Cat Lift Trucks. For use with K21/K25 and S4S Engine Service Manuals (2007)

TRANSMISSION

Disassembly

Sequence

12 Strainer, O-ring

Oil seal

Accumulator plug, O-ring

13 lnching plug, O-ring

Snap ring

14 lnching stopper

Snap ring

Main spring seat, O-ring

15 lnching return spring

Accumulator spring seat,

Main relief spring (thin)

16 lnching rod

O-ring

Main relief spring (thick)

17 lnching valve spring

Inner spring

Regulator valve

18 lnching valve

Outer spring

Slug

19 Return spring

Accumulator piston

Snap ring

20 lnching sleeve

Snap ring

Main relief plug

inspection after Disassembly

(1) Valve housing

(3) Springs

(a) Check all oil holes for clogging.

(a) Check for fatigue and damage

(2) Valves

(4) Oil seal

(a) Check for wear or damage. Make sure the

(a) Check the lip for damage.

sliding surfaces are smooth.

(b) Check the small holes for clogging

TRANSMISSION

Main relief plug

Accumulator spring seat, O-ring

Snap ring

Slug

Snap ring

Regulator valve

Oil seal

Main relief spring (thick)

lnching sleeve

Main relief spring (thin)

Return spring

Main spring seat, O-ring

lnching valve

Snap ring

lnching valve spring

Accumulator plug, O-ring

lnching rod

Snap ring

lnching return spring

Accumulator piston

lnching stopper

Outer spring

lnching plug, O-ring

Inner spring

Strainer, O-ring

Suggestions for Reassembly

(1) Cleaning oil passages

(a) The oil passages in the valve housing must be

cleaned thoroughly. Make sure there is no

clogging in any passage before reassembling the

control valve.

(2) Tightening torques

(a) Tighten the following parts to the specified

torques.

TRANSMISSION

Suggestions for Reassembly

(1) Tightening torques

(a) Tighten the following parts to the specified

torques.

Bolts fastening valve plate 27

6.0 to 8.0

(0.6 to 0.8

to 5.9

Plug 30

35.3 to 43.1

Bolt for installing inching

(3.6 to 4.4

lever 31

[26 to 32

6.0 to 8.0

Plug 35

(0.6 to 0.8

Bolt for installing solenoid

to 5.9

valve 37

(2) Direction of spring pin slit

(a) The spring pin 33 should be installed with its slit

toward the end of the inching shaft.

TRANSMISSION

Sequence

Ball bearing, Sealing ring, Spacer

Angular ball bearing, Snap ring (2 pieces)

Forward gear

Reverse gear

Pressure plate, Belleville spring (coned disc

spring), Mating plate (6 pieces), Friction plate

(5 pieces), Snap ring

Clutch spring, Snap ring, Spring retainer

Clutch piston, Piston ring

lnput shaft assembly

Sealing ring (3 pieces)

Seal ring

Roller bearing, lnput shaft spacer

Set screw (2 pieces)

Suggestions for Disassembly

(1) Removing input shaft ball bearing

(a) Use the special tools to remove the ball bearing

from the input shaft.

Special tool needed

Puller

91268 - 13810

Plate

91268 - 13820

- 10020

Gear puller

(2) Disassembling input shaft

(a) With the clutch spring compressed using the

special tool or a press, remove the snap ring.

Special tool needed

Piston tool

91268 - 17100

POWERSHIFT TRANSMISSION

Inspection after Disassembly

Input shaft

(a) Check splines for wear or other damage.

(b) Check the seal rings A and their grooves for wear

or damage, and measure the width of each groove.

(d) Check the clutch drum and input shaft for

looseness.

(2) Gear

(a) Check gear and splines for wear or damage.

(3) Drum

(a) Check the plate sliding surfaces for wear or other

damage.

(b) Check the clutch piston sliding surfaces for wear or

other damage.

(4) Friction plates and mating plates

(a) Check for burns, trace of uneven contact,

deformation and wear.

(b) Check splines for wear or other damage.

(5) Piston ring

Check piston ring for wear or damage.

A: Standard value B: Repair or service limit

2.6

0.10 mm

Thickness of friction plate

(0.102

0.004 in.)

2.2 mm (0.087 in.)

Thickness of mating plate

TRANSMISSION

Sequence

Input shaft assembly

Seal ring (3 pieces)

Seal ring

Clutch piston, Piston ring

Clutch spring, Snap ring, Spring retainer

Pressure plate, Belleville spring (coned disc

spring), Mating plate (6 pieces), Friction plate

(5 pieces), Snap ring

Reverse gear

Forward gear

Angular ball bearing, Snap ring (2 pieces)

Bearing, Snap ring, Spacer

Roller bearing, Spacer

Set screw (2 pieces)

Suggestions for Reassembly

(1) Assembling clutch piston

(a) Install seal rings on the input shaft and apply a thin

coat of ATF on the sliding surfaces of the clutch

piston. Take care not to damage or bend the rings.

(b) Install the piston ring on the clutch piston, and

apply a thin coat of ATF.

careful not to damage any of the parts.

Assembling plates

Pressure plate Mating plate

(a) When replacing the friction plates, also replace the

mating plates.

(I piece) \

Drum

(b) Follow the reassembly sequence carefully. Do not

install a wrong number of plates.

before installing them.

(d) Install the Belleville spring (coned disc spring)

with its convex side facing the mating plate.

TRANSMISSION

(3) Installing snap rings

(a) Install the snap rings with the clutch spring

compressed using the special tool or a press.

Special tool needed

Piston tool

91268 - 17100

(4) Installing spacer

(a) Install the spacer with the oil grooves facing the

ball bearing.

(5) Installing bearing

(a) Drive the ball bearing into position on the input

shaft the using special tool.

Special tool needed

Inspection and Adjustment

Oil Pressure Measurement

(1) Transmission oil level check

(a) Check the transmission fluid level with the level

gauge.

(b) Start and run the engine at an idling speed for

about 3 minutes, and then stop the engine.

and check the level.

(d) The checking procedure must bc completed within

5 minutes after the engine has stopped.

(2)

Engine warm-up

(a) Warm up the engine to raise the temperature of the

transmission oil.

(3)

Engine speed measurement

(a) After the engine is warmed up, measure the idling

speed and maximum no-load speed according to

the engine service manual. Make the necessary

adjustments if either or both of the speeds do not

meet the specifications.

(4)

Preparation for oil pressure measurement

(a) Stop the engine after checking and adjusting the

engine speeds.

(b) Raise the front wheels completely clear of the

ground either by jacking up the front axle housing

or placing a wood block under the outer mast and

tilting the

forward.

Note: The front wheels turn during the clutch pressure

measurement. Be careful and stay away from

the wheels.

(d) Connect the oil pressure gauge to each of the oil

pressure taps indicated in the illustration.

a: Main pressure

b: Clutch pressure

c: Torque converter inlet pressure

d: Lubrication oil pressure

Note: When loosening the plugs a through d, tap the

plug head once or twice to make the work easier.

TRANSMISSION

(e) Use the following tools for the oil pressure measurements.

Oil pressure measurement tools

Special

Torque converter

Lubrication oil

Remarks

Main pressure

Clutch pressure

part number

inlet pressure

pressure

*Connector

G (PF)

and

65628 - 00400

Rc (PT) 118 thread

*Connector

R (PT)

and

64309 - 17733

G (PF)

thread

Connector

600 kpa

*Gauge

64309 - 17714

thread

psi]

2000

*Gauge

(20 kgflcm²)

64309 - 17713

thread

Both side

*Hose

G (PF)

64309 - 17722

Both side

*Connector

For gauge

64309 - 17731

connection

Note: Tools marked with (*) are included in the gauge kit 64309 - 17701.

TRANSMISSION

(5)

Oil pressure measurement procedure

(a) Start the engine, shift the direction lever into the neutral position and measure the main pressure, torque

converter inlet pressure, and lubrication oil pressure.

(b) Measure the clutch pressure with the lever shifted into the forward position, then measure it again with the

lever in the reverse position.

A: Standard value

Unit:

(kgf/cm²) [psi]

Engine rprn

Shift

Oil pressure

800

(rprn)

Forward

Reverse

Main pressure

1600 It 100

(rprn)

Forward

Reverse

800

(rpm)

Clutch pressure

1600

100

(rprn)

Reverse

0.14 to 0.18 (1.4 to 1.8)

to 26.11

800

(rprn)

Reverse

0.10 to 0.14 (1.0 to 1.4)

to 20.31

Torque converter

inlet pressure

0.38 to 0.42 (3.9 to 4.3)

to 60.91

1600

100

(rprn)

Reverse

0.36 to 0.40 (3.7 to 4.1)

to 58 .O]

800

(rprn)

Reverse

to 0.04 to 0.4) [0 to

Lubrication oil

pressure

1600

100

(rprn)

Clutch (Inching) Pedal Adjustment

Brake

209929

The clutch (inching) mechanism is linked to the brake

pedal. Depressing the brake pedal cuts the pressure acting

on the transmission before the brakes take effect, bringing

the transmission to a neutral condition.

A faulty inching mechanism may create such problems as

failure in clutch disengagement and partial clutch

engagement. This in turn may cause an abnormal increase

in the transmission temperature, as well as braking

malfunctions and clutch plate seizures. Be sure to make all

the following adjustments carefully so that these problems

be avoided.

Adjusting brake pedal

(a) Adjust the brake pedal height A

the floor

plate top surface to the brake pedal top surface) to

the following standard value by turning the stopper

bolt 1 and then lock it with the lock nut.

Brake pedal height A

(b) Remove the clearance between the push rod pin of

the brake master cylinder 2 and the piston (zero

clearance).

until the clearance b in the detail

adjusted to the

range indicated below.

Clearance

(0.0079 to

0.0394 in.)

0.0315 in.)

(d) Lock the clevis firmly with the lock nut.

(e) If the pedal has been properly adjusted, the brake

play becomes the range indicated below.

2,3 ton

classes

Brake

free

(0.0591 to

0.2559 in.)

0.2165 in.)

(2) Adjusting inching pedal

(a) Adjust the height A of the inching pedal (from the

floor plate top surface to the inching pedal top

surface) to the following standard value with the

stopper bolt 3.

Inching pedal height A

191

(7.52 in.)

(b) Adjust the clearance between the bolt and linkage in

the portion to the following value and lock it firmly

with the nut.

1 ton

2,3 ton

class

classes

Clearance between

10.0 mm

11.6

bolt and linkage

(0.391 in.)

(0.457 in.)

TRANSMISSION

Valve Adjustment

Start by:

(a) Blocking the rear wheels, then raising the front wheels

following the procedure described in the preceding oil

pressure measurement section;

(b) Connecting an oil pressure gauge to the oil pressure tap

(position D in the illustration);

The projection A of the inching rod (initial condition)

in.)

(d) Connect the inching cable 2 to the inching lever pin 3.

(e) Adjust the play of the inching cable to 0.5 to 1.5 mm

(0.02 to 0.060 in.) and secure the cable by inching

cable locking nut (outer) 4. Be sure to observe the

lower limit (0.5 mm

in.]) to prevent over

tensioning of the cable.

Procedure

(a) Run the engine at idle to raise the

of the

transmission oil.

(b) Shift the lever into the forward (reverse) position.

plunger 2 retract, while recording the clutch pressure

for each stroke distance of plunger 2 in order to

know the relationship between them.

(d) Check that the recorded values correspond to the

values in the fig. on the right. The oil pressure must be

exactly (zero) when the plunger 2 is fully retracted.

Troubleshooting

Tune up engine.

Oil level too low

Refill.

Air being sucked in on suction side

Replace gasket and

retighten.

Faulty action of spool in main regulator valve

Repair or replace.

Weakened spring in main regulator valve

Replace.

Torque

Worn gears in oil pump, resulting in

Overhaul and check or

converter

reduced capacity

replace defective parts

Magnet strainer clogged

Clean or replace.

Seal rings or O-rings worn

Replace.

Stator freewheel seized

Replace torque converter

assembly.

Not enough

Impeller damaged or rubbing

Replace torque converter

output power

assembly.

Air being sucked in on suction side

Retighten or replace

Water in oil

Replace oil.

Oil level too low

Refill.

Pedal linkage maladjusted (brake shift and

Readjust.

forward reverse)

Main pressure too low, resulting in slipping

Readjust.

clutches

Seal rings or O-rings worn

Replace.

Clutch piston damaged

Replace.

Friction plate seized or dragging

Replace.

Road wheels

High mechanical resistance in road wheels

Check and adjust brake

Flexible plate broken

Replace.

- Not enough oil

Refill.

Torque

Oil pump drive defective

Replace.

converter

- Turbine shaft broken

Replace.

Main pressure too low

Check pump gears for

wear or replace.

Not enough oil

Refill.

Inching pedal link maladjusted

Readjust.

Seal ring worn in servo case

Replace.

O-rings on input shaft worn

Replace.

Plug on input shaft loose or slipped off,

Repair.

resulting in oil leaks

Replace.

Shafts broken

Replace.

Clutch drum, particularly snap ring groove,

Replace.

defective

Snap ring fitted to clutch drum broken

Replace

Oil way for supplying oil pressure to clutch

Clean or replace.

piston clogged

Shaft splines worn

Replace shafts.

ront axpearts in reduction differential or

Repair or replace.

TRANSMISSION

Flexible plate broken

Replace.

Bearings damaged

Replace,

blades of running member

Replace.torque

converter.

Bolts loose

Retighten or replace.

Splines worn

Replace.

Oil pump noisy

Repair or replace.

Friction plates seized and dragging

Replace friction plate.

Bearings worn or seized

Replace.

broken

Replace.

Bolts loose

Retighten or replace.

Splines worn

Replace.

Abnormal

Clean or replace.

Magnet strainer clogged

noise

Main regulator valve defective

Wash or replace.

Restriction in oil pipe

Replace.

Oil too viscous in cold weather

Replace oil.

Instruments faulty

Replace.

Wrong

used

Replace oil.

Clean or replace.

Magnet strainer clogged

Oil pump defective

Replace,

Excessive oil leaks

Main regulator valve spring broken or

Replace.

Low noise

fatigued

(2) Main regulator valve spool defective

Repair or replace.

Air being sucked in

Retighten or replace

packing.

Oil level too low

Refill.

Leaking oil seals

- - Check lips and sliding

surfaces for wear.

Replace seals.

Leaking joint of case

- Retighten or replace

packing.

Leaking pipe connection or joint

Repair or replace pipe,

gasket and O-rings.

- Leaking drain plug

- Retighten and replace

Oil leaks

gasket.

Cracks or blowholes in case

- Replace.

Oil blowing out of transmission housing

(1) Water in oil

- Replace oil.

(2) Air being sucked in suction side

- Replace packing and

retighten.

(3) Oil leaks from air breather

- Repair.

Oil

too high

- Lower oil level.

TRANSMISSION

Oil level too high or too low

- Refill or drain.

Magnet strainer clogged

Clean or replace.

Impeller rubbing

Replace torque converter

assembly.

Stator freewheel defective

- Replace torque converter

assembly.

Torque

Air being sucked in

- Retighten or replace

converter

O-ring.

Water in oil

Replace oil.

Restriction in oil pipe (resulting in reduced

Repair or replace.

Oil temperature

circulation flow)

is too high

Bearings worn or seized

Repair or replace.

Instruments out of order

- Replace.

Friction plates dragging

Replace friction plates.

Bearings worn or seized

- Repair or replace.

Control linkage defective

- Repair or replace.

Truck not operated properly

- Urge user to operate

Others

properly.

Others

Cooling fan belt damaged

- Replace.

(2) Oil cooler clogged

- Clean or replace.

(3) Brakes grabbing

- Check and readjust.

Main regulator valve defective

Repair or replace valve

assembly.

Main pressure is too

Oil viscosity too high because of low temperature

Replace oil.

high

Wrong kind of oil used

Replace oil.

Magnet strainer clogged

- Clean or replace.

Oil pump failure

Replace.

Coil spring defective in main regulator valve

Replace.

Faulty movement of main regulator valve spool

Repair or replace.

Air being sucked in

Retighten or replace packing.

Not enough oil

Refill.

Control linkage defective

Repair or replace.

Clutch valve out of order

Repair or replace.

Magnet strainer clogged

Clean or replace.

Oil pump worn or otherwise defective

Replace.

Coil spring defective in main regulator valve

Replace.

Fautly movement of main regulator valve spool

Repair or replace.

^I Clutch pressure is too

Air being sucked in

- Retighten or replace packing.

Not enough oil

- Refill.

Control linkage out of order

Repair or replace.

Inching valve defective

- Repair or replace.

Seal ring broken in servo case

Replace.

Clutch piston seal rings broken

- Replace.

TRANSMISSION

Data

A: Standard value B: Repair or service limit

Unit:

(in.)

Truck Models

1 ton class

2 ton class

3 ton class

Items

Main pressure (engine at 1600

100 rprn)

[psi]

Clutch pressure (engine at 1600

100 rprn)

0.98 to 1.28 (9.99 to 13.1)

to 185.71

Torque converter inlet pressure

0.10 to 0.50 (1.02 to 5.10)

(engine at 1600

100 rpm)

(kgf/cm²) [psi]

-speed

Lubricating oil pressure (engine at 1600

100 rpm)

0.03 to 0.29 (0.31 to 2.95)

to 42.11

(kgf/cm²) [psi]

Automatic 2-speed

0.01 to 0.15 (0.1 to 1.5)

to 21.81

Travel time for 100 m (330 ft) starting acceleration

5 seconds, maximum

(no load)

Diameter of fitting surface in contact with

oil seal 1

41.85

(16.4763)

0.00028

(0.590

Diameter of shank

14.93 (0.5878)

TRANSMISSION

A: Standard value B: Repair or service limit

Unit: mm (in.)

Truck Models

1 ton class

2 ton class

3 ton class

Items

0.040 to 0.083 (0OO 157 to 0.00327)

Side clearance 1

0.15

(0.0059)

Top clearance 2

Backlash

Oil pump

0.2

(0.0079)

Face

of flexible plate 1

(in free state)

0.5

(0.0197)

Distance between end face of

transmission case and mating face of

50 (1.97)

flexible plate 2

Flexible

plate

A: Standard value B: Repair or service limit

Unit: rnm (in.)

Truck Models

1 ton class

2 ton class

3 ton class

Items

Thickness of mating plate

Thickness of friction plate 2

0.13 to 0.29 (0.00512 to 0.01142)

Backlash of friction plate and gear 3

0.5 (0

197)

Width of seal ring 4

2.5

(0.0984

Width of piston seal ring groove 5

2.65

(0.10433)

Free length of clutch spring 6

Spring constant:

of pressure plate 7

TRANSMISSION

A: Standard value B: Repair or service limit

Unit: mm (in.)

Truck Models

1 ton class

2 ton class

3 ton class

Items

Starter shaft seal ring width 1

2.5

(0.0984

Starter shaft piston seal ring groove

width 2

2.9

(0.1142)

Clutch piston seal ring width 3

2.8

0.05

(0.110

0.0020)

Clutch piston seal ring groove width 4

3.0

(0.1181)

2.5

0.05

(0.0984

0.0020)

Servo case shaft seal ring width 5

2.3

(0.0906)

2.5

(0.0984

Servo case shaft seal ring groove width 6

2.9

(0.1142)

Input

Servo case inside diameter contacting

shaft

seal ring 7

30.2

(1.189)

assembly

TRANSMISSION

A: Standard value B: Repair or service limit

Unit: mm (in.)

Load at height

outer spring 1

19.6 4 2 N (2

0.2 kgf)

4 0.5 Ibf]

140 in.)

Free length

78 (3.071)

Main relief

inner spring 2

Load at height

71.3

7.1 N (7.3

0.1

[16

1.6 lbf]

45.95 mm (1

in.)

9.7

1 N

4 0.1

4 0.2 lbf]

Free length

168 (6.614)

Control

Inching return

valve

spring 4

Load at height

88.3

7 N (9 4 0.7

4 1.6 lbf]

70 mm (2.756 in.)

Free length

70.89

(2.791)

Inching valve

return spring 5

9.7 4 1 N (1.0

0.1 kgf)

4 0.2 lbf]

18.2 mm (0.717 in.)

Free length

91 (3.583)

Accumulator valve

outer spring 6

Load at height

7.8 N (10 4 0.8

[22

1.8 lbf]

77.6 mm (3.055 in.)

Accumulator valve

inner spring 7

Load at height

3.9 N (4.9

0.4 kgf)

0.9 lbf]

50 mm (1.969 in.)

FRONT AXLE AND

Structure

1 Ton Class

2 Ton Class

3 Ton Class

Removal and

Front Wheels

Front Axle and Reduction Differential

Disassembly and Reassembly

Front Axle

Disassembly

Reduction Differential

Disassembly

Inspection and Repair

Reassembly

Adjustment

Troubleshooting

. 25

Data

. 26

FRONT AXLE AND REDUCTION

Structure

Class

210089

1 Front wheel hub

6 Differential gear

Input flange

2 Frame support

7 Differential case

12 Drive gear

3 Axle shaft

8 Differential carrier

13 Driven gear

4 Axle housing

9 Reduction gear

14 Carrier cover

5 Differential pinion

10 Reduction pinion

15 Backing plate

Frame support 2 is bolted to the front axle housing

The reduction differential is mounted to front axle

together with the backing plate 15 of wheel brake.

housing 4. The input Range 11 carries a drive gear

While front wheel hub 1 carries a single wheel, a

which meshes with the driven gear mounted on the

double wheel can be mounted to it with optional rim.

reduction pinion 1 0.

FRONT AXLE AND REDUCTION DIFFERENTIAL

2 Ton Class

210090

1 Front wheel hub

6 Differential gear

11 Input flange

2 Frame support

7 Differential case

12 Drive gear

3 Axle shaft

8 Differential carrier

13 Driven gear

4 Axle housing

9 Reduction gear

14 Carrier cover

5 Differential pinion

10 Reduction pinion

15 Backing plate

Frame support 2 is bolted to the front axle housing

The reduction differential is mounted to the front axle

together with the backing plate 15 of wheel brake.

housing 4. The input flange

carries a drive gear

While front wheel hub 1 carries a single wheel, a

which meshes with the driven gear mounted on the

double wheel can be mounted to it with optional rim.

reduction pinion 1 0.

FRONT AXLE AND REDUCTION DIFFERENTIAL

3 Ton Class

1 Front wheel hub

6 Differential gear

11 Input flange

2 Frame support

7 Differential case

12 Drive gear

3 Axle shaft

8 Differential carrier

13 Driven gear

4 Axle housing

9 Reduction gear

14 Carrier cover

5 Differential pinion

10 Reduction pinion

15 Backing plate

Frame support 2 is bolted to the front axle housing

The reduction differential is mounted to the front axle

together with the backing plate 15 of wheel brake.

housing 4. The input flange 11 carries a drive gear

While front wheel hub 1 carries a single wheel, a

which meshes with the driven gear mounted on the

double wheel can be

on it with optional

reduction pinion 1 0 .

FRONT AXLE AND REDUCTION DIFFERENTIAL

Removal and

Removal

[Single wheel]

1 Wheel nuts

2 Front wheel

[Double wheels]

1 Extension valve

[Double wheels]

2 Outer wheel nuts

3 Front wheel (outer)

4 Inner wheel nuts

5 Front wheel (inner)

Start by:

(a) Pull the parking

lever and block the rear wheels.

(b) Loosen the wheel nuts 1 by two turns. Then, raise the

front end of the truck using a hoist or the hydraulic

system.

(1) Hoisting

Using slings and eye-bolts at both ends of the cross

member on the outer mast, lift the front end of the

truck with a hoist.

FRONT AXLE AND REDUCTION DIFFERENTIAL

(2) Using hydraulic system

Tilt the mast all the way back and place wood

under the mast in the appropriate places. Then, tilt the

mast forward to raise the front end.

After raising the front end, place jack stands

under the frame to prevent the truck from falling.

Suggestion for Removal

Outer wheel

nut

In the case of double wheels, remove the outer wheel nuts

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

inner wheel.

Installation

To install, follow the removal sequence in reverse, paying

attention to the following points.

(1) Tighten the wheel nuts evenly to the specified torque

so that the wheels will not wobble during operation.

Tightening torque for

377.6537.8

wheel nuts

(16

1.6)

(38.5

3.9)

11.61

5 27.91

FRONT AXLE AND REDUCTION DIFFERENTIAL

Front Axle and Reduction Differential

Removal

Sequence

8 Mast

1 Front wheel

9 Brake pipe

2 Nuts

10 Parking brake cable

3 Fork, Lift bracket

11 Universal joint

4 Return hose for lift cylinder

12 Bolt, Nut

5 High-pressure hose for lift cylinder

13 Bolt, Nut

6 Tilt cylinder socket

14 Front axle and reduction differential

7 Mast support bearing cap

Note:

For removal of the front wheel I , refer to "'Front

Wheels. Removal."

(2) For removal of mast parts 2 through 8, refer to

"GROUP 12 MAST AND FORKS

(3) Before

the front axle and reduction

differential, remove the front axle drain plug

and drain transfer and differential oil.

FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Removal

Removing bolt 1 2

Bolts 12 are coupling the transmission with the differential.

Before removing these bolts, place a wood block under the

transmission to support it.

(2) Removing parking brake cable

To remove the parking brake cable, remove the parking

brake lever assembly from the dashboard and disconnect

the cable from the lever.

Note: To dismount the reduction differential alone, remove

the front axle as described above. To dismount the

reduction differential after removal of the engine and

transmission, the front axle does not need to be

removed from the truck.

Installation

To install, follow the removal sequence in reverse, paying

attention to the following points.

(1) After connecting the parking brake cable, make sure

that the brake lever operating effort is within the

specification.

245 to 294 N

Parking brake lever operating

(25 to 30 kgf)

effort

[55 to 66 lbf]

(2) Before installing the mast, bleed the brake fluid circuits

of trapped air. For bleeding, refer to '"CROUP 9

BRAKE SYSTEM."

(3) After installing the mast, make sure that tilt angles,

forward and backward, are correct and that the lift

chains, right and left, are equal in tension. Refer to

"'GROUP 12 MAST AND FORKS

(4) Fill the front axle housing with oil up to the plug hole

level.

FRONT AXLE AND REDUCTION DIFFERENTIAL

Disassembly and Reassembly

Front Axle

Disassembly

Sequence

1 Air bleeder

7 Front wheel hub, Brake drum

2 Level plug

8 Oil seal

3 Drain plug

9 Oil seal

4 Axle shaft

10 Tapered roller bearing

5 Lock ring, Lock nut

11 Brakeassembly

6 Tapered roller bearing

12 Frame support, Axle housing

Start by:

(a) Remove the mast. For replacement of the front

Note: It is not necessary to remove the axle housing or

axle housing and disassembly of the differential,

to drain the oil when removing the axle shaft or

refer to "GROUP 12 MAST AND FORKS

disassembling the wheel hub.

(b) Jack up the truck.

stands at both sides to keep the truck in the

horizontal position.

(d) Remove the front wheels.

FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Disassembly

(1) Removing

nut

Use the lock nut wrench (special tool).

Special tool needed

1 ton class

91268-00800

tool

2,3 ton classes

03703 - 59001

(2) Removing front wheel hub

Use the wheel hub puller (special tool).

Special tool needed

tool

1 ton class

2,3 ton classes

Note: It is not necessary to remove the oil seal from the

hub nor disassemble the oil deflector unless the seal

is defective.

(3) Removing bearings

The inner race of the tapered roller bearing remains in the

axle housing when the hub is drawn out. Remove this race

together with the seal retainer with a bearing puller.

Note: Trucks of 1 ton class do not have the seal retainer.

FRONT AXLE AND REDUCTION DIFFERENTIAL

Inspection after Disassembly

(1) Axle shaft

(a) Looseness of mating splines

Mount the differential level gear on the splined end of

the shaft and set a dial indicator as shown. Rotate the

bevel gear in the direction shown and read the free play

(looseness of mating splines).

A: Standard value B: Repair or service limit

Free movement

(looseness of mating

splines)

(2) Shaft deflection and flange

Deflection of shaft

(a) Set a dial indicator at the middle part of the axle

shaft. Rotate the shaft and read the dial indicator

(deflection of axial shaft).

A: Standard value B: Repair or service Iimit

1 mm (0.039 in.)

Deflection of axle shaft

of dial indicator

reading)

2.0 mm (0.079 in.)

Face

of flange

209949

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

shaft as shown. Rotate the shaft and read the face

of flange.

A: Standard value B: Repair or service limit

Face

of axle shaft

flange

0.5

(0.020 in.)

(3) Axle housing

(a) Check the surfaces of axle housing in contact with

the mast bearing for damage.

(b) Check the entire axle housing for distortion, dents

and other defects. Pay particular attention to the

welds to see if any weld is cracked to require

repair.

(4) Others

(a) Check the outer surface of oil seal and retainer for

wear or damage.

(b) Check the outer and inner oil seals for wear or

damage.

FRONT AXLE AND REDUCTION DIFFERENTIAL

Reassembly

To reassemble, follow the disassembly sequence in reverse,

paying attention to the following points.

(1) Front wheel hub

(a) Fill grease (Autolex A or equivalent) in the front

wheel hub as shown.

Stuff grease in the roller holder of the tapered

roller bearing (inner) using the palm.

Apply grease to the lip groove of oil seal.

Use care not to let grease in the brake drum.

to the flange

surfaces of the axle shaft.

FRONT AXLE AND REDUCTION DIFFERENTIAL

(2) Hub bearing preload adjustment and lock nut

(a) Install the nut hand-tight with a socket wrench

Nut

(special tool).

Lock ring

Special tool needed

2,3 ton

classes

Lock bolt

Socket wrench

91268 -

03703 - 59001

210093

(b) Rotate the hub and tap its periphery with a

head mallet for snug assembling.

preload within the specified limits.

Note: To check the hub bearing preload, hook a spring

scale on the hub bolt, then pull it to measure the

tangential force of the hub bolt.

Unit: N (kgf) [lbf]

1 ton

2,3 ton

class

classes

Tangential force of hub

bolt (increment from

when preload is zero)

Starting torque of hub

0.5 to 5

rotation (increment from

(0.1 to 0.5 kgf-m)

when preload is zero)

to 3.7

(d) Fit the lock ring into place and tighten the lock

bolt.

(e) Check the preload again.

(3) Drain plug

(a) Tighten the drain plug to the specified torque.

83.4

7.8

Tightening torque

(8.5

0.8

1.5

5.8

FRONT AXLE AND REDUCTION DIFFERENTIAL

Reduction

Disassembly

Sequence

1 Lock plate

Reduction pinion, Tapered

bearing

2 Adjusting screw

(inner), Shims

3 Bearing cap

Carrier cover

Remove parts 4 through 9 as an assembly

Tapered roller bearing

4 Tapered roller bearing

Driven gear

5 Pinion shaft

Plate

6 Differential pinion

Drive gear, Ball bearing

7 Bevel gear, Spacer

Input flange

8 Differential case

Ball bearing

9 Bevel gear

Oil seal

10 Cover, O-ring

Differential case

Lock nut, Shims

FRONT AXLE AND REDUCTION DIFFERENTIAL

Suggestions for Disassembly

Note: (1) Before disassembling the differential, except for

replacement of the reduction gear set, be sure to

measure the gear backlash to ensure correct

backlash at the time of reassembly.

Truck Model

3 ton

classes

class

Backlash between

0.20 to 0.28 mm

0.25 to 0.33

reduction gear and

(0.00'79 to

(0.0098 to

reduction pinion

0.0110 in.)

0.0130 in.)

(2) Provide a matching mark across the bearing cap,

adjusting screw and carrier on each side to

ensure correct refitting.

Removing bearing

Use a bearing puller to remove the inner bearing.

(2) Removing shims

After removing the lock nut

and shims, check and

record the total thickness of the shims. Tie the shims to the

lock nut so as not to be lost.

FRONT AXLE AND REDUCTION DIFFERENTIAL

(3) Removing tapered roller bearing

Do not remove the tapered roller bearing

from the

reduction pinion 12 unless it is defective.

(4) Removing carrier cover

Screw jack bolts in two jack bolt holes (at the positions

marked

and remove the carrier cover 1 3 while tapping

near dowel pins (2 places) with a plastic mallet,

Size

Jack bolt

Nominal length

20 mm (0.79 in.)

(5) Checking oil seal

Do not remove the oil seal 20 from the carrier cover 13

unless it is defective.

FRONT AXLE AND REDUCTION DIFFERENTIAL

Inspection and Repair

Reduction bevel gear and pinion

(a) Check the gear and pinion for tooth contact, wear,

pitting, flaking and chipping.

(b) Minor flaws on the tooth surfaces can be repaired

by grinding with an oil stone or sandpaper.

pinion is badly damaged, replace

them as a set.

Differential

(a) Check the differential case and tapered roller

bearing inner race to see if the seat surface is

fretted.

(b) Check the differential case for cracks. Check the

sliding contact surfaces of thrust washer and gears

for wear and damage.

gears for wear, pitting, chipping and galling.

(d) Check the pinions (inner surface) and pinion shafts

(outer surface) for wear.

(e) Check the differential gears and axle shaft splines

for wear and free play (looseness).

A: Standard value B: Repair or service limit

0.03 to 0.07 mm

Clearance between pinions

and shafts

0.35 mm (0.0138 in.)

A: Standard value B: Repair or service limit

Free play (looseness) of

differential gear and axle

0.5 mm (0.020 in.)

shaft splines

(3) Drive gear and driven gear

(a) Check the gears for tooth contact, wear, pitting,

galling and chipping.

(b) Replace the gears as a set if they are defective.

Note: (1) The combination of drive and driven gears is

different between one model of the truck and

another.

(2) The combination can be identified by the

alphabetical marks A up to F stamped on the

side face of the gears.

(3) Before replacing the gears, always check the

marks to make sure of the correct combination.

FRONT

AND REDUCTION

Sequence

Differential case

Bail bearing

Differential gear, Thrust washer

Plate

Differential gear, Thrust washers

Differential carrier

Differential pinion, Pinion thrust washer (2, 3

Bevel pinion, Shims, Tapered roller bearing

ton classes), Pinion shaft, Spring pin

(inner)

Bevel gear

Driven gear

Tapered roller bearing

Shims

Carrier cover

O-ring, Cover

Oil seal

Bearing cap

Ball bearing

Adjusting screw

Input flange

Lock plate

Drive gear

Suggestions for Reassembly

(1) Reassembling differential pinions

For adjusting the backlash between the differential gears

and pinions, use the thrust washers of the differential gears.

Measure the backlash and if it exceeds the standard value,

replace the thrust washers.

A: Standard value

2,3 ton

class

classes

Backlash

0.16 to 0.30

0.15 to 0.25

(2) Installing reduction gear

To install the bevel gear 2 to the differential case

apply

LOCTITE No. 271 to the threads of bolts 6 and tighten the

bolts to the specified torque.

FRONT AXLE AND REDUCTION DIFFERENTIAL

(3) Installing differential case assemblies

Place the case assembly on the carrier, and tighten cap bolts

snugly to fit the bearing caps tentatively.

(4) Installing bearing caps

The bearing cap and differential carrier are machined in

one process. Be sure to identify the left and right caps by

matching marks and install them in place.

(5) Adjusting bearing preload

Bolt

(a) Rotate the reduction gear by hand, and tap its back

side with a soft-head mallet for snug assembling.

(b) Hook a spring scale on the bolt 6, and pull it in the

tangential direction to read the force when the gear

starts rotating (preload for the bearing).

adjusting screws.

1 ton

2,3 ton

class

classes

Preload

(1.5 to 3.0

(1.3 to 2.5

to 6.6

to 5.5 lbf]

(6) Removing differential cases

The preload can be determined by doing the steps

through (5) above. Provide match marks across the

adjusting screws and bearing caps, and remove the

differential cases from the carrier.

(7) Shimming reduction pinion

Refer to page 7-23.

FRONT AXLE AND REDUCTION DIFFERENTIAL

(8) Installing oil seal

Oil seal

Using the installer (special tool), fit the oil seal

in the

carrier cover 8.

Special tool needed

Installer

91263-15400

Note: Be sure that the lip of oil seal faces in the right

direction.

(9) Applying grease to oil seal

Apply grease to the oil seal installed to the carrier cover 8

Specified grease

(10) Applying sealant

When fitting the carrier cover 8 to the differential carrier

15, apply sealant to the flange.

Sealant

FRONT AXLE AND REDUCTION DIFFERENTIAL

Adjusting reduction pinion preload

(a) After installing the tapered roller bearing 18,

measure gap between the reduction pinion and

tapered roller bearing to determine the required

total shim thickness. The standard value of total

shim thickness is 1.25 mm (0.049 in.).

(b) Five different thicknesses of shims are available -

0.05 mm (0.0020 in.),

mm (0.0039 in.), 0.2 mm

(0.00'79 in.), 0.5 mm (0.020 in.) and 1.0 mm

(0.0394 in .) . Use appropriate shims and tighten the

plate 1 4.

(c)

a spring scale onto the bolt hole of the input

flange, and pull it in the tangential direction to

check the preload for the tapered roller bearing (the

force when the flange starts rotating). Adjust the

preload by increasing or decreasing the shims.

34.32 to 49.03 N

Tangential force

(3.5 to 5.0

(spring scale reading)

(12) Adjusting reduction gear and reduction pinion tooth

contact

(a) After checking the reduction pinion preload, put

the differential carrier upside down.

(b) Install the differential cases (removed at Step 6) to

the carrier. Align the match marks on the bearing

caps and adjusting screws on each side.

FRONT AXLE AND

DIFFERENTIAL

between the reduction gear and pinion.

Set a dial gauge with its probe at a right angle to

the tooth face of the reduction gear as shown.

Turning the gear back and forth, read the tangential

play of the gear.

Backlash between reduction

0.15 to 0.25 mm

gear and pinion

(0.0059 to 0.0098 in.)

(d) When adjusting the backlash, turn the adjusting

Backlash

screws, right and left, equally in the same direction

so as not to affect the bearing preload.

Decreas

Increase

Backlash

Decrease

(e) Apply a thin and even coat of colorant to a few

reduction gear teeth, on both drive and coast sides.

Rotate the reduction gear back and forth by hand

until a contact pattern is located on both sides of

the gear teeth.

Note: Refer to "Tooth Contact Patterns and

Adjustment" on page 7-24.

(13) Tightening bearing caps

After checking the tooth contact, tighten the bearing

cap bolts to the specified torque, and bend the lock

plate to clinch the bearing cap.

Tightening torque for

FRONT AXLE AND REDUCTION DIFFERENTIAL

Adjustment

Adjusting reduction gear tooth contact

After the reduction gear and pinion have been replaced,

adjust the tooth contact as follows.

(1) Determine the required total shim thickness by

calculating on the basis of machining error marked on

the end face of the reduction pinion as follows. Put on

the determined total thickness of shims and install the

reduction gear and pinion.

Total shim thickness required

Standard value - (machining error)

(Example)

If the error is - 0.10 rnrn (- 0.004 in.), the total

thickness is 1.9

(0.075 in.)

1.8 mm (0.07 1 in

- (- 0.1 rnm (-0.004 in .) =

mm (0.071 in.) + rnm (0.004 in.)

1.9 rnrn (0.075 in.)

(2) If the tooth contact of the gears assembled according to

the reduction differential reassembling sequence is

improper, adjust it as follows.

FRONT AXLE AND REDUCTION DIFFERENTIAL

Tooth Contact Patterns and Adjustment

Tooth contact

Adjustment

Extends from toe to

middle portion,

covering 50% or

Correct tooth contact

of tooth length.

Short contact at toe of

1. Move gear away from pinion.

tooth (Toe)

2. Move pinion toward gear for correct

backlash by increasing shim thickness.

209971 -6

Short contact at heel

Move gear toward pinion.

of tooth (Heel)

2. Move pinion away from gear for correct

backlash by decreasing shim thickness.

209971 -7

Heavy contact on face

Move pinion toward gear by increasing

or top half (addendum)

shim thickness.

of tooth (Face)

2. Move gear away from pinion for correct

backlash.

Heavy contact on

1. Move pinion away from gear by

bottom half

decreasing shim thickness.

(addendum) of tooth

2. Move gear toward pinion for correct

(Flank)

backlash.

Note: For "Toe" or "Heel" contact, see the contact pattern on the outside (convex) of the reduction gear tooth. In the

case of "Face" or "Flank" contact, repeat the above adjustment until the correct tooth contact is obtained.

FRONT AXLE AND REDUCTION DIFFERENTIAL

Troubleshooting

Reduction bevel gear teeth badly worn

- Replace.

Bearing preload too much or too little, or bearings worn

Readjust or replace.

out continuously

excessively

Hub bearings damaged

- Replace.

Improper tooth contact between reduction bevel pinion

Readjust.

and reduction gear

Reduction taper roller bearings or hub bearings broken

Replace.

Differential gears having broken teeth, or thrust washers

- Replace gears or washers.

comes out during

worn

Foreign substance in axle housing

- Clean and replace oil.

Bolts securing axle shaft or differential carrier

- Retighten.

Fit of differential gears in differential case out of

- Replace worn parts.

specification due to wear

r damaged byaw

eetg

broorpor seized on spider,

- Replace defective parts.

Bearings damage due to excessive preload

- Replace bearings and

Overheated

readjust preload.

reduction case

Backlash between reduction bevel pinion (on output shaft)

Readjust tooth contact

and reduction bevel gear too

and backlash.

FRONT AXLE AND REDUCTION DIFFERENTIAL

Data

A: Standard value B: Repair or service limit

Unit: mm (in.)

Truck Models

2 ton class

3 ton class

Items

0.08

(0.0031)

Face

of axle shaft flange

0.5

(0.0197)

0.5

(0.0197)

of Axle shaft

of gauge reading)

0.5

(0.0

maximum

Preload for hub bearing 1

0.5 to 4.9 (5 to 50)

to 3.61

Hub bearing lock nuts

(outer) 2

shaft bolts 3

9.8 (10

7.21

Tightening

Backing plate bolts

(14.9

1.5)

(21.7

2.2)

11.11

15.71

torque

Axle support nuts 5

378

38 (38.5

3.9)

Wheel nuts 6

Rim bolts 7

2 ton classes

3 ton class

Hub and

wheels

FRONT AXLE AND REDUCTION DIFFERENTIAL

A: Standard value B: Repair or service limit

Unit:

(in.)

Truck Models

2 ton class

3 ton class

-------

Items

0.16 to 0.30

0.15 to 0.25

(0.0063 to 0.0118)

(0.0059 to 0.0099)

Backlash of reduction differential gear 1

0.5

(0.0197)

0.02 to 0.07

0.02 to 0.09

0.17 to 0.27

(0.0079 to 0.0028)

(0.0079 to 0.0035)

(0.0067 to 0.0106)

spider 2

0.35

(0.0138)

Preload for differential case side bearing 3

Face

of reduction bevel gear 4

Backlash of reduction bevel gear and

pinion 5

Free play of gear and shaft spline 6

Reduction

differential

Tightening torque of reduction bevel gear

118 19 .8

mounting bolts 7

(12

1.O)

[87

Tightening torque of differential case

mounting bolts 8

Tightening torque of side bearing cap

157

5.9

bolts 9

(16 10.1)

14.41

Tightening torque of differential carrier

bolts 10

Tightening torque of differential carrier

cover bolts 1 1

Tightening torque of lock nut 12

Tightening torque of input flange bolts

REAR AXLE

structure and Functions

Rear Axle in General

Structure of Each Component

8 -

Steering Cylinder

8 -

Removal and

8 -

Rear Wheel and Rear Axle Assembly

8 -

Disassembly

and Reassembly

8 -

1. Disassembly and Reassembly of Wheel Hub

8 -

2. Disassembly and Reassembly of Knuckle (King Pin)

8 -

3. Disassembly and Reassembly of Steering Cylinder

8 -

4. Disassembly and Reassembly of Tie Rod

8 - 10

AXLE

Structure and Functions

Rear Axle in General

---

Main Components

1 Rear axle main unit

6 Right-side king pin (with tire angle sensor)

2 Mount bushing (rear axle support)

7 Steering cylinder

3 Wheel hub

8 Tie rod

4 Knuckle

9 Wheel bolt

5 Left-side king pin

10 Rubber shim (rear of vehicle only)

Specifications for wheel alignment and steering angle

1 ton

2 ton

3 ton

class

King pin inclination angle

Distance between king

740

818

pins

mm (in.)

(29)

(32)

Camber angle

Caster angle

Toe angle

Stroke

83.5

98.5

Maximum steering angle

(3.29)

(3.88)

of inner wheel A

Wheel bolt size

Maximum steering angle

of outer wheel

Note: The steering angle is automatically determined by stroke of the steering cylinder. It is not structured to be

changed by adjustment.

8-1

REAR AXLE

Structure of Each Component

Main components of wheel hub

Spindle of knuckle

Oil seal

Bearing cone (inner race)

Cup (outer race)

Bearing cone (inner race)

Cup (outer race)

Nut (hexagon nut)

Lock plate

Bolt

Hub cup

Left-side king pin

Thrust bearing

Shim (for adjusting clearance)

Dust seal

Detail of wheel hab

Detail of king pin

Needle bearing

King pin cover

Bolt, Nut (for securing king pin)

Grease nipple

Tie rod

Tie rod pin

Dust seal

Bushing

Retainer

Dust seal

Bolt and washer

assembly

Grease nipple

Detail of tie rod

209688

(rubber),

Rubber shim

This acts as a c

when the rear a

moves rearward.

Center of rear axle

209689

REAR

and

Rear Wheel and Rear Axle Assembly

! I

Center of rear axle

Stopper plate

Tightening torque of axle mounting bolt

1 ton class:

49.0 to 68.6

(5.0 to 7.0

Removal of rear wheels

Removal sequence of axle assembly

1 Wheel nut (6 pcs.)

5 Rubber shim

Set the parking brake, and block the front wheels.

2 Rear wheel

6 Rear axle (with

2. Loosen the wheel nut about two turns and raise the

3 Hose or pipe

cylinder)

rear end of the truck by using a jack or crane at the

4 Bolt, Stopper plate

specified point.

(1) Method using a jack

Suggestions for Removal

Position the jack under the counterweight at the

Refer to "Removal of rear wheels" in previous

jacking point and raise the rear tire.

pages to remove the rear wheels.

(2) Method using a crane

2. Raise the truck with a jack and support the bottom

of both sides of the frame with jack stands.

Attach lifting sling to the

pin in the

[Approx. 500 mm (19.7 in.) is sufficient for the

counterweight, and lift it.

distance between the bottom of the frame and the

ground .]

3. Disconnect the hose or pipe 3 from the cylinder

When the truck is raised by either method,

elbow (2 places). Disconnect the tire sensor

place jack stands under the frame to

harness from the connector.

securely.

4. Place a garage jack under the axle to support the axle.

5. Remove rear axle mounting bolts, stopper plate

3. Remove the wheels.

and rubber shim 5.

6. Lower the garage jack and pull out the rear axle

lnstallation of rear wheels

(with cylinder) from the truck.

Follow the sequence of disassembly in reverse.

lnstallation

Note: Tighten wheel nuts evenly to the specified

Follow the sequence of disassembly in reverse, paying

torque.

attention to the following points.

Be sure to insert the rubber shim

2. Tighten bolts 4 to the specified torque.

REAR AXLE

Disassembly and Reassembly

Disassembly and Reassembly of Wheel Hub

Suggestions for Disassembly

1. Remove rear wheels as preparatory work.

2. Check the hub for looseness. If there is looseness, the

bearing may be worn.

3. If the bearing is not damaged, it is not necessary to

remove it.

4. The cup and the cone of the bearing make a pair. When

replacing, replace them as a set.

5. When removing the oil seal 8, replace it with a new

one. Do not reuse it.

6. Use a special service tool to remove the bearing.

after disassembly

Bearing

Replace the bearing with a new one if damage, seizure,

peel, rotation failure or abnormal noises are found.

A grease

2. Hub

Replace the hub with a new one if cracks are detected by

209692

dye check.

Disassembly sequence

3. Oil seal

Hub cup

Replace a

or worn oil seal with a new one.

Bolt

Lock plate

Lock nut (hexagon nut)

Reassembly

Bearing cone

Follow the sequence of disassembly in reverse, paying

Hub (with bearing cup)

attention to the following points.

Bearing cone

1. Fill "AUTOLEX A" grease or equivalent wheel bearing

Oil seal

grease in the shaded area in the illustration on the right.

Bearing cup

Be careful to sufficiently fill it in the roller retainer.

Bearing cup

Apply grease also to the oil seal lip groove.

2. Adjust the bearing. Refer to "Adjusting procedure of

wheel bearing reassembly" on the following page.

3. Fill grease in the inside of the hub cup 1 before

pushing in the hub cup

REAR AXLE

Adjusting procedure of wheel bearing reassembly

1. Apply oil or grease to the contact surface of the lock

nut 1 with the wheel bearing.

2. Turn the wheel hub 3 by hand and tighten the lock nut

1 until the turn becomes difficult. Then, loosen the

lock nut by approx. 60 degrees from the position.

3. Turn the rear wheel hub back and forth two to three

times in the above condition to settle the cup and cone

of the wheel bearing.

4. Turn the wheel hub 3 by hand again and tighten the

lock nut 1 until the turn becomes heavy.

5. Insert the tab of the lock plate 2 aligning with the

knuckle groove and gradually loosen the lock nut 1

until the hole position of the lock plate 2 aligns with

the screw position of the lock nut 1. Then, secure the

lock nut 1 and lock plate 2 with two bolts

Note: Reversing the lock plate 2 changes the hole position.

(See the illustration on the right.)

6. Turn the wheel hub back and forth two to three

Measurement of

and make sure that the rotational driving force or

tangential force

starting tangential force is within the range below. If

out of the range, readjust. In case of a long-used

bearing, aim a low value of the allowance.

Unit: N (kgf) [lbf]

2 ton

3 ton

class

Tangential force

of hub bolt

Lock plate shape

Hole of 6.5 mm

Starting torque of

(0.26 in.)

hub rotation

(increment from

when preload is

zero)

No looseness is allowed in the axial direction.

8-6

REAR AXLE

Disassembly and Reassembly of Knuckle (King Pin)

Suggestions for Disassembly

Start by:

(a) Remove rear wheels.

(b) Remove wheel hubs

Separation of tie rod

1. For only separating the knuckle from the tie rod,

remove the bolt washer assembly 1 and spacer 2 on the

knuckle and pull out the tie rod pin 3.

2. Further disassemble to implement a full overhaul. For

details, see the page 10-10.

Removal of king pin

Left-side king pin

1. Loosen the lock nut 1 and remove the stopper bolt 2.

2. Remove the king pin cover 3 and grease nipple 4.

3. Apply a soft metal piece to the king pin from above

and drive the king pin downward. Support the king pin

by hand so that it will not fall down.

4. Remove the thrust bearing 5 , shim 6 and knuckle 7.

5. Pull out the dust seal and needle bearing from the rear

axle body as necessary.

Inspection after disassembly

Clean and inspect disassembled parts.

Needle bearing and thrust bearing: Replace the bearings

with new ones if damage, seizure, peel, rotation failure or

abnormal noises are found.

Clearance:

0.2 mm (0.0079 in.)

Dust seal: Replace a damaged or worn seal with a new

one.

210102

Reassembly

Follow the sequence of disassembly in reverse, paying

attention to the following points.

1. Reassemble the king pin inserting from the lower side

toward the upper side. (Reassembly in the opposite

direction may damage the shim 6.)

2. Reassemble the thrust bearing 5 in the direction as

illustrated. Adjust with a shim 6 so that clearance in

the axial direction becomes 0.2 mm (0.0079 in.) or less.

3. When replacing the dust seal and needle bearing, install

them to the direction and dimensions as shown in the

illustration on the right using a driving tool.

4. Apply a sufficient amount of grease after reassembly.

Apply grease until it comes out of the boundary

between the axle and the knuckle.

REAR AXLE

3. Disassembly and Reassembly Steering Cylinder

Removal

,Tie rod pin

Start

(a) Remove the rear axle assembly (with

cylinder) from the truck.

(b) Pull out right and left tie rod pins on the

cylinder to disconnect the knuckle from

the cylinder.

g bolt

Removal of cylinder

Tightening torque:

Remove cylinder mounting bolts (4 pcs.)

ton

137 to 186

to remove the steering cylinder.

(14 to 19

to 137

2, 3 ton classes: 265 to 292

(27 to 30

95 to 215

Disassembly of steering cylinder

Shrinkage fit

Detail of "A¹"

Detail of

Sequence

1 Stay rod, Washer and Nut

5 Dust seal

11 O-ring

2 Header (with parts 5 through

6 Backup ring

12 Piston seal

10 assembled)

7 Rod seal

13 Guide ring

3 Body

8 Bushing

14 Snap ring

4 Rod assembly (with parts 12

Snap ring

15 Bail joint

through 1 5 assembled)

10 O-ring

REAR AXLE

Suggestions for Disassembly

Reassembly

1. Activate the piston by blowing compressed air from

Follow the sequence of disassembly in reverse, paying

the oil port to discharge oil in the inside.

attention to the following points.

2. When the stay rod 1 is removed, the cylinder is

1. Reassemble in a clean place where no dust or

divided into three parts.

abrasive foreign substance enters.

3. Remove damaged or worn seals as necessary. Do

2. Reassemble parts while lubricating them with

not reuse removed seals.

hydraulic oil.

3. Replace seal kit parts with new ones as much as

possible.

4. Be careful not to twist O-rings when installing.

4. Disassembly and Reassembly of Tie Rod

Disassembly

Sequence

1 Grease nipple

5 Retainer

2 Bolt and washer assembly

6 Dust seal

3 Spacer

7 Dust seal

4 Tie rod pin

8 Bushing

Reassembly

Follow the sequence of disassembly in reverse, paying

attention to the following points.

1. Replace a damaged or worn dust seal with a new one.

sufficient amount of grease after reassembly.

Apply grease until it comes out of the dust seal.

BRAKE SYSTEM

Brake System

9 -

Disassembly and Reassembly

Master Cylinder

9 -

Disassembly

9 -

Reassembly

9 -

Wheel Brakes

9 -

Disassembly

9 -

Reassembly

9 -

Wheel

Cylinder

9 - 12

Disassembly

9 - 12

Reassembly

9 - 13

Inspection and Adjustment

- 14

Automatic Adjuster Test

9 - 14

Manual Adjustment

Parking

Brake Cable Adjustment

Brake Pedal Adjustment

- 16

Bleeding Brake Lines

Braking Performance Test

9 - 17

Parking

Brake Lever

9 - 18

Troubleshooting

Data

BRAKE SYSTEM

Inspection after disassembly

Cylinder

Check the cylinder bore for rusting, erosion, abnormal

(2) Check the inlet and relief ports for restriction. Check

the threads on each joint for damage. Also, check the

boot and other parts for damage.

2. Piston

Check the piston for damage. Replace if it is damaged.

Insert the piston into the cylinder, and measure the

to-cylinder clearance. If the clearance is in excess of the

service limit, replace the cylinder and piston.

A: Standard value

B: Service limit

0.020 to 0.105 mm

Clearance between

(0.00079 to 0.00413 in .)

cylinder and piston

0.15 mm (0.0059 in.)

3. Return spring

Replace the spring if it is severely damaged or its free

length is at or less than the service limit.

A: Standard value

Service limit

Spring free length

53.9

(2.1 in.)

4. Cups in piston assembly

Check the rubber parts for damage or swelling. If the lips

are damaged even slightly, the base is bitten, or abnormal

fatigue, wear or swelling is evident, replace the piston

assembly. If the cup tightness is 0.4 mm (0.0157 in.) or

less, replace the piston assembly.

Note: The cups must be replaced periodically. It is a safe

and good practice to replace

whenever the

master cylinder is disassembled.

Reassembly

To reassemble, follow the disassembly procedure in

reverse, paying attention to the following points.

(I)

all metal parts with volatile cleaning solvent, and

completely dry them with compressed air.

(2) Apply a thin coat of rubber grease exclusively designed

for brake components or brake fluid to the cylinder

bore, piston CUPS, and the inner face of the filler union

bushing mounting hole.

BRAKE SYSTEM

Wheel Brakes (2, 3 ton classes)

Drum

rotating

direction

during

forward

movement

to expand shoes

Section A - A

The illustration shows a left-hand wheel brake.

209784

Backing plate assembly

Pin, Hold-down spring, Cup

Parking brake cable, Snap ring

Shoe guide plate

Wheel cylinder

Cable with spring

Parking brake lever

Return spring (primary)

Primary shoe and lining assembly

Return spring (secondary)

Retainer, Washer

Adjusting lever, Adjusting spring

Pin, Sheave, Washer

Adjusting screw

Secondary shoe and lining assembly

Return spring

Strut, Anti-rattle spring

BRAKE SYSTEM

Wheel Brakes

Disassembly

Sequence

1 Return spring

7 Strap, Anti-rattle spring

2 Cable with spring

8 Shoe and lining (primary), Parking brake lever,

3 Hold-down spring, Cup, Pin

Retainer, Spring washer

4 Adjusting lever, Adjusting spring, Return

9 Wheel cylinder

spring

10 Parking brake cable

5 Cable guide, Sheave, Adjusting screw, Pin,

Mounting bolt, Spring washer

Washer

12 Backing plate

Shoe guide plate, Shoe and lining (secondary)

Note: The part

to be changed periodically are included

in the Brake Repair Kit.

Start by:

(a) Remove the front wheel.

(b) Remove the wheel hub and brake drum.

bottom of wheel brake.

(d) Disconnect the brake pipe from the wheel brake

assembly.

BRAKE SYSTEM

Suggestions for Disassembly

1. Removing return springs

Use a special tool to remove the return springs

the

shoe guide plates.

Special tool needed

Spring remover

64309 - 15411

2. Removing hold-down springs

Use a special tool to remove the hold-down springs from

the backing plate.

Special tool needed

Spring retainer

64309 - 15412

Inspection after Disassembly

Backing plate

(1) Check the backing plate for cracks.

2. Shoes and lining

(1) Check each shoe and lining for cracks.

(2) Replace the lining if it is heavily fouled with grease,

burnt or otherwise deteriorated.

(3) Measure the thickness of the lining. Replace if it is

worn to less than the service limit.

A: Standard value

B: Service limit

1 ton

ton

class

classes

4.87 mm

5.7 mm

(0.19 in.)

(0.22 in.)

Thickness of

lining

1 mm

1.0 mm

(0.04 in.)

BRAKE SYSTEM

3. Brake drums

Check the inside (friction) surface of the drum for

abnormal wear, grooving and other defects. Minor

grooving can be removed by grinding,

that the

inside diameter does not exceed the service limit.

A: Standard value

B: Service limit

ton

2,3ton

class

classes

Inside diameter

(10.0 in.)

(12.2 in.)

of brake drum

256 mm

312

(10.1 in.)

(12.3 in.)

4. Adjusting screws

Check the wheel teeth for wear. Turn the screw by hand to

see if its rotating parts turn smoothly.

5. Parking brake cable

Replace a cable if it shows stretching, rust or damage.

Other parts

Check the shoe return springs for cracks or fatigue.

(2) Check the adjusting springs for cracks or fatigue.

(3) Check the cable with spring for stretching.

BRAKE SYSTEM

Reassembly

ton class

Section A - A

1 Wheel cylinder

9 Hold-down spring, Cup, Pin

2 Backing plate

10 Shoe guide plate

3 Shoe and lining (primary)

11 Cable with spring

4 Parking brake lever

12 Return spring

5 Retainer, Washer

13 Cable guide, Sheave, Pin, Washer

6 Shoe and lining (secondary)

14 Adjusting lever, Adjusting screw, Adjusting

7 Strap

spring

8 Anti-rattle spring

BRAKE SYSTEM

2, 3 ton classes

Section A - A

The illustration shows a left-hand wheel brake.

209784

Sequence

1 Backing plate assembly

Strut, Anti-rattling spring

2 Parking brake cable, Snap ring

Pin, Hold-down spring, Cup

3 Wheel cylinder

Shoe guide plate

Prepare Parts 4,5 and 6 in assembly beforehand.

with spring

4 Parking brake lever

Return spring (primary)

5 Primary shoe and lining assembly

Return spring (secondary)

6 Retainer, Washer

Adjusting lever, Adjusting spring

Prepare Parts 7 and 8 in assembly beforehand.

Adjusting screw

7 Pin, Sheave, Washer

Return spring

8 Secondary shoe and lining assembly

BRAKE SYSTEM

Suggestions for Reassembly

Wheel cylinder installation

Apply liquid packing to the mounting face of the wheel

cylinder before installing it. Tighten to the specified

torque.

2. Greasing

Apply a thin coat of the specified brake grease to the

following areas.

(1) Shoe ledges (6 locations)

The ledges are those portions of the backing plate in

contact with the shoe.

(2) Anchor pin surface in contact with the shoe ends

3. Shoe and lining installation

Ensure that each connector link of the wheel cylinder has

been correctly inserted into the shoe web.

4. Return spring installation

Use a special tool to install the return springs to the

backing plate pins.

5. Automatic adjuster installation

Clean the adjusting screw and associated parts. Apply

grease to the threaded portions and the screw socket.

Ensure that the screw turns easily when rotated by

hand.

If the screw is hard to turn, replace it with a new one.

(2) Identification of adjusting screws and levers

Note: After reassembly, bleed air out of the brake lines.

(Refer to "Inspection and Adjustment

BRAKE SYSTEM

and Repair

(1) Cylinder body

(a) Check the bore for rusting, erosion or scoring.

(b) Check the threads of bleeder screw and oil pipe for

damage.

(2) Pistons

(a) Check the sliding surface for rusting or scratching.

(b) With the piston installed in the cylinder body,

measure the piston-to-cylinder clearance. Replace

if the clearance is in excess of the service limit.

A: Standard value

B: Service limit

0.020 to 0.105

between piston

and cylinder

0.15 rnm (0.0059 in.)

(3) Piston cups

Check for swelling, damage or other defects. Replace the

cup if defective even slightly.

A: Standard value

B: Service limit

Tightness between piston

cup and cylinder body

0.65 rnm (0.025 in.)

(4) Boots

Replace the boots if they show damage or aged

deterioration. In any event, the boots must be replaced

every year.

Reassembly

To reassemble, follow the disassembly procedure in

reverse, paying attention to the following points.

(1) Wash all metal parts clean with volatile cleaning

solvent, and completely dry them with compressed air.

(2) Apply a thin coat of rubber grease exclusively designed

for brake components or brake fluid to the cylinder

bore and piston cups.

(3) Be careful not to damage the lips of the cups.

(4) Make sure that the cups face the correct directions

when reassembled.

(5) Tighten the bleeder screw to the specified torque.

5.9 to 8.8

Tightening torque

(0.6 to 0.9

to 6.5

BRAKE SYSTEM

inspection and Adjustment

Automatic Adjuster Test

(I) With clearance A between the lining and drum, set

approximate to specification, pull the cable with

attached spring using a finger as shown. The lever

should turn the adjusting screw wheel by one notch

and, when the cable is released, return to the original

position.

Unit:

(in.)

ton

class

classes

Drum inside diameter

254

310 (12.2)

Drum-to-lining

0.5 to 0.5

0.1 to 0.35

clearance A

(0.010 to 0.020)

(0.004 to 0.014)

(2) If the lever

or is slow to turn the adjusting screw

wheel, check the position of the lever relative to the

toothed wheel. The lever's actuating tip should touch

the toothed wheel at approximately to 9 mm (0.28 to

0.35 in.) below the centerline of the screw. If the lever

contact is out of the range, the lever will not correctly

engage with the toothed wheel, therefore failing or

slow to turn the wheel.

200282

(3) If the automatic adjuster fails to operate correctly, take

the following actions.

(a) Ensure that the adjusting spring is correctly hooked

to the primary shoe.

(b) Replace the fitting cable.

(d) Replace the adjusting screw

Manual Adjustment

Using a screwdriver through the slotted hole on the back of

the backing plate, adjust the

clearance to

specification by rotating the adjusting screw wheel.

Note: Turning the wheel by one tooth corresponds to a

change of 0.03 mm (0.001 in.) in shoe diameter.

BRAKE SYSTEM

Parking Brake Cable Adjustment

(1)

the parking brake cable to the parking brake

lever as shown. Set the lever "free" (the lever resting

on the inner surface of the shoe, as indicated by the

chain double-dashed line).

(2) With the lever set "free,"

the cable until the shoe

just starts to work on the drum. The amount of cable

pulled A should meet the specification listed below.

(3) Move the parking brake lever by the amount specified

below. This is the neutral position. In the neutral

Shoe

position, the inner cable length C should be as

209785

specified below.

Unit:

(in.)

1 ton

3 ton

class

classes

Cable pull A before

shoe works on drum

maximum

Distance B to reach

neutral

Inner cable length C

4 (1.73

0.16)

BRAKE SYSTEM

Brake Pedal Adjustment

Using the stop bolt, adjust the installed height A of the

brake pedal (from the floor to the top of the pad). After

Stop bolt

adjustment, lock the stop bolt.

(2) Adjust the push rod length of the master cylinder

Truck with powershift transmission

With the push rod-to-piston clearance removed,

adjust the clearance to specification by turning the

push rod. After adjustment, lock the clevis with the

nut.

(3) Ensure that the pedal play is to specification.

Note: (a) Ensure that the clevis pin between the brake

pedal and push rod is firmly in place as

illustrated.

(b) Ensure that the snap pin is firmly engaged.

without obstruction or other problems.

Unit: mm (in.)

2,3 ton

Pedal height from floor

182 to 200 (7.16 to 7

Clearance

Push rod-to-piston

clearance

Pedal play

Detail B

209789

BRAKE SYSTEM

Bleeding Brake Lines

After any portion of the brake fluid lines has been

disassembled for repair or service, or if the brake pedal

feels spongy, bleed the brake lines as follows:

Install one end of a transparent vinyl tube onto the

bleeder screw of the right-hand wheel cylinder, which

is located farther from the master cylinder than the left-

hand wheel cylinder. Put the loose end of the tube into

a container filled with brake fluid.

(2)

the brake fluid level in the reservoir tank. Fill

up as necessary.

(3) After cycling the pedal several times, depress the pedal

and keep it depressed. With the pedal depressed,

loosen the bleeder screw. While the brake fluid is

flowing through the tube, tighten the bleeder screw.

(4) Repeat Step (3) until the fluid flowing through the tube

is free of air bubbles. Repeat the same procedures for

the left-hand wheel cylinder. With the brake lines free

of air, fill brake fluid into the reservoir tank to the

specified level.

Note: (a) Take care to maintain the brake fluid in the

reservoir tank at sufficient levels while the

bleeding operation is in progress.

(b) Use only the brake fluid of specified brand and

grade. Avoid mixing different types of fluids.

Braking Performance Test

With all of the required adjustments completed after

check the braking force at a speed

of 10

Readjust as necessary by referring to "Manual

Adjustment

BRAKE SYSTEM

Parking Brake Lever

Applied

Lever support pin

3 Parking brake lever assembly

2 Adjusting screw

4 Parking brake switch

Inspection and Repair

(1) If the lever support pin

the pin hole in the lever

are badly worn, replace the worn

(2) Replace the parking brake cable if it is stretched,

damaged or rusted.

Reassembly

With the parking brake cable and lever connected, the force

required to pull the lever should be 245 to 295 N (25 to 30

kfg)

to 66 lbf].

BRAKE SYSTEM

Troubleshooting

Oil leaking past primary cup in master

*Replace piston

if cylinder

cylinder

is free from unacceptable wear.

Replace the

and fluid

Oil leaking past cups in wheel cylinder

with genuine parts if the

is distorted.

Oil leaking from oil pipe connection

Retighten, or replace pipe and

connector.

Shoe lining worn

--- Replace.

Shoe lining dirty with oil or grease

Clean or replace.

Air trapped in brake fluid lines

Bleed air at master and

wheel cylinders.

Piston cup defective in master cylinder

Replace.

enough fluid in reservoir tank

Refill.

stroke

Push rod to piston clearance too large in

Readjust.

master cylinder

Brake fluid leakage

Refer to above.

Automatic adjuster inoperative

Ensure that cable guide and

adjusting spring are correctly

installed. If still inoperative,

replace cable with spring, lever,

and adjusting screw.

brakes

Lining or drum dirty with oil or grease

Clean with gasoline. If lining

in less effective brake

still dirty, replace.

Wobbly or loose-mounted drum in less

Replace drum. If loose, readjust

effective brake

and retighten.

Wheel tires inflated unequally

Reinflate to specification

Lining glazed

Sand.

Worn lining

Replace shoe and lining

assemblies.

Brake squeals

- Backing plate securing bolts loose

Retighten.

Wheel bearings loose

Readjust preload and retighten.

Brake drum dirty

Clean with cleaning solvent.

Anchored ends of shoes rattling

Repair or replace.

on anchor

Shoe ledges badly worn

Replace backing plate.

Pistons badly worn in wheel cylinder

Replace wheel cylinder.

BRAKE SYSTEM

- Readjust.

Will squeal

Lining to drum clearance too small

- Readjust.

Brake drum badly distorted

Repair or replace.

brake

Parking brake cable longer than

- Check lining to drum clearance.

specification

If brake will still not apply,

readjust cable length.

lining worn to the service limit

- Replace shoe and lining

Will not apply

assemblies.

Lining to drum clearance too large

- Readjust.

Lever lacks operating force

- Readjust to specification.

BRAKE SYSTEM

Data

A: Standard value

B: Service limit

Unit: mm (in.)

Truck Models

ton class

2, 3 ton classes

Items

Cylinder bore size

19.05

(0.7500)

Diameter of piston 2

19.05

(0.7500)

0.020 to 0.105 (0.00079 to 0.00413)

Clearance between cylinder and piston

0.15

(0.0059)

(0.039)

Primary cup tightness 3

0.4

(0.016)

(Replace every year or whenever overhauling)

1.1

(0.043)

Secondary cup tightness 4

0.4

(0.016)

(Replace every year or whenever overhauling)

59.2

(2.3)

Free length of return spring 5

53.9

(2.1)

Master

(Replace every year or whenever overhauling)

cylinder

BRAKE SYSTEM

A: Standard value

B: Service

Unit:

(in.)

Truck Models

1 ton class

2,3ton classes

Items

Inside diameter of brake

Thickness of lining 2

Clearance between drum and lining 3

0.5 to

120 (4.72)

Free length

102 (4.02)

Secondary: 139.3 (5.48)

Primary: 134 (5.3)

Length under set force

111 (4.4)

Secondary: 145.5 (5.8)

Return

spring

Primary:

Set force

157

16 (16

1.6)

226

23 (23

2.3)

3.61

Secondary:

(23f 2.3)

Free length

79 (3.11)

104.5

(4.11)

122 (4.8)

Length under set force

98.5

(3.9)

Set force

137

14 (14

1.4)

8 (8

0.8)

[31

3.11

1.81

Tightening torque for backing plate

215 (21.9)

brakes

4 secondary spirng

Cat Lift Trucks. For use with K21/K25 and S4S Engine Service Manuals (2007) - page 2