Service Manual

Chassis, Mast & Options

GP15K AT31A-50001-up, AT31B-50001-up
GP18K AT31A-50001-up, AT31B-50001-up
GP20K AT17B-10001-up, AT17C-10001-up
GP20K-HP AT17B-95001-up, AT17C-95001-up
GP25K AT17B-10001-up, AT17C-10001-up
GP25K-HP AT17B-95001-up, AT17C-95001-up
GP30K AT13D-35001-up, AT13E-30001-up
GP35K AT13D-55001-up, AT13E-50001-up
DP20K AT18B-05001-up
DP25K AT18B-05001-up
DP30K AT14C-35001-up
DP35K AT14C-55001-up

For use with 4G63/4G64 and S4S Engine Service Manual. 99719-82130
 FOREWORD

This service manual is a guide to servicing of Cat® Lift Trucks for 1.5 thru 3.5 ton classes. The
instructions are grouped by systems to serve the convenience of your ready reference.

Long productive life of your lift trucks depends to a great extent on correct servicing — the
servicing consistent with what you will learn from this service manual. Read the respective
sections of this manual carefully and familiarize yourself with the components you will work
on before attempting to start a test, repair or rebuild job.

The descriptions, illustrations and specifications contained in this manual are of the trucks of
serial numbers in effect at the time it was approved for printing. Cat lift truck reserves the right
to change specifications or design without notice and without incurring obligation.

For the items pertaining to the engines, refer to the following service manuals:
• 4G63/4G64 Gasoline Engine Service Manual (Pub. No. 99729-74110)
• 4DQ7/S4S Diesel Engine Service Manual (Pub. No. 99719-95100)

Safety Related Signs

The following safety related signs are used in this service

manual to emphasize important and critical instructions:

Indicates a specific potential hazard

! WARNING that could result in serious bodily
injury or death.

Indicates a specific potential hazard

! CAUTION
that could result in bodily injury, or
damage to, or destruction of, the
machine.

Indicates a condition that can cause

NOTE
damage to, or shorten service life of,
the machine.

Pub. No. 99719-82130

 ! WARNING

SAFETY

! WARNING ! WARNING
The proper and safe lubrication and Do not operate this truck unless you have read
maintenance for this lift truck, recommended and understand the instructions in the
by Cat lift truck, are outlined in the OPERATION OPERATION & MAINTENANCE MANUAL.
& MAINTENANCE MANUAL for these trucks. Improper truck operation is dangerous and
Improper performance of lubrication or could result in injury or death.
maintenance procedures is dangerous and
could result in injury or death. Read and 4. Lower the forks or other implements to the ground
understand the OPERATION & MAINTENANCE before performing any work on the truck. If this
MANUAL before performing any lubrication or cannot be done, make sure the forks or other
maintenance. implements are blocked correctly to prevent them
from dropping unexpectedly.
5. Use steps and grab handles (if applicable) when
The serviceman or mechanic may be unfamiliar with mounting or dismounting a truck. Clean any mud
many of the systems on this truck. This makes it or debris from steps, walkways or work platforms
important to use caution when performing service before using. Always face truck when using steps,
work. A knowledge of the system and/or components ladders and walkways. When it is not possible to
is important before the removal or disassembly of any use the designed access system, provide ladders,
component. scaffolds, or work platforms to perform safe repair
Because of the size of some of the truck components, operations.
the serviceman or mechanic should check the weights 6. To avoid back injury, use a hoist when lifting
noted in this Manual. Use proper lifting procedures components which weigh 23 kg (50 lb.) or more.
when removing any components. Make sure all chains, hooks, slings, etc., are in
Following is a list of basic precautions that should good condition and are of the correct capacity. Be
always be observed. sure hooks are positioned correctly. Lifting eyes
1. Read and understand all warning plates and decals are not to be side loaded during a lifting operation.
on the truck before operating, lubricating or 7. To avoid burns, be alert for hot parts on trucks
repairing the product. which have just been stopped and hot fluids in
2. Always wear protective glasses and protective lines, tubes and compartments.
shoes when working around trucks. In particular, 8. Be careful when removing cover plates. Gradually
wear protective glasses when pounding on any part back off the last two bolts or nuts located at
of the truck or its attachments with a hammer or opposite ends of the cover or device and pry cover
sledge. Use welders gloves, hood/goggles, apron loose to relieve any spring or other pressure, before
and other protective clothing appropriate to the removing the last two bolts or nuts completely.
welding job being performed. Do not wear loose- 9. Be careful when removing filler caps, breathers and
fitting or torn clothing. Remove all rings from plugs on the truck. Hold a rag over the cap or plug
fingers when working on machinery. to prevent being sprayed or splashed by liquids
3. Do not work on any truck that is supported only by under pressure. The danger is even greater if the
lift jacks or a hoist. Always use blocks or jack truck has just been stopped because fluids can be
stands to support the truck before performing any hot.
disassembly.
10. Always use tools that are in good condition and be 19. Tighten connections to the correct torque. Make
sure you understand how to use them before sure that all heat shields, clamps and guards are
performing any service work. installed correctly to avoid excessive heat, vibration
11. Reinstall all fasteners with same part number. Do or rubbing against other parts during operation.
not use a lesser quality fastener if replacements are Shields that protect against oil spray onto hot
necessary. exhaust components in event of a line, tube or seal
failure, must be installed correctly.
12. If possible, make all repairs with the truck parked
on a level, hard surface. Block truck so it does not 20. Relieve all pressure in air, oil or water systems
roll while working on or under truck. before any lines, fittings or related items are
disconnected or removed. Always make sure all
13. Disconnect battery and discharge any capacitors
raised components are blocked correctly and be
(electric trucks) before starting to work on truck.
alert for possible pressure when disconnecting any
Hang “Do not Operate” tag in the Operator’s
device from a system that utilizes pressure.
Compartment.
21. Do not operate a truck if any rotating part is
14. Repairs, which require welding, should be
damaged or contacts any other part during
performed only with the benefit of the appropriate
operation. Any high speed rotating component that
reference information and by personnel adequately
has been damaged or altered should be checked for
trained and knowledgeable in welding procedures.
balance before reusing.
Determine type of metal being welded and select
correct welding procedure and electrodes, rods or
wire to provide a weld metal strength equivalent at
least to that of parent metal.
15. Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will it
be damaged in operation by contacting sharp
corners, or by rubbing against some object or hot
surface. Place wiring away from oil pipe.
16. Be sure all protective devices including guards and
shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair work,
use extra caution.
17. Always support the mast and carriage to keep
carriage or attachments raised when maintenance
or repair work is performed, which requires the
mast in the raised position.
18. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Pin hole (very small) leaks can result
in a high velocity oil stream that will be invisible
close to the hose. This oil can penetrate the skin
and cause personal injury. Use cardboard or paper
to locate pin hole leaks.
HOW TO USE THIS MANUAL
(Removal, Installation, Assembly and Disassembly)

Disassembly diagram (example)

Procedures are described in the text.

Disassembling sequence

209603

Sequence
1 Cover , Bolt, Washer (part name)
2 Snap ring ................ (part name)

Suggestion for disassembling

1. Output shaft, Removing
Remove output shaft using a special tool.

209604

Service Data

0.11 to 0.28 mm
A
Gear Backlash (0.0043 to 0.0110 in.)
B 0.5 mm (0.020 in.)
A: Standard Value
B: Repair or Service Limit
Symbols or abbreviation
OP Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 Taper pipe thread (internal) 1/8 inch (formerly PT1/8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly PS1/8)

Units
1. SI Units are used in this manual.
2. The following table shows the conversion of SI unit and customary unit.

Item SI unit Customary unit

1N 0.102 kgf
Force
1 lbf 0.4536 kgf
1 kPa 0.0102 kgf/cm2
Pressure
1 psi 0.0703 kgf/cm2
1 N·m 0.102 kgf·m
Torque
1 lbf·ft 0.1383 kgf·m
 GROUP INDEX

GROUP INDEX Items

Vehicle exterior, Models, Serial number locations,
GENERAL INFORMATION Dimensions, Technical data 1

COOLING SYSTEM Fan belt removal, Fan belt inspection, Fan belt adjustment
2
Console box, Combination meter, Starter switch (with anti-restart lock),
ELECTRICAL SYSTEM Lighting switch, Fuse box, Spare terminals, Battery maintenance, Light
bulb specifications, Electrical system schematics
3

POWER TRAIN Engine and transmission

4
Hydraulic circuit, Control, Transmission assembly, Pump assembly,
POWERSHIFT TRANSMISSION Control valve, Testing hydraulic pressure, Adjusting inching pedal, Testing
clutch valve, 10-m (33-ft) Start acceleration test
5

FRONT AXLE AND Front wheels, Front axle and reduction differential, Tooth contact patterns
REDUCTION DIFFERENTIAL and adjustment 6

Rear axle, Steering cylinder, Rear wheels, Rear axle, Steering cylinder,
REAR AXLE Minimum turning radius adjustment 7
Automatic adjusting device, Brake pedal and assembly, Master cylinder,
BRAKE SYSTEM Wheel brakes, Wheel cylinders, Brake pedal adjustment, Bleeding air out
of the brake fluid line, Brake test
8

STEERING SYSTEM Steering system, Steering control valve, Tilt steering assembly
9

Hydraulic line, Hydraulic tank, Hydraulic pump, Control valve, Lift and
HYDRAULIC SYSTEM tilt cylinders, Flow regulator valve, Down safety valve 10

MAST AND FORKS Simplex mast, Duplex mast, Triplex mast

11

LP-GAS SYSTEM Structure and function, Operating instructions, Troubleshooting

12
Tightening torques for standard bolts and nuts, Periodic replacement parts,
SERVICE DATA Fuel and lubricant specifications, Recommended brands of lubricants, 13
Refill capacities (approximate)
 GENERAL INFORMATION

1
Vehicle Exterior ........................................................................................ 1– 1
Models ....................................................................................................... 1– 1
Serial Number Locations ...................................................................... 1– 2
Dimensions ............................................................................................... 1– 4
Technical Data (Standard Models) ..................................................... 1– 6
 GENERAL INFORMATION

Vehicle Exterior

This Service Manual deals with all components or systems of the Cat Lift Trucks; except for the engine and
attachment, which are covered in the respective manuals.

207151

Models

This Service Manual furnishes servicing and maintenance information for the following trucks:

Truck Model Serial Number Engine Mounted

GP15K AT31A-50001-up, AT31B-50001-up Mitsubishi 4G63 Gasoline Engine
GP15K ET31A-60244-up Mitsubishi 4G63 Gasoline Engine
GP18K AT31A-50001-up, AT31B-50001-up Mitsubishi 4G63 Gasoline Engine
GP20K AT17B-10001-up, AT17C-10001-up Mitsubishi 4G63 Gasoline Engine
GP20K-HP AT17B-95001-up, AT17C-95001-up Mitsubishi 4G63 Gasoline Engine
GP25K AT17B-10001-up, AT17C-10001-up Mitsubishi 4G63 Gasoline Engine
GP25K-HP AT17B-95001-up, AT17C-95001-up Mitsubishi 4G63 Gasoline Engine
GP30K AT13D-35001-up, AT13E-30001-up Mitsubishi 4G64 Gasoline Engine
GP35K AT13D-55001-up, AT13E-50001-up Mitsubishi 4G64 Gasoline Engine
DP20K AT18B-05001-up Mitsubishi S4S Diesel Engine
DP25K AT18B-05001-up Mitsubishi S4S Diesel Engine
DP30K AT14C-35001-up Mitsubishi S4S Diesel Engine
DP35K AT14C-55001-up Mitsubishi S4S Diesel Engine
1-1
GENERAL INFORMATION

Serial Number Locations

Engine Serial Number

Nameplate Chassis Serial Number
(gasoline models)
1 ton class

2 – 3 ton classes

Engine Serial Number

(diesel models)

Mast Serial Number Transmission Serial Number

207344

1-2
 GENERAL INFORMATION

Memo

1-3
GENERAL INFORMATION

Dimensions

G C K

H I

P
B

D N M

F
211083

1-4
 GENERAL INFORMATION

Unit: mm (in.)
Ref. Truck Models GP20K GP25K
GP30K GP35K
No. Items GP15K GP18K GP20K-HP GP25K-HP
DP30K DP35K
DP20K DP25K
A Maximum lift 3300 (130) 3300 (130) 3300 (130)
Simplex mast 115 (4.5) 140 (5.5) 145 (5.7)
Free lift
B Duplex mast 1120 1125 1125 1130 1160 1295
(floor to fork top)
Triplex mast (44.1) (44.3) (44.3) (44.5) (45.7) (51)

240 to 920 240 to 975 285 to 1000

C Fork spread
(9.45 to 36.2) (9.45 to 38.4) (11.2 to 39.4)
D Fork length 1070 (42) 1070 (42) 1070 (42)
E Tilt angle (forward-backward) 6° –10° 6° –10° 6° –10°
3290 3320 3535 3590 3795 3840
F Overall length
(129.5) (130.7) (139.2) (141.3) (149.4) (151.2)
1275 1290
Overall width (w/single tires) 1070 (42.1) 1150 (45.3)
(50.2) (50.8)
G
Overall width
1330 (52.4) 1480 (58.3) 1490 (58.7)
(w/double tires) (outside)
Overall height 2210 2320
H 2145 (84.4) 2145 (84.4)
(to top of mast lowered) (87) (91.3)
Overall height 2095 2105
I 2080 (81.9) 2100 (82.7)
(to top of overhead guard) (82.5) (82.9)
Simplex mast 4030 (158.7) 4030 (158.7) 4135 (180.1)
J Overall height
Duplex mast 4350 (171.3) 4355 (171.5) 4305 (169.5) 4355 (171.5)
(mast extended)
Triplex mast 5805 (228.5) 5805 (228.5) 5755 (226.6)
Tread (front-single tires) 890 (35.0) 960 (37.8) 1060 (41.7)
K
Tread (front-double tires) 1025 (40.4) 1140 (44.9) 1140 (44.9)
L Tread (rear) 895 (35.2) 975 (38.4) 975 (38.4)
M Wheelbase 1390 (54.7) 1600 (63.0) 1750 (68.9)
N Front overhang 402 (15.8) 457 (18) 490 (19.3)
1990 2020 2185 2245 2445 2485
O Minimum turning radius
(78.3) (79.5) (86.0) (88.4) (88.4) (97.8)
P Underclearance (at frame) 155 (6.1) 175 (6.9) 180 (7.1) 200 (7.9)

1-5
GENERAL INFORMATION

Technical Data (Standard Models)

Truck Model GP15K GP18K GP20K, GP20K-HP DP20K
Designation AT31A, AT31B AT31A, AT31B AT17B, AT17C AT18B
Capacity/load kg/mm 1500/500 1750/500 2000/500
center (lb/in.) (3000/24) (3500/24) (4000/24)
Maximum lift height mm (in.) 3300 (130) 3300 (130) 3300 (130)
Work performance

Lift speed (rated load) mm/sec 490 (96) 490 (96) 510 (100) 640 (126)
Lowering speed (rated load) (fpm) 500 (98) 500 (98) 500 (98)
Mast tilt
degree 6-10 6-10 6-10
(forward - backward)
Simplex mast 110 (4.3) 110 (4.3) 140 (5.5)
Free lift Duplex mast mm (in.) 1120 (44.1) 1125 (44.3) 1125 (44.3)
Triplex mast 1120 (44.1) 1125 (44.3) 1125 (44.3)

PowershiftForward 0 to 19 (0 to 11.8) 0 to 19 (0 to 11.8) 0 to 18 (0 to 11.2)

Travel transmission km/h
Traveling performance

speed (mph) 0 to 18 0 to 19
models Reverse 0 to 19 (0 to 11.8) 0 to 19 (0 to 11.8) (0 to 11.2) (0 to 11.8)
Minimum turning radius 1990 (78.3) 2020 (79.5) 2185 (86)
Minimum Single wheels mm (in.) 1780 (70.1) 1800 (70.9) 1900 (74.8)
intersecting isle Double wheels 1880 (74.0) 1900 (74.8) 2020 (79.5)
Powershift
Gradeability
transmission % (tan) 30 28 28 35
(rated load)
models
Overall length 3280 (129.1) 3315 (130.5) 3515 (138.4)
Single wheels 1065 (41.9) 1065 (41.9) 1150 (45.3)
Overall width
Double wheels 1330 (52.4) 1330 (52.4) 1480 (58.3)
To top of mast
2145 (84.4) 2145 (84.4) 2210 (87)
lowered
To top of mast
Overall height 4030 (158.7) 4030 (158.7) 4030 (158.7)
extended
To top of
2055 (80.9) 2055 (80.9) 2070 (81.5)
overhead guard mm (in.)
Wheel base 1390 (54.7) 1390 (54.7) 1600 (63.0)
Dimensions

Single wheels 890 (35.0) 890 (35.0) 960 (37.8)

Front
Tread Double wheels 1025 (40.4) 1025 (40.4) 1140 (44.9)
Rear 900 (35.4) 900 (35.4) 980 (38.6)
Front 402 (15.8) 402 (15.8) 457 (18)
Overhang
Rear 418 (16.5) 453 (17.8) 388 (15.3)
Underclearance (at frame) 150 (5.9) 150 (5.9) 160 (6.3)
6.50-10-10 6.50-10-10 7.00-12-12
Single wheels
686 (7) [100] 686 (7) [100] 686 (7) [100]
Tire size Front kPa
(kgf/cm2) 4.50-12-8 4.50-12-8 5.00-15-8
and Double wheels
686 (7) [100] 686 (7) [100] 686 (7) [100]
pressure [psi]
5.00-8-8 5.00-8-8 6.00-9-10
Rear
686 (7) [100] 686 (7) [100] 686 (7) [100]
2530 2690 3260 3380
Service weight
(5580) (5930) (7190) (7450)
Single
Weight

wheels 1040 1000 1460 1500

Front axle kg (lb)
(without Load (2290) (2210) (3220) (3310)
load) distribution 1430 1640 1770 1850
Rear axle
(3150) (3620) (3900) (4080)

1-6
 GENERAL INFORMATION

GP25K, GP25K-HP DP25K GP30K DP30K GP35K DP35K

AT17B, AT17C AT18B AT13D, AT13E AT14C AT13D, AT13E AT14C
2500/500 3000/500 3500/500
(5000/24) (6000/24) (7000/24)
3300 (130) 3300 (130) 3300 (130)
550 (108) 660 (130) 470 (93) 510 (100) 400 (79) 430 (85)
500 (98) 530 (104) 440 (87)

6-10 6-10 6-10

140 (5.5) 150 (5.9) 150 (5.9)

1130 (44.5) 1160 (45.7) 1295 (51)
1130 (44.5) 1160 (45.7) 1295 (51)
0 to 18 0 to 19 0 to 19 0 to 18
(0 to 11.2) (0 to 11.8) (0 to 11.8) (0 to 11.2)
0 to 18 0 to 19 0 to 19 0 to 19 0 to 19
(0 to 11.2) (0 to 11.8) (0 to 11.8) (0 to 11.8) (0 to 11.8)
2245 (88.4) 2445 (96.2) 2485 (97.8)
1970 (77.6) 2090 (82.3) 2120 (83.5)
2090 (82.3) 2170 (85.4) 2190 (86.2)

23 29 23 24 19 20

3585 (141.1) 3775 (143) 3830 (150.8)

1150 (45.3) 1275 (50.2) 1290 (50.8)
1480 (58.3) 1490 (58.7) 1490 (58.7)

2210 (87) 2210 (87) 2320 (91.3)

4030 (158.7) 4135 (162.8) 4135 (162.8)

2070 (81.5) 2095 (82.5) 2105 (82.9)

1600 (63.0) 1750 (68.9) 1750 (68.9)

960 (37.8) 1060 (41.7) 1060 (41.7)
1140 (44.9) 1140 (44.9) 1140 (44.9)
980 (38.6) 980 (38.6) 980 (38.6)
457 (18) 490 (19.3) 490 (19.3)
458 (18) 465 (18.3) 520 (20.5)
160 (6.3) 190 (7.5) 200 (7.9)
7.00-12-12 28 × 9-15-14 250-15-16
686 (7) [100] 686 (7) [117] 834 (8.5) [120]
5.00-15-8 6.50-10-10 6.50-10-10
686 (7) [100] 686 (7) [100] 686 (7) [100]
6.00-9-10 6.50-10-10 6.50-10-12
686 (7) [100] 686 (7) [100] 883 (9.0) [128]
3590 3710 4270 4390 4630 4750
(7920) (8180) (9420) (9680) (10210) (10480)
1400 1440 1760 1710 1790 1830
(3090) (3180) (3880) (3770) (3950) (4040)
2220 2300 2460 2530 2810 2890
(4900) (5070) (5420) (5580) (6200) (6370)

1-7
GENERAL INFORMATION

Truck Model GP15K GP18K GP20K, GP20K-HP DP20K

2500 2670 3330 3450
Service weight
(5510) (5890) (7340) (7610)
Double
Weight

wheels 1070 1030 1530 1570

Front axle kg (lb)
(without Load (2360) (2270) (3370) (3460)
load) distribution 1430 1640 1770 1850
Rear axle
(3150) (3620) (3900) (4080)
Engine model 4G63 4G63 4G63 S4S
Mitsubishi
Manufacturer Mitsubishi Motors Mitsubishi Motors MHI
Motors
Type Gasoline Gasoline Gasoline Diesel
Cooling System Water Water Water
No. of cylinders - arrangement 4 -in-line 4 -in-line 4 -in-line
No. of strokes 4 4 4
Semi-
Types of combustion chambers Semi-spherical Semi-spherical Swirl
spherical

Valve arrangement OHC OHC OHC OHV

Integral with
Integral with Integral with
Type of cylinder liners cylinder Dry
cylinder block cylinder block
block
85 × 88 85 × 88 85 × 88 94 ×120
Cylinder bore × stroke mm (in.)
(3.346 × 3.465) (3.346 × 3.465) (3.346 × 3.465) (3.701 × 4.724)

Displacement cc 1997 1997 1997 3331

(cu. in.) (121.8) (121.8) (121.8) (203.2)
Compression ratio 8.5 :1 8.5 : 1 8.5 : 1 22 : 1
Rated output PS/rpm 42/2400 42/2400 42/2400 60/2200
Engine

Maximum torque N·m (kgf·m) 134 (13.7) 134 (13.7) 134 (13.7) 201 (20.5)
[lbf·ft]/rpm [99]/1600 [99]/1600 [99]/1600 [148]/1400
653 × 604 647 × 552
Dimensions mm (in.) 653 × 604 × 759 653 × 604 × 759 × 759 × 712
(length × width × height) (25.7 × 23.8 × 29.9) (25.7 × 23.8 × 29.9) (25.7 × 23.8 (25.5 × 21.7
× 29.9) × 28)
Weight (service) kg (lb) 150 (330) 150 (330) 150 (330) 260 (570)
Location Rear Rear Rear
Open BTDC 12 12 12 30
Intake valves
Close ABDC 40 40 40 50
degree
Open BBDC 54 54 54 74
Exhaust valves
Close ATDC 6 6 6 30
0.25 (0.0098)
Intake valves 0.00 (hot) 0.00 (hot) 0.00 (hot)
(cold)
Valve clearance mm (in.)
0.25 (0.0098)
Exhaust valves 0.00 (hot) 0.00 (hot) 0.00 (hot)
(cold)
Ignition Spark Spark Spark Compression
Firing order 1-3-4-2 1-3-4-2 1-3-4-2
Ignition timing BTDC degree/rpm 6/650 6/650 6/650 –
Injection timing BTDC degree – – – 20

Fuel tank rated capacity liter 53 (14) 53 (14) 76 (20)

(U.S. gal)

1-8
 GENERAL INFORMATION

GP25K, GP25K-HP DP25K GP30K DP30K GP35K DP35K

3690 3810 4240 4360 4620 4740
(8140) (8400) (9350) (9610) (10190) (10450)
1470 1520 1780 1830 1810 1850
(3240) (3550) (3920) (4040) (3990) (4080)
2220 2290 2460 2530 2810 2890
(4900) (5050) (5420) (5580) (6200) (6870)
4G63 S4S 4G64 S4S 4G64 S4S
Mitsubishi Mitsubishi Mitsubishi
MHI MHI MHI
Motors Motors Motors
Gasoline Diesel Gasoline Diesel Gasoline Diesel
Water Water Water
4 -in-line 4 -in-line 4 -in-line
4 4 4
Semi- Semi- Semi-
Swirl Swirl Swirl
spherical spherical spherical

OHC OHV OHC OHV OHC OHV

Integral with Integral with Integral with

cylinder Dry cylinder Dry cylinder Dry
block block block
85 × 88 94 × 120 86.5 × 100 94 × 120 86.5 × 100 94 × 120
(3.346 × 3.465) (3.701 × 4.724) (3.406 × 3.937) (3.701 × 4.724) (3.406 × 3.937) (3.701 × 4.724)
1997 3331 2350 3331 2350 3331
(121.8) (203.2) (143.4) (203.2) (143.4) (203.2)
8.5 : 1 22 : 1 8.6 : 1 22 : 1 8.6 : 1 22 : 1
42/2400 60/2200 50/2400 60/2200 50/2400 60/2200
134 (13.7) 201 (20.5) 167 (17) 201 (20.5) 167 (17) 201 (20.5)
[99]/1600 [148]/1400 [123]/1600 [148]/1400 [123]/1600 [148]/1400
653 × 604 647 × 552 653 × 604 647 × 552 653 × 604 647 × 552
× 759 × 712 × 759 × 712 × 759 × 712
(25.7 × 23.8 (25.5 × 21.7 (25.7 × 23.8 (25.5 × 21.7 (25.7 × 23.8 (25.5 × 21.7
× 29.9) × 28) × 29.9) × 28) × 29.9) × 28)
150 (330) 260 (570) 150 (330) 260 (570) 150 (330) 260 (570)
Rear Rear Rear
12 30 12 30 12 30
40 50 40 50 40 50
54 74 54 74 54 74
6 30 6 30 6 30
0.25 (0.0098) 0.25 (0.0098) 0.25 (0.0098)
0.00 (hot) (cold) 0.00 (hot) (cold) 0.00 (hot) (cold)
0.25 (0.0098) 0.25 (0.0098) 0.25 (0.0098)
0.00 (hot) 0.00 (hot) 0.00 (hot)
(cold) (cold) (cold)
Spark Compression Spark Compression Spark Compression
1-3-4-2 1-3-4-2 1-3-4-2
6/650 – 6/650 – 6/650 –
– 20 – 20 – 20

76 (20) 76 (20) 76 (20)

1-9
GENERAL INFORMATION

Truck Model GP15K GP18K GP20K, GP20K-HP DP20K

Type With external With external With external –

resistor resistor resistor
Ignition coil
Manufacturer Mitsubishi Mitsubishi Mitsubishi –
Electric Electric Electric
Ignition system (gasoline models)

Non-contact Non-contact Non-contact

Type point type point type point type –
(C.E.I.) (C.E.I.) (C.E.I.)
Distributor Manufacturer Mitsubishi Mitsubishi Mitsubishi –
Electric Electric Electric

Spark advancer Centrifugal Centrifugal Centrifugal –

pneumatic type pneumatic type pneumatic type
Type W14EX-U W14EX-U W14EX-U –

Manufacturer Nippon Nippon Nippon –

Denso Denso Denso
Spark plugs Size 14 × 1.25 14 × 1.25 14 × 1.25 –
(0.55 × 0.049) (0.55 × 0.049) (0.55 × 0.049)
mm (in.)
Gap 0.7 to 0.8 0.7 to 0.8 0.7 to 0.8 –
(0.028 to 0.031) (0.028 to 0.031) (0.028 to 0.031)
Down-draft Down-draft Down-draft
Carburetor Type –
type type type
Mikuni Mikuni Mikuni
Manufacturer –
Kogyo Kogyo Kogyo
Fuel system (gasoline models)

Pneumatic Pneumatic Pneumatic

Governor Type –
type type type
Mikuni Mikuni Mikuni
Manufacturer –
Kogyo Kogyo Kogyo
Diaphragm Diaphragm Diaphragm
Fuel pump Type –
type type type
Kyosan Kyosan Kyosan
Manufacturer –
Electric Electric Electric
Cyclone- Cyclone- Cyclone-
Type × number paper paper paper –
Air cleaner element × 1 element × 1 element × 1
Nippon Nippon Nippon
Manufacturer –
Rokaki Rokaki Rokaki
Distributor
Type – – –
type (DPK)
Mikuni
Fuel injection Manufacturer – – –
Precision
Fuel system (diesel models)

pump
Plunger diam. – – – 7.0 (0.275)
Cam lift mm (in.)
(one side) – – – 1.5 (0.059)

Throttle
Type – – –
type
Spray holes, – – 1.00
mm (in.) –
Fuel injection diam. × number (0.0394) × 1
nozzle +1079
13729000 0
kPa
Injection (kgf/cm2) – – – (140 +11
+ 5)
pressure [psi] +156
[1990 + 71]

1-10
 GENERAL INFORMATION

GP25K, GP25K-HP DP25K GP30K DP30K GP35K DP35K

With external With external With external
– – –
resistor resistor resistor
Mitsubishi Mitsubishi Mitsubishi
– – –
Electric Electric Electric
Non-contact Non-contact Non-contact
point type – point type – point type –
(C.E.I.) (C.E.I.) (C.E.I.)
Mitsubishi Mitsubishi Mitsubishi
– – –
Electric Electric Electric
Centrifugal Centrifugal Centrifugal
– – –
pneumatic type pneumatic type pneumatic type
W14EX-U – W14EX-U – W14EX-U –
Nippon Nippon Nippon
– – –
Denso Denso Denso
14 × 1.25 14 × 1.25 14 × 1.25
– – –
(0.55 × 0.049) (0.55 × 0.049) (0.55 × 0.049)
0.7 to 0.8 0.7 to 0.8 0.7 to 0.8
– – –
(0.028 to 0.031) (0.028 to 0.031) (0.028 to 0.031)
Down-draft Down-draft Down-draft
– – –
type type type
Mikuni Mikuni Mikuni
– – –
Kogyo Kogyo Kogyo
Pneumatic Pneumatic Pneumatic
– – –
type type type
Mikuni – Mikuni Mikuni
– –
Kogyo Kogyo Kogyo
Diaphragm Diaphragm Diaphragm
– – –
type type type
Kyosan Kyosan Kyosan
– – –
Electric Electric Electric
Cyclone- Cyclone- Cyclone-
paper – paper – paper –
element × 1 element × 1 element × 1
Nippon Nippon Nippon
– – –
Rokaki Rokaki Rokaki
Distributor Distributor Distributor
– – –
type (DPK) type (DPK) type (DPK)
Mikuni Mikuni Mikuni
– – –
Precision Precision Precision
– 7.0 (0.256) – 7.0 (0.256) – 7.0 (0.275)

– 1.5 (0.059) – 1.5 (0.059) – 1.5 (0.059)

Throttle Throttle Throttle

– – –
type type type
1.00 1.00 1.00
– – –
(0.0394) × 1 (0.0394) × 1 (0.0394) × 1
+1079 +1079 +1079
13729000
+ 490 13729000
+ 490 13729000
+ 490

– (140 +11
+ 5) – (140 +11
+ 5) – (140 +11
+ 5)
+156
[1990 +156
+ 71 ] [1990 +156
+ 71 ] [1990 + 71 ]

1-11
GENERAL INFORMATION

Truck Model GP15K GP18K GP20K, GP20K-HP DP20K

Type – – – Sheathed type
Heater plugs
Air and fuel (diesel model)

Voltage-current V-A – – – 22 – 5.4

Type – – – Vane type
Fuel feed pump
Manufacturer – – – Lusus CAV
Cyclone-
Type × number – – – paper
Air cleaner element × 1
Nippon
Manufacturer – – –
Rokaki
Type Pressure feed type Pressure feed type Pressure feed type
Lubrication system

Oil pump Throchoid type Throchoid type Throchoid type

Oil filter Paper-element Paper-element Paper-element
Oil pan 4.5 (1.2) 4.5 (1.2) 4.5 (1.2) 9.0 (2.4)
liter
Refill capacities Oil filter 0.3 (0.1) 0.3 (0.1) 0.3 (0.1) 1.0 (0.3)
(U.S. gal)
Total 4.8 (1.3) 4.8 (1.3) 4.8 (1.3) 10.0 (2.7)
Type Forced circulation Forced circulation Forced circulation
Corrugated fin Corrugated fin Corrugated fin
Cooling system

Radiator
(pressure) type (pressure) type (pressure) type
liter 8.9 9.6
Refill capacity 7.65 (2.0) 7.65 (2.0)
(U.S. gal) (2.3) (2.5)
Water pump Centrifugal type Centrifugal type Centrifugal type
Thermostat Wax type Wax type Wax type
Alternator and Battery

Voltage V 12 12 12 12
Capacity Ah 30 30 40 80
Alternator type 3-phase AC 3-phase AC 3-phase AC
regulator

Manufacturer Mitsubishi Electric Mitsubishi Electric Mitsubishi Electric

Capacity V-A 12 – 50 12 – 50 12 – 50 12 – 50
Regulator Built-in IC type Built-in IC type Built-in IC type
Type Lever-shift type Lever-shift type Lever-shift type
Starter

Manufacturer Mitsubishi Electric Mitsubishi Electric Mitsubishi Electric

Voltage - output V-kW 12 – 1.2 12 – 1.2 12 – 1.2 12 – 2.2
3-element, 1-stage, 3-element, 1-stage, 3-element, 1-stage,
Power train

Type
2-phase 2-phase 2-phase
Torque converter Manufacturer’s type Daikin 66H7 Daikin 66H7 Daikin 66H8
Stall torque ratio 2.8 2.8 3.0

1-12
 GENERAL INFORMATION

GP25K, GP25K-HP DP25K GP30K DP30K GP35K DP35K

– Sheathed type – Sheathed type – Sheathed type
– 22–5.4 – 22–5.4 – 22–5.4
– Vane type – Vane type – Vane type
– Lusus CAV – Lusus CAV – Lusus CAV
Cyclone- Cyclone- Cyclone-
– paper – paper – paper
element × 1 element × 1 element × 1
Nippon Nippon Nippon
– – –
Rokaki Rokaki Rokaki
Pressure feed type Pressure feed type Pressure feed type
Throchoid type Throchoid type Throchoid type
Paper-element Paper-element Paper-element
4.5 (1.2) 9.0 (2.4) 4.5 (1.2) 9.0 (2.4) 4.5 (1.2) 9.0 (2.4)
0.3 (0.1) 1.0 (0.3) 0.3 (0.1) 1.0 (0.3) 0.3 (0.1) 1.0 (0.3)
4.8 (1.3) 10.0 (2.7) 4.8 (1.3) 10.0 (2.7) 4.8 (1.3) 10.0 (2.7)
Forced circulation Forced circulation Forced circulation
Corrugated fin Corrugated fin Corrugated fin
(pressure) type (pressure) type (pressure) type
8.9 9.6 8.9 9.6 8.9 9.6
(2.3) (2.5) (2.3) (2.5) (2.3) (2.5)
Centrifugal type Centrifugal type Centrifugal type
Wax type Wax type Wax type
12 12 12 12 12 12
40 80 40 80 40 80
3-phase AC 3-phase AC 3-phase AC
Mitsubishi Electric Mitsubishi Electric Mitsubishi Electric
12–50 12–50 12–50 12–50 12–50 12–50
Built-in IC type Built-in IC type Built-in IC type
Lever-shift type Lever-shift type Lever-shift type
Mitsubishi Electric Mitsubishi Electric Mitsubishi Electric
12–1.2 12–2.2 12–1.2 12–2.2 12–1.2 12–2.2
3-element, 1-stage, 3-element, 1-stage, 3-element, 1-stage,
2-phase 2-phase 2-phase
Daikin 66H8 Daikin 66H88 Daikin 66H8
3.0 3.0 3.0

1-13
GENERAL INFORMATION

Truck Model GP15K GP18K GP20K, GP20K-HP DP20K

Hydraulic column Hydraulic column Hydraulic column
Control and shift
shift shift shift
Transmission
Power- Ratios Forward 2.195 2.195 2.195
shaft Reverse 2.258 2.258 2.258
Type of gears Spur Spur Spur
Power train

Transfer Powershift
Gear ratio 1.394 1.394 1.394 1.167
transmission
Type of gears Spiral bevel Spiral bevel Spiral bevel
Reduction gear
Ratio 4.571 4.571 5.667
Axle housing Banjo Banjo Banjo
Differential Type of Gears Straight bevel - 2 Straight bevel - 2 Straight bevel - 2
gears-
number Pinions Straight bevel - 2 Straight bevel - 2 Straight bevel - 2
Full Hydrostatic Full Hydrostatic Full Hydrostatic
Type
power steering power steering power steering
Inside 82° 82° 83°
Turning angle degree
Outside 55° 55° 56°
Steering system

Steering wheel diameter mm (in.) 330 (13) 330 (13) 330 (13)
Steering cylinder
63 × 40 (2.48 × 1.575) 63 × 40 (2.48 × 1.575) 75 × 50 (2.953 × 1.068)
ID × rod OD mm (in.)
Steering Effective stroke 215 (8.46) 215 (8.46) 210 (8.27)
cylinder kPa (kgf/
Relief pressure 7.355 (75) [1066] 7.355 (75) [1066] 7.355 (75) [1066]
cm2)[psi]
liter (cu.
Flow rate 10.5 ± 0.5 (640.1 ± 30.5) 10.5 ± 0.5 (640.1 ± 30.5) 10.5 ± 0.5 (640.1 ± 30.5)
in.)/min
Full-floating tubular Full-floating tubular Full-floating tubular
Front axle
type type type
Rear axle Elliott type Elliott type Elliott type
Traveling system

Front wheels Fixed type Fixed type Fixed type

Mounting
Rear wheels Center-pivot type Center-pivot type Center-pivot type
Toe-in mm (in.) 0 0 0

Wheel Camber 1 1 1
alignment Caster degree 0 0 0
Kingpin
0 0 0
inclination
Hydraulic, duo-servo, Hydraulic, duo-servo, Hydraulic, duo-servo,
Type
mounted on front wheels mounted on front wheels mounted on front wheels
Drum diameter 254 (10.00) 254 (10.00) 310 (12.20)
Lining (lgth × width 274.2 × 48.5 × 4.78 × 2 274.2 × 48.5 × 4.78 × 2 344 × 60.0 × 6.4 × 2
Brake system

Service brake
× thk × number) mm (in.) (10.80 × 1.91 × 0.19 × 2) (10.80 × 1.91 × 0.19 × 2) (13.54 × 2.36 × 0.24 × 2)
Master cylinder ID 19.05 (0.7500) 19.05 (0.7500) 19.05 (0.7500)
Wheel cylinder ID 22.22 (0.8748) 22.22 (0.8748) 28.58 (1.1252)
Mechanical, mounted Mechanical, mounted Mechanical, mounted
Type
on front wheels on front wheels on front wheels
Parking brake
Drum diameter mm (in.) 254 (10) 254 (10) 310 (12.2)

1-14
 GENERAL INFORMATION

GP25K, GP25K-HP DP25K GP30K DP30K GP35K DP35K

Hydraulic column Hydraulic column Hydraulic column
shift shift shift
2.195 2.195 2.195
2.258 2.258 2.258
Spur Spur Spur

1.394 1.167 1.394 1.257 1.394 1.257

Spiral bevel Spiral bevel Spiral bevel

5.667 5.667 5.667
Banjo Banjo Banjo
Straight bevel - 2 Straight bevel - 2 Straight bevel - 2

Straight bevel - 2 Straight bevel - 2 Straight bevel - 2

Full Hydrostatic Full Hydrostatic Full Hydrostatic
power steering power steering power steering
83° 83° 83°
56° 56° 56°
330 (13) 330 (13) 330 (13)

75 × 50 (2.953 × 1.068) 75 × 50 (2.953 × 1.068) 75 × 50 (2.953 × 1.068)

210 (8.27) 210 (8.27) 210 (8.27)

7.355 (75) [1066] 7.355 (75) [1066] 7.355 (75) [1066]

10.5 ± 0.5 12 ± 1.0

10.5 ± 0.5 (640.1 ± 30.5) 10.5 ± 0.5 (640.1 ± 30.5)
(640.1 ± 30.5) (732.3 ± 61.0)
Full-floating tubular Full-floating tubular Full-floating tubular
type type type
Elliott type Elliott type Elliott type
Fixed type Fixed type Fixed type
Center-pivot type Center-pivot type Center-pivot type
0 0 0
1 1 1
0 0 0

0 0 0

Hydraulic, duo-servo, Hydraulic, duo-servo, Hydraulic, duo-servo,

mounted on front wheels mounted on front wheels mounted on front wheels
310 (12.20) 310 (12.20) 310 (12.20)
344 × 60.0 × 6.0 × 2 344 × 60.0 × 6.0 × 2 344 × 60.0 × 6.0 × 2
(13.54 × 2.36 × 0.24 × 2) (13.54 × 2.36 × 0.24 × 2) (13.54 × 2.36 × 0.24 × 2)
19.05 (0.7500) 19.05 (0.7500) 19.05 (0.7500)
28.58 (1.1252) 28.58 (1.1252) 28.58 (1.1252)
Mechanical, mounted Mechanical, mounted Mechanical, mounted
on front wheels on front wheels on front wheels
310 (12.2) 310 (12.2) 310 (12.2)

1-15
GENERAL INFORMATION

Truck Model GP15K GP18K GP20K, GP20K-HP DP20K

Body-frame Unitized type Unitized type Unitized type
Type Gear Gear Gear
Manufacturer’s type KRP4 KRP4 KRP4 KFP3240
Hydraulic pump Rated liter 63.6 (3881) 63.6 (3881) 72 (4394) 88 (5370)
displacement (cu. in.) /2400 rpm /2400 rpm /2400 rpm /2200 rpm
Drive line Universal joint Universal joint Universal joint
Model KVSF65 KVSF65 KVSF65
Control valve kPa (kgf/ 18142+490 +5
18142+490 +5
18142+490 +5
+ 0 (185 +0 ) + 0 (185 +0 ) + 0 (185 +0 )
Relief pressure +71 +71 +71
cm2) (psi) [2331+ 0 ] [2631+ 0 ] [2631 + 0 ]
Type Variable Variable Variable
Flow regulator
valve Regulated flow liter (cu.
50 (3051) 50 (3051) 65 (3967)
rate in.)/min
Hydraulic system

Lift cylinders ID 45 (1.77) 45 (1.77) 50 (1.97)

(Simplex mast) Stroke 1500 (59) 1500 (59) 1500 (59)
No.1 Lift cylinder ID 70 (2.76) 70 (2.76) 75 (2.95)
(Duplex mast) Stroke 850 (33.5) 850 (33.5) 850 (33.5)
No.2 Lift cylinder ID mm (in.) 45 (1.77) 45 (1.77) 45 (1.77)
(Duplex mast) Stroke 1595 (62.8) 1595 (62.8) 1600 (63)
No.1 Lift cylinder ID 70 (2.76) 70 (2.76) 75 (2.95)
(Triplex mast) Stroke 850 (33.5) 850 (33.5) 850 (33.5)
No.2 Lift cylinder ID 45 (1.77) 45 (1.77) 50 (1.97)
(Triplex mast) Stroke 1525 (60) 1525 (60) 1525 (60)
ID 63 (2.48) 63 (2.48) 70 (2.76)
Tilt cylinders
Stroke 125 (4.92) 125 (4.92) 141 (5.55)
Hydraulic tank N level liter 27.8 (7.3) 27.8 (7.3) 40.1 (10.6)
capacity (approx.) H level (U.S. gal) 30.9 (8.2) 30.9 (8.2) 45.1 (11.9)
Mast Roller type CL Roller type CL Roller type CL
100 × 17 × 19 × 11 100 × 17 × 19 × 11 115 × 22 × 27 × 12
Mast dimensions Outer (3.94 × 0.67 × 0.75 × 0.43) (3.94 × 0.67 × 0.75 × 0.43) (4.53 × 0.87 × 1.06 × 0.47)
(Flange inside width
× Flange thk (Fr.) Middle mm (in.) 100 × 17 × 19 × 10 100 × 17 × 19 × 10 115 × 22 × 23 × 11
(3.94 × 0.67 × 0.75 × 0.39) (3.94 × 0.67 × 0.75 × 0.39) (4.53 × 0.87 × 0.91 × 0.43)
× Flange thk (Re.)
× Web thk) 100 × 17 × 19 × 10 100 × 17 × 19 × 10 115 × 22 × 23 × 11
Inner
(3.94 × 0.67 × 0.75 × 0.39) (3.94 × 0.67 × 0.75 × 0.39) (4.53 × 0.87 × 0.91 × 0.43)
Mast and forks

Type #6308 ball bearing #6308 ball bearing #6309 ball bearing
Main rollers
Diam × width mm (in.) 100 × 27 (3.94 × 1.06) 100 × 27 (3.94 × 1.06) 115 × 30 (4.53 × 1.18)
Lubricating type Lubricating type Lubricating type
Type needle roller bearing needle roller bearing needle roller bearing
Side rollers
Diam × width mm (in.) 42 × 36 (1.65 × 1.42) 42 × 36 (1.65 × 1.42) 42 × 36 (1.65 × 1.42)
Lift chains BL534 BL534 BL634
1070 × 100 × 40 1070 × 100 × 40 1070 × 100 × 45
Fork (lgth × width × thk)
(42.1 × 3.9 × 1.6) (42.1 × 3.9 × 1.6) (42.1 × 3.9 × 1.8)
mm (in.)
200 to 820 250 to 920 250 to 920
Fork spacing (out to out)
(7.9 to 32.3) (9.8 to 36.2) (9.8 to 36.2)

1-16
 GENERAL INFORMATION

GP25K, GP25K-HP DP25K GP30K DP30K GP35K DP35K

Unitized type Unitized type Unitized type
Gear Gear Gear
KRP4 KFP3240 KRP4 KFP3240 KRP4 KFP3240
72.0 (4394) 88.0 (5370) 79.9 (4876) 88.0 (5370) 79.9 (4876) 88.0 (5370)
/2400 rpm /2200 rpm /2400 rpm /2200 rpm /2400 rpm /2200 rpm
Universal joint Universal joint Universal joint
KVSF65 KVSF65 KVSF65
+490 +5 +490 +5
18142+490 +5
+ 0 (185 +0 ) 18142+ 0 (185 +0 ) 18142+ 0 (185 +0 )
+71
[2631+ 0 ] [2631+71
+ 0 ] [2631+71
+ 0 ]

Variable type Variable type Variable type

65 (3967) 75 (4577) 75 (4577)

50 (1.97) 55.2 (2.17) 60 (2.56)

1500 (59) 1500 (59) 1500 (59)
75 (2.95) 85.2 (3.35) 90 (3.54)
850 (33.5) 835 (32.9) 850 (33.5)
45 (1.77) 50 (1.97) 55 (2.16)
1600 (63) 1580 (62.2) 1600 (63)
75 (2.95) 85.2 (3.35) 90 (3.54)
850 (33.5) 835 (32.9) 850 (33.5)
50 (1.97) 55.2 (2.17) 60 (2.36)
1525 (60) 1515 (59.6) 1500 (59.1)
70 (2.76) 80 (3.15) 80 (3.15)
141 (5.55) 141 (5.55) 141 (5.55)
40.1 (10.6) 40.1 (10.6) 40.1 (10.6)
45.1 (11.9) 45.1 (11.9) 45.1 (11.9)
Roller type CL Roller type CL Roller type CL
115 × 22 × 27 × 12 115 × 22 × 27 × 12 115 × 22 × 27 × 12
(4.53 × 0.87 × 1.06 × 0.47) (4.53 × 0.87 × 1.06 × 0.47) (4.53 × 0.87 × 1.06 × 0.47)
115 × 22 × 23 × 11 115 × 22 × 23 × 11 115 × 22 × 23 × 11
(4.53 × 0.87 × 0.91 × 0.43) (4.53 × 0.87 × 0.91 × 0.43) (4.53 × 0.87 × 0.91 × 0.43)
115 × 22 × 23 × 11 115 × 22 × 23 × 11 115 × 22 × 23 × 11
(4.53 × 0.87 × 0.91 × 0.43) (4.53 × 0.87 × 0.91 × 0.43) (4.53 × 0.87 × 0.91 × 0.43)
#6309 ball bearing #6309 ball bearing #6309 ball bearing
115 × 30 (4.53 × 1.18) 115 × 30 (4.53 × 1.18) 115 × 30 (4.53 × 1.18)
Lubricating type Lubricating type Lubricating type
needle roller bearing needle roller bearing needle roller bearing
42 × 36 (1.65 × 1.42) 42 × 36 (1.65 × 1.42) 42 × 36 (1.65 × 1.42)
BL634 BL834 BL834
1070 × 100 × 45 1070 × 125 × 45 1070 × 125 × 50
(42 × 3.9 × 1.8) (42 × 5 × 1.8) (42 × 5 × 1.97)
250 to 920 250 to 960 250 to 960
(9.8 to 32.3) (9.8 to 37.8) (9.8 to 37.8)

1-17
 COOLING SYSTEM

Description ................................................................................................ 2 – 1
Removal and Installation ....................................................................... 2 – 2
2
Fan Belt Removal ....................................................................................... 2 – 2
Inspection and Adjustment ................................................................... 2 – 3
Fan Belt Inspection..................................................................................... 2 – 3
Fan Belt Adjustment ................................................................................... 2 – 3
 COOLING SYSTEM

Description

Radiator

Air flow

Cooling fan

To transmission

From transmission
206418E

Powershift transmission models

The cooling fan is installed inside with the radiator (in
the engine compartment). This helps minimize radiator
core clogging and retain high cooling efficiency even in
continuous operation for hours (pusher for system). In
the powershift transmission models, the radiator lower
tank has a built-in transmission oil cooler.

2-1
COOLING SYSTEM

Removal and Installation

Fan Belt Removal

2
1

4
206419

Sequence
1 Fan guard 4 Universal joint
2 Tensioner, Tensioner pulley 5 Fan belt
3 Support, Cooling fan

Start by:
At first stop the engine, then remove the engine hood and
gas spring.

Suggestion for removal

Make sure the muffler, engine and exhaust pipe are cool
enough to touch with your hand.

2-2
 COOLING SYSTEM

To install, follow the reverse of removal sequence and take

the following steps:
(1) After removing the belt, turn the fan to examine the
bearings for abnormal noise. Replace the bearings if
abnormally noisy.
(2) After installing the belt, push it inward midway
between the pulleys to make sure the tensioner pulley
moves freely before tightening the tensioner lock bolt
and mounting bolt.
206420

Inspection and Adjustment

Fan Belt Inspection

(1) Make sure the belt is free from oil, grease or other
foreign matter. Replace the belt if necessary. A
slightly dirty belt can be reused by cleaning with cloth
or paper. Do not clean the belt with gasoline or the
like.
(2) At the time of overhauling the engine or adjusting the
belt tension, check the belt and replace it if defective.

Fan Belt Adjustment

(1) Loosen the tensioner lock bolt and mounting bolt.
Tensioner lock
(2) Insert a small-diameter bar (or screwdriver) into the bolt
tension adjustment hole for leverage, and adjust the Tension
belt tension. adjustment
hole

NOTE Tensioner
mounting bolt
Be careful not to damage the radiator core with the bar
(screwdriver) during belt tension adjustment.
16 mm
(0.6 in.)

(3) Adjust the belt so that its deflection is 16 mm (0.6 in.) 206461A
when the belt is pushed downward with 98 N (10 kgf)
[22 lbf] force exerted midway between the fan pulley
and tensioner pulley.
(4) Tighten the tensioner lock bolt and mounting bolt.
(5) After the adjustment, install the fan guard.
If cracks or other abnormalities are found in the fan
guard, replace the fan guard.

2-3
 ELECTRICAL SYSTEM

Description ................................................................................................ 3 – 1
Console Box ............................................................................................... 3 – 1
Electrical Components Mounted on Body................................................... 3 – 2
Suggestions for Removal and Installation ........................................ 3 – 3
3
Console Box ............................................................................................... 3 – 3
Disassembly and Reassembly ............................................................. 3 – 4
Console Box ............................................................................................... 3 – 4
Components in Console Box ...................................................................... 3 – 5
Combination Meter ..................................................................................... 3 – 6
Major Electrical Components ............................................................... 3 – 7
Starter Switch (with Anti-restart Lock) ........................................................ 3 – 7
Lighting Switch ........................................................................................... 3 – 8
Fuse Box ................................................................................................... 3 – 9
Spare Terminals ......................................................................................... 3 – 9
Battery Maintenance ............................................................................... 3 – 10
Lamp Bulb Specifications ..................................................................... 3 – 11
Wire Color .................................................................................................. 3 – 12
Troubleshooting ........................................................................................ 3 – 13
Electrical Schematics ............................................................................. 3 – 17
 ELECTRICAL SYSTEM

Description 5 4

Console Box
1
1 Engine coolant temperature gauge 3
2 Choke control (GAS only)
3 Fuel gauge
4 Service hourmeter
5 OK monitor
7
6 Starter switch 2
7 Light switch 6
8 Fuse box 8

207221
OK monitor

1 2 3 4 5 6 7 8

207222
Function

No. Indicator light OFF ON or flickering Remarks

1 Powershift transmission oil temp. indicator light Normal Overheating Option
2 Air cleaner element indicator light Normal Clogged Option
3 Brake fluid level indicator light Normal Low
4 Engine oil pressure indicator light Normal Low
5 Alternator not charging indicator light Normal Abnormal
6 Glow plug indicator light Heating completed Heating Diesel models
7 Fuel filter indicator light Normal Drain water Diesel models
8 Engine coolant level indicator light Normal Low Option

How to check indicator light bulbs

The bulbs are normal if the indicator lights 1, 2, 3 and 7 come ON when the starter switch key is turned to
(ON) position. (The indicator lights will go OFF when the engine starts.)

3-1
ELECTRICAL SYSTEM

Electrical Components Mounted on Body

8 1 2 5 10 3 4

Electrical components connected

to console box

C
11

7
6

1
207212A

1 Main harness 8 Diode

2 Fusible link (R.H.) 9 Alternator relay
3 Fusible link (L.H.) 10 Engine cover harness
4 Fuse 11 System harness
5 Fuse A: to Directional lever
6 Diode B: to Turn signal switch
7 Diode assembly C: to Ignition coil

3-2
 ELECTRICAL SYSTEM

Suggestions for Removal and Installation

Console Box
Removal

5
2

1
207210

Start by:
Turn off the starter switch, and disconnect the negative
(grounding) cable from the battery.

Removal sequence 5. Remove screws on cover (U-FR) 5, and remove the

1. Disconnect the electrical wires at connectors 1. (In cover.
the gasoline models, disconnect the choke cable on 6. Remove bolts on console box assembly 6, and
the engine side.) remove the console box assembly.
2. Disconnect the electrical wires at connectors, and
remove directional lever 2. Installation
3. Remove screws on cover 3 using a flat-tip
To install, follow the reverse of removal sequence.
screwdriver, and remove the cover.
4. Remove screws on cover (U-RE) 4, and remove the
cover.

3-3
ELECTRICAL SYSTEM

Disassembly and Reassembly

Console Box

3
207175

Disassembly Reassembly
1. Remove screws 1 (two) securing the cover. (Use a To reassemble the console box, follow the reverse of
flat-tip screwdriver (–)) disassembly sequence.
2. Remove screws 2 (six) and separate the front and
rear panels.
3. Remove screws 3 (four) securing the instrument
panel.

NOTE
To replace the instrument panel bulbs, remove
screws 2 and 3.

3-4
 ELECTRICAL SYSTEM

Components in Console Box

1 7

206423

1 Power relay 5 Glow plug relay (diesel models)

2 Power relay 6 Light switch
3 Turn signal relay 7 Starter switch
4 Glow plug relay (diesel models) 8 Fuses

3-5
ELECTRICAL SYSTEM

Combination Meter
Disassembly

2
3

8
9
206480

Sequence
1 Instrument panel 6 Meter case
2 Dial 7 Printed circuit
3 Engine coolant temperature gauge 8 Bulb
4 Service hour meter 9 Socket
5 Fuel gauge

! CAUTION
Be careful not to damage the printed circuit
when disassembling the combination meter.

Reassembly Bulb replacement

To reassemble the combination meter, follow the For bulb replacement, remove the socket from the
reverse of disassembly sequence. printed circuit by turning it counterclockwise. For
configuration of the indicator lights, refer to “OK
Monitor.”

3-6
 ELECTRICAL SYSTEM

Major Electrical Components

Starter Switch (with Anti-restart Lock)

This switch has a built-in anti-restart lock, so the key models use the same starter switch. In the diesel
cannot be turned from (ON) to (START) position models, (ON) position of the switch is for energizing
while the engine is running. The gasoline and diesel the glow plugs.

(OFF)
(ON)

(START) B

203561A

Connection for gasoline models

Terminal B M S

Component Fuse box, batteries, Fuse box, fuel-cut Starter, neutral switch
Key alternator solenoid (powershift transmis-
position sion models)

(OFF) 
(ON)  
(START)   

Connection for diesel models

Terminal B M S

Component Fuse box, glow Fuse box, fuel-cut Neutral switch,

Key plug relay, battery solenoid, glow plug timer, glow plug timer
position alternator glow plug timer relay

(OFF) 
(ON)  
(START)   

3-7
ELECTRICAL SYSTEM

Lighting Switch

OFF 1st 2nd Knob position

Stroke

8 (0.3)
8 (0.3)
[Unit: mm (in.)]

206481

Connection chart

Terminal B T H P
Component Tail lamps, license
Knob Batteries plate light (option), Head lights Turn signals,
position (fuses) instrument light clearance lights

(OFF)
1st position   
2nd position    

3-8
 ELECTRICAL SYSTEM

Fuse Box

Symbol Capacity Circuit

A 10 A Backup lights (manual trans-

mission models, stop lights)
A
Instrument panel light, turn
B B 15 A signals, backup lights (power-
C shift transmission models)
D
C 15 A Spare terminal, engine thermo
E switch
F
G D 15 A Tail lights, clearance lights,
H
working lights (option)
J E 15 A Head lights
F 10 A Spare fuse
G 10 A Horn
H 15 A Spare fuse
101441D J 10 A Spare fuse

Spare Terminals
The spare terminal cord extends from the fuse box in the
console box.
(Another spare terminal is located on the chassis-side main
harness. The spare power supply terminal cord measuring
approximately 50 mm (2 in.) extends from the junction of
the transmission power supply located on the right side of
the main harness. This terminal is secured to the main
harness with red vinyl tape.)

Color code Lg (light green)

Removing the console box rear panel will expose this spare
terminal which is fastened to the harness protector with
vinyl tape. Spare terminal

207209

3-9
ELECTRICAL SYSTEM

Battery Maintenance

1. State of charge and electrolyte specific gravity (S.G.) adjustment

Specific gravity reading

State of charge Adjustment
at 20 °C (68 °F)
1.280 to 1.265 Fully charged If difference in S.G. between any two cells is 0.04 or
more, effect a high current discharge to minimize the
difference and then recharge battery. Adjust S.G.
during recharging.
1.260 to 1.225 One-half charged Recharge battery and adjust electrolyte S.G. Make sure
there is neither faulty components, loosely connected
cord nor corroded connection.
1.220 or below Discharged Recharge battery. If difference in S.G. is large, adjust it
during recharging.
If difference in S.G. is A cell with a low S.G. During recharging, adjust S.G. to 1.280 to 1.265.
more than 0.040 is in shorted condition. If difference in S.G. is more than 0.040 and a low S.G.
Recharge until voltage is found in certain cells only, replace battery. After
and S.G. stabilize and leaving battery for 12 to 96 hours, conduct a high
have remained constant current discharge test.
for more than 2 hours.

2. Specific gravity reading and state of (4) When connecting the cables to the battery, begin
charge with the cable for the positive (+) terminal. When
disconnecting them from the battery, begin with the
To check the battery for state of charge, take
cable for the negative (–) terminal.
hydrometer readings on its electrolyte. The battery may
be fully charged if the S.G. reading is 1.280 to 1.265 at
20 °C (68 °F). The state of charge can be told from the ! CAUTION
way the electrolyte level goes down to expose the cell
Be sure to turn OFF the starter switch and
plates. If addition of distilled water is necessary every
lighting switch before disconnecting or
month or so, the battery is overcharged. If addition is
connecting the battery cables to prevent the
not required for more than 3 months, it is likely that the
IC regulator from suffering damage.
battery is inadequately charged.

3. Charging precautions
(1) In slow charging, the charging current should be
about 1/10 the capacity of the battery to be charged.
(2) In quick charging, the battery capacity in ampere
should not be exceeded.
(3) During charging, adjust the charging current to
prevent the electrolyte temperature from rising
beyond 45 °C (113 °F).

3-10
 ELECTRICAL SYSTEM

Lamp Bulb Specifications

Item No.of Color of Watts

Shape Remarks
Type of lamp bulbs lens 12 volt

Headlamps 2 Colorless 55

Turn signal lamps 2 Amber 27 Optional

Combination
lamps (front)

Clearance lamps 2 Colorless 10 Optional

Turn signal lamps 2 Amber 23

Combination
Tail/stop lamps 2 Red 8/23
lamps (rear)

Back-up lamps 2 Colorless 10

Working lamps (front and rear) 4 Colorless 55 Optional

License plate lamps 1 Colorless 10 Optional

Instrument panel lamps 2 Colorless 3.8

OK monitor indicator lamps 11 Colorless 3

204964

3-11
ELECTRICAL SYSTEM

Wire Color

Wire colors listed in the table below show standard colors (base colors). For wiring composed of two colors, the first
color shows a base color and the second color a marking color.
Example: The wire color of BW shows that its base color is B with a marking W.

BW
Marking color
Base color

Note: For wiring identification, the same color, in principle, must be used for the circuit from the power supply to the
load.

! CAUTION
Be careful that allowable current differs between solid wires and stranded wires even if they are of the
same gauge.

List of wire colors

Wire color Color

B BLACK
W WHITE
R RED
G GREEN
Y YELLOW
Br BROWN
L BLUE
Lg LIGHT GREEN
O ORANGE
P PINK
Gr GRAY
Lb LIGHT BLUE
Dg DARK GREEN
ch CHOCOLATE

3-12
 ELECTRICAL SYSTEM

Troubleshooting

Starter System
Weak or dead battery Recharge or replace.
Short or open circuit Repair or replace.
Starter will not crank
Poor continuity in starter switch Replace.
engine
Starter or starter relay defective Replace.
Forward-reverse lever not in neutral Move lever to neutral
Starter switch position position.
Turning off starter Open or short circuit Repair or replace.
switch will not stop Engine stop solenoid defective Replace or readjust.
engine Control timer defective Replace.

Gauges
Rigid board defective Replace.
Will not indicate at Open or short circuit Repair or replace.
all Gauge internally defective Replace.
Gauge unit defective Replace.
Water Gauge or gauge unit not of the type Replace to a correct
Will not indicate called for one.
temperature
accurately
gauge Loose terminal connection Repair.
Will indicate higher Circuit between gauge and gauge unit Repair.
than actual grounded
temperature Gauge internally defective Replace.

Rigid board defective Replace.

Will not indicate at Open or short circuit Repair or replace.
all Gauge internally defective Replace.
Gauge unit defective Replace.
Gauge or gauge unit not of the type Replace to a correct
Will not indicate called for one.
accurately
Loose terminal connection Repair.
Fuel gauge Circuit between gauge and gauge unit Repair.
Will indicate “full” open or short
regardless of amount
Gauge internally defective Replace.
of fuel left in tank
Gauge unit defective Replace.
Will indicate Circuit between gauge and gauge unit Repair.
“empty” regardless grounded
of amount of fuel Gauge unit defective Replace.
left in tank Gauge internally defective Replace.

3-13
ELECTRICAL SYSTEM

Lighting System
Weak or dead battery Recharge or replace.
Fuses blown out Check and replace.
Open or short circuit Repair or replace.
Will not light Poor grounding Clean ground spot and
re-make connection.
Switch defective Replace.
Lamps - general Bulbs burnt out Replace.
Weak battery Check and recharge.
Contact points in switches defective Repair or replace.
Loose terminals Repair.
Will light dimly
Dirty lenses Clean.
Waterdrops inside lenses Dry and replace packings.
Bulbs expired in service life Replace.
Lighting switch defective Replace.
Head lamps Will not light
Bulbs burnt out Replace.
Turn signal switch defective Replace.
Will not flicker
Turn signal relay defective Replace.
Turn signal relay defective Replace.
Will not go out
Bulbs burnt out Replace.
Turn signals Low wattage of bulbs Replace to a correct one.
Will flicker too
slow Bulbs burnt out Replace.
Turn signal relay defective Replace.
Will flicker too High wattage of bulbs Replace to a correct one.
fast Turn signal relay defective Replace.

Backup lamps Backup lamp switch defective Repair or replace.

will not light Bulbs burnt out Replace.
Other lamps
License number Lighting switch defective Replace.
plate lamp will
not light Bulb burnt out Replace.

Alarm Unit
Fuse blown out Check and replace.
Open or short circuit Repair or replace.
Will not give
blast of sound Horn switch defective Replace.
Horn defective Replace.
Horn Horn button defective Repair or replace.
Will give ugly Horn switch defective Replace.
blast of sound Horn defective Replace.

3-14
 ELECTRICAL SYSTEM

Battery
Drive belt slipping Readjust.
❋ Alternator
Stator coil grounded or open-circuited Repair or replace.
Rotor coil open Replace.
Brushes poorly seating on slip rings Replace brushes if worn.
Clean holder and polish
slip rings.
Diode ruptured Replace.
Tends to run down ❋ Regulator
rapidly
Regulated voltage setting too low Replace.
❋ Battery
Terminal connections loose Clean and retighten.
❋ Wiring
Open or loose connection between starter switch and Repair.
regulator IC terminal
Fuse blown, or loosely set in holder Replace and repair.
Open or loose connection between F terminals of Repair.
regulator and alternator

❋ Wiring
Regulator IC and F terminals shorted or miswired Repair.
Poor grounding of regulator F terminal Repair.
Tends to get
overcharged ❋ Regulator
Pressure coil open-circuited Replace.
Regulated voltage too high Replace.

3-15
 MITSUBISHI CATERPILLAR FORKLIFT
AMERICA INC.

SCHEMATIC(S) INSERTION

Schematic(s) name/number

Insert copy of 11" x 17" schematic

99719-82130s.pdf (page 1 of 2)
 MITSUBISHI CATERPILLAR FORKLIFT
AMERICA INC.

SCHEMATIC(S) INSERTION

Schematic(s) name/number

Insert copy of 11" x 17" schematic

99719-82130s.pdf (page 2 of 2)
 POWER TRAIN

Removal and Installation ...................................................................... 4 – 1

Engine and Transmission ........................................................................... 4 – 1

4
 POWER TRAIN

Removal and Installation

Engine and Transmission

Removal
The engine can be removed by itself but the
NOTE
transmission has to be removed with the engine. These
pages are devoted to the explanation of removal of the Removal and installation procedures of the gasoline
transmission and engine together as a unit. engine differ from those of the diesel engine.

Overhead Guard, Cover and Air Cleaner

3 5 2 6
1

8
(Diesel models)

(Gasoline 9
models)
(Diesel models)
8
4
7
10

(Gasoline models)

207345

Sequence
1 Overhead guard, Head lamps 6 Radiator cover
2 Battery, Cables 7 Front cover, Floor plate
3 Steering wheel 8 Air hose, Air cleaner
4 Gas spring 9 Exhaust pipe
5 Engine hood, Seat 10 Fuel hose

4-1
POWER TRAIN

Suggestions for Removal

1. When removing. Battery 2, be sure to disconnect the
cable from the negative (–) terminal of the battery 2
first.
2. Remove front cover 7 together with the accelerator
pedal. For this removal, disconnect the pedal from the
link rod.
3. Disconnect exhaust pipe 9 at the engine side.
4. Before disconnecting fuel hose 10, close the fuel
shutoff valve.

4-2
 POWER TRAIN

Control Linkage

15
(Gasoline models)

15
(Diesel models)
15
(Gasoline models)
15

12

Inching
bracket

11

14

13
207153

Sequence
11 Brake pipes 14 Pedal assembly
12 Inching cable, Clevis pin, Washer, Snap pin 15 Throttle cable, Accelerator pedal bracket, Pin,
13 Connector (Brake fluid level sensor, Stop lamp Washer, Choke cable
switch)

Suggestion for Removal

To remove inching cable 12, pull out pins and loosen lock
nuts at the transmission and inching pedal sides of the
cable.

4-3
POWER TRAIN

Harness and Cables 16 (gasoline models)

Transmission
solenoid valve
Lamp Battery
Horn

Torque converter
oil temp. unit

Ignition coil
Cable
Starter
Engine coolant temp. unit

Alternator

Brake fluid Alternator

Stop lamp
switches level sensor
Oil pressure
switch

Lamps
207341

Sequence
Harness and cables
(between transmission case and frame)

Parts to be removed
(1) Already removed.

(2) To be removed.

4-4
 POWER TRAIN

Harness and Cables 16 (diesel models)

Transmission
solenoid valve
Torque converter
oil temp. unit Fuel cut solenoid
Lamp
Battery
Starter

Heater plug

Cable
Sedimenter water
level sensor Alternator
Alternator
Engine coolant temp. unit
Stop lamp Brake fluid
switches level sensor

Oil pressure switch

Lamps

207342

Sequence
Harness and cables
(between transmission case and frame)

Parts to be removed
(1) Already removed.

(2) To be removed.

Suggestion for Removal

Disconnect the harness from the engine and transmission at
the sockets or terminals. Tie the disconnected harnesses to
the main harness to prevent them from damage.

4-5
POWER TRAIN

Piping and Cooling Fan

24

25

25
18

23

21 22
19
26
20

17
27
207154A

Sequence
17 Reservoir 23 Hose (upper)
18 Coolant hoses 24 Hose (lower)
19 Fan guard 25 Cooler hose
20 Tensioner, Tensioner pulley 26 Universal joint (between engine and oil pump)
21 Support, Cooling fan 27 Universal joint (between transmission and
22 Fan belt differential)

Start by: Suggestions for Removal

1. Remove the coolant drain plug of the engine and 1. Disconnect cooler hose 18 at the transmission side,
drain coolant. (The drain plug location differs from put it on the right side of the frame.
one model of the engine to another.)
2. Automatic transmission fluid will flow out from the
2. Loosen the cock at the bottom of the radiator and cooler when cooler hose 25 is disconnected. Catch
drain coolant. the fluid in a container after disconnecting the hose.

4-6
 POWER TRAIN

Engine and Transmission

29

Engine coolant
drain plug

Engine mount

28
Transmission
mounting bolt
Engine support

Engine mount
(frame side)
Transmission oil Engine oil
drain plug 28
drain plug

204822

Sequence
28 Bolts (for transmission and engine supports) 29 Engine and transmission assembly

Start by:
Lift the engine and transmission assembly by a hoist.

4-7
POWER TRAIN

Suggestions for Removal

1. When removing bolts 28, lift the engine and
transmission assembly just enough to free the mount
cushion. On the engine side, remove bolts 28 from the
engine support.
2. When removing the engine and transmission assembly,
lift it off while moving it backward. Before lifting the
assembly, know the location of the center of gravity of
the assembly.

NOTE
1) Drain transmission oil with the assembly lifted.
2) The powershift transmission has one drain plug.

Installation
To install, follow the reverse of removal sequence.

Suggestions for Installation

1. When installing the engine and transmission assembly, Engine side
carefully lower it while aligning the cushion mounting
28 Bolt
bolts with their holes on the transmission side. On the
engine side, align engine support mounting bolts 28
with their holes in the frame-side engine mounts. Engine
support

Cushion

Frame-side
engine mount

204912

2. After connecting the cable between the inching pedal

and transmission, make sure that the plunger projection Unit: mm (in.)
is adjusted within specifications or readjust if 1 ton 9 to 9.5
necessary. Plunger class (0.35 to 0.37)
projection 2, 3 ton 6 to 9.5
classes (0.24 to 0.37)

4-8
 POWER TRAIN

3. Connect the accelerator pedal to the throttle cable, and

make sure that the injection pump lever is in the full
throttle position when the accelerator pedal is
depressed all the way (diesel models). On the gasoline
models, connect the accelerator pedal to the throttle
cable, and make sure that the throttle lever is in the full
throttle position when the accelerator pedal is
depressed all the way.
4. After connecting the brake pipes, bleed air out of the
fluid lines.
5. When installing the exhaust pipe to the engine, use a
new gasket.
6. Connect the battery cable to the negative (–) terminal
of the battery last. After making sure that all the
harnesses and cables have been properly connected.
7. Refill the engine with oil and coolant and the
transmission with oil, and check for leaks. Unless
otherwise specified, use antifreeze of 35%
concentration by volume.
8. Prime the fuel system.
9. After completing the inspection, start the engine, and
check it. Move the mast and steering for a while, and
check the oil level in the hydraulic tank. Also, check
the engine oil level, coolant level and transmission oil
level.

4-9
 POWERSHIFT TRANSMISSION

Description ................................................................................................ 5 – 1
Hydraulic Circuit ......................................................................................... 5 – 2
Control ....................................................................................................... 5 – 3
Removal and Installation ....................................................................... 5 – 3
Disassembly and Reassembly ............................................................. 5 – 4
Transmission Assembly .............................................................................. 5 – 4
Disassembly ............................................................................................. 5 – 4
Reassembly.............................................................................................. 5 – 10
Pump Assembly ..................................................................................... 5 – 10 5
Transmission Assembly .......................................................................... 5 – 14
Control Valve .............................................................................................. 5 – 17
Disassembly ............................................................................................ 5 – 17
Reassembly.............................................................................................. 5 – 18
Inspection and Adjustment ................................................................... 5 – 19
Testing Hydraulic Pressure......................................................................... 5 – 19
Adjusting Inching Pedal .............................................................................. 5 – 21
Testing Clutch Valve ................................................................................... 5 – 23
Testing Stall Speed..................................................................................... 5 – 23
10-m (33-ft) Start Acceleration Test ............................................................ 5 – 24
Troubleshooting ........................................................................................ 5 – 25
Service Data .............................................................................................. 5 – 29
 POWERSHIFT TRANSMISSION

Description

b
a (31)
(36)

d
(31)

c
(35) e
(70)

Figures shown in ( ) indicate

the number of gear teeth.

207116

The transmission, integrally coupled to the torque 1.0 to 1.8 ton classes 2 to 3.5 ton classes
converter, provides a choice of one forward ratio and
one reverse ratio. It has built-in multi-disc clutches, Model 66H7 66H8
which are hydraulically actuated to control the flow of Type Three-element, single-stage, two-phase
drive from the converter. The control lever — shift
lever — is for operating a hydraulic control valve.
Range Powerflow
Thus this transmission is of a “powershift” type.
F (Forward) a ⎯→ cde
The transmission housing and the torque converter
housing can be separated from each other. R (Reverse) b ⎯⎯→ e
The pump, turbine and stator can be removed as one
assembled unit from the starter shaft and from the input Transmission reduction ratio
shaft.
F 35 70
The torque converter is of one-piece construction (Forward) 36 × 31 = 2.195
fabricated by welding and is meant to be replaced as
R 70
one assembled unit. (Reverse) 31 = 2.258
The transmission parts, except for torque converter,
clutch valve, the output flange and universal joints, are
common to all models.

5-1
 Torque converter inlet pressure
Lube oil
e Oil cooler
c

Accumulator
Hydraulic Circuit

valve

F R Main regulator
POWERSHIFT TRANSMISSION

valve

Clutch valve

F ←⎯→ R
Selector d
valve
F Torque converter
b outlet pressure

5-2
b

a Unit: kPa (kgf/cm2) [psi]

Filter (100 mesh)
with magnet 883 to 1079
a Main pressure (9 to 11)
[128 to 156]
883 to 1079
b Clutch pressure (9 to 11)
[128 to 156]
196 to 490
c Torque converter inlet (2 to 5)
pressure [28 to 71]
147 to 294
Oil pump d Torque converter outlet (1.5 to 3)
Actual capacity : 36 liters (2197 cu. in.)/2400 rpm (Gasoline models) pressure [21 to 43]
33 liters (2014 cu. in.)/2200 rpm (Diesel models)
98 to 147
e Lube oil pressure (1 to 1.5)
[14 to 21]
Engine speed: 1500 ± 100 rpm
204869
 POWERSHIFT TRANSMISSION

Control

R
N 1
F

6 2
5

207136

1 Transmission shift lever 5 Clutch valve plunger

2 Clutch (inching) pedal 6 Solenoid valve assembly
3 Bracket (inching) (for forward-reverse)
4 Control valve assembly

Removal and Installation Installation

(1) Couple the torque converter and transmission to the
Removal engine. To do this, place the torque converter in
(1) Remove the engine and transmission as an the transmission housing so that the distance
assembly from the truck. between the end face of the housing and the mating
face of flexible plate is 50 to 52 mm (1.97 to 2.05
NOTE in.). The clearance between the flywheel and
For the removal and installation of the engine and flexible plate should be 1 to 5 mm (0.04 to 0.20 in.)
transmission, refer to “GROUP 4 POWER when the torque converter is coupled to the engine.
TRAIN”. If this clearance is zero, it is an indication that the
torque converter is improperly coupled to the
engine; recouple the converter to the engine
(2) Unscrew the bolts securing the flexible plate properly.
through the access hole in the torque converter
(2) Tighten the bolts securing the flexible plate to the
housing.
flywheel through the access hole in the converter
(3) Separate the torque converter and transmission housing.
from the engine.
NOTE
Tighten the bolts in a criss-cross pattern.

5-3
POWERSHIFT TRANSMISSION

Disassembly and Reassembly

Transmission Assembly
Disassembly

20
16
17 19 10

3 9
18 5
15
14 1
21

12
Bracket (inching)
2

8 11

24 2
5 23

22
6
Mount bracket

11
7
207119

Sequence
1 Torque converter assembly, Flexible plate 14 Seal ring, Ball bearing, Thrust washer
2 Sender unit, Drain plug, Gasket 15 FORWARD gear, Needle roller bearing, Thrust
3 Oil level gauge, Pipe washer
4 Air breather 16 Seal ring, Ball bearing, Thrust washer
5 Oil pipe, Eye joint, Gasket 17 REVERSE gear, Needle roller bearing, Thrust
6 Output flange washer
7 Filter case, Magnet strainer 18 Snap ring, Spring retainer, Clutch spring
8 Control valve 19 Snap ring, Pressure plate, Mating plates,
9 Stator shaft, Relief valve, Spring, Washer, Friction plates, Belleville spring
Snap ring, O-ring, Steel ball 20 Clutch piston, Seal ring, Input shaft
10 Pump body, Internal gear, Drive gear, Oil seal, 21 Idler shaft, Ball bearing, Snap ring
O-ring 22 Output gear, Ball bearing
11 Transmission housing, Gasket, O-ring, Steel 23 Baffle plate
ball, Plug 24 Torque converter housing, O-ring, Steel ball
12 Ball bearing, Idler gear
13 Input shaft assembly
(consisting of 14 thru 20)
5-4
 POWERSHIFT TRANSMISSION

NOTE
1) Remove the pump as an assembly including 9 and
10.
2) Remove the input shaft as an assembly including
14 thru 20, and disassemble it in the order shown.

Start by:
1. Remove two mount brackets from the transmission
housing.
2. Remove the brackets (inching) and springs.

Suggestions for Disassembly

1. Removing torque converter assembly
Remove the torque converter assembly complete with the
flexible plate.
Prepare a container to catch the oil that flows out of the
converter.

204829

5-5
POWERSHIFT TRANSMISSION

2. Removing pump assembly

Lifting bolt holes
Unscrew the pump mounting bolts and screw two bolts (at locations
marked ❋) ❋
(special tool) into the M8 × 1.25 holes in the pump body to
remove the pump assembly. Be sure to tighten the bolts
equally, or the threads will suffer damage. Use M8 × 1.25
bolts having an effective thread length of 55 mm (2.2 in.)
Special tools needed

Bolt 91268 - 05100

❋
209911
3. Removing transmission housing bolts
After removing the pump assembly, unscrew two
transmission housing bolts (F1805 - 10025) from the torque
converter housing side.

4. Removing transmission housing

Lay the transmission and torque converter assembly with
transmission housing down. Unscrew the transmission
housing bolts. Hang the transmission housing to a hoist, tap
the transmission and clutch housing flanges near the dowel
pins with a plastic hammer to separate the transmission
housing from the torque converter housing.

204830

5. Removing input shaft ball bearing

Using a special tool, remove the ball bearing from the input 1
shaft.

Special tools needed

Ref.
Tool name Part No. Q’ty
No.
4 2 3
1 Puller 91268 - 13810 2 207120

2 Plate 91268 - 13820 1

3 Bolt F1035 - 10020 2

Gear puller T-24

4 – 1
(BANZAI make)

5-6
 POWERSHIFT TRANSMISSION

6. Disassembling input shaft

Using a special tool or an arbor press, compress the clutch
spring, and remove the snap ring.

Special tools needed

Piston tool 91268 - 07100

NOTE
1) Do not remove steel balls and sealing caps from 207160
the transmission housing and torque converter
housing.
2) Do not remove oil seals from the pump body and
transmission housing unless they are defective.

Inspection after disassembly

1. Input shaft
(1) Check the splines for wear or damage.
(2) Check the width of each seal ring groove for wear; also
Seal ring grooves
check the groove for damage.
(3) Check to be sure that oil grooves and passages are open
and clean, free from sign of clogging.

2. Gears Oil passages

Check the gears and splines for wear or defects.

207121

3. Clutch drums
(1) Check the sliding surfaces of mating and friction plates
for wear or damage.

5-7
POWERSHIFT TRANSMISSION

4. Friction plates and mating plates

(1) Check for sign of seizure, uneven contact, warpage or
excessive wear.
Mating plate
(2) Check the splines for wear or damage.

A: Standard value B: Repair or service limit Friction

plate
Unit: mm (in.)
1.6 ± 0.10
Thickness of mating A
(0.063 ± 0.0039)
207122
plate
B 1.3 (0.051)
2.6 ± 0.1
Thickness of friction A
(0.1023 ± 0.004)
plate
B 2.2 (0.087)

5. Clutch pistons
(1) Shake each piston, make sure that the balls move freely
in it. When piston is overhauled and cleaned, screw the
plug until its head gets into piston end face, and caulk
the plug. Seal ring
Plug
NOTE
Do not disassemble the piston unless it is defective.

(2) Check the seal rings and their grooves for wear or
damage.
Seal ring
207123
6. Transmission housing
Check the seal ring contact surfaces for wear or damage.

7. Magnet strainer
Check for clogging or breakage.

8. Idler shaft
Check the splines for wear or damage.

9. Output flange
Check the splines for wear or damage. Also, check the oil
seal contact surface for defects.

5-8
 POWERSHIFT TRANSMISSION

10. Oil pump

(1) Check top clearance A between the drive gear and B
pump body with feeler gauges.
(2) Check side clearance B between the internal gear and A
drive gear and the pump body with a straight edge and
C
feeler gauges.
(3) Check the backlash between the drive gear and internal
gear with feeler gauges.
(4) Put the drive gear on the torque converter pump
Drive gear
impeller, and check clearance C between the gear and 204831
pump boss.

A: Standard value B: Repair or service limit

Unit: mm (in.)
No. Item Dimension
0.30 to 0.33
A Top clearance A
(0.0118 to 0.0130)
0.040 to 0.083
A
B Side clearance (0.00157 to 0.00327)
B 0.150 (0.00591)
Clearance
C between pump A 0.1 to 0.4
boss and drive gear (0.004 to 0.016)

0.10 to 0.18
A
Gear backlash (0.0039 to 0.0071)
B 0.30 (0.0118)

5-9
POWERSHIFT TRANSMISSION

Reassembly
Pump Assembly

3
204832

Sequence
1 Stator shaft, Relief valve, Spring, Washer, 3 Internal gear, Drive gear, O-ring, Bolt, Washer
Snap ring
2 Pump body, Oil seal

Suggestions for Reassembly

1. Installing oil seal
Using installer (special tool), install the oil seal to the pump
Oil seal
body.
Special tools needed

Installer 91268 - 05300

204833

5-10
 POWERSHIFT TRANSMISSION

2. Installing pump
Internal gear Oil pump body
When installing the pump, coat automatic transmission
fluid to the pump body interior, internal gear and drive
gear.

3. Inspection after reassembly

Turn the drive gear by hand to make sure the pump gears
rotate smoothly.
Drive gear 209927

1
3

5
8

207124

Sequence
1 Input shaft, Clutch piston, Seal ring 5 Thrust washer, Ball bearing
2 Clutch spring, Spring retainer, Snap ring 6 Thrust washer, Needle roller bearing
3 Belleville spring, Mating plates, Friction plates, REVERSE gear
Pressure plate, Snap ring 7 Thrust washer, Ball bearing, Seal ring
4 Thrust washer, Needle roller bearing, 8 Seal ring
FORWARD gear
NOTE
Reassembly of the clutch spring and plates on the
REVERSE gear side is the same as that on the
FORWARD gear side.

5-11
POWERSHIFT TRANSMISSION

Suggestions for Reassembly

1. Installing piston assembly
When installing the piston assembly to the input shaft, coat
to the seal ring automatic transmission fluid.

2. Reassembling input shaft

To install the snap ring, compress the clutch spring with a
special tool or an arbor press.
Special tools needed

Piston tool 91268 - 07100

207160

3. Installing plate
(1) Make sure that the combination and number of plates Mating plate (6) Drum
are correct. Friction plate (5)
Number of plates
Belleville
1 ton class 2, 3 ton classes spring (1)

Friction plate 3 5
Mating plate 4 6
Pressure
plate (1)
207125

(2) Coat the mating plates and friction plates with

automatic transmission fluid when installing them.
Belleville spring Piston
(3) The friction plates and the mating plates should be
replaced as a set.

207126

5-12
 POWERSHIFT TRANSMISSION

4. Installing FORWARD gear and REVERSE gear

Make sure that the oil groove side of the thrust washer
faces the gear when installed.

200213

5. Installing bearing
To install the ball bearing to the input shaft, use installer
(special tool).
Special tools needed

Installer 91268 - 04100

207127

6. Testing clutch piston FORWARD side

After reassembling the input shaft, apply air to the clutch REVERSE side
piston through oil hole on the FORWARD gear side to
make sure that the piston moves freely.

FORWARD

REVERSE

207128

5-13
POWERSHIFT TRANSMISSION

Transmission Assembly

10 8
9
14

12 7

11
13

1
2

6
207129

Sequence
1 Torque converter housing, Baffle plate 9 Gasket, Control valve, O-ring
2 Output gear, Ball bearing 10 Oil pipe, Eyebolt, Gasket
3 Idler shaft, Ball bearing, Snap ring 11 Output flange
4 Input shaft assembly 12 Magnet strainer, Filter case
5 Idler gear, Ball bearing 13 Drain plug, Gasket, Sender unit
6 Gasket, O-ring 14 Torque converter assembly
7 Transmission housing, Oil seal
8 Pump assembly, O-ring

5-14
 POWERSHIFT TRANSMISSION

Suggestions for Reassembly

1. Reassembling sequence
To reassemble, follow the reverse of disassembly sequence.

2. Placing the torque converter housing

Lay the torque converter housing with its engine side down.

3. Applying grease
Apply grease to the lips of the oil seals of the pump
assembly and transmission housing.

4. Applying oil on seal ring

Coat to the input shaft seal ring with automatic
transmission fluid.
204839

5. Mounting the transmission housing

Set the transmission housing to a hoist with slings and eye
bolts. Lower the housing onto the torque converter housing
by aligning the input shaft with the transmission.

204830

6. Installing pump assembly

(1) Lay the transmission housing in a normal position.
(2) Drive the input shaft (which has not been inserted into
the transmission yet) into position with a copper rod
from the torque converter side.
(3) Tighten two torque converter housing mounting bolts.
(4) Put the O-ring on the pump assembly. Apply grease to
the O-ring, and install the pump assembly to the torque
converter assembly. Be sure to install the O-ring in the
oil inlet port.

5-15
POWERSHIFT TRANSMISSION

7. Installing torque converter

(1) Install the torque converter in position by mating the
splines of stator shaft and by positioning the groove of
pump drive gear correctly. 50 to 52 mm
(1.97 to 2.05 in.)
(2) Make sure that the distance between the end face of
torque converter housing and the mating face of
flexible plate is 50 to 52 mm (1.97 to 2.05 in.).
(3) Support the flexible plate to the torque converter
housing with a wire to prevent the torque converter
from slipping out of position until the torque converter
is coupled to the engine.
204840

8. Filling torque converter with AFT

Fill the torque converter after the transmission has been
mounted on the truck and the engine is ready to be started.
Run the engine at idle speed for a while. Stop the engine
and, after 1 minute, check the oil level in the transmission
with the oil level gauge in 15 minutes.

5-16
 POWERSHIFT TRANSMISSION

Control Valve
Disassembly

10
4

9
2
5
1

8 6

7
206450

Sequence
1 Solenoid valve 6 Clutch valve plunger, Valve spring, Clutch
2 Plug, O-ring, Strainer valve, Return spring, Slug, Stopper pin, O-ring
3 Cover, O-ring 7 Oil seal
4 Accumulator piston, Spring 8 Plug, Bearing roller, O-ring
5 Main regulator valve, Spring seat, O-ring, Main 9 Accumulator spring seat, Pin, O-ring
regulator spring, Plug 10 Drain plug, Gasket

Inspection after disassembly

(1) Check oil ways and passages for clogging.
(2) Check each spool for sign of wear, damage or seizure.
(3) Check oil seals for damaged lips.
(4) Check the orifice in the main regulator valve for
cleanliness; also check the valve spring for fatigue or
damage.

200220

5-17
POWERSHIFT TRANSMISSION

Reassembly

8 1
Section A-A 7

2 6

A A
4 B B 5
4 3
Section B-B 9

10 11
Section C-C
206451A

Sequence
1 Accumulator spring seat, O-ring, Pin 7 Accumulator piston, Spring
2 Plug, O-ring, Bearing roller 8 O-ring, Cover
3 Oil seal 9 Drain plug, Gasket
4 Clutch valve plunger, O-ring, Stopper pin 10 Strainer, O-ring, Plug
5 Clutch valve, Valve spring, Slug, Return spring 11 Solenoid valve assembly
6 Main regulator valve, Slug, Main regulator
spring, O-ring, Spring seat

Start by:
Thoroughly clean the oil ways and passages in the valve.

5-18
 POWERSHIFT TRANSMISSION

Inspection and Adjustment

Testing Hydraulic Pressure

1. Run the engine at idle speed for a while. Stop the
engine and, after one minute check the oil level in the
transmission with the oil level gauge in 15 minutes.
2. Warm up until the transmission oil temperature rises.
3. Check the no-load minimum and maximum speeds of
the engine. If the speeds are not correct, make an
adjustment by referring to SERVICE MANUAL for the
engine.
Unit: rpm
Truck Model 1.0 to 1.8 ton 2 to 3.5 ton
Item classes classes
No-load
650 650
minimum
(650) (650)
speed
No-load
2600 2600
maximum
(2300) (2300)
speed

( ); Diesel model

4. After checking the engine speeds, stop the engine. c Torque converter
Raise the front wheels. To do this, jack the front axle inlet pressure
housing, or place wood blocks under the outer mast and a Main pressure

tilt the mast forward.

! CAUTION
The front wheels will rotate when the clutch
pressure is tested.

e Lube oil pressure

5. Connect a pressure gauge to the tap for a pressure to be
tested. The pressure taps are located as shown.
b Clutch pressure
d Torque converter
outlet pressure
207130

5-19
POWERSHIFT TRANSMISSION

6. Use the following tools when testing the oil pressure:

Tool name/ Pressure taps

Remarks
Tool No. a b c d,e
Connector M14 × 1.5
— — —
91268 - 04400 thread
*Connector R(PT)1/8
—
64309 - 17733 thread
Connector M14 × 1.5
— — —
91268 - 02300 thread
600 kPa
*Gauge
(6 kgf/cm2) — —
64309 - 17714
[90 psi]
2000 kPa
*Gauge
(20 kgf/cm2) — —
64309 - 17713
[300 psi]
*Hose
64309 - 17722
*Connector
For gauge
64309 - 17331
Remark: The asterisked tools are included in the gauge kit
(64309 - 17701).
7. Start the engine. Move the transmission shift lever to
the neutral position, and test the main pressure, torque
converter inlet pressure, torque converter outlet
pressure and lube oil pressure.
8. Move the transmission shift lever to the FORWARD
and REVERSE position, and test the clutch pressure.

A: Standard value
Unit: kPa (kgf/cm2) [psi]
883 to 1079
a Main pressure A (9 to 11)
[128 to 156]
883 to 1079
b Clutch pressure A (9 to 11)
[128 to 156]
196 to 490
Torque converter inlet
c A (2 to 5)
pressure
[28 to 71]
147 to 294
Torque converter outlet
d A (1.5 to 3)
pressure
[21 to 43]
98 to 147
e Lube oil pressure A (1 to 1.5)
[14 to 21]
Engine speed: 1500 ± 100 rpm

5-20
 POWERSHIFT TRANSMISSION

Adjusting Inching Pedal

ing
at Free play
actu
e
r ak e
B rok
st
A

E
Push rod length 207323

The inching pedal is interlocked with the brake pedal so

that, when this pedal is depressed, hydraulic pressure acting
on the transmission is reduced to zero before the brake is
applied to bring the transmission into neutral condition. If
this linkage is out of adjustment, the transmission clutch
will not disengage or grab, resulting in poor braking,
abnormal temperature rise or clutch disc seizure. To adjust
the clutch pedal, proceed as follows:

1. Adjusting the brake

(1) Adjust the released height A of the brake pedal to 220
± 3 mm (8.7 ± 0.1 in.).
(2) Set the master cylinder pushrod length E to 103.2 mm
(4.06 in.).
Unit: mm (in.)

Pushrod length E 103.2 (4.06)

(3) Adjust and confirm the brake drum-to-lining clearance.

Do not adjust the clearance by setting the pushrod
length.
Unit: mm (in.)
Truck Model 1.0 to 1.8 ton 2 to 3.5 ton
Item classes classes
Drum-to-lining 0.5 to 1.0 0.2 to 0.7
clearance (0.02 to 0.04) (0.01 to 0.03)
Stroke for brake 40 to 61 49 to 95
application (1.57 to 2.4) (1.93 to 3.74)
5-21
POWERSHIFT TRANSMISSION

2. Adjusting the inching pedal

Start by:
Warm up the transmission oil, raise the front wheels, and
block the rear wheels.

Adjusting
(1) Connect a pressure gauge to the clutch pressure tap.
(2) Adjust the released height A of the inching pedal to
220 mm (8.7 in.) by the stopper bolt. Set the clearance
B between the inching pedal and brake pedal A
connecting parts to 9 to 9.5 mm (0.354 to 0.374 in.) for
the 1 ton class or 0.1 to 0.5 mm (0.004 to 0.020 in.) for
the 2 to 3 ton classes.
(3) Start the engine, and release the brake pedal. Depress
the inching pedal until the brake starts to be applied
(the pedal encounters resistance). Under this condition, B
make an adjustment by means of the push rod so that
the clutch valve plunger stroke (D) is 16.5 mm (0.65
207131A
in.) at 0 kgf/cm2 hydraulic pressure.
(4) Release the inching pedal, and make sure that clutch
valve plunger stroke (C) is 9 to 9.5 mm (0.354 to 0.374 D C
in.) for the 1 ton class or 6 to 9.5 mm (0.236 to 0.374
in.) for the 2 to 3 ton classes at 883 to 1079 kPa (9 to
11 kgf/cm 2) [128 to 156 psi] read on the pressure

kPa (kgf/cm2) [psi]

gauge. Make an adjustment by means of the inching

Clutch pressure,
cable. If the plunger stroke is out of specification,
readjust the brake and brake pedal, and repeat the 981
adjustment. (10)
[142]
• If the plunger stroke is more than 9.6 mm (0.378 in.) , 588
the drum-to-lining clearance is too small. 13.5 5 (6)
(0.531) (0.20) [85]
• If the plunger stroke is less than 8.9 mm (0.350 in.) for
the 1 ton class or 5.9 mm (0.232 in.) for the 2 to 3 ton Clutch valve plunger stroke, mm (in.)
200244
classes, the drum-to-lining clearance is too large.
Truck Model 1.0 to 1.8 ton 2 to 3.5 ton
Item classes classes
Released height 220
A
pedal (8.7)
Clearance
between inching
9 to 9.5 0.1 to 0.5
B pedal and brake
(0.354 to 0.374) (0.004 to 0.020)
pedal connecting
parts
Clutch valve 9 to 9.5 6 to 9.5
C plunger stroke (0.354 to 0.374) (0.236 to 0.374)
Plunger
D projection when 16.5 (0.65)
brake is applied
5-22
 POWERSHIFT TRANSMISSION

Testing Clutch Valve

1. Connect a pressure gauge to the clutch pressure tap. 981
(10)

kPa (kgf/cm2) [psi]

2. Start the engine, and move the transmission shift lever

Clutch pressure,
[142]
to the FORWARD position. 588
(6)
3. Depress the inching pedal. Gradually pull out the
[85]
clutch valve plunger from its fully pushed position, and
plot the hydraulic pressure curve relative to the clutch
valve plunger stroke. Make sure that the plotted
pressure curve is identical with the curve shown. 0 5 10
(0.20) (0.39)
Clutch valve plunger stroke, mm (in.)
206468

Testing Stall Speed

! WARNING
Make tests in a clear level area only. There must
be one operator. Keep all other personnel away
from the lift truck. Check the operation of the
brakes before the tests are made.

1. Check to make sure that the transmission oil level is

correct. (See the topic, 1. Testing hydraulic pressure.)
2. Warm up until the transmission oil temperature reaches
40 °C to 60 °C (104 °F to 140 °F).
3. Block the front and rear wheels, and apply the parking
brake.
4. Check the no-load maximum speed of the engine.
5. Run the engine at idle speed.
6. Move the lever to the FORWARD position. Gradually
depress the accelerator pedal all the way by the right
foot. Under this condition, read the stall speed with an
electric or stroboscopic tachometer.

! CAUTION
Do not depress the inching pedal. Also, do not
allow the engine to keep on running at the highest
speed attained or the torque converter may suffer
damage. Stall-speed running of the engine is
limited to 30 seconds or less.

5-23
POWERSHIFT TRANSMISSION

7. Similarly read the stall speed for reverse drive.

Unit: rpm

Truck GP20K DP20K

Model GP15K GP20K-HP GP30K DP25K
GP18K GP25K GP35K DP30K
Item GP25K-HP DP35K
Stall speed
(tolerance: 1870 1791 1971 2095
± 100)

NOTE
1. Any stall speed within ±100 rpm of the specified
speed is allowed.
2. LPG models will show stall speed about 100 rpm
lower than the specified speed.
3. When the engine or the torque converter is
changed, the stall speed will vary as it is
determined by the engine and torque converter
combination.

10-m (33-ft) Start Acceleration Test

1. Stand ready to start with the engine idling and the
transmission shift lever in the neutral position.
2. At the signal, shift into forward and, at the same time,
depress the accelerator pedal all the way.
3. Measure the amount of time that the truck elapses to
travel 10 meters (33 feet) by using a watch.
4. Measure for reverse, too.

Time required for 10 m (33 ft) 5 seconds,

travel (no load) maximum

5-24
 POWERSHIFT TRANSMISSION

Troubleshooting
Engine lacks power Tune up engine.
Engine
Poor performance of engine Tune up engine.

Oil level too low Refill.

Air being sucked in on suction side Replace gasket and
retighten.
Faulty action of spool in main regulator valve Repair or replace.
Weakened spring in main regulator valve Replace.
Torque Worn gears in oil pump, resulting in Overhaul and check or
converter reduced capacity replace defective parts.
Magnet strainer clogged Clean or replace.
Seal rings or O-rings worn Replace.
Stator freewheel seized Replace torque converter
assembly.
Not enough
Impeller damaged or rubbing Replace torque converter
output power assembly.
Air being sucked in on suction side Retighten or replace.
Water in oil Replace oil.
Oil level too low Refill.
Pedal linkage maladjusted (brake shift and Readjust.
Transmission forward reverse)
Main pressure too low, resulting in slipping Readjust.
clutches
Seal rings or O-rings worn Replace.
Clutch piston damaged Replace.
Friction plate seized or dragging Replace.
Road wheels High mechanical resistance in road wheels Check and adjust brake
system

Flexible plate broken Replace.

Not enough oil Refill.
Torque
converter Oil pump drive defective Replace.
Turbine shaft broken Replace.
Main pressure too low Check pump gears for
wear or replace.
Not enough oil Refill.
Inching pedal link maladjusted Readjust.
Seal ring worn in servo case Replace.
O-rings on input shaft worn Replace.
Plug on input shaft loose or slipped off, Repair.
No power flow resulting in oil leaks
Transmission Clutch seized Replace.
Shafts broken Replace.
Clutch drum, particularly snap ring groove, Replace.
defective
Snap ring fitted to clutch drum broken Replace.
Oil way for supplying oil pressure to clutch Clean or replace.
piston clogged
Shaft splines worn Replace shafts.
Power train Broken parts in reduction differential or Repair or replace.
front axle

5-25
POWERSHIFT TRANSMISSION

Flexible plate broken Replace.

Bearings damaged Replace.
Rubbing blades of running member Replace.torque
Torque converter.
converter
Bolts loose Retighten or replace.
Splines worn Replace.
Oil pump noisy Repair or replace.

Friction plates seized and dragging Replace friction plate.

Bearings worn or seized Replace.
Transmission Gears broken Replace.
Bolts loose Retighten or replace.
Splines worn Replace.
Abnormal
Magnet strainer clogged Clean or replace.
noise
Main regulator valve defective Wash or replace.
Loud noise Restriction in oil pipe Replace.
Oil too viscous in cold weather Replace oil.
Instruments faulty Replace.
Wrong kind of oil used Replace oil.

Magnet strainer clogged Clean or replace.

Oil pump defective Replace.
Excessive oil leaks
(1) Main regulator valve spring broken or Replace.
Low noise fatigued
(2) Main regulator valve spool defective Repair or replace.
Air being sucked in Retighten or replace
packing.
Oil level too low Refill.

Leaking oil seals Check lips and sliding

surfaces for wear.
Replace seals.
Leaking joint of case Retighten or replace
packing.
Leaking pipe connection or joint Repair or replace pipe,
gasket and O-rings.
Leaking drain plug Retighten and replace
Oil leaks gasket.
Cracks or blowholes in case Replace.
Oil blowing out of transmission housing
(1) Water in oil Replace oil.
(2) Air being sucked in suction side Replace packing and
retighten.
(3) Oil leaks from air breather Repair.
Oil level too high Lower oil level.

5-26
 POWERSHIFT TRANSMISSION

Oil level too high or too low Refill or drain.

Magnet strainer clogged Clean or replace.
Impeller rubbing Replace torque converter
assembly.
Stator freewheel defective Replace torque converter
assembly.
Torque
converter Air being sucked in Retighten or replace
O-ring.
Water in oil Replace oil.
Restriction in oil pipe (resulting in reduced Repair or replace.
Oil temperature circulation flow)
is too high Bearings worn or seized Repair or replace.
Instruments out of order Replace.
Friction plates dragging Replace friction plates.
Transmission Bearings worn or seized Repair or replace.
Control linkage defective Repair or replace.
Truck not operated properly Urge user to operate
Others properly.
Others
(1) Cooling fan belt damaged Replace.
(2) Oil cooler clogged Clean or replace.
(3) Brakes grabbing Check and readjust.

Main regulator valve defective Repair or replace valve

assembly.
Main pressure is too
high Oil viscosity too high because of low temperature Replace oil.

Wrong kind of oil used Replace oil.

Magnet strainer clogged Clean or replace.

Oil pump failure Replace.
Coil spring defective in main regulator valve Replace.
Main pressure is too Faulty movement of main regulator valve spool Repair or replace.
low Air being sucked in Retighten or replace packing.
Not enough oil Refill.
Control linkage defective Repair or replace.
Clutch valve out of order Repair or replace.

Magnet strainer clogged Clean or replace.

Oil pump worn or otherwise defective Replace.
Coil spring defective in main regulator valve Replace.
Faulty movement of main regulator valve spool Repair or replace.
Clutch pressure is too Air being sucked in Retighten or replace packing.
low Not enough oil Refill.
Control linkage out of order Repair or replace.
Inching valve defective Repair or replace.
Seal ring broken in servo case Replace.
Clutch piston seal rings broken Replace.

5-27
POWERSHIFT TRANSMISSION

Lack of engine power if the speed is slightly low in Tune up engine.

both forward and reverse drive
Stall speed out of
specification Stator and freewheel damaged if the speed is Replace stator assembly.
excessively low in both forward and reverse drive
Inching pedal linkage defective, or friction plates Repair or replace.
slipping if the speed is too high

5-28
 POWERSHIFT TRANSMISSION

Service Data
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model GP20K
GP15K GP20K-HP DP20K GP/DP30K
GP18K GP25K DP25K GP/DP35K
Item GP25K-HP
GP:1971
Stall speed (tolerance ± 100 rpm) rpm A 1870
DP: 2095
Engine at 1500 ± 100 rpm
A 883 to 1079 (9 to 11) [128 to 156]
kPa (kgf/cm2) [psi]
Main Engine at 800 ± 50 rpm
B 785 (8) [144]
pressure kPa (kgf/cm2) [psi]
Engine at 2500 ± 100 rpm
B 785 to 1177 (8 to 12) [114 to 171]
kPa (kgf/cm2) [psi]
Engine at 1500 ± 100 rpm
A 883 to 1079 (9 to 11) [128 to 156]
kPa (kgf/cm2) [psi]
Clutch Engine at 800 ± 50 rpm
B 785 (8) [144]
pressure kPa (kgf/cm2) [psi]
Engine at 2500 ± 100 rpm
B 785 to 1177 (8 to 12) [114 to 171]
kPa (kgf/cm2) [psi]
Engine at 1500 ± 100 rpm
A 196 to 490 (2 to 5) [28.4 to 71.1]
kPa (kgf/cm2) [psi]
Torque Engine at 800 ± 50 rpm
converter B 98 (1) [14]
kPa (kgf/cm2) [psi]
inlet pressure
Engine at 2500 ± 100 rpm
B 98 to 588 (1 to 6) [14.2 to 85]
kPa (kgf/cm2) [psi]
Engine at 1500 ± 100 rpm
A 147 to 245 (1.5 to 3) [21.3 to 43]
kPa (kgf/cm2) [psi]
Torque Engine at 800 ± 50 rpm
converter B 49 (0.5) [7.1]
kPa (kgf/cm2) [psi]
outlet pressure
Engine at 2500 ± 100 rpm
B 49 to 343 (0.5 to 3.5) [7.1 to 50]
kPa (kgf/cm2) [psi]
Lubricating Engine at 1500 ± 100 rpm
A 98 to 147 (1 to 1.5) [14.2 to 21.3]
oil pressure kPa (kgf/cm2) [psi]
10-m (33 ft) starting acceleration (no load) sec. A Within 5
0
Outside diameter of sliding surface to oil A 90− 0.030 (3.54 − 00.00138)
seal 1 B 89.90 (3.5394)
2.5 ± 0.05
A
Width or seal ring 2 (0.098 ± 0.0020)
B 2.0 (0.079)
+ 0.2
A 2.5 + 0.1 (0.098 ++ 0.008
0.004 )
Width of seal ring groove 3
Pump boss B 3.0 (0.118)

2, 3 1 204984

5-29
POWERSHIFT TRANSMISSION

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP20K
GP15K GP20K-HP DP20K GP/DP30K
GP18K GP25K DP25K GP/DP35K
Item GP25K-HP
A 15−− 0.006 − 0.00024
0.024 (0.59 − 0.00094 )
Diameter 1
B 14.95 (0.5886)

Pilot boss
1

200411

Top clearance 1 A 0.3 to 0.33 (0.012 to 0.0130)

A 0.040 to 0.083 (0.00157 to 0.00327)
Side clearance 2
B 0.15 (0.0059)
Clearance between pump boss and drive
A 0.1 to 0.4 (0.004 to 0.016)
gear 3

Gear backlash A 0.1 to 0.18 (0.004 to 0.0071)

B 0.3 (0.012)
DP: 33 [2014] at 2200 rpm
A
GP: 36 [2197] at 2400 rpm
Capacity liter (cu.in.)/min
Oil pump DP: 23 [1404] at 2200 rpm
B
GP: 26 [1587] at 2400 rpm

3 1

204831

5-30
 POWERSHIFT TRANSMISSION

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP20K
GP15K GP20K-HP DP20K GP/DP30K
GP18K GP25K DP25K GP/DP35K
Item GP25K-HP
A 0.2 (0.008)
Face runout 1 (in free state)
B 0.5 (0.020)
Clearance between engine flywheel and
flexible plate mounting surface on torque 1 to 5
A
converter 2 (0.04 to 0.20)
(to be measured before bolts are torqued)
Flexible plate
1 2

200412
A 1.6 ± 0.1 (0.063 ± 0.004)
Thickness of mating plate 1
B 1.3 (0.051)
A 2.6 ± 0.1 (0.1023 ± 0.004)
Thickness of friction plate 2
B 2.2 (0.087)
A 4.0 ± 0.3 (0.157 ± 0.012)
Thickness of pressure plate 3
B 3.3 (0.13)
Backlash between friction plate and gear 4 A 0.13 to 0.285 (0.0051 to 0.01122)
A 2 ± 0.1 (0.08 ± 0.004)
Width of seal ring 5
B 1.5 (0.060)
Clutches A 2.3 ± 0.05 (0.091 ± 0.0020)
Width of piston seal ring groove 6
B 2.5 (0.098)

Free length of clutch spring 7 A 75.5 (2.97) [k = 18.476 (1.884) [105.417]]

Spring constant:
k = N/mm (kgf/mm) [lbf/in] B 72.5 (2.85)

2 1
4
3
5

7 6

207132

5-31
POWERSHIFT TRANSMISSION

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP20K
GP15K GP20K-HP DP20K GP/DP30K
GP18K GP25K DP25K GP/DP35K
Item GP25K-HP
A 2.5 ± 0.05 (0.098 ± 0.0020)
Width of stator shaft seal ring 1
B 2.0 (0.079)
+0.2 +0.008
Width of piston seal ring groove in stator A 2.5 (0.098 +0.004 )
+0.1

shaft 2 B 3.0 (0.118)

A 2.5 ± 0.05 (0.098 ± 0.0020)
Width of clutch piston seal ring 3
B 2.0 (0.079)
A 2.8 ± 0.05 (0.110 ± 0.0020)
Width of clutch piston seal ring groove 4
B 3.0 (0.118)
A 2.5 ± 0.05 (0.098 ± 0.0020)
Width of transmission housing seal ring 5
B 2.0 (0.079)
+0.008
Input shaft Width of transmission housing seal ring A 2.5 +0.2
+0.1 (0.098 +0.004 )

and servo groove 6 B 3.0 (0.118)

case +0.00083
Inside diameter in transmission housing for A 30 +0.021
+0 (1.18 +0 )
seal ring 7 B 30.2 (1.189)
A 2.5 (0.098)
Thickness of input shaft thrust washer 8
B 2.2 (0.087)
A 3.0 (0.118)
Thickness of input shaft thrust washer 9
B 2.7 (0.106)

1, 2

5, 6 7 8 9 3, 4 8
207133

5-32
 POWERSHIFT TRANSMISSION

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP20K
GP15K GP20K-HP DP20K GP/DP30K
GP18K GP25K DP25K GP/DP35K
Item GP25K-HP
Free movement of idler gear
A 0.12 to 0.26 (0.0047 to 0.010)
(looseness of mating splines) 1

Measuring point

Idler gear 1
shaft

204987

Free movement of output flange gear

A 0.054 to 0.14 (0.00213 to 0.0055)
(looseness of mating splines) 1

Measuring point

Output shaft
1

204988

A 0.12 to 0.28 (0.0047 to 0.0110)

Gear backlash
B 0.5 (0.020)

Free length of clutch spring 1 A 75 (2.95) [k = 2.112 (0.2154) [12.0525]]

Spring constant:
k = N/mm (kgf/mm) [lbf/in] B 72 (2.83)

Free length of clutch spring 2 A 50 (1.97) [k = 0.838 (0.0855) [4.784]]

Spring constant:
k = N/mm (kgf/mm) [lbf/in] B 48 (1.89)
Control valve
Free length of clutch spring 3 A 36.8 (1.45) [k = 5.883 (0.6003) [33.59]]
Spring constant:
k = N/mm (kgf/mm) [lbf/in] B 35.5 (1.40)

Free length of clutch spring 4 A 28 (1.10) [k = 0.478 (0.0488) [2.730]]

Spring constant:
k = N/mm (kgf/mm) [lbf/in] B 26.5 (1.04)

5-33
POWERSHIFT TRANSMISSION

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP20K
GP15K GP20K-HP DP20K GP/DP30K
GP18K GP25K DP25K GP/DP35K
Item GP25K-HP
Free length of torque converter outlet and A 25 (0.98) [k = 4.187 (0.427) [23.892]]
inlet regulator valve springs 5
Spring constant:
k = N/mm (kgf/mm) [lbf/in] B 24 (0.94)
Free length of accumulator valve spring A 130 (5.12) [k = 0.597 (0.0609) [3.408]]
(inner) 6
Spring constant:
k = N/mm (kgf/mm) [lbf/in] B 128 (5.04)
Free length of accumulator valve spring A 91 (3.58) [k = 7.303 (0.7447) [41.669]]
(outer) 7
Spring constant:
k = N/mm (kgf/mm) [lbf/in] B 89 (3.50)
Control
valve 6

7
2
1

3
4

206451 200418
Height of inching pedal 1 A 220 ± 3 (8.7 ± 0.12)
9 to 9.5 0.1 to 0.5
Clearance in pedal linkage 2 A (0.354 to 0.374) (0.004 to 0.020)
9 to 9.5 6 to 9.5
Plunger projection 3 A (0.236 to 0.374)
(0.354 to 0.374)
Plunger projection when brake starts to
apply 4 A 16.5 (0.650)
Push rod length 5 A 103.2 (4.06)
Inching pedal
control

3
2
4
200419 5 207131A

5-34
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Description ................................................................................................ 6 – 1
Removal and Installation ...................................................................... 6 – 2
Front Wheels .............................................................................................. 6 – 2
Front Axle and Reduction Differential ......................................................... 6 – 4
Disassembly and Reassembly ............................................................. 6 – 6
Front Axle ................................................................................................... 6 – 6
Reduction Differential ................................................................................. 6 – 11
Adjustment................................................................................................. 6 – 21
Tooth Contact Patterns and Adjustment ..................................................... 6 – 21
Troubleshooting ........................................................................................ 6 – 22
Service Data .............................................................................................. 6 – 23 6
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Description

1.5 to 2.5 ton classes 11

13
12
14

Nut

10 8

15 2 4 3 7 9 5 6
1
206452

3 to 3.5 ton classes 11

13
12
14
Remarks:
Hub nut is identical with
those of
1.5 to 2.5 ton classes

1 15 2 4 3 7 9 5 6 10 8
206453

1 Front wheel hub 6 Differential gear 11 Input flange

2 Frame support 7 Differential case 12 Drive gear
3 Axle shaft 8 Differential carrier 13 Driven gear
4 Axle housing 9 Reduction bevel gear 14 Carrier cover
5 Differential pinion 10 Reduction bevel pinion 15 Backing plate

The frame support is bolted to the front axle housing, mounted on the axle housing. The input flange carries a
together with the backing plate of wheel brake. The hub drive gear which is in mesh with the driven gear
carries a single wheel but, with optional rim, double mounted on the reduction bevel pinion.
tires can be mounted on it. The reduction differential is

6-1
FRONT AXLE AND REDUCTION DIFFERENTIAL

Removal and Installation 2

1
[Single wheel]
Front Wheels
Removal
[Single wheel]
1 Wheel nuts
[Double wheels]
2 Front wheel
[Double wheels] 5
4
1 Extension valve
2 Outer wheel nuts
3 Front wheel (outer) 3
4 Inner wheel nuts 1
5 Front wheel (inner) 2

200225

Suggestions for Removal

1. Block the rear wheels.
2. Pull the parking brake lever, and loosen the wheel nuts
1 to 2 turns.
3. Raise the front end of the truck by jacking or hoisting.
(1) Method using a hoist
Use two eye-bolts and slings as shown. And lift the
front end with a hoist.

204845

6-2
 FRONT AXLE AND REDUCTION DIFFERENTIAL

(2) Method using hydraulic system

Tilt the mast all the way backward. Put wood blocks
under the mast, and tilt the mast forward to raise the
front end.

! CAUTION
After raising the front end, securely support it by
blocking properly.
200227

4. In case of the double wheels, remove the outer wheel

nuts and outer wheel. Then, remove the inner wheel Outer wheel nut
nuts and the inner wheel.

Inner wheel nut

200228

Installation 1
To install, follow the reverse of removal sequence, and do
the following steps: 6 3
1. Tighten the wheel nuts to the specified torque so that
the wheels will not wobble during operation.

Truck Model 1.0 to 1.8 ton 2 to 3.5 ton 4 5

Item classes classes
2
Tightening 157 N·m 378 N·m 200229
torque for (16 kgf·m) (38.5 kgf·m)
wheel nuts [116 lbf·ft] [278 lbf·ft]

Loosen outer Tighten inner Tighten outer

! CAUTION
wheel nuts. wheel nuts. wheel nuts.
When retightening the wheel nuts for the double
wheels, be careful not to forget tightening the
inner wheel nuts.

Double wheel nut tightening sequence

200230

6-3
FRONT AXLE AND REDUCTION DIFFERENTIAL

Front Axle and Reduction Differential

Removal

13 9 12 11 4

10
6

2
14

Oil level plug

Drain plug

8 7
3 1
207134

Sequence
1 Front wheel 8 Mast
2 Nuts 9 Brake pipe
3 Forks, Lift bracket 10 Parking brake cable
4 Return hose for lift cylinder 11 Universal joint
5 High-pressure hose for lift cylinder 12 Bolt, Nut
6 Tilt cylinder socket pin 13 Bolt, Nut
7 Mast support bearing cap 14 Front axle and Reduction differential

NOTE
1) For removal of front wheel 1, refer to Removal,
Front Wheels.
2) For removal of mast parts 2 thru 8, refer to
“GROUP 11 MAST AND FORKS”.
3) Before removing the front axle and reduction
differential, drain differential oil by removing the
front axle drain plug.

6-4
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Removal

1. Removing bolt 12
Bolt 12, right and left, are coupling the transmission with
the differential. Before removing these bolts, place a jack
stands under the transmission.

Bolt

2. Removing parking brake cable 210997

To remove the parking brake cable, remove the parking
brake lever from the dashboard, and disconnect the cable
from the lever.

NOTE
To dismount the differential only, remove the front
axle as explained above. To dismount the engine &
transmission assembly, remove the differential with the
front axle on the frame.

Installation
To install, follow the reverse of removal sequence, and do
the following steps:
1. After installing the parking brake cable, make sure that 245 to 294 N
the brake lever operating effort is within the Parking brake lever (25 to 30 kgf)
operating effort [55 to 66 lbf]
specifications.
2. Before installing the mast, bleed the brake fluid
circuits. For bleeding, refer to “GROUP 8 BRAKE
SYSTEM”.
3. After installing the mast, make sure that the tilt angles,
forward and backward, are correct and that the lift
chains, right and left, are equal in tension. Refer to
“GROUP 11 MAST AND FORKS”.
Truck Model 1 ton 2, 3 ton
4. Fill the front axle housing with oil up to the plug hole. Item class classes
Refill capacity
of front axle 4.2 liters 5.0 liters
housing [1.1 U.S. gal] [1.3 U.S. gal]

6-5
FRONT AXLE AND REDUCTION DIFFERENTIAL

Disassembly and Reassembly

Front Axle
Disassembly

6
7

5
204848

Sequence
1 Axle shaft 4 Tapered roller bearing (outer), Oil seal, Oil
2 Lock nut, Lock washer, Oil seal, Tapered roller deflector
bearing (inner) 5 Tapered roller bearing (inner), Seal retainer
3 Hub & Drum assembly [Front wheel hub, Brake 6 Brake assembly
drum, Wheel bolts, Drum nuts, Tapered roller 7 Frame support, Axle housing
bearing (outer)]

Start by:
1. Remove the mast. For replacement of the front axle
housing and disassembly of the differential, refer to
“GROUP 11 MAST AND FORKS”.
2. Jack up the truck. NOTE
3. Support the front end of the truck at both sides with It is not necessary to remove the axle housing nor
blocks or stands to keep the truck in horizontal to drain the oil for removing the axle shaft only.
position.
4. Remove the front wheels.

6-6
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Disassembly

1. Removing lock nut
Use a lock nut wrench (special tool).
Special tool needed Special tool
Truck Model 1.0 to 1.8 ton 2 to 3.5 ton
Tool Name classes classes

Lock nut wrench 91268 - 00800 03703 - 59001

204849

2. Removing front wheel hub

Use a wheel hub puller (special tool).
Special tool needed Special tool
Truck Model 1.0 to 1.8 ton 2 to 3.5 ton
Tool Name classes classes
Wheel hub puller 64309 - 40100
MH061017
(puller seat) (64309 - 10601)

204850
NOTE
It is not necessary to remove the oil seal from the hub
nor to disassemble the oil deflector unless the seal is
defective.

3. Removing bearings
The inner race of the tapered roller bearing remains in the
axle housing when the hub is drawn out. Remove this race
together with the seal retainer with a bearing puller.

204851

6-7
FRONT AXLE AND REDUCTION DIFFERENTIAL

Inspection after disassembly

1. Axle shafts
(1) Looseness of mating splines
Mount the differential bevel gear on the splined end of
the shaft, and set a dial indicator as shown. Rotate the
bevel gear against the contact point of the indicator and
read the free movement (looseness of mating splines).

A: Standard value B: Repair or service limit

200235
Unit: mm (in.)

Free movement 0.007 to 0.17

A (0.0028 to 0.0067)
(looseness of
mating splines)
B 0.5 (0.020)

(2) Runout
(a) Set a dial indicator at the middle part of the axle Runout of shaft
shaft. Rotate the shaft against the contact point of
the indicator and read the runout of the shaft.

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model 1.0 to 1.8 ton 2 to 3.5 ton
Item classes classes Face runout of flange
200236
Runout of axle 0.5 (0.020) 1.0 (0.039)
A
shaft (1/2 of dial maximum maximum
indicator reading)
B 1.0 (0.039) 2.0 (0.079)

(b) Set a dial indicator against the flange of the axle

shaft as shown. Rotate the shaft against the contact
point and read the face runout of the flange.
A: Standard value B: Repair or service limit
Unit: mm (in.)

Face runout of A 0.05 (0.0020)

axle shaft flange B 0.5 (0.020)

2. Axle housing
(1) Check the surfaces of axle housing in contact with the
mast bearing for damage.
(2) Check the entire axle housing for distortion, dents and
other defects, paying particular attention to the welds
to see if any weld is cracked to require repair.

6-8
 FRONT AXLE AND REDUCTION DIFFERENTIAL

3. Others
(1) Check the outer surface of the oil seal retainer for wear
or damage.
(2) Check the outer and inner oil seals for wear and
damage.
Reassembly
To reassemble, follow the reverse of disassembly sequence,
and do the following steps:

1. Front wheel hub

(1) Fill the front wheel hub, especially the roller holder
and oil seal lip groove, with grease.

! CAUTION
Take care not to apply grease to the brake drum.

(2) Install the inner race and oil seal retainer of the wheel
hub bearing with an installer (special tool).
200238
Special tool needed

Truck Model 1.0 to 1.8 ton 2 to 3.5 ton

Tool Name classes classes
Installer 64309 - 12300 91468 - 00300

Special tool

204852

(3) Apply sealant (oil resistant liquid gasket such as

ThreeBond #1104) to the flange surfaces of the axle
shaft.

6-9
FRONT AXLE AND REDUCTION DIFFERENTIAL

2. Hub bearing preload

1 ton class

1.0 to 1.8 ton classes

Tighten the inner nut to obtain the required preload.
Tighten the outer nut to the specified torque; and check the
preload. Where the bearings removed in disassembly are
reused, try to produce a preload in the lower side of the
specified range.
Inner nut Outer nut
200468

2 to 3.5 ton classes

Tighten the nut to 137 N·m (14 kgf·m) [101 lbf·ft], and 2, 3 ton classes
back it off 80º of rotation. Rotate the drum assembly more
than 3 turns, and check the preload. If the preload meets the
Bolt
specification, put lock ring and tighten the bolts.

Truck Model 1.0 to 1.8 ton 2 to 3.5 ton

Item classes classes
0.5 to 4.9 N·m Lock ring
Preload for hub
(5 to 50 kgf·cm)
bearings Nut
[0.4 to 3.6 lbf·ft] 200239
Force applied to 5.4 to 54 N 4.4 to 44 N
hub in tangential (0.55 to 5.5 kgf) (0.45 to 4.5 kgf)
direction [1.2 to 12 lbf] [0.4 to 3.6 lbf]
196 N·m
Tightening torque
(20 kgf·m) —
for lock nuts
[145 lbf·ft]

NOTE
To check the preload, hook a spring balancer to the
hub bolt, and measure the tangential force to rotate the
wheel.

6-10
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Reduction Differential
Disassembly

1.0 to 2.5 ton classes 3 to 3.5 ton classes

7
1 20 12

9
10
22
19 21
9 18
8
7 24 13

4 16 12

15 1
17
7

14

3 23
10 11 3
9
7 8
6
5
4
2 207155

Sequence [3 ton class]

1 Mount bracket assembly (right and left) 13 Lock nut, Shims
2 Lock washer, Lock pawl, Bolt, Plate 14 Reduction bevel pinion, Tapered roller bearing
3 Adjusting screw (inner), Shims
4 Bearing cap, Lock washer, Bolt 15 Carrier cover
5 Differential case (right), Tapered roller bearing 16 Tapered roller bearing
6 Differential gear, Thrust washer 17 Driven gear
7 Differential pinion, Thrust washer (not used in 18 Plate
1 ton class) 19 Drive gear, Ball bearing
8 Differential spider 20 Input flange
9 Differential gear, Thrust washer 21 Ball bearing
10 Differential case (left), Tapered roller bearing 22 Oil seal
11 Reduction bevel gear 23 Differential carrier
12 Cover, O-ring

NOTE
For the disassembly sequence for 1, 2 ton classes,
see the next page.

6-11
FRONT AXLE AND REDUCTION DIFFERENTIAL

Sequence [1, 2 ton classes]

NOTE
24 Spring pin
1) Remove the parts 5 thru 11 as an assembly.
8 Differential spider
2) Two-piece differential case is used in 3 ton 7 Differential pinion, thrust washer
class while one-piece differential case is used (2 ton class only)
in 1, 2 ton classes. The disassembly sequence 9 Differential gear, thrust washer
for the one-piece case differs from that for the
two-piece case.

Suggestions for Disassembly

NOTE
Before disassembling the differential except for
replacement of the reduction gear set, measure the
gear backlash to aid in obtaining correct backlash at
the time of reassembly.

Unit: mm (in.)

Backlash between reduction 0.15 to 0.25

gear and pinion (0.0059 to 0.0098) 204596

NOTE
Mark across the bearing cap, and carrier on each
side to ensure correct refitting.

204597

6-12
 FRONT AXLE AND REDUCTION DIFFERENTIAL

1. Removing bearing
Use a bearing puller to remove the inner bearing 5.

2. Removing shims
After removing plate 18 and shims 13, make a record of
the total thickness of the shims, and tie the shims to the
plate to prevent missing.

204598

3. Removing carrier cover

To remove carrier cover 15, attach a sling to the bracket
mounting holes, and lift off the cover with a hoist while
tapping it with a plastic hammer at two places close to the
dowel pins.

4. Checking tapered roller bearing

Do not remove the taper roller bearing 14 (inner) from
reduction pinion 14 unless it is defective.

5. Checking oil seal

Do not remove oil seal 22 from carrier cover 15 unless it is
defective.

204854A

6-13
FRONT AXLE AND REDUCTION DIFFERENTIAL

Inspection after repair

1. Reduction gear and pinion
Check the gear and pinion for wear, pitting, flaking and
chipping. Minor flaws on the tooth surfaces can be
repaired by grinding with an oil stone or a sand paper.
Check the teeth for contact. If the gear and/or pinion is
badly damaged, replace the gear and pinion as a set.

2. Differential
3 ton class
(1) Check the differential case 10 for damage. Check, in
particular, the seat formed of each case for carrying
tapered roller bearing inner race to see whether the seat
surface is fretted or not.
(2) Check the sliding surfaces of thrust washers and gears
for wear and damage.
(3) Check the teeth of the differential pinions and gears for
wear, pitting chipping and galling.
(4) Check the pinions (inside diameter) and pinion shafts
(diameter) for wear.
(5) Check the differential gears and axle shaft splines for
free movement (looseness). 206455

A: Standard value B: Repair or service limit 1, 2 ton classes

Unit: mm (in.)
0.03 to 0.07
Clearance between A (0.0012 to 0.0028)
pinions and shafts
B 0.35 (0.0138)

B: Repair or service limit

Unit: mm (in.)
Free movement (looseness of
differential gear and axle B 0.5 (0.020)
shaft splines)
206456

3. Drive gear and driven gear

Check the gears for wear, pitting, flaking and chipping.
NOTE
Check the teeth for contact. If the gears are defective,
replace them as a set. The combination of drive and driven gears is
different from one model of the truck to another.
This combination can be identified by the marking
“A” to “F” punching on the side face of each gear.
When replacing the gears, check the marking to
ensure the proper combination of the gears as
before.

6-14
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Reassembly

16 14 15 13 21 22 23 25

25
20

12

17

18 19

11 24 8 10 4 3 1 2 5 6 7 8 11 24 206457

Sequence
1 Differential case (left) 14 Ball bearing
2 Reduction bevel gear 15 Input flange
3 Bolt 16 Drive gear
4 Differential gear, Thrust washer 17 Ball bearing
5 Differential spider, Differential pinion, Thrust 18 Plate
washer 19 Reduction bevel pinion, Shims, Taper roller
6 Differential gear, Thrust washer bearing
7 Differential case (right)-Bolts, Spacer 20 Driven gear
8 Tapered roller bearing 21 Taper roller bearing
9 Differential carrier 22 Shims
10 Bearing cap 23 Lock nut, O-ring, Cover
11 Adjusting screw 24 Lock plate, Lock pawl
12 Carrier cover 25 Mount bracket assemblies (left and right)
13 Oil seal

6-15
FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Reassembly Truck Model 1.0 to 1.8 ton 2 to 3.5 ton
1. Installing reduction gear Item classes classes

To install reduction Bevel Gear 2 to differential case (left) Tightening torque 188 N·m 216 N·m
for reduction (12.0 kgf·m) (22.0 kgf·m)
1, apply LOCTITE No. 271 to the threads of bolts 3, and
gear bolts [86.8 lbf·ft] [159.1 lbf·ft]
tighten the bolts to the specified torque.

2. Reassembling differential pinions

The thrust washers of the differential gears are used for
adjusting the backlash between the differential gears and
pinions. Measure the backlash and, if it is in excess of the
service limit, replace the thrust washers.
Backlash between differential gears and pinions

A: Standard value B: Repair or service limit

Unit: mm (in.)
1.0 to 1.8 ton 2 to 2.5 ton 3 to 3.5 ton
classes classes classes
204858
0.18 to 0.23 0.19 to 0.25 0.15 to 0.35
A
(0.0071 to 0.0091) (0.0075 to 0.0098) (0.0059 to 0.0138)
B 0.5 (0.020)

3. Installing differential cases [GP/DP30K/35K]

Put the right and left differential cases together with the
marks in alignment. Apply LOCTITE No. 271 to the
threads of the bolts, and tighten the bolts to the specified
torque.

123 N·m
Tightening torque for (12.5 kgf·m)
differential case bolts [90 lbf·ft]

4. Reassembling differential cases

After positioning the case assembly on the carrier, install
the bearing caps tentatively by making the cap bolts snug-
tight. The caps are to be secured tight after the bearing
preload has been adjusted.

5. Installing bearing caps

Be sure to discriminate between the left and right caps and
to put each cap in place correctly.

6-16
 FRONT AXLE AND REDUCTION DIFFERENTIAL

6. Adjusting bearing preload

Tie a wire on the reduction gear tooth. Hook a spring
balancer to the wire, and pull the balancer in the tangential
direction to check the preload for the bearing (the force
when the gear starts rotating).
Adjust the preload by means of the adjusting screws, right
and left.

NOTE
Before measuring the preload, give light taps of a
copper hammer to the back of the reduction gear while 204857
rotating the gear by hand for running-in.

Preload

1.0 to 1.8 ton classes 2 to 2.5 ton classes 3 to 3.5 ton classes
1.5 to 2.9 N·m (15 to 30 kgf·cm) [1 to 2 lbf·ft]
13 to 25 N 11 to 22 N 18 to 34N
(1.32 to 2.5 kgf) (1.1 to 2.2 kgf) (1.8 to 3.5 kgf)
[2.9 to 5.5 lbf] as [2.4 to 4.9 lbf] as [4.0 to 7.7 lbf] as
force applied to force applied to force applied to
reduction gear reduction case reduction case
in tangential in tangential in tangential
direction direction direction

7. Removing differential cases

The preload can be checked by doing the steps 1 thru 6
above. Mark across the adjusting screws and bearing caps,
and remove the differential cases from the carrier.

8. Shimming reduction pinion

Put shims on the reduction pinion in order to adjust the
tooth contact of the reduction bevel gear and bevel pinion.
The standard value of total shim thickness is 1.8 mm (0.071
in.) but it should be increased or decreased on the basis of
machining error which is inscribed on the end face of the
reduction bevel pinion.

204859

6-17
FRONT AXLE AND REDUCTION DIFFERENTIAL

[Example]
Where the error is -0.10 mm (-0.004 in.), the total shim
thickness to be 1.9 mm (0.075 in.):
1.8 + 0.1 mm (0.071 + 0.004 in.) = 1.9 mm (0.075 in.)
The shims are available in four sizes, 0.1 mm (0.04 in.), 0.2
Shims
mm (0.008 in.), 0.5 mm (0.20 in.) and 1.0 mm (0.039 in.).

9. Installing oil seal

Using an installer (special tool), put oil seal 13 in carrier
cover 21. 206458
Special tools needed

Installer 91268 - 05400

10. Applying grease to oil seal

Apply grease to the oil seal installed to carrier cover 12.

Recommended grease LG2

11. Applying sealant

When putting differential carrier 9 and carrier cover 12
together, apply sealant to the flange.

206459

12. Adjusting reduction pinion preload

(1) After installing tapered roller bearing 21, measure
difference between the reduction pinion and tapered
roller bearing to determine the required amount of
shim thickness. The standard value of total shim
thickness is 2.3 mm (0.091 in.)

204862

6-18
 FRONT AXLE AND REDUCTION DIFFERENTIAL

(2) Put the required amount of shims, and tighten the lock
nut 23. The shims are available in five sizes, 0.05 mm
(0.0020 in.), 0.1 mm (0.004 in.), 0.2 mm (0.008 in.),
0.5 mm (0.020 in.) and 1.0 mm (0.039 in.).

294 ± 20 N·m
Lock nut tightening torque (30 ± 2 kgf·m)
[217 ± 14 lbf·ft]

(3) Hook a spring balancer to the bolt hole of the input

flange, and pull the balancer in the tangential direction
to check the preload for the tapered roller bearing (the
force when the flange starts rotating). Adjust the
preload by adding or subtracting the shims.

Force applied to input flange

Gear symbol
in tangential direction
34 to 49 N
A, B, C (3.5 to 5.0 kgf)
[7.7 to 11 lbf]
206460A
(4) After the preload adjustment, stake the upper part of
the lock nut to prevent loosening.

13. Adjusting reduction bevel gear and bevel pinion

tooth contact
(1) Turn the differential carrier upside down.
(2) Install the differential cases (removed in Step 7) to the
carrier. Align the marks on the bearing caps and adjust
screws on each side.
(3) Adjust the backlash between the reduction bevel gear
pinion by turning the adjusting screws. Set a dial gauge
as shown. At the periphery of the reduction bevel gear,
read the tangential play of the gear.
Unit: mm (in.)

Backlash between reduction 0.15 to 0.25

bevel gear and bevel pinion (0.0059 to 0.0098)

204864

6-19
FRONT AXLE AND REDUCTION DIFFERENTIAL

(4) To adjust the backlash, turn the adjusting screws, right

and left, equally in the same direction so as not to Backlash

disturb the bearing preload. Increase

Decrease

Increase
Decrease

Increase

Backlash Decrease 206461

(5) Brush a light coating of coloring past on several

reduction bevel gear teeth, on both the drive and coast
sides. Press forward on the pinion, and rotate back and
forth until a contact pattern is noted on both the drive
and coast sides.

NOTE
Refer to Tooth Contact Patterns and Adjustment on the
next page.
204865

14. Tightening bearing caps

Upon checking the tooth contact, tighten the bearing cap
bolts to the specified torque, and bent the lock washer.

Truck Model 1.0 to 1.8 ton 2 to 3.5 ton

Item classes classes
Tightening 123 N·m 163 N·m
torque for (12.5 kgf·m) (16.6 kgf·m)
bearing cap bolts [90 lbf·ft] [120 lbf·ft]

6-20
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Adjustment

After the reduction gear and pinion have been replaced,

adjust the tooth contact as follows:
(1) Determine the required amount of shim thickness S on
the basis of machining error inscribed on the end face Shims
of the pinion. It is given by this formula:
S = standard value - (machining error)
[Example]
Where the error is -0.10 mm (-0.004 in.), the total shim
thickness to be 1.9 mm (0.075 in.): 206458

1.8 mm (0.071 in.) - {-0.1 mm (-0.004 in.)}=

1.8 mm (0.071 in.) + 0.1 mm (0.004 in.) =
1.9 mm (0.075 in.)
(2) Put the shims and install the reduction gear and pinion.
(3) Adjust the tooth contact as shown below.

Tooth Contact Patterns and Adjustment

Tooth contact Adjustment
Extends from toe to
middle portion,
1 covering not less Correct tooth contact
than 50% of tooth
length.

(1) Move gear away from pinion.

2 Short contact at toe 2 (2) Move pinion toward gear by
of tooth increasing shim thickness to secure
1 correct backlash.
1 (1) Move gear toward pinion.
Short contact at heel (2) Move pinion away from gear by
3
of tooth decreasing shim thickness to secure
2 correct backlash.
1
Heavy contact on (1) Move pinion toward gear by
face or top half increasing shim thickness.
4
(addendum) of tooth (2) Move gear away from pinion to
2 secure correct backlash.

Heavy contact on (1) Move pinion away from gear by

bottom half 1 decreasing shim thickness.
5
(dedendum) of tooth (2) Move gear toward pinion to secure
2 correct backlash.

Remark: Repeat the above adjustment until the correct tooth contact is obtained. 203669

6-21
FRONT AXLE AND REDUCTION DIFFERENTIAL

Troubleshooting

Reduction bevel gear teeth badly worn Replace.

Gear noise comes Bearing preload too much or too little, or bearings worn Readjust or replace.
out continuously excessively
during traveling Hub bearings damaged Replace.
Improper tooth contact between reduction bevel pinion Readjust.
and reduction gear

Reduction taper roller bearings or hub bearings broken Replace.

Irregular noise Differential gears having broken teeth, or thrust washers Replace gears or washers.
comes out during worn
traveling Foreign substance in axle housing Clean and replace oil.
Bolts securing axle shaft or differential carrier Retighten.

Abnormal noise Fit of differential gears in differential case out of Replace worn parts.
comes out when specification due to wear
turning a corner Differential gear teeth broken or seized on spider, Replace defective parts.
or damaged by wear gear or pinions.

Bearings damage due to excessive preload Replace bearings and

Overheated readjust preload.
reduction case
after traveling Backlash between reduction bevel pinion (on output shaft) Readjust tooth contact
and reduction bevel gear too small and backlash.

6-22
 FRONT AXLE AND REDUCTION DIFFERENTIAL

Service Data
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model GP20K
GP15K GP20K-HP DP20K GP/DP30K
GP18K GP25K DP25K GP/DP35K
Item GP25K-HP
A 0.05 (0.0020)
Face runout of axle shaft flange
B 0.5 (0.020)
Runout of axle shaft (1/2 of dial indicator A 0.5 (0.020)
reading) B 1.0 (0.039)
Preload for hub bearing 1
A 0.5 to 4.9 (5 to 50) [0.4 to 3.6]
N·m (kgf·cm) [lbf·ft]
Hub bearing lock nuts
A 196 (20) [145]
(outer) 2

Tightening Axle shaft bolts 3 A 86 (8.8) [64]

torque Nuts 4 A 215 (21.9) [158]
N·m (kgf·m) Hub blot lock nuts 5 A 59 (6) [43] 181 (18.5) [134]
[lbf·ft] Axle support bolts 6 A 378 (38.5) [278]
Rim bolts 7 A 86 (8.8) [64] 202 (20.6) [149] —
Wheel nuts 8 A 157 (16) [116] 378 (38.5) [278]
Hubs and
wheels
GP15K, 18K, GP/DP20K, 25K GP/DP30K, 35K

5 5 6
6
8

8
1

4 3
4

204990

6-23
FRONT AXLE AND REDUCTION DIFFERENTIAL

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP20K
GP15K GP20K-HP DP20K GP/DP30K
GP18K GP25K DP25K GP/DP35K
Item GP25K-HP
0.18 to 0.23 0.15 to 0.35
0.19 to 0.25
A (0.0071 to (0.0059 to
Gear backlash 1 (0.0075 to 0.0098)
0.0091) 0.0138)
B 0.5 (0.020)
A 0.02 to 0.07 (0.0008 to 0.0028)
Fit of bevel pinion on spider 2
B 0.35 (0.0138)
13 to 25 N 18 to 34 N
(1.3 to 2.5 kgf) (1.8 to 3.5 kgf)
11 to 22 N
[2.9 to 5.5 lbf] [4.0 to 7.7 lbf]
(1.1 to 2.2 kgf)
as force as force
[2.4 to 4.9 lbf]
Preload for differential case bearing 3 A applied to applied to
as force applied to
N·m (kgf·cm) [lbf·ft] reduction differential
differential case in
gear in case in
tangential direction
tangential tangential
direction direction
0.05 (0.0020),
A 0.15 (0.0059), max
Face runout of reduction bevel gear 4 max
B 0.05 (0.0020) 0.15 (0.0059)
Reduction Backlash between reduction bevel gear and
A 0.15 to 0.25 (0.0059 to 0.0098)
differential bevel pinion 5
Free movement (looseness) of axle A 0.07 to 0.17 (0.0028 to 0.0067)
shaft splines 6 B 0.5 (0.020)
Reduction bevel gear
A 118 (12) [87] 216 (22) [159]
bolts 7
Case bolts 8 A — 123 (12.5) [90]
123 ± 5 163 ± 5
Side bearing cap
A (12.5 ± 0.5) (16.6 ± 0.5)
bolts 9
Tightening [90 ± 4] [120 ± 4]
torque
Carrier bolts 10 A 60 (6.1) [44]
N·m (kgf·m)
[lbf·ft] Differential carrier
A 44 (4.5) [33]
cover bolts 11
Mount bolts 12 A 78 (8) [58]
Lock nut 13 A 294 ± 20 (30 ± 2) [217 ± 14]
Input flange bolts 14 A 49 (5) [36]
Preload for reduction bevel pinion taper
A 0.3 to 0.5 (3.5 to 5.0) [0.3 to 0.4]
roller bearing 15 N·m (kgf·cm) [lbf·ft]

6-24
 FRONT AXLE AND REDUCTION DIFFERENTIAL

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP20K
GP15K GP20K-HP DP20K GP/DP30K
GP18K GP25K DP25K GP/DP35K
Item GP25K-HP

13

12

11

12 15
14
5
Reduction 10
3
differential

6
1
7 8
4 2

205017A

6-25
 REAR AXLE

Structure ..................................................................................................... 7 – 1
Rear Axle ................................................................................................... 7 – 1
Steering Cylinder........................................................................................ 7 – 2
Removal and Installation ....................................................................... 7 – 3
Rear Wheels............................................................................................... 7 – 3
Rear Axle ................................................................................................... 7 – 4
Rear Axle Assembly ................................................................................ 7 – 7
Disassembly ............................................................................................... 7 – 7
Inspection after Disassembly...................................................................... 7 – 8
Reassembly................................................................................................ 7 – 9
Steering Cylinder ..................................................................................... 7 – 14
Disassembly ............................................................................................... 7 – 14
Inspection and Repair ................................................................................ 7 – 15 7
Reassembly................................................................................................ 7 – 16
Inspection and Adjustment ................................................................... 7 – 18
Minimum Turning Radius Adjustment ......................................................... 7 – 18
Troubleshooting ........................................................................................ 7 – 19
Service Data .............................................................................................. 7 – 20
 REAR AXLE

Structure

Rear Axle

207066

1 Rear axle 5 Tie rods

2 Steering cylinder 6 Wheel hub
3 Steering knuckles 7 Shims
4 King pins

The lift truck is steered by the rear wheels. The rear Because of the center pivoting feature, the rear axle can
axle is connected to the frame by its center pivot shaft. oscillate up to 3° in each direction.

7-1
REAR AXLE

Steering Cylinder

❋
1.0 to 1.8 ton classes ❋: Parts contained in seal kit
12
❋
11 ❋ ❋
17 14 13 6

9
❋ 8
10 16 7

2 15 1
3 ❋ 4 207168

2 to 3.5 ton classes ❋

❋ ❋
6 13
11 12 17

10 16

7
5
1 8
2
15 9
3 ❋ 4 207111

1 Cylinder tube 7 Tie-rod 13 O-ring

2 Piston rod 8 Nut 14 O-ring
3 Cylinder head 9 Spring washer 15 Guide ring
4 Cylinder head 10 Stopper ring 16 Piston seal
5 Pivot joint 11 Wiper 17 Bushing
6 Snap ring 12 U-seal

Double-action cylinder is used.

7-2
 REAR AXLE

Removal and Installation

Rear Wheels
Removal
1 Wheel nuts
2 Rear wheel

1
Start by:
2 204897
1. Set the parking brake, and block the front wheels.
2. Raise the rear end of the lift truck with a jack or hoist.
(1) Method using a jack
Position the jack under the counterweight at the jacking
point and raise the rear tire.

104364

(2) Method using a crane

Attach lifting slings to the lift holes in the
counterweight, and lift it.

! CAUTION
When the vehicle is raised, place jack stands
under the side frame to support it.

204898

Installation
To install, follow the reverse of removal procedure.
1

NOTE 6 3

Tighten the wheel nuts to the specified torque.

157 N·m 4 5
Tightening torque for (16 kgf·m)
wheel nuts [116 lbf·ft] 2 101212

7-3
REAR AXLE

Rear Axle
Removal

207112

Sequence
1 Rear wheel, wheel nut 3 Bearing support
2 Steering hose 4 Rear axle assembly [thrust washer]

Start by:
1. Apply the parking brake and block the front wheel.
2. Raise the rear end of the truck with a jack and
place jack stands under the side frames (with the
left and right rear wheels slightly clearing the
floor).
3. A hoist can be used instead of the jack to raise the
rear end (counterweight).

! WARNING
Be sure the pressure in the hydraulic system is
released before any lines or hoses are
disconnected. 104364

7-4
 REAR AXLE

Suggestion for Removal

1. Removing wheel assembly
Remove the wheel assembly from the rear axle. Be careful
not to cause damage to the oil seal fitted to the rim. After
removing the assembly, raise the counterweight to a
position 400 to 500 mm (16 to 20 in.) from the floor.

2. Removing rear axle assembly

Support the rear axle at its center with a garage jack and
remove the bolts that hold the bearing supports.

Truck Model 1.0 to 1.8 ton 2 to 3.5 ton

Item classes classes
Weight of rear axle 182 kg (402 lb) 220 kg (486 lb)

Wheel block
Installation
To install, follow the reverse of removal sequence and do Jack stand
the following steps:
104365

1. Adjusting bearing support clearances

Adjust clearance between bearing support to be 0.8 mm
(0.031 in.) or less in total by using thrust washers.

NOTE

0.8 mm (0.03 in.)

Insert thrust washers evenly.

or less
0.8 mm (0.031 in.)
Thrust washer type 2.0 mm (0.078 in.) 206651

7-5
REAR AXLE

2. Removing support bushing

Do not remove the bushing in the support if not necessary.
When replace the blushing, place the mating line at the
bottom (align with the grease nipple).

Bushing mating line

205431

3. Tightening bearing support

Tighten the bolts holding the bearing support to the
specified torque.

145 N·m
Tightening torque for (14.8 kgf·m)
bearing support bolts [107 lbf·ft]

7-6
 REAR AXLE

Rear Axle Assembly

Disassembly

16

14 17
15
4
17 2
15
19

13
11

10

9 3
8

6
18

10
5 1

12

207108

Sequence
1 Taper roller bearing (inner), Retainer 10 Oil seal
2 Tie-rod pin, Bolt, Spring washer, Plain washer, 11 Cover, Retainer
Collar, Grease nipple 12 Boot
3 Spherical bushing, Ring, Retainer, Dust seal 13 Cover
4 Tie-rod 14 Clamp, Bolt, Spring washer
5 Kingpin plate, Shim 15 Pipe (L.H., R.H.)
6 Kingpin, O-ring 16 Steering cylinder [Bolt, Spring washer, Nut]
Remove parts 7 through 12 as assembly. 17 Elbow, O-ring
7 Knuckle 18 Stopper bolt, Lock nut
8 O-ring 19 Rear axle housing
9 Taper roller bearing

7-7
REAR AXLE

Suggestions for Disassembly

Removing retainer and bearing
Use a puller to remove the retainer and inner bearing 1
from the knuckle.

Inspection after Disassembly

1. Tie-rods and pins 207031

(1) Make sure that the pins are free of any surface flaws
such as grooving or stepped wear. Examine the tie-rod
pin weld for cracking.
(2) Examine the bearings for wear or damage.
(3) Examine the tie-rods for damage and alignment.
Inspect the welds for signs of cracks.

NOTE
If a pin must be replaced, replace its bearing as well.

2. Kingpins
Check the kingpins for any surface flaws such as grooving
or stepped wear. Inspect the pins for cracks at the bearing
shoulder.
3. Kingpin bearings
Examine the rollers and bearing races for grooving,
abrasive wear, pitting, bruising, or corrosion. Replace both
the cup and cone of damaged bearings.
4. Knuckles
Inspect the inside of each knuckle for wear or damage. Be
sure to examine for casting cracks. Check the tie rod pin
hole. Examine the wheel nut threads for damage.
5. Seals and O-rings
Examine all seals and O-rings for damage such as cuts and
tears. Replace seals which show signs of aging.
6. Hydraulic pipes
Inspect the hydraulic pipes for cracks, especially at the
joints with the end fittings. Check for leaks.
7. Cylinder rod
Examine the rod for surface or plating damage. Inspect the
rod for straightness. Examine the piston for damage check
the tie rod pin hole for damage or wear.

7-8
 REAR AXLE

Reassembly

5 3
4
16
3 17

4
1

15
11

10

9 7
8

13
18

10
14 19

12

207108

Sequence
1 Rear axle 11 Cover, Retainer
2 Steering cylinder [Bolt, Spring washer, Nut] 12 Boot
3 Elbow, O-ring 13 Kingpin, O-ring, Bolt, Spring washer
4 Pipe (L.H., R.H.) 14 Kingpin plate, Shim, Bolt, Spring washer
5 Clamp, Bolt, Spring washer 15 Cover
6 Knuckle 16 Tie-rod
7 Spherical bushing, Ring, Retainer, Dust seal 17 Tie-rod pin, Bolt, Spring washer, Plain washer,
8 O-ring Collar, Grease nipple
9 Taper roller bearing 18 Stopper bolt, Lock nut
10 Oil seal 19 Retainer, Taper roller bearing

7-9
REAR AXLE

Suggestions for Reassembly

1. Reassembling steering cylinder
Use an alternating tightening pattern to tighten the
mounting bolts when attaching the cylinder assembly to the
rear axle.

262 N·m
Tightening torque for bolts (26.7 kgf·m)
[193 lbf·ft]

2. Reassembling knuckles
(1) Insert bearing cups into knuckles. Adequately fill
bearing cages with “AUTOLEX A” grease. Apply a
coat of grease to the oil seal grooves. Insert the bearing
cages in the knuckles and apply additional grease as
required to meet the recommended amount.
Unit: cc (cu. in.)

Truck Model 1.0 to 1.8 ton 2 to 3.5 ton

Item classes classes
Quantity of grease 40 (2.44) 80 (4.88)

(2) Reassemble remaining components (seals, O-rings,

covers, and boots).
(3) Assemble parts, knuckle 6 through boot 12, and insert
this sub-assembly into the rear axle housing.

3. Reassembling kingpins
(1) Install the kingpins and measure the distances “A” on
both the left and right kingpins.

A 207037

7-10
 REAR AXLE

(2) Add shims to each side to within 0.1 mm (0.004 in.) of

the measured distance “A” and tighten kingpin bolt
“B”.
Unit: mm (in.)

1.0 (0.039)
0.3 (0.012)
Shim thickness
0.2 (0.008)
0.1 (0.004)

Shims

Kingpin bolt B

Keeper plate bolts

207038

(3) Measure the tangential force at point “C”. When the

tangential force is larger than the values shown in the
table below, add shims. When the tangential force is
smaller than the values shown in the table below,
remove shims. Repeat this procedure until the values in
the table attained. C

30.4 to 79.4 N
Tangential force for kingpin
(3.1 to 8.1 kgf)
bearings
[6.8 to 17.8 lbf] 207039

(4) Tighten kingpin keeper plate bolts.

Unit: N·m (kgf·m) [lbf·ft]

Kingpin bolt Keeper plate bolts

Item
16.7 33.4
Tightening torque
(1.7) (3.4)
for bolts [12.3] [24.6]

207040

7-11
REAR AXLE

4. Reassembling tie-rods
Bolt
Replace dust seals. Tighten tie-rod pin bolts to the specified
torque. Grease the joints using the grease gun.
Collar

Tie-rod pin
6.9 N·m
Tightening torque for bolts (0.7 kgf·m)
[5 lbf·ft]

Grease nipple

Dust
seals

207107

5. Reassembling rear axle hub

(1) The inner race of the inner bearing must be driven onto
the shaft by using a special tool, as shown:

Special tool needed

Truck Model 1.0 to 1.8 ton 2 to 3.5 ton

Item classes classes

Bearing installer 91268 - 01500 64309 - 40400 207032

(2) There is a space between two tapered roller bearings

inside the rear axle hub. Be sure to fill up this space
with grease. Grease the oil seal lip groove and roller
retainers, too. Do not overfill the oil seal lip groove as Fill up with grease
this can cause leakage.

Oil seal

207110

7-12
 REAR AXLE

(3) Bearing preload is specified. Tighten the inside nut first

to secure the prescribed preload; after this tightening,
tighten the outside nut (lock nut) to the specified torque
value; and then re-check the preload. If the hub
bearings (taper roller bearings) have long been in
service, it is advisable to aim at a value of preload in
the lower half of the specified range.

Truck Model 1 ton 2, 3 ton

Item class classes 207169
0.5 to 4.9 N·m
Preload for hub
(5 to 50 kgf·cm)
bearing
[0.4 to 3.6 lbf·ft]
Tangential force for 6.8 to 68 5.4 to 54 Inside nut
hub bearing at hub bolt (0.7 to 6.7) (0.55 to 5.5)
N (kgf) [lbf] [1.5 to 15] [1.2 to 12]
157 N·m
Tightening torque Outside nut
(16 kgf·m) (lock nut)
for lock nut
[116 lbf·ft]

207110

(4) Use a new lockwasher and bend it to both sides (inward

Wrong
and outward).

(5) Fill the cap with grease, and install the cap.
Right

205436

Raise the rear end of the truck and remove the blocking
from the side frames. Lower the truck until the rear wheels
just touch the floor.

7-13
REAR AXLE

Steering Cylinder

Disassembly
❋: Parts contained in seal kit
❋
10

11

A
11
❋
3
4
5
2
1
6
❋
❋ 7 7 ❋
❋ A 6

2 5

1 3
❋

8 1
207036

Sequence
1 Nut, Spring washer, Stud 6 Wiper
Remove parts 2 through 7 as assembly. 7 U-seal
2 Cylinder head 8 Cylinder tube
3 O-ring 9 Piston rod
4 Snap ring 10 Guide ring, Piston seal
5 Bushing 11 Stopper ring, Pivot joint

NOTE
(1) Do not remove bushing 5 from the cylinder head 2
if not necessary.
(2) Do not remove bearing 11 from piston rod 9 if not
necessary.

7-14
 REAR AXLE

Suggestions for Disassembly

Mark cylinder end caps Mark
Mark the cylinder end caps for proper alignment before
they are disassembled from the cylinder.

Mark

207035

Inspection and Repair

(1) Cylinder tube 8
Check for wear, damage or rust inside the cylinder.
(2) Piston rod 9
Check for rust, damage, scratches or impact marks on
the rod surface.
(3) Rings and gaskets
Replace the entire seal kit with new one.
205439
A: Standard value
Unit: mm (in.)
Truck Model 1.0 to 1.8 ton 2 to 3.5 ton
Item classes classes
Internal diameter
A 63 (2.480) 75 (2.953)
of cylinder tube 1
External diameter
A 40 (1.575) 50 (1.968)
of piston rod 2

2 1

207034

7-15
REAR AXLE

Reassembly

9
6 10 11 7

13
14
16
2 12

15

1 3 4
5 5 207168

Sequence
1 Piston rod 7 Snap ring 13 Spring washer
2 Piston seal 8 U-seal 14 Nut
3 Guide ring 9 Wiper 15 Pivot joint
4 Cylinder tube 10 O-ring 16 Stopper ring
5 Cylinder head 11 O-ring
6 Bushing 12 Tie rod

Suggestions for Reassembly

1. Replace all seals and O-rings whenever reassembling
cylinder. Smear hydraulic fluid on seals and O-rings.
2. Assemble Wiper and U-seal as shown.

Wiper U-seal 207042

7-16
 REAR AXLE

3. Align marks on the end caps to marks on the cylinder

body. Tighten nuts.
Unit: N·m (kgf·m) [lbf·ft] Mark

19 to 23
Tightening torque for
(1.9 to 2.3)
cylinder nuts
[14 to 17]

Mark

207035

4. Pressure test cylinder reassembly for leaks.

Unit: kPa (kgf/cm2) [psi]
Truck Model 1.0 to 1.8 ton 2 to 3.5 ton
Item classes classes
10500 15690
Minimum
(107) (160)
test pressure
[1522] [2275]

7-17
REAR AXLE

Inspection and Adjustment

Minimum Turning Radius Adjustment

R
1. Use a turning radius gauge, and measure the angular
swing of rear wheels.
2. Setting the turning angle of each rear wheel to the
specification is not enough. The lift truck must be
driven to make the sharpest possible turn to either side,
and the radius of the track left behind by the outer 202800
wheel must be measured for confirmation. The
standard minimum turning radius is indicated below.

Truck Model 1.0 to 1.8 ton 2 to 3.5 ton

Item classes classes
Steering angle
Inside 82° 83°
Outside 55° 56°
Tightening
67 N·m
torque for
(6.8 kgf·m)
knuckle stopper
[49 lbf·ft]
bolt lock nut

3. Drive the lift truck at low speeds in such a manner as to

make the sharpest possible turn to either side, and
measure the radius of track left by the outer rear wheel.
4. The minimum turning radius R is the distance from the
turning center to the center of tire contact with the
surface of the wheel describing the largest circle, while
the truck is executing its sharpest practicable turn, plus
the rear overhang (the distance from the center of rear
tire to the outermost end of counterweight).
Unit: mm (in.)
Item
Minimum turning radius
Truck Model
GP15K 1990 (78.3)
GP18K 2020 (79.5)
GP/DP20K,
2185 (86.0)
GP20K-HP
GP/DP25K,
2245 (88.4)
GP25K-HP
GP/DP30K 2445 (96.2)
GP/DP35K 2485 (97.8)

7-18
 REAR AXLE

Troubleshooting

When performing troubleshooting for steering system-related problems, problems possibly existing in its hydraulic
system should also be troubleshooted.

Overloaded steer axle Reduce load

Damaged mechanical linkage Replace
Hard steering Dry mechanical linkage joints Lubricate
Mechanical joints too tight Readjust
Kingpin bearings improperly preloaded Readjust

Damaged or worn mechanical linkage Replace

Truck wanders
Loose cylinder piston Replace cylinder rod

Damaged or worn mechanical linkage Replaces

Truck drifts
Tire diameter differs between right and left Replace tire

Erratic steering Loose cylinder piston Replace cylinder rod

Excessive free play at Damaged or worn linkage between cylinder Replace

steered wheels and steered wheels

Excessive clearance between the kingpin Repair or replace

Axle shimmy and its bearings
Worn or damaged hub bearing Replace

Rear tires wear prematurely

or unevenly Tire on one side differs in kind or brand from Replace tires
that on the other side.

7-19
REAR AXLE

Service Data
A: Standard value B: Repair or service limit
Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
Item GP25K-HP
Oscillating angle A 3°
Toe-in A 0°
Caster A 0°
Camber A 1°
A 0.8 (0.031)
Total fore-aft play of axle at center pin 1
B 1.2 (0.047)
Inside 2 A 82° 83°
Turning angle
Outside 3 A 55° 56°
Tightening torque Support bolts 4 A 145 (14.8) [107]
N·m (kgf·m) [lbf·ft] Stopper bolt nuts 5 A 67 (6.8) [49]
Cylinder minimum test pressure
A 10500 (107) [1522] 15690 (160) [2275]
kPa (kgf/cm2) [psi]

2
4 5

207043

7-20
 REAR AXLE

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
Item GP25K-HP
Outer locknut 6 A 157 (16) [116]
Cylinder nuts 7 A 19 to 23 (1.9 to 2.3) [14 to 17]
Tightening torque Cylinder bolts 8 A 262 (26.7) [193]
N·m (kgf·m) [lbf·ft] Kingpin bolts 9 A 16.7 (1.7) [12.3]
Keeper plate bolts 10 A 33.4 (3.4) [24.6]
Tie rod bolts 11 A 6.9 (0.7) [5]
Tangential force for hub bearing 12 6.8 to 68 5.4 to 54
at hub bolt A (0.7 to 6.7) (0.55 to 5.5)
N (kgf) [lbf] [1.5 to 15] [1.2 to 12]
Preload for hub bearings 12
A 0.5 to 4.9 (5 to 50) [0.4 to 3.6]
N·m (kgf·cm) [lbf·ft]
Tangential force for kingpin bearings 13
A 30.4 to 79.4 (3.1 to 8.1) [6.8 to 17.8]
N (kgf) [lbf]
GP/DP20K GP/DP35K
thru 30K
2.24 to 5.88 GP20K-HP
Preload for kingpin bearings 13
A (22.9 to 60.0) GP25K-HP
N·m (kgf·cm) [lbf·ft]
[1.65 to 4.34] 2.73 to 7.14 2.43 to 6.35
(27.9 to 72.9) (24.8 to 64.8)
[2.02 to 5.27] [1.79 to 4.68]
11

13

8
12

13

12

10 9
6
207067

7-21
REAR AXLE

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
Item GP25K-HP
Internal diameter of cylinder tube 1 A 63 (2.480) 75 (2.953)
External diameter of piston rod 2 A 40 (1.575) 50 (1.068)

2 1

207034

7-22
 BRAKE SYSTEM

Description ................................................................................................ 8 – 1
Automatic Adjusting Device ........................................................................ 8 – 1
Brake Pedal and Assembly......................................................................... 8 – 1
Disassembly and Reassembly ............................................................. 8 – 2
Master Cylinder .......................................................................................... 8 – 2
Disassembly ............................................................................................. 8 – 2
Inspection after Disassembly.................................................................... 8 – 3
Reassembly.............................................................................................. 8 – 3
Wheel Brakes ............................................................................................. 8 – 4
Disassembly ............................................................................................. 8 – 4
Inspection after Disassembly.................................................................... 8 – 5
Reassembly.............................................................................................. 8 – 7
Wheel Cylinders ......................................................................................... 8 – 10
Disassembly ............................................................................................. 8 – 10
Inspection after Disassembly.................................................................... 8 – 11 8
Reassembly.............................................................................................. 8 – 11
Inspection and Adjustment ................................................................... 8 – 12
Automatic Adjusting Device ........................................................................ 8 – 12
Manual Adjustment..................................................................................... 8 – 12
Brake Pedal Adjustment ............................................................................. 8 – 13
Bleeding Air Out of the Brake Fluid Line..................................................... 8 – 13
Brake Test .................................................................................................. 8 – 13
Troubleshooting ........................................................................................ 8 – 14
Service Data .............................................................................................. 8 – 16
 BRAKE SYSTEM

Description

207074

Automatic Adjusting Device

This device adjusts the drum-to-lining clearance shoes closer to the drum. This adjustment corresponds
automatically. As the clearance increases due to lining to 1/24 of one rotation or 15°. In the course of usage,
wear, the lever mechanism of this device turns the the adjusting process repeats itself at long intervals.
adjusting screw by one notch or tooth to reposition the

Brake Pedal and Assembly

This clutch pedal is the one used in the Direct-Drive lift
truck.

Stop lamp switch

Brake pedal

Clutch pedal 2 mm
Stop lamp switch (0.08 in.)

204923 204965

8-1
BRAKE SYSTEM

Disassembly and Reassembly

Master Cylinder
Disassembly

❋
6 7
❋
5
❋
❋ 4
❋ 3
2

204924

Sequence
1 Clevis, Lock nut, Push rod 5 Spring seat, Primary cup, Cup spacer
2 Boot 6 Return spring
3 Stopper ring 7 Cylinder body
4 Secondary cup, Piston 8 Fluid reservoir, Wire band

NOTE
The parts (❋) to be changed periodically are involved
in the brake repair kit.

8-2
 BRAKE SYSTEM

Inspection after Disassembly

1. Brake fluid level sensor
(1) Connect the level sensor at the bottom of fluid
reservoir, and turn the starter switch to ON.
(2) The sensor is satisfactory when the brake fluid level
warning lamp of the OK monitor glows when the
reservoir filler is positioned upward and goes out when
ON OFF
it is positioned downward.
2. Cylinder body 200270

(1) Check the bore of the cylinder for rusting, erosion and
scoring.
(2) Check the inlet port and relief port for cleanliness.
Also, check the threads of screw connection of each
joint for damage. Make sure that the boot is free from
any defects.
A: Standard value B: Repair or service limit
3. Piston Unit: mm (in.)
Replace the piston if it is damaged. Check the piston 0.020 to 0.105
Clearance A
clearance in the cylinder body. Replace the cylinder body (0.00079 to 0.00413)
between piston
and piston if the clearance is in excess of the service limit. and cylinder
B 0.2 (0.008)
4. Return spring
Replace the return spring every 1 year.
5. Primary cup, secondary cup and valve
Check these rubber parts for swelling, tearing and
deterioration due to aging. Replace them every 1 year.

Reassembly
To reassemble, follow the reverse of disassembly
procedure, and proceed as follows
(1) Wash all metal parts clean with a volatile cleaning
solvent, and dry them with pressure air.
(2) Apply a thin coat of rubber grease (METAL RUBBER
#20) or brake fluid to the piston cups and the bore of
the cylinder.

8-3
BRAKE SYSTEM

Wheel Brakes
Disassembly

10
9
9

3
11

5❋

8 7

2❋

5 4
207208

Sequence
1 Return spring 7 Strap and Anti-rattle spring
2 Fitting cable 8 Shoe and lining (primary), Parking brake lever,
3 Hold-down spring, Cup, Pin Retainer, Spring washer
4 Adjusting lever, Adjusting spring and Return 9 Wheel cylinder
spring 10 Parking brake cable
5 Cable guide, Sheave, Adjusting screw, Pin, 11 Backing plate
Washer
6 Shoe guide plate, Shoe and lining (secondary)

NOTE Start by:

1. Remove the front wheel.
The part (❋ ) to be changed periodically are
involved in the brake repair kit. 2. Remove the wheel hub and brake drum.
3. Separate the parking brake lever and cable at the
bottom of wheel brake.
4. Disconnect the brake pipe from the wheel brake
assembly.

8-4
 BRAKE SYSTEM

Suggestions for Disassembly

1. Removing return springs
Use a special tool to remove the return springs.
Special tool needed

Spring remover 64309 - 15411

200271

2. Hold-down springs removal

Use a special tool to remove the hold-down springs.
Special tool needed

Spring retainer 64309 - 15412

200272

Inspection after Disassembly

157 N·m
1. Backing plate Tightening torque for (16 kgf·m)
(1) Check the backing plate for cracks. backing plate mounting bolts [116 lbf·ft]
(2) Tighten the backing plate mounting bolts to the
specified torque.

2. Shoes and linings

(1) Check each shoe and lining for cracks.
(2) Replace the lining if it is fouled with grease matter,
burnt or glazed.
(3) Check the thickness of the lining, and replace the lining
if it is worn to the service limit.

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model 1.0 to 1.8 ton 2 to 3.5 ton 203005
Item classes classes
A 4.87 (0.19) 6 (0.24)
Thickness of
linings 2.5 (0.10) 3 (0.12)
B
maximum maximum

8-5
BRAKE SYSTEM

3. Brake drums A: Standard value B: Repair or service limit

Check the inside (friction) surface of the drum for Unit: mm (in.)
abnormal wear, grooving and other defects. Minor Truck Model 1.0 to 1.8 ton 2 to 3.5 ton
grooving can be removed by grinding, provided that the Item classes classes
inside diameter does not exceed the service limit.
254 +0.13
+0 310 +0.15
+0
Inside A
diameter of (10.2 +0.0051
+0 ) (12.2 +0.0059
+0 )
brake drum
B 256 (10.08) 312 (12.28)

4. Adjusting screws
Check the wheel teeth for wear. Turn the screw by hand to
see if its rotating parts turn smoothly.

200274

5. Parking brake cable

Replace the cable if it shows stretch, rust or damage.

6. Others
(1) Check the return springs for cracks or fatigue.
(2) Check the adjusting springs for cracks or fatigue.
(3) Check the fitting cables for stretching.

8-6
 BRAKE SYSTEM

Reassembly

4 3 7 5 12 10 1 2 12 8 13 6
A

11

14 Section A-A
A

203586

Sequence
1 Wheel cylinder 9 Hold-down spring, Cup, Pin
2 Backing plate 10 Shoe guide plate
3 Shoe and lining (primary) 11 Fitting cable
4 Parking brake lever 12 Return spring
5 Retainer, Washer 13 Cable guide, Sheave, Pin, Washer
6 Shoe and lining (secondary) 14 Adjusting lever, Adjusting screw, Adjusting
7 Strap spring
8 Anti-rattle spring

8-7
BRAKE SYSTEM

Suggestions for Reassembly

1. Wheel cylinder installation
Apply the liquid packing to the mounting face of the wheel
cylinder before positioning the cylinder in place; and secure
it by tightening to the specified torque:

A: Standard value B: Repair or service limit

Unit: N·m (kgf·m) [lbf·ft]
Truck Model 1.0 to 1.8 ton 2 to 3.5 ton 200275
Item classes classes
8 to 12 18 to 26
Tightening torque
(0.8 to 1.2) (1.8 to 2.7)
for wheel cylinder
[6 to 9] [13 to 20]

2. Greasing
Apply the specified brake grease to the following parts,
forming a thin coat of grease at each:
(1) Shoe ledges (6 places):
The ledges are those portions of the backing plate in
contact with the shoe.
(2) Anchor pin surface in contact with the shoe ends

3. Shoe and lining installation

Check to be sure that each push rod of the wheel cylinder is
snugly fitted to its shoe web.

4. Return spring installation

Use a special tool to install the return springs to the
backing plate pins.
Special tool needed

Spring installer 65309 - 15413

200276

8-8
 BRAKE SYSTEM

5. Automatic adjusting device installation

(1) Clean the adjusting screw and associated parts and
apply a thin cost of grease to the screw threads and
screw socket. Check that the screw turns smoothly
when rotated by hand.
If the screw is hard to turn, replace it by a new one.
(2) Discriminate the right-hand adjusting screw and lever
from the left-hand ones by the color:
200277
Right-hand adjusting screw and lever
Yellowish color
(left-hand thread)
Left-hand adjusting screw and lever
Whitish color
(right-hand thread)

NOTE
After reassembly, bleed air out of the brake fluid lines.
(Refer to Inspection and Adjustment.)

8-9
BRAKE SYSTEM

Wheel Cylinders
Disassembly

1
❋
2
3
❋
4
❋
5

❋
4

3
❋
2

200278

200279

Sequence
1 Connector link 5 Return spring
2 Boot 6 Bleeder screw, Cap
3 Piston 7 Cylinder body
4 Piston cup

NOTE
The part (❋ ) to be changed periodically are
involved in the brake repair kit.

8-10
 BRAKE SYSTEM

Inspection after Disassembly

1. Cylinder bodies
(1) Check the bore for rusting, erosion and scoring.
(2) Check the threads of bleeder screw and oil pipe for
damage.
2. Pistons
(1) Check the sliding surface for rusting and scratching.
(2) Check the piston clearance in the cylinder body.
Replace the cylinder body and piston if the clearance is
in excess of the service limit.

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model 1.0 to 1.8 ton 2 to 3.5 ton 200280
Item classes classes
0.040 to 0.020 to
Clearance 0.125 0.125
A
between piston (0.00157 to (0.00079 to
and cylinder 0.00492) 0.00413)
B 0.15 (0.0059)

3. Piston cups
Check for swelling or other defects. Replace the cups at the
time of overhaul and every 1 year.
4. Boots
Replace the boots if they are hardened, damaged or
otherwise deteriorated.

Reassembly
To reassemble, follow the reverse of disassembly. Do the
following steps:
(1) Coat the piston cups and the cylinder bore with brake
fluid.
(2) Be careful not to damage the lips of the cups.

8-11
BRAKE SYSTEM

Inspection and Adjustment

Automatic Adjusting Device

1. Assemble the wheel brake. Adjust the drum-to-lining
clearance to the specification. Push the cable with your
thumb to pull the adjusting lever. Observe that the lever
turns the adjusting screw by one tooth. Remove your
thumb and observe the adjusting screw return to the
original position. 200281

2. If the lever fails or the adjusting screw is sluggish to

turn in the above test, the likely cause is that the lever
is not properly positioned relative to the toothed wheel.
Be sure that the lever is positioned so that its actuating
tip touches the toothed wheel at a level about 9 mm
(0.35 in.) under the center line of the screw, as shown.
3. Where the automatic adjusting device is suspected of 9 mm
malfunctioning during normal use of the machine, the (0.35 in.)
following possible causes must be considered:
200282
(1) Adjusting spring is not correctly hooked to primary
shoe. Adjusting toothed wheel and
(2) Any of these parts is in bad condition to require lever positions
replacement:
a) fitting cable, b) adjusting lever, and c) adjusting
screw.

Manual Adjustment
The drum-to-lining clearance can be adjusted by rotating
the adjusting screw with a screwdriver set onto the toothed
wheel. The hole thorough which the screwdriver tip can be
inserted is provided in the backing plate.

200283

8-12
 BRAKE SYSTEM

Brake Pedal Adjustment

C
1. Set the height A (from the frame to the top of pad) of
the pedal to the specified value.
2. Set the length B of push rod to the specified value, and A
push in the rod into the master cylinder. Stopper bolt

3. Make sure that the pedal stroke C (to a point where the
brakes are applied) is correct.
Unit: mm (in.)
Truck Model 1.0 to 1.8 ton 2 to 3.5 ton
Item classes classes
Pedal height A 220 (8.7)
Push rod length B 103.2 (4.06)
B
40 to 61 49 to 95
Pedal stroke C 207076
(1.57 to 2.4) (1.93 to 3.74)

Bleeding Air Out of the Brake Fluid Line

Whenever any part of the brake fluid line was disconnected
in servicing work, an air bleeding operation must be carried
out to complete the work. With air trapped in any part of
the fluid line, the pedal will “feel” spongy.
The procedure for air bleeding operation is as follows:
1. Connect a flexible tube, such as a clear plastic pipe, to
the bleeder screw on wheel cylinder. Pour enough clean
200285
brake fluid in to the jar, and immerse the end of pipe.
2. Pump the brake pedal and depress the pedal all the
way. While keeping the pedal depressed, loosen the
bleeder screw and, when air bubbles cease to come out
(as seen in the jar), tighten the screw. Repeat this
process until nothing but brake fluid flows into the
vessel.
3. Carry out the foregoing steps at each wheel brake, and
fill up the brake fluid reservoir to level.
Brake Test
NOTE
After completion of necessary adjustments, test the
1) Be sure that, at no time during the bleeding brake force by traveling the truck at a speed of 10
operation, the reservoir becomes empty of fluid. km/h [6.2 mph].
2) Use the specified brake fluid, and avoid different Refer to Manual Adjustment for necessary
brands of brake fluid getting mixed before and readjustment.
after filling up the reservoir.

8-13
BRAKE SYSTEM

Troubleshooting

Oil leaking past primary cup in master *Replace piston cup(s) if cylinder
cylinder is free from unacceptable wear.
Replace the cup(s) and fluid
Oil leaking past cups in wheel cylinder with genuine parts if the cup(s)
Lack of braking is distorted.
force Oil leaking from oil pipe connection Retighten, or replace pipe and
connector.
Shoe linings worn Replace.
Shoe linings dirty with oil or grease Clean or replace.

Air trapped in brake fluid lines Bleed air at master and

wheel cylinders.
Piston cup defective in master cylinder Replace.
Excessive pedal Not enough fluid in reservoir tank Refill.
stroke Push rod to piston clearance too large in Readjust.
master cylinder
Brake fluid leakage Refer to * above.
Automatic adjuster inoperative Ensure that cable guide and
adjusting spring are correctly
installed. If still inoperative,
replace cable with spring, lever,
Wheel and adjusting screw.
brakes
Lining or drum dirty with oil or grease Clean with gasoline. If lining
Uneven braking
in less effective brake still dirty, replace.
(wheel brake is
more effective on Wobbly or loose-mounted drum in less Replace drum. If loose, readjust
one side than on effective brake and retighten.
the other)
Wheel tires inflated unequally Reinflate to specification.

Lining glazed Sand.

Worn linings Replace shoe and lining
assemblies.
Brake squeals
Backing plate securing bolts loose Retighten.
Wheel bearings loose Readjust preload and retighten.
Brake drum dirty Clean with cleaning solvent.

Anchored ends of shoes rattling Repair or replace.

Brake chatters on anchor
or clatters Shoe ledges badly worn Replace backing plate.
Pistons badly worn in wheel cylinder Replace wheel cylinder.

8-14
 BRAKE SYSTEM

Lever stroke is
too small Lining to drum clearance too small Readjust.

Will squeal Lining to drum clearance too small Readjust.

Parking during traveling Brake drum badly distorted Repair or replace.
brake

Parking brake cable longer than Check lining to drum clearance.

specification If brake will still not apply,
readjust cable length.
Will not apply Linings worn to the service limit Replace shoe and lining
assemblies.
Lining to drum clearance too large Readjust.
Lever lacks operating force Readjust to specification.

8-15
BRAKE SYSTEM

Service Data A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
Item GP25K-HP
Height of pedal 1 A 220 (8.7)
Stroke (to a point where brakes start 40 to 61 49 to 95
A
to apply) 2 (1.57 to 2.4) (1.93 to 3.74)
Free play of pedal 3 A 10 to 16 (0.4 to 0.6)
Set length of push rod 4 A 103.2 (4.06)
Projection of stop lamp switch 5 A 2 (0.08)

2
3

Brake pedal

5
4
204944

+0.052 +0.00205
Inside diameter of cylinder body 1 A 19.05 +0 (0.7500+0 )

–0.020 –0.00079
Diameter of piston 2 A 19.05 –0.053 (0.7500 –0.00209 )

A 0.020 to 0.105 (0.00079 to 0.00413)

Clearance between cylinder and piston
B 0.2 (0.008)

Diameter of primary cup (lip side) 3 A 20 – 00.3 (0.79 – 00.012 )

B (Replace every year)
Master A 20.2 ± 0.2 (0.795 ± 0.008)
cylinder Diameter of secondary cup (lip side) 4
B (Replace every year)
A 46.8 (1.843)
Free length of return spring 5
B (Replace every year)

4 2 5

1 3 207077

8-16
 BRAKE SYSTEM

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
Item GP25K-HP
22.22+0.052
+0 28.58 +0.052
+0
Inside diameter of cylinder body 1 A (0.8748 +0.00205 ) (1.1252 +0.00205 )
+0 +0
–0.040 –0.020
22.22 –0.078 28.58 –0.058
Diameter of piston 2 A (0.8748 –0.00157 (1.1252 –0.00079
–0.00307 ) –0.00228 )
0.040 to 0.125 0.020 to 0.105
Clearance between cylinder and piston A (0.00157 to 0.00492) (0.00079 to 0.00413)
B 0.15 (0.0059)
23.7 ± 0.2 30.5 ± 0.25
Diameter of piston cup (lip side) 3 A (0.933 ± 0.0079) (1.201 ± 0.0098)
B (Replace every year)
Free length A 49.5 (1.95) 58 (2.28)
Wheel Length under test force A 20 (0.79) 22 (0.91)
cylinder Return
spring 4 12 ± 1 (1.2 ± 0.1) 13 ± 1 (1.3 ± 0.1)
Test force A [2.6 ± 0.2] [2.9 ± 0.2]
N (kgf)[lbf] B (Replace every year)
Tightening 8 to 1.2 (0.8 to 1.2) 18 to 26 (1.8 to 2.7)
torque Wheel cylinder bolts 5 A [6 to 9] [13 to 20]
N·m (kgf·m)
[lbf·ft] Bleeder screw 6 A 6 to 9 (0.6 to 0.9) [4 to 7]
1 6 5

2 3 4 200426
+0.13
254 –0
Inside diameter of brake drum 1 A (10.00 +0.0051 ) 310+0.15 +0.0059
– 0 (12.20 – 0 )
–0
B 256 (10.08) 312 (12.28)
A 4.87 (0.19) 6 (0.24)
Thickness of lining 2
B 2.5 (0.098) 3 (0.118)
Clearance between drum and 0.5 to 1.0 0.2 to 0.7
lining 3 (one side) A (0.02 to 0.04) (0.01 to 0.03)
Primary: 120 (4.72)
Free length A 102 (4.02) Secondary: 139.3 (5.48)
Wheel brakes Return Primary: 134 (5.28)
spring 4 Length under test force A 111 (4.37) Secondary: 145.4 (5.72)
157 ± 16 (16 ± 1.6) 226 ± 23 (23 ± 2.3)
Test force N (kgf) [lbf] A [35 ± 3.5] [51 ± 5.1]
Free length A 79 (3.11) 104.5 (4.11)
Adjusting Length under test force A 98.5 (3.88) 122 (4.80)
spring 5 Test force 137 ± 14 (14 ± 1.4) 78 ± 8 (8 ± 0.8)
N (kgf) [lbf] A [31 ± 3] [18 ± 2]
Tightening torque for backing plate bolt 6
N·m (kgf·m) [lbf·ft] A 215 (21.9) [158]

8-17
BRAKE SYSTEM

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
Item GP25K-HP

1
4

4 Secondary spring
2 6

Service brakes
Free length

204962

Lever swing angle A A 71° to 76°

Lever operating effort F 245 to 294 (25 to 30)
A
N (kgf) [lbf] [55 to 66]

Parking brake

204967

8-18
 STEERING SYSTEM

Structure ..................................................................................................... 9 – 1
Steering System ......................................................................................... 9 – 1
Steering Control Valve ................................................................................ 9 – 2
Tilt Steering Assembly................................................................................ 9 – 3
Procedures and Key Points for Removal and Installation ............ 9 – 4
Tilt Steering and Steering Control Valve Assembly..................................... 9 – 4
Steering Control Valve ............................................................................ 9 – 6
Disassembly ............................................................................................... 9 – 6
Inspection After Disassembly ..................................................................... 9 – 10
Reassembly................................................................................................ 9 – 10
Troubleshooting ........................................................................................ 9 – 16
Service Data .............................................................................................. 9 – 17

9
 STEERING SYSTEM

Structure

Steering System

4 F

G
C D E

A
C
D E

6
B 2
1
207167

1 Tank (hydraulic) 4 Steering control valve

2 Oil pump 5 Steering wheel
3 Inlet section 6 Steering cylinder
(with built-in flow divider valve)

The steering system uses a hydraulic mechanism Oil flow:

consisting of a steering control valve (orbit roll) and a Left turn E
flow divider valve to reduce the operator’s steering A B C F G
Right turn D
effort.
The force applied to the steering wheel is converted to
hydraulic pressure by the steering control valve. This
hydraulic pressure is then converted to the rear axle
steering force by the steering cylinder.
The flow divider valve controls the flow of hydraulic
oil discharged from the oil pump. The flow divider
valve supplies to the steering control valve the amount
of oil required only for steering operation, and sends
the remaining oil to the hydraulic circuits of other
devices.

9-1
STEERING SYSTEM

Steering Control Valve

13

T L R P

5 6 7 8 1 9 10 2 11 3 12 4

200786

1 Long housing 10 Control spool

2 Spacer plate 11 Spacer
3 Meter (Gerotor) 12 Spacer
4 End cap 13 Check valve
5 Needle thrust bearing P: Pump port
6 Centering spring T: Tank port
7 Pin L: Cylinder port (left)
8 Drive R: Cylinder port (right)
9 Control sleeve

9-2
 STEERING SYSTEM

Tilt Steering Assembly

6°

6°
1
9

10

4
3

2
6

206670A

1 Column housing 6 Universal joint

2 Lower shaft 7 Upper shaft
3 Column bracket 8 Column bushing
4 Lock cylinder 9 Bushing housing
5 Knob 10 Horn cord

The tilt steering assembly is installed to the bracket forward and backward.
under the dash board. The tilt steering assembly can tilt ± 6° around the
Pull down the knob, and move the steering wheel universal joint.

9-3
STEERING SYSTEM

Procedures and Key Points for Removal and Installation

Tilt Steering and Steering Control Valve Assembly

10
2

5
3

11

6 4 A

12 14

7
8
16

16
A
9 16
15

13
16

13 13

207059

Sequence
1 Steering wheel cap, Nut, Washer 9 Lower cover (rear)
2 Steering wheel 10 Cover (front)
3 Transmission shift lever 11 Floor plate
4 Console box cover 12 Tilt steering assembly
5 Console box 13 Hoses
6 Upper cover (front) 14 Bolt, Washer, Cushion, Collar, Spring washer
7 Lower cover (front) 15 Steering control box assembly
8 Upper cover (rear) 16 Elbows, Connectors, Pipes

9-4
 STEERING SYSTEM

Suggestions for Removal

Removing steering wheel
Use a special tool to remove the steering wheel. Steering wheel puller

Special tool needed

Steering wheel puller 91268 - 10600

! CAUTION
Do not hit the end of steering shaft when the 205770
steering wheel is removed.

Inspection after installation

Steering wheel play
Check the steering wheel play while idling the engine.

Steering effort
(1) Pull the hand brake lever. Run the engine and warm the
hydraulic oil to a operation temperature of 40 to 60 °C
(104 to 140 °F).
(2) Attach a spring balance to the rim (or a spoke) of the
steering wheel, and measure the steering torque
required to turn the steering wheel clockwise or
205771A
counterclockwise.

Steering effort 1.96 (0.2) [1.44]

N·m (kgf·m) [lbf·ft]
Tangential force 12.7 (1.3) [2.87]
N (kgf) [lbf]

Air bleeding
Air in the hydraulic system such as the steering cylinder,
the flow divider valve and the piping may cause shimmy
and abnormal noise.
(1) Jack up the rear tires. For procedures, refer to REAR
AXLE section.
(2) Depress and release the accelerator pedal repeatedly to
change the engine revolution speed, while turning the
steering wheel to lock-to-lock positions.

9-5
STEERING SYSTEM

Steering Control Valve

Disassembly

5
4

207179

Sequence
1 End cap, Screws, Seal 5 Needle thrust bearing
2 Meter, Seal, Spacer 6 Spool and sleeve assembly
3 Spacer plate, Drive, Seal 7 Check valve
4 Seal gland bushing assembly

9-6
 STEERING SYSTEM

Suggestions for Disassembly

Removing the end cap
Clamp the unit in a vise with the meter end up. Clamp
lightly on the edges of the mounting area, using protective
material on the vise jaws. Housing distortion can result if
the jaws are overtightened.

207180

Remove the cap screws and the end cap. Remove the seal
Seal washer
from the end cap.

Cap screw

End cap

Seal 207181

Removing the meter

Remove the meter, taking care not to let the star drop. Seal
Remove the seal from the meter. Remove the drive
spacer(s).

Meter
Spacer(s)

207182

Removing the drive

Remove the drive and spacer plate. Remove the seal from
the housing.

Spacer plate

Drive
Seal
207183

9-7
STEERING SYSTEM

Removing the seal gland bushing

Use a thin-bladed screwdriver to pry the retaining ring from
the housing.

200665

Rotate the spool and sleeve assembly until the pin is

horizontal. Push the spool and sleeve assembly forward
with you thumbs just far enough to free the gland bushing
assembly from the housing.

200666

Remove the quad ring seal from the seal gland bushing.
Use a thin-bladed screwdriver to pry the dust seal from the
bushing. Do not damage the bushing.
Quad
ring
seal

Seal gland
bushing
Dust seal
207184

Removing the needle thrust bearing

Remove the two bearing races and the needle thrust bearing
Needle Bearing
from the spool and sleeve assembly. thrust race
bearing

Bearing
race
207185

9-8
 STEERING SYSTEM

Removing spool and sleeve assembly

Remove the spool and sleeve assembly from the end of the
housing. Do not jam the spool and sleeve assembly. Rotate
it slowly when removing it from the housing. Pull the pin
from the spool and sleeve assembly.

Pin

200667

Pull the spool partially from the control end of the sleeve Spring
and carefully remove the centering springs from the spool package
by fingers. Push the spool back through and out of the
sleeve. Rotate the spool slowly when removing it from the
sleeve.

200668

Removing the check valve

Seal
Remove the seal from the housing. Remove the set screw.
Screw a # 10-24 machine screw into the end of the check
ball seat. Then, by pulling on the screw with pliers, lift the
seat out of the housing. Remove the two seals from the seat.
Tip the housing to remove the check ball and check ball
retainer.
Check ball
5/8” seal retainer
Check
Set 7/16” ball
screw Check ball seal
seat 207188

9-9
STEERING SYSTEM

Inspection After Disassembly

1. Check all mating surfaces. Replace any parts that have
scratches or burrs that could cause leaks.
2. Clean all metal parts in clean solvent. Blow dry with
air. Do not wipe dry with cloth or paper towels because
lint or other materials in the hydraulic system cause
damage. Do not use a coarse grit or try to file or grind
these parts.

Reassembly

5
4

207189

Sequence
1 Check valve 5 Spacer plate and Seal
2 Spool and Sleeve assembly 6 Drive
3 Needle thrust bearing 7 Meter and Seal
4 Seal gland bushing assembly 8 End cap, Screw, Seal

9-10
 STEERING SYSTEM

NOTE
Replace seals once disturbed. Lubricate all seals with
clean petroleum jelly such as Vaseline.

Suggestions for Reassembly

Reassembling the check valve
Use needlenose pliers to place the check ball retainer into
the housing. Make sure that the check vale is square in the Set screw
housing. Install the ball into the housing.
Lubricate the seals and install them on the check ball seat. Seal Check ball seat
Lubricate the seat and lower it into the housing. Do not
Seal
twist or damage the seals. Push the seat to the shoulder of Check ball
the housing.
Check ball
Install the set screw. Use a 1/4” Allen wrench to tighten the retainer
set screw. Make sure that the top of the set screw is slightly
207190
below the housing mounting surface.

11.3 N·m
Tightening torque for (1.2 kgf·m)
set screw [8.3 lbf·ft]

Reassembly the spool and sleeve

Spring
Assemble the spool and sleeve so that the spring slots line Control slot
up. Rotate the spool while sliding into the parts together. sleeve
Some sets have identification marks. Align these marks.
Test for free rotation. Spring
Align spring slots of both parts in line. Position one end of slot
Control
the centering springs in Spring Installation Tool and spool
compress the other end. Push the spring set into the spool Identification
marks
sleeve assembly while withdrawing the installation tool at 207191
the same time.
Special tool needed

Spring installation tool 97157 - 00100

9-11
STEERING SYSTEM

Center the spring set in parts so that they push down evenly
and flush with the upper surfaces of the spool and sleeve.

200671

Install the pin through the spool and sleeve to the point
where pin ends are flush with the sleeve.
Insert the spool and sleeve assembly, placing the splined
end to enter the housing first.

Pin
207192

NOTE
Be extremely careful that the parts do not jam. Push
the parts into place with a slight rotating action. Keep
the pin nearly horizontal and check for free rotation
without allowing the pin to drop into the discharge
groove in the housing.

Reassembling the needle bearing Needle

thrust
Install the seal in the housing. Install the two races and the Bearing
bearing
needle thrust bearing as shown. race (2)

Seal

207193

9-12
 STEERING SYSTEM

Reassembling the seal gland bushing

1. Install the dust seal in the bushing with the flat side Retaining
ring
facing towards the bushing.
2. Install the quad ring seal in the bushing by smoothing it Seal
into place with your finger. Do not use any seal that gland
bushing
falls freely into the pocket of the bushing.
(with seals)
3. Install the bushing assembly over the spool end with a
twisting motion. Tap it into place with a rubber head
hammer. Make sure the bushing is flush against with 200673
the bearing race.
4. Install the retaining ring in the housing and tap on the
Screwdriver
ring end or pry it with a screwdriver around the entire Dust seal
circumference to ensure a good setting.
Retaining ring

Seal gland
bushing
Quad ring seal
Seal

207195

Reassembling the spacer plate

1. Clamp the housing in a vise, equipped with soft jaws or
softened with rag, clamping lightly over the edges of
the mounting area. Do not overtighten the vise jaws.

NOTE
Check that the spool and sleeve are flush with or
slightly below the surface of the housing.
207196

9-13
STEERING SYSTEM

2. Install the seal in the housing. Place the spacer plate on

the housing and align the bolt holes with the tapped
holes in the housing.

207197

Reassembling the driver

Port surface
1. Make a mark across the splined end of the drive to
indicate the direction of the slot at the opposite end of Drive
the drive.
2. Rotate the spool and sleeve assembly until the pin is Pin parallel with
parallel with the port surface. Install the drive and port surface
make sure that it engages the pin. This mark should be
parallel to the port surface.
Pin
200675

Reassembling the meter

1. Install seal in the meter. Meter
(Gerotor)

Seal

207198

9-14
 STEERING SYSTEM

2. With the seal side of the meter towards the spacer plate,
Meter (Gerotor)
align spline of the star (wheel) (A) on the drive (B). star valley A
Noting the parallelism of reference lines A, B, C, and
D, align the bolt holes without disengaging the meter B
from the drive.
Drive
(marked)
C

Port
Pin face 207199

Reassembling the end cap End Cap

cap screw
1. Install the drive spacer(s) in the meter. Install the seal Seal
Drive
in the end cap. Install the end cap in the meter and spacer
align the holes. Seal
washer

207200

2. Install dry cap screw with new seal washers. Pretighten

all of the screws, then tighten them progressively in the
sequence as shown.

14.7 N·m
Initial torque for screws (1.5 kgf·m)
[10.8 lbf·ft]
23.5 N·m
Finishing torque for screws (2.4 kgf·m)
[17.3 lbf·ft]
200677

After installing the end cap, install the steering wheel to the
spool and make sure the spool rotates smoothly.

9-15
STEERING SYSTEM

Troubleshooting

No steering flow
(1) Foreign materials clogged in spool — Disassemble and clean.
pit
(2) Fatigued or damaged spring in the — Replace spring.
spool
Defect in flow Malfunction of relief valve
priority valve
(1) Low relief pressure — Adjust relief pressure.
(2) Damaged valve seating surface — Replace valve assembly.
(3) Fatigued or damaged spring — Replace springs and
adjust relief pressure.
Oil leak from relief valve
(1) Damaged O-rings on the valve — Replace O-rings.
body circumference

Clogging in “Gerotor” — Disassemble and clean.

Stiff steering Malfunction by spool seizure — Replace.

Defect in due to foreign material
wheel operation steering valve
Damaged bearing — Replace.
Excessive tightening of end cap bolt — Reassemble.

Defect in Bent piston rod — Repair or replace.

steering cylinder Faulty piston seal — Replace.

Misalignment Faulty installation of steering valve to — Readjust.

tilt column

Other defects Flattened pipe — Replace.

Defect in Seizure of spool or sleeve — Replace.

steering valve Breakage of centering spring — Replace.
Unstable steering
operation
Trapped air — Bleed.
Other defects Flattened pipe — Replace.
Faulty piston seal of steering cylinder — Replace.

9-16
 STEERING SYSTEM

Service Data
A: Standard value
Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
Item GP25K-HP
Steering torque (at steering wheel rim)
N·m (kgf·m) [lbf·ft]
A 1.96 (0.2) [1.44]
While engine is running at low idle, rotate wheel at a
rate of one full turn per second, keeping
Inward (deg) A 82 83
Turning angle
Outward (deg) A 55 56
Tightening torque of steering wheel nuts
A 53.9 to 58.8 (5.5 to 6.0) [39.7 to 43.3]
N·m (kgf·m) [lbf·ft]
Tightening torque of steering bracket bolts
A 29.4 (3) [21.7]
N·m (kgf·m) [lbf·ft]
Displacement cc (cu. in.)/rev. A 73.8 (4.50) 96 (5.86)
Flow rate liter (U.S. gal.)/min 11 (3.00) 15 (4.00)
Maximum operating pressure +490 +5 +71
Steering A 7355 0 (75 0 ) [1066 0 ]
kPa (kgf/cm2) [psi]
control valve
Tightening torque of end cap bolt 1
A 31.2 (3.2) [23]
N·m (kgf·m) [lbf·ft]
Tightening torque of check valve set
A 11.3 (1.2) [8.3]
screw 2 N·m (kgf·m) [lbf·ft]

2 1

200786

9-17
 HYDRAULIC SYSTEM

Description ................................................................................................10 – 1
Hydraulic Line ............................................................................................10 – 1
Hydraulic Tank ............................................................................................10 – 2
Hydraulic Pump ..........................................................................................10 – 3
Control Valve ..............................................................................................10 – 5
Lift and Tilt Cylinders ..................................................................................10 – 6
Flow Regulator Valve..................................................................................10 – 7
Down Safety Valve......................................................................................10 – 7
Removal and Installation .......................................................................10 – 8
Hydraulic Pump ..........................................................................................10 – 8
Control Valve .............................................................................................. 10 – 10
Lift Cylinders .............................................................................................. 10 – 11
Tilt Cylinders .............................................................................................. 10 – 17
Disassembly and Reassembly ............................................................. 10 – 18
Hydraulic Pump .......................................................................................... 10 – 18
Control Valve .............................................................................................. 10 – 21
Lift Cylinders .............................................................................................. 10 – 24
Tilt Cylinders .............................................................................................. 10 – 30
Flow Regulator Valve.................................................................................. 10 – 32 10
Inspection and Adjustment ................................................................... 10 – 33
Hydraulic Tank ............................................................................................ 10 – 33
Hydraulic Pump .......................................................................................... 10 – 34
Control Valve .............................................................................................. 10 – 35
Lift and Tilt Cylinders .................................................................................. 10 – 39
Flow Regulator Valve.................................................................................. 10 – 40
Testing........................................................................................................ 10 – 41
Hydraulic Circuit Diagram ..................................................................... 10 – 42
Troubleshooting ........................................................................................ 10 – 43
Service Data .............................................................................................. 10 – 46
 HYDRAULIC SYSTEM

Description

Hydraulic Line
11 12 10 11

13 13

9 6
7
8
5

14

15
1 3 2

207337

1 Hydraulic tank 9 Main relief valve

2 Suction strainer 10 Flow regulator valve
3 Return filter 11 Lift cylinders
4 Gear pump 12 Down safety valve
5 Inlet section (with built-in flow divider valve) 13 Tilt cylinders
6 Lift spool 14 Steering control valve
7 Tilt spool (with built-in tilt lock valve) 15 Steering cylinder
8 Attachment spool

The hydraulic pump draws oil from the oil tank. The steering cylinder.
discharged oil flows through the flow divider, and is Steering control valve and steering cylinder are covered
divided into two control valves, one for controlling the in “GROUP 9 STEERING SYSTEM” and “GROUP 7
lift and tilt cylinders and the other for controlling the REAR AXLE”.

10-1
HYDRAULIC SYSTEM

Hydraulic Tank

2 1

To hydraulic
pump

From control
valve

6 5 4
3

207339

1 Air breather, Cap 4 Suction strainer

2 Oil level gauge 5 Return filter
3 Drain plug 6 Return pipe

The tank is internally provided with two filtering

means, suction strainer 4 with a 150-mesh screen for
catching gritty particles in the oil, and return filter with
the relief valve and capable of catching 15-micron and
larger particles in the oil returning from the control
valve.

10-2
 HYDRAULIC SYSTEM

Hydraulic Pump

Hydraulic pump
Engine

Universal joint

204970

This is a gear pump capable of developing very high

pressure on its discharge side. A special arrangement is
incorporated in the pump construction for the purpose of
keeping the side clearances minimized between bushings
on the one side and pump gears on the other. Note, in the
illustration, that discharge pressure is applied to the back
of each bushing through internal oilways.

Operation Driven gear

Essentially the pump consists of two gears — drive gear
and driven gear — smoothly fitted in the housing. The oil
is carried around the periphery of the revolving gears from
the suction to discharge side. The teeth are meshing
between the two gears and thus prevent return of oil from
the discharge to the suction side.

Drive gear
203585

10-3
HYDRAULIC SYSTEM

Pressure loading mechanism

End clearance
The oil leak in pump decreases the pump efficiency. The
pressure loading mechanism, where the high discharge
pressure is applied to the bush back faces, reduces this leak
by minimizing the clearance between pump gears and
bushes. Even when sliding faces of gear or bushes are
worn, this mechanism keeps the clearance between gears
and bushes, and maintains the good pump efficiency.
Outlet
200333

10-4
 HYDRAULIC SYSTEM

Control Valve

6
6 8

P
5

T2

T1
7
PF A1 2 3 8 4

207135

1 Inlet section (with built -in flow divider valve) 8 Shutoff valve assembly [overload relief valve
2 Lift section (option)]
3 Tilt section (with built-in tilt lock valve) P: From hydraulic pump
4 Attachment section PF:To steering control valve
5 End cover T1: To hydraulic tank
6 Main relief valve T2: From steering control valve
7 Relief valve for flow divider valve (PF port relief A1:To lift cylinders
valve)

The control valve consists of four sections; namely, is in the oil passage from the oil pump and prevents
inlet, lift, tilt and attachment, all being of spool type. high oil pressure which could damage the pump. The
The inlet section has a built-in flow divider valve. The relief valve for flow divider valve controls the oil
tilt section has a built-in tilt lock valve. pressure below the maximum pressure in the steering
The attachment section has a built-in shutoff valve or circuit. The overload relief valve prevents high oil
an optional overload relief valve. The main relief valve pressure occurring in the attachment circuit.

10-5
HYDRAULIC SYSTEM

Lift and Tilt Cylinders

Lift cylinder
(Simplex mast)
(Triplex mast second cylinder)

1 2 3 207073

(Duplex and triplex mast first cylinder)

1 2 3 207604

(Duplex mast second cylinder)

207605

Tilt cylinder

207033

The lift cylinders, left and right, are of single-acting The tilt cylinders, left and right, are of double-acting
type. Air and oil remaining inside air chamber 1 of the type. The piston rod carries a screw-on socket. This
rod and inside rod chamber 2 between the tubes open socket is to be repositioned by turning, as necessary,
check valve 3 when compressed, thus the air and oil when the cylinder is connected to the outer mast. The
flow out of the cylinder. right and left cylinders are hydraulically connected to
Only the second cylinders of the Duplex Mast are each other. The tilt angle can be increased or decreased
provided with bleeding valves. by means of spacer and shim of each cylinder.
10-6
 HYDRAULIC SYSTEM

Flow Regulator Valve

From control valve To control valve

To lift cylinder From lift cylinder 203558

The flow regulator valve is located between each lift lowered to keep a constant safe lowering speed
cylinder and control valve. It limits the flow of oil regardless of load.
forced out of the cylinder when the loaded forks are

Down Safety Valve

When in normal condition

Broken area

When piping is broken 204971

The down safety valve is located at the bottom side of preventing the load from lowering, unsafely, rapidly,
right-hand lift cylinder. This valve provides a means of when the hose bursts.

10-7
HYDRAULIC SYSTEM

Removal and Installation

Hydraulic Pump

206471

Sequence
1 Universal joint 4 Suction hose, Clamp, Elbow, O-ring
2 Drive pulley, Lock nut, Boss 5 Hydraulic pump
3 Main delivery hose, Joint, O-ring

Start by:
1. Remove the counterweight.
2. Loosen the fan belt.

10-8
 HYDRAULIC SYSTEM

Suggestions for Removal

1. Remove the drive pulley lock nut 2 with special tools.
Special tool needed

Truck Model
Tool Name GP15K thru 35K DP20K thru 35K

91268 - 00100 91268 - 00100

91268 - 00200 91868 - 00100
Wrench
(to be used in (to be used in
combination) combination) 204929

NOTE
The drive pulley lock nut has left-hand threads.

2. To reassemble, follow the reverse of disassembly

sequence. Tighten the counterweight bolts, pump outlet
joint and main delivery hose to the specified torque.
Tightening torque
Unit: N·m (kgf·m) [lbf·ft]
412 to 490
Counterweight bolts (42 to 50)
[304 to 362]
Pump outlet joint 167 (17) [123]
Main delivery hose 118 (12) [87]

10-9
HYDRAULIC SYSTEM

Control Valve

1 2

6
4

207048

Sequence
1 Clevis pin, Rod 5 Steering delivery pipe
2 Tilt pipe, Connector, O-ring 6 Steering return hose, Pipe
3 Main delivery hose, Joint, O-ring 7 Return hose
4 Lift pipe 8 Control valve

Start by:
1. Remove the floor plate and dashboard cover.
2. Before disconnecting pipes, tilt the mast to vertical
position, lower the forks all the way, and relieve the
pressure in the pipes.

10-10
 HYDRAULIC SYSTEM

Lift Cylinders
Dual-stage Panoramic Mast (Simplex Mast)

7 6

1
3

2 207637

Sequence
1 Nuts 4 High-pressure hose 6 Cylinder clamp
2 Fork, Lift bracket 5 Set bolt, Shims [Cushion, Collar, Shims]
3 Hose guard 7 Lift cylinder, Bracket

Suggestions for Removal

1. Lift bracket removal
(1) Tilt the mast forward, and lower the inner mast to the
bottom. Slacken the lift chains, and remove the nuts
from the anchor bolts.
(2) Tilt the mast back to vertical position. Raise the inner
mast until the lift bracket becomes free. Then, back the
truck away from the lift bracket and fork assembly.

204873A

10-11
HYDRAULIC SYSTEM

2. Disconnecting high-pressure hoses

Right-hand cylinder Left-hand cylinder
Disconnect the high-pressure hoses at the joints indicated
by arrows. Use a container to catch oil flowing out of the
hoses.

204933

3. Removing set bolts

(1) Remove the set bolt at the top of each lift cylinder. Lift
the inner mast to separate the cylinder rod ends. To lift
the inner mast, hitch a sling around the mast with
protective rag.

NOTE
The rod end of either lift cylinder is shim adjusted to
eliminate the difference in stroke between the
cylinders. Before removing the set bolts, make a record
of the amount of shims and cylinders to which the 204934
shims are fitted.

(2) Tie wood blocks under the inner mast and detach the
sling. Use blocks strong enough to support the mast.

202983

10-12
 HYDRAULIC SYSTEM

4. Removing lift cylinders

Hitch a sling to the lift cylinder from the rear side of the
mast, and remove the cylinder. Hitch the sling before
removing the cylinder clamp.

204935

Installation
To install, follow the reverse of removal sequence, and do
the following steps:
1. Extend and retract the lift cylinders several times under
no load condition to bleed air out of the cylinder
circuits and to make sure that the cylinders move
smoothly.
2. Check the oil level in the hydraulic tank with an oil
level gauge. (Make reference to Hydraulic Tank
section, Inspection and Adjustment.)
3. Check to make sure that the lift height is correct.
4. After the lift cylinders or piston rods have been
replaced, check for difference in stroke between the
two cylinders. (Make reference to “GROUP 11 MAST
AND FORKS”.)

10-13
HYDRAULIC SYSTEM

Lift Cylinders
The following describes the procedures for removing and installing the mast assembly. Note that the triple-stage full
free panoramic mast (Triplex Mast) is used as an example.

Triple-stage Full Free Panoramic Mast (Triplex Mast)

3
1
207612

Sequence
1 Nuts 4 Chain wheel support assembly
2 Lift bracket assembly 5 Second lift cylinder
3 First lift cylinder

Suggestions for Removal

1. Removing lift bracket assembly 2
(1) Lower lift bracket assembly 2, and place wood blocks
under the assembly. Tilt the mast forward, lower the
inner mast to the bottom, then remove nuts 1 from the
anchor bolts of the first lift chains. 1

207613

10-14
 HYDRAULIC SYSTEM

(2) Position the mast upright. Raise the inner mast until
main rollers 6 of lift bracket assembly 2 become free.
Then, slowly move the vehicle in reverse to separate
from lift bracket 2.

201735

2. Removing first lift cylinder 3

(1) Tie a wire rope to first lift cylinder 3, and suspend the
cylinder with a crane. Wind the rope securely to
prevent slipping.
(2) Remove the lift cylinder connecting and mounting bolts,
and gently dismount first lift cylinder 3.

207616

3. Removing second lift cylinders 5

(1) Disconnect hoses from second lift cylinders 5.
(2) Remove stopper bolts at the upper sections of second
lift cylinders 5, and lift the inner mast [dual-stage full
free panoramic mast] or middle mast [triple-stage full
free panoramic mast] approximately 550 mm (21.67
in.) using wire ropes.
5

207617

10-15
HYDRAULIC SYSTEM

(3) Place wood blocks under the inner mast [dual-stage full
free panoramic mast] or middle mast [triple-stage full
free panoramic mast].
Make sure the right and left wood blocks are the same
in height.

202983

(4) Tie a wire rope on second lift cylinder 5 behind the

mast, remove cylinder clamp retaining bolts, and gently
remove second lift cylinder 5.
Tie the wire rope securely to the cylinder. The cylinder
cannot be lifted straight up since the mast cross-
member is located above the cylinder. Tilt the cylinder
and move it away from the cross-member to remove.
Be careful not have the hands caught between the
cylinder and mast.

Installation
5
To reinstall, follow the removal sequence in reverse, and
service as follows.

207618
(1) Install chain wheel support assembly 4 parallel to a
line connecting the centers of chain anchor bolt holes
on first lift cylinder 3 to prevent chains from twisting.
(2) Adjust the chain tensions.
(See the section on inspection and adjustment.)
(3) After proper operation is confirmed, check the oil level.

Good Bad

207638

10-16
 HYDRAULIC SYSTEM

Tilt Cylinders
1 Tilt socket pin [spacer]
2 Rubber hose
2
3 Cylinder pin [spacer]
4 Tilt cylinder

207049

Start by:
1. Lower the forks to the bottom, and tilt the mast fully
forward.
2. Hitch lifting slings to the top crossmember of outer
mast by using eye-bolts, and support the weight of the
mast with a hoist.

Suggestions for Removal

204845
1. Retracting piston rod
Remove tilt cylinder pin 1. Start the engine and retract the
piston rod to the full stroke, then stop the engine.

2. Disconnecting hoses
Disconnect hoses 2 from the cylinder at the connectors.
Use a container to catch oil from floating out of the
cylinder. Attach caps to the connectors of the cylinder to
protect the threads of the connectors and to prevent oil from
flowing out of the cylinder when the cylinder is removed.

10-17
HYDRAULIC SYSTEM

Disassembly and Reassembly

Hydraulic Pump

GP15K thru 35K

6
4

3
1

3
8

204937

Sequence
1 Cover, Bolts 5 Drive gear
2 Mounting flange, Snap ring, Oil seal 6 Driven gear
3 Body seal, Bushing seal 7 Backing rings, Bushings
4 Backing rings, Bushings 8 Body

General working tips

(1) Do not use a hammer or similar hard tool in an (4) Replace seals and seal rings once disturbed.
attempt to loosen or force out cover 1 and (5) Give a thin coat of grease to the lip of each oil seal
mounting flange 2. Use a plastic hammer. and to the seals just before fitting them.
(2) Prepare suitable containers to place parts in the (6) There are four bushings for the two pump gears.
disassembled order. This applies in particular to the Assemble them in their original locations.
pump gears and their bushings to ensure the correct
reassembly.
(3) Before starting reassembly, visually inspect all
parts to be for cleanliness, and apply hydraulic oil
to the sliding surfaces of the pump body.

10-18
 HYDRAULIC SYSTEM

(7) Each bushing has a flat. Be sure to locate the flat (9) The fit of the pump gears in the reassembled pump
correctly in the pump body. may be deemed satisfactory if the pump shaft
(8) Tighten the cover those bolts to the specification. rotates smoothly and lightly when turned over by
hand with an adjustable wrench.

DP20K thru 35K 2

4
6

3
1 204938

Sequence
1 Cover, Bolt 5 Drive gear
2 Mounting flange, Snap ring, Oil seal 6 Driven gear
3 Backup ring, Plate seal 7 Pressure plate
4 Pressure plate 8 Gear plate

General working tips

(1) Do not use a hammer or similar hard tool in an (3) Before starting reassembly, visually inspect all
attempt to loosen or force out cover 1 and parts to be sure they are perfectly clean, and apply
mounting flange 2. Use a plastic hammer. hydraulic oil to the sliding surfaces of the gear
(2) Prepare suitable containers to place parts in the plate.
disassembled order. This applies in particular to the (4) Replace oil seals; backup rings and plate seals once
pump gears and their bushings to ensure the correct disturbed.
reassembly.

10-19
HYDRAULIC SYSTEM

(5) Give a thin coat of grease to the lip of each oil seal and
to the seals just before fitting them.
(6) Tightening torque for the cover securing bolts is
specified. Tighten those bolts to the specification.
(7) The fit of the pump gears in the reassembled pump may
be deemed satisfactory if the pump shaft rotates
smoothly and lightly when turned over by hand with an
adjustable wrench.

Inspection after disassembly

1. Drive and driven gears
Inspect the gear teeth for wear and damage. Inspect the
journals and splines as above.

200344

2. Pump covers, body and bushings

Inspect these parts for wear and damage.

200346

10-20
 HYDRAULIC SYSTEM

Control Valve

32 39
1
33 34
2

36

39
37

40

25
35

31
38
24 27

28
29 14

23
21

26 15

20
30
17

5
18
7
13
22
3

16 9
8 10
19 11
6
12

207340

10-21
HYDRAULIC SYSTEM

Sequence
1 Tie rod bolts, Nuts 22 Lift section
2 End cover 23 O-ring
3 O-ring 24 Spring, Poppet
4 Main relief valve, O-ring 25 Cap, Screw
5 Connector, O-ring 26 Spool
6 Plug, O-ring 27 Screw, O-ring, Seat, Spring
7 Sleeve, Snap ring 28 Plate, Wiper, O-ring
8 Spool, Spring 29 Tilt lock valve, Spring
9 Plug 30 Plate, Wiper, O-ring, Screw
10 Housing, O-ring, Poppet 31 Tilt section
11 Spring 32 O-ring
12 Inlet section 33 Spring, Poppet
13 O-ring 34 Cap, Screw
14 Spring, Poppet 35 Spool
15 Cap, Screw 36 Screw, Seat, Spring
16 Spool 37 Plate, Wiper, O-ring
17 Screw, Seat, Spring 38 Plate, Wiper, O-ring, Screw
18 Plate, Wiper, O-ring 39 Shutoff valve assembly (or Overload relief
19 Plate, Wiper, O-ring, Screw valve (option))
20 Plug, O-ring 40 Attachment section
21 Connector, O-ring

Suggestions for Disassembly

1. Main relief valve
Do not remove main relief valve 4 unless it is defective. Plug
This applies to overload relief valve 39 (option) of the
attachment section.

NOTE
Lock nut
To remove the main relief valve for cleaning or
inspection, loosen its plug. Loosening the lock nut will
disturb the pressure setting. 205025

2. Inlet section
(1) To remove connector 5, loosen plug 6 two or three full
turns.
(2) To remove spool 8, screw a bolt into the hole (M6 × 1)
of the spool and pull out the spool squarely by gripping
the bolt before removing sleeve 7.

205026

10-22
 HYDRAULIC SYSTEM

NOTE Snap ring

1. Do not force spool 8 to pull it out.
2. Do not remove the snap ring from sleeve 7 unless
absolutely necessary. The snap ring would be
distorted if it should be removed.
3. Do not disassemble connector 5 any more.

205027

3. Lift, tilt and attachment sections

(1) Remove the spool from the section, together with plate
18 and screw 17. This applies to spools 26 and 35.
(2) Hold the spool in a vise with soft jaw caps, and remove
the screw 17 with an Allen wrench.

205028
Inspection after disassembly
Sections, spools and return springs
(1) Check each sliding surfaces for cracks and defects.
Also, check the check-valve seat for wear.
(2) Check the spools for burns and distortion. Also, check
for operating force.

177 to 216 N
Spool operating force (18 to 22 kgf)
[40 to 49 lbf]

(3) Check the tilt lock valve for damage and seizure.
Reassembly
To reassemble, follow the reverse of disassembly sequence
and do the following steps:
1. Clean all parts except for O-rings with solvent. Tilt lock valve

2. Apply hydraulic oil to O-rings when installing them.

3. Make sure that each spool moves freely.

203517

10-23
HYDRAULIC SYSTEM

Lift Cylinders
(Simplex mast, triplex mast second cylinder)

❋ : Parts contained in seal kit

8
1 2❋

3
7❋

6
❋
5

207064

Sequence
1 Retainer 5 Washer
2 Wiper, Rod seal, Backup rings, O-ring 6 Check valve, O-ring
3 Spacer 7 Wiper ring, Piston seal, Backup ring
Remove parts 4 through 8 as assembly. 8 Cylinder rod
4 Circlip, Sleeve 9 Cylinder tube

10-24
 HYDRAULIC SYSTEM

Reassembly

❋ : Parts contained in seal kit

❋
1 2 3 4 5 6 7

13 15 14 16 17 18 12 11 8 9 10
❋ ❋ ❋ ❋ ❋ ❋ ❋ ❋

207073

Sequence
1 Piston rod, Piston 7 Circlip 13 Retainer
Install parts 2 through 10 8 Backup ring Install parts 14 through 18
to part 1. 9 Piston seal to part 13.
2 Check valve 10 Wiper ring 14 Rod seal
3 O-ring 11 Spacer 15 Wiper
4 Washer 12 Cylinder tube 16 Backup ring
5 Circlip 17 O-ring
6 Sleeve 18 Backup ring

Suggestions for Reassembly 4. Tighten the retainer to the specified torque.

1. Use all parts in the seal kit to replace removed
parts. Unit: N·m (kgf·m) [lbf·ft]
2. After installing seal kit parts, apply hydraulic oil Truck GP/DP20K
before installing to the cylinder tube or piston rod. Model GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
3. Fill the space between the cylinder tube and piston Item GP25K-HP
rod with the specified amount of hydraulic oil
Retainer 170 to 240 200 to 270 270 to 304
before installing the retainer. tightening (17.3 to 24.5)(20.4 to 27.5) 27.5 to 31.0)
torque [125 to 175] [150 to 200] [200 to 225]
Unit: cc (cu. in.)
Truck GP/DP20K
Model GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
Item GP25K-HP
Amount of 75 to 85 75 to 85 90 to 100
hydraulic (4.57 to (4.57 to (5.49 to
oil 5.19) 5.19) 6.10)

10-25
HYDRAULIC SYSTEM

Lift Cylinders
(Duplex mast, triplex mast fast cylinder)

❋ : Parts contained in seal kit

1 2❋

❋3

❋
4

207642

Sequence
1 Retainer 3 Wear ring, Nylon ring, Piston seal
2 O-ring, Backup ring, Rod seal, Wiper 4 Circlip, Washer, O-ring, Check valve
Remove parts 3 through 5 as sub-assembly 5 Piston rod, Piston
from part 6. 6 Cylinder tube

10-26
 HYDRAULIC SYSTEM

Reassembly

❋ : Parts contained in seal kit

❋ ❋ ❋ ❋ ❋ ❋ ❋ ❋
13 12 14 15 1 6 7 8 9

11 10 2 3 4 5
❋

207604

Sequence
1 Piston rod, Piston 9 Wear ring
Install parts 2 through 10 to part 1. 10 Cylinder tube
2 Check valve 11 Retainer
3 O-ring Install parts 12 through 15 to part 11.
4 Washer 12 Rod seal
5 Circlip 13 Wiper
6 Nylon ring 14 Backup ring
7 Piston seal 15 O-ring
8 Nylon ring

Suggestions for Reassembly 4. Tighten the retainer to the specified torque.

1. Use all parts in the seal kit to replace removed
parts. Unit: N·m (kgf·m) [lbf·ft]
2. After installing seal kit parts, apply hydraulic oil Truck GP/DP20K
before installing to the cylinder tube or piston rod. Model GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
3. Fill the space between the cylinder tube and piston Item GP25K-HP
rod with the specified amount of hydraulic oil
Retainer 305 to 370 340 to 405 440 to 475
before installing the retainer.
tightening (31 to 37.7) (34.7 to 41.3) (44.9 to 48.5)
torque [225 to 275] [250 to 300] [325 to 350]
Unit: cc (cu. in.)
Truck GP/DP20K
Model GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
Item GP25K-HP
Amount of 70 to 80 85 to 90 125 to 130
hydraulic oil (4.27 to 4.88)(5.18 to 5.49) (7.62 to 7.93)

10-27
HYDRAULIC SYSTEM

Lift Cylinders
(Duplex mast second cylinders)

❋ : Parts contained in seal kit

6
3
2

1
5❋

7 4

207641

Sequence
1 Holder 4 Cylinder head, Bushing
Remove parts 1 through 6 5 Wiper ring, O-ring, U-ring, Backup ring
as sub-assembly from part 1. 6 Piston rod
2 Slide ring, Set screw, Piston 7 Cylinder tube, Set screw, Steel ball
3 Spacer, Snap ring

NOTE
Spacer is installed in cylinders with lifting height of
3.7 mm (145.7 in.) or more.

10-28
 HYDRAULIC SYSTEM

Reassembly

❋ : Parts contained in seal kit

2 7 8 16 15 12

11
6 3 4 5 14 1 9 10 13
❋ ❋ ❋ ❋
207605

Sequence
1 Piston rod 4 U-ring 11 Piston
Install parts 2 through 13 5 O-ring 12 Set screw
to part 1. 6 Wiper ring 13 Slide ring
2 Holder 7 Cylinder head 14 Cylinder tube
Install parts 3 through 6 8 Bushing 15 Steel ball
to part 2. 9 Spacer 16 Set screw
3 Backup ring 10 Snap ring

Suggestions for Reassembly 4. Tighten the set screws (2 locations) to the specified
torque.
1. Use all parts in the seal kit to replace removed
parts.
2. Apply hydraulic oil to the sliding sections on the Unit: N·m (kgf·m) [lbf·ft]
cylinder tube inner surface and piston rod outer 3.92 ± 0.98
surface before installation. Set screw tightening torque (0.4 ± 0.1)
[2.9 ± 0.72]
3. Tighten the piston and holder to the specified
torque.

Unit: N·m (kgf·m) [lbf·ft]

Truck GP/DP20K
Model GP15K GP20K-HP
GP/DP30K GP/DP35K
GP18K GP/DP25K
Item GP25K-HP
24.5 ± 44.1
Piston 196 ± 35 (20 ± 3.6) [145 ± 26] (25 ± 4.5)
[180 ± 32.5]
206 ± 39.2 235 ± 54 304 ± 70.6
Holder (21 ± 4) (24 ± 5.5) (31 ± 7.2)
[152 ± 29] [174 ± 39.8] [224 ± 52]

10-29
HYDRAULIC SYSTEM

Tilt Cylinders

❋ : Parts contained in seal kit

4

3
❋

1 ❋
❋
❋

1
207140

Sequence
1 Tilt socket, Bolt, Nut, Bearing, Grease nipple 3 Piston rod, Piston, Piston seal, Nut
2 Guide bushing, O-ring, Dust seal, Packing, 4 Cylinder tube, Bushing
Buffer ring

NOTE
Do not remove the tilt socket bearing and cylinder tube
bushing unless they are defective.

Suggestions for Disassembly

Removing bushing
(1) Wrap the cylinder with a rag, and clamp it in a vise.
Using a wrench, remove the bushing from the cylinder.
(2) When removing the bushing from the piston rod, be
careful not to damage the buffer ring, packing, O-ring
against the threads of the piston rod.

200351

10-30
 HYDRAULIC SYSTEM

Inspection after disassembly

1. Cylinder tube
(1) Check the bore wall for wear, grooving, scratch marks
and rusting.
(2) Check the welds for cracks.
2. Piston rod
(1) Check for deflection in as shown.
(2) Check for surface flaws such as grooving, scratch
marks, rusting and wear. The rod must be replaced if
200319
its threads show a sign of stripping or any other
damage.
3. Packings and rings
Replace all parts contained in the seal kit, once disturbed.

Precautions for reassembly of lift and tilt

cylinders
(1) Carefully clean all parts to remove any gritty particle.
(2) Reassemble the cylinder in the reverse sequence of the
disassembling, apply hydraulic oil to the bore wall of
the cylinder tube, and also to sealing parts — O-rings,
U-rings, wiper rings, nylon heels, piston seals, dust
seals and packings — so that they will smoothly slide
into the bore.
(3) When clamping the cylinder tube in the vise in order to
run the head into the cylinder tube, be careful not to
200352
distort the tube.
(4) Before fitting the piston seal to the tilt-cylinder piston,
squeeze the seal by hand 5 or 6 times to soften it. Hold
the piston steady by clamping the rod in the vise; apply
a small amount of hydraulic oil to the seal; fit a portion
of the seal to the groove; and push the other portions
just a little at a time into the groove.

200353

10-31
HYDRAULIC SYSTEM

Flow Regulator Valve

1
5

203559

Sequence
1 Lock nut 4 Piston, Pin, Washer, Spring, Valve
2 Plug, O-ring 5 Valve body
3 Spring, Shims

Inspection after disassembly

1. Check the springs for fatigue.
2. Check seat and sliding faces of valve and piston.
3. Check the sliding surfaces of the piston and valve body
for damage.

NOTE
Replace the flow regulator valve as an assembly if any
part is defective.

10-32
 HYDRAULIC SYSTEM

Inspection and Adjustment

Hydraulic Tank
1. Hydraulic oil
Check the hydraulic oil in the tank for cleanliness. Oil
showing discoloring (Slightly whitish color is allowed as it
always appears after the operation.) must be changed.
2. Refill capacities and the amount of oil required.

”H” high level

“N” neutral level
“L” low level

Refill Refill Refill

H+5
capacity Lift height (meter) Refill capacity Lift height (meter) (1 liter, capacity
(7.0) capacity (7.0) approx.) GP/DP30K
GP/DP20K GP/DP30K
(6.5) (6.5)
GP/DP25K (6.0) 6.0 GP15K “H” 45 , 6.0 45 ,
“H” “H”
45 , (5.5) 5.5 GP18K (45.1 ,) 5.5 (45.1 ,)
“H” “N” 5.0
(45.1 ,) 5.0 5.0 43.1 , 5.0
“N” 40.1 , 40.1 , “N”
4.78 (30.9 ,) “L” 4.7
“N” 40.1 , 4.5 -1.8 , 4.5 -1.8 ,
27.8 , “L” (38.3 ,) “L”
-1.8 , 4.33 (38.3 ,) 4.3
30

“L” -1.2 , 4.0 4.0 4.0

(38.3 ,) 4.0 4.0 4.0
3.7 3.7 3.7 (26.6 ,) 3.7 3.7 3.7
50

10 3.5 3.5
3.5 3.5
3.3 3.3 3.3 3.3
3.0 3.0 3.0 3.0
2.7 2.7
246

2.5 2.5
2.0 2.0
Bottom of
*1 *2 *3 *1 *2 *3
hydraulic tank

*1 Dual stage panoramic Equivalents:

*2 Dual stage full free panoramic Meter = approx. 3.3 feet
*3 Triple stage full free panoramic Liter = approx. 0.26 U.S. gal
207162C

Remarks
(1) How to read the chart
[Example]
1.5, 1.8 ton classes: In the truck equipped with a triple-stage full free 5.0 m (165.5 ft) panoramic mast, maintain
the oil level at “N” mark on the level gauge with the mast lowered to the bottom. In the case
of 5.5 to 7.0 m (18.2 to 23.1 ft) masts, maintain the level at “H” mark with the mast lowered
to the bottom.
3.5 ton classes: In the truck equipped with any of the dual-stage full free masts up to 3.7 m (12.2 ft) lift
height, maintain the oil level at “N” mark. In the case of 4.0 m (13.2 ft) masts, maintain the
level at “H” mark with the mast lowered all the way.
(2) Another general rules: In any machine, regardless of the mast-and-attachment combination, the oil level should
not be above “H” mark on the level gauge when the mast is at the bottom. In addition, the oil level must be 5 mm
(0.12 in.) from the bottom end of the gauge or higher when the mast is at the top.
10-33
HYDRAULIC SYSTEM

3. Suction strainer
Check the suction strainer for clogging or damage.
4. Return filter
Check the return filter for clogging or damage.

Hydraulic Pump
The purpose of test run is to break-in the overhauled pump
and verify its performance. The use of a pump testing
equipment, specially designed as such and commonly used
in the service shop, is recommended but is not mandatory.
The following procedure, however, assumes that the pump
is installed on the truck:

1. Install a pressure gauge capable of measuring up to

25000 kPa (250 kgf/cm 2) [3555 psi]. To install the
pressure gauge, remove the plug from the delivery hose
joint and attach the following tools:
Special tool needed
64309 - 17733
Connector
[R (PT) 1/8 thread]
Hose 64309 - 17722
Connector 64309 - 17731 (for gauge)
64309 - 17712
Gauge 25000 kPa (250 kgf/cm2)
[3555 psi]

NOTE
These tools are included in the gauge kit 64309 -
17701.

2. Position the control levers in neutral. Run the engine at

500 to 1000 rpm, keeping the discharge pressure at a
level not higher than 981 kPa (10 kgf/cm2) [142 psi] or
below. Maintain this condition for 10 minutes to
break-in the pump.
3. Raise the engine speed from 1500 to 2000 rpm, and run
the engine for another 10 minutes in the no-load
condition.

10-34
 HYDRAULIC SYSTEM

4. While the pump is running, loosen the adjusting screw,

and shift the control levers into the operating positions.
Next, set the adjusting screw to obtain a gauge reading
of 2942 kPa (30 kgf/cm 2) [427 psi], and run for 5
minutes at this pressure. Then raise the pressure by
changing the setting of adjusting screw in increments
of 1961 kPa (20 kgf/cm2) [284 psi] each, running the
pump for 5 minutes at each raised pressure until the
prescribed set pressure of the relief valve is reached.
5. Pay attention to the temperatures of oil and pump
surfaces and to the running noise while raising the
pressure. If any abnormal condition is noted, bring the 207137
pump to no-load condition to cool the oil or pump or,
as necessary, discontinue the test run, and overhaul the
pump once again. Do not keep on raising the pressure
when an abnormal condition is noted.
6. After doing Steps 2. thru 5. above, reset the relief valve
as specified and operate the fork and mast to see if the
tilt and lift cylinders work with the specified speeds.

Control Valve
1. External leakage
(1) Check for oil leaks from the joint between adjacent
valve housings sealed by O-ring.
(2) Check for oil leaks from the scrapers sealed by O-
rings.
(3) Check for oil leaks from the screw connections.

10-35
HYDRAULIC SYSTEM

2. Internal leakage
3 to 4 °
It is not practical to check the control valve alone for
internal leakage. The leakage to be checked includes
leakages occurring at the lift spool, tilt spool, tilt lock valve
and check valves.
[Test oil temperature: 50 °C (122 °F), approx.]
(1) Pick up a load equal to the rated capacity, and lift it
approximately 1 meter (3 feet) high. Tilt the mast
1 meter (3 ft.),
about 3° to 4° forward, and stop the engine. approx.
(2) Quickly disconnect the oil return hose, and start
collecting the oil coming out of this hose as shown. 204942

The amount of oil 500 cc (30.5 cu. in.),

collected for 15 minutes maximum

(3) If the tilt cylinders or lift cylinders drift (the mast tilts
forward or the fork lowers) excessively in spite of that
the amount of oil collected for 15 minutes is less than
500 cc (30.5 cu. in.), measure the internal leakage of
each cylinder. (The measurement is the assembly
standard and not the service limit.)

3. Main relief valve adjustment

(1) Attach a pressure gauge capable of measuring up to 207138
25000 kPa (250 kgf/cm 2) [3555 psi] to the delivery
hose connector. Use the gauge, connectors and hose
used for testing the gear pump.
(2) Start the engine and run it at the maximum speed.
Move the tilt control lever to the backward tilt position.
If the pressure is relieved at 18142 +490 0 kPa
+5 +71
(185 0 kgf/cm ) [2631 0 psi] when the tilt cylinders
2

reach the end of their stroke, the main relief valve

setting is correct.

207137

10-36
 HYDRAULIC SYSTEM

(3) If the setting is incorrect, loosen the lock nut of

adjusting screw and, while observing the pressure
gauge reading, slowly turn the adjusting screw in either
direction until the gauge indicates the prescribed set
valve.
(4) While holding the adjusting screw, tighten the lock nut
to secure the adjusting screw.
(5) After securing the adjusting screw, recheck the setting.

18412 + 490 kPa

Main relief valve setting (185 + 5 kgf/cm2)
[2631 + 71 psi]

4. Flow divider relief valve adjustment

(1) Set up a pressure gauge capable of measuring up to 5
25000 kPa (250 kgf/cm2) [3555 psi] as shown.
Special tools needed 4
3
1 Connector 91268 - 06200
2 Connector 64309 - 17733 [R(PT)1/8 thread]
3 Hose 64309 - 17722
4 Connector 64309 - 17731 (for gauge)
2
64309 - 17712
5 Gauge 25000 kPa (250 kgf/cm2)
[3555 psi] 1
207045

NOTE
1) The tools 2 thru 5 are included in the gauge kit
64309 - 17701.
2) Use the gauge included in this gauge kit.

(2) Start the engine. With the engine running at the

maximum speed, turn the steering wheel
counterclockwise to the lock, and check the flow
divider valve for setting.

10-37
HYDRAULIC SYSTEM

Unit: kPa (kgf/cm2) [psi]

Flow divider relief valve

7355 +490 +5 +71
0 (75 0 ) [1066 0 ]
setting

(3) If the setting is incorrect, loosen the lock nut of

adjusting screw and, while observing the pressure
gauge reading, slowly turn the adjusting screw until the
gauge indicates the prescribed set value.
(4) While holding the adjusting screw, tighten the lock nut
to secure the adjusting screw.
(5) After securing the adjusting screw, recheck the setting.
207139
5. Overload relief valve adjustment (OP.)
(1) Attach a pressure gauge capable of measuring up to
25000 kPa (250 kgf/cm 2) [3555 psi] to the delivery
hose connector.

NOTE
Use the tools used for adjusting the main relief valve.

(2) Start the engine. With the engine running at the

maximum speed, move the attachment control lever
forward or backward. If the pressure is relieved when
the attachment actuator is moved, the overload relief
valve setting is correct.
(3) If the setting is incorrect, loosen the lock nut of
adjusting screw and, while observing the pressure
gauge reading, turn the adjusting screw.
(4) While holding the adjusting screw, tighten the lock nut
to secure the adjusting screw.
(5) After securing the adjusting screw, recheck the setting.

10-38
 HYDRAULIC SYSTEM

Lift and Tilt Cylinders

1. Mast tilt angle adjustment
(1) Adjust the tire pressure correctly, and place on a flat
and level ground.
(2) Tilt the mast fully backward, and stop the engine.
(3) Measure the tilt angle of mast at both sides.
(4) To adjust the tilt angle, loosen the bolt A on the tilt
cylinder socket and adjust the rod length by turning the
rod. Adjust a cylinder so that there is no difference in
A
stroke tilt angle between the cylinders. 207054

NOTE
It is not necessary to adjust the forward tilt angle,
provided that the backward tilt angle is properly
adjusted.

Forward — backward tilt angle 6° — 10°

2. Lift cylinder stroke adjustment

(1) Slowly raise the inner mast, and observe the stopping
of piston rod, right and left, at the moment the inner
mast reaches its maximum lift height.
(2) If the top of mast rolls at that moment, it should be
adjusted with shims. Abnormal condition can be
detected by a little time lag in stopping between right-
hand and left-hand piston rods and rolling of the rod
with a longer cylinder stroke.

204698

10-39
HYDRAULIC SYSTEM

[Adjusting method]
(1) Raise the inner mast, tie blocks under the right and left
sides of the mast, and lower the mast until it rests on
the blocks.

202983

(2) Remove the stopper bolt at the top of lift cylinder

which stopped first, retract the piston rod, and insert
shims at the top of piston rod end.
Shims

NOTE
To retract the piston rod, move the lift control lever to
the lowering position to let the oil escape from the lift
cylinder.

200365
(3) Extend the piston rod, and tighten the cylinder stopper
bolt. Remove the blocks from under the inner mast.
(4) Slowly lower the inner mast to the bottom to ensure the
piston rods move smoothly.

Flow Regulator Valve

Measure the lowering speed with rated load. If the speed is
out of specification, readjust, or replace the flow regulator
valve. Lock nut

1 to 2.5 ton 500 mm/sec

classes [98 fpm]
Lowering 530 mm/sec
3 ton class Adjustment
speed [104 fpm]
screw
440 mm/sec
3.5 ton class
[87 fpm] 205972

Bleeding lift cylinder

Air and oil remaining inside air chamber of the rod and
inside rod chamber between the tubes open the check valve
and flow out when they are compressed. Therefore, there is
no need to bleed the lift cylinder.

10-40
 HYDRAULIC SYSTEM

Testing
1. Load drift test
(1) Pick up a rated load, tilt the mast substantially vertical,
raise the forks 1 to 1.5 m (3.3 to 4.9 ft) from the floor,
and stop the engine.
(2) Mark a line on the mast column, and measure the
amount of descent for 15 minutes.

Unit: mm (in.)/15 min

207055
Truck Model 1 to 2.5 ton 3 ton 3.5 ton
Item classes class class
Load drop
50 (1.97),
test (rated 40 (1.57) 35 (1.38)
maximum
load)

2. Forward tilt test

(1) Pick up a rated load, tilt the mast substantially vertical,
raise the forks about 50 cm (20 in.) from the floor, and
stop the engine.
(2) Measure the extension of tilt cylinder for 15 minutes.

Unit: mm (in.)/15 min 207056

Truck Model 1 to 1.8 ton 2 to 2.5 ton 3 to 3.5 ton
Item classes classes classes
Forward tilt
test (rated 22 (0.87) 20 (0.79) 15 (0.59)
load)

3. Piping
(1) Check each hydraulic circuit for leaks.
(2) Make sure that each hose is free from twisting or
excessive loops.

10-41
 T1
Steering control valve

B5
A5
L R
HYDRAULIC SYSTEM

B4
A4
T P Steering cylinder

B3
Hydraulic Circuit Diagram

A3
B2
Std tilt cylinder

A2
T P

10-42
Gear pump

B1
Flow reg. valve

Return filter Suction strainer

A1
Flow divider relief valve

Main relief valve

Lift cylinder with P T2 PF

down safety valve

Hydraulic control valve

207338
 HYDRAULIC SYSTEM

Troubleshooting
Not enough oil in hydraulic tank Refill.
Oil viscosity improper Change upon referring to “Fuel
and Lubricant Specifications” on
page 13-10.
Overload Check working conditions and, if
over-loaded, urge the operator to
Hydraulic tank stay within the load limit.
heats excessively Local overheating of oil line due to Clean oil line.
a large restriction to flow
Relief valve adjustment improper Readjust pressure setting.
Pressure drop due to fatigued or Disassemble or replace and
broken springs readjust pressure.
Hydraulic
tank Gear pump worn Replace pump.
Outlet pipe or tube flattened, or Repair or replace.
restriction to flow
Shortage of oil due to a natural loss Replenish oil upon referring to
“Fuel and Lubricant Specifications”
Cylinders move on page 13-10.
too slow Oil leakage due to damaged oil line Repair or replace.
and seals
Oil viscosity too high Replenish oil upon referring to
“Fuel and Lubricant Specifications”
on page 13-10.
Gear pump does not pump oil Check pump and piping; repair or
replace.
Cylinders move
too slow Oil leakage from oil line Check oil for level and condition;
add or change oil.
Gear pump internally leaking Replace pump.
Poor pumping Replenish oil upon referring to
“Fuel and Lubricant Specifications”
Noisy on page 13-10.
Cavitation (1) Check suction pipe for any flat
portion or loose connection;
retighten or replace.
(2) Check shaft oil seal for
airtightness; replace pump.
(3) Check pump body for any
Gear pump outside interference; repair.
Pump case, drive Pressure too high Replace pump. (Check to see if
gear or pump port relief valve setting is correct.)
flange damaged Distortion or damage due to external Replace pump.
strain or stress
(1) Check to see if return line is
blocked or restricted.
(2) Check to see if pipe
connections have been
externally strained or stressed.
Oil leakage past oil seal Replace shaft seal.

Oil leakage from Oil leakage past sliding surfaces of Replace whole pump assembly.
drive shaft
pump
Pump securing bolts loose Retighten. Replace if needed.
Degraded performance of sealing Replace gasket.
inside pump
10-43
HYDRAULIC SYSTEM

Relief valve set pressure lowered Readjust pressure.

Relief valve piston seizure Wash piston and check to see if it
moves smoothly; or replace whole
Slow or no relief valve assembly.
motion of lift and
O-ring on relief valve body damaged Replace O-ring.
tilt cylinders
Control lever installed loose, Readjust.
resulting in not enough spool stroke
Abnormal oil temperature rise Check control valve spool for
misalignment; repair or replace.
Control
valve Load descends or
mast tilts forward Control valve internally leaking Replace a leaky block assembly.

Oil leakage from spool ring cap Replace O-ring; check spool for
flaws and if any, repair or replace a
Oil leakage leaky block assembly.
Loose plug Retighten plug.
O-ring damaged Replace O-ring.

Not enough oil in hydraulic tank Replenish oil upon referring to

“Fuel and Lubricant Specifications”
on page 13-10.
Mast will not lift
or tilt forward or Relief valve out of order, because of:
backward (1) Seized main valve Replace.
(2) Broken valve spring Replace.
Gear pump defective Replace.

Relief valve out of order, because of:

(1) Too low a relief valve setting Readjust pressure.
(2) Defective plunger or poppet seat Replace.
Will not lift rated
load (3) Fatigued spring Replace.
(4) Damaged O-ring in valve case Replace.
Gear pump defective Replace.
Piston seals worn or damaged Replace.

Lift and tilt Engine speed too low Adjust engine.

cylinders
Control lever installed loose, Adjust.
Lifting speed is resulting in not enough spool stroke
too slow
Tank strainer clogged Clean or replace.
Pump not delivering enough oil Repair or replace.

Lowering speed is Sleeve seized in flow regulator valve Repair.

too slow Dirt in flow regulator valve, Clean, repair system and replace
abnormal resistance to flow due to defective hose.
flattened hose or local clogging

10-44
 HYDRAULIC SYSTEM

Piston rod distorted Repair or replace.

Cylinder vibrates Air trapped in oil circuit Bleed air by operating cylinder
when actuated through full stroke.
Not enough oil in hydraulic tank Refill.

Control valve spool internally Replace a leaky block assembly.

leaking
Sliding (inside) surface of cylinder Repair or replace.
Load descends tube slightly grooved
fast Sliding (inside) surface of cylinder Replace cylinder assembly.
tube badly grooved
Piston seals broken or distorted Replace seal kit.
Oil leakage from piping Repair or replace.

Lift and tilt Control valve spool internally Replace a leaky block assembly.
leaking
cylinders
Mast tilts forward Foreign particles lodged in packing Replace packing.
(drift)
Piston seals damaged Replace seals.
Other abnormal distortion, oil Repair or replace.
leakage from piping

Lift cylinders
descend or tilt Sliding surface of cylinder tube Repair or replace.
cylinders tilt badly grooved or rusted at one point
forward (drift) at
a certain point of Cylinder tube distorted Replace.
stroke

Foreign particles lodged between Replace.

sealing members such as oil seals and
dust seals
Oil leakage at
bushing Oil seals and dust seals grooved Replace.
O-rings damaged Replace O-rings.
Cylinder abnormally distorted Repair or replace.

10-45
HYDRAULIC SYSTEM

Service Data
A: Standard value
Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP
GP/DP30K GP/DP35K
GP18K GP/DP25K
Item GP25K-HP
GP20K/25K: GP30K: GP35K:
Lift speed (rated load/no load) 510/550 470/500 400/430
490/520 [100/108] [93/98] [79/85]
A
mm/sec [fpm] [96/102] DP20K/25K: DP30K: DP35K:
[Simplex mast] 640/660 510/550 430/460
[126/130] [100/108] [85/91]
Lowering speed (rated load)
mm/sec [fpm] A 500 [98] 530 [104] 440 [87]
[Simplex mast]
Simplex mast
Forward tilt angle A 6°
Backward tilt angle A 10°
Lift cylinder rod drift (rated load)
mm (in.)/15 min. A 50 (1.97), max 40 (1.57) 35 (1.38)
[Oil temperature 45 °C (113 °F)]
Tilt cylinder rod drift (forward) (rated load)
mm (in.)/15 min. A 22 (0.87), max 20 (0.8), max 15 (0.59), max
[Oil temperature 45 °C (113 °F)]
Main relief valve setting +490 +5 +71
A 18142+0 (185 +0 ) [2631+0 ]
kPa (kgf/cm2) [psi]
Power steering relief valve setting +490 +5 +71
A 7355+0 (75 +0 ) [1066 +0 ]
kPa (kgf/cm2) [psi]
GP20K/25K: GP30K: GP35K:
72 (4394) / 79.9 (4876) / 79.9 (4876) /
Capacity 63.6 (3881) / 2400 rpm 2400 rpm 2400 rpm
A
liter (cu. in.)/min 2400 rpm DP20K/25K: DP30K: DP35K:
88 (5370) / 88 (5370) / 88 (5370) /
2200 rpm 2200 rpm 2200 rpm
Hydraulic GP20K/25K: GP30K: GP35K:
pump 47 to 49 47 to 49 47 to 49
(4.75 to 5.0) (4.75 to 5.0) (4.75 to 5.0)
47 to 49
Tightening torque for oil pump bolts [34 to 36] [34 to 36] [34 to 36]
A (4.75 to 5.0)
N·m (kgf·m) [lbf·ft] DP20K/25K: DP30K: DP35K:
[34 to 36]
123 to 132 123 to 132 123 to 132
(12.5 to 13.5) (12.5 to 13.5) (12.5 to 13.5)
[90 to 98] [90 to 98] [90 to 98]
Tightening torque Tie bolts (M10) A 46 (4.7) [34]
Control valve
N·m (kgf·m) [lbf·ft] Tie bolts (M8) A 19 (1.9) [14]

10-46
 HYDRAULIC SYSTEM

A: Standard value
Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP
GP/DP30K GP/DP35K
GP18K GP/DP25K
Item GP25K-HP
GP20K/25K: GP30K: GP35K:
Lift speed (rated load/no load) 555/570 440/455 370/385
450/490 [109/112] [86/89] [73/75]
A
mm/sec [fpm] [88/96] DP20K/25K: DP30K: DP35K:
[duplex mast] 640/635 460/490 390/415
[125/125] [90/96] [76/81]
Lowering speed (rated load)
mm/sec [fpm] A 480 [94] 450 [88] 390 [76]
[duplex mast]
Duplex mast
Forward tilt angle A 6°
Backward tilt angle A 10°
No. 1
Lift cylinder rod drift (rated load)
mm (in.)/15 min. A –
[Oil temperature 45 °C (113 °F)]
No. 2
Tilt cylinder rod drift (forward) (rated load)
mm (in.)/15 min. A 22 (0.87), max 20 (0.8), max 15 (0.59), max
[Oil temperature 45 °C (113 °F)]
GP20K/25K: GP30K: GP35K:
560/575 460/480 395/415
Lift speed (rated load/no load) 465/505 [110/113] [90/94] [77/81]
A
mm/sec [fpm] [91/99] DP20K/25K: DP30K: DP35K:
[triplex mast] 595/640 400/515 415/445
[117/125] [94/101] [81/87]
Lowering speed (rated load)
mm/sec [fpm] A 490 [96] 470 [92] 430 [82]
[triplex mast]
Triplex Forward tilt angle A 6°
mast
Backward tilt angle A 6°
No. 1
Lift cylinder rod drift (rated load)
mm (in.)/15 min. A –
[Oil temperature 45 °C (113 °F)]
No. 2
Tilt cylinder rod drift (forward) (rated load)
mm (in.)/15 min. A 22 (0.87), max 20 (0.8), max 15 (0.59), max
[Oil temperature 45 °C (113 °F)]

10-47
HYDRAULIC SYSTEM

A: Standard value
Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP
GP/DP30K GP/DP35K
GP18K GP/DP25K
Item GP25K-HP
[piston] 45 50
A 55.2 (2.17) 60 (2.36)
Inside diameter of cylinder tube 1 (1.77) (1.97)
Diameter of piston rod 2 A 35 (1.38) 40 (1.57) 42 (1.65) 45 (1.77)
170 to 240 200 to 270 270 to 304
Tightening torque for retainer 3
A (17.3 to 24.5) (20.4 to 27.5) (27.5 to 31.0)
N·m (kgf·m) [lbf·ft]
[125 to 175] [150 to 200] [200 to 225]
75 to 85 90 to 100
Amount of hydraulic oil 4 cc (cu. in.) A
Lift cylinders (4.57 to 5.19) (5.49 to 6.10)
(Simplex mast)
2 1

3 4
207073

Return filter Tightening torque N·m (kgf·m) [lbf·ft] A 49 ± 10 (5 ± 1) [36 ± 7.2]

Flow regulator
Flow rate (no load) liter (cu. in.)/min A 50 (3051) 65 (3967) 75 (4577)
valve

10-48
 HYDRAULIC SYSTEM

A: Standard value
Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP
GP/DP30K GP/DP35K
GP18K GP/DP25K
Item GP25K-HP
[piston] 70 75 85.2 90
A
Inside diameter of cylinder tube 1 (2.76) (2.95) (3.35) (3.54)
Diameter of piston rod 2 A 50.8 (2) 55 (2.16)
305 to 370 340 to 405 420 to 455 440 to 475
Tightening torque for retainer 3
A (31 to 37.7) (34.7 to 41.3) (42.8 to 46.4) (44.9 to 48.5)
N·m (kgf·m) [lbf·ft]
[225 to 275] [250 to 300] [310 to 335] [325 to 350]
70 to 80 85 to 90 125 to 130
Amount of hydraulic oil 4 cc (cu. in.) A
Lift cylinders (4.27 to 4.88) (5.18 to 5.49) (7.62 to 7.93)
(Duplex mast,
triplex mast
2 1
first cylinder)

3 4
207604

10-49
HYDRAULIC SYSTEM

A: Standard value
Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP
GP/DP30K GP/DP35K
GP18K GP/DP25K
Item GP25K-HP
[piston] 45 50 55
A
Inside diameter of cylinder tube 1 (1.77) (1.97) (2.16)
Diameter of piston rod 2 A 32 (1.26) 35 (1.38) 40 (1.57) 42 (1.65)
206 ± 39.2 235 ± 54.0 304 ± 70.6
Tightening torque for retainer 3
A (21 ± 4) (24 ± 5.5) (31 ± 7.2)
N·m (kgf·m) [lbf·ft]
[152 ± 29] [174 ± 39.8] [224 ± 52]
Holder thread diameter 3 A M52 × 2 M57 × 2 M63 × 2
196 ± 35 245 ± 44.1
Piston tightening torque 4
A (20 ± 3.6) (25 ± 4.5)
Lift cylinders N·m (kgf·m) [lbf·ft]
[145 ± 26] [180 ± 32.5]
(Duplex mast
second 3.92 ± 0.98
Set screw tightening torque 5
cylinders) A (0.4 ± 0.1)
N·m (kgf·m) [lbf·ft]
[2.9 ± 0.72]

5 1 2 5

3 4
207605

10-50
 HYDRAULIC SYSTEM

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP
GP/DP30K GP/DP35K
GP18K GP/DP25K
Item GP25K-HP
63 +0.1
+0 70 +0.1
+0 80 +0.1
+0
A
(2.48 +0.004
+0 ) (2.76 +0.004
+0 ) (3.15 +0.004
+0 )
Inside diameter of cylinder tube 1
63.12 70.12 80.12
B
(2.4850) (2.7606) (3.1543)
+0.045
[Guide bushing] 25 +0.045
+0.025 30 +0.025 35 +0.04
+0.03
A
Diameter of piston rod 2 (0.98 +0.0018 +0.0018
+0.0010 ) (1.18 +0.0010 ) (1.38 +0.0015
+0.0012 )

Inside diameter of tilt socket A 35 –0 –0

–0.012 (1.38 –0.0005 )

bushing (fitted) 3 B 35.5 (1.39)

+0.085 +0.0033
Inside diameter of cylinder tube head A 32 +0 (1.26 +0 )
bushing (fitted) 4 B 32.6 (1.283)
[Guide bushing]
A M68 × 2 M75 × 2 M85 × 2
Thread diameter 5
[Guide bushing] 265 ± 29 314 ± 31 373 ± 37
Tilt cylinders Tightening torque 5 A (27 ± 3) (32 ± 3.2) (38 ± 3.8)
N·m (kgf·m) [lbf·ft] [195 ± 21.7] [231 ± 23] [275 ± 27]
[Tilt socket]
A M24 × 1.5 M27 × 1.5 M30 × 1.5
Thread diameter 6
Tilt socket bolt 7 A 127 to 152 (13 to 15.5) [94 to 112]
Tightening torque 127 ± 9.8 235 ± 19.6 392 ± 25
N·m (kgf·m) [lbf·ft] Self-locking nut 8 A (13 ± 1.0) (24 ± 2.0) (40 ± 2.5)
[94 ± 7.2] [173 ± 14.4] [289 ± 18]

4
3

6 7 5 1 2 8
207113

10-51
 MAST AND FORKS

Description ................................................................................................11 – 1
Dual-stage Panoramic Mast (Simplex Mast) ..............................................11 – 1
Dual-stage Full Free Panoramic Mast (Duplex Mast) .................................11 – 2
Triple-stage Full Free Panoramic Mast (Triplex Mast) ................................11 – 3
Operation of Dual-stage Full Free Panoramic Mast ...................................11 – 4
Operation of Triple-stage Full Free Panoramic Mast ..................................11 – 4
Removal and Installation .......................................................................11 – 5
Mast and Lift Bracket Assembly ................................................................11 – 5
Disassembly and Reassembly ............................................................. 11 – 11
Dual-stage Panoramic Mast (Simplex Mast) .............................................. 11 – 11
Dual-stage Full Free Panoramic Mast (Duplex Mast) ................................. 11 – 15
Triple-stage Full Free Panoramic Mast (Triplex Mast) ................................ 11 – 19
Inspection and Adjustment ................................................................... 11 – 23
Forks ........................................................................................................ 11 – 23
Chain Tension Adjustment ......................................................................... 11 – 24
Clearance Adjustment on Lift Bracket ........................................................ 11 – 27
Mast Clearance Adjustment ...................................................................... 11 – 29
Main Roller Shim Replacement (Simplex Mast) ......................................... 11 – 31
Mast Strip Adjustment ............................................................................... 11 – 35
Tilt Angle Adjustment ................................................................................ 11 – 35
Lift Cylinder Stroke Adjustment ................................................................. 11 – 36
11
Troubleshooting ........................................................................................ 11 – 37
Service Data .............................................................................................. 11 – 38
 MAST AND FORKS

Description

Dual-stage Panoramic Mast (Simplex Mast)

1
Forward Forward
A

Detail of A Detail of F
2

Forward Forward

B
Detail of B, C Detail of D
D

C
Forward
E

Detail of E Detail of G
4 207082
F
Unit: mm (in.)
Diam of
1 ton class 2, 3 ton classes
5 main roller
S 99 (3.90) 113.8 (4.48)
M 100 (2.94) 115 (4.53)
207163
L 101 (3.98) 116 (4.54)
LL 102 (4.02) 117 (4.60)

1 Inner mast A: Main roller F: Main roller

2 Outer mast B: Main roller G: Mast strip
3 Lift chain C: Main roller
4 Lift bracket D: Side roller
5 Mast-support bearing cap E: Main roller

The Panoramic mast features two lift cylinders placed Mast strips are fitted to the top end of outer mast. These
behind the mast columns, right and left, to provide strips are for backing up the inner mast when the mast
maximum visibility. is tilted backward.

11-1
MAST AND FORKS

Dual-stage Full Free Panoramic Mast (Duplex Mast)

207608

1 Lift chain 5 Outer mast 9 Mast upper main roller

2 First lift cylinder 6 Lift bracket 10 Mast lower main roller
3 Second lift cylinder 7 Chain wheel
4 Inner mast 8 Lift bracket main roller

In the dual-stage full free panoramic mast, the first For lifting operation, oil is first sent to the first lift
cylinder raises the forks without increasing the overall cylinder which raises the forks until the cylinder rod
mast height (free-lift) until the upper edge of the reaches its stroke end.
backrest exceeds the top of the mast. When the first lift cylinder rod extends fully, the second
The mast assembly consists of the inner mast, outer lift cylinders raise the assembly consisting of the lift
mast, lift bracket, first lift cylinder and second lift bracket, first lift cylinder and inner mast.
cylinders. The shoulder sections of the mast main rollers contact
The first lift cylinder raises the lift bracket, while the the mast rails. The rollers are installed perpendicular to
second cylinders operate the inner mast and lift bracket. the sliding surfaces.
The main rollers used in the 1 ton and 2, 3 ton classes
are the same as those in dual-stage panoramic mast.

11-2
 MAST AND FORKS

Triple-stage Full Free Panoramic Mast (Triplex Mast)

207609 207610

1 First lift chain 5 Inner mast 9 Second chain wheel

2 First lift cylinder 6 Middle mast 10 Lift bracket main roller
3 Second lift chain 7 Outer mast 11 Mast upper main roller
4 Second lift cylinder 8 Lift bracket 12 Mast lower main roller

In the triple-stage full free panoramic mast, the free-lift For lifting operation, oil is first sent to the first lift
height extends to the top of the mast, and the overall cylinder which raises the forks until the cylinder rod
mast height remains the same until the upper edge of reaches its stroke end.
the backrest exceeds the top of the mast. When the first lift cylinder rod extends fully, the second
The mast assembly consists of the inner mast, middle lift cylinders raise the assembly consisting of the lift
mast, outer mast, lift bracket, first lift cylinder and bracket, first lift cylinder, inner mast and middle mast.
second lift cylinders. The shoulder sections of the mast main rollers contact
The first lift cylinder raises the lift bracket, while the the mast rails. The rollers are installed perpendicular to
second cylinder operates the three-stage telescopic the sliding surfaces.
mechanism and lift bracket. Two pairs of lift chains are The main rollers used in the 1 ton and 2, 3 ton classes
installed. The cylinders and lift chains are designed for are the same as those in dual-stage panoramic mast.
smooth and effective operation.

11-3
MAST AND FORKS

Operation of Dual-stage Full Free Panoramic Mast

203598

Operation of Triple-stage Full Free Panoramic Mast

203600

11-4
 MAST AND FORKS

Removal and Installation

Mast and Lift Bracket Assembly

Dual-stage Panoramic Mast (Simplex Mast)

5 4
1

2
207346

Sequence
1 Nuts 4 Tilt cylinders
2 Forks, Lift bracket 5 High-pressure hose for lift cylinders
3 Tilt socket pins 6 Mast-support bearing cap and Bushing

Suggestions for Removal

1. Lift bracket removal
(1) Tilt the mast forward, and lower the inner mast to the
bottom.
Slacken the lift chains, and remove the nuts from the
anchor bolts.
(2) Tilt the mast back to vertical position. Raise the inner
mast until the lift bracket becomes free.
Then, back the truck away, from the lift bracket and
fork assembly.

207084

11-5
MAST AND FORKS

2. Removing lift cylinder high pressure hoses

Place the mast in the bottom position, disconnect the hoses
at the flow regulator valve.

3. Removing tilt cylinders

(1) Hitch a sling to the mast. Using two eye-bolts and a
sling as shown and support the mast with a hoist.

! CAUTION
Be sure to use a hoist having a capacity enough
to support the mast assembly.

204845

(2) Remove the tilt socket pins, and separate the masts
from the tilt cylinders.
(3) Start the engine, and pull back the tilt lever to contract
the tilt cylinder rods.
(4) Disconnect the high-pressure hose for lift cylinders.

Tilt socket pin

207086

4. Removing mast support bearing caps

(1) Mark the bearing caps to ensure the correct
reassembling before removing them.
(2) Remove the cap bolts and lift off the mast assembly.
Lay it down flat on a level floor.

NOTE Match marks

Lay the mast assembly on a floor large enough to

disassemble the parts.
207087

11-6
 MAST AND FORKS

Installation
To install, follow the removal sequence in reverse, and
service as follows. 5
6
1. Procedure for mounting mast support bushings 6 and
caps 6.
(1) Apply grease to the inner surfaces of caps and mast
support bushings.
(2) Install mast support bushings 6 and caps 6, making
sure that the sides with larger chamfered area face Apply grease
toward the center of the vehicle. Chamfered faces
(3) Be sure to tighten the support tightening bolts securely. 203712

Truck Model 1.0 to 1.8 ton 2 to 3.5 ton

Item classes classes
74 N·m 178 N·m
Bolt tightening
(7.5 kgf·m) (18.2 kgf·m)
torque
[54 lbf·ft] [132 lbf·ft]

2. Adjust the chain tensions.

(Refer to the Inspection and Adjustment section.)
Tighten the nuts to the specified torque.

Tightening torque
Unit: N·m (kgf·m) [lbf·ft]
Truck Model 1.0 to 2.5 ton 2.8 to 3.5 ton
Item classes classes
Upper nut 2 57 (5.8) [42.0] 84 (8.6) [62.2]
Double nut
(lower) 1 98 (10.0) [72.3] 147 (15.0) [108.5]

3. Air bleeding of lift cylinders 102709

Due to internal drain type cylinder, the lift cylinders do not
require air bleeding.
4. After proper operation is confirmed, check the oil level.

11-7
MAST AND FORKS

The following describes the procedures for removing and reinstalling the mast assembly. Note that the triple-stage
full free panoramic mast (Triplex Mast) is used as an example.

Triple-stage Full Free Panoramic Mast (Triplex Mast)

2 6 5 4
207611

Sequence
1 Nut 4 High-pressure hose for lift cylinders
2 Fork, Lift bracket assembly 5 Mast support cap
3 Tilt socket pin 6 Mast support bushing

Suggestions for Removal

1. Removing lift bracket assembly 2
(1) Lower lift bracket assembly 2, and place wood blocks
under the assembly. Tilt the mast forward, lower the
inner mast to the bottom, then remove nuts 1 from the
anchor bolts of the first lift chains.

207613

11-8
 MAST AND FORKS

(2) Position the mast upright. Raise the inner mast until
main rollers 7 of the lift bracket become free. Then,
slowly move the vehicle in reverse to separate from lift
bracket 2.

201735

2. Separating mast and tilt cylinders

(1) Lower the inner mast. Hitch a sling to the upper cross-
member of the outer mast. For sling attachment, install
eye-bolts in the holes on the right and left sides. Use a
crane and lift.

! CAUTION
Be sure to use a hoist having a capacity enough
to support the mast assembly.

207614

(2) Place wood blocks under the tilt cylinder mounting

sections, and remove pins 3. Start the engine, and pull
back the tilt lever to contract the tilt cylinder rods.
(3) Disconnect high-pressure hose 4 for lift cylinders.

Tilt socket pin

207086

3. Removing mast support caps 5

(1) Mark caps 5 to ensure the caps are reinstalled in
original positions during reassembly.
(2) Remove cap mounting bolts. Dismount the mast
assembly from vehicle in the suspended condition.
With the lift bracket side facing up, place the mast
assembly horizontally on wooden blocks on the level
5
ground.
207615

11-9
MAST AND FORKS

Installation
5
To install, follow the removal sequence in reverse, and 6
service as follows.
1. Procedure for installing mast support bushings 6 and
caps 5
(1) Apply grease to the inner surfaces of caps and mast
support bushings.
(2) Install mast support bushings 6 and caps 5, making Apply grease
sure that the sides with larger chamfered area face Chamfered faces
toward the center of the vehicle. 203712
(3) Be sure to tighten the support tightening bolts securely.

Truck Model 1.0 to 1.8 ton 2 to 3.5 ton

Item classes classes
74 N·m 178 N·m
Bolt tightening
(7.5 kgf·m) (18.2 kgf·m)
torque
[54 lbf·ft] [132 lbf·ft]

2. Adjust the chain tensions.

(Refer to the Inspection and Adjustment section.)
Tighten the nuts to the specified torque.

Tightening torque
Unit: N·m (kgf·m) [lbf·ft]
Truck Model 1.0 to 2.5 ton 2.8 to 3.5 ton
Item classes classes
Upper nut 2 57 (5.8) [42.0] 84 (8.6) [62.2]
Double nut
(lower) 1 98 (10.0) [72.3] 147 (15.0) [108.5]

102709
3. Bleeding lift cylinders.
In the dual-stage full free panoramic mast, only the second
lift cylinders are provided with air bleeding valves.
The other lift cylinder does not require air bleeding since it
is an internal drain type cylinder.
4. After proper operation is confirmed, check the oil level.

11-10
 MAST AND FORKS

Disassembly and Reassembly

Dual-stage Panoramic Mast (Simplex Mast)

Disassembly

12 10
15
3

11
10

9 13

2
16 17

8
2

6
6

6 14
1
4
5 207347

Sequence
1 Nuts 10 Cylinder clamps, Seats, Shims, Cushion,
2 Forks, Lift bracket Collar, Bolts
3 Backrest 11 Bolt, Shims
4 Main roller, Shims 12 Mast strip, Shims
5 Main roller, Shims 13 Main roller, Shims
6 Side roller, Brackets, Shims 14 Main roller, Shims
7 Hose guard 15 Inner mast
8 Lift hose (high pressure) 16 Lift cylinders
[Rubber hose, T-joint, Down safety valve] 17 Outer mast
9 Snap ring, Chain wheel

Suggestions for Removal

1. Removing mast strips and main rollers
Remove bolts 10, 11 to free lift cylinder 16. Displace the tops
of the two lift cylinders from inner mast 15. Slide inner mast
15 toward the bottom of outer mast 17, and remove main
rollers 13, 14 and mast strips 12.

11-11
MAST AND FORKS

2. Inner mast removal

After removing the main rollers, hitch a sling to the inner
mast crossmember and slide the inner mast to the upper
side of the outer mast to clear the outer mast roller shafts.
Hitch a sling to the inner mast again and remove it from the
outer mast.

207089

Inspection after disassembly

1. Mast
(1) Check each roller for wear, binding or other defects.
(2) Check each roller on rolling surface for pitting or other
defects.
(3) Check the mast member and the welded joints of cross
members, shafts and supports for cracks.
(4) Check the mast support bushings for wear or other
defects.

207090

2. Lift bracket
(1) Check the main rollers and side rollers for smooth
rotation. Inspect each roller for wear and cracks.
(2) Check the welded portions of the bracket for cracks.
(3) Check the finger bar for bend or distortion.
A: Standard value
5 mm (0.2 in.)
Distortion of finger bar A
maximum

207091

11-12
 MAST AND FORKS

3. Lift chains, chain wheels and chain wheel

supports
(1) Measure the length of each chain to make sure that two
chains are equal in length. Also check the chains for
wear, indication of breakage, link binding and twist.
(2) Check each chain anchor bolt for cracks or defects on
thread.
(3) Check each chain wheel support and chain wheel for
crack or wear. Check that the wheels rotate smoothly.

Length of lift chain (per 20 links)

A: Standard value B: Repair or service limit

Unit: mm (in.)
1 ton 2 ton 3 ton
class class class
A 318 (12.52) 381 (15.00) 508 (20.00)
B 327 (12.87) 392 (15.43) 523 (20.59)

4. Mast strips
Check the mast strips for damage, wear or distortion.

Reassembly
To reassemble, follow the reverse of disassembly
procedure, and service as follows:
1. Longitudinal clearance adjustment between mast
and lift bracket Clearance

Rollers for mast and lift bracket are available in three sizes
(diameters) for selective use. Select the size that will
provide a longitudinal clearance of 1 mm (0.04 in.) or less.
Roller sizes Clearance
Unit : mm (in.)
Truck Model 1 ton 2, 3 ton
Size class classes
(Diameter) Lower roller Upper/middle roller
S 99 (3.90) 113.8 (4.48) 207096
M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57)
LL 102 (4.02) 117 (4.60)

11-13
MAST AND FORKS

2. Cylinder clamps
Install each lift cylinder in place (in vertical position) by
fitting to the support, and see if there is any clearance
between the outer mast and cylinder. Reduce the clearance,
if any, to zero by shimming.

Shims

207093

3. Mast supports
(1) Apply grease to the inside surfaces and grooves of the
caps.
Mast cap
(2) Install mast support bushings and caps placing the
Bushing
chamfered faces inward.
Place wood blocks under mast to apply grease easily.

Apply grease
Chamfered faces
203712

4. Precautions for installing chain anchor kit

Be careful not to install the center plate in the position for
link plate. 2
3

4 Stamped mark

207094

1 Link plate (stamped mark on surface)

2 Center plate (no stamped mark)
3 Link
4 Split pin

11-14
 MAST AND FORKS

Dual-stage Full Free Panoramic Mast (Duplex Mast)

Disassembly

17

10

16
15
14 8

9
1 15
11
6
5

6 8
12
A
A
1
4
A 12
2
9 1
3
2
13 13 19

18

7 207607

Sequence
1 High-pressure hose for first cylinder, Clamp 11 Mast strip, Shims
2 Bolt, Washer, Shims 12 Main roller, Shims
3 First lift cylinder 13 Stopper cushion, Cushion plate, Shims,
4 Chain guard Bolt, Washer
5 Chain wheel support, Pin 14 Inner mast
6 Chain wheel, Snap ring 15 Second lift cylinder
7 Cylinder guard, Bolt, Washer 16 Cylinder bracket
8 High-pressure hose 17 O-ring, Plug
9 Cushion, Collar, Shims, Bolt, Washer, Clamp 18 Mast cap, Bolt, Washer
10 Bolt, Washer, Shims 19 Outer mast, Grease nipple

NOTE
The lift bracket disassembly procedure is the same as
for the dual-stage panoramic mast.

11-15
MAST AND FORKS

Preparation
With the lift bracket facing up, place the mast horizontally
on wood blocks. Place a wood block as a wedge to prevent
3
the inner and middle masts from sliding.

Suggestions for Disassembly

1. Removing first lift cylinder 3
(1) Remove retaining bolts from the first lift cylinder.
(2) Tie wire ropes on first lift cylinder 3, and gently
remove the cylinder. 207619
Use two wire ropes. Wind or tie ropes securely to
prevent slipping.

2. Removing main rollers 12 and mast strips 11

(1) Remove clamp bolts from the second lift cylinders.
(2) Remove bolts from the upper rod sections of the second 11 12
lift cylinders, and place the cylinders on the outer mast.
(3) Check the number of shims and the shim thickness at
the rod end sections.
(4) Move the inner mast down, then remove main rollers
12, mast strips and shims 11.

12 207620
3. Removing inner mast 14
Using ropes, lift and remove inner mast 14, steering it clear
of the roller shaft sections of outer mast 19.

Inspection after disassembly

Follow the same inspection procedure as for the dual-stage
panoramic mast. 19

14
207621

11-16
 MAST AND FORKS

Reassembly
To reinstall, follow the removal sequence in reverse, and
service as follows. 12

1. Main rollers
(1) Adjust the right and left clearances by increasing or
decreasing the thickness of shims 12.

207622

(2) When replacing lift bracket main rollers, make sure

clearance A between each roller and mast surface is 1
mm or less. A

207623

(3) To install main rollers on shafts, use a driving tool. Be

careful not to accidentally strike the outer roller surface
with the driving tool.
The side of the roller with larger chamfered area must
face toward the outside.

202263

2. Installing second lift cylinders

When installing second lift cylinders 15, make sure the
cylinders are parallel to the mast to prevent torsional stress
on the lift cylinders when the mast is positioned at the
bottom. Adjust the installation positions of lift cylinder 9
15
brackets 16 with shims 9.

16 207632

11-17
MAST AND FORKS

3. Installing first lift cylinder

The first lift cylinder must be installed parallel to the mast
when the lift cylinder rod is contracted.
Make sure the cylinder does not tilt forward. Using shims

20 mm (0.79 in.)
2, adjust the backward inclination so that clearance at
section B is 0 to + 0.5 mm (0 to + 0.02 in.) larger than 2
clearance at section A.

A 201752

4. Precaution for installation of chain anchor kit

2
Do not use center plate in place of link plate. 3

4 Stamped mark

207094

1 Link plate (stamped mark on surface)

2 Center plate (no stamped mark)
3 Link
4 Split pin

11-18
 MAST AND FORKS

Triple-stage Full Free Panoramic Mast (Triplex Mast)

Disassembly
15
17

9 16

1
15
1
23
26 19
10

28
22 20

24 19
25

12 21
7 8
6
19
19
7 8

27
14
30

5 19
13
3 29
4
2
11
18
207606

Sequence
1 Hose for first lift cylinder, Clamp, Bolt, Washer 17 Snap ring, Hose pulley, Shaft,
2 Bolt, Washer Snap ring, Chain wheel
3 Shims 18 Hose guard, Bolt, Washer
4 First lift cylinder 19 Hose, clamp, Bolt, Washer
5 Chain guard 20 Joint, Connector, Bolt, Washer
6 Chain wheel support, Pin 21 Bolt, Seat, Cushion, Collar
7 Snap ring, Chain wheel 22 Cushion, Shims, Bracket
8 Nut (chain for second lift cylinder) 23 Bolt, Washer, Shims
9 Mast strip, Shims 24 Second lift cylinder
10 Main roller, Shims 25 Mast strip, Shims
11 Main roller, Shims 26 Main roller, Shims
12 Inner mast 27 Main roller, Shims
13 Nuts 28 Middle mast
14 Lift chain (for second lift cylinder) 29 Cap, Bolt, Washer
15 Chain guard, Bolt, Washer 30 Outer mast, Grease nipple
16 Snap ring, Chain wheel

11-19
MAST AND FORKS

NOTE
The lift bracket disassembly procedure is the same as
for the dual-stage panoramic mast.

Preparation
With the lift bracket facing up, place the mast horizontally
on wood blocks. Place a wood block as a wedge to prevent
the inner and middle masts from sliding.

Suggestions for Disassembly

1. Removing first lift cylinder 4
(1) Remove retaining bolts from the first lift cylinder.
4
(2) Tie wire ropes on lift cylinder 4, and gently remove the
cylinder.
Use two wire ropes. Wind or tie ropes securely to
prevent slipping.

207624

2. Removing inner mast and main rollers

12
Lower inner mast 12 until the main rollers can be removed.
9
Remove main rollers 10, 11 and mast strips 9.

11

10 207625

3. Removing inner mast

Using ropes, lift and remove the inner mast, steering it clear
of the roller shaft sections of the middle mast.

12 207626

11-20
 MAST AND FORKS

4. Removing main rollers 26, 27 from middle mast 28

and outer mast 30 28

Remove the bolts that are holding second lift cylinders 24. 24
Place the cylinder rod ends on the outer mast. Lower
middle mast 28 until main rollers 26, 27 can be removed.
Then, remove the main rollers. 27

30

26
207627

Inspection after disassembly

Follow the same inspection procedure as for the dual-stage
panoramic mast.

Reassembly
To reinstall, follow the removal sequence in reverse, and
service as follows.

1. Main rollers
(1) Adjust the right and left clearances by increasing or
decreasing the thickness of shims.
Shims Main
roller

207630

(2) When replacing lift bracket main rollers, make sure Outer mast
Middle mast
clearance A between each roller and mast surface is 1 Inner mast
mm (0.04 in.) or less.
A

207629
Lift bracket

11-21
MAST AND FORKS

(3) To install main rollers on shafts, use a driving tool. Be

careful not to accidentally strike the outer roller surface
with the driving tool.

202263

2. Installing second lift cylinders 24

When installing second lift cylinders 24, make sure the
cylinders are parallel to the mast to prevent torsional stress
on the lift cylinders when the mast is positioned at the
bottom. Adjust the installation positions of lift cylinder 22
brackets with shims 22. 24

207631

3. Installing first lift cylinders

The first lift cylinder must be installed parallel to the mast
when the lift cylinder rod is contracted.
20 mm (0.79 in.)

Make sure the cylinder does not tilt forward. Using shims
3, adjust the backward inclination so that clearance at 3
section B is 0 to + 0.5 mm (0 to + 0.02 in.) larger than
clearance at section A.

A 201752

4. Precautions for installation of chain anchor kit

2
Do not use center plate in place of link plate. 3

1 Link plate (stamped mark on surface)

2 Center plate (no stamped mark)
3 Link
4 Split pin
1

4 Stamped mark

207094

11-22
 MAST AND FORKS

Inspection and Adjustment

The inspection and adjustment in this chapter can be done

without dismounting or disassembling. Conduct inspection
whenever a defect is suspected.

Forks (all mast models)

Fork calipers perform two tasks at once.

OUTSIDE INSIDE They measure the thickness of the fork arm
JAWS JAWS shank (Fig. 1) and then automatically
100% 90% indicate what a 10% wear factor would be when
the calipers are applied to the blade cross section (Fig. 2).

NEW FORK ARM

SHANK CROSS
50 mm / 2 in. SECTION = 100%
Figure 1

Figure 2
REPLACE
FORK FORK WITH
OK 10% WEAR

Not for use on full taperd forks. 210995

Forks are often mistreated and forgotten. As drum or on the boom hook makes the safety
insubstantial as they seem, neglecting forks could make difference.
them dangerous. • Forks are often used to open rail car doors and break
Forks carry larger loads than almost any lifting device loads out or away from other loads. They are also
but there are no mandatory requirements for used to pick up capacity loads not seated against the
maintenance or inspection. fork shank and to pick up off-balanced loads far from
You can find thousands of extra parts for lift trucks in the side of the truck. The fork tips are sometimes
some fleet repair shops, but you’ll seldom see spare inserted under other fork trucks to lift them during
forks. Even when all the trucks on the fleet are the maintenance operations.
same, fleet maintenance managers rarely order spare • Lift trucks may collide with building columns and
forks. Forks last a long time if treated properly, but walls, and though the forks show no discernible
they can deceive by looking as good from most viewing bend, they may be damaged beyond safety.
angles when they are worn as when they are new. • Any time excessive heat is applied to any part of a
It’s true that most forks are customized to the truck by fork—during repair, for instance—hidden damage
model and capacity: they are big and heavy and thought may occur.
of as indestructible. But forks can be abused or ruined The fork itself is a concern but so are the hooks that
in the course of daily work. secure them to the lift carriage.
Here are some examples of ways that forks can be damaged:
• Forks can be overloaded either by picking up a load DESIGNED TO TAKE A BEATING
too far out on the forks, or simply by picking up Forks for counterbalanced and straddle lift trucks are
loads heavier than the truck rating. not just bent bars of steel. The manufacturing process
• Maintenance shops may bend forks back into shape, is careful and precise with many checks and inspections
weld on them, or drill holes through them. Lift truck critical to their safety. Some factors essential to fork
users can add attachments to the truck that stress the manufacture include the steel, the bend and thickness of
forks. Drum clamps and portable booms can be the heel, the welding of the hooks that hold them on the
supported on the forks–but what is contained in the carriage, and the heat treatment of the finished product.

11-23
MAST AND FORKS

Chain Tension Adjustment

Simplex Mast
NOTE
Follow the same chain tightening procedure for all
masts except for the Simplex Mast chains on the lift
bracket side.

! WARNING
Personal injury can be caused by sudden
movement of the mast and lift bracket. Use blocks
to fix the mast and lift bracket from any movement
while the adjustments are made. Keep hands and
feet clear of any parts that can move.

1. Have the truck on a level floor, with the mast vertical

and the fork lowered to the bottom.
Check that the lift cylinders are fully retracted.
2. Loosen the double nut 1 (lower) and 2 (upper).
3. Set the anchor bolts with double nut (upper) 3.
4. Raise the forks slightly and push the chains inward 102709
midway between the chain wheel and anchor
alternately to check the tension. When adjusting the
chains by means of the double nut (upper) 3, tilt the
mast forward to slacken the chains to facilitate
adjustment.
5. Turn double nut (upper) 3 to adjust the chain tension.
Then, hold the anchor bolt in place with a wrench and
tighten upper nut 2 to the specified torque.
6. Hold double nut (upper) 3 in place with a wrench, and
tighten double nut (lower) 1 to the specified torque.
Tightening torque
102708
Unit: N·m (kgf·m) [lbf·ft]
Truck Model 1, 2 ton 3 ton
Item classes class
Upper nut 2 57 (5.8) [42.0] 84 (8.6) [62.2]
Double nut
(lower) 1 98 (10.0) [72.3] 147 (15.0) [108.5]

7. With the lift cylinder rods fully contracted, make sure

the amount of protrusion of each lift bracket main
roller is 40% of the roller diameter or less.
40% or less
8. Make sure that the chain tension is correct with the
207634
mast in vertical (0°) position.
11-24
 MAST AND FORKS

Dual-stage full free panoramic mast

(Duplex Mast)
1. On the level ground, position the mast at a right angle
to the ground surface, lower the forks to the ground,
and make sure the lift cylinder rods are contracted
fully.
2. Secure the anchor bolts on the lift bracket side by
tightening the upper nuts and double nuts.

207633

3. Adjust the chain tensions by turning the double nuts

(upper) on the lift cylinder side. With the mast standing
perpendicular to the ground, lift the forks slightly, then
press the chains alternately at a midpoint between the
chain wheel and the secured end of the chain to make
sure the tension is the same in both chains.

NOTE
Tilting the mast slightly forward causes the chains to
102708
sag, thus making it easier to adjust the chain tensions
with the double nuts (upper).

4. Tighten the upper nuts and double nuts on the cylinder

side to the specified torque.
5. With the lift cylinder rods fully contracted, make sure
the amount of protrusion of each lift bracket main
roller is 40% of the roller diameter or less.
6. Conduct final adjustment with the mast positioned
perpendicular to the ground.

40% or less
207634

11-25
MAST AND FORKS

Triple-stage full free panoramic mast

(Triplex Mast)
Adjust each of the first and second chains (total of four).

1. On the level ground, position the mast perpendicular to

the ground surface, lower the forks to the ground, and
make sure the lift cylinder rods are contracted fully.
2. Secure the anchor bolts on the lift bracket (first chains)
side and the lower inner mast section (second chains)
by tightening the upper nuts and double nuts.

NOTE
When installing the second chains (between inner mast
and outer mast) in the triple-stage full free panoramic
mast, adjust the chain tensions slightly tighter. If the 207635
chains are loose, damage can occur to the hose pulley.

3. Adjust the chain tensions by turning the double nuts

(upper) on the lift cylinder side. With the mast standing
perpendicular to the ground, lift the forks slightly, then
press the chains alternately at a midpoint between the
chain wheel and the secured end of the chain to make
sure the tension is the same in both chains.

NOTE
Tilting the mast slightly forward causes the chains to
sag, thus making it easier to adjust the chain tensions 102708
with the double nuts (upper).

4. Tighten the upper nuts and double nuts on the cylinder

side to the specified torque.
5. With the lift cylinder rods fully contracted, make sure
the amount of protrusion of each lift bracket main
roller is 40% of the roller diameter or less.
6. Conduct final adjustment with the mast positioned
perpendicular to the ground.

40% or less
207634

11-26
 MAST AND FORKS

Clearance Adjustment on Lift Bracket

NOTE
The adjustment procedure for the lift bracket is the same
for the Simplex Mast, Duplex Mast and Triplex Mast.

1. Longitudinal clearance adjustment on lift bracket

main rollers F
(1) Raise the forks a little from the floor.
(2) Insert a bar between the upper part of lift bracket and
the inner mast, and push the inner mast to one side.
Using feeler gauges, measure the clearance F between
the main roller and inner mast on the opposite side.
0.1 to 1.0 mm
Clearance F 207095
(0.004 to 0.039 in.)

(3) If the clearance F is out of specification, use oversize

rollers. F
Roller sizes
Unit : mm (in.)
Truck Model 1 ton 2, 3 ton
Size class classes F
(Diameter)
S 99 (3.90) 113.8 (4.48)
Lower roller Upper/middle roller
M 100 (3.94) 115 (4.53) 207096
L 101 (3.98) 116 (4.57)
LL 102 (4.02) 117 (4.60)

(4) Lift bracket main rollers (upper and center rollers)

The upper rollers should be the same in size or 1-rank
larger than the center rollers.
2. Lateral clearance adjustment on lift bracket main
rollers and side rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the inner mast with its contact
point rested on the side of the lift bracket.
(3) Go over to the opposite side of the mast, and push the 203818
lift bracket to one side with a bar. Set the indicator to
zero.
(4) Insert a bar between the inner mast and lift bracket on
1 1
the indicator side, and push the lift bracket to the
opposite side. G1

(5) Read the indicator. 2 2

0.1 to 0.5 mm
Clearance G1 (0.004 to 0.020 in.)

(6) Adjust clearance G1 between the center main roller

and weld plate 2 at the maximum lift position by
increasing or decreasing the thickness of the shim. 202276
Do not install a shim at upper main roller 1.
11-27
MAST AND FORKS

For the lift bracket upper main roller or center main

roller, to extend 0.5 mm (0.02 in.), insert a 0.5 mm Inner mast
(0.02 in.) shim (a) on the inside and remove the 0.5 mm
(0.02 in.) shim (b) from the lower stopper, then tighten Shims (b)
the bolts.

Shims (a)

207156

(7) Lower the lift bracket slightly from the top, then adjust
clearance G2 between the side roller and mast by
increasing or decreasing the thickness of the shims. G2

Side
Side
roller
roller

202277

Adjust the side roller clearance by adding shims

between the roller bracket and lift bracket.

Shims
Roller

Bracket
207098

(8) With the lift bracket at the top, adjust clearance G3

with shims.

G3
207158

11-28
 MAST AND FORKS

Mast Clearance Adjustment

NOTE
Adjust mast clearances at the locations indicated
below.
1. Simplex Mast and Duplex Mast: Main rollers
between the outer mast and inner mast Shims
2. Triplex Mast: Main rollers between the outer mast
and middle mast, and main rollers between the
middle mast and inner mast
207157

1. Longitudinal clearance adjustment on mast main

rollers
(1) Tilt the mast fully backward.
(2) Using feeler gauges, measure the clearance H between H
the inner mast lower roller and outer mast.

0.1 to 1.0 mm
Clearance H (0.004 to 0.039 in.)

(3) If the clearance H is out of the specification, use

oversize rollers. 207099

Roller sizes
Unit : mm (in.)
Truck Model 1 ton 2, 3 ton
Size class classes
(Diameter)
S 99 (3.90) 113.8 (4.48)
M 100 (3.94) 115 (4.53)
L 101 (3.98) 116 (4.57)
LL 102 (4.02) 117 (4.60)

2. Lateral clearance adjustment on inner mast main

rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the inside of the outer mast with
its contact point rested on the inner mast.
(3) Go over to the opposite side of the mast, and push the
inner mast against the outer mast. Set the indicator to
zero.

204886

11-29
MAST AND FORKS

(4) Insert a bar between the outer and inner masts on the
indicator side, and push the inner mast to the opposite
side.
(5) Read the indicator.

0.1 to 0.5 mm
Clearance J (0.004 to 0.020 in.)

J
207101

(6) If the clearance J is out of specification, adjust by

shims.

NOTE
Refer to Main Roller Shim Replacement.
Shims

207102

3. Lateral clearance adjustment on outer mast main

rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the outer mast with its contact
point rested on the inner mast.
(3) Go over to the opposite side of the mast, and push the
outer mast against the inner mast with a bar. Set the
indicator to zero.
(4) Insert a bar between the outer and inner mast, and push 204889
the inner mast to the opposite side.
(5) Read the indicator.

0.1 to 0.5 mm
Clearance K (0.004 to 0.020 in.)

207103

11-30
 MAST AND FORKS

(6) If the clearance K is out of specification, adjust it by

shims.

NOTE
Refer to Main Roller Shim Replacement.

Shims

207104

Main Roller Shim Replacement (Simplex

Mast)
1. Remove the lift bracket from the mast.

NOTE
Refer to Removal and Installation,
1. Lift bracket removal.

2. Lower the inner mast below the outer mast as follows:

(1) Raise the front end of the truck, and support that end
with block or the like.
(2) Remove the upper set bolts from the lift cylinders, and
lift the inner mast with a hoist. Remove the hose guard.
(3) Remove the clamps from the lift cylinders. Pull the
bottom ends of the cylinders from the outer mast, tilt
the cylinders to the center of the mast, and tie them to
the crossmember of outer mast with rope.
(4) Slowly lower the inner mast until it comes in contact
with the lift cylinders.
(5) Now the main rollers can be removed from the inner
and outer masts. Remove the mast strips and shims in
advance because they are apt to come off under this
202961
condition.

11-31
MAST AND FORKS

Procedure for replacing main roller shims [Dual-

stage full free panoramic mast (Duplex Mast)]

1. Separate the lift bracket from the mast.

NOTE
Refer to "Separating lift bracket" in the Hydraulic
System section.

2. Removing first lift cylinder

(1) Tie a wire rope on the first lift cylinder, and suspend it
with a crane. Wind the rope securely to prevent
slipping.
(2) Remove lift cylinder connecting bolts and mounting
bolts, and gently remove the first lift cylinder.

NOTE
Subsequent removal procedure is the same as the
removal procedure for the Simplex Mast (see
"Procedure for replacing main roller shims").

207616
3. Position the inner mast lower than the outer mast by
following operations.
(1) Lift the front side of the vehicle with a rigid rack or
other equipment.
(2) Remove set bolts from the upper sections of the lift
cylinders, then lift the inner mast.
(3) Remove two lift cylinder clamps, dismount the
cylinders from the mounting sections at the lower outer
mast section. Tilt the cylinders by moving the top
sections towards the center of the vehicle, then secure
the cylinders to the cross-member of the outer mast
with a rope. 202961
(4) Lower the inner mast until it contacts the lift cylinders.
(5) In this condition, main rollers can be removed from the
inner mast and outer mast. Since the mast strips and
shims can fall off, remove these parts first.

11-32
 MAST AND FORKS

Procedure for replacing main roller shims [Triple-

stage full free panoramic mast (Triplex Mast)]

1. Separate the lift bracket from the mast.

NOTE
Refer to "Separating lift bracket" section in the
Hydraulic System section.

2. Removing first lift cylinder

(1) Tie a wire rope on the first lift cylinder, and suspend it
with a crane. Wind the rope securely to prevent
slipping.
(2) Remove lift cylinder connecting bolts and mounting
bolts, and gently remove the first lift cylinder.

3. Position the inner mast lower than the middle mast by

following operations. 207616

(1) Lift the front side of the vehicle with a rigid rack or
other equipment.
(2) Tie wire ropes to the upper cross-member of the inner
mast, and suspend with a crane.
(3) Remove the chain guards for the second lift chain
wheels.
(4) Dismount the second lift chains on the outer mast side,
and place them in front of the inner mast.
(5) Lower the inner mast until main rollers can be
removed.
(6) Place wood blocks under the inner mast for support.
207639
(7) In this condition, main rollers can be removed from the
inner mast and outer mast. Since the mast strips and
shims can fall off, remove these parts first.

NOTE
In this condition, second lift cylinders cannot be
dismounted.

11-33
MAST AND FORKS

4. Position the middle mast lower than the outer mast by

following operations.
(1) Lift the inner mast to the height of the middle mast,
then place wood blocks for support.
(2) Tie wire ropes to both middle mast and inner mast, and
suspend with a crane.
(3) Remove set bolts from the upper sections of the middle
mast lift cylinders, then lift the middle mast and inner
mast.
(4) Remove two lift cylinder clamps, dismount the
cylinders from the mounting sections at the lower outer
mast section. Tilt the cylinders by moving the top
sections towards the center of the vehicle, then secure
the cylinders to the cross-member of the outer mast
with a rope.
(5) Lower the middle mast and inner mast until main
rollers can be removed.
(6) Place wood blocks under the middle mast and inner
mast for support.
(7) In this condition, main rollers can be removed from the
inner mast and outer mast. Since the mast strips and
shims can fall off, remove these parts first.

207640

11-34
 MAST AND FORKS

Mast Strip Adjustment

1. Check the clearance L with the clearance between the
outer mast rollers and inner mast set to zero (0) in L
maximum lift position.

0.1 to 0.5 mm
Clearance L (0.004 to 0.020 in.)

200391

2. If the clearance L is out of specification, adjust it by

shims.
Shims
NOTE
Refer to Main Roller Shim Replacement.

3. After adjusting the all clearance, move the mast and

lift bracket slowly to make sure that they move
smoothly through their full stroke.

200392

Tilt Angle Adjustment

1. Adjust the tire pressure correctly and park the truck on
a level floor.
2. Tilt the mast fully backward and stop the engine.
3. Measure the backward tilt angle of the mast at both
sides.
4. To adjust the tilt angle, loosen the bolt of tilt cylinder
socket, and adjust the rod length by turning the rod. Bolt
Adjust cylinder so that there is no difference in stroke
tilt angle between the cylinders, left and right.
207105
NOTE
It is not necessary to adjust the forward tilt angle if the
backward tilt angle is properly adjusted.

Forward - backward tilt angle 6° - 10° (standard)

11-35
MAST AND FORKS

5. After adjusting the tilt angle, tighten the socket bolts to

the specified torque.

127 to 152 N·m

Tightening torque (13 to 15.5 kgf·m)
for tilt cylinder socket bolt [94 to 112 lbf·ft]

Lift Cylinder Stroke Adjustment

1. Slowly raise the inner mast, and observe how the piston
rods, left and right, stop at the moment the inner mast
reaches its maximum height.
2. If the top of the inner mast rolls at that moment, make a
shim adjustment. Abnormal condition can be detected
by a little time lag in stopping between the piston rods,
left and right, and rolling of the rod with a longer
cylinder stroke.
204698

3. Adjusting method
(1) Raise the inner mast, place blocks under the left and
right sides of the inner mast, and lower the mast until
its rests on the blocks.
(2) Remove the set bolt at the top of lift cylinder which
stopped first, retract the piston rod, and insert shims at
the top of piston rod end.
(3) Extend the piston rod, and tighten the cylinder set bolt.
Remove the blocks from under the inner mast.
202983
(4) Slowly lower the inner mast to the bottom to ensure the
piston rods move smoothly and that the left and right
lift cylinders come to the end of stroke simultaneously.

Bleeding lift cylinders

Set bolt
When air and oil remaining inside the air chamber of the
rod and inside the rod chamber between the tubes are Shims
compressed, they open the check valve and flow out of the
cylinder. Therefore, there is no need to bleed the lift
cylinders.

200365

11-36
 MAST AND FORKS

Troubleshooting

Faulty rotation of side roller Replace rollers.

Lift bracket, inner mast and Faulty rotation of main rollers Replace rollers.
middle mast do not rise or
lower smoothly. Improper mast strip clearance Adjust with shims.
Improper main roller or side roller Adjust front-to-back and
clearance right-to-left clearances.

Uneven chain tension between right and Adjust chain tension.

Lift bracket or inner mast is out left chains
of square. Excessive side roller clearance Adjust by adding shims.
Uneven adjustment of shims between Adjust by removing shims.
right and left lift cylinders
(at maximum lift position)

Faulty rotation of side roller Replace rollers.

Abnormal noise is generated by
Faulty rotation of main rollers Replace rollers.
mast.
Defective hose pulley bearing Replace.
(Triplex mast system only)

Damaged gaskets in lift cylinders Replace.

Lift cylinder drift is too large.
Internal leak of control valve Replace.

Entire mast shake Worn mast support bushings and caps Retighten, or replace bushings
and caps.

Mast is deformed in shape. Uneven cargo load or overload Replace assembly.

Bent finger bars Repair or replace.

Uneven fork end heights Bent forks Replace.
Mast deformation due to uneven cargo Repair or replace.
load

Low oil temperature Increase oil temperature by

raising and lowering lift
Second lift cylinders move when bracket.
first lift cylinder operates No clearance for lift bracket roller Readjust rollers.
(only in Duplex and Triplex surfaces
masts).
Clogged pipes Inspect and clean hydraulic line.
Improper air bleeding Bleed hydraulic system.

Lift bracket is spongy when it

Air is present under each lift cylinder Bleed hydraulic system.
stops in lifting operation.
piston due to poor air bleeding.

11-37
MAST AND FORKS

Service Data

Simplex Mast A: Standard value B: Repair or service limit

Duplex Mast Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
Item GP25K-HP
Difference in height between fork tips A 5 (0.20)
Forks and
chains A 318 (12.52) 381 (15.00) 508 (20.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43) 523 (20.59)
S A 99 (3.90) 113.8 (4.48)
M A 100 (3.94) 115 (4.53)
Diameter of main roller
Rollers L A 101 (3.98) 116 (4.57)
LL A 102 (4.02) 117 (4.60)
Diameter of side roller A 42 (1.65)
Distance between outer mast main rollers
A 523 (20.59) 575 (22.64)
(inside to inside) A
Distance between middle mast main rollers
A 581 (22.87) 639 (25.16)
(outside to outside) B
Distance between lift bracket main rollers
A 396 (15.60) 437 (17.22)
(outside to outside) C1
Distance between lift bracket main rollers
A 396 (15.60) 437 (17.22)
(outside to outside) C2
Distance between lift bracket main rollers
A 401 (15.80) 439 (17.30)
(outside to outside) D
Distance between lift bracket side rollers
A 406 (16.00) 446 (17.57)
(outside to outside) E
Longitudinal clearance of lift bracket middle
A 0.1 to 1.0 (0.004 to 0.039)
rollers (with forks slightly lifted) F
Mast
and lift Lateral clearance of lift bracket middle
A 0.1 to 0.5 (0.004 to 0.020)
bracket main rollers (fully raised) G1
Lateral clearance of lift bracket side rollers
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G2
Lateral clearance of lift bracket lower main
A 0.1 to 0.5 (0.004 to 0.020)
rollers (fully raised) G3
Longitudinal clearance of mast main rollers
A 0.1 to 1.0 (0.004 to 0.039)
(in the whole lift range) H
Lateral clearance of middle mast, inner mast
A 0.1 to 0.5 (0.004 to 0.020)
main rollers (fully raised) J
Lateral clearance of outer mast, middle mast
A 0.1 to 0.5 (0.004 to 0.020)
main rollers (fully raised) K
Mast strip clearance (fully raised) L A 0.1 to 0.5 (0.004 to 0.020)
Distance between middle mast main roller M A 433 (17.06) 475 (18.72)
Distance between inner mast main roller N A 491 (19.35) 539 (21.24)

11-38
 MAST AND FORKS

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
Item GP25K-HP

F
L
G1

G3

G2
F B
Inner mast

Lift bracket
A C1
K

H E

J C2

Outer mast D

207106

Mast support bolts A 74 (7.5) [54] 178 (18.2) [132]

Tightening torque
Upper nut 2 57 (5.8) [42.0] 84 (8.6) [62.2]
N·m (kgf·m)[Ibf·ft] A
Double nut (lower) 1 98 (10) [72.3] 147 (15.0) [108.5]
Distortion of finger bar A 5 (0.2)

102709

11-39
MAST AND FORKS

Triplex Mast A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
Item GP25K-HP
Difference in height between fork tips A 5 (0.20)
Forks and
chains A 318 (12.52) 381 (15.00) 508 (20.00)
Length of tilt chains (per 20 links)
B 327 (12.87) 392 (15.43) 523 (20.59)
S A 99 (3.90) 113.8 (4.48)
M A 100 (3.94) 115 (4.53)
Diameter of main roller
Rollers L A 101 (3.98) 116 (4.57)
LL A 102 (4.02) 117 (4.60)
Diameter of side roller A 42 (1.65)
Distance between outer mast main rollers
A 523 (20.59) 575 (22.64)
(inside to inside) A
Distance between inner mast main rollers
A 581 (22.87) 639 (25.16)
(outside to outside) B
Distance between lift bracket main rollers
A 485 (19.09) 535 (21.06)
(outside to outside) C1
Distance between lift bracket main rollers
A 487 (19.17) 537 (21.14)
(outside to outside) C2
Distance between lift bracket main rollers
A 491 (19.33) 539 (21.22)
(outside to outside) D
Distance between lift bracket side rollers
A 496 (19.53) 546 (21.50)
(outside to outside) E
Longitudinal clearance of lift bracket middle
A 0.1 to 1.0 (0.004 to 0.039)
rollers (with forks slightly lifted) F
Mast
and lift Lateral clearance of lift bracket middle
A 0.1 to 0.5 (0.004 to 0.020)
bracket main rollers (fully raised) G1
Lateral clearance of lift bracket side rollers
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G2
Lateral clearance of lift bracket lower main
A 0.1 to 0.5 (0.004 to 0.020)
rollers (fully raised) G3
Longitudinal clearance of mast main rollers
A 0.1 to 1.0 (0.004 to 0.039)
(in the whole lift range) H
Lateral clearance of inner mast main rollers
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) J
Lateral clearance of outer mast main rollers
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) K
Mast strip clearance (fully raised) L A 0.1 to 0.5 (0.004 to 0.020)
Distance between middle mast main roller M A 433 (17.06) 475 (18.72)
Distance between inner mast main roller N A 491 (19.35) 539 (21.24)

11-40
 MAST AND FORKS

A: Standard value B: Repair or service limit

Unit: mm (in.)
Truck Model GP/DP20K
GP15K GP20K-HP GP/DP30K
GP18K GP/DP25K GP/DP35K
Item GP25K-HP
F
L
G1

G3
Middle mast G2
F B
N
Inner mast Lift bracket

C1
K
Outer mast E
A
H M J C2
Middle mast
K
D

207644

Mast support bolts A 74 (7.5) [54] 178 (18.2) [132]

Tightening torque
Upper nut 2 57 (5.8) [42.0] 84 (8.6) [62.2]
N·m (kgf·m)[Ibf·ft] A
Double nut (lower) 1 98 (10) [72.3] 147 (15.0) [108.5]
Distortion of finger bar A 5 (0.2)

102709

11-41
 LP-GAS SYSTEM

Types of LP-gas .......................................................................................12 – 1

Guideline for Selecting LP-gas for Forklift-truck Engines ...........................12 – 1
LP-gas Knock Rating and Octane Number ................................................12 – 2
Adverse Effects of Olefins on LP-gas Fuel System ...................................12 – 2
Vapor Pressure vs. Temperature for Mixture of Propane and
Normal Butane ..........................................................................................12 – 2
Construction and Function ...................................................................12 – 4
Outline of LP-gas Device ...........................................................................12 – 4
LP-gas Device Layout ................................................................................12 – 5
Main Component Structures ......................................................................12 – 6
Actions to be Taken in the Event of a Failure ..................................12 – 11
Troubleshooting .......................................................................................12 – 13
Disassembly and Reassembly ............................................................12 – 16
Main Components of LP-gas Device .........................................................12 – 16
Disassembly and Reassembly of LP-gas Carburetor .................................12 – 17
Disassembly and Reassembly of Converter (vaporizer) ............................12 – 19
Disassembly and Reassembly of LP-gas Filter ..........................................12 – 25
Inspection and Adjustment ..................................................................12 – 31
LP-gas Tank Inspection .............................................................................12 – 31
Filter Inspection .........................................................................................12 – 31
Converter (vaporizer) Inspection and Adjustment ......................................12 – 32
Idle Speed Adjustment ..............................................................................12 – 33
Output Power Adjustment ..........................................................................12 – 33
12
Ignition Timing Adjustment ........................................................................12 – 34
Gas Leak Check Procedure .......................................................................12 – 34
Periodic Inspection Schedule ....................................................................12 – 35
 LP-GAS SYSTEM

Types of LP-gas

LP-gases (liquefied. petroleum gases) are commercial The simplest one is methane whose basic structure is
fuels. They are supplied in liquid form, so that they can composed of one carbon atom and four hydrogen atoms
be conveniently transported, stored and used. They are (C1H4); it is the first member of the paraffin series. The
mixtures of hydrocarbons, liquefied by pressurization. second is ethane (C2H6); the third, propane. (C3H8); the
Though commercially classified as propane LP-gas, fourth, butane (C4H10); the fifth, pentane (C5H12), and so
butane LP-gas and propane-butane mixture LP-gas, they on. This series, otherwise called the alkane series,
contain other hydrocarbons (methane, ethane, ethylene, increases the number of hydrogen and carbon atoms
etc.) in small quantities. They are high in calorific value according to the general formula CnH2n+2.
and, as fuel for automotive engines, can take the place The olefin series is another: it starts out with ethylene
of gasoline mainly because of their high octane number. (C2H4); followed by propylene (C3H6); butylene (C4H8);
Hydrocarbons, or compounds of hydrogen (H) with and so on, the general formula being CnH2n. For use as
valence of 1 and carbon (C) with valence of 4, are truly fuel, olefins are undesirable compounds for the reasons
many in kind. to be stated later.

Structure of methane Structure of ethylene

(an alkane) (an olefin)

206353

Since butane is a major hydrocarbon for LP-gas, it may 2. Make sure that the selected LP-gas contains no
be well to note here that this alkane occurs in two olefins (unsaturated hydrocarbons) and, if it does,
molecular structures to take two names: one is normal that the percent olefin content does not exceed the
butane with a boiling point of 0.6 °C (33.1 °F), and the prescribed limit.
other is isobutane with a b.p. of -10 °C (14.0 °F). 3. Make sure that the selected LP-gas contains no
Obviously the latter is more volatile. impurities.
* “Vapor pressure” is a function of temperature and
Guideline for Selecting LP-gas for may be defined, loosely, as the pressure at or below
Forklift-truck Engines which the liquid can turn to gas where its
temperature is given. The v.p. of water at 0 °C (32.0
We have seen that not all LP-gases are fit for use as
°F) is 0.5 mmHg (0.020 in.Hg), at 100 °C (212 °F),
engine fuel, and that ambient temperature has a great
it is 760 mmHg (29.9 in.Hg) (=1 atm). This means
deal to do with LP-gas selection. The rules of thumbs
that even a water of 0 °C (32.0 °F) can turn to vapor
are these:
if the pressure acting on it is reduced to and under
1. Be sure that the selected LP-gas is satisfactory with 0.5 mmHg (0.020 in.Hg).
respect to vapor pressure*.

12-1
LP-GAS SYSTEM

Gasoline is volatile, so must be the LP-gas. The the LP-gas fuel system. Moreover, they are erosive:
yardstick of volatility is the vapor pressure. Here eroded diaphragms in the vaporizer are often explained
resides the reason why the maximum vapor pressure is by the presence of these olefins in the LP-gas.
specified for each grade of LP-gas. Water and compounds of sulfur or sulfides as impurities
The LP-gas is contained in the supply tank at a pressure can play the serious mischief with metal surfaces in the
sufficiently higher than that of the atmosphere, so that, LP-gas fuel system by their corrosive action and also
when its outlet valve is opened, it will flow out by its with the engine exhaust line by giving rise to sulfureous
own pressure: this is one of the reasons why a pump is acid gas in the outgoing gases.
not used to forward it to the engine. Imagine a tank
containing mostly butane and suppose that the tank gets
chilled deep to drastically lower the temperature of its
Vapor Pressure vs. Temperature for
LP-gas inside. Then, the inside pressure will fall and
Mixture of Propane and Normal Butane
the LP-gas might not flow out by its own pressure. The statement made earlier to the effect that “vapor
Even if the butane came out, it might not turn to gas pressure” of a liquid is a function of its temperature is
because its vapor pressure at low temperatures is low. graphically illustrated, below, for eleven mixtures of
The remedy in such a case is to use a more volatile LP- propane and normal butane in varied proportions.
gas.

LP-gas Knock Rating and Octane

Number
As compared with gasoline, LP-gases are generally
high in terms of anti-knock value and hence octane
number. An LP-gas of nearly 100% propane is reported
to have an octane number of well over 100; the octane
number of the 100% butane is reported to range from
97 to 98, a level not far from that of what is sold as
“premium gasoline” today.
The octane number of a fuel for the spark-ignition
engine is a measure of its anti-knock quality: the higher
the octane number, the less is the tendency of the fuel to
knock.

Adverse Effects of Olefins on LP-gas

Fuel System
Olefins (unsaturated hydrocarbons) are trouble-makers:
they are more prone to undergo chemical reactions.
Take ethylene, the first and therefore simplest olefin of
the series, for example: it can combine with chlorine
gas (Cl2) to form ethylene dichloride through what is
called “addition reaction.” Ethylene molecules can
combine to form a larger molecule, polyethylene,
through “polymerization reaction.”
Propylene (C3H6) and butylene (C4H8), both olefins, are
more reactive than ethylene and, if present in the LP-
gas, are likely to form tar-like and rubbery substances
and thus foul up the vaporizer, an important device in
12-2
 LP-GAS SYSTEM

Vapor pressure vs. temperature

1.3 (13) [185]

Normal
Propane butane

1.2 (12) [171] C3H8 C4H10

Vapor pressure as gauge pressure MPa (kgf/cm2) [psi]

1.1 (11) [156]

1.0 (10) [142]

0.9 (9) [128]

0.8 (8) [114]

0.7 (7) [96]

0.6 (6) [85]

0.5 (5) [71]

0.4 (4) [57]

0.3 (3) [43]

0.2 (2) [28]

0.1 (1) [14]

0 -30 -20 -10 0 10 20 30 40 50 60

(-22) (-4) (14) (32) (50) (68) (86) (104) (122) (140)

Temperature °C (°F)
202307

12-3
LP-GAS SYSTEM

Construction and Function

Outline of LP-gas Device

1
5 3

4
Hot water Hot water Liquid LP-gas

Vaporized LP-gas

Air (from air cleaner)

LP-gas + air

205393

1 LP-gas tank 4 Vacuum fuel lock filter

2 LP-gas filling valve 5 Converter
3 LP-gas fuel valve 6 LP-gas carburetor

12-4
 LP-GAS SYSTEM

LP-gas Device Layout

3
9

207150

1 LP-gas tank 6 LP-gas carburetor

2 Gas outlet valve 7 Hot-water hose
3 Gas charge valve 8 Gas outlet hose
4 Filter 9 Tank bracket
5 Converter (vaporizer)

12-5
LP-GAS SYSTEM

Main Component Structures

LP-gas tank
This tank is constructed as shown below. It has a The tank is fastened securely to the bracket and needs
service valve, a sight gauge, an elbow adapter with a to be covered to avoid its exposure to direct sunlight. Its
raincap, a pressure relief valve, and a fixed liquid level fastening bands can be loosened to remove the tank as
gauge. when the engine is serviced.

3 2

1
4

5
206356 206367

1 Service valve (liquid) 3 Fixed liquid level gauge

2 Elbow adapter with raincap and pressure relief 4 Plug (vapor)
valve 5 Sight gauge

NOTE
Exact version may vary depending on tank fitted.

Pressure relief valve

This relief valve is a fully internal “pop action” type and is
located between the elbow adapter and tank body. This
valve serves as a primary relief valve and reduces the
possibility of foreign material which can prevent proper
functioning of the relief mechanism. Its guide, stem and
adjusting components are located within the tank — not
exposed directly to foreign materials and debris from the
atmosphere.
206358

12-6
 LP-GAS SYSTEM

Fixed liquid level gauge

Having No. 54 drill size orifice, this gauge is for the LP-gas
tank having a dip tube welded in the tank. It is also used
where the tank is mounted at the maximum allowable
filling level.

206359

Service valve
The excess flow check valve located at the inlet consists of
a spring, a valve disk complete with a stem, and a nozzle
having a seat for the disk.
When the fuel flow rate is normal, the pressure acting on
the face of the disk due to fuel velocity is not high, so that
the spring keeps the disk pushed off the seat formed of the
nozzle.
In the event of an excess flow rate caused, for instance, by
failure of a hose connection, the pressure acting on the disk 206360
will be so high as to push in the disk against the force of
the spring, thereby closing the nozzle to limit the flow of
the fuel. This limiting action is due to the equalizing nozzle
built in the disk.
The disk pushed against the nozzle will remain seated when
a small amount of the fuel is flowing out through the
equalizing nozzle but, as the pressure difference across the
disk decreases and disappears, the spring will force the disk
off to its normal lifted position.

12-7
LP-GAS SYSTEM

Fuel level indicator

Just as the fuel gauge has a float in the gasoline tank, other is mounted on the end of the drive shaft. These
this indicator operates with its float in the tank. As the magnets, between which lies a non-magnetic flange, are
fuel level in the tank rises or falls, the float also rises or in such a position that, as the magnet on the drive shaft
falls. This vertical movement of the float causes the turns, the magnet on the dial scale turns by the same
sector shaft to rotate by an amount corresponding to the amount. The scale is calibrated to translate the position
float movement. of the float into a percentage of the fuel in the tank.
In the head section of the indicator, which is secured to Thus, when the fuel level is halfway up, the needle will
the tank shell, there are two permanent magnets. The be at “50” to mean that the tank is 50% full.
one outside of the dial scale carries a needle, and the

6
1
3
5
2

206361

1 Plexiglas crystal 4 Float

2 Head 5 Float rod
3 Drive shaft 6 Counterweight

12-8
 LP-GAS SYSTEM

Filter
❋ Components included in the repair kit
The filter removes impurities contained in liquid LP-gas.
The filter can be removed for cleaning and replacement. 1❋

The hose connecting the filter and carburetor supplies

2
negative pressure to the filter.
The valve provided on the filter opens when it receives
3❋
negative pressure during engine startup, allowing LP-gas to
flow.
4
When the engine is not operating, the lack of negative 5
pressure closes the valve, thus stopping the LP-gas flow.
6
1 Screw (6) 8❋
2 Diaphragm cover
3 Diaphragm 7
4 Screw (2)
5 Fulcrum
9❋
6 Valve operating lever
7 Valve body 10❋
8 Retaining washer 11❋
9 O-ring lip seal
10 Valve operating pin 12
11 Valve seat
13
12 Valve spring
14❋
13 Screw (1)
14 Screen
15 Filter 15❋
16 Gasket
17 Filter cover 16❋
18 Screw (10)
17
Parts indicated with an asterisk (❋) are included in the
repair kit.
18❋

205399

12-9
LP-GAS SYSTEM

Converter (vaporizer) and LP-gas carburetor LP-gas carburetor

Converter (vaporizer) The LP-gas carburetor mixes vaporized LP-gas supplied

from the converter with air, and feeds the mixture into
The converter vaporizes liquid LP-gas and adjusts the
the engine.
gas pressure to a level of 9.8 to 14.7 kPa (0.1 to 0.15
kgf/cm2) [1.4 to 2.1 psi]. The negative pressure resulting from the piston’s
downstroke process pulls down the air valve in the LP-
Liquid LP-gas pressurized inside the tank presses opens
gas carburetor. (Diagram below shows the air valve
the primary valve in the converter and enters the
pulled to a lower position.)
primary chamber. The liquid LP-gas changes to a gas
inside the primary chamber due to the heat of the The amount of air valve travel is determined by the
engine cooling water (hot water). amount of negative pressure resulting from the engine’s
intake operation and the tension of the air valve spring.
The vaporized LP-gas, which has a pressure of 9.8 to
The air valve is provided with a gas metering valve. The
14.7 kPa (0.1 to 0.15 kgf/cm2) [1.4 to 2.1 psi], flows
metering valve varies the size of the opening to adjust
towards the LP-gas carburetor through the secondary
the LP-gas flow rate and ensures a proper mixing rate
valve that opens due to the negative pressure of the
of LP-gas and air.
suction force supplied from the intake manifold of the
engine. The LP-gas carburetor is also equipped with an idle fuel
mixture adjustment screw and a power fuel mixture
The operation of each valve is controlled by a
adjustment valve. The idle fuel mixture adjustment
diaphragm.
screw is used to adjust the fuel mixture ratio for engine
idling operation, and the power fuel mixture adjustment
valve is used to regulate the LP-gas flow rate for
engine’s under-load operation.
View from direction A
Power fuel mixture
adjustment valve LP-gas
View from
carburetor
Power fuel mixture direction A
adjustment valve
Idle fuel
mixture Air
adjustment
screw Idle fuel (from air cleaner)
mixture
adjustment
From LP-gas tank screw
Air valve Gas
Liquid LP-gas metering
Air valve valve
Primary valve
Secondary spring
diaphragm Mixture of
Primary chamber vaporized
Hot-water
LP-gas pressure: LP-gas and air
passage
9.8 kPa (0.1
kgf/cm2) [1.4 psi]
Secondary
valve
Atmospheric vent

Primary Atmospheric
Throttle valve of
diaphragm vent
gasoline carburetor
Vaporized
LP-gas
Converter
205127A

12-10
 LP-GAS SYSTEM

Actions to be Taken in the Event of a Failure

(1) When you smell the gas or notice something wrong the relief valve.
with the LP-gas equipment during operation, (11) Close the service valve on the tank when LP-gas
immediately stop the lift truck in a safe area, turn fueled lift trucks are parked overnight or stored
the starter switch to “OFF” position, close the for a long period of time indoors with the fuel
service valve (RED) of LP-gas tank, and try to find tank in place.
the cause. (It is advisable to have a test kit on hand
(12) Close the valves on empty tanks.
for detecting gas leakage in the event of the
failure.) (13) Examine all LP-gas tanks before filling again
before reuse, for damage to the valves, liquid
(2) If the internal pressure of LP-gas tank rises too high
gauge, fitting and hand wheels.
for one reason or another to cause the safety valve
to open and let out the excess pressure, sprinkle (14) Check for dents, scrapes or other damage to the
water over the tank and, at the same time, pressure vessel and for dirt or debris in the
extinguish the fire burning near the lift truck, if any, openings.
and ventilate the working area to rarefy the leakage (15) All defective or damaged LP-gas tanks must be
gas. removed from service.
(3) When gas leakage is evident, extinguish the fire (16) The careless handling of LP-gas tanks can result
burning near by and close the service valve (RED) in a serious accident. Extreme care should be
of the tank as soon as possible, then take a split- exercised when transporting tanks so that the
second action. tanks are not damaged.
(4) If there is a possibility of fire in the event of (17) The storage and handling of liquid fuels in the
collision or overturning of the lift truck, close the U.S.A., should be in accordance with the NFPA
service valve (RED) of the tank as soon as possible. No.30, “Flammable and Combustion Code.”
(5) The LP-gas tank installed in correct position will Outside the U.S.A. store and handle in accordance
not explode even if it is in a blaze. What to do in with local regulations.
the event of emergency is to remove inflammable (18) The lift truck should be refueled only at
material from around the tank quickly. designated safe locations. Safe outdoor locations
(6) Use a dry-chemical (powder) type or carbon are preferable to those indoors.
dioxide type extinguisher. Never use water. It is a (19) DO not completely fill the tank. The fuel expands
good practice, however, to sprinkle a large quantity when it gets warm and it may overflow. This will
of water over the LP-gas tank for cooling it down create a fire hazard.
while extinguishing the fire.
(20) Only trained and authorized personnel should fill
(7) Only trained and authorized personnel should fill or or exchange LP-gas tanks.
exchange LP-gas tanks.
(21) Do not drop, throw, roll or drag LP-gas tanks. Do
(8) Personnel engaged in filling of LP-gas tanks should not strike LP-gas tanks or any associated parts of
wear protective clothing such as a face shield, long the tanks or fuel systems.
sleeves and gauntlet gloves.
(22) Check the LP-gas tank for secure mounting.
(9) Do not refuel or store LP-gas powered lift trucks Loose tanks can cause pressure fuel lines to leak,
near any underground entrances, elevator shafts, or resulting in personal injury.
any other place where LP-gas could collect in a
(23) Carefully read the caution labels.
pocket causing a potentially dangerous condition.
(10) Do not leave the lift truck, for even a short period
of time, in the vicinity of objects with high
temperatures, such as ovens and furnaces. The
heat may raise the pressure of the fuel and open

12-11
LP-GAS SYSTEM

“FUEL GAUGE” decal

“MAINTENANCE” decal

“L.P.G.” decal “FUEL” decal

207151

12-12
 LP-GAS SYSTEM

Troubleshooting

Engine does not start No LP-gas in tank Refill LP-gas tank.

even though there is no
equipment abnormality. Be sure to open gas outlet valve on
LP-gas tank.
Improper operating Do no use choke.
procedure Do not press accelerator pedal all the way.

Overactivation of excess Close gas outlet valve (red handle) on

flow valve in gas outlet LP-gas tank, and leave in that condition
valve on LP-gas tank for about 1 minute. When gas pressure
stabilizes and valve deactivates, open gas
outlet valve.
Difficulty in starting or failure to start

No LP-gas is supplied
to converter.

Clogged filter Disassemble and clean filter.

Replace filter and screen.

Improper idle speed Adjust idle fuel mixture adjustment screw

Engine starts but stalls adjustment on LP-gas carburetor.
immediately.
Excessively low cooling Use coolant (start engine using gasoline).
water temperature Check for clogs in cooling water hoses
and thermostat damage.

Faulty gasoline solenoid Check for dust adhesion on valve seat in

valve feeding gasoline and gasoline solenoid valve, and clean it, if
LP-gas at the same time necessary.
If cleaning does not solve the problem,
replace.
Insufficient gas pressure If LP-gas tank pressure is lower than 98
due to low temperature kPa (1 kgf/cm2) [14.2 psi], increase
Others propane content of LP-gas. (Ambient
temperature: 0°C [32°F])

Malfunction of LP-gas Check for sticking of air valve.

carburetor If air valve sealing ring is worn, replace.

Mixing of air due to faulty Use hose clamp to tighten the connection.
connection of air hose to
LP-gas carburetor

12-13
LP-GAS SYSTEM

Engine operation stops Improper setting of idle Make adjustment.

or is unstable at idle fuel mixture adjustment
speed, or idle speed is screw on LP-gas carburetor
too high.
Accumulation of rubber Disassemble and clean.
Faulty idling operation

particles, oil and metal

particles inside converter

Torn diaphragm Replace diaphragm.

in converter

Faulty secondary valve seat If valve does not completely rest on

in converter seat, replace seat.

Others Primary pressure exceeding Replace primary valve seat.

14.7 kPa (0.15 kgf/cm2)
[2.1 psi] and, causing rich
fuel mixture. (Damaged
primary valve seat)

Engine power decreases

Poor engine performance or stalling of engine

gradually during operation, No LP-gas Refill with LP-gas. Exchange LP-gas tank.
and engine speed does not
increase.

Engine stalls a short

Freezing of converter Hot Remove hot-water hose at outlet to check
time after startup.
water (engine cooling if hot water is properly circulating
water) temperature is too (clogged hose).
low, or insufficient LP-gas Start engine with gasoline, then switch to
LP-gas when indicator of water
temperature gauge moves to white zone.
Gas leaks from damaged Repair damaged hose.
Strong gas smell LP-gas hose

Torn primary diaphragm in Stop operation immediately, and replace

converter primary diaphragm.

12-14
 LP-GAS SYSTEM

Damaged primary valve Replace primary valve seat.

seat in converter
Poor acceleration

Improper adjustment of Adjust power fuel mixture adjustment

power fuel mixture valve until appropriate acceleration
adjustment valve on LP- performance is achieved.
gas carburetor

Internal contamination of Disassemble converter and clean

converter internal parts.

Torn secondary diaphragm Replace diaphragm.

in converter

Power fuel mixture Turn power fuel mixture adjustment

adjustment valve opening valve slightly to (L) side.
Excessive gas too large

Torn primary diaphragm in Replace diaphragm.

converter
Insufficient power

Excessive tightening of Adjust power fuel mixture adjustment

power fuel mixture valve by turning to (R) side.
adjustment valve

Insufficient gas Insufficient opening (due Replace solenoid valve.

to swelling of rubber in
most cases) of solenoid
valve
Internal contamination of Disassemble converter and clean
converter internal parts.

Torn secondary diaphragm Replace diaphragm.

in converter.
Excessive fuel consumption

Leaks in hose Repair leaks.

Strong gas smell
Torn primary valve Replace primary valve seat.
seat
Others Insufficient power (gas Adjust power fuel mixture adjustment
mixture too rich or too valve.
lean)

12-15
LP-GAS SYSTEM

Disassembly and Reassembly

Main Components of LP-gas Device

3
4

10
7

6
9
5

Hoses and other minor specifications are different for MCFE.

207152

1 Hot-water hose 6 Vacuum hose

2 Hot-water hose 7 Vacuum hose
3 Pipe 8 LP-gas converter
4 LP-gas hose 9 Filter
5 LP-gas hose 10 Carburetor

12-16
 LP-GAS SYSTEM

Disassembly and Reassembly of LP-gas

❋ Components included in the repair kit
Carburetor
1 Screw
2 Cover
3 Air valve spring 1
4 Screw
2
5 Back-up plate
6 Diaphragm
7 Air valve ring 3
8 Air valve
9 Mixer body 4
10 Fitting 5
11 Idle screw
12 Idle screw spring
13 Plug 6
14 Gasket
❋
15 Spacer
16 Adapter 7

9
13
10
12
14
11

15

14

16

205403

12-17
LP-GAS SYSTEM

(1) Remove the air valve cover and retaining screw. Place a
chalk mark on the air valve diaphragm and the mixer
body. This mark will allow correct positioning during
reassembly.
Chalk mark

205404

(2) Lift out and replace the air valve assembly in the mixer
body.

205405

(3) Press the air valve down until it bottoms into the body.

205406

(4) Align the chalk mark on the air valve diaphragm with
the chalk mark on the mixer body. Reassemble the air
valve cover and install retaining screws.

205407

12-18
 LP-GAS SYSTEM

Disassembly and Reassembly of

❋ Components included in the repair kit
Converter (vaporizer)
Disassembly
1
Sequence
1 Screw (6)
2
2 Secondary cover
3 Secondary diaphragm
4 Screw (1) 3
5 Secondary seat lever
6 Secondary seat 4
Secondary seat pin 5
7 Fulcrum pin 6
8 Spring 7
9 Screw (7) 8
10 Primary cover
11 Primary diaphragm 17
12 Primary valve pin
13 Spring ❋
16
14 Cover plate
15 Gasket
15
16 Primary valve seat
17 Converter body
14
NOTE
13
(1) Parts indicated with an asterisk (❋) are included in 12
the repair kit.
11
(2) When converter is disassembled, be sure to replace
gasket 15 with a new one during reassembly.
10

205132

(1) Repair kit contains all necessary replacement parts to

replace components subject to deterioration. All
components in the repair kit should be used when
overhauling converter or when converter has not been
used for an extended period of time. Converter gaskets
and diaphragms deteriorate if converter is stored for a
prolonged period after being used.

12-19
LP-GAS SYSTEM

(2) Start disassembly by removing secondary cover. Take

out six screws, and tap the perimeter of the cover with
the plastic handle of a screwdriver to loosen secondary
cover from its mounting position.

206713

(3) Remove secondary diaphragm.

Slide secondary diaphragm toward gas inlet side to
disengage diaphragm link from secondary seat lever.

206714

(4) At this stage, secondary seat lever is still positioned in

link slot. Move secondary diaphragm to clear the slot.

206715

(5) Remove screw, and dismount secondary seat lever,

secondary seat, secondary seat pin, fulcrum pin and
spring from converter body.
Note that locating tabs for spring are provided on both
sides of lever. These tabs, together with the tab on the
top of lever, retain the spring in proper position and
prevent it from slipping out of place.

206716

12-20
 LP-GAS SYSTEM

(6) Take out seven screws, and remove primary cover and
primary diaphragm.
Note rectangular lever riveted to primary diaphragm.
This lever is supported on the upper side by a fulcrum
cast in the cover. The lever rocks on the fulcrum to
depress primary valve pin and spring. In photo, the
pencil points to pressure sensing port.

206717

(7) Primary valve is operated by primary valve pin that

moves through a boss in the cover plate of converter
body. This prevents diaphragm from contacting LP-gas,
thus preventing diaphragm stiffening caused by
refrigeration.

206718

(8) Illustration on the right shows converter with cover

plate and gasket removed.
Located inside the body are serrated vaporizing
chamber and heat exchange circuit which heats
vaporized LP-gas.

206719

(9) In illustration, the pencil points to aluminum alloy

backing of primary valve in vaporizing chamber.
Viton sheet is bonded to this backing.

(10) Remove gasket from cover plate of converter body.

206720

12-21
LP-GAS SYSTEM

Reassembly
(1) Take out parts from the repair kit.
Secondary diaphragm (1)
Secondary seat (1)
Secondary seat pin (1)
Gasket (1)
Primary valve pin (1)
Primary diaphragm (1)

(2) Position gasket and cover plate of converter in place,

and mount primary valve pin and spring.

206721

(3) Position primary cover, diaphragm and converter body

cover plate in place, and tighten seven screws until they
contact the cover. Then, tighten screws in a diagonal
sequence until all screws are tightened evenly.

NOTE
Primary cover has marks that indicate positions of gas
inlet, hot water inlet and outlet, and primary pressure
check plug. Orifice located below the bottom mark is a
vent for primary diaphragm. 206722

(4) Bend or straighten old secondary seat pin and remove

secondary seat (right).
Replace with new secondary seat and secondary seat
pin.

206723

12-22
 LP-GAS SYSTEM

(5) Draw pin through secondary seat lever.

Pull the pin until the head of the pin contacts seat, but
leave it loose enough so that seat can tilt to allow
alignment with secondary jet.

206724

(6) Bend pin and hold seat in place.

Cut off excess part of the pin.

206725

(7) Install spring, and mount secondary seat lever with

screw.

206726

(8) When installing secondary seat lever, insert secondary

seat lever and fulcrum pin into the locating groove, and
tighten screw to secure the parts in place.

206727

12-23
LP-GAS SYSTEM

(9) Align diaphragm link slot to the end section of

secondary seat lever.
Gap from which link is punched should face gas inlet.
Refer to steps (3) and (4) of the disassembly procedure.

206728

(10) Position secondary diaphragm in place, and mount

secondary cover with six screws.
Tighten screws until they contact secondary cover.
Then, tighten screws from one side to the other until
all screws are tightened evenly.

! CAUTION
Use only brass fittings in the hot water inlet
and outlet passages. Steel fittings cause
206729
casting to deteriorate due to electrolysis.

! CAUTION
After assembly in complete, conduct a
pressure test using a soapy solution or testing
solution to make sure there is no leak.

12-24
 LP-GAS SYSTEM

Disassembly and Reassembly of LP-gas Filter

! CAUTION
1. DO NOT use Teflon thread tape on any of the NPT pipe-thread fittings where fuel travels. Use a
suitable fuel resistant joint compound.
2. Be sure to leak-check all fittings and covers for fuel tanks, using a soapy solution.

Disassembly
❋ Components included in the repair kit
Sequence
1 Screw (10) 12
2 Filter cover
3 Gasket 13
4 Filter
5 Screen 14
6 Screw (1)
7 Valve spring 15
8 Valve seat
16
9 Valve operating pin
17
10 Retaining washer
10
11 O-ring lip seal ❋
12 Screw (6)
18
13 Diaphragm cover
14 Diaphragm
15 Screw (2) 11
16 Fulcrum 9
17 Valve operating lever
8
18 Valve body
7

6
5

205399

12-25
LP-GAS SYSTEM

(1) Take out ten screws, and remove filter cover and
gasket.

206730

(2) Remove filter and screen.

206731

(3) Take out screw, and remove valve spring.

206732

(4) Remove valve seat and valve operating pin.

206733

12-26
 LP-GAS SYSTEM

(5) Diagram on the right shows the relationship of valve

spring, valve seat, valve operating pin, seat retaining
washer and O-ring.
When valve operating pin is removed, seat retaining
washer can be taken out through the “Fuel Out”
opening.

206734

(6) Insert wire through the “Fuel Out” jet hole, hook the
wire on retaining washer, then pull it out.

206735

(7) Using the same wire, take out O-ring lip seal through
the hole from which valve operating pin is removed in
step (4).
Wash body, cover and jet as needed, using kerosene or
cleaning oil. Do not use carburetor cleaner since it
erodes synthetic rubber seals.

206736

(8) Take out six screws on diaphragm side, and remove

diaphragm cover and diaphragm.
Wash parts as needed, using kerosene or cleaning oil.
Do not remove fulcrum or valve activating lever on
diaphragm side.

206737

12-27
LP-GAS SYSTEM

Reassembly
(1) Seat holder (H1-14236) should be positioned as shown Installation pin
in illustration (bottom tool).
Note that the hole in which the O-ring lip seal is
installed is tapered, and that the wider end of the
Seat holder
opening faces up.
Replacement seal must be coated with silicone grease
before it is inserted into holder. Place greased O-ring
lip seal into the holder using installation pin (P1-
206738
14235), and re-coat seal with silicone grease.
The seal must be in the position shown in illustration,
with groove facing up and visible. Seal is tapered to
match the hole in the holder.

NOTE
“H1-14236” and “P1-14235” are special tool numbers
of Impco Company.

(2) With O-ring lip seal in the holder, groove visible and
facing up, slide holder (with O-ring lip seal) into the
body.
Look through the fuel hole to check positioning of the
seal. The seal must be positioned above the cavity of
the seal recess.
Coat installation pin with silicone grease, and push seal
through holder and into the seal recess of the body.
Remove installation pin, and look through the fuel hole
206739
to check for proper installation.
The seal should be seated in the seal recess, and groove
should be visible.

(3) Use needle nose pliers to install retaining washer

through the “Fuel Out” opening.
Refer to the cross-sectional diagram for step (5) of the
disassembly procedure.

206740

12-28
 LP-GAS SYSTEM

(4) Coat valve operating pin with silicone grease, and

insert in the body, so that pin passes through retaining
washer and O-ring lip seal. Rotate pin slowly to ease
passage through washer and O-ring.

206741

(5) Place valve seat on top of the head of operating pin,

with aluminum side facing up. Make sure that Viton
side is positioned towards the head of the pin.

206742

(6) Mount valve spring with screw. Lift valve spring

slightly to confirm its freedom of movement.

206743

(7) Install screen and filter, place gasket, then mount filter
cover with screws.

206744

12-29
LP-GAS SYSTEM

(8) Reassembly of diaphragm side

Check valve operating lever for freedom of movement.
Use silicone grease to coat the surface of the gasket
that contacts the body. Note that holes align only when
the gasket is installed correctly.
Rivet heads on diaphragm should be on the cover side,
not the body side.

206745

(9) Install diaphragm to the body, and mount diaphragm

cover with screws.
Tighten screws evenly.

206746

12-30
 LP-GAS SYSTEM

Inspection and Adjustment

LP-gas Tank Inspection
Disassembly of components that are subject to high
pressure, such as container, valve, level indicator device,
must be performed by persons legally qualified and in
shops certified under regulations. Request a certified shop
to inspect the LP-gas tank.

Filter Inspection
(1) It is not necessary to check the filter unless the ❋ Components included in the repair kit
solenoid valve is defective. However, disassemble and
clean the filter at least once a year. 1
(2) Parts replacement after filter disassembly
2
With the parts contained in the repair kit, replace the
filter, screen, gasket and other parts.
3
(3) Tighten the cover securely during the reassembly
process.
4
After reassembly, check to make sure that there is no 5
gas leak.
6
8
❋
1 Screw
3 Diaphragm 7
8 Retaining washer
9 O-ring lip seal
9
10 Valve operating pin
10
11 Valve seat
14 Screen 11
15 Filter
16 Gasket 12

18 Screw 13
14

15

16

17

18

205399

12-31
LP-GAS SYSTEM

Converter (vaporizer) Inspection and

Adjustment
(1) Hot-water hose inspection
The converter uses heat supplied by the engine cooling
water to vaporize fuel. Inspect the hot-water hoses for
damage.
(2) Bleeding converter
If hot water does not circulate properly, bleed the
converter to remove air trapped in the water core. Air vent plug

To bleed the converter, remove the air vent plug on the

side of the converter, and let the engine idle.
After making sure that intermittent flows of coolant
with air from the plug hole have changed to a smooth
flow, install the plug. (Apply ThreeBond No. 1142 or
equivalent sealant on plug threads.)
205134

(3) Primary chamber pressure measurement

Remove the plug located on the back side of the
converter. Mount an R (PT) 1/4 connector and a
pressure gauge to the pressure measuring port. Operate
the engine with LP-gas. If the pressure indication
shows a value from 9.8 to 14.7 kPa (0.1 to 0.15
kgf/cm2) [1.4 to 2.1 psi], it is normal.
If the pressure is less than 9.8 kPa (0.1 kgf/cm2) [1.4 Remove plug
psi], the engine lacks power on an upgrade inclination.
If the pressure is higher than 14.7 kPa (0.15 kgf/cm2) 205135
[2.1 psi], the engine produces high output power but
fuel consumption increases.
If the measured pressure is outside the specified range,
disassemble the converter and replace the secondary
seat.

12-32
 LP-GAS SYSTEM

Idle Speed Adjustment

After sufficient engine warm-up operation, adjust the idle
fuel mixture adjustment screw of the LP-gas carburetor so
that the engine idles at 650 to 700 rpm.
(1) Connect a tachometer.
Connect the positive (+) lead wire of the tachometer to
the negative (-) terminal of the ignition coil, and the
negative (-) lead wire to the vehicle chassis.
(2) Let engine idle.
(3) Set speed adjusting screw of the gasoline carburetor so
that the engine runs at a speed of 600 to 650 rpm. Ignition coil

202327

(4) Turn the idle fuel mixture adjustment screw of the LP-
gas carburetor to the right until the engine operation
becomes most stable.
Idle fuel mixture Fuel mixture Engine condition
adjustment screw condition
Open
Lean Unstable idling
(turn to the left)
High fuel
consumption
Close
Rich (Increases CO 205136A
(turn clockwise)
discharge and
LP-gas smell)

Output Power Adjustment

Adjust the power fuel mixture adjustment valve on the LP-
gas carburetor by following the procedure below.
(1) Turn the power fuel mixture adjustment valve toward
the “L” side when the engine is operating under full
load or working load.
(2) Turn the power fuel mixture adjustment valve slowly
toward the “R” side. From the position at which the
engine speed increases, further turn the power fuel
mixture adjustment valve by 1 mm (0.039 in.) towards
the “R” side.

Power fuel mixture

LP-gas 205137A
adjustment valve
Turn toward “L” side Lean
Turn toward “R” side Rich
12-33
LP-GAS SYSTEM

Ignition Timing Adjustment

The combustion speed is different for gasoline and LP-gas.
Therefore, the optimum ignition timing also differs.
When the engine operates mostly on LP-gas, advance the
ignition timing by 5° or 6° from the ignition timing for
gasoline operation. This provides improved performance
and better fuel economy.

Gas Leak Check Procedure

(1) Open the gas outlet valve on the LP-gas tank.
(2) Set the gasoline/LPG selector to the [LPG] position.
(3) Turn the starter switch to the [START] position to start
the engine.
(4) Use a gas leak tester or soapy solution to check the
pipe joints for leaks.

12-34
 LP-GAS SYSTEM

Periodic Inspection Schedule

Every 4800 service

Every 2400 service
Every 1200 service
hours or 6 months
Every 200 service
hours or monthly
Every 10 service

hours or 2 years
hours or 1 year
hours or daily
(pre-start)
Item Service

Check bracket for installation. ● ● ● ● ●

LP-gas tank and
Check bands for tightness. ● ● ● ● ●
bracket
Check valves and gauge for leaks. ● ● ● ● ●
High-pressure Check hoses and fittings for damage. ● ● ● ●
hoses Replace hoses. ● ●
Check for installation. ● ● ● ●
LP-gas filter Check fuel lines for leaks. ● ● ● ● ●
Replace kit parts. ●
Check for installation. ● ● ● ●
Solenoid valve
Check fuel lines for leaks. ● ● ● ● ●
(dual fuel type)
Check for function. ● ● ● ●
Remove tar. ● ● ● ●
Check connectors for tightness. ● ● ● ●
Converter (vaporizer)
Check fuel lines for leaks. ● ● ● ● ●
Replace kit parts. ●
Check for installation. ● ● ● ●
LP-gas carburetor Check fuel lines for leaks. ● ● ● ● ●
Replace kit parts. ●
Low-pressure hoses Check for installation. ● ● ● ●
(gas hoses) Check bands for tightness. ● ● ● ●
Check for damage. ● ● ● ●
Hot-water hoses
Check bands for tightness. ● ● ● ●
Idling and acceleration ● ● ● ●
Engine
CO measurement ● ● ●

12-35
 SERVICE DATA

Maintenance Chart .................................................................................13 – 1

Tightening Torques for Standard Bolts and Nuts ..........................13 – 9
Periodic Replacement Parts ................................................................ 13 – 11
Lubrication Chart .................................................................................... 13 – 13
Fuel and Lubricant Specifications .............................................................. 13 – 14
Recommended Brands of Lubricants ........................................................ 13 – 15
Refill Capacities (Approximate) ................................................................. 13 – 16
Weight of Major Components (Approximate) ................................. 13 – 17
Special Service Tools ............................................................................. 13 – 18
Inspection Guide ..................................................................................... 13 – 25

13
 SERVICE DATA

Maintenance Chart

: Check or clean
: Change or adjust

Intervals

12 month
Pre-start

1 month
Inspection point How to check Service data

Water leaks Visual

Radiator filler cap — function Visual

Coolant level Visual

Cooling
system Fan belt — tension and Visual/ Adjust by means of
condition measure tension pulley.
Cooling fan — condition Visual

Rubber hoses — condition Visual

Starting and noise Test/listen

Engine Idling and acceleration Tachometer/test 650 rpm

operation
Exhaust smoke Visual

Distributor cap Visual

Spark plugs — gap and 0.7 to 0.8 mm

cleanliness Plug gauge (0.028 to 0.031 in.)
Ignition
system 4G63/4G64:
Ignition timing Timing lamp
(gasoline 4° ± 1° BTDC/650 rpm
models) Advance mechanism — Timing lamp/
vacuum advance vacuum gauge
Ignition coil — resistance Circuit tester

4G63/4G64 (hot)
Inlet/exhaust: 0 mm
Valves Clearance for all valves Thickness gauge S4S (cold)
Inlet/exhaust:
0.25 mm (0.0098 in.)
Air cleaner Element — clogging or damage Visual Every 6 months or 1200
hours, change element.
Oil leaks Visual

Lubrication Oil — level and contamination Visual Every 6 months or 1200

system hours, change element.
Oil filter element — clogging Check Every 6 months or 1200
hours, change element.
Governor No-load maximum speed Tachometer

13-1
SERVICE DATA

Intervals

12 month
Pre-start

1 month
Inspection point How to check Service data

Fuel leaks Visual

Carburetor — cleanliness Visual

Carburetor link — condition Test

Carburetor throttle valve

and choke valve Test

Every 6 months or 1200

Fuel filter — clogging Check
Fuel system hours, change filter.
S4S:
Injection nozzles — injection 14318 +1079
+490 kPa
Nozzle tester +11
pressure and discharge pattern (146 +5 kgf/cm2)
[2076 +156
+71 psi]

Injection timing (interval) Test S4S: 20°BTDC

Injection pump — injection
Bench tester
quality

Feed pump — function Test

Compression Compression
All cylinders
pressure gauge

Starter Pinion — meshing action Test

Alternator Charging Test/visual

Level of electrolyte Visual

Battery
Specific gravity of electrolyte Hydrometer 1.28 or above

Electrical Insulators, connectors and

wires battery terminals — looseness, Visual
damage or corrosion

Looseness, rattle Test

Steering wheel
Centering Test

13-2
 SERVICE DATA

Intervals

12 month
Pre-start

1 month
Inspection point How to check Service data

Knuckles Rattle of kingpins

Rear axle Distortion, damage Visual

Oil leaks Visual

Steering
cylinder
Installation Wrench

Free play and height of Free play: 10 to 16 mm

Scale
pedal depressed (0.4 to 0.6 in.)
Stroke to the point where
brakes start applying
Brake pedal 1 ton class:
40 to 61 mm
Braking distance Test/measure
(1.57 to 2.4 in.)
2 thru 3.5 ton classes:
49 to 95 mm
(1.93 to 3.74 in.)
Lever swing angle:
71° to 76°
Test/spring Operating effort:
Parking brake Performance balancer 245 to 294 N
(25 to 30 kgf)
[55 to 66 lbf]
Brake hoses Fluid leaks, damage or
and pipes installation Visual

Brake fluid Level in reservoir Visual 130 cc (7.9 cu.in.)

Master cylinder and wheel

Wheel brakes cylinders — operation, wear Overhaul/visual
and damage
1 ton class:
0.2 to 0.5 mm
(0.01 to 0.02 in.)
Drum to lining clearance Thickness gauge 2 thru 3.5 ton classes:
0.2 to 0.6 mm
Brake drums (0.01 to 0.02 in.)
and shoes
Service limit
Sliding surfaces of shoes Disassemble/ 1 ton class:
and wear of lining calipers 2.5 mm (0.01 in.)
2 thru 3.5 ton classes:
3.0 mm (0.12 in.)

13-3
SERVICE DATA

Intervals

12 month
Pre-start

1 month
Inspection point How to check Service data

Service limit
1 ton class:
256 mm
Drum — wear or damage Visual/scale (10.08 in.)
2 thru 3.5 ton classes:
312 mm
Brake drums (12.28 in.)
and shoes —
continued Free length of return springs Scale

Operation of shoes Test

Anchor pins — seizure Visual

Distortion, cracks or damage Dye check

Backing plates Fitting cables — damage and length Visual/scale

Ratchet — wear or damage Visual

Every 6 months or 1200

Oil level and oil leaks Visual hours, change oil.
8.0 liters (2.1 U.S. gal)
Strainer — clogging Visual Every 6 months or 1200
hours, change oil.
Inching pedal height
(above floor):
220 mm (8.7 in.)
Clearance between inching
and brake pedal connecting
parts:
1 ton class:
Powershift 9 to 9.5 mm
transmission (0.354 to 0.374 in.)
2-3 ton classes:
0.1 to 0.5 mm
Clutch (inching) pedal — Scale/test (0.004 to 0.020 in.)
adjustment Valve plunger projection:
1 ton class:
9 to 9.5 mm
(0.354 to 0.374 in.)
2-3 ton classes:
6 to 9.5 mm
(0.236 to 0.374 in.)
Valve plunger projection
at which brake starts to
be applied:
16.5 mm (0.65 in.)

13-4
 SERVICE DATA

Intervals

12 month
Pre-start

1 month
Inspection point How to check Service data

Pressure (engine at Specification

1500 ± 100 rpm) kPa (kgf/cm2) [psi]
Main 883 to 1079 (9 to 11) [128 to 156]
Powershift Clutch 883 to 1079 (9 to 11) [128 to 156]
transmission Torque converter inlet 196 to 490 (2 to 5) [28 to 71]
— continued Torque converter outlet 147 to 294 (1.5 to 3) [21 to 43]
Lubrication 98 to 147 (1 to 1.5) [14 to 21]
Stall speed Refer to Service data.
10 m (33 ft) starting
acceleration Within 5 seconds

Cracks, distortion or other Dye check/

defects visual
Hub bearings preload
0.5 to 4.9 N·m
Front wheel bearings — Spring (5 to 50 kgf·cm)
preload balancer [0.4 to 3.6 lbf·ft]
Front axle
see page 6-10

Fore-aft play Test

Cracks, distortion or other

defects Visual

1 ton class:
4.2 liters (1.1 U.S. gal)
Differential Oil level and oil leaks Visual 2 thru 3.5 ton classes:
and transfer 5 liters (1.3 U.S. gal)

Mounting bolts Torque wrench

Hub bearing preload:

0.5 to 4.9 N·m
Spring balancer/ (5 to 50 kgf·cm)
Rear axle Rear wheel bearings — preload torque wrench [0.4 to 3.6 lbf·ft]
see page 7-13
Lock nut (outside)
157 N·m (16 kgf·cm)
[116 lbf·ft]

13-5
SERVICE DATA

Intervals

12 month
Pre-start

1 month
Inspection point How to check Service data

686 kPa (7 kgf/cm2)

[100 psi]
Front 3.5 ton class single:
834 kPa (8.5 kgf/cm2)
Front and [121 psi]
rear axle Tire pressure Tire gauge 686 kPa (7 kgf/cm2)
[100 psi]
Rear 3.5 ton class:
883 kPa (9 kgf/cm2)
[128 psi]
Tires — cuts or gouges Visual

Tires — wear Depth gauge

Tires — imbedded objects Visual

Rim bolts and wheel nuts — Torque wrench

tightness
Unit: N·m (kgf·m) [lbf·ft]
1 ton class 2 thru 3.5 ton classes
Wheels Front 2 to 2.5 ton classes:
wheel 68 (8.8) [64] 202 (20.6) [149]
Rim
bolts 46 to 51 82 to 90
Rear (4.7 to 5.2) (8.4 to 9.2)
wheel [34 to 38] [61 to 67]
Front
378 (38.5) [278]
Wheel wheel
nuts Rear 157 (16) [116] 157 (16) [116]
wheel 3.5 ton class: 233 (23.8) [172]

Rims, side rings and wheel Visual

discs — damage
Oil level and contamination Visual

Hydraulic Strainer — clogging Visual

tank
Return filter — clogging Visual

Hydraulic pump Oil leaks or abnormal noise Visual/listen

Oil leaks Visual

Flow divider 7355 + 490

0 kPa
valve +5
Relief valve setting Pressure gauge (75 0 kgf/cm2)
(power steering) [1066 + 071 psi]

13-6
 SERVICE DATA

Intervals

12 month
Pre-start

1 month
Inspection point How to check Service data

Oil leaks Visual

18142 kPa (185 kgf/cm2)
Main relief valve setting Pressure gauge
[2631 psi]
Control valve Overload relief valve setting
Pressure gauge
(optional)
Control levers and links —
Test
rattle
Cracks, distortion or other
Visual
defects
Drop test (rated load)
Visual/watch/ 1 thru 3 ton classes:
Lift cylinders Rod drift (rated load) scale 50 mm (2.0 in.)/15 min
3.5 ton class:
35 mm (1.4 in.)/15 min
Attachment
Mounting bolts — tightness Wrench
Oil leaks Visual
Lowering speed (rated
load)
1 ton class:
Flow regulator 520 mm/sec (102 fpm)
valve 2 thru 2.5 ton classes:
Lowering speed Watch/scale 500 mm/sec (98 fpm)
3 ton class:
530 mm/sec (104 fpm)
3.5 ton class:
440 mm/sec (87 fpm)
Cracks, distortion or other
Visual
defects
Oil leaks Visual
20 mm (0.8 in.)/
Forward rod drift (rated load) Watch/scale
Tilt cylinders 15 min
Mounts — rattle or damage Visual/free
127 to 152 N·m
Rod socket bolt — tightness Torque wrench (13 to 15.5 kgf·m)
[94 to 112 lbf·ft]
Oil leaks Visual
Rubber hoses — damage Visual
Piping
Hose reels and swivel joint —
Visual
distortion or other defects

13-7
SERVICE DATA

Intervals

12 month
Pre-start

1 month
Inspection point How to check Service data

Cracks, distortion or other

defects Visual/dye check
Mast supports — rattle or
Mast and lift damage
bracket Each roller to mast
Main rollers — clearance, Feeler gauge/ clearance (at max. height):
damage dial gauge 0.1 to 0.5 mm
(0.004 to 0.020 in.)
Service limit
1 ton class:
327 mm (12.87 in.)
Length of lift chains (20 links) Scale 2 thru 2.5 ton classes:
392 mm (15.43 in.)
3 thru 3.5 ton classes:
523 mm (20.59 in.)
Both chains to be equal
Lift chains Tension deflection of lift chains Scale in tension
and
chain wheels Chain wheels —
damage or rusting Visual
Chain wheels — wear,
distortion or other defects Visual
Chain wheel bearings — rattle Feel
Chain anchor bolts —
distortion or damage Visual
Fork thickness
Forks — wear and distortion Visual/scale Refer to Service Data.
Fork stopper pins — damage
Forks and or distortion Visual
backrest Backrest mounting bolts —
tightness Torque wrench
Backrest — distortion or damage Visual
Lights Operation Test/visual

Turn signals Operation Test

Rear view Rear vision Visual
mirrors
Overhead
guard Installation and damage Visual/wrench
Loosen bolts or nuts Wrench
Operator’s seat — damage
and installation Visual
Chassis
Lubricate mast supports
Lubrication points Lubricate every week.
Oil change Inspect
13-8
 SERVICE DATA

Tightening Torques for Standard Bolts and Nuts

With spring washer 101656

Nominal Pitch
size 7 8 10
mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
6 0.24 1 0.04 7.4 0.75 5.4 9.6 0.98 7.1 12.7 1.3 9.4
8 0.32 1.25 0.05 16.7 1.7 12.3 22.6 2.3 16.6 30.4 3.1 22.4
10 0.39 1.25 0.05 34.3 3.5 25.3 45.1 4.6 33.3 69.6 7.1 51.4
12 0.47 1.25 0.05 63.7 6.5 47.0 82.4 8.4 60.8 122.6 12.5 90.4
14 0.55 1.5 0.06 102.0 10.4 75.2 132.4 13.5 97.6 192.2 19.5 141.8
16 0.63 1.5 0.06 157.9 16.1 116.5 202.0 20.6 149.0 287.3 29.3 211.9
18 0.71 1.5 0.06 224.6 22.9 165.6 292.2 29.8 215.5 413.8 42.2 305.2
20 0.79 1.5 0.06 310.9 31.7 229.3 404.0 41.2 298.0 573.7 58.5 423.1
22 0.87 1.5 0.06 413.8 42.2 605.2 537.4 54.8 396.4 763.0 77.8 562.7
24 0.95 1.5 0.06 547.2 55.8 403.6 711.0 72.5 524.4 1006.2 102.6 742.1
27 1.06 1.5 0.06 794.3 81.0 585.9 1032.6 105.3 761.6 1451.1 148.0 1070.5
30 1.18 1.5 0.06 1100.3 112.2 811.5 1430.8 145.9 1055.3 2012.3 205.2 1484.2
33 1.30 1.5 0.06 1467.1 149.6 1082.1 1907.4 194.5 1406.8 2680.2 273.3 1976.8
36 1.42 1.5 0.06 1918.2 195.6 1414.8 2493.8 254.3 1839.4 3497.1 356.6 2579.3
39 1.54 1.5 0.06 2461.5 251.0 1815.5 3198.8 326.2 2359.4 4469.9 455.8 3296.8
With spring washer 101656
Metric
fine Nominal
thread size Pitch 7 8 10
mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
6 0.24 1 0.04 8.6 0.88 6.4 10.8 1.1 8.0 14.7 1.5 10.8
8 0.32 1.25 0.05 19.6 2.0 14.5 26.5 2.7 19.5 36.6 3.7 26.8
10 0.39 1.25 0.05 41.2 4.2 30.4 53.0 5.4 29.1 81.4 8.3 60.0
12 0.47 1.25 0.05 74.5 7.6 55.0 97.1 9.9 71.6 144.2 14.7 106.3
14 0.55 1.5 0.06 119.6 12.2 88.2 155.9 15.9 115.0 226.5 23.1 167.1
16 0.63 1.5 0.06 182.4 18.6 134.5 237.3 24.2 175.0 338.3 34.5 249.5
18 0.71 1.5 0.06 263.8 26.9 194.6 343.2 35.0 253.2 487.4 49.7 359.5
20 0.79 1.5 0.06 365.8 37.3 269.8 475.6 48.5 350.8 674.7 68.8 497.6
22 0.87 1.5 0.06 486.4 49.6 358.8 632.5 64.5 466.5 897.3 91.5 661.8
24 0.95 1.5 0.06 643.3 65.6 474.5 836.5 85.3 617.0 1183.7 120.7 873.0
27 1.06 1.5 0.06 934.6 95.3 689.3 1216.0 123.9 894.2 1707.3 174.1 1259.3
30 1.18 1.5 0.06 1294.5 132.0 954.8 1682.8 171.6 1241.2 2367.3 241.4 1746.0
33 1.30 1.5 0.06 1726.0 176.0 1273.0 2243.8 228.8 1654.9 3153.8 321.6 2326.1
36 1.42 1.5 0.06 2256.5 230.1 1664.3 2934.1 299.2 2164.1 4114.0 419.6 3035.0
39 1.54 1.5 0.06 2896.0 295.3 2135.9 3763.8 383.8 2776.0 5258.3 536.2 3878.3

Remarks: 1. The tolerance on the torque is ±10%

2. The torques are for “dry” condition.

13-9
SERVICE DATA

With spring washer 101656

Nominal Pitch
size

mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
10 0.39 1.5 0.06 33.3 3.4 24.6 43.1 4.4 31.8 67.7 6.9 49.9
12 0.47 1.75 0.07 58.8 6.0 43.4 76.5 7.8 56.4 115.7 11.8 85.3
14 0.55 2 0.08 96.4 9.8 70.9 124.5 12.7 91.9 182.4 18.6 134.5
16 0.63 2 0.08 147.1 15.0 108.5 191.2 19.5 141.0 274.6 28.0 202.5
18 0.71 2.5 0.10 203.0 20.7 149.7 264.8 27.0 195.3 383.4 39.1 282.8
20 0.79 2.5 0.10 286.4 29.2 211.2 371.7 37.9 274.1 536.4 54.7 395.6
22 0.87 2.5 0.10 383.4 39.1 282.8 499.2 50.9 368.2 725.9 74.0 535.2
24 0.95 3 0.12 492.3 50.2 363.1 640.4 65.3 472.3 924.8 94.3 682.1
27 1.06 3 0.12 724.7 73.9 534.5 942.2 96.1 695.1 1350.4 137.7 996.0
30 1.18 3.5 0.14 969.9 98.9 715.3 1259.2 128.4 928.7 1843.7 188.0 1359.8
33 1.30 3.5 0.14 1328.8 135.5 980.1 1727.0 176.1 1273.7 2477.2 252.6 1827.1
36 1.42 4 0.16 1676.0 170.9 1236.1 2180.0 222.3 1607.9 3199.9 326.3 2360.1
39 1.54 4 0.16 2219.2 226.3 1636.8 2884.1 294.1 2127.2 4118.8 420.0 3037.9
42 1.65 4.5 0.18 2754.7 280.9 2031.8 3581.4 365.2 2641.5 5137.7 523.9 3789.4
With spring washer 101656
Metric
coarse Nominal Pitch
thread size

mm in. mm in. N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft
10 0.39 1.5 0.06 39.2 4.0 28.9 51.0 5.2 37.6 79.4 8.1 58.6
12 0.47 1.75 0.07 69.6 7.1 51.4 90.2 9.2 66.5 135.3 13.8 99.8
14 0.55 2 0.08 112.8 11.5 83.2 146.1 14.9 107.8 215.7 22.0 159.1
16 0.63 2 0.08 172.6 17.6 127.3 224.6 22.9 165.6 323.6 33.0 238.7
18 0.71 2.5 0.10 239.3 24.4 176.5 311.9 31.8 230.0 451.1 46.0 332.7
20 0.79 2.5 0.10 336.4 34.3 248.1 437.4 44.6 322.6 630.6 64.3 465.1
22 0.87 2.5 0.10 392.3 40.0 289.3 587.4 59.9 433.3 842.4 85.9 621.3
24 0.95 3 0.12 578.6 59.0 426.7 753.2 76.8 555.5 1088.5 111.0 802.9
27 1.06 3 0.12 852.2 86.9 628.5 1108.2 113.0 817.3 1588.7 162.0 1171.7
30 1.18 3.5 0.14 1140.5 116.3 841.2 1481.8 151.1 1092.9 2168.3 221.1 1599.2
33 1.30 3.5 0.14 1563.2 159.4 1153.0 2031.9 207.2 1498.7 2915.5 297.3 2150.4
36 1.42 4 0.16 1972.1 201.1 1454.6 2564.4 261.5 1891.4 3765.8 384.0 2777.5
39 1.54 4 0.16 2610.5 266.2 1925.4 3393.1 346.0 2502.6 4845.5 494.1 3573.8
42 1.65 4.5 0.18 3241.1 330.5 2390.5 4212.9 429.6 3107.3 6044.8 616.4 4458.4

Remarks: 1. The tolerance on the torque is ±10%

2. The torques are for “dry” condition.

13-10
 SERVICE DATA

Periodic Replacement Parts

The parts listed below are important for the safe shop is requested to adhere to the replacement schedule
working of the truck, and are specially designated as the given here on all trucks brought into its care:
parts to be replaced at specified periods. Each service

Period
Periodic replacement parts Service 1 month
after 1 month 6 months 1 year 2 years
delivery
*Rubber parts for brake master
1 Replace
cylinder
*Rubber parts for brake wheel
2 Replace
cylinder
3 *Hydraulic hoses Replace
4 *Hoses for steering cylinder Replace
5 *Rubber parts for steering cylinder Replace
6 *Fuel hoses Replace
7 *Lift chain Replace
8 *Fuel filter element Replace
9 Engine oil filter element Replace
10 Hydraulic tank return filter Replace
Clean
11 Air cleaner element
Replace

Footnote: *indicated important safety-related parts.

13-11
SERVICE DATA

Location of Important Safety-related Parts

▲ 7

▲
▲
3
3

▲
▲
5
▲
▲

▲
▲

▲
▲
▲
2
▲ 8
▲
6
4
1
2
3 4

207141

13-12
 Lift bracket side rollers

MPG EO Lift chains

Mast strips (sliding surface)

MPG Tilt sockets

Lubrication Chart

MPG

Mast supports GO GO Differential case

MPG

MPG MPG Tilt cylinders

Universal joints (front and rear)

Torque converter oil ATF ATF

HO Hydraulic oil

EO Engine oil

13-13
Brake fluid BF

Rear axle center pin (front) MPG

Rear axle center pin (rear) MPG MPG Tie rod pin

MPG Tie rod pin

Every 50 hours or weekly

ATF — Torque converter oil
MPG — Multi-purpose grease
Every 200 hours or monthly Check and refill
GO — Gear oil
Change
EO — Engine oil
Every 1200 hours or 6 monthly Lubrication point on
BF — Brake fluid
both sides
HO — Hydraulic oil Every 2400 hours or 1 year

207142
SERVICE DATA
SERVICE DATA

Fuel and Lubricant Specifications

Recommendation for ambient temperature °C (°F)

Fuel or lubricant Recommendation -30 -20 -10 0 10 20 30
(-22) (-4) (14) (32) (50) (68) (86)

Gasoline
Gasoline
model
Fuel Consult your dealer
Diesel
Diesel fuel
model
Gasoline API service
Engine model classification SC SAE 10W or SAE 30
oils Diesel API service SAE 10W – 30
model classification CC SAE 20
API service
Differential oil classification GL-4 SAE 80 SAE 90
(multi-purpose)
Powershift
Dexron Consult your dealer
transmission oil
Hydraulic oil ISOVG 32
Brake fluid F.M.V.S.S. No.116 — DOT 3 or DOT 4 (SAE J1703)
NLGI No.2 grade
multi-purpose type
Wheel
(lithium base)
bearings
Consistency:
Grease 265–295
Consult your dealer
NLGI No.1 grade
multi-purpose type
Chassis (lithium base)
Consistency:
310–340

Ambient temperature, -39 -30 -25 -20 -15 -10

Antifreeze solution °C (°F) (-38.2) (-22) (-13) (-4) (5) (14)
(Long Life Coolant)
Concentration, % 55 50 45 40 35 30

Remarks: Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and
deteriorate when mixed. It is best to stick with one and the same brand at successive service intervals.

13-14
 SERVICE DATA

Recommended Brands of Lubricants

Engine oils (gasoline)
Specifications API service classification SC
Viscosity
Manufacturer SAE 10W SAE 20W SAE 30
Mobil HD Para-purpose Motor Oil 10W HD Para-purpose Motor Oil 20W HD Para-purpose Motor Oil 30
Shell Shell Select Motor Oil 10W Shell Select Motor Oil 20W Shell Select Motor Oil 30
Exxon XD-3 15W-40
Castrol Castrol Deusol CRB 10W Castrol Deusol CRB 20W Castrol Deusol CRB 30

Engine oils (diesel)

Specifications API service classification CC or MIL-L-2104B equivalents
Viscosity
Manufacturer SAE 10W SAE 20W SAE 30
Mobil 10W Mobil Delvac 1100, 1200 20W Mobil Delvac 1100, 1200 30W Mobil Delvac 1100, 1200
Shell Shell Rotella SX 10W Shell Rotella SX 20W Shell Rotella SX 30
Exxon XD-3 15W-40
Castrol Castrol Deusol CRX 10W Castrol Deusol CRX 20W Castrol Deusol CRX 30

Transfer and differential oils Greases

Specifications API service classification GL-4 NLGI No.1 NLGI No.2
Viscosity
Manufacturer SAE 90 Consistency 310 to 340 Consistency 265 to 295
Mobil 90 Pegasus Gear Oil Mobil Grease JL 77 No.1 Mobil Grease JL 77 No.2
Shell Shell Spirax EP90 Retinax A No.1 Retinax A No.2
Exxon Gear Oil GX 80W-90 Ronex MP
Castrol Castrol Hypoy Castrol LM Grease Castrol Spheerol API

Transmission oils Brake fluids

Specifications Dexron
Viscosity
Manufacturer — SAE J1703f
Mobil Mobil ATF220, 200 Mobil Super Heavy Duty Brake Fluid
Shell Shell Dexron II Shell Brake Fluid 250
Exxon Superfld ATF Brake Fluid DOT-3
Castrol Castrol TQ Dexron R II Castrol Brake Fluid Crimson

Hydraulic oils
Specifications
Viscosity
Manufacturer SAE 5W SAE 10W
Mobil — Hydraulic oil 28 LP
Shell Tellus oil 22 Tellus oil T-32
Exxon Nuto H32
Castrol Castrol Hyspin AWS32 Castrol Hyspin AWS68

Remarks: Brands of oils are subject to change without notice. When you buy oils, select recommended brands and
check specification (for example API service classification SC, SAE 10W).

13-15
SERVICE DATA

Refill Capacities (Approximate)

Unit: liter (U.S. gal)
Truck Models GP20K
GP15K GP20K-HP DP20K GP30K DP30K
GP18K GP25K DP25K GP35K DP35K
Items GP25K-HP
53 76
Fuel tank
(14) (20)
Cooling system
6.85 8.65 8.75 8.95 9.05
[incl. 0.65 liter (0.2 U.S. gal)
(1.8) (2.3) (2.3) (2.4) (2.4)
capacity of reserve tank]
4.5 9.0 4.5 9.0
Engine
(1.2) (2.4) (1.2) (2.4)
Engine lubrication 0.3 1.0 0.3 1.0
Oil filter
system (0.1) (0.3) (0.1) (0.3)
4.8 10.0 4.8 10.0
Total
(1.3) (2.7) (1.3) (2.7)
8.0
Powershift transmission
(2.1)
4.2 5.0
Transfer and differential
(1.1) (1.3)
27.8 40.1
Hydraulic system
(7.3) (10.6)
Brake fluid reservoir 130 cc (8 cu. in.)

NOTE: Engine oil refill capacities updated on 3/25/2008.

13-16
 SERVICE DATA

Weight of Major Components (Approximate)

Unit: kg (lb)
Truck Models GP20K GP25K
GP30K GP35K
GP15K GP18K GP20K-HP GP25K-HP
DP30K DP35K
Components DP20K DP25K
810 970 1180 1510 1920 2210
Counterweight
(1790) (2140) (2600) (3330) (4230) (4870)
Engine service weight
120 150
Gasoline models
(260) (330)
180 260
Diesel models
(400) (570)
Power train
Engine, transmission
(excl. reduction gear &
differential)
280 290
Gasoline models
(620) (640)
350 395
Diesel models
(770) (870)
60
Overhead guard
(130)
182 210 220
Rear axle
(402) (464) (486)
Mast 505 680 830 870
(3 m Simplex mast) (1110) (1450) (1830) (1920)
155 220 240 250
Outer mast
(340) (485) (530) (550)
130 170 180 190
Inner mast
(290) (375) (400) (420)
Lift bracket 90 130 160 165
(incl. backrest) (200) (290) (350) (360)
80 100 130 165
Forks (two)
(180) (220) (290) (360)
Lift cylinder and 50 60 85 100
related parts (110) (130) (190) (220)
Mast 550 690 720 870 905
(3.3 m Duplex mast) (1210) (1520) (1585) (1915) (1995)
Mast 720 955 985 1135 1180
(4.8 m Triplex mast) (1585) (2105) (2170) (2500) (2600)

13-17
SERVICE DATA

Special Service Tools

Ref Truck model 1 ton 2 ton 3 ton

Part number Part name
No. Used for class class class

1 91268 - 00100 Wrench Removal and installation of pulley

(To be used with 91268 - 00200)

2 91268 - 00200 Wrench Removal and installation of pulley

3 91268 - 00701 Socket wrench Removal and installation of rear wheel nuts and
counterweight bolts

4 91268 - 05100 Bolt Removal of powershift transmission pump body and manual
transmission shifter case

5 91268 - 05300 Installer Installation of pump body oil seal

6 91268 - 05500 Installer Installation of transmission output shaft oil seal

7 91268 - 13810 Puller Removal of powershift transmission bearing

91268 - 13820 Plate
F1035 - 10020 Bolt
T-24 Puller

8 91268 - 04100 Installer Installation of powershift transmission ball bearings

9 91268 - 07100 Piston tool Removal and installation of powershift transmission clutch
return springs

10 91268 - 00500 Ring puller Removal and installation of powershift transmission snap
ring

11 64309 - 17701 Gauge kit Measurement of powershift transmission hydraulic pressure

12 91268 - 00400 Connector Measurement of powershift transmission hydraulic pressure

(to be used with 64309 - 17701)

13 91268 - 00800 Socket wrench Removal and installation of front wheel hub nuts — —

14 03703 - 59001 Socket wrench Removal and installation of front wheel hub nuts —

15 64309 - 40100 Bevel pinion puller Removal of front wheel hubs — —

64309 - 10601 Puller seat — —
MH061017 Wheel hub puller —

16 91468 - 00300 Installer Installation of front axle wheel bearing inner races —
64309 - 12300 Installer — —

17 91268 - 05400 Installer Installation of carrier cover input flange oil seal

18 91268 - 05600 Installer Installation of bevel pinion taper roller bearing on

differential carrier side

19 91268 - 05700 Installer Installation of bevel pinion taper roller bearing on carrier
cover side

20 91268 - 05800 Installer Installation of bevel pinion taper roller bearing

21 91268 - 05900 Installer Installation of drive gear ball bearing on carrier cover side

13-18
 SERVICE DATA

Ref Truck model 1 ton 2 ton 3 ton

Part number Part name
No. Used for class class class

22 91268 - 01500 Installer Installation of rear axle inner bearing inner race — —

23 64309 - 40400 Installer Installation of rear axle inner bearing inner race —

24 91268 - 01400 Installer Installation of rear axle outer bearing inner race — —

25 91468 - 00400 Installer Installation of rear axle outer bearing outer race —

26 91468 - 00500 Installer Installation of rear axle pivot bushing —

27 64309 - 15411 Spring remover Removal of return spring

28 64309 - 15412 Spring retainer Removal and installation of brake shoes

29 64309 - 15413 Spring hook Installation of return spring

(Tools 27, 28 and 29 are included in 64309 - 15400 tool set.)

30 91268 - 10600 Steering wheel Removal of steering wheel

puller

31 91268 - 03200 Puller Removal of steering column needle roller bearing

32 91268 - 06200 Connector Measurement of power steering relief

pressure (to be used with 64309 - 17701 gauge kit)

33 91268 - 01600 Installer Installation of tilt cylinder tube bushing

34 09305 - 00680 Hook wrench Removal and installation of tilt cylinder guide bushing — —
09305 - 00750 — —
09305 - 00880 — —

35 64309 - 16300 Pipe Connector Measurement of control valve main relief pressure and
F4540 - 06300 overload relief pressure
(to be used with 64309 - 17701 gauge kit)

36 97157 - 00100 Spring installer Install centering spring in steer gear

13-19
SERVICE DATA

1 5 φ58.5 − 00.2 (φ2.30 − 00.008 )

φ120 (φ4.72)
36
39 (1.42)
(1.54) )
9. 84
0(
25

12 (0.47)
130 (5.12)
200434 20 (0.79) 204974

2 φ15 (φ0.59) 6 φ43 − 00.2 (φ1.69 + 00.008 )

φ18 (φ0.71)

φ78 (φ3.07)
Detail of splines

35 φ26 )
9.84
(1.38) 0(
25
12 (0.47)
130 (5.12)
20 (0.79)
200435 204976

3 7 φ11 12
46 (φ0.43) (0.47)
(1.81)
)
63
3 (5.
14
6
) (0.24)
17
(2.
55 ) 25
2 .35 (0.
10 ) 98
(0.08) 3( 54 ) )
26
0 (3. 2.44
250 (9.84) 9 2(
6
21 6 (0.24)
(0.83)
M10 × 1.25
200440 203541

4 8
17
M8 × 1.25
φ33 (φ1.30) (0.67)
C1.5
φ39 (φ1.54)
φ45 (φ1.77)

55 (2.17) 238 (9.37)

250 (9.84)

200465 203542

13-20
 SERVICE DATA

9 13
φ86
(φ3
70 6) .39
7 )
(2. 19
(0.75)

φ105 (φ4.13)

φ125 (φ4.92)
φ84
(φ3
.31
) 23
(0.91)
207171 200441

10 14
90
(3.54)

200438 203546

11 15

M16 × 1.5

)
7. 09
0(
18

φ14
(φ0.55)

203544 203568

12 16 Dimensions in [ ] are for 1 ton class

φ89 (φ3.50) [φ76.3 (φ3.00)]
φ76 (φ2.99) [φ72.3 (φ2.85)]
G(PF)3/8 M14 × 1.5
φ78 (φ3.07)

35 70
φ71.1
(1.38) (2.76)
10 (φ2.80)
(0.39) [145 (5.71)]
203545 200461

13-21
SERVICE DATA

17 φ53 − 00.2 (φ2.09 + 00.008 ) 21

φ45 −− 0.1 − 0.004
0.2 (φ1.77 − 0.008 )

φ60 (φ2.36)
φ88 (φ3.46)

20
(0.79) 130 (5.12)
35
12 (0.47) (1.38)
130 (5.12)
20 (0.79) 204975 204980

18 22
0.2 (φ4.02 − 0.008 )
− 0.004

φ41 (φ1.61)
φ52 (φ2.05)
φ102 −− 0.1

10
80 (3.15)
130 (5.12) (0.39)
10 (0.39)
204977 200447

19 23
0.2 (φ4.33 − 0.008 )
− 0.004

φ102 (φ4.02)

φ70 (φ2.76)
φ57 (φ2.24)
φ110 −− 0.1

20 (0.79) 115 (4.53)

30 (1.18) 130 (5.12)
204978 203547

20 24
+ 0.2 + 0.008
φ55 + 0.1 (φ2.17 + 0.004 ) φ31 (φ1.22)
φ48 (φ1.89)
φ70 (φ2.76)

30
90 (3.54) 130 (5.12) (1.18)
230 (9.06) 40
(1.57)
204979 200446

13-22
 SERVICE DATA

25 29

φ66 (φ2.60)
φ71 (φ2.80)

10
(0.39)

200462 203550

26 30

φ50 (φ1.97) φ32

(φ1.26)
φ55 (φ2.17)

φ35 30 45
45 50 (φ1.38) (1.18) (1.77)
(1.77) (1.97)
200463 200448

27 31

Flame hardened Hv>500,

depth: 2 mm (0.08 in)
203548 203556

28 32

M14 × 1.5 G(PF)3/8

R(PT)1/8

203549 203557

13-23
SERVICE DATA

33

207343

13-24
 SERVICE DATA

Inspection Guide
Check For (item or defect) How
Antifriction These items —
bearings a) Fit on shaft Measure inside diameter with an
indicator hole gauge and shaft outside
diameter with and indicating
micrometer.
b) Fit in housing Measure outside diameter with an
indicating micrometer and housing inside
diameter with an indicator hole gauge.
c) Preload (small initial load applied to absorb As stated in service manual.
initial bearing deformation)
These defects —
a) High running temperature (caused by As shown.
overlubrication)
b) Noise (humming), vibration, or rough running

Radial bearing Thrust bearing

c) Creep (marked of circumferential slip on inner Visually.

ring’s surface in contact with shaft or on outer
rings surface in contact with housing due to
loose fit of bearing)

d) Corrosion Visually.

e) True brinelling (caused by careless installation

or removal)

13-25
SERVICE DATA

Check For (item or defect) How

Antifriction f) False brinelling (caused by constant vibration Visually.
bearings or oscillation of non-rotating bearing through
small arc)

g) Cracked race (caused by forcing bearing on Visually.

oversize shaft or by cooking race when
installing or removing)

h) Broken separator (caused by dirt, metal chips, Visually.

or lack of lubricant)

i) Damaged seal (caused by improper use of Visually.

tools)

j) Spalled race (caused by loose a fit) Visually.

13-26
 SERVICE DATA

Check For (item or defect) How

Antifriction k) Bad discoloration (caused by overheating due Visually.
bearings to poor lubrication)

l) Craters (caused by passage of electric current) Visually.

Bushings or This item — Determine by measuring inside

sleeve bearings Fit on shaft diameter of bushing and outside
diameter of shaft.
These defects —
Nicks, burrs or other flaws on bearing surface Hold bushing toward a light and sight
through bore.
Fasteners These defects —
a) Stripped or otherwise damaged threads Visually.
(bolts, nuts, screws, etc.)
b) Distortion or loss of tension Examine by compressing.
(spring lock washers, snap rings, etc.)
Gears These items —
a) Fit on bearing, bushing, spline or key As stated in service manual
b) Backlash As stated in service manual
These defects —
a) Excessive wear on teeth, thrust faces and end Visually.
faces of hub
b) Scratching wear (caused by large particles than Visually.
those associated with abrasive wear)

13-27
SERVICE DATA

Check For (item or defect) How

Gears c) Abrasive wear (caused by five particles carried Virtually.
in lubricant)

d) Overload wear Virtually.

e) Pitting Virtually.

f) Spalling Virtually.

g) Overload breakage Virtually.

h) Fatigue breakage Virtually.

13-28
 SERVICE DATA

Check For (item or defect) How

Gears i) Corrosive wear Visually.

Keys and Wear on sides making parts no fit tightly Examine by placing.
keyways
Oil seals Damage to lip Visually.
Roller chains a) Wear on pins, bushing, rollers and plates in Visually.
and sprockets each link tending to increase pitch
b) Wear on sprocket teeth

Chain load

Sprocket rotation

NEW OLD

Rubber parts Hardening or softening, swelling, tackiness, Visually.

tearing, and deterioration due to aging

13-29
SERVICE DATA

Check For (item or defect) How

Splines and This item —
serrations Fit
These defects —
a) Nicks, burrs, ships, etc. Visually.
b) Free movement (looseness) of mating splines Examine.
c) Excessive wear polish on sides (sliding fit Visually.
splines)
d) Ridge or edge left between worn and unworn Visually.
areas (sliding fit splines)

Springs These items —

a) Type called for See specification.
b) Squareness Use a square.

c) Free length Examine.

d) Test force
These defects —
a) Excessive clearance space between coils Visually.
(compression springs) in free state
b) Any clearance space between coils (tension
springs) in free state

c) Condition of ends or hooks Visually.

d) Cracks or breakage Visually.

13-30
 TECHNICAL PUBLICATIONS FEEDBACK

Date:

(Please Print)
Dealer Name: Submitted By:
Address: P.O. Box:
City: State:
Zip Code: Country:

The following discrepancy or omission has been discovered in:

❏ Operation & Maintenance Manual ❏ Option Bulletin

❏ Part List/Manual ❏ Special Instructions
❏ Service Manual ❏ Service Data Manual
❏ Electronic Manual ❏ Other
Publication # Engine Model #

Truck model # Issue date #

Truck serial # Page #

(Please Print)
Explanation of discrepancy or omission:

(Please fax or mail completed form to):

Mitsubishi Caterpillar Forklift America Inc. Mitsubishi Caterpillar Forklift Europe B.V.
Attn: Technical Publications Attn: Service Engineering
2121 W. Sam Houston Parkway N. P.O Box 30171
Houston, Texas 77043-2305 1303 AC, Almere, The Netherlands
Fax: 713-365-1616 Fax: 31-36-5494-695

Mitsubishi Caterpillar Forklift Asia Pte. Ltd.

RCB No. 199203169H
Attn: Service Engineering
No. 2 Tuas Avenue 20
Singapore 638818
Republic of Singapore
Fax: 65-6861-9277
Cat Lift Trucks Service Manual GP15K-GP35K, DP20K-DP35K Lift Trucks 99719-82130
 Mitsubishi Caterpillar Forklift America Inc.
2121 W. Sam Houston Parkway N.
Houston, TX 77043-2305

Copyright © 2005 by MCFA. All Rights Reserved.

99719-82130 CATERPILLAR and CAT are registered trademarks of Caterpillar Inc. Printed in the U.S.A.