Senb8474t SM Ec35-55n

®
Lift
Trucks
Service Manual
Chassis & Mast

EC35N, EC40N, EC45N A2EC4-60200-up
EC55N A2EC5-60200-up
For use with GE SX Control Service Manual. SENB8474

TABLE OF CONTENTS
CHAPTER 1: GENERAL INFORMATION

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Truck Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Nameplate and Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Dimensions Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
General Information (Standard Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
CHAPTER 2: FRONT AXLE AND REDUCTION DIFFERENTIAL

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Procedures and Key Points for Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Front Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Reduction and Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Axle Shaft and Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
Adjustments .................................................................... 2.15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
CHAPTER 3: TRANSFER ASSEMBLY

Structure and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Reassembly .................................................................... 3.5
Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
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CHAPTER 4: REAR AXLE

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Procedures and Key Points for Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Adjustment of Minimum Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
CHAPTER 5: BRAKE SYSTEM

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Master Cylinder and Reservoir Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Wheel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
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CHAPTER 5: BRAKE SYSTEM (cont.)

Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Adjustment and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Automatic Adjuster Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Procedure for Manual Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
Brake Fluid Line Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
Inspecting Reservoir Tank Level Sensor .............................................. 5.15
Procedures for Brake Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.16
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
CHAPTER 6: STEERING SYSTEM

Steering System
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Oil Flow Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Steering Gear
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Inspection after Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
Working Rules and Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Steer Pump
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
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CHAPTER 7: HYDRAULIC SYSTEM

Hydraulic System
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
Flow Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10
Down Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Removal and Installation Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Hydraulic Pump
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
Inspection after Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Inspection after Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
Control Valve
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
Lift and Tilt Cylinders
Removal
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
Disassembly
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.47
Precautions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.50
Inspection and Adjustment
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.53
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.54
Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
Adjusting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
iv
TABLE OF CONTENTS
CHAPTER 8: MAST AND FORKS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Dual-stage Panoramic Mast (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Triple-stage Full Free Panoramic Mast (Triplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
Dual-stage Panoramic Mast (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
Dual-stage Full Free Panoramic Mast (Duplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
Triple-stage Full Free Panoramic Mast (Triplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.21
Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
Chain, Chain Wheel Support and Chain Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
Chain Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.27
Clearance Adjustment on Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30
Mast Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.32
Main Roller Shim Replacement (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34
Mast Strip Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34
Tilt Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.38
Lift Cylinder Stroke Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.39
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.41
CHAPTER 9: SERVICE DATA

Tightening Torques for Standard Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Fine Thread with Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Fine Thread without Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Course Thread with Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Course Thread without Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Periodic Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
Fuel and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
Weight of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
Special Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
Special Tool Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
v
GENERAL INFORMATION
CHAPTER 1: GENERAL INFORMATION
Scope.............................................................................................................................................................. 1.1
Truck Models Covered.................................................................................................................................... 1.1
Nameplate and Serial Number Locations....................................................................................................... 1.2
Dimensions ..................................................................................................................................................... 1.3
Dimensions Chart ........................................................................................................................................... 1.4
General Information (Standard Models) ......................................................................................................... 1.5
GENERAL INFORMATION
Scope
This service manual deals with all components or systems of the Cat Lift Trucks, except for the electrical
system, which is covered in a separate manual.
Truck Models Covered

This service manual furnishes service and maintenance information for the following trucks.
Truck Model Serial Number

1.1
GENERAL INFORMATION
Nameplate and Serial Number Locations
1.2
GENERAL INFORMATION
Dimensions
1.3
GENERAL INFORMATION
Dimensions Chart
Ref# Truck Model EC35N EC40N EC45N EC55N
A Maximum Lift 4650 (183) 4650 (183) 5055 (199) 5320 (209)
B Free Lift 150 (5.9) 150 (5.9) 160 (6.3) 160 (6.3)
Maximum Fork Spacing

C 1060 (41.5) 1060 (41.5) 1060 (41.5) 1060 (41.5)
(outside to outside)
D Fork Length 1220 (48) 1220 (48) 1220 (48) 1220 (48)
Tilt Angle
E 6° / 8° 6° / 8° 6° / 8° 6° / 8°
(forward/backward)
F Overall Length 3640 (143.3) 3691 (145.3) 3746 (147.5) 3912 (154.0)
Overall Width
G 1270 (50.0) 1270 (50.0) 1315 (52.0) 1420 (55.9)
(outside of tires)
Overall Height (to top of

H 2270 (89.5) 2270 (89.5) 2350 (92.5) 2120 (83.5)
mast, lowered)

I 2341 (92.2) 2341 (92.2) 2341 (92.2) 2341 (92.2)
overhead guard)

J 4550 (179.1) 4550 (179.1) 4115 (162.0) 4125 (162.4)
mast, extended)
K Tread (front) 1040 (41.0) 1040 (41.0) 1065 (42.0) 1116 (44.0)
L Tread (rear) 965 (38.0) 965 (38.0) 965 (38.0) 965 (38.0)
M Wheelbase 1575 (62.0) 1575 (62.0) 1575 (62.0) 1720 (67.7)
N Front Overhang 450 (17.7) 450 (17.7) 465 (18.3) 480 (18.9)
O Rear Overhang 395 (16) 446 (18) 486 (19) 492 (19)
Underclearance
P 106 (4.2) 106 (4.2) 106 (4.2) 106 (4.2)
(at center of wheelbase)
Unit: mm (in.)
1.4
GENERAL INFORMATION
General Information (Standard Models)
Truck Model
Units EC35N EC40N EC45N EC55N
Standard Controller GE SX Controller

Standard Simplex Mast Size meters 3.3 3.3 3.3 2.9
Without 4581 4833 5677 6448
Service Weight Battery (10099) (10656) (12516) (14215)
kg (lb)
(standard axle) With Max. 6849 7101 7945 8716
Battery (15099) (15656) (17516) (19215)
Rated Capacity/ kg/mm 3500/500 4000/500 4500/600 5500/600

Load Center (lb/in.) (7000/24) (8000/24) (10,000/24) (12,000/24)
Maximum Fork Height mm (in.) 4650 (183) 4650 (183) 5055 (199) 5320 (209)
Lift Speed 36V m/sec. 0.25 (50) 0.22 (43) 0.20 (39) 0.17 (33)
(Rated Load) 48V (fpm) 0.31 (64) 0.34 (67)) 0.25 (49) 0.21 (41)
Performance
Lowering Speed (rated load) 0.54 (106) 0.56 (110)
Tilt Angle (forward/backward) degrees 6° / 8°

Work
Free Lift mm (in.) 150 (5.9) 160 (6.3)
Travel Speed 36V km/h 14.0 (8.7) 13.8 (8.6) 13.7 (8.5) 13.6 (7.3)
Performance
(Without Load) (mph)

Traveling
48V 17.0 (10.6) 16.9 (10.5) 15.8 (10.3) 16.6 (10.3)
Minimum Turning mm 2214 2258 2294 2468

Radius (in.) (87) (89) (90) (97)
Traction Motor 36V 60min. 15.3 (11.4)

Output 48V HP(kW) 20.9 (15.5)
Transfer Type Spur

Gear Ratio 5.131
Reduction Type Spiral Bevel

Gear Ratio 4.571
Power Train
Axle Housing Banjo
Differential Gear Type/ Gears Straight Bevel/2
Number Pinions Straight Bevel/2
1.5
GENERAL INFORMATION
Truck Model
Units EC35N thru EC55N
Type Dynamic Load Sense

Power Steering System
Inside 82°
Turning Angle Degrees
Outside 59°
Steering Wheel Diameter mm (in.) 328 (13)

2
Cylinder Minimum kgf/cm
120 (1706) [11,768]
Test Pressure (psi) [kPa]
Type Self-Adjusting Duo-Servo
Inside Drum
mm (in.) 317.5 (12.50)
Diameter
Service Brake
Lining
mm (in.) 10 (0.39)
Thickness
Master Primary 31.75 (1.25)

mm (in.)
Cylinder ID Secondary 19.05 (0.75)
Wheel 31.75 (1.250)

Cylinder ID
Brake System
Type Mechanical, Mounted on Front Wheels
Park Brake Lever kgf 25 to 30

Operating (lbf) (55 to 66)
Effort [N] [245 to 295]
Front Wheels Fixed Type

Mounting
Traveling System
Rear Wheels Center Pivot Type
Wheel Oscillation 3°
Alignment Angle Degrees
Camber 1°
1.6
GENERAL INFORMATION
Truck Model
Units EC35N EC40N EC45N EC55N
Type Gear
Hydraulic Pump Make Haldex - Barnes
Model W1500
Displacement cc (cu in.) 38 (2.32)
Make Husco International
Control Valve Model 5000CC Sectional Valve
Relief kgf /cm2 Aux 155 (2250) 15513
Pressure (psi) [kPa] Lift Tilt 197 (2850) 19650
Flow Regulator Type Variable
Valve Regulated liter
100 (6100) 115 (7018)
Flow Rate (cu.in.) / min
Hydraulic System
Lift Cylinders ID 60 (2.36) 70 (2.75)

Stroke 1650 (64.96)
mm (in.)
ID 100 (3.937)
Tilt Cylinders
Stroke 120 (4.724)
Hydraulic Tank Capacity liter Liter 48 (12.7)
(Approx) (US gal.)
Mast Model CJ type
Flange ID X flange 130x30x26x15
Outer 118x28x24x13 (4.6x1.1x0.9x0.5)
back thickness X (5.1x1.2x1.0x0.6)
flange front
thickness X web Inner, Middle 118x24x24x12 (4.6x0.9x0.9x0.47) 130x26x26x13
thickness (5.1x1.0x1.0x0.5)
Main Rollers Bearing Ball Bearing
Diameter x Width, mm (in.) 118x32 (4.65x1.26) 130x34 (5.12x1.34)
Side Rollers Bearing Lubricating type needle roller bearing
Diameter x Width, mm (in.) 52x36 (2.05x1.42)

Mast and Forks
Lift Chains BL834 BL1034
Forks (length x width x thick), mm (in.) 1220x150x50 (48x6x2)
Fork Spread (outer width), mm (in.) 1060 (41.5)
Voltage 36 / 48
Amp Hours (6 hr. rate) 36V 1760
48V 1540
Compartment
Height 590 (23.22)
Dimensions mm (in.)
Length 1003 (39.5)
Battery
Width 1156 (45.5)

Weight (Min/Max) kg (lb) 1500 / 2268 1650 / 2268 1800 / 2268
(3400 / 5000) (3600 / 5000) (3975 / 5000)
1.7
FRONT AXLE AND REDUCTION DIFFERENTIAL
CHAPTER 2: FRONT AXLE AND REDUCTION DIFFERENTIAL
Specifications ................................................................................................................................................. 2.1

Structure ................................................................................................................................................... 2.2
Procedures and Key Points for Removal and Installation .............................................................................. 2.3
Front Tire ................................................................................................................................................ 2.3
Front Axle Assembly ................................................................................................................................ 2.4
Reduction and Differential ...................................................................................................................... 2.6
Axle Shaft and Hub ........................................................................................................................................ 2.6
Disassembly............................................................................................................................................. 2.7
Inspection and Repair.............................................................................................................................. 2.8
Assembly ................................................................................................................................................. 2.9
Adjustments ............................................................................................................................................ 2.15
Troubleshooting .............................................................................................................................................. 2.18
Service Data .................................................................................................................................................. 2.19
Secifications
Truck Models EC35N thru EC55N

Items
Reduction
Gear type Spiral bevel gear
Reduction ratio 4.571

Housing type Banjo type
Differential
Large Straight bevel gear x 2

Type and number of gears
Small Straight bevel gear x2
Running
Front axle type Full-floating axle tube type

Gear
Suspension Front wheel Frame fixing type
2.1
Structure
1 5 6 7 8
•
• ••
• •
2 3 4
206653
Sequence
1 Front wheel hub drum
2 Front axle support
3 Axle shaft
4 Axle housing
5 Reduction bevel pinion
6 Reduction bevel gear
7 Differential case
8 Differential carrier
2.2
Procedures and Key Points for Removal and Installation

Front Tire
Removal
1 Wheel nut 2 Front tire
Special tool needed 2
Wheel socket MCF-1098
Preparation 1
(1) Pull the hand brake lever, and place wheel
stoppers at the rear tires.
(2) Loosen the wheel nuts about two rotations,
and lift the vehicle with a crane or a hydraulic
unit. 206654
(a) Lifting the vehicle with a crane, attach

a cable to the outer and inner mast
crossmembers, and lift the vehicle.
Use protection cloth for the cable.
(b) Lifting the vehicle with the mast, tilt

206665
the mast fully backward, place wood
blocks which can bear the weight under
the mast, and tilt the mast forward until
the front tires are off the ground.
NOTE
For both methods, place wood blocks under
the frame to prevent it from falling.
Installation 200227
Follow the removal sequence in reverse. Be
careful with the following key point.
Tighten wheel nuts evenly to the specified Tightening sequence
torque to prevent tire shimmy. 1
8 5
NOTE
Insure wheel nut mounting holes are free of
paint and grease before torquing wheel nuts. 4 3
6 7
Wheel nut tightening torque 551±55
N·m (kgf·m) [lbf·ft] (56.2 ± 5.6) 2
206655
[406.5 ± 40.6]
2.3
Front Axle Assembly

Preparation
(1) Pull the hand brake lever, and place wheel
stoppers at the front and rear tires.
(2) Remove the mast and the lift bracket assem-
bly. (Refer to Mast and Fork section.)
(3) Loosen the front tire nuts about two rotations,
and jack up the vehicle.
(4) Place a stand or wood blocks under the frame
on both sides at the front so that the vehicle
becomes level.
(5) Remove the front tires. (Refer to Front Tire
Removal procedure.)
(6) Drain differential oil.
NOTE
If replacing the front axle housing, carry out
the above preparation.
Removal
3
2
206666
Sequence
1 Axle shaft, Bolt, Spring washer
2 Bolt, Spring washer
3 Nuts, Spring washers, Bolts
4 Front axle assembly
2.4
Key points for removal

(1) Removing axle support bolts
(a) Place wood blocks under the front of the
transmission to support it.
206667
(b) Attach a cable with protection cloth to the Reduction and Differential
mast fitting on the front axle assembly, When replacing the reduction gear, replace the
and lift the assembly until the cable is reduction pinion, too.
taught. Wind the cable rope twice firmly. Tooth contact of the reduction gear and the
(c) To remove bolts, remove the bolts at the reduction pinion must be adjusted by mating
top on both sides, and insert a guide bar. the transfer assembly on the pinion side and
Then remove the other bolts. the differential carrier on the gear side.
Therefore remove the transfer assembly and
the differential carrier from the frame before
Installation adjusting the tooth contact.
Follow the removal sequence in reverse. Be care- Dismount the traction motor before removing
ful with the following key points. or installing the transfer assembly. (Refer to
(1) Clean the mounting surface on the differential Power Line section.)
carrier completely, and apply liquid gasket Place the transfer assembly on a stable work
before installation. bench, and remove the differential carrier.
(2) Apply liquid gasket to the mounting surface of
the axle shaft, and tighten bolts.
Tightening torque of 128.3 ± 12.8
axle shaft bolts (13.1 ± 1.3)
N·m (kgf·m) [lbf·ft] [94.7 ± 9.4]
(3) Tighten axle support bolts to the specified

torque.
Tightening EC35N
torque of axle thru
support bolts EC55N
N-m 693.8
(kgf•m) (70.8)
[lbf•ft] [512]
2.5
Axle Shaft and Hub

Disassembly
1
5
4
3
206656
Sequence Preparation
1 Front tire (1) Loosen front wheel nuts about two rotations,
2 Axle shaft, Bolt, Spring washer and jack up the vehicle.
3 Bolt, Lock washer, Lock nut (2) Place stands or wood blocks under the frame
4 Taper roller bearing (inner) on both sides at the front so that the vehicle is
5 Front hub drum assembly at the level position when viewed from the
Taper roller bearing (outer), Oil seal, front.
Taper roller bearing, Spacer and Oil seal (3) Remove the front tires.
6 Retainer, O-ring (4) Drain differential oil.
NOTE
Normally, disassemble the front axle while the
axle housing is installed to the frame.
2.6
Key points for disassembly

(1) Removing lock nut
Use the special tool A to remove the lock nut.
Special tool needed

A
Socket wrench A MCF-1102
200232
(2) Removing front wheel hub

Use a hub puller or a gear puller to remove
the front wheel hub.
If the interfit of the taper roller bearing (inner Special tool
race) is tight, the inner oil seal may fall off and
the taper roller bearing may remain in the axle
housing.
In this case, insert a wedge-shape tool
between the taper roller bearing (inner) and
the retainer to take out the taper roller bearing.
200233
(3) Using a bearing puller, remove the inner race

of tapered roller bearing left on the axle
housing, along with the seal retainer.
203651
2.7
Inspection and Repair

(1) Axle shaft 2
(a) Insert the differential bevel gear to the
axle shaft, and measure looseness in the
rotating direction with a dial gauge.
A: Standard value B: Repair limit
Service limit
Looseness of the 0.07 to 0.17

A
axle shaft spline (0.0028 to 0.0067)
mm (in.) B 0.5 (0.020)
(b) Measuring axle shaft bend 200235
(i) Attach a dial gauge to the center of the
axle shaft, and rotate the axle shaft.
Measure bend of the axle shaft.
Service limit
Axle shaft bend 1.0 or less

A
(1/2 of gauge reading) (0.039)
mm (in.) B 2.0 (0.079)
(ii) Attach a dial gauge to the edge of the

flange, and rotate the axle shaft.
Measure deflection of the flange.
200276
Service limit
Flange deflection A 0.04 (0.0015)

mm (in.) B 0.5 (0.020)
(2) Retainer 6
Check for wear or damage on the retainer cir-
cumference.
(3) Front hub drum 5
If uneven wear or damage is found on the
inner surface of the brake drum, grind and
repair.
Service limit
Inner diameter A 317.5 + 0.2 (12.5 + 0.078 )
0 0
of brake drum
mm (in.) B 318.5 (12.539)
2.8
Assembly
6
•
••
•
5 •
• • • •
3 ••
• •
5
2d 2 2a 2c 2b 1
206657
Sequence
1 Retainer, O-ring
2 Front hub drum assembly
2a Taper roller bearing (outer)
2b Spacer
2c Oil seal
2d Oil seal
3 Taper roller bearing (inner)
4 Lock nut, Lock washer, Bolt
5 Axle shaft, Bolt, Spring washer
6 Front tire, Wheel nut
2.9
Key points for assembly

(1) Front hub drum assembly [2]
(a) Press in the taper roller bearing (outer).
(b) Strike in a new oil seal straightway. Make
sure that the lip is in correct direction.
(c) Press in the taper roller bearing (outer).
(d) Insert the spacer.
(e) Fill the roller holder of the taper roller (a)
bearing (inner) with grease. Use a palm to Grease (g)
push grease into the roller holder. Insert (e)
the taper roller bearing (inner).
(f) Press in a new oil seal straightway. Make (b)
sure that the lip is in correct direction. (c)
(d)
(g) Fill the front hub with grease. (Refer to the
figure on the right.) (f)
206658
Apply grease thinly to oil seal lips. Make
sure that no grease is in the drum.
(2) Hub bearing preload

Wind a wire around the hub bolt twice, attach
a spring balance to the wire. Pull and measure
the tangential force.
Hub bolt pitch: ø260 mm (10.23 in.)
Tangential force at 25.5 to 40
the hub bolt (2.3 to 4.1)
N (kgf) [lbf] [5.06 to 9.02]
If the preload is within the standard range,
insert the lock ring, apply LOCTITE No. 271,
206659
and tighten bolts.
9.8 ± 1.0
Bolt tightening torque
(1.0 ± 0.1)
N·m (kgf·m) [lbf·ft]
(3) Axle shaft 5

When installing the axle shaft, apply liquid
gasket to the mating surface with the hub, and
tighten bolts to the specified torque.
Axle shaft tightening 128.3 ± 12.8
torque (13.1 ± 1.3)
N·m (kgf·m) [lbf·ft] [94.7 ± 9.4]
(4) Wheel nuts 6
Tighten wheel nuts to the specified torque
evenly to prevent tire shimmy.
(Refer to Front Tires Installation section.)
2.10
Reduction Differential
Disassembly
3
5
6
7 4
7
8
5
7 9
2 1 10 3
206660
1 Bolt, Lock washer, Lock plate Remove the differential carrier from the transmis-
2 Bolt, Lock washer, Bearing cap sion case.
3 Side bearing nuts
5 Taper roller bearing,
Bolt, Spring washer,
Differential case (right)
6 Differential bevel gear, Thrust washer
7 Differential bevel pinion, Thrust washer
8 Spider
9 Differential bevel gear, Thrust plate
10 Taper roller bearing, Bolt,
Differential case (left),
Reduction bevel gear
2.11
NOTE
(1) Measure the backlash of the gear before
disassembly, and use the measurement
for assembly.
(2) Put a match mark across one of the
bearing gap adjusting screws and the
carrier, and use the mark for assembly.
A: Standard value
Item 200241
Backlash between 0.25 to 0.33
reduction gear and A (0.0098 to
pinion mm (in.) 0.0129)
Removing bearing
Remove the inner bearing with a bearing puller.

(1) Reduction gear
(a) Check the reduction gear and pinion for
tooth contact, wear, pitch, scoring, and
loss of the teeth. Repair slight damages
which do not affect operation with Oil 202821
stone and a hand grinder. If replacing the
reduction gear, replace the pinion, too.
(2) Differential
(a) Check for scoring at the mating part of the
differential case and the side bearing
inner race.
(b) Check for crack on the differential case,
and for wear or damage on the sliding
part between the gear and the thrust
washer.
(c) Check for wear, loss or scoring on the dif-
ferential bevel gear and the pinion gear
teeth. Check for wear or damage on the
thrust washer plate.
(d) Check the internal diameter of the differ-
ential pinion gear and for wear of the spi-
der shaft.
Service limit
Clearance between 0.169 to 0.278

A
pinion gear and (0.0066 to 0.0109)
spider mm (in.) B 0.5 (0.02)
2.12
Assembly
7 5
9 •
•
•
•
• • •
8
8
•
• • 11
11 • ••
•
•
•
• • •
12
•
10
• 3
6 • 1
10 5 4
2
206661
Sequence Key points for assembly

1 Differential case (left) (1) Tightening reduction bevel gear
2 Reduction bevel gear, Bolt Apply LOCTITE No. 271 to bolts, and tighten to
3 Differential gear, Thrust washer the specified torque.
4 Spider Reduction gear 225.5 ± 9.8
5 Differential bevel pinion, Thrust washer tightening torque (23.0 ± 1.0)
6 Differential bevel gear, Thrust washer N·m (kgf·m) [lbf·ft] [166.3 ± 7.2]
7 Differential case (right), Bolt
8 Taper roller bearing
10 Bearing cap, Bolt, Lock washer
11 Side bearing nut
12 Bolt, Lock plate, Lock washer
202786
2.13
(2) Assembling differential bevel pinion

Adjust the backlash between the differential
bevel gear and the pinion gear by the thick-
ness of the thrust washer for the differential
bevel gear.
Measure the backlash. If the backlash
exceeds the service limit, replace the thrust
washer with a new one.
A: Standard valueB: Repair limit
Service limit
0.20 to 0.40
Backlash of the A
(0.008 to 0.016)
differential bevel
gear mm (in.) 0.6
B
(0.024)
(3) Installing differential case

(a) Assemble the left and right cases by
using the match mark, and tighten bolts.
(b) Apply LOCTITE No. 271 to bolts, and
tighten to the specified torque.
Differential case 122.5 ± 9.8

tightening torque (12.5 ± 1.0)
N·m (kgf·m) [lbf·ft] [90.4 ± 7.2]
202787
(4) Assembling differential case assembly

(a) Install the differential case assembly to
the differential carrier. Place the bearing
cap, and tighten bolts temporarily.
(b) Since the bearing cap and the differential
carrier are integrated, make sure the cor-
rect position of the match mark.
(c) Tighten bolts to the specified torque.
Bearing cap 161.8 ± 9.8

tightening torque (16.5 ± 1.0) 200241
N·m (kgf·m) [lbf·ft] [119.3 ± 7.2]
2.14
Adjustment
Adjusting bearing preload
Wind a coil on a reduction gear bolt, attach a
spring scale to the coil and pull. Read the tan-
gential force when the gear starts rotation.
Adjust the preload by tightening the side bear-
ing nuts on both sides.
NOTE
Before measuring the preload, tap the back
of the bevel gear with a copper hammer while
winding the gear with a hand. 206662
Tangential force 12.7 to 25.4

at side bearing (1.3 to 2.6)
N (kgf) [lbf] [2.8 to 5.7]
Inspecting back runout

Attach a dial gauge to the back surface of the
reduction gear at the largest radius, and
measure the back runout while rotating the
gear.
If the measurement exceeds the standard
value, inspect the reduction gear tightening
and the taper roller bearing. If the measure-
ment exceeds the standard value, replace 202249
together with the pinion gear.
Service limit
0.15 or less
Back runout of A
(0.006)
reduction bevel
gear mm (in.) 0.20
B
(0.008)
2.15
Adjusting backlash
Adjust the backlash after installing the differential
carrier assembly to the transmission case.
Attach the dial gauge needle vertically to the tooth
surface of the bevel gear. Move the bevel gear for-
ward and backward (in rotating direction) and
check the deflection of the needle.
Adjust the backlash with the side bearing nut.
A: Standard value
Item 200247
Reduction gear 0.25 to 0.33
and pinion gear A (0.0098 to
mm (in.) 0.0129) Large
Large
Small
Large
Small Backlash
Large
Small
205611
Adjusting tooth contact

Apply machinist’s dye on three or four teeth of the
reduction gear thinly and evenly. Rotate the reduc-
tion gear forward and backward by hand several
times. Check tooth contact by the shape of contact
area. Adjust faulty tooth contact as follows.
Backlash
Small
200250
2.16
Tooth Contact of Reduction Gear
Condition of tooth contact Adjustment
Contact area is
1 1/2 or more of the Not required.
tooth.
Only small end of 1. Insert the reduction pinion gear shim
the tooth has to increase engagement.
2
strong contact. 1 2. Move the reduction gear away from
(Toe contact) the pinion gear to adjust backlash.
2
Only large end of 1 1. Pull the reduction pinion gear shim

the tooth has to reduce engagement.
3
strong contact. 2. Move the reduction gear closer to the
(Heel contact) 2 pinion gear to adjust backlash.
1
Only upper end of 1. Insert the reduction pinion gear shim
the tooth has to increase engagement slightly.
4
strong contact. 2. Move the reduction gear away from
2
(Face contact) the pinion gear to adjust backlash.
Only lower end of 1. Pull the reduction pinion gear shim

the tooth has 1 to reduce engagement slightly.
5
strong contact. 2. Move the reduction gear closer to the
(Flank contact) 2 pinion gear to adjust backlash.
203670
NOTE
For contact at the toe or the heel, judge the
condition of tooth contact according to
the contact of the reduction gear teeth as
shown in figures above. For contact at the
face or the flank, repeat the above procedure
until good contact is obtained.
2.17
Troubleshooting
Front axle and reduction differential
Wear of reduction gear teeth — Replace the reduction gear

Abnormal noise Maladjustment or wear of the — Repair or replace the
generated continu- reduction gear bearing bearing
ally during driving Breakage of hub bearing — Replace the bearing
Faulty engagement of the reduction — Adjust the tooth contact
pinion gear and the reduction gear
of the output shaft
Breakage of reduction gear — Replace bearing

bearing or hub bearing
Abnormal noise Loss of differential gear tooth — Replace the gear or the
generated irregu- or wear of thrust washer washer
larly during driving Mixing of foreign matter in — Clean the housing and
axle housing replace oil
Loose axle shaft bolt or — Tighten bolts
differential carrier bolt
Abnormal noise Wear of contact area between — Replace

generated at differential gear and differential case
curves Loss or wear of the differential — Replace
gear or the pinion gear teeth, or
seizure, wear or tear with the spider
Overheated reduc- Breakage of bearing due to excessive — Replace the bearing and
tion case after preload on bearing adjust the preload
driving Insufficient backlash of the output — Adjust the tooth contact
shaft reduction gear and backlash
2.18
Service Data
Front Axle
Service limit
Unit: mm (in.)
Item
Axle shaft flange deflection A 0.04 (0.0016)
B 0.5 (0.02)
Axle shaft bend (1/2 of gauge reading) A 1.0 or less (0.04) or less
B 2.0 (0.08)
Hub bearing preload 1
Tangential force at the hub bolts position A 22.5 to 40 (2.3 to 4.1) [5.06 to 9.02]
N (kgf) [lbf]
Tightening torque of axle shaft bolts 2
A 128.3 ± 12.8 (13.1 ± 1.3) [94.7 ± 9.4]
Tightening torque of wheel bolt nuts 3
A 307.9 ± 30.7 (31.4 ± 3.1) [227.1 ± 22.7]
Tightening torque of front axle support bolts 4
A 693.8 (70.8) [512]
Tightening torque of wheel nuts 5
A 551 ± 55 (56.2 ± 5.6) [406.5 ± 40.6]
Tightening torque of lock ring bolts 6
Hub and Wheel
A 9.8 ± 1.0 (1.0 ± 0.1) [7.2 ± 0.7]

Tire service limit 7 B 48.3 (1.9)
4 •
5 3 7
•
•
6 •
2 1
206663
2.19
Service Data
Reduction Differential A: Standard value B: Repair limit

Service limit
Unit: mm (in.)
Item
Differential bevel gear backlash 1 A 0.20 to 0.40 (0.008 to 0.016)
B 0.6 (0.024)
Clearance between differential bevel pinion and A 0.169 to 0.278 (0.0066 to 0.0109)
spider 2
B 0.5 (0.02)
Preload at differential side bearing 3
Tangential force at reduction bevel gear bolt A 12.7 to 25.4 (1.3 to 2.6) [2.8 to 5.7]
N (kgf) [lbf]
Back runout of reduction bevel gear 4 A 0.15 or less (0.006)
B 0.2 (0.08)
Backlash between reduction bevel gear and A 0.25 to 0.33
T/M pinion gear 5 (0.0098 to 0.0129)
Looseness of the axle shaft spline 6 A 0.07 to 0.17 (0.0028 to 0.0067)
B 0.5 (0.02)
Tightening torque of reduction bevel
A 225.5 ± 9.8 (23.0 ± 1.0) [166.3 ± 7.2]
Reduction differential
gear bolts 7 N·m (kgf·m) [lbf·ft]

Tightening torque of differential
A 122.5 ± 9.8 (12.5 ± 1.0) [90.4 ± 7.2]
case bolts 8 N·m (kgf·m) [lbf·ft]
Tightening torque of side bearing
A 161.8 ± 9.8 (16.5 ± 1.0) [119.3 ± 7.2]
cap bolts 9 N·m (kgf·m) [lbf·ft]
9 6 3
8 1 2
7
4 206664
2.20
TRANSFER ASSEMBLY
CHAPTER 3: TRANSFER ASSEMBLY
Structure and Functions ................................................................................................................................ 3.1

Disassembly and Reassembly........................................................................................................................ 3.2
Disassembly ............................................................................................................................................ 3.2
Inspection after Disassembly................................................................................................................... 3.4
Reassembly ............................................................................................................................................ 3.5
Tightening Torque ........................................................................................................................................... 3.8
TRANSFER ASSEMBLY
Structure and Functions
1 2
4 3
11
5
11
10
11 11
8
12
8
7
Main Components The transfer transmitts drive power generated by

1. Transfer Case the motor to the drive shaft.
2. Transfer Plate The recommended lubrication oil for the transfer
3. Input Gear (24T) assembly is the same as that for the differential:
4. 2nd Gear (63T) API class GL-4, 5, SAE90.
5. 3rd Shaft The oil capacity is approximately 12 liters
6. 4th Gear
7. Bevel Gear Set
8. Taper Roller Bearing
9. Lock Nut
10. Shaft Cover
11. Ball Bearing
12. Pulse Generator
3.1
TRANSFER ASSEMBLY
Disassembly and Reassembly

Disassembly
Start by:
(a) Remove the drain plug on the front axle hous- (c) Withdraw out of the front axle housing the trac-
ing to let the oil drain out. tion motor, reduction and differential assembly,
(b) Disconnect the connectors of the traction and transfer assembly all together.
motor harnesses and pulse generator (d) Separate the three assemblies removed in
harness. step (c) from each other.
1
24 26
27 25 2
23
21
4 3
18 20
16
22
17
28
19
12 11
8 5
7
14 13 15 10
210771
Sequence
Remove the transfer plate 2 and 10 Bearing cone 20 2nd gear
the traction motor as unit. 11 4th gear 21 Spacer
1 Bolt 12 Pinion spacer 22 Ball bearing
2 Transfer plate 13 Pinion spacer 2 23 Snap ring
3 Bolt 14 Bearing cup Remove parts 24 to 26 as unit.
4 Cover plate 15 Bearing cup 24 Input gear
5 Nut 16 Bolt 25 Ball bearing
6 Shim 17 Shaft cover 26 Ball bearing
Remove parts 7 to 9 as unit. Remove parts 18 to 19 as unit. 27 Transfer case
7 Bevel pinion shaft 18 3rd shaft 28 Pulse generator
8 Shim 19 Ball bearing
9 Bearing cone
3.2
TRANSFER ASSEMBLY
Suggestions for Disassembly
1. REMOVE THE BEVEL PINION SHAFT 7
Shaft locking
(1) Using a chisel, cut the staked portion of the 24 bar fixing bolt
nut 5, taking care not to damage the bevel
pinion shaft. Shaft locking
bar
27
(2) Hold the input gear 24 with the special tool to
Special tool
prevent the bevel pinion 7 from rotating, then
remove the nut 5 and shims 6.
14
Special tool needed
9
Staked
Transfer bearing tool 97G67 - 00100
(3) Using the bevel pinion puller (special tool),

5
pull the bevel pinion 7 out of the bearing cone
7 6
10 (See the drawing on the right). 11 15 10
210772
Special tool needed
Bevel pinion puller 91868 - 02100
(4) If the bearing cone 9 needs to be removed,

use a bearing puller and a press to pull it from
the bevel pinion 7.
(5) If the bearing cups 14 and 15 need to be
removed, use a bearing cup puller to pull
them out of the transfer case 27.
205829
NOTE
(1) The taper roller bearing cup and cone are a

exclusive pair. If either the cup or cone of a
pair is faulty, replace them as a set.
(2) The removed shims should be kept togeth-
er until they are reinstalled. (This only
applies when the bevel pinion and/or taper
roller bearing are/is reused.)
205830
(3) The bevel pinion and bevel gear are a
exclusive pair. If either of them is defective,
φ 49 mm (1.93 in.)
replace them as a set. or less
φ 31 mm (1.22 in.)
(4) If no threaded hole is provided on the bevel or more
pinion 7, remove it using a jig and a press. 45 mm
(1.77 in.)
or more
210778
3.3
TRANSFER ASSEMBLY
2. REMOVE THE 3RD SHAFT 18

18 20 22 Vice
(1) Remove the bolt 16 and the shaft cover 17.
19
(2) Hold the 2nd gear 20 with two vices as shown
and push out the 3rd shaft using a rod.
(3) If the ball bearing 19 and 22 need to be
removed, use puller to pull them out. Do not
attempt to tap them out.
Vice 210777
3. REMOVE THE INPUT GEAR

(1) Remove the snap ring 23.
(2) Using a puller, pull out the input gear 24 com-
plete with the ball bearings out of the case 27.
(3) If the ball bearings 25 and 26 need to be
removed, use a puller to pull them out. Do
not attempt to tap them out.
Inspection after Disassembly

(1) Check the output gear 10 and the input gear
15 for damaged/worn teeth an worn splines.
(2) Check the bearings for wear or damage.
Make sure that they rotate freely without making
noise.
(3) Check the transfer case for cracks or other
damage.
(4) Check the bevel pinion and the bevel gear for
incorrect tooth contact, damage and wear.
3.4
TRANSFER ASSEMBLY
Reassembly
Follow the disassembly sequence in reverse.
28
1
2 27
3 5
20
25 26
4
18
21
22 8
24
23
13
19 14
15
10
17
16
7
9 11 6 12
210774
Sequence
1 Transfer case Assemble the parts 9, 10 and 11. 20 Spacer
Assemble the parts 2 to 4 first, 9 Bevel pinion shaft 21 2nd gear
then install the assembly into 10 Shim 22 Shaft cover
the case 1. 11 Bearing cone 23 Bolt
2 Input gear 12 Pinion spacer 24 Pulse generator
3 Ball bearing 13 4th gear 25 Cover plate
4 Ball bearing 14 Pinion spacer 2 26 Bolt
5 Snap ring 15 Bearing cone Assemble the part 27 and the
Press-fit the parts 6, 7 and 8 16 Shim traction motor first by the bolt,
into the case 1. 17 Nut then install the assembly into
6 Bearing cup Assemble the parts 18 and 19 the case 1.
7 Bearing cup first, then install the assembly 27 Transfer plate
8 Ball bearing into the case 1. 28 Bolt
18 3rd shaft
19 Ball bearing
3.5
TRANSFER ASSEMBLY
Suggestions for Reassembly
CAUTION
Mark “b” is indicated here.
Ball bearings and taper roller bearings can be
Axle center
fitted onto shafts more easily when they are
warmed in hot oil. However, do not increase the
oil temperature above 120°C (250°F).
1. INSTALL THE INPUT GEAR 2

(1) Press-fit the ball bearings 3 and 4 onto the input
gear 2. Force the assembly into the transfer
case 1.
(2) Install the snap ring 5.
2. SUB-ASSEMBLE THE BEVEL PINION SHAFT 9 B
(1) Place shim stock 10 and bearing cone 11 on the A

bevel pinion 9, then install these into place using
Mark “a” is indicated here.
a press. The thickness C of shims 10 can be cal- 209005
culated using the following equation.
C = 2.0 + a/100 - b (unit: mm)
a: Machining error in the differential carrier
dimension A
b: Machining error in the bevel pinion dimen-
sion B
The machining error “a” is stamped on the top
surface of the differential carrier. (No stamping
is present if the error is within ±0.05 mm.)
The machining error “b” is marked on the end
surface of the bevel pinion using electric mark-
ing pen. No mark is present if the error “b” is ±0. 1.0 mm (0.04 in.)
thick shim Standard shim
C stock thickness
NOTE
209006 2.0 mm (0.08 in.)
When installing shim stock 10, be sure to locate a
1.0 mm (0.04 in.) thick shim closest to the bevel
pinion.
(2) While inserting the bevel pinion shaft sub-

assembly into the case, install the pinion spacer
12, 4th gear 13, the pinion spacer 2 14, bearing
cone 15, and shim stock 16. Reuse the origi-
nally installed shim stock 16.
3.6
TRANSFER ASSEMBLY
3. INSTALL THE 3RD SHAFT 18

(1) Press-fit the ball bearing 8 into the case 1.
(2) Press-fit the ball bearing 19 onto the 3rd shaft
18.
(3) While inserting the 3rd shaft sub-assembly
into the case 1, install the spacer 20 and the
2nd gear 21.
2
Attach spring scale
4. PRELOAD ADJUSTMENT OF TAPER ROLLER BEARING hook here to measure
(1) Hold the input gear 2 to prevent the bevel pin- the tangential force.
ion shaft 9 from rotating. Special tool
Special tool needed
12
Transfer bearing tool 97G67 - 00100
15
9
(2) Install a new nut 17 on the bevel pinion shaft 17
9. Tighten and loosen the nut several times, 16
each time after rotating the shaft a little, so
that the bearing cups and cones settle com-
pletely on each other. Finally, tighten the nut 14
13 210775
to the torque shown below. Do not give the
bearings too much preload.
Tightening torque 294±20 N·m
of nut 17 (30.0±2.0 kgf·m)
[217±14.5 lbf·ft]
(3) With the special tool installed on the input

gear 2, measure the preload of the taper roller
bearing on the bevel pinion gear shaft 9. The
preload is measured in terms of the tangential (1) Stake the nut completely against the
bottom of the groove on the bevel pinion.
force required to start the input gear 2 rotat- (2) The staked portion should have a flat of
ing. The measurement should meet the fol- φ 4 mm (φ 0.16 in.) or more.
lowing spacified value.
Tangential force required to 76 to 95 N
to start input gear 2 (7.7 to 9.7 kgf)
rotating [17 to 21 lbf]
(4) Adjust the preload as required by increasing

or decreasing he thickness of the shim stock
16. The greater the shim stock thickness, the Staking tool needed A screwdriver is not
smaller the preload. The smaller the shim appropriate for staking.
stock thickness, the greater the preload.
Repeat the steps (2) and (3) until the specified
preload is obtained.
(5) After the specified preload is obtained, lock
the nut 17 on the bevel pinion shaft 9 by stak- R R
ing to prevent it from loosening. (See the φ 4 to 6 mm
drawing shown on the right.) (φ 0.16 to 0.24 in.) 209008
3.7
TRANSFER ASSEMBLY
5. BOLTS TO BE TIGHTENED TO SPECIAL TORQUES
4
3 1
2
210776
Tightening torque
60±6 N·m
Plate-to-traction motor 1 (6.1±0.6 kgf·m)
[44.3±4.4 lbf·ft]
33±2 N·m
Cover 2 (3.4±0.3 kgf·m)
[24.3±1.4 lbf·ft]
20 +10
-2 N·m
Pulse generator 3 (2.0 +1.0
- 0.2 kgf·m)
[14.8 +7.4
- 1.4 lbf·ft]
60±6 N·m
Case-to-cover 4 (6.1±0.6 kgf·m)
[44.3±4.4 lbf·ft]
294±20 N·m
Lock nut 5 (30.0±2.0 kgf·m)
[217±14.5 lbf·ft]
3.8
REAR AXLE
CHAPTER 4: REAR AXLE
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Procedures and Key Points for Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
Rear Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Adjustment of Minimum Turning Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17
REAR AXLE
Specifications

Item
Axle type Elliot
Suspension Center pivot
Toe-in mm (in.) 0
Rear axle
Camber angle 1.0°

Wheel alignment
Caster angle 0°
Kingpin angle 0°
Steering cylinder inner diameter ¥
85 ¥ 60 (3.34 ¥ 2.36)
Rod external diameter mm (in.)
Effective stroke mm (in.) 155 (6.10)
4.1
REAR AXLE
Structure
Rear Axle
8 6 4
6
•
• A
• • •
• A
2
4 3
•
1 3
8
206637
Sequence
1 Rear axle
2 Steering cylinder
3 Tie rods (left and right)
4 Knuckles (left and right)
5 Rims (left and right)
6 Stopper bolts (left and right)
7 Pins (two pins for each side)
8 Rear axle supports (front and rear)
9 Tires (left and right)
The knuckle is operated with a double-action

steering cylinder.
The rims to which the tires are inserted serve as
wheel hubs.
4.2
REAR AXLE
Steering Cylinder
4 3 11 4
12 13
6 7, 8 5 9 10 2 1
206640
Sequence
1 Cylinder tube
2 Piston rod
3 Piston
4 Cylinder head
5 Bushing
6 Dust seal
7 Oil seal
8 Backup ring
9 Wear ring
10 Piston seal
11 Bolt
12 Spherical bushing
13 Stopper ring
Double-action cylinder is used.
4.3
REAR AXLE
Procedures and Key Points for Removal and Installation

Rear Tires
Preparation
(1) Pull the parking brake lever, and place wheel
stoppers at the front tires.
(2) Use the balance weight lifting hole and lift the
vehicle, or use a jack.
(3) Lift the vehicle until the right and left rear tires
are off the ground and rotate freely.
(4) Place wood blocks under the flat bottom of the
rear axle on both sides, and lower the vehicle.
206641
Removal
5 6
6
3
4
2
1
206642
Sequence
1 Cap, Gasket
2 Lock nut, Lock plate
3 Taper bearing (inner)
Remove 4 to 6 together.
4 Rim tire assembly
5 Oil seal
6 Taper bearing (outer)
4.4
REAR AXLE
Key points for removal

1. Since the rim tire assembly falls easily, prevent
fall with a sleeper block before removal. Be
careful not to damage the oil seal on the rim.
2. Strike out the outer race of the taper bearing by
attaching a batten to the notch inside the rim.
Installation
Follow the removal sequence in reverse. Be sure
to follow the key points below.
Key points for installation 206643

1. Replace the oil seal with a new one.
2. Clean grease off the taper bearing and the rim. (3) After adjusting the preload, tighten a new
Fill in new grease. Apply grease to the oil seal lip. lock washer and an outer nut to the
specified torque.
Truck Model EC35N thru EC55N

Item
Oil Seal Outer nut tightening 157+20
torque (16 +20 )
N•m (kgf•m) [115.7+14]
[lbf•ft]
Grease
•
Lock
washer
Outer nut
•
•
Inner nut
206639
206639
3. Adjust the hub bearing preload.
(1) Tighten the inner nut temporarily. (4) Bend the lock washer to both sides
(2) Insert a ø24 round bar to the cast hole of (inward and outward).
the rim. Attach a spring scale to the round (5) Fill the cap with grease, and install the cap.
bar, and measure the tangential force.
Item
Tangential 41.2 to 49.0 44.1 to 52.9
force (4.2 to 5.0) (4.5 to 5.4)
N (kgf) [lbf] [9.2 to 11.0] [9.9 to 11.9]
Tighten the inner nut to achieve the specified 205436

value.
4.5
REAR AXLE
Rear Axle
Remove the rear tires before removing the rear
axle.
Refer to Rear Tires Removal procedure as
mentioned before. Be sure to carry out the
preparation, and follow the key points for removal.
Removal
3 2
1
207747
Sequence Key points for removal

1 Steering hose (1) Remove the steering hose. Put a plug on the
2 Rear axle support, Bolt and Washer removed hose to prevent oil leakage.
3 Rear axle assembly, Thrust washer Plug: 05530-30300 (G 3/8)
(2) Before removing the rear axle support bolt, pry
the rear axle assembly with a bar, and meas-
ure the front and rear clearances. If the total
value is 0.8 mm (0.03 in.) or more, insert thrust
washers and adjust the clearances when
installing the bolt.
(3) After removing the rear axle support bolt,
remove the rear axle assembly to the side
square to the vehicle.
4.6
REAR AXLE
Preparation
(1) After removing the rear tires, remove the wood
blocks under the rear axle, and insert a car-
riage.
Insert the carriage so that the rear axle can be
removed to the side.
(2) Place wood blocks under the balance weight
on both sides.
206645
Installation
Follow the removal sequence in reverse. Carry out
the following procedures.
(1) Adjusting bearing support clearances

Adjust the front and rear clearances by using
thrust washers so that the total clearance
becomes 0.8 mm (0.03 in.) or less.
0.8 mm (0.03 in.)
NOTE or less
Insert thrust washers evenly.
206651
Unit: mm (in.)
Item
1.0 (0.039)
Thrust washer type
2.0 (0.078)
(2) Removing support bushing

Do not remove the bushing in the support if
acceptable.
If not, replace the bushing together with the
support assembly, or break and remove the
bushing.
Assemble a new bushing so that the match
mark faces downward (toward the grease
Bushing joint
nipple). 205431
NOTE
Assemble a new bushing so that the joint
faces downward (toward the grease nipple).
4.7
REAR AXLE
Rear Axle Assembly

Disassembly
8
14
5
8
5 2
11
3
12 10
6
13 10
9 1
207748
Sequence
1 Taper roller bearing (inner), Retainer 8 Elbows, O-rings
2 Bolt, Washer, Tie rod pin, Spacer, 9 Cover, Plate, O-ring, Taper roller bearing
Dust seal, Ring, Bearing (outer), Oil seal, Bolt, Washer
3 Tie rod 10 Taper roller bearings (inner), Knuckle
4 Bolt, Washer, Clamp 11 Plug
5 Oil pipes (L.H., R.H.) 12 Oil seal, Taper roller bearing (outer)
6 Bolt, Spring washer 13 Bolt, Lock nut
7 Steering cylinder 14 Rear axle housing
4.8
REAR AXLE

(1) Removing cover
(a) Remove the six bolts from cover 9.
(b) Remove the plug at the center of the cover.
(c) Screw in a cover puller bolt (nominal diam-
eter: 12 mm, pitch: 1.25 mm, thread length:
50 mm or more), and remove cover 9.
Puller bolt
9
205430A
(2) Inspect the taper roller bearing (outer) and the

oil seal that are pressed into cover 9. Do not
disassemble if acceptable.
Do not disassemble the taper roller bearing
(outer) and oil seal 12 that are pressed into
rear axle 14 if acceptable.
(3) Rings and bearings 2 remain at knuckle 10 and
steering cylinder 7 respectively at disassembly. 2 2
Inspect the rings and bearings, and do not 7 10
disassemble if acceptable.
(4) Remove oil pipes 5 from the elbows. Then
remove elbows 8.
• • • •
206638
4.9
REAR AXLE
Assembly
12 12
13
10
9 9
A B B
• •
A
11 7 11 206647
1
1 5
11
2 • • 3
• •
• 14
•
• • • •
•
•• •
•
• • •
•
8 7 6 3 •
• • 3
•
• •
Section A-A •
206638
Section B-B
4
206648
Sequence
1 Rear axle housing 8 Bearing, Ring
2 Taper roller bearing (outer), Oil seal 9 Elbows (L.H., R.H.)
3 Knuckle, Taper roller bearing (inner) 10 Bolt, Spring washer
4 Cover, Taper roller bearing (outer), 11 Tie rod, Tie rod pin, Dust seal, Collar, Spacer,
Oil seal, O-ring, Plate, Plug Bolt, Spring washer
5 Plug 12 Oil pipes (L.H., R.H.)
6 Bearing, Ring 13 Bolt, Lock nut
7 Steering cylinder 14 Taper roller bearing (inner), Retainer
4.10
REAR AXLE

1 Filling grease
Fill the taper roller bearing at knuckle 3 with • Grease
grease. In particular, apply sufficient grease in
•
the roller holder. Apply grease to the oil seal lip, Oil seal
too.
Oil seal
• Grease
•
206648
2 Tighten bolt 10 of steering cylinder 7 to the

specified torque.
262 ± 40
Tightening torque
(26.7 ± 4)
[193.1 ± 28.9]
3 Adjusting knuckle bearing preload
Drive in cover 4 without inserting a plate, and
measure the clearance between rear axle
housing 1 and the cover.
Insert a plate thinner than the clearance by 0.1
mm (0.0039 in.), and tighten the cover with a
bolt.
Attach a spring scale to the edge of the knuck-
le arm, and check that the tangential force is
the specified value.
Truck Models
EC35N thru EC55N
Item
Clearance
30.4 to 79.4 26.5 to 67.6
Tangential force
(3.1 to 8.1) (2.7 to 6.9) 206649
N (kgf) [lbf]
[6.82 to 17.82] [5.94 to 15.18]
If the specified value is not obtained, readjust
the plate.
4.11
REAR AXLE
Steering Cylinder
Disassembly
6
4
A
6
2
2
1
1 A
1
3
206650
Sequence NOTE
1 Nut, Spring washer, Bolt (1) Do not remove bushing 2 from the
2 Cylinder head, Dust seal, Backup ring, cylinder head if acceptable.
Oil seal, O-ring, Bushing (2) Do not remove bearing 6 from piston
3 Cylinder tube rod 4 if acceptable.
4 Piston rod, Piston
5 Wear rings (2 pieces), Piston seal
6 Stopper ring, Bearing
4.12
REAR AXLE

(1) Cylinder tube 3
Check for wear, damage or rust inside the
cylinder.
(2) Piston rod 4
Check for rust, damage, scratches or impact
marks on the rod surface.
(3) Rings and gaskets
Replace the entire seal kit with new one.
205439
Service limit
Unit: mm (in.)
Internal diameter A 85 (3.346)
of cylinder tube 1 B 85.15 (3.352)
External diameter
A 60 (2.36)
of piston rod 2
2 1
206640
4.13
REAR AXLE
Assembly
NOTE: Parts marked with * are included in the seal kit.
6 3 5
4 6
1 1
2
* * * * * 206640
Sequence
1 Piston rod, Piston 5 Cylinder head, Bushing, O-ring, Oil seal,
2 Bearing, Stopper ring Backup ring, Dust seal
3 Wear rings (2 pieces), Piston seal 6 Bolt, Spring washer, Nut
4 Cylinder tube

(1) Replace the seal kit parts shown in the above
figure when assembling.
(2) Clean the parts completely before assembly,
and make sure that no dust is on them.
(3) Apply oil to the piston seal, O-ring, gasket,
dust seal and inside the cylinder before
assembly.
(4) Procedure for installing piston seal
(a) Grip the piston seal lightly by hand five or
six times to soften the seal before
installation.
200352
(b) Grip the piston rod in a vice so that the
vice does not damage the rod. Apply a
little oil to the piston seal. Insert one side
of the seal into the fitting groove of the
piston, and insert the other side.
(c) After installing the piston seal, insert the
wear ring.
(5) Make sure that seal and rings on the cylinder
head are installed in correct directions.
(6) Tighten nut 6 to the specified torque.
Nut tightening torque
59.8 (6.1) [44]
205552
4.14
REAR AXLE
Adjustment
Adjusting of Minimum Turning Radius

(1) Measure the turn angle of the rear wheel by
using a turning radius gauge. Stopper bolt
(2) If the turning angle is out of the specified (left and right)
range, adjust the angle with the stopper bolt
on the knuckle. Lock nut
Truck Models
EC35N thru EC55N
Item
Turning angle (inward) 82°
(outward) 59°
degree
NOTE
Check clearance between stopper bolt,
thread end and steer cylinder rod when
fully turned in both directions. 206652
(3) While driving the vehicle at low speed, turn

the steering wheel fully in both directions, and
check the diameter of the tire tracks at the
outside of the rear wheel in both turning
operations.
(4) Minimum turning radius R is obtained from R
half of the turning diameter plus the length
from the center of the rear tire to the outside
edge of the counterweight.
Unit: mm (in.)
Item Minimum turning radius
Truck Models
E7000 2214 (87)
202800
E8000 2258 (89)
E10000 2294 (90)
E12000 2468 (97)
4.15
REAR AXLE
Troubleshooting
Insufficient grease in rear axle or — Supply grease

Heavy steering
steering parts
wheel operation
Faulty steering system — Refer to Steering System
Troubleshooting section
Slow return of Over-tightening of steering system — Retighten to the specified

steering wheel or rear axle parts torque
Steering wheel
Gap in external diameters between
prone to move to — Replace with proper size tires
right and left tires
one side
Shudder of Wear or breakage of taper roller bearing — Replace the bearing

steering wheel Faulty steering system — Refer to Steering System
section, and inspect or
repair
Uneven or early Misalignment of wheels — Realign wheels

wear of rear tires Different tire types for right and left wheels — Replace with proper size tires
4.16
REAR AXLE
Service Data
Service limit
Unit: mm (in.)
Items
Turning angle (L.H., R.H.) (deg) A 3°
Toe-in A 0
Caster (deg) A 0°
Camber (deg) A 1°
Steering angle Inward (deg) A 82°
Outward (deg) A 59°
Tangential force at knuckle bearing 1 A 30.4 to 79.4 (3.1 to 8.1)
N (kgf) [lbf] [6.82 to 17.82]
Tangential force at hub bearing 2 41.2 to 49.0
N (kgf) [lbf] A (4.2 to 5.0)
[9.2 to 11.0]
Front and back clearance for center pin 3 A 0.8 or less (0.031)
(total) B 1.2 (0.047)
Tightening torque of steering cylinder A 262 ± 40 (26.7 ± 4) [193.1 ± 28.9]
bolt 4 N·m (kgf·m) [lbf·ft]
Outer nut tightening torque 5 A 157 +20
(16 +2) [115.7 +14
]
Hose tightening torque 6 A 49 ± 4.9 (5 ± 0.5) [36.1 ± 3.6]
Tire service limit 7 B 45.7 (1.8))
7
←⎯
1
6
4
←
2
•
• •
•
3
•
206637
5
206639
4.17
REAR AXLE

Service limit
Unit: mm (in.)
Item
A 85 (3.346)
Internal diameter of cylinder tube 1
B 85.15 (3.352)
External diameter of piston rod 2 A 60 (2.36)
Bolt tightening torque 3
Steering Cylinder
A 59.8 (6.1) [44]

2 1
206640
4.18
BRAKE SYSTEM
CHAPTER 5: BRAKE SYSTEM
Specifications .................................................................................................................................................... 5.1

Structure ............................................................................................................................................................ 5.2
Brake System ............................................................................................................................................ 5.2
Master Cylinder and Reservoir Tank .......................................................................................................... 5.3
Wheel Brake .............................................................................................................................................. 5.4
Master Cylinder.................................................................................................................................................. 5.5
Disassembly................................................................................................................................................ 5.5
Wheel Cylinder .................................................................................................................................................. 5.6
Disassembly................................................................................................................................................ 5.6
Inspection and Repair ................................................................................................................................ 5.7
Assembly .................................................................................................................................................... 5.7
Wheel Brake ...................................................................................................................................................... 5.8
Disassembly................................................................................................................................................ 5.8
Inspection and Repair ................................................................................................................................ 5.9
Assembly .................................................................................................................................................. 5.11
Parking Brake Lever ...................................................................................................................................... 5.13
Inspection and Repair .............................................................................................................................. 5.13
Installation................................................................................................................................................ 5.13
Adjustment and Tests ...................................................................................................................................... 5.14
Automatic Adjuster Test ............................................................................................................................ 5.14
Procedure for Manual Adjustment .......................................................................................................... 5.14
Brake Fluid Line Bleeding........................................................................................................................ 5.15
Inspecting Reservoir Tank Level Sensor ................................................................................................ 5.15
Procedures for Brake Pedal Adjustment ................................................................................................ 5.16
Troubleshooting .............................................................................................................................................. 5.17
Service Data .................................................................................................................................................... 5.19
BRAKE SYSTEM
Specifications

Items
Type Hydraulic front-wheel braking drum internal
expansion duo-servo type
Drum diameter mm (in.) 317.5 (12.50)
Lining dimension mm (in.) 330 X 63 X 10 - 2
Main Brake
Brake System
(Length X Width X Thickness - (13 X 2.48 X 0.39 - 2)

Number of unit)
Master cylinder internal diameter Primary 31.75 (1.25)
mm (in.) Secondary 19.05 (0.75)
Wheel cylinder internal diameter 31.75 (1.250)
mm (in.)
Parking brake Type Hydraulic front-wheel braking drum internal expansion type
5.1
BRAKE SYSTEM
Structure
Brake System
Sequence
1 Wheel Brake 5 Wheel Cylinder
2 Parking Brake Lever 6 Reservoir Tank
3 Brake Pedal 7 Brake Piping
4 Master Cylinder 8 Brake Hose
5.2
BRAKE SYSTEM
Master Cylinder and Reservoir Tank
Sequence
1 Primary Piston 10 Secondary Seal
2 Primary Spring 11 Cup Seal
3 Inlet Fitting 12 Reservoir Tank Cap Seal
4 Master Cylinder Reservoir 13 Reservoir Tank Cup
5 Secondary Valve 14 Low Fluid Indicator Assembly
6 Secondary Spring 15 Cap Assembly
7 Secondary Piston 16 Reservoir
8 Check Valve 17 Reservoir Assembly
9 Fitting
5.3
BRAKE SYSTEM
Wheel Brake
5
4
3 6
11
A A
7 10
8 9
12
13 Section A-A
206671
Sequence
1 Parking lever 8 Adjusting screw
2 Shoe and lining (primary) 9 Adjusting lever
3 Strut 10 Fitting link assembly
4 Return spring 11 Shoe and lining (secondary)
5 Wheel cylinder 12 Parking cable
6 Dust shield 13 Backing plate
7 Return spring
5.4
BRAKE SYSTEM
Master Cylinder
Disassembly
Sequence
1 Master Cylinder
2 Lock Nut
3 Yoke
4 Elbow
5 Bolt w/hole
6 Gasket
7 Inlet Connection
8 Gasket
5.5
BRAKE SYSTEM
Wheel Cylinder
Disassembly
NOTE: Parts markedk with are included in the Seal Kit.

*
200812
Sequence
1 Connector Ring
2 Boot
3 Piston
4 Piston Cup
5 Return Spring
6 Bleeder Screw, Cap
7 Cylinder Body
NOTE
Repair Kit parts should be replaced
periodically.
5.6
BRAKE SYSTEM

(1) Cylinder body
(a) Check the bore of the body for rusting,
erosion or scoring.
(b) Check the threads of the bleeder screw
and oil pipe screw connections for
damage.
(2) Piston
(a) Check the outer surfaces for rusting or
scoring.
(b) Insert the piston to the body. If the
clearance between the piston and body
exceeds the service limit, replace the
piston and body.
Service limit
0.020 to 0.105
Clearance between A (0.0008 to 0.00413) 200280
cylinder and piston
mm (in.) 0.15
B (0.0059)
(3) Piston cups

Check each cup for swelling or other defects
and replace if any defect is found.
Service limit
Fit of the piston 1.85
A
cups in cylinder (0.0728)
body 0.65
mm (in.) B
(0.0256)
(4) Boot
Replace the boot if it is damaged or
deteriorated due to aging.
Replace the boot every year.
NOTE
If Wheel Cylinders are disassembled for
inspection a new Seal Kit should be installed
or the wheel cylinder replaced.
Assembly
Follow the disassembly sequence in reverse. Be
careful with the following key points.
(1) Apply brake fluid evenly to the cylinder bore
and the piston cup.
(2) Be careful not to damage the lip of the cup.
(3) Assemble the cup in correct direction.
5.7
BRAKE SYSTEM
Wheel Brake
Disassembly
6 13 12 11
8 2
1
2
5
7 3
10 6 9
206796
1 Return springs (1) Remove the front tires.
2 Fitting link assembly, Split pin, Plane (2) Remove the wheel hub and drum.
washer, Spring and link assembly, Lever (3) Separate the parking lever at the lower side of
and Link the wheel brake and the parking cable fitting.
3 Adjusting lever, Adjusting spring
(4) Remove the brake pipe from the wheel brake
4 Return spring assembly.
5 Adjusting screw
6 Hold-down spring, Cup and Pin
7 Strut, Retainer and Web washer
8 Shoe and lining (secondary)
9 Shoe and lining (primary)
10 Parking lever, Retainer and Web washer
11 Wheel cylinder
12 Parking cable
13 Backing plate
5.8
BRAKE SYSTEM

(1) Removing return springs
Use the special tool A to remove the return
springs from the shoe guide plate.
Special tool needed

A
Spring remover A 64309-15411
200271
(2) Removing hold-down springs
Use the special tool B to remove the shoe
hold-down springs from the backing plate.
Special tool needed B

Spring retainer B 91868-00600

(1) Backing plate
(a) Check the backing plate for cracks. 200272
(b) Check the tightening torque of mounting
bolts.
Tightening torque
N·m 238.3 to 284.3
(kgf·m) (24.3 to 29.0)
[lbf·ft] [53.5 to 63.9]
(2) Shoe and lining assembly

(a) Check the lining and shoe for crack or
breakage.
(b) Replace the lining if severely stained
with oil, burned or otherwise deteriorat-
ed.
(c) Check the lining thickness. If the
thickness exceeds the service unit,
replace the lining.
A: Standard value B: Repair or

Service limit
Lining thickness A 10 (0.39)

203005
mm (in.) B 4.2 (0.16)
5.9
BRAKE SYSTEM
(3) Brake drums

If uneven wear or damage is found inside
each brake drum, grind and repair.
A: Standard value B: Repair or
Service limit
317.5 +0.2
+00
A
Brake drum (12.500 +0.008 )
+0
internal diameter
mm (in.) 318.5
B
(12.539)
(4) Adjusting screw

Check for wear on wheel teeth. Also check if
the wheel rotates smoothly.
200274
(5) Parking brake link

(a) Check the lever support pin and pin hole
for wear, and replace the link if severely
worn.
(b) Check the parking cable, and replace if it
is stretched, damaged or rusted.
(6) Other inspection parts

(a) Check the shoe return spring for cracks or
fatigue.
(b) Check the adjusting screw for cracks or
fatigue.
5.10
BRAKE SYSTEM
Assembly
3
13
1
7
5
12
A A
10
9 11
2
Section A-A
206680
Sequence 8 Hold-down Spring, Cup and Pin

1 Backing Plate 9 Adjusting Screw
2 Parking Cable 10 Return Spring
3 Wheel Cylinder 11 Adjusting Lever, Adjusting Spring
4 Parking Lever, Retainer and Web washer 12 Fitting Link assembly,
5 Shoe and Lining (primary) Link, Lever, Spring and Link assembly,
6 Shoe and Lining (secondary) Plane washer, and Split pin
7 Strut, Retainer and Web washer 13 Return Spring
5.11
BRAKE SYSTEM

(1) Installing wheel cylinder
Apply liquid gasket to the mounting surface of
cylinder, then tighten the bolt to the specified
torque.
17.6 to 26.4
Tightening torque
(1.8 to 2.7)
[13.0 to 19.5]
(2) Greasing
Thinly apply specified grease to the following
brake parts.
(a) Shoe ledges (6 places)
(Backing plate surface contacting with the
shoes) 206678
(b) Anchor pin surface contacting with the shoe
web
(c) Pin surface interfitting to the automatic
adjust lever hole
(3) Installing shoes and linings
Make sure that the push rod of the wheel cylin-
der is correctly inserted to the shoe web.
(4) Installing return springs

Use the special tool A to install the return springs
to the backing plate pins. A
Special tool needed
Spring installer A 64309-15413
200276
(5) Installing automatic adjuster
Clean adjusting screw parts and apply grease to
the threads and the fitting of screw socket. Make
sure the screw rotates smoothly by hand. If the
screw rotation is sluggish, replace the screw with
a new one.
(6) Installing parking cable
Tighten the parking cable to the specified torque.
Parking cable tightening

torque 41.1 to 54.9
N-m (4.2 to 5.6) 200277
(kgf•m) [30.3 to 40.5]
[lbf•ft]
5.12
BRAKE SYSTEM
Parking Brake Lever
Sequence
1 Lever Support Pin
2 Adjusting Screw
3 Parking Brake Lever Assembly
4 Parking Brake Switch
Inspection and Repair Adjustment

(1) Replace the lever support pin if the pin or pin Put the lever to the release position. Turn the rod
hole is severely worn. clockwise to increase the lever’s tension; counter-
(2) Replace the parking brake cable if stretched, clockwise to decrease it.
damaged or rusted.
Installation
After connecting the parking brake wire, the oper-
ating force required to pull the parking brake
lever should be 245 to 294 N (25 to 30 kgf) [55 to
66 lbf].
5.13
BRAKE SYSTEM
Adjustment and Tests
Automatic Adjuster Test

(1) Adjust the clearance between the lining and the
drum close to the specified value. Pull the fitting
link assembly toward you with finger. The lever
turns the wheel by one tooth and returns to the
original position.
206676
(2) If the lever does not move as in (1) or is sluggish

to turn the wheel after returning the fitting link
assembly, check the lever position under the
adjusting screw wheel.
The lever should be in contact with the wheel of
adjusting screw at approx. 9 mm (0.354 in.)
below the center line of the screw. If this
positioning is wrong, the lever fails to come in
contact with the wheel teeth correctly, thus the
wheel fails to turn correctly when the lever is
activated. 200282
(3) If the automatic adjuster does not activate
correctly, carry out the following actions.
(a) Make sure that the adjusting spring is
correctly attached to the specified hole of the
primary shoe.
(b) Replace the fitting link assembly.
(c) Replace the lever.
(d) Replace the adjusting screw.
Procedure for Manual Adjustment

Insert a screw driver to the adjustment hole on the
back of the backing plate. Force down and rotate the
wheel of adjusting screw to adjust the clearance
between the drum and lining.
Clearance between drum

0.4 to 0.6
and lining (one side)
(0.016 to 0.024)
mm (in.)
200283
5.14
BRAKE SYSTEM
Brake Fluid Line Bleeding

When part of the brake fluid line is disassembled
for repair, or when brake pedal movement is
spongy, bleed the brake fluid line.
Bleeding requires two people. Start the engine
and keep it idling during bleeding operation.
(1) Insert a vinyl tube to the bleeder screw of the

wheel cylinder. Insert the other end of the
tube to a container filled with brake fluid.
(2) Have one person step (pump) on the brake
pedal several times and while holding the
pedal depressed, release the bleeder screw.
Before the fluid stops flowing in the vinyl
tube, tighten the bleeder screw. 206677
(3) Repeat the above procedure until there is no

air bubbles in the brake fluid. Fill the reser-
voir tank with brake fluid to the specified level
NOTE
(a) Be careful to maintain sufficient fluid
level in the reservoir tank.
(b) Use brake fluid of the specified brand.
Do not mix different types of fluids.
(c) Start bleeding with the brake fluid of the
wheel cylinder on the right side (far side
from the master cylinder).
Inspecting Reservoir Tank Level Sensor

(a) The sensor is normal if OK monitor lamp
lights when brake fluid level is under MIN line
of the oil tank.
(b) If the lamp does not light, check the lamp
bulb for breakage.
(c) If the bulb is normal, carry out continuity test
for the lever sensor of reservoir tank.
206673
5.15
BRAKE SYSTEM
Procedures for Brake Pedal Adjustment
(1) Adjust yoke to dimension (A) of

40 ± 1 mm
(.16 ± .04 in)
5.16
BRAKE SYSTEM
Troubleshooting
Oil leakage from master cylinder *Check cylinder for wear. If
primary cup piston cup is deformed,
Oil leakage from wheel cylinder replace Master Cylinder
cup and brake fluid. Use
Insufficient
genuine parts and brake
braking force
fluid
Oil leakage from oil pipe joint — Retighten or replace pipe
and joint
Worn lining — Replace
Oil on lining — Clean or replace lining
Air in hydraulic system — Bleed master cylinder and

wheel cylinder
Defective master cylinder piston — Replace piston cup
Excessive pedal cup
Low oil level in reservoir tank — Supply oil
stroke
Excessive clearance of master — Adjust
cylinder push rod
Brake fluid leakage — Refer to above section
marked with *
Automatic adjuster not activate — Check cable guide and
Wheel Brake
adjusting screw for correct

installation. If automatic
adjuster still does not
activate, replace fitting link
assembly, lever, and
adjusting screw
Oil or grease on lining or drum — Clean with brake cleaner

21651 and repair. If oil and
Imbalance in
grease cannot be removed
braking power from lining, replace lining
Brake drum shimmy or loose — Replace drum. Adjust and
mounting retighten loose mounting
Lining surface too smooth — Scrub lining surface with

abrasive paper
Worn lining — Replace shoe and lining
assembly
Brake squeaking Loose mounting bolt of backing — Retighten
plate
Loose wheel bearing — Adjust pre-load and
retighten
Dirty drum — Clean drum with brake
cleaner 21651
Abnormal noise Shoe anchor end contacting with — Repair or replace
anchor
from brake
Excessive wear of shoe ledge — Replace backing plate
(clicking noise)
Excessive wear of wheel cylinder — Replace wheel cylinder
piston
5.17
BRAKE SYSTEM
Heavy pedal Foreign matter mixing in brake — Clean cylinder and supply
cylinder cylinder liquid
Insufficient brake cylinder fluid — Supply

Spongy pedal Brake cylinder liquid leakage — Repair or replace
Improper bleeding — Bleed
Insufficient Insufficient clearance between — Adjust to standard

parking brake brake and lining clearance
stroke
Abnormal noise Insufficient clearance between — Adjust to standard

from parking brake lining and drum clearance
Parking Brake
brake in driving Warped brake drum — Repair brake drum

according to repair
standard, or replace
Parking brake cable exceeding — Adjust clearance between

specified length brake lining and drum. If
parking brake still does not
produce stopping force,
Parking brake check parking brake cable
not producing length
stopping force Brake lining worn beyond service — Replace shoe and lining
limit assembly
Excessive clearance between — Adjust clearance between
brake lining and drum brake lining and drum
Insufficient pulling force of parking — Adjust pulling force to 245
brake lever to 294 N (25 to 30 kgf) [55
to 66 lbf]
5.18
BRAKE SYSTEM
Service Data
A : Standard value
Unit: mm (in.)

Item
Pedal height 1
(between top surface of floor plate and upper 1 138
pedal edge)
Free play of brake pedal 2 2 10
Brake pedal stroke 3 3 45
Tightening torque of master cylinder 4
4 34 ± 3(3.4 ± 0.3) [25 ± 3]
N•m (Kgf•m) [lbf•ft]
Brake System
123456
5.19
BRAKE SYSTEM
A : Standard value B : Repair or Service limit
Unit: mm (in.)
Items
Cylinder body internal diameter 1 A 31.75 +0.062
+0 (1.25 +0.00244
+0 )
Piston external diameter 2 A 31.75 –0.025 –0.00098
–0.064 (1.2500 –0.00252 )
Clearance between cylinder and piston A 0.020 to 0.105 (0.0008 to 0.00413)

B 0.15 (0.006)
Piston cup lip-side external diameter 3 A 33.6 ± 0.25 (1.32 ± 0.0098)
B (Replace every year)
Return spring 4 Free-movement length A 33.4 (1.31)
Mount length A 14 (0.55)
Mount weight N (kgf) [lbf] A 13 ± 2 (1.6 ± 0.1) [3.5 ± 0.2]
B (Replace every year)
Tightening torque of wheel cylinder A 18 to 26 (1.8 to 2.7) [13.0 to 20]
mounting bolt 5 N·m (kgf·m) [lbf·ft]
Tightening torque of bleeder screw 6 A 6 to 9 (0.6 to 0.9) [4.3 to 6.5]
Wheel Cylinder
200426
5.20
BRAKE SYSTEM
A : Standard value B : Repair or Service limit
Unit: mm (in.)

Item
A 317.5 +0.2 +0.008
+0 (12.500 +0 )
Brake drum internal diameter 1
B 318.5 (12.539)
A 10 (0.39)
Lining thickness 2
B 4.2 (0.17)
Clearance between drum and lining 3 (one-side) A 0.4 to 0.60 (0.016 to 0.024)
Return spring 4 Free-movement length A 93 (3.66)
Mount length A 101.2 (3.98)
Mount weight N (kgf) [lbf] A 245 (25) [55
Adjusting spring 5 Free-movement length A 132.2 (4.85)
Mount length A 152 (5.98)
Mount weight N (kgf) [lbf] A 78 (8) [18]
Link (upper) Upper: 97 (3.82)
A
Link assembly (lower) length 6 Lower: 97.8 (3.85)
Tightening torque of backing plate
A 238 to 284 (24.3 to 29.0) [176 to 210]
mounting bolt 7 N·m (kgf·m) [lbf·ft]
Wheel Brake
Tightening torque of parking cable 8

A 41.1 to 54.9 (4.2 to 5.6) [30.3 to 40.5]
1
4
4 2
3
6
7
A A
5 6
Section A-A 8
206679
5.21
BRAKE SYSTEM
A : Standard value
Item
Lever swing angle A (deg) A 71° to 76°
Lever operating effort F N (kgf) [lbf] A 245 to 295 (25 to 30) [55 to 66]
Parking Brake
5.22
STEERING SYSTEM
CHAPTER 6: STEERING SYSTEM
Steering System
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Oil Flow Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Steering Gear
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Inspection after Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
Steer Pump
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
STEERING SYSTEM
Steering System Description
8609044
Oil Flow Sequence

1. From hydraulic tank
2. Steering pump
3. Steer gear
4. Steering cylinder
5. Mast operating valve
6. To hydraulic tank
General Information
This steering system is an open-center type,
where the steering fluid is provided by a dedicat-
ed steering pump. The oil is constantly available
and flows through the steer gear and back to the
tank via the mast operating valve.
In this type of steering system, only the small
dedicated steer pump is pressurized, providing
an efficient, energy-conservation system.
6.1
STEERING SYSTEM
Steering Gear
Removal & Installation
8609016
Sequence
1. Nut, washer
2. Wheel
Removal
Use a special tool. Installation
To install, follow the reverse of the removal
Special Tool Part Number sequence.
Wheel puller 91268-10600
Wheel puller
203466A
6.2
STEERING SYSTEM
Steering Gear
Removal & Installation
Sequence Inspection after Removal

1. Column & Kick cover mounting hardware 1. Inspect the grommets for cracks or tears in
2. Column & Kick covers the rubber or for signs of aging. Check the
O-rings for damage.
3. Hoses, connectors and o-rings
4. Steer column mounting bolts Installation
5. Steer column To install, follow the reverse order of the removal
6. Steer gear sequence. Tighten bolts to the specified torque
! WARNING 2.9 ± 0.3 kgf•m

Tightening torque for bolts (20.9 ± 2.1 lbf•ft)
Hydraulic pressure can cause personal injury. [28.4 ± 2.9 N•m]
Before any steering system hydraulic lines or
components are disconnected, make sure all
hydraulic pressure is released in the steering
system. Move the steer wheels to the left and
right, then straight.
NOTE
For servicing the steer cylinder, see REAR
AXLE section.
6.3
STEERING SYSTEM
Steering Gear
Disassembly
6.4
STEERING SYSTEM
Steering Gear Disassembly

Working Rules and Tips 1. Remove the plug and inlet relief valve.
The steering gear is a precision-machined compo- Note: The manual steering check is part of the
nent, so it must be handled with extreme care. inlet relief valve. If inlet relief valve is not present,
Cleanliness is Imperative: work in a clean place and the manual steering check is in the housing.
use clean tools. 2. Remove the four cap screws and the end cap
and disassemble the the steer gear.
1. Before disconnecting the hydraulic lines, clean 3. Slide the spool and sleeve from the housing.
the port area of the steer gear unit. 4. Remove the thrust bearing and bearing races.
2. Before disassembly, drain the oil and then plug 5. Remove the seal.
the ports and thoroughly clean the exterior of 6. Using a small blade screwdriver, carefully pry
the steer gear unit. the dust seal from the housing.
3. Clean the disassembled parts with a volatile solvent 7. Remove the pin that holds the spool and sleeve
such as trichlene or chlorobenzene, and dry together.
them with compressed air. This does not apply 8. Carefully slide the spool out of the sleeve. The
to rubber parts. springs and retaining ring will stay with the spool
4. Oil seals, O-rings, and the like are rubber parts. as it’s removed.
Never clean them with solvents. Blow dirt off rub- 9. Remove the retaining ring and springs.
ber parts with compressed air and keep them Caution: The centering springs are under tension;
immersed in a pool of hydraulic oil until they are remove the retaining ring carefully.
ready for reassembly. A rubber part showing
even slight wear and tear must be replaced. Inspection after Disassembly
Rubber parts are expendable components that
should be replaced once a year. 1. Check all mating surfaces. Replace any parts
5. Parts that need to be installed by pressing or that have scratches or burrs that could cause
forcing need special treatment. leaks.
a. Oil Seals 2. Clean all metal parts in clean solvent. Blow dry
Oil seals, once removed, must not be reused. with air. Do not wipe dry with cloth or paper
After disassembly, examine the oil seals in towels because lint or other matter can get into
place. If they are in good condition, leave the hydraulic system and cause damage. Do not
them in place. When installing a replacement use a coarse grit or try to file or grind these parts.
oil seal, be careful not to score or scratch the
lip area.
Suggestions:
The steer gear is designed with very few serviceable

components. Only disassemble the steer gear if you
plan to replace one of the following:
1. Dust Seal
2. Pressure Seal
3. O-rings
4. Thrust Race and/or Bearings
If replacing these parts does not improve per-
formance, you must replace the entire steer gear
assembly. Refer to your parts manual for order-
ing information.
6.5
STEERING SYSTEM
Steering Gear Reassembly

Suggestions
Note: DO NOT disassemble the steer gear 10. Clamp the housing in a vise. Use just
further than required to replace serviceable enough clamping force to hold the housing
components. Doing do may result in securely.
replacing entire gear.
11. Install manual steering check ball and pin
into housing, if no relief valve is present.
Note: Always use new seals when reassembling
hydraulic steer gear units. 12. Lubricate and install a new o-ring seal in the
groove in the housing.
Note: During reassembly lubricate the new seals 13. Install the wear plate and align the timing
with petroleum jelly. Lubricate machined surfaces groove on plate with the timing groove on
and bearings with clean hydraulic fluid. the housing.
Note: The holes in the wear plate are not
symmetrical.
1. Install the quad seal
• Put one of the bearing races and sleeve 14. Install the drive, be sure the slot in the drive
into the housing. engages the pin.
• Together, the housing and bearing race 15. Lubricate and install a new o-ring and seal
create a groove into which the quad seal ring in the groove in the wear plate.
will be installed.
• Hold the bearing race tightly against the 16. Install the gerotor and align the timing
input end of the housing by pushing on the groove with the timing groove in the wear
gerotor end of the sleeve. plate.
• Fit the quad seal into its seat through the 17. Lubricate and install a new o-ring seal in the
input end of the housing. Be sure the seal groove in gerotor ring.
is not twisted.
18. Lubricate and install a new o-ring and seal
• Remove the sleeve and the bearing race.
ring in the groove in the gerotor star.
2. Lubricate and install the dust seal. 19. Install the spacer.
3. Install the centering springs in the spool. It is 20. Install end cap and four cap screws. Align
best to install the two flat pieces first. Next, timing groove on end cap with timing groove
install the curve pieces, three at a time. on gerotor. Tighten cap screws in a criss
cross pattern, to 16 – 18 Nm [250 lb-in].
4. Fit the retaining ring over the centering springs.
21. Install the relief valve/check if present. Use
5. Apply a light coating of clean hydraulic fluid to a new o-ring and tighten the plug to 17 Nm
the spool and slide it into the sleeve. Be sure [150 lb-in].
the centering springs fit into the notches in the
sleeve. 22. Remove the steering gear from the vise.
6. Install the pin. 23. Check the steering gear and confirm that all
timing grooves are in line.
7. Apply a light coat of petroleum jelly to the inner
Note: If timing grooves are not aligned
edge of the dust and quad seals.
properly, steering gear will not operate
8. Put the thrust bearing and races into the housing. properly.
The thrust bearing goes between the two races.
9. Apply a light coating of clean hydraulic fluid to
the spool and sleeve assembly and slide it into
the housing. Important: Do not damage the dust
or quad seals.
6.6
STEERING SYSTEM
Steer Pump
Removal
Sequence Suggestions
1. Motor Mounting Hardware Removing the Motor and Pump Assembly
2. Motor After disconnecting the steer pump hoses,
motor cables, and harness leads, remove the
3. Pump Mounting Hardware pump and motor assembly by removing the
4. Pump motor bracket mounting hardware where the
bracket is bolted to the frame.
Removing the Pump

Start By: Remove the pump from the motor.
1. Remove the battery.
2. Remove the acid tray. Installation
3. Disconnect the cables and wires from the 1. To install, reverse removal sequence.
steer pump motor. Mark the wire leads and
cables so they can be correctly reconnected.
4. Disconnect the hydraulic lines from the pump.
6.7
HYDRAULIC SYSTEM
CHAPTER 7: HYDRAULIC SYSTEM
Hydraulic System
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
Down Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Removal and Installation Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
Hydraulic Pump
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.16
Inspection after Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.20
Control Valve
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.23
Suggestions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.24
Removal
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.25
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.31
Disassembly
Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.33
Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.47
Precautions for Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.50
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.53
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.54
Lift and Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
Adjusting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.56
HYDRAULIC SYSTEM
Hydraulic System Description

Schematic for Trucks
Sequence General Information

1. Hydraulic tank The hydraulic pump draws oil from the oil tank and
2. Hydraulic lift pump delivers it to the main control valve, which dispens-
3. Steer pump es it for lift and tilt functions.
4. Steer gear The steer gear and steer pump are covered in the
5. Main control valve STEERING SYSTEM section and the steering cylin-
6. Flow regulator valve der is covered in the REAR AXLE section.
7. Down safety valve
8. Lift cylinder
9. Tilt cylinder
10. Steering cylinder
11. Suction Strainer
12 Return Filter
Main Control Valve
7.1
HYDRAULIC SYSTEM
Hydraulic Tank
Sequence
1. Cap
2. Oil level gauge
3. Drain plug
4. Return line filter
5. Suction line strainer
General Information
The tank contains internal filtering means including
a strainer on the suction line and a filter on the
return line.
The lift cylinder return pipe allows the cylinders to
draw fluid when they retract, providing the bore
walls with oil which inhibits corrosion.
7.2
HYDRAULIC SYSTEM
Hydraulic Pump
General Information Pressure Loading Principle

This gear pump is capable of developing very This pump is a self-balanced type based on
high pressure on its discharge side. A special the principle of pressure loading, balancing
arrangement is incorporated in the pump con- for equal pressure on all sides of the revolv-
struction for the purpose of keeping the side ing gear. This reduces bushing and gear
clearances minimized between bushings on the wear. In operation, the high-pressure oil on
one side and pump gears on the other. See illus- the discharge side is fed back to the suction
tration 203585, below. Discharge pressure is side. On the suction side, pressure is exerted
applied to the back of each bushing through equally on both sides of the gears and shafts,
internal oilways. thereby cancelling out unequal pressure to
balance the pump.
Hydraulic Pump Operation
Essentially the pump consists of two gears—the
drive gear and the driven gear—closely fitted in
the housing. The oil is carried around the periph- Clearance
ery of the revolving gears from the suction to the
discharge side. The teeth meshing between the
two gears prevents the return of oil from the dis-
charge to the suction side.
Driven Gear
Discharge Side
200333
Drive Gear
203585
7.3
HYDRAULIC SYSTEM
Control Valve
Sequence General Information

1. Inlet / Unloader Spool The control valve consists of three valve
2. Tilt Spool blocks, all spool-type. The spools are finished
3. Auxiliary Spool by lapping for their respective blocks and their
combination should not be changed. The lift
4. Auxiliary Attachment Spool
valve assembly has a built-in load check
5. Outlet Spool valve. The tilt valve spool has a built-in tilt lock
6. Flow Control Screws valve. The attachment valve assembly has a
7. Pump Port built-in overload relief valve.
8. From Steering Control Valve
9. To Tank
10. Main Relief Valve, Auxiliary Valve (back)
11. Auxiliary Relief Valve (front)
12. Tie bolt
13. Nut
14. Switches
7.4
HYDRAULIC SYSTEM

Simplex Mast
Lift Cylinders (A40A)
Parts marked with * are included in the seal kit. 206951
Sequence
1 Cylinder tube 5 U-ring 9 Backup ring
2 Piston rod 6 Wiper ring 10 Bushing
3 Cylinder head 7 O-ring 11 Spacer
4 Bushing 8 U-ring
Simplex Mast
Lift Cylinders
(A45A, A55A)
Sequence
1 Cylinder tube 6 U-ring 11 U-ring Holder
2 Piston rod 7 Wiper ring 12 Stopper
3 Cylinder head 8 O-ring 13 Spacer
4 Bushing 9 Piston ring
5 Holder 10 U-ring Assembly
7.5
HYDRAULIC SYSTEM
Duplex Mast Triplex Mast

First Lift Cylinder (B40A, B45A, B55A) First Lift Cylinders (C40A thru C55A)
Sequence
1 Cylinder tube 6 Wiper ring 11 Check valve
2 Piston rod 7 O-ring 12 Snap ring
3 Cylinder head 8 O-ring 13 Plug
4 Bushing 9 Seal ring assembly 14 Gasket
5 U-ring 10 Slide ring
Duplex Mast
Second Lift Cylinders (B45A, B55A)
Parts marked with * are included in the seal kit.

206948
Sequence
1 Cylinder tube 8 Spacer 15 Snap ring
2 Piston rod 9 Piston 16 Valve
3 Cylinder head 10 Set screw 17 Steel ball
4 Bushing 11 Slide ring 18 Spacer
5 U-ring 12 Check valve 19 Snap ring
6 Wiper ring 13 Cushion spool
7 O-ring 14 Spring
7.6
HYDRAULIC SYSTEM
Duplex Mast
Second Lift Cylinders (B40A)
Sequence
1 Cylinder tube 7 Backup ring 13 Check valve
2 Piston rod 8 Wiper ring 14 Cushion spool
3 Cylinder head 9 O-ring 15 Spring
4 Bushing 10 Piston 16 Snap ring
5 Holder 11 Slide ring 17 Steel ball
6 U-ring 12 Set screw 18 Set screw
Triplex Mast
Second Lift Cylinders (C40A)

207778A
Sequence
1 Cylinder tube 7 O-ring 13 Cushion spool
2 Piston rod 8 U-ring 14 Pin
3 Cylinder head 9 Backup ring 15 Snap ring
4 Bushing 10 Bushing 16 Spacer
5 U-ring 11 Spring guide
6 Wiper ring 12 Spring
7.7
HYDRAULIC SYSTEM
Triplex Mast
Second Lift Cylinders (C45A, C55A)
Parts marked with * are included in the seal kit. 207779A
Sequence
1 Cylinder tube 7 Wiper ring 13 Spring guide
2 Piston rod 8 O-ring 14 Spring
3 Cylinder head 9 Piston ring 15 Cushion rod
4 Bushing 10 U-ring assembly 16 Spring pin
5 Holder 11 Holder 17 Spacer
6 U-ring 12 Stopper
7.8
HYDRAULIC SYSTEM
Tilt Cylinders
Sequence
1 Cylinder tube
2 Piston rod
3 Guide bushing
4 Piston
5 Tilt socket
6 Piston seal
7 O-ring
8 Packing
9 Dust seal
10 Buffer ring
11 Self-lock nut
12 Collar
13 Bolt
14 Spring washer
7.9
HYDRAULIC SYSTEM
Flow Regulator Valve
E7000 thru E12000
202978
Sequence
1 Set Bolt, Lock Nut
2 Sleeve, O-ring
3 Piston, Spring Pin, Washer Spring, Valve
4 Spring
5 Spring Guide, O-ring
6 Valve Body
7.10
HYDRAULIC SYSTEM
Down Safety Valve
204626
Sequence Removal and Installation Warning

1 Connector
2 Valve ! WARNING
3 Spring
4 Spring pin Hydraulic oil under pressure can remain in
the hydraulic system after the truck and
The down safety valve is located at the bottom side pump have been stopped. To avoid personal
of right-hand lift cylinder. This valve provides a injury, this pressure must be released before
means of preventing the load from lowering, any work is done on the hydraulic system.
unsafely, rapidly, when a hose bursts. To prevent possible injury, lower the lift
bracket to the ground, turn the truck off, and
Simplex A40A A45A move the control levers to make sure all
Model
Mast
Duplex B40A B45A,B55A hydraulic pressure is released before any fit-

Triplex C40A C45A,C55A ting, plug, or hose is loosened, tightened,
90 –0 120 +5
removed, or adjusted.
Cut-off flow rate –15 –10
liter (U.S. gal)/min (23.8 –0

–4 ) (31.7 +1.3
–2.6 ) Always move the lift truck to a clean and
level location away from the path of other
machines.
Be sure that no personnel are near the
WARNING machine when the truck is running and tests
Do not reuse down safety valve after a or adjustments are being made.
lift line hose failure.
7.11
HYDRAULIC SYSTEM
Hydraulic Pump Removal
Sequence
1 Hardware
2 Pump
3 Elbow (outlet)
4 Connector (inlet)
Start By: Installation

1. Disconnect the battery from the truck. 1. To install, follow the reverse sequence of the
2. Disconnect the hoses attached to the pump disassembly procedure. Before installing
fittings. hydraulic fittings in the pump, inspect all
O-rings for damage or aging and replace
3. Disconnect the power cables and wire leads them as required.
from the pump motor.
2. Tighten hose connections to the following
4. Make sure that the truck is stable and secure specifications.
in the raised position.
5. Secure the motor from above with a crane, Tightening Torque for Hydraulic Fittings
hoist, or other adequate device, or support it EC35N thru EC55N
at its center with a garage jack.
Inlet N•m (Kgf•m) [lbf•ft] 147 ±15 (15 ±1.5) [108 ±11]
6. Remove the motor and pump assembly from Outlet Elbow N•m (Kgf•m) [lbf•ft] 59 ± 6 (6 ± 0.6) [46 ±.4]
the truck. Delivery Hose N•m (Kgf•m) [lbf•ft] 100 ± 12 (12 ±1.2 ) [74 ± 8]
7. Remove the hydraulic fittings from the pump.
8. Remove the pump from the motor.
7.12
HYDRAULIC SYSTEM
Disassembly
Working Rules and Tips Oil Seal

The hydraulic pump is a precision-machined com- An oil seal, once removed, must not be reused.
ponent and as such must be handled with extreme After disassembly, examine the oil seal in place
care. Clean-liness is imperative: use clean tools (in the pump flange) and, if in good condition,
and work in a clean place. leave it in place. When installing a replacement
1. Clean the disassembled parts with a volatile oil seal, be careful not to score or scratch its lip
solvent such as trichlene or chlorobenzene portion.
and dry them with compressed air. This does
not apply to rubber parts.
2. Oil seals, O-rings, and the like are rubber
parts. Never clean them with solvent. Blow
dirt off rubber parts with compressed air, and
keep them immersed in hydraulic oil until they
are ready for reassembly. A rubber part show-
ing even slight wear and tear must be
replaced. Rubber parts are expendable items
that should be replaced once a year.
3. Parts that are installed by pressing or forcing
need special treatment.
7.13
HYDRAULIC SYSTEM
7.14
HYDRAULIC SYSTEM
7.15
HYDRAULIC SYSTEM
7.16
HYDRAULIC SYSTEM
7.17
HYDRAULIC SYSTEM
7.18
HYDRAULIC SYSTEM
7.19
HYDRAULIC SYSTEM
Inspection after Reassembly
Pour a small amount of clean hydraulic fluid into a It is recommended that, initially, the unit is run in
port and check that the shaft can be rotated with- at 1500 rpm at zero pressure for one minute. The
out undue force using a smooth-jawed vise. pressure should then be increased in intervals of
35 bars a minute until maximum pressure is
Running In; After Reassembly reached. Check the system temperature frequent-
A unit which has been reassembled with either ly, ensuring that it does not exceed the maximum
new gears, bushes, or body, must be carefully run permissible temperature of 80°C. If the tempera-
in before it is subjected to full working conditions. ture exceeds the system or unit specification, the
Ideally, this should be done on a test rig, where test must be delayed and operated off-load until
pressure can be applied gradually and any wipings the temperature is lowered to an acceptable
from the body cut-in can be arrested by filters. range.
Pressure
Test gauge
unit Micronic
Variable
filter
restrictor
Flow
Strainer Relief meter
Tank
valve
Typical pump test circuit
8609116
7.20
HYDRAULIC SYSTEM
Control Valve Removal
Sequence Start By:

1. Auxiliary lines, connectors, and O-rings 1. Remove the floorplates and the front dashboard
2. Steering return hose, connector, and O-ring cover.
3. Lift hose and connector 2. Tilt the mast to vertical position, lower the forks
4. Delivery hose, connector, and O-ring all the way, and relieve the pressure in the
5. Tilt lines, connectors, and O-rings hydraulic lines.
6. Return Hose.
3. Disconnect the battery
7. Control Valve
8. Switches 4. Disconnect the wire leads to the valve switches.
9. Solenoid 5. Disconnect the hydraulic lines per the listed
10. Lower Switch sequence solenoid, and lower switch.
6. Remove the 3 mounting bolts from the front of
the dash.
7. Remove the valve from the truck.
7.21
HYDRAULIC SYSTEM
Control Valve Installation
1. To install, follow the reverse of the disas- Tightening Torque for Hoses
sembly sequence. Before installing hydraulic
25 ± 0.5 N•m
fittings, inspect all O-rings for damage or A Tilt hoses 2.5 ± 0.5 kgf•m
aging and replace them as required. 18 ± 3.6 lbf•ft
118 ± 12 N•m
2. Tighten hoses to the specifications shown in
B Delivery hose 12 ± 1 kgf•m
the chart. 87 ± 7 lbf•ft
65 ± 7 N•m
C Lift Hose 6.5 ± 0.7 kgf•m
47 ± 5 lbf•ft
48 ± 5 N•m
D Aux Hoses 5.0 ± 0.5 kgf•m
36.2 ± 3.6 lbf•ft
Steer Gear 39 ± 4 N•m
E Return Hose 4 ± 0.4 kgf•m
29 ± 3 lbf•ft
100 ± 10 N•m
F Return Hose 10 ± 1.0 kgf•m
72 ± 7.2 lbf•ft
7.22
HYDRAULIC SYSTEM
Disassembly
7.23
HYDRAULIC SYSTEM
Suggestions Reassembly
Main Relief Valve Before Reassembly;

1. Wash all parts except for O-rings with solvent.
NOTE 2. Apply hydraulic oil to O-rings when installing them.
To remove main relief valve for cleaning or 3. Make sure that each spool moves freely.
inspection, loosen its plug. Loosening the
lock nut will disturb the pressure setting. 1. Lay out valve components on a clean, flat working
surface. The inlet assembly will include an o-ring,
and the spool sections include an o-ring, a load
Do not remove the main relief valve unless it is check poppet and a load check spring. Tools
required for basic valve assembly include 1/2” and
defective. This also applies to shut-off valve
9/16” open or box end wrenches and a torque
assembly. wrench with thin wall sockets.
Plug 2. Assemble tie rod nuts to one end of each tie rod
with one or two threads showing. Insert rods
through tie rod holes of inlet (larger tie rod at top).
Lay inlet on end with tie rods up, place o-ring into
position.
Lock nut 3. Place first spool section (o-ring side up) on inlet
section, position o-ring and insert load check
poppet (nose down) and spring (behind poppet)
205025
into load check cavity as shown. Repeat this
procedure for each spool section; the load check
springs are compressed by the following sections
during assembly.
Auxiliary Relief Valve
4. Position end section on last spool section and
NOTE hand tighten tie rod nuts. The end section is a
“turn around” section without ports. Universal outlet
To remove auxiliary relief valve for cleaning
/ power beyond section and power beyond and
or inspection, loosen its plug. Loosening the closed center sections are also used as end
lock nut will disturb the pressure setting. sections. These end sections do not have o-ring
grooves.
Do not remove the auxiliary relief valve unless it 5. Position valve assembly with the mounting pads of
is defective. This also applies to shut-off valve the end sections on a flat surface. To obtain proper
assembly. alignment of end sections relative to the spool
sections apply downward pressure to the end
sections; snug tie rod nuts to about 10 ft-lb.
Plug
Final torque the two 1.2” nuts to 14 ft-lb; final
torque the 9/16” nut to 33 ft-lb. check for proper
spool movement.
6. Install auxiliary valves and plugs and torque to

Lock nut proper specifications
205025
7.24
HYDRAULIC SYSTEM
Lift Cylinders
Dual-stage Panoramic Mast (Simplex Mast)
6
7
8
5
3
1 4
2
207784
Sequence
1 Nuts
2 Fork, Lift bracket
3 Return (low-pressure) hose
4 Hose guard
5 High-pressure hose
6 Set bolt, Shims
7 Cylinder clamp, Cushion, Collar, Shims
8 Lift cylinder, Bracket
Suggestions
1. Lift bracket removal
(1) Tilt the mast forward, and lower the inner mast
to the bottom. Slacken the lift chains, and
remove the nuts from the anchor bolts.
(2) Tilt the mast back to vertical position. Raise
the inner mast until the lift bracket becomes
free. Then, back the truck away from the lift
bracket and fork assembly. 204873A
7.25
HYDRAULIC SYSTEM
2. Removing return hose

Lift the mast to the maximum lift position, and
turn the key switch off. Disconnect the return To hydraulic tank
hose from the right and left lift cylinders at the
connectors.
206965
3. Disconnecting high-pressure hoses

Slowly push the lift lever forward to lower the lift Right cylinder Left cylinder
bracket to the ground. Disconnect the high-pres-
sure hoses at the joints indicated by arrows. Use
a container to catch oil flowing out of the hoses.
206691
4. Removing set bolts

(1) Remove the set bolt at the top of each lift cylin-
der. Lift the inner mast to separate the cylinder
rod ends. To lift the inner mast, hitch a sling
around the mast with protective rag.
NOTE
The rod end of either lift cylinder is shim adjusted
to eliminate the difference in stroke between the
cylinders. Before removing the set bolts, make a
record of the amount of shims and cylinders to 206967
which the shims are fitted.
(2) Tie wood blocks under the inner mast and

detach the sling. Make sure the right and left
wood blocks are the same in height.
202983
7.26
HYDRAULIC SYSTEM
5. Removing lift cylinders

Hitch a sling to the lift cylinder from the rear
side of the mast, and remove the cylinder.
Hitch the sling before removing the cylinder
clamp.
206968
Installation
To install, follow the reverse of removal
sequence, and do the following steps once com-
pleted:
1. Extend and retract the lift cylinders several
times under no load condition to bleed air out
of the cylinder circuits and to make sure that
the cylinders move smoothly.
2. Check the oil level in the hydraulic tank with
an oil level gauge. (Make reference to
Hydraulic Tank section.)
3. Check to make sure that the lift height is
correct.
4. After the lift cylinders or piston rods have
been replaced, check for difference in stroke
between the two cylinders. (Make reference
to Group 11 MAST AND FORKS.)
7.27
HYDRAULIC SYSTEM
Lift Cylinders
The following describes the procedures for removing and installing the mast assembly. Note that the triple-
stage full free panoramic mast (Triplex Mast) is used as an example.
Triple-stage Full Free Panoramic Mast (Duplex and Triplex Masts)
3
1
207785
Sequence
1 Nuts
2 Lift bracket assembly
3 First lift cylinder
4 Chain wheel support assembly
5 Second lift cylinders
Suggestions
1. Removing lift bracket assembly 2

1
(1) Lower lift bracket assembly 2, and place wood
blocks under the assembly. Tilt the mast
forward, lower the inner mast to the bottom,
then remove nuts 1 from the anchor bolts of
the first lift chains. 207786
7.28
HYDRAULIC SYSTEM
(2) Position the mast upright. Raise the inner mast

until main rollers 6 of lift bracket assembly 2
become free. Then, slowly move the vehicle in
reverse to separate from lift bracket 2.
201735
2. Removing first Lift Cylinder 3
(1) Hitch a sling to first lift cylinder 3, and suspend

the cylinder with a crane. Wind the sling
securely to prevent slipping.
(2) Remove the lift cylinder connecting and mount-

ing bolts, and gently dismount first lift cylinder
3.
207787
3. Removing second Lift Cylinders 5
(1) Disconnect hoses from second lift cylinders 5.
(2) Remove stopper bolts at the upper sections of

second lift cylinders 5, and lift the inner mast
[dual-stage full free panoramic mast] or middle
mast [triple-stage full free panoramic mast]
approximately 550 mm (21.67 in.) using slings. 5
207788
7.29
HYDRAULIC SYSTEM
(3) Place wood blocks under the inner mast [dual-

stage full free panoramic mast] or middle mast
[triple-stage full free panoramic mast].
Make sure the right and left wood blocks are
the same in height.
202983
(4) Hitch a sling to second lift cylinder 5 behind the

mast, remove cylinder clamp retaining bolts,
and gently remove second lift cylinder 5.
Wind the sling securely to the cylinder. The
cylinder cannot be lifted straight up since the
mast cross-member is located above the
cylinder. Tilt the cylinder and move it away from
the cross-member to remove. Be careful not
have the hands caught between the cylinder
and mast.
5
Installation
To reinstall, follow the removal sequence in 207789

reverse, and service as follows.
(1) Install chain wheel support assembly 4 parallel

to a line connecting the centers of chain anchor
bolt holes on first lift cylinder 3 to prevent
chains from twisting.
(2) Adjust the chain tensions.

(See the section Inspection and Adjustment.)
Good Bad
(3) Extend and retract the lift cylinders several
times under no load condition to bleed air out
207638
of the cylinder circuits and to make sure that
the cylinders move smoothly.
(4) After proper operation is confirmed, check the

oil level.
7.30
HYDRAULIC SYSTEM
Tilt Cylinders
3
206971
Sequence
1 Tilt cylinder pin
2 Hoses
3 Tilt cylinder pin
4 Tilt cylinder
Start by:
(1) Lower the forks to the bottom, and tilt the mast
fully forward.
(2) Hitch a sling to the top crossmember of outer
mast, and support the weight of the mast with
a hoist.
Suggestions
1. Retracting piston rod
Remove tilt cylinder pin 1. Start the engine and
retract the piston rod to the full stroke, then
stop the engine.
2. Disconnecting hoses
206970
Disconnect hoses 2 from the cylinder at the
connectors. Use a container to catch oil from
flowing out of the cylinder. Attach caps to the
connectors of the cylinder to protect the
threads of the connectors and to prevent oil
from flowing out of the cylinder when the cylinder
is removed.
7.31
HYDRAULIC SYSTEM
Inspection after disassembly
Sections, spools and return springs Reassembly

(1) Check each sliding surfaces for cracks and To reassemble, follow the reverse of disassembly
defects. Also, check the check-valve seat for sequence and do the following steps:
wear. 1. Clean all parts except O-rings with solvent.
(2) Check the spools for burns and distortion. Also, 2. Apply hydraulic oil to O-rings when installing
check for operating force. them.
177 to 216N 3. Make sure that each spool moves freely.
Spool operating force (18 to 22 kgf)
[40 to 49 lbf]
7.32
HYDRAULIC SYSTEM
Lift Cylinders (Simplex Mast)

Disassembly (No.1)
For mast model A40A Parts marked with * are included in the seal kit.
4 2
*
7
*
5 3
*
206954
Sequence
1 Cylinder head
2 Wiper ring, U-ring, O-ring NOTE
3 Collar
Do not remove bushing 6 from cylinder head 1
4 Piston rod
unless they are defective.
5 U-ring, Backup ring, Bushing
6 Bushing
7 Cylinder tube

Removing holder
To remove the holder from the A70A cylinder, wrap the
cylinder in cloth and hold it with a vice. Remove the
holder using the wrench.
Special tool needed
Wrench 05312-10500
200351
7.33
HYDRAULIC SYSTEM
Disassembly (No.2)
For mast models A45A and A55A Parts marked with * are included in the seal kit.
4
*
1
*
6
7
2
* 5
202986
Sequence
1 Holder, Wiper ring
2 Cylinder head, U-ring, O-ring
3 Collar
4 Piston rod
5 Piston ring, U-ring, Holder, Stopper
6 Bushing Key points for disassembly
7 Cylinder tube Removing holder
Remove the holder from the A45A, A55A cylinder

using the spanner.
NOTE
Do not remove bushing 6 from cylinder head 2
unless they are defective. Spanner width across flats 85 mm (3.35 in.)
7.34
HYDRAULIC SYSTEM

1. Cylinder tube
(1) Check the bore wall for wear, grooving,
scratch marks and rusting.
(2) Check the welds for cracks.
2. Piston rod
(1) Check for deflection in as shown.
(2) Check for surface flaws such as grooving,
scratch marks, rusting and wear. The rod
must be replaced if its threads show a sign of
200319
stripping or any other damage.
3. Packings and rings
Replace all parts contained in the seal kit,
once disturbed.
Reassembly
1 6 5 4 3 2 202976
Key points for reassembly

Sequence
(1) Clean parts completely before reassembly, and
(A45A, A55A)
make sure that parts are free of dust and other
1 Piston rod
particles.
2 Piston ring, U-ring, Holder, Stopper
(2) For reassembly, use new seal kit parts.
3 Collar
(3) Apply oil to the U-ring, piston ring, O-ring, bushing,
4 Cylinder tube
wiper ring and the cylinder bore before reassembly.
5 Cylinder head, bushing, U-ring, O-ring
(4) When holding the cylinder with a vice, be careful
not to deform the cylinder by over-tightening.
(5) Before tightening the cylinder head and the
(A40A) holder, apply liquid gasket (THREEBOND
1 Piston rod #1901) to the threaded sections.
2 Bushing, Backup ring, U-ring
3 Collar Mast Models A45A,
A40A
4 Cylinder tube Item A55A
5 Cylinder head, Wiper ring, U-ring, Tightening torque
Bushing, O-ring of cylinder head or 304 422
holder N·m (31) (43)
(kgf·m) [224] [311]
[lbf·ft]
7.35
HYDRAULIC SYSTEM
Lift Cylinders (Duplex Mast, Triplex Mast)

Disassembly (No.3) — First Lift Cylinders
For mast models B40A thru B55A, C40A thru C55A
*
4
2 *3
*6
5
Parts marked with * are included in
the repair kit.
206955
Sequence Key points for disassembly

1 Plug, Gasket Removing cylinder head
2 Cylinder head To remove the cylinder head, hold the lift chain
3 U-ring, Wiper ring, O-ring, O-ring mounting area with a vice. Remove the cylinder
4 Piston rod head using the wrench. Special tool needed:
5 Check valve, Snap ring
6 Slide ring, Seal ring
05312-10800 (B40A, C40A)
7 Bushing
Wrench 05312-11000
8 Cylinder tube
(B45A, B55A, C45A thru C55A)
NOTE
Do not remove bushing 7 from cylinder head
2 unless they are defective.
7.36
HYDRAULIC SYSTEM
Disassembly (No.4) — Second Lift Cylinders
For mast model B40A Parts marked with * are included in the seal kit.
6
9
5 *4
10
7
8
206957A
Sequence 6 Slide ring, Set screw, Piston

1 Valve, Steel ball 7 Snap ring, Check valve, Spring, Cushion spool
2 Holder 8 Bushing
3 Cylinder head 9 Steel ball, Screw
4 Wiper ring, U-ring, Backup ring, O-ring 10 Cylinder tube
5 Piston rod
NOTE
Do not remove bushing 8 from cylinder head
3 unless they are defective.

Removing holder
To remove the holder, wrap the cylinder tube in
cloth and hold it with a vice. Remove the holder
using the spanner.
Spanner width across flats 65 mm (2.56 in.)
7.37
HYDRAULIC SYSTEM
For mast model B45A, B55A Parts marked with * are included in the seal kit.
6 1
7
5
2
10 9
*4
8
206956
Sequence
1 Valve, Steel ball NOTE
2 Cylinder head Do not remove bushing 9 from cylinder head
3 Spacer 2 unless they are defective.
4 U-ring, Wiper ring, O-ring
5 Piston rod
6 Spacer, Snap ring
7 Slide ring, Set screw, Piston
Removing cylinder head
8 Snap ring, Check valve, Spring, Cushion spool
To remove the cylinder head, hold the mast fitting
9 Bushing
area of the cylinder tube with a vice. Remove the
10 Cylinder tube
cylinder head using the wrench.
Special tool needed
Wrench 05312-10500
7.38
HYDRAULIC SYSTEM
1. Cylinder tube
(1) Check the bore wall for wear, grooving, scratch
marks and rusting.
2. Piston rod
scratch marks, rusting and wear. The rod must
be replaced if its threads show a sign of
200319
Replace all parts contained in the seal kit,
once disturbed.
Reassembly
First Lift Cylinder (B40A thru B55A, C40A thru C55A)
6 7 1 4 3 2
*
*
*
5
206950A
Sequence
1 Piston rod
2 Check valve, Snap ring
3 Slid ring, Seal ring
4 Cylinder tube
5 Cylinder head, Bushing
Install parts 6 to part 5
6 U-ring, Wiper ring, O-ring
7 Plug, Gasket
7.39
HYDRAULIC SYSTEM
Second Lift Cylinders (B40A)
7 8 1 4 3
*
6 5 2 206949A
Sequence
1 Piston rod 5 Cylinder head, Bushing
2 Cushion spool, Spring, Check vlave, 6 Holder
Snap ring Install parts 7 to part 6
3 Piston, Set screw, Slid ring 7 Backup ring, U-ring, Wiper ring, O-ring
4 Cylinder tube 8 Steel ball, Screw
Second Lift Cylinders (B45A, B55A)

9 6 1 5 4 3
*
10 8
7 2
206948A
Sequence
1 Piston rod 6 Spacer
2 Cushion spool, Spring, Check valve, 7 Cylinder head
Snap ring Install parts 8 and 9 to part 7
3 Piston, Set screw, Slid ring 8 Bushing
4 Spacer, Snap ring 9 U-ring, Wiper ring, O-ring
5 Cylinder tube 10 Steel ball, Valve
7.40
HYDRAULIC SYSTEM
particles.
(2) Use new seal kit parts and repair kit parts.
(3) Apply oil to the seal kit parts such as U-ring,
wiper ring, seal ring and the O-ring and to the
slide ring and the bushing before reassembly.
Also apply oil to the cylinder bore before
reassembly.
(4) When holding the cylinder with a vice, be
careful not to deform the cylinder by over-
tightening.
(5) Tighten parts such as the cylinder head,
holder, piston, set screw and the valve to the
specified torque.
(Refer to Service Data.)
holder, apply liquid gasket (THREEBOND
#1901) to the threaded sections.
(7) After reassembling the first lift cylinder, fill the
rod chamber with hydraulic oil. Plug Rod Chamber
Supply hydraulic oil from the plug, and tighten
the plug to the specified torque.
•
B40A, B45A, B55A

C40A C45A, C55A
Amount of 160 to 180 190 to 210
hydraulic oil (9.76 to 10.98) (11.59 to 12.81)
cc (cu. in.) 206950
7.41
HYDRAULIC SYSTEM
Lift Cylinders (Triplex Mast)


For mast model C40A
*
7 *
2
* 1
*
5
6
*
3
4
8
207781
Sequence
1 Cylinder head, bushing NOTE
2 Wiper ring, U-ring, O-ring
3 Spacer Do not remove bushing 1 from cylinder head 1
4 Piston rod unless they are defective.
5 Snap ring, Pin
6 Spring guide, Spring, Cushion spool
7 U-ring, Backup ring, Bushing
8 Cylinder tube
7.42
HYDRAULIC SYSTEM
For mast model C45A, C55A Parts marked with * are included in the seal kit.
7 1
*
5
2
6
207782
Sequence NOTE
2 Cylinder head, U-ring, Bushing, O-ring Do not remove bushing 2 from cylinder head 2
3 Spacer unless they are defective.
4 Piston rod
5 Holder, Stopper, Spring pin
6 Spring guide, Spring, Cushion rod
7 U-ring assembly, Piston ring
8 Cylinder tube
7.43
HYDRAULIC SYSTEM

1. Removing cylinder head or holder
To remove the cylinder head or holder, wrap the
cylinder tube in cloth and hold it with a vice.
200351
2. Remove the cylinder head or holder using the
wrench or the spanner.
Special tool needed (C40A)

Wrench 05312-10500
(C45A, C55A)
Spanner width across flats 85 mm (3.35 in.)

1. Cylinder tube
marks and rusting.
2. Piston rod
be replaced if its threads show a sign of stripping 200319
or any other damage.
Replace all parts contained in the seal kit, once
disturbed.
7.44
HYDRAULIC SYSTEM
Reassembly
Second Lift Cylinders (C40A)
14 13 12 15 1 11 10 5 6 2 3 4 9 8 7
207778A
Sequence
1 Piston rod 5 Spring seat 11 Cylinder tube
Install parts 2 through 9 6 Spring 12 Cylinder head kit
to part 1. 7 Cushion spool Install parts 13 through 15
2 Bushing 8 Pin to part 12.
3 Backup ring 9 Snap ring 13 U-ring
4 U-ring 10 Spacer 14 Wiper ring
15 O-ring
Second Lift Cylinders (C45A, C55A)
17 14 16 13 12 15 1 11 10 4 5 2 3 9 8 7 6
207779A
Sequence
1 Piston rod 6 Cushion rod Install parts 13 through 15
Install parts 2 through 9 7 Spring pin to part 12.
to part 1. 8 Stopper 13 Bushing
2 Piston ring 9 Holder 14 U-ring
3 U-ring assembly 10 Spacer 15 O-ring
4 Spring guide 11 Cylinder tube 16 Holder
5 Spring 12 Cylinder head 17 Wiper ring
7.45
HYDRAULIC SYSTEM

particles.
(2) Use new seal kit parts and repair kit parts.
(3) Apply oil to the seal kit parts such as U-ring,
wiper ring, seal ring and the O-ring and to the
piston ring and the bushing before reassembly.
Also apply oil to the cylinder bore before
reassembly.
(4) When holding the cylinder with a vice, be
careful not to deform the cylinder by over-
tightening.
(5) Tighten parts such as the cylinder head, holder,
piston, set screw and the valve to the specified
torque.
holder, apply liquid gasket (THREEBOND
#1901) to the threaded sections.
7.46
HYDRAULIC SYSTEM
Tilt Cylinders Disassembly
EC35N thru EC55N

7
*
3
6
5
4
*
* *
2
1
13
9
11
10
206953
Sequence NOTE
1 Bolt, Spring washer
2 Socket (1) The figure above apply to cylinder models
Remove 3 to 7 as a subassembly. E7000 thru E12000.
3 Guide bushing (2) Do not disassemble piston 10 unless they
4 Dust seal are defective.
5 Packing (3) Collar 12 is for forward tilt angle of 3
6 Buffer ring degree.
7 O-ring
8 Piston rod
9 Self-lock nut
10 Piston
11 Piston seal
12 Collar
13 Cylinder tube
7.47
HYDRAULIC SYSTEM

Removing guide bushing
To remove the guide bushing, wrap the tilt cylinder
in cloth and hold it with a vice. Remove the guide
bushing using the wrench.
Special tool needed
EC35N thru EC55N

Wrench 05312-10800

200351
1. Cylinder tube
marks and rusting.
2. Piston rod
be replaced if its threads show a sign of
Replace all parts contained in the seal kit, once
disturbed.
200319
A: Standard value
Unit: mm (in.)
Truck Models
EC35N thru EC55N
Items
Inside diameter of cylinder tube 1 A 100 (3.937)
[Guide bushing] A 40 (1.574)
Diameter of piston rod 2
Inside diameter of tilt socket bushing (fitted) 3 A 40 +0.10 +0.004
+0.05 (1.574 +0.002 )
Inside diameter of cylinder tube head bushing

A 50 +0.039
+0 (1.968 +0.0015
+0 )
(fitted) 4
[Guide bushing]
A M105 X 2.0
Thread diameter 5
[Guide bushing]
A 696 ± 69 (71 ± 7) [513 ± 50]
Tightening torque 5 N·m (kgf·m) [lbf·ft]
[Tilt socket]
A M38 X 1.5
Thread diameter 6
Tightening torque Tilt socket bolt 7 A 262 ± 13 (27 ± 1.4) [195 ± 10.1]
N·m (kgf·m) [lbf·ft] Self-locking nut 8 A 588 ± 29 (60 ± 3) [434 ± 21.7]
7.48
HYDRAULIC SYSTEM
5 8
3 6 4
2 1
7
206947
Reassembly
Follow the disassembly sequence in reverse.

(1) Carefully clean all parts to remove any gritty
particle.
(2) Reassemble the cylinder in the reverse
sequence of the disassembling, apply
hydraulic oil to the bore wall of the cylinder
tube, and also to sealing parts — O-rings, U-
rings, wiper rings, nylon heels, piston seals,
dust seals and packings — so that they will
smoothly slide into the bore.
(3) When clamping the cylinder tube in the vise in
order to run the head into the cylinder tube, be 200352
careful not to distort the tube.
(4) Before fitting the piston seal to the tilt-cylinder
piston, squeeze the seal by hand 5 or 6 times
to soften it. Hold the piston steady by clamping
the rod in the vise; apply a small amount of
hydraulic oil to the seal; fit a portion of the seal
to the groove; and push the other portions just
a little at a time into the groove.
200353
7.49
HYDRAULIC SYSTEM
Flow Regulator Valve

Disassembly (No.1)
E7000 thru E12000
2
5 1
4
3
203722
Sequence Cautions for assembly

1 Lock nut, Set bolt (1) Clean parts completely before assembly, and
2 Sleeve, O-ring make sure that parts are free of dust and other
3 Piston, Valve, Spring, Pin and Washer particles.
4 Spring, Shims (2) Be careful to mounting direction of piston 3
5 Guide, O-ring when installing to the flow regulator valve.
6 Body (3) Use set bolt dimension L for assembly as
follows. Measure and check the lowering
speed under rated load.
(1) Check the springs for fatigue.
(2) Check seat and sliding faces of valve and L
piston.
▲
(3) Check the sliding surfaces of the piston and

valve body for damage.
NOTE
Replace the flow regulator valve as an
203708
assembly if any part is defective.
115 liter/min 1.5 mm

EC45N thru EC55N
(30.38 U.S.gal) (0.059 in.)
Control flow rate Dimension L
100 liter/min 3 mm
EC35N thru EC40N
(26.42 U.S.gal) (0.118 in.)
7.50
HYDRAULIC SYSTEM
Adjusting mast tilt angle (Simplex, Duplex)
(1) Place the vehicle on level ground.
(2) Tilt the masts backward to the maximum tilt
position for a mast without tilt cylinder spacers,
then stop the engine.
(3) Measure the backward-tilt angle of the left and
right masts.
(4) Loosen the tightening bolt of tilt cylinder sock-
et, rotate the tilt cylinder rod and adjust the
cylinder stroke until the right and left masts are
207653
tilted at the same angle.
NOTE Lift cylinder stroke adjustment
It is not necessary to adjust the forward tilt (1) Slowly raise the inner mast, and observe the
angle, provided that the backward tilt angle is stopping of piston rod, right and left, at the
properly adjusted on a mast without spacers. moment the inner mast reaches its maximum
lift height.
Item (2) If the top of mast rolls at that moment, it should
be adjusted with shims. Abnormal condition
Simplex
can be detected by a little time lag in stopping
Forward tilt - between right-hand and left-hand piston rods
6°-8°
Backward tilt deg
and rolling of the rod with a longer cylinder
Adjutsting mast tilt angle (Triplex) stroke.
(1) Place the vehicle on level ground.
(2) Raise the forks up so when mast is tilted for-
ward to the maximum tilt position the forks will
not hit the floor.
(3) Measure the forward tilt angle of the left and
right masts.
(4) Loosen the tightening bolt of tilt cylinder sock-
et, rotate the tilt cylinder rod and adjust the tilt 200363
angle.
Adjusting method
(5) Tilt mast backward and then slowly tilt mast
forward, and observe the stopping of piston (1) Raise the inner mast, tie blocks under the
rod, right and left, at the moment the tilt cylin- right and left sides of the mast, and lower the
der reaches its maximum backward tilt. mast until it rests on the blocks.
(6) If right ot left piston rods stops before and mast (2) Remove the stopper bolt at the top of lift
cocks, adjust cylinder rod so that right and left cylinder which stopped first, retract the piston
stops at the same time. rod, and insert shims at the top of piston rod
(7) Slowly tilt mast backward observing the stop- end.
ping point at tilt cylinder spacers.
(8) Add Shims between tilt cylinder socket and
spacer, tighten to specified torque.
Truck Models E7000 thru E12000
Item
Triplex
Forward tilt -
6°-5°
Backward tilt deg 202983
7.51
HYDRAULIC SYSTEM
NOTE (2) Forward tilt by internal leakages

(Leakdown)
To retract the piston rod, move the lift control
(a) Position the mast upright with rated load,
lever to the lowering position to let the oil
raise the forks approx. 50 cm (20 in.), then
escape from the lift cylinder.
stop the engine.
(b) Measure the amount of tilt cylinder
(3) Extend the piston rod, and tighten the cylinder extension after 15 minutes. mm(in.)
stopper bolt. Remove the blocks from under
the inner mast.
Truck Models
(4) Slowly lower the inner mast to the bottom to EC35N thru EC55N
ensure the piston rods move smoothly. Item
Forward tilt test 30
(rated load) (1.18)
Shims
206974
Tests
(1) Descent by internal leakages (Leakdown)
206985
(a) Position the mast upright with rated load,
raise the forks approx. 1 m [40 in.]. Turn off
key.
(b) Draw a reference line on a mast, and
measure the distance of fork lowering after
15 minutes. mm(in.)
Truck Models
EC35N thru EC55N
Item
Load descent test 50
(rated load) (1.97)
206984
7.52
HYDRAULIC SYSTEM
Hydraulic Tank
Hydraulic Oil
1. Check the hydraulic oil in the tank for cleanli- NOTE
ness. Oil appearing dirty or whitish (showing A general rule: in any machine, regardless of
more or less emulsification) must be changed. the mast-and-attachment combination, the oil
2. Refill capacities in the amount of oil required. level should not be above the “H” mark on the
level gauge when the mast is all the way down.
! WARNING
Remove the hydraulic tank filler cap only
after the truck has been stopped and the Suction Strainer
fill cap is cool enough to remove with your
Check the suction strainer for clogging or damage.
bare hand.
Return Filter
Hydraulic Tank Refill Capacities Check the return filter for clogging or damage.
EC35N thru EC55N
45 (12)
Unit: liter (U.S. gal)
7.53
HYDRAULIC SYSTEM
Control Valve
External Leakage
1. Check for oil leaks from the joint between 2. Quickly disconnect the oil return hose and
adjacent valve housings sealed by O-ring. start collecting the oil coming out of the valve
2. Check for oil leaks from the scrapers sealed from the oil return port A.
by O-rings.
3. Check for oil leaks from the screw
connections.
Internal Leakage
It is not practical to check the control valve alone
for internal leakage. The correct way to check the
control valve in place under normal operating
conditions follows.
The internal leakage to be checked includes leak-
age occurring at the lift spool, tilt spool, tilt lock 333333
valve, and check valves.
[Test oil temperature: approx. 50°C (122°F)]
Amount of oil collected 500 cc (30.5 cu. in.)
1. Pick up a load equal to the rated capacity. Lift
for 15 minutes maximum
it approximately 1 meter (3 ft) high. Tilt the
mast forward 3° - 4° and turn off key.
3. If the tilt cylinders or lift cylinders drift (the
mast tilts forward or the fork lowers) exces-
3° - 4°
sively even though the amount of oil collected
in 15 minutes is less than 500 cc (30.5 cu. in.),
measure the internal leakage of each cylinder.
(The measurement is the assembly standard
and not the service limit.)
approx.
1 meter
(3 feet)
203521A
7.54
HYDRAULIC SYSTEM
Main Relief Valve Adjustment Auxiliary Relief Valve Adjustment

1. Screw in special tool (6V3965) pressure port 1. Screw in special tool (6V3965) pressure port
with o-ring into gauge port on valve(B). with o-ring into delivery hose port on valve(B).
2. Attach a pressure gauge capable of measur- 2. Attach a pressure gauge capable of measur-
ing up to 250 kgf•cm2 (3555 psi) [25,000 kPa] ing up to 250 kgf•cm2 (3555 psi) [25,000 kPa]
to the pressure port. to the pressure port.
3. Start the truck and move the control lever to 3. Start the truck and move the Auxiliary 1 con-
the backward tilt position and hold. If the relief trol lever to the far right position and hold. If
pressure reading is the relief pressure reading is
197 ± 3 kgf/cm2 158 ± 5 kgf/cm2
(2850 ± 50 psi) (2250 ± 71 psi)
[19,650 ± 34 kPa] [15,513 ± 490 kPa]
when the tilt cylinders reach the end of their the auxiliary relief valve setting is correct.
stroke, the main relief valve setting is correct.
B 44444b
333333
4. If the setting is incorrect, loosen the lock nut
4. If the setting is incorrect, loosen the lock nut
of the adjusting screw and, while observing
of the adjusting screw and, while observing
the pressure gauge reading, slowly turn the
the pressure gauge reading, slowly turn the
adjusting screw in either direction until the
adjusting screw in either direction until the
gauge indicates the prescribed set value.
gauge indicates the prescribed set value.
5. While holding the adjusting screw, tighten the
5. While holding the adjusting screw, tighten the
lock nut to secure the adjusting screw.
lock nut to secure the adjusting screw.
6. After securing the adjusting screw, recheck
6. After securing the adjusting screw, recheck
the setting.
the setting.
158 ± 5 kgf/cm2
197 ± 3 kgf/cm2 Auxiliary relief valve setting (2250 ± 71 psi)
Main relief valve setting (2850 ± 50 psi) [15,513 ± 490 kPa]
[19,650 ± 34 kPa]
7.55
HYDRAULIC SYSTEM
Mast Tilt Angle Adjustment

1. Place machine in a horizontal position.
NOTE
2. Tilt the mast all the way backward, and stop It is not necessary to adjust the forward tilt
the truck. angle, provided that the backward tilt angle
3. Measure the tilt angle of the mast at both sides. is properly adjusted.
4. To adjust the tilt angle, loosen bolt A of the tilt
cylinder socket, and adjust the cylinder stroke
by turning the rod on either cylinder so that Forward / Backward Triplex 5° – 6°
there is no difference in stroke between the
Tilt Angle Simplex 6° – 8°
cylinders.
Lift Cylinder Stroke Adjustment

1. Slowly raise the inner mast and check the
stopping manner of the left and right piston
rods at the moment the inner mast reaches
its maximum lift height.
207054
Tightening torque 127 to 152

for tilt cylinder (13 to 15.5)
socket bolt [94 to 112]
204698
2. If the top of the mast rocks at that moment, it

should be adjusted with shims. Abnormal con-
ditions will appear as a time lag in stopping
between right- and left-hand piston rods and
rocking of the rod with a longer cylinder
stroke.
7.56
MAST AND FORKS
CHAPTER 8: MAST AND FORKS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Description ......................................................................... 8.2
Dual-stage Panoramic Mast (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Triple-stage Full Free Panoramic Mast (Triplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
Dual-stage Panoramic Mast (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.12
Dual-stage Full Free Panoramic Mast (Duplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.16
Triple-stage Full Free Panoramic Mast (Triplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.21
Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.25
Chain, Chain Wheel Support and Chain Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
Chain Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.27
Clearance Adjustment on Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30
Mast Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.32
Main Roller Shim Replacement (Simplex Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34
Mast Strip Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.34
Tilt Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.38
Lift Cylinder Stroke Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.39
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.40
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.41
MAST AND FORKS
Specifications
Truck Models EC35N thru EC40N EC45N thru EC55N
Items
Mast type CJ type
Mast dimension mm (in.) 118x28x24x13 130x30x26x15
Outer
(flange internal width x (4.6x1.1x0.9x0.5) (5.1x1.2x1.0x0.6)
flange back-side thickness x
flange front-side thickness x 118x24x24x12 130x26x26x13
Inner (4.6x0.9x0.9x0.47) (5.1x1.0x1.0x0.6)
web thickness)
Type Ball bearing
Cargo Gear
Main roller Diameter x width

118x32 (4.65x1.26) 130x34 (5.12x1.34))
mm (in.)
Type Grease needle
Side roller Diameter x width
52x36 (2.05x1.42) 52x36 (2.05x1.42)
mm (in.)
Lift chain type BL834 BL1034
Fork (length x width x thickness) 1220x150x50 1220x150x60
mm (in.) (48x6x2) (48x6x2.4)
Fork adjustment interval
1052 (41.4) 1052 (41.4)
(external width) mm (in.)
8.1
MAST AND FORKS
Description
Simplex Mast (A40A, A45A, A55A)
9
5
4 •
14
1
2
6
10
13
•
207795
12 11
12 11 10 9 8
D
Section A-A Section B-B Section C-C Section D-D

206696
Sequence
1 Outer mast 6 Backrest 11 Main roller (inner mast lower)
2 Inner mast 7 Fork 12 Main roller (lift bracket lower)
3 Lift bracket 8 Mast strip 13 Side roller
4 Lift cylinder 9 Main roller (mast upper) 14 Chain wheel
5 Lift chain 10 Main roller (lift bracket upper)
8.2
MAST AND FORKS
Duplex Mast (B40A, B45A, B55A)
C C
5
2
1
6
B B 3
8
A A
207794
15 16 14 13 11 12
Section A-A Section B-B Section C-C 10
9 Side roller detail

3
206973
Sequence
1 Outer mast 7 Backrest 13 Main roller (outer mast upper)
2 Inner mast 8 Fork 14 Main roller (lift bracket middle)
3 Lift bracket 9 Side roller bracket 15 Main roller (lift bracket lower)
4 First lift cylinder 10 Side roller 16 Main roller (outer mast lower)
5 Second lift cylinder 11 Mast strip
6 Lift chain 12 Main roller (lift bracket upper)
8.3
MAST AND FORKS
Triplex Mast (C40A, C45A, C55A)
C C
3
2
1
7
B B 4
9
A A
207791
12 13
16
11
17 18 19 14 15 10
4
Section A-A Section B-B Section C-C
207792
Sequence
1 Outer mast 7 Lift chain 13 Main roller (lift bracket upper)
2 Middle mast 8 Backrest 14 Main roller (outer mast upper)
3 Inner mast 9 Fork 15 Main roller (middle mast upper)
4 Lift bracket 10 Side roller bracket 16 Main roller (lift bracket middle)
5 First lift cylinder 11 Side roller 17 Main roller (lift bracket lower)
6 Second lift cylinder 12 Mast strip 18 Main roller (middle mast lower)
19 Main roller (outer mast lower)
8.4
MAST AND FORKS
Operation of Dual-stage Full Free Panoramic Mast (Duplex Mast)
Inner Mast
First Lift Cylinder
Second Lift Cylinder
Free-lift
height Outer Mast
Forks on the ground Maximum free lift Maximum Lift 203598
Operation of Triple-stage Full Free Panoramic Mast (Triplex Mast)
First Lift Chain
Inner Mast
First Lift Cylinder
Middle Mast
Second Lift Chain
Second Lift Cylinder
Free-lift Outer Mast

height
Forks on the ground Maximum free lift Maximum lift

203600
8.5
MAST AND FORKS
Removal and Installation

Mast and Lift Bracket Assembly
6 5
1
206697A
Sequence
1 Nuts
2 Forks, Lift bracket
3 Tilt socket pins
4 High-pressure hose for lift cylinders
5 Mast-support bearing cap
6 Mast-support bushing
Suggestions
1. Lift bracket removal

(1) Tilt the mast forward, and lower the inner
mast to the bottom. Slacken the lift chains, and
remove the nuts from the anchor bolts.
(2) Tilt the mast back to vertical position. Raise
the inner mast until the lift bracket becomes
free. Then, back the truck away, from the
lift bracket and fork assembly. 207084
8.6
MAST AND FORKS
2. Removing lift cylinder high pressure hoses

Place the mast in the bottom position, discon-
nect the hoses at the flow regulator valve.
3. Removing tilt cylinders

(1) Hitch a sling to the upper cross-member of the
outer and inner masts, then lift with a crane.
CAUTION
Be sure to use a hoist having a capacity
enough to support the mast assembly.
206939
(2) Remove the tilt socket pins, and separate the

masts from the tilt cylinders.
(3) Start the engine, and pull back the tilt lever to
retract the tilt cylinder rods.
(4) Disconnect the high-pressure hose for lift
cylinders.
206940
4. Removing mast support bearing caps

(1) Mark the bearing caps to ensure the correct
reassembling before removing them.
(2) Remove the cap bolts and lift off the mast
assembly. Lay it down flat on a level floor.
NOTE
Lay the mast assembly on a floor large
enough to disassemble the parts.
206941
8.7
MAST AND FORKS
Installation
To install, follow the removal sequence in

6
7
1. Procedure for mounting mast support
bushings 7 and caps 6.
(1) Apply grease to the inner surfaces of caps
and mast support bushings.
(2) Install mast support bushings 7 and caps 6,
making sure that the sides with larger
Apply grease
chamfered area face toward the center of
Chamfered faces
the vehicle.
(3) Be sure to tighten the support tightening 203712
bolts securely.
Model
A40A thru A55A
Item
Bolt tightening torque
290 (29.6) [214]
2. Adjust the chain tensions.

(Refer to the Inspection and Adjustment
section.) Anchor bolt
Tighten the nuts to the specified torque.
➁ Upper nut
Tightening torque
Unit: N·m (kgf·m) [lbf·ft]
Model A45A, A55A, ➂ Double nut (upper)

A40A
Item ➀ Double nut (lower)
Upper nut ➁ 102709
Double nut 210 (21.4) [155] 290 (29.6) [214]
(lower) ➀
3. Air bleeding of lift cylinders

Raise and lower the lift bracket with full
stroke several times to bleed the cylinder.
4. After proper operation is confirmed, check

the oil level.
8.8
MAST AND FORKS
Removal and Installation
Mast and lift bracket assembly
The following describes the procedures for removing and reinstalling the mast assembly. Note that the triple-
stage full free panoramic mast (Triplex Mast) is used as an example.
Dual-stage Full Free Panoramic Mast and Triple-stage Full Free Panoramic Mast
(Duplex and Triplex Mast)
1 4
6
5
2
207800
Sequence
1 Nut
2 Fork, Lift bracket assembly
3 Tilt socket pin, Collar, Washer, Bolt
4 High-pressure hose for lift cylinders
5 Mast support bearing cap
6 Mast support bushing
Suggestions
1. Removing lift bracket assembly 2
(1) Lower lift bracket assembly 2, and place wood 1
blocks under the assembly. Tilt the mast for-
ward, lower the inner mast to the bottom, then
remove nuts 1 from the anchor bolts of the first
lift chains. 207786
8.9
MAST AND FORKS
(2) Position the mast upright. Raise the inner mast

until main rollers 8 of the lift bracket become
free. Then, slowly move the vehicle in reverse
to separate from lift bracket 2.
2. Separating mast and tilt cylinders

(1) Lower the inner mast. 8
Hitch a sling to the upper cross-member of the
2
outer, middle and inner masts, then lift with a
crane.
201735
CAUTION
Be sure to use a hoist having a capacity
enough to support the mast assembly.
207796
(2) Place wood blocks under the tilt cylinder

mounting sections, and remove pins. Pull back
the tilt lever to retract the tilt cylinder rods.
(3) Disconnect high-pressure hose 5 for lift
cylinders.
Tilt socket pin

3. Removing mast support caps 6 207798
(1) Mark caps 6 to ensure the caps are reinstalled
in original positions during reassembly.
(2) Remove cap mounting bolts. Dismount the
mast assembly from vehicle in the suspended
condition. With the lift bracket side facing up,
place the mast assembly horizontally on
wooden blocks on the level ground.
207799
8.10
MAST AND FORKS
Installation
6
To install, follow the removal sequence in reverse, 7
and service as follows.
1. Procedure for installing mast support bush-

ings 7 and caps 6
(1) Apply grease to the inner surfaces of caps
and mast support bushings.
(2) Install mast support bushings 7 and caps 6, Apply grease
Chamfered faces
making sure that the sides with larger
chamfered area face toward the center of the 203712
vehicle.
(3) Be sure to tighten the support tightening bolts
securely.
Model B40A thru B55A

Item C40A thru C55A
Bolt tightening
torque N·m (29.6) [214]
(kgf·m) [lbf·ft]
2. Adjust the chain tensions.

(Refer to the Inspection and Adjustment sec-
tion.) Anchor bolt
Tighten the nuts to the specified torque.
➁ Upper nut
Tightening torque
Model B40A
Items C40A ➂ Double nut (upper)
Upper nut ➁ ➀ Double nut (lower)
Double nut 210 (21.4) [155] 102709
(lower) ➀
3. Bleeding lift cylinders

In the dual-stage full free panoramic mast, only
the second lift cylinders are provided with air
bleeding valves.
The first lift cylinder does not require air
bleeding since it is an internal drain type
cylinder.
In the triple-stage full free panoramic mast,
start the engine, raise and lower the lift brack-
et with several strokes to bleed the cylinder.
4. After proper operation is confirmed, check the

oil level
8.11
MAST AND FORKS
Disassembly and Reassembly

Disassembly
12 10
15
3
11
16
9 13 10
2
8 17
5
7
2 16
6
14
1
4
206942A
Sequence Suggestions
1 Nuts 1. Removing mast strips and main rollers
2 Forks, Lift bracket Remove bolts 10, 11 to free lift cylinder 16.
3 Backrest Displace the tops of the two lift cylinders from
4 Main roller, Shims inner mast 15. Slide inner mast 15 toward the
5 Main roller, Snap ring bottom of outer mast 17, and remove main
6 Side roller, Brackets, Shims rollers 13, 14 and mast strips 12.
7 Lift hose (high pressure), Rubber hose,
T-joint, Down safety valve
8 Hose (low pressure)
9 Snap ring, Chain wheel
10 Cylinder clamps, Seats, Shims, Cushion,
Collar, Bolts
11 Bolt, Shims
12 Mast strip, Shims
13 Main roller, Shims
14 Main roller, Shims
15 Inner mast
16 Lift cylinders
17 Outer mast
8.12
MAST AND FORKS
2. Inner mast removal

After removing the main rollers, hitch a sling to
the inner mast crossmember and slide the
inner mast to the upper side of the outer mast
to clear the outer mast roller shafts. Hitch a
sling to the inner mast again and remove it
from the outer mast.
207801
1. Mast
(1) Check each roller for wear, binding or other
defects.
(2) Check each roller on rolling surface for pitting
or other defects.
(3) Check the mast member and the welded
joints of cross members, shafts and supports
for cracks.
(4) Check the mast support bushings for wear or
other defects. 207802
2. Lift bracket
(1) Check the main rollers and side rollers for
smooth rotation. Inspect each roller for wear
and cracks.
(2) Check the welded portions of the bracket for
cracks.
(3) Check the finger bar for bend or distortion.
A: Assembly standard
5 mm (0.2 in.)
Distortion of finger bar A
maximum
207091
8.13
MAST AND FORKS
3. Lift chains, chain wheels and chain wheel

supports
(1) Measure the length of each chain to make
sure that two chains are equal in length. Also
check the chains for wear, indication of break-
age, link binding and twist.
(2) Check each chain anchor bolt for cracks or
defects on thread.
(3) Check each chain wheel support and chain
wheel for crack or wear. Check that the
wheels rotate smoothly.
Length of lift chain (per 20 links)
B: Repair or service limit Unit: mm (in.)
A45A
A40A
A55A
A 508 (20) 635 (25)
B 523 (20.6) 654 (25.7)
4. Mast strips
Check the mast strips for damage, wear or
distortion.
Reassembly
To reassemble, follow the reverse of disassembly

procedure, and service as follows:
1. Longitudinal clearance adjustment between
mast and lift bracket Clearance
Rollers for mast and lift bracket are available
in three sizes (diameters) for selective use.
Select the size that will provide a longitudinal
clearance of 1 mm (0.04 in.) or less. Clearance
Roller sizes
Unit: mm (in.)
Diam of A45A Lower roller
A40A Upper/middle roller
main roller A55A
207806
S 117 (4.6) 129 (5.08)
M 118 (4.65) 130 (5.12)
L 119 (4.68) 131 (5.16)
8.14
MAST AND FORKS
2. Cylinder clamps
Install each lift cylinder in place (in vertical
position) by fitting to the support, and see if there
is any clearance between the outer mast and
cylinder. Reduce the clearance, if any, to zero by
shimming. Shims
207003
3. Mast supports
(1) Apply grease to the inside surfaces and Mast cap
grooves of the caps. Bushing
(2) Install mast support bushings and caps placing
the chamfered faces inward.
Apply grease
Chamfered faces
203712
4. Precautions for installing chain anchor kit

2
Be careful not to install the center plate in the
position for link plate. (For C40A only)
3
Stamped mark
4
207808
1 Link plate (mark is stamped)

2 Center plate (no mark)
3 Link
4 Split pin
8.15
MAST AND FORKS
Dual-stage Full Free Panoramic Mast (Duplex Mast)

Disassembly
14
15 13
11
12 18
2
16 2
5
6 9 11
7 11 19 10
3 22
3
7 16
18 1 17
22
4
9
14 21 20 18
8
13
207807
Sequence
1 Hose clamp, Bolt, Washer 12 Mast strip, Shims
2 High-pressure hose (First lift cylinder) 13 Stopper, Shim, Bolt, Washer
3 Bolt, Washer, Shims 14 Main roller, Shims
4 First lift cylinder 15 Inner mast
5 Chain guard, Bolt 16 Second lift cylinder
6 Chain wheel, Snap ring 17 Down safety valve, O-ring
7 Chain wheel support, Bolt, Washer 18 Elbows, O-rings
8 Down safety valve, O-ring 19 Cylinder bracket
9 High-pressure hose (Second lift cylinder), 20 Mast cap, Bolt, Washer
Connector 21 Bushing
10 Cushion, Collar, Shim, Bolt, Washer, Clamp 22 Outer mast, Grease nipple
11 Bolt, Washer, Shims
NOTE
The lift bracket disassembly procedure is the
same as the dual-stage panoramic mast.
8.16
MAST AND FORKS
Preparation
With the lift bracket facing up, place the mast

horizontally on wood blocks. Place a wood block
as a wedge to prevent the inner and middle masts 4
from sliding.
Suggestions
1. Removing first lift cylinder 4

(1) Remove retaining bolts 3 from the first lift
cylinder.
(2) Hitch slings on first lift cylinder 4, and gently 3
remove the cylinder. 207006
Use two slings. Wind or tie slings securely to
prevent slipping.
2. Removing main rollers 14 and mast strips 12

(1) Remove clamp bolts from the second lift cylin-
12
ders.
(2) Remove bolts from the upper rod sections of
the second lift cylinders, and place the
cylinders on the outer mast.
(3) Check the number of shims and the shim 14
thickness at the rod end sections.
(4) Move the inner mast down, then remove main
rollers 14, mast strips and shims 12. 14
3. Removing inner mast 15

207007
Using ropes, lift and remove inner mast 15,
steering it clear of the roller shaft sections of outer
mast 22.
Follow the same inspection procedure as for the

dual-stage panoramic mast.
22
15
207008
8.17
MAST AND FORKS
Reassembly
Follow the disassembly sequence in reverse. Be
Inner mast
careful with the following key point. Outer mast
1. Front-to-back clearance between the mast • •
and lift bracket
Select and install roller so that the clearance is
1 mm (0.04 in.) or less. Lift
Bracket
Roller size Unit: mm (in.)
•
Mast Models B45A
B40A
Items B55A
117 129
S
(4.60) (5.08)
118 130 207080
M
(4.64) (5.12)
119 131
L
(4.68) (5.16)
2. Left-to-right clearance of the inner mast

(1) Raise the inner mast to the maximum lift
position. Inner mast
Press one side of the inner mast against •
Shims b
the outer mast and measure the clearance
between the main roller and the outer mast
on the other side. The clearance is
adequate if the measurement is in the • Outer mast
specified range.
Left-to-right Shims a
clearance between 0.1 to 0.5
A
outer mast and (0.004 to 0.020) 206688
inner mast mm (in.)
Shims a
Shims b
(2) If the clearance is out of the specified
range, adjust the clearance by increasing
and decreasing shim thicknesses a and b.
For example, to shift the clearance of 0.5
mm (0.020 in.) outward, insert inner shims
a by 0.5 mm (0.020 in.), and remove outer
shims b by 0.5 mm (0.020 in.) and tighten
bolts.
206686
8.18
MAST AND FORKS
3. Mast strip
At the highest raising position, adjust the Shims
clearance between the outer mast roller and the
rolling surface of inner mast to the specified range
with increasing and decreasing shims.
0.1 to 0.5
A mm (in.)
(0.004 to 0.020)
207004
4. Clearance of lift bracket

(1) Measure the front-to-back clearance of
the lift bracket main roller. The clearance
is adequate if the measurement is in the
specified range.
Front-to-back
clearance when in 0.1 to 1.0
A
the entire lifting (0.004 to 0.04)
range mm (in.)
If the clearance is not adequate, replace
the main roller with an oversize main
roller. Lift bracket Inner mast
(2) Left-to-right clearance of lift bracket •

Raise the lift bracket to the maximum lift •
position. Tilt the lift bracket in the inner
mast and measure the clearance between
the main roller and side roller. The
clearance is adequate if the measurement
is in the standard range.
206687A
Left-to-right
clearance at the 0.1 to 0.5
A
highest raising (0.004 to 0.020)
height mm (in.)
Shims
(3) If the left-to-right clearance is not adequate,
adjust the clearance by increasing shim Roller
thickness at the side roller.
Bracket
206689
8.19
MAST AND FORKS
(4) If the left-to-right clearance of the main

roller is not adequate, adjust the clear-
ance by increasing and decreasing shims
a and b, following the adjustment proce-
dure for main roller clearance between
outer mast and inner mast.
NOTE
Use the main roller at the upper end of the lift
bracket to ensure the front-to-back clearance.
Use side rollers to ensure the left-to-right
clearance.
5. Installing lift cylinder

To prevent bend force on the lift cylinder, install lift
cylinder vertically to the mast when the mast is at
the lowest position If any defect is found, adjust
Shims
with shims.
207003
6. Cautions for assembling chain anchor kit

Never assemble the center plate to the assem-
bling position of link plate.
(2)
(1) Link plate (with stamp on surface) (3)
(2) Center plate (no stamp on surface)
(3) Link
(4) Split pin
(1)
(4)
Stamp
200383
7. Installing first lift cylinder

Install the first lift cylinder of duplex mast so that
the lift cylinder is vertical to the mast when the lift
20 mm (0.79 in.)
cylinder rod is at the lowest position.

Make sure that the cylinder does not tilt forward
but tilts backward at fitting B against A by 0 to 0.5 Shims
mm (0 to 0.02 in.). Use shims for adjustment.
A 201752
8.20
MAST AND FORKS
Triple-stage Full Free Panoramic Mast (Triplex Mast)

Disassembly
18
17
11
24
1
9 1
27
29 27
25
12 23
1
12
26
21
7
8 14 19 20
6 10
28
8 19
7 28 22
2 31 19 21
16
5 13
13
4 3 15
30
207810
Sequence
1 Hose for first lift cylinder, Clamp, Bolt, 16 Lift chain (for second lift cylinder)
Washer 17 Chain guard, Bolt
2 Bolt, Washer 18 Snap ring, Chain wheel
3 Shims 19 Hose, Band
4 First lift cylinder 20 Joint, Connector, Bolt, Washer
5 Stopper bolt, Washer 21 Hose, Clamp
6 Chain wheel support 22 Bolt, Seat, Cushion, Collar
7 Chain guard, Plug 23 Cushion, Shims, Bracket
8 Snap ring, Chain wheel 24 Bolt, Washer, Shims
9 Pulley bracket, Pulley, Bar, Bolt 25 Second lift cylinder
10 Nut (chain for second lift cylinder) 26 Mast strip, Shims
11 Mast strip, Shims 27 Main roller, Shims
12 Main roller, Shims 28 Main roller, Shims
13 Main roller, Shims 29 Middle mast
14 Inner mast 30 Cap, Bolt, Washer
15 Nuts 31 Outer mast, Grease nipple
8.21
MAST AND FORKS
NOTE
The lift bracket disassembly procedure is the
same as for the dual-stage full free panoramic
mast.
Preparation
With the lift bracket facing up, place the mast hor-
izontally on wood blocks. Place a wood block as a
wedge to prevent the inner and middle masts from
sliding.
4
Suggestions
1. Removing first lift cylinder 4

(1) Remove retaining bolts from the first lift cylin-
der.
(2) Hitch slings on lift cylinder 4, and gently
remove the cylinder.
Use two slings. Wind or tie slings securely to
prevent slipping. 207811
14
13
2. Removing inner mast and main rollers
11
Lower inner mast 14 until the main rollers can be
removed. Remove main rollers 12, 13 and mast
strips 11.
12
207812
3. Removing inner mast

Using slings, lift and remove the inner mast,
steering it clear of the roller shaft sections of the
middle mast.
14 207813
8.22
MAST AND FORKS
4. Removing main rollers 26, 27 from middle

28
mast 28 and outer mast 30 Remove the bolts
that are holding second lift cylinders 24. Place 27
the cylinder rod ends on the outer mast. 24
Lower middle mast 28 until main rollers 26, 27
can be removed. Then, remove the main
rollers.
30
26 207814
Follow the same inspection procedure as for the

dual-stage full free panoramic mast.
Reassembly
To reinstall, follow the removal sequence in

1. Front-to-back clearance between the mast

and lift bracket
Select and install roller so that the clearance
Inner Mast Middle Mast
is 1 mm (0.04 in.) or less.
Roller size Unit: mm (in.)
Mast Models C45A
C40A
Items C55A
Lift
117 129 Bracket
S
(4.60) (5.08)
118 130
M
(4.64) (5.12)
119 131
L
(4.68) (5.16)
Outer Mast
207815
8.23
MAST AND FORKS
2. Left-to-right clearance of the inner mast

(1) Raise the inner mast to the maximum lift
Inner Mast
position.
Press one side of the inner mast against
Shims b
the outer mast and measure the
clearance between the main roller and the
outer mast on the other side. The
clearance is adequate if the measurement
is in the specified range.
Shims a
Left-to-right
Outer Mast
clearance between 0.1 to 0.5 Middle Mast
A
outer mast and (0.004 to 0.020) 207816
inner mast mm (in.)
(2) If the clearance is out of the specified

range, adjust the clearance by increasing
and decreasing shim thicknesses a and b.
Shims a
For example, to shift the clearance of 0.5
mm (0.020 in.) outward, insert inner shims Shims b
a by 0.5 mm (0.020 in.), and remove outer
shims b by 0.5 mm (0.020 in.) and tighten
bolts.
For the items below follow the same reassem-

bly procedures as for the dual-stage full free
panoramic mast.
207817
3. Mast strip
4. Clearance of lift bracket
5. Installing lift cylinder
6. Cautions for assembling chain anchor kit
7. Installing first lift cylinder
8.24
MAST AND FORKS

Forks
1. Carefully inspect the forks for cracks. Special
attention should be given to the heel section
A, all weld areas and mounting brackets B.
Forks with cracks should be removed from
service.
Magnetic particle inspection is generally pre- B
ferred due to its sensitivity and the ease of
interpreting the results. A
101628
2. Check the difference in height of one fork tip

to the other when mounted on the fork carrier.
A difference in fork tip height can result in
uneven support of the load and cause prob-
lems when loaded.
The maximum allowable difference in fork tip C
elevation C is 5 mm (0.20 in.) for pallet forks.
Replace one or both forks when the difference
in fork tip height exceeds the maximum allow-
able difference. 101629
3. Check the fork blade D. The fork should be

withdrawn from service if the thickness is
reduced to less than the allowable thickness.
Fork blade length may also be reduced by
wear, especially on tapered forks and platens.
Withdraw the forks from service when the D
blade length is no longer adequate for the
load size.
A: Assembly standard B: Repair or
Service limit 101630
Truck Models EC35N

thru EC55N
Item EC45N
A 50 60
Fork thickness (2) (2.4)
mm (in) B 45 51
(1.77) (2.00)
8.25
MAST AND FORKS
Chain, Chain Wheel Support and Chain Wheel
(1) Check the right and left chains for uneven

length, wear, adhesion or torsion.
Lift the forks high enough to put their full
weight on the cariage and chains.
Check to be sure the lift chains have equal
tension.
(2) Check the chain anchor bolt for cracks or 20 links
damaged thread.
(3) Check the chain wheel support and the chain
wheel for cracks, wear or adhesion.
201768
NOTE
To lubricate lift chains, molybdenum disulfide
oil (spray type) is recommended since it is
easy to use and provides long lubrication.
Super chain guard oil: 9101M-00150
A: Assembly standard B: Repair or service limit

Mast model A40A A55A B55A
Item B40A
Chain extension A 508 (20) 635 (25)

mm (in.) /20 links B 523 (20.6) 654 (25.7)
8.26
MAST AND FORKS
Chain Tension Adjustment

Dual-stage panoramic mast (Simplex Mast) Tightening Torque
! WARNING Models A40A A45A thru A55A
Turn the key switch to the O (OFF) position Items
before making the inspection or adjustment
of lift chains, anchor bolts and nuts. Place Upper nut ➁
blocks below the forks when they are lifted.
210 (21.4) [155] 290 (29.6) [21.4]
Double nut
1. Inspection of chain tension (lower) ➀
(1) Place the mast vertical on a level ground,
then lower the forks to the ground. Check
that the lift cylinders are fully retracted.
(2) Raise the forks approx. 100 mm from the
ground. Anchor Bolt
(3) Turn the key to the O (OFF) position.
(4) Place blocks approx. 90 mm high below
the forks. ➁ Upper Nut
(5) Push the chains at the middle point
between the chain wheel and chains fixed
end on the lift bracket. Check the right
and left chains for even tightness. ➂ Double Nut (upper)
2. Adjustment of right and left chain balance ➀ Double Nut (lower)
(1) Remove the blocks below the forks.
Turn the key to I (ON) position. 102709
(2) Lower the forks to the ground and tilt for-
ward until the tips come in contact with
the ground.
The chains are now slack to facilitate the
adjustment.
(4) Loosen double nut (lower) ➀, then upper
nut ➁.
(5) Turn double nut (upper) ➂ to adjust the
chain tension.
(6) Turn the key to the I (ON) position, and
place the mast vertical again.
(7) Repeat (2) through (5) of procedure 1. to 102708
check the chain tension.
3. Tightening of nuts after adjustment
(1) Hold the anchor bolt at two flats with a
wrench so as not to twist the chain, then
tighten the upper nut ➁ to the specified
torque.
(2) Hold the double nut (upper) ➂ with a
wrench and tighten double nut (lower) ➀
to the specified torque.
8.27
MAST AND FORKS
Dual-stage Full Free Panoramic mast

(Duplex Mast)
! WARNING
Turn the key switch to the O (OFF) position
before making the inspection or adjustment
of lift chains, anchor bolts and nuts. Place
blocks below the forks when they are lifted.
1. Inspection of chain tension

ground.
the forks.
between the chain wheel and chains fixed 207633
end on the lift bracket. Check the right
and left chains for even tightness.
2. Adjustment of right and left chain balance
Turn the key to I (ON) position.
ward until the tips come in contact with
the ground.
The chains are now slack to facilitate the
adjustment.
(4) Fix anchor bolts on the lift bracket.
(5) Turn double nut (upper) ➂ on the lift cylin-
der to adjust the chain tension. 102708
(7) Repeat (2) through (5) of procedure 1. to
3. Tightening of nuts after adjustment
tighten upper nut ➁ to the specified torque.
(2) Hold double nut (upper) ➂ with a wrench
and tighten double nut (lower) ➀ to the
specified torque.
4. When the lift cylinders are fully extended or
retracted, check the protrusion of each lift 40 % or less
bracket main roller to be 40 % of the roller
diameter or less. 207818
8.28
MAST AND FORKS
Triple-stage Full Free Panoramic mast
(Triplex Mast)
! WARNING
Turn the key switch to the O (OFF) position
before making the inspection or adjustment of
lift chains, anchor bolts and nuts. Place blocks
below the forks when they are lifted.
1. Inspection of chain tension

ground.
the forks. 207635
between the chain wheel and chain fixed
end on the lift bracket. Check the right and
left chains for even tightness. Adjust the
primary and secondary chains (four
chains).
2. Adjustment of right and left chain balance
Turn the key to I (ON) position.
ward until the tips come in contact with the
ground. The chains are now slack to facili-
tate the adjustment.
(4) Fix anchor bolts on the lift bracket (primary
chains) and under the inner masts (sec-
ondary chains).
(5) Turn double nut (upper) ➂ on the lift cylin-
der to adjust the chain tension. When the
secondary chains are replaced, adjust 102708
their tension relatively tight to reduce the
risk of interference with the piping pulleys.
(7) Repeat (2) through (5) the procedure 1. to
3. Tightening of nuts after the adjustment
tighten upper nut ➁ to the specified torque.
(2) Hold double nut (upper) ➂ with a wrench
and tighten double nut (lower) ➀ to the
specified torque.
4. When the lift cylinders are fully extended or
retracted, check the protrusion of each lift 40% or less
bracket main roller to be 40 % of the roller 207634
diameter or less.
8.29
MAST AND FORKS
Clearance Adjustment on Lift Bracket
NOTE
The adjustment procedure for the lift bracket is
the same for the Simplex Mast, Duplex Mast
and Triplex Mast.
1. Longitudinal clearance adjustment on lift

bracket main rollers
F
(1) Raise the forks a little from the floor.
(2) Insert a bar between the upper part of lift
bracket and the inner mast, and push the
inner mast to one side. Using feeler gauges,
measure the clearance F between the main
roller and inner mast on the opposite side.
Clearance F 0.1 to 1.0 mm

(0.004 to 0.039 in.) F
207095
(3) If the clearance F is out of specification, use

oversize rollers. F
Roller sizes
Unit: mm (in.)
Diam. of 45A
40A
main roller 55A F
S 117 (4.60) 129 (5.08)
M 118 (4.64) 130 (5.12)
L 119 (4.68) 131 (5.16) Middle / Lower Upper Roller
Roller 207806
(4) Lift bracket main rollers (upper and center rollers)
The upper rollers should be the same in size or
1-rank larger than the center rollers.
2. Lateral clearance adjustment on lift bracket
main rollers and side rollers
(1) Raise the mast to the top.
(2) Set a dial indicator on the inner mast with its
contact point rested on the side of the lift bracket.
(3) Go over to the opposite side of the mast, and
push the lift bracket to one side with a bar. Set
the indicator to zero.
203818
(4) Insert a bar between the inner mast and lift
bracket on the indicator side, and push the lift
bracket to the opposite side. ➀ ➀
(5) Read the indicator. G1
Clearance G1
0.1 to 0.5 mm ➁
(0.004 to 0.020 in.) ➁
(6) Adjust clearance G1 between the center main

roller and weld plate ➁ at the maximum lift
position by increasing or decreasing the
thickness of the shim.
Do not install a shim at upper main rolller ➀.
207821
8.30
MAST AND FORKS
For the lift bracket center main roller, to

extend 0.5 mm (0.02 in.) , insert a 0.5 mm Inner Mast
(0.02 in.) shim (a) on the inside and remove
the 0.5 mm (0.02 in.) shim (b) from the lower
Shims (b)
stopper, then tighten the bolts.
>
>
Shims (a)
207156
(7) Lower the lift bracket slightly from the top,
Side Roller
then adjust clearance G2 between the side
roller and mast by increasing or decreasing
G2 •
the thickness of the shims. •
206687A
Adjust the side roller clearance by adding

shims between the roller bracket and lift
bracket.
Shims
Roller
Bracket
206689
(8) With the lift bracket at the top, adjust

clearance G3 with shims.
NOTE
The lower main rollers are the same to the
center main rollers in construction.
G3
207822
8.31
MAST AND FORKS
Mast Clearance Adjustment

NOTE
Adjust mast clearances at the locations
indicated below.
1. Simplex Mast and Duplex Mast: Main
rollers between the outer mast and inner
mast
2. Triplex Mast: Main rollers between the outer
mast and middle mast, and main rollers
between the middle mast and inner mast.
1. Longitudinal clearance adjustment on mast

main rollers InnerMast Outer
(1) Tilt the mast fully backward. Mast
(2) Using feeler gauges, measure the clearance H
between the inner mast lower roller and outer Lift
mast. Bracket
0.1 to 1.0 mm
Clearance H
(0.004 to 0.039 in.)
H
(3) If the clearance H is out of the specification,
use oversize rollers. 207099
Roller sizes
Unit: mm (in.)
Diam. of 45A
40A
main roller 55A
S 117 (4.60) 129 (5.08)
M 118 (4.64) 130 (5.12)
L 119 (4.68) 131 (5.16)
2. Lateral clearance adjustment on inner mast

main rollers
(2) Set a dial indicator on the inside of the outer
mast with its contact point rested on the inner
mast.
push the inner mast against the outer mast. Set
the indicator to zero.
J
204886
8.32
MAST AND FORKS
(4) Insert a bar between the outer and inner J

masts on the indicator side, and push the Inner Mast
inner mast to the opposite side. Shims b
(5) Read the indicator.
0.1 to 0.5 mm Outer Mast

Clearance J
(0.004 to 0.020 in.)
Shims A
J
206688
(6) If the clearance J is out of specification, adjust Shims a

by shims.
Shims b
NOTE
Refer to Main Roller Shim Replacement.
206686
3. Lateral clearance adjustment on outer mast

main rollers
(2) Set a dial indicator on the outer mast with its
contact point rested on the inner mast.
K
push the outer mast against the inner mast
with a bar. Set the indicator to zero.
(4) Insert a bar between the outer and inner mast,
and push the inner mast to the opposite side.
204889
(5) Read the indicator.
0.1 to 0.5 mm
Clearance K K
(0.004 to 0.020 in.)
207103
8.33
MAST AND FORKS
(6) If the clearance K is out of specification, adjust Shims a

it by shims.
Shims b
NOTE
207823
Main Roller Shim Replacement (Simplex Mast)
1. Remove the lift bracket from the mast.
NOTE
Refer to REMOVAL AND INSTALLATION,
1. Lift bracket removal.
2. Lower the inner mast below the outer mast as

follows:
(1) Raise the front end of the truck, and support
that end with block or the like.
(2) Remove the upper set bolts from the lift
cylinders, and lift the inner mast with a hoist.
Remove the hose guard.
(3) Remove the clamps from the lift cylinders. Pull
the bottom ends of the cylinders from the
outer mast, tilt the cylinders to the center of
the mast, and tie them to the crossmember of
outer mast with rope.
(4) Slowly lower the inner mast until it comes in
contact with the lift cylinders.
(5) Now the main rollers can be removed from the
inner and outer masts. Remove the mast
strips and shims in advance because they are 202961
apt to come off under this condition.
8.34
MAST AND FORKS
Procedure for replacing main roller shims

[Dual-stage full free panoramic mast (Duplex
Mast)]
1. Separate the lift bracket from the mast.
NOTE
Refer to "Separating lift bracket" in the
Hydraulic System section.
2. Removing first lift cylinder

(1) Hitch a sling on the first lift cylinder, and
suspend it with a crane. Wind the rope
(2) Remove lift cylinder connecting bolts and
mounting bolts, and gently remove the first lift
cylinder.
NOTE
Subsequent removal procedure is the same
as the removal procedure for the Simplex
Mast (see "Procedure for replacing main roller
shims").
3. Position the inner mast lower than the outer 207824

mast by following operations.
(1) Lift the front side of the vehicle with a rigid rack
or other equipment.
(2) Remove set bolts from the upper sections of
the lift cylinders, then lift the inner mast.
(3) Remove two lift cylinder clamps, dismount the
cylinders from the mounting sections at the
lower outer mast section. Tilt the cylinders by
moving the top sections towards the center of
the vehicle, then secure the cylinders to the
cross-member of the outer mast with a rope.
(4) Lower the inner mast until it contacts the lift
cylinders. 202961
(5) In this condition, main rollers can be removed
from the inner mast and outer mast. Since the
mast strips and shims can fall off, remove
these parts first.
8.35
MAST AND FORKS
Procedure for replacing main roller shims
[Triple-stage full free panoramic mast (Triplex
Mast)]
1. Separate the lift bracket from the mast.

NOTE
Refer to "Separating lift bracket" section in the
Hydraulic System section.
2. Removing first lift cylinder

(1) Hitch a sling on the first lift cylinder, and
suspend it with a crane. Wind the rope
(2) Remove lift cylinder connecting bolts and
mounting bolts, and gently remove the first lift
cylinder.
First Lift
Cylinder
3. Position the inner mast lower than the middle

(1) Lift the front side of the vehicle with a rigid rack 207787
or other equipment.
(2) Hitch slings to the upper cross-member of the
inner mast, and suspend with a crane.
(3) Remove the chain guards for the second lift
chain wheels.
(4) Dismount the second lift chains on the outer
mast side, and place them in front of the inner
mast.
(5) Lower the inner mast until main rollers can be
removed.
(6) Place wood blocks under the inner mast for
207826
support.
these parts first.
NOTE
In this condition, second lift cylinders cannot
be dismounted.
8.36
MAST AND FORKS
4. Position the middle mast lower than the outer

(1) Lift the inner mast to the height of the middle
mast, then place wood blocks for support.
(2) Hitch slings to both middle mast and inner
mast, and suspend with a crane.
(3) Remove set bolts from the upper sections of
the middle mast lift cylinders, then lift the mid-
dle mast and inner mast.
(4) Remove two lift cylinder clamps, dismount the
cylinders from the mounting sections at the
lower outer mast section. Tilt the cylinders by
moving the top sections towards the center of
the vehicle, then secure the cylinders to the
cross-member of the outer mast with a rope.
(5) Lower the middle mast and inner mast until
main rollers can be removed.
(6) Place wood blocks under the middle mast and
inner mast for support.
these parts first.
207827
8.37
MAST AND FORKS
Mast Strip Adjustment

L
1. Check the clearance L with the clearance
between the outer mast rollers and inner mast
set to zero (0) in maximum lift position.
0.l to 0.5 mm
Clearance L
(0.004 to 0.020 in.)
200391
2. If the clearance L is out of specification, adjust

it by shims. Shims
NOTE
3. After adjusting the all clearance, move the

mast and lift bracket slowly to make sure that
they move smoothly through their full stroke.
207004
Tilt Angle Adjustment
1. Adjust the tire pressure correctly and park the

truck on a level floor.
2. Tilt the mast fully backward and stop the
engine.
3. Measure the backward tilt angle of the mast at
both sides.
4. To adjust the tilt angle, loosen the bolt of tilt
Bolt
cylinder socket, and adjust the rod length by
turning the rod. Adjust cylinder so that there is
no difference in stroke tilt angle between the
cylinders, left and right.
207828
NOTE
It is not necessary to adjust the forward tilt angle
if the backward tilt angle is properly adjusted.
Truck Models EC35N thru

Item EC55N
Forward - backward
5° - 10°
tilt angle deg
8.38
MAST AND FORKS
5. After adjusting the tilt angle, tighten the socket

bolts to the specified torque.
Tightening torque 262 ± 13
for tilt cylinder (27 ± 1.4)
socket bolt [195 ± 10]
Lift Cylinder Stroke Adjustment
1. Slowly raise the inner mast, and observe how

the piston rods, left and right, stop at the
moment the inner mast reaches its maximum
height.
2. If the top of the inner mast rolls at that
moment, make a shim adjustment. Abnormal
condition can be detected by a little time lag in
stopping between the piston rods, left and
right, and rolling of the rod with a longer cylin-
der stroke.
204698
3. Adjusting method
(1) Raise the inner mast, place blocks under the
right and left sides of the inner mast, and
lower the mast until its rests on the blocks.
(2) Remove the set bolt at the top of lift cylinder
which stopped first, retract the piston rod, and
insert shims at the top of piston rod end.
(3) Extend the piston rod, and tighten the cylinder
set bolt. Remove the blocks from under the
inner mast.
(4) Slowly lower the inner mast to the bottom to 202983
ensure the piston rods move smoothly and
that the left and right lift cylinders come to the
end of stroke simultaneously. Shims
206974
8.39
MAST AND FORKS
Troubleshooting
Complaints Possible causes Remedies

Lift bracket and inner mast a) Clearance between lift rollers and side rollers Readjust clearance,
will not move smoothly incorrect see page 11-32
b) Rollers binding on their shafts Relubricate of replace.
c) Lift chains strained in movement Relubricate of replace.
d) Mast strip clearance incorrect Shim adjust.
0.1 to 0.5mm
(0.004 to 0.020 in.)
Lift bracket or inner mast a) Too much clearance on side rollers Readjust by means of
binds shims.
0.1 to 0.5mm
(0.004 to 0.020 in.)
b) Lift chains unequally tensioned Readjust, see page 11-27
c) Shim adjustments unequally made on between Readjust, see page 11-39
left and right lift cylinders (at maximum height)
Mast makes noise Rollers not rotating smoothly on their shafts Relubricate of replace.
Load descends (drift) a) Lift cylinder packing damaged Replace.
b) Sliding (inside) surface of lift cylinder tube Replace.
damaged
Retighten or replace,
Whole mast shakes Mast-support bushing or metal worn
see page 11-42
Mast is distorted Off-center loading or overload Replace mast assembly.
Fork tips differ in height a) Finger bar bent Repair or replace.
b) Forks bent Repair or replace.
c) Un-even loading Repair or replace.
Low oil temperature Increase oil temperature to

40-50 °C.
Second lift cylinders Insufficient clearances between lift
Readjust rollers.
operate while first lift bracket rollers and sliding surfaces
cylinder is moving.
[Triple-stage full free Inspect and clean hydraulic
Clogged pipe lines.
panoramic mast]
Insufficient air bleeding Bleed air completely.
Lift bracket is
spongy when it stops Insufficient air bleeding Bleed air completely.
in lifting operation.
8.40
MAST AND FORKS
Service Data
Simplex Mast A: Assembly standard B: Repair or service limit
Duplex Mast Unit: mm (in.)
Truck Models EC35N thru EC45N thru
Items EC40N EC55N
Difference in height between fork tips A 5 (0.2) or less
150 x 50 ± 0.8 150 x 60 ± 1.5

A
Forks and Chains
(5.9 x 2 ± 0.03) (5.9 x 2.4 ± 0.06)
Thickness of forks (width X thickness)
150 x 45 150 x 51
B
(5.9 x 1.77) (5.9 x 2.00)
A 508 (20) 635 (25)

Length of tilt chains (per 20 links)
B 523 (20.6) 654 (25.7)
S A 117 (4.6) 129 (5.08)
Rollers
Diameter of main roller M A 118 (4.65) 130 (5.12)

L A 119 (4.68) 131 (5.16)
Diameter of side roller A 52 (2.05) 52 (2.05)
Distance between outer mast main rollers
A 576 (22.68) 566 (22.28)
(inside to inside) A
Distance between inner mast main rollers
A 644 (25.35) 640 (25.20)
(outside to outside) B
Distance between lift bracket main rollers
A 525 (20.67) 513 (20.20)
(outside to outside) C1
A 525 (20.67) 513 (20.20)
(outside to outside) C2
A 532 (20.94) 521 (20.51)
(outside to outside) D
Mast and Lift Bracket
Distance between lift bracket side rollers

A 524 (21.34) 530 (20.87)
(outside to outside) E
Longitudinal clearance of lift bracket middle
A 0.1 to 1.0 (0.004 to 0.039)
rollers (with forks slightly lifted) F
Lateral clearance of lift bracket middle
A 0.1 to 0.5 (0.004 to 0.020)
main rollers (fully raised) G1
Lateral clearance of lift bracket side rollers
A 0.1 to 0.5 (0.004 to 0.020)
(fully raised) G2
Lateral clearance of lift bracket lower main
A 0.1 to 0.5 (0.004 to 0.020)
rollers (fully raised) G3
Longitudinal clearance of mast main rollers
A 0.1 to 1.0 (0.004 to 0.039)
(in the whole lift range) H
Lateral clearance of outer mast, inner mast
A 0.1 to 0.5 (0.004 to 0.020)
main rollers (fully raised) J
Lateral clearance of outer mast, inner mast
A 0.1 to 0.5 (0.004 to 0.020)
main rollers (fully raised) K
Mast strip clearance (fully raised) L A 0.1 to 0.5 (0.004 to 0.020)
8.41
MAST AND FORKS
Simplex Mast A: Assembly standard

Duplex Mast Unit: mm (in.)
Items EC40N EC55N
F
G1
L
G3
G2
B
F Lift Bracket
Inner Mast
C1
A
K
E
H
C2
J
Outer Mast
207829
Mast support bolts A 290 (29.6) [214]
Tightening torque
Upper nut ➁ 210 (21.4) [155] 290 (29.6) [214]
N·m(kgf·m)[Ibf·ft] A
Double nut (lower) ➀ 210 (21.4) [155] 290 (29.6) [214]
Distortion of finger bar A 5 (0.2)
Anchor Bolt
➁ Upper Nut
➂ Double Nut (upper)
➀ Double Nut (lower)

102709
8.42
MAST AND FORKS
Triplex Mast A: Assembly standard B: Repair or service limit

Unit: mm (in.)
Items EC40N EC55N
Difference in height between fork tips A 5 (0.2) or less
150 x 50 ± 0.8 150 x 60 ± 1.5

Forks and Chains
A (5.9 x 2 ± 0.03) (5.9 x 2.4 ± 0.06)
Thickness of forks (width x thickness)
150 x 45 150 x 51
B (5.9 x 1.77) (5.9 x 2.00)
A 508 (20) 635 (25)

Length of tilt chains (per 20 links)
B 523 (20.6) 654 (25.7)
S A 117 (4.6) 129 (5.08)
Rollers
Diameter of main roller M A 118 (4.65) 130 (5.12)

L A 119 (4.68) 131 (5.16)
Diameter of side roller A 52 (2.05) 52 (2.05)
Distance between outer mast main rollers
(inside to inside) A A 676 (26.61) 666 (26.22)
Distance between middle mast main rollers

(outside to outside) B A 745 (29.33) 740 (29.13)

(outside to outside) C1 A 513 (20.20) 493 (19.41)

(outside to outside) C2 A 530 (20.87) 510 (20.08)

(outside to outside) D A 513 (20.20) 493 (19.41)
Distance between lift bracket side rollers

Mast and Lift Bracket
(outside to outside) E A 520 (20.47) 501 (19.72)
Longitudinal clearance of lift bracket middle

rollers (with forks slightly lifted) F A 0.1 to 1.0 (0.004 to 0.039)
Lateral clearance of lift bracket middle

main rollers (fully raised) G1 A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of lift bracket side rollers

(fully raised) G2 A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of lift bracket lower main

rollers (fully raised) G3 A 0.1 to 0.5 (0.004 to 0.020)
Longitudinal clearance of mast main rollers

(in the whole lift range) H A 0.1 to 1.0 (0.004 to 0.039)
Lateral clearance ofmiddle and inner mast

main rollers (fully raised) J A 0.1 to 0.5 (0.004 to 0.020)
Lateral clearance of outer and middle mast

main rollers (fully raised) K A 0.1 to 0.5 (0.004 to 0.020)
Mast strip clearance (fully raised) L A 0.1 to 0.5 (0.004 to 0.020)

Distance between middle mast main rollers M A 564 (22.20) 546 (22.20)
Distance between inner mast main rollers N A 633 (24.92) 621 (24.45)
8.43
MAST AND FORKS
Triplex Mast
Unit: mm (in.)
Items EC40N EC55N
G1 L
F
G3
Middle Mast
G2
Lift Bracket
B
N
Inner Mast C1
F K
E
Outer Mast
H A J C2
M K
Middle Mast D
207830
Mast support bolts A 290 (29.6) [214]
Tightening torque
Upper nut ➁ 210 (21.4) [155] 290 (29.6) [214]
N·m (kgf·m) [Ibf·ft] A
Double nut (lower) ➀ 210 (21.4) [155] 290 (29.6) [214]
Distortion of finger bar A 5 (0.2)
Anchor Bolt
➁ Upper Nut
➂ Double Nut (upper)
➀ Double Nut (lower)

102709
8.44
SERVICE DATA
CHAPTER 9: SERVICE DATA
Tightening Torques for Standard Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

Fine Thread with Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
Fine Thread without Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
Course Thread with Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
Course Thread without Spring Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
Periodic Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12
Fuel and Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13
Weight of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.14
Special Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15
Special Tool Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
Inspection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.19
SERVICE DATA: GENERAL
Tightening Torques for Standard Bolts and Nuts

Fine Thread – With Spring Washer
With Spring Washer
Nominal Size Pitch
mm in. mm in. kgf·m lbf·ft N·m kgf·m lbf·ft N·m kgf·m lbf·ft N·m
6 0.24 1 0.04 0.75 5.4 7.4 0.98 7.1 9.6 1.3 9.4 12.7
8 0.32 1.25 0.05 1.7 12.3 16.7 2.3 16.6 22.6 3.1 22.4 30.4
10 0.39 1.25 0.05 3.5 25.3 34.3 4.6 33.3 45.1 7.1 51.4 69.6
Metric Fine Thread
12 0.47 1.25 0.05 6.5 47.0 63.7 8.4 60.8 82.4 12.5 90.4 122.6
14 0.55 1.5 0.06 10.4 75.2 102.0 13.5 97.6 132.4 19.5 141.8 192.2
16 0.63 1.5 0.06 15.8 114.3 154.9 20.6 149.0 202.0 29.3 211.9 287.3
18 0.71 1.5 0.06 22.9 165.6 224.6 29.8 215.5 292.2 42.2 305.2 413.8
20 0.79 1.5 0.06 31.7 229.3 310.9 41.2 298.0 404.0 58.5 423.1 573.7
22 0.87 1.5 0.06 42.2 305.2 413.8 54.8 396.4 537.4 77.8 562.7 763.0
24 0.95 1.5 0.06 55.8 403.6 547.2 72.5 524.4 711.0 102.6 742.1 1006.2
27 1.06 1.5 0.06 81.0 585.9 794.3 105.3 761.6 1032.6 148.0 1070.5 1451.4
30 1.18 1.5 0.06 112.2 811.5 1100.3 145.9 1055.3 1430.8 205.2 1484.2 2012.3
33 1.30 1.5 0.06 149.6 1082.1 1467.1 194.5 1406.8 1907.4 273.3 1976.8 2680.2
36 1.42 1.5 0.06 195.6 1414.8 1918.2 254.3 1839.4 2493.8 356.6 2579.3 3497.1
39 1.54 1.5 0.06 251.0 1815.5 2461.5 326.2 2359.4 3198.9 455.8 3296.8 4469.9
Note
1. The tolerance on these torques is ± 10%.
2. These torques are for “dry” conditions.
9.1

Fine Thread – Without Spring Washer
Without Spring Washer
Nominal Size Pitch
6 0.24 1 0.04 0.88 6.4 8.6 1.1 8.0 10.8 1.5 10.8 14.7
8 0.32 1.25 0.05 2.0 14.5 19.6 2.7 19.5 26.5 3.7 26.8 36.3
10 0.39 1.25 0.05 4.2 30.4 41.2 5.4 39.1 53.0 8.3 60.0 81.4
Metric Fine Thread
12 0.47 1.25 0.05 7.6 55.0 74.5 9.9 71.6 97.1 14.7 106.3 144.2
14 0.55 1.5 0.06 12.2 88.2 119.6 15.9 115.0 155.9 23.1 167.1 226.5
16 0.63 1.5 0.06 18.6 134.5 182.4 24.2 175.0 237.3 34.5 249.5 338.3
18 0.71 1.5 0.06 26.9 194.6 263.8 35.0 253.2 343.2 49.7 359.5 487.4
20 0.79 1.5 0.06 37.3 269.8 365.8 48.5 350.8 475.6 68.8 497.6 674.7
22 0.87 1.5 0.06 49.6 358.8 486.4 64.5 466.5 632.5 91.5 661.8 897.3
24 0.95 1.5 0.06 65.6 474.5 643.3 85.3 617.0 836.5 120.7 873.0 1183.7
27 1.06 1.5 0.06 95.3 689.3 934.6 123.9 896.2 1216.0 174.1 1259.3 1707.3
30 1.18 1.5 0.06 132.0 954.8 1294.5 171.6 1241.2 1682.8 241.4 1746.0 2367.3
33 1.30 1.5 0.06 176.0 1273.0 1726.0 228.8 1654.9 2243.8 321.6 2326.1 3153.8
36 1.42 1.5 0.06 230.1 1664.3 2256.5 299.2 2164.1 2934.1 419.6 3035.0 4114.0
39 1.54 1.5 0.06 295.3 2135.9 2896.0 383.8 2776.0 3763.8 536.2 3878.3 5258.3
Note
9.2
Coarse Thread – With Spring Washer
With Spring Washer
Nominal Size Pitch
10 0.39 1.5 0.06 3.4 24.6 33.3 4.4 31.8 43.1 6.9 49.9 67.7
12 0.47 1.75 0.07 6.0 43.4 58.8 7.8 56.4 76.5 11.8 85.3 115.7
14 0.55 2 0.08 9.8 70.9 96.1 12.7 91.9 124.5 18.6 134.5 182.4
Metric Fine Thread
16 0.63 2 0.08 15.0 108.5 147.1 19.5 141.0 191.2 28.0 202.5 274.6
18 0.71 2.5 0.10 20.7 149.7 203.0 27.0 195.3 264.8 39.1 282.8 383.4
20 0.79 2.5 0.10 29.2 211.2 286.4 37.9 274.1 371.7 54.7 395.6 536.4
22 0.87 2.5 0.10 39.1 282.8 383.4 50.9 368.2 499.2 73.0 528.0 715.9
24 0.95 3 0.12 50.2 363.1 492.3 65.3 472.3 640.4 94.3 682.1 924.8
27 1.06 3 0.12 73.9 534.5 724.7 96.1 695.1 942.2 137.7 996.0 1350.4
30 1.18 3.5 0.14 98.9 715.3 969.9 128.4 928.7 1259.2 188.0 1359.8 1843.7
33 1.30 3.5 0.14 135.5 980.12 1328.8 176.1 1273.7 1727.0 252.6 1827.1 2477.2
36 1.42 4 0.16 170.9 1236.1 1676.0 222.3 1607.9 2180.0 326.3 2360.1 3199.9
39 1.54 4 0.16 226.3 1636.8 2219.2 294.1 2127.2 2884.1 420.0 3037.9 4118.8
42 1.65 4.5 0.18 280.9 2031.8 2754.7 365.2 2641.5 3581.4 523.9 3789.4 5137.7
Note
9.3
Coarse Thread – Without Spring Washer
Without Spring Washer
Nominal Size Pitch
10 0.39 1.5 0.06 4.0 28.9 39.2 5.2 37.6 51.0 8.1 58.6 79.4
12 0.47 1.75 0.07 7.1 51.4 69.6 9.2 66.5 90.2 13.8 99.8 135.3
14 0.55 2 0.08 11.5 83.2 112.8 14.9 107.8 146.1 22.0 159.1 215.7
Metric Fine Thread
16 0.63 2 0.08 17.6 127.3 172.6 22.9 165.6 224.6 33.0 238.7 323.6
18 0.71 2.5 0.10 24.4 176.5 239.3 31.8 230.0 311.9 46.0 332.7 451.1
20 0.79 2.5 0.10 34.3 248.1 336.4 44.6 322.6 437.4 64.3 465.1 630.6
22 0.87 2.5 0.10 40.0 289.3 392.3 59.9 433.3 587.4 85.9 621.3 842.2
24 0.95 3 0.12 59.0 426.7 578.6 76.8 555.5 753.2 111.0 802.9 1088.5
27 1.06 3 0.12 86.9 628.5 852.2 113.0 817.3 1108.2 162.0 1171.7 1588.7
30 1.18 3.5 0.14 116.3 841.2 1140.5 151.1 1092.9 1481.8 221.1 1599.2 2168.3
33 1.30 3.5 0.14 159.4 1153.0 1563.2 207.2 1498.7 2031.9 297.3 2150.4 2915.5
36 1.42 4 0.16 201.1 1454.6 1972.1 261.5 1891.4 2564.4 384.0 2777.5 3765.8
39 1.54 4 0.16 266.2 1925.4 2610.5 346.0 2502.6 3393.1 494.1 3573.8 4845.5
42 1.65 4.5 0.18 330.5 2390.5 3241.1 429.5 3107.3 4212.9 616.4 4458.4 6044.8
Note
9.4
Maintenance Chart
Use the service chart to determine servicing intervals. Calendar intervals shown (weekly, monthly, etc.)
may be used instead of service meter intervals if they provide more convenient servicing schedules and
approximate the indicated service meter reading. Recommended service should always be performed at
the interval that occurs first.
Perform service on items at multiples of the original requirement. For example, at every 1000 hours or 6
months, also service those items listed under every 500 hours or monthly, every 50 hours or weekly and
daily (pre-start).
● = Check or clean
★ = Change or adjust
Maintenance Intervals
Every 2000 hours

Every 1000 hours
Every 500 hours
Daily (pre-start)
Every 50 hours
Inspection Point How to Check Service Data
or 6 months
or 3 months
or weekly
or 1 year
Motors Bearing lubrication, damage Visual ● ● Lubricate
Winding to case resistance Test ● ● Resistance to be > 1

Mega Ω
Armature to case resistance Test ● ●
Brush contact area Visual ● ● Change brush
Brush length Visual ● ● Change brush
Brush spring force Test ● ● Change spring
Commutator surface condition Visual ● ●
Commutator discoloration Visual ● ●
Interior, exterior cleanliness Visual ● ● ● Clean
Steering wheel Free-play, looseness, rattling Test ● ● ● ● ●
Operation Test ● ● ● ● ●
Steering gear Oil leaks Visual ● ● ● ● ●
Mounting bolts, tightness Wrench ● ● ●
Steering Beam structural damage Visual ●

linkage
Cylinder leaks Visual ● ● ● ● ●
Cylinder mounting bolts Wrench ●
Tie rod bearings and pins Visual ●
Kingpin looseness Test ●
Trunnion fore-aft looseness Test ● Nominal 0.8 mm

(0.031 in.) clearance
9.5
Every 2000 hours or

Every 1000 hours or
Every 50 hours or
Every 500 hours

Daily (pre-start)
or 3 months
6 months
weekly
1 year
130 ± 3 mm
Brake pedal Height of pedal above floor Scale ● ● ● ● ● (5.1 ± 0.12 in.)
Stroke to point where brakes Scale ● ● ● ● ● 5 to 10 mm
start applying (0.20 to 0.4 in.)
Parking brake Lever lock position:

Performance Test/spring 4° - 5°
balancer ● ● ● ● ●
Operating effort:
25 to 30 kgf
(55 to 66 lb)
[245 to 295 N]
Brake hoses Fluid leaks, damage or Visual ● ● ● ● ●

and pipes installation
Brake fluid Level in reservoir Visual ● ● ● ● ★ 103cc (7.9 cu. in.)
Wheel brakes Master cylinder and wheel Overhaul/Visual

cylinders—operation, wear and ★
damage
Brakes drums
and shoes 0.4 to 0.6 mm
Drum-to- lining clearance Feeler gauge ● ● ● (0.16 to 0.024)
Sliding surfaces of shoes and Disassemble/ ● 4.2 mm (0.17 in.)

wear of lining calipers or more
318.5 mm
Drum—wear or damage Visual scale ● (12.539 in.)
Free length of return springs Scale ●
Operation of shoes Test ●
Anchor pins—seizure Visual ●
9.6
Every 1000 hours or
Every 2000 hours or

Every 50 hours or
Every 500 hours

Daily (pre-start)
or 3 months
6 months
weekly
1 year
Backing plates Distortion, cracks, or damage Dye check ●
Fitting cables– Visual/scale ●

damage and length
Ratchet–wear or damage Visual ●
Front axle Cracks, distortion, Dye check/ ●

or other defects visual
Front wheel bearings–preload Spring balancer ● Hub bearing preload

22.5 to 40N
(2.3 to 4.1 kgf)
[5.06 to 9.02 16f]
Fore-aft play Test ●
Cracks, distortion, or Visual ●

other defects
Differential Oil level and oil leaks Visual ● ● ●

6.2 liters (1.64 U.S. gal)
Mounting bolts Torque wrench ●
Rear axle Front wheel bearings–preload Spring balancer ● Hub bearing preload
Torque wrench 4.1 to 5.0 kgf
(9 to 11 lbf•ft)
[40 to 49 N•m]
Lock Nut (outside)

19.99 kgf•cm (130.6 lbf•ft)
[177 N•m]
Wheels Tires–cuts or gouges Visual ● ● ● ● ●
Tires–wear Depth gauge ● ● ● ● ●
Tires–imbedded objects Visual ● ● ● ● ●
Wheel nuts–tightness Torque wrench ● ● ●
Wheel nut tightening torque 551±55

N•m (kgf•m) [lbf•ft] (56.2 ± 5.6)
[406.5 ± 40.6]
Rims–damage Visual ● ● ● ● ●
9.7
Every 2000 hours

Every 1000 hours
Every 500 hours
Daily (pre-start)
Every 50 hours
or 6 months
or 3 months
or weekly
or 1 year
Hydraulic tank Oil level and contamination Visual ● ● ● ● ★
Strainer—clogging Visual ★
Return filter—clogging Visual ★
Hydraulic pump Oil leaks or abnormal noise Visual / listen ● ● ●
Control valve Oil leaks Visual ● ● ● ● ●
200 kgf/cm2
Main relief valve setting Pressure gauge ● (2850 psi)
[19,650 kPa]
Auxiliary relief valve setting Pressure gauge ● 158±5 kgf/cm2
2250±71psi
15,513 ± 490 kpa
Overload relief setting (optional) Pressure gauge ●
Control levers and links—rattle Test ● ● ● ● ●
Lift cylinders Cracks, distortion, or Visual ● ● ● ● ●
other defects
● ● ● ● ●
Rod drift (rated load) Visual/watch/
scale
Attachment ● ● ● ● ●
Mounting bolts—tightness Wrench ● ● ●
Oil Leaks Visual ● ● ● ● ●
Flow regulator Lowering speed Watch/scale ● ● ● Lowering speed
valve (rated load)
EC35N-EC40N
540 mm/sec (106 fpm)
EC45N-EC55N
560 mm/sec (98 fpm)
9.8
Every 1000 hours

Every 500 hours
Daily (pre-start)
hours or 1 year
Every 50 hours
or 3 months
or 6 months
Every 2000
or weekly
Tilt cylinders Cracks, distortion, Visual ● ● ● ● ●
or other defects
Oil leaks Visual ● ● ● ● ●
Forward rod drift (rated load) Watch/scale ● ● ●
15 mm (0.6 in.)/15 min
Mounts—rattle or damage Visual/free ● ● ● ● ●

Rod socket nut—tightness Torque wrench ● ● ● ● ●
40 kgf·m
(289 lbf·ft)
[392 N·m]
Piping Oil leaks Visual ● ● ● ● ●
Rubber hoses: damage Visual ● ● ●
Hose reels and swivel joint— Visual ● ● ●
distortion or other defects
Mast and Cracks, distortion, Visual/ ● ● ● ● ●
lift bracket or other defects dye check
Mast supports—rattle or ● ● ●
damage
Main rollers—clearance, Feeler gauge/ ● ● ● Each roller to
damage dial gauge mast clearance
(at max. height):
0.1 to 0.5 mm
(0.004 to 0.020 in.)
9.9
Every 1000 hours or

Every 50 hours or
Every 2000 hours

Every 500 hours
Daily (pre-start)
or 3 months
6 months
or 1 year
weekly
Lift chains and Length of lift chains (20 links) Scale ● EC35N - EC40N
chain wheels 523 mm (20.6 in.)
EC45N-EC55N
654 mm (25.7 in.)
Tension deflection of lift chains Scale ● ● ● ● ● Both chains to

equal in tension
Chains—damaged or rusting Visual ● ● ● ● ●
Chains wheels—wear, Visual ● ● ●
distortion, or other defects
Chain wheel bearings—rattle Feel ● ● ●
Chain anchor bolts—distortion Visual ● ● ●
or damage
Forks and Forks—wear and distortion Visual/scale ● ● ● ● ● Fork thickness—
backrest refer to Service Data
Forks stopper pins— Visual ● ● ● ● ●
damage or distortion
Backrest mounting bolts— Torque wrench ● ● ● ● ●
tightness
Backrest—distortion or damage Visual ● ● ● ● ●
Lights Operation Test/visual ● ● ● ● ●
Turn signals
Operation Test ● ● ● ● ●
(optional)
Rear view Rear vision Visual ● ● ● ● ●
mirrors (optional)
Overhead guard Installation and damage Visual/wrench ● ● ● ● ●
Chassis Loosen bolts or nuts Wrench ●
Operator’s seat— Visual ● ● ●
damage and installation
Lubricate mast supports
Lubrication points Lubricate ● ● ●
every 50 hours or weekly
Oil change Inspect ● ● ●
9.10
Periodic Replacement Parts

The parts listed below are important for the safe operation of the truck, and especially designed to be
replaced at specified periods. Each service shop is requested to adhere to the replacement schedule
given here on all trucks brought into its care.
Periodic Replacement Parts Service Period
1 month 3 months 6 months 1 year 2 years

after (500 hours) (1000 hours) (2000 hours) (4000 hours)
delivery
1 ★
Rubber parts for brake Replace ● ●
master cylinder
2 ★
Rubber parts for brake Replace ● ●
wheel cylinders
3 ★
Hydraulic hoses Replace ● ●
4 ★
Hoses for power steering Replace ●
5 ★
Rubber parts for Replace ●
steering cylinder
6 ★
Lift chains Replace ●
7 Hydraulic tank return filter Replace ● ● ● ●
8 Drum to lining clearance Check or replace ● ●
9 Motor brushes Check or replace ● ●

★
Indicates important safety-related parts
9.11
9.12
LUBRICATION AND MAINTENANCE CHART BE SURE TO PERFORM SERVICE ITEMS QUOTED BELOW
CHECK LUBRICATE
Lubrication Chart
EVERY 10 HR. OR DAILY EVERY 50 HR. OR WEEKLY

MULTIPURPOSE-TYPE GREASE
SPECIFIC GRAVITY OF BATTERY
ENGINE OIL
OIL LEAKS BOLTS, NUTS
EVERY 50 HR. OR WEEKLY
TIRES, WHEEL NUTS EVERY 500 HR. OR 3 MONTHS MAST SUPPORTS

DIFFERENTIAL OIL LEVEL EVERY 500 HR. OR 3 MONTHS
BRAKE FLUID LEVEL
MAST STRIPS, ROLLER
HYDRAULIC OIL LEVEL EVERY 500 HR. OR 3 MONTHS SURFACES (EACH SIDE)
CONTACTORS LIFT BRACKET SIDE
BATTERY ELECTROLYTE LEVEL MOTOR BRUSHES ROLLERS (EACH SIDE)
BATTERY RESTRAINT LIFT CHAIN (EACH SIDE)
MAST, FORKS, LIFT CHAINS TILT SOCKET (EACH SIDE)

CHANGE FRONT AXLE SUPPORT
SEAT BELT AND RAILS (EACH SIDE)
STEERING
OIL FLUID FILTER,
TILT CYLINDER (EACH SIDE)
SERVICE BRAKES EVERY 1200 HR. OR 6 MONTHS
TRANSFER AND DIFFERENTIAL OIL BRAKE PEDAL
PARKING BRAKE HYDRAULIC TANK OIL FILTER TIE ROD ENDS (4 FITTINGS) REAR
ACCELERATOR PEDAL AXLE CENTER PIN
(FRONT/REAR)
HORN EVERY 2400 HR. OR 1 YEAR
HYDRAULIC OIL
DASH MONITOR BRAKE FLUID
NOTE: REDUCE SERVICING INTERVALS IN DUSTY OR SEVERE CONDITIONS. REFER TO OPERATION MANUAL 97182-12900
◆
Recommendation for ambient temperatures [°C (°F)]
Oil Recommendation (-22) (-4) (14) (32) (50) (68) (86)

-30 -20 -10 0 10 20 30
| | | | | | | | | | | | |
API service classification ISO Grade 32 ISO Grade 68
Gear oil multipurpose type GL-5 SAE 80W SAE 90W
(hypoid gear oil) AGMA-1EP AGMA-2EP
Hydraulic oil SAE 5W SAE 10W
Brake fluid F.M.V.S.S. No. 116—DOT 3 or DOT4 (SAE J1703)
Wheel bearings NLGI No. 2 grade multipurpose type (lithium base), consistency: 265 - 295
Grease
Chassis NLGI No. 1 grade multipurpose type (lithium base), consistency: 310 - 340
• Avoid mixing lubricants. In some cases, different brands of lubricants are not compatible with each other and deteriorate when mixed. It is best to stick with the same
brand at successive service intervals.
Fuel and Lubricant Specifications
EP 68 Gear oil with borate additives are not recommended.
Gear Oil Greases Hydraulic oils

Specifications
API service classification GL-5 NLGI No. 1 NLGI No. 2
Visc
osity
SAE90W Consistency 310-340 Consistency 265-295 SAE5W SAE10W
Manufacturer
Mobil 90 Pegasus Gear Oil Mobil Grease JL 77 No. 1 Mobil Grease JL 77 No. 2 — Hydraulic oil 28 LP
Shell Shell Spirax EP90 Retinax A No. 1 Retinax A No. 2 Tellus oil 22 Tellus oil T-32
Exxon Gear Oil GX 80W90 ---- Ronex MP UNIVISN 22 Nuto H32
Castrol Castrol Hypoy Castrol LM Grease Castrol Spheerol API Castrol Hyspin Castrol Hyspin
AWS32 AWS68
■ Brands of oil are subject to change without notice.
■ When you buy oil, select recommended brands and check specifications.
9.13
Weight of Major Components (Approximate)
Component / Model EC35N EC40N EC45N EC55N
Counterweight 590 (1300) 894 (1971) 1390 (3064) 2100 (4630)
Power train
(Motor, transfer box, reduction 836 (1843) 836 (1843) 836 (1843) 836 (1843)
gear and differential)
Overhead guard 120 (265) 120 (265) 120 (265) 120 (265)
Rear axle 341 (750) 341 (750) 341 (750) 341 (750)
Mast (3.3 m simplex mast) 1110 (2440) 1110 (2440) 1209 (2820) 1209 (2820)
Outer mast 318 (700) 318 (700) 359 (790) 359 (790)
Inner mast 206 (450) 206 (450) 234 (515) 234 (515)
Lift bracket (including backrest) 228 (500) 228 (500) 229 (660) 229 (660)
Forks (two) 258 (570) 258 (570) 258 (570) 258 (570)
Lift cylinder and related parts 100 (220) 100 (220) 129 (285) 129 (285)
Hydraulic motor 95 (209) 95 (209) 95 (209) 95 (209)
Traction motor 164 (362) 164 (362) 164 (362) 164 (362)
Unit: kg (lb)
9.14
SERVICE DATA: SPECIAL TOOLS
Special Service Tools
Part Number Part Name Application Truck Models

EC35N - EC55N
MCF - 1098 Wheel Socket Removal and installation of front wheel nuts •
MCF - 1102 Socket Wrench A Remove lock nut on front axle •
97667-00100 Transfer Bearing Tool Removal of bevel pinion shaft •
91868-02100 Bevel Pinion Puller Removal of bevel pinion assembly •
64309-15411 Spring Remover Removal of return spring •
91868-00600 Spring Retainer B Removal of shoe hold down springs •
64309-15413 Spring Installer A Installation of return springs •
91268-10600 Wheel Puller Removal of steering wheel •
05312-10500 Wrench Removal of cylinder head •
05312-10800 Wrench Removal of guide bushing •
6V3965 Pressure Port Tool Main relief valve pressure port •
9.15
Inspection Guide
Check For (item or defect) How
Antifriction bearings ITEMS Measure inside diameter with an indicator

hole gauge and shaft outside diameter with
a) Fit on shaft an indicating micrometer
b) Fit in housing Measure outside diameter with an indicat-

ing micrometer and housing inside
diameter with an indicator hole gauge
c) Preload (small initial load applied to As stated in service manual

absorb initial bearing deformation)
DEFECTS
a) High running temperature (caused by As shown

over lubrication)
b) Noise (humming), vibration, or rough

running
Radial bearing Thrust bearing
c) Creep (marks of circumferential slip 8609153

on inner ring’s surface in contact with Visually
shaft or on outer ring’s surface in
contact with housing due to loose fit
of bearing)
d) Corrosion Visually
8609151
e) True brineling (caused by careless

installation or removal)
8609152
9.16
Antifriction bearings f) False brineling (caused by a constant vibration Visually

or oscillation of non-rotating bearings through
small arc)
8609154
g) Cracked race (caused by forcing bearing or Visually

oversize shaft or by cooking race when installing
or removing)
8609155
h) Broken separator (caused by dirt, metal chips, Visually

or lack of lubricant)
8609156
i) Damaged seal (caused by improper use of tools) Visually
8609157
j) Spalled race (caused by too loose a fit) Visually
8609158
9.17
Antifriction bearings k) Bad discoloration (caused by overheating due to Visually

poor lubrication)
8609159
i) Craters (caused by passage of electric current) Visually
8609160
Bushings or sleeve ITEM

bearings Fit on shaft Determine by measuring inside
diameter of bushing and outside
diameter of shaft
DEFECTS
Nicks, burrs, or other flaws on bearing surface Hold bushing toward a light and look
through bore
Fasteners DEFECTS
a) Striped or otherwise damaged threads (bolts, Visually

nuts, screws, etc.)
b) Distortion or loss of tension (spring lock Examine by compressing

washers, snap rings, etc.)
Gears ITEMS
a) Fit on bearing, bushing, spline or key As stated in service manual
b) Backlash As stated in service manual
DEFECTS
a) Excessive wear on teeth, thrust faces, and end Visually

faces on hub
b) Scratching wear (caused by large particles other Visually

than associated with abrasive wear)
9.18
Gears c) Abrasive wear (caused by fine particles carried Visually

in lubricant)
d) Overload wear Visually
e) Pitting Visually
f) Spalling Visually
g) Overload breakage Visually
h) Fatigue breakage Visually
i) Corrosive wear Visually
9.19
Rubber Hardening or softening, swelling, tackiness, Visually

tearing, and deterioration due to aging.
Splines ITEM
Fit
DEFECTS
a) Nicks, burns, chips, etc. Visually
b) Free movement (looseness) of mating splines Examine
c) Excessive wear, polish on sides (sliding fit Visually

splines)
d) Ridge or edge left between worn and Visually

areas (sliding fit spline)
8609170
9.20
NOTES
TECHNICAL PUBLICATIONS FEEDBACK
Date:
(Please Print)
Dealer Name: Submitted By:
Address: P.O. Box:
City: State:
Zip Code: Country:
The following discrepancy or omission has been discovered in:
❏ Operation & Maintenance Manual ❏ Option Bulletin

❏ Part List/Manual ❏ Special Instructions
❏ Service Manual ❏ Service Data Manual
❏ Electronic Manual ❏ Other
Publication # Engine Model #
Truck model # Issue date #
Truck serial # Page #
(Please Print)
Explanation of discrepancy or omission:
(Please fax or mail completed form to):

Mitsubishi Caterpillar Forklift America Inc. Mitsubishi Caterpillar Forklift Europe B.V.
Attn: Technical Publications Attn: Service Engineering
2121 W. Sam Houston Parkway N. P.O Box 30171
Houston, Texas 77043-2305 1303 AC, Almere, The Netherlands
Fax: 713-365-1616 Fax: 31-36-5494-695
Mitsubishi Caterpillar Forklift Asia Pte. Ltd.

RCB No. 199203169H
Attn: Service Engineering
No. 2 Tuas Avenue 20
Singapore 638818
Republic of Singapore
Fax: 65-6861-9277
Cat Lift Trucks Service Manual EC35N, EC40N, EC45N, EC55N Lift Trucks SENB8474
®
Lift
Trucks
Mitsubishi Caterpillar Forklift Europe B.V.

Hefbrugweg 77 1332 AM
Almere, The Netherlands
Copyright © 2004 by MCFA. All Rights Reserved.

SENB8474 CATERPILLAR and CAT are registered trademarks of Caterpillar Inc. Printed in the U.S.A.

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Chassis & Mast

For use with GE SX Control Service Manual. SENB8474

CHAPTER 1: GENERAL INFORMATION

CHAPTER 2: FRONT AXLE AND REDUCTION DIFFERENTIAL

CHAPTER 3: TRANSFER ASSEMBLY

CHAPTER 4: REAR AXLE

CHAPTER 5: BRAKE SYSTEM

CHAPTER 5: BRAKE SYSTEM (cont.)

CHAPTER 6: STEERING SYSTEM

CHAPTER 7: HYDRAULIC SYSTEM

CHAPTER 8: MAST AND FORKS

CHAPTER 9: SERVICE DATA

CHAPTER 1: GENERAL INFORMATION

Truck Models Covered

Truck Model Serial Number

Nameplate and Serial Number Locations

Maximum Fork Spacing

Overall Height (to top of

Overall Height (to top of

Overall Height (to top of

M Wheelbase 1575 (62.0) 1575 (62.0) 1575 (62.0) 1720 (67.7)

General Information (Standard Models)

Units EC35N EC40N EC45N EC55N

Standard Controller GE SX Controller

Rated Capacity/ kg/mm 3500/500 4000/500 4500/600 5500/600

Lowering Speed (rated load) 0.54 (106) 0.56 (110)

Tilt Angle (forward/backward) degrees 6° / 8°

Free Lift mm (in.) 150 (5.9) 160 (6.3)

(Without Load) (mph)

48V 17.0 (10.6) 16.9 (10.5) 15.8 (10.3) 16.6 (10.3)

Minimum Turning mm 2214 2258 2294 2468

Traction Motor 36V 60min. 15.3 (11.4)

Transfer Type Spur

Reduction Type Spiral Bevel

Axle Housing Banjo

Differential Gear Type/ Gears Straight Bevel/2

Number Pinions Straight Bevel/2

Units EC35N thru EC55N

Type Dynamic Load Sense

Steering Wheel Diameter mm (in.) 328 (13)

Type Self-Adjusting Duo-Servo

Master Primary 31.75 (1.25)

Wheel 31.75 (1.250)

Type Mechanical, Mounted on Front Wheels

Park Brake Lever kgf 25 to 30

Front Wheels Fixed Type

Rear Wheels Center Pivot Type

Lift Cylinders ID 60 (2.36) 70 (2.75)

Diameter x Width, mm (in.) 52x36 (2.05x1.42)

Lift Chains BL834 BL1034

Forks (length x width x thick), mm (in.) 1220x150x50 (48x6x2)

Fork Spread (outer width), mm (in.) 1060 (41.5)

Width 1156 (45.5)

CHAPTER 2: FRONT AXLE AND REDUCTION DIFFERENTIAL

Specifications ................................................................................................................................................. 2.1

Truck Models EC35N thru EC55N

Gear type Spiral bevel gear

Reduction ratio 4.571

Large Straight bevel gear x 2

Front axle type Full-floating axle tube type

Suspension Front wheel Frame fixing type

Procedures and Key Points for Removal and Installation