FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT
6FGUIGFDU15- 30. Please use this manual for providing quick, correct
servicing of the corresponding forklift models.
This manual deals with the above models as of July 1995. Please
understand that disagreement can take place between the descriptions
in the manual and actual vehicles due t o change in design and specifications. Any change or modifications thereafter will be informed by
Toyota Industrial Equipment Parts & Service News.
For the service procedures of the mounted engine, read the repair
manuals listed below as reference together with this manual.
(Reference)
Repair manuals related t o this manual are as follows:
TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINE
REPAIR MANUAL (N O. CE602-1)
TOYOTA INDUSTRIAL EQUIPMENT GM4-181 ENGINE
REPAIR MANUAL (No. CU629)
TOYOTA INDUSTRIAL EQUIPMENT 1DZ ENGINE
REPAIR MANUAL (No. CE618)
TOYOTA Material Handling Company
A Division of TOYOTA INDUmIES CORPORATION
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SECTION INDEX
7
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NAME
1
-
p
p
p
-
-
-
-
-
-
--
GENERAL
ENGINE
TORQUE CONVERTER
PROPELLER SH
DIFFERENTIAL
FRONT AXLE
REAR AXLE
--
-
-
L
-
I
--
-
7-
L
-
BRAKE
-
-
-
--
A
P
P
MATERIAL HANDLING
MAST
CYLINDER
L
I
OIL PUMP
~ILCONTROLVALVE
-APPENDIX
--
--
--
-
7
:
-
-
-
-
-
-
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--
0
P
-
--
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-
--
L
-
- - -
-
3
-
--
n
GENERAL
Page
EXTERIOR VIEWS ............................................... 0-2
VEHICLE MODEL ............................................... 0-3
FRAME NUMBER ................................................. 0-4
HOW TO READ THIS MANUAL .......................... 0-5
....................................... 0-5
TERMINOLOGY .................................................... 0-6
ABBREVIATIONS .................................................. 0-6
OPERATIONAL TIPS ............................................ 0-7
EXPLANATION METHOD
STANDARD BOLT & NUT TIGHTENING
TORQUE ........................................................ 0-8
BOLT STRENGTH TYPE IDENTIFICATION
METHOD .......................................................... 0-8
................................ 0-9
PRECOAT BOLTS ................................................ 0-10
TIGHTENING TORQUE TABLE
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE .....................................0-10
WIRE ROPE SUSPENSION ANGLE LIST
............. 0-11
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE ....................................... 0-11
COMPONENTS WEIGHT
..................................... 0-12
RECOMMENDED LUBRICANT
QUANTITY & TYPES ........................................ 0-13
LUBRICATION CHART ........................................ 0-14
PERIODIC MAINTENANCE .................................. 0-15
PERIODIC REPLACEMENT OF PARTS
AND LUBRICANTS ........................................... 0-21
EXTERIOR VIEWS
VEHICLE MODEL
Series
Load capacity
Model
Engine model
Engine type
Drive system
42-6FGU 1 5
4Y
Gasoline
Torque converter
02-6FDU 1 5
1 DZ
Diesel
t
42-6FGU 1 8
4Y
Gasoline
T
02-6FDU 1 8
1 DZ
Diesel
t
42-6FGU20
4Y
Gasoline
t
52-6FGU20
GM
t
t
62-6FDU20
1 DZ
Diesel
t
42-6FGU25
4Y
Gasoline
t
52-6FGU25
GM
t
t
62-6FDU25
1 DZ
Diesel
t
02-6FGU30
4Y
Gasoline
t
52-6FGU30
GM
t
t
62-6FDU30
1 DZ
Diesel
t
1.5 t o n
1 ton series
1.75 ton
2.0 ton
2 ton series
2.5 ton
3 ton series
3 . 0 ton
0-4
FRAME NUMBER
Frame No. Punching Position
Punching position
on the stiffener belo
Engine
Model
Punching format
42-6FGU 1 5
4Y
406FGU 18-6001 1
42-6FGU 1 8
1 ton series
02-6FDU 1 5
1 DZ
6FDU 18-6001 1
02-6FDU 1 8
42-6FGU20
4Y
406FGU25-60011
42-6FGU25
52-6FGU20
2 ton series
506FGU25-60011
GM
52-6FGU25
62-6FDU20
606FDU25-60011
1 DZ
62-6FDU25
3 ton series
4Y
02-6FGU30
6FGU30-60011
GM
52-6FGU30
506FGU30-60011
1 DZ
62-6FDU30
606FDU30-60011
HOW TO READ THIS MANUAL
EXPLANATION METHOD
1.
Operation procedure
( 1 ) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with a photo or illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration,
followed by ex'planation of cautions and notes summarized a s point operations.
Example of description in pattern B
/
DISASSEMBLY-INSPECTION-REASSEMBLY
Tightening torque unit T = N.m (kgf-cm) [fb-lbfl
If a place or part cannot be indicated
directly, the part name is described on
the either side of the illustration.
Example:
1 Piping
8
Disassembly Procedure
1
Remove the cover. [Point 11
2
Remove the bush [Point 21 4- Operation explained later
3
Remove the gear.
Point operations
[Point 1 I
is assembly:
[Point 21
Inspection:
Explanation of key point for operation with an illustration
d
Put a match mark when removing the pump cover.
Measure the bush inside diameter.
Bush inside diameter limit: 19.12 mm (0.7528 in)
I
2.
3.
H o w t o read components figures
( 1 ) The components figure uses the illustration
in the parts catalog for the vehicle model.
Please refer t o the catalog for checking the
part name.
The number at the right shoulder of each
components figure indicates the Fig. number inthe parts catalog.
(Example)
FIG number in parts catalog
Matters omitted in this manual
( 1 ) This manual omits description of the following jobs, but perform them in actual operation
@ Cleaning and washing of removed parts as required
@ Visual inspection (partially described)
TERMINOLOGY
Caution:
lmportant matters of which negligence may cause accidents. Be sure to abserve them.
Note:
lmportant items of which negligence may cause accidents, or matters in operation procedure requiring special attention.
Standard: Values showing allowable range in inspection and adjustment.
Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONS
Abbreviation (code)
Meaning
Abbreviation (code)
Meaning
ASSY
Assembly
SST
Special service tool
LH
Left hand
STD
Standard
LLC
Long life coolant
T =
Tightening torque
0PT
Option
O O T
Number of teeth (00)
01s
Oversize
UIS
Undersize
PS
Power steering
W/
With
RH
Right hand
L/
Less
SAE
Society of Automotive
Engineers (USA)
OPERATIONAL TIPS
1.
Safe operation
( 1 ) After jacking up, always support w i t h rigid stands.
( 2 ) When hoisting the vehicle or its heavy component, use wire repe(s) w i t h a sufficient reserve in
load capacity.
( 3 ) Always disconnect the battery plugs before the inspection or servicing o f electrical parts.
2.
Tactful operation
( 1 ) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge, etc.) and SSTs before starting operation.
( 2 ) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts
neatly t o prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools
and operate in a clean location.
( 5 ) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace, gaskets, packings and O-rings w i t h n e w ones each time they are disassembled.
( 7 ) Use genuine Toyota parts for replacement.
(8) Use specified bolts and nuts. Observe the specified tightening torque at the time o f reassembly.
If no tightening torque is specified, tighten the bolt or nut according t o the standard tightening
torque table.
3.
Grasping the trouble state
When a trouble occurs, d o n o t attempt immediate disassembly or replacement b u t first check if
the trouble requires disassembly or replacement for remedying.
0-8
STANDARD BOLT & NUT TIGHTENING TORQUE
Standard bolt and tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1.
2.
Find out the type of the bolt from the list below and then find the bolt tightening torque from the table.
The nut tightening torque can be judged from the mating bolt type.
BOLT STRENGTH TYPE IDENTIFICATION METHOD
1.
lndentification by bolt shape
2.
Identification by part No.
Hexagon head bolt
Bolt head No.
Parts No.
9161 1-40625
-LLength (mm)
Diameter (mm)
iameter
T w o protruding
T w o protruding
Stud bolt
Three protruding
Part No.
92 1 32-406 14
Four protruding
Length (mm)
Diameter (mm)
iameter
TIGHTENING TORQUE TABLE
Specified torque
Class
Diameter
rnrn
Pitch
rnm
Hexagon
head bolt
N.m
Bllll
1 kgf-crn
ft-lbf
I
4T
6
8
10
12
14
16
1 .O
1.25
1.25
1.25
1.5
1.5
5.4
13
25
47
75
113
1
I
1
j
1
I
1
1
55
130
260
480
760
1150
5T
6.4
16
32
59
91
137
1
I
/
1
I
1
I
1
65
160
330
600
930
1400
I
6T
7T
5
8
10
12
14
16
1 .O
1.25
1.25
1.25
1.5
1 .O
1.25
1.25
1.25
1.5
1.5
7.8
19
39
72
-
11
25
52
95
147
226
1
80
8T
1.25
1.25
1.25
29
61
110
j
j
1
19
35
55
83
i
56 in.-lbf
1 12
I
1 24
j 43
67
1101
1
I
I
I
1
1
t
1
I
1
1
1
110
260
530
970
1500
2300
1
1
j
I
8
1 19
I
1 38
I
1 70
108
j 166
/
1
\
I
1
I
It
I
-
I
I
I
I
79
123
1
1I
1
12
28
58
103
167
-
22
45
80
33
68
120
1
1
I
1
I
1
1
I
I
I
I
1
1
/
I
-
-
I
I
I
I
I
I
I
I
I
21
43
/
I
I
I
I
I
I
I
I
I
I
I
I
I
1
52 in.-lbf
10
1 2 1
39
j 61
-
90
1
78 in.-lbf
I
215
440
810
1250
1 1 6
j 32
59
90
/
I
I
1
j
/
I
8.8
1
ft-lbf
I
290
540
850
I
-
I
I
I
I
300
620
1100
1
1
60
145
I
-
-
1
I
I
69 in.-lbf
I
I
I
I
I
I
I
/
1
/
I
I
I
I
I
j
I
-
1 kgf-crn
I
14
29
53
1
195
400
730
I
8
10
12
1
5.9
14
28
53
83
I
I
1
1
1
48 in.-lbf
9
I
I
I
6
8
10
12
14
i
I
I
I
I
1 .O
1.25
1.25
1.25
1.5
1.5
N.m
1
I
6
8
10
12
14
16
Hexagon
flange bolt
120
290
590
1050
1700
-
j 9
1 2 1
I
1 43
I
1 76
:I23
I
I
I
I
330
690
1250
1
1
I
1
-
24
50
90
PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1.
Do not use the precoat bolt as it is in either of the
following cases:
(a) After it is removed.
(b) When the precoat bolt is moved (loosened or tightened) by tightness check, etc.
Note:
For torque check, use the lower limit of the allowable tightening torque range. If the bolt moves, retighten it according
to the steps below.
2. Method for reuse of precoat bolts
Wash the bolt and threaded hole. (The threaded hole
must be washed even for replacement of the bolt.)
( 2 ) Parfectly dry the washed parts by air blowing.
(3) Coat the specified seal lock agent t o the threaded portion of the bolt.
(1
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
1.
When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces
with clean cloth t o remove foreign matters and dirt. Also check no dent or other damage on the
contact surfaces before installation.
2.
When connecting a high pressure hose, hold the hose t o align the fitting with the nipple and tighten
the fitting.
3.
The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter
of screw
Tightening range
Standard
-
7116
-
20UNF
25 ( 250) [ 18.11
24
-
26 ( 240
9/16
-
18UNF
49 ( 500) [ 36.21
47
-
52 ( 480
16UNF
59 ( 600) [ 43.41
56
-
62 ( 570
-
718 - 14UNF
59 ( 600) [ 43.41
56
-
62 ( 570
718 - 14UNF
78 ( 800) [ 57.91
74
-
-
82 ( 760
1.1/16-12UNF
1 1 8 ( 1 2 0 0 ) [ 86.81
1.5116 - 12UNF
137 (1400) [101.31
PF 1 I 4
25 ( 250) [ 18.11
PF3/8
49 ( 500) [ 36.21
PF 1 I 2
59 ( 600) [ 43.41
PF314
11 8 (1200) [ 86.81
PF 1
137 (1400) [101.3]
314
-
Hose inside
diameter
mm (in)
Standard tightening torque N.m (kgf-cm) [ft-lbfl
270) [ I 7.4
-
630) L41.2 530) [34.7
19.51
6 (0.24)
38.31
9 (0.35)
45.61
12 (0.47)
- 840) I55.0 -
45.61
12 (0.47)
60.81
1 5 (0.59)
1 1 2 - 123(1140- 1250)[82.5-
90.41
19 (0.75)
630) l41.2
- 144 (1330 - 1470) [96.2 - 106.41
24 - 26 ( 240 - 270) 117.4 - 19.51
47 - 52 ( 480 - 530) [34.7 - 38.31
56 - 62 ( 570 - 630) 141.2 - 45.61
11 2 - 123 ( 1 140 - 1250) [82.5 - 90.41
130 - 144 (1330 - 1470) [96.2 - 106.41
130
25 (0.98)
6 (0.24)
9 (0.35)
12 (0.47)
19 (0.75)
25 (0.98)
WlRE ROPE SUSPENSION ANGLE LIST
Lifting
angle
0O
Tension
Compression
1.OO time
0 time
Suspension
method
Tension
Compression
1.41 time
1.OO time
Lifting
angel
90 O
Suspension
method
30 O
1.04 time
2'
do
1 20°
0.27 time
A$
b?\
,!z
2.00 time
1.73 time
-
60°
1.16 time
0.58 time
h'
SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE
Cutting
Rope
load
diameter
Single-rope
suspension
unit:
N (ton) [lbfl
Four-rope suspension
Two-rope suspension
0O
0O
30°
60 O
90 O
0O
30°
60O
90O
21 380
(2.18)
[4807]
3040
(0.31)
[683.61
6080
(0.62)
[ 13671
5880
4310
(0.44)
(1.2)
[2646]
10400
(1.06)
[2337]
8630
(0.88)
[ I 9401
31 480
8 mm
(3.21)
(0.32 in)
[7078]
4410
(0.45)
[992.3]
8830
(0.9)
[I
9851
8530
(0.87)
[I
91 81
7650
(0.78)
[I7201
[970]
6280
(0.64)
[I41 I ]
12160
(1.24)
[27341
11770
[I
3231
5200
(0.53)
[I1691
(1.8)
139691
17060
(1.74)
[3937]
15300
(1.56)
[34401
12550
(1.28)
[23221
10 mm
(0.4 in)
49230
(5.02)
[l
1.691
6960
(0.71)
[I565.61
14020
(1.43)
[31531
13440
(1.37)
13021I
11770
9810
27460
26480
23540
19610
(1.2)
[26461
(1.0)
[22051
(2.8)
[61741
(2.7)
[59541
(2.4)
[52921
(2.0)
[44101
12.5 mm
(0.5 in)
76880
(7.84)
1173871
10980
(1.12)
[2469.5]
21570
21280
18630
14710
43150
41 190
37270
(2.2)
[4851]
(2.1)
[46311
(1.9)
[41901
(1.5)
[33081
(4.4)
[97021
(4.2)
[92611
(3.8)
[83791
29420
(3.0)
[66151
14 mm
(0.56 in)
96400
(9.83)
[21675]
13730
27460
26480
(2.7)
[59541
23540
18630
(2.4)
[52921
(1.9)
[4190]
6 mm
(0.24 in)
(1.4)
[30871
(0.6)
17650
52960
47070 37270
(3.8)
(5.4)
(4.8)
(5.6)
[I23481 [ I 19071 [ l o 5 8 4 1 183791
54920
1
COMPONENTS WEIGHT
Unit:
Component
Engine
Weight (mass)
4Y
1 3 4 (295)
GM
1 5 0 (331)
1DZ
176 (388)
For 1 speed
128 (282)
For 2 speeds
163 (359)
1.5 ton model
Approx. 785 ( 1731)
1.75 ton model
Approx. 925 (2040)
2.0 ton model
Approx. 1 1 6 0 (2558)
2.5 ton model
Approx. 1470 (3241)
3.0 ton model
Approx. 1880 (4145)
1 ton series
Approx. 41 0 (904)
2 ton series
Approx. 5 1 0 (1 125)
3 ton series
Approx. 5 9 0 ( 1301)
1 ton series
Approx. 3 4 0 (750)
2 ton series
Approx. 41 5 (915)
3 ton series
Approx. 465 ( 1025)
Torque converter
Balance weight
V mast ASSY Wllift bracket
(with lift cylinder, without fork, max.
lifting height: 3000 m m ( 11 8 in))
V mast ASSY Lllift bracket and fork
(with lift cylinder max. lifting height:
3 0 0 0 m m (118 in))
kg (Ib)
RECOMMENDED LUBRICANT QUANTITY & TYPES
Classification
Description
Gasoline
Motor oil
SAE30
(SAE20 in cold area)
API
SD, SE
SAE20W-40
(SAE1OW-30 in cold
area)
Engine
Diesel
Torque converter
Diesel engine oil
SAE30
(SAE2O in cold area)
API
CC, CD
or better
Hydraulic oil
[Max. for height =
3 0 0 0 m m ( 11 8 in)]
Hypoid gear oil
SAE85W-90
IS0
VG32
Hydraulic oil
SAE J - 1 7 0 3
Brake line
Chassis parts
Coolant
(Reservoir Tank)
Attached Table 1
4Y
4.0 1 ( 1 . 0 6 US gal)
GM
3.8 1 ( 1.OO US gal)
1 DZ
7 . 9 1 (2.09 US gal)
1-speed
11.5 1 ( 3 . 0 4 US gal)
2-speed
14.0 C (3.70 US gal)
1 ton series
5.4 C (1.43 US gal)
2 t o n series
6.4 C ( 1 . 6 9 US gal )
3 t o n series
9.0 1 (2.38 US gal)
1 ton series
2 7 1 (7.1 US gal)
2 ton series
3 4 1 (9.0 US gal)
3 t o n series
3 7 1 ( 9 . 8 US gal)
1 t o n series
4 5 1 ( 11.9 US gal)
2 t o n series
6 5 1 ( 1 7 . 2 US gal)
3 t o n series
6 5 C ( 17.2 US gal)
All models
Proper quantity
Reservoir Tank
0 . 2 C (0.05 US gal)
All models
Proper quantity
G M Dexronm I1
ATF
Fuel tank
Coolant
(exclulding reservoir
tank)
Quantity
SAE 1 OW-30
API
GL-4
GL-5
Differential
Application
Type
LLC 3 0 -5 0 % mixture
(for winter or
all-season)
Cooland w i t h rustinhibitor (for spring,
summer and autumn)
LLC
t
t
Attached Table 1
Coolant volume
All models
Coolant volume
1.1 C ( 0 . 2 9 US gal)
(at Full level)
Unit:
l (US gal)
Engine
1 t o n series
2 ton series
3 ton series
4Y
9 . 6 (2.53)
9 . 3 (2.46)
9.6 (2.53)
8 . 8 (2.32)
t
8 . 3 (2.19)
t
GM
1 DZ
8.1 (2.14)
LUBRICATION CHART
0
Inspection
Replacement
@ M P grease
@ Engine oil
@ Hypoid gear oil
@ Hydraulic oil
@ Automatic transmission fluid
@ Brake flluid
Molykote G-n paste
I.
II.
Ill.
IV.
V.
a
Chain
Differential gear
Front wheel bearing
Brake master cylinder
Torque converter case
Rear wheel bearing
Steering knuckle king pin
Power steering cylinder pin
Oil tank
10
11
12
13
14
15
lnspect
lnspect
lnspect
lnspect
lnspect
Engine crankshaft
Tilt steering locking mechanism
Mast support bushing
Tilt cylinder front pin
Propeller shaft
Oil pump spline shaft
(GM engine model)
every
every
every
every
every
8 hours (daily)
4 0 hours (weekly)
1 7 0 hours (monthly)
1 0 0 0 hours ( 6 monthly)
2 0 0 0 hours (annually)
PERIODIC MAINTENANCE
INSPECTION METHOD
I : Inspection. Repair or replacement if required.
M : Measurement. Repair or adjustment if required.
T : Retightening C : Cleaning L : Lubrication
* : For n e w vehicle * 1 : Flaw detector
Every
1 month
Every
3 months
6 months
Every
1 2 months
Every
1 7 0 hours
Every
5 0 0 hours
Every
1 0 0 0 hours
Every
2 0 0 0 hours
I
t
t
t
Rotating condition at idling
M
t
t
t
Rotating condition during
acceleration
M
t
t
t
Exhaust gas condition
I
t
4-
t
Air cleaner element
C
t
t
t
Inspection Period
Item
Every
ENGINE
Proper starting and abnormal noise
Main body
Valve clearance
M
Compression
M
Cylinder head bolt loosening
T
Muffler rubber mount
I
PCV system
Cologging and damage in PCV valve
and piping
Governor
No-lead maximum rpm
Lubrication
system
Fuel system
I
c
c
t
M
t
c
t
Oil leak
I
+
c
t
Oil level
I
t
t
c
Clogging and dirt of oil filter
I
t
t
t
Fuel leak
I
t
t
t
Operation of carburetor link
mechanism
I
4-
4-
t
Dirt and clogging of fuel filter and
element
I
t
t
t
M
t
Injection timing
lnjection nozzle injection pressure
and spray status
M
Draining of sedimenter
Cooling
system
I
+
Coolant level in radiator and leak
I
t
t
t
Rubber hose degradation
I
t
t
t
Radiator cap condition
I
t
t
t
I
t
t
t
Fan belt tension, looseness and
damage
Radiator rubber mount
I
I
Every
1 month
Every
3 months
Every
6 months
Every
12 months
Every
1 7 0 hours
Every
5 0 0 hours
Every
1 0 0 0 hours
Every
2 0 0 0 hours
Leak
I
t
t
t
Oil level
I
t
t
t
Inspection Period
Item
POWER TRANSMISSION SYSTEM
Differential
T
Bolt loosening
Torque
converter
and
transmission
Leak
I
t
t
t
Fluid level
I
+
t
C
Operating mechanism function and
looseness
I
+-
+
t
Control valve and clutch functions
I
t
t
t
Inching valve function
I
t
t
t
M
4-
t
+-
Stall and hydraulic pressure
measurement
Propeller
shaft and
axle shaft
T
Loose joint
Looseness of universal joint
I
Twisting and cracks of axle shaft
I
DRIVE SYSTEM
Wheels
Tire inflation pressure
M
+-
+-
t
Tire cuts, damage and uneven
wearing
I
t
t
t
Loose rim and hub nuts
T
t
t
t
Tire groove depth
M
t
t
t
Metal chips, pebbles and other foreign matter trapped in tire grooves
I
t
t
t
Rim, side ring and disc wheel
damage
I
t
t
t
Abnormal sound and looseness of
front wheel bearing
I
t
t
t
Abnormal sound and looseness of
rear wheel bearing
I
t
t
t
Front axle
Crack, damage and deformation of
houseing
I
Rear axle
Cracks, damage and deformation of
beem
I
Every
1 month
Every
3 months
Every
6 months
Every
1 2 months
Every
1 7 0 hours
Every
5 0 0 hours
Every
1 0 0 0 hours
Every
2 0 0 0 hours
Play and looseness
I
t
C
t
Function
I
+
C
t
Oii leak
I
t
t
t
Looseness of mounting
T
+-
+-
+-
Oil leak
I
e
t
t
Mounting and linkage looseness
I
t
t
c
Inspection Period
Item
STEERING SYSTEM
Steering
wheel
Steering
valve
Power
Steering
I
Damage of power steering hose
King pin looseness
Knuckle
I
t
t
t
I
Cracks and deformation
BRAKING SYSTEM
Brake pedal
Parking
brake
Brake pipe
Play and reserve
M
+-
+-
t
Braking effect
I
+-
+-
t
Operating force
I
c
t
t
Braking effect
I
t
t
t
Rod and cable looseness and
damage
I
t
e
e
I
t
t
C
I
4-
e
t
Leak, damage and mounting con-
dition
Reservoir
tank
Leak and fluid level
Master cylinder and
wheel cylinder
Function, wear, damage,
leak and mounting looseness
Clearance between drum and lining
Brake drum
and brake
shoe
Backing
plate
I
M
t
t
e
Wear of shoe sliding portion and
lining
I
Drum wear and damage
I
Shoe operating condition
I
Anchor pin rusting
I
Return spring fatigue
M
Automatic adjuster function
I
Deformation, cracks and damage
I
Loose mounting
T
MATERIAL HANDLING SYSTEM
Forks
Abnormality of fork and stopper pin
I
t
4-
t
Misalignment between left and right
fork fingers
I
t
t
t
Cracks at fork root and welded part
I+'
Every
1 month
Every
Every
3 months
6 months
Every
1 2 months
Every
1 7 0 hours
Every
5 0 0 hours
Every
1 0 0 0 hours
Every
2 0 0 0 hours
Deformation and damage of each
part and crack at welded part
I
t
t
t
Mast and lift bracket looseness
I
t
t
t
Inspection Period
Item
Mast and lift
bracket
Wear and damage of mast support
bush
Wear, damage and rotating condition of rollers
I
I
t
t
I
Wear and damage of roller pins
Chain and
chain wheel
Various
attachments
t
Wear and damage of mast strip
I
t
t
t
Tension, deformation and damage of
chain
I
t
t
t
Chain lubrication
I
t
t
t
Abnormality of chain anchor bolt
I
t
t
t
Wear, damage and rotating condition of chain wheel
I
t
4-
t
Abnormality and mounting condition
of each part
I
t
t
t
Loosening and damage of cylinder
mounting
I
4-
C
4-
Deformation and damage of rod, rod
screw and rod end
I
t
t
t
Cylinder operation
I
t
t
t
Natural drop and natural forward tilt
(hydraulic drift)
M
c
t
t
Oil leak and damage
I
t
t
+-
Wear and damage of pin and
cylinder bearing
I
t
t
t
M
+-
t
t
HYDRAULIC SYSTEM
Cylinder
Lifting speed
Oil pump
Hydraulic
oil tank
Control
lever
Uneven movement
I
t
t
t
Oil leak and abnormal sound
I
t
+
t
Oil level and contamination
I
t
t
t
C
t
Tank and oil strainer
Oil leak
I
t
t
t
Loose linkage
I
t
t
t
Operation
I
t
t
t
Inspection Period
Item
Oil leak
Oil control
valve
Hydraulic
piping
Every
1 month
Every
3 months
Every
6 months
Every
12 months
Every
1 7 0 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
I
t
t
t
M
Relief pressure measurement
Relief valve and tilt lock valve
functions
I
I
t
t
t
Oil leak
I
4-
t
t
Deformation and damage
I
t
t
t
Loose joint
T
t
t
t
Cracks on distributor cap
I
t
+-
t
Spark plug burning and gap
I
t
t
t
Distributor side terminal burning
I
t
t
t
Distributor cap center piece wear
and damage
I
t
t
t
ELECTRICAL SYSTEM
lgnition
timing
I
Plug cord internal discontinuity
Ignition timing
M
t
Starting
motor
Pinion gear meshing status
I
t
t
t
Charger
Charging function
I
t
t
t
Battery fluid level
I
+-
+-
c
M
t
Battery
Battery fluid specific gravity
Electrical
wiring
Damage of wiring harness
I
t
t
t
Fuses
I
t
t
c
Preheater
Open-circuit in glow plug
I
t
Engine
stopping
system
Diesel engine key stop device
function
I
t
t
t
Cracks at welded portion
I
t
t
t
Deformation and damage
I
t
t
t
Loosening of mounting
T
t
t
t
Deformation, crack and damage
I
t
+-
+-
Lighting
system
Function and mounting condition
I
t
t
t
Horn
Function and mounting condition
I
t
t
t
SAVETY DEVICES, ETC.
Head guard
Back-rest
-
Inspection Per~od
Item
Every
1 month
Every
Every
3 months
6 months
Every
12 months
Every
170 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
Direction
indicator
Function and mounting c o n d ~ t ~ o n
I
t
t
t
Instruments
Functions
I
t
t
t
Backup
buzzer
Function and mounting condition
I
t
t
t
Rear-view
mirror
Dirt, damage
I
t
t
C
Rear reflection status
I
t
t
t
Seat
Loosening and damage of mounting
I
t
+-
t
Mounting looseness
I
+-
t
t
Webbing damage
I
t
t
t
Plate damage
I
t
c
t
Buckle damage
I
+-
+-
+
Seat belt
Body
Others
Damage and cracks of frame, cross
members, etc.
I
Bolt looseness
T
Grease up
L
+-
4-
+-
PERIODIC REPLACEMENT QF PARTS AND LUBRICANTS
a:Replacement
Every
1 month
Every
Every
3 months
6 months
Every
1 2 months
Every
1 7 0 hours
Every
5 0 0 hours
Every
1 0 0 0 hours
Every
2 0 0 0 hours
Engine oil
•
t
+-
+-
Engine oil filter
a*
t
+-
t
t
Interval
Item
•
•
Engine coolant (every 2 years for LLC)
•
•
•
Fuel filter
Torque converter oil
Torque converter oil filter
++t
•
Differential oil
•
•
Hydraulic oil
Hydraulic oil return filter
@*I
+t
•
Wheel bearing grease
•
Spark plugs
+-
Air cleaner element
•
Cups and seals for brake master and wheel
cylinders
a
•
Brake fluid
t
a+2
ax2
ax2
ax2
a*2
a*2
ax3
Power steering hoses
Power steering rubbers parts
Hydraulic hoses
Brake fluid reservoir tank hose
Fuel hoses
Torque converter rubber hoses
Chains
*I:
for n e w vehicle
*2:
Every 2 years
*3:
Every 3 years
Replacement shall be made upon arrival o f the operation hours or months, whichever is earlier.
ENGINE
Page
.................................1-2
MAJOR SPEClFlCATlONS ................................... 1-5
ENGINE PERFORMANCE CURVES ...................... 1-6
ENGINE ASSY .................................................... 1-8
ENGINE EXTERIOR VIEWS
ENGINE WITORQUE CONVERTER
REMOVAL.INSTALLATION ................................. 1-8
........................ 1-11
ENGINE SPEED ADJUSTMENT ........................... 1-I3
AIR CLEANER ...................................................... 1-17
ENGINE REMOVAL.INSTALLATION
RADIATOR .......................................................... 1-21
MUFFLER & EXHAUST PIPE ............................... 1-23
BATTERY ............................................................. 1-27
STARTING MOTOR ............................................. 1-29
ALTERNATOR .................................................... 1-30
ACCELERATOR PEDAL ....................................... 1-32
ENGINE EXTERIOR VIEWS
4 Y Engine
G M Engine
1 DZ Engine
MAJOR SPECIFICATIONS
Gasoline Engines
4Y ( 1 . 2 ton series)
4Y ( 3 ton series)
GM ( 2 . 3 series)
Engine type
Gasoline 4-cycle
t
t
Number of cylinders and
arrangement
lnline 4-cylinder
. longitudinal
t
t
Wedge type
t
t
OHV.chain drive
t
OHV.gear drive
x 86.0
x 3.386)
t
101.6 x 91.4
(4.000 x 3.600)
t
2965 (241.96)
Combustion chamber type
Valve mechanism
Bore x Stroke
Total displacement
Compression ratio
Maximum power
Maximum torque
cc (cu-in)
2237 (136.51)
I
P S I ~ D I~
kgf-mlrpm
Maximum specific fuel
consumption
Service weight
91.0
(3.583
mm (in)
kg (lb)
No-load maximum rpm
rPm
1
/
8.8
5412400
I
I
t
5812600
I
I
8.2
I
6012400
I
16.511 8 0 0
t
1911 4 0 0
1 3 4 (295)
t
1 5 0 (331)
2650
2800
2600
Diesel Engines
Engine type
Number of cylinders and
arrangement
Combustion chamber type
Valve mechanism
Bore x Stroke
Total displacement
mm (in)
cc (cu-in)
Compression ratio
1DZ (1 ton series)
1 DZ ( 2 . 3 ton series)
Diesel 4-cycle
t
In line 4 cylinder
. longitudinal
t
Vortex chamber type
4-
OHVgear drive
t
86.0 x 107.0
(3.386 x 4.213)
t
2486 ( 151.71)
t
21.5
t
Maximum power
PSIrpm
5512400
6012600
Maximum torque
kgf-mlrpm
17.0 ( 1600)
c
18511 400
t
176 (338)
t
2600
2800
Maximum specific fuel
consumption
Service weight
No-load maximum rpm
SIPS-h (rpm)
kg (Ib)
rPm
1-6
ENGINE P E R F O R M A N C E C U R V E S
4 Y Engine
-Gasoline
--- ---
-Gasol~ne
LPG Only
-- -
LPG Only
- - - - - - Gasol~neand LPG
16.0/1800
-g
t
5
50'
40-
40-
w
C
E
8
30-
0
$
iD
20-
10-
:2 0 10
A
-
w
1'0
1'4
1'8
2'2
Engine Speed Irpml
2$X 10'
L
i
6
10
t
14
18
22
26
Engine Speed lrpml
3 ton series
1.2 ton series
GM Engine
L
6
10
14
18
22
26
Englne Speed Irpml
30x102
I
.
3Ox1O2
1 DZ Engine
I
1
10
14
18
22
Engine Speed lrprnl
1 ton series
26x10'
Eng~neSpeed lrprnl
2.3 ton series
ENGINE ASSY
ENGINE WITORQUE CONVERTER REMOVAL-INSTALLATION
Removal Procedure
1
Remove the radiator cover.
2
Remove the engine hood.
3
Remove the toe board.
4
Remove the battery and battery case.
5
Remove the radiator reservoir tank and bracket.
6
Remove the air cleaner.
7
Remove the flame side cover
8
Drain the coolant.
9
Remove the radiator and fan shroud.
1 0 Disconnect the exhaust pipe.
11
Disconnect the fuel hose. [Point 1I
1 2 Disconnect the accelerator wire (on the carburetor side in gasoline engine models, or on the injection pump side in diesel engine models).
1 3 Remove the oil pump Wlpump hose. ( 4 Y - 1DZ)
Disconnect the pump universal joint. (GM)
1 4 Remove the horn.
1 5 Disconnect the shift lever link rod
1 6 Disconnect the inching wire.
17
Disconnect the torque converter cooler hose.
1 8 Disconnect the electrical wiring.
1 9 Remove the propeller shaft cover and propeller shaft.
2 0 Remove the torque converter mounting set bolts.
21
Remove the engine mounting set nuts.
2 2 Remove the engine Wltorque converter. [Point 21
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Carry out the following job after engine installation:
Air bleeding from fuel system (in diesel engine models only1
Inching wire adjustment (see page 8 -2 8 . )
The tightening torque for each parts is as follows.
88 N.m ( 5 0 0 9 0 0 kgf-cm) 136 6 5 ft-lbfl
Torque converter mounting bolt. T = 4 9
9 9 . 0 N - m ( 5 5 0 1 0 1 0 kgf-cm) 139.8 7 3 . 1 ft-lbfl
T = 53.9
Engine mounting set nut.
-
-
-
-
-
-
1-10
Bleeding Air from Fuel System (Diesel engine model)
IDZ engine
Operate the fuel filter band pump unit till the pump operation becomes heavy t o indicate the end of air bleeding.
Point Operations
[Point 1I
Removal:
Installation:
Always close the fuel piping cock.
Do not mistake the fuel hose connecting position. (Gasoline engine model.)
[Point 21
Removal. Installation: SST 0 9 0 1 0-201 1 1-7 1
Removal: Remove after checking through disconnection of
the wiring, hoses and cables.
ENGINE REMOVAL-INSTALLATION
Note:
The procedure described here covers the jobs after removing the engine Wltorque converter.
Removal Procedure
1
Remove the cover plate.
2
Remove the drive plate set bolts ( 6 pcs.). [Point 11
3
Slightly hoist the torque converter housing
4
Remove the torque converter housing and engine connecting bolts t o disconnect the torque converter housing, and remove the engine.
5
Remove the flywheel.
6
Remove the starting motor.
7
Remove the torque converter end plate.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Tighten the flywheel set bolts after applying thread tightener ( 0 8 8 3 3 -0 0 0 7 0 ) .
The tightening torque for each part is as folldws:
Unit:
Torque converter end plate set bolts
Drive plate set bolts (for connecting to the
engine crankshaft)
49.03
-
78.45 ( 5 0 0
-
N . m (kgf-cm) [ft-lbfl
800) [36.18
-
-
57.881
660) L41.96 - 47.751
4Y: 56.88 - 64.72 ( 5 8 0
G M I D Z : 76.49 - 93.16 ( 7 8 0
950) [56.43 - 68.731
-
Drive plate set bolts (flywheel set bolts)
(for connecting to torque converter)
14.71
-
21.57 ( 1 5 0
- 220) [10.85 - 15.921
Torque converter housing set bolts
29.42
-
44.13 ( 3 0 0
-
450) [21.71
-
32.561
Point Operations
[Point 1 I
I
-iT
Removal~lnstallation: Rotate the flywheel by using a
crankshaft pulley set bolt.
ENGINE SPEED ADJUSTMENT
GM
4Y
-
4 Y . G M Engine
Tachometer
Tachometer
Idle up and Idling Speed Inspection and Adjustment
1.
Warm up the engine.
Coolant temperature: 80°C (176OF) or above
Engine oil: 70°C (158OF) or above
Hydraulic oil temperature: 50°C (122OF) or above
Auto choke cancellation
connector
2.
3.
Install the engine tachometer.
lnspect and adjust the idle up speed.
( 1) Disconnect the idle up actuator hose and inspect the
idle up speed.
4Y: 1 2 5 0 & 25 rpm
GM: 1 0 5 0 & 5 0 rpm
(2) Turn the adjusting screw (A) t o adjust the idle up
speed.
Increasing the speed: Clockwise turn
Decreasing the speed: Counterclockwise turn
(3) Connect the idle up'actuator hose.
4.
lnspect and adjust the idling speed.
( 1) lnspect the idling speed.
Idling speed
4Y: 7 5 0
GM: 7 0 0
+zO rpm
+zO rpm
(2) Turn the idle adjusting screw (B) t o adjust the idling
speed.
(3) If the speed cannot be decreased b y turning the adjusting screw (B), make adjustment as follows:
@
Raise the coolant temperature when the auto choke
cam is in contact with the throttle lever roller.
@ When the idle up actuator rod is in contact w i t h
the adjusting screw (A), turn the adjusting screw
counterclockwise.
No-load Maximum Speed Inspection and Adjustment
1.
Warm u p the engine.
Coolant temperature: 80°C ( 176OF) or above
Engine oil temperature: 7 0 C ( 158O F) or above
Hydraulic oil temperature: 50°C ( 122OF) or above
Maximum speed adjustment
2.
Install the engine tachometer.
3.
lnspect the no-load maximum speed.
No-load maximum speed
4 Y ( 1 . 2 ton series): 2650 & 5 0 rprn
4 Y ( 3 ton series): 2800
5 0 rprn
=t
50lrpm
GM: 2600
*
4.
Adjust the no-load maximum speed.
( 1 ) Remove the sealing wire.
( 2 ) Fully depress the accelerator pedal, and make adjustment b y means of the air governor adjusting n u t
and screw.
5.
lnspect the relief speed.
Operate the material handling lever w h e n the engine is
running at the maximum speed and measure the engine
speed in the full relief state. Confirm that the speed
decrease (relief d o w n ) satisfies the following value:
Engine speed down at full relief
4 Y ( 1- 2 ton series): 2 5 0 rprn or less
4 Y (3 ton series): 250 rprn or less
GM: 2 5 0 rprn or less
6.
Seal the engine w i t h wire after adjustment.
Note:
Turn the adjusting nut clockwise to increase the engine speed.
Turn the screw clockwise to increase the engine speed.
If the engine speed decrease in relief state is excessive, turn the adjusting nut clockwise and the screw
counterclockwise. In the process of this adjustment, the engine is about to start hunting. Stop adjustment immediately before hunting starts.
* If the engine running at the maximum speed is not stabilized (hunting), turn the adjusting nut counterclockwise and the screw clockwise. Excessive turning may increase the relief down to cause hunting.
If the relief down is about 2 0 0 rprn in the new vehicle state or is 3 0 0 rprn or above, make adjustment
by means of the engine, carburetor and air governor.
1 DZ Engine
Idling speed inspection and adjustment
1.
Warm up the engine.
Coolant temperature: 80°C (176OF) or above
Engine oil temperature: 70°C (158OF) or above
Hydraulic oil temperature: 50°C (122OF) or above
2.
Install the engine tachometer.
3.
lnspect the idling speed.
Idling speed
l D Z : 750 & 2 5 rprn
(Model with high capacity alternator (OPT):
8 0 0 & 2 5 rprn
4.
Adjust the idling speed.
( 11 Loosen the lock nut, and make adjustment by means
of the idle adjusting screw.
No-load maximum speed inspection and adjustment
1.
Warm up the engine.
Coolant temperature: 80°C (176OF) or above
Engine oil temperature: 70°C ( 158OF) or above
Hydraulic oil temperature: 50°C ( 122O F) or above
2.
Install the engine tachometer.
3.
lnspect the no-load maximum speed.
Fully depress the accelerator pedal and inspect the noload maximum speed.
No-load maximum speed
1DZ ( 1 ton series): 2600 & 5 0 rprn
(2.3 ton series): 2800 & 5 0 rprn
Model with high capacity alternator (OPT)
1 ton series: 2600 & 5 0 rprn
2.3 ton series: 2800 & 5 0 rprn
(Model with high capacity alternator (OPT): 2480
5 0 rpm)
I
4.
I
Adjust the no-load maximum speed.
( 1) Remove the seal.
( 2 ) Make adjustment by means of the maximum speed
adjusting screw.
5.
Inspect the relief speed.
Operate the material handling lever when the engine is
running at the maximum speed, and measure the engine
speed decrease at full relief (relief d o w n ) satisfies the
following value:
Engine speed down at full relief
l D Z (all models): 250 rpm or less
6.
Seal the engine w i t h wire after adjustment.
1-17
AIR CLEANER
GENERAL
Dust discharge val;e
SPECIFICATIONS
Single (STD)
Double (OPT)
Type
Cyclone type
t
Size
6-inch
c
Fresh air introduction type
t
Intake type
Outer:
Filtering area
cm2 (in*)
Inner:
Others
1 4 0 0 0 (2170.0)
1 4 0 0 0 ( 2170.0)
W i t h dust discharge valve
5 7 0 (88.4)
t
COMPONENTS
AIR CLEANER CLEANING-INSPECTION
1.
Open the engine hood.
2.
Remove the element.
Note:
In case of the double element type (OPT), do not remove the
inner element for other than replacement.
3.
Clean the element.
(1) For ordinary cleaning, blow w i t h compressed air
[ 6 9 0 kPa ( 7 kgIcm2) [ I 0 0 psil or less] vertically along
the pleats from the inside of the element.
If heavily contaminated, washing is possible.
(2) Element washing method
Dissolve neutral detergent in tepid water (approx.
40°C (104OF) and immerse the element in it for
about 3 0 minutes. Then, rinse the element well w i t h
clear water. [Water pressure: 2 7 5 kPa (2.8 kg/cm2)
[ 4 0 psil or lessl
After washing, naturally dry the element or dry the
element with a dryer (cold air).
Note
Do not damage the element during washing.
Never use compressed air or hot air for drying.
4.
Clean the dust discharge valve.
Hold the tip end of the vacator valve and discharge dust
and dirt from the inside of the valve.
5.
Inspect the element.
After cleaning, place an electric valve in the element t o
inspect any damage in the element. If any pinhole, tear
or damage is found, replace it w i t h a new element.
6.
Element replacement
Replace the element after it is washed six times or
generally at intervals of 1 2 months.
CLOGGING WARNING SYSTEM INSPECTION
1.
Warning lamp inspection
( 1 ) See that the air cleaner warning lamp comes on when
the ignition s w i t c h is turned ON and goes o u t when
the engine starts.
2.
Individual inspection
(1) Use a m i t y vac t o apply a negative pressure t o the
vacuum switch, and inspect conduction.
Standard
Gasoline models:
2 9 4 2 & 2 9 4 Pa (300 & 3 0 mmAq)
(22.1 k 2.2 mmHg): Conduction
Diesel models:
7473
5 6 9 Pa (762 & 5 8 mmAq)
(56.0 & 4 . 3 mmHg): Conduction
RADIATOR
COMPONENTS
(RADIATOR SCREEN)
7
SPECIFICATIONS
I
Crossflow
I
Corrugated fin
Fin type
I Coolant capacity (in radiator)
Cap opening pressure
I
See the table below
kPa (kgf/cm2)[psi]
73.5
-
103.0 (0.75
-
1.05) L10.7
-
14.91
Built in torque converter cooler
Others
COOLANT CAPACITY AND ANTIFREEZE TABLE
l (US gal)
Unit:
LLC mixing
LLC mixing
LLC rnlxrng
ratio at 25 % ratio at 30 % ratio at 50 %
(to - 12°C)
(to - 15OC) (to - 35OC)
Antirust
mixing at
5 %
Radiator
capacrty
Total
amount of
coolant
4Y
3.7 (0.98)
9.6 (2.53)
2.4 (0.63)
2.9 (0.61)
4.8 (1.27)
0.5 (0.11)
1DZ
4.2 (1.11)
8.1 (2.14)
2.0 (0.53)
2.4 (0.63)
4.1 (1.08)
0 . 4 (0.11)
4Y
3.7(0.98)
9.3(2.46)
2.3(0.61)
2.8(0.74)
4.7(1.24)
0.5(0.12)
1 ton
series
--
2 ton
series
3 ton
series
(Note)
~
--
-
GM
4.2 (1.11)
8.8 (2.32)
2.2 (0.58)
2.7 (0.71)
4.4 (1.16)
0.4 (0.11)
1 DZ
4.2 (1.11)
8.3 (2.19)
2.1 (0.55)
2.5 (0.66)
4.2 (1.11)
0 . 4 (0.11)
4Y
3.7(0.98)
9.6(2.53)
2.4(0.63)
2.9(0.77)
4.8(1.27)
0.5(0.12)
GM
4.2(1.11)
8.8(2.32)
2.2(0.58)
2.7(0.71)
4.4(1.16)
0.4(0.11)
1 DZ
4.2 (1.11)
8.3 (2.19)
2.1 (0.55)
2.5 (0.66)
4.2 (1.11)
0.4 (0.11)
The t o t a l amount o f coolant does n o t include the capacity of the reservoir tank.
Reservoir tank capacity: 1.1 l (0.29 US gal) (at FULL mark position)
MUFFLER & EXHAUST PIPE
GENERAL
Muffler (STD)
Catalytic muffler (OPT)
Gasoline model
Diesel model
COMPONENTS
4Y.GM
1702
MUFFLER REMOVAL-INSTALLATION
Muffler set bolts
\
)
/
Removal Procedure
\
1
Remove the radiator cover.
2
Remove the balance weight. (See page 0-1 2 for the weight of the balance weight.)
3
Remove the muffler set bolts.
4
Disconnect the exhaust pipe and remove the muffler.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
1-26
CATALYTIC MUFFLER MAINTENANCE
Jobs Every Year (2000 Hours)
Catalytic Pellets Replacement (Gasoline Engine Models)
1.
Remove the muffler.
2.
Remove old pellets from the muffler for replacement with
new pellets.
Catalytic Honeycomb Muffler Replacement (Diesel Engine
Models)
1.
Remove the muffler
2.
For honeycomb replacement, replace the whole muffler
ASSY.
BATTERY
COMPONENTS
Refer to FIG 5601
SPECIFICATIONS
Battery type list (The battery is selected according t o the equipped engine.)
STD
4Y
GM
1 DZ
GR35
(JIS 55D23L equipment)
t
GR24R
(JIS 80D26L equipment)
Voltage
5-hour rate capacity
GR35
(55D23L equipment)
GR24R
(80D26L equipment)
V
12
+
Ah
48
55
Specific gravity of battery
fluid in use (at 20°C (68OF))
Cold cranking current
Battery weight
1.280
A
kg (Ib)
=k
0.010
t
500
650
16.2 ( 3 5 . 7 )
19.0 (41.9)
INSPECTION
1.
lnspect the battery fluid level.
( 1) lnspect if the battery fluid level is in the range of M A X
* MIN. If insufficient, add distilled water to the M A X
level.
2.
lnspect the specific gravity of the battery fluid.
( 1) Use a hydrometer and measure the specific gravity of
the battery fluid.
Standard: 1 . 2 8 0 (at 20°C (68OF))
Calculating equation
0.0007 (t-20)
S 2 0 = St
S20: Specific gravity converted t o 20°C (68OF)
St: Measured specific gravity at t ° C
t: Fluid temperature at the time of measurement
+
3.
lnspect the battery terminals.
(1) If battery terminals are contaminated t o white, clean
then and apply a thin coat of M P grease on terminals.
4.
Install the battery terminals and the harness connecting portion for loosening.
(1) Retighten the battery terminals and the harness connecting portion.
Battery Removal
1.
Disconnect battery terminals.
Caution:
Disconnect the negative terminal first.
2.
Remove the battery stopper.
3.
Remove the battery.
Battery Installation
Reverse the removal procedure.
STARTING MOTOR
REMOVAL- INSTALLATION
Note:
The starting motor removing direction is either upward or downward, which varies with the vehicle
model. select the appropriate direction by grasping the situations around.
The starting motor installing position is either on the right side or left side of the vehicle, which varies
with the engine. The explanation here is given for the case of the left side. In the case of the right
side, change "battery" i n step 2 below t o "air cleaner".
1 Battery negative terminal
2 Battery
Removal Procedure
1
Disconnect the battery negative terminal.
2
Remove the battery.
3
Disconnect the starting motor wiring.
4
Remove the starting motor ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
ALTERNATOR
REMOVAL- INSTALLATION
1 Battery negative terminal
2 Air cleaner
Removal Procedure
1
Disconnect t h e battery negative terminal.
2
Remove t h e air cleaner.
3
Disconnect the alternator wiring.
4
Remove the alternator ASSY.
Installation Procedure
The installation procedure is the reverse o f the removal procedure.
Note:
Adjust the V belt tension after installation.
V Belt Tension Adjustment
1.
Inspect the V belt tension.
Standard [Deflection when pushed with a force of 98
N (10 kgf) [22 Ibfll
4Y 8
13 mm (0.31
0.51 in)
GM 8
16 mm (0.31
0.63 in)
1DZ 8
13 mm (0.31
0.51 in)
-
-
Standard [When the tension gauge (SST) is used1
SST 0921 6-00021
- 490 N (30 - 50 kgf) [66 - 110 Ibf]
- 390 N (30 - 40 kgf) 166 - 88 Ibfl
- 559 N (33 - 57 kgf) [73 - 126 Ibf]
4Y 294
GM 294
1DZ 324
Adjust the V belt tension.
4Y
Make adjustment by turning the adjust bolt.
G M -1DZ
Use a lever rod and move the alternator for adjustment.
ACCELERATOR PEDAL
COMPONENTS
ACCELERATOR PEDAL ADJUSTMENT
1.
(1
Adjust the accelerator pedal height.
Adjust accelerator link stopper bolt @ t o make pedal
height A satisfy the following dimension:
Accelerator pedal roller height
A = 133 & 2 mm (5.24 & 0.08 in)
(from accelerator bracket t o t o p o f roller)
B = 18 m m ( 0 . 7 1 in) (reference value)
2.
Adjust the height o f accelerator pedal stopper bolt @.
C = 90 m m ( 3 . 5 4 in)(reference value)
4 Y . G M engine models
( 1 ) Depress the accelerator pedal gradually, and adjust the
height of stopper bolt @ so that the carburetor throttle
lever stops immediately before the full opening
position.
1 DZ engine models
( 1 ) Adjust the height o f stopper bolt @ so that the clearance between the injection pump lever and maximum
speed adjusting screw satisfies the following range
w h e n the accelerator pedal is in contact w i t h stopper
bolt @.
0 m m (0 in) clearance here means that the accelerator pedal comes into contact w i t h the stopper bolt at
the same time w i t h establishment of the contact bet w e e n the lever and adjusting screw.
TORQUE CONVERTER
Page
GENERAL .............................................................2-2
........................ 2-6
SPECIFICATIONS ................................................ 2-8
TROUBLESHOOTING ........................................... 2-9
COMPONENTS .................................................... 2-15
HYDRAULIC CIRCUIT DIAGRAM
TRANSMISSION COVER &
CONTROL VALVE ASSY (1 SPEED) ................ 2-24
REMOVAL. INSTALLATION
.................................... 2-24
DISASSEMBLY . INSPECTION . REASSEMBLY ............. 2-25
TORQUE CONVERTER OIL PUMP (I SPEED) ..... 2-29
m
.................................... 2-29
TRANSMISSION (1 SPEED) ................................ 2-32
DISASSEMBLY . INSPECTION . REASSEMBLY ............. 2-32
REMOVAL.INSTALLATION
CLUTCH SHAFT DISASSEMBLY.INSPECTION*
REASSEMBLY ................................................... 2-39
TRANSMISSION COVER &
CONTROL VALVE ASSY (2 SPEEDS)
REMOVAL. INSTALLATION
.............. 2-43
.................................... 2-43
DISASSEMBLY . INSPECTION.REASSEMBLY
............. 2-44
TORQUE CONVERTER.OIL PUMP (2 SPEEDS) .. 2-48
REMOVAL. INSTALLATION
.................................... 2-48
TRANSMISSION (2 SPEEDS) .............................. 2-51
DISASSEMBLY . INSPECTION . REASSEMBLY ............. 2-51
CLUTCH SHAFT DISASSEMBLY-INSPECTIONREASSEMBLY ............................................... 2-59
SHIFT LEVER ....................................................... 2-65
..................................................... 2-65
INCHING ADJUSTMENT ..................................... 2-66
MEASUREMENTmTEST........................................ 2-67
ADJUSTMENT
GENERAL
1 Speed Torque Converter (STDI
2 Speeds Torque Converter (OPT)
Control Valve (For 1 Speed)
Regulator valve (D-D)
-2=J--
Inching valve
(C-C)
Selector valve (B-B)
-
Modulator valve ( A -A )
Control Valve (For 2 Speeds)
(for l u b r ~ c a t ~ o n )
M o d u l a t o r valve
HYDRAULIC CIRCUIT DIAGRAM
For 1 Speed
For 2 Speeds
2-8
SPECIFICATIONS
2 speeds torque
converter (OPT)
1 speed torque converter (STD)
Item
AlSlN SElKl
Manufacturer
4-
Torque converter type
3-element, single-stage,
two-phase type
+-
Torque converter name
AlSlN
@
4Y.GM. 1 DZ:
Stall torque ratio
t
4Y.GM: 2 1 0 0
1DZ: 2 1 5 0
rPm
Stall speed
2.68
39
-
6 5 7 ( 0 . 4 - 6.7)
[5.7
951
-
4 Y G M : 2100
1DZ: 2 1 5 0
39
-
-
490 (0.4
5.0)
[5.7
7.11
-
Module control pressure
kPa (kgfIcm2) [psi]
Clutch operating pressure
(main pressure)
kPa (kgf/cm2) [psi]
9 8 1 (10.0) [ I 4 2 1
+-
Torque converter outlet
pressure
kPa (kgfIcm2) [psi]
2 9 4 (3.0) 1431
3 9 2 (4.0) [571
1 1.5 (3.0)
1 4 (3.7)
Auto fluid
t
Torque converter oil capacity
C (US gal)
Torque converter oil
(Note)
The hydraulic pressure is indicated by the value at an engine speed of 2000 rprn.
Gear ratio
2 speeds torque
converter
1 speed torque converter
1 t o n series
2 t o n series
3 t o n series
2.3 t o n series
4Y. 1DZ
4 Y G M 1 DZ
4Y.GM. 1 DZ
4Y.GM. 1 DZ
Forward 1st
speed
1.030
1.21 7
1.363
1.474
Forward 2nd
speed
-
-
-
1.040
1.028
1,214
1.359
1.214
Reverse
TROUBLESHOOTING
Fault status
Inspection method
1. The vehicle
does not move
at all or moves
very slowly
(Failure of power
transmission by
clutch)
1.1 Inspect the main pressure.
Check both in the case of shifting t o
forward or reverse and at the neutral
state.
Standard: (See the measurement-test
section.)
Oil level check
gage.
I.I
.a The oil pressure in the neutral state
is lower than the standard.
Regulator valve sticking
Check foreign
matter trapping, etc., and wash the regulator valve.
Break d o w n or fatigue of regulator valve
spring + Replacement
Oil pump malfunction
@ Oil pump defect
Replacement
@ Damage of extension sleeve -+
Replacement
Defect in suction line
@ Clogged oil strainer -+ Replacement
@ Air suction
Check the O-ring or
gasket at each joint.
Clogging of oil leakage in the oil path between the pump and control valve
Oil
Check the O-ring
path inspection
andlor replace the gasket.
Judgment-estimated cause-action
+
Check by the level
-+
+
+
+
-+
1.1 .b Abnormally high hydraulic pressure
Clogged orifice or sticking of regulator
Valve inspection and washing
valve
+
1.1 .c The hydraulic pressures (clutch pressures) for both forward traveling and
reverse traveling are both below the
standard. (Normal in neutral state)
Sticking of inching valve spool -+ Check
foreign matter trapping, etc. and wash.
lnching lever sliding motion defect
Repair or replace.
lnching rod return defect
lnspect
and/or replace the rod link.
Modulator valve sticking -+ Check
foreign matter trapping, etc. and wash.
Clogged orifice valve
Washing
+
+
-+
1.1 .d The hydraulic pressure ( c l u t c h
pressure) is lower than the standard
for either f o r w a r d traveling or
reverse traveling.
-
See item 1.2 below.
-
1 . 2 lnspect the clutch pressure.
Standard: (See the measurement-test
section.)
The clutch pressure is slightly lower than
the main pressure.
1.2.a. The main pressure is normal, but the
clutch pressure (for both forward
traveling and reverse traveling) does
not rise at all or IS abnormally low.
The inching spool is sticking t o close the
oil path.
Check foreign matter trapping, etc. and wash.
+
Fault status
Inspection method
1.2.b The clutch pressure in either forward
traveling or reverse traveling is lower than the standard.
Judgment-estimated cause-action
Oil leak in anywhere between the selector valve and main shaft + Oil path inspection + Repair or replacement
Worn or broken seal ring (main shaft collar) -+ Replacement ( 2 speeds)
Fallen plug from main shaft oil path
Repair or replacement
Damage at clutch piston, broken piston
ring, piston freeing, etc. -+ Overhaul the
clutch
-+
2. Insufficient
gradeability or
tractive force (insufficient power)
(due t o torque
converter failure
in torque
generation)
1.3 Both the main pressure and clutch
pressure are normal.
Clogging in the oil path between the
selector valve and clutch piston (oil path
in the forward side if forward traveling
fails) + Oil path inspection and clogged
material removal
Clutch piston sticking
1.3.a Mechanical trouble in other part of
the transmission (Excessive oil temperature rise involving abnormal
noise generation is likely t o occur in
this case.)
Overhaul the torque converter
2.1 Inspect the oil level.
Check the level gage.
2.2 lnspect the engine no-load maximum
rpm and loaded maximum rpm.
(See the measurement-test section.)
Tune up the engine if either speed does
not satisfy the standard.
(See the engine tune-up section.)
2 . 3 lnspect the main pressure and clutch
pressure.
(See the measurement-test section.)
If the main pressure or clutch pressure
is abnormal, inspect according t o 1.1 and
1.2 above.
2.4 Inspect the stall speed.
Carry out a stall test, and measure the
engine speed at the time.
(Note) Always check the engine output
(loaded maximum rpm), main pressure
and clutch pressure t o confirm that the
engine and clutch systems are normal
before inspecting the stall speed.
(See the measurement-test section.)
(Note) the stall speed may be about 1 0 0
rpm above or below the standard above
depending on slight performance dispersions of the engine and torque converter as well as delicate matching between
them.
Therefore, use the standard as a
guideline for defect judgment.
Inspect t h e stall speed and judge
whether the defect exists on the converter side or clutch side.
a. The stall speed is too low ( 3 0 0 rpm or
more below the standard).
The oneway clutch of the stator is slipping.
Replace the converter ASSY.
b. The stall speed is too high. + The
clutch is slipping tremendously. + Inspect and replace the clutch parts.
+
+
Fault status
Inspection method
3. The vehicle does
not travel in either
t h e f o r w a r d or
reverse direction.
3.1. Set the shift lever neutral and inspect
in which direction the vehicle travels.
When the vehicle travels -t Clutch
seizure + Disassemble and replace the
clutch.
When the vehicle does not travel
See
3 . 2 below.
+
3.2
4. Excessive time lag
at starting
Judgment-estimated cause-action
lnspect the clutch pressure on the
faulty side.
(See the measurement-test section.)
When the clutch pressure is normal 4
Clutch slipping or clutch piston sliding
Disassemble and
motion defect
replace the clutch.
When the clutch pressure is abnormal +
See 3.3 below.
+
3 . 3 Inspect the selector valve.
Selector valve defect 4 Disassemble
and replace.
When the selector valve is normal 4 See
3 . 4 below.
3 . 4 Inspect the main shaft seal ring.
Seal ring defect 4 Replace.
When the seal ring is normal 4 Disassemble the clutch as the clutch system
is defective.
4.1 Depress the accelerator pedal simultaneously w i t h shifting t o judge starting delay.
(It is desirable t o compare w i t h a normal vehicle if any.)
-
4.2 lnspect the main pressure and clutch
pressure.
lnspect t h e clutch pressure rise
characteristic at the same time.
(See the measurement-test section.)
When the main pressure and/or clutch
pressure is abnormal -+ Inspect according t o 1.1 and 1.2 above.
4.2.a When the clutch pressure rise is abnormal (too slow).
Breakdown or fatigue of the modulator
valve spring + Disassembly, inspection
and replacement
Clogged orifice valve + Disassembly, inspection and washing
Clogged orifice of regulator valve
Disassembly, inspection and washing
lnching spool return defect
Foreign
matter trapping or breakdown or fatigue
of spring 4 Disassembly, washing or
replacement
lnching lever sliding motion defect 4
Correct or replace the lever.
lnching rod return defect 4 lnspect and
replace the rod link.
+
+
4 . 3 Inspect the oil.
Insufficient oil level, clogged oil strainer
or air suction -r Oil addition, disassembly and washing
Fault status
5. Inching defect or
Inspection method
5.1 Inspect inching operation.
jerking
(shock
ge_neration)
Judgment-estimated cause-action
Inching rod return defect
Inspect and
replace the rod link and return spring.
Inching lever sliding motion defect
Greasing or replacement
lnching spool return defect
Foreign
matter trapping, breakdown or fatigue of
spring
Disassembly, washing and
replacement
+
+
+
+
5.2 lnspect the main pressure and clutch
pressure.
Operate the inching pedal and inspect
the clutch pressure variation.
(See the measurement-test section.)
5.2.a When t h e clutch pressure rise
characteristic is abnormal
lnching spool sticking -+ Check foreign
matter trapping, etc. and wash.
lnching lever sliding motion defect
Greasing or replacement
lnching rod return defect -+ Rod link and
return spring inspection and replacement
Clogged orifice valve
Washing
+
+
5.2.b When the clutch pressure rise
characteristic is normal (Inspect the
clutch pack.)
Breakdown or fatigue of clutch return
spring
Disassembly and replacement
Clutch piston motion detect
Disassembly, inspection and replacement
Clutch plate abnormal wear
Disassembly and replacement
-+
+
-+
5.3 After shifting the shift lever, release
the inching pedal suddenly t o inspect
the shock at starting.
Fatigue of camber plate
Disassembly,
inspection and replacement
+
6. Clutch connecting 6.1 lnspect the oil pressure (clutch prespoint is either too
high or t o o low.
sure) at the time of inching.
6.1.a When the inching pressure is too
high
6.I .b When the inching pressure is too low
Breakdown or fatigue of spring for inching spool No. 1 (inching rod side) -+
Replacement
Breakdown or fatigue of inching spool
Replacement
No.2
+
7. Overheat
7.1 Inspect the torque converter oil level
and oil quality.
Inappropriate oil level
Check excessive
or insufficient oil level and correct it t o
the proper level.
Air suction
lnspect the O-ring at each
joint.
Moisture content in oil
Oil replacement
+
+
-+
7.2 lnspect the main pressure, clutch pressure and torque converter pressure
(outlet pressure).
(See the measurement-test section.)
Fault status
Inspection method
Judgment-estimated cause-action
7.2.a When the main pressure or clutch
pressure is lower than the standard
lnspect according t o 1 . 1 and 1 . 2 above.
7.2.b When the torque converter pressure
is lower than the standard
Regulator valve sticking -t Disassembly,
inspection and washing
Excessive resistance of internal oil path
Oil path clogging inspection
Clogged oil strainer
Disassembly,
washing and replacement
-+
-+
7 . 3 lnspect the clutch portion. Set t o the
neutral position and check if the vehicle travels or not.
7.3.a When the vehicle travels in either the
forward or reverse direction
Clutch seizure or damage at clutch pack
Disassembly, i n s p e c t i o n and
replacement
7.4 lnspect the torque converter portion.
Defect in converter portion
Stator sticking
Converter ASSY
replacement
Impeller contact
Judge by checking
the oil filter and replace the converter
ASSY if defective.
Decreased circulating f l o w rate
Clogged stator shaft orifice, etc.
Disassembly, inspection and replacement
+
+
*
-+
-+
+
7.5 Inspect the transmission portion.
Defect in transmission
Clutch dragging Disassembly, inspection and replacement
Bearing wear or seizure
Disassembly,
inspection and replacement
+
+
8 . Abnormal noise is
generated.
7 . 6 Check the use status at the user.
Check the operation status b y the
operator, use status and operating
place.
Check no push-up, etc. especially by performing inching operation.
Check if excessive switch-back is performed.
8 . 1 lnspect the torque converter portion.
Damaged drive plate -t Replacement
Damaged bearing
Replacement
Contact of impeller (fragment inspection
Converter replacement
at oil filter)
Loosened bolt -+ Retightening
Damaged gear pump --+ lnspection and
replacement
+
+
8 . 2 Inspect the transmission portion.
Dragging noise due t o clutch seizure -+
lnspection and replacement
Wear or damage at bearing
lnspection
and replacement
Gear damage
Replacement
Spline wear
Replacement
+
+
-+
Fault status
9. Oil leak
Inspection method
Judgment-estimated cause-action
9.1 Inspect oil seals.
Inspect each seal lip and t h e mating side
sliding contact face for damage or wear,
and replace if defective.
9.2 Inspect t h e case joint.
Bolt retightening, or replacement o f Oring or packing
9.3 Inspect for flowhole or crack.
Repair or replacement
9.4 If oil is leaking f r o m t h e air breather
Overheat
Excessive oil
COMPONENTS
Torque Converter Housing
For 1 speed
For 2 speeds
2-1 6
Torque Converter
For 1 speed
For 2 speeds
Torque Converter Clutch
For 1 speed
3203
For 2 speeds (for forward)
3203
Torque Converter Gear
For 1 speed
Refer to
FIG.3203
I
----
Control Valve
For 1 speed
10
101K = (INCL.
*)I
For 2 speeds
3206
Torque Converter Piping
3213
&9161 1-40814
Shift Lever
321 5
2-24
TRANSMISSION COVER & CONTROL VALVE ASSY ( 1 SPEED)
REMOVAL. INSTALLATION
Removal Procedure
1
Remove the toe board.
2
Disconnect the inching wire.
3
Disconnect the shift rod.
4
Disconnect electrical wiring.
5
Disconnect the torque converter cooler hose.
6
Remove the transmission cover & control valve ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
T
=
N . m (kgf-cm) [ft-Ibf]
DISASSEMBLY- INSPECTION REASSEMBLY
m
T = N.m (kgf-cm) [ft-lbf]
Bolt size : M6
T = 5.30
9.41
96)
(54
--
Bolt size : M8
T = 14.91
22.36
(152
228)
16.501
111.00
---
-6
-
Disassembly Procedure
1
Remove the neutral switch and backup lamp s w i t c h (OPT). [Point 11
2
Remove the inching lever.
3
Remove the inching cam lever
4
Remove the shift lever. [Point 21
5
Remove the shift cam lever.
6
Remove the valve body plate cover. [Point 31
7
Remove the valve body plate. [Point 41
8
Remove the regulator valve.
9
Remove the inching valve. [Point 51
1 0 Remove the detent spring and steel ball.
1 1 Remove the selector valve.
1 2 Remove the orifice valve and modulator valve. [Point 61
1 3 Remove the oil seal. [Point 71
Reassembly Procedure
The reassembly procedure is the reverse o f the disassembly procedure.
Note:
When installing the inching cam lever and shift cam lever, apply a thin coat MP grease on the inside
of the upper cover and oil seal.
Coat torque converter oil on each valve before reassembly.
Point Operations
[Point 1I
Inspection:
I
Inspect
Neutral
Normal
Backup
Normal
the switches.
switch:
if turned OFF w h e n depressed.
lamp switch:
if turned ON when depressed.
[Point 21
Inspection:
Check the shift lever operating force. Set a
spring scale at the tip end of the shift lever t o
measure the operating force. The operating
force cannot be adjusted.
Shift lever operating force (Reference):
34.3 53.9 N (3.5 5.5kgf) [7.7 12.1
Ibfl
-
-
-
[Point 31
Disassembly:
Reassembly:
Carefully operate so as n o t t o lose the steel
ball as it will be ejected b y the spring force
when the valve body plate cover is removed.
Install the steel ball in the correct position.
[Point 41
Reassembly:
Install the steel ball in the correct position.
[Point 51
Disassembly:
Reassembly:
Use the service bolt t o extract the plug.
Service bolt size: M8 x 1.25
Coat grease on the O-ring o f plug before installation.
[Point 61
Disassembly:
Use the service bolt t o extract the plug.
Service bolt size: M8 x 1.25
Reassembly:
Coat grease on the O-ring o f plug before installation.
Inspection:
Inspect the orifice valve.
Push the center o f the valve a f e w times lightly w i t h a finger t o confirm smooth movement
without sticking.
Inspection:
Measure the free length of each spring.
Unit:
Ive compression
[Point 71
Reassembly:
SST 09620-3001 0
mm (in)
TORQUE CONVERTER-OIL PUMP (1 SPEED)
REMOVAL. INSTALLATION
Torque converter oil
Engine Wltorque converter
Torque converter housing ASSY
T = N.m (kgf-cm) [ft-lbf]
4
Removal Procedure
1
Drain torque converter oil.
2
Remove the engine Wltorque converter. (See page 1-8 in the engine section.)
3
Disconnect the engine and torque converter housing ASSY. (See steps 1 t o 4 of the removal proce'dure on page 1-1 1 in the engine section.)
4
Remove the torque converter ASSY. [Point 1I
5
Remove the oil pump Wlstator shaft. [Point 21
6
Remove the stator shaft.
7
Remove the oil pump gear. [Point 31
8
Remove the oil seal. [Point 41
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
18.63 Nsm (10 0
1 9 0 kgf-cm) [7.24
Oil pump set bolt tightening torque: T = 9.81
ft-lbfl
15.69 N - m(100 1 6 0 kgf-cm) i 7 . 2 4
Stator shaft set bolt tightening torque: T = 9.81
ft-lbfl
See the note for the engine installation procedure. (See page 1 -9 and 1-1 2.1
-
-
- 13.75
- 11.58
Point Operations
[Point 11
Removal:
Be careful as oil exists in the torque converter
ASSY.
The torque converter ASSY cannot be disassembled.
Installation:
Coat grease on the seal ring and oil seal lip before installation.
Installation:
Install the torque converter ASSY w i t h rotation
so that the extension pawl fits into the oil pump
drive gear groove.
[Point 21
Removal:
SST 09950-40010
[Point 31
Inspection:
Measure the clearance between the oil pump
driven gear and pump body.
Limit clearance:
Inspection:
Measure the clearance between oil pump
driven gear and crescent.
Limit clearance:
Inspection:
0 . 3 mm ( 0 . 0 12 in)
0 . 4 mm (0.01 6 in)
Measure the clearance between the oil pump
drive gear and crescent.
Limit clearance: 0 . 4 mm ( 0 . 0 1 6 in)
Inspection:
Measure the clearance between the pump body
and each gear.
Limit clearance:
Inspection:
0 . 1 m m ( 0 . 0 0 4 in)
Measure t h e clearance between the oil pump
driven gear bushing and stator shaft.
Limit clearance:
0 . 1 5 m m ( 0 . 0 0 5 9 in)
[Point 41
Installation:
SST 09608-3501 4
TRANSMISSION ( 1 SPEED)
DISASSEMBLY. INSPECTION-REASSEMBLY
Note:
The explanation here covers the jobs for disassembly from torque converter housing ASSY. For disassembly of the oil pump, however, see page 2-29 (torque converter-oil pump section). See page 2-39
for disassembly of the clutch shaft parts.
(Engine Wltorque converter removal-installation: page 1-81
(Engine and torque converter disconnection: See steps 1 to 4 in the removal procedure on page 1-11 .)
Torque
1
Drain torque converter oil
2
Remove the transmission cover & control valve ASSY.
3
Remove the torque converter ASSY. [Point 1 I
4
Remove the oil pump Wlstator shaft. [Point 21
5
Remove the front cover
6
Remove the counter gear No. 1.
7
Remove the counter gear bearing. [Point 31
8
Remove the idle shaft. [Point 41
9
Remove the clutch shaft No. 1 W/clutch drum No. 1. [Point 51
1 0 Remove the idle gear No. 1 Wlbearing.
1 1 Remove the idle gear No. 1 bearing. [Point 61
1 2 Remove the oil pan.
1 3 Remove the output shaft No. 1 and output gear No. 2 [Point 71
1 4 Remove the output shaft bearing No. 1. [Point 81
1 5 Remove the oil strainer.
1 6 Remove the bearing No. 1 (for clutch shaft No. 1). [Point 91
1 7 Remove the output shaft bearing No. 2. [Point 101
1 8 Remove the oil filter. [Point 111
1 9 Remove the magnet. [Point 121
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
The tightening torque for each part is as follows:
Unit:
N . m (kgf-cm) [ft-lbfl
9.81
-
15.69 (100
Oil pump set bolt
- 1601 [7.24 - 11.581
5.88 - 7.85 (60 - 80) [4.34 - 5.791
4.90 - 9.81 (50 - 100) [3.62 - 7.241
3.92 - 6.86 (40 - 70) L2.89 - 5.061
18.63 - 30.40 ( 1 90 - 310) [ I 3.75 - 22.431
9.81 - 15.69 (100 - 160) L7.24 - 11.581
9.81 - 15.69 (100 - 160) [7.24 - 11.581
9.81 - 18.63 (100 - 190) [7.24 - 13.751
Transmission output cover set bolt
18.63
-
30.40 (190
Oil strainer set bolt
Oil pan set bolt
ldle shaft
ldle shaft set bolt
Front cover set bolt
Transmission cover (upper cover) set bolt
Stator shaft set bolt
-
310) [13.75 - 22.431
Point Operations
[Point 1 I
Disassembly:
Be careful as oil exists in the torque converter ASSY.
The torque converter ASSY cannot be disassembled.
Reassembly:
Coat grease on the seal ring and oil seal lip before installation.
Reassembly:
Rotate the torque converter ASSY t o make the
extension pawl fit into the oil pump drive gear
groove.
[Point 21
Disassembly:
SST 0 9 9 5 0 -4 0 0 1 0
[Point 31
Disassembly:
SST 09950-4001 0
[Point 41
Disassembly:
After removing the set bolt and lock plate, rotate the idle shaft counterclockwise for
removal.
Reassembly:
Clean the idle shaft threaded portion, and
check if it can be screwed in lightly without
the idle gear.
Reassembly:
Tighten the idle shaft t o the specified torque.
-
T = 4.90
9.81 N - m
(50
100 kgf-cm) [3.62
-
-
7 . 2 4 ft-lbfl
Tigten the set bolt after locking with the lock
plate.
[Point 51
Shim
Disassembly:
Extract clutch shaft No. 1 Wlclutch drum
No. 1 t o the converter side.
Reassembly:
Coat grease on the seal ring and install it at
the end of the clutch shaft.
Reassembly:
Adjust the thrust clearance o f clutch shaft
No. 1.
1.
Install the shim o n the stator shaft and temporarily install the oil pump Wlstator shaft.
2.
Set a dial gage on the front end o f t h e clutch shaft, and
measure the thrust clearance b y moving the clutch drum
t o and fro.
Standard clearance:
3.
-
0.20
0.62 mm
0 . 0 2 4 in)
(0.0079
-
If the measured value is not within the standard range,
select and change the shim thickness at the stator shaft.
Shim thickness:
[Point 61
Disassembly:
Reassembly:
0 . 7 1 , 0 . 9 , 1 . 1 2 and 1 . 4 m m
( 0 . 0 2 8 0 , 0 . 0 3 5 , 0 . 0 4 4 1 and
0 . 0 5 5 in)
SST 0 9 3 0 8 - 0 0 0 1 0
SST 0 9 6 2 0 - 3 0 0 1 0
[Point 71
Disassembly:
Use the service bolt for removal.
Service bolt size M 1 0 x 1 . 2 5
Reassembly:
Adjust the thrust clearances related t o the output shaft.
1.
Place a spacer and shim(s) on the output gear No. 2, and
temporarily install the output cover Wloutput shaft.
2.
Tap the output shaft w i t h a hammer t o eliminate the
thrust clearance of the gear, spacer and shim.
3.
Set a dial gage on the upper face of the output shaft,
and pry upward w i t h a screwdriver t o measure the
movement (thrust clearance).
Standard clearance:
4.
-
0.03
0.51 mm (0.0012
0.0201 in)
-
If the measured value does n o t satisfy the standard,
select the shims t o be used.
Shim thickness:
0.9, 1.25 and 1.6 mm (0.035,
0 . 0 4 9 2 and 0 . 0 6 3 in)
[Point 81
Disassembly:
After removing the snap ring w i t h the SST,
remove the shaft b y tapping its end w i t h a
plastic hammer.
SST 0 9 9 0 5 - 0 0 0 1 2
Disassembly:
Remove the bearing from the output cover.
SST 0 9 6 2 0 - 3 0 0 1 0
Reassembly:
Install the bearing in the output cover
SST 09608-3501 4
Reassembly:
Install the oil seal flush with the output cover
so as not t o damage its lip.
SST 09150-10170-71
After installation, coat grease on the oil seal
lip.
[Point 91
Disassembly:
Reassembly:
SST 09308-00010
SST 09370-1041 0-71
[Point 101
Disassembly:
SST 09308-00010
Reassembly:
SST 09608-3501 4
[Point 1 1 I
Disassembly Reassembly:
SST 09228-07500
[Point 121
Magnet
1
f
Reassembly:
0
0
i
0
I
Oil pan
J
Remove the metalic burrs and powders stuck
t o the magnets. Then place the magnet pieces
as shown.
2-39
CLUTCH SHAFT DISASSEMBLY.INSPECTION-REASSEMBLY
,
1
Seal rlng (for clutch shaft)
3
Disassembly Procedure
1
Remove the seal ring (for clutch shaft).
2
Remove the bearing and spacer.
3
Remove the clutch gear (reverse). [Point 11
4
Remove the spacer.
5
Remove the clutch gear (forward). [Point 11
6
Remove the clutch shaft No. 1 . [Point 21
7
Remove the snap ring.
8
Remove the backing plate, clutch disc, clutch plate and camber plate. [Point 31
9
Remove the clutch return spring. [Point 41
10 Remove the clutch piston. [Point 51
11
Remove the seal ring (for clutch drum).
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Coat grease o n the seal ring before reassembly.
After washing each part, coat torque converter oil sufficiently before reassembly.
Bearing pressing side
Point Operations
[Point 1 I
Disassembly:
The clutch gear bearing cannot be removed.
Always replace the bearing with the clutch
gear as a set.
Reassembly:
-,
Reassembly:
When pressing the bearing into the gear,
slowly push it w i t h a press and make sure
that the snap ring at the center of the bearing fits securaly into the gear groove.
Before installing the clutch gear on the clutch
drum, align disc serrations with a screwdriver,
etc.
[Point 21
Inspection:
Measure the clearance between each clutch
shaft and seal ring.
Limit clearance:
0.2m m (0.008in)
[Point 31
Inspection:
Measure the clutch disc thickness.
Standard thickness:
Limit thickness:
2.6m m (0.102in)
2.3 m m (0.091in)
Inspection:
Measure the clutch plate thickness.
Standard thickness:
Limit thickness:
Inspection:
2 . 0 mm ( 0 . 0 7 9 in)
1 . 8 mm ( 0 . 0 7 1 in)
Measure the camber plate convex height.
Standard convex height: 3 . 4 mm ( 0 . 1 3 4 in)
3 . 1 mm ( 0 . 1 2 2 in)
Limit convex height:
Clutch gear
Reassembly:
0
sidi7
dC
Install the camber plate on the clutch drum,
w i t h the A punch mark o n the upper side.
a
Piston side
Reassembly:
Install the clutch plates and clutch discs alternately o n the clutch drum while coating
torque converter oil.
Reassembly:
Adjust the clearance between the backing
plate and clutch disc.
Camber plate
1.
Install the camber plate, clutch plate, clutch disc, backing plate and snap ring on the clutch drum.
2.
Measure the clearance between the backing plate and
clutch disc w i t h a thickness gage.
Standard clearance:
1.0
- 1.6 mm (0.039 - 0.063 in)
3.
If the measured value does not satisfy the standard,
select and use an appropriate backing plate.
A = 3.0 and 3.5 m m
(0.118 a n d 0.138
in
Backing plate thickness:
[Point 41
Disassembly.Reassembly:
Inspection:
SST 0 9 2 2 0 - 2 2 0 0 0 - 7 1
Measure the free length o f the clutch return
spring.
Free length:
Limit free length:
63.4 m m (2.496 in)
58.5 m m (2.303 in)
[Point 51
Inspection:
Measure the clearance between the clutch
piston and piston ring.
Standard clearance:
Inspection:
Reassembly:
0.17 m m (0.0067 in)
Clean the check valve installed in the clutch
piston b y blowing compressed air.
Install the piston ring w i t h its side marked
w i t h white paint facing high pressure side.
TRANSMISSION COVER & CONTROL VALVE ASSY ( 2 SPEEDS)
REMOVALmINSTALLATION( 2 SPEEDS)
1
Toe board
Removal Procedure
1
Remove the toe board.
2
Disconnect the inching wire.
3
Disconnect the shift rod.
4
Disconnect electrical wiring.
5
Disconnect the torque converter cooler hose.
6
Remove the transmission cover & control valve ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
T = N . m (kgf-cm) [ft-lbf]
2-44
DISASSEMBLY.lNSPECTIONmREASSEMBLY( 2 SPEEDS)
T
=
N.m (kgf-cm) [ft-lbfl
T = 3.92- 6.56
T = 14.71-22.56)
I
-
T = 9.81 15.69
(100- 160)
I7.24- 11.581
T
(150-230)
110.85- 16.641
=
9.81 - 15.69
2-45
Disassembly Procedure
1
Remove the switches (neutral switch and backup lamp switch). [Point 11
2
Remove the inching lever.
3
Remove the shift lever. [Point 21
4
Remove the shift cam lever.
5
Remove the control valve (control Wlregulator cover ASSY).
6
Remove the steel ball. [Point 31
7
Remove the spring and steel ball. [Point 41
8
Remove the inching cam lever.
9
Remove the valve body plate cover.
1 0 Remove the valve body plate and gasket.
1 1 Remove the selector valve. [Point 51
1 2 Remove the oil seal. [Point 61
1 3 Remove the valve holder plate. (Pay attention t o spring jumping out.)
1 4 Remove the inching valve. [Point 71
1 5 Remove the valve holder plate. (Pay attention t o spring jumping out.)
1 6 Remove the regulator valve, inching rod, orifice valve and modulator valve. [Point 71
1 7 Remove the change valve. [Point 81
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
When installing the inching cam lever and shift cam lever, apply a thin coat M P grease on the inside
of the upper cover and oil seal.
Coat torque converter oil on each valve before reassembly.
Point Operations
[Point 1 I
Inspection:
Inspect
Neutral
Normal
Backup
Normal
the switches.
switch:
if turned OFF when depressed.
lamp switch:
if turned ON w h e n depressed.
[Point 21
Adjustment:
Adjust the shift lever operating force.
Set a spring scale a t the shift lever rod installation hole and measure the operating force.
Adjust the operating force t o the standard level
b y turning the adjusting bolt.
Shift lever operating force:
34.3
- 53.9 N (3.5- 5.5kgf) [7.7- 12.1
Ibfl
[Point 31
Reassembly:
Install the steel ball in the correct position.
[Point 41
Reassembly:
Reassembly:
Place the steel ball in the detent hole, coat
grease on the detent spring and paste it on
the lock ball.
Coat grease on the steel ball (safety valve) and
paste it t o stand on the safety valve contact
face of the upper cover.
[Point 51
Disassembly:
Use the service bolt t o extract the selector
valve stopper.
Service bolt size: M6 x 1.0
[Point 61
Reassembly:
Use the SST t o drive in the oil seal until it is
flush with the cover.
SST 09620-3001 0
[Point 71
Inspection:
lnspect the regulator valve, inching valve,
modulator valve and orifice valve for clogging
of the orifice.
Inspection:
lnspect the orifice valve.
Push the center of the valve a f e w times lightly w i t h a finger t o confirm smooth movement
without sticking.
Inspection:
Measure the free length of each spring.
Unit:
m m (in)
Free length
Free length limit
Regulator valve
88.8 (3.496)
85.0 (3.346)
Inching valve
34.5 (1.358)
33.0 (1.299)
lnching valve
(Compression)
49.4 (1.945)
47.0 (1.850)
Modulator valve
50.5(1.988)
48.5(1.909)
Orifice valve
50.0 (1.969)
47.5 (1.870)
Spring
[Point 81
Reassembly:
Use the SST t o drive in the spring pin until it
is flush w i t h the body.
SST 09700-30200-7 1
TORQUE CONVERTER -OIL PUMP ( 2 SPEEDS)
REMOVAL-INSTALLATION (2 SPEEDS)
1
2
3
T
=
N . m (kgf-cm) [ft-lbfl
Torque converter oil
Engine Wltorque converter
Torque converter housing ASSY
Removal Procedure
1
Drain torque converter oil.
2
Remove the engine Wltorque converter. (See page 1-8 in the engine section.)
3
Disconnect the engine and torque converter housing ASSY. (See steps 1 t o 4 of the removal procedure on page 1-1 1 in the engine section.)
4
Remove the torque converter ASSY. [Point 11
5
Remove the oil pump Wlstator shaft. [Point 21
6
Remove the stator shaft.
7
Remove the oil pump gear. [Point 31
8
Remove the oil seal. [Point 41
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Oil pump set bolt tightening torque: T = 13.73 - 30.40 N.m (140 310 kgf-cm) [10.13
ft-lbfl
15.69 N.m ( I 0 0 160 kgf-cm) [7.24
Stator shaft set bolt tightening torque: T = 9.81
ft-lbfl
See the note for the engine installation procedure. (See page 1-9 and 1-1 2.1
-
-
- 22.43
- 11.58
Point Operations
[Point 1 I
Removal:
Be careful as oil exists in the torque converter
ASSY.
The torque converter ASSY cannot be disassembled.
Installation:
Coat grease on the seal ring and oil seal lip before installation.
Installation:
Install the torque converter ASSY with rotation
so that the extension pawl fits into the oil pump
drive gear groove.
[Point 21
Removal:
SST 0 9 9 5 0 -2 0 0 1 7
[Point 31
Inspection:
Measure the clearance between the oil pump
driven gear and pump body.
Limit clearance:
Inspection:
Measure the clearance between oil pump driven
gear and crescent.
Limit clearance:
Inspection:
0.3 mm (0.Q12in)
0.4 mm (0.016 in)
Measure the clearance between the oil pump
drive gear and crescent.
Limit clearance:
0 . 4 mm (0.016 in)
Inspection:
Measure the clearance between the pump body
and each gear.
Limit clearance:
Inspection:
0.1 m m (0.004 in)
Measure the clearance between the oil pump
driven gear bushing and stator shaft.
Limit clearance:
0.1 5 m m (0.0059 in)
[Point 41
Installation:
SST 09608-3501 4
TRANSMISSION ( 2 SPEEDS)
DISASSEMBLY- INSPECTION. REASSEMBLY ( 2 SPEEDS)
Note:
The explanation here covers the jobs for disassembly from torque convertre housing ASSY. For disassembly of the oil pump, however, see page 2-29 (torque converter-oil pump section). See page 2-59
for disassembly of the clutch shaft parts.
(Engine Wltorque converter removal-installation: page 1-8)
(Engine and torque converter disconnection: See steps 1 to 4 in the removal procedure on page 1-1 1 .)
T = N.m (kgf-cm) [ft-lbfl
I
1
Torque converter
011
Disassembly Procedure
1
Drain torque converter oil.
2
Remove the transmission cover & control valve ASSY.
3
Remove the torque converter ASSY. [Point 1I
4
Remove the oil pump Wtstator shaft. [Point 21
5
Remove the front cover. [Point 31
6
Remove the side cover.
7
Remove idle gear No. 2. [Point 41
8
Remove idle gear No. 2 bearing. [Point 51
9
Remove clutch shaft No. 2 Wlclutch drum No. 2 (forward). [Point 81
1 0 Remove idle gear No. 1 and idle shaft. [Point 71
11 Remove idle gear No. 1 bearing. [Point 81
12
Remove clutch shaft No. '1 Wlclutch drum No. 1 (reverse). [Point 91
13 Remove the oil strainer
1 4 Remove output shaft No. 1 and output gear No. 2. [Point 101
15 Remove output shaft bearing No. 1. [Point 111
1 6 Remove bearing No. 1 (for clutch shaft No. 1). [Point 121
17 Remove bearing No. 2 (for clutch shaft No. 2). [Point 131
1 8 Remove output shaft bearing No. 2. [Point 141
19 Remove the oil filter. (Use the SST 09228-07500.)
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
The tightening torque for each part is as follows:
Unit:
Oil strainer set bolt
Oil pan set bolt
ldle shaft
ldle shaft set bolt
Front cover set bolt
Side cover set bolt
N.m (kgf-cm) [ft-lbfl
- 15.69 (100 - 160) [7.24 - 11.581
5.88 - 7.85 (60 - 80) 14.34 - 5.791
4.90 - 9.81 (50 - 100) [3.62 - 7.241
3.92 - 6.86 (40 - 70) 12.89 - 5.061
18.63 - 30.40 (190 - 310) [13.75 - 22.431
9.81
3.92
Transmission cover (upper cover) set bolt
9.81
Stator shaft set bolt
9.81
-
-
6.86 (40 - 70) f2.89 - 5.061
15.69 (100
-
160) [7.24
- 11.581
15.69 (100 - 160) [7.24 - 11.581
2-53
Point Operations
[Point 1I
Disassembly:
Becareful as oil exists in the torque converter ASSY.
The torque converter ASSY cannot be
disassembled.
Reassembly:
Coat grease on the seal ring and oil seal lip before installation.
Reassembly:
Rotate the torque converter ASSY to make the
extension pawl fit into the oil pump drive gear
groove.
[Point 21
Disassembly:
SST 0 9 9 5 0 -2 0 0 1 7
(or SST 0 9 9 5 0 -4 0 0 1 0)
[Point 31
Disassembly:
Use the service bolt for removal.
Service bolt size: M 1 0 x 1.25
[Point 41
Disassembly:
Extract the idle shaft b y inserting a
screwdriver or the like in the lock plate
groove.
Reassembly:
Adjust the thrust clearance of idle gear No. 2.
1.
Push the idle gear t o one side and measure the clearance between the bearing and spacer.
Standard clearance:
0.04
0.6 mm (0.0016
-
2.
-
0.024 in9
If the measured value does not satisfy the standard,
replace the spacer switch new ones.
Install spaces on both sides of the idle gear.
2-54
[Point 51
Disassembly:
Reassembly:
SST 0 9 3 0 8 - 0 0 0 1 0
SST 0 9 6 2 0 - 3 0 0 1 0
[Point 61
Disassembly:
Use a copper rod and tap the end of the shaft
from the rear side t o drive the shaft out t o
the front side. Hold the clutch drum during
this operation.
Disasembly:
After removing the clutch shaft Wlclutch
drum, remove output gear No. 1 remaining
i n the case.
Reassembly:
Coat grease on the seal ring and install it at
the end o f the clutch shaft.
Reassembly:
Adjust the thrust clearance o f clutch shaft
No. 2 (forward).
1.
After installing clutch shaft No. 2 Wlclutch drum No. 2
in the case, install shims on the shaft and temporarily
install the front cover.
2.
Set a dial gage on the side of the clutch gear, and measure the thrust clearance b y moving the clutch drum back
and forth.
Standard clearance:
3.
0.05 - 0.55 m m (0.0020 0.0217 in)
If the measured value does not satisfy the standard,
select the shims t o be used at the tip end of the shaft.
Shim thickness:
0.5.0.9and 1.25m m (0.020,0.035
and 0.0492 in)
[Point 71
Disassembly:
After removing the set bolt and lock plate, rotate the idle shaft counterclockwise for
removal.
Reassembly:
Clean the idle shaft threaded portion, and
check if it can be screwed in lightly without
the idle gear.
nbly:
Install the bearing inner race on the idle gear
and tape the bearing so as not t o let it fall. After inserting the idle gear into the case, remove the tape and insert the idle shaft.
Tighten the idle shaft t o the specified torque.
-
T = 4.90
9.81 N . m
(50
100 kgf-cm) [3.62
-
- 7.24 ft-lbfl
Tighten the set bolt after locking with the lock
plate.
[Point 81
Disassembly:
Reassembly:
SST 09308-0001 0
SST 09620-3001 0
[Point 91
Disassembly:
Extract clutch shaft No. 1 Wlclutch drum
No. 1 t o the converter side.
Reassembly:
Coat grease on the seal ring and install it at
the end of the clutch shaft.
Reassembly:
Adjust the thrust clearance of clutch shaft
No. 1 (reverse).
I.
Install the shim on the stator shaft and temporarily install the oil pump Wistator shaft.
2.
Set a dial gage on the front end o f the clutch shaft, and
measure the thrust clearance b y moving the clutch drum
t o and fro.
Standard clearance:
3.
-
0 . 15
0.75 mm
0.0296 in)
(0.0059
-
If the measured value is not within the standard range,
select and change the shim thickness at the stator shaft.
Shim thickness:
0.71, 0 . 9 , 1.12 and 1.4 mm
(0.0280, 0.035, 0.0441 and
0.055 in)
[Point 101
Disassembly:
After removing the output cover set bolts,
use the SST for removal.
SST 098 10-201 72-7 1
Reassembly:
Adjust the thrust clearances related t o the outp u t shaft.
1.
Place a spacer and shim(s) on the output gear No. 2, and
temporarily install the output cover Wloutput shaft.
2.
Tap the output shaft w i t h a hammer t o eliminate the
thrust clearance of the gear, spacer and shim.
3.
Set a dial gage on the upper face of the output shaft,
and pry upward with a screwdriver t o measure the movement (thrust clearance).
Standard clearance:
4.
-
0.03
0.51 mm (0.0012
0.0201 in)
-
If the measured value does n o t satisfy the standard,
select the shims t o be used.
Shim thickness:
0 . 9 , 1.25 and 1.6 mm (0.035,
0 . 0 4 9 2 and 0 . 0 6 3 in)
Disassembly:
After removing the snap ring with the SST,
remove the shaft by tapping its end with a
plastic hammer.
SST 09905-0001 2
Disassembly:
Remove the bearing from the output cover.
SST 09620-3001 0
I
a
I
IL
Reassembly:
lnstall the bearing in the output cover.
SST 09608-3501 4
Reassembly:
Install the oil seal flush with the output cover
so as not to damage its lip.
SST 091 50-1 01 70-71
After installation, coat grease on the oil seal
lip.
[Point 121
Disassembly:
SST 09308-00010
Reassembly:
SST 09370- 104 10-7 1
[Point 131
Disassembly:
Reassembly:
SST 09308-0001 0
SST 09370- 1041 0-7 1
SST
[Point 141
Disassembly:
Reassembly:
SST 09308-0001 0
SST 09608-3501 4
CLUTCH SHAFT DISASSEMBLY. INSPECTION- REASSEMBLY ( 2 SPEED)
1 Clutch shaft No. 1 (reverse)
Clutch shaft No. 2 (forward)
Disassembly Procedure [Clutch Shaft No. 1 (Reverse)]
1
Remove the forward input gear.
2
Remove the seal ring.
3
Remove the clutch gear. [Point 11
4
Remove clutch shaft No. 1. [Point 21
5
Remove the snap ring.
6
Remove the backing plate, clutch disc, clutch plate and camber plate. [Point 31
7
Remove the clutch return spring. [Point 41
8
Remove the clutch piston. [Point 51
Disassembly Procedure [Clutch Shaft No. 2 (Forward)]
1
Remove the shim.
2
Remove the clutch gear. [Point 11
3
Remove clutch shaft No. 2. [Point 21
4
Remove the clutch gear. [Point 11
5
Remove the snap ring.
6
Remove the backing plate, clutch disc, clutch plate and camber plate. [Point 31
7
Remove the clutch return spring. [Point 41
8
Remove the clutch piston. [Point 51
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Coat grease on the seal ring before reassembly.
After wasing each part, coat torque converter oil sufficiently before reassembly.
Point Operations
I
[Point 11
I
Disassembly:
Use the SST and remove the stator shaft
bearing and clutch gear (reverse). (in clutch
shaft No. 1 only)
SST 09950-20017
(or SST 09950-40010)
Disassembly:
Remove the clutch gear bearing.
SST 09308-0001 0
Reassembly:
Install the clutch bearing.
SST 09608-3501 4
Reassembly:
Before installing the clutch gear on the clutch
drum, align disc serrations with a screwdriver,
etc.
[Point 21
Inspection:
Measure the clearance between each clutch
shaft and seal ring.
Limit clearance:
0 . 2 m m ( 0 . 0 0 8 in)
2-62
[Point 31
Inspection:
Measure the clutch disc thickness.
Standard thickness:
Limit thickness:
Inspection:
Measure the clutch plate thickness.
Standard thickness:
Limit thickness:
Inspection:
2 . 6 mm ( 0 . 1 0 2 in)
2 . 3 mm ( 0 . 0 9 1 in)
1 . 8 mm ( 0 . 0 7 1 in)
1 . 6 mm ( 0 . 0 6 3 in)
Measure the camber plate convex height.
Standard convex height: 3 . 4 mm ( 0 . 1 3 4 in)
Limit convex height:
3 . 1 mm (0.1 2 2 in)
Clutch gear s ~ d e
u
Reassembly:
Install the camber plate on the clutch drum,
w i t h the A punch mark o n the upper side.
Reassembly:
Install the clutch plates and clutch discs alternately on the clutch drum while coating torque converter oil.
0
4
a
Plston s ~ d e
Camber plate
Reassembly:
Adjust the clearance between the backing
plate and clutch disc.
1.
Install the camber plate, clutch plate, clutch disc, backing plate and snap ring on the clutch drum.
2.
Set a dial gage o n the upper face o f the clutch disc and
lift the clutch disc w i t h a screwdriver t o measure the
clearance w i t h the backing plate.
Standard clearance:
-
1.0
1 . 6 mm
0 . 0 6 3 in)
(0.039
-
3. If the measured value does n o t satisfy the standard,
select and use an appropriate backing plate.
Backing plate thickness:
A = 3 . 0 and 3 . 5 mrn
(0.1 1 8 and 0.1 3 8 in)
[Point 41
Disassembly.Reassembly: SST 0 9 2 2 0 - 2 2 0 0 0 - 7 1
Inspection:
Measure the free length o f the clutch return
spring.
Free length:
Limit free length:
92.1 mm (3.626 in)
8 5 . 0 mm (3.346 in)
[Point 51
Inspection:
Measure the clearance between the clutch
piston and piston ring.
Standard clearance:
Inspection:
Reassembly:
0 . 1 5 mm (0.0059 in)
Clean the check valve installed i n the clutch
piston b y blowing compressed air.
Install the piston ring w i t h the side w i t h the
"R" punch mark facing the hydraulic oil pressure side.
Reassembly:
Use the SST and a straight edge screwdriver
for inserting the clutch piston Wlpiston ring
into the clutch drum.
SST 09220-22000-71
With the clutch piston held slightly with the
SST as shown in the figure, use the straightedge screwdriver to push the piston ring
toward the piston.
SHIFT LEVER
ADJUSTMENT
s
s
Neutral posctlon
1.
Adjust the shift lever position.
(1) Set the shift lever in the neutral position.
(2) Adjust the rod length (dimension L) so that the dimension A from the instrument panel cut face
t o the lever satisfies the following standard:
A = 27 mm (1.06 in)
Dimension L (reference)
Vehicle model
1
-
3 ton
series
Dimension L
rnm (in)
INCHING ADJUSTMENT
Note:
Perform inching adjustment after the inching wire is replaced or when an abnormality such as slow
vehicle speed or failure in releasing the torque converter clutch by inching pedal depression is felt.
For the inching pedal height and play adjustment procedure, see the brake pedal adjustment section
(on page 8-28].
I
I
Stopper bolt
Unit:
A
137
(5.39
-
B
142
142
5.59) (5.59
C (Reference)
- 147
-
5.79)
10
(0.39)
D
10
(0.39
- 20
- 0.79)
mm (in)
E (Reference)
13
(0.51)
1.
Oil level measurement
( 1 ) Keep the vehicle in horizontal state, set the shift lever
in the neutral position, and keep the engine in the idling
state.
( 2 ) After warming u p the engine, keep it running a t the
idling speed. Measure the oil level w i t h the level gage.
The oil level is appropriate if it is between the upper
limit (F) and lower limit (L).
If insufficient, add oil through the level gage mounting port.
2.
Oil pressure measurement
( 1 ) After warming up the engine, measure the idling speed
and no-load maximum speed.
Note:
See the engine speed adjustment section (on page 1-13).
1 speed torque converter
Oil Pressure measuring ports
Main pressure (size PT 118)
A:
B: Torque converter outlet pressure (size
PT 118)
Clutch operating pressure (size PT 118)
C:
2 speeds torque converter
Oil Pressure measuring ports
A:
B:
C:
Main pressure (size PT 1/81
Torque converter outlet pressure (size
PT 118)
Clutch operating pressure (size PT 118)
( 2 ) Stop the engine and jack u p the front axle t o make the tires (both wheels) float above the ground.
(3) Remove the toe board and set an oil pressure gage. If three oil pressure gages are available, it
is desirable t o measure the main pressure, clutch pressure and torque converter pressure at the
same time.
(4) Start the engine. With the shift lever set in the neutral position, measure the main pressure at
each of idling and 2 0 0 0 rpm, and the torque converter outlet pressure at 2 0 0 0 rpm.
(5) With the shift lever set at each shift position, measure the clutch operating pressure at each of
idling and 2000 rpm.
Note:
Do not depress the inching pedal while measuring the oil pressure.
Standard Oil Pressure Values
1 speed torque converter:
Idling
441
196
(2.0 - 4.5)
128 641
-
Main pressure
kPa (kgfIcm2) [psi]
Clutch pressure
kPa (kgf/cm2)[psi]
T
Torque converter pressure (outlet pressure)
kPa (kgfIcm2) [psil
-
-
2000 rpm
-
-
13.0)
- 1226 (9.0 - 1781
12.5)
1275 (9.5
932
[ 1 3 5 - 1851
883
[I28
200
-
590 (2
-
6) [30
- 901
2 speeds torque converter:
Main pressure
kPa(kgf/cm2)[psi]
Clutch pressure
kPa (kgfIcm2) [psi]
Torque converter pressure (outlet pressure)
kPa (kgf/cm2) [psil
,&@j
(MZ~
3.
Idling
490 981
(5.0- 10.0)
1421
[71
441 - 834
(4.5 - 8.5)
[64 1211
-
2000 rpm
932
[I35
t
-
-
- 1373 (9.5 - 14.0)
- 1991
200
- 590 (2 - 61 130 - 901
Stall test
( 1) Load a cargo near the allowable maximum load, chock
the vihicle front and rear wheels securely and apply
the parking brake.
Accelerator pedal
Note:
Keep the vehicle in perfectly stopped state, and stretch wires
to make the vehicle immovable for safety.
(2) Warm up the engine, and measure the idling speed and
no-load maximum speed.
Note:
See the engine speed adjustment section (on page 1-1 3).
(3) Check the engine output by the maximum speed in
loaded state.
Method
After adjusting the no-load maximum speed, operate
the tilt lever for backward tilting.
Measure the maximum speed at full acceleration in
relief state.
Standard
The relief d o w n from the no-load maximum speed
shall be as follows:
-
300 rpm
Gasoline engine models: 150
200 rpm
Diesel engine models: 100
-
The relief d o w n in the LPG engine model in slightly
more than the above values.
Judgment
If the engine speed drops excessively, engine tuneup defect may be the reason.
(4) Start engine, set the control lever in the forward traveling position, race the engine fully, and
measure the stall speed after stabilization.
Engine
Stall speed
rpm
4Y
GM
1DZ
2100
210 0
21 50
PROPELLER SHAFT
Page
GENERAL .............................................................3-2
SPECIFICATIONS ................................................3-2
COMPONENTS ...................................................3-3
PROPELLER SHAFT .............................................3-4
REMOVAL. INSTALLATION
................................... 3-4
DISASSEMBLY . INSPECTION. REASSEMBLY ............. 3-5
GENERAL
SPECIFICATIONS
Joint type
Length
Cross type
A
77.5 (3.051
B
108.5 (4.272)
rnrn (in)
COMPONENTS
PROPELLER SHAFT
REMOVAL- INSTALLATION
Removal Procedure
1
Remove the cover.
2
Remove the set bolt.
3
Remove the propeller shaft ASSY
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Add M P grease through the grease fitting.
T = N . m (kgf-cm) [ft-lbfl
DISASSEMBLY. INSPECTION. REASSEMBLY
Disassembly Procedure
1
Remove the snap ring.
2
Remove the bearing cup, and remove the universal spider set. [Point 11
Reassembly Procedure
The reassembly procedure is the reverse o f the disassembly procedure.
Point Operation
[Point 1 I
Disassemblyreassembly:
Inspection:
Reassembly:
Use a press and b o x wrench for
removing t h e bearing cup.
Make sure t h a t the grease p a t h in the spider is
n o t clogged.
Coat M P grease o n the needle roller in the
bearing cup.
DIFFERENTIAL
Page
GENERAL ............................................................4-2
SPECIFICATIONS ................................................4-5
COMPONENTS ....................................................4-6
DIFFERENTIAL ASSY .......................................... 4-8
REMOVAL. INSTALLATION
.................................... 4-8
DISASSEMBLY . INSPECTION REASSEMBLY
rn
............. 4-12
DIFFERENTIAL HOUSING.FRONT
AXLE HOUSING ................................................ 4-20
REMOVAL. INSTALLATION
.................................... 4-20
4- 2
GENERAL
Differential (1 Ton Series)
Differential (2 Ton Series)
Differential (3 Ton Series)
Reduction Gear (1 Ton Series)
Reduction Gear ( 2 Ton Series)
Reduction Gear (3Ton Series)
SPECIFICATIONS
Vehicle model
1
1 t o n series
2.3 ton series
Differential case type.
Banjo type
t
Reduction ratio
(ring gearidrive pinion)
5.833
t
6
t
Item
I
Differential
11
Number of
teeth
Number of
teeth x
quantity
Drive pinion
1
Pinion gear
10
x 4
t
Side gear
14 x 2
c
Reduction ratio
(output gearireduction gear)
Reduction
gear
I
Number of
teeth
Differential oil quantity
1
Ring gear
I
I
Reduction gear
22
t
Output gear
52
t
I (US gal)
5.4 ( 1 - 4 3 )
2 ton series:
3 ton series:
6.4 (1.69)
9 . 0 (2.38)
COMPONENTS
DIFFERENTIAL ASSY
REMOVAL.INSTALLATION
1
2
3
6
8
11
17
Mast ASSY
Differential oil
Front wheel
Toe board
Brake pipe
Hoist the front axle
Carrier bracket and joint flange yoke
Removal Procedure
1
Remove the mast ASSY. (See the mast removal-installation section on page 11-51,
2
Drain differential oil.
3
Jack up the vehicle and remove the front wheels.
4
Remove the axle shaft.
5
Remove the propeller shaft.
6
Remove the toe board.
7
Disconnect the parking brake cable and cable clamp.
8
After draining the brake oil, disconnect the brake pipe from the wheel cylinder
9
Remove the torque converter case mount bolts, nuts and mounting insulator (lower side).
10 Support the bottom of the torque converter case with wooden blocks. [Point 11
11
Slightly hoist the front axle. [Point 21
1 2 Remove the front axle bracket and differential carrier cover connecting bolt (RH). [Point 31
1 3 Remove the front axle bracket set bolts. [Point 41
1 4 Remove the front axle Wldifferential. [Point 51
15
Remove the front axle bracket and differential carrier cover connecting bolt (LH).
1 6 Remove the differential carrier ASSY. [Point 61
1 7 Remove the carrier bracket and joint flange yoke.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Coat chassis grease on the joint flange yoke surface in sliding contact with the oil seal.
Tighten the axle bracket and differential carrier cover connecting bolts after applying thread tightener
(0833-00070).
See the note for mast installation procedure (on page 11-6).
After installation, carry out parking brake adjustment. (See page 8-26).
After installation, bleed air from the brake circuit. (See page 8-18).
The tightening torque for each portion is as follows:
T = N.m (kgf-cm) [ft-lbfl
Carrier bracket set bolt
Differential carrier set bolt
Front axle bracket set bolt
Axle bracket and differential carrier
cover connecting bolt
Torque converter case m o u n t bolt
Propeller shaft set bolt
Propeller shaft cover set bolt
Axle shaft set bolt
Front wheel hub n u t
- 78.45(500 49.03 - 78.45(500 156.91 - 215.75(1600 49.03
800) L36.18 800)136.18
57.881
57.881
- 159.171
294.20 - 392.27 (3000 - 4000) L217.05 - 289.401
49.03 - 88.26(500 - 900) L36.18 - 65.121
35.30 - 40.21 (360 - 410) L26.05 - 29.661
2200) [I 15.76
9.81 - 15.69 (100 - 160)L7.24 - 11.581
-
-
1.2t o n series: 68.65 88.26(700 - 900) L50.65 65.121
3 t o n series: 98.07 127.49(1000 - 1300)172.35 94.061
-
See page 5- 1 0
Point Operations
[Point 1 I
Removal:
Sling wires on the torque converter case, hoist
it slightly and support the bottom of the case with
wooden blocks or a pantograph jack.
[Point 21
Removal:
Sling wires at hub bolts on the left and right sides,
lock wires with hub nuts and slightly hoist the
front axle. Support the bottom of the differential
carrier w i t h a garage jack.
[Point 31
Installation:
Make shim adjustment until the clearance between the axle bracket (RH) and differential carrier cover satisfies the following standard:
Clearance : A = 0.5 mm (0.020in) or less
Shim thickness:
0.6 and 1.0 mm (0.024and 0.039in)
After shim installation, tighten the bracket and
cover clamping bolt t o the specified torque.
[Point 41
Removal:
T w o out of four on each side are reamer bolts.
Remove them by using the SST.
SST 093 1 0-22000-7 1
[Point 51
Removal.installation:
Use the hoist and garage jack for this
operation.
[Point 61
Removal:
Turn the differential t o make the carrier face
upward.
Sling wires on the carrier bracket and hoist it
slightly.
Remove the set bolts and use the service bolt for
separation.
Service bolt size: M 10 x 1.25
4-1 2
DISASSEMBLY. INSPECTION. REASSEMBLY
Disassembly Procedure
1
Measure the ring gear backlash and runout. (Runout measurement applies only t o the 1 t o n
series) [Point 1 I
2
Remove the thrust screw. (Only in 1 t o n series) [Point 2
1
3
Remove the bearing cap and adjusting nut. [Point 31
4
Remove the differential case ASSY
5
Remove the side bearing. [Point 41
6
Remove the differential upper case. [Point 51
7
Remove the side gear, pinion gear, spider and thrust washer. [Point 61
8
Remove the ring gear.
9
Remove the differential carrier cover
1 0 Remove the drive pinion bearing retainer set bolts, and remove the retainer Wldrive pinion &
output gear and the reduction gear Wlbearing. [Point 71
11
Remove the output gear. [Point 81
1 2 Remove the drive pinion. [Point 91
13
Remove the reduction gear. [Point 101
1 4 Remove the oil seal. [Point 1 1 I
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Coat thread tightener (08833-00070)
on the ring gear set bolt before tightening it.
Coat thread tightener (08833-00080)on the drive pinion bearing retainer set bolt before tightening it.
Coat sealing agent (08826-00090)
on the mating surfaces between the differential carrier cover and
differential carrier.
The tightening torque for each portion is as follows:
Unit: T = N - m (kgf-cm) [ft-lbfl
Output gear lock nut
Drive pinion bearing retainer set bolt
Differential carrier cover set bolt
Ring gear set bolt
Differential upper case set bolt
343.23- 392.27(3500 - 4000) i253.23- 289.401
88.26 - 1 1 7.68(900 - 1200)165.12
-
86.821
29.42- 44.13(300 - 450)121.71 - 32.561
127.49 - 176.52(1300
-
1800)i94.06- 130.231
1.2t o n series: 43.15 - 53.94(440 - 550)131.83 - 39.791
3 t o n series: 86.30- 102.97(880 - 1050)163.67- 75.971
Differential case bearing cap set bolt
1 1 7.68 - 137.29(1200 - 1400)186.82 - 101.291
Thrust screw lock nut
(1 ton series only)
102.97- 127.49(1050 - 1300)175.97 - 94.061
Point Operations
[Point 1 I
Disassembly:
1.
Measure the ring gear backlash and runout
before starting disassembly.
Measure the ring gear backlash.
Backlash:
1 - 2 ton series: 0 . 2
0 . 3 mm ( 0 . 0 0 8
3 ton series: 0 . 3
0 . 4 mm (0.012
-
2.
-
- 0 . 0 1 2 in)
- 0 . 0 1 6 in)
Measure the ring gear runout ( 1 t o n series only).
Ring gear runout limit:
0.1 mm (0.004 in)
[Point 21
Inspection:
Measure the thrust screw cap length
Standard length: 13.0 mm ( 0 . 5 1 2 in)
Limit length: 1 2 . 2 mm ( 0 . 4 8 0 in)
Reassembly:
Coat liquid packing ( 0 8 8 2 6 - 0 0 0 8 0 ) on the
threaded portion o f the thrust screw before
reassembly.
Reassembly:
Adjust the clearance between the thrust
screw cap and rear face o f the ring gear.
(Fully tighten the thrust screw, and return it
b y 116 turn.)
Clearance:
0 . 3 mm (0.008
0.2
-
-
0 . 0 1 2 in)
[Point 31
Disassembly:
Punch a match mark on the bearing cap and
carrier.
Reassembly:
Align the match marks on the bearing cap and
carrier at the time of reassembly.
Reassembly:
When tightening the bearing cap set bolt,
temporarily tighten t o the following torque
first. After adjusting the side bearing starting
force and ring gear backlash, tighten t o the
final tightening torque shown below.
Temporary tightening:
T = 19.61 N-m(200 kgf-cm) [14.47 ft-lbfl
Flnal tightening:
T = 117.68 - 137.29 N.m
(12 0 0
1400 kgf-cm)
[86.82
101.29 ft-lbf]
-
Reassembly:
1.
(1
Make the following adjustments after installing the adjusting nut.
Adjust the side bearing starting force.
Set a dial gage on the rear face of the ring gear.
(2) Tighten the adjusting nuts on both sides until the
thrust clearance is eliminated.
1.2 ton series: SST 09630-1 01 10-71
3 ton series: SST 09330- 101 70-7 1
(3) Tighten the adjusting nuts on both sides one more
notch each from the position where the thrust
clearance becomes 0.
2.
Adjust the backlash between the drive pinion and ring
gear.
(1) Set a dial gage into vertical contact with the ring gear
tip surface.
(2) For adjustment, move the differential case by loosening one adjusting nut by one notch while tightening
the other by one notch until the backlash satisfies the
following standard:
Backlash:
1-2 ton series:
3 ton series:
-
0.2
0.3 rnm
(0.008
0.012 in)
0.3
0.4 mrn
(0.012
0.016 in)
-
-
-
(3) After backlash adjustment, tighten the side bearing
adjusting nut on the ring gear side by 1.5 to 2 notches.
3.
Collect t o o t h c o n t a c t
~
Check teeth contact between the drive pinion and ring
gear.
(11 Coat red lead thinly and uniformly on 7 t o 8 teeth of
the ring gear.
Set a box wrench on the lock nut of the output gear
and turn the ring gear several turns in the forward and
in the reverse traveling directions.
Check according to the teeth contact trace.
If the teeth contact is incorrect, carry out drive pinion
protrusion adjustment and ring gear backlash
adjustment.
( 2 ) Correct teeth contact
The teeth contact should be slightly on the small end
size of the center of the tooth width as illustrated.
Heel contact
Face contact
Decrease the drive pinion adjusting shim thickness to bring the pinion closer to the ring gear,
and move the ring gear away from the pinion
for backlash adjustment.
r
Toe contact
Flank contact
Increase the drive pinion adjusting shim thickness to bring the pinion away from the ring
gear, and bring the ring gear closer to the
pinion for backlash adjustment.
[Point 41
Disassembly:
SST 0 9 9 5 0 -2 0 0 1 7
(or SST 09950-4001 0)
[Point 51
Disassembly:
Punch a match mark on the differential upper
and lower cases.
Reassembly:
Align the case match marks for reassembly.
Reassembly:
After washing and degreasing the female
screw portion of the lower case, coat thread
tightener (08833-00070) on the threaded
portion of the set bolts.
[Point 61
Inspection:
Measure the backlash between the side gear
and pinion gear.
Install the side gear and pinion gear on the case.
Lightly push the spider t o bring pinion gear and
side gear close t o the thrust washer for
measurement.
Backlash:
0.2 - 0.3 mm (0.008- 0.012in)
Reassembly:
Install the thrust washer of the side gear with
its oil groove side facing the tooth flank.
Reassembly:
Coat chassis grease (molybdenum disulfide
grease) uniformly on both sides of the spider
pinion thrust washer before reassembly.
[Point 71
Inspection:
Measure the backlash between the output gear
and reduction gear.
Backlash:
0.1
0 . 2 rnm (0.004
-
Reassembly :
-
0.008 in)
Adjust the drive pinion protrusion by means
of the drive pinion bearing retainer shims.
Select the shim by teeth contact inspection.
(See Point 3 . )
Shim thickness:
0.10.0.1 5-0.35 and 0.45 rnm
( 0 . 0 0 3 9 ~ 0 . 0 0 5 9 ~ 0 . 0 1 3and
8 0.01 7 7 in)
[Point 81
Reassembly:
0
Good examples
0
After the end of teeth contact inspection and
drive pinion protrusion adjustment, caulk the
output gear lock nut.
Point contact
[Point 91
Disassembly:
SST 09950-2001 7
(or SST 09950-4001 0)
Reassembly:
After installing the drive pinion pilot bearing,
caulk the tip end of the drive pinion at 3
places.
Reassembly:
SST 09370-20270-7 1
Reassembly:
Adjust the drive pinion bearing starting torque.
Caul
1.
Install the output gear and tighten the lock nut t o the
specified torque.
2.
Set a torque wrench on the lock nut, and measure the
starting torque.
Starting torque:
1.2 ton series:
3 ton series:
3.
-
10.79
13.24 N.m
(110
135 kgf-cm)
t7.96 - 9 . 7 7 ft-lbfl
13.73 N-m
1 1.28
(115
1 4 0 kgf-crn)
[8.32
10.13 ft-lbf]
-
If the starting torque does not satisfy the standard make
adjustment by changing the shim thickness.
Shim thickness:
0 . 0 3 ~ 0 . 1 0 ~ 0 . 1 5 ~ 0and
. 3 50.45 mm
3 8 0.01 7 7 in)
(0.0012 ~ 0 . 0 0 3 9 ~ 0 . 0 0 5 9 ~ 0 . 0 1and
[Point 101
Disassembly:
SST 09950-2001 7
(or SST 09950-4001 0)
[Point 1 1 I
Reassembly:
Use the SST t o drive in the oil seal until i t is
flush w i t h the carrier cover. Then use a proper driving rod and drive the oil seal in further
t o 1 mm (0.04 in) b e l o w the cover end face.
SST 0 9 3 7 0 - 2 0 2 7 0 - 7 1
Reassembly:
Coat M P grease o n t h e oil seal lip
DIFFERENTIAL HOUSING=FRONTAXLE HOUSING
REMOVAL- INSTALLATION
Removal Procedure
1
Remove the differential ASSY. (See page 4-81.
2
Remove the front axle hub. (See removal procedure steps 7 and 8 in the front axle hub removal,
installation section on page 5-9).
3
Remove the brake ASSY.
4
Remove the axle bracket. [Point 11
5
Remove the differential housing and front axle housing. [Point 21
-
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Axle housing set bolt tightening torque T = 73.55
98.07 N - m (750
1000 kgf-cm) [54.26
72.35 ft-lbfl
See the note (page 4-9) for the differential ASSY installation procedure.
Coat liquid packing (08826-00100) on the joint surfaces of the brake backing plate and axle bracket.
Brake ASSY set nut (backing plate self lock nut) tightening torque T = 117.68
137.29 N.m ( 1200
1400 kgf-cm) L86.82
101.29 ft-lbfl
After installation, adjust the brake performance. For adjustment, make the vehicle travel in the forward and reverse directions about 1 0 times each. Drepress the brake pedal each time for stopping
the vehicle. (This operation is especially required when the brake auto adjuster is moved to the shortening side.)
-
-
-
-
-
-
[Point 1 I
Installation:
r
-
1
housing
Coat grease on the entire periphery of the 0 ring before reassembly.
[Point 21
Installation:
Coat grease on the entire periphery of the 0ring before reassembly.
Installation:
Apply a thread sealing and locking agent
(08833-00080)on the set bolts ( 8 ~ c s .on
) the
LH side of the axle housing. (In 3 ton series
only)
(Bolt sealing is necessary as the bolt holes on
the LH side of the differential housing on 3 ton
series are through holes.)
Installation:
Install the oil seal on the axle housing.
SST 09608-3501 4
Installation:
Coat MP grease on the oil seal lip.
a
O-ring
FRONT AXLE
Page
GENERAL .............................................................5-2
SPECIFICATIONS ..................................................5-5
COMPONENTS ...................................................... 5-6
FRONT AXLE SHAFT-HUB ....................................5-9
REMOVAL . INSTALLATION
...................................... 5-9
5- 2
GENERAL
1 ton series
2 ton series
3 ton series
SPECIFICATIONS
Vehicle model
Item
Front axle type
Suspension type
1 t o n series
2 t o n series
3 t o n series
Full-floating
e
t
Fixed t o frame
t
t
Axle shaft diameter
rnm (in)
4 0 (1.57)
+-
4 2 (1.65)
Axle shaft diameter (spline portion)
m m (in)
40 (1.57)
t
49.5 (1.949)
6.50-1 0-lOPR(1)
7.00-1 2-1 2PR(I)
2 8 x 9-1 5-1 2PR(I)
Tire size
Wheel (STD)
Rim size
Inflating pressure
kPa (kgf/cm2) [psi]
10
x 5.00F
12
7 8 5 (8.0) [ I 141
x
1 5 x 7.00BD
5.00s
8 3 4 (8.5) [ I 2 0 1
t
Tire inflating pressure
1 ton
series
Tire size
Specifications
Tire inflating pressure
kPa (kgf/cm2)[psil
6.50-10-10PR(I)
Single
7 8 5 (8.0) [ I 141
t
Single (Wide)
t
7.00-1 2-1 2PR(I)
Single
8 3 4 (8.5) [ 1201
2 ton
series
3 ton
series
Single (Wide)
I
t
t
Special double
t
2 8 x 9-15-12PR(I)
Single
?
Single (Wide)
Special double
1
I
t
t
I
I
I
COMPONENTS
2 ton series
3 ton series
FRONT AXLE SHAFT-HUB
REMOVAL- INSTALLATION
Rear wheel
Jack up
Front wheel
Differential oil
Removal Procedure
1
Check the rear wheels.
2
Loosen the front wheel hub nuts.
3
Jack up the frame and support its bottom w i t h a stand or wooden blocks.
4
Remove the front wheels.
5
Drain differential oil.
6
Remove the axle shaft. [Point 11
7
Remove the bearing lock nut and lock nut plate. [Point 21
8
Remove the front axle hub. [Point 31
9
Remove the spacer. (Only in 3 ton series)
10 Remove the oil seal. [Point 41
11
Remove the bearing.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Coat thread tightener (08833-00070) on the hub bolt set nut before tightening.
Adjust the braking performance after installation. Make the vehicle travel in the forward and reverse
directions about 1 0 times and depress the brake pedal to stop the vehicle each time.
The tightening torque for each portion is as follows:
Unit:
Hub bolt set nut
Bearing lock nut stopper bolt
Axle shaft set bolt
Hub nut (single tire)
- 88.26 (700 - 900) L50.65 - 86.821
- , 186.33 (1500 - 1900) [108.53 - 137.471
3tonseries:
- 205.94(1700 - 2100)[123.00 - 151.941
14.71 - 21.57 (150 - 220) [10.85 - 15.921
1.2 t o n series: 68.65 - 88.26 (700 - 900) [50.65 - 86.821
3 t o n series: 98.07 - 127.49 (1000 - 1300) 172.35 - 94.061
1 t o n series: 107.87 - 196.13 ( 1 100 - 2000) [79.59 - 144.701
2 t o n series: 176.52 - 392.27 ( 1800 - 4000) 1130.23 - 289.401
3 t o n series: 294.20 - 588.40 (3000 - 6000) l217.05 - 434.101
1 t o n series:
2 t o n series:
68.65
147.10
166.71
2 t o n series:
Inside: 176.52
392.27 (1800
4000) 1130.23
289.401
Outside: 176.52 - 392.27 (1800
4000) L130.23
289.401
3 t o n series:
Inside: 294.20 - 588.40 (3000
6000) [217.05 - 434.101
Outside: 294.20 - 588.40 (3000
6000) L217.05
434.101
-
Hub nut (double tire)
N-m (kgf-cm) [ft-lbfl
-
-
-
-
-
4
Point Operation
[Point 1I
Removal:
After removing the axle shaft set bolts, lightly tap
the center of the axle shaft flange with a copper
hammer for easy removal.
Removal.installation:
Carefully operate so as not to damage
the oil seal.
[Point 21
Removal.installation:
Installation:
1.
SST
2.
1 - 2 ton series
3 ton series
SST 09509-55020
SST 09509-55030
Adjust the front axle bearing starting torque.
Fully tighten the bearing lock nut, rotate the hub by 4
t o 5 turns. Then loosen the lock nut by 1 112 t o 116 turn
and rotate the hub by 4 t o 5 turns again.
Set a spring scale on the hub bolt and measure the starting force.
Starting force
25.5
72.6 N (2.6
-
- 7.4 kgf) 15.7 - 16.3 Ibfl
3.
If the measured value does not satisfy the standard
above, make adjustment by tightening or loosening the
lock nut.
4.
Align the lock nut plate stopper hole with the lock nut
threaded hole.
5.
Coat thread tightener (08833-00070) on the lock nut
stopper bolt, and tighten it.
[Point 31
Removal:
SST 0931 0-1 01 60-71
Installation:
Turn the brake auto adjuster screw t o contract
the brake shoe slightly for easier brake drum
installtion.
Installation:
Fill MP grease in the hub and bearing before
installing the front axle hub.
Installation:
1.2 t o n series SST 09370-1 041 0-71
3 t o n series SST 0942 1-33020-7 1
[Point 41
Installation:
SST 09608-3501 4
Installation:
Coat grease on the oil seal lip.
REAR AXLE
Page
GENERAL ..........................................................6 - 2
SPECIFICATIONS ...............................................6 - 4
COMPONENTS ....................................................6 -5
REAR AXLE ASSY ..............................................6 -7
.................................... 6 - 7
REAR AXLE HUBmSTEERING KNUCKLE ............. 6-9
REMOVAL. INSTALLATION ....................................6 -9
REAR AXLE CYLINDER .......................................6 - 1 4
REMOVAL. INSTALLATION ....................................6 - 1 4
DISASSEMBLY . INSPECTION . REASSEMBLY ............. 6-1 5
REMOVAL. INSTALLATION
6-2
GENERAL
Rear Axle Cylinder
SPECIFICATIONS
Vehicle model
2 ton series
1 ton series
Item
Rear axle type
Elliot type
Rear axle suspension type
Center-supported right-left rocking type
Toe-in
Wheel
alignment
mm (in)
0 (0)
Camber
degree
0O
Caster
degree
0O
0O
King pin angle
1.5 ton:
Minimum turning radius
(outermost)
1930
(76)
1.75 ton: 1950
(76.5)
mm (in)
Tire size
Wheel (STD)
5.7015.00-8-8PR(I)
2.0 ton:
21 50
(84.5)
2.5 ton: 2220
(87.5)
2300
(90.5)
6.9016.00-9-10PR(I)
x 3.00
6.50-1 0-1 OPR(I)
x 4.00E
x
Rim size
8
Inflating pressure
kPa (kgf/cm2) [psi]
785
(8.0) [1141
686
(7.0) [ I 0 0 1
760
(7.75) [ I 1 0 1
Double acting
t
t
Cylinder bore mm (in)
76.2 (3.00)
t
8 0 (3.15)
Piston rod outside
diameter
mm (in)
50 ( I .97)
t
Cylinder type
Rear axle
cylinder
3 ton series
9
10
5.00F
t
Tire lnflating Pressure
Vehicle model
1 ton series
2 ton series
3 ton series
Inflating pressure
Tire size
Rim type
5.7015.00-8-8PR(I)
Divided
785 (8.0) [I141
5.7015.00-8-8PR(I)
Side ring (OPT)
t
6.9016.00-9-1 OPR(I)
Divided
686 (7.0) [ I 001
6.9016.00-9-1OPR(I)
Side ring (OPT)
t
6.50-1 0-1 OPR(I)
Divided
7 6 0 (7.75) [I101
6.50-1 0-1 OPR(I)
Side ring (OPT)
?
kPa (kgf/cm2)[psi]
COMPONENTS
430 1
REAR AXLE ASSY
REMOVAL- INSTALLATION
1
2
3
Radiator cover
Balance weight
Front wheels
Removal Procedure
1
Remove the radiator cover.
2
Remove the balance weight.
3
Check the front wheels.
4
Loosen the rear wheel hub nuts.
5
Jack up the frame and support it with a stand or wooden blocks.
6
Remove the rear wheels.
7
Disconnect the rear axle cylinder hose.
8
Remove the rear axle ASSY. [Point 11
9
Remove the rear axle cushion rubber. [Point 21
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Supply grease through each grease fitting after installation.
The tightening torque for each portion is as follows:
Rear axle support set bolt
Hub n u t
11 7.68
-
166.71 (1200
Unit:
-
N.m (kgf-cm) [ft-lbfl
1700) L86.82
See page 6- 1 0
-
123.001
6-8
Point O~erations
[Point 1 I
Removal:
-
Remove according to the following procedure:
1.
Sling the rear axle beam with wires at the left and right
and slightly suspend with a hoist.
2.
Remove the rear axle support set bolts (4 pcs.).
3.
Operate the hoist slowly and remove the rear axle.
If the cushion rubber sticks to the frame and does not
come off, separate them by prying with a bar inserted
between the beam and fram.
[Point 21
Upper r ~ d e
Installation:
Install the cushion rubber in the correct
direction.
Place the "UP" mark on the upper side. (Thicker side up)
Installation:
Match the taper of the beam side pin with the
taper of the cushion rubber, and push the cushion rubber fully against the beam.
(*;
A>B
REAR AXLE HUB-STEERING KNUCKLE
REMOVAL- INSTALLATION
1
2
3
4
Front wheel
Hub nuts
Jack up
Rear wheel
Removal Procedure
1
Check the front wheels.
2
Loosen the rear wheel hub nuts.
3
Jack u p the frame and support its bottom w i t h a stand or wooden blocks.
4
Remove the rear wheel. [Point 11
5
Remove the hub cap. [Point 21
6
Remove the rear axle hub Wlbearing. [Point 31
7
Remove the bearing and oil seal f r o m the steering knuckle. [Point 41
8
Remove the bearing f r o m the hub.
9
Remove the tie rod ASSY. [Point 51
10 Remove the king pin lock bolt, and remove the king pin. [Point 61
1 1 Remove the steering knuckle and thrust bearing. [Point 71
12 Remove the oil seal and bearing from the rear axle beam. [Point 81
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Supply MP grease through the king pin grease fitting.
The tightening torque for each portion is as follows:
Unit:
-
19.61
King pin lock bolt, lock nut
147.10
Tie rod end castle nut
-
31.38 (200
N - m (kgf-cm) [ft-lbfl
- 23.151
-
320) [14.47
-
2000) i108.53
- 144.701
29.42 - 44.1 3 (300 - 450) L21.71 - 32.561
196.13 (1500
Divided rim bolt set nut
1 ton series:
2.3 ton series:
Hub nut
1 ton series (Both divided rim and side ring rim):
88.26
156.9 (900 - 1600) [65.12
11 5.761
2 ton series (divided rim):
196.13 (1200
2000) l86.82
144.701
1 17.68
2 ton series (side ring rim):
392.27 (1800
4000) [130.23
289.401
176.52
3 ton series (Both divided rim and side ring rim):
117.68
196.13 (1200
2000) L86.82
144.701
49.03
-
68.85 (500
-
-
700) 136.18
- 50.651
-
-
-
-
Point Operations
Make the chamfered side
face the center
[Point 1 I
Installation:
In the case of a divided rim type wheel, install
w i t h the divided rim set bolt head on the outer
side of the vehicle.
Disassembly:
When a wheel is removed for disassembly,
always discharge air fully before disassembling the wheel.
Reassembly:
The divided rim set bolt shall be installed w i t h
its head chamfered side facing the center of
the wheel.
[Point 21
Installation:
Fill M P grease in the cap.
Installation:
Install by tapping the cap flange portion.
[Point 31
Removal:
SST 0 9 9 5 0 -4 0 0 1 0
(or SST 0 9 9 5 0 -2 0 0 1 7)
Installation:
Fill grease in the hub and knuckle spindle.
Installation:
SST 09370-20270-71
Installation:
Adjust the rear axle hub starting force.
1.
Temporarily tighten the castle nut while rotating the hub.
Temporary tightening torque:
1 ton series
11.77
32.36 N-m ( 12 0
23.88 ft-lbfl
2.3 ton series
14.71 4 4 . 1 3 N-rn(150
32.56 ft-lbf]
-
-
-
-
-
- 4 5 0 kgf-crn) t10.85
3 3 0 kgf-crn) [8.68
After temporary tightening, rotate the hub by 3 t o 5
turns.
2.
Set a spring scale on the hub bolt, and measure the starting force.
Starting force:
1 ton series
3 9 . 2 N (1.5
14.7
2.3 ton series
14.7
44.1 N (1.5
3.
-
- 4.0 kgf) t3.3 - 8 . 8 Ibf]
-
-
4.5 kgf) [3.3
-
9 . 9 Ibfl
If the measured value does not satisfy the standard,
make adjustment by tightening or loosening the castle
nut.
[Point 41
Removal:
SST 09950-4001 0
(or SST 09950-2001 71
6-1 2
Installation:
SST 09370-20270-7 1
[Point 51
SST 0961 0-2001 2
Removal:
[Point 61
Inspection:
Measure the king pin outside diameter.
Standard outside diameter:
28.0 mm (1 .I02in)
Limit outside diameter:
27.8 mm (1.094in)
Installation:
Align the king pin cut groove and lock bolt hole,
tighten the lock bolt, and lock by tightening the
lock nut.
[Point 71
Installation:
Adjust the steering knuckle starting force.
1.
Insert the shim on the upper side of the thrust bearing
and install the king pin.
2.
Set a spring scale on the tip end of the knuckle and measure the starting force.
Starting force:
29
3.
- 49 N (3 - 5 kgf) [6.6 -
1 1 Ibf]
If the measured value does not satisfy the standard,
make adjustment by changing the shim.
Shim thickness:
0.1.0.2-0.5
and 1.0 mm
(0.22.0.44-1.1
and 2.2in)
[Point 81
Installation:
Pay attention t o t h e relative positions of t h e
needle bearing and oil seal i n t h e assembled
state.
SST 09620-30010
--
REAR AXLE CYLINDER
REMOVAL. INSTALLATION
Removal Procedure
1
Remove the radiator cover
2
Remove the balance weight.
3
Remove the piston rod end pin.
4
Remove the pipe clamp set bolt.
5
Disconnect the rear axle cylinder pipe.
6
Remove the fitting.
7
Remove the rear axle cylinder ASSY
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Supply MP grease through the piston rod end pin grease fitting.
The tightening torque for each portion is as follows:
Unit:
Cylinder ASSY set bolt
p
-
1
166.71
-
21 5.75 ( 1700
-
N.rn (kgf-cm) [ft-lbfl
2200) 1123.00
-
159.1 71
I
Disassembly Procedure
1
Remove the tie rod.
2
Remove the rod guide
3
Extract the piston rod. [Point 11
T
4
Remove the cylinder. [Point 21
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Coat hydraulic oil before reassembly.
Tie rod nut tightening torque T = 88.3
- 95.1 N - m ( 9 0 0 - 9 7 0 kgf-cm) [65 - 7 0 ft-lbfl
Point Operations
[Point 1 I
Inspection:
Measure the piston rod outside diameter.
1
Inspection:
-
3 ton series
Standard outside diameter:
50.0 m m (1.969in)
Limit outside diameter:
49.92 rnrn (1.9654in)
Measure the piston rod bend.
Limit bend:
0.5 mm (0.020in)
[Point 21
Inspection:
Measure the cylinder bore.
1 a2 ton series
Standard bore:
Limit bore:
76.2 rnrn (3.000in)
76.55 rnrn (3.0138in)
3 ton series
Standard bore:
Limit bore:
80 rnrn (3.15in)
80.35rnm (3.1634in)
STEERING
Page
GENERAL ............................................................7-2
SPECIFICATIONS ................................................ 7-4
COMPONENTS ...................................................7-4
STEERING WHEEL-MAST JACKET ..................... 7-8
.................................... 7-8
HYDROSTATIC STEERING VALVE ASSY .......... 7-11
REMOVAL. INSTALLATION ....................................7-11
DISASSEMBLY . INSPECTION. REASSEMBLY ............. 7-12
RELIEF PRESSURE MEASUREMENT ........................ 7-16
REMOVAL. INSTALLATION
GENERAL
7-3
Hydrostatic Steering Valve
7-4
SPECIFICATIONS
Vehicle model
2.3 ton series
1 ton series
Item
Steering wheel diameter
m m (in)
Steering wheel play (at idling)
mm (in)
3 6 0 (14.17)
25
-
50 (0.98
1.97)
Hydrostatic power steering
Power steering type
EATON
Manufacturer
Hydrostatic
steering
valve
-
Flow rate Umin (US gal/mim)
1 2 (3.2)
1 3 (3.4)
Relief valve set pressure
kPa (kgf/cm2) [psi]
7 8 5 0 (80) [ 1 1401
c
Relief valve type
Built-in type
COMPONENTS
4501
1 ton series
2-3ton series
STEERING WHEELmMAST JACKET
REMOVAL- INSTALLATION
1
h
1 Toe board
2 Accelerator bracket ASSY
3 Front protector cover
8 Combination meter ASSY set bolt
9 Combination meter wiring
16 Steering valve set bolt
Removal Procedure
1
Remove the toe board.
2
Disconnect the accelerator wire, and remove the accelerator bracket ASSY
3
Remove the front protector cover (RH, LH).
4
Remove the steering wheel. [Point 11
5
Remove the steering column cover (turn signal switch cover). [Point 21
6
Remove the steering column cover.
7
Remove the boot.
8
Remove the combination meter ASSY set bolts.
9
Disconnect the combination meter wiring.
10
Remove the combination meter ASSY
11
Remove the instrument panel (RH).
12
Remove the tilt lock lever.
13
Remove the shift lever knob.
1 4 Remove the instrument panel (LH).
15
Remove the tilt lock device. [Point 31
16
Remove the steering valve set bolt.
17
Remove the mast jacket Witilt steering shaft. [Point 41
18
Remove the mast jacket. [Point 51
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Coat MP grease on the tilt steering shaft spline portion (steering valve side).
Coat MP grease on the tilt lock device and each sliding contact portion.
The tightening torque for each portion is as follows:
Unit: N - m (kgf-cm) [ft-lbfl
Steering valve set bolt
I
Mast jacket set bolt
I
Steering wheel set nut
44.13 44.13
I
I
19.61
- 39.791
53.94 (450 - 550) [32.56 - 39.791
- 23.42 (200 - 300) L14.47 - 21.711
53.94 (450
-
550) L32.56
Point Operations
[Point 1 I
Removal:
SST 0 9 9 5 0 -4 0 0 10
[Point 21
Removal:
Hold the steering column cover by applying forces from the top and bottom for removal.
I
I
7-1 0
[Point 31
Left screw
Installation:
Check the functioning of the tilt lock device.
[Point 41
Removal:
Remove the parking brake brocket set bolts t o
free the parking brake ASSY before removing the
mast jacket set bolts. (Otherwise, the most braket set bolts cannot be taken out.)
[Point 51
Removal:
Install a service nut at the end of the steering
shaft and extract the shaft by tapping the service
nut lightly with a plastic hammer.
Removal:
Fix the mast jacket in a vice. Apply screwdriver
t o the groove at the end of the mast jacket and
top it lightly w i t h a plastic hammer t o separate
the mast jacket from the bracket.
HYDROSTATIC STEERING VALVE ASSY
REMOVAL-INSTALLATION
Removal Procedure
1
Remove the instrument panel (RH, LH). (See removal procedure step 1 to 14 in the steering wheel
and mast jacket removal, installation section on page 7-8.)
2
Disconnect the piping.
3
Remove the steering valve ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
See the note (page 7-91 for the steering wheel and mast jacket installation procedure.
The tightening torque for each portion is as follows:
Unit: N-m (kgf-cm) [ft-lbfl
Steering valve set bolt
44.13
-
53.94 (450
-
550) [32.56
-
39.791
DISASSEMBLY. INSPECTION- REASSEMBLY
1
fitting
Disassembly Procedure
1
Remove the fitting. [Point 11
2
Remove the end cap. [Point 21
3
Remove the spacer, the gerotor, the drive and the wear plate. [Point 31
4
Remove the retaining ring. [Point 41
5
Remove the seal stopper Wlseal.
6
Remove the needle bearing.
7
Remove the sleeve and spool set. [Point 51
8
Remove the relief valve. [Point 61
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure
Note:
Wash each part w i t h clean hydraulic oil before assembly.
The tightening torque for each portion is as follows:
Unit:
End cap set screw
31.09 (317 ) [22.931
N.m (kgf-cm) [ft-lbfl
pdmp
Point Operations
[Point 1I
port fitting
Reassembly:
A check valve is built in the pump port fitting.
Install the fitting in the correct position.
\
P
[Point 21
Disassembly~Reassembly: lnstall with the end cap facing
upward as illustrated, and fix
the flange portion in a vise.
Use aluminium places pads for
protection and do not tighten
the vice excessively.
Reassembly:
Tighten the screws in accordance with the
order numbers as shown in the illustration.
Tighten all the seven screws with the preliminary tightening torque of 16.97 N.m
(173 kgf-cm) [ I 2.52 ft-lbfl and then tighten
again evenly with the standard torque.
[Point 31
Reassembly:
Pin parallel
with port face
Reassemble according t o the following procedure.
1.
Install spacer plate. Align bolt holes in wear plate with
tapped holes in housing.
2.
Rotate spool and sleeve assembly until pin is parrallel
with port face.
Gerotor star valley
3.
Install drive, make sure you engage drive with pin. To
assure proper alignment, mark drive as shown. Note relationship between slotted end of drive t o splined end of
drive when marking.
4.
With seal side of meter toward spacer plate, align star
valleys (ref. A) on drive (ref. B). Note the parallel relationship of reference lines A, B, C, and D. Align bolt
holes without disengaging meter from drive.
A
Port face
[Point 41
Disassembly:
Place housing on a clean soft cloth t o protect
surface finish. Use a thin bladed screwdriver
t o pry retaining ring from housing, as shown.
[Point 51
Reassembly:
Spring
slot
Identification
Reassemble according t o the following procedure.
1.
Assemble spool and sleeve carefully so that the spring
slots line up at the same end. Rotate spool while sliding
parts together. Some spool and sleeve sets have identification marks, align these marks as shown in figure.
Test for free rotation. Spool should rotate smoothly in
sleeve w i t h finger tip force applied at splined end.
2.
Set springs back t o back with the notched portions at
both ends facing downward.
spool
3.
Install pin through spool and sleeve assembly until pin
becomes flush at both sides of sleeve.
4.
Position the spool and sleeve assembly so that the splined end of the spool enters the end of housing first, as
shown.
Be extremely careful that the parts do not tilt out of position while inserting. Push parts gently into place w i t h
slight rotating action, keep pin nearly horizontal. Bring
the spool assembly entirely within the housing bore until the parts are flush at the end of housing. With the
spool assembly in this flush position, check for free
rotation within the housing b y turning w i t h light finger
tip force at the splined end.
[Point 61
Plug
Disassembly:
Do not remove the relief valve unless it is estimated t o be defective.
The valve seat cannot be removed.
Relief valve
Disassembly:
Measure the plug screwed-in depth before
disassembly.
Reassembly:
Reassemble by adjusting t o the screwed-in
depth of the plug measured before disassembly. After installing the steering valve
ASSY on the vehicle, measure the relief pressure. If it is not within the standard range,
adjust it by changing the screwed-in depth
of the plug.
Valve seat
RELIEF PRESSURE MEASUREMENT
1.
Measure the power steering relief pressure.
(1) Disconnect the steering valve piping (at one place
shown in the figure: pump port) and install the SST.
Then set an oil pressure gage.
SST 09450-2361 0 -7 1
Plug size: PT 118
(2) Start the engine and turn the steering wheel slowly
clockwise and counterclockwise.
(3) Start the engine, rotate the steering wheel and measure the relief pressure when the relief occurs.
Standard relief pressure
7850 & 490 kPa (80 & 5 kgf/cm21 11140
* 70 psi1
BRAKE
Page
HYDRAULIC CIRCUIT DIAGRAM ........................ 8 - 2
SPECIFICATIONS ................................................ 8-3
FRONT BRAKE ..................................................8-4
COMPONENTS
.....................................................8-6
DISASSEMBLY . INSPECTION . REASSEMBLY
( 1 TON SERIES) ..............................................8 - 8
DISASSEMBLY INSPECTION- REASSEMBLY
( 2 . 3 TON SERIES) ..............................................8 - 1 3
................... 8 - 1 8
BRAKING FORCE INSPECTION ADJUSTMENT ......... 8 - 1 9
MASTER CYLINDER ............................................8-20
COMPONENTS .....................................................8-20
REMOVAL . INSTALLATION .................................... 8 - 2 2
DISASSEMBLY . INSPECTION. REASSEMBLY ............. 8-23
PARKING BRAKE .................................................8-24
COMPONENTS ....................................................8 - 2 4
KEY POINTS IN SERVICE JOBS ............................. 8 - 2 5
ADJUSTMENT ...................................................8-26
BRAKE PEDAL .....................................................8 - 2 7
COMPONENTS ....................................................8 - 2 7
ADJUSTMENT .....................................................8 - 2 8
AIR BLEEDING FROM BRAKE SYSTEM
m
8- 2
HYDRAULIC CIRCUIT DIAGRAM
( 1 ) Inching and brake pedal
(2) Reservoir tank
13) Brake master cvlinder
(4) Brake wheel cyiinder
(5) Oil tank
(6) Oil pump
(7) Flow divider
(8) Oil control valve
(9) Lift cylinder
( 10)Tilt cylinder
(11 ) Steering valve
( 1 2) Power steering cylinder
8-3
SPECIFICATIONS
Vehicle model
2 ton series
1 ton series
Hydraulic internal expansion type duo servo brake
Front brake type
Brake drum inside diameter
mm (in)
254 (10.00)
Dimensions (width x
thickness
length)
mm (in)
Wheel cylinder bore
Brake master
cylinder
Applicable oil
3 1 0 (12.20)
t
Resin model (non-asbestos)
Material
Brake lining
3 ton series
279 x 48.5 x 5
(10.98 x 1.909 x 0.20)
323 x 60 x 7
(12.72 x 2.36 x 0.28)
343 x 60 x 7
(13.50 x 2.36 x 0.28)
22.2 (0.874)
28.5 (1.122)
c
+-
t
@
+-
Bore
mm (in)
19.05 (0.7500)
Stroke
mm (in)
3 0 (1.18)
Brake fluid
8-4
FRONT BRAKE
Brake Sectional View ( 1 Ton Series)
Wheel Cylinder Sectional View (1 Ton Series)
Brake Sectional View (2.3Ton Series)
Wheel Cylinder Sectional View (2.3 Ton Series)
COMPONENTS
1 Ton Series
01[RH]
02[LH]
Refer to
FIG.4601
8-7
2.3 Ton Series
DISASSEMBLY-INSPECTION- REASSEMBLY ( 1 TON SERIES)
1
Front axle hub (brake drum)
9
Brake fluid
10 Brake pipe
Disassembly Procedure
1
Remove the front axle hub (brake drum). [Point 11
(See the front axle shaft, hub removal section on page 5-9.)
2
Remove the hold down spring. [Point 21
3
Remove the anchor-to-shoe spring. [Point 31
4
Remove the cable and cable guide.
5
Remove the strut lever. [Point 41
6
Remove the adjuster spring and adjusting screw. [Point 51
7
Disconnect the parking brake cable. [Point 61
8
Remove the brake shoe. [Point 71
9
Drain brake fluid.
10 Disconnect the brake pipe.
11
Remove the wheel cylinder ASSY. [Point 81
12 Remove the backing plate. [Point 91
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
See the note for front axle shaft, hub installation. (See Page 5-10.)
Check no oil or grease adhesion on the brake lining and interior surface of the brake drum before reassembly.
Set the installed brake shoe outside diameter t o the value below by tightening the adjusting screw
before installing the hub Wlbrake drum. (Set t o 1 m m (0.04 in) smaller than the brake drum inside
diameter.)
Installed brake shoe outside diameter: 2 5 3 m m (9.96 in)
0 Bleed air from the brake system after reassembly.
Adjust the brake performance after reassembly. For adjustment, repeat forward travel and reverse
travel of the vehicle, and stop the vehicle each time b y depressing the brake pedal.
The tightening torque for each portion is as follows:
Backing plate self lock nut
T = 117.68
137.29 N-m ( 1 2 0 0
1400 kgf-cm) t86.82
101.29 ft-lbfl
Wheel cylinder set bolt
T = 7.85
11.77 N - m (80
1 2 0 kgf-cm) [5.79
8.68 ft-lbfl
-
-
-
-
-
-
9
1
Point Operations
[Point 11
Inspection:
Measure the inside diameter of the brake drum.
Standard inside diameter: 2 5 4 m m (10.00 in)
Limit inside diameter: 2 5 6 m m (10.08 in)
1
Disassernbly~Reassembly: SST 095 10-3 1960-71
Inspection:
Measure the free length of the hold d o w n
spring.
Standard free length: 25.7 m m (1.012 in)
Limit free length: 2 3 m m (0.91 in)
Reassembly:
Coat liquid packing (08826-00080)on shoe
hold down pin and the contact face on the rear
side of the backing plate t o eliminate any
clearance.
[Point 31
Disassembly:
Inspection:
SST 0971 7-2001 0
Measure the free length of the anchor-to-shoe
spring.
Standard free length: 1 0 2 mm ( 4 . 0 2 in)
Limit free length: Replace if there is any
clearance in the coil.
Reassembly:
SST 097 18-20010
[Point 41
Inspection:
Measure the free length of the strut-to-shoe
spring.
Standard free length: 2 0 mm (0.79 in)
Limit free length: 17 mm (0.67 in)
8-1 1
[Point 51
Inspection:
Measure the free length of the adjuster spring.
Standard free length: 79 m m (3.11 in)
Limit free length: Replace if there is any
clearance in the coil.
Reassembly:
Apply grease on the threaded portion of the
adjusting screw and in the cap.
Reassembly:
Tie a wire at the end of the adjuster spring and
set the spring by pulling it with a screw driver.
[Point 61
Reassembly:
Coat liquid packing (08826-00080) on the
parking brake cable port of the backing plate
t o eliminate any clearance.
[Point 71
Inspection:
Measure the brake lining thickness.
Standard thickness: 5.0 m m (0.197 in)
Limit thickness: 1.0 m m (0.039 in)
Reassembly:
Coat grease on the illustrated portions ( 6 places in contact with the shoe rim and anchor
pin) of the backing plate before installing the
brake shoe.
[Point 81
Inspection:
Measure the clearance between the wheel cylinder and piston.
Limit piston clearance:
0.125 m m (0.00492 in)
Reassembly:
Coat liquid packing (08826-00080) on the
wheel cylinder portion for fitting t o the backing plate and whole circumference on the set
bolt t o eliminate any clearance.
[Point 91
Reassembly:
Coat liquid packing (08826-00080) o n the
joint face between the backing plate and front
axle bracket t o eliminate any clearance.
DISASSEMBLY-INSPECTION- REASSEMBLY (2.3TON SERIES)
1
10
11
Front axle hub (brake drum)
Brake fluid
Brake pipe
Disassembly Procedure
1
Remove the front axle hub (brake drum). (See the front axle shaft, hub removal section on page
5-9.) [Point 11
2
Remove the hold d o w n spring. [Point 21
3
Remove the pawl lever stopper. [Point 31
Remove the pawl lever.
Remove the anchor-to-shoe spring. [Point 41
Remove the strut lever. [Point 51
Remove the adjuster spring and adjusting screw. [Point 61
Disconnect the parking brake cable. [Point 71
Remove the brake shoe. [Point 81
Drain brake fluid.
Disconnect the brake pipe.
Remove the wheel cylinder ASSY. [Point 91
Remove the backing plate. [Point 101
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
In the reassembly procedure, however, reverse the order of steps 2 and 3 in disassembly procedure.
(Install the p a w l lever stopper after installing the hold spring.)
Note:
Refer t o the note for the front axle shaft, hub installation procedure (on page 5-9.)
Check no grease or oil adhesion on the brake lining and brake drum interior surface before reassembly.
Set the installed brake shoe outside diameter to the following dimension by tightening the adjusting
screw before installing the hub Wlbrake drum. (Set it to approx. 1 m m (0.04 in) smaller than the
brake drum inside diameter.)
Installed brake shoe outside diameter: 309 rnm ( 12.17 in)
Drain air from the brake system after reassembly.
After reassembly, adjust the brake performance. For adjustment repeat vehicle forward travel and
reverse travel and stop the vehicle by depressing the brake pedal each time.
The tightening torque for each portion is as follows:
Backing plate self lock nut
137.29 N - m (1200
1400 kgf-cm) [86.82
101.29 ft-lbfl
T = 117.68
Wheel cylinder set bolt
T = 14.71
19.61 N - m (150
2 0 0 kgf-cm) [10.85
14.47 ft-lbfl
-
-
-
-
-
Point Operations
[Point 1I
Inspection:
Measure the brake drum inside diameter.
Standard inside diameter: 3 1 0 m m ( 12.20 in)
Limit inside diameter: 3 1 2 m m (12.28 in)
[Point 21
Disassembly~Reassembly: SST 095 10-31 960-7 1
Inspection:
Measure the free length of the hold d o w n
spring.
Standard free length: 31.3 m m (1.232 in)
Limit free length: 28.2 m m (1.11 0 in)
Reassembly:
Coat liquid packing (08826-00080) on the
shoe hold down pin contact portion the rear
side of the backing plate t o eliminate any
clearance.
[Point 31
Inspection:
Measure the free length of the actuator spring.
Standard free length: 124.5 mm (4.902 in)
Limit free length: Replace if there is any
clearance in the coil.
Reassembly:
Use snap ring pliers and install the pawl lever
stopper and actuator spring.
[Point 41
Disassembly:
Inspection:
SST 0971 7-2001 0
Measure the free length of the anchor-to-shoe
spring.
Standard free length: 106 mm (4.17 in)
Limit free length: Replace if there is any
clearance in the coil.
Reassembly:
, I
I
SST 097 18-2001 0
[Point 51
Inspection:
Measure the free length of the strut-to-shoe
spring.
Standard free length: 23 mm (0.91 in)
Limit free length: 20 m m (0.79 in)
[Point 61
Inspection:
Measure the free length of the adjuster spring.
Standard free length: 86 m m (3.39 in)
Limit free length: Replace if there is any
clearance in the coil.
Reassembly:
Apply grease to the threaded portion of the
adjusting spring and in the cap.
[Point 71
Inspection:
Coat liquid packing (08826-00080) on the
parking brake cable outlet in the backing plate
to eliminate any clearance.
8-17
[Point 81
Inspection:
Measure the brake lining thickness.
Standard thickness: 7.0 m m (0.276 in)
Limit thickness: 2.0 m m (0.08 in)
Reassembly:
Before installing the brake shoe, coat grease
on the illustrated portions ( 6 places in contact
w i t h the shoe rim and anchor pin) of the backing plate.
[Point 91
Inspection:
Measure the clearance between the wheel cylinder and piston:
Limit piston clearance:
0.145 m m (0.00571 in)
Reassembly:
Coat liquid packing ( 0 8 8 2 6 - 0 0 0 8 0 ) on the
wheel cylinder portion for fitting in the backing plate and whole circumference of the set
bolt t o eliminate any clearance.
[Point 101
Reassembly:
Coat liquid packing (08826-000801 on the
joint face of the backing plate w i t h the front
axle bracket t o eliminate any clearance.
AIR BLEEDING FROM BRAKE SYSTEM
lnching lever
Note:
Carry out air bleeding operation while adding brake fluid
to reservoir tank to prevent it from becoming insufficient.
When the pedal needs to be pushed all the way for air bleeding, torque converter inching cable shall be disconnect
from torque converter inching lever.
lnching wire
1.
Bleed air f r o m the brake master cylinder.
( 1) Depress the brake pedal several times t o compress the
air in the piping and maintain that state.
( 2 ) Loosen the breather plug t o bleed air in the piping w i t h
the brake fluid and tighten the plug immediately before
the brake fluid discharge stops.
( 3 ) Repeat steps ( 1 ) and (2) above until no air bubble is
seen in the flowing o u t brake fluid.
2.
Bleed air from wheel cylinders RH and LH
( 11 Perform the same operation as above for each o f the
wheel cylinder RH and LH at a time.
3.
Add brake fluid t o the specified level.
(1) For addition, pour brake fluid through the filter provided at the reservoir tank.
( 2 ) A d d brake fluid t o the shouldered portion in the reservoir tank.
Filter
BRAKING FORCE INSPECTION-ADJUSTMENT
1.
Inspect the braking force b y using a brake tester or b y the brake test.
Braking distance (no-load state)
1 t o n series
2 t o n series
3 t o n series
Initial speed o f braking kmlh
(mph)
1 9 . 0 ( 11 . 8 )
1 8 . 0 ( 11.2)
+-
Stopping distance
m (ft)
5.0 ( 1 6 . 4 ) or less
t
t
2.
Adjust the braking force.
(1) Repeat forward travel and reverse travel, and adjust the brake shoe clearance.
The adjusting screw automatically adjust the brake shoe clearance when the brake pedal is depressed at the time o f reverse traveling.
(2) When the braking force is insufficient, remove the brake drum and perform inspection as adjuster malfunction, lining contact defect, foreign matter adhesion on lining surface, brake fluid leakage or other defect is suspected.
(3) When the brake shoe is replaced w i t h a n e w one, repeat forward travel and reverse travel for
running in.
MASTER CYLINDER
Residual pressure valve
I
COMPONENTS
1
REMOVAL-INSTALLATION
Removal Procedure
1
2
3
4
5
6
Remove the protector.
Disconnect the brake side hose from the reservoir tank and drain brake fluid.
Remove the toe boad.
Disconnect piping.
Remove the push rod clevispin.
Remove the brake master cylinder.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
See the brake pedal sdjustment procedure (on page 8-28) for adjustment after installation.
Carry out air bleeding (on page 8-1 8).
DISASSEMBLY-INSPECTION-REASSEMBLY
T = N.m (kgf-cm) [ft-lbfl
Disassembly Procedure
1
2
3
4
Turn up
Remove
Remove
Remove
the
the
the
the
boot and remove the snap ring t o remove the push rod.
piston, spring and valve.
end cap.
cylinder cup and spacer.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Coat rubber grease on the cup portion of the piston before reassembly.
8-24
PARKING BRAKE
COMPONENTS
KEY POINTS IN SERVICE JOBS
7
1.
Parking brake knob (A) removal and installation procedure:
(1) Remove the lever.
(2) Immerse the knob in hot water ( 7 0 - 80°C (1 58
water at 1 OO°C (212OF) or above.)
(3) Remove knob set screw (B).
(4) Extract the knob upward.
(5) Operate in the reverse order for installation.
2.
-
176OF)) for 1 0 t o 2 0 seconds. (Do not use
Key points for reassembly
(1)
(2)
(3)
(4)
(5)
Coat grease on the link pin and moving surface (C).
Coat grease on the rod threaded portion (Dl.
Sufficiently apply M P grease at the compression spring installing portion (El.
Coat thread tightener (08833-00070) on the threaded portion (F).
After fully tightening knob (GI,return it by a half turn, and tighten knob (HI.
Tightening torque T = 9.81
15.69 N-m (100
160 kgf-cm) r7.24
11.58 ft-lbfl
-
-
-
3.
Lock parking cable set dimention (L) on each of the left and right sides t o the following value:
L = 0
2 mm ( 0
0.08 in)
4.
Adjust the parking brake lever operating force. (See page 8-26.)
-
-
ADJUSTMENT
1.
Adjust the parking brake lever operating force.
( 1)
Set a spring scale at the center of the lever knob and
pull i t backward t o measure the operating force.
Operating force
1 ton series:
147
196 N (15
2 0 kgf) 133
44 Ibf]
2 . 3 ton series:
196
245 N (20
2 5 kgf) 144
5 5 lbf]
(2) When the operating force does n o t satisfy the standard, turn the knob at the end o f the lever for
adjustment.
Make adjustment while the brake is released.
-
-
-
-
-
Clockwise turn: To increase the operating force.
Counterclockwise turn: To decrease the operating
force.
8-27
BRAKE PEDAL
COMPONENTS
ADJUSTMENT
Brake Pedal (Inching Pedal) Adjustment
Note:
When the pedal needs to be pushed all the way, torque converter inching cable shall be disconnect from
at torque converter F portion.
Stopper bolt
1.
Adjust the brake pedal height and play.
Adjust the stop lump switch (OPT) or stopper bolt length (dimension C ) to mark the brake pedal
height (dimension A or B) safety the standard below.
(2) Adjust the push rod length t o mark the brake pedal play (dimension D) safety the standard below.
(1
2.
Adjust the inching cable.
( 1 ) Adjust t o dimension E with the adjusting nut "G".
Unit:
A
C
(Reference)
B
137 - 142 142 - 147
(5.39 (5.59
5.59)
5.79)
-
D
-
(0.39)
10
20
(0.39 0.79)
rnm (in)
E*
(Reference)
13
(0.51)
A:
B:
C:
D:
Dimension without pad
Dimension with pad
Reference dimension
Pedal play
* After connecting "F", tighten the nut
"G", as keeping the wire in free state.
BODY
Page
COMPONENTS ....................................................9-2
ENGINE HOOD LOCK CABLE ..............................9-7
...........................................................9-7
INSTALLATION .................................................... 9-7
BALANCE WEIGHT ............................................ 9-7
REMOVAL.INSTALLATION .................................... 9-7
HOISTING THE VEHICLE ....................................9-8
COMBINATION METER .......................................9-9
REMOVAL. INSTALLATION .................................... 9-9
FUEL SENDER GAGE ..........................................9-1 I
INSPECTION ........................................................ 9-1 I
FUSE ....................................................................9-1 2
REMOVAL
COMPONENTS
Caution:
Renew all the warning and caution indicators or labels when replacing the overhead
guard.
Overhead guard set bolts tightening torque
T = 102.97
122.58 N - m (1050
1250 kgf-cm) [75.97
90.44 ft-lbf]
-
-
-
.
\,,
,
ENGINE HOOD LOCK CABLE
To steering lock
Hand bra
bracket
REMOVAL
1.
Open the engine hood.
2.
Remove the toe board.
3. Remove the engine hood lock cable.
Loosen the cable lock nut and disconnect the end of
the cable from the hood lock hook on the lever side.
(2) Disconnect the end of the cable from the stopper plate
on the engine hood side.
( 1)
Engine hood lock
:I
E n g ~ n ehood
D l r e c t ~ o nof
adjustment
Striker
Return sprtng
INSTALLATION
The installation procedure is the reverse of the removal
procedure.
Note:
Apply grease t o the lever pin and the stopper plate portion
in sliding contact with the hood.
Action when the engine hood cannot be opened.
When the engine hood cannot be opened because of disconnection of the engine hood lock cable or other reason, release
the stopper by inserting a thin strip as illustrated.
BALANCE WEIGHT
REMOVAL-INSTALLATION
1.
Remove the radiator cover.
2.
Hook the wire rope in the hoisting hole provided on top
of the weight.
Caution:
Use a wire rope having sufficient strength. (See page 0-12
for the weight of the balance weight and page 0-11 for the
safe load for each wire rope.)
3. Remove the weight set bolts and remove the weight.
4.
The installation procedure is the reverse of the removal
procedure.
9-8
HOISTING THE VEHICLE
When hoisting the vehicle, use the mast hook on the
front of the vehicle and a wire net on the rear wheel.
Caution:
Use wire ropes having sufficiation strength.
Never hoist the forklift by the weight hook holes or head
guard.
C O M B I N A T I O N METER
REMOVAL- INSTALLATION
1
5
Tilt steering
Combination meter wiring
Removal Procedure
1
Tilt the tilt steering post backward.
2
Remove the steering column cover. [Point 11
3
Remove the combination meter cover.
4
Remove the combination meter set bolts.
5
Disconnect the combination meter wiring.
6
Remove the combination meter ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operation
[Point 11
Disassembly:
Hold the steering column cover by applying
forces from the top and bottom for removal.
FUEL SENDER GAGE
INSPECTION
1.
Measure the resistance.
( 1) Check t o see that the float moves smoothly.
(2) Measure the resistance between the sender positive terminal and sender negative (body grounding) terminal while the float position is moved from point F t o point E. Also check continuous
variation of the resistance value.
Note:
Measure with the float being lowered in the direction from point F to point E.
The resistance at each of point F and point E shall be measured with the arm in contact with the stopper.
Standard
F
1 I2
E
198
Resistance
rnrn (in)
Float position
+
8 (7.80
&
0.31)
322 (12.68) (Reference valve)
414
+
8 (16.30
+
0.31)
Q
3 + 2
32.5 (Reference valve)
110
&
7
FUSE
Portions protected by fuses
No.
Name
Capacity
Main protected portion
@
HORN
7.5A
Horn
@
ENGINE
7.5A
I.I.A. and fuel cut solenoid
0
0
-
-
-
-
-
-
@
STOP
7.5A
Stop lamp
@
TURN
7.5A
Turn signal lamp and turn signal flasher
@
LAMP
*OA
Head lamps, clearance lamps, tail lamps, rear working lamp and
meter lamps
@
METER
15A
Alternator, water temperature meter, fuel meter, glow indicator
lamp, hour meter and warning lamps (engine oil pressure, charge,
brake, air cleaner, fuel and cooling water)
MATERIAL HANDRING SYSTEM
Page
HYDRAULIC SYSTEM DIAGRAM ....................... 10-2
COMPONENTS ....................................................10-3
RETURN FILTER SUCTION FILTER .....................10-7
rn
REMOVAL.INSTALLATION ....................................10-7
NATURAL DROP TEST .......................................10-8
NATURAL FORWARD TILT TEST ....................... 10-8
OIL LEAK TEST ................................................... 10-9
.................................................... 10-9
TILT CYLINDER ....................................................10-9
LIFT CYLINDER
10-2
HYDRAULIC SYSTEM DIAGRAM
(1) Inching and brake pedal
(8) Oil control valve
(2) Reservoir tank
(9) Lift cylinder
(3) Brake master cylinder
( 1 0 ) Tilt cylinder
(4) Brake wheel cylinder
/ 1 1 ) Steering valve
(5)Oil tank
( 12) Power steering cylinder
( 6 ) Oil pump
(7)Flow divider
COMPONENTS
---
V (2.3ton series)
-
---
--
-
V ( 1 ton series).FV ( 1
-
3 ton series)
RETURN FILTER-SUCTION FILTER
REMOVAL- INSTALLATION
I
1
Breather
Removal Procedure
1
Disconnect the hydraulic oil breather from the air cleaner.
2
Disconnect the hoses (control valve t o tank hose) from the tank side.
3
Remove the tank cover Wheturn filter.
4
Disconnect the return filter.
5
Disconnect the hose (tank t o oil pump hose) from the tank.
6
Remove the set nut on the side of the tank and remove the pipe Wlsuction filter.
7
Disconnect the suction filter.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
I
NATURAL DROP TEST
1.
Set the mast in the vertical position with the standard
load on the fork. Lift the fork by 1 t o 1.5 m (40 t o 59
in), and stop the engine.
2.
Draw datum lines on the inner and outer masts, and
measure the drop in 15 minutes.
-
Vehicle model
Natural drop amount
m m (in)
1 ton series
9 0 (3.54) or less
2 t o n series
t
3 t o n series
t
NATURAL FORWARD TILT TEST
1.
Set the mast in the vertical position with standard load
on the fork. Lift the fork by about 50 cm (19.7 in) and
stop the engine.
2.
Measure the tilt cylinder rod extension in 15 minutes.
Vehicle model
Natural forward tilt amount
m m (in)
1 ton series
3 0 (1.18) or less
2 t o n series
45 (1.77) or less
3 ton series
t
OIL LEAK TEST
LIFT CYLINDER
1.
Set the mast in the vertical position with the standard
load on the fork. Lift the fork by 1 t o 1.5 m ( 4 0 to 5 9 in).
2.
Slowly tilt the mast fully forward, and stop the engine.
After 5 minutes, disconnect the oil control valve t o oil
tank hose. Place a measuring cylinder under the elbow
and measure the amount of oil leaking in one minute.
Standard oil leak amount (at lift port):
16 cc (0.98 cu-in) or less
Note:
If the natural drop is great even though the oil leak amount
is within the standard, the lift cylinder packing is defective.
TILT CYLINDER
1.
Set the mast in the vertical position with standard load
on the fork. Lift the fork by about 5 0 c m ( 19.7 in) and
stop the engine.
2.
After waiting for 5 minutes, disconnect the oil control
valve t o oil tank hose. Place a measuring cylinder under
the elbow and measure the amount of oil leaking in one
minute.
Standard oil leak amount (total for lift and tilt):
32 cc (1.95 cu-in) or less
3. The leak amount at the tilt port is the total leak amount
less the leak amount from the lift port.
Note:
If the natural forward tilt is great even though the oil leak
amount is within the standard, either the tilt lock valve or the
tilt cylinder packing is defective.
MAST
Page
V MAST ASSY .................................................. 11-2
.................................................. 11-2
REMOVAL. INSTALLATION .................................. 11-5
COMPONENTS
MAST DISASSEMBLYINSPECTION.REASSEMBLY
.............................. 11-7
LlFT BRACKET DISASSEMBLY .
INSPECTION"REASSEMBLY ...............................11-9
.......................................... 1 1-1 1
CHAIN ................................................................ 11-17
INSPECTION .................................................. 1 1-1 7
REASSEMBLY .................................................... 1 1-1 7
ADJUSTMENT ................................................. 1 1-18
FORK ................................................................. 1 1-18
MAST ADJUSTMENT
..................................................... 1 1-18
FV MAST ASSY ................................................ 11-19
COMPONENTS ................................................... 1 1-1 9
MAST ADJUSTMENT .......................................... 1 1-21
FSV MAST ASSY .............................................. 11-25
COMPONENTS ................................................... 1 1-25
MAST ADJUSTMENT .......................................... 1 1-27
INSPECTION
LlFT CYLINDER ROD SHIM
ADJUSTMENT ................................................ 11-31
V MAST ASSY
COMPONENTS
6101
1
1 - 2 ton series
3 ton series
6302
REMOVAL-INSTALLATION
0
0
1
5
Mast position
Piping
Removal Procedure
1
Set the mast vertical and lower the bottom position.
2
Disconnect the chain.
3
Remove the chain wheel. [Point 11
4
Remove the lift bracket. (Raise the inner mast until it comes off from the lift bracket, and slowly
move the vehicle in the reverse direction t o depart from the lift bracket. Then stop the engine.)
5
Disconnect the piping.
6
Slightly hoist the mast.
7
Remove the mast support caps.
8
Remove the tilt cylinder front pin. [Point 21
9
Remove the mast ASSY.
Installation Procedure
The installation procedure is the reverse o f the removal procedure
Note:
Apply MP grease on the interior surface of the mast support bushing, inner surface of the mast support cap and tilt cylinder front pin.
Mast support cap set bolt tightening torque:
T = 68.65
107.87 N - m (700
1 1 0 0 kgf-cm) [50.65
79.59 ft-lbfl
If any of the mast ASSY, outer mast, inner mast and lift cylinder is replaced, it is necessary to inspect
and adjust uneven motion of the lift cylinder. See the lift cylinder rod shim adjustment section (on
page 1 1 -31) for the inspection and adjustment method.
0 Adjust the chain tension. (See page 11-18)
-
-
-
Point Operations
[Point 1I
Removal:
Installation:
Use the SST for removal if the fitting is tight.
SST 09950-4001 0
Install the chain wheel w i t h its side having
greater radius at the periphery of its hole facing the boss of the mast side pin.
[Point 21
Removal:
SST 0981 0-201 72-71
MAST DISASSEMBLY. INSPECTION. REASSEMBLY
2 Hoses and flowregurator housing
Disassembly Procedure
1
Remove the hose cover.
2
Remove the hoses and flowregurator housing.
3
Remove the cylinder rod end set bolt and disconnect the rod end. [Point 11
4
Remove the cylinder support. [Point 21
5
Remove the cylinder bottom set bolts and remove the lift cylinder.
6
Slide the inner mast in the lowering direction and remove the lift rollers.
7
Remove the mast strip. [Point 31
8
Remove the outer mast.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 1I
Disassembly:
Shim adjustment has been made a t the lift
cylinder rod end for prevention of cylinder uneven motion between the left and right sides.
Take a note on which side the shim adjustment is made and the number o f shims used.
[Point 21
Disassembly:
Take a note on the number o f cylinder support shims used.
Reassembly:
When the mast or cylinder is replaced, make
shim adjustment at the cylinder support. With
the cylinder rod end inserted t o the inner mast,
eliminate the clearance between the cylinder
support and outer mast b y inserting shims.
The shim thickness should be slightly thicker.
[Point 31
Inspection:
Measure the mast strip thickness.
Thickness limit:
A = 2.7 m m (0.106 in)
B = 1.3 m m (0.051 in)
LIFT BRACKET DISASSEMBLY.INSPECTION-REASSEMBLY
Disassembly Procedure
1
Remove the lift rollers. [Point 11
2
Remove the side rollers. [Point 21
3
Remove the back rest.
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
1 8 4 . 8 6 N m m( 1 0 1 5
Back rest set bolt tightening torque T = 9 9 . 5 4
173.44
1 3 6 . 3 8 ft-lbf]
-
-
-
1 8 8 5 kgf-cm)
1 1 -1 0
Point Operations
[Point 1 I
Disassembly:
SST 09950-4001 0
[Point 21
Reassembly:
Do not mistake the side roller mounting
direction.
The side where the chamfering radius of the
roller outer circumference shall face the front
side.
MAST ADJUSTMENT (V MAST)
Mast Lift Roller Adjustment
lnner mast
ring into contac
This roller
Bring into contact
1,
lnner mast roller clearance adjustment
( 1 ) Measure the clearance with the mast overlap at near
450 mm (17.72 in).
(2) Shift the inner mast t o one side t o bring the roller into
contact with the outer mast, and adjust the clearance
between the roller side face and mast at the closest
position on the opposite t o the following value by inserting the inner mast roller shim.
-
Standard clearance A = 0
0.8 rnrn
(0
0.031 in)
Shim thickness: 0.5 and 1.O rnm
(0.020 and 0.039 in)
-
(3) Distribute the shim thickness equally t o the left and
right rollers. (See the "mast roller removal.installation" section for the shim replacement procedure.)
(4) After the adjustment, check that the inner mast
moves smoothly in the outer mast.
This roller
A
Bring into contact
2.
All
Outer mast
Inner mast
Outer mast roller clearance adjustment
(1) Measure the clearance with the mast overlap at near
450 m m ( 17.72 in).
(2) Shift the inner mast t o one side t o bring the roller into
contact with the outer mast, and adjust the clearance
between the roller side face and mast at the closest
position on the opposite side t o the following value
by inserting the outer mast roller shim:
Standard clearance B = 0
-
0.5 m m
(0 0.020 in)
Shim thickness: 0.5 and 1.0 m m
(0.020and 0.039 in)
-
(3) Distribute the shim thickness equally t o the left and
right sides. (See the "mast roller removal- installation"
section for the shim replacement procedure.)
(4) After the adjustment, check that the inner mast
moves smoothly in the outer mast.
Mast Roller Removal.lnstallation
I
1.
Remove the lift bracket. (See the mast ASSY removal
procedure steps 1 t o 4 on page 11-5.)
2.
Jack up the vehicle and support the tires w i t h wooden
blocks. Lock the front and rear tires t o prevent rotation.
3.
Tilt the lift cylinder.
( 1) Remove the hose cover at the bottom of the mast and
disconnect the lift cylinder hose on the LH side.
( 2 ) Remove the lift cylinder bottom set bolts.
( 3 ) Sling the innder mast upper tie beam with a wire and
slightly hoist it.
(4) Remove the lift cylinder rod end set bolts, and disconnect the rod end by hoisting the inner mast.
( 5 ) Remove the lift cylinder support.
(6) Tilt the lift cylinders LH and RH and tie them w i t h
ropes t o the outer mast tie beam.
4.
Remove the mast rollers.
( 1) Lower the hoisted inner mast slowly until mast rollers
are visible, and support the bottom w i t h wooden
blocks.
(2) Remove the inner mast rollers and shims.
(3) Remove the outer mast rollers and shims.
5.
The installation procedure is the reverse of the removal
procedure.
Shim
,
Lift Bracket Roller Adjustment
100 mm (3.44 in)
Bracket
Outer mast
Inner mast
1.
Lift roller and side roller clearance adjustment
Measure the clearance when the center of the lift
bracket upper side roller is 100 m m (3.93 in) from the
top of the inner mast.
(2) The upper lift rollers need no adjustment because they
are fixed by snap rings.
(3) Measure the clearances at the middle and lower lift
rollers after removing the side rollers.
Shift the lift bracket t o one side t o bring the roller into
contact with the inner mast, and measure the clearance between the roller side face and the mast at the
closest position on the opposite side t o the following value by inserting the lift roller shim.
(1
-
Standard clearance C = 0
0 . 8 mm
(0
0 . 0 3 1 in)
Shim thickness: 0 . 5 and 1 . 0 mm
( 0 . 0 2 0 and 0 . 0 3 9 in)
-
(4) Distribute the shim thickness equally t o the left and
right sides. (For the shim replacement procedure, see
the lift bracket disassembly section on page 11-9.)
( 5 ) Install the side rollers.
( 6 ) Side roller adjustment shall be made after adjusting
the middle and lower lift rollers.
Bring the side roller on one side into contact with the
mast side surface, and make adjustment by shim insertion t o make the clearance between the side roller
and inner mast side surface on the opposite side satisf y the following standard.
-
Standard clearance D = 0
0 . 6 mm
(0
0 . 0 2 4 in)
Shim thickness: 0.5 and 1 . 0 mm
( 0 . 0 2 0 and 0 . 0 3 9 in)
( 7 ) The shim thickness shall be distributed equally into
the left and right sides. (Shim replacement is possible on the vehicle. For the side roller installation, see
the lift bracket disassembly section on page 11-9.)
-
2.
After the adjustment, the lift bracket should move
smoothly along the overall mast length.
Mast Strip Adjustment
1.
Mast strip clearance adjustment
( 1) Measure the clearance w i t h the inner mast a t the bott o m position.
(2) W i t h the inner mast in contact w i t h the outer mast
roller, adjust the clearance between the mast strip and
inner mast t o the following value b y inserting the
mast strip shim. (The shim replacement procedure is
the same as that described in the " mast roller
removal -installation" section on page 1 1-1 3.)
-
Standard clearance E = 0 . 5
1 .O mm
0 . 0 3 9 in)
(0.020
Shim thickness: 0 . 5 and 1 . 0 mm ( 0 . 0 2 0 and
0 . 0 3 9 in)
-
(3) A f t e r t h e adjustment, t h e m a s t should move
smoothly.
Note:
Make sure the direction of taper of the mast strip to install.
The higher tapered side should be faced out side. (See the
upper illustration)
CHAIN
INSPECTION
1.
I n s p e c t t h e c h a i n elongation.
SST 09631-22000-7 1
Note:
When inspecting the chain elongation, use the SST above
and inspect without removal from the vehicle.
Standard chain link pitch.
1 ton series: 15.88 m m (0.6252 in) (Type: BL534)
2 ton series: 19.05 m m (0.7500 in) (Type: BL634)
3 ton series: 25.4 m m (1.000 in) (Type: BL823)
REASSEMBLY
mast and
portion
FV: Lift bracket
FSV: Lift bracket
V: Lift bracket
Center of
vehicle
Outside of
vehicle
0
Cotter pin
FSV: Inner mast
Rear of
vehicle
0
Cotter ptn
Sketch
Install w i t h the cotter pin on the
vehicle center side.
c=
Cotter pin
Install w i t h the cotter pin on the
vehicle outside.
Install w i t h the cotter pin on the
vehicle rear side.
Chain Adjusting Nut Tightening Sequence
1
Tighten n u t @ and
0.
Tightening torque T
= 49.03
-
78.45 N.m (500
-
8 0 0 kgf-cm)
136.18 - 57.88 ft-lbfl
2
Tighten n u t
Applicable
mast and
portion
Sketch
0.
V: Outer mast
FV: Front cylinder
( 1- 2 t o n series)
FSV: Front cylinder
( 1 . 2 t o n series)
FV: Front cylinder
( 3 t o n series)
FSV: Front cylinder
( 3 t o n series)
::
0
A
\LJ
FSV: Outer mast
Clamp
11-18
ADJUSTMENT
1
Place the vehicle on a flat ground, and set the mast in the vertical position.
2
After moving the fork up and down several times without a load, check that the chain tension on
the left and right sides are equal.
3
Turn the adjusting nut so that the fork bottom surface is about t o come into contact with the ground
surface without slackening the chain.
4
Check the chains for equal tension on the left and right sides.
5
Check that the chains are not twisted
6
Check that the maximum fork height is as specified.
FORK
REMOVAL
1.
Position the fork at 20 c m (7.9 in) above the ground.
2. Place a wooden block under the notched portion of the
fork rail.
3.
Unlock after lifting the fork stopper pin, and shift the fork
blades one by one t o the center.
4.
Gradually lower the fork and remove it.
INSTALLATION
The installation procedure is the reverse of the removal
procedure.
INSPECTION
1.
Inspect the fork.
Fork tip end limit misalignment:
10 mm (0.39 in)
Note:
If the tip end limit misalignment is exceeded, inspect the bend,
fork mounting looseness and lift bracket finger bar distortion
for each blade.
FV MAST ASSY
COMPONENTS
MAST ADJUSTMENT (FV MAST)
Mast Lift Roller Adjustment (FV)
lnner mast
Outer
Bring into contact
This roller
1.
lnner mast roller clearance adjustment
( 1 ) Measure the clearance with the mast overlap at near 450 m m ( 1 7.72 in).
(2) Shift the inner mast t o one side t o bring the roller into contact with the outer mast, and adjust
the clearance between the roller side face and mast at the closest position on the opposite side
t o the following value by inserting the inner mast roller shim.
-
-
Standard clearance A = 0
0 . 8 mm (0
0.031 in)
Shim thickness: 0 . 5 and 1.0 mm ( 0 . 0 2 0 and 0 . 0 3 9 in)
(3) Distribute the shim thickness equally t o the left and right rollers.
(4) After the adjustment, check that the inner mast moves smoothly in the outer mast.
This roller
fi
Bring into contact
Outer mast
Bring into contact
2.
Inner mast
Outer mast roller clearance adjustment
(1) Measure the clearance w i t h the mast overlap at near 4 5 0 m m ( 17.72 in).
(2) Shift the inner mast t o one side t o bring the roller into contact with the outer mast, and adjust
the clearance between the roller side face and mast at the closest position on the opposite
side t o the following value by inserting the outer mast roller shim:
-
-
Standard clearance B = 0
0 . 5 mm (0
0 . 0 2 0 in)
Shim thickness: 0 . 5 and 1.0 mm (0.020 and 0 . 0 3 9 in)
(3) Distribute the shim thickness equally t o the left and right rollers.
(4)
After the adjustment, check that the inner mast moves smoothly in the outer mast.
Lift Bracket Roller Adjustment (FV)
rt1
Lower lift roller
100 m m (3.94 in)
+
bracket
1.
Lift roller and side roller clearance adjustment
(1) Measure the clearance when the center of the lift bracket upper side roller is 1 0 0 rnm (3.94 in)
from the top of the inner mast.
( 2 ) The upper and middle lift rollers need no adjustment because they are fixed by snap rings.
(3) For the lower lift roller, shift the lift bracket t o one side t o bring the roller into contact with the
inner mast, and adjust the clearance between the roller side face and the mast at the closest
position on the opposite side t o the following value by inserting the lift roller shim.
-
-
0 . 5 m m (0
0.020 in)
Standard clearance C = 0
Shim thickness: 0.5 and 1.0 m m (0.020 and 0.039 in)
(4) Distribute the shim thickness equally to the left and right sides.
(5) Adjust the side rollers after adjusting the lower lift rollers. Bring the side roller on one side into
contact with the mast side surface and adjust the clearance between the side roller and inner
mast on the opposite side t o the following value by inserting the side roller shim:
-
-
Standard clearance D = 0
0.6 m m ( 0
0.024 in)
Shim thickness: 0.5 and 1.0 m m (0.020 and 0 . 0 3 9 in)
(6) Distribute the shim thickness equally t o the left and right side rollers.
2.
After the adjustment, the lift bracket should move smoothly along the overall mast length.
Mast Strip Adjustment (FV)
1.
M a s t strip clearance adjustment
( 1 ) Measure the clearance w i t h the inner mast a t the b o t t o m position.
(2) W i t h the inner mast in contact w i t h the outer mast roller, adjust the clearance between the mast
strip and inner mast t o the following value b y inserting the mast strip shim.
-
-
Standard clearance E = 0 . 5
1.0 mm (0.020
0.039 in)
0
.
5
and
1.0
mm
(0.020
and
0
.
0
3
9 in)
Shim thickness:
(3) After the adjustment, the mast should move smoothly
--
FSV MAST ASSY
COMPONENTS
1.2 ton series
MAST ADJUSTMENT (FSV MAST)
Mast Lift Roller Adjustment (FSV)
Outer mast
lnner mast
This roller
1.
lnner mast roller and middle mast lower roller clearance adjustment.
(1) Measure the clearance w i t h the mast overlap at near 450 m m ( 17.72 in).
(2) Shift the inner mast t o one side t o bring the roller into contact w i t h the outer mast and the middle mast, and adjust the clearance between the roller side face and mast at the closest position
on the opposite side t o the following value b y inserting the inner mast roller shim and middle
mast lower roller shim, respectively.
-
-
Standard clearance A = 0
0 . 8 mm ( 0
0 . 0 3 1 in)
Shim thickness: 0 . 5 and 1 . 0 mm ( 0 . 0 2 0 and 0 . 0 3 9 in)
(3) Distribute the shim thickness equally t o the left and right rollers.
(4) After the adjustment, check that the inner mast moves smoothly in the middle mast, and the
middle mast moves smoothly in the outer mast.
This roller
Outer
Middle
Inner
2.
Outer mast roller and middle mast upper roller clearance adjustment.
( 1 ) Measure the clearance with the mast overlap at near 450 m m ( 1 7 . 7 2 in).
(2) Shift the inner mast t o one side t o bring the roller into contact with the inner mast and middle
mast, and adjust the clearance between the roller and mast at the closest position on the opposite side t o the following value by inserting the outer mast roller shim and middle mast upper
roller shim respectively.
-
-
Standard clearance B = 0
0 . 5 mm (0
0 . 0 2 0 in)
Shim thickness: 0 . 5 and 1.0 mm (0.020 and 0 . 0 3 9 in)
(3) Distribute the shim thickness equally t o the left and right sides.
(4) After the adjustment, check that the inner mast moves smoothly in the middle mast and the
middle mast moves smoothly in the ounter mast.
- -
-
Lift Bracket Roller Adjustment (FSV)
Lower lift roller
Lift Bracket
/
Bring into contact
1.
Lift roller and side roller clearance adjustment
( 1 ) Measure the clearance with the lift bracket at the uppermost position.
(2) The upper lift rollers need no adjustment because they are fixed by snap rings.
(3) For the lower lift rollers, shift the lift bracket t o one side t o bring the roller into contact with
the inner mast, and measure the clearance between the roller side face and the mast at the closest
position on the opposite side t o the following value by inserting the lift roller shim.
-
-
Standard clearance C = 0
0 . 5 mm (0
0 . 0 2 0 in)
Shim thickness: 0 . 5 and 1 . 0 mm ( 0 . 0 2 0 and 0 . 0 3 9 in)
(4)
(5)
Distribute the shim thickness equally t o the left and right rollers.
Adjust the side rollers after adjusting the lower lift rollers.
Bring the side roller on one side into contact with the mast side surface, and adjust the clearance between the side roller and inner mast side surface t o the following value by inserting the
side roller shim:
-
- 0 . 0 2 4 in)
Standard clearance D = 0
0 . 6 mm ( 0
Shim thickness: 0 . 5 and 1 . 0 mm ( 0 . 0 2 0
-
0 . 0 3 9 in)
(6) Distribute the shim thickness equally t o the left and right sides.
2.
After the adjustment, the lift bracket should move smoothly along the overall mast length.
Mast Strip Adjustment (FSV)
I
I
Middle mast
1.
Mast strip clearance adjustment
(1) Measure the clearance with the inner mast or middle mast at the bottom position.
(2) With the inner mast in contact w i t h the middle mast upper roller, adjust the clearance between
the mast strip and inner mast t o the value shown below by inserting the mast strip shim.
Then, with the middle mast in contact with the outer mast roller, adjust the clearance between
the mast strip and the middle mast t o the value shown below by inserting the mast strip shim.
-
-
1.0 mm (0.020
0.039 in)
Standard clearance E = 0 . 5
Shim thickness: 0.5 and 1.0 m m (0.020
0.039 in)
-
(3) After the adjustment, the mast should move smoothly
LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN
LIFTING)
Note:
For double lift cylinders, inspection and adjustment are required to prevent uneven lifting on the left
and right sides due to tolerances of parts, etc.
The inspection and adjustments must be made whenever any of the following parts is replaced: Lift
cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY,
and inner mast SUB-ASSY.
1.
Inspection method
Slowly raise the inner mast, and observe the stopping
states of the left and right cylinder rods at the moment
when the inner mast reaches the maximum height.
( 1 Normal case
Both the left and right rods stop almost simultaneously with almost no shaking of the inner mast.
( 2 ) Abnormal case
The rods stop with slight difference and the top of
the inner mast shakes at the time of stopping. To correct this, add shims t o the cylinder that stops first.
2.
Adjustment method
( 1 ) Raise the inner mast, set the SST t o the outer mast
tie beam, and lower the inner mast until it reaches
the SST.
SST 0961 0-22000-71
(2) Remove the set bolt of the cylinder rod end on the
side requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
Place
shims on the cylinder rod end. Slowly raise the
(4)
cylinder rod end into the inner mast.
(5) Fix the set bolt of the cylinder rod end.
(6) Raise the inner mast for reinspection.
(7) Repeat the inspection and adjustment until the number of shims is determined.
Shim thickness:
0.5 and 1.0 mm (0.020 and 0.039 in)
CYLINDER
Page
LlFT CYLINDER (V).
REAR LIFT CYLINDER (FV. FSV) .................... 12-2
.......................................................... 12-2
SPECIFICATIONS .............................................. 12-4
COMPONENTS ................................................... 12-5
GENERAL
REMOVAL. INSTALLATION
.................................. 12-8
DISASSEMBLY INSPECTION- REASSEMBLY
(V.FV(LH).FSV) ........................................ 12-10
DISASSEMBLY . INSPECTION REASSEMBLY
(FV(RH)) ........................................................ 12-1 2
FLOW REGULATOR VALVE (V.FV. FSV)
.......... 12-14
REMOVAL. INSTALLATION
.................................. 12-15
SAFETY DOWN VALVE (V.FVm
FSV) ................ 12-16
REMOVAL. INSTALLATION .................................. 12-17
FRONT LIFT CYLINDER (FVm
FSV)
GENERAL
..................... 12-18
.........................................................
SPECIFICATIONS
12- 18
............................................... 12-19
................................................... 12-20
REMOVAL. INSTALLATION .................................. 12-21
COMPONENTS
TILT CYLINDER ( V m
FVm
FSV)
GENERAL
.............................
12-23
......................................................... 12-23
................................................ 12-23
COMPONENTS .................................................. 12-24
REMOVAL. INSTALLATION .................................. 12-25
SPECIFICATIONS
DISASSEMBLY .INSPECT10NmREASSEMBLY
........... 12-27
LlFT CYLINDER (V).REAR LlFT CYLINDER (FV.FSV)
GENERAL
Lift Cylinder (V)
Safety down valve
Rear Lift Cylinder (FV)
Safety down valve
Rear Lift Cylinder (FSV)
12-4
SPECIFICATIONS
Lift Cylinder (V)
Vehicle model
1 ton series
2 ton series
3 t o n series
Single acting
t
t
m m (in)
4 4 . 4 5 (1.750)
5 0 (1.97)
5 5 (2.17)
Piston rod outside diameter
m m (in)
34.93 (1.375)
4 2 (1.65)
4 5 (1.77)
Piston seal type
U packing
t
t
Rod seal type
U packing
+-
+
With safety down valve
t
t
1 ton series
2 ton series
3 ton series
Single acting
+-
t
m m (in)
4 5 (1.77)
5 0 (1.97)
5 5 (2.17)
Piston rod outside diameter
m m (in)
3 2 (1.26)
3 4 . 9 (1.374)
40 (1.57)
Rod seal type
U packing
t
+-
With safety d o w n valve (LH)
+
t
1 ton series
2 t o n series
3 ton series
Single acting
t
4-
m m (in)
44.45 (1.750)
5 0 (1.97)
55 (2.17)
Piston rod outside diameter
m m (in)
3 4 . 9 3 (1.375)
4 2 (1.65)
4 5 (1.77)
Piston seal type
U packing
t
t
Rod seal type
U packing
t
+-
With safety d o w n valve
t
t
Lift cylinder type
Lift cylinder bore
-
Others
Rear Lift Cylinder (FV)
Vehicle model
Lift cylinder type
Lift cylinder bore
Others
Rear Lift Cylinder (FSV)
Vehicle model
Lift cylinder type
Lift cylinder bore
Others
COMPONENTS
Lift Cylinder (V)
12-6
Rear Lift Cylinder (FV)
Rear Lift Cylinder (FSVI
REMOVAL- INSTALLATION
I
1
Lift bracket
1
Removal Procedure
1
Remove the lift bracket. (See removal procedure steps 1 to 4 in mast removal-installation section
on page 1 1-51
2
Remove the piston rod end set bolt and cylinder bottom set bolt.
3
Disconnect the piston rod end. [Point 11
4
Remove the hose cover.
5
Disconnect the hose.
6
Remove the lift cylinder support. [Point 21
7
Remove the lift cylinder ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Perform the following operations after installing the lift cylinder:
Repeat lifting and lowering to stroke ends without load to bleed the air and to check normal operation.
After the operation check, check the hydraulic oil level and add oil if insufficient.
Inspect the lift cylinders for uneven movements and make adjustment if necessary. (See the lift cylinder
rod shim adjustment section on page 11-31 1
Point Operations
[Point 1I
Removal:
Hoist the inner mast (middle mast) and set the
SST t o the inner mast (middle mast) tie beam.
SST 0961 0-22000-7 1
Removal:
Shim adjustment is made at the lift cylinder rod
end t o prevent uneven movements of the lift
cylinders RH and LH. Take a note on which side
the adjustment is made and the number of shims
used.
[Point 21
Shim
Installation:
The cylinder support shall be tightened temporarily here and make shim adjustment after
rod end connection.
Adjustment:
With the rod end connected, insert shims between the cylinder support and outer mast t o
eliminate the clearance. The shim thickness
shall be slightly on the thicker side.
DISASSEMBLY. INSPECTION- REASSEMBLY (V-FV(LH)-FSV)
Note:
Oil will leak if the U packing or dust seal at the rod guide portion is defective.
Natural drop will occur if the U packing at the piston portion is defective.
Disassembly Procedure
1
Remove the safety d o w n valve.
2
Remove the cylinder cover. [Point 11
3
Remove the piston rod Wlpiston. [Point 21
4
Remove the seals from the piston side.
5
Remove the check valve.
6
Remove the lift cylinder. [Point 31
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Do not install dry parts but apply hydraulic oil
Cylinder cover tightening torque
237 N-rn (17 3 0
1 ton series T = 170
2 ton series T = 203 - 271 N-rn (2070
3 ton series T = 237
305 N-rn (2420
-
-
before reassembly.
2420 kgf-crn) [ I 2 5
2760 kgf-crn) [ I 5 0
3 1 1 0 kgf-crn) [ I 7 5
- 175 ft-lbf]
- 200 ft-lbfl
- 225 ft-lbf]
Point Operations
[Point 1 I
Disassembly-Reassembly:
SST 09620-1 0100-71
[Point 21
Inspection:
Measure the piston rod outside diameter.
Unit: m m (in)
Inspection:
Measure the piston rod bend.
Limit bend:
2.0 m m (0.079 in)
[Point 31
Inspection:
Measure the lift cyinder bore.
Unit: rnm (in)
1 ton series
3 ton series
45.20 (1.7795)
DISASSEMBLY. INSPECTION- REASSEMBLY (FV (RH))
Note:
@ Oil will leak if the U packing or dust seal at the rod guide portion is defective.
0 Natural drop will occur if the U packing at the piston portion is defective.
Disassembly Procedure
1
Loosen the cylinder cover. [Point 11
2
Remove the cylinder cover and piston rod Wlpiston. [Point 21
3
Remove the seal from the piston side.
4
Remove the piston. [Point 31
5
Remove the lift cylinder. [Point 41
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Do not install dry parts but apply hydraulic oil
Cylinder cover tightening torque
1 ton series T = 170
237 N - m (1730
2 ton series T = 203
271 N - m(2070
3 ton series T = 237
305 N - m(2420
-
-
-
-
before reassembly.
2420 kgf-cm) [I25 - 175 ft-lbfl
2760 kgf-cm) [I50- 200 ft-lbfl
31 10 kgf-cm) [I 75 - 225 ft-lbfl
Point Operations
[Point 1 I
Disassembly. Reassembly:
SST 09620-1 01 00-7 1
[Point 21
Inspection:
Measure the piston rod outside diameter.
(See page 1 2-1 1
Inspection:
Measure the piston rod bend
(See page 1 2- 1 1 )
[Point 31
Disassembly. Reassembly:
Follow the procedure view
1.
Fix the boss portion at the tip end of the piston rod in
a vise.
2.
Use a screwdriver and rotate the piston t o remove the
wire.
3.
The installation procedure is the reverse.
[Point 41
Inspection:
Measure the lift cylinder bore.
(See page 1 2- 1 1 )
FLOW REGULATOR VALVE (V-FVmFSV)
Specifications
1 ton series
Maximum pressure kPa (kgf/cm*)[psil
Control flow rate
l l m i n (US gallmin)
2 ton series
3 t o n series
20590 (210)[29901
t
t
50 (13.2)
60 (15.8)
70 (18.5)
Unit: mmlsec (fpm)
Lowering Speed
V
FV
FSV
No load
550 (108)
420 (83)
450 (89)
Loaded
500 (98)
480 (94)
480 (94)
No load
500 (98)
420 (83)
450 (89)
Loaded
500 (98)
480 (94)
480 (94)
No load
500 (98)
390 (77)
420 (83)
Loaded
500 (98)
460 (91)
460 (91)
Vehicle model
1 ton series
2 t o n series
-
3 ton series
REMOVAL. INSTALLATION
Removal Procedure
1
Lower the fork t o the bottom piston.
2
Remove the flow regulator valve.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Flow regulator valve tightning torque
T = 58.8
68.6 N-rn (600
700 kgf-crn) i43.4
-
-
- 50.6 ft-lbfl
12-16
SAFETY DOWN VALVE (VmFV.FSV)
Safety Down Valve Sectional View (for V-FV-FSVRear Lift Cylinder)
Safety Down Valve Sectional View (for FV-FSV Front Lift Cylinder)
Specifications
V Lift Cylinder and FVmFSV Rear Lift Cylinder
-
1 ton series
2 t o n series
3 t o n series
Piston seat f l o w rate
Ilrnin (US gallrnin)
6 0 (15.8)
t
+
Control after piston seat
Ilrnin (US gallrnin)
1 5 (4.0)
+
+-
1 t o n series
2 ton series
3 ton series
t
1 2 0 (31.7)
t
1 5 (4.0)
FVaFSV Front Lift Cylinder
Piston seat f l o w rate
Ilrnin (US gallmin)
Control after piston seat
Urnin (US gallrnin)
8 0 ( 2 1 .'I)
19 (5.0)
REMOVAL INSTALLATION
s
Removal Procedure
1
2
3
Disconnect the piston rod end and hoist the inner mast. [Point 11
Remove the front cover
Disconnect the hoses and remove the safety d o w n valve. [Point 21
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[Point 1 I
Removal~installation: Sling the inner mast (middle rnast)
with a wire rope, and hoist it. Set the
SST on the inner mast (middle rnast)
tie beam and lower the inner mast until it comes into contact with the SST.
SST 0 9 6 1 0-22000-71
[Point 21
Inspection:
Check the safety d o w n valve orifice for
dogging.
12-1 8
FRONT LIFT CYLINDER (FV-FSV)
GENERAL
Front Lift Cylinder (FV)
Front Lift Cylinder (FSV)
SPECIFICATIONS
Vehicle model
1 ton series
2 ton series
3 ton series
Single acting
t
c
7 0 (2.76)
75 (2.95)
8 5 (3.35)
50.8 ( 2 . 0 0 )
t
c
Piston seal type
Wear ring
t
c
Rod seal type
U packing
+
+-
With safety d o w n valve
t
c
Cylinder type
Lift cylinder bore
mm (in)
Piston rod outside diameter
m m (in)
Others
COMPONENTS
FV mast
FSV mast
REMOVAL. INSTALLATION
Note:
9 See the lift cylinder ASSY (V) removal section for the removal of the front lift cylinder ASSY.
Perform the following operations after installation:
Repeat lifting and lowering t o stroke ends without load for air bleeding and check normal operation.
9 After the operation check, check the hydraulic oil level and add if insufficient.
9 Adjust the lift chain tension equally on the left and right sides.
DISASSEMBLY-INSPECTION-REASSEMBLY
Disassembly Procedure
1
Remove the safety down valve.
2
Remove the chain wheel supporter.
3
Remove the cylinder rod guide. [Point 11
4
Remove the piston rod Wlpiston. [Point 21
5
Remove the check valve.
6
Remove the lift cylinder. [Point 31
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Do not reassemble dry parts, but apply hydraulic oil before reassembly.
Rod guide tightening torque
3 7 3 N - m (31 10
3800 kgf-cm) [225
275 ft-lbf]
1 ton series T = 305
407 N-m (3460
4 1 5 0 kgf-cm) [250
3 0 0 ft-lbf]
2 ton series T = 3 3 9
4 5 4 N-rn (4280
4630 kgf-cm) [310
335 ft-lbf]
3 ton series T = 4 2 0
-
-
-
-
-
-
Point Operations
[Point 1 I
Disassembly- Reassembly:
SST 09620- 101 00-7 1
[Point 21
Inspection:
Measure the piston rod outside diameter.
Unit: m m (in)
Standard outside
diameter
Limit outside
diameter
1 ton series
50.8 (2.00)
50.72 (1.9968)
2 ton series
50.8 (2.00)
50.72 (1.9968)
3 ton series
50.8 (2.00)
50.72 (1.9968)
Inspection:
Measure the piston rod bend.
Limit bend:
2.0 rnrn (0.079 in)
[Point 31
Inspection:
Measure the lift cylinder bore.
Unit: m m (in)
I
1
2 ton series
1
Standard bore
/
Limit bore
I
/
75 (2.95)
1
75.35 (2.96651
1
--
3 ton series
85 (3.35)
85.40 (3.3622)
TILT CYLINDER ( V . F V . F S V )
GENERAL
SPECIFICATIONS
Vehicle model
Item
Cylinder type
1 t o n series
2 t o n series
3 t o n series
Double action
t
t
Cylinder bore
m m (in)
69.85 (2.750)
t
76.2 (3.00)
Piston rod outside diameter
m m (in)
31.75 (1.250)
t
t
Piston seal type
U packin
t
t
Rod seal type
U packin
+
t
COMPONENTS
1 2-25
REMOVAL. INSTALLATION
7 Piping
8 Mast
Removal Procedure
1 Remove the toe boad.
2 Remove the side cover and step.
3 Remove the protector
4 Disconnect the tilt hose. (The case of RH cylinder)
5 Disconnect the acceleration wire and remove the acceleration bracket ASSY. (The case of RH cylinder)
6 Remove the horn. (The case of LH cylinder)
7 Disconnect the piping.
8 Slightly hoist the mast.
9 Remove the tilt cylinder rear pin. [Point 11
10 Remove the tilt cylinder front pin. [Point 21
11 Remove the tilt cylinder ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply MP grease on the tilt cylinder front pin and rear pin inserting portions.
Tilt the mast slowly forward and backward a f e w times t o confirm normal operation.
Check the hydraulic oil level and add if insufficient.
Tile the mast fully forward and backward t o check no uneven movements between the left and right
sides. To adjust uneven movements, change the screw-in amount of the rod joint.
12-26
Point Operations
[Point 1 I
Disassembly:
Use a drift pin for driving out the spring pin.
[Point 21
Disassembly:
SST 0981 0-201 72-71
DISASSEMBLY- INSPECTION REASSEMBLY
Disassembly Procedure
1
Remove the rod guide wire. [Point 11
2
Disconnect the rod guide from the tilt cylinder.
3
Remove the rod guide and piston rod Wlpiston.
4
Remove the tilt cylinder. [Point 21
5
Remove the piston.
6
Remove the rod guide.
7
Remove the piston rod. [Point 31
8
Remove the rod joint. [Point 41
Reassembly Procedure
The reassembly pocedure is the reverse of the disassembly procedure.
Note:
Do not disassemble dry parts but apply hydraulic oil before reassembly.
Piston castle nut tightening torque
T = 2 5 8 . 0 N.m ( 2 6 3 0 kgf-cm) [ I 9 0 ft-lbfl
Rod joint lock nut tightening torque
T = 333.2
392.0 N-m (3400
4 0 0 0 kgf-cm) [ 2 4 6
2 8 9 ft-lbfl
-
-
-
Point Operations
[Point 1 I
Disassembly Reassembly:
Use the pipe wrench t o remove
the ring.
[Point 21
Inspection:
Measure the cylinder bore.
Standard bore:
2 ton series 69.85 mm (2.75 in)
1
76.2 mm (3.00 in)
3 ton series
Limit bore:
1
2 ton series 70.20 mm (2.7638 in)
76.55 m (3.0138 in)
3 ton series
-
-
[Point 31
Inspection:
Measure the piston rod outside diameter.
Standard outside diameter:
3 1 . 7 5 mm (1.250 in)
Limit outside diameter:
31.67 mm (1.247 in)
Inspection:
Measure the piston rod bend.
Limit bend:
1.0 mm (0.039 in)
[Point 41
Match mark
Disassembly:
Put a match mark.
Reassembly:
Check the match mark.
Reassembly:
When the rod or rod joint is replaced, adjust
the installed dimensions t o be equal on the
left and right sides.
Unit: m m (in)
OIL PUMP
Page
GENERAL ...........................................................1 3 -2
............................................... 13-3
COMPONENTS .................................................. 13-4
OIL PUMP ASSY ................................................ 13-5
REMOVAL. INSTALLATION (4Y. 1 DZ) .................... 13-5
REMOVAL. INSTALLATION (GM) .......................... 13-6
DISASSEMBLY . INSPECTION.REASSEMBLY ........... 13-7
TEST METHOD ................................................. 13-10
SPECIFICATIONS
GENERAL
SPECIFICATIONS
GM
4Y
1 DZ
1 t o n series
A
A
2 t o n series
B
C
D
3 t o n series
C
C
D
A
B
C
D
Manufacturer
ULTRA
t
t
+
Oil p u m p kind
Single p u m p
t
t
+
Oil p u m p t y p e
Gear p u m p
t
t
t
Theoretical discharge rate
cm3lrev (in3lrev)
24
(1.46)
28.5
(1.74)
27
(1.65)
36
(2.20)
Discharge rate (at p u m p speed o f
I l m i n (US gallmin)
1 5 0 0 rpm)
36.0
(9.50)
42.8
( 11.30)
40.5
( 10 . 6 9 )
54.0
( 14 . 2 3 )
12.0 (3.17)
13.0 (3.43)
c
t
Flow divider f l o w rate
l l m i n (US gallrnin)
Others
Oil pump drive type
PTO ratio
Built-in f l o w divider valve
4Y
1 DZ
GM
PTO silent chain drive
PTO gear drive
Universal joint
1.25
c
1 .O
COMPONENTS
OIL PUMP ASSY
REMOVAL-INSTALLATION (4Y.1 DZ)
4
Hose Wlflange
Removal Procedure
1
Disconnect the high pressure hose.
2
Disconnect the inlet hose. (oil tank side)
3
Remove the oil pump ASSY Wlinlet hose.
4
Disconnect the inlet hose Wlflange from the pump ASSY
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply grease (molybdenum disulfide grease) on the pump spline portion before installation.
Clean the fitting mounting portion thoroughly to prevent damage to the O-ring.
REMOVAL- INSTALLATION (GM)
Removal Procedure
1
Remove the air cleaner
2
Remove the radiator reservoir tank.
3 Remove the radiator cover.
4 Drain the coolant.
5 Remove the radiator and fan shuroud.
6 Disconnect the inlet hose. (oil tank side)
7 Disconnect the pump port drive pipe.
8 Disconnect the PS port pipe.
9 Remove the pipe clump bolt.
1 0 Remove the universal joint installation bolt.
11
Remove the oil pump set bolt.
1 2 Remove the oil pump ASSY and universal joint.
Installation Procedure
lnstallation pocedure is the reverse of the removal procedure.
Note:
Apply grease (molykote G-n paste) on the pump spline portion before installation.
Clean the fitting mounting portion throughly t o prevent damage t o the O-ring.
DISASSEMBLY-INSPECTION. REASSEMBLY
T = N.m (kgf-cm) [ f t -l b f l
1
Disassembly Procedure
1
Remove the cover W l f l o w divider. [Point 11
2 Remove the seals.
3 Remove the bushing set. [Point 21
4 Remove the pump gear. [Point 31
5 Remove the body. [Point 41
6 Remove the bushing set. [Point 21
7 Remove the seals.
8 Remove the cover (mounting flange).
9 Remove the oil seal.
10 Remove the f l o w divider valve. [Point 51
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Wash each part, blow with compressed air and apply hydraulic oil before reassembly.
Use new seals for reassembly.
13-8
Point Operations
[Point 1I
Disassembly:
Punch a match mark.
Reassembly:
Align the match marks.
[Point 21
Disassembly:
Make a match mark. Do n o t damage the
bushing.
Reassembly:
Align the match marks.
Inspection:
Measure the bushing inside diameter.
Limit inside diameter:
16.57 mm (0.6524 in)
4Y.1DZ
GM
2 1 . 2 2 mm (0.8354 in)
Inspection:
Inspect the inside surface in sliding contact.
Normal = Glossy contact trace on about half
on suction side
[Point 31
Disassembly:
Make a match mark. Do n o t damage the
gear.
Reassembly:
Align the match marks.
Inspection:
Measure the gear shaft outside diameter.
Limit outside diameter:
4Y.IDZ
16.34mm(0.6433in)
GM
20.95 mm (0.8248 in)
13-9
[Point 41
Inspection:
Inspect the depth of flaw on the inside surface
of the body.
Limit flaw depth:
0.08 mm (0.0031 in)
ar teeth crest
contact trace
[Point 51
Inspection:
Reassembly:
Check the flow divider valve orifice for clogging.
Carefully install the flow divider valve in the
correct direction.
TEST METHOD
Note:
A bench test shall be performed for strict testing. Since it is impossible in actual service jobs, install
the oil pump on an actual vehicle and judge the oil pump delivery quality by the cylinder operation state.
1.
Install an oil pressure gage and engine tachometer.
(1) Set the oil pressure gage on the oil control valve.
(2) Set the engine tachometer on the engine.
2.
Operate the oil pump for running in.
( 1 1 Start the engine. With the oil control valve lever in the neutral position, run the engine for 1 0
minutes at 5 0 0 t o 1 0 0 0 rpm.
3.
If no abnormality is found in the oil pump, run the engine for 1 0 minutes by raising the speed t o
1 5 0 0 t o 2 0 0 0 rpm.
Note:
If any abnormality is found is step 2 or 3 above, immediately stop the engine and disassemble the oil
pump again.
4.
Check if the relief set pressure of the oil control valve is as specified. See the oil control valve adjustment section (on page 14-8) for details.
5.
Check if the engine speed is as specified. See the engine speed adjustment section (on page 1-1 3)
for details.
6.
Lifting speed table (average for full stroke)
Lifting speed
Vehicle model
Engine model
4Y
mmlsec (fpm)
Mast type
No-load
Loaded
V
6 4 0 (126)
6 0 0 ( 1 1 8)
FV
6 0 0 ( 118)
540 ( 106)
FSV
6 1 0 (120)
550 (108)
V
6 7 0 (132)
6 5 0 (128)
FV
6 0 0 (1 18)
560 (1 10)
FSV
650 (128)
620 ( 122)
V
640 ( 126)
6 0 0 (1 18)
FV
6 0 0 (11 8)
560 ( 110)
FSV
600 (118)
560 (110)
V
650 ( 128)
6 1 0 (120)
FV
600 ( 1 18)
560 ( 1 10)
FSV
610 (120)
570 (1 12)
V
6 4 0 (126)
6 1 0 (120)
FV
6 1 0 (120)
570 ( 1 12)
FSV
6 1 0 (120)
6 0 0 ( 1 18)
V
550 (108)
510 (100)
FV
4 9 0 (97)
FSV
510 (100)
470 (93)
V
550 (108)
510 (100)
FV
4 8 0 (95)
4 4 0 (87)
FSV
500 (98)
4 7 0 (93)
V
530 (104)
500 (98)
FV
4 7 0 (93)
4 4 0 (87)
FSV
500 (98)
500 (98)
1 ton series
1DZ
4Y
2 ton series
GM
1 DZ
4Y
3 ton series
GM
1 DZ
4 5 0 (89)
OIL CONTROL VALVE
Page
GENERAL ............................................................. 14-2
SPECIFICATIONS .................................................14-3
COMPONENTS ....................................................14-4
OIL CONTROL VALVE ASSY .............................. 14-5
REMOVAL . INSTALLATION
....................................14-5
DISASSEMBLY . INSPECTION. REASSEMBLY ............. 14-6
ADJUSTMENT .....................................................14-8
GENERAL
Oil Control Valve
Att achn
Hydraulic Circuit
1
Tilt r e l ~ e fvalve
Inlet
Outlet section
valve
Main
\
Tilt spool section
Lift spool section
Power steering
Gauge port
y-'
1
m
SPECIFICATIONS
Vehicle model
I Oil control valve type
Relief set pressure
kPa (kgf/cm2)[psi]
Others
All models
Add-on type
Lift
191 23 ( 195) [27731
Tilt
16181 (165) [23461
Built-in tilt lock valve
I
COMPONENTS
6705
OIL CONTROL VALVE ASSY
REMOVAL. INSTALLATION
Note:
Before disconnecting the control lever link, release the residual pressure in the material handling
system piping by operating the control lever, set the mast in the neutral state and lowering the fork t o
the bottom position.
2
3
6
Toe board
Acceleration bracket
Front protector
Set bolt
Removal Procedure
1
Remove the toe board.
2
Remove the acceleration bracket.
3
Remove the front protector cover
4
Disconnect the control valve lever link.
5
Disconnect the piping.
6
Remove the oil control valve set bolt.
7
Remove the oil control valve ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply grease the oil control valve lever link parts.
Check the hydraulic oil level, and add if insufficient.
DISASSEMBLY. INSPECTION. REASSEMBLY
Note:
Operate in a clean place.
0 As each part is finished with high precision, carefully disassemble them to prevent any damage.
Disassembly Procedure
1
Remove the through bolt.
2
Separate each housing.
3
Remove the O-ring, spring and check valve.
4
Remove the seal holder.
5
Remove the spring holder.
6
Remove the spool Wispring.
7
Remove the spring. [Point 11
8
Remove the tilt lock valve (tile spool only). [Point 21
9
Remove the relief valve. [Point 31
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
Wash each part thoroughly, blow w i t h compressed air and apply hydraulic oil before reassembly.
Tightening torque for each part is as follows:
4 9 . 4 N.m ( 4 0 9
5 0 4 kgf/cm 2 ) r29.5
36.5 ft-lbfl
Top tie rod: T = 40.0
21.0 N.m ( 1 7 3
2 1 4 kgf/cm 2 ) [12.5
15.5 ft-lbfl
Bottom t w o tie rods: T = 17.0
-
-
-
-
-
-
Point Operations
[Point 1I
Disassembly:
Be careful as the spring may jump out.
[Point 21
Inspection:
Check the tilt lock valve orifice for clogging.
[Point 31
Reassembly:
When the relief valve is disassembled, always
loosen the adjust screw fully.
ADJUSTMENT
Note:
Always make adjustment according to the procedure described below. Careless adjustment may generate a high pressure to cause damage to the oil pump or other hydraulic devices.
Always check that the no-load maximum speed is as specified.
1.
Install an oil pressure page.
( 1 ) Remove t h e oil pressure d e t e c t i o n p l u g
(9116-1 8UNF-2B) installed on side of the oil control
valve, and install the oil pressure gage.
2.
Check loosening of the adjust screw.
( 1) Loosen the lock nut at the end of each of the lift and
tilt relief valves. Then loosen the adjusting screw t o
a position before it comes off from the body.
3.
Start the engine and check for no oil leak or abnormal
noise.
4.
Adjust the lift side relief pressure.
( 1 ) Set the control lever t o the lift position and gradually
tighten the adjust screw on the lift side until the fork
starts t o rise.
(2) Run the engine at the maximum speed, and read the
pressure gage when the fork is raised t o the maximum
height. Adjust the oil pressure then t o the specified
level by turning the adjust screw and lock w i t h the
lock nut.
5.
Adjust the tilt side relief pressure.
( 1) Set the control lever at the backward tilt position, and
gradually tighten the adjust screw on the tilt side until the mast starts t o be tilted backward.
(2) Run the engine at the maximum speed, and read the
oil pressure gage when the mast is tilted fully backward. Adjust the oil pressure then t o the specified
level by turning the adjust screw and lock by the lock
nut.
Relief valve (for tilt)
Relief set pressure
Unit: kPa (kgf/cm2) [psi]
All models
6.
Inspect the relief pressure again.
Lift
191 23&245(195&2.5)[2773&361
7.
Remove the oil pressure gage, and tighten the plug.
Tilt
16181 +~90(165+~)[2346+~11
APPENDIX
Page
SST LIST ........................................................... 15-2
SERVICE STANDARDS LIST ............................. 15-5
WIRING DIAGRAM
............................................15-1 9
SST LIST
I
Part No.
lllustrat~on
Sectlon
Part Name
1
fl,
1
;5"
@
'
d
09370-20270-71
Drlve plnlon
bear~ngreplacer
0942 1-33020-7 1
Front axle hub
replacer
09450-2361 0-71
Adaptor
095 10-3 1 960-7 1
Brake hold d o w n
sprlng remover
and replacer
?dl
@
5 7
~WL=-'
--
0961 0-22000-7 1
Inner mast
stopper
09620-1 01 00-7 1
Cylinder cap
remover and
replacer
09630- 10 1 10-7 1
Tilt cyllnder cap
remover and
replacer
09631 -22000-71
Wear scale c h a ~ n
2
4
5
6
0
7
8
1
1
1
2
0
0
0
0
0
0
0
0
- .Lll
,-75
=
R
)
09700-30200-71
Sprlng pln
J o ~ n tpln
0981 0-20172-71
-=yP
remover
0
1
0
0
0
0
SERVICE STANDARDS LIST
ENGINE
Engine
4Y.GM
Standard
Idling speed
Standard
No-load static
maximum speed
rpm
GM
Full relief engine speed d o w n
rpm
1.2 t o n series
Standard
2650
&
50
3 t o n series
Standard
2800
&
50
2.3 ton series
Standard
2600
&
50
1 t o n series
Standard
2600
+
50
2.3 t o n series
Standard
2800
&
50
4Y
Standard
2 5 0 or less
GM
Standard
t
1 DZ
Standard
t
I
Air cleaner
Vacuum switch conduction
Gasoline engine
test (conduction base)
Pa (mm H 2 0 ) [ m m Hgl
Diesel engine
Standard
2942
&
294 (300
&
30) L22.1
&
2.21
Standard
7473
&
569 (762
&
58) i 5 6 . 0
+
4.31
Radiator
73.5
Standard
Radiator cap opening pressure kPa(kgflcm2) (psi)
-
103.0 (0.75
-
1.05) [10.7
-
14.91
I Battery
Electrolyte specific gravity
I
(at 20°C [68O1)
I
1.280
Standard
Alternator
Fan belt tension (when pushed with 9 8 N ( 1 0 kgf) [ 2 2 Ibfl)
mrn (in) -
Fan belt tension (when
measured w i t h a tension gage
(SST))
N (kgf) [Ibfl
I
I
I
I
4Y
Standard
GM
Standard
1 DZ
Standard
4Y
Standard
GM
Standard
1 DZ
Standard
- 0.51)
8
1 6 (0.31 - 0.63)
8 - 1 3 ( 0 . 3 1 - 0.51)
2 9 4 - 4 9 0 ( 3 0 - 50) [ 6 6 - 1101
2 9 4 - 3 9 0 ( 3 0 - 40) [ 6 6 - 881
3 2 4 - 5 5 9 ( 3 3 - 57) [ 7 3 - 1261
8
-
13 (0.31
I
Accelerator ~ e d a l
Pedal roller height (from accelerator bracket t o
m m (in)
top of roller)
Standard
I
133
&
2 (5.24
* 0.08)
Tightening torque
Unit.
N.m (kgf-cm) [ft-lbfl
Standard
Torque converter end plate set bolt
49.03
Standard
53.9
800) L36.18
88 (500
-
900) [ 3 6
99.0 (550
-
101) [39.8
-
-
Engine mounting set nut
-
78.45 (500
49
Standard
Torque converter mounting bolt
-
-
-
-
57.881
651
-
73.11
4Y
Standard
56.88
-
64.72 (580
-
660) l 4 1 . 9 6
-
47.751
GM.1DZ
Standard
76.49
-
93.16 ( 7 8 0
-
950) L56.43
-
68.731
Drive plate set bolt
(for torque converter connection)
Standard
14.71
-
21.57 ( 150
-
220) L10.85
-
15.921
Torque converter housing set bolt
Standard
29.42
-
44.13 (300
-
450) [ 21.71
-
32.561
Drive plate set bolt (for engine
crankshaft connection)
I
TORQUE CONVERTER ( 1 SPEED)
Transmission cover & control valve ASSY
Shift lever operating force (reference)
N (kgf) [Ibf]
Standard
34.3
-
53.9 (3.5
-
5.5) [7.7
Standard
91 .O (3.583)
Limit
86.5 (3.406)
Standard
42.0 (1.654)
Limit
40.0 (1.575)
Standard
4 0 . 0 (1.575)
Limit
38.0 (1.496)
Standard
48.0 (1.890)
Limit
46.0 (1.81 1)
Standard
46.0 (1.81 1)
Limit
44.0 (1.732)
Standard
50.0 (1.970)
Limit
47.5 (1.870)
Standard
33.5 (1.319)
Limit
32.0 (1.260)
Oil pump driven gear to pump body clearance mm (in)
Limit
0.3 (0.012)
Oil pump driven gear to crescent clearance
mm (in)
Limit
0 . 4 (0.016)
Oil pump drive gear to crescent clearance
mm (in)
Limit
T
Pump body to each gear clearance
mm (in)
Limit
0 . 1 (0.004)
Limit
0.15 (0.0059)
Regulator valve spring free length
Inching valve spring free length
mm (in)
mm (in)
lnching valve spring free length (compression) mm (in)
Modulator valve spring free length (outer)
Modulator valve spring free length (Inner)
Orifice valve spring free length
Detent lever lock spring free length
rnm (in)
mm (in)
rnm (in)
mm (in)
-
12. I]
Torque converter and oil pump
Oil pump drive gear bushing to stator shaft
clearance
mm
Transmission
Clutch shaft No. 1 thrust clearance
mm (in) Standard
0.20
- 0.62 (0.0079 - 0.024)
Output shaft thrust clearance
mrn (in) Standard
Each clutch shaft to seal ring clearance
mrn (in)
Clutch disc thickness
mm (in)
Clutch plate thickness
0.03
-
0.51 (0.0012
Limit
0 . 2 (0.008)
Standard
2.6 (0.102)
Limit
2.3 (0.091)
Standard
2.0 (0.079)
Limit
1.8 (0.071)
Standard
3.4 (0.134)
Limit
3.1 (0.122)
- 0.0201)
mm (in)
Camber plate warpage height
mm (in)
Clutch disc to backing plate clearance
mrn (in) Standard
Clutch return spring free length
mm (in)
Clutch piston to piston ring clearance
1 .O
-
1.6 (0.039
- 0.063)
Standard
63.4 (2.496)
Limit
58.5 (2.303)
mm (in) Standard
0.17 (0.0067)
mm (in) Standard
27 (1.06)
Shift lever
Instrument panel notch to lever clearance
Measurement and tests
Stall speed
rPm
Main pressure
kPa (kgf/cm2)[psi]
Clutch pressure
kPa (kgf/cm2)[psi1
Torque convertor pressure
(outlet pressure)
kPa (kgflcm*) [psi]
Tightening torque
Unit:
4Y
Standard
21 0 0
GM
Standard
t
1 DZ
Standard
21 50
At idling
Standard
At 2000 rpm
Standard
At idling
Standard
At 2000 rpm
Standard
At 2000 rpm
Standard
- 4.5) [28 - 641
9 3 2 - 1275 (9.5 - 13.0) 1135 - 1851
196 - 441 (2.0 - 4.5) [28 - 641
8 8 3 - 1226 19.0 - 12.5) [ I 2 8 - 1781
196
-
200
441 (2.0
-
590 ( 2 - 6) [ 3 0
- 901
N.m (kgf-cm) [ft-lbf]
Stator shaft set bolt
Standard
9.81
-
Oil pump set bolt
Standard
9.81
-
Oil strainer set bolt
Standard
9.81
1 5 . 6 9 ( 1 0 0 - 1 6 0 1 1 7 . 2 4 - 11.581
- 190) L7.24 - 13.751
- 15.69 (100 - 160) [7.24 - 11.581
18.63 (100
Oil pan set bolt
Idle shaft
Standard
Idle shaft set bolt
Standard
Front cover set bolt
Standard
Transmission out put cover set bolt
Standard
Transmission cover (upper cover) set bolt
Standard
-
5.88
Standard
4.90
-
-
9.81 ( 5 0
-
80) L4.34
-
100) [3.62
5.791
-
-
7.241
- 70) i2.89 - 5.061
- 30.40 (190 - 310) [13.75 - 22.431
3.92
18.63
-
7.85 ( 6 0
6.86 ( 4 0
t
9.8 1
-
1 5.69 ( 10 0
-
160) [7.24
-
1 1.581
TORQUE CONVERTER (2 SPEEDS)
-
Transmission cover & control valve ASSY
Shift lever operating force
N (kgf) [Ibfl
Regulator valve spring free length
Inching valve spring free length
Orifice valve spring free length
34.3
-
53.9 (3.5
-
5.5) l7.7
Standard
88.3 (3.496)
Limit
85.0 (3.346)
Standard
34.5 (1.358)
Limit
33.0 (1.299)
Standard
49.4 (1.945)
Limit
47.0 (1.850)
Standard
50.5 (1.988)
Limit
48.5 (1.909)
Standard
50.0 (1.969)
Limit
47.5 (1.870)
Limit
0 . 3 (0.012)
-
12.11
m m (in)
mm (in) -
lnching valve spring free length (compression)
mm (in)
Modulator valve spring free length
Standard
-
mm (in)
mm (in)
Torque converter and oil pump
Oil pump driven gear to pump body clearance
mm (in)
-
Oil pump driven gear to crescent clearance
mm (in)
Limit
0 . 4 (0.016)
Oil pump drive gear to crescent clearance
mm (in)
Limit
T
Pump body t o each gear clearance
m m (in)
Limit
0.1 (0.004)
Oil pump drive gear bushing to stator shaft
clearance
m m (in)
Limit
0.15 (0.0059)
Transmission
Idle gear No. 2 thrust clearance
-
- 0.024)
mm (in)
Standard
Clutch shaft No. 2 (forward) thrust clearance mm (in)
Standard
0.05
-
0.55 (0.0020
-
0.021 7)
Clutch shaft No. 1 (reverse) thrust clearance mm (in)
Standard
0.1 5
-
0.75 (0.0059
-
0.0295)
0.04
0.6 (0.0016
Output shaft thrust clearance
rnrn (in) Standard
Each clutch shaft to seal ring clearance
mrn (in)
Clutch disc thickness
mm (in)
Clutch plate thickness
0.03
-
0.51 (0.0012
- 0.0201)
Limit
0.2 (0.008)
Standard
2.6 (0.102)
Limit
2.3 (0.091)
Standard
1.8 (0.071)
Limit
1.6 (0.063)
Standard
3 . 4 (0.134)
Limit
3.1 (0.122)
rnrn (in)
rnrn (in)
Camber plate warpage height
Clutch disc to backing plate clearance
mm (in) Standard
Clutch return spring free length
mm (in)
1 .O
Standard
1.6 (0.039
-
0.063)
92.1 (3.626)
85.0 (3.346)
Limit
Clutch piston t o piston ring clearance
-
mm (in) Standard
0.15 (0.0059)
mm (in) Standard
27 (1.06)
Shift lever
Instrument panel notch to lever clearance
Measurement and tests
Stall speed
rPm
Main pressure
kPa (kgficmZ)
Clutch pressure
kPa (kgf/cm2) [psil
Torque converter pressure
(outlet pressure)
kPa (kgfIcm2) [psil
Tightening torque
Unit:
4Y
Standard
21 0 0
GM
Standard
t
1 DZ
Standard
21 5 0
At idling
Standard
At 2000 rpm
Standard
At idling
Standard
At 2000 rpm
Standard
At 2000 rprn
Standard
- 981 (5.0 - 10.0) [71 - 1421
3 5 - 1991
932 - 1373 (9.5 - 14.0) [I
441 - 8 3 4 (4.5 - 8.5) [ 6 4 - 1211
932 - 1373 (9.5 - 14.0) 1135 - 1991
490
200
-
590 ( 2
- 6 ) [ 3 0 - 901
N.m (kgf-cm) [ft-lbfl
Stator shaft set bolt
Standard
Oil strainer set bolt
Standard
9.81
-
15.69 ( 1 0 0
t
160) [7.24
-
11.581
Oil pan set bolt
Standard
Idle shaft
Standard
Idle shaft set bolt
Standard
Front cover set bolt
Standard
Side cover set bolt
Standard
Transmission cover (upper cover) set bolt
Standard
-
5.88
4.90
-
7.85 (60
-
80) 14.34
-
5.791
9.81 (50 - 100) [3.62 - 7.241
- 70) i2.89 - 5.061
18.63 - 30.40 ( 190 - 310) [ I 3.75 - 22.431
3.92 - 6.86 (40 - 70) 12.89 - 5.061
3.92
9.81
-
-
6.86 (40
15.69 ( 100
-
160) i7.24
-
11.581
DIFFERENTIAL
Differential
Clearance between t h e axle bracket (RH) t o
differential carrier cover
m m (in)
Ring gear backlash
Ring gear runout
1.2 t o n series
Standard
0.2
-
0.3 (0.008 - 0.012)
3 t o n series
Standard
0.3
-
0.4 (0.012
m m (in)
m m (in) 1 t o n series only
Thrust screw cap t o ring gear
face clearance
m m (in)
Side gear and pinion gear backlash
m m (in)
Output gear and reduction gear
backlash
m m (in)
Drive pinion bearing
starting torque
N.rn (kgf-cm) [ft-lbf]
Unit:
-
Limit
0.1 (0.004)
Standard
13.0 (0.512)
Limit
12.2 (0.480)
0.016)
m m (in)
Thrust screw cap length
Tightening torque
0.5 (0.020)or less
Standard
Standard
0.2
-
-
0.012)
Standard
0.2
- 0.3 (0.008 -
0.012)
Standard
0.1
-
1.2 t o n series
Standard
10.79
3 t o n series
Standard
11.28
-
0.3 (0.008
0.2 (0.004 - 0.008)
13.24 ( 110
13.73 ( 115
-
135) i7.96
-
9.771
140) [8.32 - 10.1 31
N.m (kgf-cm) [ft-lbfl
-
-
-
Carrier bracket set bolt
Standard
Differential carrier set bolt
Standard
Front axle bracket set bolt
Standard
156.91 - 2 1 5 . 7 5 ( 1 6 0 0 - 2 2 0 0 ) [ 1 1 5 . 7 6 - 1 5 9 . 1 7 1
Axle bracket and differential
carrier cover connecting bolt
Standard
294.20
Torque converter case m o u n t bolt
Standard
Propeller shaft set bolt
Standard
Propeller shaft cover set bolt
Standard
9.81
1.2 t o n series
Standard
68.65
3 t o n series
Standard
49.03
78.45 (500
800) 136.18
57.681
t
-
392.27 (3000
35.30 -
49.03
Axle shaft set bolt
98.07
-
4000) [217.05 - 289.401
88.26 (500 - 900) [36.18 - 65.1 21
40.21 (360
-
410) i26.05
-
15.69 (100
-
160) i7.24
-
88.26 (700
- 127.49 (1000 -
-
-
900) i50.65
11,581
-
1300) i72.35
29.661
65.121
-
94.061
- 392.27 (3500 88.26 - 11 7.68 (900 -
343.23
Output gear lock n u t
Standard
Drive p i n ~ o nbearing retainer set bolt
Standard
Differential carrier cover set bolt
Standard
Ring gear set bolt
Standard
127.49
1.2 t o n series
Standard
3 t o n series
Standard
-
29.42
-
176.52 (1300
450) (21.71
-
-
1800) [94.06
289.401
86.82)
32.561
-
130.231
Differential case bearing cap set bolt
Standard
- 550) L31.83 - 39.791
86.30 - 102.97 (880 - 1050) L63.67 - 75.971
1 1 7.68 - 137.29 (1200 - 1400) [86.82 - 101.291
Thrust screw lock
nut
Standard
102.97
Differential upper
case set bolt
1 t o n series only
-
-
1200) 165.1 2
-
44.13 (300
-
4000) 1253.23
43.15
'
-
53.94 (440
I
Axle housing set bolt tightening
torque
Standard
73.55
-
127.49 (1050
-
98.07 (750
-
1300) 175.79
1000) 154.26
-
-
94.061
72.351
FRONT AXLE
I Front axle shaft hub
Front axle bearing starting force
N (kgf) [Ibfl
I
Tightening torque
Unit:
1
/
N s r n Ikgf-crn) [ft-lbfl
1 t o n series
68.65
Standard
2 t o n series
Hub bolt set n u t
Standard
166.71 -
147.10
Standard
I
3 t o n series
I
Bearing lock n u t stopper bolt
Axle shaft set
bolt
1
Standard
1.2 t o n series
Standard
3 t o n series
Standard
1 t o n series
Standard
2 t o n series
Standard
Front wheel hub
nut (single tire)
Front wheel
hub n u t (double tire)
Standard
[
series
-
900) 157.88
-
79.591
205.94 ( 1700 - 2100) [ I 23.00 -
186.33 ( 1500
-
1900) [108.53
137.471
151.941
1
1
- 86.821
98.07 - 127.49 (1000 - 1300) 172.35 - 94.061
107.87 - 196.13 ( 1 100 - 2000) [79.59 - 144.701
176.52 - 392.27 ( 1800 - 4000) [I30.23 - 289.401
68.65
294.20
Standard
88.26 (700
1
-
Outside
-
-
-
88.26 (700
-
900) [50.65
588.40 (3000
-
6000) 2 1 7.05
t
-
434.101
15-12
REAR AXLE
Rear axle hub and steering knuckle
Rear axle hub starting force
(at hub bolt)
(kgf) [Ibf1
1 ton series
Standard
14.7
-
39.2 (1.5
-
4.0) 13.3
-
8.81
2.3 ton series
Standard
14.7
-
44.1 (1.5
-
4.5) L3.3
-
9.91
Standard
28.0 (1.102)
Limit
27.8 (1.094)
mm (in)
King pin outside diameter
Steering knuckle starting force
(at front end of knuckle)
N (kgf) [Ibfl
Standard
29
-
49 ( 3
-
5) 16.6
-
11 .Ol
Rear axle cylinder
Piston rod outside diameter
Piston rod bend
Standard
50.0 (1.969)
Limit
49.92 (1.9654)
Limit
0.5 (0.020)
mm (in)
mm (in)
1.2 ton series
76.2 (3.00)
3 ton series
80 (3.15)
1.2 ton series
76.55 (3.0138)
3 ton series
80.35 (3.1634)
Standard
Cylinder bore
mm (in)
Limit
Tightening torque
Unit:
N - m (kgf-cm) [ft-lbfl
Rear axle support set bolt
Standard
King pin lock bolt, lock nut
Standard
Tie rod end castle nut
Standard
Divided rim bolt set
nut
1 ton
series
Hub nut
2 ton
series
series
,
-
11 7.68
-
19.61
-
147.10
-
1700) 186.82
-
31.38 (200
-
320) 114.47
196.13 ( 1500
-
2000) L108.53
-
44.13 (300
Standard
2.3 ton series
Standard
Divided rim
Standard
88.26
-
156.91 (900
Divided rim
Standard
11 7.68
-
196.13 (1200
Side ring rim
Standard
Divided rim
Standard
11 7.68
Standard
166.71
176.52
-
392.27 (1800
-
-
-
21 5.75 ( 1700
32.561
50.651
-
11 5.761
-
144.701
4000) 1130.23
-
289.401
-
123.001
-
144.701
2000) 186.82
-
-
166.71 (1200
450) 121.71
1600) [65.12
123.01
23.151
49.03 - 68.65 (500 - 700) 136.18 -
29.42
1 ton series
Rear axle cylinder ASSY set bolt
-
166.71 (1200
1700) 186.82
2200) [ I 23.00
-
159.171
STEERING
Hydrostatic steering valve ASSY
Relief valve set pressure
kPa (kgf/cm2) [psi]
Tightening torque
Unit:
Standard
&
490 (80
=t5)
[I140
=t 701
N.m (kgf-cm) [ft-lbfl
Steering valve set bolt
Standard
Mast jacket set bolt
Standard
Steering wheel set nut
Standard
Steering valve
7850
End cap set screw
44.13
-
53.94 (450
-
550) [32.56
-
39.791
300) l14.47
-
21.711
T
19.61
-
29.42 (200
-
31.09 (31 7) i22.931
Standard
BRAKE
Front brake (1 ton series)
Hold down spring free length
Anchor to shoe spring free length
Strut to shoe spring free length
Adjuster spring free length
Brake lining length
Standard
25.7 (1.012)
Limit
23 (0.91)
Standard
102 (4.02)
Limit
Replace if any clearance in coil exists.
Standard
2 0 (0.79)
Limit
17 (0.67)
Standard
79 (3.1 1)
Limit
Replace if any clearance in coil exists.
Standard
5.0 (0.197)
Limit
1 .O (0.039)
Limit
0.125 (0.00492)
Standard
254 (10.00)
Limit
256 ( 10.08)
Standard
31.3 (1.232)
Limit
28.2 (1.1 10)
Standard
1 24.5 (4.902)
Limit
Replace if any clearance in coil exists.
mm (in)
mm (in)
m m (in)
mm (in)
mm (in)
Wheel cylinder to piston clearance
mm (in)
Brake drum inside diameter
mm (in)
Front brake (2.3 ton series)
Hold down spring free length
Actuator spring free length
mm (in)
mm (in)
/
1
Standard
mm (in)
Anchor t o shoe spring free length
Limit
Replace if any clearance in coil exists.
Standard
23 (0.91)
Limit
20 (0.79)
Standard
/
Limit
I
mm (in)
Adjuster spring free length
-
mm (in)
mm (in)
Brake drum inside diameter
mm (in)
Limit
Standard
310 (12.20)
Limit
312 (12.28)
I
Parking brake
Parking brake operating force
(measured at center of lever knob)
N (kgf) [Ibf]
1 ton series
Standard
2.3 ton series
Standard
196 - 245 ( 2 0 147
-
196 (15
20) [ 3 3
-
25) [ 4 4
- 551
441
Brake pedal (Inching pedal)
Brake pedal (Inching pedal) height
(from toe board: with pad)
rnm (in)
Brake pedal (Inching pedal) play
mm (in) Standard
Unit:
Wheel cylinder
set bolt
Standard
10
-
20 (0.39
-
0.79)
N-rn (kgf-cm) [ft-lbfl
Backing plate self lock nut
I
I
I
I
Limit
Wheel cylinder to piston clearance
Replace if any clearance in coil exists.
/
-
Standard
Brake lining thickness
Tightening torque
I
I
mm (in)
Strut to shoe spring free length
I
106 (4.17)
Standard 11 7.68
1 ton series
Standard
2.3 ton series
Standard
- 137.29 (1200 - 1400) 186.82 - 101.291
7.85
14.71
-
-
11.77 (80
-
120) L5.79
-
19.61 (150
-
200) L10.85
8.681
-
14.471
MATERIAL HANDLING SYSTEM
Natural drop test
Natural drop
m m (in)
1 t o n series
Standard
9 0 (3.54) or less
2 t o n series
Standard
t
3 t o n series
Standard
T
1 t o n series
Standard
3 0 (1.18) or less
2 t o n series
Standard
4 5 (1.77) or less
3 t o n series
Standard
t
Natural forward tilt test
Natural forward tilt
m m (in)
Oil leak test
Lift cylinder oil leak amount
cm3 (in3)
Standard
1 6 (0.98) or less
Tilt cylinder oil leak amount (total for lift and tilt)
cm3 (in3)
Standard
3 2 ( 1- 9 5 ) or less
MAST
Mast adjustment (V mast)
Mast
rollers
Lift
bracket
rollers
Inner mast roller
clearance
m m (in)
Outer mast roller
clearance
m m (in)
Sandard
0
-
0.8 (0
-
Standard
0
-
0.5 (0
- 0.020)
Middle and lower lift
roller clearance
m m (in)
Standard
0
-
0.8 (0
-
Side roller clearance
m m (in)
Standard
0
-
0.6 (0
- 0.024)
0.031)
0.031)
.
Mast strip t o inner mast
clearance
m m (in)
0.5
Standard
-
1.0 (0.020
-
0.039)
Fork
Fork front end misalignment
Tightening torque
Unit:
m m (in)
1 0 (0.39)
Limit
N.m (kgf-crn) [ft-lbfl
Mast support cap set bolt
Standard
Back rest set bolt
Standard
Chain adjusting nut
Standard
9 9 . 5 4 - 1 8 4 . 8 6 ( 1 0 15 49.03 - 78.45 ( 5 0 0 68.65
-
107.87 ( 7 0 0
1100) 150.65
- 79.591
1885) [73.44
-
800) [ 3 6 . 1 8
-
136.381
57.881
CYLINDERS
I
Lift cylinder
1 t o n series
v
FSV
2 t o n series
Standard
45 (1.77)
Limit
44.92 (1.7685)
Standard
32 (1.26)
Limit
31.92 (1.2567)
3 t o n series
Piston rod outside diameter
m m (in)
1 t o n series
Standard
34.90 (1.374)
Limit
34.82 (1.3709)
Standard
40 (1.57)
Limit
39.92 (1.5717)
2 t o n series
3 t o n series
V.FSV
44.45 (1.750)
FV
45 (1.77)
V.FSV
44.65 (1.7579)
FV
45.20 (1.7795)
Standard
1 t o n series
Limit
Lift cylinder bore
m m (in)
2 t o n series
/ Standard
1 Limit I
Standard
55 (2.17)
Limit
55.35 (2.1791)
3 t o n series
Front lift cylinder (FV.FSV)
Standard
70 (2.76)
Limit
70.35 (2.7697)
Standard
75 (2.95)
Limit
75.35 (2.9665)
Standard
85 (3.35)
Limit
85.40 (3.3622)
Standard
50.8 (2.00)
1 t o n series
--
Lift cylinder bore
m m (in)
2 t o n series
3 t o n series
1 t o n series
Limit
Piston rod outside diameter
m m (in)
,
50.72 (1.9968)
Standard
50.8 (2.00)
Limit
50.72 (1.9968)
Standard
50.8 (2.00)
Limit
50.72 (1.9968)
2 t o n series
3 t o n series
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