CATERPILLAR CAT DP100 DP115 DP135 DP150 FORKLIFT LIFT TRUCKS Service Repair Manual Instant Download

1
Service Manual
Chassis Mast
DP100 DP115 DP135 DP150
3DP-10011-up
4DP-10011-up
5DP-10011-up
6DP-10011-up
99799-80120
For use with 6D16TL Engine Service Manual.
2
FOREWORD
This service manual is a guide to servicing of
Cat Lift Trucks 10 ton to 15 ton pneumatic
models. The instructions are grouped by systems
to serve the convenience of your ready
reference. Long productive life of your lift
trucks depends to a great extent on correct
servicing the servicing consistent with what
you will learn from this service manual. We hope
you read the respective sections of this manual
carefully and know all the components you will
work on before attempting to start a test,
repair or rebuild job. The descriptions,
illustrations and specifications contained in
this manual were of the trucks of serial numbers
in effect at the time it was approved for
printing. Cat lift truck reserves the right to
change specifications or design without notice
and without incurring obligation. These lift
trucks are powered by Mitsubishi 6D16TL diesel
engine. For the items of the engine, refer to
the following service manual 6D16 Diesel Engine
Service Manual (Pub. No. 99709-68130) Safety
Related Signs The following safety related signs
are used in this service manual to emphasize
important and critical instructions
Indicates a specific potential hazard resulting
in serious bodily injury or death.
WARNING
Indicates a specific potential hazard resulting
in bodily injury, or damage to, or destruction
of, the machine.
CAUTION
Indicates a condition that can cause damage to,
or shorten service life of, the machine.
NOTE
Pub. No. 99799-80120
3
WARNING
SAFETY
4. 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 unexpectedly.
WARNING
The proper and safe lubrication and maintenance
for this lift truck, recommended by Cat lift
truck, are outlined in the OPERATION
MAINTENANCE MANUAL for these trucks. Improper
performance of lubrication or maintenance
procedures is dangerous and could result in
injury or death. Read and
WARNING
Do not operate this truck unless you have read
and understand the instructions in the OPERATION
MAINTENANCE MANUAL. Improper truck operation is
dangerous and could result in injury or death.
understand the OPERATION MAINTENANCE MANUAL
before performing any lubrication or maintenance.

1. Use steps and grab handles (if applicable) when
   mounting 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 walkways. When it is not
   possible to use the designed access system,
   provide ladders, scaffolds, or work platforms to
   perform safe repair operations.
2. To avoid back injury, use a hoist when lifting
   components which weigh 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 positioned correctly. Lifting
   eyes are not to be side loaded during a lifting
   operation.
3. To avoid burns, be alert for hot parts on trucks
   which have just been stopped and hot fluids in
   lines, tubes and compartments.
4. 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.
5. 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.

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. Followin
g is a list of basic precautions that should
always be observed.

1. Read and understand all warning plates and decals
   on the truck before operating, lubricating or
   repairing the product.
2. Always wear protective glasses and protective
   shoes when working around trucks. In particular,
   wear protective glasses when pounding on any
   part of the truck or its attachments with a
   hammer or sledge. Use welders gloves,
   hood/goggles, apron and other protective
   clothing appropriate to the welding job being
   performed. Do not wear loose-fitting or torn
   clothing. Remove all rings from fingers when
   working on machinery.
3. 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.

4

1. Always use tools that are in good condition and
   be sure you understand how to use them before
   performing any service work.
2. Reinstall all fasteners with same part number.
   Do not use a lesser quality fastener if
   replacements are necessary. Do not mix metric
   fasteners with standard nuts and bolts.
3. 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.
4. Disconnect battery and discharge any capacitors
   (electric trucks) before starting to work on
   truck. Hang Do not Operate tag in the
   Operators Compartment.
5. Repairs, which require welding, should be
   performed only with the benefit of the
   appropriate reference information and by
   personnel adequately trained and knowledgeable
   in welding procedures. Determine type of metal
   being welded and select correct welding
   procedure and electrodes, rods or wire to provide
   a weld metal strength equivalent at least to
   that of parent metal.
6. Do not damage wiring during removal operations.
   Reinstall the wiring so it is not damaged nor
   will it be damaged in operation by contacting
   sharp corners, or by rubbing against some object
   or hot surface. Do not connect wiring to a line
   containing fluid.
7. 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.

1. 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.
2. Loose or damaged fuel, lubricant and hydraulic
   lines, tubes and hoses can cause fires. Do not
   bend or strike high pressure lines or install
   ones which have been bent or damaged. Inspect
   lines, tubes and hoses carefully. Do not check
   for leaks with your hands. Pin hole (very small)
   leaks can result in a high velocity oil stream
   that will be invisible close to the hose. This
   oil can penetrate the skin and cause personal
   injury. Use cardboard or paper to locate pin
   hole leaks.
3. 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 protect against oil spray
   onto hot exhaust components in event of a line,
   tube or seal failure, must be installed
   correctly.
4. 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 utilizes pressure.
5. 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.

5
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HOW TO READ THIS MANUAL 1. Service data in the
text Example A Standard value B Repair or
service limit Unit mm (in.)
Clearance between cylinder and piston A 0.020 to 0.105 (0.00079 to 0.00413)
Clearance between cylinder and piston B 0.15 (0.0059)
2. 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)
7
GENERAL INFORMATION
Model View
210310
Truck Models Covered This Service Manual
furnishes servicing and maintenance information
for the following trucks
Truck model Transmission Designation Serial number Engine mounted
DP100 Powershift 3DP 10011- up Mitsubishi 6D16TL diesel engine
DP115 Powershift 4DP 10011- up Mitsubishi 6D16TL diesel engine
DP135 Powershift 5DP 10011- up Mitsubishi 6D16TL diesel engine
DP150 Powershift 6DP 10011- up Mitsubishi 6D16TL diesel engine
8
GENERAL INFORMATION Serial Number Locations
Chassis serial number
Name plate
Transmission serial number
Mast serial number
Diesel engine serial number
210311
9
GENERAL INFORMATION
Technical Data
Truck Model Item Truck Model Item Truck Model Item Truck Model Item DP100 DP115 DP135 DP150
Designation Designation Designation Designation 3DP 4DP 5DP 6DP
Type Type Type Type Standard (with 3-speed powershift transmission) Standard (with 3-speed powershift transmission) Standard (with 3-speed powershift transmission) Standard (with 3-speed powershift transmission)
General Capacity/load center kgf/mm (lbf/in.) Capacity/load center kgf/mm (lbf/in.) Capacity/load center kgf/mm (lbf/in.) 10000/600 (22000/24) 11500/600 (25000/24) 13500/600 (30000/24) 15000/600 (33000/24)
General Lift mm (in.) Lift mm (in.) Lift mm (in.) 3000 (120) 3000 (120) 3300 (130) 3300 (130)
General Lift speed (unloaded/loaded) mm/sec (fpm) Lift speed (unloaded/loaded) mm/sec (fpm) Lift speed (unloaded/loaded) mm/sec (fpm) 360/300 (71/65) 360/340 (71/67) 310/290 (61/57) 310/280 (61/55)
General Lowering speed (unloaded/loaded) mm/sec (fpm) Lowering speed (unloaded/loaded) mm/sec (fpm) Lowering speed (unloaded/loaded) mm/sec (fpm) 500/450 (98/89) 500/450 (98/89) 420/380 (83/75) 420/380 (83/75)
General Tilt angle (forward backward) Tilt angle (forward backward) Tilt angle (forward backward) 15 12 15 12 15 12 15 12
General Free lift mm (in.) Free lift mm (in.) Free lift mm (in.) 0 0 0 0
Performance Travel speeds (unloaded/ loaded) km/h (mph) Travel speeds (unloaded/ loaded) km/h (mph) Forward 31.5/24.5 (20/15) 31.5/24.5 (20/15) 33.0/22.0 (20/14) 33.0/22.0 (20/14)
Performance Travel speeds (unloaded/ loaded) km/h (mph) Travel speeds (unloaded/ loaded) km/h (mph) Reverse 31.5/24.5 (20/15) 31.5/24.5 (20/15) 33.0/22.0 (20/14) 33.0/22.0 (20/14)
Performance Minimum turning radius mm (in.) Minimum turning radius mm (in.) Minimum turning radius mm (in.) 4000 (157) 4060 (160) 4160 (164) 4550 (179)
Performance Turning angle Turning angle Inside 7827 7827 7827 7827
Performance Turning angle Turning angle Outside 5114 5114 5114 5114
Performance Minimum intersecting aisle mm (in.) Minimum intersecting aisle mm (in.) Minimum intersecting aisle mm (in.) 3550 (140) 3590 (141) 3680 (145) 3830 (151)
Tires Gradeability (rated load) At 1.6 km/h (1 mph) At 1.6 km/h (1 mph) 32 29 23 23
Tires Gradeability (rated load) At 2 km/h (1.2 mph) At 2 km/h (1.2 mph) 21 19 15 14
Tires Size of tires (front and rear) Size of tires (front and rear) Size of tires (front and rear) 10.00-20- 14PR (I) 10.00-20- 16PR (I) 12.00-20-18PR (I) 12.00-20-18PR (I)
Tires Inflation pressure of tires (front and rear) kPa (kgf/cm2) psi Inflation pressure of tires (front and rear) kPa (kgf/cm2) psi Inflation pressure of tires (front and rear) kPa (kgf/cm2) psi 700 (7.0) 101 800 (8.0) 116 800 (8.0) 116 800 (8.0) 116
Weight and axle loading (unloaded) Weight kg (lb) Weight kg (lb) Weight kg (lb) 14450 (31860) 15330 (33800) 17320 (38190) 17760 (39160)
Weight and axle loading (unloaded) Front axle loading kg (lb) Front axle loading kg (lb) Front axle loading kg (lb) 7090 (15630) 6950 (15320) 7460 (16450) 7940 (17510)
Weight and axle loading (unloaded) Rear axle loading kg (lb) Rear axle loading kg (lb) Rear axle loading kg (lb) 7360 (16230) 8380 (18480) 9860 (21740) 9820 (21650)
10
GENERAL INFORMATION Dimensions (Approximate)
C
G I
J
N
E
E
A H
D
M L K B F
210312
11
GENERAL INFORMATION Unit mm (in.)
Ref. No. Truck Model Item DP100 DP115 DP135 DP150
A Lift 3300 (130) 3300 (130) 3300 (130) 3300 (130)
B Fork length 1220 (48) 1220 (48) 1220 (48) 1220 (48)
C Fork width 180 (7.1) 180 (7.1) 180 (7.1) 180 (7.1)
D Fork thickness 70 (2.8) 70 (2.8) 90 (3.5) 90 (3.5)
E Tilt angle (forward backward) 15 12 15 12 15 12 15 12
F Overall length 4293 (169) 4371 (172) 4528 (178) 4830 (190)
G Overall width (outside of tires) 2514 (99) 2514 (99) 2599 (102) 2599 (102)
H Overall height (to top of mast lowered) 3137 (124) 3137 (124) 3483 (137) 3483 (137)
I Tread (front) 1900 (75) 1900 (75) 1906 (75) 1906 (75)
J Tread (rear) 1930 (76) 1930 (76) 1890 (74) 1890 (74)
K Wheelbase 2800 (110) 2800 (110) 2800 (110) 3100 (122)
L Front overhang 754 (29.7) 759 (29.9) 792 (31.2) 794 (31.3)
M Ground clearance (at frame) 340 (13.4) 340 (13.4) 380 (15.0) 380 (15.0)
N Minimum turning radius 4000 (157) 4060 (160) 4160 (164) 4550 (179)
1-5
12
COOLING SYSTEM
Specifications
Truck Model Item DP100 DP115 DP135 DP150
Type Forced circulation Forced circulation Forced circulation Forced circulation
Radiator type Corrugated fin with pressure cap (with built-in transmission oil cooler) Corrugated fin with pressure cap (with built-in transmission oil cooler) Corrugated fin with pressure cap (with built-in transmission oil cooler) Corrugated fin with pressure cap (with built-in transmission oil cooler)
Oil cooler type Plate fin type Plate fin type Plate fin type Plate fin type
Capacity (complete system) liter (U.S. gal.) 23 (6.1) 23 (6.1) 23 (6.1) 23 (6.1)
13
COOLING SYSTEM Description
1
4
Detail of transmission oil cooler
2
4
7
6
9
1
3
8
5 To torque converter From torque converter
210313

1. Intercooler
2. Intake hose (intercooler)
3. Outlet hose (intercooler)
4. Radiator
5. Transmission oil cooler

1. Drain cock
2. Upper hose (radiator)
3. Lower hose (radiator)
4. Reserve tank

The radiator with a tube-and-fin type core comes
standard. The fins are corrugated. The cooling
fan is of pusher type and has eight blades to
provide high cooling efficiency. The lower tank
has a built-in transmission oil cooler which, in
operation, is constantly removing heat from the
transmission oil returning from the torque
converter.
14
COOLING SYSTEM
Removal and Installation Radiator and
Intercooler Removal
11
2
1
11
12 13
1
9
4
3
10
6
7
5
9
10
13 14
8
210314
Sequence

1. Engine cover, Gas spring
2. Radiator cover
3. Reserve tank hose
4. Fan guard
5. Intercooler intake hose
6. Intercooler outlet hose
7. Radiator hoses (upper)

1. Radiator hose (lower)
2. Clamp
3. Oil cooler pipe
4. Intercooler mount, Grommet, Collar, Washers
5. Intercooler
6. Radiator mount, Grommet, Collar, Washers
7. Radiator

Start by Loosen the radiator drain cock to drain
coolant from the radiator.
WARNING Make sure the coolant temperature is cool
before opening the drain cock.
15
COOLING SYSTEM Suggestions for Removal

• 1. Intercooler
• Install eyebolts in the bracket mounting bolt
  holes.
• Hitch a sling into the eyebolts and lift the
  intercooler with a crane to remove.

210139
Weight of intercooler
9 kg (20 lb)
2. Radiator (1) Hitch a sling to the radiator
and support the radiator.
206547
Weight of radiator
30 kg (66 lb)
(2) Remove the radiator mounts (at 4 places) and
lift off the radiator.

• Inspection
• 1. Intercooler
• Replace the mounting rubber if it lacks
  elasticity or if it is hardened.
• If foreign substances such as insects or dust
  adhere to the core fins, blow compressed air
  from the opposite direction to remove them,
  taking care not to damage the fins.
• Replace the intercooler if corrosion and rusting
  are remarkable or if the fins are unrepairable.
• Check the intercooler hoses (upper and lower) for
  expansion and damage to the hose clamp. Replace
  them if any abnormality is found.
• 2. Radiator
• (1) Blow dirt and bugs, if any, from the radiator
  fins with compressed air. Be careful not to bend
  the fins because this will decrease cooling
  efficiency.

16
COOLING SYSTEM

• Replace the radiator if the fins are damaged
  beyond repair.
• Check the rubber cushions of the radiator mounts
  and replace them if damaged or deteriorated.
• Check the radiator hoses, upper and lower, and
  replace them if damaged or deteriorated.
• Installation
• To install, follow the reverse of removal
  sequence and do the following steps

1. Intercooler Lower the intercooler, aligning
the lower mount with the mounting pin of the
frame mount.
Mount 210315
2. Hose When connecting a hose to the
intercooler or radiator, insert it fully to the
base. Securely tighten the clamp and make sure
that it stops at the flair of the base and that
it does not come out.

• 3. Antifreeze and Coolant
• Mix antifreeze with distilled water to the
  specified concentration and fill the mixed
  solution to the radiator neck.
• Likewise, fill the mixed solution to the
  specified level in the reserve tank.
• Start the engine and warm it up with attention to
  noise.
• If coolant in the reserve tank decreases, fill
  the mixed solution to the specified level.

101641
Fill within this range. 101465B
17
COOLING SYSTEM Troubleshooting
Radiator corroded
Repair or replace.
Hose clamps loose
Retighten or replace.
Coolant leaks from radiator
Upper or lower hose deteriorated due to aging
Replace.
Drain cock defective
Replace.
Cracks in coolant passage in engine
Check and repair.
Debris in radiator fin
Clean.
Radiator fins distorted
Repair or replace.
Cooling system overheats
Water pump belt loose
Readjust. Check for elongation or cracks due to
aging and replace if necessary.
Thermostat defective
Repair or replace.
Hose clamps loose
Retighten or replace.
Oil leaks from oil cooler hose
Oil cooler corroded
Repair or replace.
18
ELECTRICAL SYSTEM
Specifications
Truck Model Item Truck Model Item DP100 DP115 DP135 DP150
Battery Model nomenclature No. of batteries 95E41R 2 95E41R 2 95E41R 2 95E41R 2
Battery Voltage V 12 12 12 12
Battery Capacity Ah 80 80 80 80
Transmission shift lever Transmission shift lever Electric Electric Electric Electric
Console box Console box With OK monitor With OK monitor With OK monitor With OK monitor
Automatic transmission controller Automatic transmission controller Electronic Control Unit (ECU) Electronic Control Unit (ECU) Electronic Control Unit (ECU) Electronic Control Unit (ECU)
Starter switch Starter switch Anti-restart type Anti-restart type Anti-restart type Anti-restart type
Lamps Lamps See Lamp Bulb Specifications. See Lamp Bulb Specifications. See Lamp Bulb Specifications. See Lamp Bulb Specifications.
19
ELECTRICAL SYSTEM Location of Components
Front combination light
Harnass A
Right side
Seat frame
Heater cable
To air heater relay
Engine
Left side
To battery relay
To engine coolant temperature gauge unit
Harness C
Rear combination light
Harness B
210316
For the components to which harnesses A, B and C
are connected, see the pages which
follow. CAUTION Clamp the harnesses away from
moving parts or sharp edges. Repair a frayed
harnesses with vinyl tape.
20
ELECTRICAL SYSTEM
Memo
21
ELECTRICAL SYSTEM Harness A (located under the
seat frame) Part 1
2
13
1
3
21
6
4
1
16
12
8
5
23
10
9
12
11 18
17
19 20
7
15
22 14
14
See page 3-6. 14
210317
22
ELECTRICAL SYSTEM

1. Console box
2. Sub-meter
3. Steering column
4. Horn switch
5. Transmission shift lever
6. Turn signal switch
7. Stop lamp switch
8. RH front combination lamp
9. RH high beam
10. LH front combination lamp
11. LH high beam
12. Diode
13. Ground point
14. To harness B
15. To transmission harness
16. Junction connector
17. RH working lamp (option)
18. LH working lamp (option)
19. Cab power supply (option)

23
ELECTRICAL SYSTEM Harness A (located under the
seat frame) Part 2
4
7
5
8
6
2
3
1
11 10
9
210318
24
ELECTRICAL SYSTEM

1. ECU
2. Relay for battery relay
3. Relay for air dryer
4. F signal relay
5. R signal relay
6. Battery fuse
7. Fuse holder A
8. Fuse holder B
9. Speedometer power supply (option)
10. Speedometer signal (option)
11. Option terminal

25
ELECTRICAL SYSTEM Harness B (located at the left
of engine compartment)
4
5 1
1
1
16
8
2
9 10
6
2
3
7
12
15
11
14
13
210319
26
ELECTRICAL SYSTEM

1. To harness A
2. To harness C
3. Glow plug
4. Electronic horn
5. Lining wear detection switch
6. Fuel tank unit
7. Battery relay
8. M5 terminal
9. Battery side terminal
10. Frame side terminal
11. Battery
12. Starter relay
13. Alternator
14. Engine coolant temperature gauge unit
15. Ground point
16. Earphone switch (option)

27
ELECTRICAL SYSTEM Harness C (located at the
right of engine compartment)
1
2
3
5
4
5
6
12 11
7
8
13 14
9
10
210320
28
ELECTRICAL SYSTEM

• 1. To harness B
• 2 Low air pressure switch
• Air dryer
• Air pressure gauge unit
• Engine stop control timer
• Engine stop solenoid
• Oil bypass alarm switch
• Engine oil pressure switch
• RH rear combination lamp
• LH rear combination lamp
• Ground point
• Air cleaner dust indicator (option)
• Working and license plate lamp (option)
• Back-up buzzer (option)

3-11
29
ELECTRICAL SYSTEM
Description Console Box
4
3
5
1

1. Engine coolant temperature gauge
2. Travel speed select switch
3. Fuel gauge
4. Service hourmeter
5. OK monitor
6. Starter switch
7. Lighting switch
8. Fuse box

7 6
8
2 207464
OK Monitor
5
4
3
2
1
6
7
8
9
207465
Function
No. Indicator light OFF ON or flickering Remarks
1 Powershift transmission oil temp. indicator light Normal Overheating
2 Air cleaner element indicator light Normal Clogged Option
3 Brake fluid level indicator light Normal Low
4 Engine oil pressure indicator light Normal Low
5 Alternator not charging indicator light Normal Abnormal
6 Glow plug indicator light Heating completed Heating
7 Turn signal indicator light Turn signal OFF Turn signal ON
8 Engine coolant level indicator light Normal Low Option
9 Headlamp beam indicator light Low High Option
How to check indicator light bulbs The bulbs are
normal if the indicator lights 1, 2, 3 and 8 come
ON when the starter switch key is turned to (ON)
position. (The indicator lights will go OFF when
the engine starts.)
3-12
30
ELECTRICAL SYSTEM
Components
9 6
5
4 3 2
1
7
8
207176

1. Power relay
2. Power relay
3. Turn signal relay

1. Glow plug relay
2. Glow plug timer
3. Lighting switch

1. Starter switch
2. Fuses
3. Travel speed select switch

Spare Terminals The spare terminal cord 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 taped to the harness protector.
Spare terminal
207209
3-13
31
ELECTRICAL SYSTEM Side Instrument Panels
8
5
7
1 1
2
6
4
3
210321

1. Working lamp switches (option)
2. Working lamp indicators (option)
3. Windshield wiper switches (option)
4. Brake lining wear indicator

1. Brake air pressure gauge
2. Battery switch
3. Powershift transmission oil temperature gauge
4. Speedometer (option)

3-14
32
ELECTRICAL SYSTEM
Major Components Electronic Control Unit (ECU)
Failure indicator lights
LED (green)
LED (red)
Rear (mounting) face
205509
The Electronic Control Unit (ECU) has a built-in
1- chip microcomputer. This computer processes
signals from the travel speed sensor for
actuating the 2-speed automatic
transmission. The ECU has self-diagnostic
failure indicator lights which come on when any
problem occurs in the electrical system, thereby
allowing the operator to locate the problem. It
has the following fail-safe
systems so that failure of power, control
circuit, or other components will not endanger
the operator.
NOTE
The failure indicator lights are located on the
rear (mounting) face of the ECU. This makes it
necessary to remove the ECU from the truck to
observe these lights.
Fail-safe Systems
Failure Function
Solenoid output signal circuit open Turns OFF the power line and causes an indicator light to come on when the solenoid output signal circuit is open.
Travel speed sensor circuit open Allows the truck to run at the present travel speed but causes an indicator light to come on.
Failure Indicator Light Flashing Patterns
Failure Flashing pattern
Travel speed sensor circuit open
2-speed automatic transmission control circuit open
204697
NOTE The failure indicator lights come ON and
go OFF as shown below
ON OFF

204668
3-15
33
ELECTRICAL SYSTEM
Starter Switch (Anti-restart Type) This switch
has a built-in mechanical lockout. This lockout
restrains the key from turning to (START)
position from (ON) position (as when the engine is
running) to help prevent damage to the starter
pinion or flywheel ring gear. The (ON) position
of the switch is for energizing the glow plugs.
(OFF) (ON)
M
B
(START)
S 203561A
Connection Chart
Key position Terminal B M S
Key position Component Fuse box, batteries, alternator, glow plugs Fuse box, engine stop control timer, glow plug timer and relay Transmission shift lever, glow plug timer
(OFF) (OFF) ?
(ON) (ON) ? ?
(START) (START) ? ? ?
Lighting Switch
OFF 1st 2nd Knob position 8 8 Stroke (0.3)
(0.3) Unit mm (in.)
206481
Connection Chart Terminal
B
T
H
P
Tail lamps, license plate lamp (option),
instrument panel lamp
Component
Batteries (fuses)
Front combination lamps
Headlamps
Knob position
(OFF) 1st position 2nd position
? ?
? ?
? ?
?
3-16
34
ELECTRICAL SYSTEM
Fuse Box
Symbol Capacity Circuit
A 10 A Transmission shift lever
B 10 A Instrument panel lamp, turn signals
C 10 A Spare terminal
D 15 A Lamps
E 10 A Horn
F 10 A Spare
G 10 A Transmission controller, vacuum buzzer, stop lamps
H 10 A Back-up lamps
J 15 A Spare
A B C D E F G H J
101441F
Optional fuses
Fuse holder B Fuse holder A Battery
fuse 210322
Fuse Capacity Circuit
Battery fuse 15 A
Fuse holder A 15 A Working lamps
Fuse holder A 10 A Revolving lamp
Fuse holder A 10 A Air dryer relay
Fuse holder B 15 A Air conditioner
Fuse holder B 5 A Car heater
Fuse holder B 20 A Windshield wiper
Fuse holder B 10 A Cab
3-17
35
ELECTRICAL SYSTEM Lamp Bulb Specifications
Item Type of lamp Item Type of lamp Quantity of bulbs Color of lens Bulb Bulb Remarks
Item Type of lamp Item Type of lamp Quantity of bulbs Color of lens For 24V system Schematic drawing Remarks
Headlamps Headlamps 2 Frosted 60W 60/60W (option)
Combination lamps (front) Turn signal lamps 2 Amber 25W Standard (mounted on overhead guard)
Combination lamps (front) Clearance lamps 2 Frosted 12W Standard (mounted on overhead guard)
Combination lamps (rear) Stop and tail lamps 2 Red 10W/25W
Combination lamps (rear) Turn signal lamps 2 Amber 25W
Combination lamps (rear) Back-up lamps 2 Frosted 25W
Working lamps (front) Working lamps (front) 2 Frosted 60W/60W Option
Working lamps (rear) Working lamps (rear) 2 Frosted 60W/60W Option
License plate lamp License plate lamp 1 Frosted 12W Option
Instrument panel lamps Instrument panel lamps 2 Frosted 3W For combination meter
OK monitor indicator lamps OK monitor indicator lamps 5 Frosted 3W For combination meter
207466
3-18
36
ELECTRICAL SYSTEM
Removal and Installation Console Box Removal
6
5
2
5
4
3
1
207539A

• Start by
• Turn off the starter switch, and disconnect the
  negative (grounding) cable from the battery.
• Remove nut and washer on steering wheel, and
  remove the steering wheel.

1. Disconnect the electrical wires at connectors,
   and remove transmission shift lever and turn
   signal lever 5.
2. Remove bolts on console box assembly 6, and
   remove the console box assembly.

Installation To install, follow the reverse of
removal sequence.
Suggestions for Removal

1. Disconnect the electrical wires at connectors 1.
2. Remove screws on cover 2 using a flat-tip
   screwdriver, and remove the cover.
3. Remove screws on cover (U-RE) 3, and remove the
   cover.
4. Remove screws on cover (U-FR) 4, and remove the
   cover.

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37
ELECTRICAL SYSTEM Disassembly and
Reassembly Console Box Disassembly
1
2
3
207175
Reassembly To reassemble the console box, follow
the reverse of disassembly sequence.
Suggestions for Disassembly

1. Remove two screws 1 securing the cover. (Use a
   flat-tip screwdriver.)
2. Remove six screws 2 and separate the front and
   rear panels.
3. Remove four screws 3 securing the instrument
   panel.

NOTE To replace the instrument panel bulbs,
remove screws 2 and 3.
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38
ELECTRICAL SYSTEM
Components in Console Box Disassembly
10 7 6 5 4 3 2 8 9 1 207558
Sequence

1. Glow plug timer
2. Lighting switch
3. Starter switch
4. Fuses
5. Travel speed select switch

1. Harness
2. Power relay
3. Power relay
4. Turn signal relay
5. Glow plug relay

Reassembly To reassemble the console box, follow
the reverse of disassembly sequence.
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39
ELECTRICAL SYSTEM Combination Meter Disassembly
1 2 3 4 5 6 7 8 9 206480
Sequence

1. Meter case
2. Printed circuit plate
3. Bulb
4. Socket

1. Instrument panel
2. Dial
3. Engine coolant temperature gauge
4. Service hourmeter
5. Fuel gauge

Bulb replacement For bulb replacement, remove the
socket from the printed circuit plate by turning
it counterclockwise. For configuration of the
indicator lights, refer to OK Monitor.
CAUTION
Be careful not to damage the printed circuit
plate when disassembling the combination meter.
Reassembly To reassemble the combination meter,
follow the reverse of disassembly sequence.
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40
ELECTRICAL SYSTEM
Sub-Meter Disassembly
6 7
4
8
5
3
9
10
2
11
12 1
210323

• Sequence
• Disconnect the harness at connectors 1.
• Remove three bolts 2 that hold the side
  instrument panel, and remove the instrument
  panel from the seat frame.
• Remove four screws 3 and separate panel 4 from
  cover
• 5.
• Remove the following components
• Brake air pressure gauge
• Battery switch
• Brake lining wear indicator
• Powershift transmission temperature gauge
• Low air pressure buzzer
• Power relay
• Brake lining wear buzzer

3-23
41
ELECTRICAL SYSTEM Reassembly Follow the reverse
of disassembly sequence. NOTE Connect the air
pressure gauge harness to the correct terminal.
(Green/red) Air pressure gauge
terminal (Green) (Blue)
(Black)
To brake lining wear indicator To battery
switch
To low air pressure buzzer
To power relay
To brake lining wear buzzer
210324
3-24
42
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43
ELECTRICAL SYSTEM
Precautions for installing other parts
1. Engine stop solenoid installation (1) Before
installing the solenoid, push the plunger all the
way into it to make sure that the plunger stroke
coincides with the standard value.
0
0
L26 mm (1.02 in.)
-1.5
-0.063
Stroke L
26 0 mm (1.02 0 in.) 0.063
1.6
Note Record the measured value of plunger stroke.
210325

1. After installing the solenoid, connect a lamp (or
   tester) and power supply to it.
2. Energize the solenoid to see if the lamp is lit.
   (Check voltage when the tester is used.)

V
Testa Lamp
NOTE

• When testing the solenoid -
• Do not energize any longer than 5 seconds.
• Do not energize any more than 5 times.

DC24V
AUX
210326
3-25
44
ELECTRICAL SYSTEM Batteries 1. Electrolyte
specific gravity (S.G.) reading and battery
condition
Electrolyte S.G. reading at 20C (68F) Battery condition Adjustment
1.280 to 1.265 Battery is fully or well charged. Check each cell for S.G.
1.260 to 1.225 Battery is half charged. Recharge the battery. Make sure there is neither faulty component, short-circuited cord nor corroded connection in the system.
1.220 or lower Battery is discharged. Recharge the battery. If difference in S.G. among the cell is large, adjust the S.G. during recharging.
When S.G. difference among cells is more than 0.040 A cell with a low S.G. is in shorted condition. Some electrolyte has been lost. Too much electrolyte, or water in electrolyte, too. Recharge until voltage and S.G. stabilize and have remained 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.

1. During charging, adjust the charging current to
   prevent the battery electrolyte temperature from
   rising beyond 45C (113F).
2. When connecting the cables to the battery, begin
   with the cable for the positive () terminal.
   When disconnecting them from the battery, begin
   with the cable for the negative (-) terminal.

2. Relationship between electrolyte specific
gravity and charging rate

• To check the battery for charging, take
  hydrometer readings on its electrolyte the
  battery may be deemed to be fully charged if the
  readings are between 1.280 and 1.265 at normal
  temperature. The tendency of the charging system
  can be told from the way the electrolyte level
  goes down to expose cell plates. If refilling
  (with distilled water) 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.
• 3. Precautions for battery charging
• In slow-charging a dead battery, the charging
  current should be about 1/10 the capacity of the
  battery to be charged.
• In quick-charging the battery, the battery
  capacity in ampere should not be exceeded.

CAUTION
Be sure to turn off the starter switch and
lighting switch before disconnecting or
connecting the battery cables to prevent the IC
regulator from suffering damage.
3-26
45
ELECTRICAL SYSTEM
Troubleshooting Starter System
Dead or weak battery Starter circuit
defective Poor continuity in starter switch
Starter or starter relay defective Transmission
shift lever not in neutral position
Recharge or replace. Repair or
replace. Replace. Replace. Move the lever to
neutral position.
Starter will not crank engine
Starter switch
Turning off starter switch will not stop engine
Open or short circuit Engine stop solenoid
defective Control timer defective
Repair or replace. Replace or readjust. Replace.
Gauges
Open or short circuit Gauge internally defective
Gauge unit defective
Repair or replace. Replace. Replace.
Will not indicate at all
Temperature gauges
Will not indicate accurately
Wrong type of gauge or gauge unit Loose terminal
connection
Replace. Repair.
Circuit between gauge and gauge unit
Repair.
Will indicate higher than actual temperature
grounded
Gauge internally defective
Replace.
Open or short circuit Gauge internally defective
Gauge unit defective
Repair or replace. Replace. Replace.
Will not indicate at all
Gauge or gauge unit not of the type
Replace.
Will not indicate accurately
called for
Loose terminal connection
Repair.
Fuel gauge
Circuit between gauge and gauge unit
grounded Gauge internally defective Gauge unit
defective
Repair.
Will indicate Full regardless of fuel level
in tank
Replace. Replace.
Circuit between gauge and gauge unit open or
short Gauge unit defective Gauge internally
defective
Repair.
Will indicate Empty regardless of fuel level
in tank
Replace. Replace.
Will not indicate (even if air pressure is
acting on gauge unit)
Open or short circuit Gauge defective Gauge
unit defective
Repair or replace. Replace. Replace.
Air pressure gauge
Indication will not return to 0 (when air
pressure is 0 kPa (0 kgf/cm2) 0 psi)
Circuit between gauge and gauge unit
grounded Gauge defective Gauge unit defective
Repair.
Replace. Replace.
3-27
46
ELECTRICAL SYSTEM Lighting System
Dead or weak battery Fuses blown out Open or
short circuit Poor grounding
Recharge or replace. Check and replace. Repair
or replace. Clean ground spot and re-make
connection. Replace.
Will not light
Bulbs burnt out
Lamps general
Dead or weak battery Burned contact points in
switches Loose terminals Dirty lenses Waterdrops
inside lenses Bulbs expired in service life
Check and recharge. Repair or replace. Repair.
Clean. Dry and replace packings. Replace.
Will light dimly
Headlamps
Light switch defective Bulbs burnt out
Replace. Replace.
Will not light
Bulbs burnt out Turn signal relay defective
Replace. Replace.
Will not flash
Turn signal relay defective Turn signal switch
defective
Replace. Replace.
Will not go out
Turn signal lamps
Wrong wattage of bulbs Weak battery Turn signal
relay detective
Replace. Recharge or replace. Replace.
Will flash too slow
Wrong wattage of bulbs Turn signal relay
defective
Replace. Replace.
Will flash too fast
Back-up lamp switch defective
Correct if improperly installed replace if
internally defective. Replace.
Back-up lamps will not lights
Other lamps
Bulbs burnt out
License plate lamp will not lights
Lighting switch defective Bulb burnt out
Replace. Replace.
Alarm Unit
Fuse blown out Open or short circuit Horn switch
defective Horn defective Horn button defective
Check and replace. Repair or replace.
Repair or replace. Replace. Replace.
Will not give blast of sound
Horn
Will give abnorm- al blast of sound
Horn switch defective Horn defective
Replace. Replace.
3-28
47
ELECTRICAL SYSTEM
Batteries
Alternator belt slipping
Readjust.
Alternator Stator coil grounded or
open-circuited Rotor coil open Brushes poorly
seating on slip rings
Repair or replace. Replace. Replace brushes if
worn. Clean holder and polish slip
rings. Replace.
Diode ruptured
Regulator
Regulated voltage setting too low
Readjust.
Tends to run down rapidly
Batteries Not enough electrolyte or wrong
proportion of acid to water Battery cell plates
deteriorated (possibly internal
short-circuit) Terminal connections loose
Refill and check specific gravity 1.280 Replace.
Clean and retighten.
Wiring Open or loose connection between starter
switch and regulator IC terminal Fuse blown, or
loosely set in holder
Repair.
Replace and repair. Repair.
Open or loose connection between F terminals of
regulator and alternator
Wiring
Circuit between regulator IC and F terminals
shorted or miswired Poor grounding of regulator F
terminal
Repair.
Repair.
Tends to get overcharged
Regulator Pressure coil open-circuited
Replace. Readjust.
Regulated voltage too high
3-29
48
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