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Nissan Forklift Internal Combustion D02 Series Service Repair Manual.pdf

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SERVICE MANUAL &
TECHNICAL BULLETIN
SERVICE MANUAL &
TECHNICAL BULLETIN
SERVICE
MANUAL
TECHNICAL
BULLETIN
MODEL
DX
SERIES
MODEL D01/D02 SERIES
DIFFERENTIAL CARRIER
SECTION DF
CONTENTS
SERVICE DATA AND SPECIFICATIONS .......................2
General Specifications.................................................2
Inspection and Adjustment ..........................................3
Tightening Torque ........................................................3
TROUBLE DIAGNOSES AND CORRECTIONS.............4
DIFFERENTIAL CARRIER..............................................5
Construction.................................................................5
SPECIAL SERVICE TOOLS............................................7
General Specifications
D01 SERIES
Applied model FD01A15-18 PD01A15-18
Model H263
Gear ratio 5.286 5.857
Number of teeth (Ring gear/Drive pinion) 37/7 41/7
Differential gear 2-pinion
Number of teeth (Side gear/Pinion mate gear) 16/10
Oil capacity  (US qt, Imp qt) 2.7 (2-7/8, 2-3/8)
D02 SERIES
Applied model
UD02A20-25
FD02A20-25
UGD02A30
Model H296 H310
Gear ratio 5.857 6.166
Number of teeth
(Ring gear/Drive pinion)
41/7 37/6
Differential gear 4-pinion
Number of teeth
(Side gear/Pinion mate gear)
18/10 16/10
Oil capacity  (US qt, Imp qt) 3.0 (3-1/8, 2-5/8) 5.5 (5-7/8, 4-7/8)
SERVICE DATA AND SPECIFICATIONS
DF-2
Inspection and Adjustment
Drive pinion starting torque
N⋅m (kg-cm, in-lb)
A/T models 1.8 - 2.3 (18 - 23, 16 - 20)
Backlash mm (in)
Side gear to pinion mate gear 0.15 - 0.20 (0.0059 - 0.0079)
Drive pinion to ring gear
H263 0.18 - 0.23 (0.0071 - 0.0091)
H296 & H310 0.20 - 0.28 (0.0079 - 0.0110)
Distance between left and right
bearing caps
(Side bearing preload) mm (in)
H263
262.88 - 262.93
(10.3496 - 10.3516)
H296
282.86 - 282.93
(11.1358 - 11.1390)
H310
302.85 - 302.93
(11.9232 - 11.9264)
SIDE GEAR THRUST WASHER
Unit: mm (in)
H263
H296
H310
1.55 (0.0610)
1.60 (0.0630)
1.65 (0.0650)
—
—
—
1.54 (0.0606)
1.57 (0.0618)
1.60 (0.0630)
1.63 (0.0642)
1.66 (0.0654)
1.69 (0.0665)
DRIVE PINION BEARING ADJUST SHIM
Unit: mm (in)
0.15 (0.0059)
0.18 (0.0071)
0.20 (0.0079)
0.25 (0.0098)
0.30 (0.0118)
0.50 (0.0197)
PINION HEIGHT ADJUST SHIM
Unit: mm (in)
0.05 (0.0020)
0.07 (0.0028)
0.10 (0.0039)
0.30 (0.0118)
0.50 (0.0197)
1.00 (0.0394)
Tightening Torque
Unit N⋅m kg-m ft-lb
Differential case to ring gear
H263 197 - 225 20 - 23 145 - 166
H296 197 - 225 20 - 23 145 - 166
H310 255 - 294 26 - 30 188 - 216
Differential case
H263 — — —
H296 74 - 81 7.5 - 8.3 55 - 60
H310 98 - 137 10 - 14 73 - 101
Drive pinion lock nut 275 - 343 28 - 35 203 - 253
Drive pinion sleeve to gear
carrier
77 - 98 7.8 - 10.0 57 - 72
Side bearing cap bolt
H263 79 - 98 8 - 10 58 - 72
H296 90 - 117 9.1 - 12.0 66 - 86
H310 128 - 147 13 - 15 94 - 108
Differential carrier to trans-
mission
31 - 40 3.1 - 4.1 23 - 29
Differential carrier to axle
housing
H263 19 - 24 1.9 - 2.5 14 - 18
H296 & H310 39 - 51 3.9 - 5.3 29 - 38
SERVICE DATA AND SPECIFICATIONS
DF-3
Gear carrier failures can be classified as oil leakage, seizure,
unusual noise, noisy operation, and damage, according to the phe-
nomena. Shown below are the trouble phenomena, their possible
causes, and remedies to be taken.
Condition Probable cause Corrective action
Oil leakage Distinguish between oil staining and oil leakage, and locate the point of leak, then take proper correc-
tive action.
I Worn, faulty, or improperly installed oil seal
I Loose gear carrier mounting bolts
I Faulty gasket
I Loose filler plug or drain plug
I Clogged or faulty air breather
I Faulty axle housing O-ring
I Worn, faulty, or improperly installed axle shaft oil
seal
Replace oil seal.
Retighten, or replace gasket.
Replace gasket.
Retighten.
Repair or replace.
Replace.
Replace oil seal.
Seizure Replace any seized or damaged parts. Check related parts for condition. Repair or replace them if
necessary.
I Bearing seizure
I Too large preload
I Too small backlash
I Insufficient oil, or use of improper oil
Replace.
Disassemble and readjust.
Disassemble and readjust.
Add or replace oil as specified.
Unusual noise Before disassembling the gear carrier, make sure that the noise is not being produced in clutch, trans-
mission or wheel bearing.
1. When starting off or
shifting gears
I Improper hypoid gear backlash
I Improper differential gear backlash
I Too small drive pinion bearing preload
I Pitted or worn gear tooth surface, or broken
tooth
I Loose pinion nut, or any other bolts or nuts
I Insufficient oil, or use of improper oil
Readjust.
Readjust.
Readjust.
Replace.
Retighten.
Add or change oil as specified.
2. When making a turn I Abnormally worn or broken differential gear
I Abnormally worn or broken thrust washer
I Broken pinion mate shaft
I Seized or broken side bearing
I Insufficient oil, or use of improper oil
Replace.
Replace.
Replace.
Replace.
Add or change oil as specified.
Gear noise Perform test carefully as gear noise is often mistaken for engine noise, transmission noise, or wheel
bearing noise.
Test method:
Check for gear noise in coasting, accelerating, or in constant-speed driving, or by jacking up the front
wheels.
I Improper contact of hypoid gear teeth
I Improper hypoid gear backlash
I Worn, or broken hypoid gear tooth surface
I Seized hypoid gear
I Improper pinion bearing preload
I Seized, or broken pinion bearing
I Seized or broken side bearing
I Differential case runout
I Loose bolts and nuts
Adjust, or replace as a gear set.
Readjust.
Replace as a gear set.
Replace as a gear set.
Readjust.
Replace.
Replace.
Replace.
Retighten.
TROUBLE DIAGNOSES AND CORRECTIONS
DF-4
Construction
H263 (2-pinion)
q
1 Drive pinion
q
2 Drive pinion front bearing
q
3 O-ring
q
4 Oil seal
q
5 Distance piece
q
6 Pinion height adjust shim
q
7 Drive pinion bearing sleeve
q
8 Drive pinion bearing adjust shim
q
9 Drive pinion rear bearing
q
10 O-ring (large)
q
11 Drive pinion bearing lock nut
q
12 Bearing (rear end)
q
13 Washer
q
14 Nut
q
15 Gear carrier
q
16 Knock pin
q
17 Side bearing cap
q
18 Side bearing adjust nut
q
19 Side bearing
q
20 Lock plate
q
21 Side bearing cap bolt
q
22 Gasket
q
23 Differential case
q
24 Ring gear
q
25 Side gear thrust washer
q
26 Side gear
q
27 Pinion mate shaft
q
28 Mate gear thrust washer
q
29 Mate gear
Tightening torque
: 246 - 294 (25 - 30, 181 - 216)
: 9 - 11 (0.9 - 1.2, 79 - 104)
: 197 - 225 (20 - 23, 145 - 166)
: 79 - 98 (8 - 10, 58 - 72)
: 76 - 98 (7.8 - 10.0, 57 - 72)
: 275 - 343 (28 - 35, 203 - 253)
: N⋅m (kg-m, ft-lb)
: N⋅m (kg-m, in-lb)
DFM0051
DIFFERENTIAL CARRIER
DF-5

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  • 1. SERVICE MANUAL & TECHNICAL BULLETIN SERVICE MANUAL & TECHNICAL BULLETIN SERVICE MANUAL TECHNICAL BULLETIN MODEL DX SERIES MODEL D01/D02 SERIES
  • 2. DIFFERENTIAL CARRIER SECTION DF CONTENTS SERVICE DATA AND SPECIFICATIONS .......................2 General Specifications.................................................2 Inspection and Adjustment ..........................................3 Tightening Torque ........................................................3 TROUBLE DIAGNOSES AND CORRECTIONS.............4 DIFFERENTIAL CARRIER..............................................5 Construction.................................................................5 SPECIAL SERVICE TOOLS............................................7
  • 3. General Specifications D01 SERIES Applied model FD01A15-18 PD01A15-18 Model H263 Gear ratio 5.286 5.857 Number of teeth (Ring gear/Drive pinion) 37/7 41/7 Differential gear 2-pinion Number of teeth (Side gear/Pinion mate gear) 16/10 Oil capacity  (US qt, Imp qt) 2.7 (2-7/8, 2-3/8) D02 SERIES Applied model UD02A20-25 FD02A20-25 UGD02A30 Model H296 H310 Gear ratio 5.857 6.166 Number of teeth (Ring gear/Drive pinion) 41/7 37/6 Differential gear 4-pinion Number of teeth (Side gear/Pinion mate gear) 18/10 16/10 Oil capacity  (US qt, Imp qt) 3.0 (3-1/8, 2-5/8) 5.5 (5-7/8, 4-7/8) SERVICE DATA AND SPECIFICATIONS DF-2
  • 4. Inspection and Adjustment Drive pinion starting torque N⋅m (kg-cm, in-lb) A/T models 1.8 - 2.3 (18 - 23, 16 - 20) Backlash mm (in) Side gear to pinion mate gear 0.15 - 0.20 (0.0059 - 0.0079) Drive pinion to ring gear H263 0.18 - 0.23 (0.0071 - 0.0091) H296 & H310 0.20 - 0.28 (0.0079 - 0.0110) Distance between left and right bearing caps (Side bearing preload) mm (in) H263 262.88 - 262.93 (10.3496 - 10.3516) H296 282.86 - 282.93 (11.1358 - 11.1390) H310 302.85 - 302.93 (11.9232 - 11.9264) SIDE GEAR THRUST WASHER Unit: mm (in) H263 H296 H310 1.55 (0.0610) 1.60 (0.0630) 1.65 (0.0650) — — — 1.54 (0.0606) 1.57 (0.0618) 1.60 (0.0630) 1.63 (0.0642) 1.66 (0.0654) 1.69 (0.0665) DRIVE PINION BEARING ADJUST SHIM Unit: mm (in) 0.15 (0.0059) 0.18 (0.0071) 0.20 (0.0079) 0.25 (0.0098) 0.30 (0.0118) 0.50 (0.0197) PINION HEIGHT ADJUST SHIM Unit: mm (in) 0.05 (0.0020) 0.07 (0.0028) 0.10 (0.0039) 0.30 (0.0118) 0.50 (0.0197) 1.00 (0.0394) Tightening Torque Unit N⋅m kg-m ft-lb Differential case to ring gear H263 197 - 225 20 - 23 145 - 166 H296 197 - 225 20 - 23 145 - 166 H310 255 - 294 26 - 30 188 - 216 Differential case H263 — — — H296 74 - 81 7.5 - 8.3 55 - 60 H310 98 - 137 10 - 14 73 - 101 Drive pinion lock nut 275 - 343 28 - 35 203 - 253 Drive pinion sleeve to gear carrier 77 - 98 7.8 - 10.0 57 - 72 Side bearing cap bolt H263 79 - 98 8 - 10 58 - 72 H296 90 - 117 9.1 - 12.0 66 - 86 H310 128 - 147 13 - 15 94 - 108 Differential carrier to trans- mission 31 - 40 3.1 - 4.1 23 - 29 Differential carrier to axle housing H263 19 - 24 1.9 - 2.5 14 - 18 H296 & H310 39 - 51 3.9 - 5.3 29 - 38 SERVICE DATA AND SPECIFICATIONS DF-3
  • 5. Gear carrier failures can be classified as oil leakage, seizure, unusual noise, noisy operation, and damage, according to the phe- nomena. Shown below are the trouble phenomena, their possible causes, and remedies to be taken. Condition Probable cause Corrective action Oil leakage Distinguish between oil staining and oil leakage, and locate the point of leak, then take proper correc- tive action. I Worn, faulty, or improperly installed oil seal I Loose gear carrier mounting bolts I Faulty gasket I Loose filler plug or drain plug I Clogged or faulty air breather I Faulty axle housing O-ring I Worn, faulty, or improperly installed axle shaft oil seal Replace oil seal. Retighten, or replace gasket. Replace gasket. Retighten. Repair or replace. Replace. Replace oil seal. Seizure Replace any seized or damaged parts. Check related parts for condition. Repair or replace them if necessary. I Bearing seizure I Too large preload I Too small backlash I Insufficient oil, or use of improper oil Replace. Disassemble and readjust. Disassemble and readjust. Add or replace oil as specified. Unusual noise Before disassembling the gear carrier, make sure that the noise is not being produced in clutch, trans- mission or wheel bearing. 1. When starting off or shifting gears I Improper hypoid gear backlash I Improper differential gear backlash I Too small drive pinion bearing preload I Pitted or worn gear tooth surface, or broken tooth I Loose pinion nut, or any other bolts or nuts I Insufficient oil, or use of improper oil Readjust. Readjust. Readjust. Replace. Retighten. Add or change oil as specified. 2. When making a turn I Abnormally worn or broken differential gear I Abnormally worn or broken thrust washer I Broken pinion mate shaft I Seized or broken side bearing I Insufficient oil, or use of improper oil Replace. Replace. Replace. Replace. Add or change oil as specified. Gear noise Perform test carefully as gear noise is often mistaken for engine noise, transmission noise, or wheel bearing noise. Test method: Check for gear noise in coasting, accelerating, or in constant-speed driving, or by jacking up the front wheels. I Improper contact of hypoid gear teeth I Improper hypoid gear backlash I Worn, or broken hypoid gear tooth surface I Seized hypoid gear I Improper pinion bearing preload I Seized, or broken pinion bearing I Seized or broken side bearing I Differential case runout I Loose bolts and nuts Adjust, or replace as a gear set. Readjust. Replace as a gear set. Replace as a gear set. Readjust. Replace. Replace. Replace. Retighten. TROUBLE DIAGNOSES AND CORRECTIONS DF-4
  • 6. Construction H263 (2-pinion) q 1 Drive pinion q 2 Drive pinion front bearing q 3 O-ring q 4 Oil seal q 5 Distance piece q 6 Pinion height adjust shim q 7 Drive pinion bearing sleeve q 8 Drive pinion bearing adjust shim q 9 Drive pinion rear bearing q 10 O-ring (large) q 11 Drive pinion bearing lock nut q 12 Bearing (rear end) q 13 Washer q 14 Nut q 15 Gear carrier q 16 Knock pin q 17 Side bearing cap q 18 Side bearing adjust nut q 19 Side bearing q 20 Lock plate q 21 Side bearing cap bolt q 22 Gasket q 23 Differential case q 24 Ring gear q 25 Side gear thrust washer q 26 Side gear q 27 Pinion mate shaft q 28 Mate gear thrust washer q 29 Mate gear Tightening torque : 246 - 294 (25 - 30, 181 - 216) : 9 - 11 (0.9 - 1.2, 79 - 104) : 197 - 225 (20 - 23, 145 - 166) : 79 - 98 (8 - 10, 58 - 72) : 76 - 98 (7.8 - 10.0, 57 - 72) : 275 - 343 (28 - 35, 203 - 253) : N⋅m (kg-m, ft-lb) : N⋅m (kg-m, in-lb) DFM0051 DIFFERENTIAL CARRIER DF-5
  • 7. H296 and H310 (4-pinion) q 1 Drive pinion q 2 Drive pinion front bearing q 3 O-ring q 4 Oil seal q 5 Distance piece q 6 Pinion height adjust shim q 7 Drive pinion bearing sleeve q 8 Drive pinion bearing adjust shim q 9 Drive pinion rear bearing q 10 O-ring (large) q 11 Drive pinion bearing lock nut q 12 Bearing (rear end) q 13 Washer q 14 Nut q 15 Gear carrier q 16 Knock pin q 17 Side bearing cap q 18 Side bearing adjust nut q 19 Side bearing q 20 Lock plate q 21 Side bearing cap bolt q 22 Gasket q 23 Differential case q 24 Ring gear q 25 Side gear thrust washer q 26 Side gear q 27 Pinion mate shaft q 28 Mate gear thrust washer q 29 Mate gear Tightening torque : 246 - 294 (25 - 30, 181 - 216) : H296 ... 9 - 11 (0.9 - 1.2, 79 - 104) H310 ... 10 - 14 (1.0 - 1.5, 87 - 130) : H296 ... 197 - 225 (20 - 23, 145 - 166) H310 ... 255 - 294 (26 - 30, 188 - 216) : H296 ... 74 - 81 (7.5 - 8.3, 55 - 60) H310 ... 98 - 137 (10 - 14, 73 - 101) : H296 ... 90 - 117 (9.1 - 12.0, 66 - 86) H310 ... 128 - 147 (13 - 15, 94 - 108) : 77 - 98 (7.8 - 10.0, 57 - 72) : 275 - 343 (28 - 35, 203 - 253) : N⋅m (kg-m, ft-lb) : N⋅m (kg-m, in-lb) DFM0052 DIFFERENTIAL CARRIER Construction (Cont’d) DF-6
  • 8. Tool number Tool name Unit application H263 H296 H310 KV31100300 Pin punch DFM0053 X KV381045S0 Drive pinion lock nut replacer q 1 KV38104510 Torque arm q 2 KV38104520 Spanner DFM0054 X X X SPECIAL SERVICE TOOLS DF-7
  • 9. The information in this bulletin should not be interpreted as base for claims, unless so designated May 2002 FDF 02-D01 Applied Model : D02 3.2ton model / D01/D02 SERIES Applied From : Production in April, 2002 Subject : DIFFERENTIAL CARRIER (DF) Introduction: 3.2 ton model UGD02A32PQ (LPG model) and FGD02A32Q (Diesel model) have been newly added to the D02 series. At the same time, several specifications have been changed in D01/D02 series. Modification Notice: In accordance with this change, Update the following pages in D01/D02 Service manual with new pages. The details of this change are described at “Technical Service Note” in next page. 1, “GI” section Update page GI - 4, 5, 6, 8. 2, “MA” section Update page MA - 6, 27. 3, “ER” section Update page ER - 4. 4, “DF” section Update page DF - 2. 5, “FA” section Update page FA - 2, 6. 6, “RA” section Update page RA - 2. 7, “BR” section Update all page 8, “HD” section Update page HD – 3, 4. 9, “LM” section Update page LM – 3, 10, 11, 22. 10, “BF” section Update page BF - 2. 11, “BE” section Update page BE – 5, 6, 11, 20,63.
  • 10. Technical Service Notice: [ For 3.2 ton model] 1, 3.2 Ton model added 1) 3.2 ton model information is added. GI section DF section FA section RA section HD section LM section 2, Parts change 1) The size and weight of Counterweight increase. BF section 2) Drive axle is reinforced. ( Hardness is changed. Size is same) Not described 3) Brake is reinforced. (DS31H model <- DS31 model) Not described 4) Mast is reinforced. (Tilt Bracket shape changed and Rib added) Not described ( for 3.0 ton and 3.2ton mast, except 3V mast) Not described 5) Down Safety Valve is changed (Flow rate change 15 <- 22 L/min) Not described ( for 3.0 ton and 3.2ton mast, except 2F mast) Not described 6) Fork capacity mark is changed ( 1600 X 500 <- 1500 X 500) Not described ( for 3.0 ton and 3.2ton mast) Not described [ For all D01/D02 model] 1, Brake specification change (Brake Booster deleted) 1) Brake Vacuum Booster deleted. ( all D02 ) BR, MA section 2) Pedal link ratio changed. ( all D01/D02 : 4.91 <- 5.14) Not described 3) Pedal stroke changed. ( D01 : 42 <- 44mm, D02 : 68 <- 51mm ) Not described 4) Master cylinder changed. ( D01: no change, D02: 3/4” <- 15/16”) BR section 5) Return Spring changed. ( all D01/D02 : 2.9 <- 5.9 N/mm ) Not described 6) Vacuum Port for Brake booster deleted. ( H20, H25 engine) Not described 7) Vacuum Pump deleted. ( TD27 engine) BR section 2, Temperature sensor for Catalytic muffler deleted (H20, H25 engine) 1) Temperature sensor for Catalytic muffler deleted. BE, BF section 2) Muffler temperature warning lamp in Meter panel deleted. BE section 3) Chassis harness and rear harness changed. (Circuit deleted.) BE section
  • 11. General Specifications D01 SERIES Applied model FD01A15-18 PD01A15-18 Model H263 Gear ratio 5.286 5.857 Number of teeth (Ring gear/Drive pinion) 37/7 41/7 Differential gear 2-pinion Number of teeth (Side gear/Pinion mate gear) 16/10 Oil capacity (US qt, Imp qt) 2.7 (2-7/8, 2-3/8) D02 SERIES Applied model UD02A20-25 FD02A20-25 UGD02A30-32 FGD02A30-32 Model H296 H310 Gear ratio 5.857 6.166 Number of teeth (Ring gear/Drive pinion) 41/7 37/6 Differential gear 4-pinion Number of teeth (Side gear/Pinion mate gear) 18/10 16/10 Oil capacity (US qt, Imp qt) 3.0 (3-1/8, 2-5/8) 5.5 (5-7/8, 4-7/8) SERVICE DATA AND SPECIFICATIONS DF-2 l l
  • 12. FRONT AXLE SECTION FA CONTENTS SERVICE DATA AND SPECIFICATIONS .......................2 TROUBLE DIAGNOSES AND CORRECTIONS.............3 FRONT AXLE ..................................................................4
  • 13. GENERAL SPECIFICATIONS Axle type Full floating, direct frame mount D01 D02 D03 Tread mm (in) 890 (35.04) 965 (37.99) 1,005 (39.57) INSPECTION AND ADJUSTMENT Wheel hub rotation starting torque at hub bolt N (kg, lb) 10 - 29 (1 - 3, 2 - 7) Axial play of wheel bearing mm (in) Less than 0.08 (0.0031) TIGHTENING TORQUE D01 series D02 series 2.0 - 2.5 ton 3.0 ton N⋅m kg-m ft-lb N⋅m kg-m ft-lb N⋅m kg-m ft-lb Axle case to axle tube — — — 118 - 147 12 - 15 87 - 108 118 - 147 12 - 15 87 - 108 Axle mounting bracket to backing plate 79 - 105 8.0 - 10.8 58 - 78 128 - 166 13.0 - 17.0 94 - 122 128 - 166 13.0 - 17.0 94 - 122 Axle mounting bracket to frame 187 - 235 19 - 24 138 - 173 324 - 372 33 - 38 239 - 274 324 - 372 33 - 38 239 - 274 Axle case to differential carrier 19 - 24 1.9 - 2.5 14 - 18 39 - 51 3.9 - 5.3 29 - 38 39 - 51 3.9 - 5.3 29 - 38 Drive wheel hub to axle shaft 40 - 53 4.0 - 5.5 29 - 39 74 - 88 7.5 - 9.0 55 - 65 74 - 88 7.5 - 9.0 55 - 65 Brake tube flare nut 15 - 17 1.5 - 1.8 11 - 13 15 - 17 1.5 - 1.8 11 - 13 15 - 17 1.5 - 1.8 11 - 13 Road wheel nut Single tire 167 - 225 17 - 23 123 - 166 246 - 294 25 - 30 181 - 216 442 - 588 45 - 60 326 - 433 Double tire Direct connecting type Hub bolt installing nut — — — — — — 344 - 441 35 - 45 254 - 325 Inner nut — — — — — — 540 - 686 55 - 70 398 - 506 Outer nut — — — — — — 589 - 735 60 - 75 434 - 542 Outer hub type Inner wheel attaching nut 167 - 225 17 - 23 123 - 166 246 - 294 25 - 30 181 - 216 — — — Outer wheel attaching nut 167 - 225 17 - 23 123 - 166 246 - 294 25 - 30 181 - 216 — — — Outer hub connecting nut 79 - 98 8 - 10 58 - 72 246 - 294 25 - 30 181 - 216 — — — Rim set bolt 69 - 98 7 - 10 51 - 72 157 - 196 16 - 20 116 - 114 — — — SERVICE DATA AND SPECIFICATIONS FA-2
  • 14. Condition Probable cause Corrective action Abnormal noise Before attempting a correction, make sure the noise is coming from the drive shaft—not from the final drive gear. Loose axle mounting bracket bolts Loose axle tube mounting bolts Loose wheel nuts Other retaining parts loose Worn or damaged wheel bearing Wheel bearing not properly adjusted Worn axle shaft splines Insufficient lubrication Tighten. Tighten. Tighten. Tighten. Replace. Adjust. Replace. Lubricate. Unstable driving Also refer to the Trouble Diagnoses and Corrections in the RA section. Loose wheel nut Deformed road wheel Worn or damaged wheel bearing Loose axle mounting bracket bolts Wheel bearing not properly adjusted Improper tire pressure Tighten. Replace. Replace. Tighten. Adjust. Adjust. Oil leakage Worn or damaged axle shaft oil seal Final drive improperly installed Loose filler or drain plug Damaged axle tube O-ring Replace. Replace gasket. Tighten. Replace. TROUBLE DIAGNOSES AND CORRECTIONS FA-3
  • 16. PNEUMATIC TIRE MODEL D01 single-tire Outer hub type double-tire for D02 2.0-ton & 2.5-ton models FAM0052 FAM0053 FRONT AXLE FA-5
  • 17. D02 single-tire for 2.0-ton & 2.5-ton models D02 direct connecting type double tire for 3.0-ton models and single-tire for 3.0-ton models FAM0054 FAM0055 FRONT AXLE FA-6
  • 18. The information in this bulletin should not be interpreted as base for claims, unless so designated May 2002 FFA 02-D01 Applied Model : D02 3.2ton model / D01/D02 SERIES Applied From : Production in April, 2002 Subject : FRONT AXLE (FA) Introduction: 3.2 ton model UGD02A32PQ (LPG model) and FGD02A32Q (Diesel model) have been newly added to the D02 series. At the same time, several specifications have been changed in D01/D02 series. Modification Notice: In accordance with this change, Update the following pages in D01/D02 Service manual with new pages. The details of this change are described at “Technical Service Note” in next page. 1, “GI” section Update page GI - 4, 5, 6, 8. 2, “MA” section Update page MA - 6, 27. 3, “ER” section Update page ER - 4. 4, “DF” section Update page DF - 2. 5, “FA” section Update page FA - 2, 6. 6, “RA” section Update page RA - 2. 7, “BR” section Update all page 8, “HD” section Update page HD – 3, 4. 9, “LM” section Update page LM – 3, 10, 11, 22. 10, “BF” section Update page BF - 2. 11, “BE” section Update page BE – 5, 6, 11, 20,63.
  • 19. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it. GET MORE OTHER MANUALS https://www.aservicemanualpdf.com/ GET MORE OTHER MANUALS https://www.aservicemanualpdf.com/
  • 20. Technical Service Notice: [ For 3.2 ton model] 1, 3.2 Ton model added 1) 3.2 ton model information is added. GI section DF section FA section RA section HD section LM section 2, Parts change 1) The size and weight of Counterweight increase. BF section 2) Drive axle is reinforced. ( Hardness is changed. Size is same) Not described 3) Brake is reinforced. (DS31H model <- DS31 model) Not described 4) Mast is reinforced. (Tilt Bracket shape changed and Rib added) Not described ( for 3.0 ton and 3.2ton mast, except 3V mast) Not described 5) Down Safety Valve is changed (Flow rate change 15 <- 22 L/min) Not described ( for 3.0 ton and 3.2ton mast, except 2F mast) Not described 6) Fork capacity mark is changed ( 1600 X 500 <- 1500 X 500) Not described ( for 3.0 ton and 3.2ton mast) Not described [ For all D01/D02 model] 1, Brake specification change (Brake Booster deleted) 1) Brake Vacuum Booster deleted. ( all D02 ) BR, MA section 2) Pedal link ratio changed. ( all D01/D02 : 4.91 <- 5.14) Not described 3) Pedal stroke changed. ( D01 : 42 <- 44mm, D02 : 68 <- 51mm ) Not described 4) Master cylinder changed. ( D01: no change, D02: 3/4” <- 15/16”) BR section 5) Return Spring changed. ( all D01/D02 : 2.9 <- 5.9 N/mm ) Not described 6) Vacuum Port for Brake booster deleted. ( H20, H25 engine) Not described 7) Vacuum Pump deleted. ( TD27 engine) BR section 2, Temperature sensor for Catalytic muffler deleted (H20, H25 engine) 1) Temperature sensor for Catalytic muffler deleted. BE, BF section 2) Muffler temperature warning lamp in Meter panel deleted. BE section 3) Chassis harness and rear harness changed. (Circuit deleted.) BE section
  • 21. GENERAL SPECIFICA TIONS Axle type Full floating, direct frame mount D01 D02 D03 Tread mm (in) 890 (35.04) 965 (37.99) 1,005 (39.57) INSPECTION AND ADJUSTMENT Wheel hub rotation starting torque at hub bolt N (kg, lb) 10 - 29 (1 - 3, 2 - 7 ) Axial play of wheel bearing mm (in) Less than 0.08 (0.0031) TIGHTENING TORQUE D01 series D02 series 2.0 - 2.5 ton 3.0 -3.2ton N×m kg-m ft-lb N×m kg-m ft-lb N×m kg-m ft-lb Axle case to axle tube 18 - 147 12 - 15 87 - 108 118 - 147 12 - 15 87 - 108 Axle mounting bracket to backing plate 79 - 105 8.0 - 10.8 58 - 78 128 - 166 13.0 - 17.0 94 - 122 128 - 166 13.0 - 17.0 94 - 122 Axle mounting bracket to frame 187 - 235 19 - 24 138 - 173 324 - 372 33 - 38 239 - 274 324 - 372 33 - 38 239 - 274 Axle case to differential carrier 19 - 24 1.9 - 2.5 14 - 18 39 - 51 3.9 - 5.3 29 - 38 39 - 51 3.9 - 5.3 29 - 38 Drive wheel hub to axle shaft 40 - 53 4.0 - 5.5 29 - 39 74 - 88 7.5 - 9.0 55 - 65 74 - 88 7.5 - 9.0 55 - 65 Brake tube flare nut 15 - 17 1.5 - 1.8 11 - 13 15 - 17 1.5 - 1.8 11 - 13 15 - 17 1.5 - 1.8 11 - 13 Road wheel nut Single tire 167 - 225 17 - 23 123 - 166 246 - 294 25 - 30 181 - 216 442 - 588 45 - 60 326 - 433 Double tire Direct connecting type Hub bolt installing nut 44 - 441 35 - 45 254 - 325 Inner nut 40 - 686 55 - 70 398 - 506 Outer nut 89 - 735 60 - 75 434 - 542 Outer hub type Inner wheel attaching nut 167 - 225 17 - 23 123 - 166 246 - 294 25 - 30 181 - 216 Outer wheel attaching nut 167 - 225 17 - 23 123 - 166 246 - 294 25 - 30 181 - 216 Outer hub connecting nut 79 - 98 8 - 10 58 - 72 246 - 294 25 - 30 181 - 216 Rim set bolt 69 - 98 7 - 10 51 - 72 157 - 196 16 - 20 116 - 114 SERVICE DATA AND SPECIFICATIONS FA-2
  • 22. D02 single-tire for 2.0-ton & 2.5-ton models and single-tirefor 3.0-ton & 3.2-ton models D02 direct connecting type double tire for 3.0-ton & 3.2-ton models FAM0054 FAM0055 FRONT AXLE FA-6