Technical documentation .

Index

Code word: SONGIFA

Order number: 01 379 Volume: 2
Chapter: 600 - Equipment for maintenance

AAT item Designation Revision Register

600 02 01 Fork lift

 MECHANICAL WORKSHOP
FOR
SONG GIANH CEMENT PLANT
Client

MIDLAND
CONSTRUCTION CORPORATION S. R.

VIETNAM
Contractor

POLYSIUS AG

OPERATION AND MAINTENANCE MANUAL

(MECHANICAL WORKSHOP)

Volume 2 of 5

33704000
POLYSIUS P.O. NO.: EKC-ERNST KOMROWSKI GMBH
MECHANICAL KATTREPEL 2
WORKSHOP EQUiPMENT 20095 HAMBURG
GERMANY
EKC-PROJECT NO.: PoLYS'US
E-MAIL: [email protected]
A 400.3006 SONGlFA PHONE NO.: ++49-40- 32903-05
FAX NO.: ++49-40- 32903-622

ISSUE DATE: DOCUMENT CODE:

REVISION:
APRIL 2004 O EKC-3006-OM-01
 INDEX

ITEM MANUFACTURER l
DESCRlPTlON MODEL
NO. SUPPLlER

VOLUME I OF 5

600-01 Truck Crane Gril 830 Locatelli

VOLUME 2 OF 5

600-02 IForklift IFD 30 T6 TCM

VOLUME 3 OF 5

600-03 Forklift FD 20 T6 TCM

VOLUME 4 OF 5
600-04 Wheel Loader L 16-2 TCM

VOLUME 5 OF 5
600-05 Wheel Loader L 20-2 TCM
lveco Eurocargo
600-06 Flat Body Truck lveco
170 E 21 H, 4x2
 MECHANICAL WOMSHOP
FOR
SONG GIANH CEMENT PLANT
Client

MIDLAND
CONSTRUCTION CORPORATION S. R.

VIETNAM
Contractor

POLYSIUS AG

OPERATION AND MAINTENANCE MANUAL

(MECHANICAL WORKSHOP)

ITEM 1 TAG NO. : 600-02

I DESCRIPTION : FORKLIFT

MODEL : FD30T6

I SUPPLER
: TCM

33704000
POLYSIUS P.O. NO.: EKC-ERNST KOMROWSKI GMBH
MECHANICAL KATTREPEL 2
WORKSHOP EQUIPMENT 20095 HAMBURG
GERMANY
EKC-PROJECT NO.: POLYSIUS PROJECT:
E-MAIL: [email protected]
A 400.3006 SONGIFA PHONE NO.: ++49-40- 32903-05
FAX NO.: ++49-40- 32903-622

ISSUE DATE: REVISION: DOCUMENT CODE:

APRIL 2004 0
 SONG GlANH CEMENT PLANT 1 VIETNAM
WORKSHOP EQUIPMENT
EKC-PROJECT NO. 3006

ITEM NO. 600-02

1 FORK LIFT WlTH 3 TONS LIFTING CAPACITY

MODEL: FD 30 T6.

TECHNICAL DATA:
Lifting height 3000 mm, 2 stage VM 300 Mast
f' Rated capacity 3000 kg
Load centre 500 mm
Fork length 1.070 mm
Engine Diesel, lsuzu C240
4 cylinders, 52,2HP, 2369 cc.
Tyres Pneumatic tires

ACCESSORIES INCLUDED:
00 Hourmeter
00 Water temperature meter
00 Fuel meter
U0 Engine oil pressure warning indicator
00 Charge indicator

M:\Jurkschat\3006Vietnarn\Spec\Contract Spec\600-02 Fork liit 3 tonsTCM.doc

 SONG GlANH CEMENT PLANT EKC- PROJECT NO. 3006
WORKSHOP /VIETNAM

ATTACHMENT - 1

INSPECTION RECORD
/"'

ITEM 60042
P
-'
DESCFWTION : FORK.I;IFT

MODEL FD 30 T6 , ,#*-

.J
.F'-
MANUFACTURER : TCM

QUANTITY one

r
ITEMS INSPECTED RESULTS

(1) QUANTrrY CHECK

Main Body Good

Accessories Good

Others (LONG FORK Good

(2) VISUAL CHECK

Surface and Welding Surface Good

Painting and Colour (manufacturer's standard) Good

Bolts and screws tightening Good

Name plates ( main body ) Good

Name plates (engine, alternator, transmission, etc.) Good

(3) DIMENSIONAL CHECK

Principal dimensions ( complete attached
DIMENSIONAL CHECK RECORD ) See attachment-2

Location of utility supply inlets / outlets Shiga plant

Reviewed by : Place : SHIGA PLANT

Signature : Date : 14. Feb. 2004

SONG GlANH CEMENT PLANT EKC- PROJECT NO. 3006
WORKSHOP / VIETNAM

ATTACHMENT 2 -
DIMENSIONAL CHECK RECORD

ITEM 600-02

DESCRPTION : FORK LIFT

MODEL FD 30 T6

MANUFACTURER : TCM

QUANTITY one

TEST PART NOMINAL MEASURED TEST

DIMENSION DIMENSION RESULT
LIFTING HEIGHT, 2 stage 3000 mm 303Omm Good
VM 300 Mast
LIFTING WEIGHT 3000 kg 3000 kg Good
OVERALL HEIGHT FOFX 4250 mm 4265mm Good
RAISED
LENGTH T 0 FORK FACE 2660 mm 2669mm Good
TOTAL LENGTH WITH 3730 mm 3739mm Good
FON
TOTAL WIDTH 1225 mm 1225mm Good
WHEEL BASE 1700 mm 1698mm Good

REMARK: NOMINAL DIMENSIONS PLEASE SEE LEAFLET.

MEASURING INSTRUMENTS SHOULD BE ACCORDING T 0 DIN 1 ISO
REQUIREMENTS.

Reviewed by : S. N O Z M Place : SHIGA PLANT

Date : 14. Feb. 2004

SONG GlANH CEMENT PLANT EKC- PROJECT NO. 3006
WORKSHOP /VIETNAM

ATTACHMENT -3

FUNCTION TEST RECORD

ITEM 600-02

DESClUPTION : FORK LIFT

MODEL FD 30 T6

MANUFACTURER : TCM

QUANTITY one

No. Test Item Type of Test Result

Foilowing functions to be checked and recorded:

1 Oil Filling / Proper oil filling of engineers, differential Good

Lubricants transmission hydraulic, brake fluid and general
lubrication
2 Hydraulic Tank Check the tank of the filling, damage or leak Good
Capacity: litres
3 Engine Engine starting Good
Engine idle speed
Engine governed speed
Cooling system operation
Exhaust system
4 Brakes Service brake operation Good
Park brake operation
5 Gear Box & Gear shifting Good
Steering Forward 1reverse shifting
Steering operation to full extend
6 Electric and Operational lights Good
Instruments Instrumentation, incl. lights, indicator lamps

7 Alarm Set Check the acoustical device operation Good

8 Pump for Check the pump operation Good

hydraulic Check the lowhigh pressure operation
system of the
crane
9 Gauges for Check the pump operation Good
coolant
temperature,
fuel
SONG GlANH CEMENT PLANT EKC- PROJECT NO. 3006
WORKSHOP 1 VIETNAM

ATTACHMENT -4

No. Test Item Type of Test Result

Following functions to be checked and recorded:

10 Travel Controls Check the following controls: Good

Front steering axle
High-low range speeds
Transmission gear selection
Forward-reverse shift
Parking brakes controls
11 Valves, Fitting Check the connection and centralised system Good
and Coupling for hydraulic pressure controls
12 Max. Travelling Good
speed Max.speed 19.3 km/h
Without Load
13 Max. Travelling Good
speed
Max. speed 17.7 km/h
With max.
Load
Lifting Check the function of lifting up to 3,O m Good
l4 Capacity

Testing the Lifting with Load according to manufacturer9stest sheet

Description 1. Test 2. Test 3. Test 4. Test
b
Lifting Height in m:

Load in kg:

Test Result:

Place: SHIGA PLANT

Date : 14. Feb. 2004

 @Maximumtorque :
~~~~#~m(d~.~kais~m~/i8~~~8"p.m.
ODisplacement :
@lncreasedtorque by 10% 58%less : brake pedal vibratlon
at idling-l000r.p.m. @Wide flat floor for driver cornfort
@Foot-rest reduce fatigue
@Combisaedtype switch lever(1ightingand turn-signal)
Turn-signalwith self-cancelling rnechanisrn
@Widerview by 15% @Electric shiR control for ease of operation
PaEDDeluxe operator seat with safety belt OSide view mirrors
@Durableoverkead guard
OShock less liR-cylinder
@Tilt cylinder Cover
@Parking brake lever
with safety lock
STANDARD SPEClFlCATlONS
1 Manufacturer TCM
Power shift TIM FG30T6
Model
8 Manual shifi TIM FG3OC6
3 3 LoadCapacity kg 3000

1
U 6
4
5

7
LoadCenter
Power Type
ControlType
TireType I Front / Rear
mm 500
Gasoline
Sit Down Rider Type
Pneumatic
-
\* T-

8 Wheels (X=driven) I Front/ Rear 2x12

9 Maximum Fork Height mm 3000
10 Free Lift mm 135
13 ForkSize 1 LxWxT mm 1070x125x45''
14 Tilt Angle I Fwd/ Bwd deg 6112
15 Length to Fork Face mm 2660
, 16 Overall Width mm 1225
.-
0 17
In
Mast Height Fork Lowered mm 2075
C 18 Overall Height Fork Raised mm 4250
19 Overhead Ouard Height mm 2090 '
21 Turning Radius (Outside) mm 2400
-
Fork Overhang
22 (Centerlineof front axle to front face of forks) mm 480

Minimum Aisle9O"stack
23 (Add load length and clearance) mm 2880
Travel Max. with load kmin 18.0
24 '----
I

(FwdiRvs.) without load kmin 19.5 6l

with load mds 450
- L-.--

25 Speeds Lifting
without load mds 500
8- with load mmis
8 26 Lowenng
without load mds
450
450

'
4?
28
Power shii T/M wtthiwiihout load
Manual shift TiM withhithout load
Power shifl T/M wthlwthout load
kN
kN
YO
13.2 / 9.8
10.819.8
Gradeability at 17/20
29 1.6km/h (lmph)*
Manualshii TiM withlwithout load % 14/20
30 Max. Gradeability** Power shii TM withiwithout load OO
/ 19/20
32 Total Weight kg 4200
Em 33 Fmnt &I 6400
.- - with load
Rear kg 800
Weight Distribution
Front kg 1670 -
34 without load
Rear kg 2530
35 Number Front / Rear 212
36 Tires Front 28x9-15-12PR
Size
37 Rear 6.50-10-10PR
38 Wheelbase mm
.-
U>
U>
Front mm
1700

m 39 Tread Rear mm
1000
i
-
6 970 P

40 at lowest point (Mast) mm 140

41 Ground clearance Frame mm 140
42
- Service Hydraulic-Foot pedal
Brake
43 Parking Mechanical-Hand lever
45 Battery Voltage ICapacity(5hr) VIAH 12/30
49 Model NISSAN H20
.-0-50 Rated Output / r.p.m.
32.4kW/2300r.p.m.:44PS/23OOr.p.m.
$
- Interna1 (SAE GROSS 46HPl2300r.p.m.)
'E Maximum Toque / r.p.m. 142.1N~mll600r.p.m.
51 Combustion
- Engine (SAE GROSS)
pm Number of Cylinders
14.5kgf.m/1600r.p.m.
4 I
Displacement Iit
.-E0)52 1.982
Fuel Tank Capacity litt 70
5 Power shil TIM 1-1 Power shift TIM
I
55 Transmission Number of Speed Fwd 1 Rvs-Type ,
Manualsh~HTIM 2-2 Manual shift TIM I
57 Operating Pressure For Attachment Mpa(kg/cm2) 17.7(180)
*Power shift TIM "Computed Values 1)ln European and Scandinavian Export Twcks 11OOmm fork length
I
2)ln Scandinavian Export Tmcks 2150mm

I
 TCM
FD30T6
FD30C6
3000
4
- 500
Diesel
Sit Down Rider Type
Pneumatic
2x12
3000
135
107OX125X45"
6112
2660
1225
LOAD CENTER(mm)
2075
I I
4250
2090 Note:
Caoacities shown are c o r n ~ ~ t e
with
d uorioht in vertical position. Load Centers are dete-
2400 rrnhed frorn front face of forks. ~ a ~ a c i i i e s a based
re on a 1OOOrnrn cube load con-
- figuration with the center of gravity (C.G.) at the true center of the cube, and standard forks.
Truck capacities with upright in forward tilt position will be iess. Long forks, and unusualiy
480 .
wide or tall ioads rnav also reduce caoacitv.
information on irreguiar loads.
.
, Contact TCM representative for caoacitv.
Specific capacities are shown on truck narneplates.
2880
TCM products and specifications are subject to irnprovement and change without notice.
. ,. 18.0
TCM industriai Trucks are equipped with certain safety devices as standard equiprnent.
TCM will not assurne any liabiiity for injuries or damage arising frorn or caused by the
4 - 19.5 rernoval of any safety devices from any of its products.

450 NOTES:
470 Meets following rnajor Standards and code
ISO 1074 Counter Balanced Lift Trucks,
450 Stability & Safety Test (Int'l) JIS D6001industrial Lift ~ r u c k s(Japan) ANS1 B56.1 Low &
High Lift Trucks (U.S.A)
450 Overhead guard meets ISO 6055, JIS 6021
14.719.8 In conforrnity with provision of the Machinery Directive 98/37/EC, as arnended, and with
national irnplernenting legisiation.
11.819.8
18/20
15120
19/20
4310
6430
880
- 1690
2620
212
28x9-15-12PR
6.50-10-10PR
1700

- I
1000
970
140
140
Hydrauiic-Foot pedal
Mechanical-Hand lever
12/55
ISUZU C240
38.3kWl2500r.p.m.:52PS/2500r.p.m.
(SAE GROSS 52.2HPl2500r.p.m.)
153.9N.m/1800r.p.m.
15.7kgf. ml1800r.p.m.
4
2.369
-
70
1-1 Power shift TIM
2-2 Manual shift TIM
17.7(180)
kTa
STANDARD EQUIPMENT
FORK LIFT TRUCK
OPTIONAL LOADING OPTIONAL EQUIPMENT AND
AND ACCESSORIES AiTACHMENT ACCESSORIES
[Equipment] [Equipment]
Asbestos-free brake Bale clamp Auxiliary hydraulic valve modules
Cvclone air cleaner Block clamp Central greasing System
Cilinder type bonnet stay with locking function Crane arm @Colortire (white, green)
Deluxe Suspension seat with safety belt Fork clamp Cooler for steel cabin
Dipstick for hydraulic oil Fork extension sleeves Diesel particulatefilter exhaust system 0
Dipstick for tynsmisson oil (power shift TIM) Fork positioner hydraulic, manual type) Double element air cleaner 0
Drawbar device High, wide typeload backrest Exhaust purify 3-way catalystic muffler 0
Durable overhead guard Hinged forks, bucket Exhaust purify catalystic muffler
Engine after glow system D Load push-pul1 Fishery industry package
En ine auto glow system D Load stabilizer Front dual drive wheels
Fuhransistorized i n i t i o n a l ) 0 Long forks Full hydrostatic power steering
Idle-u device (IUDQ 0 Multi purpose clamp Full-open cabin
ITA c k s s Jii carriage Ram Heater
. .- .
. .- .
@ J-lug Ion life tires Rotating bale clamp Hiah orofile overhead auard (2150mm)
Lift circug cut-off valve Rotating forks (hook-on, integraltype) Loh ljrofile overhead fuard ('1995mmj
Load backrest Rotating Paper roll clamp LPG exclusive or dual fuel oackaae G
Load check valve Side shifi hook-on, integral type) Oil clutch (manual shift TIM)
Overhead air intake system Sieeve-in Look @ Overhead exhaust svstem
Power steering(Ful1hydrostatic power steering)% Wide type fork carriage Plate fin radiator *
Radiator rese~oir. Wide view full free 2-stage VFM mast Power clutch (manual shift TIM)
Return hydraulic filter Wide view full free %tage LFHkI) mast Pre-air cleaner
Suction hydraulic filter
Tilt lock valve
Water separator 0
Radiator dust,screen (fine, medium mesh
Smoke reducition/soark arrester muffler
Solid tires (Unique cushion tires)
&
V

Wide view mast Steel cabin

2-s ool control valve with pressure relief valve Steering post +70mm up
10?0mm forksli Windshieid with wiper
[Controls] [Accessories]
Electric shift control leverloower shift TIM) Auxiliary seat adjuster
Lift and tilt levers Custom coloring paint
Fire extin uisher
(
Parking brake lever with safety lock
Tilt adjustabie steering post Rear woring light
Turn signal lights with self-cancelling mechanism Rotating warning light
Rust-proof painting
[Accessories] Short-sticks electric lift/tilt control fingertip control
Ö Back-up buzzer - ((power shift TIM]
Back-up lights Steel net (for overhead guard)
Deluxe floor mat Steering cylinder boot
Electric horn Tilt cylinder boots
Glove compartment1Pen holder [Instruments and Switch]
Haloaen head liahts
Hand" rip " Ammeter
0pera?or tool kit O.K. monitor (fuel level, batte electrolyte level,
Overhead guard canvas coolant level, parkingTrake, air-cleaner)
Rear combination lights Speedometer
Side view mirrors Torque convertor oil pressure gauge
Torque convertor oil temperature gauge
[Instruments and Switch]
Charge indicator
Engine oil pressure warning indicator
Fuel meter
Glow indicator 0
8:
D : Diesel engine models only
Gasoline
' engine models only

Hourmeter
I nition ke engine stop 0 Other on request
Jeutral sarety switch
Water separator indicator 0
Water temperature meter

Diesel engine models only

Gasoline engine models only
% : In European, Oceanic and
Scandinavian Export Trucks
(Fuil hydrostatic power steering)
1)ln European and Scandinavian
Export Trucks(l100mm forks)

Features and equipment may

vary depending on market.

Our production site in Japan (Shiga Plant) is certified ISO 9001 & ISO 14001.

i
 Wide View Mast VM

NOTE: 11. For height without backrest: -580mm.

121 For frea iih witho~tOacnreSI' +5BOmm.
Welghi without backrest. -30kg

Wide View Full-Free 3-Staae Mast VFHM

Weight wlihout backrast:-30kg

NOTE: Rated Capaciiy wiih ('): Shows capaciiy with front duai tires.
Service Weight with Dual iires: +150kg with spacial dual tires (28x9-15-12PR"J").
t35kg with duai tires (6.W-15-10 PWJ").
Service Weight of VMNFM550-600 and of VFHM650-700 represents the weight of vahicia aquipped with "special dual tires".
Loading Speed with VFMNFHM Mast: Lifting spaed with VFM FG400mmiswith load. 450mmIs without ioad.
FD 4OOmm/s with load. 420mmls wiihout load.
with VFHM FG4lOmmh with iaad. 470mm/s without load.
FD 420mm/s wlih ioad. 440mmls without load.
Lowenng spaed wiih VFMNFHM 400mmk with ioad.300mmk without load.
Overall Vahicie Lengih with VFHM Mast: +15mm ionger than that of STD model with VM mast.
 I - Ire)
STANDARD DIMENSIONS (Front Single
Model FGiD30T6 C6
mm
0 Overall height, Fork raised (with backrest) 4250 ( '1

8 Max. fork height 3000 1

@Overall helght, Fork lowered (upright) 2075
@Backrest height (from upper face of forks) 1220
B) Free lift 135
8 Fork thlckness 45
0 Min. under-clearance (bottom of mast) 140
@Overall length (with fork) 3730
@Overall length (without forks) 2660
@Fork length 1070"
(D Fork overhang 480
QWheel base 1700
(D Rear overhang 480
0 Drawbar height 445 .
@O
i verhead guard clearance (from face of seat) 1 1005"
@Overall height (overhead guard) 2090"
@Overall width 1225
-
'
@I Lateral fork adjustment (outside of fork) 250 1090
O Tread (front) 1000 /"'*

@ Tread (rear) 970 ,

1 8 Fork width I 125 I
1 Inside turnino radiuc 1 1
I @Outside turning radius 1 2400 I
8 Min. intersecting aisle 21 10
gTilting angles (forward-backward) 6'-12'
1)ln European and Scandinavian Export Trucks : 1100mm
2)ln Scandinavian Export Trucks : @ 1065mm clearance.
@ 21 50mm height overhead guard.

DUAL DRIVE TlRE DIMENSIONS

ModeJ FGi030T6. C6
~ i i Sze
e ,
6.00- 28%9- '
1k1,~10PR~15i12PR
. rnm ,'mm
g Overall width 1520 1750
@ Tread (front) 1 1170 1 1260
I Q3 Inside turning radius 1I 100 1I 100 1
Q Outside turning radius 1 2430 1 2500,
@ Min. intersecting aisle 1 2210 1 229(

Manufactured by I Distributed by

1-15-5, Nishi-shimbashi Minato-ku,

Tokyo,105-0003,Japan
Cataiog No. FMOG-FGIDBOEB
FAX: JAPAN 3-3591-8152 Printed in Japan T-031005
 FORKLIFT TRUCK
Gas. & LPG Powered Diesel Powered
F G lOc19 FG15cs~ F D lOc19 FDI5c9~
FGIOTI~ FG15T ~ H FDIOTIS F D ~ ~ T ~ H
FG15c19 FG18cs~ FDI5~19 FD18cs~
FG15~49 FG18T ~ H FDI 5~19 FDI8 ~ 9 ~
FGI8c19 FG20cs~ FD18c19 Fü20c6~
FG18~is FG20 T ~ H FDI8~19 FD~OT~H
FG20c6 FG25c6~ FD20c6 Fü25c6~
FG20 ~6 FG25T6H FD20~6 Fü25~6~
FG25c6 FG30cs~ FD25cs FD30c6~
FG25~6 FG30 T6H FD25~6 FD30T ~ H
FG30c6 FD30cs
FG30 T6 FD30~6

a It is the responsibility of the Operator and Supervisor to read and understand this manual.
Protect the earth and be kind to your lift truck.

TCM CORPORATION
P!.

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CONTENTS

FOR SUPERVISORS ...................................................... 1 . 1

PROPER AND IMPROPER USES ............................ 1 . 2
PLANNING AND WORKING AREA ........................... 1. 3
TRAVELlNG ON PUBLIC ROADS ............................ 1 . 6
OPERATORS ........................................................... I . 7
TYPES OF VEHICLES AND LOADS ........................ 1. 9
INSPECTION .............................................................. 1-1 2
INSPECTIONITRANSPORTING THE LIFT
TRUCK ........................................................................ 1-1 3
HOW THE LIFT TRUCK WORKS .................................. 1-1 5
TRAVELING .................................................................... 1-1 8
LOAD HANDLING ........................................................ 1 -23
PARKING...................................................................... 1-27
INSPECTION AND SERVICE ........................................ 1-28
CAUTION PLATES ......................................................... 1-34
 --
P

'.-
-
- I L-
-
The following symbols, found throughout this manual, alert you FOR SUPERVISORS
to potentially dangerous conditions to the owner and the
operator. Become completely familiar with the truck before Lift truck accidents cause dozens or hundreds of deaths every
proceeding with operating, checking and servicing the truck. year, and even greater numbers of personal injuries.

This manual and the decals affixed to the truck use the following TCM has steadily improved the design and fabrication of our
safety alert indications. lift trucks so they may be used more safely and efficiently, but
many accidents still occur due to improper use. Accidents are
SIGNAL WORD CLASSIFICATION often the result of more than just "bad driving". The use of

a DANGER
Failure to follow the instructions in the
message will likely cause a serious accident
or death.
inappropriate types of equipment, the selection of inappropriate
attachments or accessories, in appropriate operating
environments, careless designation of operators, and failure
A WARNlNG Failure to follow the instructions in the
message might cause a serious accident or
death.
to properly train the operator are other common causes of
accidents.

a CAUTION
Failure to follow the instructions in the
message may cause personal injury or
damage to the truck or other property.
This chapter Covers the methods of accident prevention which
are primarily the responsibility of supervisory personnel.
The information will help to proiong the
NOTE service life of the truck. The message is not
directly related to accident prevention. Pages 1-2 through 1-14 contain instructions which should
be enforced by the personnel supervising the operation of
Right the lift truck. Please make Sure the operators also read these
pages.
t Page 1-15 and the following pages contain specific
precautions directly related to the operation of the lift truck.
Forward C + Backward
+
Left

The diagram above indicates the meanings of the terms

"forward", "backward", "right" and "left" used in this manual.
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 FOR SUPERVISOPS ~T~X~Ü~NG
AND WORKING MEA I
H KEEP PEOPLE OUT OFTHE OPERATING AREA IKEEP THE GROUND LEVEL AND DRY

Closed to Pedestrians

No other personnel should be allowed in areas where the lift

truck is used. Be sure that all areas where the lift truck travels are level and
Where other people must be present, post a guide whose job regular. Clear away pools of oil or water.
is to make Sure people stay clear of moving vehicles.
PROVIDE ADEQUATE LlGHTlNG
IKEEP UNAUTHORIZED VEHICLES OUT

Safe operation requires well-lit traveling routes, so pedestrians

Ut~authorizedvehicles t ~ ~ ube
s t kept out of the load handling and obstacles can be easily Seen. Use headlights, taillights,
areas. Post signs or give signals as required. helmet lamps or other lights as appropriate.
pu,w S U ~ t K V l ~ u K 3
WPLnNNUUG AND WORKING AREA I
L
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-
4

IASSIGN TRAFFIC GUIDES T 0 CONGESTED AREAS H PROVIDE AND MAlNTAlN EMERGENCY EQUIPMENT

Post a traffic guide in confined or congested areas where other Fire extinguishers and first aid kits should be provided and
people or vehicles may pass. All personnel must obey the maintained for use in case of a fire or accident. All personnel
guide's signals. should understand the location and use of emergency equipment.

B KNOW W H 0 T 0 CALL IN AN EMERGENCY H SAFETY MEASURES FOR DANGER SPOTS

3.Ambulance

Keep information on hand to allow immediate calls for help in Post warning signs or take other appropriate measures to
case of a fire, accident or other emergency. ensure that lift truck Operators keep away from danger spots
as they travel.
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tun SUrLKViULJKU ( OPERMORS I
- -
L' Li z k 2 /I

IWEAR PROTECTIVE GEAR

Always wear proper work clothes for driving. Work clothes

should be designed to prevent any part from accidentally
catching on knobs or other parts of the truck or equipment.
For example, shirts and trousers should have tight cuffs.
Always wear a hard hat and safety shoes.
Wear other protective gear as appropriate to the conditions
of the work site, i.e., goggles or gloves.
-I
I .
- / : FOR
. SUPERVISORS
'.
-
II TRAIN YOUR STAFF T 0 STACK SAFELY II TlRED OR UNWELL? SEND THEM HOME!

"Stacking" means piling palleted load or materials directly on

top of each other, without using racks or shelves to separate
them. If the stacking werk is not done proper'y' the loadsmay
D0 not let people take chances. An Operator who is o v e ~ o r k e d
'lip Or fall, endangering the Operator as weil as any Other
or fatigued, an Operator who is feeling unwell, or an Operator
personnel in the area.
who is intoxicated must not be allowed in the driver's seat.
Safety classes should be held to train all operators in the proper
methods of stacking and unstacking loads.
(Your TCM dealer can provide information about training for
safe stacking.)
Be Sure the type and capacity of the lift truck is suitable for the Popular Attachment Examples
work environment.

Check Point Choice

@
: RollI
Clamp
Capacity Load capacities range from 0.5 to 42 tons. Pay (For paper roll or drum
particular attention to the load Center. handling)
(TCM Lift Truck Capacities: 0.5, 0.7, 0.9, 1, 1.35,
1.5, 2, 2.25, 2.5, 2.75, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 10,
@ : Rotating Fork
10.5, 11.5, 12, 13.5, 15, 18,20,22,23,24,25,30, (For damping work or
37, or 42 tons.) charging work)
@ : Hinged Fork
Power Source Gasoline, natural gas, diesel, and battery- powered (for lumber handling)
models are available. Fuel costs and exhaust @ : Side Shift
composition will vary. (For precise stacking
in containers or other
Balance On counterbalanced models, the counterweight narrow spaces)
at the rear makes the vehicle longer than reach @ : Crane Arm
trucks. A reach truck performs loading and (For slinging work)
unloading by extending the front part of the mast
outward, which gives it the advantage of
compactness.

Tires For indoor use, there are models with solid tires (best
for reach trucks) and cushion tires (engine type or
batteiy type). Both are compact.
For outdoor use, pneumatic tires work well. Solid
cushion tires, with the Same dimensions as
pneumatic tires, may be the best choice in cases
where the load materials or surface conditions could
puncture pneumatic tires.

FlammableMaterials For handling flammable materials such as

petrochemicals, a combustion engine is too
dangerous. An electric vehicle with explosion-proof
or safety-reinforced construction is required. (A
battery power source always offers better protection
against fire than a combustion engine.) Avoid hoisting a load with wire rope hung from the forks
or an attachment, or avoid lifting a freight container with
forks, because there is danger of the truck tipping. If
necessary, have a qualified Operator use a hook or crane
I arm attachment. I
 - \ FOR SUPERVISORS.~YPES
OF VEHICLES AND LOADS (

INO OPERATION WITHOUT LIGHTS, OVERHEAD IKEEP DECALS LEGIBLE

GUARD, OR BACKREST

IIII
I O~S.8.WdD'amUll.
cIs-r~ULr<CeL~.
;CIU8CI.L

I I ~ ~ ~ c ~ e w ~ s e ~ m i i r < e e i ~ .
z~
IIII The decals on the truck describe

. safetv ~recautionsand o ~ e r a t i n a
I ~ ~ D D M R U ~ W L E U .
~.UCllsh5eO~'r<~CL~.
n.

II II
I
1 3C
.mU . . Oan.
M ~ . in
m m
. onr am us ~u mm *~r ~ n~ a) ama * ~ ~ a

. instructions. Replace any damaged

The lift truck cannot be used if the headlights, taillights, i U L C C L C L i . <S..C...<)
I4 W I + I C W L I 1 V R N Y
.C. ¶lilMmnml.v.
*OIllaXI
or missing decals. Check that the
overhead guard, backrest, horn or turn signals have been decals are legible during regular
a.m u e . D > + - m . s c ~ r < a c r b
removed. Any parts that have been temporarily removed for inspections.
some reason must be reattached immediately.
W D 0 NOT RELY ON THE OVERHEAD GUARD
W OBTAIN APPROVAL FOR ANY MODlFlCATlON

without approval.

The overhead guard is a protective device that will moderate

Modifications or additions that affect the capacity, construction
the impact of an object falling from overhead, but it cannot
Or strength Of the truck must not be performed by the
withstand every impact. If a heavy object seems likely to fall
without the manufacturer's prior permission. For example, don't
on the truck, make every effort to prevent it from doing so.
add a counterweight.
T V n 3 U T L n V IJVB i u I I r c e vr V L I IIWLLQ
I AIIW Lwnww I
F

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-
-2

HAVE A GOOD VENTILATION STACK LOADS SECURELY

When the engine is run indoors such as in an enclosed When stacking loads, place them in a stable manner that they
warehouse, have a fresh-air ventilation. Exhaust fumes can will not easily come apart, and be Sure the weight is evenly
cause chemical poisoning, and in the worst case exhaust fumes distributed. Secure the top layer with a cord wrapped like a
can kill. When warming up or operating the truck indoors, Open headband or in a similar fashion.
the windows and doors or use a fan to make Sure there is a
good ventilation. KNOW THE WITHSTAND LOAD OF YOUR FLOOR

IUSE STURDY PALLET MATERIALS

The lift truck is heavier than it appears. For example, a 2-ton

truck weighs almost 3.5 tons even when empty. Furthermore,
Pallets and skids must be strong enough to withstand the heavy when loaded, 80 to 90% of the total weight is concentrated on
weights of loading and unloading. Remove or repair any the front wheels. Check the strength of your floors and
damaged pallet. roadways, and if necessary reinforce them.
 -
FOR SUPERVISORS IINSPECTION
I
-I
".
'~

IALWAYS INSPECT BEFORE OPERATING REPLACE SAFETY PARTS REGULARLY

Recommendedreplace-
Name of safety parts
ment interval (year)
1 Master cylinder and wheel cylinder cups
1
and dust seals
2 Power steering hose 2
3 Reserve tank tubing 2-4
4 Fuel hose 2-4
5 Torque converter rubber hose 2
6 Rubber parts inside power steering unit 2
7 Lift chain 2-4
8 Load handling means hoses 1-2
The operator should always inspect the truck before each use
to verify that all essential safety features are working. Any Certain critical parts must be replaced at regular intervals.
abnormality is to be reported to the supervisor, who is Since it is difficult to detect wear on the above parts by visual
responsible for correcting it. inspection, they must be replaced at the intervals specified,
because a failure would result in a falling load or runaway truck.
PERlODlC INSPECTIONS ARE MANDATORY
Monthly and annual inspections must be performed thoroughly, NEVER USE AN UN-MAINTAINED TRUCK
and any abnormality promptly repaired. Only a certified expert
who has the advanced skills and equipment is allowed to
conduct inspections. Preserve the inspection logs for at least
three years.

A truck that has not passed an inspection must never be

operated. Hang a sign on the truck and remove the ignition
switch, to make sure no one uses it. Then report the problem
to the supervisor and wait for the repair to be completed.
 DESIGNATE A REPAIR AND ASSEMBLY
SUPERVISOR

Use a level, hard road surface when loading the truck onto or
R e ~ a i r sarid the mounting arid dismounting of attachments unloading from a trailer and when unloading it. Be certain that
must be ~ e r f o r m e dunder the direction of a designated the ramps have sufficient length and width as well as strength.
supervisor. ~ h body e and major parts of the lift truck are quite Do not load or unload the truck when it is raining, unless the
heavy and under very high pressure. Repair or assembly work are fitted with an anti-slipping surfacec.
undertaken without careful and thorough preparation can lead ~tis safest 10 use a self-loading trailer truck equipped with a
to serious injury. jack and winch. For loading, tilt the pallet with the jack, attach
the winch to the towing pin of the lift truck, and pul1 it up. The
operator must not ride on the lift truck during loading or
unloading.
Y X FOR F!JPERVlSORS
$
II N S P t E C T I C ~ N I U
1' -1
C K

USE OPTIONAL "LIFTING EYES" FOR LIFTING

YOUR LIFT TRUCK

Never hoist your lift truck at its overhead guard or Observe the following conditions when lifting the lift
counterweight; otherwise there is a danger of the truck truck:
falling. Use optional "Lifting Eyes".
If hoisting the lift truck is necessary for any reason, Use ropes strong enough to withstand the weight of
use optional "Lifting Eyes." the truck.
Do not use any wire rope which is kinked, deformed
or f rayed.
Lifting the truck should be performed only by qualified
personnel.
Do not enter under a lifted truck.
II V Y W I I IL LII I B B E U V B \ W W v l B l W W m

iKEEPING THE TRUCK BALANCED

center of gravity
Truck's center

Truck's center of

Truck's center of gravit

Lift trucks are equipped with load handling means including a with Standard mast
raised

I
mast and forks at its front part. The front wheels of the truck Lift truck viewed from front

work as a fulcrum to balance the center of gravity of the truck

and the center of gravity of the load. The relationship between
the locations of those two centers of gravity is vitally important The stability of the Iift truck is determined by the overall center
for safety. of gravity, which is the product of the centers of gravity of the
truck and the load. When the truck is empty, this point is the
IKNOW THE CENTER OF GRAVITY OFYOUR LOAD Same as the center of gravity for the truck, and when it is loaded
it shifts according to the center of gravity of the load. Since
the center of gravity of the load changes whenever the mast is
tilted forward or backward or the fork is raised or lowered, the
overall center of gravity also changes. The center of gravity is
also governed by the following factors:

Size, weight and shape * Acceleration, deceleration

of the load and turning
Unloading height Surface condition and
Tilt angle of the fork gradient of the road
Materials of various shapes such as boxes or flat or cylindrical Tire material e Type of attachment
items may be loaded on the lift truck. In order to accurately judge
the stability of the truck, it is vitally important for the operator to
know the location of the center of gravity for each type of load.
 / , T HOWE. LIFT TRUCK WORKS? 1

W OUTSIDE THE TRIANGLE OF BALANCE, THE RATED LOAD (LOAD WEIGHT AND LOAD
TRUCK TlPS CENTER)
For a lift truck to remain stable, the overall center of gravity The load center is the distance from the front face of the forks
must be inside the triangle formed by the contact points of the to the center of gravity of the load. The rated load is the
left and right front tires and the center point between the maximum weight allowable with the nominal load center.
steering wheels. The triangle defines the area of stability for The Load Chart, showing the relationship between the load
the center of gravity. center and the rated load, is attached to the truck as a decal.
If the overall center of gravity moves further forward than the The rated load decreases as the load center moves toward
front wheels, the truck will tip forward with the front wheels as the tip of the forks, and as the overall center of gravity moves
the fulcrum. If the overall center of gravity moves outside the forward.
triangle to the right or the left, the truck will fall over in that
direction.

HOW T 0 READ THE LOAD CHART 1

The higher the load is raised, and the further forward
from the front wheels the load is moved, the more the
weight of the load increases.
If the center of gravity
Point B (Slightly heavier loads can be carried with dual tires)
W1 rnoves outward
past the axis of lateral

( A s t h e c e n t e r of
gravity Comes closer
to the rear axle, the
Front space between the
wheels centerline of the truck
and the axis of lateral
stability narrows, and
Lift truck Viewed the truck will roll more
from Above easily.
nuvv I nc LIT I I nubn vvt~nna:
-
-
-
L

IACCELERATING, DECELERATING AND

TURNING
The principle of inertia provides that a stationary object will
remain stationary as long as there is no external force acting
on it, and that a moving object will continue moving at a
constant speed as long as there is no external force acting on
it.
Due to inertia, when the lift truck starts to move there is a
momentary backward force, and when it stops there is a
momentary forward force. As a result, if the brakes are applied
suddenly, there is a very strong hazard that the forward force
will become strong enough for the truck to tip forward.
Likewise, when the truck is turning there is a centrifugal force
that pulls it outward from the turning center. This force can
cause the truck to fall sideways. Since the Zone of lateral
stability is especially narrow, it is necessary to slow down
substantially when turning in order to prevent the truck from
tipping.
When the load is elevated the overall center of gravity is raised,
increasing the danger of the truck tipping over to the front or
side.
A Read manual and decals A Keep the truck's center of gravity low during traveling
(when loaded in particular)
When traveling (when loaded in particular), keep the forks 20
cm above the floor or ground and tilted back, so as to lower
the truck's center of gravity as far as possible.

A Do not jerk the forks (lift, down, and tilt) when loaded
Read the Operation & Maintenance manual and caution plates
on the truck, and become familiar with your truck and operating
procedures. Remember that individual lift trucks might be
different in design and construction from one another. Observe
the caution decals on the truck. Keep this Operation and
Maintenance manual on the truck as a ready reference for
anyone who may drive or service it.
A When starting the engine
When starting the engine, make Sure to:
Apply the parking brake securely.
Place the direction shift lever and speed range shift lever (C The truck might tip Over-
type) or shift lever (T type) into neutral.
Press the clutch pedal (C type) or brake pedal (T type).
Adjust the steering column angle and driver's seat position
A Avoid sharp starts, stops and turns
before starting the engine.
Do not try to adjust them during operation; otherwise a
serious accident might occur.
After adjustment, make Sure they are securely locked.
Make Sure there is no one under or around the truck, and
start the engine.
A Before reversing the direction of travel, bring the
truck to a complete stop
It is dangerous to reverse the direction of travel abruptly.
Start, stop and turn slowly. Before turning, slow down the truck
A Carry the load low sufficiently. In particular, an unloaded truck might tip over when
It is dangerous t0 travei with forks lifted higher than is it is turned sharply, because the rear of the truck is heavy.
appropriate, regardless of whether loaded or not. Keep the
load as low as possible while traveling. Do not turn the truck
with the load raised high.
2 .-
 I n n vc ~ i i u u s

-
L d

Back down and drive up: When driving over a dockboard:

Do not make turns on a gradient. There is danger of the

truck upsetting.
Keep the forks and pallet at an appropriate ground clearance
Do not ride on the edge of the dockboard or bridgeplates;
height.
otherwise the truck might fall down, leading to personal injury
When operating an unloaded truck on grades, have the rear
or even death.
end of your truck pointed up-hill.
Before driving over a dockboard or bridgeplate, make Sure
When operating a loaded truck on grades, have the rear
it is properly secured. Never exceed its rated capacity. Do
end of your truck pointed down-hill.
not use a damaged dockboard or bridgeplate.
When descending a grade, use engine braking.
Have the brakes Set and wheels blocked in place to prevent
If the truck goes faster than you want, press the foot brake
the trailer from moving.
pedal from time to time. While using engine braking, do not
Jacks must be installed to support the trailer when the truck
operate the shift lever(s) nor press the inching pedal.
goes into the trailer.
A Stay away from the edge of road Drive carefully and slowly across the dockboard or
bridgeplate.
Watch for bystanders.
Give instructions to the trailer driver not to move the trailer
until load handling is finished.
Make Sure the dockboard or bridgeplate is secured.

There is a fear of the edge of a soft ground breaking. Stay

away from such a place. Keep appropriate distance from the
edge of a narrow road or a platform.
1-19
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I I l n v LLIIIH
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.-
A M o u n t properiy A Do not shut off the engine during traveling
Never mount or dismount a moving truck. When mounting or (trucks with power steering and power brake)
dismounting the truck, use proper procedures, make Sure the If the engine stops during traveling, both the power steering
truck is at a complete stop. Support your body using the steps unit and the power brake goes inoperative.
and hand grips properly. Keep the steps always clean.
A Engine braking is not available when the inching
pedal is pressed (T type)
A Do not move controls unless properly seated
When the inching pedal is pressed to the bottom, the brake is
applied to the truck, but engine braking is not available because
the clutch unit is disengaged.

A Safe traveiing:

I 1

Do not operate the controls (levers and pedals) unless you

are properly seated. * Always look in the direction of travel
Always look in the direction of travel; failure to do so will
A Sound horn when starting lead to an accident. When passing an oncoming truck each
other, slow down and use caution to have a safe distance.
Moreover, maintain a safe distance from the truck ahead of
you at all times.
Observe speed limits
Observe the specified speed limits.
Make Sure there is no one or obstacle around the truck
and in the direction of travel or turning
Do not go past other trucks where vision is restricted
Do not go past other trucks at intersections, corners, narrow
aisles and other locations where your vision is restricted.
Slow down at corners
Before starting, make Sure no one is near the truck. Let other Slow down and sound horn at intersections and other
workmen and bystanders know you are starting up by sounding locations where your vision is restricted.
horn. Come to a complete stop before crossing roads or at Corners
1-21
 TRAVELING

A Do not travel over a floor or ground surface covered

with water
A When going into areas where there are limyts in
height and width, use the following cautions:
Do not travel over a floor or ground surface covered with water. 0 Make Sure there is enough height and width for the truck to
Go round any pothole in the road. pass.
Do not put your hands and feet outside the truck.
A DO not get into a soft ground area Make sure there is no one around the truck.
Watch out for outdoor electric cables and other obstacles.

A ~ e asteer,
r rear swing
When the truck is turned in forward driving, the rear of the
truck swings outwards. Before turning, make sure there is
enough clearance from the wall and other obstacles.

A Brake the truck in good time

The truck takes a little longer to come to a stop on a slippery
surface than on a usual surface. Brake the truck in good time.
In addition, the stopping distance of the truck is longer on a
a ditches)
Do not ride on obstacles (curb, railroad tracks, downhill. Keep the traveling speed under.your control.

If unavoidable, be careful. A Practice safe driving and load handling techniques

Before using the lift truck, you must practice safe driving and
A Avoid running on a slippery surface load handling techniques. Even after getting familiar with the
operation of the truck, operate the truck carefully; reckless
A Know the load bearing capacity of the floor driving and operation will cause a personal injury or an
Before entering a building or going into an elevator, make Sure accident.
the floor is strong enough to withstand the weights of the truck
and the loads.
When using multiple trucks
When operating multiple trucks, remember that their operating
controls have their own characteristics even if the trucks are
of the Same specification. If you change the trucks, keep this
point in mind. In particular, pay attention to the brake system.
 ,
a Do not lift off-centered loads
L'

Make sure that the loads are evenly positioned across the forks
, Know the rated capacity and that the load's center of gravity is aligned with the truck's
of your lift truck and its
center of gravity. Off-centered loads might cause the truck to
attachment, i f any, and
never exceed it; otherwise turn over.
the rear wheels will be
raised, t h u s making it A Make loads in contact with load backrest
difficult to travel and turn. Insert the forks into the pallet as far as possible to make the
There i s also danger of
loads in contact with the load backrest.
the truck tipping over.

Never l i f t a l o a d over Do not lift unstable loads

anyone Do not handle unstable loads. When handling loose loads,
Never permit anyone t o make Sure they are stable enough before lifting.
stand under raised forks.
The forks might fall down
unexpectedly, thus
a Use due caution when handling loads
causing a personal injury. When handling loads, fix them with ropes or others, to prevent
from falling off.
Never elevate a man
Never allow other
person(s) t o ride o n the
A Do not stack loads too high o n forks
forks. He might fall off the Do not stack loads on forks in such a way that the top of loads
forks, getting injured. exceeds the load backrest height; otherwise, loads might fall
on the part of the Operator, and in the worst case lead to a
Do not put your hands or serious injury or death.
feet into the load handling
System
Never put your hands or
feet on the mast or mast
c o n n e c t i n g members;
otherwise your hands or
feet might be cut i f the
mast moves unexpectedly.
A Do not tilt the mast with loads high Do not push other trucks.
Do not hoist loads, using ropes hung on the forks.
Do not tow another vehicle using the draw bar.
Do not push or pul1 loads with forks; otherwise, the load might
fall off or get damaged. In particular, the truck with the max.
lift height of more than 150 cm might tip over, if you try to do
that.

A Adjust fork spacing properly

Adjust the fork spacing suitable according to the size of the
load.
Use minimum forward and reverse tilt when stacking and
unstacking loads. Never tilt forward unless the load is over
stack; otherwise the truck might tip over.
A Adjust fork spacing with your feet

A Do not lift or start with mast tilted forward

When the mast is tilted forward, do not perform the following
operations: lifting the forks and starting and traveling the truck.

A Do not stack or unstack loads on a sloping grade

A Keep the chains tight

A slack chain means a mast rail or carriage hang-up, which
might cause the sudden fall of loads or carriage or the truck to Adjust the fork spacing with your feet. Do not use your hands.
tip over. Keep the lift chains stretched tight at all time. You hands might get pinched between the forks and carriage.

A Do not use your truck for purposes other than A Make Sure forks are securely locked
specif ied: After adjusting the fork spacing, lock the forks with fork
Do not use the truck to Open or close the doors of freight stoppers. Unlocked forks will slide during traveling, causing
cars or warehouses. the load to fall off.
LUAU HANVLiiYb
U

Keep the tension of the right and left chains even A Be alert for overhead hazards
Uneven tension of the right and left chains means uneven loads Use caution not to let the mast or overhead guard contact
even if they are properly placed on the forks. It may also lead overhead power cables, piping, sprinklers or overhead cross
to broken chains. beams. If part of the truck Comes in contact with them, the
load might fall off the forks or the truck tip over. Remember
a Pay attention to the fork tips that the mast height becomes higher when the forks are raised.
The fork tips are sharp and could cause personal injury. In
addition, if they catch on obstructions, the truck might lose A Do not pick up loads from other truck
control, leading to an accident. Do not pick up loads from raised forks of other truck. This
might cause an off-centered load or the load to fall off.
a Keep anyone but a guide away from the working area A Do not hold loads on the forks by hand
A Do not let other persons or truck approach your lift
truck during operation
Do not hold loads on the forks by hand. If the truck moves
unexpectedly, the load might fall off, getting the person caught
under it.
When working in a group, have a person present to
give guidance and follow his instructions A DOnot squeeze loads into the stack

a Use pallets and skids strong enough Do not squeeze loads into the stack using the truck's traction
force. This will cause damage to the truck or loads, causing
Pallets and skids must be strong enough to withstand the the truck to tip over.
weight of loads. Use of a damaged pallet'or skid might let the
load fall off the forks.

a loads
Use extreme caution when handling long or bulky

Lift and lower the load carefully so as not to hit it against

something around the truck. Keep the load as low as possible.
Be careful when turning the truck, to prevent it from moving
out of position or falling off.
X

L
,
,
i

+I
-
i -
LOAD HANDLING
A Do not hang loads with wire ropes attached directly
on the forks:

Do not hang loads with wire ropes attached directly on the

forks or attachment. If the wire ropes break or slide off, a
personal injury might result. In particular, the use of a wire
rope hung on one of the forks might cause the truck to turn
ove r.
Use a hook attachment or crane arm attachment to hang
loads.
Make Sure that the wire ropes are strong enough to withstand
the weight of the load and properly attached. The length of
the ropes should be as short as possible but with adequate
spread angle between legs.
Carefully travel and turn when hanging a load with wire ropes;
otherwise, if the load swings, the truck might turn over. Keep
the load as low as possible.
rAnniiuu
-'
A
L .-X

A When leaving the truck, observe the following

conditions:
Block the wheels when parking on a slope
-
If unavoidable to park on a slope, apply the parking brake
securely and block the wheels

A When parking a faulty truck

When it is not possible to lower the forks on the ground due to
a faulty load handling mechanism, attach a sign to the tip of
the forks to prevent pedestrians and other vehicles from
bumping against the forks. Park the truck at an out-of-traffic
area and take measures so as not to let people pass under
the raised forks.

Park the truck on an out-of-traffic area and lower the forks

on the ground.
A Remove the key from a faulty truck arid put up a sign
Remove the starter key and attach a sign saying D 0 NOT
Tilt the mast a little forward and make the fork tips in contact
OPERATE.
with the ground surface.
Apply the parking brake.
Place the shift levers (speed and direction) in neutral.
A Do not ride on front guard

Turn the key switch "OFF" to shut off the engine.

Remove the key.

A Park at the specified area

A Park on a hard surface

A Park at an out-of-traffic area

Park at an out-of-traffic area. Avoid parking near emergency
exits, stairs, or fire hydrants.
It is dangerous to use the truck body or mast as a ladder to
A Do not park near flammables ride on a high place.
You might be caught between the mast and truck body, resulting
in a serious accident.
 :qSPECTION AND SERVICE

A Before starting inspection or maintenance, place the

control levers in neutral
lnspection and maintenance of the truck should be
performed only by qualified and authorized personnel. Make sure the shift lever(s) and load handling levers are in
lmproper inspection, maintenance or repairs will cause neutral before starting inspection or maintenance.
damage to the truck or a serious accident.
A Wipe any spilt oil or grease
A Park on a hard, level ground Wipe any spilt oil or grease. If the truck is contaminated with
Before performing inspection and maintenance, make Sure to oil or grease, it is difficult for you to find possible cracks or
park the truck on a hard, level surface. Also make sure the other defects.
place is dry and without dust.
A No fire (when handling lubricants, batteries, cloth
A Have a good ventilation wetted with oil)
When performing inspection and maintenance indoors, have No fire. Never smoke or use fire or naked flame when handling
a good ventilation. lubricants, batteries or cloth wetted with oil.

A Have a fire prevention equipment handy A Avoid loose fitting clothing

Have a fire prevention equipment handy wheneverworking Wear protective clothing called for by job conditions.
indoors. Know how to use it.
A Wear safety gear devices (hard hat, safety shoes,
safety glasses, gloves)
A Make Sure the forks and other attachment (if any)
are on the ground
A Use caution not to fall down from the truck when
working on the truck
A Before starting inspection shut off the engine
Make Sure the engine is shut off before trying to start inspection
or maintenance.
A Do not put your feet under the forks

A Unless otherwise specified, shut off the engine

A Use caution not to get your fingers pinched in the
floor plates or hood
Unless otherwise specified, inspection or maintenance should Be careful so as not to get your fingers caught when closing
be performed with the engine shut off. the battery Cover or doors.
 ~~~~~

./ 1

A If unavoidable t o work under raised f o r k s o r A Loosen radiator cap slowly to allow steam to escape
attachment, use a stable support under the inner
mast andlor the carriage t o prevent the forks or
attachment from falling down unexpectedly A Make Sure the engine is cool enough before servicing
it

a When working in a group, have a leader and follow

his instructions
lmmediately after the engine is shut down, the engine oil is
hot and in high pressure. Do not try to drain oil or replace the
filter.
A Use appropriate tools Hot engine oil might spout out to cause burns.
Use appropriate tools suitable for the job you have been
assigned. Use of inappropriate tools might cause a serious
A Hydraulic oil is hot immediately after the engine is
shut down
accident. lmmediately after the engine is shut down, the hydraulic oil is
hot and in high pressure. Do not try to drain the hydraulic oil
A DOnot use tools for purposes other than specified
or replace the filter. Hot oil might spout out to cause burns.
Do not use tools for purposes other than specified. lt can cause
a serious accident. A Release oil pressure before working
A Do not remove radiator cap when the cooling water
temperature is high
The hydraulic circuit has residual pressure. Before working
on the System, release the pressure. To check for oil leaks,
wear safety glasses and gloves and use a piece of cardboard
or wood. High pressure oil penetrates the skin. It can cause
blindness.

A Checking of accumulator and piping is hazardous

lnspection of piping where an accumulator is installed is
hazardous. When it needs to be inspected, ask your TCM
dealer.

A When high pressure oil Comes in contact with your

body, immediately get medical attention
lmmediately after the engine is shut down, the cooling water
is hot and in high pressure.
Do not try to remove the radiator cap in this state. H,ot cooling
water might spout out to cause a serious personal injury or burns.
1-29
 -.i
.WSPECTlON AND SERUCE
- . ( #*
7

A Shut down the engine before working on rotating A Caution to be taken when adjusting tire inflation
parts pressure (rim, compressor):

Use due caution when working on rotating parts, not to get When checking tire inflation pressure, position yourself in
your body or fingers entangled in them. Before checking a the path of rotation, not on the side of the tire.
rotating part, make Sure the engine is shut down. Do not bring When inflating a tire using a compressor, first adjust the air
something near rotating parts. pressure of the compressor; otherwise the air pressure will
rise to the maximum pressure of the compressor, leading to
A Do not use the mast as a ladder: a serious accident.
When carrying out checks or adjustment, do not use the lnflating tires to a high pressure requires special skill.
connecting member or load backrest as a ladder. The mast lnflating tires requires special skill. Tires must be inflated
might move unexpectedly, pinching or cutting your hands or only by a qualified Person.
feet. When using compressed air, wear safety glasses and mask.
Do not use the mast as a ladder. You might fall down from When inflating tires, wear safety glasses and mask because
the mast, leading to a serious accident. dust might get into your eyes or mouth.

A Leave the disassembly and reassembly of tires,

tubes and rims to a specialist
The inflation pressure of tires of the lift truck is very high (about
700 - 1,000 kPa) and thus due caution must be required to
disassemble or reassemble the tires. An improperly
reassembled tire might cause explosion to let parts fly into
pieces, resulting in a serious personal injury.
A D o n o t l o o s e n t h e wheel assembly n u t s when
changing a tire (see the sketch on Page 4-24)
Cautions to be taken when using the jack
The wheel assembly is locked in two ways: Hub nut type and Do not enter under the truck while it is jacked up. The
nut type. In the hub nut type wheel assembly, the wheel is truck might fall, getting you caught under it.
installed to the hub; in the nut type, a wedge ring is inserted Before jacking up the truck, remove the loads from
between the wheel and the hub to lock the wheel assembly. the truck.
The tire is secured with the side ring and the lock ring. When jacking up the truck, the operator must leave
When removing a tire from the truck, make Sure the lock ring the truck.
is securely installed; otherwise, the side ring, tire, and wedge Lift the truck a little off the ground surface and put
supports at both sides of the frame to prevent the truck
ring might burst out, resulting in a severe accident.
from falling.
Before jacking up, block the wheels to prevent them
A Do not loosen bolts and nuts of split rim assembly:
from rotating unexpectedly.
The wheel has hub nuts that secure the wheel to the hub Lifting the truck must be performed only by qualified
and rirn nuts and bolts that assemble two rims together. personnel (for crane or slinging work).
When removing a tire from the truck, do not loosen the bolts The truck must be lifted by attaching wire ropes t o
and nuts of the split rirn assembly. the designated Parts.
Use strong wire ropes
If the bolts and nuts of the split rirn assembly are removed,
Make Sure the wire ropes are strong enough to lift the
the rims, bolts or nuts might blow off due.to the internal
truck and free from damage.
pressure of the tire, to cause a serious personal injury.
When replacing the rirn assembly, install a new rirn assembly
with the head of each of the dowel bolts of the rim assembly A Cautions t o be taken when handling batteries:
pointing outside. (This helps make it difficult to loosen the If electrolyte gets on your skin, flush it off with a copious
rirn bolts with the tire attached to the truck. Some bolts have amount of water
a special shape for this purpose.) The battery electrolyte contains dilute sulfuric acid, a very
After replacing tires, test run the truck to check to See if the corrosive material. It can destroy most things it touches. It
hub nuts are securely tightened. If a loose hub nut is found, will cause painful and serious burns if it gets on the skin. It
tighten it to the specified torque. can cause blindness if it gets into eyes. If battery electrolyte
Comes in contact with the skin or clothing, wash it away
immediately with a copious amount of water.
If electrolyte gets into your eyes, get medical attention
If electrolyte gets into your eyes, flush it off immediately with
a copious amount of water and get medical attention.
C i

Wear safety glasses when handling batteries

-
.I

Wear rubber gloves, rubber boots, safety glasses when

changing or charging batteries, adding battery elect
or adjusting the specific gravity of the battery electro
If anyone swallowed electrolyte accidentally:
I

II
I

Let him drink a copious amount of water or milk with egq white
and salad oil mixed in it and take a rest. Send for a do
.WSPECTION AND SERVICE
causing an accident.
Pay attention to battery electrolyte level
Do not operate the truck or charge the battery when the
battery electrolyte level is below the LOWER LEVEL marking;
otherwise, the components inside the battery may be
deteriorated and the battery life shortened, and in the worst
case an explosion might occur. Keep the battery electrolyte
No fire level between the UPPER LEVEL and LOWER LEVEL
Since explosive hydrogen gases are always being markings at all times. Add purified water if the level is low.
from the battery, there is a danger of causing an explpsion. When cleaning the battery, make Sure the battery caps
Never smoke or use fire or naked flame near the battery. are securely tightened
No sparks. II Have a good ventilation when charging
To prevent the generation of sparks, turn off the Since hydrogen gases are released from the battery during
switch before connecting or disconnecting the charging. Have a good ventilation; otherwise an explosion
charger cable. I might result. Keep the battery case Cover Open.
Do not short both poles for checking the battery'sl state When charging the battery, follow the instructions in the
of charge 1 lnstruction Manual of the charger
Remove the negative (-) terminal of the battery fir t and No fire during charging
reinstall it last (Engine trucks)
When removing the battery, disconnect the negative (-)
? i Batteries give off hydrogen gases during charging. No fire.
No sparks.
terminal first. When reinstalling, connect the positibe (+) Make Sure the battery electrolyte temperature i s below
t'
terminal first, and then connect the negative (-) termi al.
Do not connect or disconnect the battery receptaclep with
35°C
Hydrogen gases are released from the battery during
the battery circuit conducting (Electric trucks) 1 charging, causing the battery to heat. Before trying to charge
Do not put any metal tool on the battery case
Do not short the battery terminals
, I
I
the battery, make Sure the battery electrolyte temperature is
below 35°C.
Do not short the battery terminals by placing a piece ofi metal (If the electrolyte temperature reaches 50°C or more,
between the positive and negative terminals. A loose discontinue charging and wait until the electrolyte
terminal might cause sparks, causing an explosion.

lake
Sure the terminals are tight. Use caution not to ha e the
wrong connections of the battery terminals.
temperature drops to 35°C or lower.)
The truck's batteries are high voltage
The batteries used for electric trucks are high voltages more

use caution not to aHow the t001to ~ O U the t

When turning the screw of the positive pole of the b ttery,
C ~ meta1parts
of the truck, such as the engine (Engine trucks) i
than 48 V. If anyone touches it inadvertently, he can get an
electrical shock accident or burn.
Static electricity is hazardous
If the tool touches metal parts, there might occur sbarks, Static electricity is generated when cleaning the top surface
I
l l Y 3 r C b Il V l Y M I Y Y J L l l V I W L
. #

- L

or connections of the battery with a dry cloth, or covering A Handling Long Life Coolant (LLC) (Engine trucks)
the battery with a vinyl sheet. It might cause an explosion. The LLC is flammable and poisonous . When storing it, attach
Static electricity from the body a label "Dangerous substance" and keep it out of reach of
Before checking or cleaning the battery, remove static children.
electricity from your body by touching metallic parts at a place The LLC is flammable. When handling the LLC, never smoke
away from the battery. or use fire or naked flame near the LLC.
The LLC is poisonous. Do not swallow it. If anyone
A Caution to be taken when starting the engine using
a booster cable (Engine trucks):
swallowed it accidentally, let him drink a lot of water, induce
vomiting and get medical attention immediately.
When starting the engine using a booster cable, wear safety
glasses. When starting the engine using the battery of A When hoisting the lift truck, use "Lifting Eyes"
another vehicle, use caution to prevent the truck whose
battery is dead from coming in contact with the vehicle with
a charged battery.
Shut down the engine and connect the cable.
Use caution to prevent the cable from getting entangled in
the fan or fan belt.
Do not have the wrong connections of the booster cable.
Use due caution to prevent the positive (+) terminal from
coming in contact with the negative (-) terminal.

A Do not try to jump stait the truck. The truck might

jerk, causing an accident (Engine trucks):
A -
A Use the specified brand of brake fluid Never hoist your lift truck by attaching ropes or wires
to its overhead guard or counterweight; otherwise there
A Use caution not to allow the entrance of dust into is the possibility of the chassis getting damage or
falling.
the brake fluid reservoir
If hoisting the lift truck is necessary for any reason such
A Use caution to keep the breather of the brake fluid
reservoir cap from clogging
as transportation, use an optional "Chassis Lifting Eye".
For the Chassis Lifting Eye, consult your TCM dealer.

A Obey regulations
When disposing of waste oil, solvent, or discharged battery,
obey the regulations and rules.
 -
- 1 CAUTION PLATES
i
/ 1
i 1 %
.

The caution plates attached to the lift truck explain cautions to be taken when using the truck, and procedures for operating the
truck. Read messages on the caution plates as well as the description in this manual. Damaged or missing decals must be
replaced with new ones.

View looking from @

F
' View looking from @

0 (inside) H : Decal for lubricant capacities

I : Decal for fuel
A CAUTION J : Decal for parking brake
adjustment
The instructions on the caution plates carried in this manual may differ from
L : Decal for lubricating locations
those on the caution plates attached to the truck body. In such a case, observe
0 : LLC label
the instructions on the caution plates attached to the truck body.
GAU I IVN r ~ wtz
i, -
- \
i -
A. Safe operation B. Warning decal for handling C. Warning decal for mast
inflated tires connecting member

'a WARNING '

. Operate truck only if trained and authorized by

@-V
AVOlD SEVERE INJURY OR DEATH.
Tim sewicing requims special training.
D0 mal lake limsoli iwck unlil atl air pressure
your employer. Know Operation & Maintenance 1s oul. Loasen miy WHEEL LUG NUTS "A".
Manual and all work rules. Do not loossn whsel assembly nuls "8"unlil
B!! pmS8Ure 1s DU1 01 Ure.
2. Safety check truck every day. Do not start if See OPERATORS MANUAL lor more
importanlinsiwciims for whesl sewics snd
damaged or faulty; stop if problems start. massembly.
Make aure alt nula and bolls sre in placs and
Repair allowed only by trained, authorized light.
Never add air fo a tim that looks low. Let all
air oul and chsok for proper asssmbfy.
3. Turn, start, stop, and handle loads smoothly and lnflale all tires in a safety cage. See

[ @
MANUAL iar proper pressums.

Carry loads low and tilted back; stack only on

ievel using minimum tilt.
4. Look where you are going. Watch out for people,
hazards on floors and overhead, drop-offs and Splil-type Safely Gage
tail swing clearance.
5. Truck overturn can kill you. Slow for turns even
when empty. Never turn on inclines.
6. Do not lift overweight or loose loads.
Move slowly with wide, high, or Iong loads. D, E Warning decal for load F. Warning decal for fan and
Keep forks wide and fully under loads. handling means other rotating parts
Travel in reverse if loads block view.
Attachments require special training, ask your

7. Keep loads upgrade on all inclines. Stay clear

of ramp and dock edges. Make Sure dockboards
and trailers are secure before going on them. Do not let riders on
8. Overhead guard and load backrest must be on
forks or pallet.
Always keep yourself completely inside guard.
9. Stop engine when refueling. Follow Operation &
Maintenance Manual and employer's work rules
about fuel, battery and tire maintenance hazards. se caution not to
10. Forks can fall rapidly even with light loads.
Do not raise people or allow them under forks. get entangled while
No passengers allowed on truck. the engine running.
11. Park only in authorized areas, never on inclines.
Lower forks to bottom, put direction control in
neutral, turn off key and make Sure parking brake

12. Fasten the seat belt, when operating the lift truck.

4
The following symbols, found throughout this manual, alert you
to potentially hazardous conditions to the owner and the
operator.
Become completely familiar with the truck before proceeding CONTENTS
with operating, checking and servicing.
PICTORIAL NOMENCLATURE ........................................ 2- 1
This manual and decals affixed to the truck use the following INSTRUMENTS AND CONTROLS .................................. 2- 3
safety alert indications. SWITCHES ..................................................................2- 5
METERS AND WARNING LIGHTS ........................... 2- 7
SIGNALWORD I CLASSlFlCATlON LEVERS 'AND PEDALS .............................................. 2-10

A DANGER 1 Failure t o follow the instructions i n the

message will likely cause a serious accident
or death. -
TRUCK BODY ............................................................. 2-14
OPTIONAL EQUlPMENT ........................................... 2-22

A WARNING Failure t o follow the instructions i n the

message might cause a serious accident or
death.
Failure t o follow the instructions i n the
CAUTION message may csuse personal injury or
damage to the truck or other property.
The information will help t o prolong the
service life of the truck. The message is not
directly related to accident prevention.
 21
2!n
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rn

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28
C2
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.
-,
INSTWMENTS AND CONTRQLS
INSTRUMtN I 3 ANU C;UIY+~UL~ -
'
. .-
SWITCHES

STARTER SWITCH to the "START" position. While the engine While the engine is running, do not
OFF is running, keep the key switch at the "ON" turn the key switch to the "START"
STOP position. position. It will cause a damaged
The position at which the key is inserted starter motor.
or drawn out. START Do not keep the starter motor turning
The starter switch is "OFF" at this position. The engine starts. After the engine starts for more than 10 seconds at a time.
The engine stops when the starter switch up, remove your hand from the key. The If the engine won't start, wait about
is turned to this position. key switch will automatically return to the 20 seconds before trying again.
"ON" position. The engine won't start up unless the
ON direction and speed range shift
The electric circuit for the starter motor
$3 NOTE levers are in neutral "N". (C type)
and others is closed. Do not keep the key switch in the The engine won't start up unless the
On the diese1 engine truck, the glow "ON" position while the engine is not direction shift lever is in neutral "N".
indicator will come on when the key running. This will cause a discharged (T type)
switch is turned to "ON". After the glow battery. While the engine is running, 0 For the automatic choke, see Page

indicator goes out, turn the starter switch keep the key switch in the "ON" 3-5. (Gasoline engine trucks)
position.
a, V)
s g
Us üL
3 (d
0 U)
"'L!
0
C V)
,U
, C E
a, 3 -0
f -5
0
U)E Q
.E C
8' a) 0
2C
V)
-z
F'cn
C

Z Z Z Z
@ 0 0 0 0

z z z k
0 0 0 0 0

LI LLLILLLL
LL L L L L L L L
0 0 0 0 0

Q)

C ECT) ma ,g
L

Q) .- C %
-
INSTRUMEN I S A N U GUN J-qULb
. -/
-
-
.--'
METERS AND WARNING LIGHTS
GLOW INDICATOR

ENGINE WATER
FUEL GAUGE TEMP. GAUGE HOUR METER

COMBlNATlON METER ENGINE WATER TEMP. GAUGE HOUR METER

The meter panel contains meters and This gauge indicates the temperature of The hour meter operates only while the
monitors. Use them t o check the the engine cooling water. Under the starter switch is "ON", and records total
operating status of the truck. normal operating condition, the pointer operating time of the truck in hours and
stays in the "white" range. If the point tenth of an hour (6 minutes). Use it to
FUEL GAUGE enters the "H" (red) range, it suggests that determine maintenance schedule.
The fuel gauge indicates the fuel level in the engine is overheating. Park the truck
at an out-of-traffic area and let the engine GLOW INDICATOR LAMP
the fuel tank.
run at idle rpm until the pointer returns to I ~ i e s eengine
l truckl
8 NOTE the "white" range. When the key switch is turned to "ON", the
When checking the fuel level, park engine is preheated with the glow indicator
NOTE coming On.
the truck on a l e v e l surface;
otherwise you cannot get the correct Do not shut off the engine even if the The glow indicator goes out in about 3.5
pointer enters the "red" range; seconds after the key switch is turned to
fuel level.
Add fuel before the fuel level drops otherwise the engine might cause "ON", indicating that the engine is ready for
malfunction. starting.
to the minimum, to avoid the
For the procedure for remedying an Note that the glow indicator will go out
entrance of air into the fuel System.
overheated engine, see Page 3-12. immediately when the engine cooling water
temperature is more than 60°C (140°F).
 INSTPVMENTS AND CONTRO-LS

CHARGE WARNING LIGHT

ENGINE OIL PRESS.
SEDIMENTER WARNING LlGHT
WARNING LlGHT

-
SEDIMENTER WARNING LlGHT CHARGE WARNING LlGHT ENGINE OIL PRESS. WARNING
l ~ i e s eengine
l truckl L i g h t comes o n when the power
LlGHT
t
generating system fails to operate Light comes on when the engine oil
normally. This warning light comes on pressure drops.
If the truck is used neglecting the when the starter switch is turned to "ON", Light also comes on when the starter
warning light, the fuel injection and goes out when the engine starts up. switch is turned to "ON" and goes out
pump might be seized. when the engine speed is increased by
If light does not go out after the engine
For the procedure for draining
starts up, it suggests that the fan belt is pressing the accelerator pedal after
water from the sedimenter, see
Page 4-20. loose or broken, or that the power cranking the engine.
generating system is defective. Stop the If light comes on during operation, it
Light comes on when the water level in operation immediately and troubleshoot. suggests that the engine oil level is low
the sedimenter exceeds the specified or the lubricating system is defective.
value. Stop the operation immediately and
The fuel injection pump lubricates inside
troubleshoot.
the engine using fuel. For this reason, the
water content in the fuel is removed using
the sedimenter. lf light comes on during
operation, stop the operation immediately
and drain water.
 EXHAUST GAS TEMP. SYSTEM CHECK FUEL LEVEL
WARNING LlGHT
RNlNG LlGHT
PARKING BRAKE
INDICATOR LlGHT
RADIATOR WATER
AIR CLEANER WARNING LIGHT
CLOGGING
WARNING
LlGHT

OIL TEMP.'ONVERTER
GAUGE ~OPTIONALEOUIPMENT~

AIR CLEANER CLOGGING SYSTEM CHECK WARNING LIGHT RADIATOR WATER WARNING
WARNING LIGHT (trucks with ter-catalyst muffler) LIGHT
Light comes on when the air cleaner l ~ a s o l i n eengine trucksl Light comes on when the cooling water
becomes clogged. I f light comes on in the radiator reservoir tank drops below
Light comes on when the truck's exhaust
during operation, stop the engine the lower limit. I f light comes On, add
system fails to operate normally.
immediately and clean the element and cooling water up to the upper limit of the
dust cup. reservoir tank.
FUEL LEVEL WARNING LlGHT
PARKING BRAKE INDICATOR Light comes on when the fuel level in the TORQUE CONVERTER OIL
Light comes on when the parking brake fuel tank drops below the specified value. TEMP. GAUGE
is applied and goes out when the parking The gauge indicates the temperature of
brake is released. BATTERY ELECTROLYTE LEVEL the torque converter oil.
WARNING LlGHT
EXHAUST GAS TEMPI WARNING Light comes on when the electrolyte level $33 NOTE
LIGHT ( trucks with ter-catalyst drops below the LOWER LEVEL. If light If the pointer enters the red range, stop
muff ler) comes On, add purified water for battery the truck and check the torque converter
l ~ a s o l i n eengine trucksl up to the UPPER LEVEL. oil level and piping for leaks. If the oil
Light comes on when the exhaust gas level is proper and no oil leaks are found,
temperature is too high. consult your local TCM dealer.
- ..-
/
-"-,
3 INSTWMENTS
t AND CONTROLS ' I
-
LEVERS AND PEDALS

DlRECTlON SHIFT LEVER (C TYPE) SHIFT LEVER (T TYPE)

SPEED RANGE SHIFT LEVER (C $3 NOTE
TYPE) A CAUTION
The direction shift lever (C type) and
Press the brake pedal to the floor shift lever (Tfype) have a neutral switch.
The truck is equipped with two floor-shift before operating the shift lever.
shift levers (forward/backward and speed The truck start moving slowly or Before starting the engine, make sure
range: 2 speeds in forward and reverse, creeps when the brake is released if the lever is in neutral. Neither the C- or
respectively). the shift lever is in positions other T- type truck won't start if the direction
than neutral. shift lever (C type) or the shift lever (T
When the direction shift lever is placed in Do not release the brake pedal until
the reverse "Rn, the back-up lamp comes you are ready to start. type) is not in neutral.
on and the back-up buzzer sounds.
The truck is equipped with a single shift
Before 'Witchingthe ranges O r lever on the steering column (1 . speed
. for
reversing the traveiing direction, press the forward arid reverse).
clutch pedal to the floor. In addition, bring
- When the shift lever is placed in the reverse
the truck to a complete stop when position "R", the back-up lamp comes on
and the back-up buzzer sounds.
reversing the traveling direction, from Brina the truck to comDlete stoD when
forward to reverse or vice versa. rev&sing the direction'of travel, from
forward to reverse or vice versa.
LIFT LEVER TlLT LEVER
NOTE
A CAUTION a CAUTION When the engine is not running, the
mast won't tilt forward even if the tilt
Seat yourself in the driver's seat Seat yourself in the driver's seat
and make Sure there Cs no one and make Sure there is no one lever is operated, because the tilt-lock
around the truck before operating around the truck before operating mechanism installed in the control
the lift lever. the tilt lever. valve operates.
Note that the forks drop when the lift
Pull back on the lever to raise the forks lever is pushed forward, even when
Pull back on the tilt lever to tilt back the
and push forward on it to lower the forks. mast and push forward on it to tilt the mast the engine is not running.
The lifting speed of the forks can be forward.
controlled by the tilt angle of the lever and The tilting speed of the mast can be
accelerator pedal effort or engine speed. controlled by the tilt angle of the tilt lever
Note that the lowering speed of the forks and accelerator pedal effort or engine
is controlled by the tilt angle of the lift lever speed.
alone. T h e engine s p e e d has no
connection with the lowering speed of the
forks.
3-11
 *
-X--
INSTRUMENTS AND CONTROLS
- >
r $ '

STEERING WHEEL

STEERING WHEEL STEERING COLUMN TlLT LEVER PARKING BRAKE LEVER

A CAUTION A CAUTION
When the engine i s not running, Adjust the steering column angle Block the wheels when parking on
power steering is inoperative. If the properly before starting the day's an incline.
engine stops during operation, re- work or shift.
s t a r t t h e e n g i n e as s o o n as After adjustment, turn the lever i n Pull back on the lever to apply the brakes
possible. t h e d i r e c t i o n "A" t o l o c k t h e to the front two wheels. The lever is locked
steering column securely. Do not there. To release the parking brake, press
try to adjust the steering column
When traveling the truck, hold the and hold down the lock release button on
angle during operation.
steering wheel knob with your left hand. the tip of the lever while pushing forward
Do not remove your hand from the knob Adjust t h e steering columnangle on the parking brake lever.
during traveling. The truck Comes with according to the individual Operator's
power steering to provide smooth, light physique.
steering while the engine is running. Turn the lever in the direction "B" and
adjust the steering column angle properly,
and then turn the lever in the direction " A
to lock securely.
IN3-lKUMtN 13 ANU L V N I,MUL3 -
-/
L/ /

INCHING PEDAL
\ Y A J

PEDALS INCHING PEDAL (T TYPE) BRAKE PEDAL

The truck has three foot controls: clutch Press the brake pedal to slow down the
(or inching pedal), brake pedal and a CAUTION truck. Brake lamps come on when the
accelerator pedal. Do not press the inching pedal for brake pedal is pressed.
slowing down the traveling speed,
CLUTCH PEDAL (C TYPE) when starting uphill, or when ACCELERATOR PEDAL
descending downhill; otherwise the
The clutch pedal turns on and off the clutch is disengaged to make Press the accelerator pedal to increase
power transmission from the engine. The engine braking unavailable. engine speed. When the accelerator
clutch is disengaged by pressing the pedal is released, the engine runs at idle
pedal and engaged by releasing. Use the inching pedal to move the truck rpm.
slowly while operating the load handling
@' NOTE means at high speed.
When the inching pedal is pressed lGasOline engine trucksl
Do not travel the truck with the clutch slightly, the hydraulic clutch pressure Use the fully-automatic choke to start the
engaged slightly, as much as possible. drops (clutch engaged slightly). If the engine in cold weather.
Pedal is further pressedr the clutch is Fo;more information, look up "STARTING
completely disengaged and the brake is COLD 3-5.
applied to the truck.
For more information, look up "Using the
inching pedal" on Page 3-3.
 INST/@UMtNI S ANU GUN I KULS
-
6

i i 7 .

TRUCK BODY

DRIVER'S SEAT SUSPENSION SEAT ADJUSTMENT LEVER DOCUMENTS POCKET AND

RECLlNlNG CONTROL LEVER MAGAZINE BOX
A CAUTION The driver's seat has a document pocket
and magazine box at its back. Use them for
Adjust the suspension of t h e A CAUTION storing the lnstruction Manual and others.
Remember to close the document pocket
driver's seat using the adjustment Adjust the seat position before before operation.
knob before starting the day's work starting your day's work or each shift.
or each shift. Do not try to adjust Make Sure the seat is securely locked. SEAT BELT
the suspension during operation.
Adjust the driver's seat to a position to Be Sure to fasten the seat belt before
Adjust the driver's seat suspension suit the individual operator's physique. starting traveling or operation; otherwise,
properly to suit the individual operator's if the truck turns over, the operator might
To unlock, pul1 up the lever. be thrown out and, in the worst case, the
physique and to provide best comfort. After adjustment, try to move the seat operator can be crushed by the truck
Turn the adjustment knob to the value of back and forth to make Sure that the seat causing severe injury or even death.
your weight. The seat absorbs shock and is securely locked. Pull out the connector at the right side and
vibration to provide comfort during insert it into the receptacle at the left side
traveling and operation. until it clicks into place.
To unfasten the seat belt, press the red
button by the receptacle, and the belt
automatically winds up into the seat.
ENGlNE HOOD OPENlNG LEVER 11fthe engine hood won't openl BRAKEICLUTCH FLUID
If the engine hood won't be opened by RESERVOIR
A CAUTION pulling the hood opening lever, follow the This reservoir tank, shared by both the
To close the engine hood, unlock instructions below. brake unit and the clutch unit, is located
the damper. Use caution not to 1) Get a thin iron plate, about 20 cm long, at the right section inside the dashboard.
pinch your hand when closing the such as an iron rule. (brake fluid reservoir only for the T type).
engine hood. 2) Using the iron plate, unlock the latch The fluid level can be checked from
inside the hood by pushing it in the outside the reservoir. (The above sketch
Pull the lever to the full to Open the engine
direction indicated by the arrow. shows the reservoir tank of the T type
hood. The hood Opens by the action Of 3) When the latch is unlocked, the engine truck).
the damper to allow easy maintenance.
hood automatically Opens.
 INSTTUMENTS AND CONTRQLS

OVERHEADGUARD

OVERHEAD GUARD LOAD BACKREST SAFETY STEP AND HAND GRlP

The overhead guard is an important

A CAUTION A CAUTION
safety device which protects the The load backrest is an important Use the safety step and hand grip
operator from falling objects. safety device which protects the when mounting and dismounting.
Make sure it is securely installed. operator from a falling load if the Do not hold the levers when getting
Do not use t h e t r u c k w i t h the forks disengage from the carriage. on or off. Do not mount or dismount
overhead guard removed or Make sure the load backrest i s while the truck is i n motion.
modified; otherwise it might cause securely installed. Do not use the
a serious accident. truck with the load backrest The truck is equipped with safety steps
removed or modified; otherwise it at right and left sides of the truck body
might cause a serious accident. and a hand grip on the left front pole of
the overhead guard. When mounting or
Keep the vinyl rain gutter always clear dismounting, use the safety step and
of dust. hand grip.
INSTRUMENTS ANU GUN CYUi-3

DRAWBAR FORK STOPPER FORK LOCK BOLT

A CAUTION A CAUTION A CAUTION

Do not use the drawbar for towing eThe f o r k s s h o u l d b e set Do not remove the fork lock bolt
another vehicle or for being towed symmetrically t o the truck other than the following cases;
by another vehicle. centerline, and f o r k stoppers otherwise the forks might
should always be set. disengage f r o m t h e carriage,
Use the drawbar f o r the following When adjusting fork spacing, hold causing personal injury.
cases: When removal of the forks i s
the load backrest and push the
needed.
When the truck has bogged down in the forks with your foot. Do not use
e When gathering the right and left
mud or a side ditch. your hand. forks together to the center for any
When loading onto or unloading from reason.
a trailer for transportation. Secure the forks with the fork stoppers.
Pul1 UP the fork Stoppers a little arid turn When a fork prong is moved to the center,
SO0. Then adjust the fork spacing using it will come off the carriage. This bolt
your foot according to the size of the load prevents the fork from being used at the
you are going to carry. center.
 -
- C , 4 INSTRUMENTS AND CONTROLS
- , 7

FUEL TANK CAP

Never use naked flame (match or $J' NOTE
lighter) for checking the fuel level
A CAUTION Use gasoline for gasoline engine
trucks and light oil for diesel engine
When adding fuel, stop the truck, The fuel tank cap is located at the left side trucks.
shut down the engine, and apply of the truck. Diesel fuel
the parking brake securely. Never Turn the cap counterclockwise to Open. Use good quality of light oil as diesel
smoke. Keep fire or naked flame Inside the cap is a breather which allows fuel. The light oil freezes when the
away from the truck. The operator the entrance of air into the tank. ambient temperature is below -10°C
must get off the truck. Make Sure the breather is not damaged (14"F), causing the fuel piping to
* After adding fuel, tighten the cap or clogged; otherwise the fuel system become clogged. lf the truck is to be
securely. A loose fuel cap might might malfunction. used in cold regions, use proper
cause fuel leaks, leading t o a
quality of light oil according to the
serious accident.
weather condition of the region.
I Before starting the engine, make
Do not use kerosene as the fuel;
Sure the fuel tank cap i s securely
otherwise the engine performance
tightened and any spilt fuel wiped
will be deteriorated or the fuel
away.
injection pump might be damaged.
 HEAD LAMP SlDEVlEW

LIGHTS AND LAMPS Rear side SlDEVlEW MIRRORS

The truck has rear combination lamps (tail
A CAUTION lamps, brake lamps, back-up lamps, turn A CAUTION
signals and rear reflector) at its rear.
Check that lights and lamps come When traveling in reverse, always
on and off properly. If any light bulb look i n the direction of travel. Do
i s blown out, replace with a new not rely too much on the sideview
one. If the lens is contaminated or mirrors.
damaged, clean or repair. Keep the mirror surfaces always
clean.
Front side Adjust the sideview mirrors to gain
The truck has head lamps and front full rear vision.
combination lamps (turn signal and
clearance lamps) at its front side. The sideview mirrors are provided on the
front poles of the overhead guard, one for
each.
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INSTRUMENTS AND GON LWULS
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RADIATOR CAP

RADIATOR CAP RADIATOR RESERVOIR TANK

The radiator reservoir tank is located
A CAUTION behind the battery unit inside the engine
Do not remove the radiator cap hood.
abruptly while the engine is hot. You can check the cooling water level
Make Sure the engine has cooled using this tank.
down completely and turn the cap
counterclockwise a little to relieve
the pressure in the radiator, and
then remove the cap.

The radiator cap is located inside the

Cover at the rear part of the engine hood.
To remove the cap, turn it 90".
 ,/-
INSTPIIMENTS AND CONTRQ,LS
-_ 1
1
- -
OPTlONAL EQUIPMENT SPEEDOMETER (SM) TlRE CHAlN (TC)
Here are some pieces of optional The speedometer indicates the traveling Fit tire chains over the tires of the truck
equipment which are deeply related to Safe speed (km/h) and the distance traveled to increase traction and prevent skidding
operation of the truck. For more information by the truck. on roads covered with ice or snow.
about optional equipment, consult your VVhen the light switch is turned On, the
local TCM dealer. Also see Page 5-13. dial is illuminated by a built-in lamp. NOTE
Some models may require tire chain
REAR WORK LIGHT (RWL) SPEED ALARM SYSTEM (SAS) fitting parts. For more information,
The SAS gives an alarm by sounding the consult your local TCM dealer.
A CAUTION buzzer and flashing the beacon light when
It is advisable to use an optional the traveling speed exceeds the preset
rear work light when you are speed. The speed can be preset for FIRE EXTlNGUlSHER (FE)
working in a place where sufficient 5 km/h, 10 km/h or 15 km/h. Use the fire extinguisher for putting out a
light is not available. fire. An optional fire extinguisher will be
HIGH LOAD BACKREST (HBR) attached to one of the rear supports of
The rear werk light illuminates the road U S the
~ high load backrest for handling the overhead guard.
or floor behind the truck at night to allow high loads.
the operator to recognize obstacles, if POWER BRAKE (POB)
any, on the road or floor easily. OVERHEAD GUARD WITHWIRE (High-power models with capacities
NETTING from 2 to 3 tons)
BEACON LIGHT The overhead guard with wire netting
Use an optional beacon light in the case protects the operator from falling objects,
when the truck is required to work near e s ~ e c i a fwhen
f ~ handling Parts at
fellow workers or bystanders or when the a high place.
hydraulic lines. Use ordinary brake
work place is noisy. oil (vegetable oil) for one including
PNEUMATIC TYPE CUSHION
TlRE (UNIQUE TIRE, TROI) t h e master cylinder and use
SOUND VOLUME-ADJUSTABLE hydraulic oil (mineral oil) for the
BACK-UP BUZZER Use tires of this type when you are going other including the brake booster.
You can switch over the sound volumes to work in an area where there are debris
in two Stages, according to the noise level or anything that might blow the tires on
at the work place. the road or floor surface.
The following symbols, found throughout this manual, alert you
to potentially hazardous conditions to the owner and the
operator. CONTENTS
Become completely familiar with the truck before proceeding
with operating, checking and servicing. PROPER OPERATION ...................................................... 3- 1
DURING BREAK-IN ...................................................... 3- 1
This manual and decals affixed to the truck use the following RELATIONSHIP BETWEEN LOAD AND STABlLlTY
safety alert indications. OF TRUCK ..................................................................... 3- 1
BASIC LOAD CENTER AND RATED LOAD .............. 3- 2
SIGNALWORD I CLASSlFlCATlON
STABlLlTY OF LIFT TRUCK ........................................ 3- 3
a DANGER

WARNING
Failure t o follow the instructions i n the
message will likely cause a serious accident
or death.
Failure to follow the instructions i n the
message might cause a serious accident or
death.
USlNG INCHlNG PEDAL (T TYPE) ............................. 3- 3
TRAVELING AND STARTING ON A SLOPE .............. 3- 3
TRANSPORTING LIFT TRUCK ................................... 3- 4
OPERATING LIFT TRUCK ........................................... 3- 4
MEASURES AGAlNST COLD OR HOT WEATHER ....... 3-10
I
a CAUTION
Failure t o follow the instructions i n the
message may cause personal injury or
damage to the truck or other property.
IN COLD WEATHER ..................................................... 3-10
IN HOT WEATHER .................................................... 3-12
LOAD HANDLING ............................................................ 3-13
9NOTE The information will help to prolong the
service life of the truck. The message is not PICK-UP .................................................................. 3-13
directly related to accident prevention. STACKING .................................................................. 3-13
UNSTACKING ................................................................ 3-14
STORING ............................................................................ 3-15
BEFORE STORING; DAILY STORAGE ...................... 3-15
LONG-TERM STORAGE; OPERATING AFTER
LONG-TERM STORAGE .............................................. 3-16
rnurtn u r c m ~iuiu
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To operate the lift truck safely and get the most out of it, correct RELATIONCHIP BETWEEN LOAD AND
procedures are described on the following pages: STABlLlTY OF TRUCK
The lift truck keeps a balance of weight between the truck and
DURING BREAK-IN the load on the forks with the center of the front wheels as a
We recommend to operate the truck under light load conditions fulcrum when the rated capacity load is placed in position.
for the first stage of operation to get the most from it. Especially, Due care should be paid to the weight and the load's center of
the requirements given below should be observed while the gravity to maintain stability.
truck is in a stage of 200 hours of operation.

A Always warm up your truck before putting it into work

regardless of the seasons.

A Perform specified preventive maintenance services

carefully and completely.

A Never "race" or play games with the truck. Avoid

sudden stops, starts or turns.

A Oil changes and lubrication are recommended to do If the rated capacity is exceeded, there is a danger of the rear
earlier than specified. wheels being raised and in the worst case, the truck will turn
over, resulting in a fatal accident. The load placed near the
fork tips practically has the Same effect that the weight of the
A Do not run the engine needlessly at high rpm without
load is increased. In this case, the load weight must be reduced
load.
accordingly.
 / 1
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---,
5 PROPER OPERATWN
: -
BASIC LOAD CENTER AND RATED LOAD
A CAUTION
e When traveling with loads, keep the forks 15 to 20 cm
(6 to 18 in.) above the ground surface and keep the
mast tilted back fully.
The allowable load of a truck equipped with an
attachment is reduced in comparison with that of the
standard truck.

If the truck is equipped with a load-handling means such as a

hinged fork, load grab, or rotating clamp, its allowable load
will be reduced as compared with that of the standard truck
(a truck without any attachment) for the following reasons:
Never exceed the allowable load indicated on the load The basic load center is the distance from the front face of the
chart attached onto the truck or attachment. forks to the load's center of gravity. The chart given above
Reasons for a reduction in the allowable load: shows the relationship between the basic load center and the
The weight of an attachment is added. weight of loads to be allowable for the 2-ton truck. This chart
The attachment shifts the basic load center position is called a load chart and is attached to the truck.
forward, and thus the allowable load is reduced.
 -
STABlLlTY OF LIFT TRUCK USING INCHING PEDAL (T TYPE)
The stability of lift trucks is stipulated in JIS (Japanese industrial The inching pedal works in the Same manner as the clutch
Standards) or in other national industrial standards, and TCM pedal of the C type truck.
lift trucks are manufactured complying with these standards. Use the inching pedal to move the truck inch by inch while
However, note that the stability oflift trucks is not assured at operating the load handling means at high speed.
all times, but only when the following conditions are properly 1) Press the inching pedal to the floor.
observed. 2) Place the direction shift lever into the forward (or reverse)
position.
The ground or floor surface is level and hard. 3) Step on the accelerator pedal gradually while releasing the
The truck travels under standard loaded or unloaded inching pedal little by little, to move the truck inch by inch.
condition.
The truck is operated carefully and the forks are properly TRAVELING AND STARTING ON A SLOPE
manipulated; that is, the forks are not tilted forward more When traveling on a slope with a load on the forks, have the
than necessary, when stacking or unstacking. load pointed up-hill.
Load handling is carried out carefully and slowly. When traveling on a slope without load, have the rear end
of the truck pointed up-hill to prevent the drive wheels from
In addition, keep the truck in good working condition for safe skidding.
operation and traveling. When descending or on a slope, use the brake pedal, but
not the inching pedal. If the inching pedal is pressed on a
Standard unloaded condition downward slope, engine braking will not be available to make
This means that the forks are raised 30 cm (12 in.) above it difficult to brake the truck. If the inching pedal is used when
the ground or floor surface and tilted back fully without starting the truck on an uphill slope, the truck might slip down.
loads.

Standard loaded condition

This means that the forks are raised 30 cm (12 in.) above
the ground or floor surface with a load placed at the basic
load center position of the forks.
 -- -
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3
PROPER OPERATION ;

TRANSPORTING LIFT TRUCK OPERATING LlFT TRUCK

MOUNTING AND DISMOUNTING
a CAUTION
Transporting the lift truck on a trailer truck A CAUTION
Securely lock the lift truck in place to prevent it from Do not hold the steering wheel when mounting or
moving on the trailer truck by fastening with wire ropes dismounting. Do not jump on or off the truck.You could
and blocking the wheels. slip or fall and get injured.
When loading or unloading the lift truck onto or from
a trailer truck or when traveling over public roads, pay 1) Make sure there is no approaching vehicle or passerby.
attention t o the overall length, overall height, and Make Sure the truck is at a complete stop.
weight and observe the local traffic regulations. 2) Get on or off the truck from the left side of the truck, using
.
the safety step and hand grip properly.
CAUTIONS T 0 BE TAKEN WHEN LOADING AND 3) Fasten your seat belt securely. The seat belt helps protect
UNLOADING LIFT TRUCK you if there is an accident.

A CAUTION STARTING ENGINE AND AFTER ENGINE HAS

STARTED
Never try to move the steering wheel when halfway up
a ramp; otherwise the truck might fall down, leading
to a serious accident.
a CAUTION
Use ramps of sufficient length, width, and strength. Do not try to start the engine unless you are seated
Before loading or unloading the lift truck, make sure properly in the driver's seat.
to apply the parking brake to the trailer truck and block Make sure there is no one around the truck before
its wheels. starting the engine.
Ramps must be securely locked t o the trailer truck. When starting the engine indoors, Open the windows or
Their surface must be clean and dry. doors and run the fan to prevent exhaust gas poisoning.
Loading and unloading must be carried out on a level
surface. The right and left ramps must be the Same Make Sure the shift lever is in neutral "N" and the parking and
height. the parking brake is applied securely.
When loading the lift truck onto a trailer truck, back it
up the ramps slowly with care. 1) Seat yourself in the driver's seat and insert the starter key
into the starter switch.
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WHEN ENGINE WON'T START 2) Pull back on the tilt lever to tilt back the mast fully.
3) Make sure there is no one around the truck and let other
A CAUTION workmen and bystanders know you are starting up by
honking.
Never try to start the engine by pushing or towing the
truck.
STARTING LlFT TRUCK
Do not keep the starter motor engaged for more than 10
seconds at a time. If the engine does not start 10 seconds A CAUTION
after engaging the starter motor, stop the operation of the Slow down when:
starter motor. Wait for a while and start-all over again. Making turns
If the engine is hard to start despite several tries, check the Running at narrow aisles
fuel level in the fuel tank, the fuel system for mixing of air, or Running on rough surfaces
the electrical wiring for a broken wire. Approaching to ioads or obstacles.
The engine might not start if the starter motor does not reach
a specified rpm. If this is the case, start the engine using an
auxiliary battery and booster cable. 1) Press the clutch pedal to the floor.
2) Place the direction shift lever in the forward (reverse)
$j'NOTE position.
For "Starting with Auxiliary Battery", see Page 4-26. 3) Place the speed range shift lever in the Low position.
4) Release the parking brake lever.
5) Press the accelerator pedal while releasing the clutch pedal
BEFORE STARTING LlFT TRUCK slowly to start the truck.

A CAUTION 8 NOTE
Make sure there is no one around the truck and let other Do not keep your foot on the clutch pedal after the truck
workmen and bystanders know you are starting up by has started; otherwise the clutch dick will wear out
honking. prematurely.

1) Pull back on the lift lever to raise the forks 15 to 20 cm from

the ground or floor surface.
rnurti-r urcnili i u i u
- . -

versa, start the truck and accelerate the speed. Then, release
the accelerator pedal while pressing the clutch pedal and
A CAUTION change the speed range. Press the accelerator pedal while
Press the brake pedal to the floor before placing the releasing the clutch pedal quickly.
shift lever into the forward (or reverse) position;
otherwise the truck starts moving slowly or creeps when
the shift lever is placed into forward or reverse. When reversing the direction of travel, from forward to reverse
or vice versa, be Sure to bring the truck to a complete stop.
NOTE
SLOWING DOWN
Do not keep your foot on the inching pedal during traveling
after the truck has started.
Release the accelerator pedal and press the clutch pedal. Place
1) Press the brake pedal. the speed range shift lever into Low and press the accelerator
2) Place the shift lever in the forward (or reverse) position. pedal. Press the brake pedal as necessary.
3) Release the parking brake lever.
4) Release the brake pedal and press the accelerator pedal to
start the truck. Ease up on the accelerator pedal. If necessary, press the brake
pedal.
GEARSHIFTING

A CAUTION
When traveling in reverse, look in the direction of travel
and be alert for pedestrians, other trucks or obstacles
in your path of travel. Do not rely too much on the side
view mirrors.

pq
e When reversing the direction of travel, from forward to reverse
or vice versa, be Sure to bring the truck to a complete stop.
When changing the speed range from Low to High or vice
-
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7

A CAUTION
A CAUTION Safe parking
Note that the rear end (counterweight) of the truck Park the truck on a level ground, preferably in a wide
swings when you turn the truck. area.
If parking the truck without load on a slope is unavoidable,
Unlike general passenger cars, the steer wheels are located position the load handling means down-hill and block
at the rear of the truck. This causes'the rear end of the truck the wheels to prevent accidental roll.
to swing out when a turn is made. Slow down the truck and Park the truck in a designated area or out-of-traffic area.
If necessary, put signposts or signal lights around the
move toward a side to which you are turning. The steering
truck.
wheel.should be turned a bit earlier than as with the front-
Park the truck on a hard ground. Avoid soft ground, deep
wheel steering car.
mud or slippery surfaces.
Grab the steering wheel knob with your left hand.
If you cannot lower the forks on the ground due to a
You right hand is used to operate the load handling levers.
broken load handling system, put a caution cloth to the
fork end and park in an out-of-traffic area.
Pay attention to the ground condition because it might
Slow down the truck and press the brake pedal to bring the be slippery.
truck to a stop. Press the clutch pedal (C type) and place the Dismount from the truck after making sure it has come
shift lever into the neutral "N" position. to a complete stop. Do not dismount from the truck in
motion.
$J NOTE Never jump off the truck.
Dismount from the truck, facing the truck and using the
Do not stop the truck on an up-hill slope by controlling the safety step and hand grip.
accelerator pedal; otherwise the clutch disk will wear out
or the torque converter oil temperature will rise abnormally. Park the truck in an out-of-traffic area and follow the procedure
given below:
1) Pull the parking brake lever to the full to apply the parking
brake.
2) Lower the forks on the ground.
3) Turn the key switch "OFF" to shut down the engine.
4) Dismount from the truck carefully.
rnurtn u r t n ~IUN
- i ..
-
' 1 . 1 -
GROUND CONDlTlON VRAVELING ON SNOWY OR FROZEN ROAD

A CAUTION A CAUTION
Use due caution when traveling on a rough surface. Note that fitting of optional tire chains will increase
When crossing a railroad, be Sure to once stop, make traction, but can hardly prevent the t r u c k from
Sure to be safe and Cross the railroad track at an angle sideslipping.
wherever possible.
Go around obstacles such as rocks and stumps, or When traveling on a snowy or frozen road, use tire chains.
pot holes. If unavoidable, reduce the speed and go Avoid sudden acceleration, stops or turns; otherwise the truck
over slowly and carefuliy. Use caution not to damage might skid to cause a serious accident.
the bottom of the truck. Cross a small bump diagonally Control the traveling speed carefully using the accelerator
if the aisle width is enough to do so. pedal.

Lift truck performance depends upon the ground condition or $3 NOTE

floor condition and travel speed should be adjusted properly.
Some trucks require the replacement of some parts when
using tire chains.
For more information, consult your local TCM dealer.
 MEASURES AGAINS;T COLD OR HOT WEATHER
IN COLD WEATHER
When using the truck in a cold weather, special care should V

be taken more than when using it in a hot weather. 2 0

3
+-
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-
-20
Caution to be taken when adding fuel al
-30
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A CAUTION C

al
-40

1 -50
When adding fuel, make Sure to shut down the engine. LL 0 10 232530 40 50 60 70 80 90 100

Never smoke. Concentration

Add fuel up to the upper limit of the tank. This will help prevent
the freezing of water content contained in the air inside the Fr0zet-1cooling water might damage the engine or radiator.
tank or the fuel system from corroding, which makes it difficult VVhen the ambient temPerature is anticipated to be below O°C,
for the engine to start. add anti-freeze into the cooling water. If you do not use anti-
freeze, make sure to remove all the cooling water after the
f$
! NOTE day's work. When the truck has a label given at the right, it
Make Sure the fuel cap is securely tightened. uses cooling water containing 50% LLC (Long Life Coolant).
(A loose cap will allow rain water or Snow to enter the fuel If this is the case, there is no need to change the cooling water
tank.) for 2 years. When addition of cooling water is needed, use
cooling water containing one part of water and one part of LLC.
Caution to be taken for the cooling system

A CAUTION
Handling LLC
The LLC is flammable. Do not use Open flame when
adding, changing or storing it.
The LLC is poisonous. (Lethal dose: 100 cc). Do not
swallow it. If anyone swallowed it accidentally, induce
vomiting immediately and get medical attention.
When storing, put a sign "Dangerous substance" and
keep it out of reach of children.
MkASUKtS ASAAINSs I GUF - V U K i!U 1 V V t i r i ncn
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Battery care

A CAUTION Cautions to be taken when handling battery

Never pour hot water over the battery case even if you
find it difficult to start the engine. The battery case might Gases produced by the battery can be explosive. Do
break, causing a serious accident. not smoke. Do not use Open flame for inspection.
No fire. Do not smoke. Keep sparks or Open flame away
The battery hardly freezes and works efficiently when it is from the battery.
completely charged and has a greater specific gravity of the Keep proper electrolyte level. If the level is too low
electrolyte. (below LOWER LIMIT), the battery will build up heat,
If the electrolyte freezes, the battery case will be broken. Keep leading to an explosion.
the battery in fully charged condition at all times. Have a good ventilation. Do not use or store batteries
The battery electrolyte usually freezes at about -35°C when in a closed place or an area where ventilation is poor.
the battery is in a fully charged condition. Avoid electroshock accident. Wear rubber gloves when
servicing and inspecting the battery.
To prevent freezing Sulfuric acid. The electrolyte is sulfuric acid and thus
Keep the battery's state of charge to more than 70%. it might cause burns or blindness if it comes in contact
Keep the specific gravity of electrolyte at 1.280 or less. with the skin, eye, or clothing.
When the truck is not in use, remove the battery from the If electrolyte comes i n contact with your skin or
truck and store in a warm place. clothing, wash it away using a copious amount of
water immediately.
NOTE If electrolyte gets into your eyes, wash your eyes with
When adding purified water to the battery, make Sure to a copious amount of water immediately and get
add it immediately before charging or starting the truck. medical attention.
 MEASURES AGAINST COLD OR HOT WEATHER
IN HOT WEATHER Measures to be taken when the engine has
overheated
Cooling system
A CAUTION
A CAUTION If the engine has overheated, do not Open the radiator
cap. In addition, do not touch the radiator reservoir
Make sure the engine is cold before opening or closing
tank. Hot steam might spout out, causing burns.
the radiator cap. Hot cooling water might spout out to
cause serious burns.
When the engine has overheated:
1) Let the engine run at idle rpm for a while and Open the engine
To get a good cooling effect, use caution not to allow leakage
hood fully to get a good ventilation.
of cooling water and the forming of scale or corrosion in the
2) After making sure the temperature of the cooling water cools
cooling system.
In hot weather, the cooling system is apt to cause scale or down sufficiently, shut down the engine.
3) Open the reservoir tank and add cooling water.
corrosion. Use caution to get the circulation of clean water
4) Check for water leaks of the cooling system, clogged radiator
at all times. The LLC can be used for all seasons, because
fin, and loose fan belt.
it has anti-rust and anti-corrosion effect in addition to anti-
freezing effect.
A clogged radiator fin will cause an overheated engine. Keep
the radiator fins always clean. In addition, check for water
leaks.
Check for a loose fan belt. If the fan belt is loose, adjust it
for the specified tension.
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- LOAD HANDLING
- C V
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UNSTACKING
1) When approaching the area where the load is to be
retrieved, slow down the truck.
2) Once stop the truck right in front of the load so that the
distance between the fork tips and the load is about 30 cm.
3) Check the condition of the stack.
4) Tilt the mast forward until the forks become horizontal and
lift up to the position of the pallet or skid.
5) Make Sure the forks are positioned properly for the pallet.
Move forward slowly to insert the forks into the pallet as far
as possible. Stop the truck.
* If the forks are hard to be fully inserted, use the following
procedure:
@ Move forward to insert 3/4 of the forks. Raise the forks 5
to 10 Cm, back away 10 to 20 cm with the pallet or skid
on the forks. Lower the pallet or skid on the stack.
@ Move forward again to insert the forks into the pallet fully.
6) Raise the forks 5 to 10 cm off the stack.
7) Check all around the truck to ensure that the path of travel
is unobstructed and back away slowly.
8) Slowly lower the load to a height of 15 to 20 cm above the
ground or floor surface. Tilt back the mast fully and move to
the desired area.
3 I_UKlNU
- -
V L L i .
BEFORE STORING DAILY STORAGE
Park the truck at a specified place and block the wheels.
A CAUTION Place the shift lever(s) in neutral "Nmand pul1 the parking
If any time your lift truck is found to be in need of repair, brake lever fully.
defective or in any way unsafe, the condition should be Shut down the engine and operate the load handling levers
reported to the supervisor, and the truck should be taken several times slowly to remove the residual pressure from
out of service until it has been restored to safe operating the cylinders and hoses.
condition. Remove the starter key and keep it in a safe place.

Before storing the lift truck, clean it thoroughly and perform

inspection using the following procedure:
Wipe away grease, oil, etc., adhering to the body of the truck
with shop rag. Use water, if needed.
While washing the truck, check the general condition of the
truck. Especially check the truck body for dents or cracks,
the tires for wear or nails or stones in the tread.
Check the fuel level and add if necessary.
Check for leakage of hydraulic oil, engine oil, fuel or cooling
water.
Apply grease, where needed.
Check for looseness of the hub nuts and cylinder piston rod
joints.
Check the mast rollers to See that they rotate smoothly.
Lift the forks up to the top position and lower to the lower
limit. Repeat this procedure to prime oil into the lift cylinders.
Drain off the cooling water completely from the cooling
system in winter or cold weather if anti-freeze or LLC is not
used.
 r s

LONG-TERM STORAGE OPERATING AFTER LONG-TERM STORAGE

Perform the following checks in addition to "BEFORE Remove Covers used to seal off moisture.
STORING" and "DAILY STORAGE" services. Remove antirust from the exposed parts.
Taking the rainy season into consideration, park the truck at Drain the crankcase, transmission (C type), differential, and
a higher and hard ground. torque converter (T type), clean their inside and add new
Remove the battery from the truck. oil.
a Even though the truck is parked indoors, if the place is hot Drain foreign matter and water from the hydraulic oil tank
or humid, the battery should be kept in a dry, cool place, and fuel tank.
and charged once a month. Remove the engine cylinder head Cover and lubricate the
Apply anti-rust to the exposed parts such as cylinder rods valves and rocker shafts. Check the valves for proper
and shafts that tend to rust. operation.
Cover components which may be caught with humidity, such Add cooling water to the specified level.
as the air breather and air cleaner. Charge the battery and mount it on the truck. Connect the
Put the truck in the operating state once a week and start cables.
the engine. Warm it up sufficiently before moving the truck Perform pre-operational checks carefully.
a little back and forth. Warm up the engine.
Avoid parking on a soft ground such as an asphalt ground in
Summer.
The following symbols, found throughout this manual, alert you
to potentially hazardous conditions to the owner and the
operator. CONTENTS
Become completely familiar with the truck before proceeding
with operating, checking and servicing. PREOPERATIONAL CHECKS .......................................... 4- 1
GENERAL RULES ON INSPECTION ......................... 4- I
This manual and decals affixed to the truck use the following ITEMS T 0 BE CHECKED ............................................ 4- 3
safety alert indications. PREVENTIVE MAINTENANCE ........................................ 4-16
ENGINE ROOM ............................................................. 4-16
SIGNALWORD I
- -
CLASSIFICATION REPLACING TlRES AND REPAIRING FLAT TlRE ... 4-24
Failure t o follow the instructions i n the REPLACING LAMP BULBS ......................................... 4-25
message will likely cause a serious accident
or death. WHEN YOU CANNOT START THE ENGINE
BECAUSE THE BATTERY HAS BEEN
Failure t o follow the instructions i n the

I
WARNING message might cause a serious accident or EXHAUSTED ................................................................. 4-26
death. ADJUSTING OPERATING FORCE OF PARKING
BRAKE ...........................................................................
A CAUTION Failure t o follow the.instructions i n the
message may cause personal injury or
damage to the truck or other property.
PERlODlC INSPECTION ..................................................
4-27
4-28
PERlODlCAL REPLACEMENT OF SECURITY
The information will help t o prolong the
8NOTE service life of the truck. The message is not
directly related to accident prevention.
PARTS ............................................................................
MONTHLY (200 HOURS) CHECKS ............................
4-29
4-30
3 MONTHS (600HOURS) CHECKS ........................... 4-36
6 MONTHS (1200HOURS) CHECKS ........................ 4-39
ANNUAL (2400HOURS) CHECKS ............................. 4-41
PREVENTIVE MAINTENANCE SCHEDULE ............. 4-42
rn-curcrrnli v l u n r , W - I C U ~ R ~
- L&
-
Before starting the iift truck, be Sure to inspect the foiiowing GENERAL RULES ON INSPECTION
items for safety sake and increased productivity. Use TCM's genuine parts only.
Use TCM's genuine or recommended lubricants only.
A CAUTION Clean the oil fillers and grease fittings using a brush or shop
rag before adding oil or fuel or greasing.
If any fault i s found by preoperational inspection,
Oil level checks and addition of oil should be made with the
attach a sign i n the control area stating D 0 NOT
truck parked on a level surface.
OPERATE, remove the starter key and report the
Preventive maintenance services should be done in an
condition t o the supervisor. Operation of the truck
orderly manner and due care taken to prevent personal injury.
should be halted until the truck is completely repaired.
If unavoidable to work under raised forks or attachment, use
Check for oil leaks. Remember that oil leaks might
a stable support to prevent the forks or attachment from
cause a fire.
falling down unexpectedly.
Waste fluid caused from lubricant change services
Any time the operator finds that the truck or the controls are
must not be thrown away thoughtlessly, because they
not functioning properly, operation of the truck should be
will be a cause of air, water, earth pollution.
halted and the condition reported to the supervisor. Never
The service personnel or employer i s required t o
operate a faulty truck.
dispose of it properly.
1
 PREOPERATIONAL CHECKS -T

IGeneral condition IOil or water leaks

Check the general condition of the truck, in particular, the truck Check for oil or water leaks under the truck. If there is a pool
body for dents or cracks and tires for wear or nails caught in of oil or water on the ground or floor surface, contact your local
the tread. TCM dealer.

State of the truck

Check the inclination of the truck. If the truck is tilted to either
side, it suggests that the tires or wheels are defective. Contact
your local TCM dealer.
PREOPERAI IUNAL GiiEbP 3
- --_i
L d d
-
ITEMS T 0 BE CHECKED
CHECKTHE RESULT OF REPAIRS
PERFORMED ON PREVIOUS CHECKING

A CAUTION
Never try to operate a faulty truck.
Underinflation Good Overinflation
Check to See if any defect found on the previous inspection
has been repaired properly.
The standard tire pressure is indicated on the decal at the left
side of the front guard.
TlRE INFLATION PRESSURE AND TlRE
CONDlTlON CHECK
Front wheels
(both single and double tires) ............... 700 kPa (7 kg/cm2)
A CAUTION Rear wheels
The tires of the lift truck have a high inflation pressure. 1- to 1.8-ton ............................................800 kPa (8 kg/cm2)
Make Sure the tires and rims are normal and inflate the
2- to 3-ton ................................................ 700 kPa (7 kg/cm2)
tires to the standard air pressure. Do not overinflate the
tires.
When using an air compressor to inflate the tires, first Turn the tire valve cap counterclockwise and remove it. Using
adjust the compressor ai r pressure properly. Failure to a tire pressure gauge, measure the inflation pressure and
do so will cause a serious accident since the compressor adjust for the standard inflation pressure.
delivers the maximum pressure. Then, make Sure there is no air leakage from the tire valve,
A small bend of the rim or a slightly damaged tire might reinstall the tire cap.
cause a flat tire, leading to a serious accident. If you find
any failure, contact your local TCM dealer.
Check that each tire does not get damaged at the tread surface
or side face or bending at the rim.
pressure of the tires alwa~s
the inflation at proper level'
The lift truck needs tires that have a high inflation pressure for
8 NOTE carrying heavy loads.

Low air pressure reduces tire service life. Unevenness of

air pressure between right and left tires will cause hard
steering or the truck to wander.
 PREOPERATIONAL CHECKS
-/ . f
* \
+

HUB NUT CHECK

A CAUTION
A CAUTION Do not use tires whose bolts securing the split type rim
assembly are loose.
A loose hub nut can be dangerous. In the worst case, the The front single tires and rear tires use split type rim
wheel Comes off the truck, causing the truck to tip over. assembly in which the inner and outer rims are bolted
together. If any tire has a loose rim connecting bolt, do
Check the hub nuts for looseness. All hub nuts should be not operate the truck.
Remove the air valve core to remove the air from the tire
tightened to the specified torque. and detach the tire from the truck. (For more information
about the procedure for removing the tire, See Page 4 -24.)
HUB NUT TlGHTENlNG TORQUE Loosen the split rim connecting bolts using a special tool.
It i s advisable t o ask a specialist t o retighten the
Unit: N-m (kgf-m)
connecting bolts, disassemble and reassemble the tire
Front wheels (Single tire) Rear wheels and rim, and inflate the tire. (The disassembly, reassembly
and inflation of tires should be performed only by qualified
1- to 1.8-ton 147 - 172 (15-17.5) personnel.)
trucks [Double tires: 226 - 275 (23 - 28)]

2- to 2.5-ton 471 - 549 (48 - 56) 128 - 190

trucks The double-tire specification is the same. (13 - 19.4)

471 - 549 (48 - 56)

3-ton trucks
The double-tire specification is the same.

Tightening order for double nuts

Double tires are installed by locking the inner tire rim with inner
1.O- to 2.5-ton trucks (front wheel)
hub nuts (square nuts) and then by locking the outer tire rim
with outer hub nuts (hex. nuts).
First, tighten the inner nuts (square nuts) in a diagonal order
to the specified torque and then tighten the outer nuts (hex.
nuts) in the same manner as above.
Tightening drive shaft mounting bolts (nuts)
If any loose bolt or nut is found, retighten it to the following @ Hub nuts
torque: @ Rim connecting bolts
- -
96 11 N-m (9.8 11.3 kgf-m) @ Drive shaft mounting bolts
 .I J
.

OVERHEAD GUARD
1A CAUTION
Pull the hood opening lever and Open the hood fully. Make
sure the hood is locked securely and remove your hand.

BATTERY ELECTROLYTE LEVEL

A CAUTION
Do not use or charge the battery with the electrolyte
level below the "LOWER LEVEL"; otherwise the inside
of the battery deteriorates to cause a short battery life
and in the worst case it might cause an explosion.
Check the overhead guard for loose mounting bolts or nuts or Never use Open flame for checking the electrolyte level.
darnage. There is a danger of causing an explosion.

BRAKE FLUID LEVEL (excl. trucks with power

brake)

You can check the brake fluid level from outside the reservoir Check the battery electrolyte level.
tank, without having to remove the tank cap. Keep the electrolyte level between the "UPPER LEVEL" and
Make Sure the fluid level is as specified. "LOWER LEVELJJon the battery case.
 COOLING WATER LEVEL REMOVING RADIATOR CAP

A CAUTION
Do not try to remove the radiator cap when the engine
is hot; otherwise you will get burnt. The cooling water
level should be checked before starting the engine or
when the engine is cold.

When removal of the radiator cap is needed, observe the

following conditions:
Release the pressure before removing the cap
There is a pressure inside the radiator. First, loosen the cap
by turning it counterclockwise a little to release the pressure,
Check the cooling water level when the radiator is cold. Make
Sure that the cooling water level between "FULL" and "LOW"
markings on the cooling water reservoir tank.
. and then remove the cap.
U„ mution not to get burnt
When releasing the pressure, use a thick waste cloth. (Avoid
If addition of cooling water is needed, remove the reservoir putting on gloves since you may get burnt at your hand if
tank cap and add clean (soft) water. hot water splashes on it. Do not peep into the filler port. It is
dangerous.)
PREOPERATIUNAL C;HtGw.S
- .-d /-
i
U
i
'-
-
ENGINE OIL LEVEL

A CAUTION
The exhaust system is hot immediately after the engine
is shut down. Use caution not to get burnt.

The engine oil level dipstick is located at the left side of the
engine. Remove the dipstick, clean the rod and reinstall. Pull
it out again and check the oil level. The level should be within
the range between the High and Low marks on the dipstick.
Do not add engine oil above the High mark on the dipstick.

$f NOTE
Engine oil level check should be performed with the truck
parked on a level surface before starting the engine. You
cannot know the correct oil level immediately after the
engine is shut down. Wait for about 10 minutes before
checking the oil level.
 PpEOPERATlONAL CHECKS
F.

FAN BELT Check the fan belt for proper tension and cracks or damage.
Belt deflection
CAUTION Engine mode' (when a pressure of 98 N (10 kgf) is applied)
Make sure the engine is shut down before checking the H15 . H20 . H25 12 - 14 mm
fan belt for tension. 4LB1 10 mm
C240 10-15mm
V3300 10 - 12 mm

GE
PU
CRANK PULLEY
CRANK PULLEY

pzEö4q pi-1

NG Keep fingers or objects' R

away from fan when

engine is running.
J CRANK PULLEY
rneurtnili IUNWL
- L~ELF-~
-
-- d

REAR COMBlNATlON LAMP 1

11
1HYDRAULIC OIL PlPlNG AND CYLINDERS
check the rear combination lamps (turn signals, tail lamps, Visually check the hydraulic oil piping and lift and tilt cylinders
brake lamp, back-up lamp, and rear reflector) for a damaged for eil leaks.
or contaminated lens.
1121TORQUE CONVERTER OIL LEVEL (TTYPE)
1101HYDRAULIC OIL LEVEL

Check the hydraulic oil level in the tank using the oil level
dipstick.
Remove the dipstick, clean the rod with a clean cloth and
reinsert it. Remove the dipstick again and check the oil level.
If the level is low, add hydraulic oil.
"H" mark: Highest position of the standard truck
"L" mark: Lowest position of the standard truck
"S"mark: For trucks with a lift height of 6 m or more or for
The torque converter filler cap is located under the
special trucks, the oil level should be within 10 mm
floorboard.
above or below this mark.
Remove the oil dipstick of the filler cap. Clean the rod with a
"HP" mark: Use this mark for 2- to 3-ton trucks with high-power
clean arid reinStall it.
specification.
Remove the dipstick again and check the oil level.
The oil level should be within the specified range. lf the level
$3 NOTE is low, add oil.
The oil level check should be performed with the engine
shut down, the mast vertical, the forks on the ground or
floor surface, and the truck parked on a level surface.
1131LOAD BACKREST 1
15 HEAD LAMPS AND COMBlNATlON LAMPS
Check for dirty or damaged lens of the head lamps. Check
A CAUTION also the combination lamps (clearance lamps and turn signals)
Do not modify or remove the load backrest. for a dirty or damaged lens.
The Operator might get injured by a falling load.
The forks might come off the carriage.

A CAUTION
Take care not to pinch your fingers in the hood.

116)ADJUSTING DRIVER'S SEAT AND STEERING

COLUMN ANGLE
Get on the truck and adjust the driver's seat to a position which
provides easy access to all foot and hand controls. Also make
Sure you can operate the steering wheel smoothly.
Check the load backrest for damage or loose or missing After adjustment of the driver's seat position arid steering
mounting bolts. column angle, lock the seat and steering column securely.
Retighten where needed.

1141 FORKS AND FORK STOPPERS 1171SIDEVIEW MIRRORS

I

Check the sideview mirrors for contamination or damage.

FORK STOPPER
Adjust the mirrors to gain full rearview when you are seated in
the driver's seat.

Check that the fork stopper are properly engaged, the fork lock
bolt at the middle of the carriage is not damaged, the forks are
not bent and do not have cracks.
 1221FUEL LEVEL
-4

SHIFT LEVERS
Check the direction and speed range shift levers (C type) Check the fuel level using the fuel level gauge on the meter
and shift lever (T type) for looseness and smooth operation. panel.
Make Sure the fuel level is sufficient for the day's work or for
119 LOAD HANDLING LEVERS each shift. In addition, if the truck is equipped with a water
temperature gauge or oil temperature gauge, check it, too, for
CAUTION proper operation.
Note that the forks drop when the lift lever is pushed
forward even if the engine is not running.
123 LIGHTS AND LAMPS
Operate the lighting switch to check if the lights and lamps
Check the load handling levers (lift, tilt and attachment) for come on and off properly.
looseness and smooth operation.
1241TURN SIGNALS
1201PARKING BRAKE OPERATION Operate the turn signal lever to See if the turn signals blink
Pull the parking brake lever to check if the parking brake is normally.
properly applied.
1
x
1HORN
Press the horn at the center of the steering wheel to check if
A CAUTION the horn sounds properly.

Make Sure the shift levers are in neutral "N" and the
parking brake is applied before starting the engine.

1211WARNING LIGHTS
Turn the starter switch from "OFFn to "ON". Make Sure the
warning lights come on in red and go out soon after the engine
has started.
1261CLUTCH PEDAL (C TYPE) BRAKE AND INCHING PEDALS
CLUTCHPEDAL A CAUTION
If the pedal returns poorly or the pedal height is not as
specified, check the return spring and take necessary
measures. If neglected, the pedal might become locked,
making it difficult to press.

BRAKE PEDAL

Press the clutch pedal to check if it operates smoothly. Release

the pedal to check if it returns securely. Play: 5 mm (C type)
15 mm ( T type)
(For trucks with power clutch, start the engine before checking
the clutch pedal.)
type)
type)

INCHING PEDAL
Press the brake pedal and inching pedal (T type) to check if 1291LIFT CHAlN TENSION
the pedal can be pressed smoothly and returns securely.
Check the brake pedal and inching pedal for play (see the
sketches).

1281MAST OPERATION
Operate each of the lift and tilt levers to check if the forks and
mast operate smoothly without squeaking. Check also each
lever for looseness. (If the truck is equipped with a hydraulic
attachment, check the attachment itself and its control lever.)

NOTE
WARMING UP CYLINDERS
Before starting the day's work, warm up the cylinders. This
lubricates packings and seals in the cylinders to make them
Raise the forks 50 mm off the ground or floor surface and check
ready for operation.
that the right and left lift chains have the same tension.
I f uneven tension is found, adjust the tension using the
adjusting nut @ of the chain anchor bolt. After adjustment,
securely tighten the lock nut @.
 ,. PPEOPERATIONAL CHECKS

1301STEERING WHEEL 1311EXHAUST GAS CONDlTlON

A CAUTION
Exhaust fumes are very dangerous. When starting the
lift truck i n an enclosed space, make sure there i s
enough ventilation. The exhaust gas check should be
done outdoors.
Especially use caution t o avoid fire hazards. Pay
special attention to signs of oil or fuel leaks, and never
leave waste cloth or paper inside the engine room.
Make sure you know where the fire extinguishers are
kept and how to use them.

Check the condition of exhaust gas after the engine has been
Turn the steering wheel counterclockwise and clockwise to
warmed up.
check for play.
Colorless or light blue: Normal (Complete combustion)
The normal play is within the range of 50 to 100 mm. Check
Black: .................Abnormal (Incomplete combustion)
also for vertical looseness.
White: ................Abnormal (Oil burns)
Check also the engine for abnormal noise or vibration.
#(at an out-of-traffic area)
. . #

1321CLUTCH PEDAL OPERATION TEST (C TYPE)

Run the truck slowly and press the clutch pedal for proper
operation.
Run the truck slowly and press the inching pedal (T type)
a little to check if the truck slows down.

1331BRAKE TEST

Run the truck at a low speed and turn the steering wheel a
little to the right and left to check if the truck is steered properly.

1351PARKING BRAKE TEST

Pull the parking brake lever to check if the truck is properly
braked.
Also make Sure the truck does not move and keeps its stopping
Run the truck slowly and press the brake pedal to check if the
truck is braked properly without being pulled to one side.
Make Sure the brake lamps come on when the brake pedal is 1361BACK-UP LIGHT AND ALARM TEST
pressed. Check that the back-up lamp Comes on and alarm sounds when
the shift lever is shifted into reverse "Rn.
 1 , . PPEVENTIVE MAINTENANCE

ENGINE ROOM

HYDRAULIC 1 CARBURETOR \
I
DISTRIBUTOR
OIL TANK CAP I
HYDRAULIC OIL TANK BLOW-BY
SUCTION PIPE GAS HOSE
r m g v CIY I I V E, iviniiu I ICIYHIY,\~L
- /' -1

ENGINE ROOM

HYDRAULIC
OILTANK CAP \
HYDRAULIC OIL
I
BLOW-BY
GAS
\
CRANKCASE
WATER
I

SEDIMENTER

SUCTION PIPE BREATHER

REMOVING WATER FROM SEDIMENTER 3) Pump the priming pump a few times to drain water from
- ~

inside the sedimenter.

4) Tighten the drain plug securely and pump the priming pump
A CAUTION another few times to make sure there is no fuel leak from
the drain plug.
Wipe away any split fuel from areas around the 5) Start the engine and make Sure the sedimenter warning light
sedimenter. There is a danger of causing a fire hazard. is off.

FILTER GASE

The water sedimenter separates water from fuel. It is integral

with the fuel filter.
When the sedimenter warning light Comes On, it indicates that
more than the specified amount of water has accumulated in
the sedimenter. Remove the water in the following manner:
1) Shut down the engine.
2) Turn the drain plug to loosen it.

NOTE
Do not loosen the drain plug exceedingly; otherwise fuel
might spill.
r n c V c i u I IV c i v i n i l u r C I u n I p L
i
-
L' L
-,

AIR BLEEDING FUEL SYSTEM

1) Loosen the air bleeding plug (overflow valve) of the injection
pump.
A CAUTION 2) Loosen the priming pump of the sedimenter and pump the
Make Sure there is not any fuel leak from the air priming pump until the fuel' coming from the plug hole is
bleeding plug port. If any, there is a danger of causing free from bubbles.
a fire hazard. 3) Reinstall the air bleeding plug securely.
Wipe away any split fuel from areas around the air 4) Tighten the priming pump securely.
bleeding plug. There is a danger of causing a fire
hazard.
This engine uses an automatic air bleeding system.
1) Turn the starter switch to the "ON" position.
The electromagnetic fuel pump operates to send fuel under
pressure into the nozzle holder and piping so that any air
trapped in the system will be forced out into the fuel tank.
2) Start the engine to make Sure there is no fuel leak from the
fuel system.

Whenever the fuel filter is replaced or the fuel tank is drained,

air bleed the fuel system in the following manner:
 REPLACING FUEL FILTER CARTRIDGE
A CAUTION
Keep the air bleeding cock always closed except when
performing air bleeding; otherwise the engine will stall. A CAUTION
Use caution to prevent dust or dirt from adhering to the
filter when installing a new filter cartridge. The entrance
of dust or dirt into the fuel will result i n premature wear
of the fuel injection pump or the injection nozzle.

AIR BLEEDING JOINT BOLT JOINT BOLT

1) Fill the fuel tank with fuel and Open the cock.
2) Loosen the joint bolt of the fuel filter a few turns.
3) Wait until the fuel coming from the joint bolt hole is free
from air bubbles. Then, tighten the joint bolt. 1) Replace the fuel filter cartridge according to the
4) Open the air bleeding cock above the injection pump. PREVENTIVE MAINTENANCE SCHEDULE.
5) Wait until the fuel coming from the air bleeding cock is free 2) Apply thin coat of fuel the packing of new filter
from air bubbles. Then close the air bleeding cock. cartridge and install the cartridge by hand tightening
securely without using the filter wrench.
3) After replacement, air bleed the fuel system.
REPLACING FUSES FUSIBLE LINK (MAIN FUSE)

TAIL, BRAKE LIGHTS

TURN SIGNAL

BACK-UP BUZZEWLAMP
TRANSMISSION

Check to See that the components in each @ - @ : They function regardless of the As the main fuse for the entire truck, a
circuit are operating properly. If every key switch position. fusible link wire (red cable) is provided at
component in a circuit is not functioning, @-@ I:function when the key
They the positive (+) side of the battery. If the
it indicates that the corresponding fuse switch is in "ON". entire electrical circuit of the truck does
is blown out. Replace the blown fuse with not function, replace this fusible link wire
a spare fuse of the same capacity arid with a new one.
color. Look through here

6@
If some of the components in a circuit do
not function properly, it suggests that a
bulb has burnt out. Replace the burnt bulb
with a new one of the same capacity.
Normal fuse Blown-out fuse
8 NOTE
The fuses protect the electric circuit
against overcurrent. Use fuses of the
specific ampere rating.
REPLACING TlRES AND wheels. ~ u at jack under the truck
REPAlRlNG FLAT TlRE frame.
3) Jack up the truck to an extent that the
tire still remains on the ground. Loosen
the hub nuts ( @ - B).Do not remove
them yet.
4) Jack up the truck until the tire leaves
off the ground. Remove the hub nuts.
5) Remove the tire from the hub.
6) When reinstalling the tire, use the
reverse order of removal.
Tighten the hub nuts in a diagonal
order and evenly.
ssure is out. Loosen only WHEEL LUG
Hub nut tightening torque: See Page
4-4.
After installing the tire to the truck, L for more
heel service
Get tools and jack necessary for replacing adjust the inflation pressure to the
t ires. standard inflation pressure, if needed.

Front wheel / pizGGii1 all air out and check for proper assembly.
lnflate all tires in a safety cage. See
Proceed in the same manner as with the MANUAL for proper pressures.
A CAUTION front wheel tire, except that the position
When removing a tire from the of the jack goes under the counterweight.
truck, remove air from the tire Hub nut tightening torque: See Page 4-4.
completely and then remove the
hub nuts.
1

1 ) Park the truck on a level, hard surface

and shut down the engine. Do not have
any load on the forks.
2) Apply the parking brake and block the
i W L = V k NI I V t I V l B i N I C I l A l m b C
- - , , J
-
Remove a tire from the rim REPLACING LAMP BULBS
If any light bulb burns out, replace it with
A CAUTION a new one of the Same capacity, referring
Before removing a tire from the to the following table:
rim, remove thervalve core t o
release the air pressure from the
Lamp capacity
tire completely. In the case of the
split type rim, remove air from the 1. Head lamp .................... 12V - 55W
tire before loosening the split rim 2. Clearance lamp ........... 12V - 10W
connecting bolt (B); in the case of
the side ring type rim, remove air 3. Turn signal
from the tire before removing the Front .............................. 12V - 27W
side ring (lock ring). Rear .............................. 12V - 23W
The assembling of a tire, tube, rim, 4. Tail lamp ....................... 12V - 8W
and flap and inflating of a tire 5. License number plate
which has been removed from the lamp (option) ................ 12V - 10W
truck should b e done only by 6. Rear work light
qualified personnel. The lift truck
uses tires which have an inflation
(option) ......................... 12V - 55W
pressure far higher than those of 7. Brake lamp ................... 12V - 23W
general passenger cars. The use of 8. Back-up lamp ............... 12V - 10W
improper parts or work procedure 9. Meter panel light ......... 14V - 1.4W
will cause a serious accident. Tires
s h o u l d be i n f l a t e d w i t h them
attached to the truck or by putting
i n a safety cage, even if you are
qualified to inflate tires.
The split r i m connecting bolts
must be tightened to the specified
torque using the special tool, with
the tire inf lation pressure removed
completely.
lnstall the split rim on the truck
with the rim connecting bolt head
pointing outside.
WHEN YOU CANNOT START STARTING WlTH AUXlLlARY @ Connect the red cable (+) to the (+)
THE ENGINE BECAUSE THE BATTERy terminal of the battery on the truck.
BATTERY HAS BEEN @ Connect the black cable (-) to the
EXHAUSTED A CAUTION (-) terminal of the auxiliary battery.
Keep the booster cable in place @ Connect the black cable (-) to the
while the starter motor i s turning; (-) terminal of the frame at a point
Do not push or tow the truck to jump
otherwise sparks occur t o cause away from the battery on the truck,
start it when the battery is exhausted.
an accident. such as to either of the two tilt
While the engine i s not running,
Never allow the (+) terminal of the cylinders.
power steering and power brake are
booster cable to come in contact 3) Start the engine.
inoperative.
with the (-) terminal of the booster
When the battery has been exhausted, cable. $f NOTE
use an auxiliary battery to start the For more information, see "STARTING
engine. ENGINE AND AFTER ENGINE HAS
STARTED" on Page 3-4.
CAUTION T 0 BE TAKEN WHEN
STARTING ENGINE WlTH 4) After the engine has started, remove
AUXlLlARY BATTERY
the booster cables in the reverse order
of connection.
I When starting the engine using an I
II auxiliary battery, make sure t o
c o n n e c t t h e (-) c a b l e finally.
Connect the cable to a point away
II
I from the battery, such as either of I
I the two tilt cylinders, but not to the I
1) Make sure that the auxiliary battery
help prevent t h e occurrence of supplies 12 V.
2) Connect the booster cables in the
following order:
@ Connect the red cable (+) to the (+)
terminal of the auxiliary battery.
 r n g v c i u i i v t ivilriiu I CIYHIUGE 7
- "

'. ' 'J

ADJUSTING OPERATING
FORCE OF PARKING BRAKE

ADJUSTMENT 3) The cable of a new truck tends to

1) Engage the spring scale to the parking elongate. It is advisable to adjust it
brake lever as shown above and sometimes after the day's work or each
measure the force required to operate shift.
the lever.
Standard operating force: 200 - 250
N (20 - 25 kg).
2) If the measurement is not within the
range of the standard operating force,
turn the adjustment bolt with a
screwdriver to adjust the operating
force of the lever.
Reduce by turning the bolt
counterclockwise.
lncrease by turning the bolt clockwise.
Just as your body needs to undergo physical examinations,
your truck needs periodical checks and maintenance.
When the truck appears to be in good condition, checks and
maintenance are likely to be neglected. But early discovery of
trouble which may decrease truck efficiency and immediate
correction, will greatly increase the working capacity of the
truck, bring about greater productivity, prolong its life Span and
make it more economical.

Preoperational checks, the addition of oil, grease and fuel, and

cleaning of filter elements should be carried out by the customer
and other complicated checks and maintenance should be left
to your TCM dealer. If enough knowledge, special tools or
equipment is not available, personal injury could occur during
checking or servicing. In this manual, the periodic inspection
intervals are indicated as the number of months (years) as
well as operating hours. Every one month of operation is
calculated as 200 operating hours.

A CAUTION
Be Sure to read INSPECTION AND MAINTENANCE in this
manual before checking or servicing the truck.
r c r i l u u 1 b I I Y ~ II~ IUIY
C ~
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-

L L,
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PERlODlCAL REPLACEMENT OF SAFETY
PARTS
In order to perform safe operation, the importance of preventive
maintenance of the truck cannot be overemphasized.
Especially, the parts listed in the table below must be replaced
periodically since they are the most important parts for safety
of the truck and operator.
Moreover these safety parts are liable to be damaged and
deteriorated in the Course of time, and it is difficult to determine
by ordinary maintenance whether they are beyond their
respective service Iimits or not. The safety parts must be
replaced with new ones when their respective service limits
have been reached, even if their appearances are good.

8 NOTE
The safety parts are, however, not the objects of warranty
Claim.

Recommended
Name of safety parts replacement
interval (year)
1 Master cylinder and wheel cylinder
cups and dust seals 1
2 Power steering hose 2
3 Reserve tank tubing 2-4
4 Fuel hose 2-4
5 Torque converter rubber hose 2
6 Rubber parts inside power steering
unit 2
7 Lift chain 2-4
8 Load handling means hose 1-2
MONTHLY (200 OPERATING HOURS) ltems to be checked
CHECKS
Air cleaner - Clean element.
Engine oil - Change [I week (50 operating hours) for the
Perform preoperational checks in addition to the following.
first time only].
Cylinder head bolt - Retighten (gasoline engine trucks,
The adjustment and replacement of components and parts
for the first time only).
listed as monthly check items are difficult and need a sufficient
Fuel filter - Check for clogging (gasoline engine trucks).
technical knowledge and special tools.
Cooling system rubber hose - Check for deterioration.
Radiator cap - Check for function and proper installation.
Shift levers - Check for proper operation and looseness.
Torque converter and transmission - Check oil level.
Front axle - Check for oil leak.
Front axle mount bolt - Check for looseness.
Tire tread - Check for wear or foreign matter.
Front and rear axles - Check for deformation, cracks or
damage.
Steering gear box - Check for oil leak.
Rod, arm and king pin - Check for looseness, warping or
damage.
Rear axle - Check for proper installation.
Clutch booster - Check master cylinder oil level (trucks
with power clutch)
Clutch booster - Check piping, master cylinder and release
cylinder for oil leak.
Oil clutch - Check oil level in the tank (trucks with optional
oil clutch).
 I
L
-1

ltems to be checked
LUBRICATING LIFT CHAlN
Brake piping - Check for the entrance of air.
Brake system rods and cables - Check for proper
operation and looseness.
Brake piping - Check for damage, leaks, intervention or
looseness.
Brake fluid - Check for leaks.
Forks - Check for cracks or wear.
Mast - Check for cracks or damage.
Mast support - Check cap bolts (first time only)
Lift cylinders - Check for looseness of tail fixing bolts,
piston rod head mounting bolts, cylinder U bolts and piston
head guide mounting bolts (first time only).
Carriage - Check for cracks or damage.
Mast rollers - Check loose rollers, cracked or damaged
roller pins. Apply engine o'il to the lift chains using an oiler or brush. To
Lift chain - Check for elongation. allow oil to enter between each pin and link plate of the lift
Lift chain - Lubricate. chain, observe the following conditions:
1) Loosen the chain sufficiently.
Lift chain and anchor pin - Check for looseness.
2) After applying engine oil, move the mast up and down at
Sheaves and sheave bearings - Check for deformation,
damage or looseness. least 10 times.
Attachment - Check for proper operation and installation.
Control valve - Check for proper operation of relief valve $3 NOTE
and tilt lock valve. If your lift truck is used near a port or coastal area, the lift
Battery - Check electrolyte level and clean. chains might be damaged from salty breezes. After a storm
Wire harness - Check for damage or loose clamp. or typhoon, it is advisable to wach them with water before
Chassis - Lubricate. lubricating in the above manner.
A CAUTION
Do not climb the mast. Do not pour your hand or foot
on the connecting members or into the mast assembly.
You might get injured if the mast moves accidentally.

Apply grease on the U-shape guides shown in the sketch (for

masts with free lift mechanism)
D CHECKING AIR CLEANER ELEMENT Removing the element
Remove the two (or three) clips of the case and remove the
ELEMENT wing nut securing the element. Then you can take the element
out.

Open the engine hood and disengage the air cleaner case clip
and remove the element.
Check the element for contamination or damage. Also check
the rubber seal for cracks or contamination.

Cleaning element

A CAUTION
When using compressed air, wear safety glasses.

To clean the element, blow compressed air from inside out or

tap lightly by hand.
Also check for a rupture or pin holes in the element.
Clean the element once a month (200 hours of operation) and
change with a new one every 6 months (1200 hours of
operation).
 CHANGING ENGINE OIL Oil change (The following explanation is written using the
H20 as an example.)
A CAUTION 1) Remove the engine oil fill port cap.
Do not drain waste oil into a waterway nor throw it away 2) Wipe the cap clean with shop rag.
on the ground. Disposal of waste oil should be left to a 3) Put a pan under the drain plug of the oil Pan.
specialist. TCM dealers will undertake oil change job, if 4) Wipe the drain plug (B) and oil pan clean with shop rag.
required. 5) Loosen the plug using a socket wrench.
6) Once the plug becomes loose, turn it with fingers.
7) Oil will spout out. Place an oil catching pan properly.
8) Clean the drain plug.
9) After oil is drained off completely, reinstall the drain plug.
10) Wipe clean on and around the drain plug.
11) Wind cloth around the oil fill port neck to catch spilt oil.
12) Add oil up to the specified level, leaving a room of about
one liter. Then, gradually add oil, checking the oil level
with the oil level dipstick.
13) Wipe clean areas around the fill port and reinstall the oil
Change the engine oil once a month (200 hours of operation).
However, for new trucks, the engine oil should be changed at fill port cap securely.
the first 50 hours or after one week. 14) Start the engine and run it at idle rpm to prime oil throughout
the engine.
15) Shut down the engine. After a while, check the oil level
CAUTION
using the oil level dipstick. The oil level should be between
Do not try to change the engine oil immediately after the H and L marks on the dipstick. If the level is low, add
the engine is shut down. oil.
The engine oil is very hot. Change the engine oil when
the oil is properly warm.

Before changing engine oil

When the engine is cold, start the engine and let it run at low
rpm to warm it up.
Then, move to a level surface and pul1 the parking brake lever
to park the truck and remove the key. Open the engine hood
fully.
- /- >
F-.
$.
-1
, X
PERIODIC INSPECTION
. --
3 MONTHS (600 OPERATING HOURS) ltems to be checked
CHECKS
Cooling water - Change (every 2 years for trucks using
LLC).
Perform the following checks in addition to preoperational
Crankcase - Check the air breather for contamination and
checks and one month (200 operating hours) checks.
clean if necessary (C240 engine)
Engine oil filter - Change (200 hours for first time only)
Fuel filter - Clean (gasoline engine trucks)
Fuel filter - Change (diese1 engine trucks)
Fuel tank - Drain water.
Fork stopper pins - Check for damage or wear.
Distributor - Check for cracked cap (gasoline engine
trucks)
Distributor - Check the air gap between rotor and stator
and the general condition of rotor (gasoline engine trucks).
Spark plug - Adjust the gap (gasoline engine trucks).
Spark plug - Clean (gasoline engine trucks).
Distributor shaft - Lubricate (gasoline engine trucks).
Starter pinion gear - Check for proper engagement.
Charger - Check for proper operation.
Battery - Check the specific gravity of the electrolyte.
Electrical wiring - Check for loose connections.
 d

CLEANING FUEL FILTER

1 ~ a s o l i n eengine trucks I Diesel engine trucks

A CAUTION
The cleaning and replacement of the fuel filter should
be done with the engine shut down. Keep Open flame
away from the work place.

g
FILTER CASE

SEDIMENTER

... BOWL

ELEMENT
Using a filter wrench, remove the filter case from the cover.
Remove the sedimenter sensor from the bottom of the filter
case. Attach the sedimenter sensor to a new filter case and
DRAIN PLUG install the filter case into the cover.
Sedimenter sensor tightening torque: 12 - 14 N-m (120 -
140 kgf-cm)
Filter case mounting torque: 12 - 14 N-m (120 - 140 kgf-cm)

Loosen the nut and remove the bowl. Remove the element
and clean.
When reinstalling the bowl, remember to install the packing.
Tighten the nut securely.
Use the drain plug when you want to drain contamination or
water from the filter.
CHANGING ENGINE OIL FILTER

H15lH20lH25 C240 V3300

4LB1

A CAUTION Rough guide for tightening

The engine is very hot immediately after the engine is H15, H20, H25: about 113 of a turn
shut down,. Change the engine oil filter after the engine C240: 1/4 of a turn
cools down enough. 4LB1: 314 of a turn

Change the engine oil filter in the following manner: 6) Make sure there is no oil leak from the filter mounting area.
1) Using a filter wrench, loosen the filter cartridge and remove. (Add engine oil to the specified level, start the engine and
2) Get a new filter cartridge. run it at idle rpm for a while.)
3) Wipe clean the cylinder block in the cartridge mounting area.
4) Apply a thin coat of engine oil on the gasket of the new filter $3 NOTE
cartridge. In general, the engine oil filter should be changed for every
5) Hand tighten the new filter cartridge. After the gasket two changes of engine oil.
touches the seal surface, use a filter wrench to tighten the When removing the filter cartridge, engine oil might spill
cartridge (see the table below). over the floor. Put an oil receiving pan or cloth. (The filter
For the V3300, do not use the filter wrench. Hand tighten cartridge holds about 0.54 liters of oil.)
securely.
PtKlUUIG IN3)JtC;I IUN
- .-
i
, .
7

6 MONTHS (1200 OPERATING HOURS) ltems to be checked

CHECKS
Air cleaner element - Change.
Valve clearance - Check.
Perform the following checks in addition to daily checks, one
Blow-by gas reducing device- Check metering valve and
month (200 operating hours) checks, and 3 months (600
piping for clogging or damage (gasoline engine trucks)
operating hours) checks.
Engine oil filter - Change.
lnjection nozzle - Check injection pressure and Spray
pattern.
Clutch and brake fluid - Change
Fuel tank - Clean inside.
Torque converter oil (engine oil or torque converter oil)
and transmission oil (gear oil) - Change.
Torque converter type transmission inline filter - Change
(T type).
Hydraulic oil tank suction filter -Clean.
Hydraulic oil - Change.
Front axle - Change oil.
Front axle: - Check oil level.
Wheel bearing - Check for looseness and noise.
Wheel bearing - Change grease.
Suction strainer - Change.
Steering gear box - Check loose mounting bolt.
Mast support - Check for loose cap bolt.
Lift cylinder (of the view mast) - Check for looseness of
cylinder tail fixing bolts, piston rod-to-connecting member
bolts and cylinder fixing U bolts and retighten where
necessary.
Control valve - Measure relief pressure.
Driver's seat - Check for damage and loose mounting
bolts.
REPLACINGTRANSMISSION INLINE FILTER (TTYPE)

Shut down the engine and release the pressure from the power
transmission line. Remove the filter cartridge shown above and
replace it with a new one. Apply a coat of engine oil to the
packing of the new filter cartridge and install the filter cartridge
by hand tightening. After the packing touches the seat, hand
tighten the filter securely.
The filter cartridge should be replaced with a new one at the
initial 200 hours of operation and thereafter every 1200 hours
of operation.
PEHIUUIG INSPtG I IUN -
-- -/ L, -/

ANNUAL (2400 OPERATING HOURS) ltems to be checked

CHECKS
Cylinder head bolts - Retighten (C240 engine)
Cylinder - Measure compression pressure.
Perform the following checks in addition to daily checks, one
lnjection timing - Check.
month (200 operating hours) checks, and 3 months (600
Governor - Check proper operation (maximum rpm under
operating hours) checks, and 6 months (1200 operating hours)
unloaded condition).
checks.
Fuel filter - Change (gasoline engine trucks).
Clutch retainer bearing - Lubricate.
Clutch oil tank (trucks with optional oil clutch) - Change
clutch oil and clean strainer.
Parking brake - Check for proper operation, wear and
damage.
Master cylinder and wheel cylinder - Check for proper
operation, oil leaks and damage.
Master cylinder and wheel cylinder - Change piston cup
and check valve.
Wheel brake - Disassemble, check, adjust and change
brake drum and brake shoe.
Mast support - Check bushings for wear or damage.
Hydraulic pump drive - Check for wear.
Distributor cap - Check the insertion of high-voltage cable.
Distributor Segment - Check for burns.
Distributor center-piece - Check for wear or damage.
High-voltage cable - Check for breakage.
Main frame and Cross members - Check for damage,
cracks, loose rivets or bolts.
PREVENTIVE MAINTENANCE SCHEDULE
This maintenance schedule is worked out on the assumption that the lift truck will be used under typical working conditions. If the
lift truck is used under severer working conditions, earlier preventive maintenance is required. (The black dots in the table mean
"Change or addition".)
10:Gasoline engine @: Diesel engine I
Checking Monthly Trimonthly Semiannually Annually
Service Required Tools Daily (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
item

Visually check for proper rotation Visual 0 0 0 0 0

Check working noise Auditory 0 0 0 0 0

Check exhaust gas (color) Visual 0 0 0 0 0
Check air cleaner element for contamination and clean, Visual 0 0
if needed

Check crankcase air breather for contamination and Operate 0 0 0

Engine
clean, if needed

Thickness 0 0
Check valve clearance
gauge

Retighten cylinder head bolts

Torque 0 0 (C240)
wrench (first time oniy G)
Compression 0
Check cylinder compression pressure
gauge
Blow-by gas Visual &
reducing Check metering valve and piping for clogging or damage auditory 0 0
device

Governor Check maximum speed under unloaded condition Tachometer 0

Check for engine oil leaks Visual 0 0 0 0 0
Check engine oil for level and contamination Visual 0 0 0 0 0
Lubrication
System
Change engine 0il Operate (at initial 50 hrs)

Change engine oil filter Operate (first time only)

PEBIODIC INSPEC;I IUN

Checking Monthly Trimonthly Semiannually Annually

Service Required Tools Daily (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
item

Check for fuel leaks (piping, pump tank). Visual 0 0 0 0 0

Check for fuel filter for clogging. Visual 0 0 0
Clean fuel filter G. Operate 0 0
Change fuel filter element 0. Visual a
Check injection nozzle for injection pressure and
Spray Pattern D. Nozzle tester 0 0

Check carburetor for loose linkage and contamination G. Visual 0 0 0

Check ignition timing G. Timing light 0 0
Check injection timing D. Operate 0
Drain water from fuel tank D. Operate 0 0 0
Clean the inside of fuel tank. Visual 0 0
Check fuel level. Visual 0 0 0 0 0
Check cooling water level. Visual 0 0 0 0 0
Check for water leaks. Visual 0 0 0 0 0
Check rubber hose for deterioration. Visual 0 0 0 0
Check radiator cap for proper function and installstion. Visual 0 0 0 0
(every 2 years
Clean and change water. Operate
when LLC is used.)

Check fan belt for proper tension and damage. Visual 0 0 0 0 0

- I !
'

POWER TRAINS
Checking Monthly Trimonthly Semiannually Annually
item Service Required Tools Daily (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)

Check clutch pedal for play and the clearance between Operate
pedal and floorboard when disengaged. and scale 0 0 0 0 0

Check for noise and proper disengagement. Operate 0 0 0 0 0

Check for slipping and proper engagement. Operate 0 0 0 0 0
Check master cylinder and release cylinder for fluid
Clutch
leaks and change fluid.
Operate 0 0 e
Check the function of booster (trucks with power clutch). Operate 0 0 0 0 0
Check booster for oil leaks (trucks with power clutch). Operate 0 0 0 0 0
Check clutch oil level in tank of trucks with optional oil
clutch (Clean strainer whenever oil is changed.)
Visual 0 0 0

Check shift levers for operation and looseness. Operate 0 0 0 0

Transmission Check for oil leaks. Visual 0 0 0 0 0
Check oil level and change oil if necessary. Operate

Check for oil leaks. Visual 0 0 0 0 0

Change oil. Visual 0 0 e
Check shift lever for operation and looseness. Operate 0 0 0 0
Torque
converter type Check control valve and clutch for proper function. Operate 0 0 0 0 0
transmission
Check inching valve for function. Operate 0 0 0 0 0
Check inching pedal for play and travel. Operate 0 0 0 0 0
Change inline filter and element. Operate (first time onty) e
Check for oil leaks. Visual 0 0 0 0 0
V

Front axle Change oil. Visual a

Check for loose mount bolt. Visual 0 0 0 0
PERIUUIG INSPtG I IUN -%
-
r :
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STEERING SYSTEM
Checking Monthly Trimonthly Semiannually Annually
Service Required Tools Daily (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
item

Check inflation pressure Tire gauge 0 0 0 0 0

Check for cracks or damage Visual 0 0 0 0 0
Tire Check tread depth Depth gauge 0 0 0 0
Check for undue wear Visual 0 0 0 0 0
Check for debris, stones or foreign matter in tread Visual 0 0 0 0
Hub, rim Check for looseness Test hammer 0 0 0 0 0
mounting
bolt, nut Check for damage Visual 0 0 0 0 0
Rim, side ring Check rim, side ring, and dick wheel for damage Visual 0 0 0 0 0

Wheel
Check for looseness or noise Touch 0 0 0 0
bearing
Disassemble and Change grease Operate

Axle Check for deformation, cracks or damage Visual 0 0 0 0

CONTROLS
Checking Monthly Trimonthly Semiannually Annually
item Service Required Tools Daily (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)

Check for play. Operate 0 0 0 0 0

Check for looseness in axial direction. Touch 0 0 0 0 0
Steering wheel
Check for looseness in radial direction. Touch 0 0 0 0 0
Check for proper operation. Operate 0 0 0 0 0

Steering gear Check for loose mounting bolt. Operate 0 0 0 0

box

Check for looseness. Operate 0 0 0 0

Rod, arm
Check for bending, damage or wear. Visual 0 0 0 0
CONTROLS
Checking Monthly Trimonthly Semiannually Annually
item Service Required Tools Daily (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)

Knuckle Check king pin for looseness or damage. Touch 0 0 0 0

P P - - - -

Check for bending, damage or wear. Visual 0 0 0 0

Rear axle
Check mounting condition. Test hammer 0 0 0 0
Check for proper operation. Operate 0 0 0 0 0
Power steering Check for oil leaks. Visual 0 0 0 0 0
Check for loose mounting or linkage. Visual 0 0 0 0

BRAKE SYSTEM
Checking Monthly Trimonthly Semiannually Annually
item Service Required Tools Daily (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)

Check for play. Scale 0 0 0 0 0

Check for pedal height and returning. Scale 0 0 0 0 0
Check for braking or uneven braking. Operate 0 0 0 0 0
Brake pedal
Check for the entrance of air into braking piping. Operate 0 0 0 0
Check booster for proper function and oil leaks
(trucks with power brake).
Operate 0 0 0 0 0

Parking brake Check for proper operation and allowance. Operate 0 0 0 0 0

lever
Check for braking effect. Operate 0 0 0 0 0
Check for proper operation. Operate 0 0 0 0
Rod, cable
Check for loose linkage. Touch 0 0 0 0
Check for damage, leaks or intervention. Visual 0 0 0 0
Hose and pipe
Check for loose connections or clamp. Touch 0 0 0 0
rI=muvIb ~ i u a r c =Ibi v i u '* -
, .
.
L
/

L-

BRAKE SYSTEM
Checking Monthly Trimonthly Semiannually Annually
Service Required Tools Daily (200 hrs) (600 hrs) (1 200 hrs) (2400 hrs)
item

Check for fluid leaks (oil leaks for trucks with power Visual 0 0 0 0
brake).

Check fluid level. Visual 0 0 0

Check master cylinder and wheel cylinder for proper Operate 0
Oil brake operation.

Check master cylinder and wheel cylinder for oil leaks Visual 0
or damage.

Check master cylinder, piston cup and check valve for Disassembly
wear or damage, and replace if needed.

Check brake drum for loose installation. Test hammer 0 0 0 0

Check loose lining. Vernier calipers 0
Check brake shoe for operation. Operate 0
Brake drum Visual 0
Check anchor pin for corrosion.
and brake shoe
Check return spring for deterioration. Scale 0
Check automatic clearance adjuster for operation. Operate 0
Check drum for wear or damage. Visual 0
Check for deformation. Visual 0

Back plate Check for cracks. Visual 0

Check loose installation. Test hammer 0
LOAD HANDLING SYSTEM
Checking Monthly Trimonthly Semiannually Annually
Service Required Tools Daily (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
item

Check for damage, deformation or wear. Visual 0 0 0 0 0

Forks Check fork Stopper pin for damage or wear. Visual 0 0 0

Check for roots and teeth welded area for cracks or wear. Visual 0 0 0 0
Check mast Cross members for cracked weld or damage. Visual 0 0 0 0
Check tilt cylinder bracket and mast for cracks or Visual 0 0 0 0
damage in welded areas.

Check outer and inner masts for cracked weld or damage. Visual 0 0 0 0
Check carriage for cracked weld or damage. Visual 0 0 0 0
Mast and
carriage
Check roller bearing for looseness. Touch 0 0 0 0
Check mast support bushing for wear or damage. Visual 0
Check mast support cap bolts for looseness. Torque wrench 0 (first time only) 0 0
Check for looseness of lift cylinder tail bolts, piston 0 (first time only)
rod head bolts, U bolts, piston head guide bolts.
Test hammer 0 0

Check rollers, roller pins and welds for cracks or damage. Visual 0 0 0 0
Check chains for tension, deformation, damage or
corrosion.
Touch 0 0 0 0 0

Check chains for elongation. Gauge 0 0 0 0

Chains and Lubricate chains. Operate e
sheaves
Check loose linkage of chain anchor pin and chain. Visual 0 0 0 0
Check sheaves for deformation or damage. Visual 0 0 0 0
Check sheave bearings for looseness. Touch 0 0 0 0
Attachments Check for operation and installation. Operate/visual 0 0 0 0
LOAD HANDLING SYSTEM
Checking Monthly Trimonthly Semiannually Annually
Service Required Tools Daily (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)
item

Check piston rod, rod bolt, rod end for looseness, Visuall
test hammer
0 0 0 0 0
deformation or damage.

Cylinder
Check for proper operation Operate 0 0 0 0 0
Check for oil leaks Visual 0 0 0 0 0
Check pin and cylinder bushing for wear or damage Visual 0 0 0 0
Check for oil leaks or noise Visual & auditory 0 0 0 0 0
Hydraulic
Pump Check drive for wear Visual & auditory 0

HYDRAULIC SYSTEM
Checking Monthly Trimonthly Semiannually Annually
Service Required Tools Daily (200 hrs) (600 hrs) (1 200 hrs) (2400 hrs)
item

Check oil level and change oil, if contaminated. Visual 0 0 0

Hydraulic
Oil Change suction strainer. Operate
tank
Change return filter. Operate 0

Check for loose linkage of the lever. Operate 0 0 0 0 0

Control valve
lever Check for function of the lever. Operate 0 0 0 0 0
Check for oil leaks. Visual 0 0 0 0 0
Check relief valve and tilt-lock valve for function. Auditory 0 0 0 0
Control valve
Oil pressure
Measure relief valve pressure. 0 0
gauge

Hose, piping, Check for oil leaks, looseness, deformation or damage. Visuallauditory 0 0 0 0 0
hose reel, and
swivel joint Check load handling hose Operate 0 (1 - 2 years)
 C
-- ,
PERlODlC INSPECTION
--.

ELECTRICAL SYSTEM
Checking Monthly Trimonthly Semiannually Annually
item Service Required Tools Daily (200 hrs) (600 hrs) (1200 hrs) (2400 hrs)

Check distributor cap for cracks. Visual 0 0 0

Check spark plug for burn. Visual 0
Adjust spark plug gap. Plug gaP gauge 0 0 0
Clean spark plug. Operate 0 0 0
Check the insertion of high-voltage cable into distributor
lgnition device
cap.
Visual 0
(gasoline
engine trucks) Check distributor Segment for burn Visual 0
Check distributor center-piece for wear or damage. Visual 0
Check gap between signal rotor and Stator. Thickness gauge 0 0 0
Lubricate distributor shaft. Operate 0 0 0
Check high-voltage cable for breakage. Tester 0
Starter Check proper engagement of pinion gears Operate 0 0 0
Charger Check for proper operation Ammeter 0 0 0
Check electrolyte level and clean Visual & audiory 0 0 0 0
Battery
Check specific gravity of electrolyte Gravimeter 0 0 0

Electrical Check wire harness for damage and loose clamp Visual 0 0 0 0
wiring
Check for loose connections touch 0 0 0
 - 4 -1

SAFETY DEVICE AND OTHERS

Checking Monthly Trimonthly Semiannually Annually
Service Required Tools Daily (200 hrs)
item (600 hrs) (1 200 hrs) (2400 hrs)

Overhead Check for loose mounting Test hamrner 0 0 0 0 0

guard and
load backrest Check for deformation, cracks or darnage Visual 0 0 0 0 0
Turn signai Check for operation and installation Operate 0 0 0 0 0
Alarm Check for operation and installation Operate 0 0 0 0 0
Lights Check for operation and installation Operate 0 0 0 0 0
Back-up alarm Check for operation and installation Operate 0 0 0 0 0

Sideview
Check for contamination or damage Visual 0 0 0 0 0
mirrors
Check for proper visibility Visual 0 0 0 0 0
Meters Check for operation Operate 0 0 0 0 0
Rear reflectorl
License Check for contamination or damage Visual 0 0 0 0 0
number plate

Driver's seat Check for damage or loose mounting bolts Visual 0 0

Check frame and Cross members for damage or cracks Visual 0
Check for loose rivets and bolts Test hammer 0
Truck body
Check the results of previous checks Visual 0 0 0 0 0
Check general condition of truck Visual 0 0 0 0 0
After cleaning, check for lubrication of each part Grease pump
Lubricants and
oil change
Check condition of lubricants Check 0
 -
'
--i

5. SPECIFIC ~ ~ o N& S
SERVICE DATA
The following symbols, found throughout this manual, alert you
to potentially hazardous conditions to the owner and the CONTENTS
operator.
Become completely familiar with the truck before proceeding SPECIFICATIONS ..............................................................5- 1
with operating, checking and servicing. EQUIPMENT .................................................................... 5-13
LOAD CHART ................................................................... 5-14
This manual and decals affixed to the truck use the following SERVICE DATA ............................................................... 5-16
safety alert indications. BOLT AND NUT TORQUE ............................................ 5-17
REFILL CAPACITY .:...................................................... 5-18
SIGNALWORD ( CLASSlFlCATlON AFTER-THE-SALE SERVICE ........................................... 5-20
I Failure
-- t o follow the instructions i n the
- - - .
- - - -
TRUCK SERIAL NUMBER ........................................... 5-20
DANGER
I message wiii likely cause a serious accident
or death. SERIAL NUMBERS OF MAJOR COMPONENTS ..... 5-20
ENGINE SERIAL NUMBER ......................................... 5-21
A WARNING Failure t o follow the instructions i n the
message might cause a serious accident or
death.
GENUINE TCM PARTS ............................................... 5-22
GENUINE TCM LUBRICANTS .................................... 5-22
TRUCK DATA ........................................................
,........ 5-23
A CAUTION P-
Failure t o follow the instructions i n the
message may c a u r e personal injury or
damage to the truck or other property.

B NOTE The information will heip t o prolong the

service life of the truck. The message is not
directly related to accident prevention.
-
V)
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(D
0
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I.

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0'
J
V)

a
V)
s
CT
Ci.

(D
0,
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0
5
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J
(CI
(D

s-.
5
0
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-
 \
-'-.
SPEClFlCATlONS
- 8' 4 i
(---L_

- Truck model FDl Oc19 FD1OTI

FG1 Oc19 FG1 OTI 9 9
Leading particulars
Rated load kg (Ibs) 1000 EXC 900 (2000)
Basic load center mm (in.) 500 EXC 600 (24)
Max. height A mm (in.) 3000 (118.1)
Free lift B mm (in.) 150 (5.9)
Fork lifting speed mmls (fpm)
No load 650 (128.0) 620 (122.0)
Loaded 590 116.1) 580 (114.2)
Traveling speed (fwdlrev) kmlh (mph)
1st speed 8.0 (5.0) 14.5 (9.0) 8.0 (5.0) 14.5 (9.0)
2nd speed 14.5 (9.0) - 14.5 (9.0) -
Gradability (1.6 kmlh) 'Yo
No load 22 23
Loaded 30 37 24 28
Min. turning radius C mm (in.) 1905 (75.0)
Min. stacking aisle width mm (in.) 1720 (67.7)
Overall length D mm (in.) 3060 (120.7)
Overall width E mm (in.) 1070 (42.1)
Overall height (mast) F mm (in.) 1995 (78.5)
(overhead guard) G mm (in.) 2070 EXN 2130 (81.5)
Overall height, mast raised H mm (in.) 4030 EXC 4250 (167.3)
Wheelbase mm (in.) 1400 (55.1)
Tread, front mm (in.) 890 (35.0)
rear mm (in.) 920 (36.2)
Fork size mm (in.)
length (K) X width (M) X thickness (N) 920 X 100 X 35 (36.2 X 3.9 X 1.38)
Fork spacing P mm (in.) 200 - 920 (7.9 - 36.2)
Ground clearance (mast) mm (in.) 110 (4.3)
Weight kg (Ibs) 2110 EXC 2120 (4680) 2140 EXC 2150 (4740)
Engine
Model Nissan H15 gasoline engine lsuzu 4LB1 diese1 engine
TYpe 4-cycle water cooling 4-cycle water cooling
Total displacement P (CU.in.) 1.486 (91) 1.499 (91.8)
Rated output 25.0 kW (34 PS)/2400 rpm 22.4 kW (30.5 PS)/2500 rpm
[27.2 kW (37 HP)/2400 rpm SAE GROSS] [23.5 kW (31.5 HP)/2500 rpm SAE GROSS]
Maximum torque 112.8 N-m (11.5 kgf-m)/1600 rpm 88.3 N-m (9.0 kgf-m)/1800 rpm
[ I 12.8 N-m (83.2 ft-lbs)/1600 rpm] [88.3 N-m (65.1 ft-lb~)/1800rpm]
Tire
Front 6.50-1 0-1OPR(I)
Rim size 5.00F X 1ODT
Inflation pressure 700 kPa, 70 kg/cm2 (100 psi)
Rear 5.00-8-8PR(I)
Rim size 3.00D-8DT
Inflation pressure 800 kPa, 8.0 kg/cm2 (114 psi)
- -
 FG15cig FG1 TI 9 FD15c19 FD157-I 9

Rated load kg (Ibs) 1500 EXC 1350 (3000)

Basic load center mm (in.) 500 EXC 600 (24)
Max. height A mm (in.) 3000 (118.1)
Free lift B mm (in.) 155 (6.1)
Fork lifting speed mmls (fpm)
No load 650 (128.0) 620 (122.0)
Loaded 590 (116.1) 580 (114.2)
Traveling speed (fwdlrev) kmlh (mph)
1st speed 8.0 (5.0) 14.5 (9.0) 8.0 (5.0) 14.5 (9.0)
2nd speed 14.5 (9.0) - 14.5 (9.0) -
Gradability (1.6 kmlh) YO
No load 18 18
Loaded 23 27 18 21
Min. turning radius C mm (in.) 1980 (78.0)
Min. stacking aisle width mm (in.) 1780 (70.1)
Overall length D mm (in.) 3125 (123.1)
Overall width E mm (in.) 1070 (42.1)
Overall height (mast) F mm (in.) 1995 (78.5)
(overhead guard) G mm (in.) 2070 EXN 2130 (81.5)
Overall height, mast raised H mm (in.) 4030 EXC 4250 (167.3)
Wheelbase mm (in.) 1400 (55.1)
Tread, front mm (in.) 890 (35.0)
rear mm (in.) 920 (36.2)
Fork size mm (in.)
length (K) X width (M) X thickness (N) 920 X 100 X 35 (36.2 X 3.9 X 1.38)
Fork spacing P mm (in.) 200 - 920 (7.9 - 36.2)
. Ground clearance (mast) mm (in.) 110 (4.3)
Weight kg (Ibs) 2520 EXC 2540 (5600) 2550 EXC 2570 (5670)
Engine
Model Nissan H15 gasoline engine Isuzu 4LB1 diese1 engine
TYP^ 4-cycle water cooling 4-cycle water cooling
Total displacement p (CU.in.) 1.486 (91) 1.499 (91.8)
Rated output 25.0 kW (34 PS)/2400 rpm 22.4 kW (30.5 PS)/2500 rpm
[27.2 kW (37 HP)/2400 rpm SAE GROSS] [23.5 kW (31.5 HP)/2500 rpm SAE GROSS]
Maximum torque 112.8 N-m (11.5 kgf-m)/1600 rpm 88.3 N-m (9.0 kgf-m)/1800 rpm
[ I 12.8 N-m (83.2 ft-lbs)/1600 rpm] [88.3 N-m (65.1 ft-lbs)/1800 rpm]
Tire
Front 6.50-1 0-1OPR(I)
Rim size 5.00F X 1ODT
Inflation pressure 700 kPa, 70 kg/cm2 (100 psi)
Rear 5.00-8-8PR(I)
Rim size 3.00D-8DT
Inflation pressure 800 kPa, 8.0 kg/cm2 (114 psi)
 Truck model
FG18ct 9 FG18~19 FD18c19 FD1STI 9

Rated load kg (Ibs) 1750 EXC 1580 (3500)

Basic load center mm (in.) 500 EXC 600 (24)
Max. height A mm (in.) 3000 (118.1)
Free lift B mm (in.) 155 (6.1)
Fork lifting speed mm/s (fpm)
No load 650 (128.0) 620 (122.0)
Loaded 590 (116.1) 580 (114.2)
Traveling speed (fwdlrev)
1st s ~ e e d
2nd Speed
km/h (mph)
I 8.0 (5.0)
14.5 '(9.0)
II 14.5 (9.0)
-
I
I
8.0 (5.0)
14.5 (9.0)
1I 14.5 (9.0)
-
Gradabilitv (1.6 km/h) % I
No load- ' 17 16
Loaded 20 24 16 18
Min. turning radius C mm (in.) 2010 (79.1)
Min. stacking aisle width mm (in.) 1800 (70.9)
Overall length D rnm (in.) 3175 (124.9)
Overall width E mm (in.) 1100 (43.3)
Overall height (mast) F mm (in.) 1995 (78.5)
(overhead guard) G mm (in.) 2070 EXN 2130 (81.5)
Overall height, mast raised H mm (in.) 4030 EXC 4250 (167.3)
Wheelbase mm (in.) 1400 (55.1)
Tread, front mm (in.) 920 (36.2)
rear mm (in.) 920 (36.2)
Fork size mm (in.)
length (K) X width (M) X thickness (N) 920 X 100 X 35 (36.2 X 3.9 X 1.38)
Fork spacing P mm (in.) 200 - 920 (7.9 - 36.2)
Ground clearance (mast) mm (in.) 110 (4.3)
Weight kg (Ibs) 2740 EXC 2760 (6090) I 2780 EXC 2800 (6170)
Ennine
Model Nissan H15 gasoline engine Isuzu 4LB1 diese1 engine
TYpe 4-cycle water cooling 4-cycle water cooling
Total displacement e (CU.in.) 1.486 (91) 1.499 (91.8)
Rated output 25.0 kW (34 PS)/2400 rpm 22.4 kW (30.5 PS)/2500 rpm
[27.2 kW (37 HP)/2400 rpm SAE GROSS] [23.5 kW (31-5 HP)/2500 rpm SAE GROSS]
Maximum torque 112.8 N-m (11.5 kgf-m)/1600 rpm 88.3 N-m (9.0 kgf-m)/1800 rpm
[ I 12.8 N-m (83.2 ft-lbs)/1600 rpm] [88.3 N-m (65.1 ft-lbs)/1800 rpm]
I Tire 1
Front 6.50-1 0-1OPR(1)
Rim size 5.00F X lOTB
Inflation pressure 700 kPa, 70 kg/cm2 (100 psi)
Rear 5.00-8-8PR(I)
Rim size 3.00D-8DT
Inflation pressure 800 kPa, 8.0 kg/cm2 (114 psi)
 FG2Oc6 FG20~6 FD20cti FD20~6

Rated load kg (Ibs) 2000 EXC 1810 (4000)

Basic load center mm (in.) 500 EXC 600 (24)
Max. height A mm (in.) 3000 (118.1)
Free lift B mm (in.) 155 (6.1)
Fork lifting speed mmls (fpm)
No load 600 (118.1) 580 (114.2)
Loaded 570 112.2) 550 (108.3)
Traveling speed (fwdlrev) kmlh (mph)
1st speed 8.0 (5.0) 19.0 (11.8) 8.0 (5.0) 19.0 (11.8)
2nd speed 19.0 (11.8) - 18.5 (11.5) -
Gradability (1.6 kmlh) YO
No load 20 20
Loaded 20 26 21 27
Min. turning radius G mm (in.) 2170 (85.4)
Min. stacking aisle width mm (in.) 1920 (75.6)
Overall length D mm (in.) 3375 (132.8)
Overall width E mm (in.) 1150 (45.3)
Overall height (mast) F mm (in.) 1995 (78.5)
(overhead guard) G mm (in.) 2070 EXN 2130 (81.5)
Overall height, mast raised H mm (in.) 4030 EXC 4250 (167.3)
Wheelbase mm (in.) 1600 (63.0)
Tread, front mm (in.) 970 (38.2)
rear mm (in.) 970 (38.2)
Fork size mm (in.)
length (K) X width (M) X thickness (N) 920 X 122 X 36 (36.2 X 4.8 X 1.4)
Fork spacing P mm (in.) 245 - 1020 (9.6 - 40.2)
Ground clearance (mast) mm (in.) 110 (4.3)
Weight kg (Ibs) 3240 (7150) 3330 (7340)
Engine
Model Nissan H20 gasoline engine Isuzu C240 diese1 engine
4-cycle water cooling 4-cycle water cooling
Type
Total displacement P (CU.in.) 1.982 (121.O) 2.369 (145)
Rated output 32.3 k~ (44 ~ ~ ) / 2 3 rpm
00 38.3 kW (52 PS)/2500 rpm
[34.3 kW (46 HP)/2300 rpm SAE GROSS] [38.5 kW (52.2 HP)/2500 rpm SAE GROSS]
Maximum torque 142.1 N-m (14.5 kgf-m)/1600 rpm 153.9 N-m (15.7 kgf-m)/1800 rpm
[ I42.1 N-m (104.9 ft-lb~)/1600rpm] 1153.9 N-m (113.6 ft-lb~)/1800rpm]
Tire
Front 7.00-1 2-12PR(I)
Rim size 5.00s X l2DT
Inflation pressure 700 kPa, 70 kg/cm2 (100 psi)
Rear 6.00-9-1 OPR(I)
Rim size 4.00E-9DT
Inflation pressure 700 kPa, 7.0 kg/cm2 (100 psi)
 Truck model FG25~6 FD25~6 FD25T6
FG25~6
Leading particulars
Rated load kg (Ibs) 2500 EXC 2260 (5000)
Basic load center mm (in.) 500 EXC 600 (24)
Max. height A mm (in.) 3000 (118.1)
Free lift B mm (in.) 160 (6.3)
Fork lifting speed mm/s (fpm)
No load 600 (118.1) 580 (114.2)
Loaded 570 112.2) 550 '108.3)
Traveling speed (fwdlrev) km/h (mph)
1st speed 8.0 (5.0) 19.0 (11.8) 8.0 (5.0) 19.0 (11.8)
2nd speed 19.0 (11.8) - 18.5 (11.5) -
Gradability (1.6 km/h) '30
No load 18 18
Loaded 19 22 18 23
Min. turning radius C mm (in.) 2240 (88.2)
Min. stacking aisle width mm (in.) 2010 (79.1)
Overall length D mm (in.) 3600 (141.7)
Overall width E mm (in.) 1150 (45.3)
Overall height (mast) F mm (in.) 1995 (78.5)
(overhead guard) G mm (in.) 2070 EXN 2130 (81.5)
Overall height, mast raised H mm (in.) 4030 EXC 4250 (167.3)
Wheelbase mm (in.) 1600 (63.0)
Tread, front mm (in.) 970 (38.2)
rear mm (in.) 970 (38.2)
Fork size mm (in.)
length (K) X width (M) X thickness (N) 1070x 1 2 2 x 4 0 (42.1 ~ 4 . 1.6)
8 ~
Fork spacing P mm (in.) 245 - 1020 (9.6 - 40.2)
Ground clearance (mast) mm (in.) 110 (4.3)
Weight kg (Ibs) 3580 (7900) 3670 (8090)
Engine
Model Nissan H20 gasoline engine lsuzu C240 diese1 engine
TYPe 4-cycle water cooling 4-cycle water cooling
Total displacement P (CU.in.) 1.982 (121.0) 2.369 (145)
Rated output 32.3 kW (44 PS)/2300 rpm 38.3 kW (52 PS)/2500 rpm
[34.3 kW (46 HP)/2300 rpm SAE GROSS] [38.5 kW (52.2 HP)/2500 rpm SAE GROSS]
Maximum torque 142.1 N-m (14.5 kgf-m)/1600 rpm 153.9 N-m (15.7 kgf-m)/1800 rpm
[142.1 N-m (104.9 ft-lbs)/1600 rpm] [ I53.9 N-m (113.6 ft-lbs)/1800 rpm]
Tire
Front 7.00-12-12PR(I)
Rim size 5.00s X l2DT
Inflation pressure 700 kPa, 70 kg/cm2 (100 psi)
Rear 6.00-9-1OPR(I)
Rim size 4.00E-9DT
Inflation pressure 700 kPa, 7.0 kg/cm2 (100 psi)
 Truck model FG30~6 FD3Oc6 FD30~6
FG30~6
Leading particular - - =

Rated load kg (Ibs) 3000 EXC 2720 (6000)

Basic load center mm (in.) 500 EXC 600 (24)
Max. height A mm (in.) 3000 (118.1)
Free lift B mm (in.) 135 (5.3)
Fork lifting speed mmls (fpm)
No load 500 (98.4) 470 (92.5)
Loaded 450 (88.6) 450 (88.6)
Traveling speed (fwdlrev) km/h (mph)
1st speed 8.5 (5.3) 19.5 (12.1) 8.5 (5.3) 19.5 (12.1)
2nd speed 19.5 (12.1) - 19.5 (12.1) -
Gradability (1.6 kmlh) %
No load 20 20
Loaded 14 17 15 18
Min. turning radius C mm (in.) 2400 (94.5)
Min. stacking aisle width mm (in.) 2110 (83.1)
Overall length D mm (in.) 3730 (146.8)
Overall width E mm (in.) 1225 (48.2)
Overall height (mast) F mm (in.) 2075 (81.7)
(overhead guard) G mm (in.) 2090 EXN 2150 (82.5)
Overall height, mast raised H mm (in.) 4250 EXC 4470 (176.0)
Wheelbase mm (in.) 1700 (66.9)
Tread, front mm (in.) 1000 (39.4)
rear mm (in.) 970 (38.2)
Fork size mm (in.)
length (K) X width (M) X thickness (N) 1070 X 125 X 45 (42.1 X 4.9 X 1.8)
Fork spacing P mm (in.) 250 - 1090 (9.8 - 42.9)
Ground clearance (mast) mm (in.) 140 (5.5)
Weight kg (Ibs) 4200 (9260) 4310 (9500)
Engine
Model Nissan H20 gasoline engine Isuzu C240 diese1 engine
TYpe 4-cycle water cooling 4-cycle water cooling
Total displacement e (CU.in.) 1.982 (121.O) 2.369 (145)
Rated output 32.3 kW (44 PS)/2300 rpm 38.3 kW (52 PS)/2500 rpm
[34.3 kW (46 HP)/2300 rpm SAE GROSS] [38.5 kW (52.2 HP)/2500 rpm SAE GROSS]
Maximum torque 142.1 N-m (14.5 kgf-m)/1600 rpm 153.9 N-m (15.7 kgf-m)/1800 rpm
[ I 42.1 N-m (104.9 ft-lbs)/1600 rpm] [ I53.9 N-m (113.6 ft-lbs)/1800 rpm]
Tire
Front 28x9-15-12PR(I)
Rim size 7.0OT-15
Inflation pressure 700 kPa, 70 kg/cm2 (100 psi)
Rear 6.50-10-10PR(I)
Rim size 5.OOF-10
Inflation pressure 700 kPa, 7.0 kg/cm2 (100 psi)
 SPECIFICATIONS , ,

Truck model
FG1~ C S H F G ~ ~ T ~ H F D l SCSH F D ~ ~ T ~ H
Leading particulars
Rated load kg (Ibs) 1500 EXC 1350 (3000)
Basic load center mm (in.) 500 EXC 600 (24)
Max. height A mm (in.) 3000 (118.1)
Free lift B mm (in.) 155 (6.1)
Fork lifting speed mmls (fpm)
No load 650 (128.0) 660 (129.9)
Loaded 600 (118.1) 640 I126.0)
Traveling speed (fwdlrev) km/h (mph)
1st speed 8.0 (5.0) 19.5 (12.1) 8.5 (5.3) 19.5 (12.1)
2nd speed 18.5 (11.5) - 19.0 (11.9) -
Gradability (1.6 kmlh) YO
No load 18 18
Loaded 25 31 25 31
Min. turning radius C mm (in.) 1980 (78.0)
Min. stacking aisle width mm (in.) 1780 (70.1)
Overall length D mm (in.) 3125 (123.1)
Overall width E mm (in.) 1070 (42.1)
Overall height (mast) F mm (in.) 1995 (78.5)
(overhead guard) G mm (in.) 2070 EXN 2130 (81.5)
Overall height, mast raised H mm (in.) 4030 EXC 4250 (167.3)
Wheelbase mm (in.) 1400 (55.1)
Tread, front mm (in.) 890 (35.0)
rear mm (in.) 920 (36.2)
Fork size mm (in.)
length (K) X width (M) X thickness (N) 920 X 100 X 35 (36.2 X 3.9 X 1.38)
Fork spacing P mm (in.) 200 - 920 (7.9 - 36.2)
Ground clearance (mast) mm (in.) 110 (4.3)
Weight kg (Ibs) 2510 EXC 2530 (5580) 2600 EXC 2620 (5780)
Engine
Model Nissan H20 gasoline engine Isuzu C240 diese1 engine
Type 4-cycle water cooling 4-cycle water cooling
Total displacement l (CU.in.) 1.982 (121.O) 2.369 (145)
Rated output 32.3 kW (44 PS)/2300 rpm 38.3 kW (52 PS)/2500 rpm
[34.3 kW (46 HP)/2300 rpm SAE GROSS] [38.5 kW (52.2 HP)/2500 rpm SAE GROSS]
Maximum torque 142.1 N-m (14.5 kgf-m)/1600 rpm 153.9 N-m (15.7 kgf-m)/1800 rpm
[ I 42.1 N-m (104.9 ft-lbs)/1600 rpm] [ I 53.9 N-m (113.6 ft-lbs)/1800 rpm]
Tire
Front 6.50-10-lOPR(I)
Rim size 5.00F X 10DT
Inflation pressure 700 kPa, 70 kg/cm2 (100 psi)
Rear 5.00-8-8PR(I)
Rim size 3.00D-8DT
Inflation pressure 800 kPa, 8.0 kg/cm2 (114 psi)
-
- Truck model
Leading p a r t i c u ~ a r s ~
FG18 c 9 ~ F G ~ ~ T ~ H FD18c9~ FDI~T~H

Rated load kg (Ibs) 1750 EXC 1580 (3500)

Basic load center mm (in.) 500 EXC 600 (24)
Max. height A mm (in.) 3000 (118.1)
Free lift B mm (in.) 155 (6.1)
Fork lifting speed mmls (fpm)
No load 650 (128.0) 660 (129.9)
Loaded 600 (118.1) 640 (126.0)
Traveling speed (fwdlrev) kmlh (mph)
1st speed 8.0 (5.0) 19.5 (12.1) 8.5 (5.3) 19.5 (12.1)
2nd speed 18.5 (11.5) 19.0 (11.9) -
Gradability (1.6 kmlh) %
No load 17 17
Loaded 22 29 22 29
Min. turning radius C mm (in.) 2010 (79.1)
Min. stacking aisle width mm (in.) 1800 (70.9)
Overall length D rnm (in.) 3175 (124.9)
Overall width E mm (in.) 1100 (43.3)
Overall height (mast) F mm (in.) 1995 (78.5)
(overhead guard) G mrn (in.) 2070 EXN 2130 (81.5)
Overall height, mast raised H mm (in.) 4030 EXC 4250 (167.3)
Wheelbase mm (in.) 1400 (55.1)
Tread, front mm (in.) 920 (36.2)
rear mm (in.) 920 (36.2)
Fork size mm (in.)
length (K) X width (M) X thickness (N) 920 X 100 X 35 (36.2 X 3.9 X 1.38)
Fork spacing P mm (in.) 200 - 920 (7.9 - 36.2)
Ground clearance (mast) mm (in.) 110 (4.3)
Weight kg (Ibs) 2740 EXC 2760 (6090) 2830 EXC 2850 (6290)
Engine
Model Nissan H20 gasoline engine lsuzu C240 diese1 engine
TYPe 4-cycle water cooling 4-cycle water cooling
Total displacement L (CU.in.) 1.982 (121 .O) 2.369 (145)
Rated output 32.3 kW (44 PS)/2300 rpm 38.3 kW (52 PS)/2500 rpm
[34.3 kW (46 HP)/2300 rpm SAE GROSS] [38.5 kW (52.2 HP)/2500 rpm SAE GROSS]
Maximum torque 142.1 N-m (14.5 kgf-m)/1600 rpm 153.9 N-m (15.7 kgf-m)l1800 rpm
[142.1 N-m (104.9 ft-lbs)l1600 rpm] [ I 53.9 N-m (113.6 ft-lbs)/1800 rpm]
Tire
Front 6.50-1 0-1OPR(I)
Rim size 5.00F X 10DT
Inflation pressure 700 kPa, 70 kglcm2 (100 psi)
Rear 5.00-8-8PR(I)
Rim size 3.00D-8DT
Inflation pressure 800 kPa, 8.0 kg/cm2 (114 psi)
 Truck model
FG25c6~ F G ~ ~ T ~ H FD25c6~ F D ~ ~ T ~ H

Rated load kg (Ibs) 2500 EXC 2260 (5000)

Basic load center rnm (in.) 500 EXC 600 (24)
Max. height A rnrn (in.) 3000 (118.1)
Free lift B mm (in.) 160 (6.3)
Fork lifting speed mm/s (fpm)
No load 620 (122.1) 650 (128.0)
Loaded 600 118.1) 630 (124.0)
Traveling speed (fwdlrev) kmlh (rnph)
1st speed 9.0 (5.6) 19.0 (11.8) 9.0 (5.6) 18.5 (11.5)
2nd speed 19.0 (11.8) - 18.5 (11.5) -
Gradability (1.6 krnlh) YO
No load 18 18
Loaded 20 30 20 32
Min. turning radius C mm (in.) 2240 (88.2)
Min. stacking aisle width rnm (in.) 2010 (79.1)
Overall length D rnm (in.) 3600 (141.7)
Overall width E mm (in.) 1150 (45.3)
Overall height (mast) F mm (in.) 1995 (78.5)
(overhead guard) G rnrn (in.) 2070 EXN 2130 (81.5)
Overall height, mast raised H mm (in.) 4030 EXC 4250 (167.3)
Wheelbase rnrn (in.) 1600 (63.0)
Tread, front mm (in.) 970 (38.2)
rear mrn (in.) 970 (38.2)
Fork size mm (in.)
length (K) X width (M) X thickness (N) 1 0 7 0 x 1 2 2 ~ 4 0(42.1 x4.8x1.6)
Fork spacing P rnm (in.) 245 - 1020 (9.6 - 40.2)
Ground clearance (mast) rnrn (in.) 110 (4.3)
Weight kg (Ibs) 3590 (7920) 3730 (8220)
Engine
Model Nissan H25 gasoline engine Kubota V3300 diese1 engine
Type 4-cycle water cooling 4-cycle water cooling
Total displacement p (CU.in.) 2.472 (150.9) 3.31 8 (203.1)
Rated output 42.7 kW (58 PS)/2400 rpm 50 kW (67 PS)/2500 rpm
[46.2 kW (62 HP)/2400 rpm SAE GROSS] [49.3 kW (66.1 HP)/2500 rpm SAE GROSS]
Maximum torque 179.5 N-m (18.3 kgf-m)/1600 rpm 226.4 N-rn (23.1 kgf-rn)/1800 rpm
[ I 79.5 N-m (132.4 ft-lbs)/1600 rpm] [226.4 N-rn (167.1 ft-lbs)/1800 rprn]
Tire
Front 7.00-12-12PR(l)
Rim size 5.00s X 12DT
Inflation pressure 700 kPa, 70 kg/cm2 (100 psi)
Rear 6.00-9-1 OPR(I)
Rim size 4.00E-9DT
Inflation pressure 700 kPa, 7.0 kg/crn2 (100 psi)
 :
C-

,
-\

?
SPECIFICATIONS
? -7

I
Truck model FG~OT~H FD~OC~H FD3016H
FG~OC~H

Rated load kg (Ibs) 3000 EXC 2720 (6000)

Basic load center mm (in.) 500 EXC 600 (24)
Max. height A mm (in.) 3000 (118.1)
Free lift B mm (in.) 135 (5.3)
Fork lifting speed mmls (fpm)
No load 520 (102.4) 550 (108.3)
Loaded 500 (98.4) 530 (104.4)
Traveling speed (fwdlrev) kmlh (mph)
1st speed 9.5 (5.9) 19.5 (12.1) 9.5 (5.9) 19.5 (12.1)
2nd speed 19.5 (12.1) - 19.5 (12.1) -
Gradability (1.6 km/h) YO
No load 20 20
Loaded 15 23 15 24
Min. turning radius C mm (in.) 2400 (94.5)
Min. stacking aisle width mm (in.) 2110 (83.1)
Overall length D mm (in.) 3730 (146.9)
Overall width E mm (in.) 1225 (48.2)
Overall height (mast) F mm (in.) 2075 (81.7)
(overhead guard) G mm (in.) 2090 EXN 2150 (82.5)
Overall height, mast raised H mm (in.) 4250 EXC 4470 (176.0)
Wheelbase mm (in.) 1700 (66.9)
Tread, front mm (in.) 1000 (39.4)
rear mm (in.) 970 (38.2)
Fork size mm (in.)
length (K) X width (M) X thickness (N) 1 0 7 0 x 1 2 5 ~ 4 5(42.1 x4.9x1.8)
Fork spacing P mm (in.) 250 - 1090 (9.8 - 42.9)
Ground clearance (mast) mm (in.) 140 (5.5)
Weight kg (Ibs) 4210 (9280) 4340 (9570)
Engine
Model Nissan H25 gasoline engine Kubota V3300 diese1 engine
TYpe 4-cycle water cooling 4-cycle water cooling
Total displacement e (CU.in.) 2.472 (150.9) 3.31 8 (203.1)
Rated output 42.7 kW (58 PS)/2400 rpm 50 kW (67 PS)/2500 rprn
[46.2 kW (62 HP)/2400 rpm SAE GROSS] 149.3 kW (66.1 HP)/2500 rpm SAE GROSS]
Maximum torque 179.5 N-m (18.3 kgf-m)/1600 rpm 226.4 N-m (23.1 kgf-m)/1800 rpm
[ I79.5 N-m (132.4 ft-lbs)/1600 rpm] [226.4 N-m (167.1 ft-lbs)/I 800 rpm]
Tire
Front 28x9-15-12PR(I)
Rim size 7.001-15
Inflation pressure 700 kPa, 70 kg/cm2 (100 psi)
Rear 6.50-10-10PR(I)
Rim size 5.OOF-10
Inflation pressure 700 kPa, 7.0 kg/cm2 (100 psi)

- .-
 -
U
, L

Standard equipment *Turn signal *Ammeter

*View mast *Lamp guard *Spark prevention muffler (D)
*Forks (920 mm for 1- to 2-ton trucks, *FuII-transistor ignition system (G) *Exhaust purification muffler
ksedirnenter (D) *DPF muffler (D)
* 1070 mm for 2- to 3-ton trucks)
J-lug tire
*Power steering
*Hour meter
*Engine water temp. gauge
*Tertiary catalyst muffler (G)
*Upward-pointed tail pipe
*Overhead guard *Fuel gauge *Fire extinguisher
*Suspension seat with seat belt *Engine oil pressure gauge *Tilt cylinder boot
*Drawbar *Charge warning light *Steering cylinder boot
*Cyclone pack air cleaner *Sedimenter warning light (D) *LPG unit [LPG only or LPGIgasoline]
*Parking brake lever (W. lock) *Glow plug indication light (D) (G)
*Dual valve (lift and tile) safety valve *Automatie glow pl"g unit (D) SrRear work light
(EXB) *Key stop (D) *Yellow beacon light
ATriple valve (excl. EXB) *Hand grip koverhead guard with wire netting
*Torque converter eil dipstick (T type) *Glove compartment with pen holder SrOverhead guard canvas (EXA)
AHydraulic oil dipstick *Overhead guard canvas (excl. EXA) *Paint color specified by the customer
kcartridge filter (T type) *Triple (quadruple, quintuple) valves and
*Cut-off valve Optional equipment piping
(Restricts the fork lowering speed if the *Front double tires (W/fender) *Radiator dust screen (excl. trucks with
lift hose should burst.)
*Tilt-lock valve (Prevents mast from
*Unique tire
SrSteel cab (2- to 3-ton trucks) * oil clutch)
Fishery specification
*Non-slip differential (2- to 3-ton T type)
tilting while engine is not running.)
* Flow control valve
*Halogen head lamp
*Steel cab (w./heater)
*Steel cab (W/cooler)
*OK monitors
*Double-element air cleaner (2- to 2.5-
ton trucks)
*Rear combination lamp *Color tires (white, green) Pre-cleaner
* Rearlside view mirror
*Back-up buzzer
*Oil clutch (2- to 3-ton trucks and 1.5-
t o 3401-1t r u c k s of h i g h p o w e r
*Centralized lubrication system (1- to 3-
ton trucks)
*Horn specification) *Plate-fin radiator
*Neutral switch *Power brake (2-to 3-ton trucks of high *Lifting eye
jr Floor mat power specification *Joystick control lever
*Engine hood damper stay *Power clutch (2-to 3-ton trucks, 1.5- *Torque converter oil temp. gauge
*Upward air intake port to 3 - t o n t r u c k s of h i g h p o w e r
*Radiator reservoir tank specification) G: Gasoline engine trucks
*Tilt steering wheel *Speedometer D: Diesel engine trucks
 --
r i LOAD CHART

A CAUTION
The load charts given below refer to lift trucks of standard specifications and those with high
mast whose lifting height is less than 5 m. Note that load charts for lift trucks with a high mast
whose lifting height is more than 5 m or those with an attachment have different load charts.

r s i i ~ o S I N G L E T ~ R EO>

-
FGlOcis FG~OTIS
FDl Ocis . FD1OTIS
 -
t ' i
F,

SERVICE M T A
3 < 7

Tire inflation pressure: ....................................... See Page 4-3.

Lift chain deflection:
...............No difference in deflection between both chains
are allowed when they are pressed with the
thumbs of both hands at the Same time.
Steering wheel play: ............................................. 50 - 100 mm
Pedal settings: .................................................. See Page 4-12.
Hub nuts: ...................................................... See Page 4- 4.
Spark plug 0.8 - 0.9 C C - - - Drive shaft: .......................................................See Page 4- 4.
gaP mm
Spark plug BP4ES
(BPR4ES)
C C - - -
tYPe
Fuel injection - - 1-3-4-2 C C
order
Fuel injection
timing
- - - 16" 9" 16"

Fuel injection
start pressure - - - (beforeTDC)
13.23 (135)
(beforeTDC) (before TDC)
11.76 (120) 13.7 (140)
MPa (kg/crnz)

Compression .27 1.23 1.27 3.0 3.0 2.8 - 9.2

(13.0)/300 (12.5)/300 (13.0)/300 (31)/250 (31)/200 (29-33)/350
MPa (kglcm2)lrpm

Valve
clearance 0.38 0.4 0.45 -
0.23 0.27
(both intake (when C C (when (when (when
and exhaust warm) cold) cold) cold)
valves) mm
For the deflection of the generator and fan belt tension, See Page 4-8.
3
I
-
i
P. SERVICE DATA
--
Truck model Ambient tem-
Standard Standard High-power High-pOwer perature when Grade of viscosity
1- to 1.8-ton 2- to 3-ton 1.5- to 1.8-ton 2- t" 3-t0n engine is started
-1 5°C & above ISO VG32
1. Hydraulic oil tank 18 C 32 C 18 C 37 C
-40°C & above ISO VG22

2. Brake reservoir tank 0.2 C 0.2 0.2 C 0.2 C FMVSS DOT-3

-10°C & above SAE 90
3. Transmission, G D G D G D G D -25°C & above SAE 80W
differential (C type) 7.5 C 5.5 C 9.5C 11.OC 7.54 5.5 C 11.5C 1l.OC
-40°C & above SAE 75W

D -25°C & above SAE 10W

4. Reduction gear, G D G D G D G
differential (T type) 4.5 C 3.5 C 8.0 C 7.5 C 4.5 C 3.5 C 8.0 C 7.5 -40°C & above ATF

(2- to (3-ton) (2- to (3-ton) -25°C & above SAE 10W

5. Transmission, torque 7.0 C 2.5-ton) 7.0 C 2.5-ton)
converter (T type) 8.0 C 7.0 C 8.0 C 7.0 C -40°C & above ATF

(H15) (4LB1) (H20) (C240) (H20) (C240) (H25) (V3300)

6. Radiator 7.6 C 7.0 C 9.04 10.71 8.0C 9.0 C 9.0 C 10.0 C

7. Fuel tank 50 C 70 C 50 C 70 C
0°C & above SAE 30
-25°C to 0°C SAE 1OW
6.6 -
(4LB1) (H20) (C240) (H20) (C240) (H25) (V3300)
8. Engine crankcase 4.2
3.3 1
3.8 C 5.2 C 4.2 C 5.5 C 3.8 3m2C -25°C & above
,
SAE 1OW-30,l OW-40,
0W-50J 5W-40

-40°C & above SAE 5W-20, 5W-40

9. Grease fittings As required Consistency number: NLGl No. 0, 1, or 2

Notes: 1. G: Gasoline engine, D: Diesel engine

2. Use light oil for diese1 engine trucks.
3. For more information about lubricants to be used, contact your local TCM dealer.
~ C H V I ~ vnin
C -
7

L i

Brands of Lubricants (Continued)

API Class CC and Higher
CC (for Gasoline & Diesel) CD (for Diesel)
MOBIL Delvac 1100 Series (IOW, 20W-20, 30) MOBIL Delvac 1300 Series (10W-20, 20W-20, 30)
MOBIL MOBIL Delvac 1200 Series (1OW, 20W-20,30) MOBIL Delvac Super (15W-40), MOBIL Delvac 1 (5W-30)
MOBIL Delvac Special (10W-30, 20W-40) MOBIL Delvac SHC (5W-30)
GASOLINE SHELL Rotella TX Oil (10W-30, 20W-50) SHELL Rimula X Oil (lOW, 20W-20, 30)
SHELL SHELL Rotella SX Oil (20W-20, 30) SHELL Myrina Oil (20W-40, 20W-20, 30)
or
DIESEL ESSO Lube D-3 (lOW, 30)
ESSO ESSO Lube HDX (IOW, 20W, 30) ,

ESSO Lube XD-3 Extra (IOW, 30)

ENGINE OIL
RPM Delo 400 Oil (15W-40, 1OW, 20-20W, 30) RPM Delo 400 Oil (15W-40, 1OW, 20-20W, 30)
CALTEX RPM Delo 200 Oil (10W-30, 10W-40, 20W-40, 20W-50, 1OW, 20-20W, 30) RPM Delo 300 Oil (IOW, 20-20W, 30)
RPM Delo 100 Oil (1OW, 20-20W, 30)
R&O ANTlW EAR
HYDRAULIC MOBIL MOBIL DTE Oil Light MOBIL DTE 24
OIL SHELL SHELL Tellus Oil C-32 SHELL Tellus Oil 32
ESSO Teresso 32 Nuto HP-32
CALTEX Rando Oil32 Rando Oil HD32
GM-rnake DEXRON or equipment
ATF MOBIL MOBIL ATF 220
DEXRON SHELL SHELL Dexron
ESSO ESSO ATF
CALTEX Texamatic Fluid (Dexron II)
API Class GL-4 and Higher
GL4 GL5
MOBIL Mobilube 40 Series (75W, 80W, 90) Mobilube HD (75W, 80W, 80W-90, 90)
GEAR OIL SHELL Spirax EP (80W, 90) SHELL Spirax HP (80W, 90)
. SHELL
ESSO ESSO Gear Oil GP (80W, 80W-90, 85W-90) ESSO Gear Oil GX (80W, 80W-90, 85W-90)
CALTEX Universal Thuban (80W, 90) Multipurpose Thuban EP (80W-90, 80W, 90)
Lithium Base Multipurpose Grease (NLGI No. 0, 1 or 2)
MOBIL MOBIL Grease 70 Series, MOBIL Grease MP
SHELL SHELL Albania Grease R Series, SHELL Albania Grease EPR Series, SHELL Retinax A
ESSO Beacon Series

>\
CALTEX Marfak All Purpose 2, 3, Marfak Multipurpose 2, 3, Multifak EP 0, 1, 2
Class
DOT-3 (FMVSS)
BRAKE MOBIL MOBIL Super Heavy Duty Brake Fluid
FLUID SHELL See NOTE.
ESSO See NOTE.
CALTEX Heavv Dutv Brake Fluid

NOTE: Brake fluids supplied by SHELL and ESSO have no particular names. Consult your TCM's dealer or oil supplier.
5 - 19
- f \ I
-
* I -
PSTER-THE-SALE SERVICE
;I

TRUCK SERIAL NUMBER SERIAL NUMBERS OF

MAJOR COMPONENTS

The truck serial number is imprinted on In addition to the truck serial number, the
the upper surface of the left fender of the serial numbers (unit numbers) of the
truck. major components are imprinted on the
truck or indicated on name plates. The
above sketch shows the serial number
plate of the mast. These decals should
be replaced immediately if missing or
defaced (damaged or illegible).
 'W 4

ENGINE SERIAL NUMBER

GASOLINE ENGINE DIESEL ENGINE
GENUINE TCM PARTS GENUINE TCM LUBRICANTS
However excellent a part is, it is inevitably Use gen U i ne TC M's lU b r icants for
deteriorates in performance with a long- lubrication.
time use.To ensure the best performance
of the lift truck, use genuine TCM's parts
which are used for new trucks.
When ordering spare parts, be Sure to
designate TCM's genuine parts.
 V MANUAL

FORKLIFT TRUCK
DIESEL & GAS POWERED
FDIOTIS FGlOcig FGIOTI~
FD15i19 FG1Sc19 FG15~19
F D ~ ~ T I HFG15cs~ F G ~ ~ T ~
FD18~19 FG18c19 FG18~19
F D I ~ T I H FG18cs~ F G ~ ~ T ~
FD20~6 FG20c6 FG20~6
FD~OT~H F G ~ O C ~FHG ~ O T ~ H
Fü25~6 FG25c6 FG25~6
F D ~ ~ TF~GH~ ~ cF ~GH~ ~ T ~
FD30~6 FG3Ocs FG30~6
FD~OT~H F G ~ O C ~FHG ~ O T ~ H

TCM CORPORATION
 FOREWORD

TCM's 1.0 to 3.0 ton capacity forklift trucks feature low operating noise and reduced vibration, and
come equipped with new high-performance engines.

The gasoline engines are equipped with an FTI system, auto-choke, and idle-up device, while the diese1
engines come with a distribution type injection pump and an auto-glow system to improve startability as
standard equipment.

The flow divider of the hydraulic circuit is located within the main control valve, the hydraulic lines
have been simplified, and the instrument panel accomrnodates optional OK monitors which allow the
Operator to check the water level, air cleaner plugging, and batteiy condition of charge with just a glance.
! The serviceability of these trucks has been greatly improved by these changes.

This Service Manual describes all of the major components and their service procedures for the 1 to 3
ton class trucks. We encourage you to make practical use of it while servicing the trucks.

We also hope you will understand that, due to on-going improvements of the parts and components, the
values and some of the descriptions in this manual are subject to change without notice.

January, 2002

The specifications and equipment covered in this manual will vary according to the intended
destination. In our documents and manuals, these differentes are coded according to the destination as
follows:

Export specification code Destination

EXA North America
EXB All regions excluding North America, Greater Europe, Oceania, and Russia
EXC Oceania
EXD Germany and Austria
EXE All of Europe excluding Germany, Austria, and the Nordic countries
EXN Nordic countries
EXR Russia
EXK South Africa
EXH All of West Europe excluding those covered by EXD, EXE and EXN.
 0181 OLL2 06SZ OPSZ OZIZ (%Y) ]qa!aM Bu!je.iadg

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H6.L H63 611 613 H6.L H63 611 6lL 613 L]!g!qaaps.i~
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5'6 1 5'8 SP I 0'8 S61 5'8 S'P I 0'8 5'9 1 0'8 1s 1 A ~ J
* 0'6 1 * S'P I * 0'6 1 * C'P I * S'P I PLIZ
S'6 I S'8 S'PI 0'8 5'6 1 S'8 S'P I 0'8 S'P1 0'8 lsl PMJ
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paatls y !I
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 SPECIFICATIONS (4)
EXB, EXE, EXN
FD20C6 FD20C6H FD25C6 FD25C6H FD30C6 FD30C613
FD20T6 FD20T61-I FD25T6 FD25T61-I FD3OT6 FD30T6ti
Performance
Max. load (kg) 2000 .- 2500 + 3000 .-
Basic load cenler
Lift heighl
Tilt angle (fwd - hwd)
(nini)
(nini)
(O )
500
3000
6-12
t

+
-.-
t +
+
+
-
+

+
t

.--
Free lift (iilni) A 160 t + + 135 +

Lift speed (nin~/s)

(unloaded) 580 650 580 650 470 550

Traveling speed (kinili) T6 C6H T6H C6 T6 C6H T6H C6 T6 C6H T6H

fwd Ist 19.0 9.0 8.5 19.5 9.5 19.5
2nd 18.5 * 19.5 * 19.5 *
rev Ist 19.0 9.0 18.5 8.5 19.5 9.5 19.5
* * *
Max. drawhr pul1 kN I kgf 1 T6 C6H T6H C6H T6H C6 T6 C6H T6H
(unloaded) 8.3(850) t t t 9.8 ( 1000) t t

(unloaded) 115.0 + + +

(loaded) 114.8 113.7 114.4 1 112.6 115.6 114.3 115.0 1 113.1 116.7 115.6 114.2
Min. turning radius (nini) B 2170 t
2240 .-- 2400 t

Min. interspectingaisle (nini) 1920 t

2010 + 21 10 C

1)iniesions
Overall length (mm) C 3375 t
3600 +
3730 .--
Overall width (nlni) D I I50 t + +
.- 1225 t

Overall height (at overlieod guard)

Overall height with extended niast
(iiiiii) E
(nim) F
2070
4030
+

t .-
+- C

+.-
2090
4250
+

Wheel hase (mni) G 1600 t + +

1700 +

~iaad
(front)
(inm)
H 970
970
.-
+
- t

*-
IOOO
t -
t

(reür) J t

Fork overliong (nini) K 445 t 450 + 480 +

_ Rear overhang (nini) L 410 t 480 t
t t

Fork size (nlni)

(LengihiM)X Width(N)X Thick(P)) 1070X122X40 .t 1070X125X45 +
-
t t

(iiim) Q _ -
245 1020 250 1090
Fork spacing --------------
-
t t t +

Under cleaiance (at mast) (nini) 110 +

t 140 t

Weight
Operating weight (kg) 3330 3400 3670 I 3730 4310 4340
 Unit: rnm [in]

I
Fig. 1 Truck Dimensions
 TABLE OF CONTENTS

.
1 ENGINE .........................................................................................................................................
i
1.1 GENERAL DESCRIPTION ...........................................................................................................2
1.1.1 FUELSYSTEM ......................................................................................................................... 11
1.1.2 COOLING SYSTEM ................................................................................................................. 17
1.1.3 ACCELERATOR PEDAL ......................................................................................................... 23
1.2 INSPECTION AND ADJUSTMENT ............................................................................................. 24
1.2.1 AIR CLEANER .......................................................................................................................... 24
1.2.2 FUEL FILTER ............................................................................................................................
25
1.2.3 OIL FLLTER ...............................................................................................................................
26
C. . 1.2.4COOLINGSYSTEM ................................................................ ............................................... 27
1.2.5 AIR BLEEDING ........................................................................................................................ 29
1.2.6 TIGHTENING CYLINDER HEAD BOLTS ............................................................................. 30
1.2.7 VAL= CLEARANCE ADJUSTMENT ...................................................................................30
1.2.8 IGNITION TIMING ADJUSTMENT ................;......................................................................31
1.2.9.ENGINE SPEED ADJUSTMENT .............................................................................................31

.
2 CLUTCH TYPE DRIVE UNIT .............................................................................................35
2.1 GENERAL DESCRIPTION ........................................................................................................... 35
2.1.1 SYNCHROMESH TYPE TRANSMISSION ............................................................................ 40
2.1.2 REDUCTION GEAR AND DIFFERENTIAL .......................................................................... 44
2.1.3 CLUTCH COVER AND CLUTCH DISK ................................................................................47
2.1.4 RELEASE CYLINDER ............................................................................................................. 50
i
2.1.5 MASTER CYLINDER .............................................................................................................. 50
2.1.6 CLUTCH PEDAL ......................................................................................................................51
2.2 MAINTENANCE ............................................................................................................................
55
2.2.1 CLUTCH PEDAL ADJUSTMENT ...........................................................................................55
2.2.2 CLUTCH DISK REPLACEMENT ..........................................................................................55

.
3 TORQUE CONVERTER TYPE DRIVE UNIT .............................................................57
3.1 GENERAL DESCRIPTION ........................................................................................................... 57
3.1.1 TORQUE CONVERTER ........................................................................................................... 62
3.1.2 CHARGING PUMP ...................................................................................................................
63
3.1.3 TRANSMISSION .....................................................................................................................
64
 .
4 DRIVE AXLE ...........................:.................................................................................................75
4.1 GENERAL DESCRIPTION ........................................................................................................... 75

.
5 BRAKE SYSTEM ..................................................................................................................... 81
5.1 GENERAL DESCRIPTION ........................................................................................................... 81
5.1.1 BRAKE PEDAL ........................................................................................................................81
5.1.2 MASTER CYLINDER ..............................................................................................................86
5.1.3 WHEEL BRAKE .......................................................................................................................87
5.1.4 PARKING BRAKE LEVER .....................................................................................................89
5.2 MAINTENANCE ............................................................................................................................93
5.2.1 WHEEL BRAKE DISASSEMBLY ..........................................................................................93
5.2.2 INSPECTION ..............................................................................................................................
95
5.2.3 m E L BRAKE REASSEMBLY ............................................................................................ 96
5.2.4 OPERATION TEST OF AUTOMATIC CLEARANCE ADJUSTER ...................................... 98
5.2.5 BRAKE PEDAL ADJUSTMENT .............................................................................................99
5.2.6 WHEEL BRAKE TROUBLESHOOTING ............................................................................... 100

6. STEERING SYSTEM (ORBITROL TYPE) ..................................................................ioi

6.1 GENERAL DESCRIPTION ............................................................................................................ 101
6.1.1 STEERING AXLE ...................................................................................................................... 102
6.1.2 STEERING WHEEL ASSEMBLY.............................................................................................. 104
6.1.3 ORBITROL .................................................................................................................................
105
6.1.4 POWER CYLINDER .................................................................................................................. 108
6.2 PREVENTNE MAINTENANCE ................................................................................................... 109
6.2.1 DISASSEMBLY AND MAINTENANCE OF ORBITROL ............................1 ......................... 109 .
6.2.2 REASSEMBLY OF ORBITROL................................................................................................ 112

.
7 HYDRAULIC SYSTEM .......................................................................................................... 117
7.1 GENERAL DESCRIPTION ........................................................................................................... 118
7.1.1 MAIN PUMP ............................................................................................................................
118
7.1.2 CONTROL VALVE ...................................................................................................................121
7.1.3 VALVE CONTROLS ................................................................................................................. 128
7.1.4 LIFT CYLINDER ......................................................................................................................129
7.1.5 FLOW REGULATOR VALVE ..................................................................................................132
7.1.6 TILT CYLINDER ......................................................................................................................133
7.1.7 OILTANK ...............................................................................................................................
134
 *

7.2 MAINTENANCE ............................................................................................................................

137
7.2.1 DISASSEMBLY AND REASSEMBLY OF CONTROL VALVE ............................................ 137
7.2.2 PUMP MAINTENANCE............................................................................................................
140
7.2.3 TROUBLE SHOOTING GUIDE ...............................................................................................
153

.
8 LOAD HANDLING SYSTEM .............................................................................................. 155
8.1 GENERAL DESCRIPTION ........................................................................................................... 156
8.1.1 OUTER AND INNER CHANNELS ......................................................................................... 156
8.1.2 LIFT BRACKET ........................................................................................................................
157
8.1.3 LOCATIONS OF ROLLERS ..................................................................................................... 158
8.2 MAINTENANCE ............................................................................................................................
159
8.2.1 ADJUSTING LIFT CYLINDER ROD WITH SHIMS .............................................................159
i
8.2.2 ADJUSTING HEIGHT OF LIFT BRACKET ...........................................................................159
8.2.3 PROCEDURE FOR REPLACING ROLLERS AT LIFT BRACKET SIDE ............................161
8.2.4 PROCEDURE FOR REPLACING ROLLERS AT MAST SIDE ........................................163
8.2.5 PROCEDURE FOR ADDING OR OMITTING SHIMS .......................................................... 164

.
9 STEERING SYSTEM (SEMI-INTEGRAL TYPE) .....................................................165
9.1 GENERAL DESCRIPTION ........................................................................................................... 166
9.1.1 STEERING WHEEL UNIT ....................................................................................................... 166
9.1.2 STEERING GEAR BOX .......................................................................................................... 167
9.1.3 STEERING LINKAGE .............................................................................................................. 170
9.1.4 POWER CYLINDER ................................................................................................................. 171
9.1.5 STEERING AXLE ..................................................................................................................... 172
1 9.2 MAINTENANCE ............................................................................................................................
175
9.2.1 DISASSEMBLY OF STEERING GEAR BOX ......................................................................... 175
9.2.2 INSPECTION .............................................................................................................................
177
9.2.3 REASSEMBLY OF STEERING GEAR BOX .......................................................................... 178
9.2.4 REAR WHEEL BEARING PRE-LOAD ADJUSTMENT ....................................................... 182
9.2.5 ASSEMBLING WHEELS ......................................................................................................... 183
9.2.6 TROUBLESHOOTING GUIDE ................................................................................................ 183
 1. ENGINE

1. ENGINE

II Gasoline Engines
Truck Model FG10C19FG10TTi9 FG20c6 F G 2 0 ~ 6 FG20c6~F G ~ O T ~ H
FG150n FG15~9n FG25c6FG25T6 FG25c6~F G ~ ~ T ~ H
FG15Ci9 FG15T19 FG18c9~W j 1 8 9 ~ FG30c6 FG30T6
FG18cis F G 1 8 ~ i s FG30c6~F G ~ O T ~ H

Name H15 H20 H25

TYpe 4-cycle. water-cooled, in-line. overhead valve type gasoline engine
No. of cylinders - Bore X stroke 4 - 75.5 X 83.0 4 - 87.2 X 83.0 4 - 92.0 X 93.0
mm [in] [2.97 X 3.271 [3.43 X 3.271 [3.62 X 3.661
Total displacement cc [in'] 1486 [91] 1982 [I 20.91 2472 [150.8]
Compression ratio 9.0 8.7 ...-
Performance
Rated speed 'F" 2400 2300 2400
f Rated output kW {HP) 27.2 {37) 34.3 {46) 42.7 (62)
Maximum torque 112.8{11.5) [83.2]/1600 142.2{i4.5)[iO4.9]/1600 i79.5{1S.3)[132.6]/1600
N-m {kgf-m)[ft-lbs]/rpm
Full-load rated fuel consumption 292{215}[4.8] 286{210} [4.7] 272{200} I4.51
glkw-h{g/ps-h] [lbs/HP.h]
No-load minimum speed '-Pm 700 C 4--

Weight kg [Ibs] 159 [351] 160 13531 161 [355]

Dimensions mm [in] 688.2 X 561 X 677 708.2 X 561 X 677 C

[27.1 X 22.1 X 26.71 [27.9 X 22.1 X 26.71

Ignition order 1-3-4-2
Rotational direction Clockwise when viewed from the fan

Diesel Engines

Name 4LB 1 C240 I Y3300

4-cycle. water-cooled. in-line. overhead valve-type diese1 engine with vortex chamber
Type
No. of cylinders - Bore X stroke mm[in] 4 - 77.4 X 79.7 4 - 8 6 102
~ 4-98x110
[3.05 X 3.141 [3.39 X 4.021 [3.86 X 4.331
Total displacement cc [in"] 1499 [91.8] 2369 [I451 3318 [203.1]
Compression ratio 22 21.3 22.6
Performance
Rated speed Vm
Rated output kW {HP)
Maximum torque
N-m{kgf-m} [ft-lbs]/rpm
Full-load rated fuel consumption
Lg/kw-h{g/ps-h}[lbs/HP.h]
No-load minimum speed Tm 800 700 t

Weight kg [lbs] 252 [556] 272 16001

,
Dimensions mm [in] 618.4 X 527.5 X 553.3 715 X 561 X 667 710 X 544.5 X 732.5
L24.4 X 20.8 X 21.81 [28.2 X 22.1 X 26.31 [28.0 X 21.4 X 28.81
Ignition order 1-3-4-2
Rotational direction Clockwise when viewed from the fan
1.I GENERAL DESCRlPTlON
This series Comes in either the gasoline or the diese1 engine type. The engine is connected to the drive
unit. The engine proper is supported through cushioning materials to the frame to reduce vibration from
the engine to the frame.
 7'sTR1BuT0R
THERMO SENSOR
ERATOR
CARBURETOR

FUEL PUMP

H20 H25
- 18
-16 E
$
-14
-12
-10
-
3

2'
- 8
- 6
- 4
- 2
-0 V,

---- Upper lirnit

- Standard limit
---Lower lirnit

g
C

300

8 12 1 6 20 2'4 28 3'2 8 12 16 20 24 28

I Engine speed (X 100 rprn)

Fig. 1.2 Gasoline Engine (H15, H20, H25)

 H20 H25

Main Construction
Type of cylinder liner Cylinder and cylinder block cast + C

into one piece

Valve operation
Suction valve
opens at BTDC: 14" C +

closes at ABDC: 30" C +

Exhaust valve
opens at BBDC: 32" C C

closes at ATDC: 12" C C

Valve clearance,
suction valve 0.38 mm [0.015 in] t +

exhaust valve 0.38 mm [0.015 in] + C

Ignition system Full-transistor type C. C

Ignition tirning BTDC 6" at 700 rpm 4"/700 ipm C

Ignition order 1-3-4-2 C- C

Ignition coil Incorporated in distributor + C

Distributor T6T877 (Mitsubishi Electric) C C

Ignition plug BP4ES (Nihon Tokushu Yogyo) t C

Spark gap 0.8 - 0.9 mm [0.031 - 0.035 in] t +

Governor Pneumatic type, fixed-range control + +

Carburetor Nihon Carburetor C C

Gas valve diameter 30 mm [1.18 in] t C

Venturi diarneter 22 mrn [0.87 in] 24 mm [0.95 in] 26 [1.02 in1

Fuel pump Diaphragm type t C

Air cleaner Filter paper type C- +

Lubrication system Forced lubrication + +

Lubrication pump Gear type C +

Lubrication oil filter Filter paper C C

Filtration Full-flow filtration C +

Cooling System Water-cooling, forced circulation t +

Cooling fan Pusher type, 6-blade, C t

O.D. of 380 mm f15.0 in]

Drive V-belt drive, pulley ratio 1:1.10"' C- +

Water pump Centrifugal type + C

Drive V-belt drive, pulley ratio 1: 1.10' C C

Water temperature regulator Wax type (valve opening temp.: t C

82 C or 179.6"F)
Starting motor Magnet shift type C C

Voltage 12 V C +

Output 0.8 kW t 1.2 kW2

Notes: *:I. The pulley ratio is 1:1.25 for EXA, 1:0.92 for EXN.
$2. 1.4 kW for EXN
Charging generator A7T033 (Mitsubishi Electric)
Voltage 12 V
Output 50 A
Generation 3-phase a.c.
Drive V-belt drive, pulley ratio 1:2.15
Voltage/current regulator
Type Transistor type (built in charging
generator)
Water and oil capacities
Lubrication oil 3.8 liter [ l gal]
(oil pan 3.5 liter [0.92 gal],
oil filter 0.3 liter [0.08 gal])
Cooling water 3.5 liter [0.92 gal] for engine only
 ,GENERATOR

STARTER MOTOR

. THERMOSTAT

OIL FlLTE

'ION PUMP
%-J t-3
DRAIN PLUG

I Engine speed (X 100 rprn) I

Fig. 1.3 Diesel Engine (C240)

-6-
 / INJECTION PUMP
/ SEDIMENTER

' DRAIN PLUG (QIL)

Fig. 1.4 Diesel Engine (V3300)

 INJECTION PUMP
.

THERMOSENDER
\ r-7

DRAIN PLUG (WAT

OIL PRESSURE

' OIL FILTER

STARTER MOTO
DRAIN PLUG (OIL) '

I Engine speed (X 100 rpm) I

Fig. 1.5 Diesel Engine (4LB1 for 1.0 - 1.75 ton trucks)

-8-
Major Construction
Valve system Overhead type
Fuel system
Injection pump Bosch, distribution type Bosch Bosch, PFR-1KX
Plunger (diameter X stroke) 9 rnrn X 2.2 mm 7.5 mm X 7.0 nlnl 5.5 rnm X 7.0 rnrn
[0.35 X 0.87 in] [0.30 X 0.276 in] [0.217 X 0.276 in]
Injection nozzle Throttle type t t

Fuel feed pump Diaphragm type C

Solenoid type
Fuel filter Paper filter with sedimentor t t

Governor
Governing Centrifugal all-speed control t

Lubiication Forced circulation Fuel lubrication Splash type

Lubrication system
Pump Trochoid type C C

Drive Cam shaft drive Clank shaft drive *

Oil pressure regulator Pistonlspring type t C

Oil pressure indicator Switch type t t

Filtration Full-flow, paper filter type t C

Oil cooler Not provided Plat type Not provided

Cooling system
Cooling method Water cooling C

Cooling fan Pusher type, 6-blade, C C

O.D. of 380 mrn 115 in] O.D. of 430 mm [17 in] O.D.of 380 mm [I5 in]
Drive Belt drive t t

Pump Vortex type t C

Drive Belt drive t

Water temperature regulator

TYpe Wax pellet type Wax type Wax pellet type
Temperature at which 82°C [179.6"F] 76.5"C [169.7"F] 76.5"C [169.7"F]
valve begins to Open
Temperature at which
valve Opens fully
Starting motor
TYpe Engage magnet type t t

Voltage 12 V t t

Output 2.2 kW 3.0 kW 1.4 kW

Stopping device Fuel cut-off type C C

Engine preheater Provided (QOS-LII) Provided Provided (QOS-111)

 C240 V3300 4LB1

Charging generator
Type A.C. generator, diode t t

rectification
Voltage 12 V C +

Output 35 A - 45 A 35 A
Drive V-belt drive *- +

Automatic charging Transistor type (built in IC type (built in +

regulator generator) generator)

Reference data
Oil sump capacity 5.2litermax.-4.0literniin 13.2liternlax.- 6.1 liter max. -
[I .37 gal max. - 1.06 gal 8.8 liter min 3.3 liter min
rnin.] [3.49 gal max. - 11.51 gal max. -
2.33 gal min.] 0.87 gal min.]
Cooling water volume 5.2 liter C1.37 gal] 4.0 liter [I. 1 gal] 2.9 liter [0.77 gal]
Valve clearance
Suction valve 0.45 mm [0.018 in] 0.23 - 0.27 mm 0.2 mm [0.008 in]
[0.009 - 0.011 in]
Exhaust valve 0.45 mm [0.0 18 in] 0.23 - 0.27 mm 0.2 rnm C0.008 in]
[0.009 - 0.011 in]
Valve operation
Suction valve
opens at BTDC 11" 14" 15"
closes at ABDC 49" 36" 29"
Exhaust valve
opens at BBDC 5 1" 45" 40"
closes at ATDC 9" 17" 16"
Injection tiniing 8" 16" 16"
Injection start pressure 11.8{120}[1706.8] -
13.7 14.7 13.2{135}[1920.1]
MPa{kgf/cm2}[psi] -
{ 140 150)
-
[1992.6 21351
Conlpression pressure 3.0{31} [440.9] at 200 rpm -
2.8 3.2 3.0{31}[440.9]
MPa{kgf/cn12}[psi] -
(29 33) at 200 rpm
-
[412.8 4701
at 200 rpm

Note: * 2. 60 A for EXN.

I 1. ENGINE

1.1.I FUEL SYSTEM

The fuel System is integral with the truck frame and consists of a fuel tank, filter, pump and carburetor
(for gasoline engine model) OS injection pump (for diesel engine model).

(1) Fuel tank

The fuel tank is welded into one integral body with the frame and located at the left side of the frame.
The fuel tank has on its top a tank Cover where a level sender is provided to check the fuel level in the
tank. The gasoline engine model has a suction pipe, but the diesel engine model has a return pipe in
addition to it.

I to ENGINE

LEVEL SENDER

DRAIN PLUG Capacity: 50 liters [13.2 U.S. gal] for

1.O- to 1.75-ton trucks
69 liters [ I 8.2 U.S. gal] for
2.0- to 3.0-ton trucks

I Note: The Sketches show the fuel tank for the 1.O- to 1.75-ton trucks, but tha fuel tank for the other rnodels is alrnost the sarne.
I
Fig. 1.6 Fuel Tank (for gasoline engine model)
1. ENGlNE

[108688] to ENGINE Capacity: 50 liters [13.2 U.S. gal] for

1.0- to 1.75-ton trucks
69 liters [18.2 U.S. gal] for
2.0- to 3.0-ton trucks

STOP VALVE

i
DRAIN PLUG

Fig. 1.7 Fuel System (for gasoline engine model, EXA)

Capacity: 50 liters [13.2 U.S. gal]

FUEL PUMP

SEDIMENTOR -.

LEVEL SENDER

Fig. 1.8 Fuel System (4LB 1 diese1 engine for 1.O- to 1.75-ton trucks)

- 12-
 Capacity: 50 liters [13.2 U.S. gal] for
1.5- to 1.75-ton trucks
69 liters [18.2 U.S. gal] for
2.0- to 3.0-ton trucks

CAP

-;=

\
DRAIN PLUG
I
Fig. 1.9 Fuel System (C240 diesel engine for 1.5- to 3.0-ton trucks)

[I083281 . Capacity: 50 liters [13.2 U.S. gal] for

1.5- to 1.75-ton trucks
69 liters [18.2 U.S. gal] for
2.0- to 3.0-ton trucks

CAP

DRAIN PLUG

Fig. 1.10 Fuel System (diesel engine for 1.5- to 3.0-ton EXA trucks)
[239A2-20011] Capacity: 69 liters [18.2 U.S. ga11

CAP

LEVEL SENDER

DRAIN PLUG I
Fig. 1.11 Fuel System (V3300 diese1 engine for 2.0- to 3.0-ton high-power models)
 (i 1. ENGINE

The level sender convei-ts the fuel level in the tank into an electric current signal. Figure 1.13 shows its
construction. For conversion of fuel level into electric signal, a variable resistor with nichrome wire is
used, with a sliding element linked to a float. As the float moves up and down, the resistance varies
accordingly so that the amount of electric current passing across the resistance also varies. The fuel meter
is a bimetal type whose pointer swings depending upon the amount of electric current passing through the
heating unit of the bimetal. When the float is at the highest position, the level sender reads a resistance of
9.5 to 11 ohms. This allows a large amount of electric current to pass through the resistance, thus causing
the bimetal to bend largely so that the fuel meter pointer indicates the F mark. As the fuel level drops, the
float goes down and the resistance becomes greater to reduce the amount of electric current passing
through it, thus causing the fuel meter pointer to swing
toward the E mark. The level sender is provided with a
1 [216~2-4030 11 FUEL LAMP
(OPTION) 1 I
level switch which infoins the Operator with an optional
lamp and level switch when the fuel level drops below a
( certain value. The fuel meter and the optional fuel larnp
are incorporated in the combination meter panel.

FUEL METER

Fig. 1.12 Combination Meter Panel

to FUEL METER
'q
to FUEL LAMP

View lwkino irom

FUEL METER

(OPTION)

Connection diagram
m
I
I I

Fig. 1.13 Tank Unit

-15-
(2) Fuel filter
The fuel filter removes dust and dirt from the fuel to be supplied to the engine. It is located on the fuel
pump (for the gasoline engine model) and on the fuel tank (for the diesel engine model). The fuel filter for
the diesel engine model also removes water from the fuel.

*& Q

LEVEL SWITCH

for diese1 engine rnodel

for gasoline engine rnodel

Fig. 1.14 Fuel Filter

i
1.I .2 COOLING SYSTEM
The cooling system consists of a water pump, a fan, a radiator, and a reserve tank, and its construction is
shown in Figs. 1.15 thru 1.20.
The water pump is attached to the engine. As the engine stai-ts running, it is also driven through the V-
[219M2-100111

Y
z
a

Fig. 1.16 Cooling System (foi C240 diese1 engine, 1.5 - 1.75 ton models)
[219G2-10011]

Y
z
a
F
W
>
a
U

Fig. 1.17 Cooling System (for 4LB 1 diese1 engine, 1.0 - 1.75 ton models)
I
Fig. 1.20 Cooling System (for V3300 diese1 engine, 2.0 - 3.0 ton high-power models)
1.I.3 ACCELERATOR PEDAL
The accelerator pedal, installed as shown in Fig. 1.2 1, controls the output of the engine.
As the accelerator pedal is pressed, its movement is transmitted thsough the cable to the engine thsottle.
In the case of trucks with a creep speed controller, a switch is installed to detect the depsession of the
accelerator pedal.

I ijl
I I

ii!
i; 111
1 1 ,

I II
=========I,*-=,
Table. Pedal Height
Unit : mm [in]

Adjust the pedal stopper height to the value as shown in Table "Pedal Height".
Adjust the looseness of the link to 0.5 - 1.0 m m [0.02 - 0.04 in] with the nut .
Fig. 1.21 Accelerator Pedal
1. ENGlNE

1.2 INSPECTION AND ADJUSTMENT

It is necessary to inspect and adjust, if necessary, the engine at periodic intervals to keep it in good
operating condition. The procedure for inspecting and adjusting the engine is explained on pages that
follow.

1.2.1 AIR CLEANER

(1) Remove the air cleaner element.
(2) Inspect the element for contamination and damage. If the element is dirty, clean it by blowing low-
pressure air from inside to outside. If the element is damaged or clogged, replace it with a new one.
(3) Clean the filter Cover.

[216G1-020511
FREE AIR
LATCH COVER
b \ / b ENGINE

Fig. 1.22 Air Cleaner

Be careful not to touch the muffier and evhaust manifold since they are hot when the engin is
running and for a while after it is shut off; otherwise you might burn your hand.
 1.2.2 FUEL FILTER
A WARNING
Turn the key switch off and make Sure the engine
is completely shut off. BAND ASSEMBLY
Select a well ventilation area. Keep away Open
flames.
After removing the cover or cartridge, fuel might
Spill. Clean u p spilled fuel completely with a FILTER SPRING
waste cloth.
Gasoline engine model
(1) Loosen the Part of the band assembly and
remove the cover.
'* :2) Check the filter elenlent and replace with a new one
if it is damaged or clogged.

Fig. 1.23

Diesel engine model

(1) Using a suitable filter wrench, remove the filter.
(2) Apply fuel on the packing of a new filter, install the
filter. After the packing contacts the filter body, give
another 213 of a turn.
(3) When the sedimentor warning light Comes On,
loosen the drain cock to discharge water through the CARTRIDGE
(FILTER)
cock.
CAUTION: After removing water, make Sure to close
the drain cock.

DRAIN COCK .
(for water removal)

Fig. 1.24
1.2.3 OlL FILTER
A WARNING
Turn the key switch off and make Sure the engine
is completely shut off.
The oil filter is very hot for a while after the
engine is shut off. Be careful not to burn your
hand.
After removing the oil filter, oil might Spill.
Clean up spilled oil with a waste cloth.

4 Gasoline engine model

(1) Using a suitable filter wrench, remove the filter.
(2) Apply engine oil at the packing of a new filter and
W- OIL FILTER

install the filter. After the packing touches the base, L I

give the filter another 213 of a turn. Fig. 1.25

Diesel engine model

(1) Using a suitable filter wrench, remove the filter.
(2) Apply engine oil at the packing of a new filter,
install the filter. Give the filter another 2/3 of a turn
after it touches the base.
f--qc FILTER

Fig. 1.26
 1.2.4 COOLING SYSTEM
(1) Checking cooling liquid
Check the cooling liquid level in the reserve tank. If
the level is below the LOW mark, add cooling liquid of
appropriate concentration listed in Table 1.1, to bring
level:
Up to the FULL mark when the engine is warm
2/3 of the capacity when the engine is cold.

(2) Changing cooling liquid

Q Shut off the engine and wait for more than 30
minutes.
Q Remove the radiator cap and Ioosen the drain cock
at the radiator side.
i @ Loosen the drain cock at the engine side to drain off
the cooling liquid. Fig. 1.27 Reserve tank
@ Tighten the drain cocks at both the radiator and the engine sides.
Add cooling liquid of appropriate concentration listed in Table 1.1, into the radiator.
The rate of addition is less than 2 literlmin [ O S gallmin].

Table 1.1 Unit: liter [U.S.gal]

1.O- to 1.75-ton trucks

2.0- to 3.0-ton tmcks

T 6.5 [1.72] 7.2 11.91 6.7 [1.77] 8.9 [2.35] * 7.7 [2.03]

Coolant concentration: 30% for general-climate regions

50% for cold regions
i, "
@ After adding cooling liquid, start the engine and let
it run at idle rpm for a couple of minutes and check
the cooling liquid level. If the level is low, add
appropriate cooling liquid.
Tighten the radiator cap securely. Add cooling
liquid to bring level up to 213 of the capacity.

Fig. 1.28 Drain Cock Location

(3) Adjusting fan belt tension
Make Sure the engine is shut off.
Loosen generator fitting bolts.
@ Move the generator away frorn the engine to adjust the belt tension, so that the fan belt has a
deflection of 10 nlm (0.4 in) at on the Span when pressed by a finger pressure of about 98.1N { 10
kg} [22.1 lbs].
@ Tighten the fitting bolts and then .

Fig. 1.29 Fan Belt

- 28 -
1.2.5 AIR BLEEDING
(1) C240, V3300 engines
@ Operate the fuel filter (sedimentor) pump to send PUMP
fuel into the injection pump.
B After it feels a little hard, operate the pump 5 to 10
more times.

Fig. 1.30 Air Bleeding

(2) 4LB1 engine
@ Turn the key switch to the ON position, not to the START position. Wait for about 10 to 20 seconds.
Turn the key switch to the OFF position.
1.2.6 TlGHTENlNG CYLINDER HEAD BOLTS
Gasoline engine model
Tighten the cylinder head bolts to 29.4 N-m (3.0
kgf-m} [21.7 ft-lbs] in the numerical order as shown
inFig. 1.31.
@ Give them additional 78.5 N-m (8.0 kgf-m} [57.9
ft-lbs] torque.
@ Loosen all the bolts in a sequence opposite to that in
Fig. 1.31.
@ Tighten them to 29.4 N-m (3.0 kgf-m) [21.7 ft-lbs]
Fig. 1.31 Cylinder Head Bolts
torque again.
- -
@ Tighten to 68.7 83.4 N-m {7.0 8.5 kgf-m} [50.6 - 61.5 ft-lbs].

Diesel engine model

Tighten the bolts in the numerical order shown in
Fig. 1.32.

- -
@ Give them additional 80.4 90.2 N-m (8.2 9.2
kgf-m} [59.3 66.6 ft-lbs] torque.
-
98.1 - 107.9 N-m { I 0- 11 kgf-m} [72.3 -
Note: When the bolts are to be reused, tighten them to
79.6 ft-
lbs] torque. The bolts may be reused up to 5 times.

Fig. 1.32 Cylinder Head Bolts

1.2.7 VALVE CLEARANCE ADJUSTMENT
The valve clearance must be adjusted when the engine is warm (for the gasoline engine model) or cold
(for the diese1 engine model).
Remove the cylinder head Cover.
@ Adjust the valve clearances of the valves in the
manner as shown in Table 1.3.
Table 1.2 Unit: rnm [in]
Suction valve Exhaust valve
H15, H20, H25 0.38 [0.015] c

C240 0.45 [0.018] c

-
0.23 0.27
V3300 -
[0.009 0.01 11
C THICKNESS GAUGE

4LB 1 0.2 [0.008] c

Fig. 1.33 Valve Clearance
Table 1.3
1st 2nd 3rd 4th
Suc. Ex. Suc. Ex. Suc. Ex. Suc. Ex.
No. 1 cylinder at top dead Center on compression stroke 0 0 0 0
No.4 cylinder at top dead Center on compression stroke 8 0 0 0
 1. ENGINE -

1.2.8 IGNlTlON TIMING ADJUSTMENT

Install a tachometer and timing light on the engine.
a Start the engine and check the ignition tinling by
observing the timing marks on the engine front
Cover and on the crank pulley.
Note: The timing marks on the crank pulley are
calibrated in divisions of 5 degrees.
BTDCIrpm
H15 H20 H25
6"/700 4"/700 +

Fig. 1.34 Ignition Tinling

@ If the ignition timing is not proper, loosen the distributor fitting bolt and turn the distributor to the
,4 right or left to obtain the correct ignition timing.
l
i.

1.2.9 ENGINE SPEED ADJUSTMENT

Engine speed adjustment should be made when the engine water temperature is more than 75'C [167'F].

(1) Idling rpm

Make sure to shut off the engine. Loosen the screw
of the carburetor 2.5 turns from fully-closed
state.
a Install a engine tachometer on the engine and start
the engine.
@ Turn the screw )to the right or left to adjust
idling speed to the specified 700 rpm

Fig. 1.35 Carburetor

1. ENGINE
i
(2) Maximum rpm
The maximum rpm of the engine is adjusted with the governor. Remember that hunting may occur if it
is changed too frequently.
1

I Areas to be adjusted
Allen wrench
[width across Rats: 2.5 mm or 0.098 in]
I

Width across Rats:

12 mm or 0.47 in

BURETOR

UTOR

Same as before

Fig. 1.36 Governor

Cautions to be taken when adjusting
When adjusting the adjustment handle @, turn the screw @ counterclockwise.
@ When tightening the screw @, first tighten it until it lightly touches the adjustment handle and give
additional 114 or 112 of a turn.
@ After adjustment, apply a piece of sealing tape @ to Cover entirely both the screw @ and the cap @.

Adjusting no-load maximum rprn

Remove the rubber cap and turn the adjustment handle to adjust the no-load maximum rpm for the
specified value. The value is increased by turning the handle clockwise and is reduced by turning it
counterclockwise.

Adjusting maximum rpm under loaded condition (with relief valve in operation)
Turn the adjustment screw to adjust the maximum
rpm under loaded condition. At this time, adjust the
no-load maximum rpm, too. (The adjustment screw
for no-load maximum rpm is inside the adjustment
handle and its direction of revolution is the Same as
the adjustment screw for the n~aximumrpm under
loaded condition)
@ If the maximum rpm under loaded condition cannot
be properly adjusted with the adjustment screw, the Fig. 1.37
cam should be adjusted. However, cam adjustment
requires a high degree of skill and poor adjustment will lead to the occurrence of hunting.

Cam adjustment procedure (reference)

Loosen the cam Set screw and move the cam angle in the direction of the arrow in Figure 1.37. Remember
that the output will increase but hunting rnight tend to occur.
 Table 1.4
&
H15 H20 H25
Momentary 2890 - 3090 2990 - 3 150 3050 - 3250
No-load maximum rpm
Steady 2820 - 2900 2820 - 3080 2900 - 3100

Inspecting and adjusting hunting

Hunting means a phenomenon that engine speed rapidly fluctuates. The engine must be checked for
hunting whenever no-load maximum rpm or loaded maximum rpm (with relief valve in operation) is
adjusted.

Inspection
Shut off the hydraulic system and place the gears in neutral. With the engine running at idling rpm,
tramp on the accelerator pedal to check for hunting.

Adjustrnent
If hunting occurs for more than three times, make adjustment as follows:
Tuin the adjustment screw clockwise. Also adjust the no-load maximum rpm.
If hunting is not eliminated by the above adjustment, use the cam set screw.

Problem Probable cause Remedy

Engine speed won't increase ' Cm1 roPe broken Replace cam rope kit.
under no-loaded condition Deteriorated or broken spring
Travel speed won't increase. ' Incorrect adjustment of cam spring Adjust.
Hunting (no hunting when . Stabilizer piston stuck Clean or replace governor
lifting) assembly.
Travel speed won't increase. Incorrect adjustment of carn spring Adjust.
Slow lifting. Deteriorated carn spring Replace cam rope kit.
Slow lifting (travel speed is . Incorrect adjustment of cam spring Adjust.
normal).
Incorrect adjustment of canl spring Adjust.
Travel speed increases too . Stabilizer stuck Clean or replace governor
easily. Governor valve shaft stuck assembly.
Incorrect adjustment of cap spring Adjust.
Hunting occurs for more than . Stabilizer stuck Clean or replace governor
three times. Governor valve shaft stuck assembly.
NOTE
 2. CLUTCH TYPE DRIVE UNlT

2. CLUTCH TYPE DRIVE UNlT

\
Truck Model FGlOci9 FG20c6
FG15ci9 FG15c9~ FG25c6 FD20c6~
FG20c6~
FG18ci9 FG18c9~ FG30c6 FD~SC~H
FG25c6H
FDlOci9 FD15c9~ FD20C6 FD~OC~H
FG30c6H
FD15ci9 FD18c9~ FD25~6
FD18cig FD30c6

Transmission
Type Synchronlesh type transmission
Model 166-25 11M-25 36F-25 37A-25 39A-25
Reduction ratio
Fwd Ist 2.619 3.253 3.025 2.719 C

Fwd 2nd 1.407 t 1.355 C C

Rev Ist 2.580 2.580 3.033 2.726 C

Rev 2nd 1.386 t 1.359 t C

Reduction gear
2.5 1.909 2.444 + C
Reduction ratio
Differential
c c
Reduction ratio 5.7 t 5.273
Q'ty of oil to be used
Weight 136kg [300 lbs] 145kg [320 lbs] 170kg [375 lbs] + t

Clutch
Type Dry single plate type
Operation Foot-pedal type
Facing size
Outer diarneter 2 7 5 m [10.83 in]
Inter diameter 1 7 5 m [6.89 in]
Thickness 8.93~0.3mnl[0.35f 0.012 in]
Surface area 354cn1' [67.9 inchl]
(one side)
Clutch Cover weight I 12.5kg [27.56 lbs]

2.1 GENERAL DESCRlPTlON

The clutch type drive unit consists of a synchromesh type transmission, a differential unit, and a clutch
unit.
2. CLUTCH TYPE DRIVE UNlT
i

[OO 10081

1. SNAP RING 12. "W-RING 22. NEEDLE BEARING 32. SLEEVE

2. BALL BEARING 13. SLIDE BOLT 23. FORWARD GEAR 33. INSERT
3. SPACER 14. RETAINER 24. STEEL BALL 34. SYNCHRONIZING
4. BALL BEARING 15. DRIVE SHAFT 25. SHAFT CONE
5. INPUT GEAR 16. IDLE GEAR 26. NEEDLE BEARING 35. FIRST-SPEED GEAR
6. NEEDLE BEARING 17. TAPERED ROLLER 27. COUNTER GEAR 36. MAIN SHAFT
7. SPACER BEARING 28. SPACER 37. BALL BEARING
8. NEEDLE BEARING 18. OUTPUT GEAR 29. NEEDLE BEARING 38. CLUTCH HUB
9. CLUSTER GEAR 19. LOCK NUT 30. REVERSE GEAR 39. TAPERED ROLLER
10. BALL BEARING 20. SPACER 3 1. SECOND-SPEED BEARING
11. OIL SEAL 2 1. BALL BEARING GEAR 40. SNAP RING

Fig. 2.1 Synchromesh Type Transmission (for 1.O- to 1.75-ton trucks) 112
Fig. 2.2 Synchromesh Type Drive Unit (for 1.O- to 1.75-ton ti-ucks) 212
2. CLUTCH TYPE DRIVE UNlT I
I

1. BALL BEARING 10. CLUTCH COVER 20. NEEDLE BEARING 29. SECOND-SPEED
2. INPUT GEAR 11. RETAINER 2 1. COUNTER GEAR GEAR
3. TAPERED ROLLER 12. BEARING 22. SPACER 30. MAIN SHAFT
BEARING 13. SHIFT BLOCK 23. NEEDLE BEARING 3 1. BALL BEARING
4. LOCK NUT 14. DRIVE SHAFT 24. FORWARD GEAR 32. CLUTCH HUB
5. IDLE GEAR 15. OUTPUT GEAR 25. FIRST-SPEED GEAR 33. TAPERED ROLLER
6. SPACER 16. BALL BEARING 26. INSERT BEARING
7. BALL BEARING 17. BALL BEARING 27. SLEEVE
8. "0"-RING 18. REVERSE GEAR 28. SYNCHRONIZING
9. O E SEAL 19. SHAFT CONE

Fig. 2.3 Synchromesh Type Drive Unit (for 2.0- to 3.0-ton trucks) 112
2. CLUTCH TYPE DRIVE UNlT
2. CLUTCH TYPE DRIVE UNlT

2.1 .I SYNCHROMESH TYPE TRANSMISSION

The transmission consists primarily of a main drive shaft, an output shaft, a main shaft, and a reverse
drive shaft, each shaft having gears of varying sizes. The gears are shifted with the aid of the sliding
sleeves installed on the main shaft by operation of the shift arms. The power from the output shaft is
transmitted through the reduction gear and the differential to the drive shaft.

(1) Power flow

[In neutral position]
The power from the main drive shaft is transmitted through the cluster gears @ and @ always
meshing with the input gear to the high gear @ and low gear @. But, the speed shift sleeve and
directional shift sleeve are in the neutral position, the main shaft, driven gear, and output shaft are not
rotated, so the power is not transmitted to the differential.

[Gear shifting]
When the change lever is shifted, the shift arms move the sleeves to allow gears to mesh with the clutch I
t

hub and the main shaft. Power is transmitted in the following order: Main drive shaft, input gear, cluster
gear, high gear or low gear, synchromesh mechanism, main shaft, synchromesh mechanism, reverse gear
of fonvard gear, driven gear and output shaft.

Power Flow In Forward 1st Speed Gear Position: @+@b+@+@+@+@+@+@-+@-+@+a

Power Flow In Forward 2nd Speed Gear Position: Q+aa+@+O+@+@+@+@+@+@+a
Power Flow In Reverse Ist Speed Gear Position: Q+@b+@+Q+@+@+@+@+a
Power Flow In Reverse 2nd Speed Gear Position: Q+@a+@+@+@+@-+@+M

1. MAIN DRIVE SHAFT

,a
IN 2. INPUT GEAR
,b
0 3. HIGH GEAR
4. LOW GEAR
-7 -o 5. REVERSE GEAR
6. FORWARD GEAR
'-
7. OUTPUT GEAR
P 8. COUNTER GEAR
9. COUNTER GEAR
10. SLEEVE
11. SYNCHRONIZING CONE
12. SYNCHRONIZING CONE
13. SLEEVE
14. SYNCHRONIZING CONE
15. SYNCHRONIZING CONE

Fig. 2.5 Power Flow

 r 2. CLUTCH TYPE DRIVE UNlT

(2) Synchronizer
The synchronizer synchronizes gears which are about to mesh by letting the block ring come in contact
with the tapered flanks of the gears.

1. GEAR TEETH OF BLOCK RING @

2. BLOCK RING
3. DOG TEETH OF GEAR @
4. SYNCHRONIZING CONE
5. SLEEEVE
6. SPLINES OF SLEEVE @
7. INSERT
8. RING.SPRING
9. CLUTCH HUB
10. SHIFTARM
11. CONSTANT-MESH GEAR
12. GEAR TEETH OF GEAR ( . )
13. CONSTANT-MESH GEAR
14. GEAR TEETH OF GEAR @:J

Fig. 2.6 Synchronizer

The synchromesh mechanism consists primarily of: (1) synchronizing cones, (2) block rings and (3)
inseris.
(1) Synchronizing Cone: This nleshes with the gear Q through splines, and has a male cone friction
Li
surface and the dog teeth @ which are engaged with the sleeve splines @.
(2) Block Ring: This has a female cone friction surface which is the mating surface of the male friction
surface of the synchronizing cone @, and it also has three notches arranged on the circumference to
position on the index position together with the sleeve splines @ as well as the gear to press the
block ring to the cone friction surface in an axial direction through the sleeve splines @.
(3) Insert: The Center prajection of the insert is fitted in the inner annular groove provided in the splines
@ of the sleeve @ and forced against the inner side of the sleeve splines @ by the ring spring @ so
that an intial load is created to guide the block ring @ to the index position.
2. CLUTCH TYPE DRIVE UNlT
i

The operation of the synchromesh mechanism has the following six steps from the neutral position to
the completion of meshing. In the explanation given below, the gear in Fig. 2.6 is regarded as a gear to
be synchronized.

D First stage
When force F is applied on the change lever, it is
transrnitted to the sleeve @ through the shift arm,
so that the sleeve @ and insert are shifted in an
axial direction by X, and X, respectively. In this
case the center projection of the insert is fitted in
the annular groove of the sleeve splines @.

Fig. 2.7

Second stage
When the clearances X, and X, have been filled,
a force is applied to the inserta, block ring @ and
cone friction surface since the insert a goes out of
the annular groove of the sleeve splines @. This
force is a function of the contacting angle formed by
the center projection of the insert Q and the inner
annular groove of sleeve spline and the clamping
force of the ring spring @ forcing the insert Q to
the inside of the sleeve @. The sleeve @ is shifted
by this force by a clearance Z.
Fig. 2.8

@ Third stage
The force applied to the block ring @ through
the insert a creates friction force on the cone
friction surface. This force allows the one end of
the block ring notch to get in contact with the side
face of the insert as shown in Fig. 2.9 (The position
occupied by the block ring teeth and sleeve
splines @ is called an index position.)

Fig. 2.9
 2. CLUTCH TYPE DRIVE UNlT
(
@ Fourth stage
When the block ring @ is brought into the 3rd
step position, the sleeve @ shifts by a clearance Z
so that the chamfer @ of the tooth D of the block
ring @ comes into contact with the chamfer of the
sleeve splines @. At this time, the cone torque Tc
necessary for synchronization is created on the cone
friction surface, causing practically synchronization.

Fig. 2.10
Fifth stage
When the relative speed of the synchronized
$-'
L constant-mesh gear 0and sleeve has become
zero, completing synchronization, the cone torque Tc
becomes also zero. At this time, as T is smaller
than Tc, the block ring @ shifts in the peripheral
direction to allow the sleeve splines @ between the
tooth D. At this moment, the synchronization is
completed, so that the block ring @ is free of
external force and brought into an idle state. The
sleeve splines @ can, accordingly, pass between the
tooth of the block ring @ freely.
Fig. 2.11
@ Sixth stage
When the synchronization has been completed, the sleeve splines @ passes across the block ring
@, shifting by a clearance Y, indicated in Fig. 2.10, so that the chamfer of the sleeve splines @
comes into contact with the chamfer of the dog- tooth @ of the gear 0. (See Fig. 2.12.) Due to
contact of chamfers, torque T, acts on the dog tooth @ to pass the sleeve splines @ so that the gear
- 0 shifts in the peripheral direction. This allows the sleeve splines @ to pass between the dog tooth
\r
@ of the gear 0, completing meshing. Power is carried through the shaft, clutch hub @, sleeve
and dog tooth B. This, the gearshifting operation is accomplished.
I I

Fig. 2.12

- 43 -
2. CLUTCH TYPE DRIVE UNlT
I
2.1.2 REDUCTION GEAR AND DIFFERENTIAL
The reduction gear is located in front of the transmission case, and reduces the power fronl the
transmission output shaft, transmitting to the differential.
The reduction gear consists primarily of the output shaft inserted into the transmission case, a bevel
gear, and a speed reduction shaft. The bevel gear is splined to the speed reduction shaft, which is
supported by tapered roller bearings at both ends. Between the reduction gear case and each bearing Cover
is shims for backlash adjustment.
The differential is fitted to the rear case through ball bearings with bearing caps and covered with the
axle housing. The differential cross case is a split type containing two side gears and four pinion gears,
with thrust plates installed between the cross case and each gear according to their backlash. Each of the
pinion gears is supported by the pinion shaft, which is secured to the cross case with a knock-out pin. On
the outer diarneter of the cross case is a ring gear bolted. Each side gear is splined to the drive shaft so that
the power sent from the transmission through the reduction gear is further reduced and differentiated by
this device to drive the drive shaft. 1 -
 2. CLUTCH TYPE DRIVE UNlT

1.5- to 1.75-ton high-power trucks (11M-25)

1. RING GEAR
2. BALL BEARING
3. SIDE GEAR
4. WASHER
5. CROSS CASE
6. COVER
7. TAPERED ROLLER BEARING
8. "0"-RING
9. GEAR
10. SPACER
11. BEVEL GEAR
12. SHIM
13. C M
14. PINION GEAR
15. WASHER
1.D- to 1.8-ton trucks (166-25)
16. SPIDER
17. TAPERED ROLLER PIN

Fig. 2.13 Reduction Gear and Differential (for 1.O- to 1.75-ton trucks)
2. CLUTCH TYPE DRIVE UNlT

1. RING GEAR 9. GEAR

2. BALL BEARING 10. SPACER
3. WASHER 11. BEVEL GEAR
4. SIDE GEAR 12. SHIM
5. CROSS CASE 13. CAP
6. COVER 14. PINION GEAR
7. TAPERED ROLLER BEARING 15. WASHER
8. "0-RING 16. SPIDER

Fig. 2.14 Reduction Gear and Differential (for 2.0- to 3.0-ton trucks)
('*
2. CLUTCH TYPE DRIVE UNlT

2.1.3 CLUTCH COVER AND CLUTCH DlSK

The clutch cover is attached to the engine flywheel and its construction is shown in Fig. 2.15. The
clutch disk is located between the clutch cover pressure plate and the flywheel, with the clutch disk boss
splined to the transrnission drive shaft. As the shift block moves, the release lever is pushed in to let the
pressure plate leave the clutch disk, thus shutting off the power from the engine.
2. CLUTCH TYPE DRIVE UNlT
2. CLUTCH TYPE DRIVE UNlT
i
2.1.4 RELEASE CYLINDER
Figure 2.18 shows a sectional view of the release cylinder. It is installed on the left side of the
transmission case. This cylinder consists of a piston, a spring, and a push rod, and its rnovement is
transmitted through the push rod to the shift arm.

[214A5-323 123

1. BLEEDER 6. PUSH ROD

2. CYLINDER 7. BOOT
3. SPRING 8. LOCK NUT
4. CUP 9. CLEVIS
5. PISTON

Fig. 2.18 Release Cylinder

2.1.5 MASTER CYLINDER

The master cylinder has a sectional view as shown in Fig. 2.19, and is installed on the clutch pedal
section of the transmission case. The master cylinder consists of a piston, a spring, a reserve tank, and a
push rod. The movement of the pedal is transmitted through the push rod to the piston, converting pedal
effort into hydraulic pressure.

[239A5-4050 11

c from RESERVE TANK 1. YoKE

2. PUSH ROD
to RELEASE CYLINDER 3. BOOT
P-] 4. SNAP RING
Sectional view - rn 5. STOP PLATE
6. PISTON
7. CUP
8. SPRING
9. VALVE ROD
10.CYLINDER

Fig. 2.19 Clutch Master Cylinder

- 50 -
2. CLUTCH TYPE DRIVE UNlT
2. CLUTCH TYPE DRIVE UNIT

BRAKE MASTER CYLINDER

CLUTCH MASTER CYL

BRAKEPEDAL

I
View looking from E

Fig. 2.21 Clutch and Brake Pedals (for 1.O- to 1.75-ton trucks) 212
 2. CLUTCH TYPE DRIVE UNlT

Fig. 2.22 Clutch and Brake Pedals (for 2.0- to 3-ton trucks) 112
 RAKE MASTER CYLINDER

CLUTCH MASTER CYLINDER

View looking from !EI

 2. CLUTCH TYPE DRIVE UNIT
i

2.2 MAINTENANCE
2.2.1 CLUTCH PEDAL ADJUSTMENT
(1) Remove the floorboard.
(2) Loosen the pedal stopper lock nut.
(3) Turn the pedal stopper to the right or left to adjust
the pedal height.
(4) Tighten the lock nut and ieinstall the floorboasd.

2.2.2 CLUTCH DlSK REPLACEMENT

(1) Remove the clutch housing cover.
(2) Press the clutch pedal and hold the pressure plate
with the pull-up bolt.
,.- I1.0- to 1.75-ton trucks
I
---------------------------. I

{ ' / (3) Turn the slide bolt counterclockwise and put the /
I
IL - - - - - - - drive shaft into the transmision case.
----------------------------------------------J
I

- 2.0- to 3.0-ton trucks , --- -- ---- - - -- - - - -------------I

I I Fig. 2.24 Clutch Pedal Height
j (3) Turn the spline teeth of the drive shaft to a
j position which allows removal of the clip pin, j
: using a flat-bladed screw driver. Remove the clip j CLUTCHCOVER
j pin from the drive shaft. I
I
I
I
I
Push the drive shaft into the transmission case j
PULL-UP BOLT
:L-----------------------------------------------------J
to remove the clutch disk from the drive shaft.
(4) Remove the bolt securing the clutch cover, move the
clutch cover towqasd the shift block, and remove the
clutch disk.
(5) Put a new clutch disk in the housing, with the longer
spline boss pointed toward the transmission, and
remove the drive shaft.
[On 1.0- t o 1.75-ton trucks, turn the slide bolt Fig. 2.25 Pull-up Bolt
clockwise to renlove the drive shaft.]
Note: Align the teeth on the clutch disk with the
splines on the drive shaft splines.
- I1.0- to 1.75-ton trucks - - - - - - - - - - - - - - - - - - - - - - - - - - - I

/ (6) Make Sure the drive shaft is completely drawn

I
I
out.
L-----------------------------------------------------J I

r- 2.0- to 3.0-ton trucks .-----------------------------I I

I

! (6) Connect the drive shaft to the input gear with the j
/ clip pin.
L,-----------------------------------------------------l
I
I
I

(7) Reinstall the clutch cover on the flywheel.

(8) Press the clutch pedal and remove the pull-up bolt. Fig. 2.26 Release Cylinder
(9) Check the clutch pedal play and adjust, if necessary.
Play : 0 rnrn
(10) Make sure the clearance between the release arm and stopper is 14 mm [OS5 in.].
2. CLUTCH TYPE DRIVE UNlT

NOTE
 3. TORQUE CONVERTER TYPE DRIVE UNlT
(

3. TORQUE CONVERTER TYPE DRIVE UNlT

18H-25 1 18N-25
1 fwdlrev

3-element, 1-stage
2-phase type
Stall torque ratio 3.O
Charging oil 0.49 - 0.69 MPa ( 5 - 7 kgf/cm2}
pressure [71.1 - 99.6 psi]

Charging pump
Type Interna1 gear type
Discharge 14 cclrev
Transmission
Type Power-shift type t

Reduction ratio 1.348 fwdlrev 1.333 fwdlrev

Clutch disk
Dimensions 125 X 81 X 2.7 mrn 125 X 81 x2.6mm
[4.921 X 3.189 X 0.1061 i4.921 X 3.189 X 0.1021
Clutch oil pressure 1.18- 1.47MPa ( 1 2 - 15 kgflcm'} 0.79 - 1.67 MPa {8- 17 kgf/cm2)
[170.7 - 213.4 psi] [113.8 - 241.8 psi]

Reduction gear
Reduction ratio
Differential
Reduction ratio 5.7
Weight kg [lbsl 155 [341.8]
Oil capacity liter [gal] 10 [2.6]
Oil to be used SAE 10W or equivalent

3.1 GENERAL DESCRlPTlON

The torque converter type drive unit consists of a torque converter, a power-shift transmission, and a
differential.
3. TORQUE CONVERTER TYPE DRIVE UNlT

[001331]

INLINE FILTER
CHARGING PUMP
SOLENOID VALVE
TORQUE CONVERTER

CLUTCH PACK

OUTPUT SHAFT

Fig. 3.1 Torque Converter Type Drive Unit (for 1.O- to 1.75-ton trucks) 112

-58-
3. TORQUE CONVERTER TYPE DRIVE UNlT

CHARGING PUMP

TORQUE CONVERTER

CLUTCH PACK,
I.

Fig. 3.3 Torque Converter Type Drive Unit (for 2.0- to 3.0-ton trucks) 112
 3. TORQUE CONVERTER TYPE DRIVE UNIT

REGULATOR VALVE
I
ACCUMULATOR
I
CONTROL VALVE

STRAINER ' / INLINE FILTER

Detail of area

Fig. 3.4 Torque Converter Type Drive Unit (for 2.0- to 3.0-ton trucks) 212
3. TORQUE CONVERTER TYPE DRIVE UNlT

3.1.1 TORQUE CONVERTER

The torque convei-ter consists of a pump wheel, a turbine wheel, and a stator wheel, as shown in Figures
3.5 and 3.6.
As the engine is started, the pump wheel is driven and the fluid inside the pump wheel begins to be
ejected along with the row of pump wheel vanes under centrifugal force, flowing into the row of turbine
wheel vanes to transmit torque to the output shaft. The direction of fluid leaving the turbine wheel is
changed by the stator wheel so that it may flow into the pump wheel at a proper angle. At this time,
reaction torque pushing the stator is created so that the output torque exceeds the input torque by this
reaction torque.
If the rotational speed of the turbine wheel increases and gets closer to the input rotational speed, the
angle change in the fluid will become smaller and the output shaft torque will decrease, finally letting the
fluid flow into the row of stator vanes in the reverse direction, causing reveres reaction torque. As a result
of this, the output shaft torque will become smaller than the input shaft torque. To prevent this from
happening, the stator wheel is designed to rotate freely when reaction torque acts in the reverse direction.
The output torque is kept equal to the input torque so that highly effective operation is ensured. Since
the phase of torque transmission is converted by the mechanical means, this type of torque conversion is
called 2-phase type, which ensure smooth and effective operation.
The pump wheel of the torque converter is connected through the input plate to the engine flywheel,
with the pump wheel boss claw driving the charging pump.

[124S3-803011

TURBINE WHEEL PUMP WHEEL

STATOR WHEEL

ONE-WAY CLUTCH

TURBINE SHAFT

r
Detail of area W

Fig. 3.5 Torque Converter (for 1.O- to 1.75-ton trucks)

- 62 -
3.1.2 CHARGING PUMP
The charging pump consists of a drive gear, a internal gear, a case, and a Cover, as shown in Figure 3.5,
and is housed in the torque converter housing.
The drive gear is driven by the boss fitted to the torque converter pump wheel and picks up oil fsom the
bottom of the transmission case and sends it to the transrnission control valve.

DECHARGE PORT
CASE I

DRIVE GEAR
INTERNAL GEAR
OIL SEAL
SUCTION

I I

Fig. 3.7 Charging Pump

3. TORQUE CONVERTER TYPE DRIVE UNlT

3.1.3 TRANSMISSION
The transrnission is a power-shift type consisting of a clutch pack, an output shaft, a reverse gear, and
transmission control valve. (See Figures 3.1 and 3.2.)
(1) Clutch pack
The clutch pack consists of a pair of hydraulic clutch units, each of which is composed primarily of a
piston, a spring, clutch disks, and steel plates. The piston is always forced against drum by the spring and
the oil pressure is applied, the piston locks up the clutch disks and steel plates. The clutch lock-up oil is
fed through the grooves in one end of the clutch shaft while the lubrication oil is fed through the oil holes
in the shaft end.

12082891 for 1.O- to 1.75-ton trucks

CHECK BALL HELICAL PLATE
REVERSE GEAR
BALL BEARING

BALL BEARING
REV CLUTCH OIL PRESSURE

LUBRlCATlNG OIL +

SEAL RING
FWD CLUTCH OIL PRESSURE
NEEDLE BEARING
FORWARD GEAR

[2145.93] for 3.0- to 3.0-ton trucks

CHECK BALL
REVERSE GEAR, I
BALL
BEARING

d t
REV CLUTCH OIL PRESSURE

RND CLUTCH OIL

BALL BEARING

BALL BEARING FORWARD GEAR

Fig. 3.8 Clutch Pack

- 64 -
 3. TORQUE CONVERTER TYPE DRIVE UNlT

(2) Controll valve

18H-25,18N-25
The transmission control valve consists of a regulator valve and an accumulator and is installed on the
transrnission case Cover.
The regulator valve controls the clutch oil pressure to 1.18 to 1.47 MPa { 12 - 15 kgf/cm2) [170.6 - 213.3
psi]. The oil relieved flows through the torque converter and oil cooler to cool and lubricate each before
returning back into the transmission case.
The accumulator slows down the rise of the clutch oil pressure to alleviate the shock caused by clutch
engagement.
3. TORQUE CONVERTER TYPE DRIVE UNIT

37B-25, LCE-34G-25
The transmission control valve, installed on the left side of the transmission case, consists of a solenoid
valve, a modulation valve, and an inching valve.
The solenoid valve is installed as shown in Fig. 3.8 and used to select the traveling direction of the
truck, or fonvard and reverse.
The modulation valve, linked with the accumulator, slows down the rise of the clutch oil pressure to
 3. TORQUE CONVERTER TYPE DRIVE UNlT

(3) Transmission Hydraulic Circuit

When the engine is started and the charging pump is driven, the oil is picked up from the bottom of the
transmission case and flows through the strainer to the regulator valve where the clutch oil pressure is
regulated to the specified value.
The oil relieved from the regulator valve flows, passing through the inline filter, torque converter and oil
cooler, to each part to cool and lubricate them before returning to the bottom of the transmission case.
The oil pressure inside the torque converter is controlled by the converter inlet relief valve to the
specified value.

In neutral
When the selector spool is in neutral, the oil is blocked by the selector spool and thus all the oil supplied
from the charging pump flows to the torque converter.
i
On trucks with capacities from 2.0 to 3.0 tons, the modulation valve spool is moved to the right side and
( held there.

215534
TORQUECONVERTER
OIL COOLER

TORQUE CONVERTER
INLET RELIEF VALVE

INLINE FILTER

REGULATOR VALVE
1

CHARGING PUMP INCHING VALVE Ii

Fig. 3.11 Transmission Hydraulic System Schematic Diagram (Neutral: for 1.O- to 1.75-ton trucks)
3. TORQUE CONVERTER TYPE DRIVE UNlT

[2143081
TORQUE CONVERTER
OIL COOLER

TORQUE INLINE FILTER

CONVERTER INLET
RELIEF VALVE
0.49-0.69 MPa
{5-7kgf/crnz}

LENOID VALVE
REGULATOR VALVE
0.79-1.67 MPa CLUTCHPACK

INCHING VALVE
CHARGING PUMP

Fig. 3.12 Transmission Hydraulic System Schematic Diagram (Neutral: for 2.0- to 3-ton trucks)

@ In fonvard gear
for 1.0- to 1.75-ton trucks
When the solenoid valve is switched over to the fonvard position, the oil flows both into the forward
i
clutch pack and into the accumulator. As long as the oil flows into the accumulator, oil pressure increase
is gradual and the clutch disks are locked up loosely. Once the accumulator is filled with oil, the clutch oil
pressure rapidly increases to the specified value, thus locking up the clutch disks completely.
i 3. TORQUE CONVERTER TYPE DRIVE UNlT

I 1
ACCUMULATOR (REV)
I

ACCUMULATOR (FWD)
I I/ SOLENOID VALVE

from REGULATOR VALVE -+

INCHING VALVE II
1%
Fig. 3.13 Transmission Hydraulic System Schematic Diagram (Forward travel: for 1.O- to 1.75-ton trucks)

for 2.0- to 3-ton trucks

When the solenoid valve is switched over the forward position, the oil flows into the forward clutch
pack to reduce the oil pressure at the area H , thus moving the modulation valve spool to the left. The oil
thus flows into the accumulator to alleviate the increase in clutch oil pressure. Once the accumulator is
filled with oil, the oil pressure at the area rapidly increases to move the modulation valve spool to the
left. This drains off the oil from the accumulator to lock up the clutch disks completely.

i~ from ACCUMULATOR
4 I I l I
I/ I I I SOLENOID VALVE
C/ /F R
When clutch pack is locked up

C T, - , MODULATIONVALVE

II II ACCUMULATOR
INCHING VALVE

from
REGULATOR VALVE - L.LJ t

Fig. 3.14 Transmission Hydraulic System Schematic Diagram (Forward travel: for 2.0- to 3-ton trucks)
3. TORQUE CONVERTER TYPE DRIVE UNlT

@ Inching
When the inching spool moves, the oil to the clutch packs is drained through the inching spool piston to
reduce the oil pressure.

to TRANSMISSION CASE

from REGULATOR VALV

drops

Fig. 3.15 Transmission Hydraulic System Schematic Diagram (Inching)

 3. TORQUE CONVERTER TYPE DRIVE UNlT
i
(4) Regulator valve (37B-25, LCE-34G-25)
The regulator valve is incorporated into the right side of the transmission case, together with the torque
converter inlet relief valve. Both valves control the clutch oil pressure and the torque converter oil
pressure, respectively.
An accumulator is incorporated in the tiansmission case side of the torque converter fitting section.

[110196]

I REGULATOR PISTON
SPRING

\
CONVERTER INLET
RELIEF VALVE

Fig. 3.16
3. TORQUE CONVERTER TYPE DRIVE UNlT

Fig. 3.17 Oil Pressure Check Ports (foi 1.0- to 1.75-ton trucks)
3. TORQUE CONVERTER TYPE DRIVE UNlT

NOTE
 4. DRIVE AXLE

4. DRIVE AXLE
Truck Model

/ Type
Wheel
Full-floating type

Size 2-6.50- 10- lOPR(1)

Tread Pattern J-LUG
Rim
Type Split type Disk type
Size 5.00F X 1ODT 7.00T X 15
[1.8 t: 5.00F X lOTB]
Tire inflation 0.69 MPa (7.0 kgf/cm2}
pressure [99.6 psi]

4.1 GENERAL DESCRlPTlON

The drive axle has a construction as shown in Figure 4.1 thru 4.3 and is mounted on the front area of the
frame.
i It has a wheel hub and a wheel brake at its each spindle end and an axle shaft running through its Center.
The wheel hub is provided with a brake drum, which is installed on the spindle through two tapered roller
bearings. The two tapered roller bearings have oil seals to prevent the grease inside from oozing out and
water from entering the brake unit.
4. DRIVE AXLE

I
Fig. 4.1 Drive Axle (for 1.0 - 1.75 ton trucks)
I . HOUSING 6. TAPERED ROLLER BEARING 1 1 . RIM
2. AXLE SHAFT 7. HUB 12. ADJUSTMENT NUT
3. WHEEL BRAKE 8. TAPERED ROLLER BEARING 13. LOCK NUT
4. BRAKE DRUM 9. OIL SEAL
5. OTL SEAL 10. TIRE
Torque all the bolts rnarked with ' to 205.9 - 225.6
N-rn (2100 - 2300 kgf-cm) [151.90 - 166.36-ft-lbs].

1 . HOUSING 6. TAPERED ROLLER BEARING 1 1 . RIM

2. AXLE SHAFT 7. HUB 12. ADJUSTMENT NUT
3. WHEEL BRAKE 8. TAPERED ROLLER BEARING 13. LOCK NUT
4. BRAKE DRUM 9. OIL SEAL
5. OIL SEAL 10. TIRE
 4. DRIVE AXLE

Wheel hub installation procedure

(1) Fill the space in the wheel hub with 100 cc
grease and install the spindle.
(2) Tighten the adjustment nut to about 9.8 N-m { 1 kgf-
m} [7.2 ft-lbs] torque and back it off 112 of a turn.
(3) Set a spring balance on the stud bolt and adjust the
hub starting torque for the specified value, gradually
tightening the adjustment nut.
Starting force: 49 - 147.1 N ( 5 - 15 kgf}
ADJUSTMENT NUT
[36 - 109 lbs] LOCK WACHER

Fig. 4.4 Filling Grease

,
4) Install the lock washer and lock nut and secure the
lock nut by bending the tang on the lock washer.

Fig. 4.5 Measuring Starting Torque

(5) Assembling wheels

Put a tube and flap in a tire and assemble the rims, observing the following conditions:
Notes: 1. The air valve should be pointed outward, being matched with the rim notch.
2. The rim assernling bolts should be installed with their heads pointing the outside of the truck.

-- @--
I/
I

Configuration of rim assembling bolt

1. TIRE 1. RIM (INSIDE)

2. TUBE 5. RIM (OUTSIDE)
3. FLAP 6. ASSEMBLING BOLT

Fig. 4.6 Wheel Assernbly

- 79 -
4. DRIVE AXLE

NOTE
 5. BRAKE SYSTEM

5. BRAKE SYSTEM

Front two-wheel braking internal expansion, hydraulic type

1
/ Pedal ratio 6.3
Master cylinder bore 19.05 mm [0.750 in]
Wheel brake
Type Duo-servo type
Wheel cylinder bore 22.22 mm [0.875 in] 28.58 mrn 11.125 in] t

Brake drum inner dia. 254 mm [10 in] 310 mm [12.2 in] 314 mm [12.36 in]
Lining size 279 mm X 48.5 mm X 4.87 mm 324mmx60mmx7mm 348 mm X 76 mm X 7.67 mm
[10.98 in X 19.1 in X 0.19 in] [12.76 in X 2.36 in X 0.26 in] [13.70 in X 3.0 in X 0.30 in]
Surface area 4 X 13530 mm2 [2.097 in2] 4 X 19440 mm' [3.013 in2] 4 X 26400 mm2 [4.092in2]
Parking brake
TYpe Front two-wheel braking internal expansion, mechanical type

5.1 GENERAL DESCRlPTlON

The brake system is a front two-wheel braking internal expansion, hydraulic type consisting of a brake
pedal, master cylinder, check valve and wheel brakes.

5.1.1 BRAKE PEDAL

The brake pedal unit has a structure as shown in Fig. 5.1 and is installed through a bracket on the front
guarde.
Pedal movement pushes the the rnaster cylinder piston through the push rod, converting brake pedal
effort to oil pressure.
5. BRAKE SYSTEM

CHECK

DRIVE UNlT
' INCHING VALVE

Note: See Fig. 2.20 for trucks with clutch.

Fig. 5.1 Brake Pedal (for 1.0- to 1.75-ton trucks with torque converter) 112
 5. BRAKE SYSTEM

BRAKE MASTER CYLINDER

RESERVE TANK, BRAKE LAMP SWITCH \ I

View looking from

Note: See Fig. 2.2 1 for trucks with clutch.

Fig. 5.2 Brake Pedal (for 1.0- to 1.75-ton trucks with torque converter) 212
5. BRAKE SYSTEM

Note: See Fig. 2.22 for trucks with clutch.

Fig. 5.3 Brake Pedal (for 2.0- to 3.0-ton tmcks with torque converter) 112
 5. BRAKE SYSTEM
i

BRAKE LAMP SWlTCH BRAKE MASTER CYLINDER

RESERVE TANK
\ \

View lookina from TAI

Note: See Fig. 2.23 for trucks with clutch.

Fig. 5.4 Brake Pedal (for 2.0- to 3.0-ton trucks with torque converter) 212
5. BRAKE SYSTEM
1
5.1.2 MASTER CYLINDER
The master cylinder has a structure as shown in Fig. 5.5 and is fitted to the bracket on the brake pedal.
Built in the master cylinder are a spring and piston, which are kept in position by a stop ring.
The piston has a primary cup and a secondary cup and is slid in the cylinder by operating the brake
pedal.

[239A5-401011
BLEEDER PLUG

from RESERVE TANK %

PRIMARY CUP
SECONDARY CUP

Fig. 5.5 Masier Cylinder

The brake fluid in the wheel cylinders and brake lines has
to WHEEL BRAKE
a residual pressure proportioned to the Set pressure of the
check valve, which makes each wheel cylinder piston cup t
securely seated t o prevent oil leakage and eliminates
possibility of vapor lock. GASKET

VALVE

VALVE SEAT

SPRING

t
from MASTER CYLlNDER

Fig. 5.6 Check Valve

 5. BRAKE SYSTEM
i

5.1.3 WHEEL BRAKE

The wheel brake is a duo-servo type, and is mounted
on each of the both ends of the drive axle.
The wheel brake consists of two pairs of brake shoes, a
wheel cylinder and an adjuster. The brake shoe, one end
of it being connected to the anchor pin and the other end
to the adjuster, is forced against the backing plate with a
hold spring and pin.
In addition, the wheel brake is provided with a parking
brake mechanism and an automatic clearance adjuster.
ADJUSTER

I I
Fig. 5.7 Braking Operation in Forward
, Travel
(1) Wheel brake operation
Wheel brake operation in forward travel is as shown
by Fig. 5.7. Operation of the wheel cylinder presses the
primasy and secondary shoes with an equal force to the
drum, and then the lining turns together with the brake
drum. When the secondasy shoe top Comes in contact
with the anchor pin, the lining-to-brake drum friction
force is produced. Besides, the primary shoe presses
against the secondary shoe with force greater than
offered by operation of the wheel cylinder, thus
providing large braking force.
In backward travel, the braking force works in the
reverse direction in the case of fonvard travel. (See Fig. Fig. 5.8 Braking Operation in Backward
5.8) Travel

(2) Parking brake

The parking brake unit is built in the wheel brake unit
SECONDARY SHOE
and consists of a lever and a strut. The lever is pinned to
the primary shoe and movement of the lever is
LEVER
transrnitted to the secondaiy shoe through the stirit.

PRIMARY SHOE

Fig. 5.9 Parking Brake Unit

5. BRAKE SYSTEM

(3) Autornatic clearance adjuster

The automatic clearance adjuster keeps a proper lining-to-brake drum clearance automatically. The
structures of the adjuster are shown in Figs. 5.10 and 5.11. This adjuster actuates only when the truck is
braked in reverse travel. These are two types of adjuster according to the truck capacity (1.0- to 1.75 ton
and 2.0- to 2.5-ton trucks and 3.0-ton trucks) and they have different structures and modes of operation.

Fig. 5.10 Trucks with Capacities from Fig. 5.11 Trucks with Capacities from
2.0 to 2.5 ton 1.0 to 1.75 ton and 3.0 ton

Automatic clearance adjuster operation

@ Adjuster of tmcks with capacities from 2.0 to 2.5 ton
When the brake is applied in reverse travel, the
secondary shoe and the brake &um rotate together
slightly. Therefore, the lever turns to the right
around the section shown in Fig. 5.10, causing
the section rnto rise.
When the brake is released, the lever turns to the
left around the section by spring force, causing
the section to move down. i

As the lining-to-brake drum clearance becomes

larger, the vertical movement of the section
grows. When the clearance becomes more than
0.4 mm [0.016 in], the section is engaged with
the next tooth of the adjuster. When the section
engaged with the tooth moves down, the adjuster
length expands to extend the shoe.
The clearance is adjusted within the range from
0.4 to 0.45 mm [0.016 - 0.018 in] by the operation Expands in this direction

above.

Fig. 5.12 Automatic Clearance Adjuster

(2.0 to 2.5 ton)
 5. BRAKE SYSTEM
i;
Adjuster of trucks with capadities from 1.0 to 1.75
ton and 3.0 ton
When the brake is applied in reverse travel, the
secondary shoe and the brake drum rotate together
slightly. Therefore, the lever turns to the right
around the section H shown in Fig. 5.11. Then the
lever section turns the adjuster. As the brake
force is further applied, compression force applied
on the adjuster thread becomes larger so that the
lever force cannot turn the adjuster.
When the brake is released, the brake shoe returns
to the original position. Then the lever turns to the
left around the section , causing the section to
i , move down. For this procedure, the section rn
which the position of the adjuster tooth is aligned
with is engaged with the next tooth, adjusting the
clearance within the range from 0.25 to 0.4 mm
[0.010 - 0.016 in]. Fig. 5.13 Automatie Clearance Adjuster
(1.0 to 1.75 ton and 3.0 ton)

5.1.4 PARKING BRAKE LEVER

The parking brake lever is a toggle type which allows adjustment of braking force with the adjuster at
the tip of the lever. The brake lever is installed as shown in Fig. 5.14.

RELEASE BUTTON

View looking from

M Adjusting parking brake lever operating force

(1) Place the parking brake lever in the release position.
(2) Adjust the lever so that it has the operating position as
shown in the sketch when the point @l of the lever is pulled
with a force of 29.4 to 49.0 N {3 - 5 kgf] [6.6 - 11.1 lbfl.
Turn the point clockwise to make the pulling force
stronger and counterclockwise to make it weaker.

Fig. 5.14 Parking Brake Lever

5. BRAKE SYSTEM

" .L. Sectional view -E

Sectional view -H Sectional view of wheel cylinder

1. BRAKE LEVER 8. HOLD PIN 15. BOOT

2. SECONDARY SHOE 9. PRIMARY SHOE 16. CYLINDER
3. E-RETAINER 10. SPRING 17. PISTON
4. WHEEL CYLINDER 11. ADJUSTER LEVER 18. SPRING
5. RETURN SPRING 12. ADJUSTER 19. CUP
6. STRUT 13. SPRING
7. SPRING 14. PUSH ROD

Fig. 5.15 Wheel Brake (for 1.0- to 1.75-ton trucks)

 5. BRAKE SYSTEM

V.
.. '
Sectional view - rp;j

1. PUSH ROD 8. ROD 15. BRAKE LEVER

2. PISTON 9. LEVER 16. STRUT
3. CUP 10. SECONDARY SHOE 17. WHEEL CYLINDER
4. SPRING 11. BACKING PLATE 18. PIN
5. CYLINDER 12. ADJUSTER 19. SPRING
6. SPRING 13. SPRING 20. PRIMARY SHOE
7. SPRING 14. CABLE

Fig. 5.16 Wheel Brake (for 2.0- to 2.5-ton trucks)

- 91 -
5. BRAKE SYSTEM

Sectional view -

Sectional

Sectional view -

Sectional view - Sectional view of wheel cylinder

1. WHEEL CYLINDER 8. SPRING 15. PUSH ROD

2. SPRING 9. LEVER 16. PISTON
3. CABLE 10. ADJUSTER 17. CUP
4. SECONDARY SHOE 11. SPRING 18. SPRING
5. BACKWG PLATE 12. BRAKE LEVER 19. CYLINDER
6. STRUT 13. PRLMARY SHOE
7. PIN 14. SPRING

Fig. 5.17 Wheel Brake (for 3.0-ton tmcks)

 5. BRAKE SYSTEM

5.2 MAINTENANCE
This paragraph Covers the procedures for disassembling, reassembling and adjusting the wheel brake
and the procedures for adjusting the brake pedal, using the wheel brake of the 1.0- to 1.75-ton and 3.0-ton
trucks. The maintenance procedures for the 2.0- to 2.5-ton trucks are almost the Same except that the
wheel brake adjuster design is different.

5.2.1 WHEEL BRAKE DISASSEMBLY

(1) Remove the secondary shoe hold-down pin, adjuster
lever, adjuster and spring Fig. 5.18.

Fig. 5.18

(2) Remove the shoe return spring.

Fig. 5.19

(3) Remove the primary shoe hold-down spring.

Fig. 5.20
5. BRAKE SYSTEM

(4) Remove the primary and secondary shoes along with

the adjuster and adjuster spring.

Fig. 5.21

(5) Remove the brake pipe from the wheel cylinder.

Remove the wheel cylinder mounting bolts and take
the wheel cylinder off the backing plate.

Fig. 5.22

(6) Remove the E retainer securing the parking brake

cable to the backing plate.
Remove the backing plate fitting bolts and detach
the backing plate from the axle.

Fig. 5.23

(7) Remove the boot, and push the piston into the
cylinder from one side while removing the parts at
the other side. Then push out the remaining parts
from opposite side.

Fig. 5.24
 5. BRAKE SYSTEM

Inspect all the parts for wear and damage. Repair or replace any defective parts with new ones.

(1) Inspect the wheel cylinder's inner surface and

piston's outer surface for sign of rust.
Measure the clearance between the piston and
cylinder.
Specified value: 0.03-0.10 mm [0.0012-0.0039 in]
Limit: 0.15 mm C0.006 in]

Fig. 5.25

0
(2) Visually check the piston cup for damage or defomation, and replace it, if defective, with a new one.

(3) Measure the free length of the wheel cylinder spring. If unsatisfactory, replace.

(4) Measure the brake lining thickness, and if worn

beyond the limit, replace it with a new one.

Unit: rnm [in]

1.0- 1.75 t 2.0-2.5t 3.0 t

-
Standard size 4.87 7.67 t
[O. 1921 [0.302]

Liniit 2.5 5.0

[0.098] [O. 1971
t
Fig. 5.26

Visually check the brake drum inner surface for

scratches, nicks or uneven wear, and if found, repair
by grinding.
If the surface is badly scratched or worn, replace.
Unit: mm [in]

1.0 - 1.75 t 2.0 - 2.5 t 3.0 t

Standard size 254 3 10 3 14

[10.0] [12.205] [12.362]
Fig. 5.27
Limit 256 312 316
[10.079] [12.283] C12.4411
5. BRAKE SYSTEM

5.2.3 WHEEL BRAKE REASSEMBLY

(1) Apply brake fluid to the wheel cylinder cup and piston, and reinstall the spring, piston cup, piston and
boot in that order.
(2) Install the wheel cylinder on the backing plate.
Tightening torque: 14.7 - 19.6 N-m { 150 - 200 kgf-cm} [I30 - 174 in-lbs] for 2.0 to 2.5-ton trucks
Tightening torque: 17.7 - 26.5 N-m { 180 - 270 kgf-cm} [I56 - 234 in-lbs] for 1.0 to 1.75-ton and 3.0-
ton trucks
(3) Install the backing plate to the drive axle.
Tightening torque: 205.9 - 225.6 N-m (2100 - 2300 kgf-cm} [151.9 - 166.4 ft-lbs]
(4) Apply heat-resisting grease on the points indicated in Fig. 5.28, using caution so as not to allow the
lining to be contaminated with grease.

(a) Backing plate shoe ledge surface (b)

(b) Anchor pin

(C) Cable guide surface on which adjuster
cable is to contact
(d) Parking brake lever pin
(e) Adjuster thread and its rotating part

Fig. 5.28

(5) Install the parking brake cable with E retainer.

(6) Install the shoes with hold-down spring.

Fig. 5.29

(7) Put the anti-rattle spring in the strut and install them on the shoe.
 5. BRAKE SYSTEM

(8) Install the shoe guide pin on the anchor pin. Install
the shoe return spring. For this procedure, stai-t with
the primary shoe and then proceed with the
secondary one.

Fig. 5.30

/
(9) Install the spring, adjuster, adjuster spring and
e adjuster lever, observing the following points:
The left-side brake unit has a left threaded adjuster
and the right-side brake unit has a right threaded
one.
@ The adjuster teeth do not contact the spring.
@ The adjuster shoe retui-n spring is installed with the
longer hook going to the adjuster lever.
@ After reassembly, make Sure the adjuster lever end is
in contact with the adjuster teeth. Fig. 5.31

(10) Install the brake pipe on the wheel cylinder.

(1 1) Measure the brake drum inner diarneter and the shoe

outer diarneter. Adjust the adjuster so that the brake
shoe outer diameter is (drum inner diameter -
I '
1.0 rnm or [0.04 in]).

Fig. 5.32
5. BRAKE SYSTEM
i
5.2.4 OPERATION TEST OF AUTOMATIC CLEARANCE ADJUSTER
(1) Make the brake shoe diameter nearly to the specified setting size, and pul1 the adjuster lever with
your finger to turn the adjuster gear. When removing off your finger, the adjuster lever returns to the
original position.
Note: The adjuster gear may turn back slightly along with the adjuster lever when removing your finger,
but the adjuster will operate normally when it is put back on the truck.
(2) If the adjuster fails to do normal operation when pushing the adjuster lever, take the following steps.
(a) Make sure the adjuster lever, adjuster, adjuster spring, adjuster cable and shoe return spring are
securely installed.
(b) Check the shoe return spring and adjuster spring for deterioration. Also check whether the adjuster is
rotating properly, its teeth are free from damage and proper in contact with the adjuster lever.
Replace any defective parts with new ones.

ADJUSTER ' \ ADJUSTER LEVER

Fig. 5.33
( 5. BRAKE SYSTEM

5.2.5 BRAKE PEDAL ADJUSTMENT

(1) Shorten the master cylinder push rod properly.
(2) Adjust the pedal height with the stopper bolt as shown in Fig. 5.34.
(3) Keeping the pedal pressed by the play, extend the push rod so that its end contact the master cylinder
piston.
(4) Tighten the push rod lock nut.

Fig. 5.34

Brake switch adjustment

(1) After making Sure that the brake pedal height is as indicated in Fig. 5.34, loosen the brake switch lock
nut.
(2) Remove the brake switch lead wire from the connector.
(3) Turn the switch so that the size at is 1 rnrn [0.04 in].
(4) Make Sure the brake lamps turn on when the brake pedal is pressed by the play.
5. BRAKE SYSTEM

5.2.6 WHEEL BRAKE TROUBLE SHOOTING

Problem Problem cause Remedy

1. Fluid leaks from brake system Repair.
Check and adjust
2. Maladjustment of brake shoe clearance
adjuster.
3. Overheated brake Check for dragging.
Poor braking
4. Poor contact between brake drum and lining Repair or replace.
5. Foreign matter adhered to lining Repair or replace.
6. Foreign matter mixed in brake fluid Check brake fluid.
7. Maladjustment of brake pedal Adjust.
1. Hardened lining surface or foreign matter adhered thereto Repair or replace.
2. Deformed backing plate Repair or replace.
Noisy brake 3. Deformed or improperly installed shoe Repair or replace.
4. Uneven wear of lining Replace.
5. Defective wheel bearing Replace.
1. Contaminated lining Repair or replace.
Check and adjust
2. Maladjustment of brake shoe clearance
adjuster.
Uneven braking 3. ~ a l f u n c t i o n i nwheel
~ cylinder Repair or replace.
4. Defective shoe return spring Replace.
5. Run out of drum Repair or replace.
6. Irnproper inflation pressure of tire Adjust
1. Brake fluid leaks from system Repair.
Check and adjust
2. Maladjustment of brake shoe clearance
Soft or spongy adjuster.
brake Bleed air out of
3. Air mixed in brake system
system.
4. Maladjustment of brake pedal Adjust.
 6. STEERING SYSTEM (ORBITROL TYPE)
i
6. STEERING SYSTEM (ORBITROL TYPE)

Steering axle:
Type: Center-pin supported, Elliot type with box-shaped
Cross section of weld construction
King pin spacing: 780 mm [30.7 in] I 810 mm [31.9 in]
King pin angle: 0"
Toe-in: 0 mm
Camber: 1"
Caster: 0"
Steering angle:
Inner wheel:
Outer wheel:
Orbitrol:
Type: Open-centered, non-load reaction type
Discharge: 96 C& [5.85 in3/rev.]
Power cylinder:
Type: Double-acting piston type
Cylinder bore: 7 1 min [2.8 in]
Piston rod diameter: 40 mm [1.6 in]
Stroke: 168 rnm [6.6 in] 173 mm [6.8 in]
Valve unit: (Include
control valve)
Flow rate: 11 literlmin [2.91 gallmiil] 16 literlmin [4.23 gaVmiil]
Pressure setting: 6.9 MPa (70 kgf/cm2] [995 psi] 8.8 MPa {90kgf/cm2) [I280 psi]

Note: For the semi-integral type steering system, refer to Chapter 9.

6.1 GENERAL DESCRIPTION

The steering system consists primarily of a steering wheel, orbitrol, flow regulator valve, and power
cylinder. When the steering wheel is turned, the rotation is transnitted to the orbitrol. The oil passages in
the orbitrol are changed over to direct the hydraulic pressure from the flow regulator valve to the power
cylinder which extends or contracts depending on the hydraulic pressure, thereby steering the truck.
6. STEERING SYSTEM (ORBITROL TYPE)

6.1.1 STEERING AXLE

The steering axle is of steel-welded construction with a box shaped Cross section, incorporating a power
cylinder inside it. See Figure 6.1 and 6.2. The power cylinder is housed in the axle to protect it from
being damaged by obstacles on the road surface. The axle is installed onto the truck frame thsough a
center pin with bushing and cap, and it cradles around this center pin.

[106608]

0
0

8
0
@
@

1. OIL SEAL 7. TAPERED ROLLER BEARING 13. KNUCKLE

2. BEARING 8. OIL SEAL 14. AXLE
3. THRUST BEARING 9. LOCKPIN 15. POWER CYLINDER
4. HUB 10. BEARING 16. PIN
5. NUT 11. OILSEAL 17. JOINT
6. TAPERED ROLLER BEARING 12. KING PIN 18. PIN

Fig. 6.1 Steering Axle (for 1.0 - 1.75 ton tmcks)

- 102 -
 6. STEERlNG SYSTEM (ORBITROL TYPE)

I
I' 1. OIL SEAL 7. TAPERED ROLLER BEARING 13. KNUCKLE
2. BEARING 8. O L SEAL 14. AXLE
3. THRUST BEARING 9. LOCKPIN 15. POWER CYLINDER
4. HUB 10. BEARING 16. PIN
5. NUT 11. OIL SEAL 17. JOINT
6. TAPERED ROLLER BEARING 12. KING PIN 18. PIN

I
Fig. 6.2 Steering Axle (for 2.0 - 3.0 ton trucks)
6. STEERING SYSTEM (ORBITROL TYPE)

6.1.2 STEERING WHEEL ASSEMBLY

The steering wheel assembly is arranged as shown in Figures 6.3. The orbitrol is located at the bottom
of the assembly. At the Center of the wheel is the horn button.
The steering shaft is connected through the universal joint to the drive shaft of the orbitrol so that the
steering wheel can be moved to a certain extent back and forth to suit the driver's physique.

[539A2-400011

STEERING WHEEL

TlLT LOCK LEVER

UNIVERSAL JOINT

Fig. 6.3 Steering Wheel Assembly

 6. STEERING SYSTEM (ORBITROL TYPE)

6.1.3 ORBITROL
The orbitrol sends pressure oil from the pump selectively to the power cylinder. It consists primaiily of
a control valve and a metering device. Figure 6.4 shows the cross sectional views of the orbitrol.
The control valve used in the orbitrol is not an ordinary spool valve whose spool moves in the axial
direction, but a rotatry valve which consists of a sleeve and a spool that rotate together forming different
oil passages through the combination of their oil holes. The valve housing is provided with four ports
which lead to the pump, tank, right and left chambers of the cylinder. Between the inlet port and return
Port is a check valve.
The metering device consists of an internally toothed stator and an externally toothed rotor. During
normal operation, it operates as an oil motoc In an emergency, it can be used as hand pump. The rotor is
mechanically linked with the sleeve through the drive shaft so that feedback operation is possible.
The sleeve is interlocked with the motor's rotor through the cross pin and drive shaft while the spool is
splined to the steering shaft.
C
CHECK VALVE
D1 I I E \
OUT
t f SLEMSPO0L
MOTOR

THRUST

I \
DRIVE SHAFT I
6. STEERING SYSTEM (ORBITROL TYPE)

(1) Operation of orbitrol

(a) In "Neutral'
While the steering wheel is in straight position, the oil from
the pump flows through oil passage to oil groove @. The
sleeve has 24 oil holes @ which are now in line with the holes
@ in the spool so that the oil that flowed into groove @ passes
through oil holes @ and @ to space @ between the spool and
drive shaft. Then the oil flows through spool groove @ and
sleeve groove back to the oil tank.
Since cylinder ports @ J and @ are respectively Open to oil
holes @ and @in the sleeve but not to groove @ nor @ in the
spool, the oil in the cylinder does not go any where.
Oil passage @ that leads to the hydraulic motor is Open to
oil hole @$in the sleeve which is used as the inlet and outlet
for the hydraulic motor, but not to grooves @l nor @ in the
spool and thus the oil remain unmoved.

Fig. 6.6

(b) When steering wheel is turned counterclockwise

As the steering wheel is turned counterclockwise, the
grooves in the spool shift to the left in relation with the holes
and grooves in the sleeve so that holes @ in the spool get out
of line with holes @in the sleeve. The oil that has flowed into
groove @ thus far begins to flow into hole @ I sleeve,
in the
passing through grooves @ and @l in the spool, hole @ in the
sleeve, and oil passage @ in the housing, to the hydraulic
motor.
The hydraulic motor thus rotates in the counterclockwise
direction and the oil discharged from the hydraulic motor
flows through oil hole @ in the sleeve, groove @ in the spool,
and oil hole @ in the sleeve to the cylinder Port L and thus
actuates the steering cylinder.

Fig. 6.7
 6. STEERING SYSTEM (ORBITROL TYPE)

The returning oil from the power cylinder flows, passing through the cylinder port R, groove in the
valve housing, oil hole @ in the sleeve, groove @ in the spool, oil hole @ in the sleeve, and groove @ in
the valve housing, back to the oil tank.

(C) When steering wheel is tuimed clockwise

t
As the steering wheel is turned clockwise, the grooves
in the spool shaft to the right in relation to the oil holes
and grooves in the sleeve so that oil holes @in the spool
get out of line with holes @ in the sleeve. The oil that has
flowed into groove thus far begins to flow into oil hole
@ in the sleeve and then flows through grooves @ and @
in the spool, oil hole @ in the sleeve, and oil Passage @in
the valve housing to the hydraulic motor. The hydraulic
iotor thus rotates in the clockwise direction and the oil
discharged from the hydraulic motor flows through oil
hole @ in the sleeve, groove @ in the spool, and oil hole
Q in the sleeve to the cylinder Port R in the housing and
thus actuates the power cylinder.
The returning oil from the power cylinder flows, passing
through the cylinder port L, groove @ in the housing, oil
hole @! in the sleeve, groove @ in the spool, oil hole @
in the sleeve and groove @ in the housing back to the oil
tank.

4 t
OUT M

Fig. 6.8

(2) Relationship between rotating speed and operating force of steering wheel
In principle, the force required to operate the orbitrol is only the force to change over the valve, i.e. the
force of compressing the centering the centering spring or 2.9 N-m (0.3 kgf-m} [2.17 ft-lbs]. In other
words, since there are no mechanical connections between the steering wheel and the tires and only the
spring compressing force is required, constant steering force is kept even at increased rotational speed.
The discharge of oil supplied from the rotor of the orbitrol to the cylinder is 96 cm"5.86 in')/revolution.

(3) Neutral feedback of orbitrol

The neutral feedback of the orbitrol is performed by changing-over in oil passages of the valve, due to
the reactions force of centering spring. (When the steering wheel is turned and then released with the
6. STEERING SYSTEM (ORBITROL TYPE)
i

engine at rest, the steering wheel returns to the initial position.) Unless the neutral feedback is completely
performed, the steering wheel may be turned, even though the Operator does not turn the steering wheel.

(4) Steering with defective pump

When the pump fails to supply hydraulic oil the orbitrol serves as an emergency hand steering device.
When the steering wheel is turned, the spool rotates. When turned by about 8", the spool contacts the
Cross pin, which rotates the drive shaft, which in turn rotates the rotates the rotor. Thus the metering
device serves as a hand pump to supply oil to the cylinder. In this case the check valve provided between
the return port and the suction port Opens, so that oil flows from the cylinder to the suction side, thereby
effecting an emergency steering.

6.1.4 POWER CYLINDER

The power cylinder is installed in the steering axle and is operated by oil from the orbitrol. The cylinder
body is secured to the axle, with both rod ends connected to the knuckle with joints.
The cylinder cap has a bushing, oil seal, and dust seal, being secured to the cylinder with a lock washer.

[349796]

1. BUSHING 6. "On-RING
2. PISTON ROD 7. BUSHING
3. PACKING 8. PACKING
4. CYLINDER 9. DUST SEAL
5. CYLINDER CAP 10. BUSHING

Fig. 6.9 Power Cylinder (for 1.0 - 1.75 ton trucks)

i
6. STEERING SYSTEM (ORBITROL TYPE)

6.2 PREVENTIVE MAINTENANCE

6.2.1 DISASSEMBLY AND MAINTENANCE OF ORBITROL
Prior to attempting to disassemble the orbitsol, clean the exterior of the unit and select a clean wosking
place.
(1) Hold the flange of the orbitrol in a vise.

Fig. 6.10

(2) Remove the fitting bolts from the end cap and
remove the end cap.

END CAP
"0"-RING

Fig. 6.11

(3) Remove the rotor Set from the housing. Use

caution so as not to lose the stas in the rotor Set.
Remove the space and "0"-ring.

Fig. 6.12
6. STEERING SYSTEM (ORBITROL TYPE)

(4) Remove the spacer plate and drive from the

housing.

"0"-RING DRIVE

Fig. 6.13

(5) Remove the housing from the vise and put it on

clean cloth with the machined surfaced down.
Remove the retaining ring from the housing by
first prying its end off with a small screwdriver.

Fig. 6.14

(6) Turn the spool and sleeve so that the pin is parallel
with the Port surface. Then push the spool and
sleeve in the housing, removing the seal gland
bushing from the housing.
SEAL GLAND
BUSHING

Fig. 6.15

( 7 ) Remove X-ring seal and dust seal from the seal

gland bushing.

DUST SEAL:'

Fig. 6.16

- 110-
 / 6. STEERING SYSTEM (ORBITROL TYPE)
i

(8) Remove the thrust bearing.

BEARING RACE

Fig. 6.17

(9) Remove the spool and sleeve from the housing in

the direction indicated by arrow in Figure 6.18.
Remove the pin from the spool and sleeve
assembly.
f

Fig. 6.18

(10) Remove the spool a part way from the sleeve and
remove the centering spring from the spool.

Fig. 6.19

(11) Remove the Set screw from the housing and

remove the check seat, ball and check ball
retainei.

1.0. 7.6 mm [0.299 in]

Fig. 6.20
6. STEERING SYSTEM (ORBITROL TYPE)

6.2.2 REASSEMBLY OF ORBITROL

Inspect the contact surfaces of all parts for Scores, scratches or burrs which would cause oil leak if
neglected, and if unsatisfactory, replace with new ones. Clean all metallic parts and dry with compressed
air. For drying purpose, do not use cloth or paper; otherwise lint or paper dust sticks on the surface and
would cause trouble in the hydraulic equipment. Replace will "0"-rings and seals with new ones.

(1) Using a pair of tweezers, install the check ball

@- SET SCREW
retainer and ball in the housing. Install "0"-ring
on the check seat. Install the check seat on the
housing.

Fig. 6.21

(2) After applying LOCTITE #242 on the thread part, tighten the set screw with an Allen wrench.

(3) Align the'grooves in the spool with those in the

sleeve and put the spool into the sleeve, turning
the spool slowly.

Fig. 6.22

(4) Align the spring groove in the spool with that in

the sleeve and put them on a plane plate. Install
the spring.

Fig. 6.23

(5) Insert the pin through the spool and sleeve holes.

Fig. 6.24

- 112 -
 6. STEERlNG SYSTEM (ORBITROL TYPE)

Install the spool and sleeve assembly in the

housing from the rear side. Use caution not to
allow the sleeve assembly end face to go farther
inside from the housing shoulder surface.

Fig. 6.25

Install the thrust bearing and "0"-ring on the

housing. THRUST NEEDLE

"0"-RING

Fig. 6.26

Install the dust seal and X-ring seal on the seal

gland bushing .

SEAL GLWD -
0- RETAiNlNG
RING

BUSHING
(W. SEAL)

Fig. 6.27

Insert the seal gland bushing into the spool,

turning the latter slowly. Drive the bushing in
place with a plastic h m e r . Install the retaining
RETAiNlNG RING
ring on the housing.

Fig. 6.28
6. STEERING SYSTEM (ORBITROL TYPE)

(10) Hold the housing in a vise. Make sure that the end
faces of the spool and sleeve are sunk frorn the
housing surface.

Fig. 6.29

(11) Install the "0"-ring on the housing. Clean the

surfaces of the housing and spacer plate, then put
the spacer plate on the housing.

Fig. 6.30

(12) Turn the spool and sleeve assembly so that the port
'.&+-/
PORT SURFACE
surface is parallel to the pin and install the drive.
Draw a line on the drive's spline end face, parallel
to the pin.

PIN

Fig. 6.31

(13) Install the "0"-ring on the rotor Set.

Fig. 6.32
 i
6. STEERING SYSTEM (ORBITROL TYPE)

(14) Putting the "0"-ring side of the rotor Set toward ROOT OF ROTOR SET STAR
the spacer plate side, place the rotor on the
housing, with the star's root aligned with the drive
(see Figure 6.33). Then, securing the engagenlent
of the drive and the stas, align the bolt holes in the
rotor Set with those in the housing.

PORT SURFACE

Fig. 6.33

(15) Install the spacer in the rotor Set and install the
"0"-ring on the end cap.

Fig. 6.34

(16) Put the end cap on the rotor Set and align the bolt
holes with each other. Apply oil on the thread
parts of the bolts and tighten them to the torque of
14.7 N-m (1.5 kgf-m) [10.8 ft-lbs]. Then tighten
(
them to 25.5 - 28.4 N-m {2.6 to 2.9 kgf-m} [18.8 -
21.0 ft-lbs] torque in the order indicated in Figure
6.35. Fig. 6.35
6. STEERING SYSTEM (ORBITROL TYPE)

NOTE
i 7. HYDRAULIC SYSTEM

7 . HYDRAULIC SYSTEM

Main pump
Type Gear type
Model name SGPlA27 SGPlA27
' Discharge 27.8 cm.' 27.8 c d
[1.9 inylrev. [1.6 in3]/rev.
II Control valve
Type 2-spool sliding type, with relief valve, flow divider and tilt-lock valve
Model name KVSF-65VPF

I Pressure setting
Main
Steering
17.7 MPa (180 kgf/cm2) [2560 psi]
6.9 MPa (70 kgf/cm2)[995.6 psi]
+

8.8 MPa {90kgf/cm2}[I280 psi]

Lift cylinder
TYpe Single-acting piston t

Cylinder bore 45 mm [1.772 in] 50 mm [I .969 in]

Stroke 1495 mm [58.858 in] t

Tilt cylinder
Type Double-acting piston t

Cylinder bore 65 rnm [2.56 in] 70 mm [2.76 in]

Rod diameter 30 mm [1.18 in] t

Stroke 151 mm [5.95 in] 158 mm L6.22 in]

Oil tank
Capacity 18 liter [4.76 gal] 32 liter [8.45 gal]
1 37 liter
[9.76 gal]
7. HYDRAULIC SYSTEM

7.1 GENERAL DESCRlPTlON

The hydraulic System consists of a main pump, control valve, lift cylinders and tilt cylinders. The oil is
supplied from the tank at the right of the frame.

7.1.1 MAlN PUMP

The main pump is a gear type directly driven by the engine PT0 device and picks up oil from the oil
tank and sends to the control valve.
The main pump consists of a pump body, a pair of gears, bushings and packings. This pump uses
pressure-balanced bearings and a special lubrication method to rninirnize the clearance of the gear flank.
The pressure-balanced method is to press the pressure plate toward the gear side by introducing part of the
discharge oil between the pressure plate and the pump body.

[345662]

1. DRIVE GEAR
2. SNAP RING
3. OIL SEAL
4. BUSHING
5. FRONT COVER
6. BODY
7. GASKET
8. BUSHING
9. REAR COVER
10. DRIVEN GEAR
11. SIDE PLATE
12. GASKET

Fig. 7.1 Main Pump

 7. HYDRAULIC SYSTEM

(1) Oil flow

The oil which has flowed through the inlet port in the rear Cover then enters the chamber formed by the
tooth spaces of the gears, side plates, and the pump body, and flows along the peripheries of the gears out
of the discharge pol-t.
I I

TOOTH SPACE

DECHARGE PORT SUCTION PORT

: Oil flow

Fig. 7.2 Hydraulic Oil Flow

(2) Pressure balance

While the pump is not operating or the discharge pressure is low, the side plates is pressed against the
gears' side faces by the rubber gasket. When the discharge pressure becornes high, a force which repels
the side plates acts on the shaded section in Fig. 7.3. At the same time, the oil pressure also acts on the
back side of the side plates, pressing the shaded section in Fig. 7.4. The shapes and surface areas of both
shaded sections are almost the sarne, so that the side plates is always pressed against the sides faces of the
gears with a constant elastic force, regardless of the discharge pressure of the pump.
I I

I I

Fig. 7.3 Pressure Distribution on Side-Plate Side Fig. 7.4 Pressure Distribution on Gear Side
7. HYDRAULIC SYSTEM
I

(3) Body wipe

While the discharge pressure is low, the centers of the gears are almost aligned with the centers of the
pump body holes, maintaining the radial clearance which is determined by machined size. When the
discharge pressure increases, the gears are pushed toward the low-pressure side by the clearance between
the gear and bearing and a deflection of the shaft, to make the gear teeth to contact with the pump body.
During this process, the Cast pump body is worn away, because the gears, which are usually heat treated,
are harder than the pump body. This is called "body wipe."
In order to keep the optimum radial clearance of gears when loaded, the pump is run-in at a little higher
pressure than the rated pressure before it is delivered to the customer. Also, the pump is tested for
discharge and specified torque.

I Wipe depth
Eccentricitv a. 0.01 - 0.06

Center of
pump body

Discharge pori .Suction

wipe

- A
' ,
1

Fig. 7.5 Body Wipe \.

 7. HYDRAULIC SYSTEM

7.1.2 CONTROL VALVE

The control valve consists of an inlet section, two plungers sections and an outlet section, which are

Fig. 7.6 Control Valve (for 1.0 - 1.75 trucks)

7. HYDRAULIC SYSTEM
I

RELIEF VALVE

GAUGE PORT (PF)

RELIEF VALVE .
(STEERING)
.)
to STEERING ClRCUlT

PF OAUGEPORT
(Pm

Fig. 7.7 Control Valve (for 2.0 - 3.0 ton trucks)

 7. HYDRAULIC SYSTEM
i
Control valve operation
(1) Inlet section
As shown in Figure 7.8, the inlet section has a relief valve which regulates the steering circuit oil
pressure, and a flow divider which divides the oil flow from the main pump into two lines: load handling
and steering. The inlet section also has a cartridge type main relief valve which sets the load handling
ciicuit oil pressure.

NTROL ORlFlCE (G)

N REUEF VALVE (D)

DAMPER ORlFlCE (I)

METERING ORlFlCE (H)

Fig. 7.8 Inlet Section

Flow divider operation

(,- (a) Pump discharge is smaller than preset flow rate
i
The oil flows, passing through port P, oil passage (J)
and orifice (G) to port P E Part of the oil passing CM)

through oil passage (J) flows through oil passage (K)

to the plug side of the spool (A). Part of the oil
passing through orifice (G) flow through orifices
(H) and (I) to the spring side (B) of the spool (A),
but the pressure differential across orifice (G) is
smaller than the force of the spring (B), and thus the
Part (M) of the spool (A) is kept closed so that all the (NI
oil flows to the PF side.
Fig. 7.9 Discharge is smaller than preset
flow rate
7. HYDRAULIC SYSTEM

(b) Pump discharge is greater than preset flow rate

When the pump discharge is greater than the preset
flow rate, the pressure differential across orifice (G)
increases to move the spool (A) to the right so that
the part (M) is opened to allow excess oil to flow to
the EF side. If the PF side circuit actuates and the
pressure in the circuit rises, the spool (A)
automatically shifts so that the opening of the part
(M) becomes smaller, thus striking a balance to
attain the specified working pressure and flow rate.

Fig. 7.10 Discharge is greater than preset

flow rate

(C) Actuation of EF side circuit (EF: load handling circuit)

When t k EF circuit is actuated enough to increase the oil pressure and the pressure differential across
orifice (G) becomes greater, the spool (A) moves to the right, narrowing the opening of the part (N) to
prevent the amount of more than the preset flow rate to flow to the PF side.

(d) Simultaneous actuation of both PF and EF circuits (PF: steering circuit)

When pressures in both the PF and the EF circuits increase simultaneously, the opening at the part
(M) of the spool (A) is automatically determined so that the flow rate be kept constant.

(e) When PF circuit pressure reaches relief pressure

When the PF circuit pressure increases enough to actuate the relief valve (E), the oil flows into the oil
tank at the flow rate determined by orifice (H) and the flow of oil to the EF side increases
accordingly.
 7. HYDRAULIC SYSTEM

Operation of main relief valve

(a) The oil in the high-pressure passage "HP" flows
through the oil hole in the piston "C" to affect the
two areas JAi and which are different in diameter,
so that the poppets "D" and "Ku are securely seated.

Fig. 7.11

(b) When the pressure in the high-pressure passage

"HP" reaches the Setting pressure of the pilot spring,
t/ the pilot poppet "E" opens. The oil passes around
the poppet, flows through the drilled hole to the low-
pressure side "LP".

Fig. 7.12

(C) As the pilot poppet "E" is opened, the pressure

behind the poppet "D" drops. As compared to the
pressure at the high-pressure side HP, the inner
pressure becomes unbalanced, causing the poppet
"D" to Open and thereby sending the oil directly to
the low-psessure passage "LP".

Fig. 7.13

(d) When the pressure in the high-pressure passage

"HP" is lower than that in the low-pressure passage,
the poppet "D" opens due to the difference
between the areas and B, allowing enough oil
from the low-pressure passage "LP" to the high-
pressure passage "HP".
7. HYDRAULIC SYSTEM

(2) Plunger section

There are two plunger sections, one for the lift circuit and one for the tilt circuit. Their construction is
shown in Figure 7.15.
The plunger is attached to the housing and is kept in neutral by the return spring. The configuration of
the lift circuit plunger is different from that of the tilt circuit plunger.

Fig.7.15 Plunger Section

Operation of plunger
(a) Neutral
Oil discharged from the main pump flows through
the neutral passage back to the oiltank. PORT "B" PORT "An

(b) Pushing in of plunger

The.neutra1 passage is closed and the oil flows
through parallel feeder, pushing up the load check
valve, into the cylinder Port "B". The oil returning
from the cylinder Port "A" flows through the low-
pressure passage to the tank. The plunger is restored
to the neutral position by the return spring.
Fig. 7.16 Pushing in of Plunger
 7. HYDRAULIC SYSTEM

(C) Drawing out of plunger

With the neutral passage closed, the oil pushes up PORT "B" PORT " A
the load check valve, passing through the parallel
feeder, and flows into the cylinder port "AM.The oil
returning from the cylinder port "B" flows through
the low-pressure passage to the tank. The plunger is
restored to the neutral position by the return spring.

Fig. 7.17 Drawing out of Plunger

Operation of tilt lock valve

(a) Drawing out of plunger
When the plunger is drawn out, the oil flows in the
i

r, Same manner as in Fig. 7.17.

Figure 7.18 shows a plunger section with a tilt lock
valve in neutral.

Fig. 7.18 Neutral

(b) Pushing in of plunger (pump in operation)

The oil from the main pump flow through the port
"B" to the tilt cylinders. The oil returning from the
cylinders flows through the oil hole @ to actuate
the poppet. This allows the oil to pass through the
plunger holes @ and @ toIthe low-pressure
i
passage and back to the tank.

Fig. 7.19

(C) Pushing in of plunger (pump at rest)

When the plunger is pushed in with the pump at rest,
: PORT ''Au : PORT "B"
the oil does not flow to the cylinder port "B" or the
pressure at area @ does not rise.
Also, the poppet does not move so that the oil at the
cylinder port "Audoes not return to the tank. The
cylinders thus remains unmoved.

Fig. 7.20
7. HYDRAULIC SYSTEM

7.1.3 VALVE CONTROLS

The control valve plungers are actuated with the levers as shown in Fig. 7.21, with each lever mounted
on a single shaft.
The shafts are supported by brackets which attached to the front guard. Movement of each lever is
transrnitted through a rod to the respective plungers.

[218G7-400111

ATTACHMENT LEVER (OPTION)

1 ;
, ,

CONTROL VALVE

Detail of area

Fig. 7.21 Valve Controls

( 7. HYDRAULIC SYSTEM

7.1.4 LIFT CYLINDER

The lift cylinder is a single-acting piston type consisting of a cylinder, piston rod, piston and cylinder
cap. On this series of trucks, two lift cylinders are located behind the outer mast frame.
The piston is secured to the piston rod with a snap ring, with a wear ring and packing on its outer
diameter.
At the bottom of one cylinder is a cut-off valve which will act as a safety device if the high-pressure
hose connecting the right and left lift cylinders bursts for any reason.
The cylinder cap has a bushing and an oil seal pressed to Support the piston rod and provide dust
proofness for the cylinder.

Cut-off valve operation

When the oil in the cylinder returns into the oil tank, it
Passes through the holes and in the piston.
If the flow rate of the oil passing through those holes is
less than the setting of the flow regulator valve, the
pressure differential across the piston is smaller than the
spring force so that the piston won't move.
If its flow rate becomes greater than the flow regulator
valve setting due to a burst of the high-pressure hose or
for any other reason, the pressure differential across the
piston becomes greater than the spring force to move the
piston to the right, so that the piston area on the case.
This prevents the oil from flowing out of the cylinder, to
stop the lowering of the forks.
Fig. 7.22 Flow Rate Smaller than Setting

Fig. 7.23 Flow Rate Greater than Setting

7. HYDRAULIC SYSTEM

Cylinder support

1. PISTON HEAD
2. SHIM
3. WIPER SEAL
4. U RING
5. HOLDER
6. "0"-RING
7. BUSHING
8. CYLINDER
9. ROD
10. LOCK RING
11. PACKING
12. WEAR RING
13. PISTON
14. SNAP RING
15. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT NUT
19. LOCK NUT
20. COTTER PIN

Fig. 7.24 Lift Cylinder (VM-18G, VM- 18J)

- 130 -
 7. HYDRAULIC SYSTEM

Cvlinder SUDDO~-t

1. PISTON HEAD
2. SHIM
3. WIPER SEAL
4. ROD PACKING
5. CYLINDER CAP
6. "0-RING
7. BUSHING
8. CYLINDER
9. ROD
10. LOCK RING
11. WEAR RING
12. PACKING
13. PISTON
14. SNAP RING
15. SHEAVE
16. CHAIN
17. ANCHOR PIN
18. ADJUSTMENT NUT
19. LOCK NUT
20. COTTER PIN

Fig. 7.25 Lift Cylinder (VM-39A, VM-39F)

7. HYDRAULIC SYSTEM

7.1.5 FLOW REGULATOR VALVE

The flow regulator valve controls fork descending
speed and acts as a safety device if the high-pressure hose
bursts for any reason. It is located as shown in Fig: 7.26.

Flow regulator valve operation

The oil returning from the lift cylinders enters the
chamber lb], passing through chambers m, 0 ,D, a ,
B , and W , back to the control valve.
The more the oil flows through the hole q in the
piston @, the greater the pressure differential across the
piston @ becomes to move the piston @ to the sight.
For this reason, the hole rn is narrowed by the hole
so that the oil flow is restricted to slow the fork
descending speed.
When the forks are raised, the high-pressure oil from Fig. 7.26
the control valve flows, passing through W , B , D, ,
m, and lb], into the lift cylinders.

[348044]

FREE FLOW

i ) CONTROLLED FLOW

UFT CYLINDER SlDE CONTROL VALVE SIDE

1. CASE 6. ORIFICE
2. SPRING 7. SPRING
3. BALL 8. "0"-RING
4. PISTON 9. NIPPLE
5. SLEEVE

Fig. 7.27 Flow Regulator Valve

 (' 7. HYDRAULIC SYSTEM

7.1.6 TlLT CYLINDER

The tilt cylinder is a double-acting type, and its piston rod end is supported by the mast and the cylinder
tail is connected to the frame with a pin. This truck is provided with two tilt cylinders on both sides of the
front of the truck.
The tilt cylinder assembly consists primarily of a cylinder body, cylinder cap, piston and piston rod. The
piston, attached to the piston rod with lock nuts, has a back-up ring and an "0"-ring installed on its
circumference, and moves along the inner surface of the cylinder by the force of hydraulic oil. A bushing
is press-fitted inside the cylinder cap to Support the piston rod, with a packing and dust Seal to provide oil
tightness for the piston rod and the cylinder cap. The cylinder cap, fitted with an "0"-ring on its outer
periphery, is screwed into the cylinder body and fastened with a lock ring.
When the tilt lever in the driver's room is tilted forward, high-pressure oil enters the cylinder tail side,
moving the piston foiward. This causes the mast to tilt forward 6 degrees. When the tilt lever is tilted
backward, high-pressure oil enters the cylinder cap side and moves the piston backward, tilting the mast
'
i*2 degrees backward.

. I
d
1. JOINT 6. CYLINDER CAP 11. PISTON
2. DUST SEAL 7. LOCK RING 12. PACKTNG
3. BUSHING 8. "0"-RING 13. LOCK NUT
4. “ 0 - R I N G 9. ROD
5. PACKING 10. CYLINDER

Fig. 7.28 Tilt Cylinder

7. HYDRAULIC SYSTEM

7.1.7 OI'L TANK

The oil tank is integral with the frame and located at the right-hand side of the truck body. Figure 7.29
shows its construction.
Inside the oil tank are a suction filter and return filter to remove dust from the oil.

RETURN FILTER' 'SUCTION 'DRAIN PLUG

FILTER

Fig. 7.29 Oil Tank

 7. HYDRAULIC SYSTEM
t

Fig. 7.30 Hydraulic Oil Piping (1)

- 135 -
 7. HYDRAULIC SYSTEM
I
7.2 MAINTENANCE
7.2.1 DISASSEMBLY AND REASSEMBLY OF CONTROL VALVE
(1) Disassembly

Fig. 7.32

(a) Loosen the plug a by two or three turns and remove the connector @ from the housing @.
Note: Do not remove the plug a at this Stage. The spool Q may drop on the land of the housing at
the moment the connector leaves off the housing, so that the land may be damaged by the spring @.
( a
'b) Remove the plug from the housing.
(C) Holding the sleeve @, install a bolt into the threaded area of the end of the spool @ and remove the
sleeve @.
(d) Remove the spool @ slowly. Care should be exercised so as not to allow it to drop on the land of the
housing @.
(e) The ring @ Comes out along with the spool @.
(0 Remove the connector (6-1) and plug (6-3) from the connector @ along with the ball (6-2).
(g) Do not remove the snap ring @ from the sleeve @; otherwise it may get deformed.
(h) Remove the "0"-ring from the plugs (0,6-3) and connector (6-1).
7. HYDRAULIC SYSTEM

(2) Reassembly
After disassembly, clean all parts in clean mineral oil. Inspect each part for burrs, scratches or other
defects. Due attention should be paid to the sliding area of the housing and diameter of the spool @.
All "0"-rings should be replaced with new ones.

Fig. 7.33

(a) Apply a good quality grease on new "0"-rings and install them on the respective positions.
(b) Install the sleeve @ with the snap ring B o n the housing a.
(C) Install a bolt into the threaded area in the spool @ and attach the spring B. Install the spool @ and
a
spring into the housing carefully.
(d) Push in the spool @ slightly, and the sleeve @ will project at the opposite side of the housing a.
Holding both ends of the spool @ and sleeve @ with your fingers, check to See if the spool @ moves
smoothly.
(e) Screw in the plug by two or three turns so as not to allow the spool @ to drop on the land of the
housing a and install the connector @ from the opposite side. (The connector @ should be
reassembled in the sequence opposite to disassembly.)
(f) Tighten the plugs ( 0 , 6 - 3 ) and connector (6-1) to the specified torque.
 / 7. HYDRAULIC SYSTEM
f?

(3) Disassembly of relief valve

(a) Loosen the plug (V) and renlove it from the housing 0.
Note: If the lock nut is loosened, be Sure to check the relief pressure with a pressure gauge thereafter.
(b) Hold the convex part of the housing @ in round pliers and remove the housing @ from the housing
0.
(C) The poppet @J Comes out along with the housing 0.
(d) Put the housing @ vertical and remove the spring @.

(4) Reassembly
Clean all parts and make Sure to get all necessary parts. Visually check the seats of the housing Q and
poppet for any sign of defect. Reassembly should be performed in a sequence opposite to disassembly.

(5) Adjustment of relief valve

' Main relief valve
(a) Install a pressure gauge on the outlet section gauge Port (PT114).
(b) Loosen the lock nut of the relief valve and turn loose the adjuster by 114 or 112 of a turn.
(C) Start the engine. Actuate the tilt cylinders to their stroke end and read the pressure gauge.
(d) When the reading is not as specified, obtain the specified value by turning the adjuster.
(e) Tighten the lock nut and recheck the pressure.
(f) Remove the pressure gauge. Install the plug on the gauge port.
Main relief pressure: 17.7 MPa { 180 kgflcm'} C2560 psi]

II PS relief valve
(a) Install a pressure gauge on the outlet section PF gauge port (PT114).
(b) Loosen the lock nut of the PS relief valve and turn loose the adjuster by 114 or 112 or a turn.
(C) Start the engine. Turn the steering wheel as far as possible in either direction and read the pressure
gauge.
(d) When the reading is not as specified, obtain the specified value by turning the adjuster.
(e) Tighten the lock nut and recheck the pressure.
(f) Remove the pressure gauge. Install the plug on the gauge port.
PS relief pressure: 6.9 MPa {70kgf/cm2}[996 psi] for 1.0- to 1.75-ton trucks
8.8 MPa (90 kgf/cm2}[I 280 psi] for 2.0- to 3.0-ton trucks
7. HYDRAULIC SYSTEM

7.2.2 PUMP MAINTENANCE

Cautions

1. Before disassembling the pump, check for oil leaks from the oil seal, the mating section of the
pump body and cover, and other areas.
2. Remove rust, dust and dirt at the shaft end and the pump body. Failure to do so might damage the
parts or allow them to enter the inside of the pump during disassembly, thus rnisleading your
diagnosis about the pump.
3. The pump has some syrnmetrical parts. Before disassembling the pump, mark the parts in the
manner shown in the "disassembly procedure", to ensure correct reassembly. For this purpose, use
oil paint not to damage the parts.
4. Disassembly is a means of finding out the cause of a trouble. Observe the procedure for
disassembling the pump.
5 . Before disassembly, make Sure you get new packings, gaskets, and oil seals.

(1) Disassembly
Q Hold the front cover in a vice with the input shaft
side downward.
Notes 1. The bolts will be loosened during
disassembly. Make sure to hold the
front cover in a vice securely as shown
in Figure 7.34, to prevent the pump
from the vice when a force is applied on
the pump.
2. Mark the rear and front Covers and the
drive gear side of the pump body with Fig. 7.34
oil paint.

@ Turn the four fitting bolts with a torque wrench in

the tightening direction, to check whether they are
properly tightened to 88.3 - 98.1 N-m 19 - 10
kgf-m} [65.1 - 72.3 ft-lbs].

Fig. 7.35
 7. HYDRAULIC SYSTEM

@ Remove the four fitting bolts.

Fig. 7.36

@ Remove the rear cover by tapping the side face of

the pump body with a plastic mallet. If the gaskets
( remain inside the pump body, move them toward
C
K- b
the rear cover side.

Fig. 7.37

@ Remove the pump body. If the gaskets remain

inside the pump body, mobe them toward the front
cover side.

Fig. 7.38

@ Put the mark "RV" the rear cover side plate at the
drive gear side before removing the side plate.

Fig. 7.39
7. HYDRAULIC SYSTEM

Put the mark "RNon the driven gear shaft end and
remove the drive gear.

Fig. 7.40

Holding the front side plate, remove the drive gear.

Fig. 7.41

@ Put the mark "FV" on the front side plate at the

drive gear side, and remove the side plate.

Fig. 7.42

@ Turn over the front Cover and hold it again in the

vice. Remove the snap ring.

Fig. 7.43
 7. HYDRAULIC SYSTEM

@ Remove the oil seal from the front Cover.

Fig. 7.44
7. HYDRAULIC SYSTEM

(2) Inspection

1. Inspections are carried out to locate the cause of troubles and to determine whether parts are
reusable or not. Inspections must be carried out only by personnel with a certain amount of
knowledge and experience in hydraulic equipment.
2. The "useful limit" shown in this section should be used as a rough guide. We do not always
guarantee the performance of a part if it does not reach its useful lirnit.

Name of component Items to be checked Remarks (cause and others)

I
1.................................................
I
Q Front cover

t (a) Check for cracks or damage.

................................................

A
Oil pressure is too high.

( c ~ N )
The mating section between the front cover and the pump body looks black in some parts.
This is caused by the friction between aluminuin parts and is not a problern.

Q Pump body (cast iron) Check for cracks or damage.

................................................
(b) Check wipe depth or wipe surface. I
Useful limit
Oil pressure is too high
.................................................
Oil pressure is too high.

Wipe depth limit: less than 0.04 mm [0.0016 in]

(C) Check for signs of interference with gear at Runout of g a r s

discharge side. Pump's performance is not affected if there is a
sign of interference.

(3 Drive and driven gears Check shaft ends and keyways for cracks,
damage or undue wear.
................................................
(b) Check journal (in the area which slides on
the bearing) for discoloration, undue wear,
or roughness.
I They might occur when gears are runout or
insufficiently lubricated. or when oil pressure is
too high.
.................................................
Contaminants in oil. too high oil temperature
(120°C [248"F] or higher), too frequently idle
operations

I ,,.. ,
n i t ccnl
Lr3L aLnL
L&
SIDE PLATE
BUSHING& BUSHING
The shaft might have the following scratches or
Scores on its outer diarneter:
(a), Those caused bv a hard obiect between the
\ -- --

shaft and bushing.

(b) Those caused by the oil seal's main lip
(C) Those caused by the oil seal's dust lip
I Example of 1st pump drive shafi I
Useful limit
Roughness on journal (a): 0.8s - 1.6s
Roughness on oil seals (b and C): 1.6s - 3.2s
t 7. HYDRAULIC SYSTEM
- -

Name of component Items to be checked Remarks (cause and others)

(C) Check for discoloration, undue wear, or Contarninants in oil, too high oil temperature
roughness on the gears. (120°C [248"F] or higher), too frequently idle
operations

II Useful limit

-Cm-
0.1 rnrn (0.0040 in) or less

.................................................
(d) Check gear teeth for roughness or pitching. Ihegular rotation at high speeds
................................................ .................................................
(e) Check for missing or broken gear teeth Too high oil pressure or a hard object caught in
gear

'?$ Side plate (a) Check side plate in the gear sliding area for Fine dust between side plate and gears
i wear or nicks or Scores.

I (b) Check the gears for erosion at or near the

engagement area.
Cavitation or aeration

Useful lirnit
Wear Limit: 0.1 5 mm (0.006 in) or less
t

6 Bushing Check the inner surfaces of bushings for The bushings are made of copper with the back
The bushings are fitted roughness or wem. plate made of lead brass. The back plate
into front and rear consists of porous and PTFE (polytetrafluoro-
- -
Covers. / ethylene) layers.
Useful lirnit

II When the back plate of the bushing is exposed to view. I

iz:~Gasket
t (b) Check rubber parts for swelling.
I
(a) Check gaskets for proper installation or cut. Too high oil temperature
.................................................
Fire retardant hydraulic oil (phosphate) or
gasoline is used.

I
Oil seal

damaged when the drive

gear is disassembled or
I

t
(a) Check oil seal for round or peeled edge.

.............................................
(b) Check main lip for warping outward.
I Wear occurs due to contaminants in oil, dust
which enters oil due to undue external negative
pressure, or rust due to moisture.
.................................................
Increased internal oil leaks or high oil pressure
(0.2 - 0.3 MPa { 2 - 3 kgf/cm2} [28.5 - 42.7 psi]
or more) applied on oil seal
when it is removed from the

I
front cover. It is difficult to (C) Check rubber parts for swelling. Fire retardant hydraulic oil (phosphate) or
locate the cause of damage gasoline is used.
when removing it from the
front cover.
7. HYDRAULIC SYSTEM

(3) Pump reassembly

Q As shown in Fig. 7.45, hold the front cover in a
vice.

Fig. 7.45

@ Install a new gasket in the groove in the front cover.

Fig. 7.46

@ Install a new "E" gasket in the groove in the front

cover, referring to Fig. 7.48.

Fig. 7.47

The "E" gasket should

be installed with its flat
surface pointing to the Flat surface

(b) "E" gasket

Fig. 7.48 Gasket Installation

- 146 -
 7. HYDRAULIC SYSTEM

@ Install the pump body on the front cover, referring

to Fig. 7.50.

Fig. 7.49

I Counterclockwise
rotation:
Front side
Counterclockwise rotation: Clockwise rotation:
Rear side Rear side
Clockwise rotation:
Front side

Projection (to be always

pointed to drive side)

Fig. 7.50

@ Install the front side plate oll the front cover,

referring to Fig. 7.52.

Fig. 7.51

LBC surface Back plate

(yellow) (SC material)

Discharge side
(smaller radius)

The LBS surface should be

always pointed to gear's side face

Fig. 7.52

- 147 -
7. HYDRAULIC SYSTEM

@ Install the drive gear in the pump body, with its

splines pointed downward.

Fig. 7.53

Install the drive gear in the pump body, as shown in

Fig. 7.55.

Fig. 7.54

A @mi
The sketch shows the engagement of an L-shaped pump. Since the tooth profiles of the two gears
are asymmetric, install them with their larger pressure angle sides pointed to each other. Failure to
do so rnight darnage the gear teeth.

Greater pressure angie side

(driven-side engagement surface)
Smaller pressure r

Greater pressure angie side

Smaller pressure angle side (drive-side engagement surface)

2
(a) Engagement of 1st pump (b) Engagement of asymmetric tooth profiles

L
Fig. 7.55
,r
7. HYDRAULIC SYSTEM

@ Install the rear side plate in the pump body, as

shown in Fig. 7.52.

Fig. 7.56

@ Apply grease on a new gasket in some points and

install the gasket in the rear cover groove.

Fig. 7.57

Discharge side

The rear cover is commonly used for the "L"

(counterclockwise rotation) type and the "Rn
(clockwise rotation) type. Align the d~scharge
side with the suction side.

Fig. 7.58

@ Install the "E" gasket in the rear Cover, as shown in

Fig. 7.48.

Fig. 7.59
 HYDRAULIC SYSTEM

Install the rear cover in the pump body with its

gasket pointed downward.

Fig. 7.60

@ Install the four bolts and tighten them to the

specified torque:
Tightening torque: 88.3 - 98.1 N-m 19 - 10 kgf-m)
[65.1 - 72.3 ft-lbs]

Fig. 7.61

@ Remove the pump from the vice and put it on a

work bench.
Apply grease on the area between the lips and on
the outer diameter of a new oil seal. Install it on
the oil Seal guide shown in Fig. 7.67. Put it on the
drive shaft of the pump, and install the oil seal onto
the front cover with an oil seal snap.

Fig. 7.62

-
Direction in which
oil seal is installed. Apply a thin coat of
grease on outer
diameter of oil seal.

Apply grease area

between oil seal lips.
1 I

Fig. 7.63 Fig. 7.64

 7. HYDRAULIC SYSTEM

@ Secure the oil seal with a snap ring and remove the oil seal guide.

Fig. 7.65 Fig. 7.66

Fig. 7.67
7. HYDRAULIC SYSTEM

(4) TRIAL RUN

Trial runs should be perfoi-med to run in an assembled pump and to ensure that it delivers the specified
performance. Trial runs are preferably carried on a special test stand, but may be carried out with the
pump on the machine using the following manner:
(If the pump were disassembled because of a seized pump or an abnormally worn internal component,
be Sure to change the hydraulic oil and replace the filters with new ones before trying Co make a trial run.)

(a) Install the pump on the truck. Install a pressure gauge on the oil pressure check port of the control
valve.
(b) Loosen the relief valve adjustment screw and operate the pump at 500 to 1000 rpm for about 10
minutes. Make Sure the pressure is less than 1 MPa { 10 kgf/cm2) [I42 psi].
(C) Increase the pump speed to 1500 to 2000 rpm and let the pump operate for about 10 minutes.
(d) Keeping the pump speed at 1500 to 2000 rpm, increase the pressure by 2 - 3 MPa {20 to 30 kgflcnl?}
[284 to 427 psi] up to 17.7 MPa (180 kgf/cm2} [2560 psi], letting the pump operate at each pressure (
for about 5 minutes. Operate each circuit for 5 minutes and replace the return filter with a new one.
While increasing the pressure, check the oil temperature and pump surface temperature. Check also
for operating noise. If the oil temperature or pump surface temperature rises excessively, reduce the
load and drop the temperature before continuing the test.
(e) After the test is over, Set the oil pressure for 17.7 MPa (180 kgf/cm2}[2560 psi], perform a discharge
test. The pump discharge is checked by observing the lift speed.
 7. HYDRAULIC SYSTEM

7.2.3 TROUBLE SHOOTING GUlDE

If any trouble occurs in the hydraulic System, locate the cause and take the necessaiy remedy according
to the charts given below.
(1) Control valve

Problem Cause Remedy

Disassemble and clean.

Spool sticking
PF circuit pressure does not Clean hydraulic oil.
Defective sliding surface
increase Replace spool.
Broken spring
Specified flow rate not Replace spring.
Clogged orifice
obtained Disassemble and clean.
Maladjustment of relief valve
Readjust relief valve.
I
CF circuit pressure does not Spool sticking Disassemble and clean.
i Disassemble and clean.
increase Clogged orifice

Spool sticking Disassemble and clean.

~ibration
Insufficient air bleeding Bleed air sufficiently.
Slow pressure rise
Spool sticking Disassemble and clean.

PF circuit pressure higher Spool sticking Disassemble and clean.

than pressure setting Clogged orifice Disassemble and clean.

Specified flow rate not

Relief valve inalfunctioning Readjust.
obtained

Relief valve malfunctioning Readjust.

Noisy operation
Sliding area worn Replace relief valve.
I Replace "0"-ring.
Oil leak (external) "0"-ring deteriorated or damaged
I: I
*

Spring defective Replace spring.

Low pressure setting
Seat surface defective Readjust or replace relief valve.

Oil leak (internal) Seat surface damaged Correct seat surface.

High pressure Setting Poppet sticking Disassemble and clean.
7. HYDRAULIC SYSTEM

(2) Main pump

I Problem
No oil discharged from gear
Cause
Low oil level in oil tank
Remedy
Add oil to specified level.
1
I

Pump Clogged suction tube or strainer Clean or change oil if necessary.

Worn pressure plate I I

Worn bearing
Replace with new one
Defective plate seal, bushing Seal or
back-up

Adjust relief valve setting with a

Gear pump pressure won't rise Maladjusted relief valve
pressure gauge.

I Retighten suction side piping I

connections.
Air being sucked
Add oil into oil tank.
Check pump oil seal.

Collapsed suction hose or clogged

Check hose or Service strainer.
strainer causes cavitation

Air being sucked due to a loose

Retighten a loose joint.
suction side joint

Change to oil of proper viscosity

TOO viscous o i ~
causes cavitatioi I Operate pump at proper I
temperature.

Find the cause of air bubbles and

Air bubbles in oil
take necessary measures.

Defective pump oil seal or plate seal Replace with new ones.
Oil leaks from pump
Defective pump Replace pump with a new one.
 8. LOAD HANDLING SYSTEM

8. LOAD HANDLING SYSTEM

Name VM-18G (1.75 ton: VM-181) I VM-39A I VM-39F

TYpe Roller type 2-stage telescopic mast with free Iift
Standard max. lifting height 3000 mm [118.11 in]
i ?ork lifting system Hydraulic
Fork tilting system Hydraulic
Lift chain Leaf chain BL623 Leaf chain BL634 Leaf chain BL823

A: 44 mm C1.732 in] A: 48 mm [1.89 in]

B: 102.5 mm L4.035 in] B: 119.5 rnrn [4.705 in]
C: 134.5 mm [5.295 in] C: 161.5 mm [6.36 in]

A: 43 mm [1.69 in] A: 45 mm L1.77 in]

B: 102.5 mm [4.035 in] B: 119.5 mrn [4.705 in]
C: 134.5 mm 115.295 in] C: 159.5 mm [6.28 in]
D: 72 mm [2.83 in] D: 76 rnm [2.99 in]
8. LOAD HANDLING SYSTEM

8.1 GENERAL DESCRlPTlON

The load handling System is of roller type having a two-staged telescopic mast. It consists of an outer
channel, inner channel, and lift bracket.

8.1.1 OUTER AND INNER CHANNELS

Outer and inner channels are of welded construction. The lower Part of the outer channel is provided
with a support to be used for installing the mast assembly on the drive axle.
The Center of the outer channel is supported by the frame via the tilt cylinder. The mast assembly tilts
forward and rearward by expanding and contracting the tilt cylinder.
At the inner channel, the end roller is installed on the lower outside. At the outer channel, it is installed
on the upper inside through the shim.

1. Inner channel
2. Outer channel
3. End roller
4. Shim
5. Stopper
6. End roller
7. Shim
8. Slipper
9. Shim
10. Pin
11. Cap
12. Bush

Fig. 8.1 Outer and Inner Channels

- 156 -
 8. LOAD HANDLING SYSTEM
i

8.1.2 LIFT BRACKET

Behind the lift bracket located are the end rollers which roll along inside the inner channels and each of
which is held by a snap ring on the end roller shaft with a bearing. The end roller shafts are welded to the
lift bracket. The upper end roller is adjusted by adding or subtracting shims and the lower end roller is
secured with a snap ring.
The lift bracket is so designed that the top of the end roller is projected over the mast when the load is
in maximum lifting position. Longitudinal load is received by the end rollers, and lateral load by the
lower-located side rollers.

1. Fork
2. Stopper
/
3. Spring
I 4. Handle
5. Lift bracket
6. End roller
7. Snap ring
8. Side roller

11. Spacer
12. Back rest

f,

Fig. 8.2 Lift Bracket

8. LOAD HANDLING SYSTEM

8.1.3 LOCATIONS OF ROLLERS

The end and side rollers are installed on the lift bracket. The end rollers support longitudinal load and
the side rollers support lateral load so that the inner channels and lift bracket are raised and lowered
smoothly.

[I1092 11
Upper section Lower section i,--. \.. .-.q
i i
i i
INNER CHANNEL, i i

END ROLLER
(adjusted with shirns)

LlFT CYLINDER

Fig. 8.3 Roller Locations (for 1.O- to 1.75-ton trucks)

[110940] Upper section Lower section

INNER CHANNEL

END ROLLER
(adjusted with shirns)

LlFT CYLINDER

Fig. 8.4 Roller Locations (for 2.0- to 3.0-ton trucks)

- 158 -
 8. LOAD HANDLING SYSTEM

8.2 MAINTENANCE
8.2.1 ADJUSTING LlFT CYLINDER ROD WlTH SHlMS
After the lift cylinder, inner channel, and outer channel are replaced, the lift cylinder rod length needs
to be adjusted.
(1) Install a piston head on each rod of the right and
left cylinders without shim.
Shim
(2) Extend the lift cylinder rod slowly and check the
difference of the time till each of the right and left
cylinder rods reaches the stroke end.
(3) Add shim between the rod and piston head which
stop first.
Shim thickness: 0.2 and 0.5 rn C0.008 - 0.02 in]
(4) Adjust the lift chain tension.

Fig. 8.5

8.2.2 ADJUSTING HEIGHT OF LlFT BRACKET

(1) Stop the truck on a level surface and stand the Tire
mast vertically.
(2) Keep the fork bottom on the ground and adjust
the projected amount @ of the lift bracket lower
end roller to the value as shown in Table 8-1,
using the chain anchor pin at the mast side.

Table 8-1
,l
Model Mast Type rnm [in]
Fig. 8.6
1 - 1.5 ton VM-18G 36 - 41 t1.42 - 1.611
1.75 ton VM-185 36 - 41 [1.42 - 1.611
2 - 2.5 ton VM-39A 34 - 39 [1.34 - 1.541
3 ton VM-39F 44 - 49 [1.73 - 1.931
8. LOAD HANDLING SYSTEM

(3) Make Sure that the clearance between the lift

nner channel stopper
bracket and the inner channel Stoppers is 0 mm
when the fork is raised to the maximum lifting
height.

Note 1: When the rnast lifting height is over 4000 mm

[157.5 in], the dimension is + 50 mm [2 Lifi bracket
stopper
in].

a7 Chain anchor pin at

mast side

Fig. 8.7

(4) Adjust the tension of the right and left chains to

the Same value with the chain anchor pin at the
mast side when the fork is at the bottom position Chain
and the mast is tilted back all the way.

Anchor pin

Adjustment nut

Lock nut

Fig. 8.8
 8. LOAD HANDLING SYSTEM
d
8.2.3 PROCEDURE FOR REPLACING ROLLERS AT LIFT BRACKET SlDE
(1) Attach the pallet to the fork and stop the truck on
a level surface.

(2) Lower the fork with the pallet to the ground.

(3) Remove the joint link of the mast side anchor pin
and remove the chain from the sheave.

(4) Extend the lift cylinder rod to raise the inner

channel. (See O in Fig. 8.9.)

(5) Move the truck backwards after making Sure that

the lift bracket is removed from the inner channel.
(See in Fig. 8.9.)
r, Fig. 8.9
(6) Replacing end rollers
Remove the lower e n d roller with a puller,
keeping the shim.
@ Install a new end roller with the shim removed in Stamp (S or SS) +
step O. Check the starnp of S or SS and install
the roller which is marked the Same stamp,
pointing the starnp side to the lift bracket side.
@ Remove the snap ring and remove the upper end
roller with a puller.
@ Install a new end roller and secure it with the snap
ring.

(7) Replacing side rollers

M-
O Remove the side roller assembly. Keep the Fig. 8.10
i, numbers of the shims and their combination as
they were.
@ Install a new roller with the shims removed in
step Q, pointing the groove for the balls to the
shim side. (See Fig. 8.12.) Shim

@ If there is excessive looseness between the side

roller and inner channel, add the shims between
the end roller and side roller, seeing "8.2.5
PROCEDURE FOR ADJUSTING SHIMS".

Fig. 8.11
8. LOAD HANDLING SYSTEM

(8) Extend the lift cylinder rod so that the inner

channel bottom projects the upper section of the
lift bracket.

(9) Bring the truck close to the lift bracket side so Groove for balls
that each roller enters inside of the outer channel.

(10) Contract the lift cylinder rod to lower the inner

channels gradually. Place each roller of the lift
bracket into the inner channels.
I
(1 1) Engage the chain with the sheave and connect the
chain and anchor through the joint link.
Fig, 8.12 Side Roller Assembly
(12) Adjust the height of the lift bracket. (See 8.2.2.)

Fig. 8.13
8. LOAD HANDLING SYSTEM

8.2.5 PROCEDURE FOR ADDING OR OMITTING SHlMS

(1) Move the inner channel and lift bracket to one side of the outer channel. Measure the clearance
between the end roller at the opposite side and each channel.
Clearance between roller and channel: 0 to 0.5 mm [0 - 0.02 in]
 (, 9. STEERING SYSTEM

9. STEERING SYSTEM (SEMI-INTEGRAL TYPE)

I I
TYP^ Rear-wheel steering with power steering
Steering gear box Semi-integral type I t
I
I Type 18.9 : 1
Reduction ratio 84"
Working angle Left
Ball screw direction 8.8 MPa (90 kgf/cm2}
Maximum oil pressure [I280 psi]
I0 literlmin (2.6 gal/min)
Maximum flow rate
Power cylinder Double-acting piston
Type 50 mm [I .969 in] C

Cylinder bore 22 mm L0.866 in] 25 mrn [0.984 in]

Cylinder rod diameter 240 mm [9.449 in] C

Stroke
Steering axle
Type Center-pin supported, Elliot type with box-shaped section
Steering angle
4 Inner wheel
Outer wheel 51" 54"
King pin spacing 780 mm [30.709 in] 810 [31.890 in]
Swivel radius 70 mm C2.756 in] 50 rnrn [1.969 in]
Camber
Wheel
Wheel size
Tread Pattern J-LUG
Rim size 3.OOD-8DT
Tire inflation pressure 0.69 MPa {7.0 kgf/cm2}
[99.6 psi]

Note: For the orbitrol type power steering, see Chapter 6.

9. STEERING SYSTEM

9.1 GENERAL DESCRlPTlON

The steering system is a rear-wheel steering type with power steering, consisting primasily of a steering
handwheel, a steering gear box, a power cylinder, and a steering axle.

9.1.1 STEERING HANDWHEEL UNlT

The steering handwheel unit consists of a steering handwheel, a steering shaft, and a steering gear box.
The steering shaft is connected to the steering geas box through a universal joint. The steering colurnn
supporting the steering shaft can be tilted to a certain extent.

[239A4-1002 11

STEERlNG WHEEL

',TILT LOCK LEVER

UNIVERSAL JOINT

STEERING GEA

Fig. 9.1 Steering Handwheel Unit

i 9. STEERING SYSTEM

9.1.2 STEERING GEAR BOX

The steering gear box is a semi-integral type which consists of a combination of a ball nut type worm
shaft and a contsol valve.
In the screw grooves between the ball nut and worm shaft are steel balls which recirculate as the worm
shaft rotates, thus providing smooth, easy action of the steering wheel. The threaded area of the ball nut is
in mesh with the threaded area of the sector shaft to convert linear motion of the ball nut into rotating
motion of the sector shaft.
The sector shaft is supported through bushings by the gear box and the side cover and has an adjustment
screw at the side cover side to adjust the engagement of the gears.
Under the bottom of the gear box is a control valve consisting of a housing, a spool, and a spring. The
spool is fitted to the worm shaft with nuts. The power cylinder oil flow is contsolled by switching over the
oil grooves in the control valve housing and those in the spool.
9. STEERING SYSTEM I

1. TOP COVER
R PORT
2. OIL SEAL
I 3. BALL BEARING
4. "0-RING
5. BALLNUT
6. BUSHING
7. SPOOL
8. VALVE HOUSING
9. SPRING
10. THRUST RACE
11. THRUST BEARING
L PORT
12. LOCK NUT
13. END COVER
(@ PUMP PORT 14. "0-RING
15. THRUST RACE
View looking from 16. "W-RING
17. THRUST BEARING
18. CAP NUT
19. GASKET
20. LOCKNUT
21. GASKET
22. "0"-RING
23. ADJUSTMENT SCREW
24. BUSHING
25. OIL SEAL
26. SNAP RING
27. SECTOR SHAFT
Tightening torque:
Tightening torque:
20 - 29 N-m
(203.9 - 295.7 kgf-cm)
[14.8 - 21.4 Ibs-ft]

Tightening torque:
20 - 29 N-m
(203.9 - 295.7 kgf-crn)
[14.8 - 21.4 Ibs-ft]

Sectional view -H

Fig. 9.2 Steering Gear Box

t/ 9. STEERING SYSTEM
<

(1) Steering handwheel in straight position

When the steering handwheel is in straight position, the spool @ is in the position shown in Figure 9.3,
by operation of the centering spring B. At this time, the gaps A, B, C and D are equal in size, and the oil
from the pump flows through the control valve, back into the tank.
I I

Fig. 9.3 Neutral

(2) When steering handwheel is turned counter-

clockwise
When the steering handwheel is turned
counterclockwise, the ball nut applies force to the
sector shaft. Due to resistance of the truck body, the
aector shaft won't rotate and the worm shaft a shifts
downward instead. Along with this, the spool @ also
moves downward, closing the gaps A and C while
widening B and D. The oil from the pump thus flows
through the gap B to the tail side of the power cylinder.
On the other hand, the oil returning from the power
cylinder cap passes through the gap D, back into the tank.
The above operation continues while the steering
handwheel is being turned. When the rotation of the
steering handwheel is discontinued, the worm shaft @ is
returned to the original position by the centering spring
@, thus putting the gaps A, B, C, and D in neutral.
Fig. 9.4 Counterclockwise rotation
9. STEERING SYSTEM

(3) When steering handwheel is turned clockwise

When the steering handwheel is turned clockwise, the
worm shaft @ moves upward, closing the gaps B and D
while widening A and C, so that the oil from the pump
flows through the gap C to the power cylinder cap. The
oil returning from the power cylinder tail flows through
the gap A into the tank. The subsequent operation is the
Same as described in step (2).

Fig. 9.5 Clockwise rotation

9.1.3 STEERING LINKAGE
The steering linkage consists of a drag link and a power cylinder, as shown in Figs. 9.6 and 9.7.
The drag link feeds back movement of the power cylinder to the sector shaft of the steering gear box.
Tightening torque:
Tightening torque: 140-210 N-rn
160 - 200 N-rn (1400 - 2100 kgf-cm} Tightening torque:
(1600 - 2000 kgf-cm) [103.3 - 154.9 I~s-ft] 190-286~m
[118.0 - 147.5 Ibs-ft]
BOOT (OPTIONI
, (1900 - 2860 kgf-Cm)
[140.1 - 210.9 Ibs-ft]
\
hole is
[The aiioointed
vent '\ I .I

I POWER CYLINDER

Fig. 9.6 Steering Linkage (for 1.O- to 1.75-ton trucks)

 9. STEERING SYSTEM

Tightening torque: 237 - 355 N-rn ,.." 181 .I - 110.6Ibc-ft]

(2370- 3550 kgf-CM)
-
[174.8 261.8 IbS-ft]

Tightening torque: 190 - 286 N-m

(1900 - 2860 kgf-cm)
-
[140.1 210.9 IbS-ft]

Detail of boot (option)

Fig. 9.7 Steering Linkage (for 2.0- to 3.0-ton trucks)

9.1.4 POWER CYLINDER

The power cylinder is a double-acting piston type, the cylinder tail being fitted to the frame and the rod
side to the steering axle Center arm.
The power cylinder is controlled by the control valve in the steering gear box. When the steering
handwheel is turned counterclockwise, oil pressure is applied to the cylinder tail side and when the
steering handwheel is turned clockwise, it is applied to the cylinder cap side.

Tightening torque 170 N-rn (1700kgf-cm) Tightening torque. 100 N-m {I000kgf-crn)
[I25 4 Ibs-ft] 173.8 Ibs-ft]
[Apply LOCTITE #270 ]

1. BALL JOINT 5. PACKING 9. "0-RING

2. LOCK NUT 6. CYLINDER 10. CAP
3. LOCK NUT 7. ROD 11. PACKING
4. PISTON 8. BUSHING 12. SEAL

Fig. 9.8 Power Cylinder

9. STEERING SYSTEM

9.1.5 STEERING AXLE

The steering axle is an Elliot type consisting of a center arm at the center, knuckles at both opposite
ends, and tie rods which transrnit movenlent of the center arm.
The ball joints at the opposite ends of each tie rod have left-hand threads at the center arm side and
right-hand threads at the knuckle side.

(1) Knuckle and king pin

The knuckle is supported with a king pin which in turn is secured at the knuckle side with a lock pin.
The top and bottom of the king pin are fitted to the axle boss with needle bearings.
Between the axle boss and the knuckle is a thrust bearing to let the knuckle smoothly rotate around the
king pin, sustaining load.
The needle bearings and thrust bearing are lubricated by grease supplied through the grease fittings at
top and bottom of the king pin.

THRUST BEARl

Fig. 9.9 Knuckle

(2) Wheel hub

The wheel hub is mounted on the knuckle spindle with two taper roller bearings and its preload is
adjusted with a nut.
 9. STEERING SYSTEM

1 I

1. OIL SEAL 7. CAP 15. TIE ROD

2. NEEDLE BEARTNG 8. LOCK NUT 16. CENTER ARM
3. THRUST BEARING 9. HUB 17. TIE ROD
4. OIL SEAL 10. LOCK PIN 18. REAR AXLE
5. TAPERED ROLLER 11. NEEDLE BEARING 19. OIL SEAL
BEARING 12. OIL SEAL 20. NEEDLE BEARING
6. TAPERED ROLLER 13. KING PIN 2 1. CENTER ARM PIN
BEARING 14. KNUCKLE

Fig. 9.10 Rear Axle (for 1.O- to 1.75-ton trucks)

9. STEERING SYSTEM I

[109972]
!

1. OIL SEAL 7. CAP 15. T E ROD

2. NEEDLE BEARING 8. LOCK NUT 16. CENTER ARM
3. THRUST BEARING 9. HUB 17. T E ROD
4. OIL SEAL 10. LOCK PIN 18. REAR AXLE
5. TAPERED ROLLER 11. NEEDLE BEARING 19. OIL SEAL
BEARING 12. OIL SEAL 20. NEEDLE BEARING
6. TAPERED ROLLER 13. KING PIN 2 1. CENTER ARM PIN
BEARING 14. KNUCKLE

Fig. 9.11 Steering Axle (for 2.0- to 3.0-ton trucks)

 9. STEERING SYSTEM

9.2 MAINTENANCE
Note: The shapes of some parts may be different from those of your truck. However, the procedure for
maintenance and the values shown in this section are the Same as those of your truck.
9.2.1 DISASSEMBLY OF STEERING GEAR BOX
(1) Hold the steering gearbox in a vise.

Fig. 9.12
I,
(2) Remove the box nut and packing from the adjust
screw. Remove the side cover mounting bolts and
turn the adjustment screw clockwise. This causes
the side cover to come off.
Note: Exercise care not to lose the "0"-ring fitted to the
side cover.
Remove the adjustment screw and shims fitted to
the sector shaft.
Fig. 9.13

(3) Rotate the worm shaft so that the sector shaft teeth
are positioned as shown in Fig. 9.14.
Lightly tapping the sector shaft serration by hand,
remove the sector shaft.

Fig. 9.14

(4) Remove the bolts securing the end cover and detach
the end cover, using caution not to lose the "0"-ring.

Fig. 9.15
9. STEERING SYSTEM

(5) Install the disassembly jig (Fig. 9.17) as shown in

Fig. 9.16.
Straighten the tang of the lock nut with use of a
screwdriver and remove the lock nut. Then remove
the thrust race and thrust bearing.

Fig. 9.16

Unit: mm [in]
-
3 10.50

Fig. 9.17 Jigs

(6) Loosen the two bolts alternately in such a way that

the disassembly jig does not incline. Remove the
bolts, supporting the valve housing by hand, with
care not to allow the valve housing.

Fig. 9.18

(7) Remove the top cover fitting bolts and take off the
top cover by lightly prying it with use of a screw
driver. Use caution not to damage the "0"-ring.

Fig. 9.19
 9. STEERING SYSTEM

(8) Carefully remove the ball nut assembly from the

gear case. Keep the ball nut horizontal at all times.
Failure to do so will damage the ball scooping area,
resulting in the malfunction of the ball nut assembly.

Fig. 9.20

9.2.2 INSPECTION
Clean all the disassembled parts in cleaning oil. Do not use gasoline for cleaning the rubber parts.
J ' Sfter cleaning, inspect all parts for scratches or scores, wear or cracks. Put them in order in a place free
<
from dust and dirt until reinstallation.

(1) Replace the "W-ring, gasket, packing and oil seal with new ones.

(2) Operate the ball nut assembly to See if it is operating normally. If not, clean it, slowly opeiating in
cleaning oil. Replace the ball nut assembly when the threaded grooves show sign of flaking, dent, or
undue wear.

(3) Inspect the sector shaft for evidence of excessive scores on the gear teeth or undue wear on the shaft.
Replace the sector shaft if defective.

(4) Inspect the bearing and side cover bushing in the gear case assembly to See if they are excessively
worn. Replace if necessaly.

;5) Inspect the bearing, oil Seal and bushing inside the top cover for defect.

(6) Inspecting the valve housing

Inspect the valve housing inner surface, especially the orifice areas for sign of battering or damage.
If unsatisfactory, replace the valve housing assembly.
@ Inspect the spool diameter and orifice areas for sign of battering and damage. If unsatisfactory,
replace the spool.
@ Inspect the spring for cracks or breakage, replacing the spring if defective.
9. STEERING SYSTEM

9.2.3 REASSEMBLY OF STEERING GEAR BOX

(1) Reassembly of control valve
@JInstall the spool in the valve housing, matching the
"P" mark on the housing with the smaller chamfered
diameter of the spool.
@ Install the Center spring in the valve body.

Fig. 9.21

Fig. 9.22

(2) Hold the gear case in a vise and apply grease on the
oil seal inside the gear case.

Fig. 9.23

(3) Install the ball nut assembly in the gear case, with
the rack gear upward.

Fig. 9.24
 9. STEERING SYSTEM
i
(4) Fill the colurnn bushing with grease and apply a thin
coat of grease on the "0"-ring at the gear case in the
top cover fitting area. Slowly insert the top cover
through the gear case. Forceful insertion might
damage the "0"-ring.

Fig. 9.25

(5) Install the thiust race, thrust bearing and thrust race
onto the worm shaft.
/

Fig. 9.26

(6) Install the valve housing assembly on the gear case.

Make Sure the "0"-ring of the gear case is securely
settled in the groove.

Fig. 9.27

(7) Install the jig on the valve housing with 3 bolts.

Then install the thrust race, thrust bearing and thrust
race in that order.

Fig. 9.28
9. STEERING SYSTEM

(8) Rotate the worm shaft counterclockwise to stop and

hand tighten the nut until thrust bearing has no
clearance, and mark the groove position in the shaft
on the lock nut. Back off lock nut and check to see
if the marked position remains unchanged. If
satisfactory, retighten the lock nut about 5".
Shaft rotating force: below 0.98 N-m { 10 kgf-cm}
[0.72 ft-lbs]
Fig. 9.29

(9) Caulk the lock nut.

Fig. 9.30

(10) Install the "0"-ring in the groove of the valve

housing and attach the end cover.
Tightening torque: 20 - 29 N-m

Fig. 9.31

(1 1) Install the ball nut assembly so that the center of the

rack gear is aligned with the center of the side cover
fitting window.

Fig. 9.32
 I 9. STEERING SYSTEM

(12) Install the sector shaft on the gear case. Install the
adjust screw and shims in the sector shaft groove,
and match the side cover screw hole with the
adjustment screw. Install the side cover, turning the
adjust screw. At the Same time, install an "0"-ring
into the groove in the side coves.
Tightening torque: 20 - 29 N-m

Fig. 9.33

(13) Set the pitman arm in the middle of the whole

rotating angle of the steering wheel. Set a dial
gauge at a position 150 mm [5.9 in] away from the
4' pitman arm center and measure for looseness.

Looseness: below 0.3 mm [0.0118 in]

Fig. 9.34

If there is a looseness of more than 0.3 mnl

(0.0118 in), adjust with the adjustment screw. After
adjustment, install the packing and secure with lock
nut. Finally, install the box nut.
Tightening torque: 20 - 29 N-m

Fig. 9.35

(14) Rotate the steering wheel to Count the nunlber of turns from stop to stop.
Total Number of turns: 4 213 turns

(15) Rotate the steering wheel clockwise or counterclockwise to stop and release it. Make Sure it returns
about 50" smoothly.
9. STEERING SYSTEM

9.2.4 REAR WHEEL BEARING PRE-LOAD ADJUSTMENT

(1) As shown in Fig. 9.36, apply grease on the hub, inner bearing, outer bearing and cap. Also apply
grease on the lip of the oil seals.

(2) Set bearings on the hub and install the hub on the knuckle spindle.

(3) Install a plain washer and tighten the adjustment nut to the torque of 206.0 - 235.4 N-m (21 - 24 kgf-
m} [I52 - 174 ft-lbs]. Back off the adjustment nut then retighten to the torque of 9.8 N-m { 1 kgf-m}
[7.2 ft-lbs].

(4) Lightly tapping the hub with a wooden hammer, rotate the hub 3 to 4 turns to make certain there is no
looseness.

(5) Tighten the adjustment nut to the position which allows the cotter pin to be Set.

(6) Tapping the hub with a wooden hammer, rotate the hub 3 to 4 turns to secure smooth rotation and
measure the starting torque.
Starting torque: 2.94 - 7.85 N-m {0.3 - 0.8 kgf-nl} [2.2 - 5.8 ft-lbs]

(7) When the starting torque is other than the specified, replace the plain washer and castled nut.
 I' 9. STEERING SYSTEM

9.2.5 ASSEMBLING WHEELS

Put a tube and flap in a tire, and assemble the rims, observing the following conditions:
1. The air valve should be pointed outwasd, being matched with the rim notch.
2. The rirn assembling bolts should be installed with their heads pointing the outside of the truck.
3. When iilflating a tire, make Sure no one is on the side (bead side) of the tire.
4. When the tire inflation pressure is about 98 kPa { 1 kgf/cm2} 114.2 psi], tap the entire tire with a
mallet to fit the tube and flap into the rims.

I
I Configuration of rim assembling bolt

1. TIRE 4. RIM (INSIDE)

2. TUBE 5. RIM (OUTSIDE)
3. FLAP 6. ASSEMBLING BOLT

Fig. 9.37 Wheel Assembly

9.2.6 TROUBLE SHOOTING GUlDE

Problem Possible cause Remedy
Defective or damaged pump Replace.
( . Steering wheel won't Relief valve stuck or damaged Clean or replace.
operate Control valve stuck, damaged, or worn Replace or repair.
Damaged hose joint or clogged oil line Replace or clean.
Low oil level in oil tank Add oil.
Insufficient air bleeding Bleed air.
Hard steering wheel
LOWpressure See preceding item.
Control valve stuck or damaged Clean or replace.
Loose control valve spool Retighten lock nut.
Truck wanders or
Damaged control valve Replace.
vibrates.
Broken or deteriorated spring Replace.
Low oil level in oil tank Add oil
Noisy operation Clogged suction pipe or filter Clean or replace.
Control valve stuck or dainaged Replace.
Improperly-installed or damaged "On-ringor oil seal Replace.
Oil leaks
for piping or control valve.
 STEERING SYSTEM

NOTE
 10. ELECTRIC WlRlNG

10. ELECTRIC WlRlNG

The electric components of the truck are wired through several types of wire harnesses and color coded
by circuit.
The wire harnesses are connected with connectors (2 types) or screw.

Table 10.1 Color symbols and examples

Y L B Black R Red

E markingcoating with a blue

Yellow
G

P
Green

Blue

Orange

Pink
W

Sb
White

Yellow

Lg Light green
Light blue
Example:
White
rnarking P /:,'

coating without

-
Table 10.2 Connector symbol

Connection type Plug-in side Receptacle side Remarks

Housing F
1
Plug-in
type
The alphabetic letters mean
Plug
colors. (Table 10.1)

Screw type - Y
-
The dotted lines in the circuit diagrams are given for optional equipment.

A DANGER: Use due caution when handling the battery unit.

1. Never short the circuit, Spark, smoke or use fire near the battery unit. Since flammable gas is
always released from the battery, there is a danger of causing an explosion.
2. The battery electrolyte is dilute sulfuric acid. It will cause burns if it gets on the skin. If
electrolyte Comes in contact with the skin, flush with water. It can cause blindness if it gets into
eyes. If electrolyte gets into your eyes, flush our eyes out with water and get to a doctor.
to HORN
 to REAR COMBlNATlON LAMP (RIGHT)

to BACK-UP BUZZER

PLATE LAMP

OIL TEMP. SENDER

to DISTRIBUTOR

to OIL PRESSURE SWITCH

to REAR COM

to WlRE HARNESS, FR

FUSE BOX

to FLACHER UNlT
to AUTOMATIC CHOKE
 to REGULATOR [ALTERNATOR) -
N
W

E
ÄN
t)
W
Y

to BACK-UP BUZZER

PLATE LAMP

to OIL PRESSURE SWITCH

to FUEL PUMP
to REAR COMBlNATlON LAMP (LEFT)

to GLOW PLUG RELAY

FUSE BOX
to FUSE BOX
to aos-iiiTIMER
to FLASHER UNlT
 2

to REGULATOR (ALTERNATOR) n P
W
W
rn
cy; r
m
I
to STARTER P
2
N
N
+ z0
W
U

3
2 2
'-9 z
+ C,
S
+
F;'
CD
3:
P:
z
V>
vi

F
E-
PLATE LAMP (OPTION)

I i?
T2 to FUEL CUT-OFF VALVE
h)
I
g
Ci.
".
C
to FUEL LEVEL SENDER
5-
8a to GLOW PLUG RELAY

t3
P
0
8
@?.

i?
V

FUSE BOX
to FUSE BOX
to QOS-I11TIMER
to REGULATOR (ALTERNATOR) G I
NOTE
 FRONT COMBINATION LAMP

PARKING BREAK SW

f-
\ I
i
i

RADIATOR

AIR CLEANER

(' ,

\,

FUSIBLE LINK

STARTER

REAR COMBlNATlONLAMP

ENGINE GROUNDING

FRAME GROUNDING

L.-.-.-
-.-.-.-
REAR COMBINATION LAMP
,:
:;
<~
Fig. 10.11 Wiring Diagram (gasoline engine trucks with clutch)

- 197 -
 COMBlNATlONM R E R
FRONT COMBINATiONLAMP
WATER CONVERTER FRONT COMBlNATlON LAMP
OIL PRESS. HOUR

1111 I,
1111 I!

PARKING BREAK SW

----------
---------W

('
i
s,

NEUTRALSW.

RADIATOR
L N E L SENSOR

I,.
(L,

FUEL CUT-OFF VALVE

(4102.C240)

REAR COMBlNATlONLAMP

FRAME GROUNOING

REAR COMBlNATlONLAMP
GLOW PLUG
\

Fig. 10.13 Wiring Diagram (diese1 engine trucks with clutch)

 I

COMBINAVONM
FRONT COMBINATIONLAMP FRONT COMBlNATlONiAMP

L.-.-.-.-.
PARKING BREAK SW

RADIATOR
LEVEL SENSOR

AIR CLEANER

LlCENCENUMBER ,P;---~-*---
P*TE *MP <L,--- -0 ----
FRAME GROUNOING

L.-._.d

REAR COMBlNATlONLAMP LGLOW

- wPLUG
+-Jh
- -P -P

Fig. 10.14 Wiring Diagram (diese1 engine trucks with torque converter)
 Issued: January 2002

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