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SERVICE MANUAL - Ages Heftruck Service BV

1. AINO SMONYL 1 18 40 SV9 1905 ala q HOSN3S 01 35014 0 IM T HOLIMS SNINHV31 1 e SVL LSV4 91 YOLOAPNI 94190 SON GION31OS LSISSV 94101 M2 19 1 wa qa L L L H ZN T HALVSH 21 4 YOLOW 213 12 1 YB MOH LB Y OSN3S 39 39 9419 9 9 v 8 ST
2. Detail of Fig 5 1 Steering Axle Trucks with capacities from 1 5 to 1 75 tons 74 5 STEERING SYSTEM KNUCKLE SUPPORT Lomas KNUCKLE LEFT rise RIGHT 3 LEFT YOKE RIGHT m xu dS STEERING SENSOR SUPPORT gt Mm See Fig 5 3 Detail of Fig 5 2 Steering Axle Trucks with capacities from 2 0 to 3 5 tons 5 STEERING SYSTEM 1 Knuckle and king pin The knuckle is supported with a king pin which in turn 15 secured at the knuckle side with a lock pin The top and bottom of the king pin are fitted to the axle boss with needle bearings Between the axle boss and the knuckle is a thrust bearing to let the knuckle smoothly rotate around the king pin sustaining load The needle bearings and thrust bearing are lubricated by grease supplied through the grease fittings at top and bottom of the king pin NEEDLE BEARING OIL SEAL THRUST BEARING LOCK NUT TAPERED ROLLER BEARING OIL SEAL OIL S
3. 1 4 I Fig 1 28 Cleaner Gas powered 1 5 to 1 8 ton trucks with 21 or K25 29 1 ENGINE x lt a He AIR CLEANER to ENGINE Fig 1 29 Air Cleaner Gas powered 2 0 to 3 5 ton trucks with K21 or K25 30 1 ENGINE Fig 1 30 Air Cleaner Gas powered trucks with K21 or K25 31 1 ENGINE AIR CLEANER V OUTSIDE AIR to ENGINE Fig 1 31 Air Cleaner Diesel powered trucks with TD27 QD32 E Um 1 ENGINE OUTSIDE AIR ELEMENT to ENGINE FILTER BODY EVACUATION VALVE Fig 1 32 Air Cleaner Diesel powered trucks with TD27 QD32 je 1 ENGINE Air cleaner inspection and replacement 1 Remove the air cleaner element 2 Inspect the element for contamination and damage If the element is
4. 9 ACCUMULATOR CLUTCH PACK ASSEMBLY Fig 2 6 Transmission Oil Pressure Circuit Diagram in neutral 43 2 AUTOMATIC TRANSMISSION SYSTEM 2 In forward gear As the solenoid valve is switch to the forward position the oil flows to the forward clutch pack while the shuttle valve moves to the right to allow the oil to flow also to the accumulator Until the accumulator is filled with oil the clutch oil pressure increases gradually and the clutch lock up pressure is weak Once accumulator 15 filled with oil however the clutch lock up oil pressure rises rapidly to the specified value to lock up the forward clutch pack completely TORQUE CONVERTER OIL COOLER INLINE C FILTER TORQUE CONVERTER RELIEF VALVE 0 39 0 69 3 98 7 04 kgf cm d 56 6 100 1 psi MAIN RELIEF VALVE INCHING VALVE 1 di I pn 1 11 01 14 99 kgf cm 156 6 213 2 psi lt gt CHARGING 6 PUMP R SOLENOID VALVE LE VALVE L 5 ACCUMULATOR 1 08 1 47 MPa 4 gt FILTER
5. OUTPUT FLANGE OIL SEAL STRAINER OUTPUT GEAR Fig 2 1 Automatic Transmission System 1 2 38 2 AUTOMATIC TRANSMISSION SYSTEM CONVERTER BREATHER RELIEF VALVE INLINE FILTER OIL LEVEL GAUGE Fig 2 2 Automatic Transmission System 2 2 39 2 AUTOMATIC TRANSMISSION SYSTEM 2 1 4 TORQUE CONVERTER The torque converter consists of a pump wheel a turbine wheel and a stator wheel as shown in Figure 2 3 As the engine is started the pump wheel is driven and the fluid inside the pump wheel begins to be ejected along with the row of pump wheel vanes under centrigugal force flowing into the row of turbine wheel vanes The direction of fluid leaving the turbine wheel is changed by the stator wheel so that it may flow into the pump wheel at a proper angle At this time reaction torque pushing the stator is created so that the output torque exceeds the input torque by this reaction torque If the rotational speed of the turbine wheel increases and gets closer to the input rotational speed the angle change in the fluid will become smaller and the output shaft torque will decrease finally letting the fluid flow into the row of stator vanes in the reverse direction causing reverse reaction torque As a result of this the output shaft torque will become smaller than the
6. HOLIMS 1V3S 1 15 3 IV GION3 IOS 4 NHOH us I39 dWV1 QV3H 1944 ALAAVS 1199 I99 H313ANOLLN3 LOd 19 49 1495 91319373 8 8cl LTL 652 syed EONA JO suoneooT 8 814 JIS jo om YALYVLS SS3NHVH 115 Av 13H 2 8 HOSN3S 1904 I II gt HOLIMS 1945 04 Xoa 3814 uoo 3079 8010 u3zzna X V9 015I52 SS3NHVH SHIM 01 MI X V9 LM V 39M5V14 1 08 L 9 L uazzna X V9 MI
7. P Fig 5 9 Power Cylinder 81 5 STEERING SYSTEM 5 1 5 STEERING WHEEL DEVIATION CONTROL The orbitrol type steering system has a drawback that the steering wheel operating angle does not agree with the rotational angle of the knuckle exactly In particular the steering wheel may move gradually away from the center position which the operator wants to hold while traveling To correct the drawback the truck has a steering wheel deviation control unit consisting of an EPACS controller a compensation valve and a tire angle sensor The steering angle sensor is located on top of the left side king pin of the rear axle CONTROLLER STEERING WHEEL ANGLE SENSOR X 2 2 Wire color Function Input of power supply Red rated voltage 12 V or 24V Black Input of power supply 0 V Output of power supply for tire Pink angle sensor Yellow Input of tire angle sensor signal output Purple Tire angle sensor GND GND Output of solenoid valve driving Light green signal Output for solenoid valve driving Brown signal Plug White Input of initial setting receptacle Plug Input of initial setting GND receptacle M Fig 5 10 EPACS Controller 82 5 STEERING SYSTEM 1 Schematic dia
8. 9 9 VIV1 V91IVI3M o o 1938 MS 8LI6 3 VI53 Nado xrivnsn z 319VI 335 M9V31 25 5415 MS N3do 335 LXL t dSA 06 dNVH v8 TM 22 599 5 1 ESSI MS ML 99 RR 1116 9 V QN9 8 94970 SE 7 22 VO OUT L MSMONS Z 49 V 0M9 m vHENI 17 VO 9 093 MONS MS MSN9I 601 V NOI 08 Ten I 2 M5 18 5 9 19 20410319373 HA 15 191 N 5 5 wow F 110 13 95 1 9 ATH O NIVIA 29 m dnd 1903 2135 39MI109V5 153
9. 91919573 8 1938 LTAL 88 014 M0IIVMI9M09 02 35 015X0V9 mez 01854098 4015 IL M8 TII mez M L 344 139 MOVE Noo ido OO 1199 1 36 59 wove 2 WI ML AMALLVS M L TH NHOH 9015 1 MCIII50 9 3803 9 0IV1 999 I T 2 Agog MS WHLNAN 5
10. ANIONA gt SS3NHVH 01 quvn9 LNOHH SS3NuVH XMI I 3181503 500 HAWIL HOLIMS 1938 J3NION3 SS3NuVH WHV1V 09V 5 AL33VS Qva AVI T SUPPE 0 ONIHS3IS 0 EN GION310S TVH LO3N 4018 91319373 8 6cl STM sseured 978 SIT YOSNAS aaads oi HJTIOHLNOO SS3NHVH 01 M X 91 Od SMONYL OdT NOILdO 3NION3 GION31OS V SS3NMHVH 51404 HOLIMS 9 9 19120 20082 YOSNAS 01 9 d 9 YOSNAS 9 390 IV 3 VV5 L 5 g 01 905M3 dVW 9 04 v 103136 9919 V 106 941
11. H31HdJANOO ANOYOL Fig 2 12 Oil Pressure Check Ports 49 2 AUTOMATIC TRANSMISSION SYSTEM 50 3 DRIVE AXLE 3 DRIVE AXLE Truck Model 2013 FD20m FG3013 15 3 18 2013 20 FHG3013 FG3513s 15 3 18 25 3 25 FD3013 FD35rss 251 25 FHD3013a Item Type Full floating type 729 lt Wheel Size 2 6 50 10 10PR I 2 7 00 12 12PR I 2 28 9 15 12 1 2 250 15 16PR 2 Tread pattern J LUG lt c ct Rim Type Split type 1 5 t Split type Disc type go Disc type 1 8 t Size 5 00 x 10DT 1 5 t 5 00S x 12DT 7 00T x 15 2 5 00F 10 1 8 t Tire inflation pressure 690 kPa 100 psi 850 kPa 123 psi 3 1 GENERAL DESCRIPTION The drive axle has a construction as shown in Figures 3 1 and 3 2 and is mounted on the front area of the frame It has a wheel hub and a wheel brake at its each spindle end and an axle shaft running through its center The wheel hub is provided with a brake drum which is installed on the spindle through two tapered roller bearings The two tapered roller bearings have oil seals to prevent grease inside from oozing out and water from entering the brake unit At the center of the housing is a differential which transmits the power from the
12. LI TRANSMISSION CONTROL VALVE CLUTCH PACK ASSEMBLY Fig 2 8 Transmission Oil Pressure Circuit Diagram in reverse gear 45 2 AUTOMATIC TRANSMISSION SYSTEM 4 Inching When the inching spool is pushed in the oil flowing to the clutch pack assembly is drained through the inching spool piston In addition the oil returning from the clutch pack assembly is also drained INCHING VALVE Fig 2 9 Transmission Oil Pressure Circuit Diagram during inching 2 1 4 TRANSMISSION CONTROL VALVE The transmission control valve consists of an inching valve a regulator valve and an accumulator as shown in Figure 2 10 It is attached to the transmission case cover The inching valve spool is controlled by the lever installed on the case cover The lever is in turn controlled through the cable connected to the left side brake pedal As the left side brake pedal is pressed the cable is pulled so that the lever pushes the inching valve spool The case cover has a solenoid valve which switches over the directions of travel 46 2 AUTOMATIC TRANSMISSION SYSTEM Detail of connector M
13. LI 39VIHHVO 931109 Adis epis H3TIOS TANNVHO YANNI epis Fig 7 6 Locations of Rollers VM 2N5 VM 2N9 121 7 LOAD HANDLING SYSTEM peisnfpe 931109 peisn pe uius peisn pe uius f p 931 10 TANNVHO 931 0 wiys peisnfpe 941103 931109 J3NNVHO YANNI epis Fig 7 7 Locations of Rollers VM 2Y5 122 8 ELECTRIC WIRING 8 ELECTRIC WIRING The electric components of the truck are wired through several types of wire harnesses and color coded by circuit The wire harnesses are connected with connectors 2 types or screw Table 8 1 Color symbols and examples Red White Yellow Light green Example Yellow coating with a blue marking i Light blue Example White coating without marking Table 8 2 Connector symbol Connection type Plug in side Receptacle side Remarks The alphabetic letters means colors Housing Yt YL P 1 Plug in type Plug RW RW YB Screw type 70 The dotted lines in the circuit diagrams are given for optional equipment DANGER Use due caution when handling battery unit 1 Never short the circu
14. FW Fig 6 42 Lift Cylinder VM 2M5 106 gt PISTON HEAD SHIM WIPER SEAL U RING HOLDER BUSHING CYLINDER ROD LOCK RING PISTON WEAR RING PACKING SNAP RING SHEAVE CHAIN ANCHOR PIN ADJUSTMENT NUT LOCK NUT COTTER PIN 6 HYDRAULIC SYSTEM Fig 6 43 Lift Cylinder VM 2N9 107 O 4 FW gt Details of cylinder support PISTON HEAD SHIM WIPER SEAL U RING HOLDER BUSHING CYLINDER ROD LOCK RING PISTON WEAR RING PACKING SNAP RING SHEAVE CHAIN ANCHOR PIN ADJUSTMENT NUT LOCK NUT COTTER PIN 6 HYDRAULIC SYSTEM Details of cylinder support
15. 35 2 AUTOMATIC TRANSMISSION 37 2d GENERAL DESCRIPTION eve totu ut ek ot dace 37 2511 TORQUE CONVERTER 40 XEEDNROINGEPUMOD hae eres Mesas esti oua ux edd 41 2 TRANSMISSION 42 2 1 4 TRANSMISSION CONTROL VALVE hec Eu 46 DRIVE AXLE 51 AI GENERATE SCRIP EIGN ial darks bast ata 51 311 REDUCTION GEAR AND DIFFERENTPIAL esee 57 4 BRAKE SYSTEM 61 4 1 GENERAL DESCRIPTION 61 Uu lesan oil 61 MASTER i din salah 66 cue 67 414 PARKING BRAKE LEVER 69 412 WHEEL BRAKE TROUBLESHOOTING 2159 20 Apes aged 72 5 STEERING SYSTEM 73 So GENERA LODE SCRTE HON 73 74 iS DEERING ASSEMBLY
16. 5 MV OL No SEF OF7BE TCM SERVICE MANUAL FORKLIFT TRUCK 10203 86146014 105 ves 56 L 148694 10 94 10294 15 8 20 20 25 FHD2573A FD35rss 513 813 20 20 25 25 FG35rss TCM CORPORATION 39740 43 TCM CORPORATION No SEF 0F7BE FOREWORD TCM s new forklift trucks with capacities from 1 5 through 3 5 tons feature low operating noise and reduced vibration as well as improved controllability and higher safety and come equipped with new high performance engines The gasoline engines used for this series are equipped with an electronically controlled fuel supply unit to reduce emissions from the engine The steering system can correct steering wheel knob deviation automatically to provide better driver control The instrument panel accommodates optional OK monitors which allow the operator to check the water level air cleaner plugging and battery condition of charge with just a glance The serviceability of these trucks has been greatly improved by these changes This Service Manual describes all of the major components and their service procedures We encourage you to make practical use of it while servicing the trucks W
17. TRANSMISSION CONTROL VALVE CLUTCH PACK ASSEMBLY Fig 2 7 Transmission Oil Pressure Circuit Diagram in forward gear 44 2 AUTOMATIC TRANSMISSION SYSTEM 3 In reverse gear When the solenoid valve is switch to the reverse position the oil flows to the reverse clutch pack while the shuttle valve moves to the left to allow the oil to flow also to the accumulator Until the accumulator is filled with oil the clutch oil pressure increases gradually and the clutch lock up pressure is weak Once the accumulator is filled with oil however the clutch lock up oil pressure rises rapidly to the specified value to lock up the reverse clutch pack completely TORQUE CONVERTER OIL COOLER INLINE C 3 FILTER TORQUE CONVERTER RELIEF VALVE 0 39 0 69 MPa 4 3 98 7 04 kgf cm 56 6 100 1 psi MAIN RELIEF VALVE INCHING VALVE 9 jp 1 08 1 47 MPa 4 1 11 01 14 99 kgf cm 156 6 213 2 psi COIN FILTER lt S7 CHARGING PUMP SOLENOID VALVE gt SHUTTLE VALVE 9 AccuMuLATOR
18. Detail of area Detail of sensor Fig 1 26 Accelerator Pedal Gasoline engine 1 ENGINE 2 Diesel engine The accelerator pedal controls engine output It is installed as shown in Figure 1 27 The movement of the accelerator pedal is transmitted by way of a wire cable to the engine l Adjust the wire length with the nut B Pedal height Unit mm in H TD27 QD32 so that the looseness of the link 0 0197 to 0 0394 in when the engine is running at idle rpm Fig 1 27 Accelerator Pedal TD27 QD32 4065 19 0 75 is 0 5 to 1 0 mm 1 ENGINE 1 1 6 AIR CLEANER The air cleaner removes dust and dirt from the air to be supplied to the engine It is located on top of the oil tank at the right side of the frame The outside air enters the air cleaner through the duct provided at the mounting part of the rear right pillar of the overhead guard Dust and other foreign matter is removed by the air cleaner element before being supplied to the engine AIR CLEANER to ENGINE
19. IVMIVI 3L 190 5 91 4 x IV35 fug WEIDSN UU 30380 98 TOM 74015 359V95 ax tee uivT 3x tasas 84 e e e e e a z u ADIT JOTAIN 5050 GNO SW3IHSIVM 13M31 1309 9313VI Y YM eH NOLIVNIATTTI 52 JW 13M113 4 TANYA JAZOLLOLN N lo C 0000 aL 1 H N o 0 L O pao HOLIMS TWNOIS HOLIMS HOLIMS NHOH HOLIMS HOLMS NOLLO3MIG SVNIWHSL NOILdO 99 NOLIVNIGI 7 WOO INOY4 No SEF 0F7BE Issued February 2007 Revised February 2010 TCM CORPORATION MARKETING GROUP 1 15 5 N
20. Fig 4 1 Brake Pedal Trucks with capacities from 1 5 to 1 75 tons 1 2 62 4 BRAKE SYSTEM 3 3 35 0 02 in Detail of brake master cylinder Detail of brake lamp switch Fig 4 2 Brake Pedal Trucks with capacities from 1 5 to 1 75 tons 2 2 63 4 BRAKE SYSTEM CABLE SN 7 BRAKE PEDAL RIGHT 1 BRAKE MASTER CYLINDER 777 BRAKE LAMP SWITCH p BRAKE PEDAL LEFT I INCHING PEDAL 5 Ke RESERVE TANK Brake pedal play 10 mm 0 394 in Inching pedal play 50 m
21. Fig 61 Main Pump Trucks with capacities from 1 5 to 1 75 tons 86 6 HYDRAULIC SYSTEM DRIVE GEAR GASKET SNAP RING BUSHING OILSEAL REAR COVER BUSHING DRIVEN GEAR FRONT COVER SIDE PLATE BODY GASKET Fig 6 2 Main Pump Trucks with capacities from 2 0 to 3 5 tons 87 6 HYDRAULIC SYSTEM 1 Oil flow The oil which has flowed through the inlet port in the rear cover then enters the chamber formed by the tooth spaces of the gears side plates and the pump body and flows along the peripheries of the gears out of the discharge port TOOTH SPACE SUCTION PORT DISCHARGE PORT A by gt 22222 flow Fig 6 3 Hydraulic Flow 2 Pressure balance While the pump is not operating or the discharge pressure is low the side plates are pressed against the gears side faces by the rubber gasket When the discharge pressure becomes high a force which repels the side plates acts on the shaded section in Fig 6 4 At the same time the oil pressure also acts on the back side of the side plates pressing the shaded section in Fig 6 5 The shapes and surface areas of both shaded sections are almost the same so that the side plates are always pressed against the sides faces of the gears with a constant elastic force regardless of the discharge pressure of the pump Fig 6 4 Pressure Distribution on Side Plate Side Fig 6 5 Pressure Distribution
22. 5 1404415 5 III I9I C CLV 682 0 9 0 07 699 26 8 10 VIV9IV6IL 80695 0 114 LON ILNHIAALLSDfQV 2001 QH3HdVIL 7 991 6 190 062 012 922 902 8 10 VIV91V6I L LAVHS DNISNOH 6 18 801 w 64 8 6 4 LLL 96 VIV91V6 L 6 V0V 7276 0 98 0 8 U N 6V9 LZY nb10 01 Fig 3 4 Drive Axle Trucks with a capacity of 3 5 tons 55 3 DRIVE AXLE Wheel hub installation procedure 1 Fill the space A in the wheel hub with approximate 100 cc of grease and install the wheel hub on the spindle 2 Tighten the adjustment nut to about 9 8 N m 11 7 2 Ibf ft torque and back it off 1 2 ofa turn 3 Set a spring balance on the stud bolt and adjust the hub starting torque for the specified value gradually ADJUSTMENT NUT tightening the adjustment nut LOCK WASHER Starting force 49 147 1 5 15 kgf 11 33 1 Ibf 4 Install the lock washe
23. LB YR Lg RL R YL 8 Cs 9 5634 dSA IHYA 0 S rB Lg BY BG WO ber WB WL pe H313WNOLLN3 Od HOJVH3T3JOOV 91919573 8 0tI ITA 8 Yala T ANIONS 931M3VI036 oped 83LVVI8 905M95 AWAL 380953996 9731 93IVM OA TaAST TANS T 1 YILIN 501 XH LINN T V8I 3M ABS ANN 318I8n4 2959 1 t 1179 NOLLVNIIAC TTE gt X 019891MI AIINS 9 9
24. SUCTION PORT DISCHARGE Fig 2 4 Charging Pump 41 2 AUTOMATIC TRANSMISSION SYSTEM 2 1 3 TRANSMISSION The transmission is a power shift type consisting of a clutch pack assembly an output shaft a reverse gear and transmission control valve See Figures 2 1 and 2 2 1 Clutch pack assembly The clutch pack assembly consists of forward and reverse clutch packs each of which consists primarily of a piston a spring clutch discs and a steel plate The piston 15 always forced against the far end of the drum by the spring When the oil pressure 15 applied the piston locks up the inner and outer discs The clutch lock up oil is supplied through the groove in the clutch shaft and the lubrication oil is fed through the oil hole in one end of the shaft OUTER DISC CHECK BALL SNAP RING INNER DISC SEAL RING END PLATE PISTON SPRING O RING SNAP RING BALL BEARING BALL BEARING BALL BEARING 7 BALL BEARING REV CLUTCH OIL PRESSURE 1 LUBRICATION OIL FWD CLUTCH OIL PRESSURE SEAL RING SEAL RING SNAP RING SNAP RING FORWARD GEAR REVERSE GEAR Fig 2 5 Clutch Pack A
25. eoeds 14 114 6 L8 8 04 6 086 U N LLL 96 1 8 10 VIV91V6 L TIVAS TJIHHA LAVHS TIXV ONISNOH 7 991 6 L9LI 6 0022 0012 922 902 nb10 VIV91V6 L Fig 3 2 Drive Axle Trucks with capacities from 2 0 to 2 5 tons 53 3 DRIVE AXLE LON ADOT LAN LNANLISALAV TIVAS Q3 THd VL Wa CCLV L 682 6 00 6 0009 699 26 8 10 VIV91V6 L 2441 7276 0095 0085 W N 6V9 8 10 1 10 99 00 eoeds stu 114 6 L8 802 LV 6X 086 U N LLL 96 gt 8 10 IV91V6IL 5 TIO 5 TIHHA 14 5 TIXV ONISNOH 7 991 6 190 6 0022 0012 922 902 8 10 VIV91V6 L Fig 3 3 Drive Axle Trucks with a capacity of 3 0 tons 254 3 DRIVE AXLE
26. mm N gt QN Mast side Lift bracket side N Fig 6 44 Lift Cylinder VM 2Y5 108 00 1 gt PISTON HEAD SHIM WIPER SEAL U RING HOLDER O RING BUSHING CYLINDER ROD LOCK RING PISTON WEAR RING PACKING SNAP RING SHEAVE CHAIN ANCHOR PIN ADJUSTMENT NUT LOCK NUT 6 1 5 FLOW REGULATOR VALVE The flow regulator valve controls the fork descending speed and acts as a safety device if the high pressure hose bursts for any reason It is located as shown in Fig 6 44 Flow regulator valve operation The oil returning from the lift cylinders enters the chamber G passing through chambers and back to the control valve The more the oil flows through the hole C in the piston 4 the greater the pressure differential across the piston 4 becomes to move the piston 4 to the right For this reason the hole is narrowed by the hole C so that the oil flow is restricted to slow the fork descending speed When the forks are raised the high pressure oil from the control valve flows passing through D Fjand G into the lift cylinders
27. 6 HYDRAULIC SYSTEM NOTE 114 7 LOAD HANDLING SYSTEM 7 LOAD HANDLING SYSTEM 15 207 FD2073 18 FHG20 5 FHD20r4 FG30 30 35 15 FG255 FD2513 FHG30r 0 FD3513s 1813 25 FHD25r4 VM 2M5 VM 2M9 Type Roller type 2 stage telescopic mast with free lift Standard max lifting height 3000 mm 118 11 in Fork lifting system Hydraulic Fork tilting system Hydraulic Lift chain Leaf chain BL534 Leaf chain BL634 Leaf chain BL823 Leaf chain BL834 Channel shape Outer channel 44mm 1 73 in 48 mm 1 89 in A 60mm 2 36 in B 102 5 mm 4 04 in 119 5 mm 4 7 in 124 mm 9 88 in 134 5 mm 5 3 in 161 5 mm 6 36 in C 170 mm 6 69 in Inner channel 43 mm 1 69 in A 48 mm 1 89 in 45 mm 1 77 in 102 5 mm 4 04 in B 119 5 mm 4 7 in 119 5 mm 4 70 in 134 5 mm 5 3 in C 161 5 mm 6 36 in 159 5 mm 6 28 in 72 mm 2 83 in D 76 mm 2 99 in 76 mm 2 99 in 115 7 LOAD HANDLING SYSTEM 7 1 GENERAL DESCRIPTION The roller type two stage telescopic upright consists of an outer channel an inner channel and a carriage 7 1 1 OUTER AND INNER CHANNELS The outer and inner channels are of welded construction The outer channel has a support at its lower part with which the up
28. SIDE ROLLER SHIM SHIM SPACER LOAD BACKREST 4 22 N 7 3 Carriage VM 0A7 118 Fig 7 4 Carriage VM 2N5 VMI 2M9 VM 2Y5 19 9 n Q9 7 LOAD HANDLING SYSTEM FORKS STOPPER SPRING HANDLE CARRIAGE END ROLLER LOCK BOLT SIDE ROLLER SHIM SHIM SPACER LOAD BACKREST 7 LOAD HANDLING SYSTEM 7 1 3 LOCATIONS OF ROLLERS The end and side rollers are installed on the carriage The end rollers support the fore and aft load and the side rollers support the lateral load so that the inner channels and carriage are raised and lowered smoothly END ROLLER shim adjusted END ROLLER shim adjusted CARRIAGE LI oS 2 jue 22 27 INNER CHANNEL OUTER CHANNEL END ROLLER shim adjusted SLIPPER shim adjusted END ROLLER shim adjusted Fig 7 5 Locations of Rollers VM 0A7 120 7 LOAD HANDLING SYSTEM peisnfpe peisnfpe 931109 peisn pe peisnfpe ulus
29. TNTISISVSdT PI 018 INNY 58 85 1 05390 9 sav 16 LNN 86 259V AYOM 28 V 0M9 13 V 06 Ly 901 LSdY 2841 69 1541 09 2V 0M5 99 9010 9 3XV99 MS 03345 7 TVNOIS NANI ATHLON tL SNOT 10V no 26 c MSTAN mw 4 04 IM M 13 4 IMI 021 IM 9d1 SS 991 399195 1 4 33055 Ge 504 NHOH GISVHdNJS vL Lva MVII5I5 NANI Come 5 THOANVT ANOS INSET amp NOILISOd 5 OVIA SATA 973 Move SIW NOILdO 1
30. The FDM front cover contains a main relief valve a flow priority valve and a PF relief valve The combination valve is composed of a lift section and a tilt section LIFT PLUNGER TILT PLUNGER PF PORT FDM REAR COVER FDM FRONT COVER COMBINATION VALVE B2 A2 e B Fig 6 19 Control Valve Trucks with capacities from 2 0 to 3 5 tons 95 6 HYDRAULIC SYSTEM 1 Operation of flow priority valve The flow priority valve receives a single stream of oil through the P port and divides it into separate output streams the priority flow PF flow of a constant flow setting and the excess flow MF flow The PF flow is supplied to the steering system and the MF flow to the load handling system The oil coming through the pump port P port flows passing through the PF throttle hole the control orifice and load check in the FD spool to the PF port As the flow rate of oil coming through the P port increases the pressure differential across the control orifice also increases This moves the FD spool both ends of which receive the pressure across the control orifice into the direction that closes the PF throttle hole thus reducing the PF flow As a result the pressure differential across the control orifice also drops so that the priority flow is maintained at the flow setting determined by both the control orifice and set spring a MF flow pressure 15 lower than PF flow pressure durin
31. 3AH3S3H l340VH8 3GdIS 3 AV3J 1 30I5 90 LIVICV 49 465 0 617 aunsseid dvo Fig 1 21 Cooling System Gas powered trucks up ENGINE 1 HOJVIQVH pu 6 841 5 J3AH3S3H E 7 49 465 670 eunsseJd Duiuedo qvo Fig 1 22 Cooling System Diesel powered trucks 24 1 ENGINE Adjusting fan belt tension Make sure engine is shut off 21 25 D Loosen generator fitting bolts 2 Move the generator away from the engine to adjust the belt tension So that the fan belt has a deflection of 10 mm at on the span when pressed by a finger pressure of about 98 1 10 kgf 8 Tighten the fitting bolts B and then C 8 TD27 QD32 D Loose
32. 7 LIFT CYLINDER as CASE SPRING BALL PISTON SLEEVE 6 HYDRAULIC SYSTEM LIFT CYLINDER RIGHT LIFT CYLINDER LEFT Fig 6 44 CONTROL VALVE SIDE ORIFICE SPRING O RING NIPPLE Fig 6 45 Flow Regulator Valve 109 6 HYDRAULIC SYSTEM 6 1 6 TILT CYLINDER The tilt cylinder is a double acting type and its piston rod end is supported by the mast and the cylinder tail is connected to the frame with a pin This truck is provided with two tilt cylinders on both sides of the front of the truck The tilt cylinder assembly consists primary of a cylinder body a cylinder cap a piston and a piston rod The piston attached to the piston rod with lock nuts has a back up ring and an O ring installed on its circumference and moves along the inner surface of the cylinder by the force of hydraulic oil A bushing is press fitted inside the cylinder cap to support the piston rod with a packing and dust seal to provide oil tightness for the piston rod and the cylinder cap The cylinder cap fitted with an O ring on its outer periphery is screwed into the cylinder body When the tilt lever in the operator s compartment is tilted forward high pressure oil enters the cylinder tail side moving the piston forward tilting the mast forward When the tilt lever is tilted backward high pressure oil enters the cylinder cap side and moves the piston backward
33. 77 1 3 7 POWER CYEINDER 81 5 1 5 gt STEERING WHEEL DEVIATION CONTROL 82 No SEF 0F7BE 6 HYDRAULIC SYSTEM 25 onte ot tates pet A 85 6 1 GENERAT DESCRIPTION 86 MAINPUMP 86 CONTROL VALV athe Ua 90 6 13 VALVE CONTROL 103 YENDER 104 6 1 5 109 taint 110 111 T LOAD HANDLING aida MP ta uale 115 TA SGENERATEDESCRIPTION ie 116 7 1 1 OUTER AND INNER CHANNELS spss coos UA HU 116 7 12 IX 118 7 1 3 LOCATIONS 6 5 5 5 5 56 120 8 ELECTRIC WIRING 8 Gasoline and LPG engine Name Type No of cylinders Bore x stroke mm in cc in Total displacement Compressi
34. SOHO OLNV 9 pesn 10M 5 Age 3 1 A 3ATVA 9 HOLIMS 9 aul ad 91 XX W03 SS3NHVH IM094 SS3NHVH 0 Fig 8 2 Wire Harness Engine K21 K25 125 8 ELECTRIC WIRING to WIRE HARNESS FRONT GUARD to F R SOLENOID VALVE XC wal CL HEAD AND POSITION STOP HORN RWL OPTION TURN to FUSE BOX 2 TH METER WY BrY 2R CV LY YR E G to BACK UP _ LAMP RELAY OLA o OPTION E GROUND to FUEL CUT RT to STARTER OFF VALVE FUSE BOX LB RL to OIL toFUEL METER pressure LEVEL SWITCH SENDER to RELAY V8 xm to GLOW PLUG O to WATER TEMP SENDER I
35. 17011 081 8 1 0861 OPSIE 8 06 ur snipes ur 0 I 10091 1761 0751 002 69 popeo pepeor BAGSH NA _ ind reqmeIp xe 117211 1 1 71 S61 puc 151 AOI puc 381 poods LCII 059 6 621 099 I6 LcT 069 6 221 089 7221 oco 6 621 099 6151 069 I6 CCII 089 1 9 159 popeor 117 9914 8 AHA I81 II SNOILVOI3IO3dS 781 000 pz 009 000 0961 Iojuoo orsegq peo 94 No SEF 0F7BE 0656 0927 0266 055 0684 0866 0484 0155 0114 055 080 1 0126 Surje1odo TSIM me s s 071 22 eet on 19 I6 CV 8 6 cC Or 59 6 0601 OSZ d 0201 SHT Suroeds x10 S TX 6t X 127 oT X 9 v X ssouyory L x 4 x 8 _C9VXCCI X 0401 _ Or X OZOI _ Or X 22I XOLOI _ _ _ 9215 coz 6 61 sos IBY 6811 087 111057 LLU OSY c8cl 0 6 88 0 6 6 99100 1 0 29 0091 _ _ 9589 2 891 0927 LoT seu
36. 2567 psi Steering 6 9 MPa 70 kgf cm 1000 psi 8 8 MPa 90 kgf cm 1276 psi Lift cylinder Type Single acting piston Cylinder bore 45 mm 1 77 in 2 2 5t 50mm 1 97 in 3t 55 mm 2 17 in 3 5 t 60 mm 2 36 in Stroke 1495 mm 58 9 in Tilt cylinder Type Double acting piston Cylinder bore 65 mm 2 56 in 80 mm 3 15 in Rod diameter 30 mm 1 18 35 mm 1 38 in Stroke 130 mm 5 12 in 128 mm 5 04 in Oil tank Capacity 21 liters 5 55 U S gal 32 liters 8 45 gal 85 6 HYDRAULIC SYSTEM 6 1 GENERAL DESCRIPTION The hydraulic system consists of a main pump a control valve lift cylinders and tilt cylinders The oil is supplied from the tank at the right side of the frame 6 1 1 MAIN PUMP The main pump is a gear type directly driven by the engine PTO device and picks up oil from the oil tank and sends to the control valve The main pump consists of a pump body a pair of gears bushings and packings This pump uses pressure balanced bearings and a special lubrication method to minimize the clearance of the gear flank The pressure balanced method is to press the pressure plate toward the gear side by introducing part of the discharge oil between the pressure plate and the pump body GEAR PLATE MOUNTING FLANGE DRIVEN GEAR SNAP RING SIDE PLATE OIL SEAL PLATE SEAL PLATE SEAL BACK UP 7 O 5 2 Section B Section SIDE PLATE
37. tilting the mast backward JOINT CYLINDER CAP 11 PISTON DUST SEAL LOCK RING 12 PACKING BUSHING O RING 13 LOCK NUT O RING ROD PACKING CYLINDER Fig 6 46 Tilt Cylinder 110 6 HYDRAULIC SYSTEM 6 1 7 OIL TANK The oil tank is integral with the frame and located at the right hand side of the truck body Figure 6 47 shows its construction Inside the oil tank are a suction filter and a return filter to remove dust from the oil BREATHER to LIFT CYLINDER to PUMP STEERING RET URN RETURN FILTER DRAIN PLUG Fig 6 47 Oil Tank 111 6 HYDRAULIC SYSTEM OIL TANK POWER CYLINDER TILT CYLINDER RIGHT toUPPER _ PART OF gt CYLINDER LL u W CC 80 to LOWER ORBITROL TILT CYLINDER Fig 6 48 Hydraulic Oil Piping Trucks with capacities from 1 5 to 1 75 tons 12 6 HYDRAULIC SYSTEM OIL TANK TILT CYLINDER POWER CYLINDER LI d gt o LL S G CONTROL VALVE ORBITROL TILT CYLINDER LEFT Fig 6 49 Hydraulic Oil Piping Engine powered 2 0 to 3 5 ton trucks 113
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39. dirty clean it by blowing low pressure air from inside to outside If the element 15 damaged or clogged replace it with a new one 3 Clean the filter cover ELEMENT to ENGINE EVACUATION Free air VALVE Fig 1 33 Air Cleaner Be careful not to touch muffler and exhaust manifold since they are hot when the engine is running and for a while after it is shut off otherwise you might burn your hand 34 1 ENGINE 1 1 7 MUFFLER The muffler helps reduce the sound of escaping gases of the engine and it is provided between the radiator and the counterweight at the rear of the truck from ENGINE CUM s Detail of area EXHAUST EMISSION CONTROL SYSTEM THREE WAY CATALYST MUFFLER 1 5 to 1 8t EXHAUST Detail of area MUFFLER EXHAUST EXHAUST EMISSION CONTROL SYSTEM 2to3 5t THREE WAY CATALYST Fig 1 34 Exhaust System Gasoline Trucks 35 1 ENGINE MUFFLER lt gt EXHAUST Fig 1 35 Exhaust System Diesel Trucks 2365 2 AUTOMATIC TRANSMISSION SYSTEM 2 AUTOMATIC TRANSMISSIO
40. has a construction shown in Fig 1 13 It converts high pressure gas supplied from the LPG cylinder into low pressure gas High pressure gas from the LPG cylinder flows between the valve seat and valve and enters the pressure reducing chamber so that the pressure inside the pressure reducing chamber rises Therefore the diaphragm pushes up the diaphragm spring and the hook pulls up the valve lever so that the valve is pressed against the valve seat The higher the pressure inside the pressure reducing chamber the stronger the valve is pressed against the valve seat When the pressure inside the pressure reducing valve is high enough to reach the set value the gas flow is cut off by the valve When the pressure inside the pressure reducing valve drops below the set value the diaphragm spring is decompressed to reduce the lever pulling up force This opens the valve to allow high pressure LPG to enter the pressure reducing chamber This process is repeated to maintain the pressure inside the pressure reducing chamber at a constant value 19 6 35 3 kPa 2 9 5 1 psi 0 20 0 36 kgf cm 14 15 mm 0 55 0 59 to INJECTOR HOLDER VALVE DIAPHRAGM SPRING VALVE SEAT HOOK PRESSURE REDUCING LEVER CHAMBER PRESSURE CHECK DIAPHRAGM PORT PLUG Fig 1 13 Vaporizer Outline 18 1 ENGINE 1 1 3 ENGINE CONTROL SYSTEM Gasoline and LPG The gasoline and LPG engines are electronically controll
41. install the filter After the packing comes in contact with the body give an additional 2 3 of a turn 3 If the sedimentor warning light comes on loosen the drain cock to drain off water Note After draining off water make sure to close the drain cock DRAIN COCK for water removal 15 1 ENGINE Air bleeding Diesel engine D Operate the fuel filter sedimentor pump to send fuel into the injection pump 2 After it feels a little hard operate the pump 5 to 10 more times Fig 1 11 Air Bleeding 16 1 ENGINE 1 1 2 FUEL SYSTEM LPG The fuel system that uses LPG as a fuel has a construction shown in Fig 1 12 It consists of a LPG cylinder a vaporizer and a solenoid valve The LPG cylinder is attached to the upper part of the rear counterweight and both the vaporizer and the solenoid valve are located at the left side inside the engine room LPG flows from the LPG cylinder through the solenoid valve to the vaporizer where the gas pressure is properly regulated before being controlled by the LPG injector and then injected into the cylinders of the engine The vaporizer case is warmed by the radiator water to prevent the vaporizer from freezing due to latent heat which occurs when the fuel vaporizes CYLINDER SOLENOID VALVE w FILTER 24 VAPORIZER 22 Dag Y RELIEF VALVE Fig 1 12 LPG Fuel System Outline 17 1 ENGINE Vaporizer The vaporizer
42. jeuBis Josues JezuodeA 0441 01 U09 9131044 9Iu04129 3 indino uonoefur jen indino dq 01002 Jojenjoe 041009 8I1101V1 2129 3 suieis s euis Josues uonisod 9110441 indui 105095 indino 0002 Jejeeu Josues 08 89LI sueis s Indu 10sues uonisod jeped ANIM 1 91 0 193 CCM0642 Fig 1 19 Electronic Controlled System Diagram LPG 1 ENGINE 1 1 4 COOLING SYSTEM The cooling system consists primarily of a radiator and a reserve tank as shown in Figure 1 20 The radiator is a cross flow type On the automatic transmission trucks the outlet tank has an oil cooler inside it The water pump is attached to the engine and driven by way of the V belt as the engine starts running RADIATOR RI P nd RESERVE TANK Qu 9 DRAIN VALVE Ed Fig 1 20 Cooling System ENGINE 1 HOJVIOVMH Jo
43. on Gear Side 88 6 HYDRAULIC SYSTEM 3 Body wipe While the discharge pressure is low the centers of the gears are almost aligned with the centers of the pump body holes maintaining the radial clearance which is determined by machined size When the discharge pressure increases the gears are pushed toward the low pressure side by the clearance between the gear and bearing and a deflection of the shaft to make the gear teeth to contact with the pump body During this process the cast pump body is worn away because the gears which are usually heat treated are harder than the pump body This 15 called body wipe In order to keep the optimum radial clearance of gears when loaded the pump is run in at a little higher pressure than the rated pressure before it is delivered to the customer Also the pump is tested for discharge and specified torque D Wipe depth 0 01 0 06 mm Eccentricity 0 00039 0 0024 in Center of pump body Discharge i port Suction port Trace of wipe CROSS 6 6 Body Wipe 89 6 HYDRAULIC SYSTEM 6 1 2 CONTROL VALVE B 1 5 to 1 75 tons The control valve consists of two types of spool sections assembled with three bolts as shown in Figure 6 7 The lift spool section contains a main relief valve a flow priority valve and a PF relief valve MAIN RELIEF VALVE LIFT PLUNGER TILT PLUNGER PORT B2 PORT PF PS RELIEF VA
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45. shoe and movement of the lever is transmitted to the secondary shoe through the strut 67 4 BRAKE SYSTEM ADJUSTER Fig 4 6 Braking Operation in Forward Travel e orking force PRIMARY SECONDARY PRIMARY SHOE Fig 4 8 Parking Brake Unit 4 BRAKE SYSTEM 3 Automatic clearance adjuster The automatic clearance adjuster keeps a proper lining to brake drum clearance automatically The structure of the adjuster is shown in Figures 4 9 and 4 10 This adjuster actuates only when the truck is braked in reverse travel It varies in structured and operation with different truck models E gt SPRING _ 2 d 4 9 Trucks with capacities from 2 0 Fig 4 10 Trucks with capacities from to 2 5 tons 1 5 to 1 75 and 3 0 to 3 5 tons Automatic clearance adjuster operation D Trucks with capacities from 2 0 to 2 5 tons When the brake is applied in reverse travel the secondary shoe and the brake drum rotate together slightly The lever turns to the right round the section shown in Figure 4 9 causing the section to rise When the brake is released the lever is turned to the left round the section M by spring force causing the section B to move down As the lining to brake drum clearance becomes larger the vertical movement of the section grows When the clearance becomes more than 0 4 mm 0
46. the front guard The movement of each lever is transmitted through a rod to the respective plungers TILT LEVER ATTACHMENT LEVER LIFT LEVER OPTION CONTROL VALVE SPACER Detail of 6 38 Valve Controls Ref 103 6 HYDRAULIC SYSTEM 6 1 4 LIFT CYLINDER The lift cylinder is a single acting piston type consisting of a cylinder a piston rod a piston and a holder The piston is secured to the piston rod with a snap ring with a wear ring and packing on its outer diameter At the bottom of one cylinder is a cut off valve which will act as a safety device if the high pressure hose connecting the right and left lift cylinders bursts for any reason The holder has a bushing and an oil seal pressed to support the piston rod and provide dust proofness for the cylinder E Cut off valve operation When the oil in the cylinder returns into the oil tank it passes through the holes and in the piston If the flow rate of the oil passing through those holes is less than the setting of the flow regulator valve the pressure differential across the piston is smaller than the spring force so that the piston won t move If its flow rate becomes greater than the flow regulator valve pressure setting due to a burst of the high pressure hose or for any other reason the pressure differential across the piston becomes greater than the spring force to mov
47. transmission to the right and left wheels 51 3 DRIVE AXLE 2928 3111201 9 MOOT LAN LNHACULLSOfGV TIVAS VATION 1 621 9011 6 0821 009L U N 921 091 8 10 10 22 00 eoeds siu 114 C 68 c4 086 5 TIO 5 12XV 1989 TIHHA LAVHS ONISNOH 856986 jo jews e G G 3111901 86 9 9 3111001 SOL 5981 6 00VL 0021 W N oz IV91V6 L 8 10 om 8 L Fig 3 1 Drive Axle Trucks with capacities from 1 5 to 1 8 tons E P 3 DRIVE AXLE LON MOOT LOAN LNJAUCSOfGV ONTAVA QT3Hd VL QT3Hd VL 1 688 0028 000 699 26 8 10 u Jd 7276 6 0099 0087 U N 6V9 LZY 8 10 IV91V6IL eseoJb 001
48. with steering wheel knob deviation control 80 cm 4 88 96 cm 5 86 in rev Double acting piston type 7 mm 2 8 in 40 mm 1 57 in 132 mm 5 2 in 80 mm 3 15 in 50 mm 1 97 in 171 mm 6 73 in 177 mm 6 97 in 20 liters 5 28 U S gal min 6 86 MPa 70 kgf cm 995 psi 60 liters 15 85 U S gal min 8 8 MPa 90 kgf cm 1276 psi 5 1 GENERAL DESCRIPTION The steering system consists primarily of a steering wheel an orbitrol and a power cylinder When the steering wheel is turned the rotation is transmitted to the orbitrol the oil passages in the orbitrol are changed over to direct the hydraulic pressure from the flow divider valve to the power cylinder which extends or contracts depending on the hydraulic pressure thereby steering the truck 73 5 STEERING SYSTEM 5 1 1 STEERING AXLE The steering axle 15 of steel welded construction with a box shaped cross section incorporating a power cylinder inside it See Figures 5 1 and 5 2 The power cylinder is housed in the axle to protect it from being damaged by obstacles on the road surface The axle is installed onto the truck frame through a center pin with bushing and cap and it cradles around this center pin 1 KNUCKLE KNUCKLE se XX RIGHT LEFT 188 SUPPORT FRONT SUPPORT REAR STEERING SENSOR See Fig 5 3
49. 016 in the section B is engaged with the next tooth of the adjuster When the section B engaged with the tooth moves down the adjuster length expands to 110 extend the shoe 6 The clearance is thus adjusted within the range Pra Expands in this direction from 0 4 to 0 45 mm 0 016 to 0 018 in by the above operation Fig 4 11 Automatic Clearance Adjuster Trucks with capacities from 2 0 to 2 5 tons 68 4 BRAKE SYSTEM 2 Trucks with a capacity of 1 5 to 1 75 tons and 3 0 to 3 5 tons When the brake is applied in reverse travel the secondary shoe and the brake drum rotate together slightly This turns the lever clockwise round the section A shown in Figure 4 10 thus making the section B turn the adjuster If the braking force increases further the force applied on the adjuster thread becomes so great that the adjuster cannot be turned any further When the brake is released the brake shoe returns to the original position This turns the lever counterclockwise round the section while the section moves down At this time if the position of an adjuster tooth is aligned with the section 8 of the lever they engage with each other so that the clearance is adjusted to 0 25 to 0 4 mm 0 0098 to 0 016 in Fig 4 12 Automatic Clearance Adjuster Trucks with capacities from 1 5 to
50. 1 75 tons and 3 0 to 3 5 tons 4 1 4 PARKING BRAKE LEVER The parking brake lever is a toggle type and installed as shown in Figure 4 13 The lever has an adjuster on its head with which you can adjust the braking force properly RELEASE RELEASE BUTTON BUTTON RIGHT SIDE CABLE LEFT SIDE CABLE E Adjusting parking brake lever operating force 1 Place the parking brake lever in the release position 2 Adjust the lever so that it has the operating position as shown the sketch when the point of the lever is pulled with a force of 200 to 250 20 to 25 44 to 55 Ibf Turn the point clockwise to make the pulling force stronger and counterclockwise to make it weaker Fig 4 13 Parking Brake Lever 69 4 BRAKE SYSTEM i Section Shoe expands in this direction Section Section B i 2154 PUSHROD PRIMARY SHOE PISTON LEVER BRAKE LEVER CUP SECONDARY SHOE STRUT SPRING BACKING
51. 5 U S gal max 4 0 liters 1 06 U S gal min 5 4 hters 1 43 U S gal 0 35 mm 0 014 in at warm 0 35 mm 0 014 in at warm 16 52 66 12 5 9 8 MPa 100 kgf cm 1421 psi 2 94 MPa 30 kgf cm 426 psi 200 rpm 6 5 liters 1 72 U S gal max 5 0 hters 1 32 U S gal min 6 2 hters 1 64 U S gal 1 1 119211 1 1 1 ENGINE 1 1 1 FUEL SYSTEM Gasoline and Diesel The fuel system is integral with the truck frame and consists of a fuel tank filter pump and level sender 1 Fuel tank Gasoline The fuel tank is welded into one integral body with the frame and located at the left side of the frame The fuel tank has on its top a tank cover where a tank unit is provided to check the fuel level in the tank to ENGINE STOP VALVE LEVEL SENDER FUEL PUMP DRAIN PLUG Fig 1 4 Fuel Tank Gasoline 10 1 ENGINE Fuel pump Gasoline The fuel pump has a design as shown in Fig 1 5 It consists of a pump a regulator and a filter The fuel pump is started when the key switch is turned to ON to send fuel under pressure to the engine injector to ENGI
52. 8 2513 FHD2513a 35138 Item FD35rss Type Front two wheel braking internal expansion hydraulic type Pedal ratio 5 3 6 3 Master cylinder bore 19 05 mm 0 75 1 3 4 Wheel brake Type Duo servo type Wheel cylinder bore 22 22 mm 0 87 28 58 mm 1 13 in 9 8 Brake drum inner dia 254 mm 10 in 310 mm 12 21 in 314 mm 12 36 in Lining size 279 x 48 5 x 5 mm 324 x 60 x 7 mm 348 x 76 x 7 67 mm 10 98 x 1 91 x 0 01 in 12 76 x 2 36 x 0 28 in 13 7 x 2 99 x 0 30 in Surface brake 4 x 13530 mm 4 x 19440 mm 4 x 26400 mm 4 x 20 97 11 2 4 x 38 37 11 2 4 x 40 92 Parking brake Type Front two wheel braking internal expansion mechanical type 4 1 GENERAL DESCRIPTION The brake system is a front two wheel braking internal expansion hydraulic type consisting of a brake pedal master cylinder and wheel brakes 4 1 1 BRAKE PEDAL The brake pedal unit has a structure as shown in Figure 4 1 and is installed through a bracket on the left side of the frame Pedal movement pushes the master cylinder piston through the push rod converting brake pedal effort to oil pressure 61 4 BRAKE SYSTEM BRAKE PEDAL RIGHT BRAKE MASTER CYLINDER BRAKE LAMP SWITCH BRAKE PEDAL LEFT INCHING PEDAL RESERVE TANK Brake pedal play 10 mm 0 394 in Inching pedal play 40 mm 1 575 in until the master cylinder moves
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54. AIN RELIEF VALVE ACCUMULATOR to BRAKE PEDAL MANUAL BUTTON SOLENOID VALVE the forward position is selected by pushing SHUTTLE VALVE INCHING VALVE Fig 2 10 Transmission Control Valve 1 2 47 2 AUTOMATIC TRANSMISSION SYSTEM SNAP RING PLUG O RING SNAP RING SPOOL SNAP RING 2 PLUG SHUTTLE VALVE O RING CL SPRING SPRING Os VALVE Detail of Inching valve O RING SNAP RING Detail of shuttle valve accumulator and main relief valve O RING OIL SEAL COIN FILTER Detail of lever Fig 2 11 Transmission Control Valve 2 2 48 2 AUTOMATIC TRANSMISSION SYSTEM H3NIVH IS NOILONS V38V ONILNNOW dial X71009 110 31000 110 91 3 53 10 9NIOHVHO 3 53 3 539 9 390553 L TO
55. E BRACKET Apply LOCTITE 262 Fig 1 4 Engine Mounting 5 2 1 ENGINE ALTERNATOR INJECTOR GAS INJECTOR AIR FLOW METER LPG THROTTLE IGNITION COIL CHAMBER DRAIN PLUG WATER PRESSURE SWITCH STARTER DRAIN PLUG OIL FILTER Fig 1 2 Gasoline and LPG Engines 4 Main Construction Type of cylinder liner Valve operation Suction valve opens at BTDC closes at ABDC Exhaust valve opens at BBDC closes at ATDC Valve clearance suction valve exhaust valve Ignition system Ignition timing Ignition order Ignition coil Ignition plug Spark gap Governor Air cleaner Lubrication system Lubrication pump Lubrication oil filter Filtration Cooling system Cooling fan Drive Water pump Drive Water temperature regulator Starting motor Voltage Output Cylinder and cylinder block cast into one piece 09 0 38 mm 0 015 in 0 38 mm 0 015 in Ignition type BTDC 0 at 700 rpm 1 3 4 2 Incorporated in igniter FR2A D NGK 0 8 0 9 mm 0 032 0 035 in Electronic type fixed range control Filter paper type Forced lubrication Gear type Filter paper Full flow filtration Water cooling forced circulation Pusher type 10 blade O D of 400 mm 15 8 in V belt drive pulley ratio 1 1 20 Centrifugal type V belt drive pulley ratio 1 1 20 Wax type valve opening temp 82 C or 179 6 F M
56. EAL NEEDLE BEARING LOCK PIN OIL SEAL KING PIN Fig 5 3 Knuckle 2 Wheel hub The wheel hub is mounted on the knuckle spindle with two tapered roller bearings and its preload is adjusted with a nut 296 5 STEERING SYSTEM 5 1 2 STEERING WHEEL ASSEMBLY The steering wheel assembly is arranged as shown in Figure 5 4 The orbitrol 15 located at the bottom of the assembly At the center of the steering wheel is the horn button The steering shaft is connected to the drive shaft of the orbitrol The steering wheel can be moved to a certain extent back and forth to suit the driver s physique TILT LOCK LEVER ORBITROL Fig 5 4 Steering Wheel Assembly 5 STEERING SYSTEM 5 1 3 ORBITROL The orbitrol sends pressure oil from the pump selectively to the steering cylinder It consists primarily of a control valve and a metering device The control valve used in this orbitrol is not an ordinary spool type whose spool moves in the axial direction but a rotary type consisting of a sleeve and a spool which rotates to switch over the oil passages The housing has four ports which lead to the pump tank right and left chambers of the steering cylinder respectively Between the P port and T port is a check valve provided The metering device consists of an internally toothed stator and an externally toothed rotor It works as an oil motor under normal operating conditions and can be used as a hand pump II the truck becom
57. H 0 NOLIVNISINOO 9 NYOH V I9 10913 TWNOILdO 40 HOLIMS Age uv vv ev E L T HOLIMS 01 HOLIMS 124 8 ELECTRIC WIRING HOLIMS Ares 17387 NOlLdO M1 9 7679 9 3bM 8 A 41 9 9 8 19 dn x u3zzna NOILdO 14 dn MOvg 9 PAM es VIV I NOLLVNISINOO 01 3015 NOILISOd v 46 Nd 8 LI sam 09 18 0 ONIMAALS 0 a LINN H3HSV 14 HOLIMS 39 539 10 01 XIII I 3 19509 YOLVNYSLTV 9 a IM pesn 10M YALYVLS 0 n LE MH3ON3S ie 3n vedi 01 930M3 T3A31 1303 0 N p uM 18 085 10M 7 pejoeuuoo
58. I to ALTERNATOR VI 8 VC GB to FLASHER UNIT to STARTER RELAY 1 1 gem 3BL 3BY QOS3 to TIMER to DETECTOR to SEDIMENTER IN 5 ses al le wg to STEERING POTENTIOMETER to GLOW PLUG RELAY to BACK UP BUZZER to REAR WORK S to REAR COMBINATION LAMP LIGHT OPTION SR to LICENSE RB RL NUMBER PLATE LAMP OPTION Fig 8 3 Wire Harness Engine Trucks with TD27 QD32 126 Lcl STM 10 song 4 seg eornoo q Jo 814 2 NOILOANNOO lt 40146 HOLIMS 3018 HOLIMS HOLIMS 199 01 10 LINN d33dS H3LLHVILS X0 ASNA 4415 1 144 a a 932209 H M
59. Ignition coil The ignition coils are used only for the ignition plugs and directly attached to them Inside each ignition coil is an igniter using transistors 20 ENGINE 1 eujoseo yug edA u1n18J uou eutoseo Sv jen4 Aejes 80 4 Josues uonisod MI9 108095 dwa 1V6I00 uonnquisip Josues uonisod 2 Je HniN 10895 em 914 Josues SSEW pjojrueui isneuxy 2 V indui 2461 10sues 8 16 9 VI81 indui W a Y quioq Od 201081 jan 16155 108498 eJnsseud jen4 indjno 8VII0565 uonoelui ena indino 64015 indui jeuBis einjejeduie euiDu3 jeubis 10sues 10111804 1 6V 5XV918 josues 56555556 155555 2061 105085 10111504 yeysweg indino jand 2 164615 041009 18405 V91IM exeig 15 8415 uontub yeubis 69I 1 8 3 indui
60. LVE PORT A1 Note See Figure 6 8 for each cross section Fig 6 7 Control Valve Trucks with capacities from 1 5 to 1 75 tons 90 6 HYDRAULIC SYSTEM 1 Lift spool section The lift spool section consists of a lift plunger a PF relief valve which controls the steering circuit oil pressure and a flow divider valve which distributes the oil flow from the main pump into both the load handling circuit and the steering circuit The lift spool section is also provided with a cartridge type relief valve which sets the load handling circuit oil pressure and the steering circuit oil pressure FLOW DIVIDER PART MAIN RELIEF VALVE MOUNTING PART Section C LOW PRESSURE PASSAGE Section LOAD CHECK VALVE Section Fig 6 8 Lift Spool Section 91 6 HYDRAULIC SYSTEM Main relief valve operation a b c d The oil in the high pressure oil passage HP flows through the oil in the piston C to act on two different surface areas and so that the poppets D and K are securely seated When the oil pressure in the high pressure oil passage HP reaches to the preset pilot spring force the pilot poppet E opens to allow the oil to flow around the poppet passing through the drilled hole to the low pressure side LP When the pilot poppet E opens the pressure at the back of the poppet D drops to cause pressure differential bet
61. N SYSTEM Model Speeds Torque converter Type Stall torque ratio Charging oil pressure Charging pump Type Discharge Transmission Type Reduction ratio Clutch disc Dimensions Clutch oil pressure Differential Reduction ratio Weight Oil capacity Oil to be used 2N5 25 1 fwd rev 3 element 1 stage 2 phase type 3 0 39 0 69 MPa 3 98 7 04 56 6 100 1 psi Internal gear type 15 93 cm 0 97 in rev Constant mesh power shift type 1 638 for fwd 1 674 for rev 125 x 81 x 2 6 mm 4 92 x 3 19 x 0 102 in 1 08 1 47 MPa 11 01 15 0 156 6 213 2 psi 5 833 110 kg 242 5 Ibs 9 0 liters 2 4 U S gal SAEIOW or equivalent 2 1 GENERAL DESCRIPTION The automatic transmission system consists of a torque converter and a power shift transmission as shown in Figures 2 1 and 2 2 37 2 AUTOMATIC TRANSMISSION SYSTEM TORQUE CONVERTER CHARGING PUMP 53 gt gt 20 CLUTCH PACK mt COUNTER GEAR
62. NE QUICK CONNECTOR to CHAMBER CHAMBER FILTER FILTER Fig 1 5 Fuel Pump Gasoline Engine 11 1 ENGINE 2 Fuel tank Diesel Capacity 70 liters 18 5 U S gal to FUEL FILTER from ENGINE t STOP VALVE FUEL LEVEL SENDER DRAIN PLUG Fig 1 6 Fuel System diesel powered trucks with TD27 QD32 12 1 ENGINE The fuel level sender converts the fuel level in the fuel tank into an electric current signal Its construction is shown in Figure 1 7 The resistance element is a variable resistor made of nichrome wire The slider that changes the resistance is connected to the float When the float is at the top level the resistance value between the grounding and terminal is in the range of about 9 5 to 10 5 O As the float lowers the resistance value becomes greater Changes in the resistance are transmitted to the CPU in the combination meter The fuel meter indicator moves in the direction when the resistance is small and moves in the direc
63. PLATE PIN CYLINDER ADJUSTER SPRING SPRING SPRING WHEEL CYLINDER SPRING CABLE Fig 4 14 Wheel Brake Trucks with capacities from 2 0 to 2 5 tons 70 Section D Section PUSHROD SPRING PISTON SECONDARY SHOE CUP BACKING PLATE SPRING PIN SPRING SPRING STRUT LEVER 4 BRAKE SYSTEM Section Shoe expands in this direction Section 13 ADJUSTER 14 SPRING 15 PRIMARY SHOE 16 BRAKE LEVER Fig 4 15 Wheel Brake Trucks with capacities from 1 5 to 1 75 tons and 3 0 to 3 5 tons 71 4 BRAKE SYSTEM 4 1 5 WHEEL BRAKE TROUBLESHOOTING Problem Probable cause Remedy Poor braking Fluid leaks from brake system Repair Maladjustment of brake shoe clearance Check and adjust adjuster Overheated brake Check for dragging Poor contact between brake drum and lining Adjust contact Foreign matter adhered to lining Replace Foreign matter mixed in brake fluid Change brake fluid Maladjustment of brake pedal Adjust Noisy brake Uneven braking Soft or spongy brake Hardened lining surface or foreign matter adhered thereto Replace Deform
64. agnet shift type 12V 1 2 kW Po ap alr qx poa 1 ENGINE 1 ENGINE Charging generator Voltage Output Generation Drive Voltage current regulator Type Water and oil capacities Lubrication oil Cooling water 12V 50A 3 phase a c V belt drive pulley ratio 1 2 15 Transistor type built in charging generator 3 8 1 gal oil pan 3 5 liter 0 92 gal oil filter 0 3 liter 0 08 gal 3 5 liter 0 92 gal 1 ENGINE ALTERNATOR DRAIN PLUG STARTER WATER INJECTION PUMP OIL FILTER DRAIN PLUG U N 10 HEYS I M 10 HEYS nb enb put put kW e Shaft out Shaft out ee e 16 wes 1 ejes V 16 Jo 5 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 Engine speed min 1000 1200 1400 1600 1800 2000 2200 2400 26 Engine speed min TD27 9 032 Fig 1 3 Diesel Engine TD27 QD32 1 ENGINE Item Main Construction Valve system Fuel system Injection pump Plunger diameter x stroke Injection nozzle Fuel feed pump Fuel filter Governor Governing Lubrication Lubrication system Pump Drive Oil pressure regulator Oil pressure indicator Filtration Oil cooler Cooling system Cooling method Cooling fa
65. ays off for a while and then repeats this cycle it indicates that the steering wheel angle sensor or tire angle sensor is defective See 4 Operating status LED 4 Put the steering wheel and the tires in the straight ahead position You can skip this step if truck is in the straight ahead position before the key switch is turned on in step 5 With the key switch turned ON disconnect the plug receptacles from each other 6 Make sure that the LED blinks twice continuously and repeats it 7 Turn the steering wheel from center to clockwise end turn it to counterclockwise end and then return to the center position Caution should be exercised not to allow the tires to slip at each of the turning ends You cannot complete the setting if the steering wheel is not turned more than 1 5 turns from center to end in each direction 8 Make sure the LED comes on If the LED does not stay on but blinks twice and repeats it start all over again 4 Operating status LED Operating status of controller LED Centering is not yet finished 1 blink Controller has been initialized with plug receptacles connected nitial setting mode selected 2 blinks setting error is detected you cannot exit the initial setting mode 1 Initial setting completed ready for operation LED stays on 2 Steering wheel sensor defective 3 blinks e Sensor coil broken Tire angle detection potentiometer defectiv
66. d level If the level is low add appropriate cooling liquid 7 Tighten the radiator cap securely Add cooling liquid to bring level up to 2 3 of the capacity Fig 1 25 Drain Cock Location 26 1 ENGINE 1 1 5 ACCELERATOR PEDAL 1 Gasoline engine The accelerator pedal designed as shown in Fig 1 26 is installed on the floorboard The movement of the pedal is converted into voltage by the potentiometer and outputted to the engine control module Adjustment of K type engine accelerator pedal No Description D a sensor to the accelerator pedal Apply a voltage of 5 12 V output power supply to the AVCC1 and AVCC2 Monitor the APS1 and APS2 output signals at the same time Adjust the sensor mounting angle so that APS1 output is 0 67 to 0 87 V when the accelerator is fully opened and then tighten the sensor mounting bolt securely Under the condition of step 2 make sure the APS2 output is within 0 33 to 0 43 V Make sure the accelerator fully open stroke is within the specified range Step 4 can be controlled according to AWU ouptut but not the stroke With the accelerator fully opened make sure APS1 output is within the range of 4 4 to 4 6 V With the accelerator fully closed make sure APS1 output is 0 67 to 0 87 V 8 LI SENSOR
67. displacement cc Compression ratio Performance Rated speed rpm Rated output kW HP Maximum torque N m kgf m Ibf ft Full load rated fuel consumption g kw h g ps h No load minimum speed rpm Weight kg Ibs Dimensions L x W x H mm in Ignition order Rotational direction TD27 20 25 FD35rss QD32 4 cycle water cooled overhead valve type diesel engine with swirl chamber 4 96 x 92 4 3 78 x 3 62 2663 24 6 2300 41 55 170 17 31 125 2300 253 186 750 259 571 787 x 614 x 722 31 x 242 x 284 4 99 2 x 102 4 3 91 x 4 02 3153 22 2300 44 60 189 19 3 139 4 1800 255 187 750 262 578 794 x 616 x 747 31 3 x 24 3 x 29 4 1 3 4 2 Clockwise when viewed from fan 1 ENGINE 1 1 GENERAL DESCRIPTION This series comes equipped with either a gasoline or diesel engine The engine is installed inside the truck frame along with the drive unit to deliver power to both the drive and hydraulic systems The engine is rubber mounted at four points in the frame ENGINE SIDE BRACKET Apply LOCTITE 262 BRACKET Apply 262 FRAME SID
68. e Wire leading to tire angle sensor or controller is broken 4 blinks Wire leading to tire angle sensor or controller is shorted 3 Power voltage is lower than rated voltage CPU inside controller is defective Controller 15 being initialized 1 Setting error A setting error occurs if the steering wheel is not turned more than 1 5 turns in each of the clockwise and counterclockwise directions or if the steering wheel is returned in midstream through rotation from center to end or vice versa 2 No error is detected LED stays on 3 1 Shorting between V terminal and signal output terminal of tire angle sensor 2 Steering wheel angle sensor has one of the following errors e Shorting between sin drive signal wires e Shorting between cos signal wires e Shorting between sin signal wires 3 Solenoid valve driving FET is defective 84 6 HYDRAULIC SYSTEM 6 HYDRAULIC SYSTEM 2013 FHG2013 2513 FHD15r3 2513 0201 FHD2513a FG35rss 18 0 FD2515 FHD30 FHG3073 Ts FD3013 FD35r3s Main pump Type Gear type Model name KFP2328 KFP2325 SGP1A30 8 SGP1A27 SGP1A36 SGP1A32 Discharge 28 2 cm rev 24 5 em rev 30 8 cm rev 27 8 em rev 36 6 cm rev 33 2 cm rev Control valve Type Model name 2 spool sliding type with relief valve flow divider and tilt lock valve KVMF 70VPF MSV04A Pressure setting Main 17 7 MPa 180 kgf cm
69. e the piston to the right so that the piston comes in close contact with the area 0 on the case This prevents the oil from flowing cut of the cylinder to stop the lowering of the forks Fig 6 39 Flow Rate Smaller than Setting Fig 6 40 Flow Rate Greater than Setting 104 6 HYDRAULIC SYSTEM e 9 gt 4 N Fig 6 41 Lift Cylinder VM 0A7 105 Details of mast support PISTON HEAD SHIM WIPER SEAL U RING HOLDER BUSHING CYLINDER ROD LOCK RING PISTON WEAR RING PACKING SNAP RING SHEAVE CHAIN ANCHOR PIN ADJUSTMENT NUT LOCK NUT COTTER PIN 6 HYDRAULIC SYSTEM Details of cylinder support
70. e also hope you will understand that due to on going improvements of the parts and components the values and some of the descriptions in this manual are subject to change without notice February 2010 TCM CORPORATION The specifications and equipment covered in this manual will vary according to the intended destination In our documents and manuals these differences are coded according to the destination as follows Export specification code Destination EXA North America EXB All regions excluding North America EU member countries Oceania and South Africa EXC Oceania EXE EU member countries excluding Scandinavia EXK South Africa EXN Scandinavia No SEF 0F7BE No SEF 0F7BE 0219 08 5 0859 0195 0826 ococ 0855 orsz 14310m JUS gt LL XI SOT 220CI69 2 c9c 64 076 002 IV I X 6 C CC X 001 X 076 Suroeds x104 O ssouyory L x 4 x 8 9215 L 91 9 61 566 1894 310 c 9 056 sc 068 I 951 ScvI 1891 Quoy peoip eseqioouA eer 0011 18 5211 6616 C 011 OST T8 0 07 0401 5916 jseur 448194 I619 0 piens 16 1V819 YSU 6I9 0 1 6 02 0081 _ 176 0107
71. e tilt cylinders tries to flow out the port A2 However since no pilot pressure is supplied the pilot spool does not move so that the return passage to the oil tank is closed This prevents the tilt cylinders from operating See Figure 6 28 98 LOAD CHECK FORT A1 PILOT SPOOL 2 FORT B2 PASSAGE PARALLEL UNLOAD PASSAGE 6 HYDRAULIC SYSTEM 4 Accessory section option In LOAD CHECK PARALLEL The oil from the pump flows through the unload PASSAGE passage back into the oil tank The ports A and B are blocked so that no oil pressure 15 supplied to the cylinder See Figure 6 29 PASSAGE PASSAGE Fig 6 29 b Spool pulled out The unload passage is closed and the oil from the pump flows through the parallel passage to push open the load check and enters the cylinder through the port A The oil returning from the cylinder flows through the port B past the tank passage back into the oil tank If the load inside the cylinder is higher than the relief valve pressure setting the relief valve opens to allow oil to return into the oil tank The spool is returned to neutral by the return spring See Figure 6 30 c Spool pushed in The unload passage is closed and the oil from the pump flows through the parallel passage to push open the load check and enters the cylinder through the port B The oil returning from the cylinder flows through the port A past t
72. ed and the schematic diagrams of their control systems are shown in Figs 1 19 and 1 20 The amount of fuel mixing ratio and ignition timing are controlled by the ECM based on the information about the amount of accelerator pedal depression the quantity of air to be sucked and rotating angles of the crankshaft and camshaft The amount of accelerator pedal depression is detected by the accelerator sensor shown in Fig 1 21 and the quantity of air to be sucked 15 detected by the air flow sensor installed on the air horn The rotating angle of the crankshaft is detected by the position sensor POS installed on the front cover of the engine and the rotating angle of the camshaft by the position sensor PHASE installed inside the chain housing of the engine CRANKSHAFT POSITION POS SENSOR L Nec POSITION PHASE SENSOR Fig 1 16 PHASE 19 1 ENGINE Injector LPG engines The amount of fuel to be injected 1s controlled by the injectors Four injectors are installed on the intake manifold and independently controlled respectively MAIN INJECTOR HARNESS CONNECTOR for main injector FU PRESSURE SENSOR ASSIST INJECTOR B Throttle The quantity of air to sucked is controlled by the throttle shown in Fig 1 18 The throttle valve is driven by a motor which is controlled by the THROTTLE INTAKE MANIFOLD Fig 1 18 Throttle
73. ed backing plate Replace Deformed or improperly installed shoe Repair or replace Uneven wear of lining Replace Defective wheel bearing Contaminated lining Replace Replace Maladjustment of brake shoe clearance Check and adjust adjuster Malfunctioning wheel cylinder Repair or replace Defective shoe return spring Replace Run out of drum Repair or replace Improper inflation pressure of tire Fluid leaks from brake system Adjust Repair Maladjustment of break shoe clearance Check and adjust adjuster Air mixed in brake system Bleed air out of system Maladjustment of brake pedal 72 Adjust Truck Model Item 5 STEERING SYSTEM 5 STEERING SYSTEM 2013 FD201 30 2013 20 251 25 FD3013 25 25 FHD30134 FHG1513 FHD1513 18 FHD1813 FG35rss FD3513s Steering axle Type King pin spacing King pin angle Toe in Camber Caster Steering angle Inner wheel Outer wheel Discharge Power cylinder Type Cylinder bore Piston rod diameter Stroke Flow divider valve Flow rate Pressure setting Center pin supported Elliot type with box shaped cross section of weld construction 780 mm 30 71 in 810 mm 31 89 in 02 12 02 78 9 54 1 Open centered non load reaction type
74. edback not function properly the steering wheel might turn by itself when the operator does not turn it 80 5 STEERING SYSTEM 4 When the pump fails to operate normally If the pump fails to supply pressure oil to the orbitrol the orbitrol can serve as an emergency manual steering device Even if the orbitrol does not receive pressure oil from the pump you can rotate the spool by turning the steering wheel However when the spool turns 89 it hits against the cross pin which in turn turns the rotor through the drive shaft This way the metering device of the orbitrol works as a hand pump to send oil to the steering cylinder At this time the check valve provided between the return port and the suction port opens to allow the oil to flow from the cylinder to the suction side making it possible to steer the truck manually 5 1 4 POWER CYLINDER The power cylinder is attached to the steering axle and operated by oil from the orbitrol The cylinder body is secured to the axle with both ends of the piston rod connected to the knuckles with joints The cylinder cap has a bushing an oil seal and a dust seal and is assembled on the cylinder with two bolts BUSHING BUSHING 6 5 mm AL 0 256 in Tightening torque 27 7 41 5 N m 282 5 423 2 kgf cm 20 43 30 6 Ibf ft BUSHING PISTON ROD PACKING O RING ROD PACKING DUST SEAL
75. es disable for any reason The rotor is mechanically linked to the sleeve with the drive shaft so that feedback operation is possible The sleeve is interlocked with the motor s rotor through the cross pin and drive shaft while the spool is splined to the steering shaft EPACS CONTROLLER CONTROLLER STATUS DISPLAY LED DEVIATION CONTROL VALVE SOLENOID Fig 5 5 Orbitrol 78 1 Operation of orbitrol a In Neutral While the steering wheel is in straight position the oil from the pump flows through oil passage to oil groove 2 The sleeve has 24 oil holes 3 which are now in line with the holes 4 in the spool so that the oil that flowed into groove 2 passes through oil holes 3 and 4 to space 5 between the spool and drive shaft Then the oil flows through spool groove 6 and sleeve groove 7 back to the oil tank Since cylinder ports 00 and are respectively open to oil holes 18 and 7 in the sleeve but not to groove nor 19 in the spool the oil in the cylinder does not go any where Oil passage 19 that leads to the hydraulic motor is open to oil hole in the sleeve which is used as the inlet and outlet for the hydraulic motor but not to grooves 13 nor 9 in the spool and thus the oil remain unmoved b When steering wheel is turned counterclockwise As the steering wheel is turned counterclockwise the grooves in the spool shift to the left in relation with the holes and grooves in t
76. g steering When the steering wheel is turned the PF flow pressure MF FLOW MF THROTTLE FLOW increases and thus the entire oil pressure of the hydraulic system also increases This allows more oil to flow to the MF flow side because it is lower in pressure than the PF mom flow side For this reason the flow rate of oil to the control orifice drops to create a pressure differential across the AD TR NE Pup control orifice thus shifting the FD spool into the direction RELIEF that closes the MF throttle hole so that the pressure CHECK differential across the control orifice is maintained to keep TANK PASSAGE to L OAD the priority flow at the fixed flow setting See Figure 6 20 Fig 6 20 MF pressure lt PF pressure b MF low pressure is higher than PF flow pressure during load handling When the load handling means is operated the MF flow pressure increases and thus the entire oil pressure of the hydraulic system also increases Since the PF flow pressure is lower than the MF flow pressure the priority flow begins to increase Therefore the pressure differential across the control orifice increases so that the FD spool moves in the direction that closes the PF throttle hole to keep the control flow constant See Figure 6 21 Fig 6 21 MF pressure gt PF pressure 306 2 Lift section a In netural The oil discharged from the pump flows through the unload passage back to the oil tank The
77. gram STEERING WHEEL DEVIATION CONTROL UNIT STATUS INDICATING LED OUTPUT OF P D ANALOG gt COMPENSATION VALVE CIRCUIT DRIVING SIGNAL STEERING ANGLE SENSOR INPUT OF TIRE ANGLE DETECTION BUFFER gt POTENTIOMETER CENTER POSITION SETTING INPUT OF POWER 7 NOISE M DC DC ze SUPPLY DC10V FILTER CONVERTER DC26 4 V 2 Connection diagram INITIAL SETTING w TERMINAL E 241 NORMALLY CLOSED VALVE VALVE 2A CONTROL UNIT 6195 0003 Sumitomo Denso STEERING WHEEL DEVIATION CN1 6195 0054 Sumitomo Denso 22 DC10V 26 AV POWER SUPPLY INPUT about 50 mA with solenoid valve off 1 CONTROLLER OPERATING STATUS LED 2 1 be selected according to the potentiometer mounting position 2 is recommended TIRE ANGLE DETECTION OUTPUT VOLTAGE 0 POTENTIOMETER TIRE ANGLE DETECTION POTENTIOMETER I 0V STEERING WHEEL ROTATIONAL POSITION LEAD OUT WIRE FROM CONTROLLER AUTOMOTIVE HEAT RESISTANT LOW VOLTAGE WIRE AEX 0 5 f Sumitomo Denso Fig 5 41 Schematic and Connection Diagrams 28 5 STEERING SYSTEM 3 How to set the center position of the steering wheel D Turn off the key switch and connect the plug receptacles M and F shown in Figure 5 10 2 Turn the key switch on 3 Make sure the LED blinks once and then repeats it If the LED blinks three or four times and st
78. he sleeve so that holes 4 in the spool get out of line with holes 3 in the sleeve The oil that has flowed into groove 2 thus far begins to flow into hole 12 in the sleeve passing through grooves Q3 and 13 the spool hole 4 in the sleeve and oil passage 5 in the housing to the hydraulic motor The hydraulic motor thus rotates in the counterclockwise direction and the oil discharged from the hydraulic motor flows through oil hole in the sleeve groove 00 in the spool and oil hole 8 in the sleeve to the cylinder port L in the housing and thus actuates the steering cylinder 79 5 STEERING SYSTEM 5 STEERING SYSTEM The returning oil from the power cylinder flows passing through the cylinder port IL groove 1 in the valve housing oil hole 7 in the sleeve groove 19 in the spool oil hole 02 in the sleeve and groove 8 in the valve housing back to the oil tank c When steering wheel is turned clockwise As the steering wheel is turned clockwise the grooves in the spool shift to the right in relation to the oil holes and grooves in the sleeve so that oil holes 4 AOR in the spool get out of line with holes 9 the sleeve 6 88 i The oil that has flowed into groove 2 thus far begins to flow into oil hole 2 in the sleeve and then flows through grooves 03 and 9 in the spool oil hole 4 in the sleeve and oil passage 19 in the valve housing
79. he tank passage back into the oil tank If the load inside the cylinder is higher than the relief valve pressure setting the relief valve opens to allow oil to return to the tank passage The spool 15 returned to neutral by the return spring See Figure 6 31 99 6 HYDRAULIC SYSTEM 5 Operation of main relief valve a When relief valve is closed If the circuit oil pressure is lower than the relief valve pressure setting the relief valve is closed The oil at the port P flows through the orifice in the poppet to fill the spring chamber The oil inside the spring chamber acts on the pilot poppet which is however forced against the seat by spring pressure to block oil flow to the tank passage The main poppet is closely seated to the sleeve by both the spring force and the difference in area on which the oil pressure acts to block the oil passage to the tank port Therefore all the oil sent into the circuit flows to the operating area See Figure 6 32 b When relief valve opens If the circuit oil pressure becomes higher than the relief valve pressure setting the relief valve opens That is when the oil pressure in the circuit reaches the pilot poppet pressure setting the pressure oil pushes up the pilot poppet to flow into the tank passage This causes a pressure differential across the orifice in the main poppet to push open the main poppet to allow the oil to flow from the port P to the tank passage thus con
80. input shaft torque To prevent this from happening the stator wheel is designed to rotate freely when reaction torque acts in the reverse direction The output torque is kept equal to the input torque so that highly effective operation is ensured Since the phase of torque transmission is converted by the mechanical means this type of torque conversion is called 2 phase type which ensure smooth and effective operation The pump wheel of the torque converter is connected through the input plate to the engine flywheel with area of the pump wheel boss driving the charging pump TURBINE WHEEL PUMP WHEEL STATOR WHEEL Detail of ONE WAY CLUTCH Fig 2 3 Torque Converter 40 2 AUTOMATIC TRANSMISSION SYSTEM 2 1 2 CHARGING PUMP The charging pump consists of a drive gear driven gear a case and a stator support as shown in Figure 2 4 and is incorporated into the torque converter housing The drive gear 15 driven by the pump wheel boss of the torque converter to pick up oil from the lower part of the transmission case and send it to the transmission and the torque converter Tightening torque 0 98 2 94 N m 0 1 0 3 kgf m 0 723 2 17 Ibf ft OIL SEAL DRIVE GEAR Tightening torque DRIVEN GEAR 2 04 2 65 kgf m 14 75 19 18 Ibf ft Section
81. ishi shimbashi Minato ku Tokyo 105 0003 Japan FAX JAPAN 81 3 35918154 All rights reserved JB 1002010 HO Printed in Japan
82. it spark smoke or use fire near the battery unit Since flammable gas is always released from the battery there is a danger of causing an explosion 2 The battery electrolyte is dilute sulfuric acid It will cause burns if it gets on the skin If electrolyte comes in contact with the skin flush with water It can cause blindness if it gets into eyes If electrolyte gets into your eyes flush your eyes out with water and get to a doctor 123 8 ELECTRIC WIRING SS3NHVH 01 3 VIV V 3 VIV V 1944 IVHLON 9 MOO TH3 NI 01 32071 141190 68 18 89 893227089 WHV IV 9 9 6L 61 9 L AV Tau ALAAVS 9 0398 ALIHM 0 n 9 1457 ME TUE SSANYVH JAIM IE 141 HOLIMS 01 SS 9 8 1 Wire Harness Front Guard 919 201 A9 MA SA 5 98 96 06 00L 96 NYO
83. m 1 969 in 131 mm 5 16 in Fig 4 3 Brake Pedal Trucks with capacities from 2 0 to 3 5 tons 1 2 64 4 BRAKE SYSTEM PEDAL STOPPER R PEDAL STOPPER L Detail of B 85 mm 3 mm 3 35 in 0 02 in Detail of brake master cylinder Detail of brake lamp switch Fig 4 4 Brake Pedal Trucks with capacities from 2 0 to 3 5 tons 2 2 65 4 BRAKE SYSTEM 4 1 2 MASTER CYLINDER The master cylinder has a structure as shown in Figure 4 5 and is fitted to the bracket on the brake pedal Built in the master cylinder are a spring and a piston which are kept in position by a snap ring The piston has a primary cup and a secondary cup and is slid in the cylinder by operating the brake pedal SNAP RING from RESERVE to WHEEL SPRING PRIMARY CUP SECONDARY CUP CHECK VALVE PISTON Fig 4 5 Mas
84. n Drive Pump Drive Water temperature regulator Type Temperature at which valve begins to open Temperature at which valve opens fully Starting motor Type Voltage Output Stopping device Engine preheater Overhead valve type Bosch distributor type 10 mm x 2 2 mm 0 394 in x 0 087 in Throttle type Vane type Filter paper type with sedimenter Centrifugal all speed control Fuel lubrication Gear type Gear driven Regulator valve Switch type Full flow filter paper type Incorporated water cooling Water cooling Pusher type with 6 blades O D 380 mm 14 96 in Belt drive Centrifugal type Belt drive Wax type 82 C 179 6 LI 95 C 1203261 Magnet shift type 12V 2 5 kW Fuel cut off type Provided QGS C 11 mm x 2 88 mm 0 433 in x 0 113 in E gis O D 430 mm 16 93 in lt 2 8 kW Provided 1 ENGINE 1027 QD32 Item Charging generator Type A C generation lt diode rectification Voltage 12V Output 60 Drive Belt drive Automatic charging regulator IC type lt Reference data Oil sump capacity Cooling water volume Valve clearance Suction valve Exhaust valve Valve operation Suction valve opens at BTDC closes at ABDC Exhaust valve opens at BBDC closes at ATDC Injection timing BTDC Injection start pressure Compression pressure built in generator 5 5 1 4
85. n the tension pulley nut 2 Adjust the adjust bolt so that the fan belt has a deflection of 10 mm when the area is pressed with a force of 98 1 10 kgf 8 Tighten the tension pulley nut ADJUSTMENT PULLEY NUT TD27 QD32 Fig 1 23 Fan Belt 1 ENGINE 8 Checking cooling liquid Check the cooling liquid in the reserve tank If the level is below the LOW mark add cooling liquid of appropriate concentration listed in Table 1 1 to bring level Up to the FULL mark when the engine is warm 2 3 of the capacity when the engine is cold 8 Charging cooling liquid D Shut off the engine and wait for more than 30 minutes 2 Remove the radiator cap and loosen the drain cock at the radiator side 3 Loosen the drain cock at the engine side to drain off Fig 1 24 Reserve tank the cooling liquid 4 Tighten the drain cocks at both the radiator and the engine sides 5 Add cooling liquid of appropriate concentration listed in Table 1 1 into the radiator The rate of addition is less than 2 liter min Table 1 1 Unit liter K21 TD27 QD32 1 5 to 1 75 ton trucks 8 0 2 11 2 0 to 3 5 ton trucks 9 0 2 38 9 9 2 62 Coolant concentration 30 for general climate regions 50 for cold regions 6 After adding cooling liquid start the engine and let it run at idle rpm for a couple of minutes and check the cooling liqui
86. of a gear tooth and then back it off 1 4 1 3 of a turn SPEED SENSOR OPTION LOCK NUT TAPERED ROLLER BEARING Tightening torque DRIVEN GEAR 234 5 30 6 kgf cm TAPERED ROLLER 17 0 2 21 Ibf ft BEARING D A DRIVE PINION GEAR WASHER CROSS CASE PLANE HALF ADJUSTMENT NUT TAPERED ROLLER BEARING SIDEGEAR PINION GEAR RING GEAR THRUST WASHER CROSS CASE torque FLANGE HALF 458 9 51 0 kgf cm 1 SPIDER 33 2 3 69 Ibf ft 16 BEARING Tightening torque BALL BEARING 15 23 3 N m 234 5 30 6 kgf cm DRIVE GEAR 4 C 17 0 2 21 14 8 ROLLER BEARING OIL SEAL INPUT FLANGE 3 c Tightening torque 216 20 N m 2203 203 9 kgf cm 199 3 1486 Tightening torque Tightening torque 78 10 N m 157 20 N m 795 102 0 kgf cm 1601 203 9 kgf cm 57 5 7 38 Ibf ft 115 8 14 8 Ibf ft 10 Fig 3 9 Reduction Gear and Differential Trucks with capacities from 2 0 to 3 5 tons 59 3 DRIVE AXLE NOTE 60 4 BRAKE SYSTEM 4 BRAKE SYSTEM Truck Model Taek Mode FG3015 15 2013 FD201 41813 FHG2013 20 03013 15 25 25 0 1
87. on ratio GAS LPG Exclusive Dual fuel Performance Rated speed rpm Rated output kW PS HP GAS Exclusive and Dual LPG Exclusive LPG Dual Max torque N m kgf m Ibs ft rpm GAS Exclusive and Dual LPG Exclusive LPG Dual Full load rated fuel consumption g kW h g PS h rpm GAS Exclusive and Dual LPG Exclusive LPG Dual No load minimum speed rpm Weight kg Ibs GAS LPG Exclusive Dual fuel Dimensions Ignition order Rotational direction 1 ENGINE 20 2513 0 K21 1 ENGINE 20 25 FHG3013 FG35rss K25 4 cycle water cooled in line overhead valve type gasoline engine 4 89 x 83 0 4 3 50 x 3 27 2065 126 8 7 9 3 8 7 2700 38 7 52 61 51 9 40 0 54 31 53 7 39 8 54 11 53 4 148 15 13 109 2 2000 151 15 4 111 4 2000 150 15 31 110 6 2000 303 2233 1600 230 1693 2000 235 1733 2000 700 rpm off the truck 151 333 151 333 152 335 4 89 x 100 4 3 50 x 3 94 2488 151 8 44 7 60 8 59 9 44 6 60 71 59 8 44 4 60 4 59 4 174 17 71 128 4 1600 185 18 4 136 5 1600 183 18 71 135 0 1600 302 2221 1600 215 1581 1600 223 1641 1600 152 335 152 335 153 337 719 4 x 568 x 726 28 3 x 22 4 x 28 6 1 3 4 2 Clockwise when viewed from the fan 1 ENGINE Diesel engine Name Type No of cylinders Bore x stroke mm in Total
88. plunger 15 pulled out the neutral oil passage is blocked up The oil from the parallel feeder pushes open the load check valve and flows to the cylinder port A The oil returning from the cylinder port B flows to the low pressure oil passage and back into the oil tank The plunger is pushed back to neutral by the return spring Tilt lock valve operation a b c Plunger pulled out With the plunger pulled out the oil flows in the same manner as in shown Figure 6 15 Figure 6 16 shows a spool section in neutral with a tilt lock valve incorporated inside Plunger pushed in pump in operation When the plunger 15 pushed the oil from the pump flows from the cylinder port B into the cylinder The oil from the cylinder enters the hole A in the plunger to move the poppet Therefore the oil returning from the cylinder flows through the holes and B in the plunger passing through the low pressure oil passage back into the tank Plunger pushed in pump at rest If the plunger is pushed in with the pump at rest the oil won t flow to the cylinder port B and the pressure at area also won t rise The poppet does not move so that the cylinder won t move and thus the oil at the cylinder port A also does not return back into the tank 94 6 HYDRAULIC SYSTEM 2 0 to 3 5 tons The control valve consists of FDM front and rear covers and a combination valve which are assembled with three bolts
89. port A1 is blocked so that no pressure oil is supplied to the lift cylinders See Figure 6 22 b Spool pulled out when forks are lifted The unload passage 1s closed so that the oil from the pump flows through the parallel passage to push open the load check and lock poppet and enters the lift cylinders through the port A1 The spool is returned to neutral by the return spring See Figure 6 23 c Spool pushed in when forks are lowered When the spool is pushed in the unload passage is not closed and thus the oil from the pump returns to the tank passage The oil that has the lift cylinders through the port A1 flows to the return passage returning into the oil tank The spool is returned to neutral by the return spring See Figure 6 24 97 6 HYDRAULIC SYSTEM to PORT A1 LOAD CHECK PARALLEL PASSAGE UNLOAD PASSAGE EL LI ge uisi Ero 6 HYDRAULIC SYSTEM 3 Tilt section a In neutral The oil discharged from the pump flows passing through the unload passage back into the oil tank The ports A2 and B2 are blocked so that the no pressure oil is supplied to the tilt cylinders b Spool pulled out when upright is tilted back When the unload passage 15 closed the oil from the pump flows through the parallel passage to push open the load check and enters the tilt cylinders through the port A2 The oil ret
90. quum je MS 99399 9 I t L 179 5 0 6 sd 807 voL AINO O 0109130 hes 5 AINO M0 90L BAA 1 0I0M310 X90 1831NI AVIY 1 CICM3108 9VIV HOLIMS 4 4 6 44 1 6 144 9X 82 X50113n Svea 2218 VIMVIV 9X I az LI LI YAWIL E NOLIVNIBINO 919195373 8 1 4 1
91. r and lock nut and secure the lock nut by bending the tang on the lock washer Starting force 49 147 1 N 5 15 kgf 11 33 1 165 3 6 Measuring Starting Force 5 Assembling wheels Put a tube and flap in a tire and assemble the rims observing the following conditions Note 1 The air valve should be pointed outward being matched with the rim notch 2 The rim assembling bolts should be installed with their heads pointing the outside of the truck Configuration of rim assembling bolt 1 TIRE 4 RIM INSIDE 2 TUBE 5 RIM OUTSIDE 3 FLAP 6 ASSEMBLING BOLT Fig 3 7 Wheel Assembly Trucks with capacities from 1 5 2 0 to 2 5 tons 2563 3 DRIVE AXLE 3 1 1 REDUCTION GEAR AND DIFFERENTIAL The reduction gear is located on the input shaft of the differential and reduces the power from the transmission transmitting it to the differential The differential is fitted to the differential carrier through ball bearings with bearing caps and housed in the axle housing The differential cross case is a split type containing two side gears and four pinion gears with thrust plates installed between the cross case and each gear according to their backlash The pinion gear is supported by the spider On the outer diameter of the cross case 15 a ring gear bolted Each side gear is splined to the drive shaft so that the power sent from the transmission through the reduction gear is further reduced and differen
92. right assembly is mounted on the drive axle The outer channel is supported to the frame through the tilt cylinders which extend and retract to tilt the upright forward and backward respectively The end rollers are installed on the lower outside of the inner channel and upper inside of the outer channel with shims INNER CHANNEL OUTER CHANNEL END ROLLER SHIM END ROLLER SHIM SLIPPER SHIM PIN CAP BUSHING Fig 7 1 Outer and Inner Channels VM 0A7 116 7 LOAD HANDLING SYSTEM INNER CHANNEL OUTER CHANNEL END ROLLER SHIM END ROLLER SHIM SLIPPER SHIM PIN CAP BUSHING Fig 7 2 Outer and Inner Channels VM 2N5 VM 2N9 VM 2Y5 117 7 LOAD HANDLING SYSTEM 7 1 2 CARRIAGE The carriage has end rollers installed with bearings on its end roller shafts welded to the carriage The end rollers are shim adjusted and roll along inside the inner channel assembly The fore and aft load 1s sustained by the end rollers and the lateral load by the side rollers provided at the lower part of the carriage When the forks are raised to the top position the top end rollers come out beyond the top of the upright FORKS STOPPER SPRING HANDLE CARRIAGE END ROLLER LOCK
93. sage to the tank port Therefore all the oil sent into the circuit flows to the operating area See Figure 6 36 101 6 HYDRAULIC SYSTEM b When port relief valve opens If the circuit oil pressure becomes higher than the relief PORTAORB valve pressure setting the pressure pushes up the pilot poppet to flow into the tank passage This causes a pressure differential across the orifice in the intermediate piston so that intermediate piston is forced against the front end of the pilot poppet As a result the oil pressure in the spring chamber drops to cause a pressure differential across the main poppet This opens the main poppet and thus the TANK PASSAGE passage to the tank port is also opened to allow the pressure oil to flow into the tank See Figure 6 37 6 37 Port Relief Valve open c Anticavitation If the oil pressure at the port A or B is lower than the oil pressure in the tank passage a force occurs in the direction that opens the main poppet because of the difference in area across the main poppet This force opens the main poppet to direct the oil from the tank passage into the port A or B thus preventing the actuator pressure from going negative See Figure 6 37 102 6 HYDRAULIC SYSTEM 6 1 3 VALVE CONTROLS The control valve plungers are actuated with the levers as shown in Fig 6 38 with each lever mounted on a single shaft The shafts are supported by brackets which are attached to
94. ssembly 42 2 AUTOMATIC TRANSMISSION SYSTEM 2 Transmission oil pressure circuit As the engine is started and the charging pump is driven oil is picked up from the lower part of the transmission case to flow through the strainer to the main relief valve where it is regulated to the specified clutch oil pressure The oil relieved from the main relief valve flows passing through the torque converter oil cooler and inline filter to some parts of the truck for cooling and lubrication before returning into the transmission case The oil pressure inside the torque converter is controlled to a specified value by the torque converter relief valve D In neutral With the solenoid vale in neutral the oil is blocked by the solenoid valve and therefore all the oil supplied from the charging pump flows to the torque converter TORQUE CONVERTER OIL COOLER INLINE FILTER TORQUE CONVERTER RELIEF VALVE 0 39 0 69 MPa RE 3 98 7 04 kgf cm 56 6 100 1 psi MAIN RELIEF VALVE INCHING VALVE x DEEST 1 08 1 47 MPa 11 01 14 99 kgf cm 156 6 213 2 psi COIN FILTER gt 1 LI TRANSMISSION CONTROL VALVE CHARGING PUMP SOLENOID VALVE SHUTTLE VALVE
95. ter Cylinder The check valve works to leave some pressure inside the wheel cylinder and brake pipe in order to lock up the piston cup of the wheel cylinder This prevents oil leakage and the occurrence of vapor lock 66 4 1 3 WHEEL BRAKE The wheel brake is a duo servo type and is mounted on each of both ends of the drive axle The wheel brake consists of two pairs of brake shoes a wheel cylinder and an adjuster The brake shoe one end of it being connected to the anchor pin and the other end to the adjuster is forced against the backing plate with a hold spring and pin In addition the wheel brake is provided with a parking brake mechanism and an automatic clearance adjuster 1 Wheel brake operation As the wheel cylinder presses the primary and secondary shoes with an equal force to the brake drum they turn together with the brake drum until the secondary shoe top comes in contact with the anchor pin When the secondary shoe top comes in contact with the anchor pin the brake lining to brake drum friction force is produced and the primary shoe presses against the secondary shoe with force greater than offered by operation of the wheel cylinder thus providing large braking force See Fig 4 6 In reverse travel the braking force works in the reverse direction See Fig 4 7 2 Parking brake The parking brake unit is built in the wheel brake unit and consists of a lever and a strut The lever is pinned to the primary
96. tiated by this device to drive the drive shaft 3 DRIVE AXLE 0 4 0 5 mm 0 016 0 02 in Let the front end of the speed sensor come in slight contact with the tip of a gear tooth and then back it off 1 4 1 3 of a turn SPEED SENSOR OPTION Tightening torque 57242 Tightening torque 1 LOCK NUT Apply ThreeBond 1324 1458 2 hei 2 TAPERED ROLLER 33 2 3 69 Ibf ft BEARING DRIVEN GEAR 4 TAPERED ROLLER BEARING DRIVE PINION GEAR 6 WASHER CROSS CASE PLANE HALF ADJUSTMENT NUT TAPERED ROLLER BEARING SIDE GEAR PINION GEAR RING GEAR THRUST WASHER CROSS CASE FLANGE HALF SPIDER Tightening torque BEARING 1804 203 9 kgf om 115 8 14 8 Ibf ft ROLLER BEARING Apply ThreeBond 1324N OIL SEAL Tightening torque 45 5 N m 458 9 51 0 kgf cm INPUT FLANGE 33 2 3 69 Ibf ft Apply ThreeBond 1324N Tightening torque 78 10 N m 795 102 0 kgf cm 57 5 x 7 38 Ibf ft Apply ThreeBond 1324N 3 8 Reduction Gear and Differential Trucks with capacities from 1 5 to 1 75 tons 58 3 DRIVE AXLE 0 4 to 0 5 mm 0 016 to 0 02 in Let the front end of the speed sensor come in slight contact with the tip
97. tion when the resistance value 15 large In addition if the float lowers near to the bottom the CPU sends the signal to light the fuel lamp to inform the operator that fuel should be added C FUEL LEVEL SENDER FUEL LAMP BATTERY Resistance value 0 10 0 5 19 32 1 0 49 5 87 1 5 Fig 1 7 Fuel Level Sender 13 1 ENGINE ENGINE COOLING FUEL METER WATER TEMP GAUGE 1 Car v BOB HOUR METER LOAD HANDLING AND TRAVELING INTERLOCK WARNING LIGHT PREHEATER INDICATOR FOR DIESEL TRUCKS NEUTRAL WARNING LIGHT ENGINE OIL PRESSURE WARNING LIGHT BATTERY CHARGE WARNING LIGHT FUEL LEVEL WARNING LIGHT Fig 1 8 Combination Meter 14 1 ENGINE 3 Fuel Filter Diesel The fuel filter removes dust and dirt from the fuel to be supplied to the engine It is located on the fuel tank The fuel filter for the diesel engine model also removes water from the fuel LEVEL SWITCH DRAIN COCK for diesel engine model Fig 1 9 Fuel Filter Diesel engine Replacement of fuel filter There is no need to replace the fuel filter of the gasoline engine because it is incorporated into the fuel pump 1 Using a filter wrench remove the filter Replacement criteria Damage or clogging 2 Apply fuel oil on the packing of a new filter and
98. to the hydraulic motor The hydraulic motor thus rotates in the clockwise direction and the oil discharged from the hydraulic motor flows through oil hole 4 in the sleeve groove 16 in the spool and oil hole 7 in the sleeve to the cylinder port R in the housing and thus actuates the power cylinder The returning oil from the power cylinder flows passing through the cylinder port L groove in the housing oil hole 18 in the sleeve groove 19 in the spool oil hole Q2 in the sleeve and groove 9 in the housing back to the oil tank Fig 5 8 2 Relationship between the rotating speed and operating force of the steering wheel The force required to operate the orbitrol is basically a valve operating force the force required to compress the centering spring 2 9 N m 0 3 kgf m 2 14 Ibf ft That is there is no mechanical linkage between the steering wheel and the tires and thus the operating force of the steering wheel remains constant regardless of the rotating speed of the steering wheel The discharge of oil from the orbitrol rotor to the steering cylinder is 96 cc revolution 3 Neutral feedback of orbitrol The neutral feedback function of the orbitrol is performed by the valve switching over the oil passages according to the reaction force of the centering spring If the steering wheel is turned and then released with the engine turned off it will automatically return to the straight ahead position Should the neutral fe
99. trolling the oil pressure in the circuit See Figure 6 33 100 PILOT POPPET MAIN POPPET SLEEVE SPRING ORIFICE CHAMBER Fig 6 32 Main Relief Valve closed Fig 6 33 Main Relief Valve open 6 HYDRAULIC SYSTEM 6 Operation of PF relief valve The PF relief valve is a direct acting type The main MAIN POPPET poppet is closely seated to the valve body by the spring If the PF flow pressure is higher than the pressure setting of the relief valve main poppet opens to direct the PF flow to the tank passage See Figures 6 34 and 6 35 1 TANK PASSAGE Fig 6 34 PF Relief Valve closed cm 8 Fig 6 35 PF Relief Valve open 7 Operation of port relief valve a When port relief valve is closed Bids If the circuit oil pressure is lower than the pressure POPPET setting the relief valve is closed The oil at the port A or B flows through the orifice in the intermediate piston inside the main poppet to fill the spring chamber The oil in the spring chamber acts on the pilot poppet which is however forced against the seat SPR NG by spring pressure to block oil flow to the tank passage CHAMBER TANK ORIFICE The main poppet is closely seated to the sleeve by both spring force and in area on which the Fig 636 Port Relief Valve closed oil pressure acts to block the oil pas
100. urning from the tilt cylinders flows through the port B2 and tank passage back into the oil tank If the load inside the tilt cylinders is higher than the relief valve pressure setting the relief valve opens to allow oil to return into the tank passage The spool is returned to neutral by the return spring See Figure 6 26 c Spool pushed in when upright is tilted forward With the unload passage closed the oil from the pump flows though the parallel passage to push open the load check and enters the tilt cylinders through the port B2 The oil returning from the tilt cylinders enters at the port A2 but is blocked by the tilt lock valve However as the oil pressure rises the pilot spool moves in the direction that compresses the spring so that the oil at the port A2 flows through the oil passage inside the spool back into the oil tank If the load inside the tilt cylinders is higher than the relief valve pressure setting the relief valve opens to allow oil to return to the tank passage The spool is returned to neutral by the return spring See Figure 6 27 d Tilt lock mechanism The tilt spool is provided with a tilt lock mechanism that prevents the tilt cylinders from moving when the tilt lever is placed in the forward tilt position with no oil flow to the main valve If the spool is pushed in the tilt lever is placed in the forward tilt position with no oil flow from the pump the oil at the loaded side inside each of th
101. ween the high pressure side HP and the low pressure side so that the poppet D is opened to allow the oil to flow directly to the low pressure oil passage LP If the pressure in the high pressure oil passage HP is lower than the pressure in the low pressure oil passage LP the poppet D opens due to the difference in area between and to allow enough oil to flow from the low pressure oil passage LP into the high pressure oil passage HP to fill the space 92 Fig 6 9 Fig 6 11 6 HYDRAULIC SYSTEM 2 Tilt spool section Figure 6 13 shows sectional views of the tilt spool section The plunger attached to the housing is kept in neutral by the return spring The plunger incorporates a tilt lock valve LOAD CHECK VALVE RETURN SPRING LOW PRESSURE PASSAGE Fig 6 13 Tilt Spool Section B Tilt spool section operation a In neutral When the plunger is in neutral position oil discharged from the pump returns to the tank by way of the neutral passage b Plunger pushed in When the plunger is pushed in it blocks up the neutral passage so the oil runs to the cylinder port B by pushing up the load check valve The oil returning from the cylinder port A runs to the low pressure passage through which it then flows into the tank Then plunger 15 put back in neutral position by the return spring Fig 6 14 Pushed In 93 6 HYDRAULIC SYSTEM c Plunger pulled out When the
102. z 00 0004 005 59 Suroosiojut 06 snipes ur 391 931 NO popeor popeor puc 151 puc 381 poods popeor pepeojun poods 1ILL 9914 91805 ILL IoJUIO orsegq peor XC6V 93UEULIOJ I2q No SEF 0F7BE Unit mm in d S 993 v 0006 Fig 1 Truck Dimensions No SEF 0F7BE No SEF 0F7BE TABLE OF CONTENTS TS ENGINE 5 1 IT GENERAL DES CRIP 3 1 1 1 FUEL SYSTEM Gasoline and 1686 10 17 113 ENGINE CONTROL SYSTEM Gasoline and LPG 19 ll COOLING SX S LEM 22 KES ACCELERATOR 27 1316 AIR MERA NTE AN TR NUT TANT RUT WN TORR TEN SRA 29 C

SERVICE MANUAL - Ages Heftruck Service BV

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