FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 6FGU16FDU33-45,
6FGAU16FDAU50. Please use this manual for
providing quick, correct servicing of the corresponding forklift models. This manual deals with the above models as of March 1997. Please understand that disagreement can take place between the descriptions i n the manual and actual vehicles d u e t o change i n design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News. For the service procedures of the mounted engine, read the repair manuals listed below as reference together with this manual. (Reference) Repair manuals related to this manual are as follows:
TOYOTA INDUSTRIAL EQUIPMENT GM6-262 ENGINE REPAIR MANUAL (No. C4630) TOYOTA INDUSTRIAL EQUIPMENT 11Z,12Z,13Z,14Z ENGINE REPAIR MANUAL (No. C4615)
TOYOTA MOTOR CORPORATION
SECTION INDEX I
NAME
I GENERAL
1 SECTION
I
ENGINE TORQUE CONVERTER FRONT AXLE REAR AXLE
rn STEERlNG BRAKE MATERIAL HANDLING SYSTEM
0 0
MAST CYLINDER OIL CONTROL VALVE APPENDIX
o
GENERAL Page
EXTERIOR VIEWS
............................................... 0-2
VEHICLE MODEL-FRAME NUMBER
................... 0-3
......................... 0-4 EXPLANATION METHOD ...................................... 0-4 TERMINOLOGY ................................................... 0-5 ABBREVIATIONS .................................................0-5 OPERATIONAL TIPS ........................................... 0-6
HOW TO READ THIS MANUAL
STANDARD BOLT AND NUT TIGHTENING TORQUE ...........................................................0-7 BOLT STRENGTH TYPE IDENTIFICATION METHOD ........................................................ 0-7
............................... 0-8 ............................................... 0-9
TIGHTENING TORQUE TABLE
PRECOAT BOLTS
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE ..................................... 0-9 WIRE ROPE SUSPENSION ANGLE LIST
............. 0-10
SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE ....................................... 0-10 COMPONENTS WEIGHT
.....................................
0-11
RECOMMENDED LUBRICANT QUANTITY & TYPES ....................................... 0-12
........................................ 0-13 PERIODIC MAINTENANCE .................................. 0-14 LUBRICATION CHART
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS ........................................... 0-20
0-2
EXTERIOR VIEWS
VEHICLE MODEL * FRAME NUMBER Load capacity *
Model
02-6FDU33
3.25 (7000)
02-6FDU35
3.5 (8000)
Engine
Drive system
Punching format
TOYOTA 132
Torque converter --
-
02-6FDU40
--
4.0 (9000) TOYOTA 132
02-6FDAU 50
*:
5.0 (11000)
TOYOTA 132
When the load center is 600 m m (24 in)
Frame No. punching position
I
506FGU45-60011
HOW TO READ THIS MANUAL EXPLANATION METHOD 1.
Operation procedure ( 1 ) The operation procedure is described in either pattern A or pattern B below. Pattern A: Explanation of each operation step with an illustration. Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, followed by explanation of cautions and notes summarized as point operations.
Example of description in pattern I3 DISASSEMBLY .INSPECTION.REASSEMBLY
Tightening torque unit T = N.m (kgf-cm) [fb-lbf]
1
'T
= 46.09 - 48.05 (470 - 4901 134.00 -- 35 451
8
Disassembly Procedure
-
1
Remove the cover. [Point 11
2
Remove the bush [Point 21
3
Remove the gear.
Point operations
Operation explained later
Explanation of key point for operation with an illustration
1
[Point 11 Disassembly: Put a match mark when removing the pump cover. [Point 21 Inspection:
Measure the bush inside diameter. Bush inside diameter limit: 19.12 m m (0.7528 in)
2.
3.
H o w t o read components figures ( 1 1 T h e components figure uses the illustrat i o n in the parts catalog for the vehicle model. Please refer to the catalog for checking t h e part name. T h e number a t the right shoulder of each components figure indicates the Fig. number in the parts catalog.
(Example)
FIG number in parts catalog
M a t t e r s o m i t t e d in this manual ( 1 ) This manual o m i t s descript~ono f the following jobs, but perform them in actual operation: Cleaning and washing of removed parts as required 2 Visual inspection (partially described)
8
TERMINOLOGY Caution: Important matters of which negligence may cause accidents. Be sure to abserve them. Note: Important items of which negligence may cause accidents, or matters in operation procedure requiring special attention. Standard: Values showing allowable range i n inspection and adjustment. L i m i t : M a x i m u m or minimum allowable value in inspection or adjustment.
ABBREVIATIONS Abbreviation (code)
Meaning
Abbreviation (code)
Meaning
ASSY
Assembly
RH
Righthand
SAE
Society of Automotive Engineers (USA)
FHPS
Full hydraulic power steering
L/
Less
SST
Special service tool
LH
Lefthand
STD
Standard
LLC
Long life coolant
T =
Tightening torque
0PT
Option
01s
Oversize
U/S
Undersize
PS
Power steering
W/
With
O T
Number of teeth
(0 0)
OPERATIONAL TIPS 1.
Safe operation ( 1 ) After jacking up, always support with rigid stands. (2) When hoisting the vehicle or its heavy component, use wire rope(s) w i t h a sufficient reserve in load capacity. ( 3 ) Always disconnect the battery plugs before the inspection or servicing of electrical parts.
2.
Tactful operation (1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge, etc.) and SSTs before starting operation. (2) Before disconnecting wiring, always check the cable color and wiring state. (3) When overhauling functional parts, complicated portions or related mechanisms, arrange the disassembled parts neatly t o prevent confusion. (4) When disassembling and inspecting such a precision part as the control valve, use clean tools and operate in a clean location. (5) Follow the described procedures for disassembly, inspection and reassembly. (6) Replace gaskets, packings and O-rings with new ones each time they are disassembled. ( 7 ) Use genuine Toyota parts for replacement. (8) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly. If no tightening torque is specified, tighten the bolt or nut according t o the standard tightening torque table.
3.
Grasping the trouble state When a trouble occurs, do not attempt immediate disassembly or replacement but first check if the trouble requires disassembly or replacement for correction.
Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING
NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
STANDARD BOLT AND NUT TIGHTENING TORQUE How to judge tightening torque of a standard bolt or nut 1.
How to judge tightening torque of a standard bolt: Find out the type of the bolt from the list below. Then, find the bolt tightening torque from the table.
2.
How to judge tightening torque of a standard nut: The nut tightening torque can be judged from the bolt type. (See the item above.)
BOLT STRENGTH TYPE IDENTIFICATION METHOD 1.
2.
Identification by bolt shape Shape and class
@
Bolt head No.
Hexagon head bolt
Hexagon flange bolt
Class
Identification by part No.
Hexagon head bolt
4 = 4T 5 = 5T 6 = 6T 7 = 7T 8 = 8T
Part No. 9161 1-40625
1T-L I
Length (mm)
D i a m e t e r (mm)
No mark
4T
No mark
4T
L Class
iameter
I
Hexagon head bolt
Two protruding lines
5T
Hexagon flange bolt
Two protruding lines
6T
Hexagon head bolt
Three protruding lines
7T
Length
I
r Stud bolt
Part No. 92 132-406 14
[TL I
Length (mm)
Hexagon head bolt
Welded bolt I
Four protruding lines
Diameter lmml
8T
4T
LClass
TIGHTENING TORQUE TABLE
5.4
55
I
48 in-lbf
I
83 16
1.5
113
/
1150
I
5T
6.4
6
1 .O
8
1.25
10
1.25
32
12
1.25
59
14
1.5
91
16
1.5
137
-
83 I
1 I 1 I I I 1 I 1
65 160 330 600 930
1 1
I I I I 1
56 in-lbf 12 24
-
43 67
11400
1101
I
I
j I
I
850
_
6T
1 .O
8
1.25
10
1.25
12
1.25
14
1.5
6
7T
8T
1 .o
7.8 l9
39 72 -
11
8
1.25
25
10
1.25
52
12
1.25
95
14
1.5
147
16
1.5
226
8
1.25
10 12
1.25 1.25
29 61 110
1
I I 1 1 1 I I
80
1
195
14
400
129
730
1 I I
I
I
I
I
1 1 1
1 1 1
1 1 1 0 260 530 970 1500 1 I I I 1 1 I
69 in-lbf
2300 300 620
11100
1
53
8
8.8 21 43 79 123
12
19
28
38
58
70
103
1108
167
1 166
I I I I I
22
33
45
68
180
120
I I
I
I
1 I I I I I I I I I I
I I I I I I I I I I I
-
I
6
61
1 I I
1 1
3
1 810 1 I 1250
I 1 I I
I
I
1 / 1 I I I I I I I
1
-
I
90 215 440
I 1 I 1
_
78 in-lbf 16 2 59 90
120
I 1
9
290
I 1
21
1
43
590 1050 1700
330 690 1250
1 7 6
1 123 I I I I I I I 1
24 50 90
PRECOAT BOLTS (Bolts with seal lock agent coating on threads)
1.
Do not use the precoat bolt as it is in either of the following cases: (a) After it is removed. (b) When the precoat bolt is moved (loosened or tightened) by tightness check, etc.
Note: For torque check, use the lower limit of the allowable tightening torque range. If the bolt moves, retighten it according t o the steps below.
2.
Method for reuse of precoat bolts (1) Wash the bolt and threaded hole. (The threaded hole must be washed even for replacement of the bolt.) (2) Perfectly dry the washed parts by air blowing. (3) Apply the specified seal lock agent on the threaded portion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 1.
When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces w i t h clean cloth t o remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before installation.
2.
When connecting a high pressure hose, hold the hose t o align the fitting with the nipple and tighten the fitting.
3.
The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter of screw
Standard
Tightening range
711 6 - 20UNF
2 5 ( 2 5 0 ) [ 18.11
24-
9/16
4 9 ( 500) [ 36.21
47
314 - 16UNF
59 ( 600) [ 43.41
56 -
718 - 14UNF
59 ( 600) [ 43.41
56
718 - 14UNF
78 ( 800) [ 57.91
74
-
18UNF
Hose inside diameter mm (in)
Standard tightening torque N.m (kgf-cm) [ft-lbfl
1.1116 - 12 UNF
118 (1200) [ 86.81
1,5116 - 12UNF
137 (1400) [101.3]
-
26(240-
19.51
6 (0.24)
52 ( 480
530) [34.7
-
38.31
9 (0.35)
62 (
630) [41.2
-
45.61
12 (0.47)
45.61
12 (0.47)
60.81
15 (0.59)
90.41
19 (0.75)
106.41
25 (0.98)
19.51
6 (0.24)
-
38.31
9 (0.35)
45.61
12 (0.47)
90.41
19 (0.75)
- 106.41
25 (0.98)
62 ( 82 (
570 5?0 760 -
270)[17.4-
630) l41.2 840) [55.0
-
- 123 (1140 - 1250) 182.5 130 - 144 (1330 - 1470) (96.2 24 - 26 ( 240 - 270) I17.4 -
112
PF 1 I 4
25 ( 250) [ 18.11
PF318
4 9 ( 500) [ 36.21
47
PF 112
59 ( 600) [ 43.41
56
PF314
1 1 8 ( 1 2 0 0 ) [ 86.81
1 1 2 - 123(1140- 1250)[82.5-
PF 1
137 (1400) [101.3]
130
-
-
52 ( 480
-
530) 134.7
62 ( 570
-
630) [41.2
144 (1330
-
1470) f96.2
WlRE ROPE SUSPENSION ANGLE LIST Suspension angle
0O
I
Tens~on
Compression
1 .OO time
0 time
Suspens~on method
Suspension angle
Tension
Compression
90 O
1.41 time
1.OO time
I
Suspens~on method
ij 1 2
30 O
1.04 time
ha
?
0.27 time
b
2.00 time
1 20°
b'
1.73 time
2 t
60O
1.16 time
0.58 time
SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE unit: Single-rope Cutting Rope suspension load diameter OD 6 mm (0.24 in) 8 mm (0.32 in) -
21380 (2.18) [4807] 31480 (3.21)
[70781
1
.I
0O
30°
60 O
90O
0O
30O
60°
90 O
3040 (0.311 [683.6]
6080 (0.62) [ 13671
5880 (0.6) [ 13231
5200 (0.53) I11691
4310 (0.44)
12160 (1.24) I27341
11 770 (1.2) [2646]
10400 (1.06) [23371
8630 (0.88) 119401
4410 (0.45) 1992.31
8830
7650 (0.78) I17201
17650
(0.9) [I9851 14020 (1.43) [31531
8530 (0.87) I 191 81
17060 (1.74) [39371
15300 (1.56) 134401
12550 (1.28) [2322]
13440 (1.37) [30211
11 770
23540 (2.4) [52921
19610
37270 (3.8) [83791
29420 (3.0) 166151
54920 52960 47070 (5.4) (5.6) (4.8) [I23481 [ 119071 [I 05841
37270 (3.8) [8379]
6960 (0.71) 11565.61
10 mm (0.4 in) 12.5 mm (0.5 in)
76880 (7.84) [ 173871
10980 (1.12) [2469.51
21570
21280
(2.21 I4851I
(2.1) 146311
96400 (9.83) [216751
13730 (1.4) [30871
27460
26480 (2.7) [59541
.
14 rnrn (0.56 tn)
Four-rope suspension
Two-rope suspension
49230 15.021 [I10691
1
N (ton) [lbfl
[9701 6280 (0.64) [ I 4 1 11
(1.8) 139691 27460
(1.2) [2646]
98iO (1.0) 122051
18630
14710
43150
26480 (2.7) [59541 41 190
(1.9) 141901
(1.5) 133081
(4.4) [97021
14.21 [9261I
23540 (2.4) I52921
18630 (1.91 141901
(2.8) [6174]
(2.0) [4410]
1