Professional Documents
Culture Documents
5FGi5FD33 - 45 series. Please use this manual for providing quick, correct
servicing of the corresponding forklift models.
This manual has been edited by combining Repair Manual Pub. No. CEO05
Part I explains the service procedures for the models produced since
August, 1988 while Part IIcovers those for the models subject to the minor
change in September, 1994. For servicing the vehicles after the minor
Please understand that disagreement can take place between the de-
For the service procedures of the mounted engine, read the repair man-
(Reference)
GENERAL
ENGINE0
CLUTCH
C R
TRANSMISSION & DIFFERENTIAL
FRONT AXLE
REAR AXLE
BRAKE a
BODY
MATERIAL HANDLING SYSTEM
MAST
CYLINDER
OIL PUMP
OIL CONTROL VALVE
APPENDIX
GENERAL
Page
EXTERIOR VIEWS ................................ 0-2
VEHICLE LISTING ................................ 0-3
ABBREVIATIONS ................................ 0 -4
OPERATIONAL TIPS ............................. 0 -4
STANDARD BOLT & NUT TIGHTENING
TORQUE ......................................... 0-5
BOLT STRENGTH TYPE IDENTIFICATION
METHOD ...................................... 0-5
TIGHTENING TORQUE TABLE .................. 0-6
PRECOAT BOLTS .............................. 0-7
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE ........................... 0-7
FRAME NUMBER ................................ 0 -8
WIRE ROPE SUSPENSION ANGLE LIST ........... 0 -9
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE ............................ 0-10
COMPONENTS WEIGHT ......................... 0-10
RECOMMENDED LUBRICANT QUANTITY
&TYPES ......................................... 0-11
LUBRICATION CHARTS .......................... 0-12
PERIODIC MAINTENANCE ....................... 0 -1 4
INSPECTION METHOD ......................... 0-14
PERIODIC REPLACEMENT LUBRICANTS
AND PARTS ..................................... 0 -2 0
EXTERIOR VIEWS
- 6 -
VEHICLE LISTING
Abbreviation Abbreviation
Meaning Meaning
(Code) (Code)
OPERATIONAL TIPS
1. Safe operation
(1) Make sure that correct size wire is used for hoisting a heavy material.
(2) After jacking up, always support with rigid racks or stands.
1. Find out the straight type of bolt from the list below and then find the bolt tightening torque from
the table.
2. The nut tightening torque can be judged from the mating bolt type.
Standard
hexagon
0 Number in relief or
hallmark on the head
5 = 5T
6 = 6T
7 = 7T
9 I 1 1 1- 4 0 61 0
-1 T ~ e n g t under
h
Nominal diamter
head
(mm)
bolt
(mm)
@ No mark 4T
- Strength type
-
I Nominal
diameter
Stud bolt
9 2 1 32-4-061 4
Standard bolt with
1 T ~ e n g t (mm)
h
Nominal diameter
(mm)
- Strength type
Nominal
diameter
Length
TIGHTENING TORQUE TABLE
PR ECOAT BOLTS
(Bolts with seal lock agent coating on threads)
Note:
For torque check, use the lower limit of the Bolts
allowable tightening torque range. I f the
bolt moves, retighten it according to the
steps below.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten
the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
5FG 3 3
"1 5FG35-10011
02-5FG 33 "2 5FG35E10011
3F "3 5FG35-20011
5FG 3 5 "4 5FG35E20011
"5 5FG35O20011
02-5FG 3 5
5FD 33
"1 5FD35-10011
02-5FD 33 "2 5FD35E10011
11Z "3 5FD35-20011
5FD 3 5 "4 5FD35E20011
*5 5FD35020011 Frame No. punching position
02-5FD 3 5
5FGE35
02-5FGE35
"1 5FG45- 1001 1
5FG 4 0 "2 5FG45E10011
3F "3 5FG45-20011
02-5FG 4 0 "4 5FG45E20011
"5 5FG45Q20011
5FG 4 5 a
02-5FG 4 5
5FDE35
02-5FDE35
"1 5FD45- 1001 1
5FD 4 0 "2 5FD45E10011
11Z "3 5FD45-20011
02-5FD 4 0 "4 5FD45E20011
"5 5FD45~20011
5FD 4 5
02-5FD 4 5
o O 1 .oo
time
0
time
:LI 90°
1.41
time loo
time
,"
ko
30°
1.04
time
1 .I6
0.27
time
0.58
fiO
A.
120°
2.00
time time
60°
time ti me
@
\'
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE
U n i t : t o n (Ib)
8 mm
(0.32 in.)
10 mm
( 0 . 4 in.)
14 mm
(0.56 in)
COMPONENTS WEIGHT
Unit: kg (lb.)
1 1 Z : 3 3 0 (728)
Engine
3F : 250 (551)
Gasoline
models
95 Q ( 2 5 US gal)
- 16 -
13
2 14
1 1
16 16
3 3
15 15
10 5
17 9
11 4
8 4
6 6
7 7
12 18
18 19
ENGINE
Oil leak I + + +
Lubrication l C t t
Oil level
system
Clogging and dirt of oil filter i t + - +
Fuel leak l C t t
Leak I + + - +
Leak I + + +
Bolt loosening T
Leak i t + +
Fluid level I + - + +
DRIVE SYSTEM
STEERING SYSTEM
wheel Function l e e + -
Oil leak l t t t
Oil leak I + + +
Power l C C t
Mounting and linkage looseness
steering
Damage of power steering hose I
BRAKING SYSTEM
Operating force l C t C
Brake booster
Function, wear, damage, leak and
and wheel I
mounting looseness
cylinder
Inspection Period Every 1 3 6 12 Months
Item Every 170 500 1000 2000 Hours
HYDRAULIC SYSTEM
Uneven movement I + + - +
Oil leak I + - + +
Oil control
Relief pressure measurement M
valve
Relief valve and tilt lock valve functions I + + - +
011leak 1 t C C
Hydraulic I + + +
Deformation and damage
piping
Loose joint T - - -
ELECTRICAL SYSTEM
Starting
Pinion gear meshing status / I + + +
motor
Engine stop- I t t t
Diesel engine key stop device function
ping system
Loosening of mounting T t t ~
Back-rest
Deformation, crack and damage l t t t
Lighting i t + +
I Function and mounting condition
system
Direction - + +
Function and mounting condition I
indicator
Instruments Functions I + + +
Other Grease up L + - + +
PERIODIC REPLACEMENT LUBRICANTS AND PARTS
l: Replacement
Interval Every Every Every Every
1 month 3 months 6 months 12 months
Every Every Every Every
Item 1 7 0 hours 5 0 0 hours 1000 hours 2000 hours
Engine • t + +
Fu,el filter • C
Transmission oil • C
Differential oil • +
Hydraulic oil • t
- 28 -
Engine Performance Curves
29.0/1600
- 29
- 28
- 27 Engine torque
26 (kg'm)
25
90 85/2200
80 -
70 -
Shaft horsepower
(PSI 60-
50 -
40 -
-
] Fuelconsumption
ratio. (g/ps.h)
I I
10 14 18 22
Engine speed (rpm) x 1O2
Gasoline model
LPG model only 26.0/1200
- - - - - -. Gasoline LPG model
25.0/1200
Shaft horsepower
200/2000
- 29 -
SPECIFICATIONS
-
11 Z (Diesel) 3F (Gasoline)
Number of cylinders 6 6
pslrpm
Rated output (SAE NET: ~ p h ~ 85/2200
~ ) (8112200) 72/21 00 (6912100)
kg-mlrpm
Maximum torque 2911600 (202/1600) 26/1200 (182/1200)
(SAE NET : ft-lblrpm)
Injectio n order 1- 4- 2- 6- 3- 5
Ignition order 1- 5- 3- 6- 2- 4
Caution:
Always disconnect the negative (-) terminal
first.
- 34 -
12. Remove the exhaust pipe.
(1) Set nut
(2) Clamp bolt
(3) Exhaust pipe
engine.
Disconnecting the Oil Pump Drive LAQ70-20, 19
Note:
See "Clutch Removal" in section 2 for the
removal procedure for the clutch disc, clutch
cover and flywheel.
(1 ) Clutch disc
(2) Clutch cover
(3) Flywheel
Removing the Clutch Disc and
Clutch Cover
- 35 -
Hoisting the Engine LAQ~I-19
- 36 -
Disconnecting the Engine LAQBI-26-30
Caution:
0 See the cautions for "Clutch Removal" in section 2.
0 Bleed air from the fuel system. (11 Z engine model)
0 Connect the battery negative (-) terminal after checking correctness of electrical wiring.
0 Check the coolant and engine oil levels. I f insufficient, start engine adjustment after addition to
the specified levels.
0 Exhaust pipe set nuts tightening torque : 11Z: T = 2.4 -- 4.4 kg-m (17.3 -- 31.8 ft-lb)
3F: T = 3.4 -- 6.4 kg-m (24.6 -- 46.3 ft-lb)
REMOVAL (TORQUE CONVERTER MODEL)
Note:
0 Since the engine removal procedure for the torque converter model is the same as that for the
clutch model up t o step 13 (oil pump drive disconnection), refer to that section. Torque converter
oil cooler piping disconnection is added to the radiator hose disconnection.
The procedure afer the oil pump drive disconnection is described below.
0 Since the engine i s removed in the state of the engine with torque converter end plate, the starting
motor and flywheel are to be removed after the engine removal from the vehicle.
Note:
Sling with a aufficiently strong wire and
shackle as short as possible t o provide a suf-
ficient hoisting stroke.
- 38 -
4. Support the torque converter lower side
with wooden blocks.
-
1 l Z : T = 10- 16 kg-m (72.2 -- 115 ft-lb)
3F: T = 6 9 kg-m (43.3 -- 65.0 ft-lb)
0 Torque converter end plate tightening
torque
T = 5 -- 8 kg-m (36.1 -- 57.6 ft-lb) Removing the Engine
39 -
AIR BLEEDING FROM FUEL SYSTEM
(DIESEL ENGINE MODEL)
Caution:
Do not loosen the cock excessively to prevent
fuel spillage from outer circumference of the
cock.
Caution:
Cleanly wipe off light oil smearing around
the drain cock.
ENGINE SPEED ADJUSTMENT
(DIESEL ENGINE MODEL)
3. Inspecttheidlingspeed.
(1 ) Check returning of the accelerator wire. Setting the Engine Tachometer 1~045-8,9
(2) l nspect the idling speed.
Idling speed: 750 + 25 rpm
1. Warmuptheengine.
Cool ant temperature: 80 -- 9 0 " ~
- 43 -
(6) If hunting occurs, use the air governor
bush and adjust screw for adjustment.
Adjust screw: For hunting adjustment
Bush: For maximum speed adjustment
Note:
o reduce hunching
0 If the hunting lasts only a few times, it i s
regarded as no hunting.
0 Repeat steps (3) -- (6) to set the maxi-
mum speed at the standard value.
1. Loosen the set bolt of accelerator wire bracket @ to free the accelerator wire
3. Measure the height from the side floor to the front end of the accelerator pedal (with pad).
Accelerator pedal height standard: With pad A = 136 mm (5.31 in.)
With out pad B = 125 mm (4.92 in.)
4. If the measured height does not satisfy the above standard, adjust it to the standard value by turning
pedal height adjusting screw @ and securely fasten with lock nut 0.
5. After the adjustment, tighten the accelerator wire bracket set bolt.
1. Adjust the height of accelerator pedal stopper bolt @ from the floor to the following value and
securely fasten with lock nut @ :
Pedal stopper bolt height: C = 50 mm (1.96 in.)
AIR CLEANER
COMPONENTS
02
!
.
..
.I
SPEC1FICATIONS
Size 6 inch
Caution:
Carefully protect the filtering paper from
damage during washin.
Caution:
Do not use compressed air or hot air for
driving.
Washing the Element
5. Element inspection
After cleaning, put an electric bulb in the
element and inspect the element for damage.
If any pinhole, tear or damage i s found, re-
place i t with a new element.
6. Element replacement
Replace the element after washing 6 times or
every 12 months in general .cases.
Caution:
Do not apply a negative pressure of 75 mm
Hg or more to the vacuum switch. I
2. Individual inspection
(1) Use Mighty Vac and inspect vacuum
switch for conduction upon application
of a negative pressure.
General
SPEC1FICATIONS
65x500~430 8 3 x 500x430 6 5 x 5 0 0 ~ 4 9 0
Core (T x W x H) mm (in.) (2.6~19.7~16.9) t +
( 3 . 3 ~ 1 9 . 7 ~ 1 6 . 9(2.6~19.7~19.3)
)
Pressure
valve 0.9 (12.8) c t t c
Tank cap valve o ening
f
pressure kglcm (psi) Negative
pressure 0.5 (0.7) t t t c
valve
Coolant capacity 3.8 (I .00)
Q (US gal) 3.9 (1.03) 3.2 (0.84) 3.9 (1.03) 5.0 ( 1 . 3 2 )
(in radiator)
Diesel engine model 13.0 (3.43) 3.3 (0.87) 3.9 (1.03) 5.2 (1.37) 0.7 (0.18)
Gasoline engine
model 13.0 (3.43) 3.3 (0.87) 3.9 (1.03) 5.2 (1.37) 0.7 (0.18)
I
I
\
Universal joint
-
Fan Drive System (1988.6 1990.7) LAQM9, LAQS125.126
Fan Specifications
INSPECTION
- 54 -
Loosening the Plate Set Nuts ~~027-12
Pulley
Battery ASSY
Cable SUB-ASSY, battery to starter
Case SUB-ASSY, battery
Cable SUB-ASSY, battery to battery
Cable, battery earth
Bolt
Stopper, battery
Nut
SPEC1FICATIONS
5-hour rati ng Ah 64 36 t
Page
GENERAL ....*.................................. 2-2
SPECIFICATIONS ................................. 2-3
COMPONENTS .................................. 2-4
CLUTCH ......................................... 2-5
REMOVAL ..................................... 2-5
DISASSEMBLY ................................ 2-8
INSPECTION ................................... 2-10
ASSEMBLY .................................... 2-13
INSTALLATION ................................ 2-16
OIL CLUTCH AND CLUTCH HOUSING AND
RELEASE FORK SHAFT .......................... 2-17
REMOVAL ..................................... 2-17
DISASSEMBLY ................................ 2-19
INSPECTION .................................. 2-21
ASSEMBLY .................................... 2-22
INSTALLATION ................................ 2-22
CLUTCH BOOSTER .............................. 2-23
GENERAL ..................................... 2-23
TROUBLESHOOTING .......................... 2-23
COMPONENTS ................................ 2-24
REMOVAL ..................................... 2-25
DISASSEMBLY ................................ 2-26
INSPECTION .................................. 2-29
ASSEMBLY .................................... 2-31
lN STALLATI 0N ................................2-34
CLUTCH RELEASE CYLINDER .................... 2-35
GENERAL ..................................... 2-35
COMPONENTS ................................ 2-35
REMOVAL ..................................... 2-36
DISASSEMBLY ................................ 2-37
INSPECTION ................................... 2-37
ASSEMBLY .................................... 2-38
INSTALLATION ................................ 2-38
AIR BLEEDING FROM CLUTCH ................... 2-38
CLUTCH ADJUSTMENT .......................... 2-39
GENERAL
I I I I Venturi
- 60 -
SPECIFICATIONS
Outside diameter x
300 x 175 (11.8 x 6.9)
inside diameter mm (in.)
Servo ratio 5
3F engine vehicle
10 Cover ASSY, clutch AA Pin, clutch release lever
11 C Disc ASSY, oil clutch AB Bushing
12 Hub ASSY, clutch release bearing AC Bolt, eye
30 Shaft SUB-ASSY, clutch release fork AD Pin, clutch pressure plate
30A Spring, tension (For release fork shaft) AE Bushing
40 Housing, clutch AF Plate, adjusting nut lock
40A Bearing (For clutch release fork shaft) Al Nut
408 Ring, 0 (For clutch housing) AJ Cover, clutch
40C Seal, oil (For clutch housing) AK Holder, spring
40D Plug (For clutch housing drain) AM Pin, straight
40E Gasket (For clutch housing drain plug) AR Seat, strap
40F Seal, oil (For clutch release fork shaft) AU Ring, 0
41 Bearing, clutch release AY Ring, 0
42 Fork, clutch release BC Nipple
43 Plate, clutch pressure BD Ring, 0
44 Lever, clutch release BF Plate, pin lock
46 Spring, torsion (For clutch pressure lever) BH Cover, clutch case, front
49 Spring, compression (For clutch) BL R~ng,0
52 Spring, tension (For clutch hub) BM Ring, 0
53 Plate, clutch release bearing BP Union
53A Spring, clutch release bearing plate DC Nipple (Nozzle)
54 Hose, oil clutch (For clutch housing ~ n l e t ) DG Pipe SUB-ASSY, oil clutch
57 Venturi DH Connector SUB-ASSY, venturi
57A Packing (For venturi) DK Nozzle, oil clutch
61 Cover, clutch housing DU Plug, breather
61A Packing DV Hose, low pressure
Clutch Component
- 62 -
CLUTCH
REMOVAL
Caution:
Because of oil clutch adoption, carefully
prevent entrance of foreign matters and dust
into the housing after removal of the clutch
housing cover.
Caution:
Rotate the flywheel with a screw driver to a
position to enable easy installation.
Caution:
Rotate the flywheel with a screwdriver t o a
position to enable easy removal.
Caution:
o Carefully operate so as not t o damage or
deform the spray nozzle of the oil clutch.
o Operation for clutch disc replacement
ends with this step 7.
- 64 -
8. Remove the clutch cover.
Caution:
Before starting disassembly, check defective
points such as faulty pressure plate contact,
cover cracking and release lever wear, and
carry out proper disassembly and repair.
Caution:
Inspect each part and repair or replace any
defective part detected.
. . "
Inspecting the Clutch Cover LAG^^-26
spring.
- 68 -
Release lever inspection.
(1) Wear, damage and deformation of the
release lever.
(2) Looseness of the release lever (in
mounted state).
(3) Wear o f the pin.
(4) Wear of the eye bolt pin bushing.
(5) Wear at the spherical surface of the
adjusting nut.
Flywheel inspection.
(1) Wear and damage of the clutch disc
contact surface.
(2) Chipping, damage and wear of the
tooth surface.
(3) Damage and fatigue of the O-ring (gaso-
line model).
- 69 -
(2 ) Release bearing.
a. Rotation status, abnormal sound,
and wear at the contact surface with
the bearing plate.
Caution:
Shince the release bearing is of grease-sealed
type (lubrication-f ree) do not wash the bear-
ing at any event. Be sure t o replace with a
new one when a defect is found.
- 70 -
ASSEMBLY
Caution:
Thinly coat grease (molybdenum disulfide Assembling the Release Lever LAQ~O-1.3
base grease) on the surface of the release lever
contacting with the release bearing plate
(top and side of the lever end).
Caution:
When assembling the clutch cover and pres-
sure plate again, align the match marks.
( I f either part is replaced with a new one,
balance adjustment is necessary.)
4. Installthestrapseat.
T = 1.8 -- 3.0 kg-m (13.0 -- 21.7 ft-lb)
Caution:
When installing the adjusting nut, thinly coat
grease (molybdenum disulfide base) on the
. . . -
Caution:
0 I f the oil in the clutch housing or the inside of the housing is contaminated, discharge the oil from
the drain plug and clean the housing inside.
0 When installing the flywheel, coat grease on the oil seal and O-ring, and coat liquid seal on the
knock pin for the engine and flywheel. Carefully mount so as not to damage the oil seal. (Gaso-
line model)
0 Flywheel set bolts shall be tightened after coating a screw locking agent.
Tightening torque
T = 6 -- 9 kg-m (43.3 -- 65.0 ft-lb)
0 Remove foulding (rust, anticorrosive agent or impurities adhered) on the pressure plate sliding
con tact surface with snadpaper.
0 Apply a small amount of grease (molybdenum disulfide base grease) on the input shaft spline
portion, release bearing surface to contact the bearing plate and release hub surface to contact the
release fork.
o When installing the clutch cover, carefully prevent damage or deformation of the hydraulic clutch
spray nozzle.
0 Set the clutch disc with the longer boss side on the transmission side.
0 It is recommended to hold the clutch disc with long-nose pliers when inserting the input shaft.
0 Be sure to remove service bolts (4 pcs.) after the clutch cover is mounted.
0 After installing the input shaft lock ring, check that the input shaft sliding is surely locked by the
lock ring.
0 Inspect the hydraulic oil level.
o If the oil in the clutch housing is discharged, supply the same amount of new hydraulic oil.
OIL CLUTCH AND CLUTCH HOUSING AND RELEASE FORK SHAFT
REMOVAL
Note:
0 The clutch housing removal procedures are classified into the three following cases:
1. Remove the engine and then remove the clutch housing.
2. Remove the transmission & differential and the remove the clutch housing.
3. Remove from the differential to the clutch housing in assembled state and then remove the
clutch housing.
0 The procedure explained here is case 2 above.
0 The oil clutch mechanism can be disassembled on the vehicle.
Caution:
See steps 5 -- 10 of the Clutch Removal sec-
tion for the procedure.
Caution:
Remove only when a defect i s found as a
result of inspection. The oil seal must be
replaced with a new one.
INSTALLATION
Caution:
0 Coat grease on the O-ring and oil seal of the clutch housing.
0 Carefully install the clutch housing so as not t o damage the oil seal. (Diesel model)
0 Also refer t o cautions in "Clutch Installation".
CLUTCH BOOSTER
GENERAL
Flow divider
Note:
Since most seals are not supplied as individual parts, replace each piston or valve SUBASSY.
COMPONENTS
..J
- 82 -
REMOVAL
-
(2) Clutch link with push rod
(3) Clutch link bush
(4) Spacer
DISASSEMBLY
( 5 ) S- n a ~rina
s - , --I-
Caution:
Disassemble the reaction piston only when it
is found defective.
-86-
8. Remove the Control valve
(1 ) Snap ring
(2) Piston plug
(3) Spring
(4) Control valve
Caution:
0 Wash each part with new hydraulic oil
and inspect the items described below:
Replace any part that in found defective.
0 I f the cylinder body, piston or valve is
defective, replace the booster ASSY as a
unit.
Caution:
The piston SUB-ASSY must be replaced as a
unit.
Piston Inspection LAOI09-21
Caution:
The piston SUB-ASSY or valve SUB-ASSY
must be replaced as a unit.
Caution:
When the seal or O-ring of the control valve
seat is damaged, replace the valve & valve
SU B-ASSY as a unit.
Reaction Piston Parts Inspection LAO^ 10-26
(4) Deformation and fatigue of spring.
(5) Damage and wear of cylinder cup.
ASSEMBLY
Caution:
o Coat hydraulic oil on each part.
o Coat silicone grease on the cylinder cup, and hydraulic oil on the O-ring and seal ring.
--
that the ball moves.
T = 0.8 1.2 kg-m
(5.78 8.66 ft-lb)
--
(3) Install the plug and gasket.
T = 2.7 3.5 kg-m
(19.50 25.27 ft-lb)
(4) Put another check ball in the cylinder,
Installing the Check Ball ~~0111-1
and install the snap ring.
2. Install the flow divider spool.
(1 ) Insert the relief valve into the body.
(2) After checking that i t is smoothly in-
serted with a light push with a hand,
push i t further with a spring.
- 89 -
-
90 -
5. lnstall the reaction piston.
(1) l nstall the O-ring on the reaction piston.
(2) 1 nsert the control valve seat into the re-
action piston.
I NSTAL LATlON
Caution:
0 Carefully operate to prevent the O-ring at the joint between the clutch booster and brake booster
-
from being trapped.
-
T = 3.5 4.5 kg-m (25.3 32.5 ft-lb)
o Bleed air from the clutch system. (See page 2-38.)
0 Adjust the clutch pedal. (See page 2-39.)
CLUTCH RELEASE CYLINDER
GENERAL
COMPONENTS
i 46 Cap, bleeder
47 Piston, release cylinder
51 Boot (For clevis pin)
53 Bracket, clutch release cylinder
AB Washer, plate
AC Clevis
AD Pin, w/hole
AM Hose, flexible
AN Clip
L... AQ Bracket SUB-ASSY, hose
AS Hook, spring
Caution:
Cover the output side with cloth and grad- ?
ually blow air from the oil inlet for removal.
i
Caution:
0 Wash each part with new hydraulic oil
( I S 0 VG32) and inspect the following
points. Replace any defective part.
0 Replace the whole release cylinder ASSY
if the cylinder body or piston is defective.
95 -
2. Cylinder cup inspection.
(1 ) Wear, damage and deterioration.
3. Piston inspection.
(1 ) Wear and damage
ASSEMBLY
Caution:
0 Bleeder plug tightening torque
T = 9 -- 13 kg-m (64.98 -- 93.86 ft-lb)
0 Temporarily set the push rod length t o
the illustrated dimension. Readjust the
length after installation.
Temporarily Setting the Push Rod Length LAQS141
INSTALLATION
Caution:
o See the clutch adjustment section (page 2-39) for the adjustment after installation.
0 Carry out air bleeding.
Caution:
Do not depress the clutch pedal.
-96-
CLUTCH ADJUSTMENT
1. Adjust the clutch pedal height, the dimension from the top center of the clutch pedal to the toe-board
to the following value:
Pedal height (excluding the pad) : 144 -- 149 mm (5.7 -- 5.9 in.)
(with pad) : 150- 155mm (5.9-6.1 in.)
Note:
For the clutch adjustment procedure, refer to
Parts & Service News No. GE-8013 because
it has been changed.
--
1 - 2 mm
Adjust to A = -
(0.04 0.08 in:)
Bring the cylinder
bottom into sure
contact with the piston,
and the piston with the
push rod.
Note: The sectional view is partially different from that on the actual vehicle.
(2) Start the engine and bleed air from the release cylinder
Caution:
BB sure to start the engine because air bleeding fails if the engine is stopped.
(3) After air bleeding, fully depress the clutch pedal and check that the release cylinder push rod
does not enter the cylinder when i t is pushed.
TORQUE CONVERTER
Page
GENERAL ..................................... 3-2
HYDRAULIC CIRCUIT DIAGRAM .............. 3-5
...............................
SPECIFICATION 3-6
TROUBLESHOOTING .......................... 3-7
COMPONENTS ................................ 3-15
TRANSMISSION COVER AND CONTROL
VALVE ASSY .................................. 3-21
REMOVAL .................................. 3-22
DISASSEMBLY ............................. 3-24
INSPECTION ................................ 3-27
ASSEMBLY ................................. 3-29
INSTALLATION ............................. 3-31
TORQUE CONVERTER ........................ 3-32
REMOVAL .................................. 3-32
DISASSEMBLY ............................. 3-34
INSPECTION ................................ 3-36
ASSEMBLY ................................. 3-38
INSTALLATION ............................. 3-41
STATOR SHAFT AND OIL PUMP ............... 3-42
REMOVAL .................................. 3-42
DISASSEMBLY ............................. 3-42
INSPECTION ................................ 3-44
ASSEMBLY ................................. 3-46
INSTALLATION ............................. 3-47
TORQUE CONVERTER AND TRANSMISSION
ASSY WITH DIFFERENTIAL .................... 3-48
REMOVAL .................................. 3-48
TRANSMISSION .............................. 3-55
DISASSEMBLY ............................. 3-55
INSPECTION ................................. 3-66
ASSEMBLY ................................. 3-72
lNSTALLATION ............................. 3-83
OUTPUT GEAR AND DIFFERENTIAL ........... 3-84
REMOVAL .................................. 3-84
DISASSEMBLY. INSPECTION AND
ASSEMBLY ................................. 3-84
INSTALLATION ............................. 3-84
MEASUREMENT AND TEST ................... 3-85
Reference:
As for inching pedal adjustment. refer t o the section of brake.
1 1 Z Engine
3F Engine
- 101 -
27T: Drum gear No.1 (2nd)
Model
3.25-4.5 Ton vehicles
ltem (F1, F2/R torque converter vehicle)
Reverse (R ) 1.1 1
1. The vehicle does not 1 .I Check the main pressure. 0 Check the oil level with the
run at all or i t runs (More than 4 kg/cm2 (57 psi) level gauge.
very slowly. at idling. Std. 8-1 2 kg/cm2
[The clutch does not (114-1 7 1 psi) at 1,500 rpm)
transmit power] Check the main pressure in the
forward, reverse and neutral
positions.
1.3 When both the main pressure 0 Clogged oil path between the
and the clutch pressure are selector valve and the clutch
normal. piston. Check the oil path
-+
2. l nsufficient upgrading 2.1 Check the no-load static ro- 2.1.a When the rotational frequency
or insufficient traction tational frequency of the is not within the specified
(When power is insuf- engine and the load maxi- range, adjust the engine.
ficient) mum rotational frequency. Note: See the engine adjustment
section.
[When the torque con-
verter does not produce
torque.]
Symptom Check point Diagnosis, possi ble causeand action
2.2 Check the main pressure and 2.2.a When the main pressure and
the clutch pressure. the clutch pressure are abnor-
Std. (More than 4 kg/cm2 (57 psi) mal. (Check them according
at idling 8-12 kg/cm2 (11 4 - to the procedures described
171 psi) at 1,500 rpm) in I. I and I.2.)
2.3 Check the stall rotational fre- (Judge if the defective part is on
quency. the torque converter side (the
Stator Or O n the clutch side
0 Conduct the stall test t o measure
the engine rotational frequency. from the checked stall rotational
Note: Before checking the stall ro- frequency.)
tational frequency, be sure t o
check the engine output (the load
maximum rotational frequency),
the main bressure and the clutch
pressure to confirm that the en-
gine and the clutch system are
normal.
Symptom Check point Diagnosis, possible cause and action
3.2 Check the main and clutch 3.2.a Abnormal main and clutch
pressures. Also check the rise pressure.
characteristics of the clutch Refer t o 1 . I or 1.2.
pressure.
3.2.b Clutch pressure rise charac-
teristics are abnormal (too
slow).
0 Broken or fatigued accumulator
(More than 4 kg/cm2 (57 spring.
Std.
psi) at idling 8-12 kg/cm2 + Disassemble for inspection.
(Main
(114-171 psi) at 1,500 Replace it, if necessary.
press.)
rpm) 0 Clogged accumulator orifice.
( M than ~ (57
~ 4 ~kglcm2 + Disassemble it for inspection
Stdm
(Clutch psi) at idling 8-12 kg/cm2 and wash it1 if necessary.
(1 14-1 71 psi) at 1,500 o Improper return of the inching
press).
rPm valve.
+ Check the link parts and
adjust it, if necessary.
0 Clogged inching orifice.
+ Disassemble it for inspection.
Wash it, i f necessary.
4. Defective inching 4.1 Check the inching lever oper- 4.1.a Improper operation of inching
with jerk (shock). ation. Check the operation of lever.
the inching lever visually. + Disassemble the link parts
4.2 Check the main and clutch 4.2.a When the clutch pressure rise
pressures. Depress the inching characteristics are abnormal.
pedal to check the clutch 0 Clogged inching orifice. + Dis-
pressure. assemble it for inspection. Wash
it, if necessary.
(More than 4 kg/cm2 (57 0 Broken or fatigued accumulator
Stdm
psi) at idling 8-12 kg/cm2 spring. + Disassemble it for
(Main
(114-1 7 1 psi) at 1,500 inspection. Replace it, if neces-
press. )
rpm) sary.
0 Clogged accumulator orif ice. +
Std. (More than kg'cm2 (57 Disassemble it for inspection.
psi) at idling 8-12 kg/cm2
(Main) Wash it, if necessary.
( I 4-1 71 psi) at 1500
press.) 6 Improper inching spool opera-
rpm)
tion. + Disassemble it for
inspection, Wash it, if neces-
sary.
5. Differential oil 5.1 Smell torque converter oil t o 5.1.a When hypoid oil is smelt.
moving check if hypoid mixes in it- 0 improperly positioned oil seal of
the pinion unit or peeled off lip.
+ Disassemble i t for inspection.
Replace it if necessary.
0 Defective pinion unit 0 ring.
+ Replace it.
0 Defective retainer bolt seal.
+ Correct or retighten it.
0 Clogged air breather. + Replace it.
6. Overheat 6.1 Check torque converter oil. 6.1.a Defective torque converter
Check the oil level and quality. oil and improper oil level.
0 Inadequate oil level. -+Check the
oil level and adjust it t o the
adequate level, if necessary.
0 Air suction -+ Check each joint
0 ring.
0 Oil contains water. + Replace oil.
6.2 Check the main, clutch and 6.2.a The main and clutch pressures
torque converter (outlet) are lower than the standard
pressure. values. (Check them according
The main and clutch pressures. to the procedures described in
1 . I and 1.2.)
Std.: (More than 4 kg/cm2 (57
psi) at idling 8-1 2 kg/cm2 6.2. b The torque converter pressure
(114-1 71 psi) at 1,500 is lower than the standard
rpm) va lue
Torque converter pressure
0 Clogged regulator valve orifice.
Std. : (0.8-4 kg/cm2 (11-57 psi) + Disassemble it for inspection.
at 1,500 rpm) Wash it, if necessary.
0 High resistance of the internal oil
path piping. + Check clogging
of the internal oil path.
0 Clogged oil strainer. + Disas-
semble i t for inspection. Replace
it, if necessary.
6.6 Check the user's operation 6.6.a Check the operator's oper-
conditions. ation conditions, use condi-
tions and the working place.
o Check if excessive pushing is
made while performing the
inch operation.
o Check if the excessive switch
back is performed.
Replace it.
0 Damaged bearing. -+ Replace it.
8. Oil leakage 8.1 Check the oil seal. 0 Check the damage and wear of
(total) each seal lip and the correspond-
ing sliding face. Replace defective
part with a new one.
8.2 Check the case joint. 0 Retighten the bolts and replace
the 0 ring and packings.
8.3 Check cavity and crack. o Repair or replace it.
8.4 Oil blow-out through the 0 Overheat
air breather 0 Excessive oil
COMPONENTS
TORQUE CONVERTER CASE
(llZ) (3F)
&
QJ
&-A=
O - A 1
31
(1-SPEED)
de
pi
(2-SPEED)
-113-
TORQUE CONVERTER
Clutch Components
-115-
COUNTER GEAR
Shaft, counter
Bearing, No. 1 (For counter shaft)
Gear, counter, No. 1
Gear, counter, No. 2
Gear, output, No. 1
Spacer
Spacer
Plate, lock
Washer, lock
-116-
CONTROL VALVE
01
r"' -7
i
...- GL
...
4
- 117-
TORQUE CONVERTER PIPING
Gasoline Diesel
Orifice Orifice
[42.3 m m (0.09 i n L [41.6 m m (0.06 in)]
A-A Sectional View
Selector lever
6-6Sectional View
@ Inching valve
@ Regulator valve
@) Accumulator
@ Selector valve
- 119-
REMOVAL
2. Piping disconnection
(1) Disconnect the oil control valve inlet
pipe on the valve side.
(2) Disconnect the oil control valve outlet
hose on the valve side.
Caution:
Since the set bolts are different in length,
check the positions they are used.
Caution:
0 Use the cover & valve set bolt as the ser-
Removing the Cover & Valve ASSY ~ ~ ~ 1 8 . 2 0
vice bolt.
0 Since the O-ring i s used under the bottom
face of the cover, carefully prevent it
from falling.
0 After removing the cover, cover the open-
ing with cloth or proper material to pre-
vent material to prevent dust entrance in-
to the transmission.
DISASSEMBLY
Caution:
0 Carefully operate because the spring will
fly out when the detent cover is removed.
0 The steel ball will drop when the detent
cover is removed.
Carefully operate so as not to lose the
ball.
(1 ) Detent cover
(2) Spring
Removing the Detent Cover ~~0.3-7
(3) Detent sleeve
(4) Steel ball
(5) Selector valve
Caution:
Carefully operate because thespring will f l y
out when the plug is removed.
(1) Plug
(2) Outer spring
(3) Inner spring
(4) Spring retainer
( 5 ) Plug
(6) Regulator valve
Caution:
Carefully operate because the spring will fly
out when the plug i s removed.
Caution:
The orifice diameter i s greater on one side
and smaller on the other side. Since the
mounting direction is determined, record the
direction when the orifice i s removed.
(1) Plug
(2) Orifice
Caution:
Thoroughly wash each part in washing liquid
to eliminate dirt dust perfectly.
- 125-
Accumulator piston inspection
( I ) Wear and damage a t sliding contact sur-
f ace
(2) Fatigue of spring
Free length: 153.5 mm (6.043 in.)
Free length limit: 138.5 mm (5.453 in.)
Switch inspection
(1 ) Neutral switch conduction
The switch is normal if it is turned off
when pressed.
(2) Back switch conduction
The switch is normal if i t is turned on
when pressed.
- 126-
ASSEMBLY
Caution:
0 After washing each part, fully coat torque
converter oil before assembly.
0 Replace packings and oil seals with new
ones.
Note:
Coat thread tightner on the set bolt before
tightening it.
Caution:
lnstall the orifice in the correct direction. L
(See the figure at right.) d
S
(2) Packing d
(3) Plug
3F engine vehicle 112 engine vehicle
- 127-
Installing the Regulator Valve 1.~05-22
Note:
The valve can be installed easily by turning
the body with the plug on the lower side.
Finally, set it correctly and fasten the plug.
Note:
Install the spring and cover with the detent
sleeve in a state of held so as not to drop the
steel ball.
8. lnstall the inching cam lever.
( I ) Bush
(2) Fit the pin at the tip end of the inching
cam lever into the groove on the inching
valve.
Caution:
lnstall the lever with the groove on the lever Installing the lnching Lever Related Parts LAQS-34.36
boss end face on the upper side.
Caution:
Place the groove on the lever boss end face
on the upper side when installing the lever.
Caution:
0 Coat grease on the O-ring and carefully
prevent it from falling during installation.
0 Cover & valve ASSY set bolt tightening
torque.
T = 1.9 2.5 kg-m (13.7 -- 18.1 ft-lb)
0 Carefully operate t o connect the selector
lever and connecting rod in the correct di-
rection.
Installing the Connecting Rod L A Q M ~ ~
TORQUE CONVERTER
REMOVAL
Note:
To turn the flywheel, turn the torque con-
verter.
Note:
See the Engine removal section for the en-
gine removal.
Note:
Tap the pilot boss with a plastic hammer.
ASSY
Removing the ~or~ueconverter LAQ~I-5
DISASSEMBLY
Note:
Remove the reassembling sequence and re-
assembling direction of thrust washers (3
pieces).
Note:
Before removing the stator, rotate the im-
peller while holding the stator hub manually
to check i f it is stuck in both directions or it
does not lock in both directions (slipping).
7. Disassemble the stator SU B-ASSY. Removing the Stator SUB-ASSY LAQI 1-20
(1) Stator hub
Caution:
0 Remove the stator hub slowly and care-
fully.
0 When removing the stator hub, the roller,
etc. are disassembled at a time. Do not
lose them.
(2) Roller
(3) Spring cap
(4) Spring
(5) Stator Disassembling the Stator LAQ~~-22
8. Remove the pump boss from the pump im-
pel ler.
(1) Set bolt
(2) Pump boss
Caution:
Wash each part in washing solution carefully
before the inspection to remove dirt com-
pletely.
- 134-
3. Turbine runner inspection
(1). Crack and damage
(2) Damage blades
- 135-
(7) Wear and damage of roller, spring and
spring cap
Roller outside diameter standard:
8.3 mm (0.327 in.)
Roller outside diameter limit:
8.17 mm (0.322 in.)
ASSEMBLY
Caution:
After washing the parts again, apply torque
converter oil to them sufficiently and reas-
semble them.
Caution:
Apply grease to the O-ring and reassemble it.
36 -
3. Reassemble the stator
(1) Spring and spring cap
Note:
0 Apply grease to the spring and the spring
cap.
0 Place the spring in the spring cap and re-
assemble spring with tweezers, etc.
Note:
As shown in the figure, confirm that when
oil i s applied to the back of the stator blade,
the stator rotates and when oil is applied t o
the curved side of the blade, the stator is
locked by turning it manually in both direc-
tions.
Caution:
Direct the thrust bearing in the correct re-
assembling direction and observe the reas-
sembling procedure.
Caution:
Place the drive cover with the pump impelter
O-ring removed.
Dimension A Measurement ~~0.13-26,
LAQSI 51
(2) Measure the height B from the pilot
boss flange ,face to the bearing contact
face with a slide calipers.
Measure the bearing thickness C.
Calculate the thrust gap between the
pump impeller and the drive cover bear-
ing by the following equation.
Select an adequate spacer in the table
below.
Thrust clearance (D):
0.2 - 0.8 mm (0.008 -0.031 in.)
D + Spacer thickness = A - B - C
Spacer item No. Thickness Pilot Boss Dimension B Measurement LAQI 3-7
32223-31940-71 2.5mm(O.O98in.)
32224-31940-7 1 2.7 mm (0.106 in.)
32222-31940-71 3.0 mm (0.118 in.) I
Caution:
After the measurement, be sure to reassem-
ble the pump impeller O-ring.
Note:
Reassemble the pilot boss and the flexible
plate on the vehicle.
INSTALLATION
Caution:
0 Before mounting, be sure to apply grease to the pump boss seal ring, the oil seal on the pump body
and the pilot boss O-ring.
0 Pilot boss set bolts tightening torque:
T = 1.9 -- 2.5 kg-m (13.7 -- 18.1 ft-lb)
0 Flexible plate set bolts tightening torque:
T = 1.9 -- 2.5 kg-m (13.7 -- 18.1 ft-lb)
STATOR SHAFT AND OIL PUMP
REMOVAL
Caution:
The stator shaft and oil pump are remvoed
immediately after the removal of the torque
converter desc'ribed in the preceding para-
graph, s o see the preceding paragraph for the
procedure up to the removal of the torque
converter.
Removing the Torque Converter ASSY LAQPI-s
DISASSEMBLY
Note:
Tap the turbine shaft with a plastic hammer
to remove it.
Note:
Remove by using service bolts (2 pieces) and
SST.
(3) O-ring
(4) Oil seal
- 141 -
INSPECTION
Caution:
Wash each in washing solution carefully
before the inspection to remove dirt com-
pletely.
Caution:
Check the following points. When any defect
is detected, replace the pump ASSY (the
pump body, drive and driven gears).
(I
) Oil pump body and gear
@ Crack and damage
@ Wear and damage of pump boss-
seal ring contact face.
@ Wear and damage of drive and
Inspecting the Oil Pump Body and Gear LAQ~O-28
driven gears.
Check the wear of the oil pump body
and gear.
@ Measure gap between the driven
gear and the pump body.
Clearance standard:
0.1 2-0.2 mm (0.0047-0.0079 in,)
Clearance limit: 0.3 mm (0.012 in.)
Caution:
After washing each part again, apply torque
converter oil to it sufficiently and reassem-
ble it.
Caution:
Apply grease to the O-ring and reassemble it.
(1 ) Set bolts
T = 1.9 -- 2.5 kg-m (13.7 -- 18.1 ft-lb)
Caution:
Apply grease to the seal ring sufficiently.
Pay attention so as not to damage it when
inserting it.
INSTALLATION
Caution:
Use the new packing.
Note:
See the preceding paragraph for the operat-
tion after the torque converter ASSY install-
ing operation.
TORQUE CONVERTER AND TRANSMISSION ASSY
WITH DIFFERENTIAL
REMOVAL
Caution:
0 There are 2 kinds of methods for the torque converter and the transmission removal procedure.
Select either one according to the required repair.
@ When chiefly replacing the torque converter @ When chiefly repairing the clutch and gear
ASSY and repairing to the differential, etc. (excluding the output gear), etc.
Removing the Torque Converter and LAa24-s Removing the torque converter and ~0.21-15
Transmission ( 1 Transmission (2)
o In this manual, method @ is described. In the case of method @ , remove the engine, and dis-
connect it from the differential carrier.
Note:
See the Mast removal section for the re-
moving procedure.
Note:
To facilitate the operation, place a block
about 15 cm (6 in.) under the rear tire. Sup-
port the frame front both sides with stands
so as to keep the vehcile horizontally.
- 146 -
4. Remove the front wheel.
5. Drain oil
( 1) Differential oil
(2) Torque converter oil
Caution:
Wind the cloth around the tilt cylinder rod
to prevent the cylinder from being damaged
by the wire rope.
Note:
To rotate the flywheel, turn the torque con-
verter.
Note:
The torque converter plate is mounted on
the engine side without removing it, so
place a block under the lower part of the
torque converter end plate.
Caution:
Pull out the vehcile by operating the hoist
and the garage jack.
Reference:
0 By doing so, the torque converter and
transmission ASSY with differential are
removed.
0 In the subsequent paragraphs, each func-
Removing the Torque Converter and ~ ~ 2 4 - 9
tion removal procedure is described. Transmission with Differential
- 151 -
27. Remove the transmission cover and the con-
trol valve ASSY.
(1) Set bolts
(2) Remove the control valve ASSY by
using the service bolts.
Note:
Tap the torque converter with a plastic ham-
mer to remove it.
- 152-
'TRANSMISSION
Note:
Do not reuse the seal plate once removed
since the plate suffers deformation.
Note:
Strike to the counter shaft with a copper
bar, then the seal plate comes off and the
counter shaft can be removed with the bear-
ing (on the rear side).
Caution:
Remove the gear on 2 counter gears on the
greater diameter side after removing the F I I
R clutch.
(4) Spacer
- 155-
8. Remove the F1/R clutch ASSY.
Note:
Support the clutch drum. Tap the shaft end
with a plastic hammer remove it.
Note:
Disassemble the clutch drum on the forward
and reverse sides in the same procedure.
- 158 -
(9) Clutch piston
F2 CLUTCH PARTS
Note:
It is not necessary to remove the servo case
since it i s driven out on the opposite side
(front side).
Note:
It i s not able to reuse to deform when the
seal plate removes it once.
- 162-
(9) Clutch piston
Caution:
Wash each part in washing solution before
the inspection t o remove dirt completely.
Caution:
Exchange the seal plate on the front side
with the new article.
Caution:
When the plates are extremely discolored by
overheat, replace both the clutch disc and
the clutch plate at a time.
- 166 -
9. Clutch piston inspection
(1) Crack and damage
(2) Clogging of oil hole
Note:
Check these defect by using compressed air,
etc.
Note:
These parts are the same as those of the
main clutch.
See the F 1/R clutch for the inspection items.
Caution:
0 When reassembling the torque converter
case, pay attention so that dust, etc. does
not enter it.
0 Before reassembling each sliding part, be
sure to apply torque converter oil to it
sufficiently.
F2 CLUTCH PARTS
Reassembling the Piston Ring
1. Reassemble the F2 clutch ASSY.
(1) Reassemble the piston ring on the
clutch piston.
(2) Reassemble the seal ring on the clutch
drum.
(3) Insert the piston in the clutch drum.
Note:
0 Apply torque converter oil to the piston
sufficiently.
0 It i s not necessary to f i t the piston ring
normally.
Caution:
0 Reassemble the clutch plates (6 pieces)
and the clutch discs (6 pieces) alternately
in the order of the clutch plate and clutch
disc.
0 Be sure to fill the clearances between the
plates with torque converter oil.
-
Dimension A:
1.0 2.5 mm (0.039 -- 0.098 in.)
Reassembling the Pressure Plate and
Camber Plate
LAQS-7,8
Note:
Align the serration of the clutch disc with a
screwdriver, etc. before reassembling.
. .
(2) Bearing
SST 09608-3501 4
( 3 ) Snap ring
(4) seal ring and O-ring
Caution:
After reassembling, apply grease to the seal
ring.
- 172-
4. Reassemble the F2 clutch ASSY and the
clutch shaft.
( 1 ) Place the torque converter case on a
block with the differential side down.
Note:
Place the torque converter case on the block
so that the inserted condition of the shaft
can be confirmed by the hand inserted from
the below.
Caution:
Stop the driving-in of the clutch shaft when
the bearing on the shaft is just fit in the tor-
que converter case.
(In this case, the shaft end enters slightly the
clutch gear bearing.)
Caution:
0 Insert the hand from below so that the
spacer does not deviate.
0 Place the shaft spring pin in the drum
groove.
~ e a s s e m b l i nthe
~ Plate and Snap Ring ~~14-18.19
6. Reassemble the seal plate.
Caution:
0 As for the seal plate, use the new article.
0 Tap the seal plate with a plastic hammer
to reassemble it.
Note:
0 Check the F2 clutch operation by using
compressed air.
0 Throttle compressed air to the minimum
and blow it to the clutch operation oil
path to check if the F2 clutch piston
operates surely.
/R CLUTCH PARTS
Caution:
Place the counter gear under the position
where it i s reassembled in the correct direc-
tion.
(After reassembling the main clutch, reas-
sem ble the counter gear.)
- 174 -
10. Reassemble the F1/R clutch ASSY.
Note:
Reassemble the F1/R clutch. assembles on
the forward and reverse sides by the same
procedure.
Caution:
0 After reassembling, apply grease to the
seal ring.
0 It is not necessary to reassemble the
piston ring on the servo case side.
Note:
0 Apply torque converter oil sufficiently to
the piston.
0 It i s not necessary to fit the piston ring
normally.
Caution:
0 Reassemble the clutch plates (6 pieces)
and the clutch discs (6 pieces) alternately
in the order of the clutch plate and disc.
0 Be sure to fill the clearances between the
plates with torque converter oil.
-
Dimension A:
1.0 2.5 mm (0.039 -- 0.098 in.)
Reassembling the Pressure Plate and
Camber Plate
~ ~ 0 . 7 - 38-2
6,
Clearance Measurement
- 176 -
(9) Assemble the bearings on the forward
gear and the reverse gear.
@ Bearing
SST 09608-350 1 4
@ Snap ring
Caution:
0 Align the serration of the clutch Idisc with
a screwdriver, etc. before reassembling.
0 Do not confuse the forward side with the
reverse side.
(Confirm them by the number of teeth.)
(11 ) Spacer
(12) Snap ring (on the forward gear side)
Note:
Reassemble the servo case so that the bear-
ing does not move when reassembling the
F I / R clutch ASSY.
Caution:
After reassembling apply grease to them.
Caution:
0 Apply grease to the O-ring.
0 Pay attention so that the oil hole O-ring
does not come off.
0 Tap the servo case with a plastic hammer
to reassemble it.
Note:
0 Check the FI/R clutch operation by
using compressed air.
0 Throttle compressed air to the minimum
and blow it to the clutch operation oil
path to check if the clutch piston oper-
ates surely.
Caution:
Do not direct the counter gear in the wrong
direction.
Caution:
0 As for the seal plate, use the new article.
(on the front side)
0 Apply grease to the O-ring. (on the rear
side)
0 Tap the seal plate with a plastic hammer
to reassemble it.
INSTALLATION
Caution:
-
0 Oil filter tightening torque
T = 1.5 2.0 kg-m (10.8 -- 14.4 ft-lb)
Caution:
When the engine speed i s out of standard
value, adjust it referring to the item of En-
gine Adjustment.
Diesel Gasoline
Engine rpm Measurement LAQ~E-6
model model
,
Idling speed 750k2.5 rpm t
No-load maxi-
mum governed 2350 +I00 rpm 2,350 *50 rpm
speed
- 183 -
(5) Set the shift lever to each position.
Measure the clutch operation pressures
at the idling rpm and at 1500 rpm.
Caution:
2
0 Use a 20 kg/cm class oil pressure gauge.
0 It is desirable to measure the torque con-
verter pressure (the outlet pressure) with
a 5 kg/cm2 class oil pressure gauge.
0 Do not dperate the brake pedal when
measuring the oil pressure.
Stall test
(1) Load a cargo near the allowable load
limit on the vehicle. Choke the front
and rear wheels surely. Pull the parking
brake lever fully.
Caution:
Be sure to keep the vehicle under the stop
status perfectly and wire rope off the vehicle
to prevent i t s moving for safety.
Note:
See 2 Oil pressure measurement.
(Judgement)
When the engine rprn decreases markedly, the engine is not properly adjusted. Adjust the engine by mani-
pulating the air governor, etc.
(See Engine adjustment.)
In the case of an LPG model, decrement from the maximum static rprn 'is somewhat greater than the
above mentioned values.
(4) Start the engine. Set the shift lever to the forward position or reverse position. Rotate the engine
fully. Measure the rprn as i t becomes stabilized.
(Stall rpm)
TRANSMISSION & DIFFERENTIAL
Page
GENERAL ....................................... 4-2
SPECIFICATIONS ............................... 4 - 4
COMPONENTS .................................. 4-5
TRANSMISSION & DIFFERENTIAL ............... 4 -9
REMOVAL .................................... 4-9
DISASSEMBLY ............................... 4-15
INSPECTION .................................. 4-29
ASSEMBLY ................................... 4-37
INSTALLATION ............................... 4-56
GENERAL
1996. 2 -
- 188-
Differential Sectional View
- 189 -
SPECIFICATIONS
TRANSMISSION
4
Is t 37
Speed gears
2nd 57
Is t gear 67
2nd gear 47
Number of Counter shaft .
Reverseidle 35
gears No. 2 33
Output gears 50
Dl FFERENTIAL
Ring gear 36 35
Drive pinion 7 6
Number of
gear teeth
Side gear 14x2~~s.
- 191 -
TRANSMISSION GEAR
54
- 192 -
GEAR SHIFT LEVER & FORK
21
46
47
20 Lever SUB-ASSY, high & low shift 59 Plate SUB-ASSY, transmission case cover
20A Key (For shift lever) 59A Gasket
21 Lever SUB-ASSY, forward & reverse shift 77 Gage, oil level
22 Knob SUB-ASSY, high & low AA Pin, spring
23 Knob SUB-ASSY, forward & reverse AN Ring, 0
40 Shaft, 1 st & 2nd shift fork AP Bolt
41 Shaft, forward & reverse shift fork AZ Spacer
42 Fork, 1st & 2nd shift BX Bolt, fork shaft taper
43 Fork, forward & reverse gear shift CM Pin, straight
46 Spring, compression (For lock ball) CP Washer, lock
47 Ball, gear shift fork lock CZ Washer, thrust
48 Cover, transmission case ED Lever, shift & selector (Turn lever)
48A Gasket, gear case cover EP Washer, thrust
56 Shaft, forward & reverse shift EQ Needle, turn lever
56A Ring, 0 (For shift shaft) ER Shaft, turn lever
57 Shaft, high & low shift ES Bolt, turn lever
58 Lever, shift ET Cap, seal
58A Pin, lock (For shift leer)
- 193 -
DIFFERENTIAL
02
Differential Components
- 194 -
TRANSMISSION & DIFFERENTIAL
REMOVAL
Note:
0 The transmission & differential shall be removed toward the front side after removing the mast and
front axle.
0 The transmission case cover components can be removed on rhe vehicle.
Note:
See the MAST REMOVAL section for the
mast removal procedure.
Note:
0 Both the transmission and differential use
the same oil (hypoid gear oil).
0 Since the transmission oil drain plug has a
magnet, remove iron particles collected
on the magnet.
Note:
Two set bolts (one each at top and bottom)
out of eight bolts are reamer bolts.
Note:
0 Operate the hoist and garage jack to pull
out the transmission & differential to-
ward the front side of the vehicle.
0 Carefully operate because the clutch re-
lease hub may fall during removal.
Caution:
Remove one set bolt at the front cover
mounting portion.
Keep it separately from other bolts after re-
moval.
Note:
Install a service nut to the lock pin and tap
the upper surface of the nut for removal.
Note:
Receive the lock ball which falls when the
fork shaft is extracted.
Note:
I f bearing fitting i s tight, use the SST for re-
moval.
SST 09950-2001 7
- 205 -
(2) Remove the input shaft with the seal
cap by tapping the end surface of the
input shaft with a plastic hammer.
@ Seal cap
@ lnput shaft
- 206 -
Remove the counter shaft nut.
(1) Uncaulk the nut.
(2) Counter shaft nut
Note:
0 Apply a tool to the flat sides a t the rear
end of the counter shaft to stop rotation
during nut removal.
Width across flats of nut:
32 mm (1.3 in.)
Width across flats at shaft end:
32 mm (1.3 in.)
Removing the Nut LAQ35-11
0 It is recommended to use the SST pro-
vided for easy removal of the nut.
SST 09330-32880-71
Caution:
0 The gear and synchronizer ring parts fall
when the counter shaft is extracted. Al-
ways let an assistant operator hold them
when extracting the counter shaft.
0 Record the mounting positions of gears
and synchronizer ring parts to prevent
incorrect positioning at the time of re-
assembly.
Extracting the Counter Shaft ~~036-12
Note:
The reading of the spring scale is the resul-
tant force including the needle bearing pre-
load.
Measuring the Bearing Starting Torque ~ ~ 3 9 - 1 5
- 210 -
Remove the output gear & drive pinion
ASSY.
(1) Set bolt
Caution:
Since the drive pinion ASSY may fall when
the set bolt is removed, do not place the
hand under it.
Caution:
Since the drive pinion ASSY drops suddenly,
do not place the hand under it.
(3) Shim
( 2 ) Shim
Note:
Record the number of shims and thickness.
(3) Spacer
(4) O-ring
Caution:
Remove when any defect i s found in the
drive pinion, ring gear or differential case.
Caution:
After cleaning each part, inspect the follow-
ing items. Correct or replace the part if any
defect is found.
- 215 -
(4) Measure the clearance between the shift
fork and clutch hub sleeve.
Clearance limit: 1.0 mm (0.039 in.)
Transmission Gear
- 218 -
@ Inspect the clearance between the
synchronizer ring and gear.
Standard clearance:
1.10 -- 2.30 mm
(0.0433 -- 0.091 in.)
Clearance limit: 0.3 mm (0.012 in.)
Note:
The procedure is the same as that for syn-
chronizer ring ASSY No. 2 (for forward &
reverse).
The explanation here i s for items different
from synchronizer ring ASSY No. 2.
- 219 -
(1) Synchronizer ring inspection
@ Inspect the clearance between the
synchronizer ring and gear.
Standard clearance:
1.10- 1.90 mm
(0.0433 -- 0.0748 in.)
Clearance limit: 0.3 mm (0.012 in.)
Caution:
Always replace the drive pinion and ring gear
as a set even when only one of them i s found
defective.
Inspecting the Pinion and Ring Gear 1.~041 -1s
(4) Damage, rotation status and abnormal
noise of pilot bearing
( 3 ) Wear of spider
Standard outside diameter:
22.00 mm (0.866 in.)
Wear limit: 21.75 mm (0.856 in.)
- 221 -
18. Thrust screw cap inspection
(1) Damage of threading
(2) Wear and damage of cap
Standard length: 13.0 mm (0.51 2 in.)
Wear limit: 12.2 mm (0.480 in.)
21 . Transmission case
(1) Crack and damage of transmission case
(2) Damage of transmission carrier cap
Note:
0 Use new set bolts and coat thread tighten-
Installing the Ring Gear LA~~I-29
er (Locktite #271 or equivalent) on the
threaded portion before installation.
0 Tighten bolts diagonally first, and finally
tighten them in circular order to the spec-
ified tightening torque.
Caution:
Install the thrust washer with i t s oil groove
facing the side gear.
Caution:
Be sure to match the match marks.
Note:
0 Be sure to clean and degrease the bolts
and bolt holes.
0 Coat thread tightener (Locktite #271 or
equivalent ) on the bolt threaded portion
and tighten them to the specified torque.
(4) O-ring
(5) Spacer
Caution:
Install the spacer with i t s chamfered side (at
hole edge) facing the front side.
Caution:
0 Always use a new lock nut.
0 After tighteniag the lock nut, tap the
shaft with a plastic hammer and recheck
the tightening torque.
0 Lock the lock nut after checking the
startinq- toraue.
.
the Output Gear LAQ42-16
0 Insert the retainer set bolt in the retainer
before output gear insertion in a vehicle
with the torque converter.
Note:
Wind a string around the output gear and
pull a spring scale connected to it at a con-
stant speed t o measure the starting torque.
Caution:
0 Be sure to caulk at two places.
0 A in the illustration shall be in close con-
tact.
Note:
Make adjustment by changing the shim
thickness at the retainer flange portion.
Note:
The part No., set No. and dimension C are
indicated on the rear end of the drive pinion.
Dimension C i s not indicated if it i s 0.
Example: Pinion mounting distance
146.00 mm + No indication of dimension C.
146.25 mm + 25 is indicated as dimension C.
Dimension C Indicated Position LAQ~Z-21
(4) Calculate the shim thickness by the fol- Transmission model
lowing equation: Shim part No. Thickness mm (in.)
@ Transmission model
33436-32880-7 1 0.10 (0.0039)
t = ( A - 29) + B/100 + C/100
t = shim thickness (mm) 33437-32880-7 1 0.1 5 (0.0059)
@ Torque converter model 33438-32880-7 1 0.35 (0.0138)
t = ( A - 24) + B/100+ C/100
33439-32880-7 1 0.45 (0.0177)
t = shim thickness (mm)
Note:
0 The bolt and hole shall be cleaned and
Installing the Drive Pinion ASSY ~~043-2.42-23
degreased.
0 Coat thread tightener (Locktite #242 or
equivalent) on the bolt theads, and
tighten the bolt to the specified torque.
0 Since a bolt with a hole i s used on the
torque converter model, lock the bolt
with a lock wire.
- 229 -
11. lnstall the bearing to the differential case
ASSY.
(1) Bearing inner race
SST 09608-35014
(2) Bearing outer race
(3) Bearing inner race
SST 09608-35014
(4) Bearing outer race
Note:
When installing the differential case ASSY,
make the ring gear contact the drive pinion.
Note:
Align the match marks a t the time of install-
ation.
Note:
To adjust the backlash, loosen the adjusting
nut on one side by one notch and tighten
the adjusting nut on the other side by one
notch to gradually shift the differential case
while watching the dial gauge reading.
- 231 -
16. Measure the differential case bearing starting
torque.
(1) Wind a cord around the output gear and
measure the starting torque with a
spring scale.
Starting torque:
Starting torque specified in 7(2) + 2 kg
(4.4 Ib)
Note:
The value indicated by the spring scale also
includes the pinion bearing starting torque.
Measuring the Differential Case LAQ~S-IS
Bearing starting Torque
If the measured value is outside the
above standard range, adjust the starting
torque by turning the adjusting nuts as
follows:
@ To increase the starting torque:
Tighten the adjusting nuts on the
left and right sides by the same
amount.
@ To decrease the starting torque:
Loosen the adjusting nuts on the
left and right sides by the same
amount.
Adjusting the Bearing Starting Torque LAQ~~-36
Note:
After adjusting the starting torque, measure
the backlash again to confirm that it is
written the standard range.
Heel Contact
Toe Contact L A C S ~ ~
Flank Contact
- 233 -
(6) Face contact (high shallow contact)
Move the pinion closer to the ring gear
by decreasing the drive pinion adjusting
shim thickness. Then move the ring gear
away from the pinion to adjust the
backlash.
Face Contact L A C S ~ ~
Caution:
When meatching the adjusting lock position,
turn the adjusting nuts in the tightening
direction.
( 2 ) Wire lock
(MTM: Discontinued since Nov. 1995)
(ATM: Discontinued since Jan. 1994)
Caution:
Coat liquid seal on the thrust screw before
installing it.
- 234 -
Installing the Seal Cap LAQ~~-6
Transmission Gear
Caution:
0 lnstall each synchronizer ring part in i t s
original position before disassembly.
0 When installing synchromesh key springs,
offset their joint positions. (See the illust-
ration.)
0 Do not mistake the relative positions of
the gear and bush.
Key Spring Joint Positions LAOS346
Clutch Gear Set 1.~038-29.30
Note:
Fit the protrusing of the thrust washer into
the groove notched on the reverse idle gear.
Shift Forks
Note:
Use a new spring pin.
The shift shaft shorter in the overall length is Ins*a11inathe Shift Lever ~~036-18
Note:
Coat grease on the O-ring.
Note:
Insert the tip ends of the shift levers and
turn lever into the holes in the upper part of
the fork.
Filling Oil
-
Install the differential housing.
(1) Install the O-ring to the differential car-
rier.
Note:
Coat grease on the O-ring.
Caution:
Tighten from the front cover mounting por-
tion. installing the Differential ~ousing 1~~44-6.7
INSTALLATION
Caution:
0 Refer to the cautions in the Front Axle Installation section.
0 Refer to the cautions in the Mast Installation section.
0 Check the differential oil level, transmission oil level and hydraulic oil level.
0 Check no oil i s leaking from each joint.
FRONT AXLE
Page
GENERAL ....................................... 5-2
- 244 -
SPECIFICATIONS
Front axle type Half-floating
Front axle suspension Fixed to frame
Reduction gear type Planetary gear reduction
Reduction ratio 3.00
Planet gear tooth number 15,3 pcs (one side)
Internal gear tooth number 62
Sun gear tooth number 31
Wheels
- 1
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I
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48A
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741 H
- 246 -
FRONT AXLE ASSY
REMOVAL
Note:
The front axle shaft cannot be removed on
the vehicle because of i t s structure.
Note:
See MAST REMOVAL for the removing me-
Removing the Mast ~047-20
thod.
Note:
To facilitate the operation, place about 15
cm (6 in.) furring under the tires and then
support the frame with a stand at the front
on both sides so as to keep the vehicle hori-
zontal.
- 247 -
Disconnecting the Brake Piping ~~033-3
Caution:
Wind the cloth to the tilt cylinder rod. Be-
cause, it i s to be get damaged to the tilt
cylinder rod by the wire rope.
249 -
DISASSEMBLY
Caution:
Punch the match marks so that you
easily distinguish between right and left,
between the face and reverse side.
Caution:
Only when the bushing show any defect, dis-
assemble it. Also, if the gear is found to be
defective, replace this bushing with a new
one as well.
Caution:
Punch the match marks on the front axle
housing and internal gear so that you can
easily distinguish between right and left, and
between the direction of aligning surface.
Caution:
0 Only when the bearing or axle shaft show
any defect, disassemble it.
0 Use a bearing remover (SST) and press to-
gether for disassembly (same procedure as
for removing the bearing from the planet
gear carrier).
- 253 -
I NSPECTION
Note:
o Use a steel pipe for pressing it in.
0 Bearing inner diameter: 80 mm (3.15 in.)
Caution:
Apply a light and uniform coating of molyb-
denum disulphide grease over the planet gear
bushing inner surface and shaft outer cir-
cumference, nefore assembling.
Note:
0 Coat MP grease over the oil seal lip part.
0 Fill MP grease in the B portion in the
illustration.
Grease amount:
68 -- 170 g (0.15 -- 0.37 Ib)
Assembling the Oil Seal
3. Assemble the internal gear.
(1) O-ring
(2) lnternal gear
(3) Reamer bolt
Note:
0 Coat the O-ring with grease before aseem-
bling.
0 Align the internal gear match marks.
- 257 -
Assembling the Carrier ASSY LAQ~S-31
-
(4) Lock nut (always use a new one).
T = 30 35 kg-m (212 -- 253 ft-lb)
Caution:
0 After tightening the lock nut, rotate the
axle housing several times to work the
bearing to a good smooth fit.
0 Leave the lock nut uncaulked here.
Note:
0 Hook a spring balance onto the set bolt,
slowly draw it tangentially and measure
the value when the housing starts to ro-
tate.
0 Pay attention to protecting the housing
from dirt. Measuring the Preload ~ ~ 2 6 - 3 5
Caution:
Stake the lock to ensure that A part comes
into a contact as shown. Staking may cause
cracking on B part.
Note:
Turn the brake adjuster, and assemble the
brake drum when the outer diameter of the
brake shoe i s reduced t o the minimum.
For assembly, tap the brake drum with a
plastic hammer, or set the hub nuts at two
or four symmetrical positions, before tight-
ening.
INSTALLATION
Reverse the removal procedure for installing the components back onto the vehicle.
Caution:
0 Apply locking compound to the set bolts for the front axle housing and differential housing, and
then tighten to the standard torque.
T = 22.5 -- 33 kg-m (162 -- 238 ft-lb)
0 Tighten the bolt of the front axle bracket which had been temporarily tightened.
- -
T = 25 33 kg-m (181 238 ft-lb)
0 After assembling the front axle housing onto the differential housing, make sure that the brake
drum part can smoothly rotate.
0 Tighten the hub nut to the standard torque.
Single tire T = 30 -- 33 kg-m (212 -- 238 ft-lb)
Double tire (inside) T = 30 -- 35 kg-m (212 -- 253 ft-lb)
Double tire (outside) T = 35 -- 40 kg-m (253 -- 289 ft-lb)
0 After re-filling the differential oil, no oil should leak from the connecting part.
o Carry out air bleeding from the brake system and brake adjustment.
[Refer to the brake section (pages 8-16 and 8-18.)]
REAR AXLE
Page
GENERAL ....................................... 6-2
SPECIFICATIONS ............................... 6-2
COMPONENTS .................................. 6 -3
REAR AXLEASSY ............................... 6-4
REMOVAL .................................... 6 -4
DISASSEMBLY ................................ 6-6
INSPECTION .................................. 6-10
ASSEMBLY ................................... 6-13
INSTALLATION ................................ 6-18
REAR AXLE HUB ................................ 6-20
REMOVAL AND DISASSEMBLY ............... 6-20
INSPECTION .................................. 6-21
ASSEMBLY AND ADJUSTMENT ............... 6-22
STEERING KNUCKLE AND KING PIN ............. 6-24
REMOVAL AND DISASSEMBLY ............... 6-24
INSPECTION .................................. 6-25
ASSEMBLY AND ADJUSTMENT ............... 6-26
REAR WHEEL ALIGNMENT ...................... 6-28
TOE-IN ....................................... 6-28
TURNING RADIUS ............................ 6-28
CAMBER. CASTER AND
KING-PIN ANGLES ............................ 6-29
TIE ROD END BOOTS FITTING PROCEDURE ........... 6-30
GENERAL
I I
SPECIFICATIONS
r
Tire pressure
kglcrn2
(psi)
3.25 - 4.0 ton model 7.0 (99.54)
4.5 ton model 8.5 (110.87)
COMPONENTS
01 ~ Z O A
"'1
:
:b. ...d
Cc440
01 Axle ASSY, RR 42E Seal, oil, No. 2
10 End ASSY, Tie-rod, No. 1 42K Seal, kit, king pin
11 End ASSY, Tie-rod, No. 2 43 Pin, king pin lock
13K Tie-rod kit 44 Hub, rear axle
20 Beam SUB-ASSY, rear axle 44A Bearing, inner
20A Bushing, rear axle beam 44B Bearing, outer
20B Shim, rear axle beam 44C Bolt, hub
23 Bellcrank SUB-ASSY, steering 44D Nut, hub
23A Bearing (For steering bellcrank) 44F Seal, oil (For rear axle hub)
238 Seal, oil (For steering bellcrank) 44H Washer, claw (For rear axle hub)
23K Seal kit, bellcrank pin 45 Cap, rear axle hub
40 Knuckle, steering, RH 47 Tie-rod
41 Knuckle, steering, LH 48 Pin, bellcrank
42 Pin, steering knuckle king 58 Boot, Tie-rod end
42A Bearing, steering knuckle thrust AE Shim
428 Seal, oil, No. 1 AF Plate, stopper
42C Bearing, needle BL Washer, thrust
42D Shim, steering knuckle
- 263 -
REAR AXLE ASSY
REMOVAL
Caution:
0 Always support the weight with stands on the left and right sides.
0 To facilitate removal, set the distance between the ground and counterweight bottom to 300 -
400 mm ( 11.8 -- 15.7 in.).
0 Always use the parking brake and use wheel blocks.
Caution:
Support the weight underside with blocks
and make sure that they do not slip off.
Caution:
Punch different match marks for the front
and rear to prevent confusion.
DISASSEMBLY
Removing the Rear Axle ASSY LAQSS-16
Caution:
Explanation here describes disassembly of
the rear axle ASSY after it i s removed from
the vehicle. Since disassembly, repair and ad-
justment of the rear axle hub and steering
knuckle are possible without removal from
the vehicle, see repesctive parts of this
manual for removal and installation proce-
dure.
Caution:
Remove the bearing only when abnormal
wear, noise or other fault is found.
Caution:
Keep removed shims in order, check the
quantity and thickness so as not to lose
them.
Caution:
Remove the oil seal only when the oil seal
and needle bearing are damaged.
Caution:
Remove the needle bearing only when it is
damaged.
Caution:
Be careful not to lose the adjusting shim.
Caution:
Remove the oil seal and needle bearing only
when they are damaged or worn.
Caution:
0 After cleaning and washing the components, inspect the following components and repalce i f de-
fective.
0 Visually inspect each bearing and rotate them to check the rotation status, abnormal noise, loose-
ness or damage.
Caution:
If the wear limit i s exceeded, replace the
king pin together with the knuckle bearing.
lnspecting the King Pin
(3) Bending and damage of the lock pin
Bearing inspection
(1) Wear, damage and rotation status of the
needle bearing for the king pin
(2) Damage of the oil seal for the king pin
(3) Wear, damage and rotation status of the
thrust bearing for the king pin
(4) Wear, damage and rotation status of the
needle bearing for the bell crank pin
(5) Damage of the oil seal for the bell crank
pin
- 270 -
4. Support pin bushing inspection
( 1) Wear of bushing bore
Wear limit: 67.0 mm (2.64 in.)
Note:
Be sure t o replace the bushing when the oil
retaining force is lost.
(2) Clogging of oil groove in the bushing
Caution:
0 After the inspection, clean each compo-
nent again before assembling. Be sure to
grease the bellcrank and king pin needle
bearing.
0 Rubber parts such as the oil seal must al-
ways be rep1aced after disassembly.
Caution:
Mount the oil seal with the lip facing out-
side.
Caution:
Install the oil seal with the lip facing outside.
Caution:
Assemble the thrust bearing above the steer-
ing knuckle
- 275 -
Assembling the Inner Bearing LAG68-10
(1) Attach a Spring scale to the hub bolt Assembling the Rear Axle ~ " b LAG68-11
-
Rear axle hub pre-load:
1.4 -- 4.3 kg (3.1 9.5 Ib)
Note:
For pre-load adjustment, first tighten the
nuts firmly and back off about 114 turn. Tap
the hub for loose turning. Retighten the nuts
and measure the pre-load.
Note:
Tie rod adjustment must be made equally on
the right and left sides.
- 278 -
Installing the Power Cylinder Rod lAQ68-19
Caution:
Remove the bearing only when abnormal
sound, excessive wear or other defect is ob-
served.
Caution:
Remove only when bearing abnormality is
found.
INSPECTION
Caution:
Take care not to drive in a t an angle.
Otherwise, the knuckle spindle section may
be damaged.
282 -
5. Measure the rear axle hub pre-load.
(1) Attach a spring scale to the hub bolt,
and measure the rear axle hub rotating
pre-load if the rear axle hub.
Rear axle hub pre-load:
1.4 -- 4.3 kg (3.1 -- 9.5 I b)
Note:
For pre-load adjustment, first tighten the
nuts fully and back off about 114 turn. Tap
the hub for loose turning, retighten the nuts
and then measure the pre-load.
Measuring the Rear Axle Hub Pre-load ~~057-28
Caution:
Keep the shims in arranged state to prevent
missing, and record the number and thick-
ness.
Caution:
Remove the oil seal only when damage or
wear of the needle bearing and oil seal i s
found.
Caution:
Remove the needle bearing only when
damage or wear is found.
Caution:
Use of a flow detector or flaw detecting
agent is recommended for inspection.
Caution:
I f the wear limit is exceeded, replace the
king pin with the steering knuckle.
(3) Bending and damage of the lock pin lnspecting the King Pin LAQ57-16
3. Bearing inspection
( 1 ) Wear, damage and poor rotation of the
needle bearing for the king pin
(2) Damage of the oil seal for the king pin
(3) Wear, damage and poor revolution of
the thrust bearing for the king pin
(4) Wear, damage and poor revolution of
the needle bearing for the bell crank pin
(5) Damage of the oil seal for the bell crank
pin
Caution:
The oil seal must be installed with the lip
side facing outside. Driving in the Needle Bearing and
Oil Seal (2)
Caution:
The thrust bearing must be installed above
the steering knuckle.
--
Specified clearance:
0.02 0.15 mm
(0.0008 0.0059 in.)
Shim thickness:
0.1 5 mm (0.0059 in.)
0.25 mm (0.0098 in.)
0.35 mm (0.0138 in.)
King pin
Mounting the King Pin ~~056-27
(5) Adjust the steering knuckle pre-load.
@ After shim adjustment, attach a
spring scale to the knuckle spindle
end and measure the pre-load.
Specified steering knuckle pre-load:
-
3 -- 5 kg (6.6 11.0 Ib)
@ If the specified pre-load i s not at-
tained, readjust with shims.
Caution:
The rear axle ASSY must be remove before
toe-in measurement and adjustment.
- 288 -
CAMBER, CASTER AND KING-PIN
ANGLES
Page
GENERAL....................................... 7-2
COMPONENTS................................... 7-3
- 292 -
COMPONENTS
10
r"' "'7
:
1- I
%
\
-'---ll
@@
b..-
12
...
a
- 293 -
20 Jacket SUB-ASSY, mast EC Ring
23 Bracket SUB-ASSY, tilt steering ED Ring
24 Stopper SUB-ASSY, steering shaft ES Spring, compressison
25 Stopper SUB-ASSY, steering ET Spring, tension
26 Shaft SUB-ASSY, tilt steering EU Spring, tension
49 Grommet, steering column (Insulator) EV Pipe
69 Wire, tilt steering EW Collar, tilt lock
AF Clamp EX Hose
AG Clamp, steering column, lower EY Lever SUB-ASSY, tilt lock
BN Bushing EZ Bolt, tilt lock
BR Boot, mast jacket FA Nut, adjusting, RH
BT Jacket FB Nut, adjusting, LH
BW Bolt
- 294 -
01 Cylinder ASSY, power Ring, snap
01 K Packing kit, power cylinder Seal, dust
20 Cylinder SUB-ASSY, power Ring, 0
40 Rod, piston Collar, rear cover
40A Nut, self lock (For piston) Seat
41 Piston Ring, snap
42 Ring, piston Packing, U
43 Guide, rod Ring, back up
AA Bushing Ring, back up
- 295 -
0A
10
- 296 -
Wheel ASSY, steering
Knob ASSY, steering wheel
Knob SUB-ASSY, steering wheel
Button, horn
Plate, horn contact
Seat, horn contact
Spring, horn
Plate, lead
Washer
Cap, steering wheel
Bolt, steering wheel knob set
Ring, horn contact No. 1
SPECIFICATIONS
1
Steering wheel diameter mm (in.) 380 (15.0)
Gear type Recirculating ball screw
Gear ratio 1 : 18.5
Steering gear
Lock to lock 3.9
Ball twisting direction Counterclockwise
TYpe Semi-integral
Booster 2
Relief valve set pressure kg/cm (psi) 120 ( 1706)
Caution:
Carefully operate because the spring force is
strong.
Caution:
The adjusting nuts use right hand thread on
the left side and left hand thread on the
right side.
Caution :
Prepare waste cloth around the hydraulic
piping because some oil will flow out from
the disconnected piping.
DISASSEMBLY
Caution:
Check the match mark on the sector shaft
and pitman arm at the time of disassembly.
- 301 -
3. Remove the end cover.
(1) Remove the set bolts ( 4 pcs.) to remove
the end cover.
Caution:
After removing the end cover, temporarily
tighten the control valve body by using two
end cover set bolts.
7. Removethesidecoverwithsectorshaft.
(1) Remove the set bolts ( 4 pcs.).
(2) Loosen the adjusted bolt lock nut, and
screw in the adjusting nut.
-
(3) Remove the side cover with sector shaft.
Caution:
Place the ball screw nut at the lock-to-lock
center position, and draw out the sector
shaft carefully to prevent oil shaft damage.
Note:
If relief valve set removal i s difficult, reverse
the valve body and strike it lightly against a
wooden block.
INSPECTION
Caution:
Disassembled parts shall be washed with
washing fluid and shall be checked for the
following points.
Thickness: 2.00 mm
(0.0787 in.)
(0.0768 in.)
Caution :
Inspect the oil seal and needle bearing as
they are installed t o the gear box. Replace
the oil seal or needle bearing only when it
i s found defective.
Gear Box Inspection ~~0121-10
Caution:
0 Blow compressed air for sufficient clean-
ing before inspection.
o Replace the valve body as an ASSY when
Control Valve Inspection 1.~0122-12
any defect is found.
Caution:
Disassemble the relief valve only when the
relief pressure measured in installed state is
abnormal.
- 305 -
(4) Disassemble the relief valve set, and in-
spect fatigue of relief valve spring and
damage on steel ball surface.
(5) Existence of foreign matters at filter
Caution:
Replace the relief valve set when any defect
i s found.
Caution:
When an abnormality of the bearing, etc. is
found, carry out replacement according to
the following procedure:
1. Gear box
(1) Use the SST and remove the bearing on
the end cover side.
SST 09608-20012 Replacing the Gear Box Bearing 1.~0121-11
(2) Use the SST and drive the bearing into
the gear box.
SST 09608-20012
Note:
The driven-in bearing surface must be flush
with the gear box outer end surface.
Note:
The driven-in bearing surface must be flush
with the gear box outer end surface.
~ r i v i the
n ~ Bearing into Side Cover 1.~0121-19
3. Top cover
(1) Use a screwdriver and remove the bear-
ing and oil seal.
Caution:
Clean each part with compressed air before
starting assembly
Caution:
Place the protrusion a t the same position as
before disassem'bly.
Caution:
Coat hydraulic fluid on the O-ring.
- 309 -
Assembling the Sector Shaft 1.~0122-3s
-
Cap nut:
T = 3.0 4.5 kg-m (21.7 -- 32.5 ft-lb)
Caution:
0 Install the mast jacket by placing the
spring hook on the front side.
0 Do not forget to use the nylon bush when
installing the mast jacket set bolt.
Installing the Mast Jacket ASSY LAQ~I-27
Caution:
lnstall the lever so that it is positioned B-C
when it is locked.
Section A-A
(3) After installing the adjust lever, move
the lever and check if it is locked at the
desired position.
Installing the Tilt Adjusting Bolt
-
the specified torque.
-
T = 2.0 3.9 kg-m (14.4 21.7 ft-lb)
(4) Install the horn button.
Caution:
Refer to the items 1 -- 7 of the "STEERING
, GEAR BOX ASSY REMOVAL".
DISASSEMBLY
INSTALLATION
REMOVAL
Note:
0 Turn the steering wheel until the power
cylinder end protrudes from the rear axle.
0 Receive the oil leaking from the piping
with an oil receiving tray.
Caution:
0 Inspect oil leakage and piston rod damage before starting disassembly.
0 Measure the dimension between both ends of the cylinder in retracted state for reference at the
time of reassembly.
Caution:
0 When fixing the power cylinder with a
vice, carefully operate so as not to dam-
age the cylinder.
o For 3.25 -- 4.0 ton models, merely loosen
the rear cover and extract it together with
the piston rod. Remove the piston and
Removing the Rear Cover ~ ~ ~ 5 2 . 3 5
then the rear cover.
- 320 -
(2) Piston (outer)
(3) Piston ring
(4) Piston (inner)
Caution:
Disassemble only when oil leak the rear
cover i s found.
INSPECTION
Note:
When using above gauge, measure the wear
and departure from roundness a t a place
about 200 mm (8 in.) from the cylinder
edge.
Cylinder bore standard: 55 mm (2.165 in.)
Cylinder bore limit: 55.35 mm (2.179 in.)
Inspecting the Cylinder ~~053-16
- 321 -
3. Piston and piston ring inspection
(1) Wear and damage of the piston
(2) Wear and damage of the piston ring
Caution:
Remove and replace the dust seal only when
a defect is found.
Caution:
Use a hand press to drive in the dust seal
only when it is replaced.
Assembling the Rear Cover ~ ~ 6 3 - 1 4
2. Assemble the piston rings to the piston.
3. Assemble the piston to piston rod.
(1 ) Piston w/ piston ring
(2) Self-lock nut
T = 1 6 - 2 3 kg-m (108- 166ft-lb)
Caution :
Use a new self-lock nut.
- 1995. 3 :
T = 15-
1995. 3 -
2 3 kg-m ( 1 0 8 - 166ft-lb)
:
T = 1 2 -- 1 6 kg-m ( 8 7 - 1 1 6 ft-lb)
- 322 -
4. Insert the piston into the cylinder.
. . . . . . ..
5. Assemble the rear cover to the power cylin-
der.
SST 09620-10100-71
(1) Rear cover
(2) Staking
Note:
Coat liquid seal on the threaded portion of
the power cylinder rear cover.
6. Install the power steering rear end and power steering end.
See the illustration below for the installed dimensions.
- 323 -
INSTALLATION
DRAG LINK
ADJUSTMENT
1. Adjust the drag link end screwed-in depths to satisfy the dimensions specified below.
C
L (Actual length)
I-
- 324 -
BRAKE
Page
GENERAL ........................................ 8-2
SPECIFICATIONS ................................ 8-4
FRONT BRAKE ................................... 8-5
COMPONENTS ................................ 8 - 6
REMOVAL ..................................... 8 -7
INSPECTION ................................... 8-11
ASSEMBLY .................................... 8 - 1 3
AIR BLEEDING ................................. 8-16
AUTOMATIC ADJUSTER OPERATION TEST ..... 8 - 1 7
BRAKE ADJUSTMENT AND BRAKING FORCE
INSPECTION ................................... 8-18
BRAKE BOOSTER ................................ 8-19
TROUBLESHOOTING ........................... 8-19
COMPONENTS ................................ 8-20
REMOVAL ..................................... 8-22
DISASSEMBLY ................................. 8-23
INSPECTION ................................... 8-26
ASSEMBLY 8 -2 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a .
- 326 -
Parking Brake System Diagram
SPECIFICATIONS
L
- 329 -
COMPONENTS (Brake Components)
01 (RH)
01 (LH)
I
r-- --I
10 1 OK=(INCL.@) I
I --.,
I
I
A
.- I
r
II
--
%3
%.;
'@
/
(RH)
L -- AY (LH)
- -- J
Brake Components
- 330 -
8-7
REMOVAL
Caution:
0 There are 2 kinds of brake removal method, the method t o remove the brake ASSY and the
method to disassemble the brake sequentially on the vehicle. For example, the latter is used to
replace the brake shoe, etc. with a new one, and the former is used to replace the backing plate,
etc. with a new one. Select either of these two methods according t o the repair operation.
0 The method to disassemble the brake on the vehicle will be described below.
Note:
Remove the brake drum by using 2 service
bolts ( M I 4 X 1.5 pitch).
~emovin
Brake
~ Drum ~ ~ 2 2 - 1 6
Note:
0 Hook a wire t o the spring and remove it
forcibly with a screwdriver.
0 (Reference) when removing the brake
ASSY, the following SST can be used:
SST 0971 7-20010
Note:
Hook a wire to the spring and remove it with
a screwdriver forcedly.
Note:
Three shoe hold springs (the small, large and
middle springs from top to bottom) are
mounted on the shoe on one side. To re-
move the large and middle (the upper and
lower springs), pay special attention because
it is difficult to set the SST to them stably.
- 333 -
13. Remove actuator lever.
(1) Loosen the lock nut.
(2) Snap ring
(3) Actuator lever
Note:
On overhaul, replace the old seals with new
ones.
- 335 -
Spring link and lever inspection
(1) Deformation and fatigue of the shoe re-
turn spring
(2) Deformation and fatigue of the adjuster
spring
(3) Deformation and fatigue of the shoe
hold spring
@ Upper (small):
Free length: 25.4 mm (1.0 in.)
@ Middle (targel:
Free length: 43.7 mm (1.72 in.)
@ Lower (middle): inspecting the Spring ~ ~ 2 3 - 6
Free length: 27.8 mm (1.09 in.)
@ Damage and deformation of the
hold washer link
Deformation and fatigue of the adjuster
lower link
Fatigue of the lever return spring
Damage and wear of the adjuster lever
link
Deformation and damage of the adjuster
upper link
Damage of the automatic adjuster lever
and wear of the adjuster meshing part
5. Adjuster inspection
(1) Wear, damage and deformation of the
teeth
(2) Wear and rotational conditions of the
threaded part
5. Assemblethewheelcylinder.
(1) Baffle plate
(2) Snap ring
(3) Assemble the O-ring, backup ring and U-
packing to the piston. lnsert the result- Connecting the Parking Cable LAGSS-9
ing assembly in the cylinder.
Note:
Before assembly apply hydraulic oil to these
parts sufficiently.
(4) Boots
Note:
Before assembly, apply non-melt lub to the
rotational shaft (shown by the arrow) of the
adjuster lever link.
- 338 -
8. lnstall the brake shoe and adjuster.
(1) Apply non-melt lub to the part (shown
by the arrow).
@ 3 positions on secondary shoe
@ 3 positions on primary shoe
@ 6 positions on backing plate
Note:
Apply non-melt lub to the brake shoe rim
and the backing plate sliding part.
Note:
Tighten the threaded part of the adjuster
fully to decrease i t s full length to the mini-
mum. Install the adjuster together with the
brake shoe and engage the notch of the ad-
juster lever to the gear.
Note:
0 Hook a wire to the spring and guide the
spring to the spring hook hole with a
screwdriver to install it.
0 Follow the assembly order correctly.
30 -- 33 kg-m
Single tire
(212 -- 238 ft-l b)
l nside
30
(212
- 35 kg-m.
253 ft-lb)
Double tire
35 -- 40 kg-m
Outside
-
(253 289 ft-l b)
Tightening the Hub Nuts
13. Release brake air and adjust the brakes.
AIR BLEEDING
Note:
0 Two operators are required for air release
operations.
0 Start the engine and loosen the breather
plug with the brake pedal depressed.
When the bubbles are not observed any
longer in hydraulic oil flowing out,
tighten the breather plug.
Bleeding Wheel Cylinder Air LAQ27.26
AUTOMATIC ADJUSTER OPERATION TEST
Note:
Operate the parking brake lever with the brake drum removed to check the adjuster operation.
Note:
When the meshing part of the screw of the
adjuster lever wears or i s deformed, the pro-
per engagement is impossible and the adjust-
ment screw cannot be adjusted.
LAQ25-24, LAQSI 33
Lever and Screw
BRAKE ADJUSTMENT AND BRAKING FORCE INSPECTION
Brake Adjustment
Note:
When disassembling repairing and replacing the brakes, be sure to adjust the brakes.
1. Advance and back the vehicle repeatedly to adjust the clearance between the brake drum and the
brake shoes.
Note:
0 Forward and backward the vehicle repeatedly in a short distance and apply the foot brake to stop
it.
0 Repeat the forward motion and the backward motion as often as possible.
0 The auto adjuster operates automatically by repetition of braking operation. Finally the clearance
between the brake shoe and brake drum is adjusted to the following value:
3.25, 3.5 ton model: 0.25 -- 0.35 mm (0.0098 -- 0.01 38 in.)
(Clearance on one side)
E3.5, 4.0, 4.5 ton model: 0.3 -- 0.5 mm (0.012 -- 0.020 in.)
(Clearance on one side)
0 When the brake operation is uneven or the braking force is insufficient, remove the brake drum to
check improper adjuster operation, insufficient lining contact, foreign matter adhered to the lining
brake oil (hydraulic oil) leakage, etc.
2. Check the braking force with a brake tester or the running test.
TROUBLESHOOTING
Phenomenon Possible cause Corrective action
Oil leak from hydraulic piping or insufficient oil Repair or oil
level in tank supply
l nsufficient or Damaged reaction piston O-ring Replacement
delayed braking Foreign matter trapping by piston Cleaning or repair
Increased play caused by loosened clevis lock nut Clevis adjustment
Air entrance in wheel cylinder circuit Air bleeding
Spool holding due t o loosened clevis lock nut Adjustment
Brake dragging Foreign matter trapping by spool Cleaning and
correction
i
Caution:
When any of the above phenomena occurs, do not disassemble the brake booster immediately but
check the oil pressure between the brake booster and wheel cylinder. I f the oil pressure i s insufficient,
check the brake booster reaction piston stroke and pump pressure rise. Disassemble and inspect the
brake booster only when it is found to be the cause.
COMPONENTS
- 344 -
-
- 345 -
REMOVAL
DISASSEMBLY
Caution:
Disassemble only when the reaction piston
or cylinder cup i s found defective.
- 348 -
5. Remove the flow divider spool.
(1) Snap ring
(2) Plug
(3) Spring
(4) Flow divider spool
INSPECTION
Caution:
Wash each part with new hydraylic oil, and
inspect the following points. Replace any
defective part.
I f the cylinder body, piston or valve is defec-
tive, replace as SUB-ASSY.
Caution:
When replacement is necessary, always re-
place the piston SUB-ASSY.
Piston SUB-ASSY Inspection 1.~042-2s
Caution:
Always replace the piston SUB-ASSY or
valve SUB-ASSY.
- 350 -
Reaction piston related parts inspection
(1) Scuffing and damage of piston sliding
surf ace
(2) Damage and wear of seal and valve seat
(3) Damage and deformation of control
valve seat
Caution:
Always replace the valve & valve SUB-ASSY
when the seal or O-ring of the control valve
seat is defective.
-
if the ball moves.
T = 0.8 1.2 kg-m (5.78-- 8.66 ft-lb)
- -
( 3 ) lnstall the plug and gasket.
T = 2.7 3.5 kg-m (1 9.5 25.3 ft-lb)
- 352 -
Install the master cylinder pinston SUB-
ASSY.
(1) Fix the body in a vise with the pin hole
on the rear side facing upward.
Caution:
For the clutch model, do not damage the oil
path to the clutch booster when fixing in the
vise.
- 354 -
9. Install the power piston & reaction piston.
(1) Insert the power piston & reaction pis-
ton into the cylinder.
(2) Piston guide
(3) Snap ring
(4) Push the reaction piston with a hand to
check its smooth stroke.
INSTALLATION
Caution:
o Carefully prevent the O-ring at the brake booster and clutch booster joint from being caught.
Connection bolt tightening torque:
T = 3.5 -- 4.5 kg-m (25.3 -- 32.5 ft-lb)
0 Bleed air from the brake system. (See page 8-1 6.)
0 Adjust the brake pedal. (See page 8-36.)
PARKING BRAKE
COMPONENTS
- 356 -
TIPS O N SERVICE OPERATION
1. The removal and disassembly procedures for the parking brake lever ASSY are the same as those for
the 5FG20 series.
5. Coat seal lock agent (Locktite #271 or equivalent) on the threaded portion (D).
6. After fully tightening the knob (E), loosen i t by a half turn. Then tighten knob (F) to the specified
torque.
Knob (F) tightening torque:
T = I .O -- 1.6 kg-m (7.23 -- 11.6 ft-lb)
ADJUSTMENT Clearance
or more
1. Parking brake cable adjustment
( 1 ) Be sure that the parking cables are
correctly installed to the clamps.
Matching marks
- 358 -
8-35
BRAKE PEDAL
COMPONENTS
12 w i r e ASSY, inching
20 Pedal SUB-ASSY, brake
20A Bushing (For brake pedal)
21 Link SUB-ASSY, brake, No. 1
23 Link SUB-ASSY, brake, No. 2
23A Bushing (For brake link)
28 Link SUB-ASSY, inching
34 Pedal SUB-ASSY, inching brake
34A Bushing (For inching brake pedal)
40 Pad, pedal
43 Spring, torsion (For pedal return)
57 Spring, torsion (For pedal return)
AA Spacer
AE Spacer
Al Pin, w/ hole
AK Pin, w/ hole
AQ Bolt
ET Spacer
-
Up to '88 Sep.
-
10 15 mm (0.39 0.59 in.)
From '88 Oct.
5 -- 8 mm (0.20 -- 0.31 in.)
Push rod play:
1 - 2 mm (0.04 -- 0.08 in.)
Push Rod Play
I
(3) After the above adjustment, depress the
brake pedal fully and check the depress-
ed brake pedal height. \
\
Depressed brake pedal height: \
\
\
90 mm (3.54 in.) or more \
\
Floor clearance
F~
0.5
(Pedal
mmplay)
(0.02 in.)
Page
COMPONENTS .................................... 9-2
COMBINATION METER ............................ 9 -4
REMOVAL ...................................... 9-5
DISASSEMBLY ................................. 9-5
ASSEMBLY AND INSTALLATION ................ 9-6
BALANCE WEIGHT ................................ 9 - 7
REMOVAL ...................................... 9 - 7
COMPONENTS
28 Boot Cover
30 Toe-board SUB-ASSY, No. 1 Cover
AG Safety walk Spacer
AH Cover Rubber
AP Plug, hole Cover
BZ Grommet Floor SUB-ASSY, No. 1
CU Rubber Box SUB-ASSY, instrument panel
CW Rubber Packing
CY Rubber Silencer
DA Rubber Clip
- 364 -
COMBINATION METER
Hour meter
Air cleaner cleaning warning lamp
Engine oil pressure warning lamp
Charge warning lamp
Preheating indicator lamp
(diesel models: Standard in designated area)
Water temperature gauge
Sedimenter warning lamp (diesel models)
Fuel gauge
Fuel warning lamp (OK monitor: OPT)
Engine coolant level warning lamp
(OK monitor: OPT)
Battery electrolyte level warning lamp
(OK monitor: OPT)
Brake warning lamp (OK monitor: OPT)
Torque converter oil temperature gauge (OPT)
Combination Meter
- 366 -
REMOVAL
1. Removethecover.
( 1 ) Set screws
(2) Cover
DISASSEMBLY
-
3. Remove the instrument panel box.
(1) Screws
(2) lnstrument panel box
- 368 -
BALANCE WEIGHT
REMOVAL
~ e m o v i the
n ~ Set ~ o tand
t Cap LAQ~~-2.3
Weight (approx.)
Vehicle model
kg (Ib)
3.25 ton model 1920 (4234)
3.5 ton model 2220 (4895)
E3.5 ton model 2130 (4410)
4.0 ton model 2520 (5557)
4.5 ton model 2830 (6240) Removing the Balance Weight LAQ66-6
MATERIAL HANDLING SYSTEM
Page
HYDRAULIC PRESSURE PIPING ............... 10-2
HYDRAULIC CIRCUIT ......................... 10-3
CLUTCH VEHICLE HYDRAULIC
CIRCUIT (STD) ..............................
TORQUE CONVERTER VEHICLE
HYDRAULIC CIRCUIT (STD) .................
NATURAL DROP TEST .........................
NATURAL FORWARD TEST ....................
OIL LEAK TEST ................................
LIFT CYLINDER .............................
TILT CYLINDER .............................
HYDRAULIC PRESSURE PIPING (V mast)
Oil tank
Return filter
Clutch master
- 373 -
Brake wheel cylinder
- -
load conditions. Raise the forks by about 1
1.5 m (40 60 in.) and stop the engine.
-
load conditions. Raise the forks by about 1
-
1.5 m (40 60 in.)
-
Oil leak amount standard (at lift port) :
-
6 16 cc (0.37 0.98 cu.in.)
Note:
When the natural drop is great even through
the oil leakage amount is within the standard
value, the lift cylinder packing is defective.
TILT CYLINDER
- 381 -
REMOVAL
Caution:
0 Check the operation of the mast and the related parts and the clearance between the rollers t o
check any defect correctly before removing the mast.
0 When removing the mast ASSY after removing the tilt bracket, it can be comparatively easily re-
moved.
Caution:
When raising the inner mast, pay attention
so that the slackened chain does not tangle
around the inner mast.
4. Disconnectthehose.
(1) Lower the inner mast fully.
(2) Overflow hose
(3) High pressure hose
"
ASSY with a new one, it is not necessary Matching Marks ~ ~ 6 3 - 1 1
Caution:
0 Never lean the removed mast against the
wall, etc. Lay down it at the height as low
as possible.
0 Place the removed mast in a wide margin
in the up and down directions and the
mast sliding direction (about one mast
Laying-down the Mast ~047-34
length) to disassembly it freely.
DISASSEMBLY
- -
. - -
. . - -
(2) Plate
(3) Shim
(4) Lift cylinder support
Note:
When the lift roller is firmly fit, use SST
09950-20017.
Note:
When the lift roller is firmly fit, use SST
09950-20017.
Note:
Replace the mast strip when no oil is re-
tained.
Caution:
Replace when oil pockets are won out.
ASSEMBLY
Caution:
0 Assemble each roller of the mast sequently while adjusting the shim according to the mast adjust-
ment standard.
0 Apply MP grease to the inner mast sliding face of the mast strip.
Note:
0 Add the shims to stop the gap caused
after the mast clearance measurement.
0 Shim thickness: 0.5 and 1.0 mm (0.02
and 0.04 in.)
Note:
Selecting the Shims (Inner Mast Roller) 1.~048-24
Place a block under the outer mast side so
that the inner mast can slide as before disas-
sembly.
INSTALLATION
Caution:
o Before assembly, apply MP grease to the mast support bushing and the tilt cylinder front pin.
0 When installing the mast support cap and the tilt cylinder front pin, confirm that the match marks.
0 When replacing the old mast ASSY outer mast, inner mast or lift cylinder with a new one, check
the uneven motion of the lift cylinder and adjust it, if necessary. See lift cylinder rod shim adjust-
ment section for the inspection and adjustment methods.
LIFT BRACKET
REMOVAL
Note:
0 When replacing the old lift bracket roller
with a new one or when adjusting the
shims, be sure to remove the bracket.
0 See Mast ASSY removal, paragraph 1
through 3 for the lift bracket removal
procedure.
Removing the Lift Bracket ~ ~ 6 3 - 3 3
1. Remove the lift bracket.
DISASSEMBLY
-391 -
2. Remove the side rollers.
4.5 t o n model
( 1 ) Set bolts
(2) Holder
(3) Shim
(4) Spacer
(5) Side roller shaft
(6) Side roller
INSPECTION
Note:
0 See Mast ASSY removal section, para-
graph 1 and 2 for the chain wheel remov-
al procedure.
0 See the Mast ASSY removal section, para-
graph 1 through 3 for the removal pro-
cedure up to the lift bracket removal of
the chain. See the paragraph 2 given be- ~emovin
the
~ Chain Wheel LAQ65-31
low for the subsequent operation.
INSPECTION
1. Chains inspection
(1) Expansion
SST 09631 -22000-7 1
Caution:
Check the chain expansion before removing
the chain from the vehicle.
Caution:
0 Refer to the section under "Chain Adjust-
ing" to install the parts correctly.
0 Tighten the adjust nut in accordance with
the procedure for Tightening. The chain Chain anchor bolt
must be tightened correctly in parallel to
the chain wheel without torsion. Chain Installation
-----
7
H2000-H3700 H4000--
Lift bracket side Outer mast side
H4000 -
1. Same as steps 1 and 2 for the lift bracket
side.
4.5 ton model
7-------
3
i 0
@+
0 0
1. Fully fasten 0 to @ .
2. Fully fasten @ to @ .
Tighten 0 and 0 .
3.
-
T = 10 15 kg-m (72 - 108 ft-lb)
ADJUSTMENT
Note:
QZ,)
Tire
0 Measure the distance between the fork
Inner mast
bottom and ground (dimension h) as
Lift bracket roller
shown in figure on the right. Fork
0 When the fork is at the position of the di-
mension h, the bottom of the l i f t bracket r-.
h A B
mm (in.) mm (in.) mm (in.)
3.25-4.0 0-5 40 110
ton models (0-0.2) (1.6) (4.3)
4.5 ton 0-5 59 75 Chain Adjusting with the Fork at the Highest ~~Qs139
model (0-0.2) (2.3) (3.0) Position (3.25-4.0ton models)
Note:
0 Dimension A is taken when h = 0.
0 Dimension B is a reference value.
INSTALLATION
INSPECTION
1. Forks inspection
(1 ) Bend, crack and unaligned tips.
Fork bend limit: 15 mm (0.16 in.)
Fork tip alignment error limit: 10 mm
(0.4 in.)
Inspecting the Forks ~~0.59-28
Caution:
When the unaligned tip exceeds the limit,
check the bend of the single fork, play of
the fork installed part and the distortion of
the lift bracket finger bar.
the mast titled forward. Lift Bracket Raised Position
(3) Attach a wire to the backrest when ad-
justing the upper roller and to the finger
bar underside when adjusting the lower
roller, then raise up. -
(0.02 0.08 in.)
Important:
Stop raising just before the lift bracket
upper rollers comes out from the inner mast.
(2) If incorrect, change t o an over sized roller. See " Lift bracket" heading for the replacement pro-
cedure.
Caution:
0 When changing to an over size, the clearance should be no smaller than 0.5 mm (0.0197 in.)
0 When changing to an over size, prior to installation, confirm whether it is slidable or not by moving
the lower portion of the mast with the over size roller, if not, the lower portion of the mast needs
to be adjusted with a grinder to make it slidable.
Adjustment in lateral direciton
(1) Mount a dial gauge on the inner mast.
(2) From the opposite side, press the lift
bracket against the inner mast with a
screw driver, align the dial gauge in con-
tact with the lift bracket side and set
the indicator t o "0".
(3) Insert a screw driver between the dial
gauge lift bracket side and the inner
mast, press the lift bracket lower rollers
against the inner mast.
(4) Measure the amount of shift in lateral
Adjusting in Lateral Direction (Lower Roller) wQ62-1
direction at the lower roller.
-
Specified shift:
0 0.5 mm (0-- 0.020 in.)
(5) If defective, take the following actions:
@ Screw in bolt @ fully to the lower
roller pin of the lift bracket.
@ Install lower lift roller @ .
@ Fix lower lift roller @ to bolt @ @ Bottom recessed lift roller
by snap ring @ .
@ Adjust the lower lift roller. Lift bracket
@ Lock bolt @ by nut @ .
@ Nut
4.5 ton model
Note:
Lift rollers among lift bracket rollers require
no adjustment because they are fixed by
snap rings.
Bring into
contact
Outer
Measure with this rolling
surface in close contact
0-0.5mm(0-0.020in.)
- 399 -
LIFT BRACKET SIDE ROLLER
ADJUSTMENT
Note:
Do not project the lift bracket upper roller
beyond the inner mast.
3. Shim adjustment
- 400 -
Apply a wire to the inner mast lower tie Masts Raised Position
beam and lift it by a hoist, etc. for safety
operation.
V, SV mast
\
Bring into conLact This roller
(0-0.03in.)
LAQS1 44
Clearance between the Outer Mast and the lnner Mast Roller
Outer mast roller measurement
(1) Set the dial gauge to the outer mast.
(2) Press the inner mast against the outer
mast roller with a screwdriver from the
side opposite to the side where the dial
gauge is set to apply t o the dial gauge t o
the inner mast inside and adjust the
pointer t o the "0" position.
(3) Insert the screwdriver between the inner
mast on the side where the dial gauge is
set and the outer mast to press the inner
mast against the outer mast roller.
Adjusting the Outer Mast Roller ~ ~ 6 2 - 8
(4) Measure the moving distance of the inner
mast in the right and left directions.
Moving distance standard: 0 -- 0.8 mm (0-- 0.03 in.)
(5) When the outer mast roller is defective, adjust the outer mast roller shims.
V, SV mast
This roller
(0-0.03 in.)
(Position where the
roller is the nearest)
Clearance between the Inner Mast and the Outer Mast Roller LAQSI~~
Note:
0 When the roller and the shims are judged
defective by the measurement, replace
them with new ones.
0 Adjust the roller and the shims with the
lift bracket removed. See Mast ASSY re-
moval paragraph 1 through 3 for the re-
moval procedure.
Caution:
0 When hoisting the lift cylinder ASSY try
safe operation.
0 Remove the lift cylinder not to damage
the elbow at the cylinder bottom fittings.
0 Lay the removed cylinder down securely
on blocks.
Note:
Tilt the mast backward.
Note:
Confirm that the inner mast is in contact
with the outer mast roller.
Note:
0 Carry out adjustment when the measured
clearance is judged defective.
0 Use shims for adjustment.
0 Refer to steps (1) to (4) in the preceding
roller and shim adjustment section (from
lift bracket removal to inner mast lower-
ing) for the mast strip removal procedure.
Inspection method
Slowly raise the inner mast, and observe the
stopping of the right and left cylinder rods
the moment the inner mast reaches the
maximum height.
(1) Normal case
Both the right and left 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 the mo- 1~063-3
Inspecting Uneven Movement of Lift Cylinder
ment the later rod stops. To correct,
add shims to the cylinder that stops
first.
2. Adjustment method
(1) Raise the inner mast. Set SST to the
outer master tie-beam, and lower the
inner mast until i t reaches SST.
(2) Remove the set bolt of the cylinder rod
end on the side for shim adjustment.
(3) Slowly lower the lift cylinder rod t o dis-
connect the rod end.
(4) Place the shims on the cylinder rod end.
Slowly raise the lift cilinder rod into SSTSet
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 decided.
Shim thickness:
0.5 and 1.0 mm' (0.02 and 0.04 in.)
Shim Adjustment
- 406 -
20 Mast SUB-ASSY, outer
20B Bushing, mast support
21 Mast SUB-ASSY, inner
30 Strip SUB-ASSY, outer mast
30A Shim, outer mast strip
40 Roller, lift (For outer mast)
40A Shim, lift roller (For outer mast)
41 Roller, lift (For inner mast)
41A Shim, lift roller (For,inner mast)
53 Cushion, mast (For inner mast)
AC Stoper, inner mast U
AD Fitting, grease
AJ Shim, stopper
BH Cap, mast support
- 408 -
Mast SUB-ASSY, outer Shim, lift roller (For middle mast upper)
Bushing, mast support Roller, lift (For middle mast lower)
Mast SUB-ASSY, inner Shim, lift roller (For middle mast lower)
Mast SUB-ASSY, middle Roller, side (For inner mast)
Strip SUB-ASSY, outer mast Ring, shaft snap (For inner mast side roller)
Shim, outer mast strip Shaft, side roller (For inner mast)
Strip SUB-ASSY, middle mast Holder, side roller shaft (For inner mast)
Shim, middle mast strip Shim (For inner mast shaft holder)
Roller, lift (For outer mast) Fitting, grease
Shim, lift roller (For outer mast) Cover, roller
Roller, lift (For inner mast) Cap, mast support
Shim, lift roller (For inner mast) Guard, pipe
Roller, lift (For middle mast upper)
- 409 -
Backet SUB-ASSY
Fork SUB-ASSY
Bracket SUB-ASSY, lift
Roller, lift (Upper, lower)
Ring, shaft snap (Upper, lower)
Roller, lift (Center)
Ring, shaft snap (Center)
Roller, side
Pin, fork stopper
Knob, fork stopper pin
Spring, fork stopper pin
Pin, spring (For fork stopper pin)
Pin, side roller
Shim (For side roller pin)
Cover, lift bracket roller
Plate, side
Bolt
Ring, snap
Collar
- 410-
m;)
[LBACKREST]
~ - - A A
,
21 .
( W GERMANY)
20 Bracket SUB-ASSY
B
21 Fork SUB-ASSY
22 Bracket SUB-ASSY, lift
40 Roller, lift (Upper, lower)
40A Ring, shaft snap (Upper, lower)
42 Roller, side
42B Spacer (For side roller)
43 Shaft, side roller
44 Holder, side roller shaft
44A Shim (For shaft holder)
46 Pin, fork stopper
47 Knob, fork stopper pin
48 Spring, fork stopper pin
49 Pin, spring (For fork stopper pin)
AA Cover, lift bracket roller
AB Plate, side
- 411 -
20 Chain SUB ASSY
20A Nut, chain adjust
20M Bolt kit, chain eye
20N Link kit, chain joint
30 Beam SUB-ASSY, chain
30A Bushing
31 Pin SUB-ASSY, chain wheel
40 Wheel, chain
AC Clamp, chain anchor bolt
AE Washer, chain special
AN Nut, hexagon
A0 Pin, spring
AP Collar, chain wheel
BW Bolt
- 413-
Chain SUB ASSY (Front) Ring, shaft snap (For chain wheel)
Nut, chain adjust (Front) Support, chain wheel
Bolt kit, chain anchor, No. 1 (Front) Clamp, chain anchor bolt
Bolt kit, chain anchor, No. 2 (Front) Washer, chain special
Chain SUB-ASSY (Rear) Cover, chain wheel
Nut, chain adjust (Rear) Cover, chain wheel
Bolt kit, chain eye Nut, hexagon
Link kit, chain joint Nut, lock
Wheel, chain (Front) Stopper, chain
Ring, shaft snap (For front chain wheel) Bolt
Wheel, chain (Rear)
- 414-
-
FV mast
Adjusting the Clearance between Lift Bracket Rollers and Inner Mast LAOSI47
1. Make adjustment with the upper lift roller of the lift bracket placed at 100 mm (4.0 in.) from the top
end of the inner mast.
2. No clearance adjustment is rewuired for the upper and center lift rollers because they are fixed by
snap rings.
- -
3. For the lower lift roller, shift the lift bracket to one side to bring the roller into contact with the mast
and adjust the clearance to 0 0.5 mm (0 0.020 in.) at the roller side surface nearest to the mast
on the opposite side.
4. Start the upper side roller adjustment after the lower lift roller (in step 3 above). Bring the side roller
- -
on one side into contact with the mast, and adjust the clearance between the side roller and mast on
the opposite side to 0 0.5 mm (0 0.020 in.)
5. Start the lower side roller adjustment after adjusting the lower lift roller and upper side roller (in step
3 and 4 above). Shift the lift bracket to one side to bring the upper side roller and lower lift roller
into contact with the mast, and adjust the clearance between the mast inside surface and lower side
roller t o 0.5 -- 1 mm (0.020 -- 0.039 in.). Make the same adjustment on the opposite side.
6. After making moves smoothly along the overall mast length and that the lower side roller is not ro-
tated by contact with the mast. If the side roller is rotated, repeat adjustment in step 5 to increase the
clearance between the roller and mast slightly and check that the lower side roller is not rotated
throughout the overall mast length.
* The lower side roller is a bottom-recessed roller. The installation method is shown below.
1. Of the lift bracket rollers for all masts for 4.5 ton model, lift rollers requires no adjustment because
they are fixed by snap rings. For side rollers, bring the side roller on one side into contact with the
mast, and adjust the clearance between the side roller and mast inside surface on the opposite side to
2.
- -
0 0.8 mm (0 0.032 in.).
For adjustment, place the center of the upper lift roller of the lift bracket at 100 mm (3.9 in.) from
the top end of the inner mast.
3. After adjustment, check that the lift bracket moves smoothly along the overall mast length.
LIFT ROLLER ADJUSTMENT AT MAST
All Masts
FV mast
This roller
FSV mast
Bring into conta
Outer
This roller
(4) After the adjustments, check that the inner mast moves smoothly in the outer and middle masts
and the middle mast moves smoothly in the outer mast.
2. Middle mast and inner mast rollers (FSV, 4.5 ton model)
(1) Since inner mast rollers are cross rollers, the lift rollers are fixed by snap rings. For side rollers,
bring the side roller on one side into contact with the mast side surface and adjust the clearance
between the side roller and mast side surface on the opposite side to 0 -- 0.8 mm (0 - 0.03 in.).
(2) Afterthe adjustment, check the mast moves smoothly in the middle mast.
(3) Carry out measurement when the mast overlap is near 500 mm (19.7 in.).
FV mast
This roller
Outer'
roller is the nearest)
Middle
(4) After the adjustment, check that the mutual mast movements are smooth.
- 418 -
CYLINDER
Page
I
!2
Lift Cylinder Sectional View (4.5 ton Model)
- 420 -
Rear Lift Cylinder (FSV)
n
'rr'
- - - - -- - -
*---*---
Qn
L
- 422 -
SPECIFICATIONS
Lift Cylinder (VmSV)
1
3.25 -- 4.0 ton models 4.5 ton model
l tem V, SV V
Cyl inder type Single-acting hydraulic system t
Cylinder number 2 t
Cyl inder stroke mm (in.) 1500 (59) Lifting height: 3000 (118)
Piston seal type U-Packing t
Cylinder number 1 t t t
Cylinder number 2 t t t
Lift Cylinder
r.-- I
02K
11
-.-q
7
1 AI--43
- 9
I
II.-
& ..-J Bpf2!,,.,,$. AK
02(LH)
/1&~ BP
O~(RH)
...q
:
-01K
I :
L.. .-.J b--. 0-0 J
- 425 -
REMOVAL (V)
Note:
When the chain wheel is firmly fit, use SST
09950-2001 7.
Caution:
When raising the inner mast, pay attention
so that the slackened chain does not tangle
around the inner mast.
Caution:
To prevent the uneven movement of the
right and left lift cylinders, the shims at: the
lift cylinder rod end are adjusted. RemenI ber
which cylinder i s used for adjustment and
the number of shims.
Caution:
0 When raising the lift cylinder, pay atten-
tion for the safety operation.
0 When taking out the lift cylinder ASSY,
do not damage the bottom elbow.
DISASSEMBLY (V)
Caution:
Pull out the lift cylinder rod in parallel with
the cylinder without scratching it.
Caution:
The piston and the piston rod cannot be
disassembled.
Caution:
0 The flow regulator valve is installed in the
lift cylinder RH.
0 The safety down valve is installed in the
lift cylinder LH.
Caution:
0 Oil leaks when the rod guide U-packing or dust seal i s defective.
0 Hydraulic drift occurs when the piston U-packing i s defective.
0 Wash each part and replace any defective or damaged part.
7. Valve inspection
(1) Flow regulator valve
(2) Safety down valve
- 431 -
ASSEMBLY (V)
Caution:
0 Do not assemble the dry parts. Apply hydraulic oil to the parts before assembly.
0 When assembling the parts after disassembly, be sure to use the new O-rings, U-packing and dust
seals.
INSTALLATION (V)
Caution:
0 Adjust the tension of the right and left lift chains equally.
0 Raise and lower the forks through the entire stroke repeatedly under no load conditions t o release
air and to confirm that the operation in normal.
0 After confirming the operation, check the hydraulic oil amount with the oil level gauge. When it is
insufficient, replenish hydraulic oil No. 90.
0 Confirm that the lifting height is normal.
0 When replacing the old lift cylinder ASSY, lift cylinder SUB-ASSY or lift cylinder rod SUB-ASSY
with a new one, check the uneven motion of the lift cylinder and adjust the operation. See Lift
cylinder rod shim adjustment section for the inspection and adjustment method.
REMOVAL
Caution:
o The flow regulator valve can be removed on the vehicle.
0 Before removal, measure the lowering speed for quality judgement.
0 The flow regulator valve i s set to the lift cylinder RH.
INSPECTION
Removing the Flow Regulator Valve ~ ~ 6 9 - 5
1. Check the top cover for slippage or damage.
INSTALLATION
The installation procedure is the reverse of the Inspecting the Flow Regu1at0rVa1ve LAQ49-22
removal procedure.
Caution:
Flow regulator valve tightening torque:
T = 9.0 -- 10.0 kg-m (65.0 -- 72.2 ft-lb)
SAFETY DOWN VALVE
SPEC1FICATIONS
REMOVAL
Caution:
0 The safety down valve can be removed on the vehicle.
o The safety down valve is set to the lift cylinder LH.
DISASSEMBLY
INSPECTION
2. Check the spring for fatigue, Or damage ins- Removing the valve and spring ~ ~ 4 9 - 2 6
pection.
INSTALLATION
Caution:
-
Safety down valve tightening torque
T = 6.0 7.0 kg-m (43.3-- 50.5 ft-1b)
Safety Down Valve Inspection LAQ49-27
TILT CYLINDER
GENERAL
SPECIFICATIONS
Cylinder type Double acting
No. of cylinder 2
Cylinder outside diameter mm (in.) $1 02 (4.02)
Cylinder inside diameter mm (in.) $90 (3.54)
Piston rod outside diameter mm (in.) $40 (1.57)
Piston stroke mm (in.) 184 (7.24)
Piston seal type U-packing
Rod seal type U-packing
REMOVAL
Caution:
The U-packing of the tilt cylinder can be re-
placed on the vehicle without removing the
cylinder ASSY. The method to disassemble
the cylinder ASSY after removing it will be
described below.
theaded hole or stamp the match marks. Removing the Stopper Plate ~ ~ 6 3 - 1 2
DISASSEMBLY
Caution:
Pull out the piston rod in parallel with the
cy tinder.
(3) Piston
Caution:
0 Inspect the U-packing while it is installed
t o the piston. Remove it when any defect
is found.
0 Wind the vinyl tape, etc. around a spatula
so as not to damage the piston.
Caution:
Only when the damage of the sleeve i s ob-
Disassembling the Rod Guide ~054-5
served remove it with a press.
INSPECTION
Caution:
0 When the U-packing of the rod guide and1
or the dust seal is defective, oil leaks.
0 When the U-packing of the piston is de-
fective. the natural forward tilt occurs.
0 Wash each part. Replace any defective or
damaged part with a new one.
Piston inspection
(1) Wear and damage of the piston
(2) Wear and damage .and denaturation of
the U-packing
(3) Wear, damage and crack of the sleeve
- 442 -
4. Rod guide inspection
(1) Wear and damage of the guide sleeve
(2) Wear, damage and denaturation of the
U-packing
(3) Wear, damage and denaturation ring of
the dust seal, O-ring and backup ring
(4) Damage of the rod guide
5. Cylinder inspection
(1) Damage of the threaded part
(2) Crack of the cylinder cover
ASSEMBLY
Caution:
0 Do not assemble the dry parts. Apply hydraulic oil to them.
0 Be sure to use the new U-packing and O-ring, etc. except that they are not damaged or used for a
short time.
INSTALLATION
Caution:
0 Apply chassis grease special (MP grease) to the front pin insertion part and the rear pin insertion
part.
0 Confirm the match mark on the front pin. When replacing the old tilt-cylinder with a new one, as-
(3) When adjusting the stopper plate by *45O, the rod length can be adjusted by k3.5 mm (0.14 in.).
Adjustment (3)
- 445 -
(4) When adjusting the front pin by *60°, the rod length can be adjusted by f4.3 mm (0.17 in.).
(5) Follow the procedures (1) through (4) by combining them according to the necessity to satisfy
the standards.
OIL PUMP
Page
OIL PUMP ...................................... 13-2
GENERAL .................................... 13-2
SPECIFICATIONS ............................ 13-2
COMPONENTS .............................. 13-3
REMOVAL ................................... 13-4
DISASSEMBLY .............................. 13-6
INSPECTION ................................. 13-10
ASSEMBLY .................................. 13-12
INSTALLATION .............................. 13-1 4
TEST METHOD ............................... 13-15
OIL PUMP DRIVE SHAFT ....................... 13-1 6
GENERAL .................................... 13-16
COMPONENTS .............................. 13-17
REMOVAL ................................... 13-1 8
DISASSEMBLY .............................. 13-1 8
INSPECTION ................................. 13-1 9
ASSEMBLY .................................. 13-19
INSTALLATION .............................. 13-19
OIL PUMP
GENERAL
SPECIFICATIONS
Main pump
(Front side) 52.7 (3.21 ) 44.6 (2.72)
Theoretical discharge amount
cclrev (cu-in.) Sub pump
(Rear side) 7.1 (0.43) t
Main pump
Discharge (Front side) 76 (20.1) 64 ( 16.9)
Qlmin (US gallmin)
Sub pump
(at Pump speed of 1500 rpm) (Rear side) 10 (2.6) t
Caution:
Tie the oil pump drive shaft with a wire to
prevent separation.
DISASSEMBLY
Caution:
0 Perform the operation in a clean place.
0 Wash the parts in new hydraulic oil.
7. Remove t h e seals.
(1 ) Back up ring
(2) Gasket
(3) Gasket
( 4 ) Side plate A
- 454 -
Putting the Match Marks ~ ~ 5 4 - 3 6
- 455 -
1 1. Remove the sea Is.
(1 ) Back up ring
(2) Gasket
(3) Gasket
Caution:
After disassembly, confirm the dirt and dis-
coloration of the parts and wash them for
inspection.
Caution:
Be sure to replace a set of the wears
- at a time.
Inspecting the Gears ~ ~ 0 5 5 - 115
4.
4. Seals inspection
(1) Tear and cutting of the gasket
(2) Damage of the spacer
Caution:
Clean every component part sufficiently,
blow them with compressed air, apply them
hydraulic oil, and then assemble them.
Caution:
Assemble the drive and driven gears sccord-
ing to the match marks so that the tooth sur-
faces in mesh are engaged with each other
again.
- 459 -
9. Assemble the seals.
(1 ) Apply grease to seals.
(2) Gasket
(3) Gasket
(4) Side plate B
Caution:
Assemble the drive and driven gears sccord-
ing to the match marks so that the tooth sur-
faces in mesh are engaged with each other
again.
INSTALLATION
Reamer bolt
TEST METHOD
Caution:
I t is necessary to conduct the bench test t o test the oil pump strictly. However, it is impossible to
conduct such test in the actual field service. The oil pump discharge amount i s checked by the rise of
the lift cylinder after mounting it on the vehicle.
1. Set the oil pressure gauge (200 k g /cm 2 ) to the oil control valve and the tachometer to the engine.
2.
3.
Start the engine.
Operate the engine at the rotational frequency of 500
control valve lever set at the neutral position.
- 1,000 rpm for 10 minutes with the oil
4. When the oil pump is normal, operate the oil pump by rotating the engine at 1,500- 2,000 rpm for
10 minutes.
Caution:
When any abnormality is observed in the test described in the paragraph 3 and 4, stop the engine
immediately and disassemble the oil pump again.
5. Confirm that the relief set pressure of the oil control valve is as specified.
See Oil control valve adjustment section for details.
6. Confirm that the engine rotational frequency is as specified.
See Engine rotational frequency adjustment section for details.
7. Check the lift cylinder raising speed.
- 463 -
REMOVAL
Caution:
For removing sequence of the oil pump drive
shaft, refer to Items 2 to 5 of the "OIL
PUMP REMOVAL".
DISASSEMBLY
- 464 -
INSPECTION
Caution:
0 Wash each part. Repair or replace any defective part.
0 Although some part can be disassembled, the service parts are not available. In this case, it is
necessary to replace one ASSY with a new one.
0 Do not disconnect the coupling yoke.
Spider inspection.
(1 ) Deformation, crack, damage and wear
Yoke inspection
(1) Deformation, crack, damage and wear
ASSEMBLY
Caution :
0 Apply MP grease sufficiently in the needle roller bearing cup.
0 Confirm the match marks. Assemble the spider, yoke and piece.
0 Do not disconnect the coupling yoke.
0 I f the coupling yoke is disconnected, either replace with a new ASSY or connect the
coupling yoke according to the steps below.
( 1) Uncaulk the seal cover and remove the seal w/cover.
(2) Fit the seal w/cover to the yoke shaft.
(3) Connect the coupling yoke.
(4) Caulk the seal cover.
INSTALLATION
Page
GENERAL ...................................... 14-2
HYDRAULIC PRESSURE CIRCUIT
DIAGRAM ...................................... 14-4
SPECIFICATIONS ............................... 14-4
COMPONENTS ................................. 14-5
OIL CONTROL VALVE ASSY ..................... 14-7
REMOVAL .................................... 14-7
DISASSEMBLY ............................... 14-8
INSPECTION ................................. 14-1 1
ASSEMBLY ................................... 14-13
INSTALLATION ............................... 14-15
ADJUSTMENT ............................... 14-16
GENERAL
Oil Control Valve
Relief Valve
Orifice
- 468 -
Check Valve
\
Check valve
Tilt spool
I
Tilt Lock Valve Sectional View (When i n Neutral Point) LAOSI 82
I
Flow Divider
--c2
c3
T1 T2 P PS
-
Hydraulic Pressure Circuit Diagram LAOS102
SPECIFICATIONS
h
ltem
- Model 3.25 - 4.5 ton models
- 471 -
20 Lever SUB-ASSY, control valve, No. 1
21 Lever SUB-ASSY, control valve, No. 2
30 Rod SUB-ASSY, control valve lever, No. 1
30A Pin (For control valve lever rod)
40 Knob, oil control valve lever
49 Boot, control valve link, NO. 2
66 Bolt (For valve lever)
66A Bushing
AA Bracket SUB-ASSY
- 472 -
Removing the Toe-Board LAQS~-32,
35
Caution:
0 Perform the operation in a clean place.
0 Since each part is finished with high
accuracy, do not scratch it.
(4) Stopper
(5) Valve seat
(3) Spring
(4) Tilt lock plunger
-
INSPECTION
Caution:
0 Wash each part carefully. Repair or re-
place any defective part.
0 Although some part can be disassembled,
the service part is not available. It is
necessary t o replace one ASSY at a time.
2. Spool inspection
( 1) Damage of the lift spool
(2) Damage of the tilt spool
Note:
Conduct the oil leak test t o check the wear
o f the spool.
- 477 -
Flow divider valve inspect ion
(1) Sliding conditions of the piston
(2) Damage o f the ctieck valve
(3) Break and fatigue of the spring
2. Assemblethefitting
Note:
When disassembling the relief valve, be sure
to loosen the adjusting screw fully.
Caution:
Assemble the seal holder in the correct direc-
tion.
480 -
Assembling the Spool 1.~061-17
Caution:
Assemble the seal holder in the correct
direction.
INSTALLATION
Note:
0 Install the toe board after making the adjustment.
0 Apply chassis grease special (molybdenum disulfide grease) to the links of the oil control valve
lever.
Caution:
Be sure to make the adjustment according t o
the procedure given below. I f not so, the
hydraulic devices such as the oil pump may
be damaged by improperly adjusted hydrau-
lic pressure.
Note:
0 Confirm that the no-load static maximum
rotational frequency is as specified. See
Engine adjustment section for details.
0 When the hydraulic oil pressure exceeds
the specified value, set the control lever
to the neutral position immediately.
5. After adjusting the hydraulic oil pressure, tighten the lock nut and the cap nut.
6. Remove the oil pressure gauge and mount the toe board.
APPENDIX
Page
SSTLlST ....................................... 1 5 -2
SERVICE STANDARDS ......................... 15-7
WIRING DIAGRAM ............................. 15-21
SST LIST
09220-22000-71
Remover & replacer,
torque converter
clutch drum spring
09228-4401 1
Wrench, oil filter
0
09230-201 50-7 1
Remover, torque
converter drive cover 0
09310-22000-71
Remover, reamer
09320-23000-71
Remover, bearing
Illustration Parts Number 1 2 3 4 5 6 7 811127314
and Name
@
09330-30010
Tool, universal
joint flange holding 0
09330-32880-7 1
rB Wrench, counter
shaft nut
09370-20270-7 1
0
Replacer, drive
pinion bearing 0 0 0
09420-201 50-7 1
Remover & replacer,
king pin needle 0
bearing
09420-23000-7 1
Remover, bearing
0
Illustration Parts Number 1 2 3 4 5 6 7 8 1 1 121314
and Name
09 510-3 1 960-7 1
Remover & replacer,
brake hold down 0
spring
09608-2001 2
Tool set. front hub
GB e
d 0 0
S @CB
09608-300 1 2
09608-3501 4
e$g!j:
m
Ir.R
-Qab@
TOOI set, axle hub
& drive pinion
bearing
0 0 0 0
09609-2001 1
Puller, steering
wheel 0
Remover & replacer,
oil control valve
096 10-2001 2
Puller, pitman arm
096 1 1-20015
Puller, tie-rod end
0
09620-101 00-71
Remover & replacer,
cylinder cap 0 0
09620-10160-71
Remover & replacer,
cylinder cap 0
09620-30010
Q
fa Replacer, steering
gear box 0 0 0 0 0 0
Q
Q
Illustration Parts Number 1 2 3 4 5 6 7 811121314
and Name
09631 -22000-71
f.-MRY+
r*.'*yyy.' ~~~~:])
:-.?i
Chain wear scale
.--- .
0
-roroG
"
FOR.+
' . -
-zz=cizz
,$
09700-30200-71
Remover, spring
pin tool 0
0971 7-20010
Remover, brake shoe
return spring 0
09718-20010
Replacer, brake shoe
return spring 0
09810-201 72-71
Remover, joint pin
0 0 0
09905-00012
Expander, snap ring
0 0
09950-20017
Puller, universal
0 0 0 0 0 0 0
SERVICE STANDARDS
ENGINE
CLUTCH
TORQUE CONVERTER
Item 1 3.25 - 4.5 ton models
I Inner
I Standard I 1 53.5 ( 6 . 0 4 3 )
Regulator valve spring free
length mm (in.)
Outer
Limit 1 3 5 . 0 (5.31 5)
Transmis-
slon cover Standard 153.5 (6.043)
Accumulator spring free length mm (in.)
& cotrol Limit 138.5 (5.453)
valve
Standard 128 (5.04)
Inching valve spring free length mm (in.)
Limit 115.5 (4.574)
Standard 6 4 (2.52)
Selector valve spring free length mm (in.)
Limit 58 (2.28)
Standard 7 0 . 0 (2.756)
Pump boss outside diameter mm (in.)
Limit 69.85 ( 2 . 7 5 0 )
Standard 8.3 (0.327)
Torque Stator roller outs~ded~ameter mm (in.)
converter Limit 8.17 (0.322)
0.08 - 0.1 19
Stator hub to cam clearance mm (in.)
Standard
( 0 0 0 31 - 0.0047)
Limit 0.1 5 (0.0059)
- 490 -
Item 3.25 - 4.5 ton models
Stator shaft outside diameter Standard 55 (2.17)
(sliding contact portion with oil pump gear)
mm (in) Limit 54.9 ( 2 . 16 1 )
Standard
0.12 - 0.20
Driven gear to pump body clearance (0.0047 - 0.0079)
mm (in.)
Limit 0 . 3 ( 0 . 01 2)
Stator Driven gear to crescent clearance Limit 0.4 (0.016)
shaft & oil mm (in.)
Pump Drive gear to crescent clearance rnm (in.) Limit 0 . 2 5 (0.010 )
Standard
0.03 - 0.079
Pump drive gear bush to stator shaft (0.001 2 - 0.003 1 )
clearance mm (in.)
Limit 0.1 5 (0.0059)
-
0 . 0 5 0.10
Pump body surface to drive/driven gear
clearance mm (in.)
Standard
-
(0.002 0.0039)
Limit 0.1 3 (0.0051 )
Main shaft piston seal ring side
Limit 0.3 (0.012)
clearance mm (in.)
F2 clutch drum piston seal ring side
Limit 0.3 (0.012)
clearance mm (in.)
Main shaft servo seal ring side clearance
Limit 0.29 (0.011 )
mm (in.)
F2 clutch shaft servo seal ring side
Limit 0.29 ( 0 . 01 1 )
clearance mm (in.)
Standard 4.5 (0.177)
Clutch pressure plate thickness mm (in.)
Limit 4.3 (0.169)
Transmis- Standard 2.0 (0.0079)
sion Clutch plate thickness mm (in.)
Limit 1.8 (0.071 )
Standard 2.6 (0.102)
Clutch disc plate thickness mm (in.)
Limit 2 . 4 (0.094)
Standard 3 . 4 (0.134)
C1utc.h camber plate warp mm (in.)
Limit 3.1 (0.122)
Standard 6 2 (2.44)
Clutch return spring free length mm (in.)
Limit 56 (2.20)
clutch piston ring side clearance mm (in.) Standard 0 . I5 (0.0059)
. Clutch camber plate to snap ring
clearance mm (in.)
Standard 1 .O - 2.5 (0.039- 0.098)
1 1 Z engine Standard 1950
Stall speed rpm
Measure- 3F engine Standard 2010
ment and -- - -
Standard
-
0.05 0.1 5
Backlash (0.0020 -- 0.0059)
~ ~ ~ between
~ gears ~ mm~ (in.) i ~ -
sion gears Limit 0.26 (0.010 2 )
Input shaft bend mm (in.) Limit 0.1 (0.0039)
- -- -p
Ring gear backlash mm (in.) Standard 0.2 - 0.3 (0.008 - 0.0 12)
Differential pinion inside diameter Standard 22.12 (0.871 )
mm (in.) Limit 22.22 (0.875)
Standard 22.00 (0.866)
Spider outside diameter mm (in.)
Output Limit 2 1.75 (0.856)
gear & dif-
ferential Thrust washer thickness Standard I .6 (0.063)
(differential pinion side) (in.) ~imit 1 .O (0.039)
FRONT AXLE
Item 3.25
0.02 - 0 . 5 0
Front to back play mm (in.) Standard (0.0008 - 0.020)
utside
O
Standard 3 5 . 0 (1.38)
diamter
King pln mm (in.) Outside
diameter Limit 34.8 (1.37)
wear
Bush inside diamter wear mm (in.) Limit 67.0 (2.64)
utside
O
Standard 28.0 (1.10)
diameter
Rear axle Bell-crank pin mrn (in.)
ASSY Outside
diameter Limit 27.8 (1.09)
wear
King pin angle degree Standard 6"
-
0.02 0 . 5 0
Bell-crank clearance mm (in.) Standard
-
(0.0008 0.020)
0.02 - 0.1 5
Steering knuckle clearance mm (in.) Standard (0.0008 - 0.0059)
Steering knuckle starting force kg (Ib) Standard 3 - 5 (6.6 -- 1 1 .O)
Rear axle hub starting force kg (lb) Standard 1.4 - 4.3 (3.1 - 9.5)
- -
Tightening Torque
Tie rod castle nut kg-m (ft-lb) 7 - 8(51 - 5 7 )
Bell-crank pin set nut kg-m (ft-lb) 1.9 - 3.1 (13.7 - 22.4)
Steering knuckle lock nut kg-m (ft-lb) 3 - 4 . 5 (22 - 32)
Tie rod lock nut kg-m (ft-lb) 12- 15(87-105)
Drag link rod castle nut kg-m (ft-lb) 7 - 8 (51 - 5 7 )
Power cylinder rod castle nut kg-m (ft-lb) 12-15(87-105)
Rear wheel hub nut kg-m (ft-lb) 18-20(130- 144)
STEERING
BRAKE
( 1 2.50)
Brake drum ~ n s ~ dd~ameter
e mm (in.)
31 9.5
Limit C
Front ( 1 2.581
brake 9.3 9.1
Standard (0.36)
10.371
Brake shoe lining thickness mm (in.)
4.3
Limit (0.169)
C
BRAKE (Cont'd)
Upper
(small)
Standard
h504 -
Shoe hold spring free
clearance mm (in.)
Center
(large)
Standard
43.7
,72,
-
Front
brake Lower
(medium)
Standard (,
27.8
,09)
-
0.25-0.35
0.3 - 0.5
Brake drum to lining clearance mm (in.) Standard (0.0098-
0.01 38)
(O.O1 - 0.020)
Master cylinder to piston diameter 0.032
Limit t
Parking 2 0 -- 25 25-30
brake Lever operating force kg (Ib) Standard
-
(44.1 55.1) (55.1-66.1)
Oil leak
Lift cylinder oil leak amount
(at lift port) cc (CU. in.)
Standard 6 - 16 (0.37 - 0.98)
test
1 4 - 3 4 (0.85 - 2.08)
Tilt cylinder oil leak amount
Standard
(total of lift and tilt) cc ( CU . in.)
MAST
~ i froller
t at lift
Roller rolling face to
inner mast clearance
Standard 0.5- 2 . 0 (0.02 - 0.08)
bracket mm (in.)
0 - 0.5 ( 0 - 0.020)
Each lower roller
lateral movement Standad
V mast
Side roller at lift
bracket mm (in.)
Side roller lateral
movement
Standard - 0.5 (O - 0,020)
adjustment
0 - 0.8 ( 0 -- 0.03)
Inner mast roller
atera l Standard
Lift roller at mast l
mm (in.) Outer mast roller
Standard 0 - 0 . 8 ( 0 - 0.03)
lateral movement
Mast strip Mast strip inner
Standard 0.5 - 1.0 (0.02 - 0.04)
mm (in.) mast clearance
Nol Standard 1 24.5 (4.90)
middle
Lift bracket Upper No. 2 Standard 125.2 (4.93)
FV, SV, roller outside
FSV mast diameter Lower No. 3 Standard 124.5 (4.90)
adjustment mm (in)
-
(3.25 4.0
~ower No. 4 Standard 125.2 (4.93)
ton models) Side No. 5 Standard 93.3 (3.67)
Inner mast/middle mast No. 1 Standard 124.5 (4.90)
roller outside diameter
mm (in,) N O. 2 Standard 125.2 (4.93)
FV, FSV
mast Inner mast/middle mast
adjustment roller outside diameter No. 1 Standard 1 64.5 (6.48)
(4.5 ton mm (in.)
model)
FV, SV,
FSV mast
adjustment Outer mast roller. middle Outside
Standard 124.5 (4.90)
-
(3,25 4,0 mast upper roller mm (in.) diameter
ton models)
FV, FSV,
mast Outer mast roller, middle
adjustment Outside
mast upper roller mm (in.) diameter Standard 164.5 (6.48)
(4.5 ton
ton model)
15 - 19
MAST (Cont'd)
CYLINDERS
- 504 -
1- : Optional parts.
Wiring Diagram (Gasoline model: 3F)
- 506 -
1-: Optional parts.
PART II: 1994.9- (Minor change)
SECTION INDEX (CE014)
GENERAL
ENGINE
STEERING
APPENDIX
Supplement
capacity
Load I Model
5FG33
Engine model Drive system Remarks
Gasoline
02-5FG33
3.25 ton
5FD33
Diesel
02-5FD33 Torque converter Wheelbase:
1800 mm
5FG35 (71 in)
IFZ Gasoline
02-5FG35 Torque converter
Diesel
Torque converter
3 . 5 ton
5FGE35
IFZ Gasoline
02-5FGE35 Torque converter
Diesel
Torque converter
-- - - - - - - - - - - - - - -
5FG40 Clutch
1 FZ Gasoline
02-5FG40 Torque converter Wheelbase:
4 . 0 ton 2000 m m
5FD40 Clutch (78.5 in)
11Z Diesel
02-5FD40 Torque converter
5FG45
1 FZ Gasoline
02-5FG45 Torque converter
4 . 5 ton
5FD45 I Clutch 1
02-5FD45
11z Diesel
Wheelbase:
5.0 ton 5FDA50 Torque converter 2200 mm
(86.5 in)
0- 4
FRAME NUMBER
Frame No. Punching Position
02-5FG33 A5FG35-3000 1
1 FZ
5FG35 *A5FG35@30001
02-5FG35
5FD33
02-5FD33 5FD35-30001
11z
5FD35
02-5FD35
*5~D35@30001
lli 1 5FDA501
5FDA50-30001
* 5FDA50@30001
5FGE35
*: EEC spec.
02-5FGE35
5FG40 A5FG45-30001
1 FZ
02-5FG4O *A5FG45@30001
5FG45
02-5FG45
HOW TO READ THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
Example: 1 Piping
1
T = 46.09 - 48.05
(470 - 490)
[34.00 - 35.451
Disassembly Procedure
1 Remove the cover. [Point I ]
[Point 11 I
Disassembly: Put a match mark when removing the pump cover.
[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.12 mm (0.7528 in)
How to read components figures
(Example)
I
(1) The components figure uses the illustra-
tion in the parts catalog for the vehicle
model. Please refer to the catalog for
checking the part name. FIG number in parts catalog
The number at the right shoulder of each
components figure indicates the Fig. num-
ber in the parts catalog.
(1) This manual omits description of the following jobs, but perform them in actual operation:
Note:
lmportant items of which negligence may cause accidents, or matters in operation procedure re-
quiring special attention.
Diesel models
951 ( 2 5 US gal)
Fuel tank 5FD33, 3 5
Diesel models
5FDE35, 1201 ( 3 2 US gal)
5FD40, 4 5
5FDA50
0 Inspection
Replacement
@ MP grease
@) Engine oil I. Inspect every 8 hours (daily)
a
@
Hypoid gear oil
Hydraulic oil
11.
111.
Inspect
Inspect
every
every
4 0 hours (weekly)
170 hours (monthly)
@ Hypoid gear oil IV. Inspect every 1000 hours ( 6 monthly)
@ Molybdenum disulfide grease V. Inspect every 2000 hours (annually)
0 Inspection
Replacement
@ MP grease
@ Engine oil lnspect every 8 hours (daily)
@ Hypoid gear oil lnspect every 4 0 hours (weekly)
@ Hydraulic oil lnspect every 1 7 0 hours (monthly)
@ Automatic transmission fluid lnspect every 1000 hours (6 monthly)
@ Molybdenum disulfide grease lnspect every 2 0 0 0 hours (annually)
Engine l e 4- t
Fuel filter l t
Transmission oil l
Differential oil l
Hydraulic oil l +
Chains l *3
Replacement shall be made upon arrival of the operation hours or months, whichever is earlier
ENGINE
Page
ENGINE SECTIONAL VIEWS .............................. 1-2
MAJOR SPECIFICATIONS ................................. 1-3
ENGINE PERFORMANCE CURVES ..................... 1-3
I FZ ENGINE ASSY ............................................. 1-4
ENGINE REMOVAL-INSTALLATION ....................... 1-4
ENGINE SPEED ADJUSTMENT (1 FZ) ..................... 1-6
AIR CLEANER ..................................................... I -I O
RADIATOR ......................................................... 1-I 4
BATTERY ........................................................... 1-14
STARTING MOTOR ............................................ 1-15
ALTERNATOR .................................................. 1-I6
ACCELERATOR PEDAL ...................................... 1-18
ENGINE SECTIONAL VIEWS
1 FZ Engine
MAJOR SPECIFICATIONS
Gasoline spec.
- - - - - -LPG spec.,30.0'1200
I I I I
10 14 18 22x lo2
Engine Speed (rpm)
IF2 ENGINE ASSY
ENGINE REMOVAL.INSTALLATI0N
1 Toe board
3 Radiator cover
9 Cooling water
13 Accelerator wire
14 Electrical wiring
17 Temporary hoisting of engine
24 Starting motor, flywheel, torque converter end plate
(torque converter vehicle)
Removal Prpcedure
Remove the toe board.
Remove the engine hood.
Remove the radiator cover.
Remove the air cleaner.
Remove the radiator reservoir tank and tank bracket.
Remove the battery and battery case Wlignitor.
Remove the fuel pipe and hose Wlfuel filter.
Remove the harness bracket.
Drain cooling water.
Remove the radiator and fan shroud.
Remove the exhaust pipe.
Remove the oil pump drive shaft ASSY.
Disconnect the accelerator wire.
Disconnect electrical wiring.
Remove the clutch housing cover, and remove the clutch cover, clutch disc and flywheel. (Clutch
vehicle)
(Refer t o " Clutch Removal" in Section 2 of published repair manual No. CE005.)
Remove the torque converter case cover, and remove the flexible plate set bolts. (Torque con-
verter vehicle) [Point 1 I
Slightly hoist the engine. [Point 21
Remove the engine mounting set nuts.
Remove the engine mounting brackets (RH and LH).
Support the lower side of the clutch housing (clutch vehicle) or torque converter case (torque con-
verter vehicle) w i t h a wooden block.
Disconnect the clutch housing and engine. (Clutch vehicle)
Disconnect the torque converter case and engine. (Torque converter vehicle)
Remove the engine. [Point 31
Remove the starting motor, flywheel, and torque converter end plate. (Torque converter vehicle)
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Tighten the flywheel set bolt after applying a thread tightener (08833-00070). (Clutch vehicle and
torque converter vehicle)
The tightening torque of each bolt is as follows:
Unit: N.m (kgf-crn)[ft-lbfl
Torque converter end plate set bolt 49.03- 78.45 (500-800)[36.18 - 57.881
Clutch vehicle: 98.06- 156.91 (1000- 1600)[72.35- 115.761
(or 19.61 (200)[14.471+additional turn of 90")
Flywheel set bolt -
Torque converter vehicle: 98.06- 156.91 (1000- 1600)[72.35 1 15.761
(or 19.61 (200)[14.471+additional turn of 9 0 " )
Point Operations
[Point 1 1
[Point 21
[Point 31
fast 0
Before warming up
(initial state)
idle cT 0
Standards
Note:
If the idle speed does not drop because of the idle up ad-
justing screw in contact with the lower side the idle up ac-
tuator rod, loosen the adjusting screw.
1. Install a tachometer.
3. Start the engine and race it lightly until the fast idle le-
ver is engaged with the 4th stage of the cam.
Standard: 1 5 0 0 rpm
2. Install a tachometer.
(1) Start the engine and measure the speed with the
vacuum hose disconnected from the idle up actuator
and its end plugged.
Note:
The speed increases when the adjusting screw is tuned
clockwise.
2. Install a tachometer.
5. Adjust hunting.
Note:
If hunting disappears in several times, it should be treated
as no hunting.
Evacuator valve
SPECIFICATIONS
Size 7-inch c
Outer: 1 8 6 0 0 (2883)
Filtering area cm 2 (in 2 ) 1 4 6 0 0 (2263)
Inner: 51 0 (79.1 )
Note:
In case of the double element type (OPT), do not remove
the inner element for other than replacement.
Note:
Do not damage the element during washing.
Never use compressed air or hot air for drying.
6. Element replacement
Standard
Gasoline model ( 1FZI-Diesel model ( 1 121:
7473 *
5 6 9 Pa ( 7 6 2 5 8 mmH20)
(56.0 & 4.3 mmHg)[30 & 2.28 inH20]
*
[2.205 0 . 1 6 9 inHg1: Conduction
1-14
RADIATOR
RADIATOR SPECIFICATIONS
- - - - - - - -
Torque converter
Clutch Torque converter Clutch
3.25.3.5 ton E3.5 - 4.5 ton
Heat radiation capacity kcallh 30400 35300 30400 35300 37500
P r 88
~ (0.9)~112.81~ ~
c e c c
valve
Diesel vehicle (11 Z) 13.0 (3.43) 3.3 (0.87) 3.9 (1.03) 5.2 (1.37) 0.7 (0.18)
Gasoline vehicle (1FZ) 13.0 (3.43) 3.3 (0.87) 3.9 (1.03) 5.2 (1.37) 0.7 (0.18)
FAN SPECIFICATIONS
11Z 1 FZ
BATTERY
SPECIFICATIONS
11z 11z
1FZ
( 1 2V Specifications) (24V Specifications)
Note:
The starting motor installing position is on either the right or the left side depending on the engine
model. The explanation here is for the case of the right side (1FZ engine). Remove the sedimenter first
for the case of the left side (112 engine).
Removal Procedure
1 Disconnect the battery negative terminal.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
1-16
ALTERNATOR
REMOVALmINSTALLATION
Removal Procedure
1 Disconnect the battery negative terminal.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Adjust the V belt tension.
V belt (alternator drive) tension adjustment
1FZ
(1) Make adjustment by turning the adjusting bolt. Keep
pivot bolt A and lock bolt C, and adjust the tension
by turning adjusting bolt B.
11z
(1) Use a lever and move the alternator for adjustment.
ACCELERATOR PEDAL
ADJUSTMENT
1. Adjust the accelerator pedal height.
(1) Adjust accelerator link stopper bolt @ t o make
pedal height A satisfy the following dimension:
1 1 Z engine models
(1) Adjust the height of stopper bolt @ so that the
clearance between the injection pump lever and
maximum speed adjusting screw satisfies the fol-
lowing range when the accelerator pedal is in con-
tact with stopper bolt @.
/ - -
SPECIFICATIONS
Steering wheel diameter mm (in) 360 (14.17)
TYpe Double-acting
COMPONENTS
450 1
01
---7
93510-1M10 -4
L... ...J
4m~0
STEERING WHEELuMAST JACKET
REMOVAL.INSTALLATION
Removal Procedure
1 Remove the steering wheel. [Point 11
Note:
Coat MP grease on the tilt lock device and each sliding contact portion.
Add MP grease through the grease fitting of the steering universal joint.
The tightening torque for each portion is as follows:
Steering universal joint set bolt 17.65 - 24.52 (180 - 250) [13.02 - 18.091
Mast jacket set nut 34.32 - 53.94 (350 - 550) [25.32 - 39.791
Steering wheel set nut 19.61 - 29.42 (200 - 300) [14.47 - 21.711
Point Operations
SST
[Point 1I
[Point 21
[Point 31
Left screw
STEERING GEAR BOX ASSY
REMOVAL-INSTALLATION
5 6 4
Removal Procedure
1 Operate the steering wheel t o bring the pitman arm and drag link connecting position t o the front
side.
2 Remove the toe board.
3 Remove the steering universal joint. (See mast jacket removal procedure steps 1 t o 7 on page
2-5.)
4 Disconnect the piping.
5 Disconnect the drag link. [Point I ]
6 Remove the steering gear box ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
The tightening torque o f each part is as follows:
C
L (Actual length)
C
-
-
View A
2. The torque converter for the 5.0 ton model is the same as that for the 4.5 ton model.
Engine speed
- - 11Z 1FZ
--
Idling speed rPm 750*25 750* 50
Stall speed
-
11Z 1FZ
-
R
I
I
New models
Old models (Common t o 1 FZ and 1 1Z engine vehicles)
TRANSMISSION & DIFFERENTIAL
GENERAL
1. The transmission remains unchanged.
FRONT AXLE
GENERAL
1. The front axle remains unchanged.
2. The front axle for the 5.0 t o n vehicle is the same as that for the 4.5 ton vehicle.
% : STD
REAR AXLE
GENERAL
The structure of the rear axle remains unchanged.
GENERAL
1. The brake structures (front brake, brake booster, parking brake and brake pedal) remain un-
changed.
2. The brake specifications f o r t h e 5.0 ton vehicle are the same as those for the 4.5 t o n
vehicle. Refer t o Part I, Section 6 i n this manual for service jobs and apply the service
standard values for the 4.5 t o n vehicle.
BODY
COMBINATION METER REMOVAL.INSTALLATION
1 Tilt steering
5 Combination meter wiring
Removal Procedure
1 Tilt the tilt steering post backward.
2 Remove the turn signal switch cover.
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.
BALANCE WEIGHT
The weight of the balance weight is described on page 0-7.
MATERIAL HANDLING SYSTEM
GENERAL
1. The hydraulic circuit remains unchanged.
2. Refer t o Part I,Section 10 in this manual for the natural drop test and natural forward tilt test
procedures. The service standards are as shown below.
The oil leak test remains unchanged.
-
4 0 120mm 18- 60mm
3.25.3.5 t o n vehicle
( 1- 6 - 4.7in)
3.25.3.5 t o n vehicle
-
(0.7 2.3in)
E3.5.4.0 t o n vehicle
-
6 0 150mm E3.5.4.0 t o n vehicle t
( 2 . 4- 5.9in)
4 . 5 t o n vehicle t
4 0 - 1 20mm
4.5 t o n vehicle 5 . 0 t o n vehicle t
(1.6-4.7in)
5.0 t o n vehicle T
GENERAL
1. The mast structure remains unchanged.
GENERAL
1. The structures of the lift and tilt cylinders remain unchanged.
SERVICE STANDARDS
ENGINE
Engine
1FZ Standard 750* 50
Idling speed rPm
11Z Standard 750 * 25
1FZ Standard 2350& 50
No load stabilized maximum speed rPm
1 12 Standard 2350+Aoo
Alternator driving V belt tension 1FZ Standard 147- 343 (15- 35)133-771
(when tension gage EST) is used)
N (kgf) [Ibfl 112 Standard 1 96 - 392 (20- 40) I44- 881
Accelerator pedal
Pedal rolier height 1FZ Standard 56.5&2 (2.224 & 0.08)
(from accelerator bracket to top of roller)
mm (in) 11Z Standard 66.5&2 (2.618 & 0.08)
Clutch Standard
98.06 -172.35
156.91 (1000 - 1600)
- 11 5.761
Flywheel set bolt
Torque Standard t
converter
STEERING
Tightening torque Unit: N.m (kgf-cm) [ft-lbfl
Steering universal joint set bolt Standard 17.65 - 24.52 (180 - 250) 113.02 - 18,091
Mast jacket set nut Standard 34.32 - 53.94 (350 - 550) 125.32 - 39.791
Steering wheel set nut Standard 19.61 - 29.42 (200 - 300) 114.47 - 21.711
Steering gear box set nut Standard 49.03 - 78.45 (500 - 800) 136.18 - 57.881
TORQUE CONVERTER
Measurement-test
1FZ Standard 1950
Stall speed rPm
112 Standard 1950
REAR AXLE
Rear wheel alignment
3.25 ton Standard 2600 ( 102)
WIRING DIAGRAM
1 FZ ENGINE VEHICLE
- - . . .
r]
: Optional parts.
4-8
I I Z ENGINE VEHICLE
. . .