Service Manual

Service Manual
Chassis, Mast & Options

DP70E T20C-70001-up
For use with the S6S Engine Service Manual. 99709-81100

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 respective sections of this manual carefully and familiarize yourself with all of
the components before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are for trucks
with serial numbers in effect at the time of printing. Cat Lift Trucks reserves the right to
change specifications or design without notice and without incurring obligation.
The trucks listed in this manual are powered by S6S diesel engines. For the engine servic-
ing, please refer to the applicable engine service manual.
WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in death or serious injury or
CAUTION damage to the machine.
Indicates a condition that can cause damage to, or shorten service life of, the lift truck.
NOTE
This document shall not be transferred, rented, or reproduced to a third party without per-
mission.
Pub.No. 99709-71100
1
WARNING WARNING
The proper and safe lubrication and maintenance for Do not operate these trucks unless you have read and
these lift trucks, recommended by Cat Lift Trucks, are understood the instructions in the OPERATION &
outlined in the OPERATION & MAINTENANCE MAN- MAINTENANCE MANUAL. Improper truck operation
UAL for these trucks. is dangerous and could result in injury or death.
Improper performance of lubrication or maintenance
procedures is dangerous and could result in injury or
death. Read and understand the OPERATION &
MAINTENANCE MANUAL before performing any
lubrication or maintenance on these trucks.
The serviceman or mechanic may be unfamiliar with many access system, provide ladders, scaffolds, or work plat-
of the systems on this truck. This makes it important to use forms to perform safe repair operations.
caution when performing service work. A knowledge of the (6) To avoid back injury, use a hoist when lifting compo-
system and/or components is important before the removal nents which weight 23 kg (50 lb.) or more. Make sure
or disassembly of any component. all chains, hooks, slings, etc., are in good condition and
Because of the size of some of the truck components, the are of the correct capacity. Be sure hooks are posi-
serviceman or mechanic should check the weights noted in tioned correctly. Lifting eyes are not to be side loaded
this Manual. Use proper lifting procedures when removing during a lifting operation.
any components. (7) To avoid burns, be alert for hot parts on trucks which
Following is a list of basic precautions that should always have just been stopped and hot fluids in lines, tubes and
be observed. compartments.
(1) Read and understand all warning plates and decals on (8) Be careful when removing cover plates. Gradually
the truck before operating, lubricating or repairing the back off the last two bolts or nuts located at opposite
product. ends of the cover or device and pry cover loose to
(2) Always wear protective glasses and protective shoes relieve any spring or other pressure, before removing
when working around trucks. In particular, wear pro- the last two bolts or nuts completely.
tective glasses when pounding on any part of the truck (9) Be careful when removing filler caps, breathers and
or its attachments with a hammer or sledge. Use weld- plugs on the truck. Hold a rag over the cap or plug to
ers gloves, hood/goggles, apron and other protective prevent being sprayed or splashed by liquids under
clothing appropriate to the welding job being per- pressure. The danger is even greater if the truck has just
formed. Do not wear loose-fitting or torn clothing. been stopped because fluids can be hot.
Remove all rings from fingers when working on (10)Always use tools that are in good condition and be sure
machinery. you understand how to use them before performing any
(3) Do not work on any truck that is supported only by lift service work.
jacks or a hoist. Always use blocks or jack stands to (11)Reinstall all fasteners with same part number. Do not
support the truck before performing any disassembly. use a lesser quality fastener if replacements are neces-
(4) Lower the forks or other implements to the ground sary.
before performing any work on the truck. If this cannot (12)If possible, make all repairs with the truck parked on a
be done, make sure the forks or other implements are level, hard surface. Block truck so it does not roll while
blocked correctly to prevent them from dropping unex- working on or under truck.
pectedly. (13)Disconnect battery and discharge any capacitors (elec-
(5) Use steps and grab handles (if applicable) when mount- tric trucks) before starting to work on truck. Hang “Do
ing or dismounting a truck. Clean any mud or debris not Operate” tag in the Operator’s Compartment.
from steps, walkways or work platforms before using.
Always face truck when using steps, ladders and walk-
ways. When it is not possible to use the designed
2
(14)Repairs, which require welding, should be performed
only with the benefit of the appropriate reference infor-
mation and by personnel adequately trained and knowl-
edgeable in welding procedures. Determine type of
metal being welded and select correct welding proce-
dure and electrodes, rods or wire to provide a weld
metal strength equivalent at least to that of parent
metal.
(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. Place
wiring away form oil pipe.
(16)Be sure all protective devices including guards and
shields are properly installed and functioning correctly
before starting a repair. If a guard or shield must be
removed to perform the repair work, use extra caution.
(17)Always support the mast and carriage to keep carriage
or attachments raised when maintenance or repair work
is performed, which requires the mast in the raised
position.
(18)Loose or damaged fuel, lubricant and hydraulic lines,
tubes and hoses 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 (Mounting, Dismounting, Disas-
sembly, and Assembly)
Disassembly
The suggestion for

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

(1) Output shaft removal
Use the special tools to remove output shaft.
209604
Service data provided in this man-
ual
Clearance between Standard val- 0.020 to 0.105 mm
cylinder body and ue (0.00079 to 0.00413
piston
in.)
Repair or ser- 0.15 mm
vice limit (0.059 in.)
4
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)
Units
• SI Units are used in this manual.
• The following table shows the conversion of SI unit and
customary unit.
Item SI unit Customary unit

Force 1N 0.1020 kgf
Pressure 1 kPa 0.0102 kgf/cm2
Torque 1 N•m 0.1020 kgf•m
5
6
GROUP INDEX
GROUP INDEX Items
Model View, Truck Models Covered, Serial Number Locations,

GENERAL INFORMATION
Main specifications, Chassis and Mast Model Identification, Dimensions 1
Specifications, Structure, Suggestions for Removal and Installation,
COOLING SYSTEM
Inspection and Adjustment 2
Specifications, Location of Components, Structure,
ELECTRICAL SYSTEM Disassembly and Reassembly, Batteries and Charging,
Troubleshooting, Electrical Wiring Diagram 3
Specifications, Structure, Reduction Ratio
POWER TRAIN
Removal and Installation of Engine and Transmission Unit 4
POWERSHIFT TRANSMIS- Specifications, Structure, Suggestions for Removal and Installation,
SIONS Disassembly and Reassembly, Readjust, Troubleshooting, Service Data 5
FRONT AXLE AND REDUC- Specifications, Structure, Suggestions for Removal and Installation,
TION DIFFERENTIAL Disassembly and Reassembly, Troubleshooting, Service Data 6
Specifications, Description, Removal and Installation,
REAR AXLE
Disassembly and Reassembly, Adjusting, Troubleshooting, Service Data 7
Specifications, Structure, Disassembly and Reassembly,
BRAKE SYSTEM
Adjustment and Testing, Troubleshooting, Service Data 8
Specifications, Structure and Functions, Removal and Installation,
STEERING SYSTEM
Disassembly and Reassembly, Troubleshooting, Service Data 9
Specifications, Structure and Functions, Removal and Installation,
HYDRAULIC SYSTEM Disassembly and Reassembly, Inspection and Adjustment,
Testing, Troubleshooting, Service Data
10
Specifications, Structure, Operation of Triplex Mast,
MASTS AND FORKS Suggestions for Removal and Installation, Disassembly and Reassembly,
Readjust, Troubleshooting, Service Data
11
Applicable Attachment Models, Specifications, Structure,
FORK POSITIONER Suggestions for Removal and Installation, Disassembly and Reassembly,
Troubleshooting, Service Data
12
Applicable Attachment Models, Specifications, Structure,
SIDE SHIFTER Suggestions for Removal and Installation, Disassembly and Reassembly,
Troubleshooting, Service Data
13
Inspection Point, Tightening Torque of Standard Bolts,
SERVICE DATA Periodic Replacement Parts, Lubrication Standards,
Weight of Major Components, Special Tools
14
7
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 2

5. Chassis and Mast Model Identification......................................................................... 1-5
3
6. Dimensions .................................................................................................................. 1-6
4
5
6
7
8
9
10
11
12
13
14
1-1
GENERAL INFORMATION
1. Model View
213311
2. Truck Models Covered

This Service Manual applies to the following truck models (common names).
Model code - Serial
Truck model Transmission Engine mounted
number
Torque converter drive trans-
DP70E T20C-70001-up Mitsubishi S6S diesel engine
mission
1-2
GENERAL INFORMATION
3. Serial Number Locations
Diesel-engine serial number Chassis serial number
Mast serial number Name plate Transmission serial number

213291
1-3
GENERAL INFORMATION
4. Main specifications
Truck model DP70E

Truck Model Cat T20C
Type Standard (with 2-speed powershift transmission)
7000/600 kgf/mm
Capacity/load center
(15432/24 lbf/in.)
Lift, maximum 3300 mm (130 in.)
Lift speed (unloaded/loaded) 470/440 mm/sec (93/87 fpm)
Lowering speed (unloaded/loaded) 550 mm/sec (108 fpm)
Mast tilt angle (forward-backward) 6˚– 12˚
Free lift 205 mm (8.1 in.)
Forward travel speed (1st/2nd)
10/27.5 km/h (6.2/17.1 mph)
Reverse travel speed (1st/2nd)
Minimum turning radius 3395 mm (133.7 in.)
Minimum intersecting aisle 3050 mm (120 in.)
Front wheel (double- Size 8.25-15-12PR (1)
tire) Inflation 0.7MPa (7kgf/cm2) [101 psi]
Size 8.25-15-12PR (1)
Rear wheel
Inflation 0.7MPa (7kgf/cm2) [101 psi]
Relief-valve setting of power steering 10.8 MPa (110 kgf/cm2) [1567 psi]
Relief-valve setting of control valve 19.1 MPa (195 kgf/cm2) [2770 psi]
Truck weight 9320 kg (20546 lb)
1-4
GENERAL INFORMATION
5. Chassis and Mast Model Identification
[Chassis]
DP 70E
Maximum capacity
60: 6000 kg (13228 lb)
70: 7000 kg (15432 lb)
Engine type
DP: Diesel engine type
[Mast]
4 P 70 C 25
Maximum lifting height

["25" stand for 2500 mm (98.4 in.)]
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

70: 6,7 ton class
Kind of mast
P: simplex mast
M: triplex mast
Major change
("2" for the original, "3" for the first change,
and so on up to "9")
1-5
GENERAL INFORMATION
6. Dimensions
J K L
H1 H2
C U
S G
P T
N M
E I
213292
1-6
GENERAL INFORMATION
No. Truck model DP70E

A Maximum lift 3300 mm (130 in.)
B Overall height at maximum lift 4580 mm (180.3 in.)
Overall mast height
C 2720 mm (107.1 in)
Height of mast lowered
D Free lift 205 mm (8.1 in.)
E Fork length 1220 mm (48 in.)
F Fork width 150 mm (5.9 in.)
G Fork thickness 60 mm (2.4 in.)
Mast tilt angle (forward-back-
H1, H2 6˚–12˚
ward)
I Truck length 4855 mm (191.1 in.)
J Overall width (outside of tires) 2170 mm (85.4 in.)
K Tread (front wheel) 1650 mm (65 in)
L Tread (rear wheel) 1650 mm (65 in)
M Wheelbase 2300 mm (90.6 in)
N Front overhang 586 mm (23 in.)
P Minimum height from ground 265 mm (10.4 in.)
R Minimum radius 3395 mm (134 in.)
S Underclearance (at mast) 170 mm (6.7 in.)
Underclearance (at counter-
T 240 mm (9.5 in.)
weight)
Overall height (head-guard
U 2420 mm (95.3 in.)
height)
1-7
COOLING SYSTEM
1. Specifications ............................................................................................................... 2-2
2. Structure....................................................................................................................... 2-3
1
3. Suggestions for Removal and Installation.................................................................... 2-4
3.1 Removing Fan Belt ............................................................................................................................... 2-4
3.1.1 Suggestions for Removal and Installation................................................................................................... 2-4 2
4. Inspection and Adjustment........................................................................................... 2-6
4.1 Inspection of Fan Belt ........................................................................................................................... 2-6
3
4.2 Fan Belt Tension Adjustment................................................................................................................ 2-6
4
5
6
7
8
9
10
11
12
13
14
2-1
COOLING SYSTEM
1. Specifications
Truck model DP70E

Cooling method Forced circulation of coolant
Radiator type Corrugated fins with pressure cap
Total coolant capacity 13.5 L (3.57 U.S. gal.)
Water pump type Volute type, V-belt driven
Thermostat type Wax pellet
2-2
COOLING SYSTEM
2. Structure
5
4
213105
1 Cooling fan 5 Upper hose

2 Fan belt 6 Lower hose
3 Radiator 7 Intercooler
4 Reserve tank 8 Oil pipe
2-3
COOLING SYSTEM
3. Suggestions for Removal and Installation

3.1 Removing Fan Belt
3.1.1 Suggestions for Removal and Installation
(1) Preparation
(a) Remove the radiator cover.
7 1
213106
(2) Removal sequence

1 Drain cock 5 Radiator
2 Cap 6 Intercooler
3 Hose (for coolant) 7 Cooling fan
4 Oil pipe 8 Fan belt
2-4
COOLING SYSTEM
(3) Suggestions for Removal

(a) Make sure that engine coolant is not hot, then open the
drain cock to allow the coolant to be drained.
(b) Loosen the alternator adjusting bolt and mounting bolt.
Tilt the alternator toward the engine and loosen the fan
belt.
(c) Remove four radiator fan mounting bolts and remove
the radiator fan from the engine.
Be careful not to damage the fins of the radiator.
(d) Remove the fan belt.
213107
(4) Installation
Follow the removal procedure in reverse while noting
the following instructions.
(a) Check the fan bearing for smooth rotation with the belt
removed. Replace the bearing if it generates abnormal
sound.
(b) Install the fan belt. Check that the deflection of the belt
98 N f]
is 12 mm (0.47 in.) when a point, midway on the belt, rox. lb
App f) [22 mm
3
0 kg 12 7 in.)
between the drive pulley and the alternator pulley is ( 1 (0.4
4
pushed with a force of 98 N (10 kgf).
1
(c) Connect each hose to the radiator making sure that the
5
end of the hose reaches the root of the fitting. Tighten
the clamp and make sure the hose end is stopped at the
6
flare of the fitting. 2
(d) Pour antifreeze and coolant into the radiator and start
the engine. Warm-up the engine while checking for 213382
abnormal sounds. Check the reserve tank to see
whether it is filled with the specified quantity of cool- 1 Fan Pulley 4 Adjusting Plate
ant. 2 Crank Shaft Pulley 5 Alternator Pulley
3 Adjusting Bolt 6 Bolt
2-5
COOLING SYSTEM
4. Inspection and Adjustment

4.1 Inspection of Fan Belt
(1) Check the belt for contamination of oil, grease or dust.
If the belt is only slightly dirty, remove it and clean
with a shop towel or paper. If necessary, replace the
belt. Never use gasoline, petroleum or oil for washing
the belt.
(2) Check the belt thoroughly and closely when the engine
is overhauled or the belt tension is adjusted. If any
damage is found, replace the belt with a new one.
4.2 Fan Belt Tension Adjustment

(1) Loosen all the mounting bolts of the alternator and the 98 N
p rox. 2 lbf]
adjusting plate. A p [2 mm
3
kgf) 12 7 in.)
(2) Adjust the belt tension to the standard value by adjust- (10 (0.4
4
ing the alternator mounting position at the adjusting
1
plate and tighten the adjusting bolt.
5
(3) Tighten all the mounting bolts of the alternator and the
adjusting plate.
6
2
213382
1 Fan Pulley 4 Adjusting Plate

2 Crank Shaft Pulley 5 Alternator Pulley
3 Adjusting Bolt 6 Bolt
2-6
ELECTRICAL SYSTEM
1. Specifications ............................................................................................................... 3-3
2. Location of Components .............................................................................................. 3-4

1
3. Structure....................................................................................................................... 3-5
3.1 Console box .......................................................................................................................................... 3-5
3.2 OK Monitor............................................................................................................................................ 3-5 2
3.3 Major Components................................................................................................................................ 3-6
3.3.1 ECU (Electronic Control Unit) ..................................................................................................................... 3-6
3.3.2 Starter Switch (Anti-restart Type)................................................................................................................ 3-7
3
3.3.3 Lighting switch............................................................................................................................................. 3-8
3.3.4 Fuse box ..................................................................................................................................................... 3-8 4
3.3.5 Spare terminal............................................................................................................................................. 3-9
3.3.6 Lamp Bulb Specifications............................................................................................................................ 3-9
5
4. Disassembly and Reassembly ................................................................................... 3-10
4.1 Disassembly of Console Box .............................................................................................................. 3-10 6
4.1.1 Disassembly sequence ............................................................................................................................. 3-10
4.1.2 Reassembly .............................................................................................................................................. 3-10
4.2 Combination Meter.............................................................................................................................. 3-11 7
4.2.1 Disassembly.............................................................................................................................................. 3-11
4.2.2 Reassembly .............................................................................................................................................. 3-11
4.3 Electrical Components in the Console Box......................................................................................... 3-12
8
5. Batteries and Charging .............................................................................................. 3-13 9
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 10
5.4 Precautions for Servicing the Charging System with Alternator ......................................................... 3-14
11
6. LC (Lever control System) ......................................................................................... 3-15
6.1 Nomenclature...................................................................................................................................... 3-15
6.2 Maintenance Precautions ................................................................................................................... 3-16 12
6.3 Description .......................................................................................................................................... 3-17
6.3.1 Lever control system ................................................................................................................................. 3-17
6.3.2 Auto-light system....................................................................................................................................... 3-18
13
6.4 Operating Principles............................................................................................................................ 3-18
6.4.1 Lever control system ................................................................................................................................. 3-18 14
6.4.2 Auto-light system....................................................................................................................................... 3-22
3-1
ELECTRICAL SYSTEM
6.5 How to Set Controller.......................................................................................................................... 3-26

6.5.1 Setting switches ........................................................................................................................................ 3-27
6.5.2 Auto-light sensitivity adjusting knob .......................................................................................................... 3-28
6.5.3 Working precautions ................................................................................................................................. 3-28
6.6 LC (Lever control System) .................................................................................................................. 3-29
6.6.1 Preparatory steps...................................................................................................................................... 3-29
6.6.2 Connecting the GSE to the Controller....................................................................................................... 3-31
6.6.3 Troubleshooting Cases as Examples........................................................................................................ 3-32
6.6.4 How to Move the Mast in an Emergency .................................................................................................. 3-44
6.6.5 How to Clean Harness Connectors and System Components ................................................................. 3-48
6.6.6 Troubleshooting Guide for Solenoid Control Valves ................................................................................. 3-49
6.6.7 Troubleshooting Guide for Solenoid Control Valves ................................................................................. 3-49
7. Troubleshooting ......................................................................................................... 3-50

7.1 Starter System .................................................................................................................................... 3-50
7.2 Gauges ............................................................................................................................................... 3-51
7.3 Lighting System .................................................................................................................................. 3-52
7.4 Alarm Unit ........................................................................................................................................... 3-53
7.5 Battery................................................................................................................................................. 3-54
8. Electrical Wiring Diagram........................................................................................... 3-55
3-2
ELECTRICAL SYSTEM
1. Specifications
Truck model DP70E

Model number and
65D23R × 2
quantity
Battery
Voltage (V) 12
Capacity (Ah) 52
Direction lever Electric
Console box With OK monitor
2-speed automatic transmission controller ECU (Electronic Control Unit)
Anti-restart type (with the built-in mechanical lockout for preventing duplicated start-
Starter switch
ing)
Lamps 24V, Refer to “Lamp Bulb Specifications”.
3-3
ELECTRICAL SYSTEM
2. Location of Components
Safety relay
Engine stop control timer
Console box
Horn
Turn signal switch
Front combination
lamp
Stop lamp switch
Front combination
lamp
E.C.U
Head lamp Head lamp
Solenoid
(F-R switching)
Fuel tank unit Solenoid(speed select)
Brake oil sensor

Ground of solenoid
(speed select)
FC controller
Battery
Starting motor relay
Glow plug
Pressure switch
(vacuum tank)
Battery
Engine oil
pressure switch
Back buzzer
Alternator
Rear combination lamp(L.H) Rear combination lamp(R.H)
Engine thermostat unit Seat switch

213113
NOTE
Every harness should be properly secured to avoid interfer-
ence or rubbing against other parts.
3-4
ELECTRICAL SYSTEM
3. Structure
3.1 Console box
1 Engine coolant temperature gauge
2 Speed selector switch
3 Fuel gauge
4 Service hourmeter
5 OK monitor
6 Starter switch
7 Lighting switch
8 Fuse box
213114
3.2 OK Monitor
213115
Function
No. Indicator lamp OFF ON or Flashing Remark

1 Brake fluid level indicator lamp Normal fluid level Low fluid level
Transmission oil temperature indica- Normal tempera-
2 Overheating
tor lamp ture
3 Glow plug indicator lamp Heating completed Heating
4 Charging indicator lamp Normally charged Charging system abnormal
5 Engine oil pressure indicator lamp Normal oil pressure Low oil pressure
Normal element
6 Air cleaner element indicator lamp Element clogged Option
condition
7 Head lamp beam indicator lamp Low beam High beam Option
8 Engine coolant level indicator lamp Normal level Low level Option
9 Turn signal indicator lamp Turn signal ON
3-5
ELECTRICAL SYSTEM
How to check indicator lamp bulbs

A bulb is normal if the indicator lamp comes ON when the key switch is turned to the (ON) position. The charge condition indi-
cator lamp and engine oil pressure indicator lamp will not be illuminated.
3.3 Major Components
3.3.1 ECU (Electronic Control Unit)
Failure indicator lights
LED (green)
LED (red)
Rear (mounting) face

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

solenoid circuit open
3-6
ELECTRICAL SYSTEM
NOTE
Each failure indicator lamp turns ON or turns OFF in the
following situations.
ON
OFF
204668
3.3.2 Starter Switch (Anti-restart Type) engine troubles or starter damages possibly caused by any
This switch has a built-in mechanical lockout to prevent operation mistake.
duplicated starting. The starter switch is wired in such a way to energize the
Since this lockout mechanism restraints the starter switch glow plugs, if it is set in the (ON) position for preheating.
(key) from moving from (ON) position to (START)
position while the engine is running, it serves as to prevent
203561A
3-7
ELECTRICAL SYSTEM
3.3.3 Lighting switch

Connection Chart
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 cable extends from the fuse box in the
console box. (Another spare terminal is in the chassis-side
main harness.)
Color code Lg (light green)
Removing the console box rear panel will permit you to

gain access to this spare terminal, which is usually taped
onto the harness protector with vinyl tape.
Spare terminal
207209
3.3.6 Lamp Bulb Specifications
Valves
Qua Color of
Item For 24V sys- Schematic dia- Remark
ntity lens
tem gram
Head lamps 2 Frosted 60W A 60/60W, option
Combination lamps Turn signal lamps 2 Amber 25W B Standard (mounted on the
(front) Clearance lamps 2 Frosted 12W C overhead guard)
Tail and stop

2 Red 10/25W B
lamps
Combination 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 from 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 Bulb
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
Reassemble in the reverse order of disassembly sequence.
3-11
ELECTRICAL SYSTEM
4.3 Electrical Components in the Console Box
206423
1 Power relay 5 Glow plug timer

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

5.1 Battery Conditions and Adjustment Method Based on the Electrolyte Specific Gravity (S.G.)
Electrolyte S.G. reading
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 in an efficient manner. If the
condition is improved, recharge the battery while adjust-
ing the electrolyte specific gravity.
Recharge the battery. Check for any short-circuited
1.260 to 1.225 Battery is half charged. cables or corroded cable connections 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

Charging Capacity
To tell whether a battery is fully charged, check the electro-
lyte S.G. of each cell with a hydrometer; It should read
between 1.280 and 1.265. However, it can also be judged
theoretically from the reduction rate of the electrolyte quan-
tity. If refilling is necessary every month or so, the system is
tending to over-charge the battery. If refilling is not required
for over 3 months, it is likely that the system is inadequately
charging.
5.3 Precautions for Battery Charging

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

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

6.1 Nomenclature
6
7
213319
1 Light sensor 5 Seat switch

2 Auto-light switch 6 Emergency switch
3 Flow regulator valve 7 Joystick levers (Lever control system)
4 Solenoid control valve 8 Controller
3-15
ELECTRICAL SYSTEM
6.2 Maintenance Precautions

The FC model contains a microcomputer. Following are the
precautions to be observed in performing any maintenance
on the FC model.
(1) When removing the controller cover, make sure to pro-
tect the controller from outside moisture and water.
(2) Use the controller setting switch, to make sure the con-
trol system is within truck specifications.
NOTE
Improper setting of the system will result in an inability to
lower the forks while inching. (See “How to Set Control-
ler”.) Controller
(3) Before performing repairs which require welding, be
213321
sure to disconnect the cable from the battery positive
(+) terminal and the controller from the system at its
connectors.
(4) When handling the controller by hand, never touch its
electrical terminals, or your body charge will rupture
some of the electronic components in the internal con-
troller circuits.
208776
3-16
ELECTRICAL SYSTEM
6.3 Description
6.3.1 Lever control system
This system, unlike the conventional mechanical control, is
electronically actuated to help reduce the effort required of
the operator in moving the control levers for lift, tilt and
attachment functions.
213275
(1) This system provides the following emergency func-

tions:
(a) The lift, tilt and attachment functions are not performed
even if the control levers are moved when the engine is
not running.
(b) The lift, tilt and attachment functions are not performed
even if the control levers are moved when the emer-
gency switch is in ON (pushed) position.
(c) The lift, tilt and attachment functions are not performed
even if the control levers are moved when the seat
switch is not ON (the operator is not seated).
(d) The system indicator light in the OK monitor
alerts the operator to problems occurring in the electri-
cal system and, at the same time, stops function. (If any
problem occurs in the lift system, for example, the sys-
tem becomes inoperative.)
3-17
ELECTRICAL SYSTEM
6.3.2 Auto-light system

The head lamps are under the control of a switch and sen-
sor. With the auto-light switch ON, the head lamps turns
ON automatically as the truck is driven into a dark area. The
head lamps can be turned ON or OFF manually.
6.4 Operating Principles

6.4.1 Lever control system
(1) The system is activated by turning OFF the emergency
switch when the key is switched to the ON position and
the seat switch is ON (activated when the operator is
properly seated.)
(2) As the control levers (joysticks) are moved to operate
the equipment (mast and forks), the amount of lever
movement will be translated into an electrical signal:
this signal goes into the controller, where it is con-
verted into an output signal. At this point the controller
issues an ON signal to the unload solenoid, thereby
turning ON the solenoid which introduces hydraulic
pressure into the control valve. The system is now
ready to actuate the equipment. The output signal
applies to the proportioning solenoid selected by the
direction of the joystick movement. Inside the control
valve of the solenoid, the spool is forced to slide, alter-
nating the internal oil passage by directing the oil to the
corresponding cylinders. The spool keeps on sliding
until it comes to the position where the pressure of its
pilot chamber becomes equal to the force of its center-
ing spring. In the meantime, the cylinder extends or
retracts against its load. As the joystick is moved back
to its neutral position, the signal to the proportioning
solenoid decreases which lowers the pilot chamber
pressure and allows the centering spring to push the
spool to its neutral position, whereby the line to the cyl-
inder becomes shut off: the pressure in the line is now
trapped, holding the cylinder there. At the same time,
the ON signal to the unload solenoid goes OFF, so that
the part of the system actuating the equipment goes
into no-load state.
3-18
ELECTRICAL SYSTEM
(3) Supply power to the controller is initiated from the

Power Relay through a 10-Amp fuse and emergency
switch. Pressing this switch into the ON position shuts
down the controller without shutting down the main
controller.
(4) With the starter switch and emergency switch turned
ON, the unloading solenoid and proportioning solenoid
are under control of the joysticks. With the engine shut
down (and hence the hydraulic pump standing still), the
spools in the control valves are inoperative because no
pressure develops in their pilot chambers. Conse-
quently, the equipment remains inoperative even when
the starter switch and emergency switch are turned ON.
3-19
3-20
Lever control system schematic
Control (joystick) box Emergency switch (OFF)
Control
Console box lever
(joystick)
ELECTRICAL SYSTEM
System Emergency
indicator switch (ON) Power supply
light Seat switch
(ON)
Starter
switch
(ON)
Lever stroke signal
Fuse
10 A ON-OFF signal
Power supply
ON-OFF signal
Solenoid Power supply
control valve
Proportioning Proportioning
solenoid solenoid
Battery
Spool Pilot pressure Controller
passage
Centering spring
Pilot pressure
Unload passage
solenoid
Setting
window
Detail of control valve
Lift cylinder
Flow control signal
Hydraulic
pump
213299
ELECTRICAL SYSTEM
(5) In addition to the functions explained above, the con-

troller monitors the supply voltage and the electrical
connections for the control levers (joysticks), solenoids
and other input/output devices, and alerts the operator
if a problem occurs, by flickering the system indicator
light and LED (as shown in the chart). Such a problem
is usually a fault in the harness or connector and must
be located by inspecting. The hydraulic components
such as pump control valve, etc. are not monitored.
208778
System
Pat-
LED flickering pattern Problem detected Effect indicator
tern
light
LED flickers
1.2 sec. 1.2 1.2 1.2

A (Normal) OFF
LED flickers
0.3 2.1 0.3 2.1

Open- or short-circuit in con-
No power supply to par-
B trol lever (with starter switch ON
ticular system
in ON position)
Supply voltage too high (over

0.6 0.6 No power supply to all
LED flickers
32 volts or too low under 9

system
C volts) ON
Open- or short-circuit in sole- No power supply to par-
noid ticular system
Control lever neutral position No power supply to par-
LED flickers
1.2 0.6 0.6 0.6 0.6 1.2 displaced ticular system

D Open- or short-circuit in con- Flickers
trol lever (with starter switch
in ON position)
LED flickers
1.2 0.3 0.3 0.3 0.9

0.6 0.6 0.6 Seat switch OFF, of open-cir- No power supply to all
E Flickers
cuit in it system
F LED remains ON Problem in controller OFF
0.3 0.3 0.3 0.3 0.3 0.3

The AC system check
LED flickers
lamp operates in the

G Set check mode. same manner as usual but OFF
an attachment operates in
check mode.
0.3 0.3 0.3 0.3 0.3
NOTE: Any problem does not cause the engine to shut down.
3-21
ELECTRICAL SYSTEM
6.4.2 Auto-light system Example: The auto-light system functions regardless of

(1) The auto-light system turns ON the head lamps auto- ON-OFF of the seat switch. The Lever control system
matically when the truck is driven into a dark area, with functions even if the light sensor is faulty.
the starter switch in (ON) position, the emergency

switch ON and the auto-light switch ON. The control-
ler and the Lever control system is common to this sys-
tem, but the circuits of the system are independent so
the components of these systems do not affect each
other.
Light sensor
Controller
208779
213321
Power relay 208781
Major Components of Auto-light System

NOTE
The controller has no auto-light system diagnosing func-
tion.
3-22
ELECTRICAL SYSTEM
(2) The light sensor is basically a resistance device, whose

resistance is compared to the variable resistor (the auto-
light sensitivity adjusting knob) inside the controller.
The sensor resistance increases as brightness decreases.
When, in operation, the sensor resistance becomes
greater than the resistance in the variable resistor, the
comparing circuit energizes the power relay to close its
contacts to turn ON the head lamps.
With auto-light switch ON, starter switch

|(ON)and emergency switch ON
Control (joystick) box
Head lamp
Instrument panel lamp
Tail lamp Power supply
Console box Emergency switch

Lighting (ON)
Clearance B PHT
lamp switch
Starter switch
(ON)
10 A Controller
(ON)
20 A Auto-light
switch (ON)
Battery
Setting
Dark window
Light
Power relay
sensor
(ON)
Auto-light sensitivity
adjusting knob
213305
Operation-1
3-23
ELECTRICAL SYSTEM
(3) With the auto-light switch turned OFF, the lighting

switch can be used to turn ON a light selected by the
position of this switch. Even under this condition, the
power relay goes ON or OFF in response to changes in
ambient brightness but this does not affect the light
turned ON by the lighting switch. With the auto-light
switch OFF, the starter switch (ON) and the emer-
gency switch ON.
With auto-light switch OFF, starter switch

|(ON) and emergency switch ON
Head lamp
Clearance
lamp
Lighting (ON)
B PHT
switch
Starter switch
(ON)
10 A Controller
(ON)
20 A
Auto-light Battery
switch (OFF)
Setting
Dark window
Light
Power relay
sensor
(ON)
213306
Operation-2
3-24
ELECTRICAL SYSTEM
(4) Turning OFF the emergency switch with the auto-light

switch ON causes the power relay to remain OFF.
Under this condition, all lamps will remain OFF. If the
auto-light switch is OFF, the lighting switch is effective
and can turn ON each selected light, regardless of the
emergency switch and starter switch.
With auto-light switch ON and emergency switch ON

Head lamp

Clearance
lamp
(OFF)
B P HT Lighting
switch
Starter
switch
10 A Controller
(OFF)
20 A
Auto-light Battery
switch (ON)
Setting
Dark window
Light
Power
sensor
relay
213307
Operation-3
Operation logic:
Auto-light switch ON
Auto-light switch OFF
Dark Bright
1st 2nd 1st 2nd 1st 2nd
Lighting switch OFF OFF OFF
position position position position position position
Clearance, tail lamps O O O O O
Head lamps O O O O
3-25
ELECTRICAL SYSTEM
6.5 How to Set Controller

Set the controller after any of the following occasions:
Occasion Setting
After mast has been changed, or optional equipment
Resetting of setting switches
added
When auto-light system is adjusted Adjustment of brightness at which light sensor operates
After control valve lift section solenoid has been
Adjustment of maximum lowering speed (when required)
replaced (or control valve replaced)
• Resetting of setting switches
• Adjustment of maximum lowering speed (when required)
After controller assembly has been replaced
• Adjustment of brightness at which light sensor operates (when
required)
208785
3-26
ELECTRICAL SYSTEM
6.5.1 Setting switches

The controller has a total of 16 setting switches.
NOTE
Use a screwdriver to move each switch. The switch is made
of resin; be careful not to damage the switch head in setting.
(1) Switch setting pattern (Black dot indicates switch
head.)
205001
Setting window
Mode Normal Check

Switch SW 2–1 OFF ON
Truck model 60K 70K Spare Spare
Transmission speed 1200 bps 9600 bps Switch SW 3–1 OFF ON – –
Switch SW 2–2 OFF ON SW 3–2 OFF OFF – –
Spear Normal –
No. of spools 2V 3V 4V 5V
1 1
Seat switch With Without 2 2 Switch SW 3–3 OFF ON OFF ON
Switch SW 2–4 OFF ON 3 3 SW 3–4 OFF OFF ON ON
OFF
OFF
4 4
5 5
Oil pressure sensor Without (With) 6 6 Mast model All
7 7
Switch SW 2–5 OFF ON 8 8 Switch SW 3–5 OFF
SW 3–6 OFF
Spear Normal – SW2 SW3
Seat switch timer 3sec 2sec
WDT operation Normal mode WDT disabled OFF ON Switch SW 3–7 OFF ON
Spear Normal –
Program mode User program Boot mode Switch SW 3–8 OFF ON
213297
*: Switch setting of controller when shipped from facto-
ry
Switches 1, 2, 3, 4, and 7 of SW3 should be set again de-
pending on models and region.
(2) Example of setting
Truck: FG40K
No. of spools: 3V
Mast: 4V40A (simplex) 60 K
Option: Speedometer with indicator light
3V
Seat switch
3sec
SW2 SW3
213298
3-27
ELECTRICAL SYSTEM
6.5.2 Auto-light sensitivity adjusting knob

The controller has a total of 16 setting switches.
(1) This knob is for adjusting the sensitivity level at which
the auto-light system turns ON and OFF the head
lamps.
(2) The knob has been set as shown.
(3) Turning the knob to the right, will lower the sensitivity
at which the system turns the head lamps ON and OFF.
NOTE
(a) Use a screwdriver to turn the knob.
(b) Be careful not to damage the groove of the knob when
using a screwdriver. 205005
6.5.3 Working precautions

(1) When installing the controller, position it correctly. Be
careful not to turn it upside down.
(2) When resetting or adjusting the controller on the truck,
be sure to turn OFF the starter switch and light switch.
(3) When removing the rubber cover, check to see if the
sealing label was removed in the past. (If this label has
been removed ask the user for the removed label.)
(4) Be careful not to damage the rubber cover when it is
removed from the controller.
(5) Do not let any foreign matter fall into the controller
through the setting window.
205037
3-28
ELECTRICAL SYSTEM
6.6 LC (Lever control System)

6.6.1 Preparatory steps
(1) This system comes into operation when the starter
switch is turned to the ON position and the emergency
switch is turned ON. The Lever control comes into
operation after the seat switch has been closed (the
operator has been seated) and the engine has been
started.
(2) Before deciding to replace a blown fuse, be sure to
check that the harness connectors in the power line are
all in sound condition, free of any sign of short-circuit.
(3) The use of the test-use connector (special tool) is pre-
scribed for checking the connector-to-connector lines
for continuity and for reading the voltage across two
terminals and the ohmic resistance of a line.
(4) The controller’s capabilities include that of self-diag-

nosis (for the control system only) function. With this
function, any problem symptom occurring in an ener-
gized state goes into the memory as a data error. (This
memory capability is limited, however, to the latest sin-
gle case of trouble symptom for one input/output chan-
nel: previous symptoms are not stored, meaning that
their chronological order and data are not traceable).
The limited trouble symptom data can be read by the
ground support equipment (GSE). If one of the follow-
ing steps listed below is taken, the stored data will be
erased and lost.
205038
(a) Disconnecting battery lead from the battery terminal, (e) Turning starter switch or emergency switch ON and
positive (+) or negative (-). OFF twice in succession. (Turning the switch in this
(b) Uncoupling CN1 or CN4 connector on the console manner is the same thing as performing the cycle of
box. energizing and de-energizing the controller twice in
(c) Removing the 10-A fuse (6th fuse as counted from top) succession.)
in the fuse box.
(d) Uncoupling CN53 connector on the controller.
3-29
ELECTRICAL SYSTEM
(5) When coupling or uncoupling a connector, make sure (6) Before starting troubleshooting work, check to be sure
that the starter switch is OFF. Never try to forcibly that the following conditions are met on the machine
insert or pull off the connector half, or its pins may be side:
damaged. When coupling a connector, be sure that the
inserted half snaps into its self-locking position.
Conditions in the
Check item What to check Remedy
machine
Hoses, pipes and connectors for damage and Repair leaking or damaged
Hydraulic line
signs of leakage. parts.
Check control valve and hydraulic cylinders for Repair damaged or leaking
Hydraulic devices
Starter switch OFF damage and oil leaks. parts, if any.
Emergency switch Check connectors for tightness, burns and
OFF Electrical connectors
breakage; check wires for insulator stripping Repair.
and wires
and signs of rubbing.
Check to be sure that voltage is at least 10 V as Correct alternator or battery if
Power source voltage
read across battery’s terminals. this voltage is too low.
Check to be sure the lamp goes ON and OFF
System check lamp Replace lamp bulb if blown.
properly; if not, check its bulb.
After making sure check light bulb is OK, see if
Auto-light unit Refer to Case 1 and 2.
Engine at standstill auto-light works properly.
Starter switch ON Proper functioning of LED
Emergency switch LED indicator (red) in
Be sure that red LED go ON and OFF correctly. indicator is essential to trouble-
ON the controller
shooting.
(Proper functioning of control-
Trouble-data reading Connect GSE to controller and check its input
ler is essential to troubleshoot-
function of controller and output actions.
ing.)
With your hands off the control levers, listen Refer to the sections dealing
carefully whether the solenoid valve and with control valve and hydrau-
hydraulic pump are making abnormal sounds. lic pump, respectively.
Operate control lever to see if any abnormal
Hydraulic devices sound, indicative of flow throttling, comes from
(Proper function of solenoid
Engine running control solenoid valve or from any other sole-
valves is essential to trouble-
Emergency switch noid valve. Check to see if unload solenoid
shooting.)
ON valve operates properly, in response to a lever
being moved.
Check each work attachment for the following:
Refer to Case 3.
(a) Does it work properly?
Work attachments Refer to Case 4.
(b) Does it “inch” properly?
Refer to Case 5.
(c) Does mast go down with proper speed?
3-30
ELECTRICAL SYSTEM
6.6.2 Connecting the GSE to the Controller

(1) Remove the rubber cap.
208788
(2) First, turn ON the starter switch. After this, select the
lift menu (by referring to the GSE operation manual).
NOTE
Before plugging in or unplugging the GSE cable, be sure to
have the starter switch turned OFF.
3-31
ELECTRICAL SYSTEM
6.6.3 Troubleshooting Cases as Examples

(1) Explanatory notes and reminders
(a) In the following text and diagrams, electrical connec-
tors are abbreviated as CN. An individual CN will be
identified by a number suffix (used in the electrical wir-
ing and connecting diagrams).
(b) In the flowchart diagrams, the numerical notation in the
box, , is a circuit number. Also, the terminals
of the connector will be identified by the circuit num-
bers. As to the configuration of terminals in each con-
nector, refer to the wiring diagram.
Male Female
(c) The wiring diagrams show the connector's terminal
(As seen from the connector's end face)
configuration on its male side: remember, the configu-
ration on the female side is a mirror image of the male-
side configuration.
(d) In the trouble cases cited hereunder, “Check the con-
nector coupling” means “uncouple and then couple the 205042
connector, inserting the connector, inserting the con-
nector half all the way to self-locking position.”
(e) In the trouble cases cited, “continuity check” will be Component Trouble Symptom
directed for some harnesses. This direction applies also Control levers Short-circuit
to “check the connector coupling”: when checking a Solenoid valves Short-circuit, oil leakage
connector as in (d), above, be sure to check the connec-
tor for circuit continuity immediately after coupling it. NOTE
(f) When reading voltage with a volt meter, be sure to dis-
For the method of deleting the data stored in the controller,
criminate between polarities, (+) and (-), so that the
refer to (a) thru (e), 1.(4)
meter will not suffer internal damage.
(g) Trouble data stored in the controller, as explained in
6.6.1 (4), can be read by the GSE. Such a read out is
about “previous data” and must not be interpreted as
data about troubles that already exist. To illustrate this
point, assume that the data are currently displayed as
shown on the following page and that the indicated
faulty condition has already been corrected and
repaired. In this case, the work attachment in question
remains inoperative. Thus, it is important to remember
that, each time a detected malfunction is corrected and
eliminated, the trouble data is changed promptly to
reflect the affected correction.
3-32
ELECTRICAL SYSTEM
(h) Not withstanding what is stated in (g), about “previous

data on past troubles” as read into the GSE from the
controller, can be useful information for checking for
such malfunctions (like an open due to a loose contact
in a circuit) it may not show up later when trouble-
shooting work is being performed. The diagram below,
illustrates an example of a precarious type of malfunc-
tion:
The malfunction shown in the illustration on the left,

detected at the time of the trouble occurrence, will
go into the data as an “open circuit” if it happens to
be open.
Trouble symptom data Open-circuit
Suppose, that as you start the troubleshooting process

with the GSE, the fault happens to be in a precariously
closed condition: the GSE will indicate whether the
circuit in question, in the device, is normal whereas
the data held in the controller reads "open-circuit" for
that device.
Trouble symptom data Device
Past Open-circuit
Now Normal
208790
3-33
Auto-light system schematic Note: Circuit Nos.are indicated by small-character numbers.
3-34
Head lamp
Emergency switch

ELECTRICAL SYSTEM

Clearance
lamp Console box
(2)Auto-light System Troubleshooting
B P H T Lighting Auto-light
switch sensitivity
Starter adjusting knob
switch Turn-On
Bright Dark
10 A 201
Controller
20 A Auto-light
switch
OFF ON Battery 182
183
Setting 186
187
window 169
177
173
184
Light
sensor
Power
relay
184 ON or OFF signal
173
177
169
213308
ELECTRICAL SYSTEM
(a) Case 1: Head lamps will not go ON in darkness.
Troubleshooting procedure
Is the LED (red) ON in the No Refer to Case 7:

controller? "Controller' s LED (red) will not go ON."
Yes
Do the head lamps go ON when Yes Set the sensitivity to make the lamps turn ON at the
the sensitivity is re-adjusted? desired degree of darkness.
No
Do the head lamps go ON when

circuit 173 (CN51) is grounded Yes Check CN51, CN52 and CN53 for continuity. If
(shorted to the ground)? (Does these connectors are OK, it means that the controller
this shorting cause the power is in faulty condition and needs to be replaced.
relay to trip ?)
No
Have circuit 184 shorted to

No Check the circuits of power relay and auto-light
circuit 201 at the male side of
switch (in the console box) for continuity. As
CN4. Then, ground circuit 173 :
necessary, repair or replace.
will this turn ON the head lamps?
Yes
Check harness B for continuity and repair faulty part
or line, if any.
3-35
ELECTRICAL SYSTEM
(b) Case 2: Head lamps will not go OFF when bright.
Is the LED (red) ON in the No Refer to Case7:

controller? "Controller' s LED (red) will not go ON."
Yes
Do the head lamps go OFF when Yes Set the sensitivity so that the lamps will go OFF at
the sensitivity is re-adjusted? the desired degree of darkness.
No
Do the head lamps go OFF when Yes Is the resistance through CN52 (between circuits
CN51 is disconnected? 177 and 169 ) less than 20 kilohms?
No No Yes
Do the head lamps go OFF when Check the light sensor

CN4 is disconnected? circuit for continuity and
repair or replace.
No Yes
Check power relay and Check CN51, CN52 and

auto-light switch (in the CN53. If these connectors
console box) for short- are OK, it means the
circuit, and repair or controller is in faulty
replace. condition and needs to be
replaced.
See if circuit 173 of

harness B is shorted to
chassis or to ground
circuit and, if so, repair.
3-36
Control system schematic
Console box Control

lever
(joystick) Emergency
System switch
(3) Control System Troubleshooting
indicator
Seat switch Power supply
light
Starter
switch
Lever position signal
10 A On or OFF signal
Proportioning
solenoid
Controller
Control
valve
Unload unit
Setting
solenoid
window
Flow control signal
Lift cylinder
Hydraulic
pump
213309
3-37
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
(a) Case 3: No motion of hydraulic cylinders.
OFF No Turn OFF
Is the system check lamp ON or OFF? Is emergency switch off ?
emergency switch.
Stays ON or flickers Ye s
No Is the controller set to Move the control lever: does throttling The control valve
Re-set. match the machine noise or any other abnormal noise come Ye s is internally in
specification? from the control valve? (Does the faulty condition.
unload solenoid operate?)
Ye s
Connect the GSE to the controller and Flicker No
read the current trouble data. Is the controller's LED (red) ON or
OFF?
Use GSE to Stays ON Stays OFF
Are all levers normal?
monitor trouble. Refer to case 8. Refer to case 7.
No Check the harness and connectors of the lever in question for

Are all input trouble data (on a lever), as
continuity. If open-circuit condition is noted, replace the lever
read by the GSE, normal?
assembly.
Ye s
No Check for continuity on the harness and connectors of
Are all output trouble data (on the
the component in question. If open-circuit is noted, replace
sensor), as read, normal?
the component.
Ye s
Are all output trouble data (standard), as No
read, normal?
Ye s Check for continuity on the harness and connectors of the solenoid
Are all output trouble data (on the work in question. If open-circuit is noted, replace the solenoid.
attachment), as read, normal? (This does No (Refer to the section on solenoid control valves.)
not apply to the two-element control
valve unit.)
Ye s
Read the past trouble data into the GSE.
Are all input trouble data (on the lever), No Check for continuity on the harness and connectors of the lever in
as read, normal? question. If short-circuit is noted, replace the lever assembly.
Ye s
No Check for continuity on the harness and connectors of the
Are all input trouble data (on the
component in question. If short-circuit is noted, replace the
sensor), as read, normal?
component.
Ye s
Are all output trouble data (standard), as No
read, normal? Check for continuity on the harness and connectors of the solenoid
Ye s in question and, if short-circuit is noted, replace the solenoid.
Are all output trouble data (on the No (Refer to the section on solenoid control valves.)
attachment), as read, normal?
Ye s
To deal with an internal malfunction of
any solenoid control valve, refer to the
section on solenoid control valves. If
necessary, contact the manufacturer.
3-38
ELECTRICAL SYSTEM
(b) Case 4: No inching motion of hydraulic cylinders
Does abnormal noise fade out Ye s Check for hitching, sticking and rattling. Repair to
when the mast is operated at
smoothen the movements.
normal working speed?
No
Is the controller set to match the No

Re-set.
machine specifications?
Ye s
Connect the GSE to the controller

and read "Input condition" into
the GSE. Check to be sure that
the data, as read, indicate the
control lever 76 HEX to 8A
HEX.
Move the control levers slowly

back and forth and check that
indication varies continuously
between 0 and 100%. No
The cause is a malfunction within the solenoid control
Test the control lever, as above, valve. If necessary, contact the manufacturer.
twice or thrice, to be sure there is
no jump or dip in the rising
indication.
Ye s
Check the harness and connectors

of the lever in question for
continuity. If discontinuity is
noted, replace the lever assembly.
3-39
ELECTRICAL SYSTEM
(c)Case 5: The maximum lowering speed of the mast is too high (or too low).

Re-set.
Yes
Is the adjusting knob (for the

max. lowering speed of the mast) Yes
(End)
effective in adjusting this speed
of the mast?
No

and read out "Input condition"
into the GSE.
Does the indication on the output

monitor screen vary between 0 No The lever is faulty or there is something wrong with
and 100% as the lever angle is the harness.
changed?
Yes
Are there changes in current of No The controller is faulty or there is something wrong
the order of 0.4 to 0.9 A? with the harness.
Yes
The solenoid valve is faulty or

there is something wrong with the
harness.
3-40
ELECTRICAL SYSTEM
(d)Case 6: Actuating speed differs during the lowering action of the lift cylinder.

Re-set.
Ye s

and read out "Input state (2)" into
the GSE.
Operate the mast: see if the lift

cylinder indication make an ON-
to-OFF change when 2nd
cylinder starts rising from its Ye s
Contact the manufacture.
fully retracted position. Will the
change occur? (Test twice or
thrice to be sure of the lift
cylinder action.)
No
Check for continuity on the harness

and connectors of the lift cylinder
circuit. As necessary, replace the lift
cylinder.
3-41
ELECTRICAL SYSTEM
(e) Case 7: Controller’s LED (red) will not go ON.
Check the fuse. Is the fuse OK or NG Replace the fuse, and check the harnesses for opens
NG? or shorts.
OK
Read the voltage between ground

and circuits 182 and 183 No Is the voltage between circuit 201 on the male side
(CN53). Is the reading at least 10
of CN4 and ground at least 10 volts?
volts? (Is power being supplied to
the controller?) Ye s
No
Ye s
Check the power supply
Is there continuity between
circuit (inside the console
circuits 186 and 187 and the
box) for continuity.
ground?
If open, correct and repair.
Ye s No
Is there continuity between circuit 201 (on the
Check to be sure that
female side of CN4) and circuits 182 and 183 (at
CN51, CN52 and CN53
CN53)?
are all in sound
condition. If the trouble Ye s No
persists, replace the
controller. While making sure that
each connector is coupled
up tight, check to see if
the LED turns ON; if not,
contact the manufacturer.
Check harness B for continuity.

Ye s Is there continuity between circuits 183 and 201
Repair and correct an open, if
any. at the male side of CN54?
No
C h e c k t h e e m e rg e n cy s w i t c h a n d e n g i n e h o o d
harness for open-circuits. If there is an open-circuit,
repair and correct, or replace the switch.
3-42
ELECTRICAL SYSTEM
(f) Case 8: Controller’s LED (red) will remain ON.
Does the LED remain OFF, No Is the voltage between circuit 201 on the male side
indicating the power supply is of CN4 and ground at least 10 volts?
faulty?
Ye s No
Check the power supply

circuit (inside the console
box) for continuity.
If open, correct and
repair.
Is the resistance between circuit 201 (on the female

side of CN4) and circuits 182 and 183 (at CN53)
less than 0.1 ohm?
Ye s No
While making sure that

each connector is coupled
up tight, check to see if
the LED turns ON; if not,
contact the manufacturer.
Check harness B for continuity. Ye s If the resistance between circuits 183 and 201 on
If open, correct and repair. the male side of CN54 less than 0.05 ohm?
No
C h e c k t h e e m e rg e n cy s w i t c h a n d e n g i n e h o o d
harness for open-circuits. If there is an open-circuit,
repair and correct, or replace the switch.
If the LED remains ON;

Are the DIP switches correctly No
Re-set.
set?
Is the SW2-8 set OFF?
Ye s
Replace the controller.
3-43
ELECTRICAL SYSTEM
6.6.4 How to Move the Mast in an Emergency

If the mast fails during operation, and you have to drive the
truck (if the engine is OK) or tow it to some distant place
like the repair shop, do the following steps: 1
(1) Mast lowering
(a) Loosen lock nut 1 on the lift section of the control
valve. 2
(b) Using an Allen wrench, slowly loosen screw 2. This
causes the mast to go down by gravity: tighten screw 2
and the mast will stop.
CAUTION
Before doing these steps, be sure that there is no
one standing under the mast.
(c) Tighten lock nut 1.
CAUTION
213293
Leaving nut 1 loose is dangerous: the mast might
suddenly start going down by itself.
(2) Lifting, tilting or auxiliary function
CAUTION
Steps (a) thru (i), below, are dangerous for the fol-
lowing actions:
Action Remarks
Mast will move in free-fall-
Lowering the mast
ing manner.
Dumping the hinged fork (or
bucket) Jerky dumping action. (The
Dumping the dump fork (or load will fall off.)
bucket)
Releasing clamped load The load will fall.
3-44
ELECTRICAL SYSTEM
(a) Remove the unload solenoid connector of the control

valve. Remove the proportional solenoid connector on
that end of the control valve which is for the action you Proportioning solenoid connectors
need.
(b) Using a volt-ohm meter, check the two solenoids Tilt forward Attachment 1
(unload solenoid and proportional solenoid) for shorts Mast down Attachment 2
or opens. If the solenoid is defective, it must be Attachment 3
replaced. (If the proportional solenoid, from which you

pulled off the connector half, is defective, you may
replace it temporarily by substituting another solenoid
in its place on the control valve.)
From
bottom
to top
Unload
solenoid
connector
Attachment 3
Mast up Attachemnt 2
Tilt backward Attachment 1
Proportioning solenoid connectors
213294
(c) Couple the female halves of the emergency-use harness
(special tool), as shown to the female halves discon-
nected in step (a), above.
Special tool needed
Emergency-use harness 91105-00400
(d) Connect the “black” alligator clip (from the opposite

end of the harness) to the negative (-) terminal of the
battery. Connect the (red) alligator clip to the harness,
as shown.
(e) Start up the engine.
205010
3-45
ELECTRICAL SYSTEM
(f) While the engine is idling; look around the machine to

make sure no one is standing near the truck. Now,
remove the “red” alligator clip and touch the battery's
positive (+) terminal with it: as you do so, the solenoid
(corresponding to that of the proportional solenoid now
connected to the battery) will activate: the action will
stop when the “red” clip is removed from the terminal.
CAUTION
(a) Do not touch the “red” alligator clip constantly to the
battery terminal (+) or the solenoid will burn up. Touch
Intermittently.
(b) You may raise the engine speed while intermit-
tently energizing the solenoid but do so cau-
tiously, keeping an eye on the action in
progress. 205011
(g) If the desired action does not occur in step (f), above, it
means that there is some malfunction inside the control
valve.
(h) Stop the engine, and remove the emergency-use har-
ness.
(i) Re-couple the connectors of unload solenoid and pro-
portioning solenoid.
3-46
ELECTRICAL SYSTEM
(3) When troubleshooting a failed seat switch, your trou-

bleshooting might reveal that the seat switch is an open
circuit or is defective and will not function.
In this case, you can create temporary circuit continuity
through the seat switch cable. The method is explained
in the illustration below. The seat switch is a safety part.
If it is defective, be sure to replace it with a new one as
soon as possible.
Two connectors are in the seat switch

line at the indicated location. Open
these connectors, and couple up the
male and female connector halves to
form a circuit bypassing the seat
switch.
213324
NOTE
Illustrated above is a band-aid method permissible only in
an emergency situation. Be sure to restore the seat switch
cable to the normal hookup after replacing the failed switch.
3-47
ELECTRICAL SYSTEM
6.6.5 How to Clean Harness Connectors and System

Components
(1) Open-circuit trouble is often due to the harness connec-
tors and components in dirty conditions: dust, together
with greasy matter, forms grime which, in time, pene-
trates electrical connections, resulting in loose metal-
to-metal contact, or worse, electrical separation of sur-
faces in contacts. For this reason, it is essential that the
connectors and components be cleaned at each periodic
inspection and at the time of servicing the machine.
Instead of a commonly used solvent, use electronic
parts cleaner (in the manner illustrated on the right).
Electronic parts cleaner ThreeBond 29B 208795
NOTE
The cleaner liquid is volatile. All you have to do is just
spray to wash off grime. No need to wipe off the sprayed
liquid.
(2) After checking the connector for continuity, wash it as

above. Then, uncouple the connector and spray contact
surface activator onto contact surfaces. Now, install and
remove the connector several times to wet the surfaces
thoroughly with the activator liquid. After coupling up
the connector that was sprayed on, make sure that it is
in locked state.
Contact surfaces activator ThreeBond 2501S (aerosol)
NOTE
Do not spray too much: bear in mind that this spray liquid
reacts with some resins (plastic materials).
205047
3-48
ELECTRICAL SYSTEM
6.6.6 Troubleshooting Guide for Solenoid Control Valves
Trouble symptoms Possible causes Remedies

1. Unload solenoid not working Remedies
2. Sticky plunger in proportioning solenoid of reduc-
Remedies
ing valve, or sticky shuttle in reducing valve
3. Open in lead wire or in solenoid coil Repair or replace.
The pump discharge
pressure will not build up 4. Input current to solenoid too small Check to make sure that solenoid is drawing
specified maximum input current.
• Check unload solenoid for action.
5. Unload valve stuck open
• Check unload valve for action.
6. Spool stuck in flow-divider valve Disassemble and clean by washing.
Sticky plunger in proportioning solenoid of reducing Disassemble and clean by washing.
Sticky spool
valve, or sticky shuttle in reducing valve. If plunger is sticky, replace solenoid.
6.6.7 Troubleshooting Guide for Solenoid Control Valves
LED
System
ON-
Components Trouble Condition Threshold Action check
OFF
lamp
pattern
1 - - Normal A - No action OFF
Control Control levers are not in their
Not in neu- 128 10 (A/D Turn off corresponding
levers (1) neutral positions when power D Flash
tral value) solenoid's outputs.
Lift lever (2) supply is turned on.
Tilt lever (3)
2 Input level is higher than lever 245 to 255 Turn off corresponding
Attachment Open circuit B ON
maximum position level. (A/D value) solenoid's outputs.
1 lever (4)
Attachment Input level is lower than lever 0 to 10 (A/D Turn off corresponding
Short circuit B ON
2 lever minimum position level. value) solenoid's outputs.
Abnormal if current is 0 when 120 mA or Turn off abnormal sole-
Open circuit C ON
Solenoids solenoid output is ON. lower noid’s output.
(1) Lift (2)
Abnormal if solenoid output
Tilt (3) 2.4 A or Turn off abnormal sole-
3 Short circuit current level is higher than C ON
Attachment higher noid’s output.
threshold level.
1 (4) Attach-
ment 2 Abnormal current is detected 140 mA or Turn off all solenoids’
Leakage C ON
during emergency operation. higher outputs
OFF for 15
Check I/O levels. Abnormal if Turn off all solenoids’
4 Seat switch Open circuit E seconds or Flash
signal stays OFF. outputs
longer
(CPU does not run.) (WDT Turn off all solenoids’
5 CPU Abnormality F - Irregular
causes CPU reset.) outputs
Lower than
Battery volt- Voltage drop, Turn off all solenoids’
6 Voltage is out of specification C 10 V; higher ON
age overvoltage outputs
than 32 V
Start check mode opera-
Setting
7 Check mode Setting of SW 2 (DIP switch) G S1 ON tion (solenoid opera- (OFF)
switch
tion)
3-49
ELECTRICAL SYSTEM
7. Troubleshooting
7.1 Starter System
• Weak or dead battery • Recharge or replace.

• Open or short circuit • Repair or replace.
Starter will
not crank • Poor continuity in starter switch • Replace.
engine
• Starter or starter relay defective • Replace.
Starter
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 will • Engine stop solenoid defective • Replace.
not stop • Control timer defective • Replace.
engine
3-50
ELECTRICAL SYSTEM
7.2 Gauges

Will not
indicate at • Gauge internally defective • Replace.
all
• Gauge unit defective • Replace.
Tempera- Will not • Gauge or gauge unit is not of the specified type. • Replace.
ture indicate
gauges accurately • Loose terminal connection • Repair.
Will indi- • Wiring between gauge and gauge unit grounded • Repair.
cate higher
than actual • Gauge internally defective • Replace.
temperature
• Open or short circuit • Repair.
Will not
indicate at • Gauge internally defective • Replace.
all
• Gauge unit defective • Replace.
Will not • Gauge or gauge unit is not of the specified type. • Replace.
indicate
accurately • Loose terminal connection • Repair.
Will indi- • Wiring between gauge and gauge unit grounded • Repair.
Fuel cate “full”
regardless of • Gauge internally defective • Replace.
gauge
amount of • Gauge unit defective • Replace.
fuel left in
tank
Will indi- • Open or short circuit between gauge and gauge unit • Repair.
cate “empty”
regardless of • Gauge internally defective • Replace.
amount of • Gauge unit defective • Replace.
fuel left in
tank
3-51
ELECTRICAL SYSTEM
7.3 Lighting System
• Weak or dead battery • Recharge or replace.

• Fuses blown • Check and replace.
Will not • Open or short circuit • Repair or replace.
light
• Poor grounding • Remove corrosion from the terminal or
retighten.
• Bulbs burnt out • Replace.
Lamps -
general • Weak or dead battery • Check and recharge.
• Burned contact points in switches • Repair or replace.
Will light • Loose terminals • Repair.

dimly • Dirty lenses • Clean.
• Waterdrops inside lenses • Dry and replace the packings.
• Bulbs service life expired • Replace.
Head Will not • Lighting switch defective • Replace.

lamps light • Bulbs burnt out • Replace.
Will not • Turn signal switch defective • Replace.

flash • Turn signal relay defective • Replace.
Will not go • Turn signal relay defective • Replace.
out
Turn sig-
nal lamps Will flash • Bulb wattage less than the rating • Replace it with specified bulb.
too slow • Turn signal relay defective • Replace.
Will flash • Bulb wattage greater than the rating • Replace it with specified bulb.
too fast • Turn signal relay defective • Replace.
Backup • Backup lamp switch defective • Correct if improperly installed: replace if

lamps will internally defective.
not light • Bulbs burnt out • Replace.
Other
lamps License • Lighting switch defective • Replace.
number plate
lamp will • Bulbs burnt out • Replace.
not light
3-52
ELECTRICAL SYSTEM
7.4 Alarm Unit
• Fuses blown • Check and replace.

Will not
• Horn button defective • Repair or replace.
sound
Horn • Horn switch defective • Replace.
• Horn defective • Replace.
Will give an • Horn switch defective • Replace.
offensive
sound • Horn defective • Replace.
Vacuum Will not • Vacuum switch defective • Replace.

buzzer sound • Buzzer defective • Replace.
3-53
ELECTRICAL SYSTEM
7.5 Battery
• Drive belt slipping • Adjust the tension.

Alternator
• Stator coil wire broken • Repair or replace.
• Open rotor coil • Replace.
• Brushes poorly seated on slip rings • Replace brushes if worn. Clean holder and
polish slip rings.
• Diode short or open • Replace.
Regulator
• Regulated voltage setting too low • Readjust.
Battery
Tends to run
down rapidly • Defective or inappropriate electrolyte • Refill or adjust the S.G.
• Defective cell plates (internal short-circuit) • Replace.
• Poor terminal connections due to insufficient tight- • Clean and tighten.
Battery ening torque
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 ter- • Repair.
minal and alternator terminal
Wiring
• Wrong connection or short circuit between the regu- • Repair.
lator 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.
3-54
LIGHTING SW.
WIRING CHART
TERMINAL
NO. CORD OFF 1 2
AV1.25
B B
CONSOLE BOX FOR FC AV1.25 CONTROLLER FC
T B
AV1.25
P B
AV1.25
H B
KEY B G 1 G2 M S CONTROLLER CN53 CONTROLLER CN52 CONTROLLER CN51

LIGHTING SW. LIGHTING SW.
2 SPEED T/M CONTROLLER TURN SIGNAL WIRING CHART OFF
LAMP RELAY B P H T ON 182 183 BLANK BLANK162 156 160 154 159 153 151 157 163 177 BLANK 178111 BLANK BLANK 107 120 113 BLANK BLANK BLANK BLANK BLANK BLANK 126 119 BLANK BLANK
FC
RG START 186187 BLANK 110a 179 BLANK BLANK BLANK 161 155 158 152 171 169 BLANK 179 BLANK BLANK BLANK BLANK BLANK 121 BLANK BLANK BLANK BLANK BLANK 118 127 BLANK BLANK 173
AIR CLEANER RADIATOR
ENG. OIL FUEL SYSTEM WATER YL CN4
R
RB
ELEMENT
WR
3
GB
OIL TEMP BRAKE OIL PRESSURE CHARGE GLOW FILTER CHECK (OP)
6 110a 187186 156 161 154 155 153 158 151 152 157 159 160 162 163 171 179 183 182 178 179 120 169 177 107 111 173 119 127 126 121 113 118
61 62 63 64 65 66 68 69 67 70 R GW 10A
LR 18 3Y 181 BLANK 110a 173 173 110a BLANK BLANK
LR
W
B
15A 91
WR
BW
RG
BR
WL
BY
59 LR
11 Lg Lg 15A 177 169 184 201 201 184 169 177
0.5L
0.5Y
0.5OL
0.5RW
0.5GR
0.5YW
0.5B
0.5BL
0.5RY
0.5WY
0.5WG
0.5OG
0.5LgY
0.5RG
WG
GW
0.5OW
0.5B
0.5B
0.5O
0.5BW
0.5WL
0.5BG
0.5Br
0.5BrY
0.5LY
0.5OG
0.5LW
0.5BrW
0.5P
0.5PW
0.5BrR
0.5PB
LR
0.5L
SPEED METER GB BLANK BLANK 119 126 BLANK BLANK BLANK BLANK BLANK BLANK 113
15A B
CONTROL BOX GB 15A
3BY YB 181 163 157 151 153 159 154 160 156 162 BLANK BLANK 183 182 120 107 BLANK BLANK 111 BLANK BLANK 177 173 BLANK BLANK 127118 BLANK BLANK BLANK BLANK BLANK 121
61 63 65 68 113 YB 90 OW 0.50W 0.50W
GB
62 64 66 69 70 10A WB 110a 110a 171 152 158 155 161 BLANK BLANK BLANK 179110 BLANK 187 186 BLANK BLANK BLANK BLANK BLANK BLANK BLANK 169
5BR
OB 184
0.5RL 184
0.5RL
8 93
RL RW 0.5RW
WR
10A 2 169 169 0.5RW 169 0.5RW
7 RG 15A
GR 177
0.5GR 177
0.5GR 177
0.5GR
POWER RELAY(HEAD LAMP) GL 2Y BL 0.5BL 0.5BL 0.5BL
YB
10A 92 173 173 173
RW GB GL GL GL GL
OW
0.85LgW 201 201 201
WL 0.5OL
RW
25 5 RELAY 181 120
RG
LR
GL
GB
3a
YB
GW
GB
GR
1 110 POWER RELAY 183
HOUR METER 0.5B
OB
5 4 3a BR 3
WR
71 181 10 169 111
B
BL
WATER TEMP FUEL 13b 30 201 27 GLOW TIMER 177
GL
00003 0.85B
13a 3 6 4 OR 4 184
17a
WY 2 173
SPEED SELECT
7 WRYL
3 201
SWITCH
0.85RW 107 183 113 118 127
61 ON OFF 211 201 121 126 119
LR
GL
0.5YW
0.5B
0.5RY
0.5WY
0.5WG
0.5OG
0.5LgY
0.5RG
ACCELERATOR SW.(OPTION) AUTO LIGHT SELECT SW
29
GW POWER RELAY(BACK UP LAMP)
184 29 SWITCH,EMERGENCY 183 201 107 211 119 127 126 121 113 118
71 B AUTO LIGHT SENSOR 600 601 635 989 821 818 815 810 811 812
RL
GW
BY
OW
Lg
G
R
RW
B
0.85B
RB
173 17
WR
0.5O
0.5BW
0.5WL
0.5BG
0.5Br
0.5BrY
0.5LY
0.5OG
0.5LW
0.5BrW
0.5P
0.5PW
WY
BL 17
OB 173
BrB 184
BW
GL RG 600 635 818 812 811
13b 110
RG
61 15 17 21 601 989
156 154 153 151 157 160 163 178 821 815 810
BR
G
GW
0.5W
0.5B
13a 11 16 18 20 22
0.5G
0.5BY
0.5BR
0.5YB
0.5RW
0.5BW
62 161 155 158 152 159 162a 171 179
WL
SPEED SENSOR 63 0.85B BrB
BY
13c 17 WY
64 BrB
65 29 4/5
601 600
W
66 16 R SELECT SW RELAY (B)
B
181 YB
G
64 63 B OW 167 162a 179
0.5BrR
0.5PB
GW
2 1 13b 110
68 13a
0.85B 201
GL 162 189
69 13c 0.85B
RG BR WL
63 BR 24 70
64 179 162a 167
189 162
CABLE BATTERY (+)
BR
5BW
G
R
RW
RB
RB
RL
GW
BY
GL
BrB
BR
19
WL
5B
GW
6 8 10 12 14 0.5B
WR
BW
HARNESS (A) FOR FC 60 189
OB
RB
3 5 7 9 11 13 15 17 19 21 23 9 70 2 LEVER, FC
16 18 20 22 24 24 71 1
10 11 60 19a LIFT LEVER
Lg
22 15 CABLE BATTERY (-) CABLE BATTERY (-)
OB
RB
9 14 21 20
65 G VOUT VIN
40B
13 12 60B
B
B 85a
G
R
RW
RB
RL
GW
BY
GL
BR
RB
1
Lg
BrB
BR
60B
WL
FLW0.85R
0.85YG
0.85WR
0.85W
0.85YB
0.85YR
0.85LW
0.85LR
0.85L
0.85YL
GW
8 7 B 23 + - + -
85 83 2
3 B 5 6 7 8 9 10 11 12 13 14
3 B 16 17 83 85 24 87
811 812 810 810 812 811
B B 15 16 17 18 19 20 21 22 23 85a 24 87
6 5
WR
CN1
BW
Br
W
L
18 19
BR
GW
YG
WR
YB
YR
LW
LR
YW
2B
YL
G
R
RW
GB
RB
RL
GW
BY
GL
BUZZER(VACUUM TANK 0.3W
61 (WHITE) (GREEN) CN8 812
AIR PURESSURE) 5B 8B 8B
0.5BrY
1 1 811
0.3R (5V)
62
0.5OG
0.5LW
CN3
0.5BrW
CN2
0.5BG
0.3G (GND)
0.5P
5BW 5BW
0.5BW
0.5RB
0.5PB
0.5PW
2 5BW 2 810
WL
W
B
BY
0.5BrR
0.5PB
202 203 204 205 206
8B
65
LIFT CN57
68 157 159 160 162 167
66 69 163
43 M 171
B
G
B
B S M LEVER, FC
171 163 157 202 159 203 160 204 162 205 167 206
5BR S 111 TILT LEVER
HORN
5BW
2R
SW 120
BR
L
163
202
203
204
205
206
202 157 204 160

160
187 163 171

157
203 159 206 167

171
159
167
162
77 2 205 162 G VOUT VIN

BW
0.5B
4
62 STARTING MOTOR 186
WR
0.5OL
61 CORD, (S) SOL1 LIFT(B) TILT(B) ATT1(B) ATT2(B) ATT3(B)
4
0.5B
20 RL 20 RL 24V-5kW 814 815 813 813 815 814
(ENGINE GROUP) (ENGINE GROUP) CN60 CN62 CN64 CN66 CN68 CN70
0.5B
78 (B) (B) (B) (B) (B)
53 G B B 0.3W
BR
HORN SW 69 30 815
W 0.3R (5V)
68 814
L T A A A 813
0.3G (GND)
329
BR
I I T T T TILT CN58
114
B BY BY BY F L T T T
22 22 22 FUEL CUT SOLENOID
14 YL
14 B ON/OFF T T 1 2 3
37 37 B 30 SOL1
W W (TILT,LIFT) LIFT(A) TILT(A) ATT1(A) ATT2(A) ATT3(A) LEVER, FC
6 WR 6 WR CN61 (A) CN63 (A) CN65 (A) CN67 (A) CN69 (A)
14 37 5 ATT 1 LEVER
14 14 YB 5 YB
7 YG 7 YG
37 37 3 3 152 151 158 153 155 154 161 156 166 165 G VOUT VIN
Y
B
166
165
152
151
158
153
155
154
161
156
FUEL TANK UNIT 151 152 153 158 154 155 156 161 165 166 817 818 816 816 818 817
W
WR
YB N.C 0.3W
818
152 0.5OG 817
0.3R (5V)
151 0.5LY 816
0.3G (GND)
158
0.5BrY
OIL PRES SW 0.5Br ATT 1 CN59
153
(ENGINE GROUP) 155
0.5BG
154
0.5WL
FRONT COBINATION LAMP 0.5BW
W
WR
161
6 5 156a
0.5O
0.5GR GR YG 6 5 0.5L LEVER, FC
178
0.5R GL B L R 190 0.5B 4/5 ATT 2 LEVER
B
5BW
221 (POWER SUPPLY) SELECT SW
HEAD LAMP YW YW ENGINE THERMO UNIT FC CONTROLLER EARTH RELAY (A) G VOUT VIN
11
0.5 F
167 156a 178
POWER RELAY POWER RELAY 165 190 820 821 819 819 821 820
R
24V-60W (SEAT SW) (SEAT SW)
ALTERNATOR (ENGINE GROUP) 821 0.3W
178 156a 167
IC REGULATOR
350
353
318
120
351
354
210
820 0.3R (5V)

190 165 819 0.3G (GND)
101b102 351 210
GW
GW 352
B
R
Br
TURN SIGNAL LEVER GLOW PLUGS ATT 2 CN60
B
13b 101a 354120

0.5B
GW
0.5OL
WL
G
46 83
R
GY
BY
42 41 Y R 352 351 210
RW
GW
YR
GR 4/5
GB
47 39 B L 65 15
LW
G F 66 87 120
0.5OL
15 G 16 SELECT SW
RB
B
LR
41 TURN SIGNAL LAMP 8 17 352 GW
0.5B 0.5B
Lg
HEAD LAMP HARNESS 39 LEVER CHART 9 18 30 111 210
L
CHASSIS EARTH
R
ENGINE GROUP B B
GL
GR
15 110 19 353 354
GW
TERMINAL R
2B
GL
15 LEVER F L R 316 318
LEFT L 12 21 23 87 GW 87 GW
43 41
NEUTRAL N 13
R
RW
RIGHT R
316
Lg R 39 35 43 REAR COMBINATION LAMP
318
47 46 GW 47 50 BLANK
G 87 (24V) 0.5B 989
R 15 R 23 GL G
16 16 44 GY 0.5W 635
RW RW 44 G GB GB B TURN SIGNAL LAMP (25W)
17 17 18 48 G
GY GY GY GY GB TAIL &STOP LAMP (10/25W)
GR 42 40 41 GR 41 GR 41 B GL
39 RB 39 RB 97 GL BACK UP LAMP (12W)
17 16 RB 54 54 GW GW 19 52
21 G 86
44 2B 45 G
13 13 B BACK UP BUZZER (OPTION)
R
HEAD LAMP HARNESS
GL
GR
(24V)
SHIFT LEVER(F-N-R) GL 93
Br Br
SEAT BELT
R 83
17 LgR 83 LgR
23
F BR 75 BR 75 18 GW
40 SHIFT LEVER CHART N WL 321 321 GW
LW
B
B1
GW 45
16 TERMINAL GW 86 GW 86 96
9 LEVER B1B2 F N R B2 325 325 316 318 323 321 SEAT SW
28 FORWARD F 39 RB
NEUTRAL N 83 321 75 19 RB WORKING LAMP(OPTION)
HEAD LAMP REVERSE R 316 318 321 322 323 325 326 329
325 326 329 322 (24V)
LW
B
BLNK
325 86
R 112 RB
B
G
28 ( 2 ) CIRCUIT SHOWN BY CHAIN DOUBLE - DASHED LINE ( ) MUST BE OPTIONAL CIRCUIT.
GW
24V-60W
21
FRONT COBINATION LAMP 44 NOTES ( 1 ) UNLESS OTHERWISE SPECIFIED, WIRE SIZE MUST BE 25 mm2.
RB
0.5GR GL
0.5R GR EARTH STRAP
G
B Black Red Green Yellow Blue White Brown Light green
GW
220
60B
LR
COOLANT SENSOR(OP) 66 75 8 T/M CASE(R.H)
L
321
B
B
65 74 T/M HARNESS 317 320 322 318 319 320 317
54 (CONDENCE TANK) 110 12 FR INTERLOCK CONTROLLER B R G Y L W Br Lg
FUSE(5A) 319 321 318 322 102
RY
BY
Br
YR
LgR
111 35 8
YW
LR
B
R
BR
G
YR
L
75
B
317 320 322 318 321 319
WORKING LAMP(OPTION) RB 1 2 3 4 5 6
B 74104
(24V) STOP LAMP SWITCH
5A
B 103 327 326
LR
B
326
327
328
329
320 323
323
320
324
325
WORKING LAMP WIRE(OPTION) TERMINAL MUST BE TIGHTEN WITH 1 328 329

BOLT FOR VALVE COVER. 324 325
Br
316
LgR
WL
R
B
BR
66
316
CAT
GW
LR
B
W
65 76 79 78 317 3 8 1 REAR COMBINATION LAMP

0.85G
0.85B
Lg
RY
YW 317
BY
B
T/C OIL THERMOSTAT SW. (24V) Schematic No. User for Truck No. Serial No.
74 75 7 4 319 330
5
(TRANSMISSION GROUP)
CPU
6 3 GL BACK UP LAMP (12W)

4 GB ES009-81100 99709-81100 DP70E T20C-70001-up
DUST INDICATOR(OPTION) BRAKE FLUID SENSOR SR SF 5
2
2 G TAIL &STOP LAMP (10/25W)
(AIR CLEANER) (MASTER CYLINDER) B
SOLENOID (SPEED SELECT) SOLENOID (F - R) POWER RELAY POWER RELAY GR TURN SIGNAL LAMP (25W)
PRESSURE SW. 6 LAMP, PILOT
(TRANSMISSION GROUP) (TRANSMISSION GROUP) (VACUUM TANK) (FR INTERLOCK) (FR INTERLOCK)
N-24V
Pub. No. 99709-81100
3-55
POWER TRAIN
1. Specifications ............................................................................................................... 4-2
2. Structure....................................................................................................................... 4-3
1
3. Reduction ratio ............................................................................................................. 4-4
4. Removal and Installation of Engine and Transmission Unit......................................... 4-5 2

4.1 Preparation ........................................................................................................................................... 4-5
4.1.1 Draining Oil and Coolant ............................................................................................................................. 4-5
4.2 Removing Overhead Guard and Covers............................................................................................... 4-6
3
4.2.1 Removal sequence ..................................................................................................................................... 4-6
4.2.2 Suggestions for Removal ............................................................................................................................ 4-7 4
4.3 Removing Controls ............................................................................................................................... 4-8
4.3.1 Removal Sequence..................................................................................................................................... 4-8
4.3.2 Suggestions for Removal ............................................................................................................................ 4-9
5
4.4 Removing Harnesses.......................................................................................................................... 4-10
4.4.1 Suggestions for Removal .......................................................................................................................... 4-10
6
4.5 Removing Radiator (transmission oil cooler), Pipes and Hoses ......................................................... 4-11
4.5.1 Removal sequence ................................................................................................................................... 4-11
4.5.2 Suggestions for Removal .......................................................................................................................... 4-12 7
4.6 Removal of Engine and Transmission Unit......................................................................................... 4-12
4.7 Installation........................................................................................................................................... 4-13
8
4.7.1 Installation sequence ................................................................................................................................ 4-13
4.7.2 Suggestions for Removal .......................................................................................................................... 4-13 9
4.8 Capacity .............................................................................................................................................. 4-15
10
11
12
13
14
4-1
POWER TRAIN
1. Specifications
Truck model DP70E

Type 3-element, 1-stage, 2-phase
Torque converter Maker model ML15
Stall torque ratio 2.9
Forward/reverse switching electrical column shift, H/L automatic
Operation method
drive
1st: 2.138
Transmission Forward
2nd: 0.685
Gear ratio
1st: 2.138
Reverse
2nd: 0.685
Gear type Hypoid gear
Reduction gear
Reduction ratio 4.111
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
4-2
POWER TRAIN
2. Structure
205488A
1 Engine 9 Pump drive gear

2 Flywheel 10 Hydraulic pump
3 Torque converter 11 Universal joint
4 Transmission 12 Parking brake
5 Input shaft 13 Front axle
6 Countershaft 14 Reduction differential
7 Output shaft 15 Final drive
8 Speed sensor gear 16 Wheel brake
The power transmission system, which serves to transmit (4) Reduction differential 14
power produced by the engine to the drive wheels, consists Not only reduces the speed but also distributes the pow-
of the following components. er to the right and left drive wheels.
(1) Torque converter 3 It also functions to prevent slipping by differentiating
The torque converter itself not only works as a clutch between both (right and left) drive wheels in terms of
but also transmits the increased engine torque to the their number of rotations, when they have a difference
transmission. in the rotating speed as a result of vehicle's turning to
(2) Transmission 4 the right or left.
This is a device to change the revolving speed and direc- (5) Final drive 15
tion of universal joint from those which are derived Final reduction system using planetary gears.
from the engine operation.
(3) Universal joint 11
Transmits power from the transmission to the reduction
differential.
4-3
POWER TRAIN
3. Reduction ratio
Figures in ( ) indicate number of gear teeth. (39)
(60)
(12) (39)
(54)
(52) (29)
(42)
(54)
(29)
(42)
(9) (52)
(37) (37)
(62)
205448B
Reduction bevel
Truck model Transmission Final drive Total gear ratio
gear
1st 2.138 (52/52 × 62/29) 37.354
Forward
2nd 0.685 (52/52 × 37/54) 4.111 4.250 11.972
1st 2.138 (62/29) (37/9) (39/12 + 1) 37.354
Reverse
2nd 0.685 (37/54) 11.972
PTO gear ratio: 0.929 (60/42 ∞ 39/60)
4-4
POWER TRAIN
4. Removal and Installation of Engine and Transmission Unit

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

Transmission oil drain plug
213116
Drain engine oil, transmission oil and engine coolant.
4-5
POWER TRAIN
4.2 Removing Overhead Guard and Covers
11
6
4 5
10
10
3
10
7
10
8
9
213117
4.2.1 Removal sequence
1 Overhead guard, Combination lamps, Head lamps 7 Floor mat

2 Batteries (Cords) 8 Floor plate (A), (Accelerator Pedal Link)
3 Engine cover, Seat 9 Floor plate (B)
4 Gas-filled cylinder 10 Air cleaner, Socket (Vacuum Switch)
5 Cover 11 Steering wheel
6 Radiator cover
4-6
POWER TRAIN
4.2.2 Suggestions for Removal

(1) When removing the batteries, be sure to disconnect the
ground (negative) side cable first.
(2) Remove the accelerator pedal by disconnecting the link
rod, then remove the floor plate 7.
100488
(3) Use the Puller (special tool) to remove the steering

wheel. Unit: mm (in.)
Puller 91268-10600
Puller M12 × 1.25
M8 × 1.25
30
55 (1
(2. .18)
17
)
213383
4-7
POWER TRAIN
4.3 Removing Controls
1 2
7
4
9
1
6
211307
4.3.1 Removal Sequence

1 Clevis pin, Washer, Pin 5 Clevis pin, Washer, Pin
2 Inching cable 6 Brake pedal bracket
3 Connector (Brake oil sensor, Stop lamp switch) 7 Brake booster bracket
4 Brake pipe 8 Throttle cable
9 Exhaust pipe
4-8
POWER TRAIN

(1) Remove the brake pedal and clutch pedal together with
bracket 6 on which they are assembled.
(2) Remove the brake booster and master cylinder together
with brake booster bracket 7 on which they are assem-
bled.
(3) Do not remove the inching bracket while it is mounted
on top of the transmission control valve.
(4) Only the engine-side throttle cable 8 should be
removed and laid along the right inside of the frame.
4-9
POWER TRAIN
4.4 Removing Harnesses
Stop lamp switch
Brake oil sensor Solenoid

(F-R switching)
Solenoid(speed select)
FC controller
Ground of solenoid
(speed select)
Starting motor relay
Battery
Glow plug
Pessure switch
(vacuum tank)
Battery
Engine oil
pressure switch
Alternator
Engine thermostat unit

213118
(1) 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
side the main harness, so it cannot be damaged.
4-10
POWER TRAIN
4.5 Removing Radiator (transmission oil cooler),

Pipes and Hoses
5
11
1
3
E.O. 8
E.I.
10
2 6
12
15
14 13
15
4
213384

1 Delivery hose 7 Hose (for transmission oil) 13 Universal joint, Bearing strap, Bolt, Washer
2 Delivery hose 8 Reservoir tank, Tube 14 Parking brake wire, Bolt, Nut
3 Suction hose 9 Radiator 15 Bolt, Washer, Cushion, Castle nut, Split pin
4 Hose 10 Transmission oil cooler E.O.: Engine outlet port
5 Radiator hose (upper) 11 Cowl (upper) E.I.: Engine inlet port
6 Radiator hose (lower) 12 Cowl (lower)
4-11
POWER TRAIN

(1) Propeller shaft 10 should be removed at the engine
side.
4.6 Removal of Engine and Transmission Unit
213120

Fasten a hoist to the engine and transmission unit with wire
ropes hitched to two lifting eyes on the engine and a sling
chain hitched to one eye on the transmission while placing a
levelling block under the unit. Adjust the length of the chain
sling with the lever block so that the unit is horizontal. Then
slowly lift the unit while moving it backward to remove in
the upward direction.
Weight of engine and transmission unit 620 kg (1367 lb)
4-12
POWER TRAIN
4.7 Installation
4.7.1 Installation sequence
Install in the reverse sequence of the disassembly proce-
dure.
4.7.2 Suggestions for Removal Output shaft
(1) When mounting the engine and transmission unit on
the frame, position it on the mounting brackets so that
the universal joint in front of the unit is aligned with the
transmission output flange.
Output flange
205457
(2) When installing the engine mounting nuts, first screw

down each nut until it comes in contact with the mount-
ing bracket, then tighten the nut further a quarter (1/4)
of a turn. If the pin hole in the bolt is not in alignment
Bracket
with any slots in the nut, tighten the nut the minimum
necessary amount to make them align with each other.
Cushion
Frame-side
bracket
206507
(3) After installing the parking brake wire with balls and
nut, make sure that the operating effort of the parking
brake lever is the standard value.
245 to 294 N
Operating effort of parking brake lever (25 to 30 kgf)
[55 to 66 lbf]
(4) When installing the engine exhaust pipe, use a new

gasket.
(5) Install the brake pedal and inching pedal rods and
cables, and check whether the height of each pedal and
the stroke of the clutch valve plunger are set to the
respective standard value.
220 mm
Height of pedal
(8.66 in.)
Stroke of clutch valve plunger with inch- 6 to 9.5 mm
ing pedal released (0.24 to 0.37 in.)
4-13
POWER TRAIN
(6) Connect the accelerator pedal link of floor plate A to

the injection pump lever, and make sure that the lever is
in full throttle position when the pedal is depressed all
the way.
(7) Make sure that all wires have been connected properly,
and then fasten the ground (negative) battery cable to
the corresponding terminal.
(8) 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.
(9) Fill the brake oil and bleed the brake oil lines.
(10)Also bleed the engine fuel lines.
(11)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. Operate the mast, forks and
steering and check the hydraulic oil level, refill as nec-
essary. Also check the engine oil, coolant and transmis-
sion oil levels, and refill each if necessary.
4-14
POWER TRAIN
4.8 Capacity
Fuels and Oils DP70E

Antifreeze 13.5 L (3.57 U.S. gal.)
Torque converter oil 22 L (5.81 U.S. gal.)
Gear oil
14 L (3.69 U.S. gal.)
(differential gear, front axle final gear)
Brake oil 240 cc (0.06 U.S. gal.)
Hydraulic oil 105 L (27.7 U.S. gal.)
Fuel 135 L (35.56 U.S. gal.)
Engine body: 16.5 L (4.37 U.S. gal.)
Engine oil Oil filter: 1 L (0.26 U.S. gal.)
Total: 17.5 L (4.62 U.S. gal.)
NOTE
Refer to the Service Data Section for the brand name of
each oil.
4-15
POWERSHIFT TRANSMISSION
1. Specifications ............................................................................................................... 5-3
2. Structure....................................................................................................................... 5-4
2.1 Torque converter................................................................................................................................... 5-4 1
2.2 Transmission......................................................................................................................................... 5-5
2.3 Power Train Line................................................................................................................................... 5-6
2.4 Control Valve ........................................................................................................................................ 5-7 2
2.5 Main Regulator Valve............................................................................................................................ 5-7
2.6 Torque Converter Drive Transmission Hydraulic System Schematic ................................................... 5-8
2.7 Automatic 2-speed Shifting Mechanism................................................................................................ 5-9
3
2.8 Torque Converter Drive Control System............................................................................................. 5-11
4
3. Suggestions for Removal and Installation.................................................................. 5-12
3.1 Removal.............................................................................................................................................. 5-12
3.1.1 Transmission Removal.............................................................................................................................. 5-12 5
3.1.2 Torque Converter Removal....................................................................................................................... 5-12
3.2 Installation........................................................................................................................................... 5-13 6
4.1 Torque converter................................................................................................................................. 5-14 7
4.1.1 Disassembly.............................................................................................................................................. 5-14
4.1.2 Inspection and Repair ............................................................................................................................... 5-15
4.1.3 Reassembly .............................................................................................................................................. 5-17
8
4.2 Transmission (2nd) ............................................................................................................................. 5-19
4.2.1 Disassembly.............................................................................................................................................. 5-19 9
4.2.3 Reassembly .............................................................................................................................................. 5-32
4.3 Control Valve ...................................................................................................................................... 5-39 10
4.3.1 Disassembly.............................................................................................................................................. 5-39
4.3.3 Reassembly .............................................................................................................................................. 5-42
11
4.4 Main Regulator Valve.......................................................................................................................... 5-43
4.4.1 Disassembly.............................................................................................................................................. 5-43 12
4.4.3 Reassembly .............................................................................................................................................. 5-43
13
5. Readjust ..................................................................................................................... 5-44
5.1 Oil Pressure Measurement ................................................................................................................. 5-44 14
5.1.1 Preparation................................................................................................................................................ 5-44
5-1
5.2 Clutch Valve Test................................................................................................................................ 5-45

5.2.1 Preparation................................................................................................................................................ 5-45
5.2.2 Testing procedure ..................................................................................................................................... 5-45
5.3 Stall Speed Measurement................................................................................................................... 5-46
5.3.1 Measurement procedure ........................................................................................................................... 5-46
5.4 10m (33 ft) Start Acceleration Test ..................................................................................................... 5-47
5.4.1 Testing procedure ..................................................................................................................................... 5-47
5.5 Confirming the function of “Automatic 2-speed transmission” ............................................................ 5-47
5.6 Inching Pedal Adjustment ................................................................................................................... 5-48
5.6.1 Preparation................................................................................................................................................ 5-48
5.6.2 Readjust .................................................................................................................................................... 5-49
7. Service Data............................................................................................................... 5-55

7.1 Stall Speed.......................................................................................................................................... 5-55
7.2 Pump boss .......................................................................................................................................... 5-55
7.3 Pilot boss ............................................................................................................................................ 5-56
7.4 Oil Pump ............................................................................................................................................. 5-56
7.5 Stator .................................................................................................................................................. 5-57
7.6 Flexible plate....................................................................................................................................... 5-57
7.7 Clutches .............................................................................................................................................. 5-58
7.8 Input shaft, Counter shaft and Transmission Cover............................................................................ 5-59
7.9 Backlash of Gears............................................................................................................................... 5-60
7.10 Control Valve ...................................................................................................................................... 5-61
7.11 Main Regulator Valve.......................................................................................................................... 5-62
7.12 Inching Pedal Control.......................................................................................................................... 5-63
5-2
1. Specifications
Truck model DP70E

Type 3-element, 1-stage, 2-phase
Torque converter Maker model ML15
Stall torque ratio 2.9
Forward/
Forward/reverse switching electrical column shift
Operation method Reverse
Reverse H/L automatic drive
Transmission 1st: 2.138
Forward
2nd: 0.685
Reduction ratio
1st: 2.138
Reverse
2nd: 0.685
5-3
2. Structure
2.1 Torque converter
205458
1 Turbine runner 7 Hub 13 Thrust bearing

2 Stator assembly 8 Roller 14 Spacer
3 Pump impeller 9 Spring 15 Ball bearing
4 Drive cover 10 Spring cap 16 Pilot boss
5 Pump boss 11 Thrust washer 17 Flexible plate
6 Ball bearing 12 Thrust washer
5-4
2.2 Transmission
205459
1 Flexible plates 4 Countershaft 7 Pump idler gear

2 Torque converter assembly 5 Output shaft 8 Pump drive gear
3 Input shaft 6 PTO drive gear 9 Pump case
The transmission is the powershift type and has two speeds

forward and two speeds reverse. The gear shifting is a
power-shift type implemented by the hydraulic multi-disc
type clutch.
5-5
2.3 Power Train Line
Figures in ( ) indicate number of gear teeth.

Reverse 1st
Forward 1st
Forward 2nd Reverse 2nd
205460B
Speed Gears engaged Gear ratio

1st 52/52 × 62/29 2.138
Forward
2nd 52/52 × 37/54 0.685
1st 62/29 2.138
Reverse
2nd 37/54 0.685
PTO gear 60/42 × 39/60 0.929
5-6
2.4 Control Valve
Section A − A
Section B − B
Section C − C
213387
1 Accumulator valve 3 Clutch valve plunger 5 Speed (H/L) valve

2 Directional valve 4 Clutch valve
2.5 Main Regulator Valve
10 9 8
7 6 5 4 3 2 1
213385
1 Bolt 5 Spool 8 Drain port

2 Cover 6 Body 9 Main pressure port
3 O-ring 7 Spring 10 Torque converter inlet pressure
port
4 Slug
5-7
5-8
Orifice: Diam. 0.8 mm (0.031 in.) Solenoid valve
(direction selection) Orifice: Diam. 0.8 mm (0.031 in.)
Last chance filter 230 m Last chance filter 230 m
Torque converter
Solenoid valve
(speed selection)
Chassis area
Diam. 6 mm Solenoid valve

(0.24 in.) Orifice: Diam. 0.8 mm (direction selection)
Oil cooler (0.031 in.)
Last chance filter

230 m
Torque converter bypass orifice: Oil filter

Diam. 4.0 mm (0.157 in.) Oil filter for
forward/
reverse
98 to 981 kPa k clutches
Torque converter inlet relief valve Pc
(1.0 to 10.0 kgf/cm 2) Pc (particle size 95 m)
Setting: 49 to 490 kPa [14 to 142 psi] Response
(0.5 to 5.0 kgf/cm 2) Tap (plug) for (inching) valve
[7 to 71 psi] torque converter Setting: 0 to 216
inlet pressure kPa (0 to 2.2
(marked "T") k kgf/cm 2)
k
Pp
2.6 Torque Converter Drive Transmission Hydraulic System Schematic
[0 to 31.3 psi]
Lubrication relief valve Tap (plug) for
Setting: 20 to 147 kPa main pressure
(marked "M") k Main orifice: Diam. 2.0 mm
(0.2 to 1.5 kgf/cm 2) (0.079 in.) Accumulator valve
[3 to 21 psi] Pressure at start of
charging: 206 kPa
Main regulator valve (2.1 kgf/cm 2) [30 psi]
Lubrication
line Setting: 1079 to 1373 kPa
Pressure at end of
(11.0 to 14 kgf/cm 2)
Oil pump charging: 706 kPa
[156 to 199 psi]
Capacity: 70 liters (7.2 kgf/cm 2) [102 psi]
(18.5 U.S. gal)/min
at 2300 rpm
Transmission oil reservoir

Suction strainer with magnet
100 mesh (particle size 220 m)
205923
2.7 Automatic 2-speed Shifting Mechanism
Control System
Travel speed selector switch
1st speed clutch

Electronic Control Unit Travel speed
Output
(ECU) (solenoid) valve
gear 2nd speed clutch
Pulse generator Electric signal

Hydraulic pressure signal
0.5 mm Transmission case
(0.02 in.)
Electronic Control Unit

(ECU)
Power
source
Speed selector switch
Solenoid valves
Pulse generator
205646
The automatic 2-speed transmission is made up of a combi-
nation of the torque converter drive transmission enabling 2
Selector switch position
speeds for each of the forward and reverse directions with Travel speed
(mode)
the dedicated control system, which consists of the pulse
0 to 6 km/h
generator, ECU, and solenoid valves. 1st
(0 to 6.2 mph)
With the speed selection switch, it is possible to shift the Automatic 2-speed
6 to 27.5 km/h
travel speed manually between the “Automatic 2-speed” 2nd
(6.2 to 17.1 mph)
and “Fixed 1st speed” modes whichever is more suitable for
Fixed 1st speed 0 to 10 km/h (0 to 6.2 mph)
the current operational situation.
5-9
NOTE
ECU is an acronym for Electronic Control Unit.
5-10
2.8 Torque Converter Drive Control System
211312
1 Direction lever 6 Clutch valve plunger

2 Inching bracket 7 Inching lever
3 Control Valve 8 Cable
4 Solenoid valve (for 1st and 2nd) 9 ECU
5 Solenoid valve (for forward/reverse) 10 Inching pedal
5-11

When installing and removing the transmission assembly
to/from the truck, handle it as an unit of the engine. For the
actual operation practices refer to “4. 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 gear pump from the transmis-
sion.
(3) Fasten a hoist to the transmission and lift the transmis-
sion just enough to take the weight of the transmission.
To lift the transmission, tie a wire rope around the
torque converter case. To lift the transmission, tie a wire
rope around the torque converter case and install an eye
bolt to the transmission cover, hitching a chain with le-
ver block to the eye bolt as shown. Use this 2-point lift-
ing method with the leveling block inserted under the
transmission to ensure its level.
(4) Remove the bolts that hold the flexible plate through
the access hole in the transmission case. 205464
(5) Separate the transmission from the engine by lifting the
transmission with the hoist.
3.1.2 Torque Converter Removal
(1) The torque converter can be removed easily, since it is
merely inserted into the stator shift, PTO drive gear,
and input shaft of the transmission, which is just
removed as an assembly.
NOTE
Because the torque converter does not have a drain plug, it
is not possible to completely drain the remaining oil. The
oil must be drained by turning the pump boss side down
during removal.
5-12
3.2 Installation
(1) Couple the torque converter to the transmission. Make
sure that the distance from the flexible plate mounting
face to the end face of the torque converter case is 43
mm (1.693 in.). If this distance is less than 43 mm
(1.693 in), it is necessary to re-assemble the torque
converter, it is an indication of defective engagement
between the splines of the input shaft and torque con-
verter stator shaft.
(2) Lift the transmission with the hoist to couple with the
engine unit.
(3) When the transmission is coupled with the engine,
make sure there is a clearance of 0 to 2 mm (0 to 0.08
in.) between the flywheel and flexible plate.
(4) Tighten the bolts that hold the flexible plate to the fly-
wheel through the access hole in the case. The bolts
should be tightened evenly in a crisscross pattern. The 205921
torque converter should be rotated, if necessary for fas-
tening the flexible plate, by a heavy-duty screwdriver
inserted through the window at the side of the torque
converter case and hooked on one of the bolts set on the
torque converter.
(5) Install the hydraulic gear pump to the transmission.
5-13

4.1 Torque converter
4.1.1 Disassembly
205465

1 Flexible plates, Pilot boss, O-ring, Bolts, Washers 5 Thrust washer
2 Bolts, Drive cover, Ball bearing 6 Stator assembly, Rollers, Hub, Spring, Spring caps
3 Spacer, Turbine runner 7 Ball bearing, O-ring, Pump boss, Pump impeller, Bolts,
Washers
4 Thrust washer, Thrust bearing
5-14
(2) Suggestion for disassembly

To remove the stator assembly, slightly force the stator
by turning it counterclockwise to prevent the rollers
from falling out. Pull the stator together with the hub by
sliding the splines in the stator shaft.
204530
4.1.2 Inspection and Repair

(1) Pump impeller
(a) Check for cracks in the pump impeller.
(b) Check for oil leaks due to looseness of the bolts hold-
ing the boss to the pump, or defective O-ring.
(c) Check for any wear on the contact surfaces of the pump
boss and oil seal.
(d) Check for any wear on the contact surfaces of the pump
boss and seal ring.
Seal ring Oil se O-ring

205466
5-15
(2) Stator
(a) Check the blades for cracks. Also check the fit of the
stator on the clutch cam.
(b) Check for any damage or wear on the clutch hub and
clutch cam.
(c) Check for any distortion, wear or fracture on the spring
or spring caps.
(d) Check the rollers for any damage, deformities, or wear.
(e) Check for any damage on the spline of the clutch hub.
(f) Check for the thrust washers for any wear or damage.
64.951 to 64.97 205467
Standard
mm
Outside diameter of value
(2.557 to 2.558 in.)
clutch hub 1
Repair or 64.9 mm
service limit (2.555 in.)
Standard 8.285 to 8.3 mm
Outside diameter of value (0.326 to 0.327 in.)
clutch roller 2 Repair or 8.2 mm
Thickness of thrust value (0.232 to 0.240 in.)
washer 3 Repair or 5.8 mm
Thickness of thrust value (0.037 to 0.041 in.)
washer 4 Repair or 0.9 mm
(3) Turbine runner

(a) Check for any cracks on the turbine runner.
(b) Check for the fit of turbine runner with the turbine
boss.
(c) Check for any damage on the spline of the turbine boss.
(4) Pilot boss
Check for any wear or damage on the pilot bearing part
referencing the following information.
19.980 to
Standard 19.993 mm
Outside diameter of a part value (0.7866 to 200411
in which to insert 0.7871 in.)
flywheel1
Repair or 19.9 mm
5-16
4.1.3 Reassembly
205458A
(1) Reassembly sequence

1 Pump impeller 8 Thrust washer
2 Pump boss, O-ring, Bolt, Washer 9 Thrust bearing, Thrust washer
3 Ball bearing 10 Turbine runner
4 Stator assembly 11 Drive cover, O-ring, Bolt, Washer
5 Springs, Spring caps 12 Spacer, Ball bearing, Pilot boss, O-ring
6 Roller 13 Flexible plate, Bolt, Washer
7 Hub
5-17
(2) Suggestion for reassembly

(a) Stator assembly
• Place hub 7 in the position as shown in the figure at the
right. Put spring 5 and spring cap 5 in each mounting
hole. Press in roller 6 in place while pressing spring cap 5.
• After installing a total of ten rollers, restore the hub to its
original position.
• After this assembly, turn the hub by hand to make sure
that it turns in one direction only.
(b) Selection of spacer
Measure the dimensions A, B and C in the figure at the
right. Select a spacer likely to fit in the clearance with
dimension (D) and put it in place.
202885A
Part No. Thickness of spacer
2.5 mm
91823-01700
(0.098 in.)
3.0 mm
91823-01400
(0.118 in.)
22.1 mm
A
(0.87 in.)
16 mm
Standard dimensions B
(0.63 in.)
3.5 ± 0.05 mm
C
(0.138 ± 0.001 in.)
(c) Flexible plate

After having installed the flexible plates, measure the
face runout of the plates with a dial indicator. Correct
205468
the error, if it exceeds the repair or service limit.
0.2 mm
Standard
(0.008
value
Face runout of flexible plate in.)
(in free state) 0.5 mm
Repair or
(0.020
service limit
in.)
5-18
4.2 Transmission (2nd)

4.2.1 Disassembly
(1)Control valve and external parts
205477
(a) Disassembly sequence

1 Inching bracket, Spring, Bolt, Washer 10 Main regulator valve, Gasket, Bolt, Washer
2 Breather 11 Bracket, Bolt, Washer
3 Oil level gauge, Plug 12 Bracket, Bolt, Washer
4 Oil pipe, Eye bolt, Gasket 13 Pulse generator cover, Pulse generator, Bolt, Washer
5 Oil pipe, Eye bolt, Gasket 14 Thermounit
6 Oil pipe, O-ring, Bolt, Washer 15 Plug, Gasket
7 Oil pipe, O-ring, Bolt, Washer 16 Oil Filter
8 Oil pipe, Eye bolt, Gasket 17 Cover, O-ring, Bolts, Washers
9 Control valve, Gasket, Bolts, Washers 18 Magnet strainer assembly
5-19
(2)Transmission cover and input, counter, and output shafts
205478
1 Transmission cover subassembly, 6 Baffle plate, Bolt, Washer 11 Speed sensor gear, Lock plate,
Gasket, O-ring, Bolts, Washers Bolts
2 Oil Seals 7 Countershaft subassembly 12 Ball bearing
3 Ball bearing 8 Input shaft subassembly 13 Output gear
4 Output gear 9 Baffle plate, Bolt, 14 Snap ring
Washer
5 Snap ring 10 Output shaft
5-20
(b) Suggestion for disassembly

• Transmission cover subassembly 1 removal
Turn two bolts (special tools) into the M10 × 1.25 holes in Bolts (jack bolt)
the cover evenly to remove the cover.
When the cover is raised approximately 25 mm (1 in.),
part of the cover which has been engaged in the bearing is
disengaged. Carefully remove the cover while taking care
not to damage each seal ring of the input shaft and coun-
tershaft.
Do not attempt to remove the relief valve being attached
to the cover.
Special tools
Bolt 67284-15400 205479
• Output gear (outside) 4 removal

When removing the output gears, remove the mounting
bolts of baffle plate beforehand. Output gear 4 should be
removed together with ball bearing 3 using a gear puller.
• Removal of input shaft 8 and countershaft 7 subas-
semblies
Hit the torque converter side of the input shaft subassem-
bly to pull its front-side bearing. This will cause the front-
side bearing of the countershaft assembly to come off.
Then, remove the countershaft subassembly while turning
it aside the input shaft subassembly. Then remove the
input shaft subassembly.
• Removal of output shaft 10
Turn the sliding hammer attached in the M10 × 1.25
screw hole at the end of the output shaft to remove it
together with the output gear, ball bearing, and speed sen-
sor gear.
Output gear
Sliding hammer
205480
5-21
(3) Stator shaft and oil pump
1 13
18
9 3
2
4 12
19
3
15
14
16
17
11
20
10
205481
5-22

1 PTO cover, O-ring, Bolt, Washer 11 Oil Seals
2 Snap ring 12 Idler gear shaft
3 Pump drive gear, Seal ring 13 Roller bearing
4 Ball bearing 14 PTO drive gear
5 Pump case, O-ring, Bolt, Washer 15 Ball bearing
6 Pump plate, O-ring, Gasket, Bolt, Washer 16 Ball bearing
7 Internal gear 17 Stator shaft, Seal ring, Bolt, Washer
8 Pump gear 18 Pump idler gear
9 Ball bearing 19 Roller bearing
10 Torque converter housing, Gasket, Bolts, Washers 20 Transmission case, Dowel pin
5-23

• Torque converter housing 10 removal
Utilize the housing removal bolt holes (M10 × 1.25) by
driving in two special-tool bolts (jack bolts) into them.
Turn the bolts evenly to remove the housing. When the
housing is raised approximately 18 mm (0.7 in.), a part of
the PTO drive gear which has been engaged in the ball
bearing will be disengaged. Then, fasten a hoist and
remove the housing.
Special tool needed
Bolt 67284-15400
• Oil pump removal

Remove the oil pump as an integral assembly including
pump case 5, pump plate 6, internal gear 7, and pump gear
8.
• Idler gear shaft 12 removal
Utilize the M20 × 1.5 screw hole at the inside surface the
shaft, to install the special tool, for pulling out the shaft.
Drive the sliding hammer into this screw hole, which has
been used for removing output shaft 10, and turn it to
remove the shaft.
Special tools
Shaft puller To be made by dealer 12
• Removal of PTO drive gear 14

Engage the gear puller ends on ball bearing 15, place a
protective plate on the head-side of the stator shaft, and 205482
then remove the drive gear together with two ball bear-
ings.
• Removal of stator shaft 17
Into the M10 × 1.25 bolt holes for removing stator shaft,
drive-in two special tools (jack bolts) and turn them
14
evenly to remove the stator shaft.
Special tools
Bolt 67284-15400
Or, tap out from the other end via a protective plate.
• Roller bearing outer race
Do not remove the outer race of roller bearing 19 for idler 205483
gear 18 unless any defect is found through inspection.
5-24
(4)Input shaft subassembly
205484

1 Seal ring 9 Thrust washer, Snap ring
2 Ball bearing 10 Snap ring, Pressure plate
3 Thrust washer 11 Friction plate, Mating plate
4 Gear (R2 drive), Needle roller bearing 12 Snap ring, Retainer
5 Thrust washer, Snap ring 13 Clutch spring
6 Ball bearing 14 Clutch piston, Steel ball, Screw, Piston seal
7 Thrust washer 15 Seal ring
8 Gear (R1 drive), Needle roller bearing 16 Input shaft
NOTE
Do not attempt to remove the screws from the input shaft.
It is not necessary to disassemble clutch pistons 14 if the
balls move freely in the pistons when they are shaken.
5-25

• Input shaft ball bearing 6 removal
Use the special tools to remove ball bearings 6 from the
input shaft.
202926
Special tools
Unit: mm (in.) 4 (0 12
ø11 .47
Ref.
Tool name Part No. Q’ty (0.43) )
No.
)
87
1 Puller 91268-13810 2 0 (7.
20
6
2 Plate 91268-13820 1 55 7) (0.24)
1
(2.
3 Bolt F1035-10020 2 2 ) )
(0.
08 .60 (0 25
( 12 ) .98
Gear puller 0 54 )
32 (3. )
4 (Manufacturer: T-24 1 0 44
9
2 (2.
BANZAI) 6
6
(0.24)
21
(0.83) 1 2 M10 × 1.25
213386
• Input shaft disassembling

With the special tool A or an arbor press, compress clutch
spring 13 and retainer 12, and remove snap ring 12.
Special tools
Piston tool 92267-00300
202896
5-26
(5)Countershaft subassembly
205485

1 Seal ring 9 Thrust washer, Snap ring
2 Ball bearing 10 Snap ring, Pressure plate
3 Thrust washer 11 Friction plate, Mating plate
4 Gear (F2 drive), Needle roller bearing, Spacer 12 Snap ring, Retainer
5 Thrust washer 13 Clutch spring
6 Ball bearing 14 Clutch piston, Steel ball, Screw, Piston seal
7 Thrust washer 15 Seal ring
8 Gear (F1 drive), Needle roller bearing 16 Countershaft
NOTE
Do not attempt to remove the screws being driven into the The critical points on disassembling the countershaft
countershaft. It is not necessary to disassemble clutch pis- are same as for disassembling the input shaft.
tons 14 if the balls are found to move freely in the piston
when they are shaken.
5-27

(1) Oil pump
(a) With the internal gear and pump gear assembled in the
pump case, measure top clearance 2.
(b) Measure also side clearance 1 between the pump gear
and case using a dial indicator.
0.04 to 0.078
Standard mm
value (0.00157 to
Side clearance 1 0.00307 in.)
Repair or 0.09 mm
0.3 to 0.345
Standard mm 205486
value (0.0118 to
Top clearance 2 0.0136 in.)
Repair or 0.35 mm
5-28
(2) Stator shaft

(a) Check the spline 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) Input shaft and countershaft clutches drums

(a) Check the mating plate sliding surfaces for wear or
damage.
(b) Check the clutch piston sliding surfaces for wear or
damage.
Standard 2.3 ± 0.07 mm

Thickness of mating value (0.091 ± 0.0028 in.)
plate 1 Repair or 2.1 mm
Thickness of friction value (0.102 ± 0.004 in.)
plate 2 Repair or 2.2 mm
Free movement of Standard 0.10 to 0.30 mm
friction plate on gear 3 value (0.0039 to 0.0118 in.)
-0.01
Standard 4 -0.03 mm
Width of piston seal value -0.0004
(0.16 -0.0012 in.) 211313
ring 4
Repair or 3.5 mm
+0.2
Standard 4 +0.1 mm
Width of piston seal value +0.008
(0.16 +0.004 in.)
groove in piston 5
Repair or 4.5 mm
62.9 mm (2.48 in.)
Free length of clutch Standard
(k=39.2 (3.992)
spring 6 (k: spring value
[223.3])
constant N/mm (kgf/
mm) [lbf/in.]) Repair or 60 mm
Width of clutch pis- value (0.098 ± 0.0020 in.)
ton seal ring 7 Repair or 2.0 mm
+0.2
Standard 2.5 +0.1 mm
Width of clutch pis- value +0.008
(0.098 +0.004 in.)
ton seal ring groove 8
Repair or 3.0 mm
5-29
(5) Input shaft and countershaft

(a) Check the seal rings and their contact surfaces for any
wear or damage.
2.5 ± 0.05 mm
Standard
(0.098 ± 0.0020
Width of piston seal value
in.)
ring for input shaft1
Repair or 2.0 mm
+0.2
Width of piston seal value +0.008
(0.098 +0.004 in.)
ring for input shaft2
Repair or 3.0 mm
+0.025
Standard 35 0 mm
Inside diameter of stator value +0.00098
shaft in contact with (1.38 0 in.)
seal ring 3 Repair or 35.2 mm
2.5 ± 0.05 mm
Standard
Width of seal ring for (0.098 ± 0.0020
value
input shaft and counter- in.)
shaft 4 Repair or 2.0 mm
+0.2
Width of seal ring value +0.008
groove in input shaft (0.098 +0.004 in.)
and countershaft 5 Repair or 3.0 mm
+0.025
Standard 35 0 mm
Inside diameter trans- value +0.00098
mission cover in contact (1.38 0 in.)
with seal ring 6 Repair or 35.2 mm
5-30
205487
NOTE
The input shaft is shown above. Objective sections to be
checked other than 1, 2, and 3 are common to both input
shaft and countershaft.
(b) Check the spline for wear or damage.
(c) Check the oil passages for clogging.
(6) Gears
Check the gear tooth faces and spline for wear or dam-
age.
(7) Magnet strainer assembly
Disassemble and clean the strainer. Replace if damaged.
(8) Transmission cover and torque converter case oil seals
Replace with new ones.
5-31
4.2.3 Reassembly
(1) Input shaft subassembly
(countershaft subassembly)
205488
(a) Reassembly sequence

1 Input shaft or countershaft 12 Needle roller bearing
2 Seal ring, Piston seal 13 Gear (R1 drive)
3 Piston 14 Thrust washer
4 Spring 15 Ball bearing
5 Retainer 16 Snap ring, Thrust washer
6 Snap ring 17 Needle roller bearing
7 Mating plate 18 Gear (R2 drive)
8 Friction plate 19 Thrust washer
9 Pressure plate 20 Ball bearing
10 Snap ring 21 Seal ring
11 Snap ring, Thrust washer
NOTE
The countershaft subassembly has a spacer inserted in gear
18 (R2 drive gear), since the needle roller bearing corre-
sponding to this part is long.
In addition, the torque converter side of the countershaft
does not extend beyond the ball bearing.
Critical points and sequence on reassembly are same for
both input shaft and countershaft except the above men-
tioned differences.
5-32
(b) Suggestion for reassembly

• Piston installation
Before inserting pistons 3 in the clutch drum, apply ATF
oil to their seal ring contact surfaces.
• Return spring installation
Use special tool A or arbor press to compress spring 4 and
retainer 5, then install snap ring 6.
Special tools
Piston tool A 92267-00300
202896
• Reassembly of friction plate and mating plate
Make sure the correct number and order of plates to be
reassembled and apply ATF oil to them before reassem-
bly.
When replacing the friction plates, replace the mating Friction plate
plates at the same time. Mating plate
Installation of thrust washer 205489

Install thrust washers 11, 14, 16, and 19 with each side
having an oil groove facing to the gear.
• Piston testing
Apply air pressure of approximately 686 kPa (7 kgf/cm2) 203800
[100 psi] through the oil hole provided on the reassem-
bled piston assembly to make sure the piston can move
smoothly and no sign of air leak is observed.
5-33
(2)Stator shaft and oil pump
205490
1 Transmission case, Dowel pin 11 Torque converter housing, Gasket, Bolt, Washer
2 Roller bearing 12 Pump case, O-ring, Bolt, Washer
3 Idler gear 13 Internal gear
4 Stator shaft, Seal ring, Bolt, Washer 14 Pump gear
5 Ball bearing 15 Pump plate, O-ring, Gasket, Bolt, Washer
6 PTO drive gear 16 Ball bearing
7 Ball bearing 17 Pump drive gear, Seal ring
8 Idler shaft 18 Ball bearing
9 Roller bearing 19 Snap ring
10 Oil Seals 20 PTO cover, O-ring, Bolt, Washer
case, torque converter housing, and transmission cover sub-
NOTE
assembly during reassembly.)
The dowel pins sunk into the transmission case have not
been removed. (These pins are for positioning the pump
5-34

• PTO drive gear installation
Press-fit ball bearings 5 and 7 to PTO drive gear 6, then
drive this gear assembly into stator shaft 4.
• Oil seal installation
Replace the oil seal with a new one.
Unit: mm (in.)
Use the Installer (special tool) to insert oil seal 10 into the
torque converter housing before reassembly.
(3.88)
(5.51)
Oil seal installer To be made by dealer
φ 40 (1.57)
13 (0.51) 8 (0.31)
(5.91)
• Oil pump subassembly
Provisionally assemble pump case 12, internal gear 13, 205491
pump gear 14, and pump plate 15 together.
At this time, apply oil to the internal gear and pump gear,
and do not forget to install the O-ring.
• Oil pump subassembly installation
Do not forget to install the gasket and fit the O-ring in the
oil hole when installing the oil pump subassembly in the
transmission case.
• Oil pump drive gear assembling
Press-fit ball bearing 16 to pump drive gear 17, then drive
this gear assembly in the transmission case after installing
two seal rings coated with oil. In this operation exercise
care for the alignment with the spline of pump gear 14.
• Ball bearing installation
Tapping-in of ball bearing 18 will possibly make the
pump drive gear pushed outward. Therefore, in this oper-
Unit: mm (in.)
ation, use the Holder (special tool) to restrict the gear (0.51)
from being pushed out.
Pump drive gear holder To be made by dealer

(6.
06)
When installing the ball bearing, have someone press the

gear with a copper bar, etc. in order to prevent the pump
drive gear from being pushed outward.
(1. 17)
39)
(7.
(4.9
(0. 31)
57)
09)
0.
8(
9)
( 0.3
10 10)
(1.
205492
5-35
(3)Input, counter and output shafts and transmission cover
10
14
13 13 12 11 6 8 1 2 7 3 4
205493

1 Output shaft 8 Baffle plate, Bolt, Washer
2 Snap ring 9 Input shaft subassembly
3 Output gear 10 Countershaft subassembly
4 Ball bearing 11 Output gear
5 Plate, Lock plate, Bolt 12 Ball bearing
6 Snap ring 13 Oil Seals
7 Baffle plate, Bolt, Washer 14 Transmission cover subassembly, Gasket, O-ring,
Bolts, Washers
5-36

• Output shaft reassembly
Integrate output shaft 1, snap rings 2 and 6, output gear 3,
ball bearing 4, and speed sensor gear 5 into a subassem-
bly, then install it in the transmission case.
Replace the lock plate for speed sensor gear with a new
one.
• Input shaft subassembly installation
Transmission
Do not forget to install a total of four seal rings, one on cover
the front side and three rear side of the input shaft. Also,
apply oil to these seal rings before installation.
• Oil seal installation
Replace both oil seals with new ones.
Install both oil seals 13 using the Oil Seal installer (spe-
cial tool).
Note that in this operation that both main lips face the
inside. Apply grease to the lip part.
205494
Oil seal installer To be made by dealer

Unit: mm (in.) 1 (0.04) chamfer
φ 68.5 (2.70)
φ 94.5 (3.72)
φ 108 (4.25)
(1.57)
φ 40
10 (0.39) 28 (1.10)
170 (6.69)
1.5 (0.06) 205495
• Transmission cover installation

Utilizing the bolt holes for removing transmission cover,
install hooks and hitch slings to them to hoist the cover.
Also, do not forget to coat oil on the servo cases to be
formed when the cover is installed.
Do not forget to put the O-rings in the oil holes before
placing the gasket on the transmission case.
205496
5-37
(4)Control valve and external parts
205477A

1 Magnet strainer assembly 10 Control valve, Gasket, Bolts, Washers
2 Cover, O-ring, Bolts, Washers 11 Oil pipe, Eye bolt, Gasket
3 Oil Filter 12 Oil pipe, O-ring, Bolt, Washer
4 Plug, Gasket 13 Oil pipe, O-ring, Bolt, Washer
5 Thermounit 14 Oil pipe, Eye bolt, Gasket
6 Pulse generator cover, Pulse generator, Bolt, Washer 15 Oil pipe, Eye bolt, Gasket
7 Bracket, Bolt, Washer 16 Plug, Oil level gauge
8 Bracket, Bolt, Washer 17 Breather
9 Main regulator valve, Gasket, Bolt, Washer 18 Inching bracket, Spring, Bolt, Washer
5-38
4.3 Control Valve

4.3.1 Disassembly
205473

1 Solenoid valve, O-ring 9 Roller bearing, Plug, O-ring
2 Speed (H/L) valve, Spring 10 Plate, O-ring
3 Spring, Directional valve 11 Accumulator piston, Spring guide, Springs (outer and
inner)
4 Plug, O-ring, Roller bearing 12 Oil Seals
5 Oil filter, O-ring 13 Oil filter
6 Stopper pin, O-ring 14 Plug, O-ring
7 Clutch valve plunger, Spring 15 Valve body, Gasket
8 Clutch valve, Spring, Slug
5-39
NOTE
Loosen each bolt and solenoid so that the spring, spool, and
plunger, etc. do not accidentally fly out.
(a) Stopper pin 6 removal
Drive a M4 ∞ 0.7 screw into the stopper pin to remove
it. Carefully proceed this operation, because clutch
valve plunger 7 may fly out when the stopper pin is re-
moved.
5-40

(1) Check the oil holes in the valve body for restriction.
(2) Check each valve and plunger for any wear or damage,
and whether their sliding is smooth.
(3) Check the orifice in the clutch valve for restriction.
Also check the spring for damage or degradation.
(4) Replace oil seal 12 with a new one.
(5) Replace filter 13 with a new one.
(6) Wash filter 5, or replace it with a new one.
Free length of solenoid 87.5 mm (3.44 in.)

Standard
spring 1 (k = 3.88 (0.396)
value
(k: spring constant [22.2])
200220
N/mm (kgf/mm) Repair or 85 mm
[lbf/in.]) service limit (3.35 in.)
Free length of direc- 32 mm (1.26 in.)

Standard
tional spring 2 (k = 8.62 (0.8786)
value
N/mm (kgf/mm) Repair or 31.5 mm
Free length of clutch 36.8 mm (1.45 in.)

Standard
valve spring 3 (k = 2.13 (0.217)
value
Free length of return 28 mm (1.11 in.)

Standard
spring 4 (k = 0.479 (0.0488)
value
[lbf/in.]) service limit (1.04 in.) 205699
Free length of accumu- 109.5 mm (4.31 in.)
Standard
lator valve spring 5 (k = 6.38 (0.651)
value
Free length of accumu- 154 mm (6.06 in.)
Standard
lator valve inner (k = 6.76 (0.6893)
value
spring 6 [38.6])
(k: spring constant
5-41
4.3.3 Reassembly
(1) Preparation
Wash the oil passages in the valve housing completely
and make sure no oil passage is restricted before reas-
sembly.
Section A − A
Section B − B
Section C − C
213388

1 Valve body 9 Spring, Clutch valve plunger
2 Oil filter 10 Stopper pin, O-ring
3 Oil Seals 11 Oil filter, O-ring
4 Plate, O-ring 12 Spring, Directional valve
5 Accumulator piston, Inner spring, Outer spring, Spring 13 Solenoid valve
seat
6 Plate, O-ring 14 Plug, O-ring, Roller bearing
7 Plug, O-ring, Roller bearing 15 Spring, Speed (H/L) valve, Solenoid valve
8 Clutch valve, Spring, Slug 16 Plug, O-ring
5-42

4.4.1 Disassembly
200554B

1 Cover, O-ring, Bolts, Washers 4 Spring
2 Slug 5 Cover, O-ring, Bolts, Washers
3 Main relief valve 6 Body
CAUTION
Loosen the bolt of cover 1 slowly so that the slug,
spool, and spring, etc. do not accidentally fly out
when the cover is removed.
4.4.2 Inspection and Repair 4.4.3 Reassembly
(1) Check each oil hole in the valve body for restriction. (1) Reassembly sequence
(2) Check the valve for any wear or damage, and whether Reassemble in the reverse order of disassembly se-
the sliding is smooth. quence.
(3) Check the springs for any damage or degradation. (2) Suggestion for Reassembly
Apply oil to the main relief spool and slug before as-
112 mm
(4.41 in.)
sembling them in the body.
Free length of main regula- Standard
(k = 4.99
tor valve spring value
(0.5087)
(k: spring constant N/ [28.48])
mm (kgf/mm) [lbf/in.])
Repair or 109 mm
5-43
5. Readjust
5.1 Oil Pressure Measurement
5.1.1 Preparation Torque converter
inlet pressure tap (T)
(1) Connect a pressure gauge with the rating of 1961 kPa Clutch pressure tap (PC)
(20 kgf/cm2) [284 psi] to the main pressure tap. Do the
same for the clutch pressure tap.
Special tools
M
*Connector 64309-17733
*Hose 64309-17722 T
*Connector 64309-17731
*Gauge 64309-17713
NOTE
Tools marked with an asterisk (*) are included in the Gauge Main pressure tap (M)
Kit 64309-17701. 205472
(2) Start and run the engine at an idling speed, and check
that the oil level is correct in the transmission case.
(3) Warm up the engine to raise the transmission oil tem-
perature.
(4) Run the engine at speed between 1000 and 1500 rpm.
NOTE
Measure the idling speed with an engine tachometer.
Main pressure, Speed 1.08 to 1.37 MPa

clutch pressure Standard (11.0 to 14.0 kgf/
(engine at 1500 ± value cm2)
100 rpm) [156.7 to 198.7 psi]
1.08 to 1.37 MPa
Direction clutch pressure
Standard (11.0 to 14.0 kgf/
(engine at 1500 ±
value cm2)
100 rpm)
[157 to 233 psi]
Torque converter inlet
0.05 to 0.49 MPa
pressure Standard
(0.5 to 4.9 kgf/cm2)
(engine at 1500 ± value
[7.3 to 71.0 psi]
100 rpm)
Lubrication oil pressure 0.02 to 0.15 MPa
Standard
(engine at 1500 ± (0.2 to 1.5 kgf/cm2)
value
100 rpm) [2.9 to 21.8 psi]
5-44
5.2 Clutch Valve Test

5.2.1 Preparation
(1) Raise the front wheels.
To do this, jack up the front axle housing, or fully tilt the
mast backward, place the wooden blocks under the out-
er mast then tilt the mast forward.
Support the raised truck securely on axle stands or other
rigid supports placed under the frame so that the truck
does not accidentally fall.
(2) Block the rear wheels.
CAUTION
The front wheels will turn when the clutch pres-
sure is measured. Use barricades to keep unau-
thorized persons away from the area where you
will be working.
5.2.2 Testing procedure

0.98
MPa (kgf/cm2) [psi]
(1) Set the inching pedal stroke to the specified value.
(10)
Clutch pressure,
(2) Connect a pressure gauge to the direction clutch pres- [142]
sure tap.
Use the same special tools as for measuring the main
pressure.
(3) Move the direction lever to the forward direction. 0.22
(4) Gradually pull out the clutch (inching) valve plunger (2.2)
[31.9]
from its fully depressed position. and plot the hydraulic
pressure curve relative to the plunger stroke. Make sure 0 5 10
that the pressure curve coincides with the curve shown. (0.20) (0.39)
Inching valve stroke, mm (in.) 211314
5-45
5.3 Stall Speed Measurement

5.3.1 Measurement procedure
(1) Start and run the engine at an idling speed, and check
that the oil level is correct in the transmission case.
(2) Warm up the engine to raise the transmission oil tem-
perature.
(3) Block both the front and rear wheels, and further apply
the parking brake.
(4) Run the engine at the idling speed.
(5) Move the direction lever to the forward direction, and
gradually depress the accelerator pedal all the way by
your right foot while depressing the brake pedal by our
left foot. Under this condition measure the stall speed
with the engine tachometer.
Stall speed
2050 rpm
(tolerance: ±100 rpm)
WARNING
Do not attempt to depress the inching pedal. Do
not continue operation in stall condition for more
than 30 seconds.
A failure to follow this precaution would result in
destruction of the torque converter.
(6) Similarly measure the stall speed when the direction

lever is turned to the reverse side.
NOTE
(a) Any speed within ± 100 rpm tolerance of the specifica-
tion is satisfactory.
(b) The stall speed varies depending which engine is com-
bined with which torque converter. Accordingly, the
stall speed takes a different value if the engine or
torque converter is changed to other.
5-46
5.4 10m (33 ft) Start Acceleration Test

5.4.1 Testing procedure
(1) Stand ready to start with the engine running at the
idling speed, the direction lever in the neutral position
and the speed selector switch in “Automatic 2-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
meters (33 feet) with a stop watch.
(4) This must be done for both the forward and reverse
directions.
5 seconds,
Travel time (unloaded)
maximum
213326
5.5 Confirming the function of “Automatic 2-speed
transmission”
Move the speed selector switch mounted on the console box
to each position, and make sure that the truck travels at var-
ious speeds. Move the switch when the truck is at standstill.
In the “Fixed 1st speed” position, the truck can run at a
maximum speed of 10 km/h (6.3 mph) and the engine gains
a greater torque.
In the “Automatic 2-speed” position, the transmission auto-
matically shift from the 1st to the 2nd speed when the travel
speed reaches 6 km/h (3.7 mph) to allow the truck to run at
a maximum speed of 27.5 km/h (17.1 mph).
5-47
5.6 Inching Pedal Adjustment

5.6.1 Preparation
Conduct the brake adjustment in advance.
(1) Bleed air out of the piping between the brake fluid res-
ervoir tank and master cylinder and between the master
cylinder and wheel cylinders.
(2) Turn the push rod as far as it goes toward the clevis of
the brake pedal side.
Push rod
Clevis
204550A
(3) Install the lock nut on the operating rod of the booster
and drive-in the push rod to a dimension of 10 mm as Unit: mm (in.)
shown in the figure at the right, then lock the push rod
with the lock nut.
For this operation insert the boot before driving-in the
push rod.
10 (0.39)
204710
(4) Adjust the brake pedal height A to 220 mm by turning

the stopper bolt, then lock the stopper bolt with the
lock nut.
(5) Turn the clevis of the push rod to make the pin inser-
tion hole aligned with that of the brake pedal. Install
the pin and lock the clevis with the lock nut.
(6) Adjust the brake lining-to-drum clearance and make
sure of the results. Do not adjust this clearance with the
setting of the push rod but use the automatic adjuster
function.
0.45 to 0.65 mm
Brake lining-to-drum clearance (one
(0.0177 to
side)
0.0256 in.)
206509
5-48
5.6.2 Readjust
Adjustment of inching pedal should be carried out after
completing the brake function adjustment.
(1) Connect a pressure gauge to the clutch pressure tap.
NOTE
For the oil pressure measurement tools needed refer to the
above description of clutch valve test.
(2) Adjust the inching pedal height A above the frame to
220 mm with the stopper bolt.
At this time make sure that the clearance B between the
inching pedal and brake pedal is 0.1 to 0.5 mm.
(3) Start the engine. With the brakes released, depress the
inching pedal until the brakes just begin to work (the
brake pedal starts being felt heavy). The plunger pro-
trusion amount D at this position should be adjusted to
16.5 mm (under zero oil pressure) by changing the
cable length or inching bracket fastening position.
Pedal stroke 46 to 73 mm 206510

(to point at which the brake starts (1.811 to 2.87
working) in.)
(4) Make sure the plunger protrusion amount C when the

inching pedal is released is 7 to 9.5 mm (pressure gage
reading is 1.08 to 1.37 MPa).
If this plunger protrusion amount C does not fall within
the standard range, readjust the brake and brake pedal to
the following criteria, and then readjust the inching ped-
al.
• 9.6 mm (0.378 in.) or longer: Too small lining-to-drum
clearance
• 5.9 mm (0.232 in.) or shorter: Too large lining-to-drum
End face of control
clearance valve body
Pedal height (from frame top sur- 220 mm D
A
face to pedal top end) (8.66 in.) C
2.8 ± 0.2 mm
Inching pedal to brake pedal
B (0.11 ± 0.008
clearance
in.) 6
Clutch oil pressure
MPa (kg/cm2) [psi]
(0.236)
Plunger protrusion length 7 to 9.5 mm
C (without inching pedal (0.276 to 0.98 (10) [142.3]
depressed) 0.374 in.)
Stroke end 0.49 (5) [71.13]
Plunger protrusion amount 16.5 mm (0.65
D 0.22 (2.2) [31.3]
(when brakes start working) in.) or more
0
15 10 5
(0.59) (0.39)(0.197)
13.5
(0.53)
Clutch valve plunger stroke

mm (in.) 211315
5-49
6. Troubleshooting
• reduced engine power output (Low compression • Adjust engine

pressure, Increased the fuel consumption, Low oil
Engine
pressure, Difficulty in starting, etc.)
• Reduced engine performance • Adjust engine
• Insufficient oil level • Refill.
• Swirling of air from the intake side • Retighten, or replace pipe and gasket.
• Defective main regulator valve spool operation • Repair or replace.
• Main regulator valve spring deteriorated • Replace spring.
Torque con- • Worn oil pump (Discharge capacity insufficient or • Disassemble for inspection, or replace any
verter reduced) defective part.
• Clogging of magnet strainer • Replace magnet strainer.
Not
• Worn seal ring or O-ring • Measure oil pressure, replace defective part.
enough
output • Seizure of stator flywheel • Replace the stator assembly, hub, and rollers.
power • Blades of running members damaged or worn • Repair or replace.
• Swirling of air from the inlet side • Retighten or replace.
• Outlet pressure is excessively low to make air bub- • Adjust the pressure.
bles generated inside.
• Water mixed in oil • Replace oil.
Transmis- • Insufficient oil level • Refill.
sion
• Clutch slipping due to reduced main oil pressure. • Measure oil pressure, readjust.
• Worn seal ring or O-ring • Measure oil pressure, replace defective part.
• Damaged clutch piston • Replace.
• Seizure or drag of friction plate • Replace.
Truck body • Large running resistance in the suspension • Check or adjust brake system.
5-50
• Flexible plate damaged • Replace.

Torque con-
• Defective oil pump driving system • Replace.
verter
• Turbine shaft damaged • Replace.
• Insufficient oil pressure (main pressure) • Check pump gear for wear, or replace.
• Improper adjustment of inching pedal • Readjust.
• Worn servo piston case seal ring • Replace.
No power • Worn input shaft O-ring • Replace.
flow • Plug omitted to be removed from input shaft • Repair.
Transmis-
• Seizure of clutch • Replace.
sion
• Damaged shafts • Replace.
• Clutch drum damaged (at the snap ring groove) • Replace.
• Damaged snap ring for clutch drum • Replace.
• Clogging in the clutch oil passage • Wash or replace.
• Worn shafts spline • Replace.
• Damage in the power train (reduction gear, differen- • Refer to the description for each damaged
Truck body
tial gear, front axle) section.
5-51
• Flexible plate damaged • Replace.

• Bearings damaged • Replace.
Torque con- • Stator interferes with something. • Replace.
verter • Loose bolt • Retighten, or replace bolt.
• Spline worn • Replace.
• Oil pump worn • Disassemble for check, or replace.
• Drag sound caused by seized clutch • Replace clutch plate.
• Wear or seizure of bearing • Replace.
Transmis-
• Gears damaged • Replace.
sion
• Loose bolt • Retighten, or replace bolt.
• Spline worn • Replace.
• Clogging of oil strainer • Wash or replace.
Abnor- • Defective main regulator valve spool operation • Disassemble and wash, or replace.
mal noise
• Large restriction in pipe causing unsmooth oil flow • Replace.
High abnor- • During winter season (too high viscosity) • Refer to the “List of Applicable Lubricant”,
mal sound and replace.
• Instrument failure • Replace.
• Inappropriate oil is used. • Refer to the “List of Applicable Lubricant”,
and replace.
• Oil pump failed • Replace.
• Large oil leaks
Low abnor-
(1) Defective main regulator valve spring • Replace spring.
mal sound
(2) Defective main regulator valve spool • Repair or replace spool.
• Swirling of air • Retighten, or replace packing.
• From oil seal • Check the lip part and sliding surfaces for
wear, or replace the seal.
• From the connection part to the case • Retighten, or replace packing.
• From each connection and pipe • Repair or replace pipe, gasket and O-ring.
• From drain plug • Retighten, or replace gasket.
Oil leak • From cracks • Replace.
• Oil jet out of transmission case
(1) Water mixed in oil • Replace oil.
(2) Swirling of air from the inlet-side connection • Retighten, or replace packing.
(3) Oil leak from air breather hole • Repair.
• Excessive oil quantity • Drain the oil to the specified level.
5-52
• Inappropriate oil quantity • Refill or drain.

• Stator interferes with something. • Repair or replace stator.
• Stator system failed • Replace stator assembly.
Torque con-
• Swirling of air • Retighten or replace O-ring.
verter
• Water mixed in oil • Replace oil.
• Large restriction in pipe causing unsmooth oil flow • Repair or replace.
Abnor- • Wear or seizure of bearings • Repair or replace.
mal oil
• Instrument failure • Replace.
tempera-
ture rise • Drag of clutch • Replace clutch plate.
Transmis-
• Wear or seizure of bearings • Repair or replace.
sion
• Control link defective • Repair or replace.
• Inappropriate use of truck body • Drive truck. correctly.
• Truck body failure
Truck body (1) Damage of fan belt • Replace.
(2) Clogging of oil cooler • Wash or replace.
(3) Drag of brake • Check and adjust.
• Main regulator valve failed • Correct or replace valve assembly.

• During winter season • Refer to the “List of Applicable Lubricant”,
Main oil pressure is too
and replace oil.
high
• Inappropriate oil is used. • Refer to the “List of Applicable Lubricant”,
and replace oil.
• Clogging of magnet strainer • Wash or replace.

• Oil pump failed • Replace.
• Defective coil spring in main regulator valve • Replace spring.
Main oil pressure is too • Defective spool in main regulator valve • Repair or replace spool.
low • Swirling of air • Retighten, or replace packing.
• Defective clutch valve • Repair or replace.
5-53
• Clogging of magnet strainer • Wash or replace.

• Oil pump failed (worn) • Replace.
• Defective coil spring in main regulator valve • Replace spring.
• Defective spool in main regulator valve • Repair or replace spool.
Clutch oil pressure is too • Swirling of air • Retighten, or replace packing.
low • Insufficient oil level • Refill.
• Defective clutch valve • Repair or replace.
• Fracture of seal ring in servo case part • Replace.
• Damaged clutch seal ring • Replace.
• Engine output likely to be reduced if the stall speed • Adjust engine

is slightly low for both directions
Stall speed does not fall
• Stator or flywheel failure suspected if the speed is • Replace stator assembly.
within the standard
range. too low for both directions
• Defective inching link or slipping of clutch if the • Repair or replace.
speed exceeds the standard range.
• Speed selector switch remained in the “Fixed 1st • Change the switch to “Auto” position.
speed” position.
• Defective solenoid valve • Replace.
Speed not shifted • Clogging of solenoid valve inlet orifice • Wash or replace.
• Defective solenoid valve spool • Repair or replace spool.
• Defective solenoid valve spring • Replace spring.
• Internal failure of ECU control box • Check or replace.
Shift up the speed with • Open circuit in the switch harness • Harness connections
speed selector switch
• Defective switch • Replace switch.
set to “Fixed 1st
speed” position.
5-54
7. Service Data
7.1 Stall Speed
Truck model DP70E

Standard
Stall Speed 2050 ± 100 rpm
value
1.08 to 1.37 MPa
Main pressure, Speed selector clutch pressure Standard
(11.0 to 14.0 kgf/cm2)
(engine at 1500 ± 100 rpm) value
[157 to 233 psi]
1.08 to 1.37 MPa
Clutch pressure Standard
(11.0 to 14.0 kgf/cm2)
[157 to 233 psi]
0.05 to 0.49 MPa
Torque converter inlet pressure Standard
(0.5 to 5.0 kgf/cm2)
[7.3 to 71.1 psi]
0.02 to 0.15 MPa
Lubrication oil pressure Standard
(0.2 to 1.5 kgf/cm2)
[3 to 21.8 psi]
Standard
10 m (33 ft) start 5 seconds, maximum
value
7.2 Pump boss
Truck model DP70E

0
Standard 100 -0.035 mm
Diameter of fitting surface in contact with oil seal value 0
(3.94 -0.0014 in.)
1
Repair or 99.9 mm
207863
5-55
7.3 Pilot boss
Truck model DP70E

-0.007 -0.00028
Outside diameter of a part in which to insert Standard value 20.0 -0.020 mm (0.78 -0.00079 in.)
flywheel 1 Repair or service limit 19.85 mm (0.781 in.)
200411A
7.4 Oil Pump
Truck model DP70E

Standard value 0.040 to 0.078 mm (0.0028 to 0.0043 in.)
Side clearance 1
Repair or service limit 0.09 mm (0.0079 in.)
Top clearance 2
205486A
5-56
7.5 Stator
Truck model DP70E

-0.03 -0.0012
Standard value 65 -0.49 mm (2.56 -0.00193 in.)
Outside diameter of clutch hub 1
0 0
Standard value 8.3 -0.015 mm (0.33 -0.00059 in.)
Outside diameter of clutch roller 2
Standard value 6.0 ± 0.1 mm (0.236 ± 0.0039 in.)
Thickness of thrust washer 3
205467A
7.6 Flexible plate

Truck model DP70E
Face runout of flexible plate 1 Standard value 0.2 mm (0.008 in.)
(in free state) Repair or service limit 0.5 mm (0.020 in.)
Distance from case edge face to flexible plate
Standard value 43 mm (1.69 in.)
mounting face 2
205474
5-57
7.7 Clutches
Truck model DP70E

Standard
2.3 ± 0.07 mm (0.091 ± 0.0028 in.)
value
Thickness of mating plate 1
Repair or
2.1 mm (0.083 in.)
service limit
Standard
2.6 ± 0.1 mm (0.102 ± 0.004 in.)
value
Thickness of friction plate 2
Repair or
2.2 mm (0.087 in.)
service limit
Standard
Free movement of friction plate on gear 3 0.1 to 0.3 mm (0.0039 to 0.0118 in.)
value
Standard -0.01 -0.0004
value 4 -0.03 mm (0.16 -0.0012 in.)
Width of piston seal ring 4
Repair or
3.5 mm (0.138 in.)
service limit
Standard +0.2 +0.008
value 4 +0.1 mm (0.16 +0.004 in.)
Width of clutch piston seal ring groove 5
Repair or
4.5 mm (0.177 in.)
service limit
Standard 62.9 mm (2.48 in.)
Free length of clutch spring 6 value k = 39.1 (3.992) [223.3]
Spring constant: k = N/mm (kgf/mm) [lbf/in] Repair or
60 mm (2.36 in.)
service limit
205475
5-58
7.8 Input shaft, Counter shaft and Transmission Cover
Truck model DP70E

Width of piston seal ring for input shaft 1
+0.2 +0.008
Standard value 2.5 +0.1 mm (0.098 +0.004 in.)
Width of seal ring groove of input shaft 2
+0.025 +0.00098
Inside diameter of input shaft in contact with Standard value 35 +0 mm (1.38 0 in.)
seal ring 3 Repair or service limit 35.2 mm (1.386 in.)
Width of seal ring for input shaft and counter- Standard value 2.5 ± 0.05 mm (0.098 ± 0.0020 in.)
shaft 4 Repair or service limit 2.0 mm (0.079 in.)
+0.2 +0.008
Width of seal ring groove of input shaft and Standard value 2.5 +0.1 mm (0.098 +0.004 in.)
countershaft 5 Repair or service limit 3.0 mm (0.118 in.)
+0.025 +0.00098
Inside diameter transmission cover in contact Standard value 35 +0 mm (1.38 0 in.)
with seal ring 6 Repair or service limit 35.2 mm (1.386 in.)
Width of clutch piston seal ring for input shaft Standard value 2.5 ± 0.05 mm (0.098 ± 0.0020 in.)
and countershaft 7 Repair or service limit 2.0 mm (0.079 in.)
+0.2 +0.008
Width of clutch piston seal ring groove of Standard value 2.5 +0.1 mm (0.098 +0.004 in.)
input shaft and countershaft 8 Repair or service limit 3.0 mm (0.118 in.)
205487A
NOTE
The input shaft is shown above. Objective sections to be
checked other than 1, 2, and 3 are common to both input
shaft and countershaft.
5-59
7.9 Backlash of Gears
Truck model DP70E

Input gear and counter gear 1 Standard value 0.12 to 0.28 mm (0.0047 to 0.0110 in.)
Forward 1st speed gear and reverse 1st speed gear 2 Standard value 0.13 to 0.32 mm (0.0051 to 0.0126 in.)
Forward 2nd speed gear and reverse 2nd speed gear 3 Standard value 0.13 to 0.32 mm (0.0051 to 0.0126 in.)
Pump drive gear and idler gear 4 Standard value 0.12 to 0.26 mm (0.0047 to 0.0102 in.)
PTO drive gear and idler gear 5 Standard value 0.12 to 0.26 mm (0.0047 to 0.0102 in.)
205459A
5-60
7.10 Control Valve
Truck model DP70E

Free length of clutch spring 1 value k = 3.88 (0.396) [22.2]
Spring constant: k = N/mm (kgf/mm) [lbf/
in.] Repair or
85 mm (3.35 in.)
service limit
Standard 32 mm (1.26 in.)
Free length of directional spring 2 value k = 8.62 (0.8786) [49.2]
in.] Repair or
31.5 mm (1.24 in.)
service limit
Free length of clutch valve spring 3 value k = 5.88 (0.6) [33.6]
in.] Repair or
36 mm (1.42 in.)
service limit
Free length of return spring 4 value k = 0.488 (0.0488) [2.73]
in.] Repair or
26.5 mm (1.04 in.)
service limit
Free length of accumulator valve outer spring 5 value k = 6.38 (0.651) [36.4]
in.] Repair or
107.5 mm (4.23 in.)
service limit
Free length of accumulator valve inner spring 6 value k = 6.76 (0.6893) [38.6]
in.] Repair or
152 mm (5.98 in.)
service limit
205699A
5-61
Truck model DP70E

Free length of main regulator valve inner spring 1 value k = 4.99 (0.5087) [28.48]
in.] Repair or
109 mm (4.29 in.)
service limit
Free length of main regulator valve outer spring 2 value k = 3.93 (0.401) [22.42]
in.] Repair or
90 mm (3.54 in.)
service limit
200554C
5-62
7.12 Inching Pedal Control
Truck model DP70E

Height above floor of inching pedal 1
Standard
(from frame top surface to top end of pedal 220 mm (8.66 in.)
value
pad)
Clearance between inching and brake pedal con- Standard
2.8 ± 0.2 mm (0.11 ± 0.008 in.)
necting parts 2 value
Protrusion amount of plunger 3 Standard
7 to 9.5 mm (0.276 to 0.374 in.)
(with inching pedal not being depressed) value
Protrusion amount of plunger 4 when brakes start Repair or
16.5 mm (0.65 in.) or more
working service limit
3
4
213389
5-63
FRONT AXLE AND REDUCTION DIFFERENTIAL
1. Specifications ............................................................................................................... 6-2
2. Structure....................................................................................................................... 6-3
1
3. Suggestions for Removal and Installation.................................................................... 6-4
3.1 Front Wheels (Tires) ............................................................................................................................. 6-4
3.1.1 Preparation.................................................................................................................................................. 6-4 2
3.1.4 Installation ................................................................................................................................................... 6-5
3
3.2 Front axle and reduction differential assembly ..................................................................................... 6-6
3.2.1 Preparation.................................................................................................................................................. 6-6 4
3.2.4 Installation ................................................................................................................................................... 6-8
5
4. Disassembly and Reassembly ..................................................................................... 6-9
4.1 Front axle .............................................................................................................................................. 6-9
6
4.1.1 Disassembly................................................................................................................................................ 6-9
4.1.2 Inspection and Repair ............................................................................................................................... 6-12 7
4.1.3 Reassembly .............................................................................................................................................. 6-13
4.2 Reduction differential .......................................................................................................................... 6-16
4.2.1 Disassembly.............................................................................................................................................. 6-16
8
4.2.3 Reassembly .............................................................................................................................................. 6-20 9
10
6. Service Data............................................................................................................... 6-29
6.1 Front axle ............................................................................................................................................ 6-29 11
6.2 Reduction differential .......................................................................................................................... 6-30
12
13
14
6-1
1. Specifications
Truck model DP70E

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 × 2
Front axle type Full-floating, tubular
Suspension method Fixed to frame
6-2
2. Structure
205501A
1 Front wheel hub 9 Differential gear

2 Front axle housing 10 Differential pinion
3 Axle shaft 11 Reduction gear
4 Ring gear 12 Reduction pinion
5 Planetary gear 13 Input flange
6 Wheel brake assembly 14 Parking brake drum
7 Reduction and differential assembly 15 Parking brake bracket
8 Differential case 16 Parking brake assembly
The front axle is of full-floating type with a banjo-type axle bly. The reduction and differential assembly consists of
housing bolted to the front side of the frame and is provided reduction pinions, input flanges, and parking brake drums.
with the planetary gear-type final drive system. This front The parking brake assembly is mounted on the parking
axle housing is also provided with the wheel brake assem- brake bracket.
6-3

3.1 Front Wheels (Tires)
3.1.1 Preparation
Loosen the outer wheel nuts about two turns. Block the rear
wheels.
1 Extension valve
2 Outer wheel nut
3 Front wheel (tire) (outer)
4 Inner wheel nut
5 Front wheel (tire) (inner)
204579

(1) Truck lifting Tilt backward Tilt forward
(a) Utilizing a hydraulic system
Fully tilt the mast backward, place the wooden blocks
under the mast then tilt the mast forward, and the front
wheels are raised off from the ground.
(b) Jacking
Position two jacks under the frame at the front axle
mounts.
Block
101325
(c) 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, place jack stands
under the frame to prevent the truck from falling.
Block the rear wheels.
213108
6-4
(2) Removing wheels

(a) Remove the outer wheel nuts.
(b) Remove the outer wheel (tire). Outer wheel nut
(c) Lower the truck to the ground once, and loosen the
inner wheel nuts about two turns. Inner wheel nut
(d) Raise the wheels.
(e) Remove the inner wheel nuts.
(f) Remove the inner wheel (tire).
202820
3.1.4 Installation
Follow the removal procedure in reverse while noting the
following instructions.
(1) Wheel nuts should be tightened to the specified torque
evenly so that the runout of wheels can be avoided as
much as possible.
382 ± 38 N•m
Tightening torque (39 ± 3.9 kgf•m)
[282 ± 28 lbf•ft]
101209A
(2) When retightening the wheel nuts for the dual tires, be
careful not to forget to tighten the inner wheel nuts.
Loosen oueter Tighten oueter
wheel nuts. wheel nuts.
Tighten inner
wheel nuts.
200230
6-5
3.2 Front axle and reduction differential assembly

3.2.1 Preparation
(1) Block the rear wheels. Tilt backward Tilt forward
(2) Fully tilt the mast backward, place the wooden blocks
under the mast then tilt the mast forward, and the front
wheels are raised off from the ground.
(3) Insert solid stands under the frame to prevent the truck
from falling.
Block
Stands 213392

1 Front Wheels (Tires)
2 Mast assembly
3 Wheel brake pipes (right and left)
4 Parking brake wire
5 Front axle, Reduction and differential assembly,
Bolt, Nut, Washer
204583A
6-6

(1) Front Wheels (Tires)
Refer to “3.1 Front Wheels (Tires)”.
(2) Mast assembly
For the removal procedure of mast assembly, refer to the
section of “Mast and Fork”.
(3) 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.
(4) Front axle and reduction differential assembly
(a) Disconnecting universal joint
Disconnect the universal joint at the input flange side. In
Transmission
addition, fasten the universal joint to the transmission Disconnect here.
body with a rope, etc. to prevent it from coming off from
the output shaft of the transmission.
(b) Lifting assembly
To remove the front axle and reduction differential as-
sembly, fasten a hoist to and lift the mast support bear-
ings of the axle housing with a chain or wire rope via
some protective cloth. During this operation be careful
not to damage the mast support bearings.
204585A
6-7
3.2.4 Installation
Follow the removal procedure in reverse while noting the
following instructions.
(1) Tightening torque
(a) When mounting the front axle and reduction differen-
tial assembly to the frame, firmly tighten the nuts to the
specified torque.
344 to 420 N•m

Tightening torque (35.1 to 42.8 kgf•m)
[253.9 to 310.0 lbf•ft]
(b) Fasten the universal joint to the specified torque.

61 to 81 N•m
Tightening torque (6.2 to 8.3 kgf•m)
[45 to 60 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
Lever operating effort (25 to 30 kgf)
[55 to 66 lbf]
(3) Bleeding brake oil line

After installing the wheel brake pipes, thoroughly bleed
air from the brake oil lines. Check also for oil leaks.
This operation will be easier, if it is performed before
installing the front wheels and mast.
6-8

4.1 Front axle
4.1.1 Disassembly
NOTE
(1) Preparation
Drain the gear oil remaining in the right and left axle Since this operation can be performed with the axle housing
housings. This operation can be performed with cover 2 mounted on the frame, prepare for it in the same way as the
plug being removed. removal of front wheels.
204586A

1 Plug, Gasket 5 Lock plate, Bolt, Washer, Nut
2 Cover, Gasket, Bolt, Washer 6 Ring gear, Tapered roller bearing (inner race)
3 Planet carrier assembly, Planet carrier, O-ring, Planet 7 Hub drum assembly, Front wheel hub, Wheel bolt, Nut,
pin, Steel ball, Thrust washer, Planet gear, Bushing Brake drum, Studs bolt, Nut, Tapered roller bearing
(outer race), Oil seal, Oil deflector, Bolt
4 Axle shaft, Sleeve 8 Tapered roller bearing (inner race), Oil seal retainer (O-
ring)
6-9

(a) Oil Draining
Have a container available to catch the oil that flows
from the axle housing when the plug is removed. Have
a container available to catch any residual oil when the
planetary carrier assembly is removed.
(b) Removing planet carrier assembly
To remove the cover, drive two bolts (approx. 100 mm
[3.9 in.] long) into the bolt holes on the cover. Pull the
planet pins to remove the planet gears and thrust wash-
ers from the carrier.
204587
(c) Removing axle shaft

Drive the sliding hammer in the screw hole M10 ∞ 1.25
in the end of the axle shaft to remove the axle shaft. Socket wrench
(d) Removing nuts

Use Socket wrench (special tool) to remove the nut.
Special tool
Socket wrench
92067-00200
Width across flats: 112 mm
205926
(e) Removing hub drum assembly

Support the hub drum assembly with a transmission
jack. Remove the front wheel hub with a wheel hub
puller.
204589
6-10
(f) Removing bearing

The inner race of the tapered roller bearing remaining in
the axle housing should be removed with the seal retain-
er using a bearing puller.
NOTE
At this time, the axle housing has the wheel brake assembly
204590
still mounted. For disassembly, inspection and reassembly
of the wheel brake assembly, refer to “Brake System”.
6-11

(1) Axle shaft
Measuring deflection of axle shaft
Apply a dial indicator at the middle of the axle shaft,
and rotate the shaft to measure the deflection.
0.05 mm
Standard value (0.0020
Deflection of axle shaft (1/ in.)
2 of dial indicator reading) 0.2 mm
Repair or ser-
(0.008
vice limit
in.)
200860
(2) Axle housing (4) Planet carrier
(a) Check the mast support bearing contact surfaces for (a) Measure the inside diameter of the planet gear bush-
wear or damage. ings and the diameter of the planet pins.
(b) Check the outer and inner oil seals for wear or damage. Check the outside surface for wear and damage.
(c) Check the axle housing for distortion, dents, or other +0.10
26 +0.04 mm
defects. Also check the welds for cracks. Standard value +0.004
Inside diameter of (1.02 -0.002 in.)
planet gear bushings
(3) Hub drum assembly Repair or ser- 26.3 mm
(a) Check the oil seals for wear and damage.
+0.009
(b) Check the brake drum inside surfaces for wear and 26 -0.004 mm
Standard value +0.0004
damage. Outside diameter of (1.02 -0.0002 in.)
planet pins
317.5
+0.2
0 mm Repair or ser- 25.9 mm
Standard value +0.008 vice limit (1.02 in.)
Brake drum inside (12.5 0 in.)
diameter
Repair or ser- 318.5 mm (b) Check the thrust washers for wear or damage.
vice limit (12.54 in.) -0.1
2.3 -0.2 mm
Standard value -0.004
(c) Check the tapered roller bearing (outer race) for wear Thickness of thrust (0.091 -0.008 in.)
or damage. washer
(5) OTHERS
(a) Check the outside surface of oil seal retainer for wear
and damage.
(b) Check the tapered roller bearing (inner race) for wear
or damage.
6-12
4.1.3 Reassembly
(1) Preparation
Reassemble the planet carrier assembly.
10
11
8 5 6 7
3 2 4 205604
1 Front axle housing 7 Lock plate, Bolt, Washer
2 Oil seal retainer, O-ring 8 Sleeve, Axle shaft
3 Tapered roller bearing (inner race) 9 Planet carrier assembly, Planet carrier, Planet gear,
Bushing, Thrust washer, Planet gear, Steel ball, O-ring
4 Hub drum assembly, Front wheel hub, Wheel bolt, Nut, 10 Cover, Gasket, Bolt, Washer
Brake drum, Stud bolt, Nut, Tapered roller bearing (out-
er race), Oil seal, Oil deflector, Bolt
5 Ring gear, Tapered roller bearing (inner race) 11 Plug, Gasket
6 Nut
6-13

(a) When any of the hub drum assembly parts has been
replaced, reassemble the hub drum assembly. Align the
extension valve grooves in the brake drum and front
wheel hub.
When installing the oil deflector, do not forget to apply
gasket adhesive to the mating surfaces.
245 ± 24.5 N•m

Tightening torque of brake
(25.0 ± 2.5 kgf•m)
drum nut
[181 ± 18.1 lbf•ft]
NOTE
211825
Replace all oil seals that have been installed in the front
axle housing with new ones.
(b) Reassembling tapered roller bearing (inner race)

Using an installer, replace the tapered roller bearing in-
ner race in position together with the seal retainer.
204592
(c) Wheel hub bearing preload adjustment

Hook a spring scale to one of the hub bolts and measure
the preload. Adjust the preload by means of the nut that
holds the ring gear. However, it is advisable to aim at a
value of preload in the lower tolerance limit, if the bear-
ings have long been in service.
Preload of hub bearing (force 147 to 167 N

applied to the hub bolt in the (15 to 17 kgf)
tangential direction) [33 to 38 lbf]
204593
6-14
(d) Reassembling planet carrier

When installing the planet pins to the carrier, coat the
inside surfaces of the planet gear with the oil to be used Level mark Oil level plug
in filling the axle housing.
(e) Oil filling

Position the level mark of either the right or left cover to
be horizontal. At this time, make sure that the level plug
hole in the cover on the other side is above horizontal.
Remove the level plugs from both the left and right cov-
ers.
Remove the plug from the differential side of the axle
housing and pour oil through this plug. Since the oil
used in the axle housing has a high viscosity and it will
take time to appear in the level plug holes, exercise care
so the oil does not overflow out of the refill port. 213391
Hypoid gear oil: SAE#90
(API Class GL-4)
Approx. 14 L
6-15
4.2 Reduction differential

4.2.1 Disassembly
(1) Preparation
(a) Drain the gear oil.
At the drain port, remove one of the level plugs located
on the lower part of the housing.
(b) Remove the reduction differential assembly from the
front axle housing. If the front axle assembly is not
required to be disassembled, first draw out the axle
shaft about 150 mm, then remove the reduction differ-
ential assembly.
NOTE
(a) For disassembly, inspection and reassembly of the
wheel brake assembly, refer to “Brake System”.
(b) Replace the oil seals that have been used in the parking
brake bracket with new ones.
(c) Before disassembling the differential gear assembly,
except for replacing the reduction gear set for a new
one, measure the reduction gear backlash to aid in reas-
sembling the gear assembly correctly.
Backlash between reduction 0.20 to 0.28 mm

gear and pinion (0.0079 to 0.011 in.)
204596
6-16
(d) Adjusting the bearing cap of one side

Put alignment marks on the screw and carrier to be use-
ful for subsequent reassembly.
(e) Before removing the bearing retainer from the differen-

tial carrier, record the gap or the number of shims
inserted between the bearing retainer and differential
carrier.
204597
6-17
204595A

1 Bolt, Washer, Lock plate 6 Self-lock nut, O-ring
2 Side bearing nut 7 Input flange, Parking brake drum, Reamer bolt, Washer,
Dust plug
3 Carrier cap set, Bolt, Lock washer, Bearing cap, Differ- 8 Parking brake assembly, Bolt, Washer
ential carrier
4 Differential gear assembly, Reduction gear, Spring pin, 9 Parking brake bracket, Oil seal, O-ring, Bolt, Washer
Pinion shaft, Differential pinion, Differential gear, Wash-
er, Differential case, Bolt
5 Tapered roller bearing 10 Reduction pinion, Oil separator, Tapered roller bearing,
Collar, Bearing retainer, Tapered roller bearing, Shims,
O-ring
6-18
(3)Suggestion for disassembly

(a) When the bearing retainer has been removed from the
differential carrier, record the thickness (number of
shims) inserted between them, and exercise care so as
not to lose them.
(b) Remove the inner bearing using a bearing puller.
204598
(1) Reduction gear and reduction pinion
Check the reduction gear and reduction pinion for tooth
contact. Check the gear teeth for wear, pitting, flaking or
chipping. Minor flaws on the tooth surfaces can be re-
paired by grinding with an oil stone or hand grinder.
If the gears are damaged to require replacement, replace
the reduction gear and pinion as a set.
(2) Differential
(a) Check the differential case and the tapered roller bear-
ing for damage. Check, in particular, the seat formed of 0.02 to 0.07 mm
Standard
Clearance between the (0.0008 to
each case for carrying the tapered roller bearing inner value
differential pinion and 0.0028 in.)
race to see whether the seat surface is galled or not.
pinion shaft. Repair or 0.35 mm
(b) Check the differential case for crack, and check the service limit (0.014 in.)
sliding surfaces of differential gears and washers for
wear or damage. Play between the dif-
Repair or 0.5 mm
ferential gear and axle
(c) Check the teeth of the differential pinions and bevel service limit (0.02 in.)
shaft spline
gears for wear, pitting, chipping, galling, etc. Check
also the washer supporting parts for wear or damage.
(d) Check the inside surface of the differential pinion and
outside surface of pinion shaft for wear.
(e) Check the differential gear and axle shaft spline for
wear that may cause excessive play.
(3) Parking brake drum

(a) Check the brake drum inside surfaces for wear and +0.3
Standard 203.2 0 mm
damage. value +0.012
Inside diameter of (8 0 in.)
(b) When the inside diameter of the drum exceeds the drum
repair or service limit, replace the drum with a new Repair or 205 mm
one.
6-19
4.2.3 Reassembly
213397

1 Differential case assembly, Differential case, Washer, 8 Tapered roller bearing (inner race), Oil separator
Differential gear, Differential pinion, Pinion shaft, Spring
pin
2 Reduction gear, Bolt 9 Parking brake bracket, Oil seal, O-ring, Bolt, Washer
3 Tapered roller bearing 10 Parking brake assembly, Bolt, Washer
4 Carrier cap set, Differential carrier, Bearing cap, Lock 11 Input flange, Parking brake drum, Reamer bolt, Washer,
washer, Bolt Nut, Plug
5 Side bearing nut 12 Self-lock nut, O-ring
6 Reduction pinion, Tapered roller bearing (inner race), 13 Lock plate, Bolt, Washer
Collar
7 Bearing retainer, Tapered roller bearing (outer race), O-
ring, Shim
6-20

(a) Reassembling differential case assembly
• When you attempt to set the spring pin after the pinion
shaft has been inserted in the differential case, position
the slit of the spring in the position shown or in the oppo-
site position.
204600
• The backlash between the differential gear and pinion is

adjusted by using washers of different thicknesses on the
differential gear.
Measure the backlash, and if it exceeds the repair or ser-
vice limit, replace the washers with new ones.

Backlash between value (0.004 to 0.012 in.)
differential gear and
pinion Repair or 0.5 mm
200244
(b) Installing reduction gear
To install the reduction gear in the differential case, put
LOCTITE No. 271 on the threads of the mounting bolts,
and tighten them evenly to the specified torque.
196 N•m
Tightening torque of reduction
(20 kgf•m)
gear
[145 lbf•ft]
6-21
(c) Installing bearing cap

The bearing caps are machined together with the differ-
ential carrier. Identify the right and left caps by referring
to the alignment marks to avoid mistaking between
them.
Fit the caps tentatively by tightening the cap bolts finger
tight. The caps are to be secured tight after the preload
for the differential case tapered roller bearing and the
tooth contact of the reduction gear and pinion have been
adjusted.
146 to 178 N•m

Tightening torque of cap bolt (15 to 18 kgf•m)
[108 to 131 lbf•ft]
(d) Adjustment of differential case tapered roller bearing

preload
Check the preload for the differential case assembly be-
fore installing the reduction pinion.
Tie a wire around the around the differential case, and
hook a spring scale to the wire. Pull the scale in tangen-
tial direction and take a reading on the scale just when
the differential case begins to rotate.
Adjust the preload by means of the right and left bearing
nuts.
2.2 to 3.1 N•m

(0.2 to 0.3 kgf•m)
[1.6 to 2.3 lbf•ft]
204601
15.4 to 21.6 N
Preload
(1.6 to 2.2 kgf)
[3.5 to 4.9 lbf]
as force applied to reduc-
tion gear in the tangential
direction.
NOTE
Tighten the side bearing nuts evenly so as not to disturb the
backlash. Before measuring the preload, tap the back of the
reduction bevel gear with a copper-face hammer while
rotating the gear by hand for run-in.
6-22
(e) Adjustment of reduction pinion preload

• Tentatively assemble the reduction pinion with the fol-
lowing procedure in order to make sure the preload of the
tapered roller bearing of the reduction pinion.
Install parts 6, 7, 8 and 11 input flange and self-lock nut
Collar
12.
• Tighten the self-lock nut to the specified torque.
196 to 294 N•m

Tightening torque for self-lock
(20 to 30 kgf•m)
nut
[145 to 218 lbf•ft]
204602
• Hold the input flange in a vise and wrap a few turns of

wire around the bearing retainer. Hook a spring scale on
the outer end of the wire and pull the spring scale to read
the force the moment the bearing retainer begins to rotate.
1.96 to 2.94 N•m

(0.2 to 0.3 kgf•m)
[1.4 to 2.2 lbf•ft]
31.4 to 48 N
Preload
(3.2 to 4.9 kgf)
[7.1 to 10.8 lbf]
as force applied to bearing
retainer in the tangential
204603
direction.
The preload can be adjusted by means of varying the

thickness of a collar to be inserted. There are nine toler-
ances of collars from 15.50 mm (0.1620 in.) to 15.90 mm
(0.6260 in.) in increments of 0.50 mm (0.0020 in.). When
readjusting, disassembling or assembling the reduction
pinion without replacing any parts, adjust the preload to
80% of the standard value, since the tapered roller bearing
has already been set.
6-23
(f) Adjustment of reduction gear and pinion tooth contact

and backlash
• Install the reduction pinion in the differential carrier
assembly.
Tentatively install the reduction pinion as a tentative
assembly of the reduction pinion as described above.
• Install the original amount of shim(s) in position and ten-
tatively secure the bearing retainer.
• Move the reduction gear toward the reduction pinion to
obtain the standard backlash.
Backlash between reduction 0.20 to 0.28 mm

gear and pinion (0.079 to 0.0110 in.)
NOTE
Difference in the turn in or turn out, between the right and
left side bearing nuts, will move the preload away from the
standard value.
204604
• For measuring the backlash, set up a dial tooth indicator

with its spindle pointing squarely to the tooth face of the
reduction gear. In this condition, move the reduction gear
back and forth (in a rotating direction) to observe how the
indicator hand shakes.
204596
6-24
• Spread a thin coat of red lead uniformly on both the con-

cave and convex faces of three to four reduction gear
teeth. Rotate the reduction gear back and forth by hand
until a contact pattern is noted on both the concave and
convex faces of the gear teeth. If a correct contact pattern
is not obtained, perform the following adjustment.
204605
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.
204606
NOTE
For toe contact or heel contact, observe contacts on the outer side (convex face) of the reduction gear for judgement. For face
contact or flank contact, repeat the steps above for adjustment until satisfactory tooth contact is obtained. After this adjustment
is completed, make sure the backlash.
6-25
(g) Installation of oil seal

When inserting the oil seal in the hand brake bracket, al- φ 95.5 (φ 3.76) Unit: mm (in.)
ways use an installer for press-fitting. Before reassem- φ 82 (3.23)
bling, apply grease to the lips of the seal.
9 (0.35)
18 (0.71)
33 (1.30)
φ 60 (2.36)
204607
(h) Determination of shim thickness when reduction gear

or reduction pinion is replaced
• Temporarily assemble the reduction pinion and all the
parts necessary for preload measurement, make sure of a
correct preload, then measure dimension E.
Standard value of dimension E 45.35 mm (1.79 in.)
Calculate the difference of the measurement from the

standard value of dimension E as follows.
e = F – (48 + 45.35) – g
204608A
• The standard value of each dimension and their machin-

ing errors are represented in the following table.
Standard dimension Error

D (shim thickness) 1.6 mm (0.063 in.) –
A 191.75 mm (7.55 in.) a
B 148 mm (5.83 in.) b
E 45.35 mm (1.79 in.) e
Shim thickness D is obtained as follows:

D = 1.6 + b + e – a
a: Machining error of differential carrier 204609
(indicated on the periphery of the flange in units of 1/100
mm)
b: Machining error of reduction pinion
(indicated as the actual measurement on the end surface
of the pinion)
6-26
(i) Installation of reduction and differential assembly

when installing the reduction and differential assembly
on the front axle housing, apply gasket adhesive to the
mounting surface of the assembly. (Three Bond No.
1104)
6-27
5. Troubleshooting
• Reduction bevel gear teeth badly worn • Replace reduction bevel gear.
• Improper adjustment or excessive wear of reduc- • Readjust or replace the bearing.
Gear noise cones out tion bevel gear bearing
continuously during • Hub bearings damaged • Replace the bearing.
normal traveling
• Improper tooth contact between the reduction • Readjust the tooth contact.
bevel pinion and reduction bevel gear of the out-
put shaft
• Reduction bevel gear bearing or hub bearing bro- • Replace the bearing.
ken.
Irregular noise comes • Differential gear teeth broken or thrust washers • Replace gear or washer.
out during normal trav- worn.
eling • Metal chips in axle housing • Clean and change oil.
• Bolts securing axle shaft or differential carrier • Retighten.
loose
• Fit of differential gear in differential case out of • Replace.
Abnormal noise comes specification due to wear
out when turning a cor-
ner. • Teeth of differential gear or pinion broken, seized • Replace.
on spiders, or worn or damaged
• Bearing damaged due to excessive preload • Replace bearing and readjust preload.
Differential carrier
overheats after traveling • Backlash between pinion gear and reduction • Readjust tooth contact and backlash.
bevel gear too small
• Shortage of oil or poor oil quality • Add or change oil.
Abnormal noise from
• Planetary gears worn or damaged • Replace gears.
final reduction gearing
• Planetary gear bushings worn • Replace bushings.
6-28
6. Service Data
6.1 Front axle
Truck model DP70E
Deflection of axle shaft 1 Standard value 0.05 mm (0.0020 in.)
(1/2 of dial indicator reading) Repair or service limit 0.2 mm (0.008 in.)
Preload of hub bearing 2
(force applied to the hub bolt in tangential Standard value 147 to 167 N (15 to 17 kgf) [33 to 37 lbf]
direction)
245 ± 24.5 N•m (25.0 ± 2.5 kgf•m) [180.8 ± 18.1 lbf•ft]
Tightening torque of brake drum nut 3 Standard value
(Note: Apply LOCTITE No. 271)
Tightening torque of brake backing plate 235 ± 23.5 N•m (24.0 ± 2.4 kgf•m) [173.4 ± 17.3 lbf•ft]
Standard value
mounting nut 4 (Note: Apply LOCTITE No. 271)
Tightening torque of front axle housing
Standard value 390 N•m (39.8 kgf•m) [288 lbf•ft]
mounting bolt 5
Inner
Tightening torque of wheel nut 6 Standard value 382 ± 38.2 N•m (39 ± 3.9 kgf•m) [282 ± 28 lbf•ft]
Outer
Tightening torque of wheel bolt nut 7 Standard value 294 ± 39 N•m (30 ± 4.0 kgf•m) [217 ± 29 lbf•ft]
+0.009 +0.0004
Outside diameter of planet pin 8
+0.10 +0.004
Standard value 26 +0.04 mm (1.02 +0.002 in.)
Inside diameter of planet gear bushing 9
-0.1 -0.004
Standard value 2.3 -0.2 mm (0.091 -0.008 in.)
8 9 10 2 3 4 5
6 7 1
205613
6-29
6.2 Reduction differential

Truck model DP70E
Differential gear backlash 1 Repair or ser-
0.5 mm (0.020 in.)
vice limit
Fit of differential pinion and pinion shaft 2 Repair or ser-
0.35 mm (0.014 in.)
vice limit
Preload of differential case side bearing 3 Standard value 2.2 to 3.1 N•m (0.2 to 0.3 kgf•m) [1.62 to 2.29 lbf•ft]
(Force applied in the tangential direction on the dif-
Standard value 15.4 to 21.6 N (1.6 to 2.2 kgf) [3.46 to 4.86 lbf]
ferential case periphery)
Backlash between reduction bevel gear and pinion 4 Standard value 0.20 to 0.28 mm (0.0079 to 0.0110 in.)
Free movement on axle shaft spline 5 Repair or ser-
0.5 mm (0.020 in.)
vice limit
Tightening torque of reduction bevel gear mounting 177 to 216 N•m (18.0 to 22.0 kgf•m) [130 to 159 lbf•ft]
Standard value
bolt 6 (Note: Apply LOCTITE No. 271.)
Tightening torque of side bearing cap bolt 7 Standard value 145 to 178 N•m (14.8 to 18.2 kgf•m) [107 to 131 lbf•ft]
141 to 173 N•m (14.4 to 17.6 kgf•m) [104 to 128 lbf•ft]
Tightening torque of differential carrier mounting
Standard value (Note: Apply THREEBOND No. 1104 to the mounting
bolt 8
surface.)
Tightening torque of input flange mounting bolt 9 Standard value 196 to 294 N•m (20.0 to 30.0 kgf•m) [145 to 217 lbf•ft]
Preload of reduction bevel pinion bearing 10 Standard value 1.96 to 3.14 N•m (0.2 to 0.3 kgf•m) [1.45 to 2.32 lbf•ft]
(Force applied in the tangential direction on the bear-
Standard value 31.4 to 48.0 N (3.2 to 4.9 kgf) [7.1 to 10.8 lbf]
ing retainer periphery)
4
10
6
1
5
8
3 7
2
213390
6-30
REAR AXLE
1. Specifications ............................................................................................................... 7-2
2. Description ................................................................................................................... 7-3

2.1 Rear Axle .............................................................................................................................................. 7-3 1
2.2 Power Cylinder...................................................................................................................................... 7-4
3. Removal and Installation.............................................................................................. 7-5 2

3.1 Rear Wheel (Tire) ................................................................................................................................. 7-5
3.1.1 Start by:....................................................................................................................................................... 7-5
3.1.2 Removal ...................................................................................................................................................... 7-5
3
3.1.3 Installation ................................................................................................................................................... 7-6
3.2 Rear Axle .............................................................................................................................................. 7-7 4
3.2.1 Start by:....................................................................................................................................................... 7-7
3.2.2 Sequence of removal .................................................................................................................................. 7-7
5
3.2.4 Installation ................................................................................................................................................... 7-8
3.2.5 Rear Axle Support Clearance Adjustment .................................................................................................. 7-8
6
4. Disassembly and reassembly ...................................................................................... 7-9
4.1 Disassembly.......................................................................................................................................... 7-9 7
4.1.1 Sequence .................................................................................................................................................... 7-9
4.1.2 Suggestions for Disassembly.................................................................................................................... 7-10
4.2 Reassembly ........................................................................................................................................ 7-11
8
4.2.1 Sequence .................................................................................................................................................. 7-11
4.2.2 Suggestions for Reassembly .................................................................................................................... 7-12 9
4.3 Power Cylinder.................................................................................................................................... 7-14
4.3.1 Disassembly.............................................................................................................................................. 7-14
4.3.2 Inspection.................................................................................................................................................. 7-15 10
4.3.3 Reassembly .............................................................................................................................................. 7-16
11
5. Adjusting .................................................................................................................... 7-17
5.1 Minimum Turning Radius .................................................................................................................... 7-17
12
7. Service Data............................................................................................................... 7-19

13
7.1 Turning angle ...................................................................................................................................... 7-19
7.2 Power cylinder .................................................................................................................................... 7-20 14
7-1
REAR AXLE
1. Specifications
Truck Model DP70E

Steering knuckle arrangement Elliott
Mounting method Center pin
Toe-in 0
Wheel Camber 1.0 deg
alignment Caster 0 deg
Kingpin inclination 5 deg
7-2
REAR AXLE
2. Description
2.1 Rear Axle
6 1 8 2 6
B B
A 4
A
4 3 3
8
Section A – A
Section B – B
213394
1 Rear axle housing 5 Wheel hubs (right and left)

2 Power cylinder 6 Stopper bolts (right and left)
3 Tie rods (right and left) 7 Pins (two on each side)
4 Steering knuckles (right and left) 8 Rear axle supports (front and rear)
7-3
REAR AXLE
2.2 Power Cylinder
1 2 34 5 6 7 8 9 10
16 15 14 13 12 11
205425
1 Bearing 9 Wear ring

2 Stopper ring 10 Cylinder tube
3 Piston rod 11 Ring
4 Cylinder head 12 O-ring
5 O-ring 13 Piston
6 Bushing 14 Packing
7 Wear ring 15 Back-up ring
8 Piston seal 16 Dust seal
7-4
REAR AXLE
3. Removal and Installation

3.1 Rear Wheel (Tire)
3.1.1 Start by:
(1) Set the parking brake and block the front wheels.
(2) Loosen the wheel nuts two turns and raise the rear end
of the machine with a jack or a hoist until the tire clears
the ground.
(a) [Jacking instructions]
Position the jack under the counterweight at the slotted
point as shown.
Capacity of jack 6000 kgf (14000 lbf)
(b) [Hoisting instructions] 101346

Hitch three slings to the holes in the counterweight as
shown.
3.1.2 Removal 204657

1 Wheel nuts
2 Rear wheel (tire)
204656
7-5
REAR AXLE
3.1.3 Installation
Follow the reverse of removal sequence.
NOTE
Hand tighten all wheel nuts 1 through 6, turn only in num-
bered sequence.
Tightening torque for 403 N•m (41.1 kgf•m) [297

wheel nuts lbf•ft]
101212
7-6
REAR AXLE
3.2 Rear Axle

3.2.1 Start by:
(1) Set the parking brake and block the front wheels.
(2) Raise the rear end of the truck with a jack and put sup-
porting stands or blocks of wood under the frame on
both sides so the bottom of the counterweight is 400 to
500 mm (16 to 20 in.) from the ground.
Capacity of jack 6000 kgf (14000 lbf)
101346
1
2
205554
3.2.2 Sequence of removal
1 Rear wheel (tire), Wheel nuts 3 Rear axle supports
2 Steering hoses 4 Rear axle assembly, Thrust washers
7-7
REAR AXLE

(1) Disconnect the steering hoses from the power cylinder
pipes. Install service plugs to all openings to prevent
the oil from flowing out.
Service plug 05530 - 30300 (G 3/8)
205558
(2) Position a wide-saddle jack under the rear axle from
the rear end of the machine to support the axle.
Weight of rear axle 5586 N (570 kg) [125 lb]
(3) Remove the rear axle supports, front and rear. Carefully
lower the rear axle by operating the jack and pull it out
diagonally to the rear of the machine.
3.2.4 Installation
Follow the reverse of removal sequence.
3.2.5 Rear Axle Support Clearance Adjustment 205428
Adjust the total clearance of the front and rear supports with
thrust washer(s) so that it is less than 0.8 mm (0.031 in.).
NOTE
Install the same amount of thrust washer(s) on the front and
rear supports. 0.8 mm
(0.031 in.)
3.2 mm maximum
(0.126 in.)
Thickness of thrust washers 1.6 mm
available (0.063 in.)
0.8 mm
(0.031 in.)
202793
7-8
REAR AXLE
4. Disassembly and reassembly

4.1 Disassembly
4
8
6
3
8
7
7
7 2
4
7
5
5
1
205429
4.1.1 Sequence
1 Hub cap, Gasket, Nuts, Lock washer, Roller bearing (in- 5 Cover, Shims, O-ring, Roller bearing (outer race), Oil
ner race) seal, Lower dust cover
2 Rear axle hub, Roller bearing, Oil seal, Oil seal retainer 6 Cap
3 Tie rod, Pin, Spacer, Dust seal, Stopper ring, Spherical 7 Steering knuckle, Roller bearing (inner race), Oil seal
roller bearing retainer, O-ring
4 Power cylinder, Clamp, Pipes 8 Rear axle housing, Roller bearing (outer race), Oil seal
7-9
REAR AXLE
4.1.2 Suggestions for Disassembly

(1) Rear axle hub removal
Remove the hub from the rear axle with a puller.
(2) Roller bearing (outer race) removal

Do not remove the outer race unless it is defective. Re- 200259A
place the outer and inner races at the same time.
(3) Cover removal
(a) Remove the bolts (six) that hold the cover in position.
(b) Remove the plug from the cover.
(c) Install a jack bolt, 16 mm (0.63 in.) diameter, 1.5 mm
(0.059 in.) pitch and 100 mm (3.94 in.) long, in the
hole for the plug. Turn the jack bolt in until the cover is
free.
Jack bolt
Cover
205430
(4) Rear axle support bushing removal
Do not remove the bushing from the support unless it is
defective. If the bushing is defective, remove it by
breaking. Install a new bushing with the joint in align-
ment with the grease fitting.
Bushing joint
205431
7-10
REAR AXLE
4.2 Reassembly
10
5
B B
6 6 A
A
1 3 2
7
6 2 8
2
4
Section A – A Section B – B
205556
4.2.1 Sequence
1 Rear axle housing, Roller bearing (outer race), Oil seal 6 Tie rod, Pin, Spacer, Dust seal, Stopper ring, Spherical
roller bearing
2 Steering knuckle, Roller bearings (inner races), Oil seal 7 Rear axle hub, Roller bearings, Oil seal, Oil seal retain-
retainer, O-ring er
3 Cap 8 Hub cap, Nuts, Lock washer, Roller bearing (inner race)
4 Cover, Shims, O-ring, Roller bearing (outer race), Oil 9 Rear axle supports, Bushings
seal, Lower dust cover
5 Power cylinder, Pipes, Clamp 10 Power cylinder hoses
7-11
REAR AXLE
4.2.2 Suggestions for Reassembly

(1) Rear axle hub installation
(a) Install the oil seal retainer and the inner race of the
inner bearing in position with a bearing installer.
204664A
(b) Fill the pocket (hatched portion) with grease. Apply

grease to the roller holders and oil seal lip grooves.
205433
(2) Steering knuckle bearing preload adjustment

Install the cover to the axle housing without installing
shims. Measure the clearance between the cover and the
housing. Remove the cover. Put shim(s) which is 0.1
mm (0.004 in.) smaller in thickness than the clearance
measured. Install the cover and tighten the bolts that
hold the cover. Hook a spring scale to the arm of the
steering knuckle. Pull the scale in tangential direction
and read the scale to find the preload. If the preload is
not correct, make a shim adjustment again.
14.02 to 36.38 N
Tangential force (1.43 to 3.71 kgf)
[3.15 to 8.18 lbf]
NOTE Clearance
Adjusting shims are 2-piece type. 205434
7-12
REAR AXLE
(3) Hub bearing preload adjustment

(a) Tighten the inner nut. Hook a spring scale to the hub
bolt. Pull the scale in the tangential direction and look
at the reading on the scale to find the preload. If the
preload is not correct, make an adjustment by turning
the inner nut in either direction.
60.8 to 101.9 N
Tangential force (6.2 to 10.4 kgf)
[13.7 to 22.9 lbf]
NOTE
If the hub bearings are reused, aim at a value of preload in
the lower half of the range. 204666A
(b) After having adjusted the hub bearing preload, install

the outer nut and lock washer, and tighten the outer nut Outer nut
to the specified torque.
196 N•m
Tightening torque for outer
(20 kgf•m)
nut
[145 lbf•ft]
Since the preload must vary as the result of tightening/

loosening the outer nut, always check the preload after
tightening the outer nut. Do the same operation for the
inner nut by re-tightening it so that the preload can fall
Inner nut
within the specified range of value.
205435
(c) Bend the lock washer against the flats of the inner and Wrong
outer nuts.
Right
205435
7-13
REAR AXLE
4.3 Power Cylinder

4.3.1 Disassembly
3
2 2
1
1
4
205437
(1) Sequence
1 Cylinder head, Dust seal, Back-up ring, Rod seal, O- 3 Stopper rings, Bearings
ring
2 Piston rod, Wear rings, Piston seal 4 Cylinder tube
NOTE
(1) Do not remove bushing from cylinder head 1.
(2) Do not remove piston from piston rod 2.
(2) Suggestion for Disassembly

(a) Cylinder head removal
Wrap the cylinder tube with cloth, and hold it in a vise.
Remove the guide bushing with the hook wrench A.
Special tool needed
Hook wrench A 09305 - 00680
A 205438
7-14
REAR AXLE
4.3.2 Inspection
(1) Cylinder tube l
(a) Check the bore surface for wear, scuffs, scratches or
rust.
(b) Check the welds for cracks.
(2) Piston rod
Check the rod surface for rust, scratches or dents. Re-
place the rod if the threads are stripped or badly dam-
aged.
(3) Rings and packings
(a) Check the packings and rings for damage or distortion.
(b) Check for deterioration due to aging.
Item Service data
Inside diameter of
cylinder tube 1 Repair or service 85.15 mm
limit (3.352 in.)
Diameter of pis-
ton rod 2
Clearance Standard value 0.1 mm (0.004 in.)

between piston Repair or service
rod and bushing 3 0.2 mm (0.008 in.)
limit
2 1
205425
7-15
REAR AXLE
4.3.3 Reassembly
3 1
*:Seal kit parts. *
* * 2
205425
(1) Sequence
1 Piston rod, Wear rings, Piston seal, Stopper ring Bear- 3 Cylinder head, Dust seal, Back-up ring, Rod seal, O-
ing ring
2 Cylinder tube 4 Stopper ring, Bearing
(2) Suggestions for Reassembly

(a) Replace the seal kit parts.
(b) Thoroughly wash all parts and components.
(c) Apply hydraulic oil to the sealing parts and the inside
surfaces of the cylinder.
(d) When clamping the cylinder tube in a vise while
installing the head, be careful not to damage the tube.
(e) Install the piston seal to the piston as follows:
• Squeeze the piston seal by hand five or six times to soften
it. Hold the piston rod in a vise. Apply a small amount of 200352
hydraulic oil to the piston seal. Fit a small portion of the
seal into the groove of the piston, continue pushing the
rest of the seal, a little at a time into the groove.
• Mount the wear rings into position.
NOTE
Install the seals and rings on the cylinder head correctly.
(f) Tighten the cylinder head to the specified torque.
392 ± 49 N•m
Tightening torque for cylin-
(40 ± 5 kgf•m)
der head
[289 ± 36 lbf•ft] 205552
7-16
REAR AXLE
5. Adjusting
5.1 Minimum Turning Radius
(1) Measure the turning angle of the rear wheels, inside
and outside, with a turning radius gauge.
(2) If the turning angle is not correct, adjust it with knuckle
stopper bolts. Stopper bolts
(left and right)
Inside wheel 76˚16’
Turning angle Lock nut
Outside wheel 49˚41’
223 N•m
Tightening torque for knuckle stopper
(22.7 kgf•m)
bolt lock nut
[164 lbf•ft].
(3) Drive the machine at low speeds and make the sharpest
practicable turn to both sides. After making a turn to
each side, measure the distance from the turning center
to the center of tire contact with the ground of the out-
ermost rear wheel.
(4) The minimum turning radius R is the distance from the 205441
turning center to the center of tire contact with the
ground of the outermost rear wheel plus the rear over-
hang (the distance from the center of rear tire to the
outermost end of the counterweight).
Truck Model DP70E

Minimum R
3395 mm (134 in.)
turning radius
213393
7-17
REAR AXLE
6. Troubleshooting
• Toe-in does not show normal condition. • Adjust toe-in.
• Insufficient grease in rear axle or steer- • Supply grease.
Heavy steering wheel operation
ing parts
• Low tire inflation pressure. • Adjust inflation pressure.
• Over-tightening of steering system or • Retighten to specified torque.
Slow return of steering wheel
rear axle parts
• Gap in external diameters between right • Replace with genuine tires.
and left tires
Steering wheel prone to move to one side
• Tire inflation pressure differs between • Adjust inflation pressure.
the right and left tires
• Wear or breakage of taper roller bearing • Replace the bearing.
• Ball joint at the tie rod end is exces- • Replace tie-rod end
Steering wheel shuddering sively worn
• Faulty steering system • Refer to “GROUP 9 STEERING SYS-
TEM”, and inspect or repair.
• Misalignment of wheels • Realign wheels.
Uneven or early wear of rear tires • Type or inflation pressure differs • Replace wheels with specified ones and
between the right and left wheels adjust inflation pressure.
7-18
REAR AXLE
7. Service Data
7.1 Turning angle
Truck Model DP70E
Toe-in Standard value 0 mm
Caster Standard value 0˚ deg
Camber Standard value 1˚ deg
14.02 to 36.38 N
Tangential force at knuckle bearing 1 Standard value (1.43 to 3.71 kgf)
[3.15 to 8.18 lbf]
60.8 to 101.9 N
Tangential force at hub bearing 2 Standard value (6.2 to 10.4 kgf)
[13.7 to 22.9 lbf]
Standard value 0.8 mm (0.031 in.) or less
Front and back clearance for center pin 3 (total)
Tightening torque of stopper bolt 4 Standard value 223 N•m (22.7 kgf•m) [164 lbf•ft]
Outer nut tightening torque 5 Standard value 196 N•m (20 kgf•m) [145 lbf•ft]
Inward Standard value 76˚16’ deg
Steering angle
Outward Standard value 49˚41’ deg
1
4
205557
7-19
REAR AXLE
7.2 Power cylinder

Truck Model DP70E
Inside diameter of cylinder tube 1
Diameter of piston rod 2 Standard value 65 mm (2.56 in.)
Standard value 0.1 mm (0.004 in.)
Clearance between piston rod and bushing 3
Tightening torque for cylinder head 4 Standard value 392 ± 49 N•m (40 ± 5 kgf•m) [289 ± 36 lbf•ft]
4 3
2 1
205425
7-20
BRAKE SYSTEM
1. Specifications ............................................................................................................... 8-3
2. Structure....................................................................................................................... 8-4
2.1 Brake System........................................................................................................................................ 8-4 1
2.2 Wheel brake.......................................................................................................................................... 8-5
2.3 Brake booster........................................................................................................................................ 8-6
2.4 Master cylinder...................................................................................................................................... 8-7 2
2.5 Parking brake........................................................................................................................................ 8-8
3. Disassembly and Reassembly ..................................................................................... 8-9

3
3.1 Wheel brake.......................................................................................................................................... 8-9
3.1.1 Disassembly................................................................................................................................................ 8-9 4
3.1.3 Reassembly .............................................................................................................................................. 8-12
3.2 Wheel cylinder .................................................................................................................................... 8-15
5
3.2.1 Disassembly.............................................................................................................................................. 8-15
6
3.2.3 Reassembly .............................................................................................................................................. 8-16
3.3 Master cylinder.................................................................................................................................... 8-17
3.3.1 Disassembly.............................................................................................................................................. 8-17 7
3.3.3 Reassembly .............................................................................................................................................. 8-19
8
3.4 Parking brake...................................................................................................................................... 8-20
3.4.1 Disassembly.............................................................................................................................................. 8-20 9
3.4.3 Reassembly .............................................................................................................................................. 8-21
3.5 Parking brake lever ............................................................................................................................. 8-22 10
3.5.1 Disassembly.............................................................................................................................................. 8-22
3.5.3 Reassembly .............................................................................................................................................. 8-22
11
4. Adjustment and Testing ............................................................................................. 8-23 12

4.1 Wheel brake........................................................................................................................................ 8-23
4.1.1 Automatic Adjuster Operation Test ........................................................................................................... 8-23
4.1.2 Manual Adjustment ................................................................................................................................... 8-23
13
4.1.3 Brake Line Bleeding .................................................................................................................................. 8-24
4.1.4 Brake Pedal Adjustment Procedure .......................................................................................................... 8-24 14
4.2 Brake Booster Operation Test ............................................................................................................ 8-26
8-1
BRAKE SYSTEM
4.2.1 Method for testing without using instruments............................................................................................ 8-26

4.2.2 Method for testing using instruments ........................................................................................................ 8-27
4.3 Parking brake...................................................................................................................................... 8-28
4.3.1 Adjustment of Parking Brake Lining-to-Drum Clearance .......................................................................... 8-28
6. Service Data............................................................................................................... 8-31

6.1 Brake System...................................................................................................................................... 8-31
6.2 Master cylinder.................................................................................................................................... 8-32
6.3 Wheel cylinder .................................................................................................................................... 8-33
6.4 Wheel brake........................................................................................................................................ 8-34
6.5 Parking brake lever ............................................................................................................................. 8-35
6.6 Parking brake...................................................................................................................................... 8-35
8-2
BRAKE SYSTEM
1. Specifications
Truck model DP70E

Type Internally expanding hydraulic duo-servo type in front-wheel
brake drums
Drum diameter 317.5 mm (12.5 in.)
Brake shoe lining dimensions 324 × 100 × 10 mm (12.76 × 3.94 × 0.39 in.) -2
Wheel brake (length × width × thickness – number
of shoes per brake)
Master cylinder inside diameter 25.4 mm (1 in.)
Wheel cylinder inside diameter 31.75 mm (1.25 in.)
Brake booster Brake booster master-vac (vacuum brake booster)
Parking brake Type Internally expanding type in center brake drum
8-3
BRAKE SYSTEM
2. Structure
2.1 Brake System
213323
1 Parking brake lever 6 Oil tank

2 Parking brake 7 Master cylinder
3 Wheel brake 8 Alternator and vacuum pump
4 Wheel cylinder 9 Vacuum tank
5 Brake booster 10 Brake pedal
The brake system incorporates a brake booster. The wheel A vacuum tank is provided so that the brake system oper-
brakes are an automatically adjusted duo-servo type. The ates consistently when the brakes are used frequently and to
brake booster enhances braking effect using the pressure enable brake operation when the engine is not running.
difference between vacuum pressure produced by a vacuum The brake shoe linings do not contain asbestos. The parking
pump and the atmospheric pressure. brake is activated by means of the parking brake lever and a
flexible cable. Its shoes expand inside a brake drum
mounted on the reduction pinion.
8-4
BRAKE SYSTEM
2.2 Wheel brake
Section A - A
Illustration shows left-hand wheel brake.

204555
1 Backing plate 9 Spring

2 Wheel cylinder 10 Fitting link assembly
3 Shoe and lining 11 Toggle lever
4 Shoe and lining 12 Return spring (rear)
5 Return spring (front) 13 Hold-down spring
6 Adjuster assembly 14 Shoe hold-down cap
7 Adjusting spring 15 Shoe hold-down pin
8 Adjusting lever 16 Dust seal
8-5
BRAKE SYSTEM
2.3 Brake booster
204556
1 Retainer 11 Key 21 Poppet washer

2 Silencer 12 Reaction disc 22 Valve plunger
3 Oil filter 13 Pushrod body 23 Cylinder seal (rear)
4 Retainer 14 Rod 24 Diaphragm
5 Spring 15 Pushrod seal 25 Diaphragm plate
6 Spring 16 Plate 26 Valve body
7 Retainer 17 Retainer 27 Spring
8 Valve body seal 18 Operating rod 28 Cylinder seal (front)
9 Bearings 19 Valve body guard 29 Check valve
10 Retainer 20 Poppet assembly
8-6
BRAKE SYSTEM
2.4 Master cylinder
10 9
13
11
12
2 1 4 3 5 6 7 8
213327
1 Cylinder body 8 Return spring

2 Stopper ring 9 Oil tank
3 Piston 10 Tank cap
4 Secondary cup 11 Baffle plate
5 Cup spacer, Primary cup 12 Wire band
6 Spring seat 13 Brake fluid level sensor
7 Snap ring
8-7
BRAKE SYSTEM
2.5 Parking brake
Section A - A
204557A
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 an internally expanding type where a

cam operation expands the brake shoe inside the drum. It
has an adjuster assembly installed at the bottom to adjust
the clearance between the lining and the drum.
8-8
BRAKE SYSTEM

3.1 Wheel brake (b) Disassemble the front axle in accordance with the front
3.1.1 Disassembly axle disassembly sequence.
(1) Preparation (c) Disconnect the brake pipe from the wheel brake assem-
(a) Remove the front wheel. bly.
204558

1 Bolt 8 Spring, Adjusting lever
2 Washer 9 Adjuster
3 Return spring 10 Hold-down spring, Cup, Pin
4 Fitting link 11 Shoe and lining
5 Fitting link assembly 12 Shoe and lining
6 Lever, Washer, Pin 13 Wheel cylinder, Bolt, Washer
7 Adjusting spring 14 Dust shield, Bolt, Washer, Grommet
15 Backing plate
8-9
BRAKE SYSTEM

(a) Removing return springs
Use Special Tool A to remove the return spring from the
shoe guide plate.
Special tool needed
Spring Remover 64309-15411
200271
(b) Removing hold-down springs
Use Special Tool B to remove the hold-down spring
from the backing plate.
Special tool needed
Spring Retainer 91868-00600
200272
(1) Backing plate
(a) Check the backing plate for cracks.
(b) If the backing plate is not to be removed, check the
tightening torque of each bolt.
211.5 to 258.5 N•m

Backing plate bolt tight-
(21.6 to 26.4 kgf•m)
ening torque
[156 to 191 lbf•ft]
(2) Shoe and lining assemblies

(a) Check the lining and shoe for any crack or fracture.
(b) Replace the lining if it has been badly contaminated by
oil or has been glazed or otherwise set or deteriorated
from friction heat, etc.
(c) Check the thickness of the lining, and replace if it is
worn beyond the service limit.
10.0 mm
Standard value
(0.39 in.)
Lining thickness
203005
8-10
BRAKE SYSTEM
(3) Brake drum

Check the inside surface for any scoring and uneven
wear. If necessary, rectify the inside surface by grinding
it.
+0.2
Standard 317.5 0 mm
Brake drum inside value (12.500
+0.008
0 in.)
diameter
Repair or 318.5 mm
(4) Adjuster
Check the adjuster wheel teeth for wear, and check
whether all rotating parts turn smoothly.
If they do not rotate smoothly, lubricate the rotating
parts. Also, if the adjuster moves stiffly, replace it with
a new one.
200274
(5) Return springs and fitting link

Measure the free length of each return spring, and re-
place all that exceeds the service limit.
Standard
90 mm (3.54 in.)
value
Front 90 mm (3.54 in.)
Repair or
Replace once per
service limit
Return spring year.
free length Standard
93 mm (3.66 in.)
value
Rear 93 mm (3.66 in.)
Repair or
Replace once per
service limit
year.
(6) Other parts to be checked

(a) Check the shoe return spring for cracks or degradation.
(b) Check the adjusting spring for cracks or degradation.
8-11
BRAKE SYSTEM
3.1.3 Reassembly
204559

1 Backing plate 6 Hold-down spring, Cup, Pin 11 Lever, Washer, Pin
2 Dust shield, Bolt, Washer 7 Adjuster 12 Fitting link assembly
3 Wheel cylinder, Bolt, Washer 8 Adjusting lever 13 Fitting link
4 Shoe and lining 9 Spring 14 Return spring
5 Shoe and lining 10 Adjusting spring
8-12
BRAKE SYSTEM

(a) Backing plate RH/LH confirmation
An “RH” (right-hand) or “LH” (left-hand) identification
mark is stamped in indelible ink at the bottom of each
backing plate below the area where the adjuster assem-
bly is fitted, which helps to avoid mistaking between the
right and left on reassembly.
(b) Installing wheel cylinder
Apply sealant to the cylinder mounting surface, and
tighten the bolts to the specified torque.
17.6 to 26.5 N•m

Wheel cylinder bolt
(1.8 to 2.7 kgf•m)
tightening torque 204560
[13 to 19.5 lbf•ft]
(c) Greasing
Apply a thin coat of specified brake grease to the fol-
lowing parts:
• shoe ledges (six places)
(the portions of the backing plate in contact with the
shoes)
• anchor pin surface in contact with shoe web
• part of pin fitted in the adjusting lever hole
(d) Installing shoes and linings
Make sure that the notches provided on the wheel cylin-
der connector link hold the shoe and lining from the
both sides.
(e) Return spring installation

Use Special Tool A to fit the return spring onto the pins
on the backing plate.
Special tool need
Spring Installer 64309-15413
200276
8-13
BRAKE SYSTEM
(f) Installing automatic adjuster

Clean each part of the adjuster assembly and apply
grease to the threads and to the adjuster socket mount-
ing part. Make sure that the adjuster can be easily turned
by hand.
200277
(g) Installing wheel brake assembly

When each of the right and left wheel brake assemblies
is fitted on the corresponding front axle housing, 10
equal-length bolts are used for retaining each. However,
Use collars for the lower six pieces of bolt. In addition,
apply Loctite No. 271 to each bolt, and tighten each to
the specified torque.
235 ± 23.5 N•m

Wheel brake assembly bolt
(24.0 ± 2.4 kgf•m)
tightening torque
[173.4 ± 17.3 lbf•ft]
(h) Connecting brake piping

When connecting the brake piping to the cylinder, tight-
en the bolts to the specified torque.
12.7 to 17.6 N•m

Bolt tightening torque (1.3 to 1.8 kgf•m)
[9.4 to 13 lbf•ft]
8-14
BRAKE SYSTEM
3.2 Wheel cylinder

3.2.1 Disassembly
200812

1 Connector link 5 Return spring
2 Boot 6 Bleeder screw, Cap
3 Piston 7 Cylinder body
4 Piston cup
NOTE
(a) Parts with an asterisk (*) are included in the Repair
Kit.
(b) These repair kit parts are for periodic replacement.
8-15
BRAKE SYSTEM

(1) Cylinder body
(a) Check the bore of the cylinder body for rust, corrosion,
and scoring.
(b) Check the bleeder screw and oil pipe screw connec-
tions for damage.
(2) Piston
(a) Check the sliding surfaces of the piston for rust or scor-
ing.
(b) Insert the piston into the cylinder body and measure the
clearance between them.
If this clearance exceeds the service limit, replace the
wheel cylinder assembly as a whole.

Clearance value (0.00079 to 0.00413 in.)
between cylinder
body and piston Repair or 0.15 mm
200280
(3) Piston cup

Check each cup for expansion or damage, and replace
whichever has any defect, however minor.
1.85 mm
Standard value
Interference between pis- (0.0728 in.)
ton cup and cylinder body Repair or ser- 0.65 mm
(4) Boot
Replace the boot if it has become hard or has otherwise
aged and deteriorated. Replace it once per year.
3.2.3 Reassembly
Reassembly should be performed in the sequence reverse to
that of disassembly, but the following precautions must be
observed.
(1) Apply an even coat of brake fluid to the cylinder bore
and piston cups.
(2) Be careful not to damage the lips of the piston cups.
(3) Also make sure the cups are correctly aligned.
8-16
BRAKE SYSTEM
3.3 Master cylinder

3.3.1 Disassembly
3
4
5
6
2
7
1
213328
1 Stopper ring 6 Primary cup, Cup spacer
2 Piston 7 Secondary cup
3 Return spring 8 Oil tank, Brake fluid level sensor
4 Snap ring 9 First fill valve assembly
5 Spring seat 10 Cylinder body
NOTE
Kit.
8-17
BRAKE SYSTEM

(1) Brake fluid level sensor
(a) If the bulb is normal, conduct a continuity test for the
oil tank level sensor.
202813
(2) Cylinder body

(a) Check the bore of the cylinder body for rust, corrosion,
and scoring.
(b) Check the inlet port and relief port for any contamina-
tion, and check the threads of each joint for damage.
(3) Piston
Check pistons for damage. Replace any piston which
has been damaged. Insert the piston into the cylinder
body and measure the clearance between them. If this
clearance exceeds the service limit, replace the piston
together with the cylinder body.
Replace the master cylinder assembly as a whole.

Clearance value (0.00079 to 0.00413 in.)
between cylinder
body and piston Repair or 0.2 mm (0.008 in.)
service limit Replace once per year.
(4) Return spring

Measure the free length of each return spring, and re-
place all that exceeds the service limit.
Standard
89 mm (3.50 in.)
Return spring free value
length Repair or 89 mm (3.50 in.)
service limit Replace once per year.
8-18
BRAKE SYSTEM
3.3.3 Reassembly
8 7 2 1 3 4 5 6
213329
1 Piston 6 Return spring
2 Secondary cup 7 Cylinder body
3 Primary cup, Cup spacer 8 Stopper ring
4 Spring seat 9 Oil tank, Brake fluid level sensor
5 Snap ring
NOTE
Kit.
(c) Wash all metal parts soaked in volatile cleaning sol-
vent, and remove the remaining cleaning solvent by
exposing the parts to compressed air.
(d) Apply an even coat of brake fluid to the cylinder's
inside surface and piston cups.

(1) The sensor is normal if the OK monitor lamp is on
when the brake fluid level in the oil tank is below the
“MIN” line.
(2) If the lamp fails to illuminate, check whether the bulb
has blown.
8-19
BRAKE SYSTEM
3.4 Parking brake

3.4.1 Disassembly
204562

1 Nut 5 Brace
2 Parking brake drum, Nut, Washer, Taper plug 6 Shoe and lining assembly, Adjuster assembly, Spring
3 Input flange, Bolt, O-ring 7 Camshaft, Camshaft lever
4 Return spring 8 Support plate assembly, Dust shield, Bolt, Washer

(1) Shoe and lining assemblies
(a) Check the linings for any crack or fracture.
(b) Replace the linings, if they are badly contaminated by
oil or have been glazed otherwise set or deteriorated
from friction heat, etc.
(c) Check the thickness of the lining, and replace if it is
worn beyond the service limit.
Standard
4 mm (0.157 in.)
value
Lining thickness
Repair or
1 mm (0.039 in.)
service limit
8-20
BRAKE SYSTEM
(2) Brake drum

Check the inside surface for any scoring and uneven
wear. If necessary, rectify the inside surface by grinding
it.
Standard
ø203.2 mm (8 in.)
Brake drum inside value
diameter Repair or
ø205.0 mm (8.07 in.)
service limit
(3) Adjuster assembly

Check the adjuster wheel teeth for wear, and check
whether all rotating parts turn smoothly.
3.4.3 Reassembly
Reassembly should be performed in the sequence reverse to
that of disassembly, but the following precautions must be
observed.
(1) Do not allow the brake linings to be contaminated with
grease or oil.
(2) Before performing reassembly, apply grease to the fol-
lowing places.
(a) anchor pin surface in contact with brake shoe web
(b) web end faces that fit into slots at both ends of adjuster
assembly
(c) ends and threads of adjuster assembly
(d) shoe guide surfaces of support plate (six places)
(3) When fitting the lever on the camshaft, make sure the
alignment marks meet.
8-21
BRAKE SYSTEM
3.5 Parking brake lever

3.5.1 Disassembly
Reliesed Applied
205504

1 Grip 4 Rod assembly 6 Parking brake cable
2 Stud 5 Bracket 7 Pin
3 Lever assembly

(1) If there is a serious wear on the lever support pin and/or
the pin hole in the lever, replace the lever assembly.
(2) Replace the parking brake cable if it is stretched, dam-
aged or rusty.
3.5.3 Reassembly
After connecting the parking cable, make sure your effort
required to operate the lever is between 245 N to 294 N (25
to 30 kgf) [55 to 66 lbf].
8-22
BRAKE SYSTEM
4. Adjustment and Testing

4.1 Wheel brake
4.1.1 Automatic Adjuster Operation Test
(1) With the lining-to-drum clearance on each side set to
0.45 to 0.65 mm (0.018 to 0.026 in.), pull the fitting
link assembly toward you with a thumb and release it to
check that the lever turns the adjuster wheel by one
tooth and then returns to the original position.
(2) If the operation of step (1) fails to take place or the
lever moves sluggishly, the lever under the wheel is
probably not correctly positioned relative to the wheel.
The lever should be positioned such that it touches the
wheel of the adjuster assembly at a level 9 mm (0.354 204563
in.) below the center line of the adjuster. If the lever is
not correctly positioned, it will not mesh correctly with
the teeth of the wheel and its movement will not cause
the wheel to run properly.
(3) If the automatic adjuster does not operate properly, take
the following steps:
(a) Make sure the adjuster spring is correctly fitted in the
specified hole in the primary shoe.
(b) Replace the fitting link assembly.
(c) Replace the lever.
(d) Replace the adjuster assembly.
4.1.2 Manual Adjustment
200282
The lining-to-drum clearance can be adjusted by turning the
adjuster wheel with a screwdriver inserted through the hole
provided in the backing plate.
8-23
BRAKE SYSTEM
4.1.3 Brake Line Bleeding

Whenever any part of the brake fluid line is disassembled
for servicing, or if the brake pedal's reaction is weak (feels
like a sponge) when depressed, bleed the brake lines.
This bleeding operation must be performed by two persons;
one at the brake pedal and the other at the bleeder screw of
the wheel cylinder while keeping the engine in the idling
state.
(1) Connect one end of a vinyl tube to the bleeder screw of
the wheel cylinder. Guide 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 200285
bleeder screw must loosen the bleeder screw to allow
the brake fluid to flow into the container. The latter
should be tighten the bleeder screw while the brake
fluid flows as a solid stream without any bubbles.
(3) Repeat the above steps until no air bubbles are seen in
the tube, and there is a quantity of brake fluid in the oil
tank.
NOTE
(a) Exercise care so that the brake fluid level in the oil tank
becomes too low during this operation.
(b) Be sure to use the specified brand of brake fluid, and
never mix it with other brand.
4.1.4 Brake Pedal Adjustment Procedure

(1) Bleed air out of the piping between the brake fluid res-
ervoir tank and master cylinder and between the master
cylinder and wheel cylinders.
(2) Screw the clevis at the brake pedal side of the push rod
down the thread as far as it will go.
204550A
8-24
BRAKE SYSTEM
(3) The valve body guard should be inserted in place

before screwing-in the push rod. Install the lock nut on
the operating rod of the booster and screw-in the push
rod to a dimension of 10 mm as shown in the figure at
the right, then lock the push rod with the lock nut.
Valve body guard

204710
(4) Adjust the brake pedal height A to 220 mm (8.66 in.)
by turning the stopper bolt, then lock the stopper bolt
with the lock nut.
(5) Turn the clevis of the push rod to make the pin inser-
tion hole aligned with that of the brake pedal. Install
the pin and lock the clevis with the lock nut.
(6) Adjust the brake lining-to-drum clearance and make
sure the result.
Do not adjust this clearance with the setting of the push
rod but use the automatic adjuster function.
0.45 to 0.65 mm
Lining-to-drum clearance
(0.018 to 0.026 in.)
206509
(7) Pedal play and stroke:
(a) When the brake pedal has been adjusted in accordance Full stroke C
B
with steps (1) through (5), its play B should be 12 to 31
mm (0.47 to 1.22 in.).
(b) The brake pedal's full stroke should be 158 mm (6.22
in.), however, the pedal stroke C until the brakes start
working is 96 mm (3.8 in).
12 to 31 mm
Brake pedal play B
(0.47 to 1.22 in.)
Brake pedal stroke until brakes 96 mm
start to work C (3.8 in.)
158 mm
Brake pedal full stroke
(6.22 in.)
213400
8-25
BRAKE SYSTEM
4.2 Brake Booster Operation Test

4.2.1 Method for testing without using instruments
The brake booster may be considered normal if it passes
each of the following three tests:
(1) Run the engine at idling speed for 1 to 2 minutes, then
stop it. Next, depress the brake pedal with normal force
several times.
If the brake pedal stroke decreases each time you de-
press the pedal, the brake booster is judged satisfactory.
If there is no change in the pedal stroke, the brake boost-
er is faulty.
(2) Depress the brake pedal several times with the engine
not running. Then, start the engine with the brake pedal
depressed. If the brake pedal goes all the way, the brake
booster is satisfactory. Otherwise if no change occurs
in the engine, the brake booster is faulty.
(3) Depress the brake pedal several times with the engine
running.
Stop the engine in this condition. And, if the pedal
height does not change for about 30 seconds, the brake
booster is satisfactory.
8-26
BRAKE SYSTEM
4.2.2 Method for testing using instruments

Connect a vacuum gauge, pressure gauge, and a force gauge
as shown in the illustration. The pressure gauge should be
bled of air beforehand.
(1) No-load airtightness test
Start the engine and stop it when the vacuum gauge
shows about 500 mmHg (20 in. Hg).
The brake booster is satisfactory if the drop in vacuum
pressure in the 15-second period after engine shutdown
is no more than 25 mmHg (1 in. Hg).
(2) Under-load airtightness test
Start the engine, then depress the brake pedal with a
force of 196 N (20 kgf) [44 lbf]. Stop the engine when 202818
the vacuum gauge shows about 500 mmHg (20 in. Hg).
The brake booster is satisfactory if the drop in vacuum
1 Pressure gauge 3 Force gauge
pressure in the 15-second period after engine shutdown
is no more than 25 mmHg (1 in. Hg). 2 Vacuum gauge 4 Vacuum pump
(3) Brake booster characteristic tests
Perform these tests after confirming the result of tests
(1) and (2).
(a) Non booster action test
Make sure the vacuum gauge shows 0 mmHg with the Operating effort 98 N 0.49 MPa (5 kgf/cm2)
engine not running. Then, depress the brake pedal with Fluid (10 kgf) [22 lbf] [71 psi] or higher
forces of 98 N (10 kgf) [22 lbf] and 196 N (20 kgf) [44 pressure Operating effort 196 N 1.47 MPa (15 kgf/cm2)
lbf] and check whether the resulting fluid pressure are (20 kgf) [44 lbf] [213 psi] or higher
within the standard range.
(b) Booster action test
Start the engine. When the vacuum gauge shows 500
Operating effort 98 N 3.53 MPa (36 kgf/cm2)
mmHg (20 in. Hg), depress the brake pedal with forces (10 kgf) [22 lbf] [512 psi] or higher
Fluid
of 98 N (10 kgf) [22 lbf] and 196 N (20 kgf) [44 lbf] and
pressure Operating effort 196 N 5.78 MPa (59 kgf/cm2)
check whether the resulting fluid pressure are within the
(20 kgf) [44 lbf] [838 psi] or higher
standard range.
NOTE
The booster operation test outlined above is a simplified
field test. If the booster appears faulty, be sure to verify its
condition by subjecting it to a bench test as specified by the
manufacturer.
8-27
BRAKE SYSTEM
4.3 Parking brake

4.3.1 Adjustment of Parking Brake Lining-to-Drum
Clearance
(1) Move the truck a little 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.
From this position, turn the adjuster assembly back
(down) for about eight notches to obtain the correct lin- Turn adjuster
ing-to-drum clearance. to spread shoes.
200658
(4) To measure the lining-to-drum clearance, remove the
grommet from the dust cover and insert a thickness
gauge.
8-28
BRAKE SYSTEM
5. Troubleshooting
• Oil leaking past primary cup in master cylinder • *Replace piston cup(s) if cylinder is free
• Oil leaking past cups in wheel cylinder from unacceptable wear. Replace the
cup(s) and fluid with genuine parts if the
Lack of brak- cup(s) is distorted.
ing force
• Oil leaking from oil pipe connection • Retighten, or replace pipe and connector.
• Shoe linings worn • Replace.
• Shoe linings dirty with oil or grease • Clean or replace.
• Air trapped in brake fluid lines • Bleed air at master and wheel cylinders.
• Piston cup defective in master cylinder • Replace.
• Not enough fluid in reservoir tank • Refill.
• Push rod to piston clearance too large in master • Readjust.
Excessive cylinder
pedal stroke
• Brake fluid leakage • Refer to * above.
• Automatic adjuster inoperative • Ensure that cable guide and adjusting
Wheel spring are correctly installed. If still
brake inoperative, replace cable with spring,
lever, and adjusting screw.
Uneven brak- • Lining or drum dirty with oil or grease in less • Clean with cleaner. If lining still dirty,
ing (wheel effective brake replace.
brake is more
• Wobbly or loose-mounted drum in less effective • Replace drum. If loose, readjust and
effective on
one side than brake retighten.
on the other) • Wheel tires inflated unequally • Reinflate to specification.
• Lining glazed • Sand.
• Worn linings • Replace shoe and lining assemblies.
Brake squeals • Backing plate securing bolts loose • Retighten.
• Wheel bearings loose • Readjust preload and retighten.
• Brake drum dirty • Clean with cleaning solvent.
• Anchored ends of shoes rattling on anchor • Repair or replace.
Brake chatters
• Shoe ledges badly worn • Replace backing plate.
or clatters
• Pistons badly worn in wheel cylinder • Replace wheel cylinder.
8-29
BRAKE SYSTEM
• Vacuum hose connection loose • Repair.

• Vacuum hose collapsed or torn • Replace.
• Defective vacuum pump operation • Repair or replace.
• Alternator belt loose • Readjust.
• Vacuum or atmospheric pressure valve inside the • Repair or replace.
Pedal is heavy
brake booster is attached with foreign matters, or
Wheel is damaged.
brake
• Brake booster element clogging • Clean or replace.
• Brake booster diaphragm damaged • Replace.
• Foreign matters in brake cylinder • Wash and refill brake fluid.
No reaction • Lack of brake cylinder fluid • Refill.

from pedal if • Brake cylinder fluid leaks • Repair or replace.
depressed
• Incomplete air bleeding • Air-bleed.
Lever stroke is • Lining to drum clearance too small • Readjust.

too small
Will squeal • Lining to drum clearance too small • Readjust.
during travel-
• Brake drum badly distorted • Repair or replace.
Parking ing
brake • Linings worn to the service limit • Replace shoe and lining assemblies.
• Lining to drum clearance too big • Readjust.
Will not apply
• Lever lacks operating force too small • Readjust to between 245 N to 294 N (25
to 30 kgf) [55 to 66 lbf].
8-30
BRAKE SYSTEM
6. Service Data
6.1 Brake System
Truck model DP70E

Height above floor of brake pedal 1 Standard
220 mm (8.66 in.)
(from frame top to top end of pedal pad) value
Standard
Brake pedal play 2 12 to 31 mm (0.47 to 1.22 in.)
value
Standard
Brake pedal stroke until brakes start to work 3 96 mm (3.8 in.)
value
Standard
Brake pedal full stroke 158 mm (6.22 in.)
value
Tightening torque of master cylinder mounting Standard
11.76 N•m (1.2 kgf•m) [8.7 lbf•ft]
nuts 4 value
Tightening torque of brake booster mounting Standard
11.76 N•m (1.2 kgf•m) [8.7 lbf•ft]
nuts 5 value
Standard
Tightening torque of brake pipe union nut 6 13 to 18 N•m (1.3 to 1.8 kgf•m) [9.4 to 13 lbf•ft]
value
3 2
4 6
213401
8-31
BRAKE SYSTEM
6.2 Master cylinder
Truck model DP70E

Standard
Inside diameter of cylinder body 1 25.4 mm (1.0 in.)
value
Standard
Outside diameter of piston 2 25.4 mm (1.0 in.)
value
Standard
0.020 to 0.105 mm (0.00079 to 0.00413 in.)
value
Clearance between cylinder body and piston
Repair or 0.2 mm (0.008 in.)
service limit (Replace once per year.)
Standard
26 ± 0.2 mm (1.02 ± 0.0079 in.)
value
Diameter of primary cup (lip side) 3
Standard
33.4 ± 0.25 mm (1.31 ± 0.0098 in.)
value
Diameter of secondary cup (lip side) 4
Standard
89 mm (3.5 in.)
value
Free length of return spring 5
Repair or 89 mm (3.5 in.)
1 4 2 3 5
213330
8-32
BRAKE SYSTEM
6.3 Wheel cylinder
Truck model DP70E

Standard +0.062 +0.00244
Inside diameter of cylinder body 1 31.75 0 mm (1.2500 0 in.)
value
Standard -0.025 -0.00098
Outside diameter of piston 2 31.75 -0.064 mm (1.2500 -0.00252 in.)
value
Standard
0.020 to 0.105 mm (0.00079 to 0.00413 in.)
value
Clearance between cylinder body and piston
Repair or
0.15 mm (0.0059 in.)
service limit
Standard
33.6 ± 0.25 mm (1.323 ± 0.0098 in.)
value
Diameter of primary cup (lip side) 3
Free Standard
33.4 mm (1.31 in.)
length value
Installed Standard
14 mm (0.55 in.)
length value
Return spring 4
Standard
15.7 ± 0.98 N (1.6 ± 0.1 kgf) [3.5 ± 0.2 lbf]
Installed value
load Repair or 33.4 mm (1.31 in.)
Tightening torque of wheel cylinder mounting Standard
17.6 to 26.5 N•m (1.8 to 2.7 kgf•m) [13 to 20 lbf•ft]
bolts 5 value
Standard
Tightening torque of bleeder screw 6 5.88 to 8.83 N•m (0.6 to 0.9 kgf•m) [4 to 7 lbf•ft]
value
1 6 5
2 3 4
213395
8-33
BRAKE SYSTEM
6.4 Wheel brake
Truck model DP70E

Standard +0.2 +0.008
value 317.5 0 mm (12.500 0 in.)
Brake drum inside diameter 1
Repair or
318.5 mm (12.539 in.)
service limit
Standard
10 mm (0.39 in.)
value
Thickness of lining 2
Repair or
4.8 mm (0.19 in.)
service limit
Standard
Clearance between drum and lining 3 (one side) 0.45 to 0.65 mm (0.018 to 0.026 in.)
value
Standard
90 mm (3.54 in.)
value
(front)
Return spring 4 Free length
Standard
93 mm (3.66 in.)
value
(rear)
Adjusting spring 5 Standard
122 mm (4.8 in.)
Free length value
Tightening torque of backing plate mounting Standard
211.5 to 258.5 N•m (21.6 to 26.4 kgf•m) [156.1 to 190.8 lbf•ft]
bolts 6 value
4
4
213396
8-34
BRAKE SYSTEM
6.5 Parking brake lever
Truck model DP70E

Standard
Lever locked position (A) 71˚ to 76˚
value
Standard
Operating effort (F) 245 to 294 N (25 to 30 kgf) [55 to 66 lbf]
value
F
A
213399
6.6 Parking brake
Truck model DP70E

Standard
203.2 mm (8 in.)
value
Inside diameter of brake drum 1
Repair or
205.0 mm (8.07 in.)
service limit
Standard
4 mm (0.16 in.)
value
Thickness of brake lining 2
Repair or
1 mm (0.039 in)
service limit
1
2
213398
8-35
STEERING SYSTEM
1. Specifications ............................................................................................................... 9-2
2. Structure and Functions ............................................................................................... 9-3

2.1 General ................................................................................................................................................. 9-3 1
2.2 Steering Hydraulic System.................................................................................................................... 9-5
2.3 Steering Gear........................................................................................................................................ 9-6
2.4 Tilt Steering Assembly .......................................................................................................................... 9-7 2
3. Removal and Installation.............................................................................................. 9-8
3.1 Removal................................................................................................................................................ 9-8
3
3.1.1 Start by:....................................................................................................................................................... 9-8
3.1.2 Sequence .................................................................................................................................................... 9-8 4
3.1.3 Suggestion for Removal.............................................................................................................................. 9-9
3.2 Installation............................................................................................................................................. 9-9
3.2.1 Inspection after Installation ......................................................................................................................... 9-9
5
4. Disassembly and Reassembly ................................................................................... 9-10 6
4.1 Steering Valve..................................................................................................................................... 9-10
4.1.1 Disassembly.............................................................................................................................................. 9-10
4.1.2 Suggestions for Disassembly.................................................................................................................... 9-11 7
4.1.3 Inspection.................................................................................................................................................. 9-12
4.1.4 Reassembly .............................................................................................................................................. 9-13
8
9
6. Service Data............................................................................................................... 9-19
6.1 Steering Wheel ................................................................................................................................... 9-19
6.2 Steering Valve..................................................................................................................................... 9-19 10
11
12
13
14
9-1
STEERING SYSTEM
1. Specifications
Truck Model DP70E

Type All hydraulic power steering
Diameter of steering wheel 330 mm (13 in.)
Steering control Manufacturer Sumitomo Eaton

valve Flow rate 22.7 L (1386 cu in./min)
9-2
STEERING SYSTEM
2. Structure and Functions

2.1 General
2 7
5 3
9 10
6
13
4 8
11 12
213122
(1) Main steering system components.
1 Steering wheel 8 Steering relief valve
2 Steering column shaft 9 Control valve to steering valve feed hose
3 Steering tilt lever 10 Steering relief valve to control valve return hose
4 Steering valve 11 Steering valve to control valve return hose
5 Hydraulic control valve 12 Steering relief valve to steering valve feed hose
6 Inlet valve section 13 High-pressure oil hose between steering valve and
steering cylinder
7 Steering cylinder
This truck is equipped with a full hydraulic steering system rod is transmitted to the rear wheels’ knuckles through
with a tilt steering column. mechanical linkage, thus causing the truck to steer.
The steering valve 4 constitutes a key component of the sys- The oil to the steering valve 4 is supplied from the hydraulic
tem. It is mechanically connected to the steering wheel 1 pump. The hydraulic pump also supplies oil to the mast
via the steering column shaft 2. So the spool-and-sleeve control cylinders, but the oil to the steering valve is given
valve and small pump in the steering valve rotate when the priority over the other by the function of the priority valve
operator turns the steering wheel to control the direction which is located in the inlet valve section 6 of the hydraulic
and amount of pressure oil to the steering cylinder 7. control valve 5.
The pressure oil from the steering valve pushes the piston Since the steering hydraulic system constitutes a part of the
rod in the steering cylinder in the direction selected by the truck hydraulic system, it is recommended to refer to the
spool-and-sleeve valve proportional to the amount of oil “GROUP 7 REAR AXLE” and “GROUP 10 HYDRAULIC
metered by the small pump. The movement of the piston
9-3
STEERING SYSTEM
SYSTEM” of this manual in addition to the following pages

to understand better the operation of the system.
9-4
STEERING SYSTEM
2.2 Steering Hydraulic System
5
Steering valve 6
Steering cylinder
R T P L
7
9
2
P2
A1
3
4
PF 8
T1
P2
T2 P1 1
P1 T2
213123
1 Hydraulic tank 4 Flow priority valve 7 Steering system relief valve

2 Hydraulic pump 5 Steering valve 8 Main relief valve
3 Hydraulic control valve 6 Steering cylinder 9 Return line
The oil drawn by hydraulic pump 2 from hydraulic tank 1 Simultaneously, the spool-and-sleeve valve in the steering
enters the inlet section of the hydraulic control valve 3 valve 5 opens the return oil passage from the right chamber
through the P port. There is built-in flow priority valve 4 in of the steering cylinder to the hydraulic tank 1. (The return
the inlet section. The function of the flow priority valve is to oil goes through the steering valve’s T port and then the
deliver pressure oil preferentially to steering valve 5 hydraulic control valve 3 to the hydraulic tank 1.) These
through the PF port. (For the structure of the priority valve, two steering valve’s actions allow the tire wheels to turn to
refer to the “GROUP 10 HYDRAULIC SYSTEM”.) From the right steering direction.
the PF port, the oil flows to the P port of the steering valve. When the steering wheel is turned left, the L port of the
When the steering wheel is not turned (in the straight ahead steering valve 5 opens, allowing pressure oil to the right
position), the oil flows through the steering valve’s T port to chamber of the steering cylinder. The oil flow in each pas-
the T2 port in the hydraulic control valve’s inlet section and sage is now reverse to that when the steering wheel is
then returns to hydraulic tank 1 through return line 9. turned right, so that the truck makes a left turn.
When the steering wheel is turned right, the oil from the PF The hydraulic pressure of the steering system is maintained
port enters the “Gerotor” passing through the P port and at a level lower than the maximum pressure by steering sys-
spool-and-sleeve valve in the steering valve 5. (The Gerotor tem relief valve 7 which opens when the pressure is sensed
is a small trochoid pump capable of delivering oil at a rate at the PF port of the inlet cover section exceeds the limit.
proportional to the number of turns in which the steering The relief valve is located below the inlet cover section and
+0.5 +5.1
wheel is turned.) The oil delivered from the Gerotor is its opening pressure is set at 19.1 0 MPa (195. 0 kgf/cm2)
+72.5
directed to the left chamber of steering cylinder through the [2770.5 0 psi].
R port, applying a rightward pressure to the cylinder rod.
9-5
STEERING SYSTEM
2.3 Steering Gear
a, b, c: Metering pump inlets

d, e, f: Metering pump outlets
208745
1 Spool 7 Drive shaft A: Control section

2 Sleeve 8 Centering spring B: Metering section
3 Outlet port (port T) 9 Pin
4 Inlet port (port P) 10 Left turn port (port L)
5 Rotor 11 Right turn port (port R)
6 Rotor ring 12 Housing
The steering valve consists of two sections: control section When the operator turns the steering wheel clockwise, the
A and metering section B. passage in the steering valve opens, allowing pressure oil to
Control section A includes spool 1, sleeve 2, and housing flow through inlet port 4 into areas a, b, and c.
12, constituting a rotary type directional control valve. As rotor 5 turns together with the steering wheel, the oil in
Spool 1 is spline-coupled to the steering shaft. When spool areas d, e, and f is forced into the steering cylinder through
1 is turned, sleeve 2 rotates, opening the following passages right turn port 11. When the steering wheel is turned coun-
to form a hydraulic circuit: terclockwise, oil flows in the direction reverse to the above,
(1) A passage that allows oil to flow from inlet port 4 to entering the steering cylinder through left turn port 10.
metering section B Since the pressure oil from port 4 applies rotating force to
(2) A passage that allows oil to flow from metering section rotor 5, operator’s effort on the steering wheel is reduced.
B to port L or R When the operator stops turning the steering wheel, center-
(3) A passage that allows the return oil from the steering ing spring 8 returns spool 1 to the original position. In this
cylinder to port T position, spool 1 and sleeve 2 block the oil flow from the
Metering section B is a trochoid-gear type, small hydraulic main hydraulic pump into the steering valve and also close
pump consisting of rotor ring 6 and rotor 5. Spool 1 and the passages between ports.
rotor 5 are connected to each other with drive shaft 7. The
rotor, therefore, turns in the same direction and at the same
speed as the steering wheel. When the operator does not
turn the steering wheel, the oil flows from the P port to T
port and finally returns to the hydraulic tank. The oil does
not flow to the metering section B as it is blocked by the
spool 1 and sleeve 2.
9-6
STEERING SYSTEM
2.4 Tilt Steering Assembly
213272
1 Steering wheel 6 Drive shaft

2 Column bushing 7 Universal joint
3 Steering shaft 8 Tilt lock knob
4 Column housing 9 Steering valve
5 Horn cord
The tilt steering cylinder assembly is attached to the dash- The steering shaft 3 and drive shaft 6 are connected through
board with bolts. the universal joint 7, so the angle between them can be
The steering wheel 1, steering shaft 3, joint 7 (with univer- changed. The operator can select the driving position as
sal joint) and drive shaft 6 of steering valve 9 are all splined desired by moving the steering wheel 1 forward or back-
to each other and rotate as a single unit when the steering ward while pushing down the tilt lock knob 8. The tilt angle
wheel is turned. can be changed in an angle range of 6˚ both forward and
backward from the center.
9-7
STEERING SYSTEM

3.1 Removal
3.1.1 Start by:
Disconnect the electric wire cables from the console box
and horn.
213310
3.1.2 Sequence
1 Steering wheel cap, Nut, Washer 7 Upper cover (rear)

2 Steering wheel 8 Lower cover (rear)
3 Turn signal switch, Forward-reverse lever 9 Floor plate, Floor Mat
4 Console box, Connector 10 Tilt steering assembly
5 Upper cover (front) 11 Piping connected to steering valve
6 Lower cover (front)
WARNING
Hydraulic pressure can cause personal injury.
Before any steering system hydraulic lines or
components are disconnected, make sure all
hydraulic pressure is released from the steering
system. Move the steering wheels to the right and
left, then straight.
9-8
STEERING SYSTEM
3.1.3 Suggestion for Removal

Steering wheel removal
Remove the steering wheel with a soft head mallet.
NOTE
Do not hit the end of steering shaft when the steering wheel
is removed.
213146
3.2 Installation
Follow the removal steps in reverse.
3.2.1 Inspection after Installation
(1) Steering wheel play
Check the steering wheel play while idling the engine.
(2) Steering
(a) Pull the hand brake lever. Run the engine and warm the
hydraulic oil to an operation temperature of 40 to 60 ˚C
(104 to 140 ˚F).
(b) Attach a spring scale to the rim (or a spoke) of the
steering wheel, and measure the steering effort required
to turn the steering wheel clockwise or counterclock- 213270
wise.
1.96 N•m (0.2 kgf•m) [1.44

Steering
lbf•ft]
Tangential force 12.7 N (1.3 kgf) [2.87 lbf]
(3) Air bleeding

Air in the hydraulic system such as the steering cylinder,
the flow divider valve and the piping may cause shimmy
and abnormal noise.
(a) Jack up the tires. For procedures, refer to the “GROUP
7 REAR AXLE”.
(b) Depress an release the accelerator pedal repeatedly to
change the engine revolution speed, while turning the
steering wheel to lock-to-lock positions.
9-9
STEERING SYSTEM

4.1 Steering Valve
4.1.1 Disassembly
209437
(1) Sequence
1 End cap, Bolts, O-ring and Spacers 7 Control sleeve
2 “Gerotor” set, O-ring 8 Control spool
3 Drive shaft, Spacer plate and O-ring 9 Pin
4 Retaining ring 10 Centering springs
5 Seal gland bushing, O-ring, Oil seal and Dust seal 11 Retainer, Adapter, Ball
6 Thrust needle, Race bearing 12 Long housing
9-10
STEERING SYSTEM
4.1.2 Suggestions for Disassembly

(1) Retaining ring removal.
Remove the ring from the housing by prying its end out
of the groove.
208233
(2) Seal gland bushing removal
Position the control spool and control sleeve assembly
so that the pin is even with the center of the assembly.
Remove the bushing.
(3) Control spool and sleeve removal

208234
Remove the control spool and sleeve assembly from the
housing by pulling it toward the end of the housing op-
posite to the flange. Remove the pin from the assembly.
NOTE
When removing the assembly, slowly turn it in the housing
in both directions while pulling out to prevent damage to
the housing.
(4) Control spool and sleeve disassembly

Pull the control spool from the sleeve enough to permit 208235
removal of the centering springs. Remove the centering
springs. Remove the spool from the sleeve by pulling it
toward the rear end of the sleeve while turning slowly.
NOTE
Before removing the spool from the sleeve, put a mark
across the spool and sleeve so that the spool can be installed
in the same position.
200668
9-11
STEERING SYSTEM
4.1.3 Inspection
Spool movement in housing and sleeve
(1) Check the spool in sub-assembly condition for free
movement.
(2) If the spool is sticky or otherwise erratic in its move-
ment, disassemble the steering control valve, and check
its sliding surfaces for abnormal condition. If the slid-
ing surfaces are found in bad condition, replace the
whole control valve assembly.
9-12
STEERING SYSTEM
4.1.4 Reassembly
(1) Start by:
(a) Replace worn or defective parts.
(b) Wash all metal parts and blow dry.
(c) Replace O-rings and seals.
(d) Apply grease to O-rings and other sealing parts.
208236A
(2) Sequence
1 Long housing 7 Seal gland bushing, Oil seal, Dust seal and O-ring
2 Control sleeve 8 Retaining ring
3 Control spool 9 Drive shaft, Spacer plate and O-ring
4 Centering spring 10 Metering “Gerotor” set, O-ring
5 Pin 11 End cap, O-ring, Spacer and Bolts
6 Thrust needle, Race bearings
9-13
STEERING SYSTEM

(a) Control spool and sleeve assembling
Put the spool in the sleeve with the spring groove in
alignment with the spring groove in the sleeve. Make
sure the marks put during disassembly are in alignment.
NOTE
Make sure the spool rotates freely in the sleeve.
200670
(b) Centering spring installation
Hold two sets of three springs back to back. Using
Spring Inserting Tool, put these sets of the springs in the
groove with the bevel ends at the bottom.
Special tool needed
Spring inserting tool 97157-00100
200671
(c) Control spool and sleeve assembly installation to hous-
ing
Put the pin in the holes in the spool and sleeve. Put the
control spool and sleeve assembly in the housing from
the rear side while rotating it in both directions with the
pin kept level with center of the spool.
NOTE
Make sure the rear end of the spool and sleeve assembly is
even with the rear end of the housing.
208238
(d) Seal installation
Put the dust seal in position on the seal gland bushing
with the flat side down. Also, put the oil seal in position
on the bushing.
207184
9-14
STEERING SYSTEM
(e) Reassembling the seal gland bushing

• Install the dust seal in the bushing with the flat side facing
towards the bushing.
• Install the quad ring seal in the bushing by smoothing it
into place with your fingers.
• Install the bushing assembly over the spool end with a
twisting motion. Tap it into place with a soft head mallet.
Make sure the bushing is flush against the bearing race.
208239
• Install the retaining ring in the housing and pry it with a
screwdriver around the entire circumference to ensure a
good fitting.
(f) Reassembling the wear plate

• Clamp the housing in a vise, equipped with soft jaws or 207195
softened with rag. Clamp lightly over the flats of the
flange. Do not overtighten the vise jaws.
NOTE
Check that the spool and sleeve are flush with or slightly
below the surface of the housing.
• Install the O-ring in the housing. Place the wear plate on

the housing and align the bolt holes with the tapped holes
in the housing.
208240
208241
9-15
STEERING SYSTEM
(g) Reassembling the driver

• Make a mark across the splined end of the drive to indi-
cate the direction of the slot at the opposite end of the
drive.
• Rotate the spool and sleeve assembly until the pin is par-
allel with the port surface. Install the drive and make sure
that it engages the pin. The mark should be parallel to the
port surface.
208242
(h) Reassembling the gerotor set
• Install O-ring in the gerotor set.
• With the O-ring side of the gerotor set towards the wear
plate, align the star valleys A with the mark on the drive
B. Noting the parallelism of reference lines A, B, C, and
D, align the bolt holes without disengaging the gerotor set
from the drive
208243
9-16
STEERING SYSTEM
(i) Reassembling the end cap

• Install the drive spacer in the gerotor set. Install the O-
ring in the end cap. Install the end cap in the gerotor set
and align the holes
208244
• Tighten all screws snug, then tighten them progressively
to the specified torque in the sequence as shown.
17 N•m (1.7 kgf•m) [12.5

Initial torque for screws
lbf•ft]
22.6 N•m (2.3 kgf•m) [16.6
Finishing torque for screws
lbf•ft]
After installing the end cap, install the steering wheel to

the spool and make sure the spool rotates smoothly. 200677
9-17
STEERING SYSTEM
5. Troubleshooting
Clogged metering section Disassemble and clean.
Steering valve mal-
Faulty spool operation Disassemble and clean.
function
Faulty bearing Disassemble and replace.
Heavy steering wheel
operation Rear axle cylinder
Faulty piston seal Replace.
malfunction
Flattened pipe, mixing of foreign parti-
Others Clean or replace oil line.
cles
Steering gear malfunc- Sticking of spool or sleeve Replace.

tion Damaged centering spring Replace.
Instability in steering
wheel operation Flattened pipe, mixing of foreign parti-
Clean or replace oil line.
Others cles
Faulty piston seal in rear axle cylinder Replace.
9-18
STEERING SYSTEM
6. Service Data
6.1 Steering Wheel
Truck Model DP70E
Steering effort (at steering wheel rim), (Standard value measured
with engine running, steering wheel turning speed of 1 revolution/ Standard value 1.96 N•m (0.2 kgf•m) [1.44 lbf•ft]
sec, and stationary swing operation)
54 to 59 N•m (5.5 to 6.0 kgf•m) [40
Steering wheel nut Standard value
Tightening torque to 43 lbf•ft]
Steering bracket bolts Standard value 29.4 N•m (3 kgf•m) [21.7 lbf•ft]
6.2 Steering Valve

Type of system: Open center, non-load reaction type
Model: Orbitrol® UE-T1-D
Truck Model DP70E

Displacement Standard value 159 CC (9.70 cu in./rev.)
Tightening torque End cap screw 1 Standard value 22.6 N•m (2.3 kgf•m) [16.6 lbf•ft]
208246A
9-19
HYDRAULIC SYSTEM
1. Specifications ............................................................................................................. 10-3
2. Structure and Functions ............................................................................................. 10-4

2.1 Hydraulic Line ..................................................................................................................................... 10-4 1
2.2 Hydraulic Tank .................................................................................................................................... 10-5
2.3 Hydraulic Pump (Gear Pump)............................................................................................................. 10-6
2.4 Control Valve ...................................................................................................................................... 10-7 2
2.5 Lift Cylinder ......................................................................................................................................... 10-8
2.6 Tilt cylinder.......................................................................................................................................... 10-9
2.7 Flow Regulator Valve........................................................................................................................ 10-10
3
2.7.1 Schematic ............................................................................................................................................... 10-10
2.8 Down Safety Valve............................................................................................................................ 10-11 4
2.9 Piping of Hydraulic System ............................................................................................................... 10-12
3. Removal and Installation.......................................................................................... 10-13

5
3.1 Preparation for Removal (1).............................................................................................................. 10-13
3.1.1 Hydraulic Pump (Gear Pump) ................................................................................................................. 10-13
6
3.1.2 Control Valve........................................................................................................................................... 10-14
3.2.1 Lift Cylinders ........................................................................................................................................... 10-15 7
3.3.1 Tilt cylinder .............................................................................................................................................. 10-17
8
4. Disassembly and Reassembly ................................................................................. 10-19
4.1 Hydraulic Pump (Gear Pump)........................................................................................................... 10-19 9
4.1.1 Disassembly............................................................................................................................................ 10-19
4.1.2 Inspection and Repair ............................................................................................................................. 10-20
4.1.3 Reassembly ............................................................................................................................................ 10-22 10
4.2 Lift Cylinders ..................................................................................................................................... 10-24
4.2.1 Disassembly............................................................................................................................................ 10-24
11
4.2.3 Reassembly ............................................................................................................................................ 10-27
4.3 Tilt Cylinder ....................................................................................................................................... 10-28 12
4.3.1 Disassembly............................................................................................................................................ 10-28
4.3.3 Reassembly ............................................................................................................................................ 10-31
13
4.4.1 Disassembly............................................................................................................................................ 10-32 14
10-1
HYDRAULIC SYSTEM
4.4.3 Reassembly ............................................................................................................................................ 10-33

4.5 Down Safety Valve............................................................................................................................ 10-33
4.5.1 Disassembly............................................................................................................................................ 10-33
4.5.2 Inspection................................................................................................................................................ 10-33
4.5.3 Reassembly ............................................................................................................................................ 10-33
5. Inspection and Adjustment....................................................................................... 10-34

5.1 Hydraulic oil ...................................................................................................................................... 10-34
5.2 Suction strainer, Return filter ............................................................................................................ 10-34
5.3 Hydraulic Pump Test Run ................................................................................................................. 10-34
5.4 Control Valve .................................................................................................................................... 10-35
5.4.1 External leakage ..................................................................................................................................... 10-35
5.4.2 Internal leakage....................................................................................................................................... 10-35
5.4.3 Main Relief Valve .................................................................................................................................... 10-36
5.5 Steering System Relief Valve ........................................................................................................... 10-37
5.6 Adjusting flow regulator valve ........................................................................................................... 10-38
6. Testing ..................................................................................................................... 10-39

6.1 Lift cylinder drift test .......................................................................................................................... 10-39
6.2 Tilt cylinder drift test .......................................................................................................................... 10-39
7. Troubleshooting ....................................................................................................... 10-40
8. Service Data............................................................................................................. 10-44

8.1 Gear pump ........................................................................................................................................ 10-44
8.2 Control Valve .................................................................................................................................... 10-45
8.3 Steering control valve ....................................................................................................................... 10-46
8.4 Hydraulic Tank .................................................................................................................................. 10-46
8.6 Lift cylinder........................................................................................................................................ 10-48
8.7 Tilt cylinder........................................................................................................................................ 10-49
10-2
HYDRAULIC SYSTEM
1. Specifications
Truck Model DP70E

Type Gear
Manufacturer Shimadzu
Hydraulic pump Model FGP30 + SP20
Rated output 115 L (30.38 U.S. gal.) / 2300 rpm
Drive Directly driven by torque converter
Priority relief valve
12.3 MPa (125 kgf/cm2) [1778 psi]
setting
Model KVS
Control valve
Manufacturer Kayaba
Main relief valve set-
19.11 MPa (195 kgf/cm2) [2770 psi]
ting
Flow regulator Type Variable (adjustable)
valve Flow rate 165 ± 12 L (43.6 ± 3.2 U.S. gal.)
Inside diameter 80 mm (3.15 in.)
Lift cylinders
Stroke 1650 mm (64.96 in.)
Inside diameter 90 mm (3.54 in.)
Tilt cylinders
Stroke 229 mm (9.02 in.)
Hydraulic tank capacity N level: 105 L (27.7 U.S. gal.)
10-3
HYDRAULIC SYSTEM
2. Structure and Functions

2.1 Hydraulic Line
16
15
8 17
7 21
12
14
22 13
2
5
20 19
1 18 13
4
10 6
213124
1 Suction strainer 9 Lift cylinder (L.H.) 17 Oil return line from steering valve
2 Hydraulic pump 10 Flow regulator valve 18 Hydraulic tank
3 Pump delivery hose 11 End cover section 19 Breather
4 Inlet valve 12 Return line 20 Cap
5 Hydraulic control valve 13 Return filter 21 Relief valve
6 Tilt cylinder (L.H.) 14 Oil feed line to steering valve 22 Lift return valve
7 Tilt cylinder (R.H.) 15 Steering valve
8 Lift cylinder (R.H.) 16 Steering cylinder
The hydraulic system of this truck includes the mast control through the oil feed line 14. The priority valve distributes
circuit and the full-hydraulic steering system circuit. the remainder of the oil to the mast control circuit. In the
The oil drawn by the hydraulic pump 2 from the hydraulic standard configuration, the following three valve sections
tank 18 flows into the control valve inlet valve 4 through the are used for the mast control purposes:
pump delivery hose 3. (1) Lift control valve section
The flow priority valve in the control valve inlet valve 4 (2) Tilt control valve section
preferentially distributes the oil to the steering valve 15 (3) Attachment control valve section
10-4
HYDRAULIC SYSTEM
The lift control valve section controls the operation of the The attachment control valve section controls the operation
lift cylinders 8 and 9 to raise or lower the mast. of the attachment actuators.
The tilt control valve section controls extension and retrac- The return oils from the steering valve and mast control cyl-
tion of the tilt cylinders 6 and 7 to cause the mast to lean inders go to the hydraulic tank through the control valve’s
forward or backward. end cover section 11 and return hose 12.
2.2 Hydraulic Tank
2
4 3
To hydraulic pump
From control
valve
7 5
206518
1 Cap 5 Drain plug

2 Air breather 6 Suction strainer
3 Strainer 7 Return filter
4 Oil level gage
The hydraulic tank is an all-welded structure and is bolted

to the middle of the right-hand side frame member. Oil is
lifted from the tank through suction strainer (105 μ) by the
gear pump. The oil returning from the lift cylinders joins
the oil returning from the hydraulic and steering control
valves and returns to the tank through return filter (25 μ).
10-5
HYDRAULIC SYSTEM
2.3 Hydraulic Pump (Gear Pump)
19 23 1 6 3 2 5 7 11 8 9 12 11 13 23 21
25 24 17 14,16 4 6 17 22 20 18 15 12 10 11 18 15
204621
1 Front cover 10 Driven gear 19 Bolt

2 Body 11 Bearing 20 Bolt
3 Drive gear 12 Side plate 21 Bolt
4 Driven gear 13 Rear cover 22 Washer
5 Bearing 14 Backup strip 23 Washer
6 Side plate 15 Backup strip, Gasket 24 Oil seal
7 Adapter plate 16 Gasket 25 Snap ring
8 Body 17 O-ring
9 Drive gear 18 O-ring
The gear pump (an external-gear type) pumps the hydraulic

oil that is needed to activate the hydraulic cylinders. It has a
tandem structure that effectively consists of a No. 1 gear
pump and a No. 2 gear pump.
10-6
HYDRAULIC SYSTEM
2.4 Control Valve
4
T2 P1 2 P2 3 5
PF 1 T1
213125
1 Inlet valve assy (Priority valve, relief valve) P1 From No. 1 pump.
2 Lift valve P2 From No. 2 pump
3 Tilt valve PF To steering control valve
4 Attachment valve (option) T1 To tank
5 End cover T2 From steering control valve
The priority valve serves to distribute a required quantity of

pressured oil for power steering as well as an extra quantity
for loading regardless how much oil is discharged from
No. 1 gear pump. The extra oil from No. 1 gear pump joins
with the pressured oil from No. 2 gear pump to be used to
operate the loading equipment including lift cylinder and
tilt cylinder, etc. This lift truck has a tilt lock valve installed
as a safety device that can prevent the mast from tilting for-
ward should the tilt lever be operated carelessly while the
engine is stopping.
10-7
HYDRAULIC SYSTEM
2.5 Lift Cylinder
2 6 3 5 4 8 13 9 10 11
7 1 12 205531
1 Cylinder tube 8 Holder

2 Piston rod assembly 9 Piston ring
3 Cylinder head 10 U-ring assembly
4 Bushing 11 U-ring holder
5 U-ring 12 Stopper
6 Wiper ring 13 Spacer
7 O-ring
The two lift cylinders are a single-acting type. One is

located on the left-hand side of the mast, and one is located
on the right-hand side of the mast.
On a truck with a maximum mast lift height of 6 m (19.8 ft),
the piston rod outside diameter is 60 mm (2.36 in.).
On a truck with a mast lift height of 6.5 m to 7 m (21.5 to
23.1 ft), the piston rod outside diameter is 65 mm (2.56 in.).
On a truck with a mast lift height of 5 m to 7 m (16.5 to 23.1
ft), the piston rod of each lift cylinder is fitted with a spacer.
10-8
HYDRAULIC SYSTEM
2.6 Tilt cylinder
5 12 10 3 9 8 1 2 7 4 11 6
15 13 14
Letter stamped D
View A
205759
1 Cylinder tube 7 Piston seal 13 Spacer
2 Piston rod 8 O-ring 14 O-ring
3 Guide bushing 9 Packing 15 Shim
4 Piston 10 Dust seal
5 Socket kit 11 Self-locking nut
6 Bushing 12 Nut
This tilt cylinder is of a dual-working type capable of mak-

ing the mast tilted forward and backward.
Spacer 13 is used for creating backward tilt angle 6.
Raised height of Tilt angle for- Letter stamped on

mast ward-backward tilt cylinder
3 to 5 m 6˚– 12˚ D
5.5 to 7 m 6˚– 6˚ D
10-9
HYDRAULIC SYSTEM
2.7 Flow Regulator Valve
A 10
Free flow
of oil
9 8 6 2
Control flow
of oil
11 13 1 3 7 14 4 12 13 5
205532
1 Body 8 Disc springs

2 Plug 9 Plate
3 Piston 10 Connector
4 Spring 11 Elbow
5 Lock nut 12 Spring pin
6 Stopper 13 O-ring
7 Valve 14 Snap ring
The flow regulator valve for controlling the lowering speed This valve controls the flow of oil from the cylinder,
of loaded forks is located between the lift cylinder and con- depending on the load, to maintain safe lowering speed.
trol valve.
2.7.1 Schematic
1 Lift cylinder
1
2 Flow regulator valve
3 Lift valve
4 Pump
B 2
5 Hydraulic tank
A:Free flow port
B:Control flow port
A
5
3
4
205551
10-10
HYDRAULIC SYSTEM
2.8 Down Safety Valve
G (PF) 3/4-B
3 4 2
1
Identification "230"
B 12
Control flow
Free flow of oil of oil
213402
6 Connector 8 Spring
7 Valve 9 Spring pin
The down safety valve is built into the bottom of the left-
hand lift cylinder. This valve interrupts the flow of oil from
the lift cylinder when the hose between the lift cylinder and
flow regulator valve is ruptured, thereby preventing loaded
forks from unsafely free falling.
+20
230 0 L/min
Control flow rate +5.28
(60.8 0 U.S. gal./min)
10-11
10-12
Steering cylinder
Lift cylinder
(R.H)
HYDRAULIC SYSTEM
Relief valve
Steering valve
2.9 Piping of Hydraulic System
Tilt cylinder Hydraulic pump

Return hose (gear pump)
T1 Lift return alve Pump delivery hose
Attachment
Breather
Tilt Cup
Lift
B2 A2
A1
Down safty
valve
Level gauge
PF T2 Suction strainer Return filter

Flare
Tilt cylinder Tube
Flow regulator valve
Hight-pressure hose
Lift cylinder Low-pressure hose
(L.H)
213126
HYDRAULIC SYSTEM

3.1 Preparation for Removal (1)
(1) Start the engine and lower the forks to the bottom.
Then, make the mast vertical.
(2) Stop the engine and remove the residual pressure from
the pipe.
(3) Remove the floor plate.
(4) Prepare a container to catch the oil, then disconnect
each pipe.
(5) Take preventive measures so as not to allow dirt or dust
from entering in each opening of the pipes and connec-
tors.
3.1.1 Hydraulic Pump (Gear Pump)
2
1
6
4
No. 1 pump
No. 2 pump
213145
(1) Sequence
1 Split flange, Bolts, Spring washers 4 Split flange, Bolt, Spring washers
2 Delivery hose, O-ring 5 Delivery hose, O-ring
3 Suction elbow, O-ring, Bolts, Washers 6 Hydraulic pump
(2) Suggestion for Removal

To remove the hydraulic pump, have it in a sling with a
hoist.
Weight of gear pump 19.5 kg (43 lb)
10-13
HYDRAULIC SYSTEM
3.1.2 Control Valve
1 2 5
4
10
7
8
213127
(1) Sequence
1 Attachment pipe 6 Control valve to steering valve feed hose
2 Tilt pipes, Connectors, O-rings 7 Steering relief valve to control valve return hose
3 Lift pipe 8 Steering valve to control valve feed hose
4 Main delivery hose, Connectors, O-ring 9 Return hose, Connector
5 Sub delivery hose, Connectors, O-ring 10 Control valve
(2) Start by
(a) Before disconnecting the pipes from the control valve,
bring the mast to the vertical position and place the
fork to the lowest position in order to release the resid-
ual pressure in the pipes.
(b) Support the weight of the mast with a crane.
(c) If an attachment is connected, take necessary measures
to prevent it from moving.
(d) Remove the floor plate and dashboard cover.
10-14
HYDRAULIC SYSTEM

(1) Start the engine and raise the lift bracket to the highest
position, then stop the engine.
3.2.1 Lift Cylinders
5
4
5
1
3
6
7
8
204631
1 Return hose, Clamp 5 Cylinder clamp, Cushion, Collar, Shim
2 Hose clamp 6 Lift cylinder, Bracket
3 High-pressure hose 7 Connector
4 Stopper bolt, Shim 8 Elbow, Down-safety valve
(2) Removing return hose

Disconnect each return hose for the right and left lift
cylinders at their connectors.
NOTE
During this operation never touch the lift lever of the con-
trol valve.
(3) Lower the lift bracket.
Push the lift lever of the control valve forward slowly to
lower the lift bracket.
10-15
HYDRAULIC SYSTEM
(4) Removing high-pressure hose

Remove the high-pressure hose from the joint at the
lower part of the lift cylinder. Place a drip pan to catch
oil from the hose. Right cylinder Left cylinder
(5) Removing stopper bolt
(a) Before lifting up the inner mast, wrap the inner mast
with a protective cloth and install the wire rope so that
it includes an extra turn.
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.
NOTE 204933
As the rod end section of the lift cylinder has some shims
inserted, record how many number of shims inserted in
which cylinder, right or left, before removal.
(b) Place wooden blocks with enough strength to support
the weight of the inner mast under the mast, then
remove the wire rope.
(6) Removing lift cylinder
Put a wire rope on the lift cylinder before removing the
cylinder clamp. Hoist the lift cylinder from the rear of
the mast with a rope to carefully remove it.
204632
204633
10-16
HYDRAULIC SYSTEM

(1) Start the engine and lower the forks to the bottom.
Then, fully tilt the mast forward.
(2) Stop the engine.
(3) Put a wire rope to the right and left lifting eyes pro-
vided in the cross-member at the top of the outer mast
and support the outer mast with a crane.
(4) Remove tilt cylinder pin 1 (see the illustration below).
(5) Start the engine, and retract the tilt cylinder rod to the
minimum.
(6) Stop the engine.
213108
3.3.1 Tilt cylinder
213129
10-17
HYDRAULIC SYSTEM

1 Tilt cylinder pin 3 Tilt cylinder pin
2 Hose 4 Tilt cylinder
NOTE
Tilt cylinder pin 1 has been already removed during the pre-
paratory operation.
(2) Removing hose
Disconnect hose 2 from the connection to the cylinder.
Place a drip pan to catch oil from the hose. Install a cap,
etc. to the opening of the disconnected connector to pro-
tect the thread section and to prevent oil in the tilt cylin-
der from flowing out when it is removed.
10-18
HYDRAULIC SYSTEM

4.1 Hydraulic Pump (Gear Pump)
NOTE
As a general rule, disassembly, repair, and reassembly of
the gear pump should be performed by the gear pump’s
manufacturer. If an emergency situation forces you to per-
form these tasks, work carefully in accordance with the sug-
gestions for disassembly described later. The gear pump’s
manufacturer cannot guarantee the gear pump’s perfor-
mance in such circumstances.
4.1.1 Disassembly
13
14
22
23
16
21
15 17
18 11
19
20
19
18
9
17
5
12 10
4
2 6
1
7
8
7
6
205535
10-19
HYDRAULIC SYSTEM
(1) Sequence
1 Bolt, washer 13 Bolt, Washer
2 Rear cover 14 Front cover
3 Backup strip, Gasket 15 O-ring
4 Body 16 Body
5 Backup strip, Gasket 17 Backup strip, Gasket
6 Bearing 18 Bearing
7 Side plate 19 Side plate
8 Drive gear 20 Drive gear
9 Driven gear 21 Driven gear
10 Bolt, Washer 22 Snap ring
11 Adapter plate 23 Oil seal
12 O-ring
(2) Suggestions for Disassembly

(a) After removing each bolt and washer 1, remove the
first of the gear pump assemblies and sequentially
remove the parts from the rear cover 2 to the driven
gear 9.
(b) The front cover 14, rear cover 2, adapter plate 11, and
bearings 6, 18 are made of an aluminum alloy that can
be damaged easily. Do not strike them with a metal
hammer. Use a wooden hammer or plastic hammer
instead.
205535-1

(1) Check each of the drive and driven gears for
(a) damage and wear on the tooth flanks and tooth tips;
(b) damage and wear on the side faces; and
(c) damage and wear on the shaft.
10-20
HYDRAULIC SYSTEM
(2) Check cover, body, and adapter plate for any damage or
wear.
205535-2
(3) Check oil seal, gasket, and O-ring for damage, wear or
setting.
205535-3
10-21
HYDRAULIC SYSTEM
4.1.3 Reassembly
12 1 *11 *9 7 4 5 7 *13 14 21 20 18 20 21 24 26
*3 *2 *10 8 6 8 *15 16 *23 *22 19 17 *25
204621A
(1) Sequence
1 Front cover 10 Gasket 19 Driven gear
2 Oil seal 11 O-ring 20 Side plate
3 Snap ring 12 Bolt, Washer 21 Bearing
4 Body 13 Backup strip, Gasket 22 Backup strip, Gasket
5 Drive gear 14 Adapter plate 23 O-ring
6 Driven gear 15 O-ring 24 Rear cover
7 Side plate 16 Bolt, Washer 25 Backup strip, Gasket, O-ring
8 Bearing 17 Body 26 Bolt, Washer
9 Backup strip 18 Drive gear
NOTE
Marked * are the parts included in the repair kit.
10-22
HYDRAULIC SYSTEM
(2) Suggestion for Reassembly

(a) During reassembly, do not forget to replace the Repair
Kit parts marked with an asterisk (*) in the figure.
(b) Completely remove oil from the mating surfaces of the
cover 1 and 14 and 24 and body 4 and 17.
(c) Apply grease to the oil seal lip.
(d) Be careful not to damage the lip of the oil seal with the
spline edges of drive gear 5.
(e) Tighten the bolts evenly.
55.9 to 62.7 N•m
Tightening torque of bolt 12 (5.7 to 6.4 kgf•m)
[41.2 to 46.2 lbf•ft]
55.9 to 62.7 N•m
[41.2 to 46.2 lbf•ft]
38.2 to 43.1 N•m
[28.2 to 31.8 lbf•ft]
10-23
HYDRAULIC SYSTEM
4.2 Lift Cylinders

4.2.1 Disassembly
NOTE
Parts marked with * are repair kit parts.
4
*
1
2
6
* 5
*
3
213403
(1) Sequence
1 Cylinder head, Wiper ring 4 Piston rod
2 Holder, U-ring, Bushing, O-ring 5 Piston ring, U-ring, Holder, Stopper
3 Spacer 6 Cylinder tube
NOTE
Do not remove the U-ring, bushing 2, and wiper ring 1
unless they appear abnormal when inspected.
10-24
HYDRAULIC SYSTEM
(2) Removal of piston rod

(a) Wrap the cylinder tube with cloth, and hold it in a vise.
Remove the guide bushing with hook wrench A.
Special tool needed
(b) When removing the piston rod from the cylinder make
sure not to damage the piston seals.
Remove the piston rod from the cylinder as shown in the A
illustration. Be sure not to damage the rings.
602303

(1) Cylinder tube
(a) Check the inside surface of the cylinder for wear, dam-
age, or rust.
(b) Check the welded part for cracks, damage, and dent.
(2) Piston rod
(a) 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.
(b) Check the rod surfaces for rust, damage, sliding trace,
200319
and dent.
Replace the piston rod, if it is seriously damaged in the
threaded part.
0 mm
Standard value
Runout of piston rod (0 in.)
(measurement) Repair or service 1 mm
limit (0.0394 in.)
10-25
HYDRAULIC SYSTEM
(3) Ring and packing (b) Check each ring for deterioration.
(a) Check the lips of packing and buffer ring for damage or
distortion.
Item Service Date
+0.2 +0.0079
Standard value 80 0 mm (3.15 0 in.)
[Piston section] Inside diameter of cylinder tube 1
0 0
Standard value 60-0.05 mm (2.36 -0.00197 in.)
Thickness of piston ring 2Standard value
-0.06 -0.00236
60-0.13 mm (2.36-0.00512 in.)
-0.06
Standard value (Mast height 6500 to 7000: 65-0.13 mm
-0.00236
[Cylinder head section] Outside diameter of piston rod 3 [2.56-0.00512 in.])
59.84 mm (2.3559 in.)
Repair or service limit (Mast height 6500 to 7000: 64.84 mm
[2.5528 in.])
+0.12 +0.0047
60 0 mm (2.36 0 in.)
+0.12
Standard value (Mast height 6500 to 7000: 65 0 mm
+0.0047
Inside diameter of cylinder head bushing 4 [2.56 0 in.])
60.17 mm (2.3689 in.)
Repair or service limit (Mast height 6500 to 7000: 65.17 mm
[2.5657 in.])
Thread diameter 5 Standard value M90 × 2 mm (0.0788 in.)
Cylinder head tightening torque 6 Standard value 490 N•m (50 kg•m) [362 lbf•ft]
6 5
3 4 1
205531A
10-26
HYDRAULIC SYSTEM
4.2.3 Reassembly
NOTE
Marked * are the parts included in the seal kit.
1 5 4 3 2
* * * *
205531B
NOTE
The spacer 3 is fitted in the cylinder if the truck has a mast
lift height of 5 m (16.5 ft) or greater.
(1) Sequence
1 Piston rod 4 Cylinder tube
2 Piston ring, U-ring, Holder, Stopper 5 Cylinder head, Wiper ring, U-ring, Bushing, O-ring,
3 Spacer Holder

(a) When performing reassembly, replace each part
marked * in the illustration with a new one from the
seal kit.
(b) Clean all parts thoroughly before reassembling them.
Keep them free of dirt and other foreign substances until
they are assembled.
(c) Smear oil on the U-rings, piston ring, O-ring, bushing,
wiper ring, and cylinder bore before assembling the
parts.
(d) When clamping the cylinder in a vise, tighten the vise
carefully so as not to deform the cylinder.
(e) Before fitting the cylinder head, apply adhesive to the
thread of the cylinder tube.
490 N•m
Cylinder head tightening
(50 kg•m)
torque
[361 lbf•ft]
10-27
HYDRAULIC SYSTEM
4.3 Tilt Cylinder

4.3.1 Disassembly
NOTE
Used on truck capable of 6° forward

and rearward tilt angles
*
*
**
204639B
(1) Sequence
1 Socket, bushing, nut 4 Cylinder tube, Bushing
2 Bushing, O-ring, Dust seal, Packing 5 Shim
3 Piston rod, Piston, Nut, Piston seal 6 Collar, O-ring
NOTE
(a) The collars 6 are used on a truck capable of a 6˚ for-
ward and rearward tilt angles.
(b) The shims 5 are for right-left tilt-angle adjustment.
(c) Do not remove the bushings that are press-fitted into
the cylinder tube 4 and socket 1 unless they appear
abnormal when inspected.
10-28
HYDRAULIC SYSTEM
(2) Removal of bushing

(a) Wrap the tilt cylinder with rags and grip it in a vise.
Remove the bushing using hook wrench A.
Special tool needed
(b) Before removing the bushing from the piston rod, wrap
vinyl tape around the threaded part of the piston rod to
avoid damaging the buffer ring and packing inside the
bushing. A
Using the illustration, remove the piston rod from the
213411
shell. Take care not to damage the rings.

(1) Cylinder tube
age, or rust.
(2) Piston rod
(b) Check the rod surfaces for rust, damage, sliding trace,
and dent. 200319
threaded part.
10-29
HYDRAULIC SYSTEM
(3) Ring and packing

(a) Check the lips of packing and buffer ring for damage or
distortion.
(b) Check each ring for deterioration.
Item Service Date

-0.025 -0.00096
[Bushing section] Outside diameter of piston rod 2 Standard value 40-0.064 mm (1.57-0.00252 in.)
Clearance between rod and bushing
+0.085 +0.00355
Inside diameter of bushing at the mast side 3 (under Standard value 40 0 mm (1.57 0 in.)
press-fit) Repair or service limit 40.6 mm (1.598 in.)
+0.085 +0.00355
Inside diameter of bushing at the frame side 4 (under Standard value 40 0 mm (1.57 0 in.)
[Bushing] Thread diameter 5 Standard value M95 × 2.0 mm (0.0788 in.)
637 ± 64 N•m
Tightening torque of bushing 5 Standard value (65 ± 6.5 kgf•m)
[470 ± 47.2 lbf•ft]
588 ± 29.4 N•m
Tightening torque of piston rod nut 6 Repair or service limit (60 ± 3 kgf•m)
[4.34 ± 21.7 lbf•ft]
Standard value M38 × 1.5 mm
[Socket] Thread diameter Tightening torque of rod 539 to 637 N•m
socket nut 7 Standard value (55 to 65 kgf•m)
[398 to 470 lbf•ft]
2 1 6
7 5
3 4
204640B
10-30
HYDRAULIC SYSTEM
4.3.3 Reassembly
NOTE
Stamped mark
* *** * *
44 3 2 1
204640D
(1) Sequence
1 Piston rod, Piston, Nut, Piston seal 3 Bushing, Packing, Dust seal, O-ring
2 Cylinder tube, Bushing 4 Socket, Bushing, Nut

(a) When performing reassembly, replace each part
marked * in the illustration with a new one from the
seal kit.
(b) Clean all parts thoroughly before reassembling them.
Keep them free of dirt and other foreign substances
until they are assembled.
(c) Smear oil on the piston seal, O-ring, packing, dust seal,
and cylinder bore before assembling the parts.
(d) When clamping the cylinder in a vise, tighten the vise
200352
carefully so as not to deform the cylinder.
(e) Install the tilt cylinder’s piston seal as follows:
• Soften the piston seal by gently squeezing it five or six
times by hand.
• Grip the piston rod in a vise (be careful not to damage it),
then smear a little oil on the piston seal. Fit one side of the
piston seal into the installation groove in the piston, then
push the other side into position.
(f) Make sure the packing and dust seal are aligned cor-
rectly when pressing them into the bushing.
204641
10-31
HYDRAULIC SYSTEM

4.4.1 Disassembly
9
10
11
12
13
3 2
5
7
8
205537
(1) Disassembly Sequence
1 Elbow, O-ring 5 Spring 9 Snap ring
2 Connector, O-ring 6 Pin 10 Plate
3 Nut 7 Stopper 11 Valve
4 Plug, O-ring 8 Disk spring 12 Piston
13 Body
NOTE NOTE
Disassembly for pin 6 to piston 12 should be performed When any of the parts are damaged, replace the whole
after pulling out the piston. assembly.
(1) Check the spring for deterioration.
(2) Check each contact surface of the valve and piston for
damage or sliding trace.
(3) Check each sliding surface of the piston and valve body
for damage.
10-32
HYDRAULIC SYSTEM
4.4.3 Reassembly
Reassembly should be followed in the reverse order of dis-
assembly.
4.5 Down Safety Valve

4.5.1 Disassembly
(1) Sequence
1 Spring pin
2 Valve
3 Spring 2
4 Connector, O-ring 1
3
4.5.2 Inspection
4
(1) Check the valve orifice for clogging or damage.
(2) Check the spring for fatigue. 200355
(3) Check for stripped threads.
NOTE
Replace the down safety valve as an assembly if any part is
defective.
4.5.3 Reassembly
To reassemble, follow the reverse of disassembly sequence.
10-33
HYDRAULIC SYSTEM
5. Inspection and Adjustment

5.1 Hydraulic oil
Cloudy oil should be changed, because it is suspected that
water has been mixed in. When the oil is checked immedi-
ately after operating the hydraulic lever, be careful not to
mistake the bubbles of oil as a mixture with water.
5.2 Suction strainer, Return filter
Check for damage or clogging, and clean or replace.
5.3 Hydraulic Pump Test Run
The purpose of a test run is to break-in the overhauled pump
and verify its performance. The use of specially designed
testing equipment commonly used in the service shop, is
recommended but not mandatory.
The following procedure, however, assumes that the pump
is installed on the truck:
(1) Install a pressure gauge capable of measuring up to 25
MPa (250 kgf/cm2) [3555 psi].
213325
To install the pressure gauge, remove the plug from the
inlet valve and attach the following tools:
Plug 92067-00800 (G3/4-G3/8 thread)

Hose 64309 - 17722
Connector 64309 - 17731 (for gauge)
64309 - 17712
Gauge
25 MPa (250 kgf/cm2) [3555 psi]
NOTE
These tools are included in the gauge kit 64309 - 17701.
(2) With the control levers in neutral, run the engine at a
speed between 500 and 1000 rpm, holding the dis-
charge pressure at a level not higher than 0.981 MPa
(10 kgf/cm2) [142 psi]. Run the pump under this condi- 213331
tion for 10 minutes for break-in, listening for noise.
(3) Raise the engine speed to a speed between 1500 and
2000 rpm, and run the engine for another 10 minutes in
the no-load condition.
(4) While the pump is being run, loosen the adjusting
screw, and shift the control levers into their operating
positions. Next set the adjusting screw, to obtain a
gauge reading of 2.94 MPa (30 kgf/cm2) [427 psi], and
run for 5 minutes at this pressure. Following this, raise
the pressure by changing the setting of adjusting screw
in increments of 1.96 MPa (20 kgf/cm2) [284 psi] each,
running the pump for 5 minutes at each raised pressure
until, finally, the prescribed set pressure of the relief
valve is reached.
10-34
HYDRAULIC SYSTEM
(5) Pay attention to the oil and pump surface temperatures

and to running noises while raising the pressure and, if
any abnormal condition is noted, bring the pump to a
no-load condition to cool the oil or pump as necessary,
or discontinue the test run and overhaul the pump
again. Do not keep on raising the pressure when an
abnormal condition is noted.
(6) After doing Steps (2) thru (5) above, reset the relief
valve as specified and operate the fork and mast to see
if the lift and tilt cylinders work with the specified
speeds.
5.4 Control Valve

5.4.1 External leakage 3° to 4°
(1) Check for oil leaks from the joint between adjacent
valve housings sealed by O-ring.
(2) Check for oil leaks from the scrapers sealed by O-rings.
(3) Check for oil leaks from the screw connections.
5.4.2 Internal leakage
It is not practical to check the control valve alone for inter-
nal leakage. How to check the control valve in place (under 1 m (3.3 ft),
normal operating conditions) will be described. approx.
The internal leakage to be checked includes leakages occur-
ring at the lift spool, tilt spool, tilt lock valve and check 213405
valves.
Test oil temperature 50˚C (122˚F), approx.
(1) Pick up a load equal to the rated capacity, and lift it

approximately 1 m (3.3 ft) high. Tilt the mast about 3˚
to 4˚ forward, and stop the engine.
(2) Quickly disconnect the oil return hose, and start col-
lecting the oil coming out of this hose as shown.
Amount of oil collected for

380 cc (23.2 cu in.)
15 minutes
(3) If the lift cylinders or tilt cylinders drift (the mast tilts
forward or the fork lowers) excessively in spite of that
the amount of oil collected for 15 minutes is less than 213322
380 cc (23.2 cu in.), measure the internal leakage of
each cylinder. (The measurement is the assembly stan-
dard and not the service limit.)
10-35
HYDRAULIC SYSTEM
5.4.3 Main Relief Valve

(1) Install a pressure gauge capable of measuring up to 25
MPa (250 kgf/cm2) [3555 psi] to the inlet valve. Use
the gauge, connectors and hose used for testing the gear
pump.
(2) Start the engine and run it at the maximum speed.
Move the tilt control lever to the backward tilt position.
+0.49 +5
If the pressure is relieved at 19.12 0 MPa (195 0 kgf/
+71
cm2) [2773 0 psi] when the tilt cylinders reach the end
of their stroke, the main relief valve setting is correct.
(3) If the setting is incorrect, loosen the lock nut of adjust-
ing screw and, while observing the pressure gauge
reading, slowly rotate the adjusting screw until the
gauge indicates the prescribed set value.
NOTE
One rotation of the adjusting screw changes the pressure by
approximately 9.2 MPa (93.8 kgf/cm2) [1334 psi]. 213325
(4) While holding the adjusting screw, tighten the lock nut
to secure the adjusting screw.
(5) After securing the adjusting screw, recheck the setting.
+0.5
19.1 0 MPa
+5
Main relief valve setting (194.8 0 kgf/cm2)
+72.5
[2770.5 0 psi]
10-36
HYDRAULIC SYSTEM
5.5 Steering System Relief Valve

(1) Install a hydraulic pressure gauge to the position indi-
cated in the figure to the right.
Connector 1 91268 - 01700 3
Hose 2 64309 - 17722

2
64309 - 17712
Gauge 3
25 MPa (255 kgf/cm2) [3627 psi]
NOTE
Tools 1 to 3 are included in the gauge kit. 1
213144
(2) Start the engine, and turn the steering wheel fully to the
left at the maximum engine speed. When the steering
wheel stroke reaches the limit, check the pressure
gauge. The steering system relief valve is in good con-
dition if the oil pressure is relieved and the gauge read-
ing is the following standard value.
12.0 to 12.6 MPa

Steering system relief valve
(120.4 to 128.5 kgf/cm2)
setting
[1741 to 1828 psi]
(3) If the steering system relief valve opening pressure is

out of specification, adjust the valve.
213134
10-37
HYDRAULIC SYSTEM
5.6 Adjusting flow regulator valve

Measure the lowering speed under the rated load.
If the lowering speed does not meet the standard value,
loosen the lock nut and adjust the speed by incrementally or
decrementally turning the plug 1/2 turn with an Allen
wrench.
Increment/decrement of the
Approx. 17 mm
lowering speed per 1/2 turn of
(0.67 in.)/sec.
plug
213143
10-38
HYDRAULIC SYSTEM
6. Testing
6.1 Lift cylinder drift test
(1) Pick up a load equal to the rated capacity, place the
mast to a vertical position, lift the fork 1 to 1.5 m (3.3
to 4.9 ft), and stop the engine.
(2) Mark a reference line on the mast, and measure the
drift (retraction of the piston rods) for 15 minutes.
Lift cylinder drift (in 15 minutes 55 mm (2.2 in.),

under rated load weight) maximum
213136
6.2 Tilt cylinder drift test

(1) Pick up a load equal to the rated capacity, place the
mast to a vertical position, lift the fork about 50 cm (20
in.), and stop the engine.
(2) Measure the extension of tilt cylinder piston rods for 15
minutes.
Truck Model DP70E

Tilt cylinder drift (in 15
minutes under rated load 24 mm (0.94 in.)
weight)
213137
10-39
HYDRAULIC SYSTEM
7. Troubleshooting
• Not enough oil • Refill.
• Inappropriate oil viscosity • Refer to the “List of Applicable
Lubricant”, and replace.
• Operating conditions are hard and • Check the working conditions, and
over-loaded. if over-loaded, urge the operator to
stay within the load limit
Hydraulic tank heats • Local overheating of oil line due to • Clean oil line.
excessively
a large restriction to flow
• Relief valve adjustment improper • Adjust pressure setting.
Hydraulic tank • Hydraulic pump worn • Replace pump.
• Outlet-side line flattened or restric- • Repair or replace.
tion to flow
• Clogging of oil cooler • Clean
• Shortage of oil due to a natural loss • Refer to the “List of Applicable
Lubricant”, and add oil.
Cylinders move too • Oil leakage due to damaged oil • Repair or replace.
slow line, seal, etc.
• Oil viscosity is too high • Refer to the “List of Applicable
Lubricant”, and change oil.
10-40
HYDRAULIC SYSTEM
• Gear pump does not pump-in oil • Check pump and piping. Repair or
replace if required.
• Oil leaks from part of the hydraulic • Check the oil level and contamina-
Cylinders move too line tion. Add or change oil if neces-
slow sary.
• Oil level abnormally high • Check the control valve spools for
misalignment. Repair or replace.
• Hydraulic pump internal leakage • Replace pump.
• Poor pumping of oil • Refer to the “List of Applicable
• Cavitation Lubricant”, and add oil.
(1) Check suction pipe for any flat
portion or loose connection.
Pump too noisy Retighten or replace.
(2) Check shaft oil seal for air-tight-
ness. Replace the pump.
(3) Check pump body for any out-
Gear pump side interference. Repair.
• Subjected to pressure greater than • Check if pressure control valve
that rated operates normally. Replace the
pump.
Pump case, drive gear • Distortion or damage due to exter- • Replace pump.
or pump port flange nal strain or stress (1) Check if the return line has been
damage blocked or restricted to flow.
(2) Check if pipe connection has
been externally strained or
stressed.
• Oil leakage from oil seal • Replace seal.
• Oil leakage through sliding sur- • Replace pump assembly.
faces of drive shaft
Oil leakage from pump
• Pump securing bolt loose • Retighten, and replace parts if
required.
• Seal ring inside pump deteriorated • Replace O-ring.
10-41
HYDRAULIC SYSTEM
• Too low valve opening pressure • Adjust the pressure.

setting
• Relief valve piston sticks • Clean piston and check to see if it
moves smoothly; or replace relief
Slow or no motions of valve assembly.
lift and tilt cylinders • Outer O-ring on relief valve body • Replace O-ring.
damaged
• Control lever installed loose, • Readjust.
Control Valve resulting in not enough spool
stroke
Lift drops or tilts for- • Control valve spool internal leak- • Replace each block assembly.
ward age
• Oil leakage from spool ring cap • Replace O-ring; check spool. If
necessary, repair or replace each
Oil leakage block assembly.
• Plug loose • Retighten.
• O-ring damaged • Replace O-ring.
• Insufficient oil in hydraulic tank • Refer to the “List of Applicable

Lubricant”, and add oil.
Mast will not ascend, • Relief valve defects • Replace.
tilt forward or back-
ward. (1) Main valve jamming
(2) Valve spring fracture • Replace.
• Hydraulic pump defects • Replace.
• Relief valve defects • Adjust the pressure.
(1) Too low valve opening pressure
setting
Unable to lift rated

(2) Plunger or poppet seat defects • Replace.
load (3) Spring deteriorated • Replace.
(4) O-ring in valve case damaged • Replace.
• Hydraulic pump defects • Replace.
Lift and tilt cylinder
• Piston seal worn or damaged • Replace.
• Engine speed too slow • Adjust engine
• Control lever installed loose, • Readjust
resulting in not enough spool
Lifting speed too slow
stroke
• Clogging of tank strainer • Wash or replace.
• Gear pump delivery rate too low • Repair or replace.
• Sleeve seized in flow regulator • Repair
valve
• Hydraulic line extremely restricted • Clean or repair the hydraulic sys-
Lowering speed of lift
cylinder too slow from smooth flowing due to dirt tem or replace defective hose.
clogged in flow regulator valve, or
hydraulic hose fractured or locally
stopped.
10-42
HYDRAULIC SYSTEM
• Piston rod bend • Repair or replace.

Cylinder vibrates dur- • Air mixed in hydraulic line • Bleed air by operating cylinder
ing operation across full stroke.
• Insufficient oil in tank • Refill.
• Control valve spool internal leak- • Replace each block assembly.
age
• Scratches on sliding surface of cyl- • Repair or replace.
inder tube that can be felt by finger
Lift cylinder descend nail.
excessively
• Sliding surface of cylinder tube • Replace cylinder assembly.
badly grooved
• Piston seal damaged or distorted • Replace seal.
• Oil leakage from hydraulic line • Repair or replace.
• Control valve spool internal leak- • Replace each block assembly.
Lift and tilt cylinder age
Tilt cylinder tilt for- • Foreign matter lodged in packing • Replace packing.
ward excessively • Piston seal damaged • Replace seal.
• Abnormal distortion or oil leakage • Repair or replace.
from hydraulic line
Lift cylinder or tilt cyl- • Inside surface of cylinder badly • Repair or replace.
inder will descend or grooved or rusted
tilt forward at a certain
point • Cylinder distortion • Replace.
• Foreign matter lodged in oil seal or • Replace.

dust seal
Oil leakage from bush- • Inner or outer diameter of oil seal • Replace.
ing or dust seal damaged
• O-ring damaged • Replace O-ring.
• Abnormal distortion • Repair or replace.
10-43
HYDRAULIC SYSTEM
8. Service Data
8.1 Gear pump
Truck Model DP70E
Fork ascending speed (under the rated load) [Dual pan- 440 mm/sec
Standard value
orama mast] (at maximum engine speed) (86 fpm)
Fork ascending speed (under no load) (at maximum 470 mm/sec
Standard value
engine speed) (92.5 fpm)
Fork descending speed (under the rated load) [Dual pan- 550 mm/sec
Standard value
orama mast] (at maximum engine speed) (108 fpm)
Forward tilt angle [Standard dual panorama mast truck] Standard value 6˚
Backward tilt angle [Standard dual panorama mast
Standard value 12˚
truck]
Free descending amount of lift cylinder (under rated 55 mm/15 min maximum
Standard value
load) (Oil temperature: 45˚C) (rod retraction length) (2.2 in./15 min maximum)
Free tilting angle of tilt cylinder (under rated load) (Oil 15 mm (0.59 in.) 24 mm (0.94 in.)
Standard value
temperature: 45˚C) (rod extension length) /15 min maximum /15 min maximum
Discharge capacity Standard value 115/2300 L/rpm
Mounting bolt and nut tightening torque 1 Standard value 56.8 N•m (5.79 kgf•m) [41.9 lbf•ft]
37 to 48 N•m (3.77 to 4.89 kgf•m)
Delivery hose mounting bolt tightening torque 2 Standard value
[27.3 to 35.4 lbf•ft]
2 1
213273
10-44
HYDRAULIC SYSTEM
8.2 Control Valve

Truck Model DP70E
19.1 to 19.6 MPa (194.8 to 199.9 kgf/cm2)
Main relief pressure 1 Standard value
[2771 to 2843 psi]
Tilt pipe tightening torque 2 Standard value 58.8 N•m (5.690 kgf•m) [41.159 lbf•ft]
58.8 ± 5.9 N•m (5.99 ± 0.6 kgf•m)
Tilt pipe connector tightening torque 3 Standard value
[43.39 ± 4.35 lbf•ft]
58.8 ± 5.9 N•m (5.99 ± 0.6 kgf•m)
Lift pipe connector tightening torque 4 Standard value
[43.39 ± 4.35 lbf•ft]
137 N•m (13.97 kgf•m)
Return pipe connector tightening torque 5 Standard value
[101.11 lbf•ft]
Delivery hose connector tightening torque 6 Standard value 118 N•m (12.03 kgf•m) [87.08 lbf•ft]
Return pipe connector tightening torque 7 Standard value 49 N•m (4.997 kgf•m) [36.16 lbf•ft]
59 N•m (6.02 kgf•m)
Return pipe connector tightening torque 8 Standard value
[43.54 lbf•ft]
58.8 ± 5.9 N•m (5.99 ± 0.6 kgf•m)
Attachment connector tightening torque 9 Standard value
[43.39 ± 4.35 lbf•ft]
6 8 7 2 3 9 5
4 1
213138
10-45
HYDRAULIC SYSTEM
8.3 Steering control valve

Truck Model DP70E
Return pipe connector tightening torque 1 Standard value 59 N•m (6 kgf•m) [44 lbf•ft]
Return pipe connector tightening torque 2 Standard value 49 N•m (5 kgf•m) [36 lbf•ft]
Delivery pipe connector tightening torque 3 Standard value 59 N•m (6 kgf•m) [44 lbf•ft]
Check valve connector tightening torque 4 Standard value 49 N•m (5 kgf•m) [36 lbf•ft]
Steering cylinder hose connector tightening torque 5 Standard value 59 N•m (6 kgf•m) [44 lbf•ft]
1
2
4
5
213332
8.4 Hydraulic Tank

Truck Model DP70E
Return filter tightening torque 1 Standard value 49 N•m (5 kgf•m) [36.1 lbf•ft]
Suction strainer tightening torque 2 Standard value 49 N•m (5 kgf•m) [36.1 lbf•ft]
176 to 196 N•m (17.9 to 19.9 kgf•m)
Drain plug tightening torque 3 Standard value
[130 to 145 lbf•ft]
3 2
205529
10-46
HYDRAULIC SYSTEM

Truck Model DP70E
Regulated flow rate (under no load) Standard value 150 ± 12 L/min (39.6 ± 3.2 U.S. gal./min)
Return pipe tightening torque 1 Standard value 118 N•m (12 kgf•m) [87.1 lbf•ft]
213139
10-47
HYDRAULIC SYSTEM
8.6 Lift cylinder

Truck Model DP70E
+0.2 +0.00788
Standard value 80 0 mm (3.147 0 in.)
Cylinder tube inside diameter 1
0 0
Piston ring thickness 2
-0.06
65 -0.13 mm
-0.00236
Standard value (2.36-0.00512 in.)
(mast lift height:
Piston rod outside diameter 3 6.5 to 7 m)
64.84 mm (2.5528 in.)
Repair or service limit (mast lift height:
6.5 to 7 m)
+0.12
65 0 mm
+0.00473
Standard value (2.56 0 in.)
(mast lift height:
Cylinder head bushing inside diameter 4 6.5 to 7 m)
65.17 mm (2.5657 in.)
Repair or service limit (mast lift height:
6.5 to 7 m)
Nominal size of cylinder head thread 5 Standard value M90 × 2.0 mm (0.0788 in.)
Cylinder head bolt tightening torque 6 Standard value 490 N•m (49.969 kgf•m) [361.4 lbf•ft]
6 5
3 4 1
205531A
10-48
HYDRAULIC SYSTEM
8.7 Tilt cylinder

Truck Model DP70E
-0.025 -0.00099
[Bushing] Outside diameter of piston rod 2 Standard value 40 -0.064 mm (1.57-0.00252 in.)
Clearance between rod and bushing
+0.085 -0.00335
Inside diameter of socket bushing at the mast side 3 Standard value 40 0 mm (1.57 0 in.)
(under press-fit) Repair or service limit 40.6 mm (1.598 in.)
Inside diameter of bushing at the frame side 4 (under Standard value 40 mm (1.57 in.)
Thread diameter of guide bushing 5 Standard value M95 × 2.0 mm (0.0788 in.)
637 ± 64 N•m (65 ± 6.6 kgf•m)
Guide bushing tightening torqueStandard value Standard value
[470.1 ± 47.2 lbf•ft]
588 ± 29 N•m (59.96 ± 2.958 kgf•m)
Tightening torque of piston rod nut 6 Standard value
[433.7 ± 21.4 lbf•ft]
539 to 637 N•m (54.97 to 64.97 kgf•m)
Tightening torque of rod socket nut 7 Standard value
[397.6 to 469.9 lbf•ft]
Tilt hose tightening torque Standard value 49 N•m (5.00 kgf•m) [36.1 lbf•ft]
2 1 6
7 5
3 4
204640B
10-49
MAST AND FORKS
1. Specifications ............................................................................................................. 11-3
2. Structure..................................................................................................................... 11-4
2.1 Simplex Mast (4P70B, 4P70C) ........................................................................................................... 11-4 1
2.2 Triplex Mast (4M70A, 4M70B) ............................................................................................................ 11-5
3. Operation of Triplex Mast........................................................................................... 11-6 2

4. Suggestions for Removal and Installation.................................................................. 11-7
4.1 Removal.............................................................................................................................................. 11-7
3
4.1.1 Removing Simplex Mast ........................................................................................................................... 11-7
4.1.2 Removing Triplex Mast ........................................................................................................................... 11-11 4
5. Disassembly and Reassembly ................................................................................. 11-14
5.1 Simplex Mast .................................................................................................................................... 11-14
5
5.1.1 Removal sequence ................................................................................................................................. 11-14
5.1.2 Preparation.............................................................................................................................................. 11-14
6
5.1.3 Removing mast strip and main roller....................................................................................................... 11-14
5.1.4 Removing inner mast .............................................................................................................................. 11-15
5.2 Triplex Mast ...................................................................................................................................... 11-16 7
5.2.1 Preparation.............................................................................................................................................. 11-16
5.2.2 Removal sequence ................................................................................................................................. 11-16
5.2.3 Removing first lift cylinder 4 .................................................................................................................... 11-17
8
5.2.4 Removing inner mast and main roller ..................................................................................................... 11-17
5.2.5 Removing inner mast .............................................................................................................................. 11-17 9
5.2.6 Removing second lift cylinder 24, main rollers 27 from middle mast 28 and outer mast 31 ................... 11-17
5.3 Inspection and Repair ....................................................................................................................... 11-18
5.3.1 Mast ........................................................................................................................................................ 11-18 10
5.3.2 Lift bracket............................................................................................................................................... 11-18
5.3.3 Chain, Chain wheel, and Chain wheel support ....................................................................................... 11-18
5.3.4 Mast strip................................................................................................................................................. 11-19
11
5.3.5 Fork ......................................................................................................................................................... 11-19
5.4 Removing lift cylinder high-pressure hose ........................................................................................ 11-20 12
5.4.1 Installing lift bracket roller (all mast models) ........................................................................................... 11-20
5.4.2 Installing mast roller (all mast models).................................................................................................... 11-23
5.4.3 Measuring and adjusting clearance G2 between mast strip and inner mast (all mast models) .............. 11-23
13
5.4.4 Installing first lift cylinder (triplex mast model)......................................................................................... 11-24
5.4.5 Installing second lift cylinder (all mast models) ....................................................................................... 11-24 14
5.4.6 Installing chain on lift bracket .................................................................................................................. 11-25
11-1
MAST AND FORKS
5.4.7 Inspection and adjustment ...................................................................................................................... 11-26
6. Readjust. .................................................................................................................. 11-27

6.1 Inspecting and Adjusting Chain Tension........................................................................................... 11-27
6.1.1 Simplex Mast........................................................................................................................................... 11-27
6.1.2 Triplex Mast............................................................................................................................................. 11-29
6.1.3 Chain, Chain wheel support and Chain wheel ........................................................................................ 11-29
6.1.4 Checking Clearance between Lift Bracket Roller and Inner Mast........................................................... 11-30
6.1.5 Necessity of clearance check for lift bracket roller .................................................................................. 11-31
6.1.6 Inspecting Clearance for Mast Roller ...................................................................................................... 11-33
6.2 Removing mast rollers (simplex mast).............................................................................................. 11-36
6.2.1 Separate the lift bracket from the mast. .................................................................................................. 11-36
6.2.2 Removing mast rollers ............................................................................................................................ 11-36
6.3 Removing mast rollers (triplex mast) ................................................................................................ 11-37
6.3.1 Separate the lift bracket from the mast. .................................................................................................. 11-37
6.3.2 Removing first lift cylinder. ...................................................................................................................... 11-37
6.3.3 With the following procedure lower the inner mast so it takes a lower position than the middle mast.... 11-37
6.3.4 With the following procedure lower the middle mast so it takes a lower position than the outer mast.... 11-38
6.3.5 Inspecting and Adjusting Mast Strip Clearance ...................................................................................... 11-39
6.3.6 Tilt Angle Adjustment .............................................................................................................................. 11-39
6.3.7 Inspecting and Adjusting Lift Cylinder Stroke.......................................................................................... 11-40
8. Service Data............................................................................................................. 11-42
11-2
MAST AND FORKS
1. Specifications
Truck model DP70E

Mast type CJ type
Mast dimensions Outer 150 × 30 × 20 mm
(Flange inside width ×
Flange thickness × Web Inner 150 × 30 × 15 mm
thickness)
Type Ball bearing
Main roller Diameter ×
150 × 36 mm
Width
Type Lubricated needle
Side roller Diameter ×
58 × 40 mm
Width
Lift-chain type EKBL-1034
Fork length (width × thickness) 1220 – 150 × 60 mm
Fork width adjustment (outside width) 350 to 1700 mm
11-3
MAST AND FORKS
2. Structure
2.1 Simplex Mast (4P70B, 4P70C)
Section A − A Section B − B Section C − C Side roller detail

213407
1 Inner mast 5 Fork 9 Mast support cap

2 Outer mast 6 Lift cylinder 10 Mast strip
3 Lift chain 7 Main roller
4 Lift bracket 8 Side roller
11-4
MAST AND FORKS
2.2 Triplex Mast (4M70A, 4M70B)
D D
6
10
3
7
2
1
8
C C
B D
B
A A 9
209456
Section A − A Section B − B Section C − C Section D − D Side roller

213409
1 Outer mast 8 Backrest 14 Main roller (top side of outer mast)

2 Middle mast 9 Fork 15 Main roller (top side of middle mast)
3 Inner mast 10 Chain wheel 16 Main roller (at the midway of lift bracket)
4 Lift bracket 11 Side roller 17 Main roller (bottom side of lift bracket)
5 First lift cylinder 12 Mast strip 18 Main roller (bottom side of middle mast)
6 Second lift cylinder 13 Main roller (top side of lift bracket) 19 Main roller (bottom side of inner mast)
7 Lift chain
11-5
MAST AND FORKS
3. Operation of Triplex Mast
203600
11-6
MAST AND FORKS

WARNING
(1) When performing inspections or doing service
work around the mast, never place your body
in between the overhead guard and mast while
the engine is running.
(2) Be sure to take appropriate measures to pre-
vent the inner mast from falling, which may
take place even while the engine is stopped.
(3) Do not attempt to service the mast from the
Operator's Compartment.
4.1 Removal
4.1.1 Removing Simplex Mast
205521
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
11-7
MAST AND FORKS
(1) Removing lift bracket

(a) Tilt the mast forward, and lower the inner mast to the
bottom. Slacken the lift chains, and remove the nuts
from the anchor bolts. Keep the chains hung over the
backrest. The forks do not have to be removed.
(b) Place the supporting wooden blocks under the lift
bracket to make the forks and lift bracket stable.
(c) Raise the mast vertically and raise also the inner mast.
Slowly back the truck away to separate the lift bracket
from the truck.
205515
(2) Removing lift cylinder low-pressure return hose
(a) Start the engine and raise the mast up to the highest
position, then stop the engine. Remove the hose at the
return connector side.
(b) Lower the mast.
(3) Removing lift cylinder high-pressure hose
Operate the lift lever to remove the remaining pressure
in the lift cylinder hydraulic lines, and disconnect the
high-pressure hose from the joint to the flow regulator
valve.
11-8
MAST AND FORKS
(4) Removing tilt cylinder

(a) Hitch a sling to the upper cross-member at the top of
the mast, then lift with a hoist.
WARNING
For this operation be sure to use a hoist having
enough capacity to support the mast assembly.
Weight of Each Component (Simplex Mast, raised
height: 3 m)
Truck model DP70E

Outer mast 600 kg
Inner mast 405 kg 213108
Lift bracket (including backrest) 465 kg
Forks (two) Standard fork 300 kg
Lift cylinders, etc. 150 kg
Total 1920 kg
Tilt socket pin
(b) Remove the tilt pin and separate the tilt cylinder from
the mast.
(c) Start the engine and pull back the tilt lever to retract the
tilt cylinder rods.
(5) Removing the lift cylinder high-pressure hose: Lower

206532
the mast to the bottom, then disconnect the hose from
the flow regulator valve.
(6) Removing mast support bearing caps

(a) Put alignment marks on the caps.
(b) Remove the cap mounting bolts and separate the whole
mast assembly while lifting it up from the truck. Lay it
down flat with the tilt bracket side facing upward on a
level ground.
NOTE
In order to avoid any obstructions during disassembly, lay Match marks
the removed mast assembly in an area with sufficient space.
This will allow the mast to slide in both directions (top and
bottom) without interference.
213406
11-9
MAST AND FORKS
(7) Installation
Follow the removal procedure in reverse while servicing
the following sections.
(a) Procedure for installing mast support bushing 7 and
caps 6
• Apply grease to the inner surfaces of caps and mast sup-
port bushings.
• Install mast support bushings 7 and caps 6, making sure
that the sides with larger chamfered area face toward the
center of the truck. Apply grease
• Firmly tighten the support tightening bolts. Chamfered faces
Truck Model DP70E 203712

490 ± 49 N•m
Bolt tightening torque (50 ± 5.0 kgf•m)
[362 ± 36.2 lbf•ft]
(b) Adjust the chain tensions. (Refer to 11-26 “Chain Ten-

sion Adjustment”.)
(c) Bleeding lift cylinder
Start the engine. Move the lift bracket up and down sev-
eral times to the full stroke to bleed air from the cylin-
der.
(d) After confirming proper operation, check the oil level.
11-10
MAST AND FORKS
4.1.2 Removing Triplex Mast
206533
1 Fork, Lift bracket 7 Cylinder clamp, Bolts, Seat, Shim, Cushion, Collar
2 Side roller, Bracket, Grease nipple, Shim 8 Bolt, Shim
3 Main roller, Snap ring 9 Mast strip, Shim
4 Rubber hose, Connector, Elbow, O-ring, Down safety 10 Main roller, Snap ring
valve
5 Hose, Clamp 11 Main mast
6 Chain wheel, Chain guard, Snap ring 12 Lift cylinder
13 Outer mast
(2) Removing lift bracket 2

(a) Lower lift bracket 2 and place the wooden block under
the mast assembly. Tilt the mast forward, and lower the
inner mast to the bottom. Slacken the first lift chain,
and remove nut 1 from the anchor bolt.
207613
11-11
MAST AND FORKS
(b) Tilt the mast back so it can stand vertically. Raise the
inner mast until main roller 8 of the lift bracket
becomes free. Then, back the truck away to separate lift
bracket 2 from the mast.
213111
(3) Separating tilt cylinder and mast
(a) Lower the inner mast. Hitch a sling to the upper cross
members of the outer, middle and inner masts and lift
the mast assembly with a hoist.
CAUTION
Make sure the hoist has enough capacity to sup-
port the mast assembly.
(b) Place the wooden blocks under the tilt cylinder mount-
ing part of the mast assembly and remove tilt socket pin
3. Start the engine and pull back the tilt lever to retract
207796
the tilt cylinder rods.
(4) Removing lift cylinder high-pressure hose

Lower the mast to the bottom, then disconnect the hose
from the flow regulator valve.
Tilt socket pin
206532
(5) Removing mast support bearing caps 6
(a) Before removing the bearing caps, put alignment marks
on the caps so that reassembly can be performed cor-
rectly.
(b) Remove the cap bolts and lift the mast assembly to sep-
arate it from the truck. Lay the mast assembly flat on
the level ground.
Match marks
213406
11-12
MAST AND FORKS
(6) Installation
Follow the removal procedure in reverse while servicing
the following sections.
(a) Procedure for installing mast support bushing 7 and
caps 6
• Apply grease to the inner surfaces of caps and mast sup-
port bushings.
• Install mast support bushings 7 and caps 6, making sure
that the sides with larger chamfered area face toward the
center of the truck. Apply grease
• Firmly tighten the support tightening bolts. Chamfered faces
Truck Model DP70E 203712

490 ± 49 N•m
Bolt tightening torque (50 ± 5.0 kgf•m)
[362 ± 36.2 lbf•ft]
(b) Removing mast support bearing cap 6

Adjust the chain tensions. (Refer to 11-26 “Chain Ten-
sion Adjustment”.) Tighten the nut to the specified
torque.
(c) Bleeding lift cylinder
For Triplex Mast, start the engine and move the lift
bracket up and down several times to the full stroke to
bleed air from the cylinder.
(d) After confirming the proper operation, check the oil
level.
11-13
MAST AND FORKS

5.1 Simplex Mast
206533
1 Fork, Lift bracket 5 Hose, Clamp 9 Mast strip, Shim

2 Side roller, Bracket, Grease nipple, 6 Chain wheel, Chain guard, Snap ring 10 Main roller, Snap ring
Shim
3 Main roller, Snap ring 7 Cylinder clamp, Bolt, Seat, Shim, 11 Main mast
Cushion, Collar
4 Rubber hose, Connector, Elbow, O- 8 Bolt, Shim 12 Lift cylinder
ring, Down safety valve
13 Outer mast
5.1.2 Preparation
Before disassembling the mast and fork assembly, measure
and record every clearance such as between each lift
bracket and roller and between each mast and roller. Use
these recorded measurements for future clearance adjust-
ments, which may be required after any roller or shim is
replaced. Refer to pages 11-29 to 11-34.
5.1.3 Removing mast strip and main roller

Remove bolts 7, 8 to free lift cylinder 12. Displace the tops
of the two lift cylinders from inner mast 11. Slide inner
mast 11 toward the bottom of outer mast 13, and remove
main rollers 3, 10 and mast strips 9.
11-14
MAST AND FORKS
5.1.4 Removing inner mast

After removing the main rollers, hitch a sling to the inner
mast cross-member and slide the inner mast to the upper
side of the outer mast to clear the outer mast roller shafts.
Hitch a sling to the inner mast again and remove it from the
outer mast.
206944
11-15
MAST AND FORKS
5.2 Triplex Mast

wedge to prevent the inner and middle masts from slid-
NOTE
ing.
The lift bracket disassembly procedure for the triplex mast (2) Before disassembling the mast and fork assembly, mea-
is the same as the simplex mast. sure and record every clearance such as between each
5.2.1 Preparation lift bracket and roller and between each mast and roller.
Use these recorded measurements for future clearance
(1) With the lift bracket facing up, place the mast horizon-
adjustments, which may be required after any roller or
tally on wooden blocks. Place a wooden block as a
shim is replaced. Refer to pages 11-29 to 11-34.
209474
1 Hose for first lift cylinder, Clamp, 11 Mast strip, Shim 21 Bolt, Seat, Cushion, Collar
Bolt, Washer
2 Bolt, Washer 12 Stopper, Shim, Bolt, Washer 22 Cushion, Shim, Bracket
3 Shim 13 Main roller, Shim 23 Bolt, Washer, Shim
4 First lift cylinder 14 Inner mast 24 Second lift cylinder
5 Stopper bolt, Washer 15 Lift chain (for second lift cylinder) 25 Mast strip, Shim
6 Chain wheel support 16 Chain guard, Bolt 26 Stopper, Shim, Bolt, Washer
7 Chain guard, Plug 17 Snap ring, Chain wheel 27 Main roller, Shim
8 Snap ring, Chain wheel 18 Hose, Band 28 Middle mast
9 Pulley bracket, Pulley, Bar, Bolt 19 Joint, Connector, Bolt, Washer 29 Cap, Bolt, Washer
10 Nut (chain for second lift cylinder) 20 Lift chain (for second lift cylinder) 30 Mast support bushing
31 Outer mast
11-16
MAST AND FORKS
5.2.3 Removing first lift cylinder 4

(1) Remove the retaining bolt from the first lift cylinder.
(2) Hitch slings on lift cylinder 4, and carefully remove the
cylinder. Use two slings. Wind or tie the slings securely
to prevent slipping.
207811
5.2.4 Removing inner mast and main roller
Lower inner mast 14 until the main rollers can be removed.
Remove main rollers 12, 13, and mast strips 11.
207812
5.2.5 Removing inner mast
Use slings, lift and remove the inner mast, steering it clear
of the roller shaft sections of the middle mast.
207813
5.2.6 Removing second lift cylinder 24, main rollers
27 from middle mast 28 and outer mast 31
Remove the bolts that secure second lift cylinder 24. Place
the cylinder rods ends on the outer mast. Lower middle
mast 28 until main rollers 27 can be removed. Then, remove
the main rollers.
207814
11-17
MAST AND FORKS
5.3 Inspection and Repair

5.3.1 Mast
(1) Check the roller for wear, binding or crack.
(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.
204676
5.3.2 Lift bracket
(1) Check the main rollers and side rollers for sticking,
wear or cracks.
(2) Check the welded part of the lift bracket for cracks.
(3) Check the finger bars for bend or distortion.
Stan-
5 mm (0.2 in.)
Distortion of figer bar dard
or less
value
205517
5.3.3 Chain, Chain wheel, and Chain wheel support
(1) Check right and left chains for uneven length, wear,
adhesion, or distortion.
(2) Check the chain anchor bolt for cracks or defects on
thread.
(3) Check the chain wheel support and the chain wheel for
crack or wear, or adhesion.
Standard 635 mm (25 in.)/

Stretch of lift value 20 links
chains Repair or ser- 654 mm (25.7 in.)/
vice limit 20 links
11-18
MAST AND FORKS
5.3.4 Mast strip

Check for damage, chipping or distortion.

Thickness of mast
strip Repair or ser-
2.5 mm (0.1 in.)
vice limit
5.3.5 Fork
(1) Check the fork for bend, misalignment of tips, and
cracks.

Misaligned fork tips
value or less
(2) Check the forks for wear. If it exceeds the repair or ser-
vice limit, replace.
Truck model DP70E

Standard
60 mm (2.4 in)
value
Fork thickness 205518
Repair or 50 mm 54 mm
service limit (2 in.) (2.16 in.)
11-19
MAST AND FORKS
5.4 Removing lift cylinder high-pressure hose

Lower the mast to the bottom, then disconnect the hose from the flow regulator valve.
Suggestion for reassembly
5.4.1 Installing lift bracket roller (all mast models)
Shim
Thrust plate
Upper roller Middle roller
Lower roller Side roller

208729
Removal sequence
1 Lift bracket upper roller 6 Inner mast
2 Lift bracket middle roller F: Clearance between roller circumference and inner mst thrust surface (back-to-front play)
3 Lift bracket lower roller G: Clearance between roller side surface and inner mst thrust surface (right-to-left play)
4 Side roller G1: Clearance between side roller circumference and inner mast side roller thrust surface
5 Lift bracket
As shown in the above figure, the lift bracket has three main
roller bearings at one side and a side roller at both sides.
Clearances F and G must be maintained between these roll-
ers and thrust surface of the inner mast.
• Clearance F is used for determining the proper size of the
rollers.
1.0 mm (0.04 in.)

Clearance F
or less
• Clearance G is used for determining the correct amount of

shims at the bearing seat.
0.1 to 0.5 mm
Clearance G
(0.004 to 0.020 in.)
11-20
MAST AND FORKS
Roller size
Lift bracket middle/lower roller
Truck Model DP70E
S 149 mm (5.87 in.)
5 (Lift bracket) 6 (Inner mast)
Diameter of main
M 150 mm (5.91 in.)
roller
L 151 mm (5.94 in.)
(1) Selecting main rollers of the appropriate diameter Roller

Shim A stopper
NOTE
Shim B
Always use S-size rollers for the two middle rollers.
• As for upper roller 1 and lower roller 3, take measure-
ments of clearance F. Based on the measurements, select
rollers of the appropriate size from the table.
• Rollers should rotate smoothly after they are installed.
G 0.1 to 0.5 mm
(2) Measuring and adjusting right-to-left clearance G at lift
(0.004 to 0.020 in.)
bracket middle roller and lower rollers
• Measurement
Move lift bracket to the top of the inner mast and press the
208730
bracket to either the leftmost or rightmost position. Mea-
sure the clearance G between the side surface of roller and
inner mast.
• Adjustment
If clearance G is excessive, a proper amount of shims
should be added at location A and the same amount of
shims should be removed from location B, theoretically.
However, shims for location A are available in three
sizes: 0.5 mm (0.02 in.), 1.0 mm (0.04 in.), and 2.0 mm
(0.08 in.). Shims for location B are available in only one
size: 1.0 mm. When a 0.5 mm thick shim is added at loca-
tion A, there is no shim to replace at location B. There-
fore, it is not necessary to remove the shim at location B
[the 0.5 mm (0.02 in.) difference can be ignored].
NOTE
It is not necessary to adjust the lift bracket upper roller with
shims.
11-21
MAST AND FORKS
(3) Installation
To install main rollers on shafts, prepare a driving tool.
Be careful not to accidentally strike the outer roller sur-
face with the driving tool. The side of the roller with
larger chamfered area must face toward the outside.
Make sure the rollers rotate smoothly after they are
installed.
(4) Measuring and adjusting clearance G1 between side
roller and inner mast
• Measurement
Move side roller to the top of the inner mast and press the
lift bracket to either the leftmost or rightmost position.
202263
Measure the clearance G1 between the roller circumfer-
ence and inner mast. Side roller 0.2 to 1.0 mm
• Adjustment (0.008 to 0.039 in.)
5 (Lift bracket)
If the measurement of clearance G1 is excessive, add a
proper amount of shims under the seat of the roller
bracket. Roller mounting
bolt
Shim
4
(Side roller)
6
(Inner mast)
208731
11-22
MAST AND FORKS
5.4.2 Installing mast roller (all mast models)

Triple mast
Mast roller is identical in shape and size with lift bracket
Middle mast
lower roller. Therefore:
• Clearance F should be 1.0 mm [0.04 in.] or less.
• Clearance G should be 0.1 to 0.5 mm [0.004 to 0.020 in.].
For mast rollers, both clearances F and G should meet the Innner mast
specifications.
(1) Select appropriate roller size. Refer to “Selecting main
rollers of the appropriate diameter” on page 11-21. Outer mast
(2) Adjust to proper clearance. Refer to “Measuring and
adjusting right-to-left clearance G at lift bracket middle
Outer mast roller Middle mast upper roller
roller and lower rollers” on page 11-21. 208732
(3) The installation procedure and precautions are same as Outer mast roller and middle mast upper roller
those for the lift bracket main rollers.
Triplex mast
Inner mast Middle mast
Lift bracket
Outer
mast
208733A
Lift bracket, middle mast lower roller and inner mast
roller
5.4.3 Measuring and adjusting clearance G2
Outer mast
between mast strip and inner mast (all mast Shim
models)
• Measurement
Provided a clearance between the mast strip and inner
mast. Insert a thickness gauge to measure the clearance
G2.
Mast strip
0.1 to 0.5 mm
Clearance G2
(0.004 to 0.020 in.)
Inner mast
• Adjustment
If the measurement of clearance G2 is excessive, add a
proper amount of shims under the mast strip. Usually, a
1.0 mm (0.04 in.) thick shim is already used.
208734
11-23
MAST AND FORKS
5.4.4 Installing first lift cylinder (triplex mast model)

Adjust with shims so that the first lift cylinder becomes ver-
tical when it is installed and placed at the lowered position.
• Usually, a 1.0 mm (0.04 in.) thick shim is already used.
• Adjust shims to 1.0 mm (0.04 in.) thick.
• Forward inclination is undesirable. It should be rather
First lift sylinder
inclined rearward.
Shims
208735
5.4.5 Installing second lift cylinder (all mast models)

(1) Install cylinder bracket on lift cylinder.
(2) Install lift cylinder between outer mast and inner mast.
(3) Attach the upper part of the cylinder rod to the appro- Shim A
priate position on the inner mast. If shim A was
removed during disassembly, install shim A. Usually,
shim A is not used.
(4) With the cylinder rod fully retracted, take measurement

of clearance H. 206974
1.6 mm (0.063 in.)
Clearance H
or less
If clearance H is excessive, add shim B to adjust.

Usually, shim A is not used. 1.6 mm [0.063 in.] thick
shim is available as service parts.
(5) After reassembly, perform an operation test to check if
the stroke of the right and left cylinders is the same. For
the check procedure, refer to page 11-39.
Shim B
207003A
11-24
MAST AND FORKS
5.4.6 Installing chain on lift bracket
(1) (2) (3)
Link plate Link

Sprit pin
(B)
Standard
Center plate
mark
(A) (A)
213410
(1)Mast model 4P70B (simplex) (4)Mast model 4M70A, 4M70B (triplex), second chain
(2)Mast model 4P70C (simplex)
(3)Mast model 4M70A, 4M70B (triplex), first chain
(1) Install the chain to the lift bracket.

Be careful not to mistake the center plate and the link
plate. (Illustration (1))
(2) Set the chain over the chain wheel and then install it to
the cylinder. Adjust the chain tension using the anchor
bolt at the cylinder.
(3) Tighten the nuts to the torque specified in the following
table. (Illustration (2) and (3))
(4) If either of the anchor bolts at both ends of the chain
assembly is damaged, anchor kits are available as ser-
vice parts for replacement.
Truck Model DP70E

+49
176 0 N•m
+5.0
Nut (A) (18 0 kgf•m)
+36
[130 0 lbf•ft]
0
139 -19.6 N•m
0
Nut (B) (14.2 -2.0 kgf•m)
0
[103 -14.0 lbf•ft]
11-25
MAST AND FORKS
5.4.7 Inspection and adjustment

The inspection and adjustment in this chapter can be done
without dismounting or disassembling. Conduct inspection
whenever a defect is suspected.
Forks (all mast models)
Fork calipers perform two tasks at once.

OUTSIDE INSIDE They measure the thickness of the fork arm
JAWS JAWS shank (Fig. 1) and then automatically
100% 90% indicate what a 10% wear factor would be when
the calipers are applied to the blade cross section (Fig. 2).
NEW FORK ARM

SHANK CROSS
50 mm (2 in.) SECTION = 100%
Figure 1
Figure 2
REPLACE
FORK FORK WITH
OK 10% WEAR
Not for use on full tapered forks.

210995
Forks are often mistreated and forgotten. As insubstantial as forks–but what is contained in the drum or on the boom
they seem, neglecting forks could make them dangerous. hook makes the safety difference.
Forks carry larger loads than almost any lifting device but • Forks are often used to open rail car doors and break loads
there are no mandatory requirements for maintenance or out or away from other loads. They are also used to pick
inspection. up capacity loads not seated against the fork shank and to
You can find thousands of extra parts for lift trucks in some pick up off-balanced loads far from the side of the truck.
fleet repair shops, but you’ll seldom see spare forks. Even The fork tips are sometimes inserted under other fork
when all the trucks on the fleet are the same, fleet mainte- trucks to lift them during maintenance operations.
nance managers rarely order spare forks. Forks last a long • Lift trucks may collide with building columns and walls,
time if treated properly, but they can be deceiving by look- and though the forks show no discernible bend, they may
ing as good from most viewing angles when they are worn be damaged beyond safety.
as when they are new. • Any time excessive heat is applied to any part of a fork–
It’s true that most forks are customized to the truck by during repair, for instance–hidden damage may occur.
model and capacity: they are big and heavy and thought of The fork itself is a concern but so are the hooks that secure
as indestructible. But forks can be abused or ruined in the them to the lift carriage.
course of daily work.
Here are some examples of ways that forks can be damaged: DESIGNED TO TAKE A BEATING
• Forks can be overloaded either by picking up a load too Forks for counterbalanced and straddle lift trucks are not
far out on the forks, or simply by picking up loads heavier just bent bars of steel. The manufacturing process is careful
than the truck rating. and precise with many checks and inspections critical to
• Maintenance shops may bend forks back into shape, weld their safety. Some factors essential to fork manufacture
on them, or drill holes through them. Lift truck users can include the steel, the bend and thickness of the heel, the
add attachments to the truck that stress the forks. Drum welding of the hooks that hold them on the carriage, and the
clamps and portable booms can be supported on the heat treatment of the finished product.
11-26
MAST AND FORKS
6. Readjust.
6.1 Inspecting and Adjusting Chain Tension
6.1.1 Simplex Mast
WARNING
Turn the engine/main key to the O (OFF) position
before making the inspection or adjustment of lift Anchor bolt
chain, anchor bolt and nut. Place the wooden

blocks under the forks when they are raised. (2)Upper nut
(1) Inspecting chain tension

(a) Place the mast vertical on a level ground, then lower
(3)Double nut (upper)
the forks to the ground. Check that the lift cylinders are
fully retracted. (1)Double nut (lower)
(b) Raise the forks approximately 100 mm (4.0 in.) from
the ground. 102709
(c) Turn the key to the (OFF) position.
(d) Place the wooden blocks approx. 90 mm (3.5 in.) high
below the forks.
(e) Push the chain at the middle point between the chain
wheel and fixed end of the chain on the lift bracket.
Check the right and left chains for even tightness.
(2) Inspecting chain tension

(a) Place the wooden blocks laid under the forks. Turn the
key to (ON) position.
(b) Lower the forks to the ground and tilt the mast forward
until the fork tips touch the ground. The chains are now
slack to facilitate the adjustment.
(c) Turn the key to the (OFF) position.
(d) Loosen double nut (lower) (1), then upper nut (2).
(e) Turn the double nut (upper) (3) to adjust the chain ten-
sion.
(f) Turn the key to (ON) position, and make the mast
102708
vertical again.
(g) Repeat steps (b) through (e) to check the chain tension.
11-27
MAST AND FORKS
(3) Tightening of nuts after adjustment

(a) Hold the anchor bolt at two flats with a wrench so as
not to twist the chain, then tighten the upper nut (2) to
(b) Hold the double nut (upper) (3) with a wrench and
tighten the double nut (lower) (1) to the specified
torque.
40% or less
213408
(4) When the lift cylinder are fully extended or retracted,
check the protrusion of each lift bracket main roller to
be 40% of the roller diameter or less.
Tightening torque
Truck Model DP70E

Upper nut (2) 385 N•m
(39.3 kgf•m)
Double nut (lower) (1) [284 lbf•ft]
11-28
MAST AND FORKS
6.1.2 Triplex Mast
Turn nuts for

adjustment
Turn nuts for

adjustment
207635
The inspection and adjustment procedure are completely
the same as those for simplex mast models. Follow the pro-
cedures in the previous page to perform inspection or
adjustment as necessary.
6.1.3 Chain, Chain wheel support and Chain wheel
(1) Check the right and left chains for uneven length, wear,
adhesion, or distortion. Lift the forks high enough to
20 links
put their full weight on the carriage and chains. Check
for the lift chains having equal tension.
(2) Check the chain anchor bolt for cracks or damaged
thread.
(3) Check the chain wheel support and the chain wheel for 201768
cracks, wear, or adhesion.
(4) Replace chain or chain anchor bolts. If new parts are
installed for replacement, refer to “Installing chain on
lift bracket” on page 11-25.
11-29
MAST AND FORKS
NOTE
To lubricate lift chains, molybdenum disulfide oil (Spray
type) is recommended since it is easy to use and provides
long lubrication properties. Super chain guard oil: 9101M-
00150
Truck Model DP70E

Standard
635 mm (25 in.)
Length of chain value
(mm/20 links) Repair or
654 mm (25.7 in)
service limit
6.1.4 Checking Clearance between Lift Bracket

Lift bracket Inner mast
Roller and Inner Mast middle roller
NOTE
Lift bracket
The check procedure for the lift bracket is the same for the
Simplex mast and Triplex mast.
For the lift bracket to move smoothly, it is essential that the
following three kinds of clearance are within the specified
range.
(1) Clearance F between main roller circumference and Thrust plate
mast thrust surface a
208730
1.0 mm (0.04 in.)
Clearance F Typical relation between main roller and inner mast posi-
or less
tions
(2) Clearance G between roller side surface and mast *:Only the middle roller requires clearance to the thrust
thrust surface b plate.
0.1 to 0.5 mm
Clearance G
(0.004 to 0.020 in.)
(3) Clearance G1 between side roller circumference and

mast side roller thrust surface
0.1 to 0.5 mm
Clearance G1
(0.004 to 0.020 in.)
11-30
MAST AND FORKS
6.1.5 Necessity of clearance check for lift bracket

roller
Clearance Clearance F Clearance G

Upper roller require ** not require
Middle roller *** not require require
Lower roller require require
**:Not necessary to adjust. Roller structure allows no shim

adjustment.
***:Always use S-size rollers.
208731A
Relation between side roller and inner mast
(1) Back-to-front clearance check for lift bracket main

rollers
(a) Raise the forks a little from the floor.
(b) Insert a bar between the upper part of lift bracket and
the inner mast, and push the inner mast to one side.
Using feeler gauges, measure the clearance F between
the main roller and inner mast on the opposite side.
(c) If clearance F is out of specification, it is necessary to
use other rollers with a greater size. If this is the case,
remove the lift bracket from the mast, and replace the
rollers with an increased size. For this roller replace-
207095
ment procedure, refer to “Installing lift bracket rollers”
on page 11-19 and 11-20.
(2) Right-to-left clearance check for lift bracket main roll-

ers and side rollers
(a) Raise the mast to the top.
(b) Set a dial indicator for such a point on the inner mast
that may come in contact with the side of the lift
bracket.
(c) Move to the opposite side of the mast and push the lift
bracket to one side with a bar. Set the indicator to zero.
(d) Insert a bar between the inner mast and the dial indica-
tor-side lift bracket, and push the lift bracket to the
opposite side.
203818
11-31
MAST AND FORKS
(e) Read the dial indicator.

This reading is the clearance G between the middle (1)
(1)
roller and thrust plate (2).
(f) If the clearance G is out of specification, it is necessary
to add shims to the seat of the roller to adjust to correct
(2) (2)
clearance. Remove the lift bracket from the mast and
adjust the amount (thickness) of shims for the rollers.
For the adjustment and installation procedure refer to
“Installing lift bracket rollers” on page 11-22.
207821
(1) Upper roller (2) Thrust plate
(g) Lower the lift bracket slightly from the top, then check
clearance G1 for the side rollers.
If the clearance G1 is out of specification, it is neces- Side roller
sary to add shims to the seat of the roller bracket to
adjust to correct clearance. Remove the lift bracket
from the mast and adjust the amount (thickness) of
shims for the rollers. For the adjustment and installa-
tion procedure refer to “Installing lift bracket rollers”
on page 11-20.
206687A
(h) With the lift bracket raised to the top, check clearance
NOTE
G.
If the clearance G is out of specification, it is necessary The lower main rollers are the same to the middle main roll-
ers in construction.
clearance. Remove the lift bracket from the mast and
adjust the amount (thickness) of shims for the rollers.
“Installing lift bracket rollers” on page 11-20.
207822
11-32
MAST AND FORKS
6.1.6 Inspecting Clearance for Mast Roller
NOTE
• Adjust mast clearances at the locations indicated
below.
1.Simplex Mast: Main rollers between outer mast and
inner mast
2.Triplex mast: Main rollers between outer mast and
middle mast, and main rollers between middle
mast and inner mast.
• For the structure, refer to page 11-14.
Regardless of the mast model, the inner mast slides up and
down as guided by the outer mast. The mast rollers should Triplex mast
move smoothly and the two clearance locations are within Inner mast Middle mast
specified range. Lift brackt
(1) Clearance F between main roller circumference and
mast thrust surface a
Outer
1.0 mm (0.04 in.) mast
Clearance F
or less
(2) Clearance G between roller side surface and mast chan-

nel surface b
0.1 to 0.5 mm 208733

Clearance G
(0.004 to 0.020 in.) Lift bracket, middle mast lower roller and inner mast
roller
Check each clearance between the mast rollers and mast

channels as follows:
(1) Back-to-front clearance check on mast main rollers
(a) Tilt the mast fully backward. F
(b) Using feeler gauges, measure the clearance F between
the inner mast lower roller and outer mast.
(c) If clearance F is out of specification, it is necessary to
use other rollers with a greater size.
“Installing mast rollers” on page 11-23. For the removal
procedure of mast rollers refer to “Removing mast roll-
ers” on page 11-36.
207099
11-33
MAST AND FORKS
(2) Right-to-left clearance inspection on inner mast main

rollers
(b) Set a dial indicator for such a point on the inner side of
the outer mast that may come in contact with the inner
mast.
(c) Move to the opposite side of the mast and push the
inner mast to the outer mast. Set the indicator to zero.
(d) Insert a bar between the outer mast and the dial indica-
tor-side inner mast, and push the inner mast to the
opposite side.
204886
This reading is the clearance G between the inner mast
roller and outer mast.
(f) If the clearance G is out of specification, it is necessary
clearance. For the adjustment and installation proce-
dure refer to “Installing mast rollers” on page 11-23.
For the removal procedure of mast rollers refer to
“Removing mast rollers” on page 11-36.
11-34
MAST AND FORKS
(3) Right-to-left clearance inspection on outer mast main

rollers
(b) Set a dial indicator for such a point on the outer mast
that may come in contact with the inner mast.
(c) Move to the opposite side of the mast and push the
inner mast to the outer mast. Set the indicator to zero.
(d) Insert a bar between the outer mast and inner mast, and
push the inner mast to the opposite side.
This reading is the clearance G between the outer mast
204889
roller and inner mast.
(f) If this clearance G is out of specification, it is necessary
to adjust the clearance by the amount of shims.
To adjust to correct clearance, it is necessary to add or
remove shim(s) at the seat of the roller. For the adjust-
ment and installation procedure refer to “Installing mast
rollers” on page 11-23. For the removal procedure of
mast rollers refer to “Removing mast rollers” on page
11-36.
11-35
MAST AND FORKS
6.2 Removing mast rollers (simplex mast)

6.2.1 Separate the lift bracket from the mast.
NOTE
For the removal procedure of lift bracket refer to “Remov-
ing lift bracket” on page 11-8.
6.2.2 Removing mast rollers
(1) Raise the front end of the truck, and support that end
with block or the like.
(2) Remove the upper set bolt from the lift cylinders, and
lift the inner mast with a hoist. Remove the hose guard.
(3) Remove the clamps from the first lift cylinders. Pull out
the bottom ends of the cylinders from the outer mast,
tilt the cylinders to the center of the mast, and tie them
to the cross-member of outer mast with rope.
(4) Slowly lower the inner mast until it comes in contact
with the lift cylinder.
(5) Now the main rollers can be removed from the inner
and outer masts. Remove the mast strips and shims in
advance because they are apt to come off under this
condition. 213141
11-36
MAST AND FORKS
6.3 Removing mast rollers (triplex mast)

6.3.1 Separate the lift bracket from the mast.
NOTE
For the removal procedure of lift bracket refer to “Remov-
ing lift bracket” on page 11-8.
6.3.2 Removing first lift cylinder.
(1) Hitch a sling on the first lift cylinder, and suspend it
with a crane. Wind the sling securely to prevent from
slipping.
(2) Remove cylinder bolt connecting bolts and mounting
bolts, and carefully remove the first lift cylinder.
First lift
cylinder
207787
6.3.3 With the following procedure lower the inner

mast so it takes a lower position than the mid-
dle mast.
(1) Raise the front end of the truck, and support that end
with block or the like.
(2) Hitch a sling on the upper cross-member of the inner
mast, and suspend it with a crane.
(3) Remove the chain guards for the second lift chain
wheels.
(4) Dismount the second lift chains on the outer mast side,
and place them in front of the inner mast.
(5) Lower the inner mast until main rollers can be 207826
removed.
(6) Place wooden blocks under the inner mast for support.
(7) Now the main rollers can be removed from the inner
and outer masts. Remove the mast strips and shims in
advance because they are apt to come off under this
condition.
NOTE
However, under this condition, the second lift cylinder can
not be dismounted.
11-37
MAST AND FORKS
6.3.4 With the following procedure lower the middle

mast so it takes a lower position than the outer
mast.
(1) Raise the inner mast to the height of the middle mast,
then place wooden blocks for support.
(2) Hitch slings to both middle mast and inner mast, and
suspend them with a crane.
(3) Remove set bolts from the upper sections of the middle
mast cylinders, then lift the middle mast and inner
mast.
(4) Remove two lift cylinder clamps, dismount the cylin-
ders from the mounting sections at the lower outer mast
section. Tilt the cylinders by moving the top sections
towards the center of the truck, then secure the cylin-
ders to the cross-member of the outer mast with a rope.
(5) Lower the middle and inner masts until main rollers
can be removed.
(6) Place wooden blocks under the middle mast and inner
mast for support them.
(7) Remove the mast strips and shims in advance because
they are apt to come off under this condition.
207827
11-38
MAST AND FORKS
6.3.5 Inspecting and Adjusting Mast Strip Clearance

(1) Check clearance G2 with the clearance between the
outer mast rollers and inner mast set to zero (0) at the
maximum lift position.
0.1 to 0.5 mm
Clearance G2
(0.004 to 0.020 in.)
(2) If the clearance G2 is out of specification, remove the

upper mast rollers (refer to “Removing mast rollers”).
Remove the mast strips, then adjust the clearance at
each section concerned. For the adjustment procedure,
refer to “Measuring and adjusting clearance G2 200391
between mast strip and inner mast” on page 11-23.
(3) After adjusting all clearance items, move the mast and
lift brackets slowly to make sure that they move
smoothly across the full stroke range.
6.3.6 Tilt Angle Adjustment

(1) Regulate the inflation pressure for all the wheels, then
park the truck on a level floor.
(2) Tilt the mast fully backward and stop the engine.
(3) Measure the backward tilt angle of the mast at both
sides. Tilt socket pin
(4) To adjust the tilt angle, loosen the bolt of tilt cylinder
socket, and turn the rod to adjust its length. The tilt cyl-
inders should be adjusted in such that the right and left
cylinders have no difference in the stroke to generate
each tilt angle.
NOTE 206532
It is not necessary to adjust the forward tilt angle if the

backward tilt angle is properly adjusted.
(5) After adjusting the tilt angle, tighten the socket bolts to
539 ± 49 N•m
Tightening torque for tilt cylin-
(55 ± 5 kgf•m)
der socket lock-nut
[398 ± 36 lbf•ft]
Standard tilt angle
Mast Models Forward Backward

4.5 m (14.8 ft)
Simplex 6˚ 10˚
or less
mast, lift-
ing height 4.5 m (14.8 ft)
6˚ 6˚
or more
Triplex Mast 6˚ 6˚
11-39
MAST AND FORKS
6.3.7 Inspecting and Adjusting Lift Cylinder Stroke

(1) While observing each motion of the right and left pis-
ton rods, slowly raise the inner mast and stop it at the
moment when it reaches the maximum height.
(2) If the top of the inner mast jolts at that moment, under-
take shim adjustment. Abnormal condition can be
detected by a little time lag in stopping between the
right and left piston rods, and shaking of the rod with a
longer cylinder stroke.
(3) Adjusting method 204698

(a) Raise the inner mast, place blocks under the right and
left sides of the inner mast, and lower the mast until it
rests on the blocks.
(b) Remove the set bolt located at the top of the lift cylin- 202983
der which can be seen at the early stage of stroke,
retract the piston rod, and insert shims at the top end of
the piston rod.
(c) Extend the piston rod, and tighten the cylinder set bolt.
Shim A
Remove the blocks from under the inner mast.
(d) Slowly lower the inner mast to the bottom to ensure
that the piston rods move smoothly and that the right
and left cylinders come to the end of stroke simulta-
neously.
206974
11-40
MAST AND FORKS
7. Troubleshooting
a) Clearance between lift rollers and side rollers incor- • Readjust clearance.
rect
Lift bracket and inner b) Rollers binding on their shafts • Relubricate or replace.
mast will not move
smoothly c) Lift chains strained in movement • Relubricate or replace.
• Shim adjust. 0.1 to 0.5mm (0.004 to 0.020
d) Mast strip clearance incorrect
in.)
• Readjust by means of shims. 0.1 to 0.5mm
a) Too much clearance on side rollers
(0.004 to 0.020 in.)
Lift bracket or inner mast
binds b) Lift chains unequally tensioned • Readjust.
c) Shim adjustments unequally made on between right • Readjust.
and left lift cylinders (at maximum height)
Mast makes noise • Rollers not rotating smoothly on their shafts • Relubricate of replace.
a) Lift cylinder packing damaged • Replace.
Load descends (drift) b) Sliding (inside) surface of lift cylinder tube dam- • Replace.
aged
Whole mast shakes • Mast support bushings worn • Retighten or replace.
Mast is distorted • Off-center loading or overload • Replace mast assembly.
a) Finger bar bent • Repair or replace.
Fork tips differ in height b) Fork bent • Repair or replace.
c) Un-even loading • Repair or replace.
• Low oil temperature • Increase oil temperature to 40 to 50˚C (104
to 122˚F.
Second lift cylinders
operate while first lift • Insufficient clearance between lift bracket rollers • Readjust rollers.
cylinder is moving (Tri- and sliding surfaces
plex mast). • Pipe clogged • Inspect and clean hydraulic lines.
• Insufficient air bleeding • Bleed air completely.
Lift bracket is spongy • Insufficient air bleeding • Bleed air completely.
when it stops in lifting
operation.
11-41
MAST AND FORKS
8. Service Data
Truck Model DP70E

Standard
Unevenness of fork tip height 5 mm (0.2 in.) or less
value
Standard
60 mm (2.4 in)
value
Fork thickness
Repair or ser-
50 mm (2.0 in) 54 mm (2.1 in.)
vice limit
Standard
635 mm (25 in.)/20 links
value
Stretch of lift chains
Repair or ser-
654 mm (25.7 in.)/20 links
vice limit
385 N•m
Tightening torque of lock nut (double nut) for chain Standard
(39.3 kgf•m)
anchor bolts (both ends) value
[284 lbf•ft]
Standard
S-size 149 mm (5.87 in.)
value
Main roller external diameter Standard
M-size 150 mm (5.91 in.)
(for lift bracket and mast) value
Standard
L-size 151 mm (5.94 in.)
value
Standard 0 0
Side roller external diameter 58 -0.1 mm (2.28 -0.004 in.)
value
Standard
Width of outer mast B 890 mm (35.0 in.)
value
Standard
Simplex mast Width of inner mast B2 722 mm (28.4 in.)
value
Standard
Width of lift bracket C 564 mm (22.2 in.)
value
Standard
Width of outer mast B 890 mm (35.0 in.)
value
Standard
Width of middle mast B1 752 mm (29.6 in.)
value
Triplex Mast
Standard
Width of inner mast B2 624 mm (24.6 in.)
value
Standard
Width of lift bracket C 466 mm (18.3 in.)
value
Clearance F between main roller
Standard
circumference and mast thrust sur- 1.0 mm (0.04 in.)
value
face
Mast Clearance G between main roller Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
side surface and mast thrust surface value
Clearance G2 between inside mast Standard
0.1 to 0.5 mm (0.004 to 0.020 in.)
and mast strip value
11-42
MAST AND FORKS
Clearance F between upper and

Standard
lower roller circumference and 1.0 mm (0.04 in.)
value
inner mast thrust surface
Clearance G between middle roller
Standard
side surface and inner mast thrust 0.1 to 0.5 mm (0.004 to 0.020 in.)
value
plate
Lift bracket
Clearance G between lower roller
Standard
side surface and inner mast thrust 0.1 to 0.5 mm (0.004 to 0.020 in.)
value
surface
Clearance G1 between side roller
Standard
circumference and inner mast sur- 0.1 to 0.5 mm (0.004 to 0.020 in.)
value
face
Standard
Bend of finger bar 5.0 mm (0.2 in.)
value
Standard
Tightening torque of mast cap mounting bolts 490 ± 49 N•m (50 ± 5.0 kgf•m) [362 ± 36.2 lbf•ft]
value
11-43
MAST AND FORKS
Lift bracket
Simplex mast Triplex mast
208742
11-44
FORK POSITIONER
1. Applicable Attachment Models................................................................................... 12-2
2. Specifications ............................................................................................................. 12-2

1
3. Structure..................................................................................................................... 12-3
4. Suggestions for Removal and Installation.................................................................. 12-4 2

4.1 Removal.............................................................................................................................................. 12-4
4.1.1 Preparation................................................................................................................................................ 12-4
3
4.2 Inspection and Repair ......................................................................................................................... 12-6
4.2.1 Lift bracket................................................................................................................................................. 12-6 4
4.2.2 Fork ........................................................................................................................................................... 12-6
4.2.3 Hose.......................................................................................................................................................... 12-6
4.3 Installation........................................................................................................................................... 12-7
5
4.3.1 Suggestions for Installation ....................................................................................................................... 12-7
6
5.1 Disassembly........................................................................................................................................ 12-8
5.1.1 Disassembly sequence ............................................................................................................................. 12-8 7
5.1.2 Suggestion for disassembly ...................................................................................................................... 12-9
5.2 Inspection and Repair ......................................................................................................................... 12-9
5.2.1 Cylinder tube ............................................................................................................................................. 12-9
8
5.2.2 Piston rod .................................................................................................................................................. 12-9
5.3 Reassembly ...................................................................................................................................... 12-10 9
5.3.1 Reassembly sequence............................................................................................................................ 12-10
5.3.2 Suggestion for reassembly...................................................................................................................... 12-11
5.4 Inspection and Adjustment................................................................................................................ 12-11 10
5.4.1 Inspecting right and left shift amounts..................................................................................................... 12-11
11
7. Service Data............................................................................................................. 12-13 12

7.1 Fork positioner cylinder..................................................................................................................... 12-13
13
14
12-1
FORK POSITIONER
1. Applicable Attachment Models
Attachment model Truck Models Covered Applicable mast model Mast piping
4MP70BVH (hand-operated)
DP70E 4V70C Inner
4HP70BVH (hydraulic)
2. Specifications
Attachment model 4MP70BVH (hand-operated) 4HP70BVH (hydraulic)

Positioner cylinder
– 640 mm (25.2 in.)
stroke (in each of right and left directions)
Loading center 600 mm (23.6 in)
Free lift 205 mm (8.0 in.)
Outside fork spread (maximum) 1600 mm (63.0 in.) 1595 mm (62.8 in.)
Outside fork spread (minimum) 300 mm (11.8 in.) 315 mm (12.4 in.)
Mast tilt angle (forward - backward) 6˚ to 12˚
Fork length (width × thickness) *Standard
1220 mm (48.1 in.) [150 mm (5.9 in.) × 65 mm (2.6 in.)]
specification
Front overhang 590 mm (23.3 in.)
Attachment weight *Including standard
300 kg (661 lb) 350 kg (772 lb)
fork.
12-2
FORK POSITIONER
3. Structure
209345
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 changed frequently to ensure the 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.
Each fork positioner cylinder is attached to the correspond-
ing fork prong and lift bracket, and slides the fork prong
sideways by extending or retracting itself.
The right and left fork prongs can shift independently.
12-3
FORK POSITIONER

4.1 Removal (3) Raise the mast vertically and lower the fork down to
4.1.1 Preparation the pallet for easy removal.
(4) Place the wooden blocks under the lift bracket.
(1) Park the fork lift truck on a flat, level and solid ground.
(5) Stop the engine, and move the fork positioner lever
(2) Start the engine, and fully compress the fork positioner
back and forth several times so that the remaining pres-
cylinder.
sure in the lines is completely removed.
209348
1 Main roller 4 Hose (cylinder side)

2 Side roller 5 Fork positioner cylinder
3 Lift bracket 6 Fork
12-4
FORK POSITIONER

(1) Removing hydraulic hoses
(a) Prepare containers to receive oil, which should remain
in the cylinder and hydraulic hoses.
(b) Disconnect hoses (4 pieces) from the pulleys at the
positions shown.
(c) Remove the split pins from the lift chain, and remove
the anchor nut and lock nut.
209347
(2) Removing fork positioner cylinder
(a) Remove the cylinder rod from its connector while exer-
cising care not to damage the threaded part.
NOTE
This removal is recommended to be performed with the cyl-
inder rod fully retracted.
(3) Removing forks
(a) Connect to fork 6 a wire rope with a vise-type clamp
attached on both ends to hold each prong, and strain the
rope using the crane.
(b) Start the engine and raise the lift bracket to a height
(about 25 mm [0.98 in.] above the bottom) at which the 210553
heel hold part of fork 6 becomes free, then back the
truck away.
(c) Combine the removed forks 6 (2 pieces) together and
tie them with a rope, etc. to prevent them from falling.
Then, move it to a safe place.
(d) Place the supporting wooden blocks under the lift
bracket.
12-5
FORK POSITIONER
(4) Removing lift bracket

(a) Remove the split pins from the lift chain, and remove
(b) Remove the lift bracket with the following procedure.
• Bind the ends of the two lift chains with a rope, etc. Leave
an extra 3 m (10 ft) length at the ends of the rope.
• Bind the four hoses in the same manner with a rope, leav-
ing an extra 3 m (10 ft) length at the ends of the rope.
• Start the engine and raise the inner mast up to a position
where the main rollers of the lift bracket come off. At this
point, pull the lift chains and hoses taut by drawing the
attached rope downward to prevent them from coming off
from the chain wheels or hose reels.
• When the inner masts reach to the position where the
main rollers of the lift bracket can be removed, reverse the
truck, and separate the lift bracket from the truck.
CAUTION
When the masts are rising, never touch any con-
trol levers except the lift lever.
213109

4.2.1 Lift bracket
(1) Check the main rollers and side rollers for sticking,
wear or cracks.
(2) Check the welded part of the lift bracket for cracks.
(3) Check the guide bars whether they are bent or
deformed.
4.2.2 Fork
(1) Check the fork for bend, misalignment of tips, and
cracks.
4.2.3 Hose
(1) Replace the hoses every two years.
12-6
FORK POSITIONER
4.3 Installation
Replacement must follow the reverse order of removal.
4.3.1 Suggestions for Installation
(1) Driving in main roller
(a) For this operation use a driving jig and exercise care
not to hit the outer ring of the roller.
(2) Installing lift chains
(a) Lift chains can be replaced as-is unless the positions of
the upper lock nuts are modified. Tighten the lock nuts
and anchor nuts to each specified torque.
385 N•m
Nut tightening torque (39.3 kgf•m)
[284 lbf•ft]
(3) Adjusting hose tension

(a) The tension of each hose should be 196 N (20 kgf)
[44.1 lbf].
12.5 mm
When the midpoint of a 1 m (3.3 ft.) long hose is (0.49 in.)
pushed with a force of 9.8 N (1.0 kgf) [2.2 lbf], its ten- 9.8 N
(1.0 kg)
sion is appropriate if it deflects approx. 12.5 mm (41.3 [2.2 lbf]
ft).
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 (6.6 ft) from the
pulley to the bottom joint when the mast is raised to the
highest position, the tension of the hose is acceptable if
213413
it deflects when the hose is pushed with a force of 9.8
N (1.0 kg) [2.2 lbf].
12-7
FORK POSITIONER

5.1 Disassembly
209351
5.1.1 Disassembly sequence

1 Guide bushing 6 Self-locking nut
2 O-ring 7 Piston
3 Dust seal 8 O-ring
4 Rod packing 9 Piston rod
5 Backup ring 10 Cylinder tube
12-8
FORK POSITIONER
5.1.2 Suggestion for disassembly

(1) Removing guide bushing
Wrap the cylinder tube with a piece of waste cloth, and
hold it in a vise. Remove the guide bushing with Hook
Wrench A.
Special tool
Hook wrench A 05312-10600
213411
5.2.1 Cylinder tube
(1) Check the inside surface of the cylinder for wear, dam-
age, or rust.
(2) Check the welded part for cracks, damage, and dent.
5.2.2 Piston rod
(1) Check the piston rod for runout.
(2) Check the rod surfaces for rust, damage, sliding trace,
and dent. 200319
threaded part.
Attachment model 4HP70BVH

Standard
Inside diameter of cylinder tube 1 45 mm (1.77 in.)
value
Standard
Piston rod 2 25 mm (0.98 in.)
value
Standard
Stroke 3 640 mm (25.08 in.)
value
Standard
Overall length when retracted 4 853 mm (33.46 in.)
value
Standard
Tightening torque of guide bushing 5 250 N•m (25.5 kgf•m) [184 lbf•ft]
value
Standard
Tightening torque of self-locking nut 6 200 N•m (20.4 kgf•m) [148 lbf•ft]
value
Standard
0.5 mm (0.020 in.) or less
Runout of piston rod 7 value
Limit 1.0 mm (0.039 in.) or less
NOTE
For the index numbers after the items refer to the illustra-
tion on the next page.
12-9
FORK POSITIONER
209352
5.3 Reassembly
Reassemble the alternator in the reverse order of the disas-
sembly procedure.
8 6 7 9 2
5 3 1 4
213412
5.3.1 Reassembly sequence

1 Piston 6 Guide bushing
2 Piston seal 7 Rod packing
3 Piston rod 8 Dust seal
4 Self-locking nut 9 O-ring
5 Cylinder tube
12-10
FORK POSITIONER
5.3.2 Suggestion for reassembly

(1) Preparation
(a) During reassembly, do not forget to replace the Seal Kit
parts marked with an asterisk (*) in the figure.
(b) Thoroughly clean all parts before reassembly making
sure they are completely free from dirt or dust.
(2) Tightening of self-locking nut
Insert piston 1 into piston rod 3, and tighten self-locking
nut 4 to the specified torque.
Tightening torque 200 N•m (20.4 kgf•m) [148 lbf•ft]
NOTE
If the self-locking nut has been used two or three times,
replace it with a new one.
(3) Insertion of rod packing and dust seal
(a) Insert rod packing 7 into guide bushing 6 with the main
lip facing inward.
(b) Insert dust seal 8 into the guide bushing with the main
lip facing outward.
(4) Tightening of guide bushing
(a) Tighten guide bushing 6 to the specified torque.
Tightening torque 250 N•m (25.5 kgf•m) [184 lbf•ft]
(b) Caulk the cylinder tube at the guide bushing.
210561
5.4 Inspection and Adjustment
5.4.1 Inspecting right and left shift amounts
After reassembly, make sure that both the right and left
forks can move across their full stroke within each frame.
12-11
FORK POSITIONER
6. Troubleshooting
• Insufficient oil in hydraulic tank • Add hydraulic oil.

• Too low gear pump delivery rate • Replace pump assembly.
• Port relief valve defects:
(1) Too low valve opening pressure setting • Adjust port relief valve.
(2) Defective pilot valve seat surface or foreign matter • Replace port relief valve assembly or dis-
Shifts of right and left in valve assemble and clean it.
fork prongs too slow or
sluggish (3) Damaged valve housing O-ring • Replace O-ring.
• Cylinder defects:
(1) Foreign matter lodged in rod packing • Replace rod packing.
(2) Scratches on bore of rod packing • Replace rod packing.
(3) Damaged piston seal • Replace piston seal.
(4) Deformation • Replace.
Unsmooth shifts of fork: • Scars on lift bracket to fork contact surfaces • Repair and apply grease.
(1) Jamming • Scars on guide surface of forks • Repair and apply grease.
(2) Too much looseness
• Bent fork • Replace.
Misaligned fork tips • Uneven loading • Instruct operator to handle only loads
within indicated capacity.
12-12
FORK POSITIONER
7. Service Data
7.1 Fork positioner cylinder
Attachment model 4HP70BVH
Standard
value
Standard
value
Standard
Stroke 3 640 mm (25.08 in.)
value
Standard
value
Standard
Tightening torque of guide bushing 5 250 N•m (25.5 kgf•m) [184 lbf•ft]
value
Standard
Tightening torque of self-locking nut 6 200 N•m (20.4 kgf•m) [148 lbf•ft]
value
Standard
0.5 mm (0.020 in.) or less
value
Runout of piston rod 7 Repair or
service 1.0 mm (0.039 in.) or less
limit
209352
12-13
SIDE SHIFTER
1. Applicable Attachment Models................................................................................... 13-2
2. Specifications ............................................................................................................. 13-2

1
3. Structure..................................................................................................................... 13-3
4. Suggestions for Removal and Installation.................................................................. 13-4 2

4.1 Removal.............................................................................................................................................. 13-4
4.1.1 Removing forks ......................................................................................................................................... 13-4
4.1.2 Removing side shifter assembly ............................................................................................................... 13-4
3
4.2 Installation........................................................................................................................................... 13-5
4.2.1 Suggestions for Installation ....................................................................................................................... 13-5 4
5.1 Side shifter assembly.......................................................................................................................... 13-6
5
5.1.1 Disassembly.............................................................................................................................................. 13-6
6
5.1.3 Reassembly .............................................................................................................................................. 13-8
5.2 Side shift cylinder................................................................................................................................ 13-8
5.2.1 Disassembly.............................................................................................................................................. 13-8 7
5.2.3 Reassembly ............................................................................................................................................ 13-10
5.2.4 Inspection and Adjustment...................................................................................................................... 13-11
8
6. Troubleshooting ....................................................................................................... 13-12 9
7. Service Data............................................................................................................. 13-13
7.1 Side shift cylinder.............................................................................................................................. 13-13 10
11
12
13
14
13-1
SIDE SHIFTER
1. Applicable Attachment Models
Applicable mast
Attachment model Truck Models Covered Mast piping
model
4SS70BVH DP70E 4V70C Inner pulley
2. Specifications
Attachment model 4SS70BVH

Side shift stroke (in each of right and left directions) 140 mm (5.5 in.)
Loading center 600 mm (23.6 in.)
Free lift 0 mm (0 in.)
Outside fork spread (maximum) 1600 mm (63.0 in.)
Outside fork spread (minimum) 300 mm (11.8 in.)
Mast tilt angle (forward - backward) 6˚ to 12˚
Fork length (width × thickness) *Standard specification 1220 (150 × 65) mm [48.1 (5.9 × 2.6) in.]
Front overhang 680 mm (26.8 in.)
Attachment weight
330 kg (728 lb)
*Including standard fork.
13-2
SIDE SHIFTER
3. Structure
209424
1 Lift bracket 4 Guide bar

2 Main roller 5 Side shift cylinder
3 Carriage 6 Fork
Horizontal shift of the fork can be implemented by the car-

riage placed in front of the lift bracket via hydraulic cylin-
ders, which contracts or expands for the carriage to slide in
either right or left direction.
It is sometimes hard for a large lift truck to access to the
best position required for loading or unloading. A lift truck,
if provided with the side shifter, can slide its fork which
currently carries some load on without further relocating
itself, resulting that the loading work efficiency is greatly
improved.
13-3
SIDE SHIFTER

4.1 Removal
4.1.1 Removing forks Lift bracket
Guide bar
(1) Attract both the right and left forks to the center.
(2) Lower the forks down onto a pallet for easy removal.
(3) Remove the plate and pull out the guide bars.
(4) Start the engine and raise the carriage to such a height
(about 25 mm above the bottom) at which the heel hold
part of the fork comes off, then back the truck away.
(5) Combine the removed forks 6 (2 pieces) together and
tie them with a rope, etc. to prevent their fall. Then,
move it to a safe place.
(6) Place the supporting wooden blocks under the lift Plate
bracket and the carriage.
Carriage
209425
4.1.2 Removing side shifter assembly

(1) Remove the hose from the pulley.
(2) Remove the split pins from the lift chain, and remove
(3) Remove the side shifter assembly with the following
procedure.
(a) Bind the ends of the two lift chains with a rope, etc.
Leave an approximately 1 m (3.3 ft) long extras at the
ends of the rope.
(b) Bind the two hoses in the same manner with a rope,
leaving an approximately 1 m (3.3 ft) extras at the ends
of the rope. 210567
13-4
SIDE SHIFTER
(c) Start the engine and raise the inner mast up to a posi-
tion where the main rollers of the lift bracket come off.
At this point, pull the lift chains and hoses taut by
drawing the attached rope downward to prevent them
from coming off from the chain wheels or hose reels.
(d) When the inner masts reach to the position where the
main rollers of the lift bracket can be removed, reverse
the truck, and separate the lift bracket from the truck.
WARNING
When the masts are rising, never touch any con-
trol levers except the lift lever.
213110
4.2 Installation
Replacement must follow the reverse order of removal.
4.2.1 Suggestions for Installation
(1) Installing lift chains
(a) Lift chains can be replaced as-is unless the positions of
the upper lock nuts are modified.
Tighten the lock nuts and anchor nuts to each specified
torque.
385 N•m
Tightening torque (39.3 kgf•m)
[284 lbf•ft]
(b) Raise the forks slightly from the ground and try to push
the middle point of the right and left chains alternately 12.5 mm
to make sure that the tensions of the two chains are (0.49 in.)
9.8 N
even. (1.0 kg)
(2) Adjusting hose tension [2.2 lbf]
(a) The tension of each hose should be 196 N (20.0 kgf)
[44.1 lbf].
When the midpoint of a 1 m (39.4 in.) long hose is
pushed with a force of 9.8 N (1.0 kgf) [2.2 lbf], its ten-
sion is appropriate if it deflects approx. 12.5 mm (0.49
in.).
213413
Adjust tension according to the length of hoses which
differs with the raised height of the mast.
Example: If the hose length is 2 m (6.6 ft) from the pul-

ley to the bottom joint when the mast is raised to the
highest position, the tension of the hose is acceptable if
the hose deflects approx. 25 mm when the midpoint of
the hose is pushed with a force of 9.8 N (1.0 kgf) [2.2
lbf].
13-5
SIDE SHIFTER

5.1 Side shifter assembly (b) Prepare containers to receive oil, which should remain
5.1.1 Disassembly in the cylinder and hydraulic hoses.
(1) Preparation
(a) Place the fork positioner assembly removed from the
truck on wooden blocks with the lift bracket on the bot-
tom side.
Lift bracket
209427

1 Hose (cylinder side) 6 Bushing
2 Joint 7 Carriage
3 Bolt 8 Pin
4 Guide bar 9 Side shift cylinder
5 Stopper plate 10 Shifter roller
13-6
SIDE SHIFTER

(a) Removing carriage
• Hoist the carriage with ropes at 3 places, i.e. two guide
bar mounting holes (for each of the right and left sides)
and middle lower plate, and support it with crane.
• Lift the carriage to a height at which a part of the carriage
fit in the lift bracket can come off, and move to the direc-
tion of the shown arrow. Once the fitting is cleared, lift
further the carriage to remove it from the lift bracket. Move and lift
carrier up.
(b) Removing pipe and hose
Disconnect the hoses from each connection to the cylin-
der, and remove the pipes as being secured on the plate
together with the hoses.
(c) Removing side shifter
Remove the side shifter while exercising care so as not
to damage the threaded part of the cylinder rod and con-
nector.
This removal is recommended to be performed with the
Disengage by lifting
cylinder rod fully retracted. carrier up.
209428

(a) Lift bracket
• Check the main rollers and side rollers for sticking, wear
or cracks.
• Check the welded part of the lift bracket for cracks.
• Check the guide bars whether they are bent or deformed.
(b) Fork
• Check the fork for bend, misalignment of tips, and cracks.
(c) Hose
• Replace the hoses every two years.
(d) Carriage
• Check the welded part for cracks.
• Check the sliding surfaces for scoring.
• Check the fork shift screw bushing bore for damage.
• Check the fork shift screw threads for damage or wear.
13-7
SIDE SHIFTER
5.1.3 Reassembly
Reassemble the alternator in the reverse order of the disas-
sembly procedure.
(a) Driving in main roller
For this operation use a driving jig and exercise care not
to hit the outer ring of the roller.
5.2 Side shift cylinder

5.2.1 Disassembly
209429
1 Cylinder head 6 Dust seal
2 Piston rod 7 Packing
3 Self-locking nut 8 O-ring
4 Piston 9 Cylinder tube
5 Piston seal
NOTE
13-8
SIDE SHIFTER

(a) Removing cylinder head
Wrap the cylinder tube with a piece of waste cloth, and
hold it in a vise. Remove the snap ring with Ring Puller.
(1) Cylinder tube
age, or rust.
(2) Piston rod

(b) Check the rod surfaces for rust, damage, sliding trace, 200319
and dent.
threaded part.

Standard
value
Standard
value
Standard
Stroke 3 280 mm (11.02 in.)
value
Standard
value
Standard
0.5 mm (0.020 in.) or less
Runout of piston rod 5 value
Limit 1.0 mm (0.039 in.) or less
NOTE
For the index numbers after the items refer to the illustra-
tion in the next page.
13-9
SIDE SHIFTER
209430
5.2.3 Reassembly
209431

1 Piston 6 Dust seal
2 Piston seal 7 Packing
3 Piston rod 8 O-ring
4 Self-locking nut 9 Cylinder head
5 Cylinder tube
13-10
SIDE SHIFTER

(a) Cleaning of each part
Thoroughly clean all parts before reassembly making
sure they are completely free from dirt or dust.
(b) Inserting piston seal
Insert the piston seal into the piston.
(c) Inserting seals
Seals to be inserted into the cylinder head must be in-
serted with the main lip facing inward.
Also, the dust seal should be inserted with the main lip
facing outward.
5.2.4 Inspection and Adjustment

(1) Inspecting right and left shift amounts
After reassembly, make sure that the right and left car-
riages move smoothly and the rightward and leftward
shift amounts are even.
13-11
SIDE SHIFTER
6. Troubleshooting
• Insufficient oil in hydraulic tank • Add hydraulic oil.

• Too low gear pump delivery rate • Replace pump assembly.
• Port relief valve defects:
(1) Too low valve opening pressure setting • Adjust port relief valve.
(2) Defective pilot valve seat surface or foreign matter • Replace port relief valve assembly or dis-
Shifts of right and left in valve assemble and clean it.
fork prongs too slow or
sluggish (3) Damaged valve housing O-ring • Replace O-ring.
• Cylinder defects:
(1) Foreign matter lodged in rod packing • Replace rod packing.
(2) Scratches on bore of rod packing • Replace rod packing.
(3) Damaged piston seal • Replace piston seal.
(4) Deformation • Replace.
Unsmooth shifts of fork: • Scratches or rust on side shift bar • Repair and apply grease.
(1) Jamming • Wear on carriage sliding surfaces • Replace.
(2) Too large looseness • Bend of carriage • Repair or replace.
• Bent side shift bar • Repair or replace.
• Bent fork • Replace.
Misaligned fork tips
• Uneven loading • Instruct operator to handle only loads
within indicated capacity.
13-12
SIDE SHIFTER
7. Service Data
7.1 Side shift cylinder

Standard
value
Standard
value
Standard
Stroke 3 280 mm (11.02 in.)
value
Standard
value
Standard
0.5 mm (0.020 in.) or less
value
Runout of piston rod 5
Repair or
1.0 mm (0.039 in.) or less
service limit
209430A
13-13
SERVICE DATA
1. Inspection point .......................................................................................................... 14-2
2. Tightening torque of standard bolts............................................................................ 14-9

2.1 Metric screw thread for automobiles ................................................................................................... 14-9 1
2.2 Metric Coarse Thread ....................................................................................................................... 14-10
3. Periodic replacement parts ...................................................................................... 14-11 2

4. Lubrication Standards .............................................................................................. 14-13
4.1 Lubrication Chart............................................................................................................................... 14-13
3
4.2 Fuel and Lubricant Specifications ..................................................................................................... 14-14
4.3 Capacity ............................................................................................................................................ 14-15 4
5. Weight of Major Components................................................................................... 14-16
5
6. Special Tools............................................................................................................ 14-17
6
7
8
9
10
11
12
13
14
14-1
SERVICE DATA
1. Inspection point
: Check or clean
⊗: Replace or adjust
Intervals Maintenance standards
Inspection and maintenance points Pre- Every 200 Every 2400
Procedure
and items start hours or hours or 12 DP70E
monthly months
Water leaks Visual
Radiator filler cap - func-
Visual/feel
tion
Cooling Coolant level Visual 13.5 L (3.57 U.S. gal.)
system Fan belt - tension and Visual/ Automatic tension pulley -

damage measure readjustment
Cooling fan - damage Visual/feel
Rubber hoses - damage Visual/feel
Operation
Starting and noise
test/listen
Engine Tachome-
operation Idling and acceleration ter/opera- 650 rpm
tion test
Exhaust smoke Visual
Intake: 0.25
mm (0.0098
All valves - valve clear- Thickness When engine in.)
Valves
ance gage is cold Exhaust: 0.25
mm (0.0098
in.)
Air Element - clogging or Replace every 6 months or
Visual ⊗
cleaner damage 1200 hours.
Oil leaks Visual
Replace every month or 200
Lubrica- Oil - level and contami-
Visual/feel ⊗ ⊗ hours.
tion sys- nation
Capacity: 13 L (790 cu.in)
tem
Oil filter element - clog- Replace every 1 months or
Check ⊗ ⊗
ging 200 hours.
Governor No-load maximum speed Tachometer 0
2480 -50 rpm
Fuel leaks Visual
Replace every 6 months or
Fuel filter - clogging Check ⊗
1200 hours.
Injection nozzles - injec- 11.77 MPa
Nozzle
Fuel sys- tion pressure and dis- (120.0 kgf/cm2)
tester
tem charge pattern [1707.3 psi]
Operation
Injection timing BTDC 20˚
test
Operation
Feed pump - function
test
Compres-
All cylinders - measure- Compres- 3.23 MPa (32.9 kgf/cm2)
sion pres-
ment sion gauge [468.5 psi] (at 300 rpm)
sure
14-2
SERVICE DATA

Procedure
monthly months
Operation
Starter Pinion - meshing action
test
Alterna- Operation
Charging
tor test/visual
Fluid level Visual
Battery Specific gravity of elec- Hydrome-
1.26 or more
trolyte ter
insulator, connectors and
Electri-
battery terminals - loose-
cal wir- Visual/feel
ness, damage or corro-
ing
sion
Feel/mea- 15 to 30 mm (0.6 to 1.2 in.)
Play, looseness, rattle
Steering sure with engine idling
wheel Operation
Response
test
Oil leak Visual
Gear box
Loose installation Wrench
Looseness, rattle, bend, Wrench/
Rods and
damage visual
arms
Missing of split pin Visual
Rattle in the connection
Knuckle Feel
(king pin)
Steering Bend or damage of steer-
Visual/feel
axis ing axis
Fit of bellcrank pin and
Feel
Bellcrank bellcrank
Vertical play of bellcrank Feel
Power Oil leak Visual
steering Loose installation Wrench
Play: 12 to 31 mm (0.5 to 1.2
Play and height of pedal in.)
Measure
depressed Pedal height (to top of pedal
pad) 220 mm (8.7 in.)
Brake
pedal 5 m (16 ft), maximum with
Operation rated load
Performance test/mea- Stroke to the point where
sure brake start working: 38 to 65
mm (1.5 to 2.6 in.)
Lever operation angle 71˚ to
Operation 76˚
Parking
Performance test/spring Operating effort: 245 to 294 N
brake
balancer (25.0 to 30.0 kgf) [55.1 to
66.1 lbf]
Brake
Fluid leak, damage, or
hoses and Visual
installation
pipes
14-3
SERVICE DATA

Procedure
monthly months
Brake
Fluid level Visual 240 cc (0.06 U.S. gal.)
fluid
Brake Operation
Performance
booster test
Master cylinder and
Wheel Overhaul/
wheel cylinders - opera- ⊗
brake visual
tion, wear, and damage
Lining-to-drum clear- Thickness 0.45 to 0.65 (0.017 to 0.026

ance gage in.)
Sliding surfaces of shoes Disassem-
10 mm (0.4 in.)
and wear of lining. ble/calipers
Brake Visual/
Drum - wear or damage 317.5 mm (12.50 in.)
drum and measure
shoes Deterioration (free Front side: 90 mm (3.54 in.)
Measure
length) of return spring Rear side: 93 mm (3.66 in)
Operation
Operation of shoes
test
Anchor pins - seizure Visual
Distortion, cracks or
Dye check
damage
Backing
Fitting cable - damage Visual
plate
Ratchet - wear or dam-
Visual
age
Replace every 6 months or
Torque
converter Oil level and leak Visual ⊗ 1200 hours.
drive 22 L (5.8 U.S. gal.)
transmis- Strainer - clogging Visual ⊗ Replace or clean every 6
sion
Control valve filters ⊗ months or 1200 hours.
14-4
SERVICE DATA

Procedure
monthly months
Inching pedal height above
floor (from frame top to top of
pedal pad):
220 mm (8.7 in.)
Clearance between inching
pedal and brake pedal con-
Operation
Inching pedal - adjust- necting parts:
test/mea-
ment 0.1 to 0.5 mm (0.004 to 0.02
sure
in.)
Inching valve plunger stroke:
6 to 9.5 mm (0.24 to 0.37 in.)
Torque Inching valve plunger stroke
converter at which brake starts working:
drive 16.5 mm (0.65 in.)
transmis-
Item Maintenance standards
sion
Main pressure Eng at 1500 ± 100 rpm 1.08 to 1.37 MPa (11 to 14
kgf/cm2) [157 to 199 psi]
Clutch pressure Eng at 1500 ± 100 rpm 1.08 to 1.37 MPa (11 to 14
kgf/cm2) [157 to 199 psi]
T/C inlet pressure Eng at 1500 ± 100 rpm 0.05 to 0.49 MPa (0.51 to 4.9
kgf/cm2) [7.25 to 71.1 psi]
Lubrication pressure Eng at 1500 ± 100 rpm 0.02 to 0.15 MPa (0.204 to
1.53 kgf/cm2) [2.9 to 21.8 psi]
Stall speed, rpm 2050 ± 100
10 m (33 ft) starting acceleration (unloaded) 5 seconds, maximum
Front Cracks, distortion, or Dye check/

axle other defects visual
Oil level and leak Visual 14 L (3.7 U.S. gal.)
Mounting bolts - loose- Torque
Front
ness wrench
axle and
differen- Preload of hub bearing (tan-
tial Rattle in the front wheel Spring bal- gent force on hub bolt)

bearing ancer 147 to 167 N (14.99 to 17.03
kgf) [33.0 to 37.5 lbf]
Operation
Fore-aft play
test
Cracks, distortion, or
Visual
other defects
Preload of hub bearing (tan-
Rear axle gent force on hub bolt):
Spring bal-
60.8 to 102 N (6.2 to 10.4 kgf)
Play in the rear wheel ancer
[13.7 to 22.9 lbf]
bearing Torque
Lock nut (outer only)
wrench
196 N•m (20.0 kgf•m) [144.6
lbf•ft]
Front and Both front and rear Tire pres-
0.7 MPa
rear axles wheels - inflation sure gauge
14-5
SERVICE DATA

Procedure
monthly months
Tire - groove depth and
Visual
abnormal wear
Metal chip, stone, or
other foreign object dug Visual
in
Wheel Front 382 ± 38.2 N•m (39.0 ±
3.90 kgf•m) [282 ± 28.2
Torque
Loose wheel nut lbf•ft]
wrench
Rear 403 N•m (41.1 kgf•m)
[297 lbf•ft]
Wheel disc - damage Visual
Replace oil every 12 months
Oil level Visual ⊗ or 2400 hours
N level: 105 L (6407 cu.in)
Hydrau-
Every 12 months or 2400
lic tank Strainer - clogging Visual ⊗
hours, clean or change.
Every 12 months or 2400
Return filter - clogging ⊗
hours, clean or change.
Gear Oil leaks or abnormal Visual/lis-

pump sound ten
Priority relief pressure Pressure
10.78 to 11.27 MPa
(power cylinder) gauge
Oil leak Visual
Pressure
Control Main relief pressure 19.1 to 19.6 MPa
gauge
Valve
*Overload relief pres- Pressure

sure gauge
Control levers and links - Operation

rattle test/feel
Cracks, damage or dis-
Visual
tortion
Fork rising speed (under the
rated load): 440 mm/sec.
Visual/ (86.6 fpm)
Lift cyl- Function, wear and leak watch/mea-
sure Lift cylinder free fall (under
inder
the rated load): 55 mm (2.2
in.)/15 min or less
Attachments
Mounting bolts - loose-
Wrench
ness
Oil leak Visual
Flow reg-
ulator Fork descending speed (under
Abnormal descending Watch/
valve the rated load): 550 mm/sec
speed measure
(110 fpm)
* marks: Optional
14-6
SERVICE DATA

Inspection and maintenance points Every 200 Every 2400
Procedure Pre-start
and items hours or hours or 12 DP70E
monthly months
Visual
tortion
Oil leak Visual
Drift
(rated load)
Watch/
Tilt cylin- Function and wear 15 mm (0.59 24 mm (0.94
measure
der in.)/15 min in.)/15 min
maximum maximum
Mounts - rattle or dam-
Visual/feel
age
Rod socket nut - loose- Torque 539 to 637 N•m (55.0 to 65.0

ness wrench kgf•m) [397.8 to 470.1 lbf•ft]
Oil leak Visual
Rubber hoses - damage Visual
Piping hose reels and swivel
joint - damage or distor- Visual
tion
Visual
tortion
Mast supports - rattle or
Mast and
damage
lift
bracket Feeler Each roller to mast clearance
Main rollers - rattle, gauge/ (at max. height)

damage dial indica- 0.1 to 0.5 mm (0.004 to 0.020
tor in.)
Length of lift chains (20 links)
Stretch of lift chains Measure
654 mm (25.7 in) or less
Both chains to be equal in ten-
Tension of lift chains Feel
sion.
Chains - damage, distor-
Lift chain Visual
tion or rusting
and chain
Chain wheels - wear,
wheels Visual
damage or distortion
Chain wheel bearings -
Visual
rattle
Chain anchor bolts -
Visual
damage or distortion
Fork blade thickness
FD60: 50 mm (1.97 in.) or
Forks - wear, damage Visual/
less
and distortion measure
FD70: 54 mm (2.13 in.) or
less
Forks and Fork stopper pins - dam-
backrest Visual
age and distortion
Backrest mounting bolts
Wrench
- looseness
Backrest - distortion and
Visual
damage
14-7
SERVICE DATA

Inspection and maintenance points Every 200 Every 2400
Procedure Pre-start
and items hours or hours or 12 DP70E
monthly months
Operation
Lamps Operation
test/visual
Operation
Horn Operation
test/listen
Turn sig- Operation
Operation
nals test/visual
Rear
view mir- Rear vision Visual
ror
Over-
Visual/
head Damage or looseness
wrench
guard
Visual/
Damage or looseness
wrench
Operator's seat - damage
Visual
Chassis or looseness
Lubricate mast supports every
Lubrication points Lubricate
week.
Oil change Check
14-8
SERVICE DATA
2. Tightening torque of standard bolts

2.1 Metric screw thread for automobiles
With spring washer 101656
Nominal size Pitch

7 8 10
mm in. mm in. N·m kgf·m lbf·m N·m kgf·m lbf·m N·m kgf·m lbf·m
6 0.24 1 0.04 7.4 0.75 5.4 9.6 0.98 7.1 12.7 1.3 9.4
8 0.32 1.25 0.05 16.7 1.7 12.3 22.6 2.3 16.6 30.4 3.1 22.4
10 0.39 1.25 0.05 34.3 3.5 25.3 45.1 4.6 33.3 69.6 7.1 51.4
12 0.47 1.25 0.05 63.7 6.5 47.0 82.4 8.4 60.8 122.6 12.5 90.4
14 0.55 1.5 0.06 102.0 10.4 75.2 132.4 13.5 97.6 192.2 19.5 141.8
16 0.63 1.5 0.06 154.9 15.8 114.3 202.0 20.6 149.0 287.3 29.3 211.9
18 0.71 1.5 0.06 224.6 22.9 165.5 292.2 29.8 215.5 413.8 42.2 305.2
20 0.79 1.5 0.06 310.9 31.7 229.3 404.0 41.2 298.0 573.7 58.5 423.1
22 0.87 1.5 0.06 413.8 42.2 305.2 537.5 54.8 396.4 763.0 77.8 562.7
24 0.95 1.5 0.06 547.2 55.8 403.6 711.0 72.5 524.4 1006.2 102.6 742.1
27 1.06 1.5 0.06 794.3 81.0 585.9 1032.6 105.3 761.6 1451.1 148.0 1070.5
30 1.18 1.5 0.06 1100.3 112.2 811.5 1430.8 145.9 1055.3 2012.3 205.2 1484.2
33 1.30 1.5 0.06 1467.1 149.6 1082.1 1907.4 194.5 1406.8 2680.2 273.3 1976.8
36 1.42 1.5 0.06 1918.2 195.5 1414.8 2493.8 254.3 1839.4 3497.1 356.6 2579.3
39 1.54 1.5 0.06 2461.5 251.0 1815.5 3198.8 326.2 2359.4 4469.9 455.8 3296.8
Metric Without spring washer 101656
fine
thread Nominal size Pitch
7 8 10
6 0.24 1 0.04 8.6 0.88 6.4 10.8 1.1 8.0 14.7 1.5 10.8
8 0.32 1.25 0.05 19.6 2.0 14.5 26.5 2.7 19.5 36.6 3.7 26.8
10 0.39 1.25 0.05 41.2 4.2 30.4 53.0 5.4 29.1 81.4 8.3 60.0
12 0.47 1.25 0.05 74.5 7.6 55.0 97.1 9.9 71.6 144.2 14.7 106.3
14 0.55 1.5 0.06 119.6 12.2 88.2 155.9 15.9 115.0 226.5 23.1 167.1
16 0.63 1.5 0.06 182.4 18.6 134.5 237.3 24.2 175.0 338.3 34.5 249.5
18 0.71 1.5 0.06 263.8 26.9 194.6 343.2 35.0 253.2 487.4 49.7 359.5
20 0.79 1.5 0.06 365.8 37.3 269.8 475.6 48.5 350.8 674.7 68.8 497.6
22 0.87 1.5 0.06 486.4 49.6 358.8 632.5 64.5 466.5 897.3 91.5 661.8
24 0.95 1.5 0.06 643.3 65.6 474.5 836.5 85.3 617.0 1183.7 120.7 873.0
27 1.06 1.5 0.06 934.6 95.3 689.3 1216.0 123.9 894.2 1707.3 174.1 1259.3
30 1.18 1.5 0.06 1294.5 132.0 954.8 1682.8 171.6 1241.2 2367.3 241.4 1746.0
33 1.30 1.5 0.06 1726.0 176.0 1273.0 2243.8 228.8 1654.9 3153.8 321.6 2326.1
36 1.42 1.5 0.06 2256.5 230.1 1664.3 2934.1 299.2 2164.1 4114.0 419.6 3035.0
39 1.54 1.5 0.06 2896.0 295.3 2135.9 3763.8 383.8 2776.0 5258.3 536.2 3878.3
Remarks:
1. The tolerance on these torque is ± 10%.
2. These torques are for “dry” condition.
14-9
SERVICE DATA
2.2 Metric Coarse Thread
With spring washer 101656
Nominal size Pitch
mm in. mm in. N·m kgf·m lbf·m N·m kgf·m lbf·m N·m kgf·m lbf·m
10 0.39 1.5 0.06 33.3 3.4 24.6 43.1 4.4 31.8 67.7 6.9 49.9
12 0.47 1.75 0.07 58.8 6.0 43.4 76.5 7.8 56.4 115.7 11.8 85.3
14 0.55 2 0.08 96.4 9.8 70.9 124.5 12.7 91.9 182.4 18.6 134.5
16 0.63 2 0.08 147.14 15.0 108.5 191.2 19.5 141.0 274.6 28.0 202.5
18 0.71 2.5 0.10 203.0 20.7 149.7 264.8 27.0 195.3 383.4 39.1 282.8
20 0.79 2.5 0.10 286.4 29.2 211.2 371.7 37.9 274.1 536.4 54.7 395.6
22 0.87 2.5 0.10 383.4 39.1 282.8 499.2 50.9 368.2 715.9 73.0 528.0
24 0.95 3 0.12 492.3 50.2 363.1 640.4 65.3 472.3 924.8 94.3 682.1
27 1.06 3 0.12 724.7 73.9 534.5 942.2 96.1 695.1 1350.4 137.7 996.0
30 1.18 3.5 0.14 969.9 98.9 715.3 1259.2 128.4 928.7 1843.7 188.0 1359.8
33 1.30 3.5 0.14 1328.8 135.5 980.1 1727.0 176.1 1273.7 2477.2 252.6 1827.1
36 1.42 4 0.16 1676.0 170.9 1236.1 2180.0 222.3 1607.9 3199.9 326.3 2360.1
39 1.54 4 0.16 2219.2 226.3 1636.8 2884.1 294.1 2127.2 4118.8 420.0 3037.9
42 1.65 4.5 0.18 2754.7 280.9 2031.8 3581.4 365.2 2641.5 5137.7 523.9 3789.4
Metric Without spring washer 101656

coarse
thread Nominal size Pitch
10 0.39 1.5 0.06 39.2 4.0 28.9 51.0 5.2 37.6 79.4 8.1 58.6
12 0.47 1.75 0.07 69.6 7.1 51.4 90.2 9.2 66.5 135.3 13.8 99.8
14 0.55 2 0.08 112.8 11.5 83.2 146.1 14.9 107.8 215.7 22.0 159.1
16 0.63 2 0.08 172.6 17.6 127.3 224.6 22.9 165.6 323.6 33.0 238.7
18 0.71 2.5 0.10 239.3 24.4 176.5 311.9 31.8 230.0 451.1 46.0 332.7
20 0.79 2.5 0.10 336.4 34.3 248.1 437.4 44.6 322.6 630.6 64.3 465.1
22 0.87 2.5 0.10 392.3 40.0 289.3 587.4 59.9 433.3 842.4 85.9 621.3
24 0.95 3 0.12 578.6 59.0 426.7 753.2 76.8 555.5 1088.5 111.0 802.9
27 1.06 3 0.12 852.2 86.9 628.5 1108.2 113.0 817.3 1588.7 162.0 1171.7
30 1.18 3.5 0.14 1140.5 116.3 841.2 1481.8 151.1 1092.9 2168.3 221.1 1599.2
33 1.30 3.5 0.14 1563.2 159.4 1153.0 2031.9 207.2 1498.7 2915.5 297.3 2150.4
36 1.42 4 0.16 1972.1 201.1 1454.6 2564.4 261.5 1891.4 3765.8 384.0 2777.5
39 1.54 4 0.16 2610.5 266.2 1925.4 3393.1 346.0 2502.6 4845.5 494.1 3573.8
42 1.65 4.5 0.18 3241.1 330.5 2390.5 4212.9 429.6 3107.3 6044.8 616.4 4458.4
Remarks:
1. The tolerance on these torque is ± 10%.
2. These torques are for “dry” condition.
14-10
SERVICE DATA
3. Periodic replacement parts

The following safety-critical parts and elements must be replaced at the specified periods.
Period
Proce- 1 month Every Every
No. Periodic replacement parts Every Every
dure after 1 6
1 years 2 years
delivery months months
1 * Lift chain Replace.
2 * Hoses for power cylinder Replace.
* Repair kit parts for master cylinder and wheel cylinder (pis-
3 Replace.
ton cups, dust seals, etc.)
* Repair kit parts for brake booster (seal retainer assembly,
4 diaphragm, retainer, silencer, filter, disc assembly, valve rod Replace.
assembly)
5 * Stop lamp switch (gear type) Replace.
6 * Rubber parts for power steering Replace.
7 * Hoses for power steering Replace.
8 * Fuel hose Replace.
9 Engine oil filter element Replace.
10 Fuel filter element Replace.
11 Hydraulic tank suction strainer Replace.
12 Hydraulic tank return filter Replace.
13 Transmission control valve oil filter Replace.
Clean.
14 Air cleaner element
Replace.
NOTE
* indicates important safety-related parts.
14-11
SERVICE DATA
Important safety-related parts
5 10
5
7
5 5 3
206544
14-12
SERVICE DATA
4. Lubrication Standards
4.1 Lubrication Chart
❋ ❋
Lift bracket side roller MPG Tilt cylinder socket
MPG
(4 places)
❋ ❋
Mast side roller (4 places) MPG EO Lift chain
❋
Mast strip (sliding surface) MPG GO GO Differential/final drive
❋ ❋
Mast support MPG MPG Universal joint
MPG Tilt cylinder
Brake fluid reservoir BF MPG Universal joint
HO Hydraulic tank
Torque converter ATF ATF EO Engine oil pan
MPG Water pump

❋
Rear axle center pin (front) MPG MPG Tie rod pin
❋
Rear axle center pin (rear) MPG MPG Tie rod pin
Every 50 hours or weekly
Every 200 hours or monthly
Every 1200 hours or 6 months
Every 2400 hours or 12 months
Key to lubricants:
ATF = Automatic transmission fluid
MPG = Multipurpose grease
= Check and refill
= Change GO = Gear oil
❋ = Lubricate points on both sides EO = Engine oil

BF = Brake fluid
HO = Hydraulic oil
205525A
14-13
SERVICE DATA
4.2 Fuel and Lubricant Specifications
Fuels and Oils Recommendation Service range

Consult your local
Fuel ––
API service classification C), 0˚C or higher: SAE30
Engine oil
min. 0˚C or lower: SAE10W or SAE10W-30
-10˚C or higher: SAE90
Gear oil GL-4
-10˚C or lower: SAE80
Consult your local
Power shift transmission oil Dexron
-10˚C or higher: SAE10W
Hydraulic oil ––
-10˚C or lower: SAE5W
FMVSS DOT3 or DOT4
Brake fluid
(SAEJ1703)
NLGI No. 2 grade multi-
Wheel bear-
purpose type (lithium base)
ing
Consistency: 265 to 295
Grease See “Recommended Brands of Lubricants.”
NLGI No. 1 grade multi-
Chassis purpose type (lithium base)
Consistency: 310 to 340
Anti-freeze solution -39 -30 -25 -20 -15 -10

Ambient temperature ˚C (˚F)
(Long Life Coolant) (-38.2) (-22) (-13) (-4) (5) (14)
(Replace every two years) Anti-freeze concentration (%) 55 50 45 40 35 30
Remarks:
Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when
mixed. It is best to stick with one and the same brand at successive service intervals.
14-14
SERVICE DATA
4.3 Capacity
Truck model DP70E

Fuel tank 135 L (35.7 U.S. gal.)
Engine, radiator 11.7 L (3.1 U.S. gal.)
Engine coolant Reserve tank 0.65 L (0.17 U.S. gal.)
Total 13.5 L (3.6 U.S. gal.)
Oil pan 12 L (3.2 U.S. gal.)
Engine oil Oil Filter 1 L (0.26 U.S. gal.)
Total 13 L (3.4 U.S. gal.)
Torque converter oil 22 L (5.8 U.S. gal.)
Differential gear oil
14 L (3.7 U.S. gal.)
Final drive gear oil
Hydraulic oil N Level: 105 L (27.7 U.S. gal.)
Brake fluid 240 cc (0.06 U.S. gal.)
14-15
SERVICE DATA
5. Weight of Major Components
Truck model DP70E

Counterweight 3350 kg (7385 lb)
Engine (service weight) 350 kg (772 lb)
Power train
885 kg (1950 lb)
engine, transmission
Overhead guard 100 kg (209 lb)
Front axle 855 kg (1880 lb)
Rear axle 570 kg (1260 lb)
Outer mast 830 kg (1830 lb)
Inner mast 805 kg (1775 lb)
Mast Lift bracket (including backrest) 910 kg (2006 lb)
Dual panorama
mast (3 m) (130 in.) Forks (two) 390 kg (860 lb)
Lift cylinders, etc. 240 kg (529 lb)
Total weight 3175 kg (7000 lb)
14-16
SERVICE DATA
6. Special Tools
In- Truck Models

dex Part No. Name Use Covered
No. DP70E
For removing/installing rear wheel nut and weight
1 91268-00701 Socket wrench
bolt
For removing torque converter drive transmission
2 67284-15400 Bolt
cover and shifter shaft
For removing/installing torque drive transmission
3 92267-00300 Piston tool
clutch return spring
For removing/installing torque converter drive trans-
4 91268-00500 Ring puller
mission snap spring
5 64309-17701 Gauge Kit For measuring transmission and hydraulic oil pressure
6 92067-00200 Socket wrench For removing/installing front wheel hub nut
7 64309-15411 Spring remover For removing return spring
8 91868-00600 Spring retainer For removing/installing brake shoe
9 64309-15413 Spring hook For installing return spring
10 91268-10600 Puller For removing steering wheel
11 91268-03200 Puller For removing steering column needle roller bearing
For measuring pressure at gear pump oil pressure
12 92067-00800 Plug
(used with 64309-17701 gauge kit as a set)
For measuring pressure at power steering oil pressure
13 91268-01700 Connector relief valve (used with 64309-17701 gauge kit as a
set)
14 09305-00880 Hook wrench For removing/installing tilt cylinder bushing
15 05312-10600 Hook wrench For removing/installing tilt cylinder head
14-17
SERVICE DATA
46 mm
(1.81 in.)
250 mm (9.84 in.)
1 5
200440 203544
M10 × 1.25
112
75 mm (2.95 in.) (4.4 in.)
2 6
200465 205925
(φ 5.12 in.)
φ 130 mm
3 7
200465 203548
4 8
200438 203549
14-18
SERVICE DATA
G (PF) 3/8-B G (PF) 3/8-A
RP (PS) 1/8-A
9
203550 13 213334
M12 × 1.25
M8 × 1.25
3
(1. 0 mm
18
5 in.
(2. 5 mm )
17
in.
)
10
200438 14
213335
11 15
203552 213336
12
213333
14-19

Service Manual - Truck

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Chassis, Mast & Options

For use with the S6S Engine Service Manual. 99709-81100

The suggestion for

Suggestion for disassembly

Item SI unit Customary unit

GROUP INDEX Items

Model View, Truck Models Covered, Serial Number Locations,

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

4. Main specifications....................................................................................................... 1-4 2

2. Truck Models Covered

3. Serial Number Locations

Diesel-engine serial number Chassis serial number

Mast serial number Name plate Transmission serial number

Truck model DP70E

5. Chassis and Mast Model Identiﬁcation

Maximum lifting height

Applicable truck model designation

No. Truck model DP70E

Truck model DP70E

1 Cooling fan 5 Upper hose

3. Suggestions for Removal and Installation

(2) Removal sequence

(3) Suggestions for Removal

4. Inspection and Adjustment

4.2 Fan Belt Tension Adjustment

1 Fan Pulley 4 Adjusting Plate

2. Location of Components .............................................................................................. 3-4

6.5 How to Set Controller.......................................................................................................................... 3-26

7. Troubleshooting ......................................................................................................... 3-50

8. Electrical Wiring Diagram........................................................................................... 3-55

Truck model DP70E

Stop lamp switch

Fuel tank unit Solenoid(speed select)

Brake oil sensor

Rear combination lamp(L.H) Rear combination lamp(R.H)

Engine thermostat unit Seat switch

No. Indicator lamp OFF ON or Flashing Remark

How to check indicator lamp bulbs

Failure indicator lights

Rear (mounting) face

Failure indicator lamp

Cause of trouble Failure indicator lamp flashing pattern

Travel speed sensor circuit open

2-speed automatic transmission

3.3.3 Lighting switch

3.3.4 Fuse box

3.3.5 Spare terminal

Color code Lg (light green)

Removing the console box rear panel will permit you to

3.3.6 Lamp Bulb Speciﬁcations

Tail and stop

4. Disassembly and Reassembly

4.1.1 Disassembly sequence

4.2 Combination Meter

4.3 Electrical Components in the Console Box

1 Power relay 5 Glow plug timer

5. Batteries and Charging

5.2 Relationship between Electrolyte S.G. and

5.3 Precautions for Battery Charging