TCM FD35C9 Workshop Manual Download

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2-39

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Grounding

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Distributor wiring (for TB42 only)

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Fuel cut valve wiring

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Glow plug wiring (for S6S only)

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Sedimenter wiring (for S6S only)

DISTRIBUTOR WIRING

FUEL CUT VALVE WIRING

GLOW PLUG WIRING

SEDIMENTER WIRING

Summary of Contents for FD35C9

Page 1: ...R K S H O PM A N U A L F O R K L I F T TRUCK O O Z C F D 3 5 T 9 F D 4 0 T 9 F D 4 5 T 9 F D 5 0 T 9 F D 3 5 c 9 F D 4 0 C 9 F D 4 5 c 9 F G 3 5 T 9 F G 4 0 T 9 H U U 2 u a H O 0 4 d TCMC O R P O R A...

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Page 3: ...scribes basic safety instructions for servicing the lift truck Before starting study the safety instructions carefully and become completely familiar with the procedures for servicing the lift truck a...

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Page 5: ...e inspect and adjust them at regular intervals as well as to operate them properly The purpose of this workshop manual is to serve as a guide to proper service inspection and adjustment techniques for...

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Page 7: ...1 GENERAL DESCRIPTION 1 1 SAFETY INSTRUCTIONS 1 1 1 2 BASIC SERVICING KNOWLEDGE 1 17 1 3 List of lubricants 1 26 1 4 PRE OPERATION INSPECTION 1 27 1 5 PERIODIC INSPECTIONS 1 29...

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Page 9: ...personal safety gear devices called for by the job conditions such as a hard hat gloves safety shoes safety glasses goggles and other 2 Shirts and pants should have tight cuffs 3 Wear a rubber apron...

Page 10: ...TE when the truck is being repaired 4 In principle you should not run the engine while servicing the truck Remove the ignition key when leaving the truck unattended 5 Keep yourself in good shape befor...

Page 11: ...leaving the equipment unattended during maintenance turn it off If the power fails turn off the power switch on the equipment For example Lower any raised load to the ground Turn off the switch to an...

Page 12: ...to the truck might void your warranty Do not try to modify your truck Modifications to your truck which affect the performance safety or strength of the truck might cause an accident and will void you...

Page 13: ...the truck while it is on a trailer 8 Do not try to work while sitting on a tire Use a suitable step stool or an elevating work platform 9 If you must go under the truck use goggles or safety glasses...

Page 14: ...the rated capacity Lift the truck from two points or more never from a single point The lifting angle of the chains or cable must be less than 60 degrees and the position of the center of gravity of...

Page 15: ...forks 1 With the forks raised a little off the ground place blocks under the root of the forks Bring both fork prongs to the center by alternately pushing on the top and bottom heel of the fork face D...

Page 16: ...the rims tighten them to the specified torque with the tire deflated 3 Use a safety cage for inflating the tire If one is not available place the tire on the ground or floor with the lock ring or side...

Page 17: ...inder If the piston rod is hard to remove by hand apply compressed air from the tail side of the cylinder to push the piston rod out 6 When using compressed air fit a cylinder cap over the piston rod...

Page 18: ...ised take the necessary steps to prevent the mast from falling unexpectedly or install control lever stoppers 8 Apply genuine TCM Chain Coat chain lubricant to the lift chains from the front of the ma...

Page 19: ...battery relay Make sure the cables are not wet or frayed Avoid using any electric tool in a wet atmosphere Be careful not to drop a wire tools or parts inside the truck If you drop something make sur...

Page 20: ...of angle iron inside the bucket first to prevent the bucket from being deformed Do not use a jack instead of welding in a piece of angle iron Using a jack creates the danger of the jack coming loose...

Page 21: ...such as a power switch in a position where the worker can operate it without leaving his working position 3 Make sure the machine is turned off before cleaning inspecting or repairing the machine or c...

Page 22: ...rds 1 Do not park the truck where the exhaust or hot parts on the truck can contact flammable debris leaves paper etc 2 Do not carry loads which could cause a fire or explosion when they come in conta...

Page 23: ...raulic line that contains fluid If the connector on a corroded pipe sticks loosen it using a penetrating agent box wrench and a long spanner 6 When working in a group make sure everyone understands th...

Page 24: ...8 Use a special jig with a handle to remove the king pin 19 Use a suitable tool with the correct diameter and a lock guide to install bushings 20 Use a round drift to install a quenched or hardened pi...

Page 25: ...them when installing otherwise they might stay twisted causing oil leakage When using an O ring and back up ring as a set such as when hydraulic pressure is high position the O ring at the side which...

Page 26: ...parts When removing parts which were installed with the application of LOCTITE use tools such as a spanner wrench and pulley remover If you fear that a part may break due to the effect of LOCTITE if...

Page 27: ...ned and warmed This will aid the evaporation of the cleaning solution and rise water Parts cleaned in solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali Care shou...

Page 28: ...efer to the Shop Manual and Service Manual of your truck model when 1 Special nuts are used 2 Synthetic resin or rubber is used for tightening 3 Specified tightening torque is given Division by streng...

Page 29: ...11 S45C 6 8 01114 SCM435 Boron steel 8 8 01117 Full thread normal M4 M8 coarse and M10 M39 fine SS400 4 6 Black 01121 SS400 4 6 Yellow Chromate 01120 S45C 6 8 01123 SCM435 Boron steel 8 8 01126 SCM435...

Page 30: ...7 70 1 15 15 0 22 6 27 7 41 5 43 4 65 3 67 5 100 99 1 148 139 208 188 282 234 351 342 515 480 720 650 974 792 1190 1020 1540 0 82 1 24 1 70 2 53 2 85 4 29 7 00 10 5 13 9 20 9 24 4 36 6 39 0 55 8 61 6...

Page 31: ...3 0 30 0 45 0 55 1 82 7 86 9 129 135 202 198 296 278 416 376 565 469 702 685 1030 958 1440 1290 1950 1580 2370 2050 3070 1 65 2 47 3 36 5 06 5 70 8 54 14 0 21 0 27 8 41 7 48 6 73 1 78 1 117 123 185 16...

Page 32: ...1 6 01 7 37 11 0 11 6 17 4 18 0 27 0 26 4 39 5 37 0 55 5 50 2 75 3 62 6 93 8 91 3 137 128 192 173 259 211 316 273 409 2 19 3 30 4 49 6 74 7 60 11 4 18 6 28 0 37 1 55 7 64 9 97 4 104 156 164 246 224 33...

Page 33: ...8 88 4 109 162 171 255 265 396 387 582 544 815 738 1110 919 1380 1330 2020 1880 2820 2540 3810 3110 4650 4010 6020 3 22 4 83 6 60 9 91 11 2 16 8 27 4 41 1 54 5 81 9 95 4 143 153 230 241 362 330 493 4...

Page 34: ...bove 32 F above TCM Lube Life X 3 0 C to 25 C 32 F to 13 F Hydraulic oil tank Hydraulic oil TCM Hydraulic Oil wear resistance type 25 C above 13 F above Automatic transmission Engine oil TCM Lube Life...

Page 35: ...k Brake oil level A Check brake oil level in reserve tank Service brake Brake pedal freeplay and braking effect A Press brake pedal until some resistance is felt to check for freeplay normal freeplay...

Page 36: ...ation A All warning lights come on when starter switch is turned to position 1 and go out when engine starts Pumps Oil leakages and noise A Start engine to check for oil leakage or noise from pumps Co...

Page 37: ...rom developing TCM specifies that the forklift truck must be serviced every 200 hours or once every month In addition it is mandatory to keep records of inspections and maintenance performed for three...

Page 38: ...pump oil Fuel filter element Oil filter element Valve clearance Injection nozzle Injection nozzle Injection nozzle Crankcase breather Fuel tank Fuel tank Fuel pump Oil level Contamination Tension Dam...

Page 39: ...ine filter Front axle Front axle Front axle mounting bolts Brake Brake pedal Brake pedal Brake oil Brake piping Contamination Wear Wear Fuel leakage Contamination Looseness Condition Exhaust leakage D...

Page 40: ...eering Power steering Power steering rod Rear axle Rear axle installation Tie rod Tie rod Tie rod King pin Deformation Cracks Damage Braking effect Travel Looseness Looseness Play Damage Operation Pla...

Page 41: ...rs Side rollers Side roller mounting bolts Retaining rollers Retaining rollers Operation Operation Function Function Function Operation Level Contamination Contamination Tension Lubrication Damage Def...

Page 42: ...Load backrest Load backrest mounting bolts Mast support mounting bolts Operator s seat Operator s seat mounting bolts Grease fittings Looseness Operation Oil leakage Damage Operation Oil leakage Dama...

Page 43: ...4 COUNTERWEIGHT 2 18 2 5 MUFFLER 2 20 2 6 RADIATOR 2 22 2 7 AIR CLEANER 2 25 2 8 FRONT GUARD 2 27 2 9A BRAKE PEDAL automatic transmission trucks 2 31 2 9B BRAKE PEDAL AND CLUTCH PEDAL manual transmiss...

Page 44: ...2...

Page 45: ...e harness 1 on the overhead guard Remove the nut 1 and the washer 2 Remove the head lamp 4 from the overhead guard 3 REINSTALLATION Install the head lamp 2 on the overhead guard 1 using the nut 3 and...

Page 46: ...n the overhead guard Remove the two screws 1 and then remove the front combination lamp 3 from the overhead guard 2 REINSTALLATION Install the front combination lamp 2 on the overhead guard 1 using th...

Page 47: ...isconnect the connector of the rear combination lamp 2 from the connector of the wire harness 1 on the overhead guard REINSTALLATION Connect the connector 2 of the rear combination lamp to the connect...

Page 48: ...3 from the negative terminal 2 of the battery 2 1 Make sure to disconnect the negative battery cable first Disconnect the positive battery cable 3 from the positive terminal 2 of the battery 1 1 Remo...

Page 49: ...and washer 4 from the battery 1 s anchor bolt 1 and then remove the battery holder 5 Remove the nut 2 spring washer 3 and washer 4 from the battery 2 s anchor bolt 1 and then remove the battery holder...

Page 50: ...inals Install the battery holder 2 and anchor bolt 3 on the battery 2 1 and secure them using the nut 4 spring washer 5 and washer 6 2 9 4 8 N m 0 3 0 5 kgf m 2 4 3 5 lbf ft Install the battery holder...

Page 51: ...terminal 1 and the battery 2 s positive terminal 2 Connect the positive battery cable 2 to the battery 1 s positive terminal 1 Make sure to connect the battery cable to the positive terminal of the ba...

Page 52: ...ttery s negative terminal 1 Make sure to disconnect the negative battery cable first Disconnect the positive battery cable 2 from the battery s positive terminal 1 Remove the nut 2 spring washer 3 and...

Page 53: ...and secure them using the nut 3 spring washer 4 and washer 5 2 9 4 8 N m 0 3 0 5 kgf m 2 1 3 5 lbf ft Connect the positive battery cable 2 to the positive terminal 1 of the battery Make sure to connec...

Page 54: ...cording to the specified procedure See 1 1 10 Safety rules for maintenance Before starting maintenance Remove the air cleaner See 2 7 AIR CLEANER Open the engine hood 1 Keep the engine hood open by fa...

Page 55: ...the front guard wire harness Remove the connectors of the overhead guard wire harness rear 1 from the connectors of the engine wire harness Remove the hose 3 from between the fuel tank 1 and the overh...

Page 56: ...2 12 Fig 2 39 Fig 2 40 Remove the bolts 1 securing the overhead guard Hoist the overhead guard 1 off from the frame with the wire ropes attached to sections A 154 kg 340 lbs...

Page 57: ...s attached to sections A Then install the overhead guard 1 on the frame 2 154 kg 340 lbs Secure the overhead guard 2 using the bolts 1 31 4 47 1 N m 3 2 4 8 kgf m 23 2 34 7 lbf ft Connect the connecto...

Page 58: ...g 2 44 Fig 2 45 Connect the connectors of the overhead guard wire harness front 1 to the connectors of the front guard wire harness 2 Install both side covers 1 on the front guard 5 N m 0 5 kgf m 3 7...

Page 59: ...ve the overhead guard See 2 2 HOOD AND OVERHEAD GUARD Remove the clip 3 and washer 4 securing the gas spring 1 to the overhead guard 2 Raise the engine hood so that the gas spring 1 is fully stretched...

Page 60: ...2 16 Fig 2 48 Fig 2 49 Unlock the engine hood 1 and then lower it carefully Remove the bolts 2 securing the bracket 1 in place Then remove the bracket 1 and engine hood 3 together...

Page 61: ...he bolts 3 21 2 N m 2 16 kgf m 15 6 lbf ft Raise the engine hood 1 Keep the engine hood raised by fastening it to the overhead guard 2 using a rope 27 kg 59 5 lbs Install the gas spring 1 on the overh...

Page 62: ...ach hole in the counterweight 1 and then attach a ring to each end of the wire rope Remove the bolts 1 spring washers 2 and washers 3 securing the counterweight Hoist the counterweight 1 off the frame...

Page 63: ...section of the frame 2 Align section A of the frame with the recess of the counterweight kg lbs 3 5 tons 2044 4506 4 0 tons 2474 5454 4 5 tons 2764 6094 5 0 tons 2764 6094 Secure the counterweight in...

Page 64: ...MUFFLER REMOVAL Remove the counterweight See 2 4 COUNTERWEIGHT Remove the bolt 1 and nut 2 securing the muffler and remove the washers 3 and cushions 4 Remove the nut 1 on the engine side flange and...

Page 65: ...e stud of the exhaust manifold flange Secure the muffler using the cushions 1 bolt 2 washers 3 and nut 4 Install the nut 5 on the engine side flange Nut 4 11 N m 1 1 kgf m 8 1 lbf ft Nut 5 21 2 N m 2...

Page 66: ...er 1 Remove the counterweight See 2 4 COUNTERWEIGHT Drain the coolant Remove the radiator hoses 1 For an automatic transmission truck remove the oil cooler hose as well Tag all hoses for proper reinst...

Page 67: ...e radiator 2 Bring the removed fan shroud near the engine Remove the bolts 1 washers 2 rubber cushions 3 and nuts 4 that secure the radiator in place and then remove the radiator 5 Remove the fan shro...

Page 68: ...of the tank of the radiator 2 Secure it using the bolts 3 7 8 11 7 N m 0 8 1 2 kgf m 5 8 8 6 lbf ft Connect one end of the hose 1 leading from the reserve tank to the radiator cap 2 Connect the radiat...

Page 69: ...e hood and then lock the gas spring securely Remove one end of the hose 1 leading to the engine from the air cleaner 2 Cover the opening end of the hose Remove one end of the plastic duct 1 leading to...

Page 70: ...to 1 2 kgf m 5 8 8 6 lbf ft Connect one end of the plastic duct 1 leading from the rear pipe to the air cleaner 2 Remove the cover from the opening end of the hose 1 that connects between the engine...

Page 71: ...wheel See 2 13 STEERING WHEEL Disconnect the connectors of the front guard wire harness 1 from the connectors of the engine wire harness 2 Remove all the plastic covers Remove the floorboard kit 1 Re...

Page 72: ...ervoir Note The reservoir should be removed with brake oil in it Remove the bolts 3 that secure the pipes 2 leading to the tilt cylinders 1 to the front guard Remove the four mounting bolts 2 at the r...

Page 73: ...1 using the four bolts 2 spring washers 3 and washers 4 at the right and left sides of the front guard 31 4 47 1 N m 3 2 4 8 kgf m 23 2 34 7 lbf ft Install the tilt cylinder piping 1 on the front gua...

Page 74: ...nt guard using the bolts 2 Connect the connectors of the front guard wire harness 1 to the connectors of the engine wire harness 2 Install the floorboard kit 1 Install the steering wheel See 2 13 STEE...

Page 75: ...trucks REMOVAL Remove the floorboard kit See 2 8 FRONT GUARD Remove the brake pipes 2 from the brake booster 1 Remove the high pressure hose 2 from the brake booster 1 Remove the two return hoses 3 f...

Page 76: ...Fig 2 94 Fig 2 93 Remove the pedal assembly 2 from the transmission 1 REINSTALLATION Install the pedal assembly 1 on the transmission 2 21 2 N m 2 16 kgf m 15 6 lbf ft Install the connecting rod 2 on...

Page 77: ...Fig 2 96 Install the brake pipes 2 on the brake booster 1 Install the high pressure hose 2 on the brake booster 1 Install the two return hoses 3 on the brake booster 1 Install the floorboard kit See 2...

Page 78: ...mission trucks REMOVAL Remove the floorboard kit See 2 8 FRONT GUARD Remove the split pin 1 washer 2 and pin 3 and then remove the clutch release cylinder 5 from the arm 4 Remove the brake pipes 2 fro...

Page 79: ...2 102 Remove the return hoses 3 from the brake booster 1 and clutch booster 2 Remove the pedal assembly 2 from the transmission 1 REINSTALLATION Install the pedal assembly 1 on the transmission 2 21...

Page 80: ...sing the pin 3 and secure them using the washer 4 and split pin 5 Install the brake pipes 2 on the brake booster 1 Connect the high pressure hose 2 to the brake booster 1 Connect the return hoses 4 to...

Page 81: ...ght See 2 4 COUNTERWEIGHT Remove the muffler and exhaust pipe See 2 5 MUFFLER Remove the radiator See 2 6 RADIATOR Remove the air cleaner See 2 7 AIR CLEANER Remove the accelerator cable from the fron...

Page 82: ...he engine Starter wiring Alternator wiring Oil pressure switch wiring Temperature sender wiring STARTER WIRING STARTER WIRING ALTERNATOR WIRING ALTERNATOR WIRING OIL PRESSURE SWITCH WIRING OIL PRESSUR...

Page 83: ...Distributor wiring for TB42 only Fuel cut valve wiring Glow plug wiring for S6S only Sedimenter wiring for S6S only DISTRIBUTOR WIRING FUEL CUT VALVE WIRING FUEL CUT VALVE WIRING GLOW PLUG WIRING SED...

Page 84: ...from the solenoid valve in the transmission control valve assembly Disconnect the oil cooler hoses 1 from the transmission case 2 For a manual transmission truck Disconnect the oil cooler hoses 1 from...

Page 85: ...e the mounting bolt 1 washers 2 cushions 3 and nut 4 22 Remove the bolts 1 and washers 2 Then remove the axle support caps 3 23 Slowly hoist the engine and drive unit assembly and remove it Be careful...

Page 86: ...Lift the engine 1 and drive unit 2 over the frame together and carefully lower them in the mounting position 1100 kg 2425 lbs Secure the engine and drive unit using the cushions 1 mount bolt 2 washers...

Page 87: ...upport caps 1 using the bolts 2 and washers 3 175 N m 17 8 kgf m 129 1 lbf ft Apply LOCTITE 572 For an automatic transmission truck Connect the wire harness 2 to the transmission solenoid valve 1 Conn...

Page 88: ...2 44 Fig 2 119 Fig 2 120 For a manual transmission truck Connect the oil cooler hoses 1 to the transmission case 2 Connect the wire harness to the neutral switch 1 and the reverse switch 2...

Page 89: ...Starter wiring Alternator wiring Oil pressure switch wiring Temperature sender wiring STARTER WIRING STARTER WIRING ALTERNATOR WIRING ALTERNATOR WIRING OIL PRESSURE SWITCH WIRING OIL PRESSURE SWITCH W...

Page 90: ...Distributor wiring for TB42 only Fuel cut valve wiring Glow plug wiring for S6S only Sedimenter wiring for S6S only DISTRIBUTOR WIRING GLOW PLUG WIRING SEDIMENTER WIRING FUEL CUT VALVE WIRING FUEL CU...

Page 91: ...nstall the front guard and the floorboard kit See 2 8 FRONT GUARD Install the accelerator cable on the front plate Install the radiator See 2 6 RADIATOR Install the counterweight See 2 4 COUNTERWEIGHT...

Page 92: ...ont end of the truck and support the truck frame with a support stand 1 Place blocks 2 on each rear wheel Remove the wheels Remove the mast assembly See 2 17 MAST ASSEMBLY Drain the gear oil Remove th...

Page 93: ...ove the axle shafts 1 Support the transmission and then remove the bolts 1 that connect the drive axle to the transmission Support the drive axle with a crane and wire ropes Remove the support caps 1...

Page 94: ...the frame where the drive axle is to be installed Apply liquid gasket to the fitting surface of the drive axle 1 and then install the drive axle 1 on the transmission 2 Secure the drive axle to the fr...

Page 95: ...2 51 Fig 2 133 Connect the parking brake cables 1 to the brake lever 2 Add gear oil Install the mast assembly See 2 17 MAST ASSEMBLY Install the wheels Remove the support stand...

Page 96: ...support the frame of the truck with a stand 1 Place blocks 2 on each front wheel Remove the counterweight See 2 4 COUNTERWEIGHT Remove the wheels Remove the ball joint 3 of the steering cylinder rod...

Page 97: ...re the axle supports 2 in place Gradually lower the garage jack and remove the steering axle 1 from the frame 2 REINSTALLATION Place the steering axle 1 on the garage jack Then place the steering axle...

Page 98: ...rts 1 on the frame using the bolts 2 and spring washers 3 175 N m 17 8 kgf m 129 1 lbf ft Apply LOCTITE 578 Install the ball joint 3 of the drag link 2 on the center arm 1 Install the ball joint 3 of...

Page 99: ...the bolts 1 and then remove the covers A 2 and B 3 Remove the bolts 1 and move the combination meter assembly 2 toward the front guard side At this point the wire harness must remain connected Remove...

Page 100: ...146 Fig 2 147 Fig 2 148 Remove the bolt 1 and washer 2 Then remove the steering wheel lock lever 3 Remove the lock bolt 1 and washer 2 Remove the bolts 1 and bushings 2 Then remove the steering wheel...

Page 101: ...steering wheel assembly 5 on the front guard 6 and secure it using the bushings 3 and bolts 4 21 2 N m 2 16 kgf m 15 6 lbf ft Install the lock bolt 1 and washer 2 39 1 N m 4 0 kgf m 28 8 lbf ft Insta...

Page 102: ...1 Install the combination meter 1 and cover C 2 on the steering wheel column 3 using the bolts 4 3 2 4 8 N m 0 3 0 5 kgf m 2 4 3 5 lbf ft Install the covers A 1 and B 2 using the bolts 3 M4 1 2 N m 0...

Page 103: ...ropes REMOVAL Remove the plastic covers 1 and then remove the tilt cylinder covers 2 Disconnect the hoses 2 from the tilt cylinder 1 Before disconnecting these hoses release any residual pressure in t...

Page 104: ...er 2 in the mounting position on the frame Pay attention to the positions of the right and left hydraulic ports 1 Install the connecting pin 1 at the frame side and then secure it using the bolts 2 17...

Page 105: ...2 61 Fig 2 162 Fig 2 163 Connect the hydraulic hoses 2 to each tilt cylinder 1 Install the tilt cylinder covers 1 and plastic covers 2...

Page 106: ...weight See 2 4 COUNTERWEIGHT Disconnect the hose 1 from the main pump 2 that leads to the oil tank Disconnect the hoses 1 from the main pump 2 one leading to the control valve and the other to the pri...

Page 107: ...N m 3 5 5 2 kgf m 24 9 37 5 lbf ft Connect one end of the hose 1 leading from the oil tank to the main pump 2 Caution must be used when connecting the hose Oil may leak from the hose Connect the hoses...

Page 108: ...cotter pin 3 Then remove the rod 4 from each spool Disconnect the hoses 2 from the control valve 1 Temporarily secure each return hose with its end at a level that is higher than the oil level in the...

Page 109: ...262 or SCOTCH GRIP 2352 to the threads of the bolts 3 Connect the hose 2 to each port of the control valve 1 Port P1 From the main pump Port P2 To the priority valve Port PF To the steering gear box...

Page 110: ...he mast assembly using a crane Remove the bolts 1 and plate 2 Then remove the mast side connecting pin 4 of the tilt cylinder 3 Disconnect the hoses 2 from the lift cylinders 1 Remove the bolts 1 and...

Page 111: ...ssembly in the groove in the drive axle 2 using the bushings 3 3 5 tons 4 0 tons 980 kg 2161 lbs 4 5 tons 1120 kg 2469 lbs 5 0 tons 1250 kg 2756 lbs For a standard mast assembly with a lifting height...

Page 112: ...2 68 Fig 2 182 Connect the hoses 2 to the lift cylinders 1 2...

Page 113: ...RIVE UNIT 3 21 3 2 1 TORQUE CONVERTER TYPE TRANSMISSION 3 21 3 2 2 SYNCHROMESH TYPE TRANSMISSION 3 50 3 3 DRIVE AXLE 3 67 3 4 WHEEL BRAKE 3 71 3 4 1 3 5 to 4 0 ton trucks 3 71 3 4 2 4 5 to 5 0 ton tru...

Page 114: ...2...

Page 115: ...ion trucks DISASSEMBLY Remove the springs 3 from the brake pedal 1 and inching pedal 2 Remove the split pins 1 washers 2 and pins 3 Then remove the joint 5 and inching rod 6 from the linkage 4 Remove...

Page 116: ...bracket 1 Remove the split pin 1 washer 2 and pin 3 from the brake booster 4 Remove the bolt 1 and remove the shaft 2 Then remove the brake pedal 4 and inching pedal 5 from the pedal bracket 3 Remove...

Page 117: ...racket 1 using the bolts 3 21 2 N m 2 2 kgf m 15 6 lbf ft Place the brake pedal 1 and inching pedal 2 in the pedal bracket 3 and then secure them using the shaft 4 9 8 N m 1 0 kgf m 7 2 lbf ft Install...

Page 118: ...dal bracket 3 Then secure them using the shaft 4 M8 9 8 N m 1 0 kgf m 7 2 lbf ft M6 4 0 N m 0 4 kgf m 3 0 lbf ft Install the joint 2 and inching rod 3 on the linkage 1 using the pins 4 washers 5 and s...

Page 119: ...on trucks DISASSEMBLY Remove the pipe 3 connecting the clutch release cylinder 1 and the clutch booster 2 Remove the bolts 1 and remove the clutch release cylinder 2 Remove the springs 3 from the brak...

Page 120: ...utch booster 1 and brake booster 2 and then remove the pins 4 and washers 5 Remove the bolts 1 and then remove the clutch booster 2 and brake booster 3 Remove the bolt 1 and remove the shaft 2 Then re...

Page 121: ...racket using the shaft 4 9 8 N m 1 0 kgf m 7 2 lbf ft Install the clutch booster 1 and brake booster 2 on the pedal bracket 4 using the bolts 3 21 2 N m 2 2 kgf m 15 6 lbf ft Secure the brake booster...

Page 122: ...springs 3 on the brake pedal 1 and clutch pedal 2 Install the clutch release cylinder 2 on the pedal bracket 1 using the bolts 3 21 2 N m 2 2 kgf m 15 6 lbf ft Install the pipe 3 connecting the clutc...

Page 123: ...the disassembly Use the new parts from the kit during reassembly DISASSEMBLY Remove the push rod assembly 2 along with the boot 1 Slightly push in the guide assembly 1 and remove the stopper ring 2 R...

Page 124: ...master cylinder piston 1 and remove the pin 2 Then remove the master cylinder piston 1 and spring 3 Remove the snap ring 1 and remove the plug 2 spring 3 and spool 4 Disassembling the reaction piston...

Page 125: ...Remove the reaction piston 2 1 and spring 2 from the power piston 3 4 Remove the snap ring 1 and remove the plug 3 spring 4 and control valve 5 from the power piston 2 5 Push in the control valve seat...

Page 126: ...3 into the power piston 4 Then install the snap ring 5 2 Install the spring 2 onto the reaction piston 1 1 Pushing in the control valve seat 3 install the pin 4 3 Install the reaction piston 2 2 and...

Page 127: ...piston 1 1 Install the spring 1 and master cylinder piston 2 on the cylinder section Pushing in the master cylinder piston 2 install the pin 3 Install the bolt 2 using a new gasket 1 Install the react...

Page 128: ...3 14 Fig 3 46 Fig 3 45 Install the spool 1 spring 2 and plug 3 Then install the snap ring 4 Install the push rod 1 along with the boot 2...

Page 129: ...r kit handy before starting the disassembly Use the new parts from the kit during reassembly DISASSEMBLY Remove the push rod assembly 2 along with the boot 1 Slightly push in the guide assembly 1 and...

Page 130: ...the master cylinder piston 1 and remove the pin 2 Then remove the master cylinder piston 1 and spring 3 Remove the snap ring 1 and remove the plug 2 spring 3 and spool 4 Disassembling the reaction pi...

Page 131: ...ring 2 from the power piston 3 4 Remove the snap ring 1 and remove the plug 3 spring 4 and control valve 5 from the power piston 2 5 Push in the control valve seat 1 and remove the pin 2 Then remove t...

Page 132: ...3 into the power piston 4 Then install the snap ring 5 2 Install the spring 2 onto the reaction piston 1 1 Pushing in the control valve seat 3 install the pin 4 3 Install the reaction piston 2 2 and...

Page 133: ...piston 1 1 Install the spring 1 and master cylinder piston 2 on the cylinder section Pushing in the master cylinder piston 2 install the pin 3 Install the bolt 2 using a new gasket 1 Install the react...

Page 134: ...3 20 Fig 3 67 1 2 3 4 Fig 3 66 Install the spool 1 spring 2 and plug 3 Then install the snap ring 4 Install the push rod 1 along with the boot 2...

Page 135: ...assembly 1 Remove the transmission control valve 1 Note Remove the old gaskets from the mating surfaces Use caution to prevent gasket scraps from entering the oil or screw holes Remove the differentia...

Page 136: ...housing Note Remove the old gaskets from the mating surfaces Use caution to prevent gasket scraps from entering the oil or screw holes Remove the strainer 1 from the converter housing Note Remove the...

Page 137: ...et install the charging pump 1 on the torque converter housing Install the strainer 1 on the converter housing With an O ring 2 and gasket 3 install the cover 4 Install the converter relief valve 1 an...

Page 138: ...move the forward reverse clutch pack 1 and 2nd clutch pack 2 from the transmission case Remove the counter gear 1 from the transmission case Remove the suction pipe 1 from the transmission case for 43...

Page 139: ...25 only Note The suction pipe 1 is not used with the 44E 25 Install the counter gear 1 in the transmission case Install the clutch packs 2 3 and output gear 1 in the transmission case Note Make sure...

Page 140: ...heir respective locations see Fig 3 86 A 30 mm 1 18 in long 10 pcs B 70 mm 2 76 in long 3 pcs C 90 mm 3 54 in long 3 pcs With a gasket install the differential on the transmission case for 43E 25 only...

Page 141: ...e explanation about other clutch packs is omitted because they are similar in construction to the forward reverse clutch pack Remove the three seal rings 1 from the shaft Using a puller 1 remove the f...

Page 142: ...iction plates 1 and separator plates 2 Friction plates Separator plates Fwd 5 6 Rev 5 6 2nd 5 6 Using a jig 1 compress the return spring and remove the snap ring from the groove Release the compressio...

Page 143: ...98 Fig 3 97 Remove the piston 1 from the clutch drum Remove the seal ring 1 from the piston Remove the seal ring 1 from the shaft Follow the same steps for disassembling the reverse clutch pack and t...

Page 144: ...they are similar in construction to the forward reverse clutch pack Install the seal ring 1 on the outer diameter of the piston Install the seal ring 1 on the clutch shaft Install the piston assembly...

Page 145: ...Install one separator plate first and then one friction plate Keep installing pairs of plates in that order ending with a separator plate Friction plates Separator plates Fwd 5 6 Rev 5 6 2nd 5 6 Insta...

Page 146: ...3 32 Fig 3 107 Fig 3 108 Install the thrust washer 1 and bearing 2 Install the seal rings 1 Follow the same steps for reassembling the reverse clutch pack and 2nd clutch pack...

Page 147: ...ASSEMBLING CHARGING PUMP Remove the bolts assembling the charging pump Separate the case 1 from the stator support 2 Remove the drive gear 1 and driven gear 2 from the case Remove the oil seal 1 from...

Page 148: ...116 Fig 3 115 Fig 3 114 REASSEMBLING CHARGING PUMP Install the seal ring 1 on the case Install the oil seal 2 on the case 1 Install the drive gear 1 and driven gear 2 on the case Install the stator s...

Page 149: ...3 118 DISASSEMBLING CONTROL VALVE Remove the forward reverse solenoid valve 1 and 2nd solenoid valve 2 from the valve body Remove the front cover 1 Remove the accumulator piston 1 three springs 2 and...

Page 150: ...Fig 3 121 Fig 3 123 Fig 3 122 Remove the inching valve piston 1 and spring 2 Remove the inching spool 1 along with the spring 2 Remove the speed range selector spool 2nd 1 and spring 2 from the valve...

Page 151: ...the selector spool 1 and the spring 2 in the valve body Install the accumulator springs outer 1 middle 2 inner 3 in that order and then install the pin 4 and piston 5 Install the modulation piston 1 i...

Page 152: ...tall the piston 1 and spring 2 to the back of the inching spool Install the front cover 2 with a gasket 1 into the valve body Install the directional solenoid valve 1 onto the valve body Install the s...

Page 153: ...g 3 133 DISASSEMBLING DIFFERENTIAL Remove the bearing cap stopper 1 Remove the split pin 1 and nuts 2 and remove the bearing cap 3 Remove the cross case assembly Remove the drive pinion assembly 1 Not...

Page 154: ...1 Remove the ring gear 1 from the cross case assembly 2 Put the cross case upright with the flange half upward and remove the assembling bolts and nuts 3 Separate the cross case into the flange half a...

Page 155: ...41 Fig 3 139 1 Fig 3 140 Disassembling drive pinion assembly 1 Extend the caulked part 1 of the lock nut outward 2 Remove the lock nut 3 Remove the drive pinion from the bearing cage Fig 3 141 Press J...

Page 156: ...spacer 2 from the drive pinion Note Record the type and number of shims 5 Remove the outside bearing cup 1 and oil seal 2 from the bearing cage 6 Remove the bearing cup 1 from inside the bearing cage...

Page 157: ...tall the oil seal 2 on the bearing cage 1 Note Pay attention to the direction of the oil seal when installing it 2 Install the inside and outside bearing cups 1 on the bearing cage 3 Install the insid...

Page 158: ...the inner diameter of the spacer 1 5 Install the spacer 1 and shims 2 on the drive pinion Note Install the same number and type of shims as removed 6 Install the bearing cage on the drive pinion and...

Page 159: ...on If the measurement is out of the standard value adjust it by increasing or reducing the number of shims described in step 5 Starting torque 2 9 to 3 9 N m 30 to 40 kgf cm 0 22 to 0 29 ft lbs Reasse...

Page 160: ...6 mm 0 07 0 075 0 078 0 087 0 091 0 102 in 5 Install the same types of thrust washers and side gear as for the plain half on the flange half 6 Holding the side gear of the flange half case by your ha...

Page 161: ...mbly on the housing and lightly tighten the cap fitting nuts Install the two adjustment nuts Adjusting backlash and engagement When the ring gear requires moving loosen the adjustment nuts 1 and move...

Page 162: ...drive pinion Ring gear too close to drive pinion Move ring gear further away from drive pinion Reduce the number of bearing cage shims Increase the number of bearing cage shims Reduce the number of be...

Page 163: ...curing the cap nut and bearing cage Cap nut tightening torque 217 7 to 325 6 N m 2220 to 3320 kgf cm 161 to 240 ft lbs Note Apply LOCTITE 270 on the threaded part Install the adjustment nut stopper an...

Page 164: ...the clutch release arm Holding the yoke by hand pull out the clutch release arm 1 from the yoke and then remove the yoke 2 and retainer 3 Remove the snap ring 4 from the shaft and then remove the clut...

Page 165: ...3 51 Fig 3 167 Fig 3 168 Make sure the drive unit is placed on the workbench with the differential pointed upward and then remove the clutch housing Remove the cover 1 and remove the strainer...

Page 166: ...install the snap ring 1 on the arm assembly Install the arm assembly on the boss of the clutch housing aligning the splines of the arm assembly with the splines of the shift arm Install the snap ring...

Page 167: ...3 using the O ring 1 and gasket 2 Install the differential assembly on the transmission using a new gasket Note Always install the differential assembly parallel to the transmission aligning the spli...

Page 168: ...transmission case cover 1 Remove the fwd rev shift lever and 1st 2nd speed shift lever Remove the neutral switch 1 and reverse switch 2 Remove the shift rod support 1 and remove the shift fork assemb...

Page 169: ...Fig 3 183 Fig 3 182 Fig 3 181 Remove the input shaft assembly 1 Remove the main shaft assembly 1 Remove the main shaft cover 1 and snap ring 2 from the clutch housing Remove the output gear 1 from the...

Page 170: ...th shafts properly Install the output gear 1 on the clutch housing Apply LOCTITE 270 to the threads of the bolts securing the stopper Install the clutch housing 1 on the transmission using a new gaske...

Page 171: ...secure with the snap ring 3 Shim thickness 0 1 0 2 0 5 mm 0 004 0 008 0 020 in Axial movement of shaft less than 0 2 mm 0 008 in Apply LOCTITE 575 to the outer edge of the cap and install the cap Inst...

Page 172: ...lar and therefore this disassembly procedure pertains to both For the purpose of easy reassembly the component parts of the main shaft are shown in Fig 3 192 Remove the snap ring from the end of the m...

Page 173: ...rev side only 2 and gear 3 Disassembling synchronizer 1 Remove the synchronizer support springs 2 Remove the inserts 1 and sleeve 3 from the hub 4 2 Disassemble the 1st 2nd speed side of the main shaf...

Page 174: ...procedure pertains to both Understand the direction and position of the component parts on the main shaft by referring to Figure 3 198 Install the low gear 1 and needle bearing 2 onto the end of the...

Page 175: ...Then install the snap ring 3 using a spacer Reassemble the fwd rev side using the same steps except that you don t install the shaft end bearing immediately after installing the forward gear The shaft...

Page 176: ...3 62 Fig 3 203 DISASSEMBLING INPUT SHAFT Remove the snap ring 1 Using a suitable jig remove the thrust washer bearing and counter gear Fig 3 204 INSERT Press JIG RUBBER PLATE...

Page 177: ...to the counter gear 1 Install the thrust washer 1 and counter gear assembly 2 onto the input shaft Install the thrust washer and press fit the bearing 1 onto the input shaft Then install the snap ring...

Page 178: ...3 64 Fig 3 208 Fig 3 209 DISASSEMBLING OUTPUT GEAR Remove the snap ring 1 Using a puller 1 and insert 2 remove the bearings...

Page 179: ...3 65 Fig 3 210 Fig 3 211 REASSEMBLING OUTPUT GEAR Using a jig 1 and press install the bearings 2 Install the snap ring 1 1 2 1...

Page 180: ...Fig 3 213 REASSEMBLING SHIFT FORK Using a jig 1 install the spring 2 and ball 3 into the shift fork 4 and insert the shaft 5 into it Note Use caution not to have the wrong direction of the shaft See t...

Page 181: ...k washer 1 Remove the adjustment nut 1 Using a puller remove the hub 3 together with the drum 1 and outer tapered roller bearing 2 Remove the cone 1 oil seal 2 and retainer 3 from the inner tapered ro...

Page 182: ...iner 4 and oil seal 5 3 Remove the outer tapered roller bearing 6 Note Put an identifying mark or number on each set of tapered roller bearings so that you can distinguish one set from another 4 Remov...

Page 183: ...Note Check the identification marks made during disassembly 3 Install the outer oil seal 3 and retainer 4 4 Install the drum 5 using the bolts 6 and nuts 7 500 N m 50 0 kgf m 368 8 lbf ft Install the...

Page 184: ...rk or number on the inner tapered roller bearing cup in the hub assembly is the same as that on the inner tapered roller bearing cone at the drive axle side Install the adjustment nut 1 and then adjus...

Page 185: ...EL BRAKE 3 4 1 3 5 to 4 0 ton trucks DISASSEMBLY Remove the hold pins 3 and spring retainers 4 from each of the primary shoe 1 and secondary shoe 2 Remove the two return springs 1 Remove the strut 1 R...

Page 186: ...ry shoe 2 together with the adjuster 3 and adjuster spring 4 Remove the brake pipe from the wheel cylinder 1 Remove the two wheel cylinder mounting bolts 2 and then remove the wheel cylinder 1 from th...

Page 187: ...ecuring the brake lever 1 to the primary shoe 2 Remove the brake lever 1 Disassemble the wheel cylinder as follows Remove the push rod 1 and dust cover 2 from each side of the wheel cylinder Press one...

Page 188: ...06 in Visually check the piston cup for damage or deformation replacing any defective piston cup with a new one Measure the brake lining thickness and if worn beyond the limit replace with a new one U...

Page 189: ...acking plate 3 with two bolts 2 27 3 49 N m 2 8 5 0 kgf m 20 1 36 1 lbf ft Install the backing plate 1 to the drive axle 3 with eight bolts 2 274 323 N m 30 0 33 0 kgf m 202 1 238 2 lbf ft Apply LOCTI...

Page 190: ...Install the primary shoe 1 and secondary shoe 2 to the backing plate 3 Install the adjuster 4 and adjuster spring 5 between the two shoes The adjuster thread direction should be left for the left side...

Page 191: ...and install the strut between the shoes Install two return springs 1 observing the following conditions The return springs should be installed first to the secondary shoe side and then to the primary...

Page 192: ...3 78 Fig 3 252 Measure the inner diameter a of the brake drum and the outer diameter b of the shoe assembly Adjust the adjuster 1 so that a b equals 1 0 mm 0 04 in a b...

Page 193: ...djuster will operate normally when it is mounted back on the truck If the adjuster won t operate as mentioned above when the adjuster lever is pushed up or released take the following steps Check the...

Page 194: ...the pushrod lock nut a ADJUST BOLT b LOCK NUT ADJUSTING BRAKE SWITCH Make sure the brake pedal height is as indicated in Figure 3 254 and then loosen the brake switch lock nut Remove the brake switch...

Page 195: ...5 to 5 0 ton trucks DISASSEMBLY Remove the hold pins 3 and spring retainers 4 from each of the primary shoe 1 and secondary shoe 2 Remove the return spring 2 from the secondary shoe 1 Remove the retur...

Page 196: ...rking brake cable 3 from the parking lever 2 on the primary shoe 1 Remove the adjuster lever 1 and spring 2 Remove the linkages 1 and 2 lever 3 washer 4 and split pin 5 Remove the primary shoe 1 and s...

Page 197: ...emove the brake pipe from the wheel cylinder 1 Remove the two wheel cylinder mounting bolts 2 and then remove the wheel cylinder 1 from the backing plate 3 Remove the eight backing plate mounting bolt...

Page 198: ...e the push rod 1 and dust cover 2 from each side of the wheel cylinder Press one piston 3 into one end of the cylinder to remove the piston 4 back up ring 5 piston cup 6 and spring 7 from the other en...

Page 199: ...piston cup with a new one Measure the free length of the wheel cylinder spring If unsatisfactory replace Unit mm in 4 5 to 5 0 ton Load N length 16 14 0 551 or 7 25 0 984 Free length Ref 33 5 1 319 Me...

Page 200: ...f the cylinder Install the backing plate 1 to the drive axle 3 with eight bolts 2 274 323 N m 30 0 33 0 kgf m 202 1 238 2 lbf ft Install the wheel cylinder 1 to the backing plate 3 with two bolts 2 17...

Page 201: ...shoe 1 and secure with the retainer 3 and washer 4 Install the adjuster 3 and spring 4 that connect between the primary shoe 1 and secondary shoe 2 Install the primary and secondary shoe assembly 1 o...

Page 202: ...ig 3 281 Fig 3 280 Install the adjuster lever 1 and spring 2 onto the backing plate Connect the parking cable 3 to the parking lever 2 on the primary shoe 1 Install the strut 1 Install the return spri...

Page 203: ...pipe to the wheel cylinder Secure the primary shoe 1 and the secondary shoe 2 in place with the hold pins 3 and the spring retainers 4 Measure the inner diameter a of the brake drum and the outer dia...

Page 204: ...but the adjuster will operate normally when it is mounted back on the truck If the adjuster won t operate as mentioned above when the adjuster lever is pushed up or released take the following steps C...

Page 205: ...288 3 5 STEERING AXLE DISASSEMBLY Remove the wheel cap 2 from the hub 1 Release the lock on the lock washer 1 and then remove the lock nut 2 Remove the bearing nut 1 Using a puller remove the hub 1 t...

Page 206: ...a puller remove the tapered roller bearing cone 2 from the spindle of the knuckle 1 Remove the oil seal 1 Remove the nut 1 and split pin 2 and remove each tie rod 3 Remove the nut 1 spring washer 2 an...

Page 207: ...rust bearing 3 needle bearings 4 shims 5 spacer 6 O rings 7 and oil seals 8 from between the bosses of the steering axle 1 Note Do not reuse the O rings and oil seals that have been removed Use new on...

Page 208: ...3 94 Fig 3 299 Remove the tapered roller bearing cup 2 from the hub 1...

Page 209: ...he center arm pin 1 7 8 11 7 N m 0 8 1 2 kgf m 5 8 8 6 lbf ft Select appropriate shims as follows Place the thrust bearing 2 and knuckle 3 between the bosses of the steering axle 1 Select shims 4 of c...

Page 210: ...sses Insert the king pin so that the notch 1 in the king pin is aligned with the lock pin hole 2 of the knuckle Lock the king pin 2 with the lock pin 1 and secure with the nut 3 spring washer 4 and wa...

Page 211: ...Install the needle bearings 2 to the top of the king pin 1 Install the dust seal 2 to the top 1 of the king pin Install the tie rod 2 on the steering axle 1 using the nut 3 and split pin 4 Install the...

Page 212: ...earing cone 1 onto the spindle of the knuckle Install the hub 3 onto the spindle against the oil seal 2 installed in step Install the tapered roller bearing 1 and bearing nut 2 onto the knuckle spindl...

Page 213: ...NDER DISASSEMBLY Hold the steering cylinder assembly 1 in a vise Loosen the nut 2 on the rod 1 and remove the ball joint assembly 3 Loosen the nut 2 on the rod 1 and remove the rod 1 Extend the caulke...

Page 214: ...3 321 Remove the rod assembly 1 from the cylinder 2 Remove the nut 2 from the rod 1 and remove the piston 3 Remove the slipper seal 2 from the piston 1 Remove the snap ring 2 from the cylinder cap 1...

Page 215: ...3 101 Fig 3 324 Fig 3 325 Remove the packing 2 from the cylinder cap 1 Loosen the nut 2 on the tail end 1 of the cylinder and remove the ball joint assembly 3...

Page 216: ...the cylinder 294 N m 30 kgf m 216 8 lbf ft Apply LOCTITE 270 on the threaded part Install the packing 2 and oil seal 3 on the cylinder cap 1 and secure with the snap ring 4 Install the O ring 2 and b...

Page 217: ...y 1 into the cylinder 2 and install the cylinder cap assembly 3 on the cylinder 2 Stake the cylinder 2 at one place 98 N m 10 kgf m 72 3 lbf ft Install the rod 1 and secure with the nut 2 Install the...

Page 218: ...side cover by turning the adjustment screw clockwise Note Use caution not to lose the side cover O ring Remove the adjustment screw and shims from the sector shaft Rotate the worm shaft so that the se...

Page 219: ...ly so that the jig does not tilt Use caution not to allow the action piston to drop out Make sure to hold the control valve with one hand while removing each bolt Failure to do so will cause the contr...

Page 220: ...ipping nicks indentations or abnormal wear If any defects are found replace the ball nut assembly with a new one Check the sector shaft gear teeth for scoring Also check the sector shaft for excessive...

Page 221: ...e P mark on the valve housing with the end of the spool that has a smaller chamfer on the inner diameter 2 Install the reaction pistons and centering springs in the valve body Hold the gear case in a...

Page 222: ...it into position to prevent damaging the O ring 34 3 53 0 N m 350 540 kgf cm 25 3 39 1 lbf ft Install the thrust race needle bearing and thrust race on the worm shaft Install the control valve assembl...

Page 223: ...en the lock nut and make it finger tight again Check to make sure if the position of the mark has not changed If it is unchanged tighten the lock nut about 5 degrees further Starting torque 0 98 N m 1...

Page 224: ...ge 150 mm 5 906 in away from the center of the pitman arm Measure any looseness in the pitman arm Tolerance less than 0 3 mm 0 012 in If the measured looseness is greater than 0 3 mm 0 012 in adjust i...

Page 225: ...the other side of the tilt cylinder with the block 3 Loosen the lock nut 4 and remove the joint 5 and collar 6 from the rod Remove the cylinder cap 1 using a hook wrench Pull out the rod 1 to remove...

Page 226: ...cylinder cap Remove the packing 2 back up ring 3 dust seal 4 and bushing 5 from the inner diameter of the cylinder cap REASSEMBLY Install the back up ring 1 packing 2 dust seal 3 and bushing 4 on the...

Page 227: ...he edge 735 74 N m 75 7 5 kgf m 542 1 54 6 lbf ft Install the rod assembly 1 into the cylinder 2 Install the cylinder cap 1 on the cylinder 2 392 49 N m 40 5 kgf m 289 1 36 1 lbf ft Apply THREEBOND 13...

Page 228: ...cover 3 adapter 4 and front cover 2 and the drive gear side of the pump body half 2 5 and pump body half 1 6 with oil paint Turn the four fitting bolts 1 with a torque wrench in the tightening directi...

Page 229: ...nside the pump body half 2 1 move them toward the adapter 2 side Put the mark RV2 on the rear cover side plate 1 at the drive gear 2 side before removing the side plate 1 Put the mark R2 on the driven...

Page 230: ...the side face of the pump body half 1 1 with a plastic mallet If the gaskets remain inside the pump body half 1 1 move them toward the adapter 2 side Remove the pump body half 1 1 If the gaskets remai...

Page 231: ...383 Put the mark R1 on the driven gear 1 shaft end and remove the driven gear 1 Holding the front side plate 1 remove the drive gear 2 Turn over the front cover 1 and hold it again in the vise Remove...

Page 232: ...th or wipe surface Oil pressure is too high Useful limit Wipe depth limit less than 0 04 mm 0 0016 in c Check for signs of interference with gear at discharge side Runout of gears Pump s performance i...

Page 233: ...ts of porous and PTFE polytetrafluoro ethylene layers Useful limit When the back plate of the bushing is exposed to view 6 E Gasket a C h e c k g a s k e t s f o r p r o p e r installation or cut Too...

Page 234: ...over 1 Note Use caution not to twist the gasket Install a new E gasket 2 in the groove in the front cover 1 referring to Fig 3 388 Discharge side E gasket groove The E gasket should be installed with...

Page 235: ...Rear side Clockwise rotation Front side Counterclockwise rotation Front side Clockwise rotation Rear side Discharge port smaller radius Drive side Suction port larger radius Driven side Projection to...

Page 236: ...tooth profiles of the two gears are asymmetric install them with their larger pressure angle sides pointed to each other Failure to do so might damage the gear teeth Greater pressure angle side driven...

Page 237: ...a new gasket 2 in some points and install the gasket 2 in the adapter 1 groove Install the E gasket 1 on the adapter 2 as shown in Fig 3 388 Gasket groove E gasket Suction side Discharge side The adap...

Page 238: ...e adapter 1 Note Use caution not to twist the gasket Install a new E gasket 2 in the groove in the adapter 1 referring to Fig 3 403 E gasket groove Discharge side Suction side The E gasket should be i...

Page 239: ...ar side Clockwise rotation Front side Counterclockwise rotation Front side Clockwise rotation Rear side Discharge port smaller radius Drive side Suction port larger radius Driven side Projection to be...

Page 240: ...tooth profiles of the two gears are asymmetric install them with their larger pressure angle sides pointed to each other Failure to do so might damage the gear teeth Greater pressure angle side driven...

Page 241: ...gasket 2 in some points and install the gasket 2 in the rear cover 1 groove Install the E gasket 1 on the rear cover 2 as shown in Fig 3 403 Gasket groove E gasket Suction side Discharge side The rear...

Page 242: ...pump from the vise and put it on a work bench Apply grease on the area between the lips and on the outer diameter of a new oil seal 1 Install it on the oil seal guide shown in Fig 3 422 Put it on the...

Page 243: ...lock ring Side at which corner is chamfered Front cover Oil seal Fig 3 422 Oil seal guide Oil seal snap Unit mm in 115 4 5 100 3 9 4 0 16 R2 0 08 R2 0 08 R2 0 08 4 0 16 17 0 069 R5 0 2 2 0 06 62 2 44...

Page 244: ...out 10 minutes Make sure the pressure is less than 1 MPa 10 kgf cm2 142 psi c Increase the pump speed to 1500 to 2000 rpm and let the pump operate for about 10 minutes d Keeping the pump speed at 1500...

Page 245: ...led seals O rings back up rings and wipers with new ones 1 Disassembling valve assembly Remove the main relief valve 1 and PF relief valve 2 from the inlet section 3 Note The relief valve should be re...

Page 246: ...ces Note Tag the spring and poppet for proper reassembly Loosen the socket head bolt 1 and then remove the cap 2 Remove the spool 3 as a sub assembly with the seal plate 4 wiper 5 and O ring 6 of the...

Page 247: ...and then disassemble the spring seat 3 and spring 4 Remove the O ring 5 and wiper 6 Note Use caution when loosening the cap screw because it might pop out due to spring reaction Remove the spring 2 fr...

Page 248: ...3 and O ring 4 Hold the sub assembly of the spool 1 that has been removed in step in a vise equipped with soft jaws pieces of hard wood shown in Figure 3 432 with care not to damage its exterior Loose...

Page 249: ...et 2 and spring 3 from the plug 1 Note Tag the spring and poppet that have been removed for proper reassembly Remove the sleeve 1 Remove the main poppet 2 and spring 3 Note Tag the spring and poppet t...

Page 250: ...y set Remove the plug 1 from the cap 2 Loosen and remove the adjuster kit 3 Remove the wave washer 2 from the plug 1 and then remove the pilot poppet 3 and spring 4 Note Tag the spring and poppet that...

Page 251: ...ngs with new ones If the cap or plug was removed inspect each hole and plug seat and around them for foreign matter REASSEMBLY Note 1 Cautions as to handling spools Too large torque to the threads wil...

Page 252: ...ed the assembly A Place the pilot poppet 2 and spring 3 into the plug 1 and then install the adjuster kit 5 with O ring 4 attached temporarily Install the O ring 2 wave washer 3 back up ring 4 and O r...

Page 253: ...p ring 5 attached Install O rings 3 onto the cap 1 and plug 2 Install the pilot poppet 2 and spring 3 into the plug 1 Install the adjuster kit 5 with O ring 4 attached temporarily Install the parts as...

Page 254: ...ring 2 wiper 3 and seal plate 4 to the spool 1 Install the spring seats 2 and spring 3 to the spool 1 and then tighten the cap screw 4 18 6 N m 1 9 kgf m 13 7 lbf ft Threads Hydraulic oil Install the...

Page 255: ...lic oil 4 Reassembling tilt spool section Hold the spool 1 in a vise equipped with soft jaws pieces of hard wood shown in Figure 3 452 with care not to damage its exterior Insert the valve 2 into the...

Page 256: ...f m 8 9 10 3 lbf ft Threads Hydraulic oil Install the O ring 2 wiper 3 and seal plate 4 to the valve housing 1 Tighten the screw 5 2 9 N m 0 3 kgf m 2 14 lbf ft Threads Hydraulic oil Insert the spool...

Page 257: ...ction 2 Threads Hydraulic oil Install the lift spool section 1 tilt spool section 2 and outlet section 3 to the inlet section in that order and then secure with the nuts 4 Nut M8 19 N m 1 9 kgf m 14 0...

Page 258: ...troke Adjust the adjuster properly so that the necessary pressure be obtained When the specified pressure is obtained hold the adjuster in place and tighten the lock nut 27 31 N m 2 8 3 2 kgf m 19 9 2...

Page 259: ...and fork assembly on the pallet and loosen the chains Remove the split pins from the joint linkage and remove the chains from the outer mast Put the chains on the pallet and raise the inner mast hydr...

Page 260: ...lacing rollers of the mast Put the front tires on stands 300 mm 12 in high Remove the piston head bolt from each of both cylinders Move the lift lever a few times to remove the oil pressure from the p...

Page 261: ...an oil pan under the cylinders to receive oil drained from the cylinders and piping Remove the hoses from the cylinders Remove the set bolts from the bottom of each cylinder Remove the return hose fro...

Page 262: ...e U bolt Use caution not to lose the rubber parts Remove the two lift cylinders Using a hoist crane lower the inner mast so that the rollers at the top and bottom of the mast can be accessed Replace o...

Page 263: ...3 149 1 Fig 3 477 Fig 3 478 Remove the end rollers For safety s sake put a wooden block under the bottom of the inner mast...

Page 264: ...t the inner mast into the outer mast from below Check the gap between the outer mast channel and the side of the inner mast end roller Measure the gaps at points A B and C of the outer mast and adjust...

Page 265: ...djuster adjust the distance between the outer mast and each cylinder so that it is the same for both cylinders Note Do not overtighten the U bolt otherwise the cylinder may be damaged 14 7 16 7 N m 1...

Page 266: ...d shim between the rod and piston head which stop first Shim thickness 0 2 and 0 5 mm 0 008 0 01 in 4 Adjust the lift chain tension ADJUSTING CARRIAGE HEIGHT 1 Stop the truck on a level surface and st...

Page 267: ...16 5 in or more 100 mm 4 in is added to dimension B Model Mast Type Free lift mechanism B mm in 3 5 4 ton VM 43A None 19 24 0 75 0 95 4 5 ton VM 43F None 19 24 0 75 0 95 5 0 ton VM 43H None 43 48 1 69...

Page 268: ...sted adjust them to the same length 1 Loosen the lock nut at the rod end 2 Turn the piston rod to the right or left to adjust the length If the piston rod is hard to turn turn it while tilting the mas...

Page 269: ...ctive replace the connecting member Check also the inner mast for deformation or warping 3 Measure the inner width of each of the inner and outer masts along which the end roller rolls and calculate t...

Page 270: ...t of load on the forks place the mast in an vertical position raise the forks to the eye level and shut off the engine b Measure the length of the piston rod from the front end of the cylinder cap to...

Page 271: ...18 6 N m 12 1 kgf m 87 5 lbf ft Apply LOCTITE 262 75 4 N m 7 7 kgf m 55 6 lbf ft 148 223 N m 15 1 22 7 kgf m 109 2 164 5 lbf ft 26 5 30 4 N m 2 7 3 1 kgf m 19 5 22 4 lbf ft Apply LOCTITE 262 47 1 71 6...

Page 272: ...o remove the mast from the truck 2 Caution When lifting the inner mast for the purpose of repairing take necessary measures to prevent the inner mast from dropping before trying to repair It is danger...

Page 273: ...omplete assembly Lower the carriage and fork assembly on the pallet and loosen the chains Remove the chain stopper and lift the chains to remove them from the chain sleeves Remove the piston heads Usi...

Page 274: ...sary 2 Adjusting or replacing the inner or outer mast rollers Put the front tires on stands 300 mm 12 in high Put the chain over the top connecting members of the middle and inner masts Lift the middl...

Page 275: ...and sheave bearing assembly from each of both sides Put the chains in free state Remove the rear cylinder ram bolts Raise the middle and inner masts to their respective maximum heights Secure or suppo...

Page 276: ...Remove the right side rear cylinder hose at its top position Remove the left side cylinder cross over hose at the point connected to the right side cylinder Support both cylinders securely remove the...

Page 277: ...middle and inner masts Supporting the inner mast alone lower the middle mast below the usual position so that the bottom rollers of the middle mast and the top rollers of the inner mast can be access...

Page 278: ...mast with the middle mast in the usual position so that the bottom rollers of the inner mast and the top rollers of the middle mast can be accessed Replace or adjust the rollers as necessary Replace...

Page 279: ...the U ring from the cylinder cap Note Do not reuse the U ring that has been removed Remove the O ring from the cylinder cap Note Do not reuse the O ring that has been removed Remove the bushing from...

Page 280: ...nto the piston Install the rod and piston assembly to the cylinder Install a new U ring to the cylinder cap Install a new wiper ring to the cylinder cap Install a new O ring to the cylinder cap Instal...

Page 281: ...NCHROMESH TYPE 4 1 4 3 DRIVE UNIT TORQUE CONVERTER TYPE 4 2 4 4 REDUCTION GEAR AND DIFFERENTIAL 4 3 4 5 BRAKE 4 3 4 6 STEERING WHEEL 4 4 4 7 STEERING AXLE 4 4 4 8 MAIN PUMP 4 5 4 9 CONTROL VALVE 4 5 4...

Page 282: ...2...

Page 283: ...d Replace Retainer worn or damaged Replace Support worn or damaged Replace Clutch yoke end worn Replace 4 2 DRIVE UNIT SYNCHROMESH TYPE Problem Probable cause Remedy 1 Transmission noisy Low lubricant...

Page 284: ...lutch slips because clutch oil pressure is lower than specified See Problem 3 3 Low oil pressure Charging pump damaged or pump drive unit damaged Replace Control valve defective Replace Seals damaged...

Page 285: ...l If the differential fails to operate normally jack up the front wheels and check the differential from the front tire side to verify that the cause of the trouble lies in the differential 1 The truc...

Page 286: ...ct Knuckle bearing defective Replace Rear axle deformed Correct or replace Tire inflation pressure improper Adjust Loose ball joints on steering cylinder knuckle arm and center arm Replace 4 7 STEERIN...

Page 287: ...change oil Lever or linkage bent Repair Plunger bent Replace valve assembly Return spring damaged Replace 2 Oil leakage from oil seal Seal contaminated with paint Replace seal and clean control valve...

Page 288: ...4 9 CONTROL VALVE 4 12 MAST Problem Probable cause Remedy 1 Noisy while lifting or lowering Side rollers unevenly worn or bearing damaged Replace End roller bearing damaged Replace Carriage bent Repa...

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TCM FD35C9, Workshop Manual

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