Ce056 13 0707

13-1
OIL PUMP
Page
GENERAL.............................................................13-2
0
SPECIFICATIONS ................................................13-4
1
COMPONENTS ....................................................13-5
2
OIL PUMP ASSY ..................................................13-7
REMOVAL·INSTALLATION
3
(Dry Brake Spec.) ................................................13-7 4
REMOVAL·INSTALLATION
(Wet Brake Spec.) ................................................13-8 5
DISASSEMBLY·INSPECTION·REASSEMBLY 6
(4Y (STD), 1DZ-III, 3Z) ..........................................13-9
7
DISASSEMBLY·INSPECTION·REASSEMBLY
(4Y (Cabin Spec., Low Noise Spec.)) ...................13-13 8
DISASSEMBLY·INSPECTION·REASSEMBLY
(Wet Brake Spec.) ..............................................13-17
9
PERFORMANCE TEST......................................13-23 10
11
12
13
14
15
16
17
18
19
20
21
E
13-2
GENERAL
4Y (STD), 1DZ-III, 3Z
4Y (Cabin Spec., Low Noise Spec.)

13-3
Wet Brake Spec.
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
13-4
SPECIFICATIONS
Dry Brake Spec.
Theoretical
Vehicle model Engine Specification Maker (Model) Pump type discharge
cm3 (in3) /rev
STD KYB (KFS23) Gear pump/single gear 25.7 (1.568)
4Y
1 ton series Cabin spec·Low noise spec KYB (DGP23) Gear pump/double gear 25.0 (1.526)
1DZ-III KYB (KFS23) Gear pump/single gear 25.7 (1.568)
4Y
K2 ton series Cabin spec·Low noise spec KYB (DGP23) Gear pump/double gear 26.5 (1.617)
4Y
Cabin spec·Low noise spec KYB (DGP23) Gear pump/double gear 26.5 (1.617)
2 ton series
3Z KYB (KFS23) Gear pump/single gear 32.8 (2.002)
4Y
Cabin spec·Low noise spec KYB (DGP23) Gear pump/double gear 28.6 (1.745)
3 ton series
4Y
J3.5 ton series Cabin spec·Low noise spec KYB (DGP23) Gear pump/double gear 28.6 (1.745)
Wet Brake Spec.
Vehicle model Engine Maker (Model) Pump type Theoretical discharge cm3 (in3) /rev
4Y KYB (KFS23-9C) Gear pump/tandem gear Main 27.8 (1.696) /Sub 9.4 (0.574)
2 ton series 1DZ-III KYB (KFS23-9C) Gear pump/tandem gear Main 27.8 (1.696) /Sub 9.4 (0.574)
3Z KYB (KFS23-9C) Gear pump/tandem gear Main 31.2 (1.904) /Sub 9.4 (0.574)
3 ton series 1DZ-III KYB (KFS23-9C) Gear pump/tandem gear Main 27.8 (1.696) /Sub 9.4 (0.574)
J3.5 ton series
13-5
COMPONENTS
4Y (STD), 1DZ-III, 3Z
6701
0
1
2
3
4
5
6
7
8
9
10
4Y (Cabin Spec., Low Noise Spec.) 11
6701 12
13
14
15
16
17
18
19
20
21
E
13-6
Wet Brake Spec.
6701
13-7
OIL PUMP ASSY

REMOVAL·INSTALLATION (Dry Brake Spec.)
T = N·m (kgf·cm) [ft·lbf]
T = 24.0 ~ 33.0
(245 ~ 337)
[17.73 ~ 24.38]
7
10
10
9
Removal Procedure
1 Open the engine hood.
2 Remove the toe board.
3 Remove the RH rear tire cover.
4 Remove the air cleaner.
5 Disconnect the outlet hose.
6 Disconnect the inlet hose at the tank side.
7 Remove the oil pump ASSY W/ inlet hose.
8 Remove the oil pump gasket.
9 Remove the inlet hose from the oil pump ASSY.
10 Remove the fitting from the oil pump ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply grease (molybdenum disulfide grease) on the pump shaft spline section before installation.
13-8
REMOVAL·INSTALLATION (Wet Brake Spec.)

T = 24.0 ~ 33.0
(245 ~ 337)
[17.73 ~ 24.38]
7
5
11
10
9
11
10
Removal Procedure
1 Open the engine hood.
2 Remove the toe board.
3 Remove the RH rear tire cover.
4 Remove the air cleaner.
5 Disconnect the outlet hose.
6 Disconnect the inlet hose at the tank side.
7 Remove the oil pump ASSY W/ inlet hose.
8 Remove the oil pump gasket.
9 Remove the inlet hose from the oil pump ASSY.
10 Disconnect the brake cooling hose.
11 Remove the fitting from the oil pump ASSY.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply grease (molybdenum disulfide grease) on the pump shaft spline section before installation.
13-9
DISASSEMBLY·INSPECTION·REASSEMBLY (4Y (STD), 1DZ-III, 3Z)

4
4
6
1·8
4 7
T = 88 ~ 98
(900 ~ 1000)
[64.92 ~ 72.30]
1·2·8
3
3
4
1·5
Disassembly Procedure
1 Put match marks on the cover, gear plate and mounting flange.
2 Remove the cover. [Point 1]
3 Remove the plate seal, back up, and dowel pin. [Point 2]
4 Remove the side plate, drive gear and driven gear. [Point 3]
5 Remove the gear plate. [Point 4]
7 Remove the oil seal. [Point 5]
8 Inspect the cover and mounting flange. [Point 6]
Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Note:
• Use new seals for reassembly.
• Apply the hydraulic oil before reassembly.
13-10
Point Operations
[Point 1]
Reassembly:
Intake side The reassembly procedure is as follows.
1. Temporarily tighten the through bolt to the specified torque
below.
Discharge side T = 2.0 ~ 4.9 N·m (20 ~ 50 kgf·cm) [1.45 ~ 3.62 ft·lbf]
2. As shown in the illustration, place the oil pump ASSY with the
intake side facing upward and keep the pump horizontal with
wooden blocks placed under the mounting flange and cover.
Tap the gear plate using a plastic hammer to slide the gear
plate.
3. Secure the pump in a vise and tighten the through bolt to the
proper torque.
Bushing [Point 2]
Back up
Reassembly:
The plate seal and back up are not to protrude from the cover
Not to protrude
or the bushing of the mounting flange.
Plate seal
[Point 3]
Inspection:
Measure the side plate thickness.
Limit: 2.927 mm (0.1152 in)
Inspection:
Inspect traces of contact with the side plate.
Intake side Standard:
There should be a shiny contact area on the side of the
surface that is in sliding contact with the gear.
Contact area
13-11
Reassembly:
Intake side Install with the copper alloy side facing towards the inside of
the pump. Also, be careful not to mistake the direction of the
intake side and discharge side when assembling.
Discharge side
Disassembly:
Put match marks on the teeth of the drive and driven gears.
Reassembly:
Align match marks at the time of reassembly.
Match marks
Inspection:
Measure the outside diameter of each gear shaft.
Limit: 20.99 mm (0.8264 in)
[Point 4]
Inspection:
A Inspect the gear plate inside surface (intake chamber side) for
Intake chamber traces of contact with the gears.
Standard:
Trace of The traces of contact should not exceed half of the
contact circumference.
Inspection:
Trace of contact Measure the depth of the flaw at the gear plate inside surface.
Limit: 0.20 mm (0.0079 in)
Reassembly:
Do not get the direction confused.
13-12
[Point 5]
Flat head screwdriver Disassembly:
Oil seal Use a flat head screwdriver to prise it off.
Reassembly:
SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
SST(1)
Apply MP grease on the oil seal lip section after reassembly.
SST(2)
[Point 6]
Bearing
section Inspection:
150° Inspect for wear on the inside surface of the bearing section of
the cover and mounting flange.
Intake Standard:
chamber The area of bare metal exposed (color = reddy copper
color) should not exceed 150 °.
150°
Bearing
section
13-13
DISASSEMBLY·INSPECTION·REASSEMBLY (4Y (Cabin Spec., Low Noise Spec.))

1·7
1 · 10
4
4
8
3
6
6
1 · 2 · 10
T = 88 ~ 98 3
(900 ~ 1000)
[65.1 ~ 72.4]
1 Put match marks on the cover, body and mounting flange.
2 Remove the cover. [Point 1]
4 Remove the side plate, rear drive gear and rear driven gear. [Point 3]
5 Remove the center bushing. [Point 4]
6 Remove the side plate, front drive gear and front driven gear. [Point 3]
7 Remove the body. [Point 5]
9 Remove the oil seal. [Point 6]
10 Inspect the cover and mounting flange. [Point 7]
Note:
• Use new seals for reassembly.
• Apply the hydraulic oil before reassembly.
13-14
Point Operations
[Point 1]
Reassembly:
Intake side The reassembly procedure is as follows.
below.
Discharge side T = 2.0 ~ 4.9 N·m (20 ~ 50 kgf·cm) [1.45 ~ 3.62 ft·lbf]
2. As shown in the illustration, place the oil pump ASSY with the
Tap the body using a plastic hammer to slide the body.
proper torque.
Bushing [Point 2]
Back up
Reassembly:
The plate seal and back up are not to protrude from the cover
Not to protrude or the bushing of the mounting flange.
Plate seal
[Point 3]
Inspection:
Limit: 2.927 mm (0.1152 in)
Inspection:
Contact area
13-15
Reassembly:
Discharge side
Disassembly:
Put match marks on the teeth of the drive and driven gears.
Reassembly:
Match marks
Inspection:
Measure the outside diameter of each gear shaft.
Limit: 20.961 mm (0.8252 in)
Thickness
[Point 4]
Inspection:
Inspect traces of contact with the center bushing.
Standard:
Intake side There should be a shiny contact area on the side of the
Inspection:
Inspect the thickness of the center bushing.
Contact area Limit: 41.38 mm (1.6291 in)
Inspection:
Inspect for wear on the inside surface of the bearing section of
the center bushing.
150°
Intake Standard:
side The area of bare metal exposed (color = reddy copper
color) should not exceed 150 °.
150°
13-16
Reassembly:
Intake side Reassemble 2 center bushings simultaneously, paying
attention to their direction.
Discharge side
[Point 5]
Inspection:
A Inspect the body inside surface (intake side) for traces of
Intake side contact with the gears.
Standard:
contact circumference
Inspection:
Trace of contact Measure the depth of the flaw at the body inside surface.
Limit: 0.2 mm (0.0079 in)
Reassembly:
Flat head screwdriver Do not get the direction confused.
Oil seal
[Point 6]
Disassembly:
Use a flat head screwdriver to prise it off.
SST 09950-76018-71................................. (1)

(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
SST(1)
SST(2)
[Point 7]
Bearing
section Inspection:
150° Inspect for wear on the inside surface of the bearing section of
the cover and the mounting flange.
Standard:
Intake
The area of bare metal exposed (color = reddy copper
chamber
150° color) should not exceed 150 °.
Bearing
section
13-17
DISASSEMBLY·INSPECTION·REASSEMBLY (Wet Brake Spec.)

7
9
6
10
2
8
11
T = 88 ~ 98
(900 ~ 1000)
5
[65.1 ~ 72.4]
3
12
1 Secure the mounting flange in a vise and put match marks. [Point 1]
2 Remove the cover and dowel pin. [Pont 2]
3 Remove the plate seal and backup. [Point 3]
4 Remove the side plates, rear drive gear and driven gear. [Point 4]
5 Remove the rear body, snap ring and oil seals. [Point 5]
6 Remove the spline cup ring, bushing and O-ring.
7 Remove the cover plate and dowel pin.
8 Remove the plate seal and backup. [Point 6]
9 Remove the side plates, front drive gear and driven gear. [Point 7]
10 Remove the gear plate and dowel pin. [Point 8]
11 Remove the plate seal, backup and dowel pin. [Point 9]
12 Remove the snap ring and oil seal. [Point 10]
13 Inspect the cover, cover plate and mounting flange. [Point 11]
Note:
• Be sure to use new seals.
• Be sure to apply hydraulic oil before reassembly.
13-18
Point Operations
[Point 1]
Disassembly:
Match marks Put match marks on the cover, rear body, cover plate, gear
plate and mounting flange.
[Point 2]
Reassembly:
The reassembly procedure is as follows.
Intake side
below.
T = 2.0 ~ 4.9 N·m (20 ~ 50 kgf·cm) [1.45 ~ 3.62 ft·lbf]
Discharge side 2. As shown in the illustration, place the oil pump ASSY with the
Tap the body using a plastic hammer to slide the gear plate.
proper torque.
[Point 3]
Bushing
Back up Reassembly:
Do not allow the plate seal and backup to protrude from the
cover or seal groove.
No protrusion
Plate seal
[Point 4]
Inspection:
Limit: 2.927 mm (0.1152 in)
13-19
Inspection:
Contact area
Reassembly:
Discharge side
Reassembly:
Intake side Intake side Be sure to install the front side plate and rear side plate to the
correct positions.
Discharge side Discharge side
For front pump For rear pump
Inspection:
Inspect the outside diameter of the front drive gear shaft and
driven gear shaft.
Limit: 20.99 mm (0.8264 in)
Disassembly:
Put match marks on the tooth faces of the rear drive gear and
driven gear.
Reassembly:
Match marks
13-20
[Point 5]
Inspection:
Standard:
Inspection:
Limit: 0.2 mm (0.0079 in)
Reassembly:
Do not get the direction confused.
SST(1) SST 09950-76018-71................................. (1)
(09950-60010)
09950-76020-71................................. (2)
SST(2) (09950-70010)
Reassembly:
Oil seal Install the oil seals and snap ring as shown in the illustration.
Snap ring
Bushing [Point 6]
Back up
Reassembly:
No protrusion cover or seal groove.
Plate seal
[Point 7]
Inspection:
Limit: 2.927 mm (0.1152 in)
13-21
Inspection:
Contact area
Reassembly:
Discharge side
Reassembly:
Intake side Intake side Be sure to install the front side plate and rear side plate to the
correct positions.
Discharge side Discharge side
For front pump For rear pump
Disassembly:
Put match marks on the tooth faces of the rear drive gear and
driven gear.
Reassembly:
Match marks
Inspection:
Inspect the outside diameter of the front drive gear shaft and
driven gear shaft.
Limit: 20.99 mm (0.8264 in)
13-22
[Point 8]
Inspection:
Standard:
Inspection:
Limit: 0.2 mm (0.0079 in)
Reassembly:
Bushing
Back up Do not get the direction confused.
[Point 9]
No protrusion
cover or mounting flange bushing.
Plate seal
[Point 10]
Flat head screwdriver
Oil seal Disassembly:
Use a flat head screwdriver to prise it off.
SST 09950-76018-71................................. (1)

(09950-60010)
09950-76020-71................................. (2)
(09950-70010)
SST(1)
SST(2)
[Point 11]
Bearing
section Inspection:
150° Inspect the bearing contact surfaces of the cover, cover plate
and mounting flange for wear.
Standard:
Intake
The area of bare metal exposed (color = reddy copper
chamber
150° color) should not exceed 150 °.
Bearing
section
13-23
PERFORMANCE TEST
As the performance test in servicing of the oil pump, judge the quality by the lifting speed of the fork by installing the
oil pump on the vehicle. Bench test measurements shall be made for strict testing of the performance.
Note:
The engine rpm and relief pressure shall be adjusted to satisfy respective standards.
(See the engine rpm adjustment procedure on page 1-14, and the relief pressure adjustment procedure on
page 14-47.)
1. Set the engine tachometer.
2. Operate the oil pump for running in.
Note:
• Do not operate material handling levers.
• Immediately stop the engine if any abnormality is observed.
(1) Start the engine and operate at the idling speed to 1,000 rpm for 10 minutes.
(2) If no abnormality is found in the oil pump, operate for another 10 minutes by raising the engine speed to
1,500 to 2,000 rpm.
3. Measure the full-stroke lifting time of the lift cylinder, and calculate the lifting speed for performance judgment.
Lifting Speed
Lifting speed (loaded/no-load) mm/sec (fpm)
Vehicle model Engine type V mast FSV mast FV mast FSW mast
Full load No load Full load No load Full load No load Full load No load
4Y 665 (131) 680 (134) 620 (122) 635 (125) 615 (121) 630 (124) — —
1 ton series
1DZ-III 650 (128) 675 (133) 620 (122) 650 (128) 600 (118) 640 (126) — —
4Y 600 (118) 640 (126) 560 (110) 600 (118) 560 (110) 600 (118) — —
K2 ton series
1DZ-III 580 (114) 600 (118) 550 (108) 575 (113) 550 (108) 585 (115) — —
4Y 600 (118) 640 (126) 565 (111) 600 (118) 575 (113) 600 (118) 555 (109) 565 (111)
2 ton series 1DZ-III 615 (121) 655 (129) 590 (116) 630 (124) 600 (118) 640 (126) 575 (113) 615 (121)
3Z 665 (131) 700 (138) 640 (126) 670 (132) 650 (128) 680 (134) 625 (123) 655 (129)
4Y 510 (100) 550 (108) 480 (94) 520 (102) 460 (91) 490 (96) 480 (94) 520 (102)
3 ton series 1DZ-III 500 (98) 530 (104) 470 (93) 500 (98) 445 (88) 480 (94) 470 (93) 500 (98)
3Z 550 (108) 570 (112) 510 (100) 530 (104) 485 (95) 510 (100) 510 (100) 530 (104)
4Y 425 (84) 450 (89) 410 (81) 440 (87) 440 (87) 460 (91) — —
J3.5 ton series
3Z 450 (89) 475 (94) 430 (85) 460 (91) 465 (92) 490 (96) — —

Ce056 13 0707

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13-1

4Y (Cabin Spec., Low Noise Spec.)

Wet Brake Spec.

Wet Brake Spec.

Wet Brake Spec.

OIL PUMP ASSY

REMOVAL·INSTALLATION (Wet Brake Spec.)

DISASSEMBLY·INSPECTION·REASSEMBLY (4Y (STD), 1DZ-III, 3Z)

DISASSEMBLY·INSPECTION·REASSEMBLY (4Y (Cabin Spec., Low Noise Spec.))

SST 09950-76018-71................................. (1)

DISASSEMBLY·INSPECTION·REASSEMBLY (Wet Brake Spec.)

Discharge side Discharge side

For front pump For rear pump

Discharge side Discharge side

For front pump For rear pump

SST 09950-76018-71................................. (1)

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