Toyota 42 6fgu18 forklift service repair manual by 163048

FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 6FGUIGFDU15- 30. Please use this manual for providing quick, correct servicing of the corresponding forklift models. This manual deals with the above models as of July 1995. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due t o change in 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 t o this manual are as follows:

TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINE REPAIR MANUAL (N O. CE602-1) TOYOTA INDUSTRIAL EQUIPMENT GM4-181 ENGINE REPAIR MANUAL (No. CU629) TOYOTA INDUSTRIAL EQUIPMENT 1DZ ENGINE REPAIR MANUAL (No. CE618)

TOYOTA Material Handling Company A Division of TOYOTA INDUmIES CORPORATION

SECTION INDEX 7

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NAME

p p p

GENERAL ENGINE TORQUE CONVERTER PROPELLER SH DIFFERENTIAL FRONT AXLE REAR AXLE --

BRAKE -

A P

MATERIAL HANDLING MAST CYLINDER L I OIL PUMP ~ILCONTROLVALVE -APPENDIX --

: -

P -

---

- - -

GENERAL Page

EXTERIOR VIEWS ............................................... 0-2 VEHICLE MODEL ............................................... 0-3 FRAME NUMBER ................................................. 0-4 HOW TO READ THIS MANUAL .......................... 0-5

....................................... 0-5 TERMINOLOGY .................................................... 0-6 ABBREVIATIONS .................................................. 0-6 OPERATIONAL TIPS ............................................ 0-7 EXPLANATION METHOD

STANDARD BOLT & NUT TIGHTENING TORQUE ........................................................ 0-8 BOLT STRENGTH TYPE IDENTIFICATION METHOD .......................................................... 0-8

................................ 0-9 PRECOAT BOLTS ................................................ 0-10 TIGHTENING TORQUE TABLE

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE .....................................0-10 WIRE ROPE SUSPENSION ANGLE LIST

............. 0-11

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE ....................................... 0-11 COMPONENTS WEIGHT

..................................... 0-12

RECOMMENDED LUBRICANT QUANTITY & TYPES ........................................ 0-13 LUBRICATION CHART ........................................ 0-14 PERIODIC MAINTENANCE .................................. 0-15 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS ........................................... 0-21

EXTERIOR VIEWS

VEHICLE MODEL Series

Load capacity

Model

Engine model

Engine type

Drive system

42-6FGU 1 5

Gasoline

Torque converter

02-6FDU 1 5

1 DZ

Diesel

42-6FGU 1 8

Gasoline

02-6FDU 1 8

1 DZ

Diesel

42-6FGU20

Gasoline

52-6FGU20

62-6FDU20

1 DZ

Diesel

42-6FGU25

Gasoline

52-6FGU25

62-6FDU25

1 DZ

Diesel

02-6FGU30

Gasoline

52-6FGU30

62-6FDU30

1 DZ

Diesel

1.5 t o n 1 ton series 1.75 ton

2.0 ton

2 ton series

2.5 ton

3 ton series

3 . 0 ton

0-4

FRAME NUMBER Frame No. Punching Position

Punching position on the stiffener belo

Engine

Model

Punching format

42-6FGU 1 5 4Y

406FGU 18-6001 1 42-6FGU 1 8

1 ton series 02-6FDU 1 5 1 DZ

6FDU 18-6001 1 02-6FDU 1 8 42-6FGU20

406FGU25-60011 42-6FGU25 52-6FGU20

2 ton series

506FGU25-60011

GM 52-6FGU25 62-6FDU20

606FDU25-60011

1 DZ 62-6FDU25

3 ton series

02-6FGU30

6FGU30-60011

52-6FGU30

506FGU30-60011

1 DZ

62-6FDU30

606FDU30-60011

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 a photo or illustration. Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, followed by ex'planation of cautions and notes summarized a s point operations.

Example of description in pattern B

DISASSEMBLY-INSPECTION-REASSEMBLY

Tightening torque unit T = N.m (kgf-cm) [fb-lbfl

If a place or part cannot be indicated directly, the part name is described on the either side of the illustration. Example:

1 Piping

Disassembly Procedure 1 Remove the cover. [Point 11 2

Remove the bush [Point 21 4- Operation explained later

Remove the gear.

Point operations [Point 1 I

is assembly: [Point 21 Inspection:

Explanation of key point for operation with an illustration

d Put a match mark when removing the pump cover.

Measure the bush inside diameter. Bush inside diameter limit: 19.12 mm (0.7528 in)

H o w t o read components figures ( 1 ) The components figure uses the illustration in the parts catalog for the vehicle model. Please refer t o the catalog for checking the part name. The number at the right shoulder of each components figure indicates the Fig. number inthe parts catalog.

(Example)

FIG number in parts catalog

Matters omitted in this manual ( 1 ) This manual omits description of the following jobs, but perform them in actual operation @ Cleaning and washing of removed parts as required @ Visual inspection (partially described)

TERMINOLOGY Caution: lmportant matters of which negligence may cause accidents. Be sure to abserve them. Note: lmportant items of which negligence may cause accidents, or matters in operation procedure requiring special attention. Standard: Values showing allowable range in inspection and adjustment. Limit: Maximum or minimum allowable value in inspection or adjustment.

ABBREVIATIONS Abbreviation (code)

Meaning

Abbreviation (code)

Meaning

ASSY

Assembly

SST

Special service tool

Left hand

STD

Standard

LLC

Long life coolant

T =

Tightening torque

0PT

Option

O O T

Number of teeth (00)

01s

Oversize

UIS

Undersize

Power steering

With

Right hand

Less

SAE

Society of Automotive Engineers (USA)

OPERATIONAL TIPS 1.

Safe operation ( 1 ) After jacking up, always support w i t h rigid stands. ( 2 ) When hoisting the vehicle or its heavy component, use wire repe(s) w i t h a sufficient reserve in load capacity. ( 3 ) Always disconnect the battery plugs before the inspection or servicing o f electrical parts.

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 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 w i t h n e w 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 o f reassembly. If no tightening torque is specified, tighten the bolt or nut according t o the standard tightening torque table.

Grasping the trouble state When a trouble occurs, d o n o t attempt immediate disassembly or replacement b u t first check if the trouble requires disassembly or replacement for remedying.

0-8

STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and tightening torques are not indicated. Judge the standard tightening torque as shown below.

1. 2.

Find out the type of the bolt from the list below and then find the bolt tightening torque from the table. The nut tightening torque can be judged from the mating bolt type.

BOLT STRENGTH TYPE IDENTIFICATION METHOD 1.

lndentification by bolt shape

Identification by part No.

Hexagon head bolt

Bolt head No.

Parts No. 9161 1-40625

-LLength (mm) Diameter (mm)

iameter

T w o protruding

T w o protruding Stud bolt Three protruding

Part No. 92 1 32-406 14 Four protruding

Length (mm) Diameter (mm)

iameter

TIGHTENING TORQUE TABLE Specified torque Class

Diameter rnrn

Pitch rnm

Hexagon head bolt N.m

Bllll 1 kgf-crn

ft-lbf

6 8 10 12 14 16

1 .O 1.25 1.25 1.25 1.5 1.5

5.4 13 25 47 75 113

1 I

j 1

1 1

55 130 260 480 760 1150

6.4 16 32 59 91 137

1 I

65 160 330 600 930 1400

5 8 10 12 14 16

1 .O 1.25 1.25 1.25 1.5 1 .O 1.25 1.25 1.25 1.5 1.5

7.8 19 39 72 -

11 25 52 95 147 226

1.25 1.25 1.25

29 61 110

j j 1

19 35 55 83

56 in.-lbf 1 12 I 1 24 j 43 67 1101

1 1 t

1 I

1 1

110 260 530 970 1500 2300

1 1

8 1 19 I 1 38 I 1 70 108 j 166

1 I

It I

I I

79 123

1 1I

12 28 58 103 167

22 45 80

33 68 120

1 1 I

1 1

I I I I

1 1

I I I I I I I I

21 43

I I I I I I I I I I

I I I

52 in.-lbf 10

1 2 1 39 j 61

78 in.-lbf

215 440 810 1250

1 1 6 j 32 59 90

8.8

ft-lbf

290 540 850

300 620 1100

60 145

1 I

69 in.-lbf

I I I

I I

I I I

1 kgf-crn

14 29 53

195 400 730

8 10 12

5.9 14 28 53 83

1 1

48 in.-lbf 9

I I

6 8 10 12 14

i I

I I

1 .O 1.25 1.25 1.25 1.5 1.5

N.m

6 8 10 12 14 16

Hexagon flange bolt

120 290 590 1050 1700

j 9 1 2 1 I 1 43 I 1 76 :I23 I I

I I

330 690 1250

1 1 I

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 to the steps below.

2. Method for reuse of precoat bolts Wash the bolt and threaded hole. (The threaded hole must be washed even for replacement of the bolt.) ( 2 ) Parfectly dry the washed parts by air blowing. (3) Coat the specified seal lock agent t o the threaded portion of the bolt. (1

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 1.

When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with clean cloth t o remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before installation.

When connecting a high pressure hose, hold the hose t o align the fitting with the nipple and tighten the fitting.

The maximum tightening torque must not exceed twice the standard tightening torque.

Nominal diameter of screw

Tightening range

Standard

7116

20UNF

25 ( 250) [ 18.11

26 ( 240

9/16

18UNF

49 ( 500) [ 36.21

52 ( 480

16UNF

59 ( 600) [ 43.41

62 ( 570

718 - 14UNF

59 ( 600) [ 43.41

62 ( 570

718 - 14UNF

78 ( 800) [ 57.91

82 ( 760

1.1/16-12UNF

1 1 8 ( 1 2 0 0 ) [ 86.81

1.5116 - 12UNF

137 (1400) [101.31

PF 1 I 4

25 ( 250) [ 18.11

PF3/8

49 ( 500) [ 36.21

PF 1 I 2

59 ( 600) [ 43.41

PF314

11 8 (1200) [ 86.81

PF 1

137 (1400) [101.3]

314

Hose inside diameter mm (in)

Standard tightening torque N.m (kgf-cm) [ft-lbfl

270) [ I 7.4

630) L41.2 530) [34.7

19.51

6 (0.24)

38.31

9 (0.35)

45.61

12 (0.47)

- 840) I55.0 -

45.61

12 (0.47)

60.81

1 5 (0.59)

1 1 2 - 123(1140- 1250)[82.5-

90.41

19 (0.75)

630) l41.2

- 144 (1330 - 1470) [96.2 - 106.41 24 - 26 ( 240 - 270) 117.4 - 19.51 47 - 52 ( 480 - 530) [34.7 - 38.31 56 - 62 ( 570 - 630) 141.2 - 45.61 11 2 - 123 ( 1 140 - 1250) [82.5 - 90.41 130 - 144 (1330 - 1470) [96.2 - 106.41 130

25 (0.98) 6 (0.24) 9 (0.35) 12 (0.47) 19 (0.75) 25 (0.98)

WlRE ROPE SUSPENSION ANGLE LIST Lifting angle

Tension

Compression

1.OO time

0 time

Suspension method

Tension

Compression

1.41 time

1.OO time

Lifting angel

90 O

Suspension method

30 O

1.04 time

1 20째

0.27 time

b?\

,!z

2.00 time

1.73 time

60째

1.16 time

0.58 time

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE Cutting Rope load diameter

Single-rope suspension

unit:

N (ton) [lbfl

Four-rope suspension

Two-rope suspension

30째

60 O

90 O

30째

60O

90O

21 380 (2.18) [4807]

3040 (0.31) [683.61

6080 (0.62) [ 13671

5880

4310 (0.44)

(1.2) [2646]

10400 (1.06) [2337]

8630 (0.88) [ I 9401

31 480 8 mm (3.21) (0.32 in) [7078]

4410 (0.45) [992.3]

8830 (0.9) [I 9851

8530 (0.87) [I 91 81

7650 (0.78) [I7201

[970] 6280 (0.64) [I41 I ]

12160 (1.24) [27341

11770

[I 3231

5200 (0.53) [I1691

(1.8) 139691

17060 (1.74) [3937]

15300 (1.56) [34401

12550 (1.28) [23221

10 mm (0.4 in)

49230 (5.02) [l 1.691

6960 (0.71) [I565.61

14020 (1.43) [31531

13440 (1.37) 13021I

11770

9810

27460

26480

23540

19610

(1.2) [26461

(1.0) [22051

(2.8) [61741

(2.7) [59541

(2.4) [52921

(2.0) [44101

12.5 mm (0.5 in)

76880 (7.84) 1173871

10980 (1.12) [2469.5]

21570

21280

18630

14710

43150

41 190

37270

(2.2) [4851]

(2.1) [46311

(1.9) [41901

(1.5) [33081

(4.4) [97021

(4.2) [92611

(3.8) [83791

29420 (3.0) [66151

14 mm (0.56 in)

96400 (9.83) [21675]

13730

27460

26480 (2.7) [59541

23540

18630

(2.4) [52921

(1.9) [4190]

6 mm (0.24 in)

(1.4) [30871

(0.6)

17650

52960 47070 37270 (3.8) (5.4) (4.8) (5.6) [I23481 [ I 19071 [ l o 5 8 4 1 183791 54920

COMPONENTS WEIGHT

Unit:

Component

Engine

Weight (mass) 4Y

1 3 4 (295)

1 5 0 (331)

1DZ

176 (388)

For 1 speed

128 (282)

For 2 speeds

163 (359)

1.5 ton model

Approx. 785 ( 1731)

1.75 ton model

Approx. 925 (2040)

2.0 ton model

Approx. 1 1 6 0 (2558)

2.5 ton model

Approx. 1470 (3241)

3.0 ton model

Approx. 1880 (4145)

1 ton series

Approx. 41 0 (904)

2 ton series

Approx. 5 1 0 (1 125)

3 ton series

Approx. 5 9 0 ( 1301)

1 ton series

Approx. 3 4 0 (750)

2 ton series

Approx. 41 5 (915)

3 ton series

Approx. 465 ( 1025)

Torque converter

Balance weight

V mast ASSY Wllift bracket (with lift cylinder, without fork, max. lifting height: 3000 m m ( 11 8 in))

V mast ASSY Lllift bracket and fork (with lift cylinder max. lifting height: 3 0 0 0 m m (118 in))

kg (Ib)

RECOMMENDED LUBRICANT QUANTITY & TYPES Classification

Description

Gasoline

Motor oil SAE30 (SAE20 in cold area)

API SD, SE

SAE20W-40 (SAE1OW-30 in cold area)

Engine

Diesel

Torque converter

Diesel engine oil SAE30 (SAE2O in cold area)

API CC, CD or better

Hydraulic oil [Max. for height = 3 0 0 0 m m ( 11 8 in)]

Hypoid gear oil SAE85W-90

IS0 VG32

Hydraulic oil

SAE J - 1 7 0 3

Brake line Chassis parts

Coolant (Reservoir Tank)

Attached Table 1

4.0 1 ( 1 . 0 6 US gal)

3.8 1 ( 1.OO US gal)

1 DZ

7 . 9 1 (2.09 US gal)

1-speed

11.5 1 ( 3 . 0 4 US gal)

2-speed

14.0 C (3.70 US gal)

1 ton series

5.4 C (1.43 US gal)

2 t o n series

6.4 C ( 1 . 6 9 US gal )

3 t o n series

9.0 1 (2.38 US gal)

1 ton series

2 7 1 (7.1 US gal)

2 ton series

3 4 1 (9.0 US gal)

3 t o n series

3 7 1 ( 9 . 8 US gal)

1 t o n series

4 5 1 ( 11.9 US gal)

2 t o n series

6 5 1 ( 1 7 . 2 US gal)

3 t o n series

6 5 C ( 17.2 US gal)

All models

Proper quantity Reservoir Tank 0 . 2 C (0.05 US gal)

All models

Proper quantity

G M Dexronm I1

ATF

Fuel tank

Coolant (exclulding reservoir tank)

Quantity

SAE 1 OW-30

API GL-4 GL-5

Differential

Application

Type

LLC 3 0 -5 0 % mixture (for winter or all-season) Cooland w i t h rustinhibitor (for spring, summer and autumn)

LLC

Attached Table 1 Coolant volume

All models

Coolant volume

1.1 C ( 0 . 2 9 US gal) (at Full level)

Unit:

l (US gal)

Engine

1 t o n series

2 ton series

3 ton series

9 . 6 (2.53)

9 . 3 (2.46)

9.6 (2.53)

8 . 8 (2.32)

8 . 3 (2.19)

GM 1 DZ

8.1 (2.14)

LUBRICATION CHART

Inspection Replacement @ M P grease @ Engine oil @ Hypoid gear oil @ Hydraulic oil @ Automatic transmission fluid @ Brake flluid Molykote G-n paste

I. II. Ill. IV. V.

Chain Differential gear Front wheel bearing Brake master cylinder Torque converter case Rear wheel bearing Steering knuckle king pin Power steering cylinder pin Oil tank

10 11 12 13 14 15

lnspect lnspect lnspect lnspect lnspect

Engine crankshaft Tilt steering locking mechanism Mast support bushing Tilt cylinder front pin Propeller shaft Oil pump spline shaft (GM engine model)

every every every every every

8 hours (daily) 4 0 hours (weekly) 1 7 0 hours (monthly) 1 0 0 0 hours ( 6 monthly) 2 0 0 0 hours (annually)

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 Every 1 month

Every 3 months

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

Rotating condition at idling

Rotating condition during acceleration

Exhaust gas condition

Air cleaner element

Inspection Period Item

Every

ENGINE Proper starting and abnormal noise

Main body

Valve clearance

Compression

Cylinder head bolt loosening

Muffler rubber mount

PCV system

Cologging and damage in PCV valve and piping

Governor

No-lead maximum rpm

Lubrication system

Fuel system

Oil leak

Oil level

Clogging and dirt of oil filter

Fuel leak

Operation of carburetor link mechanism

Dirt and clogging of fuel filter and element

Injection timing lnjection nozzle injection pressure and spray status

Draining of sedimenter

Cooling system

Coolant level in radiator and leak

Rubber hose degradation

Radiator cap condition

Fan belt tension, looseness and damage Radiator rubber mount

Every 1 month

Every 3 months

Every 6 months

Every 12 months

Every 1 7 0 hours

Every 5 0 0 hours

Every 1 0 0 0 hours

Every 2 0 0 0 hours

Leak

Oil level

Inspection Period Item POWER TRANSMISSION SYSTEM

Differential

Bolt loosening

Torque converter and transmission

Leak

Fluid level

Operating mechanism function and looseness

Control valve and clutch functions

Inching valve function

Stall and hydraulic pressure measurement Propeller shaft and axle shaft

Loose joint Looseness of universal joint

Twisting and cracks of axle shaft

DRIVE SYSTEM

Wheels

Tire inflation pressure

Tire cuts, damage and uneven wearing

Loose rim and hub nuts

Tire groove depth

Metal chips, pebbles and other foreign matter trapped in tire grooves

Rim, side ring and disc wheel damage

Abnormal sound and looseness of front wheel bearing

Abnormal sound and looseness of rear wheel bearing

Front axle

Crack, damage and deformation of houseing

Rear axle

Cracks, damage and deformation of beem

Every 1 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

Play and looseness

Function

Oii leak

Looseness of mounting

Oil leak

Mounting and linkage looseness

Inspection Period Item STEERING SYSTEM Steering wheel Steering valve Power Steering

Damage of power steering hose King pin looseness Knuckle

Cracks and deformation

BRAKING SYSTEM Brake pedal

Parking brake

Brake pipe

Play and reserve

Braking effect

Operating force

Braking effect

Rod and cable looseness and damage

Leak, damage and mounting con-

dition Reservoir tank

Leak and fluid level

Master cylinder and wheel cylinder

Function, wear, damage, leak and mounting looseness

Clearance between drum and lining

Brake drum and brake shoe

Backing plate

Wear of shoe sliding portion and lining

Drum wear and damage

Shoe operating condition

Anchor pin rusting

Return spring fatigue

Automatic adjuster function

Deformation, cracks and damage

Loose mounting

MATERIAL HANDLING SYSTEM

Forks

Abnormality of fork and stopper pin

Misalignment between left and right fork fingers

Cracks at fork root and welded part

I+'

Every 1 month

Every

3 months

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

Deformation and damage of each part and crack at welded part

Mast and lift bracket looseness

Inspection Period Item

Mast and lift bracket

Wear and damage of mast support bush Wear, damage and rotating condition of rollers

I I

Wear and damage of roller pins

Chain and chain wheel

Various attachments

Wear and damage of mast strip

Tension, deformation and damage of chain

Chain lubrication

Abnormality of chain anchor bolt

Wear, damage and rotating condition of chain wheel

Abnormality and mounting condition of each part

Loosening and damage of cylinder mounting

Deformation and damage of rod, rod screw and rod end

Cylinder operation

Natural drop and natural forward tilt (hydraulic drift)

Oil leak and damage

Wear and damage of pin and cylinder bearing

HYDRAULIC SYSTEM

Cylinder

Lifting speed

Oil pump Hydraulic oil tank

Control lever

Uneven movement

Oil leak and abnormal sound

Oil level and contamination

Tank and oil strainer Oil leak

Loose linkage

Operation

Inspection Period Item Oil leak Oil control valve

Hydraulic piping

Every 1 month

Every 3 months

Every 6 months

Every 12 months

Every 1 7 0 hours

Every 500 hours

Every 1000 hours

Every 2000 hours

Relief pressure measurement Relief valve and tilt lock valve functions

Oil leak

Deformation and damage

Loose joint

Cracks on distributor cap

Spark plug burning and gap

Distributor side terminal burning

Distributor cap center piece wear and damage

ELECTRICAL SYSTEM

lgnition timing

Plug cord internal discontinuity Ignition timing

Starting motor

Pinion gear meshing status

Charger

Charging function

Battery fluid level

Battery

Battery fluid specific gravity

Electrical wiring

Damage of wiring harness

Fuses

Preheater

Open-circuit in glow plug

Engine stopping system

Diesel engine key stop device function

Cracks at welded portion

Deformation and damage

Loosening of mounting

Deformation, crack and damage

Lighting system

Function and mounting condition

Horn

Function and mounting condition

SAVETY DEVICES, ETC. Head guard

Back-rest -

Inspection Per~od Item

Every 1 month

Every

3 months

6 months

Every 12 months

Every 170 hours

Every 500 hours

Every 1000 hours

Every 2000 hours

Direction indicator

Function and mounting c o n d ~ t ~ o n

Instruments

Functions

Backup buzzer

Function and mounting condition

Rear-view mirror

Dirt, damage

Rear reflection status

Seat

Loosening and damage of mounting

Mounting looseness

Webbing damage

Plate damage

Buckle damage

Seat belt

Body

Others

Damage and cracks of frame, cross members, etc.

Bolt looseness

Grease up

PERIODIC REPLACEMENT QF PARTS AND LUBRICANTS

a:Replacement Every 1 month

Every

3 months

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

Engine oil

•

Engine oil filter

Interval Item

• •

Engine coolant (every 2 years for LLC)

• • •

Fuel filter Torque converter oil Torque converter oil filter

++t

•

Differential oil

• •

Hydraulic oil Hydraulic oil return filter

@*I

•

Wheel bearing grease

•

Spark plugs

Air cleaner element

•

Cups and seals for brake master and wheel cylinders

•

Brake fluid

a+2 ax2 ax2 ax2 a*2 a*2 ax3

Power steering hoses Power steering rubbers parts Hydraulic hoses Brake fluid reservoir tank hose Fuel hoses Torque converter rubber hoses Chains *I:

for n e w vehicle

*2:

Every 2 years

*3:

Every 3 years

Replacement shall be made upon arrival o f the operation hours or months, whichever is earlier.

ENGINE Page

.................................1-2 MAJOR SPEClFlCATlONS ................................... 1-5 ENGINE PERFORMANCE CURVES ...................... 1-6 ENGINE ASSY .................................................... 1-8 ENGINE EXTERIOR VIEWS

ENGINE WITORQUE CONVERTER REMOVAL.INSTALLATION ................................. 1-8

........................ 1-11 ENGINE SPEED ADJUSTMENT ........................... 1-I3 AIR CLEANER ...................................................... 1-17 ENGINE REMOVAL.INSTALLATION

RADIATOR .......................................................... 1-21 MUFFLER & EXHAUST PIPE ............................... 1-23 BATTERY ............................................................. 1-27 STARTING MOTOR ............................................. 1-29 ALTERNATOR .................................................... 1-30 ACCELERATOR PEDAL ....................................... 1-32

ENGINE EXTERIOR VIEWS 4 Y Engine

G M Engine

1 DZ Engine

MAJOR SPECIFICATIONS Gasoline Engines 4Y ( 1 . 2 ton series)

4Y ( 3 ton series)

GM ( 2 . 3 series)

Engine type

Gasoline 4-cycle

Number of cylinders and arrangement

lnline 4-cylinder . longitudinal

Wedge type

OHV.chain drive

OHV.gear drive

x 86.0 x 3.386)

101.6 x 91.4 (4.000 x 3.600)

2965 (241.96)

Combustion chamber type Valve mechanism Bore x Stroke Total displacement Compression ratio Maximum power Maximum torque

cc (cu-in)

2237 (136.51)

I P S I ~ D I~ kgf-mlrpm

Maximum specific fuel consumption Service weight

91.0 (3.583

mm (in)

kg (lb)

No-load maximum rpm

rPm

1 /

8.8 5412400

I I

5812600

I I

8.2

6012400

16.511 8 0 0

1911 4 0 0

1 3 4 (295)

1 5 0 (331)

2650

2800

2600

Diesel Engines

Engine type Number of cylinders and arrangement Combustion chamber type Valve mechanism Bore x Stroke Total displacement

mm (in) cc (cu-in)

Compression ratio

1DZ (1 ton series)

1 DZ ( 2 . 3 ton series)

Diesel 4-cycle

In line 4 cylinder . longitudinal

Vortex chamber type

OHVgear drive

86.0 x 107.0 (3.386 x 4.213)

2486 ( 151.71)

21.5

Maximum power

PSIrpm

5512400

6012600

Maximum torque

kgf-mlrpm

17.0 ( 1600)

18511 400

176 (338)

2600

2800

Maximum specific fuel consumption Service weight No-load maximum rpm

SIPS-h (rpm) kg (Ib) rPm

1-6

ENGINE P E R F O R M A N C E C U R V E S 4 Y Engine

-Gasoline --- ---

-Gasol~ne LPG Only

-- -

LPG Only

- - - - - - Gasol~neand LPG 16.0/1800

-g t 5

50'

40-

30-

20-

10-

:2 0 10

1'0

1'4 1'8 2'2 Engine Speed Irpml

2$X 10'

14 18 22 26 Engine Speed lrpml

3 ton series

1.2 ton series

GM Engine

14 18 22 26 Englne Speed Irpml

30x102

3Ox1O2

1 DZ Engine I

14 18 22 Engine Speed lrprnl

1 ton series

26x10' Eng~neSpeed lrprnl

2.3 ton series

ENGINE ASSY ENGINE WITORQUE CONVERTER REMOVAL-INSTALLATION

Removal Procedure 1

Remove the radiator cover.

Remove the engine hood.

Remove the toe board.

Remove the battery and battery case.

Remove the radiator reservoir tank and bracket.

Remove the air cleaner.

Remove the flame side cover

Drain the coolant.

Remove the radiator and fan shroud.

1 0 Disconnect the exhaust pipe. 11

Disconnect the fuel hose. [Point 1I

1 2 Disconnect the accelerator wire (on the carburetor side in gasoline engine models, or on the injection pump side in diesel engine models). 1 3 Remove the oil pump Wlpump hose. ( 4 Y - 1DZ) Disconnect the pump universal joint. (GM) 1 4 Remove the horn.

1 5 Disconnect the shift lever link rod 1 6 Disconnect the inching wire. 17

Disconnect the torque converter cooler hose.

1 8 Disconnect the electrical wiring. 1 9 Remove the propeller shaft cover and propeller shaft. 2 0 Remove the torque converter mounting set bolts. 21

Remove the engine mounting set nuts.

2 2 Remove the engine Wltorque converter. [Point 21

Installation Procedure The installation procedure is the reverse of the removal procedure.

Note: Carry out the following job after engine installation: Air bleeding from fuel system (in diesel engine models only1 Inching wire adjustment (see page 8 -2 8 . ) The tightening torque for each parts is as follows. 88 N.m ( 5 0 0 9 0 0 kgf-cm) 136 6 5 ft-lbfl Torque converter mounting bolt. T = 4 9 9 9 . 0 N - m ( 5 5 0 1 0 1 0 kgf-cm) 139.8 7 3 . 1 ft-lbfl T = 53.9 Engine mounting set nut.

1-10

Bleeding Air from Fuel System (Diesel engine model) IDZ engine Operate the fuel filter band pump unit till the pump operation becomes heavy t o indicate the end of air bleeding.

Point Operations [Point 1I

Removal: Installation:

Always close the fuel piping cock. Do not mistake the fuel hose connecting position. (Gasoline engine model.)

[Point 21

Removal. Installation: SST 0 9 0 1 0-201 1 1-7 1 Removal: Remove after checking through disconnection of the wiring, hoses and cables.

ENGINE REMOVAL-INSTALLATION Note: The procedure described here covers the jobs after removing the engine Wltorque converter.

Removal Procedure 1

Remove the cover plate.

Remove the drive plate set bolts ( 6 pcs.). [Point 11

Slightly hoist the torque converter housing

Remove the torque converter housing and engine connecting bolts t o disconnect the torque converter housing, and remove the engine.

Remove the flywheel.

Remove the starting motor.

Remove the torque converter end plate.

Installation Procedure The installation procedure is the reverse of the removal procedure. Note: Tighten the flywheel set bolts after applying thread tightener ( 0 8 8 3 3 -0 0 0 7 0 ) . The tightening torque for each part is as folldws:

Unit: Torque converter end plate set bolts Drive plate set bolts (for connecting to the engine crankshaft)

49.03

78.45 ( 5 0 0

N . m (kgf-cm) [ft-lbfl

800) [36.18

57.881

660) L41.96 - 47.751 4Y: 56.88 - 64.72 ( 5 8 0 G M I D Z : 76.49 - 93.16 ( 7 8 0 950) [56.43 - 68.731

Drive plate set bolts (flywheel set bolts) (for connecting to torque converter)

14.71

21.57 ( 1 5 0

- 220) [10.85 - 15.921

Torque converter housing set bolts

29.42

44.13 ( 3 0 0

450) [21.71

32.561

Point Operations [Point 1 I

-iT

Removal~lnstallation: Rotate the flywheel by using a crankshaft pulley set bolt.

ENGINE SPEED ADJUSTMENT

4 Y . G M Engine

Tachometer Tachometer

Idle up and Idling Speed Inspection and Adjustment 1.

Warm up the engine.

Coolant temperature: 80°C (176OF) or above Engine oil: 70°C (158OF) or above Hydraulic oil temperature: 50°C (122OF) or above Auto choke cancellation

connector

2. 3.

Install the engine tachometer. lnspect and adjust the idle up speed. ( 1) Disconnect the idle up actuator hose and inspect the idle up speed.

4Y: 1 2 5 0 & 25 rpm GM: 1 0 5 0 & 5 0 rpm

(2) Turn the adjusting screw (A) t o adjust the idle up speed. Increasing the speed: Clockwise turn Decreasing the speed: Counterclockwise turn (3) Connect the idle up'actuator hose. 4.

lnspect and adjust the idling speed. ( 1) lnspect the idling speed.

Idling speed 4Y: 7 5 0 GM: 7 0 0

+zO rpm +zO rpm

(2) Turn the idle adjusting screw (B) t o adjust the idling speed. (3) If the speed cannot be decreased b y turning the adjusting screw (B), make adjustment as follows:

Raise the coolant temperature when the auto choke cam is in contact with the throttle lever roller.

@ When the idle up actuator rod is in contact w i t h the adjusting screw (A), turn the adjusting screw counterclockwise.

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