the valve in the following sequence.
• Apply a thin coat of lapping compound to the seat contact sur-
face of the valve. Adding a small amount of engine oil to the lap-
ping compound can facilitate even application.
CAUTION
• Do not put any compound on the stem.
• Start with an intermediate-grit compound (120 to 150 grit) and

finish with a fine-grit compound (200 grit or more).
• Strike the valve several times against the valve seat while rotat-
ing the valve a little at a time.
• Wash away the compound with diesel fuel.
• Apply engine oil to the valve contact surface of the valve seat
and rub in the valve and seat well.
• Inspect the contact pattern of the valve and valve seat again.
• If the contact pattern is still defective, replace the valve seat.
Inspection: Valve seats

(1) Valve seat width
• If the measurement exceeds the limit, reface or replace the
valve seat.
valve seat and valve.
(2) Valve sinkage from cylinder head bottom surface

• Perform measurement keeping the valve in close contact with
the valve seat.
• If the measurement exceeds the limit, adjust or replace the de-
fective part(s).
valve seat and valve.
11-37
Refacing the valve seat
• Grind the valve seat using a valve seat cutter or valve seat
grinder.
• Place a piece of sandpaper of approximately #400 between the
cutter and valve seat and grind the valve seat lightly.
• Use a 15° or 75° cutter to cut the valve seat to a width within the
standard range.
CAUTION
• Make sure that the valve seat refacing does not cause the
valve sinkage to exceed the specified limit.
• Lap the valve and valve seat.
Replacement of valve seat

[Removal]
• The valve seats are installed by expansion fitting. To remove a
valve seat, grind inside the metal stock to reduce the wall thick-
ness, then remove the valve seat at room temperature.
[Installation]
• Check that the diameters of the valve seat holes in the cylinder
head conform with the values shown below.
Diameters of the Intake side φ42 +0.025
0 mm
valve seat holes Exhaust side φ38 +0.025
0 mm
• Replace the cylinder head if necessary.
• Chill the valve seat thoroughly by immersing in it in liquid nitro-

gen.
• Install the valve seat in the cylinder head using and .
• Lap the valve seat and valve.
Inspection: Cylinder head bottom surface distortion

• If the distortion exceeds the specified limit, rectify it using a sur-
face grinder.
CAUTION
• Make sure that the height of the cylinder head from the top
surface to the bottom surface is not reduced to a value be-
low the specified limit.
11-38
11
Installation: Valve stem seal
• Apply engine oil to the lip of the valve stem seal.
• Install the valve stem seal until sits snugly on the cylinder
head.
CAUTION
• After installing the valve stem seal, check that its spring is
not deformed or damaged.
Installation: Valve spring

• Install the outer and inner valve springs onto the cylinder head
while facing them as shown in the illustration.
Installation: Valve cotter

• Using , and , install the valve cotter while com-
pressing the valve spring(s) evenly.
CAUTION
• Do not compress the valve spring(s) too much, or the upper
retainer will contact the valve stem seal and damage will re-
sult.
11-39
PISTON AND CONNECTING ROD, CYLINDER LINER
1 Lower connecting rod bearing
2 Connecting rod cap
3 Upper connecting rod bearing
4 Piston and connecting rod
(See later sections.)
5 Cylinder liner
: Locating pin
Assembly sequence
verse.

– Piston projection from crankcase top surface 0.81 to 1.01 – Inspect
– Connecting rod end play 0.15 to 0.45 0.6 Inspect
Oil clearance 0.034 to 0.093 0.2
1, 3 Connecting rod bearing Less than Replace
Span when free –
74.5
4, 5 Piston and connecting rod-to-cylinder liner clearance 0.19 to 0.21 – Replace
Flange projection 0.03 to 0.10 –
5 Cylinder liner Bore φ118 to 118.03 φ118.25 Replace
Out of roundness 0.03 or less –

Bolt (connecting rod cap installation) 29 {3} + 90° (± 5°) Wet

Threaded portion of connecting rod bolt
Inside surface of connecting rod bearing
Outside periphery of cylinder liner
Outside periphery of piston

Phone: 1 269 673 1638
11-40
11
Piston guide clamp MH061760
Piston guide lever MH061658
Installation of piston and connecting

rod
Socket wrench MH061560
Cylinder liner extractor

A MH061761 Removal of cylinder liner
φ117.5
Cylinder liner installer

A MH061771 Installation of cylinder liner
φ117.5
Inspection before removal

Retaining cylinder liners
• The cylinder liners may move up when the crankcase is turned
over, or the crankshaft is rotated after the pistons are installed.
To prevent this, retain the cylinder liners by holding their flanges
with bolts and washers.
11-41
Inspection: Piston projection from crankcase top surface
CAUTION
• The amount of piston projection affects engine perfor-
mance and must therefore be inspected without fail.
• Set the piston at the top dead center.

• Mark reference points A (seven points in total) on the top sur-
face of the crankcase as shown in the illustration. Using each of
the marks as a zero point, measure the amount of piston projec-
tion relative to the zero point (height of measurement point B –
height of reference point A).
• Make the measurements at the two measurement points B for
each cylinder (twelve points in total) using the reference point A
nearest to each measurement point, and calculate the average
value of all the measurements.
• If the average value is out of the standard value range, check
the clearances between all relevant parts.
Inspection: Connecting rod end play

• Measure the end play for every connecting rod.
• If any measurement exceeds the specified limit, replace the de-
fective part(s).
Inspection: Cylinder liner flange projection

• If the measurement deviates from the standard value, inspect
the installation and replace the defective part(s).
CAUTION
• If the cylinder liner flange protrusion is less than the speci-
fied value, the contact pressure of the cylinder head gasket
against the bore of the cylinder will not be high enough to
prevent gas leakage.
Inspection: Connecting rod bearing span when free
CAUTION
• Do not attempt to manually expand the bearings.
• If the span is less than the specified limit, replace both the upper
and lower bearings.
11-42
11
Inspection: Connecting rod bearing oil clearance
• Fit the lower bearing to the connecting rod cap and the upper
bearing to the connecting rod, then tighten the nut to a torque of
29 N·m {3 kgf·m}.
• Measure the inside diameter of the bearing and the outside di-
ameter of the crankshaft pin.
• If the clearance exceeds the limit, replace the defective part(s).
• If a bearing has to be replaced with an undersized one, machine
the crankshaft pin to the specified undersize diameter.
(See CRANKSHAFT AND CRANKCASE.)
Inspection: Clearance between piston and cylinder sleeve

A: Measuring point on the crankcase (in direction of the crank-
case axis).
B: Measuring point on the crankcase (vertical to the crankcase
axis).
C: Measuring point on the piston outer diameter (vertical to the
piston pin hole).
Replacement of cylinder liner

[Removal]
• If the cylinder liners will need to be reused for some reason or
other, make countermarks to ensure correct reassembly.
11-43
[Installation]
• The cylinder liner being installed must have the same size mark
as that on the crankcase as well as that on the piston.
Size mark Size mark Size mark

on crankcase on cylinder liner on piston
“1” “1A” “A”

“1B”
“2A”
“2” “2B” “B”
“3A”
“3” “3B”
CAUTION
• Using a piston with the size mark different from the size
mark of the cylinder liner can lead to engine seizure.
• Apply a thin coat of engine oil onto the outside periphery

(hatched area) of the cylinder liner.
• While pushing the top surface of evenly with hands, gently

insert the cylinder liner into the crankcase.
CAUTION
• Cylinder liners are thinly structured. Therefore, they must
be handled with extreme care.
Installation: Connecting rod bearings
CAUTION
• Do not reverse the positions of the lower bearing and the
upper bearing (with oil hole) when installing, as this may
cause seizure in the engine.
11-44
11
Installation: Piston and connecting rod
• Check that the piston ring end gaps are in their correct positions.
A: 1st compression ring gap
B: 2nd compression ring gap
C: Oil ring gap
D: Oil ring expander spring gap
“ ”: Front mark on piston
• Ensure that the size mark (“A”, “B”) on the piston is the same as
that on the cylinder liner.
• Face the front mark “ ” of the piston toward the front of the en-
gine.
• With and installed around the piston skirt, tighten the
adjusting bolt of until the inside diameter of matches
the outside diameter of the piston skirt.
• Remove and from the piston. Apply engine oil to the
following areas. Then, install and over the rings of the
piston.
• Outside surface of piston
• Inside surface of
• Cylinder liner inside surface
• Install the piston and connecting rod, taking care not to damage
the inside surface of the cylinder liner or the crank pin with the
connecting rod.
CAUTION
• Be careful not to scratch or damage head of the piston (a
part of the combustion chamber).
• Make sure that the connecting rod does not hit oil jet.
11-45
• After the piston and connecting rod have been installed, install
the connecting rod cap onto the connecting rod, ensuring that
the alignment marks are aligned. Tighten the bolts alternately as
follows.
• Tighten the bolts to a torque of 29 N·m {3 kgf·m}.
• Further tighten the bolts in the following sequence.
• Turn the holder of counterclockwise to preload the built-in

spring.
crankshaft by the force of the spring.
• From the reference point, turn the socket by 90° ± 5° in the di-
rection shown. Each division on the socket scale represents 5°.
• With the connecting rod cap installed, check the following items.
• Connecting rod end play
• Piston protrusion

Phone: 1 269 673 1638
11-46
11
M E M O
11-47
Piston and Connecting Rod
1 1st compression ring
2 2nd compression ring
3 Oil ring
4 Snap ring
5 Piston pin
6 Connecting rod bushing
7 Connecting rod
8 Piston
Assembly sequence
verse.

1st compression ring
0.45 +0.05
–0.10
1 to 3 Piston ring end gap 2nd compression ring 1.5 Replace
Oil ring 0.3 to 0.55
1st compression ring 0.13 to 0.18 0.2
Piston ring side clear-
1 to 3, 9 2nd compression ring 0.065 to 0.105 Replace
ance in piston groove 0.15
Oil ring 0.025 to 0.065
5, 6 Piston pin-to-connecting rod bushing clearance 0.02 to 0.055 0.1 Replace
5, 8 Piston pin-to-piston clearance 0.004 to 0.022 0.05 Replace
Bend – 0.05
7 Connecting rod Replace
Twist – 0.1

Piston pin outside surface
Connecting rod bushing outside surface Engine oil As required
Connecting rod bushing fitting surface of connecting rod
11-48
11
Special tools
Removal and installation of piston

Piston ring tool 30091-07100
rings
Connecting rod bushing Removal and installation of connect-

MH062556
puller kit ing rod bushings
Removal procedure
Removal: Piston ring
Removal: Piston pin

• Remove the piston pin by striking it with a rod and hammer.
• If the piston pin is difficult to remove, first heat the piston in hot
water or with a piston heater.
Inspection: Piston ring end gap
• Using the crown of a piston, push the piston ring horizontally into
a cylinder in the crankcase until it reaches the lower part of the
cylinder liner, where there is relatively small wear.
• Taking care not to move the piston ring, measure the end gap.
• If any of the rings has a gap exceeding the specified limit, re-
place all the piston rings as a set.
11-49
Inspection: Piston ring side clearance in piston groove
• Remove any carbon deposits from the ring groove in the piston.
• Measure the side clearance of each ring around the piston’s en-
tire periphery.
• If any of the measurements exceeds the specified limit, replace
the defective part(s). If any of the piston rings is defective, re-
place all the rings on the piston as a set.
• The side clearance of the 1st compression ring must be mea-
sured using a feeler gauge while holding the ring against the pis-
ton ring groove with a straight edge.
Inspection: Piston pin-to-piston clearance

• If the measurement exceeds the specified limit, replace the de-
fective part(s).
Inspection: Piston pin-to-connecting rod bushing clearance

the bushing.
11-50
11
Replacement of connecting rod bushing
• Replace the connecting rod bushing using .
[Removal]
• Remove the upper bearing (if fitted) from the large end of the
connecting rod.
• Mount the connecting rod on the base and lock it in position with
the bracket and plate.
• Fit collar A over the puller with its ends facing in the illustrated di-
rections. Then, slowly apply a pressure of approximately 49 kN
{5,000 kgf} to the puller with a press to force out the connecting
rod bushing.
[Installation]
• Apply engine oil to the outside surface of the connecting rod
bushing and the bushing fitting surface of the connecting rod.
• Fit collar B, the bushing, and collar A over the puller in the illus-
trated directions and lock this arrangement together with the nut.
• Align the oil holes in the connecting rod bushing and the con-
necting rod. Then, use a press to slowly apply a pressure of ap-
proximately 49 kN {5,000 kgf} to the puller until the bushing is
forced into place.
• After press-fitting the connecting rod bushing, measure the
clearance between the piston pin and connecting rod bushing.
• If the measurement is less than the standard clearance range,
ream the bushing.
11-51
Inspection: Connecting rod bend and twist
• Mount the connecting rod on the connecting rod aligner. Also
mount the connecting rod bearings, piston pin, and connecting
rod cap to create the same conditions as are expected when the
connecting rod is mounted on a crankshaft. Tighten the nuts of
the connecting rod bearing cap to a torque of 29 N·m {3 kgf·m}.
• Measure the extent of bend and twist in the connecting rod.
• If either measurement exceeds the specified limit, replace the
connecting rod.
Installation: Piston and connecting rod

• If the piston and/or connecting rod have been replaced, assem-
ble them while paying attention to the following:
• The connecting rods on the same engine must all have the
same mass mark (A to E).
• Apply engine oil to the piston pin, and assemble the piston
and connecting rod with their marks facing in the illustrated di-
rections.
“ ”: Front mark
• If the piston pin is difficult to insert, heat the piston in hot water
or with a piston heater.
Installation: Piston rings

• With the manufacturer’s marks (found near the piston ring end
gaps) facing up, install the piston rings so that the end gap of
each ring is positioned as illustrated.
A: 1st compression ring end gap
B: 2nd compression ring end gap
C: Oil ring end gap
D: Oil ring’s expander spring end gap
“ ”: Front mark on piston
The manufacturer’s marks are present only on the 1st (“T”) and
2nd (“T1”) compression rings.
11-52
11
M E M O
11-53
FLYWHEEL
1 Washer plate 9 Air outlet pipe 18 O-ring
2 Pilot bearing 10 Air suction pipe 19 Rear oil seal
<Type A, Type B> 11 Eyebolt 20 Stiffener
3 Ring gear 12 Water inlet pipe 21 Flywheel housing
4 Flywheel 13 Eyebolt
5 Engine speed sensor 14 Oil pipe : Non-reusable parts
6 Adapter <*a> 15 Eyebolt *a: Varies depending on specifi-
7 Plug 16 Water outlet pipe cations
8 Eyebolt 17 Air compressor (See Gr61.)
11-54
11
Assembly sequence
Service standards
Correct or
Friction surface distortion 0.05 or less 0.2
replace
Flywheel Type A 21 20
4 Friction surface height Replace
<Type A, Type B> Type B 44.5 43.5
Friction surface runout Correct or
– 0.2
(when fitted) replace
Eccentricity of flywheel housing measured at spigot Inspect or
21 – 0.2
joint section (when fitted) replace

• Wet
+10°
Bolt (flywheel mounting) 98 {10} + 150° 0 • Can be reused
up to 3 times
Plug 88 {9} –
Eyebolt (air outlet pipe mounting) 98 {10} –
Bolt (air suction pipe mounting) 19 to 28 {1.9 to 2.8} –
Eyebolt (water inlet pipe mounting)
50 {5.0} –
Eyebolt (water outlet pipe mounting)
Eyebolt (oil pipe mounting) 21 {2.1} –

Thread of bolts
O-ring Engine oil As required
Rear oil seal lip
Rear oil seal surface to be mated with flywheel housing
ThreeBond 1207C As required
Engine mounting surface of flywheel housing

Phone: 1 269 673 1638
11-55
FLYWHEEL
Special tools
Socket wrench MH062354
Installation of flywheel
Magnet base MH062356

Inspection: Flywheel friction surface runout when fitted
• If the measurement exceeds the limit, check if the bolts are cor-
rectly tightened as well as the crankshaft mounting surface. Cor-
rect or replace the flywheel as required.
Removal procedure
Removal: Flywheel
• To remove the flywheel, use bolts (M16 × 1.5 mm, Length 60
mm) inserted into the dedicated holes in the flywheel.
Removal: Ring gear

• Heat the ring gear evenly with a gas burner or the like until it
reaches approximately 200°C, then remove it from the flywheel.
WARNING
• You may burn yourself if you touch the heated ring gear.
11-56
11
Inspection: Flywheel
(1) Friction surface height
• If the height is less than the limit, replace the flywheel.
(2) Friction surface distortion

• If the measurement exceeds the limit, rectify or replace the fly-
wheel.
• If the ring gear is evidently defective, replace the ring gear be-
fore inspecting the friction surface for distortion.
Rectification of friction surface

• Rectify the friction surface so that its height is not below the
specified limit, and it is parallel with surface A with an error not
exceeding 0.1 mm.
11-57
FLYWHEEL
Installation: Flywheel housing
[Installation]
• Clean the flywheel housing surface where sealant is to be ap-
plied.
• Apply an even and continuous bead of sealant onto the flywheel
housing surface where the crankcase is to be mounted.
• Install the flywheel housing onto the crankcase within 3 minutes
following the application. Be careful not to smear the sealant
bead.
CAUTION
• Do not start the engine at least for an hour after the flywheel
housing has been installed.
• If the flywheel housing mounting bolts are subsequently
loosened, be sure to apply sealant again upon reassembly.
[Inspection]
• While turning the crankshaft, measure the flywheel housing for
any eccentricity at the location indicated in the illustration.
• If the eccentricity exceeds the limit, reassemble the flywheel.
• If the eccentricity still exceeds the limit after reassembly, replace
Installation: Rear oil seal

• Clean the rear oil seal surface where sealant is to be applied.
• Apply an even and continuous bead of sealant on the rear oil
seal as shown in the illustration.
• Install the rear oil seal onto the flywheel housing within 3 min-
utes following the application. Be careful not to smear the seal-
ant bead.
CAUTION
• Do not start the engine at least for an hour after the rear oil
seal has been installed.
• If the rear oil seal mounting bolts are subsequently loos-
ened, be sure to apply sealant again upon reassembly.
• Apply engine oil to the rear oil seal lip.

• Install the rear oil seal onto the flywheel housing ensuring that
the seal is faced in the illustrated direction.
11-58
11
Installation: Air compressor
• Bring the No. 1 cylinder of the engine to top dead center of the
compression stroke.
• After aligning inscribed lines with each other, install the air com-
pressor to the flywheel housing.
• Remove the inspection plug and check if the inscribed line is

aligned with the pointer.
• If not aligned, remove and refit the air compressor.
Installation: Ring gear

• Heat the ring gear evenly with a gas burner or the like until it
reaches approximately 200°C.
WARNING
• You may burn yourself if you touch the heated ring gear.
• Fit the ring gear with the side having non-chamfered tooth edges
toward the flywheel.
Installation: Flywheel
CAUTION
• Before installing a bolt, check the number of punch marks
on the bolt head. (Bolts with up to two punch marks can be
reused.)
The number of punch marks indicates the number of times
the bolt has been tightened in the past within the plastic re-
gion. If there are three punch marks (tightened three times
in the past), replace the bolt.
11-59
FLYWHEEL
• Tighten the flywheel mounting bolts to a torque of 98 N·m {10
kgf·m}.
• Further tighten the bolts in the following procedure.
• Turn the holder of counterclockwise to preload the built-
in spring.
• Set such that the rod (extension) is pressed against
by the force of the spring.
• From the reference point, turn the socket by 150° +10° 0° clock-
wise. Each division on the socket scale represents 5°.
• After tightening the bolt within the plastic region, make a
punch mark on the bolt head for subsequent identification.
CAUTION
• The bolts should be tightened within the plastic region.
Never tighten them further than the specified angle.
11-60
11
M E M O
11-61
TIMING GEARS
1 No. 1 idler shaft 7 No. 2 idler bolt a: Air compressor gear
2 No. 1 idler gear bushing 8 Thrust plate
*b: Crankshaft gear
3 No.1 idler gear 9 No. 2 idler gear bushing
*
4 O-ring 10 No. 2 idler gear : Non-reusable parts
5 Collar 11 No. 2 idler shaft
6 O-ring
Assembly sequence

Phone: 1 269 673 1638
11-62
11
No. 1 idler gear and air
0.08 to 0.15 0.35 Replace
compressor gear
No. 1 idler gear and No. 2
– Backlash between gears 0.08 to 0.15 0.35 Replace
idler gear
No. 1 idler gear and crank-
0.08 to 0.14 0.35 Replace
shaft gear
Clearance between No. 1 idler shaft and No. 1 idler
1, 2 0.01 to 0.05 0.2 Replace
gear bushing
3, 10 Idler gear end play 0.05 to 0.15 0.3 Replace
Clearance between No. 2 idler gear bushing and No. 2
9, 11 0.01 to 0.05 0.2 Replace
idler shaft

Bolt (No.1 idler gear mounting) 88 {9} –
Nut (collar mounting) 82 {8.4} –
No. 2 idler bolt 95 {9.7} –


Gear puller MH061326 Removal of No. 1 idler shaft and gear
Idler gear push-puller Removal and installation of No. 1 and

MH062601
A B No. 2 idler gear bushings
φ 37 φ 40
No. 2 idler shaft puller

MH062562 Removal of No. 2 idler gear shaft
A B
M12 × 1.25 M10 × 1.5
11-63
TIMING GEARS
Inspection: Backlash between gears
• For each pair of gears, measure the backlash at more than three
teeth.
Inspection: Idler gear end play

• If the measurement exceeds the specified limit, replace the de-
fective part(s).
Removal procedure
Removal: No. 1 idler shaft and No. 1 idler gear
• With the bolt loosened by approximately 15 mm, pull out the No.
1 idler shaft from the crankcase using .
• Remove the bolt. Remove the No. 1 idler shaft and No. 1 idler
gear.
Removal: No. 2 idler shaft
Inspection: Clearance between No. 1 idler shaft and No. 1
idler gear bushing
[Inspection]
11-64
11
[Removal]
[Installation]
• Place the No. 1 idler gear as shown in the illustration. Using
, insert the bushing until contacts the chamfered tooth
edge of the gear.
bushing.
Inspection: Clearance between No. 2 idler gear bushing and

No. 2 idler shaft
[Inspection]

[Removal]
[Installation]
• Place the No. 2 idler gear as shown in the illustration. Using
, insert the bushing until contacts the chamfered tooth
edge of the gear.
bushing.
11-65
TIMING GEARS
Installation: No. 2 idler shaft
• Install the No. 2 idler shaft onto the crankcase ensuring that the
boss of the shaft faces down.
Installation: No. 1 idler gear

• Install the No. 1 idler gear such that the alignment mark “2” on
the gear is aligned with the alignment mark “2 2” on the air com-
pressor gear.
• When installing the No. 1 idler gear, also ensure that the align-
ment mark “1 1” on the gear is aligned with the alignment mark
“1” on the crankshaft gear.
11-66
11
M E M O
11-67
CRANKSHAFT AND CRANKCASE
11-68
11
1 Torsional damper 8 Front oil seal slinger 15 Oil jet
2 Crankshaft pulley 9 Rear oil seal slinger 16 Crankcase
3 Front oil seal 10 Crankshaft gear
4 Front cover 11 Crankshaft : Locating pin
5 Main bearing cap 12 Rear plate : Non-reusable parts
6 Lower main bearing 13 Upper main bearing
7 Thrust plate 14 Check valve
CAUTION
• The check valve has been tightened using thread-locking compound and so, may deform during removal.
Once removed, the check valve must not be reused. Do not remove it unless defects are evident.
Assembly sequence

Oil clearance 0.039 to 0.101 0.15 Replace
6, 13 Main bearing Less than
Span when free – Replace
89.5
End play 0.10 to 0.25 0.4 Replace
Bend 0.025 or less 0.05 Rectify or replace
11 Crankshaft Out-of-round-
0.01 or less 0.03 Rectify or replace
Pins and journals ness
Taper 0.006 or less – Rectify or replace
16 Distortion of crankcase top surface 0.07 or less 0.2 Replace

Bolt (crankshaft pulley installation) 190 {19} –
Bolt (torsional damper installation) 78 {8} –
• Wet
Bolt (main bearing cap installation) 78 + 90° +10° +10°
0 {8 + 90° 0 } • Reusable up
to 3 times
Check valve 34 {3.5} –

Front cover surface to be mated with crankcase ThreeBond 1207C As required
Front oil seal lip
Thread of bolts Engine oil As required
Inside surface of main bearing
Crankcase mounting surface of rear plate ThreeBond 1217H As required
11-69
Main bearing cap ex-

tractor MH061189 Removal of main bearing cap
A B
32 M8 × 1.25
Socket wrench MH061560 Installation of main bearing cap
Front oil seal slinger

installer
MH062710 Installation of front oil seal slinger
A
φ 76
Rear oil seal slinger in-

staller
MH061470 Installation of rear oil seal slinger
A B C
φ 104.5 φ 100 φ 14
Gear puller MH061326 Removal of crankshaft gear
11-70
11
Inspection: Crankshaft end play
• If the measurement exceeds the specified limit, replace the
thrust plates with oversized ones.
Removal procedure
Removal: Main bearing caps
Removal: Front oil seal slinger

• Taking care not to damage the crankshaft, split the rear oil seal
slinger using a chisel or a similar tool.
Removal: Rear oil seal slinger

• Taking care not to damage the crankshaft, split the rear oil seal
slinger using a chisel or a similar tool.
Removal: Crankshaft gear

CAUTION
• Do not tap off the crankshaft gear as this can damage it.
Inspection: Main bearing
(1) Main bearing span when free
CAUTION
• Do not attempt to manually expand the bearings.
• If the measurement exceeds the specified limit, replace the up-

per and lower bearings as a set.
11-71
(2) Main bearing-to-crankshaft clearance (oil clearance)
• Fit the upper main bearing into the crankcase and the lower
main bearing into the main bearing cap.
• Tighten the main bearing cap bolts to a torque of 78 N·m {8
kgf·m}.
• Measure the inside diameter of the main bearing and the diame-
ter of the corresponding crankshaft journal.
• If the difference between the measurements exceeds the speci-
fied limit, machine the crankshaft journal to one of the specified
undersize dimensions.
Inspection: Crankshaft
(1) Bend
• Measure the crankshaft at the center journal for bend while sup-
porting the shaft at the end journals.
• A half of the dial gauge reading obtained as the crankshaft is ro-
tated by a full turn represents the bend of the crankshaft.
• If the measurement exceeds the specified limit, replace the
crankshaft.
(2) Roundness and cylindricity of crankshaft journals and

pins
• If any of the measurements exceeds the specified limits, grind
the crankshaft journal(s) and/or pin(s) to undersize(s) or replace
the crankshaft.
11-72
11
Grinding of crankshaft
CAUTION
• If the crankshaft pins and journals are ground to
undersizes, be sure to use bearings of corresponding
undersizes.
• Do not change the center-to-center distance A between the jour-

nal and pin.
A: 57.5 +0.0252
–0.075 mm
• Do not change the journal width B and the pin width C.
B: 37 +0.2
0 mm
C: 42 +0.2
0 mm
• Finish the fillets D smoothly.
D: R4 ± 0.2 mm
• Carry out a magnetic inspection to check for cracks possibly
caused by grinding. Also, check that the hardness of the surface
has not dropped below Shore hardness number (Hs) 75.
• Replace the crankshaft if defects are evident.
Crankshaft undersize dimensions (Unit: mm)

Undersizes
0.25 0.50 0.75 1.00
Finished journal outside diameter 83.685 to 83.705 83.435 to 83.455 83.185 to 83.205 82.935 to 82.955
Finished pin outside diameter 69.67 to 69.69 69.42 to 69.44 69.17 to 69.19 68.92 to 68.94
Out-of-roundness 0.01 or less
Taper 0.006 or less
• When grinding, turn both the crankshaft and the grinder counter-
clockwise as viewed from the crankshaft front end.
• When finishing the crankshaft with whetstone or sandpaper, ro-
tate the crankshaft clockwise.
Inspection: Distortion of crankcase top surface

• If the measurement exceeds the limit, correct the crankcase top
surface with a surface grinder.
CAUTION
• Do not grind the crankcase top surface so much as to com-
promise the correct piston projection.
11-73
Installation: Rear plate
• Clean the rear plate surface where sealant is to be applied.
• Apply an even and continuous bead of sealant onto the rear
plate surface where the crankcase is to be mounted.
• Install the rear plate onto the crankcase within 3 minutes follow-
ing the application. Be careful not to smear the sealant bead.
CAUTION
• Do not start the engine at least for an hour after the rear
plate has been installed.
• If the rear plate mounting bolts are subsequently loosened,
be sure to apply sealant again upon reassembly.
Installation: Crankshaft gear

• Heat the crankshaft gear to approximately 100°C with a burner
or the like.
WARNING
• Be careful not to get burned.
• Align the key fitted in the crankshaft with the slot in the crank-
shaft gear. Drive the gear into position by lightly striking its end
face with a plastic hammer.
Installation: Rear oil seal slinger

• Using , install the rear oil seal slinger onto the crankshaft
until comes into positive contact with the end face of the
crankshaft gear.
Installation: Front oil seal slinger

• Using , install the front oil seal slinger onto the crankshaft
until the end face of comes into positive contact with the
guide.
11-74
11
Installation: Main bearing
• Install the main bearings with their lugs aligned as shown in the
illustration. When the crankshaft journals have been ground to
an undersize, use undersized main bearings.
Available main bearing undersizes: 0.25 mm, 0.50 mm, 0.75
mm, 1.00 mm
CAUTION
• The upper main bearing has an oil hole. The lower main
bearing has no oil hole. Do not confuse the upper and lower
bearings, as this can cause seizure in the engine.
Installation: Thrust plate

• Install trust plates on both sides of the main bearing cap and the
rear end of the crankcase, ensuring that the oil grooves face out-
side.
: Locating pin
NOTE
• If oversized thrust plates are to be used, those with a
mark must be the same in size. Oversized thrust plates are
available in the following sizes: 2.6 mm, 2.75 mm and 2.9
mm.
CAUTION
• If thrust plates are installed with the oil grooves facing in-
side, the engine may seize.
Installation: Main bearing cap

CAUTION
• Before installing the main bearing cap bolts, check the
number of punch marks on the head of each bolt. (A bolt
with two or less marks is reusable.)
• The number of punch marks corresponds with the number
of times the main cap bolt has been tightened using the
torque-turn tightening method. Any bolt that has three
marks (i.e. that has been used three times) must be re-
placed.
• Starting at the front of the engine, fit the main bearing caps in
the order of the embossed numbers facing the illustrated direc-
tion.
11-75
• Tighten all the bolts to 78 N·m {8 kgf·m}, then additionally tighten
them according to the following procedure.
• Turn the holder of counterclockwise to pretension the inter-
nal spring.
crankshaft by the force of the spring.
• Align a scale mark on the socket with a scale mark on the hold-
er. (This point will be the point of reference, or the 0° point.)
• Starting with this point of reference, turn the socket with a
wrench in the illustrated direction until the scale on the socket in-
dicates 90°.
One graduation on the socket-side scale represents 5°.
• After tightening the bolts using the above torque-turn tightening
method, make a punch mark on the head of each bolt to indicate
the number of times that it has been used.
CAUTION
• The bolts that have been tightened using the torque-turn
method must never be additionally tightened after the final
angular tightening.
• After installing the main bearing cap, rotate the crankshaft by

hand. If it cannot be rotated smoothly, inspect the main bearing
caps for correct installation.
Installation: Front oil seal

• Install the front oil seal onto the front cover while pressing the
seal’s entire periphery evenly to prevent it from tilting.
• Install the front oil seal until its flange comes into positive contact
with the front cover.
Installation: Front cover

• Clean the front cover surface where sealant is to be applied.
• Apply an even and continuous bead of sealant onto the front
cover surface where the crankcase is to be mounted.
• Install the front cover onto the crankcase within 3 minutes follow-
ing the application. Be careful not to smear the sealant bead.
CAUTION
• Do not start the engine at least for an hour after the front
cover has been installed.
• If the front cover mounting bolts are subsequently loos-
ened, be sure to apply sealant again upon reassembly.
11-76
GROUP 12 LUBRICATION
SPECIFICATIONS .............................................................................. 12-2

1. Lubrication System ........................................................................... 12-3 12
2. Oil Pump ............................................................................................. 12-3
3. Oil Cooler ............................................................................................ 12-4
4. Oil Filter ....................................................................................... 12-5
5. Lubrication of Engine Components ................................................. 12-6
TROUBLESHOOTING ....................................................................... 12-9

1. Oil Filter Replacement ..................................................................... 12-10
2. Engine Oil Replacement .................................................................. 12-12
3. Oil Pressure Measurement ............................................................. 12-13
OIL PAN, OIL JETS AND OIL LEVEL SENSOR .............................. 12-14
OIL PUMP, OIL STRAINER ............................................................. 12-16
OIL FILTER ...................................................................................... 12-18
OIL COOLER ................................................................................... 12-20
REGULATOR VALVE ....................................................................... 12-21

Phone: 1 269 673 1638
12-1
SPECIFICATIONS
Item Specifications
Method of lubrication Oil pump type
Oil filter Spin-on paper-filter type
Oil cooler Shell and plate type (multiple-plate type)
Grade API classification CD, CD/SF, CE, CE/SF, CF-4
Engine oil Oil pan Approx. 11 {11}, 12 {12}, 16 {16}, 28 {28},
Quantity dm3 {L}
Oil filter Approx. 2.3 {2.3}
12-2
1. Lubrication System
1 Engine oil pressure switch 9 Oil pump 19 Camshaft bushing

2 Main oil gallery 10 Oil strainer 20 Rocker bushing
3 Bypass valve 11 Regulator valve 21 Roller
4 Oil cooler 12 Crankshaft main bearing 22 Valve bridge
5 Engine oil bypass alarm 13 Connecting rod bearing 23 No.1 Idler shaft
switch 14 Connecting rod bushing 24 No.2 Idler shaft
6 Full-flow filter element 15 Check valve for oil jet 25 No.3 Idler shaft
7 Bypass filter element 16 Piston 26 Turbocharger
8 Relief valve (built into oil 17 Air compressor 27 Oil pan
pump) 18 Timing gear
2. Oil Pump
• This engine uses a gear-type oil pump
driven by the rotation of the crankshaft
transmitted through the engagement
of the crankshaft gear and the oil
pump gear.
• The oil pump has a relief valve, which
prevents excessive pressure from
building up inside the lubricating sys-
tem by allowing part of the engine oil
to escape to the oil pan when the oil
pressure exceeds a specified level.
12-3
3. Oil Cooler
3.1 Bypass valve

• When the engine oil is cool and its vis-
cosity is high, or when the oil cooler el-
ement becomes clogged and restricts
the flow of the engine oil, the bypass
valve opens to let the engine oil by-
pass the oil cooler and flow directly to
the oil filter.
3.2 Engine oil pressure switch and

regulator valve
• When the pressure of the engine oil to
the main oil gallery drops below the
specified level, an electrical contact in-
side the engine oil pressure switch
closes. This causes a warning lamp on
the meter cluster to illuminate and no-
tify the operator of the excessive pres-
sure drop.
• When the oil pressure in the main oil
gallery exceeds the specified level, the
regulator valve opens to adjust the oil
pressure by allowing part of the en-
gine oil to escape to the oil pan.

Phone: 1 269 673 1638
12-4
12
4. Oil filter
• This oil filter is a spin-on paper-filter
type that incorporates both a full-flow
filter and a bypass filter.
4.1 Engine oil bypass alarm switch

• If the oil filter elements clog up, this
will restrict the flow of engine oil, caus-
ing the engine to seize. To prevent
this, the oil filter is provided with the
engine oil bypass alarm switch.
• If the oil filter clogs up, the engine oil
bypass alarm switch trips in such a
way as to direct the engine oil straight
on to the oil cooler, bypassing the full-
flow and bypass filter elements. When
the switch trips, the relevant warning
lamp illuminates to alert the operator
to the clogged oil filter.
12-5
5. Lubrication of Engine Components
• The engine oil in the main oil gallery lubricates the engine components in the following ways.
5.1 Main bearing and connecting rod bearing
• Engine oil supplied through an oil passage in the crankshaft lubricates the big end (connecting rod bearing) of
each connecting rod. Simultaneously, engine oil supplied through an oil passage in the connecting rod lubricates
the connecting rod’s small end (connecting rod bushing).
5.2 Timing gears
• Engine oil in the main oil gallery is directed through the oil passages in the crankcase and cylinder head and is
used to lubricate the various gear shafts. After lubricating the gear shafts, the oil is used to lubricate the gears be-
fore returning the oil pan.
12-6
12
5.3 Valve mechanism
• Engine oil in the main oil gallery is directed through the oil passages in the cylinder head, rocker case and front
rocker bracket. The oil is then supplied through the camshaft and rocker shaft. The oil flowing through the cam-
shaft also lubricates the camshaft journals. The oil flowing through the rocker shaft also lubricates the rockers.
The oil flowing to the adjusting screws on the rockers also lubricates the valve bridges. After lubricating the vari-
ous parts, the oil returns to the oil pan.
5.4 Check valves and oil jets

• An oil jet is fitted in the lower part of
the main oil gallery for each cylinder.
• Engine oil is sprayed out of the oil jet
into the piston to cool the piston.
• Each oil jet is fitted with a check valve
that opens and closes at predeter-
mined oil pressure levels. At low en-
gine speeds, the check valve closes to
maintain the required volume of oil in
the lubrication system and prevent re-
ductions in oil pressure.

Phone: 1 269 673 1638
12-7
5.5 Turbocharger
• Engine oil in the main oil gallery is di-
rected through a pipe to the bearing
housing to lubricate the inner compo-
nents.
• A piston ring is provided on each end
of the turbine wheel shaft. The rings
function as oil sealing.
5.6 Air compressor

• Engine oil in the main oil gallery is di-
rected through a passage in the crank-
shaft to the supply pump coupling and
also to the big ends of the connecting
rods to lubricate these parts.
At the same time, the pistons and the
small ends of the connecting rods are
splash-lubricated with engine oil by
the rotating crankshaft.
12-8
TROUBLESHOOTING 12
Symptoms
Excessive oil consumption (oil leakage)

Engine is difficult to start
Reference Gr
Low oil pressure

Overheating
Possible causes
Incorrectly mounted element O O O
Defective gasket O O O
Defective O-ring O O O
Oil cooler
Clogged element O O
Damaged element O O O
Weakened bypass valve spring O
Malfunctioning oil pump O O
Interference between oil pump gear and oil pump case
O O
and/or cover
Oil pump
Incorrectly connected oil pipe O O
Clogged oil strainer O O
Weakened relief valve spring O
Incorrect installation O
Oil filter Clogged element O O
Defective O-ring O
Front cover timing gear Defective front oil seal O
case Incorrectly mounted front cover O
Gr11
Defective rear oil seal O
Flywheel housing
Incorrectly mounted gasket O
Weakened regulator valve spring O
Defective piston cooling oil jet(s) O
Oil working its way up into combustion chamber(s) through piston rings O
Gr11
Oil working its way down into combustion chamber(s) through valves O
Too high oil viscosity O
Poor oil quality O
Deterioration of oil O
Excess of oil O
Fuel mixed with oil O
12-9
1. Oil Filter Replacement
– Drain plug (oil filter) 7.8 ± 2.0 {0.8 ± 0.2} –

Engine oil
Approx. 2.3 dm3
– Oil filter API classification CD, CD/SF, CE,
{2.3L}
CE/SF, CF-4
Special tools
Oil filter wrench MH061537 Removal of oil filter
WARNING
• Wipe up any spilled engine oil, as it can cause fires.
CAUTION
• Make sure not to put any engine oil on the V-belt when working on the oil filter. V-belts soiled with oil or
grease may easily slip, resulting in deteriorated performance of the cooling system.
[Removal]
• Remove the drain plug and drain the oil out of the oil filter.
• Remove the oil filter using .
12-10
12
[Installation]
• Clean the surface of the oil filter head where the oil filter is to be
mounted.
• Apply a thin coat of engine oil onto the oil filter gasket.
• Screw in the oil filter by hand until the gasket contacts the oil fil-
ter head. Tighten further by 1 1/8 to 1 3/8 of a turn.
• Install the drain plug.
• With the oil filter installed, start the engine and ensure that there
is no oil leakage through the gasket.
• If oil is leaking, remove and reinstall the oil filter.
• Stop the engine and check the engine oil level.
• Add engine oil if the engine oil level is low.
12-11
2. Engine Oil Replacement
– Drain plug (oil filter) 7.8 ± 2.0 {0.8 ± 0.2} –
– Drain plug (oil pan) 69 {7} –

Approx. 2.3 dm3
– Oil filter
{2.3L}
Engine oil Approx. 11 dm3
API classification CD, CD/SF, CE, {11L}, 12 dm3
– Oil pan CE/SF, CF-4 {12L}, 16 dm3
{16L}, 28 dm3
{28L}
WARNING
CAUTION
• Make sure not to put any engine oil on the V-belt when working on the oil filter. V-belts soiled with oil or
grease may easily slip, resulting in deteriorated performance of the cooling system.
[Draining]
• Remove the filler cap.
• Remove the drain plugs of the oil filter or oil pan to drain out the
engine oil.
[Refilling]
• Tighten the drain plug to the specified torque, then pour a speci-
fied amount of new engine oil into the engine.
CAUTION
• Do not add engine oil too much. An excessive oil level can
only lead to increased oil consumption or make the positive
crankcase ventilation system less efficient.
12-12
12
3. Oil Pressure Measurement
Service standards
49 kPa
145 to 295 kPa
No-load minimum speed {0.5 kgf/
Oil pressure (oil tempera- {1.5 to 3 kgf/cm2}
– cm2} Inspect
ture at 70 to 90°C)
295 to 490 kPa 195 kPa
No-load maximum speed
{3 to 5 kgf/cm2} {2 kgf/cm2}

Sealant
– Engine oil pressure switch 15 to 22 {1.5 to 2.2}
With cold engine

– Engine oil pressure switch threads Teflon tape 3 1/2 turns
• Remove the engine oil pressure switch.
• Using an adapter, connect an oil pressure gauge to the engine

oil pressure switch mounting hole.
• Warm up the engine until the oil temperature reaches 70 to
90°C.
• Measure the oil pressure while running the engine at a minimum
speed and then at maximum speed, both under no load.
• If the measurements are below the specified limits, overhaul the
lubrication system.
• After taking the measurements, wrap the threads of the engine
oil pressure switch with teflon tape and then tighten the switch to
CAUTION
• Reinstall the oil pressure switch only when the engine is
cold.
12-13
OIL PAN, OIL JETS AND OIL LEVEL SENSOR
1 Drain plug
2 Oil pan
3 Check valve
4 Oil jet
: Locating pin
Assembly sequence
verse.
CAUTION
• If overtightened, the check valve
will not operate properly, leading to
engine seizure. Be sure to tighten
the check valve to the specified
torque.

Drain plug 69 {7} –
Check valve 34 {3.5} –

Crankcase mounting surface of oil pan ThreeBond 1207C As required
12-14
12
Installation: Oil pan
• Clean the mating surfaces of each part.
• Apply a bead of sealant to the mating surface of the oil pan
evenly and without any breaks.
• Change the amount of application to A and B at four locations
shown in the illustration.
• Mount the oil pan within three minutes of applying the sealant.
Make sure that the sealant stays in place.
CAUTION
• Do not start the engine for one hour after installation. If the
oil pan mounting bolts were loosened or removed, be sure
to reapply sealant.
12-15
OIL PUMP, OIL STRAINER
1 Oil strainer 8 Relief valve 15 Oil deflector
2 Gasket 9 Relief valve spring
3 Oil pipe 10 Washer a: Crankshaft gear
4 Gasket 11 Gear and case
*b: Oil pump gear
5 Cover 12 Shim
*
6 Driven gear 13 Shim : Locating pin
7 Ring 14 Gasket : Non-reusable parts
• The oil strainer, the oil pipe and the oil pump must all be removed together as an assembly.
• Do not disassemble the oil pump unless defects are evident.
• The gear and case assembly is not serviceable. If the gear and case assembly appears defective, replace it.
Assembly sequence
Follow the disassembly procedure in reverse.

5, 11 Clearance between drive gear shaft and cover 0.04 to 0.07 0.15 Replace
Clearance between driven gear shaft and case, and
5, 6, 11 0.04 to 0.07 0.15 Replace
that between the shaft and cover
Clearance between case and tooth tips of each gear 0.10 to 0.19 0.2
6, 11 Replace
Difference between case depth and height of each gear 0.06 to 0.11 0.15
1.1 ± 0.1 MPa
8 Relief valve opening pressure – Replace
{11 ± 1 kgf/cm2}
9 Relief valve spring installed load (installed length: 30) 84N {8.6 kgf} – Replace
a, b Backlash between crankshaft gear and oil pump gear
* * 0.08 to 0.15 0.35 Adjust

Bolt (oil pump cover mounting) 25 ± 4.9 {2.5 ± 0.5} –
12-16
12
Inspection: Backlash between oil pump gear and crankshaft
gear
• If the measurement exceeds the limit, adjust by shimming.
Shim feeler Change in backlash
0.1 mm 0.073 mm
0.2 mm 0.146 mm
CAUTION
• Perform shimming such that the shim packs on both sides
will have the same feeler.
Inspection: Driven gear, Gear and case assembly
• Perform the following inspections. Replace the defective part(s)
as required.
(1) Difference between case depth and height of each gear
(2) Clearance between case and tooth tips of each gear
(3) Clearance between drive gear shaft and cover

(4) Clearance between driven gear shaft and case, and that
between the shaft and cover
12-17
OIL FILTER
Removal sequence
1 Drain plug
2 Oil filter
3 Engine oil bypass alarm switch
4 O-ring
5 Oil filter head
6 Gasket
Installation sequence
Follow the removal sequence in reverse.
WARNING
• To avoid any risk of burns, take care not to touch the engine oil when the engine is hot.
CAUTION
• When adding engine oil, be careful not to allow engine oil to smear the V-belt. A V-belt smeared with oil
will slip, resulting in reduced cooling efficiency.

Drain plug 7.8 ± 2 {0.8 ± 0.2} –
Engine oil bypass alarm switch 49 ± 4.9 {5.0 ± 0.5} –
Bolt (Oil filter head mounting) 37 to 53 {3.6 to 5.4} –

Oil filter gasket
O-ring
12-18
12
[Removal]
• Remove the drain plug and drain the oil out of the oil filter.
• Remove the oil filter using .
[Installation]
• Clean the surface of the oil filter head where the oil filter is to be
mounted.
• Apply a thin coat of engine oil onto the oil filter gasket.
• Screw in the oil filter by hand until the gasket contacts the oil fil-
ter head. Tighten further by 1 1/8 to 1 3/8 of a turn.
• Install the drain plug.
• With the oil filter installed, start the engine and ensure that there
is no oil leakage through the gasket.
• If oil is leaking, remove and reinstall the oil filter.
12-19
OIL COOLER
Removal sequence
1 Bypass valve
2 O-ring
3 Plug
4 O-ring
5 Plug
6 O-ring
7 Engine oil pressure switch
8 Regulator valve
(See later pages.)
9 O-ring
10 Plug
11 O-ring
12 Plug
13 O-ring
14 Oil cooler element
15 Gasket
16 Oil cooler cover
17 Gasket
18 O-ring
Air leakage from oil cooler element (air pressure: 1470
14 0 cm3 {0 mL} – Replace
kPa {15 kgf/cm2})

Bypass valve 15 to 20 {1.5 to 2.0} –
Nut (oil cooler element mounting) 24.5 to 32.3 {2.5 to 3.3} –
Engine oil pressure switch 15 to 22 {1.5 to 2.2} –
Regulator valve 98 to 118 {10 to 12} –
Plug 14.7 to 19.6 {1.5 to 2.0} –

Mark Points of application Lubricant and/or sealant Quantity
Engine oil pressure switch threads Teflon tape 3 1/2 turns
Inspection: Oil cooler element
• Plug the outlet of the oil cooler element and connect a hose to
the engine oil inlet port. Then, immerse the oil cooler element in
a tank of water.
• Apply a specified air pressure for 15 seconds through the hose,
and check for any air leaks.
• Replace the element if it leaks air.
12-20
REGULATOR VALVE 12
1 Snap ring
2 Valve
3 Spring
4 Body
Assembly sequence

392 ± 29 kPa
– Regulator valve opening pressure – Replace
{4.0 ± 0.3 kgf/cm2}
78.5 ± 1.96 N
3 Spring installed load (installed length 48.3) – Replace
{8.0 ± 0.2 kgf}

Phone: 1 269 673 1638
12-21
GROUP 13A
FUEL AND ENGINE CONTROL
SPECIFICATIONS ............................................................................ 13A-2

1. Fuel System (Flow of Fuel) ........................................................ 13A-3 13A
2. Fuel Filter .................................................................................. 13A-4
3. Water separator ..........................................................................13A-5
TROUBLESHOOTING ..................................................................... 13A-6

1. Air-bleeding of Fuel System....................................................... 13A-8
2. Fuel Filter Replacement ................................................................ 13A-10
3. Water Separator Element Replacement ................................... 13A-12
FUEL FILTER ................................................................................. 13A-14
WATER SEPARATOR .................................................................... 13A-16
COMMON RAIL...............................................................................13A-20
SUPPLY PUMP ...............................................................................13A-22
INJECTOR.......................................................................................13A-24

Phone: 1 269 673 1638
13A-1
SPECIFICATIONS
Item Specifications
Manufacturer DENSO
Control system Electronically-controlled pump
Supply pump
Type HP-4
Feed pump type Trochoid pump
Manufacturer DENSO
3
Common rail capacity cm {mL} 26 {26}
Common rail system Pressure limiter valve
221 ± 9 {2253 ± 91.8}
opening pressure MPa {kgf/cm2}
Common rail pressure
5
sensor supply voltage V
Manufacturer DENSO
Control system Electronically controlled
Injector
Maximum injection
155 {1580}
pressure MPa {kgf/cm2}
13A-2
STRUCTURE AND OPERATION 13A
1. Fuel System (Flow of Fuel)
• Fuel in the fuel tank is sucked up by the feed pump, which is driven by the pump camshaft within the supply
pump, and is fed through the fuel filter where foreign matter is filtered out.
• The filtered fuel is sent to the supply pump where it is pressurized, and then is accumulated in the common rail.
The accumulated fuel is then delivered through the injectors into the combustion chambers.
• If fuel leakage occurs through any of the fuel line connections between the common rail and injectors, the relevant
flow damper(s) will close, shutting off fuel supply and thus preventing any further fuel leakage out of the system.
• If the pressure of fuel in the common rail rises above the specified level, the pressure limiter valve opens to allow
fuel to return to the fuel tank.
• If the pressure of fuel in the supply pump rises above the specified limit, fuel is allowed to returned to the fuel tank.
13A-3
2. Fuel Filter
• The fuel filter removes foreign matter from fuel via the filter element. The fuel filter also incorporates a water sep-
arator which separates any water from fuel.
• Water separated from fuel accumulates at the bottom of the fuel filter assembly. When water has accumulated to
a certain level, this is detected by the water separator sensor, provided on the fuel filter assembly, which then illu-
minates a warning lamp on the meter cluster.
• The water which has collected in the water separator can be drained through the drain hole by loosening the wa-
ter separator sensor.
• To bleed air from the fuel system, a manually operated pump is provided on the fuel filter head.
13A-4
13A
3. Water separator
• The water separator separates water
in fuel.
• The float provides visual indication of
the level of the water separated from
fuel. This enables the water to be
drained at an appropriate timing
through the drain hole by loosening
the drain plug.
13A-5
TROUBLESHOOTING
Symptoms
Engine does not reach maximum speed

Engine stalls immediately after start
Engine maximum speed too high
Engine output not sufficient
Reference
Warning lamp illuminates

Excessive black smoke
Gr
Engine output unstable
Fuel supply insufficient

Engine idling unstable
Engine does not start
Engine hard to start
Engine knocks
Possible causes
Common rail system abnormal O Gr13E
Defective feed pump O O O O O O
*
Incorrect pump output O O O O O
*
Supply pump
Defective pressurized-fuel delivery system O O O O O
*
Defective SCV; Defective base supply pump O O O O O
*
SCV open-circuited, short, or intermittent connec-
O O O O O O Gr13E or
tion *
Defective sealing O O O
*
Pressure limiter valve opening pressure too low O O O O O
Operation of flow damper O O
Common rail Common rail pressure sensor circuit open, short, or
O O O O O O O Gr13E
intermittent connection
Defective sealing O O O O
Injector magnetic valve open-circuited, short, or in-
O O O O O O O Gr13E or
Incorrect
termittent connection *
injector fuel Defective injector, injector magnetic valve, or injec-
O O O O O O O
injection tion nozzle *
Orifice clogged O O O O
Fuel filter clogged O O O O O O O
Clogged water separator O O O O O
No fuel in fuel tank O O O O O O
Defective sealing or sealing surface O O O O
High-pressure Piping cracked O O O O O O
piping Piping crushed and restricted O O O O
Foreign matter stuck in piping O O O O
Low-pressure Defective sealing or sealing surface O O O O O O
piping Piping cracked or clogged O O O O O O
Air or water in fuel system O O O O O O O
Poor quality fuel is used O O O O O O O
Incorrectly adjusted accelerator pedal stopper bolt O O
Engine control
Defective accelerator position sensor O Gr13E
SCV: Suction Control Valve
: Contact DENSO Service Station for repair.
*
13A-6
13A
Symptoms
Engine does not reach maximum speed

Engine stalls immediately after start
Engine maximum speed too high
Engine output not sufficient
Reference
Warning lamp illuminates

Excessive black smoke
Gr
Fuel supply insufficient

Engine idling unstable
Engine does not start
Possible causes
Oil viscosity unsuitable O O Gr12
Valve clearance incorrect O O
Defective cylinder head gasket O O
Valve and valve seat worn and carbon deposits O O
Valve spring fatigued O O
Gr11
Piston ring worn and damaged O O
Piston ring groove worn and damaged O
Piston and cylinder liner worn O O
Crankshaft incorrectly sized O O O O
Cooling system malfunction O O Gr14
Defective starter switch O O O O
Defective glow relay O O
Engine speed Defective sensor; Sensor open-circuited, short, or intermit-
O O O O O O Gr13E
sensor; Cylinder tent connection
recognition
sensor Each sensor improperly mounted O O O O O Gr11
Defective boost pressure sensor; Boost pressure sensor open-circuited, short
O O O
or intermittent connection
Defective coolant temperature sensor; Coolant temperature sensor open-cir-
O O O
cuited, short, or intermittent connection
Defective fuel injection volume adjusting resistor; Resistor open-circuited,
O O O
short, or intermittent connection
Defective idling speed adjustment knob; Idling speed adjustment knob open- Gr13E
O O
circuited, short or intermittent connection
Defective electronic control unit main power relay; Relay open-circuited, short
O O O
or intermittent connection
Engine Defective electronic control unit O O O O O O O O
electronic
control unit Not yet initialized for supply pump unit difference O O O O
Dead battery O O O O
Alternator malfunction O O O
Blown fuse O O O
13A-7
1. Air-bleeding of Fuel System
– Plug 10 ± 2 {1 ± 0.2} –
• Loosen one of the bleeder plugs on the fuel filter.

• Feed the system with fuel by manually operating the pump up
and down.
• Continue pumping until fuel with no bubbles of air comes out of
the bleeder plug.
• With no air bubbles coming out with fuel, tighten the bleeder
plug to the specified torque.
• Continue operating the pump until there is strong pumping resis-
tance.
CAUTION
• If the fuel is cold, pumping resistance may not become
strong. Even if this is the case, be sure to cycle the pump
several times.
• Wipe up all spilled fuel, then start the engine.

• Check that no fuel leakage occurs.
WARNING
• Fuel is highly flammable. Keep it away from flames and
sources of heat.
• Be sure to wipe up all spilled fuel. Unless it is wiped up, it
could catch fire.
13A-8
13A
M E M O
13A-9
2. Fuel Filter Replacement
– Water separator sensor 5 ± 1 {0.5 ± 0.1} –
– Case 30 ± 2 {3.1 ± 0.2} –

Location Points of application Specified lubricant and/or sealant Quantity
– O-ring Engine oil As required
Special tools
Filter wrench MH063203 Removal and installation of case
[Removal]
• Drain fuel from the case by loosening the water separator sen-
sor.
• Using , remove the case.
WARNING
• Fuel is highly flammable. Keep it away from flames and
sources of heat.
• Thoroughly wipe up any spilled fuel. Otherwise, it may
catch fire.
CAUTION
• Be careful not to damage the case.
13A-10
13A
[Installation]
• Clean the surface of the fuel filter head where the O-ring is to be
mounted.
• Replace the filter element and O-rings with new parts.

• Apply a thin coat of engine oil to the O-rings. Install the O-rings
onto the case and water separator sensor.
CAUTION
• The use of non-genuine filter elements will lead to engine
problems. Be sure to use only genuine parts.
• To help prevent fuel injection problems, keep the fuel filter
and hoses free from contamination.
• Using , tighten the case to the specified torque.

• Tighten the water separator sensor to the specified torque. With
the sensor correctly installed, bleed air from the fuel system.
• Start the engine and ensure that there is no fuel leakage.
• If there is fuel leakage, remove and install the fuel filter correctly.
13A-11
3. Water Separator Element Replacement
Tightening Torque (Unit: N·m {kgf·m})

– Drain plug 1.47 ± 0.3 {0.15 ± 0.03} –
– Cover 19.6 ± 2.5 {2.0 ± 0.3} –
– Plug A 12.3 ± 2.5 {1.25 ± 0.3} –
– Plug B 17.2 ± 2.5 {1.75 ± 0.3} –

Special tools
Filter wrench MH063201 Removal and installation of cover
[Removal]
• Loosen the plugs A and B, then loosen the drain plug to let out
the fuel in the water separator.
• Remove the cover using the .
WARNING
• Fuel is highly inflammable. Keep open flame and heat
source away from it.
• Spilled fuel can easily catch a fire. Wipe it off completely.
CAUTION
• Be careful not to damage the cover.
13A-12
13A
[Installation]
• Clean the O-ring contact surface of the water separator body
and the O-ring fitting groove in the cover.
• Replace the element and O-ring with new ones.

• Apply a thin coat of engine oil to the O-ring and fit the O-ring
onto the cover.
CAUTION
• The use of inappropriate element can lead to engine prob-
lems. Be sure to use a genuine element.
• To prevent fuel injection problems, keep the water separator
and fuel hoses clear of fine dirt and other foreign matter.
• Using the with a torque wrench attached to it, tighten the

cover to the specified torque.
• Tighten the drain plug, plug A and plug B to the specified torque.
Then, bleed the fuel system of trapped air.
• If there is any fuel leakage, remove the water separator and re-
install it correctly.
13A-13
FUEL FILTER
1 Fuel hose
2 Water separator sensor
3 O-ring
4 Case
5 O-ring
6 Element
7 Plug
8 Fuel filter head
WARNING
• Fuel is highly flammable. Keep it
away from flames and sources of
heat.
• Thoroughly wipe up any spilled fu-
el. Otherwise, it may catch fire.
Assembly sequence
verse.

Water separator sensor 5 ± 1 {0.5 ± 0.1} –
Case 30 ± 2 {3.1 ± 0.2} –
Plug 10 ± 2 {1 ± 0.2} –

Special tools
Filter wrench MH063203 Removal and installation of case
Removal procedure
Removal: Case
• Drain fuel from the case by loosening the water separator sen-
sor.
• Using , remove the case.
CAUTION
13A-14
13A
Installation: Case
• Clean the surface of the fuel filter head where the O-ring is to be
mounted.
• Replace the filter element and O-rings with new parts.

• Apply a thin coat of engine oil to the O-rings. Install the O-rings
onto the case and water separator sensor.
CAUTION
• The use of non-genuine filter elements will lead to engine
problems. Be sure to use only genuine parts.
• To help prevent fuel injection problems, keep the fuel filter
and hoses free from contamination.
• Using , tighten the case to the specified torque.

• Tighten the water separator sensor to the specified torque. With
the sensor correctly installed, bleed air from the fuel system.
• If there is fuel leakage, remove and install the fuel filter correctly.
13A-15
WATER SEPARATOR
1 Fuel hose
2 Plug A
3 O-ring
4 Plug B
5 O-ring
6 Drain plug
7 O-ring
8 Cover
9 O-ring
10 Float
11 Element
12 Body
WARNING
heat.
• Thoroughly wipe up any spilled fu-
el, otherwise it may catch fire.
Assembly sequence
verse.

Plug A 12.3 ± 2.5 {1.3 ± 0.3} –
Plug B 17.2 ± 2.5 {1.8 ± 0.3} –
Drain plug 1.47 ± 0.3 {0.15 ± 0.03} –
Cover 19.6 ± 2.5 {2.0 ± 0.3} –


Filter wrench MH063201 Removal and installation of cover
13A-16
13A
Removal procedure
Removal: Fuel filter
• Drain fuel from the cover by loosening the drain plug after loos-
ening the plug A and B.
• Remove the cover using .
CAUTION
Installation: Cover
• Clean the O-ring contact surface of the water separator body
and the O-ring fitting groove in the body.
• Replace the element and O-ring with new ones.

• Apply a thin coat of engine oil to the O-ring and fit the O-ring
onto the cover.
CAUTION
• The use of an inappropriate element can lead to engine
problems. Be sure to use a genuine element.
• To prevent fuel injection problems, keep the water separator
and fuel hoses clear of fine dirt and other foreign matter.
13A-17
WATER SEPARATOR
• Using the with a torque wrench attached to it, tighten the
cover to the specified torque.
• Tighten the drain plug, plug A and plug B to the specified torque.
Then, bleed the fuel system of trapped air.
• If there is any fuel leakage, remove the water separator and re-
install it correctly.
13A-18
13A
M E M O
13A-19
COMMON RAIL
1 Fuel temperature sensor 7 Fuel overflow pipe 13 Common rail
2 O-ring 8 Fuel pipe
3 Eyebolt 9 Injection pipe *a: Crankcase
4 Fuel return pipe 10 Flow damper : Non-reusable parts
5 Connector 11 Pressure limiter
6 Eyebolt 12 Common rail pressure sensor
WARNING
• Fuel is highly flammable. Do not handle it near flames or heat.
• Spilled fuel may catch fire and therefore, must be wiped up completely.
• Any contamination of the common rail, even if it is minor, will greatly affect the performance of the en-
gine. After removing pipes or other parts, plug the openings with covers. Wash eye bolts and gaskets in
light oil and keep them away from contaminants.
• For the maintenance of the common rail, ask Denso Service Station.
Assembly sequence
Phone: 1 269 673 1638
13A-20
13A
Fuel temperature sensor 17.6 to 21.5 {1.8 to 2.2} –
Eyebolt (for fuel return pipe mounting) 25 {2.6} –
Eyebolt (for fuel overflow pipe mounting) 17.7 to 22.6 {1.8 to 2.3} –
Fuel pipe 49 to 58.8 {5.0 to 6.0} –
Injection pipe 39.2 to 49 {4.0 to 5.0} –
Flow damper
160 to 190 {16 to 19} –
Pressure limiter
Common rail pressure sensor 98 {10} –

Threads and end face of common rail pressure sensor DENSO Grease 5 As required
Installation: Common rail pressure sensor
• Apply grease onto the threaded portion and end face of the sen-
sor.
CAUTION
• Do not touch the connector terminal of the common rail
sensor.
Installation: Injection pipe and fuel pipe

• Ensure that the pipe and mounting surfaces of the connector are
flat and free from damage.
• Bring the pipe into intimate contact with mounting surfaces of
the connector evenly, and temporarily tighten it without applying
an excessive force.
• Tighten it to the specified torque after temporary tightening.
13A-21
SUPPLY PUMP
1 Eyebolt 6 Supply pump bracket *a: Air compressor
2 Fuel return pipe 7 Supply pump *b: Fuel temperature sensor
3 Eyebolt 8 Driving disc *c: Suction control valve
4 Fuel suction pipe 9 O-ring
5 Fuel pipe 10 Key : Non-reusable parts
WARNING
• Fuel is highly flammable. Do not handle it near flames or heat.
• Spilled fuel may catch fire and therefore, must be wiped up completely.
CAUTION
• Any contamination of the supply pump, even if it is minor, will greatly affect the performance of the en-
gine. After removing pipes, hoses, or other parts, plug the openings with covers. Wash eye bolts and gas-
kets in light oil and keep them away from contaminants.
• For the maintenance of the supply pump, ask Denso Service Station.
Assembly sequence
13A-22
13A
CAUTION
• If the supply pump has been replaced, perform the “initialization of supply pump unit difference learning
value” using Multi-Use Tester in order to clear the correction data (learned pump unit difference) from the
engine electronic control unit. (See Gr13E.)

Fuel pipe 39.2 to 49 {4.0 to 5.0} –
Eyebolt (for fuel return pipe mounting) 7.9 to 12.7 {0.8 to 1.3} –
Eyebolt (for fuel suction pipe mounting) 14.8 to 19.6 {1.5 to 2.0} –

Installation: Supply pump
• Position the No. 1 piston to the top dead center in the compres-
sion stroke in the following manner.
• Crank the engine to align the pointer with the “1 6” mark on
the flywheel.
• This will bring either the No. 1 piston or the No. 6 piston to the
top dead center in the compression stroke. If both the inlet
and exhaust rockers can be moved by hand by the amount of
valve clearance, that cylinder is at the top dead center in the
compression stroke. From that position, every turn of the
crankshaft will alternately bring the No.1 and No. 6 pistons to
the top dead center in the compression stroke. (See Gr11.)
• Install the supply pump while ensuring that the stamped line on
the supply pump timing cover is aligned with the stamped line on
the coupling block.

an excessive force.
13A-23
INJECTOR
1 Injection pipe
2 Injection pipe seal
3 O-ring
4 Nozzle bridge
5 Injector
6 O-ring
7 O-ring
8 Nozzle tip gasket
9 Eye bolt
10 Fuel return pipe
*a:: Two-Way electromagnetic Valve

Non-reusable parts
WARNING
heat.
• Be sure to wipe up all spilled fuel.
Unless it is wiped up, it could catch
fire.
CAUTION
• To eliminate fuel injection and other problems, protect the injectors and pipes, that have been removed,
from the ingress of contaminants.
• For the maintenance of the injector, ask Denso Service Station.
Assembly sequence
CAUTION
• Do not attempt to clean the nozzle hole with a wire brush or other similar tools, or the hole can be dam-
aged.
• Be sure to tighten the nozzle bridge bolts to the specified torque. Overtightening the bolts can deform the
injectors, resulting in incorrect fuel injection.

Bolt (for mounting nozzle bridge) 33 to 38 {3.4 to 3.9} –
Injection pipe 39.2 to 49 {4.0 to 5.0} –
Eyebolt (for mounting fuel return pipe) 25 {2.6} –

13A-24
13A
Injector extractor Removing injector

adapter MH062560
(use with MH061071)
Nozzle extractor
A MH061071 Removing injector
M8 ∞ 1.25
Removal procedure
Removal: Injector
• Using and and with the wire of engaged in the
groove on the injector, remove the injector.

an excessive force.

Phone: 1 269 673 1638
13A-25
GROUP 13E ELECTRONICALLY
CONTROLLED FUEL SYSTEM
SPECIFICATIONS ............................................................................ 13E-2

1. Overview .................................................................................. 13E-4
2. Electronic Control System ...................................................... 13E-12
3. Electronic Control Unit Connection Diagram .......................... 13E-18
13E
TROUBLESHOOTING
1. Diagnostic Procedure ................................................................... 13E-20
2. Diagnostic Precautions ................................................................ 13E-21
3. Inspections Based on Diagnostic Codes ................................... 13E-22
4. Multi-Use Tester Service Data ................................................. 13E-37
5. Reading and Erasing Diagnostic Trouble Codes ....................... 13E-39
6. Actuator Tests Performed Using Multi-Use Tester ..................... 13E-41
7. Initialization of Supply Pump Unit Difference Learning Value
in Engine Electronic Control Unit ................................................ 13E-43
8. Inspections Performed at Electronic Control Unit
Connectors ............................................................................. 13E-44
INSPECTION OF ELECTRICAL EQUIPMENT ............................. 13E-47
13E-1
SPECIFICATIONS
Item Specification
Manufacturer DENSO
Model HP-4
Control method Electronic type
Supply pump
Feed pump type Trochoid type
SCV (suction control valve) Rated voltage V 24
Max. common rail pressure MPa {kgf/cm2} [psi] 155 {1580} [22473]
Manufacturer DENSO
3
Common rail volume cm {mL} 26 {26}
Common rail 2}
Pressure limiter opening pressure MPa {kgf/cm 221 ± 9 {2250 ± 92}
Common rail pressure sensor supply voltage V 5
Manufacturer DENSO
Control method Electrical type
Injectors
Max. operating pressure MPa {kgf/cm2} [psi] 155 {1580} [22473]
Min. operating pressure MPa {kgf/cm2} [psi] 24 {245} [3485]
Engine electronic con- Manufacturer DENSO

trol unit Rated voltage V 24
13E-2
13E
M E M O
13E-3
1. Overview
• In the common rail system, an electronic control unit monitors various aspects of the engine (engine speed, throt-
tle opening, coolant temperature, etc.) using information from sensors. In accordance with these data, the elec-
tronic control unit effects control over the fuel injection quantity, fuel injection timing, and fuel injection pressure in
order to optimize the engine’s operation.
• The electronic control unit has a diagnostic function that enables it to recognize abnormalities in the common rail
system’s major components and alert the driver to them.
• The common rail system consists mainly of an electronically controlled supply pump; injectors; a common rail;
and the electronic control unit and sensors that are used to control the other components.

Phone: 1 269 673 1638
13E-4
13E
• When the engine is cranked by means of the starter switch, the feed pump (this is located inside the supply pump)
simultaneously draws fuel from the fuel tank and feeds it via the water separator and fuel filter to the SCV (suction
control valve). A quantity of fuel metered by the SCV (suction control valve) is supplied via the inlet valves to the
plunger chambers.
• The fuel in the plunger chambers is pressurized. The outlet valves are then opened, and the fuel is fed under
pressure to the common rail.
• The pressurized fuel is held in the common rail and then uniformly fed to the injectors.
• In response to signals from the engine electronic control unit, a solenoid valve in each injector causes the injector
to inject fuel into the relevant combustion chamber at the optimal timing and in the optimal quantity.
13E-5
1.1 Supply pump
13E-6
13E
CAUTION
• Be sure to connect the SCV (suction control valve) connector to the engine harness before starting the
engine. If the engine is started with the SCV (suction control valve) connector not connected, control of
the supply pump by the engine electronic control unit would not be possible and a fault would ensue.
• The supply pump pressurizes fuel and supplies it in a highly pressurized state.
• Fuel drawn from the fuel tank by the feed pump is not supplied directly to the plungers. It is supplied first to the
common rail pressure solenoid valve, which controls the amount of fuel reaching the plungers.
• If the fuel pressure exceeds a certain level, the regulating valve returns fuel to the inlet side of the feed pump. This
operation keeps the pressure of the fuel fed to SVC (suction control valve), constant.
• Rotation of the camshaft causes (via the ring cam) up-down movement of the plungers. Fuel in the plunger cham-
bers is thus highly pressurized.
(1) SCV (suction control valve)

• The SCV (suction control valve) receives fuel from the feed
pump and feeds fuel toward the plungers of the supply pump in
such a quantity that the fuel pressure corresponds to that re-
quired by the engine electronic control unit.
• When the SCV (suction control valve) is not operating, i.e., when
current is not flowing, fuel flows at its maximum rate. When cur-
rent flows, the piston in the common rail pressure solenoid valve
is pressed down such that fuel is not fed toward the plungers.
• The engine electronic control unit controls the ratio of current-off
time (duty ratio).
13E-7
1.2 Common rail
• The common rail distributes to the injectors high-pressure fuel that has been fed from the supply pump.
• Each flow damper prevents an abnormal outflow of fuel. It does so by blocking the fuel passage in the event of
fuel leakage from the injection pipe or excessive injection of fuel from the injector.
• The common rail pressure sensor is used in feedback control. It senses the fuel pressure inside the common rail
and feeds a corresponding signal to the electronic control unit.
• If the fuel pressure in the common rail exceeds a certain, set level, the piston in the pressure limiter pushes and
compresses the spring such that fuel is able to escape. The pressure limiting valve thus prevents the fuel pres-
sure from becoming higher than the set pressure.
CAUTION
• When the pressure limiter is activated, the common rail system is faulty and needs an inspection.
(1) Flow damper

• During normal operation, the piston moves (thus pushing and compressing the spring) to the extent necessary for
one injection quantity to pass through. The piston does not make contact with the seat at this time. When injection
is complete, the piston is returned to its initial position by the spring.
• If the amount of fuel passing through the flow damper becomes excessively great, the piston presses against the
seat, thereby closing the fuel passage and preventing an abnormal outflow of fuel.
When the piston has pressed against the seat, it does not return to its original position until the engine has been
stopped and the pressure in the common rail has come down.

Phone: 1 269 673 1638
13E-8
13E
1.3 Injector
• In accordance with electrical signals from the engine electronic control unit, each injector supplies high-pressure
fuel from the common rail to the relevant combustion chamber of the engine at the optimal timing and in the opti-
mal quantity.
• The injector is divided into the control section and the injector section.
• The control section consists of the control chamber, magnet, spring, valve body, valve ball, pressure pin, com-
mand piston, and orifice plate. The pressure pin is located between the control section and the injection sec-
tion.
• The injection section consists of the nozzle body, nozzle needle, nozzle spring, and retaining nut.
13E-9
(1) Operation
(1.1) Injection not taking place
• With the magnet not energized, the
valve body, is pushed up by the spring
in the magnet such that the ball seat is
closed.
• The high-pressure fuel acts upon the
control chamber via orifice plate. The
same pressure acts upon the nozzle
needle.
• The fuel pressure acting on the nozzle
needle cannot overcome the com-
mand piston and nozzle spring, so the
nozzle needle stays in its downward-
pushed position and injection does not
take place.
(1.2) Start of injection

• When the magnet is energized, the re-
sulting electromagnetic force draws
the valve body upward, causing the
ball seat to open.
• Fuel in the control chamber passes
through the orifice plate and ball seat
and flows to the fuel tank.
• With the pressure in the control cham-
ber reduced, the fuel acting on the
nozzle needle overcomes the com-
mand piston and nozzle spring, push-
ing up the nozzle needle such that
injection starts.
• If the magnet remains energized, the
injection rate reaches its maximum
level.
13E-10
13E
(1.3) End of injection
• When energization of the magnet is
stopped, the valve body is pushed
downward by the spring in the magnet
such that the ball seat closes. At this
time, fuel flows into the control cham-
ber via orifice plate, pushing down the
command piston and nozzle needle
such that injection finishes.
13E-11
2. Electronic Control System
2.1 System block diagram
Input signals Engine electronic control unit Output signals

Engine speed sensor Injector magnetic valve
Cylinder recognition sensor Fuel injection control supply pump
(SCV: suction control valve)
Engine
Water temperature sensor

Boost pressure sensor
Warm-up acceleration function Fuel injection quantity control
Common rail pressure sensor
Fuel temperature sensor
Intake air temperature sensor Fuel injection timing control
Fuel injection pressure control
Electronic control unit main power relay
Engine warning lamp

Exhaust gas recirculation valve
control function (See Gr17.)
Tachometer
Glow drive relay
Starter switch
Accelerator pedal position Starter continuous energization
sensor prevention function (See Gr54.) Glow plugs
Accelerator pedal switch
Vehicle speed sensor Pre-heat control function
Vehicle
Fuel injection rate adjustment (See Gr54.)

resistor
Memory clear switch (Connec-
tor) Fault diagnostic function Safety relay
Diagnostic switch (Connector)
Multi-Use Tester connector
Transmission neutral switch Exhaust gas recirculation solenoid
valve
CAN communication
Truck VCM and other

controls
CAN: Controller Area Network
13E-12
13E
Part Main function/operation
Engine speed sensor Sensing of engine speed
Cylinder recognition sensor Cylinder recognition
Senses that the engine is in starting condition with the starter switch in
Starter switch
START position.
Water temperature sensor Sensing of coolant temperature
Accelerator pedal position sensor Sensing of extent of accelerator pedal depression
Sensing of released/depressed condition of accelerator pedal (OFF with ped-
Accelerator pedal switch
al depressed)
Detecting of neutral position in the transmission
Transmission neutral switch
(OFF with the transmission in neutral)
Vehicle speed sensor Sensing of vehicle speed
Fuel temperature sensor Sensing of fuel temperature
Diagnostic switch Output of diagnostic codes
Memory clear switch Deletion of diagnostic codes; output of past diagnostic codes
Fuel injection rate adjustment resistor Correction of fuel injection rate
Boost pressure sensor Sensing of boost pressure
Intake air temperature sensor Sensing of intake air temperature
Multi-Use Tester connector Communication between Multi-Use Tester and common rail system
Common rail pressure sensor Sensing of common rail pressure
Injector magnetic valve Control of fuel injection rate, fuel injection quantity, and fuel injection timing
SCV (suction control valve) Control of fuel injection pressure
Electronic control unit main power relay Power on/off of electronic control unit
Engine warning lamp Indication of system abnormalities
Glow drive relay ON/OFF control of glow plugs
(Tachometer) (Indication of engine speed)
Exhaust gas recirculation solenoid valve Exhaust gas recirculation switching control
Safety relay Control of starter continuous energization prevention function
Engine data recognized by the engine electronic control unit are outputted to
the CAN bus to enable Truck VCM and other controls system to obtain data
CAN communication
needed for control. MVCU system issues signals to the engine electronic
(Truck VCM and other controls)
control unit via the CAN bus to enable it to effect engine control appropriate
for each type of system control.
2.2 Fuel injection control

(1) Pilot injection
• Pilot injection entails the injection of an extremely small amount
of fuel ahead of the main injection.
• Pilot injection suppresses heat generation early in the injection
cycle and thus suppresses NOx generation and noise at the
start of combustion.
13E-13
2.3 Fuel injection quantity control
(1) Fuel injection quantity during engine startup
• During engine startup, the fuel injection quantity is determined in
accordance with the engine speed and coolant temperature.
(2) Basic fuel injection quantity

• The basic fuel injection quantity is determined in accordance
with the engine speed and throttle opening.
(3) Maximum injection quantity

• The maximum injection quantity is calculated from the engine
speed and boost pressure.
(4) Fuel injection rate adjustment resistor correction amount

• To limit inconsistency in the injection quantity, the injection quan-
tity is corrected by the fuel injection rate adjustment resistor.
13E-14
13E
2.4 Fuel injection timing control
(1) Main injection timing
• The main injection timing is calculated from the fuel injection
quantity and engine speed.
(2) Pre injection timing

• The pre injection timing is calculated from the fuel injection
2.5 Fuel injection timing control

• The fuel injection pressure is calculated from the fuel injection
13E-15
2.6 Warm-up acceleration function
Input signals Engine electronic control unit Output signals
Comparison operations
Water temperature sensor
Accelerator pedal position sensor Idling speed control
Idling speed adjustment potentiometer
Target injection quantity
• The warm-up acceleration function increases engine warm-up by varying the engine’s idling speed in accordance
with the engine’s coolant temperature. It can operate either automatically or manually. Selection is made using the
idling speed adjustment potentiometer.
2.7 Starter continuous energizing preventing function

• This function is provided to prevent starter over-run.
• If the starter operates for longer than a predetermined period following engine startup, the Engine electronic con-
trol unit deems that it has been energized continuously for too long. The Engine electronic control unit then stops
the flow of current to the starter and starter relay, thereby preventing the starter from seizing.
• If the engine electronic control unit determines, based on the engine speed signal it receives, that the engine has
run at or above the specified speed for longer than the specified time period after start-up, the unit trips the safety
relay open.
(1) Operation mode
2.8 Preheating function

• This preheating function aims to enhance the engine start up when the engine coolant is low in cold weather or
temperature.
(1) Pre-glow and After-glow
The preheating is operated with a pre-
glow before the engine starts and an af-
ter-glow after the engine starts. They are
controlled by the starter switch (S termi-
nal) signal, engine water temperature
signal and the engine rotation signal.
13E-16
13E
(2) Operation mode
• When the engine coolant temperature
is 60°C or more.

is 0°C to 60°C.

is 0°C or less.
2.9 Fault diagnostic function

• When the starter switch is in the ON position, the system continuously monitors the sensors and other system
components. If any fault is detected, the system warns the driver of this by illuminating the warning lamp and dis-
playing the error code on the meter panel. At the same time, the system also stores a relevant diagnostic code in
the memory and starts operation in the fault mode.
• While the fault is taking place, the control limits the systems functionality to ensure vehicle and driver safety. It is
possible to read the memorized diagnostic code using a Multi-Use Tester or from flashing of the warning lamp.
• Diagnostic codes displayed on the meter panel, indicated by flashing of the warning lamp and shown by the Multi-
Use Tester are different.
• The Multi-Use Tester is capable of showing more detailed diagnostic codes.
13E-17
3. Electronic Control Unit Connection Diagram
13E-18
13E
13E-19
TROUBLESHOOTING
1. Diagnostic Procedure
• The system can be efficiently inspected for faults using Diagnozer 2.41 or later software or a Multi-Use Tester III.
System inspection can be accomplished basically in two ways according to trouble symptom and diagnostic code
as shown below.
• Check against each diagnostic code stored in memory by the electronic control unit
• Response to transient fault
Warning lamp lit
Vehicle in service shop
Read diagnostic code. (See Gr00.)
Fault code output Normal code output

Normal code output
after cleared
Check against each diagnos- Response to transient fault (See Gr00.)

tic code
Clear stored diagnostic code. (See Gr00.)
Start the engine.
After starting the engine, check for diagnostic code and warning lamp lighting. If diagnostic code is issued
and warning lamp is lit, check fault again.
Clear stored diagnostic code. (See Gr00.)
13E-20
13E
2. Diagnostic Precautions
• Before measuring voltage, check the battery for charged condition and specific gravity. If system inspection is per-
formed with the battery uncharged or reduced in specific gravity, accurate measurements cannot be achieved.
• To avoid having electrical parts damaged, set the starter switch to LOCK or OFF before disconnecting and recon-
necting battery cables.
• Before disconnecting connectors, set the starter switch to LOCK or OFF, then allow at least 20 seconds. Voltage
may remain in electric parts or connected circuit.
• When performing measurement with the tester, handle the test bar carefully so that it does not damage internal
circuit and other electrical parts of the electronic control unit to result in a short-circuit failure between terminals in
connector or between connector and car body.
• Resistance is affected by temperature. Determine the necessity of resistance measurement following given tem-
perature specification as a guide. Otherwise, use normal temperature (10 to 35°C) as the measuring condition.
13E-21
TROUBLESHOOTING
3. Inspections Based on Diagnostic Codes
3.1 Diagnostic code list
• Diagnostic codes displayed on the meter panel, indicated by flashing of the warning lamp and shown by the Multi-
Use Tester or Diagnozer 2.41 or later software are different.
• The Multi-Use Tester or Diagnozer 2.41 or later software is capable of showing more detailed diagnostic codes.
Flash- Flash-
GSE Message Code GSE Message Code
es es
E-01 24 Accel Pedal Sensor 1 P0122 E-33 33 ECU Hardware (ROM) P0605
E-01 24 Accel Pedal Sensor 1 P0123 E-33 33 ECU System (EEPROM) P1605
E-02 16 Accel Pedal Sensor 2 P0222 E-34 82 Injector Circuit 1 P0200
E-02 16 Accel Pedal Sensor 2 P0223 E-34 82 Injector Circuit 2 P1200
E-03 65 Accel SW P0510 E-34 82 Injector Circuit 3 P1210
E-04 12 Camshaft Position SNSR P0340 E-35 41 Fuel Temp. Sensor (inlet) Low P0182
E-05 23 Common Rail Pressure Defect P0254 E-35 41 Fuel Temp. Sensor (inlet) High P0183
E-05 23 Common Rail Pressure M/V 1 P0255 E-36 56 Fuel Temp. Sensor (outlet) P0187
E-05 23 Common Rail Pressure M/V 1 P0256 E-36 56 Fuel Temp. Sensor (outlet) P0188
E-05 23 Common Rail Pressure M/V 1 P0257 E-37 44 INT Air Temp. SNSR (Low) P0112
E-06 36 Common Rail Pressure Defect P0251 E-37 44 INT Air Temp. SNSR (High) P0113
E-06 36 Common Rail Pressure Defect P0252 E-39 34 Q Adjustment Resistor (Low) P1171
E-07 11 CRS Pressure SNSR (Plausibility) P0191 E-39 34 Q Adjustment Resistor (High) P1172
E-07 11 CRS Pressure SNSR (Low) P0192 E-41 25 Vehicle Speed Sensor P0500
E-07 11 CRS Pressure SNSR (High) P0193 E-42 63 CRS Press M/V 1 (Low) P1255
E-08 58 Accel Pedal Check (Plausibility) P0121 E-42 63 CRS Press M/V 1 (High) P1256
E-09 37 Injector M/V-Cylinder1 (Load) P0201 E-42 63 Common Rail Pressure M/V 1 P1257
E-10 38 Injector M/V-Cylinder2 (Load) P0202 E-43 67 EGR 1 P1267
E-15 71 Flow Limiter -Cylinder1 P1240 E-45 69 EGR 3 P1278
E-16 72 Flow Limiter -Cylinder2 P1241 E-48 26 Relay for Glow Relay P0380
E-17 73 Flow Limiter -Cylinder3 P1242 E-49 48 Starter Safety Relay (Low) P0616
E-18 74 Flow Limiter -Cylinder4 P1243 E-49 48 Starter Safety Relay (High) P0617
E-19 75 Flow Limiter -Cylinder5 P1244
E-20 76 Flow Limiter -Cylinder6 P1245
E-24 15 Engine Revolution SNSR P0335
E-25 07 Engine Overrunning P0219
E-26 32 Boost Press SNSR (Low) P0237
E-26 32 Boost Press SNSR (High) P0238
E-28 22 Common Rail Pressure Defect P0253
E-29 19 Atmospheric Pressure Sensor P0107
E-29 19 Atmospheric Pressure Sensor P0108
E-30 – CAN Communication P0600
E-32 21 Water Temp SNSR (Low) P0117
E-32 21 Water Temp SNSR (High) P0118
13E-22
13E
3.2 Diagnostic code generation conditions and inspection items
E-01: Accel Pedal Sensor 1 (warning lamp flashes: 24) P0122

Generation condition Accelerator pedal position sensor 1 voltage is below standard value.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
• Control is effected using accelerator pedal position sensor 2.
• If both sensors 1 and 2 are faulty, control is effected on assumption that accel-
Control effected by electronic control unit
erator pedal is depressed 30% when accelerator switch is on and the pedal is
not depressed when the switch is off.
22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (filtered),
Service data
24: Accel Pedal Sensor Voltage 1
Inspection 03 : Accelerator pedal position sensor
Electronic control unit connector
Electrical equipment #324: Accelerator pedal position sensor

Generation condition Accelerator pedal position sensor 1 voltage is above standard value.
Service data

Generation condition Accelerator pedal position sensor 2 voltage is below standard value.
Service data

Generation condition Accelerator pedal position sensor 2 voltage is above standard value.
Service data
13E-23
TROUBLESHOOTING
E-03: Accel SW (warning lamp flashes: 65) P0510
Accelerator pedal switch signal is abnormal when compared with accelerator
Generation condition
pedal position sensor outputs 1 and 2.
Control effected by electronic control unit Normal control is effected using accelerator pedal position sensor signals.
Service data 73: Accel SW
Inspection Electronic control unit connector 10 : Accelerator pedal switch
Electrical equipment #029: Accelerator pedal switch
E-04: Camshaft Position SNSR (warning lamp flashes: 12) P0340

Generation condition Cylinder recognition sensor emits no pulses.
• Control is effected using engine speed sensor. (If engine speed sensor also
becomes faulty, engine is stopped.)
Service data 01: Engine Revolution
Inspection Electronic control unit connector 08 : Cylinder recognition sensor
Electrical equipment #320: Cylinder recognition sensor
E-05: Common Rail Pressure Defect (warning lamp flashes: 23) P0254
Common rail pressure is slightly too high (lower than operating pressure of pres-
sure limiter)
System recovers (power is re-supplied to electronic control unit) if signal be-
Recoverability
comes normal when starter switch is turned OFF → ON.
• Main injections only enabled.
• Common rail pressure upper limit provided.
Control effected by electronic control unit • Injection rate limited to predetermined value.
• Exhaust gas recirculation control stopped.
(Common rail pressure and injection quantity are limited.)
Actuator test B9: Fuel Leak Check
• Inspection of fuel piping (See Gr13A.)
• Inspection or replacement of supply pump. (Have work performed by DENSO
Inspection Service Station.)
Other
• Pressure limiter (Have work performed by DENSO Service Station.), main
body of common rail
• Injectors (Have work performed by DENSO Service Station.)
E-05: Common Rail Pressure M/V 1 (warning lamp flashes: 23) P0255
Common rail pressure exceeds standard value for longer than standard period
during low-speed use of supply pump.
Control effected by electronic control unit Normal control
• Inspection or replacement of supply pump (Have work performed by DENSO
Inspection Service Station.)
Other • Pressure limiter (Have work performed by DENSO Service Station.), main
body of common rail
13E-24
13E
Common rail pressure exceeds standard value for longer than standard period
during mid-range-speed or high-speed use of supply pump.
• Injection rate limited to predetermined value.
Service Station.)
Inspection Other
body of common rail
Pressure-feed malfunction occurs because of fault in supply pump assembly
(fault in one cylinder).
Recoverability
• Inspection or replacement of supply pump (Have work performed by DENSO
Inspection Other
Service Station.)
Generation condition Fuel is leaking from high-pressure part of system (calculated value).
Recoverability
Control effected by electronic control unit –
• Air-bleeding of fuel system (See Gr13A.)
• Inspection of fuel piping (from supply pump to common rail) (See Gr13A.)
Inspection • Fuel filter (See Gr13A.)
Other • Supply pump (Have work performed by DENSO Service Station.), main body
of common rail
• Pressure limiter (Have work performed by DENSO Service Station.)
Common rail pressure is too high and fuel leakage (calculated value) exceeds
standard value.
Control effected by electronic control unit –
• Air-bleeding of fuel system (See Gr13A.)
Inspection • Fuel filter (See Gr13A.)
Other
• Supply pump (Have work performed by DENSO Service Station.)
• Pressure limiter (Have work performed by DENSO Service Station.)
13E-25
TROUBLESHOOTING
E-07: CRS Pressure SNSR (Plausibility) (warning lamp flashes: 11) P0191
All three conditions listed below are satisfied simultaneously while engine is be-
ing cranked or while vehicle is being driven.
• Engine speed, injection amount, common rail pressure and fuel type are with-
in specification.
• Difference between actual common rail pressure and target common rail
pressure is greater than standard value.
• Extent of changes in actual common rail pressure is smaller than standard
value.
Recoverability
• Common rail pressure open loop control is effected.
07: Reference Common Rail Pressure, 09: Actual Common Rail Pressure,
Service data
Inspection 0B: Difference Common Rail Pressure, 0C: Difference Common Rail Pressure
Electrical equipment #319: Common rail pressure sensor
E-07: CRS Pressure SNSR (Low) (warning lamp flashes: 11) P0192
Generation condition Common rail pressure sensor voltage is below standard value (0.7 V).
Service data
E-07: CRS Pressure SNSR (High) (warning lamp flashes: 11) P0193
Generation condition Common rail pressure sensor voltage is above standard value (4.95 V).
Service data
E-08: Accel Pedal Check (Plausibility) (warning lamp flashes: 58) P0121
Output voltage difference of accelerator pedal position sensors 1 and 2 is out-
side standard range.
Control is effected using value of 30% with accelerator pedal depressed and us-
ing value of 0% with accelerator pedal not depressed. (Output is reduced.)
Service data
24: Accel Pedal Sensor Voltage 1, 25: Accel Pedal Sensor Voltage 2
E-09: Injector M/V - Cylinder1 (Load) (warning lamp flashes: 37) P0201
Generation condition Injector magnetic valve (No. 1 cylinder) is short-circuited or open-circuited.
• Fuel injection stopped for faulty cylinder
Control effected by electronic control unit • Exhaust gas recirculation control stopped.
• Inter-cylinder injection amount correction valve (FCCB) learning disabled.
Actuator test BB: Injector Test 1
Inspection Electronic control unit connector 06 : Injector magnetic valve
Electrical equipment #582: Injector magnetic valve
13E-26
13E
Actuator test BF: Injector Test 5
Actuator test BD: Injector Test 3
Actuator test C0: Injector Test 6
Actuator test BC: Injector Test 2
Actuator test BE: Injector Test 4
13E-27
TROUBLESHOOTING
E-15: Flow Limiter - Cylinder1 (warning lamp flashes: 71) P1240
Inter-cylinder injection amount correction value (FCCB) is higher than standard
value and fluctuation in engine speed is greater than standard value.
Control effected by electronic control unit FCCB learning is disabled.
Service data 43: Flow Limiter (#1)
Inspection
Other • Flow damper (Have work performed by DENSO Service Station.)

Inspection

Inspection

Inspection

Inspection

Inspection
13E-28
13E
E-24: Engine Revolution SNSR (warning lamp flashes: 15) P0335
Generation condition Engine speed sensor emits no pulses.
• Control is effected using cylinder recognition sensor. (If cylinder recognition
sensor also becomes faulty, engine is stopped.)
Service data 01: Engine Revolution
Inspection Electronic control unit connector 07 : Engine speed sensor
Electrical equipment #263: Engine speed sensor
E-25: Engine Overrunning (warning lamp flashes: 07) P0219

Generation condition Engine speed is higher than specified level.
Control effected by electronic control unit Common rail system is deactivated (engine stopped immediately).
Inspection Electrical equipment Engine electronic control unit
E-26: Boost Press SNSR (Low) (warning lamp flashes: 32) P0237
Generation condition Boost pressure sensor voltage is below standard value (0.3 V).
Control is effected with boost pressure assumed as constant 101 kPa {1.03 kgf/
cm2}.
Service data 26: Boost Pressure
Inspection
Electrical equipment #318: Boost pressure sensor
E-26: Boost Press SNSR (High) (warning lamp flashes: 32) P0238
Generation condition Boost pressure sensor voltage is above standard value (4.7 V).
Control is effected with boost pressure assumed as constant 101 kPa {1.03 kgf/
cm2}.
Service data 26: Boost Pressure
Inspection
Electrical equipment #318: Boost pressure sensor
Common rail pressure is abnormally high (above 245 MPa (higher than operat-
ing pressure of pressure limiter))
Recoverability
Control effected by electronic control unit Common rail system is deactivated (engine stopped immediately).
Service Station.)
Inspection Other
body of common rail
E-29: Atmospheric Pressure Sensor (warning lamp flashes: 19) P0107

Atmospheric pressure sensor (incorporated into engine electronic control unit)
voltage is below standard value (1.9 V).
• Control is effected with atmospheric pressure assumed as constant 101 kPa
Control effected by electronic control unit {1.03 kgf/cm2}. (Exhaust emissions worsen.)
Service data 38: Atmospheric Pressure
Inspection
Electrical equipment Engine electronic control unit
13E-29
TROUBLESHOOTING
E-29: Atmospheric Pressure Sensor (warning lamp flashes: 19) P0108
Atmospheric pressure sensor (incorporated into engine electronic control unit)
voltage is above standard value (4.7 V).
• Control is effected with atmospheric pressure assumed as constant 101 kPa
Control effected by electronic control unit {1.03 kgf/cm2}. (Exhaust emissions worsen.)
Service data 38: Atmospheric Pressure
Inspection
Electrical equipment Engine electronic control unit
E-30: CAN Communication (warning lamp flashes: –) P0600

Generation condition Error occurs in CAN communication with machinery side electronic control unit.
Control effected by electronic control unit Engine speed is limited.
Service data 4A: Speed Limiter Reference Speed
Inspection • Combination of engine electronic control unit and machinery side electronic
Other control unit is confirmed.
• Vehicle speed sensor error is confirmed.
E-32: Water Temp SNSR (Low) (warning lamp flashes: 21) P0117
Generation condition Water temperature sensor voltage is below standard value (0.1 V).
• Water temperature is assumed as constant –20°C during engine startup and
Control effected by electronic control unit as constant 80°C while vehicle is being driven. (Exhaust emissions worsen.)
Service data 35: Water Temperature
Inspection Electronic control unit connector 02 : Water temperature sensor
Electrical equipment #262: Water temperature sensor
E-32: Water Temp SNSR (High) (warning lamp flashes: 21) P0118
Generation condition Water temperature sensor voltage is above standard value (4.8 V).
• Water temperature is assumed as constant –20°C during engine startup and
Control effected by electronic control unit as constant 80°C while vehicle is being driven. (Exhaust emissions worsen.)
Service data 35: Water Temperature
Inspection Electronic control unit connector 02 : Water temperature sensor
Electrical equipment #262: Water temperature sensor
E-33: ECU Hardware (ROM) (warning lamp flashes: 33) P0605

Generation condition Main CPU in electronic control unit is abnormal.
Recoverability
• Common rail system control is disabled (engine is stopped immediately) if
mutual diagnoses of main CPU and sub CPU become impossible.
Inspection Other Engine electronic control unit
13E-30
13E
E-33: ECU System (EEPROM) (warning lamp flashes: 33) P1605
Generation condition CPU in engine electronic control unit is faulty.
Recoverability
Common rail system control is disabled (engine is stopped immediately) if mutu-
al diagnoses of main CPU and sub CPU become impossible.
Inspection Other Engine electronic control unit
E-34: Injector Circuit 1 (warning lamp flashes: 82) P0200

Either one of injector magnetic valves (No. 1, 2 or 3 cylinder) is short-circuited, or
open-circuited.
• When short-circuited: System recovers (power is re-supplied to electronic
control unit) if signal becomes normal when starter switch is turned OFF →
Recoverability ON.
• When open-circuited: System recovers if signal becomes normal with starter
switch in ON position.
<When short-circuited>
<When open-circuited>
Actuator test BB: Injector Test 1, BD: Injector Test 3, BF: Injector Test 5

Either one injector magnetic valves (No. 4, 5 or 6 cylinder) is short-circuited, or
open-circuited.
• When short-circuited: System recovers (power is re-supplied to electronic
control unit) if signal becomes normal when starter switch is turned OFF →
Recoverability ON.
• When open-circuited: System recovers if signal becomes normal with starter
switch in ON position.
<When short-circuited>
• FCCB learning disabled.
<When open-circuited>
• Auto cruise control stopped.
• FCCB learning disabled.
Actuator tests BC: Injector Test 2, BE: Injector Test 4, C0: Injector Test 6
13E-31
TROUBLESHOOTING
Injector drive circuit voltage in engine electronic control unit is too low or too
high.
Recoverability
<Too low voltage>
• Common rail pressure lower limit provided.
• Idling speed is increased.
Control effected by electronic control unit • FCCB learning disabled.
• Drive with the constant current.
<Too high voltage>
• Common rail system control is disabled (engine is stopped immediately).
BB: Injector Test 1, BD: Injector Test 2,
Actuator tests BD: Injector Test 3, BE: Injector Test 4,
BF: Injector Test 5, C0: Injector Test 6
Other Engine electronic control unit
E-35: Fuel Temp. Sensor (inlet) Low (warning lamp flashes: 41) P0182
Generation condition Fuel temperature sensor (inlet) voltage is below standard value (0.1 V).
Control effected by electronic control unit Fuel temperature is assumed to be constant 40°C.
Service data 36: Fuel Temperature (inlet)
Inspection Electronic control unit connector 04 : Fuel temperature sensor (inlet)
Electrical equipment #323: Fuel temperature sensor (inlet)
E-35: Fuel Temp. Sensor (inlet) High (warning lamp flashes: 41) P0183
Generation condition Fuel temperature sensor voltage is above standard value (4.8 V).
Control effected by electronic control unit Fuel temperature is assumed to be constant 40°C.
Service data 36: Fuel Temperature (inlet)
Inspection Electronic control unit connector 04 : Fuel temperature sensor (inlet)
Electrical equipment #323: Fuel temperature sensor (inlet)
E-36: Fuel Temp. Sensor (outlet) (warning lamp flashes: 56) P0187
Generation condition Fuel temperature sensor (outlet) voltage is below standard value (0.1 V).
Fuel temperature is assumed as constant 40°C during engine startup and as
constant 80°C while vehicle is being driven.
Service data 37: Fuel Temperature
Inspection Electronic control unit connector 05 : Fuel temperature sensor (outlet)
Electrical equipment #323: Fuel temperature sensor (outlet)
E-36: Fuel Temp. Sensor (outlet) (warning lamp flashes: 56) P0188
Generation condition Fuel temperature sensor (outlet) voltage is above standard value (4.8 V).
Fuel temperature is assumed as constant 40°C during engine startup and as
constant 80°C while vehicle is being driven.
Service data 37: Fuel Temperature
Inspection Electronic control unit connector 05 : Fuel temperature sensor (outlet)
Electrical equipment #323: Fuel temperature sensor (outlet)
13E-32
13E
E-37: INT Air Temp. SNSR (Low) (warning lamp flashes: 44) P0112
Generation condition Intake air temperature sensor voltage is below standard value (0.1 V).
Boost air temperature is assumed as constant –20°C during engine startup and
as constant 25°C while vehicle is being driven.
Service data 27: Intake Air Temperature
Inspection Electronic control unit connector 01 : Intake air temperature sensor
Electrical equipment #305: Intake air temperature sensor
E-37: INT Air Temp. SNSR (High) (warning lamp flashes: 44) P0113
Generation condition Intake air temperature sensor voltage is above standard value (4.8 V).
Boost air temperature is assumed as constant –20°C during engine startup and
as constant 25°C while vehicle is being driven.
Service data 27: Intake Air Temperature
Inspection Electronic control unit connector 01 : Intake air temperature sensor
Electrical equipment #305: Intake air temperature sensor
E-39: Q Adjustment Resistor (Low) (warning lamp flashes: 34) P1171

Generation condition Fuel injection rate adjustment resistor voltage is below standard value (0.6 V).
Control is effected using fuel injection rate adjustment resistor No. 1. (Output is
slightly reduced.)
Service data 3E: Q Adjustment Resistor No.
Inspection Electronic control unit connector 11 : Fuel injection rate adjustment resistor
Electrical equipment #828: Fuel injection rate adjustment resistor
E-39: Q Adjustment Resistor (High) (warning lamp flashes: 34) P1172

Generation condition Fuel injection rate adjustment resistor voltage is above standard value (4.36 V).
Control is effected using fuel injection rate adjustment resistor No. 1. (Output is
slightly reduced.)
Service data 3E: Q Adjustment Resistor No.
Inspection Electronic control unit connector 11 : Fuel injection rate adjustment resistor
Electrical equipment #828: Fuel injection rate adjustment resistor
E-41: Vehicle Speed Sensor (warning lamp flashes: 25) P0500

Generation condition No vehicle speed sensor signal is received.
Control effected by electronic control unit • Engine speed is limited
Inspection Service data 3C: Vehicle Speed
13E-33
TROUBLESHOOTING
E-42: CRS Press M/V 1 (Low) (warning lamp flashes: 63) P1255
SCV (suction control valve) is short-circuited to ground, or open circuited,
or coil is broken.
Recoverability
Inspection Electronic control unit connector 12 : SCV (suction control valve)
Electrical equipment #574: SCV (suction control valve)
E-42: CRS Press M/V 1 (High) (warning lamp flashes: 63) P1256
Generation condition SCV (suction control valve) is shorted to power supply circuit.
Recoverability
Inspection Electronic control unit connector 12 : SCV (suction control valve) system
Electrical equipment #574: SCV (suction control valve) system
Generation condition SCV (suction control valve) binds and fails to operate.
Recoverability
Inspection Electronic control unit connector 12 : SCV (suction control valve)
Electrical equipment #574: SCV (suction control valve)
E-43: EGR 1 (warning lamp flashes: 67) P1267

Exhaust gas recirculation solenoid valve (M/V-1) is shorted-circuited to ground,
or open circuited.
Control effected by electronic control unit Exhaust gas recirculation control is stopped.
Service data 1F: EGR Position
Inspection Actuator test A1: EGR 1
Electrical equipment #530: Exhaust gas recirculation solenoid valve

Exhaust gas recirculation solenoid valve (M/V-1) is shorted to power supply cir-
cuit.
13E-34
13E
or open circuited.

cuit.

or open circuited.

cuit.
E-48: Relay for Glow Relay (warning lamp flashes: 26) P0380
Generation condition Glow drive relay is short-circuited or open circuited or overload.
Recoverability System recovers if signal becomes normal with starter switch ON position.
Control effected by electronic control unit • Suspend glow control
Service data 8D: Glow relay
Actuator test AF: Relay for glow relay
Inspection
Electronic control unit connector 13 : Glow drive relay
Electrical equipment #201: Glow drive relay
13E-35
TROUBLESHOOTING
E-49: Starter Safety Relay (Low) (warning lamp flashes: 48) P0616
Generation condition Safety relay is shorted to power supply circuit.
Recoverability System recovers if signal becomes with starter switch ON position.
Control effected by electronic control unit • Continuous energization prevention function suspended.
Service data 8F: Starter safety relay
Actuator test B1: Starter safety relay
Inspection
Electronic control unit connector 14 : Safety relay
Electrical equipment #201: Safety relay
E-49: Starter Safety Relay (High) (warning lamp flashes: 48) P0617
Generation condition Safety relay is short-circuited to ground circuit, or open circuited.
Recoverability System recovers if signal becomes with starter switch ON position.
Control effected by electronic control unit Continuous energization prevention function suspended.
Service data 8F: Starter safety relay
Actuator test B1: Starter safety relay
Inspection
Electronic control unit connector 14 : Safety relay
Electrical equipment #201: Safety relay
13E-36
13E
4. Multi-Use Tester Service Data
• It is possible to see service data and actuator tests simultaneously.
No. Item Data Inspection condition Requirement

.rpm Value corresponds to tachometer
01 Engine Revolution Racing (engine running)
indication.
02 Reference Injection Quantity . % Starter switch ON 0%
Reference Common Rail . %
07 Starter switch ON 20 to 30%
Pressure
Actual Common Rail Pres- . %
09 Starter switch ON 0%
sure
Difference Common Rail
0B . MPa Engine idling 0 MPa or lower
Pressure
Difference Common Rail
0C . % Engine idling 0% or lower
Pressure
Idling 0%
1F EGR Position [Actuator test]
. STEP
A1: EGR 1, A2: EGR 2,
A3: EGR 3
Accelerator pedal not depressed 0%
Accelerator pedal gradually de-
Accel Pedal Position (unfil- Value gradually increases.
22 . % pressed
tered)
Accelerator pedal fully de-
100%
pressed
Accelerator pedal not depressed 0%
Value gradually increases.
23 Accel Pedal Position (filtered) . % pressed
Accelerator pedal fully de-
100%
pressed
24 Accel Pedal Sensor Voltage 1 . V 0.85 to 4.15 V
pressed from released position
25 Accel Pedal Sensor Voltage 2 . V 0.85 to 4.15 V
pressed from released position
Starter switch On
Equal to atmospheric pressure
. KPa (engine stopped)
26 Boost Pressure
( . inHg) Press the accelerator pedal
Gradual raise
down after starting the engine
. °C Value corresponds to ambient tem-
27 Intake Air Temperature Engine cold
( . °F) perature.
Value corresponds to ambient tem-

Engine cold
perature.
. °C
35 Water Temperature Engine in process of warming up Value gradually increases.
( . °F)
Engine stopped after warming
Value gradually decreases.
up
Engine cold
perature.
. °C
36 Fuel Temperature (inlet) Engine in process of warming up Value gradually increases.
( . °F)
up
Engine cold
perature.
. °C
37 Fuel Temperature Engine in process of warming up Value gradually increases.
( . °F)
up
. KPa Altitude: 0 m 101 KPa (29.8 in.Hg)
38 Atmospheric Pressure
( . inHg) Altitude: 600 m 95 KPa (28.1 in.Hg)
.km/h Value corresponds to speedometer

3C Vehicle Speed Vehicle in motion
( .MPH) indication.
13E-37
TROUBLESHOOTING
No. Item Data Inspection condition Requirement
Number matches number marked
1/2/3/4/5/6/7/8/
3E Q Adjustment Resistor No. – on fuel injection rate adjustment re-
9/10/11/NON
sistor.
42 Power Supply Voltage . V Starter switch ON Value matches battery voltage.
43 Flow Limiter (#1) . Starter switch ON 0
Speed Limiter Reference .km/h Value is same as vehicle speed

4A Vehicle speed limited
Speed ( .MPH) during vehicle speed restriction.
It is adjusting or Temporary end or

4D Pump Adjustment State . Engine idling
Complete end.
Pump Adjustment Value (Last
52 . mA Engine idling –100 to + 100 mA
Time)
Pump Adjustment Value (This
53 . mA Engine idling –100 to + 100 mA
Time)
Starter Switch in ON position ON
72 Starter SW (M) ON/OFF Starter switch in position except
OFF
ON
Accelerator pedal not depressed ON
73 Accel SW ON/OFF
Accelerator pedal depressed OFF
Diagnostic switch OFF (fuse fit-
ON
ted)
83 Diagnostic SW ON/OFF
Diagnostic switch ON (fuse re-
OFF
moved)
Memory clear switch OFF (fuse
ON
fitted)
84 Memory Clear SW ON/OFF
Memory clear switch ON (fuse
OFF
removed)
Actuator test is performed ON
8D Glow relay ON/OFF Actuator test is not performed OFF
[Actuator test] AF: Relay for glow relay
8E Glow relay indicator lamp ON/OFF Actuator test is not performed OFF
[Actuator test] B0: Glow indicator lamp
8F Starter safety relay ON/OFF Actuator test is not performed OFF
[Actuator test] B1: Starter safety relay
Starter switch ON (engine not
ON
started)
91 MIL Lamp ON/OFF
No error after engine startup OFF
[Actuator test] B3: MIL Lamp
Starter switch ON (engine not
ON
started)
92 Diagnostic Lamp ON/OFF
No error after engine startup OFF
[Actuator test] B4: Diagnostic Lamp
13E-38
13E
5. Reading and Erasing Diagnostic Trouble Codes
Diagnozer or Multi-Use Tester III is used to read or erase the diagnostic trouble code. And also, a method using the
diagnostic switch and memory clear switch without these tools is available.
5.1 Method using Diagnozer or Multi-Use Tester III

Refer to each service tool manual.
5.2 Method using diagnostic switch and memory clear switch

(1) Current diagnostic trouble code
• Set the starting switch to ON.
• Disconnect the diagnostic switch connector.
• The diagnostic trouble code is displayed by flashes of the warning lamp.
(2) Reading diagnostic trouble code

• Diagnostic trouble codes are indicated by the number of times
the warning lamp flashes and their duration.
• The flashing intervals also differ between the 10s digit and
units digit.
• 10s digit: 1.2 second interval
• Units digit: 0.4 second interval
• The display of diagnostic trouble codes starts from the 10s digit
and next units digit. When the 10s digit of a diagnostic trouble
code is 0, only the units code is displayed.
• Some diagnostic trouble codes are displayed from the 10s unit
in numeral followed by alphabet in place of the numeral for the
units digit, in which case alphabetical letters are represented by
the following numbers flashes.
A: 10 times; B: 11 times; C: 12 times; D: 13 times;
E: 14 times; F: 15 times
Example)
Diagnostic trouble code 8A. The lamp flashes 8 times for the
10s digit, followed by 10 times for A as the unit’s digit.
• Each diagnostic trouble code is displayed three times in succes-
sion.
• If there is no more code stored, the sequence is then repeated
from the beginning with each code indicated three times.
• When the diagnostic switch is connected, the engine control unit
will immediately stop displaying codes.
(3) Past diagnostic trouble codes

• After reading the current diagnostic trouble codes (with the diag-
nostic switch disconnected), disconnect the memory clear
switch. Then the warning lamp will restart flashing.
• This time, the warning lamp displays the past diagnostic trouble
codes. Determine the fault locations based on the indicated
codes.
13E-39
TROUBLESHOOTING
(4) Erasing diagnostic trouble codes
Disconnect the memory clear switch connector and then recon-
nect. Then all the diagnostic trouble codes stored in the engine
control unit will be cleared.
NOTE
• Pay attention that the stored codes can be erased only by
the operation of memory clear switch.
• When you want to keep the memory contents after the indi-
cation of stored codes, leave the memory clear switch dis-
connected and turn the starter switch in the off position.
Then connect the memory clear switch connector.
• When you change the combination of the injection pump
and engine control unit, you must rewrite the pump data
stored in the engine control unit. For this purpose, be sure
to perform the diagnostic trouble code erasing procedure.
13E-40
13E
6. Actuator Tests Performed Using Multi-Use Tester
• It is possible to see service data and actuator tests simultaneously.
No. Item Explanation Confirmation method

A1 EGR 1 Switch ON/OFF exhaust gas recirculation solenoid
Operating sound of exhaust gas
valve (automatic reset after six seconds)
A2 EGR 2 recirculation solenoid valve when
[Can be executed under the following conditions]
turned ON/OFF
• Vehicle: stopped (vehicle speed 0 km/h)
[Service data]
A3 EGR 3 • Starter switch: ON
1F: EGR Position
• Engine: Stopped
Switch ON/OFF grow drive relay
(automatic reset after six seconds) Operating sound of glow drive re-
[Can be executed under the following conditions] lay when turned ON/OFF
AF Relay for glow relay
• Vehicle: stopped (vehicle speed 0 km/h) [Service data]
• Starter switch: ON 8D: Glow Relay
• Engine: Stopped
Switch ON/OFF glow indicator lamp
ON/OFF condition of indicator
(automatic reset after six seconds)
lamp
B0 Glow indicator lamp [Service data]
• Vehicle: stopped (vehicle speed 0 km/h)
8E: Glow Relay Indicator
• Starter switch: ON
Lamp
• Engine: Stopped
Switch ON/OFF safety relay
(automatic reset after six seconds) Operating sound of safety relay
[Can be executed under the following conditions] when turned ON/OFF
B1 Starter safety relay
• Starter switch: ON 8F: Starter Safety Relay
• Engine: Stopped
Switch ON/OFF engine warning lamp (orange)
(automatic reset after six seconds) ON/OFF condition of warning lamp
[Can be executed under the following conditions] (orange)
B3 MIL Lamp
• Starter switch: ON 91: MIL Lamp
• Engine: Stopped
Switch ON/OFF engine warning lamp (red)
(automatic reset after six seconds) ON/OFF condition of warning lamp
[Can be executed under the following conditions] (red)
B4 Diagnostic Lamp
• Starter switch: ON 92: Diagnostic Lamp
• Engine: stopped
13E-41
TROUBLESHOOTING
No. Item Explanation Confirmation method
Increase rail pressure for a specified six seconds
Check that no fuel leaks from fuel
B9 Fuel Leak Check • Vehicle: stopped (vehicle speed 0 km/h)
system (pipe, hose)
• Transmission: neutral
• Diagnostic switch: OFF (removal of fuse)
Force the selected injector magnetic valve to be Injector magnetic valve (No.1
BB Injector Test 1
deactivated. cylinder) should stop.
• Vehicle: stopped (vehicle speed 0 km/h) Injector magnetic valve (No.5
BC Injector Test 2
• Transmission: neutral cylinder) should stop.
• No present diagnostic codes generated Injector magnetic valve (No.3
BD Injector Test 3
cylinder) should stop.
Injector magnetic valve (No.6
BE Injector Test 4
BF Injector Test 5
C0 Injector Test 6
The service data “4D: Pump Ad-
Delete the compensation information (pump learn-
C2 Pump Adjustment Value Clear justment State” displays “Un-
ing condition) in engine electronic control unit
learned”
13E-42
13E
7. Initialization of Supply Pump Unit Difference Learning Value in Engine Electron-
ic Control Unit
• Following replacement of the engine electronic control unit or the supply pump, this item is used to program the
current supply pump data into the engine electronic control unit.
7.1 After replacement of engine electronic unit with new one
Replacement of engine electronic control unit with new one
Start engine. Allow it to warm up fully then run at low idle speed for 30 seconds. *
Check service data 4D: Pump Adjustment State.

Learning, Temporal leaning completed or Learning completed will be shown.
* New engine electronic control unit starts auto learn-

End of programming ing when the truck is in a halt condition, engine low-
idling, fuel temperature between 20 and 80˚C (68 and
176˚F) and water temperature 65˚C (149˚F) or higher
without any defect.
7.2 After re-installing of other truck’s engine electronic control unit or replacement of supply
pump without replacing engine electronic control unit. (This operation is available with Multi-
Use Tester III.)
Replacement of supply pump or replacement (re-use) of engine electronic control unit
Erase the compensation information (pump learning condition) in the electronic control unit.
Perform actuator test C2: Pump Adjustment Value Clear
Start engine. Allow it to warm up fully then run at low idle speed for 30 seconds.
Check service data 4D: Pump Adjustment State.

Learning, Temporal leaning completed or Learning completed will be shown.
End of programming
7.3 Check after engine electronic control unit programming

If the measurement values (which show the learning values) shown by service data 52: Pump Adjustment Value
(Last Time) and 53: Pump Adjustment Value (This Time) are out of specification, a defect in the supply pump or in
the engine electronic control unit is conceivable so you must replace the supply pump or engine electronic control
unit. (Initialize the engine electronic control unit again after replacing the supply pump or engine electronic control
unit.)
• New engine electronic control unit starts automatic pump adjustment after engine warming-up and various condi-
tions satisfied. To replace the supply pump and engine electronic control unit, complete all the replacement jobs
other than the replacement of engine electronic control unit. Then replace the new unit.
13E-43
TROUBLESHOOTING
8. Inspections Performed at Electronic Control Unit Connectors
• These inspections aid troubleshooting by enabling you to check whether electronic control unit signals are being
correctly transmitted via the vehicle harness and connectors.
The white-on-black numbers ( 01 , 02 , and so on) correspond to the similarly printed reference numbers in sec-
tion “3. Inspections based on diagnostic codes”.
8.1 Electronic control unit connector terminal layout
8.2 Inspection instructions

• Some inspections are performed with the connectors removed. Others are performed with the connectors fitted.
Observe the following caution:
CAUTION
• Do not touch any terminal except those specified for the inspection. Be particularly careful not to cause
short circuits between terminals using the tester probes.
• When the supply pump has been replaced, perform the “Initialization of supply pump unit difference
learning value” using the MUT and erase the compensation information (pump learning condition) in the
ECU.
Check item Measurement method

[Conditions]
• Starter switch OFF
01
• Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Resistance of intake air temperature sen-
Terminals: E25-B26
sor
• 0°C: 5.88 ± 0.588 kΩ
• 20°C: 2.45 ± 0.245 kΩ
• 80°C: 0.322 ± 0.0483 kΩ
[Conditions]
02 [Requirements]
Resistance of water temperature sensor Terminals: E24-B26
• 20°C: 2.45 ± 0.14 kΩ
• 80°C: 0.32 kΩ (reference value)
• 110°C: 147.1 ± 2 Ω (reference value)
13E-44
13E
[Conditions]
• Starter switch ON
• Vehicle-side harness connected (Perform inspection on back of connector.)
03 [Requirements]
Output voltage of accelerator pedal posi- Terminals (+)-(–)
tion sensor A24-D30 (accelerator pedal position sensor 1)
A23-D28 (accelerator pedal position sensor 2)
• With accelerator pedal not depressed: 0.85 ± 0.1 V
• With accelerator pedal depressed: 4.15 ± 0.1 V
[Conditions]
04
[Requirements]
Resistance of fuel temperature sensor (in-
Terminals: E30-B27
let)
• –20°C: 15.0 ± 1.5 kΩ
• 20°C: 2.45 ± 0.24 kΩ
• 80°C: 0.318 ± 0.008 kΩ
[Conditions]
05
[Requirements]
Resistance of fuel temperature sensor
Terminals: E31-B26
(outlet)
• 20°C: 2.45 +0.14
–0.13 kΩ
• 80°C: 0.318 ± 0.01 kΩ
• 110°C: 0.1417 ± 0.01 kΩ
[Conditions]
[Requirements]
Terminals:
06 D1 or D2-D5 (injector magnetic valve: No. 1 cylinder)
Resistance of injector magnetic valve D1 or D2-D3 (injector magnetic valve: No. 2 cylinder)
D1 or D2-D4 (injector magnetic valve: No. 3 cylinder)
E1 or E2-E5 (injector magnetic valve: No. 4 cylinder)
• 0.45 ± 0.1 Ω (20°C)
[Conditions]
07 • Disconnect connector. Perform inspection on vehicle-side connector.
Resistance of engine speed sensor [Requirements]
Terminals: B2-B1
• 125.5 ± 17 Ω (20°C)
[Conditions]
08
[Requirements]
Output of cylinder recognition sensor
Terminals: D31-D33 (+5 V to GND)
• 200 to 1800 Ω (Resistance serves as rough indication only. Pulse output moni-
tor is needed for confirmation of functionality.)
[Conditions]
09
[Requirements]
Continuity of accelerator pedal switch
• Terminals: B20 and chassis earth
• With accelerator pedal depressed: no continuity is found.
• With accelerator pedal not depressed: continuity is found.
13E-45
TROUBLESHOOTING
[Conditions]
[Requirements]
Terminals: B35-B27
• No. 1 resistor: 270 ± 13.5 Ω
10
• No. 2 resistor: 510 ± 25.5 Ω
• No. 3 resistor: 820 ± 41 Ω
Resistance of fuel injection rate adjustment
• No. 4 resistor: 1300 ± 65 Ω
resistor
• No. 5 resistor: 2000 ± 100 Ω
• No. 6 resistor: 3300 ± 165 Ω
• No. 7 resistor: 5600 ± 280 Ω
• No. 8 resistor: 15000 ± 750 Ω
• No. 9 resistor: 390 ± 19.5 Ω
• No. 10 resistor: 4300 ± 215 Ω
• No. 11 resistor: 9100 ± 455 Ω
[Conditions]
Starter switch OFF
11 Disconnect connector. Perform inspection on vehicle-side connector.
Resistance of SCV (suction control valve) [Requirements]
Terminals: E14-E16, E14-E17, E15-E16, E15-E17
• 7.9 ± 0.2 Ω
[Conditions]
• Keep the vehicle harnesses connected to the electronic control unit connector
12
halves. (Inspection is made at the back of the vehicle connectors.)
• Carry out the actuator test “AF-Relay for Glow Relay” using Multi-Use Tester.
Glow drive relay voltage
[Normal status]
Terminals (+)-(–): C7 and body earth
• Battery voltage
[Conditions]
• Keep the vehicle harnesses connected to the electronic control unit connector
13
halves. (Inspection is made at the back of the vehicle connectors.)
[Normal status]
Safety relay voltage
Terminals (+)-(–): B18 and body earth
• Relay ON: 24 V
• Relay OFF: 0 V
13E-46
INSPECTION OF ELECTRICAL EQUIPMENT 13E
#029 Inspection of accelerator pedal switch
Switch position Terminals with continuity
OFF –
ON 1–2
• If there is any abnormality, replace the switch.
#201 Inspection of relay (normally open type with 5 pins)

• Test for continuity and proper operation. If there is any abnor-
mality, replace the relay.
#262 Inspection of water temperature sensor

• Place the water temperature sensor in a container filled with en-
gine oil.
• Heat the oil to each of the specified temperatures. Stir the oil
well while doing so.
• Measure the resistance between terminals 1 and 2.
20°C 2.45 ± 0.14 kΩ
0.32 kΩ
Standard value 80°C
(reference value)
110°C 147.1 ± 2 Ω
• If either measurement is out of specification, replace the sensor.
#263 Inspection of engine speed sensor

Standard value (at 20°C) 125.5 ± 17 Ω
• If the measurement is out of specification, replace the sensor.
13E-47
INSPECTION OF ELECTRICAL EQUIPMENT
#305 Inspection of intake air temperature sensor
• Clean the sensor as dirty sensor terminals may provide false
output signals. (See Gr15.)
• Place the boost air temperature sensor in a container filled with
engine oil.
• Heat the oil to each of the specified temperatures. Stir the oil
well while doing so.
0°C 5.88 ± 0.588 kΩ
Standard value 20°C 2.45 ± 0.245 kΩ
80°C 0.322 ± 0.0483 kΩ
• If either measurement is out of specification, replace the sensor.
#318 Inspection of boost pressure sensor

• Apply 5 V DC to terminals 3 and 1.
• Apply air pressure. Gradually increase it and, while doing so,
measure the output voltage occurring at terminals 2 and 1 (see
the diagram on the left).
Air pressure
Voltage
(Gauge pressure)
101.67 kPa
Standard value Approx. 3.2 V
{1.0 kgf/cm2}
165.67 kPa
Approx. 4.5 V
{1.7 kgf/cm2}
• If any measurement is out of specification, replace the sensor.
#319 Inspection of common rail pressure sensor

• The sensor cannot easily be inspected in isolation, so you must
evaluate it indirectly by inspection of system harnesses and re-
lated parts.
• If there is no abnormality in any related part but the system is
abnormal, replace the common rail pressure sensor.
#320 Inspection of cylinder recognition sensor

• Measure the resistance between terminals 1 and 2. (The resis-
tance serves as a rough indication only. A pulse output monitor
is needed for confirmation of functionality.)
Standard value 200 to 1800 Ω
• If the measurement is out of specification, replace the sensor.
#323 Inspection of fuel temperature sensor

<Fuel temperature sensor (inlet)>
–20°C 15.0 ± 1.5 kΩ
80°C 0.318 ± 0.008 kΩ
• If any measurement is out of specification, replace the supply
pump.
13E-48
13E
<Fuel temperature sensor (outlet)>
20°C 2.45 +0.14
–0.13 kΩ

110°C 0.1417 ± 0.01 kΩ
• If any measurement is out of specification, replace the sensor.
#324 Inspection of accelerator pedal position sensor

[Inspection]
• Apply 5 V DC to terminals 4 and 6 and terminals 1 and 3 of the
accelerator pedal position sensor connector.
• Measure the output voltage at terminals 5 and 6 (sensor 1) and
the output voltage at terminals 2 and 3 (sensor 2) with the lever
in each specified position.
Lever position Output voltage
Idling position A 0.85 ± 0.1 V
Standard value Accelerator pedal switch
1.0 ± 0.2 V
operating position B
Full load position C 4.15 ± 0.1 V
A: Position in which accelerator pedal switch is fully pushed in
by lever
B: Position at which continuity between terminals 1 and 2 of ac-
celerator pedal switch connector disappears as accelerator
pedal is pushed downward
C: Position in which lever is touching stopper bolt
• If any output voltage is out of specification, make an adjustment.
• If any output voltage is still out of specification when you have
made an adjustment, replace the sensor.
[Adjustment]
• To adjust the output voltage for the accelerator pedal switch op-
erating position A, use nut D.
• To adjust the output voltage for the full load position C, loosen
nut E and make the adjustment using the stopper bolt.
• After making the adjustment, lock the stopper bolt in position
with the nut.
13E-49
#530 Inspection of exhaust gas recirculation solenoid valve
• Perform the following checks. If there is any abnormality, replace
the exhaust gas recirculation solenoid valve.
(1) Check of operation
• Gradually increase from zero the voltage applied to terminals 1
and 4 (M/V-1), 2 and 5 (M/V-2), or 3 and 6 (M/V-3).
• Observe the voltage when the exhaust gas recirculation sole-
noid valve operates. (Determine the solenoid valve’s OFF-ON
operation from the operating sound.)
Standard value
18 V or lower
(min. operating voltage)
(2) Check of continuity and airtightness

• Air pressure applied during check: 930 kPa {9.5 kgf/cm2}
#574 Inspection of SCV (suction control valve)

Standard value 7.9 ± 0.2 Ω
• If the measurement is out of specification, replace the supply
pump.
#582 Inspection of injector

Standard value (at 20°C) 0.45 ± 0.1 Ω
• If the measurement is out of specification, replace the injector.
13E-50
13E
#828 Inspection of fuel injection rate adjustment resistor
• Measure the resistance of the resistor number marked on the
fuel injection rate adjustment resistor.
1 270 ± 13.5 Ω
2 510 ± 25.5 Ω
3 820 ± 41 Ω
4 1300 ± 65 Ω
5 2000 ± 100 Ω
Standard value Resistor
6 3300 ± 165 Ω
(at 20°C) No.
7 5600 ± 280 Ω
8 15000 ± 750 Ω
9 390 ± 19.5 Ω
10 4300 ± 215 Ω
11 9100 ± 455 Ω
• If the measurement is out of specification, replace the fuel injec-
tion rate adjustment resistor with one that has the same resistor
number and same specified resistance.
CAUTION
• The fuel injection rate adjustment resistor is matched to the
engine. If you replace it, be sure to replace it with one that
has the same resistor number.
13E-51
GROUP 14 COOLING
SPECIFICATIONS ............................................................................. 14-2

1. Cooling System (Flow of Coolant) .............................................. 14-3
2. Thermostat ................................................................................. 14-4
3. Water Pump ................................................................................ 14-4

1. Coolant Replacement and Cleaning of Cooling System .............. 14-6 14
2. Air Bleeding of Cooling System .................................................. 14-8
3. Gas Leakage Test ........................................................................ 14-8
4. Inspection of V-belts ................................................................... 14-9
DISCONNECTION AND CONNECTION

OF HOSES AND PIPES .................................................................. 14-10
RADIATOR, OIL COOLER,

INTERCOOLER AND FAN SHROUD ............................................. 14-12
COOLING FAN AND V-BELT ............................................................ 14-24
WATER PUMP................................................................................... 14-28
THERMOSTAT .................................................................................. 14-32

Phone: 1 269 673 1638
14-1
SPECIFICATIONS
Item Specifications
Cooling system Forced water circulation system
Water pump Belt-driven type
Thermostat Wax pellet, bottom bypass type (with jiggle valve)
14-2
1. Cooling System (Flow of Coolant)
14-3
2. Thermostat
• The thermostat is a bottom bypass
type that uses a wax-filled pellet as its
flow-regulating element. When the
wax is heated, it melts from solid to liq-
uid, changing its total volume. This al-
lows the valve to open or close in
accordance with the coolant tempera-
ture, regulating and adjusting the flow
of coolant to the radiator and to the
water pump (bypassing the radiator).
3. Water Pump
• The water pump has a drain hole to
prevent coolant from entering the unit
bearing in case of a defect in the unit
seal.

Phone: 1 269 673 1638
14-4
TROUBLESHOOTING 14
Symptoms
Overheating (poor cooling)
Engine output insufficient

Excessive coolant loss
Reference Gr
Abnormal noise
Overcooling
Possible causes
Loose or damaged O O
V-belt Excessive tension O
Oil on belt O
Incorrectly mounted water pump O O
Defective gasket O O
Defective unit bearing O O
Water pump
Defective impeller O
Defective unit seal O O
Fit of unit bearing on flange and impeller too loose O O
Incorrectly mounted case O O
Thermostat Valve opening temperature too high
O
(valve remains closed)
Valve opening temperature too low (valve remains open) O
Clogged core O
Radiator
Cracked core and/or separation in welds O O
Intercooler Foreign matter adhered on the core O
Oil cooler
Water leaking O
<For machinery>
EGR system Gr17
Incorrectly mounted EGR cooler O O
Incorrectly mounted oil cooler O O
Oil cooler Defective gasket O O Gr12
Water leaking from water temperature sensor O O
Incorrectly mounted cylinder head O O
Cylinder head Gr11
Poorly airtight pressure cap O
Coolant quantity insufficient and/or coolant dirty O
Coolant passages dirty and/or clogged O
Hoses fitted poorly O O
Ambient temperature extremely low O
14-5
1. Coolant Replacement and Cleaning of Cooling System
• Using the radiator for extended periods of time without cleaning can increase chance of rust and scale formation,
which may cause engine overheating. The cooling system must be cleaned periodically.

– Radiator drain cock 2 {0.2} –
– Crank case drain cock 7 {0.7} –
1.1 Draining of coolant

• Before draining the coolant, loosen the pressure cap to reduce
the pressure in the cooling system. Remember to drain the cool-
ant out of the reservoir tank as well.
WARNING
• Drain the coolant only after it has cooled sufficiently to
avoid getting scalded.
• Opening the pressure cap while the coolant temperature is
still high can cause hot coolant to spray out. Cover the
pressure cap with a cloth, and loosen it slowly to let the
pressure out before opening it fully.
1.2 Cleaning procedure

CAUTION
• Water used for flushing the cooling system must be soft water that has a property meeting the require-
ments indicated below. Using hard water will cause scale and rust to form in the system.
Required properties of soft water
Total hardness .......................... 300 ppm or less
Sulfate SO 4 .............................. 100 ppm or less
Chloride CI ............................. 100 ppm or less
Total dissolved solids.............. 500 ppm or less
pH .............................................. 6 to 8
• Keep the coolant temperature at approximately 90°C so that the thermostat valve remains open and coolant con-
tinues to circulate in the radiator.
• For the sake of convenience you can raise the coolant temperature quickly by covering the front of the radiator
with corrugated cardboard or something similar.
• In cases where a great amount of rust has accumulated it is common for the radiator to leak as a result of clean-
ing. Conduct a through check for leakage after cleaning.
14-6
14
• Select an appropriate cleaning method according to the condition of the cooling system as shown below.
• Ordinary condition • Coolant extremely dirty • Radiator clogged
Cleaning using FUSO RADIATOR CLEANER (RADIPET-7)

Flushing with water
Drain out coolant
Make water solution of FUSO RADIATOR CLEANER

(RADIPET-7) at 5 to 10% concentration in volume.
Pour solution into reservoir tank.
Let the engine idle for 30 minutes with the water at approxi-
mately 90°C.
CAUTION
• Limit the engine idling period to one hour. Operating
an engine containing the cleaning solution for long-
er time may lead to damage of the cooling system.
Drain out coolant
Pour tap water (preferably hot) into the surge tank.
Let the engine idle for 10 minutes with the water

at approximately 90°C.
Drain out water
Cleaning is complete if drained water is clear

Repeat procedure if drained water is not clear
CAUTION
• After cleaning the cooling system using cleaning so-
lution, fill it with coolant containing the specified ad-
ditive as soon as possible.
• To prevent freezing of the coolant and corrosion of
the cooling system, add the specified portion of
FUSO DIESEL LONGLIFE COOLANT to the coolant.
(See the Owner’s Handbook for instructions on the
use of the additive.)
DANGER
• If you accidentally splash FUSO DIESEL LONGLIFE COOLANT or RADIATOR ANTIRUST (RADIPET9) in
your eyes, wash it out immediately with water and seek medical attention.
WARNING
• FUSO DIESEL LONGLIFE COOLANT is flammable. Keep it away from heat and flames.
14-7
2. Air Bleeding of Cooling System
• With the pressure cap removed and the coolant temperature at 90°C, let the engine idle in order to bleed air com-
pletely out of the cooling system.
• After air bleeding is completed, refill the reservoir tank with coolant as needed.
3. Gas Leakage Test

• Presence of air or exhaust gas in coolant accelerates corrosion
of the cooling system components. To prevent this, carry out air/
gas leakage tests in accordance with the following procedure.
• Remove the pressure cap.
WARNING
• If the engine is hot, boiling coolant may spurt out from the
filler port when the pressure cap is loosened. To avoid burn-
ing yourself, make sure to remove the pressure cap only
when the coolant is cold.
• Run the engine until the coolant temperature rises to approxi-

mately 90°C.
• If air bubbles appear continuously through the filler port, there is
air or exhaust gas penetrating into the cooling system.
• Presence of air in coolant can be an indication of loose cylinder
head bolts, loose water pump mounting bolts, loose hose con-
nections, and/or a damaged hose.
• Presence of exhaust gas in coolant can be an indication of a
damaged cylinder head gasket and/or cracks in the cylinder
head.
14-8
14
4. Inspection of V-belts
• Visually check the V-belts for possible cracks and damage. V-
belt replacement time varies depending on the severity of cracks
and damage that may be found through the check. Study the ta-
ble given below for the applicable replacement time.
Belt condition Remaining service life (reference)

• The driving distance over the
which the belt can still be used is
at least as long as that over which
the belt has been used since the
vehicle was new or since the belt
was replaced (whichever is more
recent).

about half of that over which the
belt has been used since the vehi-
cle was new or since the belt was
replaced (whichever is more re-
cent).

about a quarter of that over which
the belt has been used since the
vehicle was new or since the belt
was replaced (whichever is more
recent).
• The belt has reached the end of

its service life and must be re-
placed.
14-9
DISCONNECTION AND CONNECTION OF HOSES AND PIPES
Removal sequence
1 Water hose 5 Water hose 9 EGR cooler water pipe
2 Eyebolt 6 EGR cooler water pipe 10 Water hose
3 Joint pipe 7 Water hose
4 Water hose 8 Water hose EGR: Exhaust gas recirculation
CAUTION
• Install each hose clamp to the angle indicated in the illustration so that sufficient clearance is assured be-
tween the hose clamp and its surrounding parts.

Clamp 3.9 ± 0.6 {0.4 ± 0.06} –
Clamp 4 to 5 {0.4 to 0.5} –
Eyebolt (joint pipe mounting) 25 {25} –

Phone: 1 269 673 1638
14-10
14
M E M O
14-11
RADIATOR, OIL COOLER, INTERCOOLER AND FAN SHROUD
Type A
Removal sequence
1 Intercooler 5 Pressure cap 9 Shroud seal
2 Hose 6 Filler 10 Fan shroud
3 Drain cock 7 Filler hose
4 Oil cooler 8 Radiator (See later pages.)
Service standards
Air leaks from intercooler
(air pressure: 150 kPa {1.5 kgf/cm2})
Coolant side
0 cm3 {0 mL} – Replace
Air leaks from (air pressure: 20 kPa {0.2 kgf/cm2})
4
oil cooler Oil side
0 cm3 {0 mL} – Replace
49 ± 9.8 kPa
5 Pressure cap opening pressure – Replace
{0.5 ± 0.1 kgf/cm2}
Tightening Torque (Unit: N·m {kgf·m})

Clamp 3.9 ± 0.6 {0.4 ± 0.06} –
14-12
14
Tip clearance
spacer <For φ600 fan>
MC019470
A B Adjusting clearance between fan
shroud and cooling fan blades
φ600 50 5 <For φ620 fan>
ME294842
φ620 50 7
Inspection: Air leaking of intercooler
• Plug an end of the intercooler and apply a specified air pressure
from the other end with the intercooler immersed in water.
• If any leakage is found, replace the intercooler.
Inspection: Air leaking of oil cooler

• Plug an end of each coolant passage and oil passage of the oil
cooler and apply a specified air pressure from the other end with
the oil cooler immersed in water.
• Be sure to check both the coolant passage and oil passage.
• If any leakage is found, replace the oil cooler.
Inspection: Pressure cap

(1) Pressure valve opening pressure
• If the measurement does not conform to the standard value, re-
place the pressure cap.
14-13
(2) Inspection of vent valve
• Note the coolant level in the reservoir tank.
• Start the engine and run it at high speed until the coolant level in
the reservoir tank has risen to a certain degree. Stop the engine.
• Allow the system to cool down. When the coolant temperature
has dropped to the atmospheric temperature, check if the cool-
ant level in the reservoir tank has subsided to the original level
noted earlier.
• If not, the vent valve is deemed faulty. Replace the pressure
cap.
CAUTION
• If the pressure cap is opened before the coolant tempera-
ture drops to the atmospheric temperature, the negative
pressure in the radiator is canceled out. As a result, it is no
longer possible for coolant to flow into the reservoir tank.
Ensure that this does not happen.
Installation: Fan shroud
• Using , adjust the clearance between the fan shroud and
cooling fan blades to the dimension shown in the illustration.
14-14
14
Type B
Removal sequence
1 Plug 9 Packing 17 Radiator
2 Gasket 10 Pressure cap 18 Cushion
3 Intercooler 11 Pressure cap 19 Radiator
4 Protector 12 Water hose 20 Cushion
5 Packing 13 Water hose 21 Plate
6 Packing 14 Hose 22 Frame
7 Oil cooler 15 Cushion
8 Shroud 16 Bracket : Non-reusable parts
Service standards
Air leaks from intercooler
(air pressure: 1.5 MPa {15 kgf/cm2})
Air leaks from oil cooler
49 ± 9.8 kPa
10, 11 Pressure cap opening pressure – Replace
{0.5 ± 0.1 kgf/cm2}
Air leaks from radiator
17, 19 0 cm3 {0 mL} – Replace
14-15
Inspection: Air leaking of intercooler
• Plug an end of the intercooler and apply a specified air pressure
from the other end with the intercooler immersed in water.
• If any leakage is found, replace the intercooler.
Inspection: Air leaking of oil cooler

• Plug an end of each coolant passage and oil passage of the oil
cooler and apply a specified air pressure from the other end with
the oil cooler immersed in water.
• Be sure to check both the coolant passage and oil passage.
• If any leakage is found, replace the oil cooler.

Inspection: Air leaking of radiator
• Install hose and radiator cap tester and plug to upper tank.
• Insert plug in lower tank, and immerse the entire body of the ra-
diator in water.
• Apply a specified air pressure using radiator cap tester, and
check for any air leakage.
• If any leakage is found, repair or replace radiator.
Inspection: Pressure cap

(1) Pressure valve opening pressure
• If the measurement does not conform to the standard value, re-
place the pressure cap.
14-16
14
(2) Inspection of vent valve
• Note the coolant level in the reservoir tank.
• Start the engine and run it at high speed until the coolant level in
the reservoir tank has risen to a certain degree. Stop the engine.
• Allow the system to cool down. When the coolant temperature
has dropped to the atmospheric temperature, check if the cool-
ant level in the reservoir tank has subsided to the original level
noted earlier.
• If not, the vent valve is deemed faulty. Replace the pressure
cap.
CAUTION
• If the pressure cap is opened before the coolant tempera-
ture drops to the atmospheric temperature, the negative
pressure in the radiator is canceled out. As a result, it is no
longer possible for coolant to flow into the reservoir tank.
Ensure that this does not happen.
14-17
Radiator Assembly
• Only the type A radiator can be disassembled.
1 Radiator shroud 5 Packing
2 Drain cock 6 Lower tank : Non-reusable parts
3 Side member 7 Packing
4 Upper tank 8 Core
CAUTION
• Gently handle upper tank and lower tank, since they are made of a resin that can break on impact.
• If there are two paint marks on the joint between the core and upper tank or on the joint between the core
and lower tank (which indicates that the tank retaining tabs have been crimped twice before), replace the
core with a new part.
Assembly sequence
Service standards
Air leakage from radiator
8 0 cm3 {0 mL} – Repair or replace

Drain cock 2 {0.2} –
Bolt (side member mounting) 13 {1.3} –
14-18
14
Special tools
J94-Z013
Lock-and-break tool Removal of upper and lower tanks
-10000
The indicated part number is T. RAD’s part number.

Inspection: Air leaking of radiator
• Install hose and radiator cap tester and plug to upper tank.
• Insert plug in lower tank, and immerse the entire body of the ra-
diator in water.
• Apply a specified air pressure using radiator cap tester, and
check for any air leakage.
• If any leakage is found, repair or replace radiator.
• Replace the following parts according to the leakage location.

Area of leakage Cause
Tank Cracked tank
Upper tank Defective crimping
Lower tank Tank joint Defective packing
Cracked tank
Tube; Tube joint Cracked tube
CAUTION
• If there are two paint marks on the joint between the core
and upper tank or on the joint between the core and lower
tank (which indicates that the tank retaining tabs have been
crimped twice before), replace the core with a new part.
• The number of paint marks on the upper tank joint or the
lower tank joint corresponds to the number of repairs per-
formed on that joint.
Removal procedure
Removal: Upper tank and lower tank
• Use for removal and reinstallation of the tanks.
14-19
• Adjust the stopper bolt until the gap dimension shown in the il-
lustration is obtained on the attachment of .
CAUTION
• Before using , be sure to set the gap to the specified di-
mension by adjusting the stopper bolt. Otherwise, will
become damaged.
• Use to bend open tabs of retain tank in place.

• After tabs are bent open, squeeze the handle of to straight-
en tabs as illustrated.
• After straightening all tabs in the perimeter, hold the pipes con-
nected to the inlet/outlet, and remove tank.
• If it is difficult to remove tank lightly hit with rubber hammer (or

plastic hammer) to remove.
CAUTION
• Gently handle tanks, since they are made of a resin that can
break on impact.
Inspection: Tank surface where core is to be mounted
• Check the tank surface where the core is to be mounted for
cleanliness, damage, etc. Clean the surface.
• If an abnormality is found on the surface, replace the tank.
CAUTION
• To prevent adhesion of foreign substances on mounting
surface, conduct work with bare hands.
14-20
14
Inspection: Core groove where tank is to be mounted
• Check the groove on the core where the tank is to be mounted
for adhesion of foreign substances or cracks.
• If foreign substances are found, rub the area with #1000 sand-
paper or a like gently so as to avoid scratching the surface, or
use compressed air to remove them.
• If there are cracks in the groove, repair or replace.
CAUTION
• If the packing and tank are installed onto the core without
removing foreign substances from the groove, coolant leak-
age will result. Be sure to inspect and clean the tank mount-
ing groove along the entire periphery (even a hair can cause
leakage).
Repairing core
CAUTION
• The core is repaired by means of tungsten inert-gas arc
welding (TIG welding), which should only be performed by a
skilled welder.
• It is extremely dangerous to weld on a wet core. Before
welding, ensure that the core is completely dry.
• Using a stainless wire brush, brush both ends A of the leaky

tube and the areas B around the tube ends until the base alumi-
num is exposed.
• Before closing the tube at both ends by welding, drill a small
breather hole in the tube.
CAUTION
• If a breather hole is not provided, the tube may develop
small pinholes due to escaping air.
• Ground the core at the support.

CAUTION
• If welding is performed without the core properly grounded,
this can lead to short-circuit where the base metal may
melt.
14-21
• Close both end of the tube by tungsten inert-gas arc welding
(TIG welding).
Welding conditions
• Welding rod: A4043 (approx. φ2 mm)
• Welding current: AC80A
• After welding, check for the following problems. If any of them
exist, repair again or replace the core.
• Undercut
• Bead crack
• Base metal crack
CAUTION
• Improper weld can lead to recurrence of coolant leakage.
Installation: Upper tank, Lower tank
• With the tank installed, eliminate any clearance between the
tank and core plate by tapping with a rubber (or plastic) hammer.
CAUTION
• To prevent adhesion of foreign matter, use bare hands to in-
stall the packing and tank.
• Adjust the stopper bolt until the gap dimension shown in the il-
lustration is obtained on the attachment of .
• Following the sequence shown in the diagram, bend tabs for

caulking tank. To perform this work, since cannot be used
to caulk sides 1 and 2, use pliers with the tips wrapped in vinyl
tape.
1 to 4: Bend two tabs at the center.
5 to 8: Bend other tabs following the direction of the arrow.
• After crimping the tabs onto the tank, check for coolant leakage.
14-22
14
• Paint a mark on the core where it can be easily noticed to indi-
cate that the core has been crimped.
CAUTION
• Paint a mark for each repair performed on either the upper
or lower tank.
14-23
COOLING FAN AND V-BELT
1 V-belt 5 Water pump pulley 11 Connector <Type C>
2 Cooling fan 6 Inlet pipe 12 Grease nipple bracket
<Type B and Type C> 7 Inlet hose <Type C>
3 Fan spacer <Type B> 8 Tube <Type C>
4 Fan spacer 9 Straight joint <Type C> Water pump
<Type B and Type C> 10 Grease nipple <Type C>
*a:
b: Crankshaft pulley
*
Assembly sequence
CAUTION • When replacing the V-belts, replace them as a set to prevent differences in tension between the belts.
Phone: 1 269 673 1638
Website: www.HeavyEquipmentRestorationParts.com www.dp150.com/cat-dp160-engine-parts
14-24
14
Service standards (Units: mm)
Location Maintenance item Service standard Limit Remedy
1 V-belt tension 10 to 15 – Adjust

Grease nipple
12.5 ± 2.5 {1.3 ± 0.3} –
Straight joint
Tube 2.25 ± 0.25 {0.2 ± 0.03}
Clamp 39 {0.4} –

Wheel bearing grease
Grease nipple As required
[NLGI No. 2 (Li soap)]
Special tools
Belt tension gauge MH062345 Measurement of tension of V-belt
Inspection: Tension of V-belts
• Press each V-belt at a central portion between pulleys with a
force of approximately 98 N {10 kgf} as shown in the illustration
and measure the amount of deflection of the belt.
A: Alternator pulley
B: Water pump pulley
C: Crankshaft pulley
• Place the small O-ring on at the scale mark corresponding

to 98N {10 kgf} (press force).
• Place the large O-ring on at the scale mark corresponding
to the maximum permissible deflection value specified for the
belt.
14-25
COOLING FAN AND V-BELT
• Place at a central portion between pulleys of the V-belt and
push the handle (indicated by the arrow in the illustration) until
the O-ring touches the flange.
• Measure the amount of deflection of the V-belt.

• If the measured value deviates from the standard value range,
adjust the tension of the belt as follows.
Adjustment of V-belt
• Loosen alternator mounting bolts (2 locations), then adjust the
tension of V-belts by moving the alternator from side to side.
• When the adjustment is completed, tighten the bolts and nuts
securely.
CAUTION
• Excessive tension in V-belts may damage the belts and re-
lated bearings.
• When replacing the V-belts, replace them as a set to prevent
differences in tension between the two belts.
• Keep the V-belts free of oil. If the belts become oily, they
may slip, resulting in overheating of the engine and insuffi-
cient charging of the battery.
14-26
14
M E M O
14-27
WATER PUMP
1 Impeller 7 Washer 13 Cover
2 Flange 8 Water pump shaft 14 Gasket
3 Snap ring 9 Unit seal
4 Bearing 10 Grease nipple <If equipped> : Non-reusable parts
5 Spacer 11 Water pump case
6 Bearing 12 Gasket
Assembly sequence
For the sequence not mentioned below, follow the disassembly sequence in reverse.
12 → 8 → 7 → 6 → 5 → 4 → 11 → 3 → 9 → 10

Location Maintenance item Service standard Limit Remedy
Reassembly
1, 8 Flange-to-water pump shaft interference 0.03 to 0.06 – allowed only
twice
Reassembly
2, 8 Impeller-to-water pump shaft interference 0.03 to 0.08 – allowed only
twice

Bolt (water pump mounting) 24 {2.4} –
Grease nipple 9.8 to 15 {1 to 1.5} –

Pack in bearing Wheel bearing grease As required
Fill through grease nipple [NLGI No. 2 (Li soap)] 60 g
Outer periphery of unit seal ThreeBond 1102 As required
14-28
14
Impeller puller
A B
MH062192 Removal of impeller puller
49 ± 1 φ 10
Removal procedure
Removal: Impeller
Removal: Flange
Inspection: Impeller-to-water pump shaft interference
• If the measurement does not comply with the standard value, re-
place the defective part(s).
CAUTION
• Even if the measurement complies with the standard value,
reassembly must not be carried out more than twice.
Inspection: Flange-to-water pump shaft interference

• If the measurement does not comply with the standard value, re-
place the defective part(s).
CAUTION
• Even if the measurement complies with the standard value,
reassembly must not be carried out more than twice.
14-29
WATER PUMP
Installation: Flange
CAUTION
• Before installing flange, make sure that there is no or only
one punch mark in the shown location on the flange. Make
an additional punch mark on the flange to indicate that it
undergoes the disassembly and reassembly process you
are doing now.
• Punch mark(s) indicate the number of times the flange was
disassembled and reassembled in the past. If there are two
marks, the flange must be replaced.
• Place a fixture under the flange and apply the ram load of a
press to the shaft of the bearing unit.
• Ram the shaft of the bearing unit down into the flange until it
contacts the fixture.
CAUTION
• If the flange is installed without the fixture, the water pump
case will be damaged.
Installation: Impeller
CAUTION
• Before installing impeller, make sure that there is no or only
one punch mark in the shown location on the impeller. Make
an additional punch mark on the impeller to indicate that it
undergoes the disassembly and reassembly process you
are doing now.
• Punch mark(s) indicate the number of times the impeller
was disassembled and reassembled in the past. If there are
two marks, the impeller must be replaced.
• Place the water pump so that the flange side end of the water
pump shaft becomes the load bearing surface.
• Apply pressure to the impeller with a press and press-fit the im-
peller so that its end face is flush with the end of the water pump
shaft.
14-30
14
Inspection after assembly
Inspection: Flange rotation
• Rotate the flange by hand. The flange should rotate smoothly
without any binding.
• If the flange does not rotate freely, disassemble and check.
14-31
THERMOSTAT
1 Thermostat cover
2 Gasket
3 Thermostat
4 Water temperature sensor
5 Plug
6 Cock
7 Thermostat case
8 Gasket
9 O-ring
10 Joint
11 O-ring
CAUTION
• Do not remove the thermostat case
unless it has a water leak or any
other defect.
Assembly sequence
verse.

Valve opening
76.5 ± 2°C –
3 Thermostat temperature Replace
Valve lift/temperature 10 or more/90°C –

Water temperature sensor 35 ± 7 {3.6 ± 0.7} –
Cock 20 to 26 {2.0 to 2.7} –

O-ring Soapy water As required
Thread of plug Loctite 575 As required

Phone: 1 269 673 1638
14-32
14
Inspection: Thermostat
• Stir the water using a stirring rod to maintain an even water tem-
perature in the container, then conduct the tests indicated below.
• If the measured values deviate from the standard value ranges,
replace the thermostat.
(1) Valve opening temperature
• Hold the thermostat with wire to keep it away from the heat
source.
• Heat the water gradually to the valve opening temperature.
• Maintain this temperature for five minutes and make sure that
the valve is completely open.
• Make sure that the valve closes completely when the water tem-
perature drops below 65°C.
(2) Valve lift
• Heat the water to a temperature slightly higher than the valve
opening temperature. Maintain this temperature for five minutes
and measure the valve lift.
Installation: Gasket
• Fit the gasket onto the thermostat case in the illustrated direc-
tion.
14-33
GROUP 15 INTAKE AND EXHAUST
SPECIFICATIONS ............................................................................. 15-2

1. Air Cleaner .................................................................................. 15-3
2. Turbocharger .............................................................................. 15-4
AIR CLEANER .................................................................................. 15-6
TURBOCHARGER ............................................................................ 15-8
INTAKE MANIFOLD ........................................................................ 15-14 15

EXHAUST MANIFOLD .................................................................... 15-16
15-1
SPECIFICATIONS
/
Item Specifications
Air cleaner element Cyclone filter paper type
Dust indicator type Mechanical/electrical
Model TD06
Turbocharger
Manufacturer Mitsubishi Heavy Industries
15-2
1. Air Cleaner
• The air cleaner utilizes single element.
• The lower air duct incorporate a vacu-
ator valve.
• The vacuator valve automatically
works in such a way that when the en-
gine speed drops below a specified
level, the valve’s rubber boot which is
usually subdued by internal vacuum is
allowed to spring back and accumulat-
ed dust and dirt are discharged as a
result.
15-3
2. Turbocharger
2.1 Waste gate mechanism

• The waste gate mechanism, which is
operated by an actuator, is designed
to let excess exhaust gas bypass the
turbocharger, thereby preventing the
turbocharger from overrunning and
the intake manifold pressure from ris-
ing excessively. This ensures that the
boost pressure is properly controlled.
• The boost pressure is led from the
compressor cover into the actuator’s
chamber A through rubber hose.
When the boost pressure working on
the chamber A is lower than the preset
level, the actuator remains inactive, al-
lowing exhaust gas to be blown
against the turbine wheel with the
waste gate valve closed.
• When the boost pressure in the cham-

ber A becomes higher than the preset
level, it causes the waste gate valve to
be opened, and the exhaust gas being
blown against the turbine wheel is de-
creased. This reduces the revolution
of the compressor wheel and the
boost pressure returns below the pre-
set level as a result.
15-4
TROUBLESHOOTING 15
Abnormal noise or vibration in intake/exhaust

Symptoms
Excess oil consumption

Reference Gr
Poor engine power

White exhaust gas
Black exhaust gas
system
Possible causes
Air cleaner Clogged air cleaner element O O O
Carbon deposits on shaft O O
Cartridge assembly
Interference between turbine wheel and tur-

O O O
bine housing
Bent shaft O O O
Damaged turbine wheel unit O O O
Turbocharger
Interference between compressor wheel
O O O
and compressor cover
Damaged compressor wheel O O O
Compressor cover fitted poorly O O O O
Turbine housing fitted poorly O O
Incorrect valve clearances O
Head gasket defective O
Wear/carbon deposits on valves and valve seats O
Gr11
Valve spring weakened O
Piston rings worn/damaged O O
Piston ring grooves worn/damaged O O
Cooling system malfunctioning O Gr14
Engine oil quantity excessive O Gr12
Major moving parts seized O Gr11
Uneven or excessive fuel injection O Gr13E
15-5
AIR CLEANER
Removal sequence
1 Dust indicator
2 Adaptor
3 Vacuator valve
4 Cover
5 Element
6 O-ring
7 Case
Service standards
Operation of dust indicator under specified negative 6.2 ± 0.6 kPa
1 – Replace
pressure {47 ± 4.3 mmHg}

Dust indicator 3.0 to 3.5 {0.3 to 0.35} –
15-6
15
Cleaning procedure
Cleaning: Element
• Blow a jet of compressed air at a pressure not higher than 685
kPa {7 kgf/cm2} against the inside surfaces of the element.
• Move the compressed air jet up and down along all pleats of the
filter paper element.
CAUTION
• For the frequency and timing of cleaning, refer to the rele-
vant instruction manual. More frequent cleaning than nec-
essary could damage the element or cause dust and foreign
matter to be sucked into the engine.
• Do not strike the element or hit it against another object to
remove dust.
• Do not blow compressed air against outside surfaces of the
element.
Inspection: Element
• Shine some electric light inside the element.
• Replace the element if thin spots or broken parts are evident in
the filter paper, or if the packing at the top of the element is dam-
aged.
Also replace the element if the dust on the element is damp with
oily smoke or soot, regardless of the replacement schedule.
Inspection: Operation of dust indicator under specified neg-

ative pressure
<Mechanical type>
• Apply negative pressure to the dust indicator, and take the
reading when the white signal appears in the dust indicator
window.
• Replace the dust indicator if found faulty.
<Electrical type>
• Perform the following inspection and, if faulty, replace the dust
indicator.
• With no vacuum applied to the dust indicator, take mea-
surement between the terminals 1 and 2. There should be
no continuity.
• Gradually apply vacuum to the dust indicator. Measure the
vacuum when the continuity is made between the terminals
1 and 2.
15-7
TURBOCHARGER
Removal sequence
1 Air inlet pipe 7 Turbocharger cover Exhaust manifold
2 Rubber hose 8 Exhaust pipe
*a:: Non-reusable parts
3 Eyebolt 9 Gasket
4 Oil feed pipe 10 Turbocharger
5 Oil return pipe (See later section.)
6 Gasket 11 Gasket

Clamp (rubber hose mounting) 4.9 {0.5} –
Eyebolt (oil feed pipe mounting) 21 {2.1} –
Nut (exhaust pipe mounting)
41 {4.2} –
Nut (turbocharger mounting)

Turbocharger (to be filled with engine oil) Engine oil As required

Phone: 1 269 673 1638
Website: www.HeavyEquipmentRestorationParts.com www.dp150.com/cat-dp160-engine-parts
15-8
15
Installation: Turbocharger
• Before installing the turbocharger, pour engine oil into the oil
hole to ensure smooth operation of the internal parts.
15-9
TURBOCHARGER
Turbocharger
1 Hose
2 Actuator
3 Coupling
4 Turbine housing
5 Snap ring
6 Compressor cover
7 O-ring
8 Cartridge assembly
Assembly sequence
verse.
CAUTION
• The cartridge assembly cannot be tak-
en to pieces. Replace the whole as-
sembly if the turbine wheel or
compressor cover is damaged and
when the cartridge does not rotate
smoothly.

Play in axial direction of shaft 0.05 to 0.09 0.1 Replace
Cartridge Play Turbine wheel end 0.40 to 0.53 0.58 Replace
8
assembly perpendicular to
axis of shaft Compressor wheel end 0.55 to 0.66 0.72 Replace

Bolt (coupling tightening) 3.9 to 4.9 {0.4 to 0.5} Wet

Molybdenum disulfide grease
Thread of bolts As required
[NLGI No. 2 (Li soap)]
Work before removal

Alignment mark
• Put alignment marks on the coupling, turbine housing, compres-
sor cover and cartridge assembly.

Phone: 1 269 673 1638
15-10
15
Removal procedure
Removal: Turbine housing
• Lightly tap around the entire periphery of the turbine housing
with a rubber-faced hammer, taking care not to cause damage.
CAUTION
• The blades on the cartridge assembly are easily bent. Make
sure that they do not strike the turbine housing.
Removal: Compressor cover

• Lightly tap around the entire periphery of the compressor cover
with a rubber-faced hammer, taking care not to cause damage.
CAUTION
• The blades on the cartridge assembly are easily bent. Make
sure that they do not strike the compressor cover.
Work after disassembly

Cleaning
• Before cleaning, visually check the disassembled parts for
scorches, abrasion and other marks that may be difficult to see
after cleaning. Replace any part that appears defective.
• Immerse the disassembled parts in a non-flammable solvent (a
5 to 10 aqueous solution of Oil Clean from New Hope Co., Ltd.).
Take out the parts and blow them dry with compressed air. Re-
move any hard deposits with a stiff brush or plastic scraper.
CAUTION
• Do not immerse the cartridge assembly in the solvent. If the
cartridge is immersed in the solvent, O-ring in the cartridge
will swell, causing the turbocharger function to be impaired.
• Again, immerse the parts in the solvent.

• Blow them dry using compressed air.
Inspection: Cartridge assembly
• If the measurement exceeds the specified limit, replace the car-
tridge assembly.
(1) Play in axial direction of shaft
15-11
TURBOCHARGER
(2) Play perpendicular to axis of shaft
Installation: Snap ring
• With the tapered surface facing up, install the snap ring into the
compressor cover.
CAUTION
• Fit the snap ring into place using hands not to let it spring
away.
Work after installation

Inspection: Free rotation of cartridge assembly
• Turn the wheels of the cartridge assembly. They should turn
freely without binding.
• If not, disassemble again and correct.
15-12
15
M E M O
15-13
INTAKE MANIFOLD
Removal sequence
1 Boost pressure sensor
2 Intake air temperature sensor
3 Exhaust gas recirculation valve
adapter
4 Gasket
5 Plate
6 Reed valve
7 Intake manifold fitting
8 Gasket
9 Intake manifold
Cylinder head (See Gr11.)

*a:: Non-reusable parts

Bolt (boost pressure sensor mounting) 4 to 6 {0.4 to 0.6} –
Intake air temperature sensor 14.7 to 24.5 {1.5 to 2.5} –
Bolt (exhaust gas recirculation valve adapter mounting) 46 to 54 {4.7 to 5.5}

Intake manifold to cylinder head mounting surface ThreeBond 1217H As required
Installation: Intake air temperature sensor
• Check that the sensor portion is free of soot, oily substance, etc.
• If not, clean the sensor portion as follows.
• Spray a cleaner on the sensor portion from 2 or 3 cm away.
Recommended cleaners:
Non-chlorinated Brake Parts Cleaner
• In 20 to 30 seconds after spraying, wipe the sensor portion clear
of the sprayed cleaner using a soft waste cloth or the like.
CAUTION
• Be sure to wait for 20 to 30 seconds before wiping. It takes
Cat DP160 DP160N Forklift Engine Parts the cleaner that long to dissolve foreign matter.
Contact email:
EngineParts@HeavyEquipmentRestorationParts.com • If the sensor portion is fouled excessively, the positive crank-
Phone: 1 269 673 1638 case ventilation (PCV) may be faulty. Inspect the PCV valve and
Website: www.HeavyEquipmentRestorationParts.com filter to locate the cause and remove it. (See Gr17.)
15-14
15
Installation: Intake manifold
• Clean the sealing surfaces of the intake manifold and cylinder
head where they are to be mated with each other.
• Apply an even and continuous bead of sealant onto the intake
manifold surface where the cylinder head is to be mounted.
• Install the intake manifold onto the cylinder head within 3 min-
utes following the application while taking care not to spread the
sealant beyond the application area.
CAUTION
• Do not start the engine at least for an hour after the intake
manifold has been installed.
• If the intake manifold mounting bolts are subsequently
loosened or removed, be sure to apply sealant again upon
reassembly.
15-15
EXHAUST MANIFOLD
Removal sequence
1 Exhaust manifold insulator A
2 Exhaust manifold insulator B
3 Front exhaust manifold insulator
4 Exhaust manifold bracket
5 Distance piece
6 Exhaust manifold
7 Gasket
*a: Cylinder head (See Gr11.)


Nut (exhaust manifold mounting) 58 {5.9} –
Installation: Gasket
• Fit the gasket to the cylinder head in the illustrated direction.

Phone: 1 269 673 1638
15-16
GROUP 17 EMISSION CONTROL

1. Exhaust Gas Recirculation System ............................................... 17-2
2. Blowby Gas Return System .......................................................... 17-4

1. Replacement of PCV Valve Element .............................................. 17-5
EGR VALVE, EGR SOLENOID VALVE, EGR PIPE AND

EGR COOLER..................................................................................... 17-6
BLOWBY GAS RETURN SYSTEM .................................................... 17-9
17
17-1
1. Exhaust Gas Recirculation System
1.1 Overview
• EGR mixes inert gases contained in burned exhaust gases with the air on the inlet side (inlet manifold), thereby
reducing the combustion temperature and thus reducing the amount of harmful NOx (nitrogen oxides) contained
in the exhaust gases.
The EGR cooler provides cooling to increase the density of the inert gases, thereby achieving a greater EGR ef-
fect.
• The EGR system uses various sensors to detect engine operating conditions (engine speed, coolant temperature,
accelerator opening) and, based on the information obtained, lets the engine ECU control operation of the EGR
solenoid valve. (See Gr13E for the electronic control system and ECU connection diagram.)
• If black smoke occurs or the engine speed becomes erratic under heavy or low load condition of the engine, the
EGR valve control function is suspended.

Phone: 1 269 673 1638
17-2
17
(1) EGR solenoid valves
• The EGR solenoid valves are each turned ON/OFF by drive signals from the engine electronic control unit to real-
ize a 7-stage supply of air to the EGR valve.
(2) EGR valve
• The EGR valve realizes 7 stages of valve lift in accordance with the supply of air to its input ports from the EGR
solenoid valves.
17-3
2. Blowby Gas Return System
PCV: Positive Crankcase Ventilation
• The blowby gas return system returns blowby gases to an air duct to prevent them from being released to the out-
side air.
• The PCV valve keeps constant the pressure inside the crankcase.
• The oil in the blowby gas is separated by the wire mesh and the element in the PCV valve and is returned to the
oil pan.
• When the element is clogged, the regulator valve opens and the blowby gas is returned to the breather hose.

Phone: 1 269 673 1638
17-4
GENERAL INSPECTION AND ADJUSTMENT 17
1. Replacement of PCV Valve Element

CAUTION
• For information on the element replacement interval, refer
to the element instruction manual. If the element is used be-
yond its replacement interval, it may become clogged, caus-
ing the pressure inside the engine to increase such that oil
leakage occurs.
• Be sure to remove and install the cap by hand. Using tools
could result in damage.
[Removal]
• Loosen the cap by hand.
CAUTION
• Do not use any tools to loosen the cap. Otherwise, the cap
may become damaged.
[Installation]
• Clean the thread on the cap.
• Lightly smear the O-ring with engine oil and fit it on the cap.
• Securely tighten the cap until it stops slightly above the PCV
body.
CAUTION
• Be sure to use a genuine Mitsubishi Fuso element. Using an
inappropriate element could result in engine trouble.
• When replacing the element, be sure to replace the O-ring
also.
17-5
EGR VALVE, EGR SOLENOID VALVE, EGR PIPE AND EGR COOLER
Removal sequence
1 Water hose 10 Upper EGR pipe clamp 19 Gasket
2 Water hose 11 EGR pipe
3 Water hose 12 Gasket *a: EGR valve adapter
4 EGR adapter 13 Eyebolt
5 Gasket 14 EGR air pipe : Non-reusable parts
6 Gasket 15 Connector Arrows A to C indicate points to or
7 Plug 16 Connector from which pipes are connected.
8 EGR cooler 17 EGR solenoid valve EGR: Exhaust Gas Recirculation
9 Gasket 18 EGR valve

Contact email:
Installation sequence EngineParts@HeavyEquipmentRestorationParts.com
Perform installation by following the removal sequence in reverse. Phone: 1 269 673 1638
17-6
17
Service standards
0 0 –
1 1.3 ± 0.3 –
2 2.6 ± 0.3 –
3 4.6 ± 0.3 –
18 EGR valve lift Operating stage Replace
4 5.7 ± 0.3 –
5 7.7 ± 0.4 –
6 9.0 ± 0.3 –
7 11.0 ± 0.3 –

Clamp (water hose mounting) 4 to 5 {0.4 to 0.5} –
Connector (air pipe mounting) 15 to 29 {1.5 to 3.0} –
Clamp (water hose mounting) 3.9 {0.4} –
Eyebolt (water outlet pipe mounting)
25 {2.6} –
Eyebolt (EGR air pipe mounting)
Nut (EGR adapter mounting) 58 {5.9} –
Bolt (EGR adapter mounting)
Bolt (EGR pipe mounting) 46 to 54 {4.7 to 5.5} –
Bolt (EGR solenoid valve mounting)
Plug 29 {3.9} –
Inspection procedures
Inspection: EGR valve lift
• While applying air pressure of 637 to 932 kPa {6.5 to 9.5 kgf/
cm2} to the ports in accordance with the table below, measure
the valve lift in operating steps 0 to 7 on each valve.
• Replace the EGR valve if it does not conform to the standard
value.
Input port
Operating step
M/V-1 M/V-2 M/V-3
0 – – –
1 O – –
2 – O –
3 O O –
4 – – O
5 O – O
6 – O O
7 O O O
O: Air applied
–: Air not applied
17-7
EGR VALVE, EGR SOLENOID VALVE, EGR PIPE AND EGR COOLER
Inspection procedures
Inspection: EGR cooler
(1) Exhaust gas passage side
• Fit a cover over the exhaust gas outlet of the EGR cooler, and
connect a hose to the exhaust gas inlet. Then, submerge the
EGR cooler in a container of water. Make sure the coolant pas-
sage is full of water.
• Apply air pressure of 390 kPa {4 kgf/cm2} through the hose.
Check that air does not leak from any part of the EGR cooler.
• If there is any abnormality, replace the EGR cooler.
(2) Coolant passage side

• Fit covers over the EGR cooler’s exhaust gas inlet, exhaust gas
outlet, and coolant outlet, and connect a hose to the coolant in-
let. Then, submerge the EGR cooler in a container of water.
• Apply air pressure of 294 kPa {3 kgf/cm2} through the hose.
Check that air does not leak from any part of the EGR cooler.
• If there is any abnormality, replace the EGR cooler.
17-8
BLOWBY GAS RETURN SYSTEM 17
<Type A>
Removal sequence
1 Breather pipe 6 Oil hose stay *a: Rocker cover
2 Breather hose 7 Cap Breather hose
3 Breather hose 8 O-ring
*b:
4 Oil hose 9 Element : Non-reusable parts
5 PCV valve bracket 10 PCV body PCV: Positive crankcase ventilation
Perform installation by following the removal sequence in reverse.

Clamp 4.9 {0.5} –
Clamp 4.0 to 5.0 {0.4 to 0.5} –

17-9
BLOWBY GAS RETURN SYSTEM
<Type B>
Removal sequence
1 Breather hose 6 Cap *a: Rocker cover
2 Breather hose 7 O-ring Air suction pipe
3 Oil hose 8 Element
*b:
4 PCV valve bracket 9 PCV body : Non-reusable parts
5 Oil hose stay PCV: Positive crankcase ventilation

Clamp 4.9 {0.5} –

17-10
17
<Type C>
Removal sequence
1 Breather hose 7 O-ring *a: Rocker cover
2 Breather pipe 8 Element Air suction pipe
3 Breather hose 9 PCV body
*b:
4 Breather hose 10 Oil hose stay : Non-reusable parts
5 Oil hose 11 PCV valve bracket PCV: Positive crankcase ventilation
6 Cap

Clamp 4.9 {0.5} –

17-11
GROUP 54 ELECTRICAL
SPECIFICATIONS .............................................................................. 54-2

1. Starter .................................................................................................. 54-3
2. Alternator ..................................................................................... 54-4
3. Circuit diagram ............................................................................. 54-7
TROUBLESHOOTING ....................................................................... 54-8

#001 to #179 SWITCH ...................................................................... 54-10
#180 to #249 RELAY ........................................................................ 54-11
#250 to #349 SENSOR ..................................................................... 54-12
#350 to #409 CONTROL UNIT .......................................................... 54-13
#750 to #859 OTHER ....................................................................... 54-14
#930 STARTER ................................................................................ 54-15
#940 ALTERNATOR ......................................................................... 54-28 54
#950 INSPECTION OF ALTERNATOR .............................................. 54-34
#951 INSPECTION OF REGULATOR ................................................ 54-35
#955 INSPECTION OF PREHEATING SYSTEM ................................. 54-36

Phone: 1 269 673 1638
54-1
SPECIFICATIONS
Alternator
Item Specifications
Manufacturer MITSUBISHI ELECTRIC
Alternator with built-in regulator
Type
(without brush external fan)
Model A4T40379 A4T40399 A4TU7686
Output V–A 24–50
Starter, Preheat
Item Specifications
Starter Manufacturer MITSUBISHI ELECTRIC
Model M008T62271
Output V–kW 24–5.0
Magnetic switch operating
16 or less
voltage V
Model U001X33472
Excitation current V–A 24–2.3
Starter relay Closing voltage V 16 or less
Opening voltage V 4 or less
Allowable cutoff current A 200
Model Sheathed type
Glow plug
Rated voltage and current V–A 23–2.2 (reference)
Model U001T41472
Excitation current V–A 24–1.8
Closing voltage V 16 or less
Glow relay
Opening voltage V 4 or less
Allowable cutoff current A 60
Temperature fuse capacity A 127
54-2
1. Starter
• This starter uses planetary gears as its reduction gearing mech-

anism.
54-3
2. Alternator
<24V–50A>
54-4
54
2.1 Alternator with neutral diodes
(1) Features
• The alternator with neutral diodes pro-
vides higher DC output during opera-
tion at high speeds than the alternator
without neutral diodes.
(2) Variations of voltage at neutral

point and operation of neutral di-
odes
• The potential at the neutral point var-
ies up and down with the neutral point
DC voltage (1/2 of output voltage) as a
center as shown.
• When the alternator is operated at
high speeds, the voltage at the neutral
point can increase to exceed the out-
put voltage (28 V) and decrease to be-
come lower than the ground voltage (0
V), and these voltages are lost in con-
ventional system. The neutral diodes
rectifies these over-voltage and under-
voltage (shaded portions of diagram)
and adds them to the DC output.
• When the voltage at neutral point is in
the range from 0 to 28 V, the conven-
tional diodes (other than neutral di-
odes) operate.
54-5
• When the voltage at neutral point ex-
ceeds 28 V, the positive diode oper-
ates and adds extra output to the DC
output for supply to each electric
equipment.
• When the voltage at neutral point

drops below 0 V, the negative diode
supplies the output from neutral point
through other three diodes.
54-6
54
3. Circuit diagram
54-7
TROUBLESHOOTING
1. Power and Charging
Battery electrolyte decreases too early.

Symptoms
Battery is normal but over-discharged.

Charge warning lamp does not light
when starter switch is turned ON,
Alternator is normal but battery

with engine stopped.
Reference Gr
Battery overheating.
over-discharged.
Possible causes
Connector connection faulty, harness broken, grounding faulty O O
Fuse blown O O O
V-belts loose O O
Gr14
V-belts damaged O O
Battery faulty O O
Stator coil broken O
Stator coil short-circuited with core O
Field coil broken O
Alternator
Rectifier faulty O
Regulator faulty O O O
Wiring faulty O
54-8
54
2. Engine Starting, Preheating and Stopping
Symptoms Starter operates
but engine does
Does not operate cold start function.

not start.
Pinion engages with ring gear
Engine cannot be preheated.

Flywheel rotates but engine
Starter does not operate.
Pinion does not engage
Engine is hard to start.

Engine does not stop.
Reference Gr
but does not rotate.
does not start.

with ring gear.
Possible causes
Connector connection faulty, harness broken, grounding faulty O O O O O O
Fuse blown O O O
Battery insufficiently charged O O
Magnetic switch contacts stuck
O
or fused together
Open circuit in magnetic switch
O
Starter coil
Overrunning clutch malfunc-
O
tioning
Pinion worn or damaged O
Starter relay defective O
Starter switch defective O O
Flywheel ring gear worn or damaged O Gr11
Engine electronic control unit
Electronically controlled O O O O
defective Gr13E
fuel system
Supply pump defective O
Water temperature sensor defective O O
Glow plugs defective O O
Glow relay defective O O
Connecting plate connection faulty O O
Cold start switch defective
Exhaust brake 3-way magnetic valve defective O
Exhaust brake system defective O
54-9
#001 to #179 SWITCH
#024 Inspection of thermo switch
• Dip the switch in a container filled with engine oil.
• Raise the oil temperature to the specified one while stirring oil.
• Measure the operating temperature between terminals 1 and 2
respectively.
Standard value 105 ± 2°C
• If the measured value deviates from the standard value, replace
the sensor. (See Gr14.)
#044 Inspection of engine oil pressure switch

• Perform the following checks, and if any fault is found, replace
the switch. (See Gr12.)
(1) Inspection by without applying air pressure
• Make sure that there is continuity between terminal 1 and body.
(2) Inspection by applying air pressure
• Gradually apply air pressure to the switch starting from 0 kPa {0
kgf/cm2}.
• Measure the degree of air pressure at the moment when conti-
nuity is not detected between terminal 1 and body, and make
sure to confirm if the value meets the standard.
Standard value
50 ± 10 kPa {0.5 ± 0.1 kgf/cm2}
(operating pressure)
#053 Inspection of engine oil bypass alarm switch

the switch. (See Gr12.)
(1) Inspection by without applying air pressure
• Make sure that there is no continuity between terminals 1 and
body.
(2) Inspection by applying air pressure
• Gradually apply air pressure to the switch starting from 0 kPa {0
kgf/cm2}.
• Measure the degree of air pressure at the moment when conti-
nuity is detected between terminals 1 and body, and make sure
to confirm if the value meets the standard.
Standard value
185 +49
0 kPa {1.9
+0.5
0 kgf/cm2}
(operating pressure)

Phone: 1 269 673 1638
54-10
#180 to #249 RELAY 54
#187 Inspection of starter relay
• Perform continuity check and operation check, and if any fault is
found, replace the relay.
#188 Inspection of main power relay

#195 Inspection of glow relay

#201 Inspection of relay (normally open type 5 pin)

54-11
#250 to #349 SENSOR
#259 Inspection of water level sensor
• Remove the water level sensor from the radiator.
• Turn the starter switch ON.
• Dip the water level sensor in a container filled with engine cool-
ant, and check that the pilot lamp goes on and out under the fol-
lowing conditions.
Condition Pilot lamp
When water level sensor is
ON
out of the engine coolant
When water level sensor is in
OFF
the engine coolant
• If any fault is found, replace the sensor. (See Gr14.)

#262 Inspection of water temperature sensor
<For water temperature gauge>
• Dip the sensor in a container filled with engine oil.
• Measure the resistance between terminals 1 and the body.
50 ± 0.2 °C 80 ± 10 Ω
60 ± 0.2 °C 56.3 ± 5 Ω
Standard 80 ± 0.2 °C 29.5 ± 2.5 Ω

value 100 ± 0.3 °C 16.5 ± 0.9 Ω
106 ± 0.3 °C 14.3 ± 0.5 Ω
120 ± 0.3 °C 10 ± 0.3 Ω
<For water temperature gauge>

• Measure the resistance values between terminals 1 and the
body.
50 ± 0.2 °C 80 ± 10 Ω
60 °C 56.3 Ω (reference value)
Standard 80 °C 29.5 Ω (reference value)

value 100 °C 16.5 Ω (reference value)
106 ± 0.3 °C 14.3 ± 1.0 Ω
120 °C 10 Ω (reference value)
<For engine control>

• Measure resistance values between terminals 1 and 2.
20 °C 2.45 ± 0.14 kΩ
Standard 80 °C 0.32 kΩ (reference value)

value
110 °C 147.1 ± 2 Ω

54-12
#250 to #349 SENSOR, #350 to #409 CONTROL UNIT 54
#263 Inspection of engine speed sensor
• Measure the resistance values between terminals 1 and 2.
Standard value (at 20°C) 125.5 ± 17 Ω
the sensor. (See Gr13E.)
#274 Inspection of water separator sensor

Condition Continuity terminal
ON (when coolant quantity is ap-
1–2
prox. 100 cm3 or more)
OFF –
• If any fault is found, replace the sensor. (See Gr13A.)
#350 Inspection of control unit and other units

• Since the units alone cannot be readily checked in the off–vehi-
cle state, check the harness, switch and other related parts in
each system.
• If any fault is not found in the related parts, and the problem still
remains in the system, replace the control units or other units.

Phone: 1 269 673 1638
54-13
#750 to #859 OTHER
#757 Inspection of dust indicator
the dust indicator.
2 when air pressure is not applied to the dust indicator.
2 when negative pressure of 6.23 ± 0.57 kPa {635 ± 58
mmH2O} is applied to the dust indicator. (See Gr15.)
#758 Inspection of air dryer

(1) Inspection of thermostat
• Perform the following check. If any fault is found, replace the
thermostat.
• While varying the temperature around the thermostat, measure
the temperatures when the continuity is established and is lost
between terminals 1 and 2.
Temperature when
Lowering the tem- continuity is estab-
4 ± 4°C
perature lished (ON temper-
Standard ature)
value
Temperature when
Raising the temper- 20°C
continuity is lost
ature or lower
(OFF temperature)
(2) Inspection of heater

• Measure the resistance of heater as shown.
Standard value 8.2 Ω or less
• If the measured value is out of the standard value, replace the
heater.
#764 Inspection of glow plug

• Measure resistance value of glow plug as shown.
Standard value
Approx. 4 Ω
(cold resistance of glow plug)
the glow plug. (See Gr11.)

Phone: 1 269 673 1638
54-14
#930 STARTER 54
Removal sequence
1 Starter relay
2 Starter
WARNING
• Before removing the starter, dis-
connect the (–) battery cable and in-
sulate the cable and the (–) battery
terminal with tape.
• It is dangerous to leave the (–) bat-
tery cable connected since the bat-
tery cable voltage is always present
at terminal B.
54-15
#930 STARTER
1 Stopper ring 12 Brush (+) 23 Plate
2 Pinion stopper 13 Yoke 24 E-ring
3 Pinion 14 Packing 25 Gear shaft
4 Spring 15 Rear bearing 26 Washer
5 Magnetic switch 16 Washer 27 Internal gear
6 Shim 17 Armature 28 Overrunning clutch
7 Rear bracket 18 Ball 29 Lever
8 Packing 19 Cover 30 Front bearing
9 Brush spring 20 Rubber packing 31 Oil seal
10 Brush (–) 21 Planetary gear 32 Front bracket
11 Brush holder 22 Rubber packing
54-16
54
CAUTION
• When the armature is removed, the ball may come out with it. Take care not to lose the ball.
• Do not remove the bearings and unless defects are evident.

• The rubber packing is serviceable if any defect is not found in it during disassembly.
• It is not necessary to remove the pinion when only the motor section needs to be disassembled for inspection, like
when inspecting brushes and related parts.
• Be sure to remove the pinion before disassembling any other parts.
Assembly sequence
CAUTION
• Whenever the magnetic switch is replaced, the pinion gap must be adjusted.

– Pinion gap 0.5 to 2.0 – Adjust
No-load Current 85 A or less –
– With 23V applied Inspect
characteristics Rotation speed 3300 rpm or higher –
13.7 N
9 Brush spring pressure 29.2 to 39.4 N {3 to 4 kgf} Replace
{1.4 kgf}
10, 12 Brush length 18 11 Replace
Commutator outside diameter 32 31.4
0.1 or Replace
Runout of commutator periphery –
17 higher
Correct or
Mold depth between segments – 0.2 or less
replace

Lever contact surface of magnetic switch
Sliding surfaces of gear shaft and overrunning Multipurpose grease
As required
clutch [NLGI No. 2 (Li soap)]
Sliding surfaces of lever and overrunning clutch
Sliding surfaces of armature and gear shaft
Ball
Molykote AG650 As required
Teeth of planetary gear and internal gear
Washer
Multipurpose grease
Oil seal [NLGI No. 2 (Li soap)] As required
or grease attached to oil seal
Multemp OA-171
Splines of overrunning clutch As required
(Kyodo Yushi Co., Ltd.)
Special tools
Bearing puller and

installer MH063597
Removal and installation of front
A: MH063615
bearing
B: MH063629
A: Bearing puller and
installer
B: Bearing installer
54-17
#930 STARTER
Work before disassembly
Mating mark: Rear bracket and yoke
Disassembly procedure
Disassembly: Pinion
• For removal of the pinion, current must be supplied to the starter
such that the pinion springs out.
WARNING
• When the starter is energized, the pinion will spring out and
rotate. Be careful not to touch it with your hands.
• The magnetic switch may become very hot during inspec-
tions. Be careful when touching it.
CAUTION
• Do not energize the pull-in coil P for longer than 10 sec-
onds, and do not energize the holding coil H for longer than
30 seconds. If these periods are exceeded, the coils may
overheat and burn out.
• To make the pinion spring out, be sure to energize the start-
er such that its parts are positioned correctly. If the starter
is not energized and the lever is pulled to make the pinion
come out, the front bracket and/or lever may be damaged by
the shock inflicted upon them when the stopper ring is re-
moved.
• When current is supplied to the starter, a large current (100
A or higher) will flow. For inspection purposes, use booster
cables or similarly thick cables. It is also important to en-
sure that all connections are secure.
54-18
54
• Connect the starter as illustrated.
• The following operations are performed with current supplied to
the starter. Thus, the entire procedure for removal of the pinion
must be completed within 30 seconds.
• Turn ON switches 1 and 2 to supply current to the starter. The
pinion will spring out and rotate.
• After the pinion starts to rotate, quickly (within five seconds) turn
OFF switch 2 to stop the pinion’s rotation.
CAUTION
• When switches 1 and 2 are turned ON, the pull-in coil P and
holding coil H are both energized. The circuit is connected
such that no voltage is applied to starter terminal B, so cur-
rent flows to the pull-in coil while the pinion rotates. To pre-
vent the pull-in coil from burning out, it is essential to turn
OFF switch 2 quickly (within five seconds) after the pinion
starts to rotate.
• Apply a pipe-shaped implement to the pinion stopper.

• Using a hammer, lightly tap the pipe-shaped implement to re-
move the stopper ring from the ring groove of the pinion stopper.
• Remove the stopper ring and pinion.
• Turn OFF switch 1 to de-energize the starter.
CAUTION
• When the starter is de-energized, the mechanism will at-
tempt to pull in the pinion. Thus, the stopper ring may slip
back into the ring groove of the pinion stopper. If this hap-
pens, energize the starter and go through the pinion remov-
al procedure again.
54-19
#930 STARTER
Disassembly: Yoke and brush holder
• Use the following method to remove the yoke and brush holder
in order to prevent the commutator of the armature from being
damaged by the brushes.
• Lift the brushes away from the commutator and hold them lift-
ed by applying the brush springs against the sides of the
brush springs.
• Pull part A of each brush spring and pull up the brushes.

• Hold the brushes in position with the brush springs as illustrat-
ed.
• Remove the yoke and brush holder.
Disassembly: Gear shaft and internal gear

• Remove the E-rings and then the gear shaft and internal gear
from the overrunning clutch.
Proceed as follows if the gear shaft cannot be removed due to
interference of the splined section of gear shaft with internal
parts of the overrunning clutch.
• Press the gear shaft against the overrunning clutch.
• Turn the gear shaft approx. 1/8 of a turn to change the posi-
tion of splined section.
Disassembly: Front bearing
54-20
54
Inspection: Magnetic switch
• Perform the following inspections. If any abnormality is found,
replace the switch.
(1) Test for coil open circuit

• Check that continuity exists between terminals S and M.
• Check that continuity exists between terminal M and the body.
(2) Test for fused-together contacts

• Check that continuity does not exist between terminals B and M.
(3) Test for contact-to-contact continuity

• Push in the end of the magnetic switch to close the internal con-
tacts. Then, check that continuity exists between terminals B
and M.
54-21
#930 STARTER
Inspection: Brush spring pressure
• Using new brushes, measure the load required to separate each
brush spring from its brush.
• If either measurement is lower than the specified limit, replace
the brush springs.
Inspection: Brush (–)

(1) Brush length
• If either brush (–) is shorter than the limit, it must be replaced.
CAUTION
• The brush (–) and its brush holder should be replaced as a
set.
(2) Contact surface of armature’s commutator and brush

• If the commutator contact surface of either brush is rough or un-
evenly worn, rectify it with emery paper (#300 to 500).
Inspection: Brush holder

• Thoroughly clean the (+) brush holder and the (–) holder plate,
then, check that continuity does not exist between them.
• If continuity exists, there is a short circuit and the brush holder
must be replaced.
Inspection: Yoke
(1) Test for coil open circuit
• Check that continuity exists between the cable and the (+)
brush.
• If there is no continuity, there is an open circuit and the yoke or
(+) brush must be replaced.
(2) Test for coil grounding

• Check that continuity does not exist between the yoke and the
(+) brush.
• If continuity exists, the coil is grounded. Inspect the insulation,
and replace the yoke and the (+) brush if the insulation cannot
be rectified.
CAUTION
• The coil may be grounded to the yoke due to the accumula-
tion of worn-off metal particles from the brushes and/or ar-
mature.
54-22
54
Inspection: Brush (+)
(1) Brush length
• If either brush (+) is shorter than the limit, it must be replaced.
(2) Contact surface of armature’s commutator and brush

• If the commutator contact surface of either brush is rough or un-
evenly worn, rectify it with emery paper (#300 to 500).
Inspection: Armature
(1) Test for coil short circuit
• Hold an iron rod parallel with the armature.
• Slowly rotate the armature by hand.
• If the iron rod vibrates or is pulled toward the armature, the coil
is short-circuited and the armature must be replaced.
(2) Test for coil grounding

• Check that continuity does not exist between the commutator
and the core (or shaft).
• If continuity exists, the coil is grounded and the armature must
be replaced.
(3) Commutator outside diameter

• If the measurement is out of specification, replace the armature.
(4) Runout of commutator periphery

• If the reading exceeds the specified limit, rectify the commutator
of the armature, making sure the outside diameter stays within
specification.
(5) Condition of commutator surface
• If the surface is rough or has stepped wear, rectify it with emery
paper (#300 to 500).
• After rectifying the surface, check the extent of commutator
runout.
54-23
#930 STARTER
(6) Mold depth between segments
• If the measurement is lower than the specified limit, rectify or re-
place the armature.
• To rectify the armature, grind the illustrated portions.
• If the mold is worn as illustrated, rectify or replace the armature.
: Acceptable
X : Unacceptable
Inspection: Overrunning clutch

If the following inspections reveal any abnormality, replace the
overrunning clutch.
• Turn the shaft in direction B and check that it rotates smoothly.
• Turn the shaft in direction A and check that it locks.
Assembly procedure
Assembly: Front bearing
• Press-fit the front bearing using –A and –B.
• After the press fitting, caulk the front bearing using the claws on
–A.
CAUTION
• Avoid re-caulking previously caulked points.
54-24
54
Assembly: Yoke and brush holder
• To install the yoke and brush holder, follow the removal se-
quence in reverse.
(See “ Disassembly: Yoke and brush holder”)
Assembly: Magnetic switch

• Fit the magnetic switch onto the lever with terminal S aligned as
illustrated.
Assembly: Pinion
• For installation of the pinion, it is not necessary to supply current
to the starter.
• Fit the pinion stopper and pinion onto the overrunning clutch,
making sure they are oriented as illustrated.
• Fit the stopper ring into the ring groove of the overrunning
clutch.
• Pull the pinion hard and securely fit the stopper ring into the ring
groove of the pinion stopper.
54-25
#930 STARTER
Inspection after assembly
Inspection: Performance and pinion gap
• After assembling the starter, perform inspections with current
supplied to it.
WARNING
• When the starter is energized, the pinion will spring out and
rotate. Be careful not to touch it with your hands.
• The magnetic switch may become very hot during inspec-
tions. Be careful when touching it.
CAUTION
• Do not energize the pull-in coil P for longer than 10 sec-
onds, and do not energize the holding coil H for longer than
30 seconds. If these periods are exceeded, the coils may
overheat and burn out.
• When current is supplied to the starter, a large current (100
A or higher) will flow. For inspection purposes, booster ca-
bles or similarly thick cables must therefore be used. Also,
it is important to ensure that all connections are secure.
(1) Performance test

• Set the voltage to 23 Volts DC.
CAUTION
• The voltage applied must not exceed 24 V.

the starter. Thus, the entire test (consisting of measurement of
the current flowing through the starter and measurement of the
starter’s rotational speed) must be completed within 30 seconds.
• Turn ON the switch to supply current to the starter. The pinion
will spring out and rotate.
CAUTION
• When the switch is turned ON, the pull-in coil P and holding
coil H are both energized. When the large current from the
DC power supply flows from terminal B to terminal M, the
supply of current to the pull-in coil P is cut; only the holding
coil H remains energized. To prevent the holding coil from
burning out, it is essential to complete all operations within
30 seconds.
• Measure the current and the starter’s rotational speed. To

measure the rotational speed, shine a stroboscope on the pin-
ion.
• Turn OFF the switch to de-energize the starter.
• If either measurement is out of specification, disassemble and
inspect the starter again.
54-26
54
(2) Pinion gap

the starter. Thus, the entire procedure for measurement of the
pinion gap must be completed within 30 seconds.
• Turn ON switches 1 and 2 to supply current to the starter. The
pinion will spring out and rotate.
• After the pinion starts to rotate, quickly (within five seconds)

turn OFF switch 2 to stop the pinion’s rotation.
CAUTION
• When switches 1 and 2 are turned ON, the pull-in coil P and
holding coil H are both energized. The circuit is connected
such that no voltage is applied to starter terminal B, so cur-
rent flows to the pull-in coil while the pinion rotates. To pre-
vent the pull-in coil from burning out, it is essential to turn
OFF switch 2 quickly (within five seconds) after the pinion
starts to rotate.
• Pull out the end of the overrunning clutch and then lightly
push in the end of the overrunning clutch and measure the
amount of movement in the axial direction, i.e., the pinion
gap.
• Turn OFF switch 1 to de-energize the starter.
• If the measurement is out of specification, replace the lever.
54-27
#940 ALTERNATOR
Removal sequence
1 Adjusting bolt 4 Alternator
2 Adjusting shaft 5 Adjusting plate
<With adjusting shaft>
3 V-belt Alternator bracket
*a:
WARNING
• Before removing the alternator, disconnect the (–) battery cable and insulate the cable and the (–) battery
terminal with tape.
• It is dangerous to leave the (–) battery cable connected since the battery cable voltage is always present
at terminal B.
• For adjustment of V-belt tension (See Gr14).
Service standards
At 1500 rpm 24 A or more –
Alternator output current (* when al-
At 2500 rpm 38 A or more – Inspect
ternator is hot and producing 27 V)
4 At 5000 rpm 45 A or more –
Adjustment voltage of regulator
28.5 ± 0.5 V – Replace
(at 5000 rpm, 5 A is loaded)
* The hot condition is that which occurs after the alternator has been running at normal ambient temperature at 5000
rpm and maximum output for 30 minutes.
54-28
54
Inspection: Alternator
(1) Alternator output current (bench test)
• Connect the alternator as illustrated.
CAUTION
• Wires with sufficient thickness should be used for wiring
and each connection should be securely fastened.
B: Terminal B
E: Terminal E
L: Terminal L
R: Terminal R
• Increase load resistance to the maximum (condition under which

the load current hardly flows).
• Turn switch A and B ON.
• Run alternator at 5000 rpm for 30 minutes by adjusting load re-
sistance so that electric current can conform to the following
standard.
Alternator nominal current
Current
Approx. 45 A
• Measure the current at each specified revolution of alternator.

• If the measured value deviates from the standard value, disas-
semble and check alternator.
(2) Adjustment voltage of regulator (bench test)
• Connect the alternator as illustrated.
B: Terminal B
E: Terminal E
L: Terminal L
R: Terminal R
• Turn switch ON.

• Run alternator at low speeds.
• Increase the speed of alternator to 5000 rpm and measure the
voltage (adjustment voltage) at this speed. At the same time,
make sure that the current is 5 amperes or less at 5000 rpm.
• If the measured value deviates from the standard value, do as
follows:
• If higher than the standard value: Replace the regulator.
• If lower than the standard value: Inspect the alternator related
parts before replacing the regulator.
54-29
#940 ALTERNATOR
1 Pulley & fan 7 Front bracket
2 Spacer 8 Field coil
3 Rear bearing 9 Stator
4 Rotor 10 Regulator
5 Cover 11 Rectifier
6 Front bearing 12 Rear bracket
• Do not remove the rear and front bearing, stator, or unless faulty.
Assembly sequence
Service standards
8 Field coil resistance (at 20°C) 6.1 to 7.1 Ω – Replace

Nut (pulley mounting) 143 to 181 {15 to 18} –
54-30
54
Disassembly procedure
Disassembly: Rotor and front bracket
• Insert a screwdriver between front bracket and stator.
• Use the screwdriver to pry rotor and front bracket away from sta-
tor and rear bracket.
CAUTION
• Be careful not to insert the screwdriver too deep or it will
damage coil of stator and may cause a short-circuit.
Disassembly: Pulley
CAUTION
• Make sure to grip the root of the core claws when you hold
the rotor in a vice. Gripping claws can damage them.
54-31
#940 ALTERNATOR
Disassembly: Field coil
• Remove screw A (2 places).
CAUTION
• If screws B are removed first, the weight of field coil may be
placed on the joining portion with regulator which is fixed
with screw A, causing break of the joining portion. To avoid
this, remove screw A first.
• Remove screw B (3 places).

CAUTION
• If screw B are removed, the field coil will fall under its own
weight. Keep the field coil supported with your hand.
• Remove field coil.

CAUTION
• Do not remove the field coil forcibly. Otherwise the portion
that joins with the regulator may be caught by the stator
coil.
Disassembly: Stator
• Disconnect lead of stator from rectifier. The lead is soldered to
the diode of the rectifier at 4 places.
CAUTION
• Unsolder within as short a time period as possible (within 5
seconds), otherwise diode can be easily damaged by heat.
Inspection: Field coil
• Measure the resistance between the terminals of field coil.
field coil.
54-32
54
Inspection: Stator
• Perform the following inspections. If any abnormality is found,
replace the stator.
(1) Continuity between each lead wire
• Check that there is continuity between each stator lead.
• If there is no continuity, the lead has broken.
(2) Continuity between each lead wires and the core

• Check that there is no continuity between lead wires and the
core.
• If there is continuity, the lead wire has short-circuited.
Inspection: Rectifier
• Check the function of diodes within rectifier properly. If any fault
is found, replace the rectifier.
If resistance is infinite in both cases, the diode has open.

If resistance is close to 0 Ω in both cases, the diode has shorted.
A, B, C, D: Lead connecting area of stator coil

E, G: Heat sink area
F: Regulator connecting area
• Inspection should be conducted twice, changing over the posi-

tive probe and the negative probe of the tester.
CAUTION
• When inspecting using a tester, the current flowing through
the rectifier is smaller than usual. Therefore, an incorrect re-
sistance value may be indicated on the tester.
Additionally, incorrect indications become larger as the
range of the tester gets smaller. Set the tester to the largest
possible scale.
Assembly procedure
Assembly: Stator
• To install the stater, follow the disassembly sequence in reverse.
(See ‘‘ Disassembly: Stator’’.)
54-33
#950 INSPECTION OF ALTERNATOR
Performance test
• Connect the meters to the alternator as shown.
WARNING
• To prevent possible injury, be sure to disconnect the nega-
tive terminal of the battery and insulate it with tape before
working on the wiring. With the negative terminal (–) of the
battery connected, battery voltage is always applied to ter-
minal B.
• To connect to switch, use a lead wire with the same or larg-
er diameter than that of the chassis harness connected to
terminal B.
• Turn on switch and make sure that voltmeter indicates battery

voltage.
• Start the engine.
• Immediately turn on the switches for all lamps on the vehicle.
• Immediately accelerate the engine to the speed indicated below
and measure the alternator’s output current.
Approx. 1400 rpm <A4T40399>
Approx. 1900 rpm <A4T40379 (crankshaft pulley PCD 193mm)>
Approx. 2100 rpm <A4TU7686>
PCD: Pitch circle diameter
• The alternator is considered to be good if the measured value is
70% or more of the nominal output current.
Alternator nominal output
Alternator Voltage Output current
50 A 24 V 50 A
CAUTION
• The general inspection is only a simplified check. Use a test
bench for accurate checking.
54-34
#951 INSPECTION OF REGULATOR 54
Service standards
– Adjusting voltage 28.5 ± 0.5 V – Replace
• Connect the meters to the alternator as shown.
WARNING
• To prevent possible injury, be sure to disconnect the nega-
tive terminal of the battery and insulate it with tape before
working on the wiring. With the negative terminal (–) of the
battery connected, battery voltage is always applied to ter-
minal B.
• To connect to switch, use a lead wire with the same or larg-
er diameter than that of the chassis harness connected to
terminal B.
• Turn off the switches for lamps, heater, etc. so that electric loads
may not be applied during the inspection.
• Turn on switch and then start the engine.
• If the output current is 5 amperes or less when the engine speed
is raised to the appropriate speed indicated below, then mea-
sure the voltage at terminal B.
Approx. 1400 rpm <A4T40399>
Approx. 2100 rpm <A4TU7686>
Approx. 2150 rpm <A4T40379 (crankshaft pull PCD 168mm)>
PCD: Pitch circle diameter
CAUTION
• If the output current is in the range from 5 to 10 amperes,
the measured value (regulated voltage) will be slightly low-
er.
28 V – 0.2 to 0.3 V
• If the output current is 5 amperes or more, do one of the follow-

ing:
• Run the engine for a while to charge the battery.
• Replace the battery with a fully-charged one.
• If the measured value deviates from the standard value, conduct
checking again on the test bench.
54-35
#955 INSPECTION OF PREHEATING SYSTEM
Service standards
60°C or higher No pre-glow operation –
Pre-glow
0 or 60°C About 12 seconds –
time
Coolant
– 0°C or below About 20 seconds – Inspect
temperature
After-glow 0°C or higher No after-glow operation –
time 0°C or below About 168 seconds –
• Turn the starter switch to OFF.

• Connect a check lamp to the glow plug.
• Remove the water temperature sensor from the engine, and

close the sensor mounting hole with the plug (M16 × 1.5 mm).
• Connect the extension harness between the water temperature

sensor and connector.
• Place the water temperature sensor in a container of water.
• Conduct the following test while changing the temperature of
water in the container. If anything abnormal is found, check rele-
vant components.
(1) Pre-glow time checking

• Turn the starter switch to ON (without starting the engine) and
confirm that the pre-glow time or check lamp ON time at each
water temperature conform with standard values.
(2) After-glow time checking
• Start the engine and measure the check lamp ON time to en-
sure that the after-glow time conforms with the standard val-
ue.

Phone: 1 269 673 1638
54-36
GROUP 61 SPECIAL EQUIPMENT
SPECIFICATION ................................................................................. 61-2

1. Air Compressor ............................................................................ 61-4
2. Air Dryer ....................................................................................... 61-6
TROUBLESHOOTING ........................................................................ 61-9

1. Maintenance and Inspection of Air Dryer .................................... 61-10
2. Inspection and Adjustment of Air Dryer’s
Air Pressure Governor ................................................................ 61-11
AIR COMPRESSOR
<154 cm3 {154 mL}> ........................................................................ 61-14
<319 cm3 {319 mL}> ........................................................................ 61-18
AIR DRYER ....................................................................................... 61-22
61
61-1
SPECIFICATIONS
Air compressor
Item Specifications
Type Water-cooled 1 cylinder
Cylinder bore × stroke mm φ70 × 40 φ95 × 45
Cylinder displacement cm3 {mL} 154 {154} 319 {319}
Manufacturer Sanwa Seiki
Air dryer
Item Specifications
Model DU-4
Heater capacity V-W 24-70
Thermostat operating ON 4±4
temperature °C OFF 16 ± 4
Purge chamber capacity dm3 {L} 1.0 {1.0}
Required time for recycling desiccant sec. 30
Upper threshold
Air pressure governor operating 890 +29 +0.3
-20 {9.1 -0.2 }
pressure
pressure
kPa {kgf/cm } Lower threshold
2
760 ± 15 {7.8 ± 0.15}
pressure
Manufacturer Nabtesco
61-2
61
M E M O
61-3
1. Air Compressor

Phone: 1 269 673 1638
61-4
61
1.1 During suction
• When the piston goes down during the suction stroke cycle, the
vacuum causes the suction valve to open, allowing air to be
drawn into the cylinder.
1.2 During compression and delivery

• When the piston goes up during the compression and delivery
stroke cycle, the suction valve is closed by air pressure.
• Air pressure compressed by the piston forces open the delivery
valve and makes its way to the air dryer and air tank.
61-5
2. Air Dryer
• The air dryer protects brake compo-
nents by removing moisture and oil
from air that has been compressed by
the air compressor.
• The air dryer incorporates an air pres-
sure governor, which keeps the pres-
sure in the air tank constant by
releasing air compressed by the air
compressor to the atmosphere when
the pressure in the air tank makes
such operation necessary.
2.1 Drying action

• While the air tank is being charged, air
from the air compressor enters the air
dryer’s supply side. Moisture and oil
are separated from the air inside the
body and collect in the bottom. The air
then passes through the oil filter,
which removes smaller oil droplets
and particles of dust. The air then
flows into the case, where the desic-
cant removes any remaining moisture.
• As the air flows upward in the case, it
makes contact with increasingly dry
desiccant and thus contains less and
less moisture. When the air reaches
the top of the case, it is dry. It flows
through the check valve A, purge
chamber, and check valve B, and it is
then supplied from the delivery side to
the air tank. Air pressure also acts
upon the piston in the air pressure
governor.
61-6
61
2.2 Regeneration of desiccant
• When the air pressure in the air tank
reaches the upper threshold level, sig-
nal pressure from the air pressure
governor causes the valve in the air
dryer’s control port to open. As a re-
sult, the pressure in the case cleans
the oil filter and pushes the water and
oil out into the atmosphere.
• Following the rapid drop in pressure,
dry air in the purge chamber flows
through the orifice, expands, and be-
comes super-dry. As this super-dry air
flows backward through the case, it
carries moisture from the desiccant
out into the atmosphere, thereby com-
pleting the desiccant’s regeneration.
• During the regeneration process, the
check valve is closed. Thus, the signal
pressure from the air pressure gover-
nor continues to act upon the control
port and the valve remains open. Air
from the air compressor thus flows
through the valve, through the silenc-
er, and out into the atmosphere.
• The regeneration process continues
until air consumption causes the pres-
sure in the air tank to decrease to the
governor lower threshold level.
2.3 Operation when tank pressure

reaches upper threshold level
• Air pressure from the air tank continu-
ously acts upon the piston.
• When the tank pressure increases to
such a level that it overcomes the
spring, it pushes the piston upward
such that the valve closes.
• When the tank pressure increases fur-
ther and exceeds the upper threshold
level, the piston is pushed upward fur-
ther such that the exhaust stem opens
the inlet valve. Air pressure from the
air tank thus flows out of the air pres-
sure governor as signal pressure,
causing the valve to open. Regenera-
tion of the air dryer’s desiccant thus
begins.
61-7
2.4 Operation when tank pressure
reaches lower threshold level
• When the air pressure A from the air
tank drops below the lower threshold
level, the piston is pushed downward
by the spring such that the inlet valve
closes and the exhaust valve opens.
As a result, air pressure flows through
the exhaust stem and escapes to the
atmosphere.
61-8
TROUBLESHOOTING 61
Air dryer
Symptoms
Air pressure in air tank decreases markedly

Deposits come out of drain cock of air tank
No deposits come out of exhaust port
Freezing takes place within air dryer
Engine oil leaks from exhaust port

Reference
Gr
Possible causes
Deterioration of desiccating agent O
Inoperative heater causing air dryer to freeze O
Malfunctioning of valve due to adherence of foreign particles O
Heater circuit open and therefore no heat retention O
Heater malfunction due to thermostat malfunction O
Extreme lowering of temperature of air dryer main body due to ad-
O
herence of snow/ice
Heater malfunction due to disconnection with thermostat O
Dry air in air tank flows out in reverse when check valve of air dryer
O
fails to function as a non-return valve
Rising of oil level in air compressor O
61-9
1. Maintenance and Inspection of Air Dryer
Perform maintenance and inspections at each of the indicated in-
tervals or service time.
(1) Every three months or 500 hours
• Check whether the air dryer is functioning properly by opening
the drain cock on the air tank and checking whether water flows
out.
• If a small amount of water flows out, check whether the desic-
cant has changed color. If one fifth or more of the desiccant has
changed in color from white to brown, replace the desiccant us-
ing repair kit B. (See “AIR DRYER”.)
NOTE
• A small amount of moisture may collect whenever the tem-
perature in the vicinity of the air tank drops by more than
16°C.
• Place the desiccant in the case, then settle the desiccant by tap-
ping gently and evenly around the case with a plastic hammer.
• Place the soft layer side of the filter on the desiccant, and place
the filter plate on the case, then tap the desiccant down following
the manners.
• Before tapping the case against the work surface, lay two or
three layers of shop towel on the work surface to protect the
bottom of the case from scratches.
• Holding down the filter plate with both hands, lift the case to a
height of about 100 mm and tap it gently against the work sur-
face.
• Tap the case about 30 more times. Make sure the filter plate
drops by 4 to 6 mm from its original position.
WARNING
• Unless the tapping procedure is performed, particles of
desiccant may escape and create blockages in brake lines,
thus preventing normal brake operation.
• Look carefully at the water that flows out of the air dryer’s ex-
haust port. If the water is contaminated with oil, inspect the air
compressor. (See “AIR COMPRESSOR”.)
(2) Every year or 2000 hours

Disassemble the air dryer and replace the desiccant, oil filter, fil-
ter, and related rubber parts with the repair kit B. (See “AIR
DRYER”.)
(3) Every two years or 4000 hours
Disassemble the air dryer and replace the desiccant, oil filter,
and all rubber parts with repair kit A. (See “AIR DRYER”)
61-10
61
2. Inspection and Adjustment of Air Dryer’s Air Pressure Governor
Service standards
Upper threshold 890 +29
–20 kPa
– Adjust
pressure {9.1 +0.3 2
–0.2 kgf/cm }
– Threshold pressure
Lower threshold 760 ± 15 kPa
– Replace
pressure {7.8 ± 0.2 kgf/cm2}

– Plug 14.7 to 24.5 {1.5 to 2.5} –
– Cap nut (seat and plate mounting) 4.9 to 5.9 {0.5 to 0.6} –
– Nut (for retention of adjusting screw) 6.9 to 7.8 {0.7 to 0.8} –

– Plug thread ThreeBond 1110B As required
[Inspection]
(1) Air leak
• Install the air pressure gauge A between the air dryer and air
tank (wet tank side).
• Remove the plug from the air dryer at the location shown in the
drawing. Connect air pressure gauge B at that point.
• Start the engine to activate the air compressor such that the air
pressure in the air tank gradually increases. Check that the
pressures indicated by the pressure gauges A, B do not de-
crease when air is expelled from the exhaust cover.
• If the pressure indicated by either of the pressure gauges A, B
decreases, air is leaking from the check valve and air pressure
governor in the air dryer, causing continuous charging and purg-
ing. Carry out disassembly and inspection.
61-11
(2) Operating pressure of air pressure governor
• Remove the cap nut, plate, and seat.
• Start the engine and gradually increase the air pressure in the
air tank.
• Turn the adjusting screw until the pressure indicated by air pres-
sure gauge A when air is expelled from the exhaust cover is the
standard value (the upper threshold pressure).
• Reduce the air pressure to the lower threshold pressure or low-
er, then gradually increase it again. Check whether the pressure
indicated by the air pressure gauge A is the standard value (the
upper threshold pressure). If the indicated pressure deviates
from the standard value, make further adjustments.
• With the upper threshold pressure indicated, air from the air
compressor is expelled from the exhaust cover continuously.
With the equipment in this condition, open the drain cock to
gradually reduce the air pressure. When air stops being expelled
from the exhaust cover, check whether the pressure indicated by
air pressure gauge B is the standard value (the lower threshold
pressure). If the indicated pressure deviates from the standard
value, replace relevant parts of the air compressor governor.
• Tighten the nut to hold the adjusting screw in position.
61-12
61
M E M O
61-13
AIR COMPRESSOR <154 cm3 {154 mL}>
61-14
61
1 Lock washer 9 1st compression ring 17 Bearing cover
2 Compressor gear 10 2nd compression ring 18 Bearing
3 Cylinder head 11 3rd compression ring 19 Connecting rod
4 Gasket 12 Oil ring 20 Crankshaft
5 Valve seat 13 Snap ring 21 Crankcase
6 O-ring 14 Piston pin
7 Cylinder liner 15 Piston : Locating pin
8 O-ring 16 Coupling : Non-reusable parts
Assembly sequence

Clearance between cylinder Top – 0.30
7, 15 Replace
liner and piston Skirt – 0.20
Piston ring end gap (mea- Compression ring – 0.60
9 to 12 sured with ring placed in cylin- Replace
der) Oil ring – 0.65
9 to 12, Clearance between piston ring Compression ring – 0.07

Replace
15 and piston groove Oil ring – 0.075
14, 15 Clearance between piston pin and piston – 0.07 Replace
Clearance between piston pin and connecting rod
14, 19 – 0.07 Replace
small end
19 End play of connecting rod – 1.5 Replace
Clearance between connecting rod big end and
19, 20 – 0.1 Replace
crankshaft
20 Crankshaft end play – 0.7 Replace
Clearance between crankshaft and crankcase
20, 21 – 0.2 Replace
bushing inside diameter
Tightening torque (Unit: N·m {ft.lbs, kgf·m})

Nut (compressor gear mounting) 167 to 186 {17 to 19} –
Bolt (cylinder head mounting) 29 to 34 {3.0 to 3.5} –
Bolt (cylinder liner mounting) 25 to 29 {2.5 to 3.0} –
Bolt (coupling mounting) 53 to 65 {5.4 to 6.6} –
Nut (bearing cover mounting) 8.8 to 10.8 {0.9 to 1.1} –
Stud bolt 5.9 to 12 {0.6 to 1.2} –
Special tools
Removal and installation of

Piston ring tool MH060014
compression rings
61-15
Removal procedure
Removal: Compression rings
Installation: Compression rings
• Install the compression rings, ensuring that their end gaps are
located as shown in the illustration.
• Install the compression rings by following the removal sequence
in reverse.
(See “ Removal: Compression rings”.)
Installation: Lock washer, compressor gear

• Install the compressor gear onto the crankshaft, ensuring that
“O” mark on the compressor gear is aligned with “O” mark on the
crankshaft.
• Insert the protrusion of the lock washer such that the “O” mark
on the compressor gear remains exposed.
• Tighten the nut to the specified torque. Bend one part at the bot-
tom of the lock washer toward the nut to prevent the nut from
loosening.

Phone: 1 269 673 1638
61-16
61
M E M O
61-17
61-18
61
1 Lock washer 10 2nd compression ring 19 Coupling
2 Compressor gear 11 3rd compression ring 20 Bearing cover
3 Cylinder head 12 Oil ring 21 Bearing
4 Gasket 13 Snap ring 22 Crankshaft
5 Valve seat 14 Piston pin 23 Crankcase
6 O-ring 15 Piston
7 Cylinder liner 16 Lock washer : Locating pin
8 O-ring 17 Connecting rod : Non-reusable parts
9 1st compression ring 18 Connecting rod cap
Assembly sequence

Clearance between cylinder Top – 0.335
7, 15 Replace
liner and piston Skirt – 0.195
Piston ring end gap (mea- Compression ring – 1.0
9 to 12 sured with ring placed in cylin- Replace
der) Oil ring – 0.8
9 to 12, Clearance between piston ring Compression ring – 0.08

Replace
15 and piston groove Oil ring – 0.07
14, 15 Clearance between piston pin and piston – 0.08 Replace
Clearance between piston pin and connecting rod
14, 17 – 0.07 Replace
small end
17 End play of connecting rod – 0.5 Replace
17, 18, Clearance between connecting rod big end and
– 0.1 Replace
22 crankshaft
22 Crankshaft end play – 1.0 Replace
Clearance between crankshaft and crankcase
22, 23 – 0.12 Replace
bushing inside diameter
Tightening torque (Unit: N·m {ft.lbs, kgf·m})

Nut (compressor gear mounting) 167 to 186 {17 to 19} –
Bolt (cylinder head mounting) 29 to 34 {3.0 to 3.5} –
Nut (connecting rod cap mounting)
23 to 25 {2.3 to 2.6} –
Bolt (valve seat mounting)
Nut (cylinder liner cap mounting) 25 to 29 {2.5 to 3.0} –
Bolt (coupling mounting) 53 to 65 {5.4 to 6.6} –
Nut (bearing cover mounting) 8.8 to 10.8 {0.9 to 1.1} –
Stud 5.9 to 12 {0.6 to 1.2} –
Special tools
Removal and installation of

Piston ring tool MH060014
compression rings
61-19
Removal procedure
Removal: Compression rings
Installation: Connecting rod cap and connecting rod
• Assemble the connecting rod and cap while noting their align-
ment marks.
• Install bolts in such a way that the notches in the bolt heads are
directed toward the inside of the connecting rod cap.
Installation: Compression rings

• Install the compression rings, ensuring that their end gaps are
located as shown in the illustration.
• Install the compression rings by following the removal sequence
in reverse.
(See “ Removal: Compression rings”.)
Installation: Lock washer, compressor gear

• Install the compressor gear onto the crankshaft, ensuring that
“O” mark on the compressor gear is aligned with “O” mark on the
crankshaft.
• Insert the protrusion of the lock washer such that the “O” mark
on the compressor gear remains exposed.
• Tighten the nut to the specified torque. Bend one part at the bot-
tom of the lock washer toward the nut to prevent the nut from
loosening.
61-20
61
M E M O

Phone: 1 269 673 1638
61-21
AIR DRYER
61-22
61
1 Purge chamber 20 Retaining ring 39 Retaining ring
2 O-ring 21 Upper spring seat 40 Exhaust cover
3 Check valve 22 Spring 41 Retaining ring
4 Case cover 23 Lower spring seat 42 Silencer plate
5 O-ring 24 Adjusting screw 43 Silencer
6 Set spring 25 Exhaust stem 44 Silencer plate
7 Filter plate 26 Exhaust stem spring 45 O-ring
8 Filter 27 O-ring 46 Silencer case
9 Desiccant 28 Piston 47 O-ring
10 Filter 29 Valve 48 Piston
11 Filter plate 30 Valve spring 49 Valve spring
12 Case 31 Retaining ring 50 Valve body
13 Oil filter 32 O-ring 51 O-ring
14 O-ring 33 Check valve guide 52 Valve
15 Cover 34 Check valve spring 53 Plug
16 Gasket ring 35 Check valve 54 Body
17 Gasket ring 36 Thermostat
18 Plate 37 Heater : Non-reusable parts
19 Seat 38 Silencer
Assembly sequence
• Check and adjust the air pressure governor after assembly. (See “GENERAL INSPECTION AND ADJUST-
MENT”.)
Repair kit: Air dryer kit A, B

Bolt (purge chamber, cover and body mounting) 17.7 to 27.5 {1.8 to 2.8} –
Bolt (case mounting)
2.0 to 3.9 {0.2 to 0.4} –
Screw (case cover mounting)
Cap nut (seat and plate mounting) 4.9 to 5.9 {0.5 to 0.6} –
Nut (adjusting screw retaining) 6.9 to 7.8 {0.7 to 0.8} –
Screw (clamp mounting) 1.0 to 1.5 {0.1 to 0.15} –
Screw (thermostat mounting) 0.5 to 1.0 {0.05 to 0.10} –
Heater 19.6 to 29.4 {2 to 3} –
Bolt (valve, piston and valve body mounting) 3.9 to 6.9 {0.4 to 0.7} –
Plug 14.7 to 24.5 {1.5 to 2.5} –
Silencer 29.4 to 39.2 {3.0 to 4.0} –
61-23
AIR DRYER
O-ring
Adjusting screw (entire surface except thread) Multipurpose grease
As required
Outer periphery of piston and O-ring groove [NLGI No. 2 (Li soap)]
Body (inside surface)
Plug thread ThreeBond 1110B As required
Three threads
Silencer thread ThreeBond 1401B from the end of
thread
Adjustment: Adjusting screw
• Turn the adjusting screw to achieve the indicated dimension
from the top of the upper spring seat to the bottom of the lower
spring seat. Doing so will facilitate the threshold pressure adjust-
ment to the specified value.
Installation: Filters, desiccant, and filter plate

• Install the filters with their soft layers facing the desiccant.
• Place the desiccant in the case, then settle the desiccant by tap-
ping gently and evenly around the case with a plastic hammer.
61-24
61
• Place the soft layer side of the filter on the desiccant, and place
the filter plate on the case, then tap the desiccant down following
the manners.
• Before tapping the case against the work surface, lay two or
three layers of shop towel on the work surface to protect the
bottom of the case from scratches.
• Holding down the filter plate with both hands, lift the case to a
height of about 100 mm and tap it gently against the work sur-
face.
• Tap the case about 30 more times. Make sure the filter plate
drops by 4 to 6 mm from its original position.
WARNING
• Unless the tapping procedure is performed, particles of
desiccant may escape and create blockages in brake lines,
thus preventing normal brake operation.
Inspection after installation

Inspection: Air leakage
• Completely plug the delivery side of the air dryer, then apply air
pressure of 49 kPa {0.5 kgf/cm2} or 780 kPa {8 kgf/cm2} to the
supply side and check that no air leaks from any joint.
Leakage from the valve assembly must not exceed 20 cm3 per
minute.
• Increase the pressure applied to the supply side to 932 kPa {9.5
kgf/cm2} to cause purging (regeneration). Check that no air
leaks from the check valve and from the air pressure governor
(with the plug removed).
• If there is air leakage from the air pressure governor or the
check valves, charging (pressure filling) and purging (regenera-
tion) will be performed continuously. Therefore, carry out the in-
spection of the air pressure governor and check valve.
61-25

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Service Manual

Chassis, Mast & Options

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

Cat DP160 DP160N Forklift Engine Parts

Safety Related Signs

Indicates a specific potential hazard

Pub. No. 99799-63100

The suggestion for

Suggestion for disassembly

Standard 0.020 to 0.105 mm

GROUP INDEX Items

2. Truck Models Covered ................................................................................................. 1-2

4. Main specifications....................................................................................................... 1-4

5. Chassis and Mast Model Identification......................................................................... 1-5

6. Dimensions (Approximate)........................................................................................... 1-6

2. Truck Models Covered

Cat DP160 DP160N Forklift Mitsubishi 6M60TL Engine Parts

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

Cat DP160 DP160N Forklift Engine Parts

Truck model DP100N DP120N DP135N DP150N DP160N

Detail oil cooler

1 Intercooler 6 Drain cock

Cat DP160 DP160N Forklift Engine Parts

3. Suggestions for Removal and Installation

3.1.2 Removal sequence

1 Engine cover, Gas spring 8 Radiator hose (lower)

Cat DP160 DP160N Forklift Engine Parts

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

Cat DP160 DP160N Forklift Engine Parts

No. Indicator lamp OFF ON or Flashing Remark

How to check indicator lamp bulbs

3.3 Major Components

Failure indicator lights

Rear (mounting) face

Failure indicator lamp

Travel speed sensor circuit open

3-speed automatic transmission

3.3.3 Lighting switch

OFF 1st 2nd Knob position

Component Tail lamps, license Front

3.3.4 Fuse box