DOWNLOAD PDF Toyota Forklift FGC33-45 FDC33-45 Service Manual

FGC/FDC33-45 RETURN TO: MAIN INDEX RETURN TO: SERVICE MANUAL INDEX

GENERAL ENGINE TORQUE CONVERTER DIFFERENTIAL FRONT AXLE REAR AXLE STEERING BRAKE BODY MATERIAL HANDLING SYSTEM APPENDIX

PREFACE

This manual covers the inspection, adjustment and repair procedures mainly for the overhaul of the engine, chassis and material handling system of the Toyota Forklift FDC33, 35, 40, 45 Series, FGC33, 35, 40, 45 Series.

You are encouraged to read this manual to make the most of the outstanding performance and durability features of these forklifts and to perform proper servicing to maintain them in tip-top running condition.

This repair manual contains the latest information available as of DECEMBER, 1982. For any changes thereafter, you are requested to consult the Toyota Parts and Service News.

The titles of the related repair manuals are as follows: TOYOTA 2H ENGINE REPAIR MANUAL TOYOTA 2F ENGINE REPAIR MANUAL

TOYOTA MOTOR CORPORATION

-2-

0-2 VEHICLE EXTERIOR VIEWS

Fig. 0-1 Front view

-6-

VEHICLE MODELS

-7o Every model is provided with the power steering and power brake as the standard equipment. o Every torque converter model is provided with the forward 2-speed and backward 1-speed torque-converter as the standard equipment.

0-3

0-4 FRAME NUMBER

Fig. 0-3 Location of Frame Number

Fig. 0-4 Frame Number

-8-

0-5 LOAD CAPACITY CHART

Fig. 0-5 Load capacity chart

-9-

0-6 VEHICLE DIMENSIONS

Fig. 0-6 Vehicle dimension

-10-

0-7 STANDARD BOLT & NUT TIGHTENING TORQUE JUDGING PROCESS Standard bolt and nut tightening torque is not indicated, therefore tightening torque must be judged as below; 1. Find out the type of the bolt from the list below.

Then, find the bolt tightening torque from the sable.

2. The nut tightening torque can be judged from the bolt type. (See the table.)

LIST OF BOLT TYPES AND STRENGTH

-11-

0-8 STANDARD BOLT TIGHTENING TORQUE

-12-

0-9 ABBREVIATION AND OPERATIONAL TIPS

OPERATIONAL TIPS 1. Safe operation (1) Make sure that correct size wire is used when lifting heavy material.

(2) After jacking up, always be sure to support with rigid rack or stand.

2. Availability of SST and measuring tools Have the SST’s and measuring tools available before starting work.

3. Neatness and orderliness (1) Keep the working place neat and orderly so as to make it easier to work on your job.

(2) Disassembly of hydraulic equipment should always be done in clean place.

4. Genuine Toyota parts Genuine Toyota parts should be used even in the replacement of packings, gaskets, “O” rings, and similar parts.

5. Repairs on electrical system Before doing any repairs on the electrical system, disconnect the cables from the battery terminals.

Always disconnect the (-) cable first.

6. Tightening torque when installing Be sure to observe the tightening torque given in this manual. If not specified, tighten to the torque listed in ‘’Tightening Torques for Standard Bolts’’.

-13-

0-10 RECOMMENDED LUBRICANTS

-14-

PERIODIC MAINTENANCE Periodic maintenance shall be carried out without fail to keep the forklift in tip-top condition and to prevent unexpected troubles.

-150-11

0-12

-16-

0-13

-17-

0-14

-18-

0-15

-19-

0-16

-20-

0-17

-21-

0-18

-22-

0-19

-23-

PERIODIC REPLACEMENT PARTS AND LUBRICANTS 0-20

G: gasoline model D: diesel model Replace according to operation hours for vehicles operated many hours every day.

-24-

0-21 LUBRICATION

1 3 5

Inspection, Replenishment MP grease Hypoid gear oil SAE 90 Auto fluid

Fig. 0-7 Lubrication

-25-

l

2 4

Replacement Motor oil Hydraulic oil

1-2 GENERAL

Fig. 1-1 Engine compartment (2H)

Fig. 1-2 Engine compartment (2F) -28-

1-3 ENGINE PERFORMANCE CURVE

Fig. 1-3 Engine performance curve (2H)

Fig. 1-4 Engine performance curve (2F) -29-

1-4 SPECIFICATIONS

-30-

REMOVAL 1. Remove the rear toe board.

(1) Set bolts (2) Rear to board

Fig. 1-5 Removing the rear toe board 2. Remove the engine hood.

(1) Remove the catch.

(2) Disconnect the engine hood stay.

(3) Disconnect the seat stay sub-assembly At the seat side.

(4) Engine hood hinge set bolts (5) Engine hood (with driver seat)

Fig. 1-6 Removing the engine hood 3. Remove the radiator cover.

(1) Set bolts (2) Radiator cover.

Fig. 1-7 Removing the radiator cover 4.

Remove the air cleaner assembly with hose.

(1) Set bolts (2) Air cleaner assemlbly with hose

Fig. 1-8 Removing the air cleaner assembly -31-

1-6 5. Remove the battery.

(1) Battery cables (2) Battery cap (3) Battery (4) Set bolts (5) Battery case Cautions: Battery cables must be removed from the negative side first.

2 batteries are used in the diesel model while one battery is used in the gasoline model.

Fig. 1-9 Removing the battery

6. Disconnect the wiring.

(1) Line to the alternator

Fig. 1-10 Disconnecting the line to the alternator (2) Line to glow plugs (diesel model) (3) Line to the distributor and ignition coil (gasoline model) (4) Line to the starter

Fig. 1-11 Disconnecting the lines to ignition coil

7. Remove the pipes and wires.

(1) Fuel pipe (2) Accelerator wire NOTE: Remove the accelerator wire with the accelerator wire bracket for the diesel model.

(3) Choke wire (gasoline model) Fig. 1-12 Discopnnecting the wire and pipes -32-

1-7 8. Drain the coolant.

(1) Radiator draining (2) Engine draining

Fig. 1-13 Draining the coolant 9. Remove the balance weight.

(1) Put the wire around the balance weight.

(2) Set bolts (3) Balance weight Reference: Weight of balance weight FDC/FGC33 series Approx. 1,840kg (4048 lb) FDC/FGC35 series Approx. 2,190kg (4818 lb) FDC/FGC40 series Approx. 2,510kg (5522 lb) FDC/FGC45 series Approx. 2,890kg (6358 lb)

Fig. 1-14 Removing the balance weight

10. Remove the muffler assembly.

(1) Exhaust pipe connector (2) Muffler set bolts (3) Muffler assembly

Fig. 1-15 Removing the muffler assembly 11. Remove the radiator assembly and the fan shroud.

(1) Disconnect the inlet and outlet hoses.

(2) Disconnect the torque converter cooler hoses (2 pcs).

(3) Set bolts (4) Radiator assembly, fan shroud

Fig. 1-16 Removing the radiator assembly -33-

1-8 12. Disconnect the oil pump.

Diesel Model (1) Oil pump set bolts.

(2) Disconnect the oil pump.

Note: Disconnect the oil pump from the engine with the hoses attached.

Fig. 1-17 Disconnecting the oil pump (2H) Gasoline Model (1) Oil pump drive shaft set bolts (2) Disconnect the drive shaft from the engine.

Fig. 1-18 Disconnecting the oil pump drive 13. Remove the fan sub-assy.

(1) Loosen the fan belt.

(2) Fan set bolt (3) Fan sub-assy

Fig. 1-19 Removing the Fan sub-assy 14. Slighty lift the engine.

[Using SST] For lifting with a hoist SST 09010-20110-71 For lifting with a forklift SST 09020-20110-71 SST 09090-04000 Caution: SST must be inserted from the back side of the vehicle.

Fig. 1-20 Slightly lifting the engine -34-

1-9 15. Remove the engine mounting set nuts.

Fig. 1-21 Removing the mounting set nuts 16. Place a stand under the torque converter case.

17. Remove the torque converter case cover.

Fig. 1-22 Supporting the torque converter case with a stand 18. Remove the flexible plate set bolts.

(1) Set bolts (6pcs.)

Note: Turn the crankshaft pulley set bolt when rotating the flywheel.

Fig. 1-23 Removing the flexible plate set bolts 19. Disconnect the torque coverter and the engine.

(1) Set bolts (2) Disconnect the torque converter and the engine.

Fig. 1-24 Disconnecting the engine -35-

1-10 Lift the engine and remove it from the vehicle.

Caution: Be careful so as not to damage the oil pump.

Make sure that all wires and pipes are disconnected.

Carefully remove the engine so as not to strike it against the steering wheel.

Fig. 1-25 Removing the engine

INSTALLATION Installation is the reverse of the removal procedure.

Caution: Place the oil pump at a place to allow easy installation before fitting the engine. (Diesel model) Slightly turn the engine crank shaft when spline alignment with the engine during oil pump installation is not obtained.

Purge the air in the fuel system. (Diesel model) Connect the negative battery terminal after confirming that the electric wiring is correct.

Check the coolant and engine oil. If insufficient, replenish them before making engine adjustment.

-36-

1-11 ENGINE ADJUSTMENT (DIESEL MODEL) 1. Idling speed adjustment (1) Warm up the engine.

(Coolant temperature: up to 75 ~ 85°C (167 ~ 135°F).)

(2) Set the engine tachometer.

Fig. 1-26 Setting the engine tachometer (3) Turn the adjusting screw to obtain the specified idling speed.

Idling speed: 650 ± 50 rpm

Fig. 1-27 Adjusting the idling speed 2. Maximum no-load rpm adjustment (1) Warm up the engine.

(2) Set the engine tachometer.

(3) Fully depress the accelerator pedal.

(4) Turn the adjusting screw to obtain the specified maximum no-load rpm.

Maximum no-load rpm: 2350+0 100rpm

Fig. 1-28 Adjusting the maximum no-load rpm 3. Operate the material handling levers, and measure the engine rpm for full relief.

Engine rpm down for full relief: Within 250 rpm If the decrement exceeds 250 rpm, adjust the engine and injection pump.

Fig. 1-29 Measuring the engine rpm for full relief -37-

1-12 ENGINE ADJUSTMENT (GASOLINE MODEL) 1. Idling speed adjustment (1) Warm up the engine.

(Coolant temperatura: up to 75 ~ 85°C (167 ~ 185°F)) (2) Set the engine tachometer.

(3) Turn the adjusting screw to obtain the specified idling speed.

Clockwise turn: Increases the idling rpm.

Counterclockwise turn: Decreases the idling rpm.

Idling speed: 650 ± 50 rpm

Fig. 1-30 Adjusting the idling speed

2. Maximum no-load rpm adjustment (1) Warm up the engine.

(2) Set the engine tachometer.

(3) Fully depress the accelerator pedal and measure the rpm.

Maximum no-load rpm: 2350 ± 50 rpm (4) Operate the material handling levers, and measure the engine rpm for full relief.

Engine rpm down for full relief: Within 300 rpm (5) If the measured rpm is not within the specified range, adjust the governor to obtain the most stabilized rpm within the specified range and minimize the decrement for full relief.

Turn the screw with the wrench attached to the cap, and adjust the rpm by turning the bush with the SST. After adjustment, install and seal the cap.

SST 09010-30150-71

Fig. 1-31 Measuring the engine rpm for full relief

Fig. 1-32 Adjusting the air governor

AIR GOVERNOR ADJUSTMENT

-38-

1-13 ACCELERATOR PEDAL

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Pedal pad Accelerator pedal Bushing Pin Pedal bracket Connecting rod Arm bracket Rod end Link arm Pin Tension Spring

Fig. 1-33 Accelerator pedal components ACCELERATOR PEDAL ADJUSTMENT 1. Adjust the length of connecting rod (1) to obtain the following height of the accelerator pedal: Accelerator pedal height: 128mm (5.0 in.) (from the pad top end to the toe board) 2. Adjust the height of stopper bolt (2).

(1) Gradually depress the accelerator pedal. When the engine side link first comes into contact with the stoper, adjust the clearance between stopper bolt (2) and the pedal (so that excessive wire elongation or link flexure will not occur).

(2) Lock the lock nut (3).

Fig. 1-42 Adjusting the Accelerator pedal height

-39-

1-14 AIR CLEANER

1.

2.

3.

4.

5.

Clamp Air cleaner hose Air cleaner connector Gasket Band

6.

7.

8.

9.

Air cleaner assy Air cleaner cover Air cleaner element Air cleaner case

Fig. 1-35 Air cleaner components INSPECTION AND CLEANING 1. Open the engine hood.

2. Remove the air cleaner cover and take out the element.

Fig. 1-36 Removing the air cleaner 3. Inspect and clean the element.

(1) Damage and deformation of pleats (2) Clean the element with compressed air.

-40-

Fig. 1-37 Cleaning the air cleaner

1-15 RADIATOR

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Radiator Radiator cap Fan shroud Duct sub-assy Fan sub-assy Radiator outlet hose Radiator inlet hose Hase clamp “V” belt Drain cook sub-assy Packing Mounting rubber

Fig. 1-38 Radiator components COOLANT AND ANTIFREEZE VOLUMES

RADIATOR REMOVAL AND INSTALLATION 1. Drain the coolant.

(1) Radiator draining (2) Engine draining

Fig. 1-39 Draining the coolant

-41-

1-16 Remove the balance weight.

(1) Put the wire around the balance weight.

(2) Set bolts (2pcs) (3) Balance weight Reference: Weight of balance weight FDC/FGC33 series ..... Approx. 1,840kg (4,048 lb) FDC/FGC35 series ..... Approx. 2,190kg (4,818 lb) FDC/FGC40 series ..... Approx. 2,510kg (5,522 lb) FDC/FGC45 series ..... Approx. 2,890kg (6,358 lb) Remove the muffler assembly.

(1) Exhaust pipe connector (2) Muffler set bolts (3) Muffler assembly

Fig. 1-40 Removing the balance weight

Fig. 1-41 Removint the muffler assembly

Remove the radiator assembly.

(1) Disconnect the inlet and outlet hoses.

(2) Disconnect the torque converter cooler hoses. (2 pcs) (3) Set boits (4) Radiator assembly Cautions.

Remove the radiator carefully to avoid damage to the fins.

Fig. 1-42 Removing the radiator assembly NOTE: Pour coolant into the radiator. Start the engine, then add more coolant to the top.

-42-

1-17 MUFFLER 2F Engine

1.

2.

3.

2H Engine

Muffler assy Exhaust pipe sub-assy Gasket

4.

5.

Clamp Insulator

Fig. 1-43 Muffler components MUFFLER REMOVAL AND INSTALLATION Remove the balance weight.

(1) Put the wire around the balance weight.

(2) Set bolts (2pcs) (3) Balance weight Reference: Weight of balance weight FDC/FGC33 series ..... Approx. 1,840kg (4,048 lb) FDC/FGC35 series ..... Approx. 2,190kg (4,818 lb) FDC/FGC40 series ..... Approx. 2,510kg (5,522 lb) FDC/FGC45 series ..... Approx. 2,890kg (6,358 lb)

Fig. 1-44 Removing the balance weight

Remove the muffler assembly.

(1) Exhaust pipe connector (2) Muffler set bolts (3) Muffler assembly

Fig. 1-45 Removing the muffler assembly -43-

1-18 BATTERY

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Battery starter cable Battery connector cable Battery cap Battry earth cable Bolt Battery case Battrey Battery case bracket Grommet Bracket

Fig. 1-46 Battery components (2H)

1.

2.

3.

4.

5.

6.

7.

8.

9.

Battery starter cable Battery earth cable Battery cap Battery Battery case Bolt Battery case bracket Grommet Bracket

Fig. 1-47 Battery components (2F) SPECIFICATION

INSPECTION 1. Battery fluid level 2. Battery fluid specific gravity 1.260 (at 20°C at full charge)(68°F) 3. Battery terminal staining 4. Loosening of cable connections

Fig. 1-48 Inspecting the battery -44-

2-2 GENERAL

Fig. 2-1 Torque converter section

-46-

2-3

Fig. 2-2 Flywheel sectional view (2H)

Fig. 2-3 Flywheel sectional view (2F)

Fig. 2-4 Gear configuration -47-

2-4 HYDRAULIC CIRCUIT DIAGRAM

Fig. 2-5 Hydraulic circuit diagram

-48-

2-5 SPECIFICATIONS

-49-

2-6 TROUBLESHOOTING

-50-

2-7

-51-

2-8

-52-

2-9

-53-

2-10

-54-

2-11

-55-

2-12

-56-

2-13 COMPONENT PARTS TORQUE CONVERTER CASE

1. Cover 2. Suction filter 3. Eye plate 4. Torque converter end plate 5. Straight pin 6. Torque converter case 7. Nock pin 8. Orifice 9. Breather

10. Level gauge 11. Plug 12. Seal washer 13. Differential carrier 14. Bolt 15. “O” ring 16. Timing pointer 17. Torque converter end plate 18. Straight pin

Fig. 2-6 Torque converter case component parts

-57-

2-14 TORQUE CONVERTER

[Tightening torque unit: kg-m (ft-lb)]

1. Plate 2. Shim 3. Roller 4. Spring cap 5. Spring 6. Stator 7. “O” ring 8. Pump impeller 9. Oil pump assy 10. “O” ring 11. Packing 12. Piston ring 13. Bearing 14. Snap ring 15. Pilot boss 16. “O” ring 17. Bearing 18. Spacer

19. Flexible plate 20. Drive cover 21. Turbine runner 22. Thrust washer 23. Thrust bearing 24. Thrust washer 25. Thrust washer 26. Stator hub 27. Spacer 28. Bearing 29. “O” ring 30. Piston ring 31. Oil seal 32. Pump driven gear 33. Pump drive gear 34. Stator shaft 35. Turbine shaft 36. “O” ring (Suction filter)

Fig. 2-7 Torque converter component parts

-58-

2-15 MAIN CLUTCH (F1/R CLUTCH)

[Tightening torque unit: kg-m (ft-lb)]

1. Spring pin 2. Snap ring 3. Main clutch drum and shaft 4. Piston ring 5. Spacer 6. Bearing 7. Forward gear 8. Snap ring 9. Pressure plate 10. Drive plate

11. Driven plate 12. Spring retainer 13. Return spring 14. Clutch piston 15. Piston ring 16. Reverse gear 17. Spacer 18. Bearing 19. “O” ring 20. Servo case

Fig. 2-8 Main clutch component parts

-59-

2-16 FORWARD 2-SPEED CLUTCH (F2 CLUTCH)

1. Servo case 2. “O” ring 3. Spring pin 4. Clutch drum 5. Clutch drum 6. Piston ring 7. Drive plate 8. Driven plate 9. Pressure plate 10. Snap ring 11. Return spring 12. Spring retainer

13. Snap ring 14. “O” ring 15. Piston ring 16. Bearing 17. Shaft 18. Piston ring 19. Clutch gear 20. Bearing 21. Spacer 22. Lock plate 23. Lock washer 24. Seal plate

Fig. 2-9 Forward 2-speed clutch component parts

-60-

2-17 COUNTER GEAR AND OUTPUT GEAR

[Tightening torque unit: kg-m (ft-lb)]

1. Bearing 2. Counter gear A 3. Counter shaft 4. Spacer 5. Counter gear B 6. Snap ring 7. Seal plate B 8. “O” ring 9. Snap ring 10. Spacer 11. Lock plate 12. Lock washer 13. Seal plate A

14. Lock nut 15. Output gear 16. Taper roller bearing 17. Shim 18. Seal spacer 19. “O” ring 20. Oil seal 21. Bearing retainer 22. Shim 23. “O” ring 24. Ring gear and pinion set 25. Roller bearing

Fig. 2-10 Counter gear and output gear component parts

-61-

2-18 CONTROL VALVE

1. Nipple 2. Packing 3. Plug 4. Oil control valve assy 5. Regulator valve 6. Cover and control valve body 7. Nut 8. “O” ring 9. Adjustment bolt 10. Spring 11. Steel ball 12. Spring retainer 13. Spring 14. Spring 15. Inching valve sub-assy 16. Thrust washer 17. Snap ring

18. Spring pin 19. Oil seal 20. Return spring 21. Inching lever 22. Spring 23. Accumulator piston 24. Selector valve 25. Thrust washer 26. Snap ring 27. Oil seal 28. Selector lever 29. Neutral safety switch 30. Packing 31. Sub plate 32. Packing 33. Packing 34. Cover

Fig. 2-11 Control valve component parts

-62-

2-19 TORQUE CONVERTER OIL COOLER

1. Packing 2. Union 3. Union bolt 4. Hose clamp 5. Nipple 6. Low pressure hose

7. Plug 8. Union bolt 9. Union bolt 10. Oil filter 11. “O” ring 12. Suction filter

Fig. 2-12 Torque converter oil cooler component parts

-63-

2-20 SERVICE STANDARDS

-64-

2-21

-65-

2-22 UPPER COVER AND CONTROL VALVE ASSY

Fig. 2-13 Control valve sectional view

REMOVAL 1. Remove the toe board.

(1) Rear toe board (2) Front toe board 1) Inching pedal pin 2) Brake pedal pin 3) Accelerator wire pin 4) Set bolt 5) Front toe board Fig. 2-14 Removing the toe board

2. Disconnect the torque converter oil cooler piping

Fig. 2-15 Disconnecting the oil cooler piping

-66-

2-23 3. Disconnect the rod.

(1) Disconnect the connecting rod from the selector lever.

(2) Disconnect the inching rod from the inching lever.

Fig. 2-16

Disconnecting the rod

Fig. 2-17

Disconnecting the neutral switch wiring

Fig. 2-18

Removing the set bolts

Fig. 2-19

Removing the upper cover

4. Remove the neutral switch wiring from the connector.

5. Remove the upper cover.

(1) Set bolts Caution: Remove the selector stopper bolt and the inching lever stopper bolt too.

Since the set bolt length is different from each other, confirm the mounting position.

(2)

Remove the upper cover by using the service bolt.

Caution: Use the upper cover set bolt as the service bolt.

Do not drop the “O” ring attached on the underside of the upper cover.

After removal, place waste cloth, etc. as a cover so that no dust enters the transmission.

-67-

2-24 DISASSEMBLY 1.

2.

Remove the oil filter.

SST 09228-44010

Fig. 2-20

Removing the oil filter

Fig. 2-21

Removing the plug

Fig. 2-22

Removing the regulator valve

Fig. 2-23

Removing the accumulator piston

Remove the regulator valve.

(1) Plug (Large) Caution: Pay attention to the spring sprung out when removing the plug.

(2) Regulator spring (3) Spring retainer (4) Plug (Small) (5) Regulator valve

3.

Remove the accumulator piston.

(1) Plug Caution: Pay attention to the spring sprung out when removing the plug.

(2) Accumulator spring (3) Accumulator piston Note: Use the service bolt (M6 x 1.0 pitch, 50 mm (2 in.) or longer under the neck) for easy removal of the piston.

-68-

2-25 4.

Remove the inching valve.

Loosen the lever lock bolt.

(1) Inching lever (2) Return spring (3)

(4) (5) (6) (7)

5.

Fig. 2-24

Removing the inching lever

Fig. 2-25

Removing the inching valve

Fig. 2-26

disassembling the inching valve

Fig. 2-27

Removing the detent adjustment bolt

Oil seal Snap ring Thrust washer Inching valve

Disassemble the inching valve.

Caution: Disassemble only when it is absolutely necessary after inspection.

(1) (2) (3)

6.

Plug Inching piston Piston spring

Remove the selector valve.

(1) Remove the detent screw.

1) Detent lock nut 2) Detent screw 3) “O” ring 4) Spring 5) Steel ball

-69-

2-26 (2) Neutral switch

Fig. 2-28

Removing the neutral switch

Fig. 2-29

Removing the oil seal and snap ring

Fig. 2-30

Removing the selector valve

Fig. 2-31

Removing the under cover plate

(3) Loosen the selector lever lock bolt to remove the selector lever.

(4) Oil seal (5) Snap ring

(6) Thrust washer (7) Selector valve Note: When the selector valve is fit firmly, mount the selector lever, then the selector valve can be removed easily.

7.

Remove the under cover plate.

-70-

2-27 INSPECTION Caution: Before inspection, wash each part in washing solution carefully to remove dirt completely.

Pay special attention to the handling of the valve.

Fig. 2-32

Control valve assy

Fig. 2-33

Inspecting the valve body

Fig. 2-34

Inspecting the regulator valve and spring

Fig. 2-35 spring

Inspecting the accumulator piston and

1. Valve body (1) Crack and damage (2) Wear and damage each valve sliding part (3) Clogging of the orifice (4) Damage and fatigue of O-ring

2. Regulator valve and spring (1) Clogged orifice (2) Wear and damage of sliding face (3) Damage of spring retainer (4) Fatigue of spring Free length (Large): 152.5 mm (6.00 in) Free length (Small): 153.5 mm (6.04 in)

3. Accumulator piston and spring (1) Wear and damage of sliding face (2) Fatigue of spring Free length (Large): 134 mm (5.28 in)

-71-

2-28 4.

5.

Inching valve (1) Clogging of inching orifice (2) Wear and damage of sliding face (3) Wear and damage of inching valve (4) Fatigue of spring Free length: 54.1 mm (2.13 in.)

Limit value 53 mm (2.09 in.)

(5) Wear and damage of thrust washer

Fig. 2-36

Inspecting the inching valve

Fig. 2-37

Inspecting the selector valve

Fig. 2-38

Inspecting the detent screw and steel ball

Fig. 2-39

Inspecting the neutral switch

Selector valve (1) Clogging of each oil path (2) Wear and damage of sliding face (3) Wear and damage of thrust washer

6.

Detent screw, nut, steel ball and spring (1) Wear and damage of steel ball (2) Damage and fatigue of “O” ring (3) Break and fatigue of spring Free length: 37 mm (1.46 in.)

7.

Neutral switch (1) Wear and damage of sliding face

8.

Inching lever and selector lever (1) Deformation and damage of inching lever and selector lever and wear of stopper

-72-

2-29 ASSEMBLY Caution: After washing each part again, apply torque converter oil sufficiently it and reassemble it.

Replace the old packing, oil seal, etc. with new ones.

1.

2.

Assemble the under cover plate T = 1.8 ~ 2.2 kg-m (13.0 ~ 15.9 ft-lb) Assembling the under cover plate

Fig. 2-41

Assembling the selector vavle and oil seal

Fig. 2-42

Assembling the detent screw

Fig. 2-43

Selector lever operation force adjustment

Assemble the selector valve.

Selector valve (1) Thrust washer (2) Snap ring (3) Oil seal (4) SST 09608-35013 Caution: Drive in the oil seal to the same level of the body. (Do not drive it in too deep to avoid clogging of the oil hole.)

(5) (6)

Selector lever Tighten the selector lever lock bolt along the set groove on the valve side.

3.

Assemble the neutral switch.

4.

Assemble the detent screw.

Steel ball (1) Spring (2) Reassemble the “O” ring and nut on (3) the detent screw. Mount the resulting assembly on the valve body. (Do not tighten the lock nut.)

5.

Fig. 2-40

Adjust the selector lever operation force.

Set the spring balance to the selec(1) tor lever. Adjust the detent screw so that the selector lever operation force becomes the following values: Selector lever operation force: 8~ 14 kg (17.64 ~ 30.87 lb) After the adjustment, lock the detent (2) lock nut.

-73-

2-30 6. Assemble the inching valve.

(1) Spring (2) Piston (3) Plug Caution: Apply lock tight 572 to the plug thread part.

Fig. 2-44

Assembling the inching valve

Fig. 2-45

Assembling the inching valve and oil seal

Fig. 2-46

Assembling the inching lever

Fig. 2-47

Assembling the accumulator

7. Assemble the inching valve.

(1) Inching valve (2) Snap ring (3) Oil seal SST 09608-30011 Caution: Apply lock tight 638 along the periphery of the oil seal.

(4) Return spring (5) Inching lever Caution: When assembling the return spring, insert its both ends in the spring pin hole on the body side and in the hole on the arm on the lever side respectively.

(6) Tighten the inching lever lock bolt in the set groove on the valve side.

8. Assemble the accumulator.

(1) Accumulator piston (2) Springs (large and small) (3) Plug Note: As shown in the Figure, hold the accumulator with the plug side down and rotate the body side, then it can be screwed in easily. However, set the accumulator correctly finally and tighten the plug.

-74-

2-31 9. Assemble the regulator valve (1) Regulator valve Caution: Be sure to assemble the valve in the correct direction.

(2) Plug (small)

Fig. 2-48

Assembling the regulator valve

Fig. 2-49

Assembling the valve spring

Fig. 2-50

Assembling the oil filter

(3) Assemble the regulator valve spring.

1) Spring retainer 2) Spring (large and small) 3) Plug (large) Note: Hold the valve body by a vice. Assemble it by using the box wrench.

10. Assemble the oil filter.

INSTALLATION Reverse the removing procedure for the installation operation.

Caution: Apply grease to the “O” ring. Do not drop it during the installation operation.

Upper cover set bolt tightening torque T = 1.8~2.2 kg-m (13.0~15.9 ftlb) After the mounting operation, adjust the valve lever.

-75-

2-32 ADJUSTMENT SELECTOR LEVER ADJUSTMENT 1.

Adjust the height of the stopper bolts so that the gap between the selector lever and the stopper bolt becomes the following value when the selector lever is positioned at the shifted position shown in the right figure.

Gap between the selector lever and the stopper bolt: A = 0.5~1.0 mm (0.020~ 0.040 in.)

Fig. 2-51

Selector lever adjustment

Fig. 2-52

Control lever adjustment

Fig. 2-53

Inching lever operation range

Fig. 2-54

Inching pressure measurement

Caution: Description of the symbols in the figure N: Neutral position F: Forward position (F1: Forward 1-speed, F2: Forward 2speed) R: Reverse position 2.

Tighten the lock nut of the stopper bolt.

CONTROL LEVER ADJUSTMENT 1.

Adjust the length of the connecting rod so that the control lever is positioned at the indicator shifted position.

INCHING LEVER ADJUSTMENT Note: To adjust the inching lever, adjust the height of the stopper bolt.

The shifting positions of the inching lever from the ON (clutch connected position) position to the OFF (clutch disconnected position) is theoretically within 30° as shown in the right figure.

However, in some vehicles, such positions are not within this range. In that case, adjust the inching lever position after installing the oil pressure gauge.

1.

Pull the parking brake to apply the brake.

2.

Install the oil pressure gauge at the inching pressure measurement opening the control valve.

Set the engine tachometer.

3.

-76-

2-33 4. Set the stopper bolt height low.

5. Set the engine speed at 1000rpm, and check that the oil pressure at this speed is 7kg/cm2 or higher.

6. With the engine speed unchanged (1000rpm), turn the inching lever slowly to the OFF side monitoring the oil pressure gauge, until the pressure reading starts to fall. Set the stopper bolt tentatively at that position (as shown by A).

Fig. 2-55 Inching lever adjustment Reference: Before pressure starts to fall - Clutch ON position When pressure starts to fall - Inching starts Pressure keeps falling until zero - Clutch OFF position, clutch is completely disengaged, and inching completes.

8. Measure the height of the stopper bolt at the position specified in 7 above, lower the bolt by 1 mm (approximately one full turn of the stopper bolt) and tighten the lock nut (as shown by B).

Inching pedal adjustment 1. Tentatively set the inching rod 1 length at 210 mm (8.28") and assemble.

2. Adjust the rod 1 length so that the inching lever 2 is correctly linked with the brake pedal when the inching pedal is stepped in and the inching lever 2 is moved by 18 ± 1 mm (0.70 ± 0.039").

Shorten the inching rod 1 length when the inching lever does not move enough.

Extend the inching rod 1 length when the inching lever moves more than enough.

3. After the inching rod length is adjusted, check that the height of the inching pedal meets the following conditions.

Dimension A when the pedal is free: 128 10mm (5.04 0.39") At the beginning of brake pedal linkaged movement: l Approximately 15 mm (0.59") lower than the brake pedal Fig. 2-56 Inching pedal adjustment -77-

2-34 TORQUE CONVERTER

Fig. 2-57 Torque converter sectional view REMOVAL 1. Remove the flexible plate set bolts.

(1) Set bolts (6 pcs)

Fig. 2-58 Removing the flexible plate set bolts

2. Remove the engine Caution: See the Engine removal section for the engine removal.

SST to be used: When using the hoist, SST 09010-20110-71 When using a forklift, SST 09020-20110-71 SST 09090-04000

Fig 2-59 Removing the engine -78-

2-35 3. Drain torque converter oil through the drain plug

Fig. 2-60 draining the torque converter oil 4. Remove the flexible plate.

(1) Set bolts (2) Flexible plate 5. Remove the pilot boss.

(1) Set bolts (2) Pilot boss Note: Tap the pilot boss with a plastic hammer.

Fig. 2-61 Removing the flexible plate and pilot boss 7. Remove the snap ring.

Fig. 2-62 Removing the snap ring 8. Remove the torque converter assy.

Fig. 2-63 Removing the torque converter assy -79-

2-36 DISASSEMBLY 1. Stamp the match marks on the drive cover and the pump impeller.

Fig. 2-64 Stamping the matching marks 2. Remove the drive cover.

(1) Set bolts (2) Drive cover SST 09230-20150-713.

Fig. 2-65 Removing the drive cover 3. Remove the bearing from the drive cover.

SST 09230-20150-71 Caution: Remove the bearing only when any defect is observed by the inspection.

Fig. 2-66 Removing the bearing 4. Remove the turbine runner.

(1) Spacer (2) Turbine runner

Fig. 2-67 Removing the turbine runner -80-

2-37 5. Remove the thrust bearing.

(1) Thrust washer (2) Thrust bearing (3) Thrust washers (2 pieces) Caution: Remember the assembling sequence and assembling direction of the thrust washers (3 pieces)

Fig. 2-68 Removing the thrust bearing 8. Remove the stator sub-assy Caution: Before removing the st ator, rotate the

impeller while holding the stator hub manually to check if it is stuck in both directions or it does not lock in both directions (slipping).

(1) Stator sub-assy (2) Spacer Fig. 2-69 Removing the stator sub-assy 7. Disassemble the stator sub-assy (1) Stator hub Caution: Remove the stator hub slowly and carefully When removing the stator hub, the roller, etc are disassembled at a time.

Do not lose them.

(2) Roller (3) Spring cap (4) Spring (5) Stator

Fig. 2-70 Disassembling the stator

8. Remove the pump boss from the pump impeller (1) Set bolt (2) Pump boss

Fig. 2-71 Removing the pump boss -81-

2-38 9. Remove the bearing from the pump boss.

Caution: Remove the bearing only when any defect is detectod by the inspection.

(1) Snap ring (2) Bearing SST 09608-35013

Fig. 2-72 Removing the bearing INSPECTION Caution: Wash each part in washing solution carefully before the inspection to remove dirt completely.

1. Flexible plate and pilot boss (1) Crack and bend of flexible plate (2) Wear and damage of pilot boss Fig. 2-73 Inspecting the flexible plate and pilot boss

Fig. 2-74 Inspecting the drive cover

Fig. 2-75 Inspecting the turbine runner -82-

2-39 4. Pump impeller (1) Crack and damage (2) Damage of blades (3) Damage and fatigue of “O” ring

Fig. 2-76 Inspecting the pump impeller 5. Pump boss (1) Crack and damage (2) Wear and rotation of bearing (3) Wear of oil seal sliding face Boss outside diameter limit: 69.85 mm (2.75 in.)

(4) Wear of piston ring groove (5) Wear and damage of piston ring (6) Damage and fatigue of “O” ring

Fig. 2-77 Inspecting the pump boss 6. Stator sub-assy (1) Damage and wear of cam roller rotating face (2) Damage and wear of stator hub roller rotating face (3) Damage and wear of stator hub spline (4) Loosened rivet (5) Damage and wear of thrust bearing (6) Damage and wear of thrust washer and spacer Fig. 2-78 Inpecting the stator sub-assy (1) (7) Wear and damage of roller, spring and spring cap Roller outside diameter limit: 7.85 mm (0.310 in.)

Fig. 2-79 Inspecting the stator sub-assy (2) -83-

2-40 (8) Clearance between stator hub and cam Clearance limit: 0.15 mm (0.006 in.)

Fig. 2-80 Inspecting the stator

ASSEMBLY Caution: After washing the parts again, apply tor que converter oil to them sufficiently and assemble them.

1. Assemble the bearing on the pump boss.

(1) Bearing SST 09608-35013 (2) Snap ring (2) Snap ring 2. Assemble the pump boss on the pump impeller.

(1) Assemble the “O” ring and the piston ring on the pump boss.

(2) Drive in the pump boss.

SST 09608-35013

Fig. 2-81 Assembling the bearing

Caution: Apply grease to the “O” ring and assemble it.

(3) Set bolt T = 1.8 ~ 2.2 kg-m (13.0 ~ 15.9 ftlb)

Fig. 2-82 Assembling the pump boss

3. Assemble the stator.

(1) Spring and spring cap Note: Place the spring in the spring cap and assemble spring with tweezers, etc.

Fig. 2-83 Assembling the spring cap

-84-

2-41 (2)

Stator hub

Caution: Direct the stator hub correctly.

(3) Roller Note: Insert the stator hub until the spring cap can be seen. Assemble the rollers one by one while pushing in the spring can by using the roller.

Fig. 2-84 Assembling the stator hub and roller

(4) Stator operation confirmation Note: As shown in the right figure, confirm that when oil is applied to the back of the stator blade, the stator rotates and when oil is applied to the curved side of the blade, the stator is locked by turning it manually in both directions.

4. Assemble the stator on the pump impeller.

(1) Spacer (2) Stator sub-assy

Fig. 2-85 Stator operation confirmation

Caution: Pay attention to the assembling direction of the spacer and the stator. (See the section diagram.)

Fig. 2-86 Assembling the spacer and stator

5.

Assemble thrust bearing.

(1) Thrust washer (2) Thrust washer (3) Thrust bearing (4) Thrust washer

Caution: Direct the thrust bearing in the correct assembling direction and observe the assembling procedure.

Fig. 2-87 Assembling the thrust bearing

-85-

2-42 6. Select the turbine runner spacer.

(1) Assemble the turbine runner up to the conditions described in the preceding paragraph 5 (without assembling the turbine runner and spacer).

Place the drive cover and measure the dimension A shown in the right. figure.

Caution: Place the drive cover with the pump impeller “O” ring removed.

Fig. 2-88 Dimension A measurement

(2) Measure the height B from the pilot boss flange face to the bearing contact face with a slide calipers.

Fig. 2-89 Pilot boss dimension B measurement

(3) Measure the bearing thickness (4) Calculate the thrust gap between the pump impeller and the drive cover bearing by the following equa tion Select an adequate spacer in the Spacer thicknesss = A-B-C

Fig. 2-90 Bearing thickness dimension C measurement

Caution: Use the thinner spacer of the thickness nearest the measured or calculated value.

After the measurement, be sure to assemble the pump impeller “O” ring.

7. Assemble the turbine runner and the above mentioned spacer.

Fig. 2-91 Assembling the turbine runner and spacer

-86-

2-43 8. Assemble the bearing on the drive cover. cover.

(1) Install the pilot boss on the drive cover privisionally.

Fig. 2-92 Provisional mounting pilot boss

(2) Drive in the bearing.

SST 09608-35013 (3) Remove the pilot boss.

Reference: Assemble the pilot boss and the flexible plate on the vehicle.

Fig. 2-93 Assembling the bearing

9. Assemble the drive cover.

(1) Set bolt T = 1.8 ~ 2.2 kg-m (13.0 ~ 15.9 ftlb) Caution: Align the matchmark of the pump impeller to that of the drive cover.

Fig. 2-94 Assembling the drive cover

INSTALLATION

Reverse the removing procedure for installation operation.

Caution: Before mounting, be sure to apply grease to the pump boss piston ring, the oil seal on the pump body and the pilot boss “O” ring.

Pilot boss set bolt tightening torque: T = 1.8 ~ 2.2 kg-m (13.0 ~ 15.9 ft-lb) Flexible plate set bolt tightening torque: T = 1.8 ~ 2.2 kg-m (13.0 ~ 15.9 ft-lb)

-87-

2-44 STATOR SHAFT AND OIL PUMP REMOVAL Caution: The stator shaft and oil pump are removed immediately after the removal of the torque converter described in the preceding paragraph, so see the preceding paragraph for the procedure up to the removal of the torque converter.

Fig. 2-95 Removing the torque converter assy

1. Remove the stator shaft and oil pump.

(1) Stator shaft set bolt

Fig. 2-96 Removing the set bolt

(2) Removing the stator shaft and oil pump assy by using the service bolts (2 pcs).

Note: Use the stator shaft set bolt as the service bolt (shown by the arrow in the figure).

Fig. 2-97 Removing the stator shaft and pump assy

DISASSEMBLY 1. Remove the turbine shaft.

(1) Snap ring (2) Turbine shaft Note: Tap the turbine shaft with a plastic hammer to remove it.

Fig. 2-98 Removing the turbine shaft

-88-

2-45 2. Remove the bearing from the turbine shaft.

Caution: Remove the bearing only when any defect is detected by the inspection.

(1) Snap ring (2) Bearing SST 09950-20014 Fig. 2-99 Removing the bearing

3. Disconnect the stator shaft from the oil pump (1) Oil pump set bolt (2) Oil pump assy SST 09810-20171-71 Note: Use two service holes alternately for removal.

(3) Stator shaft Fig. 2-100 Disconnecting the stator shaft from oil pump

4. Disassemble the oil pump assy (1) Pump drive gear (2) Pump driven gear

Fig. 2-101 Disassembling the oil pump

(3) “O” ring (4) Oil seal Caution: Remove the oil seal only when it is found defective by the inspection.

Fig. 2-102 Removing the oil seal

-89-

2-46 INSPECTION Caution: Wash each part in washing solution carefully before the inspection to remove dirt completely.

1. Turbine shaft (1) Wear and damage of spline (2) Wear of sliding face in contact with the stator shaft (3) Wear of piston ring groove (4) Wear and damage of piston ring (5) Wear and rotation of bearing

Fig. 2-103 Inspecting the turbine shaft

2. Stator shaft (1) Wear and damage of spline (2) Clogging of oil hole (3) Wear and damage of turbine shaftpiston ring contact face.

(4) Wear and damage of pump gear sliding face

Fig. 2-104 Inspecting the stator shaft

(5) Wear of the sliding face in contact with the pump drive gear (shown by the arrow).

Stator shaft outside diameter limit: 54.9 mm (2.16 in.)

Fig. 2-105 Inspecting the drive gear sliding face

3. Oil pump assy Caution: Check the following points. When any defect is detected, replace the pump assy (the pump body, drive and driven gears).

(1) Oil pump body and gear 1) Crack and damage 2) Wear and damage of pump boss-piston ring contact face.

3) Wear and damage of drive and driven gears.

Fig. 2-106 Inspecting the oil pump body and gear.

-90-

2-47 (2) Check the wear of the oil pump body and gear.

1) Measure the clearance between the driven gear and the pump body.

Clearance standard; 0.12 0.2 mm (0.0047 0.0079 in.)

Clearance limit: 0.3 mm (0.012 in.)

Fig. 2-107 Driven gear-body clearance measurement

2) Measure the clearance between the driven gear and the crescent.

3) Measure the clearance between the drive gear and the crescent.

Clearance limit: 0.25 mm (0-010 in)

4) Measure the clearance between the drive gear bushing and the stator shaft.

Clearance standard: 0.03 0.079 mm (0.0012 0.0031 in.)

Clearance limit: 0.15mm (0.006in.)

Fig. 2-108 Driven/drive gear-crescent clearance measurement

Fig. 2-109 Drive gear bushing-stator shaft clearance measurement

5) Measure the clearance between the pump body mounting face and the drive/driven gears.

Clearance standard: 0.05~ O.13 mm (0.002 0.005 in.)

Clearance limit: 0.2 mm (0.0078 in.)

(3) Damage, deformation and deterioration of oil seal lip (4)Damage and fatigue of “O” ring

-91-

Fig. 2-110 Body mounting face-drive/driven gear clearance measurement

2-48 ASSEMBLY Caution: After washing each part again, apply torque conveter oil to it sufficiently and assemble it.

1.

Assemble the oil pump.

(1) Oil seal SST 09608-35013 (2) “O” ring (3) Driven gear (4) Drive gear

Fig. 2-11 Assembling the oil seal

2. Assemble the oil pump assy on the stator shaft.

Caution: Apply grease to the “O” ring and assemble it.

Fig. 2-112 Assembling the oil pump assy

(1) Set bolt T = 1.8 ~ 2.2 kg-m (13.0 ~ 15.9 ftlb)

Fig. 2-113 Tightening the set bolt

3. Assemble the bearing on the turbine shaft.

(1) Bearing (2) Snap ring

Fig. 2-114 Assembling the turbine shaft bearing

-92-

2 - 49 4.

Assemble the turbine shaft on the stator shaft.

(1) Turbine shaft insertion SST 09370-10410-71 Caution: Apply grease to the piston ring sufficientIy. Pay attention so as not to damage it when inserting it.

Fig. 2-115 Assembling the turbine shaft

(2) Snap ring

Fig. 2-116 Assembling the snap ring

INSTALLATION 1. InstalI the stator shaft and oil pump.

Caution: Use the new packing.

Apply grease thinly to the “O” ring of the suction filter mounted on the torque converter case side. Mount the stator shaft and oil pump with attention so as not to damage or deform the filter pipe.

(1) Set bolt T = 1.8 ~ 2.2 kg-m (13.0 ~ 15.9 ftlb) 2. Install the torque converter assy.

Caution: See the preceding paragraph for the operations after the torque converter assy installing operation.

-93-

Fig. 2-117 Installing the stator shaft and pump assy

2-50 REMOVING THE TORQUE CONVERTER AND TRANSMISSION ASSEMBLY WITH DIFFERENTIAL REMOVAL Caution: Removing work around the engine only is given below. Refer to the section on “Engine Removal” for detail since procedure for removing the torque converter and transmission assembly differential is similar to procedure for removing the engine assembly.

1. Remove the front and rear toe boards.

2. Remove the engine hood and driver seat with the radiator cover.

Fig. 2-118 Removing the engine hood assy

3. Remove the air cleaner assembly and the battery.

4. Disconnect the electric wiring, fuel piping and the accelerator wires.

Fig. 2-119 Removing the air cleaner assy

5. Remove the oil pump assembly from the engine assembly (2H Engiue).

Fig. 2-120 Removing the oil pump assy (2H)

-94-

2-51 6 Drain the coolant.

Fig. 2-121 Draining the coolant

7. Remove the balance weight.

(1) Put the wire around the balance weight.

(2) Set bolts (2 pcs) (3) Balance weight Reference: Weight of balance weight FDC/FGC33 series - Approx. 1,840 kg (4,048 lb) FDC/FGC35 series - Approx. 2,190 kg (4,818lb) FDC/FGC40 series - Approx. 2,510 kg (5,522 lb) FDC/FGC45 series.- Approx. 2,890 kg (6,358 lb)

Fig. 2-122 Removing the balance weight

8. Remove the muffler assembly and exhaust pipe.

(1) Exhaust pipe connector (2) Muffler set bolts (3) Muffler assembly (4) Exhaust pipe

Fig. 2-123 Removing the radiator assy

9. Remove the radiator assembly fan shroud and duct sub-assembly.

(1) Set bolts (2) Radiator assembly. fan shroud, duct sub-assembly 10. Disconnect the oil pump drive shaft. (2F Engine).

Fig. 2-124 Disconnecting the oil pump drive shaft (2F)

-95-

2-52 11. Disconnect the rod.

(1) Disconnect the connecting rod from the selector lever.

(2) Disconnect the inching rod from the inching lever.

12. Disconnect the torque converter oil cooler piping.

Fig. 2-125 Disconnecting the rod

13. Drain differential oil and planet gear oil.

14. Pull out the front axle shaft.

15. Remove the set bolts from the differential housing and differential carrier.

Fig. 2-126 Removing the set bolts

16. Lift the engine slightly.

When hoist is used: SST 09010-20110-71 When a forklift is used: SST 0902020110-71 Caution: Use wires and shackles of sufficient strength.

Make the wires as short as possible to maximize the lifting stroke.

Fig. 2-127 Lifting the engine slightly

17. Remove the engine mounting set nuts.

Fig. 2-128 Removing the engine mounting set nuts

-96-

2-53 18. Remove the engine with torque converter transmission.

Caution: Remove carefully not to damage the parts in the frame.

19. Remove the torque converter case cover.

Fig. 2-129 Removing the engine with torque converter transmission

20. Remove the flexible plate set bolts.

(1) Set bolts (6 pcs) Caution: Turn the crankshaft pulley set bolt to turn the flywheel. (2H Engine) Turn the torque converter assembly. (2F Engine)

Fig. 2-130 Removing the flexible plate set bolts

21. Remove the engine and torque converter housing set bolts, and disconnect the torque converter transmission.

Fig. 2-131 Disconnecting the torque converter transmission

22. Disconnect the differential carrier assembly from the torque converter transmission assembly.

-97-

2-54 23. Remove the upper cover and the control valve assy.

(1) Set bolts Caution: Remove the selector and inching lever stopper bolts too.

(2) Remove the set bolts by using the service bolts.

Fig. 2-132 Removing the upper cover

24. Remove the torque converter.

(1) Pilot boss set bolt (2) Pilot boss Caution: Tap the torque converter with a plastic hammer to remove it.

Fig. 2-133 Removing the pilot boss

(3) Snap ring (4) Torque converter

Fig. 2-134 Removing the torque converter

25. Remove the stator shaft and oil pump.

(1) Set bolt (2) Remove the stator shaft and oil pump by using the service bolts (2 pcs).

Fig. 2-135 Removing the stator shaft and pump

-98-

2-55 TRANSMISSION

Fig. 2-136 Transmission sectional view

DISASSEMBLY Note: Follow the procedure given below for disassembly.

1. Counter gear parts 2. F1/R. clutch parts 3. F2 clutch parts However, remove the gear on the greater diameter side of 2 counter gears after removing the F1/R clutch.

Fig. 2-137 Transmission disassembly procedure

-99-

2-56 COUNTER GEAR SYSTEM PARTS 1. Remove the seal plate (on the front side).

SST 09230-20150-71 SST 09810-20171-71 Note: Use these SSTs together for removal.

Fig. 2-138 Removing the seal plate

2. Remove the lock plate.

(1) Straighten the bend of the lock washer.

(2) Set bolt (3) Lock plate

Fig. 2-139 Removing the lock plate

3. Remove the counter shaft and gear.

(1) Seal plate (on the rear side) (2) Counter shaft Note: Strike the counter shaft with a copper bar, then the seal plate comes off and the counter shaft can be removed with the bearing (on the rear side).

Fig. 2-140 Removing the counter shaft

(3) Counter gear (on the small diameter side) Caution: Remove the gear on 2 counter gears on the greater diameter side after removing the F1/R clutch.

(4) Spacer

Fig. 2-141 Removing the counter gear and spacer

-100-

2-57 4. Remove the counter shaft bearing from the torque converter case.

(1) Snap ring (2) Bearing SST 09606 35013

Fig. 2-142 Removing the bearing

5. Remove the bearing from the counter shaft.

(1) Snap ring (2) Spacer (3) Bearing SST 09950-20014

Fig. 2-143 Removing the bearing

F1/R CLUTCH PARTS (MAIN CLUTCH) 6. Remove the servo case.

(1) Set bolts (2) Servo case Note: Tap the F1/R clutch system with a plastic hammer to remove it.

Fig. 2-144 Removing the servo case

7. Remove the piston rings and the snap ring.

(1) Piston rings (3 pcs) (2) Snap ring

Fig. 2-145 Removing the piston rings and snap ring

-101-

2-58 8. Remove the Fl/R clutch assy Note: Support the clutch drum. Tap the shaft end with a plastic hammer to remove it.

Fig. 2-146 Removing the F1/R clutch assy

2. Remove the main shaft bearing from the torque converter case.

(1) Snap ring (2) Main shaft bearing SST 09608-365013

10. Take out the counter gear remained in the torque converter case bottom.

Fig. 2-147 Removing the bearing

Fig. 2-148 Taking out the counter gear

11. Remove the suction filter.

(1) Set bolt (2) “O” ring (3) Suction ring

Fig. 2-149 Removing the suction filter

-102-

2-59 F1/R CLUTCH ASSY DISASSEMBLY 12. Remove the forward gear.

(1) Snap ring (2) Spacer

Fig. 2-150 Removing the snap ring and spacer.

(3) Spring pin

Fig. 2-151 Removing the spring fan

(4) Forward gear SST 09950-20014

Fig. 2-152 Removing the forward gear

13. Remove the reverse gear.

Note: Follow the forward gear removal procedure (1) Snap ring (2) Spacer (3) Spring pin (4) Reverse gear SST 09950-20014 Fig. 2-153 Removing the reverse gear

-103-

2-60 14.Remove the bearings from the forward gear and the reverse gear.

(1) Snap ring (2) Bearing Note: When the bearings are secured firmly, use SST 09608-35013.

Fig. 2-154 Removing the bearing

15.Disassemble the clutch drum.

Note: Disassemble the clutch drum on the forward and reverse sides in the same procedure.

(1) Snap ring

Fig. 2-155 Removing the snap ring

(2)Camber plate, pressure plate, driven plate and drive plate

Fig. 2-156 Removing the clutch plate

(3) Snap ring (a) SST 09420-10410-71 (b) SST 09642-67010) Note: Remove the snap ring by combining SST (a) with SST (b) by using a press.

However, any adequate steel pipe can be used as the SST (b).

Fig. 2-157 Removing the snap ring

2-61 (4) Spring retainer and piston return spring

Fig. 2-158 Removing the return spring

(5) Clutch piston

Fig. 2-159 Removing the clutch piston

(6) Remove the piston ring

Fig. 2-160 Removing the piston ring

F2 CLUTCH PARTS 16.Remove the set bolts of the servo case.

Reference: It is not necessary to remove the servo case since it is driven out on the opposite side (front side).

Fig. 2-161 Removing the set bolts

-105-

2-62 17. Remove the seal plate.

SST 09230-20150-71 SST 09810-20171-71 Note: Use the combination of these SSTs to remove the seal plate.

Fig. 2-162 Removing the seal plate

18. Remove the lock plate.

(1) Straighten the bend of the lock washer.

(2) Set bolt (3) Lock plate.

Fig. 2-163 Removing the lock plate

19. Remove the snap ring.

Fig. 2-164 Removing the snap ring

20. Remove the clutch shaft and the F2 clutch assy (1) Place a block under the lower part of the clutch drum.

Fig. 2-165 Placing a block under the clutch drum

-106-

2-63 (2)Strike the bearing face from the front side.

SST 09608-35013 Caution: Strike the bearing face until the bearings on both ends of the shaft come off from the torque converter case. Pay attention to the servo case removed on the way.

(3) Servo case Fig. 2-166 Removing the servo case

(4) Clutch shaft (with the bearing on the servo case side) SST 09620-30010 Note: Bring the clutch assy into close contact with the inside on the torque converter case rear side. Strike the shaft face from the front side. The bearing, spacer and clutch assy are removed in those order on the way.

Fig. 2-167 Removing the clutch shaft

(5) Clutch shaft bearing (on the seal plate side) (6) Spacer (7) F2 clutch assy

Fig. 2-168 Removing the bearing and F2 clutch

21. Disassemble the clutch shaft.

(1) Spring pin

Fig. 2-169 Removing the spring pin

-107-

2-64 (2) Piston ring (3) Snap ring (4) Clutch shaft bearing (on the servo case side) SST 09950-20014

Fig. 2-170 Removing the bearing

F2 CLUTCH ASSY DISASSEMBLY 22. Remove the clutch gear.

Fig. 2-171 Removing the clutch gear

23. Remove the bearing from the clutch gear.

(1) Snap ring (2) Bearing SST 09608-35013

Fig. 2-172 Removing the bearing

24. Disassemble the clutch drum.

(1) Snap ring

Fig. 2-173 Removing the snap ring

-108-

2-65 (2) Camber plate, pressure plate, driven plate and drive plate

Fig. 2-174 Removing the clutch plate

(3) Snap ring SST 09220-30200-71

Fig. 2-175 Removing the snap ring

(4) Spring retainer and piston return spring

Fig. 2-176 Removing the return spring

(5) Clutch piston (6) Remove the piston ring from the clutch piston

Fig. 2-177 Removing the piston and piston ring

-109-

2-66 INSPECTION Caution: Wash each part in washing solution before the inspection to remove dirt completely.

1.

Suction filter (1) Damage, deformation and clogging of wire netting (2) Crack of welded part (3) Damage and fatigue of “O” ring

Fig. 2-178 Inspecting the suction filter

COUNTER GEAR PARTS 2.

Counter gear and counter shaft (1) Wear and damage of gears (2) Wear and damage of spline (3) Damage of shaft (4) Damage of spacer

Fig. 2-179 Inspecting the counter gear and shaft

3.

Counter shaft bearing (1) Wear and rotation of bearing (2) Damage of spacer

Fig. 2-180 Inspecting the bearing

4.

Seal plate (1) Damage (2) Damage and fatigue of “O” ring

Fig. 2-181 Inspecting the seal plate

-110-

2-67 F1/R CLUTCH PARTS 5.

Forward gear and reverse gear (1) Wear and damage of gear (2) Clogging of oil hole (3) Wear and rotation of bearing (4) Wear and damage of spacer

Fig. 2-182 Inspecting the forward and reverse gear

6.

Clutch drum and main shaft (1) Crack, damage and biting (2) Wear and damage of gears (3) Wear and damage of spline (4) Clogging of oil path leading shaft (5) Looseness of joint rivet of shaft and drum (6) Looseness of shaft end plug (7) Damage and deformation of spring pin Fig. 2-183 Inspecting the clutch drum and shaft

(8) Wear and damage of piston ring (9) Piston ring side clearance Piston (2 positions) Limit value: 0.3 mm (0.012 in.)

Servo section (3 positions) Limit value: 0.25 mm (0.010 in.)

Fig. 2-184 Inspecting the side clearance

7.

Pressure plate, driven plate, drive plate and camber plate Caution: When the plates are extremely discolored by overheat, replace both the drive plate and the driven plate at a time.

Fig. 2-185 Inspecting the clutch plate

-111-

2-68 (1) Wear and damage of pressure plate Thickness standard: 6.5 mm (0.256 in.)

Service limit: 6.3 mm (0.248 in.)

Fig. 2-186 Inspecting the pressure plate

(2) Wear, damage, burn, deformation and discoloration of drive plate Thickness standard: 2.0 mm (0.079 in.)

Service limit: 1.8 mm (0.071 in.)

(3) Wear, damage, burn, deformation and discoloration of driven plate Thickness standard: 2.9 mm (0.114 in.)

Service limit: 2.7 mm (0.106 in.)

Fig. 2-187 Inspecting the drive plate and driven plate

(4) Wear, damage, deformation and discoloration on camber plate Curvature inspection Lay the camber plate face down on the surface plate and measure its inner circumference and its inside height.

Standard curvature 3.4 mm (0.134 in) Service limit 3.0 mm (0.118 in) Fig. 2-188 Inspecting the camber plate

8. Clutch return spring (1) Break and fatigue of spring Free length: 62 mm (2.44 in.)

Right angleness: 2ø (2) Damage of spring retainer

Fig. 2-189 Inspecting the return spring

-112-

2-69 9.

Clutch piston (1) Crack and damage (2) Clogging of oil hole Note: Check these defect by using compressed air, etc.

Fig. 2-190 Inspecting the clutch piston

(3) Wear and damage of piston ring (4) Piston ring side clearance Limit value: 0.15 mm (0.006 in.)

Fig. 2-191 Inspecting the side clearance

10. Main shaft bearing (1) Wear and rotation

Fig. 2-192 Inspecting the bearing

11. Servo case (1) Crack and damage (2) Wear and damage of piston ring sliding part (3) Clogging of oil path (4) Wear and fatigue of “O” ring

Fig. 2-193 Inspecting the servo case

-113-

2-70 F2 CLUTCH PARTS 12. Clutch gear (F2 gear) (1) Wear and damage of gear (2) Clogging of oil hole (3) Wear and rotation of bearing

Fig. 2-194 Inspecting the clutch gear

13. Clutch drum (1) Crack, damage and biting (2) Wear and damage of gears (3) Clogging of oil hole (4) Wear and damage of piston ring (5) Piston ring side clearance Limit value: 0.3 mm (0.012 in.)

Fig. 2-195 Inspecting the clutch drum

14. Clutch shaft (1) Wear and damage (2) Clogging of oil path (3) Looseness of shaft end plug (4) Damage and deformation of spring pin

Fig. 2-196 Inspecting the clutch shaft

(5) Wear and damage of piston ring and “O” ring (6) Piston ring side clearance Limit value: 0.25 mm (0.010 in.)

Fig. 2-197 Inspecting the side clearance

-114-

2-71

15. Clutch plate, return spring and clutch piston Caution: These parts are the same as those of the main clutch. See the F1/R clutch for the inspection items.

Fig. 2-198 Inspecting the plate, spring and piston

16. Clutch shaft bearing (1) Wear and rotation

Fig. 2-199 Inspecting the bearing

17. Servo case (1) Crack and damage (2) Wear and damage of piston ring sliding part (3) Clogging of oil path (4) Damage and fatigue of “O” ring 18. Seal plate (1) Damage (2) Damage and fatigue of “O” ring Fig. 2-200 Inspecting the servo case and seal ring

TORQUE CONVERTER CASE 19. Torque converter case (1) Crack and damage (2) Clogging of oil path (3) Damage and fatigue of “O” ring

Fig. 2-201 Torque converter case

-115-

2-72 ASSEMBLY Caution: When assembling the torque converter case, pay attention so that dust, etc. does not enter it.

Before assembling each sliding part, be sure to apply torque converter oil to it sufficiently.

Fig. 2-202 Assembling the piston ring

F2 CLUTCH PARTS Assemble the F2 clutch assy.

(1) Assemble the piston ring on the clutch piston.

(2) Assemble the piston ring on the clutch drum.

(3) Insert the piston in the clutch drum.

Note: Apply torque converter oil to the piston sufficiently.

It is not necessary to fit the piston ring normally.

Fig. 2-203 Piston insertion

(4) Set the piston return spring, retainer and snap ring on the drum. Compress the spring by using SST to assemble it.

SST 09220-30200-71 1) Fit the piston ring by using a screw driver and insert the piston.

Fig. 2-204 Assembling the piston

2) Retighten the SST bolt further.

Compress it to the position where the snap ring can be fit to assemble the snap ring.

Fig. 2-205 Assembling the snap ring

-116-

2-73 (5) Drive plate and driven plate Caution: Assemble the drive plates (6 pcs) and the driven plates (6 pcs) alternately in the order of the drive plate and the driven plate.

Be sure to fill the clearances between the plates with torque converter oil.

(6) Assemble the pressure plate and the camber plate.

Fig. 2-206 Assembling the drive and driven plates

Caution: Apply sufficient amount of torque converter oil on each plate.

(1) Assemble the pressure plate.

(2) Assemble the camber plate.

1) “OUT” on the camber plate must come in the clutch gear side.

2) The flangeless section (2 places) of the pressure plate and the flange of the camber plate must come together.

(3) Assemble the snap ring.

(4) Measure the clearance (A) between the snap ring and the camber plate.

Dimension A: 2.5 to 3.5 mm (0.098 ~ 0.138 in.)

If the measurement exceeds the specified dimension limits, change the order of plates. If the specified dimension is still not reached, check each plate for wear, and replace as necessary.

Fig. 2-207 Assembling the pressure plate and camber plate

Fig. 2-208 Clearance measurement

(9) Assemble the bearing on the clutch gear.

1) Bearing SST 09608-35013 2) Snap ring

Fig. 2-209 Assembling the bearing

-117-

2-74 (10) Assemble the clutch gear (F2 gear) on the drum.

Note: Align the serration of the driven gear with a screwdriver, etc. before assembling.

2.

Assemble the bearing, piston ring and spring pin on the clutch shaft.

(1) Bearing (2) Snap ring (3) Piston ring and “O” ring

Fig. 2-210 Assembling the clutch gear

Caution: After assembling, apply grease to the piston ring.

Fig. 2-211 Assembling the bearing

(4)

Spring pin

Fig. 2-212 Driving in the spring pin

3.

Assemble the clutch shaft bearing (on the seal plate side) on the torque converter case.

(1) Bearing SST 09608-35013 (2) Snap ring

Fig. 2-213 Assembling the bearing

-118-

2-75 4.

Assemble the F2 clutch assy and the clutch shaft.

(1) Place the torque converter case on a block with the differential side down.

Note: Place the torque converter case on the block so that the inserted condition of the shaft can be confirmed by the hand inserted from the below.

Fig. 2-214 Driving in the clutch shaft

(2) Place the clutch assy on the bearing in the torque converter case. Drive in the clutch shaft from the above.

SST 09620-30010 Caution: Stop the driving in of the clutch shaft when the bearing on the shaft is just fit in the torque converter case. (In this case, the shaft end enters slightly the clutch gear bearing.)

Fig. 2-215 Assembling the spacer

(3) Raise the shaft under the conditions described in (2) (with the clutch assy) and place the spacer correctly on the bearing in the torque converter case.

(4) Lower the shaft and clutch assy slowly. Drive in the clutch shaft again.

SST 09620-30010

Caution: Insert the hand from below so that the spacer does not deviate.

Place the shaft spring pin in the drum groove 5.

Fig. 2-216 Assembling the clutch shaft

Assemble the lock plate and lock nut.

(1) Lock plate (2) Lock washer (3) Set bolt (4) Bend the lock washer.

Fig. 2-217 Assembling the lock plate and lock washer

-119-

2-76 6.

Assemble the seal plate.

Caution: Apply grease to the “O” ring.

Tap the seal plate with a plastic hammer to assemble it.

Fig. 2-218 Assembling the seal plate

7.

Assemble the servo case.

Servo case Caution: Apply grease to the “O” ring.

Pay attention so that the oil hole “O” ring does not deviate.

Confirm that grease is applied to the piston ring on the shaft side.

Tap the servo case with a plastic hammer to assemble it.

Fig. 2-219 Assembling the servo case

Set bolt T = 1.8 ~ 2.2 kg-m (13.0 ~ 15.9 ft-lb.

8.

Check the F2 clutch operation.

Note Check the F2 clutch operation by using compressed air.

Throttle compressed air to the minimum and blow it to the clutch operation oil path to check if the F2 clutch piston operates surely.

Fig. 2-220 Inspecting the F2 clutch piston operation

F1/R CLUTCH PARTS Note: Before assembling the F1/R clutch system, assemble the suction filter and position the counter gear (on the larger diameter side) provisionally.

9.

Assemble the suction filter.

Suction filter Set bolt “O” ring

Fig. 2-221 Mounting the suction filter

-120-

2-77 10. Place the counter gear (on the larger diameter side) in the torque converter case.

Caution: Place the counter gear under the position where it is assembled in the correct direction. (After assembling the main clutch, assemble the counter gear.)

Fig. 2-222 Provisional positioning of the counte gear (on larger diameter side)

11. Assemble F1/R clutch assy.

Note: Assemble the F1/R clutch assemblies on the forward and reverse sides by the same procedure.

(1) Assemble the piston ring on the clutch piston.

Fig. 2-223 Assembling the piston ring

(2) Assemble the piston ring on the main shaft piston sliding part.

Caution: After assembling, apply grease to the piston ring.

It is not necessary to assemble the piston ring on the servo case side.

Fig. 2-224 Assembling the piston ring

(3) Insert the piston in the clutch drum.

Note: Apply torque converter oil sufficiently to the piston.

It is not necessary to fit the piston ring normally.

Fig. 2-225 Piston insertion

-121-

2-79 (3) (4)

Assemble the snap ring.

Measure the clearance (A) between the snap ring and the camber plate.

Dimension A: 2.5 to 3.5 mm (0.098 ~ 0.138 in) If the measurement exceeds the specified dimension limits, change the order of plates. If the specified dimension is still not reached, check each plate for wear, and replace as necessary.

Fig. 2-230 Clearance measurement

(5)

Assemble the bearings on the forward gear and the reverse gear.

1) Bearing SST 09608-35013 2) Snap ring

Fig. 2-231 Assembling the bearing

(6)

Assemble the forward and reverse gears on the main shaft.

SST 09608-35013

Caution: Align the serration of the driven plate with a screwdriver, etc. before assembling.

Do not confuse the forward side with the reverse side. (Confirm them by the number of teeth.)

(7)

Fig. 2-232 Assembling the forward and reverse gears

Spring pin

Fig. 2-233 Driving in the spring pin

-123-

2-80 (8)

Spacer and snap ring

Note: Align the notch of the inside diameter of the spacer with the spring pin on the shaft side and secure the spacer with the snap ring.

Fig. 2-234 Assembling the spacer

13. Assemble the main shaft bearing (on the servo case side) on the torque converter case.

(1) Snap ring (2) Bearing SST 09608-35013

Fig. 2-235 Assembling the bearing

14. Secure the servo case provisionally.

Reference: Assemble the servo case so that the bearing does not move when assembling the F1/R clutch assy.

Fig. 2-236 Provisional installation of the servo case

15. Assemble the F1/R clutch assy.

(1) Support the clutch drum and strike the shaft end with a copper hammer.

(2) When the shaft is driven into the. bearing on the torque converter case side to some degree, drive it in completely with a copper rod.

Fig. 2-237 Assembling the F1/R clutch assy

-124-

2-81 16. Remove the servo case.

17. Assemble the snap ring and piston ring on the main shaft.

(1) Snap ring (2) Piston rings (3 pcs) Caution: After assembling apply grease to them.

Fig. 2-238 Assembling the snap ring and piston ring

18. Assemble the servo case.

(1) Servo case Caution: Apply grease to the “O” ring Pay attention so that the oil hole “O” ring does not come off.

Tap the servo case with a plastic hammer to assemble it.

(2)

Set bolt T = 1.8 ~ 2.2 kg-m (13.0 ~ 15.9 ft-lb)

Fig. 2-239 Assembling the servo case

19. Check the F1/R clutch operation.

Note: Check the F1/R clutch operation by using compressed air.

Throttle compressed air to the minimum and blow it to the clutch operation oil path to check if the clutch piston operates surely.

(1) (2)

Check the operation of the clutch on the forward side.

Check the operation of the clutch on the reverse side.

Fig. 2-240 Inspecting the clutch operation

Fig. 2-241 Inspecting the clutch operation (on reverse side)

-125-

2-82 COUNTER GEAR PARTS 20. Assemble the bearing on the counter shaft.

(1) Bearing (on the rear side) (2) Spacer (3) Snap ring

Fig. 2-242 Assembling the bearing

21. Assemble the counter shaft bearing on the torque converter case.

(1) Bearing (on the front side) (2) SST 09608-35013 Snap ring

Fig. 2-243 Assembling the bearing

22. Assemble the counter gear, counter shaft and spacer.

(1) Hold the counter gear and the spacer in the torque converter case and insert the shaft in them.

Caution: Do not direct the counter gear in the wrong direction.

Fig. 2-244 Counter shaft insertion

(2) Strike the shaft end with a plastic hammer or a copper hammer until the shaft is engaged with the gear spline.

(3) Drive in the shaft completely with a copper rod.

Fig. 2-245 Assembling the counter shaft

-126-

2-83 23. Assemble the lock plate and lock washer.

(1) Lock plate (2) Lock washer (3) Set bolt (4) Bend the lock washer.

Fig. 2-246 Assembling the Lock Plate and lock washer

24. Assemble the seal plates. (on the front and rear sides) Caution: o Apply grease to the “O” ring. o Tap the seal plate with a plastic hammer to assemble it.

Fig. 2-247 Assembling the seal plate

INSTALLATION Follow the removing procedure in the reverse order.

Caution: See the following cautions for assembly operation.

1. Assembly of the stator shaft and oil pump.

2. Assembly of the torque converter.

3. Assembly of the upper cover and control valve assy.

4. After mounting, adjust the selector valve lever and inching valve lever. (See the adjustment section.)

5. After mounting, make measurement and tests.

6. Supply oil and water.

Differential, planetary gear - Hipold Gear Oil SAE90 Differential 5 l (1.3 US gal) Planetary gear 0.5 l (0.13 US gal) (One Side) Coolant for the radiator 2H 17.9 l (4.73 US gal) 2F 18.9 l (5.0 US gal)

-127-

2-84 MEASUREMENT AND TEST 1. Oil level measurement (1) Park the vehicle horizontally. Set the shift lever at the neutral position.

Idle the engine.

(2) After warming up, stop the engine and measure the oil level immediately with the level gauge.

When the oil mark is between the upper limit (F) and the lower limit (L), the oil level is proper.

Torque converter oil level: 15 liters (4.0 US gal.)

Fig. 2-248

Oil level measurement

Fig. 2-249

Engine rpm measurement

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

Caution: o Warm up the engine until the torque converter oil thermometer indicates the normal temperature. o When the rpm is not specified value, see Engine rpm adjustment of Engine for adjustment.

(2) Stop the engine. Jack up the front axle to raise the tires (both wheels).

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

When there are 3 oil pressure gauges, it is desirable to measure the main pressure, clutch pressure and torque converter pressure at the same time.

(4) Start the engine. Set the shift lever at the neutral position. Measure the main pressures at the idling rpm and at 1,500 rpm as well as the torque converter pressure at 1,500 rpm.

-128-

Fig. 2-250

Fig. 2-251

Measurement openings for main pressure and torque converter outlet pressure

Main pressure measurement

2-85 (1) Set the shift lever to each position.

Measure the clutch operation pressures at the idling rpm and at 1,500 rpm.

Caution: o Use a 20kg/cm² class oil pressure gauge. o It is desirable to measure the torque converter pressure (the outlet pressure) with at 5 kg/cm² class oil pressure gauge. o Do not operate the brake pedal when measuring the oil pressure.

Fig. 2-252

Clutch pressure measurement openings

Fig. 2-253

Clutch pressure measurement

Fig. 2-254

Stall test

Fig. 2-255

Engine rpm measurement

Each oil pressure standard value

3.

Stall test (1) Load a cargo near the allowable load limit on the vehicle. Choke the front and rear wheels surely. Pull the parking brake lever fully.

Caution: Since the torque converter produces the maximum torque, stop the vehicle completely.

(2) Warm up the engine. Measure the idling rpm and maximum no-load rpm.

Note: See 2 Oil pressure measurement.

-129-

2-86 (3) Confirm the engine output at the maximum rpm under the loaded condition.

(Method) After adjusting the maximum noload rpm, incline the tilt lever forward and backward and measure the maximum rpm with the accelerator fully opened.

(Standard) Decrease the rpm by the value shown below from the maximum no-load rpm to find the actual maximum rpm.

Diesel model: Less than 250 prm Gasoline model: Less than 300 rpm (Judgment) When the engine rpm decreases markedly, the engine is not properly adjusted. Adjust the engine by manipulating the air governor, etc.

(See Engine adjustment.)

In the case of an LPG model. decrement from the maximum static rpm is somewhat greater than the above mentioned values.

(4) Start the engine. Set the shift lever to the forward position or reverse position. Rotate the engine fully.

Measure the rpm as it becomes stabilized. (stall rpm).

Fig. 2-256

Fig. 2-257

Engine output confirmation

Stall rpm measurement

Note :Common for all vehicles Caution: o The brake pedal may be depressed to prevent the vehicle from rushing. Never depress the inching pedal. o See the Troubleshooting for judgment of the measured stall rpm.

-130-

3-2 GENERAL

Fig. 3-1 Differential section

SPECIFICATIONS

-132-

3-3 COMPONENT PARTS

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

1. Differential carrier 2. “O” ring 3. Bolt 4. Bearing 5. Differential case No. 1 6. Side gear thust washer 7. Differential side gear 8. Differential spider 9. Differential pinion 10. Pinion thrust washer

[Tightening torque untill: kg-cm (ft-lb)]

11. Ring gear 12. Differential case No. 2 13. Thrust screw cap 14. Ring gear thrust screw 15. Lock nut 16. Drive 17. “O” ring 18. Drive pinion adjusting shim 19. Bearing retainer 20. “O” ring 21. Bearing spacer

Fig . 3-2 Differential components parts

-133-

22. Lock nut 23. Bearing preload adjustingshim 24. Output gear 25. Breather plug 26. “O” ring 27. Adjusting nut lock 28. Adjusting nut 29. Plug 30. Packing 31. Differential housing

3-4 SERVICE STANDARDS

REMOVAL Caution: Refer to the section on “Removal of the torque converter and transmission with differential” since the differential assembly can be removed after removing the engine and torque converter transmission with differential.

1. Remove the differential carrier assembly.

Fig. 3-3

-134-

Removing the differential carrier assembly

3-5 DISASSEMBLY 1. Measure the run-out at the back of the ring gear.

Run-out limit: 0.1 mm (0.0039 in.)

Note: Apply a dial gauge vertically to the back of the ring gear and rotate the ring gear by turning the output gear lock nut.

Fig. 3-4

Measuring the run-out at the back of the ring gear

2. Measure the backlash.

Standard backlash: 0.2 ~ 0.3 mm (0.008 ~ 0.012 in.)

Fig. 3-5 Measuring the backlash

3. Measure the side bearing pre-load.

(1) Wind a string around the output gear, measure the starting force with a spring scale and record the measured value for reference at the time of assembly.

Note: The spring scale reading is the sum with the pinion bearing pre-load.

Fig. 3-6 Measuring the bearing pre-load

4. Remove the thrust screw cap. (a) Lock nut (b) Thrust screw and cap

Fig. 3-7

-135-

Removing the thrust screw

3-6 5. Punch matching marks on the differential carrier and bearing caps.

Note: Since the case and bearing cap are processed as a unit, reverse setting of the left and right direction is not allowed. Be sure to punch matching marks, and reassemble at the original position.

Fig. 3-8

Punching matching marks

Fig. 3-9

Removing the bearing cap

6. Remove the bearing cap.

(1) Lock wire (2) Lock bolt (3) Adjusting nut lock (4) Set bolts (5) Bearing cap Note: The bearing cap can be removed easily by light tapping with a plastic hammer.

7. Remove the adjusting nut.

Fig. 3-10

Removing the adjusting nut

Fig. 3-11

Removing the differential case assy

8. Remove the differential case assy.

-136-

3-7 9. Measure the drive pinion bearing pre-load.

(1) Wind a string around the output gear, measure the starting force with a spring scale, and record the measured value for reference at the time of assembly.

Fig. 3-12

Measuring the bearing pre-load

10. Remove the output gear and drive pinion assy.

(1) Set bolts

Fig. 3-13 Removing the drive pinion assy (1)

(2) Use a brass bar to drive out the drive pinion assy.

(3) Output gear and drive pinion assy

Fig. 3-14 Removing the drive pinion assy (2)

11. Remove the output gear.

(1) Loosen lock nut staking.

(2) Lock nut (3) Out put gear

Fig. 3-15 Removing the output gear

-137-

3-8 12. Remove the drive pinion.

(1) Drive out the drive pinion.

Fig. 3-16

Driving out the drive pinion

(2) Bearing spacer (3) Shim Caution: Record the number and thickness of the shims for pre-load.

Fig. 3-17 Removing the shims

13. Remove the tapered roller bearing inner race.

ST 09950-20014 Caution: Remove the bearing only when a defect is found.

Fig. 3-18 Removing the bearing inner race

14. Remove the pilot bearing.

(1) Loosen staking at the end of the drive pinion.

(2) Pilot bearing SST 09950-20014 Caution: Remove the bearing only when a defect is found.

Fig. 3-19 Removing the pilot bearing

-138-

3-9 15. Remove the tapered roller bearing outer race from the retainer.

Caution: Remove only when a defect is found as a result of retainer and bearing inspection.

Fig 3-20

Removing the outer race

Fig 3-21

Removing the differential side bearing

Fig 3-22

Cheking the matching marks

Fig 3-23

Removing the upper case

16. Remove the differential side bearing.

SST 09950-200141 Caution: Remove the bearing only when a defect is found.

17. Remove the differential upper case.

(1) Check the matching marks of the upper and lower cases.

(2) Set bolts (3) Upper case

-139-

3-10 18. Remove the side gear and differential pinion gear.

(1) Side gear and thrust washer (2) Differential spider, differential pinion gear, and thrust washer (3) Side gear and thrust washer

Fig. 3-24

Removing the side gear and pinion gear

Fig. 3-24

Removing the ring gear

19. Remove the differential ring gear.

(1) Loosen setting bolt caulking.

(2) Set bolts (3) Ring gear Caution: Remove only when a defect is found in the drive pinion, ring gear and differential case.

-140-

3-11 INSPECTION 1. Thrust screw and cap (1) Damage at the threaded portion (2) Wear and damage of the cap Standard: 13.0 mm (0.512 in.)

Wear limit: 12.2 mm (0.480 in.)

2.

Fig. 3-26

Inspecting the thrust screw and cap

Fig. 3-27

Inspecting the side bearing

Fig. 3-28

Inspecting the pinion and ring gear

Fig. 3-29

Inspecting the differential gear and side gear

Side bearing (1) Crack, damage and wear of rollers (2) Damage of the bearing holder (3) Damage and wear of the bearing outer race

3. Drive pinion and ring gear (1) Damage and wear at tooth surface (2) Crack and damage at the pilot bearing portion (3) Damage at the pinion spline portion Caution: Be sure to replace both the drive pinion and ring gear as a set when either of the two is defective.

4. Inspect damage, and wear of the side gear (1), differential pinion (2), spider (3), thrust washers, etc.

(1) Differential pinion Standard inside diameter: 22.12 mm (0.871 in.)

Limit inside diameter: 22.22 mm (0.875 in.)

-141-

3-12 (2) Thrust washer (differential pinion) Standard thickness: 1.6 mm (0.063 in.)

Wear limit: 1.0 mm (0.039 in.)

(3) Thrust washer (side gear) Standard thickness: 1.6 mm (0.063 in.)

Wear limit: 1.3 mm (0.051 in.)

Fig. 3-30

Inspecting the thrust washer

Fig. 3-31

Inspecting the spider

Fig. 3-32

Inspecting the differential case

Fig. 3-33

Inspecting the Adjusting nut

(4) Spider Standard outside diameter: 22.00 mm (0.866 in.)

Wear limit: 21.75 mm (0.856 in.)

5. Differential case (1) Crack and damage of the case

6.

Adjusting nut (1) Damage at the nut threaded portion

-142-

3-13 ASSEMBLY AND ADJUSTMENT 1.

Assemble the ring gear.

(1) Differential lower case (2) Ring gear (3) Set bolts T = 13 ~ 18 kg-m (93.9 ~ 130 ft-lb) Note: When the vehicle leaves the factory, the ring gear set bolt has been tightened to the specified torque and locked with thread tightener. When assembling, always stake the bolt after tightening to the specified torque. Do not re-use the set bolt once it has been staked.

Tighten each pair of bolts opposite to each other, and finally tighten the bolts to the specified torque successively in a circular sequence.

Fig. 3-34

Assembling the ring gear

Fig. 3-35

Caulking the set bolts

Fig. 3-36

installing the side gear

Fig. 3-37

Installing the spider pinion

2. Stake the set bolts.

(1) Stake the set bolt tips firmly in a cross form.

3. Install the side gear.

(1) Thrust washer Note: Set the thrust washer with the oil groove directed toward the side gear.

(2) Side gear

4.

Mount the spider pinion set.

(1) Spider Install these parts (2) Pinion as a set.

(3) Thrust washer

}

-143-

3-14 5. Side gear and thrust washer (1) Side gear (2) Thrust washer Note: Set the thrust washer with the oil groove directed toward the side gear.

Fig. 3-38

Installing the side gear

6. Assemble the differential upper case.

(1) Differential upper case Note: Align the matching marks exactly.

Fig. 3-39 Checking the mathing marks

(2) Lock plate (3) Set bolts T = 4.4 ~ 5.5 kg-m (31.8 ~ 39.7 ftlb)

Fig. 3-40 Tightening the set bolts

7.

Assemble the side bearing.

SST 09370-10410-71 Note: Do not set the bearing reversely.

Fig. 3-41

-144-

Assembling the side bearing

3-15 8. Assemble the bearing outer race.

(1) Bearing retainer (2) Drive in the oil seal.

SST 09608-30011 Caution: After assembly, apply grease to oil seal tip and “O” ring.

Fig. 3-42

Assembling the oil seal (only for a torque converter type vehicle)

Fig. 3-43

Assembling the pieot bearing

Fig. 3-44

Assembling the pilot bearing

(3) Bearing outer race SST 09130-30200-71

9.

Assemble the pilot bearing.

(1) Drive pinion (2) Pilot bearing SST 09608-30011

(3) Stake the drive pinion tip end at 3 points.

Fig. 3-45 Staking the drive pinion

-145-

3-16 10. Assemble the drive pinion from bearing inner race.

(1) Drive pinion (2) Front side inner race SST 09370-20270-71 Note: Do not drive in the bearing reversely.

Fig. 3-46 Assembling the bearing inner race

11. Assemble the drive pinion.

(1) Drive pinion (2) O-ring, bearing spacer (3) Bearing retainer (4) Shim Caution: When assembling the drive pinion, be sure to assemble the “O” ring before assembling the bearing space.

Fig. 3-47 Assembling the drive pinion

12. Assemble the drive pinion rear bearing inner race.

SST 09370-20270-71

Fig. 3-48 Assembling the bearing inner race

13. Assemble the output gear.

(1) Output gear

Fig. 3-49 Assembling the output gear

-146-

3-17 (2) Lock nuts T = 36 ~ 45 kg-m (263 ~ 289 ft-lb) Note: o Be sure to use new lock nuts. o After tightening lock nuts, strike the shaft with a plastic hammer, retighten it and confirm the torque. o After confirming the pre-load, caulk the lock nuts.

Fig. 3-50

Tightening the lock nuts

Fig. 3-51

Measuring the bearing pre-load

14. Measure the drive pinion bearing pre-load.

(1) Hold the bearing retainer with a vice.

(2) Measure the pre-load of the ouptut gear.

Pre-load 15.7 ~ 19.3 kg (34.6 ~ 42.6 lb) Note: Wind a string around the ouptut gear. Pull the string with a spring scale at a constant speed to measure the drive pinion bearing pre-load.

(3) When the measured pre-load is not within the above range, disassemble the drive pinion bearing. adjust the shims, tighten the drive pinion bearing again with the specified tightening torque, and measure the preload.

Note: When the pre-load is lower than the specified value, decrease the shims.

When it is higher than the specified value, increase the shims.

15. Stake the lock nuts.

Note: o Stake firmly at 2 points. o Bring part A in the right figure into sure contact.

Fig. 3-52 Staking the lock nuts

-147-

3-18 DRIVE PINION PROTRUSION ADJUSTMENT 16. Adjust the protrusion length of the drive pinion by changing the shim thickness.

Fig. 3-53 Dimension A

(Shim thickness calculation method) (1) Measure dimension A with a height gauge in units of 1/100 mm.

(2) Read dimension B stamped on the transmission case.

Note: When 15 is stamped, it means 0.15 mm (0.0059 in.).

Fig. 3-54 Dimension B stamping position

(3) Read dimension C written with an electric pen at the rear end of the drive pinion.

Note: Read ± 000±

.

of the marking of

Fig. 3-55 Dimension C marking position

-148-

3-19 Example 3.5 ton model equipped with torque converter Dimension A (Measured): 24.14 Dimension B (Stamped on the case): 08 Dimension C (Indicated on the pinion): 00 t=(24.14-24)+08/100+00/100=0.22 Use two 0.1 mm thick shims, or use one 0.1 mm thick shim and one 0.15 mm thick shim.

17. Install the drive pinion assy.

(1) Selected shim (2) Drive pinion assy (3) Set bolts Tightening torque Torque converter type vehicle: T = 7 ~ 8 kg-m (50.5 ~ 57.6 ft-lb)

Note: Wash the set bolts and the bolt holes o well with trichloroethylene. Apply liquid seal to the threaded portion of the set bolts.

Since a torque converter type vehicle o uses Allen bolts, use lock wires to prevent loosening of the bolts.

Fig. 3-56 Installing the drive pinion assy

18. Install the differential case assy.

(1) Side bearing outer race (2) Differential case assy Note: Install these parts so that the ring gear comes into contact with the drive pinion.

Fig. 3-57 Installing the differential case assy

-149-

3-20 19. Install the bearing cap.

(1) Adjusting nuts

Fig. 3-58

Installing the adjusting nuts

Fig. 3-59

Provisionally tightening the set bolts

(2) Bearing cap Note: Before installation, confirm alignment of the matching marks.

(3) Tighten the set bolts provisionally.

T = 2 kg-m (14.44 ft-lb)

RING GEAR BACKLASH AND SIDE BEARING PRELOAD ADJUSTMENT 20. Tighten the adjusting nuts.

(1) Apply a dial gauge vertically to the ring gear back.

(2) Tighten the right and left adjusting nuts alternately.

SST 09330-30010 (3) Measure the thrust gap and tighten the adjusting nuts until the gap becomes 0.

(4) Tighten both adjusting nuts by one notch each.

Fig. 3-60 Tightening the adjusting nuts

21. Measure the ring gear backlash.

(1) Apply a dial gauge vertically to the ring gear tooth surface.

(2) Move the ring gear to the clockwise and counterclockwise, and measure the backlash.

Standard backlash = 0.2 ~ 0.3 mm (0.0079 ~ 0.0118 in.)

Fig. 3-61 Measuring the backlash

-150-

3-21 22. When the measured backlash is not within the specified range, adjust the backlash according to the procedure below.

(1) When the backlash is excessive; Loosen the adjusting nut on the ring gear tooth surface side. Tighten the adjusting nut on the ring gear rear side to bring the ring gear closer to the drive pinion.

(2) When the backlash is insufficient; Loosen the adjusting nut on the ring gear rear side. Tighten the adjusting nut on the ring gear tooth surface side to bring the ring gear away from the drive pinion.

Fig. 3-62 Adjusting the backlash (1)

Note: To adjust the backlash, loosen one adjusting nut by one notch after tightening the other by one notch to slowly move the differential case while observing the dial gauge reading.

Fig. 3-63 Adjusting the backlash (2)

23. Measure the differential side bearing preload.

(1) Wind a string around the output gear to measure the pre-load with a spring scale.

Pre-load: The drive pinion pre-load measured in step 14 (2) + 2 kg (4.4 lb)

Fig. 3-64 Measuring the differential side bearing pre-load

Note: The spring balance reading is the sum with the pinion bearing pre-load.

(2) When the measured pre-load is not within the specified range, adjust it by turning the adjusting nut.

To increase the pre-load; 1 Tighten the right and left adjusting nuts equally.

To decrease the pre-load; 2 Loosen the right and left adjusting nuts equally.

-151-

Fig. 3-65 Adjusting the pre-load

3-22 Note: After adjusting the pre-load, measure the backlash to confirm it is within the specified range 24. Tighten the bearing cap set bolts with the specified torque.

T = 6 8 kg (43.3 57.6 ft-lb)

Fig. 3-66

Tightening the set bolts

Fig. 3-67

Turning the ring gear

Fig. 3-68

Proper meshing

Fig. 3-69

Heel contact

TOOTH MESHING CHECK 25. Check the meshing between the ring gear and the drive pinion.

Thinly apply red lead to both surfaces of 7 ~ 8 teeth of the ring gear. Turn the ring gear forward and backward a few times to obtain tooth meshing pattern. Check the meshing between the ring gear and the driven pinion according to the obtained pattern.

When the meshing is improper, adjust the drive pinion projection, ring gear backlash and side bearing pre-load again.

(1) Proper meshing When the pattern is near the center of the tooth surface and has proper width, the meshing is proper.

(2) Heel contact Decrease the drive pinion adjusting shims to increase the projected length of the pinion.

Move the ring gear away from the pinion to adjust the backlash.

-152-

3-23 (3) Toe contact Increase the drive pinion adjusting shims to decrease the projected length of the pinion.

Move the ring gear toward the pinion to adjust the backlash.

Fig. 3-70 Toe contact

(4) Flank contact (Deep and narrow contract) Increase the drive pinion adjusting shims to decrease the projected length of the pinion.

Move the ring gear toward the pinion to adjust the backlash.

Fig. 3-71 Flank contact

(5) Face contact Decrease the drive pinion adjusting shims to increase the projected length of the pinion.

Move the ring gear away from the pinion to adjust the backlash.

Fig. 3-72 Face contact

26. Lock the bearing cap and the set bolts with wires.

(1) Adjusting nut lock Note: To adjust the position of the adjusting nut lock, start from the adjusting nut screwing in direction.

(2) Wire lock

Fig. 3-73 Wire lock

-153-

3-24 27. Mount the ring gear, thrust screw and cap.

(1) Thrust screw and cap Note: Tighten the thrust screw fully and then loosen it by 1/8 turn.

(2) Adjust the thrust screw cap gap.

Gap: 0.2 - 0.3 mm (0.0079 - 0.0118 in.)

Fig. 3-74 Adjusting the thrust screw (1)

(3) Thrust screw lock nut T = 10.5 ~ 13 kg-m (75.8 ~ 93.9 ftlb)

Fig. 3-75 Adjusting the thrust screw (2)

ASSEMBLY Reverse the procedure for disassembly.

1.

After mounting is completed, supply oil and water.

Differential, planetary gear Hipoid gear oil SAE 90 Differential 5.0 (0.13 Us gal) Planetary gear 0.5 (0.13 US gal) (One Side) Coolant for the radiator 2H 17.9 (4.73 US gal) 2F 18.9 (5.0 US gal)

-154-

4-2 SPECIFICATIONS

SERVICE STANDARDS

-156-

4-3 GENERAL

Fig. 4-1 Front axle section

-157-

4-4 COMPONENT PARTS

1. Front axle bracket 2. “O” ring 3. Hub bolt 4. Hub nut 5. Front axle hub 6. Brake drum 7. Seal cover 8. Oil Seal 9. Inner bearing 10. Outer bearing 11. Internal gear hub 12. Oil seal

13. Ring nut 14. Front axle shat 15. “O” ring 16. Planet gear carrier 17. Thrust washer 18. Planet gear 19. Bushing 20. Planet gear shaft 21. Packing 22. Carrier cover 23. Packing 24. Plug

Figure 4-2 Front axle component parts

-158-

4-5 DISASSEMLBY 1.

Loosen the front wheel hub nuts.

2.

Jack up the frame.

(1) Put stoppers under the rear wheels.

(2) Jack up the frame, and put a support under the front section.

Fig. 4-3 Removing the front wheels (1)

3.

Remove the front wheels.

(1) Hub nuts (2) Front wheels Caution: Remove the wheels carefully not to damage the hub bolts.

Fig 4-4 Removing the front wheels (2) 4.

Drain oil from the planet gear carrier.

5.

Remove the front axle carrier cover.

Fig. 4-5 Draining oil from the planet gear carrier.

Fig. 4-6 Removing the axle carrier cover

-159-

4-6 6.

Pull out the front axle shaft.

Service bolt M10 x 1.25 pitch Caution: Pull out the axle shaft carefully not to damage the oil seals.

A small amount of oil may leak out from the differential depending on the angle of the frame. Use a waste cloth to stop it.

Fig. 4-7 Removing the front axle shaft

7.

Remove the planet gear carrier assembly.

Service bolt M10 x 1.25 pitch 35 mm min. shank length

Fig. 4-8 Removing the planet gear carrier assembly

8.

Remove the internal gear hub.

(1) Cotter pin (2) Lock nut

Fig. 4-9 Removing the lock nut

(3)

Internal gear hub

Fig. 4-10 Removing the internal gear hub

-160-

4-7 9. Remove the front axle hub with brake drum.

Caution: Place a block under the front axle hub, and slowly pull out the axle hub with brake drum horizontally.

Separate the axle hub and the brake drum when it is necessary to repair or replace individual sections.

Fig. 4-11 Removing the axle hub with brake drum

10. Disassemble the planet gear carrier assembly.

(1) Planet gear shaft (2) Planet gear (3) Thrust washer (4) Planet gear carrier

Fig. 4-12 Removing the planet gear shaft

11. Remove the axle hub outer bearing from the internal gear hub.

Service bolt M12 x 1.25 pitch 50 mm min. shank length Caution: Remove the bearing only when damage was found.

Fig 4-13 Removing the outer bearing

12. Remove the inner bearing and the oil seals from the front axle hub.

SST 09160-10170-71 SST 09320-10410-71

Fig. 4-14 Removing the inner bearing and oil seals

-161-

4-8 INSPECTION 1.

Internal gear hub (1) Break, damage and wear of the tooth face (2) Cracks, wear and damage of the spline (3) Damage, nicks and rotation smoothness of the outer bearing

2.

Front axle shaft (1) Break, damage and wear of the tooth face (2) Bend (3) Cracks, wear and damage of the spline (4) Wear in the shaft end (wheel side)

3.

Planet gear reducer (1) Planet gear thrust washer 1) Break, damage and wear of the tooth face 2) Wear of the planet gear sides Planet gear standard face width 37mm (1.46 in) Planet gear limit face width 36.5 mm (1.437 in) 3) Wear of the bushings Standard bushing inner diameter 22 mm (0.866 in) Limit bushing inner diameter 22.18 mm (0.873 in) Replace bushing when the bushing inner diameter exceeds the wear limit, or when damage is found inside the bushing.

SST 09222-30010

Fig. 4-15 Inspecting the internal gear

Fig. 4-16 Inspecting the axle shaft

Fig. 4-17 Inspecting the planet gear and thrust washer

Caution: Drive the bushing so that the distances from each end to the both sides of the gear are equal.

-162-

Fig. 4-18 Replacing the bushing

4-9 (2) Planet gear shaft 1) Wear of the gear sliding face Standard shaft outer diameter 22 mm (0.866 in) 2) Limit shaft outer diameter 21.85 mm (0.860 in) Clogging in the shaft oil hole

Fig. 4-19 Inspecting the planet gear shaft

(3) Planet gear carrier 1) Crack and damage 2) Wear of the planet gear shaft inserting area

Fig. 4-20 Planet gear carrier

4.

Front axle hub with brake drum 1) Crack and damage of the axle hub 2) Tightness of the brake drum set bolts T = 9 - 14 kg-m (65 ~ 101 ft-lb)

Fig. 4-21 Tightening torque checking

3)

4)

Damage nicks and rotation smoothness of the inner bearing Deformation of the oil seal, and damage of the lips

Fig. 4-22 Inspecting the bearing and oil seal

-163-

4-10 ASSEMBLY 1.

Assemble the planet gear carrier assembly.

Caution: Wash each part before assembly.

Apply thin coat of chassis grease (molybdenum grease) inside the planet gear bushings and along the periphery of the shaft.

Fig. 4-23 Assembling the planet gear carrier assembly

2.

Assemble the bearing in the internal gear hub.

SST 09320-10410-71 SST 09160-10170-71 Use SST 09700-30200-71 after the internal gear hub end.

Fig. 4-24 Driving the bearing

3.

Assemble the bearing and oil seals in the front axle hub with brake drum.

Caution: Apply sufficient amount of grease (MP grease) to the bearing.

SST 09320-10410-71 SST 09160-10170-71 Fig. 4-25 Assembling the bearing and oil seals

4.

Assemble the front axle hub with brake drum.

Note: Check that the brake shoe is in the most compressed condition and that the drum is installed at the center.

Fig. 4-26 Assembling the axle hub

-164-

4-11 5.

Assemble the internal gear hub in the axle hub.

6.

Adjust the lock nut until a starting force of 5 to 12kg (11 ~ 26.4 lb) (at the hub bolt) is obtained to pre-load the bearing.

Caution: To determine the cotter pin position hole, turn the lock nut in either direction depending on the measured force.

Fig. 4-27 Measuring the pre-load

7.

Assemble the planet gear carrier assembly Caution: Apply a thin coat of grease to the “O” ring.

T = 10 ~ 12 kg-m (72.2 ~ 86.6 ft-lb) Caution: Keep the parking brake set.

Fig. 4-28 Tightening torque

8.

Insert the axle shaft.

Note: Turn the axle shaft lightly to engage the gear before inserting the shaft.

Fig. 4-29 Assembling the axle shaft

9.

Mount the carrier cover.

10. Position the carrier cover horizontally with the (-) mark below the centerline.

11. Remove the level plug and supply oil until excess oil flows out of the entrance.

Oil to be used: Hipoid gear oil SAE 90 Capacity: 0.5 (0.13 Us gal) (One Side)

Fig. 4-30 (-) mark set position

-165-

4 - 12 12. Mount the front wheels, jack up the frame, and remove the block.

Fig. 4-31 Mounting the front wheels

13. Tighten the hub nuts to the specified torque.

T = 30 ~ 33 kg-m (216.6 ~ 238 ft-lb)

Fig. 4-32 Tightening the hub nuts

14. Upon assembly, make the following inspection and adjustments.

(1) (2) (3) (4)

Check the amount of differential oil.

Move the vehicle back and forth more than 10 times, use the brake each time, and adjust braking.

Adjust the parking brake lever travel (4 ~ 6 notches).

Check each part for any unusual noise or other abnormal conditions.

-166-

4-13 FRONT AXLE & DIFFERENTIAL HOUSING REMOVAL 1.

Remove the mast assembly.

Reference: Refer to the section on “Mast removal”.

2.

Loosen the front wheel hub nuts.

3.

Jack up the differential housing, and put blocks under frame sides.

4.

Remove the front wheels.

5.

Drain differential oil and planet gear oil.

Differential oil 5 (1.3 Us gal) Planet gear oil 0.5 (0.13 Us gal) (One Side)

6.

Pull out the front axle shaft.

Fig. 4-33 Removing the mast assembly

Fig 4-34 Removing the front wheels

Fig. 4-35 Removing the front axle shaft

7.

Remove the differential housing and differential carrier set bolts.

-167-

Fig. 4-36 Removing the differential housing set bolts

4-14 8.

Put a block under the transmission to support the torque converter and the transmission.

Fig. 4-37 Supporting the transmission

9.

Disconnect the brake piping.

Fig. 4-38 Disconnecting the brake piping

10. Disconnect the right and left parking brake cables.

Fig. 4-39 Disconnecting the parking brake cables

11. Put the wires at the same positions on right and left axle housings.

Fig. 4-40 Putting wires

-168-

4-15 12. Remove the front axle bracket and frame set bolts.

(1) Three central bolts on each side (2) Two end reamer bolts on each side SST 09310-22000-71

Fig. 4-41 Removing the reamer bolts

13. Remove the front axle assembly from the body.

Fig. 4-42 Removing the front axle assembly

14. Remove the planet gear carrier assembly, internal gear hub, and front axle hub with brake drum.

Reference: Refer to the section on “Front axle disassembly”.

Fig. 4-43 Removing the front axle hub

15. Remove the brake backing plate set nuts, and remove the brake assembly.

Caution: Be sure to remove the wheel cylinder set bolts.

Fig. 4-44 Removing the brake assembly

-169-

4-16 16. Remove the front axle bracket from the front axle housing.

Fig. 4-45 Removing the axle bracket

INSPECTION 1.

Front axle and differential housing.

Check for cracks visually or by coloring.

Fig. 4-46 Inspecting the front axle and differential housing

2.

Front axle bracket Check for cracks visually or by coloring.

Fig. 4-47 Inspecting the front axle bracket

-170-

4-17 ASSEMBLY Reverse the procedures for removal. Upon completion, make the following inspection and adjustments.

1.

Supply oil in the differential and planet gears.

Oil: Hypoid gear oil SAE 90 Differential: 5.0 (1.3 US gal) Planet gears: 0.5 (0.13 Us gal) (One Side)

2.

Bleed air in the brake system at the brake wheel cylinder.

3.

Move the vehicle back and forth more than ten times, use the brake each time, and lever travel

Fig. 4-48 Supplying differential oil

Fig. 4-49 Air bleeding

4.

Adjust the parking brake lever travel.

Adjusting allowance: 4 to 6 notches

5.

Check each connection for any oil leak.

6.

Check the differential housing for any unusual noise.

7.

Check the forward angle (5 ) and reverse angle (10 ) of the mast.

Fig. 4-50 Adjusting the parking brake

-171-

5-2 GENERAL

Fig. 5-2 Rear axle section

Fig. 5 -2 Rear axle cylinder section

-174-

5-3 COMPONENT PARTS

1. Bushing 2. Needle bearing 3. Steering knuckle king pin 4. Shim 5. Thrust bearing 6. Steering knuckle 7. Lock pin 8. Oil retainer 9. Bearing 10. Bearing 11. Grease cap

12. Dust seal 13. Snap ring 14. Plug 15. Ball stud seat 16. Ball stud 17. Spring 18. Bushing 19. Cylinder end 20. Bushing 21. Thrust washer

Fig. 5 - 3 Rear axle component parts

-175-

5-4

1. Rear axle cylinder assy 2. End sub-assy, rear axle 3. Sleeve 4. “O” ring 5. Cylinder sub-assy 6. “O” ring 7. “U” packing 8. Backup ring 9. Dust seal 10. Snap ring

11. Seal ring 12. Square ring 13. Sleeve 14. Rod sub-assy 15. Pin 16. Hose clamp 17. Boot 18. Snap ring

Fig. 5 - 4 Rear axle cylinder component parts

-176-

5-5 SPECIFICATION

SERVICE STANDARDS

-177-

5-6 REMOVAL 1.

Jack up the rear weight and put a block under the frame rear end.

Caution: For ease of work,ack up the weight to provide a ground clearance of 300 to 400 mm (11.8 ~ 15.7 in) under the wieght.

Set the parking brake, and put a stop per under the wheels.

2.

Fig. 5-5 Jacking up the vehicle

Remove the grease cap.

Fig. 5-6 Removing the grease cap

3.

Remove the rear wheels.

Cotter pin Castle nuts Rear wheels

Fig. 5-7 Removing the rear wheels

4.

Disconnect piping to the rear axle cylinder.

Caution: Loosen at the pipe side.

Keep record of pipe connections.

Fig. 5-8 Disconnecting piping

-178-

5-7 5.

Measure play of the rear axle in front and rear direction.

(1) Push the rear axle beam forward completely.

(2) Measure play of the rear axle in front and rear direction Standard play: 0.02 0.4 mm (0.00078 0.016 in)

Fig. 5-9 Measuring play

6.

Remove the rear axle bracket cap.

(1) Jack at the center of the rear axle.

(2) Set bolt (3) Rear axle bracket cap Front side cap radius ........ 45 mm (1.77 in) Rear side cap radius ........ 39 mm (1.56 in) Fig. 5-10 Removing the bracket caps

7.

Remove the rear axle assembly.

(1) Lower the jack slowly.

(2) Pull out to left and right direction.

Fig. 5-11 Removing the rear axle assembly

- 180 -

5-8 DISASSEMBLY Caution: This section describes disassembly procedure after the axle assembly has been removed from the vehicle. However, since the rear axle hub, or steering knuckle can be disassembled, repaired and adjusted when the axle assembly is not separated from the vehicle, refer to separate sections as appropriate.

The removed rear axle assembly should be put on a block or other appropriate support safely and at a height most convenient for subsequent work.

1.

Disconnect the piping for the rear axle cylinder.

(1) Pipe clamps (2) Cylinder pipes (2 pcs)

2.

Remove the support pin bushing.

3.

Disconnect the rear axle cylinder end.

Fig. 5-12 Removing the piping

Note: Use service nuts (M20 x 1.5 pitch).

Fig. 5-13 Disconnecting the cylinder end

4.

Remove the rear axle cylinder end.

(1) Loosen clamps. and change the boot position.

(2) Snap ring (3) Pin (4) Cylinder end

Fig 5-14 Removing the cylinder end

- 180 -

5-9 5.

Remove the rear axle cylinder set bolts.

Fig. 5-15 Removing the set bolts

6.

Remove the rear axle cylinder assembly.

Caution: Remove the rear axle cylinder assembly carefully not to damage the rear axle cylinder rod.

Fig. 5-16 Removing the axle cylinder assembly

7.

Remove the rear axle inner bearing.

SST 09950-20014

8.

Remove the oil retainer.

Fig. 5-17 Removing the inner bearing

9.

Remove the kingpin lock pin.

(1) Set nuts (2) Use a service nut to tap out.

Note: Always use a service nut to prevent damage to the threads in the lock pin.

Fig. 5-18

- 181 -

5-10 10. Pull out the kingpin.

Caution: Remove the grease fitting first.

Fig. 5-19 Tapping out the kingpin

11. Remove the steering knuckle.

Thrust bearing Shims Steering knuckle Caution: Keep shims in a safe place neatly after recording their number and thickness data.

Fig. 5-20 Removing the steering knuckle

12. Remove the oil seals.

Caution: Remove oil seals only when damage or wear is found in the needle bearing or oil seals.

Fig. 5-21 Removing the oil seals

13. Remove the needle bearing.

SST 09608-30011 Caution: Remove needle bearing only when damage or wear is found.

Fig. 5-22 Removing the needle bearing

- 182 -

5-11 14. Disassemble the cylinder end assembly.

Caution: Disassemble the cylinder end assembly only when excess gap in the ball joint, unsmooth movement or other defect is. discovered.

(1)

Remove the dust seals.

Fig. 5-23 Removing the dust seal

(2)

Remove the snap ring.

Fig. 5-24 Removing the snap ring

(3)

Remove the ball stud.

Plug 1 SST 09490-30320-71

Fig. 5-25 Removing the plug

2 3 4 5

Ball stud seat (outside) Ball stud Ball stud seat (inside) Spring

Fig. 5-26 Removing the seat and ball stud

5-12 INSPECTION Caution: Clean and inspect parts, and replace as needed.

Check each bearing for smoothness, unusual noise, excess gap or damage visually or using a shaft.

1.

Steering knuckle (1) Crack in the knuckle spindle root. damage in the threads Caution: Use crack detecting instrument or colors as much as possible.

Fig. 5-27 Inspecting the steering knuckle

2.

Kingpin, lock pin (1) Wear and damage of the kingpin Standard outer diameter Limit outer diameter wear

Caution: When the limit wear is exceeded, replace the knuckle and bearing as a unit.

(2) (3)

Bend of the kingpin Bend and damage of the lock pin Fig. 5-28 Inspecting the kingpin

3.

Bearing, seals (1) Wear, damage and smoothness in rotation of the needle bearing (2) Damage of the oil seals (3) Wear, damage and smoothness in rotation of the thrust bearing

Fig. 5-29 Inspecting the bearing and seals

- 184 -

5-13 4.

Support pin bushing, rear axle bracket cap (1) Limit inner diameter wear of the support pin bushing Front 81.5 mm (3.21 in) (2) Rear 71.5 mm (2.8 in) Crack and damage of the rear axle bracket cap

Fig. 5-30 Inspecting the bushing, bracket cap

5.

Cylinder end assembly (1) Wear and damage of the ball stud sphere Standard outer diameter 32 mm (1.26 in) Limit outer diameter wear 31.8 mm (1.25 in) (2) Wear and damage inside the seat (3) Fatigue of the spring (4) Damage of the plug threads (5) Damage of the oil seals.

6.

Wheel bearing, oil retainer (1) Smoothness in rotation, unusual noise and wear of the bearing, and damage of the roller and holder (2) Damage of the bearing race (3) Damage of the steering knuckle oil retainer

7.

Rear axle beam (1) Bend and crack of the rear axle beam (2) Measure the kingpin angle Standard kingpin angle 0 (3) Wear of the support pin Front Standard outer diameter 80 mm (3.15in) Limit outer diameter wear 79.5 mm (3.13 in) Rear Standard outer diameter 70 mm (2.76 in) Limit outer diameter wear 69.5 mm (2.73 in)

Fig. 5-31

Inspecting the cylinder end assembly

Fig. 5-32 Inspecting the bearing, oil retainer

Fig. 5-33 Inspecting the rear axle beam

- 185 -

Disassembling the rear axle cylinder 1.

Remove the cylinder top ends at cylinder ends.

Fig. 5 - 34 Removing the cylinder top ends 2.

Pull out the cylinder rod sub-assembly.

Fig. 5-35 Pulling out the rod sub-assembly

3.

Remove the sleeve, square ring and “0” ring from the the piston in the rod sub-assembly.

Fig. 5 - 36 Removing the sleeve

4.

D’sassemble the cy inder top end.

Caution: Disassemb;e oniy when demage or wear is found in the dust seal, “U” packing or sleeve.

Fig. 5 - 37 Disassembling the cylinder top end

- 186 -

5-15

INSPECTING THE REAR AXLE CYLINDER 1.

Cylinder top end (1) Wear and damage of the cylinder top end sleeve (2) Wear and damage of the dust seals (3) Wear damage and deterioration of the “U” packing

Fig. 5-38 Inspecting the cylinder top end.

2.

Cylinder rod sub-assembly (1) Scratch and wear of the rod sliding face Standard outer diameter 60 mm (2.36 in) Limit outer diameter wear 59.91 mm (2.358 in) (2) Separation, damage and rust of plating.

(3) Bend of the rod Rod bend limit 1.0 mm (0.039 in) Fig. 5-39 Inspecting the cylinder rod

3.

Sleeve, square ring, ring (1) Wear, damage and deterioration

4.

Rear axle cylinder (1) Scratch and wear of the sliding face inside the cylinder Standard cylinder inner diameter 90 mm (3.54 in) Cylinder inner diameter wear limit 90.4 mm (3.56 in) (2) Damage and rust in the cylinder (3) Dent outside the cylinder

Fig. 5-40 Inspecting the sleeve, square ring and “O” ring

Fig. 5-41 Inspecting the rear axle cylinder.

- 187 -

5-16

Assembling the rear axle cylinder Caution: Wash parts after inspection is completed.

Renew packings and seals as much as possible.

Assemble the rod sub-assembly carefully not to damage the plating.

1.

Assemble the sleeve, square ring and “O” rings to the piston in the rod sub-assembly.

Caution: Apply hydraulic oil in the piston, and assemble carefully not to damage the parts.

Fig. 5-42 Assembling the sleeve, square ring and O-ring

2.

Assemble the piston rod sub-assembly and cylinder top end to the cylinder.

Note: Apply grease on the sliding face to protect the dust seals when inserting the top end into the rod sub-assembly.

The piping holes of the top end must come in the opposite position of the cylinder mounting bolts hole.

Apply a small amount of grease on the “O” ring in the top end.

Fig. 5-43 Assembling the rod sub-assembly and top end

Fig. 5-44 Direction for assembling the top end

- 188 -

5-17 ASSEMBLY Caution: After inspection, clean the parts again and assemble. Apply grease to kingpin needle bearing.

Replace oil seat and other rubber parts.

1.

Assemble the needle bearing and oil seal in the rear axle beam.

(1) Needle bearing SST 09608-30011 (2) Oil seal SST 09608-30011

Fig. 5-45

Assembling the needle bearing and oil seal (1)

Fig. 5-46

Assembling the needle bearing and oil seal (2)

Fig. 5-47

Assembling the steering knuckle

Caution: Assemble with the oil seal lip at the outside.

2.

Assemble the steering knuckle.

(1) Steering knuckle

(2)

Thrust bearing

Caution: Assemble the thrust bearing above the steering knuckle.

Assemble the thrust bearing in the correct direction.

Fig. 5-48 Direction for assembling the thrust bearing

- 189 -

5-18 (3)

Adjust the steering knuckle with shims to obtain smoothness in rotation. Use shims at the upper side of the thrust bearing.

Standard clearance 0.02 to 0.12 mm (0.00078 ~ 0.0047 in)

Fig. 5-49

(4) (5)

(6)

Kingpin Adjust the starting force of the steering knuckle.

1) Install a spring balance at the spindle end of the steering knuckle to measure the starting force.

Steering knuckle starting force 2 to 5 kg (4.4 ~ 11 lb) 2) If the measurement differs from the standard value, readjust with shims.

Assemble the steering knuckle.

1) Position the lock pin notch of the kingpin correctly, and install the lock pin.

2) Lock nut T = 1.9 ~ 3.1 kg-m (13.7 ~ 22.4 ft-lb)

Fig. 5-50 Measuring the starting force

Fig. 5-51

3.

Shim adjustment

Assembling the steering knuckle

Assemble the oil retainer in the steering knuckle.

SST 09700-30200-71

Fig. 5-52 Assembling the oil retainer

- 190 -

5-19 4.

Assemble the inner bearing.

SST 09700-30200-71 Caution: Install the inner bearing evenly. If it is tilted when driven, the knuckle spindle may be damaged.

Fig. 5-53

5.

Assembling the inner bearing

Assemble the rear axle cylinder assembly to the rear axle beam.

Note: Cylinder mounting bolts 2pcs at the left ..... Use reamer bolts.

2pcs at the right ..... Use ordinary bolts.

Fig. 5-54 Types of bolts and their locations

6.

Tighten the rear axle cylinder mounting bolts to the specified torque.

T = 15 ~ 23 kg-m (108.3 ~ 166 ft-lb)

Fig. 5-55 Tightening to the specific torque

7.

Assemble the cylinder rod end assembly.

Note: Apply molybdenum grease to inner parts such as ball stud and seat before assembling the rod end assembly.

Apply Lock Tite #241 to the threads before tightening the plug.

Use SST 09490-30320-71 for tightening the plug.

Fig. 5-56

- 191 -

Assembling the rod end assembly

5-20 8.

Assemble the cylinder rod end.

Caution: Install the part in a correct vertical direction.

Narrower rod . . end to the pin side Larger rod end . . . . . to the snap ring side

Fig. 5-57 Assembling the rod end

9.

Tighten the rod end castle nut to the specified torque and secure the nut with a cotter pin.

T = 9 ~ 10 kg-m (65 ~ 72.2 ft-lb)

Fig. 5-58 Tightening to the specified torque

10. Assemble the rear axle support pin bushing and shims to the axle beam.

Caution: Apply molybdenum grease to the bushing.

Use shims of the same thickness as those used before.

Fig. 5-59

Assembling the bushing and shims

11. Connect the rear axle cylinder piping to the rear axle assembly.

Fig. 5-60 Connecting the piping

- 192 -

5-21 INSTALLATION 1.

Install the rear axle assembly to the frame.

Caution: Support the rear axle assembly carefully.

Tighten the rear axle bracket cap set bolts to the specified torque.

T = 9.2 kg-m (66 ft-lb)

Fig. 5-61 Installing the rear axle assembly

Fig. 5-62 Tightening torque

2.

Measure the play about the rear axle.

Standard play 0.02 to 0.40 mm (0.00078 ~ 0.016 in)

Note: Push the rear axle completely forward to measure the play at the rear side of the rear axle.

Use shims of largest possible thickness for adjustment.

If the measured play exceeds the standard value, remove the part and adjust again.

3.

Fig. 5-63 Measuring the rear axle play

Connect the rear axle cylinder piping.

Note: Make piping connections correctly.

Fig. 5-64 Pipe connection

- 193 -

5-22 4.

Mount the rear wheels.

SST 09370-20270-71 Caution: Handle the wheels carefully since they are very heavy.

Install carefully not to damage the threads at the end of the steering knuckle.

Fig. 5-65 Mounting the rear wheels

5.

Measure the starting force of the rear wheels.

(1) Hook a spring balance to the tread of the rear wheel and measure the starting force to turn the wheel.

Rear wheel starting force 3.0 to 4.5 kg (21.6 ~ 32.5 ft-lb) Note: Before measurement, tighten the castle nuts completely, then reverse them by approximately a quarter of a turn. Hit the wheel along the entire periphery to lighten rotation, then retighten the nuts and measure the starting force.

(2)

6.

Cotter pin

Install the grease cap.

Caution: Fill up the grease cap with MP grease.

-194-

Fig. 5-66 Measuring the starting force

6-2

GENERAL

1.

2.

3.

4.

Steering wheel Hydraulic control valve & relief valve Flow divider Oil tank

5.

6.

7.

8.

Engine Oil pump Rear wheel Rear axle cylinder (PS cylinder)

Fig. 6 - 1 Hydrostatic power steering

Full hydraulic hydrostatic power steering is adopted as the steering mechanism. In this system, the hydraulic oil from the oil pump enters the hydraulic control valve via the flow divider and brake valve to operate the rear axle cylinder.

When the hydraulic system is out of order (When the hydraulic pressure does not rise because of engine stop), the hydraulic control valve is operated as a hand pump driven by rotation of the steering wheel to supply oil into the rear axle cylinder so as to ensure steering operation. However, steering becomes very heavy. (Be especially careful in driving or tracting a faulty vehicle in a state of preparedness to stop it immediately by pulling the hand brake lever in danger.)

The steering mechanism consists of the hydraulic hose and the rear axle cylinder. Mechanical links such as pitman arm drag link and bellcrank are eliminated. The rear axle cylinder is housed in the rear axle beam to protect it from any external shock.

-196-

6-3

HYDRAULIC CONTROL VALVE The hydraulic control valve is the most important part for control of the power steering. It consists of the rotary valve section to change the oil path and the gerotor section to control oil supply volume to rear axle cylinder.

Fig. 6-2 Hydraulic control valve cross sectional view

STRUCTURE The spool housed in the sleeve at the rotary valve section is linked with the steering main shaft and rotates with the steering wheel. The spool and sleeve are connected by using a straight in such a manner that the spool rotates individually to a specified limit (about 10 ). When the spool rotation exceeds the said limit, the sleeve rotates with the spool. Since the spool and sleeve change the oil path by rotation within this fixed limit, a centering spring is used to keep this relative position always at neutral and to get the steering reaction force. One end of the drive shaft within the spool is linked with the straight pin connecting the spool and sleeve, and the other end is spline-connected to the rotor at the gerotor section.

The sleeve and rotor are so connected as to rotate while holding the relative position between them.

When an oil path is formed, the drive shaft stops the sleeve. After the oil path is formed, it transmits the rotor rotation to the sleeve. Simultaneously, it follows the spool movement.

-197-

6-4

HYDRAULIC CONTROL VALVE INTERNAL STRUCTURE Rotary valve section port arrangement

Fig. 6-3 Rotary valve section

Gerotor section port arrangement

Fig. 6-4 Gerotor section

-198-

6-5

OPERATION At neutral position The hydraulic oil flowing into the P port of the body acts on 6 pump groove positions (1.3.5.7.9.11.) via the sleeve. However, as the spool pump grooves and sleeve ports are isolated, no oil flows into the rear axle cylinder. Therefore, the rear axle cylinder does not work. The hydraulic oil flowing into the P port of the body, passes through the sleeve and spool small ports as shown in the below figure (right side). and after lubricating the drive shaft section, returns to tank from the T port of the body.

Fig. 6-5 Operation at neutral position

The relation between the spool and sleeve during turning When rotating the steering wheel (linked to the spool), for turning the sleeve fixed with the rotor rotates the spool so as to connect the spool pump grooves (1.3.5.7.9.11.) to the sleeve ports (a.c.e.g.i.k) at the time of clockwise turn and to the sleeve ports (l.b.d.f.h.j) at the time of counterclockwise turn.

Fig. 6-6 Relative position between sleeve and spool at the time if turning

6-6 At the time of clockwise turn Relative positions between the spool, sleeve and body ports at the time of clockwise turn are shown below. At the time of clockwise turn, the spool and sleeve ports (l-a. 3-c, 5-e, 7-g, 9-i, 11-k) are connected to circuit port (A, B, and C) to body gerotor section. The hydraulic oil from the pump goes through each port into the gerotor section, and acts on the rotor to rotate it clockwise.

At this time, circuit ports (D, E and F) from the body gerotor section are connected to the circuit to the rear axle cylinder to operate it.

When the steering wheel is further rotated, the spool and sleeve rotate together with the rotor within the body with the ports (l-a, 3-c. 5-e. 7-9, 9-i, 11-k) remained open. Therefore the circuit changes in the sequence of A, B, C, to B, C, D, and the circuit to the cylinder changes successively from D, E, F, to E, F, G, thus causing the rear axle cylinder to be operated further.

Fig. 6-7 Operation at the time of clockwise turn (initial stage)

Fig. 6-8 Operation at the time of clockwise turn (after movement by one tooth)

-200-

6-7 When specifically observing body A port at the time of clockwise turn, the oil path changes as shown in the figure below.

I. Spool 1 → Sleeve a → Body A →Gerotor (inflow) (small flow rate) II. Spool 1 → Sleeve a → Body A →Gerotor (inflow) (large flow rate) III. Gerotor → Body A →Sleeve 1 → Spool 12 (outflow) (to rear axle cylinder) Note) In state III, spool 1 and sleeve are isolated from body A port.

Fig. 6-9 Details at body A port

When the hydraulic oil from the pump acts on each body port with the steering wheel rotation the ports successively change clockwise like A.B.C →B.C.D →C.D.E Simultaneously, the rotor rotates clockwise and the oil path to the rear axle cylinder also successively changes like D.E.F→ E.F.G→ F.G.H... to supply oil smoothly to the cylinder At the time of counterclockwise turn At the time of counterclockwise turn. the operation is the same as at the time of clockwise turn except that the direction of rotation is reversed.

Fig. 6-10 Operation at the time of counterclockwise turn

6-8 Operation of gerotor section The gerotor supplies the flow rate in proportion to the steering wheel rpm to the rear axle cylinder. Since the spool directly rotates the rotor through the straight pin and drive shaft when the motor is out of order, the hydraulic control valve functions as a hand pump to supply oil to the rear axle cylinder. (In this case, steering operation becomes very heavy.)

Rotor rpm and discharge volume When rotating the steering wheel clockwise, the rotor rotates clockwise but the hydraulic oil rotates the rotor counterclockwise relative to the staotr. While the rotor rotates by one tooth clockwise (1/7 turn), the rotor center draws a circular locus in counterclockwise direction.

When the rotor rotates clockwise and moves in contact with the body for 1/7 turn, the rotor center locus makes 6/7 counterclockwise turn. While the steering wheel makes one rotation, the rotor center locus makes 6 full turns. In other words, oil replacement for 42 chambers (6 x 7) is carried out while the steering wheel makes one rotation.

Fig. 6-11 Rotor movement while it makes 1/7 turn

-202-

6-9 RELIEF VALVE The relief valve is incorporated within the hydraulic control valve, and maintains oil entering the P port at 100 kg/cm2. Pressure may be adjusted with shims, but do not readjust it unless it is absolutely necessary.

Fig. 6 - 12 Relief valve section

Relief function The relief valve is used when the rear wheels are locked. Pressurized oil from the oil pump enters P port and applies pressure to the chamber at the right side of the valve. It also affects the left chamber via the orifice. Before relief, the valve is balanced (pressure in the right chamber = pressure in the left chamber + spring force). When the relief set pressure is reached, oil in the left chamber pushes open the steel ball and flows into T port. Balance is thus lost, and the valve is forced to move to the left. As a result, P port and T port are directly connected and prevent oil pressure from exceeding the relief set pressure.

Fig. 6 - 13 Relief valve at work

-203-

6-10 HYDRAULIC CONTROL VALVE COMPONENT PARTS

1. Dust seal 2. Mounting plate 3. “Y” packing 4. Valve spool 5. Straight pin 6. Valve sleeve 7. Plug 8. Seat 9. Steel ball 10. Spring 11. Side plate 12. End cap

13. Cage 14. Side race 15. Bearing 16. Centering spring 17. Valve body 18. Stator 19. Rotor 20. Spacer 21. Relief valve assy 22. Plug 23. Nipple 24. Steel ball

25. Valve 15. Spring pin 27. Plug 28. Steel ball 29. Spring 30. Valve 31. Shim 32. Steel ball 33. Ball retainer 34. Spring

Fig. 6 - 14 Hydraulic control valve component parts

-204-

6-11 SPECIFICATION AND SERVICE STANDARD

HYDROSTATIC POWER STEERING CONTROL VALVE REMOVAL 1.

Remove the steering wheel.

(1) Horn button (2) Contact plate (3) Set nuts (4) Steering wheel SST 09609-20011 Fig. 6-15 Removing the steering wheel

2.

Remove the turn signal switch assembly.

(1) Change lever guide (2) Turn signal switch assembly

Fig. 6-16 Removing the turn signal switch assembly

3.

Remove the rear toe board.

Fig. 6-17 Removing the rear toe board

-205-

6-12 4. Remove the front toe board.

(1) Disconnect the pedal link.

(2) Front toe board

Fig. 6-18 Removing the front toe board

5. Disconnect the shift lever link.

Fig. 6-19 Disconnecting the shift lever link

6. Disconnect the power steering piping.

(1) Piping from the control valve (2) Hose to the return circuit (3) Pipes (2 pcs) to the power cylinder

Fig. 6-20 Disconnecting the piping

7. Remove the steering stay clamp.

Fig. 6-21 Removing the stay clamp

-206-

6-13 8. Remove the steering post assembly.

(1) Set bolts

Fig. 6-22 Removing the set bolts

(2) Steering post assembly

Fig. 6-23

Removing the steering post assembly

Fig. 6-24

Removing the hydraulic control valve

9. Separate the hydraulic control valve with the mast jacket with the main shaft.

(1) Mast jacket with the main shaft (2) Bracket (3) Hydraulic control valve

-207-

6-14 DISASSEMBLY 1. Remove the relief valve body.

(1) Set bolts (2) Relief valve body

Fig. 6-25 Removing the relief valve body

2. Disassemble the relief valve.

Caution: Do not disassemble the relief valve un less an abnormal condition is found in the set pressure.

Fig. 6-26 Removing the relief valve

3. Make matchmarks on the body and the stator.

Fig. 6-27 Stamping matchmarks

4. Remove the mounting plate and the needle bearing.

(1) Set bolts (2) Mounting plate (3) Side race (4) Needle bearing

Fig. 6-28 Removing the plate and needle bearing

-208-

6-15 5. Remove the cap.

(1) Set bolts (2) Cap

Fig. 6-29 Removing the cap

6. Remove the stator.

Fig. 6-30 Removing the stator

7. Remove the rotor and valve plate.

Fig. 6-31 Removing the rotor and plate

8. Remove the drive shaft.

(1) Spacer (2) Drive shaft

Fig. 6-32 Removing the drive shaft

-209-

6-16 9. Remove the sleeve and spool.

Note: Pull out turning them slowly to the gerotor side.

Fig. 6-33 Removing the sleeve and spool

10. Remove the centering spring and straight pin.

Fig. 6-34 Removing the spring and pin

11. Pull out the spool from the sleeve.

Fig. 6-35 Pulling out the spool

INSPECTION 1.

Nicks and damage of the gerotor

Fig. 6-36 Gerotor inspection

-210-

6-17 2. Nicks and damage of the spool and sleeve, and clogging of each port 3. Nicks and damage of the body 4. Fatigue of the centering spring

Fig. 6-37 Inspecting the spool and sleeve

ASSEMBLY Caution: Clean each part with hydraulic oil before assembling.

1. Assemble the needle bearing to the mounting plate.

2. Assemble the sleeve and the spool.

(1) Spool (2) Straight pin (3) Centering spring

Fig. 6-38 Assembling the needle bearing

Fig. 6-39 Assembling the spool

3. Insert the sleeve sub-assembly into the body.

(1) Sleeve sub-assembly (2) “O” ring

Fig. 6-40 Assembling the sleeve

-211-

6-18 4.

Assemble the mounting plate to the body.

(1) Mounting plate Caution: Assemble the plate carefully so the needle bearing will not fall.

(2) Set bolts T = 2.0 ~ 2.5 kg-m (14.4 ~ 18 ft-lb) Fig. 6-41 Assembling the mounting plate

5. Put the valve plate on the body. and set the matchmarks together.

Fig. 6-42 Assembling the valve plate

6.

Put the stator on the valve plate. and set the matchmarks together.

Fig. 6-43 Assembling the stator

7. Assemble the drive shaft and the rotor.

Note: Assemble so that the vertical groove of the drive shaft comes on the line connecting any two roots of the rotor teeth.

Put the rotor in the same vertical direction as before.

Fig. 6-44 Assembling the drive shaft

-212-

6-19 8. Insert the rotor and drive shaft assembly Into the stator.

Caution: Insert the assembly carefully so as not to drop the drive shaft from the rotor. Put the vertical groove the drive shaft end to the straight pin.

Fig. 6-45 Assembling the rotor and drive shaft

9.

Insert the spacer into the rotor.

10. Assemble the cap.

(1) “O” ring (2) Cap (3) Set bolts T = 3.0 ~ 3.5 k-m (21.7 ~ 25.3 ft-lb)

Fig. 6-46 Inserting the spacer

11. Assemble the relief valve body.

(1) “O” ring (2) Relief valve body (3) Set bolts T = 5 ~ 6 kg-m (36.1 ~ 43.3 ft-lb) Note: When the relief valve is disassembled, tighten the nuts and plugs to the following torque.

Nuts T = 5 ~ 6 kg-m (36.1 ~ 43.3 ft-lb) Plugs T = 4.5 ~ 5.5 kg-m (32.5 ~ 39.7 ft-lb)

Fig. 6-47 Assembling the cap

INSTALLATION Follow the procedure for removal in the reverse order.

Fig. 6-48 Assembling the relief valve body

-213-

7-2 GENERAL

Fig. 7-1 Brake system diagram

Fig. 7-2 Power brake system

-216-

7-3 SPECIFICATIONS

SERVICE STANDARDS

-217-

7-4 FOOT BRAKE

Fig. 7-3 Foot brake

Fig. 7-4 Wheel cylinder section

-218-

7-5 COMPONENT PARTS

[Tightening torque unit: kg-m (ft-lb)]

1. Snap ring 2. Actuating lever 3. Adjusting hole cover 4. Shoe hold pin 5. Shoe hold pin 6. Backing plate sub-assy 7. Return spring bolt 8. Brake (primary) shoe assy 9. Brake (secondary) shoe assy 10. Parking lever bolt 11. Lock nut 12. Snap ring 13. Parking lever 14. Brake set bolt 15. Parking cable lever 16. Anchor to secondary spring 17. Adjuster upper link 18. Parking cable assy 19. Parking cable retainer

20. Cable sheave 21. Adjuster 22. Snap ring 23. Adjuster lever link 24. Anchor to primary spring 25. Shoe hold washer 26. Shoe hold spring 27. Adjuster lower link 28. Adjuster spring 29. Automatic adjuster lever 30. Lever return spring 31. Wheel brake cylinder assy 32. Breather plug 33. Breather cup 34. Boots 35. Backup ring 36. U packing 37. Piston 38. “0” ring

Fig.7-5 Brake component parts

-219-

7-6 DISASSEMBLY Note: The brake may be repaired with the brake assembly removed or remaining on the vehicle depending on the type of repair needed. For example, the brake shoe may be replaced with the brake assembly remaining on the vehicle, and the backing plate may be replaced after removing the assembly from the vehicle.

This section describes procedures for disassembling parts without removing the brake assembly from the vehicle.

If the brake assembly must be removed from the vehicle, the mast assembly must be removed first. Refer to the section on “Mast removal”.

1. Remove the front axle hub with brake drum.

Note: Refer to the section on “Front Axle Disassembly”.

Fig. 7-6 Removing the front axle with brake drum

2. Remove the shoe return spring.

SST 09717-20010

Fig. 7-7 Removing the shoe return spring

3. Remove the adjuster spring.

Fig. 7-8 Removing the adjuster spring

-220-

7-7 4. Remove the shoe hold-down springs.

(1) Shoe hold-down cup SST 09510-30960-71 SST 09510-0170-71 Caution: Three shoe hold-down springs are used on one of the shoes, and they very in diameter (small, large, and medium from the top). Remove the medium diameter spring carefully especially since the special tool cannot be set firmly.

Fig. 7-9 Removing the shoe hold-down spring

(2) Shoe hold-down springs 5.

Remove the adjuster assembly and the primary brake shoe.

Fig. 7-10 Removing the brake shoe and adjuster assembly

6. Remove the secondary brake shoe.

Fig. 7-11 Removing the brake shoe

7. Disassemble the secondary brake shoe.

(1) Cotter pin and washer (2) Adjuster lever link (3) Adjuster lever link (4) Auto adjuster lever (5) Lever return spring (6) Adjuster upper link (7) Brake shoe

Fig. 7-12 Disassembling the brake shoe

-221-

7-8 8. Disconnect the parking brake cable.

9. Remove the actuator lever.

(1) Loosen the lock nut.

(2) Snap ring (3) Actuator lever

Fig. 7-13 Disconnecting the parking brake cable

l0. Remove the parking brake lever assembly.

(1) Snap rings (1pcs on each side) (2) Parking brake lever assembly

Fig. 7-14 Removing the parking brake lever assembly

11. Disassemble the parking brake lever as(1) Parking cable lever (2) Snap ring (3) Parking cable (4) Cable sheave (5) Cable retainer (6) Pin

Fig. 7-15 Disassembling the parking lever assembly

12. Disassemble the wheel cylinder assembly without removing it from the vehicle.

(1) Boot (2) Piston (3) U packing (4) Back-up ring (5) O-ring (6) Snap ring, baffle plate Caution: Remove the mast assembly before removing the wheel cylinder.

Fig. 7-16 Disassembling the wheel cylinder

-222-

7-9 INSPECTION 1.

Wheel cylinder (1) Damage, wear or rust in the cylinder bore (2) Clogging in the oil hole (3) Damage of the breather plug (4) Damage and deterioration of the boot (5) Damage of the baffle plate. and clogging of the orifice Fig. 7-17 Inspecting the wheel cylinder

(6) Wear and damage of the piston (7) Damage and fatigue of the U pack ing and O-ring (8) Damage of the back-up ring.

Caution: Replace seals with new parts during overhaul.

Fig. 7-18 Inspecting the wheel cylinder piston

2.

Brake drum (1) Uneven wear, taper or scratches inside the brake drum Standard inner diameter 317.5 mm (12.5 in) Corrected limit 319.5 mm (12.58 in)

Fig. 7-19 Inspecting the brake drum

3.

Brake shoe (1) Wear, damage or separation of the brake shoe lining and adhesion of oil Standard lining thickness 9.3 mm (0.37 in.)

Limit lining thickness 4.3 mm (0.17 in) (Thickness does not include the shoe rim.)

Fig. 7-20 Inspecting the brake lining

-223-

7-10 4. Spring, link and lever (1) Deformation and fatigue of the shoe return spring (2) Deformation and fatigue of the adjuster spring (3) Deformation and fatigue of the shoe hold-down spring Upper end (small) free length 1) 25.4 mm (1 in) Center (large) free length 2) mm (1.72 in) Lower end (medium) free 3) length 27.8 mm (1.09 in) Deformation and damage of 4) the hold-down cup pin (4) Deformation and fatigue of the adjuster lower link (5) Fatigue of the lever return spring (6) Damage and wear of the lever return link (7) Deformation and damage of the adjuster upper link (8) Damage of the auto adjuster lever and wear at the meshing of the adjuster

Fig. 7-21 Inspecting the spring

Fig. 7-22 Inspectinig the link and lever

5. Adjuster (1) Wear. damage and deformation of the teeth (2) Wear and smoothness of the threads

Fig. 7-23 Inspecting the adjuster

6. Parking brake system (1) Bend, deformation and crack of the cable lever (2) Aging and elongation of the cable (3) Wear and damage of the cable sheave (4) Deformation and damage of the cable retainer (5) Damage of the pin, and wear of the spline (6) Damage and bend of the actuating, lever and wear and damage of the spline

-224-

Fig. 7-24 Inspecting the parking brake system (1)

7-11 7. Backing plate Deformation, cracks and damage of the plate, contact with the drum, and adhesion of oil Note: The backing plate must be inspected without removing it from the vehicle.

The mast assembly must be removed first to replace the backing plate.

Fig. 7-25 Inspecting the backing plate

ASSEMBLY 1. Assemble the parking brake lever and related parts.

(1) Assemble the cable lever to the parking cable.

(2) Put the cable through the cable sheave, and assemble the retainer, pin and snap ring.

Fig. 7-26 Assembling the parking lever

2. Assemble the wheel cylinder.

(1) Baffle plate (2) Snap ring (3) Assemble the “O” ring, back-up ring and U-packing to the piston, and install them into the cylinder.

Caution: Apply sufficient amount of hydraulic oil first.

(4) Boot Fig. 7-27 Assembling the wheel cylinder

3. Install the parking lever assembly.

(1) Parking lever assembly Caution: Apply castle non-melt lube to the rotary shaft of the parking lever.

(2) Snap ring

Fig. 7-28 Installing the parking lever assembly

-225-

7-12 4. Install the actuating lever.

(1) Actuating lever Caution: Apply castle non-melt lube to the splineand sliding face of the lever.

Align the matchmarks.

(2) Snap ring (3) Set bolts and nuts T = 1.4 ~ 2.3 kg-m (10.1~ 16.6 ft-lb)

Fig. 7-29 Installing the actuating lever

5. Connect the parking brake cables.

(1) Pin (2) Washer (3) Cotter pin

Fig. 7-30 Connectiing parking cable

6. Assemble the secondary brake shoe.

Caution: Apply castle non-melt lube to the rotary part (indicated with an arrow) of the adjuster lever link.

Fig. 7-31 Assembling the brake shoe

7. Install the brake shoe adjuster.

(1) Apply castle non-melt lube. (where shown with an arrow).

1) Secondary shoe (3 places) 2) Primary shoe (3 places) 3) Backing plate (6 places) Note: Apply lube at the sliding face between thebrake shoe and the backing plate.

4) Threads of the adjuster screw and washers

-226-

Fig. 7-32 Applying grease

7-13 (2)

Brake shoes (primary and secondary), adjuster 1) Brake shoes 2) Hold pin 3) Hold-down cup 4) Hold-down spring 5) Hold cup SST 09510-30960-71 SST 09510-10170-71 6) Adjuster Caution: Screw in the adjuster thread completely to the minimum overall length. Install the adjuster and the brake shoe, then engage the notch on the adjuster lever to the gear.

Fig. 7-33 Installing the brake shoe (1)

Fig. 7-34 Installing the brake shoe (2)

8. Install the shoe return spring.

(1) Adjuster spring

Fig. 7-35 Installing the adjuster spring

(2) Anchor to primary spring (3) Anchor to secondary spring SST 09718-20010

Fig. 7-36 Installing the return spring

-227-

7-14 Install the front axle with brake drum through the axle hub carrier cover.

Note: Refer to the section on “Front Axle Disassembly”.

Caution: Check and remove any oil on the brake lining or drum before installing them.

Position the brake shoe at the center correctly, and be careful not to damage the brake lining.

Fig. 7-37 Installing the brake drum

10. Install the front wheels, and tentatively tighten the hub nuts.

11. Lower the vehicle carefully, and retighten the hub nuts.

T = 30 ~ 33 kg-m (216 ~ 237.6 ft-lb)

Fig. 7-38 Tightening the hub nuts

12. Bleed air from the brake system at the wheel cylinder.

Note: Air bleeding must be done by two men.

Start the engine, step in the brake pedal 2 to 3 times lightly, then press it down completely. With the brake pedal completely pressed, loosen the bleeder plug, and tighten it when hydraulic oil starts flowing out.

Repeat until the oil becomes free of bubble.

-228-

Fig. 7-39 Air bleeding

7-15 AUTO ADJUSTER TEST

Fig. 7 - 40

Work sequence of the auto adjuster

ADJUSTING TEST Note: Adjusting test is done by operating the parking brake lever without the brake drum

installed.

1. Keep pulling and releasing the parking brake lever.

(1) Check that the adjuster lever is engaged with the next tooth of the adjuster screw when the parking brake lever is pulled.

(2) Check that the adjuster lever advances the screw by one tooth, then returns to the original position.

2. If above conditions fail make the following inspection.

(1) Check that the adjuster lever and the adjuster screw are in a relative position as indicated in Fig. 7-41.

Caution: Engagement will fail and the adjusting screw will not make the adjustment when part of the adjuster lever contacting the screw is worn or deformed.

Fig. 7-41 Relative position of the adjuster lever and the adjuster screw

3. Tighten the adjuster to the minimum dimension after test.

-229-

7-16 BRAKE ADJUSTMENT Brake adjustment Caution: Brake adjustment is required every time the brake is disassembled, repaired or replaced.

(1) Move the forklift back and forth several times and adjust the brake shoe clearance.

Fig. 7-42 Adjusting the brake

Note: o Move the forklift back and forth within a short distance, stopping with the foot brake. o Repeat back and forth as many times as possible. o Through repeated braking, the auto adjuster automatically adjusts the clearance between the brake shoe and the brake drum finally to 0.30 to 0.50 mm (0.0118 ~ 0.0196 in) on each side. o When braking is not even or sufficiently effective, remove the brake drum and check inside for possible adjuster malfunctioning, insufficient contact of the lining, adhesion of foreign matter on the lining, or leak of brake oil (hydraulic oil).

-230-

7-17 BRAKE VALVE

Fig. 7-43 Brake valve section

COMPONENT PARTS

1. Brake valve spool 2. compression spring 3. Input piston sub-assembly 4. Cylinder cup 5. Plate washer 6. Snap ring 7. Nut 8. Boot 9. Push rod 10. Nut 11. Crevice 12. Hole plug 13. “O” ring 14. Closed valve 15. “O” ring 16. Valve return spring 17. Spring retainer 18. Reaction piston 19. “O” ring 20. Back-up ring 21. “O” ring 22. Union seat 23. Reaction piston guide 24. “O” ring Fig. 7-44 Brake valve component parts

-231-

7-18 TROUBLESHOOTING

Note: When any of the troubles listed above is found, do not disassemble the brake valve immediately. Check pressure between the brake valve and the wheel cylinder. If pressure is too low, check the brake valve input piston stroke and pressure increase in the pump. Disassemble the brake valve only when it is found to be defective.

7-19 BRAKE VALVE OPERATIONAL INSPECTION 1. Inspection of the brake operating hydraulic pressure (1) Attach a pressure gauge (150 kg/ m²) at the power outlet for the wheel cylinder of the brake valve.

(2) Run the engine idle,. depress the brake pedal fully, and check if the reading on the pressure gauge meets the required 1 value in the table.

2. Functional inspection of the accumulator (1) Run the engine at 1000 rpm or higher, press the brake pedal several times for full stroke to build up pressure in the accumulator to its full capacity. Then, stop the engine and disconnect the wiring from the charge pump. Then, read the pressure gauge in that condition with the brake pedal completely depressed to see if the reading meets the required value 2 in the table.

Fig. 7-45 Inspecting the hydraulic pressure (1)

Note: o Common for all models o The required value above 1 is subject to 50°C standard oil temperature and 11.5 l / min flow rate.

(2) Build up pressure in the accumulator to its maximum capacity again, stop the engine, then depress the brake pedal for full stroke five times. Read the pressure gauge to see if the reading on the fifth full pedal action is 40 kg/cm² or greater.

Fig. 7-46 Inspecting the hydraulic pressure (2)

(3) Stop the engine with the maximum pressure in the accumulator, and let stand for five minutes. After five minutes, depress the brake pedal several times for full stroke under the same condition as 2 in, and check reading on the pressure gauge to see it is the same as in 2 .

Fig. 7-47 Inspecting the hydraulic pressure (3)

-233-

7-20 REMOVAL Disconnect the negative terminal from the battery or the charge pump wiring.

Depress the brake pedal for full stroke about ten times to drain hydraulic oil in the accumulator.

Caution: The engine must be stopped before removal.

Fig. 7-48 Disconnecting the battery terminal

Disconnect the brake valve piping.

Fig. 7-49 Disconnecting the piping

Remove the brake valve.

(1) Brake valve set bolts (2) Brake valve

Fig. 7-50 Removing the brake valve

-234-

7-21 DISASSEMBLY 1. Remove the boot.

Fig. 7-51 Removing the boot

2. Remove the lock nut.

Caution: Disassemble the brake valve only when it is absolutely necessary to do so, for example, when the piston needs to be replaced. (The stroke and pressure must be adjusted when the valve is disassembled.)

Fig. 7-52 Removing the lock nut

3. Remove the input piston.

(1) Snap ring

Fig. 7-53 Removing the snap ring

(2) Plate washer (3) Input piston

Fig. 7-54 Removing the input piston

-235-

7-22 4. Remove the compression spring

Fig. 7-55 Removing the spring

5. Remove the brake valve spool and reaction piston.

Fig. 7-56 Removing the brake valve spool and reaction piston

6. Remove the hole plug.

Fig. 7-57 Removing the hole plug

7. Remove the closed valve.

(1) Closed valve (2) Valve return spring (3) Spring retainer (4) Reaction piston guide

Fig. 7-58 Closed valve

-236-

7-23 INSPECTION 1

Brake valve inspection

Fig. 7-59 Inspecting the brake valve

2. Valve body (1) Spool sliding face 1) Extreme scratches 2) Uneven wear 3) Rust

Fig. 7-60 Inspecting the valve body

3. Closed valve (1) Damaged of the valve (2) Damaged of the “O” ring

Fig. 7-61 Inspecting the closed valve

4.

Reaction piston guide (1) Reaction piston sliding face 1) Extreme scratches 2) Uneven wear 3) Rust (2) Damage of the “O” ring (3) Limit wear at meshing with the reac tion piston Limit wear 0.16 mm (diametrical clearance) Fig. 7-62 Inspecting the reaction piston guide

-237-

7-24 Brake valve spool, reaction piston (1) Nicks and damages on the sliding face (2) Damage of the “O” ring (3) Limit wear at meshing Limit wear 0.032 mm (0.00126 in) (diametrical clearance)

Fig.7-63 Inspecting the brake valve spool

Input piston (1) Wear, damage and deformation of the cylinder cup (2) Fatigue and deformation of the spring (3) Spool peripherical sliding face 1) Extreme scratches 2) Uneven wear 3) Rust (4) Limit wear at meshing Limit wear 0.16 mm (0.0063 in) (diametrical clearance) Spring (1) Fatigue and deformation of the spring 1) Spring in the input piston subassembly (outside) There should be no gap at A. 2) Compression spring inside the spool Free length 24.9 mm (0.98 in) 3) Reaction piston return spring Free length 21.9 mm (0.86 in)

-238-

Fig.7-64 Inspecting the input piston

Fig.7-65 Inspecting the spring

7-25 ASSEMBLY Caution: o Apply hydraulic oil to each part. o Apply silicone grease to the cylinder cup, and hydraulic oil to “O” ring and other parts.

Assemble the reaction piston to the brake valve.

(1) Brake valve (2) Reaction piston (3) Reaction piston guide (4) Spring retainer

Fig. 7-66 Assembling the piston (1)

Assemble the piston to the valve body (1) Brake valve body (2) Brake valve spool, reaction piston, reaction piston guide (3) Valve return spring (4) Closed valve

Fig. 7-67 Assembling the piston (2)

Assemble the plug hole.

Caution: Check smooth movement of the piston.

Fig. 7-68 Assembling the plug hole

Fig. 7-69 Assembling the input piston

-239-

7-26 Assemble the snap ring.

(1) Plate washer (2) Snap ring

Fig. 7-70 Assembling the snap ring

Tighten the hole plug to the specified torque.

T = 69 ~ 11 kg-m

Fig. 7-71 Tightening the hole plug

Adjust the input piston stroke.

Dimension A = 10 ± 1 mm (0.39 0.039 in) Lock the nut after adjusting the stroke.

T = 5 ~ 8 kg-m (36 ~ 57.6 ft-lb)

Fig. 7-72 Adjusting the input piston stroke

INSTALLATION Follow the procedure for removal in the reverse order.

Caution: Check the brake valve operating pressure after installation (referring to the section on “Brake Valve Operational Inspection”).

If the specified pressure is not present, adjust the dimension A. Increase dimension A when measurement is lower than requirement.

Decrease dimension A when measurement is higher than requirement.

-240-

Fig. 7-73 Locking the nut

7-27 ACCUMULATOR

Fig. 7 - 74 Accumulator

COMPONENT PARTS

1. Backup ring 2. “O” ring 3. Piston 4. “O” ring 5. Backup ring 6. Body cover 7. Stroke switch rod 8. “O” ring 9. “O” ring 10. Switch 11. Body Fig. 7 - 75 Accumulator

-241-

7-28 REMOVAL Caution: Stop the engine, disconnect the negative terminal of the battery, and depress the brake pedal for full stroke 5 to 10 times to completely drain pressurized oil in the accumulator before removing it.

1. Disconnect the wiring for the accumulator pilot lamp switch.

Fig. 7-76 Disconnecting the piping

2. Disconnect piping.

(1) Accumulator pipe (2) Accumulator to valve pipe (3) Low pressure hose 3. Remove the accumulator.

(1) Set bolts (2) Accumulator

Fig. 7-77 Removing the accumulator

DISASSEMBLY 1. Remove the accumulator pilot switch.

2. Remove the body cover.

Fig. 7-78 Removing the body cover

3. Remove the stroke switch rod.

4. Remove the accumulator piston.

Fig. 7-79 Removing the accumulator piston

-242-

7-29 INSPECTION 1. Body, cover (1) Damage of the piston sliding face (2) Broken spring (3) Crack in the body

Fig. 7-80 Inspecting the body

2. Piston (1) Scratch along the periphery of the piston (2) Damage of the “O” ring

ACCUMULATOR OPERATIONAL INSPECTION 1. Remove the accumulator pilot lamp switch.

2. Drain oil in the accumulator.

Fig. 7-81 Inspecting the piston

3. Measure the distance (dimension A) from the switch mounting position to the switch stroke rod with calipers or other measuring instrument.

4. Start the engine, turn the steering wheel completely to both directions until locked several times at about 1,000 rpm engine speed to build up pressure to the maximum capacity of the accumulator.

5. Measure the distance (dimension B) from the switch mounting position to the switch stroke rod at that condition.

Standard stroke (B-A) 30 mm (1.18 in)

Fig. 7-82 Inspecting the accumulator (1)

6. Refer to the section on “Inspection of the Brake valve operating hydraulic pressure” regarding other inspections.

INSTALLATION Follow the procedure for removal in the reverse order.

Fig. 7-83 Inspecting the accumulator (2)

-243-

7-30 CHARGE PUMP

Fig. 7 - 84 Charge pump section

SPECIFICATIONS

-244-

7-31 COMPONENT PARTS

1.

2.

3.

4.

5.

6.

7.

8.

9.

Pump motor assy Snap ring Seal holder “O” ring Oil seal Wave washer Pump shaft sub-assy Pump body Plug

10.

11.

12.

13.

14.

15.

16.

17.

18.

“O” ring Pump filter Compression spring Spring retainer Compression spring Pump cylinder sub-assy “O” ring Pump valve sub-assy “O” ring

Fig. 7 - 85 Charge pump component parts

-245-

7-32 REMOVAL 1. Remove the charge pump.

(1) Charge pump to accumulator pipe (2) Low pressure hose (3) Wiring (4) Set bolts

Fig. 7-86 Removing the charge pump

DISASSEMBLY Caution: The charge pump component parts are largely divided into the pump section and the motor section.

The motor is handled as an assembly, and not to be disassembled.

1. Remove the wiring.

2. Separate the pump section from the motor section.

Fig. 7-87 Separating the charge pump

3. Remove the pump valve sub-assembly.

Fig. 7-88 Removing the pump valve

4. Remove the pump cylinder.

Reference: Insert a 3 mm screw into the servicing hole to remove the pump cylinder.

Service Colt

Fig. 7-89 Removing the pump cylinder

-246-

7-33 5. Remove the pump plunger and the spring.

Fig. 7-91 Removing the pump plunger

6. Remove the strainer.

(1) Hole plug (2) Strainer, spring

Fig. 7-91 Removing the strainer

7. Remove the snap ring, and gently turn the seal holder in both directions using snap ring pliers.

Reference: When the seal holder is turned, it will be lifted with the spring force of the wave washer.

Fig. 7-92 Removing the snap ring and turning the seal holder

8. Remove the pump shaft sub-assembly.

Fig. 7-93 Removing the pump shaft

-247-

7-34 INSPECTION 1. Charge pump body (1) Crack and damage (2) Wear and nicks inside the body

Fig. 7-94 Inspecting the body

2. Pump shaft sub-assembly (1) Wear and damage (2) Noise from the bearing and smoothness of rotation

Fig. 7-95 Inspecting the pump shaft

3. Pump cylinder sub-assembly (1) Wear and damage of the cylinder and the plunger (2) Sliding condition between the cylinder and the plunger (3) Damage and fatigue of the spring

Fig. 7-96 Inspecting the pump cylinder

4. Pump valve sub-assembly (1) Push the valve with a finger to check.

(2) Foreign matter stuck in the valve

Fig. 7-97 Inspecting the pump valve

-248-

7-35 5. Strainer (1) Damage of the strainer (2) Damage and fatigue of the spring

Fig. 7-98 Inspecting the strainer

ASSEMBLY Follow the procedure for disassembly in the reverse order.

Caution: Wash each functional part, dry with compressed air, and apply hydraulic oil prior to assembling. o Always renew “O” rings, oil seals and similar parts.

Apply hydraulic oil to “O” rings, and apply grease to lips of the oil seals.

Fig. 7-99 Tightening torque (strainer side)

1. Tighten the hole plug in the strainer side to the specified torque.

T = 4.5 ~ 6.8 kg-m (31 ~ 49 ft-lb) 2. Tighten the pump valve to the specified torque.

T = 6.9 ~ 11 kg-m (49.7 ~ 79.2 lb)

INSTALLATION Follow the procedure for removal in the reverse order.

-249-

Fig. 7-100 Tightening torque (pump valve)

7-36 PARKING BRAKE

Fig. 7 - 101 Parking brake system diagram

COMPONENT PARTS

1. Parking brake assy 2. Parking brake cable 3. Clip 4. Return spring 5. Pin 6. Spacer 7. Nylon bushing 8. Equalizer bar sub-assy 9. Pulley 10. Snap pin 11. Lever sub-assy 12. Clip 13. Cable 14. Pin 15. Washer 16. Snap pin

Fig. 7 - 102 Parking brake component parts

-250-

7-37 REMOVAL 1. Remove the toe boards.

(1) Rear toe board (2) Front toe board 2. Remove the horn.

(1) Disconnect the wiring.

(2) Set bolts (3) Horn Fig. 7-103 Removing the horn

3. Remove the parking brake handle.

(1) Disconnect the cable.

(2) Clip

Fig. 7-104 Disconnecting the cable

(3) Set bolts (2 upper, 2 lower bolts) (4) Parking brake handle

Fig. 7-105 Removing the parking brake handle

.4. Remove the wire sub-assembly.

(1) Straight pin (2) Clip

Fig. 7-106 Tapping out the pin

-251-

7-38 (3) Wire (4) Parking brake handle (5) Spring (6) Stopper

Fig. 7-107 Removing the wire

5. Remove the return spring.

Fig. 7-108 Removing the return spring

6. Disconnect the cable.

(1) Loosen the cable lock nut.

(2) Disconnect the both cable ends.

1) Cotter pin 2) Pin 3) Plate washer 4) Lock

Fig. 7-109 Disconnecting the cable

7. Remove the lever, pulley and cable.

(1) Lever set bolt (2) Take out the lever, pulley and cable linkage.

8. Separate the lever, pulley and cable.

Fig. 7-110 Removing the lever set bolt

-252-

7-39 INSPECTION Caution: Inspect each part, and repair or replace as needed.

1. Parking brake handle assembly (1) Damage and deformation of the parking brake lever bracket (2) Deformation, crack and fatigue of the spring (3) Deformation and fatigue of the stopper (4) Bend of the parking brake lever, and wear in the grove

Fig. 7-111 Inspecting the handle assembly

2. Wire (1) Crack in the wire (2) Damage at the wire end 3. Parking brake lever (1)Damage and deformation of the parking brake lever Return spring 4. (1) Deformation and fatigue of the spring

Fig. 7-112 Inspecting the wire

Parking brake wire pulley 5. (1) Damage and deformation of the wire pulley

INSTALLATION Follow the procedure for disassembly in the reverse order.

Caution: Apply a thin film of castle MP grease on the sliding face of the handle.

Fig. 7-113 Inspecting the brake lever

ADJUSTMENT Adjust the parking brake handle stroke with the adjusting nut of the equalizer, and lock with the lock nut.

Fig. 7-114 Adjusting the parking brake

-253-

7-40 BRAKE PEDAL COMPONENT PARTS

1. Brake valve bracket 2. Nylon bushing 3. Torsion spring 4. Spacer 5. Inching 6. Brake link 7. Bracket 8. Pin 9. Inching rod sub-assy 10. Pedal pad 11. Brake pedal 12. Link 13. Spacer 14. Inching link sub-assy 15. End sub-assy 16. Rod sub-assy 17. Pin 18. Pedal bracket Fig. 7-115 Brake pedal component parts

ADJUSTMENT 1. Brake pedal height and play (1) Adjust the stopper position to obtain the following brake pedal height.

Brake pedal height 128 mm (from pad top to the toe board)

Fig. 7-116 Adjusting the brake pedal (1)

(2) Adjust the push rod length of the brake valve to obtain the following brake pedal play at the pedal edge.

Keep the push rod in a free condition.

Brake pedal play 2 to 3 mm

Fig. 7-117 Adjusting the brake pedal (2)

-254-

8-2 COMPONENT PARTS

1. Head guard seat 2. Soponge 3. Hose 4. Driver seat 5. Brance weight 6. Draw bar 7. Radiator upper cover 8. Radiator front cover 9. Engine hood 10. Rear toe board 11. Front toe board 12. Instrument panel

13. Engine hood stay 14. Mat 15. Mat 16. Fuel tank cover 17. Packing 18. Frame 19. Gasket 20. Drain plug 21. Catcher 22. Cushion rubber 23. Hook 24. Paper clamp

Fig. 8 - 1 Body component parts

-256-

8-3 ENGINE HOOD REMOVAL 1. Remove the engine hood.

(1) Remove the catch.

(2) Disconnect the engine hood stay.

(3) Disconnect the seat stay sub-assembly at the seat side.

(4) Front radiator cover set bolts (5) Engine hood (with front radiator cover and driver seat)

Fig. 8-2

Disconnecting the stay, and removing the set bolts

Fig. 8-3

Removing the engine hood

Fig. 8-4

Remove the rear toe board

Fig. 8-5

Removing the front toe board

(6) Engine hood (with radiator front cover and driver seat)

TOE BOARD 1. Remove the rear toe board.

(1) Set bolts (2) Rear toe board

2. Remove the front toe board.

(1) Disconnect each pedal link.

(2) Set bolts (3) Front toe board

-257-

8-4 BALANCE WEIGHT Remove the balance weight.

Weight set bolts (2spcs) Balance weight Reference: Weight of balance weight FDC/FGC33 series ..... Approx. 1,840 kg (4,048 lb) FDC/FGC35 series ..... Approx. 2,190 kg (4,818 lb) FDC/FGC40 series ..... Approx. 2,510 kg (5,522 lb) FDC/FGC45 series ..... Approx. 2,890 kg (6,358 lb)

Fig. 8-6

-258-

Removing the balance weight

8-5 WIRING DIAGRAM (DIESEL MODEL)

Fig. 8 - 7 Wiring diagram (2H engine model)

-259-

8-6 WIRING DIAGRAM (GASOLINE MODEL)

Fig. 8 - 8 Wiring diagram (2F engine model)

-260-

9-2 GENERAL The lifting implement consists of the following components.

1.

Mast A safety wide mast is a standard equipment on all models.

2.

Fork The 3.25 to 4.0 ton models are equipped with the same fork as used on the 2FD35. The 4.5 ton models are equipped with a 55 mm thick fork to give extra strength.

3.

Chain Reef chains are used on all models.

4.

Lift bracket The 3.25 - 4.0 ton models and the 4.5 ton models are equipped with different lift brackets.

5.

Lift cylinder Two lift cylinders are installed in back of the masts to greatly improve the front view. A safety down valve is installed at the right side lift cylinder bottom and a flow regulator valve is installed in the lift cylinder piping for safety purposes. The 3.25 - 4.0 ton models are equipped with special lift cylinder with 65 mm (2.56 in) bore, and the 4.5 ton models are equipped with a different special lift cylinder having a 70 mm (2.76 in) bore.

6.

Tilt cylinder The basic structure inside the cylinders has not changed. The piston rods are integrated at the joint by welding, and the tilt cylinders are connected to the mast through eccentric pins to allow adjusting.

7.

Oil pump Both the 2H and 2F engine models use the oil pumps of the same type (with different specifications).

* *

2H engine models Direct engine drive via PTO gear 2F engine models Direct engine drive via crankshaft and universal joint

8. Oil control valve Along with use of the central hydraulic power system, the add-on type oil control valve used on 3FG20 series is used after changing the set pressure. Since the same relief set pressure is now employed for both lifting and tilting, the number of relief valve adjusting locations was decreased to only one.

9.

Hydraulic piping A full flow type return circuit is used to return oil to the oil tank through an in-line filter.

Oil tank capacity ..... 41 l (10.8 US gal)

-262-

1.

2.

3.

4.

5.

6.

7.

Lift cylinder Tilt cylinder Oil control valve Return oil filter Oil Pump Suction filter Flow regulator valve

-263-

9-4 NATURAL DROP TEST 1.

Put the mast in upright position in a standard load condition, raise the fork to approximately 1.0 to 1.5 mm (39.3 ~ 59 in) then stop the engine.

Fig. 9-2

Standard load condition

Fig. 9-3

Free fal test (a) Amount of free fall

Fig. 9-4

Standard load condition

Fig. 9-5

Free forward tilt test

2. Draw reference lines on the inner mast and outer mast, and measure the amount of fall after 15 minutes.

NATURAL FORWARD TILT TEST 1.

Put the mast in upright position in a standard load condition, raise the fork to approximately 50 cm (19.7 in), then stop the engine.

2. Measure expansion of the tilt cylinder rod after 15 minutes.

-264-

9-5 OIL LEAK TEST Lift cylinder 1.

Put the mast in upright position in a standard load condition, and raise the fork to approximately 1 to 1.5 m.

2. Tilt the mast forward slowly, stop the engine, and with for five minutes. Disconnect the oil control valve to oil tank hose, attach a measuring cylinder at the elbow to measure oil leak for one minute.

Standard oil leak (at lift port) 6 ~ 16 cc (0.37 ~ 0.98 cu-in)

Fig. 9-6

Standard load condition (forward tilting)

Fig. 9-7

Oil leak test (lift)

Fig. 9-8

Standard load condition (neutral)

Fig. 9-9

Oil leak test (total)

Note: The lift cylinder packings need to be replaced if the amount of free fall in more than specification even when the oil leak is within the standard value.

Tilt cylinder 1. Put the mast in upright position in a standard load condition, and raise the fork to about 50 cm.

2. Stop the engine and wait for five minutes.

Then, disconnect the oil control valve to oil tank hose, attach a measuring cylinder at the elbow to measure oil leak for one minute.

Standard oil leak (total of lift and tilt) 14 ~ 34 cc (0.85 ~ 2.08 cu-in) 3. Oil leak at the tilt port is the total oil leak less leak at the lift port.

Note: The tilt lock valve or tilt cylinder packings need to be replaced if there is an excessive forward tilting even when the oil leak is within the standard value.

-265-

9-8 COMPONENT PARTS

1. Backrest

12. Lift roller

2. Fork stopper

13. Shim

3. Side roller

14. Mast strip

4. Snap ring

15. Shim

5. Shim

16. “O” ring

6. Side roller pin

17. Outer mast

7. Lift roller

18. Shim

8. Lift roller

19. Lift roller

9. Lift bracket

20. Grease fitting

10. Fork

21. Mast support bushing

11. Inner mast

Fig. 9-10 Mast component parts

-268-

9-9 MAST ASSEMBLY REMOVAL Note: o Check smoothness of mast operation, roller clearance, and other parts and identify defects accurately before removing the mast. o The mast assembly can be removed more easily after the lift bracket is removed.

1.

Disconnect the chain.

(1) Lower the lift bracket to the lower position, and tilt the mast forward to slacken the chain.

(2) Chain adjust nut, lock nut

Fig. 9-11 Disconnecting the chain

2. Remove the lift bracket.

(1) Put the mast in upright position, and raised the inner mast until it is separated from the lift bracket.

Note: Raise the inner mast carefully since the slacken chain sometimes become caught in the inner mast.

(2) Move the vehicle backward Fig. 9-12 Removing the lift bracket

3.

Disconnect the hoses.

(1) Lower the inner mast to the lowest position (2) Overflow hose (three-way side) (3) High pressure hose Note: Hoist the inner mast to disconnect the high pressure hose more easily.

Fig. 9-13 Disconnecting the hoses

-269-

9-10 4. Put a wire to the mast hook, and lift the mast.

Fig. 9-14

Hoisting the mast

Fig. 9-15

Stamping matchmarks

Fig. 9-16

Removing the mast support

Fig. 9-17

Stamping matchmarks

5.

Make matchmarks on the mast support cap.

6.

(1) Remove the mast support cap.

(2) Set bolts Mast support cap 7.

(1) Remove the front tilt cylinder pin.

Stamp matchmarks.

Cautions: o The matchmarks must clearly indicate the set position of the front pin and o the stopper plate.

The stopper plate set bolt must be positioned in the same screw holes when the parts are reassembled.

Stamp matchmarks, or make a note showing the location of the current o screw holes.

Matchmarks are not necessary when the mast or the mast assembly is being replaced, in which case, however, a limping them is required.

-270-

9-11 (2) Set bolt (3) Stopper plate (4) Front pin SST 09810-20171-71

8.

9.

Removing the front pin

Fig. 9-19

Removing the mast assembly

Fig. 9-20

Putting the down flat on the ground

Fig. 9-21

Disconnecting the hose

Remove the mast assembly.

Put the mast on the ground.

Put the mast on the ground with the mast tie beam facing up, and with a block under the outer mast so the inner mast can slide up and down.

Cautions: o Never put the removed mast against a wall. Put it down flat. o Put the mast down on a wide space, especially in the vertical direction of the mast sliding. (Provide an extra space about the length of the mast.)

DISASSEMBLY 1.

Fig. 9-18

Disconnect the hoses.

(1) Overflow hose (2) High pressure hose

-271-

9-12 2. Remove the flow regulator valve.

(1) Set bolt (2) Flow regulator valve 3. Remove the chain wheel.

(1) Snap ring (2) Chain wheel

4.

Fig. 9-22

Removing the flow regulator valve

Fig. 9-23

Removing the set bolt

Fig. 9-24

Disconnecting the cylinder rod end

Fig. 9-25

Removing the lift cylinder support

Disconnect the cylinder rod end.

(1) Set bolt

(2) Pull out the cylinder rod from the inner mast 1) Shim 2) Washer Caution: Shims are used at the lift cylinder rod end to prevent limping of the lift cylinder. Take note of the number of shims used, and on which cylinder they are used.

5. Remove the lift cylinder support bolt.

-272-

9-13 6. Remove the lift cylinder.

(1) Slide the inner mast nearly to the highest position.

(2) Lift cylinder Caution: Remove the lift cylinder carefully not to damage the elbow installed at the lift cylinder bottom.

Fig. 9-26

Removing the lift cylinder

Fig. 9-27

Removing the lift roller

Fig. 9-28

Removing the lift roller

Fig. 9-26

Removing the mast strip

7. Remove the lift roller.

(1) Lift roller for outer mast (2) Shim Note: SST 09950-20014 may be used when the roller is extremely tight.

(3) Lift roller for inner mast (4) Shim Note: SST 09950-20014 may be used when the roller is extremely tight.

8.

Remove the mast strip.

(1) Mast strip (2) “O” ring (3) Shim Caution: Replace the mast strip if the oil groove is lost.

-273-

9-14 9.

Pull out the outer mast from the bottom of the inner mast.

Fig. 9-30

Removing the outer mast

Fig. 9-31

Mast inspection

Fig. 9-32

Inspecting the lift roller

Fig. 9-14

Inspecting the mast strip

INSPECTION 1.

2.

Outer mast, inner mast (1) Warp, bend, nicks (2) Cracked weld (visual inspection or color checking) (3) Widening

Lift rollers (1) Wear, damage, excess gap, smoothness

3. Mast strip (1) Damage, nicks, deformation (2) Wear (replace if oil groove is lost) (3) Broke “O” ring

-274-

9-15 (2) Lift roller dimensions

-275-

9-16 ASSEMBLY Cautions: o Assemble the mast using appropriate shims in accordance with the mast adjusting standards. o Apply Toyota Genuine Castle MP grease on the sliding face of the mast strip and the inner mast.

1.

Select shims for the lift roller.

Note: Add appropriate shims as required to the original number of shims used when the standard mast clearance was measured.

Shim thicknesses 0.5 mm (0.0197 in) 1.0 mm (0.039 in)

2.

Insert the outer mast through the bottom of the inner mast.

Note: Put a block under the outer mast, as before disassembly, so the inner mast can slide up and down.

3.

Install the mast strip.

4.

Install the lift roller.

SST 09370-20270-71

5.

Then follow the procedure for disassembly in reverse order.

INSTALLATION

Fig. 9-34

Shim selection (inner mast roller)

Fig. 9-35

Shim selection (outer mast roller)l

Follow the procedure for removal in the Reverse order.

Cautions: o Apply Toyota Genuine Castle Chassis Grease Special to the mast support bushing and the tilt cylinder front pin. o Assemble the mast support cap and the tilt cylinder front pin accurately to the matchmarks. o When any of the mast assembly, outer mast, inner mast or lift cylinder was replaced, the lift cylinder must be inspected and adjusted for limping. Refer to the section on “Lift Cylinder Rod Shim Adjustment” about inspection and adjustment methods.

-276-

9-17 LIFT BRACKET REMOVAL Notes: o Remove the lift bracket before replacing or shim adjusting the lift bracket roller. o Refer to procedures 1 through 3 of “Mast Assembly Removal” to remove the lift bracket.

1. Remove the lift bracket.

Fig. 9-36

Removing the lift bracket

Fig. 9-37

Removing the lift roller

Fig. 9-38

Removing the lift roller

Fig. 9-39

Removing the side rollers

DISASSEMBLY 1. Remove the lift roller.

(1) Snap ring (2) Lift roller SST 09950-20014

2. Remove the side rollers.

(1) Snap ring (2) Upper side roller SST 09950-20014 (3) Remove the wire lock (4) Set bolt (5) Lower side roller assembly (6) Shim (7) Disassemble the lower side roller assembly.

1) Snap ring 2) Side roller SST 09950-20014 3) Side roller pin

-277-

9-18 INSPECTION 1.

2.

Lift roller (1) Wear, damage, excess gap, smoothness of rotation Side rollers (1) Wear, damage, excess gap, smoothness of rotation (2) Wear and damage of the side roller pin

ASSEMBLY AND INSTALLATION

Fig. 9-40

Inspecting the side roller (4.5 ton models)

Fig. 9-41

Lift rollers

Follow the procedure for Disassembly and Removal in the reverse order.

Cautions: o Install the side rollers in the correct direction. The illustration at the right shows a STD mast. The lower side roller on the FV and FSV masts must be installed in the opposite direction than shown in the illustration (the side with greater radius must come toward the front).

-278-

9-19 CHAIN WHEEL AND CHAIN REMOVAL Notes: Refer to steps 1 and 2 under “Mast Assembly Removal” to remove the chain wheel.

The chain and the lift bracket are removed in similar steps. To remove the chain, refer to steps 1 through 3 under “Mast Assembly Removal”, then continue on to the following.

Fig. 9-42 Removing the chain wheel

1. Remove the chain wheel.

(1) Snap ring (2) Chain wheel 2. Remove the chain (disconnecting at the lift bracket side).

(1) Adjust nut, lock nut (2) Chain

Fig. 9-43 Removing the chain INSPECTION 1. Chain wheel (1) Damage and cracks (2) Smoothness of rotation, unusual noise and excess gap of the chain wheel bearing

Fig. 9-44 Inspection the chain wheel 2. Chain (1) Elongation, crack (2) Damage, bend (anchor bolt) (3) Link movement

Fig. 9-45 Chain inspection

-279-

9-20 INSTALLATION Follow the procedure for Removal in the reverse order.

Cautions: Refer to the section under “Chain Adjusting” to install the parts correctly.

Tighten the adjust nut in accordance with the procedure for Tightening. The chain must be tightened correctly in parallel to the chain wheel without torsion.

Fig. 9-46 Chain installation

Adjust Nut Tightening Procedure 3.25 - 4.0 ton models -Lift bracket side 1. Tighten the anchor bolt at (1) and (2) first at the position as shown at the correct dimension.

T = 17~ 23 kg-m (123~166 ft-lb) 2. Then, tighten the bolt at (3).

T = 10~15 kg-m (72~108 ft-lb) -Lift cylinder side 1. Tighten at (1) and (2) first.

T= 17~23 kg-m (123~166 ft-lb)

Fig. 9-47 Nut tightening procedure

2. Then, tighten at (3).

T = 10~15 kg-m (72~108 ft-lb)

-280-

9-21

ADJUSTMENT 1.

Place the vehicle on a flat ground, and put the mast in upright position.

2.

Operate the fork up and down several times without load, and check that the tension in the both chains is equal.

3.

Adjust the chain with the adjust nut (at the lift cylinder side) so the bottom of the fork barely touches the ground without slack in the chain.

Notes: Measure the distance between the fork bottom and ground (dimension h) as shown in Fig. 9 - 50.

When the fork is at the position of the dimension h, the bottom of the lift bracket roller must not exceed the dimension A. When the fork is at the highest position, the distance between the chain wheel and the lift bracket side chain anchor must not be less than the dimension B (reference value).

Fig. 9-48 Checking the chain tension

Fig. 9-49 Chain adjusting with the fork at the low position 4.

Check that the tension in the both chains is equal.

5.

Check that the specified lift height is obtained.

Notes: Dimension A is taken when h = 0.

Dimension B is a reference value.

-281-

Fig. 9-50 Chain adjusting with the fork at the highest position

9-22 FORK REMOVAL 1. Raise the fork to about 20 cm.

2. Put a block in front of the notch in the fork rails.

3. Move the rails towards the center, one at a time.

4. Lower the fork, and remove it.

Fig. 9-51 Removing the chain wheel

INSTALLATION Follow the procedure for Removal in the reverse order.

INSPECTION 1. Fork (1) Bend, crack, misalignment at the front edge Limit bend of the fork 15 mm (0.59") Limit misalignment at the fork front edge 10 mm (0.39")

Fig. 9-52 Inspection the fork

Caution: When the misalignment at the front edge exceeds the limit value, check each fork for bend, excess gap at the fork root, and warp in the lift bracket finger bar.

-282-

9-23 MAST ADJUSTMENT LIFT BRACKET SIDE ROLLER ADJUSTMENT 1. Preparation (1) Prepare screwdriver or bar, filler gauge, dial gauge and wire.

(2) Bring the two forks farthest from each other.

2. Measuring the clearance of the upper side roller (1) Raise the fork about 20 cm, and stop the engine.

(2) Place a screwdriver or a bar between the lift bracket top and the inner. mast and push the side roller to one side. Measure the clearance with a filler gauge between the inner mast and the side roller at the opposite of the screwdriver or bar.

Standard clearance (amount of travel) 0 - 1.0 mm (0 ~ 0.039")

Fig. 9-53 Measuring clearance of the upper side roller

Fig. 9-54 Upper side roller clearance 3. Measuring the clearance of the lower side roller (1) Put a wire around the back rest, and lift the lift bracket.

Note: Lift and stop when the lift bracket top has completely come above the inner mast.

(2) Set a dial gauge to the inner mast.

(3) Push the side roller against the inner mast with a screwdriver or a bar from the opposite of the dial gauge.

Put the dial gauge to the side of the lift bracket, and set the gauge to 0.

(4) Push the side roller against the inner mast with a screwdriver or a bar between the inner mast and the lift bracket at the same side as the dial gauge.

(5) Measure the amount of travel of the side roller to the right and left directions.

Standard clearance (amount of travel) 0 - 1.0 mm (0 ~ 0.039")

Fig. 9-55 Lift bracket up position

Fig. 9-56 Measuring clearance of the lower side roller

-283-

9-24

Fig. 9 - 57 Lower side roller clearance

4. Side roller adjustment Notes: Side roller adjustment is needed only when a defect was found during clearance measurement.

Remove the lift bracket before adjustment (referring to steps 1 through 3 under ‘’Mast Assembly Removal”).

Replace the upper side roller with oversize part, and use shims at the lower side roller. Use same number of shims on right and left.

(1) (2)

Fig. 9-58 Removing the lift bracket

Remove the lift bracket.

Replace the upper side roller with oversize part List of oversize parts

Fig. 9-59 Adjusting the upper side roller

(3)

(4)

Remove the lower side roller assembly, and adjust with shims.

Shim thickness 0.5 mm, 1.0 mm (0.019") (0.039") After side roller adjustment, check that the lift bracket smoothly goes up and down along the full length of the mast.

-284-

Fig. 9-60 Adjusting the lower side roller

9-25 MAST LIFT ROLLER ADJUSTMENT 1. Preparation (1) Prepare screwdriver or bar, dial gauge, and wire (2) Bring the forks farthes from each other, and slightly tilt the mast forward.

(3) Raise the inner mast to the highest position, and stop the engine.

Note: For safety purpose, put a wire around the inner mast lower tie beam and hose the inner mast.

2. Measuring clearance of the inner mast roller (1) Set the dial gauge inside the outer mast (2) Push the inner mast roller against the outer mast with a screwdriver or a bar from the opposite side of the dial gauge. Put the dial gauge against the inner side of the inner mast, and set the gauge to 0.

(3) Place a screwdriver or a bar between the outer mast and the inner mast at the same side as the dial gauge. and push the inner mast roller against the outer mast.

(4) Measure the amount of travel of the inner mast roller in the right and left directions.

Standard clearance (amount of travel) 0-0.8 mm (0-0.0315") (5) Adjust the inner mast roller clearance with shims as needed.

Fig. 9-61 Inner mast up position

Fig. 9-62 Measuring the inner mast roller clearance

Fig. 9-63 Clearance between the outer mast and inner mast rollers

-285-

9-26 3. Measuring clearance of the outer mast roller (1) Set a dial gauge on the outer mast (2) Push the inner mast against the outer mast roller with a screwdriver or a bar. Put the dial gauge against the inner side of the inner mast and set the gauge to O (3) Place a screwdriver or a bar between the outer mast and the inner mast at the same side as the dial gauge. and push the inner mast against the outer mast roller (4) Measure the amount of travel of the inner mast in the right and left directions Standard clearance (amount of travel) 0-0.8 mm (0-0.0315'’) (5) Adjust the outer mast roller clearance with shims as needed.

Fig. 9-64 Measuring clearance of the outer mast roller

Fig 9. 65 Clearance between the inner mast and outer mast rollers 4. Mast roller adjustment Notes: Roller replacing or shim adjusting is required only when a defect was found during measurement under mast adjustment.

Roller replacing of shim adjusting can be done after the lift bracket is removed. Refer to steps 1 through 3 under “Mast Assembly Removal” to remove the lift bracket.

(1) Remove the lift bracket Fig. 9-66 Removing the lift bracket

-286-

9-27 (2) Remove the set bolt at the lift cylinder rod end, hoist the inner mast, and disconnect the cylinder rod end.

Fig. 9-67 Disconnecting the cylinder rod end (3) Disconnect the lift cylinder support. tilt the two cylinders, and secure them to the outer mast tie beam with a rope.

Fig. 9-68 Tilting the lift cylinder (4) Lower the inner mast that was hoisted.

Note: Lower the mast carefully to a tilt back position.

Fig. 9-69 Lowering the inner mast (5) Remove the inner mast roller.

SST 09950-20014

Fig. 9-70 Removing the inner mast roller

-287-

9-28 (6) Select appropriate shims for the inner mast roller. and divide them in an equal number to right and left.

Shim thickness 0.5 mm (0.019") 1.0 mm (0.039")

Fig. 9-71 Shim adjustment (7) Remove the outer mast roller SST 09950-20014

Fig. 9-72 Removing the outer mast roller (8) Select appropriate shims for the outer mast roller, and divide them in an equal number to right and left.

Shim thickness 0.5 mm (0.019") 1.0 mm (0.039")

Fig. 9-73 Shim adjustment (9) After mast roller adjustment, check that the inner mast smoothly goes up and down along the outer mast.

-288-

9-29 MAST STRIP ADJUSTMENT 1.

Preparation (1) Prepare a filler gauge (2) Bring the inner mast to the lowest position, and tilt it slightly forward

2.

Measuring clearance between the mast strip (outer mast side) and the inner mast (1) Measure clearance between the mast strip and the inner mast with a filler gauge.

Standard clearance 0.5-1.0 mm (0.019 ~ 0.039")

Fig. 9-74 Measuring mast strip clearance

Caution: Make sure that the inner mast is in contact with the outer mast roller.

Fig. 9-75 Clearance between the mast strip and the inner mast 3.

Mast strip adjustment Notes: Mast strip must be adjusted only when a defect was found during clearance measurement.

Use shims to make adjustment Refer to steps 1 through 4 (from the lift bracket removal through lowering the inner mast) under the section on “Mast Roller Adjustment’’.

(1) Remove the mast strip. and adjust with shims.

Shim thickness 0.5 mm (0.019") 1.0 mm (0.039") (2) After the mast strip adjustment, check that the inner mast smoothly goes up and down along the outer mast.

Fig. 9-76 Mast strip adjustment

-289-

9-30 SHIM ADJUSTMENT AT THE LIFT CYLINDER ROD (TO PREVENT LIMPING) Notes: o Shim adjustment at the lift cylinder rod is required to prevent limping (unequal movement between right and left cylinders) sometimes caused on models using two lift cylinders due to manufacturing errors of parts. o The lift cylinder rod must be inspected and adjusted whenever any of the following parts is replaced.

(1) Lift cylinder assembly (4) Mast assembly (2) Lift cylinder rod sub-assembly (5) Outer mast sub-assembly (3) Lift cylinder sub-assembly (6) Inner mast sub-assembly

1. Method of inspection Raised the inner mast slowly, and inspect the right and left cylinder rods at the moment the inner mast reaches the highest position and stops.

(1) Normally, both rods should stop simultaneously without causing significant vibration to the inner mast.

(2) If one of the rods stops before the other, a vibration is caused at the moment the second rod comes to a stop, and the top of the inner mast moves because of the vibration. This is an abnormal situation, and the lift cylinder rod that stops first needs adjusting with shims.

2. Method of adjustment (1) Raise the inner mast, place SST 09610-22000-71 on the outer mast tie beam as shown, and lower the inner mast slowly untilit touches the SST. (2) Remove the set bolt on the cylinder rod end that is being adjusted with shims.

(3) Lower the lift cylinder rod slowly, and disconnect the cylinder rod end.

Put shims on the cylinder rod end, raise the rod slowly and insert it into the inner mast.

(4) Install the set bolt at the cylinder rod end.

(5) Raise the inner mast again to check results.

(6) Repeat inspection and adjustment to determine the correct number of shims.

(7) Shim thickness 1.0 mm (0.039")

Fig. 9-77 Inspecting lift cylinder limping

Fig. 9-78 Placing a SST

Fig. 9-79 Shim adjustment

-290-

9-32

LIFT CYLINDER GENERAL GENERAL

Fig. 9-80 Lift cylinder section (3.25 - 4.0 ton models)

SPECIFICATIONS AND SERVICE STANDARDS

-292-

9-33 COMPONENT PARTS

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Dust seal Cylinder cover “U” packing Rod guide Bushing “O” ring Piston rod Spacer (Lifting height: 370, 400 mm (145 and 157.5 -in) Backup ring “O” ring Stopper ring Wearing Piston Backup ring

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

“U” packing Snap ring Shim Washer Shim Cylinder support bracket Pipe collar Insulator Chain wheel Snap ring Chain Lift cylinder sub-assy “O” ring Plug Safety down valve

Fig. 9-81 Lift cylinder component parts

-293-

9-34 REMOVAL 1. Disconnect the chain.

(1) Bring the fork to the lowest position and tilt the mast forward to loosen the chain.

(2) Chain adjust nut, locknut

Fig. 9-82 Disconnecting the chain 2. Remove the lift bracket (1) Put the mast in upright position, and raise the inner mast until it is completely out of the lift bracket.

Caution: When raising the inner mast, make sure that the slacked chain does not get caught in the inner mast.

(2) Move the vehicle backward Fig. 9-83 Removing the lift bracket 3. Disconnect the hoses.

(1) Overflow the hoses (2) High pressure hose

Fig. 9-84

Disconnecting the hose

4. Disconnect the lift cylinder rod end.

(1) Set bolt

Fig. 9-85 Removing the set bolt

-294-

9-35 (2) Lift the inner mast and disconnect the cylinder rod end.

(3) Shims, washers Caution: Shims are used to adjust the lift cylinder rod end to prevent limping. Shims are used in either right or left side. Make a note of the side and the number of shims used.

Fig. 9-86 Disconnecting the cylinder rod end 5. Remove the lift cylinder assembly.

(1) Lift cylinder support set bolt (2) Lift cylinder bracket set bolt (3) Shims

Fig. 9-87 Removing the support set bolt (4) Remove the lift cylinder assembly from the front of the vehicle.

Cautions: o Lift the lift cylinder carefully. o Take out the lift cylinder assembly carefully not to damage the elbow at the bottom of the cylinder.

Fig. 9-88 Removing the lift cylinder assembly

-295-

9-36 DISASSEMBLY 1. Remove the overflow hose.

(1) Hose clamp (2) Overflow hose 2. Remove the lift cylinder support bracket.

(1) Lift cylinder support bracket (2) Bushing (3) Spacer

Fig. 9-89 Removing the overflow hose 3. Remove the cylinder top cover.

SST 09620-10100-71

Fig. 9-90 Removing the top cover 4. Pull out the lift cylinder rod.

Caution: Pull out the rod in parallel to the cylinder. carefully not to damage the rod.

Fig. 9-91 Pulling out the cylinder rod 5. Remove the piston.

(1) Snap ring (2) Stopper ring (3) Piston

Fig. 9-92 Removing the piston

-296-

9-37 6. Disassemble the piston.

(1) Wear ring (2) Back-up ring (3) “U” packing (4) Piston

Fig. 9-93 Disassembling the piston 7. Remove the safety down valve Caution: Safety down valve is installed in the right and lift cylinder only.

Fig. 9-94 Removing the safety down valve

INSPECTION 1.

Lift cylinder (1) Scratch and wear in the sliding face inside the cylinder Cylinder bore limit wear 3.25 ~ 3.5 ton models 65.35 mm (2.573") 4.0 ~ 4.5 ton models 70.35 mm (2.77") (2) Deformation, damage and rust of the cylinder (3) Dents outside the cylinder

Fig. 9-95 Inspecting the lift cylinder

2. Piston rod (1) Scratch and wear in the sliding face of the rod Rod limit wear 49.88 mm (1.964") (2) Separation, damage and rust of the plating (3) Bend of the rod Rod limit bend 2.0 mm (0.0787)

Fig. 9-96 Inspecting the piston rod

-297-

9-38 3.

Rod guide (1) Wear and damage of the guide sleeve Clearance between the rod and the sleeve Standard 0.1 mm (0.0039") Limit 0.4 mm (0.0157") (2) Wear, damage and deterioration of the “U” packing (3) Damage and deterioration of the “O” ring Fig. 9-97 Inspecting the rod guide

4.

Piston (1) Wear and damage of the piston (2) Wear and damage of the war ring (3) Wear, damage and deterioration of the “U” packing (4) Damage of the back-up ring (5) Damage of the stopper ring

Fig. 9-98 Inspecting the piston 5. Lift cylinder top cover (1) Damage of the threads (2) Crack of the top cover (3) Wear and damage of the dust seal

Fig. 9-99 Inspecting the top cover 6. Lift cylinder support bracket (1) Damage of the bracket (2) Damage of the bushing (3) Damage of the spacer

Fig. 9-100 Inspecting the bracket

-298-

9-39 7. Safety down valve Refer to the section on Safety Down Valve Inspection for detail.

Fig. 9-101

ASSEMBLY Follow the procedure for Disassembly in the reverse order.

Cautions: o Do not assemble dry parts. Apply hydraulic oil first. o When parts were disassembled, renew all “O” rings, “U” packings and dust seals before assembling them.

INSTALLATION Follow the procedure for Removal in the reverse order. o Adjust the tension of the both lift chains equally. o Repeat full stroke movement without weight, and release air to check if operation is satisfactory. o Then, check the amount of hydraulic oil at the oil level gauge, and add Castle Hydraulic Oil 90 as appropriate. o Check if the lift height is correct. o When any of the lift cylinder assembly, lift cylinder sub-assembly or lift cylinder rod sub-assembly is replaced, the lift cylinder must be checked for limping and adjusted as needed. Refer to the section on “Shim Adjustment of the Lift Cylinder Rod”.

-299-

9-40 SAFETY DOWN VALVE

Fig. 9-102 Safety down valve

SPECIFICATIONS

-300-

9-41 REMOVAL 1. Brign the right hand fork to the far right position (not needed when servicing in the pit).

2. Put the mast in the lowest position.

3. Remove the safety down valve.

Fig. 9-103 Removing the safety down valve

DISASSEMBLY 1. Remove the snap ring.

Fig. 9-104 Removing the snap ring 2. Remove the valve and the spring.

Fig. 9-105 Removing the valve

INSPECTION 1. Clogging and damage of the valve orifice 2. Fatigue and damage of the spring 3. Damage of the threads

Fig. 9-106 Inspecting the safety down valve

-301-

9-42 FLOW REGULATOR VALVE

Fig. 9-107 flow regulator valve section SPECIFICATIONS

LOWERING SPEEDS

REMOVAL 1. Put the forks farthest from each other.

2. Put the mast in the lowest position.

3. Disconnect the hose (1, 2, 3).

4. Remove the flow regulator valve.

(1) Set bolt (4) (2) Flow regulator valve Fig. 9-108 Removing the flow regulator valve

-302-

9-43 DISASSEMBLY 1. Remove the elbow.

Fig. 9-109 Removing the elbow 2. Remove the plug.

Fig. 9-110 Removing the plug 3. Remove the spring and the valve.

Fig. 9-111 Removing the spring 4. Remove the steel ball and the spring.

Fig. 9-112 Removing the valve steel ball

-303-

9-44 INSPECTION 1. Flow regulator valve body (1) Damage inside the body (2) Crack and damage of the body

Fig. 9-113 Inspecting the valve body 2. Flow regulator valve (1) Damage of the valve (2) Fatigue and damage of the spring

Fig. 9-114 Inspecting the flow regulator valve 3. Elbows (1) Damage of the threads (2) Damage of the “O” rings

ASSEMBLY 1. Assemble the steel ball and the spring in the valve, then put the valve cover on the valve.

2. Reverse the valve, and assemble the spring and the plug.

Fig. 9-115 Inspecting the elbows Caution Make sure that the spring for the steel ball is correctly assembled.

3. Assemble the elbows.

INSTALLATION Follow the procedure for Removal in the reverse order.

Fig. 9-116 Assembly

-304-

9-45 TILT CYLINDER GENERAL

Fig. 9-117 Tilt cylinder section

SPECIFICATIONS AND SERVICE STANDARDS

-305-

9-46 COMPONENT PARTS

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Front pin Stoper plate Grease seal Cylinder rod Cylinder cover Snap ring Dust seal Bushing Rod guide Backup ring “U” packing Stopper plate

13. Snap ring 14. Backup ring 15. “O” ring 16. “O” ring 17. Spacer 18. Piston 19. “U” packing 20. Sleeve 21. “U” packing 22. Tilt cylinder 23. Bushing 24. Rear ping

Fig. 9-118 Tilt cylinder component parts

-306-

9-47 REMOVAL Caution: “U” packings and other parts can be replaced without removing the cylinder assembly. This section describes procedure for services with the cylinder assembly removed.

1.

Bring the fork to the lowest position, and tilt the mast forward.

Fig. 9-119 Stamping matchmarks

Caution: Lift the mast assembly with a wire for safety.

2.

Remove the tilt cylinder front pin.

(1) Stamp matchmarks.

Cautions: Make matchmarks on the front pin and the stopper plate to show their relative position.

Make matchmarks, or make a note, to show the relative position of the stopper plate set bolt and the screw hole.

Matchmarks are not needed when the tilt cylinder is being replaced. The new tilt cylinder must be inspected and adjusted as needed to prevent limping, and the tilt angle must be adjusted correctly.

(2) Set bolt, stopper plate (3) Front pin SST 09810-20171-71

3.

Fig. 9-120 Removing the stopper plate

Fig. 9-121 Removing the front pin

Disconnect the piping.

(1) High pressure hose at the rear side (2) High pressure hose at the front side

Fig. 9-122 Disconnecting the piping

-307-

9-48 4. Remove the tilt cylinder rear pin.

(1) Set bolt (2) Rear pin

Fig. 9-123 Removing the rear pin

5. Remove the tilt cylinder assembly.

Fig. 9-124 Removing the tilt cylinder

DISASSEMBLY 1. Remove the tilt cylinder cover.

SST 09620-10160-71

Fig. 9-125 Removing the cylinder cover

2. Pull out the piston rod.

Caution: Pull out the piston rod in parallel to the cylinder.

Fig. 9-126 Pulling out the piston rod

-308-

9-49 3. Remove the piston.

(1) Cotter pin (2) Castle nut

Fig. 9-127 Removing the castle nut

(3) Piston

Fig. 9-128 Removing the piston

4. Remove the rod guide.

Fig. 9-129 Removing the rod guide

5. Disassemble the piston.

(1) Sleeve (2) “U” packing Caution: Use a stick or the like wrapped with vinyl tape to prevent parts.

(3) Piston

Fig. 9-130

-309-

Disassembling the piston

9-50 6.

Disassemble the piston rod guide.

(1) Snap ring (2) Stopper plate (3) “U” packing (4) Back-up ring (5) “O” ring (6) Back-up ring (7) Dust seal Caution: Remove the sleeve with a press only when a damage was found.

Fig. 9-131 Disassembling the rod guide

INSPECTION Cautions: Any defect in the “U” packing or dust seal at the rod guide will result in oil leaks.

Any defect in the “U” packings at the piston will result in free forward tilt.

Clean each part, and replace any defective or damaged part.

1. Tilt cylinder (1) Scratch and wear inside the cylinder Limit cylinder bore wear 90.45 mm (3.56") (2) Deformation, damage and rust of the cylinder (3) Locan dents outside the cylinder 2. Piston rod (1) Scratch and wear on the sliding face of the piston rod.

(2) Separation, damage and rust of the plating (3) Bend of the piston rod Piston rod limit bend 1.0 mm (0.039")

Fig. 9-132 Inspecting the tilt cylinder

Fig. 9-133 Inspecting the piston rod

3. Piston (1) Wear and damage of the piston (2) Wear, damage and deterioration of the “U” packing (3) Wear, damage and crack of the sleeve

Fig. 9-134 Inspecting the piston

-310-

9-51 4. Rod guide (1) Wear and damage of the guide sleeve Standard clearance between the rod and the guide 0.1 mm (0.0039") Limit clearance between the rod and the guide 0.4 mm (O0157") (2) Wear, damage and deterioration of the “U” packing (3) Wear, damage and deterioration of the dust seal, “O” ring and back-up ring (4) Damage of the rod guide

Fig. 9-135 Inspecting the rod guide

5. Cylinder cover (1) Damage of the threads (2) Crack of the cylinder cover

Fig. 9-136 Inspecting the cylinder cover

ASSEMBLY Follow the procedure for Disassembly in the reverse order.

Cautions: Avoid assembling dry parts. Apply hydraulic oil first.

Replace “U” packing and “O” ring unless they are completely free of damage or have been used for a short time.

INSTALLATION Follow the procedure for Disassembly in the reverse order Cautions: Apply Castle Chassis Grease Special on the parts receiving the front pin and the rear pin.

Install the front pin at the correct position at the matchmarks. When the tilt cylinder is replaced with a new part, it must be assembled in accordance with the procedure for adjusting the mast forward/backward tilt angles.

Tilt the mast to the front and to the rear two or three times, and check smoothness of operation.

Check the amount of hydraulic oil at the oil level gauge, and add oil as needed.

-311-

9-52 MAST FORWARD/BACKWARD TILT ANGLE ADJUSTMENT The tilt cylinder front pin is off by 5 mm (0.197 in) of the center of the hexagonal flange, and the stopper plate can be locked at two places. This allows rod length adjustment from fine ± 1.3 mm (0.051 in) to ± 5 mm (0.197 in) range.

Mast forward tilt angle 5° Mast backward tilt angle 10° Tilt cylinder limping 1 mm max. (0.039")

Fig. 9-137 Relative position to the front pin and stopper plate

1.

Assemble the front pin at the low end of the flange with the mast in neutral position. On 4.5 ton models, however, bring the front pin to the completely opposite side (upper end of the flange).

2.

Check the tilt angles and limping at the pin position specified in 1. above. measurement differs from specification, turn the front pin to adjust. The range if adjustment is ± 5 mm (0.197 in).

3.

Fig. 9-138 Front pin

Turn the stopper plate to make fine adjustment. The minimum angle for adjusting at the front pin is ± 15, which is the unit of increment for further adjustment.

-312-

9-53 (1)

When the stopper plate angle is ±15°, it corresponds to ±1.3 mm adjustment of the rod length.

Fig. 9-139 Adjustment (1)

(2)

When the stopper plate angle is ±30°, it corresponds to ±2.5 mm adjustment of the rod length.

Fig. 9-140 Adjustment (2)

(3)

When the stopper plate angle is ±45°, it corresponds to ±3.5 mm adjustment of the rod length.

Fig. 9-141 Adjustment (3)

-313-

9-54 (4) When the stopper plate is ± 60°, it corresponds to ± 4.3 mm adjustment of the rod length.

Fig. 9-142 Adjustment (4)

(5) Adjustment positions (1) through (4) may be combined to meet the specifications.

-314-

9-56 OIL PUMP GENERAL

Fig. 9-143 Oil pump sectional view

SPECIFICATIONS AND SERVICE STANDARDS

-316-

9-57 COMPONENT PARTS

1. Oil pump assy 2. Bolt 3. Washer, spring 4. Cover 5. Body, seal 6. Backing ring RH 7. Backing ring LH 8. Bushing seal

9. Bushing 10. Drivengear 11. Drive gear 12. Pump body 13. Mounting flange 14. Oil seal 15. Snap ring 16. Packing

Fig. 9-144 Oil pump component parts

-317-

9-58 REMOVAL (2H ENGINE MODEL) 1.

2.

3.

Drain hydraulic oil through the hydraulic oil tank drain.

Hydraulic oil amount: 41 liters (10.8 US gal.)

Remove the engine hood.

Fig. 9-145 Removing the engine hood

Remove the oil pump (1) Inlet hose (2) Outlet pipe set bolt on the pump side (3) Oil pump set bolts and nuts (4) Oil pump

Fig. 9-146 Removing the oil pump

REMOVAL (2F ENGINE MODEL) 1.

Remove the balance weight.

(1) Balance weight set bolts (2 pcs) (2) Balance weight Reference: Weight of balance weight FDC/FGC33 series - - - Approx. 1,840 kg (4,048 lb) FDC/FGC35 series - - - Approx. 2,190 kg (4,818 lb) FDC/FGC40 series - - - Approx. 2,510 kg (5,522 lb) FDC/FGC45 series - - - Approx. 2,890 kg (6,358 lb)

2.

Fig. 9-147

Removing the balance weight

Remove the oil pump assembly.

(1) Inlet pipe (2) Outlet pipe (3) Pump assembly set bolt

Fig. 9-148 Removing the oil pump assembly

-318-

9-59

DISASSEMBLY Caution: Disassemble parts in a clean place.

Use new hydraulic oil to clean parts.

1. Stamp matchmarks on the pump body and the cover.

Fig. 9-149 Stamping matchmarks

2. Remove the pump cover (1) Set bolt (2) Pump body

Fig. 9-150 Removing the pump cover

3. Remove the bushing.

(1) Body seal (2) Backing ring (3) Bushing seal (4) Bushing

Fig. 9-151 Removing the bushing

4. Remove the pump gear.

(1) Make matchmarks.

(2) Drive gear (3) Driven gear

Fig. 9-152 Removing the pump gear

-319-

9-60 5. Remove the mounting flange.

Fig. 9-153 Removing the mounting flange

6. Remove the bushing.

Fig. 9-154 Removing the bushing

7. Remove the oil seal from the mounting flange (1) Snap ring (2) Oil seal Caution: Remove the oil seal when a defect is found.

Fig. 9-155 Removing the oil seal

-320-

9-61 INSPECTION Caution: Check each disassembled part for discoloration and stains before cleaning and inspection.

1. Body, cover and flange (1) Trace of scratch by gear contact at the inlet side inside the body (contact trace extending about 1/3 of the inside periphery of the body is acceptable.)

(2) Damage at the contact face of the body, cover and flange.

(3) Damage of the mounting and threads (4) Scratch inside the body Limit depth of scratch inside the body 0.1 mm ( 0.0039 in)

Fig. 9-156 Inspecting the pump body

Fig. 9-157 Contact trace of the gear tooth crest

2. Bushing (1) Contact of the bore sliding face (burnishing over about half of the inlet side is acceptable.)

(2) Scratch on the bore sliding face Bushing bore limit 23.7 mm (0.933 in)

Fig. 9-158 Contact trace of the bushing

(3) Contact at the side (Heavy contact at the inlet and slightly recognizable contact at the outlet are acceptable.)

(4) Scratch at the side Limit of axial length of the bushing 32.84 mm (1.29 in)

Fig. 9-159 Inspecting the bushing

-321-

9-62 3. Gear (1) Crack at the crest, and scratch on the side (2) Scratch and discoloration on the tooth surface (3) Scratch on the gear shaft Gear shaft limit diameter 23.7 mm (0.94 in) Note: Gear must be replaced as a gear set.

Fig. 9-160 Inspecting the gear

4. Seals (1) Backing ring torn or ruptured Caution: Body seals and bushing seals must be renewed after disassembly.

Fig. 9-161 Inspecting the seals

(2) Scratch and deformation of the lips on the oil seals for the mounting flange

Fig. 9-162 Oil seal inspection

-322-

9-63 ASSEMBLY 1. Clean parts, and dry with compressed air.

2. Apply a thin film of grease on parts.

(1) Body seal (2) Bushing seal (3) Oil seal lips 3. Insert two bushings to the body at the mounting flange side.

Note: Dowel must come at the inlet side.

Apply hydraulic oil inside the body.

Do not hammer in the bushings.

Install bushings in correct combination.

Install bushings correctly without creating a gap.

Fig. 9-163 Assembling the bushings

4. Assemble the drive gear and the driven gear.

(1) Reverse the body.

(2) Drive gear, driven gear.

Caution: Put the gears in the original position so the same tooth surfaces are engaged with each other as before.

5. Insert two bushings to the body at the cover side.

6. Assemble seals.

(1) Bushing seal (2) Backing ring (3) Body seal Caution: Install backing rings without overlapping at the center.

7. Place the mounting flange and the pump cover over the body, and tighten them with set bolts.

(1) Mounting flange (2) Pump cover

Fig. 9-164 Assembling the cover

(3) Set bolt T=4.7~4.96 kg-m (34~36 ft-lb) 8. Check the oil pump assembly.

(1) Secure the drive gear shaft in a vice.

(2) Turn the oil pump.

(3) The parts are assembled correctly if it turns smoothly. Re-disassemble the oil pump if it does not turn smoothly.

9. After completing assembly, fill the oil pump with hydraulic oil.

INSTALLATION Follow the procedure for Removal in the reverse order.

-323-

9-64 TESTING METHOD Caution: A strict testing needs a bench test. However, a bench test is not practical for actual servicing, and the oil

pump may be installed on the forklift to test output of the oil pump from movement of the lift cylinder.

1. Set a pressure gauge (200 kg/cm2) and a tachometer to the oil control valve.

2. Start the engine.

3. Run the engine at 500 to 1,000 rpm for ten minutes with the oil control valve lever in neutral position.

4. If the oil pump remains free of any troubles, run the engine for another ten minutes at 1,500 to 2,000 rpm.

Caution: If a trouble is found during step 3 or 4 above, stop the engine immediately, and disassemble the oil

pump again.

5. Check if the relief set pressure of the oil control valve is as specified. Refer to the section on Oil Control Valve Adjustment for detail.

6. Check if the engine speed is as specified. Refer to the section on Engine Speed Adjustment.

7. Lift cylinder speeds

-324-

9-65 PUMP DRIVE GENERAL

Fig. 9-165 Pump drive (2H engine model)

Fig. 9-166 Pump drive (2F engine model)

-325-

9-66 PUMP DRIVE SHAFT (2F ENGINE MODEL) COMPONENT PARTS

1.

2.

3.

4.

5.

6.

Flange yoke set plate Flange yoke Joint sub-assy (Spider) Coupling yoke Snap ring Spline yoke sub-assy

Fig. 9-167 Pump Drive Shaft Component Parts (2F Engine Model)

REMOVAL Note: See Engine removal section for pump drive shaft removal procedure.

To remove the pump drive shaft, remove the set bolts on both the oil pump side and the pump drive shaft side. Raise the oil pump and pull out the pump drive shaft.

Fig. 9-168 Removing the pump drive shaft

-326-

9-67 DISASSEMBLY 1. Stamp the matchmarks on the yoke and the drive shaft.

Fig. 9-169

Stamping the matchmarks

2. Remove the snap ring.

Fig. 9-170 Removing the snap ring

3. Remove the needle roller bearing cup.

(1) Pull out the needle roller bearing cup with the vice or the press by using the box wrench.

(2) Hold the needle roller bearing cup with the vice and remove the yoke by tapping.

4. Remove other needle roller bearing cups by the same procedure.

Fig. 9-171 Removing the bearing cup

5. Disassemble the needle roller bearing cup.

Fig. 9-172 Disassembling the bearing cup

-327-

9-68 INSPECTION Caution: Wash each part. Repair or replace any defective part.

Although some part can be disassembled, the service parts are not available. In this case,it is necessary to replace one assembly with a new one.

1. Spider (1) Clogging of the grease path (2) Deformation, crack, damage and wear

Fig. 9-173 Inspecting the pump drive shaft

2. Yoke (1) Deformation, crack, damage and wear 3. Universal joint piece (1) Deformation, crack, damage and wear 4. Needle roller bearing cup (1) Damage and fatigue of the oil seal lip (2) Deformation and rotational condition of the roller (3) Damage and crack of the cup

Fig. 9-174 Inspecting the needle roller

ASSEMBLY Reverse the disassembly procedure for assembly.

Caution: Pay attention to the inclination of the needle roller.

Apply MP grease sufficiently in the needle roller bearing cup.

Confirm the matchmarks. Assemble the spider, yoke and piece.

INSTALLATION Reverse the removal procedure for installation.

-328-

Fig. 9-175 Assembling the needle roller

9-70 GENERAL OIL CONTROL VALVE

Fig. 9-176 Oil control valve sectional view RELIEF VALVE

Fig. 9-177 Relief valve sectional view

-330-

9-71 TILT LOCK VALVE

Fig. 9-178 Tilt lock valve sectional view CHECK VALVE

Fig. 9-179 Check valve sectional view FLOW DIVIDER VALVE

Fig. 9-180 Flow divider valve sectional view

-331-

9-72 COMPONENT PARTS

1. Control valve assy 2. Bolt 3. Outlet housing 4. “O” ring 5. Backup ring 6. Steel ball 7. Spring 8. Tilt lock spool 9. Tilt lock stopper 10. Spring holder 11. Plate washer 12 Snap ring 13. Spring cover 14. Seal holder 15. Spool set 16. Plug

17. Plug 18. Body 19. Check plunger 20. Pilot relief valve 21. Collar 22. Relief valve piston 23. Orifice tuning wire 24. Valve seat 25. Stopper 26. Stopper 27. Flowdivider check valve 28. Stopper

Fig. 9-181 Oil control valve component parts

-332-

9-73

1. Knob 2. Tilt lever sub-assy 3. Lift lever sub-assy 4. Bracket, RH 5. Nylon bushing 6. Lever support pin

7. Pin 8. Boot 9. Rod 10. Bracket, LH 11. Boot

Fig. 9-182 Oil control lever component parts

-333-

9-74

Fig. 9-183 Hydraulic circuit diagram

SPECIFICATIONS

SPRING SPECIFICATIONS

-334-

9-75 REMOVAL 1. Remove the toe board.

(1) Open the engine hood.

(2) Rear toe board (3) Front toe board

Fig. 9-184 Removing the toe board 2. Disconnect the control lever.

(1) Peel up the boots.

(2) Cotter pin (3) Clevis pin

Fig. 9-185 Disconnecting the control lever 3. Disconnect the hydraulic piping and power steering piping.

Caution: Before removing the piping, set the mast at the neutral position, lower the forks fully to release the remaining pressure in the hydraulic mechanism piping.

Fig. 9-186 Disconnecting the piping 4. Remove the oil control valve.

(1) Set bolts (2) Oil control valve

Fig. 9-187 Removing the control valve

-335-

9-76 DISASSEMBLY Caution: ¡ Perform the operation in a clean place. ¡ Since each part is finished with high accuracy, do not scratch it.

1. Remove the seal holder.

(1) Set screws (2) Seal holder

Fig. 9-188 Removing the seal holder 2. Remove the spring cover.

(1) Set screws (2) Spring cover

Fig. 9-189 Removing the spring cover 3. Remove the lift spool and the tilt spool.

(1) Lift spool (2) Tilt spool

Fig. 9-190 Removing the lift and tilt spools 4. Disassemble the lift and tilt spools.

(1) Set SST 09610-10160-71 (2) Snap ring (3) Plate washer (4) Compression spring (5) Spring holder (6) Seal holder

Fig. 9-191 Disassembling the lift and tilt spools -336-

9-77 5. Remove the relief valve (1) Relief valve (2) Spring (3) Collar (4) Main plunger

Fig. 9-192 Removing the relief valve (5)

Stopper

Fig. 9-193 Removing the stopper (6)

Valve seat SST 09700-30200-71

Fig. 9-194 Removing the valve seat

6. Disassemble the relief valve.

(1) Lock nut (2) Adjustment nut (3) Adjustment screw (4) Spring (5) Needle valve

Fig. 9-195 Disassembling the relief valve

-337-

9-78 7. Remove the flow divider valve.

(1) Stopper (Upper side) (2) Stopper (Lower side) (3) Spring (4) Valve

Fig. 9-196 Removing the flow divider valve 8. Remove the check valve by using a hollow wrench.

(1) Plug (2) Spring (3) Check plunger

Fig. 9-197 Removing the check valve 9. Remove the outlet housing.

(1) Set bolts (2) Outlet housing

Fig. 9-198 Removing the outlet housing 10. Remove the tilt lock valve from the tilt spool.

(1) Secure the spool tip with a vice.

(2) Pass SST 09700-30200-71 through the tilt lock stopper to loosen it.

(3) Tilt lock stopper

Fig. 9-199 Removing the tilt lock stopper

-338-

9-79 (4) (5) (6) (7)

Spring Tilt lock plunger Spring Steel ball

11. Remove the nipple.

Fig. 9-200 Disassembling the tilt lock valve

INSPECTION Caution: Wash each part carefully. Repair or replace any defective part.

Although some part can be disassembled, the service part is not available. It is necessary to replace one assembly at a time.

1. Body and outlet housing (1) Sliding scratch of each spool (2) Stepped wear and crack of the check valve seat (3) Damage of each elbow and cap

Fig. 9-201 Inspecting the body

2. Spool (1) Damage of the lift spool (2) Damage of the tilt spool Note: Conduct the oil leak test to check the wear of the spool.

Fig. 9-202 Inspecting the spool 3. Relief valve (1) Stepped wear of the needle valve (2) Defect and damage of the valve seat (3) Fatigue of the spring

Fig. 9-203 Inspecting the relief valve

-339-

9-80 4. Tilt lock valve (1) Sliding conditions of the tilt lock plunger (2) Break and fatigue of the spring (3) Stepped wear of the steel ball

Fig. 9-204 Inspecting the tilt lock valve 5. Flow divider valve (1) Sliding conditions of the piston (2) Damage of the check valve (3) Break and fatigue of the spring

Fig. 9-205 Inspecting the flow divider valve 6. Check valve (1) Stepped wear of the check plunger (2) Break and fatigue of the spring

Fig. 9-206 Inspecting the check valve 7. Seal holder and spring cover (1) Break and fatigue of the spring (2) Damage of the seal holder and spring cover (3) Wear and damage of the seal holder oil seal.

Fig. 9-207 Inspecting the seal holder and spring cover

-340-

9-81 ASSEMBLY 1. Wash each part and blow it with compressed air.

2. Assemble the nipple.

Fig. 9-208 Assembling the nipple 3. Assemble the outlet housing.

(1) Outlet housing (2) Set bolts T = 3.5 4.5 kg-m (25.3 32.5 ftlb)

Fig. 9-209 Assembling the outlet housing 4. Assemble the tilt lock valve on the tilt spool.

(1) Steel ball (2) Spring (3) Tilt lock plunger (4) Spring (5) After applying lock tight (locking compound) to the tilt lock stopper, tighten it.

SST 09700-30200-71 Fig. 2-10 Assembling the tilt lock valve 5. Assemble the check valve.

(1) Check plunger (2) Spring (3) Plug

Fig. 9-211 Assembling the check valve

-341-

9-82 6. Assemble the flow divider valve.

(1) Valve (2) Spring (3) Stopper (Lower side) (4) Stopper (Upper side)

Fig. 9-212 Assembling the flow divider valve 7. Assemble the relief valve. Assemble the assembled relief valve on the control valve body.

Note: When disassembling the relief valve, be sure to loosen the adjusting screw fully.

(1) Relief valve (2) Spring (3) Collar (4) Main plunger (5) Valve seat (6) Stopper

Fig. 9-213 Loosening the adjusting screw

Fig. 9-214 Assembling the relief valve 8. Assemble the lift spool and the tilt spool on the control valve.

(1) Sea holder (2) Spring holder (3) Compression spring (4) Plate washer (5) Snap ring SST 09610-10160-71 Caution: Assemble the seal holder in the correct direction.

Fig. 9-215 Assembling the spool spring

-342-

9-83 (6) Lift spool (7) Tilt spool

Fig. 9-216 Assembling the spool 9.

Assemble the spring cover.

(1) Spring cover (2) Set screw

Fig. 9-217 Assembling the spring cover 10. Assemble the seal holder (1) Seal holder (2) Set screws Caution: Assemble the seal holder in the correct direction.

Fig. 9-218 Assembling the seal holder INSTALLATION Reverse the removal procedure for installation.

Note: o Install the toe board after making the adjustment. o Apply chassis grease special (molybdenum disulfide grease) to the links of the oil control valve lever.

-343-

9-84 ADJUSTMENT Caution: Be sure to make the adjustment according to the procedure given below. If not so, the hydraulic devices such as the oil pump may be damaged by improperly adjusted hydraulic pressure.

1. Remove the plug (PT 1/4) on the oil control valve top and mount the oil pressure gauge.

Fig. 9-219 Oil pressure gauge mounting position 2. Remove the cap nut of the relief valve on the oil control valve top to confirm that the relief valve adjusting screw is loosened fully. If not so, loosen it.

3. Start the engine to check oil leakage, abnormal sound, etc.

4. Set the control lever to lift position, and tighten the adjusting screw slowly until the forks start to rise. When the forks reach the uppermost position, read the oil pressure gauge indication. Adjust the set screw so that the oil pressure becomes normal.

Fig. 9-220 Measuring the hydraulic oil pressure

Note: o Confirm that the no-load static maximum rotational frequency is as specified. See Engine adjustment section for details. o When the hydraulic oil pressure exceeds the specified value, set the control lever to the neutral position immediately.

Fig. 9-221 Adjusting hydraulic oil pressure 5. After adjusting the hydraulic oil pressure, tighten the lock nut and the cap nut.

6. Remove the oil pressure gauge and mount the toe board.

Relief set pressure: 185 kg/cm² (2.630 psi)

-344-

10-2 SST LIST

-346-

10-3

-347-

10-4

-348-