remove
engine
clutch TORQUE converter
set BOLT
disconnect
ton
<p>FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 5FGIO- 30/5FD 7 0-30 Series. Please use this manual for providing quick, correct servicing of the corresponding forklift models. These models on the market since August 7986 are subject to minor changes in September 7986. This manual deals with the models produced in the period between A ugust 7 988 and August 7 989 as well as the models as of September 7 989 (after m~nor changes}. Any change or modifications thereafter will be informed by Toyota Industrial Vehicles' Parts & Service News. For the service procedures of the mounted engine, read the repair manuals listed below as reference together with this manual. (Reference) Repair manuals related to this manual are as follows: TOY0 TA INDUSTRIAL VEHICLE 4P ENGINE REPAIR MANUAL (No. CE604) TOYOTA INDUSTRIAL VEHICLE 4 Y ENGINE REPAIR MANUAL (No. CE602) TO YO TA INDUS TRIAL VEHICLE 2 J ENGINE REPAIR MANUAL (No. CE603) TO YO TA INDUSTRIAL VEHICLE 7Z ENGINE REPAIR MANUAL (No. CE60 7) TO YO TA INDUSTRIAL VEHICLE 5K ENGINE REPAIR MANUAL (No. CE67 7) TOYOTA INDUSTRIAL VEHICLE 7 DZ ENGINE REPAIR MANUAL (No. CE6 18) (Note: 2 -3 ton models mounted with 2J, IDZ diesel engine are only available in designated areas.) TOYOTA MOTOR CORPORATION GENERAL Page .............................. EXTERIOR VIEWS 0-2 VEHICLE LISTING .............................. 0-3 ABBREVIATIONS ................................ 0-7 ............................. OPERATIONAL TIPS 0-7 STANDARD BOLT & NUT TIGHTENING TORQUE ..................................... 0-8 HIGH PRESSURE HOSE FITTING ........................ TIGHTENING TORQUE 0-10 FRAME NUMBER ............................... 0-11 WIRE ROPE SUSPENSION ANGLE LIST ............ 0-14 SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE .......................... 0-14 COMPONENT WEIGHT ........................... 0-15 RECOMMENDED LUBRICANT QUANTITY & TYPE ...................................... 0-17 LUBRICATION CHARTS .......................... 0-21 ....................... PERIODIC MAINTENANCE 0-22 PERIODIC REPLACEMENT LUBRICANTS .................................. AND PARTS 0-29 EXTERIOR VIEWS Front View (5FG15) LATI 4-16 Rear View (5FG15) LAT14-18 VEHICLE LISTING (1986.8 - 1989.8) Se- ries % . - L % C 0 + - V) Q, .- L % 0 + CU Pay load 1.0 ton 1.35 ton 1.5 ton 1.75 ton 2.0ton Model 5FG10 02 - 5FG10 40- 5FG10 42- 5FG10 5FD10 02 - 5FD10 5FG14 02- 5FG14 40- 5FG14 42- 5FG14 5FD14 02- 5FD14 5FG 15 02 - 5FG15 40- 5FG15 42 - 5FG15 5FD15 02 - 5FD15 5FG18 02 - 5FG18 40- 5FG18 42- 5FG18 5FD18 02 - 5FD18 5FG20 02- 5FG20 40- 5FG20 42- 5FG20 5F D20 02- 5FD20 60 - 5FD20 62 - 5FD20 Engine model 4 P ? 4 Y f 2 J f 4 P f 4 Y f 2 J t 4 P f 4 Y f 2 J t 4 P f 4 Y t 2 J f 4 P t 4 Y t 1 Z f 2 J f Engine tY Pe Gasoline f f f D~esel T Gasoline f 7' t Diesel .f Gasoline t f t Diesel t Gasol i ne ? f f Diesel t Gasoline t t t Diesel t f f Drive system 1 1 " clutch Torque converter 1 1 " clutch Torque converter 1 1 " clutch Torque converter I 1 " clutch Torque converter 1 1 " clutch Torque converter 1 1" clutch Torque converter I 1 " clutch Torque converter I 1" clutch Torque converter I I" clutch Torque converter 11" clutch Torque converter 1 I " clutch Torque converter 11" clutch Torque converter 1 1 " clutch Torque converter 11" clutch Torque converter 11" clutch Torque converter 1 1 " clutch Torque converter Remarks P/S instal led as standard f f t f t f f 7. f f t f t t f f f f f t t f f t I. t 7- f f t f VEHICLE LISTING (1989.9 - Ser~es 1 ton serles 2 ton series Engine model 5K 4Y 1 DZ 5K 4Y 1 DZ 5K 4Y 1 DZ 5K 4Y 1 DZ 5K 4Y 1 z 1 DZ 5K 4Y Dr~ve system Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Load capac~ty 1.0 ton 1.35 ton 1.5 ton 1.75 ton 2.0 ton 2.25 ton Model 5FG10 02-5FG10 40-5FG10 42-5FG10 5FD10 02-5FD 10 5FG14 02-5FG14 40-5FG14 42-5FG14 5FD14 02-5FD14 5FG15 02-5FG15 40-5FG15 42-5FG15 5FD15 02-5FD15 5FG18 02-5FG18 40-5FG18 42-5FG18 5FD18 02-5FD 18 5FG20 02-5FG20 40-5FG20 42-5FG20 5FD20 02-5FD20 60-5FD20 62-5FD20 5FG23 02-5FG23 40-5FG23 42-5FG23 Series 2 ton series Load capacity 2.25 ton 2.5 ton Model 5FD23 02-5FD23 60-5FD23 62-5FD23 5FG25 02-5FG25 40-5FG25 42-5FG25 5FD25 02-5FD25 60-5FD25 62-5FD25 Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter 4Y 3 ton series Engine model 1 z 1 DZ 5K 4Y 1 z 1 DZ Drive system Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter 2.75 ton 3.0 ton 5FD28 02-5FD28 60-5FD28 62-5FD28 5FG30 02-5FG30 5FD30 02-5FD30 60-5FD30 62-5FD30 1 Z 1 DZ 4Y 1 Z 1 DZ ABBREVIATIONS Abbreviations used in this manual are as follows: OPERATIONAL TIPS 1. Safe operation ( 1 ) Make sure that correct size wire is used for hoisting a heavy material (2) After jacking up, always support with rigid racks or stands. Meaning Power Steering Right Hand Society of Automotive Engineers (USA) Special Service Tool Standard Sub-assem bly Tightening Torque N um ber of Teeth (00) U ndersize With Abbreviation (Code) ABDC ASSY ATDC ATM BBDC LH L LC MTM OHV 0 PT 0 /S PS 2. Preparation of SSTs and measuring tools ( 1 ) Prepare SSTs and measuring tools before starting operat ion. 3. Clearing and arrangement ( 1 ) Always keep the workshop neat and orderly for easy operation. (2) Disassembly of hydraulic equipment shall always be done in a clean place using clean tools. Meaning After Bottom Dead Center Assem bl y After Top Dead Center Automatic Transmission Before Bottom Dead Center Left Hand Long Life Coolant Manual Transmission Overhead valve Opt ion Oversi~e Horsepower 4. Genuine Toyota parts Genuine Toyota parts should be used even in the replacement of packings, gaskets and O-rings. Abbreviation (Code) P/S RH SA E SST STD SU B-ASSY T = OOT U/S w/ 5. Repairs on electrical system Before doing any repairs on the electrical system, disconnect the cables from the battery terminals. Be sure to disconnect the negative @ cable first. 6. Tightening torque for irlstallation Be sure to observe the tightening torque given in this manual. If not specified, tighten to the torque ' listed in standard bolt & nut tightening torque. 7. Defect status grasp Do not start disassernbly and replacement as soon as a defect is found, but first grasp whether the defect requires disassembly and replacement. In the case of torque converter for example, do not attempt torque converter disassembly upon a failure in starting the vehicle, but first check such factors as the oil, pressure and rotation status causing the failure. STANDARD BOLT AND NUT TIGHTEN ING TORQUES How to judge tightening torque of a standard bolt or nut. 1. How to judge tightening torque of a standard bolt. Find out the type of the bolt from the list below. Then, find the bolt tightening torque from the table. 2. How to judge tighting torque of a standard unit. The nut tightening torque can be judged from the bolt type. (See the item above.) LIST OF BOLT TYPES AND STRENGTH 1. Judging by part \ 1 Shape and class Hexagon head bolt @ Bolt head No* Hexagon flange bolt No mark Hexagon head bolt Hexagon Three protruding head bolt Two protruding lines Hexagon flange bolt Welded bolt @ l;') protruding Class 2. Judging by part No. Hexagon head bolt Parts No, I 91611-do625 Length (rnrn) Diameter ( mm ) Diameter Parts No. ~ e n ~ t h ( r n m ) Diameter ( m m ) Diameter STANDARD BOLT TIGHTENING TORQUES PRECOAT BOLTS (Bolts with seal lock agent coating on threads) 1. Do not use the precoat bolt as itisineither of the following cases: (a) After it is removed. (b) When the precoat bolt is moved Cloos- ened or tightened) by tightness check, etc. Note : . For torque check, use the lower limit of the Precoat ~~l~~ allowable tightening torque range. If the bolt moves, retighten it accordicg to the steps below. 2. Method for reuse of precoat bolts (I) Wash ,the bolt and threaded hole. (The (2) Perfectly dry the washed parts by air threaded hole must be washed even for blowing. replacement of the bolt.) (3) Coat the specified seal lock agent to the threaded portion of the bolt. HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before installation. 2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting. 3. The maximum tightening torque must not exceed twice.the standard tightening torque. Nominal diameter of screw 711 6 - 20'UNF 9/16 - 18UNF 314 - 16UNF 7/8 - 14UNF 11/16 - 12UNF 15/16 - 12UNF PF1/4 P F3/8 PF112 P F3/4 PF1 Hose inside d iarneter (mrn) 6 9 12 12 19 25 9 9 12 19 25 Standard tightening torque kg-m (ft-l b) Standard 2.5 ( 18.1) 5.0 ( 36.2) 6.0 ( 43.4) 6.0 ( 43.4) 12.0 ( 86.8) 14.0 (101.2) 5.0 ( 36.2) 5.0 ( 36.2) 6.0 ( 43.4) 12.0 ( 86.8) 14.0 (101.2) Tightening range 2.4 - 2.6 (17.4 - 18.8) 4.8 - 5.3 (34.7 - 38.3) 5.7 - 6.3 (41.2- 45.5) 5.7 - 6.3 (41.2 - 45.5) 11.4- 12.6 (82.4- 91.1) 13.3 - 14.7 (96.2 -- 106.3) 4.8 - 5.3 (34.7 -- 38.3) 4.8 - 5.3 (34.7 - 38.3) 5.7 -- 6.3 (41.2 - 45.5) 11.4-12.6 (82.4- 91.1) 13.3 -- 14.7 (96.2 - 106.3) FRAME NUMBER (1986.8 -- 1989.8) Punching posit ion Vehicle series Engine model Vehicle model Punching format Vehicle series Eng~ne model Vehicle model Punching format Top on rear right frame - 1 ton series 1 Z - - - - - - - - - - 4 P 5FG10 02- 5FG10 5FG14 02- 5FG14 5FG15 02- 5FG15 5FG18 02- 5FG18 5FG18 - 10001 4 Y 40- 5FG10 42- 5FG10 40- 5FG14 42- 5FG14 40- 5FG15 42- 5FG15 40- 5FG18 42- 5FG18 405FG18 - 10001 2 ton series 2 J 5FD10 02- 5FD10 5FD14 02 - 5FD14 5FD15 02 - 5FD15 5FD18 02- 5FD18 5FD18 - 10001 4 P 5FG20 02- 5FG20 5FG23 02 - 5FG23 5FG25 02 - 5FG25 5FG25 - I0001 1 Z 5FD20 02 - 5FD20 5F D23 02 - 5FD23 5FD25 02- 5FD25 5FD25 - 10001 4 Y 40- 5FG20 42- 5FG20 40- 5FG23 42- 5FG23 40- 5FG25 42- 5FG25 405FG25 - 10001 2 J 60 - 5FD20 62 - 5F D20 60 - 5FD23 62 - 5F D23 60 - 5F D25 62 - 5FD25 605FD25 - 10001 Vehicle series Engine model Vehicle model Punching format 3.0 ton series 4 P - - - - - - 2 J 60- 5FD28 62- 5FD28 60- 5FD30 62- 5FD30 605FD30 - 10001 4 Y 5FG28 02- 5FG28 5FG30 02- 5FG30 5FG30 - 10001 1 Z 5FD28 02- 5FD28 5FD30 02- 5FD30 5FD30 - 1000 1 FRAME NUMBER (1 989.9 - 1 5FG14 40-5FG14 5FD14 02-5FG14 42-5FG 14 02-5FD 14 Vehicle model 5FG15 40-5FG15 02-5FG15 42-5FG 1 5 02-5FD 1 5 5FG18 40-5FG 18 02-5FG18 42-5FG18 02-5FD 18 Punching format A5FG 1 8-400 1 1 405FG 1 8-400 1 1 A5FD 1 8-400 1 1 2 ton series 1 DZ 60-5FD20 62-5FD20 60-5FD23 62-5FD23 60-5FD25 62-5FD25 A605FD25-40011 1 Z 5FD20 02-5FD20 5FD23 02-5FD23 5FD25 02-5FD25 5FD25-40011 Engine model Vehicle model Punching format 3 ton series 5K 5FG20 02-5FG20 5FG23 02-5FG23 5FG25 02-5FG25 A5FG25-40011 4Y 40-5FG20 42-5FG20 40-5FG23 42-5FG23 40-5FG25 42-5FG25 405FG25-40011 1 DZ 60-5FD28 62-5FD28 60-5FD30 62-5FD30 A605FD30-400 1 1 A Engine model Vehicle model Punching format 4Y 5FG28 02-5FG28 5FG30 02-5FG30 5FG30-40011 1 Z 5FD28 02-5FD28 5FD30 02-5FD30 5FD30-400 1 1 WlRE ROPE SUSPENSION ANGLE LIST SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE Unit: ton (lb) Lifting angle 0" 30" 60" Rope diameter 6 mm (0.24 in.) 8 mm (0.32 in.) 10 mm (0.4 in.) 12.5 mm (0.5 in.) 14 mm (0.56 in.) Cutting load Tension 1 .OO time 1.04 time 1.16 time Single-rope suspension Two-rope suspension Com pres- 0 time 0.27 time 0.58 time Four-rope suspension Suspension met hod Lifting angle 90" 120" w F 2 t * I. Tension 1.41 time 2.00 time 2t 2t Compres- sion 1 .OO time 1.73 time Suspension method 2t 2t b COMPONENTS WEIGHT (1986.8 -- 1989.8) unit: kg (Ib) Engine 4P 4Y 2J 1 Z Transmission ASSY Torque Converter ASSY Differential & Front Axle (w/ Brake Counter Weight Mast 128 (282) 134 (295) 214 (471) 237 (523) 78 (172) AlSl N One speed 152 (335) AlSlN Twospeed 163 (359) 1 ton series 21 0 (463) 2 ton series 260 (573) 3 ton series 31 8 (701 ) 1.0 ton Approx. 430 (950) 1.35 ton Approx. 645 (1 420) 1.5 ton Approx. 785 (1 730) 1.75 ton Approx. 91 5 (2020) 2.0 ton Approx. 1 1 10 (2670) 2.25 ton Approx. 1225 (2700) 2.5 ton Approx. 1430 (3 1 50) 2.75 ton Approx. 1670 (3680) 3.0 ton Approx. 1860 (41 00) 1 .O ton Approx. 400 (880) 2.0 ton Approx. 500 (1 100) 3.0 ton Approx. 600 (1320) COMPONENTS WEIGHT (1 989.9 - unit: kg (Ib) 93 (205) 134 (295) 190 (41 9) 237 (523) 78 (1 72) 152 (335) 1 63 (359) 2 10 (463) 260 (573) 318 (701) Approx. 430 (950) Approx. 645 (1 420) Approx. 785 (1730) Approx. 9 1 5 (2020) Approx. 1 1 1 0 (2670) Approx. 1 225 (2700) Approx. 1430 (3 1 50) Approx. 1670 (3680) Approx. 1 864 (4 1 00) Approx. 400 (880) Approx. 500 (1 100) Approx. 600 ( 1 320) . . Engine 5K 4Y 1 DZ 1 Z Transmission ASSY Torque Converter ASSY Differential & Front Axle (w/ Brake) Balance Weight Mast AlSlN One speed Two speed 1 ton series 2 ton series 3 ton series 1.0 ton 1.35 ton 1.5 ton 1.75 ton 2.0 ton 2.25 ton 2.5 ton 2.75 ton 3.0 ton 1.0 ton 2.0 ton 3.0 ton RECOMMENDED LUBRICANT QUANTITY & TYPES (1 986.8 - 1989.8) Application 4 P 4 Y 2 J 1 Z MTM models AlSlN make 1 ton series 2 ton series 3 ton series 1 ton series 2 ton series 3 ton series 1 ton series All models Attached Table Description Classification AP I SD,SE,SF AP I CC,CD AP I G L-4 G L-5 ATF AP I G L-4 G L-5 I SO VG32 - LLC ?- Quantity 4.32 (1.14 USgal) 4.0 Q (1.06 US gal) 6.9 2 (1.82 US gal) 9.0 P (2.38 US gal) 4.0 2 (1.06 US gal) 14 11 (3.70 US gal) 5.8 Q (1.53 US gal) 6.8 Q (1.80 US gal) 9.0 Q (2.38 US gal) 27 2 (7.1 US gal) 34 2 (9.0 US gal) 37 11 (9.8 US gal) Proper quantity Reservoir Tank 0.2 Q (0.05 US gal) Proper quantity 1 Engine Type Motor oil SAE30 (SAE20 in cold area) SA E20W-40 (SAE 1 OW-30 in cold area) Diesel engine oil SAE30 (SAE20 in cold area) SAE 1 OW-30 Hypoid gear oil SAE85W-90 GM Dexrono II Hypoid gear oil SAE85W-90 Hydraulic oil #90 SAE J-1703 D OT- 3 MP Grease "LLC 30-50% mix- ture (for winter or al I-season) a Coolant with rust- inhibitor (for spring, summer and autumn) ? Gasoline Diesel Transmission Torque converter Differential Hydraulic oil Brake (1 .O-1.75 ton models) Chassis parts Coolant Coolant ( Reservoir Tank) Coolant volume All models 1.1 Q (0.3 US gal) (at Full level) Attached Table 1 Coolant volume unit: f (US gal) Engine 4 P 4 Y 1 z 2 J Drive method MTM ATM MTM ATM MTM ATM MTM ATM 1 .O - 1.75 ton vehicles 9.7 (2.56) 11.5 (3.03) 9.7 (2.56) 1 1.5 (3.03) - - 12.7 (3.35) 14.5 (3.70) 2.0 - 2.5 ton vehicles 9.9 (2.61) 11.2 (2.95) 9.9 (2.61) 11.2 (2.95) 9.3 (2.46) 8.6 (1 -01 14.9 (3.93) 14.2 (3.75) 2.75,3.0 ton vehicles - - 12.2 (3.22) 1 1.8 (2.92) 9.6 (2.53) 9.2 (2.43) 15.2 (4.01) 14.8 (3.72) RECOMMENDED LUBRICANT QUANTITY & TYPES (1 989.9 - 1 Quantity 4.0 Q (1.06 US gal) 4.0 11 (1.06 US gal) 6.511 (1.7 US gal) 9.0 Q (2.38 US gal) 4.0 Q (1.06 US gal) 14.0 Q (3.70 US gal) 5.8 Q (1.53 US gal) 6.8 Q (1.80 US gal) 9.0 Q (2.38 US gal) 27.0 Q (7.1 US gal) 34.0 Q (9.0 US gal) 37.0 R (9.8 US gal) 45.0 Q (1 1.9 US gal) 65.0Q(17.2USgal) 70.0 Q (1 8.5 US gal) 45.0 Q (1 1.9 US gal) 65.0 Q (1 7.2 US gal) 70.0 R ( 1 8.5 US gal) Proper quantity Reservoir Tank 0.2 R (0.05 US gal) Proper quantity 1 Application 5K 4Y 1 DZ 1 z MTM r~odels AlSlN make 1 ton series 2 ton series 3 ton series 1 ton series 2 ton series 3 ton series 1 ton series Description Coolant (Reservoir Tank) Classification API SD,SE,SF API CC, CD API G L-4 GL-5 ATF API GL-4 G L- 5 IS0 ' VG32 Engine 2tonseries 3 ton series Fuel tank 1 ton series 2 ton series 3 ton series Brake 1 ton series (1 .O-1.75 ton models) TY pe Motor oil SAE30 (SAE20 in cold area) SAE20W-40 (SAE1 OW-30 in cold area) Diesel engine oil SAE30 (SAE20 in cold area) SAE 1 OW-30 Hypoid gear oil SAE85W-90 GM Dexron@ I1 Hypoid gear oil SAE85W-90 Hydraulic oil #90 Gasoline , Diesel Chassis parts Coolant t Transmission Torque converter Differential Hydraulic oil LLC (for winter or al I-season) Coolant with rust- in hi bitor (for spring, summer and autumn) t MP grease 0" LLC 30-50% mixture Coolant volume All models Attached Table All models 1.1 Q (0.3 US gal) (at Full level) Attached Table 1 Coolant volume unit: 2 (US gal) Engine 5K 4Y 2.0 - 2.5 ton vehicles 1 z 1 DZ Drive method / MTM ATM MTM ATM 2.75, 3.0 ton vehicles 1.0 - 1.75 ton vehicles 5.5 (1.45) 7.3 (1.93) 7.5 (1.98) 9.3 (2.46) MTM ATM MTM ATM 5.7 (1.50) 7.0 (1.85) 7.7 (2.03) 9.0 (2.38) 10.0 (2.64) 9.6 (2.53) 9.7 (2.56) 9.3 (2.46) 8.3 (2.19) 7.9 (2.09) 9.4 (2.48) 8.7 (2.30) 5.8 (1.53) 7.6 (2.01) 8.0 (2.1 9) 7.3 (1.93) LUBRICATION CHARTS 2 1 Chain 2 Differential 3 Front wheel bearing 4 Brake master cylinder (1 .O-1.75 ton models) I 5 Transmission case 3 6 Rear wheel bearing 7 Steering knuckle kingpin 8 Bell crank pin 16 9 Oil tank 15 10 Engine crank case 11 Rear axle beam front 4 12 Rearaxlebeam rear 13 Tilt steering universal joint 13 14 Tilt steering liocking meachanism 15 Mast support bushing 5 16 Tilt cylinder front pin 11 17 Propeller shaft I lnspectevery8hours(daily) 7 I1 Inspect every 40 hours (weekly) I11 Inspect every 170 hours (monthly) 6 IV l nspect every 1000 hours (6 month1 y) V lnspectevery2000hours(annually) o lnspect and service Replace 1 MP grease 2 Engine oil 3 Hypoid gear oil 4 Hydraulic oil 5 Gear oil 6 Brake fluid (1 .O-1.75 ton models) Clutch Model Lubrication Chart LAOM136 Chain Differential Front wheel bearing Brake master cylinder (1 .O-1.75 ton models) Torque converter case Rear wheel bearing Steering knuckle king pin Bell crank pin Oil tank Engine crank case Rear axle beam front Rear axle beam rear Tilt steering universal joint Tilt steering liocking meachanism Mast support bushing Tilt cylinder front pin Propeller shaft l nspect every 8 hours (daily 1 lnspect every 40 hours (weekly) lnspect every 170 hours (monthly) lnspect every 1000 hours (6 monthly) lnspect every 2000 hours (annually) Inspect and service Replace MP grease Engine oil Hypoid gear oil Hydraulic oil Automatic transmission fluid Brake fluid (1 .O-1.75 ton models) Torque Converter Model Lubrication Chart 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 : Soapy water "2 : Detector "3 : Flaw detector Inspection Period l tem Months Hours 1 170 ENGINE Main body PCV system Governor Lubrication system Fuel system Cooling system Proper starting and abnormal noise Rotating condition at id1 ing Rotating condition during acceleration Exhaust gas condition Air cleaner element Valve clearance Compression Cylinder head bolt loosening Muffler rubber mount Clogging and damage in PCV valve and piping No-load maximum rpm Oil leak Oil level Clogging and dirt of oil filter Fuel leak Operation of carburetor link mechanism Dirt and clogging of fuel filter and element Injection timing l njection nozzle injection pressure and spray status Draining of sedimenter Coolant level in radiator and leak Rubber hose degradation Radiator cap condition Fan belt tension, looseness and damage Radiator rubber mount 3 500 I M M I C M M T I I M I I I I I I M M I I I I I I 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0" 0" 6 1000 12 2000 0 0 0 0 0 0 0 0 0 0 - Inspection Period l tem Months Hours POWER Clutch Transmission Differential Torque converter and Propeller shaft and axle shaft DRIVE SYSTEM 1 170 3 500 6 1000 TRANSMISSION SYSTEM Clutch pedal play Abnormal sound and functioning (connect ion) Clutch booster function and leak Fluid level Oil clutch mechanism function and leak Leak Fluid level Gear function and abnormal noise Leak Oil level Bolt loosening Lea k Fluid level Operating mechanism function and !ooseness Control valve and clutch functions Inching valve function Stall and hydrau l ic pressure measurement Loose joint Looseness at spline connections Looseness of universal joint Twisting and cracks of axle shaft. 12 2000 0 0 0 M I I I I I I I I I T I I I I I M T I I I Wheels 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Tire inflation pressure Tire cuts, damage and uneven wearing Loose rim and hub nuts tire groove depth metal chips, pebbles and other foreign matter trapped in tire grooves Rim, side bearing and disc wheel damage Abnormal sound and looseness of front wheel bearing M I T M I I I 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 inspection Period l tern Months Hours I I I M Wheel Front axle Rear axle A Abnormal sound and looseness of rear wheel bearing Cracks, damage and deformation of housing Cracks, damage and deformation of beam Looseness of axle beam in vehicle longitudinal direction STEERING SYSTEM Steering wheel Gear box Rods, links and arm Power steering Knuckle Steering shaft BRAKING 1 170 0" 3 500 0 0 0 0 6 1000 Play and looseness Function Oil leak Looseness of mounting Clogging of re1 ief valve filter Looseness and damage Linkage wear and mounting condition Oil leak Mounting and linkage looseness Damage of power steering hose King pin looseness Cracks and deformation Wheel alignment Left and right turning angle SYSTEM 12 2000 0 0 0 Brake pedal Parking brake Brake pipe Reservoir tank I I I T C I I I I I I I M M Play and reserve Braking effect Operating force Braking effect Rod and cable looseness and damage Leak, damage and mounting condition Leak and fluid level 0 0 Master cylinder or brake valve and wheel cylinder 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 I M I I I I I I Function, wear, damage, leak and rr~ounting looseness 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 Inspection Period l tem Months Hours M I I I I M I I T Brake drum and brake shoe Backing plate Clearance between drum and lining Wear of shoe sliding portion and lining Drum wear and damage Shoe operating condition Anchor pin rusting Return spring fatigue Automatic adjuster function Deformation, cracks and damage Loose mounting MATERIAL Forks Mast and fork bracket Chain and wheel Various attachments HYDRAULIC 1 170 HANDLING SYSTEM Abnormality of fork and stopper pin Misalignment between left and right fork fingers Cracks at fork root and welded part Deformation and damage of each part and crack at welded part Mast and lift bracket looseness Wear and damage of mast support bush Wear, damage and rotating condition of rollers Wear and damage of roller pins Wear and damage of mast strip Tension, deformation and damage of chain Chain lubrication Abnormality of chain anchor bolt Wear, damage and rotating condition of chain wheel Abnormality and mounting condition of each part SYSTEM 3 500 0 0 0 0 I I I *3 I I I I I I I I I I I 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 6 1000 I I I Cy I inder 12 2000 0 0 0 0 0 0 0 0 Loosening and damage of cylinder mounting Deformation and damage of rod, rod screw and rod end Cylinder operation Natural drop and natural forward tilt (hydraulic drift) 0 0 0 0 0 , 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Inspection Period Months Hours I I M I I I C I I I I M I I I T l tern Cylinder Oil purrip Hydraulic oil tank Control lever Oil control * ~ a Ive Hydrau l ic piping ELECTRICAL Oil leak and damage Wear and damage of pin and cylinder bearing Lifting speed Uneven rnovemen t Oil leak and abnormal sound Oil level and contamination Tank and oil strainer Oil leak Loose l in kage Operation Oil leak Relief pressure measurement Relief valve and tilt lock valve functions Oil leak Deformation and damage Loose joint SYSTEM Ignition timing Starting rnotor Charger \ Battery Electrical wiring 1 170 0 Cracks on distributor cap Spark plug burning and gap Distributor side terminal burning Distributor cap center piece wear and darnage Plug cord internal discontinuity Ignition timing Pinion gear meshing status Charging function Battery fluid level Battery fluid specific gravity Darnage of wiring harness Fuses 3 500 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 I I I I M I I I M I I 6 1000 0 0 12 2000 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 C 0 0 0 0 0 0 0 0 12 2000 0 0 1 170 Months Hours 1 I I - l nspection Period l tem Preheater 3 500 0 0 0 0 Open-circuit in glow plug Open-circuit in intake heater 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 SAFETY Head guard Back-rest Lighting system Horn Direction indicator l nstruments Backup buzzer Rear-view m i rror Seat Body Others 6 1000 0 0 Engine stop- poing system 1 Diesel engine key stop device function I I T I I I I I I I I I I T L DEVICES, ETC. Cracks at welded portion Deformation and damage Loosening of mounting Deformation, crack and damage Function and mounting condition Function and mounting condition Function and mounting condition Functions Function and mounting condition Dirt, damage Rear reflection status Loosening and damage of mounting Damage and cracks of frame, cross members, etc. Bolt looseness Grease up 0 G 0 0 0 0 0 0 PERIODIC REPLACEMENT LUBRICANTS AND PARTS a : Replacement *' : for new vehicle *' : Every 2 years *3 : Every 3 years Replacement shall be made upon arrival of the operation hours or months, whichever is earlier. l nterva l Item Engine Engine oil filter Engine coolant (every 2 years for LLC) Fuel filter Torque converter oil Torque converter oil filter Transmission oil Differential oil Hydraulic oil Hydraulic oil filter Wheel bearing grease Spark plugs Cyclone air cleaner element Brake va Ive rubber parts Cups and seals for master and wheel cylinders Brake fluid Power steering hoses Power steering rubbers parts Hydraulic hoses Reservoir tank tube Fuel hoses Torque converter rubber hoses Chains 1 month 170 hours a + 1 a 3 months 500 hours a a a 6 months 1000 hours a a a a a a a a 12 months 2000 hours a a a a a a a a a a a a a a a a*2 a *2 a*2 a*2 a*3 A ENGINE ........................................... GENERAL .......................... ENGINE PERFORMANCES ENGINE ASSY REMOVAL 4P ENGINE VEHICLE (1 986.8 -- 1989.8) ........... 25 ENGINE VEHICLE (1986.8 -1989.8) ............ .............................. I Z ENGINE VEHICLE 4Y ENGINE VEHICLE .............................. 5K ENGINE VEHICLE (1 989.9 - ) ........... 1 DZ ENGINE VEHICLE (1 989.9 ) .......... ENGINE ASSY DISCONNECTION ............. TORQUE CONVERTER TYPE VEHICLE ........................... CLUTCH TYPE VEHICLE ENGINE ASSY INSTALLATION 4P ENGINE VEHICLE (1986.8 -- 1989.8) ........... 2J ENGINE VEHICLE (1986.8 -- 1989.8) ........... 1 Z ENGINE VEHICLE .................. ; ...... .'. ... .............................. 4Y ENGINE VEHICLE 5K ENGINE VEHICLE (1989.9 - ) ........... 1 DZ ENGINE VEHICLE (1 989.9 - ) .......... ENGINE TUNE-UP ...................... 4P/4Y/5K ENGINE VEHICLE ..................... 2J/1 Z/l DZ ENGINE VEHICLE AIR CLEANER ....................................... RADIATOR .......................................... MUFFLER AND EXHAUST PIPE ...................... ........................................... BAlTERY STARTING MOTOR .................................. ALTERNATOR ....................................... .............................. ACCELERATOR PEDAL Page 1-2 1-8 GENERAL 1 I 4P Engine Front View (1 986.8 -- 1989.8) KAF1-1 I 1 4P Engine Rear View (1 986.8 - 1989.8) KAF25-32 4Y Engine Front View KAJ 14-2 1 4Y Engine Front View KAJl4-16 2J Engine Front View (1 986.8 - 1989.8) KAH2-2 i 2J Engine Rear View (1 986.8 - 1989.8) KAHI - 15 12 Engine Front View KAG1-14 1 Z Engine Front View 1 5K Engine Front View (1 989.9 - 1 KAPI-4 5K Engine Front View (1 989.9 - 1 KAPI-5 1 DZ Engine Front View (1 989.9 - 1 1 DZ Engine Front View (1 989.9 - 1 ENGINE PERFORMANCES (1 986.8 -- 1989.8) 1.0 - 1.75 ton 2.0 -- 2.5 ton Engine model 4P 4Y 2 J 4P 4Y Tota I displacement cc 1493 2237 248 1 1493 2237 1 1Z 2953 248 1 2237 2953 248 1 2.75 -- 3.0 ton No-load maximum governed speed rpm 3050 2450 2300 3050 2600 2J 4Y 1 Z 2 J 2600 2600 2600 2600 2600 Rated horsepower PS/rpm 35/2800 4512 1 00 4412700 3512800 5412400 Maximum torque kg-m/rpm 10.5/1800 16.511 800 14.512000 10.511 800 16.5/1800 6012400 5012500 54/2400 60/2400 5012500 18.5/1600 14.512200 1 6.5/1800 1 8.511 600 14.512260 ENGINE PERFORMANCES (1989.9 - 1 .O -- 1.75 ton 2.0 - 2.5 ton 1.75 -- 3.0 ton Engine model 5K 4Y 1 DZ 5K 4Y 1 Z 1 DZ 4Y 1 Z 1 DZ Total displacement cc 1486 2237 2486 1486 2237 2953 2486 2237 2953 2486 No-load maximum governed speed rpm 3050 2600 2600 3050 2600 2600 2600 2600 2600 2600 Rated horsepower PS/rpm 38/2800 54/2400 55/2400 38/2800 54/2400 60/2400 55/2400 54/2400 60/2400 55/2400 Maximum torque kg-m/rpm 1 1.5/2000 16.5/1800 17.0/1600 1 1.5/2000 16.5/1800 18.5/1600 1 7.0/ 1 600 16.5/1800 18.5/1600 17.0/1600 1-10 PERFORMANCE CURVES Engine speed (rpm) 4P Engine Performance Curve (1 986.8 - 1989.8) LAOM18 -I 14 2 (kg-m I 1 6 10 14 18 22 26 XI 02 Engine speed (rpm) (1 .O - 1.75 ton vehicle) 2J Engine Performance Curve (1 986.8 - 1989.8) - 43- 1 - \19511000 - - KAOM 19,20 -300 5 . - ,280 '; E -260 2 -240 -220 5 200 LL 180 (glpsh) I- 6 10 14 18 22 26 Engine speed (rpm) x1 02 (2.0 - 3.0 ton vehicle) I:: (kg-m 12 Engine Performance Curve - 44 - Engine speed (rpm) (1 .O - 1.75 ton vehicle) (kg-m ) 4Y Engine Performance Curve (1 986.8 - 1989.8) LAOM1 1,12 3 \ u Fuel consumption v, Engine horsepower CI r y Shaft torque 3 - ~ 1 0 2 Engine speed (rpm) 5K Engine Performance Curve (1 989.9 - 1 1 I I I 10 14 18 22 1 26 ~102 Engine speed (rpm) 1 DZ Engine Performance Curve (1 989.9 - 1 - 48 - ENGINE ASSY REMOVAL 4P ENGINE VEHICLE (1 986.8 -- 1989.8) 1. Engine hood removal (1) Disconnect the engine hood damper from the frame bracket. (2) Disconnect the engine hood stay from the frame bracket. (3) Remove engine hood hinge set screws (2 pcs. on each side), and remove the engine hood. Removing the Engine Hood LA064-12 ,? 3 Radiator cover and toe board removal Battery removal (1 ) Disconnect battery terminals. Caution : Always disconnect the negative terminal first. (2) Remove the battery cap. (3) Remove the battery. Removing the Battery LA054-6 Battery case removal (1 ) Remove set bolts (3 pcs.), and remove the battery case. Electrical wiring and fuel hose disconnec- tion. (1) Disconnect the starting motor bond strap. (2) Disconnect each electrical wiring con- nector. (3) Disconnect the fuel hose. Removing the Battery Case LA054-9 Air cleaner removal (1 ) Remove the hydraulic tank breather. (2) I-oosen the hose clamp for the air cleaner hose. (3) Remove air cleaner case set bolts (4 pcs.) and remove the air cleaner. Removing the Air Cleaner - 49 - 7. Radiator reserve tank removal ( 1 ) Disconnect the reserve tank hose from the radiator. (2) Remove the reserve tank. Removing the Reserve Tank LA054-23 Fan removal (1 ) Remove fan set bolts (4 pcs.) and re- move the fan. Coolant draining (1 ) Loosen the radiator drain plug to drain the coolant. (2) Loosen the engine drain plug to drain the coolant. Removing the Fan LA054-27 Radiator removal ( 1 ) Loosen the inlet and outlet hose clamps. (2) Disconnect the torque converter cooler hose (in torque converter vehicle). Caution: Identify the hose installed positions. (3) Remove radiator set bolts, and remove the radiator. Removing the Radiator LA054-29 Exhaust pipe disconnection ( 1 ) Remove flange set nuts (2 pcs.) and re. move the exhaust pipe. Accelerator cable disconnection (1 ) Disconnect the accelerator cable. Disconnecting the Exhaust Pipe Oil pump disconnection ( 1 ) Remove oil pump set bolts (2 pcs.) (2) Disconnect the oil pump from the engine. Horn removal (1 ) Disconnect the horn wiring connector. (2) Remove set bolts (2 pcs.), and remove the horn. Removing the Oil Pump ASSY LA054-32 Torque converter shift rod and inching cable disconnection (in torque converter vehicle). (1) Remove the set nut and disconnect the shift rod. (2) Disconnect the Inching Cable. Disconnecting the Rod and Cable LA059-26,28 Clutch release cylinder removal (in clutch vehicle) (1 ) Disconnect the clevis. (2) Remove set bolts (2 pcs.) the clutch release cylinder. Accelerator peda l with pedal removal and remove toe board Removing the Clutch Release Cylinder LA054-15 Oil control valve return hose removal (in clutch vehicle) (1 ) Loosen hose clamps at both ends of the hose and disconnect both ends. (2) Remove the bracket set bolt and remove the return hose. Removing the Return Hose Shift lever removal (in clutch vehicle) (1) Disconnect the shift lever rod on the transmission side. (2) Remove the shift lever set plate, and remove the shift levers (forward & reverse, and speed). (3) Remove the plate washer and spring. Disconnecting the Shift Lever R o d LA055-1 1 Shift lever shaft removal (in clutch vehicle) ( 1 ) Remove set bolts (4 pcs.), and remove the shift lever shaft. Removing the Shift Lever Shaft LA055- 10 Propeller shaft disconnection (I ) Remove set bolts (2 pa.), and remove the propeller shaft cover. (2) Remove propeller shaft set bolts (4 pcs. on one side), and disconnect the propel- ler shaft. Note : It may be disconnected on either of the differential or the transmission side. Disconnecting the Propeller Shaft ASSY LA055-7 Parking brake cable clamp removal (in torque converter model) (1 ) Remove parking brake cable clamp set bolt, and re-move the cable from the transmission case. Disconnecting the.Parking Brake Cable LA063-28 Mou ( 1 ) nting set bolt removal Remove the engine mounting set bolts left and right. Remove the torque converter & trans- mission mounting set bolts (in torque converter vehicle). Remove the transmission mounting set bolts (in clutch vehicle). Removing the Mounting Set Bolts LA052-6,7 24. Stabili~er emoval (in clutch model) (1 ) Measure the stabilizer installed dimen- sions. Measure and record for both the stabilizer at the upper left and the stabilizer at lower right. Dimension A : 83 + 1 mm (3.27 k 0.04 in.) Dimension B : 198 2 1 mm (7.8 + 0.04 in.) i Measuring the Stabilizer Installed Dimensions LAOM166 (2) Loosen the stabilizer bar lock nut. (3) Remove the set nuts at both ends, and remove the cushion rubber, plate, sta- bilizer stopper and stabilizer bar. 25. Check that all electrical wiring, cables and links are disconnected. 26. Engine ASSY with transmission removal - ( 1 ) Use the SST and remove the engine Removing the Stabilizer LA052-4 ASSY with transmission. SST 090 10-201 1 1 -7 1 Weight of ecgine ASSY with trans- mission: With torque converter & transmission: approx. 240 kg (528 Ib) With transmission: approx. 270 kg (594 Ib) Caution : Try safe operation by fully considering the center of gravity in setting the wire ropes for hoisting. Removing the Engine with Transmission LA052-8 2J ENGINE VEHICLE (1 986.8 -- 1989.8) 1. Engine hood removal ( 1 ) Disconnect the engine hood damper from the frame bracket. (2) Disconnect the engine hood stay from the frame bracket. (3) Remove the engine hood hinge set screws (2 pcs. on one side), and remove the engine hood. 2. Toe board removal Removing the Engine Hood LAO 1-6 3. Battery removal ( 1 ) Disconnect battery terminals. Caution : Always disconnect the negative terminal first. (2) Remove the battery cap. (3) Remove the battery. Removing the Battery LAO1-10 4. Battery case removal ( 1 ) Remove set bolts (3 pcs. ), and remove the battery. 5. Electrical wiring and fuel hose disconnec- tion. (1) Disconnect the starting motor bond strap. (2) Disconnect electrical wiring such as the injection pump solenoid cut wiring. (3) Disconnect the fuel hose. Disconnecting the Solenoid Cut Wiring LAO 1-20 6. Fuelfilterwith bracketremoval ( 1 ) Disconnect the fuel piping. (2) Remove the set bolts (2 pcs.), and re- move the fuel filter with bracket. Removing the Fuel Filter with Bracket LA01 -1 3 - 7. Air ( ( 1 (2) :leaner removal Remove the hydraulic tank breather. Loosen the hose clamp for the air cleaner hose. Remove air cleaner case set bolts (4 pcs.), and remove the air cleaner. Removing the Air Cleaner ASSY LA01 -1 6 Radiator cover removal (1) Remove the set knobs, and remove the radiator cover. Radiator reserve tank removal ( I ) Disconnect the reserve tank hose from the radiator. (2) Remove the reserve tnak. Removing the Radiator Cover LAO 1-28 Radiator removal ( 1 ) Loosen the radiator drain plug to drain the coolant. (2) Loosen the engine drain plug to drain the coolant. (3) Disconnect the torque converter cooler hose (in torque converter model). Caution : Identify the hose installed positions. (4) Remove the radiator set bolts and remove the radiator. Coolant Drain Plugs L A O 1 -32,30 Removing the Radiator - 55 - Exhaust pipe disconnection ( 1 ) Remove flange set nuts (3 pcs.), and dis- connect the exhaust pipe. Accelerator cable disconnection (1) Disconnect the cable clevis injection pump side. (21 Remove the accelerator cable from the manifold. on the bracket 13. Oil pump removal (1 ) Remove oil pump set bolts (2 pcs.). (2) Disconnect the oil pump from the engine. Disconnecting the Exhaust Pipe LA02-7 Disconnecting the Accelerator Cable LA01 -14 Removing the Oil Pump LA03-3 Accelerator pedal with pedal toe board removal (1 ) Remove toe board set bolts, and remove accelerator pedal with pedal toe board. Removing the Pedal Toe Board Torque converter shlft rod and inching cable disconnection (in torque converter vehicle) ( 1 ) Remove the set nut, and disconnect the shift rod. (2) Disconnect the clevis, loosen the cable set nut, and disconnect the inching cable. Disconnecting the Torque Converter LA03-8 Link Components 16. Clutch release cylinder removal (in clutch vehicle) (1 ) Remove set bolts (2 pcs.). (2) Extract the push rod, and remove the clutch release cylinder. Removing the Clutch Booster ASSY LA07-2 1 17. Oil control valve return hose removal (in cluich vehicle) ( 1 ) Loosen the hose clamps at both ends of the hose and disconnect both ends. (2) Remove the hose bracket set bolt, and remove the return hose. Removing the Valve Return Hose LA07-7 18. Shiaft lever removal (in clutch vehicle) ( 1 ) Dlsconnnect the shift lever rod from rhe transmission. (2) Remove the shift lever set plate, and remove the shift levers (forward & reverse, and speed). (3) Remove the plate washer and spring. Removing the Shlft Lever - 57 - 19. Shift lever shaft rer~loval (in ( (1 ) Rernove set bolts (4 pcs. the shift lever shaft. :lu tch vehicle) ) , and remove Removing the Shift Lever Shaft LA07-15 Propeller shaft disconnection (1) Remove set bolts (2 pcs.), and remove the propeller shaft cover. (2) Remove propeller shaft set bolts (4 pcs. on one side), and disconnect the propel- ler shaft. Note: It may be disconnected on either the differ- ential or the transmission side. Disconnecting the Propeller Shaft LA03-16 Parking brake cable calmp removal (I) Remove the parking brake clamp set bolt, and disconnect the cable from the transmission cal be. Disconnect~ng the Parking Brake Cable LA0126-31 22. Mounting set bolt removal (1) Remove the engine mounting set bolts left and right. Removlng the Eng~ne Mounting Set Bolts LA01 26-32 (2) Remove the torque converter & trans- mission mounting set bolts (in torque converter vehicle). (3) Remove the transmission mounting set bolts (in clutch vehicle). Stabiliter removal (in clutch vehicle) ( 1 ) Measure the stabilizer installed dimen- tions. (measure and recored for both the stabilirer at upper left and the stabilirer at lower right.) m m (in.) (2) Loosen the stabil~zer bar lock nut. (3) Remove set nuts at both ends, and remove the cushion rubber, plate, sta- bili~er stopper and stabilizer bar. Check that all electrical wiring, cables and links are disconnected. Dimension B 198 + 1 (7.8 + 0.04) 205.5 2 1 (8.1 ? 0.041 Vehicle model 1 .O " 2.5 ton series 2.75-3.0 tor series Removing the Mounting Set Bolts (1 ) LA03-22 Dimension A 83 ' (3.27 2 0.04) 90.5 +_ 1 (3,56 0.041 Removing the Mounting Set Bolts ( 2 ) LAO 126-34 Measuring the Stabilizer Installed Dimension LAOM166 Removing the Stab1 lizer - 59 - Engine ASSY with transmission removal (1) Use the SST and remove the engine ASSY with transmission. SST09010-20111-71 Weight of engine ASSY with transmission With torque converter & transmission: 330 kg (726 I b) With transmission : 350 kg (770 Ib) Caution: Try safe operation by fully considering the Center of gravity in setting wire ropes for Removing the Engine ASSY with Transmission LA04-9 hoisting. ENGINE VEHICLE Engine hood removal (1 ) Disconnect the engine hood damper from the frame bracket. (2) Disconnect the engine hood stay form the frame bracket. (3) Remove engine hood hinge set screws (2 pcs. on one side), and remove the engine hood. 2. Radiator cover and toe board removal Removing the Engine Hood LA088-1 Battery removal ( 1 ) Disconnect battery terminals. Caution : Always disconnect the negative terminal first. (2) Remove the battery cap. (3) Remove the battery (2 pcs.). Removing the Battery LA088-5 Battery case removal ( 1 ) Remove set bolts (3 pcs.), and remove the battery case. Electrical wiring and fuel hose disconnection (1) Disconnect the starting motor bond strap. (2) Disconnect each wiring connector. (3) Disconnect the fuel hose. Removing the Battery Case LA096-4 Coolant dra~ning (1 ) Loosen the radiator drain plug to drain the coolant. (2! Loosen the engine drain plug to drain the coolant. Radiator removal ( 1 ) Rernove the radiator reserve tank. (2) Remove the torque converter cooler hose (in torque converter vehicle). Caution : Identify the hose instal led position. Disconnecting the Torque Converter LA096- 13 Cooler Hose - 61 - (3) Disconnect the inlet and outlet hoses from the engine. (4) Disconnect the fan shroud from the radiator. Disconnecting the Fan Shroud LA096-14 (5) Remove set bolts (2 pcs.), and remove the radiator. Removing the Radiator LA096-15 Air cleaner removal (1 ) Remove the hydraulic tank breather. (2) Loosen the hose clamp for the air cleaner hose. (3) Remove air cleaner case set bolts (4 pcs.), and remove the air cleaner. Removing the Air Cleaner LA096-18 Exhaust pipe disconnection (1 ) Remove flange set nuts (3 pcs.), and dis- connect the exhaust pipe. Accelerator cable disconnection ( 1 ) Disconnect the accelerator cable from the injection pump, Disconnecting the Exhaust Pipe LA096-19 Torque converter shift rod and inching cable disconnection (in torque converter vehicle) ( 1 ) Remove the set nut and disconnect the shift rod. (2) Disconnect the inching cable. Disconnecting the Shift Rod LA096-2 1 12. Shift lever removal (in clutch vehicle) (1) Disconnect the shift lever rod on the transmission side. (2) Remove the shift lever rod set nut, and remove the plate and shift levers (for - ward & reverse, and speed). (3) Remove the plate washer and spring. Removing the Shift Lever LAO1 13-10 Disconnect the oil pump (tandem pump) (2 - 3 ton clutch model) ( 1 ) Disconnect the oil pump return hose from the hydraulic tank. Disconnecting theReturn Hose LA01 13-1 1 (2) Remove oil pump set bolts (2 pcs.). (3) Disconnect the oil pump (tandem pump) from the engine. Disconnecting the Oil Pump ASSY LA01 13-12 - 63 - Oil pump ASSY disconnection (All models excluding 2 " 3 ton clutch models) (1) Removeoil pump-set bolts (2 pcs.). (2) Disconnect the oil pump from the engine. Disconnecting the Oil Pump L A 0 8 8 - 1 9 Clutch release cylinder removal (in clutch vehicle) (1 ) Diconnect the clevis. (2) Remove set bolts (2 pcs.) and remove the clutch release cylinder. Removing the Release Cylinder L A O 1 1 3-22 16. Oil control valve return hose removal (in 2.0 - 3.0 ton clutch vehicle) ( 1 ) Loosen hose clamps at both ends of the hose. (2) Remove the return hose. Removing the Return Hose L A 0 1 13-13,14 Propeller shaft disconnection ( 1 ) Remove set bolts (2 pcs.), and remove the propeller shaft cover. (2) Remove propeller shaft set bolts (4 pcs. on each side) and disconnect the pro- pel ler shaft. Note: It may be disconnected on either the dif- ferential or the transmission side. 0isconnect;ng the Propeller Shaft L A 0 9 6 - 2 8 - 64 - Parking brake cable clamp removal (1 ) Remove the clamp set bolt at the lower part of the transmission case, and dis- connect the cable from the transmission case. Disconnecting the Parking Brake Cable LAO113-19 Mounting set bolts removal ( 1 ) Remove the engine mounting set bolts left and right. Removing the Engine Mounting Bolts LA01 13-21 (2) Remove the troque converter & trans- mission mounting set bolts (in torque converter vehicle). (3) Remove the transmission mounting set bolts (in clutch vehicle). Removing the Transmission LA096-29,1 13-20 Mounting Bolts Measuring the Stabilizer l nstalled Dimension LAOM1 66 - 65 - 20. Stabilizer removal (in clutch vehicle) (1 ) Measure the stabilizer installed dimen- sions. Measure and record for both the stabilizer at the upper left and stabilizer at lower right. mm (in.) I L _ _ ._- .> I i i I I i L:, s,( I 1 .g- - v- .. F - I \ J L ! , Dimension B 214.5 + 1 (8.44 t 0.04) 205.5 +- 1 (8.1 k 0.04) t Vehicle model 2.0 -2.5 'On series 2-75 " 3.0 'On . Demension A 99.5 t 1 (3.92 i 0.04) 905k 1 (3.56' ? 0.04) Loosen the stabilizer bar lock nut. Remove the set nuts at both ends, remove the cushion rubber, plate, bi I izer stopper and stabilizer bar. and sta- Removing the Stabilizer (Upper Left) L A 0 1 13-24 21 . Radiator reserve tank bracket removal ( 1 ) Remove set bolts (2 pcs.) and remc the reserve tank bracket. Removing the Stabilizer (Lower Right) L A O 1 13-27 Fan removal ( 1 ) Remove set bolts (4 pcs.), and remove the fan. Check that all electrical wiring, cables and l in-ks are disconnected. 24 Engine ASSY with transmission removal Removing the Fan LAO 1 13-36 ( 1 ) Use the SST and remove the engine with transmission. SST 0901 0-20 1 1 1-7 1 Weight of engine ASSY with transmission With torque converter & transmission: approx. 350 kg (770 lb) With transmission: approx. 380 kg (836 Ib) Caution : Try safe operation by fully considering the center of gravity in setting the wire ropes for hoisting. Engine ASSY with Transmission - 66 - ENGINE VEHICLE Engine hood removal ( 1 ) Disconnect the engine hood damper from the frame bracket. (2) Disconnect the engine hood stay from the frame bracket. (3) Remove the engine hood hinge set screws (2 pcs. on one side), and remove the engine hood. 2. Radiator cover and toe board removal Removing the Engine Hood Battery removal ( 1 ) Disconnect battery terminals. Caution : Always disconnect the negative terminal first. (2) Remove the battery cap (3) Remove the battery. Removing the Battery LA064-2 1 Battery case reomova l ( 1 ) Remove set bolts (3 pcs.), and remove the battery case. Electrical wiring and fuel hose disconnection (1) Disconnect the starting motor bond strap. (2) Disconnect the electrical wiring con- nector. (3) Disconnect the fuel hose. Removing the Battery Case LA054-9 Horn removal ( 1 ) Disconnec; the wiring connector. (2) Remove set bolts (2 pcs.), and remove the horn. Accelerator pedal with pedal toe board removal (1 ) Remove toe board set bolts, and remove the accelerator pedal with pedal toe board. Removing the Accelerator Pedal with LA064 - 34 Toe Board Air cleaner removal ( 1 ) Remove the hydraulic tank breather. (2) Loosen the hose clamp for the air cleaner hose. (3) Remove air cleaner case set bolts (4 pcs.), and remove the air cleaner. Removing the Air Cleaner ASSY LA057-5,6 9. Oil ( (1 :ontrol valve return pipe removal Loosen the hose clamps at both ends of pipe, and disconnect both ends. Remove the bracket set bolt, and re- move the return pipe. Removing the Return Pipe LA057 -3 Accelerator cable discon nectio ( 1 ) Disconnect the accelerato carburetor side. Exhaust pipe disconnection ( 1 ) Remove flange set nuts remove the exhaust pipe. n r cable on the (2 pcs.), and Disconnecting the Exhaust Pipe LA057-11 Radiator reserve tank removal (1 ) Disconnect the reserve tank hose from the radiator. (2) Remove the reserve tank. Removing the Reserve Tank - 68 - Coolant draining (1 ) Loosen the radiator drain plug to drain the coolant. (2) Loosen the engine drain plug to drain the coolant. Draining the Coolant LA057-21 14. Radiator removal (1 1 Loosen the inlet and outlet hose clamps. (2) Rernove the radiator set bolts, and remove the radiator. Removing the Radiator ASSY LA058 -3 15. Oil pump disconnection (tandem pump) (in 2.0 - 3.0 ton clutch model) (1) Disconnect the oil pump return hose from the hydraulic tank. .(2) Remove oil pump set bolts (2 pcs.). (3) Disconnect the oil pump from the engine. Removing the Oil Pump (Tandem Pump) LA062 -2 16. Oil pump disconnection (All models excluding 2.0 - 3.0 ton clutch models) (1) Remove oil pump set bolts (2 pcs.). (2) Disconnect the oil pump from the engine. Removing the Oil Pump ASSY Clutch release cylinder removal (1 ) Disconnect the clevis. (2) Disconnect the piping. (3) Remove set bolts (2 pcs.), and remove the clutch release cylinder. Removing the Clutch Release Cylinder LA060-4 18. Shift lever removal ( 1 ) Clisconnect the shift lever rod on the transmission side. (2) Remove the shift lever set plate, and remove the shift levers (forward & reverse, and speed). (3) Remove the plate washer and spring. Removing the Shift Lever LA057-17 Propeller shaft disconnection (1 ) Remove set bolts (2 pcs.), and remove the propeller shaft cover. (2) Remove the propeller shaft set bolts (13 mm, 4 pcs. on each side), and discon- nect the propeller shaft. Note: It may be disconnected on either the dif- ferential or the transmission side. Removing the Propeller Shaft LA058-10 20. Mounting set bolts removal ( 1 ) Hemove the englne mount~ng set bolts left and right. (2) Remove the torque converter & trans- mission mounting set bolts. Removing the Mounting Set Bolts LA058-1 1,12 21. Stabilizer removal (1 ) Measure the stabilizer instal led dimen- sions. Measure and record for both stabilizer stopper and stabilizer bar. mm (in.) (2) Loosen the stabilizer bar lock nut, (3) Remove the, set nut from both ends, and remove the cushion rubber, plate, stabilizer stopper and stabilizer bar. Check that all electrical wiring, cables and I inks are disconnected. Dimension B 198k 1 (7.8 t 0.04) 205.5 + 1 (8.1 t 0.04) L Vehicle model 1.0 -2.5 ton series 2.75 - 3.0 ton series 23. Engine ASSY with transmission removal ( 1 ) Use the SST and remove the engine ASSY with transmission: With torque converter & transmission: approx. 250 kg (550 Ib) With transmission: approx. 270 kg (594 I b) SST 0901 0-201 11-71 Demension A 83 t 1 13,27 + 0,04) 9055 1 (3.56' 0.041 Caution: Try safe operation by fully considering the center of gravity in setting wire ropes for hoisting. ! 1 %Ijf I r-j-- i 1 F -- - A?, 1 , r.. y :: 3.1 Measuring the Stabilizer Installed Dimension LAOM166 Removing the Stabilizer LA058-8,64-35 Removing the Engine with Transmission LA058-13 5K ENGINE VEHICLE (1 989.9 - 1 1 . Engine hood removal ( 1 ) Disconnect the engine hood damper from the frame bracket. (2) Disconnect the engine hood stay from the frame bracket. (3) Remove engine hood hinge set screws (2 pcs. on each side), and remove the engine hood. Removing the Engine Hood lAT3-29 Battery removal ( 1 ) Disconnect the battery terminals. Caution: Always disconnect the negative terminal first. (2) Remove the battery cap. (3) Remove the battery. Removing the Battery lAT4- 1 3. Battery case removal ( 1 ) Remove set bolts (3 pcs.) and remove the battery case. Removing the Battery Case LAT4-2 Air (1 ( 2 ) cleaner ASSY removal Remove the hydraulic tank breather. Loosen the hose clamp for the air clean- er hose. Remove air cleaner case set bolts (4 pcs.) and remove the air cleaner. Removing the air cleaner Thank you very much for your reading. Please Click Here Then Get More Information. </p>