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