YM17060003E

Chassis
for Kubota Engine
GP/GTP/GLP/GDP15-18MX, 20SMX [E812];
GP/GTP/GLP/GDP20-35MX [D871]

Safety Precautions Maintenance

and Repair
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that
the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• Disconnect the battery ground cable on internal combustion lift trucks.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), and Diesel fuel are flammable. Be sure to follow the necessary
safety precautions when handling these fuels and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a condition that can cause immediate death or injury!

CAUTION
Indicates a condition that can cause property damage!
 Disclaimer
The Service Manuals are updated on a regular basis, but may not reflect recent design changes
to the product. Updated technical service information may be available from your local authorized
Yale® dealer. Service Manuals provide general guidelines for maintenance and service and are
intended for use by trained and experienced technicians. Failure to properly maintain equipment
or to follow instructions contained in the Service Manual could result in damage to the products,
personal injury, property damage or death.
 CONTENTS

1 . Main Specifications 1
2 . Chassis 2
3 . Automatic Transmission and Torque Converter 3
4 . Hydraulic System 4
5 . Electrical System 5
6 . Inspection, Lubrication, and Periodic Parts Replacement 6
 1. Main Specifications

[1] Major Specifications Table …………………………………………………………… 1 － 1 1

(1) Diesel lift truck……………………………………………………………………… 1 － 1
 1. Main Specifications
[1] Major Specifications Table
(1) Diesel lift truck

Model
Item Unit 2.0-ton 2.5-ton

Symbol
Capacity (kg) 2,000 2,500
With load center at (mm) 500 500
Specified lifting height (mm) A 3,000 3,000
Free lift height (mm) B 155 155
Tilt of mast (forward/backward) (°) C/D 6 / 10 6 / 10
Performance

Full load (km/h) 18.0 18.0

Travel speed
No load (km/h) 19.0 19.0
Full load (mm/s) 675 675
Lifting speed
No load (mm/s) 700 700
Hill climbing capacity Full load (%) 35 30
Turning radius (outside) (mm) E 2,180 2,240
Min. aisle width (mm) 2,025 2,090
Fork length (mm) F 920 1,070
Overall length (with fork) (mm) F+G 3,470 3,685
Overall width (mm) H 1,160 1,160

Overall height (up to overhead guard) (mm) J 2,130 2,130

Major dimensions

Mast height (when fork is lowered) (mm) P 1,995 1,995

Overall height (with mast extended to

(mm) K 3,970 3,970
a maximal degree)
Max. (mm) M 1,020 1,020
Outside width of fork
Min. (mm) N 250 250
Wheelbase (mm) L 1,625 1,625
Tread (front/rear) (mm) 970/970 970/970
Min. ground clearance (mm) Q 120 120
Unladen weight (kg) 3,510 3,840
Front wheel 7.00-12-12PR(I) 7.00-12-12PR(I)
Tires

Rear wheel 6.00-9-10PR(I) 6.00-9-10PR(I)

Type V2403 V2403
Total displacement (cm3) 2,434 2,434
Engine

Rated output (kW/rpm) 43/2,400 43/2,400

Max. torque (N·m/rpm) 199/1,500 199/1,500
Fuel tank capacity (ℓ) 69 69
(mm)
Truck with W tires

Overall width 1,490 1,490

Tread (front) (mm) 1,140 1,140
Truck weight (kg) 3,640 3,970
Tires (front)* 5.50-15-8PR(I) 5.50-15-8PR(I)

1-1
 Diesel lift truck

Model
Item Unit 3.0-ton 3.5-ton

Symbol
Capacity (kg) 3,000 3,500
With load center at (mm) 500 500
Specified lifting height (mm) A 3,000 3,000
Free lift height (mm) B 160 165
Tilt of mast (forward/backward) (°) C/D 6 / 10 6 / 10
Performance

Full load (km/h) 17.5 17.5

Travel speed
No load (km/h) 18.5 18.0
Full load (mm/s) 560 490
Lifting speed
No load (mm/s) 575 505
Hill climbing capacity Full load (%) 26 21
Turning radius (outside) (mm) E 2,360 2,415
Min. aisle width (mm) 2,195 2,235
Fork length (mm) F 1,070 1,070
Overall length (with fork) (mm) F+G 3,835 3,905
Overall width (mm) H 1,235 1,235

Overall height (up to overhead guard) (mm) J 2,150 2,150

Major dimensions

Mast height (when fork is lowered) (mm) P 2,060 2,140

Overall height (with mast extended to

(mm) K 4,125 4,125
a maximal degree)
Max. (mm) M 1,060 1,065
Outside width of fork
Min. (mm) N 250 305
Wheelbase (mm) L 1,700 1,700
Tread (front/rear) (mm) 1,010/975 1,010/975
Min. ground clearance (mm) Q 140 140
Unladen weight (kg) 4,380 4,850
Front wheel 28×9-15-12PR(I) 28×9-15 SOLID
Tires

Rear wheel 6.50-10-10PR(I) 6.50-10 SOLID

Type V2403 V2403
Total displacement (cm ) 3
2,434 2,434
Engine

Rated output (kW/rpm) 43/2,400 43/2,400

Max. torque (N·m/rpm) 199/1,500 199/1,500
Fuel tank capacity (ℓ) 69 69
(mm)
Truck with W tires

Overall width 1,490 1,490

Tread (front) (mm) 1,140 1,140
Truck weight (kg) 4,480 4,880
Tires (front)* 6.00-15-10PR(I) 6.00-15 SOLID

1-2
 2. Chassis

[1] Engine…………………………………………………………………………………… 2 － 1

2
(1) Removal……………………………………………………………………………… 2 － 1
(2) Mounting……………………………………………………………………………… 2 － 2
[2] Exhaust system………………………………………………………………………… 2 － 3
(1) Diesel engine………………………………………………………………………… 2 － 3
[3] Cooling system………………………………………………………………………… 2 － 7
(1) Overview……………………………………………………………………………… 2 － 7
(2) Specifications………………………………………………………………………… 2 － 8
(3) Components………………………………………………………………………… 2 － 9
(4) Removal……………………………………………………………………………… 2 － 10
(5) Mounting……………………………………………………………………………… 2 － 11
 2. Chassis
[1] Engine

WARNING

The lift truck must be put on blocks before removal or mounting work, because removing or
mounting a heavy component, such as a mast, drive, engine, transmission, or counterweight,
will largely change the center of the gravity of the truck, and this may cause a fall.

WARNING

When repairing the engine, be sure to disconnect the negative terminal of the battery cable
first.

(1) Removal
Diesel engine
1) Remove the floor plate and hood.
2) Remove the battery cable from the engine.
3) Disconnect the air cleaner hose from the engine, and place this hose outside the truck.
4) Disconnect the exhaust pipe from the engine, and place this pipe outside the truck so that it
does not interfere with lifting the engine.
5) Disconnect the radiator hose and intercooler hose. Remove the upper section of the fan
shroud, and remove the fan.

ADVICE

When removing the fan, it is advisable to place a protective plate between the radiator core
and the fan to protect the core.

6) Remove the universal joint between the pump and the engine.
7) Disconnect the throttle linkage, wiring harness, and fuel hose.
8) By using the access port on the torque converter housing, remove the four bolts securing the
torque converter and flywheel.
9) Connect the engine to a lifting device, and place blocks under the torque converter housing to
support the transmission.
10) Remove the bolt securing the torque converter housing to the end plate.
11) Remove the nut and bolt from the engine mount.
12) Use the lifting device to carefully move the engine backward until the flywheel passes
through the torque converter housing. Confirm that all hoses, the wiring harness and cable
are disconnected, and then lift the engine upward.

2-1
 WARNING
WARNING
The weight of the diesel engine is approximately 225 kg. Before lifting the engine, check the
The weight of the diesel engine is approximately 225 kg. Before lifting the engine, check the
capacity of the lifting device to confirm that it can lift the engine.
capacity of the lifting device to confirm that it can lift the engine.

1 Access port
port
2 Torque converter
Torque converter
3 Bolt
5 4 End plate
4
5 Bolt
6 Transmission
1 7 Engine
Engine
2
3

Fig. 2-1-1

(2)
(2) Mounting
Mounting
Reverse
Reverse the
the removal procedure.
removal procedure.

2-2
2-2
[2] Exhaust system

WARNING

The exhaust system becomes hot, so be careful when disassembling it.

ADVICE

To easily remove or mount an exhaust system part, such as a muffler, you should remove the
counterweight first.

(1) Diesel engine

Disassembly
a) Remove the counterweight. The procedure is described in the chapter on the counterweight.
b) Remove the bolts securing the exhaust pipe to the engine, frame, and catalyst, and remove
the exhaust pipe.
c) Remove the bolts securing the tail pipes to the catalyst, and remove the tail pipes.
d) Remove the bolt and nut that secure the catalyst to the bracket, and remove the catalyst.
e) Remove the bolt securing the bracket to the frame, and remove the bracket.

Inspection
a) Inspect all exhaust system parts, including the catalyst and exhaust pipe, for corrosion or
breakage, and if a defective part is found, repair or replace it.

Assembly
a) Temporarily tighten the catalyst to the bracket with a bolt.
b) Temporarily tighten the bracket to the frame.
c) Temporarily tighten the exhaust pipe to the engine and catalyst.
d) Firmly tighten the bolts and nuts in the following order:
i) Tighten the bracket to frame (to a torque of 41 to 49 Nm).
ii) Tighten the exhaust pipe to engine (to a torque of 23.5 to 27.5 Nm).
iii) Tighten the exhaust pipe to catalyst (to a torque of 23.5 to 27.5 Nm).
iv) Tighten the catalyst to bracket (to a torque of 41 to 49 Nm).
e) Measure clearance "M" between the frame and the exhaust pipe. Insert shim(s) according to
the table below, and tighten a bolt and a hard lock nut.
f) Adjust the clearance between the frame and the tail pipe, and tighten a bolt and a hard lock
nut.

2-3
 ADVICE

Tighten the inner hard lock nut until the after-tightening dimension on the drawing. After that,
tighten the outer hard lock nut to a torque of 21 to 25 N • m (214 to 255 kgf • cm).

Clearance Number of shims

“M”
(mm) t = 3.2 t = 1.2

10-11 0 0

11-12 0 1

12-13 0 2

13-14 1 0

14-15 1 1

15-16 1 2

16-17 2 0

2-4
 C

3 1

5 8

1 Tail pipe
Tail pipe 5 Bolt and washer
Bolt and washer
2 Tail pipe
Tail pipe 6 Bolt and washer
Bolt and washer
3 Catalyst
Catalyst 7 Bolt and nut
Bolt and nut
4 Bracket 8 Bolt and washer
Bolt and washer

Fig.
Fig.2-2-1
2-2-1 Diesel
Diesel lift truck
lift truck

2-5
 After tightening:22.5mm
After tightening:22.5mm
thickness)
shim thickness)
25 21
After tightening:21.5mm

(excl. shim
21.5±0.5 25
DIMENSION
25

(excl.
AFTER TIGHTENING 21
21
22 22 22

M
21

24 21 23
24
24
Detailofofsection
Detail sectionDD Detail of
Detail ofsection
sectionCC

21
21 Washer
Washer
22
22 Rubber
Rubber
23
23 Shim(s)
Shim(s)
24
24 Hardlock
Hard locknut
nut
25
25 Bolt
Bolt

Fig. 2-2-2

2-6
[3] Cooling system

WARNING

Be careful not to touch the fan, pulley, or belt while the engine is running, to prevent injury.

WARNING

The radiator becomes hot, so be very careful when handling it with your hand.
If the radiator is hot, allow it to cool before working on it.

WARNING

If you loosen the radiator cap, cylinder block drain plug, or radiator drain plug while cooling
water is hot and under high pressure, this can cause the hot cooling water to spout, resulting
in a burn injury.

(1) Overview
A radiator is a device to cool the hot cooling water by absorbing heat while the cooling water
passes through a water jacket of the engine. The system consists of the radiator, a reserve tank,
and a radiator hose that connects the engine to the radiator. The radiator is composed of tanks
on the right and left and a heat-radiating core.

The radiator incorporates an oil cooler to cool the torque converter oil.

The upper section of the radiator has an inlet for receiving cooling water from the engine, as well
as a pressure-type cap, and the lower section of the radiator has an outlet for feeding cooling
water to the engine, as well as a drain cock.

The valve opening pressure for the pressure-type cap is 88 · 14.7 kPa (0.9 · 0.15 kgf/cm2), and
this has raised the cooling water's boiling point, resulting in increasing the cooling performance.

The reserve tank is connected to a filler neck and has the two roles: receiving a cooling water
increase that is caused within the radiator due to heat expansion; and refilling cooling water
to compensate for a shortage that is caused when the cooling water in the radiator is cooled
and compressed while the engine is stopped. The installation of the reserve tank prevents air
inclusion in cooling water, resulting in further improvement of the cooling performance.

The standard cooling water contains long-life coolant by approximately 40%, and does not
require replacement for two years. Cooling water level check and refilling are performed with the

2-7
 reserve tank, and the water level needs to be equal to or over the Low level on the reserve tank
while the engine is cold.
The intercooler is a device to cool air that is heated by pressure exerted by a turbocharger.
The intercooler is connected via a hose to the engine, and is composed of tanks on the right and
left and a heat-radiating core.

(2) Radiator specifications

Valve opening
88 ± 14.7kPa (0.98 ± 0.15kgf/ cm2)
pressure

Negative pressure
4.9kPa (0.05kgf/ cm2)
valve

Core type Rectangular wavy fin

Cooling water
Diesel engine : 8.2 L
capacity

Reserve tank
0.6 L (at FULL level)
capacity

2-8
(3)
(3) Components

30 23 28
10

11

21

33

24

31 22
26
32

11 Bolt
Bolt
55 Radiatorbracket,
Radiator bracket,LHLH
10
10 Bolt
Bolt
11
11 Radiatorbracket,
Radiator bracket,RHRH
21
21 Radiatorassy.
Radiator assy.
22
22 Radiatorhose,
Radiator hose, upper
upper
23
23 Radiatorhose,
Radiator hose, lower
lower
24
24 Fan shroud
Fan shroud
26
26 Hose clamp
Hose clamp
28
28 Reserve tank
Reserve tank
30
30 Intercoolerhose,
Intercooler hose,inlet
inlet
31
31 Intercoolerhose,
Intercooler hose,outlet
outlet
32
32 Intercoolerbracket
Intercooler bracket
33
33 Intercooler
Intercooler

Fig.
Fig.2-3-1
2-3-1 Diesel
Diesel lift truck
lift truck

2-9
(4) Removal (for diesel lift truck)
1) Disconnect the reserve tank hose.
Remove this hose by the radiator cap.

2) Drain the cooling water.

Remove the radiator cap, remove the drain cock from the lower section of the radiator, and
drain the cooling water from the radiator and engine.

3) Disconnect the radiator hose.

4) Remove the upper section of the shroud.
5) Disconnect the intercooler hose.
6) Remove the intercooler.
7) Remove the lower section of the shroud.
8) Remove the radiator and shroud, as follows:
(a) Remove the both mounting bolts (M8x1.25) from the upper section of the shroud.
(b) Remove the cushion rubbers from the both sides of the radiator body.
(c) Tilt the radiator body in the direction of the counterweight, and pull the shroud upward to
remove it.
(d) Pull the radiator body upward to remove it.

CAUTION

Disposal of waste water must comply with local regulations.

ADVICE

1. A hose for cooling the torque converter oil is connected to the radiator, so disconnect this
hose to remove the radiator.
2. Take care not to lose the cushion rubbers removed from the lower section of the radiator.
3. W hile removing the radiator, be careful not to cause the radiator core to contact a
surrounding object.
4. After the radiator is replaced, check the oil level for the torque converter, and refill oil to the
appropriate level, if necessary.

2-10
(5)
(5) Mounting
Mounting
Reverse the
Reverse the removal procedure.
removal procedure.

ADVICE
ADVICE
Precautions
Precautions for mounting:
for mounting:
1.When
1. Whenmounting cushion rubbers
mounting cushion rubberstotothe
the right
right andand
left left
sidessides ofradiator,
of the the radiator,
be surebetosure to
mount
mount spacers.
spacers.
2.The
2. Thebracket
bracketmounting
mounting bolt must be
bolt must be tightened
tightenedafter
aftersection
sectionAA
is is tightened.
tightened.
(This is to prevent the radiator warping after mounting.)
(This is to prevent the radiator warping after mounting.)
3.Be sure to mount a cushion rubber to the underside of the radiator.
3. Be sure to mount a cushion rubber to the underside of the radiator.
4.The plate rubber for the shroud insertion section must be attached on the shroud side.
4. The plate rubber for the shroud insertion section must be attached on the shroud side.

Radiator body
Radiator body

Plate rubber
Plate rubber
Section AA
Section

Washer
Washer

Bracket mounting
Bracket mountingbolt
bolt

Rubber
Spacer

Detail of
of section
sectionAA

Fan shroud
Fan shroud Cushion rubber
Cushion rubber

Fig. 2-3-2

2-11
 CAUTION

Use an antifreeze (long-life coolant) at an appropriate mixing ratio, because using it at an

inappropriate mixing ratio may adversely affect the cooling system.

CAUTION

Do not use an alcohol or methanol antifreeze. Doing so may result in damage to people or the
lift truck.

2-12
 3. Automatic Transmission and Torque Converter

[1] Specifications …………………………………………………………………………… 3 － 1

[2] Instructions and Inspection Items After Lift Truck Assembly completion ………… 3 － 2
(1) Instructions ………………………………………………………………………… 3 － 2

3
(2) Inspection items …………………………………………………………………… 3 － 2
[3] Troubleshooting ………………………………………………………………………… 3 － 4
 3. Automatic Transmission and Torque Converter
[1] Specifications
Engine V2403
Number of transmission teeth
55
Reverse gear
Forward gear 55
Output gear 69
Torque converter 3-element, single-stage,
Type two-phase (non-disassembly type)

Stall torque ratio 3.0

Stall speed 2090±100rpm
Converter inlet pressure 294.2 ~ 686.5kPa (3 ~ 7 kgf/cm2)
Clutch
Type Wet-type, multi-plate
Number of discs 2x5
Disc material Paper
Clutch disengagement tolerance 1.8±0.2mm
Hydraulic oil pressure 0.88 ~ 1.18MPa (9 ~ 12kgf/cm2)
Control valve
* Clutch pressure 0.88 ~ 1.18MPa (9 ~ 12kgf/cm2)
Inching Mechanical
Oil pump
Type Gear type
* Pump pressure 1.47MPa (15kgf/cm2) or less

General performance
Shifting time lag 0.5 ~ 0.8sec
Oil temperature (room temperature) 80 ~ 100℃
Oil temperature alarm lights at: 120±3℃
Inspection
Run the engine for approx. 1 minute (to fill the torque
Oil level check converter with oil) and stop the engine, and check the
oil level, using a level gauge.

Note) For pressures indicated by an asterisk (*), the pressure values at the maximum engine
speed under 80 ± 10℃ of oil temperature are specified.

3-1
[2] Instructions and Inspection Items After Lift Truck Assembly completion
[2] Instructions and Inspection Items After Lift Truck Assembly completion
(1) Instructions
(1) Instructions
1) Start the engine, and perform idle running until oil is supplied to each section.
1) Start the engine, and perform idle running until oil is supplied to each section.
2) Check each section for oil leakage, abnormal noise, or other defects.
2) Check each section for oil leakage, abnormal noise, or other defects.
3) Check whether the oil level is correct.
3) Check whether the oil level is correct.
4) Check whether the inching cable is correctly installed.
4) Check whether the inching cable is correctly installed.

(2) Inspection items

(2) Inspection items
If a value measured during the following inspection is outside the specified range, take action
If a value measured during the following inspection is outside the specified range, take action
according to the troubleshooting table.
according to the troubleshooting table.
1) Oil pressure measurement
1) Oil pressure measurement
(a) Measure the engine speeds (low idling, high idling).
(a) Measure the engine speeds (low idling, high idling).

CAUTION
CAUTION
If a measured value is outside the specified range, see the chapter on engine adjustment.
If a measured value is outside the specified range, see the chapter on engine adjustment.

<Engine speed>
<Engine speed>
Engine Low idling (rpm) High idling (rpm)
Engine Low idling (rpm) High idling (rpm)
V2403 750 ～ 850 2350 ～ 2450
V2403 750 ~ 850 2350 ~ 2450

(b) Setan
b) Set anoil
oilpressure
pressuregauge.
gauge.

Clutch pressure
Clutch pressure port
port

port
Pump pressure port Torque
Torqueconverter
converterinlet
inletport
port

Fig.
Fig.3-2-1
3-2-1Oil
Oil pressure
pressure extracting ports
extracting ports

3-2
3-2
 (c) Raise the tires off the ground.

(d) Measure the clutch pressures when you shift into forward gear and into reverse gear.

CAUTION

Clutch pressure is almost equal to pump pressure (the latter is slightly larger). Clutch pressure
is appropriate if this pressure in the range of 0.88 to 1.18 MPa (9 to 12 kgf/cm 2) while the
lift truck is in neutral and, when you shift into forward or reverse gear, the pressure drops
momentarily and returns to within the range of 0.88 to 1.18 MPa (9 to 12 kgf/cm2).

(e) Check that the clutch pressure becomes 0 MPa (0 kg/cm2) when the inching pedal is
stepped on.

2) Stall speed measurement

(a) Apply the parking brake, and firmly secure the front and rear tires with blocks to prevent
the lift truck from moving.

CAUTION

(1) Stall speed must be measured on the flattest surface possible.

(2) It is advisable to use a wire or similar to secure the lift truck to prevent it from jumping out.
If this is not possible, fully confirm the safety of the surroundings, considering that the lift
truck may jump out, before performing measurement.

(b) Shift into forward or reverse gear, and measure the engine speed while the accelerator is
fully pressed.

3-3
[3] Troubleshooting
Problem Possible cause Solution
1. Power is not a. Pump or clutch pressure too low
transmitted. ○Torque converter pump
• Drive gear driving section is worn. Disassembly and replacement
Lift truck does • Pump body or gear is worn. Disassembly and replacement
not move, ○Control valve
or moves very • Regulator valve piston is stuck or Disassembly and replacement
sluggishly. spring is broken.
○Insufficient oil level Refill oil.
○Cavitation (air suction) Check pipe and perform
retightening or replace parts.
Clean suction strainer.

b. Clutch pressure too low

○Inching pedal linkage
• Incorrect adjustment of pedal Adjust pedal.
• Incorrect adjustment of inching cable Adjust cable.
• Poor return of pedal Replace return spring.

○Control valve
• Poor return of inching valve Disassembly and replacement
(Spool or piston is stuck, or return
spring is broken.)

• Solenoid valve malfunction Perform disassembly and

washing, and replace spool
body if it is flawed.
• Valve bearing surface is obstructed. Washing
○Clutch
• Clutch shaft seal is damaged or worn. Disassembly and replacement
• Clutch piston seal is damaged or Disassembly and replacement
worn.
• Clutch operating hole is clogged. Washing
• Disc or drive plate is worn. Disassembly and replacement
c. Torque converter inlet pressure too low
○Control valve
• Cold relief valve piston is stuck or Disassembly and replacement
spring is broken.
d. Pressure is appropriate
○Torque converter
• Input plate is broken. Disassembly and replacement
• Spline section is damaged. Disassembly and replacement
○Clutch
• Disc friction coefficient is reduced. Disassembly and replacement

3-4
 Problem Possible cause Solution
2. Output a. Stall speed too low
reduction ○Engine
• Incorrect adjustment of engine speed Adjust engine speed.
Insufficient • Engine output reduction Overhaul engine.
pulling ○Torque converter
capacity • Torque converter performance
Insufficient degradation
climbing <Engine output check>
capacity ○Standard stall speed See specs. in [1].
○Use of inappropriate oil Replace oil.

b. Stall speed too high

○Clutch
• Friction coefficient reduction due to Disassembly and parts
carbonized disc, etc. replacement
c. Pump or clutch pressure too low See 1-a and 1-b.
d. Torque converter inlet pressure too low
• Oil leakage from oil seal on pump Rework or parts replacement
• Oil leakage from torque converter Rework or parts replacement
• Torque converter impeller is broken Replace assy.
or deformed.
3. Drag torque is ○Clutch
generated. • Clutch disc or drive plate is burned or Disassembly and replacement
deformed.
Lift truck • Clutch return spring is setting or Disassembly, inspection, and
moves forward broken. replacement
or backward • Clutch gear or bearing is burned. Disassembly and replacement
even when shift • Spline section of clutch cover has Disassembly and replacement
lever is set to stepped wear.
neutral. ○Control valve
• Control valve or selector valve's drain Disassembly and washing
circuit is clogged, or solenoid valve
spool return is poor.

3-5
 Problem Possible cause Solution
4. Clutch a. Clutch or pump pressure too low See 1-a and 1-b.
engagement is b. Clutch pressure is increased to
slow. specified value, although this takes time.
i) If starting is normal, when gear is
When inching changed:
pedal is ○Pedal linkage See 1-b.
released or ○Control valve
when gear is • Poor return of inching valve (spool, Disassembly and replacement
changed spring)
ii) If starting is slow, also when gear is
changed:
○Control valve
• Accumulator valve piston is stuck or Disassembly and replacement
spring is broken.
• Valve bearing surface is obstructed. Washing
○Clutch
• Piston malfunction Disassembly, washing, and
replacement
• Large amount of leakage from seal Replace seal ring.
ring
c. Others
• Time lag for current to solenoid valve Check voltage.
is excessive.
5. Shock is ○Control valve
generated. • Accumulator valve piston is stuck. Disassembly and replacement
○Clutch
• Conical plate is setting. Disassembly and replacement
• Piston return spring is broken. Disassembly and replacement
6. Lift truck does a. Lift truck moves forward or backward See item 3.
not move after when it is in neutral.
putting it in gear. b. If no drag torque is generated while lift
truck is in neutral:
○Shift linkage
• Shift switch defect Inspection
• Wiring defect Inspection
• Solenoid valve defect See [7]-(6).
• Others (the causes listed for item 1) See item 1.

Note) This lift truck has traveling

interlock function, so can only move
while driver sits on driver's seat.

3-6
 Problem Possible cause Solution
7. Lift truck still a. If lift truck moves or does not move
moves after depending on shift position:
putting it in • Shift switch defect Inspect and adjust shift
neutral. switch.
• Clutch defect See item 3.
b. If lift truck only moves in one direction,
regardless of shift position:
• Solenoid valve sticking Inspection
8. Brake does not ○Pedal linkage See 1-b.
work. • Incorrect adjustment of pedal linkage
9. Oil temperature ○System
increase • Pipe clogging Washing
• Use of inappropriate oil Replacement
• Insufficient oil level Refill oil to specified level.
• Broken or excessively worn rotation Replacement
part, e.g. bearing
○Clutch
• Clutch slip Disassembly and replacement
• Generation of drag torque (dragging) Disassembly and replacement
• Drag due to deformed clutch disc or Disassembly and replacement
drive plate
○Torque converter
• Torque converter impeller blade and Replace assy.
turbine blade contact each other.
• Bearing is burned. Disassembly and replacement
○Pump
• Overload Check operating conditions.
• Large amount of leakage inside pump Check whether circuit for
no-load operation is operated
with load.
10. Abnormal noise ○Torque converter
is emitted. • Torque converter impeller blade and Replace assy.
turbine blade contact each other.
• Input plate is broken. Disassembly and replacement
○Transmission and other general parts
• Broken gear Disassembly and replacement
• Broken or worn bearings Disassembly and replacement
11. Clutch pressure ○Control valve
increase • Regulator piston sticking Disassembly and washing
○Piping
• Pipe clogging Washing
12. Shift lever • Shift lever switch is broken. Replacement
cannot be moved.
13. Shift lever • Shift lever switch is broken. Replacement
cannot be moved
to another
position.

3-7
 4. Hydraulic System

[1] Hydraulic Pump and Pump Drive …………………………………………………… 4 － 1

(1) Structure ……………………………………………………………………………… 4 － 1
(2) Removal ……………………………………………………………………………… 4 － 2
(3) Mounting …………………………………………………………………………… 4 － 2

4
 4. Hydraulic
4. Hydraulic System
System
[1] Hydraulic
[1] Hydraulic Pump
Pump and
and Pump Drive
(1)
(1) Structure
Structure
Diesel
Diesel lift truck
lift truck

Grease nipple

Bolt and
Bolt and nut
nut

Pump
Pump
Joint
Joint

Engine Yoke
Yoke

Fig. 4-1-1

4-1
(2) Removal
1) Diesel lift truck
(a) Remove the counterweight.
(b) Wipe away any dust from the area around the pump, and disconnect the pipe, and plug the
port.
(c) Remove the bracket from the pump.
(d) Remove the mounting bolt from the yoke on the pump side, and remove the universal joint
assembly.
(3) Mounting
1) Diesel lift truck
(a) Assemble the yoke and the joint
Tightening toque 21 ~ 25N • m (211 ~ 253kg • cm)

(b) Mount the pump

Tightening toque 41 ~ 49N • m (417 ~ 500kg • cm)

ADVICE

Visually check that the front and rear joints of the universal joint assembly are aligned.

(c) Grease the yoke.

4-2
 5. Electrical System

Note) For controller and display settings, see the (separate) document about
the User Interface.

[1] Battery …………………………………………………………………………………… 5 － 1

(1) Specifications ……………………………………………………………………… 5 － 1
(2) Inspection …………………………………………………………………………… 5 － 2
(3) Maintenance ………………………………………………………………………… 5 － 3
[2] Fuse Replacement …………………………………………………………………… 5 － 4
(1) Fuse box and relay box …………………………………………………………… 5 － 4
5
(2) Fuse box and relay layout ………………………………………………………… 5 － 5
 5. Electrical System
5. Electrical System
The electrical system is a 12 V system, consisting of electrical devices for the engine (a
The electrical system is a 12 V system, consisting of electrical devices for the engine (a starter,
starter, ignition, charger, and pre-heater), an automatic transmission shifter, displays, lamps,
ignition, charger, and pre-heater), an automatic transmission shifter, displays, lamps, and wires.
and wires.
For the electrical devices for the engine, see the engine maintenance standards prepared
For the electrical devices for the engine, see the engine maintenance standards prepared
separately.
separately.
For the automatic transmission shifter, see the chapter on the automatic transmission.
For the automatic transmission shifter, see the chapter on the automatic transmission.

CAUTION
CAUTION
When washing the lift truck, be careful not to expose electrical parts to water
When washingthe
(particularly the controllers,
lift truck, be careful not sensors,
tilt angle to exposeshift
electrical parts to
switches, water
horn (particularly
button, the
indicator
controllers,
switches, tilt angle sensors,
displays, shift
display switches, and
switches, horn the
button, indicatorparts
electrical switches, displays,
within display
the engine
switches, and the An
compartment). electrical partspart
electrical within the engine
directly compartment).
exposed to water Anmayelectrical part directly
cause poor engine
exposed
starting to
or water may part
electrical cause poor engineorstarting
malfunction failure.or electrical part malfunction or failure.

[1] Battery
[1](1)Battery
Specifications
(1) Specifications
Engine V2403
Engine V2403
Standard
Standard
Type 95D31L
Type 95D31L
Capacity〔Ah/5HR〕 64
Capacity〔Ah/5HR〕 64
Terminal Large pole
Terminal Large pole
Specific gravity of electrolyte,
Specific gravity of electrolyte, 1.28
when fully charged (at 20℃ ) 1.28
when fully charged (at 20℃ )
Electrolyte volume (L) 5.0
Electrolyte volume (L) 5.0
1) Battery type
1) Battery conforms
Indication type to the JIS standards and
has Indication conforms
the following to the JIS standards and
meaning:
has
E.g 95the following
D 31 L meaning:
E.g 95 D 31 L Terminal position Size
Sizeof
of
shorter side
shorter side
Terminal position
Approximate length of battery (cm)
Size of shorterlength
Approximate of battery
side of battery (cm)
Length
Size of shorter
Performance rankside of battery
Performance rank
Fig.
Fig. 5-1-1
5-1-1
(a) Performance rank
(a) Performance
Indicated byrank
a value representing the level of total performance of a battery. As this
Indicated
value by a the
is larger, value representing
performance the level of total performance of a battery. As this
is better.
value is larger, the performance is better.

5-1
5-1
 (b) Size
Size of
of shorter
shorter side
side of
of battery
battery
Indicated
Indicated by
by an
an alphabet
alphabet letter
letter
representing
representingthe
thesize
sizeof
of the
the short side
short side
ofofthe
the battery, asshown
battery, as shownininFig.
Fig. 5-1-1.
5-1-1.
The
Thesize
sizeincreases
increasesas
asthe
the alphabetical
alphabetical
order
order increases,soso"A"
increases, "A"means
means the
the
smallest size.size.
smallest
(c)
(c) Approximate
Approximatelength
lengthofofbattery
battery(cm)
(cm)
Fig. 5-1-2
Indicatesan
Indicates anapproximate
approximate length
length of
of the
the battery in cm.
battery in cm.
(d) Terminal position
(d) Terminal position
Terminalposition
Terminal position"L""L" is located
is located as in Fig. 5-1-2.
as shown
shown in Fig. 5-1-2.
(2) Fuse Replacement
(2)1)Fuse Replacement
Appearance check
1)(a)
Appearance
Clean the check
battery terminal section if it gets rusty or corroded. If the body is dirty, wash,
(a)clean,
Cleanand
thedry
battery
it. terminal section if it gets rusty or corroded. If the body is dirty, wash,
(b)clean,
Retighten anyit.loose battery terminal.
and dry
(b) Retighten
(c) If any case
the battery looseisbattery terminal.
cracked, replace the battery.
(c) If the battery case is cracked, replace the battery.
2) Check battery fluid level
2) Check battery fluid
The battery levelUPPER LEVEL (maximum fluid level) and LOWER LEVEL (minimum
has the
fluid level) markings.
The battery Check the
has the UPPER fluid
LEVEL
(maximum
level and, iffluid level)
the level and sufficient,
is not LOWER How
How to
to read
read syringe
hydrometer
hydrometer
LEVEL (minimum
pour purified fluid
water, level) markings.
according to these
markings.
Check the fluid level and, if the level
is not sufficient, pour purified water,
3)according
Check specific gravity
to these of battery fluid
markings.
Dilute
Dilute sulfuric
sulfuric
Measure the specific gravity and acid
3) Check
checkspecific gravity of
the charging battery Since
status. fluid the
specific
M e a s u rgravity
e t h e varies
s p e c i fdepending
i c g r a v i t yonathe
nd
temperature,
check the measured
the charging status.value
Sinceneeds
the
to be converted
specific into adepending
gravity varies value at 20℃.
on the Fig.
Fig.5-1-2
5-1-2How
How to
to read syringe
syringe hydrometer
hydrometer

temperature, the measured value needs

S20＝St＋0.0007（t－20）
to be converted into a value at 20℃ .

S20 = St + 0.0007Temp.
(t - 20)at which specific gravity is measured [℃]
Measured specific gravity
Temp. attowhich
Specific gravity converted valuespecific
at 20℃gravity is measured [℃ ]
Measured
When the specific
value for "S20" gravity
is 1.22 or less, perform supplementary charging.
Specific gravity converted to value at 20℃
When the value for "S20" is 1.22 or less, perform supplementary charging.

5-2
(3) Maintenance
1) Supplementary charging
(a) If the battery fluid level is too low, pour purified water (up to below the UPPER LEVEL
marking) before charging.
(b) Before charging, disconnect the battery terminals and remove the vent plug.
(c) Be careful not to allow the battery fluid temperature to increase to 55 ℃ or higher during
charging.
(d) During charging, ensure adequate ventilation and keep fire away from the battery.
2) Others
When disconnecting the cable terminals, disconnect the terminal on the grounding side first.
When connecting these terminals, connect the terminal on the grounding side last.
Do not forcibly pry a cable terminal or strike it hard.

5-3
[2] Fuse
[2] Fuse Replacement
Replacement
Whenaalamp
When lampdoes
does not
not light
lightor
orwhen
when aa device
device in
in the
the electrical
electrical system
system does
does not operate, aa fuse
not operate, fuse
Checkfor
may have blown. Check forblowout
blowoutofof a fuse
a fuse forfor each
each faulty
faulty device.
device.
Thefuse
The fusebox
boxis is mounted
mounted on on
thethe right-hand
right-hand side side
in theinengine
the engine
hood.hood. If has
If a fuse a fuse has remove
blown, blown,
the coverthe
remove and replace
cover and the fuse.the fuse.
replace

(1)
(1) Fuse box and
Fuse box and relay
relay box
box
1)1)Diesel
Dieselliftlift
truck
truck

CB
23
SBF
100A RELAY-3
BATT
SBF 8 3
100A 9 24
18
10
ALT CB
4 RELAY-2
11
19
12
5
1 13
20 CB 25
14 RELAY-1
6
15
2 21
16
17 7
FLASHER 26
RELAY

CK 27
RELAY-2
GLOW

SBF
60A

CN
RELAY-1
28

22

1 BATTERY
BATTERY(100 (100 A)
A) 11 OPT- ECU
OPT- (20 A)
ECU (20 A) 21 SPARE
SPARE (5 (5 A)
A)
2 ALTERNATOR
ALTERNATOR(100 (100A)A) 12 ECM (25 A)
ECM (25 A) 22 GLOW
GLOW (60(60 A)
A)
3 FUSE PULLER 13 WIPER // HEATER
WIPER HEATER(20(20A)
A) 23 RELAY
IGN RELAY
4 OPT
OPT -- IGN
IGN (20
(20 A)
A) 14 STOP LT
STOP LT (10
(10 A)
A) 24 BACK LAMP
BACK LAMPRELAYRELAY
5 IGN
IGN (5
(5 A)
A) 15 WORK LT
WORK LT (20
(20 A)
A) 25 STARTER RELAY
STARTER RELAY
6 GAUGE
GAUGE //V-ECUV-ECU(10(10A)
A) 16 FUEL (5
FUEL (5 A)
A) 26 FLASHER RELAY
FLASHER RELAY
7 TURN
TURN //BACKBACKLT LT(20
(20A)A) 17 EGR (5
EGR (5 A)
A) 27 TAILLAMP
TAIL LAMPRELAYRELAY
8 MAIN
MAIN(5 (5A)
A) 18 SPARE (25
SPARE (25 A)
A) 28 HEAD LAMP
HEAD LAMPRELAYRELAY
9 HEAD
HEAD //TAILTAILLPLP(25 A)A)
(25 19 SPARE (20
SPARE (20 A)
A)
10 HORN
HORN (5 (5 A)
A) 20 SPARE (10
SPARE (10 A)
A)

Fig. 5-2-1

5-4
 CAUTION
CAUTION
・ Useaafuse
• Use fusewith
withthe
thesame
samecapacity
capacity
asas that
that of the
of the fusefuse replaced.
replaced.
・
• IfIfeven
eventhe
thenew
newfuse
fuseblows,
blows, the
the electrical
electrical system
system maymay have
have a problem,
a problem, so inspect
so inspect it. it.

(2)
(2) Fuse box and
Fuse box and relay
relay layout
layout
1)1)Diesel
Dieselliftlift
truck
truck

1 BATTERY
BATTERY
1
2 BATTERYTRAY
BATTERY TRAY
3
A
3 BATTERYCLAMP
BATTERY CLAMP&&ROD
ROD
4 FUSE BOX
FUSE 4
5 RELAYBOX
RELAY BOX
6 FUSE BOX
FUSE 5
7 SEDIMENTER RELAY
SEDIMENTER RELAY
8 ECM RELAY
ECM RELAY 6 11
10
9 GLOW RELAY
GLOW RELAY
10 FUEL PUMP
FUEL PUMPRELAY
RELAY
11 FUEL PUMP
FUEL PUMPMOTOR
MOTOR 2

ViewAA
View

10
8 7
Details of
Details ofRelay
Relay

Note)
Note)Major
Majorcomponents
componentsand
andelectrical connections
electrical notnot
connections shown for for
shown clarity.
clarity.

Fig. 5-2-2

5-5
6. Inspection, Lubrication, and Periodic Parts Replacement

[1] Schedule for Inspection, Lubrication, and Periodic Parts Replacement ………… 6 － 1

6
 6. Inspection, Lubrication, and Periodic Parts Replacement
[1] Schedule for Inspection, Lubrication, and Periodic Parts Replacement
The following table shows the schedule for inspection, lubrication, and periodic parts
replacement. Use a grease gun, brush, and syringe for lubrication.
Before lubrication, clean the surfaces of lubrication parts with clean cloth, and also wipe up
spills of lubricant with clean cloth after lubrication.

Schedule for inspection, lubrication, and periodic parts replacement

Every 2 Every 3 Every 3

Daily Weekly Monthly Annually Remarks Additional
Item months months months
inspection (50h) (200h) (2400h) information
(400h) (600h) (1200h)
Entire truck Inspection
• Engine oil Inspection 1st Replacement Oil 9.5 L V2403
Engine related Cooling system

replacement

• Engine oil filter 1st Replacement V2403

replacement

• Cooling water Inspection Water Replacement

8.2 L at 2-year
intervals

• Air cleaner element Cleaning Replacement V2403

(100H)
Fuel equipment

• Fuel Inspection 69 L V2403

• Fuel filter sedimenter Drainage

&
cleaning

• Differential gear oil

Power transmissi

1st Replacement Oil 6.5 L V2403

replacement

6-1
 Every 2 Every 3 Every 3
Daily Weekly Monthly Annually Remarks Additional
Item months months months
inspection (50h) (200h) (2400h) information
(400h) (600h) (1200h)
• Hydraulic oil Inspection Replacement Oil 30.1 L V2403
Load handling equipment

• Pump drive * Lubrication V2403

ADVICE

The above schedule for inspection, lubrication, and periodic parts replacement indicates the
intervals required under the normal use condition (approximately 200-hour operation in a
month). These maintenance activities, however, should be performed at intervals suitable for
the actual use condition of your lift truck.
This will enable you to use your lift truck with little failures and with a long life.

If you have any question, please feel free to contact our designated service shop.

6-2