Toyota 7FG 7FD 7FGK 7FDK Forklift Trucks Repair Manual PDF

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FOREWORD
Th
This
is manu
manual
al co
cove
vers
rs th
the
e se
serv
rvic
ice
e proc
proced
edur
ures
es of the
the TOY
TOYOT
OTA
A FORK
FORKLI
LIFT
FT
7FG/7F
7FG /7FD10
D10 - 30 seri
series.
es. Please
Please use th this
is manual
manual for providi
providing
ng quick,
quick, corre
correct
ct
servicing of the correspond
servicing corresponding
ing forklift
forklift models.
models.
Th
This
is manu
manual
al de
deal
als
s with
with th
the
e abov
above
e mode
models
ls as of Sept
Septem
embe
berr 20
2000
00.. Pl
Plea
ease
se
unders
understan
tand
d that
that disagr
disagreem
eement
ent can take
take pla
place
ce betwee
between
n the descrip
descriptio
tions
ns in the
manual
manual and actual
actual vehicles
vehicles due to
to cha
change
nge in design
design and sp
speci
ecific
ficati
ations
ons.. Any
ch
chan
ange
ge or mod
modif
ific
icat
atio
ions
ns th
ther
erea
eaft
fter
er will
will be inf
infor
orme
med
d by Toyo
Toyota
ta Indu
Indust
stri
rial
al
Equipm
Equipment
ent Par
Parts
ts & Service
Service News.
News.
For the
the service
service pro
proced
cedure
ures
s of tthe
he mounted
mounted eng
engine
ine,, rea
read
d the repair
repair manual
manuals
s
listed
listed below as refere
reference
nce togeth
together
er wit
with
h this manual
manual..
(Reference)
Repair
Repair manual
manuals
s rel
relate
ated
d to this
this manual
manual are as follows
follows::
TOYOTA INDUSTRIA
TOYOTA INDUSTRIAL L EQUI
EQUIPMENT
PMENT
7FG1
7FG1 0-30,
0-30, 7FD1
7FD1 0-3
0-30,
0, 7FGK20
7FGK20-30
-30,, 7FGJ35
7FGJ35,,
7FDK20
7FDK20-30
-30,, 7FOJ35
7FOJ35
REPAIR
REPAI R MANUAL
MANUAL (No. CE024
CE024))
TOYOTA INDUSTRIA
TOYOTA INDUSTRIAL
L EQUIPMEN
EQUIPMENT T 5K ENGINE
ENGINE
REPAIR
REPAIR MANUAL
MANUAL (No. C
CE617)
E617)
TOYOTA INDUSTRIA
TOYOTA INDUSTRIAL
L EQUIPMENT
EQUIPMENT 4Y ENGIN
ENGINE
E
REPAIR
REPAIR MANUAL
MANUAL (No. CE602-
CE602-1)
1)
TOYOTA INDU
TOYOTA INDUSTRIA
STRIAL
L EQUIPMENT
EQUIPMENT 1D2-1
1D2-11
1ENGINE
ENGINE
REPAIR
REPAIR MANUAL
MANUAL (No. CE618
CE618-1)
-1)
TOYOTA INDUSTRIA
TOYOTA INDUSTRIAL
L EQUI
EQUIPMENT
PMENT 22 ENGINE
ENGINE
REPAIR
REPAIR MANUAL
MANUAL (No. CE625-
CE625-1)
1)
TOYOTA INDUSTRIA
TOYOTA INDUSTRIALL EQUI
EQUIPMENT
PMENT 4Y ENGINE
ENGINE
Supplement
Supplement 4Y-ECS
4Y-ECS
REPAIR
REPAIR MANUAL
MANUAL (No. C
CU642
U642))
TOYO
TOYOTA
TA MO
MOTO
TOR
R CO
CORP
RPOR
ORATIO
ATION
N

SECT
SECTIO
ION
N INDE
INDEX
X
I ~E
I GENERAL
FEAT ES
I MAN
MANUAL
UAL TRA
TRANSM
NSMISS
ISSION
ION
I DIFFERENTIAL
I APPENDIX

0-1
GENERAL
Page
EXTE
EXTERI
RIOR
OR VI EWS
EWS 0-2
VEH
VEH ICLE
ICLE MODE
MODE L Q -3
FRAM E N UM BER
BER 0-5
HOW TO USE THIS MANU

ANUAL 0-7
E X P L A N A T IO N M E T H O D 0-7
TERMINOLOGy o -a
A B B RE V IA TI
TIOO NS o -a
OPE
OPE RATIO
RATIO NAL TI PS 0-9
HOIST
OISTIN ING
G TH E VEHI
VEHIC
CLE 0-10
C I R CUlT
CUlT TEST
TESTER
ER 0-11
STAND
STANDARD
ARD BOLT & NUT TIGHTENIN
BOLT TIGHTENING
G
TO RQUE
RQUE 0-13
BOLT ST
STRE
RENGT
NGTH
H TY
TYPE
PE IDE
DENT
NTIIFICATI
FICATION
ON MET
METHOD
HOD 0-13
0-13
T IG H T E N IN G T O R Q U E T A B L E 0-14
PRECOAT BO LTS
LTS 0-15
HIGH
HIGH PRES
PRESSU
SURE
RE HO
HOSE
SE FI
FITT
TTIN
ING
G
TI
TIGH
GHTE
TENI
NING
NG TORQ
TORQUE
UE 0-15
WIRE
IRE ROPE
OPE SUSP
SUSPEN
ENSI
SION
ON ANGLE
ANGLE LIST
LIST 0-16
SAF
AFE
E LOAD
LOAD FOR EACH
ACH WIRE ROPE
SUSP
SUSPEN
ENSI
SION
ON ANG LE 0-16
COMP
COMPON
ON ENTS
ENTS WEIG
WEIGHT
HT 0-17
RECO
RECOMM
MMEN
ENDE
DED
D LUBRICANT
LUBRICANT
QUANTITY & TYPES 0-18
LUBRIC
LUBRICATI
ATION
ON CHART
CHART 0-20
PERIOD
PERIODIC
IC MAINTENANC
MAINTENANCE
E 0-22
PER
PERIOD
IODIC REPL
REPLACE
ACEM
MENT
ENT OF PAR
PARTS
TS AND
LU BRICANTS
BRICANTS 0-28

0-2
EXTERIO
EXTERIOR
R VIEWS
VIEWS

0-3
VEHICLE MODEL
Classification
Vehicle
Vehicle Mode
Modell Transmiss
Transmission
ion Type Engine
Series Model
I
7FG10 Mff
5K Gasoline
02-7FG10 T I C
1.0 ton model
7FD10 Mff
10Z-11 Diesel
02-7FD10 T I C
7FG15 Mff
5K Gasoline
02-7FG15 T I C
1 ton ser
series
ies
40-7FG15 Mff
1.5 ton model 4Y Gasoline
42-7FG15 T I C
7FD15 Mff
10Z-11 Diesel
02-7FD15 T I C
42-7FG18 T I C 4Y Gasoline
1.75 ton mode
modell
02-7FD18 T I C 10Z-11 Diesel
7FG20 Mff
5K Gasoline
02-7FG20 T I C
4O-7FG20 Mff
4Y Gasoline
42-7FG20 T I C
2.0 ton model
6O-7FD20 Mff
10Z-11 Diesel
62-7FD20 T I C
7F020 Mff
2Z Diesel
02-7F020 T I C
2 ton serie
series
s
7FG25 Mff
5K Gasoline
02-7FG25 T I C
4O-7FG25 Mff
4Y Gasoline
42-7FG25 T I C
2.5 ton model
6O-7F025 Mff
10Z-11 Diesel
62-7F025 T I C
7F025 Mff
2Z Diesel
I
02-7F025 T I C
I

04
-
Classification
-
Vehicle Model T r a n s m is s io n T y p e E n g in e
Series Model
7FG30 MI
MITT
4Y Gasoline
02-7FG30 T I C
6O-7FD30 MI
MITT
3 ton series 3.0 ton model 62-7FD30 T I C
1D Z -II D ie s e l
7FD30 MI
MITT
2 Z Diesel
02-7FD30 T I C
7FGK20 MI
MITT
5K Gasoline
02-7FGK20 T I C
4 0 -7 F G K 2 0 M IT
K2.0 ton model 4Y G a s o l in e
42-7FGK20 T I C
7FDK 20 M IT
02-7FDK20 T I C 1DZ-II Diesel

K2 ton series
7FG K 25 M IT
- 5K Gasoline
02-7FGK25 T I C
4 0 -7 F G K 2 5 M IT
K2.5 ton model 4Y Gasoline
42-7FGK25 T I C
7FD K25 M IT
1D Z -II D ie s e l
02-7FDK25 T I C
7FGK30 MI
MITT
02-7FGK30 T I C
4Y Gasoline
K3 ton series K3.0 ton model
model
7FDK30 MI
MITT
1D Z - I I D ie s e l
02-7FDK30 T I C
7F G J35 M IT
4Y Gasoline
02-7FGJ35 T I C
J3.5ton
J3.5 ton model
series 7FDJ35 MI
MITT
2 Z Diesel
02-7FDJ35 T I C
-

0-5
FRAME NUMBER
Fra
rame
me No
No.. Punching
Punching Po
Position
sition
Punching position
Series Engine Vehic

Vehicle
le mode
modell Punching format 7FG20
7FG10 02-7FG20
5K 7 F G 2 5 -1 0 0 1 1
02-7FG10 7FG25
5K 7FG18-10011
7FG15 02-7FG25
02-7FG15 4O-7FG20
4O-7FG15 42-7FG20
4Y 407FG25-1oo11
4Y 42-7FG15 407FG 18-100
18-10011
11 4O-7FG25
1 ton series
42-7FG18 42-7FG25
2 ton seri
series
es
7FD10 7FD20
02-7FD10 02-7FD20
2Z 7FD25-1
7FD25-1 0011
10Z-11 7FD15 7F018-10011 7FD25
02-7FD15 02-7FD25
02-7FD18 6O-7FD20
62-7FD20
1 0 Z -1 1 6 0 7 F D 2 5 -1 0 0 1 1
6O-7FD25
62-7FD25

0-6
Vehicle model Punching format

Engine Vehicle
7FG30
02-7FG30
4Y 7FGJ35-1 0011
7FGJ35
02-7FGJ35
7FD30
3 ton, J3.5
ton series
02-7FD30
2Z 7FDJ35-1oo11
7FDJ35
02-7FDJ35
6O-7FD30
1DZ-II 607FD3Q-10011
62-7FD30
7FGK20
02-7FGK20
5K 7FGK25-10011
7FGK25
02-7FGK25
4Q-7FGK20
42-7FGK20
K2ton 7FGK3Q-1OO11
4Y
series 4Q-7FGK25
42-7FGK25
6O-7FDK20
62-7FDK20
1DZ-II 7FDK3Q-10011
6O-7FDK25
62-7FDK25
7FGK30
4Y 7FGK30-10011
02-7FGK30
K3 ton
series 7FDK30
1DZ-II 7FDK3Q-10011
02-7FDK30

0-7
HOW TO USE THIS MANUAL

EXPLANATION METHOD
1. Oper
Operat
atio
ion
n proc
proced
edur
ure
e
(1) The operati
operation
on proced
procedure
ure is descri
described
bed in eit
either
her pattern
pattern A or or p
patt
attern
ern B below.
below.
Patter
Pattern
n A: Explan
Explanati
ation
on of each
each operat
operation
ion ste
step
p with illust
illustrat
ration
ion..
Patter
Pattern
n B: Explan
Explanati
ation
on of operat
operation
ion proced
procedure
ure by indi
indicat
cating
ing ste
stepp number
numbers
s in one illust
illustrat
ration
ion,, fol
fol--
lowed
lowed by ex
expla
planat
nation
ion of cautio
cautions
ns and notes summar
summarize
ized
d as poin
pointt operat
operation
ions.s.
Exampl
Example
e of d
desc
escrip
riptio
tion
n in patter
pattern
n B
DISASSEMBlY·INSPECTION·REASSEMBlY Tight
Tightening
ening torque
torque unitT = N'm (kgf-cm)
(kgf-cm) [ft-I
[ft-Ibf]
bf]
• Step
Step Nos.
Nos. ar
aree part
partia
iall
lly
y some
someti
time
mes
s
omitted
omitted in illustratio
illustrations.
ns.
4
• When
When a part part rerequ
quir
irin
ing
g titigh
ghte
teni
ning
ng
torque
torque instru
instructi
ction
on is not
not ind
indica
icated
ted in
the illust
illustrat
ration
ion,, the part name is de- de-
scribe
scribed
d in the illust
illustrat
ration
ion fra
frame.
me.
T = 46.
46.1
1 - 48.1
48.1
(470
(470 - 490)
490)
[3
[34.0
4.0 - 35.5]
35.5]
Disassembly Procedure
1 Remove th
the
e cover. [Point
[Point 1]
2 Remo
mov
ve tthe bushiing [Point 2] + - Opera
he bush Operatio
tion
n explai
explained
ned lat
later
er
3 Remove tth
he gear.
Poi nt Operations Explanatio

Explanation
n of key point for operat
operation
ion with an illustrati
illustration
on
it
[Point
[Point 1]
Disass
Disassemb
embly:
ly: Put a match
match mark
mark when removi
removing
ng the pump
pump cover.
cover.
[Point
[Point 2]
Inspection
Inspection:: Measure
Measure the bus
bush
h inside
inside diamet
diameter.
er.
Limit: 19
19.1
.12
2 mm (0.75
(0.7528
28 in)

0-8
2. How
How tto
o re
read
ad co
comp
mpononen
ents
ts fifigu
gure
res
s (Example)
(1) The compo
componennents
ts fig
figure
ure uses the the illust
illustrat
ration
ion
in the
the part
parts
s cata
catalo
log
g foforr th
the
e vehi
vehicl
cle
e mode
model.l.
Please
Ple ase ref
refer
er to the
the cat
catalo
alog g for checkin
checking g the
FIG number
number in parts
parts cat
catalo
alog
g
part name.
Th
The
e nu
numb
mber
er at tthe
he ri
righ
ghtt shou
should
lder
er of ea
each
ch
compon
com ponent
ents
s fig
figure
ure indica
indicates
tes the Fig. nu
num-
m-
ber in the parts catalog.
3. Matt
Matter
ers
s omitt
omitted
ed in th
this
is m
man
anua
uall
(1) This
This manual
manual omits descrip
descriptio
tion
n of the ffoll
ollowi
owing
ng jobs,
jobs, but perf
perform
orm them
them in actual
actual operatio
operation:
n:
C D Cleani
Cleaning
ng and was
washin
hing
g of remov
removed
ed parts
parts as requir
required
ed
® Visual
Visual inspec
inspection
tion (partially
(partially descr
described)
ibed)
TERMINOLOGY
Caution:
I m p o r t an
an t m a tt
t t er
er s o f w hi
h i c h n eg
e g l ig
i g e nc
n c e m a y c au
au s e a cc
c c i d en
en t s . B e s u r e to
to o b s e rv
rv e t h em
em .
Note:
Impor tant
tant ite
items
ms of w hich negligence
negligence may cause
cause accidents,
accidents, or matter
matterss in oper ation
ation pr ocedur e
r equir
equir ing special
special attent
attention.
ion.
Standa
Standard:
rd: Values
Values show
showing
ing all
allowa
owable
ble range
range in inspec
inspectio
tion
n and adjust
adjustmen
ment.
t.
Limit:
Limit: Maximu
Maximum
m or minimu
minimum
m all
allowa
owable
ble value
value in inspec
inspectio
tion
n or adjus
adjustme
tment.
nt.
A B B R E V IA T IO N S
Abbreviation (code) Meaning Abbreviation

Abbreviation (code) Meaning
ASSY Assembly SA
SASS System of active stability
stability
LH Left hand SS T Special service tool
LLC Long life coolant S TD Standard

MfT Manual transmiss
transmission
ion T= Tightening torque
Torque converter
converter &
OP
OPTT Option TIC
transmission
O/S Oversize OO T Number

Number of te
teet
eth
h (0 0)
PS Power steering
steering U/S Undersize
RH Right hand W/ With
Society of Automotiv
Automotive
e Less
SA
SAEE U
Engineers (USA)

0-9
OPERATION
OPERATIONAL
AL TIPS
TIPS
1. Sa
Safe
fe oper
operat
atio
ion
n
(1) After
After jackin
jackingg up, alw
always
ays suppor
supportt with
with wooden
wooden blo
blocks
cks or rig
rigid
id stands
stands..
(2) When
When hoisti
hoisting
ng the vehi
vehicle
cle or its
its heav
heavyy com
compon
ponent
ent,, use wire
wire rope(s
rope(s)) with
with a suff
suffici
icient
ent reserv
reserve
e in load
load
capacity.
(3) Always
Always discon
disconnec
nectt the batte
battery
ry ter
termin
minal
al before
before the inspec
inspectio
tion
n or serv
servici
icing
ng of elect
electric
rical
al parts.
parts.
2. Ta
Tact
ctfu
full op
oper
erat
atio
ionn
(1) PrePrepar
paree the me mecha
chanicnic too
tools,
ls, nec
necess
essary
ary mea
measursuring
ing ins instru
trumen
mentsts (ci
(circu
rcuit
it teste
tester,
r, megger
megger,, oil pressu
pressure
re
gauge,
gaug e, etc.) and SSTs before before start
starting
ing opera
operation.
tion.
(2) BefBefore
ore disdiscon
connecnectin
tingg wiring
wiring,, always
always check
check the cablcable e color
color and wiri
wiring
ng state.
state.
(3) When
When overhaoverhauliuling
ng functi
functiona
onall par
parts,
ts, ccomp
ompliclicate
atedd portio
portionsns or relat
related
ed mechani
mechanisms sms,, arrarrang
angee the parts
parts
neatly
neat ly to preve
prevent nt confu
confusion
sion..
(4) When
When disassdisassemb
emblinlingg and inspe
inspecti
cting
ng such
such a precjs
precjsionion part
part as the cont
control
rol valve,
valve, use clean
clean tools
tools and
operate
opera te in a clean
clean location.
location.
(5) FolFollow
low thethe des
descri
cribed
bed proced
procedure uress for disas
disassem
sembly
bly,, inspec
inspectio
tion
n and reas
reassem
sembly
bly..
(6) RepReplaclace,
e, gas
gasket
kets,
s, packin
packingsgs and O- O-rin
rings
gs with
with new ones ones each time they they are disass
disassemb
embled
led..
(7) Use genuingenuine e Toyota
Toyota parts for for replac
replaceme
ement.
nt.
(8
(8)) UsUse e speci
specifified
ed boboltlts
s an
and
d nuts
nuts.. Obse
Observ rvee th
thee spec
specififie
iedd tigh
tighte
teni
ning
ng totorq
rque
ue at ththee time
time of reass
reassemembl
bly.
y.
Tighte
Tig hten n to the
the cen
center
ter of the
the specifi
specified
ed tig
tighte
htenin
ningg tor
torque
que range.
range.
If no tightenin
tightening g torque
torque is specified
specified,, tighten
tighten the bolt or nut accord according
ing to the standard
standard tightening
tightening torque
torque
table.
3. Graspi
Gras ping
ng the
the tr
trou
oubl
ble
e stat
state
e
When
Whe n a tro
troubl
uble
e occurs
occurs,, do not a
atte
ttempt
mpt immedi
immediate
ate disass
disassemb
embly
ly or repla
replacem
cement
ent but firs
firstt check
check if the
tro
troubl
uble
e req
requir
uires
es disass
disassemb
embly
ly or replace
replacemen
mentt for remedyi
remedying.
ng.
4. Disp
Dispososal
al of wast
waste e fl
flui
uid,
d, etc
etc..
When
Whe n draini
draining
ng waste
waste flu fluid
id fro
from
m the vehicle
vehicle,, receiv
receive
e it in a cont
contain
ainer.
er.
If any
any oil,
oil, fuel,
fuel, coolan
coolant, t, oil fil
filter
ter,, batter
battery
y or other
other harmfu
harmfull substa
substance
nce is dir
direct
ectly
ly discha
discharge
rgedd or scrapp
scrapped
ed
withou
withoutt permis
permissio sion,
n, it will
will either
either advers
adversely
ely aff
affect
ect hum
humanan health
health or destro
destroy
y the enviro
environme
nment.
nt. Always
Always
sortt waste
sor waste flufluids
ids,, etc
etc.. and treat
treat them
them proper
properly
ly by requ
request
esting
ing dispos
disposal
al by spec
special
ialize
ized
d compan
companies
ies..
5. Jack up point
pointss
Jack
Jac k up p
poin
oints
ts are provid
provided
ed in the front
front and rear
rear portions
portions
of the
the vehicl
vehicle.
e. Always
Always apply
apply jacks
jacks at the
the jack up point
points.
s.
Front side
side::
A circular groove to accept a screw jack is provided un-
der the front side
side of the
the fra
frame.
me.
I I
II I I
When
Wh en a ggar
arag
age
e ja
jack
ck is used
used,, ja
jack
ck up at
at the botto
bottom
m su
sur-
r-
= m - - For screw
screw jack
face
face of the frame.
frame.
Rear side
side::
A circular groove to accept a screw or garage jack is
provided
provided at the bottom surface
surface of the counterwei
counterweight.
ght.
I:: i
For screw jack ~

For garage
garage jack ~
0-10
HOISTI
HOISTING
NG THE VEHICLE
VEHICLE
When hoisting
hoisting the vehicle,
vehicle, sling with wire
wire rope(s) at the mast
hook holes and the rear side of the head guard.
Sli
Slinging
nging at the
the head guard is done in two ways.
Method A:
Sling after removing the head guard seat.
Method B:
Carefull
Carefullyy sling
sling so as not to
to damage rear combinat
combination
ion lamps.

0-11
CIRCUI
CIRCUIT
T TESTER
TESTER
Circuitt tes
Circui tester
ters
s are avail
availabl
able
e in both
both the ana
analog
log and digita
digitall types.
types. They
They should
should be used
used selecti
selectivel
vely
y acc
accord
ording
ing
to the
the purpo
purpose
se of measuremen
measurement. t.
Analog type: This type is convenient for observing movement during operation, but the measured value
should
should onl
only
y be used
used for ref
refere
erence
nce or roug
rough h judgem
judgement ent..
Digita
Digitall type:
type: Fairly
Fairly accu
accurat
rate
e readin
reading
g is possib
possible,
le, but itit is dif
diffic
ficult
ult to observ
observe
e the variat
variation
ion or movem
movement
ent..
1. Di
Diff
ffer
eren
ence
ce in meas
measur
urem
emen
entt re
resu
sult
lts
s wi
with
th the
the dig
digit
ital
al type
type an
and
d anal
analog
og type
type
* The result
result may be dif
differ
ferent
ent bet
betwee
ween
n measur
measureme
ements
nts with
with the a
anal
nalog
og type
type and digital
digital type.
type.
Always use a circuit tester according to its operation manual.
Cautions
Cautions when
when the polarit
polarities
ies are differ
different
ent betwee
between
n the analog
analog type
type and digi
digital
tal type
type are descr
describe
ibed
d
below.
(1
(1)) An
Anal
alog
og circ
circui
uitt tes
teste
ter
r
Forward direction Reverse direction

Meas
Measureme
urement
nt result example
example
Tester
Tester range:
range: kQ range
range
Analog type
Continuity
Continuity exist
exists
s
Forward
11 kQ
No continuity
Reverse
00
(2
(2)) Di
Digi
gita
tall circu
circuit
it test
tester
er
Measurementt resul
Measuremen resultt example
example
Forward direction Reverse direction Tester
Tester range:
range: MQ range
range
Digital
Digital type
Forward No continuity
1
Continuity
Continuity exist
exists
s
Reverse
2MQ
2MQ

0-12
2. Diff
Differ
eren
ence
ce in reresu
sult
lt of mea
measu
sure
reme
ment
nt with
with cir
circu
cuit
it te
test
ster
er
The circui
circuitt tes
tester
ter pow
power er supply
supply voltag
voltage
e depend
depends s on thethe tester
tester type.
type. 1.5 V, 3.0 V or 6.0 V is used.
used.
The resist
resistanc
ancee of a semi
semicon
conduc
ductor
tor such
such as a diod
diodee varies
varies wit
with
h the circui
circuitt tes
tester
ter power
power supply
supply vol
voltag
tage.
e.
The diode
diode charac
character
terist
istics
ics are shown
shown in the figur
figuree below.
below.
(rnA) 6 The re
The resi
sist
stan
ance
ce valu
values
es of tthe
he same
same semi
semico
cond
nducucto
torr me
mea-
a-
.1
sured with two
two types
types of ci
circuit
rcuit testers
testers having
having different
different power
power
5 supply
supply voltages
voltages are diffe
different.
rent.
I I
I I
Germanium I
~ This
This manual
manual describ
describes
es the res
result
ults
s of mea
measur
sureme
ement
nt wit
with
h a
diode J I
~ lJ I cir
circui
cuitt tester
tester whose
whose pow
power
er supply
supply vol
voltag
tage
e is 3.0 V.
Silicondio~1 I-- I--
il
/ It
IJ
/
./
....• / ...• ...
o
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Forward voltage (V)
3. Diff
Differ
eren
ence
ce in meas
measur
urem
emenentt re
resu
sult
lt by mea
measu
sure
reme
ment
nt ra
rang
nge
e (analo
(analog
g type)
type)
In the anal
analog
og typ
type
e circui
circuitt tester
tester,, changi
changing
ng the measure
measuremen
mentt range
range swi
switch
tches
es over
over the interna
internall circui
circuitt to
vary the circui

vary circuitt resist
resistanc
ance.
e. Even
Even when the same dio
diode
de is meas
measure
ured,
d, the measure
measuremen
mentt result
result varies
varies
wit
with
h the measure
measuremenmentt range.
range.
Always use the range described in the repair manual for

measurement.
Meter
~ OQ
~ Variable resistor
(SW1)
Range: x 10
Resistor
~
(SW2)
Range: x 1
I
$0
Power source: 1.5 V
1.5
e
Red
o Black

0-13
STAND
ANDARD
ARD BOLT
BOLT & NUT
NUT TIG
TIGHTENING TORQUE
Standard bolt a
Standard and
nd tighteni
tightening
ng torques
torques are not indicat
indicated.
ed.
Judge
Judge the st
stand
andard
ard tig
tighte
htenin
ning
g tor
torque
que as s
show
hownn below.
below.
1. Find
Find out
out the ty type
pe of th
the
e bolt from
from the list belo
below
w and then
then fin
find
d the bolt
bolt ttigh
ighten
tening
ing tor
torque
que fro
from
m the tabl
table.
e.
2. Th
The
e nu
nutt ttig
ight
hten
enin
ing
g to
torq
rque
ue can
can be ju
judg
dged
ed frfrom
om th
the
e ma
mati
ting
ng bo
bolt
lt type
type..
BOLT ST
TRR E NG
NG T
THH T YP
YP E I D
DE
ENT
TII FI
FI CA
CA T IIO
ON MET
TH
HOD
1. Identific
Identification
ation by bolt shape 2. Ident
Identific
ification
ation by part No.
Shape
Shape and class
class Class Hexagonhead bolt
Hexagonhead
4=4T
@- 5=5T
r
Boltt head
Bol head No. 6=6T Parts No.
7=7T
D
Hexagon 91611-4 25
8=8T
head bolt LLen
Length
gth (mm)
(mm)
0
No mark 4T Diamet
Diameter
er (mm)
(mm)
Class
Hexagon
flange bolt
flange 0) No mark 4T
Diameter
CD
Hexagon Two protruding
5T Length
head bolt lines
Hexagon
flange
flange bolt (C )
Two protruding
lines
6T
Stud bolt
Hexagon Three protruding

head bolt
@ lines
7T
Part No.
92132 -406.14
Hexagon Four protruding
8T
head bolt lines ~L Length
Length (mm)
(mm)
~
Diamet
Diameter
er (mm)
(mm)
Class
Welded bolt 4T
~
Diameter
No mark 4T
Stud bolt https://www.forkliftpdfmanuals.com/

Length
Grooved 6T
"
0-14
TIGHTE
TIGHTENI
NING
NG TORQUE
TORQUE TABLE
Specified torque
Diameter Pitch Hexagon Hexagon

Class
mm mm head bolt B
- flang
flange
e bolt ~
N·m .I kgf-cm I ft-Ibf N·m I kgf-cm I ft-Ibf

I I I I
6 1.0 5.4 I 55 I 48 in-Ibf 5.9 I 60 I 52 in-Ibf
8 1.25 13 130 9 14 145 10
I I I I
10 1.25 25 260 19 28 21
290
4T I I I I
12 1.25 47 I 480 I 35 53 I 540 I 39
14 1.5 75 I 760 I 55 83 I 850 I 61
16 1.5 113 I 1150 I 83 - I - I -
6 1.0 6.4 I 65 I 56 in-Ib

in-Ibf
f 7.5 I 75 I 65 iin-Ib
n-Ibf
f
I I 12 I 175
I 13
8 1.25 16 160 18
I I I I
10 1.25 32 330 24 36 360 26
5T I I I I
12 1.25 59 600 43 65 670 48
I I I I
14 1.5 91 I 930 I 67 100 I 1050 I 76
1.5 137 I 1400 I 101 157 I 1600 I 116
16
6 1.0 7.8 I 80 I 69 iin-Ib
n-Ibf
f 8.8 I 90 I 78 in-Ib
in-Ibf
f
8 1.25 19 I 195 I 14 21 I 215 I 16

I I I I
10 1.25 38 400 29 43 32440
6T I I I I
12 1.25 72 730 53 79 810 59
I I I I
14 1.5 110 I 1100 I 80 123 I 1250 I 90
16 1.5 170 I 1750 I 127 191 I 1950 I 141
6 1.0 11 I 110 I 8 12 I 120 I 9
8 1.25 25 I 260 I 19 28 I 290 I 21
10 1.25 52
I 530 I 38 58
I 590 I 43
IT I I I I
12 1.25 95 970 70 103 1050 76
I I I I
14 1.5 147 1500 I 108 167 1700 I 123
I I
16 1.5 226 I 2300 I 166 - I -
I -
6 1.0 12 I 125 I 9 14 I 145 I 9
8 1.25 29 I 300 I 22 32 I 330 I 24
10 1.25 61 I 620 I 45 68 I 690 I 50

aT I I I I
12 1.25 108 1100 80 123 1250 90
I I I 145
14 1.5 172 1750 I 127 196 2000
I I I I
16 1.5 265 I 2700 I 195
299 I 3050 I 221

0-15
PREC
PRECOAT
OAT BOLTS
(Bolts
(Bolts wit
with
h seal lock
lock age
agent
nt coatin
coating
g on th
threa
reads)
ds)
1. Do not
not use
use the preco
precoat
at bo
bolt
lt as
as it is iin
n ei
eith
ther
er of the
the foll
follow
ow--
ing cases:
(a
(a)) AfAfte
terr it is re
remo
move
ved.
d.
Sea
Seall lock agent (b
(b)) When
When the
the pr
prec
ecoa
oatt bolt
bolt is m
mov
oveded (l
(loo
oose
sene
ned
d or tig
tight
ht--
ened)
ened) by tightn
tightness
ess check,
check, etc
etc..
Note:
For torqu
torquee check,
check, use tthe
he lowe
lower limit
limit of the allow-
allow-
able tigh
tighte
tenin
ning
g torque
torque ra
range
nge.. If the bolt
bolt mov
movees, re
re--
tig
tighte
htenn it acco
accordi
rding
ng to the steps
steps below
below..
2. Meth
Method
od for
for reu
reuse
se of pr
prec
ecoa
oatt bo
bolt
lts
s
(1
(1)) Wash
Wash the bolt bolt and thre
thread
adeded hole
hole.. (T
(The
he thre
thread
aded
ed hole
hole
mustt be was
mus washed
hed eve
evenn for replac
replaceme
ement nt of tthe
he bol
bolt.)
t.)
(2
(2)) Perf
Perfec
ectl
tly
y dr
dry
y the wa
wash
shed
ed papart
rtss by air
air blow
blowin
ing.
g.
(3) Coa
Coatt the
the sp
speci
ecifie
fied
d seal
seal lock ag
agent
ent to the thr
thread
eaded
ed por-
por-
tion of the bolt.
HIGH
HIGH PR
PRES
ESSU
SURE
RE HO
HOSE
SE FITTI
FITTING
NG TIGH
TIGHTE
TENI
NING
NG TO
TORQ
RQUE
UE
1. When
When connec
connectin
ting
g a high
high pressu
pressure
re hose,
hose, w
wipe
ipe the
the hose
hose fittin
fitting
g and mating
mating nip
nipple
ple contact
contact surfaces
surfaces wit
with
h
clea
clean
n cl
clot
oth
h to re
remo
move
ve fofore
reig
ign
n matt
matter
ers
s and
and di
dirt
rt.. Also
Also chec
check k no de
dent
nt or oth
other
er da
dama
mage
ge on the
the cont
contac
actt
surfaces
surfaces before
before installati
installation.
on.
2. When
When connec
connectin
ting
g a high
high pressu
pressure
re hose,
hose, hold the hose
hose tto
o align
align the fitt
fitting
ing wit
with
h the nipple
nipple and tighte
tighten
n the
fitting.
3. Th
The
e maxi
maximu
mum
m ti
tigh
ghte
teni
ning
ng to
torq
rque
ue must
must not exc
excee
eed
d twice
twice the
the stan
standa
dard
rd tigh
tighte
teni
ning
ng torq
torque
ue..
Nominal diameter Stan

Standard
dard tightening
tightening torque
torque N·m (kgf
(kgf-cm)
-cm) [ft-Ibf]
[ft-Ibf]
Hose inside
of screw diamet
diameter
er mm (in)
(in)
Standard Tight
Tightening
ening rang
range
e
7/16-20UNF 25 ( 25
250)
0)[[ 18.1
18.1]] 24 - 26 ( 2
24
40- 270) [17.4- 19.5] 6 (0.2
(0.24)
4)
9/16-18UNF 49 ( 50
500)
0) [ 36
36.2
.2]] 47 - 52 ( 48
480
0- 530)
30) [34
[34.7
.7-- 38.3] 9 (0.35)
3/4-16UNF 59 ( 60
600)
0) [ 43
43.4
.4]] 56- 62 ( 570- 630
630)) [41.2 - 45.6]
[41.2 12 (0.47)
7/8-14UNF 59 ( 60
600)
0) [ 43
43.4
.4]] 56 - 62 ( 57
570-
0- 630)
30) [41
[41..2- 45.6] 12 (0.47), 15 (0.59)
1·1/16 12UNF 118 (12
(1200)
00) [ 86.8]
86.8] 11
112
2 - 123
123 (1
(114
140
0 - 12
1250
50)) [82.
[82.5
5 - 90.4
90.4]] 19(0.75)
1·5/16-12UNF 137 (1400)
(1400) [101
[101.3]
.3] 130 - 144 (1330 - 1470) [96.2 - 106.4] 25 (0.98)
PF1/4 25 ( 250)
250)[[ 18
18.1
.1]] 24 - 26 ( 240 - 270) [17.4 - 19.5] 6 (0.24)
PF3/8 49 ( 50
500)
0) [ 36
36.2
.2]] 47 - 52 ( 480 - 530) [34.7 - 38.3] 9 (0.35)
PF1/2 59 ( 60
600)
0) [ 43
43.4
.4]] 56 - 62 ( 570 - 630) [41.2 - 45.6] 12 (0.47)
PF3/4 118 (12
(1200)
00) [ 86.
86.8]
8] 112 -123 ((1
1140 -1250) [82.5 - 90
0..4] 19 (0.75)
PF1 137 (1400)
(1400) [101
[101.3]
.3] 130 -144 ((1
1330 - 1470) [96.2 -106.4] 25 (0.98)
0-16
WIRE
WIRE ROPE
ROPE SUSP
SUSPEN
ENSI
SION
ON ANGLE
ANGLE LIST
LIST
Compres- Suspension Compres- Suspension

Lifting angle Tension Lifting angle Tension
sion method sion method
1.00time o time 1.41 time 1.00 time
2t 2t
0
30 1.04time 0.27 time 2.00 time 1.73 time
1.16 time 0.S8time
SAFE
SAFE LOAD FOR
FOR EACH WIR
WIRE
E ROPE
ROPE SUSPE
SUSPENS
NSIO
ION
N ANGLE
ANGLE Unit:
Unit: N (tf)
(tf) [Ibf]
[Ibf]
Single-rope Two-rope
Two-rope suspe
suspension
nsion Four
Four-rope
-rope suspe
suspension
nsion
Rope Cutting suspension
diameter load 0 0 0 0 0 0 0
0 0
0 0 30 60 90 0 30 60 90
21380 3040 6080 5880 5200 4 310

43 12160 11770 10400 8630
6mm
(2.18) (0.31 ) (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
(0.
(0.24
24 in)
[4807] [683.6] [1367] [1323] [1169] [970] [2734] [2646] [2337] [1940]
31480 4410
44 8830 8530 7650 6280 17650 17060 15300 12550
8 mm
(3.21 ) (0.45) (0.9) (0.87) (0.78) (0.64) (1.8) (1.74) (1.56] (1.28)
(0.
(0.32
32 in)
[7078] [992.3] [1985] [1918] [1720] [1411] [3969] [3937] [3440] [2322]
49230 6960 14020 13440 11770

11 9810 27460 26480 23540 19610
10 mm (2.0)
(5.02) (0.71 ) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4)
(0.
(0.4
4 in) [4410]
[11.69] [1565.6] [3153] [3021] [2646] [2205] [6174] [5954] [5292]
76880 10980 21570 21280 18630 14710 43150 41190 37270 29420
12.5
12.5 mm (7.84) (1.12) (2.2) (2.1
(2.1 ) (1.9) (1.5) (4.4) (4.2) (3.8) (3.0)
(0.
(0.5
5 in) [6615]
[17387] [2469.5] [4851] [4631] [4190] [3308] [9702] [9261] [8379]
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 mm (3.8)
(9.83) (1.4) (2.8) (2.7) (2.4) (1.9) (5.6) (5.4) (4.8)
(0.
(0.56
56 in)
[21675] [3087] [6174] [5954]
[5 [5292] [4190] [12348] [11907] [10584] [8379]
0-17
COMP
COMPON
ONEN
ENTS
TS WEIGH
WEIGHT
T
Component Weight kg (Ib)
5K 97 ( 21
214)
4)
4Y 134 ( 295
295))
Engine
1DZ-II 176 ( 388
388))
2Z 240
240 ( 529)
529)
Mf f 75 ( 165
165)
Transmission TIC (1 speed) 124

124 ( 273)
273)
TIC (2 speeds) 153

153 ( 337)
337)
1.0 ton
ton mode
modell Appr
Approx
ox.. 400
400 ( 880)
880)
1.5 ton
ton mode
modell Appro
Approx.
x. 745 (16
(1640)
40)
1.75 ton
ton mode
modell Appro
Approx.
x. 880 (19
(1940)
40)
2.0 ton model Appr

Approx.
ox. 1150 (2535
(2535))
2.5 ton model Appr

Approx.
ox. 1500 (330
(3300)
0)
Counter
Counter weigh
weightt
3.0 ton model Appr
Approx.
ox. 1800 (400
(4000)
0)
K2.0 ton mode

modell Appr
Approx.
ox. 1140 (2510
(2510))
K2.5 ton mode

modell Appr
Approx.
ox. 1550 (3410
(3410))
K3.0 ton model Appr

Approx.
ox. 1925 (4240
(4240))
J3.5 ton model Appr

Approx.
ox. 2135 (470
(4700)
0)
1 ton series Approx. 410

410 ( 900
900))
2 ton serie
series
s App
Approx
rox.. 505 (11
(1110)
10)
V mast
mast ASSY Uba Ubackr
ckrest
est and fork
fork
(with lift cylinde
cylinder,
r, max. liftin
lifting
g heigh
height:
t: 3 ton, K3 ton series Approx. 570 ((1260)
1260)
3000
300 0 mm (11 (118
8 in
in»»
K2 ton series Approx. 465 ((1030)
1030)
J3.5 ton series Approx. 680 (1500

(1500))

0-18
RECO
RECOMM
MMEN
ENDE
DED
D LUBRICANT
LUBRICANT QUANT
QUANTITY & TYPES
ITY
Description Application Quantity f (U S g a l) C la s s i f ic a t i o n T yp e
Motor oil
5K 4.0 (1.06) SAE30
(SAE20 in cold area)
Gasoline AP
APII
SH, SJ SAE20W-40
4Y 4.0 (1.06) (SAE1
(SAE10W-30
0W-30 in cold
Engine area)
Diesel engine oil

1DZ-II 7.9 (2.09)
SAE30 (SAE20
(SAE20 in
AP
APII
Diesel cold area)
CE,CF
2Z 9.0 (2.38)
SAE10W-30
AP
APII Hypoid gear oil
Mff
Mf f 3.8 (1.0)
GL-4, GL-5 SAE85W-90
Transmission TIC (1 speed) 9.0 (2.38)

AT
ATFF GM Dexron® II
TIC (2 speeds) 10.5 (2.77)
1 ton series 6.3 (1.66)
2 ton series,
Differential K2 ton series, 7.1 (1.87) AP
APII Hypoid gear oil
K3 ton series GL-4,GL-5 SAE85W-90
3 ton series,
7.7 (2.03)
J3.5 ton series
Attached
Attached Table 1 ISO
Hydraulicc oil
Hydrauli Hydraulic oil
Hydraulicc oil volu
Hydrauli volume
me VG32
1 ton series 45(11.9)
Fuel tank K2 ton series 55 (14.5) -

Other series 65 (17.2)
Proper quanti
quantity
ty
SAEJ-1703
Brake and clutch line All models Reservoir Tank - OOT-3
0.2 (0.05)
• MPgre
MPgreasease
Chassis parts All models Proper quanti
quantity
ty - • Molybdenu
Molybdenum m
disulfide grease
• LLC 30-50%
30-50% mixture
mixture
(for winter
winter or all-
Coolant (excluding season)
Attached
Attached Table 2 Coolant volume LLC • Coolant
Coolant with
with rust-
rust-
reservoir tank)
inhibitor (for spring,
summer and
autumn)
0.6 (0.16)
Coolant (Reservoir Tank) All models f f
(at Full level)
0-19
Attached Table 1 Hydrau

Hydraulic
lic oil volume
volume [V mast,
mast, max. lifting
lifting hei
height
ght 3000 mm (118
(118 iin)]
n)] Unit: l (US gal)
Model 1 ton seri

series
es 2 ton seri
series
es 3 ton series K2·K3 ton series J3.5 ton series
5K engine
engine models
models 27 (7.1
(7.1)) 34 (9.0
(9.0)) 30 (7.9
(7.9))
4Y engine
engine models
models 27 (7.1
(7.1)) 34 (9.0
(9.0)) 36 (9.5) 30 (7.9
(7.9)) 36 (9.5)
1DZ-II engine models 27 (7.1

(7.1)) 34 (9.0
(9.0)) 36 (9.5)
2Z engine
engine mode
models
ls 39 (10.3
(10.3)) 41 (10.
(10.8)
8)
Note:
Since
Since the hydr
hydrau
aulic
lic oil volume
volume va
varie
ries
s with the mast
mast specific
specifica
ation, be sure to che
check
ck fina
finally
lly with the
levell gauge.
leve gauge.
Attached Table 2 Coolant volume Unit: l (US gal)
Engine Transmission 1 ton series K2·K3 ton series 2·3·J3.5 ton series
MfT 6.0 (1.58) 6.0 (1.5

(1.58)
8) 6.1 (1.6
(1.61)
1)
5K
T I C 6.5 (1.72) 6.5 (1.72) 7.6 (2.0
(2.01)
1)
MfT 7.0 (1.85) 8.2 (2.16) 8.4 (2.2

(2.22)
2)
4Y
T I C 8.5 (2.24) 8.5 (2.24) 9.6 (2.53)
MfT 6.7 (1.7

(1.77)
7) 6.9 (1.82) 7.1 (1.87)
1DZ-II
T I C 7.2 (1.90
(1.90)) 7.2 (1.90) 8.3 (2.19)
MfT ------------- ------------- 8.1 (2.1

(2.14)
4)
2Z
T I C ------------- ---------- 9.3 (2.4
(2.46)
6)

0-20
LUBRICATIO
LUBRICATION
N CHART
CHART
M an
an u a
all T ra
ra n s
smm i s s iio
on Mode
ell
14 2
13 14
4 13
3 3
5 12
16 15
10 20
17 8
7 9
6 7
18 6
19 18
11 19
ill
o Inspection
• Replacement
C D MPgrease L In
Insp
spec
ectt ev
ever
ery
y 8 ho
hour
urs
s (dai
(daily
ly))
® Engineoil II
II.. In
Insp
spec
ectt ev
ever
ery
y 40 hour
hourss (w
(weeeeklkly)
y)
® Hypoid
Hypoid gear oil IlL Inspec
Inspectt eve
every
ry 1
170
70 hours
hours (mon
(monthlthly)
y)
@ Hydraulic oil
Hydraulic IV. Inspec
Inspectt eve
every
ry 1
100
000
0 h
hour
ours
s (6 m mont
onthly
hly))
® Hypo
Hypoid
id gear oil V. Inspec
Inspectt eve
every
ry 20
2000
00 hours
hours (an
(annua
nual)l)
® Brake fluid https://www.forkliftpdfmanuals.com/
(j) Molybdenum disulfide grease
1 Chain 11 Rear
Rear axle
axle beam
beam re rear
ar pi
pin
n
12 Tilt steeri
steeringng lockin
locking g mecha
mechanis
nism
m
2
3 Di
Diff
Frffer
Fron
ont eren
t enti
tial
whee
wh al l bear
eel bearining
g 13 Ma
Mast st su
supp
ppor ortt bu
bushshin
ingg
4 Bra
Brake ke and clutch
clutch master
master cyl
cylind
inder
er 14 Ti
Tilt
lt cyl
cylin
inde
derr frfron
ontt ppin
in
5 Tran
Transm smisissi
sion
on cacase
se 15 Pr
Prop
opelelle
lerr shaf
shaftt
6 Re
Rearar whwheeeell bea
beari
ring
ng 16 Gear
Gear sh shif
iftt link
link
7 Ste
Steeriering
ng knuckl
knuckle e king
king pin 17 Sw
Swin ing
g lo
lock
ck cylin
cylindederr lowe
lowerr pin
pin
8 Oil tta
ank 18 Ti
Tie
e rod
rod end
end pin
9 Engi
Engine ne cran
crank k ca
case
se 19 Rear
Rear axle
axle cylin
cylindederr end
end pipin
n
10 Rear
Rear axleaxle beam
beam fr fron
ontt pin
pin 20 Gear
Gear sh shififtt leve
lever
r
0-21
Torque
Torque Conver
Converte
terr & Tran
Transmiss
smission
ion Mode
Modell
1 1
14 2
13 14
3 13
4 12
5 15
10 8
16 9
7 7
6 6
17 17
18 18
11
ill
o Inspection
• Replacement
G) MPgrease l Inspe
Inspect
ct every
every 8 hours
hours (daily)
(daily)
@ Engineoil It In
Insp
spec
ectt ev
ever
eryy 40 hour
hourss (wee
(weeklkly)
y)
® Hypo
Hypoid
id gea
gearr oil Il Inspe
Inspect
ct every
every 170 hours
hours (mon
(monthly)
thly)
@ Hydraulic oil
Hydraulic IV. Inspec
Inspectt ever
every
y 1000 hou
hours
rs (6 month
monthly)
ly)
® Automatic transmission fluid
® Brake fluid
https://www.forkliftpdfmanuals.com/ V. Inspec
Inspectt eve
every
ry 2000
2000 hou
hours
rs (annu
(annual)
al)
(j) Molybdenum disulfide grease
1 Chain 10 Rear
Rear axle
axle be
beamfron
amfrontt pi
pin
n
2 Di
Diff
ffer
eren
enti
tial
al 11 Rear
Rear axle
axle be
beam
am re
rear
ar pi
pin
n
3 Fr
Fron
ontt whee
wheell be
bear
arining
g 12 Tilt steeri
steeringng lockin
lockingg mecha
mechanisnism
m
4 Brak
Brake e ma
mast
ster
er cyli
cylind
nder
er 13 Ma
Mast st su
supp
ppor
ortt bu
bush
shin
ingg
5 To
Torq
rqueue conv
convererte
terr case
case 14 Tilt
Tilt ccyl
ylin
inde
derr fr
fron
ontt pi
pinn
6 Re
Rearar wh
whee
eell be
bear
arin
ingg 15 Prop
Propel elle
lerr shaf
shaftt
7 Steeri
Steeringng knuckl
knuckle e king
king pin 16 Swin
Swing g lo
lock
ck cyl
cylin
inde
derr low
lower
er ppin
in
8 Oil tta
ank 17 Tie
Tie rod
rod end pin
9 En
Engi
ginene cran
crankk ca
case
se 18 Rear
Rear axlaxlee cyl
cylind
inderer end pin
0-22
PERIODI
PERIODIC
C MAINTENANCE
MAINTENANCE
IN
INSPECTI
SPECTION
ON METHOD
I : Inspecti
Inspection.
on. Repair
Repair or replace
replacemen
mentt if requir
required.
ed.
M : Measur
Measureme
ement.
nt. Repair
Repair or adjust
adjustmen
mentt if requir
required.
ed.
T : Reti
Retigh
ghte
teni
ning
ng C : Clea
Cleanin
ning
g L : Lubr
Lubrica
icati
tion
on
* : For
For ne
new
w vehi
vehicl
cle
e *1:
*1: Flalaw
w detec
etecto
tor
r
Inspection Period Every Every Every Every

1 month 3 months 6 months 12 months
Every Every Every Every

Item 170 hours 500 hours 1000 hours 2000 hours
ENGINE
Proper starting and abnormal noise I +- +- +-
Rotating
Rotating condi
condition
tion at idling
idling M +- +- +-
+- +- +-
Rotating condition during acceleration

acceleration M
Exhaust gas condit
condition
ion I +- +- +-
Main body Air clean

cleaner
er element
element C +- +- +-
Valve clearance M* M
Compression M
Cylinder head bolt loosening T
Muffler rubber mount I
PCV system
system Clogging and damage in PCV valve and piping I +- +- +-
Governor No-l
No-load
oad maximum rpm M +- +- +-
+- +- +-
Oil leak I
Lubrication I +- +-
Oil level +-
system
Clogging and dirt of oil filter
filter I +- +- +-
Fuel leak I +- +- +-
Operation of carburetor link mechanism I +- +- +-
Dirt and clogging of fuel filter and element I +- +- +-
Fu
Fuee l syst
systee m Inj
Inj ect
ectiio n timi
timinn g https://www.forkliftpdfmanuals.com/
M +-
Injection
Injection nozzl
nozzlee inject
injection
ion pressure
pressure and M
spray status
status
Draining of sedimenter I +-
Coolantt level
Coolan level in radiator
radiator and leak I +- +- +-
Rubber hose degradation I +- +- +-
Cooling Radiator cap condition I +- +- +-
system
Fan belt tension,
tension, looseness
looseness and damage I +- +- +-
Radiator rubber mount I
0-23
Inspectio
Inspection
n Peri
Period
od Every Every Every Every
1 month 3 months 6 month
onthss 12 mo
mont
nths
hs
Every Every Every

Ev Every
Item 170 hours 50
500
0 ho
hour
urs
s 1000
1000 ho
hours 2000 hour
urs hours
s
POWER
POWER TRA
TRANSM
NSMISS
ISSION
ION SYSTEM
SYSTEM
Clutch
Clutch peda
pedall play M
Abnormal sound and functioning

I
- - -
(connection) - - -
Clutch Clutc
Clutch
h mast
master
er cylin
cylinder
der funct
function
ion and leak I
Fluid level I
- - -
Oil clutc
clutch
h mec
mechan
hanism
ism fun
functi
ction
on and leak
leak
- - -
I
(OPT) -
Leak I
Fluid level I
- - -
Manual
- - -
transmission Gear function
function and abno
abnormal
rmal noise I
Damage
Damage of shift leve
leverr cable boot I
Damage of cable outer
Leak I
- - - I
Differential Oil level I

-- -- --
Bolt loosening T
Leak I
Fluid level I
- - -
Torque Oper
Operating
ating mech
mechanism
anism func
function
tion and
- - -
I
converter & looseness
transmission
- - -
Control
Control valve and clutc
clutch
h funct
functions
ions I
Inching valve function I
Stall and hydraulic

hydraulic pres
pressure
sure meas
measurem
urement
ent
- - - M
Loose joint T
-
eller shaft Loos
Propeller
Prop Loosenes
eness
s at splin
spline
e connection
connections
s
- - I
and axle shaft Loosenes

Looseness
s of u
univer
niversal
sal joint I
Twisting
Twisting and crack
cracks
s of axle s
shaft
haft I
DRIVE SYSTE
SYSTEM
M
Tire inflation pressure M
Tire cuts, damage

damage and une
uneven
ven wearing I
- - -
Loose
Loose rim and hu
hub
b nut
nuts
s T
Wheels
Tire groove depth M
-- -- --
Metal chips,
Metal chips, pebb
pebbles
les and other fore
foreign
ign
I
matter
matter trap
trapped
ped in tir
tire
e grooves - - -

0-24
Inspection Period Every Every Every Every

E ve ry E very E ve ry Every
Item 170 hours 500 hours 1000
1000 hou
hoursrs 200
20000 hou
hours
rs
Rim, side bearing and disc wheel damage I
Wheels
Abnormal sound and looseness
Abnormal
wheel bearing
looseness of fro
front
nt
I
-- -- --
Abnormal sound and looseness
Abnormal
wheel bearing
looseness of rear
rear
I
- - -
Front axle Cracks,
Cracks, damage and deformatio
deformationn of housi
housing
ng I
Cracks,, damage and defor

Cracks deformatio
mationn of beam I
Rear axle
Looseness of axle
Looseness axle beam in vehicle
vehicle
M* M
longitudinal
longitudinal direction
direction
STEERING
STEERING SYSTEM
SYSTEM
Play and looseness I

- - -
Steering wheel
Function I
- - -
Steering valve
Oil leak
Looseness of mounting

I
T
- - -
I
- - -
Oil leak
- - -
Power Steering Mounting
Mounting and linka
linkage
ge looseness
looseness I

- - - I
Damage of power steering hose
King pin looseness I

Knuckle
Cranks and deformation I
BRAKING SYSTEM
- - -
Play and reserve M
- - -
Brake pedal
Braking effect I
- - -
Operating force https://www.forkliftpdfmanuals.com/
I
- - -
Parking brake Braking effect I
- - -
Rod and cable
cable looseness
looseness and damage I
- - -
Brake pipe Leak, damage and mounting
mounting conditio
conditionn I
Reservoir tank Leak and fluid level
Master
Function,
Function, wear, da
damage,
mage, leak and mounti
mounting
ng
I
-- -- --
I
cylinder
cylinder and
looseness
wheel cylinder
0-25
Inspectio
Inspection
n Perio
Period
d Every Every
Ev Every Every
1 mo
month
nth 3 months 6 month
onthss 12 month
onths
s
Every Every Every Every

Item 170 hours 500 hour
hours
s 1000 hours 2000 hour
hours
s
Clearance
Clearance betwe
between
en drum and lining M .- .- .-
Wearr of sh
Wea shoe
oe sliding
sliding por
portio
tion
n and lin
lining
ing I
Drum wear and dama

damage
ge I
Brake drum
and brake Shoe oper
operating
ating condition
condition I
shoe
Anchor pin rusting I
Return spring fatigue M
Automatic adjuster function I
Deformati
Deformation,
on, crack
cracks
s and da
damage
mage I
Backing
Backing plate
Loose mounting T
MATERIAL
MATERIAL HANDL
HANDLING
ING SYSTEM
Abnormality of fork and stopper pin I .- .- .-
Misa
Misalignm
lignment
ent be
between
tween left and right fork
Forks I .- .- .-
fingers
Cracks
Cracks at fork
fork roo
roott and weld
welded
ed part
part 1*1
Deformati
Deformation
on and damage
damage of each
each part an
and
d
crack at wel
crack welded
ded par
partt I .- .- .-
Mast and lift b

bracke
rackett loose
looseness
ness I .- .- .-
Mast and lift

Mast Wear and dama
damage
ge of mast suppo
support
rt bushing
bushing I
bracket
Wear, dama
Wear, damage
ge and rotatin
rotating
g cond
condition
ition of
rollers I .- .- .-
Wearr and da
Wea damag
mage
e of ro
rolle
llerr pin
pins
s I
Wearr and da
Wea dama
mage
ge of m
mast
ast trip I .- .- .-
Tension,
Tension, deform
deformation
ation and dama
damage
ge of chain I .- .- .-
Chain lubrication I .- .- .-
Chain and
chainwheel Abnor
Abnormalit
mality
y of chain anchor
anchor bo
bolt
lt I .- .- .-
Wear,, dama
Wear damage
ge and rot
rotating
ating condition
condition of
I . . .
chainwheel
Various Abnor
Abnormalit
mality
y and moun
mounting
ting condi
condition
tion of each
attachments I .- .- .-
part
HYDRAULIC
HYDRAULIC SYSTEM
Loosening
Loosening and dama
damage
ge of cylind
cylinder
er moun
mounting
ting T .- .- .-
Deformation
Deformat ion and damage
damage of rod, rod
rod scr
screw
ew
I .- .- .-
and rod end
Cylinder
Cylinder operation I .- .- .-
Natural drop and natura

Natural naturall forwa
forward
rd tilt
M .- .- .-
(hydraulic drift)
0-26
I n s p e c t io n P e r io d E v e ry E ve ry Every Every
E v e ry E ve ry Every Every
Item 1 7700 h oouu rrss 5 0000 h oouu rrss 1000 hours 2000 hours
Oil leak
leak and damage I
Cytinder
Wear and damage of ppin
bearing
in and cyli
cylinder
nder
I
-- -- --
Lifting speed M
- - -
Uneven movement I
- - -
Oil pump Oil leak and abnor
abnormal
mal sound I
- - -
Oil level and contamination I
- - -
Hydraulic oil
Hydraulic
Tank and oil strainer C
-
- - -
tank
Oil leak I
Loose linkage I
Control lever
Operation
Oil leak
I
I
-- -- --
Oil control M
Relief pressure measurement
- - -
valve
Relief valve and tilt lock valve functions I
Oil leak I
- - -
Hydraulic
Deformatio
Deformationn and damage I
- - -
- - -
piping
Loose joint T
ELECTRICAL SYSTEM
Cracks on distri
distributor
butor cap I
-
Spark plug burning and gap
Distributor side terminal burning

I
I
-- -- --
Ignition timing Distributor
Distribut
damage
or cap cent
center
er piece
piece wear and
I
- - -
Plug cord internal discontinuity I
Ignition timing
M
-
Starting motor Pinion
Pinion gear
gear mesh
meshing
ing status I
- - -
Charger Charging function I
- - -
Battery
Battery fluid level I
- - -
Battery fluid specific
specific gravity
- - -
M
Damage of wiring
wiring harness
harness I
- - -
Electrical
wiring Fuses I
0-27
Inspection
Inspection Per
Period
iod Every Every Every Every
Every Every
Ev Every Every
Item 170 hours 500 hour
hours
s 1000 hours 2000 hours
Open-circ
Open-circuit
uit in glow plug I +-
Preheater
Open-circ
Open-circuit
uit in inta
intake
ke heat
heater
er I +-
Engine stop
Engine stop--
ping system
system Diesell engine
Diese engine key stop
stop device func
function
tion I +- +- +-
Filter I +-
DPFMafier
Inline
Inline filt
filter
er (for ba
back
ck pres
pressure
sure sensor)
sensor) I +- +-
SAFETY
SAFETY DEVI
DEVICES
CES,, ETC.
Cracks
Cracks at weld
welded
ed port
portion
ion I +- +- +-
Head guard
Deformatio
Deformation
n and damag
damage
e I +- +- +-
Loosening
Loosening of mount
mounting
ing T +- +- +-
Back-rest
Deformatio
Deformation,
n, crac
crack
k and dam
damage
age I +- +- +-
Lighting
system Function
Function and moun
mounting
ting condition
condition I
- +- +-
Hom Func
Function
tion and moun
mounting
ting condition
condition I +- +- +-
Direction
indicator Function
Function and moun
mounting
ting cond
condition
ition I +- +- +-
Instruments Functions I +- +- +-
Backup
Backup buzze
buzzer
r Func
Function
tion and mounting
mounting condition
condition I +- +- +-
Rear-view Dirt, damage I +- +- +-
mirror Rear reflectio

reflection
n statu
status
s I 4
- 4
- +-
Loosenin
Loosening
g and damag
damage
e of mo
mountin
unting
g I 4
- +- +-
Seat
Seatbelt
Seatbelt dama
damage
ge and fun
function
ction I +- 4
- +-
Damage and cra

Damage cracks
cks of fr
frame
ame,, cro
cross
ss
memb
members,
ers, etc. I
Body
Bolt looseness https://www.forkliftpdfmanuals.com/
T
Functions I +- +- +-
Loosening and dam

Loosening damage
age at senso
sensorr moun
mounting
ting
I 4
- +- +-
portion
Damage, defo
Damage, deformat
rmation,
ion, oil leaka
leakage
ge and
SAS I 4
- +- +-
loosening
loosening of th
the
e mountin
mounting
g of fu
functio
nctional
nal part
parts
s
Loosenin
Loosening
g and damag
damage
e of wire harn
harnesses
esses I 4- 4
- +-
Lock cylinder
cylinder accum
accumulato
ulatorr perf
performa
ormance
nce I
Rusting and corrosion of load sensor I
Others Grea
Grease
se up L 4- 4
- +-
0-28
PERIO
PERIODI
DIC
C REPLACEM
REPLACEMEN
ENT
T OF PART
PARTS
S AND L UBRICANTS
UBRICANTS
• : Rep
Replac
laceme
ement
nt
Interval Every Every Every Every
1 month 3 m oonn th
th s 6 m oonn th
th s 12 months
Every Ev e r y
Ev E v e ry E ve ry
Item 170 hours 500 hours 1000 hours 2000 hours
•
Engine oil +- +- +-
Engine oil filter

• *1 • +- +-
•
Enginee cool
Engin coolant
ant (every
(every 2 years for LLC) +- +-
Fuel filter
• +-
Torque converter oil

• +-
Torque converter oil filter

• +-
Manual transmissi
transmission
on oil
Differential
Differential oil
•
•
Hydraulic
Hydraulic oil
• +-
Hydraulic oil filter

filter
.*1 • +-
•
Wheel bearing grease
Spark plugs
• +-
Air cleaner
cleaner element
•
•
Cups and seals for brake master and wheel cylinders
Brake fluid
• +-
Power steerin
steeringg hoses
.*2
Power steering
steering rubbe
rubbers
rs parts
parts
.*2
Hydraulic
Hydraulic hoses
.*2
Brake fluid reservoir tank hose
.*2
Fuel hoses
.*2
Torque converte
converterr rubbe
rubberr hoses
.*2
Chains .* 3
DPF Mafler filter (OPT)
.* 3
•
DPF M afl
afler
er back pressure sensor inline
inline filter
filter (OPT) +-
DPF Air cleaner

cleaner (OPT)
.* 2
SAS Swing lock cylinder
cylinder
.* 5
*1 : for new vehicle *2 : Every 2 years * 3: Every 3 years
years *5 : Every
Every 10000
10000 hou
hours
rs
Replac
Replaceme
ement
nt shall
shall be made
made upon arrival
arrival of the
the operat
operation
ion hou
hours
rs or mo
month
nths,
s, whiche
whichever
ver is ear
earlie
lier.
r.
1-1
FEATURES
Page
C L UTC H......
H.........
..... 1-2
M A N U A L T R A N SM
S M IS
I S SI
SIO N 1-5
F RONT A X L E -DIF
-DIF F E RE NT IA
IA L 1-9
W H EE L S . 1-13
C H A NG
N G E L E VE
VE R . . . . . . • . . . . . . . . • . . . . . . .. . • . . . • . . . . . . • . . . • • • . . • . . .. . . • • • . . . . . 1-16
STEE RING 1-17
F R A M E - W E IG
IG H T 1-18
V M A ST .........................
......................................
..........................
..........................
..........................
............. 1-19
T I L T CY
CY L I N D E R 1-19
LIFT CYLIN DER 1-20
F SV
S V ·F
·F V F R O NT
N T C Y L IN
IN D ER
ER • • • . . . . . . . . . . • . . . • . . . . .• • • • . • . . . . . . . . . . . 1-21
SA S 1-22
Refer to the
Refer the lat
latest
est data in the
the Toy
Toyot
ota
a Indus
Industr
tria
iall Equip
Equipment
ment Produc
Productt In
Info
forma
rmati
tion
on and
Toyot
Toyota
a I.E.
I.E. Sp
Speci
ecifi
ficat
catio
ion
n Man
Manual
ual for
for the main vehicl
vehicle
e speci
specifi
ficat
catio
ions.
ns.
1-2
CLUTCH
G ENERAL
The clut
clutch
ch rele
release
ase hub link
link mechani
mechanism
sm has been
been modifi
modified.
ed.
On convent
conventioional
nal vehic
vehicleles,
s, ththee pedal
pedal depre
depressi
ssion
on foforc
rcee was
transmitted from the clutch
transmitted clutch release
release cylinder
cylinder to the
the clutch cover
through
through the release
release fork shaft,
shaft, rel
release
ease fork
fork and release
release hub.
The same is transmitted
transmitted from the release
release cylinder
cylinder to the
the clutch
cover through the release fork and release hub after the modi-
fi
ficati
cation
on made thisthis time.
The clutch
clutch system,
system, theref
therefore
ore,, has been simplifi
simplified.
ed.
Vehicle
Vehi cless with
with the 4Y-ECS engineengine consisti
consisting
ng of the 4Y engengine
ine
and ECS are newly added.
CLUTCH SPECIFICATIONS
SPECIFICATIONS
5K 4Y·10Z-11 2Z
Type
-
Dry, single-plate, 4
- 4
-
spring
spring type
Clutch
Operating method Hydraulic 4
- 4
-
Size mm 278
27 8 4
- 4
-
Clutch cover Installation

Installation load N (kg) 2,354 (240) 3,236 (330) 3,923 (400)
0.0. x 1.0. x thickness (mm) 275

27 5 x 175
17 5 x 3 .5 4
- 4
-
Front frictional
frictional area (cm 2) 300.5 x 2 4
- 4
-
Clutch disc https://www.forkliftpdfmanuals.com/

Material Special woven 4
- 4
-
Type Conventional 4
- 4
-
Master cylinder
Inside diameter mm 15.87 4
- 4
-
Type Adjust-fre
Adjust-freee type 4
- 4
-
Release cylinder
Inside diameter mm 20.64 4
- 4
-
Applicable
Applicable oil Brake fluid 2500H 4
- 4
-
Note:
ote: Power-
ower-a
assist
ssist type
type clutch
clutch is a
adop
dopte
ted
d on ve
vehicle
hicles
s insta
installe
lled
d wit
with
h the optio
optiona
nall oil clutc
clutch.
h. The
power-
power-a
assist type clutch,
clutch, howe
howeve
ver,
r, is not
not provide
provided
d as an indiv
individua
iduall optio
option.
n.
1-3
C L UT
UT CH
CH M E
ECCH
HAA N IIS
SM SE
EC
CTTIIO N
NAAL V IIE
EW
Tra
Transmi
nsmissio
ssion
n side Engine
Engine side
Clu
Clutch
tch releas
release
e fo
fork
rk
1-4
OI
OILL CLUTCH (OP
(OPTI
TION)
ON)
The oil clut
clutch
ch vehicl
vehicles
es remain
remain unchan
unchanged
ged fro
from
m the old models.
models.
The 4Y -EC
-ECS
S engine
engine veh
vehicl
icles
es are ne
newly
wly added.
added.
CLUTCH SPECIFICATIONS
- 5K·4Y·1OZ-1I 'lZ.
Type
---- Wet, singl
single-pl
e-plate,
ate, coil spri
spring
ng type
-
Clutch
Operating
Operating method

Hydraulic
27 8
-
Size mm
Clutch cover
Installation
Installation load N (kg) 5,070 (517)
-
6865 (700)
0.0. x 1.0. mm 275

27 5 x 175
17 5
Front frictional
frictional area cm 2 300.5 x 2
-
Clutchh disc
Clutc -
Material Special
Special cork
Type Portless
Portless with hydra
hydrauli
ulicc booster
booster
-
Master cylinder
Inside diameter mm 25.4
-
Type Adjustabl
Adjustablee type
Release cylinder
mm 20.64
-
Inside diameter
Hydrauli
Hydraulicc oil ISO VG32
-
Applicabl
Applicablee oil
-

1-5
MANUAL TRANSMISSION
G ENERAL
The transmi
transmissi
ssion
on cas
casee has been
been change
changed d fro
from
m conven
conventio
tional
nal cas
castt iro
iron
n to alumin
aluminum
um diedie-ca
-casti
sting.
ng.
In pla
place
ce of the
the cl
clut
utch
ch hous
housin
ing
g an
andd tr
tran
ansm
smisissi
sion
on case
case in
inde
depe
pend
nden
entt fr
from
om ea
each
ch othe
otherr on conve
convent
ntio
iona
nall ve-
ve-
hicles
hic
fro
les,, the tran
front
nt case
transmi
smissi
case is integ
ssion
integrat
on cas
rated
case
ed with
e is divide
divided
with the clutch
d int
into
clutch housin
o the fron
housing. g.
frontt and rear
rear cases.

cases. In the case of dry clut
clutch
ch veh
vehicl
icles,
es, the
II
MANUA L T RANSMI SSI
SSIOO N SPECIF
SPECIF ICAT
ICAT I O NS
Transmiss
Transmission
ion type Synchromesh
Operating
Operating meth
method
od Floor shift link
Transmiss
Transmission
ion case oil capa
capacity
city l (US gal) 3.8 (1.0)
Applicable oil Hypoi

Hypoid
d gear oil SAE
SAE85W
85W -90
Change
Change Gear
Gear Ra
Ratio
tio
Change
Change gear ratio
Vehicle
Vehicle mode
modell Engine Forward Reverse
1st speed 2nd speed 1st speed 2nd speed
5K 3.715 2.127 3.722 2.132

1 ton
ton serie
series
s
*4Y·1DZ-1I 3.541 1.564
1. 3.548 1.567
5K 3.715 2.127 3.722 2.132

K2 ton serie
series
s
*4Y'1DZ-1I 3.541 1 .564
1. 3.548 1.567
5K 3.715 2.127 3.722 2.132

2 ton series *4Y·1DZ-1I 3.541 1.564 3.548 1.567
2Z 3.379 1.355 3.385 1.358
K3 ton serie
series
s *4Y·1DZ-1I 3.541 1.564 3.548 1.567
4Y f f f f
3 ton series
2Z 3.379 1.355 3.385 1.358
4Y 3.541 1.564 3.548 1.567

J3.5 ton series
2Z 3.379 1.355 3.385 1.358
*The
*The gea
gearr rat
ratios
ios of the 4Y-EC
4Y-ECS
S eng
engine
ine veh
vehicl
icles
es are the
the same as tho
those
se of the 4-Y eng
engine
ine veh
vehicl
icles.
es.
1-6
M A N U A L T R A N S MI
MI S S IO
IO N S E CT
CT IIO
O N A L V IIE
EW
Forwar
Forward
d gear
gear
Counte
Countersh
rshaft
aft gear,
gear, 1st
Forward-
Forward-reve
reverse
rse synchrom
synchromesh
esh
Countershaft
Sp
Speed
eed gear
gear sha
shaft
ft https://www.forkliftpdfmanuals.com/
Forwa
Forward
rd idl
idle
e gea
gear
r
Output
Output gear
gear
1-7
POWER TRANSMISSION
TRANSMISSION CHARTS
Forwar
Forward
d 1s
1stt spe
speed
ed Forward
Forward 2nd speed
Revers
Reverse
e 1st speed
speed Reverse
Reverse 2nd speed
1-8
MANUAL TRANSMISSI
TRANSMISSION
ON SECT
SECTIO
IONAL
NAL VI
VIEW
EW (Oil CLUTC
CLUTCHH VEHI
VEHICLE)
CLE)
Countershaft gear, 2nd Forward-reverse synchromesh
Countershaft
Speed gear shaft
Forward idle gear
1-9
FRONT AXLE-DIFFERENTIAL
MAJOR MODIFI
MODIFICATIO
CATIONS
NS
FRONT
FRONT AXLE HOUSI
HOUSING
NG
The number
number of fron
frontt axle
axle housin
housing
g bolts
bolts has been
been cha
change
nged
d fro
from
m 16 to 12 pcs./v
pcs./vehi
ehicle
cle..
Old New
F RONT
RONT AXL
AXL E BRACK
BRACKEET
The number
number of front
front axle
axle bracke
brackett set bolts has been change
changed
d fro
from
m 8 tto
o 6 pcs./
pcs./veh
vehicl
icle.
e.
Old
A DO PTIO
PT ION
N OF SERR
SE RR A TION
TI ON FOR
FO R HU B B OL TS
(1·
(1·2-TON VEHICLE
VEHICLE WITH
WITH SINGLE
SINGLE TIRES
TIRES))
The hub bolts
bolts were
were fasten
fastened
ed by lock
lock nuts
nuts on the inner
inner side
side of th
the
e bra
brake
ke dru
drum
m on the conven
conventio
tional
nal vehicl
vehicles.
es.
Serrat
Serration
ion is adopte
adopted
d for fixin
fixing
g hub bolts
bolts on the
the brake
brake dru
drum
m this tim
time.
e.
Old New
1-10
F RO
RO N T A X L E B R A C K E T R EA EA C T IO
IO N F OR
OR C E B O L T
The reactio
reaction
n force
force bol
boltt used for fix
fixing
ing the front axle bracket
bracket on the
the differen
differentia
tiall hou
housin
sing
g has bee
been
n change
changed
d to
a stan
standar
dard
d bolt.
bolt. (Exclu
(Excludin
ding
g 3.0-to
3.0-tonn and J3.5-t
J3.5-ton
on vehicl
vehicles)
es)
Old New
Reacti
Reaction
on force
force bolt
bolt Standard
Standard bolt
Tighteni
Tightening
ng torq
torque
ue Tighteni
Tightening
ng torque
torque
T=265-343
T=265-343 N'm T=294-343
T=294-343 N'm
(2700
(2700-35
-3500
00 kgf
kgf-cm
-cm)) (3000-35
(3000-3500
00 kgf-cm)
kgf-cm)
[195.3-2
[195.3-253.2
53.2 ft-Ib
ft-Ibf]
f] [217.1-2
[217.1-253.2
53.2 ft-I
ft-Ibf}
bf}
* 08833-00
08833-00070
070 applicat
application
ion

1-11
DIFFERENTIAL
The differe
differenti
ntial
al reduct
reduction
ion gear
gear portion
portion has been
been modifi
modified
ed in the dif
differ
ferent
ential
ial sec
sectio
tion.
n.
The ret
retain
ainer
er used
used in the drive
drive pinion
pinion and reducti
reduction
on gear
gear mounti
mounting
ng por
portio
tionn has been
been discont
discontinu
inued
ed and the
dif
differ
ferent
ential
ial carrie
carrierr shape
shape has been
been change
changed.
d. The spacer
spacer under
under the neck of the
the drive
drive pinion
pinion has also
also been
been
discontinued.
Old New
1 to 1.8 ton
ton series
series 2- 3 to
ton
n series
series,, J3.
J3.5
5 ton series
series
1-12
DI FF
FF ERENTI
ERENTI AL REDUCT IO
IO N G EAR RA T IO
IO SPECI
SPECIF
F IICAT
CAT I O NS
Tonnage 1.0 ton, 1.35 ton 1.5 ton, 1.75 ton
Engine 5K 10Z-11 5K 4Y'10Z-11

~
MfTvehicle 1.741 1.741

1.586 1.586
6.50-10 1-speed TIC vehicle 2.363 2.363
2-speed TIC vehicle Not provided
21 x 8-9 MfTVehicle 1.642
4.50-12 1-speed TIC vehicle 2.363 1.586 2.217

2. 1.586
6.00-9 2-speed TIC vehicle - - - -
Tonnage K2 ton serie

series
s K3 ton serie
series
s
Engine 5K 4Y 10Z-11 4Y 10Z-11

~ I I
MfTvehicle 1.642
1.586
With STO tires
tires 1-speed TIC vehicle 2.217
2-speed TIC vehicle Not provided
Tonnage 2 ton serie

series
s
Engine 5K 4Y·10Z-11 2Z.

~ I
MfTvehicle 2.00
https://www.forkliftpdfmanuals.com/ 1.846
2.75
With STO tires
tires 1 speed TIC vehicle
2-speed TIC vehicle Not provided 2.75 2.363

I
Tonnage 3.0 ton serie

series
s J3.5 ton serie
series
s
Engine 4Y·10Z-11 2 Z. 4Y·10Z-11 2 Z.
MfTvehicie
2.00 2.083
With STO tir
tires
es 1-speed TIC vehicle
2-speed TIC vehicle 2.75 2.363 2.75 2.217
1-13
WHEELS
TIRE TABLE
• : In
Indi
dica
cate
tes
s STD
STD tire
tire for model
model 6. : Indica
Indicates
tes OPT tire
tire
0: In
Indi
dica
cate
tes
s STD
STD tire
tire for each
each type
type - : Not app
applic
licabl
able
e
1.0 Ton Vehicle
Component Pneu
Pneumati
maticc Tir
Tire
e Pne
Pneuma
umati
ticc Typ
Type
e Sol
Solid
id Tire
Tire
Rim J-Lug Soft White Green

Type Tir
Tire
e Size
Size J --L
Luug
g T irir e S iz
iz e Non- N on -
No N on - No n-
Puncture Punc
Punctu
ture
re Pun
Punct
cture
ure Puncture
Single
Standard

Divided
Divi
Side
ded *'

Side ring
ring *'
6.00-9-10 •
6.00-9
~
Front ~
Tires Oversize Divided*'

6.50-10-10 6.50-10
-
Standar
Standard
d Doub
Double
le 4.50-12-8 0 4.50-12 ~
Side
Side ring
ring *'
Special
Special Doub
Double
le 6.00-9-10 ~ 6.00-9
Rear Tires
Divided
Divid
Side
ed *2
Side ring
ring *2
5 .0 0 - 8 - 8
I

•
~
5 .0 0 - 8

~
-
1.5 Ton & 1.
1.75
75 Ton Vehicle
Component Pneu
Pneumati
maticc Tire
Tire Pneu
Pneumati
maticc Type Sol
Solid
id Tire
Tire
J -L u g S o ft Wh
W h ite G ree n
Rim https://www.forkliftpdfmanuals.com/
Type T irire S iz
iz e J -L u g Ti
T i re S i z e N o n- N on -
No No n- Non-
Puncture Punct
Punctur
ure
e Pun
Punct
ctur
ure
e Puncture
Single
Standard

Divided
Divided *1 6.50-10-10
6.00-9-10*3
•
~
6.50-10
6.
6.00-
00-9
9 *3
~
Front
Tires 21 x8-9-10 ~ 21x8-9
Side
Side ring
ring *1 -
Standard
Standard Doub
Double
le 4.50-12-8 0 4.50-12 ~
Special
Special Doubl
Double
e 6.00-9-10 ~ 6.00-9
Rear Tires
Divided
Divi
Side
ded *2
Side ring
ring *2
5.00-8-8

•

~
5.00-8

~
-
*1 • Divide
Dividedd rims
rims and side
side ring
ring rims
rims are a set with
with their
their respec
respectiv
tive
e exc
exclus
lusive
ive hubs.
hubs.
• Tires
Tires are inte
interch
rchang
angeab
eable
le betwee
betweenn divide
dividedd rims,
rims, or betwe
between
en side
side ring rims, but are not inte
interch
rchang
ange-
e-
able
able betwe
between
en divide
divided
d rims
rims and side
side rin
ring
g rims.
rims.
*2 • Divide
Dividedd rims
rims and sid
side
e rin
ring
g rims
rims are a set with
with their
their respec
respectiv
tive
e exc
exclus
lusive
ive hobs.
hobs.
• DiDivid
vided
ed rims
rims and side
side rin
ringg rims
rims are not int
interc
erchan
hangea
geable
ble..
*3 • 6.0
6.00-9
0-9 is only
only set as STD for the 1.5 ton seriseries
es with
with 5K.
1-14
K2.0 Ton & K2.5 Ton Vehicl

K2.0 Vehicle
e
Pneumatic Tire Pneumat

Pneumatic
ic Type Soli
Solidd Tir
Tiree
Component R im J-Lug Soft White Green

Tire Size J-
J-Lug
Lug T irir e Size
Size Non- Non- Non- Non-
Puncture Puncture Puncture Puncture
Front Tires
Divided *1
Side ring *1

21 x8-9-14
21 x8-9-14
•
~
21 x8-9 ~
•
~
Divided *2 18x7-8-10
Rear Tires 18x7-8
Side ring *2 18x7-8-16 ~
*1 • Divided
Divided rims and side ring rims are not interchangeab
interchangeable.le.
*2 • Divide
Divided
d rims
rims and side
side rin
ring
g rims are a set
set with
with the
their
ir respec
respectiv
tive
e exc
exclus
lusive
ive hubs.
hubs.
• Div
Divide
ided
d rims
rims and side ring rims are not int
interc
erchan
hangea
geable
ble..
2.0 Ton & 2.5 Ton Vehicl

Vehicle
e
Component Pneumatic Tire Pneumat

Pneumatic
ic Type Soli
Solidd Tir
Tiree
Rim
Ri m .J-Lug Soft White Green
Type Tire Size J-Lug Tire Size Non- Non- Non- Non-
Puncture Puncture Puncture Puncture
Divided *1
Side ring *1
7.00-12-12

•
~
~
Single 7.00-12
Center
disc
Front
- -
Tires typesiderin9*2

Standard
Standard Double 5.50-15-8 0 5.50-15 ~
Side ring *1
Special
Special Double
Double 7.00-12-12 ~ 7.00-12
Rear Tires
Divided
Side ring *3
6.00-9-10 • 6.00-9

~
-
~
Oversize Divided *4 6.50-10-10'4 6.50-10 *4 ~
*1 • Div
Divide
ided
d rims
rims and sid
side
e rin
ring
g rims
rims are a set
set with
with their
their respec
respectiv
tive
e exc
exclus
lusive
ive hubs.
hubs.
• Tir
Tires
es are int
interc
erchan
hangea
geable
ble bet
betwee
ween
n divide
divided
d rims,
rims, or betwe
between
en side
side rin
ringg rims, but are
are not interc
interchan
hange-
ge-
able
able betwe
between
en div
divide
ided
d rims
rims and side
side rin
ring
g rims.
rims.
*2. Center
Center disc
disc type side ring rims are int
interc
erchan
hangea
geable
ble wit
with
h divide
divided
d rims.
rims.
*3. Side
Side rin
ring
g rims
rims are a set
set with
with their exclusiv
exclusive
e rear
rear hubs
hubs.. There is no
no int
interc
erchan
hangea
geabil
bility
ity wit
with
h div
divide
ided
d rims.
rims.
*4. Option
Option for 2.5 ton v
vehi
ehicle
cle only.
only.
1-15
K3.0
K3.0 Ton Vehicl
Vehicle
e
Pneumatic
Pneumatic Tire Pneu
Pneumatic
matic Type Soli
Solid
d Tire
Component Rim J-Lug Soft White Green

Tire Size J-Lug Ti
Tire Size Non- Non- No Non- Non-
Puncture Puncture Pun
Punctu
cture
re Pun
Punctu
cture
re
Front Tires Side ring 23x9-1 0-16 23x9-1 0
Rear Tires Side ring 18x7-8-16 • 18x7-8

l::.
3.0 Ton Vehicl

Vehicle
e
Component Pneu
Pneumati
matic
c Tire Pneu
Pneumati
matic
c Type Soli
Solid
d Tire
Rim J-Lug Soft W hi

hite Green
Type Tir
ire
e Si
Siz
ze J-L
-Lug
ug Tire Size Non- N No
on- Non- Non-
Puncture Pu
Punctur
ncture
e Punc
Puncture
ture Puncture
Front
Single 28x9-15-12
•
0
28x9-15 l::.
Tire Standard Double Side ring 6.00-15-10 6.00-15

-
Special
Special Doubl
Double
e 28x8-15-12 6 7.00-15 6.
Divided
6.50-10-10 •
6.50-10 l::.
Rear Tires Side ring·1
6
Di
Divi
vid
ded 6.50-
.50-10
10--12 - - -
*1 • Divided
Divided rims are interchang
interchangeabl
eable.
e.
J3.5
J3.5 Ton Vehicl
Vehicle
e
Component Pneu
Pneumatic
matic Tire Pneu
Pneumatic
matic Type Soli
Solid
d Tire
Rim J-Lug Soft Wh White Green

Type Tire Size J-Lug Tire Size Non- Non- No Non- Non-
Puncture
Puncture Punc
Puncture
ture Punctur
Puncture
e Pun
Punctu
cture
re
Front
Single 250-15-16
•
0
250-15 6.
Tire Standard Double 6.00-15-10 6.00-15

Side ring l::. -
Special
Special Doub
Double
le 28x8-15-12 6 7.00-15
Rear Tires 6.50-10-12

• 6.50-10 l::.
1-16
CHANGE
CHANGE LEVER
LEVER
GEN ER AL
Th
The
e shif
shiftt mech
mechan
anis
ism
m on manual
manual tran
transm
smis
issi
sion
on ve
vehi
hicl
cles
es is chan
change
ged
d fr
from
om the conv
conven
enti
tion
onal
al link
link type
type to the
cable type.
Adoption of the cable type has reduced lever vibration and stroke, resulting in easier operation.
The bra
brace
ce rod used in the link
link type is also
also eli
elimin
minate
ated.
d.

1-17
STEERING
TI
TILT
LT STEER
STEER IN
IN G LOC K MEC H AN ISM
ISM
The str
struct
ucture
ure of the
the tilt
tilt steering
steering lock
lock mechan
mechanism
ism has been cha
change
nged
d as shown
shown below.
below.
Old

1-18
FRAME-WEIGHT
HEAD GUARD
For eas
easier
ier materia
materiall handli
handling
ng in an eleva
elevated
ted locati
location,
on, a roof
roof hole is provid
provided
ed in the head guard roof.
roof. A roof
roof
cap is also
also provided for operation
operation under rainy weather.
weather.
WEIGHT
The weight
weight mass has been changed.
changed.
Vehicle
Vehicle mode
modell Tonnage Weigh
Weightt (kg)
1.0 400
1.35 610
1 ton
ton serie
series
s
1.5 745
1.75 880
2.0 1,140
Compact
Compact 2·3 ton 2.5 1,550
3.0 1,925
2.0 1,150
Standard
Standard 2 ton series 2.25 1,360
2.5 1,500
2.75 1,650
3 ton series
series 3.0 1,800
3.5 2,135
1-19
V MAST
LIFT BRACKET
The V mast lif
liftt bracket
bracket for the 1 .35 and 1.5 ton vehic
vehicles
les has been
been changed
changed as shown
shown below.
below.
Old Ne w
o o
o o
6 Uft roll
rollers/
ers/vehi
vehicle
cle 4 lift rollers/
rollers/vehi
vehicle
cle
TILT CYLINDER
The tilt
tilt cylind
cylinder
er rod guide
guide and cylin
cylinder
der bottom
bottom end struc
structur
tures
es have
have been chan
changed
ged as shown
shown bel
below.
ow.
rt-.l.-T'!
I ,. •
Bush • ' I '

'.
.
Collar
a-ring Grea
Grease
se groove
groove Oil groove
1-20
LIFT CYLINDER
LIFT CYUNDER
The pis
piston
ton rod gu
guide
ide str
struct
ucture
ure in the lif
liftt cylind
cylinder
er ASSY has been
been change
changed
d partia
partially
lly..
Old
RH
LH
II
'I
. .
II
Ne w
RH
II
LH
The structu
structural
ral change
change is the same
same also
also for th
the
e LH.
1-21
FSV··FV FRONT
FSV FRONT CYLINDER
CYLINDER
FRONT CYUNDER
The front
front cylin
cylinder
der str
struct
ucture
ure has been
been change
changed
d partia
partially
lly..
Old
New
1-22
SA S
LIFTING
LIFTING HEIGHT
HEIGHT SWITCH
SWITCH
1. Sw
Switch
itch Le
Leve
ver
r
The switch lev
lever
er rol
roller
ler str
structu
ucture
re has been changed in the lif
lifti
ting
ng height
height switch
switch for durabi
durabilility
ty improvement
improvement..
Old
Ne w
1-23
2. Switch Case
Case
The liftin
lifting
g height
height swi
switch
tch case
case set bolt
bolt has been change
changed
d fro
from
m an ordina
ordinary
ry to a tapp
tapping
ing bolt.
bolt.
Ordinary
Ordinary bolt Tapping
Tapping bolt
T=9.8-15.7
T=9.8-15.7 N·m T=22-25N'm
(100-1
(100-160
60 kgf-c
kgf-cm)
m) (224-225
(224-225 kgf-cm)
kgf-cm)
(7.2
(7.23-11
3-11.57
.57 ft-Ibf]
ft-Ibf] [16.21-1
[16.21-18.45
8.45 ft-Ibf]
ft-Ibf]
[Caution]
When the ttapp
When apping
ing bol
boltt is lo
loos
osene
enedd or re remov
moved
ed,,
remove
remove remaini
remaining
ng aluminum
aluminum particle
particles.
s.
2-1
MANUAL
MANUAL TRANSM
TRANSMISSI
ISSION
ON
Page
G EN ERAL 2-2
SPECI
SPECI FIC
FICATIO
ATION
NS 2-3
COM
COM PO
PON
N EN
ENTS
TS 2-4-
MANUAL
MANUAL TRA
TRANSM
NSMISS
ISSION
ION ASS
ASSY
Y 2-6
~E:~c:>"~·
~E:~c:>"~·I~!)1r
I~!)1r~~1rI
~~1rIc:>~
c:>~ ......•....
......•...........
.............
............
............
.............
...........
.... 2-6
DISA!)!)E:~B
DISA!)!)E:~BLy·I~S
Ly·I~SPE:C"O
PE:C"O~·RE:A
~·RE:A!)SE:~
!)SE:~BLY
BLY ............
...............••.
...••... 2-10
SPEED SHAFT ASSY 2-14

DI!)A!)!)E:~
DI!)A!)!)E:~BLY
BLY ·1~!)PE:C11C
·1~!)PE:C11C:>~·
:>~·
~E:A!)SE:~BLY 2-14
COUNTE
COUNTERSH
RSHAFT
AFT ASS
ASSY
Y 2-17
DI!)A!)!)E:~BLY·I~SPE:C"C:>~·~E: ·~E:A!)SE:~BLY 2-17
SHIFT
SHIFT LINK BR
BRAC
ACKET
KET AS
ASSY
SY 2-22
DI!)A!)!)E:~
DI!)A!)!)E:~BLY·I~
BLY·I~SPE:C"
SPE:C"c:>~
c:>~ ·~EA!)SE:
·~EA!)SE:~BLY
~BLY ........•...
........•.........
...... 2-22
SHIFT
SHIFT LEVER-
LEVER-WIR
WIRE
E CAB
CABLE
LE 2-23
~E~C:>"~
~E~C:>"~ ·1~S1r~~T
·1~S1r~~Tlc:>~
lc:>~ ............
...............•..
...•........
............
.............
.............
..........
.... 2-23
2-2
GENERAL

2-3
SPECIFICATIONS
Transmiss
Transmission
ion type Full sync
synchrom
hromesh
esh type
Operating
Operating meth
method
od Floor
Floor shift link meth
method
od
Transmiss
Transmission
ion case oil
oil capa
capacity
city l (US gal) 3.8 (1.0
(1.0))
Transmiss
Transmission
ion oil Hypoid
Hypoid gear oil
Gear
Gear ratio
Gear ratio
Vehicle
Vehicle mode
modell Engine Forward Reverse
1st speed 2nd speed 1st sp

spe
eed 2nd speed
peed
5K 3.715 2.127 3.722 2.132
1 ton serie
series
s
4Y-1DZ-1I 3.541 1.564 3_548 1.567
5K 3.715 2.127 3.722 2.132

K2 ton serie
series
s
4Y-1DZ-1I 3.541 1.564 3.548 1.567
5K 3.715 2.127 3.722 2.132
2 ton series
series 4Y-1DZ-1I 3.541 1.564 3.548 1.567
2Z 3.379 1.355 3.385 1.358
K3 ton serie
series
s 4Y-1DZ-1I 3.541 1.564 3_548 1.567
4Y-1DZ-1I f f f f
3 ton series
2Z 3.379 1.355 3.385
3. 1.358
4Y 3.541 1.564 3.548 1.567

J3.5 ton serie
series
s
2Z 3.379 1.355 3.385
3. 1.358
2-4
COMPONENTS
3301
54
3301-064A

2-6
MANUAL
MANUAL TRANSM
TRANSMISS
ISSIO
ION
N ASSY
REM OVAL-INST ALLAT ION T = N·m (kgf-cm)

(kgf-cm) [ft-Ibf]
[ft-Ibf]

2-7
R em
em o v a l P r o c e d u r e
1 Remove
Remove the engine
engine hood.
hood. (Refer
(Refer to page
page 11-5
11-5 in tthe
he 7FG/7
7FG/7FD
FD Ser
Series
ies Repair
Repair Manual
Manual (No
(No.. CE024))
CE024))
2 Remove
Remove the toe board.
board.
3 Drain coolant.
4 Remove
Remove the battery
battery and battery
battery tra
tray.
y.
5 Diesel engine
Diesel engine vehicle:
vehicle:
Remove
Rem ove the sedimen
sedimenter
ter bracke
brackett set bolt
bolt for
for fre
freein
eing.
g.
6 Disc
Discon
onne
nect
ct th
the
e a
acc
ccel
eler
erat
ator
or wire
wire and
and fu
fuel
el hos
hose.
e. [Point
[Point 1]
7 Remo
Remove
ve the fus
fuse
e box
box and
and elec
electr
tric
ical
al pa
part
rts
s plate
plate se
sett bolt
bolts
s for
for fre
freei
eing
ng..
8 Disc
Discon
onne
nect
ct conn
connec
ecto
tors
rs and
and wire
wire harn
harnes
ess
s cl
clam
amps
ps ar
arou
ound
nd the engin
engine
e an
and
d ttra
rans
nsmi
miss
ssio
ion.
n.
9 Remo
Remove
ve th
the
e ho
horn
rn W /b
/bra
rack
cket
et..
10 Ve
Vehi
hicl
cle
e with
with oil cl
clut
utch
ch::
Discon
Disconnec
nectt the oil clutch
clutch pipe.
pipe.
11 Disc
Discon
onne
nect
ct th
the
e cl
clut
utch
ch re
rele
leas
ase
e cyli
cylind
nder
er push
push rod.
12 Rem
Remove
ove the
the clutch
clutch rel
releas
ease
e cyl
cylind
inder
er set bolts
bolts and hydra
hydrauli
ulic
c pip
piping
ing clamps
clamps set bo
bolts
lts,, and k
keep
eep them
them in
free state.
13 Remo
Remove
ve th
the
e radi
radiat
ator
or..
14 Disc
Discon
onne
nect
ct th
the
e ai
airr cl
clea
eane
nerr hose
hose..
15 Remo
Remove
ve the oil pum
pump
p se
sett bolt
bolt fo
forr freei
freeing
ng..
16 Disc
Discon
onne
nect
ct th
the
e exh
exhauaustst pipe.
pipe.
17 Ve
Vehi
hicl
cle
e with
with oil cl
clut
utch
ch::
Discon
Disconnec
nectt the oil clu
clutch
tch hose.
hose.
18 Remo
Remove
ve the F/
F/R
R and 1/
1/2
2 shi
shift
ft le
leve
vers
rs and disc
discon
onne
nect
ct the
the shif
shiftt le
leve
verr cabl
cables
es.. [Point
[Point 2]
19 Disc
Discon
onne
nect
ct th
the
e cabl
cable
e from the shi
shift
ft link
link and rem
remov
ove
e th
the
e cabl
cable.
e.
20 Remo
Remove
ve th
the
e cl
clam
amp
p un
unde
derr th
the
e shif
shiftt le
leve
verr cable
cable on tthe
he lower
lower side of the
the vehic
vehicle
le.. [Point 5]
21 Disc
Discon
onne
nect
ct th
the
e oil cont
contro
roll va
valv
lve
e in
inle
lett pipe.
pipe.
22 Remo
Remove
ve th
the
e unde
underr cove
cover.
r.
23 Remove
Remove the propel
propeller
ler sha
shaft.
ft. (Refer
(Refer tto
o pag
page
e 5-3 in the 7FG/7F
7FG/7FD
D Series
Series Repair
Repair Manual
Manual (No
(No.. CE024
CE024)}
)}
24 Remo
Remove
ve the tra
trans
nsmi
miss
ssio
ion
n moun
mountt bolt
bolts
s and pin
pin bolts.. [Point
bolts [Point 3]
25 Remo
Remove
ve the
the eng
engin
ine
e moun
mountt nuts.
nuts.
26 Remove
Remove the
the engi
engine
ne W/trans
W/transmis
mission. [Point
sion. [Point 4
4]]
27 Re
Remo
move
ve the
the clu
clutc
tch
h hous
housin
ing
g co
cove
ver.
r.
28 Remove
Remove the lock ring and
and slid
slide
e the input shaf
shaftt ful
fully
ly toward
toward the front.
front. (Re
(Refer
fer to page
page 2-9 in
in the 7FG/7
7FG/7FD
FD
Series
Series Rep
Repair
air Manual
Manual (No.
(No. CE024)
CE024)))
29 Remo
Remove
ve the clut
clutch
ch ho
hous
usin
ing
g (f
(fro
ront
nt case
case)) set bolts
bolts..
30 Remo
Remove
ve the tra
trans
nsmi
miss
ssio
ion
n AS
ASSY
SY and
and rele
releas
ase
e hu
hub
b W/be
W/bear
arin
ing.
g.
31 Re
Remo
move
ve the
the clu
clutc
tch
h re
rele
leas
ase
e fo
fork
rk..
32 Remo
Remove
ve the clu
clutc
tch
h re
rele
leas
ase
e hub
hub W/be
W/bear
arin
ing.
g.
2-8
Installa
nstallation
tion Procedure
The instal
installat
lation
ion pro
proced
cedure
ure is the rev
revers
erse
e of tthe
he remova
removall proced
procedure
ure..
Point Opera
Operations
tions
[Point
[Point 1]
Removal:
Put a match
match mark
mark on the
the fuel hose
hose and joint.
joint.
Installation:
Check
Che ck the match
match mark.
mark.
Shi
Shift
ft lev
lever
er sid
side
e
[Point 2]
Reasse
Rea ssembl
mbly y :
Tra
Transm
nsmiss
ission
ion sid
side
e
1. Connec
Connectt the cable
cable to the
the 1st/2
1st/2nd
nd lever
lever by check
checking
ing the
identific
identification
ation mark (white tape).
tape).
White
White tap
tape
e
L
2. Adjust
Adjust the shift
shift lev
lever
er neutra
neutrall positi
position
on while
while adjust
adjusting
ing the
cable
cab le length
length to make the distan
distance
ce betwee
betweenn the cente
centerr of
the shift
shift lever
lever shaft
shaft and the lever knob satisf
satisfy
y the follow-
follow-
ing standard:
L 180+gmm (7.1 +g.197in)

=
3. Insp
Inspec
ectt th
the
e of
offs
fset
et be
betw
twee
eenn th
the
e FI
FIR
R anand
d 1st/2
st/2nd
nd le
leve
ver
r
knobs
knobs with
with shift
shift levers
levers in the
the neutra
neutrall positi
positions
ons..
Knob
Knob off
offset
set A: 5 mm (0.197
(0.197 in) or less
less
2-9
Pin bolts
[Point
[Point 3]
Installation:
After installing the mount bolt and pin bolt on the right side,
instal
installl those
those on the left side.
Mount bolts
[Point 4]
Removal, Installation:
SST 09010-
09010-201
20111- 71 --- C D
11-71
09010-
09010-233
23320-
20-71
71 --- @
[Point
[Point 5]
Reassembly:
After clamping shift lever cables under the differential, lead
them
them to the shift
shift lever
lever side by crossi
crossing
ng with the F IR cable
with
on the
the fro
front
nt side.
side.
*00 not cross the TCM arranarrangemen
gement.t.
2-10
T N·m
=N·m (kgf-cm ) [ft-Ibf
[ft-Ibf]]
DI
DISASS
SASSEMBLY-
EMBLY-IINSPECT
NSPECTIION -REASSE
-REASSEMBLY
MBLY
8
T=14.7-21.6
T=14.7-21.6
(150-220)
(150-220)
T =29.4-39.2 ~
(300-400) "--- -
I
Y l
[21. 7-
7 -28.9]~ T =1
=17.5-32.5
rr 1
(178.4-331.4)
9 [1
[12.
2.9-
9-24
24.0
.0]]
~c
T =29.4-44.1
(300-450) 12
[21.7-32.6]
r
~ ~
f l ~ ~
I
T =156.8-235.2
=156.8-235.2
(1600-2400)
[115.8-173.6]
2-11
Dis as
as s em bly P r oc eedur
dur e
1 Extrac
Extractt the oil level
level gau
gauge
ge and drain
drain transm
transmiss
ission
ion oil.
2 Measur
Measure
e the thrust
thrust cleara
clearance
nces
s of the 1st,
1st, 2nd and forwar
forward
d gears.
gears. [Point
[Point 1]
3 Remo
Remove
ve th
the
e fr
fron
ontt cove
cover.
r.
4 Remo
Remove
ve th
the
e co
coun
unte
ters
rsha
haft
ft bear
bearin
ing
g sn
snap
ap ring
ring.. [Point 2]
5 Rem
Remov
ove
e th
the
e lo
loc
ck nu
nutt. [Point
[Point 3]
6 Remo
Remove
ve th
the
e rea
rearr co
cove
verr and
and re
rear
ar lowe
lowerr co
cove
ver.
r.
7 Remo
Remove
ve th
the
e ou
outp
tput
ut shaf
shaft.
t. [Point 4]
8 Remo
Remove
ve th
the
e sh
shift
ift li
link
nk br
brac
acke
kett ASSY
ASSY.. [Point 5]
9 Remove
Remove the detent
detent spring
spring and steel
steel ball.
ball.
10 Remove
Remove the transmiss
transmission
ion front case.
case. [Point 6]
11 Remove
Remove the speed
speed fork shafthttps://www.forkliftpdfmanuals.com/
fork shaft sna
snapp ring.
ring.
12 Remo
Remove
ve th
the
e sh
shif
iftt fo
fork
rk and
and fork
fork sh
shaf
aft.
t.
13 Remove
Remove the output
output gear
gear and bearin
bearing.
g.
14 Remove
Remove the counte
countersh
rshaft
aft ASSY
ASSY and speed
speed shaft
shaft ASSY.
ASSY.
15 Remove
Remove the transmiss
transmission
ion rear case.
case. [Point
[Point 7]
Reas
Re as s eem
m bly P r oc eedur
dur e
The reassembly procedure is the reverse of the disassembly procedure.
Notes
• Remove
Remove the sea
sealing agen
agentt applied
pplied on the mating
mating surface
surfaces
s of the ttra
ransmis
nsmission
sion ca
case
se and
and ea
each
ch
cover.
• Apply
Apply new
new se
sea
aling age
agent by re
refe
ferring
rring to the illustr
illustrat
ations
ions below.
below.
Seal packing:
packing: 08826-0009
08826-00090
0
Counte
Countersh
rshaft
aft cov
cover
er
Shif
Shiftt link bracket
Output
Output sh
shaft
aft cov
cover
er Transmis
Transmission
sion cas
case
e
• Apply
Apply se
sea
aling age
agent al
also
so on the thread
threaded
ed portions
portions of set
set bolts at the time of rea
reassembly.
ssembly.
2-12
Point Operations
Operations
[Point 1]
[Point
Inspection:
Measure the clearance
clearance between
between the synchroni
synchronizer
zer ring and
and
each gear.
Standard:
1st·2
1st·2nd
nd gear:
gear: 1.25
1.25 - 2.
2.05
05 mm
Forwar
For ward
d gear:
gear: 1.15
1.15 - 2.
2.15
15 mm
Umit:
1st·2nd gear: 0.6 mm
Forward gear: 0.6 mm
The clear
clearance
ance is immeasu
immeasurab
rable
le for the
the reverse
reverse gear.
gear.
[Po
[Point
int 2]
Disassembly:
SST 09905-00012
[Point 3-4]
[Point 3-4]
Disassembly·Reassembly:
Lock the
the output shaft
shaft with a pipe
pipe wrench
wrench when removing
removing or
install
installing
ing the countershaf
countershaftt or output
output shaft
shaft lock nut.
Reassembly:
Good example
After
After tightening
tightening each lock nut to the
the specifi
specified
ed torque,
torque, lock it
~
securely
secure ly (in two places each).
Bad example
[Point 5]
[Point
Reassembly:
Install
Install by alignin
aligning
g the tip
tip end of the
the FIR or 1 1 2 shift link with
the groove on each shift
shift fork shaft
shaft for assembly. Install
Install the
rubber boot on the link side beforehand.
2-13
[Point
[Point 6]
Inspection:
In
Insp
spec
ectt th
the
e ou
outp
tput
ut shaf
shaftt oi
oill se
seal
al lip
lip for
for wea
wearr or damag
damage.
e. If
an
anyy excess
excessiv ive
e wear
wear or dama
damage ge is fou
found
nd,, re
repl
plac
acee the
the oi
oill
seal.
Removal:
Use a screw
screwdri
driver
ver and brass bar for removal
removal..
Reassembly:
SST 09370-10410-71
Apply MP grease on the outer periphery and lip of the oil

seal before reassembly
reassembly..
[Point
[Point 7]
Inspection:
In
Insp
spec
ectt th
the
e ou
outp
tput
ut shaf
shaftt oil
oil se
seal
al lip
lip fo
forr wear
wear or damag
damage.
e. If
an
anyy exce
excessssiv
ive
e wear
wear or dama
damagege is foun
found,
d, re
repl
plac
acee the
the oi
oill
seal.
Removal:
Use a scre
screwdr
wdrive
iverr and brass
brass bar for
for remova
removal.
l.
Reassembly:
SST 09950-
09950-7001
7001 0
09950-60010
Apply MP grease on the outer periphery and lip of the oil
seal befor
before
e reassembly
reassembly..
2-14
SPEED SHAFT ASSY

DI
DISASSEMBLY-I
SASSEMBLY-INSPE
NSPECTI
CTION
ON -REASSE
-REASSEMBL
MBL Y
5
D isassembly
isa ssembly P rocedure
1 Ins
Inspec
pectt the forwar
forward
d idle gear
gear cleara
clearance
nce.. [Poi
[Point
nt 1]
2 Remo
Remove
ve th
the
e tight
tight plu
plug,
g, sp
spac
acer
er and
and in
inpu
putt sh
shaf
aft.
t. [Point
[Point 2]
3 Remove
Remove the rear
rear bearin
bearing
g and thrust
thrust washer
washer.. [Point 3]
4 Remo
Remove
ve th
the
e fo
forw
rwar
ard
d iidle
dle gear
gear and
and need
needle
le ro
roll
ller
er bear
bearing
ing.. [Point
[Point 4]
5 Remo
Remove
ve th
the
e fr
fron
ontt be
bear
arin
ing.
g. [Point 5]
6 In
Insp
spec
ectt th
the
e spee
speed
d shaf
shaft.
t. [Point
[Point 6]
R eassembly
eassembly P rocedure
The reassembly
reassembly procedure
procedure is the reverse of the disassembly
disassembly procedure.
procedure.
Apply gear oil on each sliding contact surface.
2-15
Point Operations
Operations
[Point
[Point 1]
Inspection:
Measur
Mea sure
e the forwar
forward
d idl
idle
e gear thrust
thrust cleara
clearance
nce..
Standard:
Standa rd: 0.15
0.15 - 0.40
0.40 mm (0.0059
(0.0059 - 0.0
0.0157
157 in)
in)
Limit:
Limit: 0.7 mm (0.028
(0.028 in)
Inspection:
Measure
Meas ure the fo
forward
rward idle gear radial cleara
clearance.
nce.
Standard:
Standard: 0.010 - 0.052 mm
mm (0.00039
(0.00039 - 0.00205
0.00205 in)
in)
[Point
[Point 2]
Disassembly:
Us
Usee a plast
plastic
ic ha
hamm
mmer
er and
and tap the in
inpu
putt shaf
shaftt to re
remo
move
ve
the spacer
spacer and input shaft
shaft together
together wit
with
h the tight
tight plu
plug.
g.
Reassembly:
After installing the input shaft and spacer, use the SST and
installll the tight plug.
insta
SST 0995 09950-6
0-6001
00100 --- C D
09950-
099 50-700 10 --- @
70010
[Point
[Point 3]
Disassembly:
SST 09950-40011
09950-60010
2-16
Inspection:
Measure the thrust
thrust washer thickness.
thickness.
Limit:
Limit: 3.7 mm (0.14
(0.146
6 in)
Reassembly:
SST 09370-20270-71
[Poi
[Point
nt 4]
Inspection:
Measure the inside
inside diameter of the
the forwar
forwardd idl
idlee gear.
Limit:
Limit: 55.1
55.1 mm (2.169
(2.169 in)
[Poi
[Point
nt 5]
Disassembly:
SST 0995
09950-4
0-40011 --- G )
0011
09950-
09950-60010 --- @
60010
[P
[Poi
oint
nt 6]
Inspection:
Measure the outside diameter of the speed shaft journal
journal..
Limit:
Limit: 47.
47.9
9 mm (1.886
(1.886 in)
2-17
COUNTERSHAFTASSY
DI
DISASSEMBLY-I
SASSEMBLY-INSPE
NSPECTI
CTION
ON -REASS
-REASSEMBLY
EMBLY
D isassembly
isassembly P rocedure
1 In
Insp
spec
ectt each
each gea
gearr cle
clear
aran
ance
ce.. [Point
[Point 1]
2 Remo
Remove
ve th
the
e 1st ge
gear
ar,, synch
synchro
roni
nize
zerr ri
ring
ng and
and ne
need
edle
le ro
roll
ller
er bear
bearin
ing.
g.
3 Re
Remo
move
ve the
the rrea
earr be
bear
arin
ing
g sn
snap
ap ring.. [Point
ring [Point 2]
4 Re
Remo
move
ve the rear
rear be
bear
arin
ing,
g, th
thru
rust
st wash
washer
er an
and pin.. [Point
d pin [Point 3]
5 Remo
Remove
ve th
the
e rever
reverse
se gear
gear,, sync
synchr
hron
oniz
izer
er ri
ring
ng an
and
d need
needle
le ro
roll
ller
er bea
beari
ring
ng..
6 Remo
Remove
ve the
the clut
clutch
ch hub
hub sn
snap
ap ri
ring
ng.. [Point
[Point 4]
7 Remo
Remove
ve th
the
e clutch
clutch hu
hub
b NO.1
NO.1 ASSY,
ASSY, s
syn
ynch
chro
roni
nize
zerr ri
ring
ng,, 2nd g
gea
earr and need
needle
le ro
roll
ller
er bear
bearing. [Point 5]
ing.
8 In
Insp
spec
ectt the fo
forw
rwar
ard
d ge
gear
ar th
thru
rust
st cle
clear
aran
ance
ce.. [Point 6]
9 Remove
Remove the clut
clutch
ch hub NO.2ASSY,
NO.2ASSY, synchr
synchroni
onizer
zer rin
ring,
g, for
forwar
ward
d gear
gear and needle
needle roller
roller bearing. [Point 7]
bearing.
10 In
Insp
spec
ectt th
the
e co
coun
unte
ters
rsha
haft
ft and
and eac
each
h gear.
gear. [Point 8]
11 Disa
Disass
ssem
embl
ble
e th
the
e clu
clutc
tch
h hu
hub
b NO.
NO.1
1 ASSY
ASSY and
and NO.
NO.2
2 ASSY
ASSY.. [Point
[Point 9]
12 In
Insp
spec
ectt th
the
e shi
shift
ft fork
fork an
and
d hub
hub sle
sleev
eve
e cl
clea
eara
ranc
nce.
e. [Point 10
10]]
13 In
Insp
spec
ectt the sy
sync
nchr
hron
oniz
izer
er ring.. [Point
ring [Point 11
11]]
2-18
R eassembly
The reassem
reassembl
blyy procedu
procedure
re is the
the revers
reverse
e of the
the disass
disassembl
emblyy proced
procedure
ure..
P oint Opera
Operations
tions
[Point
[Point 1]
Reverse 2nd Inspection:
Measure the thrust
thrust clearances
clearances of the 2nd gear and reverse
reverse
gear.
2nd gear:
Standard:
Standard: 0.15
0.15 - 0.40
0.40 mm (0
(0.0
.005
059
9 - 0.01
0.0157
57 in)
Reverse
Re verse gear:
gear:
Standard:
Standard: 0.10
0.10 - 0.45
0.45 mm (0
(0.0
.003
039
9 - 0.01
0.0177
77 in)
Inspection:
Measure the radial clearance
clearance of each gear.
1 st 1st gear
gear . reve
reverse
rse gea
gear:
Standard:
Standard: 0.01
0.016
6 - 0.05
0.057
7 mm (0
(0.0
.000
0063
63 - 0.00
0.0022
224
4 in)
2nd 2nd
2nd gea
gear·
r· forwa
forward
rd gear
gear::
Standard:
Standard: 0.01
0.018
8 - 0.06
0.062
2 mm (0.00
(0.0007
071
1 - 0.00
0.0024
244
4 in)
Forward
Reverse
[Point 2]
SST Disassembly·Reassembly:
SST 09905-00012
Reassembly:
Select and install the thickest snap ring that can be installed
to make the
the rear bearing
bearing thrust
thrust clearance
clearance 0.1 mm (0.04 in)
or less.
Mark Thickness mm (in

(in))
A 2.1
2.15
5 - 2.2
2.20
0 (0.084
(0.0846
6 - 0.0
0.0866
866))
B 2.2
2.25
5 - 2.3
2.30
0 (0.088
(0.0886
6 - 0.0
0.0906
906))
C 2.3
2.35
5 - 2.4
2.40
0 (0.092
(0.0925
5 - 0.0
0.0945
945))
0 2.45
2.45 - 2.5
2.50
0 (0.096
(0.0965
5 - 0.0
0.0984
984))
E 2.5
2.55
5 - 2.6
2.60
0 (0.100
(0.1004
4 - 0.1
0.1024
024))
2-19
[Point
[Point 3]
Disassembly:
SST 09950-40011
Inspection:
Measur
Mea sure
e the thrust
thrust was
washer
her thi
thickn
ckness
ess..
Limit:
Limit: 5.9 mm (0.23
(0.232
2 in)
Reassembly:
Instal
Ins talll the thrust
thrust was
washer
her and rear
rear bearin
bearing
g by checki
checking
ng the
directions.
SST 09608-04031
[Point
[Point 4]
Reassembly:
Selectt and install
Selec install the thickest snap ring that can be installed
installed
to make
make the clut
clutch
ch huhubb clear
clearan
ance
ce 0.1
0.1 mm or less.
less.
Mark Thickness mm (in)
A 1.8
1.85
5 - 1.9
1.90
0 (0.072
(0.0728
8 - 0.0
0.0748
748))
B 1.9
1.95
5 - 2.0
2.00
0 (0.076
(0.0768
8 - 0.0
0.0787
787))
C 2.0
2.05
5 - 2.1
2.10
0 (0.080
(0.0807
7 - 0.0
0.0827
827))
D 2.1
2.15
5 - 2.2
2.20
0 (0.084
(0.0846
6 - 0.0
0.0866
866))
[Point
[Point 5]
Disassembly:
SST 09420-23000-71
2-20
Reassembly:
Press in after
after matching
matching the chamfered
chamfered side of the hub spline
spline
Chamfering
with
with the shaf
shaftt spline
spline inl
inlet.
et.
SST 09608-04031
«~
[Point
[Point 6]
Inspection:
Measur
Measure
e the for
forwar
ward
d gear
gear thr
thrust
ust cle
cleara
arance
nce..
Standard: 0.15
0.15 ....0
0.40
.40 mm (0.005
(0.0059
9 ....
....0
0.0157
.0157 in)
[Point
[Point 7]
Disassembly:
SST 09420-23000-71
Reassembly:
Press
Pre ss in after
after matchi
matching
ng the chamfer
chamfered
ed side
side of hub spline
spline
with
with the shaft spline
spline inl
inlet.
et.
SST 09608-04031
[Point
[Point 8]
Inspection:
Measure
Measu re the c
counte
ountersha
rshaft
ft journal
journal outside
outside diameter.
diameter.
1st gear
gear . reve
reverse
rse gear
gear::
Limit: 29.9 mm (1.177 in)
2nd
2nd gea
gear·
r· forwa
forward
rd gea
gear:
Limit: 39.9 mm (1.571 in)
2-21
Inspection:
Measur
Mea suree the inside
inside dia
diamet
meterer of each
each gear.
gear.
1st gear
gear . reve
reverse
rse gear
gear::
Limit: 38.1 mm (1.500 in)
2nd
2nd gear
gear·· forwa
forwardrd gear
gear::
Limit: 48.1 mm (1.894 in)
[Point
[Point 9]
Reassembly:
When
Whe n reasse
reassembl
mbling
ing the clutch
clutch hub ASSY
ASSY,, never
never align two
key spring
spring open
opening
ing positions
positions..
[Point 10
10]]
Inspection:
Meas
Me asur
uree the
the clea
cleara
ranc
nce
e be
betw
twee
een
n the
the shif
shiftt fork
fork an
and
d hu
hub
b
sleeve.
Limit: 1.
1.0
0 mm (0.03
(0.039
9 in)
[Point 11
11]]
Inspection:
Apply gear oil on the tapered portion of each gear. When
the synchro
synchroniz
nizer
er rin
ringg is brough
broughtt into
into clos
close
e con
contac
tactt and ro-
tat
tated,
ed, it shal
shalll not s
slip
lip..
Inspection:
Measur
Mea suree the clea
clearan
rance
ce bet
betwee
weenn the synch
synchron
ronize
izerr rin
ring
g and
each gear.
1st gear
gear·· 2nd
2nd gear
gear::
Standard:
Standard: 1.25
1.25 - 2.05
2.05 mm (0 (0.0
.049
492
2 - 0.08
0.0807
07 in)
Limit: 0.6 mm (0.024 in)
Forwa
Forwardrd gear
gear . re
reve
verse
rse gear
gear::
Standard:
Standard: 1.15
1.15 - 2.15
2.15 mm (0.04
(0.0453
53 - 0.08
0.0846
46 in)
Limit: 0.6 mm (0.024 in)
2-22
SHIF
SHIFT
T LIN
LINK
K BRACKE
BRACKET
T ASS
ASSY
Y
DISASSEMBlY-INSPECTION-REASSEMBlY T = N·m (kgf-c
(kgf-cm)
m)
4
Dis as
as s em bly P r oc eedur
dur e
1 Re
Remo
move
ve the
the bac
back-
k-up
up lamp
lamp sw
swit
itch
ch.. [Point
[Point 1]
2 Remo
emove th
the dust
ust boo
boot.
3 Re
Remo
move
ve the
the sh
shif
iftt lin
link
k sh
shaf
aft.
t.
4 Remo
Remove
ve th
the
e FIR
FIR shif
shiftt link
link an
and
d 1st/2
1st/2nd
nd shift
shift llin
ink.
k.
Fill greas
grease
e through
through the grease
grease fitting.
fitting.
Reas
Re as s eem
m bly P r oc eedur
dur e
The reasse
reassembl
mbly
y pro
proced
cedure
ure is the reverse
reverse of the
the disasse
disassembl
mbly
y proced
procedure
ure..
Point Operations
[Point
[Point 1]
Inspection:
Inspec
Inspectt the bac
backup
kup lamp
lamp switch
switch for contin
continuit
uity.
y.
o
o Switch position
Free
Standard
No continuity
o
Pressed Continui
Continuity
ty shall exist
2-23
SHIF
SHIFT
T LEVER-
LEVER-WI
WIRE
RE CABLE
REMO VAL-I NST ALLAT I O N
3
Removal Procedure
1 Re
Remo
movethe
vethe shif
shiftt leve
leverr knob
knob..
2 Remo
Removethe
vethe shif
shiftt leve
leverr cove
cover.
r.
3 Remo
Removethe
vethe shif
shiftt leve
lever.
r.
4 Remove
Remove the servic
service
e cover,
cover, and loosen
loosen the cable
cable lock
lock nut.
nut.
5 Remo
Remove
ve th
the
e clam
clamp
p on
on the
the llow
ower
er side
side of the
the ve
vehi
hicl
cle.
e.
6 Discon
Disconnec
nectt the cable
cable fro
fromm th
the
e transm
transmiss
ission
ion side
side..
7 Remo
Removethe
vethe shif
shiftt leve
leverr cabl
cable.
e.
I n s t a l l a ti
ti o n P r o c e d u r e
The installation
installation procedure
procedure is the reverse of the removal procedure
procedure..
3-1
DIFFERENTIAL
Page
GENERAL 3-2
S PECI FICATIONS
FIhttps://www.forkliftpdfmanuals.com/
CATIONS 3-5
CO M PON ENTS
ENTS 3-6
DIFFE
DI FFERENT
RENTIAL
IAL ASSY 3-8
REM OVA L· INSTA LlATION ..•••.••.•.

..•••.••.•....••
...••.....
.......•.•
..•.•...•.
...•......
.......•.•
..•.•.•...
.•..... 3-8
DISASSEMBlY·INSPECTION·
DISASSEMBlY·INSPECTION·REASSEMB
REASSEMB lY
(1 ton series) 3-11
DISASSEMBlY·INSPECTION·
DISASSEMBlY·INSPECTI ON·REASSEMB
REASSEMB lY
(2-3 ton series, J3.5 ton) 3-16
DIFF
DI FFERE
ERENTI
NTIAL
AL CASE ASSY 3-19
D IS A S
SSS E M B lY
lY ·IN S P E C T l O N ·R E A S
SSS E M B lY
lY 3-19
DIFFE
DI FFERENT
RENTIIAL CARRIE
CARRIERR
(2-3 ton series, J3.5 ton) 3-22
D IS A S
SSS E M B lY
lY ·IN S P E C T l O N ·R E A S
SSS E M B lY
lY 3 -2 2
3-2 .
GENERAL
Differential (1 Ton Series)
Differential (2-K2-
(2-K2-K3
K3 Ton Series)
Series)
3-3
Differ
Different
ential
ial (3 J3.
e
J3.5
5 Ton Series
Series))
Reduct
Reduction
ion Gear
Gear (1 Ton Series
Series))
3-4
Reduct
Reduction
ion Gear
Gear (2·K2·K
(2·K2·K3
3 Ton Series
Series))
Reduct
Reduction
ion Gear
Gear (3·J3.
(3·J3.5
5 Ton Series)
Series)
3-5
SPECIFICATIONS
1 ton series
2'K2'K3
2'K2'K3 ton se
serie
ries
s
1.0 ton 1.5'1
1.5'1.75
.75 ton 3·J3.5
3·J3.5 ton series
Item
I models models
Different
Differential
ial case type https://www.forkliftpdfmanuals.com/
Banjo type +- +-
Reduction ratio
Reduction
5.833 +-
+-
(ring gear
gear/driv
/drive
e pinio
pinion)
n)
Drive pinion 6 +- +-
Number
Number of teet
teeth
h
Ring gear 35 +- +-
Differential 10 x 2
(Mrr models
models with
5Kengine)
Number of Pinion gear 10 x 4 10 x 4 +-
teeth x quantity (Mrr models with

1DZ-II engine)
(All T/C models)
Side gear 14 x 2 +- +-
2·K2 ton series

series::
7.1 (1.87)
Differenti
Differential
al oil quant
quantity
ity f (US gal) 6.3 (1.6
(1.66)
6) +-
K3·3·J3.5
K3·3·J3.5 ton series:
7.7 (2.03)
3-6
COMPONENTS
2·3·K2 ·K3·J3.5 ton serie
series
s
3-7
4101
4101-144
5K'4Y'10Z-11 2Z(Mn) 4101

22 (TIC)
Ir-:;~ ~A D
~ ~ ,- ~
fL. / EV
BO I'~
94512-0120~ ~~BO. ~
JfJ I~ / 64
B 0 - - t: t: : 1 J
91619-61225
4101-145 4101-146
3-8
DIFFER
DIFFERENT
ENTIAL
IAL ASSY
REM OVAL-INST ALLAT ION

Note:
Never
Never apply impact to the frame
frame at the time of removal
removal or installa
installation
tion to protect the SAS controller
controller
from damage.
damage. (SAS
(SAS specificat
specification)https://www.forkliftpdfmanuals.com/
ion)
T = N·m (kgf-cm
(kgf-cm)) [ft-Ibf]
[ft-Ibf]
T 2.9 - 6.9
=
(3
(30
0 - 70)
70)
[2.
[2.2
2 - 5.1]
5.1]
T = 265
265 - 34
343
3
(2
(2700
700 - 3500
3500))
[ 1 9 5 ~ _ 2 : ." +
~/ ~ )~
17
~ -:
1_-
. . - -~- - - ~ :
T=*2
T=*2
3-J3.5
3-J3.5 ton series T 98.0
98.07
=7 - 12
127.
7.5
5 (100
(1000
0 - 1300
1300)) [72.
[72.35
35 - 94.0
94.06]
6]
*1
Axle shaft set bolt Other T 68.6
68.6 - 88.3
= 88.3 (700
(700 - 90
900)
0) [50.
[50.6
6 - 65
65.1
.1]]
*2 1-2 ton series, K2-K

K2-K3
3 ton series T = 107.9
107.9 - 13
137.
7.3
3 (110
(1100
0 - 14
1400
00)) [79.
[79.59
59 - 101.
101.3]
3]
Front
Front axle
axle ASSY
ASSY set bol
bolts
ts 3 ton
ton ser
series
ies,, J3.5
J3.5 ton seri
series
es T 1
127.
27.5
5 -166
= -166.7
.7 (13
(1300
00 --170
1700)
0) [94
[94.06
.06 --123
123.0]
.0]
3-9
Removal Procedure
1 Remo
Remove
ve the
the mast
mast.. (R
(Ref
efer
er to page
page 13-11
13-11 in th
the
e 7FG/7
7FG/7FD
FD Se
Seri
ries
es Repa
Repair
ir Manu
Manual
al (No.
(No. CE02
CE024)
4)))
2 Drai
Drain
n diff
differ
eren
enti
tial
al oil. [Point 1]https://www.forkliftpdfmanuals.com/
oil. [Point
3 Ja
Jack
ck up th
the
e veh
vehic
icle
le and
and rem
remov
ove
e the
the ffro
ront
nt wheel
wheels.
s.
4 Dr
Drai
ain
n brak
brake
e flui
fluid,
d, and dis
disco
conn
nnec
ectt th
the
e bra
brake
ke pi
pipe
pe (fro
(from
m the whee
wheell cylin
cylinde
der)
r)..
5 Di
Disc
scon
onne
nect
ct th
the
e park
parkin
ing
g brak
brake
e cabl
cable
e (fro
(from
m the
the lev
lever
er).
).
6 Re
Remo
move
ve the
the park
parkin
ing
g br
brak
ake
e cabl
cable
e clam
clamp.
p.
7 Re
Remo
move
ve th
the
e prop
propel
elle
lerr shaf
shaft.
t. (R
(Ref
efer
er to pa
page
ge 5-3 in th
the
e 7FG/7
7FG/7FD
FD Se
Seri
ries
es Repa
Repair
ir Manu
Manual
al (N
(No.
o. CE02
CE024)
4)))
8 Remo
Remove
ve the tra
trans
nsmi
miss
ssio
ion
n moun
mountt bo
bolt
lts
s and
and pin bo
bolts. [Point
lts. [Point 2]
9 Su
Supp
ppor
ortt th
the
e lowe
lowerr sid
side
e of th
the
e tran
transm
smis
issi
sion
on wi
with
th a pant
pantog
ogra
raph
ph ja
jack
ck or
or woo
woode
den
n bl
bloc
ock.
k.
10 Su
Supp
ppor
ortt th
the
e front
front axle
axle & dif
diffe
fere
rent
ntia
iall ASSY
ASSY wi
with
th a hoi
hoist
st and gar
garag
age
e jack.. [Point
jack [Point 3]
11 Re
Remo
move
ve th
the
e spee
speed
d sens
sensor
or cove
coverr an
and
d disco
disconn
nnec
ectt th
the
e connec
connecto
tor.
r.
12 Re
Remo
move
ve th
the
e front
front axle brac
bracke
kett th
thro
roug
ugh
h bolt
bolt..
13 Re
Remo
move
ve the fron
frontt axle
axle bra
brack
cket
et re
ream
amer bolt. [Point 4]
er bolt.
14 Re
Remo
move
ve th
the
e front
front ax
axle
le & di
diff
ffer
eren
enti
tial
al ASSY
ASSY..
15 Re
Remo
move
ve the fro
front
nt axl
axle
e s
shaft.. [Point 5]
haft
16 Re
Remo
move
ve the fron
frontt axle
axle W /b
/bra
rack
cket
et..
17 Re
Remo
move
ve the spee
speed
d sen
senso
sor.
r.
Installation Procedure
The instal
installat
lation
ion pro
proced
cedure
ure is the reverse
reverse of the rem
remova
ovall proced
procedure
ure..
Note:
Bleed air from
Blee from the brake
brake syste
system
m after
fter insta
installa
llatio
tion.
n. (Refer
fer to pa
page
ge 10-24 in the 7FG/7FD Series
ries
Repair
Repair Ma
Manual
nual (N
(No.
o. CE024
CE024»»
Point Operations
o
[Point
[Point 1]
Installation:
After reassembly, fill hypoid gear oil to the specified level.
3-10
Pin bolts
[Point
[Point 2]
Installation:
After installing the mount bolt and pin bolt on the right side,
install those on the left side.
Mount bolts
[Point 3]
Removal·1nstallation:
Install
Install hub nuts on hub bolts on the lef
leftt and right sides, and
sling
sling wire at the
the tapered portion.
portion.
[Point 4]
Removal:
SST 0931 0-23320-71
0-23320-71
[Point 5]
Removal·lnstallation:
Operate
Operat e carefull
carefullyy so as not to to bring the axle shaft int
into
o con-
tact with
with the oil seal lip
lip tto
o damage it it..
3-11
DISASSE
DISASSEMBlY-
MBlY-IN
INSPE
SPECTI
CTION-
ON-REASS
REASSEMBlY
EMBlY (1 ton serie
series)
s)
I
~J
12
T=117.7-137.3
(1200-1400)
[86.82-101.29]
1 Remo
Remove
ve the
the dri
drive
ve pi
pini
nion
on rear
rear co
cove
verr and
and the
the gaske
gasket.
t.
2 Remo
Remove
ve the
the lock
lock nut
nut and
and wa
wash
sher
er.. [Point
[Point 1]
3 Remo
Remove
ve the
the di
diff
ffer
eren
entia
tiall co
cove
ver.
r. [Point 2]
4 Meas
Measur
ure
e the
the ring
ring gear
gear back
backla
lash
sh.. [Point
[Point 3]
5 Remo
Remove
ve the
the bear
bearin
ing
g ca
cap
p and
and adju
adjust
stin
ing
g nut.
nut. [Point 4]
6 Remo
Remove
ve the
the dif
diffe
fere
rent
ntia
iall ca
case
se AS
ASSY
SY.. (See
(See page
page 3-20
3-20 fo
forr th
the
e di
disa
sass
ssem
embl
bly,
y, insp
inspec
ecti
tion
on an
and
d re
reas
asse
semb
mbly.
ly.))
7 Remo
Remove
ve the
the dr
driv
ive
e pi
pinio
nion
n W/be
W/bear
arin
ing.
g. [Point
[Point 5]
8 Remo
Remove
ve the
the dr
driv
ive
e pinio
pinion
n bear
bearin
ing.
g. [Point
[Point 6]
9 Remove
Remove the output
output gear
gear and redu
reducti
ction
on gea
gearr W/carrier
W/carrier cover.
cover. [Po
[Point
int 7]
10 Remove
Remove the reduct
reduction
ion gear
gear W/bear
W/bearing
ing.. [Point
[Point 8]
11 Remove
Remove the drive
drive pinio
pinion
n outer
outer race
race ffrom
rom the carri
carrier
er cover
cover..
12 Remove
Remove the input
input shaft
shaft dust
dust deflect
deflector.
or. [Point 9]
Reassembly Procedure
The reassembly
reassembly procedure
procedure is the reverse
reverse of disassembly proce
procedure.
dure.
3-12
Point Operations
[Po i n t 1 ]
Disassembly:
Remove the lock
Remove lock nut
nut,, washer
washer,, rear
rear bearin
bearing
g rol
roller
ler and shim.
shim.
1. Unloc
Unlockk the lock
lock nut.
nut.
2. Install
Install the input
input shaft and use a pipepipe wrench
wrench to lock the
gear from rotation.
rotation.
3. Remove
Remove the locklock nut and
and washer.
washer.
[Point 2]
Reassembly:
Apply sealing agent (Three Bond 1217C or equivalent) on
the different
differential
ial cover surface
surface to be in contact
contact with the differ
differ--
entiall housing.
entia housing.
[Point 3]
Inspection:
Measure
Measu re the ring gear backlash.
backlash.
Standard:
Sta ndard: 0.2
0.2 - 0.3
0.3 mm (0
(0.0
.008
08 - 0.01
0.0122 in)
[Point 4]
Disassembly:
provid
provide
e match
match marks
marks on the
the bearing
bearing cap and dif
differ
ferent
ential
ial
housing.
Reassembly:
Instal
Ins talll the adjust
adjusting
ing nut and
and bearing
bearing cap.
cap.
1. Install
Install the adjusting
adjusting nut.
2. Instal
Installl the bearing
bearing cap by ali
aligni
gning
ng the match marks
marks and
Match marks
marks tempor
tem porari
arily
ly tig
tighte
hten
n the set bolts
bolts..
T = 19.66 N·
19. N·m
m (2
(200
00 kg f-cm) [14.5
[14.5 ft-Ibf]
ft-Ibf]
3-13
3. Set a dial gauge in the thr

thrust
ust dir
direct
ection
ion of the differen
differentia
tiall
case.
4. Use the SST
SST an
and
d tight
tighten
en ununti
till the thrus
thrustt cl
clea
eararanc
nce
e is
eliminated.
SST 09630-1 0110-71
5. Tigh
Tighten
ten bot
both
h adjusti
adjusting
ng nuts
nuts by one notch each.
each.
6. Set the dial gauge
gauge vertic
verticall
ally
y to the
the rin
ring
g gear
gear tooth
tooth fla
flanks
nks
and measure
measure the backlash.
backlash.
Standard:
Standard: 0.2
0.2 - 0.3
0.3 mm (0
(0.0
.008
08 - 0.01
0.012
2 in)
If the standa
standard rd is not satisf
satisfied
ied,, make
make adjust
adjustmen
mentt by mov-mov-
ing the differe
differenti
ntial
al case
case ASSY in the thrust thrust dir
direct
ection
ion by
means
mea ns of th the
e adjustin
adjusting g nuts.
nuts.
When
Whe n the backlas
backlash h is excess
excessive ive::
Loos
Loosen en th thee ad
adjujust
stin
ing
g nu
nutt on the toot tooth
h flan
flanks
ks si side
de of
the rin
ringg gear and tig tighte
htenn the adju
adjustisting
ng nut on the rear
side
sid e equ
equallally
y to bring
bring the rinringg gear closer
closer to the
the dri
drive
ve
pinion.
® When
When the backlash
backlash is insuf
insuffic
ficien
ient:
t:
Loos
Loosen en th the
e ad
adju
just
stin
ingg nu
nutt on the rear si side
de of thethe riring
ng
gear
gear an and d tighte
tighten n th
thee ad
adju
just
stin
ing
g nunutt on ththe
e to
toot
oth h flan
flankk
side equally to bring the ring gear away from the drive
pinion.
7. Tight
Tightenen the adjus
adjustin
tingg nut on the rearrear side
side of the ring gear
fur
furthe
therr by 1.5 to 2 notchenotches.s.
8. Install
Install the adjust
adjusting
ing nut lock
lock pla
plate.
te.
9. Finall
Finally y tig
tighte
hten n the bearing
bearing cap set set bolts.
bolts.
T =117
=117.7.7 -137.
-137.3 3 N· N·mm (120
(12000 -1400
-1400 kgf-cm)
[86.8
[86 .822 - 101.
101.30
30 ft-Ibf]
[Point 5]
Disassembly:
1. Prev
Preven
entt th
thee dr
driv
ive
e pi
pini
nion
on frfrom
om da
dama
magege by in inse
sert
rtin
ing
g a
wooden
woode n block
block in the differ
differentia
entiall housing.
housing.
2. Use
Use a plast
plastic
ic ha
hamm
mmerer an
andd re
remo
move
ve th
thee dr
driv
ive
e pipini
nion
on W /
bearing.
3-14
Reassembly:
Assemble the shim, rear bearing roller, washer and lock
nut.
1. Whi
While
le suppor
supportin
ting
g the drive
drive pinion
pinion,, assemb
assemble le the shim,
shim,
rear bearing,
bearing, washer and lock nut. The washer claw shall
face
face the dee
deepp groove
groove side.
side.
2. Use the input shaft
shaft to prevent
prevent the gear frofrom
m rotati
rotation.
on.
3. Tighte
Tighten
n the lock
lock nut to the
the specif
specified
ied tor
torque
que..
4. Measure
Measure the drive
drive pinion
pinion starting
starting torque.
torque.
Standard:
8.82 - 13.23
8.82 13.23 N·m (90 - 135 kgf-cm
kgf-cm))
[6.51
[6.51 - 9.77
9.77 ft-Ibf
ft-Ibf]]
If the
the stan
standa
dardrd is no nott sa
sati
tisf
sfie
ied,
d, incr
increa
ease
se or de-
crease
cre ase the shim
shim thickne
thickness
ss for adjustmen
adjustment.
t.
Shim thickness:
0.13,
0.13, 0.1, 0.15,
0.15, 0.35
0.35 and
and 0.4 mm
5. Securel
Securely
y lock
lock the lock
lock nut.
nut.
[Point
[Point 6]
Disassembly:
SST 09420-23000-71
Reassembly:
Installll the drive pinion front bearing.
Insta bearing.
1. Use the SST for front bearing
bearing installat
installation.
ion.
SST 09316-60011
[Point
[Point 7]
Reassembly:
Chec
Check k th
the
e moun
mounti
ting
ng di
dire
rect
ctio
ions
ns of the
the ou
outp
tput
ut ge
gear
ar an
and
d re
re--
duction
duction gear.
3-15
Reassembly:
Apply sealing agent (Three Bond No. 1281 or equivalent)
on the
the bear
bearin
ing
g rereta
tain
iner
er surf
surfac
ace
e to be in cont
contac
actt with
with the
differenti
differential
al carri
carrier
er cover.
cover.
Reassembly:
Use the SST and drive a new oil seal to be in flush with the
inside
inside surface
surface of th
the
e diff
differe
erenti ntial
al carrie
carrierr cover.
cover.
SST 09950
09950-60
-60020
020 --- ----- C D
------
09150-10170-71 ---®
After assembly, apply grease on the oil seal lip portion.
[Point 8]
Disassembly:
SST 09950
09950-60
-60010
010 --- ----- C D
------
09950-7001
09950 -70010 ------- ®
0 -------
09420-
09420-230
23000-71 --- ®
00-71
Reassembly:
SST 099
09950-
50-600 10 --- C D
60010
09950-7001
09950 -- ®
-7001 0 ----
[Point 9]
Reassembly:
SST 09370-20270-71
3-16
DISASSEMBlY-INSPECTION-REASSEMBlY (2-3 ton series, J3.Ston)
ton N.m (kgf-cm)
(kgf-cm) [ft-Ibf]
[ft-Ibf]
T = 29.4
29.4 - 44
44.1
.1 (3
(300
00 - 45
450)
0) [2
[21.
1.7
7 - 32
32.6
.6]]
T = 11
117.7
7.7 - 137
137.3
.3
.~ (1200 - 1400)
1
~:::," •• :{; 1 0 1 .3
1
~ ::
.•.... ~
..
T = 117.7 -137.3
(1
(120
2000 - 140
1400)
0)
[86
[86.82
.82 - 101
101.3]
.3]
1 Remo
Remove
ve the
the diff
differ
eren
enti
tial
al co
cover. [Point
ver. [Point 1]
2 Me
Meas
asur
ure
e th
the
e ri
ring
ng ge
gear
ar bac
backl
klash. [Point 2]
ash.
3 Remo
Remove
ve the
the bea
beari
ring
ng ca
cap
p an
and
d adj
adjus
usti
ting
ng nu
nut.
t. [Point
[Point 3]
4 Remo
Remove
ve th
the
e diff
differ
eren
enti
tial
al case
case ASSY.
ASSY. (S
(See
ee pag
page
e 3-20
3-20 for
for the
the disas
disasse
semb
mbly
ly,, in
insp
spec
ecti
tion
on an
and
d reass
reassem
embl
bly
y
procedure.)
5 Remo
Remove
ve the
the diff
differ
eren
enti
tial
al ca
carr
rrie
ier.
r. [Point 4] (See
(See page 3-23 for the disassem
disassembly
bly,, inspec
inspectio
tion
n and reas-
reas-
sembly
sembly procedure.
procedure.))
Installation Procedure
The reasse
reassembl
mbly
y proced
procedure
ure is the reverse
reverse of the disass
disassemb
embly
ly proced
procedure
ure..
3-17
Point Operations
[Point
[Point 1]
Reassembly:
Apply sealing agent (Three Bond's NO.1217C or the equiva-
le
lent
nt)) on th
the
e mati
mating
ng surf
surfac
aces
es of the
the di
diff
ffer
eren
enti
tial
al co
cove
verr an
and
d
housing
housi ng before
before reassembl
reassembly.
y.
[Point
[Point 2]
Inspection:
Measure
Meas ure the ring gear backlash.
backlash.
Standard:
2 ton series,
series, K2·
K2·K3 ton seserie
ries:
s: 0.2 - 0.3
0.3 mm
(0
(0.0
.008
08 - 0.01
0.012
2 in)
3 ton serie
series,
s, J3
J3..5 ton se
serie
ries:
s: 0.3 - 0.4
0.4 mm
(0
(0.0
.012
12 - 0.01
0.0166 in)
[Point
[Point 3]
Disassembly:
Put match
match marks
marks on the
the bearing
bearing cap and diffe
differen
rentia
tiall hous-
hous-
ing.
Reassembly:
Instal
Ins talll the adjus
adjustin
tingg nuts
nuts and bearin
bearing g cap.
cap.
1. Install
Install the adjusting nuts.
2. Instal
Installl the bearing
bearing cap by alig alignin
ning
g the match
match marks
marks and
tempor
tem porari
arily
ly tig
tighte
htenn the setset bolt.
bolt.
T = 19.6
19.6 N·m
N·m (200 kgf-cm) [14 [14.5
.5 ft -I
-Ibf)
bf)
3. Set the dial
dial gauge
gauge in the thrustthrust direction
direction of the differen
differential
tial
case.
4. Use the SST and ti tighten
ghten until the
the thrust clearance
clearance is elimi-
elimi-
nated.
SST 09630-1 0110-71
5. Tigh
Tighten ten adj
adjust
usting
ing nuts
nuts on both
both sides by one notchnotch each.
each.
6. Set the dial
dial gauge verticvertical
al to the
the rin
ring
g gear
gear tooth
tooth surfac
surface,
e,
and measure the backlash. backlash.
Standard:
2 ton series,
series, K2.
K2. K3 to
ton
n se
serie
ries:
s: 0.2
0.2 - 0.3
0.3 mm
(0
(0.0
.008
08 - 0.01
0.012
2 in)
3 ton se
serie
ries,
s, J3
J3..5 ton se
serie
ries:
s: 0.3
0.3 - 0.4
0.4 mm
(0
(0.0
.012
12 - 0.01
0.016
6 in)
3-18
If the standard is not satisfied,
satisfied, adjust by turning
turning the adjust-
ing nut to move the differe
differenti
ntial
al case ASSY in the thrust thrust di-
rection.
(1) When the backlash
backlash is excessiv
excessive:e:
Loosenn the adjusti
Loose adjusting
ng nut onon the
the ring
ring gear teeth
teeth sid
sidee and
ti
tight
ghten
en the
the adjust
adjustin
ingg nut onon the rear
rear side
side as much to
bri
bring
ng the ring
ring gear clo
closer
ser to the
the dri
drive
ve pinion
pinion..
(2) When the backlash is insufficie
insufficient:
nt:
Loosen the adjusting nut of the rear side of the ring gear
and tighte
tightenn the adjusti
adjusting
ng nut on the teeth
teeth sid
sidee as much
to bring
bri
enngthe
7. Tighten
Tight theadjusting
ring
ring gear
adjusti away
ng nut fromrear
on the theside
drive
driveof pinion.
pin
theion.
the ring gear
furthe
furtherr by 1.5 to 2 notches.
notches.
8. Install
Install the adjusting nut lock
lock plate.
9. Finally
Finally tighten
tighten the bearing
bearing cap set bolts.
bolts.
T = 117.
117.7
7 - 137.
137.3
3 N·
N·m
m (1
(120
200
0 - 1400
1400 kg f-cm)
[86.82
[86.82 - 101.
101.3
3 ft-Ibf]
[Point 4]
Reassembly:
Applyy sealing
Appl sealing agent (08826-00090
(08826-00090)) on the
the mating surfaces
surfaces
of the
the dif
differ
ferent
ential
ial carri
carrier
er and housing
housing before
before reassembl
reassembly.
y.
Reassembly:
Coat thread
thread tightener (08833-00080)
(08833-00080) on the differ
differential
ential car-
rier set bolts
bolts before tightening
tightening it.
https://www.forkliftpdfmanuals.com/ 3-19
DIFFER
DIFFERENT
ENTIAL
IAL CASE ASSY
DI
DISASSEMBlY-
SASSEMBlY-IN
INSPE
SPECTI
CTION-
ON- REASSEMBLY T = N·m (kgf-cm)
(kgf-cm) [ft-I
[ft-Ibf]
bf]
T = 127.
127.4
4 - 176.
176.5
5 (1
(130
300
0 - 18
1800
00)) [9
[94.
4.0
0 - 13
130.
0.2]
2]
1·2·K2·K
1·2·K2·K3
3 ton series:
series:
T = 43.1
43.1 - 53.9
53.9
(440
(440 - 550)
550)
[3
[31.8
1.8 - 39.
39.8]
8]
3·J3.5
3·J3.5 ton series:
series:
T = 86.3
86.3 - 103.0
103.0
(880
(880 - 1050
1050))
[6
[63.7
3.7 - 76.
76.0]
0]
D is
i s a ssss e m b l y P r o c eedd u r e
1 Remo
Remove
ve the
the di
diff
ffer
eren
enti
tial
al case
case bear
bearin
ings
gs.. [Point
[Point 1]
2 Re
Remo
move
ve the
the di
diff
ffer
eren
enti
tial
al up
uppe
perr cas
case.
e. [Point 2]
3 Re
Remo
move
ve the side
side ge
gear
ar and
and pi
pini
nion
on gea
gear.
r. [Point
[Point 3]
4 Remov
emove
e the
the ring
ring ge
gea
ar. [Point
[Point 4]
R eassembly
e assembly P rocedure
The reasse
reassembl
mbly
y pro
proced
cedure
ure is the reverse
reverse of the disasse
disassembl
mbly
y pro
proced
cedure
ure..
3-20 https://www.forkliftpdfmanuals.com/
Point Operations
Operations
SST [P
[Poi
oint
nt 1]
Disassembly:
SST 09950-
09950-400
40011
11 ---
09950-6001
09950 -6001 0 ---
Reassembly:
Install the side bearing.
1. Use
Use ththe
e SST
SST anandd dr
driv
ive
e in tthe
he side
side be
bear
arin
ing
g to the en
end
d
surface.
SSTG)
SST 09950
09950-60 020 --- C D
-60020
09950-
099 50-700 10 --- @
70010
2. Use a strikin
striking
g dri
driver
ver and full
fully
y dri
drive
ve in the bearin
bearing.
g.
[P
[Poi
oint
nt 2]
Disassembly-Reassembly:
Check
Che ck the mat
match
ch mar
marks.
ks.
Reassembly:
Apply locking agent (08833-00070) on the set bolt threaded
Match
Match mark
marks
s
portion
portion before reassembly
reassembly..
[P
[Poi
oint
nt 3]
Inspection:
Measure
Measu re the inside
inside diamete
diameterr of the different
differential
ial pinion.
pinion.
1·2·K2
1·2 ·K2·K3
·K3 ton serseries
ies
St
Stan
anda dard
rd:: 22
22.1
.12
2 mm (0 (0.8
.870
7099 in
in))
Limit:
Lim it: 22.
22.22
22 mm (0.874
(0.8748 8 in)
3·J3.5
3·J3.5 ton ser series
ies
Standa
Sta ndard:rd: 24.67
24.67 mm (0.9713
(0.9713 in)
Limit:
Lim it: 24.
24.77
77 mm (0.975
(0.9752 2 in)
Inspection:
Measure
Measu re the spider
spider outside
outside diameter.
diameter.
1·2·K2
1·2·K2·K3
·K3 ton series
series
Standa
Sta ndard:
rd: 22.00
22.00 mm (0.8661
(0.8661 in)
Limit:
Lim it: 21.
21.75
75 mm (0.856
(0.8563
3 in)
3·J3.5 ton series
3·J3.5 series
Standa
Standard:
rd: 24.50
24.50 mm (0.9646
(0.9646 in)
Limit:
Lim it: 24.
24.25
25 mm (0.954
(0.95477 in)
3-21
Inspection:
Measur
Measuree the side gear thrust
thrust washer
washer thi
thickn
ckness
ess..
St
Stan
anda
dard
rd:: 1.6
1.6 mm
mm (0(0.0
.063
63 in)
Limit:
Limit: 1.3 mm
mm (0.051
(0.051 in
in))
Inspection:
Measur
Measuree the pinion
pinion gear
gear thr
thrust
ust was
washer
her thi
thickn
ckness
ess..
St
Stan
anda
dard
rd:: 1.6
1.6 mm
mm (0
(0.0
.063
63 in
in))
Limit:
Limit: 1.0 mm (0.039
(0.039 iin)
n)
Reassembly:
Instal
Installl the side
side gear
gear thrust
thrust was
washer
her wit
with
h its oil
oil groo
groove
ve fac
facing
ing
the gear.
Reassembly:
Apply chassis grease (molybdenum disulfide grease) on
both
both sides of the
the sp
spide
iderr pinion
pinion thr
thrust
ust was
washer
her before
before reas-
reas-
sembly.
[Poi
[Point
nt 4]
Reassembly:
Apply locking agent (08833-00070) on the set bolt threaded
portion
portio n before
before reasse
reassembl
mbly.
y. Tig
Tighte
hten
n the set bol
bolts
ts gradua
gradually
lly
in the dia
diagon
gonal
al order,
order, and
and final
finally
ly tighte
tighten
n in the circula
circularr order
order
to the
the specified
specified torque.
torque.
3-22
DIFF
DIFFER
EREN
ENTI
TIAL
AL CAR
CARRI
RIER
ER (2-3
(2-3 ton series, J 3.5
3.5 ton)
DI
DISASSEMBLY-I
SASSEMBLY-INSPE
NSPECTI
CTION·
ON· REASSEMBLY T N'm (kgf-cm) [ft-Ibf]
=
Except
1 ton seri
series
es
T = 3
343
43 - 392
392
(3500
(3500 - 4000)
4000)
[253.2
[253.2 - 289.3
289.3]]
T = 29 - 44 (300
(300 - 45
450)
0) [21.
[21.7
7 - 32
32.6
.6]]
3
D isassembly
isassembly P rocedure
1 Fix
Fix th
the
e dif
diffe
fere
rent
ntia
iall ca
carr
rrier
ier ASSY
ASSY in a vise
vise.. [Point 1]
2 Removethe
Removethe dri
drive
ve pinion
pinion rear
rear cover
cover and gasket
gasket..
3 Removethe
Removethe lock nut,
nut, was
washer
her,, rear
rear bearin
bearing
g rolle
rollerr and shim.
shim. [Point 2]
4 Removethe
Removethe dif
differ
ferent
ential
ial car
carrie
rierr ASSY from
from the vise.
vise. [Point
[Point 3]
5 Remove
Remove the bearin
bearing
g space
spacerr (1 ton seri
series)
es),, fron
frontt beari
bearing
ng rolle
roller,
r, spacer
spacer and pil
pilot
ot beari
bearing
ng (exclu
(excludin
ding
g1
ton series) from the drive pinion. [Point 4]
6 Removethe
Removethe diffe
differen
rentia
tiall carrie
carrierr c
cove
over,
r, output
output gear
gear and
and re
reduc
ductio
tion
n gear
gear W/bear
W/bearing
ing.. [Point
[Point 5]
7 Remo
Removethe
vethe re
redu
duct
ctio
ion
n gear
gear bear
bearin
ing.
g. [Point 6]
8 Remo
Removethe
vethe dr
driv
ive
e pini
pinion
on bear
bearin
ing
g oute
outerr ra
race
ce..
9 Remo
Remove
ve th
the
e in
inpu
putt sh
shaf
aftt oil
oil se
seal
al.. [Point 7]
10 Removethe
Removethe input
input shaf
shaftt dust
dust defle
deflecto
ctor.
r. [Point 8]
R eassembly
The reassembly
reassembly proced
procedure
ure is the reverse
reverse of the disassemb
disassembly
ly procedure.
procedure.
3-23
Point Operations
Operations
[Point
[Point 1]
Disassembly:
Fix the differ
different
ential
ial carrie
carrierr ASSY
ASSY in a visvise.
e.
1. Fix the SST in thethe vise.
SST 09410-23320-71
2. Use
Use the serv
servic
ice
e bobolt
lt an
and
d in
inst
stal
alll th
the
e di
diff
ffer
eren
enti
tial
al carr
carrie
ier
r
ASSY on the SST.
[Point
[Point 2]
Disassembly:
Remo
Re move
ve th
thee lo
lock
ck nu
nut,
t, washe
washer,
r, re
rear
ar beari
bearing
ng roroll
ller
er an
and
d
shim(s).
1. Unlock
Unlock the lock
lock nut.
nut.
2. Use the
the input
input shaft
shaft to stop the gear
gear fro
from
m rotati
rotation.
on.
3. Remove
Remove the locklock nut and
and washer.
washer.
4. from
Apply
Ap plydamag
a woode
wooden
damage.e. n block
block under the drive
drive pinion
pinion to prevent
prevent it
5. Use a plastic
plastic hammer
hammer and remove
remove the rear bearing
bearing roller.
roller.
6. Remove
Remove the shim(s
shim(s).
).
Reassembly:
Instal
Installl the shim(s),
shim(s), rear
rear bearing
bearing rol
roller
ler,, washer
washer and lock
lock nut.
nut.
1. While
While suppo
supporting
rting the drive
drive pinion, install
install the
the shim
shim(s),
(s), rear
bearin
bea ring,
g, washer
washer and lock
lock nut. Place
Place the washer
washer with
with its
claw on the deep
claw deep groove
groove side.
side.
2. Use the
the inp
input
ut shaft
shaft to sto
stop
p the gear fro
from
m rotati
rotation.
on.
3. Tighten
Tighte n the lock
lock nut to the specifi
specified
ed tor
torque
que..
4. Remove the input
Remove input shaft.
shaft.
5. Measure the drive pinion
Measure pinion starting
starting torque.
torque.
Standard: 8.82 -13.23

-13.23 N·m (90 -135 kgf-cm)
If th
the
e st
stan
anda
dard
rd is not
not satis
satisfi
fied
ed,, make
make ad
adju
just
stme
ment
nt by in-
in-
Good examples
examples
creasing
creasi ng or decreas
decreasing
ing the shim thithickn
ckness
ess..
Shim thickness:
0.13, 0.10, 0.15, 0.35 and 0.40 mm
(0.0051,
(0.0051, 0.0039,
0.0039, 0.0059,
0.0059, 0.018 and 0.016
0.016 in)
6. Secu
Securel
rely
y swage
swage the lock nut.
Bad examples
examples

3-24
[Point 3]
Reassembly:
Fix the
the diffe
differen
rentia
tiall carrie
carrierr ASSY
ASSY in a vise.
vise.
1. Fix the SST in the vise.
SST 09410-23320-71
2. Place
Place the drive
drive pinion
pinion in the center
center of the
the servic
service e hole.
hole.
3. Use
Use the service
service bolts
bolts and instal
installl the diffe
differen
rentia
tiall carrie
carrier
r
ASSY on the SST
[Point 4]
Disassembly:
SST 09420-23000-71
Reassembly:
Installll the drive pinion
Insta pinion front beari
bearing.
ng.
1. Check
Check correc
correctne
tness
ss of sp
spaceacerr dir
direct
ection
ion at the
the time of in-
stallation.
2. Use the SST and instalinstalll the fro
front
nt bearin
bearing.
g.
SST 09316-60011
Excluding
Excluding 1 ton series
series
Disassembly:
SST 09950-40011
SST
Excluding
Excluding 1 tton
on series
series
Reassembly:
Use the SST and install the pilot bearing.
SST 09608-04031
Check the installed
installed direction.
direction.

3-25
[Point
[Point 5]
Reassembly:
Chec
Ch eckk th
the
e in
inst
stal
alli
ling
ng di
dire
rect
ctio
ions
ns of the
the outp
output
ut gear
gear an
and
d re
re--
duction
duction gear.
Reassembly:
Apply sealing agent (08826-00090) on the bearing retainer
surf
surfac
ace
e to come
come in
into
to con
conta
tact
ct with
with the
the di
diff
ffer
eren
enti
tial
al carr
carrie
ier
r
cover.
[Point
[Point 6]
Disassembly:
09950-6001 0 ------- C D
SST 09950-6001
-7001 0 ------- ®
09950-7001
09950
09420-
09420-230
23000-71 --- ®
00-71
Reassembly:
SST 09950
09950-60 010 --- C D
-60010
09950-
09950-700
70010
10 --- @
[Point
[Point 7]
Reassembly:
Use the SST to drive
drive in tthe
he new oil seaseall to be flush
flush wit
with
h the
inside
inside end face
face of the dif
differ
ferentential
ial car
carrie
rierr cover.
cover.
SST 09950-6
09950-6002
00200 --- ----- C D
------
09150-
09150-101
10170-
70-71
71 --- ®
After installation, apply grease on the oil seal lip portion.

3-26
[Point 8]
Reassembly:
SST 09370-20270-71

4-1
APPENDIX
A PPENDIX
Page
SST
SST LIST
LIST 4-2
SERV
SERVIC
ICE
E STANDARD
STANDARD LIST 4-4

4-2
SST
SST LIST
LIST
Section
Illustration Part No.
Part Part Name
2 3
Tr
Tran
ansm
smis
isso
son
n &
~oe @~ 09316-60011
transfer
0 0
bearing
Q ::J P ~ ~
replacer
Front hub
Front
09608-04031 inner bearing 0 0
~
cone replac
replacer
er
Sna
Snap
p ring
ring NO.
NO.1
1
09905-00012 0
~? expander
~~ .,
~~ Pul
Pulle
lerr B set
set 0 0
09950-40011
~. < & e;
e; , . - 'l
~d6" cg,~ . ~ ~
0 99
99 50
50 -6
-6 0 01
01 0 R ep
ep la c e r s e t 0 0
~ I ••••••••• ~ J)
@~0 <::;)000
000 0,'

09950-60020

Repl
Replacer
NO.2
acer set
0
a~/
09950-70010 Handl
Handle
e set 0 0
(\ 09010-20111-71
Engi
Engine
ne unit
hanger
unit
0
'lIL- _-:::;;;;,
~ ,~ Engine with
Engine with
~~ 0901
09010-
0-23
2332
320-
0-71
71 tr
tran
ansm
smis
issi
sion
on 0
hanger
Transmission
? 09150-10170-71
bearing replac
replacer
er
0
~

4-3
Section
Illustration Part No. Part Name
2 3
Reamer bolt
Reamer
09310-23320-71 o
remover
Front axle bearing

Front
09370-10410-71 o
replacer
Drive pinion
09370-20270-71 0 0
II
~
bearing replacer
Differential carrier
09410-23320-71 0
stand
09420-23000-71 Bearing remover 0 0
if
Tilt cylin
cylinder
der cap
09630-10110-71 remover and 0
replacer

4-4
SERVI
SERVICE
CE STANDARD
STANDARD LIST
TRANSM
TR ANSMIISSI
SSION ASSY
Transmission ASSY
Standard 0.15
0.15-0.40
-0.40 (0.00
(0.0059-0.
59-0.0157
0157))
Forward idle gear thrust clearance mm (in)
Limit 0.70 (0.0276)
Forward idle gear radial clearance mm (in) Standard 0.010

0.010-0.05
-0.052
2 (0.00
(0.00039-0
039-0.0020
.00205)
5)
Forward idle gear thrust washer thickness m m (in ) L im it 3.7(0.146)
Forwardd idle gear inside diameter

Forwar m m (in ) L im it 55.1 (2.16
(2.169)
9)
Speed shaft journal outside diameter m m (in ) L im it 47.9 (1.88

(1.886)
6)
Second gear thrust clearance mm (i

(in)
n) S ttan
anda
dard
rd 0.15-
0.15-0.40
0.40 (0.00
(0.0059-0.
59-0.0157
0157))
Reverse gear thrust clearance mm (in) Standard 0.10-

0.10-0.45
0.45 (0.00
(0.0039-0.
39-0.0177
0177))
First gear-reverse gear radial clearance mm (i

(in)
n) S tan
tanda
dard
rd 0.01
0.016-0.0
6-0.057
57 (0.00
(0.00063-0
063-0.0022
.00224)
4)
Second gear-forward
gear-forward gear radial clearanc
clearancee mm (i
(in)
n) S ttan
anda
dard
rd 0.01
0.018-0.0
8-0.062
62 (0.00
(0.00071-0
071-0.0024
.00244)
4)
Forwardd gear thrust clearance

Forwar mm (i
(in)
n) S ttan
anda
dard
rd 0.15-
0.15-0.40
0.40 (0.00
(0.0059-0.
59-0.0157
0157))
Countershaft gear thr

Countershaft thrust
ust washer thicknes
thicknesss m m (in ) L im it 5.9 (0.2
(0.232)
32)
Countershaft journal outside First gear-reverse gear Limit 29.9 (1.17
(1.177)
7)
diameter mm (in) Second gear-forward gear Limit 39.9 (1.57

(1.571)
1)
First gear-reverse gear inside diameter

diameter m m ( in ) L im it 38.1 (1.50
(1.500)
0)
Second gear-forward
gear-forward gear inside diamet
diameter
er mm (in) Limit 48.1 (1.89
(1.894)
4)
Shiftt fork to hub grease clearance

Shif clearance m m ( in ) L im it 1.0 (0.039)
Standard 1.25
1.25-2.05
-2.05 (0.0
(0.0492-0
492-0.0807
.0807))
First gear-reverse gear
Synchronizer
Synchronizer rin
ringg to gear
gear Limit 0.6 (0.02
(0.024)
4)
clearance mm (in) Standard 1.15

1.15-2.15
-2.15 (0.0
(0.0453-0
453-0.0846
.0846))
Forward gear
Limit 0.6 (0.02
(0.024)
4)
Between center of shift lever and lever
Shift lever neutral position mm (i
(in)
n) S ttan
anda
dard
rd
knob: 180 +8 (7.086 +0.197)
Shift lever knob offset mm (in) Standard 5 (0.197) or less

(0.197)
Tightening
Tight ening Torque Unit: N·
N·m
m (kgf-cm) (ft-Ibf]
(ft-Ibf]
Transmissi
Transmission
on front
front case
case x rear case set bolt Standard 29.4-44.1
29.4-44.1 (300
(300-450)
-450) [21.7
[21.7-32.6
-32.6]]
Transmissi
Transmission
on front
front case
case x rear case set bolt
Standard 49-
49-78.
78.5
5 (50
(500-8
0-800)
00) [36
[36.2-
.2-57.
57.9]
9]
(when fastening
fastening the hanger at the
the same ti
time)
me)
Output shaft lock nut Standard 156.9

156.9-235.
-235.4
4 (1600-2
(1600-2400)
400) [115.
[115.8-17
8-173.6]
3.6]
Standard 156.9
156.9-235.
-235.4
4 (1600-24
(1600-2400)
00) [115.
[115.8-17
8-173.6]
3.6]
Countershaft lock nut
Countershaft
Releasee bearing
Releas bearing hub guide set bolt Standard 14.7-21.6 (150
(150-220
-220)) [10.9
[10.9-15.
-15.9]
9]

4-5
Output
Output shaft cover set bo
bolt
lt Standard 14.7-
14.7-21.6
21.6 (150
(150-220
-220)) [10.9
[10.9-15.9
-15.9]]
Counters
Countershaft
haft cover set bolt
bolt Standard 14.7-
14.7-21.6
21.6 (150
(150-220
-220)) [10.9
[10.9-15.9
-15.9]]
Fork
Fork set bolt Standard 29.4-
29.4-39.2
39.2 (300
(300-400
-400)) [21.7
[21.7-32.5
-32.5]]
Shift
Shift ring brack
bracket
et set bol
boltt Standard 29.4-
29.4-44.1
44.1 (300
(300-450
-450)) [21.7
[21.7-32.6
-32.6]]
Backup
Backup lamp switch Standard 26.4-
26.4-48.1
48.1 (270
(270-490
-490)) [19.5
[19.5-35.5
-35.5]]
Shift lever pin set nut Standard 21.6-

21.6-50.4
50.4 (220
(220-490
-490)) [15.9
[15.9-35.4
-35.4]]
DIFFERENTIAL
Differential
1·2·K2·K3 ton Standard 0.2-0.3

0.2-0.3 (0.00
(0.008-0.0
8-0.012)
12)
Ring gear backlash mm (in)
3·J3.5 ton Standard 0.3-0.4
0.3-0.4 (0.01
(0.012-0.0
2-0.016)
16)
Standard 22.12 (0.8709)

1·2·K2·K3 ton
Differenti
Differential
al pinio
pinion
n insid
inside
e diam
diameter
eter Limit 22.22 (0.8748)
mm (in) Standard 24.67 (0.9713)
3·J3.5 ton
Limit 24.77 (0.9752)
Standard 22.00 (0.8661)
1·2·K2·K3 ton
Spider
Spider outs
outside
ide diam
diameter
eter Limit 21.75 (0.8563)
mm (in) Standard 24.50 (0.9646)
3·J3.5 ton
Limit 24.25 (0.9547)
Standard 1.6 (0.063)

Side gear thrust
thrust washer
washer thick
thickness
ness mm (in)
Limit 1.3 (0.051)
Standard 1.6 (0.063)

Pinion
Pinion gear thru
thrust
st washe
washerr thick
thickness
ness mm (in)
Limit 1.0 (0.039)
Drive pinion bearing starting
starting torq
torque
ue N·
N·m
m (kgf
(kgf-c
-cm)
m) [ft-
[ft-Ib
Ibf]
f] St
Stan
anda
dard
rd 8.82
8.82-13.2
-13.23
3 (90-1
(90-135)
35) [6.51
[6.51-9.77
-9.77]]
Tighte
Tightening
ning To
Torque
rque Unit: N·
N·m
m (kgf-
(kgf-cm)
cm) [ft-Ibf]
Drive pinion lock nut Standard 343.2-392.3 (3500-4000) [253.23-289.40]
Drive pinion rear cover set bolt Standard 15.7-

15.7-19.6
19.6 (160-
(160-200)
200) [11.6
[11.6-14.5
-14.5]]
Different
Differential
ial carr
carrier
ier cover set bol
boltt Standard 29.4
29.4-44.1
-44.1 (300
(300-450
-450)) [21.7
[21.71-32.
1-32.56]
56]
Ring gear set bolt Standard 127.4-176.5 (1300-1800) [94.06-130.23]
1·2·K2·K3 ton Standard 43.2-

43.2-53.9
53.9 (440
(440-550
-550)) [31.8
[31.83-39
3-39.79]
.79]
Different
Differential
ial uppe
upperr case set bolt
bolt
3·J3.5 ton Standard 86.3
86.3-103.
-103.0
0 (880
(880-105
-1050)
0) [63.6
[63.67-75
7-75.97]
.97]
Different
Differential
ial case bearing cap se
sett bolt Standard 117.7-137.3 (1200-1400) [86.82-101.29]
Different
Differential
ial fron
frontt cover set bolt Standard 29.4 - 44.1 (300
(300-450
-450)) [21
[21.7-32
.7-32.6]
.6]
Different
Differential
ial carr
carrier
ier set bo
bolt
lt Standard 88.3-
88.3-117.
117.7
7 (900
(900-120
-1200)
0) [65.1
[65.1-86.8
-86.82]
2]

Edited by
TOYODA AUTOMATIC
AUTOMATIC LOOM WORKS, LTD.
Publis
Published
hed by
TOYOTA
TOYOTA MOT
MOTOR
OR CORP
CORPORATION
ORATION
1st Pr
Prin
inti
ting
ng:: Se
Sep.
p. 2000
Pub. No. CE029

CE029
Printed
Printed in Japan
Japan

Toyota 7FG 7FD 7FGK 7FDK Forklift Trucks Repair Manual PDF

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Toyota 7FG 7FD 7FGK 7FDK Forklift Trucks Repair Manual PDF

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HOW TO USE THIS MANU

02-7FDK20 T I C 1DZ-II Diesel

Series Engine Vehic

Vehicle model Punching format

HOW TO USE THIS MANUAL

Poi nt Operations Explanatio

ber in the parts catalog.

Abbreviation (code) Meaning Abbreviation

LH Left hand SS T Special service tool

LLC Long life coolant S TD Standard

O/S Oversize OO T Number

RH Right hand W/ With

For screw jack ~

Forward direction Reverse direction

Forward voltage (V)

vary the circui

Always use the range described in the repair manual for

Hexagon Three protruding

Stud bolt https://www.forkliftpdfmanuals.com/

Diameter Pitch Hexagon Hexagon

N·m .I kgf-cm I ft-Ibf N·m I kgf-cm I ft-Ibf

16 1.5 113 I 1150 I 83 - I - I -

6 1.0 6.4 I 65 I 56 in-Ib

8 1.25 19 I 195 I 14 21 I 215 I 16

6 1.0 11 I 110 I 8 12 I 120 I 9

8 1.25 25 I 260 I 19 28 I 290 I 21

6 1.0 12 I 125 I 9 14 I 145 I 9

8 1.25 29 I 300 I 22 32 I 330 I 24

10 1.25 61 I 620 I 45 68 I 690 I 50

Nominal diameter Stan

Compres- Suspension Compres- Suspension

1.00time o time 1.41 time 1.00 time

1.16 time 0.S8time

21380 3040 6080 5880 5200 4 310

49230 6960 14020 13440 11770

Component Weight kg (Ib)

Transmission TIC (1 speed) 124

TIC (2 speeds) 153

2.0 ton model Appr

2.5 ton model Appr

K2.0 ton mode

K2.5 ton mode

K3.0 ton model Appr

J3.5 ton model Appr

1 ton series Approx. 410

J3.5 ton series Approx. 680 (1500

Description Application Quantity f (U S g a l) C la s s i f ic a t i o n T yp e

Diesel engine oil

Transmission TIC (1 speed) 9.0 (2.38)

1 ton series 6.3 (1.66)

1 ton series 45(11.9)

Fuel tank K2 ton series 55 (14.5) -

Attached Table 1 Hydrau

Model 1 ton seri

1DZ-II engine models 27 (7.1

Attached Table 2 Coolant volume Unit: l (US gal)

MfT 6.0 (1.58) 6.0 (1.5

MfT 7.0 (1.85) 8.2 (2.16) 8.4 (2.2

MfT 6.7 (1.7

MfT ------------- ------------- 8.1 (2.1

Inspection Period Every Every Every Every

Every Every Every Every

Rotating condition during acceleration