Toyota 2SDK8 Skid Steer Loader Service Repair Manual

FOREWORD

This repair manual covers the inspection, adjustment and repair procedures for the overhaul of the engine, chassis and materials handling system of the TOYOTA SKID STEER LOADER 2SGK6,2SDK6,2SDK7and 2SDK8.

You are encouraged to become thoroughly familiar with this manual so as to make the most of the outstanding performance and durability features of these loaders and t o perform the proper servicing to maintain them in tip-top running condition.

This repair manual contains the latest information available as o f March, 1986.

For any changes thereafter, you are asked to consult the Parts & Service News.

Toyota reserves the right to make changes in specifications without incurring any obligation and without previous notice.

For your reference, we herewith indicate the titles of relevant manuals.

TOYOTA 4P ENGINE REPAIR MANUAL

(No. 95721)

TOYOTA2J,2J-TENGINEREPAIRMANUAL

(N0.95727)

TOYOTA 3T84H ENGINE REPAIR MANUAL

(No. 95731)

TOYOTA MOTOR CORPORATION

SECTION INDEX I

GENERAL ENGINE ' HYDROSTATIC TRANSMISSION FINAL REDUCTION GEAR

1 A

I

L

AXLE BRAKES

-

I

BODY FRAME 1 LIFT ARMS & BUCKET BRACKET CYLINDERS I OIL PUMP I OIL CONTROL VALVE

m 0

0

1 1 -

GENERAL

Page

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

0-2

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

0-3

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

0-3

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

04

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

04

..

0-5

STANDARD HIGH-PRESSURE HOSE FITTING TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . .

0-7

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

0-7

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

0-8

VEHICLE EXTERIOR VIEWS VEHICLE MODELS ABBREVIATION

TIPS ON OPERATION

RIGHT ORDER OF OPERATION

STANDARD BOLT & N U T TIGHTENING TORQUE

FRAME SERIAL NUMBER VEHICLE DIMENSIONS

GENERAL SPEC1 FlCATlONS

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

RECOMMENDED LUBRICANTS & CAPACITIES . . . . . . 0-14 PERIODIC MAINTENANCE LUBRICATION

....................... 0-15

.................................. 0-20

VEHICLE MODELS

I I

I

I

Model 2SGK6 2SDK6 2SDK7 2SDK8

I /

1 /

Engine TOYOTA 4P YANMAR 3T84H TOYOTA 2J TOYOTA 2J

1 1

/ 1

Operating Load 460 kg (1000 bs) 460 kg (1000 b s ) 520 kg (1150 b s ) 600 kg (1320 lbs)

1 1

1 1

0.28 m3 (10.0 i t 3 )

I Machine Weight 1 2100 kg (4630 b s ) I

0.28 m3 (10.0 i t 3 )

2100 kg (4630 lbs)

Bucket Capacity

0 3 1 m3 ( 1 1.0 ft3) 0.34 m3 (12.0 ft3)

/

2200 kg (4850 lbs) 2490 kg (5490 Ibs)

I I

TIPS ON OPERATION Safe operations (1) Carry out inspections and servicing with the l i f t arm lowered and the bucket on the ground.

I f such work must be performed with the l i f t arm in the air, support i t with the l i f t arm lock pin, or use the safety block or safety pillar t o prevent the arm from lowering.

(2) Always use rigid racks or stands when jecking up the vehicle. ( 3 ) When lifting with a wire rope, make sure the rope is suffic~entlystrong.

SST & measuring tools Have the mechanic tools, SST and measuring tools on hand Order & arrangement ( 1 ) Always arrange things in an orderly manner for easy operations. ( 2 ) Disassembly of the hydraulics should be done with clean tools in a clean area Troubleshooting Do not immediately disassemble when trouble occurs; first determine whether or not dlsassembly is necessary. For example, wlth the HST, the pump should not be immediately turn down srmply because there is trouble with the travel system. Troubleshoot the cause in the steerlng levers, the final reduction gear, the change oil pressure, the hydraulic oil and so on.

RIGHT ORDER OF OPERATION Disassembly Mark or punch matlng marks in a feasible location so as to facilitate dlsassembly of a complex unit.

Also, if you are reparing electricals, be sure to disconnect the cables from the battery terminals.

Always start with ( - ) terminal without fail when disconnecting cables from the battery term~nals.

Inspections during disassembly In removing each and eavry part, check for the installed condition, deformation, breakage, roughness or damage.

Assembly and installation ( 1 ) Always adhere t o the tightening torques listed. If none are given, follow the "Standard Tightening Torques."

(2) When reassembling after disassembly, use Toyota Genuine Parts t o replace packlngs, gaskets and O-rings.

(3) Apply a seal pack~ngin terms of the gasket position, and coat the sliding surfaces at the specified locations with the recommended oil; apply the recommended grease and also coat oil seal lips with MP grease, when assembling.

STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and nut tightening torques are 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 frorn the table

2.

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

List of Bolt Types and Strength 1.

2.

Judging by part

Judg~ngby part No.

I klexagon bolt 1

re:

Shape and description

@ , Hexagon bolt

;

Sample number

ber in relief or hallmark on the

91 111-40610

I Length ( m m ) : A

Standard bottom surface

No mark

Hexagon bolt (Collared bottom)

No mark I

Hexagon bolt (Standard bottom surface) Hexagon bolt (Collared bottom)

Hexagon bolt

I

I

Two re1ief lines on the head

-,

-Stud bolt

0

Sample number 921 32-,4O614

fei l ; ; ; ;

1 ines on

Length ( m m ) : A

I

Diameter ( m m ) : B Type

Welded bolt

Welding bolt Stud bolt

I

I No mark I

'I

Approximately 2 mm (0.08") hollow on either or both ends BAHS2

Standard Bolt Tightening Torque Standard t~ghteningtorque Diameter

rnm

Pitch mm

kg-cm ( i t - l b )

Seat with flange

STANDARD HIGH-PRESSURE HOSE FllTlNG TIGHTENING TORQUE 1.

When connecting a high-pressure hose, always clean the hose f ~ t i ~ nand g The opposlng nipple w i t h a clean cloth. Check that there are no dents in the contacting surfaces.

2.

When connecting a high-pressure hose, always tighten so that the hose fitting and nipple he in a straight line and not off-center

Standard tightening torque kg-m ( f t - l b ) Nominal Screw diameter

Hose inside diameter

Torque range

Standard torque

7/16 - 20 UNF 9/16 - 18 UNF

314 - 16 UNF 718 - 1 4 U N F 1-1/16 - 12 UNF 1-5/16 - 12 UNF

FRAME SERIAL NUMBER 1.

2.

Frame Serial Number Location

-

Frame Serial N u m b e r L o c a t i o n

SAE45-13

Frame Numbering System Vehicle model

Serial number

2SG K6

2SGK6-10011

VEHICLE DIMENSIONS

MODEL: 2SGK6

J Vehicle Dimensions (2SGK6)

- 12 -

SAEMl

MODEL: 2SDK6

Vehicle Dimensions (2SDK6)

- 13 -

MODEL: 2SDK7

Vehicle Dimensions (2SDK7)

- 14 -

MODEL: 2SDK8

Vehicle Dimensions (2SDK8)

- 15 -

GENERAL SPECIFICATIONS 2SG K6

l tem

2SD K6

2SDK7

( Performance ( T~ppingload (SAE)

1

1

1040 (2290)

1200 (2640)

kg(Ibs)

46011000)

c

520 (1 150)

600 (1320)

m3 (cu-ft)

0.28 (10.0)

c

0.31 11 1.O)

0.34 (12.0)

m m (in)

2210 (87.0)

c

2190 (86.2)

2160 (85.0)

Operating load (SAE) Bucket capacity

2SDK8

Dump height (at 45') Reach-fully ra~sed (at 45"

I

deu

1

I Ra~slngtime (Full load)

sec

1

(

Lower~ngtime (No load)

sec

I

Dump time (Full load)

sec

Dump angle lmax)

Travel speed kmlh (mph)

/ 1

1

4.0 2.5

1

I I

c

c

2.5

1

t

I

c

t

t 4-

t

Forward

10 (6.2)

c

c

c

Reverse

10 (6.2)

c

t

t

1700 (67.0)

c

1730 (68.0)

1750 (69.0)

Clearance c~rcle(Bucket)

m m (in)

( Traction (Full load)

1

c

Gradeability %

I

c

Reverse

1

2100 (4650)

2400 (5300)

30

c

c

t

58

c

t

c

TOYOTA 4P

YANMAR 3T84H

TOYOTA 2J

c

Engine

Model Cylinder

Bore

mm (in)

76.6 (3.02)

84 (3.31)

88 (3.46)

t

Stroke

mm (in)

81.0 (3.19)

85 (3.35)

102 (4.02)

t

cc (cu-m)

1493 (91)

1413 (86)

2481 (151)

c

PSIrpm

3012400

2812500

4012500

5012500

HPlrpm

3812600 Gross

2712500 Net

3812500 Net

4712500 Net

kg-mlrpm

10,511800

8.512000

12.012200

14.512200

ft-lbslrpm

77/2600 Gross

5912000 Net

8312200 Net

10012200 Net

Piston desplacement Rated hosepower

Rated torque

*-3

*-2

1-1

*-a

Overall length (with bucket)

mm (in)

2810 (110.5)

4-

2845 (1 12.0)

2880 (113.5)

Overall width (without bucket)

mm (in)

1520 (59.5)

c

+

c

Vehicle 2SDK6

2SG K 6 Bucket w i d t h

rnm ( i n )

Overall height (operator guard)

mm ( i n )

1

1530 (60.0)

1 I

/

c

1

t

t I

t

I

9 1 5 (36.0)

t

t

t

Front

1250 (49.2)

c

c

t

Rear

1250 (49.2)

C

t

t

1 9 0 (7.5)

t

C

C

3 0 0 ( 1 1.8)

c

t

C

Wheel base

rnm ( l n )

mm ( i n )

Tread

Ground clearance rnm ( i n )

Center X-5

Machine weight kg (Ibs) (include a f u l l fuel tank and b u c k e t ) Controls

I

t

1925 (75.5) I

c

2SDK8

2SDK7

2100 (4630)

- Hydrostatic Forward, Reverse, Variable Travel Speed and Steering Controlled b y T w o Hand Lever

Steering -

T r a n s m ~ s s ~ ownl t h l n f i n ~ t yVanable Speed l ~ w Hydrostatic o

Drwe Fuel System -

Fueltankcapacity

P(US/UKgal)1

52114111)

1

+

Brake

Mechanical

F o o t brake (OPT) *-'

/

Hand brake

Mechanical

I

t

c

+

+

c

1

+

Battery

VIAH

12/35

12/80

c

t

CCA

332

622

t

c

Tires

Front

10.00-1 6.5-4PR (OR)

C

t

C

Rear

10.00-1 6.5-4PR (OR)

c

t

t

Tire size

" Specifications and design are subject t o change w i t h o u t

notice

RECOMMENDED LUBRICANTS & CAPACITIES Location M o t o r oil API classification over SD SAE20.30

Diesel engine oil A P I classif~cation over CC S A E 1OW-30

M o t o r oil API classification over SD SAE1 OW-30, SAE7.5W-30

Diesel engine 011 API classification over CC SAE5W-30

Engine

Type

Oil tank

I

C

4Q ( 1 . 0 6 US gal)

Capacity

STD, OPT

7Q (1.85 US gal)

Auto fluid [ A T F T Y P E F1

( * c o l d area)

2511 (6.6 U S gal)

Capacity

**

I

Diesel engine

Reduction gear u n i t

Type

STD,

oil API

OPT

classification

("Cold area)

over CC S A E 1OW-30 16Q (4.22 US gal)

Capacity 1611 (4.22 US gal)

Pneumatic governor

Lubrication ooints

C

Diaphragm oil

Type

2 t o 3 drops

Capacity T Ype

M u l t ~ p u r p o sgrease

Capacity

Proper amount Gasoline

C

Diesel fuel

Fuel tank 52Q ( 1 4 US gal)

1 Engine cooling system

Type

pT STD

("Cold area)

Capacity

Long life coolant 30% Long life coolant 50% 6.2Q (1.64 US gal)

5.5Q 11.45 US gal)

3.6P (2.53 US gal)

1.9Q 12.61 US gal

: For use at a m i n i m u m temperature o f -15OC t o -25'C i n a cold season **: Precisely, capacity 25Q (6.6 U S gal) must contain 1.5Q ( 0 . 4 US gal) o f specified HST additive & Part No. 3899942800-71.

PERIODIC MAINTENANCE INSPECTION M E T H O D I : Inspect and correct and replace as required. T . Tighten C : Clean L : Lubricate M , Measure and correct and adjust as required.

INSPECTION P E R I O D Carry out according t o operating hours or months, whichever is soonest

Item

Every

1

3

6

12

Every

170

500

1000

2000

ENGINE Starting condition and unusual noise Rotating condition during idling Rotating condition during acceleration

Basic comoonents

Exhaust condition Air cleaner element Valve clearance Compression

Blow by gas Reduction Device

I Governor

Clogging and damage of PCV valve and piping

I

Maximum no-load speed Oil leakage

Lubrication system

Oil level Clogging and fouling of oil filter Fuel leakage Carburetor link mechanism operation Fouling and damage of fuel filter element

I Fuel system

Clogging of feed pump stainer Injection timing Injection nozzle injection pressure and condition

I

I Cooling system

Radiator cooling water level and leakage Rubber hose deterioration Radiator cap condition Fan belt tension and damage

":

For new vehicle

Hours

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Item

Every

1

3

6

12

Every

170

500

1000

2000

POWER TRANSMISSION SYSTEM Oil leak HST pump and motor operation, abnormal sound

HST pump and motor

HST charge pressure measurement HST working pressure measurement Oil leak Oil level

Reduction gear unit

Reduction gear operation, abnormal sound Chain bush engaged portion deformation Sprocket deformation, damage

RUNNING EQUIPMENT Tire air pressure Tire cuts, damage and uneven treads Loose hub bolts and hub nuts Tread depth Wheels

Metal fragments, stones or other forelgn objects in tires Rim, side ring and disc wheel damage Wheel bearing unusual noise and looseness

Axle

- Deformation,

crack and damage

STEERING SYSTEM Steering control lever Link rod

Looseness

I

C

t

C

Operation condition

I

t

t

c

Bending and damage

I

+

+-

t

Installed portion looseness

I

+

c

t

Braking effect

I

+-

+-

c

Pull margin

I

+-

+-

c

Braking effect

I

c

+-

c

BRAKE SYSTEM Play and reserve Brake pedal

Parking brake

Rod and cable looseness and damage Ratchet wear and damage -

Disk brake

-

-

Brake disk and pad wear and damage

M

Hours

I-----Item

Every

1

3

Every

170

500

6

12

1000 200C

MATERIALS HANDLING EQUIPMENT -

Bucket edge damage, wear Bucket

Bucket deformation, damage and crack Bucket welded portion crack Lift arm and link deformation, damage and

Lift arm and link

I crack

I

Lift arm welded portion crack Stop lever, link and pin damage Bucket bracket deformation, damage and crack

Bucket bracket

Bucket bracket welded portion crack Any abnormality and installed state of each part

attachments

HYDRAULIC EQUIPMENT Cylinder installed portion looseness Cylinder and piston rod damage Rising speed, dumping speed

Cylinder

Cylinder operating condition, natural drop, natural forward tilt

+

Cylinder oil leak Pin and cylinder bearing weark damage

Oil leak, abnormal sound

Oil pump

Oil amount and dirt

Hydraulic oil tank

Oil leak

I

Tank and strainer Each connecting portion looseness

Operating pedal

Pedal function Pedal lock f u n c t ~ o n Oil leak

Oil control valve

Safety valve function Rel~efpressure measurement Oil leak, looseness measurement

ELECTRIC EQUIPMENT Ignition system

Distributor cap cracking

I

t

+

+

Damage of contact breaker arm and point

I

+-

c

t

Hours

Every Every

Hours

Contact breaker point gap Spark plug burning and gap Ignition timing

Ignition system

Distributor side terminal burning Wear and damage of distributor cap center terminal Plug cord internal disconnection Pin~onqear meshinq

Starter Charger

Charging function

Electric wiring

Wire harness damage and connector looseness Fuses Glow plug heat coil breakage

Pre-heater

Thermo-start plug function Specific gravity

SAFETY DEVICE AND OTHERS Installed portion looseness

3perator guard 2nd side guard

Deformation, crank, damage

Iirection ndicator

Operation and installed state

Warm unit

Operation and installed state

-amp unit

I

Operation and installed state

I

I

I

c

c

+-

b - b b

Operation and mstalled state

J

c

+-

+

Dirt and damage

I

c

c

+--

Back reflection state

I

+-

+-

+

Each instrument operation

I

c

c

t

Seat

Looseness, damage

I

c

c

c

Seat Belt

Slackness, damage

I

c

c

c

3everse alarm 3ack mirror nstruments

3ady 3thers

Frame, cross member, etc. damage, crack

I

Bolt looseness

T

Each part grease up

L

c

+

t