18-1 18 APPENDIX 18 Page SST LIST........................................................................... 18-2 SERVICE STANDARDS LIST ..................................... 18-5 WIRING DIAGRAM (Conventional Lever) ............ 18-12 WIRING DIAGRAM (Mini Lever / Joystick Lever) ................................. 18-13
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SERVICE STANDARDS LIST WIRING DIAGRAM (Conventional Lever ...dealerapplications.tmhna.com/TechInfo/TechnicalDocs//service... · WIRING DIAGRAM (Conventional Lever) ... (306~1244)
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WIRING DIAGRAM (Mini Lever / Joystick Lever)................................. 18-13
sec18.book 1 ページ 2010年4月23日 金曜日 午前10時52分
18-2
SST LIST18
Illustration Part No. Part NameSection
1 5 6 7 8 9 10 13 14 15 17
09140-10920-71 Puller B set extension tool O
09310-23320-71 Reamer bolt remover O
09319-76001-71(09319-60020)
Output shaft needle roller bearing remover O
09320-23000-71 Bearing remover O
09330-21440-71 Stopper pin O
09370-10410-71 Front axle bearing replacer O O O
09370-20270-71 Drive pinion bearing replacer O
09450-23320-71 Adapter O
09509-76003-71(09509-55030)
Rear wheel bearing nut wrench O
09510-31960-71Brake hold down spring remover and replacer
O
09610-22000-71 Inner mast stopper O
sec18.book 2 ページ 2010年4月23日 金曜日 午前10時52分
18-3
18
Illustration Part No. Part NameSection
1 5 6 7 8 9 10 13 14 15 17
09620-10100-71 Cylinder cap remover and replacer O
09630-23600-71 Deep socket A O
09659-26600-71 Piston rod guide O
09700-30200-71 Spring pin tool remover O
09717-76001-71(09717-20010)
Brake shoe return spring remover O
09718-76001-71(09718-20010)
Brake shoe return spring replacer O
09810-20172-71 Joint pin remover O O
09950-76003-71(09950-50012) Puller C set O
09950-76014-71(09950-40011) Puller B set O O O O
09950-76018-71(09950-60010) Replacer set O O O O O
09950-76019-71(09950-60020) Replacer set No.2 O O
sec18.book 3 ページ 2010年4月23日 金曜日 午前10時52分
18-4
Illustration Part No. Part NameSection
1 5 6 7 8 9 10 13 14 15 17
09950-76020-71(09950-70010) Handle set O O O
25009-13201-71 Battery hanger O
sec18.book 4 ページ 2010年4月23日 金曜日 午前10時52分
18-5
18
SERVICE STANDARDS LIST
BATTERY
DRIVE MOTOR
PUMP MOTOR
Specific gravity upon full charge 1.280 [20°C (68°C)]Specific gravity upon end of discharge 1.150 [20°C (68°C)]
Discharge end voltage V36V 32.048V 42.5
Insulation resistance MΩ 1 or more
Insulation resistance MΩ 1 or moreTerminal continuity Ω 0Temperature sensor resistance kΩ Approx. 11~15Tightening torque N⋅m (kgf-cm) [ft-lbf]Revolution sensor gear set bolt Standard 13 (133) [9.59]Sensor cover Standard 5 (51) [3.69]Terminal bolt Standard 5 (51) [3.69]Terminal bracket Standard 23.7 (242) [17.49]Revolution sensor Standard 5 (51) [3.69]
Insulation resistance MΩ 1 or moreTerminal continuity Ω 0Temperature sensor resistance kΩ Approx. 11~15Tightening torque N⋅m (kgf-cm) [ft-lbf]Pump motor set nut Standard 32~122 (306~1244) [22.1~90.0]Revolution sensor gear set bolt Standard 7.8~18.2 (80~186) [5.8~13.4]Terminal bracket Standard 14.2~33.2 (145~339) [10.5~24.5]End bracket through bolt Standard 17.2~22.8 (175~232) [12.7~16.8]Revolution sensor Standard 3.0~7.0 (36~71) [2.2~5.2]
sec18.book 5 ページ 2010年4月23日 金曜日 午前10時52分
18-6
DRIVE UNIT
FRONT AXLE
Differential
Differential pinion inside diameter mm (in)Standard 22.12 (0.8709)
Limit 22.22 (0.8748)
Spider outside diameter mm (in)Standard 22.00 (0.8661)
Limit 21.75 (0.8563)
Side gear thrust washer thickness mm (in)Standard 22.00 (0.8661)
Limit 21.75 (0.8563)
Pinion gear thrust washer thickness mm (in)Standard 1.6 (0.063)
Limit 1.0 (0.039)Tightening torque N⋅m (kgf-cm) [ft-lbf]Front axle shaft Standard 98~127 (1000~1300) [72~94]Drive motor Standard 28.5~42.7 (291~435) [21.0~31.5]Axle bracket Standard 167~225 (1700~2300) [123~166]Axle bracket set bolt (through bolt) Standard 235~294 (2400~23000) [173.6~217.1]Axle bracket set bolt (reamer bolt) Standard 235~294 (2400~23000) [173.6~217.1]Drive unit cap Standard 82~123 (836~1254) [60.5~90.7]Gear case cover Standard 82~123 (836~1254) [60.5~90.7]Ring gear set bolt Standard 127~176.5 (1300~1800) [94.1~130.2]Differential upper case Standard 43.1~53.9 (440~550) [17.3~21.7]
Front axle shaft · axle hubFront axle bearing starting force N (kgf) [lbf] Standard 25.5~72.6 (2.6~7.4) [5.7~16.4]Tightening torque N⋅m (kgf-cm) [ft-lbf]Hub bolt set nut Standard 166.7~205.9 (1700~2100) [123.0~151.9]Hub nut Standard 294.2~588.4 (3000~6000) [217.1~434.1]Front axle shaft Standard 98.1~127.5 (1000~1300) [72.4~94.1]Brake ASSY set bolt Standard 137~196 (1400~2000) [101.3~144.7]Axle housing set bolt Standard 108~137 (1100~1400) [79.6~101.3]
sec18.book 6 ページ 2010年4月23日 金曜日 午前10時52分
18-7
REAR AXLE
STEERING
Rear axle ASSYRear axle front to rear clearance mm (in) Standard 0.7 (0.028) or lessRear axle center pin bushing inside diameter mm (in) Limit 52.9 (2.047)Steering knuckleRear axle wheel starting force N (kgf) [lbf] Standard 9.8~29 (1.0~3.0) [2.2~6.6]King pin outside diameter mm (in) Limit 27.8 (1.094)Steering knuckle starting force N (kgf) [lbf] Standard 19.3 (2.0) [4.4]Rear axle cylinder
Rear axle cylinder piston rod outside diameter mm (in)
Tightening torque N⋅m (kgf-cm) [ft-lbf]Axle bracket cap set bolt Standard 128~175 (1310~1780) [94.8~128.8]King pin lock bolt Standard 44.1~53.9 (450~550) [32.6~39.8]King pin lock nut Standard 35~52 (357~530) [25.8~38.4]Steering knuckle tie rod end pin lock nut Standard 49.0~73.5 (500~750) [36.2~54.3]Rear axle cylinder set bolt Standard 166.7~215.8 (1700~2200) [123.0~159.1]Rear axle cylinder rod guide set nut Standard 29.2~38.0 (298~387) [21.5~28.0]
Hydrostatic steering valve ASSY
Relief pressure MPa (kgf/cm2) [psi]20·25 Standard 7.2 (73) [1038]28~32 Standard 7.8 (80) [1138]
Tightening torque N⋅m (kgf-cm) [ft-lbf]Steering wheel set nut Standard 24.5~45.5 (250~464) [18.1~33.6]Steering column cover Standard 0.9~1.10 (9.2~11.2) [0.7~0.81]Steering valve ASSY set bolt Standard 29.8~38.8 (304~398) [22.0~28.6]Tilt lock bolt Standard 7.2~16.7 (73~171) [5.3~12.4]Mast jacket set nut Standard 35.2~52.8 (359~538) [26.0~39.0]Relief valve Standard 40~60 (408~612) [29.5~44.3]Steering valve end cap set screw Standard 24~36 (245~367) [17.7~26.6]
sec18.book 7 ページ 2010年4月23日 金曜日 午前10時52分
18-8
BRAKE
BODY
MATERIAL HANDLING SYSTEM
Front brakeHold down spring free length mm (in) Standard 25.5 (1.004)
Anchor to shoe spring free lengthmm (in)
On the side of lining W/pin Standard 139.3 (5.484)
On the side of lining L/pin Standard 121.8 (4.795)
Limit No clearance between coil turnsStrut to shoe spring free length mm (in) Standard 29.8 (1.173)
Adjuster spring free length mm (in)Standard 126.0 (4.961)
Limit No clearance between coil turns
Brake lining thickness mm (in)Standard 5.7 (0.224)
Limit 1.0 (0.039)Wheel cylinder to piston clearance mm (in) Standard 0.125 (0.00492)
Brake drum inside diameter mm (in)Standard 310 (12.20)
Limit 312 (12.28)Parking brakeParking brake cable set position mm (in) Standard 0~2 (0~0.08)Parking brake operating force N (kgf) [lbf] Standard 270~310 (27.5~31.6) [60.7~69.7]Brake pedalBrake pedal height mm (in) Standard 139~144 (5.47~5.67)Brake pedal play mm (in) Standard 5~9 (0.2~0.35)Master cylinder push rod play mm (in) Standard 1~2 (0.04~0.08)Brake pedal depressed height mm (in) Standard 84 (3.31)Tightening torque N·m (kgf-cm) [ft-lbf]Wheel cylinder set bolt Standard 17.7~26.5 (180~270) [13.0~19.5]Brake backing plate set bolt Standard 137~196 (1400~2000) [101.3~144.7]Outlet plug Standard 52.0~82.4 (530~840) [38.3~60.8]Parking brake release lever set screw Standard 9.1~16.9 (93~172) [6.7~12.5]
Tightening torque N·m (kgf-cm) [ft-lbf]Counterweight set bolt Standard 500~ (5099~ ) [368.9~ ]
Neutral drop testNeutral drop mm (in) Standard 45 (1.77)Natural forward tilt testNatural forward tilt mm (in) Standard 15 (0.59) or lessOil leak test
Lift cylinder oil leak amount (at tilt port) cm3 (in3) Standard 8 (0.49) or less
Tilt cylinder oil leak amount (total for lift and tilt) cm3 (in3) Standard 16 (0.98) or less
sec18.book 8 ページ 2010年4月23日 金曜日 午前10時52分
18-9
MAST
CYLINDER
Mast adjustment (V mast)Inner mast roller clearance mm (in) Standard 0~0.6 (0~0.024)Outer mast roller clearance mm (in) Standard 0~0.6 (0~0.024)Middle lift roller clearance mm (in) Standard 0~0.6 (0~0.024)Lower lift roller clearance mm (in) Standard 0~0.6 (0~0.024)Side roller clearance mm (in) Standard 0~0.6 (0~0.024)Mast strip to inner mast clearance mm (in) Standard 0~1.0 (0~0.039)Mast adjustment (FV·FSV mast)Inner mast roller clearance mm (in) Standard 0~0.6 (0~0.024)Middle mast lower roller clearance mm (in) Standard 0~0.6 (0~0.024)Outer mast roller clearance mm (in) Standard 0~0.6 (0~0.024)Middle mast upper roller clearance mm (in) Standard 0~0.6 (0~0.024)Lower lift roller clearance mm (in) Standard 0~0.6 (0~0.024)Side roller clearance mm (in) Standard 0~0.6 (0~0.024)Mast strip to mast clearance mm (in) Standard 0~1.0 (0~0.039)Tightening torque N·m (kgf-cm) [ft-lbf]Mast support cap set bolt Standard 84~156 (857~1591) [62.0~115.1]Tilt cylinder front pin Standard 76.8~115.2 (783~1175) [56.7~85.0]
Tightening torque N·m (kgf-cm) [ft-lbf]Oil control valve set bolt Standard 14.4~33.6 (147~343) [10.6~24.8]Lift lock unlocking bolt Standard 3.5~4.3 (36~44) [2.6~3.2]
Tightening torque N·m (kgf-cm) [ft-lbf]Yaw rate sensor bracket set bolt Standard 3.3~7.7 (33~79) [2.4~5.7]Yaw rate sensor set bolt Standard 1.0~2.0 (10~20) [0.7~1.5]Swing lock cylinder crank pin set bolt Standard 19~37 (190~370) [13.7~26.8]Swing lock cylinder pin set bolt Standard 19~37 (190~370) [13.7~26.8]Tilt angle sensor set bolt Standard 7.8~18.2 (80~186) [5.8~13.4]Tilt angle sensor link Standard 7.8~18.2 (80~186) [5.8~13.4]Load sensor Standard 22.0~26.0 (224~265) [16.2~19.2]Mast lifting height switch set bolt Standard 16.2~37.8 (165~385) [12.0~27.9]
sec18.book 11 ページ 2010年4月23日 金曜日 午前10時52分
18-12
P1
P4F1
F7
F5SWK
RYAC
PIN CODE ENTRY (OPT)
SWDRYMS
ACCEL
VRH VRTA SPLF SYR SIM1 SIM2
VRA2 LIFT LEVER
MAIN CONTROLLER
VRL1TILT LEVER
VRT1ATT1 LEVER
VRAT11ATT2 LEVER
SH SPB SWBKVRATA
SSTR
VRAT21 VRAT22VRAT12VRT2VRL2
VRA1FAN2 FAN1 FAN3
DISCONNECT SW(OPT)
F4
RYH
RYHLSWCM
LCM
LHR
BATTMBF
ACMDACMPACMDDACMDP
SPLFSSDSSPSSTRSTDMSTPMSYRSIMSTCB
DSFDSRBZCHIHSA
BATTERYCONTACTOR, BATTERYFUSE
AC MOTOR, DRIVEAC MOTOR, PUMPAC MOTOR DRIVER, DRIVEAC MOTOR DRIVER, PUMP