Toyoto Battery Forklift 5FBCU15-30 Series Supplement Service Manual

This manual covers the service procedures for the modified portions of TOYOTA BATTERY FORKLIFT 5FBCU15

- 30 series. Please use this

manual for quick accurate servicing of these vehicles and as the tool for sales and service activities.

As this manual is edited as a supplement to Repair Manual for the 5FBCU15 - 30 series, please refer to Repair Manual (Pub. No.CU305) for the matters not covered herein.

This manual deals with the above models as of October 1999. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment Parts & Service News.

For your reference, we herewith indicate the titles of relevant manuals TOYOTA INDUSTRIAL EQUIPMENT REPAIR MANUAL 5FBCU15 - 30 (No.CU305)

TOYOTA MOTOR CORPORATION

SECTION INDEX NAME

I

SECTION

GENERAL DRIVE UNIT (2.3 TON SERIES) FRONT AXLE (2.3 TON S E R I E S ) REAR AXLE (2.3 TON SERIES) MAST (2.3TON SERIES) CYLINDER (2.3 TON SERIES) OIL CONTROL VALVE APPENDIX

GENERAL EXTERIOR VIEWS .......................................................0-2 VEHICLE MODEL .....................................................0-3 LUBRICATION CHART (2.3TON SERIES) ............. 0-4 PERIODIC MAINTENANCE ..........................................0-5 INFORMATION ON REFERENCE MANUAL ........... 0-6 MEANING OF LATEST MODIFICATION ON SFBCU 2 TON AND 3 TON SERIES ...................... 0-7

EXTERIOR VIEWS

VEHICLE MODEL Load Capacity Types on Spec.

Load center

Load center = 24in (Ibs)

36Vl48V

1500

3000

5FBCU15

1750

3500

5FBCU18

2000

4000

5FBCU20

2500

5000

5FBCU25

3000

6000

5FBCU30

2000

4000

5FBCHU20

2500

5000

5FBCHU25

1500

3000

30-5FBCU15

1750

3500

30-5FBCU18

2000

4000

30-5FBCU20

2500

5000

30-5FBCU25

3000

6000

30-5FBCU30

2000

4000

30-5FBCHU20

2500

5000

30-5FBCHU25

= 500mm

(kg) 1-ton series

STD capacity battery compartment STD spec. models

2-ton series

3-ton series High capacity

*

2-ton series

1-ton series

STD capacity battery compartment Dust proof models

2-ton series

3-ton series High capacity

*

2-ton series

Model

*: These high capacity (battery compartment) models are not established in EEC specification.

Note: Way and the position of the model and frame No. indications have been unchanged.

LUBRICATION CHART (2.3TON SERIES)

I* 2* 3* 4* 5 6 7 8 9 lo* 11* 12* 13*

Chain Mast support bushing Tilt cylinder front pin Front wheel bearing Differential & transmission Brake fluid reservoir tank Tilt steering locking mechanism Tilt steering universal joint Oil tank Rear wheel bealing Steering knuckle king pin Tie rod end pin Rear axle cylinder end pin Rear axle beam front pin Rear axle beam rear pin Located on right and left sides

lnspect every 8 hours (daily) lnspect every 40 hours (weekly) lnspect every 170 hours (monthly) lnspect every 1000 hours (6 monthly) lnspect every 2000 hours (annually) lnspect and service Replace MP grease Engine oil Hypoid gear oil Hydraulic oil Brake fluid Molybdenum disulfide grease

PERIODIC MAINTENANCE INSPECTION METHOD I: Inspection. Repair or replacement if required.

M: Measurement. Repair or adjustment if required.

T Retightening C: Cleaning L: Lubrication * : For new vehicle *1: Flaw detector Note:

This manual covers only the portions different from conventional models. Refer to the Repair Manual (No.CU305) for the maintenance of other portions.

Inspection Period Item

Months

1

3

6

12

Hours

170

500

1000

2000

TRAVELING EQUIPMENT Rear axle

Cracks, damage and deformation of beam Looseness of axle beam in vehicle longitudinal direction (2.3ton series: from October 1999)

I

0

M*

0

-

INFORMATION ON REFERENCE MANUAL 3n and after October 1999 products of 5FBCU series, choose the reference publication for proper servicng in accordance with the following instructions: 0: Applicable reference

-

5FBCU15 30 Repair manual Section

Remarks Pub. No. CU305

GENERAL

0

BAlTERY

0

CONTROLCIRCUIT

0

MULTIDISPLAYFUNCTIONS

0

ELECTRICAL SYSTEM TROUBLESHOOTING

0

MOTOR

0

1 ton series

This book

0

Refer to Parts & Service News GE-8031 of Dec. 1998.

0

DRIVE UNIT 2.3 ton series

1 ton series

0

0

FRONT AXLE 2.3 ton series 1 ton series

0 0

REAR AXLE 2.3 ton series

0

STEERING

0

BRAKE

0

BODY & FRAME

0

MATERIAL HANDLING SYSTEM

0

1 ton series

0

MAST 2.3 ton series Lift

1 ton series

0

0

2.3 ton series

CYLINDER

Tilt cylinder OIL PUMP

0 0 Refer to Parts & Service

0

News GE-8024 of Oct. 1998 OIL CONTROLVALVE APPENDIX

0

0

0

MEANING OF LATEST MODIFICATION ON 5FBCU 2 TON AND 3 TON SERIES Accompanied by the model change - Development to 7FGCU 2 ton & 3 ton series from GFGCU 2 ton & 3 ton series -, several new design features of 7FGC 2 ton & 3 ton series have also been adapted for 5FBCU 2 ton & 3 ton series. As the effect that, several components have been standardized for the developments as well as for service efficiencies and conveniences.

The major components involved are tabulated as follows:

Standardization between model series Meaning of Marks Used for List item 0 Standardized between 5FBCU series and 7FGCU series, or interchangeable.

Partly standardized between 5FBCU series and 7FGCU series, or Partly Interchangeable. x Exclusively for 5FBCU series 1

Components Mast Assembly

V.FV.FSV.QFV

Front axle

Differential housing

2 ton series

3 ton series

x

x x

Axle housing

0

0

Axle bracket

0

0

Axle shaft

0

0

Wheel bearing

0

0

Wheel & hub drum

0

0

Differentialcase Rear axle

Rear axle beam

Forks Seat belt

0

0

Rear axle cylinder

0

Tie rod

0

Steering knuckle

0

Wheel bearing

0

Mount rubber or bushing Tire size

0

0

0

Front tire

x

Rear tire

0 0

0

0

DRIVE UNIT (2.3TON SERIES) GENERAL ........................................................................ page 1-2

SPECIFICATIONS .......................................................... 1-3

COMPONENTS .............................................................. 1-4 DRIVE UNIT ASSY ......................................................... 1-5 REMOVAL*INSTALLATION............................................... 1-5

DISASSEMBLY*INSPECTION*REASSEMBLY ................... 1-8

DIFFERENTIAL CASE ASSY ....................................... 1-14 DISASSEMBLY-INSPECTION-REASSEMBLY.................. 1-14

m

GENERAL

SPECIFICATIONS Vehicle Series Item

2 ton Series

STD

3 ton Series

Dustproof

STD

Dustproof

Ring gear teeth

35

+

Drive pinion teeth

6

C

5.833

+

4

+-

Gear ratio (Differential) Number of gears Pinion gear Teeth

10

C

Number of gears

2

+

Teeth

14

+

Side gear Drive gear teeth

22

17

22

17

Output gear teeth

60

65

60

65

2.727

3.824

2.727

3.824

Gear ratio (Transmission) Drive unit oil capacity

J? ( (US gal)

7.5 (1.98)

C

COMPONENTS

DRIVE UNIT ASSY REMOVAL-INSTALLATION T = N-m (kgf-cm) [ft-lbfl

Removal Procedure 1

Remove the mast. (See page 4-7)

2

Remove the battery hood Wldriver seat.

3

Remove the battery ASSY.

4

Jack up the vehicle and remove the front wheels.

5

Drain differential oil. [Point 11

6

Disconnect the drive motor wiring.

7

Disconnect the speed sensor sub-harness connector.

8

Disconnect the brake pipe (from the wheel cylinder).

9

Remove the front toe-board.

10

Disconnect the parking brake wires.

11

Remove the drive motor set bolts.

12

Support the front axle & drive motor ASSY with a hoist and garage jack. [Point 21

13

Remove the front axle bracket set bolts. [Point 31

14

Remove the front axle & drive motor ASSY.

15

Disconnect the drive unit and drive motor

16

Remove the front axle shaft. [Point 41

17

Remove the front axle housing Wlbrake.

18

Remove the speed sensor cover and the sensor.

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

Note: Bleed air from the brake system after installation.

Point Operations [Point 11 Installation: After reassembly, fill hypoid gear oil to the specified level.

A = 15 mm (0.59 in) or less

[Point 21 Removal.lnstallation: Install hub nuts on hub bolts on the left and right side, and sling wire at the tapered portion.

[Point 31 Removal: Remove the reamer bolts. (2 pcs. each at top and bottom on one side) SST 09310-23320-71

[Point 41 Removal.Installation: Operate carefully so as not to bring the axle shaft into contact with the oil seal lip to damage it.

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

Disassembly Procedure 1

Remove the differential cover. [Point 11

2

Measure the ring gear backlash. [Point 21

3

Remove the bearing cap and adjusting nut. [Point 31

4

Remove the differential case ASSY. (See page 1-1 4 for the disassembly, inspection and reassembly procedure.)

5

Remove the drive pinion ASSY. [Point 41

6

Remove the output gear. [Point 51

7

Remove the drive pinion, bearing, spacer and shim from the retainer. [Point 61

8

Remove the pilot bearing. [Point 71

9

Remove the drive pinion bearing inner race. [Point 81

10

Remove the drive gear

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

Point Operations [Point 11 Reassembly: Apply sealing agent (Three Bond's No.1217C or the equivalent) on the mating surfaces of the differential cover and housing before reassembly.

[Point 21 Inspection: Measure the ring gear backlash.

-

-

Standard: 0.2 0.3 mm (0.008 0.012 in)

[Point 31 Disassembly: Put match marks on the bearing cap and differential housing.

Reassembly: Install the adjusting nuts and bearing cap.

1, Install the adjusting nuts.

2. Install the bearing cap by aligning the match marks and temporarily tighten the set bolt.

T = 19.6 N-m(200 kgf-cm) [I4.5 ft-lbf] 3. Set the dial gauge in the thrust direction of the differential case.

4. Use the SST and tighten until the thrust clearance is eliminated.

SST 09630-10110-71 5. Tighten adjusting nuts on both sides by one notch each.

6. Set the dial gauge vertical to the ring gear tooth surface, and measure the backlash.

Standard: 0.2

- 0.3 mm (0.008 - 0.012 in)

If the standard is not satisfied, adjust by turning the adjusting nut to move the differential case ASSY in the thrust direction.

(1) When the backlash is excessive: Loosen the adjusting nut on the ring gear teeth side and tighten the adjusting nut on the rear side as much to bring the ring gear closer to the drive pinion.

(2) When the backlash is insufficient: Loosen the adjusting nut of the rear side of the ring gear and tighten the adjusting nut on the teeth side as much to bring the ring gear away from the drive pinion.

7. Side bearing starting torque (Reference only): Measure the torque by turning the output gear lock nut with a torque wrench.

Standard: 6.37 15.20 N-m(65 155 kgf-cm) [4.70 11.21 ft-lbf] 8. Tighten the adjusting nut on the rear side of the ring gear further by 1.5 to 2 notches.

9. Install the adjusting nut lock plate.

10.Finallytighten the bearing cap set bolts.

T = 117.7 137.3 N-m(1200 1400 kgf-cm) [86.82 101.3 ft-lbfl 11. Check the tooth contact.

(1) Uniformly coat red lead thinly on both faces of 7 to 8 gear teeth, and turn the ring gear forward and backward several times after installing a box wrench on the output gear lock nut. Judge the gear teeth contact by observing the pattern formed on the gear teeth. If the tooth contact is not correct, make adjustment according to the "Drive Pinion Protrusion Adjustment" and "Ring Gear Backlash and Differential Case Bearing Starting Torque Adjustment" procedures.

-

-

Heeal contact

-

-

-

(2) Correct teeth contact The pattern should be slightly leaning to the inside circle of the ring gear with respect to the center of the tooth length, as shown.

(3) Heeal contact Move the drive pinion croser to the ring gear by decreasing the drive pinion adjusting shim thickness.

Then move the ring gear away from the pinion to adjust the backlash.

(4) Toe contact Move the pinion away from the ring gear by increasing the drive pinion adjusting shim thickness. Then move the ring gear closer to the pinion to adjust the backlash.

Flank contact

Face contact

(5) Flank contact (low shallow contact) Move the pinion awayfrom the ring gear by increasing the drive pinion adjusting shim thickness. Then move the ring gear closer to the pinion to adjust the backlash.

(6) Face contact (high shallow contact) Move the pinion closer to the ring gear by decreasing the drive pinion adjusting shim thickness. Then move the ring gear away from the pinion to adjust the backlash.

[Point 41 Reassembiy: Adjust the drive pinion protrusion by means of the drive pinion bearing retainer shims. Select the shim by teeth contact inspection. (See Point 3.)

Shim thickness: 0.10.0.15.0.35 and 0.45 mm (0.0039~0.0059~0.0138 and 0.0177 in)

0

Good examples

0

[Point 51 Reassembly: After the drive pinion bearing starting torque adjustment, caulk the output gear lock nut.

Point contact

[Point 61 Reassembly: SST 09370-20270-71

Reassembly: Adjust the drive pinion bearing starting torque.

1. Install the output gear and tighten the lock nut to the specified torque.

2. Set a torque wrench on the lock nut, and measure the starting torque.

Starting torque: 10.79 13.24 N-m (110 135 kg-cm) [7.96 9.77 ft-lb]

-

3. If the starting torque does not satisfy the standard make adjustment by changing the shim thickness.

Shim thickness: 0.03.0.1 0.0.15.0.35 and 0.45 mm (0.0012~0.0039~0.0059~0.0138 and 0.0177 in)

[Point 71 Disassembly: SST 09950-40011 SST

Reassembly: Use the SST and install the pilot bearing.

SST 09608-04031 Check the installed direction.

[Point 81 Disassembly: SST 09420-23000-71

Reassembly: SST 09316-60011

DIFFERENTIAL CASE ASSY DISASSEMBLYINSPECTION-REASSEMBLY

Disassembly Procedure 1

Remove the differential case bearings. [Point I ]

2

Remove the differential upper case. [Point 21

3

Remove the side gear and pinion gear. [Point 31

4

Remove the ring gear. [Point 41

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

T = N-m (kgf-cm) [ft-lbfl

Point Operations SST

,

SST @

a

[Point I] Disassembly: SST 09950-40011 --- @ 09950-60010 --- @

Reassembly: Install the side bearing.

1. Use the SST and drive in the side bearing to the end surface.

SST 09950-60020 --- O 09950-70010 --- @ 2. Use a striking driver and fully drive in the bearing.

[Point 21 Disassembly-Reassembly: Check the match marks.

Match marks

Reassembly: Apply locking agent (08833-00070) on the set bolt threaded portion before reassembly.

[Point 31 Inspection: Measure the inside diameter of the differential pinion.

Standard: 22.12 mm(0.8709 in) Limit: 22.22 mm(0.8748 in)

Inspection: Measure the spider outside diameter Standard: 22.00 mm(0.8661 in) Limit: 21.75 mm(0.8563 in)

Inspection: Measure the side gear thrust washer thickness.

Standard: 1.6 mm (0.063 in) Limit: 1.3 mm (0.051 in)

Inspection: Measure the pinion gear thrust washer thickness.

Standard: 1.6 mm (0.063 in) Limit: 1.0 mm (0.039 in)

Reassembly: Install the side gear thrust washer with its oil groove facing the gear.

Reassembly: Apply chassis grease (molybdenum disulfide grease) on both sides of the spider pinion thrust washer before reassembly.

[Point 41 Reassembly: Apply locking agent (08833-00070) on the set bolt threaded portion before reassembly. Tighten the set bolts gradually in the diagonal order, and finally tighten in the circular order to the specified torque.

FRONT AXLE (2.3TON SERIES) Page

GENERAL ........................................................................ 2-2 SPECIFICATIONS .......................................................... 2 9 COMPONENTS .............................................................. 2 4 FRONT AXLE SHAFTmAXLE HUB ............................. 2-5 REMOVAL*INSTALLATION...............................................2-5 FRONT AXLE BRACKETmAXLE HOUSING ............ 2-9 REMOVAL*INSTALLATION............................................... 2-9

2-2

GENERAL 2 ton series

3 ton series

SPECIFICATIONS Vehicle model 2 ton series

3 ton series

Item Front axle type

Full-floating

+ +

Suspension type

Fixed to frame

+

Axle shaft diameter

mm (in)

40 (1.57)

+

Axle shaft diameter (spline portion)

mm (in)

40 (1.57)

e

COMPONENTS 2 ton series

3 ton series

FRONT AXLE SHAFTeAXLE HUB REMOVAL- INSTALLATION

T = N.m (kgf-cm) [I?-lbfl

Removal Procedure 1

Drain differential oil. [Point I]

2

Jack up the vehicle and remove front wheel

3

Remove the front axle shaft. [Point 21

4

Remove the axle shaft oil seal. [Point 31

5

Remove the bearing lock nut and plate. [Point 41

6

Remove the outer bearing roller and front axle hub. [Point 51

7

Remove the oil seal and inner bearing roller. [Point 61

8

Remove the bearing outer race. [Point 71

9

Remove the hub bolt.

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

Note: Apply thread tightener (08833-00070)on the hub bolt set nut before tightening.

Point Operations [Point I ] Installation: Fill Hypoid gear oil to the specified level after installation.

A = 15 mm (0.59 in) or less

[Point 21 Removal.lnstallation: Carefully operate so as not to damage the oil seal by contact with the axle shaft.

[Point 31 Removal: SST 09320-23000-71

Installation: SST 09950-60010 --- O 09950-70010 --- @

[Point 41 Removal.Installation: SST 09509-55020

Installation: Adjust the front axle hub starting force.

1. Install the plate.

2. Fully tighten the bearing lock nut, and rotate the hub by 4 to 5 turns to run in the bearing.

3. Return the bearing lock nut by 1/12 to 116 turn (30 to 60°), and rotate the hub by 4 to 5 turns again.

4. Set a spring scale on a hub bolt, and measure the starting force.

Standard: 25.5

- 72.6 N (2.6 - 7.4 kg9 [5.7 - 16.3 Ibf]

5. If the standard is not satisfied, adjust the degree of bear-

ing lock nut tightening for adjustment.

6. Install the nut lock bolt.

Coat thread tightener (08833-00070) on the nut lock bolt before tightening.

[Point 51 Installation: Fill MP grease in the hub before installing the front axle hub.

Installation: SST 09370-10410-7 1

[Point 61 Removal: Use a screwdriver or the like to remove the oil seal.

Installation: SST 09950-60020 --- @I 09950-70010 --- @

[Point 71 Removal: Use a brass bar to remove the bearing outer race.

Installation: SST 09950-60020 --- @I 09950-70010 --- @

FRONT AXLE BRACKET*AXLEHOUSING T = N.m (kgf-cm) [ft-lbfl

REMOVAL.INSTALLATION

T = 265

- 343 (2700 - 3500) [195.3 - 253.21

-

-

T = 107.9 137.3 (1100 1400) 179.59

T = 118

- 137 (1200 - 1400) [86.8 - 101.31

Removal Procedure 1

Remove the front axle & drive motor ASSY. (See page 1-5)

2

Remove the front axle shaft and axle hub. (See page 2-5)

3

Remove the brake ASSY. [Point 11

4

Remove the front axle bracket and O-ring.

5

Remove the axle hosing and O-ring.

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

Note: Apply grease on the O-ring before installation.

- 101.3]

Point Operations [Point I ] Installation: Apply sealing agent (08826-00080) on the mating surfaces of the brake backing plate and front axle bracket before installation.

Installation: Apply locking agent (08833-00070) on the set bolts before tightening.

REAR AXLE (2.3TON SERIES) Page

GENERAL ........................................................................3-2

SPECIFICATIONS .........................................................3-3 COMPONENTS ..............................................................3 9 REAR AXLE ASSY ....................................................... 3-5

...............................................3-5 STEERING KNUCKLE .................................................. 3-7 REMOVALINSTALLATION............................................... 3-7 REAR AXLE CYLINDER ...............................................3-11 REMOVAL*INSTALLATION............................................... 3-11 .................. 3-13 DISASSEMBLVINSPECTION~REASSEMBLY REAR WHEEL ALIGNMENT ....................................... 3-15 REMOVAL*INSTALLATION

GENERAL

Rear Axle Cylinder

SPECIFICATIONS Rear axle type

Elliot type

Rear axle suspension type

Center-supported right-left rocking type Toe-in

mm (in)

0 (0)

Camber

degree

1.5"

Caster

degree

0"

Wheel alignment 0"

King pin angle

Minimum turning radius (outermost)

mm (in)

1740 (68.5)

5FBCU20,30 - 5FBCU20

1765 (69.5)

5FBCU25,30 - 5FBCU25

1790 (70.5)

5FBCU30,30 - 5FBCU30

1960 (66.0)

5FBCHU20,30- 5FBCHU20

1920 (75.5)

5FBCHU25,30 - 5FBCHU25

1940 (76.0)

Double acting

Cylinder type Rear axle cylinder

5FBCU18,30 - 5FBCU18

Piston rod outside diameter mm (in)

50.0 (1.969)

Cylinder bore

76.0 (2.992)

mm (in)

COMPONENTS

4302 I

I

L...

a .

4302-024

REAR AXLE ASSY REMOVAL- INSTALLATION

T = N-m (kgf-cm) [ft-lbfl

Removal Procedure 1

Remove the counter weight.

2

Apply the parking brake and chock the front wheels.

3

Jack up the frame and support it with the wooden block.

4

Remove the rear wheels (See removal procedure steps 2 to 4 in steering knuckle removal section on page 3-7).

5

Disconnect the rear axle cylinder hose.

6

Support the rear axle ASSY with a garage jack.

7

Remove the rear axle ASSY. [Point I]

8

Remove the center pin bushing. [Point 21

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

Note: After installation, add grease through each grease fitting. Add genuine molybdenum disulfide grease at the rear axle beam center pins (two places). Use MP grease to other grease fittings.

Point Operations [Point I ] Inspection: Measure the rear axle front to rear clearance.

1. Before removing the rear axle ASSY, measure the front to rear clearance on the rear side.

Standard clearance: 0.7 mm (0.028 in) or less 2. If the measured value does not satisfy the standard, remove the rear axle ASSY and make adjustment by selecting the spacer.

I

L I

I

:

t

j First I Second

Spacer thickness: 1.2.2.3.3.0.3.5.4.0.4.5 and 5.0 mm (0.047~0.091~0.118~0.138~0.157~0.177 and 0.1 97 in)

3, Install the spacer at the rear side center pin.

The first spacer shall be installed with its chamfered at the inside diameter in contact with the center pin boss.

; I

[Point 21 Inspection: Inspect the inside diameter of the rear axle center pin bushing.

Limit: 52.0 mm (2.047 in)

Installation: Apply molybdenum disulfide grease on the bushing and install the bushing by aligning the grease groove in the bushing with the grease fitting position.

-rI

I I

Grease fitting

STEERING KNUCKLE REMOVAL-INSTALLATION

Removal Procedure 1

Jack up the vehicle.

2

Remove the hub cap. [Point 11

3

Remove the castle nut and claw washer. [Point 21

4

Remove the outer bearing and rear wheel. [Point 31

5

Remove the bearing outer race from the rear wheel. [Point 41

6

Remove the inner bearing roller and oil seal. [Point 51

7

Disconnect the tie rod (on the knuckle side).

8 9 10 11

Remove the king pin cover.

Remove the king pin lock bolt and king pin. [Point 61 Remove the thrust bearing, spacer and steering knuckle.

Remove the king pin oil seal and needle roller bearing. [Point 71

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

Note: After installation, add MP grease through grease fittings.

T = N-m (kgf-cm) [ft-lbfl

Point Operations [Point 11 Installation: Fill MP grease in the hub cap, and install by tapping the flange portion.

[Point 21 Installation: Adjust the rear wheel starting force.

1. Install the claw washer in the correct direction.

2. Install the castle nut and temporarily tighten it to a torque of 15 to 32 N-rn(150 to 330 kgf-cm) [I 0.9 to 23.9 ft-lbfl.

3. Rotate the hub by 3 to 5 turns to run in the bearing.

4. Set a spring scale at the outer periphery of the wheel, and measure the starting force.

Standards: 9.8

- 29 N (1.0 - 3.0 kg9 [2.2 - 6.6 Ibf]

5. If the standard is not satisfied, adjust the degree of castle nut tightening for adjustment.

6. Install a new cotter pin.

[Point 31 Installation: Fill MP grease in the hub and knuckle spindle.

Installation: Install the rear wheel and outer bearing.

SST 09370-20270-71

[Point 41 Removal: Use a brass bar and remove the bearing outer race Installation: SST 09950-60020 --- @ 09950-7001 0 --- @

SST

[Point 51 Removal: SST 09950-40011

Installation: Install the oil seal and inner bearing roller.

1. Use the SST and install the oil seal.

SST 09370-10410-71

2. Use the SST and install the inner bearing roller.

SST 09370-20270-71

[Point 61 Inspection: Measure the king pin outside diameter Limit: 27.8 mm (1.094 in)

Installation: Measure the steering knuckle starting force.

1. Temporarily install the king pin and king pin lock bolt.

Select the spacer so as to minimize vertical looseness of the knuckle, and install it on top of the thrust bearing.

2. Set a spring scale at the tip end of the knuckle spindle, and measure the starting force.

Standard: 19.3 N (2.0 kgf) [4.4 Ibf] or less

3. If the standard is exceeded, check the king pin for bend, the needle bearing for damage and axle beam for deformation.

Spacer thickness:3.0,3.5,4.0 and 4.5 mm (0.118,0.138,0.157 and 0.177 in) 4. Tighten the lock nut for the king pin lock bolt.

[Point 71 Removal: Remove the king pin oil seal and needle roller bearing.

1. Use a straight-edge screwdriver to remove the dust seal and oil seal.

2. Use the SST and remove the needle roller bearing.

SST 09950-60010 --- @ 09950-70010 --- @

Installation: Install the needle roller bearing and king pin oil seal.

1. Use the SST and install the needle bearing.

Check the needle roller bearing press-fitting surface, pressing direction and installation depth.

SST 09950-60010 --- @ 09950-70010 --- @ 2. Install the dust seal.

3. Use the SST and install the oil seal.

SST 09950-60010 --- O 09950-70010 --- @

0 rnrn (0 in)

4 rnrn

(0.16 in)

M

Press-fitting direction

3-11

REAR AXLE CYLINDER REMOVAL0lNSTALLATlON

Removal Procedure 1

Jack up the vehicle.

2

Disconnect the tie rod (on the piston rod side). [Point 11

3

Disconnect the rear axle cylinder hose and remove the fitting. [Point 21

4

Remove the rear axle cylinder.

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

T = N-m (kgf-cm) [ft-Ibfl

Point Operations [Point 11 Removal: Mark the punch mark position on each of cylinder end pins LH and RH. Installation: Install each cylinder end pin by aligning the punch mark with the mark.

[Point 21 Installation: Install the fitting in the illustrated direction.

DISASSEMBLY*lNSPECTIONgREASSEMBLY

Disassembly Procedure 1

Remove the through bolt.

2

Remove the piston rod guide.

3

Remove the piston rod. [Point I ]

4

Inspect the cylinder. [Point 21

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

Note: Coat hydraulic oil before reassembly.

T = N-m (kgf-cm) [ft-Ibfl

Point Operations [Point I ] Inspection: Measure the piston rod outside diameter.

Limit: 49.92 mm (1.9654 in)

Inspection: Measure the bend of the piston rod.

Limit: 0.5 mm (0.020 in) Reassembly: Warm the seal ring to a little below 80°C (176°F) in hot oil or water before installation.

Do not stretch it excessively.

Caution: Operate carefully to avoid scalding.

[Point 21 Inspection: Measure the rear axle cylinder bore.

Limit: 76.35 mm (3.0059 in)

REAR WHEEL ALIGNMENT Toe-in Inspection 1.

Check to see that dimensions Ar and A! of the rear axle cylinder are equal.

2.

Measure the toe-in (Bf - Br).

Standard: 0 + 4 mm (0 + 0.16 in)

Toe-in Adjustment

Punch mark on plate side

Punch mark on cylinder end pin side

1. Check to see that Ar and A! of the rear axle cylinder are equal.

2. Align the punch mark on the cylinder end pin (eccentric pin) with the punch mark on the plate on the front side for both the LH and RH sides.

3. Measure and adjust the toe-in (Bf - Br).

Standard: 0 + 4 mm (0 + 0.16 in) If the standard is not satisfied, make adjustment by the cylinder end pin in the range where the difference between Rt and Rr is within 0 t 3 mm (0.12 in). ( I ) When measued value > 4 mm (0.16 in): Measure Rt and Rr, and adjust the cylinder end pin on the smaller side toward IN. (2) When measured value < 4 mm (0.16 in): Measure Rt and Rr, and adjust the cylinder end pin on the greater side toward OUT. Note: If Rt equals to Rr, adjust the same amount on the LH and RH sides.

If the standard is not attained by adjustment on one side, make adjustment also on the other side.

4. Install the plate. The plate can be installed with either face UP. 5. After adjustment, fully steer the tires and check to see that they do not come into contact with the vehicle body.

MAST (2.3TON SERIES) Page

V MAST ASSY................................................................. 4-2

............................................................... 4-2 REMOVAL*INSTALLATION ............................................... 4-5 REMOVAL-INSTALLATION (WJLIFTBRACKET) .............. 4-7 MAST DISASSEMBLY*INSPECTION*REASSEMBLY........ 4-9 COMPONENTS

LlFTBRACKET DISASSEMBLY-INSPECTIONREASSEMBLY

............................................................. 4-11 MAST ADJUSTMENT (V MAST) ....................................... 4-13 MAST ROLLER REMOVAL-INSTALLATION ..................... 4-18 CHAIN .............................................................................4-19 INSPECTION .................................................................... 4-19 REASSEMBLY O/.FV*FSV)............................................... 4-19 REASSEMBLY (Q FV) ....................................................... 4-20 ADJUSTMENT ................................................................ 4-21 FORK................................................................................. 4-21 REMOVAL ........................................................................4-21 INSTALLATION ................................................................. 4-21 INSPECTION .................................................................... 4-21

FV*FSV MAST ASSY .................................................... 4-22 COMPONENTS ................................................................ 4-22 MAST ADJUSTMENT (FVFSV) ....................................... 4-25

QFV MAST ASSY .......................................................... 4-29 COMPONENTS ................................................................ 4-29 MAST ADJUSTMENT (an/)............................................. 4-31

LlFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING) ................. 4-33

V MAST ASSY COMPONENTS

6301

2 ton series V

FV

FSV

QFV

-

40

02

40 6301-467A

6301

3 ton series V

FV

02

6301-465

6302

3 ton series

6302-298

-

-

-

-

-

REMOVAL*INSTALLATION

T = N-m (kgf-cm) [ft-lbfl

Removal Procedure 1

Set the mast vertical and fully lower the fork.

2

Disconnect the chain. [Point 11

3

Remove the chain wheel. [Point 21

4

Remove the lift bracket. (For lift bracket removal, raise the inner mast until it comes off from the lift bracket, and slowly run the vehicle backward to depart from the lift bracket.)

5

Remove the toe board.

6

Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the inner mast, operate the lift lever several times to release the residual pressure in the lift cylinder.)

7

Slightly hoist the mast.

8

Remove the mast support cap.

9

Remove the tilt cylinder front pin. [Point 31

10

Remove the mast ASSY.

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

Note: Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior surfaces. Apply MP grease to the tilt cylinder front pin.

Adjust lift cylinder uneven movement when the mast ASSY, outer mast, inner mast or either lift cylinder is replaced. (See page 4-34.)

Adjust the chain tension after installation.

Point Operations [Point I ] Removal-Installation: SST 09630-23600-71

[Point 21 Removal: If the fitting is hard, use the SST for removal.

SST 09950-40011

[Point 31 Removal: SST 09810-20172-71

REMOVAL. INSTALLATION (WILI FT BRACKET)

T = N-m (kgf-cm) [ft-lbfj

Removal Procedure 1

Set the mast vertical.

2

Remove the forks.

3

Remove the toe board.

4

Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the inner mast and operate the lift lever several times to release the residual pressure from the lift cylinder.)

5

Slightly hoist the mast.

6

Remove the mast support cap.

7

Remove the tilt cylinder front pin. [Point I]

8

Remove the mast ASSY W/lift bracket.

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

Note: Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior surfaces. Apply MP grease to the tilt cylinder front pin.

Correct lift cylinder uneven lifting, if any, when the mast ASSY, outer mast, inner mast or either lift cylinder is replaced. (See page 4-33.)

Point Operation [Point I ] Removal: SST 09810-20172-71

MAST DISASSEMBLY-INSPECTION-REASSEMBLY

Disassembly Procedure 1

Remove the hose cover.

2

Disconnect the high pressure hose.

3

Remove each cylinder rod end set bolt, and take each rod end off. [Point 11

4

Remove each cylinder support. [Point 21

5

Remove each cylinder bottom set bolt, and remove each lift cylinder.

6

Slide the inner mast in the lowering direction, and remove the lift rollers.

7

Remove the mast strip. [Point 31

8

Remove the outer mast.

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

Shim

Point Operations [Point I ] Disassembly: Shim adjustment is made at the lift cylinder rod end for preventing uneven lifting by lift cylinders LH and RH. Take a note on the cylinder where the adjustment is made and the number of shims in use.

[Point 21 Disassmbly: Take a note on the number of cylinder support shims in use.

Reassembly: Make cylinder support shim adjustment if the mast or either cylinder is replaced.

With the cylinder rod end inserted to the inner mast, insert shim(s) between the cylinder support and outer mast to eliminate the clearance. The shim thickness should be slightly greater than the clearance.

[Point 31 Inspection: Measure the mast strip thickness.

Thickness limit: A = 2.7 mm (0.106 in) B = 1.3 mm (0.051 in)

LIFTBRACKET DISASSEMBLY*INSPECTION*REASSEMBLY

Disassembly Procedure 1

Remove lift rollers. [Point 11

2

Remove side rollers. [Point 21

3

Remove the back rest.

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

Point Operations [Point I ] Disassembly:

SST 09950-4001 1

T = N-m (kgf-cm) [ft-lbfl

[Point 21 Reassembly: Install the side roller in the correct direction.

The side chamfered with a greater radius of the roller shall be on the front side of the vehicle.

MAST ADJUSTMENT (V MAST) Lift Roller Adjustment at Mast

1.

Clearance between inner mast roller and outer mast

;::rJ Inner mast

into

These ;oilers

Adjust the mast overlap to approx. 450 mm (17.72 in).

Shift the inner mast to one side to bring the roller into contact with the outer mast, and inspect the clearance between the roller side face and mast where they are the closest.

Standard: A = 0

- 0.8 mm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the inner mast roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

I Shim

(3) Distribute shims equally to the rollers on the left and right side.

(4) After the adjustment, see that the inner mast moves smoothly in the outer mast.

2.

Clearance between outer mast roller and inner mast

These rollers

Outer mast

inner mast

Adjust the mast overlap to approx. 450 mm (17.72 in).

Shift the inner mast to one side to bring the roller into contact with the outer mast, and inspect the clearance between the roller side face and mast where they are the closest.

Standard: B = 0

- 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the outer mast roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) Distribute shims equally to the rollers on the left and right side.

(4) After the adjustment, see that the inner mast moves smoothly in the outer mast.

4-15 Roller Adjustment at Lift Bracket 1.

Middle/lower lift roller and side roller clearance adjustment

11

100 rnrn (3.94 in)

:$tif lnner mast

bracket

100 rnrn (3.94 in)

lnner mast

bracket

(1) Bring the center of the side roller in the upper part of the lift bracket to approx. 100 mm (3.94 in) from the top of the inner mast.

(2) Remove side rollers.

(3) Shift the lift bracket to one side to bring the roller into contact with the inner mast, and inspect on the opposite side the clearance between the roller side face and the mast where they are the closest. (No adjustment is necessary for the upper lift rollers since they are fastened by snap rings.)

Standard C = 0 0.5 mm (0 0.020 in)

-

-

If the standard is not satisfied, make adjustment by changing the lift roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(4) Distribute shims equally to the left and right side.

(5) Install side rollers.

(6) After adjusting the middle and lower lift rollers, bring the

side roller on one side into contact with the outer mast and measure on the opposite side the clearance between the side roller and inner mast surface.

Standard D = 0 0.5 mm (0 0.020 in)

-

-

If the standard is not satisfied, make adjustment by changing the side roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in) 7) Distribute shims equally to the left and right side. (See

Lift Bracket Disassembly-Inspection-Reassembly section for the side roller installation method. Shim replacement is possible on the vehicle.)

(8) After the adjustment, see that the lift bracket moves smoothly over the entire length of the mast.

Mast Strip Adjustment

1.

Mast strip clearance adjustment -

-

Roller

Bring into contact

Outward

Note: The strip is of tapered shape, thicker side of the width must be placed outward.

(1) Lower the inner mast fully.

(2) With the inner mast in contact with the outer mast roller, measure the clearance between the mast strip and inner mast.

Standard: E = 0.5

- 1.0 mm (0.020 - 0.039 in)

If the standard is not satisfied, make adjustment by changing the mast strip shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in) (3) After the adjustment, check the mast for smooth movement.

MAST ROLLER REMOVAL-INSTALLATION 1.

2.

3.

I

4.

Shim

5.

Remove the lift bracket. (See steps 1 to 4 of the mast ASSY removal procedure on page 4-5.)

Jack up the vehicle, and support tires with wooden blocks.

Also lock the front and rear tires from rotation.

Remove the lift cylinders. (See page 5-11.)

Remove mast rollers.

(1) Remove wooden blocks under the inner mast, and lower the hoisted inner mast slowly until mast rollers appear.

(2) Support the bottom of the inner mast with wooden blocks.

(3) Remove the inner mast rollers and shims.

(4) Remove the outer mast rollers and shims.

The installation procedure is the reverse of the removal procedure.

CHAIN INSPECTION 1.

lnspect the chain elongation according to the following procedure: SST 09631-22000-71 (1) Since the SST measurement line varies with the chain type, set the corresponding line on the chain as illustrated.

(2) Check the number of the chain to be inspected, and check the pin center position.

If the pin center is at the arrow mark on the chain gauge, it is the limit.

Chain Link Pitch Standard (V.FV.FSV.QFV) Vehicle model

Pitch mm (in)

Type

Chain No.

19.05 (0.7500)

BL634

60

3 ton series

25.4 (1 .O)

BL823

80

QFV outer chain

25.4 (1 .O)

BL834

80

2 ton series QFV inner and middle chain

Note: Perform measurement without removing the chain from the vehicle. lnspect elongation over the entire chain length since it may be localized.

REASSEMBLY O/.FV0FSV) 1.

Installing direction -

mast and portion

FV: Lift bracket FSV: Lift bracket

V: Lift bracket

Outside of vehicle

0

Rear of vehicle

'

Install with the split pin on the vehicle center side.

0

Split pin

Split pin

Sketch

2.

FSV: Inner mast

Install with the split pin on the vehicle outside.

Install with the split pin on the vehicle rear side.

Chain adjusting nut tightening order (1) Tighten nuts @ andI0.

T = 49.0 - 78.0 N-m (500 - 800 kgf-cm) [36.2 57.9 ft-lbfl (2) Tighten nut 0.

-

Applicable mast and portion

V: Outer mast FV: Front cylinder (2 ton series) FSV: ~~~~tcylinder (2 ton series)

FV: Front cylinder (3 ton series) FSV: Front cylinder (3 ton series)

FSV: Outer mast

Clamp

Sketch

0 0

0 0

0 0

REASSEMBLY (QFV) Installing direction As shown in the table below.

2. Chain adjusting nut tightening order (I) Tighten nuts @ and 0.

T = 49.0- 78.0N.m (500 - 800 kgf-cm) [36.2- 57.9fi-lbfl (2) Tighten nut @.

1.

$ Outer chain

Clamp

y7 -

T = 98.0

[72.35

147.0 N m (1000 108.5 ft-lbfl

-

ZZ

Middle chain

clamp

Inner chain

5s

yw5

@

$& :r

- 1500 kgf-cm)

Upper middle

&

Split pin lnner mast

0 T = 98.0

- 147.0 N.m (1000 - 1500 kgf-cm) - 108.5 ft-lbfl

[72.35

Chain connection

Installation side of split pin is at center side of the truck.

Installation side of split pin is outward of the truck center.

ADJUSTMENT 1.

Park the vehicle on a flat ground and set the mast vertical.

2.

Lower the fork to the ground, and make adjustment to eliminate any chain sag by turning the adjusting nut.

3. Check to see that the chain tension is equal on the left and right side.

4.

Check to see no chain twist.

5.

See that the fork height is the standard.

6.

With the fork raised fully, check to see that the lift bracket freeing prevention stopper at the inner mast is not in contact with the lift bracket.

FORK REMOVAL 1.

2.

3.

4.

Set the fork at approx. 20 cm (7.9 in) above the ground.

Place a wooden block under the knotched portion of the fork rail.

Unlock the fork by lifting the fork stopper pin, and shift the fork blades, one at a time, to the center.

Slowly lower the fork for removal.

INSTALLATION The installation procedure is the reverse of the removal procedure.

INSPECTION 1.

Inspect misalignment of the fork tip ends.

Limit: 10 mm (0.39 in) If the limit is exceeded, inspect individual fork bend, looseness of fork installation and lift bracket finger bar distortion.

FV*FSV MAST ASSY COMPONENTS

FSV

61O I

31

43A 6101-491A

6302

FV 2 ton series

21K

FV 3 ton series

6302-297

6302

FSV 2 ton series

FSV 3 ton series

6302-296

MAST ADJUSTMENT (FV-FSV) Lift Roller Adjustment at Mast 1.

Clearance between: lnner mast roller and outer mast (FV). lnner mast lower roller and middle mast (FSV).

Middle mast lower roller and outer mast (FSV).

Position where the roller is the closest

FSV mast

FV mast lnner mast

Outer mast

@ These rollers

These rollers

(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

(2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and inspect the clearance between the roller side face and mast where they are the closest.

Standard: A = 0

- 0.8 mm (0 - 0.031 in)

If the standard is not satisfied, make adjustment by changing the inner mast roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in) (3) Distribute shims equally to the rollers on the left and right sides.

(4) After the adjustment, see that mutual mast movement is smooth.

2.

Clearance between: Outer mast roller and inner mast (FV).

Middle mast upper roller and inner mast (FSV).

Outer mast upper roller and middle mast (FSV)

N mast

These rollers

FSV mast

These rollers

Outer mast Outer mast Middle mast Inner mast

(1) Adjust the mast overlap to approx. 450 mm (17.72 in).

(2) Shift the inner mast to one side to bring the roller into contact with the inner mast, and measure on the opposite side the clearance between the roller side face and mast where they are the closest.

Standard: B = 0

- 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the outer mast roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) Distribute shims equally to the rollers on the left and right sides.

(4) After the adjustment, see that mutual mast movement is smooth.

LiftISide Roller Adjustment at Lift Bracket

FV-FSV mast Lower lift roller

100 mm (3.94 in)

Lift bracket

FSV Mast

N Mast

(1) Raise the lift bracket to the uppermost position for the FSV mast, and bring the center of the upper lift roller to approx. 100 mm (3.94 in) from the top of the inner mast for FV mast.

(2) Shift the lift bracket to one side to bring the lower lift roller, and measure on the opposite side the clearance between the roller side face and the mast where they are the closest.

Standard: C = 0

- 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the shim thickness. (Distribute shims equally to the rollers on the left and right sides.)

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) After the inspection and adjustment in step (3) above, inspect and adjust the side rollers.

Bring the side roller on one side into contact with mast side surface, measure on the opposite side the clearance between the side roller and the inner mast side surface where they are the closest.

Standard: D = 0

- 0.5 mm (0 - 0.020 in)

If the standard is not satisfied, make adjustment by changing the shim thickness. (Distribute shims equally to the rollers on the left and right sides.)

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(4) After the adjustment, check to see that the lift bracket moves smoothly over the entire length of the mast.

Mast Strip Adjustment

Mast strip clearance adjustment FV mast

Bring into contact

FSV mast Bring into contact

w

(1) Lower the inner (or middle) mast fully.

(2) With the inner (or middle) mast in contact with the outer mast roller (or middle mast upper roller), measure the clearance between the mast strip and mast.

Standard: E = 0.5

- 1.0 mm (0.020 - 0.039 in)

If the standard is not satisfied, make adjustment by changing the mast strip shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in) (3) After the adjustment, check the mast for smooth movement.

4-29

QFV MAST ASSY COMPONENTS

MAST ADJUSTMENT (QFV) Lift Roller Adjustment The lift roller adjustments, for most part, are same with FSV mast. Where to be adjusted are as shown:

Channel seen from the top

Channel seen from the bottom

--

0 0.5 mm (0 0.02 in)

-

0 0.5 mm (0 0.02 in)

-

0 0.8 mm (0 0.03 in)

<

450 mm (17.7 in)

450 mm (17.7 in)

450 mm (17.7 in)

Note: The mast strip & shim adjustment between the mast channels can also be performed in the same sequence with those of V.FV.FSV.

Lift Roller Position on Each Upright:

Inner

Upper Middle

C

d

Lower Middle

e

B

Outer

f

LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING) Note: For double lift cylinders, inspection and adjustment are required t o prevent uneven lifting on the left and right sides due to tolerances of parts, etc.

The inspection and adjustment must be made whenever any of the following parts is replaced: Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast SUB-ASSY, and inner mast SUB-ASSY 1.

Inspection method Slowly raise the inner mast, and observe the stopping states of the left and right cylinder rods at the moment when the inner mast reaches the maximum height.

(1) Normal case Both the left and right rods stop almost simultaneously with almost no shaking of the inner mast.

(2) Abnormal case The rods stop with slight difference and the top of the inner mast shakes at the time of stopping. To correct this, add shims to the cylinder that stops first.

2.

Adjustment method (1) Raise the inner mast, set the SST to the outer mast tie beam, and lower the inner mast until it reaches the SST. SST 09610-22000-71 (2) Remove the set bolt of the cylinder rod end on the side requiring shim adjustment.

(3) Slowly lower the lift cylinder rod and disconnect the cylinder rod end.

(4) Place shims on the cylinder rod end. Slowly raise the cylinder rod end into the inner mast.

(5) Fix the set bolt of the cylinder rod end.

(6) Raise the inner mast for reinspection.

(7) Repeat the inspection and adjustment until the number of shims is determined.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

CYLINDER (2.3TON SERIES) Page

LlFT CYLINDER (V) REAR LIFT CYLINDER (FV-FSV*QFV)................. 5-2 GENERAL ........................................................................5-2 SPECIFICATIONS ............................................................ 5-5 COMPONENTS ................................................................ 5-7

FLOW REGULATOR VALVE (V*FV*FSV-QFV)..... 5-22 GENERAL .................................................................... 5-22 SPECIFICATIONS .............................................................5-22

SAFETY DOWN VALVE (V-FV-FSVoQFV).............. 5-23

.....................................................................5-23 FRONT LIFT CYLINDER (W-FSV-QFV) ................. 5-24 GENERA1 ........................................................................5-24 SPECIFICATIONS .............................................................5-25 COMPONENTS ............................................................... 5-26 REMOVAL~INSTALLATION ..............................................5-27 DISASSEMBLY.INSPECTI0N.REASSEMBLY.................. 5-28 TILT CYLINDER .............................................................* GENERAL

* The tilt cylinder has been unchanged.

Please refer to the Repair Manual 5FBCU15. 18.20.25. 30 Pub. No. CU305.

LlFT CYLINDER (V) REAR LlFT CYLINDER (FV*FSV*QFV) GENERAL Lift Cylinder 0//2Ton Series)

Lift Cylinder (V13 Ton Series)

Rear Lift Cylinder (FV)

Rear Lift Cylinder (FSV12 Ton Series)

Rear Lift Cylinder (FSVl3 Ton Series)

Rear Lift Cylinder (QFV)

SPECIFICATIONS Lift Cylinder O/) Vehicle model 2 ton series

3 ton series

Single-acting

Single-acting

Itern Cylinder type Cylinder bore

mrn (in)

50.0 (1.97)

55.0 (2.17)

Piston rod outside diameter

rnm (in)

42.0 (1.65)

45.0 (1.77)

Piston seal type

U packing

U packing

Rod seal type

U packing

U packing

Others

Built-in safety down valve (RH, LH)

Rear Lift Cylinder (FV) Vehicle model 2 ton series

3 ton series

Single acting

Single acting

ltem Cylinder type Cylinder bore

mm (in)

50.0 (1.97)

55.0 (2.17)

Piston rod outside diameter

mm (in)

34.9 (1.37)

40.0 (1 57)

U packing

U packing

Rod seal type

Built-in safety down valve (LH)

Others

Rear Lift Cylinder (FSV) Vehicle model 2 ton series

3 ton series

Single acting

Single acting

ltem Cylinder type Cylinder bore

mm (in)

50.2 (1.98)

55.0 (2.17)

Piston rod outside diameter

mm (in)

42.0 (1.65)

45.0 (1.77)

Piston seal type

U packing

U packing

Rod seal type

U packing

U packing

Others

Built-in safety down valve (RH)

Rear Lift Cylinder (QFV) Vehicle model 2 ton series

ltem Cylinder type

Single acting type

Cylinder bore

mm (in)

63.5 (2.50)

Piston rod outside diameter

mm (in)

50.8 (2.00)

Rod seal type Others

U packing Built-in safety down valve (LH)

5-7

COMPONENTS Lift Cylinder for V Mast (2 Ton Series)

Lift Cylinder for V Mast (3 Ton Series)

Rear Lift Cylinder for

N Mast on 2 Ton & 3 Ton Series 6503

AN

AM OP[LH]

...,

01[RH]

22

21

1

,

20

I -1.J

L...

6503-113A

Rear Lift Cylinder for FSV Mast on 2 Ton Series

Rear Lift Cylinder for FSV Mast on 3 Ton Series

6503 94125-4120-

BE+

&AI

a AM 01[RH] . . . .

I

02K

AA

91611-41014d

6503-1 12A

Rear Lift Cylinder for QFV Mast

6503

02 [LH]

01 [RH]

AW

I

I rm==

I

I r=l=

I

I

I

I

I

I

W W W

A A A

==mi

-02K

22

I I

Llll

I

I

D F C

23

I

I

,

I

11111

I

Llll

- 01K

I I I

11111

6503-0938

REMOVAL-INSTALLATION

Removal Procedure 1

Set the mast vertical and lower the fork fully.

2

Remove the lift cylinder rod end set bolt.

3

Hoist the inner mast by slinging with a wire and disconnect the lift cylinder rod end. [Point I ]

4

Hoist the inner mast further so that the lift cylinder ASSY can be removed from the front space.

5

Support the bottom of the inner mast with wooden blocks and fix the blocks by taping onto the outer mast.

6

Remove the hose cover.

7

Disconnect the hose.

8

Remove the lift cylinder bottom end set bolt.

9

Remove the lift cylinder support. [Point 21

10

Remove the lift cylinder ASSY.

Installation Procedure .

The installation procedure is the reverse of the removal procedure.

Note: After installing the lift cylinder, follow the steps below.

1. Repeat full-stroke raising and lowering of the cylinder to bleed air and check normal functioning.

2. Check the hydraulic oil level and add if insufficient.

3. Inspect lift cylinders for uneven lifting, and make necessary adjustment.

Point Operations [Point I ] Removal: Shim adjustment is made at the lift cylinder rod end to prevent uneven lifting by lift cylinders LH and RH. Take notes on the cylinder where adjustment is made and the number of shims used.

[Point 21 Installation: Temporarily fasten the cylinder support here, and eliminate any clearance between the cylinder support and outer mast by shim insertion after connecting the rod end. (Use shim(s) slightly thicker than the clearance.)

DISASSEMBLY-INSPECTION-REASSEMBLY Lift Cylinder for V Mast

T = N-m (kgf-cm) [ft-lbfl

2

2

4

4

* Cylinder cover 2 ton series: T = 230 265 (2345 2703) [I 70

-

-

- 1951

3 ton series: T = 264 305 (2695 31 10) [I 75

-

-

- 2251

Disassembly Procedure 1

Remove the safety down valve.

2

Remove the cylinder cover. [Point 11

3

Remove the seals from the cylinder cover

4

Remove the piston rod. [Point 21

5

Remove the seals on the piston rod

6

Remove the check valve from the piston rod. [Point 31

7

Remove the cylinder. [Point 41

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

Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.

Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.

Point Operations [Point I] Disassem bly-Reassembly: SST 09620-10100-71

[Point 21 Inspection: Measure the piston rod outside diameter.

2 ton series Standard: 42.0 mm(1.654 in) Limit: 41.92 mm(1.6504 in)

3 ton series Standard: 45.0 mm(1.772 in) Limit: 44.92 mm(1.7685 in) Inspection: Measure the piston rod bend.

Limit: 2.0 mm(0.079 in)

[Point 31 Reassembly: Install the check valve arrow pointing to the lower side of the cylinder.

Inspection: Measure the cylinder bore.

2 ton series Standard: 50.0 mm(1.969 in) Limit: 50.20 mm(1.9764 in) 3 ton series Standard: 55.0 mm(2.165 in) Limit: 55.35 mm(2.1791 in)

-

Rear Lift Cylinder for FV Mast

-

-

-

-

-

--

T = N-m (kgf-cm) [ft-lbfl

*-I Cylinder cover 2 ton series: T = 203 271 (2073 2764) [ I 50 2001 3 ton series: T = 2 3 7 - 305 (2419 -3110) [I75 -2251

-

-

-

*-2 Air bleed screw: T = 4.5 5.0 (46

-

- 51) [3.33 - 3.691

Disassembly Procedure (1) LH Rear Lift Cylinder.

1

Remove the safety down valve.

2

Remove the cylinder cover. [Point 11

3

Remove the seals from the cylinder cover.

4

Remove the piston rod. [Point 21

5

Remove the wear ring.

6

Remove the bleed screw.

7

Remove the cylinder. [Point 41

(2) RH Lift Cylinder.

1

Loosen the cylinder cover. [Point 11

2

Remove the piston rod. [Point 21

3

Remove the piston. [Point 31

4

Remove the piston seals.

5

Remove the cover and the seals.

6

Remove the bleed screw.

7

Remove the cylinder. [Point 41

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

Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.

Apply sealant (08833-00080)on the threaded portion of the cylinder cover before tightening.

Upon completing the installation of the FV rear lift cylinder, perform air bleeding in the following sequence: (1) Extend the N rear lift cylinder.

(2) Stop the engine.

(3) Loosen the bleed screw by the time oil will come out and tighten the bleed screw again.

Point Operations [Point 1] Disassembly.Reassernbly: SST 09620-10100-71

[Point 21

Inspection: Measure the piston rod outside diameter.

2 ton series Standard: 34.9 mm (1.374 in) Limit: 34.82 mm (1.3709 in) 3 ton series Standard: 40.0 mm (1.575 in) Limit: 39.92 mm (1.5717 in)

Inspection: Measure the piston rod bend.

Limit: 2.0 mm (0.079 in)

[Point 31

Disassembly~Reaseembly: Follow the procedure view.

1. Fix the boss portion at the tip end of the piston rod in a vise.

2. Use a screwdriver and rotate the piston to remove the wire.

3. The installation is the reverse.

[Point 41

Inspection: Measure the lift cylinder bore.

2 ton series Standard: 50.0 mm (1.969 in) Limit: 50.20 mm (1.9764 in)

3 ton series Standard: 55.0 mm (2.165 in) Limit: 55.35 mm (2.1791 in)

Rear Lift Cylinder for FSV Mast T = N-m (kgf-cm) [ft-lbfl LH

RH

2 ton series and 3 ton series *Cylinder cover: 2 ton series T = 230 265 (2345 2702) [I70 1951 T = 237 305 (2419 31 10) [I75 2251 3 ton series

-

-

-

Disassembly Procedure 1

Remove the safety down valve.

2

Remove the cylinder cover. [Point I]

3

Remove the seals from the cylinder cover.

4

Remove the piston rod. [Point 21

5

Remove the piston seals, and the check valve. [Point 31

6

Remove the cylinder. [Point 41

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

Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.

Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.

Point Operations [Point 1]

Disassembly-Reassembly: SST 09620-10100-71

[Point 21

Inspection: Measure the piston rod outside diameter.

2 ton series Standard: 42.0 mm(1.654 in) Limit: 41.92 mm(1.6504 in) 3 ton series

Standard: 45.0 mm(1.772in) Limit: 44.92 mm(1.7685 in)

Inspection: Measure the piston rod bend.

Limit: 2.0 mm(0.079 in) [Point 31

Reassembly: Install the check valve so that the arrow directs to downward of the lift cylinder.

[Point 41

Inspection: Measure the lift cylinder bore.

2 ton series Standard: 50.2 mm(1.976 in) Limit: 50.40 mm(1.9843 in)

3 ton series Standard: 55.0 mm(2.165 in) Limit: 55.20 mm(2.1732 in)

Rear Lift Cylinder for QFV Mast

Disassembly Procedure 1

Remove the safety down valve.

2

Remove the plug.

3

Remove the cylinder cover.

4

Remove the seals from the cylinder cover.

5

Remove the piston rod. [Point 11

6

Remove the piston seals.

7

Remove the cylinder. [Point 21

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

Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.

Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.

Point Operations [Point I ]

Inspection: Measure the piston rod outside diameter.

Standard: 50.8 mm (2.00 in) Limit: 50.72 mm (1.9969 in)

Inspection: Measure the piston rod bend.

Limit: 2.0 mm (0.079 in) [Point 21

Inspection: Measure the lift cylinder bore.

Standard: 63.5 mm (2.50 in) Limit: 63.85 mm (2.5138 in)

FLOW REGULATOR VALVE (V-FV-FSV-QFV) GENERAL

T = N-m (kgf-cm) [ft-lbfl

Piston

-

T = 58.8 68.6 (600 700) [43.4 50.61

SPECIFICATIONS Fork Lowering Speed

2 ton series

3 ton series

Unit: mmtsec (fpm) V

FV

FSV

QFV

No-load

500 (98)

420 (83)

450 (89)

400 (79)

Loaded

500 (98)

480 (94)

480 (94)

510 (100)

No-load

500 (98)

390 (77)

420 (83)

Loaded

500 (98)

460 (91)

460 (91)

Note: The flow regulator valve is installed in the hydraulic piping system, respectively for each model.

SAFETY DOWN VALVE (V*FV*FSV-QFV) GENERAL I I

I' I

Cartridge type Ex. FSV Rear Cyl. on 2.3 ton series

I

L---.

Internaltype

FRONT LIFT CYLINDER (FV-FSVQFV) GENERAL FV: 2 ton series FSV: 2 ton series QFV: 2 ton series

O

0

FV: 3 ton series FSV: 3 ton series

r

0 w

4 I m

0

5-25

SPECIFICATIONS Front Lift Cylinder (FV) Vehicle model 2 ton series

3 ton series

Single acting

Single acting

ltem Cylinder type Cylinder bore

mm (in)

75.0 (2.95)

85.0 (3.35)

Piston rod outside diameter

mm (in)

50.8 (2.00)

50.8 (2.00)

Rod seal type

U packing

U packing

Piston seal type

U packing

U packing Built in safety down valve

Others

Front Lift Cylinder (FSV-QFV) Vehicle model 2 ton series

3 ton series

2 ton series QFV

Single acting

Single acting

Single acting

ltem Cylinder type Cylinder bore

mm (in)

75.0 (2.95)

85.0 (3.35)

75.0 (2.95)

Piston rod outside diameter

mm (in)

50.8 (2.00)

50.8 (2.00)

50.8 (2.00)

Piston seal type

U packing

U packing

U packing

Rod seal type

U packing

U packing

U packing

Others

Built-in safety down valve

COMPONENTS Front Lift Cylinder for

N Mast

Front Lift Cylinder for FSV and QFV Mast

REMOVAL-INSTALLATION Removal Procedure 1

Remove the lift bracket Wlfork.

2

Disconnect the piping.

3

Remove the front lift cylinder

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

Note: After installing the lift cylinder, follow the steps below.

(1) Repeat full-stroke raising and lowering without load to bleed air and check normal functioning.

(2) Check the hydraulic oil level, and add if insufficient.

(3) Adjust the lift chain tension equally on the left and right sides.

Front Lift Cylinder for FV-FSV-QFV T = N-m (kgf-cm) [ft-lbfl FSVQFV

FV

4

4

* Cylinder cover FVIFSVIQFV on 2 ton series FVIFSV on 3 ton series

-

-

-

T = 339 407 (3455 4147) [250 3001 T = 420 454 (4283 4630) [310 3351

Disassembly Procedure 1

Remove the safety down valve.

2

Remove the cylinder cover. [Point I ]

3

Remove the cover seals.

4

Remove the piston rod. [Point 21

5

Remove the piston seals.

6

Remove the check valve. [Point 31

7

Remove the cylinder. [Point 41

ReassemblyProcedure The reassembly procedure is the reverse of the disassembly procedure.

Note: Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.

Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.

Fill the amount of hydraulic oil specified below into the cylinder from its top before installing the cylinder cover.

Filling amount cm3 (in3): FVIFSV 2 ton series 100 (6.10) FVIFSV 3 ton series 75 80 (4.57

-

- 4.88)

Point Operations [Point I]

Disassembly.Reassembly: SST 09620-10100-71

[Point 21

Inspection: Measure the piston rod outside diameter.

2 ton series and 3 ton series: Standard: 50.8 mm (2.0 in) Limit: 50.72 mm (1.9969 in)

Inspection: Measure the piston rod bend.

Limit: 2.0 mm (0.079 in) [Point 31

Assembly: Install the check valve so that the arrow will direct downward of the front lift cylinder.

[Point 41

Inspection: Measure the lift cylinder bore.

2 ton series Standard: 75.0 mm (2.953 in) Limit: 75.35 mm (2.9665 in)

3 ton series Standard: 85.0 mm (3.346 in) Limit: 85.40 mm (3.3622 in)

OIL CONTROL VALVE Page

GENERAL .....................................................................6-2 SPECIFICATIONS .....................................................6-4

COMPONENTS .........................................................6-4 OIL CONTROL VALVE ASSY ..................................6-5 REMOVAL.INSTALLATION........................................... 6-5

DISASSEMBLY.INSPECTI0N.REASSEMBLY ................ 6-6

RELIEF PRESSURE ADJUSTMENT ......................6-8

GENERAL Oil Control Valve

Relief Valve

Lift relief valve

Tilt relief valve

Tilt Lock Valve

Hydraulic Circuit TI

T2

P

..........-....-. ..- ---........-- -. .......-. ..

P: Pump port T: Tank port TI: To tank T2: From power steering

SPECIFICATIONS Spec. item Oil control valve type

Type & values Add on type of 3 spools (Monoblock for each spool section)

Lift relief valve set pressure kPa (kgf/cm2) [psi]

17160 (175) [2490]

Tilt relief valve set pressure kPa (kgf/cm2) [psi]

15690 (160) [2280]

COMPONENTS

OIL CONTROL VALVE ASSY REMOVAL-INSTALLATION Note: Before disconnecting the control lever link, release the residual pressure in the material handling system piping by operating the control lever, set the mast in the neutral state and lowering the fork to the bottom position.

Removal Procedure 1

Remove the toe board.

2

Disconnect the control valve lever link

3

Disconnect the piping.

4

Remove the oil control valve set bolt.

5

Remove the oil control valve ASSY.

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

Note: Apply grease to the oil control valve lever link parts.

Check the hydraulic oil level, and add if insufficient.

DISASSEMBLY-INSPECTION-REASSEMBLY Note: Operate in a clean place.

As each part is finished with high precision, carefully disassemble them to prevent any damage.

Disassembly Procedure 1

Remove the through bolt.

2

Separate each housing.

3

Remove the O-ring, spring and check valve.

4

Remove the seal holder.

5

Remove the spring holder.

6

Remove the spool Wlspring.

7

Remove the spring. [Point I ]

8

Remove the tilt lock valve.

9

Remove the relief valve. [Point 21

Point Operations [Point 11 Disassembly.Reassembly: SST 09610-10161-71

[Point 21 Reassembly: When the relief valve is disassembled, always loosen the adjust screw fully.

RELIEF PRESSURE ADJUSTMENT Note: Always make adjustment according to the procedure described below. Careless adjustment may generate a high pressure to cause damage to the oil pump or other hydraulic devices.

1.

Install an oil pressure gage.

(1) Remove the oil pressure detection plug (9116-1 8UNF2B) installed on top of the oil control valve, and install the oil pressure gage.

2.

Check loosening of the adjust screw.

(1) Remove the cap nuts and packings on top of the relief valves. Loosen the adjust screw to a degree not to come off from the body.

3.

4.

Adjust the lift side relief pressure.

(1) Set the control lever to the lift position and gradually tighten the adjust screw on the lift relief valve until the fork starts to rise.

(2) Lift the forks to the maximum height, and read the pressure gage. Adjust the oil pressure then to the specified level by turning the adjust screw.

5.

Adjust the tilt side relief pressure.

(1) Set the control lever at the backward tilt position, and gradually tighten the adjust screw on the tilt relief valve until the mast starts to be tilted backward.

(2) Tilt the mast fully backward, and read the oil pressure gage. Adjust the oil pressure then to the specified level by turning the adjust screw.

6.

After the adjustment, insert the packing and tighten the cap nut. Inspect the relief pressure again.

Relief Set Pressure Unit: kPa (kgf/cm2) [psi] All models Lift

17160:~(175::)[2490:~]

Tilt

15690::,9: (1601~)[2280:~~]

Turn the key switch on.

I

7. Remove the oil pressure gage, and tighten the plug.

APPENDIX Page

SST LlST......................................................................7-2 SERVICE STANDARDS LlST ...................................... 7 4

SST LIST lllustrat~on

Part No

Part Name

Sectlon 1

2

3

09316-60011

Transmlsson & transfer bearlng replacer

09509-55020

Rear wheel bearlng nut wrench

09608-04031

Front hub inner bearlng cone replacer

0

09950-40011

Puller B set

0

09950-60010

Replacer set

0

0

0

09950-60020

Replacer set No 2

0

0

0

0

O

0

000~

Front axle bearlng

4

5

6

Drlve pinlon bearing

011 control valve sprlng

@

4 0 -g

-c e

0

09610-22000-71

Inner mast stopper

09620-10100-71

Cylinder cap remover and replacer

09630-1

Tilt cylinder cap remover and replacer

0

09630-23600-71

Deep socket A

0

09631-22000-71

Wear scale chain

09810-20172-71

Jolnt pln remover

O

0

0

0

SERVICE STANDARDS LIST DRIVE UNIT Differential Ring gear backlash

mm (in)

Differential pinion bore

mm (in)

Spider outside diameter

Side gear thrust washer thickness

Pinion gear thrust washer thickness

0.2

- 0.3 (0.008 - 0.012)

Standard

22.12 (0.8709)

Limit

22.22 (0.8748)

Standard

22.00 (0.8661)

Limit

21.75 (0.8563)

Standard

1.6 (0.063)

Limit

1.3 (0.051)

Standard

1.6 (0.063)

Limit

1 .O (0.039)

mm (in)

mm (in)

mm (in)

Drive pinion bearing starting torque N.m (kgf-cm) [ft-lbfl

Tightening torque

Standard

Standard

10.79

- 13.24 (110 - 135) [7.96 - 9.771

Unit: N-m(kgf-cm) [ft-lbf]

Drive pinion lock nut

Standard

Drive pinion bearing retainer set bolt

Standard

Ring gear set bolt

Standard

Differential upper case set bolt

Standard

Differential case bearing cap set bolt

Standard

Differential cover set bolt

Standard

- 392 (3500 - 4000) [253.2 - 289.31 88.3 - 117.7 (900 - 1200) [65.1 - 86.821 127.4 - 176.5 (1300 - 1800) [94.0 - 130.21 43.1 - 53.9 (440 - 550) [31.8 - 39.81 117.7 - 137.3 (1200 - 1400) [86.82 - 101.31 29.4 - 44.1 (300 - 450) [21.7 - 32.61 343

FRONT AXLE

-

Front axle shaft hub Front axle bearing starting force

N (kgf) [Ibfl

Tightening torque

Standard

25.5

- 72.6 (2.6 - 7.4) [5.7 - 16.31

Unit: N.m (kgf-cm) [ft-lbf]

- 205.9 (1700 - 2100) [ I23.0 - 151.91

Hub bolt set nut

Standard

Bearing lock nut stopper bolt

Standard

Axle shaft set bolt

Standard

- 21.6 (150 - 220) [ I0.9 - 15.91 98.07 - 127.5 (1000 - 1300) [72.35 - 94.061

Front wheel hub nut

Standard

294.2 588.4 (3000 6000) [217.1 434.11

Front axle housing set bolts

Standard

107.9 - 137.3 (1100 - 1400) [79.59 - 101.31

Standard

0.7 (0.028) or less

Limit

52.0 (2.047)

166.7

14.7

REAR AXLE Rear axle ASSY Rear axle ASSY front to rear clearance mm (in) Rear axle center pin bushing inside diameter

mm (in)

Rear axle hub and steering knuckle Rear axle wheel starting force (at outer periphery of the wheel)

N (kgf) [Ibfl

9.8

Standard

- 29 (1.O - 3.0) [2.2 - 6.61

Limit

27.8 (1.094)

Standard

19.3 (2.0) [4.4] or less

Rear axle cylinder piston rod outside diameter mm (in)

Limit

49.92 (1.9654)

Rear axle cylinder piston rod bend

mm (in)

Limit

0.5 (0.017)

Rear axle cylinder inside diameter

mm (in)

Limit

76.35 (3.0059)

mm (in)

Standard

0 k 4 (0 k0.16)

King pin outside diameter Steering knuckle starting force (at front end of knuckle)

mm (in)

N (kgf) [Ibfl

Rear axle cylinder

Rear wheel alignment Toe-in

Tightening torque

Unit: N-m (kgf-cm) [ft-lbf]

Axle bracket cap set bolt

Standard

King pin lock bolt and lock nut

Standard

Rear axle cylinder rod guide set nut

Standard

Rear axle cylinder set bolt

Standard

- 166.7 (1200 - 1700) [86.82 - 123.01 44.1 - 53.9 (450 - 550) [32.6 - 39.81 88 - 118 (900 - 1200) [65.1 - 86.81

117.7

166.7-215.8(1700-2200)[123.0-159.11

Mast adjustment (V mast)

Mast 'Oilers Lift bracket 'Oilers

Inner mast roller clearance

mm (in)

Standard

Outer mast roller clearance

mm (in)

Standard

- 0.8 (0 - 0.031) 0 - 0.5 (0 - 0.020)

Standard

0

- 0.5 (0 - 0.020)

mm (in)

Standard

0

- 0.5 (0 - 0.020)

mm (in)

Limit

Middle and lower lift roller clearance mm (in) Side roller clearance

Mast strip to inner mast clearance

0

0.5

- 1 .O (0.020 - 0.039)

Fork Fork front end misalignment

Tightening torque

mm (in)

Unit: N.m (kgf-cm) [ft-lb]

Mast support cap set bolt

Standard

Back rest set bolt

Standard

Chain adjusting nut

Standard

- 107.9 (700 - 1100) [50.6 - 79.571 99.54 - 184.9 (1015 - 1885) [73.42 - 136.31 68.6

49.0

- 78.0 (500 - 800) [36.2 - 57.91

CYLINDER Lift cylinder 01) Piston rod outside diameter

mm (in)

Cylinder bore

mm (in)

2 ton series

Limit

41.92 (1.6504)

3 ton series

Limit

44.92 (1.7685)

2 ton series

Limit

50.20 (1.9764)

3 ton series

Limit

55.35 (2.1791)

Limit

2.0 (0.079)

Piston rod bend

mm (in)

Rear lift cylinder (FV-FSV-QFV) FV

Limit

34.82 (1.3709)

FSV

Limit

41.92 (1.6504)

FV

Limit

39.92 (1.5717)

FSV

Limit

44.92 (1.7685)

QFV

Limit

50.72 (1.9969)

FV

Limit

50.20 (1.9764)

FSV

Limit

50.40 (1.9843)

FV

Limit

55.35 (2.1791)

FSV

Limit

55.20 (2.1732)

QFV

Limit

63.85 (2.5138)

mm (in)

Limit

2.0 (0.079)

2 ton series Piston rod outside diameter

mm On)

3 ton series 2 ton series 2 ton series

Cylinder bore

mm (in) 3 ton series 2 ton series

Piston rod bend

Front lift cylinder (FV.FSV.QFV) FV

Limit

50.72 (1.9969)

FSV

Limit

t

FV

Limit

t

FSV

Limit

7

QFV

Limit

?

FV

Limit

75.35 (2.9665)

FSV

Limit

t

FV

Limit

85.40 (3.3622)

FSV

Limit

t

QFV

Limit

75.35 (2.9665)

mm (in)

Limit

2.0 (0.079)

2 ton series Piston rod outside diameter

mm On) 3 ton series 2 ton series 2 ton series

Cylinder bore

mm (in) 3 ton series 2 ton series

Piston rod bend

Tightening torque

Unit: N-m (kgf-cm) [ft-lbf] Standard

Flow regulator valve

58.8

- 68.7 (600 - 700) [43.4 - 50.61

OIL CONTROL VALVE Oil control valve Relief set pressure kPa (kgf/cm2) [psi]

Lift

Standard

17160 'igO(l75 'i) [2490'?]

Tilt

Standard

15690 ~ ~ ~ ~'3,) ( [2280'j:] 1 6 0