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Komatsu FD100-7 Shop Manual

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  • Page 2 PRECAUTIONS WHEN PERFORMING THE SERVICE WORK Always pay attention to “Safety” before starting any work — this is important. Never attempt any work where danger to yourself or to other persons. Whenever work requiring safety precautions are described in this manual, a flag mark inserted, always make double sure that safety measures are taken.
  • Page 3 SECTION INDEX 00. FOREWORD 10. GENERAL AND SPECIFICATIONS 20. TESTING AND ADJUSTING 30. REMOVAL AND INSTALLATION 40. DISASSEMBLY AND ASSEMBLY 50. MAINTENANCE STANDARD 60. STRUCTURE AND FUNCTION 70. TROUBLESHOOTING 80. CONVERSION TABLE 00-3 EX20 Series...

  • Page 5: Table Of Contents

    10. GENERAL AND SPECIFICATIONS Specifications ............10- 2 Periodic replacement of consumable parts .....10- 5 Safety items for maintenance .........10- 6 Standard tightening torque for bolts ......10-14 Standard tightening torque for pipe joints....10-15 10-1 EX20 Series...

  • Page 6: General And Specifications

    SPECIFICATIONS GENERAL AND SPECIFICATIONS SPECIFICATIONS 6˚ 12˚ kg (lb) kg (lb) kg (lb) FD100 FD115 FD135 11500 10000 13500 (29700) 8700 10000 11700 (19140) (22000) (25740) 6800 7900 9300 (17380) (14960) (20460) 5800 7700 (14300) (12760) (16940) 5800 6600 4800 (12760) (14520) (10560)
  • Page 7 GENERAL AND SPECIFICATIONS SPECIFICATIONS Model Manufacturer's Designations FD100-7 FD115-7 FD135-7 Power Type Electric, Diesel, Gasoline, LPG, Cable Diesel Diesel Diesel Operation Type Pedestrian, Drive Standing, Sitting, Order Picking Sitting Sitting Sitting Rated Capacity Rated Capacity kg(lb) 10000(22,000) 11500(25,000) 13500(30,000) Load Center...
  • Page 8 SPECIFICATIONS GENERAL AND SPECIFICATIONS Model Manufacturer's Designations FD150E-7 FD160E-7 Power Type Electric, Diesel, Gasoline, LPG, Cable Diesel Diesel Operation Type Pedestrian, Drive Standing, Sitting, Order Picking Sitting Sitting Rated Capacity Rated Capacity kg(lb) 15000(33,000) 16000(35,000) Load Center Rated Load Center mm(in) 600(24) 600(24)

  • Page 9: Periodic Replacement Of Consumable Parts

    GENERAL AND SPECIFICATIONS PERIODIC REPLACEMENT OF CONSUMABLE PARTS PERIODIC REPLACEMENT OF CONSUMABLE PARTS For operation safety, never fail to perform periodic main- tenance or make periodic replacement of the consum- able parts listed in the following. These parts may deteriorate in time and are susceptible to wear.

  • Page 10: Safety Items For Maintenance

    SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE FOR SAFETY OPERATION USE QUALIFIED PERSONNEL FOR INSPECTION AND MAINTENANCE • Only persons authorized by the owner or operator of the equipment and having proper certification (local or national) may carry out inspection, maintenance and repairs of the lift truck. If inspection, maintenance, or repair work is carried out incorrectly, it is very dangerous.
  • Page 11 GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE USE SUITABLE TOOLS • Always use tools that are suited for inspection and maintenance. It is extremely dangerous to use broken tools or tools designed for another purpose. REPLACE SAFETY CRITICAL PARTS PERIODICALLY •...
  • Page 12 SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS PRECAUTIONS WITH HIGH PRESSURE, HIGH TEMPERATURE OIL • Immediately after using the lift truck, the oil is at high temperature. Do not drain the oil or replace the filter when the oil is hot. Hot oil may spurt out and cause burns. •...
  • Page 13 GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE BE CAREFUL NOT TO GET CAUGHT OR FALL • Never put your hands or feet into the mast structure. There is danger that you will get caught in moving parts and be serious injured. •...
  • Page 14 SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS HANDLING TIRES Disassembly and assembly of tires should be carried out by tire dealer. The tire inflation pressure is extremely high, so caution is needed when handling tires. • The wheel is fitted with mounting nuts. It also has rim nuts and bolts used to join the rim halves. When removing the tire from the lift truck, do not loosen the rim nuts and bolts.
  • Page 15 GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE BATTERY HAZARD PREVENTION • Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill electrolyte on yourself, immediately flush the area with a large quantity of water. •...
  • Page 16 SAFETY ITEMS FOR MAINTENANCE GENERAL AND SPECIFICATIONS PRECAUTIONS WHEN CHARGING When the battery is charged, hydrogen gas is generated and the battery is heated by the chemical change. To prevent the danger of gas explosion, always do as follows. • Carry out the charging operation in a well–ventilated place. •...
  • Page 17 GENERAL AND SPECIFICATIONS SAFETY ITEMS FOR MAINTENANCE HANDLING ANTIFREEZE • Antifreeze can be a flammable. Keep away from flame when handling. • Antifreeze is poisonous, so do not drink it. If you drink it by mistake, drink large amounts of water, vomit it out, and get medical attention immediately.

  • Page 18: Standard Tightening Torque For Bolts

    Select a proper torque corresponding to the width across flats (b) of bolts and nuts. When replacing bolts and nuts, always use genuine Komatsu Forklift parts the same size as the previous ones. Thread diameter Width across...
  • Page 19 GENERAL AND SPECIFICATIONS STANDARD TIGHTENING TORQUE FOR PIPE JOINTS STANDARD TIGHTENING TORQUE FOR PIPE JOINTS Elbows, nipples and unions Width across flats B (mm) Width D (mm) Tightening torqueNm {kgm} 29.4–39.2 {3–4} 78.5–103 {8–10.5} 117.7–161.8 {12–16.5} Port size (inch) 3/4–16UNF 7/8–14UNF –...
  • Page 21 20. TESTING AND ADJUSTING Service data .............20- 2 Engine..............20- 4 Air cleaner..............20- 6 Adjusting of valve clearance ........20- 7 Tightening torque of cylinder head......20- 8 Fuel injection timing ..........20- 9 Adjusting accelerator pedal........20-11 Adjusting brake/inching pedal ........20-12 Adjusting paring brake ..........20-13 TORQFLOW transmission case.......20-14 Differential case ............20-15 Bleeding air ..............20-16...

  • Page 22: Testing And Adjusting

    SERVICE DATA TESTING AND ADJUSTING SERVICE DATA Component Inspection item Unit FD100 FD115 FD135 FD150E FD160E Engine model – Isuzu 6BG1T Idling speed 600–700 Max. speed 2,350–2,450 Engine proper Torque converter stall speed 2,000 Compression 2.5 min. {26} min./200 {kgcm } rpm Quantity of engine oil Lubricating and...
  • Page 23 TESTING AND ADJUSTING SERVICE DATA Component Check item Unit FD100 FD115 FD135 FD150E FD160E Steering wheel Play 30–60 Rear axle Min. swing radius 4,000 4,300 4,350 4,500 Stroke 120–125 Inching pedal Interlocking stroke Play 2–6 Brake pedal Stroke Quantity of brake fluid 0.15 Operating effort of parking Min.

  • Page 24: Engine

    ENGINE TESTING AND ADJUSTING ENGINE CAUTION Stop the engine and wait until its temperature low- ers sufficiently before staring its maintenance. 1. CHANGE ENGINE OIL 1) Remove the drain plug and drain the oil. After draining the all oil, tighten the drain plug. 2) Supply engine oil by the specified quantity.
  • Page 25 TESTING AND ADJUSTING ENGINE 3. REPLACEMENT FUEL FILTER 1) Remove the filter cartridge with a filter wrench. 2) Fill a new cartridge with fuel and apply engine oil thinly to its packing, then install it. 3) Loosen plug and move knob up and down until bubbles do not come out any more.

  • Page 26: Air Cleaner

    AIR CLEANER TESTING AND ADJUSTING AIR CLEANER CAUTION • Never clean or replace the air cleaner while the engine is running. • If compressed air is used to clean the element, dust will fly and there is danger that it may get into your eyes, so always wear safety goggles.

  • Page 27: Adjusting Of Valve Clearance

    TESTING AND ADJUSTING ADJUSTING OF VALVE CREARANCE ADJUSTING OF VALVE CREARANCE Bring the first or sixth piston to the compression top dead center (T.D.C). Rotate the crankshaft forward to match the “T.D.C. line” of the pulley damper to the “pointer”. At this time, check that there is “clearance”...

  • Page 28: Tightening Torque Of Cylinder Head

    TIGHTENING OF CYLINDER HEAD TESTING AND ADJUSTING TIGHTENING OF CYLINDER HEAD 1. TIGHTENING BY ANGLE METHOD Generally, tightening torque is indicated to tighten each bolt and nut at present. If the bolts and nuts are tightened to the indicated torque, however, the axial tension is dispersed largely for the indicated torque, however. Accordingly, if a bolt is tightened to obtain the necessary minimum axial tension, it may be broken at the upper limit value.

  • Page 29: Fuel Injection Timing

    TESTING AND ADJUSTING FUEL INJECTION TIMING FUEL INJECTION TIMING 1. TESTING OF INJECTION TIMING (1) Match the “T.D.C. mark” (top dead center mark)of the crankshaft pulley to the “pointer”. When the “pointer” is matched to the “T.D.C. mark”, if the stamp line on the injection pump plate is matched to the pointer on the timing gear case cover, the injection pump is installed normally.
  • Page 30 FUEL INJECTION TIMING TESTING AND ADJUSTING 3. ADJUSTING OF INJECTION TIMING In the case of the flange mount type, loosen the clamping nuts (4 pieces) of the injection pump hous- ing and pump bracket with the special tool, then change the mounting angle of the injection pump to adjust the injection timing.

  • Page 31: Adjusting Accelerator Pedal

    TESTING AND ADJUSTING ADJUSTING ACCELEATOR PEDAL ADJUSTING ACCELEATOR PEDAL 1. Pedal height (from floor plate) Adjust with turnbuckle (1). Pedal height h 137 mm (5.4 in) 2. Stroke Adjust with stopper bolt (2). ( : 61 mm (2.4 in)) Stroke 57 mm (2.2 in) 3.

  • Page 32: Adjusting Brake/Inching Pedal

    ADJUSTIN BRAKE/INCHING PEDAL TESTING AND ADJUSTING ADJUSTIN BRAKE/INCHING PEDAL BRAKE PEDAL 1. Pedal height (from floor plate) Adjust with stopper bolt (1). Pedal height (h1) 234 mm (9.21 in) 2. Valve clearance and pedal play After adjusting the pedal height, adjust the clearance of the valve plunger head and bolt with bolt (2).

  • Page 33: Adjusting Paring Brake

    TESTING AND ADJUSTING ADJUSTING PARING BRAKE ADJUSTING PARING BRAKE ADJUST OPERATING EFFORT OF LEVER Adjustment bolt Release the parking brake (push the lever forward). Adjust the operating effort of the lever with turning the adjusting bolt Operating effort of lever 196 N {20 kgf} ADJUSTING CLEARANCE Turn the adjustment wheel in the direction to expand...

  • Page 34: Torqflow Transmission Case

    TORQFLOW TRANSMISSION CASE TESTING AND ADJUSTING TORQFLOW TRANSMISSION CASE CHANGING OIL, CLEANING STRAINER CAUTION Remove the drain plug, drain the oil, then tighten the The oil is at high temperature immediately after drain plug. stopping work. Wait for the temperature to go down before starting the operation.

  • Page 35: Differential Case

    TESTING AND ADJUSTING DIFFERENTIAL CASE DIFFERENTIAL CASE CAUTION The oil is at high temperature immediately after stopping work. Wait for the temperature to go down before starting the operation. CHECKING OIL LEVEL Remove the level plug and check that the oil is near the bottom edge of the plug hole.

  • Page 36: Bleeding Air

    BLEEDING AIR TESTING AND ADJUSTING BLEEDING AIR BRAKE PIPING Remove the cap from the air bleed plug, fit one end of a vinyl hose, and put the other end of the vinyl hose in a container of brake fluid. Loosen the air bleed plug approx. 3/4 turns, then depress the brake pedal.

  • Page 37: Hydraulic Tank

    TESTING AND ADJUSTING HYDRAULIC TANK HYDRAULIC TANK CHANGE OIL IN HYDRAULIC TANK CLEAN HYDRAULIC TANK STRAINER CLEAN INSIDE OF HYDRAULIC TANK REPLACE HYDRAULIC LINE FILTER CARTRIDGE CAUTION The oil is at high temperature immediately after stopping work. Wait for the oil to cool down before starting the operation.

  • Page 38: Measuring Hydraulic Drift Of Lift Cylinder, Tilt Cylinder

    MEASURING HYDRAULIC DRIFT OF LIFT CYLINDER, TILT CYLINDER TESTING AND ADJUSTING MEASURING HYDRAULIC DRIFT OF LIFT CYLINDER, TILT CYLINDER PRECAUTIONS WHEN MEASURING When measuring, never let anyone go under the load. Do not put your feet on the mast stays or dashboard and climb up when measuring the hydraulic drift of the lift cylin- der.

  • Page 39: Oil And Greasing Chart

    OIL AND GREASING CHART (OIL, GREASE LOCATIONS TESTING AND ADJUSTING AND INSPECTION AND MAINTENANCE INTERVALS) OIL AND GREASING CHART (OIL, GREASE LOCATIONS ANDINSPECTION AND MAINTENANCE INTERVALS) Caution Symbol Type of fluid Check and add fluid if necessary Diesel engine oil Change or add oil Gasoline engine oil The figure in...

  • Page 40: Lubricant List

    TESTING AND ADJUSTING LUBRICANT LIST NOTICE: • Never use fuel mixed with kerosene. • Always use genuine Komatsu Forklift oil and grease. (Oil, grease, and anti–freeze are available from Komatsu Forklift distributors) Ambient temperature Type of fluid Capacity Lubrication point 86˚F 30˚C...

  • Page 41: Check Items For Each Equipment

    TESTING AND ADJUSTING CHECK ITEMS FOR EACH EQUIPMENT CHECK ITEMS FOR EACH EQUIPMENT Note: The numbers in the inspection item column corresponds to the numbers in “Special Self Inspection Record Table (UCE–02)”. Com- Inspection item Nature of inspection ponent Ease of starting, •...
  • Page 42 CHECK ITEMS FOR EACH EQUIPMENT TESTING AND ADJUSTING Com- Inspection item Nature of inspection ponent Cylinder head Loose cylinder head mounting bolts For details of the tightening torque and method for tightening the cylinder head mounting bolts for each engine, see TESTING AND ADJUSTING. Valve clearance Valve clearance Unit: mm (in)
  • Page 43 TESTING AND ADJUSTING CHECK ITEMS FOR EACH EQUIPMENT Com- Inspection item Nature of inspection ponent Spray condition, 1. Spray condition injection timing Check the spray condition of the injection nozzle. If defective: Remove the nozzle from the holder, clean off any carbon stuck to it, then wash it in diesel oil.
  • Page 44 CHECK ITEMS FOR EACH EQUIPMENT TESTING AND ADJUSTING Com- Inspection item Nature of inspection ponent 13. Fuel system Check for the following. 1. Leakage of fuel 2. Damage, deterioration of hoses and pipes 3. Fuel filter The condition cannot be judged visually, so replace the filter periodically. For details of the method of replacing the fuel filter, see TESTING AND ADJUSTING.
  • Page 45 TESTING AND ADJUSTING CHECK ITEMS FOR EACH EQUIPMENT Com- Inspection item Nature of inspection ponent 17. Fan, fan belt 1. Fan belt 1) Wear and damage of fan belt • Check the inside of the belt, too. • If the bottom of the pulley is lustrous, replace the fan belt since it slips easily.
  • Page 46 CHECK ITEMS FOR EACH EQUIPMENT TESTING AND ADJUSTING Com- Inspection item Nature of inspection ponent 19. Spark plug, ignition –Not applicable for this model– timing (gasoline engine truck) 20. Alternator, wring Check the following. 1. Specific gravity of battery electrolyte Be careful when handling the bat- tery electrolyte.
  • Page 47 TESTING AND ADJUSTING CHECK ITEMS FOR EACH EQUIPMENT Com- Inspection item Nature of inspection ponent 22. Transmission 1. Directional lever 1) Check that there is no play at the neutral position. 2) Check ease of shifting gear, check for play at gear position. 2.
  • Page 48 CHECK ITEMS FOR EACH EQUIPMENT TESTING AND ADJUSTING Com- Inspection item Nature of inspection ponent 22. Transmission 4. Inching pedal (continued) 1) Movement of inching spool Movement (a) 20 mm (0.79 in) For details of the method of adjustment, see TESTING AND ADJUSTING.
  • Page 49 TESTING AND ADJUSTING CHECK ITEMS FOR EACH EQUIPMENT Com- Inspection item Nature of inspection ponent 23. Torque converter For the following inspection, block the wheels of the lift truck and apply the parking securely. 1. Clutch actuation pressure Place the directional lever at FORWARD or REVERSE, depress the accelerator pedal, and measure the pressure.
  • Page 50 CHECK ITEMS FOR EACH EQUIPMENT TESTING AND ADJUSTING Com- Inspection item Nature of inspection ponent 24. Drive shaft 1. Oil leakage from seal of connecting part (case) 2. Play, damage to shaft and spider 3. Loose, damaged, missing spider connecting bolts 25.
  • Page 51 TESTING AND ADJUSTING CHECK ITEMS FOR EACH EQUIPMENT Com- Inspection item Nature of inspection ponent 27. Front axle 1. Deformation, cracks, damage Check visually or use the crack detector method. (Be particularly careful to check the weld and area around the mounting bolts with the main frame.) 2.
  • Page 52 CHECK ITEMS FOR EACH EQUIPMENT TESTING AND ADJUSTING Com- Inspection item Nature of inspection ponent 30. Wheel 1. Loose hub nut Hub nut tightening torque Unit: Nm {kgm} Front wheel Rear wheel 441.5–539.5 {45–55} 441.5–539.5 {45–55} 2. Deformation, cracks in rim, side ring Check visually or use the crack detector method.
  • Page 53 TESTING AND ADJUSTING CHECK ITEMS FOR EACH EQUIPMENT Com- Inspection item Nature of inspection ponent 31. Steering wheel 1. Shaking, pulling, dragging 2. Operating effort Play Play30–60 mm {1.2–2.4 in} Play (At engine idling) Adjustment: Adjust at gear box 3. Looseness, play 32.
  • Page 54 CHECK ITEMS FOR EACH EQUIPMENT TESTING AND ADJUSTING Com- Inspection item Nature of inspection ponent 35. Left, right turning Minimum turning radius radius 1) Have an assistant operate the truck and turn it so that the turning radius is the minimum. 2) Fit chalk to a stick, put the stick in contact with the outermost portion of the counterweight, and draw a circle on the road surface.
  • Page 55 TESTING AND ADJUSTING CHECK ITEMS FOR EACH EQUIPMENT Com- Inspection item Nature of inspection ponent 39. Travel brake 1. Brake pedal 1) Pedal height 234 mm Height When free (h) (9.21 in) 2) Play 2–6 Nm Play (0.08–0.24 in) 2. Braking effect Drive the lift truck on a flat, dry, paved road surface at full speed, then apply the brake suddenly and check for the following.
  • Page 56 CHECK ITEMS FOR EACH EQUIPMENT TESTING AND ADJUSTING Com- Inspection item Nature of inspection ponent 43. Oil brake 1. Actuation of air master, wheel cylinder Operate the brake pedal and check following. 1) Operating effort when depressing brake 2) Changes in operating effort 3) Change in position of pedal when pedal is kept depressed 4) Return of pedal when it is released 2.
  • Page 57 TESTING AND ADJUSTING CHECK ITEMS FOR EACH EQUIPMENT Com- Inspection item Nature of inspection ponent 47. Brake drum Cracks, damage, wear of drum Measure the following dimensions and check that they are within the ser- vice limit. Item FD100/115 FD135/150E/160E Inside diame- Within 393.7 mm Within 438 mm...
  • Page 58 CHECK ITEMS FOR EACH EQUIPMENT TESTING AND ADJUSTING Com- Inspection item Nature of inspection ponent 53. Fork (1) 1. Deformation, cracks, wear at fork stopper pin 2. Check that the opening of the fork tips and difference in height are within the specified range.
  • Page 59 TESTING AND ADJUSTING CHECK ITEMS FOR EACH EQUIPMENT Com- Inspection item Nature of inspection ponent 57. Fork carriage 1. Deformation, cracks, damage to fork carriage 2. Wear, play in roller 3. Cracks in roller shaft 58. Lift chain 1. Tension Set the mast perpendicular, raise the forks approx.
  • Page 60 CHECK ITEMS FOR EACH EQUIPMENT TESTING AND ADJUSTING Com- Inspection item Nature of inspection ponent 62. Hydraulic tank 1. Oil leakage 2. Oil level Check the oil level with the oil level gauge and add oil if necessary. (Check the dirtiness of the oil also.) 3.
  • Page 61 TESTING AND ADJUSTING CHECK ITEMS FOR EACH EQUIPMENT Com- Inspection item Nature of inspection ponent 68. Tilt cylinder 1. Actuation, oil leakage 2. Dents, cracks, curvature, scratches on rod 3. Tightening torque for mounting bolts 54–123 Nm {5.5–12.5 kgm} 70. Attachment 1.
  • Page 62 CHECK ITEMS FOR EACH EQUIPMENT TESTING AND ADJUSTING Com- Inspection item Nature of inspection ponent 74. Solenoid valve 1. Actuation, abnormal noise 2. Abnormal generation of heat 3. Oil leakage 20-42 EX20 Series...
  • Page 63 TESTING AND ADJUSTING CHECK ITEMS FOR EACH EQUIPMENT Com- Check item Details of check ponent 75. Chassis frame, 1. Cracks, deformation chassis 2. Loose, missing mounting bolts, nuts 76. Cab 1. Cracks, deformation 2. Corrosion, leakage of rain 3. Opening/closing of door, lock, play, breakage 77.
  • Page 65 30. REMOVAL AND INSTALLATION General locations ............30- 2 Weight table ............30- 4 Flow chart ...............30- 5 Removal and installation of unit ......30- 6 Mast ................30- 8 Power train ..............30-10 Brake system ............30-12 Hydraulic system.............30-13 Electrical system .............30-14 Adjusting of peal .............30-15 30-1 EX20 Series...

  • Page 66: Removal And Installation

    GENERAL LOCATIONS REMOVAL AND INSTALLATION GENERAL LOCATIONS 30-2 EX20 Series...
  • Page 67 REMOVAL AND INSTALLATION GENERAL LOCATIONS GENERAL LOCATIONS System Removal installation Inspection Adjustment Page Mast 40–77 20–38 Lift cylinder 40–62 20–18, 50–25 Tilt cylinder 40–64 21–18, 50–26 Brake valve 40–47 50–17 Hydraulic control valve 40–73 50–22 Front wheel 30–7 20–31, 32 Forks –...

  • Page 68: Weight Table

    WEIGHT TABLE REMOVAL AND INSTALLATION WEIGHT TABLE Unit: kg FD100 FD115 FD135 FD150E FD160E Remaks Engine assembly Torque converter assembly Transmission assembly Front Excluding frontwheel Axle Excluding power Rear steering cylinder Front Wheel (each) Rear Over head guard Counterweight 4,330 5,390 5,790 6,670...

  • Page 69: Flow Chart

    REMOVAL AND INSTALLATION FLOW CHART FLOW CHART REMOVAL AND INSTALLATION 30-5 EX20 Series...

  • Page 70: Removal And Installation Of Unit

    REMOVAL AND INSTALLATION OF UNIT REMOVAL AND INSTALLATION OF UNIT REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION OF UNIT 54–117 Nm {5.5–12 kgm} 34.3–73.5 Nm {3.5–7.5 kgm} 980.5–1,373 Nm {100–140 kgm} 34.3–73.5 Nm {3.5–7.5 kgm} 824–1,030 Nm {84–105 kgm} 30-6 EX20 Series...
  • Page 71 REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION OF UNIT REMOVAL AND INSTALLATION OF UNIT 27.5–34.3 Nm {2.8–3.5 kgm} Apply LOCTITE to threads. 54–88 Nm {5.5–9 kgm} 15–28 Nm {1.5–3.5 kgm} 15–28 Nm {1.5–3.5 kgm} 157–196 Nm {16–20 kgm} 15–28 Nm {1.5–3.5 kgm} 8.8–14.7 Nm {0.9–1.5 kgm} 490–607 Nm...

  • Page 72: Mast

    MAST REMOVAL AND INSTALLATION MAST Support with wooden blocks to prevent fork carriage from dropping. 30-8 EX20 Series...
  • Page 73 REMOVAL AND INSTALLATION MAST 54–118 Nm Method for bleeding air from lift cylinder {5.5–12 kgm} (1) Start the engine and run at low idling. (2) Raise and lower the mast. Stop the mast approx. 100 mm before reaching Inner mast the max.

  • Page 74: Power Train

    POWER TRAIN POWER TRAIN REMOVAL AND INSTALLATION POWER TRAIN (3) Centering of drive shaft (1) Rear axle support busing Direct oil hole of bushing up. 5 mm max. (in both vertical and Deviation lateral directions) (4) Centering of engine mount (2) Power steering cylinder 5 mm max.
  • Page 75 REMOVAL AND INSTALLATION POWER TRAIN POWER TRAIN 20 Nm {2 kgm} 27–34 Nm {2.8–3.5 kgm} 20 Nm {2 kgm} 59–74 Nm {6–7.5 kgm} 1,961–2,452 Nm {200–250 kgm} 30-11 EX20 Series...

  • Page 76: Brake System

    BRAKE SYSTEM REMOVAL AND INSTALLATION BRAKE SYSTEM Method of bleeding air (1) Remove the cap from the air bleed plug, fit one end of a vinyl hose, and put the other end of the vinyl hose in a container of brake fluid. (2) Loosen the air bleed plug approx.

  • Page 77: Hydraulic System

    REMOVAL AND INSTALLATION HYDRAULIC SYSTEM HYDRAULIC SYSTEM CAUTION • Fit blind plugs immediately after removing the hydraulic piping or hydraulic equipment. • Do not remove the hydraulic tank cap or radiator cap immediately after stopping operations. Hot gas or steam will spurt out.

  • Page 78: Electrical System

    ELECTRICAL SYSTEM REMOVAL AND INSTALLATION ELECTRICAL SYSTEM Water temp. Air cleaner Stop lamp Speed meter sensor sensor T/C oil sensor switch T/M valve sensor Fuel level Brake oil Coolant level Parking brake sensor switch switch switch 30-14 EX20 Series...
  • Page 79 REMOVAL AND INSTALLATION ADJUSTMENT OF PEDAL ADJUSTMENT OF PEDAL BRAKE PEDAL 1. Pedal height from floor plate Adjust with stopper bolt mm (in) Pedal height (h1) 234 mm (9.21 in) 2. Pedal play After adjusting the pedal height, adjust the pedal play by adjusting the cable position mm (in) Pedal play...
  • Page 80 ADJUSTMENT OF PEDAL REMOVAL AND INSTALLATION PARKING BRAKE Adjustment bolt Operating force of lever Max. 20 kg {196 N} Adjusting clearance (1) Turn the adjustment screw to bring the lining into tight contact with the brake drum. (2) Turn the adjustment screw back 11 notches so that the clearance between the drum and lining is 0.25 ACCELERATOR PEDAL 1.
  • Page 81 REMOVAL AND INSTALLATION ADJUSTMENT OF PEDAL WORK EQUIPMENT CONTROL LEVER Connect the yoke portion of link (A) and the control valve with pin (F). Insert a cotter pin into the pin and bend it to hold in position. (Link length: 484 mm) Align both the lift and tilt levers with bracket (B), insert support pin (C), then tighten bolt (D).
  • Page 83 40. DISASSEMBLY AND ASSEMBLY Torque converter ............40- 2 TORQFLOW transmission ........40- 9 Hydraulic pump ............40-31 Drive axle ..............40-32 Differential ..............40-35 Steering axle ............40-42 Parking brake ............40-44 Wheel brake .............40-45 Steering system ............40-52 Brake valve...............40-47 Steering system ............40-52 Lift cylinder...............40-62 Tilt cylinder...............40-64 Power steering cylinder ..........40-71 Control valve ............40-73 Mast .................40-77...

  • Page 84: Disassembly And Assembly

    TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER The numbers show the order for disassembly 40-2 EX20 Series...
  • Page 85 DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER 40-3 EX20 Series...
  • Page 86 TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY INSPECTION Judgement standard Symbol Inspection item Remedy Standard size Repair limit (mm) (mm) Wear of pilot boss (tip) 24.85 Pump boss inner diameter (seal ring contact surface) 80.15 Width 2.93 Seal ring Thickness 2.45 Stator shaft inner diameter (seal ring contact surface) 45.15 Width 1.93...
  • Page 87 DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER ASSEMBLY 1. Assembly of idler gear and shaft Assemble bearing (2) to idler gear (1), then set in the case. Assemble idler shaft (3) to the idler gear. Secure the idler shaft to the case with lock plate (4) and bolt (5). 35.3–44.1 Nm {3.6–4.5kgm} 2.
  • Page 88 TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY 2) Installation of stator shaft Using tightening bolt (1) [M12, P1.75], mesh the idler gear and pump boss gear and install to the case. 67.6–78.4 Nm {6.9–8 kgm} 3. PTO driven gear 1) Assemble bearing (1). 2) Mesh driven gear (2) with the idler gear and assemble.
  • Page 89 DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER 5. Stator 1) Assemble the collar, trust washers (1) and (2), stator, and thrust washers (3) and (4) in turn. 2) Set the tab of lock washer (5) facing the outside, and insert. 3) Secure the stator with ring nut (6). (Check that the stator rotates lightly when doing this.) 4) Secure the ring nut with the tab of the lock washer.
  • Page 90 TORQUE CONVERTER DISASSEMBLY AND ASSEMBLY 8. Hydraulic pump (torque converter charge pump) 1) Install hydraulic pump (1) (FAL3–045). 2) Tighten with bolt (2). 35.3–44.1 Nm {3.6–4.5 kgm} 9. Oil strainer 1) Assemble the oil strainer in the case. 2) Tighten with bolt (1). 35.3–44.1 Nm {3.6–4.5 kgm} 40-8 EX20 Series...

  • Page 91: Torqflow Transmission

    DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION TORQFLOW TRANSMISSION Hydraulic pump Torque converter pump 40-9 EX20 Series...
  • Page 92 TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION Gasket Transmission Torque converter 59–73.5 Nm {6–7.5 kgm} 40-10 EX20 Series...
  • Page 93 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION CONTROL VALVE (SOLENOID VALVE) Protrusion inching spool 20 mm (0.79 in) (Solenoid valve) Actuating voltage (V) Standard 29 mm Range 22–26 V (Inching spool) Torque converter Mounting bolts Insufficient tightening: Oil leakage Over tightening: Defective operation of spool 40-11 EX20 Series...
  • Page 94 TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY HYDRAULIC SYSTEM DIAGRAM 40-12 EX20 Series...
  • Page 95 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION From line filter F/R clutch Main pressure T/C oil pressure To cooler 1 1/16-12 UNF pressure port measurement port 7/8-14 UNF measurement port 1, 2, 3 speed clutch pressure port Oil level Air breather gauge Oil filler cap To line filter PF 3/4...
  • Page 96 TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY DISASSEMABLY 1. TORQFLOW transmission Lifting equipment After completion of the operation for removing the TORQFLOW transmission assembly from the chas- sis, wash the case and the area surrounding the accessory parts, then remove the following parts. •...
  • Page 97 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION (3) Disassemble the torque converter case and transmission case. • Loosen all the bolts connecting the cases (a Lifting equipment clearance of 2–3 mm is generated when the case is disconnected). • Raise the lifting equipment slightly to apply tension to the wires of the lifting equipment (do not raise the assembly from the ground).
  • Page 98 TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY 2. Clutch shaft sub assembly (Hoist) 1) Remove the 1st/2nd and 3rd clutch shaft sub assemblies. • Set the special tools to the shaft sub assem- blies. • Fit the lifting tool to the eyebolts. Lifting equipment •...
  • Page 99 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 2) Remove the FORWARD/REVERSE clutch shaft sub assembly (Remove the 1st/2nd and 3rd clutch shaft sub assemblies first.) (Hoist) • Wind a wire around the reverse clutch shaft. • Fit the lifting equipment to the wire. •...
  • Page 100 TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CLUTCH PACK ASSEMBLY (Example: 1st/2nd) The numbers indicate the order of disassembly. (1st side) Transmission case Torque converter (2nd side) CAUTION If the snap rings (13 and 14 in diagram above) used to hold the piston and return spring are removed, the force of the spring will be brought to bear and this will cause a dangerous condition.
  • Page 101 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION INSPECTION Judgement standard Symbol Inspection item Remedy Standard size Repair limit (mm) (mm) Wear of pilot boss (tip) 24.85 Pump boss inner diameter (seal ring contact surface) 80.15 Width 2.93 Seal ring Thickness 2.45 Stator shaft inner diameter (seal ring contact surface) 45.15 Width 1.93...
  • Page 102 TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY DETAL OF CLUTCH PACK Plate Plate 7 6 5 4 3 2 1 1 2 3 4 5 6 7 Plate Plate Plate (Shaft) Seal Piston Seal Snap ring Spacer Piston ring Spacer Snap ring Spring Spring Disk...
  • Page 103 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION PRECAUTIONS WHEN ASSEMBLING 1. Clutch pack assembly Blow compressed air into the oil hole to check the operation of the drive plate and driven plate. Air pressure 5 kg/cm Stroke 2.8 mm 2. Solenoid valve Tighten the mounting bolts in the order shown in the diagram on the right.
  • Page 104 TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY CONNECTORS FOR SOLENOIDVALVES CONNECTING DWG. F: 3(+), 4(-) FR VALVE R: 1(+), 2(-) 1st/2nd 1(+), 2(-) VALVE 3rd VALVE 1(+), 2(-) 1st/2nd VALVE FR VALVE 3rd VALVE Solenoid valve Inching spool 1, 2 speed 3rd, output 40-22 EX20 Series...
  • Page 105 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ASSEMBLY OF F/R (INPUT SHAFT) SHAFT SUB ASSEMBLY (Reassemble in the opposite order to disassembly.) Soak the clutch plates and discs in clean oil before assembly. Coat the seal ring with grease. (Reverse end) Torque converter (Forward end) 40-23 EX20 Series...
  • Page 106 TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY 1 9 10 11 (Reverse end) (Forward end) 32 33 8 12 13 14 16 17 15 18 19 20 21 22 Order Main F/R shaft A (FORWARD end) (REVERSE end) assembly Assemble seal to shaft assembly (F/R) Install seal ring to piston (F/R) Assemble piston to drum while checking concave Assemble spring...
  • Page 107 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ASSEMBLY OF 1ST/2ND SHAFT ASSEMBLY (Reassemble in the opposite order to disassembly.) Soak the clutch plates and discs in clean oil before assembly. Coat the seal ring with grease. (1st end) Transmission case Torque converter (2nd end) 40-25 EX20 Series...
  • Page 108 TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY 2 8 1 9 10 11 (2nd end) (1st end) 13 14 15 16 17 18 19 20 21 22 Order Main 1st/2nd shaft B (2nd end) (1st end) assembly Assemble seal to shaft assembly (1st/2nd) Install seal ring to piston (1st/2nd) Assemble piston to drum Assemble spring...
  • Page 109 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION ASSEMBLY OF 3RD (OUTPUT SHAFT) SHAFT SUB ASSEMBLY (Reassemble in the opposite order to disassembly.) Soak the clutch plates and discs in clean oil before assembly. Coat the seal ring with grease. Coat the oil seal and lip portion with grease. Transmission case (3rd end) Torque converter...
  • Page 110 TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY 3rd, output shaft 2 3 1 7 9 10 4 5 6 1213 14 15 16 17 Order Main 3rd shaft C assembly Assemble seal to shaft Install seal ring to piston Assemble piston to drum Assemble spring Assemble spacer Fix with snap ring...
  • Page 111 DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION 2. Clutch shaft sub assembly 1) Assemble the 1st/2nd and 3rd clutch shaft sub (Hoist) assemblies. Assemble the 1st/2nd and 3rd clutch shaft sub assemblies together as a set. • Set the special tools to the shaft sub assemblies. Lifting equipment •...
  • Page 112 TORQFLOW TRANSMISSION DISASSEMBLY AND ASSEMBLY 2) Assemble the F/R clutch shaft sub assembly. Assemble the 1st/2nd and 3rd clutch shaft sub assemblies first, then assemble the F/R clutch shaft sub assembly. • Wind a wire around the reverse clutch shaft. (Hoist) •...

  • Page 113: Hydraulic Pump

    DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP HYDRAULIC PUMP 1. Hydraulic pump and power steering pump The hydraulic pump and power steering pump are connected as a unit, and are driven by the torque converter PTO system. Work Item Radius Steering equipment Name of pump –...

  • Page 114: Drive Axle

    DRIVE AXLE DISASSEMBLY AND ASSEMBLY DRIVE AXLE FD100 FD115 FD135/150E FD160E Type Fixed single shaft full–floating type Reduction gear Planetary gear type Reduction ratio Tread 1,695 1,875 1,766 1,771 40-32 EX20 Series...
  • Page 115 DISASSEMBLY AND ASSEMBLY DRIVE AXLE DRIVE AXLE (Front Hub) Hub starting friction torque: 20–39 Nm {200–400 kgcm} 40-33 EX20 Series...
  • Page 116 DRIVE AXLE DISASSEMBLY AND ASSEMBLY FRONT AXLE 40-34 EX20 Series...

  • Page 117: Differential

    DISASSEMBLY AND ASSEMBLY DIFFERENTIAL DIFFERENTIAL Special tool 34B–97–9910 40-35 EX20 Series...
  • Page 118 DIFFERENTIAL DISASSEMBLY AND ASSEMBLY INSPECTION Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Backlash 0.15–0.20 – Replace Outside diameter of spider 24.959–24.998 24.75 Inside diameter of pinion gear 25.000–25.021 25.12 1.94–2.06 Replace Thickness of bushing 1.52–1.68 Outside of brake drum 216.0–216.2 218.2...
  • Page 119 DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ADJUSTING PINION SHAFT SHIM 1. Calculate values of dimensions 1) Read value displayed at the tip of the pinion shaft. 2) Measure dimension t when the preload on bear- ing 06002–30311 is 58,840 N {600 kg} and sub- tract 31.5 to obtain value in units of 1/100.
  • Page 120 DIFFERENTIAL DISASSEMBLY AND ASSEMBLY DIFFERENTIAL SUPPORT BEARING Adjust the backlash of the ring gear and pinion gear. 0.20–0.28 mm Backlash (0.008–0.011 in) Assemble to make the backlash 0.2 mm, cons- iclesing it will increase during the initial running in period. Procedure for adjusting backlash To adjust the backlash, loosen one adjustment screw 1 notch and tighten the other screw 1 notch.
  • Page 121 DISASSEMBLY AND ASSEMBLY DIFFERENTIAL Checking tooth contact Coat the tooth face of the bevel pinion lightly with red FORWARD side lead (minimum). Rotate the bevel gear forward and backward. iii) Inspect the pattern left on the teeth. iv) If the result of the inspection shows that the correct tooth contact is not being obtained, adjust again as follows.
  • Page 122 DIFFERENTIAL DISASSEMBLY AND ASSEMBLY Adjusting tooth contact Inspect the shim thickness at the pinion shaft to move the pinion in direction A closer to the bevel gear. Then move the bevel gear away from the pinion gear in direction B. Adjust the backlash again.
  • Page 123 DISASSEMBLY AND ASSEMBLY DIFFERENTIAL Reduction gear type Hypoid bevel gear set Reduction ratio 4.375 Oil capacity 40-41 EX20 Series...

  • Page 124: Steering Axle

    STEERING AXLE DISASSEMBLY AND ASSEMBLY STEERING AXLE Adjusting alignment Toe–in Camber Castor King pin angle 1,900 (10 t) Tread 1,890 (11.5 t–15 t) 1,870 (16 t) Toe–in L Tire turning angle Adjust the left and right stopper bolts so that turning angle is 76°...
  • Page 125 DISASSEMBLY AND ASSEMBLY STEERING AXLE 40-43 EX20 Series...

  • Page 126: Parking Brake

    PARKING BRAKE DISASSEMBLY AND ASSEMBLY PARKING BRAKE Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Lining Thickness 152 N {15.5 kg} 137 N {14 kg} Strength Replace = 50 mm) = 50 mm) Shoe return spring Free length 54.7 mm 40-44...

  • Page 127: Wheel Brake

    DISASSEMBLY AND ASSEMBLY WHEEL BRAKE WHEEL BRAKE FD100/115 Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Lining Thickness 12.7 33 ± 3.3 kgf 33 ± 3.3 kgf = 103.5 mm) = 103.5 mm) Shoe return spring Strength Free length: 93 mm (Reference) Replace...
  • Page 128 WHEEL BRAKE DISASSEMBLY AND ASSEMBLY FD135/150E/160E Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Lining Thickness 12.7 50 ± 5 kgf 42 ± 4 kgf =178 mm) =159 mm) Shoe return spring Strength 169.5 mm Free length: (Reference) 148 mm Replace...
  • Page 129 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE BRAKE VALVE Warning The accumulator circuit is under high hydraulic pressure. It is therefore very dangerous to loosen any connections before releasing this pressure. When removing the accumulator, first stop the engine, then repeatedly (at least 10 times) depress the brake pedal fully.
  • Page 130 WHEEL BRAKE DISASSEMBLY AND ASSEMBLY Fix body in a vice and remove plug Use a hexagonal bar wrench. Width across flats: 17 mm 0.67 in. • Remove O–ring with fingers. When fixing in the vice, be careful not to hold the flow divider mounting face.
  • Page 131 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE • Remove O–ring from valve sub–assembly with fingers. • Remove O–ring from guide with fingers. • Remove O–ring , back–up ring and O–ring from reaction piston with fingers or a hair–pin. ASSEMBLY Clean all parts and dry thoroughly. Coat the O–rings and cup with silicon grease sup- plied with O–ring kit.
  • Page 132 WHEEL BRAKE DISASSEMBLY AND ASSEMBLY Install retainer securely on tip of piston • Install spring , valve sub–assembly and plug in order. Plug 690–1,100 kgcm • Tighten plug by hand. • Fix brake valve in vice and tighten plug again. Install boot in groove of body and groove of nut...
  • Page 133 DISASSEMBLY AND ASSEMBLY WHEEL BRAKE INSPECTION Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Clearance between input piston and diam- – 0.16 eter of body mating portion Clearance between spool and diameter of – 0.032 body mating portion Clearance between reaction piston and di- –...

  • Page 134: Steering System

    STEERING SYSTEM DISASSEMBLY AND ASSEMBLY STEERING SYSTEM FD100/115 FD135/150E/160E Delivery amount 200 cc/rev 250 cc/rev Relief pressure 130 kg/cm Oil flow at inlet port /min 3BA–97–99210 Special tool Valve characteristics Open–center non–reaction type 3BA–97–99220 40-52 EX20 Series...
  • Page 135 DISASSEMBLY AND ASSEMBLY STEERING SYSTEM Housing 10. Ball 19. Screw Sleeve 11. O–ring 20. Bearing Spool 12. Seat 21. Bearing 13. Drive shaft 22. O–ring Spring 14. Plate 23. Seal Spring 15. O–ring 24. Bushing Screw 16. Girotor 25. Ring O–ring 17.
  • Page 136 STEERING SYSTEM DISASSEMBLY AND ASSEMBLY DISASSEMBLY PROCEDURE 1. Removal of relief valve assembly 1) Fit the flange of the column assembly in a vice, loosen bolts (1), and remove the column assem- bly. 2. Removal of Girotor assembly 1) Fit mounting plate (3) in the vice so that the Giro- tor end is at the top, then loosen bolt (4).
  • Page 137 DISASSEMBLY AND ASSEMBLY STEERING SYSTEM 2) Remove the snap ring, take out the bushing and O– ring, push out the sleeve and spool assembly, then remove the bearing. 3) Fix housing (1) with the port surface at the bottom, then pull out the sleeve and spool assemblies (A) from the front end (mounting plate end).
  • Page 138 STEERING SYSTEM DISASSEMBLY AND ASSEMBLY 4. Disassembly of column assembly 1) Fit the flange portion in a vice, remove the steer- ing wheel, then remove the snap ring at the col- umn and flange end. 2) Pull out shaft (18) from the flange end. Bearing (19) is press fitted to the shaft, so do no disassemble it unless there is any malfunction.
  • Page 139 DISASSEMBLY AND ASSEMBLY STEERING SYSTEM ASSEMBLY OF PROCEDURE 1. Assembly of control valve assembly 1) Set the housing on a level wooden block with the the front end (steering column end) at the top. Fit O–ring (11) to the check valve assembly, then screw into the housing.
  • Page 140 STEERING SYSTEM DISASSEMBLY AND ASSEMBLY 5) Set the port surface at the bottom or at the side, and fix the housing in position, then insert the sleeve and spool assembly inside the bore from the spool spline end. When inserting, be careful not to let the straight pin fall inside the housing groove and get caught.
  • Page 141 DISASSEMBLY AND ASSEMBLY STEERING SYSTEM 2. Assembly of Gerotor assembly 1) Prepare bolt (19). 2) Fit O–ring (15) in the groove of the end cover, then pass 2 or 3 bolts through it. 3) Fit O–ring (15) in the groove of the outside part (stator) of the Girotor, then set on the end cover with the O–ring end at the top.
  • Page 142 STEERING SYSTEM DISASSEMBLY AND ASSEMBLY 3. Assembly of column assembly 1) Fit the outside diameter of the column in the vice, coat the outside circumference of the col- umn bushing with grease, then insert inside the column. Be careful that the two protruding parts fit securely in the two protruding parts fit securely in the two holes in the column.
  • Page 143 DISASSEMBLY AND ASSEMBLY STEERING SYSTEM 3) Fit washers on the 7 bolts (19), then tighten the bolts uniformly. 24.5–29.4 {2–3 kgm} 4) Fill the joint of the column assembly shaft spline with grease (Molybdenum Disulphide Bearing Grease No. 2), then assemble the gear box. 5) Tighten the 4 bolts to complete the assembly.

  • Page 144: Lift Cylinder

    LIFT CYLINDER DISASSEMBLY AND ASSEMBLY LIFT CYLINDER 1. Cylinder 2. Piston rod 3. Piston ring 4. Wear ring 5. Cylinder head 6. O-ring 7. Dust seal 8. Rod packing 9. Wear ring 10. Collar 11. O-ring 40-62 EX20 Series...
  • Page 145 DISASSEMBLY AND ASSEMBLY LIFT CYLINDER (Lifting height: 3 m) Item Unit FD100 FD115 FD135/150E 160E Cylinder (inside diameter × outside diameter) 95 × 110 100 × 113 110 × 124 120 × 136 Stroke 1510 Outside diameter of rod Weight INSPECTION Judgement standard Symbol...

  • Page 146: Tilt Cylinder

    TILT CYLINDER DISASSEMBLY AND ASSEMBLY TILT CYLINDER 1. Cylinder 9. Backup ring 2. Piston rod 10. O–ring 3. Cylinder head 11. Piston ring 4. Snap ring 12. Wear ring 5. Dust seal 13. Bushing 6. O–ring 14. Rod head 7. Bushing 15.
  • Page 147 DISASSEMBLY AND ASSEMBLY TILT CYLINDER (lifting height: 3 m) Item Unit FD100–160E Cylinder (inside diameter × outside diameter) 125 × 142 Stroke Outside diameter of rod Three Bond # 1901 910–1110 Nm {93–113.3 kgm} INSPECTION Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm)
  • Page 148 TILT CYLINDER DISASSEMBLY AND ASSEMBLY DISASSEMBLY LIFT, TILT CYLINDER 1. Removal of cylinder head assembly Use a wrench to remove the cylinder head assembly. Outside diameter φ100–120 (FD100,115) Outside diameter φ125–130 For lift cylinder (FD135, 150E) Wrench Outside diameter φ140 (FD160E) Outside diameter φ140 For tilt...
  • Page 149 DISASSEMBLY AND ASSEMBLY TILT CYLINDER 4. Disassembly of cylinder head assembly If the seals are not damaged, do not disassemble them. If they are disassembled, replace them with new parts. 1) Remove the snap ring (tilt cylinder only), then remove the dust seal. 2) Use a screwdriver to remove the U–packing.
  • Page 150 TILT CYLINDER DISASSEMBLY AND ASSEMBLY 3) Compress the U–packing and push in until it enters groove When using a jig to push in Use a jig made of copper, aluminum or plastic and check that there are no burrs or flashes on the U– packing contact surface.
  • Page 151 DISASSEMBLY AND ASSEMBLY TILT CYLINDER 8) Use a press–fitting tool to press fit the dust seal, then install the snap ring (tilt cylinder only). 2. Assembly of piston assembly 1) To prevent damage to the seal, use an oilstone to remove any burrs of flashes at the places marked O in the diagram on the right.
  • Page 152 TILT CYLINDER DISASSEMBLY AND ASSEMBLY 4) Assemble the wear ring. 3. Assembly of piston rod assembly Assemble the piston rod assembly to the cylinder. Be careful not to damage the piston rod assembly seals with the thread of the cylinder. 4.

  • Page 153: Power Steering Cylinder

    DISASSEMBLY AND ASSEMBLY POWER STEERING CYLINDER POWER STEERING CYLINDER Cylinder Rod cover Piston rod O–ring Bushing Retainer ring Piston Dust wiper O–ring U–packing Stopper seal Bushing Retainer ring O–ring Ring Dust cap 40-71 EX20 Series...
  • Page 154 POWER STEERING CYLINDER DISASSEMBLY AND ASSEMBLY (lifting height: 3 m) Item Unit FD100–115 FD135–160E φ 90 x φ 102 φ 100 x φ 112 Cylinder (inside diameter x outside diameter) Stroke φ 60 φ 70 Outside diameter of rod INSPECTION Judgement standard Symbol Inspection item...

  • Page 155: Control Valve

    DISASSEMBLY AND ASSEMBLY CONTROL VALVE CONTROL VALVE DISASSEMBLY AND ASSEMBLY This section describes disassembling and assembling Spool assembly procedures of the representative 3-port relief model. 1) Detach button bolt (41) from lift spool (27) using When disassembling or assembling work varies accord- a 6 mm hexagon key wrench.
  • Page 156 CONTROL VALVE DISASSEMBLY AND ASSEMBLY Plug, oil seal ASSEMBLY 1) Remove three plugs (19) using a 6 mm hexagon Before starting reassembly, adequately wash and key wrench. degrease disassembled parts and prepare new oil seals. 2) Remove three O-rings (58) using a scriber. 3) Remove socket head plug (59) using a 5 mm Plunger hexagon key wrench.
  • Page 157 DISASSEMBLY AND ASSEMBLY CONTROL VALVE Port relief assembly 1) Tighten pilot sleeve (16) assembly to body (37) using a 27 mm spanner. 63.5–77.6 {6.5–7.9 kgm} Spool assembly 1) Hold the width across flats (10 mm) of lift spool (27) in a vice. 2) Install spring holder (28), spring (26), and spring holder (28) in this order to the held lift spool, and then tighten button bolt (41) using a 6 mm hexa-...
  • Page 158 CONTROL VALVE DISASSEMBLY AND ASSEMBLY 40-76 EX20 Series...

  • Page 159: Mast

    DISASSEMBLY AND ASSEMBLY MAST MAST When removing the mast and transporting it horizon- tally, secure the fork carriage and lower stay of the outer mast with wire before transporting. Set wooden blocks under the mast and lay the mast assembly horizontally with the fork carriage at the top.
  • Page 160 MAST DISASSEMBLY AND ASSEMBLY SHIM ADJUSTMENT (1) Strip shim (2) Outer main roller 0.5–1.0 mm 0–0.5 mm Adjust with shims so that Insert the same shim thickness on the left and when the main roller is right to adjust so that pressed against the rail, dimension a=0–0.5 mm clearance b between the...
  • Page 161 DISASSEMBLY AND ASSEMBLY MAST FORK CARRIAGE Shim adjustment (4) 10–ton truck upper roller No shim adjustment is needed for the upper roller or lower roller on trucks other than the 10–ton truck. (Held with snap ring) (5) Side roller (10–ton only) 0.5–1.0 mm Adjust with shims so that clear- ance d between the roller and rail...
  • Page 162 MAST DISASSEMBLY AND ASSEMBLY ADJUSTING CHAIN 1. Chain length Adjust with the chain stopper so that the bottom face of the fork is 15 mm below the ground level when the forks are lowered fully. Tightening torque for chain stopper locknut 824–1030Nm {84–105 kgfm} INSPECTION Judgement standard...

  • Page 163: Table Of Special Tools

    DISASSEMBLY AND ASSEMBLY TABLE OF SPECIAL TOOLS TABLE OF SPECIAL TOOLS Driving in differential pinion shaft oil seal Tightening differential adjusting screw nut 3ED-97-99590 34B-97-99110 Centering drive shaft Rotating differential ring gear 3EE-97-99110 3EB-97-99960 Measuring starting torque of front hub Tightening front axle lock nut 3ED-97-99570 308-968-9110...
  • Page 164 TABLE OF SPECIAL TOOLS DISASSEMBLY AND ASSEMBLY Inserting clutch pack piston Holding, tightening differential pinion shaft a 3ED-97-99151 3EC-97-99030 b 3ED-97-99180 Driving in transmission output shaft bearing, oil seal Inserting steering valve leaf spring 3EE-97-99110 3BA-97-99220 Driving in bearing Assembling steering valve Y-packing 3EB-97-99210 3BA-97-99210 Driving in transmission F shaft, R shaft bearing...
  • Page 165 DISASSEMBLY AND ASSEMBLY TABLE OF SPECIAL TOOLS TABLE OF SPECIAL TOOLS FOR POWER STEERING CYLINDER Press fitting dust wiper Removing and installing bottom assembly screw Material: SCM435 Material: SS41 Heat treatment: Quenching, tempering Piston insertion guide (for FD115/135/150E) Piston inserting guide (for FD100) There must be no burrs or flashes.
  • Page 166 TABLE OF SPECIAL TOOLS DISASSEMBLY AND ASSEMBLY Piston rod cap Material: C3602, C3604 Caulking pin rod tip Material: SK3 Heat treatment: Quenching, tempering 40-84 EX20 Series...
  • Page 167 50. MAINTENANCE STANDARD Engine..............50- 2 Accelerator pedal .............50- 3 Speedmeter sensor..........50- 4 Location of switches and sensors ......50- 5 Torque converter ............50- 7 TORQFLOW transmission ........50- 8 Drive shaft..............50-10 Differential ..............50-11 Final drive ..............50-13 Rear axle..............50-14 Steering..............50-15 Frame...............50-16 Brake................50-17 Hydraulic equipment ..........50-22 Lift cylinder...............50-25 Tilt cylinder...............50-26 Steering cylinder ............50-27...

  • Page 168: Maintenance Standard

    ENGINE MAINTENANCE STANDARD ENGINE Isuzu 6BG1T Criterion Inspection item Remedy Standard size (mm) Repair limit (mm) Fuel injection order BTDC 6° (TRL-01), BTDC 8° (TRL) Firing order 1–5–3–6–2–4 Intake 0.4 (in cold state) Valve clearance Exhaust 0.4 (in cold state) Compression pressure (2 stage type) 2.5 MPa {26 kgf/cm } min./200 rpm...

  • Page 169: Accelerator Pedal

    MAINTENANCE STANDARD ACCELERATOR PEDAL ACCELERATOR PEDAL Engine Full speed 19˚ Idling Criterion Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Adjust with Pedal height stopper bolt (A). Pedal stroke Adjust Depressing effort of pedal 49 N {5.0 kgf} Stopper bolt height (standard) Standard length of intermediate rod Free length of return spring...

  • Page 170: Speedmeter Sensor

    SPEEDOMETER SENSOR (OP) MAINTENANCE STANDARD SPEEDOMETER SENSOR (OP) Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Clearance between sensor and drum Screw in sensor and check that it contacts drum lightly, then turn back one turn and lock in position.

  • Page 171: Location Of Switches And Sensors

    MAINTENANCE STANDARD LOCATION OF SWITCHES AND SENSORS LOCATION OF SWITCHES AND SENSORS Forward/back lever Direction indicator lever High/low lever Starting switch 1.Engine coolant thermometer 2.Torque converter oil thermometer 3.Fuel gauge 4.Engine oil pressure warning lamp 5.Charge warning lamp 6.Hour meter 7.Operation indicator 8.Air cleaner clogging warning lamp 9.Radiator coolant level warning lamp...
  • Page 172 LOCATION OF SWITCHES AND SENSORS MAINTENANCE STANDARD BATTERY STARTING T/C OIL RELLY MOTOR ALTERNATOR SPEED METER T/M VALVE SENSOR COMBI LAMP SPEED SENSOR STOP LAMP SWITCH WATER TEMP SENSOR COOLANT LEVEL SWITCH COMBI LAMP BRAKE OIL OIL PRESS SWITCH PARKING BRAKE E/G STOPPER FUEL AIR PRESS...

  • Page 173: Torque Converter

    MAINTENANCE STANDARD TORQUE CONVERTER TORQUE CONVERTER Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Wear of pilot tip 24.85 Inside diameter of pump boss 80.15 (seal ring contact surface) Width 2.83–2.9 2.65 Seal ring End gap when installed 0.05–0.25 –...
  • Page 174 TORQFLOW TRANSMISSION MAINTENANCE STANDARD TORQFLOW TRANSMISSION Torque converter pump relief pressure: 1.96 MPa {20 kg/cm Clutch actuating pressure: 1.35–1.65 MPa {13–16 kg/cm Judgement standard Symbol Inspection item Remedy Standard size Repair limit (mm) (mm) Wear of pilot boss (tip) 24.85 Pump boss inner diameter (seal ring contact surface) 80.15 Width...

  • Page 175: Torqflow Transmission

    MAINTENANCE STANDARD TORQFLOW TRANSMISSION CONTROL VALVE Inching spool Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Set value for relief pressure 1.96 MPa – (main pressure) {20 kg/cm Transmission actuation pres- 1.37–1.76 MPa – sure {14–18 kg/cm Regulator valve There must be no dents or uneven wear of outside circumference,...

  • Page 176: Drive Shaft

    DRIVE SHAFT MAINTENANCE STANDARD DRIVE SHAFT Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Misalignment of drive shaft Within 5 – Inside diameter of mating portion of bearing and drive shaft There must be Outside diameter, seal contact no scratches on surface at joint boss contact surface...

  • Page 177: Differential

    MAINTENANCE STANDARD DIFFERENTIAL DIFFERENTIAL 50-11 EX20 Series...
  • Page 178 DIFFERENTIAL MAINTENANCE STANDARD Gear oil level: 20 Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Starting torque 392–784.5 Ncm {40–80 kgcm} 3FE–21–15000 Differential and pinion 0.15–0.2 0.15–0.2 Backlash {0.006–0.008 in} {0.006–0.008 in} 24.93–24.98 Outside diameter of spider, pin portrion 24.75 {0.974 in} {0.981–0.98e in} 25.0–25.02...

  • Page 179: Final Drive

    MAINTENANCE STANDARD FINAL DRIVE FINAL DRIVE Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Inside diameter of housing, dowel pin hole 18 {0.709 in} 18 {0.709 in} Outside diameter of housing, dowel pin 18 {0.709 in} 18 {0.709 in} Outside diameter of mast support mount 170 {6.693 in}...

  • Page 180: Rear Axle

    REAR AXLE MAINTENANCE STANDARD REAR AXLE Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Inside diameter of hole at axle king pin boss portion 71.998–72.018 (bearing mating portion) {2.834–2.835 in} 211.8–212.2 Height of inside of axle, king pin boss portion 211.5 {8.327 in} {8.338–8.354 in} 174.5–175.5...

  • Page 181: Steering

    MAINTENANCE STANDARD STEERING STEERING 2˚ 2˚ 68˚ Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Steering wheel play (when idling) 30–60 30–60 Steering wheel tilt angle 2° + 2° 2° + 2° Steering wheel lock lever, lock an- 68°...

  • Page 182: Frame

    FRAME MAINTENANCE STANDARD FRAME Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Inside dimension between rear axle 360 {14.17 in} 365 {14.37 in} and center support Size of center support bushing 80 × 93 × 90 inside diameter x outside diameter x –...

  • Page 183: Brake

    MAINTENANCE STANDARD BRAKE BRAKE Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) (Brake) Height of brake pedal (when free) 234 {9.2 in} Travel of brake 83 {3.26 in} 120–125 Travel of inching pedal {4.72–4.92 in} Interconnecting point between inch- 50 {1.97 in} ing and brake pedal (Brake oil pressure)
  • Page 184 BRAKE MAINTENANCE STANDARD INSPECTION Judgement standard Symbol Inspection item Remedy Standard size (mm) Standard size (mm) Clearance between input piston and – 0.16 diameter of body mating portion Clearance between spool and diam- – 0.032 eter of body mating portion Clearance between reaction piston and diameter of guide mating por- –...
  • Page 185 MAINTENANCE STANDARD BRAKE FRONT BRAKE FD 100, 115 Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) 393.5–393.9 Inside diameter of drum 396.5 {15.61 in} {15.49–15.51 in} Thickness of lining 12.7 {0.5 in} 5.5 {0.22 in} Inside diameter of wheel cylinder 41.3 {1.626 in} There must be no scratches on sliding...
  • Page 186 BRAKE MAINTENANCE STANDARD FD135, 150E, 160E Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Inside diameter of drum 438 {17.24 in} 440 {17.32 in} Thickness of lining 12.7 {0.5 in} 5.5 {0.22 in} Inside diameter of wheel cylinder 47.62 {1.875 in} Outside diameter of piston Outside diameter of piston cup...
  • Page 187 MAINTENANCE STANDARD BRAKE PARKING BRAKE Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Lining thickness 5.5 {0.216 in} 3.3 {0.13 in} 152 N {15.5 kg} 137 N {14 kg} Strength Shoe return = 50) = 50) spring Free length 54.7 {2.15 in}...

  • Page 188: Hydraulic Equipment

    HYDRAULIC EQUIPMENT MAINTENANCE STANDARD HYDRAULIC EQUIPMENT CONTROL VALVE Measuring control valve relief pressure (1) Remove the plug (control valve body, left side) and install a pressure gauge. (2) Raise the forks to the maximum lifting height, and measure the oil pressure when the circuit is relieved. Relief pressure 21.58 MPa {220 kgf/cm Judgement standard...
  • Page 189 MAINTENANCE STANDARD HYDRAULIC EQUIPMENT (Top surface of control valve) Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) (tightening torque) Coat thread of spool return set bolt 25–34.3 Nm with Locite #242. {2.5–3.5 kgm} 35–44.1 Nm Return spring cover mounting bolt {3.5–4.5 kgm Coat tightening thread of tilt spool 25–34.3 Nm...
  • Page 190 HYDRAULIC EQUIPMENT MAINTENANCE STANDARD 1. Flow control valve : Standard : For Dynamic signal 2. Relief valve Set pressure 10.2–15.2 MPa {127.5–132.5 kgf/cm 50-24 EX20 Series...

  • Page 191: Lift Cylinder

    MAINTENANCE STANDARD LIFT CYLINDER LIFT CYLINDER (Lifting height: 3m) Item Unit FD100 FD115 FD135/150E 160E Cylinder (inside diameter x outside diameter) 95 × 110 100 × 113 110 × 124 120 × 136 Stroke 1510 Outside diameter of rod Weight INSPECTION Judgement standard Symbol...

  • Page 192: Tilt Cylinder

    TILT CYLINDER MAINTENANCE STANDARD TILT CYLINDER (Lifting height: 3 m) Item Unit FD100–160E Cylinder (inside diameter x outside diameter) 125 × 142 Stroke of rod Outside diameter of rod INSPECTION Judgement standard Symbol Inspection item Remedy Standard size (mm) Repair limit (mm) Clearance between piston rod and 0.036–0.267 0.567...

  • Page 193: Steering Cylinder

    MAINTENANCE STANDARD STEERING CYLINDER STEERING CYLINDER Power steering cylinder (Lifting height: 3 m) Item Unit FD100–FD115 FD135–FD160E φ 90 × φ 102 φ 100 × φ 112 Cylinder (inside diameter x outside diameter) Stroke φ 60 φ 70 Outside diameter of rod INSPECTION Judgement standard Symbol...
  • Page 194 STEERING CYLINDER MAINTENANCE STANDARD ADJUSTING CHAIN 1. Chain length Adjust with the chain stopper so that the bottom face of the fork is 15 mm below the ground level when the forks are lowered fully. Tightening torque for chain stopper locknut 824–1030 Nm {84–105 kgm} 2.
  • Page 195 60. STRUCTURE AND FUNCTION Power train diagram ..........60- 2 Torque converter ............60- 3 TORQFLOW transmission ........60- 4 Meter panel ..............60-10 Drive axle ..............60-12 Steering axle ............60-13 Steering system ............60-14 Brake................60-18 Hydraulic pumps ............60-22 Tilt cylinder...............60-23 Hydraulic circuit diagram..........60-24 Electrical circuit diagram ..........60-25 60-1 EX20 Series...

  • Page 196: Structure And Function

    POWER TRAIN DIAGRAM STRUCTURE AND FUNCTION POWER TRAIN DIAGRAM 60-2 EX20 Series...

  • Page 197: Torque Converter

    STRUCTURE AND FUNCTION TORQUE CONVERTER TORQUE CONVERTER PTO drive A PTO drive is installed to the torque converter to drive the torque converter charging pump, power steering pump, and hydraulic pump. Torque converter cooler The torque converter cooler is built into the radiator. Item Unit Okamura Ltd.

  • Page 198: Torqflow Transmission

    TORQFLOW TRANSMISSION STRUCTURE AND FUNCTION TORQFLOW TRANSMISSION (1/3) No. 1 shaft Input shaft with F/R clutch pack No. 2 shaft Shaft with 1st/2nd clutch pack No. 3 shaft Output shaft with 3rd clutch pack Torque converter case No. 1 shaft No.
  • Page 199 STRUCTURE AND FUNCTION TORQFLOW TRANSMISSION TORQFLOW TRANSMISSION (2/3) Idller gear Input shaft 1st-2nd shaft Output shaft (Transmission case) (Torque converter case) 60-5 EX20 Series...
  • Page 200 TORQFLOW TRANSMISSION STRUCTURE AND FUNCTION TORQFLOW TRANSMISSION (3/3) Regulator valve relief pressure: 203.89 MPa {20 kg/cm Clutch actuating pressure: 142.7–183.5 MPa {14–18 kg/cm From line filter 1, 2, 3 speed pressure port Main pressure measurement port T/C oil pressure measurement port To cooler F/R clutch pressure port...
  • Page 201 STRUCTURE AND FUNCTION TORQFLOW TRANSMISSION 1. Hydraulic Circuit (Outline) 1) When the engine is started, the charging pump is driven and the oil inside the transmission case passes through the strainer and is sucked in or pumped out. 2) The oil leaving the gear pump presses through the line filter, is regulated by the main regulator valve, and fills the accumulator.
  • Page 202 TORQFLOW TRANSMISSION STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM 60-8 EX20 Series...
  • Page 203 STRUCTURE AND FUNCTION TORQFLOW TRANSMISSION INCHING VALVE This is interconnected with the pedal, and controls the oil pressure to the multiple disc clutch according to the amount that the pedal is depressed. F/R clutch pressure port Full stroke Protrusion 30 Inching spool 60-9 EX20 Series...

  • Page 204: Meter Panel

    METER PANEL STRUCTURE AND FUNCTION METER PANEL Integrated meter panel with safety checkers The integrated meter panel with safety checkers informs the operator of vehicle status that is monitored by many sensors installed in the units of the vehicle and then immediately processed for display.
  • Page 205 STRUCTURE AND FUNCTION METER PANEL Cate Symbol Display item Display timing (range) Description gory While parking brake is Parking brake state While parking brake is applied: Lit applied • When starter switch is turned ON during engine stop Lower than proper Radiator coolant level Normal state: OFF, Abnormal state: Lit level...

  • Page 206: Drive Axle

    DRIVE AXLE STRUCTURE AND FUNCTION DRIVE AXLE 1. Differential Item Unit FD100/115 FD135–160E Reduction gear type – Hypoid bevel gear Reduction ratio – 4,375 Outside diameter of torque shaft Oil capacity (including final drive) 2. Final drive Item Unit FD100/115 FD135–160E Type –...

  • Page 207: Steering Axle

    STRUCTURE AND FUNCTION STEERING AXLE STEERING AXLE This has a thick steel plate welded integrated structure with a built–in 2–rod type power steering cylinder. Specifications Item FD100 FD115–150E FD160E Center pin support, Center pin support, Center pin support, Type single–shaft type single–shaft type single–shaft type Structure of knuckle...

  • Page 208: Steering System

    STEERING SYSTEM STRUCTURE AND FUNCTION STEERING SYSTEM Full hydraulic power steering (FHPS) Compared with semi–integral power steering, full hydraulic power steering is superior in straight travel stability, there is no kick back, and it is also easier to carry out inspection and maintenance. Hydraulic circuit diagram (Oil brake) TILT CYLINDER FLOW DIVIDER...
  • Page 209 STRUCTURE AND FUNCTION STEERING SYSTEM 1. STEERING VALVE Structure Power steering system using full hydraulic power steering basically consist of a hydraulic pump, full hydraulic power Model FD100/115 FD135–160E steering body, and power steering cylinder. Discharge cc/rev /rev The internal structure of the full hydraulic power steering body can be divided into the control valve and metering Relief pressure 12.7 MPa {130 kg/cm...
  • Page 210 STEERING SYSTEM STRUCTURE AND FUNCTION Principle of operation (At neutral) • The pressure oil entering pump port of the power steering from the hydraulic pump passes through passage , goes through spool groove and pas- sage , then returns to the oil tank from tank port When this happens, cylinder port is blocked inside the sleeve, so the power steering cylinder is kept in...
  • Page 211 STRUCTURE AND FUNCTION STEERING SYSTEM Steering when there is failure in hydraulic pump Even if the hydraulic pump breaks down and no hydraulic oil is supplied, the full hydraulic power steering is designed so that the steering equipment can be operated manually. In other words, if the steering wheel is turned, the spool of the full hydraulic power steering is turned by the shaft, contacts the cross pin, and rotates the drive shaft.

  • Page 212: Brake

    BRAKE STRUCTURE AND FUNCTION BRAKE Wheel brake Model FD100/115 FD135/150E/160E Type 2–leading type 2–leading type Inside diameter of drum 393.7 mm 432 mm Brake specifications Lining material Non–asbestos Non–asbestos Lining size (width x thickness) 125 mm × 13.1 mm 125 mm × 12 mm Inside diameter of wheel cylinder 41.3 mm 47.62 mm...
  • Page 213 STRUCTURE AND FUNCTION BRAKE PRINCIPLE OF OPERATION OF BRAKE VALVE 1. When pedal is not depressed When spool (4) is at the position in the diagram above and the downstream equipment (power steering, etc.) is operated, the oil pressure at pump port (P) rises. However, pump ports (P) and (11) are blocked by normally–closed valve (b), so the pressure oil does not flow to the control pressure chamber.
  • Page 214 BRAKE STRUCTURE AND FUNCTION If the brake pedal is depressed fully, nut (8) contacts stopper (14), so the input piston cannot move further to the left from this position, and the oil pressure in the control pressure chamber becomes the maximum in this condition. When disassembling, do not loosen nut (8) unless the input piston is to be replaced.
  • Page 215 STRUCTURE AND FUNCTION BRAKE When the brake pedal is released, spool (4), reaction piston (5), and valve rod (6) move to the right, ball valve (7) returns to the valve seat, and blocks the passage between the accumulator (A) and the control pressure chamber. Valve rod (6) then moves partially, and reaction piston (5) moves further to the right, so valve (d) opens, and forms a passage between (13) and the control pressure chamber.

  • Page 216: Hydraulic Pumps

    HYDRAULIC PUMPS STRUCTURE AND FUNCTION HYDRAULIC PUMPS The pump for the work equipment and the pump for the power steering (brake) are a parent–child type and are driven by the torque converter PTO. Item Unit FD100/115/135/150E/160E Type – Work equipment: SAR90 Power steering and brake: 40 Relief set pressure MPa {kgf/cm...

  • Page 217: Tilt Cylinder

    STRUCTURE AND FUNCTION TILT CYLINDER TILT CYLINDER Item Unit FD100–160E Outside diameter of cylinder Inside diameter of cylinder Diameter of piston rod Stroke Seal type – U–packing, piston ring Weight kg–each 60-23 EX20 Series...

  • Page 218: Hydraulic Circuit Diagram

    HYDRAULIC CIRCUIT DIAGRAM STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM (OIL BRAKE) TILT CYLINDER FLOW DIVIDER l/min 220 kgf/cm CONTROL VALVE LIFT CYLINDER PUMP CONTROL VALVE DOWN SAFETY VALVE TANK CHECK VALVE BRAKE BRAKE 130 5 kgf/cm VALVE ACCUMU LATOR 140 5 kgf/cm CLOSE RELIEF CYLINDER...

  • Page 219: Electrical Circuit Diagram

    SM227 STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM ELECTRICAL CIRCUIT DIAGRAM STARTING SWITCH HEAD LAMP (60W/60W) STARTING SWITCH CONNECTION WINKER SWITCH CONNECTION LAMP SWITCH CONNECTION CIRCUIT CIRCUIT CIRCUIT OPERATE OPERATE OPERATE WINKER LAMP LEFT (25W) BATTERY NUTRAL COMBINATION SWITCH RIGHT CLEARANCE LAMP DIMMER (10W) DIM SWITCH...
  • Page 221 70. TROUBLESHOOTING Torque converter ............70-2 Control valve ..............70-5 Check brake accumulator ..........70-7 70-1 EX20 Series November 2004...
  • Page 222 TORQUE CONVERTER TROUBLESHOOTING TORQUE CONVERTER 1. Causes and remedies for failures Problem Cause Remedy Power is not transmitted No hydraulic pressure 1) Lack of oil Add oil 2) Damaged gear pump or drive por- Disassemble and check, replace tion with new parts or replace whole assembly 3) Damaged piping or joint Disassemble and replace...
  • Page 223 TROUBLESHOOTING TORQUE CONVERTER Problem Cause Remedy Abnormal noise is 1) Cavitation caused by leakage of air Add oil or check and replace parts if generated from suction piping or lack of oil necessary 2) Failure of gear pump Disassemble and replace parts or whole assembly 3) Contact caused by deformed impel- Disassemble and replace, replace...
  • Page 224 TORQUE CONVERTER TROUBLESHOOTING 70-4 EX20 Series...
  • Page 225 TROUBLESHOOTING CONTROL VALVE CONTROL VALVE Troubleshooting Problem Cause Remedy External oil leakage • Damage/deformation/disengagement of • Replace with a new O-ring. O-ring • Flaws on O-ring seal • Correct flaws with oilstone. • Damage of oil seal • Replace with a new oil seal. •...
  • Page 226 CONTROL VALVE TROUBLESHOOTING 70-6 EX20 Series...
  • Page 227 TROUBLESHOOTING CHECK BRAKE ACCUMULATOR CHECK BRAKE ACCUMULATOR (AIR BRAKE SPECIFICATION, OPTION) Sto p th e lift tr u c k o n le v e l Sta r t th e e n gine a n d d e p r e s s gr o u n d in a s a f e p l a c e , p u l l th e th e b r a k e p e d a l fu l ly .
  • Page 228 NOTES: 70-8...
  • Page 229 80. CONVERSION TABLE Millimenters to Inches ..........80-2 Inches to Millimeters ..........80-2 Cubic meters to Cubic yards........80-3 Cubic yards to Cubic meters........80-3 Liter to U.S. Gallon.............80-4 U.S. Gallon to Liter.............80-4 Liter to U.K. Gallon.............80-5 U.K. Gallon to Liter.............80-5 Kikogram to Pound ............80-6 Pound to Kilogram .............80-6 Kg/cm to Ib/in...

  • Page 230: Conversion Table

    Millimeters to Inches Inches To Millimeters CONVERSION TABLE CONVERSION TABLE Millimeters to Inches 1mm=0.03937 in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102...

  • Page 231: Cubic Meters To Cubic Yards

    Cubic meters to Cubic yards CONVERSION TABLE Cubic yards to Cubic meters Cubic meters to Cubic yards = 1.308 cu.yd 1.31 2.62 3.92 5.23 6.54 7.85 9.16 10.46 11.77 13.08 14.39 15.70 17.00 18.31 19.62 20.93 22.24 36.62 24.85 26.16 27.47 28.78 30.08...

  • Page 232: Liter To U.s. Gallon

    Liter to U.S Gallon U.S. Gallon to Liter CONVERSION TABLE Liter to U.S. Gallon = 0.2642 U.S. Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.076 6.340 6.604...

  • Page 233: Liter To U.k. Gallon

    Liter to U.K Gallon CONVERSION TABLE U.K. Gallon to Liter Liter to U.K. Gallon = 0.21997 U.K. Gal 0.200 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179 4.399 4.619 4.839 5.059 5.279 5.499...

  • Page 234: Kikogram To Pound

    Kilogram ti Pound Pound to Kilogram CONVERSION TABLE 1Kg = 2.2046 Ib Kilogram to Pound 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73...

  • Page 235: Kg/Cm 2 To Ib/In 2

    CONVERSION TABLE Kg/cm to Ib /in Kg/cm to Ib/in 1Kg/cm = 14.2233 Ib/in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7...

  • Page 236: Kgm To Ft Ib

    kgm to ft. Ib CONVERSION TABLE Kgm to ft. Ib 1Kg.m = 7.233 ft. Ib 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 72.3 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 144.7...

  • Page 237: Temperature

    CONVERSION TABLE Temperature Temperature Fahrenheit–Centigrade Conversion. –A simple way to convert a Fahrenheit temperture reading into a Centigraqde temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired it convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures abd read the corresponding Centigrade temperature in the column at the left.

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