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1. Fork carriage HVZ02022 1 Outer mast 9 Inner mast 2 Shim 10 Chain stopper 3 Roller 11 Chain stopper 4 Lift cylinder clamp 12 Lift chain 5 Tilt cylinder pin 13 Chain wheel 6 Grease fitting 7 Mast 8 Bushing 30 157 DISASSEMBLY AND ASSEMBLY MAST ADJUSTMENT 1 Outer main roller Adjusting shims Adjust with shims A so that clearance a is within O 0 2mm 0 0 008 at maximum lifting height position HVZ01703 HVZ01704 2 Inner main roller Adjusting shims Adjust with shims b so that clearance b is within O 0 2mm 0 0 008 in at maximum lifting height position HVZ01705 4 HVZ01706 30 158 DISASSEMBLY AND ASSEMBLY MAST FORK CARRIAGE 201707 Insert shims of the same thickness and adjust both sides to obtain 0 lt a lt 0 2mm 0 lt a lt 0 008 in with the fork carriage on top end THE BOARD AND TIGHTEN THE BOLT HVZ01710 b HVZ01708 Insert shims of the same thickness and adjust both sides to obtain 0 2 lt b lt 0 2mm 0 lt 5 lt 0 016 in with the fork carriage on top end HVZ01709 Insert shims of the same thickness and adjust both sides to obtain 0 lt c lt 0 2mm 0 lt c lt 0 008 in with the fork carriage on top end 30 159 MAST DISASSEMBLY AND ASSEMBLY THRUST PAD MOUNT
2. PUSH ROD SIDE HWZ01895 BOOSTER MASTER CYLINDER HWZ01896 HWZ01897 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE G Assembling the flow divider Apply hydraulic oil to the spool and insert it into the body in the proper direction After checking that the spool operates smoothly insert the spring Assemble the O ring with the cap apply grease and assemble the spring by compressing it and secure using a snap ring H Assembling the boot Assemble the boot after pressing reaction piston 2 by hand to ensure that it operates smoothly HVZ02144 1 Assembling the push rod and yoke Assemble the lock nut with the push rod and connect them to the yoke with the nut inserted e Pass the push rod through the boot and assemble them to the hole of the reaction piston 2 Lock nut 7 8 11 7 Nm 80 120 kgfm Torque 5 75 8 6 Ibft HVZ02145 30 91 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE J Joining the clutch booster and the master cylinder Assemble the booster and clutch master cylinder assemblies and tighten them using nut 31 Torque 20 6 30 3 Nm 2 1 3 1 kgfm 15 2 22 3 Ibft HVZ02146 BRAKE BOOSTER TORQFLOW LIFT TRUCK HVZ01898 30 92 DISASSEMBLY AND ASSEMBLY REAR AXLE REAR AXLE STRUCTURE HVZ01899 30 93 DISASSEMBLY AND ASSEMBLY REAR AXLE 294 490 Nm 80 50 kgfm 431 8 62 Nm 0 4
3. Backlash 0 14 0 41 Gears Replace with new parts dur Gasket O ring seals ing disassembly and assembly 30 18 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION TESTING F2 R1 TRANSMISSION OUTDOOR LIFT TRUCK HWZ02113 ral HWZ02117 HWZ02118 30 19 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION MAINTENANCE STANDARD F2 R1 TRANSMISSION OUTDOOR LIFT TRUCK bol Check item Standard size Repair limit Remedy mm mm E Thickness of drive plate 25 27 E Plate Replace Thickness of driven plate 1 93 2 07 ae Clearance at end gap when inserting piston Bias cut Replace each bly is carried out Inside diameter of seal 40 40 025 ring contact surface Seal ring insertion groove width N1 Seal ring insertion groove 2 6 2 65 width E M Piston Seal ring insertion groove width Clearance at end gap 42 Insertion groove width 4 55 4 65 Inside diameter of seal Clearance at end gap race clutch case E cut Seai ring 9 Diameter of transmission Outside diameter of oil 014 041 14 0 41 Gears Replace with new parts dur Gasket O ring seals ing disassembly and assembly 2 6 2 65 D 30 20 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION PRECAUTIONS ON ASSEMBLY OUTDOOR LIFT TRUCK 1 Cleaning each part A Before as
4. Differential gear tooth surface 8 pikes ane 30 70 Differential carrier and support cap tight 490 608 Nm ening bolt 50 62 kgfm Damage of tooth surface such as pitching and spalling Remedy Apply Loctite to screw Apply Loctite to screw Apply Loctite to screw Replace Replace with new parts during disas sembly and assembly DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ADJUSTING DIFFERENTIAL 1 Assembly of differential assembly A Assemble differential assembly Then install adjustment screw 1 B Coat hole of cap 2 with Loctite 271 Then tighten temporarily with bolts 3 2 Adjusting backlash NOTE When tightening adjustment screw 1 use special tool 34C 97 99150 A When adjusting turn either left or right adjustment screw 1 back one notch Then tighten the other adjustment screw one notch and read dial gauge indicator Backlash between ring gear and pinion gear 0 15 0 23mm 0 006 0 009 in B Rotate bevel gear and carry out adjustment procedure in Step A in four places 3 Adjusting preload of side bearings A Tighten left and right adjustment screws 1 uniformly to adjust preload Preload 21 56 33 32 Nm 2 2 3 4 kgfm 16 24 6 Ibft Lubricant Apply molybdenum grease B Check again that backlash is within specified value HWZ01863 HVZ01864 HVZ01865 30 71 DISASSEMBLY AND ASSEMBLY
5. 4 30 72 Adjusting tooth contact A Coat tooth surface of bevel gear thinly with red lead minimum B Rotate bevel gear in forward and reverse directions several times C Check tooth contact pattern left in red lead on tooth surface see Figure below Correct tooth contact no load FORWARD REVERSE HVZ01866 HVZ01867 NOTE Pattern is in center of tooth surface NOTE Pattern is in center of tooth surface and covers 40 75 of the overall length of and covers 40 75 of the overall length the tooth There should be weak contact at of the tooth There should be weak contact both ends of the pattern at both ends of the pattern D If tooth contact is not correct adjust as follows See next page for more detail 1 Pinion shaft shim 2 Backlash of bevel gear 3 Preload of bevel gear side bearing NOTE The tooth contact must be adjusted correctly for both forward and reverse directions but if it is impossible to adjust completely in both directions adjust the forward direction correctly DIFFERENTIAL DISASSEMBLY AND ASSEMBLY DIFFERENTIAL Correcting tooth contact Increase the shims at the pinion shaft to increase the protrusion of the pinion Direction Then move the bevel gear away from the pinion Direction B and adjust the back lash Decrease the shims at the pinion shaft to decrease the protrusion of the pinion Direction A Then move the bevel gear closer to the pinion Dire
6. Control valve sub assembly Remove snap ring 12 to pull out cap 11 spring 13 and valve 8 Flow divider Remove snap ring 6 cap 22 spring 23 and valve 21 WARNING BOOSTER ASSEMBLY DRAWING Do not damage the cylinder piston cups etc During disassembling pay close attention to the location of each part and how each part comes out of the assembly Place these parts in order to ensure they can be reassembled in the correct sequence When using a vice to hold a part clamp to the mounting flange and do not apply excessive force Do not remove the piston and valve set seals replace as an assembly 3 wet e 17 5 L4 POWER PISTON 14 0 7 ASSEMBLY HVZ01885 30 85 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE INSPECTION AND TESTING NOTE Follow the precautions below when cleaning parts before inspection Use ONLY alcohol or brake fluid for cleaning parts NEVER use mineral oil based liquids such as petroleum gasoline etc Mineral oil based liquids will cause the rubber parts to swell and become unusable When cleaning rubber parts such as cups with alcohol do not dip them in alcohol for more than 30 seconds After cleaning parts keep them in a clean place to prevent dirt from contaminating parts Do not allow foreign matter dust dirt grease etc to enter or damage the cylinder piston cups or other parts All brake parts must be kept clean to avoid malfunct
7. DISASSEMBLY AND ASSEMBLY LOCTITE 271 490 608 Nm TORQUE 60 62 kgfm 78 4 1225Nm TORQUE 125 kgfm Pome LOCTITE 271 HOLE SIDE OUTPUT SHAFT ASSEMBLY RUNOUT MAX 0 1 ON DIAL GAUGE 157 196 Nm TORQUE 6 20 kgfm ADJUST WITH NUT A LOCTITE 271 STARTING 21 56 33 32 Nm HOLE SIDE TORQUE 2 2 3 4 kgfm HVZ01860 30 68 DISASSEMBLY AND ASSEMBLY DIFFERENTIAL TESTING BACKLASH In ies En Be EE dL rm HWZ01861 30 69 DISASSEMBLY AND ASSEMBLY DIFFERENTIAL MAINTENANCE STANDARD Sym heck i bol Check item Backlash Outside diameter of spider and pin Differential pinion Standard size 21 56 33 32 2 2 3 4 kgfm 0 20 0 28 27 959 27 980 Criteria Repair limit 27 75 Inside diameter of pinion gear 28 0 28 052 28 152 Bushing thickness 1 52 1 68 1 3 D Pinion gear Oil groove W x D Bushing thickness 1 94 2 06 1 7 E Side gear Oil groove W x D 68 68 03 68 13 Differential case 9 side gear boss Oil groove W x 4 1 5 4x1 4 G Outside diameter of differential case boss 90 013 90 035 Bevel pinion gear backlash 0 15 0 23 78 4 122 5 Differential case tightening bolt 8 12 5 kgfm Bevel gear mounting bolt 196 8 5 196 Nm K 16 20kgfm
8. 2 5 kgfm 13 7 18 0 Ibft 30 35 DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER No Check item Gear pump Oil seal and pump boss Replace at Ammi disassembling B mm Clearance 104 965 105 0 104 8 F CLA HWZ01822 Bush and gear pump case cover Amm 54651 54 970 j learance 55 55 03 mm 0 03 0 079 0 13 Bush Gear pump case cover HW101823 inside diameter of converter case sealing contact surface Seal ring J mm HW201824 Criteria Standard size mm Converter case 35 Allowable limit mm 35 15 gt 1 1 rein 1 42 L M mm 1 43 Seal HW201792 Remedy Replace 30 36 TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY LINDYID 3 11 HWZ01825 NOILONS 34 3 3 YALYAANOS 3 5 34 34 Ld 1404 4 34314 3 8 993 4 A38 eS SATA SIONS TOS t3 Gan 14 1806 4 2 93 4 5 YALA t 1 1 orm ONIHONI 52 831003 wo YOLV1NDAY X 1 2 YOLVINANIDY X FATWA 1 801 938 i 30 37 TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY 1HOd ONIEN
9. Add or remove shims as needed to achieve desired pressure setting Tighten lock nut e Retest using same steps as above The Void Control Feature is not adjustable but it is designed to operate whenever the work port pressure is lower than the reservoir pressure RELIEF VALVE PILOT PILOT POPPET D POPPET E SECTION CHECK VALVE HOUSING POPPET K LOCK NUT PISTON ADJUSTING NUT POPPET C SPRING PISTON O RINGS SPRING HWZ02007 SERVICE AND REPAIR The cartridge type work port reliefs used in these valves are typically of the pilot poppet type with external adjustment Any malfunctioning is usu ally the result of foreign matter lodging between the piston relief valve poppet and check valve To perform service clean the surrounding area and remove the complete relief valve cartridge Examine the seat in the main valve housing and if grooves or ridges are present replace the con trol valve with a new unit The design of the pilot poppet and its seat pro vides positive seating and rarely requires any maintenance The pilot section can be removed from the car tridge housing without disturbing the setting The check valve poppet and other parts will come with it and they should be checked for any for eign matter Seats and seating surfaces should be smooth and free of nicks scratches or grooves Replace O rings and back up washers if damaged Moving parts should slide freely After inspecting and cleaning d
10. 2 Stuck solenoid valve Disassemble and 2 Output drops Hydraulic pressure is too low 1 Deteriorated spring in inlet port re Disassemble and check lief valve or regulator valve or mal Replace parts as necessary function of piston 2 Stuck solenoid valve Disassemble and replace 3 Operation of inching valve Make adjustment 3 Oil oozes out or leaks Surface of joint with gasket included 1 Loosening of bolts Retighten 2 Broken gasket Disassemble and replace 3 Scratched mating surface Correct or replace 4 Electromagnetic valve No voltage does not function 1 Defective forward reverse gear shift Check and repair or replace lever switch 2 Connector fails to make contact Check and repair 3 Fused or disconnected fuse or wir Check and repair or replace ing circuit Presence of voltage 1 Disconnected grounding circuit 2 Connector fails to make contact 3 Frame grounding wire fails to make Check and repair Check and repair Check and repair contact Stuck solenoid vaive Disconnected solenoid or wiring cir cuit Check and repair or replace 5 Check and repair or replace 30 62 DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE MAINTENANCE STANDARD Criteria No Check item Standard size Allowable limit Remedy mm mm Piston or spool and body hole inside 8 Outside diameter diameter Housing HWZ01787 Accumulator O
11. 35382 HONN OOL HLIM d 1935 N33AAL38 dV9 1113 OL LON TInd33Vvo2 38 17 29 2 385 WNIHLIT HLIM Was 138 ONY 1113 09 Sp 7 29 3 385 3 58604 WN 889 LPP WAIHLIT HLIM 1709 2 bc 7 1vas 10 40 83 38 9 os 3 8804 NO 48489 Wows 3383 WN 067 v6 43 8 25 1992 PONE eR 05 91 UN 961 69 3n03801 6 G3HOLVH 2 ASWAYS HLIM 1714 Y 3111201 91 95 7 29 3 385 3 5804 WN 60 SvZ WAIHLIT HLIM 1702 HVZ 01876 30 78 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE WHEEL BRAKE INSTALLING SURFACE 17 6 26 4 TORQUE 480 270 kgtcm Wheel brake D D Front wheel internal expanding hydraulic Duo servo 317 5 317 6 Resin mold Adhesive type C80 100CX 60 0 P80CX G D 63 0 P80 100CX G D C80CXC C80 100CX F F HWZ01877 5 62 P80CX G D 10 0 P80 100CX G D C80CXC inner diameter of wheel cylinder mm 31 75 Type Structure Inner diameter of brake drum Lining material Width Thickness 30 79 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE DISASSEMBLY AND ASSEMBLY P80CX G D C80 100CX C80CXC 17 65 26 48 Nm 180 270 kgfcm TORQUE 157 196 Nm 16 20 kgfm LOCTITE 271 3 2 SCREW TORQUE
12. 57 is a single piece that has scarf cut ends and is simply wrapped around the piston It is not intended that the cut ends meet to make a seal 30 153 DISASSEMBLY AND ASSEMBLY TILT CYLINDER CYLINDER ASSEMBLY With the above aspects of the cylinder assembly properly completed lubricate the O D of the piston including the seal and the bearing strip and install the piston and rod assembly into the tube The piston and rod assembly should enter straight into the tube however sometimes it is helpful to rock the compo nent up and down or sideways in order to move the piston into the tube It may also be necessary to apply pressure to the bearing strip at the leading edge in order to get it started into the tube To do this use a small blunted screwdriver and push inward on the bearing strip toward the center of the piston at the point where it is entering the tube while at the same time pushing the piston and rod assembly into the tube This procedure will also be helpful when the piston seal starts to enter the tube especially if the seal was stretched more than need be and has not yet returned to its proper size Lubricate the O D of the head and assemble the head onto the piston rod and into the tube so that the starter hole in the head can be seen through the slot Coat the shear ring with a suitable lubricant such as CMD Extreme Pressure Oil or Alemite Petroleum Lubricant The lubricant aids greatly in the assembly procedure and t
13. Disassemble and replace Disassemble and replace Refill Check joints and gaskets Replace as necessary Disassemble and check Re place parts as necessary Disassemble and check Re place parts as necessary Disassemble and replace Disassemble and replace Disassemble and replace Change to the specified oil Refill or drain oil Disassemble and check Re place parts as necessary Disassemble and check Re place parts as necessary Disassemble and check Re place parts as necessary DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER Problem Abnormal noise is 1 generated Cavitation caused by insufficient oil or leakage of air from the suc tion line 2 Gear pump at fault 3 Contact caused by deformed im peller 4 Breakage of input piate 5 Breakage of gear 6 Wear or breakage of bearings 7 Wear of spline 8 Loosen boit Oil oozes out or leaks A Oil seal 1 Worn or damaged lip 2 Dirt caught 3 Worn or scratched shaft 4 Hardening or deterioration of rub ber because of abnormal rise in oil temperature B O ring 1 Broken O ring 2 Scratched mating surface 3 Hardening or deterioration of rub ber because of abnormal rise in oil temperature 4 Sudden use in extremely cold weather below 15 C C Plug screw 1 Loose screw 2 Broken screw 3 Cracked mating hole Remedy Refill oil or check and re place parts as necessary Disassemble and replace parts or
14. FRONT DIESEL ENGINE LIFT TRUCK 19 16 15 13 12 3 1 H Loa A cH SECTION NOTE THIS FIGURE DISPLAYS A PUMP ROTATING COUNTER CLOCKWISE VIEWED FROM THE INPUT SHAFT WHEN THE PUMP IS ROTATED CLOCKWISE THE POSITIONS OF THE INTAKE AND DIS CHARGE SIDES ARE REVERSED SECTION HVZ01979 Figure 1 Item Description Qty Item Description Qty 1 Gear plate assembly 1 13 Dowel pin 1 2 Front drive gear 1 14 Socket head bolt 4 3 Driven gear 1 15 Flat washer 4 4 Mounting flange A 1 16 O ring 1 5 Cover plate A 1 17 Hexagon bolt 2 6 Pressure plate 2 18 Washer 2 7 Plate seal 2 19 O ring 1 8 Backup ring 2 20 Connector cover 1 9 Oil seal 1 21 Socket head bolt 2 10 Snap ring 1 22 O ring 1 11 Adapter plate 1 23 KP10 assembly 1 12 Spline coupling 1 eM 30 129 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP DISASSEMBLY OF FRONT PUMP DIESEL ENGINE LIFT TRUCK SEE FIGURE 1 1 10 When disassembling clean the surface of the pump and driveshaft Care should be taken not to contaminate scratch or nick the disassembled parts Place them on a clean paper or cloth Place the parts in order so that the proper locations of each part can be identified prior to reassembly Insert mounting flange 4 into a smooth padded vise with the pump mounting sur face downwards and secure it Remove hexagon bolt 17
15. bringing with it the bushes 21 amp 20 Remove driven gear 23 and the two remaining bushes DISMANTLING THE FRONT PUMP 1 Lightly mark the spacer body and mounting flange 16 1 amp 9 to ensure reassembly in the proper sequence Remove nuts and spring washers 11 amp 10 Turn the unit over and lightly tap the mount ing flange 9 to disengage it from the locat ing pilot and slide it squarely off the shaft Remove body O ring 8 bush seal and back up seal 3 amp 4 With the unit lying on its side hold the drive shaft 6 and pull it squarely out of the body bringing with it the bushes 5 Remove driven gear 7 and the other remaining bush plate 5 30 126 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP REASSEMBLING THE REAR UNIT Ensure that all parts are perfectly clean Lubri cate bushes and gears with clean hydraulic fluid ensure O ring recess and end faces of body remain dry This will assist assembly of compo nents into the body bores 1 Refit cover end bushes CD amp Cl into the undowelled end of the body from where they were removed The C shaped cut out in the bushes must be to the side of the body with the cusp removal flat Place the end cover 25 against the undow elled end of the body 24 and stand the assembly on the cover so the dowels are uppermost and to the left hand side Fit driveshaft 22 and driven gear 23 into their original positions in the body Ref
16. into their original positions in the body Replace 2nd balance plate 5 into its origi nal position with small holes to the low pres sure side of the pump Fit seal and back up 3 amp 4 Fit new body O ring 8 into its groove in mounting flange and apply a small amount of Loctite sealant to body lower front face out board of oval location This sealant is to pre vent moisture from entering this area and causing corrosion It is not a hydraulic seal Fit the first shaft seal 12 into mounting flange 9 bore with garter spring facing into the pump Fit the C clip 13 in mounting flange 9 groove and then fit 2nd shaft seal 12 into mounting flange 9 bore with garter spring facing out Carefully fit mounting flange in its original position The 4mm diameter drain hole in the rear face must be to the low pressure side of the pump Use caution not to damage shaft seals 12 on shaft Fit serrated washers and nuts 10 amp 11 to studs and tighten to 90 95 Nm 65 70 158 Pour a small amount of clean hydraulic fluid into a port and check that the shaft can be rotated without undue force using a smooth jawed vice 30 127 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP INSPECTION AND REPAIR Each component should be thoroughly cleaned carefully examined and checked to see if it is reusable Read the following guide for informa tion on inspecting the various components Body Inspect the body bore cut in where
17. with the sharp edges of the tongue ground blunt will work well for installing and removing seals TORQUE VALUE FOR PISTON LOCK NUTS Bore size Torque Ibft 3 1 2 290 TILT CYLINDER ASSEMBLY ORIENTATION CENTERLINE OF TUBE SLOT IN THE UP POSITION HOOKED END OF SHEAR RING THROUGH TUBE SLOT AND INTO STARTER HOLE IN HEAD ROTATE HEAD UNTIL CENTERLINE OF SPANNER WRENCH HANDLE 15 IN LINE WITH CENTERLINE OF SLOT M CENTERLINE OF SPANNER WRENCH HANDLE BEFORE ROTATING HEAD l 1 BEVELED END OF SHEAR RING THE LEFT AND DOWN 1 FACING ROD END OF CYLINDER HWZ02148 30 155 DISASSEMBLY AND ASSEMBLY POWER STEERING CYLINDER POWER STEERING CYLINDER STRUCTURE DETAIL A HWZ02018 Cylinder O D x 3 1 2 x 3 in Stroke 8 1 2 in Rod O D 2 in CHECK AND INSPECTION Check item Detail of check Remedy Piston rod cylinder Gouges nicks dents Replace Packing seal Scratches deformation of lip 30 156 DISASSEMBLY AND ASSEMBLY MAST MAST INTRODUCTION In any communication concerning your Kalmar lift truck mast refer to the mast number stamped on the nameplate If the nameplate is missing these numbers are also stamped on the right side of the head beam See Figure below Mast stamp numbers Right side of head beam Quter mast HWZ02019 13 Pa e 4 EN 1 12
18. ASSEMBLY TORQUE CONVERTER TORQUE CONVERTER Outdoor vehicle COMPONENT PARTS HWZ02101 Gy 1 Ne 7 4 Turbine shan 1 7 Gear pump assembly a 24 fonsa 3 2 29 Gasket 1 1 30 2 DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CASE ASSEMBLY AND STATOR SUPPORT COMPONENTS HVZ01786 30 3 DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER TESTING Criteria Check item Standard size Repair limit mm mm Torque converter inlet port valve Piston and housing hole 14 14 018 B mm 13 96 13 97 Clearance 0 030 0 058 Replace piston mm Free length D Installed length C mm 103 4 E Installed load 5 62 7 E kg 75 6 7 71 5 68 1 6 94 HWZ01788 Gear pump Oil seal and converter hub Gmm 61 915 61 965 011 seal Impeller hub HWZ01789 Bushing and torque converter impeller hub Hmm 61 915 61 965 Replace Imm 62 62 030 Clearance 0 035 0 115 Housing lapeiler hub 101739 Turbine shaft Housing hole and seal ring groove K Groove J mm 60 00 60 03 60 15 3 Kmm 2 4 2 5 2 6 4 Housing Turbine shaft HWZ01791 Seal ring 25 27 2 3 211 2 35 2 40 2 15 Seal ring HWZ01792 The numbers used in the No column of the table refer to the numbers in the component part drawing 30 4 DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER ASSEMBLY Carry out as
19. Clutch pack HWZ02123 30 25 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ASSEMBLY OF OUTPUT SHAFT SUB ASSEMBLY OUTDOOR LIFT TRUCK Assemble parts generally in the reverse order of disassembly HWZ02124 1 Install the inner race of bearing 2 to pinion shaft 1 2 Install O ring 3 to the inner race of bearing 2 by pressing the ring to the race to install race 4 HWZ02125 NOTE Assemble race 4 so that the tapered side faces the spline 3 Install oil seal 5 to cage 6 and put the outer races of bearings 2 and 7 to both sides NOTE Assemble the seal so that the rounded side on the back faces the pinion NOTE After assembling the seal apply lithium grease to the lip 4 Mount shim 8 NOTE Refer to the thickness of the dis assembled shim s See Shim Adjustment P part 5 Engage the roller of bearing 2 with the inner race installed on pinion shaft 1 TAPERED PART 4 6 Install cage 6 with oil seal 5 and the outer races of bearings 2 and 7 assembled on the pinion shaft HWZ01808 SHIM ADJUSTMENT P PART SHIM ADJUSTING PROCEDURE INSERT SHIMS OF t 0 5 TO SIDE t 0 3 TO SIDE b AND t 0 25 TO THE CENTER HWZ01809 30 26 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 7 Engage the roller of bearing 7 with the outer race in cage 8 8 Assemble the inner race of bearing 7 NOTE Make sure that the adjustment shim has been insta
20. DISCHARGE SIDE INTAKE SIDE SIDE PLATE B 6 Insert side plate A 6 into the back of gear plate 1 with the copper alloy surface up Pay particu lar attention to the orientation of the intake and discharge sides See Figure 8 If the side plate is tilted and cannot be moved hold the driveshaft end of drive hear 4 and lightly press inward on the higher portion to make the work easier COVER FACE TOP NOTCHED GROOVE ON THE INTAKE SIDE HVZ01997 Figure 7 DISCHARGE SIDE INTAKE SIDE Figure 8 SIDE PLATE A HVZ01998 30 141 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP 12 Insert drive gear 4 and driven gear 5 by aligning with set marks put on the shaft end during disassembly Pay close attention to the locations of the drive gear and driven gear After inserting the gears pour about 2 3 cubic centimeters of clean hydraulic oil into the grooves of the gear teeth Insert side plate B 7 in gear plate 1 with the copper alloy surface down Pay close attention to the orientation of the intake and discharge sides See Figure 8 Fit O ring 11 into the groove of cover 3 and place the cover on gear plate 1 Note that the letters IN are located on the intake side If the gap between the cover and gear plate 1 exceeds 1 3mm when cover 3 is lightly pressed the O ring is off the groove and must be reinstalled properly Insert bolt with washer 14 into the bolt hole and ti
21. Fit driveshaft 12 and driven gear 11 into their original positions in the body Refit spacer end bushes FD amp FI into their original bores remembering that the cut out must be to the side of the body with the cusp removal flat and match the cover end bushes 5 Fit new body O ring 4 ensuring that the seals locate correctly in the seal grooves 6 Holding the whole unit together carefully turn it over onto spacer and engage drive shaft into quill 14 7 Remove end cover 3 and fit new body O ring 4 bush seals and back up seals 5 amp 6 8 Replace the end cover and refit bolts and spring washers 1 amp 2 Torque bolts to 46 51 Nm 34 37 6 Ibft 9 Pour a small amount of clean hydraulic fluid into a port and check that the shaft can be rotated without undue force using a smooth jawed vice on the front pump s driveshaft REASSEMBLING THE FRONT UNIT Ensure all parts are perfectly clean and lubricate bushes and gears with clean hydraulic fluid ensure O ring recess and end faces of body remain dry This will assist assembly of compo nents into the body bores 1 Refit spacer end bushes CD amp CI into the undowelled end of the body from where they were removed The C shaped cut out in the bushes must be to the side of the body with the cusp removal flat 2 Place the spacer 13 against the undow elled end of the body 27 and stand the assembly on the cover of the rear pump
22. Mechanical breakage 1 Broken or deformed impeller 2 Deformed input plate Other 1 Non specified oil is being used 1 Incorrect oil level 2 Contact of impeller 3 Wear or seizure of bearing 4 Wear or damage of gear pump Add oil Disassemble and check replace with new parts or replace whole assembly Disassemble and replace Disassemble and replace Disassemble and replace Disassemble and replace Disassemble and replace Add oil Check joint gasket replace parts if necessary Disassemble and replace replace parts if necessary Disassemble and replace replace parts if necessary Disassemble and replace Disassemble and replace Disassemble and replace Change to specified oil Add or drain oil Disassemble and replace replace parts if necessary Disassemble and replace replace parts if necessary Disassemble and replace replace parts if necessary DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER Problem Abnormal noise is generated 1 Cavitation caused by leakage of air from suction piping or lack of oil 2 Failure of gear pump 3 Contact caused by deformed impel ler 4 Breakage of input plate 5 Breakage of gear 6 Wear or breakage of bearing 7 Wear of spline 8 Loose bolts Add oil or check and replace parts if necessary Disassemble and replace parts or whole assembly Disassemble and replace replace parts if necessary Disassemble and r
23. NOTE TWO OF THE BACKING PLATE MOUNTING BOLTS ARE REAMER BOLTS INSTALL THEM IN THEIR ORIGINAL LOCATIONS MARKED X 18 6 TESTING Criteria Check item Remedy Standard size mm Repair limit mm Inside diameter of drum 317 5 317 7 319 5 Thickness of lining 5 62 2 Deterioration of Springs 1 and 2 Free length 120 Free length 132 return spring Spring 3 Free length 139 Free length 153 Thickness of return spring hook portion 2 9 2 0 Clearance between piston and cylinder 0 0 05 0 2 Check for scratches on wheel cylinder sliding surface and for damage deterioration of the cap 30 80 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE DISASSEMBLY AND ASSEMBLY P90 100CX G D 17 65 26 48 Nm TORQUE 180 270 kgfcm 7 85 11 77 Nm TORQUE 120 kgfem 245 309 Nm TORQUE 25 31 kgfm LOCTITE 271 SCREW NOTE TWO OF THE BACKING PLATE MOUNTING BOLTS ARE REAMER BOLTS REINSTALL THEM IN THEIR ORIGINAL LOCATIONS HVZ01879 TESTING Criteria Check item Remedy Standard size mm Repair limit mm Inside diameter of drum 317 5 317 7 319 5 Thickness of lining 10 0 2 0 from the rivet head Deterioration of Spring 1 Free length 93 22 5 27 5 kgf return spring when length 101 2mm Spring 2 Free length 123 2 7 2 8 8 kgf when length 152mm Thickness of return spring hook portion 2 9 2 0 Clearance between piston
24. and washer 18 to remove rear pump KP10 assembly 23 and O ring 19 Loosen socket head bolt 14 and remove it together with plain washer 15 Remove adapter plate 11 O ring 16 spline coupling 12 and dowel pin 13 Loosen socket head bolt 21 and remove connector cover 20 and O ring 22 Caution When loosening bolts gradually apply force to prevent the mounting flange from dislodg ing from the vise Use an appropriate tool wrench that is not worn Remove cover plate 5 Remove the cover plate in an axial direction in a straight line If it is too tight to remove easily tap it lightly with a wooden hammer in the removal direc tion Remove plate seal 7 and back up ring 8 from the setting surface of cover plate 5 Pull out pressure plate 6 It can be easily pulled out if the shaft of front drive gear 2 and driven gear 3 is slightly raised Put the set mark on the shaft end face of front drive gear 2 and driven gear 3 and pull out the gear Mark with an oil stone or marker Pull out pressure plate 6 from the bottom of the gear plate assembly Do not tilt the pres sure plate If the pressure plate has been tilted and it cannot be easily removed hold and insert the spline of the front drive gear into the gear plate and lightly press the higher portion of the pressure plate The pressure plate should fall back into its original position Now pull it out without tilting and jamming 30 13
25. assembly Disassemble and check and replace parts as necessary Disassemble and replace Disassemble and replace Disassemble and replace Disassemble and replace Retighten or replace as nec essary Disassemble and replace Disassemble and check and replace as necessary Fix or replace Disassemble and replace Disassemble and replace Correct or replace Disassemble and replace Carry out warming up op eration Retighten Replace Replace 30 41 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION TORQFLOW TRANSMISSION DISASSEMBLY INDOOR LIFT TRUCK 1 Oil drain Remove the drain plug and drain oil from the case DRAIN PLUG HWZ01828 2 Transmission valve differential Unscrew the transmission valve mounting bolt 1 and differential carrier bolt 2 and remove the transmission valve and differential HWZ01829 3 Torque converter Remove flexible plate 3 and pilot boss 4 and 3 4 then remove snap ring 5 5 n Remove the converter assembly from the turbine CONVERTER shaft ASSEMBLY Ej 25S HWZ01830 30 42 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 4 Converter case Unscrew bolt 6 and remove converter case 7 HWZ01831 5 Main shafts Remove the main shafts 8 and 9 HWZ01832 30 43 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 6 Pinion shaft Unscrew bolt 10 and remove pinion shaft 11 10 HWZ01833 7 PTO driven gear oil pump assem
26. correct viscosity Run at correct oil temperature Failed centering location of shaft from pump and engine Relocate centering Air bubbles in hydraulic oil Identify and correct cause for for mation of air bubbles Oil leaks from the pump Defective pump seal 13 in the pump e Defective O ring 11 Defective balance seal 8 Replace with new parts Contaminated seal s Recheck the pump 30 145 DISASSEMBLY AND ASSEMBLY CONTROL VALVE CONTROL VALVE ASSEMBLY PROCEDURES 1 Lay out valve components on a clean flat working surface The inlet assembly will include an O ring and the spool section s include an O ring a load check poppet and a load check spring Tools required for basic valve assembly include 3 4 and 11 16 open or box end wrenches and a torque wrench with thin wall sockets Assemble tie rod nuts to one end of each tie rod with one or two threads left showing Insert tie rods through tie rod holes of inlet larger tie rod at the top Lay inlet on end with tie rods pointing up and place O ring into position Place first spool section O ring side up on inlet section position O ring and insert load check poppet nose down and spring behind poppet into load check cavity as shown Repeat this procedure for each spool section The load check springs are com pressed by the following sections during assembly Position end section on last spool section as
27. distributor plate 6 Screw out the threaded bushing over the check valve 7 Remove O ring 30 100 HWZ01912 HWZ01913 HWZ01914 M Hwzo1915 DISASSEMBLY AND ASSEMBLY PS VALVE 8 OSPC LS OSPC LSR Shake out the check valve ball and suction valve pins and balls NOTE Pins and small balls shown in Figure are not included in the unit 9 Take care to keep the cross pin in the sleeve and spool horizontal The pin can be seen through the open end of the spool Press the spool inwards and the sleeve ring bearing races and needle bearing will be pushed out of the housing together 10 Take ring bearing races and needle bearing from sleeve and spool The outer thin bearing race can sometimes stick in the housing so check that it has come out 11 Press out the cross pin Use the special screw from the end cover NOTE See Figure 11a on next page 4 HWZ01916 HWZ01917 HWZ01918 HWZ01919 30 101 DISASSEMBLY AND ASSEMBLY PS VALVE 11a A small mark has been made with a pumice stone on both the spool and the sleeve near one of the slots for the neutral position springs see Figure If the mark is not visible be sure to make a mark on the sleeve and spool BEFORE the neutral position springs are dismantled 12 Carefully press the spool out of the sleeve 13 Press the neutral position springs out of their slots in the spool 14 Remove the dust seal and O ring seal
28. injury 30 13 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 10 Output shaft sub assembly A Remove bearing cage support bolts 8 and 9 from the output shaft in order to remove the output shaft sub assembly NOTE Store shims 5 between the transmission case and the cage Keep them together by binding the shims with nylon tape or other suitable method HWZ02106 11 Intermediate shaft A Remove the intermediate shaft including the small gear and bearing F1 R1 SHAFT HWZ01800 30 14 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 12 Input shaft Disassembly of clutch pack assembly The numbers show the sequence for disassembly HVZ01801 When removing snap rings 14 and 29 A be aware that these rings are under CAUTION strong tension Use an appropriate tool for removal Snap ring tool 3EC 97 99000 3EC 97 99020 3EC 97 99010 NOTE When ordering parts note that gears 6 and REN x 21 are different depending upon type of lift truck 3EC 97 99000 HVZ01802 WHEN REMOVING SNAP RINGS 14 AND 29 ALWAYS UTILIZE APPROPRIATE TOOLS LISTED 30 15 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 13 Intermediate shaft P100CX G D F2 Disassembly of clutch pack The numbers in the Figure display the sequence for disassembly SHIFT ASSEMBLY HVZ01803 When removing snap ring 16 be aware A this ring is under strong tension Use an CAUTION appropria
29. pump See Figure 1 If the trace of contact is not more than 1 2 of the circumference of the gear pump it is nor mal Approximately 0 05mm is a normal value for the depth of the trace contact a as shown in Figure 2 If the depth exceeds 0 15mm wear of the shaft or the bearing is assumed to excessive Carefully check these parts If the depth is 0 15mm or greater replace the entire pump assembly with a new unit See Figure 7 If the diameter of the gear d is less than 24 895mm replace with a new gear set 2 Drive gear 4 and driven gear 5 If the hydraulic oil is clean the relative roughness of the gear and the side of the gear is hardly altered and they present smooth contact surfaces If the surface of the gear or the side of the gear displays gouges or scoring or the surfaces of the gear teeth are abnormally or partially worn replace with new parts See Figure 4 If the diameter of the gear d is less than 14 96mm replace with a new gear set TRACE OF CONTACT DISCHARGE CHAMBER INTAKE CHAMBER TRACE OF CONTACT Figure 3 HVZ01993 Figure 4 HVZ01994 30 139 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP 3 Side plate A 6 and side plate B 7 The side plate is normal if it presents glossy gear contact surfaces on the side of the slid ing surfaces as shown in Figure 5 f during disassembly gouges and scor ing are found on the plate surface or the sur f
30. pump pay close attention to the following items 1 there any scratches on the centering location boss on which alignment is based 2 Does the mounting flange 2 display any scratches or any contaminant on the mount ing surface Care must be taken not to over tighten the vise on the flange 3 Are there any scratches or contaminants on the flange surface of the pipe Use a fine oil stone to remove any nicks or contaminants 1 CAP MATERIAL 545 CONNECT WITH A SMOOTH R This must be free from burr SLEEVE AFTER SETTING THE CAP AND OIL SEAL PRESS THE OIL SEAL IN USING THE SLEEVE CAP PUT THE CAP ONTO THE INPUT SHAFT OF THE PUMP OIL SEAL 2 SLEEVE MATERIAL ALUMINUM SET THE OIL SEAL IN THE CAP AS SHOWN MOUNTING and 5 side plate A 6 and side plate B 7 use care to ensure that part locations and orientation are exactly the same as they were prior to disassembly FLANGE OIL SEAL INPUT SHAFT OF PUMP INJECTION is part must tree from burr Figure 10 HOLE INJECTION METHOD HVZ02000 30 143 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP TESTING THE PUMP Testing is performed in order to ensure that the pump is assembled correctly and that it will per form as designed without leakage Testing will be performed on the lift truck and should be done in the order shown below If the pump is burned or seized or the inside of the pump is abnormally worn cha
31. shown and hand tighten tie rod nuts The end section in Figure at right is a turn around section without port Universal outlet power beyond section and power beyond and closed center sections are also used as end sections These end sections do not have O ring grooves Position valve assembly with the mounting pads of the end sections on a flat surface To obtain proper alignment of end sections rela tive to the spool sections apply downward pressure to the end sections Snug tie rod nuts to about 10 Ibft Final torque the two 11 16 nuts to 48 5 Ibft Final torque the 3 4 nut to 74 8 Ibft Check for proper spool movement Install auxiliary valves and plugs and torque to proper specifications General assembly notes 1 2 Lever assemblies can be installed on section before or after complete valve assembly The load check and spring may be omitted from assembly in certain circuit conditions i e motor spools 30 146 HWZ02002 HWZ02004 HWZO02006 DISASSEMBLY AND ASSEMBLY CONTROL VALVE SETTING PRESSURE ON WORK PORT RELIEF There are several variations of the Work Port Relief however all are similar in nature regard ing service and repair A good pressure gauge must be installed in the work port relief line Apply a load in such a way as to reach the port relief set pressure Then fol low the following steps Loosen lock nut Set adjusting nut to desired pressure setting
32. the groove To replace the Teflon piston seal Item 18A cut the seal and remove from the groove being careful not to nick or scratch the sides of the groove Remove the expander Item 18B using a blunt screwdriver again using care not to damage the bottom or sides of the groove For ease of installation and to minimize the time that the piston seal is in the stretched condition the expander and the seal should be installed into the groove from the rod side of the piston The leading edge of the piston must be free of any deep nicks or burrs before installing the piston seal Lubricate this edge prior to putting the piston seal into the groove Lubricate the expander and stretch it over the edge of the piston into the groove Lift a segment of the pis ton seal over the lip of the piston and install as much of the seal as possible into the groove by pushing down on the outside of the ring to seat the on the expander Place a small blunt screwdriver under the of the seal that is outside the groove Pulling outward and inward towards the piston stretch the seal up and over the lip to align it with the groove Remove the screwdriver and the seal will snap into the groove The stretching of the seal into the groove must be done rapidly due to the memory characteristics of Teflon The longer the seal remains in the stretched condition the longer it takes the seal to return to its original shape and size The piston bearing strip Item
33. the hole in poppet C and because of the differential area between diameters A and B relief valve poppet D and check valve poppet K are tightly seated STEP 2 The oil pressure in the high pressure port HP has reached the setting of the pilot poppet spring force and unseats the pilot poppet E Oil now flows around the poppet through the cross drilled holes and to the low pressure area LP STEP 3 The loss of oil behind poppet C effected by the opening of pilot poppet E causes poppet C to move back and seat against pilot poppet E This shuts off the oil flow to the area behind relief valve poppet D and causes a low pressure area internally STEP 4 The imbalance of pressure on the inside as compared to that of the high pressure port HP forces the relief valve poppet D to open and relieve the oil directly to the low pres sure chamber LP in the valve As anti void The anti void unit supplies oil to the high pres sure port HP when cavitation has occurred A lower pressure exists in the port HP compared to the low pressure chamber LP The difference between the effective area of diameter A and G causes imbalance of the check valve poppet K which unseats allowing oil from the low pressure chamber LP to enter the port HP and fill the void See Figure to right As separate anti void The anti void check valve opens when cavitation occurs in the high pressure port HP and su
34. the spring Install the spacer 1 2 3 4 5 6 8 9 and plate t 6 0 Secure it with a ring Install the thrust washer Install the gear 2 28 install the washer Fasten with a spring Install the spacer Install the bearing Fit the seal ring Fasten it with a snap ring Instail clutch disc plates alternately Install disc 6 plate 6 t 2 3 8 9 10 11 10 13 16 21 14 18 19 HWZ01848 Main shaft Fwd Attach the seal to the shaft Fit the seal ring into the piston and install the piston in the drum Clutch pack install camber plate bellville spring Install the bearing in the gear Install bearing Main shaft Rev sub assembly 30 53 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ASSEMBLING OUTPUT SHAFT SUB ASSEMBLY Assemble in the reverse order of disassembly HWZ02124 1 Attach the inner race of bearing 1 to pinion shaft 1 2 Fit O ring 3 into the inner race of bearing 2 by pressing the ring down on the race to install race 4 HWZ02125 NOTE The tapered part of race 4 should face the spline splined side 3 Attach oil seal 5 to cage 6 and install the outer races of bearings 2 and 7 on both sides of the cage NOTE Fit the seal in such a way that the rounded side on the back faces the pinion NOTE After fitting the seal apply lithium grease to the lip TAPERED PART 4 HWZ01808 4 Install shim 8 NOTE Refer to the th
35. 0 11 12 Remove gear plate assembly 1 after mark ing the cover and mounting flange sides with identification so they can be reassembled in the same orientation Lightly tap around the gear plate assembly with a wooden hammer or the like to pull it up Since the dowel pin is press fitted into the gear plate do not remove it Remove plate seal 7 and back up 8 from mounting flange 4 Remove snap ring 10 to remove oil seal 9 Tap out the oil seal from the inside using a blunted screwdriver or similar tool Use care not to damage the oil seal press fitting hole and bearing hole DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP INSPECTION AND REPAIR PROCEDURES Check the disassembled parts for contamination or discoloration and then clean them with diesel oil DO NOT dip rubber parts in diesel oil After checking all the parts as follows repair or replace any defective parts found 1 Gear plate assembly 1 The gear pump is designed to rotate while the gear teeth tips are making contact in the inner gear hole to improve volumetric effi ciency Therefore if the pump has been driven once the evidence of contact of the tooth tips can be seen in the area of the intake port of the pump If the trace of contact is not more than 1 2 of the circumference of the gear pump it is nor mal Approximately 0 05mm is normal value of the depth of in Figure 2 If the depth a exceeds 0 12mm wear of the shaf
36. 02103 30 11 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 4 Strainer and plate A Remove bolt 12 and plate 13 to pull out F1 R1 NE strainer 14 DIPSTICK B Remove bolt 16 to remove plate 17 NOTE On F2 R1 trucks also remove bolt 18 and plate 19 5 Sensor A Remove thermal sensor 20 B Remove plug 15 NOTE On trucks equipped with optional speedometer remove it now HVZ01798 6 Accumulator A Remove plug 8 B Remove collar 9 spring 10 and piston valve 11 F2 R2 7 Plug breather and cap A Remove drain plug 21 breather 22 and DIPSTICK cap 23 B Remove blind plugs 24 NOTE Number of blind plugs F1 R1 trucks 8 F2 R1 trucks 13 HVZ01799 30 12 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 8 Removing the large gear from the intermediate shaft A Remove the bearing from the inter mediate shaft using a bearing puller B Remove the gear For the F2 R1 truck remove it as an intermediate shaft sub assembly including a clutch pack HWZ02104 9 Input shaft sub assembly including a clutch pack assembly 22 154 i Ke m HWZ02105 NOTE The intermediate shaft can be removed as an intermediate shaft sub assembly without removing the gear by removing the output shaft sub assembly mounting bolt first in order to raise the output shaft sub assembly Be sure to remove assemblies in sequence to avoid parts breakage and possible
37. 3 and bolts 4 Use following bolts M10 x 1 5 Length from neck 20mm Torque 1866 24 5 Nm 1 9 2 5 kgfm 13 7 18 1 Ibft C Install stator shaft 5 in the case D Fasten with a bolt Use following bolt M8 x 1 25 Length from neck 22mm Torque 18 6 24 5 Nm 1 9 2 5 kgfm 13 7 18 1 Ibft E Install pump boss gear 5 on the stator shaft and fit the snap ring F Install seat retainer in the case G Fasten with a bolt Use following bolt M8 x 1 25 Length from neck 22mm Torque 18 6 24 5 Nm 1 9 2 5 kgfm 13 7 18 1 Ibft 2 PTO driven gear and oil pump assembly A Assemble bearing 1 B Engage driven gear 2 with the idle gear and install them C Assemble bearing 3 D Assemble oil pump assembly 4 E Fasten with a bolt Use following bolt M8 x 1 25 Length from neck 70mm Torque 18 6 24 5 Nm 1 9 2 5 kgfm 13 7 18 1 Ibft HWZ01850 30 57 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 3 Pinion shaft assembly A Assemble pinion shaft assembly 1 in the case B Fasten with bolts Use the following bolts M12 x 1 75 Length from neck 50mm M12 x 1 75 Length from neck 130mm Torque 98 1 122 6 Nm 10 0 12 5 kgfm 72 4 90 4 Ibft Apply Loctite 572 to the internal threads BOLT HWZO01851 4 Main shaft assembly Set the direction as shown in the figure on the right using a piece of wood as a support A Assemble main sha
38. 3 8 16 NUT 26 DRIVEN GEAR 13 SPACER 27 ALUMINUM BODY 14 QUILL 30 122 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP DISMANTLING THE REAR PUMP SECTION Before starting work be sure that the unit work area and all tools are thoroughly clean to prevent contamination of the unit 1 Lightly mark the end cover body and spacer 3 9 amp 13 to ensure reassembly in the proper sequence 2 Remove bolts and spring washers 1 amp 2 3 Remove end cover 3 body O ring 4 bush seal and back up seal 6 amp 5 4 Turn the unit over and lightly tap the spacer 13 to disengage it from the locating dowels 5 Remove body O ring 4 bush seal and back up seal 6 amp 5 6 Before removing the internal components mark the bushes to denote the location in the body On a clean area away from the seal location mark FD Bush on driveshaft spacer end FI Bush on driven gear spacer end CD Bush on driveshaft cover end Cl Bush on driven gear cover end 7 With the unit lying on its side hold the drive shaft 12 and pull it squarely out of the body bringing with it the bushes 7 amp 8 8 Remove driven gear 11 and the two remaining bushes DISMANTLING THE FRONT PUMP 1 Lightly mark the spacer body and mounting flange 13 27 amp 18 to ensure reassembly in the proper sequence 2 Remove nuts and spring washers 12 amp 2 3 Remove spacer 13 body O ring 19 back ing ri
39. 4 0 88 kgfm 294 490 Nm TORQUE 30 50 kgfm 294 490 Nm 30 50 kgfm 490 608 Nm 50 62 kgfm TORQUE TORQUE TORQUE FORCE FIT USING JIG FILL WITH GREASE TO 1 3 1 2 OF CAPACITY BOTH SIDES FITTINGS AND LOCATIONS SPECIFIED USE LITHIUM GREASE G2 LI TO FILL IN DRAWING x 6 343 427 Nm 85 43 5 kgfm BEND SECURELY ul 2 5 E BEND SECURELY 343 427 Nm 85 43 5 kgfm 490 608 Nm 50 62 kgfm TORQUE TORQUE HWZ01900 30 94 DISASSEMBLY AND ASSEMBLY REAR AXLE MAINTENANCE STANDARD Sir ee rie P 35 es m HWZ01901 Mark Item Standard size Repair limit Remedy 1 D of center 55 mm 54 5 mm A2 of center pin bushing 55 mm 55 5 mm B O D of king pin 35 mm 34 8 mm Replace C1 O D of power steering pin 20 mm 19 9 mm C2 of power steering pin bushing 20 mm 20 5 mm D Backlash of knuckle pin bushing No backlash Clearance of knuckle 0 2 Adjust shims Turning radius degree 76 45 77 20 Adjust Pneumatic tire lift truck 54 54 30 95 DISASSEMBLY AND ASSEMBLY PS VALVE PS VALVE COMPONENT PARTS HVZ01902 Item Parts name Item Parts name 1 Dust seal ring 13 O ring 2 Housing and spool 14 Distributor plate 3 Ba
40. 97 99010 COLLAR HOLDER a el 3EC 97 99000 HVZ01844 WHEN INSTALLING OR REMOVING SNAP RING 13 USE THE SPECIFIED TOOL FOR SAFETY 30 47 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION SERVICING AND INSPECTION INDOOR LIFT TRUCK HWZ01841 Sym Criteria Check item Remedy bol Standard size mm Standard size mm A Pilot tip wear 20 19 85 B Pump boss inner diameter seal ring contact surface 75 75 15 Width 3 0 2 43 cosi Thickness 3 8 2 82 D Converter case inner diameter seal ring contact surface 35 35 5 E Seal rin Width 2 0 1 43 9 Thickness 1 9 142 Replace F Transmission inner diameter seal ring contact surface 35 35 15 Width 2 0 1 43 Thickness 1 9 1 42 H Clutch piston inner diameter seal ring contact surface 50 50 15 J Seal rin Width 2 5 1 93 9 Thickness 2 0 1 52 30 48 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION INSTRUCTIONS IN ASSEMBLING INDOOR LIFT TRUCK 1 Cleaning parts A Prior to assembling thoroughly clean the case bolt holes and threads and oil groove corners B Thoroughly clean the threads of the case vertical hole bolts in particular because dirty threads may result in incorrect tightening torque or broken bolts Remove all residual Loctite and debris from threads 2 Clutch pack assembly Blow the oil hole with compressed air and check operation of drive plate and driven plate A
41. ANOOY 02 tv 39 55294 pas AWA GIONS TOS SNIHONI dd aunssaud dwnd Swng 1 aunssaud 2 19 YOLVINDAY 1 1 4 OL 3ATVA 251138 184634 3unss3ud 48 4 1 3 SNOYOL Salad NOLLVOTHSIYT 5 LYOd L3 TNI X YALYAANOO 3n080L J lt lt LHOd Tauno YALYAANCO SNOYOL NOLLVOINENT OL HWZ01796 8 1355 431009 1 33 ANOYOL 30 8 DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER TROUBLE SHOOTING GUIDE CAUSES AND REMEDIES FOR FAILURES Power is not transmitted Output drops Oil pressure rises abnormally high A No hydraulic pressure 1 Lack of oil 2 Damaged gear pump or drive portion 3 Damaged piping or joint 4 Broken piston in inlet port relief valve or broken spring Mechanical breakage 1 Broken input plate 2 Broken shaft gear 3 Broken spline Hydraulic pressure is too low 1 Lack of oil 2 Leakage of air from suction piping 3 Drop in efficiency of gear pump 4 Deteriorated spring in inlet port relief valve or defective operation of piston 5 Worn or broken seal ring
42. ATION SWITCH COMBINATION SWITCH TORQFLOW TRUCK COMPONENT PARTS ENGINE WIRING HARNESS LIGHTING TURN SIGNAL LIGHT SWITCH FORWARD REVERSE TRAVEL SWITCH COVER BOOT SCREW SCREW 1 2 3 E s 6 HVZ01964 30 115 DISASSEMBLY AND ASSEMBLY COMBINATION SWITCH Checking lighting turn signal switch Without dimmer switch 1 Disconnect 8 pin coupling between combination switch cord and wiring harness 2 Check continuity between terminals at each position and check that there is continuity between O O See Tables 3 Insulating resistance Minimum 10 MQ at each terminal with 500 V megger TERMINAL ARRANGEMENT OF 8 PIN COUPLER COMBINATION SWITCH END HVZ01965 Connection positions for lighting switch Position TN 1 2 3 4 OFF Lighting switch SMALL 9 2 HEAD 6 Circuit diagram NOTE ON CLUTCH SPEC TRUCKS TERMINAL DIMMER CIRCUIT 15 A DUMMY CIRCUIT HVZ01966 Connection positions of turn signal switch Circuit diagram Circuit Position 3 R Intermediate TURN SWITCH L 2 9 D Hvzo1967 30 116 DISASSEMBLY AND ASSEMBLY COMBINATION SWITCH Checking lighting turn signal switch With dimmer switch 1 Remove connection of 8 pin coupler between combination switch cord and wiring harness 2 Check continuity between terminals at each position and check that there i
43. Fit O ring 12 into the ring groove of cage 6 THREE POINTS MUST COME IN CONTACT HWZ01812 30 55 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ADJUSTING OUTPUT SHAFT SUB ASSEMBLY PINION SHAFT PROTRUSION INDOOR LIFT TRUCK 1 Shim between the cage and the transmission Calculate the thickness using the following formula to obtain pinion shaft protrusion Standard shim is 1 2mm Shim thickness T 0 30 100 e aandb Read the numbers on the pinion shaft end After adjusting the starting torque HWZ01813 of the output shaft sub assembly adjust the protrusion using the shim Value expressing the difference against the standard length of 120 82mm in 1 100 units after measuring length L e d Read the value stamped on the transmission case on the end that houses the pinion shaft end bearing Example 25 STANDARD SHIM 1 5mm 0 6 2 4 HWZ01814 2 Example of shim calculation a 20 Value stamped on the pinion b 10 Value stamped on the pinion Calculate as follows L 120 82 x 100 121 39 120 82 x 100 57 e g L 121 39 d 25 Value stamped on transmission case d VALUE Shim thickness T 0 3 20 10 57 25 100 1 42mm HWZ01815 30 56 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ASSEMBLY 1 Idle gear and stator shaft A Setidle gear 1 in the case and install idle shaft 2 B Fasten idle shaft to case with lock plate
44. ING POSITION Retainer Thrust HVZ02023 Ref mounting bar Rear view 4211 1 t t t 1 1 1 1 1 Fork carriage HVZ02024 30 160 DISASSEMBLY AND ASSEMBLY MAST ADJUSTING CLEARANCE THRUST PAD AND RAIL Re shim the pads when the clearance becomes 0 08 to 0 08 inches at the widest portion of the inner weld ment This is done by loosening the bolts and moving the required shims to the inside under the thrust pads and retightening the bolts EXTRA SHIMS RETAINER HVZD1711 Pad changing interval Change the pad when projection s of the pad beyond the retainer decreases to the dimensions displayed below Projection s Standard projection 0 38 Projection requiring pad change 0 20 30 161 DISASSEMBLY AND ASSEMBLY MAST CHECK AND INSPECTION Criteria Chest item Standard size Repair limit Remedy mm mm To side 0 0 2 Within 2 Adjust with Clearance between inner 0 0 008 in 0 08 in shims mast and outer mast To front rear 0 3 1 0 Within 2 5 0 012 0 04 in 0 1 in To side 0 0 2 Within 2 Adjust with 0 0 008 in 0 08 in shims Clearance between inner To front rear 0 3 1 0 Within 2 5 Replace mast and fork carriage 0 012 0 04 in 0 1 in To side roller 0 3 0 7 Within 2 Replace 0 012 0 028 in 0 08 in Depth o
45. IR GUN Air pressure 5 kg cm 71 psi Stroke F1 R1 2mm 079 in Stroke F2 1 7mm 067 in HVZ02120 3 Control valve A Tighten mounting bolts in sequence as shown in the Figure at right Torque 27 34 Nm 2 6 3 5 kgfm 20 25 psi B After assembling check operation of the spool Insufficient tightening Oil leakage Excessive tightening Malfunction 4 Seal ring Apply grease to the seal ring while assembling SEAL RING eel ivo E M PII P HWZO02121 30 49 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ASSEMBLING MAIN SHAFT A ASSEMBLY REV SUB ASSEMBLY INDOOR LIFT TRUCK NOTE Dip the clutch plate and disc in oil before assembling them NOTE Apply grease to the seal ring The numbers in the Figure indicate the order of assembly SHAFT ASSEMBLY 8 9 10 10 12 12 HWZ01843 When installing snap ring 6 be aware that A it is under spring tension Use specified snap A CAUTION ring tool to avoid injury Snap ring tool 3EC 97 99000 3EC 97 99020 3EC 97 99010 COLLAR HOLDER 3EC 97 99000 HVZ01847 WHEN INSTALLING OR REMOVING SNAP RING 6 USE THE SPECIFIED TOOL FOR SAFETY 30 50 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ASSEMBLY FLOW CHART OF MAIN SHAFT REV ASSEMBLY 8 9 10 10 11 12 12 14 13 15 15 19 HWZ01845 Main shaft Rev Attach the seal to the shaft Fit the seal ring into the piston a
46. LVE INSTALLATION INSTRUCTIONS FOR THE LIP SEAL 15 Lubricate the lip seal with hydraulic oil and place it on the assembly tool HWZ01943 HWZ01944 16 Guide the assembly tool fully to the bottom HWZ01945 17 Press and turn the lip seal into place in the housing HWZ01946 30 109 DISASSEMBLY AND ASSEMBLY PS VALVE 18 With a gentle turning movement guide the spool and sleeve into the bore NOTE Insert the spool set while holding the cross pin horizontally HWZ01947 19 The spool set will push out the assembly tool guide The O ring and seal ring are now in position HWZ01948 20 Turn the steering unit until the bore is vertical again Put the check valve ball into the hole as indicated by the arrow in Figure at right HWZ01949 21 Screw the threaded bushing lightly into the check valve bore The top of the bushing must lie just below the housing surface HWZ01950 30 110 DISASSEMBLY AND ASSEMBLY PS VALVE 22 Grease the O ring with clean 10w hydraulic oil HWZ01951 23 Place the distributor plate so that the channel holes match the holes in the housing HWZ01952 24 Guide the control shaft down into the bore so that the slot is parallel with the connection flange HWZ01953 25 Place the control shaft as shown so that it is held in position by the mounting fork HWZ01954 30 111 DISASSEMBLY AND ASSEMBLY PS VALVE 26 Grease the two O rings with 10w h
47. SASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION FLOWCHART FOR ASSEMBLY OF INPUT SHAFT FOR F1 R1 AND F2 R1 SUB ASSEMBLY OUTDOOR LIFT TRUCK fo 1 Reverse travel side Put the seal on the shaft Put the seal ring on the piston and insert the piston to the drum insert the spring tnsert the spacer Fix it using a snap ring Insert the plate t 4 5 0 1 insert the clutch disk and the plate alter natively Disk 6 and plate 5 Insert the plate t 4 5 0 1 Fix it using a ring insert the spacer Assemble the gear and the bearing and in sert the gear Z 19 Insert the washer Fix it using a snap ring Insert the bearing Fix it using a snap ring Insert the seal ring input shaft lt 2 Q HWZ02122 Forward travel side Put the seal on the shaft Put the seal ring on the piston and insert the piston to the drum insert the spring Insert the spacer Fix it using a snap ring Insert the plate t 4 5 0 1 insert the clutch disk and the piate alterna tively Disk 6 and plate 5 insert the plate t 4 5 0 1 Fix it using a ring Assembie the gear and the bearing Assembie the gear and the bearing and insert the gear Z 38 Fix it using a snap ring 30 23 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ASSEMBLY OF FOR
48. SERVICE MANUAL BOOK 5779 GAS AND DIESEL ENGINE FORKLIFT TRUCK C80 100CX P80 100CX CHASSIS AND ENGINES SERIAL NO 100001A and Up WARNING Read and observe all warnings on this unit before operating it DO NOT operate this equipment unless all fac tory installed guards and shields are properly Be ISSUED OCTOBER 2002 REFERENCE SM180 30 DISASSEMBLY AND ASSEMBLY Torque converter Outdoor vehicle TORQFLOW transmission Outdoor vehicle Torque converter Indoor vehicle TORQFLOW transmission Indoor vehicle Transmission control Transmission control valve Outdoor vehicle Differential Drive axle on Ee doe Wheel brakes e Ii Rear axle icc de p Rn etri PS3alV8st s mete ere ees Combination switch Hydraulic pump Gontrol valve edem eee en ce reds Lift cylinder e ets nd seit CylIpIder ege a teint tienden Power steering 30 11 30 35 30 42 30 60 30 64 30 68 30 75 30 79 30 93 30 96 30 115 30 122 30 146 30 149 30 150 30 156 30 157 30 1 DISASSEMBLY AND
49. SPEC TRUCK TERMINAL 5 DIMMER CIRCUIT IS A DUMMY CIRCUIT Connection positions of turn signal switch Circuit diagram Circuit Position 8 R O _O Intermediate TURN SWITCH Hvzo1967 L O O 30 118 DISASSEMBLY AND ASSEMBLY COMBINATION SWITCH Checking F R switch 1 Remove connection of 8 pin and 2 pin LIGHTING TURN couplers between combination switch SIGNAL SWITCH cord and main wiring harness 2 Check continuity between terminals at each position and check that there is continuity between O O only See Table below 2 V 5 4 F R SWITCH TERMINAL ARRANGEMENT OF 6 PIN AND 2 2 PIN COUPLER 2 PIN COUPLERS 6 PIN COUPLER COMBINATION SWITCH END HVZ01971 2 1 2 3 4 5 6 Position Starting motor and N 1 F R switch R1 O O F2 Circuit diagram 30 119 DISASSEMBLY AND ASSEMBLY COMBINATION SWITCH REPLACING COMBINATION SWITCH ASSEMBLY 1 Remove 4 screws and remove steering column upper and lower covers STEERING COLUMN UPPER COVER COMBINATION SWITCH 8 PIN COUPLER STEERING COLUMN LOWER COVER 6 PIN COUPLER HVZ01973 2 Disconnect 8 pin and 6 pin couplers between combination switch cord and main wiring harness for the F2 R1 truck also disconnect the 2 pin coupler 3 Remove 2 band screws holding steering shaft and combinatio
50. SSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 3 4 30 30 Intermediate shaft A Assemble the intermediate shaft 8 Install the gear large and the bearing on the torque converter case side after assembling the input shaft sub assembly Output shaft sub assembly Make sure that nut 4 has been fully caulked Make sure that the bearing on the pinion end has been fully caulked after installation Install shim 5 and O ring 7 on cage 6 of the output shaft sub assembly and install them on the transmission case 1 5mm 0 6 2 4 Standard shim thickness Shim mounting position Mount the shim in such a manner that it comes in contact with the notch on the case boss HWZ01817 HWZ02130 HWZ01816 HWZ02131 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION B After assembling the output shaft sub assembly tighten bolts 9 and 10 from the differential side Apply Loctite to Loctite 271 hole side bolts 9 and 10 screw Initial torque 49 74 Nm 5 7 5 kgfm 36 54 6 Ibft Final torque 98 123 Nm 10 12 5 kgfm 72 90 7 Ibft HWZ02132 e Tightening order Tighten bolts in a diagonal pattern e If pinion shaft is harder to rotate after tightening the bolts than it was prior to assembly remove the output shaft sub assembly and readjust the bolts HWZ01818 5 Input shaft sub assembly Assembling the input shaft sub assembly Refer to pa
51. SVAW JHNSSJHd LATLNO H2LHSANCO ANDYOL lHOd ONINNSVAW dHOSSdHd 137NI HSLYSANOO JNOYOL ONINNSVAW JHNSSIHd 3 883 4 HOLNTO 38 8384 HOLNTO HWZ01826 30 38 DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CLUTCH PRESSURE REV HWZ01827 30 39 DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER TROUBLESHOOTING Causes Remedy No hydraulic pressure 1 Low oil level Refill oil 2 Damage to the gear pump or dam age to the drive section 3 Damage to the line or joint 4 Broken piston in the inlet relief valve or broken spring B Mechanical breakage 1 Broken input plate 2 Broken shaft or gear 3 Damage to the spline 2 Output drops Hydraulic pressure is too low 1 Low oil level 2 Leakage of air from suction line 3 Reduced efficiency of gear pump 4 Deteriorated spring in inlet port relief valve or malfunction of the piston of piston 5 Worn or broken seal ring B Mechanical breakage 1 Broken or deformed impeller 2 Deformed input plate C Other 1 Inappropriate non specified is being used 1 Incorrect oil level 2 Contact of impeller Abnormal rise in oil temperature 3 Wear or seizure of bearing 4 Wear or damaged gear pump 30 40 Disassemble and replace parts or assembly as neces sary Disassemble and replace Disassemble and replace Disassemble and replace
52. WARD TRAVEL 2ND SPEED INTERMEDIATE SHAFT SHAFT SUB ASSEMBLY OUTDOOR LIFT TRUCK Assemble parts generally in the reverse order of disassembly NOTE Dip the clutch plate and disc in oil before assembly NOTE Apply grease to the seal rings SHAFT ASSEMBLY HVZ01807 Use care when removing snap ring 6 as it A is under tension from spring 4 Use the A CAUTION specified tool when removing snap rings Snap ring tool 3EC 97 99000 3EC 97 99020 3EC 97 99010 COLLAR HOLDER 3EC 97 99000 HVZ01806 WHEN REMOVING SNAP RING 6 ALWAYS USE SPECIFIED SNAP RING TOOL 30 24 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION FLOWCHART FOR ASSEMBLING INTERMEDIATE SHAFT F2 R1 SUB ASSEMBLY OUTDOOR LIFT TRUCK 16 13 11 6 5 Intermediate shaft for F2 R1 Put the seal on the shaft Put the seal ring on the piston and insert the piston to the drum Insert the spring Insert the spacer Fix it using a snap ring Insert the plate t 5 0 07 Insert the clutch disk and the plate alter natively Disk 8 and plate 7 Insert the plate t 5 0 07 Fix it using a ring insert the spacer Assembie the gear and the bearing and in sert the gear Z z 34 insert the washer Fix it using a snap ring Mount the snap ring Assemble the gear Insert the bearing Fix it using a snap ring Insert the seal ring Insert the bearing Intermediate shaft for F2 R1 sub assembly
53. Y 1 1111 11 2 1 ayes 1 1 1 1 1 1 1 1 t lt 6 L v x 1 1 ae ALILOOT Aldd 1 SLNIOd 2 SNIXINYO HONNd EIN SON3HSHIADOMWIO YALNO JHL OL COL LF ONO 1 5 345 LVOONOW H LIAA Was HWZ01856 2 A v v v v 1 1 1 1 1 1 1 1 1 E E 2 5 cial 4 1 510 18 2 6 3 512 lt lt 90 2 gt fre lof 5 xs gt gt S9 E o gig 2 S 2 gt gt 5 gt gt Sog olo gt gt D 5 6 1515 6 6 6 gt 2 2 TIN IN 2 30 61 DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE TROUBLESHOOTING 1 Power is not transmitted No hydraulic pressure 1 Broken piston in the inlet relief Disassemble and replace valve or regulator valve or broken spring
54. ace is noticeably rough replace it with a new part 4 Mounting flange 2 and cover 3 Check the mounting flange and the cover for partial wear of the bearing See Figure 6 SURFACE If the Teflon layer is worn and the brown portion of the ground metal is exposed extending over 150 along the circumference of the bearing replace it with a new one 5 Always replace O ring 11 balance seal 8 Figure 5 HVZ01995 gaskets A 9 and B 10 oil seal 13 and snap ring 15 with new parts on every disas sembly and reassembly operation Figure 6 HVZ01996 30 140 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY SEE FIGURES 1 7 10 Clean all parts thoroughly Insert the casting surface in a padded vise with the mounting surface of mounting flange 2 downwards Fit balance seal 8 into the groove of mount ing flange 2 by pressing with finger Fit gasket B 10 and gasket A 9 in order into balance seal 8 Now press gasket A into the groove so that it is even with the mounting flange surface Insert dowel pin 12 in gear plate 1 and place it on mounting flange 2 Position it with two dowel pins Use care to ensure that gear plate is properly oriented i e intake discharge front rear The gear plate setting surface with the notched groove must be placed down on the mounting flange side See Figure 7 MOUNTING FLANGE FACE BOTTOM NOTCHED GROOVE ON THE DISCHARGE SIDE
55. and cylinder 0 0 05 0 2 Check for scratches on wheel cylinder sliding surface and for damage deterioration of the cap 30 81 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE BRAKE BOOSTER AND MASTER CYLINDER TORQFLOW LIFT TRUCK TOP VIEW OF BRAKE BOOSTER AND MASTER CYLINDER SIDE VIEW OF BRAKE BOOSTER AND MASTER CYLINDER SPECIFICATIONS 9 BOOSTER CYLINDER HVZ01881 Specifications A WARNING kem Values Fluid used Mineral hydraulic oil Never allow hydrau lic oil and brake Cylinder diameter mm in 25 4 1 0 fluid to mix Brake Maximum stroke mm in 28 1 1 booster Maximum operating MPa psi 14 7 2 132 Never allow min pressure eral oil e g gas amp petroleum to touch Maximum flow 25L min or adhere to rubber Fluid used Brake fluid parts This wil cause the parts to Cylinder diameter 25 4 1 0 swell causing brake Brake malfunction failure mastar Maximum stroke mm in 28 1 1 and possibly an cylinder Maximum operating MPa psi 9 8 1 421 TIME casing acei pressure dent Residual pressure MPa psi Brake 0 1 14 5 30 82 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE BRAKE BOOSTER AND MASTER CYLINDER DISASSEMBLY DRAWING HVZ01882 30 83 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE DISASSEMBLING AND ASSEMBLING BRAKE BOOSTER AND MASTER CYLINDER On clutch equipped lift
56. are exactly the same as before disas sembly Since a cast iron housing is used for KFP32 series special consideration must be taken to control the amount of clearance at the tooth tip This will be different from the con ventional aluminum alloy pump housing If either mounting flange 4 or cover plate 5 is replaced make sure to replace drive gear 2 and driven gear 3 with new gears Otherwise the specified and required vol ume of pump discharge may not be obtained 30 135 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP Figure 10 1 CAP MATERIAL S45C CONNECT WITH A SMOOTH R THIS PART MUST BE FREE FROM BURRS HVZ01988 2 SLEEVE MATERIAL ALUMINUM THIS PART MUST BE FREE FROM BURRS HVZ01989 SLEEVE AFTER SETTING THE CAP AND OIL SEAL PRESS THE OIL SEAL INTO IT USING THE SLEEVE CAP PUT THE CAP INTO THE INPUT SHAFT OF THE PUMP OIL SEAL SET THE OIL SEAL IN THE CAP AS SHOWN IN THIS FIGURE MOUNTING FLANGE INPUT SHAFT OF PUMP OIL SEAL INJECTION HOLE INJECTION METHOD HVZ01990 30 136 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP PUMP REAR DIESEL ENGINE LIFT TRUCK HVZ01991 Item Description Qty Item Description Qty 1 Gear plate 1 9 Gasket A 1 2 Mounting flange 1 10 Gasket B 1 3 Cover 1 11 O ring 1 4 Drive gear 1 12 Dowel pin 2 5 Driven gear 1 13 Oil seal 1 6 Side plate A 1 14 Bolt with washer 4 7 Side plate B 1 15 Snap ring 1 8 Ba
57. blunted screwdriver to remove the rod seal Item 25 being careful not to nick or scratch the sides or the top of the seal cavity In the same manner remove the rod wiper Item 24 When replacing the rod seal apply a light coating of clean lubricant to the new seal and insert it into the seal groove firmly with the fingers When replacing the rod wiper be sure it is fully seated into the groove In cases where rod end mounts or connections are welded to the piston rod it will be necessary to remove the piston Item 9 from the piston rod in order to replace the rod seal and wiper Clamp the piston rod in a soft jawed vise using caution not to damage the piston rod Remove the piston lock nut Item 14 and slide the piston off the piston rod turndown The head can now be removed from the piston rod for rod seal and wiper replacement When replacing the piston onto the piston rod it is advisable to replace the LD seal Item 11 Lubricate the piston LD and LD seal and reassemble the piston onto the piston rod with the slipper seal groove towards the rod shoulder Tighten the lock nut securely against the back face of the piston using the torque value provided 30 152 DISASSEMBLY AND ASSEMBLY TILT CYLINDER TUBE SEAL PISTON SEAL AND BEARING STRIP REPLACEMENT Examine the tube seal and tube seal back up Items 16 and 17 for nicks or cuts and replace if neces sary The new seal should be lubricated before being installed into
58. bly Unscrew the oil pump mounting bolt and remove oil pump and driven gear HWZ01834 30 44 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 8 Idle gear stator shaft Unscrew bolt 12 and remove gear seat retainer and pump boss gear 15 Unscrew bolt 13 and remove the stator shaft Remove lock plate 14 idle shaft and idle gear HWZ01835 Pump boss gear removal jig 1 1 e x CG rym HWZ01836 E 30 45 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION Main shaft A assembly REV sub assembly The number indicates the order of disassembly SHAFT ASSEMBLY 12 11 10 9 8 7 HWZ01837 When removing snap ring 13 note that this A snap ring is under spring tension Use special removal tool specified below to avoid injury A CAUTION Special tool 3EC 97 99000 3EC 97 99020 3EC 97 99010 COLLAR HOLDER 3EC 97 99000 HVZ01840 WHEN INSTALLING OR REMOVING SNAP RING 13 USE THE SPECIFIED TOOL FOR SAFETY 30 46 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION Main shaft B assembly FWD sub assembly The number indicates the order of disassembly SHAFT ASSEMBLY HWZ01839 When removing snap ring 13 note that this A snap ring is under spring tension Use special removal tool specified below to avoid injury A CAUTION Special tool 3EC 97 99000 3EC 97 99020 3EC
59. ck the mounting flange and cover for partial wear of the bearing See Figure 6 Ifthe Teflon layer is worn and the brown portion of the ground metal is exposed extending over 150 along the circum ference of the bearing replace it with a new one 5 Always replace plate seal 7 back up ring 8 oil seal 9 and snap ring 10 whenever they have been disassembled Figure 5 HVZ01983 INTAKE CHAMBER BEARING Figure 6 HVZ01984 30 132 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY OF FRONT PUMP DIESEL ENGINE LIFT TRUCK SEE FIG 1 AND 11 1 Clean the parts thoroughly 2 Insert the casting surface with the mounting surface of the mounting flange down and secured in a padded vise 3 Firmly fit plate seal 7 and back up ring 8 in the groove of mounting flange 4 so that they will not protrude from the surface of the outer circumference 4 Set gear plate assembly 1 to the dowel hole of mounting flange and install it on the mounting flange At this time dowel pins press fitted in the gear plate can be used for positioning If the dowel is too tight to press into the hole lightly tap it in with a wooden hammer 5 Insert pressure plate 6 into the bottom of gear plate assembly 1 with the grooved surface up Pay attention to the locations of the intake and discharge sides of the pres sure plate See Figure 8 If the pressure plate is tilted and it cannot be removed hold the driveshaf
60. ction B and adjust the backlash Decrease the shims at the pinion shaft to decrease the protrusion of the pinion Direction Then move the bevel gear closer to the pinion Direction and adjust the backlash Decrease the shims at the pinion shaft to decrease the protrusion of the pinion Direction A Then move the bevel gear away from the pinion Direction and adjust the backlash HVZ01868 o HVZ01869 HVZ01870 HVZ01871 Q2 N DISASSEMBLY AND ASSEMBLY DIFFERENTIAL DIFFERENTIAL ASSEMBLY DRAWING 13 5 HWZ02143 BEND COTTER PIN ENDS COMPLETELY HWZ01872 30 74 DISASSEMBLY AND ASSEMBLY DRIVE AXLE DRIVE AXLE OUTDOOR LIFT TRUCK DISASSEMBLY AND ASSEMBLY Precautions on installing the front axle on the frame 1 Degrease the mounting bolts nuts and tapped holesbefore installation 2 Tighten bolt and nuts by hand first not an impact wrench and then retighten using the wrench to check the tightening torque 662 829 Nm 67 5 84 5 kgfm 59 78 Nm 8 8 kgfm TORQUE ADJUST USING NUT STARTING 9 8 24 5 Nm TORQUE 100 250 kgfcm NOTE DO NOT APPLY LIQUEFIED GASKET SEALER TO THE MATING SURFACE BETWEEN THE HUB AND THE TORQUE SHAFT 290 608 Nm TORQUE 50 kgfm HVZ01873 30 75 DISASSEMBLY AND ASSEMBLY DRIVE AXLE DRIVE AXLE ASSEMBLY DRAWING OUTDOOR LIFT TRUCK 159 196 Nm 16 20 k
61. e outer piston circumference C Assemble valve spring 60 and check valve 59 with the cylinder and tighten bolt 57 and gasket to the cylinder HVZ01888 Torque 39 2 44 1 Nm 4 4 5 kgfm 28 9 32 5 Ibft D Assemble piston assembly 52 and with the spring insert them into the cylinder At this time align the directions of the piston groove and the stop pin hole E Assemble the gasket with the stop pin and insert them with the piston inserted into the cylinder Torque 176 21 6 Nm 1 8 2 2 kgfm 13 0 16 0 Ibft ALIGN THE DIRECTIONS HVZ01889 F Slightly press the piston and hold in place using the snap ring NOTES 6 sure to use alcohol or brake fluid to clean parts Never use mineral oil e g petroleum or gasoline 1 If mineral oil adheres to rubber parts they will swell and become unusable e Keep parts in a clean location away from dirt or contamination after cleaning Do not allow dirt dust or foreign matter to enter the cylinder piston cups etc and do not damage the parts 30 88 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE 2 Assembling the booster refer to the disassembly drawing Clean parts to be reused with detergent or mineral hydraulic oil Use mineral hydraulic oil to clean rubber parts Do not clean them with detergent oil petroleum or gasoline A Assembling the reaction piston sub assembly Assemble the O ring with the reac
62. e up the springs and center them HWZ01932 7 Guide the ring down over the sleeve NOTE The ring should be able to rotate free of the springs HWZ01933 30 105 DISASSEMBLY AND ASSEMBLY PS VALVE 8 Fit the cross pin into the spool sleeve HWZ01934 9 Fit bearing races and needle bearing as shown in Figure at below right HWZ01935 Assembly pattern for standard bearings A Outer bearing race B Needle bearing C Inner bearing race D Spool E Sleeve HWZ01936 30 106 DISASSEMBLY AND ASSEMBLY PS VALVE INSTALLATION INSTRUCTIONS FOR THE O RING AND SEAL RING STANDARD NOTE The inside chamfer on the inner bearing race must face the inner spool 10 Turn the steering unit until the bore is horizontal Guide the outer part of the assembly tool into the bore for the spool sleeve HWZ01937 30 107 DISASSEMBLY AND ASSEMBLY PS VALVE 11 Grease O ring and seal ring with hydraulic oil and place them on the tool HWZ01938 HWZ01939 12 Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool to the bottom HWZ01940 13 Press and turn the O ring and seal ring into position in the housing HWZ01941 14 Draw the inner and outer parts of the assembly tool out of the steering unit bore leaving the guide from the inner part in the bore HWZ01942 30 108 DISASSEMBLY AND ASSEMBLY PS VA
63. eplace Disassemble and replace Disassembie and replace Disassemble and replace Tighten replace if neces sary Oil oozes out or leaks A seal 1 Worn or damaged lip 2 Dirt caught 3 Worn or scratched shaft 4 Hardening or deterioration of rub ber because of abnormal rise in oil temperature B O ring 1 Broken O ring 2 Scratched mating surface 3 Hardening or deterioration of rub ber because of abnormal rise in oil temperature 4 Sudden use in extremely cold tem peratures below 15 C C Plug screw 1 Loose screw 2 Broken screw 3 Cracked hole Disassemble and replace Disassemble and replace replace parts if necessary Correct or replace Disassembie and replace Disassemble and replace Correct or replace Disassemble and replace Carry out warming up operation Tighten Replace Replace 30 10 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION TORQFLOW TRANSMISSION OUTDOOR LIFT TRUCK DISASSEMBLY 1 Draining oil Remove drain plug and drain oil from case 2 Transmission valve differential Remove transmission valve mounting bolts 1 and differential cap bolts 2 and separate to avoid mixing the bolts HWZ01797 HWZ02102 3 Torque converter A Use wooden blocks for support and place equipment as shown at right B Remove bolts 3 connecting torque converter and transmission case and move the torque converter assembly away from the transmission HW Z
64. f oil groove in mast support bushing grooved forall Replace there is an oil groove 3 51 Min 42 1 7 4 01 50 8 Min 45 Thickness of fork root 2 in 1 8 in Replace 451 48 1 9 30 162 DISASSEMBLY AND ASSEMBLY MAST ADJUSTING CLEARANCE BETWEEN INNER MAST AND FORK CARRIAGE Fit the lift chain on the outer mast and tighten the nut so that the tension on the left and on the right is the same The protrusion of the main roller from the bottom of the inner mast with the mast fully lowered should be equal to protrusion A Lock nut torque 40 60 kgm 392 588 Nm 289 434 Ibft 2 Stage Mast ADJUSTING NUTS 3 Stage Mast MOUNTING POSITION TO LIFT CHAIN NOT SHORTER THAN 4 157 in MOUNTING POSITION TO LIFT CHAIN NOT LONGER THAN 3 9 m 154 in HVZ01713 LIFT CHAINS ADJUSTING NUTS HVZ01714 RAIL A UNDERSIDE ROLLER ON FORK CARRIAGE FORK CARRIAGE HVZ01712 Protrusion A mm Model 2 Stage 3 Stage P80CX G D 30 1 18 IN 39 1 53 IN P90CX G D 35 1 37 IN 39 1 53 IN ee 35 1 37 IN 4 1 73 IN C80 100CX 35 1 37 IN 39 1 53 IN 30 163 DISASSEMBLY AND ASSEMBLY MAST ADJUSTING CLEARANCE BETWEEN INNER MAST AND MIDDLE MAST 3 Stage Mast Chain stopper adjusting procedure Adjust chain so that middle mast and inner mast lower edges B are
65. ft assembly A B Assemble main shaft assembly B HWZ01852 30 58 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 5 Assembling torque converter housing and transmission case A Assemble the torque converter housing with the transmission case B Fasten with bolts Use the following bolts M10 x 1 5 Length from neck 3mm Torque 35 3 44 1 Nm 3 6 5 5 kgfm 26 0 32 5 Ibft HWZ01853 6 Torque converter assembly A Align torque converter assembly 1 with the stator shaft and turbine shaft spline and join them B Install snap ring 2 C Install pilot boss 3 Use the following bolts M8 x 1 25 Length from neck 22mm Torque 18 6 24 5 Nm 1 9 2 5 kgfm 13 7 18 1 Ibft D Install flexible plate assembly 4 Use the following bolts M8 x 1 25 Length from neck 22mm Torque 18 6 24 5 Nm 1 9 2 5 kgfm 13 7 18 1 Ibft 30 59 DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE TRANSMISSION CONTROL VALVE DISASSEMBLING CONTROL VALVE 1 Remove bolt 1 to remove the control valve from the transmission and remove bolt 2 that fastens the solenoid valve to the valve body Then remove the solenoid valve Use a 4mm hex wrench HWZ01855 2 Pull the inching spool valves and pistons out of the valve body Keep removed parts in order so that they can be reassembled in proper sequence 30 60 TRANSMISSION CONTROL VALVE DISASSEMBLY AND ASSEMBL
66. gears may wipe into the body The body can only be reused if the cut in is bright and polished in appearance and the depth does not exceed 08mm The body should be replaced if the surface is Scored has a matte appearance or shows signs that the tip of the gears have dug in and torn away some of the surface material The body should be inspected to ensure that there is no superficial damage which may adversely affect performance or sealing Pay particular attention to the port threads and body O ring seal recesses End cover The inner surfaces should be inspected to ensure that there is no unusual wear or scoring in the regions where the body O rings and bush seals contact that may cause external leakage Bushes The side faces that abut the gears should be perfectly flat showing no signs of scoring There are normally light polished areas on this surface caused by loading against the gear side faces which is often more pronounced on the low pres sure side These should be replaced if there is any general scoring or fine scoring with a matte appearance or tearing of the surface material Often there is evidence of this where the tips of the opposing gears have wiped an overlap pat tern resembling a half moon shape There must be no noticeable wear step as it is critical that the bush side face is completely flat to the gear side face 30 128 The bush bearing liners are acceptable providing they are not scored or show
67. ges 30 22 and 3 23 A Slowly engage the input shaft sub assembly with the intermediate shaft gear in such a manner as to avoid damaging the seal ring and insert the shaft end into the transmission case shaft hole e Apply grease G2 LI to the seal ring HWZ02133 30 31 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 6 8 30 32 Intermediate shaft gear large and bearing A Engage intermediate shaft gear 11 with the input shaft sub assembly gear and install them on the intermediate shaft B Assemble bearing 12 and press fit in place sure to use a copper bar or a jig when press fitting the bearing M 2 NI N E Assembling the 2 1 lift truck and the transmission A Assemble output shaft sub assembly 1 B Assemble input shaft sub assembly 2 C Assemble intermediate shaft sub assembly 3 NOTE Follow the reverse procedure for disassembly HWZ02135 Installing the plate Install plates A and B using bolts 13 Apply Loctite Loctite 271 screw Torque bolts 59 73 Nm 6 7 7 kgfm 43 5 53 8 Ibft NOTE P90CX G D Plate A F1 R1 P100CX G D Plate A and B F2 R1 HWZ02136 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 9 Installing the torque converter assembly A Set gasket 14 on the transmission case B Align the torque converter assembly with the transmission case dowel pin and slowly bring them together C Tighten bolts 15 Torq
68. gfm LOCTITE 271 LOCKBOLT FRONT HUB STARTING TORQUE 9 8 24 5 Nm 100 250 kgfm 294 490 Nm 30 50 kgfm TORQUE As TORQUE 441 588 Nm FILL 1 2 TO 1 3 OF THE CAPACITY 45 60 kgfm LOCTITE 271 SHADED PORTION WITH GREASE 92 11 IN THE FRONT HUB TORQUE i ok ey ae 25 31 kgfm LOCTITE 271 441 588 Nm 45 60 kgfm CROSS CAULK IT 157 196 Nm 16 20 kgfm o 9 e t A LIQUEFIED GASKET TORQUE 59 78 Nm 8 8 kgfm a n W a n W e e e 80 Ei TQ40P TQ40PD TORQUE TORQUE TORQUE FILL 1 2 TO 2 3 OF THE CAPACITY HUB SIDE SHADED PORTION G2 LI 1 HVZ01874 30 76 DISASSEMBLY AND ASSEMBLY DRIVE AXLE DRIVE AXLE INDOOR LIFT TRUCK DISASSEMBLY AND ASSEMBLY Precautions on installing the front axle in the frame 1 Degrease the mounting bolts nuts and tapped holes before installation 2 Tighten bolts and nuts by hand first not an impact wrench and then retighten using the wrench to check the tightening torque 662 829 Nm 67 5 84 5 kgfm 59 78 Nm 8 8 kgfm TORQUE ADJUST USING NUT STARTING 9 8 24 5 Nm TORQUE 100 250 kgfcm LOCTITE 271 294 490 Nm TORQUE 30 50 kgfm HVZ01875 30 77 DRIVE AXLE DISASSEMBLY AND ASSEMBLY DRIVE AXLE ASSEMBLY DRAWING INDOOR LIFT TRUCK 0 8 09 3 8 64
69. ght or pinched Then insert spline cou pling 12 in the spline of front drive gear 2 Install adapter plate 11 by setting it to the dowel pin on cover plate 5 Use care that the O ring does not protrude Insert O ring 19 in adapter plate 11 Set plain washer 15 in the bolt seat of adapter plate 11 and insert socket head bolt 14 and tighten it to 118 127 Nm 87 93 7 158 Keep the threads wet Caution Make sure to tighten to the specified torque If the bolt torque is too little or too much it may cause serious hydraulic oil leakage and may result in an accident Fit O ring 22 in connector cover 20 and set it in cover plate 5 Insert socket head bolt 21 and torque to 34 39 Nm 25 28 8 Ibft Keep the threads wet Set the spline of rear pump 23 KP10 assembly to spline coupling 12 and install it on adapter plate 11 Install the rear pump while paying attention to the orientation of the intake and discharge sides Set washer 18 and bolt 17 and torque bolt to 42 46 Nm 31 34 Ibft Remove the pump from the vise and try to turn the shaft end of the drive gear with a suitable tool It should turn easily by hand If it does not turn easily by hand pressure for eign material may have entered the pump during assembly This will require disassem bly and reassembly to correct the problem 30 134 17 Fit oil seal 19 into mounting flange 4 Apply clean lithium grease to the li
70. ghten it with a torque of 34 39 Nm 25 28 8 Ibft Keep the threads wet Caution Be sure to tighten to specified torque If the bolt is improperly torqued a serious leak may occur resulting in an accident Remove the pump from the vise and fit oil seal 13 and snap ring 15 into the mount ing flange Apply a light coat of clean lithium grease to the lip of the oil seal For fitting instructions see Figure 9 When press fitting the oil seal use care not to scratch the lip and not to tilt the oil seal Applying tape over the drive gear shaft end will help to prevent scratches and damage to the seal Remove the tape after seal installa tion The oil seal can be securely press fitted by using the jig shown in Figure 10 Turn the shaft end of the drive gear with a tool If it can be turned easily by hand the drive gears are clean and seals are properly in place If it is excessively tight there may be an assembly problem and the pump will require disassembly and reassembly 30 142 SNAP RING SEAL LIP DUST LIP a INSIDE OF THE PUMP eee 1 OIL SEAL 7 Figure 9 GEAR SHAFT HVZ01999 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP Assembly of the pump is now complete Again Pay special attention to the following during reas check to be sure that assembly procedures per sembly formed and rotation direction are correct 1 When reassembling gear plate 1 gears 4 When installing the
71. gon 38 2 3 9 49 0 5 0 4 Gear pump mount bolt M10 x 1 5 x 45 28 2 36 1 13 Pressure pickup 7 35 0 75 9 8 1 0 5 PT 1 4 15 ports Hexagon socket 5 4 7 2 head plug 56 8 5 8 70 6 7 2 6 Blind plug PT 3 4 41 9 52 1 16 The numbers used in the No column of Table refer to the numbers in the component part drawing 30 6 DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER ASSEMBLY DRAWING 5 OUTDOOR PNEUMATIC LIFT TRUCK ONLY TURBINE ENGINE SIDE STATOR P TORQUE CONVERTER IMPELLER TRANSMISSION SIDE TURBINE SHAFT HOUSING CROSS SECTIONAL DRAWING OF TORQUE CONVERTER ASSEMBLY HWZ01795A FORWARD TRAVEL SIDE CLUTCH ELECTROMAGNETIC VALVE INLET PRESSURE PORT PRESSURE PORT REVERSE TRAVEL SIDE CLUTCH TEST INCHING VALVE OIL TEST PORT LUBRICATION OIL MAIN RELIEF PRESSURE TEST PORT TEST PORT 2017958 FORWARD TRAVEL SIDE TO REVERSE TRAVEL SIDE CLUTCH CLUTCH TO FORWARD TRAVEL 2ND SPEED SIDE CLUTCH TQ45P 600 TQ45PD 600 24 STROKE INCHING SPOOL 81 FROM 77 CONVERTER FROM TORQUE REGULATOR VALVE TO TORQUE OUTLET CONVERTER PUMP CONVERTER INLET HWZ01795C 30 7 TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY HOLNTO 63 OL 3Hnssdud HOL YIO 8 iv aunssaud 0 FATWA YOLVIN
72. he good adhesion qualities help to prevent corrosion build up in the joint area Facing the rod end of the cylinder with the tube slot in the up position and with the beveled end of the shear ring to the left and down insert the hooked end of the shear ring through the tube slot and into the starter hole in the head The tube slot position and the shear ring direction in relation to facing the rod end of the cylinder must be maintained regardless of which attitude vertical or horizontal the cylinder is being assembled Using a spanner wrench rotate the head clockwise thus drawing the shear ring into the keyway formed by the tube and the head Caution should be used so as not to damage the chrome plated piston rod Continue to rotate the head clockwise until almost one revolution has been completed about 335 The spanner holes in the front head have been located in relation to the starter hole so that when the centerline of the spanner wrench handle is in line with the centerline of the tube slot the shear ring is in proper posi tion The ring position can be checked visually by looking into the slot and observing that the ends of the ring are approximately 1 4 inside the edges of the slot 30 154 DISASSEMBLY AND ASSEMBLY TILT CYLINDER HAND TOOLS REQUIRED FOR DISASSEMBLY ASSEMBLY 1 Spanner wrench for rotating front head 2 Conventional screwdriver 3 Seal installation removal tool NOTE A small screwdriver
73. herwise it may significantly reduce the durability of the pump 30 144 Test pump discharge volume with load applied and without load and verify that the work equipment speed and operation is nor mal DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP TROUBLESHOOTING WHEN PUMP IS AT FAULT Problem Cause Remedy No oil is discharged from the gear pump Low oil level in the tank Add hydraulic oil to the specified level Pipe on suction side or strainer is obstructed Immediately clean and remove obstruction If oil is contaminated replace oil and filter Gear pump pressure does not increase Excessive wear to side plates A 6 and B 7 Excessive wear to bear ing press fitted into 2 and 3 Defective balance seal 8 and gaskets A 9 and B 10 Replace with new parts Improperly adjusted relief valve Adjust relief valve using pressure gauge Set to specification Air in system e Fix loose pipe on suction side e Refill tank with hydraulic oil e Check pump oil seals 0 not operate lift truck until air bubbles in tank disappear Gear pump generates abnor mal noise Cavitation caused by flat tened hose on suction side or clogged strainer Remove obstructions and or clean strainer Air drawn into system at loose joints fittings on suction side Tighten all joints and fittings Cavitation caused by exces sive oil viscosity e Install oil of
74. ickness of the dis Bo assembled shims NOTE See Shim Adjustment at right 5 Fit the roller of bearing 2 into the inner race in NUS AOUUSTINGPROSEDURE stalled on pinion shaft 1 0 3 TO SIDE b AND t 0 25 TO THE CENTER HWZ01809 6 Install cage 6 with oil seal 6 and outer races of bearings 2 and 7 assembled on pinion shaft 30 54 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 7 Fit the roller of bearing 7 into the outer race of cage 6 6 ADJUSTMENT SH ROLLER 8 Install the inner race of bearing 7 NOTE Before installing the inner race ensure that the adjustment shim has been installed 9 Install gear 9 Z 53 10 Install and tighten nut 10 Torque 314 441 Nm 32 45 kgfm HWZ01810 231 6 325 3 Ibft NOTE After tightening nut 10 to the specified torque check that the starting torque CAULK HERE is within the following range INNER RACE Starting torque 4 9 Nm 40 80 kgfm 2 9 6 6 Ibft If the starting torque does not fall within the specified range adjust shim 8 again to obtain the correct value 11 After adjusting the starting torque of the pinion HWZD1811 shaft caulk nut 10 12 Install bearing 11 and caulk Caulk three points on the circumference at equal intervals using a punch so that they come into SU contact with the bearing inner race scale FLAT PART OUTPUT SHAFT AND NUT CAULKING PROCEDURE 13
75. in the same position MIDDLE MAST INNER MAST B 201715 HVZ01716 30 164 DISASSEMBLY AND ASSEMBLY MAST MAST PAIL LUBRICATION Lubricate the full length of each rail with grease Carriage Rollers Inner rail Outer auc T Lubricate oniy where indicated the heavy line for the full length of each rail Inner rail Outer rail HVZ02025 30 165
76. ion and possible failure Booster side BRAKE BOOSTER AND MASTER CYLINDER ROD FLOW DIVIDER SPOOL POWER PISTON CONTROL VALVE RELIEF VALVE PACKING REACTION PISTON HVZ01886 No Parts Check item Check procedure Remedy Flaw or wear on sliding surface Remove small flaws with fine emery cloth Replace assembly if flaw will affect or prevent 1 Cylinder sealing of parts Replace the booster assembly Clearance between cylinder Replace if clearance is less than the limit and piston Flaw or wear on sliding surface Remove small flaws using fine emery cloth Replace the piston 2 Power piston assembly bl Damaged seal Replace if damage or wear shows on seal Control and relief valve Flaw or wear on sliding surface Remove small flaws using fine emery cloth Replace the valve assemblies Damaged seal Replace if damage or wear shows on seal assembly 4 Reaction piston Flaw or wear on sliding surface Remove small flaws using fine emery cloth Bede assembly Damaged seal Replace if damage or wear shows on seal Flaw wear or fall weakness Replace if flaw or major wear is detected 5 Spring Replace Free length Replace if length is below the limit 6 Rod Flaw or wear on sliding surface Remove small flaws with fine emery cloth Replace Flaw or wear on sliding surface Remove small flaws with fine emery cloth 7 Flow divider spool Replace if flaw will affect or prevent sealing of Rep
77. ip all parts in hydraulic oil and reassemble If the unit still does not function properly contact your dealer distributor for a replacement part Problem Probable cause Remedy No pressure Erratic pressure Incorrect pressure setting Leakage Poppet D E or K stuck open Contamination under seat Pilot poppet seat damaged Poppet C sticking in D Normal wear Lock nut and adjustment Screw loose Damaged seats Worn O rings Parts sticking contamination Check for foreign matter in the poppets and their mating parts Parts must slide freely with out sticking Replace the relief valve Clean and remove surface marks for free movement See Setting Pressure on Work Port Relief above Replace the relief valve Install seal and spring kit Disassemble and clean TROUBLESHOOTING ANTI VOID Malfunctions can usually be traced to foreign matter plugging the sensing the free movement of the poppet Also check seat for scratches nicks or other marks hole or preventing SHUT OFF VALVE Shut off valves are available to fit most work port and main relief valve machining locations HWZO02008 30 147 DISASSEMBLY AND ASSEMBLY CONTROL VALVE SERVICE INFORMATION COMBINATION WORK PORT RELIEF AND ANTI VOID UNIT As work port relief STEP 1 The relief valve is in communication between the high pressure port HP and low pressure LP Oil is admitted through
78. iption Item No Description 1 CAST IRON COVER 15 O RING 2 M12 STUD 16 SPACER 3 SEAL ELEMENT 17 BODY O RING 4 SEAL ENERGIZER 18 SEAL ELEMENT 5 BUSH PLATE 19 SEAL ENERGIZER 6 DRIVE GEAR 20 BUSH BLOCK 7 DRIVEN GEAR 21 BUSH BLOCK 8 BODY O RING 22 DRIVE GEAR 9 CAST IRON FLANGE 23 DRIVEN GEAR 10 SERRATED WASHER 24 ALUMINUM BODY 11 HEX NUT 25 CAST IRON COVER 12 SHAFT SEAL 26 SPLIT WASHER 13 C CLIP 27 3 8 19 BOLT 14 QUILL a 30 125 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP DISMANTLING THE REAR PUMP SECTION Before starting work ensure that the unit work area and all tools are thoroughly clean to prevent contamination of the unit 1 Lightly mark the end cover body and spacer 25 24 amp 16 to ensure reassembly in the correct sequence Remove bolts and spring washers 21 amp 26 Remove end cover 25 body O ring 17 bush seal and back up seal 18 amp 19 Turn the unit over and lightly tap the spacer 16 to disengage it from the locating dowels Remove body O ring 17 bush seal and back up seal 18 amp 19 Before removing the internal components mark the bushes to denote the locations in the body On a clean area away from seal location mark FD Bush on driveshaft spacer end FI Bush on driven gear spacer end CD Bush on driveshaft cover end Cl Bush on driven gear cover end With the unit lying on its side hold the drive shaft 22 and pull it squarely out of the body
79. it spacer end bushes FD amp FI into their original bores remembering that the C cut out must be to the side of the body with the cusp removal flat and match the cover end bushes Fit new body O ring 17 bush seal and back up seal 18 amp 19 ensuring that the seals locate correctly in the seal grooves Fit O rings 15 to the rear of front pump and place spacer 16 over seals Holding the whole unit together carefully turn it over onto spacer and engage drive shaft 22 into quill 14 Remove end cover 25 and fit new body O ring 17 bush seals and back up seals 18 amp 19 Replace the end cover and refit bolts and spring washers 21 amp 26 Torque bolts to 46 51 Nm 34 37 6 168 Pour a small amount of clean hydraulic fluid into a port and check that the shaft can be rotated without undue force using a smooth jawed vice on the front pump s drive shaft REASSEMBLING THE FRONT UNIT Ensure that all parts are perfectly clean Lubri cate bushes and gears with clean hydraulic fluid ensure O ring recess and end faces of body remain dry This will assist assembly of compo nents into the body bores 1 Stand pump body on the rear face fit seal 3 and back up 4 to groove in bush plate 5 and feed plate into bore Ensure that the seals remain in their groove and that the two small holes in the bush plate 5 are to the low pressure side of the pump Fit driveshaft 6 and driven gear 7
80. its original position Then pull it out squarely Remove gear plate 1 from mounting flange 2 Lightly tap around the gear plate with a wooden hammer and pull it upwards to remove Remove balance seal 8 gasket A 9 and gasket B 10 from the setting surface of mounting flange 2 At this time insert the tip of a blunted screw driver or similar tool into the hole of the balance seal and gently pull them upwards Remove snap ring 15 from mounting flange 2 and remove oil seal 13 Tap out the oil seal from the inside using a blunted screw driver or the like Use care not to damage the oil seal press fitting hole and bearing hole 30 138 11 Disassembly is now complete Use care when placing the disassembled parts Keep them in proper disassembled order to ensure proper reassembly sequence DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP INSPECTION AND REPAIR PROCEDURES First check the disassembled parts for contami nation or discoloration and then clean them with diesel oil DO NOT dip rubber parts in diesel oil Check all parts for the following items Repair or replace any defective parts 1 Gear plate 1 The gear pump is designed to rotate while the gear teeth tips are in contact with the inner gear hole surface to improve volumet ric efficiency Therefore if the pump has been driven one or more times the evidence of the contact of the gear teeth can be seen in the area of the intake port of the
81. lace parts Packing O ring and Flaw or wear on seal surface Replace if flaw or major wear is detected 8 penta seal Replace 30 86 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE MAINTENANCE STANDARD BRAKE BOOSTER AND MASTER CYLINDER HVZ 01887 No Check item Standard value SN Remedy Basic Shaft Hole Standard Limit j Clearance between dimensions clearance clearance cylinder and piston 254 0 020 0 052 0 020 0 150 0 053 0 0 105 Clearance between 0 020 0 052 0 020 cylinder and piston 295 0 053 0 0 105 0120 Free length Installed Installed Free length 3 Deterioration of spring length load kgf 37 5 33 5 7 1 36 0 4 Deterioration of spring 22 9 19 5 6 1 22 0 5 Deterioration of spring 12 2 10 5 3 1 11 5 6 Deterioration of spring 106 68 5 10 3 96 7 Tightening torque 21 30 Nm 2 1 3 1 kgfm 6 Tightening torque 7 8 11 7 Nm 0 8 1 2 kgfm Retighten 9 Tightening torque 17 6 21 6 Nm 1 8 2 2 kgfm 10 Tightening torque 39 2 44 1 Nm 4 0 4 5 kgfm 30 87 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE ASSEMBLY 1 Assembling the brake master cylinder A Clean parts to be reused with alcohol or brake fluid When cleaning rubber parts such as cups with alcohol do not dip them in alcohol for more than 30 seconds B Completely apply rubber grease or brake fluid to the inside of the cylinder and th
82. lance seal 1 MM 30 137 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP DISASSEMBLY PUMP REAR DIESEL ENGINE LIFT TRUCK SEE FIG 1 1 When disassembling clean the surface of the pump and the driveshaft Use care not to contaminate scratch or nick the disassem bled parts by placing them on clean paper or cloth Place the parts in order of disassembly so that they can be reassembled in the proper sequence Insert mounting flange 2 into a padded vise with the pump mounting surface facing down and secure it Do not over tighten the vise Loosen and remove bolt with washer 14 Caution When loosening bolts gradually apply force to prevent pulling the flange from the vise Use an appropriate tool wrench that is not worn Remove cover 3 in the axial direction in a straight line If it is too tight to remove easily lightly tap it with a wooden hammer in the same direction as removal Remove O ring 17 and side plate B 7 Put the set mark on the shaft end face of drive gear 4 and driven gear 5 and pull out the gear Mark with an oil stone or marker Pull side plate 6 out of the bottom of gear plate 1 Use care not to tilt the side plate If the side plate has been tilted and cannot easily be pulled out hold and insert the drive shaft end of the drive gear into the gear plate and lightly press against the higher portion of the side plate A The side plate should fall into
83. ll 15 Gear wheel set 4 Thread bushing 16 O ring 5 O ring 17 End cover 7 Bearing assembly 18 Washer 8 Ring 20 Screw with pin 9 Cross pin 22 Name plate 11 Control shaft 32 Check valve 12 Spring Spacer set 30 96 DISASSEMBLY AND ASSEMBLY PS VALVE TOOLS A Holding tool Code No SJ 150 9000 2 B Assembly tool for O ring and seal ring Code No SJ 150 9000 11 C Assembly tool for lip seal Code No SJ 150 9000 17 HWZ01903 HWZ01904 HWZ01905 30 97 DISASSEMBLY AND ASSEMBLY PS VALVE D Assembly tool for control shaft Code No SJ 150 9000 3 HWZ01906 E Assembly tool for dust seal Code No SJ 150 9000 22 HWZ01907 F Torque wrench 0 7 daNm 13mm socket spanner 6 8 and 12mm hexagonal sockets 12mm screwdriver 02mm screwdriver 13mm ring spanner 6 8 and 12mm hexagonal spanners Plastic hammer Tweezers The tools itemized in item F are available locally and not sold through HWZ01908 the manufacturer 30 98 DISASSEMBLY AND ASSEMBLY PS VALVE DISASSEMBLY 1 Dismantle steering column from steering unit and place the steering unit in the holding tool Remove the screws in the end cover 6 each plus one special screw HWZ01909 2 Remove the end cover sideways HWZ01910 3 Lift the gear wheel set with spacer if fitted off of the unit Take out the two O rings HWZ01911 30 99 DISASSEMBLY AND ASSEMBLY PS VALVE 4 Remove the control shaft 5 Remove the
84. lled before assembling the inner race 9 Assemble gear 9 Z 54 Compact truck Z 53 Standard truck Z 54 10 Mount and tighten nut 10 Tightening 314 441 Nm 32 45 kgfm torque 231 6 325 3 Ibft NOTE After tightening nut 10 to the specified torque make sure that the starting torque of pinion shaft 1 is within the following range 4 8 Nm 40 80 kgfm 3 6 Ibft Starting torque NOTE If the starting torque does not fall within the range above adjust shim 8 again to obtain a proper torque reading 11 After adjusting the pinion shaft starting torque caulk nut 10 12 Assemble and caulk bearing 11 Caulk three positions on the circumference at equal intervals using a punch so that it comes in contact with the bearing inner race scale 13 Install O ring 12 on the O ring groove of cage 6 8 ADJUSTMENT SH ROLLER HWZ01810 CAULK HERE INNER RACE HWZ01811 OUTPUT SHAFT AND NUT CAULKING PROCEDURE 2 MIN FLAT PART THREE POINTS MUST COME IN CONTACT HWZ01812 30 27 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ADJUSTING OUTPUT SHAFT SUB ASSEMBLY PINION SHAFT THRUST PROTRUSION 1 Shim between the bearing cage and the transmission Calculate the thickness using the following formula to obtain pinion shaft protrusion standard shim 1 2mm Shim thickness 0 30 a b c d 2 30 28 100 aandb Numbers on the pinion shaf
85. n switch and remove switch SCREW TIGHTENING TORQUE T 24 Nm 25 kgfcm 21 2 Ibin HWZ01974 4 Carry out installation in the reverse order of removal 30 120 DISASSEMBLY AND ASSEMBLY COMBINATION SWITCH REPLACING LIGHTING AND F R SWITCH 1 Remove upper and lower covers from steering column by removing 4 holding screws STEERING COLUMN UPPER COVER COMBINATION SWITCH 8 PIN COUPLER STEERING COLUMN LOWER COVER 6 PIN COUPLER HVZ01973 2 Disconnect 8 pin and 6 pin couplers between combination switch cord and main wiring harness 3 Remove 2 band screws holding steering shaft and combination switch and remove the switch 4 Remove 2 lighting switch unit mounting screws and cord tightening resin band to remove switch LIGHTING SWITCH FIR SWITCH SCREW TIGHTENING TORQUE T 2 4 Nm 25kgfcm 21 2 Ibin STEERING SHAFT HWZ01975 4 Carry out installation in the reverse order of removal 30 121 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP HYDRAULIC PUMP HVZ01976 Item No Item No Description 1 3 8 16 BOLT 15 3 8 16 STUD 2 SPLIT WASHER 16 CLIP 3 CAST IRON COVER 17 SHAFT SEAL 4 BODY O RING 18 ALUMINUM FLANGE 5 SEAL ELEMENT 19 BODY O RING 6 SEAL ENERGIZER 20 SEAL ELEMENT 7 BUSH BLOCK 21 SEAL ELEMENT 8 BUSH BLOCK 22 SEAL ENERGIZER 9 ALUMINUM BODY 23 BUSH BLOCK 10 DRIVE GEAR 24 BUSH BLOCK 11 DRIVEN GEAR 25 DRIVE GEAR 12
86. nd put the piston in the drum Install the spring Install the spacer Fasten it with a snap ring Install clutch disc plates alternately Install disc 6 plate 6 t 2 0 and plate t 4 5 MM M Install chamber plate bellville spring Fasten with a ring install the thrust washer install the thrust bearing Install the bearing in the gear Install the gear Z 21 Install the washer Install the thrust bearing Clutch pack Install the bearing Fit the seal ring Install the bearing Main shaft Rev sub assembly 30 51 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ASSEMBLING MAIN SHAFT B ASSEMBLY FWD SUB ASSEMBLY INDOOR LIFT TRUCK The numbers in the Figure indicate the order of assembly NOTE Dip the clutch plate and disc in oil before assembling them NOTE Apply grease to the seal ring 19 16 16 14 11 10 10 6 6 6 5 SHAFT ASSEMBLY 21 HWZ01846 When installing snap ring 6 be aware that A it is under spring tension Use specified snap A CAUTION ring tool to avoid injury Snap ring tool 3EC 97 99000 3EC 97 99020 3EC 97 99010 COLLAR HOLDER ple E 3EC 97 99000 HVZ01847 WHEN INSTALLING OR REMOVING SNAP RING 6 USE THE SPECIFIED TOOL FOR SAFETY 30 52 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ASSEMBLY FLOW CHART OF MAIN SHAFT FWD ASSEMBLY INDOOR LIFT TRUCK Install
87. nge the hydraulic oil and filter before testing 1 Install the pressure gauge in the line on the high pressure side in the area of the pump discharge port Carry out the test while checking the pres sure gauge Operate the pump by setting the revolutions to between 500 1 000 rpm with the control valve in the neutral position As the valve is placed in the neutral position the reading on the pressure gauge must be below 1 MPa 10kgf cm 145 psi Keep the pump run ning for 10 minutes Then increase the revolutions to 1 500 2 000 rpm and run the pump without load for 10 minutes in the same manner as Step 2 Run the pump by increasing the pressure by 2 3 MPa 20 30 kgfm cm 290 435 psi for every five minutes up to the maximum pressure at 1 500 2 000 rpm Do this by either adjusting with a relief valve or applying an appropriate load After operating each cir cuit for five minutes replace the return filter element with a new one or clean the filter Caution If the oil temperature or the surface tempera ture of the pump rises abnormally or the pump is making noise stop the test and shut down the lift truck Identify the problem and repair as necessary Upon completion of the above procedures reset the relief valve Caution Set the pressure of the relief valve precisely If the pressure is set too high it may break the pump housing causing hydraulic oil to spray out and possibly causing an accident Ot
88. ngs 20 amp 21 and bush lobe seal 22 4 Turn the unit over and lightly tap the mount ing flange 18 to disengage it from the locat ing dowels and slide it squarely off of the shaft 5 Remove body O ring 19 backing rings 20 amp 21 and bush lobe seal 22 6 Before removing the internal components mark the bushes to denote the location in the body On a clean area away from the seal location mark FD Bush on driveshaft flange end FI Bush on driven gear flange end 7 CD Bush on driveshaft spacer end Cl Bush on driven gear spacer end With the unit lying on its side hold the drive shaft 25 and pull it squarely out of the body bringing with it the bushes 23 amp 24 Remove driven gear 26 and the two remaining bushes 30 123 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP REASSEMBLING THE REAR UNIT Ensure all parts are perfectly clean and lubricate bushings and gears with clean hydraulic fluid ensure O ring recess and end faces of body remain dry This will assist assembly of compo nents into the body bores 1 Refit cover end bushes CD amp Cl into the undowelled end of the body from where they were removed The C shaped cut out in the bushes must be located to the side of the body with the cusp removal flat 2 Place the end cover 3 against the undow elled end of the body 9 and stand the assembly on the cover so the dowels are uppermost and to the left hand side 3
89. other damage The general outside area of the bush should not show any prominent signs of wear Gears The gear side faces should be examined for bruising or scoring Often operation with contam inated fluid shows signs of scoring between the root of the gear and the journal which leaves a wear step If a wear step can be felt coincidental with the root diameter by drawing a sharp pointed tool across the surface from the journal outwards to the tip of the gear then the gear is unserviceable The gear teeth should then be carefully exam ined to ensure that there are no signs of pitting The journal bearing surfaces should be com pletely free from scoring or bruising The surface should be free of scoring or bruising also The surface should appear highly polished and smooth to the touch Examine the area where the shaft seal lips run against the driveshaft This area displays a pol ished ring or rings If a noticeable groove can be felt or there is scoring the shaft should be replaced Provided the driveshaft is not damaged from the drive coupling and the gears have not been harmed as described above then the gears can be reused If however the gears are damaged they must be replaced as a matched set As a matter of good practice when pumps have been dismantled all the seals should be replaced It is most important that only the genu ine Ultra seals are used DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP PUMP
90. p plies oil from the reservoir LP to help fill this void The poppet M is held on its seat by the port pressure HP acting on the larger area behind the O ring When pressure HP drops below atmosphere the tank pressure LP operating on the annular area A1 A2 will overcome the port pressure HP and the spring force to open the poppet When the void is eliminated the spring will return the poppet which will then be tightly seated by the port pressure HP 30 148 HWZ02013 O rings Spring HWZ02014 DISASSEMBLY AND ASSEMBLY LIFT CYLINDER LIFT CYLINDER 2 Stage Mast Lifting height 3 3m 10 83 ft Item Unit 3 5t 4t 4 5t Cylinder 1 0 x O D mm 63 5 x 73 68 9 x 79 4 in 2 1 2 x 2 7 8 2 3 4 x 3 1 8 Stroke mm 50 9 54 1 in 2 2 13 Rod O D mm 50 8 in 2 Weight each kg 45 47 59 100 104 HWZ02015 3 Stage Mast Lifting height 4 7m 15 42 ft Main Lift Free Lift Item Unit 3 5t 4t 4 5t 3 5t 4t 4 5t Cylinder x O D mm 63 5 x 73 69 9 x 79 4 114 3 x 127 in 2 1 2 x 2 7 8 2 3 4 x 3 1 8 4 1 2 x 5 Stroke mm 1 517 7 857 3 in 59 3 4 33 3 4 Rod O D mm 50 8 101 6 in 2 4 Weight each kg 44 46 100 Ibs 97 102 221 HWZ02016 Check item Detail of check Remedy Piston rod cylinder Gouges nicks and dents Replace Wear ring piston seal Go
91. p of the oil seal See Figure 9 for oil seal fitting instructions When press fitting the oil seal use care not to scratch the lip and not to tilt the oil seal Apply tape over the drive gear shaft end to protect the seal lip Be sure to remove the tape afterwards The oil seal can be securely press fitted when using the jig shown in Figure 10 7 2 DUST LIP ee SHAFT END SEAL LIP INSIDE OF THE PUMP GEAR SHAFT 4 2 Figure 9 HVZ01987 Insert snap ring 10 that holds the oil seal in place Always use a new snap ring DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP Assembly of the pump is now complete Before installing the pump on the system check that assembly procedures and direction of rotation are correct Give attention to the following points when installing the pump 1 Are there any scratches or marks on the cen tering location boss on which alignment is based Are there any scratches or contaminant on the mounting surface of mounting flange 4 Special care must be taken to ensure that the vise is not over tightened on the flange Are there any scratches or contaminant on the flange surface of the pipe If there are nicks or contaminants remove them with a fine oil stone Give attention to the following points taken dur ing assembly 1 When reassembling gear assembly 1 gears 2 and 3 and pressure plate 6 care must be taken that the locations and orienta tion
92. ring 30 102 HWZ01920 HWZ01921 HWZ01922 HWZ01923 DISASSEMBLY AND ASSEMBLY PS VALVE 15 The steering unit OSPC is now completely disassembled The Figure shows a few extra parts to add A other functions OTe HWZ01924 Cleaning Clean all parts carefully in Shellsol K or similar cleaning medium Inspection and replacement Replace all seals and washers Check all parts carefully and make any necessary replacements Lubrication Before assembly lubricate all parts with hydraulic oil ASSEMBLY PATTERN AND COLOR CODE FOR NEUTRAL POSITION SPRINGS Standard springs gray 2 are flat gray Code No DF150N0628 4 are curved gray Code No DF150 0721 Gray set Spare set Code No DF150N4019 HWZ01925 30 103 DISASSEMBLY AND ASSEMBLY PS VALVE ASSEMBLY 1 Assemble spool and sleeve NOTE Assemble the spool sleeve and make sure the marks on spool and sleeve match up together See Figure HWZ01926 ALIGN MARKS HWZ01927 2 Place the two flat neutral position springs in the slot Place the curved springs between the flat ones Press them into place See Assembly Pattern on previous page HWZ01928 3 Line up the spring set HWZ01929 30 104 DISASSEMBLY AND ASSEMBLY PS VALVE 4 Guide the spool into the sleeve HWZ01930 5 Press the springs together and push the neutral position springs into place in the sleeve HWZ01931 6 Lin
93. s scratches Piston rod rod bearing front 3 Replace components on piston rod head Excessive clearance between pivot pin Pivot pin pivot bushing tube Replace components and pivot hole assembly Visible jerky or biting movement squealing or chattering noise Tube piston seal bearing strip Replace components 30 151 DISASSEMBLY AND ASSEMBLY TILT CYLINDER MAINTENANCE DISASSEMBLY AND ASSEMBLY GENERAL All parts removed from the cylinder that are to be reused should be thoroughly cleaned Be sure to clean all cavities and grooves prior to replacing parts All parts new and old should be lightly lubricated with a clean lubricant of the same type as or compatible with the fluid being used in the cylinder It is highly recommended that when the cylinder is disassembled for any type of maintenance that all seals be replaced before assembly DISASSEMBLY Cylinder disassembly is easily accomplished using a spanner wrench Simply rotate the head counter clockwise until the beveled end of the shear ring starts out of the tube slot It may be necessary to insert a screwdriver under the bevel of the shear ring to start it out of the slot Continue to rotate the head until the shear ring is completely removed from the keyway The head can now be disassembled Caution should be used to protect the chrome finish on the piston rod when removing the head from the piston rod ROD SEAL AND ROD WIPER REPLACEMENT Use a small
94. s continuity between O O See Tables 3 Insulating resistance Minimum 10MQ at each terminal with a 500 V megger TERMINAL ARRANGEMENT OF 8 PIN COUPLER COMBINATION SWITCH END HVZ01965 Connection positions for lighting switch Circuit Position 1 2 2 SMALL O Lighting switch LO O O HEAD HI O O Circuit diagram PASSING SW NE DIMMER SW wos Lee ee es t HVZ01969 Connection positions of turn signal switch Circuit diagram Circuit 5 6 7 Position R O _O Intermediate TURN SWITCH 6 Hvz01970 L 30 117 DISASSEMBLY AND ASSEMBLY COMBINATION SWITCH Checking lighting turn signal switch 1 Remove connection of 8 pin 6 pin and 2 pin LIGHTING TURN couplers between combination switch cord SIGNAL SWITCH wiring harness 2 Check continuity between terminals at each position and check that there is continuity between O O See Tables 3 Insulating resistance Minimum 10MQ at each terminal with 500 V megger 6 31211 gt lt 5 4 F R SWITCH TERMINAL ARRANGEMENT OF 6 PIN AND 2 PIN COUPLERS i as Huzoor COMBINATION SWITCH END Connection positions for lighting switch Position oa 1 2 3 OFF Lighting switch SMALL 9 2 HEAD Circuit diagram NOTE ON THE CLUTCH
95. sembly completely clean the case bolt screw holes and oil path corners B In particular ensure that all threaded holes in the case are thoroughly cleaned Old Loctite debris or other foreign matter may cause improper torque readings and can lead to bolt breakage HVZ02119 2 Clutch pack assembly Blow compressed air through the oil hole to check drive plate alignment and driven plate operation AIR GUN Air pressure 5 kg cm 70 psi Stroke F 4mm Stroke R 4mm HVZ02120 3 Control valve A Tighten the mounting bolts in the order shown in the figure on the right Torque 27 34 Nm 2 8 3 5 kgfm 20 25 Ib ft HVZ01008 4 Sealring During assembly apply grease to the seal ring 5 STA RINGS HWZ02121 30 21 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ASSEMBLY OF FORWARD REVERSE TRAVEL INPUT SHAFT SHAFT SUB ASSEMBLY OUTDOOR LIFT TRUCK Assemble parts generally in the reverse order of disassembly NOTE Dip the clutch plate and disc in oil before assembly NOTE Apply grease to the seal rings HVZ01805 When removing snap ring 6 be aware A that this snap ring is under pressure from spring 4 Always use specified tool to remove this spring Snap ring tool 3EC 97 99000 3EC 97 99020 COLLAR OLDER 0 NOTE Gear Compact truck Z ae eee Standard truck Z 19 HVZ01806 WHEN REMOVING SNAP RING 6 ALWAYS USE SPECIFIED SNAP RING TOOL 30 22 DI
96. sembly in the reverse order of the disassembly procedures Pay particular attention to the following items 1 Assembly of control valve Insert the piston and spring correctly in their original positions assemble in the proper sequence and install in the transmission housing 2 Assembly of control valve Insert the piston and spring correctly in VEO 793 their original positions and assemble in the reverse order of disassembly Tighten the countersunk head screw and check that the gear rotates smoothly If it does not rotate disassemble and then reassemble again Torque countersunk 0 98 Nm 0 1 kgfm head screw 0 72 lb ft 3 Assembly of inlet port relief valve There are two types of valves so be sure to assemble them correctly and install in their original positions Torque plug 49 Nm 5 0 kgfm 36 1 Ib ft 4 Assembly of turbine shaft Check that the seal ring is securely inserted then insert the shaft into the housing 5 Assembly of gear pump Coat O ring with thin coat of lithium grease Shell Albania Z and insert carefully into the pump casing Greasing helps to prevent breakage or splitting of the O ring during installation Coat O ring Lithium grease CASING Torque bolt 38 2 Nm 3 9 kgfm 28 2 lb ft Assemble the O ring to the casing as shown HVZ01794 on right 30 5 DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER 6 Assembly of torque converter Insert
97. so the dowels are uppermost and to the left hand side 3 Fit driveshaft 25 and driven gear 26 into their original positions in the body 4 Refit flange end bushes FD amp FI into their original bores remembering that the C cut out must be to the side of the body with the cusp removal flat and match the cover end bushes 5 Fit new body O ring 19 backing rings 20 amp 21 and bush lobe seal 22 ensuring that the seals locate correctly in the seal grooves See Figure below 6 Push shaft seal 17 squarely into the recess in the mounting flange 18 with the garter spring facing in towards the pump Then fit the C clip 16 7 Holding the whole unit together carefully turn it over making sure it is supported on the mounting flange 18 and not the shaft 8 Remove spacer 13 and fit new body O ring 19 backing rings 20 amp 21 and bush lobe seal 22 ensuring that the seals locate cor rectly in the seal grooves See Figure below 9 Replace the spacer and rear pump assem bly Refit nuts and spring washers 12 amp 2 Torque bolts to 46 51 Nm 34 37 6 Ibft Pour a small amount of clean hydraulic fluid into a port and check that the shaft can be rotated without undue force 10 ASSEMBLING THE BUSH LOBE SEAL AND BACKING RING 30 124 BACKING RING HVZ01977 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP HVZ01978 Item No Descr
98. t or the bearing is assumed to be excessive Carefully check these parts If a equals or exceeds 0 12mm replace the entire pump assembly with a new unit 2 Front drive gear 2 and driven gear 3 If hydraulic oil is clean the relative rough ness of the gear and the side of the gear hardly changes and it presents a smooth contact surface If the surface of the gear or the side of the gear is so rough as to show gouges or scoring on the surface or the sur face of the gear teeth is partially or abnor mally worn replace it with a new one See Figure 4 If the diameter of the gear d is less than 24 895mm replace with a new gear set DISCHARGE SIDE INTAKE SIDE GEAR HOLE Figure 2 HVZ01980 INTAKE CHAMBER TRACE OF CONTACT Figure 3 HVZ01981 Figure 4 HVZ01982 30 131 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP 3 Pressure plate 6 The pressure plate is normal if it presents smooth and glossy gear contact surfaces on the side of the sliding surface as shown in Figure 5 The sliding surface of the plate is black coated Even if it is partially worn and the lower layer is exposed it is not a problem unless the conditions listed below are found If the following conditions are discovered replace with new parts There are many gouges on the plate and the surface is significantly rough thickness is less than 6 676mm CONTACT SUREACE 4 Mounting flange 4 and cover plate Che
99. t end Adjust the protrusion using the shim after adjusting the starting torque of the output shaft sub assembly Value expressing the difference against the standard length of 120 82mm in 1 100 units after measuring length L e d Read the value stamped on the transmission case for housing the bearing on the pinion shaft end Example 25 Example of shim calculation a 20 stamped value on pinion b 10 stamped value on pinion the following shows measurement calculation L 120 82 x 100 121 39 120 82 x 100 57 e g L 121 39 d 25 stamped value on transmission case Shim thickness T 0 3 20 10 57 25 100 1 42mm HWZ01813 1 1 8 STANDARD SHIM 1 5mm 0 6 2 4 HWZ01814 d VALUE HWZ01815 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ASSEMBLY 1 Cleaning the transmission case and blowing out with compressed air A Remove the cap before cleaning the transmission case since Loctite is used on the cap mounting bolts HVZ02126 B Blow out the machined hole in the case with compressed air HVZ02127 2 Installing blind plugs on the transmission case NOTE For lift trucks equipped with an optional speed meter which uses a speed sensor mount the sensor after assembling the output intermediate and input shafts NOTE Number of blind plugs 2 F1 R1 truck 8 F2 R1 truck 13 HVZ02128 HVZ02129 30 29 DISA
100. t end of the front drive gear 2 and lightly press against the higher portion to unjam the plate and make the work easier 6 Insert front drive gear 2 and driven gear 3 by aligning with set marks put on the shaft end during disassembly At this time pay close attention to the locations of the drive gear and the driven gear After inserting the gears pour clean hydrau lic oil approximately 2 or 3 cubic centime ters in the grooves of the gear teeth 7 Insert pressure plate 6 with the grooved surface downward in gear plate assembly 1 At this time pay attention to the location of the intake and discharge sides See Fig ure 8 BACK UP PLATE SEAL BASE OF SEAL GROOVE Figure 7 HVZ01985 GROOVE INTAKE SIDE DISCHARGE SIDE Figure 8 HVZ01986 30 133 DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP 11 12 13 14 15 Firmly fit plate seal 7 and backup ring 8 in the groove of mounting flange 4 so that they will not protrude from the surface of the outer circumference Install cover plate 5 on gear plate assembly 1 by setting it to the dowel pin At this time use care that plate seal 7 and back up ring 8 do not fall off or protrude If the cover cannot be fully pushed in leaving 2 3mm the seals fitted in steps 3 and 8 may not be properly in position Recheck those seals Insert O ring 16 and dowel pin 13 in cover plate 5 Use care that the O ring is not cau
101. t the inching spool valves and pistons from the valve body Keep all removed parts in order so that they can be assembled in the reverse order of disassembly TRANSMISSION HWZ01857 30 64 DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE COMPONENT PARTS HVZ02142 No Name No Name No Name 1 Valve body 15 Bolt 29 Spring L 83 2 Plug 16 Spring washer 30 Spring L 107 3 Screw 17 Inching valve 31 Plug 4 Regulator valve relief 18 Inching spool 32 O ring 5 Piston 19 Spring L 27 33 Plug 6 Stopper 20 Stopper 34 Gasket 7 Spring L 55 5 21 Nut 35 Bracket 8 Spring L 73 8 22 Seal 36 Bolt 9 Lubrication relief valve 23 Snap ring 37 Inching lever 10 Spring L 33 8 24 Plate 38 Pin 11 Plug 25 Spring L 74 39 Solenoid valve 12 O ring 26 Plug 40 Bolt 13 Plate 27 O ring 14 O ring 28 Piston accumulator 30 65 DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE ASSEMBLY DRAWING MAIN RELIEF PRESSURE LUBRICATION RELIEF PRESSURE INCHING VALVE SIDE OF THE 2 ORIFICE BETWEEN THE INCHING VALVE AND ACCUMULATOR INCHING VALVE R1 CLUTCH PRESSURE SOLENOID VALVE INLET F1 CLUTCH PRESSURE HWZ01858 MAIN RELIEF VALVE LUBRICATION RELIEF VALVE FOR OP PUMP FROM T C ACCUMULATOR HWZ01859 30 66 DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE TROUBLESHOOTING Failure Power is no
102. t transmitted No oil pressure 1 Broken piston or spring of the inlet Replace after disassembling relief or regulator valve 2 Stuck solenoid valve Replace after disassembling Oil pressure is low 1 Deformed spring or piston malfunc Check it after disassembling Re tion of the inlet relief or regulator place parts as necessary valve 2 Stuck solenoid valve 3 inching valve operation The output is low Replace after disassembling Adjust it Oil leaks Gasket joint surface 1 Slacken boit 2 Broken gasket 3 Flaw on the opposite surface Retighten it Replace after disassembling Repair or replace it The electromagnetic valve does not function No voltage 1 Failed forward reverse travel lever switch 2 Wrong connector contact 3 Fused or disconnected fuse or wir ing circuit Repair or replace it after checking Repair it after checking Repair or replace it after checking Voltage available 1 Disconnected grounding circuit 2 Wrong connector contact 3 Wrong frame grounding wire con tact 4 Stuck solenoid valve 5 Disconnected solenoid or wiring cir cuit Repair it after checking Repair it after checking Repair it after checking Repair or replace it after checking Repair or replace it after checking 30 67 DISASSEMBLY AND ASSEMBLY DIFFERENTIAL DIFFERENTIAL
103. te tool for removal Snap ring tool 3EC 97 99000 3EC 97 99020 3EC 97 99010 COLLAR HOLDER 3EC 97 99000 HVZ01804 WHEN REMOVING SNAP RING 16 ALWAYS UTILIZE APPROPRIATE TOOL LISTED 30 16 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION TESTING F1 R1 TRANSMISSION OUTDOOR LIFT TRUCK HWZ02107 2 1 HWZ02108 HWZ02111 HWZ02112 30 17 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION MAINTENANCE STANDARD F1 R1 TRANSMISSION OUTDOOR LIFT TRUCK Criteria jen Check item Standard size Repair limit Remedy mm Thickness of drive plate 2 25 27 2 7 A Replace Thickness of driven plate 1 93 2 07 1 7 B2 Clearance at end gap when inserting piston Replace each ring time disassem side face A bly is carried out rae inside diameter of seal 45 45 025 45 175 ring contact surface EZ C2 Seal ring insertion groove width D1 Seal ring insertion groove 2 6 2 65 28 width D Drive shaft D2 Seal ring insertion groove 2 6 2 65 28 width Clearance at end gap EL when inserting cap Bias cut Diameter of transmission No stepped type case 1st shaft hole 354 335 025 wear should be detected Clearance at end gap 8 when inserting clutch case 03 05 Replace Inside diameter of seal G Thrust washer washer Gi Thickness 2 B EUM 3 1 Outside diameter of oil No stepped type
104. the torque converter into the pump inside the housing To avoid breakage or scratching of the oil seal and bushing during this operation fill the area between the oil seal lip 1 3 to 1 2 uniformly with lithium grease or coat with clean hydraulic oil Assembly of torque converter assembly Assemble the torque converter assembly to the transmission and the engine Replace the O rings and oil seals with new parts Use care to assemble correctly For details see the check items in the Maintenance Standard When replacing a seal with a new part coat the outside circumference with semi dry gasket sealant Example Three Bond No 1211 1104 Be careful not to get the gasket sealant on the lip or sliding surface of the shaft MAINTENANCE STANDARD 1 Checking oil pressure Location No Check item Pressure Port position Torque 1 Torque converter inlet port 0 5 0 7 MPa 5 7 kgf cm converter pressure 72 5 101 5 psi 2 Tightening torque for bolts and plugs Tightening torque Nm i i Ib ft Component No Tightening Screw specification kgfm No location Target Maximum 57 8 5 9 74 5 7 6 1 Input plate mount Hexagon bolt M10 x 1 5 x 16 42 6 54 9 1 3 Countersunk head 0 98 0 1 2 94 0 3 2 Gear pump ass y er M5 x 0 8 x 16 0 72 2 17 2 5 Inlet port valve 49 0 5 0 63 7 5 9 3 mount Plug M16 x 1 5 x 10 36 1 47 0 11 converter Small hexa
105. tion HVZ01891 piston 56 spring in the hole of the reaction piston Insert the relief valve by matching the relief valve and reaction piston holes Insert the pin after making sure that the holes have overlapped B Assembling the control valve e Apply hydraulic oil to the control valve and insert it together with the spring to the power piston HVZ01892 e Assemble the O ring with the cap insert them to the power piston and assemble them using a snap ring TN HVZ01893 C Assembling the power piston sub assembly e Apply hydraulic oil to the reaction piston and insert it to the power piston Insert the ring from the side and assemble them using a snap ring N X HVZ01894 30 89 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE D Assembling the piston guide Apply grease to cup 17 and O rings 16 and 18 and assemble them with the piston guide in the proper direction E Assembling the seal with the body Apply grease to seal 25 and O ring 16 and assemble them with the body in the proper direction F Assembling the power piston assembly Apply grease to the rod and assemble with the body e Apply hydraulic oil to the inside of the cylinder and the outer circumference of the power piston and insert the power piston assembly into the cylinder Assemble the piston guide with the reaction piston completely pressing them and assemble them using a snap ring 30 90 POWER PISTON SIDE
106. trucks the brake and clutch boosters are assembled on each assembly When disassembling them be careful not to lose the O ring on the mating face It cannot be purchased separately The Torqflow equipped lift trucks use a single unit consisting of the brake booster and master cylinder assemblies BRAKE BOOSTER 1 Separating the booster and master cylinder Remove nut 31 to separate the booster from the master cylinder 2 Disassembling the master cylinder A Remove snap ring 54 B Remove stop pin 55 Remove the stop pin by pressing the piston assembly after loosening the stop pin C Remove piston assembly 52 and spring 53 If they cannot be removed easily slightly press the piston assembly so that it comes out under the spring pressure D Remove bolt 57 to pull out check valve 59 and spring 60 from the cylinder 30 84 BRAKE MASTER CYLINDER HVZ01883 HVZ01884 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE 3 Disassembling the booster A B C Remove push rod 30 and boot 29 Remove snap ring 15 Press rod 5 from the master cylinder side to remove piston guide A power piston assembly D and the rod See Figure at right PISTON GUIDE SUB ASSEMBLY REACTION PISTON SUB ASSEMBLY CONTROL VALVE SUB ASSEMBLY POWER PISTON ASSEMBLY FLOW DIVIDER mgomwv Disassembling the sub assembly A B Reaction piston sub assembly Disassemble by pressing valve 9 and pulling pin 4
107. ue bolts 59 73 Nm 6 7 7 kgfm 43 4 53 8 158 HWZ02137 If the transmission case and the torque con A verter housing cannot be easily joined due to misalignment of the input shaft spring or the intermediate shaft bearing do not force them together by tightening the bolts Gently tap on the housing with a wooden hammer or similar tool and then tighten bolts 15 a iJ Le 7 We HWZ01819 HWZ01820 30 33 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 10 Installing the transmission valve Install it using bolts 16 and gaskets tighten two of the eight bolts together with inching change brackets Torque bolts 27 34 Nm 2 8 3 5 kgfm 20 25 158 TORQFLOW TRANSMISSION ASSEMBLY DRAWING F1 R1 HWZ02138 INVOLUTE SPLINE 35 X 19 X 1 667 CLEARANCE 040 1 16 0 6 GASKET HWZ02139 30 34 DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER TORQUE CONVERTER INDOOR LIFT TRUCK STRUCTURE HWZ01821 No Part name No Part name 1 Pump 12 Bearing 2 Pump boss 13 Thrust needle bearing 3 Turbine assembly 14 Spacer 4 Stator assembly 15 Snap ring 5 Roller 16 Bearing 6 Spring 17 O ring 7 Spring cap 18 O ring 8 Hub 19 Bolt 9 Thrust washer 20 Bolt 10 Drive cover 21 Spring washer 11 Thrust washer 22 Washer Tightening torque BoltA BandC 18 6 24 5 Nm 1 9
108. uges 30 149 DISASSEMBLY AND ASSEMBLY TILT CYLINDER TILT CYLINDER Cylinder tube Bushing Piston rod Piston Seal Lock nut Strip Seal Seal 0 Head 1 Seal 2 4 5 0 3 gt 30 150 Wiper Seal Back up seal Ring Seal Rod head Bushing Bolt Spring washer Nut Grease fitting HWZ02017 Cylinder O D x TC 6 12 7 7 32 Pneu Stroke 6 6 4 51 64 Cushion 4 59 64 Rod O D 1 3 4 DISASSEMBLY AND ASSEMBLY TILT CYLINDER HWZ02147 ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY 1 Head 1 18A Piston seal 1 2 Tube assembly 1 18B Piston seal expander 1 3 Piston rod 1 24 Rod wiper 1 9 Piston 1 25 Rod seal 1 11 Piston LD seal 1 5 Piston bearing strip 1 14 Piston lock nut 1 135 Shear ring 1 16 Tube seal 1 150 Pivot bushing 1 17 Tube seal back up 1 151 Water seal 1 Indicates recommended spare parts STANDARD SIZE AND REPAIR LIMIT SIZE The Okuno cylinder does not use repair limit sizes as maintenance criteria for hydraulic cylinders The fol lowing table displays various visual inspections which should reveal potential repair or replacement prob lems before dimensional changes in components become excessive INSPECTION CHECK ITEM ITEMS REMEDY Visible external leakage Rod seal rod wiper tube seal Replace components Abnormal wear marks dent
109. utside diameter of 31 95 31 975 Replace Inside diameter of body 32 0 32 025 Clearance 0 025 0 075 0 07 Regulator Outside diameter of piston 11 973 11 984 Inside diameter of body 12 0 12 011 Clearance 0 016 0 038 0 07 Inching regu Outside diameter of spool 9 986 9 995 lator Inside diameter of body 10 0 10 015 Clearance 0 005 0 029 0 05 Inching spool Outside diameter of spool 21 967 21 98 Inside diameter of body 22 0 22 021 Clearance 0 102 0 054 0 07 Spring KA C Free length D Installed length E Installed load E HWZ01788 Large spring of accumu lator Free length Small spring Free length 150 135 Replace Large spring of regulator Free length Small spring Free length Inching spool Large spring Free length Small spring inching regulator Free length 30 63 DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE TRANSMISSION CONTROL VALVE OUTDOOR LIFT TRUCK DISASSEMBLY OF CONTROL VALVE 1 Remove bolt 1 to remove the control valve from the transmission and remove bolt 2 that attaches HR CONTROL VALVE the solenoid valve Remove the solenoid valve from the valve body Use a 4mm hex wrench NOTE The F2 solenoid valve on the F2 F 1 lift truck is mounted on the right side of the trans mission case Remove the bolt that attaches the cover Then remove the cover and gasket 2 Pull ou
110. ydraulic oil and place them in the two grooves in the gear rim Fit the gearwheel and rim on the control shaft HWZ01955 27 NOTE IMPORTANT Fit the gearwheel rotor and control shaft so that a tooth base in the rotor is positioned in relation to the shaft slot as shown Turn the gear rim so that the seven through holes match the holes in the housing HWZ01956 28 Fit the spacer if any is being used 29 Place the end cover in position HWZ01958 30 112 DISASSEMBLY AND ASSEMBLY PS VALVE 30 31 32 33 Place the washer on the special screw and place in the hole as shown at right HWZ01959 Equip the six screws with washers and insert them Cross tighten all the screws and the rolled pin with a torque of 3 0 0 6 Nm 0 31 06 kgfm 26 6 5 3 Ibin The OSPB OSPB LS and the OSPBX LS can now be function tested HWZ01960 Place the dust seal ring in the housing With the OSPC PSPC LS and OSPC LSR the dust seal ring must be placed only AFTER the pressure relief valve and shock valves have been fitted HWZ01961 Fit the dust seal ring in the housing using special tool SJ 150 9000 22 and a plastic hammer as shown at right HWZ01962 30 113 DISASSEMBLY AND ASSEMBLY PS VALVE 30 114 Maximum tightening torque Screwed connection Nm Ibin With O ring LEFT PORT RIGHT PORT TANK PUMP HWZ01963 DISASSEMBLY AND ASSEMBLY COMBIN

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