TOYOTA ee Repair Manual MODEL 2FBCA10,13,15,20,25 FBCA3O TOYOTA MOTOR CORPORATIONTOYOTA FORKLIFT REPAIR MANUAL TOYOTA MOTOR CORPORATIONFOREWORD This manual covers the inspection, adjustment, and repair procedures for the electrical, chassis and loading system of the 2FBCA10, 13, 15, 20, 25 and FBCA20 series Toyota Battery Forklift. It is desired that this manual be used to fullest advantage in preserving the performance and durability of the battery forklift truck and for correcting troubles properly and efficiently. This manual has been edited on the basis of the data available as 1985 so that it should be understood that the vehicles manufactured at later date may not conform with the matters contained herein. Any changes made later shall be informed through the Parts & Service News. TOYOTA MOTOR CORPORATIONSECTION INDEX GENERAL : = BATTERY CHARGER CONTROL CIRCUIT __ CONTROL CIRCUIT TROUBLE SHOOTING MOTORS : Z TRANSMISSION & DIFFERENTIAL [GH FRONT AXLE REAR AXLE BRAKES STEERING OIL_ CONTROL VALVE OlL_ PUMP CYLINDERS MAST |GENERAL FRAME SERIAL NUMBER LOCATION ... WORK PREPARATION .........-...- STANDARD BOLT TIGHTENING TORQUE0-2 FRAME SERIAL NUMBER LOCATION ZF BCAZ5 —10001 WORK PREPARATION Repairing of forklifts are mostly done at site away from the repair shop and are most likely to be ac: companied by danger and difficulty because of the heavy weight components to be handled and the special nature of the work involved, Safety should always be taken into consideration in performing the repair job. In lifting up the front end or the rear end of the vehicle, the mast hooks or the weight hooks should be utilized and wire rope having sufficient reserve strength used. When the vehicle is jacked up, make sure that it is supported on stands. Even for a trifling job, the work should never be attempted with the vehicle raised up only on jack, When the vehicle front end is jacked up, place the stands under both front ends of the frame, and when the rear end is jacked up, place the stands under the frame, and then verify the safety. Before inspecting or repairing any electrical part, be sure to disconnect the battery plug and wait about three minutes before starting work. Before disconnecting any electrical wiring, note the wire color and the wired condition. In overhauling functional components, complicated places, or related mechanism, the disassembled parts should be kept in good order so as to prevent intermixing them. When disassembling and inspecting the control panel, oil pump, and other high precision component parts, clean tools should be used and the work done in a clean place. Disassembly, inspection, reassembly, and adjustment should be performed in accordance with the prescribed prccedures.10, " 12. 0-3 The specified SST should always be utilized whenever its use is prescribed. Replace the gaskets, packings, “O” rings, lock plates, and the like with new parts at each disas- sembly, Lubricants oil seals, caskets, and the like should be used at assembly should be used in accordance with the instructions i? their use has been clearly prescribed Bolts, nuts, and the like of the specified kind should be used, and then always installed at the pre- scribed places and tightened at the specified torques. In the tightening torques is not specified, refer to the Standard Bolt Tightening Torque Table and tighten at the value specitied there.0-4 STANDARD BOLT TIGHTENING TORQUE | ] Specified tightening torave (kg-m) (RIE) | Item Size | Pitch (mm), [in] we Specified Tightening torque 6 | 1 (00304 | 047 | o40~o7 [ 2893~ 5.063) a | 125 (00492) | 111 | 1.0 ~ 16 ( 7.233~ 11573) 10 | 1.25 [0.0402] | 2.25 | ta~~3. [13:743~ 22.429) aT 10 | 15 [0.089} 214 | 18 ~ 20 113019~ 14.466) see pee eee raaee 440 | 35 ~55 [25316 ~ 39.782] "4" mark) 12 | 18 {0059} | 399 | 35 ~ 5.0 (26.316 ~ 36.165) Part No 12 | 1.78 (0.069) 374 | 3.0 ~ 5.0 [21.699 ~ 36.165) (91000-40000) | 13 | 1.8 [0.059] 5.08 | 48 ~ 7.0 [32.550~ 50630) 14 | 15. (0.0591 623 | 50 ~ 8.0 [36.165~ 57864) 14 | 2 [0.0793 593 | 47 ~ 7.7 (33.995 ~ 65694) 16 | 1.5 [0.089] as7 | 75 ~11.0 (64.248~ 79563) 16 | 2 (0079) | 910 | 7.1 ~106 [51.354~ 76670] 6 | 1 {(o034) | o71 | 06 ~09[ 4340~ 65011 8 | 1.25 (00402) | 166 | 18 ~ 22 [10850~ 15913) 10 | 1.25 [0.0492] | 338 | 30 ~ 45 (21.699~ 32550] st to | 15 {0.0591 320 | 27 ~ 42 [19529~ 30379] oe ith 12 | 125 al 660 | 50 ~ 8.0 [36.165 ~ 57.864] “5 mark) 12 | 15° (0.050) 584 | 5.0 ~ 7.0 [36.165~ 50630] Part No. | 12 | 1.78 (0.069) 561 | 48 ~ 68 [34,718~ 49.2] (9100050000) | 13 | 1.8 (0,059) 763 | 65 ~90 [470 ~ 65.1) 1a | 15 (0050) | 89 7.0 ~105 [50.6 ~ 759] 14) 2 [0.079] 950 | 75 ~11.0 (542 ~ 796] ae | 15 (0.050) | 1436 | 120 ~17.0 [868 ~ 1230] 6 | 2 (0079) | 19358 | 11.5 ~165 (832 ~ 1193) 6 | 1 (00304) | o71 | 06 ~09 [434 ~ e51] 6T | 8 | 128 too | 166 | 15 ~22 1085 ~ 159] (bolt head 10 | 125 (0.0492) | 338 | 30~ 45 [2170 ~ 2256) provided with 10 | 18. (0.059) 320 | 2.7 ~ 42 [1953 ~ 30.38) "6" mark) 12 | 1.251180) 660 | 80 ~ 80 [36.165 ~ 57.864] (0.0492) | | Part No. 12 | 18° [0.059] 584 | 5.0 ~ 7.0 [36.165 ~ 50630} (91000-60000) | 12 | 1.78 [0060] 561 | 48 ~ 68 [34.718~ 49.2]0-5 Specified tightening torque (kg-m) [ft-lb Item size | Pitch (mm) |__Se2eifiedWehtening torave (kev) Fb) Specified Tightening torque 6 | 15. (0.059) 098 | 08 ~12[ 58 ~ 87) 8 | 1.25 (00421 | 220 | 20~301145 ~ 217) to | 1.25 (00402) | 450 | 40~55 [290 ~ 298] 7 10} 18 [0.059] 430 | 37~62[268 ~ 37.6] (bolt head j 12 | 1254IS0) | ago | 7.5 ~106 [ 54.248~ 75.9 5 ~105 [ 54.248~ 75.9) provided with | {0.04021 ae 12 | 15° (0.059) 778 | 7.0 ~9.0 [506 ~ 66.1] ae 12 | 1.75 (0069) | 7.48 | 60~05 (1434 ~ 6185) (@1000-70000) | 13 | 15 (0.059) | 1017 | 80~1201[579 ~ 868] 14) 18 (0059) | 1267 | 100 ~18.0 [ 723 ~ 108.5) 4] 2 (007) | 1106 | 95 ~140[ 68.7 ~ 101.3) 16 | 15 (0.059) | 19.18 | 15.0 ~23.0 (108.5 ~ 166.4) te} 2 [0.079] | 1211 | 140 ~22.0 [101.3 ~ 159.1] Caution 1. Example, 91111 — 4 0820 | Bolt iength (mm) ~ Bolt diameter (mm) Classification 2. The tightening torque is the value for tightening the same type of material, therefore, the tightening torque should be in accordance to the installed locations with vibrations or for applying suficient strength.BATTERY OUTLINE DRAWINGS SPECIFICATIONS SERVICE STANDARDS TROUBLE SHOOTING REMOVAL INSPECTION INSTALLATION PROCE DURES OF BATTERY es Page 1-2 1-11OUTLINE DRAWINGS1-3 Auanieg pabseyo Aig, ‘Areneg esen, [« 089 96 ‘Avonreg esena | 089 9€ vaneg abeing ueder |. OZOL 9€ ‘Awoneg esena] 089 98 ‘ones esena | » 089 96 vaneg eBeiis ueder| OZOL 9€ Areneg esena] 089 96 ‘Aroneg een, 089 ‘9e joneg sbe0is ueder |, S86 98 Aroneg ebeiois ueder |, S€6 96 ‘uenegesena | « 963 9e uaneg aBeios ueder | oe6 9€ Aianeg abeiois ueder | 966 9€ Aisneg esena, 963 9e uoneg abe01g ueder |, 089 oe ‘Arneg abeioig ueder], 089 9€ Aoneg ebeioig ueder |, 089 9€ uaneg ebeiorg ueder | 089 9€ ‘Aioneg ebei01s ueder | 089 98 ‘Aisneg abeinig ueder 089) 98 Assneg esena]. S92 ey Aoneg esena |, 089 8y ‘Aueneg abeing ueder |, G6g 96 Aianegesenal — G9Z 8b ‘ioneg esena| 080 ay ‘ianeg abeioig ueder 36g 9€ Aveueg esenA |, 089 8r Aeneg esena|. OLS av AnegesenA | + OLS 8y ‘Areneg esena| 089 Es ‘Arne esena] 01g ey ‘ianeg ese, 1g ay voneg ebeirg ueder |, G9Z eb ‘Aioneg abeiorg ueder |, 089 8b Auaneg ebeiois ueder |. 01g 8p uanieg abeimis ueder| — g9Z Ea Ausneg ebeig ueder| 08a ey (uanieg ebe101g ueder os 8p waneg abe1015 ueder |, 089 eb ‘Aieneg ebeiig ueder|, 1g 8p Kianeg ebeioig uedep |, Gzy a uanieg abeio1g ueder] 089 ey ‘Kieneg ebeinig ueder| _O1g ep Kianeg sbeioig veder oey a seven | itboaey. | seston sen Mapes) | eben eH Vinpesey.| stenon SPECIFICATIONS seues VOR soles Gz OZVOGIZ 891428 G1 'EL ‘OLVOSIZ =13-1-4 SERVICE STANDARDS Specific gravity when fully charged 1,280 (20°C) Spacific gravity when discharged _1.150 (20°C) | Electrolyte _ Sulfuric acid diluted with refined water “Replenishing fluid Refined water (pure water] Insulation resistance More than 1 MQ 1, Battery hanger (80201-10250-71) 2. Hydrometer 3, Thermometer 4, Insulation resistance meter (500V, 100 MQ}TROUBLE SHOOTING 1-5 Battery Symptom Probable Cause Remedy Trouble: Plates corroded © Electrolyte becomes cloudy when fully charged. © If sea water has entered in bad smell will be produced while charging, © Capacity will be reduced. © Hydrochloric acid, nitric acid, organic acid, sea water, or other impurities entered in battery. © Battery life in last stage. © Check electrolyte and replace it if excessive im- purities are present, © Replace battery with new battery, | Trouble: Sulfation © During charge — Specific gravity is low, voltage is high, and temp: erature rises excessively © During discharge — Voltage is low and capacity is small © White lead sulfate adhering on plates. © After discharge, battery was not recharged but left stand- ing for long time. © Repetition of insufficient charging. © Short circuit developed © Insufficient electrolye, © Plates exposed in air. © Continued averdischarging. © If light, may be corrected by giving equalizing charge. © Replace battery with new battery, Trouble: Plates warped and active material flaking off. © Plates warped. © Active material flaking off © Capacity deteriorated. © Continued overcharging and overdischarging © Charging current too large. © Ambient temperature too high when in use. © Battery life in last stage, © Replace battery with new battery | Trouble: Short circuit © Voltage and specific gravity are low at charge, discharge, and when idle, © Abnormal rise jn temperature when charging © Late appearance of gas at charge final stage. © Specific gravity drops early when left standing after charging, © Plates contacting due to damaged or deteriorated separators, © Accumulation of flaked active material in battery bottom contacting on plate lower ends, © Replace battery with new battery. - 6 —Trouble: Electralyte leakage and loss © Excessive loss of electrolyte | © Battery container cracked or | © Inspect container and re- broken, place it if found: defective. | © Forgot to replenish water © Add refined water, and adjust fluid level and © Overcharged too much specific gravity. © Investigate charging current and ambient temperature. Trouble: Connections loosened or corroded T TT © Terminals and connectors © Terminal parts imperfectly | © Correct connection heat up when charging and connected. © Clean off corrosion from discharging. © Terminals and connectors terminals and connectors and © Excessive corrosion formed on| dirty. coat with rust preventive terminals and connectors. grease or vaseline,BATTERY 1, Shift the steering wheel to its most forward position Note: ‘After shifting, check the lock to see that it has been properly set 2. Remove the battery hood. 3. Separate the battery plug, 4. — Raise up the Head guard, and lift out the battery with battery hanger {80201-10250- n) Note: 1, When lowering the battery, use care to soe that the battery plug anc other parts are not injured, If the battery hanger is not available, use wire rope of at least 10mm diameter. 2 Fig, 1-8 Removing Battery1-8 INSPECTION 1, Measure the electrolyte specific gravity. Specific gravity when fully charged 1.280 (20°C) Specific gravity at end of discharge 1.160 (20°C) The electrolyte specific gravity at fluid temperature of 20°C is taken as the standard specific gravity. The following equation is used to correct the measured value to that at 20°C. Specific gravity conversion equation Fig, 1-6 Measuring Specitic Gravity S20 = St + C,0007(t — 20) where Sao : Specific gravity at 20°C where St : Specific gravity measur ed at C where t : Temperature at measure- ‘ment + How to use the hydrometer 1, Insert the hydrometer nozzle into the filler hole, and draw out the electrolyte into the outer tube 2. Float the hydrometer properly within the outer tube so that it is free and not touching the upper or bottom part of the outer tube. ‘After allowing the bubbles in the drawn out fluid to die out, read the graduation at the part protruding above the electro: Iyte as shown in the illustration. 3. After measuring, wash the inner and outer side of the hydrometer with clean water (preferably refined water) and wipe dry with a cloth before | storing. Do the same with the ther mometer. Fig. 1-7 Hydrometer 2, Draw out the electrolyte and inspect it to see if it is turbid or contains impurity. If defective, take proper measures in accordance with procedures in Trouble Shooting, Fig. 1-8 Checking Electrolyte for TurbidityCheck the electrolyte level and if tow, add refined water (pure water) up to the pre- scribed level, * Electrolyte consumption An approximate calculation of the water consumed in the electrolyte can be made with the following equation. ‘Amount consumed ( &} = S:hour rate capacity x x04 x number of cells x number of charge Example: In case the battery (440 Ah/5HR) js repeatedly charged and discharged for one week, the amount ‘of water consumed in the electro- lyte will be 2-440 xo 0.4% 24%6 X Fog * 04x 24 x = 2534.4 cc= 2.68 Note: If the reduction of electrolyte was not caused bby just the loss of water resulting from charging and evaporation but from other reasons (such as spillage during transportation), measure the specific gravity and add sulfuric acid diluted with refined water to the same specific gravity. If the electreolyte level is lower than the proper level, replenish distilled water until ‘the red-float touches the stopper. Fig. 1-9 Checking Electrolyte Level (1) = Excessive (Romove the excess with a syringe.) Short” (Replenish) Fig. 1-10 Chocking Electrolyte Level (2)4, Inspect the battery plug and wiring for damage. Note: 1. The replacement of battery plug and wiring requires technical skill so that as a rule this work is performed at the battery maker's service station. 2. Damaged battery plug is extremely dangerous as it could lead to short circuit so that proper disposition should be made before short 5. Check the resistance between the battery and battery case with insulation resistance meter (megger). Insulation resistance. . . More than 1M2 Note: If the insulation resistance is less than 1 MO, remove the battery assembly from the vehicle ‘and wash it with water. After washing, check the insulation resistance again and make sure that it is more than 1 MQLbefore reinstalling the battery. + Battery Control Chart Make up a control chart for each battery and be sure to enter battery is checked. \ae Fig. 1-11 Battery Plug Sectional Views Fig. 1-12 Checking Insulation Resistance the inspection results each time the Trapection | Irepected | Specific | Electrolyte | Amountof | Date Celi No. Gravity | Temperature | Water Added Inspector's Name _1— a —_1-11 INSTALLATION PROCEDURES OF BATTERY ‘The adjust bolt and the adjust angle stoppers are provided as follows. Adjustment | Forward and Right and Left Direction Methoa | Backward [A B c Direction Jo] & Model (s) | Adjust Bort 2FBCAN0, 13, 15 90mm | 620 mm ~ 825 mm| 740 mm ~ 855 mm] 855 mm ~ 878 mm 30-2FBCA10, 13, 15 2FBCA20, 25 t 780 mm ~ 870 mm|850 mm ~ 970 mm| 970 mm ~ 992 mm 30-2FBCA20, 25, FBCA30 t 775 mm ~ 910 mm] 795 mm ~1030mm| 1030mm~1052mm 30-FBCA30 Important instructions (Caution when installing battery) 1 Be sure that the battery movement, when it is installed on the truck should be less than a total of 1/2 inch (12.7 mm) inall directions. 2 Be sure that the battery should be installed at the center of the frame, 3 a, When installing asmall sige battery, adjust the thickness of the sub-weight in order to make that space between the frame and the battery cose to be withen 90 mm.1-12 4 Various battery sizes can be accomodated, ‘a. In diagram A the angle stoppers are used book-end-fashion to accomodate smaller batteries. b. In diagram B the stopper bolts can be loosened and the angle stoppers can be rotated to acco- modate a flarger size battery. c. For even larger batteries, one angle stopper can be removed to make additional space. (Refer to Diagram C)CHARGER COMPONENT PARTS... SPECIFICATIONS SERVICE STANDARDS .........-- 222000 e eee eeeee eee 2-4 TROUBLE SHOOTING ......... 0. eee s ener cece eee teens 2-6 TAP CHANGERSETTING ......... 22.0 eeee cree renee eee 2-8 CAUSE AND REMEDY OF TROUBLES RELATING TO CHARGER PROTECTIVE PARTS... cc ee eeee eee cece rete tenets eee nena ee 2-10 INSPECTION MEASUREMENT .......-----+eeeeeee er eeee 2-1 INSPECTION... 20... cece eee eee eee e eee ete ee 2-162-2 COMPONENT PARTS Charger Assy ‘Sie Transformer Ampere Meter Magnet Switch Assy Magnet Switch ‘Thermal Relay 12, Transformer eg hene Rober cable Connector cal Terminal Charger Cable Fig. 2-1 Separately Installed Type Charger Parts2-3 SPECIFICATIONS ‘asn jo aaiBap 1saySi4y BU!pul, a1e asay2 adUIS stONposd “oD Ausieg abesoIS Ueder 40} ase UMOUS UONeDI}I98dS + | WAxgOL 4 ' ' var | Ver A088) oop | z-Aarsel—zs-fos ‘ punge—19 ° OLWNOL WSE AOSZ L vA’ v Z-Agrg9l—Zs~ "9S vou | + ago | gunz + 9-390 % | ounse—sno| 0% ABrs9 val A0SS wv vst Aoov | Z-Aarozl-z9- 4 4 AN OL 1 ‘ 4 Ble eres) Aaroz olwwsr| Ag eZ VSe AOS va ve z-Agrozt-29~"9S i i 496) ouse| ve-any ! plies e) igen foe Wal A0SS val Aoov | z-Aarozi-6o~* 1 1 vayge) + 1 + ea 69-"OS 1 VA 8S ' + 4 vos |. VS) A ooz | 2-aarozi-eo-fos ‘ ‘ : SLnge—¥19 ° WB AOSS t r 001 —Aar00l~69~ © Hf varie] + 4 + ate eens | Z-ABrooL ‘Os oewnsy| ABS waz AOS se i any v KO —A@r001-69— voor | Hsia | vax!) “Concy| ep-aivy | 082M] VLE | i nezyag| NO% | 2 \-69-fos - : Buives ‘ada abeyon Buney Aypedeg | voneinsuy | Aysedeg | adAy ada bumeg abeyj0n bunemoy adAy ‘Aydin ada - samog| wei} HOI aL iS tag v YH HOS = 25 =2-4 SERVICE STANDARDS 70M10, 70MA10 For 200V | 200v ~ 230 Power Supply Voltage For 400V 340v ~ 460 - SG, ~69-1008Y—2 (200V) sv | No load secondary voltage $6, -69—1008Y—2 (400V) 59V (ac) * SG, -69—120)8Y~2 (200V) Sv SG, -69-120)BY-2 (400V) 5IV) SG, -52—120)BY-2 (200V) aav SG, —-62—120)BY—2 (400V) aav SG, -52—165)8Y-2 (200V) aay SG, ~62—166JBY—2 (400V) aay SG, —69-100JBY-2 (200V) TV No load secondary voltage SG, —69-100JBY-2 (400V) 7 (oc) * SG, -09-120BY-2 (200V) 76V SG, ~69-120J8Y—2 (400V) 78V SG, -52—120)BY—2 (200V) 58V $G;—52—120JBY—2 (400V) sev | SG, -52—165JBY—2 (200) 58V SG, -52—165)BY—2 (400V) BBV | SM motor internal resistance 5k CLK—25UTG (250V, 254) 3002 MSCH coil resistance CLK—26UTG (560V, 18A) 12002 CLK-35UTG (250V, 3A) 3008 CLK—35UTG (650V, 35} 12008 ‘6M10, AMATO $1 forward resistance 45M20, 45MA20 about 209 70M10, 70MA10 a6M10, 45MATO SI reverse resistance 45M20, 45MA20 =2 SI tightening torque 45M10, 45MA10 1.65 kg-m (11.9 ft-lbs) 45M20; 45MA20 1.65 ka-m (11.9 ft.lbs) 70M10, 70MA10 i | 2.20 kg-m (15.9 ft.tbs)Rien resistance (for SG; —52-120JBY—2) 10002 Insulation resistance 10 M2 ‘The no load secondary voltages (AC and DC) at scutally measured may sometimes be slightly lower than the standard value so that in such case, corrections should be made with following equation. E; E9(V) Eo =E1 x € where E,(V) ° E.{V) E3(V) Not Calculated vaive Service standards Tap voltage Power supply voltage (E2 > Es) "The measured voltage differs from the standard voltage because of the tap setting being than the power supply voltage ‘and circuit tester error TIMER SETTING METHOD The timer may be set to three modes using the sete 1. Setting Method for Each Charge Operation ct switch. Mode Select switch position Normal charging NORMAL position ~ Ordinary Equalized cherging EQUAL (STD) position +, Low temperature EQUAL (COLD) position Additional charging NORMAL position "1: When battery fluid temperature is below 10°C, 2. Setting Method Using Volt Meter. Set the mode select switch as instructed in the following table for charging the battery is not dis- charged 36V Type No-load lift voltage Select switch position Under 34V NORMAL position 34V ~35V NORMAL position Above 35 7 4gv Type No-load lift voltage Select switch position Under 45 NORMAL position 45V ~47V NORMAL position Above 46V, na *2: Do not perform the sharge operation. =2-6 TROUBLE SHOOTING Probable Cause Check Method Remedy Symptom: PLCH does not light when DVT is set © PLCH defective © Contact defective © Power supply defective (© Measure voltage impressed on PLCH © Refer to following item Replace or repair if defective Symptom: MSCH does not close when DVT is set. © DVT defective © MSCH coil open © THR contacts defective ‘© Check DVT © Measure continuity of MScH coil © Measure continuity of MSCH contacts © Replace if defective © Replace if defective Repair or replace contacts Symptom: When DVT is set, AC power fuse burns out at same time © TF defective © Sidetective © Check layer short © Measure SI forward and reverse continuity Replace if defective Replace if defective ‘Symptom: PLCH it and DVT does not turn off in morning (Battery insufficiently charged] © Power stoppage or open phase in input power (© Tap changer not properly tightened © Defective contact in charging circuit © TF coil open © Si defective © FH burned out [Battery overcharged) © MSCH contacts defective © DVT actuating voltage higher than set voltage © DVT fails to actuate © DVT defective (© Measure voltage as recepta- cle. © Check tightness © Check tightness © Check continuity © Measure SI forward and reverse continuity © Measure continuity © Measure continuity © Measure actuating voltage at DVT terminals © Check actuation © Check DVT Retighten Retighten Replace if defective Replace if defective Replace if defective Replace if defective © Adjust actuating voltage Replace if defective © Replace if defective © Replace if defective(0 DVT time setting too short low © DVT actuating voltage too | 0 Measure actuating voltage at VT terminals Symptom: DVT is off but charge somewhat insufficient Sive guidance on operating method Adjust actuating voltage | Symptom: Abnormal noise produced while charging © Dirt stuck in moving part (© Remove contacts and moving or parts corroded parts and check © Vibration caused by worn | © Remove contacts and moving] or defective contacts parts and check Clean, repair, or replace Clean, repair, or replace CHARGER-BATTERY APPLICATION CHART Charger Type Applicable Battery SG3~-69—100JBY—2 BIOAH/6HR — (48.V) SG3-69~120/BY-2 680 AH/6HR (48 V) SG3-52—120JBY—2 680 AH/6HR (36 V) SG3~52—165JBY. 935 AH/GHR (36 V)2-8 TAP CHANGER SETTING Fig. 2:2 Tap Changer Installed Location 1. Measure the voltage of power supply to the charger. Tester range... AC Note: Measure the power supply voltage at the user at night (if this cannot be done, measure at some rest time during the day when the other electrical equipment are not running, Fig. 29 Measuring Power Supply VoltageSet the tap changer in accordance with the following table. After setting, place on the cover and tie securely with tie lap. For 200V Measured Voltage Tap | 199V and under 200v ~ 208V 210v 2ov~219vV. | ~— 220V 220V ~ 220V 230 For 400V red Voltage _| Tap 339V and under 340V 340V ~ 359V 360V 360V ~ 379V 380v 389V ~ 399V 400v 400v ~ 419V 420V 420V ~ 439 44ov 4aov ~ 459,V 460 Note: 1, Make the tap changer settings properly on the three phases, U, V, W. 2. The measured value will differ somewhat from the actual voltage because of instru- mental error (#2.5% in the case of circuit tester) Make the tap changer setting while keeping in mind the instrumental e’ror. 3. Always make sure that the taps have been set to proper value by carefully checking the battery charged condition (specific gravity ‘and fluid level) for about one week after setting the tap changer. Fig. 2-4 Setting Tap Changer Fig. 2-5 Placing on Cover 2m2-10 CAUSE AND REMEDY OF TROUBLES RELATING TO CHARGER PROTECTIVE PARTS (Power Supply Circuit Protective Purpose Fuses or Breakers, Thermal Relays, Charger Fuses) The charger protective parts have been provided to protect the charger so that if these parts function (such as fuses blowing out or thermal relay actuating), it can be assumed that such actions have very great possibilities of indicating serious trouble. Therefore, in case these protective parts function and immediate action is taken such as replacing the fuses or resetting the termal relays, there will be probable danger of the unaffected parts becoming damag- ed. In such a case, always make a thorough check for the cause of trouble and make proper remedy before replacing the fuses or resetting the thermal relay. [Power supply protective fuses (or breakers) burned out or thermal relay actuates Battery intemal short - ( Check for battery internal short (refer to Battery Trouble shooting) and repair battery.) Charging plug or cable shorted | ‘Check for short in charging plug and cable {by checking continuity with tester! and replace if found defective. Charger cable shorted Check for short in charger cable (by checking continuity with tester) and replace cable i found defective. Silicon rectifier shorted Check silicon rectifier continuity (check forward and reverse continuity with tester) and replace if found defective. Even if only one silicon rectifier is shorted, there is a large chance that this short has damaged the other silicons. Transformer coil layer short ies transformer coil layer short is difficult to check, have the work done at GS sevice] station, and replace transformer if coil layer short. Charger fuse burned out LL Silicon rectifiler shorted Check silicon rectifier continuity (check forward and reverse continuity with tester) and replace if found defective. Even if only one silicon rectifier is shorted, there is @ large chance that this short has resulted in damaging the other silicons,a INSPECTION MEASUREMENT Inspection measurement is the process of tracing the source of trouble by measuring the voltages succes- sively. starting from the charger power supply and proceeding through each inspection item. If the ingpection shows any abnormal condition, pin point the location of trouble by performing the probable trouble location check prescribed in the inspection item and make proper disposition before proceeding to the next inspection item, 2, 00 voltage measurement 3. 00 voltage measurement [Normal] {Check 00} [Norml] [Abnormal] [Check co) [Normal] [Check 00] [Abnormal] [Repair or replace] Caution- ‘Most of the inspection measurement is made with the charger power source connected and the timer turned on s0 that extreme caution should be taken not to accidentally touch any terminals as severe shock or unexpected trouble may arise, © (Onwehicle type) Draw out the charger functional parts, open side cover, and disconnect battery plug. ‘© (Separately installed type) HVR charger Remove the charger cover 1. Connect the charger to the power source, turn on the power, and set the timer to “ON”,2-12 2. Inspect visually. When the timer is turned on and the time set, the MSCH contacts wil’ close and the PLCH will light, At this time, verify the MSCH closing sound and t PLCH has tured on. Separately installed type rp Check PLCH [Even if PLCH is defective, the battery can still + lee charged Perform check 1 Check MSCH contacts +++ [when MSCH contacts are defective, battery will] + fail 10 be charged or else charged inatftenty | > Perfarm check 3 => b) MSCH does not close and PLCH does not light > Check TM contacts + Perform check 2 When TM is defective, MSCH will feil to ‘close and charging cannot be done. > Check MSCH coil .... FWhen MSCH is defective, MSCH will fail <9 + close and charging cannot be done J Perform check 3 7=> Power supply voltage (check phase voltages)... : [At power stoppage and missing phase in power + lupply voltage, MSCH will not close and charging Perform check 3 cannot be done LED Check THR... eer if THR has actuated, major trouble such as’ + ITF layer short or SI short could be possible so \do not reset THR but check TF and SI first Refer to Cause and Remedy of Troubles relating to Charger pro- tective Parts2-13 [by ©) MSCH closes and PLCH lights but immediately MSCH opens and PLCH turns off bn ‘ould be thought that MSCH opened in this case because of actuation in some charger pro. tective parts. 4 Refer to Cause and Remedy of Troubles Releating to Charger Protective parts 3. Power supply voltage measurements (AC) Measure the power supply voltage (phase voltages) at the MSCH terminals (R, S, T) Tester range AC Terminals measured Between R—S : Berween $ ~T Between T ~ R. Standard values Refer to values in Service Standards Very large disparsion in phase voltages Missin s wer su sing phase in Power SUPPIV > so scific phase is missing, charging can still be voltage : a [ee but charge will be somewhat insufficient timer may not turn off in the morning. Have check made by electrical shop &°¢ timer mY a serviceman, check for open circuit in charger [if specific wire in charger cable is broken, charg} cable. ing can still be done but the charge will be| + somewhat insufficient and timer may not tum| [off in the morning2-14 4, No-load secondary voltage measurement (ac) Disconnect the charger cable from power supply an k continuity of each phase. Replace cable if found defective. Tester range 2 Measurement places 3 wires to terminals Standard value 02 Measure the no-load secondary voltages at radiation block terminals (U,V, W) Tester range AC Terminals measured Between U—V Between V — W Between W—U Standard value |__ Refer to Service Standards values Wide dispersion in measured voltages Check for TF coil open-circuit (e case of open-circuit in TF coil, charging cai + be done but it will be somewhat insufficient Perform Check 7. {and timer may not switch off in the morning5, No-load secondary. voltage measurement(DC) Measure the no-load secondary voltage. Tester range C (250) Terminals measured Battery plug (frame side ) + terminal (+ probe) — — terminal (— probe) Standard value Refer to Service Standards value, No voltage present Check for open circuit in battery plug cable . + +++ (No charging if battery plug cable is open] 4 Disconnect battery plug cable and check continuity of wires. If de- fective, replace with new part. Tester range Q Place measured 2 wires [_ Standard value on Check for blown out FoH + Refer to Cause and Remedy of Troubles Relating to Charger Pro: first before replacing FCH if FH is blownout, it could mean SI is shorted] so inspect § tective Parts Voltage is low If SI is in open state, charging can stil! be done] Check for Sl opencircut lbut it will be somewhat insufficient and timer Imay not switch off in the morning i) Perform Check 62-16 INSPECTION |All functional parts are inspected while stil installed on the vehicle, but if they are to be inspected after removing from vehicle, tags should be placed on the wiring s0 os to prevent making incorrect connections when reinstalling, 2, In the inspection of the on-vehicle type charger, disconnect the battery plug frame side from battery side with ‘the plug separator before starting work. 3, If the funetional parts are to be inspected with the voltage Impressed, be very careful not to touch the terminals or other “live” parts 1. PLCH check Measure the voltage impressed on the PLCH. if proper voltage is impressed, the PLcH can be assumed to be defective so replace it with new part Measure the impressed voltage at PLCH socket. Tester range AC Terminals measured| At PLCH socket Standard value AC 200V — 230V Fig. 26 TM Actuation Check 2. TM check a. Check the DVT “TEST” ...,. Set to this position to check the timer for correct operation. If the charge operation is started after setting to this position, the battery is not charged the FAILURE lamp lights in 90 to 100 sec. Turning the power supply OFF resets to the normal state and the lamp goes OFF. b. TM actuation check Remove the HVR from the charger, and switch on the power supply and the timer. While shorting the HVR socket terminals (1) — (5) with the tester probe, verify the timer rotation. Note: If the timer rotating noise is so small that it can- not be easily verified, allow to stand for about 15 minutes and verify the timer rotation visually. Fig. 2-7 TM Actuation checkb. TM contact continuity check. Switch off the charger AC power supply and check continuity between TM wir ing (Black) — (Red). Tester range Q ] Terminals measured | TM wiring Black-Red “Standard values. | TM “ON”... 02 TM “OFF”. © | motor internal resistance measure- Switch off the charger AC power source and measure the TM motor internal resistance between TM wiring (Black) — (White) Tester range 2 Terminals measured | TM wiring Black-White Standard values TM"ON"... 5k TM“OFF".. 22 3. MSCH check a, MSCH contact continuity check ‘Switch off the charger AC power supply and measure the continuity between the MScH terminals. Q Between R —U Between S —V Between T —W. Tester ran Terminals measured Standard values Between R — U.. 08 | Between S —V., 02 | Between T —w.. 02 Note: MSCH contacts will become slightly black and uneven after use, but there is no necessity for polishing with @ file or other means. Such ‘means, will on the contrary, shorten the contact lite, Fig. 240 MScH Contact Continuity Check2-18 b. MSCH coil resistance measurement Switch off the AC power supply and measure the MSCH coil resistance between the MScH terminals (21) — (22). Tester range a Terminals measured | MSCH terminals 21-22 [Standard value Refer to Service Standards| value Fig. 2-11 MScH Coil Resistance Measurement THR check Measure the THR contact continuity between THR terminals (23) (or MSCH terminal (22)) and (24). Tester range a si THR terminal (23) (or | MScH terminal 22)—(24) Standard value on Terminals measured Fig. 212 THR Contact Continuity Check oe | Note: 4. If THR actuates and there is no voitege 25 between terminals (23) — (24), always check 23 cI 25 the cause for THR actuating and make proper disposttion before resetting THR. 2. THR is reset by lightly pushing the reset lever. 3. THR actuating current can be adjusted between 80 to 120% of the rated value by run (G_ | | 24 oa | means of the adjusting dial, but the rule is THR to set it to the Service Standards value. ~ Medium Value (Set Value) Minimum Rate Valve | | Reset Lever2-19 5, HVR check a, HVR Impressed voltage check Remove the HVR from the charger, and switch on the power supply and the tier. Then measure the HVR impress ed voltage between the HVA socket terminals (2) ~ (7). Tester range Terminals measured | (2) (+ probe)—(7) (—probel] Refor to S Fig. 213 HVR Impressed Voltage Check Standard value value (No, load secondary 7 ° b. HVR actuation check (Separtely install- ed type only) Mount the HVA in the socket, switch on the power supply and timer, and verify the timer rotation, Note: If the rototing is s0 small that it can be easily verified, allow to stand fer about 15 minutes and then check the rotation visually. Fig. 2-14 HVR Actuation Check c. HVR actuating voltage check Check the HVR actuating voltage by | means of the circuit shown in Fig. 2-16 To measure the actuating voltage, | gradually reduce the variable resistance | and read the voltmetar indication when the tester shows 0 92 (0 continuity). | Battery... Flat dry cell (67.5V) Variable resistance. .. 10k 1kQ Voltmeter . . . Class 0.5 or better Circuit tester Fig, 2.15 HVR Actuating Voltage Check Circuit Sai2-20 D. HVD actuating voltage adjustment If the HVR actuating voltage check indicates the necessity for adjusting the actuating voltage, remove the cover and make the adjustment by turning the set screw with a screwdriver. Note: After making the adjustment, make sure to coat screw lock compound on the set screw. E ov 6 SI check Fig. 246 HVR Actuating Voltage Adjusment Remove the SI and check the SI forward and reverse continuity. Tester range | 2(X 1K) [Terminals | Forward . . Anode side (probe) measured ~ Cathode side (+ probe) Reverse. . Anode side (+ probe} = Cathode side (— probe] [Standard value |Refer toService Standards value Fig, 2-47 SI Check Note: There are two kinds of SI that differ in polarity 50 that care must be taken when checking them. Fig. 218 si2-21 7. TF check a. Continuity check Check the TF primary and secondary coils by checking continuity through their terminals. Tester range a Terminals. Primary side (230V or measured 460V taps) B Between U —V | Between V —W Fig. 2-19 TF Continuity Check | Between WU Secondary side Between U2 — V2 Between V2 — Wa Between Wa — U2 Standard value 02 8 RCH check (SG5-52-18.JBY-2 only) Switch off the charger AC power source and measure the resistances between the RH terminals, Tester range a Terminals Between A —C measured Between B ~C [Standard values|Berween AC... 500.2 values Between B —C.. . About 340 Q| Fig. 220 ACH Check = 48CONTROL CIRCUIT SG FUNCTION Srnec eee 3-13 SPECIFICATIONS ........ 0... cc eeceeeeeeeeeeeeeeees 3-15 SERVICE STANDARDS............ 00.060 e eee eens 3-16 Saran 3-17 ACCELERATOR BOX ........ 0. ce cee cere e eee eee ee 3-23 DIRECTION SWITCH WIRING DIAGRAM ...... 6.0.0... cece e eee e een 3-26 CONNECTION DIAGRAM .......... 0.0 e cence eee nee 3-28 CONNECTOR DIAGRAM.............. cece cece eee eee 3-30 JUNCTION DIAGRAM ............0ceeeeeee eee eens 3-34 453-2 GENERAL As the control circuit has been changed from the SActype to 8B-type, it is described in detail here. 1. Performance Though it is fundamentally the same as the 5A type, the chopper circuit in the main circuit has been changed, The current sensor has also been eliminated 2. Reliability Reliability hes been greatly improved be: cause two thyristors are used in the main circuit, the number of SG (printed circuit board} components has been reduced, and new highly ‘liable elements have been corporated The reverse diode that is used in the BA type to imprave the commutating capacity is not used in the 8B type of controller. 3. Serviceability inspection has been simplified by combin: ing the contra! and contactor panels into fone contained in the front panel, so that only the panel need be opened for check- ing. ‘An analyzer can be used by adding an 8A- type adaptor and panel ta the conventional BA-type. The part number of the analyzer is as fol lows 09910-20410-71 5A analyzer 09910-22500-71 8A-analyzer Fig. 3:2 5A Analyzer Fig. 33 8A AnalyzerCHOPPER CIRCUIT 1 Commutating capacitor ‘C, ) charged When MF (or MA) is closed, i, flows through the next circuit to charge C,. The upper side and lower side become positive + and negative — in polarity respectively When the charge has been completed, C, becomes the battery voltage. BATT + DMD > 1, > Lo + C, > BATT — Fig. 3-4 C, Charged 2 Main thyrister (SM) ON When ON sig arta SM gp, Murs ON. Netor caret flows hou tect of BATT Ss OMG > SM = BATT 2 and ath soo ime a Hows Inthe sos eames consisting of Cy and Ly, C; voltage polarity inverses, thus causing the lower and upper side to /NN/_+ ~ w & | su | | te | cnn | Fig. 35 SM ON (C, Inversion) ae3 Sub-thyrister (SS) ON As 2 sinusoidal current flows through the circuit of Cy + Lo + Li + SM > C, during Cy inversion, a voltage is induced between L, both ends. However, when the inversion is completed, Ly voltage variation becomes 0. Utilizing this change, an OFF signal is given to the SS gate. Then, SS turns ON, and C, current ig follows through the circuit of Cy > SM > SS > Lo > Cy.When ig comes to be equal 10 motor current ig, SM turns OFF, and is do not flow. 8s 3 0FF use | Fig, 3.6 SS ON (SM OFF) Sub-thyrister (SS) OFF ‘After SM turns OFF, iz and ig enter the circuit of BATT + DMD > SS > Ly > Cy > BATT © , and ig folws, This state is called commutation. The is charges C, , and the upper and lower side become positive +B and negative = respectively. When the charge is completed, SS turns OFF Fig, 3:7 SS OFF3-5 i. Immediately after chopper OF F 9g The current energy storec in the motor inductance thereafter flows as ig; even when the chopper is ed, OFF, motor current flows through DF y,2. Therefore, DF, 2 diode is called the flywheel diode. ven, then Fig. 8 Immediately after Chopper OFF 3, After SM turns OFF, an ON signal is given to SM. This period is the chopper OFF time, and one C cycle of ON/OFF is completed vera Stu =a3-6 CIRCUIT OPERATION DURING CHOPPER OPERATION DF, pol" — of 5 (Ont Fs Du OF! we VRA un [chopper csar'f ireult ios Fig. 39 During Chopper Operation [Main circuit] — rr. (Fn 5 BATT B— eb DMp armature —> MR b:contact—> DMD waa le MF a-contact— coil (ME b-contact) coil (MR a-contact) BATT © + Chopper circuit-——— [Control circuit] BATT ®—> Fs sWky Lsay DSF Me coil. SG [SCRa1} {DSR) (MA coil) BATT © +—SG +— VRA <— SG (Constant voltage circuit) | neDURING MS CLOSING offi, Rue] (Ont OMp OF) Me 1s ts at | { sc | Fig. 3-10 During MS Closing [Main circuit] BATT + F, DMp ermature Ma b-contact DMo field MF a-contact coil (ME b-contact) coil (Mp a-contact} BATTS <—ms [Control circuit} BATT + Fs sWky Usa, OsF MF coil ~ (Os) | (MA coil) BATT - ae <5 {Constant voltage circuit) ae 1 Lsms ‘8G (SCRg,) <——MS coil Sa, coe - §G (SCR) =A3-8 SG FUNCTIONS TRAVEL CONTACTOR TURNING ON CIRCUIT © ScR,, anode © SCR,, anode | Fig. 3:11 Travel Contactor Turning on Circuit When turning on DSF or DSR, Cys is charged, When the voltage across C23 increases and exceeds the Zener potential of Z2),SCRar is turned on. Therefore, MF coil or MR coil is energized and MF contactor ‘or MA contactor is turned on, However, when one of the following conditions 1,2 and 3 is not satistied, SCR} is not turned on, The condition 1,2 and 3 are detected by Dag, Dar and Dao respectively, (Condition 1) The commutation detection circuit in SG must be normal (The SCRay must be off.) When SCRq, is short circuited or turned on, the charge current of Cay flows through Dag. In this case, Cag is not charged, so SCRay is kept OFF. (Condition 2) The MS contactor turning on circuit in the SG must be normal. (SCRg1 must be turned off.) When SCRe: is short circuited of turned on, the charge current of C33 flows through Dar. In this ca: Cas. is not charged, so SCRay is kept OFF (Condition 3) The SM, MS, etc. of the main circuit must not be short circuited When SM, MS, etc. are short circuited, the Ps voltage is low. In this case, Tray is turned on by the charge current of C3, $0 Czy is not charged and SCRa is kept OFF. In the 5A control circuit, the disconnection of the power supply and accelerator variable resistor of the control circuit is detected. However, the 8B control circuit is protected by the separate circuit in SGCOMMUTATION FAILURE DETECTION CIRCUIT Fig. 312 Commutation Failure Detection Circuit When SM cannot be turned off because of any abnormality in the main circuit control circuit during the operation of the chopper (whan the commutation fails), the motor is directly connected to the battery and becomes uncontrolable, In this case, the commutation failure detection circuit detects such condition to turn off SCRa: oF to turn off MF or MR contactor. (When the main circuit is normal} When the chopper is in normal operation, if SM is turned on, the current flows through Dag or Day ard Tray is turned of When SM is turned off, Tray is turned on by the circuit consisting of Rg — Zaz As described above, Tra, is turned on and off repeatedly, so Caz repeats charging and discharging and the voltage across Cex does not exceed the Za, potential (When commutation fails) Since SM is kept ON, the Tra is turned off, Cao is charged so that the voltage acress it exceeds the Zar voltage, and SCRg, is turned on. When SCRa, is turned on, Cap is charged with the polarity shown in the above figure. However, when SCRa) is turned on, the charge of C22 flows through the circuit (A) Asa result, SCRq) is turned off and MF and MA contactors are also turned off. (Protection circuit) When turning on MS contactor, the cathodes of Deg and Day are placed under the same conditions as those when the commutation fails. To discriminate the former from the latter, Tray is turned on by the circuit of LEMS — Dsp — Zaz, Dut SCRay is not turned on. When the SM gate and the cathode are shot circuited, or when the SM gate circuit is open, Traz is turned on to turn on the SCRay to protect it,3-10 BYPASS CONTACTOR TURNING ON CIRCUIT 1-0 Tre, © SCR,, anode ‘3-13 Bypass Contactor Turning on Circuit When turning on LSA, Cgp is charged. When the voltage across Cg exceeds the voltage determined by the characteristic of the SBSg1 , SCRg1 is turned on, Therefore, the MS coil is energized, and the MS contactor is turned on. However, when the condition 1 given below is not satisfied, SCRg: is not turned on. The condition 1 is detected by Dgs. The reset circuit consists of Dg and Dee (Condition 1) The conduction rate of the main circuit must be higher than the set value. (The ratio of the ON time of SM must be high.) The ratio of the ON time of SM is detected by Tre. When the motor voltage is low, the vo.tage at the voltage comparator (OP, ) (—) terminal becomes lower than that the voltage comparator (+) terminal Therefore, the output of OPg: is high enough to turn on Tra through Oss. As a result, Cea is not charged and SCRey is kept OFF When the vehicle is running with low SM ON ratis, for example, when the vehicles is accelerated, plugged, when the vehicle is overloaded while accending the slope, when the vehicle cannot run at high speed be- cause of defective accelerator variable resistor or defective printed circuit board, etc., SM is not turned on so acceleration shock is not felt (Reset ciucuit} When turning on the MS contactor, LSMS is turned on Tr¢y is turned on through Dgy to reset Cea. When changing over DS, the anode potential of SCRa, changed. When the anode potential is high, Tra, is turned cn through Deg to reset Caz (Reference: SBS¢) SBS is called a trigger diode having the similar function to that of a Zener diode. Since the current capa city of SBS is larger than a Zener diode, sutficitent trigger current can be obtained.3-11 CONSTANT- VOLTAGE CIRCUIT | = Constant voltage load circuit Fig. 3-14 Constant-Voltage Circuit It is necessary to operate the pulse generator (the chopping frequency setter, oscillation capacitor charger, blocking oscillator, etc.) etc. stably at the constant voltage. The battery voltage is decreased by Rx, down to the Zener voltage depending on Zor and Zio2. The above mentioned circuit is operated at the Zener voltage. When the battery voltage becomes lower than the Zener voltage, C1os and Cygg supply the current. The pulse generator, etc. operates stably by this cir- cuit in spite of the abnormal discharge of the battery. ON PULSE GENERATOR . Fig. 3-15 ON Pulse Generator When the charged voltage across C1 9¢ becomes higher than the voltage divided by Rizo and Fy 24, the current flows from the anode to the gate of PUT in ICjo,. Asa result, the PUT is turned on, the current flows through the primary side of TRya; . and the ON pulse generator gives the ON signal to the SM gate3-12 OFF PULSE GENERATOR When the SM is turnad on and the polarity of the commutation capacitor C, is reversed, the Pg potential is high and no signal is given to the SS gate. When the polarity of Cy is reversed and the current becomes 0, the voltage across Ly becomes 0 too Asa result, Trig is turned off and SS is turned on. ACCELERATOR CIRCUIT When depressing the accelerator pedal suddenly, the conduction ration of the pulse oscillation transistor is increased and the soft starter is operated at the soft start time constant depending on Ryoa and Cio, The electric brake can be adjusted by the depressed degree (or tilted degree) of the accelerator. When one of the 3 cables connecting to VRA disconnects, the conduction ratio of the pulse oscillation transistor (Trigy and Tryp ) decreases to prevent rushing PLUGGING CIRCUIT During plugging, each time MF is changed over to MR and vice versa, the motor field coil is energized in the reverse direction, Under this condition, the motor operates as a generator. The generated current cir culates through DF; or DF2. The plugging circuit detects this current to turn off the pulse generation transistor Trigy to us? Trigz only for control OCL CIRCUIT This circuit detects she voltage across the commutation capacitor Cy at Py to change the conduction ration of the pulse ossiliation transistor, No current sensor is required. During OCL, MS cannot be turned on.tir | COMPONENTS ieee ie Fig. 3-16 Control Panel and Contactor Panel Components aeAccelerator pedal Pedal rod Accelerator link arm Spring pin Tension spring Vari-ohm Micro switch Accelerator box Box bracket 10 " 12 13 4 15 16 7 Vari-ohm holder Bushing No. 2 Accelerator gear Bushing No. 1 Gear Connector cover Seal No. 2 Seal No. 1 Fig. 9-17 Accelerator Box ComponentsLever Micro switch Lever boss Lever Knob cam Micro switeh Micro switeh Tab Plug Fig. 3-18 Direction Switch Components SPECIFICATIONS eo voce! 2FBCA10, 13,15 | 7 BCA2L0.25 | 40.2 BCA20, 25 F {waveling circuit) 276A asa | SBAISTO) Fy (hydraulic equipment 225A, 3254 Sanat (ae Fuse | F3 (PS circuit) OPT 504 : a < Fe (lighting circuit) 10A, 9A (UL spec.) - 0A a Fs (Control circuit) 10A, 9A (UL spec.) - 10a SM type TS18E2D-V ~ T30J2V - = a | sswpe Hye T1s2V « | DF1,2 type RISJ2R R25J2R, -3-16 2FBCAI0, 15 bieed 2FBCA10, 13, 15 46-2FBCA20, 25 Item FBCA30 200 uF (1 piece! Cy Number & Capacity 200 uF (1 piece) enOoTeneS OC L value 4008 500A, SERVICE STANDARD Item Model 2FBCAI0, 13, 15, 20, 25; FBCA30; 40-2FBCA20, 25 ‘Accelerator Box ‘See the text When the tester probe is contacted to the C; terminal, pointer deflects, and then gradually returns to, and (C1) finally stays at °°. Note: Discharge C, with a resistance of about 100 2, before measuring in the tester range of 92 x 100, Reactor (Lo, Lil 0 @ between Lg, Ly both terminals Fuse (F; ~ Fs) 0 @ between both fuse terminals Printed board (SG) See the text TS18E20-V) © (over 10K) Forward resistance eee 730120 > (over 10KQ) ay ss TS2E = (over 10K2) TH & (over 10K) TS18E20-V & (over 10K) Reverse resistance oo 730J2V = (over 10K@) Raerrngorts | = TSI2E = (over 10KQ) THR @ (over 10KQ) TS18E20-V Approx, 15 2 Forward resitance SM T3002V Approx. 20 2 eee eee Ss TSIZE Approx. 302 TH2V Approx. 20 i TS18E20-V Approx, 15 2 Reverse resistance T30/2V, Approx, 60 2 (between G and K) - Tester range x 1 ss TSI2E Approx, 1002 TH ‘Approx. 50 2 Forward resistance DF, RISJ2R - ‘Approx. 122 puesterjrenge x OF, 262A Approx. 122 Reverse resistance DF, AI6J2R & (over 10K) eden amd OF, F25J2R @ (over 10KQ) Mg. Mp coil resistance ee eau Wg coil resistance ean wean3-17 tem Mosel | 2F8ca10, 13, 15, 20, 25; FBCASO; 40-2FBCA20, 25 Bypass suxiliary switch (LSMS) : 0 & during MS closing MP coil resistance MX 160 C 142 Forward Tester range x 1k 5KQ MP diode resistance Reverse Tester range x 1k #2 Mes coil resistance MZOIMA | 55.2 Forward Tester range x 1k 5Ka MPs diode resistance Reverse Tester range x 1 k =2 gu | TS18E20-V | Anode side 360 kg-cm (25 ft-lb) T30J2V__ [Cathode side 24 kg-em (1.7 ft-lb} ‘Thyristor tightening ss TSI2E__| Anode side 65 kg-cm (4.7 ft-lb) ode TH2V | Anode side 150 kg-cm (11 ft-1b) OF RIB/2A [Cathode side [140 kg-cm (10 ft-lb) OF, Anode sid 24 kg-om (1,7 Flo) eoson | Anodeside gem ) Cathode side | 220 kg-cm (16 ftlb} INSPECTION 1. Cy (Capacitor) Pull out the battery plug, and disconnect the C, wiring to check for continuity. Terminals Measured Both C, terminals Tester Range 2x 100 Standard When the tester probe is contacted to the C, terminal, the pointer deflects and then gradually returns to e°, and finally” stays at © (as C, is charged by current from the tester, it becomes © 2). Note: Before measuring, discharge the capacitor C, with a resistance of about 100 ©. Lo, Li (Reactors) Pull out the battery plug, then check for continuity between the terminals. Terminals Measured Both Lo, Ly terminals Tester Range 2 Standard 02 -61—3. SM, SS [Thyristors) Pull out the battery plug, and disconnect the wiring. Then check for continuity between A and K, and between Gand K. (1) Between anodes and cathodes (A — K} (Forward) anode = ———— cathode + Is measured Se (Reverse) anode + ———— cathode — Tester range Qx1k Standard Both forward and reverse e (over 10 kQ) (2) Between gates and Cathodes (G — K} (Forward) Gate 5 ———— Cathode $ Tealnal mene (Reverse) Gate # ———— Cathode = Tester range 2x1 (Forward) (Reverse) ‘TS18E20-V Approx. 159 Approx. 15 Standard T30J2V Approx. 202 Approx. 602 T5J2E Approx. 302 Approx. 1002 T72v Approx, 202 Approx. 502 (3) Inspection of aven circuit between A. and K. Cathode When it is difficult to check the open circuit between A and K witha tester, use the following procedure’ However, make sure beforehand that the circuit between G and K is nor- mal, 1) Connect the + terminal of a 12V ad car battery to the thyristor anode Lemp through @ 12V lamp, and connect the cathode to the — terminal of the battery, 2) Then connect resistor of 1 k@ to the thyristor gate lead wire, and contact it to the battery + ter- minal and then with draw it immediately ‘Momentarily bring the gate into contact with #1 ka the positive terminal Fig. 349 Thyristor (A~K) Inspection A= K interval normal A= K interval discontinuity Lamp ights up. 1 Lamp off, eo4, OF 1, DF2 (Diodes) Pull out the battery plug, and disconnect the wiring. Then check for continuity between the anode and cathodes (A—K} (Forward) anode = cathode minal Measure : Terminal Measured (Reverse) anode + cathode = (Forward) x1 met (Reverse) Qxtk (Forward) Approx. 129 Stendera (Reverse) (over 10k) 5. SG Unit (Signal Generator) Remove the SG to measure the voltage applied at the SG connector. Caution © Always make this measurement if you think that the SG unit is the cause of the trouble and wish to replace it. © Always disconnect the battery connector before removing or instal © CN; should always be ON. jing the SG unit. (1) Both terminal CNG, & Ny | Terminals Measured (2) Both terminals CNSG. Ne (3) SS, SM gate connectors ® Ni 1) DCs Tester Range (2) DC5O (3) 0c50 The following table shows the standard values when inspection comes | procedures (A), (B) and (C) have been made, Inspection procedure A: Battery plug ON B : Battery plug ON, SWky, LS8, LSAF (LSAR}, DSF (DSA), LSA,, LSAz ON C : Battery plug ON, SWky, LSB, LSAF (LSAR), DSF (DSR), LSA; LSA2 ON Close MF (Ma) a-contact with your finger. Standard Value (CNSG , } = Pin No. y. T J — ; ine — vfalsa]s| els |e] frols|r2] 1a] 14/15] x6 a a A cfofel=tefo|7|>|-lej=feie|-le|-e 3 TPlelelelelalet tele tel [el |e] ¢ “Tel fefel [elt lelelel tel te c . Approx. voltage of power source _/..... not connected Both the 36 V and 48 V vehicles use the same standard values. — 63 —3-20 Standard Value (CNSG2) T —~ Pin No. T ] Inspection —~ 1 2 3 4 5 6 7 8 9 10 procedure _| | | A 7 eon ar on olofo B t Oo mi oO oO 0 c oe *}olofo Note: Ou. OV * 1... Approx. voltage of power source / ..... not connected Bothe the 36 V and 48 V vehicle use the same standard values. Standard (SS, SM gate) Inspection CTE Point ss gate SM gate procedure — A oO : _ a GC = * Approx. veltage of power source Both the 36 V and 48 V vehicle use the same standard values. ‘sca = 84H3-21 6. OCL (Over-Current Limit) Value Measurement Lock the rear wheels while operating the vehicle, Connect an ammeter and a shunt, Then measure the drive motor lock current. Measure only over a shor: interval. Remove the harness between P3 and the DMO (B) terminal on the (B) terminal side, and connect it to the shunt + side, Connect a spare cabtyre cable to (B} terminal and the shunt = side, and also connect an ammeter in series, ‘Terminals Measured Ammeter (DC) 50mV, 750A Shunt 5OmV, 7504, Standard 400A (2FBCA10, 13,15) 500A (2FBCA20, 25; FBCA3O) Tester Range Note: Do not adjust the OCL unless it is necessary. If you must adjust the OCL, make sure you connect an ammeter, and adjust the variable resistor (R86) in the SG unit. eatt [ ala Fig. 323 OCL Adjustment Fig. 1-22 OCL Measurment 7. MF, MR (Forward/Reverse contactor) Disconnect the battery plug. Measure the coil resistance at both MF and MR terminals. [Terminals Measured [ Both MF, MR contactor coil terminals, Tester Range x1 Standard 99.42 8. MS (Bypass Contactor) Disconnect the battery plug. Measure the coil resistance at both MS terminals Terminals Measured Both MS contacotr coil terminals Tester Range 2x1 Standard 99.42 eco3-22 Check for blown fuses visual them. 9. Mp (Pump Contactor) Disconnect the battery plug. Measure the coil resistance at both MP terminals, Also, check the continuity of the diode between A and K. (1) MP coil Terminals Measured Both MP contactor coil terminals Tester Range Qxt | Standard 149 (2) OMe (Forward) anode © ———— cathode ss Measu eu (Reverse) ___anode + — cathode = Tester Range Qxik Standard (Forward) 5k (Reverse) D 10. LSMS (Auxiliary bypass switch) Disconnect the battery plug, Measure the continuity of LSMS at ON/OFF by turning the MS con tactor ON and OFF by hand “Terminals Measured Lsms terminal COM NO Tester Range a isms ON 02 Standard Usms OFF 2 11. Fi, Fa Fs, Fa. Fs (Fuses) lly, and then check for bad fuses by running continuity tests on all of Terminals Measured Both fuse terminals Tester Range Standard Q 023-23 ACCELERATOR BOX INSPECTION Disconnect the battery plug and separate CNz. Then check for continuity and measure the resistance. Check point ] Terminals measured Tester range LSA, CN, (4) 49 — CN (8) 44 LSA | CN (3) 84 — CN, (7) 65 2 VBA (51 and 62) | Ng (1) 51 — CN; (2) 52. [RA (62 and 3) _ ~ CN, (2) 52 — CNy{6) 53 QxIk VA (61 and 53), CN7(1)51 —CNz(653. | STANDARD Pedal position | eee “ Free state Slightly depressed Fully depressed LSA, | 2 0g 02 LSA2 [=a I =Q 0a - VRA (51 and 53) 10kQ 10k2Q 10kQ [_vRA(Sland62) | Changes from 0 @ to 10 k@ as the pedal is depressed VA (62 and 63) I Changes from 10 k82 to 0 2 as the pedal is depressed CONNECTION DIAGRAM CN; No P “4 _5t 7 2 62 o |, 3] 64 | mB 4 o | A | | 5 49 R ce ae Gr Fig. 3:24 AB Connection Diagram 7 55 WG a, 4 Ww a3-24 DIRECTION SWITCH INSPECTION Disconnect the battery plug and separate CNyo. Then check for continuity Check point, Terminals measured ‘Tester range sr CNyo (1) 44 — CNio (2) 45. | DSR Ngo (1) 44 — CNio (3) 46 a oOseu CNio (4) 43 — CNio (6) 103 DSH CNyo {4} 43 — CNjo (5) 48 DSPs Orange terminal (42) — Green terminal (97) STANDARD : Check point | Lever position | Ose =| osr Osau OsPs Ds Neutral 2 =o =a =o ar Forward 02 2 ex) 02 =o Reverse #2 02 02 on =a Pushed down = on CONNECTION DIAGRAM ne Nod com Nie sence OF NO. wer 46 OSR No. Pp c 430 BIS o8Mo103 oSay 1 44 w Ne ‘com 2 6 wo noes eas sy 3 46 Wei se af Ne _¥ 3 sp5 4 4B R Nos tom ¥ OO” eI 8 Fig. 3-25 DS Connection Diagram 6 103 8B3-26 WIRING DIAGRAM 908, Rr J yay, 1 i Yr Up line = | “a Mey ld | LTE i 1102, oF] 104.41 1 wt =f | at] | 3] Lt la Kel Ne Fig. 3:26 Wiring Diagram$50 us.01 f= ous G (as3-28 CONNECTION DIAGRAM ten fees EO fashe quis Cibef- 4 a 143. G) HM ee yee afk =) cus wavs eee (ser Ponte ‘HM ne peace vale C)ESeses= cms Sw Lfraecl-4 oO ( . Banna —], os eno hb urs FRESE D—§rasfuc} 4 ae [TAB[RES 12, oF onze (ess Fecal 4 Fig. 3-27 Connection Diagram192.c1 osre_ Wer ai rev ono Ion. AB) en oe - Pa —" oF > ti BATT Lag (ge WGN cng nas > Tavs! Lore Ler Lr nz {usta freclras}—Lous| $0 cut3-30 CONNECTOR DIAGRAMS. 1. Controi panel (C.P.) 2. Contactor Panel (M. P.) CN CN nec [elel7 [els] [31210 rec Pep esa zh Gahehishebhalialn fio whalishrab halal sho tas REC noyP]}c] 4 ||no.Jefe] vs [no] pe] c ifa7] of cn, @|| 1] 47 SG Dalle 2[46| ef cn @|| 2/46 SG [ 2fn| 8 3]61] 6 | cn, O|| s/t Seka 3] 10] R [4] 5 Y [ons @| | 4] Ps ss] [ales] y ‘| 5} BI CN, @]] 5] 4 SG 5] P4| Br 1 6152 6 | 52 sc | él Pil P | 7 7/ Nt Ny 7| P3] w nw B) (00) escua 8 9|P3 9| Ps 86 eae 10] 46 0 | 45 SG vol 7] P ii| 9 9 SG fra 12| 54] sa] | sc 12) 61 13] 55/ Len, @| [13/65] | sc 13] 47| 0 14] Pal er| cn, ©] [14 | Pa SG [1a] as 15] 7] P| CN, @]]15] 7 SG 15| 46] Br] CNio @| | 15] 46 MA 16[P2| L[cn, @]| 16] P2 8G 16| 2] con, @] [16] P2] | oF. 17[53[ Gr]-cn, ©] [17 [53] SG 1764] uc] en, @] f17] 54] [ms331 3. Accelerator Box (AB) 4, Harness Halfway CN, CN (exclude 40-2F BCA20, 25) REC TAB TAB REC e[7]*®] 2] °] Pope ‘eteteled] Gls No, nol etc] a No.| P 1 1/41] ¥] cue] [1] 41 | 2 2| 98) W | PLe&s 2/98 3 3|Ni} B | CN @}| 3] Ny 4 4/43] G| PLease || 4/43 5 5/101) R] Nis @ |] 8/101 6 6|N,| 8] Pea || olny 7 74104) Lu} CNys @] | 7 | 104) 8 8} 110 Gr| CN» 8 || a )110) 9} 43) G| CNs@®]| 9 4, Harness Halfway a = 119 CNg (40-2FBCA20, 25) ee oe 5. Harness Halfway CNy 6]7] 2] 9|1] [ro fe me tl2{s[4fe]] [s[4 belTel 1h Pet) Eee afer] el rrs |] 1 2|98/w| Purse || 2 Nofe[c] 4 |[nole[c] we hi al | Ne © 3[Ni[ 8 | CNa@]| 3 1fr03) | Chio@ || 1 [103] 8 | Xx g, 4/43} G| Pleas |} 4 2 2 ee ame 8101 | CN @ || 5] 3/104] Lu} CNy ® || 3/104) Le She & 6/M] 8] Pleas || 6 4 4 7{104| wu] cris @] [7 5jyi[ a] Qs 2 |] sini] e [Axo CN @ Nae © | 8/110] Gr] EN @ || 8 | 6fiai] s | tssr 6] iti] G | Nm & 9] 43] G| Cys @]| 9 10 10 t = 75 =3-32 6. Direction Switch Cio (exclude 40-2FBCA20, 25) CNio (40-2FBCA20, 25) TAB REC TAB REC a[s|e 1} 2] 3 Nol P} Cc] 4 |inoletcl J No] P J Nol Plc ial 1/44) w | oseA ifaa|w | cn, ® 1) 44| w | oseR 1} 4afw] cn, ® Taslwol ; cn, @ t 2| 45 |wo] Ose 2/45] 61 Ex @ 2] 25|wo| ose 2| 45] o[& & 5 cn, ® — 3} 46 wer] Ose 3] 46| ar| EN! 6 | 3) 46 [wer] OSA 3[45[ er] 3 : OSB, 5 Ns © — 4| 43] A | Be ala] o] ene > [aa] a | Bau 4| 43) GCN, @ 2 ene ace Leet 5] 4a] PH 5| 48) G | OSH 6| 48] P| H 6}103 B | OSBu 6}103] R | CNs © “eliog| 8 |ose, |] 6104 Al CN, © i 7 Lift switch, Tilt switch (LSU.7) CNiz (exclude 40-2FBCA20, 25) Nip (40-2FBCA20, 25) TAB REC TAB No J | [No No.] P J |iwoJefe] a 1 |43/G | Lsut 1 143} | sur 1 |43| 6 | tg © 2 |61/Gr| tsur || 2 {61|Gr| Mp ® 2 [61 Gr] Lsur 2 |61|Gr| Mp ® 8, Light control switch (SWL) Nis TAB REC a}sj6 nal eaa lies) r L 3 fio) REN, 8 4 = 5 6 [tora] Hs || 6 |r02] 0] eke 3b9. Turn signal switch (SWF) Cys (exclude 40-2FBCA20, 25) TAB REC Cys (40-2F8CA20, 25) 3-33 TAB REC al s]e if2]a Ly T 7 hole|c] 4 |(vofejc] 4 wole[c] 4 |fvofefc] 4 1 |101/Go}B 1 101) R | CN @ 1 |1o1Go| 8 1 froin [Ea [2 jrosicy| RH || 2 fos] w | cNa © 2 |ios\Gy| RH || 2 [108| w | CNa © 3 |rog}o] tH |] 3 fro] t | cra ® 3 frog | tH |{ 3 frool | cue © [a 4 4 4 5 5 5| ches 6| | +— 6 | 6 6 10. Key switch {SWky) CNig (exclude 40-2FECA20, 25) TAB REC coy >To Cig (40-2FBCA20, 25) TAB QT Pic No.| J No. 7 1 far AM 2 2 3 3 4 [43] G | cue @ 4 11 Flasher lamp (LF) Nao 21 TAB REC Na CN20 TAB REC folefc] sv |[nolefc] u fefefe] {vole feo] s 1 109} R | Le 1 |109] L | CNis @ | 1/108) R| LRA { 1 ]108; w | CNis @ 2|riof cfc |} 2 [rol Gr] cns [2[nde[ira || 2[riofGr[ cn @3-34 12, Head Lamp (LH) 13. Combination Lamp (Leu, Lst. LT) CNaa. 23 CNag. 25 REC TAB REC TAB ' cryzy 3|4 CN Nas INo.JP]c] 4s [wo] e |e] nole fo] us |inof ele] u 1 foal eR | oa 1 {102/0 | CN © yfroafuc| cn, @ |] 1 froafe Jura 2[n js [tre |[2|™ [alors © 2|ni [elon, Oi 2) Ni [@ [ETS Chas {afii[e | cn, ©] 3 1ijow csr 7 |Iwo] P Je] 9 4 [103] R| CN, O]} 4 [103[AL | Laue ur 11020 | Cris © ur || 2[N, [8 | vm No, T2 ur TT. ST, {8 jaur 111|Gw | Lst-R {1 4 [103] R| CN» © |] 4 | 103/AL [Laur JUNCTION DIAGRAM cn, ® (PalELECTRIC CIRCUIT TROUBLESHOOTING Page GENERAN eee eee ee eee 4-2 TROUBLESHOOTING METHODS ...........-es0eeeeeeees 43 BB-TYPE TRAVEL UNIT TROUBLESHOOTING ............. 44 7a4-2 GENERAL There are two methods of troubleshooting one method using on analyzer, and the ther using a tester etc, 1. Using the analyzer ‘A conventional 54-type of analyzer can be used by adding an adapter and panel. BAstype of circuit analyzer assy ..... 09910-20410-71 BAstype of circuit analyzer assy ..... 09910-22500-71 * See Analyzer Manual for the analyzer operation. Fig. 4-1 5A-Type Analyzer Fig. 4.2 8A-Type Analyzer 2. Using a tester, etc. Troubleshooting by using a tester, megger, etc, is done using the voltage resistance, or continuity measuring methods, inconjunction with wiring diagrams, specifically, the connection diagram, and connector diagrams To find a fault, it is necessary to understand the wiring and connecion diagrams throughly, and to actually measure by following the connector diagrams. ‘The troubleshocting procedures described in this manual have been prepared on the assumption that you have already mastered the use of the measuring instruments such as the tester, megger, etc. and also that you can understand wiring and connection diagrams and carry out the measuring according to the connector diagrams. Important: 1. Troubleshooting symbols Tester probe + , positive polarity on es peer __comecto ne ee Terminals Messued | 8 Tester Range Sanda aa oe (When only & is specified, it means that the entire range of the Q-meter can be used. However, when & x 1 is indicated, make sure you use only this range.)2. Removing or installirg the printed circuit SG unit, after disconnecting the battery plug. 3 When the wiring is defective, it means that there is a loose conncetor pin, a disconnected harness, or poor terminal contact, etc. During inspection, follow the wiring and connection diagrams to trace the faults, 4 During inspection, if the vehicle is to be operated, jack the rear wheels off the ground. TROUBLESHOOTING METHODS Jo locate a fault in the circuit, either of the following two methods may be used. VOLTAGE MEASUREMENT METHOD Connect the batter plug. With the power ON, measure the voltage between D-M @-N @-N O-™ to determine whether each functional compo- nent or the associated wiring is normal If normal ... voltage is indicated. If defective .......0V Note: Always connect the voltmeter in parallel for measuring. RESISTANCE AND CONTINUITY MEASURING METHOD Disconnect the battery plug. With the power OFF, check for continuity between ©®-®, @-@,8-@ to determine whether each functional compo: nent or the associated wiring is normal If normal a resistance or 0 is indicated. It detective ...... © 2 Note: Use the tester range that suits the func- tional component and its purpose Fig. 4-3 Voltage Measurement Method AAP VV. 1 wae, OHO \y Poems isa, Detective part ms YY (ej IN | Ds. 0% Fig. 4-4 Resistance and Continuity Measuring Method ee4-4 8B-TYPE CONTROL CIRCUIT UNIT TROUBLESHOOTING 1. The vehicle does not run at all (MF, MR do not attract). * First check if Fy fuse is blown out F, and SWky wiring defective Minoberativel N (Operative) (Check 1: Check VM and PI Cheek 2: Measure applied voltage between 47-N, wow (26 Vor 48) Check 3 Measure applied voKage beween 46,46N,] [Check 5: Check MS contacts \ \ | (a6 v or 48) ov (re) MpsMp coil and Chock & Measure applied woltage wing Betectve between 44.N, / \ (96 V or 48 V) (ov MS contact defective DS_.OS,, and LsprlSg.LS,, wiring detective wiring defective{not fused) ‘Check 6: Check SM continuity (Short circuit (Between A-K, over 10 kin between A-K) forward and reverse) SM defective Check 7: Measure VR. * Although VR, is defective, Me. Mp closed. ‘esistance First determine whether VR 4 is normal, A (okay Vg wiring defective SG defective (near SCRy SCR}4-6 Check 1: Check VM and PLp for operation. With battery plug and SWky ON. Check ogeration of VM and PLP If inoperative > Check fo If operative, proceed to check 2. blown fuse Fs and for defective SWky and wiring. Check 2: Measure the applied voltage between 47 and Ny With battery plug ON: SWky, LSB, LSA, DSF (DSR) ON. Terminals Measured Me, MA © side Ne Tester Range Dcs0 Standard 36 V or 48. V Mf normal—+ proceed to check 5. If defective—> proceed to check 3 Check 3: Measure the applied voltage between 45, 46 and Ny With battery plug ON: SWky, LSB, LSA, , DSF (DSA) ON. Terminals Measured ] CN; (10) 45, (2) 46 — Tester Range ocs0 Standard 36 Vor 48 V If normal—> check MF or MR coil and wiring If defective ~> proceed to check 4,Check 4: Measure the applied voltage between 44 and Ny With battery plug ON; SWky, LSB, LSA, , DSF (DSR) ON. Terminals Measured CNz (8) 44 + = Tester Range C50 Standard 36 V or 48 V If normal ——> check DSF and DSR wiring, If defective—> check the LSD, LSB, LSA; and wiring Check 5: Check the MS contact. Disconnect the battery plug, Visually check or touch the MS contacts to see if they have fused, If fused—+ Repair or replace the MS contacts. Also check MF and MR for fusing. Then trace the cause of MS contact fusing (LSMS related). If not fused -+ proceed to check 6. Check 6: Measure the SM continuity. Disconnect the battery plug. Disconnect the SM wiring and measure the SM continuity. (Forward) anode © Terminals Measured lace ats cathode cathode G Tester Range Qx1k Standard Over 10 k@ in both forward and reverse If normal ——+ proceed to check 7 If defective —> replace the SM Check 7: Measure the VRA resistance, Disconnect the battery plug. Measure the VAA resistance at CN7. Terminals Measured Ny (1) 51 CN; (6) 53 ‘Tester Range QxIk Standard 10kQ If normal — SG is defective (probably near SCRa: , SCRe , but not definitely). If defective —> VRA wiring is defective. aoe4-8 2. The vehicle does rot run at all (MF, MR atract). (Check 1: Check fuse F, Yor continuity (~ 2) to2) Fuse F, blow! defective wiring ‘Check 2: Measure applied voltage between P, -Ny tov) (36 V or 48 v) OMpy Mg oF Mp contacts, or 1” Check 3: Check SM gate wire wiring defective. {If normal) {If defective) ‘Check 4: Check LS\yg continuity or defective SM (US yyg0 8 at ON LSyg 7 at OFFI (except for the below) LSyg wiring defective SG detective (near M 101) Check 1: Check the fuse F1 for continuity Disconnect the battery plug, and check if fuse F) is blown, Poor SM gate wire contact ‘Terminals Measured Both F, fuse terminals Tester Range a Standard 02 If normal—> proceed to check 2. If defective —> check if fuse Fy is blown and if F, wiring is loose.Check 2: Measure the applied voltage between Py and Ny. With the battery plug ON: SWky, LSB, LSA, , DSF (DSR) ON, Terminals Measured Pee N= Tester Range cso Standard 36 V or 48 V If normal——> proceed to check 3, & If defective—+ DMo coil is disconnected, brushed are lifting, or there is poor MF or MR contact, or the wiring is defective Check 3: Check the SM gate wire, Disconnect the battery plug. Contact the SM gate wire connector by hand to check for snug insertion and for foreign matter loaged in the contacts. If normal—» proceed to check 4. If defective—> poor SM gate lead wire contact. Wren the gate wire is normal, check $M for continuity. Check 4: Check for LMS cortinuity. Disconnect the battery plug. Check the LSMS for continuity in the operating, and non-operating conditions. Terminals Measured LSms COM terminal LSms NO terminal Tester Range Q Lsms 0 Qat ON a LSi1s 2 0 at OFF if normal —> SG is defective (probably near M101, but not definitely), If detective—> LSMs or wiring is detective, ea3. Normal speed control not possible (vehicle runs) (Check 1: Measure applied voitage between 52-N, (Changes from 7 V to 4 V depending (except for the below) on degree of accelerator depression) Check 2: Measure resistance between 51-52 ‘Check 3: Measure $S continuity (Changes from 0 1 to 10k (Over 10 k® in both forward aapending on degree of and reverse) (except for the below] {except for below) accelerator depression} VA‘ wiring defective SG detective SS defective SG defective (defective wiring) (ea" Toa) Check 1: Measure the applied voltage between 52 and Ny With the battery plug ON; SWky, LSB, LSA,, DSF (DSR) ON Terminals Measured CNy (2) 52. uo Tester Range cso Standard As the accelerator is depressed, it changes from 7 V to 4V If normal —+ proceed to check 3, If defective proceed to check 2. Check 2: Measure the resistance between 51 and 52. Disconnect the battery plug. Measure the VRA resistance at CN, Terminals Measured CNy (1) 51 CNy (2) 52 Tester Range Qxik Standard As the accelerator is depressed, it changes from 0 © to 10 k24 Check 3: Measure the SS continuity. Disconnect the battery plug. Disconnect the SS wiring to measure the continuity between the anodes and cathodes. (Forward) anode S ——— cathode + Cael (Reverse) anode ——— cathode Tester Range QxIk Standard ‘Over 10 kQ in both forward and reverse If normal —+ SG is defective (probably, near Tyoq,, but not definitely). If defective > SS isdefective,4-12 4 Speed can be controlled, but MS contactor does not close. between 54: [Check 1: Measure applied volt (ov) (96 V or 48 Vi i Cheek 2 Measure applied voltage bewoon TON, | ov) (96 V or 48 V) ed omer Check 3: Measure applied voltage between 51-N, (0Vor 10-Vor less wry SG detective (nar Ong 9 Check 4: Measure VAL, resistance T tok) (except for the below) Check 6: Measure applied voltage between P VR pg detective (except forthe below) vow) Check 6: Meesure SS continuity SG detective (near Ry} * Measure OCL valve 7 | I tom (Over 10 ks in both forward and revers) SS detective SG defective (near Tia) Ereck 7: Measure LS, continuity (except forthe below! (0 S) with accelerator fully depressed) sp, defective Usa, Wiring detective ones4-13 Check 1: Measure the applied vcltage between 54 and Ny With the battery plug ON; SWky, LSB, LSA,, DSF (DSR), LSAz ON. Terminals Measured CN, (12) 54 F N= Tester Range cso Standard 36 Vor 48. V If normal——> proceed to check 2. If defective —> proceed to check 7 Check 2: Measure the applied voltage between 10 and Ny With the battery plug ON; SWky, LSB, LSA, , DSF (DSR), LSA, ON Terminals Measured Both MS coil terminals Tester Range cso Standard 36 Vor 48 V If normal—+ proceed to check 3. If defective—> MS coil wiring is defective. Check 3: Measure the applied voltage between 51 and Ny With the battery plug ON; SWky, LSB, LSA,, DSF (DSR) ON Terminals Measured CN, (3)51 B NS Tester Range ‘0c50 Standard WV If normal—— proceed to check 4. If defective—> SG is defective (probably near Dp.21 but not definitely). Check 4: Measure the VRA resistance. Disconnect the battery plug and measure the VRA resistance at CNy. Terminals Measured CNy (1) 51 CN; (6) 53 Tester Range Qxtk Standard 10k2 If normal——> proceed to check 5, Hf defective—> VRa is defective a4-14 Check 5: Measure the applied voltage between Pe and Ny With the battery plug ON: SWky, LSB, LSAy, DSF (DSR), LSAz ON. Terminals Measured Pe + N= Tester Range eso Standard tov If normal —+ SG is defective (probably near Rigg, but not definitely) If detective proceed to check 6. Check 6: Measure the SS continuity. Disconnect the battery plug. Disconnect the SS wiring, and measure the continuity between the anades and cathodes, Terminals Measured cathode + cathode = (Forward) anode (Reverse) anode Tester Range Qxik Standard Over 10 kQ in both forward and reverse If normal —+ SG is defective (probably near Tyoq, but not definitely). If detective—> SS is defective, Check 7: Measure LSA, continuity. Disconnect the battery plug. Measure LSA continuity at Cy. Terminals Measured CN» (3) 54 Ny (7) 56 Tester Range a Standard 0 Qwith accelerator fully depressed If normal LSA. wiring is defective, If defective—> LSA is defective,5 (Check 1: Check fuse F, mounting Commutation fails, (If normal) ! Check 2: Check Mp or Mp beontact Uf normal) (Check 3: Check $$ gate wire and terminals (If normal) i (Check 4: Check C, (The pointer first deflects and then st 416 Check §: Check SS |—utdefective) + Fuse F, terminals, or wiring defective [it detective) + Repair or replace contacts [iif defective) + Repair Lit detective) > C, wiring is defective ays at =) [lif defective) + SS or wiring is defective | (Between AK: Over 102 in both 100 9 in reverse} 1 (Check 8: Measure continuity between P; Py SSS oa) forward and reverse; Between GK: approx. 30 2 in forward. approx. Check 6: Check Ly. Ly + Ly. Ly or wiring is defective “ Check 7: Check SM fp re rewens ed ee cerenne cr oe (Over 10 kin both forward and reverse) 2) Poor brush contact, disconnected armature coil Check 9: Measure continuity between P, Py Lone rere on SG defective (near SCR) Disconnected field coil = 98Check 2 Che Check the fuse F; mounting. Disconnect the battery plug. Check the fuse F, mounting terminal for looseness, and chech the wiring If normal —> proceed to check 2. lfdefective—> Tighten the fuse F, terminal, nd check the wiring, Check the MF or MR b-contacts. Disconnect the battery plug. Check visually to see whether foreign matter has lodged in the contacts. If normal——> proceed to check 3. If defective— repair or replace the MF or MR contactor b-cantact. Check the $S gate wird and terminals, Disconnect the battery plug. Check the $$ gate wire and connector for faults, Also, check the SM, Cy, Lo, Ly terminals for poor contact. If normal—» proceed to check 4, If defective—> take remedial measures. Check 4: Check C, Disconnect the battery plug. Disconnect the C, wiring and check for continuity Note: Before checking, short C with a resistance of about 100 2. Terminals Measured Both C, terminals Tester Range 2x 100 Oren When the tester probe is contacted, the pointer deflects and then stays at 2 If normat—> proceed to check 5. If defective— after checking C, individually, check the wiring for faults Check 5: Check the SS, Disconnect the battery plug. Disconnect the $S wiring and measure forward and reverse con: tinuity between anodes and cathodes, and between the gate and cathode. Between AK | (Forward) anode = ——— cathode + ] - + z Terminals Measured (Revers) anode ¢ ——— cathode =| (Forward} gate — ———— cathode + es (Reverse) gate + cathode — Tester Range oe Between A-K Qxtk Between G-K | Qx1 |417 Between A-K Standard Over 10 kQ in both forward and reverse Between G—K Approx. 30 Q in forward, approx. 50 2 or 100 9 in reverse If normal ——> proceed to check 6, If defective —> SS or wiring is defective Check 6: Check the Lo, Li. Disconnect the battery plug. Disconnect the reactor wiring, and check for continuity. Terminals Measured Between Lo, Ly terminals Tester Range 2 Standard on If normal-—> proceed to check 7. If defective—> Lo, Ly or wiring is defective, Check 7: Check the $M, Disconnect the battery plug. Disconnect the SM wiring, and check between anodes and cathodes for shorts, (Forward) Terminals Measured (Reverse) anode 3 anode & cathode cathode © Tester Range QxIk Standard Over 10 k@ in both forward and reverse 'f normal —> proceed to check 8. If defective — SM or wiring is defective. Check 8: Measure the continuity between P, and Py Disconnect the battery plug. Remove the continuity between P2 and P3. In this case, the MF and MR b-contacts, SG unit from the control panel, and measure the insert an insulator such as a piece of paper between Terminals Measured Py Ps Tester Range a Standard 0a If normal——> preceed to check 9. If defective —> Brush lifts or DMD armature coil is disconnected.4-18 Check 9: Measure the continuity between P4 and Ps Disconnect the battery plug. Remove the SG unit from the contral panel, and measure the continuity between Py and Pg. In this case, insert an insulator such as a piece of paper between the MF and MR b-contacts. Terminals Measured | Tester Range Standard | 02 If normal——+ SG is defective (probably near SCR, , but not definitely) If defective—+ Disconnected DMo field coil Other Trouble (1), Though MF, MA attract, the vehicle moves only in one direction, © Shift the accelerator lever to the direciton in which the vehicle does not move, and do the troubleshooting procedure of item 2. (2) ME and MA attract, but part within seconds. There is no spark on contact © Defective DMD wiring, or disconnected DMD, or brush is lifting, Fuse F, blown out, (3) MS sucks attracts prematurely, creating shock (attracts within one second of start-up). © SG unt is defective, (4) MS attracts too late (takes several seconds even when lightly loaded) ‘© Troubleshooting as in item 4. (8) Fuse F, frequently blows, © Fuse F, mounting is loose. © Brake is dragging, © DMO commutator wear, or coil short. © DF, or DF2 shorts. (6) Anelectric shock is generated, @ Faulty insulation, (7) Plugging brake action is too strong © Improper adjustment of plugging set variable resistor (Ryor), o the SG unit is defective. (8) The vehicle stops sudenly and unexpectely. © Faulty terminal contact, or poor connector and S$ gate wire contact. * When operating the vehicle with the wheels jacked up, lightly tap each part with an insulator, to locate the faulty contact. Make sure that you never strive the gate wire,moTORS Page SCHEMATIC DRAWINGS & COMPONENTS PARTS............ 5-2 SPECIFICATIONS ..... 0.02. 0c ees eseeeeeueeeeneeeenens 5-5 SERVICE STANDARDS . . REMOVAL Iennnene seseenene sess eeneeeease estore eee ee eee 5-10 ee ee 5-12 Power Steering Motor. ......... ees eeeee cece eee eee 5-13 DISASSEMBLY INSPECTION. ASSEMBLV ies tec cer eh eee eee er 5-215-2 SCHEMATIC DRAWINGS & COMPONENTS PARTS onsene Oil Seat 7. Front Bracket 8. Front Cover 9. Yoke 10. Field Coil nn Rear Cover 12. Brush Brush Holder Reear Bracket Armature fe Motor Bracket No.1 Drive Motor Bracket No.2 Fig, 5-1. Drive Motor6-3 oe een Pump Motor Bracket Front Bracket Front Cover Yoke Field Coit Rear Cove Brush Brush Holder Armature Set Plate Rear Bracket Fig, 5:2 Pump Drive MotorRear bracket Armature Field coit Yoke Front cover Power steering motor bracket Insulator Front bracket Brush holder Brush Fig. §3 Power Steering Motor5-5 SPECIFICATIONS [9€"1 x og" x v9'0) [9€'L x 02"L x 08'0) [9E"L x 09"L x ¥9'0) [9€°L x O9"L X p9'0) T [961 x 0z"1 x 080) [ui vex Ob x OL EX 0€ x 02 vex Or x91 ve XOr X91 vex oe x oz | (ww) axis ysnag Topios “dwar Tepjos “aula b yuawrean + De eoleds oMREsee 1 hemp H a 3 a (Sep) vonelnsuL i > = > > 08 (Seinuiyy) Buney Sv ¢ Sie Sie 7 (oi) andino) F9v/Se € SOv/Se SOv/SE 9€ 1A) ae0A, > > > = wou185 90 adAL (s9p 100) (is) wan St "0ZWOB4z-0P “ [eeeeeoe coe oewoas-0e oevoas oewoes | _devondz-oE [ - ToioW ONG | jepow [9€'L ¥ 09'L * ¥9'0) [[9E"t X 09's x P9'O] [9E"L x OL x PTOI] [GEL x O21 x 950] [IGE x 09 x OG) [GEL XO XOSO] ve x Ov XOL ve x Ob X9L vex Ob x OL vexoexrl| — vexopxszi] — vexorxgzi| (uu) ois ysrug Tepios “duiay | sepjos “Guay Tepjos dwar opjos “diver uauieen UyBiy jeloeds | ubiy 1etoads yBiy (eioadg 61 ubiy fe}20dg piapiog | sesus soreinuwog 4 4 a 4 4 a > = = > 5 09 (eanuiyy) Guney giv sy ov ze BvILe BvILE (mw) acing) FOv/SE FOv/SE SOWIE se SF Ov/Se SOvISE (A) 210A, = | 5 > > = Sol185 0G BOL (Say G700) (ais) (aus) (sa G100) (ais) we sivoazoe sivoaiz sivoasz sevoasz ElvoasZ-0E elvoase elvoadz ozvoase sevoase ozvoasz olvoase-0E olwoaaz olwoas2 — | lapow ToVeW eANNO —an[80" x09" x09'0) (ui) (00 | Xv9'0x0'0} x [9E"L x09" L x9" ollise 409° 1 x99°01|[80' 1 *09'L *09'0] |[ 80" x09" L x0s"0]| SZx9LxOL vExXOpXPL vEXOPXHL LEXOvXGT LEXOvxSTZL LEXOPXGTL) {uus) azis ysnag ap jos ‘duor juauneon 108 ybiy jervads, Bu pazesg. pazeig oy 61 Piaplos yoyepNWIWO? 4 =a J 4 J A a (ssei9) uoneinsuy 09 > > > > = s {sounuiyy) Sunew v0 gzt/oL OL gzuoL v Sib giv (my) anding ev/Se 9v/SE se On/se se Op/SE op/Se {A} a6e110A, sues 90 punaduios oq > > > > suas 90 adAL isspan09)aus) (ssv 0109) (ais) wer oevoas oevoss G1084Z-08 SIVo8sz SIVO8sz 4010) SZVIGIT-OE S7vIasz €L983Z-0E Elwossz €Lvogsz ang. riven GZ OZVIGIT-OY | OZWIIZ-OE ozwoasz OL984z-0E olvoasz olvogsz Buysaaig Jamog “Teioyy aaug duing lepoy57 (UL Type) [80° xo8'0x0s'0] . [9E'Lx09'L x9g‘0]][9e" 1 x09" x9G'0}][80'L x09" x0S-0}|fe0"Lxo9 LxoSO]] [4] WX0EXSTL. vEXOPXEL vexopxrl| —— cexorxgzi| —_2Zxopxg'21| (wwjezis ysrug Jepjos “dust ; > | queuneen sas Bi pozeig pozeig a a pees H 4 4 J J (sseia}uone)nsuy 09 > > > > $ (seinuiy}buney v0 gzi/ol oL gzZW/oL ¢ giv (minding LvISe ovse | se opIse se ov/se ()a6e0n 3908590 punoduics 3g > > > 301188 90 adAL oewoas-0€ oswoas givossz-08 siwoaaz wet] a sewoesz-0e sevoasz ELvoEsZ-0e eLwoasz ang dwny [S2'0evoRsz-or | OzvoKse-0E ozwoesz olwosaz-0e olwoasz Burs881$ emo JOROW enlIg duing | lapoy) [9€" x02" x08°0)}[9€"t XO9'L x0S'0] |[9E" L x09" Lx 79'O} |[9E" xOz'L xO8‘0) |{9E" L x09" x09'0]][9E"L x09"L x0S'0) 9" x09"Lx0S"0]] [ut] pe xOExOe| vEXOPx9L bexOPx9L vex0Ex0Z| vEXOPX91 PEXOEXPL| —_vEXOPXG'ZL|(WUL) O18 ysrug ; apjos ‘dwiar A vepjos dua | rm Jepjos ‘dwar | auowneen J981s ML | ybiy jeroodg = 7 Usiy jeioedg oa uBiy jersads | soveinwwog 3 a a 7 7 7 5 [eagjuoperreur | > > > > > = 09) sanuiyybuney ¥ > giv v oi ce aviLe (mpanding | se > 9b/Se se SF 9v/Se se Sovse (A)e6210n = > > > | > > S085 90 adAL | givoaz-oe sivogaz wait szw08sz-06 sewoasz elvoaaz-oe elvogie cevoasroc | cevoas | az“ozvoasz-or | ozvoese-oe oewoasz olwoaaz-08 olwoade 4020/4 BAG lepow5-8 SERVICE STANDARDS Commutator repair limit Refer to text Spring standards | Drive Motor | 2FBCAtO, 13, 15 (STO) 1.4 kg (3.09 Ib) 2FBCAI0, 13, 15 (COLD 45S) 1 7 3O-2FBCATO, 13, 15 7.2 kg (2.65 1b) 2FBCA20, 25 (STD), 40-2FBCA20, 25 | 1.89 (3.97 1) 2FBCA20, 25 (COLD 455) t 30-2FBCA20, 25 1.7 kg (3.75 1b) FBCA30 (STD) 1.8k9 (39710) | FBCA30 (COLD 45S) t 30-FBCA3O 1.7 kg (3.75 1b) Drive Motor |_2F8CAT0, 13, 15 1.4 kg (3.09 Ib) (UL Type) | 30-2FBCA10, 13, 15 1.2. kg (2.65 Ib) 2FBCA20, 25; 40-2F BCA20, 25 1.8 kg (3.97 Ib) 30-2FBCA20, 25 1.7 kg (3.75 Ib) FBCA3O 7.8 kg (3.97 Ib} 30-F8CA30 1.7 kg (3.75 1b) Pump Drive | 2racato.19,15(STD): 40-2FBCA20,25 [1.4 kg (3.09 Ib) Motor 2FBCANO, 13, 16 (COLD 458) t 30-2FBCAI0, 13, 15 + 2FBCAZ0, 25, FBCA30 (STD 1.5 kg (3.31 1b) COLD 458) 30-2FBCA20, 25, 30-FBCA3O + Dump Drive | 2FBCA10,13,16; 40-2FBCA20, 25 | 1.4 kg (3.09 Ib) Motor BO-2FBCATO, 13, 15 + (UL Type) |” 2FBCA20, 25, FBCA3O 1.5 kg (331 Ib) 0-2FBCA20, 25, 30-FBCA3O + Power Steering Pump Drive Motor 0.4 kg (0.88lb) Power Steering Pump Drive Motor (UL Type) + | Brush Wear Limit | Drive Motor | 2FBCA1O, 13, 15 (STO) 12 mm (0.48") 2FBCA10, 13, 15 (COLD 45S) + 30-2FBCA10, 13, 15 15mm (060") | 2FBCA20, 25 (STD);40-2FBCA20, 25 | 13 mm (0.52") ‘2FBCA20, 25 (COLD 45S) t 30-2FBCA20, 25 14 mm (056"} FBCA30 (STD) 13 mm (0.82) | FBCA30 (COLD 45S} t 30-FBCA30 14 mm (0.56")Brush Wear Limit] DriveMotor | 2FBCA10, 13, 16 12 mm (0.48") (UL Type) 0.4 ; 15mm (0.60") ~ | 13mm (0.62") | 30-2FBCA20, 25 14 mm (0.56") FBCA3O ~ | 13 mm(052") 30-FBCAGO | t4mm(o5e) | [Pump Drive | 2F8cat0.13,15(STD); 40-2F@CA20,25 | 10 mm{0.040") Moter [2FBCA10, 13, 15 (COLD 45S) t | 30-2FBCA10, 13,15 _ t 2FBCA20, 25, FBCA30 (STD 15 mm (0.60") coLp 48s) | 30-2FBCA20, 25, 30-FBCASO t Pump Drive | 2FBCA10, 13, 16; 40-2F8CA20, 25 | 10 mm(0.40") (i type) [S02FBCAIO 13,15 at 2FBCA20, 25, FECA30 18 mm (0.60") 30-2FBCAZ0, 28, 30-FBCA3O 1 Power Steering Pump Drive Motor 16 mm (0.64”) Power Steering Pump Drive Motor (UL Type) 15 mm (0.60") Insulation reistance More than 1MQ | SST & INSTRUMENTS J 80201-10250-71 Battery Hanger 09010-10260-71 Motor Hook TOOL, Torque Wrench INSTRUMENTS | Tester, Insulation resistance meter (500V, 100 M2)5-10 REMOVAL Drive Motor 1, Remove the mest Note: (© First remove the forks from the fork bracket and then remove the mast together with lift eylinder and ‘ork bracket attached, © For mast removal, refer to procedures under Mast”, 2. Remove the battery. Note: For battery removal, refer to procedures under Battery”. tthe lead wires from the motor. Note: Place tags on the wires before disconnecting them to make sure that they will be reconnected correctly. Fig, 5:7 Disconnecting WiringRemove the motor, together with differ. ential and front axle toward the front end of vehicle, Note: For differential and front axle removal, refer to procedures under “Transmission and Differ- ential’ Drain out the differential oil, and separate the motor from the differential. Fig. 5:9 Separating Motor from Transmission Fig. 5-10 Drive Motor — 1075-12 PUMP DRIVE MOTOR 1. Remove the battery and take off the side frame cover. Separate the battery connector, and dis connect the wiring to the pump drive motor. 3. Remove the bolts attaching the pump motor set plate and take off the oil pump, 4, Remove the punp drive motor from the frame side. Fig, 6-14 Removing Purp Motor5-13 POWER STEERING MOTOR 1. Remove the side frame cover. 2. Disconnect the wiring to the power steering motor, Remove the power steering oil pump. Note: Remove all set bolts from the power steering motor bracket except one. Leave this on temporarily 4, Remove the power steering motor. Fig. 5:18 Removing Oil Pump5-14 DISASSEMBLY In construction, the ‘notors are practically the same so that in regard to disassembly, only the drive motor shall be covered in this manual. 1, Before starting disassembly, measure the insulation resistance of the motor with insulation resistance meter (S00V, 100M) Servic standard Insulation resistance | More than 1M 2. Remove the rear cover and take out the brushes. Note: When removing the brushes, note their brush holders 0 that at reassembly, the brushes will be replaced in the original brush holders. 3. Punch aligning marks on the front bracket, rear bracket, and yoke. 4, Remove the front bracket set bolts and stand up the motor with the front bracket at bottom side, Note: Use wood blocks when standing up the motor ‘and use care not to damage the motor shaft. Fig, 5:22 Removing Set BoltsRemove the rear bracket set bolts, and after disconnecting the krush holder wir- ing, remove the rear bracket together with the brush holders attached, Note: The bracket is fitted to the bearing so that in removing, use a copper hammer and drive out corefully. Remove the brush holder from the bracket only when required (such as. replacing brush holder), Remove the yoke. Note: When removing the yoke, use special care not to damage the field colls or other parts. Remove the front bracket from the arma- ture, Note: When removing the front racket, use special care not to damage the oil seal or other parts. Fig, 8-26 Removing Armature in 5-155-16 INSPECTION A. FIELD COILS 1. Clean the field coils by blowing with com. pressed air. If unable to clean off the oily or greasy dirt with compressed air, wipe lightly with cloth dipped in thinner, using care not to daniage the field coil insulation. Check the field coil continuity. Inspection Point | Terminals measured Field coil (Series motor) Terminal E — Terminal F (Compound motor) Terminal AC — Terminal] FD Tester range 2 Service standard Field coil Measure the field coil insulation resistance with insulation resistance tester (500V, 100MQ} Service Standard Insulation resistance More than 1MQ B. ARMATURE COIL 1, Clean the armature coil by blowing with compressed air, If unable to clean off the oily or greasy dirt with compressed air, wipe lightly with cloth dipped in thinner, using care not to damage the armature coil insulation Visually check the armature for damage and for loss of balance weight. Fig. $30 Cleaning Armature Coilc. COMMUTATOR 1. Clean the commutator slots with a scrubb- ing brush, For dirt that fails to come off easily, lightly wipe with cloth dipped in thinner, and then blow dry with compressed air. Fig, 5:31 Cleaning Commutator 2. Inspect the commutator for damage, discoloration, and other defects. Commutator color: Bright brown Fig, 5-32 Inspecting Commutator Note: For detailed inspection of the commutator, refer to “Motor Repair Manual” (No.95625). If found necessary to machine the commutator, do so in accordance with commutator lathe repair procedures. Bere OY ieee eee eee eee eee i | 1“ os 0.8 —te a} commutator Bar | \ OY Risv~18 [commutator | V ‘Outer Diamecer ea5-18 Applicable Velicle Standard Diameter Service Limit Drive Motor |2FBCA1O, 13, 15 (STO) Tismm (a6) | n2mmiaas") —_ | 2FBCAI0, 13, 15, (COLD 458) t t — (30-2FBCA10, 13, 15 125 mm (5.00") 122 mm (4.88"") [Brecazo,25(STOr: 40.2FBCA20,25 | 160 mm (6.00) 147 mm (8.88") |2FBCA20, 25 (COLD 45S) t | t 30-2FBCA20, 25 + ft |FBcAgO (STD) - t t FBCA3O (COLD 458) i : a 30-FBCA30 t t [Drive Motor | 2FSCAt0, 13, 15 115mm (4.60%) | 112mm (448") | (UL Type) [30-2FBCAN0, 13, 15 125 mm (5.00) 122mm (4.88") | 2FBCA20, 25; 40-2FBCA20, 25 : 150 mm (6.00") 147 mm (5.88") 30-2FBCA20, 25 t : + FBCA30 t t - 30-FBCA30 t t al Pump Drive | ESCA JS JSTOR 80 mm (3.20") 77 mm (3.08") _| Motor 2FBCAI0, 13, 15 (COLD 48S) _t t ‘30-2FBCAI0, 13, 15 t 7 t 2FBCA20, 25, FBCA3O (Sop asg)|__ 100. mm (4.00") a7 mm (338°) | 30-2FBCA20, 25, 30-FBCA30 t t Pump Drive 2FBCAIO, 13, 15 ‘80 mm (3.20") 77 mm (3.08") | Motor 30-2FBCA10, 13, 15 u t (UL Type) — | Se SPARR AE SBCASO 100 mm (4.00") | 97 mm (3.88") [30-2F8CA20, 25, 30-FBCA30 t tT Power Steering Rump Drive Motor 70 mm (2.80") 67 mm (2.68") | Power Steering Pump Drive Motor (UL Type) ft t3. Measure the insulation resistance between the shaft and commutator with insulation resistance meter. Service standard Insulation resistance | Mere than 1 MQ. ] D. BRUSH HOLDER 1, Clean the brush holders by blowing with compressed air. If unable to clean off the oily or greasy dirt with compressed air wipe off lightly with cloth dipped in thinner, Also, visually check the brush holders for damage and other defects. 2. Using spring scale, measure the spring force pushing down the brushes. Service standard Refer to Service Standards values 3. Measure the insulation resistance between the brush holder and rear bracket with insulation r resistance meter (500V, 100MM) Service standard Insulation resistance | More than MQ Fig. §36 Measuring Insulation Resistance 115 — 5-195-20 —. BRUSHES 1. Inspect the brushes for wear, and replace any found worn over the limit. Service Standard Refer to service standard values Fig. &37 Inspecting Brushes5-21 ASSEMBLY 1, Assemble the armature to the front bracket and bolt the yoke finger tight to the front bracket. Note Match the aligning marks on the yoke and front bracket. 2, Assemble the rear bracket to the yoke, Note: Match the aligning marks on the yoke and rear bracket. Assemble the front bracket to the yoke. 4, Install the brushes and then install the cover, Fig. 5-41 Installing Brushes ae6-22 5. After completing assembly, turn the shaft by hand to check that it turns smoothly and without producing abnormal noise. Then measure the insulation resistance of the motor body with insulation resistance meter (500V, 100M} Service standard ce | More than 1 MQ Insulation resiste Fig, 5-42. Measuring Insulation ResistanceTRANSMISSION & DIFFERENTIAL SECTIONAL VIEWS ......... 00.000 see eee e ened 6-2 SPECIFICATIONS 0.6.2... 0c eee eee eee eee eee eee 6-4 SERVICE STANDARDS...........0-0eeeeee eee eee need 64 REMOVAL ... 1.2... cece eee eee eee ee eee eee 6-8 DISASSEMBLY . INSPECTION Seer eee eet eye 6-15 ASSEMBLY & ADJUSTMENT. ............0000 essences 6-18 INSTALLATION .... 2.0.0.2. eee ee ence eee eee eee 6-26 - 119 =6-2 SECTIONAL VIEW fi6-4 SPECIFICATIONS [——Wencite Series ] 2F8CA10,13,15 | 2FBCA20. 25 FBCA3O Item (20-2FBCA10, 13, 15) | {a0.2FBCADD, 25) | _(30-FBCA3O) Gear type | Hypoid gear | Ring gear tooth number 38 _ < | « Drive pinion tooth number é = + Gear ratio 583 | = | = Pinion gear | Number gears 2 7 | Number tooth 10 : Side gear | Number gears | 2 Number tooth i < = | Drive gear teeth number avs 24 "22 Output gear tooth number 63 6. ae Gear ratio 2338 2.78 [ Drive gear oil capacity & 7 a (incl, transmission} (USgal) (1.85) Oil used ~Hypoid gear oil SAE9O SERVICE STANDARDS Spider T Outside dia, standard _mm(in.) | 22.00 (0.880) | Outside dia. wear limit mmlin.) | 21.75 (0.870) ‘Side gear thrust washer Thickness standard __mmiin) 7.6 (0.064) [Thickness wear limit _mmtin) | _ 1.3 (0.052) | Pinion gear thrust «| ‘Thickness standard _rmm(in) 1.6 (0.064) washer [Thickness wear limit _rm(in) | 1.0 (0.040) Side gear to pinion gear backlash mm (in) | 0.10~0.25 (0,004~0.010) Fling gear thrust screw | ‘Thickness standard __mm(in) 13 (0.52) cap Thickness wear limit _mm(in) 17.5(0.46) Drive pinion starting zorque (w/pinion) kgm _(Felb) 1.10~1.35 (7.942~9,147) “Ring gear to drive pinion backlash ~___mmtin)_[_02~0.3(0,008~0.012) | Fling gear back side runout limit “mm(in) | __0.1 (0.004) Drive pinion starting torque (w/ring gear) kgm _(ftb) 1.24~1.64 (8.952~11.696) Thrust screw cap clearance ~ mmfin) 0.20.3 (0,008~0.012) (Thrust screw screwed in fully and unscrewed 1/8 turn)6-5 09310-22000-71 09950-20016 Remover, reamer bolt Puller universal Ses 09608-20011 Tool set front hub & drive pinion Brg. 09130~-30200-71 Replacer, oil tight 09370-20270-71 Replacer, drive pinion bearing6-6 COMPONENT PARTS AND TIGHTENING TORQUE a4 po a 1240~55 kom | ines ~ 8” (29 ~ 40 feb) J V7 =a T=40~55kg-m 10 14 121314 18 (29 ~ 40 fc) T=9~12 kgm Tasker | RSERE) wees eee aie Nascetrie amen ee eee! Fig. @3 Transmission Component Parts SiT=4.4~85 kgm (32 ~40 feb} Re SR cece ee dR 1-4, we T213~18 kgm TEE) 24 e 7 x } 7 /B | | \ abe hh ob b i a 2 arvoa vow can i Howson Sia euscen nee ners iste ajeeotce 1. tt Peo eee rieona eine Taye oan 7 Phan Ga Tit Wier 18 "OB z Roncer Be. Aajocta Ne Lock oomesaa ree a aes a emcee ie been a eee aaa x Subeme Fig. 6-4 Differential Component Parts = 1986-8 REMOVAL 1. Remove the mast, Note: (© First remove the forks from the fork bracket and then remove the mast, together with the lift cylinder and fork bracket atteched. © For mast removal, refer to procedures under Mast" 2. Remove the battery. Note: For battery removal, refer to procedures under 3. Disconnect the lead wires from the motor. Note: Place tags on the wires before disconnecting them to make sure thet they can be reconnected correctly. Fig. 6-8 Disconnecting WiringRemove the motor bracket No.1 set bolt, Note: ‘The set bolt is provided with self-locking nut so that new lock nut must be used at reassembly. Disconnect the parking brake wire. Note: In 2FBCA10, 13, 16 series, remove the parking brake wire clamps first, and then disconnect the brake wire. In 2FBCA20, 25, FBCA30 series, separate the pull rod at the actuator lever. Disconnect the brake pipe to wheel cylin- der. Note: Thotoughly wipe off all spilled brake fluid, Support the vehicle on stands and remove the front wheels, Fig. 6-12 Removing Front Wheel 127 -6-10 8. With the underside of differential case supported on jack, remove the bolts attaching the front axle bracket to the frame, Note: ‘The upper and lower bolts out of the four bolts at one side are reamer bolts so remove them by using SST (09310-22000-71) 9. Sightly jack up and draw out the motor. transmission & differential and front axle together toward the front side of the vehicle, and rest the motor on stand 10. Drain out the differential oil, and separate the motor from the transmission & differ: ential, Note: Make the separation by placing a stand under the ifferential and lifting up the motor. 11, Remove the front axle shaft. Note: ‘The axle shaft can be drawn out easily by striking the shaft center with a hammer after removing the set bolts. Fig. 6-16 Removing Axle Shaft12. Remove the diferential & transmission Fig. 6-17 Removing Axle Assy. (1) DISASSEMBLY DIFFERENTIAL CASE 1, Before disassembling the cifferential case, measure the runout at ring gear back side and ring gear backlash2. Loosen the ring gear thrust screw lock nut, and remove the thrust screw. 3. Punch matching marks on the bearing caps, and remove the bearing caps. Note: ‘The carrier and bearing cop have th surfaces machined while in assembled state so that the left and richt side bearing caps are not interchangeable. 4, Remove the differential case, side bearings, ‘and adjusting nuts together. Note: Keep the removed parts In good order so that at assembly the bearing inner and outer races, and ‘adjusting nuts will not be in original comt ration. 5, Remove the side bearing inner races with SST (09950-20016). Fig. 6-24 Removing Side Bearing anDisassemble the differential case. Note: Check the aligning marks made at disassembly. If not present, punch new aligning marks. 7. Loosen the staked parts of the ring gear set bolts, remove the set bolts and take off the ring gear. Note: Do not remove the ring gesr except when re- placing the ring gear, drive pinion, or differenti case. DRIVE PINION ASSEMBLY Remove the drive pinion assembly set bolt. 9, Drive out the drive pinion assembly by utilizing SST (09608-20011) Fig, 6-28 Driving Out Pinion Assy. — 131 =6-14 10. Release the staked parts of the drive pinion assembly lock nut with a chisel, remove the lock nut and take off the output gear, 11. Securely fix the bearing retainer part, and drive out the drive pinion 12. Release the staked parts at drive pinion end, and remove the pilot bearing with SST (09950-20016) 13, Remove the tapered roller bearing inner race with SST (08950-20016). Fig, 631 Removing Pilot Bearing Fig, 6-32 Removing Inner RaceRemove the tapered roller bearing outer race from bearing retainer. 4 Fig. 6-33 Removing Outer Race INSPECTION Note: Wesh the disessembled parts and inspect them to see if worn, damaged, or otherwise defective. Repair or replace all parts found faulty. If either the ring gear or drive pinion is found faulty, both should always be replaced as a set. 1. Excessive wear or damage in spider. . Diameter Standard 22,00 mm (0.880") Wear fimit 21.75 mm (0.870") Fig. 6-24 Spider Inspection 2. Wear or damage in side gears and side gear thrust washers Side gear thrust washer Thickness Standard 1.6mm (0.064) 7 Wear limit 1.3 mm (0,052) —_— Fig, 6-25 Side Gear Inspeciton = 133 -6-16 3. Wear or damage in pinion gears and pinion gear thrust washers pinion gear thrust washer Pinion gear thrust washer Thickness Standard 1.6 mm(0.064") Wear limit 1,0 mm(0.040") 4, Side gear to pinion gear backlash Standard 0,10 ~ 0.25 mm (c.004" ~ 0.010") 5. Wear or damage in drive pinion and ring gear teeth 6. Wear or damage in bearings. Fig. 6-39 Bearing Inspection7 Damage in differential case and bearing retainer, Wear in ring gearthrust screw cap. Thickness Standard 13 mm (0.52"*) Wear limit 11.5 mm (0.46") Fig. 6-41 Cap Inspection = 135 —6-18 ASSEMBLY AND ADJUSTMENT DIFFERENTIAL CASE 1. Assemble the ring gear to the differential lower case. Note: 1. Use new set bolts and apply Stud Lock manufactured by Lock Tight Co., or equi lent lock compound, to the threads before installing. After installing, stake the bolts. 2. Tighten the bolts in over-and-across sequence, ‘and make final tightening in continuous sequence at specified torque. Tightening torque 13 ~ 18 kg-m (939 ~ 130.0 ft-Ib) 2. Assemble the side gears, pinion gears, and spider to the differential case, tighten the differential case set bolts at specified torque, and lock the bolts with lock plates. Note: 1, Assemble the side gear thrust washers with ‘their oi! groove sides faced toward the gears, 2. Verify the aligning marks when assembling case, Tightening torque = 4.4~5.5 kg-m (31.8 ~ 39,7 ftlb)Install the side bearing inner races with SST (09370-10410-71). Note: Use care not to drive in the bearing reversed. DRIVE PINION ASSEMBLY 4 Assemble the tapered roller bearing outer race to the bearing retainer with SST (09130-30200-71), Assemble the pilot bearing to the drive pinion, and using SST (08370-20270-71), install the inner race of tanered roller bear- ing front side. Assemble the bearing, outer race, retainer and spacer to the drive pinion, 6-19 Fig, 6-49 Assembling Drive Pinion - 137 —6-20 7. Install the inner race of tapered roller bear- ing rear side to the drive pinion with SST (09370-20270-71). 8. Assemble the output gear to the drive pinion, and tighten the lock nut at speci- fied torque. Tightening torque 35 ~ 40 kg-m (252.7 ~ 288.85 ft-lb) Note: Do not stake the losk nut at this time, © Tapered roller bearing preload measurement Hold the drive pinion bearing retainer part in a vise and measure the drive pinion starting torque, Starting torque 110 ~ 135 kg-m (7.942 ~ 9.747 feb) If the torque does not measure within the above range, remove the lock nut and disassemble and measure the torque once _—Fig. 6-52 Measuring Starting Torque more. Preload Adjust Shims x [Part No. timm) ote = ) Decrease the shim thickness if the preload is No.1 | 41216-20540-71 | 0.10 below the specified value, and increase the shim No.2 | 41217-20540-71 | 0.15 thickness if the preload is above the specified value, No.3 | 41218-20540-71 | 0.35 No.4 | 41219-20540-71 | 0.45 Beans9, After obtaining the proper preload, stake the lock nut securely with a chisel. Note: Stake at two places. © Drive pinion projection adjustment Measure dimension A with a height gauge to within 1/100 mm, and determine the shim thickness by the following equation: (2FBCAI0, 13, 15, 20, 25 series) t= (A-29) + B/100 + C/100 (3FBCA3O series) t= (A-34) + B/100 + C/100 Where t: Shim thickness ‘Ax Measured value B: Stamped on transmission case C: Marked with electric pen on pinion {Example} Dimension A... 34.14 (Measured value) Dimension B...... 08 (Stamped value) Dimension C.... 00 (Marked value) Incase of above values, shim thickness t will will be t= (34,14 — 34) + 8/100 + 0/100 =0.22 Thus, two 0.10 or one 0.10 and one 0.15 shims will be used. Projection Adjust Shims Part No. timmy No.1 | 3343620640-71 | 0.10 No2 | 33437-20540-71 | 0.15 No3 | 33438-20540-71 | 0.35 Noa _| 33439-20540-71 | 0.45 Note: dimension Fig. 654 Dimension A Make the final verification by checking the tooth contact with red lead. ~ 139 -10 Assemble the drive pinion assembly to the transmission case and tighten the set bolts at specified torque, Note: To prevent the sat bolts from loosening, apply stud lock made by lock Tight Co., or equivalent, to the threads before installing Tightening torque 9~12 kgm (65.0 ~ 86.6 ft-lb) 11, Assemble the differential case to the differential carrier (transmission case), and install the bearing caps and adjusting nuts. Note: Verify the match marks on the bearing caps before installing them, © Side bearing preload and ring gear backlash adjustment. a, Lightly tighten the bearing cap set bolts. Tightening torque 2 kgm (14.4 ft-lb) b, Tighten the adjusting nuts from both sides until the thrust clearance becomes zero. Note: ‘Measure the thrust clearance by setting the dial ‘gauge against the ring gear back side. Tighten the adjusting nuts aternately by same amounts. ‘The ring gear becklash could be large at this Fig. 6-60 Measuring Thrust ClearanceSet the ring gear backlash to zero by adjusting the adjusting nuts. Note Measure the backlash by setting the dial gauge against the ring gear back side, and make adjust ment with adjusting nuts by tightening one nut fone notch and loosening other nut one notch Readjust the adjusting nuts and set the ring gear backlash to 0.2~0.3 mm (0,008 ~0.012") Note: Make the adjustment by the method of turning ‘the adjusting nuts such when one side is tighten- ‘ed one notch the othor side will be loosened one notch. After obtaining the specified backlash, tighten the left and right adjusting nuts ‘one notch each, and tighten the bearing cap set bolts at specified sorque. Tightening torque §~8 kg-m (43.3 ~ 57.6 frlb) Check the ring gear back ash and back side runout, gear back side runout by setting 2 dial gauge against the back side and turning the ring gear by hand, Backlash 0,2~0.3 mm (0,008"~0.0120") Back side runout 0.1mm (0.004"") 141 Fig. 6-64 Checking Backlash 6-236-24 @. Check the side tearing preload by means of drive pinion starting torque. Starting torque 1.24~1.64 kg-m (8.952~11.696 ft-lb) © Tooth contact check Lightly coat red lead uniformally on the ring gear tooth faces (3 or 4 teeth) and check the tooth contact by the pattern formed when the ring gear is turned, If faulty, perform “Drive pinion projection adjustment”, "Side bearing preload ad- justment”, and "Ring gear backlash ad- justment™. a. Heel contact Decrease the thickness of drive pinion adjusting shims and adjust the backlash by moving the pinion near the ring gear and moving the ring gear away from the pinion gear. Fig. 667 Heel Contact b. Toe contact Increase the trickness of drive pinion adjusting shims and adjust the backlash by moving the pinion away from the ring gear and moving the ring gear near the pinion gear’ Fig, 6-68 Toe Contact — 149 —cc. Flank contact Increase the thickness of drive pinion adjusting shims and adjust the backlash by moving the pinion away from the ring gear and moving the ring gear away from the pinion gear. d. Face contact Decrease the thickness of drive pinion adjusting shims and adjust the backlash by moving the ring gear near the pinion and moving the ring gear near the pinion gear. 12. After completing all adjustments, install the adjusting nut locks and lock the bear- ing cap set bolts with lock wires. 13, Set the ring gear thrust screw and adjust the clearance between the ring gear and thrust screw cap. id seal on the thrust screw. Thrust screw cap clearance 0.2~0.3 mm. {0,008"~0.012") (Screw in the thrust screw fully and then unscrew 1/8 turn) Thrust screw lock nut tightening torque 10,5~13 kg-m (75,8~93.9 ft-lb) Fig. 6-72 Adjusting Thrust Screw = 143 —6-26 INSTALLATION 1. Install the transmission & differential to the front axle assembly (differential hous- ing) 2. Install the drive motor to transmission & differential. Drive motor set bolt tightening torque 4,0~8.5 kgm (28.9~39.7 ft-lb) 3. Install the motor, transmission & differ- ential, and front axle together on the frame. Front axle bracket set bolt tightening torque 16 ~ 22 kg-m (115.5 ~ 158.8 fttb) 4, Install the front axle shaft. Front axle shaft set bolt nut tightening torque 2FBCAI0, 13,15, 4.0~6.5 kg-m 20, 25 series, {28.9~39,7 ft-lb) FBCASO series —-6,0~8.0 kg-m (43.3~67.6 ft-lb) =a Fig. 6-76 Installing Axle Shaft —Install the front wheels Hub nut tightening torque 2FBCA1O, 13, 15, 20, 2, series 12~ 17 kgm (86.6 ~ 122.7 ttb) FBCA3O series 30 ~ 33 kg-m (211.6 ~ 238.6 ftib) Fill in the differential oil, install the park- ing brake, and connect the motor wiring Note: Use special care to see that the motor wiring is correctly connected. Connect the brake pipes to the wheel cylinders, and fill in the brake fluid, Note: After filling in the brake fluid, always make sure ro bleed the systam until all air is removed. Install the mast. Note: Check the mast support cap aligning marks before installing. Fig. 6-80 Installing MastPee ee EL: r | 3 sf Fo [ren|roe| rs F sgx]For| 0° yo | 18 | 48 ra wy) as|s (es (FS 5 BVESVES|s3 [2 |» [oye | Sf oe : | 0 yaa] 35 rmooz! on [eh tigh 1 aa TOYOTA INDUSTRIAL VEHICLES PARTS & SERVICE NEWS TOYOTA MOTOR CORPORATION seri GENERAL GROUP GE-1009, L.M.W-1 4£B10~25.2FB30.FBA10~30.2FBCA10~30. TB(A)12 SERIES CORRECTION OF THE PARTS & SERVICE NEWS February 1 1991 1. CONTENTS ‘Adoption of shims for transmission drive gear introduce include the shim selection guide. Please add it as described blow. «4 by Patts & Service News Sa CB-3040 did not 2, CORRECTIONS . ports & Service News t CB-3040, LM.W-1 differ GRANSMISSION DRIVE GEAR SHIM SELECTION GUIDE and ¢ 4 Dimension § indicated on the motor ‘Transmission case care to nected Drive motor shaft the br and fill Shim installing position gin the t 2 system | ee Shim Selection Guide - - Ti) Read value & indicated the Shim thickness mm Gn) | __ Parts Ne (2) Select the number and thickness of the Sree to be added according to the table 0.4(0.016) 33317-22580-71 Shown on the next page e mast. (9) Install the selected number of shime im 0.5 (0.020) 393818-12580-T1 tRusvosition. deseribed in the figure ee pe seribed in the Gt 0.6 (0.024) 39319-22550-71 above. 3Shim Selection Table Number of sh Smm S+0.3mm to be added Dimension indicated on the motor | Thickness of shims to be added 0.4mm | 0.5mm | 0.6mm, 0.5 0.8 2 0.6 0.9. 1} 1 0.7 1.0 2 0.8 LL Lda 0.9 1.2 2 1.0 13 ~f2 | a Ld 14 1 | 2 1.2 15 3 13 1.6 2] 1 14 aby, 1} 2 15 18 3 1.6 19 1] 3 1a 2.0 4 18 21 3]. 19 2.2 ale 2.0 2.3 a 3 21 24 4 2.2 2.5 5 2.3 2.6 4]. 24 27, 3 | 2 25, 2.8 2 3FRONT AXLE Page [2FBCA10,13, 15 SERIES) SECTIONAL VIEW AND COMPONENT PARTS ............ 7-2 SPECIFICATIONS 1.0.0.0... ccc cece e cece e eee eee 7-3 (JGZUNZSG Gooocopocgungpnc copoungonocopoDocono0 7-4 DISASSEMBLY 7-5 SRN TNe ne nO ee 7-6 ASSEMBLY .... 2... 2... o eee eee ee eee ene 7-7 INSTALLATION .. 0.0... cece eeeeeeeeeeeeeeee teens 7-8 (2FBCA20, 25, FBCA30 SERIES] SECTIONAL VIEW AND COMPONENT PARTS 7-10 Sere evvne rece runnOtnee easeaceatereeetee ee eeeeeeetee terete eee ata 71-12 SERVICE STANDARDS .............0..2 2220 eeee eee 7-12 REMOVAL ASSEMBLY .7-2 {2FBCA10, 13, 15 SERIES] SECTIONAL VIEW AND COMPONENT PARTS Fig. 7-1 Front Axle Sectinal View (2FBCA10, 13, 15 series) | T=7.5~10.0 kgm T= 16.0~22.0 kg-m (54.2 ~72.2 fib) _ (115.6 ~ 1889 ftlb) 2 3 1 T=120~14.0 kom (86.6 ~ 101.1 feb} Bearing adjusting nut Grease seal aring lock nut Front axle shaft gasket Front axle shaft Fig, 7-2 Front Axle Component Parts (2FBCA10, 13, 15 series)SPECIFICATIONS Item Series 2FBCAIO, 13,15 series Front axle type Full floating type Front axle suspension Fixed to frame Front axle shaft Spline tooth number 26 LL Length mm (in) 432 (17.28) SST & MEASURING TOOLS (09509-55010 09509-55020 Remover and replacer Bearing nut wrench 09310-10160-71 Remover, front axle ssT = hub Replacer, front axle 09870-10410-71 P bearing R front ax 09310-22000-71 eae set bolts Tools | Spring scale, Torque wrench - 149 -4 REMOVAL 1 2. Lift up the front wheels, (1) Block the rear wheels. (2) With the mast at maximum tilt to the rear position at stand under the mast, then tilt fully forward. 3. Remove the front wheels, (1) Hub nuts, (2) Front wheel 4, Remove the set nuts on the front axle shaft 5. Remove the set screw dowel. (1) Strike the middle of the flange of the axle shaft with @ hammer. (2) Spring washer. (3) Set screw dowel 6. Take out the front axle shaft, Caution: Watch out for gear ail splash. 7. Remove the hearing lock nut! SST:09509-55010 Fig. 7-6 Removing the Lock Nutsg, Remove the bearing ring Caution When not removing with a screwd service bolt (M6, P=1.00). er, use 9. _ Remove the bearing adjusting nut. SST:09509-55020 10. Remove the front axle hub. SST: 09310-10160-71 DISASSEMBLY Important After inspecting each part, disassemble if the oil seal and bearing are found defective. 1, Remove the oil seal Fig. 7-10 Removing the Oil Seat2. Remove the bearing and bearing spacer. SST: 09608-26013 Caution: Drive out from the bearing side, 3. Remove the hut bolts. (1) Nuts (2) Hub bolts 4, Remove the axle shaft set stud bolts. INSPECTION 1. Front axle shaft (1) Cracks, wear or damage of the splines (2) Bearing 2. Oil seal (1) Damage, deformation, deterioration. 3, Bearing (1) Bearing damage, scoring, poor revolution (2) Roller splitting. rp atin Fig, 7-11 Removing Bearing & Bearing Spacer. Fig, 7-14 Inspecting the Oil Seal4, Front axle hub. {1) Damaged or loose hub bolts. (2) Damaged to hub bolt lock groove. (3) Damaged or loose axle shaft set stud bolts. 5. Bearing spacer (1) Damage 6. Bearing lock nut, bearing adjusting nut, bearing ring (1) Damage to threaded portion. ASSEMBLY 1, Assemble the front axle shaft set stud bolts. T=4~ 5.5 kgm (28.9~39.7 feb) 2. Assemble the hub bolts. (1) Hub bolts (2) Nuts T = 10~ 12 kgm (72.2 ~ 86.6 ft-lb) (3) Staking Caution: Perform the staking in the shape of a cross. 3. Assemble the bearing ‘SST: 09608-36013 Caution: Grease the roller portion 18 Assembling the Bearing - 153 -18 4, Assemble the spacer SST: 09608-35013 5, Assemble the cil seal SST: 09130-30200-71 INSTALLATION 1. Install the front axle hub on the front axle, SST: 09370-10410-71 2, Tighten the adjusting nut, SST: 09509-55010 Caution: Assemble the knock pins facing the outside. Fig. 7-22 Fastening the Adjusting Nut3, Assemble the bearing ring, Caution- Align the bearing ring grooves and the adjusting ut knock pins. 4, Tighten the bearing lock nut. ‘SST: 09509-55010 6 Assemble the front axle shaft. (1) Packing (2) Frontaxle shaft (3) Set screw dowels (4) Spring washers (5) Set nuts T= 4~5.5 kgm (28.9 ~ 39.7 ftlb) 6. Install the front wheels. (1) Front wheels (2) Provisionally tighten hub nuts. (3) Remove piece of stock. (4) Fasten hub bolts to the specified tightening torque, T = 12 ~ 17 kom (86.6 ~ 122.7 ft-lb) Fig, 7-25 Assembling the Front Wheel 7. After the procedure has been completed, perform the following checks and adjust- ments. (1) Differential oil level (2) Foot brake action (3) Parking brake action (4) Possibie noise, failure of various parts. ~ 185 —7-10 {2FBCA20, 25, FBCA30 SERIES] SECTIONAL VIEW AND COMPONENT PARTS T= 16.0 ~22.0 kgm T = 16.0~22.0 kgm (115.6 ~ 158.9 ft-ib) (115.6 ~ 158.9 fb) T= 10.0 ~ 12.0 kgm (72.2 ~86.6 ft-lb} T#12.0~17.0 kgm (86.6 ~ 122.7 fr-ib) Oil seal Front axle housing Front axle bracket Front axle hub Brake drum Grease seal T=7.5~10.0 kgm Bearing lock nut (64.2 ~72.2 fb) Front axle shaft gasket T= 12.0~140 kgm So ee (86.6~ 101.1 fib) | Oil seal 11. Inner bearing 12. Outer bearing 13. Bearing adjusting nut 14, Bearing ring | on 121314 724.0 ~55 kgm (28.9 ~29.7 feb) Fig. 7-27 Front Axle Component Parts (2FSCAZ0, 25 series)Fig 728 Front Axle Sectional View (FBCASO series) Loan ase maee (115.6 ~ 1589 frib) (115-6 ~~ 158.9 Frtb) Oil seat Front axle housing Front axle bracket Front axle hub ‘Outer bearing | T=12.0~14.0 kg-m (96.6 ~101.1 ft-lb) Bearing adjusting nut T=6.0~8.0 kgm Beorng ring | (43.3 57.6 feb) Bearing lock nut 12:13 14 Front axle shaft gasket Front axle shaft Fig 7-29 Front Axle Component Parts (FBCA30 series) 157 —7-12 SPECIFICATIONS —== a Series 2FBCA20, 25 series FBCA30 series Front axle type Full floating type Front axle suspension Fixed to frame Front axle | _ Spline tooth number 26 26 oe Length mm (in) 485 (19.80) 534 (21.36) SERVICE STANDARDS —— A Pea ———__Sres 2FBCA20, 25 series FBCA30 series Front axle hub starting force kg (Ib) | 22~6.4 (4.9~ 14.1 Ib) = sst 09509-55010 Wrench, wheel nut 09310-10160-71 Remover, front axle hub 09370-10410-71 Remover, bearing 09310-22000-71 Remover, reamer boltREMOVAL 1 Loosen the front wheel hub nuts, Tilt the mast backward to place stand under the mast. With the stand placed at the side to be lifted, tilt the mast forward to lift the wheel, Remove the front wheel Remove the front axle, Note: © After removing the set nuts, strike the shaft center with a hammer. This will make it easier to draw out the shaft © Be sure that gear oil is not leaking, Remove the bearing lock nut with SST (09509-55010) Fig. 7-30 Lift the whee! Fig. 7-31 Removing Front Whee! fe Fig, 7-33 Removing Lock Nut = 189 ~7-14 5. Install service bolts in the bearing ring, and remove the bearing ring and oil seal 6. Remove the bearing adjusting nut with SST (09509-55010) 7. Remove the frovt axle hub with brake drum attached by using SST (09310- 10160-71) 8. Remove the oil seal from the front axle hub. Note: In 2FBCA20, 25, FBCA3O series, the snap ring is removed first before removing the oil seal. Fig, -37 Removing Oil Seal9, Remove the outer races of the inner and outer bearings from the front axle hub. Fig. 7-38 Removing Outer Races INSPECTION 1. Cracks or damage in axle shatt. 2. Cracks or damage in front axle hub Excessive clearance or abnormal wear in bearings. Deformation or damage oil seal lips, . 7-39 Axle Shaft Inspection Fig. 7-40 Bearing Inspection — 161 ~7-16 ASSEMBLY 1, Install the hub bolts to the front axle hub. jake sure to irstall the hub bolts properly into the hub lock stots, © Tighten the hub bolt nut with the specified tightening torque and stake the hub bolt securely. Hub bolt nut tightening torque 2FBCA20, 25 series. 10 ~~ 12 kg-m (72.2 ~ 86.6 ftlb) FBCA30 series, 17 ~ 21 kgm [122.7 ~ 151.6 felb) 2. Drive in the outer races or inner and outer bearing to the front axle hub. 3. Pack MP grease into the inner bearing inner race and insert the race into the front axle hub. Then, driven the oil seal. Note: Verify the oil seal has been positioned in correct direction before driving it in. 4, Pack grease into the front axle hub. Grease used MP greaseInstall the front axle hub with brake drum attached to the front axle housing, and then using SST (09370-10410-71), drive in the outer bearing inner rece, Note Pack MP grease into the inner race before in- stalling it. Front axle bearing preload adjustment Install the bearing adjusting nut with SST (09509-55010) Bearing adjusting nut tightening torque 30~ 35 ka-m (211.6 ~ 252.7 ft-lb) Turn the front axle hub (brake drum) 4 or 5 times, attach a spring scale to the hub bolt and measure the starting force. Not Pull the spring scale carefully in the direction tangent to the hub. Front axle hub starting force 2.2. ~ 6.4kg (4.9 ~ 14.11b) Install grease seal to bearing ring, and ingert them into the hub, Using SST (09509-55010), install the bearing lock nut and remeasure the starting force. Note: ‘In installing the bearing ring, be sure that the dowel pin fits into the bearing ring slot, Fig, 7-48 Installing Lock Nut — 163 — 7-177-18 Install the front axle shaft. Front axle shaft set bolt nut tightening torque, 2F8CA20, 25 series 4.0~ 5.5 kgm (28.9 ~39.7 fb) FBCA30 series 6.0~ 8.0 kgm [43.3 ~57.6 ftlb) 7. Install the front wheels. Hub nut tightening torque 2FBCA20, 25 series 12~ 17 kg-m (86.6 ~ 122.7 ft-lb) FBCA30 series 30 ~ 33 kg-m (211.6 ~ 298.6 ft-lb) Fig, 7-80 Installing Front Wheet —REAR AXLE Page [2FBCA10, 13, 15 SERIES] SECTIONAL VIEW 0... 20... ..0ceceeeeeeeeeeeeee eee 82 SPECIFICATIONS COMPONENT PARTS & TIGHTENING TORQUES ......... a3 SERVICE STANDARDS ...........-0.0cceeeeeeeee ees a4 REMOVAN eet ee eee eect 5 DISASSEMBLV geen teeny tec eee cr a7 INSPECTION ASSEMBLY [2FBCA20, 25, FBCA30 SERIES] SECTIONAL VIEW............0000e eee eee eee e renee 8-17 SPECIFICATIONS ......... 0c cece cece center eres 8-17 COMPONENT PARTS & TIGHTENING TORQUES .......... 8-18 SERVICE STANDARDS .............eeeseeeeeeeeeee 8-19 REMOVAL .... 2.0... cc cece c eee ee ee eee e eee 8-20 DISASSEMBLY... 1... see e eee eee eee e ncn cneeees 8-22 INSPECTION 2.2.2... 6. ce ccc eee eee eee eee 8-25 ASSEMBLY INSTALLATION 0... 0.05 ecseeeeeeeer erect eres eens 8-31 — 165 -8-2 (2FBCA10, 13, 15, SERIES] SECTIONAL VIEW Fig. 8-1 Sectional View of Rear Axle (2FBCATO, 13, 15 series) SPECIFICATIONS oo Series ‘ 7 Item ——— 2FBCA10 series) 2FBCA13 series 2FBCA15 series] Rear axle suspension system Center support, lateral swing type Rear wheel alignment Toe-in ~ 0 Camber ° Caster 0 King pin angle | __& [ 7 | inner side a2 Steering angle -- 4 Outer side 58 Minimum turning radius. mm 1660 1670 (Maximum outer side) (in) (65 3/8) - (65 3/4) Tire size 14x 4x8COMPONENT PART & TIGHTENING TORQUES 8-3 : a ir \ | 12 1 415 16 "7 T=19~3.1 kgm (93.7 ~22.4 feb) 1. Rear axle beam 10. Steering knuckle pin 2. Rear axle stopper 11, Steering knuckle oil seal 3. Rear axle bushing 12. Bearing 4, Oilseal 13. Rear dise whee! 5. Needle bearing 14. Bearing 6 Shim 15. Claw washer 7. Thrust bearing 16. Castle nut 8. Steering knuckle 17. Rear axle hub cap "Fig, 82 Rear Axle Component Parts (2F&CA10, 13, 18 series) — 167 —a4 SERVICE STANDARDS King pin Diameter Standard fmm (in) | __ 28.0 (1.120) Diameter Wear limit mm (in) 27.8 (1.112) Support bushing Inner diameter Standard mm (in) 60 (2.40) I inner diameter Wear limitmm Gin) | 60.7 (2.404) | Bell crank pin Diameter Standard mm (in) 28.0 (1.120) Diameter Wear limit mm (in) 27.8 (1.112) Steering knuckle starting force kg (Ib) 3~5(6.6~ 11.0) Rear axle hub starting force kg (Ib) 0.7 ~2.0(1.6~ 4.4) SST. TOOLS, INSTRUMENTS 09950-20016 Universal puller | Replacer set, 09620-30010 Steering gear box 09610-20012 Puller, Pitman arm ssT —— Replacer, Drive a 09370-20270-71 | Pinion bearing Tool set, Front hub anc 09608-30011 . drive pinion bearing ie 2 09810-20172-71 Remover, Joint pin —eeooe Tools | Toe-in gauge, torque wrench, Thickness gaugeREMOVAL 1, Remove the battery hood. 2. Raise up the Head guard, and lift out the battery with battery hanger (80201-19250: 7) 3. Remove the weight (1) Rise slightly with wires (2) Set bolts, set nuts (3) Weight 4, Use a block (wooden) under the frame and axle to lift the vehicle about 300 mm 12"), Fig. 8-6 Pasitioning the Blocks 169 —S. Disconnect the drag link rod or power cylinder rod from the bell crank. (1) Cotter pin (2) Castle nuts (3) Disconnect rod SST: 09610-20012 6. Jack up the rear axle, Use a wooden block to balance front and back of the vehicle, Caution: Be careful of the grease nipple beneath the rear axle, 7. Remove the rear axle stopper and rear axle bracket caps. 8. Lower the jack gradually, watching the balance in front and back.DISASSEMBLY 1. Remove the grease caps. (1) Fasten the rear axle securely on a work bench (2) Use a screwdriver to remove the screw cap. 2. Remove the castle nut. (1) Cotter pin (2) Castle nut 3. Remove the tires with disc wheels 4, Removing the inner bearing SST: 09950-20016 5. Remove the disc wheel from the outer race. Caution: Remove the bearing only when excessive wear, noise or some defect is found. Fig, 8-14 Removing the Inner Bearing “1m -Disconnect the te-rod ends. (1) Cotter pin (2) Castle nut (3) Tie-rod ends SST: 09610-20012 Remove the grease nipple. Caution: Check the direction of the grease nipples before removing, Remove the lock pin from the king pin. (1) Set nuts (2) Remove the service nuts and drive the pin out with a suitable rod, Caution To prevent breakege or damage of to the thread- ed portion of the lock pin, always use servic ‘nut (which can be sapped without any problem) Drive out the king pin. Fig, 8-15 Disconnecting Tie-Rods Fig. 8-16 Removing the Gear Nipples Fig. 8-18 Driving out the king Pin Shoe10. 1" 13, Remove the steering knukle. (1) Thrust bearing, shim (2) Steering knuckle Caution: Be careful not to lose the thrust shims; keep them in order, check their number, thickness, ete, Remove the oil seal. Caution: Remove only when needle bearing and oil seal are damaged or worn, Remove the needle bearing, SST: 09620-30010 Caution: Romove the needle bearing only when damaged Drive out the lock pin. Fig. 8-21 Removing the Needle Bearing Fig, 8:22 Removing the Lock Pin - 173 -8-10 14, Pull out the bell crank pin. SST: 09810-20172-71 15 Take out the bell crank together with the tie-rod. 16. Remove the tie-rod ends. (1) Cotter pin (2) Castle nut (3) Tie-rod ends SST: 09610-20012 Fig, 8:25 Removing the Tie-Rod EndsINSPECTION Important 2 After cleaning and washing te components, inspect the following parts and replace if defective 2 Visually inspect each bearing and rotate them to check for possible noise, looseness or damage. 1 Steering knuckle (1) Cracks or damage of the knuckle's spindie-mounting portion, threaded portion, etc. Note: A flaw detector or flaw detection solvent (red ccheck) are recommended for the inspection. Fig. 8-26 Steering Knuckle Inspection 2. King pin (1) King pin wear or damage. Diameter standard 28.0mm (1.120") Diameter wear limit 27.8m(1.112") (2) King pin bending, when the wear limit has been exceeded, Fig. 8-27 King Pin Inspection 3. _ Rear axle beam (1) Bending or cracking of rear axle beam, Fig, 8-28 Inspecting the Rear Axle Beam — 175 —a2 4, Bushing (1) Wear or damage of the bushing innor diameter, Inner diameter Standard 60 mm (2.40") Caution: Always replace the bushing if the galvanized portion has worn off, Fig. 8-29 Bushing Inspection 5. Bell crank (1) Crack or damage in bell crank (2) Wear, bending, o cracks in knobs 8:30 Bell Crank Inspection 6. Bell crank pin (1) Wear or damage of the bell crank pin. Diameter Standard 28.0 mm (1.120) Diameter Wear limit 27.8 mm (1.12”) (2) Bending of the bell crank pin Fig, 8-31 Bell Crank Pin Inspection 7. Disc whee! (1) Damaged or cracked rear axle whee! (2) Damage to surface of wheel bearing race. (3) Whee! bearing revolution, noise, wear; damage to the roller and holder. Fig. 8-32 Disc Wheel InspectionASSEMBLY Important 3, Following the inspection, clean each com- ponent once again before assembling Be sure to grease the bell craxk and king pin needle bearing Rubber parts such as the oil seal should be replaced upon disassembly. Drive the needle bearing into the rear axle beam. (1) Drive the needle bearing fully into the bottom of the king pin channel. SST: 09620-30010 Drive the needle bearing into the bell crank. (1) Drive the needle bearing into the bell crank pin inserting portion. SST: 09620-30010 Driving in the oil seal (1) Drive the oil seal above and below the needle bearing. in the king pin inserting Portion of the rear axle beam, (2) Drive the oil seal into the upper portion of the needle bearing in the bell crank in inserting portion SST: 09620-30010 Caution: Assemble the oil seal with the lip side on the outside, Assemble the bell crank with tie-rod. (1) Assemble the bell crank with tie-rod into the rear axle beam. a Fig. 8:33. Driving in the Needle Bearing Fig, 8:36 Assembling Bell Crank with Tie-Rlod -177 -a-14 (2) Adjust the bell crank space with an adjust shim, Adjust shim thickness 0.5 mm (0.02) 1.0 mm (0.04") (3) With the bell crank pin inserted, adjust the stopper plate. 5. Adjust the steering knuckle adjusting shim. (1) Install the steering knuckle and thrust bearing in the rear axle beam. (2) Adjust the steering knuckle rotation with the shim, Type shim | No.1 | No2 | No.3 | Noa | Thickness | 0.5 | 1.0 | 01 Al mm (in) | (0.02) | (0.04) | (0.004) | (0.008) 6. Adjust the steering knuckle pre-load, (1) After adjusting the shim, insert the king pin, attach a spring scale to the end of the knuckle and measure the pre- load. Steering knuckle starting force 3~5 kg (6.6 ~11.0 Ib) (2) Then the prescribed pre-load is not Present, perform the shim adjustment again and take another measurement, 7. Assemble the stesring knuckle, (1) After measuring the pre-load, align the king pin with the lock pin hole position. (2) Drive in the lock pin. (3) Lock with the lock nut. T=19~31 kgm (13.7 ~ 22.4 ft-lb} 8. Hook up the tie-rod to the steering knuckle. Fig. 8-40 Installing the Tie-Rod — 1789, Assemble the inner bearing (1) Drive in the oil seal (2) Drive in the inner bearng. SST: 09370-20270-71 Caution: Driving at an angle will damage the knuckle spindle Take care to drive it stright 10. Assemble the bearing outer race on the disc wheel 11. Assemble the disc wheel (1) Grease the disc wheel carefully. (2) Coat the inner and outer bearing with grease. (3) Install the disc wheel and drive the outer bearing. SST: 09370-20270-71 (4) Fasten with the washer castle nut T= 10 kgm (72.2 fib) 12, Measure the disc whee! pre-load. (1) After securing the castle nut, revolve the wheel several times. (2) Adjust the castle nut so that the starting force will be within 0.7 ~ 0.2 kg (1.6~ 4.4 Ib), when the outside of the tire is pulled with a spring scale. Fig. 844 Dise Wheel Pre-Load — 179 -13, a (2) (3) 14, a) (2) (3) (4) Assemble the grease caps. Lock the castle nuts with a cotter pin. Fill the grease caps with grease. Drive on the grease caps. Measure the toe-in. Position the bell crank straight ahead. Measure the distance to the center of the tread (front & back) between tires. Make a tie-rod adjustment if there is a difference in this distance between front and back tires. Caution: When adjusting the ‘tie-rod, Keep the bell crank and rear axle stationary with pins. Adjust with the tie rod so that the distance is the same on either side to the traed center. Grease each nipple, Fig, 8-47 Toe-tn Adjustment ian[2FBCA20, 25, FBCA30 SERIES] SECTIONAL VIEW oy Mt j —_ > : io. ~ oO | Fig, 8-48 Sectional View of Rear Axle (2FBCA20, 28, FBCA30 series) SPECIFICATIONS — Series ~ 2FBCA 20 series | 2FBCA 25 series | FBCA 30 series Item Rear axle suspension system Center support, lateral swing type Rear wheel alignment | Toein o Camber r Caster oO King pin 2 ange : Steering angle Inner side 78° Outer side 51° Minimum turning radius mm 1780 1800 2040 (Maximum outer side) (in) (70) (70 7/8) (80 3/8) Tire size [16 x5x 10% 16x 6x 10% | — 181 -8-18 COMPONENT PARTS & TIGHTENING TORQUES Te19~3.1 kgm (93.7 ~22.4 feb} Rear axle bracket bushing Shim Rear axle beam ‘Steering knuckle king pin Oil seal Needle bearing Shim ‘Thrust bearing King pin lock pin eexogsene 10. 1". 12. 13. 14, 16. 16. 7 Steering knuckle Steering knuckle oil seal Inner bearing Rear dise whee! Bearing Claw washer Castle nut Rear axle hub cap Fig. 8-49 Rear Axle Component Parts (2F8CA20, 25, FECA3O series)SERVICE STANDARDS 8-19 King pin Diameter Standard mm (in) 28.0 (1.120) Diameter Wear limit mm (in) 27.8 (1.112) ing pin inclination Standard e Limit More than 6° + 30° Center pin Diameter Standard _ mm (in) 50.2 (2.000) [Diameter Wear limit _mm (in) 48.5 (1.940) Bushuing [__Wear limit mm (in) 52.0 (2.08) ‘Bell crank pin [Diameter Standard mim (in) 28.0 (1.120) Diameter Wear limit mm (in) 27.8 (1.112) ‘Steering knuckle starting force kg lib) 3~5(6.6~ 11.0) Rear axle hub starting force kg (lb) 0.6~ 1.8 (1.3~40) Rear axle front-rear play SST. TOOLS. INSTRUMENTS mm (in) 0.7 (0.028) 09950.20018 Universal puller = % Replacer set, 24 09620-30010 a sst oS 09610-20012 Puller, Pitman arm — een Too! set, Front hub and S drive pinion bearing, » ; a 09370-20270-71 Replacer, Drive 6am Pinion bearing [Tools] Toe-in gauge, Torque wrench, Thickness gauge = 183 -8-20 REMOVAL Note 4. Stands (rigid racks) and other supports should always be inserted at the left and right sides, and under the weight fat surface. 2. Always have the parking brake engaged and the wheels blocked. the work, have the rear end raised so that the weight underside will be from 400 to 00 mm (76" ~29%, 1, Remave the wheels, (1) Loosen the rear whee! hub nuts. (2) Jack up the rear end. (3) Remove the hub nuts, and take off the wheels. Note ‘Set the stand (rigid rack) under the weight flat part, and make sure that it will not slip off. 2. Disconnect the power cylinder rod from the bell crank (1) Pull out the cotter pin. (2) Remove the cestle nut. (3) Using SST (C9610-55012}, disconnect the power cylinder rod from the bell crank. 3. Punch on matching marks. (1) Punch different marks on the front and rear caps to prevent intermixing them. (2) Set the jack at center of rear axle. (3) Measure the rear axle frontrear di- rection play. Frontrear direction play Limit 0.7 mm (0.028) Fig, 8-52 Punching Match Marks4, Remove the rear axle bracket cap. (1) Jack up just enough to prevent the rear axle from dropping down. (2) Remave the cap bolts. (3) Remove the cap. 5. Remove the rear axle assembly (1) Slowly lower the jack, and with the rear axle on the jack, draw it out toward the side of vehicle. Fig, 8-54 Removing Rear Axle — 185 ~8-22 DISASSEMBLY Note: In this manual, the operations are described with the rear axle assembly removed from the vehicle, but for disassembly, repair, and adjustment of parts such as rear axle hub, steering knuckle, etc., the work can be done without removing the rear axle assembly. 1, Remove the inner bearing (1) Remove the inner bearing with universal puller (09950-20016). Note: Flemove the bearing only when it has been worn, noisy, or otherwise defective. 2, Disconnect the tie rods. (1) Remove the cotter pins. (2) Remove the castle nuts. 3, Remove the king rin lock pin. (1) Remove the set nut. (2) Install service rut, and drive out the pin with suitable round bar. Note: To protect the lock pin threads from damage, service nut (one that can be wasted) should always be used. 4. Remove the steering knuckle. (1) Remove the king pin grease fitting (2) Remove the king pin, (3) Remove the thrust bearing and steering knuckle. Note: Store the thrust shims to prevent losing them, ‘and note down the number used and their thicknesses. Fig, 8-58 Removing Steering KnuckleRemove the oil seal Note: Remove only when the needle bearing and oil seal have been damaged or worn. 6. _ Remove the needle bearings. (1) Using needie bearing remover and replacer [09620-3001C],. remove the king pin needle bearings. Note: Femove the needle bearings only when they have bbeen damaged or worn. 7. Remove the bell crank pin. (1) Remove the stopper plate. (2) Drive out the bell crank pin. 8. Remove the bell crank with tie rods attached. Note: When removing the bell crank, use care not to lose the adjusting shims, Fig. 8-62 Removing Bell Crank = 187 -8-24 9, Remove the tie rod ends. 10. Remove the oil seal and needle bearing, (1) Remove the oi seal (2) Remove the needle bearing, Note: Remove the oil seal or needle bearing only when they have been damaged or worn, 11, Remove the bearing outer race from the disc wheel Note: Remove the bearing only when it has been worn, noisy or otherwise dotective. Fig, 863 Removing Tie Rod ends Fig, 864 Removing Oil Seal & Needle Bearing Fig, 865 Removing inner bearingINSPECTION Note: 4. After cleai 8-25 ing and washing the parts, inspect the following parts and repair or replace any part found defective, 2. Inspect the bearing visuelly, or insert them on shafts and check rotating condition, noise, looseness, and damage. 1. Inspect steering knuckle. (1) Carefully inspect the knuckle at spindle base part and threads, and replace if cracked or damaged. Note: Use of flaw detector or flaw detecting penetrant for inspection is recommended. 2, Inspect the king pin. (1) Wear or damage in kingpin. Diameter Standard 28.0 mm (1.120") Wear limit 27.8 mm(1.112") {2} King pin bending. Note: If worn over the limit, repiace the king pin together with kunckle bearings 3. Inspect the rear axle bear. (1) Bending or cracks in rear axle bear. (2) Measure the error in kirg pin incleation King pin inclination Standard 6° Limit 6° + 30° Fig. 868 Rear Axle Beam Inspection — 189 —8-26 4, Inspect the center pin (1) Measure the wear in center pin. Diameter Standard 50.0 mm (2.000") Wear Limit 48.5 mm (1.94") 1 8.69 Center Pin Inspection 5. _ Inspect the center pin bushings. (1) Measure the inner-diameter of bushings. Wear Limit 52.0 mm (2.08") Fig. 8-70 Bushing Inspection 6. Inspect the bell crank. (1) Crack or damage in bell crank. (2) Wear, bending, or cracks in knobs. : Fig, 7-71 Bell Crank Inspection 7. Inspect the bell crank pin. (1) Wear or damage in bell crank pin. Diameter Standard 28.0 mm (1.120") Wear Limit 27.8 mm (1.112") (2) Bending in bell crank pin. —— | Note: If worn over the limit, make replacement ‘together with the bell crank bearings. Fig. 8-72 Bell Crank Pin Inspection8-27 Disc wheel (1) Damage or cracks in rear axle wheel (2) Damage in whee! bearing races. (3) Defective turning, noise, or wear in bearing, and damage in rollers and holder. Fig. 8-73. Disc wheel Inspection — 1918-28 ASSEMBLY Note: ‘After completing the inspection, wash the parts once more before starting assembly, Always apply grease to the neesle bearings for the bell crank and king pin, and make sure to replace the rubber parts such 2s oll seal and the like. 1. Drive the needle bearings into the rear axle beam. (1) Using SST [09620-30010], drive the needle bearing into king pin insertion hole fully to the bottom side. 2. Drive the neede bearing into the bell crank, (1) Using SST[C9620-30010], drive the needie bearing into the bell crank pin insertion hole. 3, Drive in the oil seals. (1) Drive the oil seal into rear axle beam king pin insertion hole below the needle bearing, (2) Drive the oil seal into king pin in: sertion hole above the needle bearing. Note: Install the oil seal with the lip side positioned outward, ig, 8-76 Driving in Oil Seal4, Install the bell crank with tie rods (1) Set the bell crank with tie rods attached (on the rear axle bearn. (2) Adjust the bell crank clearance with shims, Shim thickness 0.5 mm & 1.0 mm (3) Insert the bell crank pin and set with stopper plate. 6. Adjust the steering knuck e with shims, (1) Mount the steering knuckle and thrust bearing to the rear axle beam. (2) Adjust the turning condition of steering knuckle with shims. Type | Thickness | Type | Thickness No.1 05mm | Nos 01mm No.2 | 1.0mm | No4 0.2 mm 6. Adjust the steering knuckle preload. (1) After completing shim adjustment, insert the king pin and measure the preload by attaching spring scale to knuckle spindel end, Steering knuckle sterting force 3~5 kg (6.6~ 11.0 Ib} (2) If proper preload cannot be attained, repeat the shim adjustment. 7. Install the steering knuckle. (1) After adjusting the preload, position the king pin so that it will be aligned with the king pin lock pin hole. (2) Drive in the lock pin. (3) Lock with lock nut. Lock nut tightening torque 1.9~3.1 kgm (13.7 ~ 22.4) Fig. 8-79 Adjusting Preload Fig, 8-80 Installing Steering Knuckle — 193 — 8-298-30 8. _ Install the inner bearing (1) Drive in the oil seal first. (2) Use SST (09370:20270-71) and drive in the inner bearing, Note: Use care in driving in the bearing, If driven in cocked, the spindle part of the knuckle can become damaged. 9. Connect the tie rods to the steering knuckles 10. Install the bearing outer race to the disc wheel 11, Measure the toe in. (1) Set the bell Crank to straight ahead position. (2) Mount tires on the rear axle hubs and measure the distance between the tire centers (front and rear) Toe-in 9 rm (3) If the front and rear center line dis- tances differ, correct by adjusting the tie rod lengths, Note: ‘Adjust the tie rods such that both left and right will be same dimension, (4) After adjusting, dismount the tires and Fig. 8-84 Measuring Toe-in and grease the parts.INSTALLATION 1. Install the rear axle. (1) Place the rear axle assembly on a jack (2) Install spacers on center pins (same thickness measured at removal) (3) Apply grease on bushings and insert them on pins. (4) Place the rear axle assembly under the frame and jack it up. (5) Bolt on the rear axle caps. 2, Measure the rear axle play, Front-rear direction play Limit 0.7 mm (0.023") Note: If the play exceeds the limit, remove the rear axle ‘and replace the spacers, after which, remeasure the play. 3. Bolt on the rear axle bracket caps, (1) Check the match marks, (2) Tighten the set bolts at specified torque. Tightening torque 8 ~ 11 kg-m (57.6~ 79.4 ft-lb) 4. Connect the power cylinder rod to the bell crank. 5. Install the disc wheel. (1) Pack grease into the disc wheel, (2) Coat grease on the inner and outer bearing, (3) Mount the disc wheel and drive in the outer bearing, (4) _ Insert the washer and tighten the castle nut. Tightening torque 11 kgm (79.4 fib) Fig. 8-88 Installing Disc wheel 195 — 8-318-32 6. Measure the rear axle hub preload, (1) After tightening the castle nut, turn the wheel 2 ~ 3 times. (2) Measure the torque required to start turning the rear axle hub. Rear axle hub starting force 0.6 ~ 1.8 kg (1.3 ~ 4.0 Ib) Fig, 8-89 Measure the Rear Axle Hub Preload,BRAKES. Page FRONT BRAKES (2FBCA10, 13, 15 SERIES] SCHEMATIC DRAWING .......0..00.00cccceeeee een eees 9-2 COMPONENT PARTS & TIGHTENING TORQUES ............ 9-3 SPECIFICATIONS «0.2.0... 00ecceceeeveeeee eter eegeees 9-4 SERVICE STANDARDS ........... 000s seeeeee rece eee eee g-4 GET'Z.1s cssccadcodsobb0denos60q socdopuaqeqeneace 9-5 INSPECTION... ...ccceeeeeeece esse eeeeeeeneeens 9-8 ASSEMBLY... 0 ec ee cseceeeeeueeeeeeeeeeeeen enone 9-10 [2FBCAZ0, 25, FBCA30 SERIES] SCHEMATICIDRAWING) tree rere tc et ea s-12 COMPONENT PARTS & TIGHTENING TORQUES ............ 9-13 SPECIFICATIONS ... 20.6.6... e cee ee eee eee eee eens 9-14 SERVICE STANDARDS ............ 0 cece eee eeeeeeeeee 9-15 INSPECTION 0.00... cece ce eeeeaeecseeeeenn seen eeees 9-19 Suan aaaet eee eeeeeReeet 02020 eeeeeEeEan Een ne aRSRESESEE OSESEEEaESETOESE 9-21 AUTOMATIC ADJUSTMENT UNIT OPERAITION TEST ..... 9-25 MASTER CYLINDER SECTIONAL VIEW ...... cece cece eee e teeter eee 9-27 COMPONENT PARTS & TIGHTENING TORQUES ............ 9-28 SERVICE STANDARDS ..........0.ccsceeeeeeeeeeeeees 9-30 REMGVAU een eee eee eee 9-30 DISASSEMBLY... 2... eee ee eee eee eee eee eens 9-31 INSPECTION 2.2.2... ccc cece cece eee eee eee tees 9-32 ASSEMBLY 2... eee eeeeeeeeeeeeee eee eeee eee eenee 9-33 PARKING BRAKE ....... 00... 0eccuseeeeeeeeeeeeeenes 9.349-2 [2FBCA10, 13, 15 SERIES] SCHEMATIC DRAWINGS Fig. $2 Wheel CylinderCONPONENT PARTS & TIGHTENING TORQUES 910111213 1516171819221 20 1. Secondary shoe sub-assy 12, Parking lever 2. Anchor to shoe spring 13, Strut lever 3. Shoa guide plate 14. Adjuster spring 4, Connecting rod 15, Adjusting screw 5. Wheel evlinder boot 16. Strut to shoe spring 6 Wheel cylinder cup 17. Automatic adjustment lever 7. Wheel evlinder spring 18, Cable & fitting sub-assy 8 Shoe hold down pin 19. Cable guide 9 Backing plate 20. Shoe hold down cup 10. Primary shoe sub-assy 21. Shoe hold down spring 11. Paring pin Fig. 93 Components & Tightening Torque ey ioqra4 SPECIFICATIONS Series’ 2FBCA10, 13, 15 series Item Foot Brake crum inner diameter mm {in} 264 (10.016) brake Brake ining dimensions (W x Th x L}) mm in) 48.5 x 5x 277 (1,940 x 0.0200 x 11.080! Brake lining material Mould ‘Wheel oylinder inner diameter mm (in) 22.22 (0.889) Parking brake type Internal expanding mechanical type SERVICE STANDARDS ‘tem es 2FBCANO, 13, 15 series | Brake drum inside diameter | Standard mm (in) | 254 (10.016) Limit mm (in) | 256 (10.096) Lining thickness Standard mm (in) | 5.0 (0.200) Limit mm (in) | 2.0 (0.080) [Drum to lining clearance mm (in) 0.25 ~ 0.5 (0.010 ~ 0.02C) Brake shoe return spring Free lenght mmi(in) | 102 (4.080) installed lenght mm (in) 711 (4.440) “Adjuster actuator spring Free lengtht _mm(in) | 79 (3.160) Tnstalled lenght mm (in) | 98.5 (3.940) Installed load _kg (ibs) 14 (30.9) SST & MEASURING TOOL oa, 09717-20010 Remover, Brake shoe Return spring Sst =| 09510-31960-71 Remover and replacer, Hold-down spring -~ = 09718-20010 Replacer, Brake shoe return spring Tools CalipersREMOVAL Impotant 2 See “Front Axle" for removal of front axle hub. 2 Be careful not to spill brake fluid on the vehicle painted surface. 2 Be especially careful not to contact any brake components with mineral resin. The brake removal can be done with the assembly removed or in the vehicle, choose your method in terms of the brake trouble. 1, Remove the front wheels, (1) Front wheels (2) Axle shaft (3) Front axle hub Caution: Refer to “Front axle” heading 2, Remove the adjusting screw, (1) Adjuster spring (2) Automatic adjustment lever. (3) Adjusting screw 3. Remove the anchor to shoe spring (1) Anchor to shoe spring SST: 09717-20010 (2) Strut lever, strut to shoe spring (3) Cable guide (4) Cable | Fig 9-6 Removing the Anchor to Shoe Spring = 201 -4, Remove the hole-down spring, (1) Hold-down cup, SST: 09610-31960-71 (2) Hold-down spring 5, Remove the brake shoe, (1) Brake shoe (2) Snap ring (3) Parking 6. Remove the parking brake cable. (1) Snap ring (2) Parking brake cable 7. Drain the brake fluid, (1) Reserver tank Caution: © Always drain the brake fluid when removing the wheel eylirder backing plate. © To prevent any entry of mineral cil, clean out carefully the container into wich the fluid is to be drained and kept. (2) Bleeder plug Fig, 9-10 Draining the Brake Fluid8, Remove the backing palte. (1) Brake pipe (2) Backing plate set nuts 9, Remove the wheel cylinder. (1) Set bolts (2) Wheel cylinder 10. Disassemble the wheel cylinder. (1) Whee! cylinder cover (2) Connecting rod (3) Piston (4) Wheel cylinder cup (5) Wheel cylinder spring a Caution: © Disassemble immediately after inspection, replacing parts with new ones after finding the trouble; then reassemble right away. © Be careful not to let any mineral resin contact the parts, Fig. 9-12 Removing the Wheel Cylinder 2FBCA15, 20, 25 series 40 mm (1.600) > FBCA30 series b, Screw the power cylincer end A into power eylinder by 37 mm (1,480") for 2FBCATS, 20, 25 series and by 45 mm (1.800") for FBCA30 series. rt 37 mm (1.480") > 2FBCA15, 20, 28 series 45 mm (1.800") > FBCA30 series ‘Set the steering wheel to lock to lock center position, rear axle straight ahead state, and install the power cylinder to the vehicle so that distance X will become 140 mm (5.600") for 2FBCA 15, 20, 25 series, 142 mm (5.680") for FBCA30 series. Make the adjustment by varying the projection of the tie rod and A. =e Rear Axle Forward a 2FBCAI5, 20, 25 series d. Connect the pitman arrr and the power cylinder rear end to the drag link rod. Note: ‘Make the adiustment by varying the projection of the tie rods A and B, and such thet both A and B will be screwed in by same amount. — 267 —OIL CONTROL VALVE Page SECTIONAL VIEW . 2.2.2... .. 0... cece cence eee 1-2 SPECIFICATIONS 1-3 SERVICE STANDARDS ...............000cecceeeee 1-3 OIL LEAK TEST 1-5 REMOVAL .. 2.20.2... eee cece cece cece scenes 1-6 DISASSEMBLY 1-8 INSPECTION 1-11 ASSEMBLY 11-13 11-13 11-1411-2 OIL CONTROL VALVE Tilt Spoo! rit to iit Lock Valve For Lift Relief Valve Lift Spoot Check Valve For Lift Relief Valve Fig. 11-1 Oil Control Valve Sectional ViewSPECIFICATIONS Oil Control Valve 11-3 ——— Series 2FBCAI3, 2FBCA25, Item __ __| 2FBCAIO series | 45, 20 series FBCA30 series Manufacturer Nishina Kogyo Co Oil control valve type ‘Add on type Lift | 1205(1706-3)] 140291190127) | 165551284674 Rated pressure kg/cm? ated pressure ka/em’ (ps) Tie [1102611964 75) | 1202811706275) | 14028(1991 2%) 2 [Lift | 170 (1564) min. [130 (1849) min. | 185 (2204) min Cracking pressure kg/cm? (psi) si Tiit__ | 100(1422) min. | 110 (1564) min, | 130 (1849) min Permissible 2/min. (US gpm) | No load 60 (15.84) ____flow Load 57 (15.08) | Hydraulic of! Hydraulic Oi! #90 or equivalent Hydraulic oll working temperature 50°~ 66°C Spool operating force | Setting 10.2 (22.1 1b) g (lb) Max. stroke 18.9 (40.7 Ib) Spring Effective Spring Total No. | Direction | Free Spring Wire dia, | Coil dia. | No. of : constant No of | oftums | oftur | length | formant Spool spring torr | tr02 iu ce Right | vas {1.93 Check valve spring | 82% | [ogmy | 16 18 vert | G8g¢%, | 0.072 niet anesoing [08 [980m 1 a5 | a7 | iam | «S80, | 00395 Relief valve pilot | 20mm | 6.3mm [265 mm | spring (oor) | 025") | 7 beft | 1036") | 747 Tilt lock valve 2.3mm | 9.2mm ; 29.5 mm spring | (o09") | 36 |" 8 Right | tr5a7) | 9 =| Tilt lock valve 05mm | 6.7mm 13mm check ball spring | (0.02) | (6.22") |_7° ae Right | (0512") | 0-058! 2.3mm | 12.7 mm 103 mm Flow divider sring | Zo'o9 | foaeey | 25 20 Rignt | 193m" | 0.550 Service Standards __ em Series Limit mm (in) ca 2FBCATO 128 (5.120) max. DFBCAI3 | 148 (6.920) max Natural drop mm (in) 2FBCATS | 168 (6.720) max (At mast) (15 minutes) 2FBCA20 | 208 (8.320) max | 2FBCAZ6 262 (70.080) max. nee ‘FBCA30 228 (9.120) max. Oil Teakage cc (US gal (Leakage in 1 minute after remain-in standard position Allseries | 34 (0.009) max. for 5 minutes) -In-11-4 Component Parts & Tightening Torques 10 13 1, Tilt Switch Bracket 10. Lift Spoot 2. Lift Switch Bracket 11. Relief Vaive 3. Body 12. Relief Valve 4, Tilt Lock Valve 13. Check Valve 5. Spring Holder 14. Check Valve 6. Spring 18. Spring Cover 7. Spring Cover 16. Spring 8 Tilt Spoo! 17. Spring Holder 9. Seal Holder Fig, 11-2 Oil Control Valve Component Parts11-5 SST, Tools, Instruments Instruments | Graduated cylinder, stop watch, convex rule Oil Leak Test Note: 1. Warm up the hydraulic system until the hy- Graulic oil temperature rises to around 50° to 70°C. 2. Place on the standard load, properly secure it land perform the test in a spacious place to en. sure safety. 1. Remove the toe board and fix the oil con- trol valve low pressure hase so that it can be quickly disconnected (from tank port} Lift Cylinder Port (Leakage Measurement) 2. Place on standard load, raise the forks about 50 cm and tilt the mast carefully to maximum forward position. (1) Actuate the stop watch, (2) Disconnect low pressure hose from tank port 3. After 5 minutes, measure the oil leakage for one minute Oil leakage limit Maximum 16 cc (0.004 USgal) Note: After measuring oil leakage, be sure to re: connect the low pressure in preparation for the next test Fig. 11-5 Oil Leak Test (Lift Port)11-6 Tilt Cylinder (Leakage Measurement) 4. Place on standard load, raise the forks about 50 cm, and set mast to vertical posi tion. (1) Actuate the stop watch. (2) Disconnect low pressure hose from tank port 5. After 5 minutes. measure the oil leakage for one minute. Oil leakage limit (Total leakage from life and tilt ports) 34. ¢ (0.009 USgal) Marimum 6. Calculate the tilt cylinder oil leakage. (5) Oil leakage — (3) Oil lekage = Tilt cylinder oil leakage Note: 1, If the above oil leak test shows the (5) leakage {all port leakage) to exceed the limit, it can be assumed from overall aspect that the tilt lock valve is at fault Removal Note: 1, Relieve all remaining pressure from the hy- draulic system by setting the mast vertically and the lift cylinder to lowest position, 2. Separate the battery plug. 3. Use core as seme hydraulic oil will be dis- ‘charged out. 1. Disconnect the wiring from hydraulic system limit switches. Fig, 11-7 Oil Leak Test (Overall) 2 3 Fig. 11-8 If the leakage in overall exceeds the limit, re- pplace the valve assembly. If the relief valve is defective, it will give off abnormal noise while in operation, Disconnecting Limit Switch Wiring3. Disconnect the hydraulic piping from the valve. Disconnect the control levers, (1) Peel up the boots (2) Pullout the cotter pins, (3) Remove the clevis pins. Note: Have turnbuckle lock nuts loosened before removing the clevis Remove the oil control valve. Fig. 11-11 Removing Oi! Control Valve O78 "1-711-8 SST, Tools, Instruments Tools | _ Snap ring pliers (for shaft), hexagon hollow screw wrench Disassembly 4 Note 4. Perform the disassembly in a clean place, and endeavor to prevent doing anything that will inconvenience reassembly. cised in handling these parts since even a small injury could cause trouble to develop after as sembly. 3, Before starting disassembly, clean the valve body exterior with compressed air or solvent, 2. The surfaces of the valve spools, relief valves ‘and check valve have been machined to high accuracy so that extreme care must be exer: 1. Remove the lift and tilt limit switches. 2. Remove the limit switch brackets Remove the spring covers Fig. 11-14 Removing Spring CoverRemove the compression springs. (1) Use snap ring pliers (for shaft} and remove the snap rings. (2) Take off the plate washers, (3) Take out the compression springs (4) Remove the “0” rings and back up rings Remove the lift and tilt spools. Remove the lift and tilt relief valves, Note: Identical relief valves are used for lift and tilt purpose, but as they have different pressure settings, it would be convenient to mark them to ‘enable telling them apart. Fig. 11-17 Removing Relief Valves Remove the stopper and valve seat from lift purpose relief valve11-10 8. Remove the check valve, (1) Use a hexagon hollow screw wrench and remove the plug (2) Take out the spring and check valve. 9, Remove the tift lock valve. Note: Remove very sarefully so as not to damage the tilt spool sliding surface. 10. Remove the needle valve from the relief valve body. Note: Do not remove unless the relief valve defective. Fig. 11-20 Removing Needle ValveWw 11, Remove the outlet housing. Fig. 11-21 Removing Outlet Housing SST, Tools, Instruments Instruments | Micrometer, torque wrench Inspection Note: 1. Carefully wash all parts and repair or replace ‘can be disassembled, their component parts any part found defective ‘are not service parts so that the entire part 2. It should be noted that although some parts ‘must be replaced as an assembly. 1, Inspect the valve body. (1) Valve body cracked or damaged (2) Scoring or wear caused by sliding of valve spools. (3) Stepped wear in valve seats. (4) Cracks, damage, or cil leak at elbows, caps, bolts, etc. 2. Inspect the valve spools. (1) Damage, burning, or wear in spools. (2) Bending or imperfect sliding of spools (3) Clogged orifices. (4) Damage in “O" rings and back up rings. Note 1. If the spools require replacement, the entire control valve assembly must be replaced. 2. Spool wear is determined by performing oil Teak test. Fig, 11-23 Spool Inspection — 279 -W-12 3, _ Inspect the relief valves. (1) Stepped wear in needle valve. (2) Defective seating or wear at valve seat {3) Breakage or loss of tension in com- pression springs, (4) Sliding condition of main plunger, and clogged orifice. 4. Inspect the tilt lock valve (1) Defective slicing condition, damaye or tapered wear in plunger (2) Breakage or loss of tension in com- pression spring (3) Stepped wear in check valve. (4) Damage in orifice adjusting wire Ingpect the check valve. (1) Stepped wear in check valve. (2) Breakage or loss of tension in com- pression spring o ce 60 esos Fig. 11-24 Relief Valve Inspection SS eco Som = = Fig. 11-25 Tit Lock Valve Inspection Fig. 11-26 Check Valve Inspection