CATERPILLAR CAT DP60 DP70 FORKLIFT LIFT TRUCKS Service Repair Manual Instant Download

1
Service Manual
Chassis, Mast Attachments
DP60 DP70
T20C-10001-up T20C-60001-up
99709-86140
For use with the S6S Engine Service Manual.
2
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.
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, may result in death or
serious injury or damage to the machine.
CAUTION
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. 99709-86140 1
3
WARNING
WARNING
The proper and safe lubrication and maintenance
for these lift trucks, recommended by Cat Lift
Trucks, are outlined in the OPERATION MAINTE-
NANCE MANUAL for these trucks. Improper
performance of lubrication or mainte- nance
procedures is dangerous and could result in
injury or death. Read and understand the OPER-
ATION MAINTENANCE MANUAL before perform- ing
any lubrication or maintenance on these trucks.
Do not operate these trucks unless you have read
and understood the instructions in the OPERA-
TION MAINTENANCE MANUAL. Improper truck
operation is dangerous and could result in injury
or death.

• The serviceman or mechanic may be unfamiliar with
  many of the systems on this truck. This makes it
  important to use caution when performing service
  work. A knowledge of the system and/or
  components is important before the removal or
  disassembly of any component.
• Because of the size of some of the truck
  components, the serviceman or mechanic should
  check the weights noted in this Manual. Use
  proper lifting procedures when removing any
  components.
• Following is a list of basic precautions that
  should always be observed.
• Read and understand all warning plates and decals
  on
• the truck before operating, lubricating or
  repairing the product.
• Always wear protective glasses and protective
  shoes
• when working around trucks. In particular, wear
  pro- tective glasses when pounding on any part
  of the truck or its attachments with a hammer or
  sledge. Use weld- ers gloves, hood/goggles,
  apron and other protective clothing appropriate
  to the welding job being per- formed. Do not
  wear loose-fitting or torn clothing. Remove all
  rings from fingers when working on machinery.
• Do not work on any truck that is supported only
  by lift
• jacks or a hoist. Always use blocks or jack
  stands to support the truck before performing
  any disassembly.
• Lower the forks or other implements to the ground
• before performing any work on the truck. If this
  cannot be done, make sure the forks or other
  implements are blocked correctly to prevent them
  from dropping unex- pectedly.
• Use steps and grab handles (if applicable) when
  mount-
• ing or dismounting a truck. Clean any mud or
  debris from steps, walkways or work platforms
  before using. Always face truck when using
  steps, ladders and walk- ways. When it is not
  possible to use the designed access system,
  provide ladders, scaffolds, or work plat- forms
  to perform safe repair operations.
• 2

• To avoid back injury, use a hoist when lifting
  compo- nents which weight 23 kg (50 lb.) or
  more. Make sure all chains, hooks, slings, etc.,
  are in good condition and are of the correct
  capacity. Be sure hooks are posi- tioned
  correctly. Lifting eyes are not to be side loaded
  during a lifting operation.
• To avoid burns, be alert for hot parts on trucks
  which
• have just been stopped and hot fluids in lines,
  tubes and compartments.
• Be careful when removing cover plates. Gradually
• back off the last two bolts or nuts located at
  opposite ends of the cover or device and pry
  cover loose to relieve any spring or other
  pressure, before removing the last two bolts or
  nuts completely.
• Be careful when removing filler caps, breathers
  and
• plugs on the truck. Hold a rag over the cap or
  plug to prevent being sprayed or splashed by
  liquids under pressure. The danger is even
  greater if the truck has just been stopped
  because fluids can be hot.
• Always use tools that are in good condition and
  be sure
• you understand how to use them before performing
  any service work.
• Reinstall all fasteners with same part number. Do
  not
• use a lesser quality fastener if replacements are
  neces- sary.
• If possible, make all repairs with the truck
  parked on a
• level, hard surface. Block truck so it does not
  roll while working on or under truck.
• Disconnect battery and discharge any capacitors
  (elec-
• tric trucks) before starting to work on truck.
  Hang Do not Operate tag in the Operators
  Compartment.

4

• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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
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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
• Bolt, Washer, Cover (part name)
• 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 cylinder body and piston Standard val- ue 0.020 to 0.105 mm (0.00079 to 0.00413 in.)
Clearance between cylinder body and piston Repair or ser- vice limit 0.15 mm (0.059 in.)
4
7

• 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 1 N 0.1020 kgf
Pressure 1 kPa 0.0102 kgf/cm2
Torque 1 Nm 0.1020 kgfm
5
8
GROUP INDEX
GROUP INDEX Items
GENERAL INFORMATION Model View, Truck Models Covered, Serial Number Locations, Main Specifications, Chassis and Mast Model Identification, Dimensions
COOLING SYSTEM Specifications, Structure, Suggestions for Removal and Installation, Inspection and Adjustment
ELECTRICAL SYSTEM Specifications, Location of Components, Structure, Disassembly and Reassembly, Batteries and Charging, Troubleshooting, Electrical Wiring Diagram
POWER TRAIN Specifications, Structure, Reduction Ratio, Removal and Installation of Engine and Transmission Unit
POWERSHIFT TRANSMIS- SIONS Specifications, Structure, Suggestions for Removal and Installation, Disassembly and Reassembly, Readjust, Troubleshooting, Service Data
FRONT AXLE AND REDUC- TION DIFFERENTIAL Specifications, Structure, Suggestions for Removal and Installation, Disassembly and Reassembly, Troubleshooting, Service Data
REAR AXLE Specifications, Description, Removal and Installation, Disassembly and Reassembly, Adjusting, Troubleshooting, Service Data
BRAKE SYSTEM Specifications, Structure, Disassembly and Reassembly, Adjustment and Testing, Troubleshooting, Service Data
STEERING SYSTEM Specifications, Structure and Functions, Removal and Installation, Disassembly and Reassembly, Troubleshooting, Service Data
HYDRAULIC SYSTEM Specifications, Structure and Functions, Removal and Installation, Disassembly and Reassembly, Inspection and Adjustment, Testing, Troubleshooting, Service Data
MASTS AND FORKS Specifications, Structure, Operation of Triplex Mast, Suggestions for Removal and Installation, Disassembly and Reassembly, Chain Adjustment, Troubleshooting, Service Data
FORK POSITIONER Applicable Attachment Models, Specifications, Structure, Suggestions for Removal and Installation, Disassembly and Reassembly, Troubleshooting, Service Data
SIDE SHIFTER Applicable Attachment Models, Specifications, Structure, Suggestions for Removal and Installation, Disassembly and Reassembly, Troubleshooting, Service Data
SERVICE DATA Inspection Point, Tightening Torque of Standard Bolts, Periodic Replacement Parts, Lubrication Standards, Weight of Major Components, Special Tools
1 2 3 4 5 6 7 8 9 10 11 12 13 14
7
9
GENERAL INFORMATION
1. Model View.....................................
..................................................
............................ 1-2
2. Truck Models Covered ..........................
..................................................
..................... 1-2
1
3. Serial Number Locations .......................
..................................................
..................... 1-3 4. Main Specifications
..................................................
..................................................
.. 1-4 5. Chassis and Mast Model
Identification....................................
..................................... 1-5 6.
Dimensions .......................................
..................................................
......................... 1-6
1-1
10
GENERAL INFORMATION
1. Model View
205711
2. Truck Models Covered This Service Manual
applies to the following truck models (common
names).
Truck model Transmission Model code - Serial number Engine mounted
DP60 Torque converter drive trans- mission T20C-10001-up Mitsubishi S6S diesel engine
DP70 Torque converter drive trans- mission T20C-60001-up Mitsubishi S6S diesel engine
1-2
11
GENERAL INFORMATION
3. Serial Number Locations
Diesel-engine serial number
Chassis serial number
Mast serial number
Name plate
Transmission serial number
206500
1-3
12
GENERAL INFORMATION
4. Main specifications
Truck model Truck model DP60 DP70
Truck Model Truck Model Cat T20C Cat T20C
Type Type Standard (with 2-speed powershift transmission) Standard (with 2-speed powershift transmission)
Capacity/load center Capacity/load center 6000/600 kgf/mm (13228/24 lbf/in.) 7000/600 kgf/mm (15432/24 lbf/in.)
Lift, maximum Lift, maximum 3300 mm (130 in.) 3300 mm (130 in.)
Lift speed (unloaded/loaded) Lift speed (unloaded/loaded) 470/440 mm/sec (93/87 fpm) 470/440 mm/sec (93/87 fpm)
Lowering speed (unloaded/loaded) Lowering speed (unloaded/loaded) 550 mm/sec (108 fpm) 550 mm/sec (108 fpm)
Mast tilt angle (forward-backward) Mast tilt angle (forward-backward) 612 612
Free lift Free lift 205 mm (8.1 in.) 205 mm (8.1 in.)
Forward travel speed (1st/2nd) Forward travel speed (1st/2nd) 10/27.5 km/h (6.2/17.1 mph) 10/27.5 km/h (6.2/17.1 mph)
Reverse travel speed (1st/2nd) Reverse travel speed (1st/2nd) 10/27.5 km/h (6.2/17.1 mph) 10/27.5 km/h (6.2/17.1 mph)
Minimum turning radius Minimum turning radius 3310 mm (130.3 in.) 3395 mm (133.7 in.)
Minimum intersecting aisle Minimum intersecting aisle 3000 mm (118.1 in.) 3050 mm (120 in.)
Front wheel (double- tire) Size 8.25-15-12PR (1) 8.25-15-12PR (1)
Front wheel (double- tire) Inflation 0.7MPa (7kgf/cm2) 101 psi 0.7MPa (7kgf/cm2) 101 psi
Rear wheel Size 8.25-15-12PR (1) 8.25-15-12PR (1)
Rear wheel Inflation 0.7MPa (7kgf/cm2) 101 psi 0.7MPa (7kgf/cm2) 101 psi
Relief-valve setting of power steering Relief-valve setting of power steering 10.8 MPa (110 kgf/cm2) 1567 psi 10.8 MPa (110 kgf/cm2) 1567 psi
Relief-valve setting of control valve Relief-valve setting of control valve 19.1 MPa (195 kgf/cm2) 2770 psi 19.1 MPa (195 kgf/cm2) 2770 psi
Truck weight Truck weight 8710 kg (19200 lb) 9320 kg (20546 lb)
1-4
13
GENERAL INFORMATION
5. Chassis and Mast Model Identification Chassis
DP 60 Maximum capacity 60 6000 kg (13228
lb) 70 7000 kg (15432 lb) Engine type DP
Diesel engine type Mast 4 P 70 B 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
14
GENERAL INFORMATION
6. Dimensions
F
J K
L
R
H1 H2
U
B A
C
T
S
G
P
M
N
E I
209433A
1-6
15
GENERAL INFORMATION
No. Truck model DP60 DP70
A Maximum lift 3300 mm (130 in.) 3300 mm (130 in.)
B Overall height at maximum lift 4580 mm (180.3 in.) 4580 mm (180.3 in.)
C Overall mast height Height of mast lowered 2720 mm (107.1 in) 2720 mm (107.1 in)
D Free lift 205 mm (8.1 in.) 205 mm (8.1 in.)
E Fork length 1220 mm (48 in.) 1220 mm (48 in.)
F Fork width 150 mm (5.9 in.) 150 mm (5.9 in.)
G Fork thickness 65 mm (2.36 in.) 65 mm (2.36 in.)
H1, H2 Mast tilt angle (forward-back- ward) 612 612
I Truck length 4805 mm (189.2 in) 4855 mm (191.1 in.)
J Overall width (outside of tires) 2170 mm (85.4 in.) 2170 mm (85.4 in.)
K Tread (front wheel) 1650 mm (65 in) 1650 mm (65 in)
L Tread (rear wheel) 1650 mm (65 in) 1650 mm (65 in)
M Wheelbase 2300 mm (90.6 in) 2300 mm (90.6 in)
N Front overhang 586 mm (23 in.) 586 mm (23 in.)
P Minimum height from ground 265 mm (10.4 in.) 265 mm (10.4 in.)
R Minimum radius 3310 mm (130 in) 3395 mm (134 in.)
S Underclearance (at mast) 170 mm (6.7 in.) 170 mm (6.7 in.)
T Underclearance (at counter- weight) 240 mm (9.5 in.) 240 mm (9.5 in.)
U Overall height (head-guard height) 2420 mm (95.3 in.) 2420 mm (95.3 in.)
1-7
16
COOLING SYSTEM
1. Specifications ................................
..................................................
............................. 2-2 2.
Structure.........................................
..................................................
............................ 2-3
3. Suggestions for Removal and Installation
..................................................
.................. 2-4 3.1 Removing Fan Belt
..................................................
..................................................
........................... 2-4
2
3.1.1 Suggestions for Removal and
Installation......................................
..................................................
........... 2-4 3.1.2 Procedure involving removal
of counterweight .................................
..................................................
........ 2-6 3.1.3 Suggestions for Removal and
installation .....................................
..................................................
............ 2-7 3.1.4 Installation
..................................................
..................................................
...............................................
2-7
4. Inspection and Adjustment .....................
..................................................
.................... 2-8 4.1 Inspection of Fan
Belt .............................................
..................................................
............................ 2-8 4.2 Fan Belt
Tension Adjustment................................
..................................................
.............................. 2-8
2-1
17
COOLING SYSTEM
1. Specifications
Truck model DP60 DP70
Cooling method Forced circulation of coolant Forced circulation of coolant
Radiator type Corrugated fins with pressure cap Corrugated fins with pressure cap
Total coolant capacity 18 L (1098 cu.in.) 4.7 U. S. gal. 18 L (1098 cu.in.) 4.7 U. S. gal.
Water pump type Volute type, V-belt driven Volute type, V-belt driven
Thermostat type Wax pellet Wax pellet
2-2
18
COOLING SYSTEM
2. Structure
211301

• Universal joint
• Pulley boss
• Tensioner pulley
• Cooling fan
• Fan belt
• Radiator
• The cooling system features a reserve tank as
  standard equipment and an arrangement that
  facilitates adjustment of the fan belt tension.

• Transmission oil cooler
• Upper hose
• Lower hose 10 Reserve tank
• 11 Transmission oil hose

The system incorporates a transmission oil cooler.
2-3
19
COOLING SYSTEM

• Suggestions for Removal and Installation
• Removing Fan Belt
• Suggestions for Removal and Installation
• Preparation
• Remove the radiator cover.
• Remove the engine cover and gas springs.

211302
(2) Removal sequence
1 Drain cock 5 Radiator
2 Cap 6 Universal joint
3 Hose (for coolant) 7 Tensioner pulley locking bolt
4 Hose (for transmission oil) 8 Fan belt
2-4
20
COOLING SYSTEM

• Suggestions for Removal
• Make sure that engine coolant is not hot, then
  open the
• drain cock to allow the coolant to be drained.
• Insert Ratchet Wrench A through the adjusting
  hole in the frame and loosen the tensioner
  pulley locking bolt one or two turns. With a
  claw bar move the tensioner pulley as far as
  possible to the fan side, then tighten the
  tensioner pulley locking bolt so that the fan
  belts can be easily removed.

203767

• Installation
• Follow the removal procedure in reverse while
  noting the following instructions.
• Check the fan bearing for smooth rotation with
  the belt
• removed. Replace the bearing if it generates
  abnormal sound.
• Install the belt and push it at a point midway
  between the driven and drive pulleys to make
  sure that the ten- sioner pulley moves, then
  tighten the pulley lock bolt firmly.
• Connect each hose to the radiator making sure
  that the end of the hose reaches the root of the
  fitting. Tighten the clamp and make sure the
  hose end is stopped at the flare of the fitting.
• Pour antifreeze and coolant into the radiator and
  start the engine. Warm-up the engine while
  checking for abnormal sound. Check the reserve
  tank to see whether it is filled with the given
  quantity of coolant.

2-5
21
COOLING SYSTEM

• 3.1.2 Procedure involving removal of
  counterweight
• Preparation
• Remove the radiator cover.
• Remove the counterweight mounting bolts, then
  remove the counterweight using slings and hoist.
• NOTE
• Before hoisting, check the weight of the
  counterweight and select a sling appropriate for
  lifting the weight.

211303

• (2) Removal sequence
• Muffler
• Fan assembly
• Universal joint

1. Radiator
2. Fan belt

2-6
22
COOLING SYSTEM
3.1.3 Suggestions for Removal and
installation (1) Remove the bolts of the fan
support, remove the belt from the driven pulley,
and remove the fan assembly. Place the fan
assembly on a bench facing the fan sup- port
down, then rotate the fan to check the bearing.
Replace the bearing if it generates abnormal
sound.
207759

• Remove the two lower radiator mounting bolts.
  Loosen (do not remove) the two upper mounting
  bolts.
• Push the radiator toward the engine to remove the
  belt
• from the tensioner pulley and let the belt drop
  onto the universal joint before it is removed.

203463

• 3.1.4 Installation
• Follow the removal sequence in reverse while
  noting the following instructions.
• Installation of fan assembly Attach the belt to
  the
• driven pulley (included in the fan assembly),
  then screw in one of the fan support lower bolts
  and finger tighten it. Loosen the tensioner
  pulley locking bolt and move the fan assembly
  until it aligns with the boss (frame) while
  holding the top of the fan support. Then,
  tighten all the remaining bolts to secure the fan
  assem- bly.
• Through a space in the fan, push the belt by hand
  at the
• midpoint between the drive and driven pulleys to
  make sure that the tensioner pulley moves. Then,
  tighten the pulley lock bolt firmly.

204533
2-7
23
COOLING SYSTEM

• Inspection and Adjustment
• Inspection of Fan Belt
• 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.
• 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
• Through the adjustment hole in the frame, loosen
  the tensioner pulley locking bolt one or two
  turns using a ratchet wrench A.
• The belt will become tight by the force of the
  tensioner spring. Then tighten the pulley
  locking bolt.

203767
2-8
24
ELECTRICAL SYSTEM
1. Specifications ................................
..................................................
............................. 3-2 2. Location of
Components .......................................
..................................................
..... 3-3 3. Structure...........................
..................................................
..........................................
3-4 3.1 Console box ............................
..................................................
..................................................
.......... 3-4 3.2 OK Monitor...................
..................................................
..................................................
..................... 3-4 3.3 Major
Components........................................
..................................................
...................................... 3-5 3.3.1
ECU (Electronic Control Unit) ....................
..................................................
...............................................
3-5 3.3.2 Starter Switch (Anti-restart
Type).............................................
..................................................
................. 3-6 3.3.3 Lighting
switch............................................
..................................................
...............................................
3-7 3.3.4 Fuse box .............................
..................................................
..................................................
.................... 3-7 3.3.5 Spare terminal
..................................................
..................................................
.........................................
3-8 3.3.6 Lamp Bulb Specifications................
..................................................
..................................................
........ 3-8 4. Disassembly and Reassembly
..................................................
................................... 3-9 4.1
Disassembly of Console Box .......................
..................................................
....................................... 3-9 4.1.1
Disassembly sequence .............................
..................................................
................................................
3-9 4.1.2 Reassembly ...........................
..................................................
..................................................
................. 3-9 4.2 Combination
Meter.............................................
..................................................
............................... 3-10 4.2.1
Disassembly ......................................
..................................................
..................................................
.... 3-10 4.2.2 Reassembly .....................
..................................................
..................................................
..................... 3-10 4.3 Electrical
Components in the Console Box.....................
..................................................
.................. 3-11 5. Batteries and
Charging .........................................
..................................................
... 3-12 5.1 Battery Conditions and Adjustment
Method Based on the Electrolyte Specific Gravity
(S.G.) ........... 3-12 5.2 Relationship between
Electrolyte S.G. and Charging Capacity
..................................................
........ 3-12 5.3 Precautions for Battery
Charging..........................................
..................................................
............ 3-12 5.4 Precautions for Servicing
the Charging System with Alternator
..................................................
....... 3-13 6. Troubleshooting
..................................................
..................................................
..... 3-14 6.1 Starter System
..................................................
..................................................
................................ 3-14 6.2
Gauges ...........................................
..................................................
..................................................
3-15 6.3 Lighting System ......................
..................................................
..................................................
........ 3-16 6.4 Alarm Unit ...................
..................................................
..................................................
.................... 3-17 6.5
Battery...........................................
..................................................
..................................................
.. 3-18 7. Electrical Wiring Diagram
..................................................
......................................... 3-19
3-1
25
ELECTRICAL SYSTEM
1. Specifications
Truck model Truck model DP60 DP70
Battery Model number and quantity 65D23R ? 2 65D23R ? 2
Battery Voltage (V) 12 12
Battery Capacity (Ah) 52 52
Direction lever Direction lever Electric Electric
Console box Console box With OK monitor With OK monitor
2-speed automatic transmission controller 2-speed automatic transmission controller ECU (Electronic Control Unit) ECU (Electronic Control Unit)
Starter switch Starter switch Anti-restart type (with the built-in mechanical lockout for preventing duplicated start- ing) Anti-restart type (with the built-in mechanical lockout for preventing duplicated start- ing)
Lamps Lamps 24V, Refer to Lamp Bulb Specifications. 24V, Refer to Lamp Bulb Specifications.
3-2
26
ELECTRICAL SYSTEM
2. Location of Components
Safety relay Engine stop control timer Turn
signal switch
Horn
Forward-reverse switching solenoid
Console box
Stop lamp switch
Front combination lamp
Electronic control unit (ECU)
Head lamp
Front combination lamp
Torque converter oil thermounit
Head lamp
Fuel tank unit
Travel speed sensor
Battery
Engine stop solenoid
Brake fluid level sensor
Glow plug
Starter relay
Back-up buzzer (optional)
Battery Engine oil pressure switch
Alternator
Rear combination lamp
Rear combination lamp
Engine thermounit
211305
NOTE Every harness should be properly secured to
avoid interfer- ence or rubbing by other parts.
Repair damaged harnesses with vinyl tape.
3-3
27
ELECTRICAL SYSTEM

• Structure
• Console box
• Engine coolant temperature gauge
• Speed selector switch
• Fuel gauge
• Service hourmeter
• OK monitor
• Starter switch
• Lighting switch
• Fuse box

207464
3.2 OK Monitor
207465
Function
No. Indicator lamp OFF ON or Flashing Remark
1 Brake fluid level indicator lamp Normal fluid level Low fluid level
2 Transmission oil temperature indica- tor lamp Normal temperature Overheating
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
6 Air cleaner element indicator lamp Normal element condition Element clogged Option
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
How to check indicator lamp bulbs Each bulb is
normal if the indicator lamp comes ON with the
starter switch key turned to (ON) position.
However, the charge condition indicator lamp and
engine oil pressure indicator lamp will not be
illuminated. 3-4
28
ELECTRICAL SYSTEM

• Major Components
• 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 microcomputer to process signals from the
travel speed sen- sor for activating the 2-speed
automatic transmission. This ECU has
self-diagnostic failure indicator lamps which
allow the mechanic to understand the problem in
the electrical system.
It is also provided with the fail-safe systems
(that allow for a unit to be switched to the
safer side should any malfunc- tion occur on it)
as shown in the table below.
NOTE
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
Solenoid output signal circuit open Turns OFF the power line and indicates the trouble content with the failure indicator lamp, if any open circuit is detected in the solenoid output signal circuit.
Travel speed sensor circuit open Allows the truck to run at the present travel speed and indicates the trouble content with the failure indicator lamp.
Failure indicator lamp
Cause of trouble Failure indicator lamp flashing pattern
Travel speed sensor circuit open
2-speed automatic transmission solenoid circuit open
3-5
29
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) This
switch has a built-in mechanical lockout to
prevent duplicated starting. Since this lockout
mechanism restraints the starter switch (key)
from moving from (ON) position to ÅiSTART)
position while the engine is running, it serves
as to prevent
engine troubles or starter damages possibly
caused by any operation mistake. The starter
switch is wired in such a way to energize the
glow plugs, if it is set in the (ON) position for
preheating.
203561A
3-6
30
ELECTRICAL SYSTEM
3.3.3 Lighting switch Connection Chart
206481
3.3.4 Fuse box Connection Chart
Symbol Capac- ity Major components to be connected
A 10A F-N-R lever
B 10A Instrument panel lamp, turn signal lamp
C 10A Spare terminal
D 15A Lamps
E 10A Horn
F 10A Spare fuse
G 10A Transmission controller, vacuum buzzer, stop lamps
H 10A Back-up lamps
J 15A Spare fuse
101441F
3-7
31
ELECTRICAL SYSTEM
3.3.5 Spare terminal The spare supply cord
extends from the fuse box in the con- sole box.
(Another spare terminal is in the chassis-side
main harness.) Color code Lg (light
green) Removing the console box rear panel will
permit you to gain access to this spare
terminal, which is usually taped onto the
harness protector with vinyl tape.
Spare terminal 207209
3.3.6 Lamp Bulb Specifications
Item Item Qua ntity Color of lens Valves Valves Remark
Item Item Qua ntity Color of lens For 24V sys- tem Schematic dia- gram Remark
Head lamps Head lamps 2 Frosted 60W A 60/60W, option
Combination lamps (front) Turn signal lamps 2 Amber 25W B Standard (mounted on the overhead guard)
Combination lamps (front) Clearance lamps 2 Frosted 12W C Standard (mounted on the overhead guard)
Combination lamps (rear) Tail and stop lamps 2 Red 10/25W B
Combination lamps (rear) Turn signal lamps 2 Amber 25W B
Combination lamps (rear) Back-up lamps 2 Frosted 12W B
Working lamps (front) Working lamps (front) 2 Frosted 60/60W A Option
Working lamps (rear) Working lamps (rear) 2 Frosted 60/60W A Option
License plate lamp License plate lamp 1 Frosted 12W C Option
Instrument panel lamps Instrument panel lamps 2 Frosted 3W D For combination meter
OK monitor indicator lamps OK monitor indicator lamps 5 Frosted 3W E For combination meter
A B C D E
205511
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32
ELECTRICAL SYSTEM

• Disassembly and Reassembly
• Disassembly of Console Box

207175

• 4.1.1 Disassembly sequence
• Disconnect the electrical wires at connectors 1.
• Remove screws 2 (four) securing the cover.
• Remove screws 3 (six) and separate the from panel
  and rear panel.
• 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.

3-9
33
ELECTRICAL SYSTEM

• Combination Meter
• Disassembly
• (1) Disassembly sequence
• Meter panel
• Meter cover
• Engine coolant temperature gauge
• Service hourmeter
• Fuel gauge
• Meter case
• Printed circuit plate
• Bulb
• Socket

206486
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.
4.2.2 Reassembly Reassemble in the reverse order
of disassembly sequence.
3-10
34
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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
3-11
36
ELECTRICAL SYSTEM

• Batteries and Charging
• Battery Conditions and Adjustment Method Based on
  the Electrolyte Specific Gravity (S.G.)

Electrolyte S.G. reading at 20C (68F) Battery condition Adjustment
1.280 to 1.265 Battery is fully or well charged. 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.Gff is greater than 0.04, discharge the battery with an efficiency-based man- ner. If the condition is improved, recharge the battery while adjusting the electrolyte specific gravity.
1.260 to 1.225 Battery is half charged. Recharge the battery. Check for any short-circuited cord or corroded connection in the electrical system.
1.220 or less Battery is discharged, requiring cares. Recharge the battery. If difference in S.G. among the cell is large, adjust the S.G. during recharging.
When the difference in S.G. is greater than 0.040 A cell with a low S.G. is in shorted condi- tion. Some electrolyte has been lost. Too much electrolyte, or water in electrolyte. Recharge until voltage and S.G. of each cell stabilize and are maintained constant for at least 2 hours. During recharging, adjust the S.G. to anywhere between 1.280 and 1.265. If difference in S.G. among the cells is more than 0.040 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 Whether the battery is fully
charged can be checked from the electrolyte S.G.
(between 1.280 and 1.265) read with a
hydrometer. However, it can also be judged
theoretically from the reduction rate of the
electrolyte quantity. If refill- ing is
necessary every month or so, the system is
tending to 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
• The charging current should be about 1/10 the
  capacity of the battery to be charged.
• For quick charging, the battery capacity in
  ampere should not be exceeded.
• During charging, adjust the charging current to
  prevent
• the electrolyte temperature from rising beyond
  45C (113F).
• 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.

CAUTION
Be sure to turn off the starter switch and
lighting switch before disconnecting or
connecting the battery cables. (IC regulator may
be damaged.)
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37
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