SERVICE DATA

Maintenance Schedule ..........................................................................15 1

Tightening Torque for Standard Bolts and Nuts .............................15 6
Periodic Replacement Parts ................................................................15 8
Location of Periodic Replacement Parts ....................................................15 9
Lubrication Instructions ........................................................................ 15 10
Lubrication Chart ....................................................................................... 15 10
Fuel and Lubricant Specifications .............................................................. 15 11
Adjustment Value and Oil Quantities ......................................................... 15 12
Special Service Tools ............................................................................. 15 14
Special Service Tools ................................................................................ 15 14
Special Service Tools (FC Truck only) ....................................................... 15 18

15
 SERVICE DATA

Maintenance Schedule

Abbreviation X: Check, C: Clean, D: Drain, L: Lubricate, R: Replace

Pre-start (daily/10 hours)

1st month (200 hrs) only

12 months (2000 hours)

6 months (1000 hours)
3 months (500 hours)

Others (see Note 1)

Weekly (50 hours)
Inspection point How to check Service data

Brake drum nuts & bolts X

1 ton: 0.5 to 1.0 mm
(0.0197 to 0.0394 in.)
Brake drum & shoe clearance Feeler gauge X
2, 3 ton: 0.1 to 0.35 mm
(0.004 to 0.014 in.)
Brake hose, pipes & joints Visual X
Powershift T/M: 7 mm
Brake pedal play Scale X (0.2756 in.)
Manual T/M: 7 mm (0.2756 in.)
1 ton: 150 to 200 N
(15 to 20 kgf) [34 to 45 lbf]
Brake

2 ton: 200 to 250 N

Parking brake lever operating effort Spring scale X
(20 to 25 kgf) [45 to 56 lbf]
3 ton: 230 to 250 N
(23 to 25 kgf) [52 to 56 lbf]

Service brake fluid level Visual X

Brake clutch/inching pedal rod
Visual/wrench L
(see Note 2)
Brake master cylinder hoses &
R
rubber parts
Service brake fluid R 135 cc (8.238 cu in.)
Brake wheel cylinder rubber parts R
Radiator fin (see Note 2) Visual C C
Cooling fan Visual/feel X
Engine coolant level Visual X
Radiator filler cap Visual/feel X X
Rubber hose condition Visual/feel X X
Cooling

V-belt (fan & alternator) tension Gasoline engine: 11 to 13 mm

(deflection) (0.43 to 0.51 in.)
Scale X
Diesel engine: 10 to 12 mm
(0.39 to 0.47 in.)
1 ton: 6.8 liter (1.80 U.S. gal.)
Engine coolant (incl. reserve tank) R 2 ton: 7.4 liter (1.96 U.S. gal.)
3 ton: 8.7 liter (2.30 U.S. gal.)

15-1
SERVICE DATA

Abbreviation X: Check, C: Clean, D: Drain, L: Lubricate, R: Replace

Pre-start (daily/10 hours)

1st month (200 hrs) only

12 months (2000 hours)

6 months (1000 hours)
3 months (500 hours)

Others (see Note 1)

Weekly (50 hours)
Inspection point How to check Service data

Alternator Operation/visual X X
Back lamps Visual X
Battery electrolyte level (see Note 4) Visual X
Battery electrolyte specific gravity
Hydrometer X X 1.28 or higher
(see Note 4)
Driving interlock system Operation/visual X
Electrical wires Visual/feel X X
Electrical

Horn Operation/aural X
Meter panel (instrument) lamps
Operation/visual X
(incl. parking brake and seat belt)
Mast interlock system Operation/visual X
Parking brake buzzer Operation/aural X
Starter Operation/aural X X
Stop lamps Operation/visual X
Working & head lamps Operation/visual X
Cylinder head bolt & manifold nut Wrench X
Engine (exhaust, noise, vibration) Visual/feel X
Engine oil level Dip stick X
Idling speed (for carburetor and Gasoline-engine models: 700 rpm
Tachometer X
diesel engine) Diesel-engine models: 750 rpm
Gasoline engine (hot):
Engine

0.38 mm (0.0150 in.)

Intake & exhaust valve clearance Feeler gauge X X X
Diesel-engine models (cold):
0.25 mm (0.0098 in.)
Positive crankcase ventilation valves
Air blow/visual X
& hoses
Engine oil R R
Engine oil filter R R
Frame assist grip Visual/wrench X
Frame & Chassis

Loosen bolts & nuts Wrench X X

Overhead guard Feel/wrench X
Seat adjustment Operation/wrench X
Seat belt Operation/visual X

15-2
 SERVICE DATA

Abbreviation X: Check, C: Clean, D: Drain, L: Lubricate, R: Replace

Pre-start (daily/10 hours)

1st month (200 hrs) only

12 months (2000 hours)

6 months (1000 hours)
3 months (500 hours)

Others (see Note 1)

Weekly (50 hours)
Inspection point How to check Service data

Tar in vaporizer (see Note 3) Check & drain D D

Fuel hose, pipes & joints (see Note 5) Visual X
Fuel level Meter panel X
Check injection nozzle (for D engine) X
Injection nozzle (for G, LP & G/L
X X
dual engines with electronic control)
Clean gasoline fuel filter (for G &
G/L dual engines w/o elec. cont.) C
Fuel

(see Note 3)
LPG fuel filter (see Note 3) C
Change diesel fuel filter (see Note 3) R R
Fuel hose R**
Change gasoline fuel filter (for G &
G/L dual engine w/o elec. cont.) R R
(see Note 3)
LPG fuel filter (see Note 3) R
Vaporizer rubber parts R
Oil pressure
Control valve X
gauge
Hydraulic hose, pipes & joints Visual X
Hydraulic oil Visual X
Hydraulic

Hydraulic pump Visual/aural X

Hydraulic tank strainer Visual C
Hydraulic hose (high-pressure hose) R*
1 ton: 28 liter (7.398 U.S. gal.)
Hydraulic oil R
2, 3 ton: 39 liter (10.30 U.S. gal.)
Hydraulic tank return oil filter R R
Check distributor point, cap & rotor
(for G & G/L dual engine w/o elec. X X
cont.)
Ignition

Check ignition timing (for G & G/L

X X
dual engine w/o elec. cont.)
Spark plug gap Plug gauge X X
Clean distributor inside (for G &
C
G/L dual engine w/o elec. cont.)

15-3
SERVICE DATA

Abbreviation X: Check, C: Clean, D: Drain, L: Lubricate, R: Replace

Pre-start (daily/10 hours)

1st month (200 hrs) only

12 months (2000 hours)

6 months (1000 hours)
3 months (500 hours)

Others (see Note 1)

Weekly (50 hours)
Inspection point How to check Service data
Intake

Air cleaner element (see Note 2) Visual C

Air cleaner element (see Note 2) R
Lift chains Operation/visual X
Lift cylinder mounting bolts Feel/wrench X
Load backrest Operation/visual X
Mast & forks Operation/visual X
Front end

Mast strip sliding surfaces Visual X

Tilt cylinder socket bolts Feel/wrench X
Lift chains (see Note 2) L L
Mast support (see Note 2) L L
Tilt socket pins (see Note 2) L L
Lift chains R***
Front axle Dye check/visual X
Power steer cylinder Operation/visual X
Rear axle Operation/visual X
Steer gear box Operation/visual X
Steer & Axle

Play 15 to 30 mm (0.5906 to
Steer wheel Operation/scale X
1.181 in.) at engine idling
King pins (see Note 2) L L
Tie rod pins (see Note 2) L L
Power steer cylinder hoses &
R**
rubber parts
Accelerator pedal Operation X
Check clutch (slipping, free play &
X
fluids for manual T/M)
Check clutch pedal (for manual T/M) X
Transmission & Drive

Differential oil Visual X X

Inching pedal (for powershift T/M) Operation X
T/M gear & bearing Operation X
T/M oil Visual X
Last chance filter (T/M control valve) Visual C
T/M strainer Visual C
Lubricate clutch pedal shifter shaft
L L
(for manual T/M)
15-4
 SERVICE DATA

Abbreviation X: Check, C: Clean, D: Drain, L: Lubricate, R: Replace

Pre-start (daily/10 hours)

1st month (200 hrs) only

12 months (2000 hours)

6 months (1000 hours)
3 months (500 hours)

Others (see Note 1)

Weekly (50 hours)
Inspection point How to check Service data

Lubricate T/M change levers

(for manual T/M)
Adjust inching pedal for powershift Cable play: 0.5 to 1.0 mm
Scale X
T/M (0.0197 to 0.0394 in.)
Clutch master cylinder hoses &
Transmission & Drive

R
rubber parts
Clutch release cylinder hoses &
R
rubber parts
1 ton: 5.5 liters (1.45 U.S. gal.)
Differential oil R 2 ton: 9.3 liters (2.46 U.S. gal.)
3 ton: 8.7 liters (2.30 U.S. gal.)
Powershift T/M:
10 liter (2.6 U.S. gal.)
Change T/M oil R
Manual T/M:
5 liter (1.3 U.S. gal.)
Tire & rims Visual X
Wheel

Wheel & nuts Torque wrench X

Knuckles Operation/visual X
General

Oil, fuel & coolant leak Walk around X

Note 1: *: Change in 1 to 2 years

**: Change in 2 years
***: Change in 2 to 4 years
Note 2: In corrosive or abrasive environments, clean, lubricate and change more frequently.
Note 3: When fuel with poor quality is used, check, drain, clean and change more frequently.
Note 4: Not required if battery is full maintenance free battery.
Note 5: Apply soap suds to the piping joints to check for any gas leakage after replacing the LPG tank.

15-5
SERVICE DATA

Tightening Torque for Standard Bolts and Nuts

With spring washer 101656

Nominal Pitch
size 7 8 10
mm in. mm in. Nm kgfm lbfft Nm kgfm lbfft Nm kgfm lbfft
6 0.24 1 0.04 7.4 0.75 5.4 9.6 0.98 7.1 12.7 1.3 9.4
8 0.32 1.25 0.05 16.7 1.7 12.3 22.6 2.3 16.6 30.4 3.1 22.4
10 0.39 1.25 0.05 34.3 3.5 25.3 45.1 4.6 33.3 69.6 7.1 51.4
12 0.47 1.25 0.05 63.7 6.5 47.0 82.4 8.4 60.8 122.6 12.5 90.4
14 0.55 1.5 0.06 102.0 10.4 75.2 132.4 13.5 97.6 192.2 19.5 141.8
16 0.63 1.5 0.06 157.9 16.1 116.5 202.0 20.6 149.0 287.3 29.3 211.9
18 0.71 1.5 0.06 224.6 22.9 165.6 292.2 29.8 215.5 413.8 42.2 305.2
20 0.79 1.5 0.06 310.9 31.7 229.3 404.0 41.2 298.0 573.7 58.5 423.1
22 0.87 1.5 0.06 413.8 42.2 305.2 537.4 54.8 396.4 763.0 77.8 562.7
24 0.95 1.5 0.06 547.2 55.8 403.6 711.0 72.5 524.4 1006.2 102.6 742.1
27 1.06 1.5 0.06 794.3 81.0 585.9 1032.6 105.3 761.6 1451.1 148.0 1070.5
30 1.18 1.5 0.06 1100.3 112.2 811.5 1430.8 145.9 1055.3 2012.3 205.2 1484.2
33 1.30 1.5 0.06 1467.1 149.6 1082.1 1907.4 194.5 1406.8 2680.2 273.3 1976.8
36 1.42 1.5 0.06 1918.2 195.6 1414.8 2493.8 254.3 1839.4 3497.1 356.6 2579.3
39 1.54 1.5 0.06 2461.5 251.0 1815.5 3198.8 326.2 2359.4 4469.9 455.8 3296.8
Without spring washer 101656
Metric
fine Nominal
thread size Pitch 7 8 10
mm in. mm in. Nm kgfm lbfft Nm kgfm lbfft Nm kgfm lbfft
6 0.24 1 0.04 8.6 0.88 6.4 10.8 1.1 8.0 14.7 1.5 10.8
8 0.32 1.25 0.05 19.6 2.0 14.5 26.5 2.7 19.5 36.6 3.7 26.8
10 0.39 1.25 0.05 41.2 4.2 30.4 53.0 5.4 39.1 81.4 8.3 60.0
12 0.47 1.25 0.05 74.5 7.6 55.0 97.1 9.9 71.6 144.2 14.7 106.3
14 0.55 1.5 0.06 119.6 12.2 88.2 155.9 15.9 115.0 226.5 23.1 167.1
16 0.63 1.5 0.06 182.4 18.6 134.5 237.3 24.2 175.0 338.3 34.5 249.5
18 0.71 1.5 0.06 263.8 26.9 194.6 343.2 35.0 253.2 487.4 49.7 359.5
20 0.79 1.5 0.06 365.8 37.3 269.8 475.6 48.5 350.8 674.7 68.8 497.6
22 0.87 1.5 0.06 486.4 49.6 358.8 632.5 64.5 466.5 897.3 91.5 661.8
24 0.95 1.5 0.06 643.3 65.6 474.5 836.5 85.3 617.0 1183.7 120.7 873.0
27 1.06 1.5 0.06 934.6 95.3 689.3 1216.0 123.9 896.9 1707.3 174.1 1259.3
30 1.18 1.5 0.06 1294.5 132.0 954.8 1682.8 171.6 1241.2 2367.3 241.4 1746.0
33 1.30 1.5 0.06 1726.0 176.0 1273.0 2243.8 228.8 1654.9 3153.8 321.6 2326.1
36 1.42 1.5 0.06 2256.5 230.1 1664.3 2934.1 299.2 2164.1 4114.0 419.6 3035.0
39 1.54 1.5 0.06 2896.0 295.3 2135.9 3763.8 383.8 2776.0 5258.3 536.2 3878.3

Remarks: 1. The tolerance on the torque is 10%.

2. The torque is for dry condition.

15-6
 SERVICE DATA

With spring washer 101656

Nominal Pitch
size

mm in. mm in. Nm kgfm lbfft Nm kgfm lbfft Nm kgfm lbfft

10 0.39 1.5 0.06 33.3 3.4 24.6 43.1 4.4 31.8 67.7 6.9 49.9
12 0.47 1.75 0.07 58.8 6.0 43.4 76.5 7.8 56.4 115.7 11.8 85.3
14 0.55 2 0.08 96.4 9.8 70.9 124.5 12.7 91.9 182.4 18.6 134.5
16 0.63 2 0.08 147.1 15.0 108.5 191.2 19.5 141.0 274.6 28.0 202.5
18 0.71 2.5 0.10 203.0 20.7 149.7 264.8 27.0 195.3 383.4 39.1 282.8
20 0.79 2.5 0.10 286.4 29.2 211.2 371.7 37.9 274.1 536.4 54.7 395.6
22 0.87 2.5 0.10 383.4 39.1 282.8 499.2 50.9 368.2 725.9 74.0 535.2
24 0.95 3 0.12 492.3 50.2 363.1 640.4 65.3 472.3 924.8 94.3 682.1
27 1.06 3 0.12 724.7 73.9 534.5 942.2 96.1 695.1 1350.4 137.7 996.0
30 1.18 3.5 0.14 969.9 98.9 715.3 1259.2 128.4 928.7 1843.7 188.0 1359.8
33 1.30 3.5 0.14 1328.8 135.5 980.1 1727.0 176.1 1273.7 2477.2 252.6 1827.1
36 1.42 4 0.16 1676.0 170.9 1236.1 2180.0 222.3 1607.9 3199.9 326.3 2360.1
39 1.54 4 0.16 2219.2 226.3 1636.8 2884.1 294.1 2127.2 4118.8 420.0 3037.9
42 1.65 4.5 0.18 2754.7 280.9 2031.8 3581.4 365.2 2641.5 5137.7 523.9 3789.4
Without spring washer 101656
Metric
coarse Nominal Pitch
thread size

mm in. mm in. Nm kgfm lbfft Nm kgfm lbfft Nm kgfm lbfft

10 0.39 1.5 0.06 39.2 4.0 28.9 51.0 5.2 37.6 79.4 8.1 58.6
12 0.47 1.75 0.07 69.6 7.1 51.4 90.2 9.2 66.5 135.3 13.8 99.8
14 0.55 2 0.08 112.8 11.5 83.2 146.1 14.9 107.8 215.7 22.0 159.1
16 0.63 2 0.08 172.6 17.6 127.3 224.6 22.9 165.6 323.6 33.0 238.7
18 0.71 2.5 0.10 239.3 24.4 176.5 311.9 31.8 230.0 451.1 46.0 332.7
20 0.79 2.5 0.10 336.4 34.3 248.1 437.4 44.6 322.6 630.6 64.3 465.1
22 0.87 2.5 0.10 392.3 40.0 289.3 587.4 59.9 433.3 842.4 85.9 621.3
24 0.95 3 0.12 578.6 59.0 426.7 753.2 76.8 555.5 1088.5 111.0 802.9
27 1.06 3 0.12 852.2 86.9 628.5 1108.2 113.0 817.3 1588.7 162.0 1171.7
30 1.18 3.5 0.14 1140.5 116.3 841.2 1481.8 151.1 1092.9 2168.3 221.1 1599.2
33 1.30 3.5 0.14 1563.2 159.4 1153.0 2031.9 207.2 1498.7 2915.5 297.3 2150.4
36 1.42 4 0.16 1972.1 201.1 1454.6 2564.4 261.5 1891.4 3765.8 384.0 2777.5
39 1.54 4 0.16 2610.5 266.2 1925.4 3393.1 346.0 2502.6 4845.5 494.1 3573.8
42 1.65 4.5 0.18 3241.1 330.5 2390.5 4212.9 429.6 3107.3 6044.8 616.4 4458.4

Remarks: 1. The tolerance on the torque is 10%.

2. The torque is for dry condition.

15-7
SERVICE DATA

Periodic Replacement Parts

The parts listed below are important for the safe operation of the truck, and are specially designated as the parts 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:

Period
1 month
Periodic replacement parts Service 1 month 6 months 1 year 2 years
after
(200 hrs) (1200 hrs) (2400 hrs) (4800 hrs)
delivery
1 *Rubber parts for brake master cylinder Replace
2 *Rubber parts for brake wheel cylinder Replace
*Rubber parts and hoses for clutch master
3 Replace
cylinder (manual transmission models)
*Rubber parts of clutch release cylinder
4 Replace
(manual transmission models)
5 *LPG repair kit Replace
6 *High pressure hoses Replace
7 *Rubber parts for power cylinder Replace
8 *Hoses for power steering Replace
9 *Lift chains Replace
10 *Fuel hoses Replace
11 Engine oil filter element Replace
12 Fuel filter element Replace
13 Hydraulic tank return filter Replace
Clean
14 Air cleaner element
Replace
Notice: (*) indicates important safety-related parts.

15-8
 SERVICE DATA

Location of Periodic Replacement Parts

10 5
8

6
4
6

2 7

10

3
8
1

104156

15-9
SERVICE DATA

Lubrication Instructions

Lubrication Chart

Lift chains
EO
Lift bracket side rollers, MPG
Mast strips MPG Tilt sockets

Roller surfaces MPG

GO GO Transfer and
differential oil
Universal joints MPG
(front and rear)
MPG Mast supports
Brake fluid BF
reservoir

Transmission oil ATF ATF

HO Hydraulic oil

EO Engine oil

MPG Tie rod pin

MPG Kingpins

Every 500 hours or 3 months

Every 1000 hours or 6 months

Every 2000 hours or 12 months

: Check and refill ATF : Torque converter oil

: Change MPG : Multi-purpose grease
: Change GO : Gear oil
EO : Engine oil
BF : Brake fluid
HO : Hydraulic oil

213077

15-10
 SERVICE DATA

Fuel and Lubricant Specifications

Recommendation for ambient temperature C (F)

Fuel or oil Recommendation -30 -20 -10 0 10 20 30
(-22) (-4) (14) (32) (50) (68) (86)

Fuel Consult your local Cat lift truck dealer

Gasoline models API service classification SJ, min. SAE10W-30

Engine
oil
Diesel models API service classification CF, min. SAE10W-30

API service classification

Transfer and differential oil multipurpose type GL-4 or SAE80W SAE90
GL-5
Powershift transmission oil Dexron II Consult your local Cat lift truck dealer
Powershift,
Hydraulic ISO VG32
dry clutch
oil
Wet clutch API service classification CD, min. SAE10W
Brake fluid F.M.V.S.S. No. 116-DOT3 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

Antifreeze Ambient temperature, C (F) 45 (49) 39 (38) 30 (22) 25 (13) 20 (4) 15 (5) 10 (14)
solution Concentration (%) 60 55 50 45 40 35 30

NOTE
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.

15-11
SERVICE DATA

Adjustment Value and Oil Quantities

Notice: The values in the following table are based on the standard model.

Truck Models GP15N DP15N GPE15N GP15ZN GP20CN

GP18N DP18N GPE18N GPE15ZN GPE20CN
GP18ZN
Items GPE18ZN
Alternator drive belt deflectionwhen pushed inward 11 to 13 10 to 12 11 to 13
with 98 N (10 kgf) [22 lbf] pressure mm (in.) (0.43 to 0.51) (0.39 to 0.47) (0.43 to 0.51)
Type FR2A-D FR2A-D
Spark plug
Gap mm (in.) 0.9 (0.04) 0.9 (0.04)
Engine idling speed rpm 700 750 700
Steering wheel free play-when measured at rim
0 to 30 (0 to 1.2)
with engine idling mm (in.)
Clutch pedal free play (dry clutch) mm (in.) 0 to 6 (0 to 0.24)
Clutch pedal free play (wet clutch) mm (in.) 0 to 6 (0 to 0.24)
Inching pedal free play mm (in.) 3 to 7 (0.12 to 0.28)
Manual truck mm (in.) 7 (0.28)
Brake pedal free play
Powershift truck mm (in.) 7 (0.28)

Parking brake lever operating effort N (kgf) [lbf] 150 to 200 (15 to 20) [34 to 45]

Front single 6.50-10-10PR(I) 6.50-10/5.00

Tire size Front dual 4.50-12-8PR(I)
Rear 5.00-8-8PR(I) 5.00-8/3.00
Front single 700 (7.1) [101]
Tire pressure, kPa (kgf/cm2)
[psi] (Pneumatic) Front dual 700 (7.1) [101]
Rear 700 (7.1) [101]

Tightening torque for wheel Front 156.9 15.7 (16 1.6) [116 11.6]
nuts, Nm (kgfm) [lbfft]
Rear 141.2 to 172.6 (14.4 to 17.6) [104.1 to 127.3]
Lift chain elongation limit mm (in.)/20 links 327 (12.9) 392 (15.4)
Fuel tank Approx. 46 (12)
Engine cooling system-0.65 litre
7.4 (2.0) 6.8 (1.8) 7.4 (2.0) 6.8 (1.8)
Refill capacities (approximate),

(0.17 U.S. gal.) reserve tank included

Engine 3.5 (0.9) 7.5 (2.0) 3.5 (0.9)
Engine oil Oil filter 0.3 (0.08) 1.0 (0.3) 0.3 (0.08)
Total 3.8 (1.0) 8.5 (2.2) 3.8 (1.0)
litre (U.S. gal.)

Manual truck Approx. 5 (1.3)

Transmission oil
Powershift truck Approx. 10 (2.6)
Transfer and differential gear oil 5.5 (1.45)
Hydraulic oil 28 (7.4)
Brake fluid reservoir cc (cu in.) 135 (8.2)
Battery electrolyte specific gravity, corrected
1.26 to 1.28
to 20C (68F)

15-12
 SERVICE DATA

DP20CN GP20N DP20N GPE20N GP20ZN GP30N DP30N GP35AN DP35AN

GP25N DP25N GPE25N GPE20ZN GPE30N GPE35AN
GP25ZN
GPE25ZN
10 to 12 11 to 13 10 to 12 11 to 13 10 to 12 11 to 13 10 to 12
(0.39 to 0.47) (0.43 to 0.51) (0.39 to 0.47) (0.43 to 0.51) (0.39 to 0.47) (0.43 to 0.51) (0.39 to 0.47)
FR2A-D FR2A-D FR2A-D
0.9 (0.04) 0.9 (0.04) 0.9 (0.04)
750 700 750 700 750 700 750

15 to 30 (0.60 to 1.2)

0 to 6 (0 to 0.24)
0 to 6 (0 to 0.24)
3 to 7 (0.12 to 0.28)
7 (0.28)
7 (0.28)
150 to 200
(15 to 20) 200 to 250 (20 to 25) [45 to 56] 230 to 250 (23 to 25) [52 to 56]
[34 to 45]
6.50-10/5.00 7.00-12-12PR(I) 28 3 9-15-12PR(I) 250-15-16PR
5.50-15-8PR(I) 6.00-15-10PR(I)
5.00-8/3.00 6.00-9-10PR(I) 6.50-10-10PR(I) 6.50-10-12PR(I)
700 (7.1) [101] 850 (8.7) [123]
700 (7.1) [101]
700 (7.1) [101] 900 (9.2) [130]
156.9 15.7
(16 1.6) 377.6 37.8 (38.5 3.9) [279 27.9]
[116 11.6]
141.2 to 172.6 (14.4 to 17.6) [104.1 to 127.3]
392 (15.4) 523 (20.6)
Approx. 46 (12) Approx. 66 (17)

6.8 (1.8) 6.8 (1.8) 8.7 (2.3) 6.8 (1.8) 7.4 (2.0) 8.7 (2.3) 7.4 (2.0) 8.7 (2.3)

7.5 (2.0) 3.5 (0.9) Approx. 9.0 (2.4) 3.5 (0.9) Approx. 9.0 (2.4) 3.5 (0.9) Approx. 9.0 (2.4)

1.0 (0.3) 0.3 (0.08) Approx. 1.0 (0.3) 0.3 (0.08) Approx. 1.0 (0.3) 0.3 (0.08) Approx. 1.0 (0.3)

8.5 (2.2) 3.8 (1.0) Approx. 10.0 (2.6) 3.8 (1.0) Approx. 10.0 (2.6) 3.8 (1.0) Approx. 10.0 (2.6)

Approx. 5 (1.3)
Approx. 10 (2.6)

5.5 (1.45) 9.3 (2.46) 8.7(2.30)

28 (7.4) 39 (10.3)
135 (8.2)

1.26 to 1.28

15-13
SERVICE DATA

Special Service Tools

Special Service Tools

Ref Truck model 1 ton 2 ton 3 ton

Part number Part name
No. Used for class class class

1 91268 - 01900 Bolt Replacement of clutch pressure plate

92301 - 02700 Washer (To be used with washer and nut)
F2300 - 10000 Nut

2 F1145 - 10050 Bolt Replacement of clutch disc (To be used with washer)
92301 - 02700 Washer

3 91268 - 02200 Clutch gauge Adjustment of release lever clearance

4 91268 - 05100 Bolt Removal of pump body (FC) and shifter case (MC)

5 64309 - 17701 Gauge kit Measurement of transmission hydraulic pressure

6 91268 - 04400 Connector Measurement of hydraulic pressure (FC)

(To be used with 64309 - 17701 Gauge kit)

7 91268 - 00800 Socket wrench Removal and installation of front wheel hub nut

8 03703 - 59001 Socket wrench Removal and installation of front wheel hub nut

9 64309 - 40100 Bevel pinion puller Removal of front wheel hub

64309 - 10601 Puller seat Removal of front wheel hub
MH061017 Wheel hub puller Removal of front wheel hub

10 91A68-00500 Installer Installation of oil seal (inner)

11 91B68-00900 Installer Installation of oil seal (outer)

12 91E68-00700 Installer Installation of oil seal (outer)

13 91B68-01100 Installer Installation of tapered roller bearings (inner, outer)

14 91E68-00900 Installer Installation of tapered roller bearing (outer)

15 91E68-00800 Installer Installation of tapered roller bearing (inner)

16 64309 - 15411 Spring remover Removal of return spring

17 64309 - 15412 Spring retainer Removal and installation of brake shoe

18 64309 - 15413 Spring hook Installation of return spring (Tools No. 16, 17 and 18 are
included in 64309 - 15400 Tool Set)

19 91268 - 10600 Steering wheel Removal of steering wheel

puller

15-14
 SERVICE DATA

1 5

M10 1.5
40
(1.57)
13)
(4.
105

203537 203544

2 6

M10 1.5 G(PF)3/8 M14 1.5

40
(1.57)
7)
( 1.9
50

203538 203545

3 7
86
(3
40 7) .39
5 )
120 (4.72) (1. 19
3.2 (0.75)
(1. 6.5
)
04

(0.13)
2

20
(0.79) 84
(3
30 .31
(1.18) ) 23
(0.91)
200453 200441

4 8
M8 1.25 90
(3.54)

55 (2.17)

200465 203546

15-15
SERVICE DATA

9 13
12 (0.472)

M16 1.5

9)

99.5 (3.917)
( 7.0
180

14
(0.55)
150 (5.906)

203568 213081

10 36 (1.417) 14
12 (0.472)
15 (0.591) 14 (0.551)

119.5 (4.705)
160 (6.299)
123 (4.843)
73 (2.874)

150 (5.906)
150 (5.906)
213078 213082

11 15 12 (0.472)
19 (0.748)

12 (0.472)
129.5 (5.098)
81.5 (3.209)
58 (2.283)

180 (7.087)
150 (5.906)
213079 213083

12 16
20 (0.787)

13 (0.512)
94.5 (3.720)
68 (2.677)

180 (7.087)

213080 203548

15-16
 SERVICE DATA

17

203549

18

203550

19
M12 1.25

M8 1.25

(1. 30
55 18
(2. )
17
)

203551

15-17
SERVICE DATA

Special Service Tools (FC Truck only)

Ref Truck model 1 ton 2 ton 3 ton

Part number Part name
No. Used for class class class

1 91105 - 00400 Emergency harness For actuating control valve in an emergency

(Connection of control valve to battery)
2 91105 - 00500 Inspection connector Male
2P-M
3 91105 - 00600 Inspection connector Female
2P-F
4 91105 - 00700 Inspection connector Male
3P-M
5 91105 - 00800 Inspection connector Female
3P-F
6 91105 - 00900 Inspection connector Male
6P-M
7 91105 - 01100 Inspection connector Female
6P-F
8 91105 - 01200 Inspection connector Male
2P-M
9 91105 - 01300 Inspection connector Female
2P-F
10 91105 - 01400 Inspection connector Male
3P-M
11 91105 - 01500 Inspection connector Female
3P-F
12 91105 - 01600 Inspection connector Male
6P-M
13 91105 - 01700 Inspection connector Female
6P-F
14 91105 - 01800 Inspection connector Male
8P-M
15 91105 - 01900 Inspection connector Female
8P-F
16 91105 - 02100 Inspection connector Male
12P-M
17 91105 - 02200 Inspection connector Female
12P-F
18 91105 - 02300 Inspection connector Male
7P-M
19 91105 - 02400 Inspection connector Female
7P-F
20 91105 - 02500 Inspection connector Male
64P-FM

15-18
 SERVICE DATA

205049

205048

Notice: There are a total of 19 types of the inspection

connectors 2 thru 20 . They are supplied as a set
or individually. The connector 4 is shown.

15-19