Service Manual

Chassis, Mast & Attachments

DP60 T20C-10001-up
DP70 T20C-60001-up

For use with the S6S Engine Service Manual. 99709-86140

 FOREWORD

This service manual is a guide for servicing Cat® lift trucks. For your convenience the in-
structions are grouped by systems as a ready reference.
The long productive life of your lift truck(s) depends on regular and proper servicing. Ser-
vicing consistent with what you will learn by reading this service manual.
Read the respective sections of this manual carefully and familiarize yourself with all of
the components before attempting to start a test, repair or rebuild job.
The descriptions, illustrations and specifications contained in this manual are for trucks
with serial numbers in effect at the time of printing. Cat Lift Trucks reserves the right to
change specifications or design without notice and without incurring obligation.
The trucks listed in this manual are powered by S6S diesel engines. For the engine servic-
ing, please refer to the applicable engine service manual.

WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may result in death or serious injury or
CAUTION damage to the machine.

Indicates a condition that can cause damage to, or shorten service life of, the lift truck.
NOTE

This document shall not be transferred, rented, or reproduced to a third party without per-
mission.

Pub.No. 99709-86140
1
 WARNING WARNING
The proper and safe lubrication and maintenance Do not operate these trucks unless you have read
for these lift trucks, recommended by Cat Lift and understood the instructions in the OPERA-
Trucks, are outlined in the OPERATION & MAINTE- TION & MAINTENANCE MANUAL. Improper truck
NANCE MANUAL for these trucks. operation is dangerous and could result in injury
Improper performance of lubrication or mainte- or death.
nance procedures is dangerous and could result
in injury or death. Read and understand the OPER-
ATION & MAINTENANCE MANUAL before perform-
ing any lubrication or maintenance on these
trucks.
The serviceman or mechanic may be unfamiliar with many (6) To avoid back injury, use a hoist when lifting compo-
of the systems on this truck. This makes it important to use nents which weight 23 kg (50 lb.) or more. Make sure
caution when performing service work. A knowledge of the all chains, hooks, slings, etc., are in good condition and
system and/or components is important before the removal are of the correct capacity. Be sure hooks are posi-
or disassembly of any component. tioned correctly. Lifting eyes are not to be side loaded
Because of the size of some of the truck components, the during a lifting operation.
serviceman or mechanic should check the weights noted in (7) To avoid burns, be alert for hot parts on trucks which
this Manual. Use proper lifting procedures when removing have just been stopped and hot fluids in lines, tubes and
any components. compartments.
Following is a list of basic precautions that should always (8) Be careful when removing cover plates. Gradually
be observed. back off the last two bolts or nuts located at opposite
(1) Read and understand all warning plates and decals on ends of the cover or device and pry cover loose to
the truck before operating, lubricating or repairing the relieve any spring or other pressure, before removing
product. the last two bolts or nuts completely.
(2) Always wear protective glasses and protective shoes (9) Be careful when removing filler caps, breathers and
when working around trucks. In particular, wear pro- plugs on the truck. Hold a rag over the cap or plug to
tective glasses when pounding on any part of the truck prevent being sprayed or splashed by liquids under
or its attachments with a hammer or sledge. Use weld- pressure. The danger is even greater if the truck has just
ers gloves, hood/goggles, apron and other protective been stopped because fluids can be hot.
clothing appropriate to the welding job being per- (10) Always use tools that are in good condition and be sure
formed. Do not wear loose-fitting or torn clothing. you understand how to use them before performing any
Remove all rings from fingers when working on service work.
machinery. (11) Reinstall all fasteners with same part number. Do not
(3) Do not work on any truck that is supported only by lift use a lesser quality fastener if replacements are neces-
jacks or a hoist. Always use blocks or jack stands to sary.
support the truck before performing any disassembly. (12) If possible, make all repairs with the truck parked on a
(4) Lower the forks or other implements to the ground level, hard surface. Block truck so it does not roll while
before performing any work on the truck. If this cannot working on or under truck.
be done, make sure the forks or other implements are (13) Disconnect battery and discharge any capacitors (elec-
blocked correctly to prevent them from dropping unex- tric trucks) before starting to work on truck. Hang “Do
pectedly. not Operate” tag in the Operator’s Compartment.
(5) Use steps and grab handles (if applicable) when mount-
ing or dismounting a truck. Clean any mud or debris
from steps, walkways or work platforms before using.
Always face truck when using steps, ladders and walk-
ways. When it is not possible to use the designed
access system, provide ladders, scaffolds, or work plat-
forms to perform safe repair operations.
2
(14) Repairs, which require welding, should be performed
only with the benefit of the appropriate reference infor-
mation and by personnel adequately trained and knowl-
edgeable in welding procedures. Determine type of
metal being welded and select correct welding proce-
dure and electrodes, rods or wire to provide a weld
metal strength equivalent at least to that of parent
metal.
(15) Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will it be
damaged in operation by contacting sharp corners, or
by rubbing against some object or hot surface. Place
wiring away form oil pipe.
(16) Be sure all protective devices including guards and
shields are properly installed and functioning correctly
before starting a repair. If a guard or shield must be
removed to perform the repair work, use extra caution.
(17) Always support the mast and carriage to keep carriage
or attachments raised when maintenance or repair work
is performed, which requires the mast in the raised
position.
(18) Loose or damaged fuel, lubricant and hydraulic lines,
tubes and hoses can cause fires. Do not bend or strike
high pressure lines or install ones which have been bent
or damaged. Inspect lines, tubes and hoses carefully.
Do not check for leaks with your hands. Pin hole (very
small) leaks can result in a high velocity oil stream that
will be invisible close to the hose. This oil can pene-
trate the skin and cause personal injury. Use cardboard
or paper to locate pin hole leaks.
(19) Tighten connections to the correct torque. Make sure
that all heat shields, clamps and guards are installed
correctly to avoid excessive heat, vibration or rubbing
against other parts during operation. Shields that pro-
tect against oil spray onto hot exhaust components in
event of a line, tube or seal failure, must be installed
correctly.
(20) Relieve all pressure in air, oil or water systems before
any lines, fittings or related items are disconnected or
removed. Always make sure all raised components are
blocked correctly and be alert for possible pressure
when disconnecting any device from a system that uti-
lizes pressure.
(21) Do not operate a truck if any rotating part is damaged
or contacts any other part during operation. Any high
speed rotating component that has been damaged or
altered should be checked for balance before reusing.

3
HOW TO READ THIS MANUAL (Mounting, Dismounting, Disas-
sembly, and Assembly)

Disassembly

The suggestion for

disassembly is shown
below.
2
Index numbers show
the sequence of
disassembly. 1

209603

Disassembly sequence
(1) Bolt, Washer, Cover (part name)
(2) Snap ring, Output shaft (part name)

Suggestion for disassembly

(1) Output shaft removal
Use the special tools to remove output shaft.

209604
Service data provided in this man-
ual
Clearance between Standard val- 0.020 to 0.105 mm
cylinder body and ue (0.00079 to 0.00413
piston
in.)
Repair or ser- 0.15 mm
vice limit (0.059 in.)

4
Symbols or abbreviations
OP Option
R1/4 Taper pipe thread (external) 1/4 inch (formerly PT1/4)
Rc1/8 Taper pipe thread (internal) 1/8 inch (formerly PT1/
8)
G1/4A Straight pipe thread (external) 1/4 inch (formerly
PF1/4-A)
Rp1/8 Straight pipe thread (internal) 1/8 inch (formerly
PS1/8)

Units
• SI Units are used in this manual.
• The following table shows the conversion of SI unit and
customary unit.

Item SI unit Customary unit

Force 1N 0.1020 kgf
Pressure 1 kPa 0.0102 kgf/cm2
Torque 1 N•m 0.1020 kgf•m

5
 GROUP INDEX

GROUP INDEX Items

Model View, Truck Models Covered, Serial Number Locations, Main

GENERAL INFORMATION
Specifications, Chassis and Mast Model Identification, Dimensions 1
Specifications, Structure, Suggestions for Removal and Installation, Inspection
COOLING SYSTEM
and Adjustment 2
Specifications, Location of Components, Structure, Disassembly and
ELECTRICAL SYSTEM Reassembly, Batteries and Charging, Troubleshooting, Electrical Wiring
Diagram 3
Specifications, Structure, Reduction Ratio, Removal and Installation of Engine
POWER TRAIN
and Transmission Unit 4
POWERSHIFT TRANSMIS- Specifications, Structure, Suggestions for Removal and Installation,
SIONS Disassembly and Reassembly, Readjust, Troubleshooting, Service Data 5
FRONT AXLE AND REDUC- Specifications, Structure, Suggestions for Removal and Installation,
TION DIFFERENTIAL Disassembly and Reassembly, Troubleshooting, Service Data 6
Specifications, Description, Removal and Installation, Disassembly and
REAR AXLE
Reassembly, Adjusting, Troubleshooting, Service Data 7
Specifications, Structure, Disassembly and Reassembly, Adjustment and Testing,
BRAKE SYSTEM
Troubleshooting, Service Data 8
Specifications, Structure and Functions, Removal and Installation, Disassembly
STEERING SYSTEM
and Reassembly, Troubleshooting, Service Data 9
Specifications, Structure and Functions, Removal and Installation, Disassembly
HYDRAULIC SYSTEM and Reassembly, Inspection and Adjustment, Testing, Troubleshooting, Service
Data
10
Specifications, Structure, Operation of Triplex Mast, Suggestions for Removal
MASTS AND FORKS and Installation, Disassembly and Reassembly, Chain Adjustment,
Troubleshooting, Service Data
11
Applicable Attachment Models, Specifications, Structure, Suggestions for
FORK POSITIONER Removal and Installation, Disassembly and Reassembly, Troubleshooting,
Service Data
12
Applicable Attachment Models, Specifications, Structure, Suggestions for
SIDE SHIFTER Removal and Installation, Disassembly and Reassembly, Troubleshooting,
Service Data
13
Inspection Point, Tightening Torque of Standard Bolts, Periodic Replacement
SERVICE DATA
Parts, Lubrication Standards, Weight of Major Components, Special Tools 14

7
 GENERAL INFORMATION
1. Model View................................................................................................................... 1-2

2. Truck Models Covered ................................................................................................. 1-2

1
3. Serial Number Locations.............................................................................................. 1-3

4. Main Specifications ...................................................................................................... 1-4 2

5. Chassis and Mast Model Identification......................................................................... 1-5
3
6. Dimensions .................................................................................................................. 1-6
4
5
6
7
8
9
10
11
12
13
14

1-1
GENERAL INFORMATION

1. Model View

205711

2. Truck Models Covered

This Service Manual applies to the following truck models (common names).
Model code - Serial
Truck model Transmission Engine mounted
number
Torque converter drive trans-
DP60 T20C-10001-up Mitsubishi S6S diesel engine
mission
Torque converter drive trans-
DP70 T20C-60001-up Mitsubishi S6S diesel engine
mission

1-2
 GENERAL INFORMATION

3. Serial Number Locations

Diesel-engine serial number Chassis serial number

Mast serial number Name plate Transmission serial number

206500

1-3
GENERAL INFORMATION

4. Main specifications

Truck model DP60 DP70

Truck Model Cat T20C
Type Standard (with 2-speed powershift transmission)
6000/600 kgf/mm 7000/600 kgf/mm
Capacity/load center
(13228/24 lbf/in.) (15432/24 lbf/in.)
Lift, maximum 3300 mm (130 in.)
Lift speed (unloaded/loaded) 470/440 mm/sec (93/87 fpm)
Lowering speed (unloaded/loaded) 550 mm/sec (108 fpm)
Mast tilt angle (forward-backward) 6˚–12˚
Free lift 205 mm (8.1 in.)
Forward travel speed (1st/2nd)
10/27.5 km/h (6.2/17.1 mph)
Reverse travel speed (1st/2nd)
Minimum turning radius 3310 mm (130.3 in.) 3395 mm (133.7 in.)
Minimum intersecting aisle 3000 mm (118.1 in.) 3050 mm (120 in.)
Front wheel (double- Size 8.25-15-12PR (1)
tire) Inflation 0.7MPa (7kgf/cm2) [101 psi]
Size 8.25-15-12PR (1)
Rear wheel
Inflation 0.7MPa (7kgf/cm2) [101 psi]
Relief-valve setting of power steering 10.8 MPa (110 kgf/cm2) [1567 psi]
Relief-valve setting of control valve 19.1 MPa (195 kgf/cm2) [2770 psi]
Truck weight 8710 kg (19200 lb) 9320 kg (20546 lb)

1-4
 GENERAL INFORMATION

5. Chassis and Mast Model Identification

[Chassis]

DP 60

Maximum capacity
60: 6000 kg (13228 lb)
70: 7000 kg (15432 lb)

Engine type
DP: Diesel engine type

[Mast]
4 P 70 B 25

Maximum lifting height

["25" stand for 2500 mm (98.4 in.)]
Order of the minor change
("A" for the original, "B" for the first change,
"C" for the second change, and so on)

Applicable truck model designation

70: 6,7 ton class

Kind of mast
P: simplex mast
M: triplex mast

Major change
("2" for the original, "3" for the first change,
and so on up to "9")

1-5
GENERAL INFORMATION

6. Dimensions

J K L

H1 H2

U
B A
C

T
S G
P

N M
E I

209433A

1-6
 GENERAL INFORMATION

No. Truck model DP60 DP70

A Maximum lift 3300 mm (130 in.)
B Overall height at maximum lift 4580 mm (180.3 in.)
Overall mast height
C 2720 mm (107.1 in)
Height of mast lowered
D Free lift 205 mm (8.1 in.)
E Fork length 1220 mm (48 in.)
F Fork width 150 mm (5.9 in.)
G Fork thickness 65 mm (2.36 in.)
Mast tilt angle (forward-back-
H1, H2 6˚–12˚
ward)
I Truck length 4805 mm (189.2 in) 4855 mm (191.1 in.)
J Overall width (outside of tires) 2170 mm (85.4 in.)
K Tread (front wheel) 1650 mm (65 in)
L Tread (rear wheel) 1650 mm (65 in)
M Wheelbase 2300 mm (90.6 in)
N Front overhang 586 mm (23 in.)
P Minimum height from ground 265 mm (10.4 in.)
R Minimum radius 3310 mm (130 in) 3395 mm (134 in.)
S Underclearance (at mast) 170 mm (6.7 in.)
Underclearance (at counter-
T 240 mm (9.5 in.)
weight)
Overall height (head-guard
U 2420 mm (95.3 in.)
height)

1-7
 COOLING SYSTEM
1. Specifications ............................................................................................................... 2-2

2. Structure....................................................................................................................... 2-3
1
3. Suggestions for Removal and Installation.................................................................... 2-4
3.1 Removing Fan Belt ............................................................................................................................... 2-4
3.1.1 Suggestions for Removal and Installation................................................................................................... 2-4 2
3.1.2 Procedure involving removal of counterweight ........................................................................................... 2-6
3.1.3 Suggestions for Removal and installation ................................................................................................... 2-7
3.1.4 Installation ................................................................................................................................................... 2-7
3
4. Inspection and Adjustment........................................................................................... 2-8 4
4.1 Inspection of Fan Belt ........................................................................................................................... 2-8
4.2 Fan Belt Tension Adjustment................................................................................................................ 2-8
5
6
7
8
9
10
11
12
13
14

2-1
COOLING SYSTEM

1. Specifications

Truck model DP60 DP70

Cooling method Forced circulation of coolant
Radiator type Corrugated fins with pressure cap
Total coolant capacity 18 L (1098 cu.in.) [4.7 U. S. gal.]
Water pump type Volute type, V-belt driven
Thermostat type Wax pellet

2-2
 COOLING SYSTEM

2. Structure

211301

1 Universal joint 7 Transmission oil cooler

2 Pulley boss 8 Upper hose
3 Tensioner pulley 9 Lower hose
4 Cooling fan 10 Reserve tank
5 Fan belt 11 Transmission oil hose
6 Radiator

The cooling system features a reserve tank as standard The system incorporates a transmission oil cooler.
equipment and an arrangement that facilitates adjustment of
the fan belt tension.

2-3
COOLING SYSTEM

3. Suggestions for Removal and Installation

3.1 Removing Fan Belt
3.1.1 Suggestions for Removal and Installation
(1) Preparation
(a) Remove the radiator cover.
(b) Remove the engine cover and gas springs.

211302

(2) Removal sequence

1 Drain cock 5 Radiator
2 Cap 6 Universal joint
3 Hose (for coolant) 7 Tensioner pulley locking bolt
4 Hose (for transmission oil) 8 Fan belt

2-4
 COOLING SYSTEM

(3) Suggestions for Removal

(a) Make sure that engine coolant is not hot, then open the
drain cock to allow the coolant to be drained.
(b) Insert Ratchet Wrench A through the adjusting hole in
the frame and loosen the tensioner pulley locking bolt
one or two turns. With a claw bar move the tensioner
pulley as far as possible to the fan side, then tighten the
tensioner pulley locking bolt so that the fan belts can be
easily removed.

203767

(4) Installation
Follow the removal procedure in reverse while noting
the following instructions.
(a) Check the fan bearing for smooth rotation with the belt
removed. Replace the bearing if it generates abnormal
sound.
(b) Install the belt and push it at a point midway between
the driven and drive pulleys to make sure that the ten-
sioner pulley moves, then tighten the pulley lock bolt
firmly.
(c) Connect each hose to the radiator making sure that the
end of the hose reaches the root of the fitting. Tighten
the clamp and make sure the hose end is stopped at the
flare of the fitting.
(d) Pour antifreeze and coolant into the radiator and start
the engine. Warm-up the engine while checking for
abnormal sound. Check the reserve tank to see whether
it is filled with the given quantity of coolant.

2-5
COOLING SYSTEM

3.1.2 Procedure involving removal of counterweight

(1) Preparation
(a) Remove the radiator cover.
(b) Remove the counterweight mounting bolts, then
remove the counterweight using slings and hoist.

NOTE
Before hoisting, check the weight of the counterweight and
select a sling appropriate for lifting the weight.

211303

(2) Removal sequence

1 Muffler 4 Radiator
2 Fan assembly 5 Fan belt
3 Universal joint

2-6
 COOLING SYSTEM

3.1.3 Suggestions for Removal and installation

(1) Remove the bolts of the fan support, remove the belt
from the driven pulley, and remove the fan assembly.
Place the fan assembly on a bench facing the fan sup-
port down, then rotate the fan to check the bearing.
Replace the bearing if it generates abnormal sound.

207759

(2) Remove the two lower radiator mounting bolts. Loosen

(do not remove) the two upper mounting bolts.
(3) Push the radiator toward the engine to remove the belt
from the tensioner pulley and let the belt drop onto the
universal joint before it is removed.

203463

3.1.4 Installation
Follow the removal sequence in reverse while noting the
following instructions.
(1) Installation of fan assembly: Attach the belt to the
driven pulley (included in the fan assembly), then
screw in one of the fan support lower bolts and finger
tighten it. Loosen the tensioner pulley locking bolt and
move the fan assembly until it aligns with the boss
(frame) while holding the top of the fan support. Then,
tighten all the remaining bolts to secure the fan assem-
bly.
(2) Through a space in the fan, push the belt by hand at the
midpoint between the drive and driven pulleys to make 204533
sure that the tensioner pulley moves. Then, tighten the
pulley lock bolt firmly.

2-7
COOLING SYSTEM

4. Inspection and Adjustment

4.1 Inspection of Fan Belt
(1) Check the belt for contamination of oil, grease or dust.
If the belt is only slightly dirty, remove it and clean
with a shop towel or paper. If necessary, replace the
belt. Never use gasoline, petroleum or oil for washing
the belt.
(2) Check the belt thoroughly and closely when the engine
is overhauled or the belt tension is adjusted. If any
damage is found, replace the belt with a new one.

4.2 Fan Belt Tension Adjustment

(1) Through the adjustment hole in the frame, loosen the
tensioner pulley locking bolt one or two turns using a
ratchet wrench A.
(2) The belt will become tight by the force of the tensioner
spring. Then tighten the pulley locking bolt.

203767

2-8
 ELECTRICAL SYSTEM
1. Specifications ............................................................................................................... 3-2

2. Location of Components .............................................................................................. 3-3

1
3. Structure....................................................................................................................... 3-4
3.1 Console box .......................................................................................................................................... 3-4
3.2 OK Monitor............................................................................................................................................ 3-4 2
3.3 Major Components................................................................................................................................ 3-5
3.3.1 ECU (Electronic Control Unit) ..................................................................................................................... 3-5
3.3.2 Starter Switch (Anti-restart Type)................................................................................................................ 3-6
3
3.3.3 Lighting switch............................................................................................................................................. 3-7
3.3.4 Fuse box ..................................................................................................................................................... 3-7 4
3.3.5 Spare terminal............................................................................................................................................. 3-8
3.3.6 Lamp Bulb Specifications............................................................................................................................ 3-8
5
4. Disassembly and Reassembly ..................................................................................... 3-9
4.1 Disassembly of Console Box ................................................................................................................ 3-9 6
4.1.1 Disassembly sequence ............................................................................................................................... 3-9
4.1.2 Reassembly ................................................................................................................................................ 3-9
4.2 Combination Meter.............................................................................................................................. 3-10 7
4.2.1 Disassembly.............................................................................................................................................. 3-10
4.2.2 Reassembly .............................................................................................................................................. 3-10
4.3 Electrical Components in the Console Box......................................................................................... 3-11
8
5. Batteries and Charging .............................................................................................. 3-12 9
5.1 Battery Conditions and Adjustment Method Based on the Electrolyte Specific Gravity (S.G.) ........... 3-12
5.2 Relationship between Electrolyte S.G. and Charging Capacity .......................................................... 3-12
5.3 Precautions for Battery Charging........................................................................................................ 3-12 10
5.4 Precautions for Servicing the Charging System with Alternator ......................................................... 3-13

11
6. Troubleshooting ......................................................................................................... 3-14
6.1 Starter System .................................................................................................................................... 3-14
6.2 Gauges ............................................................................................................................................... 3-15 12
6.3 Lighting System .................................................................................................................................. 3-16
6.4 Alarm Unit ........................................................................................................................................... 3-17
6.5 Battery................................................................................................................................................. 3-18
13
7. Electrical Wiring Diagram........................................................................................... 3-19 14

3-1
ELECTRICAL SYSTEM

1. Specifications

Truck model DP60 DP70

Model number and
65D23R × 2
quantity
Battery
Voltage (V) 12
Capacity (Ah) 52
Direction lever Electric
Console box With OK monitor
2-speed automatic transmission controller ECU (Electronic Control Unit)
Anti-restart type (with the built-in mechanical lockout for preventing duplicated start-
Starter switch
ing)
Lamps 24V, Refer to “Lamp Bulb Specifications”.

3-2
 ELECTRICAL SYSTEM

2. Location of Components

Safety relay
Engine stop control timer

Turn signal switch

Horn
Forward-reverse
Stop lamp switch Console box switching solenoid

Front combination
lamp

Electronic control unit

Head lamp (ECU)

Front combination
Torque converter lamp
oil thermounit

Head lamp
Fuel tank unit
Travel speed sensor
Battery
Engine stop
Brake fluid solenoid
level sensor

Glow plug

Starter relay Back-up buzzer

(optional)
Battery

Engine oil
pressure switch

Alternator

Rear combination lamp

Rear combination lamp
Engine thermounit
211305

NOTE
Every harness should be properly secured to avoid interfer-
ence or rubbing by other parts. Repair damaged harnesses
with vinyl tape.

3-3
ELECTRICAL SYSTEM

3. Structure
3.1 Console box
1 Engine coolant temperature gauge
2 Speed selector switch
3 Fuel gauge
4 Service hourmeter
5 OK monitor
6 Starter switch
7 Lighting switch
8 Fuse box

207464
3.2 OK Monitor

207465
Function
No. Indicator lamp OFF ON or Flashing Remark
1 Brake fluid level indicator lamp Normal fluid level Low fluid level
Transmission oil temperature indica- Normal
2 Overheating
tor lamp temperature
3 Glow plug indicator lamp Heating completed Heating
4 Charging indicator lamp Normally charged Charging system abnormal
5 Engine oil pressure indicator lamp Normal oil pressure Low oil pressure
Normal element
6 Air cleaner element indicator lamp Element clogged Option
condition
7 Head lamp beam indicator lamp Low beam High beam Option
8 Engine coolant level indicator lamp Normal level Low level Option
9 Turn signal indicator lamp Turn signal ON

How to check indicator lamp bulbs

Each bulb is normal if the indicator lamp comes ON with the starter switch key turned to (ON) position. However, the charge
condition indicator lamp and engine oil pressure indicator lamp will not be illuminated.

3-4
 ELECTRICAL SYSTEM

3.3 Major Components

3.3.1 ECU (Electronic Control Unit)

Failure indicator lights

LED (green)

LED (red)

Rear (mounting) face

205509
The Electronic Control Unit (ECU) has a built-in 1-chip It is also provided with the fail-safe systems (that allow for
microcomputer to process signals from the travel speed sen- a unit to be switched to the safer side should any malfunc-
sor for activating the 2-speed automatic transmission. tion occur on it) as shown in the table below.
This ECU has “self-diagnostic” failure indicator lamps
which allow the mechanic to understand the problem in the NOTE
electrical system. The failure indicator lamps are located on the rear (mount-
ing) face of the ECU box. This makes it necessary to
remove the ECU from the truck to observe these lamps.
Fail-safe Systems

Name Function
Turns OFF the power line and indicates the trouble content with the failure indicator lamp, if
Solenoid output signal circuit open
any open circuit is detected in the solenoid output signal circuit.
Allows the truck to run at the present travel speed and indicates the trouble content with the
Travel speed sensor circuit open
failure indicator lamp.

Failure indicator lamp

Cause of trouble Failure indicator lamp flashing pattern

Travel speed sensor circuit open

2-speed automatic transmission

solenoid circuit open

3-5
ELECTRICAL SYSTEM

NOTE
Each failure indicator lamp turns ON or turns OFF in the
following situations.

ON

OFF
204668

3.3.2 Starter Switch (Anti-restart Type) engine troubles or starter damages possibly caused by any
This switch has a built-in mechanical lockout to prevent operation mistake.
duplicated starting. The starter switch is wired in such a way to energize the
Since this lockout mechanism restraints the starter switch glow plugs, if it is set in the (ON) position for preheating.
(key) from moving from (ON) position to ÅiSTART)
position while the engine is running, it serves as to prevent

203561A

3-6
 ELECTRICAL SYSTEM

3.3.3 Lighting switch

Connection Chart

206481

3.3.4 Fuse box

Connection Chart

Capac-
Symbol Major components to be connected
ity
A 10A F-N-R lever
Instrument panel lamp, turn signal
B 10A
lamp
C 10A Spare terminal
D 15A Lamps
E 10A Horn
F 10A Spare fuse
Transmission controller, vacuum
G 10A
buzzer, stop lamps 101441F
H 10A Back-up lamps
J 15A Spare fuse

3-7
ELECTRICAL SYSTEM

3.3.5 Spare terminal

The spare supply cord extends from the fuse box in the con-
sole box. (Another spare terminal is in the chassis-side main
harness.)

Color code Lg (light green)

Removing the console box rear panel will permit you to

gain access to this spare terminal, which is usually taped
onto the harness protector with vinyl tape.

Spare terminal
207209

3.3.6 Lamp Bulb Specifications

Valves
Qua Color of
Item For 24V sys- Schematic dia- Remark
ntity lens
tem gram
Head lamps 2 Frosted 60W A 60/60W, option

Combination lamps Turn signal lamps 2 Amber 25W B Standard (mounted on the
(front) Clearance lamps 2 Frosted 12W C overhead guard)

Tail and stop

2 Red 10/25W B
lamps
Combination lamps
(rear) Turn signal lamps 2 Amber 25W B
Back-up lamps 2 Frosted 12W B
Working lamps (front) 2 Frosted 60/60W A Option
Working lamps (rear) 2 Frosted 60/60W A Option
License plate lamp 1 Frosted 12W C Option
Instrument panel lamps 2 Frosted 3W D For combination meter
OK monitor indicator lamps 5 Frosted 3W E For combination meter

A B C D E

205511

3-8
 ELECTRICAL SYSTEM

4. Disassembly and Reassembly

4.1 Disassembly of Console Box

207175

4.1.1 Disassembly sequence

(1)Disconnect the electrical wires at connectors 1.
(2)Remove screws 2 (four) securing the cover.
(3)Remove screws 3 (six) and separate the from panel and rear panel.
(4)Remove screws 4 (four) securing the combination meter panel.

NOTE
Remove screws 3 and 4 to replace any bulb in the console
box.

4.1.2 Reassembly
Reassemble in the reverse order of disassembly sequence.

3-9
ELECTRICAL SYSTEM

4.2 Combination Meter

4.2.1 Disassembly
(1) Disassembly sequence
1 Meter panel
2 Meter cover
3 Engine coolant temperature gauge
4 Service hourmeter
5 Fuel gauge
6 Meter case
7 Printed circuit plate
8 Bulb
9 Socket

NOTE
Be careful not to damage the printed circuit plate.
(2) Indicator Bulb Replacement
Turn the socket to the left to remove it from the printed
circuit plate.
Then, remove the bulb from the socket.
For the location of each bulb, refer to “OK Monitor.”

206486

4.2.2 Reassembly
Reassemble in the reverse order of disassembly sequence.

3-10
 ELECTRICAL SYSTEM

4.3 Electrical Components in the Console Box

206423

1 Power relay 5 Glow plug timer

2 Power relay 6 Lighting switch
3 Turn signal relay 7 Starter switch
4 Glow plug relay 8 Fuse

3-11
ELECTRICAL SYSTEM

5. Batteries and Charging

5.1 Battery Conditions and Adjustment Method Based on the Electrolyte Specific Gravity (S.G.)
Electrolyte S.G. reading
Battery condition Adjustment
at 20˚C (68˚F)
If difference in S.G. between any two cells is less than
0.04, continue to use the battery without additional
charging. Where the difference in S.Gff is greater than
1.280 to 1.265 Battery is fully or well charged.
0.04, discharge the battery with an efficiency-based man-
ner. If the condition is improved, recharge the battery
while adjusting the electrolyte specific gravity.
Recharge the battery. Check for any short-circuited cord
1.260 to 1.225 Battery is half charged.
or corroded connection in the electrical system.
Recharge the battery.
1.220 or less Battery is discharged, requiring cares. If difference in S.G. among the cell is large, adjust the
S.G. during recharging.
Recharge until voltage and S.G. of each cell stabilize and
are maintained constant for at least 2 hours.
A cell with a low S.G. is in shorted condi- During recharging, adjust the S.G. to anywhere between
When the difference in tion. 1.280 and 1.265.
S.G. is greater than 0.040 Some electrolyte has been lost. Too much If difference in S.G. among the cells is more than 0.040
electrolyte, or water in electrolyte. and a low S.G. is found in certain cells only, replace the
battery. After leaving it for 12 to 96 hours, give it a high
current discharge test.

5.2 Relationship between Electrolyte S.G. and

Charging Capacity
Whether the battery is fully charged can be checked from
the electrolyte S.G. (between 1.280 and 1.265) read with a
hydrometer. However, it can also be judged theoretically
from the reduction rate of the electrolyte quantity. If refill-
ing is necessary every month or so, the system is tending to
over-charge the battery. If refilling is not required for over 3
months, it is likely that the system is inadequately charging.

5.3 Precautions for Battery Charging

(1) The charging current should be about 1/10 the capacity CAUTION
Be sure to turn off the starter switch and lighting
of the battery to be charged.
switch before disconnecting or connecting the
(2) For quick charging, the battery capacity in ampere
battery cables.
should not be exceeded.
(IC regulator may be damaged.)
(3) During charging, adjust the charging current to prevent
the electrolyte temperature from rising beyond 45˚C
(113˚F).
(4) When connecting cables to the battery terminal, begin
with the cable for the positive (+) terminal. When dis-
connecting them from the battery, begin with a cable
for the negative (-) terminal.

3-12
Thank you very much
for your reading.
Please Click Here
Then Get More
Information.