Page 1

FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 6FGCU33-45. 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 due 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 MOTOR CORPORATION


SECTION INDEX NAME

SECTION

0 a ENGINE TORQUE CONVERTER FRONT AXLE

REAR0 A

STEERING

BRAKE 0

MATERIAL HANDLING SYSTEM MAST CYLINDER

APPENDIX

0 0


GENERAL Page

EXTERIOR VIEWS

...............................................

0-2

VEHICLE MODEL FRAME NUMBER ................... 0-3 m

......................... 0-4 EXPLANATION METHOD ...................................... 0-4 TERMINOLOGY ................................................... 0-5 ABBREVIATIONS ................................................. 0-5

HOW TO READ THIS MANUAL

OPERATIONAL TIPS

...........................................0-6

STANDARD BOLT & NUT TIGHTENING TORQUE .......................................................... 0-7 BOLT STRENGTH TYPE IDENTIFICATION METHOD ......................................................... 0-7

............................... 0-8 PRECOAT BOLTS ............................................... 0-9 TIGHTENING TORQUE TABLE

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 PERIODIC MAINTENANCE

..................................0-14

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS ........................................... 0-20


0-2

EXTERIOR VIEWS


VEHICLE MODEL-FRAME NUMBER Model

Load capacity * ton (Ib)

Engine

Drive system

Torque converter L

*:

When t h e load center is 600 mm (24 in).

Frame No. punching position

Punching position (Upper surface of frame RH)

Punching format


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 w i t h 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 B DISASSEMBLY -1NSPECTION.REASSEMBLY

Tightening torque unit T = N,m (kgf-cm) [ f b

disassembly Procedure 1

Remove the cover. [Point 11

2

Remove the bush [Point 2) c Operation explained later

3

Remove the gear.

Point operations

Explanation of key point for operation with an illustration

I

[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 c o m p o n e n t s figures ( 1 ) T h e c o m p o n e n t s figure uses t h e ~ l l u s t r a t i o n i n t h e p a r t s catalog for t h e vehicle m o d e l . Please refer t o t h e catalog f o r c h e c k i n g t h e p a r t name. T h e n u m b e r a t t h e right shoulder o f e a c h components figure indicates the Fig. number in t h e p a r t s catalog.

(Example)

FIG number in parts catalog

2

M a t t e r s o m i t t e d in this manual

( 1 ) T h i s m a n u a l o m i t s description o f t h e f o l l o w i n g jobs, b u t perform t h e m i n actual operation

8

Cleaning a n d w a s h i n g of r e m o v e d p a r t s a s required Visual inspection (partially described)

TERMINOLOGY Caution: Important 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 respecial attention. -

-

Standard: Values s h o w i n g allowable range in inspection and adjustment. L i m i t : M a x i m u m or m i n i m u m allowable value in inspection or adjustment.

ABBREVIATIONS Abbreviation (code)

I

ASSY

1

L/ LH

Assembly

I

Full hydraulic power steering

FHPS

I

Abbreviation (code)

Meaning

! !

Less Lefthand

I I

LLC

1

Long life coolant

I

I

0PT

1

Option

1

I

01s

1

Oversize

1

Power steering

I

STD

1 !

T =

1

s ST

0

O T

U/S W/

Righthand Society of Automotive Engineers (USA)

SAE

I

PS

RH

Meaning

Special service tool -

-

Standard Tightening torque

I Number of teeth 1

Undersize With

(0 0I


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 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 Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge, etc.) and SSTs before starting operation. Before disconnecting wiring, always check the cable color and wiring state. When overhauling functional parts, complicated portions or related mechanisms, arrange the disassembled parts neatly t o prevent confusion. When disassembling and inspecting such a precision part as the control valve, use clean tools and operate in a clean location. Follow the described procedures for disassembly, inspection and reassembly. Replace gaskets, packings and O-rings w i t h n e w ones each time they are disassembled. Use genuine Toyota parts for replacement. 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, d o not attempt immediate disassembly or replacement but first check if the trouble requires disassembly or replacement for correction.


STANDARD BOLT & NUT TIGHTENING TORQUE How to judge tightening torque of a standard bolt or nut

1.

How t o 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.

ldentification by bolt shape Shape and class

00

Bolt head No.

Hexagon head bolt

No mark

Class

ldentification by part No.

Hexagon head bolt

4 = 4T 5 = 5T 6 = 6T 7 = 7T 8 = 8T

/

Part No. 91 61 1-40625 Length (rnm) Diameter (mrn)

L Class

4T

iarneter

Hexagon flange bolt

H Length

Hexagon head bolt

T w o protruding lines

Hexagon flange bolt

T w o protruding lines

Hexagon head bolt

Hexagon head bolt

0

Three protruding lines

Four protruding lines

Stud bolt

/

Part No. 92132-40614

TTL I

Length (mm)

Diameter (rnrnl

L- Class

Welded bolt

No mark Stud bolt Grooved

I Length


TIGHTENING TORQUE TABLE Specified torque Class

Diameter mm

Pitch mm

Hexagon flange bolt

Hexagon head bolt N.m

I

kgf-cm

I

ft-lbf

N.m

5.9

14 28 53 83 I

6.4

59 91 137

65

I 1

600 930

19 39 72 -

1 I I I I

I I I 1

1 2 9

730

1

-

I I

53 -

25

1

260

1

530 970

21 43

79 123

I 1 I 1

1

8

12

19

28

38 70

58 103 167

11500

1108

226

1 I I I I 1 I

2300

166 I

-

300

I

22

33

620

I I I

45

68

1 8 0

120

11100

1 I I

1

1 1 I

90 215 440 810 1250

I

147

110

8.8

I

110

61

52 in-lbf

1

78 in-lbf

67

400

I 1

29

I

43

195

80

11

95

60

56 in-lbf

I

I

52

/

1 101 1 69 in-lbf 1 14

1400

I

7.8

1 I I I I I I I I I I

I

1

1 1 1 1

ft-lbf

kgf-cm

I I

I 1 I

1

1 / 1 I I I 1 I I I 1

1

3

I 1 I I

16 2 59 90

I

120

I 1

290 590 1050 1700 -

330 690 1250

9 21

1 43 1 7 6 1 123 I I I 1 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 to 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 w i t h 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 torque N.m (kgf-cm) [ft-lbfl Standard

Tightening range

Hose inside diameter rnm (in)


WIRE ROPE SUSPENSION ANGLE LIST Tension

Compression

0 time

1.41 time

1.OO time

1.04 time

0 . 2 7 time

2.00 time

1.73 time

1.16 time

0 . 5 8 time

Tension

Compression

1.OO time

Suspens~on method

Suspension angle

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE Rope diameter

Cutting load

6 mm (0.24 in)

Single-rope suspension 0O 3040 (0.31) 1683.61 4410 (0.45) 1992.31

10 mm (0.4 in) 12.5 mrr ( 0 . 5 in) 14 rnm (0.56 ~ n )

6960 (0.71) 11565.61 10980 (1.12) 12469.51 13730 (1.4) [30871

Two-rope suspension

unit:

Suspension method

N (ton) [lbfl

Four-rope suspension


COMPONENTS WEIGHT Nnit: Weight (mass)

Component

185 (408)

GM6-262

Engine Transmission W/ differential

Approx. 200 (441)

Torque converter W/ differential

Approx. 360 (794) Approx. 2000 (4410) "Approx. 2450 (5400)

3.25 ton model I

Counterweight

Approx. 2340 (5160)

3.5 ton model 1 5 t o n model

V mast ASSY Ltbackrest and fork (with lift cylinder max. lifting height: 3000 mm (118 in))

I

Approx. 890 (1960)

3. 25-3.5ton model

Approx. 1140 (2510)

4.5 ton model 1

*: Compact specification model (52-6FGCU35BCS) (OPT)

Approx. 3180 (7010)

1

kg (Ibf)


RECOMMENDED LUBRICANT QUANTITY & TYPES Application

Engine

I

1 $:

Motor oil SAE 30 (SAE 20 in cold area) SE, SF

Torque converter

ATF

Differential

API GL-4 GL-5

Planetary gear Hydraulic oil [Max. fork height = 3000 mm (118 in)]

All models

Hypoid gear oil SAE85W-90

/ D,

Hydraulic oil IS0 VG32

LLC

tank)

Coolant (Reservoir Tank)

'r

Q (1.11 US gal)

All models

15 l (4.0 US gal)

All models

9.5 1 (2.51 US gal)

All models

One side: 0.5 Q (0.13 US gal)

All models

68 & (18.0 US gal)

-

Propeller shaft and

4.2

SAE20W-40 (SAE1OW-30 in cold area)

3.25 3.5 ton model

I Coolant (excluding reservoir

Quantity

95

Q (25.1 US gal)

4.5 ton model

120 Q (31.7 US gal:

MP grease

All models

Proper quantity

Molybdenum disulfide grease

All models

LLC 30-50% mixure (for winter or allseason) * Coolant with rust inhibitor (for spring, summer and autumn)

All models

13.0 Q (3.43 US gal)

'r

All models

1.1 Q (0.29 US gal) (at Full level)


Torque Converter Model (W/ FHPS)

0 Replacement @ MP grease Engine 011

@ H y p o ~ dgear 011 @ Hydraul~c011 (E3 Automatic transmlsslon f l u ~ d Molybdenum disulfide grease

a

Cham D i f f e r e n t ~ agear l Planetary gear Torque converter case Rear wheel bearmg Steermg knuckle kmg pln Power steering cylinder pin and tie-rod 011tank Engine crankshaft

1. II. 111. IV. V.

lnspect every 8 hours (dally) lnspect every 4 0 hours (weekly) lnspect every 1 7 0 hours (monthly) lnspect every 1 0 0 0 hours ( 6 monthly) lnspect every 2 0 0 0 hours (annually)

Rear axle beam front Rear axle beam rear Tdt steerlng uncversal jomt T ~ l steering t l o c k ~ n gmechan~sm Mast support bush~ng Tdt cylmder front pln Propeller shaft 011pump splme shaft T ~ l cylrnder t rear pln


PERIODIC MAINTENANCE INSPECTION METHOD I : Inspection. Repair o r replacement if required. M : M e a s u r e m e n t . Repair or adjustment i f required. T : R e t i g h t e n i n g C : Cleaning L : Lubrication * : F o r n e w vehicle * 1 : F l a w d e t e c t o r Inspection period

Item ENGINE Proper starting and abnormal noise Rotating condition at idling Rotating condition during acceleration Basic components

Exhaust gas condition Air cleaner element Valve clearance Compression Cylinder head bolt loosening Muffler rubber mount

PCV system

Clogging and damage in PCV valve and piping

Governor

No-load maximum rpm Oil leakage

Lubrication system

Oil level Clogging and dirt of oil filter Fuel leakage

Fuel system

Operation of carburetor link mechanism Dirt and clogging of fuel filter and element Coolant level in radiator and leak Rubber hose degradation

Cooling system

Radiator cap condition Fan belt tension, looseness and damage Radiator rubber mount

Every month

Every 3 months

6 months

Every 1 2 months

Every 1 7 0 hours

Every 500 hours

Every 1 0 0 0 hours

Every 2 0 0 0 hours

Every


Inspection period

Every 1 7 0 hours

Item POWER TRANSMISSION SYSTEM Oil leakage Differential

Oil level Bolt loosening Leakage Fluid level

Torque converter and transmission

Operating mechanism function and looseness Control valve and clutch functions Inching valve function Stall and hydraulic pressure measurement Loose joint

Propeller shaft and axle shaft

Looseness at spline connections Looseness of universal joint Twisting and cracks of axle shaft

DRIVE SYSTEM Tire cuts, damage and uneven wear Loose rim and hub nuts Tire groove depth Metal chips, pebbles and other foreign matter trapped in tire grooves Wheels

Rim, side bearing and disc wheel damage Abnormal noise and looseness of front wheel bearing Abnormal noise and looseness of rear wheel bearing

Front axle

Every month

Crack, damage and deformation of housing Crack, damage and deformation of beam

Rear axle Looseness of axle beam in vehicle longitudinal direction

.

Every 3 months

Every 6 months

Every 12 months

Every 5 0 0 hours

Every 1 0 0 0 hours

Every 2 0 0 0 hours


Every month

Every 3 months

Every 6 months

Every 1 2 months

Every 1 7 0 hours

Every 5 0 0 hours

Every 1000 hours

Every 2 0 0 0 hours

Play and looseness

I

t

t

t

Function

I

t

t

t

Oil leakage

I

t

t

t

Looseness of mounting

T

t

t

t

Oil leakage

I

t

t

t

Mounting and linkage looseness

I

t

t

t

I

t

+

t

Inspection period

I STEERING SYSTEM Steering wheel Steering valve Power Steering

Damage of power steering hose King pin looseness

Knuckle

I

Crack and deformation

I

, BRAKING SYSTEM

Play and reserve

Brake pedal

Braking effect

I Operating force Parking brake

I

1

Brake pipe

Braking effect

I

t

Rod and cable looseness and damage

I

t

Leak, damage and mounting condition

Brake booster and wheel cylinder

Function, wear, damage, leak and mounting looseness

Clearance between drum and lining

M

Wear of shoe sliding portion and lining Brake drum and brake shoe

Drum wear and damage Shoe operating condition Anchor pin rusting Return spring fatigue Automatic adjuster function

Backing plate

I

Deformation, crack and damage

I Loose mounting

MATERIAL HANDLING SYSTEM

Forks

Abnormality of fork and stopper pin

I

t

+-

+-

Misalignment between left and right fork fingers

I

t

4-

4-

Crack at fork root and welded part

I*'


Deformation and damage of each part and crack at welded part Mast and lift bracket looseness blast and lift bracket

Wear and damage of mast support bush Wear, damage and rotating condition of rollers Wear and damage of roller pins Wear and damage of mast trip Tension, deformation and damage of chain

Chain and chain wheel

Chain lubrication Abnormality of chain anchor bolt Wear, damage and rotating condition of chain wheel1

Various attachments

Abnormality and mounting conditior of each part

HYDRAULIC SYSTEM Loosening and damage of cylinder mounting Deformation and damage of rod, roc screw and rod end Cylinder operation Cylinder

Natural drop and natural forward tilt (hydraulic drift) Oil leakage and damage Wear and damage of pin and cylinder bearing Lifting speed Uneven movement Oil leakage and abnormal sound Oil level and contamination

Hydraulic oil tank

Tank and oil strainer Oil leakage

Control lever

Loose linkage Operation

Every month

Every 3 months

Every 6 months

Every 12 months

Every 170 hours

Every 500 hours

Every 1000 hours

Every 2000 hours


Every

Inspection period

12 months Every

Every

1 7 0 hours Oil leakage Oil control valve

t

Relief pressure measurement Relief valve and tilt lock valve functions Oil leakage

Hydraulic piping

Every 2000 hours

Deformation and damage

1

Loose joint ELECTRICAL SYSTEM Crack at distributor cap Spark plug burning and gap Distributor side terminal burning lgnition timing

Distributor cap center piece wear and damage 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

SAVETY DEVICES, ETC. Crack at welded portion

I

+

+-

+-

Deformation and damage

I

+-

+-

+-

Loosening of mounting

T

+-

+-

t

Deformation, crack and damage

I

t

t

t

Lighting system

Function and mounting condition

I

+-

+-

t

Horn

Function and mounting condition

I

4-

t

t

Head guard

Back-rest


Every month Every 1 7 0 hours

I

Direction indicator

Function and mounting condition

Instruments

Functions

Backup buzzer

Function and mounting condition

Rear-view mirror

Dirt, damage Rear reflection status Loosening and damage of mounting Damage and crack of frame, cross members, etc. Bolt looseness Grease up

Every

Every

Every 12 months Every 2000 hours


1 1 1 1 ;1:; 1

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS Interval

I Engine oil

I

e:

Replacement

Every month

Every 3 months

Every 6 months

1 2 months

Every 1 7 0 hours

Every 5 0 0 hours

Every 1 0 0 0 hours

2 0 0 0 hours

.

I

C

I

C

I

C

I

Engine oil filter

0

c

c

Engine coolant (every 2 years for LLC)

0

c

c

Fuel filter

0

c

Torque converter oil

0

+

Torque converter oil filter

0

c

I

Differential oil

1

I

1

.

1 1

--

0

Planetary gear oil Hydraulic oil

*.

Hydraulic oil return filter

l

0

c

0

c

0

Wheel bearing grease

0

Spark plugs

I Air cleaner element

I

1

I

I

I

I

t

Cups and seals for brake booster and wheel cylinders Power steering hoses Power steering rubber parts

.*2

Hydraulic hoses

Ox2

IFuel hoses

I

1

I

I

Orc2

I

Ox2

Torque converter rubber hoses Chains I

1

*I:

for n e w vehicle

* * : Every 2 years

*3:

Every 3 years

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


ENGINE Page

EXTERIOR VIEWS ................................ 1-2 SPECIFICATIONS .................................. 1-2 PERFORMANCE CURVES ..................... 1-3 ASSY ..................................................... 1-4 REMOVAL.lNSTALLATl0N ................................... 1-4 ENGINE SPEED ADJUSTMENT .......................... 1-6 ELECTRONIC GOVERNOR .....................................1-9 AIR CLEANER ..................................................... 1-30 GENERAL ........................................................... 1-30 SPECIFICATIONS ................................................ 1-30 COMPONENTS ................................................. 1-31 AIR CLEANER CLEANING .INSPECTION .................. 1-31 CLOGGING WARNING SYSTEM INSPECTION .......... 1-32 RADIATOR ........................................................1-33 COMPONENTS .................................................... 1-33 SPECIFICATIONS ...................................................1-33 FAN DRIVE ....................................................... 1-34 REMOVAL INSTALLATION ................................... 1-34 DISASSEMBLY . INSPECTION REASSEMBLY ............ 1-36 MUFFLER & EXHAUST PIPE .............................. 1-39 COMPONENTS .................................................. 1-39 REMOVAL . INSTALLATION ................................... 1-40 BATTERY . SPARK PLUG ................................... 1-41 COMPONENTS ....................................................1-41 BAlTERY SPECIFICATIONS ................................... 1-41 STARTING MOTOR ........................................... 1-44 REMOVAL . INSTALLATION ...................................1-44 ALTERNATOR .....................................................1-45 REMOVAL INSTALLATION ...................................1-45 ACCELERATOR PEDAL (VEHICLE WILPG ONLY ENGINE) .................................................1-47 COMPONENTS ....................................................1-47 ACCELERATOR PEDAL ADJUSTMENT ................... 1-47 ENGINE MAJOR ENGINE ENGINE

rn

rn


ENGINE EXTERIOR VIEWS

MAJOR SPECIFICATIONS - -e t I Engine type

Engine

Gasoline

I I

/

Number of valves per cylinder

I

I

Valve mechanism Bore x stroke

mm (in)

Total displacement

cm 3 (in 3)

Compression ratio

OHV chain-driven

t

1

4300 (262.4) 9.2

1 1

t

I

I

I

t

t

t

t

t

t t

I I

t t

61 (83112350

61 (83)/2150

N-m (kgf-m)lrpm

294 (30)11200

284 (29)/1200

284 (29)/1200

g/kW-h (g/PS-h)/rpm

258 (190)/1800

249 (183)/1400

250 (184111400

Electronic governor

t

Air governor

185 (408)

t

t

2350

t

2400

kW (PS)/rpm

Maximum torque

Governor system

No-load maximum rpm

Intake valve x 1 Exhaust valvex 1

I I

I

101.60 x 88.39 (4.0 x 3.480)

1 I

t

LPG

67 (91)I2350

Maximum power

Service weight

"

I

Wedge type

Combustion chamber type

Minimum specific fuel consumption

4 - cycle

Gasoline/LPG

kg (Ib) rPm


ENGINE PERFORMANCE CURVES Gasoline LPG GasolineILPG

,

294 (30)11200

Engine speed (rpm)


ENGINE ASSY REMOVAL. INSTALLATION


Removal Procedure Remove the radiator cover. Remove the engine hood. (See page 7-4) Remove the counter weight. (See page 7-5) Remove the muffler. (See page 1-40) Remove the radiator and fan support ASSY. (See page 1-34) Remove the toe board. Remove the battery, battery case and bracket. Remove the air cleaner case ASSY. Disconnect the electrical wiring. Remove the undercover. Disconnect the oil pump drive shaft. [Point 11 Remove the exhaust pipe. Disconnect the fuel hose. Slightly hoist the engine. [Point 21 Support the torque converter lower side with wooden blocks. Remove the flexible plate set bolts. [Point 31 Disconnect the torque converter end plate from transmission case. Remove the 2 engine mount brackets. Remove the engine. [Point 41 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 89.24 (490 910) [35.45 65-84] Engine mount bracket set bolt 44.13 (300 450) [21.71 32.561 Torque converter end plate set bolt : 24.52 (150 250) r10.85 18.091 Flexible plate set bolt

-

-

-

Point Operations [Point 1I Removal:

Disconnect after tying with a string so as not t o cause disconnection at the spline.


[Point 21 Removal . Installation:

SST 09010-201 11-71

Removal. Installation:

Use a sufficiently strong wire. Set length A at approx. 250 m m (9.84 in) to obtain a sufficient hoisting stroke.

[Point 31 Removal . Installation:

Remove 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 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:

2.

3.

80°C (176 OF) 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 to the male side. (2) Disconnect the vacuum hose and install the vacuum gage. ldle speed inspection and adjustment Measure the idle speed. Standard:

750

7 rpm

A d j u s t t h e m i x t u r e adjusting screw so t h a t t h e negative pressure then is stabilized at the highest level. Note: When the idling speed is high, check if the idle adjusting screw i s pushing t h e lever. If so, loosen the screw. Check and adjust the clearance between the idle adjusting screw and lever. Standard:

0 m m (0 in)


<LPG Engine Model> 1.

2.

W a r m u p t h e e n g i n e i n t h e s a m e w a y as f o r t h e g a s o l i n e o r gasoline1LPG e n g i n e and c o n n e c t a tachometer. idle speed inspection and adjustment. (1) Adjust the idle speed with the throttle adjust screw. Standard: 800 2 25 rpm

Throttle adjust screw

(2) Turn the idle adjusting screw gradually clockwise or counterclockwise to 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 to drop, and then turn it clockwise by 45".

Idle Up Inspection- Adjustment <LPG Engine Model > 1.

Warm up the engine. Cooling water temperature: Hydraulic oil temperature:

2. 3.

80째C (176째F)or more 60째C (140째F) 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. Standard: 1250

2

50 rpm

(2) If the standard is not satisfied, make adjustment by turning the adjusting screw. Note:

Turn t h e 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


80°C (176°F)or more 60°C (140°F)or more

Cooling water temperature: Hydraulic oil temperature:

2.

Install a tachometer.

3.

l n s p e c t t h e n o -l o a d m a x i m u m speed w h e n t h e accelerator pedal is fully depressed. Standard:

2350 + 30 rpm

<LPG Engine Model >

1.

Warm up the engine. Cooling water temperature: Hydraulic oil temperature:

2. 3.

80°C (176°F)or more 60°C (140°F) or more

Install a tachometer. lnspect and adjust the no-load maximum speed. (1) Measure the speed when the accelerator pedal is fully depressed. Standard:

2400 + 50 r p m

(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 t h e bushing clockwise. Turn the bushing counterclockwise.

(4) Install the air governor bush lock bolt.

Loaded Maximum Speed Measurement Note: In t h e gasoline or gasoline1LPG engine model, t h e maximum speed is controlled electronically. <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: Standard:

2.

2150 rpm or more

If the standard is not satisfied, turn the adjusting screw for adjustment.


ELECTRONIC GOVERNOR Repair operation 1. Carefully protect electrical parts from direct water pressure (100 kPa (1 kgf/cm2) [14 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. Sensor adjustment is necessary after repairing a part related to each sensor. 2. When installing the throttle switch, avoid incorrect connection of the max. (full) side and min. (idle) 3. 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:

I

Name

Bond, etc.

09082-00050

Toyota electrical tester

SST/measuring instrument

I

Part No.

Thickness gauge

I

Thread tightener

1

08833-00070

Purpose Sensor and switch inspection and measurement Sensor and switch inspection and measurement

1 Upon sensor adjustment I

Outline of Repair Procedure Procedure Preparation

Job description 1. Prepare necessary tools.

-

Troubleshooting 1. Basic inspection 2. Functional inspection

I

1. l n s ~ e cbasic t characteristics before

staking troubleshooting. 2. Perform functional inspection (function check of each part) t o clarify the defect status. 1. Inspect according t o the self-diagnosis 3. Diagnostic inspection code. 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 or replacement and replacement. 1. Sensor adjustment is necessary if any part related to the system is repaired (removed, installed or replaced). Parts Adjustment requiring adjustment are as follows: Acceleration sensor, idle switch and throttle switch Stopped state 1. After the end of repair job, inspect Final according to the final inspection inspection procedure. Traveling state 1. Summarize the defects and repair details, End (Keep them for reference later.)

Reference p a G Page 1-9 (Items t o be prepared) Page 1-10 (basic inspection) Page 1-10 (final inspection) Page 1 - 1 I (inspection by diagnosis) Page 1-29 (inspection of defect no indicated by diagnosis)

Page 1 - 1 7 (sensor and switch adjustment)

Page 1-10 (final inspection)


Basic lnspection lnspect basic items shown below before starting troubleshooting: Content 1. lnspect the battery voltage and specific gravity of electrolyte.

I lnspection around carburetor I

11. Inspect the carburetor function. (1) carburetor link operation state (2) Stepping motor operation state I

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 order

I

1. Inspection with engine switch OFF Vehicle stopping state

Vehicle traveling state

2. lnspection before engine starting with engine switch ON 3. lnspection after engine starting

4. Self-diagnostic inspection

I

Inspection method 1. lnspect each connector for the connection state. 2. Mechanical operation of acceleration sensor and idle switch 1. Depress the accelerator pedal and check the throttle movement. 1. lnspect the CHECK lamp for lighting state. 1. lnspect the CHECK lamp during traveling. 2. Disconnect the diagnosis connector for selfdiagnostic code display, and check if any code is dis~laved.

I

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.

I 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.

1

Display of diagnostic code 5

- - - - - - - - ON

I

- - - - - - OFF

Display of diagnostic codes 5 and 7

Repetition of above cycle operation Note: The CHECK l a m p may come o n when t h e engine switch is t u r n e d t o ON or may flash during traveling (during operation). If it flashes during operation, immediately stop the vehicle and check the flashing count w i t h the engine s w i t c h a t t h e ON position (engine n o t running). The flashing count becomes the selfdiagnostic code. 0 The diagnosis i s repeated when the 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.) Checker connector

Rechecking the diagnostic result displayed before To check the diagnostic result displayed in 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.


1-12

Diagnostic Code List

0: Normal traveling A:Low-speed traveling

X : Traveling

failure

Backup Code No

Diagnostic item

Diagnosed state

Abnormal engine speed rise

Engine

Controller action upon defect detection.

The engine is stopped by setting engine ignition to off.

1

Overrun

2

When the signal from the sensor Accelerator opening signal is abnormal or the line is shorted or opened. line

ldle traveling possible.

Acceleration1 idle signal line (short circuit)

ON signal though the potentiometer opening signal is 112 or more (short circuit)

Ordinary traveling possible though the maximum speed 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.

Normal traveling possible though the maximum speed may decrease because the throttle opening is limited.

Throttle full open switch signal (short circuit)

The signal is OFF though the throttle is opened beyond the specified opening.

Throttle full close switch signal (short circuit)

The signal is ON though the throttle opening is beyond the specified level.

Throttle full open switch signal (short circuit)

The signal is ON when the throttle opening is below the specified level.

Stepping motor

The engine speed does not drop though the controller issues the throttle closing instruction.

The engine is stopped by setting the engine ignition to OFF.

Engine pulse

No engine ignition signal

ldle traveling possible.

Alternator

The alternator signal is OFF


Components


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Toyota 52 6fgcu35 forklift service repair manual  
Toyota 52 6fgcu35 forklift service repair manual  
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