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.
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
COMPONENTS WEIGHT Unit: Component
Weight (mass)
GM6-262
185 (408)
1 32
325 (717)
Engine Transmission W I differential
Approx. 200 (441)
Torque converter W/ differential
Approx. 360 (794)
Counterweight
3.25 ton model
Approx. 1920 (4230)
3.5 ton model
Approx. 2210 (4870)
4.0 ton model
Approx. 2520 (5560)
4.5 ton model
Approx. 2840 (6260)
5.0 ton model
Approx. 2840 (6260)
3.25
V mast ASSY Llbackrest and fork (with lift cylinder max. lifting height: 3000 mm (118in))
-
4.0 ton model
Approx. 890 (1960)
4.5 ton model
Approx. 1 140 (2510)
5.0 ton model
Approx. 1270 (2800)
kg (Ib)
0-1 2
RECOMMENDED LUBRICANT QUANTITY & TYPES Description
Gasoline
Classification
API SD, SE, SF
Engine
Diesel
API CC, CD or better
Type
Application
Quantity
GM6-262
4.2 Q (1.11 US gal)
132
12.5 Q (3.30 US gal)
Motor oil SAE30 (SAE2O in cold area) SAE20W-40 (SAE1 OW-30 in cold area) Diesel engine oil SAE3O (SAE20 in cold area) SAE 1 OW-30
Torque converter
ATF
G M Dexron"l1
All models
15 Q (4.0 US gal)
Differential
API GL-4 GL-5
Hypoid gear oil SAE85W-90
All models
9.5 Q (2.51 US gal)
Hydraulic oil [Max. fork height = 3000 m m (11 8 in)]
IS0 VG32
Hydraulic oil I S 0 V G 3 2
All models
68
-
Fuel tank
Chassis parts Propeller shaft and pump spline shaft
Coolant (excluding reservoir tank)
Coolant (Reservoir Tank)
Molybdenum disulfide
LLC 3 0 -5 0 % mixure (for winter or allseason) Coolant w i t h rust inhibitor (for spring, summer and autumn)
LLC
?
?
Q
( 18.0 US gal)
3'25 3'5 ton model
9 5 Q (25.1 US gal)
4.0 - 5.0 ton model
120
Q (31.7 US gal)
All models
Proper quantity
All models
t
GM6-262
13.0
Q
(3.43 US gal)
132
13.0 Q (3.43 US gal)
All models
1.1 Q (0.29 US gal) (at Full levell
LUBRICATION CHART
() lnspect~on
Replacement
(v M P grease @
a a
Eng~ne011 H y p o ~ dgear 011 Hydraul~c011 Automat~ctransmlsslon f l u ~ d Molybdenum disulfide grease
1 Cham 2 D i f f e r e n t ~ agear l 3 Front wheel bear~ng 4 Torque converter case 5 Rear wheel bear~ng 6 Steer~ngknuckle k ~ n gptn 7 Power steering cylinder pin and tie-rod 8 011tank 9 E n g ~ n ecrankshaft
I. 11. Ill. IV. V.
lnspect every 8 hours (da~ly) lnspect every 4 0 hours (weekly) lnspect every 1 7 0 hours (monthly) lnspect every 1000 hours (6 monthlyl lnspect every 2000 hours (annually)
Rear axle beam front Rear axle beam rear Tilt steerlng un~versallotnt T ~ l steerlng t lock~ngmechan~sm Mast support bush~ng T ~ l cyltnder t front ptn Propeller shaft Oil pump spline shaft Tilt cylinder rear pin
PERIODIC MAINTENANCE INSPECTION METHOD I : Inspection. Repair or replacement if required. M : Measurement. Repair or adjustment if required. T : Retightening C : Cleaning L : Lubrication : For n e w vehicle " 1 : Flaw detector
6 months
Every 1 2 months
500 hours
Every 1000 hours
Every 2 0 0 0 hours
I
+
+-
+
Rotating condition at idling
M
+-
+-
+
Rotating condition during acceleration
M
C
C
4-
Exhaust gas condition
I
e
t
c
Air cleaner element
C
+-
+
+
Inspection period
Item
Every month
Every 3 months
Every 170 hours
Every
Every
ENGINE Proper starting and abnormal noise
Basic components
'yStem Governor Lubrication system
Fuel system
Valve clearance
M
Compression
M
Cylinder head bolt loosening
T
Muffler rubber mount
I
Clogging and damage in PCV valve and piping
I
C
C
C
No-load maximum rpm
M
+-
+-
+-
Oil leakage
I
+-
+-
C
Oil level
I
+
+-
C
Clogging and dirt of oil filter
I
+-
+-
+-
Fuel leakage
I
c
+
C
Operation of carburetor link mechanism
I
C
t
t
Dirt and clogging of fuel filter and element
I
4-
t
4-
M
C
Injection timing Injection nozzle injection pressure and spray status
M
Draining of sedimenter
Cooling system
I
+
Coolant level in radiator and leak
I
+
+-
+-
Rubber hose degradation
I
c
c
+-
Radiator cap condition
I
4-
+
+
Fan belt tension, looseness and damage
I
C
C
C
Radiator rubber mount
I
Every month
Every 3 months
Every 6 months
Every 1 2 months
Every 1 7 0 hours
Every 5 0 0 hours
Every 1 0 0 0 hours
Every 2 0 0 0 hours
Oil leakage
I
+
t
t
Oil level
I
+-
+-
t
Leakage
I
+
t
+-
Fluid level
I
t
t
4-
Operating mechanism function and looseness
I
+
t
t
Control valve and clutch functions
I
t
+
+-
Inching valve function
I
t
t
t
M
t
t
t
Inspection period
Item POWER TRANSMISSION SYSTEM
Differential
T
Bolt loosening
Torque converter and transmission
Stall and hydraulic pressure measurement T
Loose joint Propeller shaft and axle
Looseness at spline connections
I
Looseness of universal joint
I
Twisting and cracks of axle shaft
I
DRIVE SYSTEM
Wheels
Front axle
Rear axle
Tire inflation pressure
M
t
t
+
Tire cuts, damage and uneven wear
I
t
t
t
Loose rim and hub nuts
T
t
+
+
Tire groove depth
M
t
t
+
Metal chips, pebbles and other foreign matter trapped in tire grooves
I
t
t
+-
Rim, side bearing and disc wheel damage
I
t
t
t
Abnormal noise and looseness of front wheel bearing
I
t
t
t
Abnormal noise and looseness of rear wheel bearing
I
t
t
t
Crack, damage and deformation of housing
I
Crack, damage and deformation of beam
I
Looseness of axle beam in vehicle longitudinal direction
M
Inspection period
Item
Every month
Every 3 months
Every 6 months
Every 12 months
Every 1 7 0 hours
Every 5 0 0 hours
Every 1000 hours
Every 2000 hours
STEERING SYSTEM Steering wheel
Play and looseness
I
t
C
t
Function
I
+-
c
t
Steering valve
Oil leakage
I
4-
t
t
Looseness of mounting
T
+
+
+-
Oil leakage
I
+
+
C
Mounting and linkage looseness
1
c
c
+-
I
+
t
+
Power Steering
I
Damage of power steering hose Knuckle
King pin looseness
I
Crack and deformation BRAKING SYSTEM Brake pedal
Parking brake
Brake pipe
Play and reserve
M
C
+-
t
Braking effect
I
+
+
+-
Operating force
I
+-
+
4-
Braking effect
I
e
+
c
Rod and cable looseness and damage
I
t
t
t
Leak, damage and mounting condition
I
+
t
+-
Brake booster and wheel cylinder
Function, wear, damage, leak and mounting looseness
Clearance between drum and lining
Brake drum and brake shoe
Backing plate
I M
+
t
+
Wear of shoe sliding portion and lining
I
Drum wear and damage
I
Shoe operating condition
I
Anchor pin rusting
I
Return spring fatigue
M
Automatic adjuster function
I
Deformation, crack and damage
I
Loose mounting
T
MATERIAL HANDLING SYSTEM
Forks
Abnormality of fork and stopper pin
I
+
+-
+-
Misalignment between left and right fork fingers
I
C
e
t
Crack at fork root and welded part
I*'
Every month
Every 3 months
Every 6 months
Every 12 months
Every 1 7 0 hours
Every 5 0 0 hours
Every 1000 hours
Every 2000 hours
Deformation and damage of each part and crack at welded part
I
t
C
t
Mast and lift bracket looseness
I
+
e
+
Inspection period
Item
Mast and lift bracket
Wear and damage of mast support bust, Wear, damage and rotating condition of rollers
I
I
C
C
I
Wear and damage of roller pins
Chain and chain
Various attachments
e
Wear and damage of mast trip
I
+
+
+
Tension, deformation and damage of chain
I
4-
C
4-
Chain lubrication
I
c
c
t
Abnormality of chain anchor bolt
I
t
c
+
Wear, damage and rotating condition of chain wheel1
I
t
C
C
Abnormality and mounting condition of each part
I
C
C
t
Loosening and damage of cylinder mounting
I
C
e
C
Deformation and damage of rod, rod screw and rod end
I
C
4-
C
Cylinder operation
I
+
c
c
Natural drop and natural forward tilt (hydraulic drift)
M
C
C
C
Oil leakage and damage
I
t
c
t
Wear and damage of pin and cylinder bearing
I
C
e
4-
Lifting speed
M
+-
+
+
Uneven movement
I
+
+
+
Oil leakage and abnormal sound
I
t
c
+
Oil level and contamination
I
+
e
+-
C
t
HYDRAULIC SYSTEM
Cylinder
Oil pump Hydraulic oil tank Control lever
Tank and oil strainer Oil leakage
I
+-
+-
+
Loose linkage
I
t
t
C
Operation
I
t
+-
C
Inspection period
Item Oil leakage Oil control valve
Hydraulic piping
Every month
Every 3 months
Every 6 months
Every 1 2 months
Every 1 7 0 hours
Every 500 hours
Every 1000 hours
Every 2000 hours
I
e
4-
+-
M
Relief pressure measurement Relief valve and tilt lock valve functions
I
4-
C
4-
Oil leakage
I
t
4-
e
Deformation and damage
I
+
c
+
Loose joint
T
t
4-
+
Crack at distributor cap
I
+
+
+
Spark plug burning and gap
I
t
d-
t
Distributor side terminal burning
I
C
t
t
Distributor cap center piece wear and damage
I
t
+-
t
ELECTRICAL SYSTEM
lgnition timing
Plug cord internal discontinuity
I
Ignition timing
M
+
Starting motor
Pinion gear meshing status
I
t
+
t
Charger
Charging function
I
t
+
+-
Battery fluid level
I
4-
4-
+
M
+-
Battery
Battery fluid specific gravity Electrical wiring Preheater Engine stopping system
Damage of wiring harness
I
C
t
C
Fuses
I
c
t
c
Open-circuit in glow plug
I
+
Open-circuit in intake heater
I
+
Diesel engine key stop device function
I
+
+-
t
Crack at welded portion
I
+-
C
+-
Deformation and damage
I
c
t
+
Loosening of mounting
T
c
C
+
Deformation, crack and damage
I
+
+
e
Lighting system
Function and mounting condition
I
+
C
+
Horn
Function and mounting condition
I
t
C
+
SAVETY DEVICES, ETC. Head guard
Back-rest
Inspection period
Item
Every month
Every 3 months
Every 6 months
Every 12 months
Every 1 7 0 hours
Every 500 hours
Every 1000 hours
Every 2000 hours
Direction indicator
Function and mounting condition
I
4-
+
+
Instruments
Functions
I
C
+
+
Backup buzzer
Function and mounting condition
I
t
+-
t
Rear-view mirror
Dirt, damage
I
C
4-
+
Rear reflection status
I
4-
e
c
Seat
Loosening and damage of mounting
I
C
+-
+-
Body
Damage and crack of frame, cross members, etc.
I
Bolt looseness
T
Others
Grease up
L
4-
+-
+ -
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS 0 : Replacement Interval Item Engine oil
Every month
Every 3 months
Every 6 months
Every 12 months
Every 1 70 hours
Every 500 hours
Every 1000 hours
Every 2000 hours
•
t
t
+
t
t
C
t
• •
Engine oil filter Engine coolant (every 2 years for LLC) Fuel filter
1
1
a
Torque converter oil
I
1
/
t
I
C
•
Torque converter oil filter
t
•
Differential oil
I I I
Hydraulic oil Hydraulic oil return filter Wheel bearing grease --
a*'
1 I
I
a
I
I
I
t
1
1 •
Spark plugs
C l t
•
Air cleaner element Cups and seals for brake booster and wheel cylinders
I
Power steering hoses
1
I
I
er2
-
Power steering rubber parts
O*
Hydraulic hoses
a*2
Fuel hoses
1
Torque converter rubber hoses
I
1
1
j Chains *I:
for n e w vehicle
*2:
Every 2 years
*3:
a*z a"3
Every 3 year
Replacement shall be made upon arrival o f the specified operation hours or months, whichever is earlier.
ENGINE Page
ENGINE EXTERIOR VIEWS ................................. 1-2 MAJOR SPECIFICATIONS .................................. 1-3 ENGINE PERFORMANCE CURVES ..................... 1- 4 ENGINE ASSY ..................................................... 1-5 REMOVAL .INSTALLATION
................................... 1-5 ENGINE SPEED ADJUSTMENT ( G M 6 - 2 6 2 ) ....... 1-8 ELECTRONIC GOVERNOR ..................................... 1-11 ENGINE SPEED ADJUSTMENT (132) ................ 1- 32 AIR CLEANER ..................................................... 1- 33 GENERAL ............................................................ 1 - 3 3 SPECIFICATIONS ................................................. 1 - 3 3 COMPONENTS .................................................... 1 - 3 4 AIR CLEANER CLEANING INSPECTION .................. 1 - 3 4 CLOGGING WARNING SYSTEM INSPECTION .......... 1-35
.
......................................................... 1-36 COMPONENTS .................................................... 1-36
RADIATOR
................................................. 1-36 FAN DRIVE ......................................................... 1- 37 REMOVAL .INSTALLATION ................................... 1-37 DISASSEMBLY .INSPECTION .REASSEMBLY ............ 1 - 3 9 SPECIFICATIONS
MUFFLER & EXHAUST PIPE .............................. 1- 42 COMPONENTS .................................................... 1- 42 REMOVAL .INSTALLATION ................................... 1- 43
.................. 1-44 COMPONENTS .................................................... 1 - 4 4 SPECIFICATIONS ................................................. 1- 44
BATTERY SPARK PLUG ( G M 6 - 2 6 2 ) rn
............................................ 1-47 REMOVAL .INSTALLATION ................................... 1-47 ALTERNATOR .................................................... 1- 48 REMOVAL . INSTALLATION ................................... 1-48 ACCELERATOR PEDAL ....................................... 1-50 COMPONENTS .................................................... 1- 50 ACCELERATOR PEDAL ADJUSTMENT ................... 1 - 5 1
STARTING MOTOR
ENGINE EXTERIOR VIEWS GM6-262 Engine
132 Engine
MAJOR SPECIFICATIONS GM6-262 Engine
Engine type
I
Number of cylinders and arrangement Combustion chamber type
Gasoline
GasolineILPG
LPG
4 - cycle
t
t
t
t
V-type 6 cylinders longitudinal Wedge type
I
Number of valves per cylinder Valve mechanism
I
Intake valve x 1 Exhaust valvex 1
t
OHV chain-driven
t
t
Bore x stroke
mm (in)
101.60 x 88.39 (4.0 x 3.480)
t
t
Total displacement
cm3(in 3)
4300 (262.4)
t
t
9.2
t
t
Compression ratio
1 N*m (kgf-m)/rpm 1
( Maximum power
kW (PS)/rpm
I Maximum torque Minimum specific fuel consumption
g/kW-h (g1PS-h)/rpm
I Governor system I Service weight
I kg (Ib) I
No-load maximum rpm
rPm
1 1
67 (91)I2350 294 (30)/1200 258 (190)/1800
2350
284 (29)/1200
1 1
I 1
t t
I I
t
132 Engine Diesel .4-cycle
Engine type
Inline 6 cylinders.vertical
Number of cylinders and arrangement
Direct injection
Combustion chamber type
Intake valve x 1 Exhaust valve x 1
Number of valves per cylinder
0HV.chain-driven
Valve mechanism Bore x stroke Total displacement
mm (in) cm3 (in 3 )
98.0 x 102.0 (3.858 x 4.016) 4616 (281) 18.5
Compression ratio Maximum power
kW (PS)/rpm
6 2 (85112200
Maximum torque
N. m (kgf-m)/rpm
284 (29111600
Minimum specific fuel consumption Service weight No-load maximum rpm
g,kW-h (g/PS-h)/rpm kg (Ib) rPm
224 (165111200 325 (717) 2400
61 (83)/2150 284 (29)/1200
1 1
250 (184)/1400
249 (183)/1400
Electronic governor 185 (408)
61 (83112350
Air governor
I
t
I
2400
ENGINE PERFORMANCE CURVES GM6-262 Engine I
I 294 (30111200
Gasoline LPG GasolinelLPG
284 (29111200
260 kW 24 60
30 2 50 249 (183)11400 1
I
10 12
I
I
1
,
I
I
14
16
18
20
22
24
Engine speed (rpm)
x
lo2
132 Engine 284 N.m (29.0 kgf-m)/1600 rpm
I
10
1
18 Engine speed (rpm) 14
22 x
lo2
ENGINE ASSY REMOVAL. INSTALLATION
Removal Procedure 1
Remove the radiator cover.
2
Remove the engine hood. (See page 7-61
3
Remove the toe board.
4
Remove the battery, battery case and bracket.
5
Remove the air cleaner case ASSY
6
Disconnect the electrical wiring.
7
Remove the undercover.
8
Disconnect the oil pump drive shaft. [Point 11
9
Remove the exhaust pipe.
1 0 Disconnect t w o radiator hoses. (GM6-262 Engine) 11 Remove the radiator and fan shroud. ( 132 Engine) 12 Disconnect the fuel hose.
13 Slightly hoist the engine. [Point 21 14 Support the torque converter lower side with wooden blocks.
1 5 Remove the flexible plate set bolts. [Point 31 1 6 Disconnect the torque converter end plate from transmission case. 17 Remove t w o engine mount brackets. 18 Remove the engine. [Point 41
19 Remove the flywheel and torque converter end plate.
Installation Procedure The installation procedure is the reverse of the removal procedure.
Note: Tighten the flexible plate set bolts after applying locking agent (08833-00070). The tightening torque for each part is as follows: Unit: N - m (kgf-cm) [ft-lbfl : 48.05 8 9 . 2 4 ( 4 9 0 - 910)[35.45 65.841 Engine mount bracket set bolt 44.13 (300 - 450) [21.71 32.561 Torque converter end plate set bolt : 29.42 : 14.71 24.52 (150 - 250) i10.85 18.091 Flexible plate set bolt Flywheel set bolt : 98.1 156.9 (1000 1600) E72.4 115.81
-
I
-
-
Bleeding Air from Fuel Line (13 2 Engine) 1.
Operate the fuel pump hand pump until it becomes heavy. Air bleeding is completed when the handle is felt heavy.
Point Operations [Point 1 I Removal:
Disconnect after tying with a string so as not to cause disconnection at the spline.
[Point 21
\
A
SST
I
Removal .Installation:
SST 09010-201 1 1-71
Removal.Installation:
Use a sufficiently strong wire. Set length A at approx. 250 mm (9.84 in) to obtain a sufficient hoisting stroke.
[Point 31 Removal Installation:
Remove nine (9)set bolts while rotating the torque converter.
[Point 41 Removal:
Remove after checking perfect disconnection of the wiring, hose and cables.
ENGINE SPEED ADJUSTMENT (GM6-262) ldle Speed Inspection .Adjustment
<Gasoline engine or
gasolinelLPG engine model >
Note: The idling speed is electronically controlled. 1.
Warm up the engine.
Cooling water temperature: Hydraulic oil temperature:
80°C (176OF) or more 60°C ( 140°F) or more
Install a tachometer and vacuum gage. ( 1) Disconnect the inspection connector and connect the tachometer measurement cord t o the male side. (2) Disconnect the vacuum hose and install the vacuum gage. ldle speed inspection and adjustment (1 Measure the idle speed. I '
I
I
I
Standard:
750;:'
rpm
Adjust the mixture adjusting screw so that the negative pressure then is stabilized at the highest level.
Note: When the idling speed is high, check if the idle adjusting screw is pushing the lever. If so, loosen the screw. (2) Check and adjust the clearance between the idle adjusting screw and lever.
Standard:
0 m m (0 in)
< LPG Engine Model > 1.
Warm up the engine in the same way as for the gasoline or gasoline1LPG engine and connect a tachometer.
2. (1
ldle speed inspection and adjustment. Adjust the idle speed with the throttle adjust screw.
Standard: Throttle adjust screw
800 t 25 rpm
(2) Turn the idle adjusting screw gradually clockwise or counterclockwise t o the position where the engine rpm is the highest. (3) Adjust the standard value by turning the throttle adjusting screw.
Note: Repeat steps (2)and (3) until the state after step (2) satisfies the standard. (4) Turn the idle adjusting screw counterclockwise until the rpm starts t o drop, and then turn it clockwise by 45O.
Idle Up Inspection. Adjustment <LPG Engine Model > 1.
Warm up the engine. Cooling water temperature: Hydraulic oil temperature:
2.
80°C (176OF) or more 60°C (140°F1 or more
Install a tachometer. Check the idle-up speed. (1) Start the engine. Disconnect the vacuum hose from the idle-up actuator and measure the speed after plugging the hose.
Plug
1
Standard:
1 2 5 0 k 5 0 rpm
(2) If the standard is not satisfied, make adjustment by turning the adjusting screw. Note: Turn the adjusting screw clockwise t o increase speed. (3) After adjustment, connect the vacuum hose.
No-Load Maximum Speed Inspection-Adjustment <Gasoline or GasolinelLPG Engine Model > Note: The maximum speed is controlled electronically. 1.
Warm up the engine. Cooling water temperature: ~ ~ d r a i loil i ctemperature:
80°C (176OF) or more 60°C (140° F) or more
2.
Install a tachometer.
3.
lnspect the no-load maximum speed when the accelerator pedal is fully depressed. Standard:
2350
+ 3 0 rpm
c LPG Engine Model > 1
'
1.
Warm up the engine Cooling water temperature: Hydraulic oil temperature:
2. 3.
80°C (176OF1 or more 60°C (140°F1 or more
Install a tachometer. lnspect and adjust the no-load maximum speed. ( 1 1 Measure the speed when the accelerator pedal is ful-
ly depressed. Standard:
2 4 0 0 ? 5 0 rpm
(2) If the standard is not satisfied, adjust the speed. (3) Remove the air governor bush lock bolt. Turn the air governor bush while fixing the adjusting screw t o adjust the speed. Note: Less than the standard: More than the standard:
Turn the bushing clockwise. Turn the bushing counterclockwise.
(4) Install the air governor bush lock bolt.
Loaded Maximum Speed Measurement Note: In the gasoline or gasolineILPG engine model, the maximum speed is controlled electronically.
c LPG Engine Model > 1.
While the engine is running at the maximum speed, operate the material handling lever and measure the engine speed at full relief. Check that the decrease in the speed is within the following range.
Adjusting screw
Standard:
2150 rpm or more
2. If the standard is n o t satisfied, turn the adjusting screw for adjustment.
ELECTRONIC GOVERNOR Repair operation 1. Carefully protect electrical parts from direct water pressure (100 kPa (1 kgf/cm 2) [ I 4 psi]) application during vehicle washing. 2. After any repair, always conduct the final inspection according t o the specified procedure. 3. Never attempt at electrical wiring modification. (Never install any electrical parts other than OPT.) Parts handling 1. Handle each part with care. Especially avoid any impact on controller sensor parts as it will bring about adverse influence. 2. Sensor adjustment is necessary after repairing a part related to each sensor. 3. When installing the throttle switch, avoid incorrect connection of the max. (full) side and min. (idle) side. (The shorter wiring is for the min. side.) 4. Three types of controllers are used selectively according to the vehicle model. Items to be provided Prepare the following tools:
Part No.
Name SSTImeasuring instrument
Toyota electrical tester
Bond, etc.
09082-00050
Thickness gauge Thread tightener
08833-00070
Purpose Sensor and switch inspection and measurement Sensor and switch inspection and measurement Upon sensor adjustment
Outline of Repair Procedure Procedure Preparation
Job description 1. Prepare necessary tools.
1. Inspect basic characteristics before starting troubleshooting. 2. Perform functional inspection (function check of each part) to clarify the defect status. 1. Inspect according to the self-diagnosis 3. Diagnostic code. inspection 4. Other inspection 2. For a defect for which no self-diagnosis Repair code is displayed, determine the operation inspection method according t o the phenomenon. Removal, installation 1. Perform removal, installation, inspection and replacement. or replacement 1. Sensor adjustment is necessary if any part related t o the system is repaired (removed, installed or replaced). Parts Adjustment requiring adjustment are as follows: Acceleration sensor, idle switch and throttle switch 1. After the end of repair job, inspect Stopped state according to the final inspection Final procedure. inspection Traveling state 1. Summarize the defects and repair details. End
Troubleshooting 1. Basic inspection 2. Functional inspection
(Keep them for reference in the later.)
Reference page Page 1-1 1 (Items to be prepared) Page 1-1 2 (basic inspection) Page 1-1 2 (final inspection) Page 1-1 3 (inspection by diagnosis) Page 1-31 (inspection of defect no indicated by diagnosis)
Page 1-19 (sensor and switch adjustment)
Page 1-1 2 (final inspection)
Basic lnspection lnspect basic items shown below before starting troubleshooting: Content
Item
1. lnspect the battery voltage and specific gravity of electrolyte.
Electrical system inspection
lnspection around carburetor
2. Inspect any blown fuse and grounding state. 3. Inspect the wiring and harness connector conditions. 1. lnspect the carburetor function. (1) Carburetor link operation state (2) Stepping motor operation state
Remarks Specific gravity: 1.280 Voltage: 10 to 14 V Erroneous diagnosis will result if the battery voltage is low. Defective grounding will cause erroneous diagnosis. Defective contact of the wiring or harness connector will cause erroneous diagnosis. There shall be no looseness in the carburetor link. Manually rotate the throttle lever and stepping motor. Shall be rotated smoothly.
Final lnspection After the end of repair, perform inspection according to the following procedure: Inspection method 1. lnspect each connector for the connection state. 1. Inspection with engine switch 2. Mechanical operation of OFF acceleration sensor and idle switch Vehicle stopping state 2. lnspection before 1. Depress the accelerator engine starting pedal and check the with engine throttle movement. switch ON 1. lnspect the CHECK lamp 3. lnspection after for lighting state. engine starting 1. lnspect the CHECK lamp during traveling. 2. Disconnect the diagnosis 4. Self-diagnostic Vehicle connector for selftraveling state inspection diagnostic code display, and check if any code is displayed. Inspection order
Inspection standard Shall not be disconnected, loosened or wetted. Shall move smoothly. The movement shall follow the accelerator pedal depression state. Shall normally be off. The CHECK lamp shall be kept off. No self-diagnostic code shall be displayed.
Check
Self-diagnosis The self-diagnostic function inform the driver of trouble occurrence and trouble position by flashing the CHECK lamp in the combination meter if any trouble occurs in electronic governor control. The trouble position is indicated by the CHECK lamp flashing count. Display of diagnostic code 5
1.2 S
- - - - - - - - ON - - - - - - OFF Display of diagnostic codes 5 and 7 0.3 S
Repetition of above cycle operation Note: The CHECK lamp may come o n when t h e engine switch i s turned t o ON or may flash during traveling (during operation). If it flashes during operation, immediately stop the vehicle and check the flashing count with the engine switch at t h e ON position (engine n o t running). The flashing count becomes the selfdiagnostic code. The diagnosis is repeated when t h e engine switch is set t o OFF once and t o ON again. If any abnormality exists, the CHECK lamp flashes. After the end of repair according t o the diagnosis, disconnect the memory clear terminal, connect the male side of the disconnected terminal t o the body ground, and turn the engine switch t o ON t o reset the ECU memory. (See the illustration below.) Rechecking the diagnostic result displayed before To check the diagnostic result displayed i n the past (after ECU memory resetting), disconnect the diagnosis connector (checker) for re-display. Once the ECU memory is reset, preceding results are not displayed.
1-14
Diagnostic Code List
0: Normal traveling
A:Low-speed traveling
X : Traveling
failure
Backup Code No
Diagnostic item
Diagnosed state
Engine
Controller action upon defect detection.
1
Overrun
Abnormal engine speed rise
X
The engine is stopped by setting engine ignition to off.
2
Accelerator opening signal line
When the signal from the sensor is abnormal or the line is shorted or opened.
A
Idle traveling possible.
3
Acceleration1 idle signal line (short circuit)
ON signal though the potentiometer opening signal is 112 or more (short circuit)
0
Ordinary traveling possible thoughthemaximumspeed may decrease.
Throttle full close switch signal (open circuit)
The signal is OFF though the stepping motor is rotated toward the throttle closing side by a specified angle or more.
O
Normal traveling possible though the maximum speed may decrease because the throttle opening is limited.
Throttlefull Open switch signal (short circuit)
The signal is OFF though the throttle is opened beyond the specified opening.
0
t
Throttlefull Close switch signal (short circuit)
The signal is ON though the throttle opening is beyond the specified level.
0
t
Throttlefull open switch signal (short circuit)
The signal is ON when the throttle opening is below the specified level.
0
7.
*
Stepping motor
The engine speed does not drop though the controller issues the throttle closing instruction.
9
Engine pulse
No engine ignition signal
A
10
Alternator
The alternator signal is OFF
A
The engine is stopped by setting the engine ignition to OFF.
Idle traveling possible.
'r
Components
1-16
System Circuit
Altern Governor ECU
Functional Parts Inspection Acceleration Sensor Note Carefully handle pins VTA a n d E2 since they are goldplated. Do not pinch a terminal directly with an alligator clip. Vc
V TA
IDL
1.
E2
Measure the resistance between Vc and and 1). Standard:
n
n
? 7,
Standard:
VTA
3.
(V)
5 - . - - - - ...
[n
r 4-
-X
0
1
-
OFF Close Open + Pedal depression Potentiometer turning angle (accelerator pedal opening)
t h e resistance shall increase in proportion t o the degree of opening.
Turn the potentiometer and measure the continuity between IDL and E2 (between 2 and 1). Standard:
r
.-
+ 1.2 kf2 (at 25 +. 10°C)
2. Turn the potentiometer and measure the resistance between VTA and Ez.
1 \
IDL
C
(between 4
Vc
E2
-m
4.0
E2
Shall be turned from O N t o OFF by about 15" when turned from the free state.
Throttle Switch 1.
lnspect the throttle switch. (1) Disconnect the connector and inspect continuity of full open (between 3 and 4) and full close (between 1 and 2) switches for ON and OFF. Standard: ON Continuity OFF No continuity
2.
lnspect the vehicle side harness. (1) Disconnect t h e connector and inspect the wire harness side connector. Standard: 1 Body ground 2 Body ground 3 Body ground 4 Body ground
-
Harness side
-
4.5 5.25 V Continuity 4.5 5.25 V Continuity
-
Stepping Motor 1.
lnspect the signal voltage on the vehicle. (1) Measure the stepping motor operating voltage with the engine switch in the ON position. Standard: Between 3 and ground:
2.
Battery voltage
lnspect continuity individually. ( 1 ) Manually rotate the stepping motor shaft and check that it is rotated smoothly. (2) Measure the resistance between 1 and 3, 2 and 3, 4 and 3, and 5 and 3. Standard: 2.97 to 3.63 R (at 25°C)
(3) Measure the i n s u l a t i o n resistance between the stepping motor and each of terminals 1, 2, 3, 4 and 5. Standard: 100 MR or more (with a 500 V DC megger)
(4) After installing the stepping motor, manually turn the throttle lever in the full opening direction (full open, 112 open and 114 open) and release it. Check to see that the lever shall be returned smoothly by the spring force.
Ignition Relay
1.
lnspect continuity of the relay coil. Standard:
.
55
-
82 R
lnspect the ignition relay for proper functioning. (1) Connect the battery to the ignition relay and inspect the switch continuity. Standard: Continuity (2) Disconnect the battery from the relay, and inspect switch continuity. Standard: No continuity
Fuse
1.
Remove the fuse from the fuse box, and inspect it. (1) Check continuity between both terminals of the fuse. Standard: Between fuse terminals: 0 R (continuity) 7.5 A for ECU Fuse capacity:
Sensor and Switch Adjustment Acceleration Sensor Note: The acceleration sensor requires adjustment after the following jobs: Acceleration sensor part replacement (removal/installation) Accelerator pedal height adjustment Accelerator Pedal Height Adjustment Accelerator link stopper bolt
Accelerator link roller
Pedal stopper bolt
Accelerator link
1.
Return side pedal height adjustment Make adjustment by turning the accelerator link stopper bolt to make the height (A) from top of the accelerator link roller to the link bracket mounting surface satisfy the following standard: Standard Accelerator link roller height: A = 83 2 2 m m (3.35 2 0.08 in)
1
[::!A
top of floor to top of roller: C = 89.5 mrn 13.524 in)
2.
Depression side pedal height adjustment Make adjustment to make the pedal stopper bolt height (6)satisfy the following standard: Standard Pedal stopper bolt height: B = 50-E mm (1.97-:,,,
in)
Acceleration Sensor Adjustment
1.
See that the accelerator pedal heights (on the return and depression sides) are normal. (See the accelerator pedal height section.)
2. Remove the accelerator link bracket Wlsensor. (1) Accelerator link bracket set bolts (2) Acceleration sensor wiring disconnection (3) Accelerator link bracket Wlsensor
3.
Adjust the acceleration sensor mounting position. (Adjustment of ON-OFF transition point of IDL switch in sensor) (1) Loosen the sensor set screw. (2) Use a c i r c u i t t e s t e r a n d check ON-OFF of the acceleration sensor switch. Between connector terminals 1 and 2 (E2and IDL) Note: Carefully operate so as not t o damage the sensor terminals.
(3) lnsert a 0.8 mm (0.031 in) thickness gauge between the accelerator link stopper bolt and accelerator link.
Insert a thickness gauge here.
Accelerator link
(4) I n the state of (31, manually turn the acceleration
sensor gradually. Tighten the acceleration sensor set screw for fixing at the position where the signal is set from ON to OFF.
Accelerator link bracket
Acceleration sensor position adjusting standard
Thickness gage IDL switch 0.8 m m (0.031 in) : ON-OFF transition point 4.
Check the IDL ONIOFF state after fixing the acceleration sensor (between terminals 1 and 2 in the same way as in step 3). (1) lnsert each of the following thickness gauges between the accelerator link stopper bolt and accelerator link for confirmation: Acceleration sensor position adjustment standard (for confirmation)
Thickness gauge IDL switch 0.8 m m (0.031 in) : ON 1.0 mm (0.039 in) : OFF
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