POWER TRAIN

Procedures and Suggestions for Removal and Installation ....... 5–1

Removal .................................................................................................... 5–1
Installation ................................................................................................. 5–7
Service Data ............................................................................................ 5–9

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Procedures and Suggestions for Removal and Installation

Removal
1. Remove the masts.
(Refer to MASTS AND FORKS section.)
2. Removing the batteries.
(1) Disconnect the battery plug.
(2) Open the battery cover, and lock it in the open
position.
(3) Remove the side covers (L.H., R.H.) and front
covers (L.H., R.H.).

Lock/unlock lever

211152

(4) Attach suspending ropes or adequate lifting device

to the batteries.
Unit: kg (lb)
Truck Model EP18KT,
EP16KT
Item EP20KT
Battery weight 1090 1225
(maximum) (2403) (2700)

(5) Remove the battery retaining plate and pin, and

then remove the batteries. 206918

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POWER TRAIN

3. Removing front wheels

(1) Pull the parking brake lever and block the rear
wheels.
(2) Loosen the wheel nuts by two turns. Then, raise
the front end of the truck using a hoist or the
hydraulic system.
(a) Hoisting
Using a sling and eye-bolts at both ends of the
cross member at the top of the outer mast, lift the
front end of the truck with a hoist.
(b) Using hydraulic system
Tilt the mast fully backward and place wood
blocks under the mast. Tilt the mast forward to
raise the front end.

! CAUTION
After raising the front end, place jack stands
under the frame to prevent the truck from falling.
210757

(3) Remove the wheel nuts.

(4) Remove the wheel.

Truck Model Cushion tire

1 ton class 2 ton class
Item
Tire size of front 18 × 7 × 12 1/8 18 × 7 × 12 1/8
wheels

211344

4. Removing steps and floor plates

(1) Steps (L.H., R.H.) (3)
(2) Step plates (L.H., R.H.) Floor plate B
(3) Floor plate
(1) (1)
(2)
Remove floor plate B. Floor plate A
Disconnect the accelerator connector mounted on the
back side of the floor plate, then remove floor plate A. (2)

211153

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 POWER TRAIN

5. Removing steering hoses

Disconnect the steering hoses and pipes at the
connectors.

206922

6. Removing delivery pipe and drive motor harness

MC models
(1) Remove the drive motor harness at the connector.
Delivery pipe
Disconnect the harnesses of the brush wear
sensors and temperature sensors located on the
right and left sides.
(2) The harnesses are secured to the delivery pipe
with clamps. Loosen the clamps, and remove the
delivery pipe.
211154

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POWER TRAIN

7. Removing brake components

(i)

(ii)

(iii)

(v)

(iv)

(vi)

206824

(1) Loosen the parking brake lever, and remove

parking brake cable assemblies (i) (L.H.) and (ii)
(R.H.).
Disconnect the parking brake cables at the
calipers, and keep the cables together on the frame
near the center brake.
(2) Position a drip pan, and disconnect brake fluid
tube (iii) at the master cylinder.
(3) Disconnect brake pipes (iv, v) (L.H., R.H.) at the
master cylinder. Disconnect the branch brake
hoses (L.H., R.H.) from the brake pipes.
(4) Remove brake pedal assembly (vi).

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 POWER TRAIN

8. Removing return hoses

Remove return hose (1) from the control valve, and
(1)
return hose (2) from the lift cylinder.

(2)

206925

9. Remove drive motors cables (L.H., R.H.).

Remove the generators (speed sensors) of the transfers (3) (3)
(L.H., R.H.).
10. Removing tension rods and brackets Left (2) (2) Right
transfer (4) transfer
Loosen right and left nuts (1) by approximately 6 mm
(0.24 in.).
Remove bolts (2), and take out bracket (3) and tension (1)
bolt (4) together from each side of the vehicle.
206926

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POWER TRAIN

11. Removing transfer assemblies, drive motors and

calipers

Left Right
transfer transfer
(iii)

Gravity
center

(ii) (ii)

(i)

(i)

Frame

Frame
(iv) Gravity (iii) (iv)
center
206927

Remove the transfer assemblies with the drive motors

and calipers mounted.
First, dismount the left transfer, lower it, then pull it
out from the front of the vehicle. Then, dismount the Cow hitch
right transfer, lower it, then pull it out from the front.
(1) When suspending the assembly, position the wire
rope at the gravity center.
The suspending wire rope must be cow hitched.
When using a textile sling, make two loops to 206928
prevent slipping.
(2) Remove bolt (i) from the lower part of the step
Total weight of transfer, 115 kg
and remove bolt (ii) from the frame, then remove drive motor and caliper (253.5 lb)
the assembly.
(3) Remove bolt (iii), and dismount the caliper
assembly.
(4) Remove bolt (iv) and dismount the drive motor.
(See illustration No. 206927.)

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 POWER TRAIN

Installation
Follow the removal sequence in reverse. For installation,
follow the instructions below.

! CAUTION
When mounting the transfer assembly on the
frame, do not insert a finger into the bolt hole to
check hole alignment.

1. Be sure to tighten bolts to the specified torque.

Front of vehicle

3 4 4 3

5 5
2

1 1
206785

A: Standard value Unit: N·m (kgf·m) [lbf·ft]

Drive motor mounting bolt 1 A 60 ± 12 (6.1 ± 1.2) [44.25 ± 8.85]
Transfer assembly mounting bolt 2 A 508 ± 51 (51.8 ± 5.2) [374.7 ± 37.6]
Tightening torque Bracket mounting bolt 3 A 176 ± 18 (17.9 ± 1.8) [129.8 ± 13.3]
Bolt nut 4 A 231 ± 24 (23.6 ± 2.4) [170.4 ± 17.7]
Hub nut 5 A 157 (16) [115.8]

2. Bleed the brake oil line.

(Refer to BRAKE SYSTEM section.)

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POWER TRAIN

3. After installing the parking brake cable, be sure to

adjust.
(Refer to BRAKE SYSTEM section.)
4. Pour oil into the transfer cases:
Left transfer
Remove oil level plug (1).
Remove oil inlet plug (2).
(2)
Pour appropriate oil in the oil inlet. Make sure the oil
level reaches the level plug location.
Unit: liter (U.S. gal)
(1)
Left transfer Right transfer

1.09 1.86
Oil quantity
(0.29) (0.49) Front
of
vehicle

Right transfer

(2)

(1)

206786

5. Bleeding hydraulic oil line and inspecting oil level

Operate the tilt cylinders in the forward and backward
directions to bleed the tilt cylinders. Operate the lift
cylinders in the vertical directions to fill the cylinders
with oil.
Lower the lift cylinders to the lowest position, and
check the oil level gauge. If the oil level is low, add oil
to the specified level.
6. Checking steering oil line
Operate the steering wheel to make sure that it operates
smoothly.

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 POWER TRAIN

Service Data
A : Standard value

Truck Models 1 ton class 2 ton class

Item
Drive motor mounting bolt 1 A 60 ± 12 (6.1 ± 1.2) [44.25 ± 8.85]
Tightening torque Transfer assembly mounting bolt 2 A 508 ± 51 (51.8 ± 5.2) [374.7 ± 37.6]
N·m Bracket mounting bolt 3 A 176 ± 18 (17.9 ± 1.8) [129.8 ± 13.3]
(kgf·m)
[lbf·ft] Bolt nut 4 A 231 ± 24 (23.6 ± 2.4) [170.4 ± 17.7]
Hub nut 5 A 157 (16) [115.8]

3 4 4 3
Power Line

5 5
2

1 1

206785

5-9