CATERPILLAR CAT EP16N EP18N EP20CN FORKLIFT LIFT TRUCKS Service Repair Manual Instant Download

1
Service Manual
MC/FC
Chassis, Mast Options
EP16N-48v EP18N-48v EP20CN-48v
ETB15-20011-up ETB15-70001-up ETB17-20011-up
For use with EP16N-EP20CN Controller Service
Manual.
99759-67100
2
FOREWORD
This service manual is a guide to servicing of
Cat lift truck of 1.6 ton, 1.8 ton and 2.0 ton
classes. 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. Safety
Related Signs The following safety related signs
are used in this service manual to emphasize
important and critical instructions
Indicate a specific potential hazard resulting
in serious bodily injury or death.
! WARNING
Indicate 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. 99759-67100
3
HOW TO READ THIS MANUAL Disassembly diagram
(example)
Each disassembly diagram is followed by
Disassembly sequence and Suggestion for
disassembly.
Disassembly sequence

• Cover, Bolt, Washer (part name)
• Output shaft (part name)
• Suggestion for disassembly
• (1) Output shaft removal

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)
A Standard value B Repair or service limit
4
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5
! WARNING
SAFETY
! WARNING
! 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 understand the
OPERATION MAINTENANCE MANUAL before performing
any lubrication or maintenance.
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.

1. 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.
2. 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.
3. 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.
4. To avoid burns, be alert for hot parts on trucks
   which have just been stopped and hot fluids in
   lines, tubes and compartments.
5. 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.
6. 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.

6

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.
8. 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.

1. 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.
2. 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.
3. 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.
4. 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.

7
GENERAL INFORMATION
Vehicle Exterior
Control lever (MC models)
Joystick box (FC models)
211146
Models This manual applies to EP16N, EP18N and
EP20CN.
Truck Model Serial Number
EP16N ETB15-20011-up
EP18N ETB15-70001-up
EP20CN ETB17-20011-up
8
GENERAL INFORMATION Serial Number Locations
Nameplate
Mast number
Chassis number
211270
9
GENERAL INFORMATION
Chassis and Mast Model Identification
Chassis EP 16 N
Generation designator Maximum capacity 16
1600 kg (3500 lb) 18 1800 kg (4000 lb) 20 2000
kg (4400 lb) Battery type
Mast 4
G
15
A
30
Maximum lifting height 30 stands for 3000 mm
(118 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 15 1 ton class 20 2 ton
class Kind of mast G simplex mast H duplex
mast J triplex mast Major change (1 for the
original, 2 for the first change, and so on up
to 9)
10
GENERAL INFORMATION Dimensions
B
E
F
C
D A
211271
11
GENERAL INFORMATION
Technical Data
Truck Models Truck Models Truck Models EP16N EP18N EP20CN
Class Class Class 1.6 ton 1.8 ton 2.0 ton
Load Capacity/Load Center Load Capacity/Load Center N (kgf)/mm lbf/in. 15690 (1600)/500 3530/20 17650 (1800)/500 3970/20 19610 (2000)/500 4410/20
Truck size Length to Fork Face A mm (in.) 2074 (81.7) 2074 (81.7) 2188 (86.1)
Truck size Width B mm (in.) 1070 (42.1) 1070 (42.1) 1130 (44.5)
Truck size Height of Overhead C Guard mm (in.) 2048 (80.6) 2048 (80.6) 2048 (80.6)
Wheelbase D Wheelbase D mm (in.) 1360 (53.5) 1360 (53.5) 1463 (57.6)
Truck weight, without load/ including battery Truck weight, without load/ including battery kg (lb) 3190 (7033) 3280 (7231) 3470 (7650)
Tread Front/Rear E/F Tread Front/Rear E/F mm (in.) 913/898 (35.9/35.4) 913/898 (35.9/35.4) 935/898 (36.8/35.4)
Tires Size Front Front 18 ? 7-8 18 ? 7-8 200/50-10
Tires Size Rear Rear 16 ? 6-8 16 ? 6-8 16 ? 6-8
Turning Radius Turning Radius mm (in.) 1810 (71.3) 1810 (71.3) 1910 (75.2)
Travel Speeds Unloaded/Loaded km/h (mph) Travel Speeds Unloaded/Loaded km/h (mph) Travel Speeds Unloaded/Loaded km/h (mph) 17/17 (10.6/10.6) 17/17 (10.6/10.6) 17/17 (10.6/10.6)
Maximum Gradeability Unloaded/Loaded Maximum Gradeability Unloaded/Loaded Maximum Gradeability Unloaded/Loaded 35/27 35/25 35/24
Lift Speeds Unloaded/Loaded Lift Speeds Unloaded/Loaded m (in.)/sec 0.60/0.50 (23.6/19.7) 0.60/0.44 (23.6/17.3) 0.60/0.40 (23.6/15.7)
Lowering Speed Unloaded/Loaded Lowering Speed Unloaded/Loaded m (in.)/sec 0.5/0.52 (19.7/20.5) 0.5/0.52 (19.7/20.5) 0.5/0.52 (19.7/20.5)
Battery Voltage Battery Voltage V 48 48 48
Battery Rated Capacity (5 hrs.) MAX Ah Battery Rated Capacity (5 hrs.) MAX Ah Battery Rated Capacity (5 hrs.) MAX Ah 600 600 720
Battery Compartment Size Battery Compartment Size mm (in.) 1006 ? 521 ? 650 (39.6 ? 20.5 ? 25.6) 1006 ? 624 ? 650 (39.6 ? 24.6 ? 25.6) 1006 ? 624 ? 650 (39.6 ? 24.6 ? 25.6)
Battery Weight Battery Weight kg (lb) 865 (1907) 865 (1907) 1000 (2205)
Tilt Angle (forwards-backwards) Tilt Angle (forwards-backwards) Tilt Angle (forwards-backwards) 6-7 6-7 6-7
Drive Motor, 60 min rating Drive Motor, 60 min rating kW 2 ? 6.3 2 ? 6.3 2 ? 6.3
Hydraulic Motor (15 duty) Hydraulic Motor (15 duty) kW 14 14 14
Drive Motor Control Method Drive Motor Control Method Drive Motor Control Method MOSFET MOSFET MOSFET
Hydraulic Motor Control Method Hydraulic Motor Control Method Hydraulic Motor Control Method MOSFET MOSFET MOSFET
1-5
12
VEHICLE ELECTRICAL COMPONENTS
1 6 2 5 3 4 103043
Console Box

1. Central vehicle monitoring system (CVMS)
2. Mode selector button
3. Steering tilt lever
4. Key switch
5. Lighting switch
6. Mode check button

NOTE
For setting the clock and selection of KPH or
MPH, refer to Selection of KPH or MPH and
Setting the clock.
Functions of Central Vehicle Monitor System (CVMS)
9 9 8
10

1 2 3 4 4 5 6 7
Operations Operations 211131
No. Monitor name Monitor name Monitor name When OFF When OFF When OFF When OFF When OFF When ON or flashing When ON or flashing When ON or flashing When ON or flashing Remarks Remarks
1 Service indicator Service indicator Service indicator Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached. Starts flashing 20 hours before set time. Remains ON when set time is reached.
Seat belt warning Seat belt warning Seat belt warning Seat belt is fastened. Seat belt is fastened. Seat belt is fastened. Seat belt is fastened. Seat belt is fastened. Seat belt is not Seat belt is not Seat belt is not Seat belt is not
2 light light light fastened when operator sits on seat fastened when operator sits on seat fastened when operator sits on seat fastened when operator sits on seat
(seat switch is turned (seat switch is turned (seat switch is turned (seat switch is turned
on). on). on). on).
2-1
13
VEHICLE ELECTRICAL COMPONENTS
No. Monitor name When OFF When ON or flashing Remarks
3 Controller/motor overheat indicator Controller, drive motors and pump motor in normal temperature Overheating Overheating causes a significant output loss. When component temperature returns to normal levels, output power returns.
4 Remaining battery charge warning light Normal battery condition Flashing indicates battery needs to be recharged soon. ON indicates battery needs to be recharged and lifting function inoperable.
5 Brake fluid level indicator Normal fluid level Low fluid level
6 Parking brake warning light Parking brake disengaged Parking brake engaged
7 Fault detection indicator Normal Vehicle malfunction Error codes appear on the error code display.
8 Vehicle speed and error code display Displays the vehicle speed during normal operation and displays an error code in the event of a malfunction. Displays the vehicle speed during normal operation and displays an error code in the event of a malfunction. The vehicle speed display can be switched between KPH and MPH. Follow the steps in Selection of KPH or MPH below.
9 Battery discharge indicator (BDI) The battery charge status is indicated by the ten element indicator. When fully charged, all elements are lit through to the right side. As the battery discharges, the indicator elements decrease toward the left side. When only one element is on, the remaining battery charge warning light 4 in the LED section will flash. When the indicator completely goes off, the remaining battery charge warning light 4 will be continuously lit and the vehicle enters power reduction mode. The battery charge status is indicated by the ten element indicator. When fully charged, all elements are lit through to the right side. As the battery discharges, the indicator elements decrease toward the left side. When only one element is on, the remaining battery charge warning light 4 in the LED section will flash. When the indicator completely goes off, the remaining battery charge warning light 4 will be continuously lit and the vehicle enters power reduction mode. The battery charge status is indicated by the ten element indicator. When fully charged, all elements are lit through to the right side. As the battery discharges, the indicator elements decrease toward the left side. When only one element is on, the remaining battery charge warning light 4 in the LED section will flash. When the indicator completely goes off, the remaining battery charge warning light 4 will be continuously lit and the vehicle enters power reduction mode.
10 Hourmeter, time display It normally displays the time. When the key switch is set to the I (ON) position, the drive motor, pump motor, and vehicle service hours are indicated sequentially. It normally displays the time. When the key switch is set to the I (ON) position, the drive motor, pump motor, and vehicle service hours are indicated sequentially. The time of clock can be adjusted. Follow the steps in Setting the clock below.
2-2
14
VEHICLE ELECTRICAL COMPONENTS
Selection of KPH or MPH

1. Apply the parking brake.
2. Place the direction lever in NEUTRAL.
3. Turn the key switch to the I (ON) position.
4. Push and hold button 1 for one to two seconds.

Button 1
Button 2
NOTICE Display will show KPH and a 24-hour clock
until it is changed. When MPH is selected, the
clock will change to a 12-hour clock.
Setting the clock
103043

1. Apply the parking brake.
2. Place the direction lever in NEUTRAL.
3. Turn the key switch to the I (ON) position.
4. Push and hold button 1 until the minutes display
   flashes.
5. Release button 1.
6. Adjust the minutes with button 2.
7. Push button 1 and release when the hours display
   flashes.
8. Adjust the hour with button 2.
9. Push button 1 to lock in the time.

2-3
15
VEHICLE ELECTRICAL COMPONENTS Error code display
Indication Indication Condition
E E Indicator flickers if seat switch is turned off during driving operation. Then, indicator turns on when seat switch is turned on again. Indicator turns off when direction lever and accelerator pedal are returned.
(E) 0 ON Right traction motor overheated
E 1 ON Left traction motor overheated
E 2 ON Pump motor overheated
E 5 ON Right traction inverter overheated
E 6 ON Left traction inverter overheated
E 7 ON Pump inverter overheated
H 1 ON Faulty setting of lift lever
H 2 ON Faulty setting of tilt lever
H 3 ON Faulty setting of attachment 1 lever
H 4 ON Faulty setting of attachment 2 lever
H 5 ON Faulty setting of attachment 3 lever
(L) (L) Indicator flickers if seat switch is turned off during lifting operation. Then, H1 to H5 turn on when seat switch is turned on again. Indicator turns off when lifting operation is suspended.
(E) means flickering.
2-4
16
VEHICLE ELECTRICAL COMPONENTS
Electrical Components in Console Box
Horn cable Monitor cable 2 Direction
lever switch cable 1 211148

1. Key switch
2. Lighting switch

2-5
17
VEHICLE ELECTRICAL COMPONENTS Disassembly and
Reassembly Disassembly
2 3 1 5 4 211149
Sequence

1. Steering tilt lever
2. Console box (rear panel)

1. Console box (front panel)
2. Central vehicle monitor panel
3. Direction lever

• Disassembly procedure
• Remove the front panel and monitor panel from the
  console box.
• Disconnect the harness connectors from the horn
  and direction lever.
• Remove the screw from the steering tilt lever,
  and remove the lever from the rear panel of the
  console box.
• Remove the rear panel.

T-nut Steering tilt lever Screw 208079
Reassembly Follow the disassembly procedure in
reverse.
2-6
18
VEHICLE ELECTRICAL COMPONENTS
Direction Lever Structure
4 1 2 3 208080

1. Lever
2. Harness

1. Connector
2. Screw

2-7
19
VEHICLE ELECTRICAL COMPONENTS Accelerator Control
Accelerator pedal
Initial position
Stopper bolt
1.5 to 2.5
Lock nut
Switching position of idle switch
Floor plate
30 to 32 mm (1.18 to 1.26 in.)
Accelerator lever
Accelerator Adjusting screw
Position meter
211136

• Adjustment procedure
• Disconnect the battery plug.
• Set the stopper bolt to 30 to 32 mm (1.18 to 1.26
  in.) from the floor to the upper face of bolt.
• Adjust the mounting angle of the position meter
  using the adjusting screw so the switch inside
  the position meter turns on when the accelerator
  lever is moved 1.5 to 2.5 from the initial
  position.
• Make sure the inside switch turns ON by checking
  the continuity between the two terminals
  (indicated by arrows) by using an ohmmeter.
• Perform the accelerator self-diagnostics
  according to the self-diagnosis table (See
  Controller Service Manual). The display shows
  OFF and Speed 0 without the accelerator
  depressed. Depress the accelerator a little. The
  display shows ON before the speed changes from 0
  to 1. If not, then readjust accelerator switch.
• Make sure the display shows Speed 16 when the
  accelerator is fully depressed. If not, readjust
  the stop bolt.

Connector CN7
208081
2-8
20
VEHICLE ELECTRICAL COMPONENTS
Key Switch
Terminal B M M
Connection destination Main fuse Battery Logic card Logic card
(OFF)
I (ON) ? ?
206806
Lighting Switch
Terminal 2, 5 3 3 6 6
Connection destination Battery Head lamps Head lamps Working lamps Working lamps
1st position (Circuit 1) ? ?
2nd position (Circuit 1 2) ? ? ?
OFF 1st (cir. 1) 2nd (cir. 1 2)
Push
2
BAT
Cir. 1 6 Cir. 2
5
3
211150
2-9
21
VEHICLE ELECTRICAL COMPONENTS Fuses
Capacity (A) Location Main connecting device
500 Contactor assembly Traction motor
500 Contactor assembly Pump motor
15 Fuse holder Key switch, Lighting switch
10 Fuse holder Power relay
NOTE Refer to Parts Manual for proper
replacement fuses.
Lamp Specification Chart
Item Lamp Quantity Bulb color Bulb Bulb Remarks
Item Lamp Quantity Bulb color 48 V External diagram Remarks
Head lamps 2 Clear 45 W
Working lamp 1 Clear 45 W
205833
2-10
22
VEHICLE ELECTRICAL COMPONENTS Troubleshooting of
Lighting and Horn Systems
Complaint Complaint Possible cause Remedy
Lamps-general Will not light Dead or weak battery Fuses blown out Open or short in circuit Poor grounding Bulbs burnt out Recharge or replace. Check and replace. Repair or replace. Clean ground spot and re-make connection. Replace.
Lamps-general Will light dimly Dead or weak battery Burned contact points in switches Loose terminals Dirty lenses Waterdrops inside lenses Bulbs expired service life Check and recharge. Repair or replace. Retighten. Clean. Dry and replace packings. Replace.
Head Will not light Lighting switch defective Bulbs burnt out Replace. Replace.
Other lamps Backup lamps will not light a) Backup lamp switch defective Correct if improperly installed replace if
Other lamps internally defective.
Other lamps b) Bulbs burnt out Replace.
Horn Will not give blast of sound Fuse blown out Open or short in circuit Check and replace. Repair or replace.
Horn c) Horn switch defective Replace.
Horn d) Horn defective Replace.
Horn e) Horn button defective Repair or replace.
Horn Will give ugly blast of sound Horn switch defective Horn defective Replace. Replace.
lamps
2-11
23
VEHICLE ELECTRICAL COMPONENTS Joystick
Box Description This system, unlike the
conventional mechanical control, is
electronically actuated to reduce the effort
required of the operator in moving the control
levers for lift, tilt and attachment functions.
(1) In the duplex and triplex full free masts,
more oil returns from the 1st lift cylinder than
from the 2nd lift cylinders to allow the 1st
lift cylinder to retract faster for better
maneuverability.
Tilt control lever Lift control lever
Backward Raise Neutral Neutral Forward Lower
211138
2-12
24
VEHICLE ELECTRICAL COMPONENTS
(2) This system provides the following safety
functions

1. When the pump motor is not running, the lift,
   tilt and attachment functions will not work even
   if the control levers are moved.
2. When the emergency switch is in the ON (pushed)
   position, the lift, tilt and attachments
   functions will not work even if the control
   levers are moved.
3. When the seat switch is not ON (the operator is
   not seated), the lift, tilt and attachments

functions will not work even if the control
levers are moved.
(d) The fault detection indicator in the LED
alerts the operator to malfunctions involving
the electrical system and also an inoperable
status. (If any problem occurs in the lift
system, for example, the system becomes
inoperative.)
2-13
25

• POWER TRAIN
• Procedures and Suggestions for Removal and
  Installation
• Removal
• Remove the masts.
• (Refer to MASTS AND FORKS section.)
• Removing batteries

1. Disconnect the battery plug.
2. Open the battery cover, and lock it in the open
   position.
3. Remove the side covers (L.H., R.H.) and front
   covers (L.H., R.H.).

Lock/unlock lever 211152
(4) Attach suspending ropes or adequate lifting
device to the batteries. Unit kg (lb)
208075
Truck Model Item 1 ton class 2 ton class
Battery weight 1090 1225
(maximum) (2403) (2701)
(5) Remove the battery retaining plate and pin,
and then remove the batteries.
26
POWER TRAIN 3. Removing front wheels

• Pull the parking brake lever and block the rear
  wheels.
• Loosen the wheel nuts by two turns. Then, raise
  the front end of the truck using a hoist or the
  hydraulic system.
• Hoisting
• Using a sling and eye-bolts at both ends of the
  cross member at the top of the outer mast, lift
  the front end of the truck with a hoist.
• Using hydraulic system
• Tilt the mast fully backward and place wood
  blocks under the mast. Tilt the mast forward to
  raise the front end.

210757
!
CAUTION
After raising the front end, place wood blocks
under the frame to prevent the truck from falling.

1. Remove the wheel nuts.
2. Remove the wheel.

Solid pneumatic tire Solid tire 206920
Truck Model Item 1 ton class 2 ton class
Tire size of front wheels 18 ? 7 - 8 200/50-10

• Removing steps and floor plates
• Steps (L.H., R.H.)
• Step plates (L.H., R.H.)
• Floor plate

(3)
Floor plate B
(1)
(1)
(2)
Remove floor plate B. Disconnect the accelerator
connector mounted on the back side of the floor
plate, then remove floor plate A.
Floor plate A
(2)
211153
27
POWER TRAIN
5. Removing steering hoses Disconnect the
steering hoses and pipes at the connectors.
206922

• Removing delivery pipe and drive motor harness
• Remove the drive motor harness at the connector.
• Disconnect the harnesses of the brush wear
  sensors and temperature sensors located on the
  right and left sides.
• The harnesses are secured to the delivery pipe
  with clamps. Loosen the clamps, and remove the
  delivery pipe.

208076
28
POWER TRAIN 7. Removing brake components
(i) (ii) (iii) (v) (iv) (
vi) 206824

• Loosen the parking brake lever, and remove
  parking brake cable assemblies (i) (L.H.) and
  (ii) (R.H.).
• Disconnect the parking brake cables at the
  calipers, and keep the cables together on the
  frame near the center brake.
• Position a drip pan, and disconnect brake fluid
  tube (iii) at the master cylinder.
• Disconnect brake pipes (iv, v) (L.H., R.H.) at
  the master cylinder. Disconnect the branch brake
  hoses (L.H., R.H.) from the brake pipes.
• Remove brake pedal assembly (vi).

29
POWER TRAIN
8. Removing return hoses Remove return hose (1)
from the control valve, and return hose (2) from
the lift cylinder.
(1) (2) 206925

• Remove drive motors cables (L.H., R.H.).
• Remove the generators (speed sensors) of the
  transfers (L.H., R.H.).
• Removing tension rods and brackets
• Loosen right and left nuts (1) by approximately 6
  mm (0.24 in.).
• Remove bolts (2), and take out bracket (3) and
  tension bolt (4) together from each side of the
  vehicle.

(3)
(3)
Left transfer
Right transfer
(2)
(2)
(4)
(1)
206926
30
POWER TRAIN 11. Removing transfer assemblies,
drive motors and calipers
Left transfer
Right transfer
(iii)
Gravity center
(ii)
(ii)
(i)
(i)
Frame
Frame
(iv)
Gravity center
(iii)
(iv)
206927
Remove the transfer assemblies with the drive
motors and calipers mounted. First, dismount the
left transfer, lower it, then pull it out from
the front of the vehicle. Then, dismount the
right transfer, lower it, then pull it out from
the front.
Cow hitch 206928

• When suspending the assembly, position the wire
  rope at the gravity center.
• The suspending wire rope must be cow hitched.
• When using a textile sling, make two loops to
  prevent slipping.
• Remove bolt (i) from the lower part of the step
  and remove bolt (ii) from the frame, then remove
  the assembly.
• Remove bolt (iii), and dismount the caliper
  assembly.
• Remove bolt (iv) and dismount the drive motor.

Total weight of transfer, drive motor and caliper
115 kg (253.5 lb)
31
POWER TRAIN
Installation Follow the removal sequence in
reverse. For installation, follow the
instructions below.
!
CAUTION
When mounting the transfer assembly on the
frame, do not insert a finger into the bolt hole
to check hole alignment. 1. Be sure to tighten
bolts to the specified torque.
Front of vehicle
3 4
4 3
5
5
2
2
1
1
206785
A Standard value
Unit Nm (kgfm) lbfft
Tightening torque Drive motor mounting bolt 1 A 60 12 (6.1 1.2) 44.25 8.85
Tightening torque Transfer assembly mounting bolt 2 A 508 51 (51.8 5.2) 375 38
Tightening torque Bracket mounting bolt 3 A 176 18 (17.9 1.8) 129.5 13.0
Tightening torque Bolt nut 4 A 231 24 (23.6 2.4) 170.7 17.4
Tightening torque Hub nut 5 A 156.9 15.7 (16.0 1.6) 115.7 11.6
2. Bleed the brake oil line. (Refer to BRAKE
SYSTEM section.)
32
POWER TRAIN

• After installing the parking brake cable, be sure
  to adjust.
• (Refer to BRAKE SYSTEM section.)
• Pour oil into the transfer cases Remove oil
  level plug (1). Remove oil inlet plug (2).
• Pour appropriate oil in the oil inlet. Make sure
  the oil level reaches the level plug location.
• Unit liter (U.S. gal)

Left transfer (2) (1) Front of
vehicle Right transfer (2) (1) 206786
Left transfer Right transfer
Oil quantity 1.09 (0.29) 1.86 (0.49)

• Bleeding hydraulic oil line and inspecting oil
  level
• Operate the tilt cylinders in the forward and
  backward directions to bleed the tilt cylinders.
  Operate the lift cylinders in the vertical
  directions to fill the cylinders with oil.
• Lower the lift cylinders to the lowest position,
  and check the oil level gauge. If the oil level
  is low, add oil to the specified level.
• Checking steering oil line
• Operate the steering wheel to make sure that it
  operates smoothly.

33
POWER TRAIN
Service Data
A Standard value
Item Item Truck Models Truck Models 1 ton class 1 ton class 1 ton class 2 ton class 2 ton class
Power Line Tightening torque Nm (kgfm) lbfft Tightening torque Nm (kgfm) lbfft Drive motor mounting bolt 1 Drive motor mounting bolt 1 Drive motor mounting bolt 1 A 60 12 (6.1 1.2) 44.25 8.85 60 12 (6.1 1.2) 44.25 8.85 60 12 (6.1 1.2) 44.25 8.85 60 12 (6.1 1.2) 44.25 8.85 60 12 (6.1 1.2) 44.25 8.85
Power Line Tightening torque Nm (kgfm) lbfft Tightening torque Nm (kgfm) lbfft Transfer assembly mounting bolt 2 Transfer assembly mounting bolt 2 Transfer assembly mounting bolt 2 A 508 51 (51.8 5.2) 375 38 508 51 (51.8 5.2) 375 38 508 51 (51.8 5.2) 375 38 508 51 (51.8 5.2) 375 38 508 51 (51.8 5.2) 375 38
Power Line Tightening torque Nm (kgfm) lbfft Tightening torque Nm (kgfm) lbfft Bracket mounting bolt 3 Bracket mounting bolt 3 Bracket mounting bolt 3 A 176 18 (17.9 1.8) 129.5 13.0 176 18 (17.9 1.8) 129.5 13.0 176 18 (17.9 1.8) 129.5 13.0 176 18 (17.9 1.8) 129.5 13.0 176 18 (17.9 1.8) 129.5 13.0
Power Line Tightening torque Nm (kgfm) lbfft Tightening torque Nm (kgfm) lbfft Bolt nut 4 Bolt nut 4 Bolt nut 4 A 231 24 (23.6 2.4) 170.7 17.4 231 24 (23.6 2.4) 170.7 17.4 231 24 (23.6 2.4) 170.7 17.4 231 24 (23.6 2.4) 170.7 17.4 231 24 (23.6 2.4) 170.7 17.4
Power Line Tightening torque Nm (kgfm) lbfft Tightening torque Nm (kgfm) lbfft Hub nut 5 Hub nut 5 Hub nut 5 A 156.9 15.7 (16.0 1.6) 115.7 11.6 156.9 15.7 (16.0 1.6) 115.7 11.6 156.9 15.7 (16.0 1.6) 115.7 11.6 156.9 15.7 (16.0 1.6) 115.7 11.6 156.9 15.7 (16.0 1.6) 115.7 11.6
Power Line 5 2 1 3 4 4 3 1 2 5 206785
3-9
34
TRANSFER UNITS
Specifications
Truck Model Item Truck Model Item 1 ton class 2 ton class
Transfer Gear type Constant-mesh type, 3 stages (helical gears) Constant-mesh type, 3 stages (helical gears)
Transfer Reducing gear ratio 58 x 83 x 45 20.151 24 16 28 58 x 83 x 45 20.151 24 16 28
35
TRANSFER UNITS Structure and Functions (Part 1)
Front of vehicle
7
7
8
8
A
A
9
6
6
3
1
5
5
2
4
206785

1. Transfer (left)
2. Drive motor (left)
3. Transfer (right)
4. Drive motor (right)
5. Frame

1. Wheel hub
2. Front tire
3. Bracket
4. Tension rod

Section A Mast support mounting section
Since two drive motors are installed in a limited
space, the drive motors are offset in
position. Tension rod 9 connects brackets 8 , and
includes a turnbuckle to serve as a thrust rod
for the left and right transfer units.
36
TRANSFER UNITS
Structure and Functions (Part 2)
18
3
4
5
2
17
18
2 3
17
4 5
211058

1. Drive motor
2. Input gear
3. Second gear
4. Third gear
5. Output shaft
6. Wheel hub
7. Cover

1. Main case
2. Nut
3. Retainer (Oil seal)
4. Oil seal
5. O-ring
6. Spacer
7. Taper roller bearing

1. Ball bearing
2. Pulse generator (DC motor models only)
3. Oil level plug
4. Air breather

Bolts marked with ? Bolts for mounting transfer
units to frame
The pulse generator detects rotating
speed. Helical gears are used for reduced
operating noise. The output shaft is provided
with two taper roller bearings to withstand
heavy loads.
The left and right transfer units are identical,
and are mounted on the frame with bolts marked
with an ? in the illustration. The left and
right transfer units are installed to the drive
motors. The motor shafts are jointed to the
involute splines of the input gears. Driving
force is transmitted via the input gear, second
gear, third gear, then to the output shaft that
rotates the wheel hub.
Transfer reducing gear ratio
20.151
37
TRANSFER UNITS Procedures and Suggestions for
Disassembly and Reassembly

• Start by
• Remove the power train consisting of the
  transfer, drive motor and caliper. (Refer to
  Removal and Installation of POWER TRAIN
  section.)
• Drain oil from the transfer.
• Disassembly

3. Remove the drive motor and caliper.
1 1 1 1 1 1
211059
Sequence
1 Bolt 7 Taper roller bearing 14 Ball bearing
Remove parts 2 to 12 as sub-assembly. 8 Retainer 15 Second gear
2 Cover 9 O-ring 16 Ball bearing
3 Cap 10 Output shaft, O-ring 17 Third gear
4 Nut 11 Taper roller bearing 18 Ball bearing
5 Spacer, O-ring 12 Oil seal 19 Main case, Dowel pin
6 Wheel hub, Hub bolt 13 Input gear
38
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39
TRANSFER UNITS
Suggestions for Disassembly
1. Removing nut 4 Nut 4 is secured to output
shaft 10 by punching. Use a chisel to scrape
punched section carefully. Do not scratch output
shaft 10. Nut 4 is not reusable.
206789
2. Cover 2 Outer laces of taper roller bearings
7 and 11 that are press- fit into cover 2 do not
have to be disassembled if inspection finds no
abnormality. Remove oil seal 12, and use a new
seal.

• Inspection after Disassembly
• Inspect the gear teeth and splines for wear and
  damage.
• Inspect the bearings for wear, damage, rotating
  resistance and noise.
• Inspect main case 19 and cover 2 for cracking and
  damage.
• Inspect the oil seal contact surface of retainer
  8 for damage.

40
TRANSFER UNITS Reassembly

211060
Sequence
Assemble parts 1 to 4 prior to final assembly. 8 Spacer, O-ring
1 Cover 9 Nut
2 Taper roller bearing (outer race) 10 Cap
3 Taper roller bearing (outer race) 11 Main case
4 Oil seal 12 Third gear
5 Output shaft, Inner race of taper roller bearing 13 Ball bearing
2, O-ring 14 Second gear
Assemble parts 6 and 7, and inner race of taper roller 15 Ball bearing
bearing 3 prior to final assembly. 16 Input gear
6 Wheel hub, Hub bolt 17 Ball bearing
7 Retainer, O-ring, Inner race of taper roller 18 Bolt
bearing 3 Install sub-assemblies 5 and 6 in cover
1.
41
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