DOWNLOAD PDF Toyota Forklift 5FD50-80, 5FG50-60, 5FDN50-60 & 5FDM60-70 Repair Manual

FOREWORD This manual covers the explanation and service procedures for the modified portions in the minor change of TOYOTA FORKLIFT 5FD50

- 80,

5FG50.60 series. Please use this manual for quick accurate servicing of the these vehicles and as the tool for sales and service activities.

As this manual is edited as a supplement t o the Repair Manual for the 5FD50 - 80, 5FG50.60 series, please refer t o the existing repair manual (No. CE007) for the matters not covered herein.

This manual deals w i t h the above models as of July 1996. Please understand that disagreement can take place between the descriptions i n the manual and actual vehicles due t o change in design and specifications.

Any change or modifications thereafter will be informed by Toyota Industrial Vehicles' Parts & Service News.

For Your reference, w e herewith indicate the titles of relevant manuals TOYOTA 5FD50 - 80,5FDM60.70,5FG50.60 REPAIR MANUAL (No. CEO071 TOYOTA 3F ENGINE REPAIR MANUAL (No. CE614) TOYOTA 112, 122, 132,142 ENGINE REPAIR MANUAL (No. C4615)

TOYOTA MOTOR CORPORATION

SECTION INDEX GENERAL EXPLANATION ENGINE TORQUE CONVERTER BRAKE OTHER MODIFICATIONS APPENDIX

0

GENERAL Page

EXTERIOR VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 VEHICLE MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 FRAME NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 COMPONENTS WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 RECOMMENDED LUBRICANT QUANTITY & TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 LUBRICATION CHART ...............................

0-6

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7

EXTERIOR VIEWS

VEHICLE MODEL Load capacity

Model

Engine model and type Gasoline I

I

5.0 t o n

1 1

2250 (88.5)

5FD50

142

Diesel

t

5FDN50

f

f

1

5FG60

3F

Gasoline

t

142

1

Diesel

6.0 t o n

5FD70

t

t

2250 (88.5)

5FDM70

t

1

2500 (98.5)

7.0 t o n

8.0 t o n

FRAME NUMBER Engine

Model

Punching format

5FG50

5FG60-12001

5FG60

* 5 ~ G 6 0 12001 0

3F 5FD50

A5FD70-12001 * A5FD70 012001

5FD60 5FD70

605FD80-12001 * 6 0 5 F ~ 8 0 12001 0

60-5FD80 142 5FDM60 5FDM70

1

A5FDM70-12001

5FDN50 5FDN60-12001 5FDN60

*: EEC spec.

Punching position

Top on front right frame

COMPONENTS WEIGHT Unit: kg (Ib) Component

I

/ Applicable vehicle

Weight

1 42

327 (721)

3F

250 (551)

All models

Approx. 290 (639)

5-ton

Approx. 2450 (5400)

6-ton

Approx. 3000 (6615)

7-ton

Approx. 3700 (8159)

8-ton

Approx. 421 0 (9283)

6-ton (M60)

Approx. 2810 (6196)

7-ton (M70)

Approx. 3560 (7850)

5 - 6-ton

Approx. 1070 (2359)

7-ton

Approx. 1110 (2448)

8-ton

Approx. 1440 (3175)

Engine Torque converter

Counter weight

Mast LILift Bracket With lift cylinder. lifting height: 3000 m m (118 in)

RECOMMENDED LUBRICANT QUANTITY & TY Description

Classification API

Motor oil

SD, SE, SF

SAE30 (SAE20 in cold area)

1 Gasoline

Planetary gear oil (one side)

API

Diesel engine oil

CC, CD

SAE30 (SAE20 in cold area) SAE1OW-30

API

12.5e (3.30 US gal)

Hypoid gear oil SAE85W-90

1.5e (0.40 US gal)

Hypoid gear oil SAE85W-90

All models

-4

All models

15.0e (3.96 US gal)

GL-5

2.0e (0.53 US gal)

ATF

Maximum fork height Hydraulic oil IS0 VG32

Hydraulic oil

below 6.0 m (236 in) 8.0 m (315 in)

Fuel tank

All models

Chassis parts

MP Grease LLC*

All models

LLC 30-50% mixture (for winter or all-season) Coolant with rustinhibitor (for spring, summer and autumn)

Coolant (Excluding reserve tank)

Coolant (Reservoir tank)

I

GL-4

Differential

Torque converter

Quantity

9.3e (2.46 US gal)

SAE20W-40 (SAE10W-30 in cold area)

Engine

Diesel

Application

f

*L.L.C = Long Life Coolant (Appropriately diluted with fresh water)

f

z 6.5t (1.72 US gal)

90t (23.8 US gal)

------I

100e (26.4 US gal) 140e (37 US gal)

Proper quantity

13.0t (3.4 US gal)

13.0e (3.4 US gal)

All models

1.1e (0.29 US gal)

I

LUBRICATION CHARTS

I. 11 111.

11'.

v

[Inspect every 8 hours (daily)] [Inspect every 40 hours (weekly)] [Inspect every 170 hours (monthly)] [Inspect every 1000 hours ( 6 monthly)] [Inspect every 2000 hours (annually)]

,. Inspection J.)

%

: Replacement Multi-purpose grease Hypoid gear oil Engine oil Hydraulic oil Automatic transmission fluid

Fork shaft (8ton models) Chain Tilt cylinder front pin Planetary gear Mast support cap Differential case Tilt steering universal joint Tilt steering locking mechanism Universal joint Tilt cylinder rear pin Torque converter and transmission case Oil tank Engine crankshaft case Rear axle beam front pin Steering knuckle king pin Tie rod end Rear wheel bearing Rear axle beam rear pin

PERIODIC REPLACEMENT PARTS AND LUBRICANTS 0 : Replacement Every 12 months

Every 3 months

Every 170 hours

Every 500 hours Every 1000 hours Every 2000 hours

l

Engine oil

Every 6 months

Every 1 month

t

t

t

l

t

t

l

t

t

Fuel filter

l

t

Torque converter oil

l

t

Torque converter oil filter

l

t

Engine oil filter

I

Engine coolant (every 2 years for LLC)

Planetary gear oil

l

Differential oil

l

Hydraulic oil Hydraulic oil filter

.*I

l

t

l

t

l

Wheel bearing grease

l

Spark plug

t

Air cleaner element

l

Brake booster (or brake valve) €4 accumulator rubber parts

l

Cups and seals for wheel cylinders

l

Power steering houses

0n2

Power steering rubber parts

0x2

Hydraulic hoses

*.2

Fuel houses

0K2

Torque converter rubber hoses

Oa2

Chains * I : for new vehicle

*2: Every 2 years

*3: Every 3 years

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

EXPLANATION Page

DEVELOPMENT OBJECTIVES . . . . . . . . . . . . . . . . . . . . . . . 1-2 FEATURES (SALES POINTS) . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 142 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

3F ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . 1-30 PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-32 SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 COMBINATION METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44 M A S T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 HYDRAULIC OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

DEVELOPMENT OBJECTIVES Development Objectives Since the full model change took place in December 1990, Toyota's 5 - 8 ton series of engine-type forklifts have been a market leader with their outstanding reliability, maneuverability and comfort.

However, with our competitors making frequent model changes, the competition for market share is getting tougher and can be expected t o get even more so. Accordingly, t o maintain product superiority and improve our market share, w e have made the following changes:

1. IMPROVED OPERABILITY (1) A world-first, the S.M.H.D. (Self Moving Hydrodynamic Drive) torque converter is used. (Standard equipment o n all models.)

This torque converter is a new type equipped with 2 starters inside it so that shifting 1 tt 2 is smoothly done automatically. This eliminates troublesome shifting.

(2) A n electronic shift is used. (Standard equipment o n all models.)

Adoption of the electronic shift lever makes the shift lever easier t o operate for forward and reverse operation. (Improved operability and shift control feeling.)

(3) A step-on type brake pedal is used (All models.)

The brake pedal has been changed f r o m the previous organ type t o the step-on type t o improve brake operability.

(4) Hydraulically assisted brakes are used (5 - 7 ton series, except the 5FDM 60170) On 5 - 7 t o n series, the previous full power type brake has been replaced b y the hydraulically assisted brake. In combination with the step-on type brake pedal, this provides closer braking feeling.(8 ton series and the 5FDM 60170 retain full power braking.)

(5) A small diameter steering wheel is used. (All models.)

The same small diameter steering wheel as the 6FG16FD10 - 30 is used t o improve steering handling. 380 m m (14.96 in) -r 360 m m (14.17 in)

2. INCREASED COMFORT (1) A new type of seat is used.

The newtype of seat developed forthe 6FB series is used t o provide improved durability and seating comfort.

(2)

A normal type muffler (wait exhausting t o the rear) is used. (Option only on models w i t h the 142 engine.)

The exhaust pipe is located after the wait, so that the suction of exhaust gases toward the driver's seat and the noise level for the operator are reduced. (As on the previous model, the u p swept muffler is standard equipment.)

3. CONCERN FOR THE ENVIRONMENT (1) The 14Zengine conforming t o European and American exhaust emissions regulations is used. (5 7 t o n series) We have developed the new 142 engine in anticipation of the introduction of the European and American emissions regulations. This new engine greatly reduces NOx and CO emissions and keeps the work environment cleaner.

(2) The 142 engine is also newly adopted for 8 ton series.

As w i t h 5 - 7 ton series, the 8 ton series is n o w equipped with the 142 engine, replacing the previous W06E engine. This will enable compliance with the anticipated European and American emissions regulations and standardizes supply parts with the 5 - 7 t o n series.

4. USER-FRIENDLY DESIGN DETAILS (1) Easier mounting or dismounting due t o smaller engine hood. (All models.)

The hood has been cut back above the left side of the driver's seat t o make it easier t o get in and out of the driver's seat smoothly.

(2) The 6FG16FD 10 - 30 type illuminated centralized unitary combination meter has been adopted.

(All models.)

The 6FGl6FD 10 - 30 type combination meter has been adopted i n all models.

1-4

FEATURES (SALES POINTS) Table of Sales Points (Features altered in this minor change) Sales Point

Implementation

0bjective

Applicable Models

Comfortable operation that doesn't tire you.

Nimble operability

S.M.H.D. torque converter is used.

(Self Moving Hydrodynamic Drive) S.M.H.D. torque converter is used.

(Self Moving Hydrodynamic Drive)

Easy operation due t o elimination of need to shift gears.

(Improved operability)

Electronic shift is used.

(Column type)

Improve operability of shift lever.

(Operating power reduced and shift feeling improved)

All models

A step-on type brake pedal is used.

lmprove operability of brake pedal.

All models

Hydraulically assisted brakes are used.

Hydraulically assisted brakes are used.

Improve operability o f brakes.

Small diameter steering wheel is used.

Improve steering operability.

All models

-

5 7 ton series only

380 mm (14.96 in) +360 mm (14.17 in)

All models

Small diameter steering wheel is used.

380 mm (14.96 in) -360 mm (14.17 in)

Advanced comfort

New type of seat is used.

(6FB type seat)

Improve seat comfort and durability.

Normal type muffler (wait faces rearward) is used.

Normal type muffler (wait faces rearward) is used.

Suction of exhaust gases toward the driver's seat and the noise level for the operator are reduced.

142 engine conforming to European and American exhaust emissions regulations is used.

142 engine conforming to European and American exhaust emissions regulations is used.

Clean emissions.

Concern for the environment by reducing NOx, HC, CO and PM emissions.

Adopt 142 engine for 8 ton series.

Conform with European and American exhaust emissions regulations.

8 ton series only

Illuminated centralized unitary combination meter is used.

Improve styling by adopting 6FG/6FD 10 - 30 type combination meter. (With smoked face.)

All models

Position-retaining type fuel gauge needle

Fuel quantity can be read without using ignition key.

All models

Cut back hood above left side of driver's seat t o make it easier t o get in and out of the driver's seat smoothly.

All models

Angle front of engine hood.

Improve appearance.

All models

Eliminate line beside the wait.

Improve appearance by streamlining.

All models

All models OPT only o n models equipped with 142 engine

Attention t o fine details Concern for the environment

Concern for operator

Make engine hood smaller.

Exterior appearance

Diesel engine for all models

142 ENGINE General The 142 engine is a 5.2 t direct injection type diesel engine newly developed exclusively for forklifts.The new 142 engine has been developed mainly as a clean emissions version of the popular 122 engine mounted in the 5FD 60 series. Like the 122 engine, it displays the l o w fuel consumption and high power output characteristics of the direct injection diesel engine. It is designed all over t o reduce vibration and noise, and t o provide increased durabi1ity.h has also been designed t o share the same parts as other Z series engines as much as possible.

ENGINE M A I N SPECIFICATIONS

I

Item

142 Engine Diesel 4-cycle

Engine type No. of cylinders and arrangement

I

Direct injection

Valve mechanism

+

I

t

OHV, gear-driven

t

Displacement

cm 3 (in 3 )

5204 (317)

4994 (304)

Bore x Stroke

m m (in)

98.0 x 115.0 (3.858 x 4.528)

96.0 x 11 5.0 (3.780 x 4.528)

Compression ratio

18.5 5 - 7 ton model: 69.8 (95)12200

Max. output I

18.6 I

I

Max. torque

I

t

6 cylinders in-line, vertically mounted

I Combustion chamber type

122 Engine

I

I

I

1

8 ton model: 73.5 (100)/2400

I

I

N.m (kgf-m)/rpm

344 (35111600

t

Fuel consumption rate gikw-h (glPS-hllrpm

214 (158)11200

t

327 (721)

335 (739)

Curb weight No-load m a x i m u m speed

kg (Ib) rpm

I

5

- 7 ton model: 2400 8 ton model: 2600

I

ENGINE PERFORMANCE CURVES

2400 r p m spec. ( 5 . 6 , 7 ton)

'

O

V

1

315 5

2600 r p m spec. I8 ton1

7

210

2400 rpm spec. 15. 6. 7 ton)

V)

2 Y.

Engine speed lrprn)

xlO Z

FEATURES

4.

5.

Direct fuel injection Helical intake air port Optimal matching between the combustion chamber type and the fuel injection system Intake air heater Inscribed trochoidal oil pump

1.

2.

3.

4.

Increased rigidity of the valve system Soft nitrified timing gear FlPG (formed-in-place gasket) Water-cooled oil coole;

1.

2.

3.

lmproved performance

/

I 1. Steel-strutted piston Reduced noise and

Improved ease of servicing by maintenance-free design

2.

3.

4.

1 5.

Crank pulley with torsional damper Timing gear cover made of cast iron Smaller modular timing gear Crankshaft having eight balanceweights

1.

Cartridge type oil filter FlPG (formed-in-place gasket) Small alternator having an IC regulator

- 2.

3.

1

Construction explanation Contents Cylinder head cover Cylinder head Cylinder block Cylinder head gasket Oil pan

Non-moving components

Designed for 1 4 2 engine Designed for 1 4 2 engine Designed for 1 4 2 engine Designed for 1 4 2 engine

11Z (Oil capacity 1 0 liters (2.6 Usgal))

Gear case

11Z

Crankshaft Connecting rod Piston Camshaft Rocker arm

122 IZ, 1 1 Z , 2 Z Designed for 1 4 2 engine

Oil p u m p Oil filter Oil strainer Oil cooler

11Z IZ, 1 1 Z , 2 Z 11Z 122

Cooling

Water p u m p

122

Intake and exhaust system

Intake manifold Intake air heater Exhaust manifold

11Z 12, 1 1 2 ( 2 4 V), 2 2 I IZ

Fuel injection system

Injection p u m p Injection nozzle

Distribution type (VE type) IZ, 11Z (1-spring nozzle)

Auxiliary equipment

Starter Alternator

IZ, 11Z (24V), 2 2 IZ, 1 1 2 ( 2 4 V, with IC regulator)

Moving components

Lubricating system

/

11Z IZ, 1 1 Z , 2 Z

Mechanical explanation ENGINE 1. Cylinder head

Exhaust

Intake

(1) The cylinder head is made very rigid t o withstand the higher combustion pressure due t o direct fuel injection. The higher rigidity ensures reliability under continuous high load and high speed operation of the engine.

(2) The inside of the intake valve seat has a curvature designed t o ensure smoother f l o w of the intake air.

(3) The nozzle is located in an optimal position t o ensure smooth fuel injection.

(4) The helical intake air port is designed t o create swirl in the air being directed into the combustion chamber.

This ensures an even mixing of fuel with air and provides efficient and quiet combustion f r o m l o w t o high rev ranges.

12.0 (0.472)

(1.004)(0.866)

Unit: mm (in)

2. Cylinder head cover, cylinder head cover gasket (1) The cylinder head cover is made of diecast aluminum, and fitted t o the cylinder head via a rubber ring type gasket t o reduce the noise.

I Gasket cross section

3. Piston, piston pin, piston rings (1) A special (trochoidal) combustion chamber is formed at the piston top. This design increases the compression height (the distance f r o m the center of the piston pin hole t o the piston top).

(2) The piston is reinforced b y a steel strut t o suppress thermal expansion. This helps t o minimize the piston clearance and reduce the engine noise.

(3) The piston pin diameter was increased t o 32 m m (1.26 in) t o increase the pin's rigidity in order t o coincide w i t h the increase in combustion pressure due t o direct fuel injection.

(4) The No. 1 compression ring is given soft nitriding t o increase resistance against wear and seizure.

ring ring

/

Steel strut

I

4. Connecting rod (1) The Connecting rod is made of forged carbon steel for structural use. The big end has a horizontal split for assembling ittothecrankshaft using a chrome molybden u m steel bolt.

Connecting rod specifications Span : 170 m m (6.69 in) Big end diameter : 58 m m (2.28 in) Small end diameter: 32 m m (1.26 in) 1

5. Crankshaft (1) The crankshaft is made of carbon steel for structural use and has seven bearings and eight balanceweights. The eight-balanceweight design minimizes cylinder t o cylinder mass imbalance and also suppresses inertial force at high speed operation. Noise and vibration are reduced as a result.

6. Crankshaft pulley Damper

(1) The crankshaft pulley has a torsional damper t o reduce vibration and noise.

Timing gear cover 1) The timing gear cover is made of cast iron t o increase rigidity and reduce noise.

8. Crankshaft oil seals

Oil seal (left hand screw) Oil seal (right hand screw)

(1) For crankshaft oil seals, the previous "T" type oil seal w i t h screw is used at the front side, and the same fabric seal that is used in the 22 is used at the rear, thus improving the dust excluding ability of the crankshaft.

/

(rubber)

I

ear 'side side

VALVE SYSTEM lniection DumD clear

1. Gear train (1) The gear train consists of helical gears of a small module (1.75). This reduces the gear noise.

(2) Gears (other than the oil p u m p gear) are given soft nitriding t o increase their resistance against pitching.

2. Valve train (1) The valves are arranged in an OHV mechanism.

(2) The valve timing is set for l o w speeds in order t o increase low-speed performance and startability.

(3) A stem cap is used t o increase wear resistance at the rocker arm pad and stem valve top.

TDC

(fabric)

I

LUBRICATION SYSTEM Construction and operation (lubrication system circuit) The lubricating oil, discharged by the oil pump, is filtered b y t h e oil filter. Then it is pumped into the main oil hold through oil cooler t o lubricate all necessary parts.

Oil being sent t o the crank journals travels through oil holes provided inside the crank arm and lubricates the connecting rod bearings and the connecting rod bushes. Then it is discharged f r o m the piston cooling jets at the upper end t o cool off the back of the piston head.

Oil that Iubricates crankshaft bearings Nos. 1,3,5 and 7 also Iubricates camshaft bearings Nos. 1,2,3 and 4 next. It travels through the oil passage at the t o p of camshaft bearing No. 1 and also in the cylinder head, is directed into the valve rocker shaft, and lubricates all parts of the valve train.

Oil pan

1. Oil pan (1) The oil pan is sealed with flexible liquid gasket (FIPG*) which has outstanding sealing performance. *FlPG = Formed-in-place gasket

2. Oil pump (1) The oil p u m p is of the inscribed trochoidal pump, and is installed at the front of the cylinder block.

The p u m p is driven by the p u m p drive shaft gear, which forms part of the timing gear train.

Oil pump specifications Discharge rate elmin (USgalImin)

Discharge pressure kPa (kgf/cm2) [Psi]

1000

8.9 (2.35)

200 (2) [301

4000 Relief valve p ressure kPa (kgf/cm2)[psil

57.6 (15.21)

290 (3) [401

Item

Pump rev rPm

490 i 49 (5.0

f

0.5) [71 i 71

3. Oil filter (1) A large-size cartridge type oil filter is used because of its large filtration area. It contains a safety valve that is activated when the element is clogged up.

(2) The oil filter also contains a regulator valve that sets the highest output pressure. Excess oil is returned t o the oil pan.

Oil filter specifications Filtration method

Filter paper cm2 (in 2 )

3000 (465)

Filter safety valve opening pressure kPa (kgf/cm2) [psil

100 i 20 (1.0 i 0.2) [14+31

Regulator valve regulating pressure kPa (kgf/cm2) [psil

390 i 29 (4.0 i 0.3) [57 i 41

Filtration area

COOLING SYSTEM Construction and opearation (cooling system circuit) The coolant being discharged by the water p u m p flows t o the cylinder block. It cools the cylinder block as it passes through water jackets between cylinders. Then it is sent t o the cylinder head t o cool it, and sent t o the thermostat located at the water p u m p outlet. When the coolant temperature is low, the thermostat is closed so that the coolant returns t o the water p u m p via a bypass. As the temperature rises and the thermostat opens, the bypass is closed. This allows the coolant t o f l o w t o the radiator where it is cooled before returning t o the water pump.

1. Water pump (1) The water p u m p is integrated with the outlet housing.

Bypass

Water pump specifications Impeller diameter : 85 m m (3.35 in) : 160 e / min (42.2 Usgal/ min) Discharge rate Pump rev 3000 rpm Lift 3mAq Pulley ratio : 1.45

Impeller

2. Thermostat (1) A bottom bypass (near the outlet) type thermostat was chosen t o further increase the cooling efficiency.

Thermostat specifications : 82°C (180°F) Threshold temperature Fully-opened temperature : 95°C (203°F)

I

p pas's valve

ELECTRICAL SYSTEM An intake air heater is used t o improve startability ofthe cold engine. The heater remains o n for a while after starting t o heat the air (after-heating) in order t o stabilize idling and reduce generation of white smoke. Unlike existing models carrying the 1Z or 11Z engine, all the new models have the 24 V intake heater, regardless of the destination specifications.

Characteristics and components of the intake heater

24 V

Voltage (intake heater) Indicator lamp lit time

-10°C (14°F)

-5°C (23°F)

+2.5"C (37°F)

20

13

0

sec.

Detected 70 seconds [turned off at 10°C (50"F)I

Duration of after-heating

Detected

Intake heater wire disconnection

C C 0

Preheating timer Components

Glow relay Coolant temperature sensor

Construction and operation Construction (1) lntake heater The intake heater is located at the entrance of the intake manifold and warms the fresh air being taken in.

The heater plates (for preheating and after-heating) are arranged in t w o rows. Both plates have identical heating capacity.

Lead

(BR)

lntake heater specifications (during after-heating)

Rated voltage

V

22

Rated current

A

58

Heater resistance

R

0.39

Heater temperature

"C (OF)

900°C (1652°F) (after 70 seconds)

(2) Coolant temperature sensor This sensor detects the temperature of the coolant, and is fitted t o t h e water pump. It contains a thermistor whose electrical resistance varies greatly according t o the temperature. The coolant temperature is detected in the f o r m of the resistance of the thermistor.

(104)(176) Water temperature " C ( O F )

(3) Preheating timer

a

This timer controls the preheating time which is determined by the coolant temperature. It also activates (deactivates) the preheating indicator lamp. @ When the starter is cranked during preheating, the timer discontinues preheating. @) After the engine starts, the timer restarts preheating depending o n the coolant temperature. @ When the intake heater wire is broken, o r w h e n the after-heating relay is burned up, it activates the preheating indicator lamp.

(4) Preheating and after-heating relay This relay allows electricity t o flow directly f r o m the battery t o the intake heater. The same relay is used for both preheating and after-heating. The relay is built into a waterproof and dustproof case.

Relay specifications Rated voltage : Minimum operating voltage : Rated exciting current : Rated energizing current :

24 V 16 V or lower 2 A or lower 100 A (90 seconds)

Sectional view

Operation

t l : Preheating time

t2: After-heating time S1: ST terminal source voltage (during cranking) S2: ST terminal grounding (when starter turned off) C1: CHG terminal 8 V or lower (before engine start) C2: CHG terminal source voltage (after engine start)

(1) When the coolant temperature is below 2.5"C (37°F) When the ignition switch is set t o the ON position (the engine stopped), the timer circuit activates the pre.-E heating indicator lamp. At the same time, it turns the +-0, heater relay on, which allows electricity t o f l o w t o the .-+ intake heater. Preheating begins as a result. The preF a! heating time ( t l ) varies according t o the temperature of the coolant.

E 2 F When the starter is cranked during preheating, the 3 0 -20 -10 o + l o hold circuit turns the heater relay off (the preheating ( - 2 2 ) (-41 1141 (321 1501 indicator lamp is turned off also) so the enough voltCoolant temperature ' C ( " F ) age is sent t o the starter. After the engine starts, the heater relay is turned on by the Lterminal signal of the regulator.This allows electricity t o f l o w t o the intake heater and the intake air is heated (preheating) by the heater. The after-heating t i m e (t2) is set t o 70 seconds.

7 w

A

(2) When the coolant temperature is above 2.5"C (37°F) or below 10°C (50°F) Preheating is not performed but after-heating is activated in this condition. But the heater relay is turned off and stops after-heating when the coolant temperature rises above 10°C (50°F) during after-heating.

(3) When the coolant temperature is over 10°C (50°F) None of the preheating or after-heating is performed in this condition.

(4) Broken wire detection function In the even the intake heater wire is broken or the heater relay is fused, the broken wire detection circuit activates the preheater indicator lamp t o alert the driver t o the problem.

IG S I W Regulator Coolant temperature detection Heater breakage or fuse blowing Indicator l a m p Heater relay

1. Alternator (1) This is a compact alternator with an IC regulator.

(2) The IC regulator activates the charge lamp when the rotor coil is broken, when the alternator B terminal or the regulator sensor (S terminal) is disconnected, or when other trouble is present.

Alternator specifications : 20 A Rated output Effective pulley diameter : 74 m m (2.91 in) Regulator regulating voltage : 28 - 29 V

2. Starting motor (1) This is a compact and lightweight reduction type starter (R type).

Starting motor specifications : 4.5 kW Rated output Non-load characteristics : Current 90 A max.

Revolution 3500 rpm min. (Voltage 23 V) Number of pinion gear teeth : 11 Direction (seem from pinion) : Right-hand

FUEL SYSTEM 1. lnjection pump (1) The injection p u m p has been structurally reinforced in order t o implement direct fuel injection.

(2) A compact, lightweight, distribution-type injection p u m p was chosen t o ensure optimal matching with the 142 engine. It can be removed without removing the timing gear cover.

The injection p u m p is basically the same i n construction as the p u m p used in the 122 engine. It is (3) lubricated by the fuel itself. It is important that a proper type of fuel is used and that the fuel is completely free of moisture.

Injection pump specifications TYpe : Bosch VE Plunger diameter : 12 m m (0.47 in) : Face cam Cam type Cam lift : 2.5 m m (0.098 in) : Centrifugal type (all speeds) Governor Timer : Built-in Engine-stop solenoid : 24 V Weight : 6.8 kg (15.0 Ib)

Fuel filter

Adjusting lever

I

Fuel tank

I

Construction and operation General The centrifugal (vane) type feed p u m p draws a fixed amount of fuel each time it completes a turn. The fuel drawing pressure of the feed p u m p is regulated by the pressure regulating valve. The fuel is sent f r o m the feed p u m p delivery p o r t t o the pumpchambervia a hole atthe t o p ofthe feed pumpcover.The p u m p plunger is driven b y a cam plate which is connected t o a drive shaft via coupling. It is pushed against the cam plate by a plunger spring. The cam plate has the same number of face cams as the cylinder bores of the engine.

As they are turned by the drive shaft, they move reciprocally around the roller over a distance equal t o the cam lift. Therefore, the plunger connected t o the cam plate is engaged in rotary and reciprocal motions t o draw in the fuel, and then distributes the fuel under pressure.

The fuel distribution begins the moment the plunger begins t o move upward (delivered through the distribution passage and delivery valve and finally injected under high pressure through the injection nozzle).

It ends when the plunger rises further and the plunger spill port is connected t o the p u m p chamber at the right-hand end surface of the spill ring. The centrifugal all-speed governor, built inside the t o p part of the injection pump, causes the spill ring (which normally plugs the plunger spill port) t o move and thus regulates the amount of fuel being injected. The hydraulic timer, located inside the lower part of the injection pump, is activated by the pressure of fuel inside the p u m p chamber. The timer moves the roller ring, advances ignition and thus regulates the timing of fuel injection. The fuel-cut solenoid is connected t o the engine ignition switch circuit. When the ignition switch is set t o the OFF position, the circuit is broken and the solenoid is closed. This cuts the fuel supply and causes the engine t o stop.

Adjusting lever

\

overflow pipe

Flyweight

A

el-cut solenoid From fuel filter

nozzle

(90' development)

Roller

Plunger spring

2. lnjection nozzle and holder (1) Accompanying the adoption of the direct injection engine with its high injection pressure, a multihole type nozzle has been adopted.

(2) The injection nozzle used in the 142 engine is called a multi-hole long stem type; it provides good injection performance and has a low fuel consumption rate.

(3) For the nozzle holder a flange screw-in type is used t o provide easier serviceability.

Injection nozzle

Nozzle type : No, of injections : Injector diameter : lnjection pressure:

Multi-hole type (long stem type) 5 0.26 m m (0.0102 in) 22560 kPa (230 kgf/cm 2 ) 13270 psi]

3. Fuel filter (1)

Acartridge type fuel filter having an integrated sedimenter and a priming p u m p was chosen t o simplify the fuel passage and improve the ease of servicing.

Fuel filter specifications Filter Filtration area Rated flow rate

3200 cm 2 (496 in 2) 1 elmin (0.3 Usgal/ min)

Sedimenter Max, water retention : Level switch ON position : Pump Pump stroke Lift Delivery

43 m m (1.69 in) 550 m m (21.65 in) 70 cm 3 (4.27 in 3 ) /st

A fuel filter having a priming pump, doubling as a sedimenter at the same time, is fitted t o the vehicle side. It further increases the ease of pumping in such cases as water draining and fuel shortage.

A suction filter is located at the t i p of the suction pipe of the fuel tank in order t o protect the fuel filter.

(3)

(2)

drain cock

EXHAUST GAS PURIFYING DEVICES 1. Blowby gas reducing device (1) This device forces the blowby gas t o return t o the air intake system so that the gas is burned completely in the engine. This prevents the blowby gas f r o m being released in atmosphere.

-------

*

Blowby gas Fresh air

take manifold

3F ENGINE General The 3F engine is the same as o n the previous model.

ENGINE PERFORMANCE CURVE DIAGRAM

ENGINE MAIN SPECIFICATIONS

-----Exclusively LPG specifications

.--------.

Combined-use LPG specifications

Irpm) xio2

Engine speed ( r p m ) x102

No-load maximum speed rpm

2600

TORQUE CONVERTER General Instead of the 5 - 7 t o n series' 2 forwardlreverse gears and the 8 ton series' 3forward/reverse gear torque converter and transmission in the previous models, all new models have a single forwardlreverse gear torque converter and transmission.

Due t o the use of the S.M.H.D. ( * I ) , their drive performance is equal t o that of models with 2 or 3 f o r w a r d l r e verse gears. Shifting into forward or reverse is done electronically and responsiveness when starting off has been improved t o improve vehicle maneuverability.

FEATURES 1.

2.

3.

4.

5.

Smooth acceleration is delivered f r o m l o w speeds u p t o t o p speed.

Starting off in 2nd or 3rd gear is not possible, so there is n o worry about overheating.

There is n o action required t o change gears and no time lag when changing gears, so operator efficiency is improved.

The quantity of torque converter oil required has been greatly decreased. (Previous models: 3 3 t (8.7 US gal. -t new models: 15t (4.0 US gal.)

The forwardlreverse switching lever is electronic so it requires less force t o operate. [Previous m o d els: 49 N (5 kgf) [ I 1 Ibfl + new models: 10 N (1 kgf) [2 Ibfl *I

S.M.H.D. S: SELF SAVE M: MOVING H: HYDRODYNAMIC D: DRIVE

CONSTRUCTION

rwi--

PTO and charge p u m p

1.

2.

The PTO and charge p u m p have the same construction as the previous model.

The converter is the same for all engines, and the stall torque ratio is changed by the counter-rotating gear.

Counter-rotating gear ratio 14Z Engine : 4.05 3F Engine : 4.05 Stall torque ratio 14Z Engine: 8.42 3F Engine : 8.42

3.

The shift ratio is the same for both forward and reverse motion.

Transmission ratio 14Z Engine: 0.675 3F Engine : 0.675

DRIVING PERFORMANCE COMPARISON WITH PREVIOUS MODEL As shown below, there is almost no performance difference between the previous model and the new m o d el. On the new model, shifting occurs automatically between 1st gear range (range requiring power) and 2nd gear range (range requiring speed). This operation iscompleted within the converter, so n o shift shock is felt.

I

Comparison with 2 gears forward1reverse

Comparison with 3 gears forwardlreverse

P r e v ~ o u Model s

P r e v ~ o u sModel

0

10

20

Vehicle Speed

30 krnlh

0

10

20

30

Vehicle Speed

kmlh

40

OPERATION

-

,

Support Gear Turb~ne

Reverse Gear

Reverse Clutch Gear No.

No.

I

F ,orward

Clutch Gear

O ,put

Gear

Forward Gear

Output Shaft

Converter Movement Speed ratio 0

0 - 0.4

0.4 - 0.8

0.8 -

No. 1 Starter

Fixed

Rotates

Idling

Idling

No. 2 Starter

Fixed

Fixed

Fixed

Idling

Power Transmission Flow Speed Ratio for 0 - 0.4 (Moving Forward) Turbine

Turbine shaft

Reverse gear

Forward gear Forward clutch gear

No. 1 Starter

Support gear

Output gear

Counter gear

Speed Ratio for 0.4 - (Moving Forward) Turbine

Turbine shaft

Reverse gear

Forward gear

Forward clutch gear

Output gear

Diagrammatic representation of the power transmission

Combined via No. l stator and one way clutch

Reverse gear Support gear

/

~eversebiutch Reverse clutch gear

Output gear

turbine and one way clutch Idler gear

Forward clutch gear

TFT 1

Counter gear

k r w a r d clutch

Forward gear

Forward 0 - 0.4

Reverse 0 - 0.4

Forward 0.4 -

Reverse 0.4

up................. ;:?; ,:,:,:,:,:,:,::. ...........

..I......

:;;; :c:;j ..:.:. ........ :.:.:.:.:.:. .:.:.

':..... ;?:

-

DIFFERENTIAL General On previous models the installation direction ofthe differential varied according to the engine. However, on all new models the installation direction on the previous 8 ton series has been adopted.

Also, the parking brake drum which was located between the differential and propeller shaft on previous models has now been positioned between the propeller shaft and torque converter on new models.

SPECIFICATIONS

Reduction gear ratio

5FD50 5FD60 5FD70 5FDN50.60

5FG50 5FG60 5FDM60 5FDM70 60-5FD80

4.111

4.875

FRONT AXLE General

SPECIFICATIONS

Reduction gear ratio Reduction gear

5FD50.5FG50 5FD60.5FG60 5FDN50.60 5FD70

5FDM60 5FDM70 60-5FD80

4.250

4.385

STEERING General 1.

2.

3.

-

The steering wheel used is the same as on the 6FG16FD10 30 to improve operability.

Hydrostatic power steering is used, the same as on the previous model.

Tilt steering is used, the same as on the previous model.

Steering Wheel GENERAL 1.

The steering wheel diameter has been changed from 380 m m (14.96 in) to 360 m m (14.17 in) t o improve operability.

Nob

Unit: mm (in)

2.

3.

4.

5.

The steering wheel has been changed from a 3 spoke type to a 2 spoke type to make it lighter and improve the driver's field of view.

The steering wheel surface is textured to provide a softer, high quality feeling.

The nob position has been changed to the most appropriate driving position. The nob is made of the same soft PVC used in the previous model, giving it a pleasant-to-hold feeling.

To prevent the nob from sticking, the cap on top of the nob is tightly sealed as on the previous model, and a collar has been added t o the lower sliding part to make it difficult for water to get into part @ in the illustration.

Cap

Sliding part

Power Steering GENERAL The power steering used is the same hydrostatic power steering used in the previous model. It has high reliability, with few parts and few parts requiring lubrication.

Tilt Steering GENERAL To provide the most appropriate driving position, the tilt steering used in the previous model is retained.

General 1.

2.

3.

The brake system in the 8 ton series and 5FDM60170 (wheelbase 2500 m m (98.5 in)) series have the same full power CHPS as in previous models.

For 5 - 7 t o n series (wheelbase 2250 m m (88.5 in)),the previous full power CHPS has been replaced by power assisted CHPS, which has had good results in the 5FD35 series and is designed t o reduce pressure damage t o the hydraulic circuits, reduce the operating temperature and improve the reliability, durability and operability of the hydraulic mechanisms.

For the parking brake, the progressive axle internal expansion type with the same 216 m m (8.5 in) diameter d r u m as the previous model has been adopted. Its location has been changed from the differential side t o the torque converter transmission side.

FULL POWER CHPS CIRCUIT DIAGRAM (Models with wheelbase 2500 mm (98.5 in))

-

Brake pedal

Material handling system

Oil tank

/

PS system

POWER ASSISTED CHPS HYDRAULIC CIRCUIT (Models with wheelbase 2250 mm (88.5 in))

-

Brake pedal

1

,I t

I

-'

-

/I I 1

-

1

Brake booster

C-

-

Oil tank

2

Material handling system

[ ~ n ~ i n e w

1

-

/

PS system

IMPROVED OPERATING FEELING (5 - 7 ton series: models with wheelbase 2250 m m (88.5 in)) In comparison t o the previous brake lining material, effectiveness of the new material decreases less as temperatures rise and as the period of use increases.The power assisted CHPS combined w i t h the step-on type pedal improves operating feeling.

BRAKE BOOSTER (5 - 7 ton series: models with wheelbase 2250 m m (88.5 in)) The previous full power CHPS has been changed t o power assisted CHPS with the adoption of the master cylinder (brake booster) with a hydraulically driven mechanism. Because braking power is thus maintained even when the engine is stopped, the accumulator has been eliminated. The outlet port has been equipped w i t h a residual pressure valve t o prevent air flow into the wheel cylinder.

CAUTIONS DURING USE (8 ton series, 5FDM60170: models with wheelbase 2500 m m (98.5 in)) 1.

2.

3.

4.

5.

Before starting the engine, make sure the parking brake is properly engaged.

Before starting the engine, turn the key switch t o ON and check that the warning buzzer stops after the p u m p has operated for a few seconds. If the pump does not operate, depress the brake pedal several times and check that the p u m p is operating.

If the warning buzzer sounds during forklift operation, immediately stop work, park w i t h the parking brake firmly engaged, check for the problem and fix it.

Never stop the engine and coast down a slope.

If the engine should stop while you are driving, d o not p u m p the brake.

PEDAL Accelerator Pedal Link GENERAL The accelerator pedal has been standardized with the 6FG16FD 10 - 30 series.

New model

Previous model

Brake Pedal GENERAL The brake pedal and inching pedal have been changed from the organ type in previous models to the step-on type.

2.

Comparison with Previous Models (1) The pedal fulcrum has been changed t o improve operation feeling. ( 2 ) The pedal has been ergonomically improved so that the pedal is operated at a comfortable angle for the operator's ankle, thus reducing fatigue for long periods of operation. (Reduction of ankle fatigue.)

(3) A large increase in the link ratio has increased the stroke and made more delicate control easier.

(4) Increasing the stroke has made it possible t o adopt power assistance that has proved so reliable in the 5FD35 series, thus improving the reliability of the hydraulic mechanisms. (Should the engine stall, manual operation is still possible, but increased pressure must be applied.)

1.

I

Previous model

New model

I

SHIFT LEVER General A n electronic shift lever has been adopted for shifting so that it is easier t o operate and helps t o reduce operator fatigue.

Electronic Shift Lever

To clearly differentiate the shift lever from the turn signal switch, the shape of the shift lever knob has been changed and it is also n o w colored yellow.

FRAME Engine Food GENERAL 1.

2.

The shape of the engine hood has been changed to make it easier for the operator to mount and dismount.

The exterior shape has been changed to increase the quality appeal and make it easier to open and close the engine hood.

CHANGES FROM THE PREVIOUS MODEL 1.

2.

The shape (size) of the engine hood has been reduced on the mounting/dismounting side (left side) and at the driver's feet at the front to make it easier to get on and off the vehicle.

At the front side the previously perpendicular edge has been bevelled and the left and right corners have been deeply cut back to improve the quality appearance. The smaller shape means that it is also lighter, so the engine hood is easier to open and close.

Dimensions on previous vehicle

previous vehicle

Unit: mm (in)

Balance Weight GENERAL The exterior shape has been changed to give it a new image.

Side g~

Seat GENERAL 1.

2.

The deluxe seat used on the 6FB series is standard equipment.

The suspension seat used on the 6FB series is an option.

FEATURES Adoption of a contour mat increasesthe amount of cushioning and greatly improvesvibration absorption when traveling over rough roads or stepped roads. *I: The seat cushion is composed of 8 springs and a grid.

Operator fatigue is greatly reduced by the ergonomically designed shape of the seat cushion and back support which provide comfortable fit and appropriate support.

By using a unitary molding manufacturing method the seat surface is without seams, greatly increasing the seat's durability and resistance t o tears.

The reliefs on the seat surface for water removal, combined with the newly developed covering, provide excellent water repellent characteristics so that even when wet the seat can be dried w i t h one wipe.

For personal comfort adjustment, a nob type weight adjustment mechanism is adopted so that anyone can easily adjust the suspension weight adjustment without tools. (Suspension Seat) The unitary molding manufacturing method permits the adoption of a brand new design that departs f r o m seat images u p until now, and the newly developed fabric provides a pleasant feeling t o touch.

The rear of the seat back is equipped with a pocket which can accommodate an operator's manual, etc.

I

Suspension seat

lnstrument Panel & Meter Box GENERAL 1.

2.

The meter box design has been changed t o give it a higher quality appearance.

The meter box has been moved from above the instrument panel to on the steering post, thus improving the operator's field of view of the combination meter and fork tips.

Combination meter Meter box

lnstrument panel

7 Previous model

Combination meter

lnstrument panel

1

Fork New model

COMBINATION METER General 1.

2.

A large stylish design has been adopted.

A non-returning fuel gauge needle has been adopted.

ADVANTAGES OF NEW METER POSITIONING The meters and warning lamps are concentrated in the one box located on the steering mast jacket below the steering wheel.

Combination

'.

1.

2.

3.

4.

5.

Concentration of the meters and warning lights in the center make them easy to check.

The warning lamps are always in the operator's field of view while working, so any warning can be detected early.

The monitors consist of easy-to-understand symbols only.

The combination meter moves with the tilt steering, so it remains easy to see.

The meter illumination comes on when the lighting switch is turned on, so the meter is readily visible at night or in dark locations.

Note: 1. The meters and meter box are rubber mounted, so if they are pushed by hand they will shake.

However, there is no problem with their strength or function.

2. If brake fluid gets on the exterior of the combination meter (black resin), it may cause cracks to appear. Promptly wipe off any brake fluid if it gets spilt on it.

1-38

METER SPECIFICATION VARIATIONS Engine

Specification

STD

142 (24V)

OK Monitors

STD

142 Without intake heater

OK Monitors

Appearance

Engine

Specification

3F

OK Monitors

STD

3F LPG use only

OK Monitors

Appearance

INSTRUMENT LOCATION

1 2 3 4 5 6

Hour meter (STD) Cooling water temperature gage (STD) Fuel gage (STD) Air cleaner clogging indicator (STD) Engine oil pressure (STD) Charge (STD)

7 8 9 10 11 12

Preheating indicator (Diesl: STD) Cooling water level warning (OPT) Battery electrolyte level (OPT) Parking brake and fluid level (OPT) Remaining fuel level (OPT) Sedimenter water level (Diesel: STD)

1. Hour meter (STD) As in the old models, the digit with the white background indicate 1/10 hour.

For easy function check, the function indicator (with red and white pattern) is adopted as in the old models.

The function indicator makes 16 revolutions per minute.

The number of hour meter digits is 6 (including the decimal digit), and the indication returns to zero upon lapse of 100,000 hours.

2. Water temperature gauge (STD) As the meter adopts wide angle characteristic for high temperatures, the deflection angle in greater for a water temperature of 95°C (203°F) or above.

As the reading precision in the important high temperature is high, accurate judgment on an abnormality is possi ble.

3. Fuel gage (STD) Air-core coil type gage structure is adopted. Because of the air-core coil type, the pointer stays at the deflected position.Thus the remaining level can be checked without using the ignition switch. The fuel gage indicates about 112 of the fuel capacity when the pointer is at the center of the scale.

The remaining level at the E position is as follows:

4. Air cleaner clogging warning (STD) When the air cleaner is clogged, the resistance t o the engine intake air increases t o cause lower output, torque reduction, black smoke generation and increased fuel consumption. As this warning lamp is set t o come o n before any of the above defects occurs, wash the element as early as possible after the lamp comes on.

(The element can be washed u p t o 6 times.)

The sensor is located in the pipe on the air cleaner outlet side.

5. Engine oil pressure warning (STD) This indicator informs the operator of the lowering of the engine lubricating oil pressure.

6. Charge warning (STD) This lamp informs the operator of a defect in the charging system.

E position

112 position F position

/

7. Preheat indicator (STD) The 142 engine is equipped with an intake heater.

Preheating operation for it is done as follows: Vehicles with 142 engine: When your key is switched to ON, the starter operates after the lamp goes off.

Note: Gasoline engines are not equipped with this.

8. Cooling water level warning (OPT) This lamp comes on when the water in the reservoir tank becomes lower than the LOW level.

It informs the operator of the insufficient cooling water level before engine overheating occurs.

Note: This lamp may come on because of unstable water level due to vehicle vibration, but it is not a trouble.

9. Battery electrolyte level warning (OPT) This lamp comes on when the battery electrolyte is decreased t o the low level to inform the operator ofthe insufficient battery fluid level before full discharge.

Note: The sensor is installed on the cap of the second cell from the lowest potential cell.

I

Sensor wosition

10. Brake warning (OPT) This lamp comes on when the parking brake is applied.

11. Remaining fuel amount warning (OPT) This lamp comes on before the fluid level reaches the meter E position.

The remaining amounts a t the E position and upon warning lamp ON are shown in the table below.

E position: approx. 20 t (5.3 US gal) Warning : approx. 30 t (7.9 US gal) Note: The switch is integrated w i t h the sender unit.

12. Sedimenter water level warning (Diesel engine models: STD) This lamp informs the operator that the water level in the sedimenter (water separator from gas oil) is approaching the upper limit.

If the vehicle is used without taking any action from this state, water will flow into the injection pump (VE pump) to cause internal rusting in the pump. Drain water by opening the white cock under the sedimenter.

Note: While the lamp is lit, chattering may occur because of vehicle vibration b u t it is not a trouble.

13. Speedometer (OPT) This is installed on the instrument panel. As on the previous model, the odometer has been eliminated, and internal illumination added. Although the odometer has been eliminated, provision of an hour meter as standard equipment makes it possible to conduct vehicle management by hours.

14. Burnt out lamp bulb check (1) In case of STD combination meter: As in the old models, all warning lamps come on when the ignition switch is turned ON (with the engine in stop state).

Note: On the 142 engine, the glow indicator lamp does not light u p at water temperatures above 2.5"C (365°F).This may be mistaken instead as a burnt out bulb or some other malfunction. If an inspection is actually necessary, disconnect the water temp. sensor connector (green color) beside the water pump, then turn the key t o ON. ( 2 ) In case of combination meter with OK monitor: Pull (apply) the parking brake lever when the ignition switch is turned to ON (with the engine in stopped state), and press the check switch in the right hand portion of the instrument panel. All warning lamps will come on.

Note: For the glow indicator lamp, the check method is the same as i n the case of the STD combination meter.

As one meter illumination lamp is provided on each of the left and right sides; check them by pressing the lighting switch.

ELECTRICAL SYSTEM Relays GENERAL The relays are located under the side cover at the left side of the frame. The preheating timer for diesel engined vehicles is located behind the body-side instrument panel.

These locations improve protection from penetration by rain water and improve reliability and durability.

RELAY TABLE

0:Provided -: Not provided

Flasher unit Starter relay Glow relay

0

Glow timer

0

Accumulator relay

0"'

-

LPG relay

-

0*2

Rotation switch

-

0"2

Backup relay

0

0

Battery level relay

0

0

Segmenter relay

0

-

* I : Only for 8 ton vehicles *2: Only for LPG vehicles

-

1.

2.

3.

The same V mast as o n the previous model is standard equipment.

The material handling speed of the V mast is the same as on the previous model.

The material handling speed (average for full stroke) of the FSV mast is as shown below.

MATERIAL HANDLING SPEED (Average for full stroke) V Mast Model (tons)

Engine type

-

Lifting speed m m l s e c (f.p.m) No load

Loaded

5- 6

3F

360 (71)

330 (65)

5-7

142

500 (98)

450 (89)

8

142

430 (85)

400 (79)

Lowering speed m m l s e c (f.p.m) No load

Loaded

500 (98)

400 (79)

FSV M a s t Lifting speed mm/sec (f.p.m) Model (tons)

1.

2.

3.

4.

Lowering speed mm/sec (f.p.m)

Engine type No load

Loaded

5- 6

3F

340 (67)

310 (61)

5-7

142

470 (92)

425 (84)

8

1 42

415 (82)

375 (74)

No load

Loaded

450 (89) 400 (79) 400 (79)

FSV mast models cannot be fitted with tire chains.

8 t o n model cannot combine the FSV mast with European specifications.

5 - 7 ton model w i t h the A418 piping cannot combine the FSV mast with European specifications.

8 ton model cannot combine the FSV mast with 10.00-20-14 tires.

HYDRAULIC OIL COOLER General 8 t o n model are equipped with the hydraulic oil cooler as standard equipment.

0: Standard equipment Model with 2 mode C/V (STD model) 60-5FD80 1.

2.

Model with 3.4 mode C/V

O

8 t o n model have a high load on their brake system, so models with a 2 mode C/V (STD model) and u p have a hydraulic oil cooler as standard equipment t o counter the consequent temperature increase.

See page 4-2 for the hydraulic circuit of the hydraulic oil cooler.

ENGINE Page

142 ENGINE EXTERIOR VIEW . . . . . . . . . . . . . . . . . . . . . . . . 2-2 142 ENGINE PERFORMANCE CURVES . . . . . . . . . . . . . . 2-3 142 ENGINE ENGINE SPEED ADJUSTMENT . . . . . . . . 2-4 IDLING SPEED INSPECTION AND ADJUSTMENT . . . . . . . . 2-4 NO-LOAD M A X I M U M SPEED INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

V BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

142 ENGINE EXTERIOR VIEW

142 ENGINE PERFORMANCE CURVES

35. Okgf

/

e

m

(344N.m) /1600rpm

95PS (69.8kw) /2200rpm 2400 r p m spec. (5, 6, 7 ton)

2600 r p m spec. (8 ton)

(g/kw

210

2400 r p m spec. ( 5 , 6, 7 ton) I

10

1

14

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18 Engine speed (rpm)

150 I

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22

26 x102

142 ENGINE ENGINE SPEED ADJUSTMENT IDLING SPEED INSPECTION AND ADJUSTMENT 1.

Warm up the engine.

Coolant temperature : 80°C (176°F) or above Engine oil temperature : 70°C (158°F) or above Hydraulic oil temperature: 50°C (122°F) or above

2.

Install the engine tachometer.

3.

Inspect the engine idling speed. ldle speed:

4.

+ 25 rpm

Adjust the engine idling speed.

Loosen the lock nut, and turn the adjusting screw t o adjust the idling speed.

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Idle speed adjusting screw

750

NO-LOAD MAXIMUM SPEED INSPECTION AND ADJUSTMENT 1.

Warm up the engine.

Coolant temperature : 80°C (176°F) or above Engine oil temperature : 70°C (158°F) or above Hydraulic oil temperature : 50°C (122°F) or above

1

Maximum speed sdjmting screw

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2.

Install the engine tachometer.

3.

Fully depress the accelerator pedal, and inspect the noload maximum speed.

No-load maximum speed 5 - 7 ton model : 2400 50 rpm 8 ton model : 2600 k 50 r p m

*

4.

Adjust the no-load maximum speed.

(1) Remove the sealing wire.

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(2) Loosen the lock nut, and make the adjustment by turning the maximum speed adjusting screw.

(3) Operate the material handling lever when the engine is running at the maximum speed and measurethe engine speed in the full relief state. Confirm that the speed decrease (relief down) satisfies the following value.

Engine speed down at full relief 5.6 t o n model: 200 r p m or less 7.8 t o n model: 250 r p m or less

Water p u m p pulley

V BELT ADJUSTMENT

Measurement position

1, Alternator pulley

Inspect the V belt tension.

Standard [Deflection when pushed w i t h a force of 98N (10 kgf) [22 Ibfl 142 engine 9 mm (0.28 - 0.35 in.) new parts installed: 7 at inspection : 8 13 mm (0.31 - 0.51 in.)

-

Crankshaft pulley

Standard [When the tension gauge (SST) is used] 142 engine new parts installed: 520 - 755 N (53 - 77 kgf) [I17 170 lbfl : 324 559N (33- 57 kgf) at inspection [73 - 126 Ibf]

-

Loosen the alternator hit bolt, and adjust the V belt t o the standard tension.

BATTERY SPECIFICATIONS Battery type

: 75D31R x 2 (N70Z)

Voltage

: 24 V

Battery capacity

: 60AH15HR

Specific gravity when fully charged : 1.280 at 20°C (68°F) Specific gravity when discharged

: 1.120 at 20°C (68°F)

Electrolyte quantity

: 5.2 e (1.37 USgal)

Battery weight

: 20 x 2 k g (44.1 x 2 Ib)

ACCELERATOR PEDAL ACCELERATOR PEDAL ADJUSTMENT

1.

2.

3.

Loosen the accelerator wire bracket @ set bolt to free the accelerator wire.

Loosen the lock nut for pedal height adjusting bolt @ .

Measure the height from the toe board to the tip end of the accelerator pedal (with pedal pad).

Standard accelerator pedal height : A = 141 mm (5.55 in) : B = 187 mm (7.36 in)

4.

5.

6.

If the standard dimension above is not satisfied, adjust to the specified dimension by turning pedal height adjusting bolt @ and fully tighten the lock nut.

Tighten the accelerator wire bracket set belt.

Adjust the height of accelerator pedal stopper bolt @ .

C = 32 m m (1.26 in) (reference value)

3F engine models (1) Depress the accelerator pedal gradually, and adjust the height of stopper bolt @ so that the carburetor throttle lever stops immediately before the full opening position.

142 engine models (1) Adjust the height of stopper bolt @ so that the clearance between the injection pump lever and maximum speed adjusting screw satisfies the following range when the accelerator pedal is in contact with stopper bolt @ .

D 0 0.5 mm (0 0.020 in) 0 m m (0 in) clearance here means that the accelerator pedal comes into contact with the stopper bolt at the same time with establishment of the contact between the lever and adjusting screw.

-

-

TORQUE CONVERTER Page

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . 3-7 SPECIFICATIONS ...................................

3-8

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 CONTROL VALVE ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 REMOVAL.INSTALLATI0N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 DISASSEMBLYINSPECTI0N.REASSEMBLY . . . . . . . . . . . . . . 3-21

TORQUE CONVERTER & TRANSMISSION . . . . . . . . . . 3-24

CLUTCH SHAFT

DISASSEMBLYINSPECTIONnREASSEMBLY. . . . . . . . . . . . 3-36

SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43

INCHING PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 3-46 MEASUREMENTTEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

GENERAL

/

F: Forward R: Reverse

Torque converter

Control valve

Accumulator piston

---

Regulator valve,torque converter inlet pressure relief valve

Clutch shaft (Forward)

Clutch shaft (Reverse)

inlet Change pump 34.7 cm3/rev (2.118 in 3 /rev)

Strainer 120 mesh

9 -------

Torque converter ASSY

SPECIFICATIONS Item

Maker Torque converter type Stall torque ratio rPm

Stall speed

5FG50.60

5FD50.60.70 5FDN50.60 5FDM60.70 60-5FD80

EXEDY

t

4-element, 2-stage, 3-phase type

t

8.42

t

1600

- 1800

1850 - 1950

Forward

0.675

t

Reverse

0.675

t

Hydraulic

t

Gear ratio Shift method Torque converter inlet pressure kPa (k g f/cm 2 ) [psi]

Idling

200 (2) [281

t

At 2000 rpm

690 (7) [1001

t

Torque converter outlet pressure kPa (kgf/cm 2 ) [psi]

Idling

98 (1) 1141

t

At 2000 rpm

490 (5) [71]

t

Clutch operating pressure kPa (kgf/cm 2 ) [psi]

Idling

1770 (18) [2561 or above

t

1770-2260 (18- 23) [256 3271

-

t

9.8 (0.1) [ I .41

t

98 (1) [I41

t

15 (4.0)

t

Torque converter oil

Auto fluid (GM ~ e x r o n % )

t

Applicable engine

3F

142

At 2000 rPm

Lubrication pressure Idling kPa (kgf/cm2) [psi1 ~t 2000 rpm Torque converter oil capacity

e (Usgal)

Note: The torque converter hydraulic pressure is measured with the torque converter oil temperature at 80°C (176 O F ) .

TROUBLESHOOTING Trouble status The power is not transmitted.

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Cause 1.

N o oil pressure (1) lnsufficient oil level (2) Damaged oil p u m p or drive part (3) Damaged piston or broken spring in torque converter inlet relief valve or regulator valve (4) Malfunction b y w o r n or damaged control valve spool or foreign matter trapping (5) Worn or damaged clutch shift sealing (6) Malfunction by w o r n clutch piston sealing or foreign matter trapping

2.

Mechanical damage (1) Damaged drive plate (2) Broken shaft or gear (3) Damaged spline (4) Damaged clutch drum

(5) Damaged snap ring at clutch drum (6) Damaged clutch plate (7) Damaged clutch disc

(8) Sticking of plates Lowered output

1.

Low oil pressure (1) Insufficient oil quantity (2) Air entrance in suction side

(3) Clogged strainer (4) Lowered oil p u m p efficiency

(5) Fatigue of regulator valve spring or piston malfunction

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Remedial action

1 Oil pressure measurement and stall test Oil addition Disassembly -+ inspection parts replacement Disassembly + inspection + parts replacement Disassembly -+ inspection -+ parts replacement Disassembly + inspection + parts replacement disassembly -t inspection -t parts replacement

Disassembly -t inspection + parts replacement Disassembly -t inspection + parts replacement Disassembly + inspection -t parts replacement Disassembly -+ inspection t parts replacement Disassembly -t inspection -+ parts replacement Disassembly + inspection + parts replacement Disassembly -t inspection -+ parts replacement Disassembly -+ inspection + parts replacement Oil pressure measurement and stall test Oil supply Gasket inspection -+ parts replacement Disassembly -t inspection + cleaning or parts replacement Disassembly -+ inspection -t cleaning or parts replacement Disassembly -+ inspection -t parts replacement

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Trouble status Lowered output

Cause

Remedial action

(6) Fatigue of spring of torque converter inlet relief valve or piston malfunction ( 7 ) Worn or damaged seal ring

Disassembly -t inspection -+ parts replacement

(8) Malfunction by damaged selector valve or inching valve in the control valve or foreign matter trapping (9) Malfunction by worn clutch piston seal ring or foreign matter trapping

2.

Mechanical Damage (1) Damaged or deformed impeller (2) Deformed clutch drum

Other (1) Use of improper oil (other than the specified type)

Replacement with specified oil -r clutch disc replacement as required

(1) Improper oil level (2) Contact of impeller (3) Worn or seizure of bearing (4) Dragging by deformed clutch disc or clutch plate (5) Malfunction of oil cooler

(6) Clutch slipping and lowered efficiency by use of improper oil (other than the specified type) (7) Worn or damaged oil p u m p Abnormal sound generation

Parts replacement

(5) One way clutch slipping

(4) Deformed clutch plate

Abnormal oil temperature rise

Disassembly -+ inspection -+ parts replacement

Disassembly -+ inspection -+ parts replacement Disassembly + inspection -t parts replacement Disassembly -t inspection + parts replacement Parts replacement

(3) Burnt clutch disc

3.

Disassembly -+ inspection -t parts replacement Disassembly + inspection -+ parts replacement

(1) Insufficient oil level or generation of cavitation by air entrance f r o m the suction side (2) Damaged oil p u m p (3) Contact of deformed impeller (4) Damaged drive plate

Oil addition or reduction Parts replacement Disassembly + inspection + parts replacement Disassembly -+ inspection + parts replacement Disassembly -t inspection -t parts replacement Replacement with specified oil -+ clutch disc replacement as required

Disassembly -t inspection -+ parts replacement Oil addition

Disassembly + inspection -+ parts replacement Parts replacement Disassembly -t inspection -t parts replacement

1

Trouble status

Cause (5) Damaged gear

Abnormal sound generation

(6) Worn or damaged bearing

(7) Worn spline (8) Wear at contact faces of clutch drum and clutch plate (9) Loosened bolt (10) Clutch slipping by lowered oil temperature (11) Generation of cavitation caused by clogged suction filter

Oil oozing or leaking

1.

Oil seal portion (1) Worn or damaged lip (2) Foreign matter (dust) trapping (3) Worn or damaged shaft (4) Hardened or fatigued rubber by abnormal oil temperature rise

2.

1

O-ring (1) Damaged O-ring (2) Scratch on mating face

(3) Hardened or fatigued rubber by abnormal temperature rise (4) Sudden use at very l o w temperature (-15°C) [5"FI 3.

1

Joint faces with gasket in-between (1) Loosened bolts (2) Damaged gasket 13) Surface defect on mating face

4.

Plugs and threaded portions (1) Loosened bolt(s) (2) Broken bolt(s) (3) Crack in internal thread (4) Defective sealing material (including tape)

Remedial action Disassembly + inspection + parts replacement Disassembly -+ inspection + parts replacement Disassembly -t inspection -t parts replacement Disassembly + inspection + parts replacement Bolt retightening Oil pressure inspection Disassembly -+ inspection + parts replacement

Disassembly + inspection -+ parts replacement Disassembly + inspection + parts replacement Disassembly -+ inspection + parts replacement Disassembly + inspection + parts replacement

Disassembly -t inspection + parts replacement Disassembly + inspection + parts replacement Disassembly -t inspection -+ parts replacement Warming u p

Retightening Disassembly + inspection + reassembly Disassembly + inspection + reassembly Retightening Disassembly + inspection + reassembly Disassembly -t inspection -+ reassembly Sealing material recoating

Trouble status

Cause

Remedial action

(4) Clutch piston malfunction by foreign matter trapping (5) Worn selector valve in control valve (6) Clogged drain circuit in control valve (7) Staged wear of clutch drum spline (8) Clogged clutch piston check valve

Disassembly + inspection -t reassembly Disassembly + inspection + reassembly Disassembly + inspection -+ reassembly Disassembly + inspection + reassembly Disassembly + inspection + reassembly Disassembly + inspection + reassembly Disassembly + inspection -+ reassembly Disassembly + inspection + reassembly

Slow clutch application

(1) Worn clutch disc or clutch plate (2) Increased oil leak due t o w o r n or damaged clutch seal ring (3) Broken spring or piston malfunction in regulator valve (4) Clogged oil path in control valve (5) Malfunction of selector valve or inching valve

Disassembly -t inspection -+ parts replacement Disassembly -+ inspection -+ parts replacement Disassembly -+ inspection -t parts replacement Disassembly + inspection + parts replacement Disassembly + inspection + parts replacement

Shock generation

(1) Fatigued or broken accumulation spring (2) Malfunction of accumulator piston (3) Fatigued or damaged camber plate (4) Insufficient clutch off margin

Disassembly + inspection + parts replacement Disassembly + inspection + parts replacement Disassembly -t inspection + parts replacement Clutch drum adjustment t o the standard value

Drag torque generation

(1) Deformed clutch disc or drive plate (2) Fatigued or broken clutch return spring (3) Clutch gear bearing seizure

COMPONENTS Torque converter housing

Torque converter

Torque converter clutch (Foward)

Torque converter clutch (Reverse)

Torque converter gear

Control valve

Oil pump & pump drive gear

Torque converter piping

CONTROL VALVE ASSY REMOVAL.INSTALLATION T = N.m (kgf-cm) [ft-lbfl

,

Removal Procedure 1

Open the engine hood.

2

Remove the toe board No. 2.

3

Disconnect the inching wire.

4

Disconnect the solenoid valve wire.

5

Remove the control valve ASSY.

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

DISASSEMBLYINSPECTION~REASSEMBLY T = N.m (kgf-cm) [ft-lbfl T = 11.8 - 14.7 (120 - 150) L8.68 - 10.851

Disassembly Procedure 1

Remove the solenoid valve. [Point 11

2

Remove the engine cover.

3

Remove the inching spool, inching spring and return spring. [Point 21

4

Remove the accumulator piston, stopper and accumulator spring. [Point 31

5

Remove the selector spool and the selector spring. [Point 41

6

Remove the oil seal. [Point 51

Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.

Note: Apply grease to the lip of the oil seal.

Thoroughly clean the piston and spool, blow them with compressed air, coat them with torque oil and reassemble them.

Point Operations [Point 11 Inspection: Inspect the continuity of the solenoid.

Standard: Continuity for forward side and reverse side.

]

[Point 21 Inspection: Measure the clearance between the inching spool and the body.

Standard: 0.02 - 0.041 m m (0.00079 0.00161 in) : 0.1 m m (0.004 in) Limit

-

[Point 31 Inspection: Measure the clearance between the accumulator piston and body.

0.03 - 0.071 m m (0.00118 - 0.00280 in) : 0.1 m m (0.004 in)

Standard: Limit

0

1

[Point 41 Inspection: Measure the clearance between the selector spool and body.

0.02 - 0.041 m m (0.00079 - 0.00161 in) : 0.1 m m (0.004 in)

Standard: Limit

Inspection: Measure the free length of each spring.

Unit: m m (in) Spring

Free length

Free length limit

lnching piston spring

31.43 (1.2374)

30.5 (1.201)

Inching return spring

79.6 (3.134)

77.0 (3.031)

Accumulator spring

149.73 (5.8949)

149.3 (5.879)

Selector spring

59.1 3 (2.3280)

58.6 (2.308)

[Point 51 Installation: SST 09950-60010 . . . (1) SST 09950-7001 0 . . . (2)

3-24

TORQUE CONVERTER & TRANSMISSION REMOVAL.INSTALLATlON

Torque converter wire Temporary suspension rope Torque converter oil

Removal Procedure 1

Remove the body.

(See page 9-6 in the 5FD50 80 Repair Manual (No. CE007)forthe body removal procedure. However, " ~ r o c e d u r e11. Remove torque converter shift rodVisnot necessary)

2

Drain hydraulic oil.

3

Disconnect the tilt lift lever rod clevis from the oil control valve.

4

Disconnect the brake tube, brake switch wire and inching wire.

5

Remove the brake pedal bracket W/ brake booster (5 - 7 ton model) or brake valve (8 ton model).

6

Disconnect all wires from the torque converter

7

Disconnect the torque converter hose.

8

Remove the oil pump for material handling.

9

Remove the propeller shaft.

-

10

Remove the flexible plate set bolt. [Point 11

11

Suspend the torque converter ASSY. [Point 21

12

Remove the torque converter housing set bolt.

13

Remove the torque converter LH mounting bracket

14

Remove the torque converter ASSY W / parking brake. [Point 31

15

Drain torque converter oil.

16

Remove the output flange W1 parking brake drum.

17

Remove the parking brake ASSY f r o m the torque converter ASSY.

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

Note: After installation, bleed air from the brakes.

After installation, adjust the inching pedal.

After installation, inspect the clearance of the parking brake shoe and the operation force of the parking lever. (See page 8-30 of the 5FD50 80 Repair Manual (No. CE007) for the inspection procedure.)

The tightening torque of each part is as follows.

-

Parking brake ASSY set bolt

Unit: N.m (kgf-m) (ft-lbf) : 147.10 - 166.71 (1500 - 1700) i108.53 - 123.001

Output flange set bolt

:

Torque converter mount set bolt

: 56.88

176.52 - 225.55 (1800

- 2300) [130.23 - 166.411

- 86.30 (580 - 880) [41.96 - 63.671

Torque converter mount bracket set bolt : 56.88 - 86.30 (580 - 880) l41.96 - 63.671 Torque converter housing set bolt Flexible plate set bolt Propeller shaft set bolt Material handling oil pump set bolt

- 450) [21.71 - 32.561 : 14.71 - 24.52 (150 - 250) 110.85 - 18.091 : 69.82 - 104.74 (712 - 1068) [51.51 - 77.271 : 50.01 - 116.70 (510 - 1190) i36.90 - 86.101 : 29.42 - 44.13 (300

Point Operations [Point 1 I

Removal~lnstallation: Remove the torque converter end plate cover and remove the flexible plate set bolt. To turn the fly wheel, apply a box wrench to the crankshaft pulley set bolt and turn it.

No. of set bolts for flexible plate 142 engine: 9 bolts 3F engine : 9 bolts

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[Point 21

Removal: Attach wire ropes to the torque converter ASSY, lift it up and support it with stands under the torque converter end plate at the engine side.

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[Point 31

Removal~lnstallation: The torque converter vanes will fall out if the torque converter housing is tilted, so tie the housing and flexible plate together with some twine t o prevent it.

w

Twine

Note: The disassembly procedure for the following parts once they have been removed from the torque converter housing is described on the pages mentioned below.

For disassembly of the control valve, see page 3-21.

For disassembly of the clutch shaft, see page 3-36.

T = N.m (kgf-cm) [ft-lbf]

Disassembly Procedure 1

Remove the torque converter housing W/ flexible plate. [Point 11

2

Remove the flexible plate.

3

Remove the torque converter case.

4

Remove the oil seal from the torque converter case. [Point 21

5

Remove the control valve.

6

Removetheoilpump.

7

Remove the PTO gear cover and the PTO gear W/ bearings.

8

Remove the bearings from the PTO gear. [Point 31

9

Remove the housing cover. [Point 41

10

Remove the output shaft bearing retainer from the housing cover.

11

Remove the oil seal from the retainer. [Point 51

12

Remove the output shaft W/ bearing.

13

Remove the output shaft gear bearing. [Point 61

14

Remove the forward clutch gear W/ bearing. (For removal/instaIlation of the gear bearing, see disassembly of the clutch shaft on page 3-36.)

15

Remove the reverse crankshaft.

16

Remove the forward crankshaft.

17

Remove the snap ring for the stator support gear bearing and the snap ring (for the hole) for idle gear No.1.

18

Remove the idle shaft No. 1 idle gear No.1 bearing.[Point 71

19

Remove the stator support gear.

20

Remove the stator support gear bearing. [Point 81

21

Remove the stator support.

22

Remove the seal ring from the stator support. [Point 91

23

Remove the PTO idle shaft No.2. [Point 101

24

Remove the PTO idle gear No.2.

25

Remove the PTO idle gear No.2 bearing. [Point 111

26

Remove the strainer.

27

Remove the regulator valve and torque converter inlet relief valve. [Point 121

28

Remove the speedometer sensor. [Point 131

Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.

Oil seal

Seal ring

Point Operations [Point 1 I Disassembly: Be careful with the torque converter - it contains oil.

The torque converter cannot be disassembled.

Reassembly: Coat grease o n the seal ring and oil seal lip before installation.

Inspection: Measure the diameter of the pilot boss.

142 and 3F

Standard: 14.966 - 14.984mm (0.58921 - 0.58992in) Limit : 14.916mm (0.58724in)

Inspection: Measure the exterior diameter of the impeller hub.

Standard diameter: 124.9 - 125.0mm (4.917- 4.921 in) Limit diameter : 124.8mm (4.913in)

Inspection: Measure the interior diameter of the impeller hub.

- 70.03mm (2.7559- 2.7571 in) : 70.13 mm (2.7610in)

Standard diameter: 70.00 Limit diameter

/

[Point 21 Reassembly: Apply sealant (08833-00080) t o the outer edge of the oil seal before installing it.

SST 09700-30200-71

SST

Reassembly: Coat grease o n the oil seal lip after installation.

[Point 31

Disassembly: Front bearing SST 09950-4001 0 . . . . . (1) SST 09950-60010 . . . . . (2)

Disassembly: Rear bearing SST 09950-40010 . . . . . (1) SST 09950-60010 . . . . . (2) SST 09420-23000-71 . . (3)

Oil seal

Reassembly: Make sure you install the front bearings (on the materials handling pump side) facing the correct direction: the surface with the bearing seal must be on the materials handling pump side.

Reassembly: Front bearing SST 09700-30200-7 1

Reassembly: Rear bearing SST 09950-6001 0 . . . . . (1) SST 09950-70010 . . . . . (2)

[Point 41 Disassembly: Using the service bolt, remove the housing cover.

Service bolt

Service bolt size:

M I 0 x 15

Inspection: Measure the inner diameter of the shaft sliding part of the housing cover.

40.20 - 40.25 m m (1.5827 1.5846 in) : 40.35 m m (1.5886 in)

Standard diameter: Limit diameter

-

[Point 51

n SST (2)

Reassembly: Coat the oil seal outer surface w i t h sealant (08833-00080) before instal lation.

SST 09950-60020 . . . . . ( 1) SST 09950-70010 . . . . . (2) Reassembly: After assembly, coat the oil seal lip w i t h grease.

Oil seal

[Point 61 Disassembly: Bearing at the bearing case side o n the retainer side.

SST 09950-40010 . . . . . (1) SST 09420-23000-71 . . (2)

Disassembly~Reassembly: Use a copper rod t o remove the gear.

Reassembly: Bearing at the bearing case side on the retainer side.

SST 09370-20270-7 1

-SST

[Point 71

Disassembly: SST 09810-20172-71

[Point 81

Disassembly: Front bearing SST 09950-40010 . . . . . (1) SST 09950-60010 . . . . . (2)

Disassembly: Rear bearing SST 09950-40010 . . . . . (1) SST 09950-60010 . . . . . (2)

Reassembly: Front bearing SST 09950-60010 . . . . . (1) SST 09950-7001 0 . . . . . (2)

Reassembly: Rear bearing SST 09700-30200-7 1

[Point 91

Inspection: Inspect the stator support ring.

Seal ring thickness Standard: 2.28 - 2.33 m m (0.0898 - 0.0917 in) Limit : 2.08 m m (0.0819 in) Seal ring opening clearance Standard: 0.03 - 0.05 m m (0.0012 - 0.0020 in) : 1.0 m m (0.039 in) Limit [Point 101

Disassembly: SST 09810-20172-71

Reassembly: SST 09950-6001 0 . . . . . (1) SST 09950-70010 . . . . . (2)

[Point 11I

Disassembly: Lightly tap the washer at the center of the idle gear bearing and remove the bearing.

SST 09700-30200-7 1

Reassembly: Make sure the washer is installed at the center of the idle gear bearing.

Washer

I [Point 121 / Inspection: lnspect the clearance between the regulator valve piston and the housing.

Standard : 0.020 - 0.071 mm (0.00079 - 0.00280 in) : 0.1 mm (0.004 in) Limit

Inspection: lnspect the free length of the regulator valve spring.

Inner spring : Standard : Limit :

107.96 mm (4.2504 in) 106.6 mm (4.197 in)

Outer spring: Standard : Limit :

98.58 mm (3.8811 in) 96.0 mm (3.780 in)

Inspection: Inspect the clearance between the torque converter inlet valve piston and the housing.

Standard: Limit

-

0.015 0.049 m m (0.00060 - 0.00193 in) : 0.1 m m (0.004 in)

Inspection: Inspect the free length of the torque converter inlet valve spring.

Standard: 64.5 m m (2.539 in) : 62.4 m m (2.457 in) Limit

[Point 131

Reassembly: Put a copper washer on the speed sensor and tighten it.

Speed

Washer thickness: 0.6 m m (0.024 in) T = 19.61 - 39.23 N.m (200 400 kgf-cm) [14.47 - 28.94 ft-lbf]

-

CLUTCH SHAFT DISASSEMBLY.INSPECTION=REASSEMBLY Note: The internal construction of the forward clutch shaft and the reverse clutch shaft are the same. Accordingly, only the disassembly procedure of the reverse clutch shaft is included here.

Forward clutch shaft

Reverse clutch shaft

8

Disassembly Procedure 1

Remove the seal ring. [Point 11

2

Remove the snap ring.

3

Remove the bearing and washer. [Point 21

4

Remove the clutch gear W/ bearing. [Point 31

5

Remove the bearing from the clutch gear. [Point 41

6

Remove the snap ring, camber plate, backing plate, clutch disc and clutch plate. [Point 51

7

Remove the clutch return spring. [Point 61

8

Remove the clutch piston. [Point 71

9

Remove the seal ring f r o m the clutch piston. [Point 81

10

Remove the seal ring f r o m the clutch shaft. [Point 91

Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.

Note: Wash each part, blow it with compressed air and apply hydraulic oil before reassembly.

Apply grease to the seal ring before reassembly.

3-38

Point Operations [Point 1 I

Inspection: lnspect the seal ring.

Seal ring thickness Standard: 2.9 - 3.0 m m (0.114 : 2.7 m m (0.106 in) Limit

- 0.118 in)

Inspection: lnspect the seal ring opening clearance.

-

Standard: 0.1 0.4 m m (0.004 - 0.016 in) Limit : 1.0 m m (0.039 in)

[Point 21

Disassembly: Front bearing SST 09950-4001 0

+

SST

Disassembly: Rear bearing (for forward use) SST 09950-400 10

Disassembly: Rear bearing (for reverse use) Insert a screwdriver between the bearing and clutch drum, and pry out the bearing.

Reassembly: Check that washers are installed on both sides of the front bearing.

Reassembly: Front bearing SST 09370-20270-71

Reassembly: Rear bearing (for reverse) SST 09700-30200-7 1

Reassembly: Rear bearing (for forward) SST 09370-20270-71

SST

[Point 31 Reassembly: Before installing the clutch gear in the clutch drum, use a screwdriver t o align the serrations of the clutch disc.

[Point 41 Disassembly: The position of the clutch bearing depends on the snap ring. Accordingly, tap the snap ring with a brass rod from the bearing interior.

Reassembly: Check that the snap ring is securely installed the groove of the clutch gear.

Reassembly: Reassemble the bearing.

SST 09370-10410-7 1

1

Inspection: Measure the camber plate convex height.

5.35 - 5.65 m m (0.2106 0.2224 in) : 5.0 m m (0.197 in)

Standard convex height:

Limit convex height

1

-

Inspection: Measure the clutch disc. thickness.

2.6 - 2.8 m m (0.102 0.110 in) : 1.7 m m (0.067 in)

Standard thickness: Limit thickness

-

I Inspection: Measure the clutch plate thickness.

Standard thickness:

Limit thickness

C a m b e r plate Snap ring

1.95 2.05 m m (0.0768 - 0.0807 in) : 1.85 m m (0.0728 in)

the clutch plates and clutch discs alternately on the clutch d r u m while coating t h e m ! Reassembly: Install with torque converter oil.

No, of clutch discs : No, of clutch plates:

9 9

Reassembly: Install the backing plate with the better finished surface facing the clutch disc side.

Reassembly: Install the camber plate o n the clutch d r u m with the punch marked A side facing down.

/

[Point 61

Inspection: Measure the free length of the clutch return spring.

Free length : 55.6 m m (2.189 in) Limit free length: 52.8 m m (2.079 in)

[Point 71

Disassembly: Remove the piston w i t h a service bolt.

Service bolt size:

M I 0 x 1.5

Inspection: Inspect the clutch piston. ) Clutch piston inner diameter Standard inner diameter: 58.0 - 58.05 m m (2.2835 Limit inner diameter: 58.15 m m (2.2894 in)

1

- 2.2854 in)

Inspection: lnspect the piston contact surface of the clutch drum.

Clutch drum inner diameter Standard inner diameter: 155.08 - 155.13 m m (6.1055 Limit inner diameter: 155.23 m m (6.1114 in)

- 6.1075 in)

[Point 81 Inspection: lnspect the piston seal ring.

Seal ring thickness 2.92 m m Standard thickness: 2.87 (0.1130 - 0.1150 in) : 2.67 m m (0.1051 in) Limit thickness Inspection Install the seal ring in the piston installation position in the clutch drum, and measure the opening clearance.

Standard clearance: 0.03 - 0.05 m m (0.0012 - 0.0020 in) : 1.0 m m (0.039 in) Limit clearance [Point 91

-

Inspection: lnspect the seal ring.

Seal ring thickness Standard thickness:

-

2.4 2.45 m m (0.0945 - 0.0965 in) : 2.2 m m (0.0866 in)

Limit thickness

/ Inspection: lnspect the seal ring opening clearance.

0.03 - 0.05 m m (0.0012 - 0.0020 in) : 1.0 m m (0.039 in)

Standard clearance: Limit clearance Opening clearance

3-43

SHIFT LEVER GENERAL

Direction switch

Turn signal switch

Turn signal switch Horn switch

Direction switch

REMOVAL4NSTALLATION T = N.m (kgf-cm) (ft-lbf) I

I

I

1

Removal Procedure 1

Remove the steering wheel. (See procedure 1 on page 5-8.)

2

Remove the turn signal switch cover. (See procedure 2 on page 5-8.)

3

Disconnect the wiring of the shift lever and turn signal switch.

4

Remove the shift lever W / turn signal switch.

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

INCHING PEDAL ADJUSTMENT 5FG / 5FD50~6O15FDN50~60,5FD70

Adjust the stopper bolt so that the inching pedal height is at dimension A or B above the toe board.

-

Adjust the inching cable until the inching lever stroke on the torque converter side is 7 8 m m (0.280.31 in) and the inching pedal plate touches the center link (there is no play in the brake booster push rod). (Adjust play C so that the play of the clevis and cable is 0.5 m m (0.02 in).) lnching pedal height (without pad) :

147 - 152 mm (5.79 - 5.98 in) 150 - 155 mm (5.91

lnching pedal height (with pad)

:

Stroke until brake starts to work

: 3

Stopper bolt length (reference)

: 23 mm (0.91 in)

lnching pedal stroke (reference)

:

- 6.10 in)

- 5 mm (0.12 - 0.20 in)

30

- 40 mm (1. I 8 - 1.57 in)

V/ldjusting nut

-

-

Adiustina nut

(Torque converter inching lever stroke) 7.5 - 8.5 mm (0.295 - 0.335 in)

i

lnching

Torque converter inching lever

(Reference)

1.

Adjust the stopper bolt so that the inching pedal height is at dimension A or B above the toe board.

2.

Adjust the inching cable until the inching lever stroke on the torque converter side is 7.5 8.5 mm (0.30 0.33 in) and the inching pedal plate touches the center link (there is no play in the brake valve push rod). (Adjust play C so that the play of the clevis and cable is 1.0 m m (0.04 in).)

-

-

A: lnching pedal height (without pad) :

147 - 152 mm (5.79 - 5.98 in)

C: Stroke until brake starts to work

- 155 mm (5.91 - 6.10 in) : 3 - 6 mm (0.12 - 0.24 in)

D: Stopper bolt length (reference)

:

20 mm (0.79 in)

E: lnching pedal stroke (reference)

:

23 - 30 mm (0.91 - 1.18 in)

6: lnching pedal height (with pad)

: 150

MEASUREMENTTEST 1.

Oil level measurement (1) Keep the vehicle horizontal, set the shift lever in neutral position and keep the engine idling.

(2) After warming up the engine, keep it idling and measure the oil level with the level gage. The oil limit is acceptable if it is between the upper limit (F) and lower limit (L). If insufficient, add oil through the level gage mounting port.

2.

Oil pressure measurement (1) After warming up the engine, measure the idling speed and no-load maximum speed.

(2) Stop the engine and jack up the front axle so that the tires (both wheels) are off the ground.

(3) Remove the toe board and set the oil pressure gage.

A: Torque converter inlet pressure (size PT118) B: Torque converter outlet pressure (size PT1/4) C: Lubrication pressure (size PT114) D: Forward clutch pressure (size P T l I 8 ) E: Reverse clutch pressure (size PT118)

Note: Do not depress the inching pedal while measuring the oil pressure.

(4) Start the engine and measure each pressure at idling and at 2000 rpm. @ With the shift lever at neutral, measure the torque converter inlet pressure (A) and the torque converter outlet pressure (B). @ With the shift lever at neutral, measure the lubrication pressure (C). @ With the shift lever at forward traveling, measure the clutch pressure (D). @ With the shift lever at reverse traveling, measure the clutch pressure (El. F~~

Idling

2000 r p m

%

Torque converter inlet pressure

kPa (k g f/cm 2 ) [psi]

200 (2) [281

690 (7) [I001

Torque converter outlet pressure

kPa (kgf/cm2) [psi]

98 (1) [I41

490 (5) [71 I

Lubrication pressure

kPa (kgf/cm 2 ) [psi]

9.8 (0.1) [1.41

98 (1) [I41

Forward clutch pressure

kPa (kgf/cm2) [psi]

1770 (18) [2561 or above

1770 - 2260 (18 - 23) [256 3271

Reverse clutch pressure

kPa (kgf/cm2) [psi]

1

t

3.

Stall test (1) Load a cargo nearthe maximum allowable load, chock the vehicle front and rear wheels securely and apply the parking brake.

Caution: Keep the vehicle i n a completely stopped state, and for safety anchor the vehicle w i t h a wire at the back t o prevent it moving.

(2) Warm up the engine, and measure the idling speed and no-load maximum speed.

(3) Check the engine output at the m a x i m u m speed in the loaded state.

Method After adjusting the n o load m a x i m u m speed, operate the tilt lever t o backward tilting. Measure the maxim u m speed at full acceleration in relief state.

Standard: Relief down from the no-load maximum speed: Gasoline engine models : 150 -300 r p m Diesel engine models : 5.6 t o n model 200 r p m or less 7.8 t o n model 250 r p m or less The relief down in the LPG engine model is slightly more than the above values.

Judgment If the engine speed drops excessively, the engine tuning may have been done incorrectly.

(4) Start the engine, set the control lever t o the forward traveling position, race the engine fully and then measure the engine speed after it stabilizes (stall speed).

Accelerator pedal

Engine Stall speed

-

rPm

3F

142

1600 - 1800

1850 - 1950

BRAKE Page

HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . 4-2 BRAKE BOOSTER (5FG/5FD50.60.5FDN50.60.5FD70) . . . . . . . 4-3 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 REMOVAL.INSTALLATI0N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

DISASSEMBLYINSPECTI0N.REASSEMBLY . . . . . . . . . . . . . . 4-6

PARKING BRAKE . . . . . . . . . . . . . . . . . . .. . .............

4-8

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 PARKING BRAKE ASSY REMOVAL.INSTALLATI0N . . . . . . . 4-9

BRAKE PEDAL . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . . . . . . . . . . 4-10 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 BRAKE PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-2

HYDRAULIC CIRCUIT DIAGRAM 5FG / 5FD50.60,5FDN50.60,5FD70 Oil control valve for material handling

Steering gear b o x

Power steering cylinder

Brake wheel cylinder

t

4 -.c I

5FDM60.70,60-5FD80 Oil control valve for material handling

7 f Steering gear box

++

--------- -- ------------- ----Power steering cylinder \

f

+ I

C I

Suction filter

+

t

C)

Brake wheel cylinder

t

A

+

Hydraulic oil cooler (Only for 60-5FD80) -.c

A

BRAKE BOOSTER (5FG /5FD50.60,5FDN50.60,5FD70) GENERAL

SPECIFICATIONS

-

5FGJ5FD50.60, 5FDN50.60, 5FD70 Master cylinder piston

Brake booster

Diameter

m m (in)

26.99 (1.0626)

Stroke

m m (in)

28 (1.10)

Power piston diameter

m m (in)

33.6 (1.323)

Diameter

m m (in)

16 (0.63)

Stroke

m m (in)

29.5 (1.161)

Reaction piston Servo ratio

Servo maximum hydraulic pressure (power relief pressure) kPa (kgf/cm2) [psi] Applicable oil

4.4 9810 (100) 114221 Hydraulic oil I S 0 VG32

COMPONENTS

TROUBLESHOOTING Fault status

Braking effect is delayed

Estimated cause

Or

Action

Fluid leak from hydraulic cylinder

Repair

Reaction piston O-ring damage

Replacement

Foreign matter trapped in piston

Washing, repair

Increased play from loosening of clevis lock nut

Adjust clevis

Air in wheel cylinder circuit

Bleed air

Pressure on spool from loosening of clevis lock nut

Adjust clevis

Foreign matter trapped in spool

Washing, repair

Brake drags

REMOVAL.INSTALLATION T = N,m (kgf-cm) [ft-lbf]

I

I

Removal Procedure 1

Open the engine hood.

2

Remove the toe board No. 2

3

Remove the toe board No. 1

4

Disconnect the brake booster pipe.

5

Remove the push rod clevis pin.

6

Remove the brake booster

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

Note: After installation, bleed air from the brakes and adjust the brake pedal height and free play.

DISASSEMBLY-INSPECTION-REASSEMBLY T = N,m (kgf-cm) [ft-lbfl

Disassembly Procedure 1

Remove the push rod pulley.

2

Remove the snap ring. [Point 11

3

Remove the reaction piston guide, reaction piston and power piston. [Point 21

4

Remove the master cylinder piston. [Point 31

5

Remove the piston return spring. [Point 41

6

Remove the snap ring, hole plug, flow divider spring and flow divider spool.

Reassembly Procedure The reassembly procedure is the reverse of the disassembly procedure.

Note: Wash each part, blow it with compressed air and coat it with hydraulic oil before reassembly.

Coat the cup and O-ring with silicon grease.

Point Operations

[Point 21

Disassembly: Lightly pushing on both ends of the reaction piston, remove the pin.

Inspection: Measure the clearance between the power piston and the body.

Clearance limit: 0.032 m m (0.00126 in)

[Point 31

Disassembly: Remove the master piston assembly.

1.

Remove the bolt and gasket.

2.

Face the piston removal opening downward, use a rod or such to drop the pin down and remove the piston.

3.

If you cannot remove the pin, tap it lightly with a plastic hammer.

Inspection: Measure the clearance between the master cylinder piston and body.

Clearance limit: 0.032 m m (0.00126 in)

4-8

PARKING BRAKE GENERAL

PARKING BRAKE ASSY REMOVAL.INSTALLATI0N T = N.m (kgf-cm) [ft-lbf]

Removal Procedure 1

Remove the torque converter oil.

2

Remove the propeller shaft

3

Disconnect the parking brake cable.

4

Remove the torque converter output flange w / parking brake drum.

5

Remove the parking brake ASSY,

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

Note: After installation, inspect the shoe clearance of the parking brake and the operating force of the parking lever. (For the inspection procedure, see page 8-30 i n the 5FD50 - 80 Repair Manual No.CE007.)

The parking brake drum and torque converter output flange are balanced, so they must be replaced as a set.

BRAKE PEDAL COMPONENTS 5FG / 5FD50.60,5FDN50.60,5FD70

[INCHING] 40

i

4-11

BRAKE PEDAL ADJUSTMENT 5FG / 5FD50.60,5FDN50.60,5FD70

1.

Adjust the stopper bolt so that the brake pedal height equals dimension A or B from the top of the toe board. (Includes adjustment of the stop lamp switch.)

2.

Adjust the push rod length so that the brake pedal play is dimension C.

A: Brake pedal height (without pad) : B: Brake pedal height (with pad)

: 150 - 155 mm (5.91 - 6.10 in)

C: Stroke until brake starts to work : D: Stopper bolt length (reference)

147 - 152 mm (5.79 - 5.98 in)

3

- 6 mm (0.12 - 0.24 in)

: 23 mm (0.91 in)

1.

Adjust the stopper bolt so that the brake pedal height equals dimension A or B from the top of the toe board. (Includes adjustment of the stop lamp switch.)

2.

Adjust the push rod length so that the brake pedal play is dimension C.

- 141 mm (5.35 - 5.55 in) : 140 - 145 mm (5.51 - 5.71 in) B: Brake pedal height (with pad) C: Stroke until brake starts to work : 4 - 7 mm (0.16 - 0.28 in) A: Brake pedal height (without pad) :

D: Stopper bolt length (reference)

136

: 23 mm (0.91 in)

OTHER MODIFICATIONS Page

PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 STEERING WHEEL-MAST JACKET REMOVAL.INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 COMBINATION METER REMOVAL.INSTALLATI0N . . . . . . . 5-14

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

. .. . . . . . . . 5-15

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS Joint type : Cross type Length A: 62 mm (2.44 in) B: 97 mm (3.82 in)

COMPONENTS

DIFFERENTIAL GENERAL The differential sectional structure has been standardized t o the following diagram. (On the previous 5 - 7 ton models and 8 ton models the ring gear direction differed.) The repair method is the same as for the previous models.

On previous models the parking brake drum was located between the differential and the propeller shaft, but on new models it is located between the propeller shaft and the torque converter. Accordingly, it is not necessary to remove the parking brake for differential removal and installation.

SPECIFICATIONS 5FD50.5FD60.5FD70 5FDN50.60

5FG50.5FG60 5FDM60.5FDM70 60-5FD80

Banjo type

t

4.111

4.875

Drive pinion

9

8

Ring gear g ear

37

39

10 x 4

t

Side gear

14x2

t

6.5 (1-72)

t

Differential case type Reduction ratio Number of teeth Number of teeth x quantity

Differential oil quantity

t (Usgal)

I

STEERING GENERAL

SPECIFICATIONS Steering wheel diameter

:

360 m m (14.17 in)

Steering wheel play (at idling): 25

- 50 mm (0.98 - 1.97 in)

Note: Specifications other than the above are the same as for previous models.

COMPONENTS

STEERING WHEEL.MAST JACKET REMOVAL.INSTALLATION T = N.m (kgf-cm) [ft-lbf]

Removal Procedure 1

Remove the steering wheel. [Point 11

8

Remove the combination meter ASSY.

2

Remove the turn signal switch cover.

[Point 21

9

Open the engine hood.

10

Remove toe board No. 2.

3

Remove the combination meter cover.

11

Remove toe board No. 1.

4

Disconnect the wiring of the shift lever and turn signal switch.

12

Remove the LH front board.

13

Remove the steering valve set bolt.

14

Remove the mast jacket W / steering shaft.

15

Remove the steering shaft.

16

Remove the tilt lock device. [Point 41

5

Remove the shift lever and turn signal switch.

6

Remove the steering shaft bracket. [Point 31

7

Disconnect the combination meter wiring.

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

Note: Coat M P grease on the tilt lock device and each sliding contact portion.

Point Operations [Point 1 I Removal: SST 09950-50010

/

[Point 21 Removal: Remove the arrowed part after pushing o n it w i t h your fingers and releasing the hook under the cove r.

[Point 31 RemovaI~InstaIIation: SST 09905-00012

Removal: Remove the bearing f r o m the steering shaft bracket.

SST 09950-70010

Installation: Install the bearing i n the steering shaft bracket.

SST 09950-60010 . . . . . (1) SST 09950-70010 . . . . . (2)

[Point 41

M

Installation: Check the functioning of the tilt lock device.

90

Unlock This surface vertical

Left screw

BODY COMPONENTS

COMBINATION METER REMOVAL.INSTALLATION T = N.m (kgf-cm) [ft-lbf]

Tilt

Removal Procedure 1

Tilt back the tilt steering.

2

Remove the combination meter cover.

3

Remove the combination meter set cover.

4

Disconnect the combination meter wiring.

5

Remove the combination meter ASSY.

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

5-1 5

OIL PUMP SPECIFICATIONS The oil p u m p specifications of 142 models are the same as the specifications of 122 models.

The repair procedure is the same as on previous models.

3F specifications are the same as the previous model.

142 engine Main p u m p

Sub p u m p

Oil p u m p name

Gear p u m

t

Pump type

KFP5171

KP1009

102.2 (26.98)

13.0 (3.43)

71 (4.33)

9.08 (0.5541)

Torque converter PTO

t

Discharge rate (at p u m p speed of 1500 rpm) e l m i n (US gallmin) Theoretical discharge rate Oil p u m p drive type

cm 3 (in3)/rev

APPENDIX Page

MAIN VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 6-2 DIMENSIONAL DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 SST LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 SERVICE STANDARDS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . . . . 6-11

The following SERVICE STANDARDS LIST applies only t o items in this publication . For other items. see the 5FD50 - 80,5FG50.60 Repair Manual (No. CEO071.

MAIN VEHICLE SPECIFICATIONS

.

.

.

.-

Length to Fork Face Overall Width Mast Lowered Height Mast Extended Height Overhead Guard Height Tuming Radius (Outside) Distance 22 Load (Centerline ol front axle to front face of forks) Basic Right An le Stacking Aisle Width 23 (Add load lengt?! and clearance) Full Load Travel, Max. 24 (FWDIRVS) No Load Full Load 25 Speeds Lining No Load Full Load Lowering 26 No Load Full Load 28 Max. Drawbar Pull No Load Full Load 29 Gradeability at 1.5 k m h (1 mph) ' Full Load 30 Max. Gradeability ' No Load 32 Total Weight Front Full Load 33 Weight Rear Distribution Front No Load 34 Rear FronVRear Number 35 Front 36 Tires Size Rear 37 15 16 17 18 19 21

-

-

-

-

38 Wheelbase Front Rear

39 Tread Min. with Load

-$-Underclearance Center of Wheelbase 42 Brake

43 45 Battery 49

50 - lntemal 51 Combustion -Engine 52 55 Transmission

perating

O 57 Pressure

Sewice (Foot) Parking VoltagelCapacity (5HR) MakdModel Rated Horsepower1r.p.m.

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

3460 (136) I995 (78.5) 2515 (99) 4370 (172) 2440 (46) 3350 (132)

3460 (136) 1995 (78.5) 2515 (99) 4370 (172) 2440 (96) 3350 (132)

3505 (138) 1995 (78.5) 251.5 (99) 4370 (172) 2440 (96) 3350 (132)

3505 (138) 1995 (78.5) 2515 (99) 4370 (172) 2440 (96) 3350 (132)

mm (in)

590 (23)

590 (23)

590 (23)

590 (23)

mrn (in) k m h (mPh) k m h (mph) mmlsec (fpm) mmlsec (fpm) mmlsec (fpm) mrnlsec (fpm) kg (Ib) kg (Ib) % (tang) % (fane) % (lane) kg (Ib) kg (Ib) kg (Ib) kg (Ib) kg (Ib)

mm (in) mm (in) mm (in) mm (in) mm (in)

VIAH

Rated Torqudr.p.m.

$pHp) JIS kg-m (SAE ft-lb)

Number of Cylinder Piston Displacement Fuel Tank Capacity

cc (cu-in) liter (USUK gal)

Stage For Attachments

NOTE: ' Computed values.

FWDIRVS kg/cm2 (psi)

3940 (155)

3940 (155)

3940 (155)

3940 (155)

23/23 (14314.3) 25/25 (15.5115.5) 330 (65) 360 (71) 400 (79) 500 (98) 5400(11900) 2600 (5750) 22 42 28 8050 (17750) 11660 (25710) 1390 (3040) 4020 (8870) 4030 (8880) 412 8.25-15-12PR (I) 8.25.15-12PR (I) 2250 (88.5) 1490 (58.7) 1670 (65.8) 165 (6.5) 235 (9.3) Hydraulic Hand 12/48 TOYOTA 3F 7512300 (7412300 Net) 2611200 (18811200 Net) 6 3955 (241) 140 (37131) Powershift 111

28/28 (17.4117.4) 30130 (18.6118.6) 450 (89) 500 (98) 400 (79) 500 (98) , 5500 (12100) 2600 (5750) 31 43 28 8160 (17990) 11690 (25770) 1470 (3220) 4050 (8930) 4110 (9060) 412 8.25-15-12PR (I) 8.25-15-12PR (I) 2250 (88.5) 1490 (58.7) 1670 (65.8) 165 (6.5) 235 (9.3) Hydraulic Hand 24/60 TOYOTA 142 9512200 (9412200 Net) 3511600 (253/1600 Net) 6 5204 (317) 140 (37131) Powershift 111

23123 (14.3'14.3) 25125 (15.5115.5) 330 (65) 360 (71) 400 (79) 500 (98) 5400 (11900) 2600 (5750) 19 37 26 8570 (18890) 13090 (28540) 1480 (3350) 3920 (8640) 4650 (10250) 412 8.25-15-12PR (I) 8.25-15-12PR (I) 2250 (88.5) 1490 (58.7) 1670 (65.8) 165 (6.5) 235 (9.3) Hydraulic Hand 12/48 TOYOTA 3F 7512300 (7412300 Net) 26l1200 (18W1200 Net) 6 3955 (241) 140 (37131) Powershift 111

28128 (17.4117.4) 30130 (18.6l18.6) 450 (89) 500 (98) 400 (79) 500 (98) 5500 (12100) 2600 (5750) 27 38 26 8680 (19140) 13120 (28610) 1560 (3530) 3950 (8710) 4730 (10430) 412 8.25-15-12PR (I) 8.25-15-12PR (I) 2250 (88.5) 1490 (58.7) 1670 (65.8)---~ 165 (6.5) 235 (9.3) Hydraulic Hand 24160 TOYOTA 142 9512200 (9412200Net) 3511600 (253/1600 Net) 6 5204 (317) 140 (37131) Powershift 111

175 (2490)

175 (2490)

175 (2490)

175 (2490)

6-3

MAIN VEHICLE SPECIFICATIONS

NOTE: ' Computed values.

DIMENSIONAL DRAWINGS

Unti:

mrn(in)

SST LIST

& /

09950-70010

09220-33901-71

Handle set

0

Torque converter clutch drum spring

0

Front axle bearing

Drive pinion bearing

0

6-6

SERVICE STANDARDS LIST ENGINE Engine Item Idling speed No-load static maximum speed

1

5.6 ton rpm rpm

Full relief engine speed down rpm Radiator Coolant volume (excluding reservoir tank) e (US gal) Battery Electrolyte specific gravity at 20°C (68°F) Specific gravity after dis charging at 20°C (68°F) Volume e (US gal) Alternator Fan belt tension (when pushed w i t h 98N (10 kgf) [22 Ibfl) m m (in)

14z

Fan belt tension (when measured w i t h a tension gage (SST)) N (kgf) [Ibfl

14'

7 ton 750 f 25

8 ton

142 142 142

Standard Standard Standard

14z

Standard

13 (3.4)

142

Standard

1.280

142

Standard

1.120

142

Standard

5.2 (1.37)

New part Inspection time New part nspection Itime

Standard

7 - 9 (0.28 - 0.35)

2400 f 50 200 or less

1

( 2600 f 50 250 or less

Standard

- 0.51) 520 - 755 (53 - 77) 1117 - 1701

Standard

324 - 559 (33 - 57) 173 - 1261

Standard

8 - 13 (0.31

TORQUE CONVERTER

1 Control valve lnching spool t o body clearance

m m (in)

Accumulator piston to body clearance m m (in) Selector spool t o body clearance m m (in) lnching piston spring free length

m m (in)

lnching return spring free length

m m (in)

Accumulator spring free length

m m (in) .

Selector spring free length

m m (in)

Standard Limit Standard Limit Standard Limit

0.02 - 0.041 (0.00079 - 0.00161) 0.1 (0.004) 0.03 0.071 (0.00118 - 0.00280) 0.1 (0.004)

Standard Limit Standard Limit Standard Limit

31.43 (1.2374) 30.5 (1.2012) 79.6 (3.134) 77.0 (3.031) 149.73 (5.8949) 149.3 (5.8791 )

Standard

59.13 (2.3280)

Limit

58.6 (2.3079)

-

0.02 - 0.041 (0.00079 0.1 (0.004)

- 0.00161)

( TORQUE CONVERTER 142 Pilot boss diameter

m m (in) 3F

Impeller hub outside diameter

m m (in) 1

Impeller hub inside diameter

m m (in)

Standard Limit Standard

Limit Standard Limit Standard Limit

14.966 - 14.984 (0.58921 14.966

-

- 0.58992)

14.91 6 (0.58724) 14.984 (0.58921 0.58992)

-

14.916 (0.58724) 124.9 125.0 (4.917 4.921) 124.8 (4.913) 70.00 - 70.03 (2.7559 2.7571)

-

-

-

70.13 (2.7610)

I

2.28 - 2.33 (0.0898 - 0.0917)

Standard Limit Standard Limit

2.08 (0.0819) 0.03 - 0.05 (0.0012 - 0.0020) I.O (0.039)

Standard Housing cover shaft inner diameter (contact part) m m (in) Limit

40.20 - 40.25 (1.5827 - 1.5846) 40.35 (1.5886)

Standard Limit Standard Torque converter inlet valve piston to housing clearance m m (in) Limit

0.020 - 0.071 (0.00079 - 0.00280) 0.1 (0.004)

Stator support seal ring thickness

m m (in)

Stator support seal ring opening clearance

m m (in)

Transmission

Regulator valve piston to housing clearance

m m (in)

Regulator valve spring free length (inner)

m m (in)

0.015

- 0.049 (0.00060 - 0.00193) 0.1 (0.004) 107.96 (4.2504)

Standard Limit

106.6 (4.197) 98.58 (3.8811)

Standard Limit Standard Torque converter inlet valve spring free length m m (in) Limit Regulator valve spring free length (outer)

m m (in)

Shaft seal ring thickness (tip of shaft)

m m (in)

Standard

Standard Limit Standard m m (in) Shaft seal ring thickness (piston part) Limit Standard Shaft seal ring opening clearance (piston part) m m (in) Limit m m (in)

m m (in)

Piston seal ring opening clearance

m m (in)

Clutch camber plate warpage height

m m (in)

Clutch disc thickness

m m (in)

Clutch plate thickness Clutch return spring

Standard Limit Standard Limit Standard Limit Standard

Limit Standard m m (in) Limit Standard m m (in) Limit

Clutch piston inner diameter

m m (in)

Clutch drum inner diameter

m m (in)

2.9

Standard Limit Standard Limit

- 3.0 (0.114 - 0.118) 2.7 (0.106)

Limit

Shaft seal ring opening clearance (tip of shaft)

Piston seal ring thickness

96.0 (3.780) 64.5 (2.539) 62.4 (2.457)

0.1

- 0.4 (0.004 - 0.01 6)

1 .O (0.039) 2.4 - 2.45 (0.0945 - 0.0965) 2.2 (0.0866) 0.03 - 0.05 (0.0012 - 0.0020) 1 .O (0.039) 2.87 - 2.92 (0.1130 - 0.1150) 2.67 (0.1051) 0.03 - 0.05 (0.0012 - 0.0020) 1 .O (0.039) 5.35 - 5.65 (0.2106 - 0.2224) 5.0 (0.197) 2.6 - 2.8 (0.102 - 0.110) 1.7 (0.067)

-

0.0807) 1.95 - 2.05 (0.0768 1.85 (0.0728) 55.6 (2.189) 52.8 (2.079)

-

58.0 - 58.05 (2.2835 2.2854) 58.15 (2.2894) 155.08 - 155.13 (6.1055 - 6.1075) 155.23 (6.1114)

Measurement and tests Idling Torque converter inlet pressure kPa (kgf/cm2) [psi1 At 2000 rpm

Standard

200 (2) [281

Standard

690 (7) [I001

Standard Standard

98 (1) I141 490 (5) [711

Standard

9.8 (0.1) [1.41

kPa (kgf/cm2) [psi] At 2000 rpm

Standard

Idling Forward clutch pressure kPa (kgf/cm2) [psi] At 2000 rpm

Standard

98 (1) [I41 1770 (18) [2561 or more

Standard

1770 - 2260 (18 - 23) [256 - 3271

Idling Reverse clutch pressure kPa (kgf/cm2) [psi] At 2000 rpm

Standard

Idling Torque converter outlet pressure kPa (kgf/cm2) [psi] At 2000 rpm Idling

Lubrication pressure

Stall speed

rpm

Standard

1770 (18) [2561 or more 1770 - 2260 (18

- 23) I256 - 3271

3F

Standard

1600 - 1800

142

Standard

1850

- 1950

Inching pedal

mm (in) Standard

Pedal height (with pad) Pedal play

m m (in)

5FGl5FD50.60, 5FD70, 5~lIN50.60 5FDM60.70, 60-5FD80

Standard Standard

- 155 (5.91 - 6.10) 3 - 5 (0.12 - 0.20) 3 - 6 (0.12 - 0.24)

150

Tightening torque

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

Oil control valve ASSY set bolt

Standard

Solenoid valve set bolt

Standard

Oil control valve cover set bolt

Standard

Parking brake ASSY set bolt

Standard

- 7.8 (50 - 80) [3.62 - 5.791 11.8 - 14.7 (120 - 150) [8.68 - 10.851 147.10 - 166.71 (1500 - 1700) [108.53 - 123.001 176.52 - 225.55 (1800 - 2300) [130.23 - 166.411

40.2 - 51.9 (410 - 530) [29.66 - 38.351 4.9

Output flange set bolt

Standard

Torque converter mount set bolt

Standard

56.88 - 86.30 (580

Torque converter mount bracket set bolt

Standard

56.88 - 86.30 (580 - 880) [41.96 - 63.671

Torque converter housing set bolt

Standard

29.42 - 44.13 (300

Flexible plate set bolt

Standard

14.71 - 24.52 (150 - 250) [10.85 - 18.091

Material handling oil pump set bolt

Standard

50.01 - 116.70 (510 - 1190) [36.90

Speed sensor

Standard

19.61

- 880) [41.96 - 63.671

- 450) [21.71 - 32.561 - 86.101

- 39.23 (200 - 400) [14.47 - 28.941

PROPELLER SHAFT AND DIFFERENTIAL Tightening torque

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

Propeller shaft set bolt

I Standard 1

69.82 - 104.74 (712 - 1068) i51.51

- 77.271

STEERING

I Steering wheel I Steering wheel play (at idling) 1 Tightening torque I Steering wheel set nut

I Steering valve set bolt

I

mrn (in) Standard / N.m (kgf-cm) [ft-lbfl

I Standard 1

I Standard I

25 - 50 (0.98 - 1.97)

- 29.42 (200 - 300) 114.47 - 21.711 14.1 2 - 32.95 (144 - 336) 110.42 - 24.31I 19.61

I I

I

1

6-9

BRAKE r

Brake booster (5FG/ 5FD50,60,5FD70, 5FDN50.60) Power piston to body clearance

mm (in)

Standard

0.032 (0.00126)

Master cylinder piston to body clearance

mm (in)

Standard

0.032 (0.00126)

Standard

150 - 155 (5.91 - 6.10)

Standard

140 - 145 (5.51 - 5.71)

Standard

3 - 6 (0.12 - 0.24)

Standard

4

Brake Pedal Pedal height (with pad) mm (in)

5FG/5FD50,60,5FD70, 5 ~ ~ ~ 5 0 . 6 0 5FDM60.70, 60-5FD80

mm (in)

5FG/5FD50,60,5FD70, 5FDN50.60 5FDM60.70, 60-5FD80

Pedal play

Tightening torque

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

Booster ASSY set bolt Brake booster (5FGI5FD50.60, Master cylinder piston 5FD70, 5FDN50.60) stopper pin lock bolt

Standard Standard

21.18 - 49.43 (216

- 7 (0.16 - 0.28) - 504) [15.63 - 36.461

7.8 - 11.8 (80 - 120) i5.79 - 8.681

BODY

-

Tightening torque Combination meter set bolt

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

/ Standard 1

2.94 - 6.86 (30

- 70) [2.17 - 5.061

WIRING DIAGRAM 3F ENGINE

Note: An item in a box indicates optional equipment

6-12

142 ENGINE

With front glass wiper m i l WIPER D T O P

-,

- ,-

,

I

1 "*&

PUMP

I

I

t

All-weather cabin ,

I

I

Air conditioning

Only for 5FDM60,70,60-5FD80 n

r\

I

\

'

A

-

Note: An item in a box indicates optional equipment