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FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT

5FGi5FD33 - 45 series. Please use this manual for providing quick, correct
servicing of the corresponding forklift models.

This manual has been edited by combining Repair Manual Pub. No. CEO05

as Part I (Sections 0 t o 15) and Repair Manual ( S u p p l e m e n t )

Pub. No. CE014. as Part 11(Sections 0 to 4).

Part I explains the service procedures for the models produced since

August, 1988 while Part IIcovers those for the models subject to the minor

change in September, 1994. For servicing the vehicles after the minor

change, please refer to both Part I and PartII.

Please understand that disagreement can take place between the de-

scriptions in the manual and actual vehicles due to change in design

and specifications. Any change or modifications thereafter will be in-

formed by Toyota Industrial Equipment Parts & Service News.

For the service procedures of the mounted engine, read the repair man-

uals listed below as reference together with this manual.

(Reference)

Repair manuals related to this manual are as follows:

TOYOTA INDUSTRIAL EQUIPMENT 3F ENGINE


REPAIR MANUAL (No. CE614)

TOYOTA INDUSTRIAL EQUIPMENT 1FZ ENGINE


REPAIR MANUAL (No. CE627)

TOYOTA INDUSTRIAL EQUIPMENT 1 IZ, 122 ENGINE


REPAIR MANUAL (NO. CE615-1)

TOYOTA MOTOR CORPORATION


PART I : 1988. 8-
SECTION INDEX (CE005)

GENERAL
ENGINE0
CLUTCH
C R
TRANSMISSION & DIFFERENTIAL
FRONT AXLE
REAR AXLE

BRAKE a

BODY
MATERIAL HANDLING SYSTEM
MAST
CYLINDER
OIL PUMP
OIL CONTROL VALVE
APPENDIX
GENERAL

Page
EXTERIOR VIEWS ................................ 0-2
VEHICLE LISTING ................................ 0-3
ABBREVIATIONS ................................ 0 -4
OPERATIONAL TIPS ............................. 0 -4
STANDARD BOLT & NUT TIGHTENING
TORQUE ......................................... 0-5
BOLT STRENGTH TYPE IDENTIFICATION
METHOD ...................................... 0-5
TIGHTENING TORQUE TABLE .................. 0-6
PRECOAT BOLTS .............................. 0-7
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE ........................... 0-7
FRAME NUMBER ................................ 0 -8
WIRE ROPE SUSPENSION ANGLE LIST ........... 0 -9
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE ............................ 0-10
COMPONENTS WEIGHT ......................... 0-10
RECOMMENDED LUBRICANT QUANTITY
&TYPES ......................................... 0-11
LUBRICATION CHARTS .......................... 0-12
PERIODIC MAINTENANCE ....................... 0 -1 4
INSPECTION METHOD ......................... 0-14
PERIODIC REPLACEMENT LUBRICANTS
AND PARTS ..................................... 0 -2 0
EXTERIOR VIEWS

Front View (5FD35) ~~0.72-1

Rear View (5FD35)

- 6 -
VEHICLE LISTING

Load Engine Engine Drive system Remarks


Model model
capaclty tY Pe

5FG33 3F Gasoline Clutch

02-5FG33 t t Torgue converter


3.25 ton
5FD33 11Z Diesel Clutch

02-5FD33 t t Torque converter Wheel base


1800 mm
( 7 1 in)
5FG35 3F Gasoline Clutch

02-5FG35 t t Torque converter

5FD35 11Z Diesel Clutch

02-5FD35 t t Torque converter


3.5 ton
5FGE35 3F Gasoline Clutch

02-5FGE35 t t Torque converter

5FDE35 11Z Diesel Clutch

02-5FDE35 t t Torque converter

5FG40 3F Gasoline Clutch

02-5FG40 t t Torque converter Wheel base


4.0 ton 2000 mm
(78.5 in)
5FD40 11Z Diesel Clutch

02-5FD40 t t Torque converter

5FG45 3F Gasoline Clutch

02-5FG45 t t Torque converter


4.5 ton
5FD45 11Z Diesel Clutch

02-5FD45 t t Torque converter


ABBREVIATIONS
Abbreviations used in this manual are as follows:
4

Abbreviation Abbreviation
Meaning Meaning
(Code) (Code)

ABDC After button dead center PS Horsepower


ASSY Assembly P/S Power steering
ATDC After top dead center RH Right hand
ATM Automatic transmission SAE Society of automotive engineers
BTDC Before top dead center (USA)
L/ Less SST Special service tool
LH Left hand STD Standard
LLC Long life coolant SUB-ASSY Su b-assembly
MTM Manual transmission T= Tightening torque
OHV Overhead valve OOT Number of teeth (00)
0PT Option U /S Undersize
0 /s Oversize W/ With

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.

2. Preparation of SSTs and measuring tools


( 1 ) Prepare SSTs and measuring tools before starting operation.

3. Clearing and arrangement


(1) Always keep the workshop neat and orderly for easy operation.
(2) Disassembly o f hydraulic equipment shall always be done in a clean place using clean tools.

4. Genuine Toyota parts


Genuine Toyota parts should be used even in the replacement of packings, gaskets and O-rings.

5. Repairs on electrical system


Before doing any repairs on the electical system, disconnect the cables from the battery terminals.
Be sure to disconnect the negative cable first.

6. Tightening torque for installation


Be sure t o observe the tightening torque given in this manual. I f not specified, tighten t o the torque
listed in standard bolt & nut tightening torque.

7. Defect status grasp


Do not start disassembly 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 dpon a failure in starting the vehicle, but first check such
factors as the oil, pressure and rotation status causing the failure.
STANDARD BOLT & NUT TIGHTENING TORQUE
Standard bolt and nut tightening torques are not indicated.
Judge the standard tightening torque as shown below.

1. Find out the straight type of bolt from the list below and then find the bolt tightening torque from
the table.
2. The nut tightening torque can be judged from the mating bolt type.

BOLT STRENGTH TYPE IDENTIFICATION METHOD

1. Identification by bolt shape 2. Identification by part No.

Shape and identification method


Strength Hexagon bolt I
type Part NO. example
4 = 4T

Standard
hexagon
0 Number in relief or
hallmark on the head
5 = 5T
6 = 6T
7 = 7T
9 I 1 1 1- 4 0 61 0

-1 T ~ e n g t under
h

Nominal diamter
head
(mm)
bolt
(mm)

@ No mark 4T
- Strength type
-

I Nominal
diameter

Length under head

Stud bolt

two rel~efl~neson Part No. example

9 2 1 32-4-061 4
Standard bolt with
1 T ~ e n g t (mm)
h
Nominal diameter
(mm)

- Strength type

Nominal
diameter

Length
TIGHTENING TORQUE TABLE
PR ECOAT BOLTS
(Bolts with seal lock agent coating on threads)

1. Do not use the precoat bolt as it is in either


of the following cases:
(a) After it is removed.
(b) When the precoat bolt is moved (loos-
ened or tightened) by tightness check,
etc.

Note:
For torque check, use the lower limit of the Bolts
allowable tightening torque range. I f the
bolt moves, retighten it according to the
steps below.

2. Method for reuse of precoat bolts


(1) 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 FllTlNG TIGHTENING TORQUE


1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact sufaces 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.

Standard tightening torque kg-cm (ft-lb)


Nominal diameter Hose inside
of screw diameter (mm)
Standard Tightening range

5 - 20 UNF 2.5 ( 18.1) 2.4 -- 2.6 ( 17.4 -- 18.8) 6


% 18 UNF 5.0 ( 36.2) 4.8 -- 5.3 (34.7 -- 38.3) 9
-

16 UNF 6.0 ( 43.4) 5.7 -6.3 (41.2 -- 45.5) 12


-
-

5 - 14 UNF 6.0 ( 43.4) 5.7- 6.3 (41.2 45.5) 12


- 12 UNF 12.0 ( 86.6) 11.4- 12.6 (82.4- 91.1) 19
I& - 12 UNF 14.0 (101.2) 13.3 - 14.7 (96.2 -- 106.3) 25

4.8 -- 5.3 (34.7 -- 38.3) 9


PF1/4
PF3/8
5.0 ( 36.2)
5.0 ( 36.2) 4.8
5.7
-
-
5.3 (34.7
6.3 (41.2
-- 38.3)
45.5)
9
12
PF1/2 6.0 ( 43.4)
PF314 12.0 ( 86.8) 11.4-12.6(82.4- 91.1) 19
PFI 14.0 (101.2) 13.3 -- 14.7 (96.2 -- 106.3) 25
FRAME NUMBER
Engine Model Punching format Punching ,position

5FG 3 3
"1 5FG35-10011
02-5FG 33 "2 5FG35E10011
3F "3 5FG35-20011
5FG 3 5 "4 5FG35E20011
"5 5FG35O20011
02-5FG 3 5

5FD 33
"1 5FD35-10011
02-5FD 33 "2 5FD35E10011
11Z "3 5FD35-20011
5FD 3 5 "4 5FD35E20011
*5 5FD35020011 Frame No. punching position
02-5FD 3 5

5FGE35

02-5FGE35
"1 5FG45- 1001 1
5FG 4 0 "2 5FG45E10011
3F "3 5FG45-20011
02-5FG 4 0 "4 5FG45E20011
"5 5FG45Q20011
5FG 4 5 a

02-5FG 4 5

5FDE35

02-5FDE35
"1 5FD45- 1001 1
5FD 4 0 "2 5FD45E10011
11Z "3 5FD45-20011
02-5FD 4 0 "4 5FD45E20011
"5 5FD45~20011
5FD 4 5

02-5FD 4 5

"1 1988.6- 1993.3 LAQS 1 29


"2 1992.11 - 1993.3 (EEC spec.)
"3 1993.4-
"4 1993.4- 1993.9 (EEC spec.)
"5 1993.10-(EEC spec.)
--

WIRE ROPE SUSPENSION ANGLE LIST


Lifting Compres- Suspension Lifting Compres- Suspension
Tension Tension
angle si o n method angle sion method

o O 1 .oo
time
0
time

:LI 90°
1.41
time loo
time
,"
ko
30°
1.04
time

1 .I6
0.27
time

0.58
fiO
A.
120°
2.00
time time

60°
time ti me
@
\'
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE
U n i t : t o n (Ib)

Two-rope suspension Four-rope suspension


I Rope Cutting
diameter load

8 mm
(0.32 in.)

10 mm
( 0 . 4 in.)

14 mm
(0.56 in)

COMPONENTS WEIGHT
Unit: kg (lb.)

1 1 Z : 3 3 0 (728)
Engine
3F : 250 (551)

Transmission with differential Approx. 200 (441 )

Torque converter with differential Approx. 3 6 0 ( 7 9 4 )

3.25 ton Approx. 1920 (4234)


3 . 5 ton Approx. 2220 ( 4 8 9 5 )
Balance weight E3.5 ton Approx. 2 1 3 0 ( 4 41 0 )
4.0 ton Approx. 2520 ( 5 5 5 7 )
4.5 ton Approx. 2830 ( 6 2 4 0 )

Mast L/ Lift Bracket 3.25 - 4.0 ton Approx. 6 5 0 ( 1 433)


(Max. Fork Height: 3 0 0 0 mm ( 1 18 in.) 4.5 ton Approx. 8 5 0 ( 1 874)
RECOMMENDED LUBRICANT QUANTITY & TYPES

Description Classification TYpe Application Quantity

API Motor Oil 3F Up to '88 Nov.


SD, SE, SF SAE30 8 . 0 Q ( 2 . 1 US gal)
(SAE20 in cold area) From ' 8 8 Dec.
Gasoline
SAE20W-40 9 . 3 Q ( 2 . 5 US gal)
(SAE1OW-30 in cold
Engine area)

API Diesel engine oil 11Z 12.5 Q ( 3 . 3 US gal)


CC, CD SAE30
Diesel
(SAE20 in cold area)
SAE1 OW-30

API Hypoid gear oil MTM models 6 . 0 Q ( 1 . 6 US gal)


Transmission GL-4 SAE85W-90
GL-5

API Hypoid gear oil All models 9 . 5 Q ( 2 . 5 US gal)


Differential GL-4 SAE85W-90
GL-5

ATF GM ATM models 15 Q ( 4 . 0 US gal)


Torque converter
DexronB I1

IS0 Hydraulic oil IS0 Fork height 60 Q ( 16 US gal)


Hydraulic oil VG32 VG32 3000 m m
( 1 18 in.)

Gasoline
models
95 Q ( 2 5 US gal)

Fuel tank 9 5 Q (25US gal)


5FD33,35
Diesel models
5FDE35, 120 Q ( 3 2 US gal)
5FD40,45
Chasis parts MP Grease All models Proper quantity

LLC @LLC30-50% mix- 3F 1 3 . 0 Q ( 3 . 4 US gal)


ture (for winter or
Coolant all season)
(Excluding reserve *Coolant with rust- 1 3 . 0 Q ( 3 . 4 US gal)
tank) inhibitor (for
spring, summer
and autumn)

Coolant (Reservoir All models 1.1 Q ( 0 . 3 US gal)


tank) T T (at Full level)

Drive shaft pulley Molybdenum disulfide All models Proper quantity


(Oil pump spline grease
shaft)
LUBRICATION CHARTS

Chain lnspect every 8 hours (daily)


Differential gear lnspect every 40 hours (weekly)
Front wheel bearing lnspect every 1 7 0 hours (monthly)
Power cylinder joint lnspect every 1000 hours (6 monthly)
Transmission case lnspect every 2000 hours (annually)
Rear wheel bearing
Steering knuckle king pin lnspect and service
Bell crank pin Replace
Oil tank
MP grease
Engine crankshaft
Engine oil
Rear axle beam front
Hypoid gear oil
Rear axle beam rear
Hydraulic oil
Tilt steering universal joint
Hypoid gear oil
Tilt steering locking mechanism
Molybdenum disulfide grease
Mast support bushing
Tilt cylinder front pin
Propeller shaft (Oil pump drive shaft)
Tie-rod end
Drive shaft pulley (Oil pump spline shaft)

Clutch Model Lubrication Chart

- 16 -
13

2 14

1 1

16 16

3 3

15 15

10 5

17 9

11 4

8 4

6 6

7 7

12 18

18 19

1. Chain I. Inspect every 8 hours (daily)


2. Differential gear n. Inspect every 40 hours (weekly)
3. Front wheel bearing 111. Inspect every 170 hours (monthly)
4. Power cylinder joint IV. Inspect every 1000 hours (6 monthly)
5. Transmission case V. Inspect every 2000 hours (annually)
6. Rear wheel bearing
7. Steering knuckle king pin 0 lnspect and service
8. Bell crank pin Replace
9. Oil tank
@ MP grease
10. Engine crankshaft
@ Engine oil
11. Rear axle beam front
@ Hypoid gear oil
12. Rear axle beam rear
@ Hydraulic oil
13. Tilt steering universal joint
@ Automatic transmission fluid
14. Tilt steering locking mechanism
@ Molybdenum disulfide grease
15. Mast support bushing
16. Tilt cylinder front pin
17. Propeller shaft (Oil pump drive shaft)
18. Tie-rod end
19. Drive shaft pulley (Oil pump spline shaft)

Torque Converter Model Lubrication Chart


PERIODIC MAINTENANCE
INSPECTION METHOD

I : Inspeciton. Repairorreplacement if required.


M : Measurement. Repair o r adjustment i f required.
T : Retightening C : Cleaning L : Lubrication
* : For new vehicle * 1 : Soapy water " 2 : Detector " 3 : Flaw detector
h

Inspection Period Every 1 3 6 12 Months


Item --------___ Every 170 500 1000 2000 Hours

ENGINE

Proper starting and abnormal noise l C t t

Rotating condition at idling M t t t

Rotating condition during acceleration M + + ~


Exhaust gas condition l C t t

Main body Air cleaner element c C t t


Valve clearance M
Compression M
Cylinder head bolt loosening T
Muffler rubber mount I

Clogging and damage in PCV valve and


PCV system l C t t
piping

Governor No-load maximum rpm ~ t t t

Oil leak I + + +
Lubrication l C t t
Oil level
system
Clogging and dirt of oil filter i t + - +

Fuel leak l C t t

Operation of carburetor link mechanism I + + +

Dirt and clogging of fuel filter and element l t t C


Fuel system Injection timing M t
lnjection nozzle injection pressure and
M
spray status
Draining of sedimenter I t

Coolant level in radiator and leak l t t C

Rubber hose degradation l t t t

Radiator cap condition I C t t


Cooling
system Fan belt tension, looseness and damage I + + +

Radiator rubber mount I


Radiator screen c t t C
Inspection Period Every 1 3 6 12 Months
Item Every 170 500 1000 2000 Hours
-

POWER TRANSMISSION SYSTEM

Clutch pedal play M - + +

Abnormal sound and functioning I C t C


Clutch (connection)
Clutch booster function and leak l C C e

Oil clutch mechanism and leak I +

Leak I + + - +

Transmission Fluid level I + - +

Gear function and abnormal noise l C t t

Leak I + + +

Differntial Oil level I t t t

Bolt loosening T

Leak i t + +

Fluid level I + - + +

Torque Operating mechanism function and I + + -


converter and looseness
transmission Control valve and clutch functions I + + +

Inching valve function I + + -

Stall and hydraulic pressure measurement M +

DRIVE SYSTEM

Tire inflation pressure M t + +

Tire cuts, damage and uneven wearing I + + +

Loose rim and hub nuts T t t c

Tire groove depth M + + +


Wheels Metal chips, pebbles and other foreign I + + + -
matter trapped in tire grooves
Rim, side bearing and disc wheel damage I + + +
Abnormal sound and looseness of front I + + +
wheel bearing
- - - Inspection Period Every 1 3 6 12 Months
Item -------- Every 170 500 1000 2000 Hours

Abnormal sound and looseness of rear wheel


Wheel l t t t
bearing

Cracks, damage and deformation of


Front axle I
housing

Cracks, damage and deformation of beam I


Rear axle Looseness of axle beam in vehicle
M
longitudinal direction

STEERING SYSTEM

Steering Play and looseness t t t

wheel Function l e e + -

Oil leak l t t t

Gear box Looseness of mounting T + + - + -

Clogging of relief valve filter C +

Rods, links Looseness and damage I ' - - ' -


and arm Linkage and wear and mounting condition I

Oil leak I + + +
Power l C C t
Mounting and linkage looseness
steering
Damage of power steering hose I

King pin looseness I + + +


Knuckle
Cracks and deformation I

Steering Wheel alignment M


shaft Left and right turning angle M

BRAKING SYSTEM

Play and reserve M + + ~


Brake pedal
Braking effect I + + +

Operating force l C t C

Parking brake Braking effect I + + +


Rod and cable looseness and damage I e e t

Brake pipe Leak, damage and mouting condition I + + + -

Brake booster
Function, wear, damage, leak and
and wheel I
mounting looseness
cylinder
Inspection Period Every 1 3 6 12 Months
Item Every 170 500 1000 2000 Hours

Clearance between drum and lining M + - + +


Wear of shoe sliding portion and lining I
Brake drum Drum wear and damage I
and brake Shoe operat~ngcondition I
shoe Anchor pin rusting I
Return spring fatique M
Automatic adjuster function I

Deformation, cracks and damage I


Backing plate
Loose mounting T

MATERIAL HANDLING SYSTEM

Abnormality of fork and stopper pin l C t t


Misalignment between left and right fork I + + ~
Forks
fingers
Cracks at fork root and welded part 1 *3

Deformation and damage of each part and


I C C C

crack at welded part


Mast and lift bracket looseness
Mast and
Wear and damage of mast support bush
fork
bracket Wear, damage and rotating consdition of Il - + ' -+ ; - I +
rollers
Wear and damage of roller pins I
Wear and damage of mast strip I - + +

Tension, deformation and damage of I C C C


chain
Chain and Chain lubrication l t t t
chain wheel Abnormality of chain anchor bolt i t + +
Wear, damage and rotating condition of I C C C
chain wheel

Various Abnormality and mounting condition of I + - -


attachment each part

HYDRAULIC SYSTEM

Loosening and damage of cylinder T t t t


mounting
Deformation and damage of rod, rod I C C C
Cylinder screw and rod end
Cylinder operation I + + +
Natural drop and natural forward tilt M C C
(hydraulic drift)
C

- Inspection Period Every 1 3 6 12 Months


Item Every 170 500 1000 2000 Hours

Oil leak and damage I - + +

Wear and damage of pin and cylinder I t + ' -


Cylinder bearing
Lifting speed M + + +

Uneven movement I + + - +

Oil pump Oil leak and abnormal sound I + + -

Oil level and contamination I - - ' -


Hydraul~c
Tank and oil strainer C +
oil tank
Oil leak I - - +

Control Loose linkage I ' - ' - ' -


lever Operation I - + +

Oil leak I + - + +
Oil control
Relief pressure measurement M
valve
Relief valve and tilt lock valve functions I + + - +

011leak 1 t C C

Hydraulic I + + +
Deformation and damage
piping
Loose joint T - - -

ELECTRICAL SYSTEM

Cracks on distributor cap I - + +

Spark plug and burning and gap ( - 1997.12) I + - + +

Distributor side terminal burning + + +

Ignition Distributor cap center piece wear and I t t C


timing damage
Distributor points gap M + + -

Plug cord internal discontinuity I


Ignition timing M t

Starting
Pinion gear meshing status / I + + +

motor

Charger Charging function I - + - -

Battery fluid level I + + -


Battery
Battery fluid specific gravity M t

Electrical Damage of wiring harness I ' - + ' -


wiring Fuses l e t +
Item
- Inspection Period
-------___Every
Every 1 3
170 500 10002000 Hours
6 12 Months

Preheater Open-circuit in intake heater I t

Engine stop- I t t t
Diesel engine key stop device function
ping system

SAFETY DEVICE, ETC.

Cracks at welded portion I + + +


Head guard
Deformation and damage l C t C

Loosening of mounting T t t ~
Back-rest
Deformation, crack and damage l t t t

Lighting i t + +
I Function and mounting condition
system

Horn Function and mounting condition I + + +

Direction - + +
Function and mounting condition I
indicator

Instruments Functions I + + +

Backup buzzer Function and mounting condition I + + - +

Rear-view Dirt, damage I t t t


mirror Rear reflection status l t C t

Seat Loosening and damage of mounting l t t t

Damage and cracks of frame, cross


I
Body members, etc
Bolt looseness T

Other Grease up L + - + +
PERIODIC REPLACEMENT LUBRICANTS AND PARTS
l: Replacement
Interval Every Every Every Every
1 month 3 months 6 months 12 months
Every Every Every Every
Item 1 7 0 hours 5 0 0 hours 1000 hours 2000 hours

Engine • t + +

Engine oil filter • + C

Engine coolant (every 2 years for LLC) • t- +

Fu,el filter • C

Torque converter oil • t

Torque converter oil filter • +

Transmission oil • C

Differential oil • +

Hydraulic oil • t

Hydraulic oil return filter a*' • +

Wheel bearing grease •


Spark plug l(-1997.12) •
Distributor points • +

Air cleaner element •


Brake booster rubber parts •
Cups and seals for wheel cylinders •
Power steering hoses e*2
Power steering rubber parts •*
Hydraulic hoses •*
Fuel hoses •
Torque converter rubber hoses
Chains •

*I: for n e w vehicle "2: Every 2 years *3: Every 3 years


Replacement shall be made u p o n arrival of the operation hours or months, w h ~ c h e v e ris'earlier.
GENERAL

1 1 Z Engine Exterior View KAI-28-26,35-1li


3F Engine Exterior View
112 Engine Sectional V i e w LAQM61.62

3F Engine Sectional View

- 28 -
Engine Performance Curves

29.0/1600
- 29
- 28
- 27 Engine torque

26 (kg'm)
25
90 85/2200

80 -

70 -
Shaft horsepower
(PSI 60-

50 -

40 -

-
] Fuelconsumption
ratio. (g/ps.h)

I I

10 14 18 22
Engine speed (rpm) x 1O2

Engine Performance Curve (1 12) KALMl

Gasoline model
LPG model only 26.0/1200
- - - - - -. Gasoline LPG model
25.0/1200

j24 Engine torque

Shaft horsepower

200/2000

1 200 Fuel consumption

185/1800 ," 180


--
10 14 18 22
Engine speed (rpm) x 1O2

Engine Performance Curve (3F) KALM 47

- 29 -
SPECIFICATIONS
-
11 Z (Diesel) 3F (Gasoline)

Piston displacement cc (cu-in.) 4429 (270) 3955 (241 )

Number of cylinders 6 6

Valve mechanism OHV gear driven t

96.0 x 102.0 94.0 x 95.0


Bore x stroke mm (in.)
(3.78 x 4.02) (3.70 x 3.74)

Compression ratio 18.6 8.1

Combustion chamber type Direct injection

pslrpm
Rated output (SAE NET: ~ p h ~ 85/2200
~ ) (8112200) 72/21 00 (6912100)
kg-mlrpm
Maximum torque 2911600 (202/1600) 26/1200 (182/1200)
(SAE NET : ft-lblrpm)

Fuel consumption ratio glps-hlrpm 1 6511 200 20011800

Injection pump type Bosch (VE)

l njection timing (BTDC)

Injectio n order 1- 4- 2- 6- 3- 5

lgnition timing (BTDC)

Ignition order 1- 5- 3- 6- 2- 4

Service weight kg (Ib.1 330 (728) 250 (551)


ENGINE ASSY
REMOVAL (CLUTCH MODEL)

1. Remove the toe board.


(1) Toe board
(2) Floor set bolts
(3) Floor

Removing the Toe Board ~ ~ 2 8 - 1 7

2. Remove the engine hood.


(1 ) Disconnect the engine hood damper on
the frame side.
(2) Disconnect the engine hood stay on the
frame bracket side.
(3) Hood hinge set screws
(4) Engine hood

Removing the Engine Hood ~ ~ 2 9 - 9

3. Remove the radiator cover

Removing the Radiator Cover ~ ~ 2 9 - 1 1

4. Remove the air cleaner ASSY.


(1) Disconnect the vacuum switch harness.
(2) Disconnect the air cleaner hose.
(3) Hydraulic oil tank breather set bolt.
(4) Air cleaner set bolt
(5) Air cleaner ASSY (with hose)

Removing the Air Cleaner ASSY ~ ~ 2 9 - 1 9


5. Remove the battery.
(1) Disconnect the battery cables.

Caution:
Always disconnect the negative (-) terminal
first.

(2) Disconnect the wiring t o the battery.


(3) Disconnect the wirings to the distribu-
tor and ignition coil. (3F)
(4) Battery stopper
(5) Battery Removing the Batery
LAQ29-22
(6) Battery case

6. Remove the sedimenter. (11 Z)


(1 ) Disconnect the fuel hose.
(2) Disconnect the wirings.
(3) Set bolt
(4) Sedimenter (with bracket)

Removing the Sedimenter w 9 - 2 7

Disconnecting Wiring (1) LAQ29-28.34

(4) Starting motor wiring


(5) Engine oil pressure switch wiring

Disconnecting Wirings (2) LAQ~o-s,~~-~s


(6) Fuel cut solenoid wiring (11 Z)
(7) Intake heater wiring (11Z )
(8) Carburetor wiring (3F)

Disconnecting Wirings (3) LAQ30-1.29-32

8. Disconnect piping and wires.


(1) Fuel piping

Disconnecting the Fuel Piping (1 lZ/3F) u Q 3 0 - 8 - 19-•

(2) Accelerator wire

Disconnecting the Accelerator Wire (1 12) LAQ~O-9

Disconnecting the Accelerator Wire (3F) ~ ~ 1 9 - 1 8


(3) Choke wire (3F)

Disconnecting the Choke Wire L A Q9-1


~ 9

9. Remove the harness bracket.


(1 ) Disconnect the harness.
(2) Bracket set bolts
(3) Bracket

Disconnecting the Harness Bracket LAQBO-16

10. Drain the coolant.


(1) Coolant draining from radiator
(2) Coolant draining from engine

Draining the Coolant LAOS-1 2.13

11. Remove the radiator.


(1) Disconnect the radiator hoses.
@ l nlet hose
@ Outlet hose
@ Reserve tank hose
(2) Radiator set bolts
(3) Fan shroud set bolts
(4) Radiator
(5) Mounting rubber
(6) Fan shroud

Removing the Radiator and Shroud LAQ~O-1s.


20

- 34 -
12. Remove the exhaust pipe.
(1) Set nut
(2) Clamp bolt
(3) Exhaust pipe

Removing the Exhaust Pipe ~030-24

engine.
Disconnecting the Oil Pump Drive LAQ70-20, 19

14. Remove the clutch disc, clutch cover and


flywheel.

Note:
See "Clutch Removal" in section 2 for the
removal procedure for the clutch disc, clutch
cover and flywheel.

(1 ) Clutch disc
(2) Clutch cover
(3) Flywheel
Removing the Clutch Disc and
Clutch Cover

Removing the Flywheel

- 35 -
Hoisting the Engine LAQ~I-19

16. Remove the engine mounting set nuts.

Removing the Mounting Nut LAQBI-21

17. Remove the engine mounting bracket.


(1 ) Set bolts
(2) Mounting bracket (RH)
(3) Mounting bracket (LH)

Removing the Bracket LAQ~I-28

Supporting the Clutch Housing

- 36 -
Disconnecting the Engine LAQBI-26-30

Removing the Engine 1.~032-32

INSTALLATION (CLUTCH MODEL)

The installation procedure is the reverse of the removal procedure.

Caution:
0 See the cautions for "Clutch Removal" in section 2.
0 Bleed air from the fuel system. (11 Z engine model)
0 Connect the battery negative (-) terminal after checking correctness of electrical wiring.
0 Check the coolant and engine oil levels. I f insufficient, start engine adjustment after addition to
the specified levels.
0 Exhaust pipe set nuts tightening torque : 11Z: T = 2.4 -- 4.4 kg-m (17.3 -- 31.8 ft-lb)
3F: T = 3.4 -- 6.4 kg-m (24.6 -- 46.3 ft-lb)
REMOVAL (TORQUE CONVERTER MODEL)

Note:
0 Since the engine removal procedure for the torque converter model is the same as that for the
clutch model up t o step 13 (oil pump drive disconnection), refer to that section. Torque converter
oil cooler piping disconnection is added to the radiator hose disconnection.
The procedure afer the oil pump drive disconnection is described below.
0 Since the engine i s removed in the state of the engine with torque converter end plate, the starting
motor and flywheel are to be removed after the engine removal from the vehicle.

Slightly hoist the engine.


SST 0901 0-201 11 -71

Note:
Sling with a aufficiently strong wire and
shackle as short as possible t o provide a suf-
ficient hoisting stroke.

Hoisting the Engine LA~O-27

2. Remove the engine mounting set nuts.

Removing the Mounting Nuts 1.~020-23

3. Remove the engine mounting bracket.


(1 ) Set bolts
(2) Mounting bracket (RH)
(3) Mounting bracket (LH)

Removing the Bracket

- 38 -
4. Support the torque converter lower side
with wooden blocks.

5. Remove the torque converter case cover.

6. Remove the flexible plate set bolts. + *


(1 ) Set bolts (9 pcs.)

Note: Supporting the Torque Converter Case ~~020.30

Removing the Flexible Plate Bolts LAQZO-21.22


Caution:

Disconnecting the Engine ~~020-28


The installation procedure is the reverse of the
removal procedure.
Caution :
0 Refer to the caution in the Engine Install-
ation (clutch model) section.
0 Flywheel tightening torque
(Coat seal lock agent (Locktite #242 or
equivalent).)

-
1 l Z : T = 10- 16 kg-m (72.2 -- 115 ft-lb)
3F: T = 6 9 kg-m (43.3 -- 65.0 ft-lb)
0 Torque converter end plate tightening
torque
T = 5 -- 8 kg-m (36.1 -- 57.6 ft-lb) Removing the Engine

39 -
AIR BLEEDING FROM FUEL SYSTEM
(DIESEL ENGINE MODEL)

1. Operate the hand pump on top of the fuel


filter until i t becomes heavy. The air bleed-
ing is completed when the pump operation
becomes heavy.

Air Bleeding from Fuel System LAQ~~-12

WATER DRAINING FROM SEDIMENTER


(DIESEL ENGINE MODEL) Priming pump

When the sedimenter warning lamp comes on,


drain water as described below because accumul-
ated water exceeds the specified level.

1. Take out the drain hose under the fuel filter


from the inner side of the vehicle and re-
ceive the drained water with a receiving
container.
Draining Water from Sedimenter LAOS1 23
2. Loosen the drain cock by 1.5 to 2 turns and
lightly push the priming pump for draining.

Caution:
Do not loosen the cock excessively to prevent
fuel spillage from outer circumference of the
cock.

3. Water draining is completed when light oil


starts t o come out. Securely fasten the drain
cock.

4. Return the drain hose t o the inner side of


the vehicle.

Caution:
Cleanly wipe off light oil smearing around
the drain cock.
ENGINE SPEED ADJUSTMENT
(DIESEL ENGINE MODEL)

Idling Speed Inspection and Adjustment

1. Warm up the engine.


Coolant temperature: 75 -- 8 5 ' ~

2. InstalI the engine tachometer.

3. Inspecttheidlingspeed.
(1 ) Check returning of the accelerator wire. Setting the Engine Tachometer 1~045-8,9
(2) l nspect the idling speed.
Idling speed: 750 + 25 rpm

4. Adjust the idling speed.


(1) Loosen the lock nut and turn the ad-
just the idling speed.

No-load Static Maximum Speed Inspec-


tion and Adjustment

1. Warm up the engine.


Coolant temperature: 75 -- 8 5 " ~

2. Install the engine tachometer. Adjusting the Idling Speed LA046-23

3. Inspect the no-load static maximum speed.


(1 ) Depress the accelerator pedal fully and
inspect the no-load static maximum
speed.
No-load static maximum speed:
2350 +Ao0 rprn

4. Adjust the no-load static maximum speed.


(1 ) Remove the sealing.
(2) Turn the maximum speed adjusting
screw to adjust the no-load static maxi-
mum speed. Adjusting the Maximum Speed ~ ~ 4 6 - 2 4

(3) Operate the material handling lever with


the engine running at the maximum
speed, and measure the engine speed at
full relief.
Check that the reduct'ion of the speed
(relief down) satisfies the following
standard:
Engine speed down at full relief:
within 200 rprn
(4) Carry out sealing after the adjustment.

Measuring the Relief Down LAQ28-7


ENGINE SPEED ADJUSTMENT
(GASOLINE ENGINE MODEL)

Idling Speed Inspection and Adjustment

1. Warmuptheengine.
Cool ant temperature: 80 -- 9 0 " ~

2. Install the engine tachometer.

3. Inspect the idling speed.


(1 ) Check returning of the accelerator wire.
Setting the Engine Tachometer
(2) lnspect the idling speed.

Vacuum Gauge Installing Position KAMB-3s

Start the engine. Turn the throttle ad-


justing screw @ and idle adjusting screw
@ alternately to maximize and stabilize
the vacuum at the specified idling speed.
ldling speed: 750 + 25 rpm
Vacuum: 400 mmHg or above

Adjusting the Idling Speed KAMII-4.5

(3) If the idling speed does not fall because


the idle up adjust screw is in contact
with the idle up actuator rod, loosen the
idle up adjust screw.

Idle Up Adjust Screw KAM6-36


No-load Static Maximum Speed Inspection
and Adjustment

1. Warm up the engine.


Coolant temperature: 80 - 90°c

2. Instal I the engine tachometer,

3. Inspect the no-load static maximum speed.


(1 ) Depress the accelerator fully and inspect
the no-load static maximum speed.
No-load static maximum speed:
Loosening the Bush Lock Bolt LAQ~~-10
2350 *50 rpm

4. Adjust the no-load static maximum speed.


To increase the spee
(1 ) Remove the seal.
(2) Loosen the air governor bush lock bolt.
(3) With the adjust screw fixed with a screw-
driver, turn the bush for adjustment.
Clockwise turn:
To increase the speed
Counterclockwise turn:
To decrease the speed

Adjusting the Maximum Speed K M S ~ ~

Operate the material handling lever


while the engine i s running at the maxi-
mum speed, and measure the engine
speed at full relief.
Check that the speed reduction (relief
down) Satisfies the following standard.
Engine speed down at full relief:
Within 250 rpm

Measuring the Relief Down

(5) If the relief down i s excessive, turn the


adjust screw counterclockwise for ad-
justment.

Adjusting the Relief Down

- 43 -
(6) If hunting occurs, use the air governor
bush and adjust screw for adjustment.
Adjust screw: For hunting adjustment
Bush: For maximum speed adjustment

Note:
o reduce hunching
0 If the hunting lasts only a few times, it i s
regarded as no hunting.
0 Repeat steps (3) -- (6) to set the maxi-
mum speed at the standard value.

(7) Carry out sealing after the adjustment.


Adjusting Hunting
ACCELERATOR PEDAL
ACCELERATOR PEDAL ADJUSTMENT

Adjusting the Accelerator Pedal L A Q M ~ ~

Pedal Height Adjustment

1. Loosen the set bolt of accelerator wire bracket @ to free the accelerator wire

2. Loosen lock nut @ of pedal height adjusting bolt @.

3. Measure the height from the side floor to the front end of the accelerator pedal (with pad).
Accelerator pedal height standard: With pad A = 136 mm (5.31 in.)
With out pad B = 125 mm (4.92 in.)

4. If the measured height does not satisfy the above standard, adjust it to the standard value by turning
pedal height adjusting screw @ and securely fasten with lock nut 0.

5. After the adjustment, tighten the accelerator wire bracket set bolt.

Depressed Pedal Height Adjustment

1. Adjust the height of accelerator pedal stopper bolt @ from the floor to the following value and
securely fasten with lock nut @ :
Pedal stopper bolt height: C = 50 mm (1.96 in.)
AIR CLEANER
COMPONENTS

02

!
.
..
.I

02 Cleaner ASSY, cyclone air


206 Element SUB-ASSY, cyclone air cleaner
20C Element SUB-ASSY, cyclone air cleaner, inner
20D Element SUB-ASSY, cyclone air cleaner, outer
23 Case SUB-ASSY, air cleaner
24 Cap SUB-ASSY, air cleaner
26 Cup, dust
27 Wing, cyclone
27A Gasket, filter element
30 Switch ASSY, vacuum
44 Hose, air cleaner, outlet No. 1
57 Louver, air inlet
AB Plate, caution
BO Nut, wing
El Hose, air cleaner
EQ Nut, wing
42 Connector, air cleaner (3F)
42A Gasket, air cleaner connector (3F)
55 Hose, hot air (3F)
58 Cover SUB-ASSY (3F)
AC Band SUB-ASSY (3F)
3F EC Plate SUB-ASSY (3F)

Air Cleaner Components

SPEC1FICATIONS

Size 6 inch

Filtering area 14200 cm2 (2201 i n 2 )

Filter medium Filter paper


INSPECTION

Air Cleaner Element Inspection and


Cleaning

1. Open the engine hood and remove the air-


cleaner cap.

2. Remove the element.

Removing the Element .LAQ~~-8

Cleaning the Air Cleaner Cap LAQ~~-10

Cleaning the Element


with clean water. (The water pressure
must be 2.8 k g /cm 2 (40 psi ) or less.)

Caution:
Carefully protect the filtering paper from
damage during washin.

After washing, dry it by standing or


with a dryer (cold air).

Caution:
Do not use compressed air or hot air for
driving.
Washing the Element
5. Element inspection
After cleaning, put an electric bulb in the
element and inspect the element for damage.
If any pinhole, tear or damage i s found, re-
place i t with a new element.

6. Element replacement
Replace the element after washing 6 times or
every 12 months in general .cases.

Inspecting the Element JABM~

Clogging Warning System Inspection


(1988.6 -- 1989.8)

1. Warning lamp inspection


(1) Check that the air cleaner warning lamp
comes on when the engine switch is
turned t o ON and goes off when the
engine i s starts.
(@' A I R CLEANER

lnspecting the Warning Lamp

2. Individual vacuum switch inspection


(1) l nspect the conduction when a negative
pressure is applied to the switch.
Standard:
11 Z engine model :
at approx. 70 mm Hg or above :
conduction
at approx. 50 mm Hg or less :
no conduction
3F engine model:
at approx. 50 mm Hg or above :
conduction
Inspecting the Individual Vacuum Switch SAES~~
a t approx. 35 mm Hg or less :
no conduction

Caution:
Do not apply a negative pressure of 75 mm
Hg or more to the vacuum switch. I

3. Vacuum switch wiring


(1 ) When connecting the cables, correctly
connect to the positive and negative
terminals. Reversed connection does not
blow the fuse, but the warning does not
come on'.
Vacuum Switch Wiring LAOS352
Clogging Warning System Inspection
(I989.9 - I
1. Warning lamp inspection
(1) Check that the air cleaner warning lamp
comes on when the ignition switch is
turned on, and goes off when the engine
starts.
Q'
A I R CLEANER

lnspecting the Warning Lamp LAOS351

2. Individual inspection
(1) Use Mighty Vac and inspect vacuum
switch for conduction upon application
of a negative pressure.

Inspecting the Individual Vacuum Switch LATS104

Vacuum switch wiring


( 1 ) A nonpolar sensor is adopted as the air
cleaner clogging sensor (warning lamp
sensor) to prevent erroneous wiring.
The sensor set pressure is different
between gasoline engine vehicles and
diesel engine vehicles.

Vacuum Switch Wiring

HOT AIR INTAKE Winter


(GASOLINE ENGINE MODEL)

General

The hot air intake system is provided in the gaso-


line engine model to prevent icing at low tem-
peratures.
If icing occurs during operation, move the select
lever in the direction toward WINTER on the @ 'Inside air

indicator. Since the air inside the engine hood


is taken in this case, the air cleaner element is
Hot Air
clogged earlier.
RADIATOR
COMPONENTS

48 Shroud, fan, No. 1


54 Rubber, mounting (For radiator)
68 Belt, fan drive
AN Bolt, stud
BX Plate
CM Insulator, edge
DE Pulley, fan & water pump
DN Clip
DP Bearing
DR Shaft, fan drive
ED Bearing
ER Bearing
FO Insulator, edge
FU Insulator
FV Spacer
01 Radiator ASSY GU Pulley
11 Screen SUB-ASSY, radiator GV Housing
30 Cap SUB-ASSY, radiator GW Ring, snap
41 Fan GX Ring, snap
41A Belt, V GY Housing
46 Hose, radiator, inlet GZ Bracket SUB-ASSY
47 Hose, radiator, outlet HA Ring, snap

Radiator Components (1988.6 - 1990.7) LAOM65

SPEC1FICATIONS

Vehicle Model 11 Z Engine Models 3F Engine Models

Torque Converter Model


Torque con- Clutch
Model verter model Model
ltern 3.25,3.5 ton 4.0,4.5,E3.5 ton

Radiation capacity k cal/h 30,400 35,300 c 37,400 37,500

65x500~430 8 3 x 500x430 6 5 x 5 0 0 ~ 4 9 0
Core (T x W x H) mm (in.) (2.6~19.7~16.9) t +
( 3 . 3 ~ 1 9 . 7 ~ 1 6 . 9(2.6~19.7~19.3)
)

Fin pitch mrn (in.) 5.012 (0.2012) 4.012 (0.1 612) t t t

Pressure
valve 0.9 (12.8) c t t c
Tank cap valve o ening
f
pressure kglcm (psi) Negative
pressure 0.5 (0.7) t t t c
valve
Coolant capacity 3.8 (I .00)
Q (US gal) 3.9 (1.03) 3.2 (0.84) 3.9 (1.03) 5.0 ( 1 . 3 2 )
(in radiator)

Reserve tank capacity Q (US gal) 1.1 (0.29) C- t c c


COOLANT AND COOLANT CAPACITY
Unit : R (US gal)
Total coolant
Antifreeze mix- Antifreeze mix- Antifreeze mix- Anticorrosive
capacity
ing ratio: 25% ing ratio: 30% ing ratio: 40% agent mixing
(to -1 2 ' ~ ) (to -1 ~ O C ) (to - 2 4 ' ~ ) ratio: 5%
reserve tank)

Diesel engine model 13.0 (3.43) 3.3 (0.87) 3.9 (1.03) 5.2 (1.37) 0.7 (0.18)
Gasoline engine
model 13.0 (3.43) 3.3 (0.87) 3.9 (1.03) 5.2 (1.37) 0.7 (0.18)

FAN DRIVE SYSTEM

STD Radiator screen


\ / Radiator

I
I
\
Universal joint

-
Fan Drive System (1988.6 1990.7) LAQM9, LAQS125.126

Fan Specifications

Fan diameter mm (in.) 410 (16.1) t

Pulley ratio 1.2 1.4


Note:
0 I t i s recommended to remove the radiator
before removing the fan and fan support
for easier operation (ease of oil pump
drive shaft disconnection and fan belt
tension adjustment).
0 To remove thk pulley on the oil pump
side, remove the oil pump with pulley
and disconnect the pulley outside the
vehicle.
Removing the Radiator
The fan pulley (lower side) removal

Removing the Housing with Pulley LAQ66-17. 19

1. Remove the fan belt.


(1) Loosen the plate set nut.
(2) Lower the plate.
(3) Disconnect the oil pump drive shaft.
(4) Fan belt.

Removing the Fan Belt LAQ~O-13

2. Remove the fan support ASSY.


(1) Housing set bolts
(2) Fan support ASSY

Removing the Fan Support ASSY LAOZO-16


3. Remove the bearing housing.
(1 ) Snap ring
(2) Housing
SST 09950-200 17

Removing the Housing ~A026-14.16

(3) Bearing (large)


SST 09950-2001 7
(4) Bearing (small)
SST 09620-3001 0

Removing the Bearings 1.~026-18.26

4. Remove the fan.


(1 ) Set bolt
(2) Fan

Removing the Fan ~~026-36

5. Remove the fan pulley.


(1) Set bolt
(2) Fan pulley

Removing the Fan Pulley ~~026-21


6. Remove the pulley (on the oil pump side).
(1 ) Snap ring
(2) Pulley

Removing the Pulley LAQB~-22-23

7. Remove the bearings.


(1) Snap ring
( 2 ) Bearings (2 pcs.)
SST 09608-3501 4

Removing the Bearings 1.~066-24.25

INSPECTION

1. lnspect the fan and fan support components.


(1 ) Damage and deformation of fan
(2) Crack and damage of fan belt
(3) Damage of pulley, shaft and housing
(4) Abnormal sound and rotation of bearing

Inspecting the Fan and Fan Support 1.~026-31


components
2. lnspect the pulley and related components
(on oil pump side).
(1) Damage of pulley
(2) Crack and damage of housing
(3) Abnormal sound and rotation of bearing

ASSEMBLY AND INSTALLATION

The procedures are the reverse of the disassembly


and removal procedures.
Caution:
Adjust the fan belt tension. Inspecting the Pulley and Bearing ~~066-32,30

- 54 -
Loosening the Plate Set Nuts ~~027-12

2. Check if the fan belt is set at the center of


the lower pulley.
Set at the center

Pulley

Relative Positions of Pulley and Belt L A O S 27


~

Adjusting the Fan Belt LAQ~~-17

4. Measure the fan belt flexure. If the measur-


ed value does not satisfy the standard below,
readjust the tension.
Fan belt flexure: 4 -- 8 mm (0.16 -- 0.31 in.)
( W h e ~the belt center is pushed with a force
of 1.2 kg (2.6 lb))

5. Fully tighten the set nuts after the adjust-


ment.

Measuring the Fan Belt Flexure LAQSI~~


FAN BELT TENSION ADJUSTMENT
(1990.7 ) -
1. Raise the right side of the plate (in the direc-
tion of arrow) with point A in figure as the ful-
crum to apply a slight tension to the belt, and
tighten four nuts.
T = 4 0 0 kg-cm ( 2 8 . 9 4 ft-lb)

Tightening the Fan Belt

2. Tentatively tighten support set bolt B to leave


no clearance at C, with the spring washer com-
pressed slightly.
3. Turn belt tension adjusting bolt D in figure to
Support
adjust the belt tension.
Fan belt flexure: 6 - 8 mm
(0.24 -0 . 3 1 in.)
(When the belt center is pushed w i t h a force
o f 3 kg (28.947 Ib))
4. Tighten the support set bolt. ( B in figure)
T = 4 0 0 kg-cm ( 2 8 . 9 4 ft-lb) Adjusting the Fan Belt Tension

5. Check the belt tension after tightening the sup-


port set bolt. Make readjustment if the tension
is varied.
Note:
Carefully operate as the belt tension tends t o
Pushing force
increase when the support set bolt is tight- 3 kg (7 Ib)
ened from the tentatively tightening torque
t o the standard tightening torque.
6. Start the engine. After running it for several Flexure
minutes, stop the engine and check the belt 6 - 8 m m (0.24 - 0.31 in.)
tension. If the tension is varied, repeat belt ten-
sion adjustment steps 2 to 5 to adjust it to the Measuring the Fan Belt Flexure
proper level.
BATTERY
COMPONENTS

Battery ASSY
Cable SUB-ASSY, battery to starter
Case SUB-ASSY, battery
Cable SUB-ASSY, battery to battery
Cable, battery earth
Bolt
Stopper, battery
Nut

Battery components LAQM66

SPEC1FICATIONS

11Z Engine Model 11 Z Engine Model 3F Engine Model


(12V specification) (24V specification)

Voltage x quantity used V 12x 1 12 x 2 12x 1

5-hour rati ng Ah 64 36 t

Electrolyte specific gravity 1,280 t t


l NSPECTION

1. Battery fluid level


(1) Check if the fluid level is between
UPPER and LOWER. If insufficient,
add distilled water t o the UPPER level.

Battery Fluid Level

2. Battery fluid specific gravity inspection


(1) Use a hydrometer and measure the spe-
cific gravity o f battery fluid.
Standard: 1.280 (at 20°c)
Equation for calculation
Sm = St + 0.0007 ( t - 20)
Szo : Specific gravity at 20°c
St : Specific gravity measured at
toc
t : Fluid temperature at the time
of measurement

Measuring the Battery Fluid Specific Gravity ~AHslo6

3. Contamination o f battery terminals


(1 ) If battery terminals are contaminated t o
present white color, clean them and
apply a thin coat o f MP grease on each
terminal.

4. Loosening o f battery terminals and harness


installation
(1) Retighten the loose terminals and
harness connection.

Inspecting the Battery Terminals LAOS362


CLUTCH

Page
GENERAL ....*.................................. 2-2
SPECIFICATIONS ................................. 2-3
COMPONENTS .................................. 2-4
CLUTCH ......................................... 2-5
REMOVAL ..................................... 2-5
DISASSEMBLY ................................ 2-8
INSPECTION ................................... 2-10
ASSEMBLY .................................... 2-13
INSTALLATION ................................ 2-16
OIL CLUTCH AND CLUTCH HOUSING AND
RELEASE FORK SHAFT .......................... 2-17
REMOVAL ..................................... 2-17
DISASSEMBLY ................................ 2-19
INSPECTION .................................. 2-21
ASSEMBLY .................................... 2-22
INSTALLATION ................................ 2-22
CLUTCH BOOSTER .............................. 2-23
GENERAL ..................................... 2-23
TROUBLESHOOTING .......................... 2-23
COMPONENTS ................................ 2-24
REMOVAL ..................................... 2-25
DISASSEMBLY ................................ 2-26
INSPECTION .................................. 2-29
ASSEMBLY .................................... 2-31
lN STALLATI 0N ................................2-34
CLUTCH RELEASE CYLINDER .................... 2-35
GENERAL ..................................... 2-35
COMPONENTS ................................ 2-35
REMOVAL ..................................... 2-36
DISASSEMBLY ................................ 2-37
INSPECTION ................................... 2-37
ASSEMBLY .................................... 2-38
INSTALLATION ................................ 2-38
AIR BLEEDING FROM CLUTCH ................... 2-38
CLUTCH ADJUSTMENT .......................... 2-39
GENERAL

I I I I Venturi

Clutch Sectional View LAQMl 1

- 60 -
SPECIFICATIONS

ltem 11 Z, 3F engine vehicle

Type Wet, single-plate, coil spring type


Clutch
Operating method Hydraulic

Size mm (in.) 304 (12.0)


Clutch cover
Installed load kg (I b ) 930 (2051)

Outside diameter x
300 x 175 (11.8 x 6.9)
inside diameter mm (in.)

Clutch disc Effective friction area cm2 (in.2) 240 x 2 (37.2 x 2)

Material Special work

TYpe Portless with hydraulic booster

Diameter 25.4 ( 1.OO)


Master cylinder piston mm (in.)
Full stroke 28 (1.10)
L '
a,
-0
.-r
- Power piston mm (in.) Diameter 25.4 (1.OO)
> .
0
L
0 Diameter 16 (0.63)
C-'
Reaction piston mm (in.)
r" Full stroke 29.5 (1 . I 6)

Servo ratio 5

Maximum servo pressure


95 (1351)
(power re1ief pressure) kg/cm2 (psi)

TYpe Adjustable type


Release cylinder
Bore mm (in.) 20.64 (0.81)

Oil used Hydraulic oil I SO-VG32


COMPONENTS

112 engine vehicle

3F engine vehicle
10 Cover ASSY, clutch AA Pin, clutch release lever
11 C Disc ASSY, oil clutch AB Bushing
12 Hub ASSY, clutch release bearing AC Bolt, eye
30 Shaft SUB-ASSY, clutch release fork AD Pin, clutch pressure plate
30A Spring, tension (For release fork shaft) AE Bushing
40 Housing, clutch AF Plate, adjusting nut lock
40A Bearing (For clutch release fork shaft) Al Nut
408 Ring, 0 (For clutch housing) AJ Cover, clutch
40C Seal, oil (For clutch housing) AK Holder, spring
40D Plug (For clutch housing drain) AM Pin, straight
40E Gasket (For clutch housing drain plug) AR Seat, strap
40F Seal, oil (For clutch release fork shaft) AU Ring, 0
41 Bearing, clutch release AY Ring, 0
42 Fork, clutch release BC Nipple
43 Plate, clutch pressure BD Ring, 0
44 Lever, clutch release BF Plate, pin lock
46 Spring, torsion (For clutch pressure lever) BH Cover, clutch case, front
49 Spring, compression (For clutch) BL R~ng,0
52 Spring, tension (For clutch hub) BM Ring, 0
53 Plate, clutch release bearing BP Union
53A Spring, clutch release bearing plate DC Nipple (Nozzle)
54 Hose, oil clutch (For clutch housing ~ n l e t ) DG Pipe SUB-ASSY, oil clutch
57 Venturi DH Connector SUB-ASSY, venturi
57A Packing (For venturi) DK Nozzle, oil clutch
61 Cover, clutch housing DU Plug, breather
61A Packing DV Hose, low pressure

Clutch Component

- 62 -
CLUTCH
REMOVAL

1. Remove the toe-board.


(1) Open theengine hood.
(2) Toe-board.

Removing the Toe-Board ~~059-32

2. Remove the clutch housing cover.

Caution:
Because of oil clutch adoption, carefully
prevent entrance of foreign matters and dust
into the housing after removal of the clutch
housing cover.

Removing the Clutch Housing Cover LAQ~O-29

3. Slide the input shaft.


(1) Lock ring
(2) Slide the input shaft fully toward the
transmission.

Sliding the Input Shaft ~~~30-33,34

4. Disconnect the clutch booster push rod.


(1) Boots
(2) Clevis pin
(3) Push rod

Disconnecting the Push Rod ~ ~ 0-23 1


5. 1 nstall service bolts to the clutch cover.
(1 ) Service bolts: 4 pcs.
Service bolt M I 0 x 60 ( P = 1 . 5 )

Caution:
Rotate the flywheel with a screw driver to a
position to enable easy installation.

Installing the Service Bolts L A Q ~-3


I

Flywheel Rotating Method LAQ~I-5

6. Remove the clutch cover set bolts.

Caution:
Rotate the flywheel with a screwdriver t o a
position to enable easy removal.

Removing the Set Bolts ~~0.31-7

Remove the clutch disc.


(1 ) Move the clutch cover to the release
bearing side.

Caution:
o Carefully operate so as not t o damage or
deform the spray nozzle of the oil clutch.
o Operation for clutch disc replacement
ends with this step 7.

(2) Clutch disc


Removing the Clutch Disc

- 64 -
8. Remove the clutch cover.

Removing the Clutch Cover lA~31-11

9. Remove the release bearing hub.


(1 ) Tension spring
(2) Release bearing hub.

Removing the Release Bearing Hub ~ ~ 0 .-1


331

10. Remove the flywheel.


( 1 ) Set bolts
(2) Flywheel
( 3 ) O-ring (gasoline model)

Removing the Flywheel ~~31-18


SASSE MBLY

Caution:
Before starting disassembly, check defective
points such as faulty pressure plate contact,
cover cracking and release lever wear, and
carry out proper disassembly and repair.

Punch the match mark.


(1 ) Clutch cover
( 2 ) Pressure p late
Punching the Match Mark LAQ68-22
Note:
Since the clutch cover balance is adjusted in
assembled state, be sure t o reassemble at the
same position.

2. Remove the strap seat.


(1 ) Set bolts
(2) Strap seat

Removing the Strap Seat LAQ~S-24

3. Remove the adjusting nut.


(1 ) Screw
(2) Nut lock plate
( 3 ) Adjusting nut

Removing the Adjusting Nut ~ ~ 6 8 - 3 0

4. Remove the clutch cover.


(1 ) Service bolts
( 2 ) Clutch cover
( 3 ) Clutch spring

Removing the Clutch Cover ~~068-32.33


5. Remove t h e r e t u r n spring.

Removing the Return Spring ~G32-28

6. Remove t h e release bearing plate.


(1 ) Plate set spring
(2) Replace bearing plate

Removing the Release Bearing Plate LAQSS-7.8

7. Remove t h e release lever.


(1 ) Pressure plate p i n
( 2 ) Release lever

Removing the Release Lever ~~069-12

8. Disassemble t h e release lever.


(1) Release lever p i n
( 2 ) Release lever eye bolt
(3) Pin lock plate
(4) Clutch release lever

Disassembling the Release Lever 1.~069-14


INSPECTION

Caution:
Inspect each part and repair or replace any
defective part detected.

1. Pressure plate inspection.


(1) Wear and damage of the clutch disc
contact surface.
(2) Damage on the clutch spring contact
surface.
(3) Wear of the release lever contact surface. Inspecting the Pressure Plate ~~0.69-16
(4) Wear of the pressure plate pin blushing.

. . "
Inspecting the Clutch Cover LAG^^-26
spring.

3. Clutch spring inspection.


(1) Deformation, fatigue and breakdown
of the spring.
(2) Free length and squareness.

Clutch spring specifications

Free length 71.9 mm (2.83 in.)

Color for Yet low inspecting the Clutch Spring ~~06s-18

lnspecting the Clutch Spring

- 68 -
Release lever inspection.
(1) Wear, damage and deformation of the
release lever.
(2) Looseness of the release lever (in
mounted state).
(3) Wear o f the pin.
(4) Wear of the eye bolt pin bushing.
(5) Wear at the spherical surface of the
adjusting nut.

Inspecting the Release Lever ~~069-22

Release bearing plate inspection.


(1) Wear of the release bearing plate bearing
and the release lever contact surface.
(2) Fatigue and breakdown o f the set spring.

Inspecting the Release Bearing Plate ~ ~ 6 9 - 2 4

Flywheel inspection.
(1) Wear and damage of the clutch disc
contact surface.
(2) Chipping, damage and wear of the
tooth surface.
(3) Damage and fatigue of the O-ring (gaso-
line model).

Inspecting the Flywheel ~ ~ 6 9 - 2 6

Release bearing hub and release bearing in-


spect ion.
(1 ) Release bearing hub.
@ Wear at the contact surface with the
release fork.
a Wear and catch at the sliding surface
with the release guide.
@) Fatigue and breakdown of the ten-
sion spring.

Inspecting the ~e1ease'~earing


Hub ~~069-28

- 69 -
(2 ) Release bearing.
a. Rotation status, abnormal sound,
and wear at the contact surface with
the bearing plate.

Caution:
Shince the release bearing is of grease-sealed
type (lubrication-f ree) do not wash the bear-
ing at any event. Be sure t o replace with a
new one when a defect is found.

Inspecting the Release Bearing ~ ~ 6 9 - 2 9

(3) Release bearing replacement.


Removal
SST 09950-2001 7
Assem bly
SST 09608-3001 2

Replacing the Release Bearing ~~069-30.31

Clutch disc inspection.


(1) Wear and crack of the facing.
wear limit (one side): 1.3 mm (0.051
in.)
(until the lattice grooves disappear)
Note:
Since the facing made of a special material is
for the oil clutch, wear by abrasion i s very
little.
Therefore, the quality of facing i s rarely
judged on the basis o f the facing thickness.
Generally the facing is judged as improper
Inspecting Clutch Disc (Fly wheel side) 1.~069-32
when clutch slipping occurs because of the
surface status change caused by thermal
influence (reduced friction force caused by
surface carbonation).
(2) Rivet looseness.
(3)Wear and damage at the spline por-
tion.
Cau tion:
0 When any defect is found in the clutch
disc, be sure t o replace with a new one.
0 I f a defective clutch disc is used as it is or
after repair, it may cause clutch off fault,
sliding or tembling. lnspecting the Clutch Disc

- 70 -
ASSEMBLY

1. Assemble the release lever.


(1 ) Clutch release lever
(2) Eye b o l t
(3) Release lever p i n
(4) Pin lock plate
(5) Pressure plate p i n
(6) Cotter p i n

Caution:
Thinly coat grease (molybdenum disulfide Assembling the Release Lever LAQ~O-1.3
base grease) on the surface of the release lever
contacting with the release bearing plate
(top and side of the lever end).

Coating the Grease LAQ~O-6

2. Install t h e release bearing plate.


(1 ) Release bearing plate
(2) Plate set spring

Installing the Release Bearing Plate LAQ~O-7

3. l nstall the Clutch Cover.


(1 ) Install t h e r e t u r n spring t o t h e c l u t c h
cover.

Installing the Return Spring LAG^^-24


(2) Clutch spring
(3) Clutch cover

Caution:
When assembling the clutch cover and pres-
sure plate again, align the match marks.
( I f either part is replaced with a new one,
balance adjustment is necessary.)

Installing the Clutch Cover ~ ~ 6 8 - 3 4

Installing the Services Bolts LAQ~~-32

4. Installthestrapseat.
T = 1.8 -- 3.0 kg-m (13.0 -- 21.7 ft-lb)

Installing the Strap Seat LAQ~O-8

Adjusting the Pressure Plate Height LAQ~O-9


(2) I nstall the adjusting nut and adjust the
release bearing plate height from the
clutch cover instal lation surface as fol-
flows:
Set height: 66.8 mm (2.63 in.)
Departure from parallelism of the plate.
(inclination): 0.5 mm (0.019 in.) max.

Caution:
When installing the adjusting nut, thinly coat
grease (molybdenum disulfide base) on the
. . . -

nut spherical surface. Adjusting the Release Bearing


Plate Height
Check that the top of the release lever
end is in contact with the bearing plate
in the set status described in (2) above.
(Release lever end deviation limit)
Maximum allowable clearance 0.15 mm
(0.006 in.)
Push the release bearing plate at least
five times with a press using 10 mm
(0.39 in.) stroke. Make sure that no
abnormal movement is observed.
Check dimension in steps ( 1 ) to (3).

Measuring Point for Release Lever


End Deviation

Installing the Nut Lock Plate LAQ~E-28

Installing the Nut Lock Plate


INSTALLATION

Follow the removal procedure in the reverse order.

Caution:
0 I f the oil in the clutch housing or the inside of the housing is contaminated, discharge the oil from
the drain plug and clean the housing inside.
0 When installing the flywheel, coat grease on the oil seal and O-ring, and coat liquid seal on the
knock pin for the engine and flywheel. Carefully mount so as not to damage the oil seal. (Gaso-
line model)
0 Flywheel set bolts shall be tightened after coating a screw locking agent.
Tightening torque
T = 6 -- 9 kg-m (43.3 -- 65.0 ft-lb)
0 Remove foulding (rust, anticorrosive agent or impurities adhered) on the pressure plate sliding
con tact surface with snadpaper.
0 Apply a small amount of grease (molybdenum disulfide base grease) on the input shaft spline
portion, release bearing surface to contact the bearing plate and release hub surface to contact the
release fork.
o When installing the clutch cover, carefully prevent damage or deformation of the hydraulic clutch
spray nozzle.
0 Set the clutch disc with the longer boss side on the transmission side.
0 It is recommended to hold the clutch disc with long-nose pliers when inserting the input shaft.
0 Be sure to remove service bolts (4 pcs.) after the clutch cover is mounted.
0 After installing the input shaft lock ring, check that the input shaft sliding is surely locked by the
lock ring.
0 Inspect the hydraulic oil level.
o If the oil in the clutch housing is discharged, supply the same amount of new hydraulic oil.
OIL CLUTCH AND CLUTCH HOUSING AND RELEASE FORK SHAFT
REMOVAL

Note:
0 The clutch housing removal procedures are classified into the three following cases:
1. Remove the engine and then remove the clutch housing.
2. Remove the transmission & differential and the remove the clutch housing.
3. Remove from the differential to the clutch housing in assembled state and then remove the
clutch housing.
0 The procedure explained here is case 2 above.
0 The oil clutch mechanism can be disassembled on the vehicle.

Removing the Transmission & Differential LAQ~~-33

2. Remove the clutch cover, clutch disc and


flywheel.

Caution:
See steps 5 -- 10 of the Clutch Removal sec-
tion for the procedure.

Removing the Clutch ~~0.31-11.18

Supporting the Engine LAG^^-26


4. Disconnect the oil piping.
(1 ) ln let hose
(2) Outlet hose
(3) Breather hose

Disconnecting the Oil Clutch Piping LAQ67-2.5

5. Disconnect the clutch release cylinder.


( 1 ) Set bolts
(2) Clutch release cylinder

Disconnecting the Clutch Release Cylinder ~ ~ 6 7 - 7

Removing the clutch Housing LAQ~~-9


DISASSEMBLY

1. Remove the starter motor.


(1) Set nut
(2) Stater motor

Removing the Starter Motor 1.~067-17

2. Remove the oil clutch pipe.


( 1 ) Lock nut
(2) Oil clutch pipe

Removing the Oil Clutch Pipe ~~067-22

3. Remove the Venturi connector.


(1) Set bolts
(2) Venturi
(3) Packing
(4) Venturi connector

Removing the Venturi Connector ~~67-23.24

4. Disassemble the releas fork shaft.


(1 ) Snap ring
(2) Release fork
(3) Release fork shaft

Disassembling the Release Fork Shaft ~~067-31


Removing the Oil Seal ~~067-36

(2) Needle bearing


SST 09620-3001O

Caution:
Remove only when a defect i s found as a
result of inspection. The oil seal must be
replaced with a new one.

Removing the Needle Bearing ~ ~ 6 7 - 3 5

Removing the Oil Seal 1.~068-3


INSPECTION

1. Oil clutch pipe and Nipple inspection.


(1) Clogging, deformation, damage and
cracking of the oi I clutch pipe.
( 2 ) Clogging and damage of the nipple (noz-
zle).

Inspecting the Pipe and Nipple ~ ~ 6 8 - 1 3

2. Venturi and Venturi connector and oil


clutch nozzle inspection.
(1) Clogging and damage of the venturi.
(2) Damage, cracking and deformation of
the Venturi connector.
(3) Clogging, deformation, damage and
cracking of the oil clutch nozzle.

lnspecting the Venturi and Venturi


Connector and Oil Clutch Nozzle
3. Release fork and fork shaft inspection.
(1) Damage and wear at the fork surface
contacting with the hub.
(2) Damage and wear at the spline portion.
(3) Wear at the shaft sliding contact por-
tion.
(4) Bending of the shaft

lnspecting the Release Fork and Shaft LAQ68-16

4. Needle bearing and oil seal inspection.


(1 ) Wear and damage of the needle bear-
Ing.
(2) Damage, deformation and deteriora-
tion of the oil seal lip.

Inspecting the Needle Bearing ~ ~ 0 3 0 - 2~3 ,~ 0-33 1


5. Clutch housing inspection.
(1) I nspect cracking by visual observa-
tion or color check.
(2) Damage, deformation and deteriora-
tion of the oil seal lip.
(3) Damage and wear of the O-ring.

Inspecting the Clutch Housing LAQ~~-8

the spline groove match marks.


Match Marks of the Release Fork and Shaft ~ ~ 6 8 - 2 0

INSTALLATION

Follow the removal procedure in the reverse order.

Caution:
0 Coat grease on the O-ring and oil seal of the clutch housing.
0 Carefully install the clutch housing so as not t o damage the oil seal. (Diesel model)
0 Also refer t o cautions in "Clutch Installation".
CLUTCH BOOSTER
GENERAL

Flow divider

Clutch Booster Sectional View


TROUBLESHOOTING

Phenomenon Estimated cause Corrective action

Push rod twisting caused by defective Mounting position adjust-


instal lation of clutch master cylinder. ment,

Heavy pedal Valve seal defect or foreign matter Cleaning or replacement of


(including inter- trapping. reaction piston or power
mittent heaviness) piston.

Seal defect. Replacement.

Clogged orifice in flow divider. Cleaning.

Control valve seat defect or foreign Cleaning or rep lacement.


matter trapping.
Sudden forced re-
• Valve seal defect or foreign matter Cleaning or replacement of
t urn of pedal upon trapping. reaction piston or power
engine stop
piston SU B-ASSY.

Seal defect. Replacement.

Clutch release Insufficient air bleeding from release Air bleeding.


failure (Pedal de- camber.
pressible with very
light force soon Seal defect Replacement
followed by clutch
reappl ication during
pedal depression)

Note:
Since most seals are not supplied as individual parts, replace each piston or valve SUBASSY.
COMPONENTS

..J

01 Booster ASSY, clutch AK Ring, snap


01 K Booster O/H kit, clutch A0 Ring,O
20 Piston SUB-ASSY, master cylinder AP Ring, 0
21 Guide SUB-ASSY, reaction piston AU Spool, flow divider
30 Rod SUB-ASSY, push, No. 1 AV Spring, flow divider
32 Piston SUB-ASSY, power AW Plug, hole
33 Piston SUB-ASSY, reaction AX Spring, control valve
36 Valve SUB-ASSY, control AY Plug, piston
37 Seat SUB-ASSY, control valve A2 Spring, relief valve
41 Cup, cylinder, No. 1 BA Spring, valve return
42 Cup, cylinder, No. 2 BB Washer
44 Boot, No. 1 BC Guide, reaction piston
48 Spring, piston return BD Nut
52 Clevis, No. 1 BE Ring, snap
55 Piston, reaction BF Ring, snap
AA Rod, push BG Pin
AB Ring, snap BH Ring, snap
AC Ring, 0 BK Ball
AD Ring, snap BL Ball
AE Pin BM Gasket
AF Ring, 0 BN Gasket
AH Ring, 0 BP Union
Al Ring,O BR Gasket
-
Clutch Booster Components

- 82 -
REMOVAL

1. Remove the toe-board.

2. Disconnected the Clutch booster

Disconnecting the Clutch Booster Uaze-18

3. Remove the clutch booster.


( 1 ) Clutch booster set bolts.
(2) Remove the bolt connecting the brake
booster.

Removing the Set Bolts ~~028-22

(3) Clutch booster

Removing the Clutch Booster ~ ~ 2 8 - 2 8

4. Remove the push rod.


(1) Clutch link set bolts

Removing the Link Set Bolts

-
(2) Clutch link with push rod
(3) Clutch link bush
(4) Spacer

Removing the Clutch Link LAQ~~-36

(5) Disconnected the clutch link from the


push rod.
@ Cotter pin
@ Washer
@ Pin
@ Push rod

Removing the Push Rod LAQ64-28

DISASSEMBLY

1. Remove the Boot.

Removing the Boot LAOI 08-36

2. Remove the reaction piston & power piston.


(1) Snap ring

Removing the Snap Ring ~~0109-2


(2) Reaction piston & Power piston

Removing the Piston LAOI 09-3

3. Remove the reaction piston & power piston.


(1) Snap ring
(2) Reaction piston
(3) Plate washer
(4) Reaction piston guide

Removing the Piston Guide LAOI 10.6, 6

( 5 ) S- n a ~rina
s - , --I-

(6) Reaction piston guide

Caution:
Disassemble the reaction piston only when it
is found defective.

Removing the Reaction Piston LAO 110-7

4. Remove the master cylinder piston.


(1) Bolt, Gasket
(2) Push the master cylinder piston with a
rod for tapping while holding the cyl-
inder.
(3) Rotate the master cylinder by a half
turn t o make the pin connecting the
piston fa1l and remove the piston.

Removing the Piston LAO~OS-6


(4) Master cylinder piston SU B-ASSY
(5) Piston return spring

Removing the Piston and Spring LAOI 09-7.8

5. Remove the Flow divider spool.


(1) Snap ring
( 2 ) Plug
( 3 ) Spring
(4) Flow divider spool

Removing the Divider Spool LAOI 09-1 0 . 1 2

6. Remove the Check ball.


(1 ) Set bolt
(2) Gasket
(3) Check ball

Removing the Check Ball LAO^ 09-1 5

Renlove the Power piston.


(1 Use a wire and remove the pin connect-
ing the reaction piston. Push the control
valve with a round rod during this oper-
ation.
Reaction piston
Control valve seat .
Valve return spring
Relief valve spring

Removing the Power Piston

-86-
8. Remove the Control valve
(1 ) Snap ring
(2) Piston plug
(3) Spring
(4) Control valve

Removing the Control Valve 1.~0110-13

Caution:
0 Wash each part with new hydraulic oil
and inspect the items described below:
Replace any part that in found defective.
0 I f the cylinder body, piston or valve is
defective, replace the booster ASSY as a
unit.

Valve body inspection.


(1) Extreme wear, u never wear and rusting Valve
of spool sliding surface.
(2 Crack, damage and wear of body

Master cylinder piston SU B-ASSY inspection.


(1 ) Wear, damage and deformation of
piston sliding surface.
Wear limit: 0.032 mm (0.0013 in.)
(Diametrical clearance)
(2) Damage and wear of cylinder cup

Caution:
The piston SUB-ASSY must be replaced as a
unit.
Piston Inspection LAOI09-21

Power piston and valve SU B-ASSY inspec-


tion.
(1 ) Scuffing and damage of sliding portion.
Wear limit: 0.032 mm (0.0013 in.)
(Diametrical clearance)
( 2 ) Damage and wear of sea l and va lve seat.
(3) Deformation and fatigue of spring.

Caution:
The piston SUB-ASSY or valve SUB-ASSY
must be replaced as a unit.

Piston and Valve Inspection


4. Reaction piston parts inspection.
(1 ) Scuffing and damage of piston sliding
surface.
(2) Damage and wear of seal and O-ring.
(3) Damage and deformation of control
valve seat.

Caution:
When the seal or O-ring of the control valve
seat is damaged, replace the valve & valve
SU B-ASSY as a unit.
Reaction Piston Parts Inspection LAO^ 10-26
(4) Deformation and fatigue of spring.
(5) Damage and wear of cylinder cup.

5. Flow divider inspection.


(1 ) Scuffing and damage of sliding surface.
(2) Deformation and fatigue of spring.
(3) Clogging of orifice
(4) Damage and wear of hole plug and 0-
ring.

Flow Divider Inspection LAOI 09-1 s

6. Check ball inspection.


(1 ) Damage and deformation of ball.
(2) Damage on check ball contact surface.

Check Ball Inspection ~~0109-16


- --

ASSEMBLY

Caution:
o Coat hydraulic oil on each part.
o Coat silicone grease on the cylinder cup, and hydraulic oil on the O-ring and seal ring.

Install the check ball.


(1) Put the check ball in the body closed
communicating hole and check that it
reaches the seat surface.
(.2) Install the bolt and gasket, and check

--
that the ball moves.
T = 0.8 1.2 kg-m
(5.78 8.66 ft-lb)

--
(3) Install the plug and gasket.
T = 2.7 3.5 kg-m
(19.50 25.27 ft-lb)
(4) Put another check ball in the cylinder,
Installing the Check Ball ~~0111-1
and install the snap ring.
2. Install the flow divider spool.
(1 ) Insert the relief valve into the body.
(2) After checking that i t is smoothly in-
serted with a light push with a hand,
push i t further with a spring.

Installing the Flow Divider Spool LAO111-2

Install the master cylinder piston SUB-ASSY.


(I)Fully coat hydraulic oil on the cylinder
bore.
(2) Insert the return spring into the cylinder
and align the piston slit groove and the
top of the body vertical axis (center line
of rear pin hole).

Installing the Piston (1)

- 89 -
-

(3) Insert the piston SUB-ASSY alowly into


the cylinder.
(4) Push the piston further into the body
until the slit groove is seen through the
body pin hole.

lnstalling the Plston (2) LAO11 1 - 7

(5) Insert the pin surely through the piston


stopper groove into the body pin hole.
(6) 1 nstal l the bolt and gasket.
T = 0.8 -- 1.2 kg-m (5.78 -- 8.66 ft-lb)

Installing the Piston (3) LAO^ 1 1-8

4. Install the control valve.


(1) Insert the control valve with the spring
into the power piston.

Installing the Control Valve (1) LAOIIO-13

(2) l nstall the O-ring t o the piston plug.


Insert them into the power piston and
fit the snap ring.

lnstalling the Control Valve (2)

90 -
5. lnstall the reaction piston.
(1) l nstall the O-ring on the reaction piston.
(2) 1 nsert the control valve seat into the re-
action piston.

Installing the Control Valve Seat 1.~041-15

(3) lnsert the relief valve spring into the


reaction piston.
(4) lnstall the valve return spring t o the re-
action piston. Match the direction of
the reaction piston pin hole and valve
seat pin hole, and slowly push i t in.
(5) Further insert reaction piston until the
valve seat pin hole appears through the
piston pin hole.
(6) lnsert the pin t o leave no protrusion
from the piston outer circumference.

Installing the Piston LAO^ 10-19

lnstall the power piston.


(1) Put in the valve return spring.
(2) Insert the reaction piston into the
power piston.
(3) lnstall the plate washer sidewaysland f i t
the snap ring.

Installing the Power Piston LAOI 10-25

7. lnstall the reaction piston guide.


(1 ) Coat silicone grease on two types of
cylinder cups, and install them in cor-
rect directions t o the piston guide.
(2) I nsert the piston guide into the reaction
piston, and f i t the snap ring.

Installing the Piston Guide LAO^ 10-35


8. install the power piston & reaction piston.
(1 ) Insert the power piston & reaction
piston into the cylinder.
(2) Piston guide
(3) Snap ring
(4) Push the reaction piston with a hand to
check its smooth stroke.

. Installing the Piston LAOI 11-4.5

9. Install the boot.

Installing the Boot LAOI 08-36

I NSTAL LATlON

Reverse the removing procedure for instal lation operation.

Caution:
0 Carefully operate to prevent the O-ring at the joint between the clutch booster and brake booster

-
from being trapped.
-
T = 3.5 4.5 kg-m (25.3 32.5 ft-lb)
o Bleed air from the clutch system. (See page 2-38.)
0 Adjust the clutch pedal. (See page 2-39.)
CLUTCH RELEASE CYLINDER
GENERAL

Clutch Release Cylinder Sectional View LAOM~O

COMPONENTS

01 Cylinder ASSY, clutch release


0 1K Cylinder O/H kit, release
20 Rod SUB-ASSY, clutch release
30 Pipe SUB-ASSY, clutch
40 Rod, release cylinder push, No. 1
42 Boot, release cylinder
45 Plug, bleeder
.
...
I

i 46 Cap, bleeder
47 Piston, release cylinder
51 Boot (For clevis pin)
53 Bracket, clutch release cylinder
AB Washer, plate
AC Clevis
AD Pin, w/hole
AM Hose, flexible
AN Clip
L... AQ Bracket SUB-ASSY, hose
AS Hook, spring

Clutch Release Cylinder Components


REMOVAL

1. Remove the toe-board.


(1 ) Open the engine hood.
(2) Toe-board

Removing the Toe-Board 1.~059-32

2. Disconnect the piping.

Disconnecting the Piping LAO&-16

3. Disconnect the push rod.


(1 ) Remove the clevis pin.

Disconnecting the Clevis Pin ~~0.45-18

Removing the Release Cylinder ~~045-17


Removing the Push Rod and Boot LAD9-22

2. Remove the release cylinder pin.

Caution:
Cover the output side with cloth and grad- ?
ually blow air from the oil inlet for removal.
i

Removing the Piston LAD^-24

3. Remove the bleeder plug cap.

4. Remove the bleeder plug.

Removing the Bleeder Plug LAD^-29

Caution:
0 Wash each part with new hydraulic oil
( I S 0 VG32) and inspect the following
points. Replace any defective part.
0 Replace the whole release cylinder ASSY
if the cylinder body or piston is defective.

Cylinder body inspection.


( 1 ) Wear, damage and corrosion of inside
surface.
Inspecting the Cylinder Body

95 -
2. Cylinder cup inspection.
(1 ) Wear, damage and deterioration.

3. Piston inspection.
(1 ) Wear and damage

4. Bleeder plug inspect ion.


(1) Clogging and damage

Inspecting the Piston

ASSEMBLY

The assembly procedure is the reverse of the dis-


assembly procedure.

Caution:
0 Bleeder plug tightening torque
T = 9 -- 13 kg-m (64.98 -- 93.86 ft-lb)
0 Temporarily set the push rod length t o
the illustrated dimension. Readjust the
length after installation.
Temporarily Setting the Push Rod Length LAQS141

INSTALLATION

The installation procedure is the reverse of the removal procedure.

Caution:
o See the clutch adjustment section (page 2-39) for the adjustment after installation.
0 Carry out air bleeding.

AIR BLEEDING FROM CLUTCH


1. Keep the engine running at the idle speed.
Slowly push the clutch release cylinder out-
put rod to its stroke end toward the cylin-
der. Push it in again aften returning. Repeat
this at lease five times.

Caution:
Do not depress the clutch pedal.

Bleeding Air from Clutch

-96-
CLUTCH ADJUSTMENT
1. Adjust the clutch pedal height, the dimension from the top center of the clutch pedal to the toe-board
to the following value:
Pedal height (excluding the pad) : 144 -- 149 mm (5.7 -- 5.9 in.)
(with pad) : 150- 155mm (5.9-6.1 in.)

Adjusting the Clutch Pedal Height

Clutch pedal play adjustment.


Adjust the clutch master cylinder push rod
length until the clutch pedal play (play to - Push rod length
ward the master cylinder) satisfies the fol-
lowing value:
Push rod play:
-
0.5 1.5 mm (0.02 - 0.06 in.)

Note:
For the clutch adjustment procedure, refer to
Parts & Service News No. GE-8013 because
it has been changed.

Adjusting the Clutch Pedal Play ~ ~ 0 ~ 1 4 2


3. Release cylinder rod adjustment.
(1) Adjust the clutch release cylinder push rod length to make the clearance between the release bear-
ing and clutch release lever (release bearing plate) becom 1 -2 mm (0.04- 0.08 in.). The release
cylinder piston must surely be in contact with the cylinder bottom during this adjustment.

--
1 - 2 mm
Adjust to A = -
(0.04 0.08 in:)
Bring the cylinder
bottom into sure
contact with the piston,
and the piston with the
push rod.

Note: The sectional view is partially different from that on the actual vehicle.

Adjusting the Release Cylinder Rod LAQM102

(2) Start the engine and bleed air from the release cylinder

Caution:
BB sure to start the engine because air bleeding fails if the engine is stopped.

(3) After air bleeding, fully depress the clutch pedal and check that the release cylinder push rod
does not enter the cylinder when i t is pushed.
TORQUE CONVERTER

Page
GENERAL ..................................... 3-2
HYDRAULIC CIRCUIT DIAGRAM .............. 3-5
...............................
SPECIFICATION 3-6
TROUBLESHOOTING .......................... 3-7
COMPONENTS ................................ 3-15
TRANSMISSION COVER AND CONTROL
VALVE ASSY .................................. 3-21
REMOVAL .................................. 3-22
DISASSEMBLY ............................. 3-24
INSPECTION ................................ 3-27
ASSEMBLY ................................. 3-29
INSTALLATION ............................. 3-31
TORQUE CONVERTER ........................ 3-32
REMOVAL .................................. 3-32
DISASSEMBLY ............................. 3-34
INSPECTION ................................ 3-36
ASSEMBLY ................................. 3-38
INSTALLATION ............................. 3-41
STATOR SHAFT AND OIL PUMP ............... 3-42
REMOVAL .................................. 3-42
DISASSEMBLY ............................. 3-42
INSPECTION ................................ 3-44
ASSEMBLY ................................. 3-46
INSTALLATION ............................. 3-47
TORQUE CONVERTER AND TRANSMISSION
ASSY WITH DIFFERENTIAL .................... 3-48
REMOVAL .................................. 3-48
TRANSMISSION .............................. 3-55
DISASSEMBLY ............................. 3-55
INSPECTION ................................. 3-66
ASSEMBLY ................................. 3-72
lNSTALLATION ............................. 3-83
OUTPUT GEAR AND DIFFERENTIAL ........... 3-84
REMOVAL .................................. 3-84
DISASSEMBLY. INSPECTION AND
ASSEMBLY ................................. 3-84
INSTALLATION ............................. 3-84
MEASUREMENT AND TEST ................... 3-85
Reference:
As for inching pedal adjustment. refer t o the section of brake.
1 1 Z Engine

Flywheel Section View (1 12) LAQLP~

3F Engine

Flywheel Section View (3F)

- 101 -
27T: Drum gear No.1 (2nd)

27T: Reverse gear

45T: Counter gear No.1 57T: Drum gear No.2

31T: Counter gear No.2


37T: Forward gear (F2)

30T: Output gear


u

Gear Configuration LAQS 4 2


SPECIFICATION

Model
3.25-4.5 Ton vehicles
ltem (F1, F2/R torque converter vehicle)

Manufacturer Okamura Seisakusho Co., Ltd.

TYpe 3-element 1-stage and 2-phase type

MT?5 (11Z engine model


Torque converter type
M I 5 (3F engine model)

2.66 (11 Z engine model)


Stal lltorque ratio
3.20 (3F engine model)

1,950 (11 Z engine model)


Sta I I/rotational frequency rP m
2,010 ( 3 F engine model)

Forward 1-speed (F1) 1.81

Transmission gear ratio Forward 2-speed (F2) 0.83

Reverse (R ) 1.1 1

Change gear system Hydraulic system

Clutch operation Engine: 1,500 rpm 8 - 1 2 (114- 171)


pressure (Main pressure)
kg/cm2 (psi) Engine: at idling More than 4 (57)

Torque converter hydrau lic


pressure (Outlet pressure) Engine: 1,500 rpm 0.8 - 4 (11 - 57)
kg/cm2 (psi)

Oil level Q (US gal) 15 (4.0)

Auto fluid GM Dexron 69 II


Hydraulic fluid (type fluid )
5.143 (33, 35 models)
Reduction ratio (Ringlgear ratio)
5.833 (E35,40,45 models)

2,350 +Aoo (1 IZ engine model )


No-load static maximum rotational frequency rpm
2;350 +50 (3F engine model)

Applicable engine type 11 Z (Diesel), 3F (Gasoline)


A
TROUBLESHOOTING
Symptom Check point Diagnosis, possible cause and action

1. The vehicle does not 1 .I Check the main pressure. 0 Check the oil level with the
run at all or i t runs (More than 4 kg/cm2 (57 psi) level gauge.
very slowly. at idling. Std. 8-1 2 kg/cm2
[The clutch does not (114-1 7 1 psi) at 1,500 rpm)
transmit power] Check the main pressure in the
forward, reverse and neutral
positions.

.a The hydraulic pressure is lower 0 Stuck regulator valve. Check


I.I --+

than the standard value at pinched foreign matters, etc.


either the reverse 0 Broken regulator valve spring.
and neutral positions. -+ Replace it.

0 l mproperly positioned inching


valve. Check and adjust the
--+

inching link system.


0 Defective oil pump operation.
1 ) Defective oil pump
-+ Replace it.

2 ) Broken pump boss.


+ Replace it.

0 Defective suction system


1 ) Clogged oil strainer.
Replace it.
--+

2 ) Improper air suction.


+Check the 0 ring and gasket
of each joint.
0 Clogging and hydraulic oil leakage
of o il path between the pump and
the control valves. -+ Check the oil
path, and replace the 0 ring or
gasket, if necessary.

I.I.b Abnormally high oil pressure. 0 Clogged regulator valve orifice.


Check and wash the valve.
--+

I . l .c When the hydraulic pressure To 1.2.


is lower than the standard value
in the forward or backward
position.

1.2 Check the clutch pressure.


Std. (More than 4 kg/cm2 (57
psi) at idling 8-12 k g /cm 2
(114-171 psi) at 1,500 rpm)
o The clutch pressure is slightly
lower than the main pressyre.
- - -
Symptom Check point Diagnosis, possible cause and action

1 -2.a The clutch pressure is lower 0 Hydraulic oil leakage between


than the standard value in the selector valve and the servo
either of the forward and collar. -+ Check the oil path. -+

backward position. Check and replace the 0 ring


(Check the next hydraulic system or gasket, if necessary.
and its parts on the abnormal side.) 0 l mproperly positioned selector
valve. -+ Adjust or replace it.
0 Worn or broken seal ring (the
servo case). -+ Replace it.
0 Damaged clutch piston, Broken
piston ring, Off piston, etc.
-+ Overhaul the clutch.

1.2.b When the clutch pressure 0 Clogged accumulator orifice.


is too lower than the standard -+ Disassemble and wash it.

value in both the forward and piston.


the backward positions. -+ Repair or replace it.
(Check the oil path between the 0 Improperly positioned inching
regulator valve and the selector valve. Check the inching link
-+

valve. ) system and adjust it, if necessary.

1.3 When both the main pressure 0 Clogged oil path between the
and the clutch pressure are selector valve and the clutch
normal. piston. Check the oil path
-+

and remove clogged foreign


matter.
o Stuck clutch piston.

1.3.a Mechanical trouble in the Overhaul the torque converter.


transmission and differential.
(In this case, the torque converter
oil temperature rises excessively
and noise, etc. is produced.)

2. l nsufficient upgrading 2.1 Check the no-load static ro- 2.1.a When the rotational frequency
or insufficient traction tational frequency of the is not within the specified
(When power is insuf- engine and the load maxi- range, adjust the engine.
ficient) mum rotational frequency. Note: See the engine adjustment
section.
[When the torque con-
verter does not produce
torque.]
Symptom Check point Diagnosis, possi ble causeand action

Procedure 1 : Check the no-load


static maximum rotational
speed of the engine.
Note: Refer to engine tune up
section.

Procedure 2: Check the load 2.1 .b When the decrease of the


maximum rotational frequency engine rotational frequency is
of the engine. greater than the standard value.
After checking the no-load static (When the engine output is
maximum rotataional frequency insufficient.)
in the procedure 1, incline the Readjust the air governor.
tilt lever forward or backward to Note: Refer to engine tune up
measure the maximum rotational section.
frequency of the engine under the
releaf condition when the acceler- O When the pedal is
ator is fu Ily opened. fully depressed, confirm that
the carbureter throttle valve
Std. is fully opened.
0 In the case of the gasoline engine,
its rotational frequency becomes
O in the case of an
slower than the no-load static LPG vehicle, its output is apt to
maximum rotational frequency by decrease compared with a gas'-
about 250 rpm. line vehicle, so adjust the regu-
lator and the governor carefully.
0 In the case of the diesel engine, -
its rotational frequency becomes 2.1 .c When the engine rotational
slower than the no-load static frequency and output are
maximum rotational frequency normal, proceed to 2.2.
by about 200 rpm.

2.2 Check the main pressure and 2.2.a When the main pressure and
the clutch pressure. the clutch pressure are abnor-
Std. (More than 4 kg/cm2 (57 psi) mal. (Check them according
at idling 8-12 kg/cm2 (11 4 - to the procedures described
171 psi) at 1,500 rpm) in I. I and I.2.)

2.3 Check the stall rotational fre- (Judge if the defective part is on
quency. the torque converter side (the
Stator Or O n the clutch side
0 Conduct the stall test t o measure
the engine rotational frequency. from the checked stall rotational
Note: Before checking the stall ro- frequency.)
tational frequency, be sure t o
check the engine output (the load
maximum rotational frequency),
the main bressure and the clutch
pressure to confirm that the en-
gine and the clutch system are
normal.
Symptom Check point Diagnosis, possible cause and action

Stall rotational frequency: 2.3.a Too low stall rotational fre-


IIZ about 1,910 rpm quency (by more than 300
3F about 2,010 rpm rpm).
Note: In some cases, the stall rota- 0 The slipping stator one-way
tional frequency deviates from clutch.
these standard values by about -+Disassemble, inspect and re-
100 rpm according to the slight place the stator.
difference of the performance of
the individual engine and torque 2.3.b Too high stall rotational fre-
converter. These standard values quency.
are for your reference in the 0-The clutch is excessively slipping.
troubleshooting. -+Check the clutch system and
replace defective part.

3. Large time lag at 3.1 Depress the accelerator pedal


start. at the same time when the shift
is made t o judge the start lag.
(Compare the start with that of
a normal vehicle, if possible.)

3.2 Check the main and clutch 3.2.a Abnormal main and clutch
pressures. Also check the rise pressure.
characteristics of the clutch Refer t o 1 . I or 1.2.
pressure.
3.2.b Clutch pressure rise charac-
teristics are abnormal (too
slow).
0 Broken or fatigued accumulator
(More than 4 kg/cm2 (57 spring.
Std.
psi) at idling 8-12 kg/cm2 + Disassemble for inspection.
(Main
(114-171 psi) at 1,500 Replace it, if necessary.
press.)
rpm) 0 Clogged accumulator orifice.
( M than ~ (57
~ 4 ~kglcm2 + Disassemble it for inspection
Stdm
(Clutch psi) at idling 8-12 kg/cm2 and wash it1 if necessary.
(1 14-1 71 psi) at 1,500 o Improper return of the inching
press).
rPm valve.
+ Check the link parts and
adjust it, if necessary.
0 Clogged inching orifice.
+ Disassemble it for inspection.
Wash it, i f necessary.

3.3 Oil inspection 3.3.a lnsuff icient oil amount,


clogged oil strainer or air
suction. -+ Disassemble i t for
washing.
Symptom Check point Diagnosis, possible cause and action

4. Defective inching 4.1 Check the inching lever oper- 4.1.a Improper operation of inching
with jerk (shock). ation. Check the operation of lever.
the inching lever visually. + Disassemble the link parts

for inspection. Adjust the


inching lever, if necessary.
4.1 .b Improperly adjusted inching
lever stopper. + Adjust (See
the inching lever stopper
section.)

4.2 Check the main and clutch 4.2.a When the clutch pressure rise
pressures. Depress the inching characteristics are abnormal.
pedal to check the clutch 0 Clogged inching orifice. + Dis-
pressure. assemble it for inspection. Wash
it, if necessary.
(More than 4 kg/cm2 (57 0 Broken or fatigued accumulator
Stdm
psi) at idling 8-12 kg/cm2 spring. + Disassemble it for
(Main
(114-1 7 1 psi) at 1,500 inspection. Replace it, if neces-
press. )
rpm) sary.
0 Clogged accumulator orif ice. +
Std. (More than kg'cm2 (57 Disassemble it for inspection.
psi) at idling 8-12 kg/cm2
(Main) Wash it, if necessary.
( I 4-1 71 psi) at 1500
press.) 6 Improper inching spool opera-
rpm)
tion. + Disassemble it for
inspection, Wash it, if neces-
sary.

4.2.b When the clutch pressure rise


characteristics are normal.
(Check the clutch pack parts.)
0 Broken or fatigued clutch return
spring. + Disassemble i t for
inspection. Repair or replace it,
if necessary.
0 l mproper operation of clutch
piston. + Disassemble it for
inspection. Repair or replace it,
if necessary.
0 Abnormally worn clutch plate.
+ Disassemble it for inspection.
Replace it, i f necessary.
Symptom Check point Diagnosis, possible cause and action

5. Differential oil 5.1 Smell torque converter oil t o 5.1.a When hypoid oil is smelt.
moving check if hypoid mixes in it- 0 improperly positioned oil seal of
the pinion unit or peeled off lip.
+ Disassemble i t for inspection.
Replace it if necessary.
0 Defective pinion unit 0 ring.
+ Replace it.
0 Defective retainer bolt seal.
+ Correct or retighten it.
0 Clogged air breather. + Replace it.

6. Overheat 6.1 Check torque converter oil. 6.1.a Defective torque converter
Check the oil level and quality. oil and improper oil level.
0 Inadequate oil level. -+Check the
oil level and adjust it t o the
adequate level, if necessary.
0 Air suction -+ Check each joint
0 ring.
0 Oil contains water. + Replace oil.

6.2 Check the main, clutch and 6.2.a The main and clutch pressures
torque converter (outlet) are lower than the standard
pressure. values. (Check them according
The main and clutch pressures. to the procedures described in
1 . I and 1.2.)
Std.: (More than 4 kg/cm2 (57
psi) at idling 8-1 2 kg/cm2 6.2. b The torque converter pressure
(114-1 71 psi) at 1,500 is lower than the standard
rpm) va lue
Torque converter pressure
0 Clogged regulator valve orifice.
Std. : (0.8-4 kg/cm2 (11-57 psi) + Disassemble it for inspection.
at 1,500 rpm) Wash it, if necessary.
0 High resistance of the internal oil
path piping. + Check clogging
of the internal oil path.
0 Clogged oil strainer. + Disas-
semble i t for inspection. Replace
it, if necessary.

6.3 Check the clutch. 6.3.a When the vehicle advances or


Check if the vehicle runs when backs with the clutch at the
the clutch is set at the neutral neutral position.
position. 0 Seized clutch or damaged clutch
pack. + Disassemble i t for in-
spection. Replace it, if neces-
Symptom Check point Diagnosis, possible cause and action

6.4 Check the torque converter. 6.4.a Defective torque converter.


0 Stuck stator. + Disassemble i t for
inspection. Replace it, if neces-
sary.
0 Contacted impeller. + Check the
oil filter. If defective, replace it.
o Decreased circulating flow rate.
+Check clogging of the internal
oil path. Wash it, if necessary.

6.5 Check the transmission. 6.5.a Defective transmission.


o Clutch dragging. -+ Disassemble
i t for inspection. Replace it, if
necessary.
o Worn or seized bearing. Disas-
-+

semble it for inspection. Repair


or replace it, if necessary.

6.6 Check the user's operation 6.6.a Check the operator's oper-
conditions. ation conditions, use condi-
tions and the working place.
o Check if excessive pushing is
made while performing the
inch operation.
o Check if the excessive switch
back is performed.

6.7 Check clogging of the radiator. 0 Inspection and cleaning.

7. Noise 7.1 Check the torque converter. 0 Damaged flexible plate. -+

Replace it.
0 Damaged bearing. -+ Replace it.

o Contacted impeller. -+ Repair or

replace it. (Check i t by the oil


f i lter. )
o Loosened bolt. -+ Retighten it.
o Damaged gear pump. +Repair
or replace it.
Symptom Check point Diagnosis, possible cause and action

7.2 Check the transmission. 0 Dragging noise by seized clutch.


-+Check the clutch. Replace i t
if necessary.
0 Worn or damaged bearings. +
Check the bearings. Replace it,
if necessary.
0 Damaged gear. -+ Replace it.
0 Worn spline. -+ Replace it.

7.3 Check the differential. 0 Check the engagement of the


pinion ring gear. Adjust or
-+

replace it, if necessary.


0 Check the damage of the bearings
and gears. -+ Check it. Replace
it, if necessary.

8. Oil leakage 8.1 Check the oil seal. 0 Check the damage and wear of
(total) each seal lip and the correspond-
ing sliding face. Replace defective
part with a new one.
8.2 Check the case joint. 0 Retighten the bolts and replace
the 0 ring and packings.
8.3 Check cavity and crack. o Repair or replace it.
8.4 Oil blow-out through the 0 Overheat
air breather 0 Excessive oil
COMPONENTS
TORQUE CONVERTER CASE

(llZ) (3F)

&
QJ

&-A=
O - A 1

31

(1-SPEED)

de

pi
(2-SPEED)

22 Case SUB-ASSY, transmission


23 Case SUB-ASSY, servo, NO. 1
238 Ring, 0 (For servo case)
24 Case SUB-ASSY, servo, NO. 2
24B Ring, 0 (For servo case)
30 Gate SUB-ASSY, oil level
31 Cover SUB-ASSY, upper
42 Plate, torqueconverter end
45B Plug, Drain
AB Ring, 0
AG Ring, 0
A1 Pin, straight
BZ Plate, seal
CA Plate, seal
CF Pin, lock
FC Cover
FW Cover
FY Cover

T0rqu.eConverter Case Components

-113-
TORQUE CONVERTER

Runner SUB-ASSY, turbine Ring, seal (For pump impeller


Shaft SUB-ASSY, stator extension)
Packing (For stator shaft) Piece, center (Boss, pilot)
Impeller SUB-ASSY, pump Shaft, turbine (Shaft, input)
Ring, 0 (For pump impeller) Bearing, turbine shaft
Stator SUB-ASSY Ring, seal (For turbine shaft)
Plate SUB-ASSY, flexible Hub (Race, inner)
Shim (For flexible plate) Bearing, thrust (For hub)
Cover SUB-ASSY, drive Washer, thrust, No. 1 (For hub)
(Disc SUB-ASSY) Washer, thrust, No. 2 (For hub)
Bearing (For drive cover) Washer, thrust, No. 3 (For hub)
Case SUB-ASSY, oil pump Roller (For stator)
Ring, 0 (For oil pump case) Spring (For stator)
Extension SUB-ASSY, pump impeller Cap, spring (For stator)
(BOSS) Ring, 0
Bearing, pump impeller extension Seal, oil
Ring, 0 (For pump impeller Spacer
extension) Spacer
Plate

Torque Converter Components


10 Drum ASSY, clutch, No. 1 (F1/R clutch) 42 Plate, clutch pressure
11 Drum ASSY, clutch, No. 2 (F2clutch) 42A Ring, Hole snap (For clutch pressure plate)
20A Ring, seal (For clutch drum) 43 Spring, clutch return
21 Drum SUB-ASSY, clutch, No. 2 45 Gear, clutch (Forward)
(F2 clutch drum) 46 Gear, clutch (Reverse)
22 Piston SUB-ASSY, clutch, No. 1 47 Gear, clutch (Forward 2nd)
22A Ring, piston (For clutch piston) 47A Bearing (For forward 2nd clutch gear)
23 Piston SUB-ASSY, clutch, No. 2 50 Plate, clutch camber
24 Shaft SUB-ASSY, clutch, No. 1 AC Ring, shaft snap
(F1/R clutch drum & main shaft) AJ Retainer, spring
24A Ring, seal (For clutch shaft) AQ Spacer
24C Ring, 0 (For clutch shaft) AT Spacer
240 Bearing, No. 1 (For No. 1 clutch shaft) AU Pin, spring
24E Bearing, No. 2 (For No. 1 clutch shaft) AV Spacer
25 Shaft SUB-ASSY, clutch, No. 2 AY Spacer
25D Bearing, No. 1 (For No. 2 clutch shaft)
40 Disc, clutch
41 Plate, clutch

Clutch Components

-115-
COUNTER GEAR

Shaft, counter
Bearing, No. 1 (For counter shaft)
Gear, counter, No. 1
Gear, counter, No. 2
Gear, output, No. 1
Spacer
Spacer
Plate, lock
Washer, lock

Counter Gear Components

-116-
CONTROL VALVE

01
r"' -7
i

...- GL
...
4

01 Cover & valve ASSY, transmission CJ Plug


31 Valve SUB-ASSY, inching CS Packing
40 Packing, transmission cover CW Packing
45 Valve, selector CX Plug
50 Valve, regulator CY Plug
51 Piston, accumulator DA Plate, sub
52 Retainer, spring (For regulator valve) DB Packing, sub plate
AA Lever, shift DC Bolt
AD Seal, oil DF Spring, regulator, outer
AF Lever, inching DG Spring, regulator, inner
AG Plug DK Orifice
AL Lever SUB-ASSY, inching cam DS Packing
AN Lever SUB-ASSY, shift cam DY Plug
AW Spring, inching valve EC Spacer
AX Ball, steel EE Spring, accumulator
BG Ring, 0 EK Bracket SUB-ASSY, inching wire
BS Bushing EX Plug
BT Bushing GB Spring, detent lever lock
BX Plug GL Cover, detent
BY Packing GV Sleeve, detent
CE Packing GX Collar
CI Packing

Control Valve Components

- 117-
TORQUE CONVERTER PIPING

Filter ASSY, oil


Strainer SUB-ASSY, oil (Screen)
Packing, oil strainer body
Hose, low pressure, No. 1 (For oil cooler)
Packing
Union
Bolt, union
Bolt
Nipple
Packing

Torque Converter Piping Components


TRANSMISSION COVER AND CONTROL VALVE ASSY

Gasoline Diesel
Orifice Orifice
[42.3 m m (0.09 i n L [41.6 m m (0.06 in)]
A-A Sectional View

Selector lever

6-6Sectional View

@ Inching valve
@ Regulator valve
@) Accumulator
@ Selector valve

Control Valve Sectional View

- 119-
REMOVAL

1. Remove the toe board.


( 1 ) Toe board
(2) Floor set bolt
(3) Floor

Removing the Toe Board 1~~17-30,18-3

2. Piping disconnection
(1) Disconnect the oil control valve inlet
pipe on the valve side.
(2) Disconnect the oil control valve outlet
hose on the valve side.

Disconnecting the Piping 1.~018-6

(3) Disconnect the brake booster piping.


@ Oil pump to brake booster pipe
@ Brake booster to tank pipe

Disconnecting the Piping L A Q8-8.9


~

3. Disconnect the torque converter oil cooler


piping.

Disconnecting the Oil Cooler Piping 1.~018-11


4. Disconnect the connecting rod from the
selector valve.

5. Disconnect the inching wire from the inch-


ing lever.

Disconnecting the Rod & Wire ~ ~ 1 8 - 117


4 ,

6. Disconnect the neutral switch wiring.

Disconnecting the Neutral Switch Wiring LAQ18-18

Transmission cover & valve ASSY removal


(1) Set bolts

Caution:
Since the set bolts are different in length,
check the positions they are used.

(2) Use the service bolt to remove the upper


cover.

Caution:
0 Use the cover & valve set bolt as the ser-
Removing the Cover & Valve ASSY ~ ~ ~ 1 8 . 2 0
vice bolt.
0 Since the O-ring i s used under the bottom
face of the cover, carefully prevent it
from falling.
0 After removing the cover, cover the open-
ing with cloth or proper material to pre-
vent material to prevent dust entrance in-
to the transmission.
DISASSEMBLY

1. Remove the switches.


(1) Neutral switch
(2) Back switch

Removing the Switches LAa3-6, 3

2. Remove the shift lever.


(1) Lever set bolt and nut
(2) Shift lever
(3) Collar
(4) Spacer

Removing the Shift Lever LAQ~-9

3. Remove the shift cam lever.


(1) Shift cam lever
(2) Bush

Removing the Shift Cam Lever 1 ~ 0 313-

4. Remove the inching lever.


(1) Lever set bolt and nut
(2) Inching lever
(3) Spacer

Removing the lnching Lever


5. Remove the inching cam lever.
(1) lnching cam lever
(2) Bush

Removing the Inching Cam Lever LAQB-15

Remove the selector valve.

Caution:
0 Carefully operate because the spring will
fly out when the detent cover is removed.
0 The steel ball will drop when the detent
cover is removed.
Carefully operate so as not to lose the
ball.

(1 ) Detent cover
(2) Spring
Removing the Detent Cover ~~0.3-7
(3) Detent sleeve
(4) Steel ball
(5) Selector valve

Removing the Selector Valve 1.~03-19

7. Remove the inching valve.


(1) Plug
(2) lnching valve
(3) Spring

Removing the Inching Valve ~~03-22


8. Remove the regulator valve.

Caution:
Carefully operate because thespring will f l y
out when the plug is removed.

(1) Plug
(2) Outer spring
(3) Inner spring
(4) Spring retainer

Removing the Regulator Spring ~~03-24

( 5 ) Plug
(6) Regulator valve

Removing the Regulator Valve LAQ~-26

9. Remove the accumulator piston.


(1 1 Plug

Caution:
Carefully operate because the spring will fly
out when the plug i s removed.

(2) Accumulator piston


(3) Accumulator spring

Removing the Accumulator Piston LAQ~-29

Remove the orifice.

Caution:
The orifice diameter i s greater on one side
and smaller on the other side. Since the
mounting direction is determined, record the
direction when the orifice i s removed.

(1) Plug
(2) Orifice

Removing the Orifice LAQ3-36


1 1. Remove the sub-plate.
(1) Set bolt
(2) Sub-plate
(3) Packing

Removing the Sub-plate ua3-31

12. Remove the oil seal from the valve body.

Removing the Oil Seal IAQ~-5

Caution:
Thoroughly wash each part in washing liquid
to eliminate dirt dust perfectly.

Control valve body inspection


(1) Crack and damage
(2) Wear and damage at valve sliding con-
tact surface
(3) Clogging of oil path
Inspecting the Control Valve Body IAQ~-2
2. Regulator valve inspection
Clogging of orifice
Wear and damage at sliding contact sur-
f ace
Damage of spring retainer
Fatigue of spring
Free length (inner) :
153.5 mrn (6.043 in.)
Free length limit (inner):
135.5 mm (5.335 in.)
Free length (outer):
152.5 mm (6.004 in.)
Free length limit (outer):
135.0 mm (5.31 5 in.) Inspecting the Regulator Valve LAW-32, 30

- 125-
Accumulator piston inspection
( I ) Wear and damage a t sliding contact sur-
f ace
(2) Fatigue of spring
Free length: 153.5 mm (6.043 in.)
Free length limit: 138.5 mm (5.453 in.)

Inspecting the Accumulator Piston LAQ4-36

Inching valve inspection


(1) Clogging of inching orifice
(2) Wear and damage at sliding contact sur-
f ace
(3) Fatigue of spring
Free length: 128 mm (5.04 in.)
Free length limit: 115.5 mm (4.547 in.)

Inspecting the Inching Valve LAQ~-22

Selector valve inspection


(1) Wear and damage at sliding contact sur-
f ace
(2) Damage of detent spring
(3) Damage of steel ball
(4) Fatigue of spring
Free length: 64 mm (2.52 in.)
Free length limit: 58 mm (2.28 in.)

Inspecting the Selector Valve LAQ~-13

Switch inspection
(1 ) Neutral switch conduction
The switch is normal if it is turned off
when pressed.
(2) Back switch conduction
The switch is normal if i t is turned on
when pressed.

Lever related parts inspection


(1) Damage and deformation of each part
(2) Damage of bush
lnspecting the Switches

- 126-
ASSEMBLY

Caution:
0 After washing each part, fully coat torque
converter oil before assembly.
0 Replace packings and oil seals with new
ones.

1. l nstall the oil seal.


SST 09620-3001 0

Install the Oil Seal UQI- 12

2. lnstall the sub-plate.


(1) Packing
(2) Sub-plate
(3) Set bolt
-
T = 0.8 1.2 kg-m (5.8 -- 7.9 ft-lb)

Note:
Coat thread tightner on the set bolt before
tightening it.

Installing the Sub-plate ~03-33

3. lnstall the orifice.


"D" punching position
(1) Orifice

Caution:
lnstall the orifice in the correct direction. L
(See the figure at right.) d
S
(2) Packing d

(3) Plug
3F engine vehicle 112 engine vehicle

Installing the Orifice LAQS53

4. lnstall the accumulator.


(1) Accumulator spring
(2) Accumulator piston
(3) Packing
(4) Plug

Installing the Accumulator

- 127-
Installing the Regulator Valve 1.~05-22

(4) Spring retainer


(5) Inner spring
(6) Outer spring
(7) Packing
(8) ' Plug

Note:
The valve can be installed easily by turning
the body with the plug on the lower side.
Finally, set it correctly and fasten the plug.

Installing the Regulator Spring LAQS-24.25

6. Install the inching valve.


(1) Spring
(2) lnching valve
(3) Packing
(4) Plug

Installing the Inching Valve LAQ~-27

7. Install the selector valve.


( 1) Selector valve
(2) Steel ball
(3) Detent sleeve
(4) Spring
(5) Packing
(6) Detent cover

Note:
Install the spring and cover with the detent
sleeve in a state of held so as not to drop the
steel ball.
8. lnstall the inching cam lever.
( I ) Bush
(2) Fit the pin at the tip end of the inching
cam lever into the groove on the inching
valve.

9. Install the inching lever.


(1) Spacer
(2) lnching lever

Caution:
lnstall the lever with the groove on the lever Installing the lnching Lever Related Parts LAQS-34.36
boss end face on the upper side.

(3) Lever set bolt and nut

10. lnstall the shift cam lever.


(1) Bush
(2) Fit the pin at the tip end of the shift
cam lever into the groove on the selec-
tor valve.

11. Install the shift lever


( I ) Spacer
(2) Collar
Installing the Shift Lever Related Parts LAQ~-I, 4
(3) Shift lever

Caution:
Place the groove on the lever boss end face
on the upper side when installing the lever.

(4) Lever set bolt and nut

12. l nstall the switches.

INSTALLATION Installing the Switches LAQ~-9

The installation procedure is the reverse of the


removal procedure.

Caution:
0 Coat grease on the O-ring and carefully
prevent it from falling during installation.
0 Cover & valve ASSY set bolt tightening
torque.
T = 1.9 2.5 kg-m (13.7 -- 18.1 ft-lb)
0 Carefully operate t o connect the selector
lever and connecting rod in the correct di-
rection.
Installing the Connecting Rod L A Q M ~ ~
TORQUE CONVERTER

Torque Converter Sectional View LAQM85

REMOVAL

1. Remove the flexible plate set bolts.


( 1) Set bolts (9 pcs.)

Note:
To turn the flywheel, turn the torque con-
verter.

Removing the Flexible Plate Set Bolts LAQZO-21

2. Remove the engine.

Note:
See the Engine removal section for the en-
gine removal.

Removing the Engine LAQ~o-34


3. Drain torque converter oil through the drain
plug.

Draining Torque Converter Oil lAQ20-36

4. Remove the pilot boss.


(1 ) Set bolts
(2) Pilot boss

Note:
Tap the pilot boss with a plastic hammer.

Removing the Flexible Plate and Pilot Boss LAQ~O-3s

5. Remove the snap ring.

Removing the snap Ring 1~~21.4

6. Remove the torque converter ASSY.

ASSY
Removing the ~or~ueconverter LAQ~I-5
DISASSEMBLY

1. Remove the flexible plate.


( 1) Set bolts
(2) Plate
(3) Flexible plate

Removing the Flexible Plate LAQ~I-13

2. Remove the drive cover.


(1) Stamp the match marks on the drive
cover and the p u m p impeller.

Stamping the Matching Marks LAQ~I-14

(2) Set bolts


(3) Drive cover
SST 09230-201 50-7 1

Removing the Drive Cover A L O ~ ~ - 1165 .

Removing the Bearing ~~012-13


4. Remove the turbine runner.
(1) Spacer
(2) Turbine runner

Removing the Turbine Runner LSAQII-1 B

5. Remove the thrust bearing.


(1) Thrust washer
(2) Thrust bearing
(3) Thrust washers (2 pieces)

Note:
Remove the reassembling sequence and re-
assembling direction of thrust washers (3
pieces).

Removing the Thrust Bearing LAQII-11)

6. Remove the stator SU B-ASSY.

Note:
Before removing the stator, rotate the im-
peller while holding the stator hub manually
to check i f it is stuck in both directions or it
does not lock in both directions (slipping).

7. Disassemble the stator SU B-ASSY. Removing the Stator SUB-ASSY LAQI 1-20
(1) Stator hub

Caution:
0 Remove the stator hub slowly and care-
fully.
0 When removing the stator hub, the roller,
etc. are disassembled at a time. Do not
lose them.

(2) Roller
(3) Spring cap
(4) Spring
(5) Stator Disassembling the Stator LAQ~~-22
8. Remove the pump boss from the pump im-
pel ler.
(1) Set bolt
(2) Pump boss

Removing the Pump Boss ~ ~ 1 1 - 2 2

9. Remove the bearing from the pump boss.


SST 09608-3501 4

Removing the Bearing L A Q1-24


~

Caution:
Wash each part in washing solution carefully
before the inspection to remove dirt com-
pletely.

Flexible plate and pilot boss inspection


(1) Crack and bend of flexible plate
(2) Wear and damage of pilot boss

inspecting the Flexible Plate and Pilot Boss uais-4

2. Drive cover inspection


(1) Crack and damage
(2) Wear and rotation of bearing

Inspecting the Drive Cover

- 134-
3. Turbine runner inspection
(1). Crack and damage
(2) Damage blades

Inspecting the Turbine Runner ~012-34

4. Pump impeller inspection


(1) Crack and damage
(2) Damage of blades

Inspecting the Pump Impeller ~~012.36

5. Pump boss inspection


(1) Crack and damage
(2) Wear and rotation of bearing
(3) Wear of oil seal sliding face
Boss outside diameter standard:
70.0 mm (2.756 in.)
Boss outside diameter limit:
69.85 mm (2.750 in.)
(4) Wear of piston ring groove
(5) Wear and damage of piston ring

Inspecting the Pump Boss L A Q2-8


~

Stator SUB-ASSY inspection


(1) Damage and wear of cam roller rota-
ting face
(2) Damage and wear of stator hub roller
rotating face
(3) Damage and wear of stator hub spline
(4) Loosened rivet
(5) Damage and wear of thrust bearing
(6) Damage and wear of thrust washer and
spacer

Inspecting the Stator SUB-ASSY (I) LAQ~~-31

- 135-
(7) Wear and damage of roller, spring and
spring cap
Roller outside diameter standard:
8.3 mm (0.327 in.)
Roller outside diameter limit:
8.17 mm (0.322 in.)

Inspecting the Stator SUB-ASSY (2) 1.~012-26

(8) Clearance between stator hub and cam


Clearance standard:
-
0.08 0.1 19 mm (0.0031 -- 0.0047 in.)
Clearance limit: 0.1 5 mm (0.0059 in.)

Inspecting the Stator (3) ~012-33

ASSEMBLY

Caution:
After washing the parts again, apply torque
converter oil to them sufficiently and reas-
semble them.

1. Reassemble the bearing on the pump boss.


SST 09608-35014

Reassembling the Bearing LAOI 2- 11

2. Reassemble the pump boss on the pump im-


pel ler.
(1) Reassemble the O-ring and the seal ring
on the pump boss.
(2) Drive in the pump boss.
SST 09608-35014 .

Caution:
Apply grease to the O-ring and reassemble it.

(3) Set bolt


T = 1.9 -- 2.5 kg-m (13.7 - 18.1 ft-lb)
Reassembling the Pump Boss

36 -
3. Reassemble the stator
(1) Spring and spring cap

Note:
0 Apply grease to the spring and the spring
cap.
0 Place the spring in the spring cap and re-
assemble spring with tweezers, etc.

(2) Stator hub


(3) Roller

Reassembling the Spring and Cap L A Q3-8


~
Note:
Reassemble the rollers one by one while
pushing in the spring cap by using the screw-
driver.
Push the hub completely while causing t o re-
volves the stator hub clockwise.

Reassembling the Stator Hub and Roller ~~ai3-13,14

(4) Stator operation confirmation

Note:
As shown in the figure, confirm that when
oil i s applied to the back of the stator blade,
the stator rotates and when oil is applied t o
the curved side of the blade, the stator is
locked by turning it manually in both direc-
tions.

(5) Reassembly the stator on the pump im-


peller.
Stator Operation Confirmation 1.~013-I 6

4. Reassemble the thrust bearing.


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

Caution:
Direct the thrust bearing in the correct re-
assembling direction and observe the reas-
sembling procedure.

Reassembling the Thrust Bearing LAQI 3-21


Select the turbine runner spacer.
(1) Reassemble the turbine runner up to the
conditions described in the preceding
paragraph 4 (without reassembling the
turbine runner and spacer).
Place the drive cover and measure the
dimension A shown in the figure.

Caution:
Place the drive cover with the pump impelter
O-ring removed.
Dimension A Measurement ~~0.13-26,
LAQSI 51
(2) Measure the height B from the pilot
boss flange ,face to the bearing contact
face with a slide calipers.
Measure the bearing thickness C.
Calculate the thrust gap between the
pump impeller and the drive cover bear-
ing by the following equation.
Select an adequate spacer in the table
below.
Thrust clearance (D):
0.2 - 0.8 mm (0.008 -0.031 in.)
D + Spacer thickness = A - B - C

Spacer item No. Thickness Pilot Boss Dimension B Measurement LAQI 3-7

32223-31940-71 2.5mm(O.O98in.)
32224-31940-7 1 2.7 mm (0.106 in.)
32222-31940-71 3.0 mm (0.118 in.) I

Caution:
After the measurement, be sure to reassem-
ble the pump impeller O-ring.

Bearing Thickness Dimension C Measuiement wain-17

Reassembling the Turbine Runner and Spacer LAQ13-27


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

Provisional Mounting Pilot Boss LAQl3-30

(2) Drive in the bearing.


SST 09608-35014

(3) Remove the pilot boss.

Note:
Reassemble the pilot boss and the flexible
plate on the vehicle.

Reassembling the Bearing ~~013-31

Reassembling the Drive Cover ~~013-34

INSTALLATION

Reverse the removing' procedure for instal lation operation.

Caution:
0 Before mounting, be sure to apply grease to the pump boss seal ring, the oil seal on the pump body
and the pilot boss O-ring.
0 Pilot boss set bolts tightening torque:
T = 1.9 -- 2.5 kg-m (13.7 -- 18.1 ft-lb)
0 Flexible plate set bolts tightening torque:
T = 1.9 -- 2.5 kg-m (13.7 -- 18.1 ft-lb)
STATOR SHAFT AND OIL PUMP
REMOVAL

Caution:
The stator shaft and oil pump are remvoed
immediately after the removal of the torque
converter desc'ribed in the preceding para-
graph, s o see the preceding paragraph for the
procedure up to the removal of the torque
converter.
Removing the Torque Converter ASSY LAQPI-s

Removing the Set Bolts L A Q Z-6


~

Removing the Stator Shaft and Pump ASSY ~ ~ 2 1 - 7

DISASSEMBLY

1. Remove the turbine shaft.


(1) Snap ring
(2) Turbine shaft

Note:
Tap the turbine shaft with a plastic hammer
to remove it.

Removing the Turbine Shaft LAQIO-13.14


2. Remove the bearing from the turbine shaft.
(1) Snap ring
(2) Bearing
SST 09950-2001 7

Removing the Bearing ~qalo-1s

Disconnect the stator shaft from the oil


pump.
(1) Oil pump set bolt
(2) Oil pump ASSY
SST 09950-2001 7

Note:
Remove by using service bolts (2 pieces) and
SST.

(3) Stator shaft


Disconnecting the Stator Shaft LAQIO-16, 17
from Oil Pump
4. Disassemble the oil pump ASSY
(1) Pump drivegear
(2) Pump driven gear

isa assembling the Oil Pump LAQIO-28

(3) O-ring
(4) Oil seal

Removing the Oil Seal

- 141 -
INSPECTION

Caution:
Wash each in washing solution carefully
before the inspection to remove dirt com-
pletely.

1. Turbine shaft inspection


(1) Wear and damage of spline
(2) Wear of sliding face in contact with the
stator shaft
(3) Wear of seal ring groove Inspecting the Turbine Shaft LAQI 0-23 '

(4) Wear and damage of seal ring


(5) Wear and rotation of bearing

Stator shaft inspection


(1) Wear and damage of spline
(2) Clogging of oil hole
(3) Wear and damage of turbine shaft seal
ring contact face
(4) Wear and damage of pump gear sliding
face

I Inspecting the Stator Shaft LAQIO-27

(5) Wear of the sliding face in contact with


the pump drive gear
Stator shaft outside diameter standard:
55 mm (2.17 in.)
Stator shaft outside diameter limit:
54.9 mm (2.161 in.)

Inspecting the Drive Gear Sliding Face LAQIO-26

Oil pump ASSY inspection

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

(I
) Oil pump body and gear
@ Crack and damage
@ Wear and damage of pump boss-
seal ring contact face.
@ Wear and damage of drive and
Inspecting the Oil Pump Body and Gear LAQ~O-28
driven gears.
Check the wear of the oil pump body
and gear.
@ Measure gap between the driven
gear and the pump body.
Clearance standard:
0.1 2-0.2 mm (0.0047-0.0079 in,)
Clearance limit: 0.3 mm (0.012 in.)

Measuring the Driven Gear-body Gap LAQ~O-29

@ Measure the clearance between the


dr~vengear and the crescent.
Clearance limit: 0.4 mm (0.016 in.)

@ Measure the clearance between the


drive gear and crescent.
Clearance limit: 0.25 mm (0.010 in.)

Measuring the Driven/ Drive LAQIO-30.31


Gear-crescent Gap
($ Measure the clearance between the
drive gear bushing and the stator
shaft.
Clearance standard:
-
0.03 0.079 mm
(0.0012 -- 0.0031 in.)
Clearance limit:
0.1 5 mm (0.0059 in.)

Measuring the Drive Gear Bushing-Stator


LAQ10-33
Shaft Gap

@ Measure clearance between the


pump body mounting face and the
drive/driven gears.
Clearance standard:
0.05-0.10 mm (0.002-0.0039 in.)
Clearance limit:
0.13 mm (0.0051 in.)

Measuring the Body Mounting Face-drive/ LnQlo-ss


driven Gear Gap
ASSEMBLY

Caution:
After washing each part again, apply torque
converter oil to it sufficiently and reassem-
ble it.

1. Reassemble the oil pump.


(1) Oil seal
SST 09608-35014
(2) O-ring
(3) Driven gear Reassembling the Oil Seal LAQI 0-36
(4) Drive gear

2. Reassemble the oil pump ASSY on the


stator shaft.

Caution:
Apply grease to the O-ring and reassemble it.

Reassembling the Oil Pump ASSY LAQII-3

(1 ) Set bolts
T = 1.9 -- 2.5 kg-m (13.7 -- 18.1 ft-lb)

Tightening the Set Bolts LAQI 1-4

3. Reassemble the bearing on the turbine shaft.


(1) Bearing
(2) Snap ring

Reassembling the Turbine Shaft Bearing LAQII-~,~


4. Reassemble the turbine shaft on the stator
shaft.
( 1 ) Turbine shaft insertion.

Caution:
Apply grease to the seal ring sufficiently.
Pay attention so as not to damage it when
inserting it.

Reassembling the Turbine Shaft L A Q1-9


~

(2) Snap ring

Reassembling the Snap Ring LAQII-10

INSTALLATION

1. Install the stator shaft and oil pump.

Caution:
Use the new packing.

(1) Set bolt


T = 1.9 -- 2.5 kg-m (13.7 -- 18.1 ft-lb)

Installing Stator Shaft and Pump ASSY LAQZI-10

2. l nstall the torque converter ASSY.

Note:
See the preceding paragraph for the operat-
tion after the torque converter ASSY install-
ing operation.
TORQUE CONVERTER AND TRANSMISSION ASSY
WITH DIFFERENTIAL
REMOVAL

Caution:
0 There are 2 kinds of methods for the torque converter and the transmission removal procedure.
Select either one according to the required repair.

@ When chiefly replacing the torque converter @ When chiefly repairing the clutch and gear
ASSY and repairing to the differential, etc. (excluding the output gear), etc.

Removing the Torque Converter and LAa24-s Removing the torque converter and ~0.21-15
Transmission ( 1 Transmission (2)
o In this manual, method @ is described. In the case of method @ , remove the engine, and dis-
connect it from the differential carrier.

1. Remove the mast.

Note:
See the Mast removal section for the re-
moving procedure.

2. Loosen teh front wheel hub nut.

Removing the Mast 1.~047-20

Jack the vehicle up.

Note:
To facilitate the operation, place a block
about 15 cm (6 in.) under the rear tire. Sup-
port the frame front both sides with stands
so as to keep the vehcile horizontally.

Jacking Up the Vehicle

- 146 -
4. Remove the front wheel.

Removing the Front Wheel LAQ22-11

5. Drain oil
( 1) Differential oil
(2) Torque converter oil

Draining the Oil LAQ23-18

6. Disconnect the brake piping.

7. Disconnect the parking brake cable.

Disconnecting the Brake Piping LAOM-17.23-23


and Parking Brake Cable

Removing the Set Nuts ~~0.23-24


9. Place a wooden block under the differential
housing to prevent torsion on the housing.

Placing the Wooden Block ~ ~ 2 3 - 2 5

Remove the front axle housing set bolts.


(1) Lightly suspend the front axle housing
ASSY.

Caution:
Wind the cloth around the tilt cylinder rod
to prevent the cylinder from being damaged
by the wire rope.

(2) Common bolts (2 bolts placed at the


top-end and bottom-end position)

Removing the Bolts ~ ~ 2 3 - 2 7

(3) Reamer bolts (on upper one and lower


one on either side)
SST 09310-22000-7 1

Removing the Reamer Bolts ' ~ ~ 2 3 - 3 1

11. Remove the front axle housing ASSY to-


gether with the brake.
(1) Front axle housing ASSY (RH)
(2) Front axle housing ASSY (LH)

Removing the Axle Housing ASSY ~~0.23-32


12. Remove the inner front axle shaft.

Removing the Axle Shaft ~~023-53

13. Remove the toe-board.


(1) Toe-board
(2) Floor set bolts
(3) Floor

Removing the Toe-Board LAO17-30.18-3

Disconnecting the Oil Cooler Piping ~ ~ 1 8 - 1 1

15. Disconnect the connecting rod from the


selector lever.

16. Disconnect the inching wire from the inch-


ing lever.

17. Disconnect the neutral switch wiring.

Disconnecting the Rod and Wire ~ ~ 1 8 - 117


4 ,
18. Remove the torque converter case cover.

19. Remove the flexible plate set bolt.


(1) Set bolts (9 pieces)

Note:
To rotate the flywheel, turn the torque con-
verter.

Removing the Flexible Plate Set Bolts LAQ~O-21

Place a block under the lower part on the en-


gine side.

Note:
The torque converter plate is mounted on
the engine side without removing it, so
place a block under the lower part of the
torque converter end plate.

Placing a Stand Under the Engine LAQ~~-3

Supporting the Front Axle with torque Converter LAQ24-6

Removing the Torque Converter Case Set Bolts ~ ~ ~ 2 4 . 6


23. Remove the torque converter and transmis-
sion with differential.

Caution:
Pull out the vehcile by operating the hoist
and the garage jack.

Reference:
0 By doing so, the torque converter and
transmission ASSY with differential are
removed.
0 In the subsequent paragraphs, each func-
Removing the Torque Converter and ~ ~ 2 4 - 9
tion removal procedure is described. Transmission with Differential

24. Remove the differential housing.

Removing the Differential Housing mole-'11

25. Remove the differential carrier ASSY.

Removing the Differential Carrier ASSY LAQ~B-8

26. Remove the oil filter.


SST 09228-440 1 1

Removing the Oil Filter

- 151 -
27. Remove the transmission cover and the con-
trol valve ASSY.
(1) Set bolts
(2) Remove the control valve ASSY by
using the service bolts.

Removing the Cover & Valve ASSY IAQI -24

28. Remove the torque converter.


( 1 ) Pilot boss set bolts
(2) Pilot boss

Note:
Tap the torque converter with a plastic ham-
mer to remove it.

Removing the Pilot Boss IAQI-27

(3) Snap ring


(4) Torque converter

Removing the Torque converter IAQ~-2s

29. Remove the stator shaft and oil pump.


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

Removing the Stator Shaft and Pump IAQ~-32

- 152-
'TRANSMISSION

Transmission Sectional View L A Q L ~ ~

Transmission Disassembly Procedure LAQI-34


COUNTER GEAR SYSTEM PARTS

1. Remove the seal plate (on the front side).

Note:
Do not reuse the seal plate once removed
since the plate suffers deformation.

Removing the Seal Plate LAQI-35

2. Remove the lock plate.


(1) Straighten the bend of the lock washer.
(2) Set bolt
(3) Lock plate

Removing the Lock Plate ~ ~ 0 2 - 3

3. Remove the counter shaft and ,gear.


(1) Seal plate (on the rear side)
(2) Counter shaft

Note:
Strike to the counter shaft with a copper
bar, then the seal plate comes off and the
counter shaft can be removed with the bear-
ing (on the rear side).

Removing the Counter Shaft L A Q ~ - 45,

(3) Counter gear (on the small diameter


side)

Caution:
Remove the gear on 2 counter gears on the
greater diameter side after removing the F I I
R clutch.

(4) Spacer

Removing the Counter Gear and Spacer lA~2-6


Removint the Bearing 1.~02-8

5. Remove the bearing from the counter shaft.


(1) Snap ring
SST 09905-00012
(2) Spacer
(3) Bearing
SST 09950-20017

Removing the Bearing LAQ~-29.31

Removing the Servo Case LAQZ-9

7. Remove the seal rings and the snap ring.


( 1) Seal rings ( 3 pieces)
(2) Snap ring
(3) Spacer

Removing the Seal Rings and Snap Ring was-11.12

- 155-
8. Remove the F1/R clutch ASSY.

Note:
Support the clutch drum. Tap the shaft end
with a plastic hammer remove it.

Removing the F1 /R Clutch ASSY LAQZ-14,15

9. Remove the clutch shaft bearing No. 2 from


the torque converter case.
SST 09620-30010

Removing the Bearing 1.~02-16

10. Take out counter gear remained in the tor-


que converter case bottom.

Taking Out the Counter Gear LAQZ-18

F I / R CLUTCH ASSY DISASSEMBLY

1 1. Remove the forward gear.


(1) Snap ring
(2) Spacer

Removing the Snap Ring and Spacer ~~06-17,'18


(3) Forward gear
SST 09950-2001 7

Removing the Forward Gear u~6-22

12. Remove the reverse gear


(1) Spacer
(2) Reversegear
SST 09950-20017

Removing the Reverse Gear ~ ~ 0 6 - 2 3

13. Remove the bearings from the forward gear


and the reverse gear.
(1 ) Snap ring
(2) Bearing
SST 09608-3501 4

Removing the Bearing LAQ~-31.32

14. Disassemble the clutch drum.

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

(1) Snap ring

Removing the Snap Ring 1-406-24


(2) Camber plate
(3) Pressure plate
(4) Clutch disc
(5) Clutch plate

Removing the Clutch Plate LAQ~-26

(6) Snap ring


SST 09220-22000-71

Setting the SST L A G S ~ ~

Removing the Snap Ring wQ6-27

(7) Spring retainer


(8) Clutch return spring

Removing the Return Spring

- 158 -
(9) Clutch piston

Removing the Clutch Piston was-29

(10) Remove the piston ring

Removing the Piston Ring ~ ~ ~ 6 . 3 0

F2 CLUTCH PARTS

15. Remove the set bolts of the servo case.

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

Removing the Set Bolts LAOZ-19

16. Remove the seal plate.

Note:
It i s not able to reuse to deform when the
seal plate removes it once.

Removing the Seal Plate LAQ~-20


--

17. Remove the snap ring and spacer

Removing the Snap ring and Spacer u02-22, 23

18. Remove the clutch shaft and the F2 clutch


ASSY.
(1) Strike the shaft face from the front side.
(2) Servo case

Removing the Servo Case 1~0.2-24

(3) Clutch shaft (with the .bearing on the


servo case side)
(4) Spacer
(5) F2 clutch ASSY

Removing the Shaft and F2 clutch LAQ~-25.26

19. Remove the bearing from the torque con-


verter case.
(1) Snap ring
(2) Bearing
SST 09608-3501 4

Removing the Bearing LA02-28


Disassemble the clutch shaft.
(1) Seal ring
(2) Clutch shaft bearing No. 1
SST 09950-20017

Removing the Bearing F Q 9 -14

(3) Spring pin

Removing the Spring Pin 1 ~ 0 91s-

F2 CLUTCH ASSY DISASSEMBLY

21. Remove the clutch gear.

Removing the Clutch Gear LAO&14

22. Remove the bearing from the clutch gear.


(1) Snap ring
(2) Bearing
SST 09608-350 14

Removing the Bearing 1.~08-28


23. Disassemble the clutch drum.
(1) Snap ring

Removing the Snap Ring LAQ8-16

(2) Camber plate


(3) Pressure plate
(4) Clutch disc
(5) Clutch plate

Removing the Clutch Plate ~ A a 817


-

(6) Snap ring


SST 09220-22000-71

Removing the Snap Ring LAQ8-18

(7) Spring retainer


(8) Clutch return spring

Removing the Return Spring

- 162-
(9) Clutch piston

Removing the Piston 1.~08-20

(10) Remove the piston ring

Removing the Piston Ring LAQ~-30

24. Remove the oil strainer.


(1) Setbolts
(2) Oil strainer

Removing the Oil Strainer 1.~02-30


INSPECTION

Caution:
Wash each part in washing solution before
the inspection t o remove dirt completely.

1. Oil strainer inspection


( I ) Damage, deformation and clogging of
wire netting
(2) Crack of welded part

lnspecting the Oil Strainer LAO10-8

COUNTER GEAR PARTS

2. Counter gear and counter shaft inspection


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

Inspecting the Counter Gear and Shaft LAOS-32

3. Counter shaft bearing inspection


(1) Wear and rotation of bearing

Inspecting the Bearing LAQ~O-2

4. Seal plate inspection


( 1 ) Damage

Caution:
Exchange the seal plate on the front side
with the new article.

Inspecting the Seal Plate LAQIO-3


FI/R CLUTCH PARTS

5. Forward gear and reverse gear inspection


(1) Wear and damage of gear
(2) Clogging of oil hole
(3) Wear and rotation of bearing

Inspecting the Forward and Reverse Gear 1.~06-33

Clutch drum and main shaft inspection


(1) Crack, damage and biting
(2) Wear and damage of gears
(3) Wear and damage of spline
(4) Clogging of oil path leading shaft
(5) Looseness of joint rivet of shaft and
drum
(6) Looseness of shaft end plug

lnspectinb the Clutch Drum and Shaft LAQ~-36

Inspecting the Side Clearance L A Q ~ .4~ ,

7. Pressure plate, clutch disc, clutch plate and


camber plate inspection

Caution:
When the plates are extremely discolored by
overheat, replace both the clutch disc and
the clutch plate at a time.

Inspecting the Clutch Plate ~~07-6,8


(1) Wear and damage of pressure plate
Thickness standard: 4.5 mm (0.177 in.)
Service limit: 4.3 mm (0.169 in.)

Inspecting the Pressure Plate 1.~07-11

Wear, damage, burn, deformation and


discoloration of clutch plate
Thickness standard: 2.0 mm (0.079 in.)
Service limit: 1.8 mm (0.071 in.)

Wear, damage, burn, deformation and


discoloration of clutch disc
Thickness standard: 2.6 mm (0.102 in.)
Service limit: 2.4 mm (0.094 in.)

inspecting the Clutch Plate and LAQ~-10.9


Clutch Disc
(4) Wear, damage, deformation and dis-
coloration on camber plate
Curvature inspection
Lay the camber plate face down on the
surface plate and measure its inner cir-
cumference and i t s inside height.
Standard curvature: 3.4 mm (0.134 in.)
Service limit: 3.1 mm (0.122 in.)

Inspecting the Camber Plate 1.~0~438

8. Clutch return spring inspection


(1) Break and fatigue of spring
Free length: 62 mm (2.44 in.)
Free length service limit: .
56 mm (2.20 in.)
(2) Damage of spring retainer

lnspecting the Return Spring

- 166 -
9. Clutch piston inspection
(1) Crack and damage
(2) Clogging of oil hole

Note:
Check these defect by using compressed air,
etc.

Inspecting the Clutch Piston 19-


LAQ~

(3) Wear and damage of piston ring


(4) Piston ring side clearance
Limit value: 0.1 5 mm (0.0059 in.)

Inspecting the Side Clearance 1.~07-20

10. Clutch shaft bearing inspection


(1) Wear and rotation

Inspecting the Bearing ~~07-22

11. Servo case inspection


( 1 ) Crack and damage
(2) Wear and damage of seal ring sliding
part
(3) Clogging of oil path

Inspecting the Servo Case ~~07-23


F2 CLUTCH PARTS

12. Clutch gear (F2 gear) inspection


(1) Wear and damage of gear
(2) Clogging of oil hole
(3) Wear and rotation of bearing

Inspecting the Clutch Gear IAQE-29

13. Clutch drum inspection


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

Inspecting the Clutch Drum 1~08-23

14. Clutch shaft inspection


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

Inspecting the Clutch Shaft LAQS-17

(5) Wear and damage of seal ring


(6) Seal ring side clearance
Limit value: 0.29 mm (0.011 in.)

Inspecting the Side clearance ~~0.9-19


1 5. Clutch plate, return spring and clutch piston
inspection

Note:
These parts are the same as those of the
main clutch.
See the F 1/R clutch for the inspection items.

Inspecting the Plate and Spring LAQS-26

Inspecting the Piston 1.~07-20

16. Clutch shaft bearing inspection


(1) Wear and rotation

17. Servo case inspection


(1) Crack and damage
(2) Wear and damage of seal ring sliding
part
(3) Clogging of oil path

Inspecting the Bearing and Servo Case LAQ~-20.


21

TORQUE CONVERTER CASE

18. Torque converter case inspection


(1) Crack and damage
(2) Clogging of oil path

Inspecting the Torque Converter Case ~~02-31


ASSEMBLY

Caution:
0 When reassembling the torque converter
case, pay attention so that dust, etc. does
not enter it.
0 Before reassembling each sliding part, be
sure to apply torque converter oil to it
sufficiently.

F2 CLUTCH PARTS
Reassembling the Piston Ring
1. Reassemble the F2 clutch ASSY.
(1) Reassemble the piston ring on the
clutch piston.
(2) Reassemble the seal ring on the clutch
drum.
(3) Insert the piston in the clutch drum.

Note:
0 Apply torque converter oil to the piston
sufficiently.
0 It i s not necessary to f i t the piston ring
normally.

Piston Insertion LAQ~-35

(4) Set the piston return spring, retainer


and snap ring on the drum.
Compress the spring by using SST to re-
assemble it.
SST 09220-22000-7 1
@ Fit the piston ring by the using a
screwdriver and insert the piston.

Reassembling the Piston ~ ~ 0 9 - 3

@ Retighten the SST nut further.


Compress it to the position where
the snap ring can be fit t o reassem-
ble the snap ring.

Reassembling the Snap Ring ~ ~ 0 9 - 4


(5) Clutch plate and clutch disc

Caution:
0 Reassemble the clutch plates (6 pieces)
and the clutch discs (6 pieces) alternately
in the order of the clutch plate and clutch
disc.
0 Be sure to fill the clearances between the
plates with torque converter oil.

Reassembling the Clutch Plate and Disc LAOS-5.6

Assemble the pressure plate and the


camber plate.
@ "OUT" on the camber plate must
come in the clutch gear side.
@ The f langeless section (2 places) of
the pressure plate and the flange of
the camber plate must come to-
gether.
Snap ring
Measure the clearance (A) between the
snap ring and the camber plate.

-
Dimension A:
1.0 2.5 mm (0.039 -- 0.098 in.)
Reassembling the Pressure Plate and
Camber Plate
LAQS-7,8

If the measurement exceeds the speci- Snap ring


fied dimension limits, change the order
of plates. Camber plat
I f the specified dimension is still not
reached, check each plate for wear, and
replace as necessary.

clearance Measurement LAGS~S

(9) Reassemble the' bearing on the clutch


gear.
@ Bearing
SST 09608-3501 4
@ Snap ring

Reassembling the Bearing ~~0.8-32


(10) Reassemble the clutch gear ( F 2 gear) on
the drum.

Note:
Align the serration of the clutch disc with a
screwdriver, etc. before reassembling.

Reassembling the Clutch Gear mag-lo, 8-14

2. Reassemble the spring pin, bearing and seal


ring on the clutch shaft.
(1) Spring pin

. .

Driving-in the Spring Pin LAQ~-23

(2) Bearing
SST 09608-3501 4
( 3 ) Snap ring
(4) seal ring and O-ring

Caution:
After reassembling, apply grease to the seal
ring.

Reassembling the Bearing ~~09-22

3. Reassemble the clutch shaft bearing (on the


seal plate side) on the torque converter case.
(1) Bearing
SST 09608-350 14
(2) Snap ring

Reassembling the Bearing L A Q4-9


~

- 172-
4. Reassemble the F2 clutch ASSY and the
clutch shaft.
( 1 ) Place the torque converter case on a
block with the differential side down.

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

(2) Place the clutch ASSY on the bearing in


Driving-in the Clutch Shaft LAQ14-11
the torque converter case.
Drive in the clutch shaft from theabove.
SST 09608-3501 4

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

(3) Raise the shaft under the conditions


described in (2) (with the clutch ASSY)
and place the spacer correctly on the Reassembling the Spacer LAQI~-15

bearing in the torque converter case.


(4) Lower the shaft and clutch ASSY slow-
ly. Drive in the clutch shaft again.
SST 09608-3501 4

Caution:
0 Insert the hand from below so that the
spacer does not deviate.
0 Place the shaft spring pin in the drum
groove.

Reassembling the Clutch Shaft ~~014-16

5. Reassemble the spacer and snap ring.


(1) Spacer
(2) Snap ring

~ e a s s e m b l i nthe
~ Plate and Snap Ring ~~14-18.19
6. Reassemble the seal plate.

Caution:
0 As for the seal plate, use the new article.
0 Tap the seal plate with a plastic hammer
to reassemble it.

Reassembling the Seal Plate lA~14-20

Reassembling the Servo Case ~~014-21


(2) Set bolt
T = 1.9- 2.5 kg-m (13.7 -- 18.1 ft-lb)

8. Check the F2 clutch operation.

Note:
0 Check the F2 clutch operation by using
compressed air.
0 Throttle compressed air to the minimum
and blow it to the clutch operation oil
path to check if the F2 clutch piston
operates surely.

Inspecting the F2 Clutch Piston Operation ~ ~ 1 4 - 2 4

/R CLUTCH PARTS

Place the counter gear (on the larger dia-


meter side) in the torque converter case.

Caution:
Place the counter gear under the position
where it i s reassembled in the correct direc-
tion.
(After reassembling the main clutch, reas-
sem ble the counter gear.)

Provisional Positioning of the counter Gear ~~014-27


(on Larger Diameter Side)

- 174 -
10. Reassemble the F1/R clutch ASSY.

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

(1) Reassemble the piston ring on the


clutch piston.

Reassembling the Piston Ring 1.~07-27

(2) Reassemble the seal ring on the clutch


shaft piston sliding part.

Caution:
0 After reassembling, apply grease to the
seal ring.
0 It is not necessary to reassemble the
piston ring on the servo case side.

Reassembling the Seal Ring LAQ7-26

(3) Insert the piston in the clutch drum.

Note:
0 Apply torque converter oil sufficiently to
the piston.
0 It i s not necessary to fit the piston ring
normally.

Piston Insertion UQ~-28

(4) Set the piston return spring, retainer


and snap ring on the drum.
Compress the spring by using SST to re-
assemble it.
SST 09220-22000-7 1
@) Fit the piston ring by using a screw-
driver and insert the piston.

Reassembling the Piston 1~07-30


@ Retighten the SST nut further.
Compress the snap ring to the
position where the snap ring can
be fitted to reassemble the snap
ring.

Reassembling the Snap Ring LAQ~-32

(5) Clutch plate and clutch disc

Caution:
0 Reassemble the clutch plates (6 pieces)
and the clutch discs (6 pieces) alternately
in the order of the clutch plate and disc.
0 Be sure to fill the clearances between the
plates with torque converter oil.

Reassembling the Plate and Disc LAQ~-33,


35

(6) Assemble the pressure plate and the


camber plate.
@) "OUT" on the camber plate must
come in the clutch gear side.
@ The flangeless section ( 2 places) of
the pressure plate and the flange of
the camber plate must come to-
gether.
(7) Snap ring
(8) Measure the clearance (A) between the
snap ring and the camber plate.

-
Dimension A:
1.0 2.5 mm (0.039 -- 0.098 in.)
Reassembling the Pressure Plate and
Camber Plate
~ ~ 0 . 7 - 38-2
6,

If the measurement exceeds the speci-


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

Clearance Measurement

- 176 -
(9) Assemble the bearings on the forward
gear and the reverse gear.
@ Bearing
SST 09608-350 1 4
@ Snap ring

Reassembling the Bearing y06-34

(10) Reassemble the forward and reverse


gears on the clutch shaft.
SST 09608-3501 4

Caution:
0 Align the serration of the clutch Idisc with
a screwdriver, etc. before reassembling.
0 Do not confuse the forward side with the
reverse side.
(Confirm them by the number of teeth.)

Reassembling the or ward and Reverse Gears mas-6, 8

(11 ) Spacer
(12) Snap ring (on the forward gear side)

Reassembling the Spacer 1.~06-18,15

Reassembling the Bearing ~~14-28 '


12. Secure the servo case provisionally.

Note:
Reassemble the servo case so that the bear-
ing does not move when reassembling the
F I / R clutch ASSY.

Provisional Installation of the Servo Case LAQI~-30

Reassemble the F 1/R clutch ASSY.


(1) Support the clutch drum and strike the
shaft end with a copper hammer.
(2) When the shaft is driven into the bearing
on the torque converter case side to
some degree, drive it in completely with
a copper rod.

Reassembling the F1 /R Clutch ASSY LAQ~~-33

14. Remove the servo case.

15. Reassemble the snap ring and seal ring on


the clutch shaft.
(1) Spacer
(2) Snap ring
(3) Seal rings (3 pieces)

Caution:
After reassembling apply grease to them.

Reassembling the Snap Ring and Seal Ring ~014-35.36

Reassemble the servo case.


( 1 ) Servo case

Caution:
0 Apply grease to the O-ring.
0 Pay attention so that the oil hole O-ring
does not come off.
0 Tap the servo case with a plastic hammer
to reassemble it.

(2) Set bolt


T = 1.9 -- 2.5 kg-m (13.7 - 18.1 ft-lb)
Reassembling the Servo Case ~~015-3
17. Check the FIIR clutch operation.

Note:
0 Check the FI/R clutch operation by
using compressed air.
0 Throttle compressed air to the minimum
and blow it to the clutch operation oil
path to check if the clutch piston oper-
ates surely.

(1) Check the operation of the clutch on


the forward side.
Clutch Operation Inspection (on forward side) LAQIS-16

(2) Check the operation of the clutch on


the reverse side.

Clutch Operation Inspection (on reverse side) ~~015-17

COUNTER GEAR PARTS

18. Reassemble the bearing on the counter shaft.


(1) Bearing (on the rear side)
SST 09608-3501 4
(2) Spacer
(3) Snap ring
SST 09905-000 12

Reassembling the Bearing LAQIO-4,6

19. Reassemble the counter shaft bearing on the


torque converter case.
(1) Bearing (on the front side)
SST 09608-350 14
(2) Snap ring

Reassembling the Bearing LAO?5-7


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

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

Counter Shaft Insertion LAOIS-11. 9

(2) Strike the shaft end with a plastic ham-


mer or a copper hammer until the shaft
is engaged with the gear spline.
(3) Drive in the shaft completely with a
copper rod.

Reassembling the Counter Shaft LAQI 5-1 2

21. Reassemble the lock plate and lock washer.


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

Reassembling Lock Plate and Lock Washer 1~02-2.15-?3

Reassemble the seal plates (on the front and


rear sides).

Caution:
0 As for the seal plate, use the new article.
(on the front side)
0 Apply grease to the O-ring. (on the rear
side)
0 Tap the seal plate with a plastic hammer
to reassemble it.

Reassembling the Seal Plate 1.~015-14. 15


23. Install the oil strainer.
( I ) Packing
(2) Oil strainer
(3) Set bolts

Reassembling the Oil Strainer LAQIS-18

INSTALLATION

Follow the removing procedure in the reverse


order.

Caution:

-
0 Oil filter tightening torque
T = 1.5 2.0 kg-m (10.8 -- 14.4 ft-lb)

Reassembling the Oil Filter ~~015-36

0 See the following cautions for assembly operation.


1. Assembly of the stator shaft and oil pump.
2. Assembly of the torque converter.
3. Assembly of the upper cover and control valve ASSY.
4. Assembly of the front axle.
(When removing the front axle by the front axle with torque converter method.)
5. Assembly of the engine.
(When removing only the transmission on the engine side.)
OUTPUT GEAR A N D DIFFERENTIAL

Output Gear Sectional View LAQME~

Removing the Differential ASSY


Note:
0 Disassemble the differential carrier ASSY
from the conditions shown in the right
figure.
0 The disassembly, inspection and reassem-
bly method of the differential carrier
ASSY i s almost the same as that of the
differential of Section 4 Transmission and
differential. See such section.

Installation shall be in the reverse order of the re-


moval procedure. Differential Carrier ASSY 1.~016-5
limit ( F ) and the lower limit (L),the oil Oil Level Measurement
level is proper.

2. Oil pressure measurement


(1) After making a warming-up run of the
engine, measure the idle speed and the
no-load maxi mum governed speed.

Caution:
When the engine speed i s out of standard
value, adjust it referring to the item of En-
gine Adjustment.

Diesel Gasoline
Engine rpm Measurement LAQ~E-6
model model
,
Idling speed 750k2.5 rpm t

No-load maxi-
mum governed 2350 +I00 rpm 2,350 *50 rpm
speed

(2) Stop the engine. Jack up the front axle


to raise the tires (both wheels).
(3) Remove the toe-board and set the oil
pressure gauge. When there are 3 oil
pressure gauges, i t is desirable to mea-
sure the main pressure, clutch pressure
and torque converter pressure at the
same time.
(4) Start the engine. Set the shift lever at
the neutral position. Measure the .main
pressure at the idling rpm and at 1500
rpm as well as the torque converter
pressure at 1500 rpm. @ Main pressure ......................... Plug PT 118
@ Clutch pressure (F1) ................. Plug PT 118
($ Clutch pressure (F2) ................. Plug PT 118
@) Clutch pressure (I?) ................... Plug PT 118

Oil Pressure Measurement Openings LAQM~~


(Main Pressure and Clutch Pressure)

- 183 -
(5) Set the shift lever to each position.
Measure the clutch operation pressures
at the idling rpm and at 1500 rpm.

Caution:
2
0 Use a 20 kg/cm class oil pressure gauge.
0 It is desirable to measure the torque con-
verter pressure (the outlet pressure) with
a 5 kg/cm2 class oil pressure gauge.
0 Do not dperate the brake pedal when
measuring the oil pressure.

Eachoilpressurestandardvalue k g /cm 2 (psi) ~ ~ ~ ~ ~ ~ ~ , " V ~ ~ , " ~ ~ ,LAQSI


" ~52 ~ r , " ~ ~
A I 1

Oil Pressure Measurement ~ ~ 2 7 - 1 9

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

Caution:
Be sure to keep the vehicle under the stop
status perfectly and wire rope off the vehicle
to prevent i t s moving for safety.

(2) Make a warming-up running of the en-


Engine Output Confirmation LAQZS-7
gine and measure its idle speed and the
no-load maximum governed speed.

Note:
See 2 Oil pressure measurement.

(3) Confirm the engine output at the maxi-


mum rpm under the'loaded condition.
( Method )
After adjusting the maximum no-load
rpm, incline the tilt lever forward and
backward and measure the maximum
rpm with the accelerator fully opened.
Stall T e s t
(Standard)
Decrease the rprn by the value shown below from the maximum no-load rprn t o find the actual maximum
rpm.
Diesel model : Less than 200 rprn
Gasoline model : Less than 250 rprn

(Judgement)
When the engine rprn decreases markedly, the engine is not properly adjusted. Adjust the engine by mani-
pulating the air governor, etc.
(See Engine adjustment.)

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

(4) Start the engine. Set the shift lever to the forward position or reverse position. Rotate the engine
fully. Measure the rprn as i t becomes stabilized.
(Stall rpm)
TRANSMISSION & DIFFERENTIAL

Page
GENERAL ....................................... 4-2
SPECIFICATIONS ............................... 4 - 4
COMPONENTS .................................. 4-5
TRANSMISSION & DIFFERENTIAL ............... 4 -9
REMOVAL .................................... 4-9
DISASSEMBLY ............................... 4-15
INSPECTION .................................. 4-29
ASSEMBLY ................................... 4-37
INSTALLATION ............................... 4-56
GENERAL

1996. 2 -

A = 3 -- 4 m m (0.12 -- 0.16 in)

Transmission Sectional View

- 188-
Differential Sectional View

- 189 -
SPECIFICATIONS
TRANSMISSION
4

3.25 -- 4.5 ton model

Transmission type Full synchromesh

Operation Direct, floor shift

Forward 1 st speed 2.323

Forward 2nd speed 1.057


Transmission gear ratio
Reverse I s t speed 2.342

Reverse 2nd speed 1.066

Is t 37
Speed gears
2nd 57
Is t gear 67
2nd gear 47
Number of Counter shaft .

gear teeth Forward gear 39


Reverse gear 41

Reverseidle 35
gears No. 2 33
Output gears 50

Transmission oil Hypoid gear oil SAE85W-90

Dl FFERENTIAL

5FG (Dl 33,35 5FG (D) (E) 35-45


Wheelbase: 1800 Wheelbase: 2000

Differential case type Banjo type

Reduction ratio 5.1 43 5.833

Ring gear 36 35

Drive pinion 7 6
Number of
gear teeth
Side gear 14x2~~s.

Pinion gear 10 x 4 pcs.

Differential oil Hypoid gear oil SAE85W-90


COMPONENTS
TRANSMISSION CASE

20 Case SUB-ASSY, transmission 50A Packing (For front cover)


20A Plug (For Drain) 58 Cover, back lamp switch
208 Gasket (For Drain Plug) 58A Gasket (For back lamp switch)
41 Cover, transmission case, RR AA Bolt
41 B Seal, oil (For transmission rear cover) AL Cap, seal
41C Ring, 0 BM Magnet, transmission
41D Ring, 0 BP Cap, seal
50 Cover, front BO Wire

Transmission Case Components

- 191 -
TRANSMISSION GEAR

54

10 Ring ASSY, synchronizer, No. 1 63 Gear, forward clutch


11 Ring ASSY, synchronizer, No. 2 63A Bushing
40 Shaft, input 64 Gear, reverse clutch
40C Ring, lock (For input shaft) 64A Bushing
42 Shaft, counter 66 Ring, synchronizer, No. 2
42A Bearing, No. 1 (For counter shaft) 70 Gear, shaft speed
42B Bearing, No. 2 (For counter shaft) 70A Bearing (For speed gear)
43 Gear, counter shaft, 1st 708 Bearing (For speed gear)
43A Bushing, counter shaft 1 st gear AD Ring, shaft snap
44 Gear, counter shaft, 2nd AK Ring, shaft snap
44A Bushing, counter shaft 2nd gear AR Key, synchromesh shifting, No. 1
47 Sleeve, transmission hub, No. 1 AS Spring, synchromesh shifting key
48 Sleeve, transmission hub, No. 2 AX Key, synchromesh shifting, NO. 2
49 Hub, transmission clutch, No. 1 AY Spring, synchromesh shifting key
50 Hub, transmission clutch, No. 2 BS Nut
51 Ring, synchronizer, No. 1 DG Washer
53 Gear, reverse idle EB Washer, reverse idle thrust
53A Bearing (For reverse idle gear) EK Ring, input shaft stop
54 Gear, output ER Cap, seal
1
Transmission Gear Components

- 192 -
GEAR SHIFT LEVER & FORK

21

46
47

20 Lever SUB-ASSY, high & low shift 59 Plate SUB-ASSY, transmission case cover
20A Key (For shift lever) 59A Gasket
21 Lever SUB-ASSY, forward & reverse shift 77 Gage, oil level
22 Knob SUB-ASSY, high & low AA Pin, spring
23 Knob SUB-ASSY, forward & reverse AN Ring, 0
40 Shaft, 1 st & 2nd shift fork AP Bolt
41 Shaft, forward & reverse shift fork AZ Spacer
42 Fork, 1st & 2nd shift BX Bolt, fork shaft taper
43 Fork, forward & reverse gear shift CM Pin, straight
46 Spring, compression (For lock ball) CP Washer, lock
47 Ball, gear shift fork lock CZ Washer, thrust
48 Cover, transmission case ED Lever, shift & selector (Turn lever)
48A Gasket, gear case cover EP Washer, thrust
56 Shaft, forward & reverse shift EQ Needle, turn lever
56A Ring, 0 (For shift shaft) ER Shaft, turn lever
57 Shaft, high & low shift ES Bolt, turn lever
58 Lever, shift ET Cap, seal
58A Pin, lock (For shift leer)

Gear Shift Lever & Fork Components

- 193 -
DIFFERENTIAL

02

02 Case ASSY, differential 48 Pinion


10 Ring gear & pinion set, differential 48A Washer, pinion thrust
10A Bearing, drive pinion 49 Plug, drain
10B Bearing, drive pinion pilot 49A Gasket, drain plug
10C Nut, lock 50 Retainer, drive pinion bearing
1 OD Shim, bearing preload adjust 506 Ring, 0 (For bearing retainer)
20 Case SUB-ASSY, differential 50C Seal, oil (For bearing retainer)
20A Nut, adjusting 50D Shim, differential drive pinion bearing
208 Bearing, differential case 54 Cap, ring gear thrust screw
21 Carrier SUB-ASSY, differential AB Bolt
21A Ring, 0 (For differential carrier) AC Screw, ring gear thrust
40 Housing, differential AF Lock, adjusting
40B Ring, 0 (For differential housing) Al Plug
46 Gear, side AJ Gasket
46A Washer, side gear thrust AN Ring, 0
47 Spider A0 Spacer, bearing

Differential Components

- 194 -
TRANSMISSION & DIFFERENTIAL
REMOVAL

Note:
0 The transmission & differential shall be removed toward the front side after removing the mast and
front axle.
0 The transmission case cover components can be removed on rhe vehicle.

1. Remove the mast.

Note:
See the MAST REMOVAL section for the
mast removal procedure.

Removing the Mast ~ ~ 4 7 - 2 0

Jacking Up the Vehicle 1.~032-30

4. Remove front wheels.

Removing the Front Wheel 1~~32-31


5. Drain oil.
(1) Differential oil
(2) Transmission oil

Note:
0 Both the transmission and differential use
the same oil (hypoid gear oil).
0 Since the transmission oil drain plug has a
magnet, remove iron particles collected
on the magnet.

(3) Drain oil (hydraulic oil) from the clutch


Draining Oil ~~032-34.36
housing.
6. Disconnect the brake piping.

Disconnecting the Brake Piping ~Q33-3

7. Disconnect the parking brake cable.

Disconnecting the Parking Brake Cable 1.~033-4

8. Remove the set nuts of the front axle hous-


ing and differential housing.

Note:
Two set bolts (one each at top and bottom)
out of eight bolts are reamer bolts.

Removing the Set Nuts ~~033-6


Supporting with Wooden Blocks ~~033-8

Removing the Bolts ~ ~ 3 3 - 9


(3) Reamer bolts (two a t top and bottom
on each side)
SST 09310-22000-71

Removing the Reamer Bolts ~~033-13

Removing the Axle Housing ASSY LAQ33-16


12. Remove the inner front axle shaft.

Removing the Axle Shaft 1.~033-18

13. Remove the toe board.


(1) Toe board
(2) Floor set bolts
(3) Floor

Removing the Toe Board LAWS-17.32-20

14. Remove the gear shift levers.


(I)Lever set bolts and nuts
(2) Gear shift lever (forward and reverse)
(3) Gear shift lever (high and low)

Removing the Gear Shift Levers ~ ~ 3 2 - 2 4

15. Remove the clutch housing cover.


(1) Set bolts
(2) Clutch housing cover

Removing the Clutch Housing Cover LAQ~O-29


16. Slide the input shaft.
(1) Lock ring
(2) Slide the input shaft fully toward the
transmission.

Extracting the Input Shaft LAQ~O-33.34

17. Remove the clutch release hub return spring.

Removing the Release Hub Spring ma31-12

18. Sling the differential housing with a wire


rope, and slightly hoist it.

Hoisting the Differential Housing ~~33-23

19. Support the bottom of the clutch housing


with a stand.

20. Place a garage jack from the front side to


support the transmission from the lower side.

21. Disconnect the back lamp switch wiring.

Supporting the Transmission LAQ~~-26


Removing the Set Bolts 1.~033-28

(2) Transmission & differential

Note:
0 Operate the hoist and garage jack to pull
out the transmission & differential to-
ward the front side of the vehicle.
0 Carefully operate because the clutch re-
lease hub may fall during removal.

Removing the Transmission & Differential ~~033-33


Removing the Switch Cover ~~033-36

2. Remove the differential housing.


(1) Front cover set bolts
(2) Front cover

Removing the Front Cover ~ ~ 3 4 - 4

(3) Differential housing set bolts

Caution:
Remove one set bolt at the front cover
mounting portion.
Keep it separately from other bolts after re-
moval.

(4) Differential housing

Removing the Differential Housing ~~0.34-5.7

Removing the Transmission Case Cover LAO.%-15, 17


4. Remove the cover plate.
(1) Set bolts
(2) Cover plate

Removing the Plate 1.~035-28

5. Remove the shift lever lock pin.


(1) Set nut
(2) Lock pin

Note:
Install a service nut to the lock pin and tap
the upper surface of the nut for removal.

Removing the Lock Pin ~ ~ 3 6 - 3 2

6. Remove the turn lever.


(1) Loosen the turn lever lock nut.
(2) Turn lever lock bolt
(3) Turn lever shaft
(4) Thrust washer
(5) Turn lever
(6) Needle bearing
(7) Thrust washer

Removing the Turn Lever 1.~036-36

7. Remove the shift shaft and shift lever.


(1) Tap the shift tip end to remove theseal
cap.
(2) Use a copper rod and drive out the shaft
from the seal cap mounting hole side.
@ ShiftIshaft
@ Shift lever

Removing the Shift Shaft and Lever UQ36-2.3


Shift Fork

8. Remove the compression spring.

Removing the Spring ~034-22

9. Remove the first & second shift fork shaft.


( 1 ) Unfold the lock washer.
(2) Taper bolt

Removing the Taper Bolt ~ ~ 3 4 - 2 4

(3) Fork shaft

Note:
Receive the lock ball which falls when the
fork shaft is extracted.

(4) Lock ball


(5) Spacer

Removing the Fork Shah ~ ~ 3 4 - 2 5

10. Remove the forward and reverse shift fork


shaft.
( 1 ) Spring pin

Removing the Spring Pin LAQ~~-27


Removing the Fork Shaft ~034-29

11. Remove the shift forks.


(1) First & second shift fork
(2) Forward and reverse shift fork

Removing the Shift Forks ~~034-32

Transmission Case Rear Cover

12. Remove the transmission case rear cover.


(1) Set bolts (precoat bolts)
(2) Rear cover

Removing the Rear Cover ~ ~ 3 4 - 2 0

13. Disassemble the rear cover.


(1) O-ring
(2) Oil seal

Removing the Oil Seal ~ ~ 3 8 - 5


Transmission Gears

14. Measure gear backlashes before removing the


gears.
Standard backlash:
-
0.05 -- 0.15 mm (0.0020 0.0059 in.)
Backlash limit: 0.26 mm (0.0102in.)

Measuring the Backlash ~~034-36

15. Remove the input shaft ASSY.


(1) Shaft snap ring
(2) Speed shaft bearing (rear side)

Note:
I f bearing fitting i s tight, use the SST for re-
moval.
SST 09950-2001 7

Removing the Bearing ~~035-7

(3) Remove the input shaft ASSY.

Removing the Input Shaft ASSY ~ ~ 3 5 - 8

16. Disassemble the input shaft ASSY.


(1) lnput shaft stop ring

Removing the Stop Ring

- 205 -
(2) Remove the input shaft with the seal
cap by tapping the end surface of the
input shaft with a plastic hammer.
@ Seal cap
@ lnput shaft

Removing the Input Shaft 1.~037-6.8

(3) Snap ring


(4) Speed shaft bearing (front side)
SST 09950-2001 7

Removing the Bearing 1.~037-10

(5) Thrust washer


(6) Reverse idlegear
(7) Thrust washer

Removing the Reverse Idle Gear ~ ~ 3 7 - 2 8

Removing the Needle Bearing

- 206 -
Remove the counter shaft nut.
(1) Uncaulk the nut.
(2) Counter shaft nut

Note:
0 Apply a tool to the flat sides a t the rear
end of the counter shaft to stop rotation
during nut removal.
Width across flats of nut:
32 mm (1.3 in.)
Width across flats at shaft end:
32 mm (1.3 in.)
Removing the Nut LAQ35-11
0 It is recommended to use the SST pro-
vided for easy removal of the nut.
SST 09330-32880-71

Removing the Nut (with SST) LAQS12 1

Remove the counter shaft, clutch gear and


synchronizer ring ASSY.

Caution:
0 The gear and synchronizer ring parts fall
when the counter shaft is extracted. Al-
ways let an assistant operator hold them
when extracting the counter shaft.
0 Record the mounting positions of gears
and synchronizer ring parts to prevent
incorrect positioning at the time of re-
assembly.
Extracting the Counter Shaft ~~036-12

(1) Counter shaft


SST 09810-20172-71
(2) Forward gear & bush
(3) Synchronizer ring ASSY No. 2
(4) Reverse gear & bush

Removing the Gears & Synchronizer Ring ~~036-15


(5) Second gear & bush
(6) Synchronizer ring ASSY No. 1
(7) First gear & bush

Removing the Gears & Synchronizer Ring ~~035-16

19. Remove the counter shaft bearings.


(1) Bearing No. 1 (front side)
(2) Bearing No. 2 (rear side)

Removing Bearings No. 1 & No. 2 ~ ~ 0 . 3 6 - 138-1


7, 0

Output Gear & Differential

20. Remove the seal cap.

Removing the seal Cap LAa39-6

Measuring the Ring Gear Rear Face Runout ~~039-11


Measuring the Backlash ~ ~ 3 9 - 1 2

23. Measure the differential case bearing starting


torque.
( 1 ) Use a spring scale and a string wound
around the output gear to measure the
starting torque and record the measured
value for reference at the time of re-
assembly.

Note:
The reading of the spring scale is the resul-
tant force including the needle bearing pre-
load.
Measuring the Bearing Starting Torque ~ ~ 3 9 - 1 5

Removing the Thrust Screw LAo39-18

Punching the Match Mark 1.~039-20


(2) Lock wire
(MTM: Discontinued since Nov. 1995)
(ATM: Discontinued since Jan. 1 994)
(3) Bolt
(4) Adjusting lock
(5) Bearing cap set bolt
(6) Bearing cap

Removing the Bearing Cap ~~042-28

26. Remove the adjusting nut.

Removing the Adjusting Nut ~ ~ 4 2 - 2 7

27. Remove the differential case ASSY.

Removing the Differential Case ASSY ~ ~ 4 2 - 2 6

Measure the drive pinion bearing starting


torque.
(1) Use a spring scale and a stiring wound
around the output gear to measure the
starting torque and record the measured
value for reference at the time of re-
assembly.

Measuring the Pinion Bearing LAQ39-29


Starting Torque

- 210 -
Remove the output gear & drive pinion
ASSY.
(1) Set bolt

Caution:
Since the drive pinion ASSY may fall when
the set bolt is removed, do not place the
hand under it.

Removing the Set Bolt LAo3s-30

(2) Use a copper rod to drive out the out-


put gear & drive pinion ASSY.

Caution:
Since the drive pinion ASSY drops suddenly,
do not place the hand under it.

(3) Shim

Removing the Drive Pinion ASSY 1.~039-31

30. Remove the out put gear.


(I)Uncaulk the lock nut.

Removing the Output Gear (1) 1.~039-36

(2) Lock nut


(3) Output gear

Removing the Output Gear (2) LAOW-3.5


Removing the Drive Pinion LAQQO-6

( 2 ) Shim

Note:
Record the number of shims and thickness.

(3) Spacer
(4) O-ring

Removing the Shims and Spacer LAQ~O-8

(5)Drive pinion bearing inner race (front


side)
SST 09950-20017

Removing the Bearing Inner Race LAQ~O-11

Removing the Pilot Bearing LAQ~O-12


32. Remove the bearing and oil seal from the re-
tainer.
(1) Bearing outer race (front side)
SST 09320-23000-7 1

Removing the Bearing Outer Race LAQ~O


13-

(2) Oil seal


(3) Bearing outer race (rear side)
SST 09320-23000-7 1

Removing the Oil Seal LAQ40-16

33. Remove the differential case bearings (2


pcs.)
SST 09950-20017

Removing the Bearing LAQ~O-24

34. Remove the differential upper case.


(1) Check the match mark on the upper and
lower cases.

Checking the Match Marks L A Q ~ -6


I
( 2 ) Set bolt
( 3 ) Upper case

Removing the Upper Case 1.~041-9

35. Remove the side gear and differential pinion


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

Removing the Side Gear and Pinion Gear - ~ ~ 0 4 1 - l11


o,

36. Remove the differential ring gear.


(1) Uncaulk the set bolt.
(2) Set bolt
( 3 ) Ring gear

Caution:
Remove when any defect i s found in the
drive pinion, ring gear or differential case.

Removing the Ring Gear LAQ~?-13


INSPECTION

Caution:
After cleaning each part, inspect the follow-
ing items. Correct or replace the part if any
defect is found.

Transmission Case Cover

1. Transmission case cover inspection


(1) Crack and damage of cover
(2) Damage at shaft insertion hole
Inspecting the Case Cover ~ ~ 3 6 - s

Shift lever parts inspection


(1) Damage of each part
(2) Wear of shift shaft
Shaft outside diameter standard:
22.0 mm (0.866 in.)
Wear limit: 21.7 mm (0.854 in.)

Inspecting the Shift Shaft U~36-10

Wear of shift lever tip end


Standard outside diameter:
13.0 mm (0.512 in.)
Wear limit: 12.5 mm (0.492 in.)

Wear of turn lever tip end


Standard outside diameter:
17 mm (0.67 in.)
Wear limit: 16.5 mm (0.650 in.)

Inspecting the Shift and Turn Levers 1.~036-12,14


Shift Fork

Shift fork inspection


(1 ) Crack and damage of fork
(2) Damage and wear of shift lever inserting
portion
Standard outside diameter:
13.0 mm (0.512 in.)
Wear limit: 13.6 mm (0.535 in.)
(3) Wear of fork tip end
Standard outside diameter:
9.8 mm (0.386 in.)
Wear limit: 9.2 mm (0.362 in.)
lnspecting the Shift Fork (1 )

- 215 -
(4) Measure the clearance between the shift
fork and clutch hub sleeve.
Clearance limit: 1.0 mm (0.039 in.)

Inspecting the Clearance between ~~038-19


Fork and Hub Sleeve
4. Fork shaft inspection
(1) Bend and damage of fork shaft
(2) Wear of lock ball groove
(3) Fatigue of lock ball spring

Inspecting the Fork Shaft ~~037-2

Transmission Gear

5. lnput shaft inspection


(1) Damage of shaft tip end
(2) Damage and conspicuous stepped wear
of spline portion
(3) Bend of shaft
Bend limit: 0.1 mm (0.0039 in.)

Inspecting the Input Shaft ~~037-20

6. Shaft speed gear and bearing inspection


(1) Crack and damage of tooth surface
(2) Damage and stepped wear of spline
portion
(3) Damage of bearing fitting portion
(4) Damage, abnormal .noise and rotation
status of bearing

Inspecting the Shaft Speed Gear LAQ~~-16


7. Reverse idle gear inspection
(1) Crack and damage of tooth surface
(2) Damage of bearing fitting portion
(3) Damage of needle bearing

Inspecting the Reverse Idle Gear ~ ~ 3 7 - 2 6

(4) Damage and wear of thrust washer


Washer A (rear side):
Standard thickness:
3.65 mm (0.1437 in.)
Wear limit: 3.35 mm (0.1319 in.)
Washer B (front side):
Standard thickness:
3.0 mm (0.118 in.)
Wear limit: 2.6 mm (0.102 in.)

Inspecting the Thrust Washer 1.~037-2s

Counter shaft and bearing inspection


(1) Damage and conspicuous stepped wear
of counter shaft spline portion
(2) Damage of threading at shaft end
(3) Damage of bearing fitting portion
(4) Damage, abnormal noise and rotation
status of bearing

lnspecting the Counter Shaft LAQ38-11

Forward gear and reverse gear inspection


(1) Damage and wear of cone portion
(2) Damage and wear of spline portion
(3) Damage and wear of gear teeth
(4) Damage and wear of gear inside surface
(5) Damage and wear of bush
Bush standard outside diameter:
44.0 mm (1.732 in.)
Wear limit: 43.7 mm (1.720 in.)
Bush standard length:
45.0 mm (1.772 in.)
Wear limit: 44.7 mm (1.760 in.)
lnspecting the Forward and Reverse Gears uase-I 2
10. Synchronizer ring ASSY No. 2 inspection
(1) Damage and wear of clutch hub outer
spline
(2) Damage and wear of shifting key fitting
portion
(3) Damage and wear of surface in contact
with gear
(4) Damage and wear of inner spline
(5) Clearance between clutch sleeve and
shift fork (see pages 4 - 30).
When the fork is inserted to the clutch
hub sleeve, it shall slide smoothly. lnspecting the Clutch Hub and Clutch Sleeve ~ ~ 3 8 - 1 5

(6) Shifting key and spring inspection


@ Damage and wear of central prot-
ruded part of key
@ Fatigue of spring and wear of por-
tions in contact with key

lnspecting the Synchronizer Key and Spring- LAOS~~O

(7) Synchronizer ring inspection


@ Damage and wear of spline portion
@ Damage and wear of tapered por-
tion

Inspecting the Synchronizer Ring (1 ) 1.~038-20

@ Coat gear oil on the gear tapered


portion
Manually bring the ring into forced
contact with the gear, and check
that the ring does not slip.

Inspecting the Synchronizer Ring (2) ~aOS342

- 218 -
@ Inspect the clearance between the
synchronizer ring and gear.
Standard clearance:
1.10 -- 2.30 mm
(0.0433 -- 0.091 in.)
Clearance limit: 0.3 mm (0.012 in.)

lnspecting the Synchronizer Ring (3) ~ ~ 0 3 8 - 2LAOSIG~


3.

11. First and second gear inspection


(1) Damage and wear of cone portion
(2) Damage and wear of spline portion
(3) Damage and wear of gear teeth
(4) Damage and wear of gear inside surface

Inspecting the First and Second Gears ~ ~ 3 8 - 3 1

(5) Damage and wear of bushes


First gear bush (rear side) :
Standard outside diameter:
44.0 mm (1.732 in.)
Wear limit: 43.7 mm (1.720 in.)
Standard length: 40.5 mm (1.594 in.)
Wear limit: 40.2 mm (1.583 in.)
Second gear bush (front side):
Standard outside diameter:
44.0 mm (1.732 in.)
Wear limit: 43.7 mm (1.720 in.)
Standard length: 32.5 mm (1.280 in.)
Inspecting the Gear Bushes 1~038-33
Wear limit: 32.2 mm (1.268 in.)

Synchronizer ring ASSY No. 1 inspection

Note:
The procedure is the same as that for syn-
chronizer ring ASSY No. 2 (for forward &
reverse).
The explanation here i s for items different
from synchronizer ring ASSY No. 2.

Inspecting the Synchronizer Ring ~~038-14

- 219 -
(1) Synchronizer ring inspection
@ Inspect the clearance between the
synchronizer ring and gear.
Standard clearance:
1.10- 1.90 mm
(0.0433 -- 0.0748 in.)
Clearance limit: 0.3 mm (0.012 in.)

Inspecting the Synchronizer Ring 1.~038-32

tput Gear & Differential

Drive pinion and ring gear inspection


(1) Damage and wear of tooth surface
(2) Damage of pinion spline portion
(3) Damage of pinion threads

Caution:
Always replace the drive pinion and ring gear
as a set even when only one of them i s found
defective.
Inspecting the Pinion and Ring Gear 1.~041 -1s
(4) Damage, rotation status and abnormal
noise of pilot bearing

14. Differential case inspection


(1) Crack and damage of case

Inspecting the Differential Case LA041-18

15. Adjusting nut and cap inspection


(1) Damage of nut threads
(2) Damage and deformation of cap

Inspecting the Adjusting Nut LAQ~I-26


16. Bearing retainer inspection
(1) Crack, damage and deformation of re-
tainer
(2) Damage, rotation status and abnormal
noise of bearing

Inspecting the Bearing Retainer LAQ40-10

17. Differential gear inspection


(1) Damage and wear of each gear
(2) Wear of differential pinion inside dia-
meter
Standard inside diameter:
22.1 2 mm (0.871 in.)
Wear limit: 22.22 mm (0.875 in.)

Inspecting the Differential Gear ~ ~ 0-20


4 1

( 3 ) Wear of spider
Standard outside diameter:
22.00 mm (0.866 in.)
Wear limit: 21.75 mm (0.856 in.)

lnspecting the Spider LAQ~I-24

Wear of thrust washer (for differential


pinion)
Standard thickness: 1.6 mm (0.063 in.)
Wear limit: 1.0 mm (0.039 in.)

Wear of thrust washer (for side gear)


Standard thickness: 1.6 mm (0.063 in.)
Wear limit: 1.3 mm (0.051 in.)

Inspecting the Thrust Washers 1.~~41-23,22

- 221 -
18. Thrust screw cap inspection
(1) Damage of threading
(2) Wear and damage of cap
Standard length: 13.0 mm (0.51 2 in.)
Wear limit: 12.2 mm (0.480 in.)

inspecting the Thrust Screw Cap L A Q ~ I- 2 7

19. Differential case bearing inspection


(1) Damage, abnormal noise, and rotation
status

Inspecting the Bearing LAQ~~-4

20. Output gear inspection


(1) Damage and wear of tooth surface
(2) Damage of spline portion

Inspecting the Output Gear LAQ41 - 2 6

21 . Transmission case
(1) Crack and damage of transmission case
(2) Damage of transmission carrier cap

Inspecting the Transmission Case ~~039-34


ASSEMBLY

Output Gear & Differential

1. Install the ring gear.


(I) Differential lower case
(2) Ring gear
(3) Set bolts
T = 13 -- 18 kg-m (93.9 -- 130 ft-lb)

Note:
0 Use new set bolts and coat thread tighten-
Installing the Ring Gear LA~~I-29
er (Locktite #271 or equivalent) on the
threaded portion before installation.
0 Tighten bolts diagonally first, and finally
tighten them in circular order to the spec-
ified tightening torque.

(4) Be sure to punch the tip end of the set


bolt in a cross shape for caul king.

Install the side gear and differential pinion


gear.
(I) Thrust washer

Caulking the Set Bolt


Caution:

Installing the Side Gear ~ ~ 0-32


4 1

lnstalling the Spider and Pinion LAQ41-33


(4) Side gear
(5) Thrust washer

Caution:
Install the thrust washer with i t s oil groove
facing the side gear.

Install the Side Gear LAQ~I-34

3. Install the differential upper case.


(1) Differential upper case

Caution:
Be sure to match the match marks.

Installing the Upper Case ~ ~ 0-35


4 1

(2) Set bolts


T = 4.4 -- 5.5 kg-m (31.8 -- 39.7 ft-lb)

Note:
0 Be sure to clean and degrease the bolts
and bolt holes.
0 Coat thread tightener (Locktite #271 or
equivalent ) on the bolt threaded portion
and tighten them to the specified torque.

Tightening the Set Bolts 1.~041 -36

4. Install the oil seal and bearing t o the re-


tainer.
(1) Oil seal
SST 09608-35014
(2) Bearing outer race (rear side)
SST 09608-35014
(3) Bearing outer race (front side)
SST 09608-35014

Installing the Oil Seal and Bearing LAQ~O-19.21


5. l nstall the drive pinion.
( 1 ) Pilot bearing
SST 09608-3001 2

Installing the Pilot Bearing '1.~042-8

(2) Caulk three places at the tip end of the


drive pinion.

Caulking the Drive Pinion ~~042-9

(3) Drive pinion bearing inner race (front


side)
SST 09370-20270-71

Installing the Bearing Inner Race 1.~042-10

(4) O-ring
(5) Spacer

Caution:
Install the spacer with i t s chamfered side (at
hole edge) facing the front side.

(6) Shim (for drive pinion bearing starting


torque adjustment)

Installing the O-ring, Spacer and Shim ~~42-12.13


(7) Drive pinion bearing inner race (rear
side)
SST 09370-20270-7 1

Installing the Bearing Inner Race ~ ~ 4 2 - 1 4

l nstall the output gear.


(1) Output gear
(2) Lock nut
-
T = 35 45 kg-m (253 - 289 ft-lb)

Caution:
0 Always use a new lock nut.
0 After tighteniag the lock nut, tap the
shaft with a plastic hammer and recheck
the tightening torque.
0 Lock the lock nut after checking the
startinq- toraue.
.
the Output Gear LAQ42-16
0 Insert the retainer set bolt in the retainer
before output gear insertion in a vehicle
with the torque converter.

7. Measure the drive pinion bearing starting tor-


que.
(I)Fix the bearing retainer in a vise.
(2) Measure the output gear starting torque.
Starting torque
Transmission model:
-
13.9 -- 17.0 kg (30.6 37.5 I b)
Torque converter model:
15.7 --'19.2 kg (34.6 -- 42.3 Ib)
Tightening the Lock Nut ~ ~ 4 2 - 1 7

Note:
Wind a string around the output gear and
pull a spring scale connected to it at a con-
stant speed t o measure the starting torque.

Measuring the Bearing Starting Torque LAQ~~-18


(3) When the starting torque is not within Transmission model
+
the above range, adjust the shim thick- Shim part No. Thickness mm (in.)
ness after assembly with the specified
tightening torque, measure the starting 41 21 3-20540-71 0.03 (0.0012)
torque again. 4121 6-20540-71 0. I 0 (0.0039)
41 21 7-20540-71 0.1 5 (0.0059)
Note:
Decrease the shim thickness if the starting 41 21 8-20540-71 0.35 (0.0138)
torque is less than the specified level, and in- 41 21 9-20540-71 0.45 (0.0177)
crease the shim thickness if above the speci-
fied level.

Torque converter model


I Shim part No. I Thickness mrn (in.) I

8. Caulk the lock nut.

Caution:
0 Be sure to caulk at two places.
0 A in the illustration shall be in close con-
tact.

Caulking the Lock Nut (1) ~~042-19

Caulking the Lock Nut (2) L A C S ~ ~


9. Adjust the drive pinion protrusion.

Note:
Make adjustment by changing the shim
thickness at the retainer flange portion.

( Shim Thickness Calculating Method )

(1 ) Measure dimension A to 1 / I 00 mm level


with a height gauge.
(2) Read dimension B punched on the
transmission case. Dimension A

Dimension B Punched position LAQ~Z-22

( 3 ) Read dimension C written on the rear


end of the drive pinion with an electric
pen.

Note:
The part No., set No. and dimension C are
indicated on the rear end of the drive pinion.
Dimension C i s not indicated if it i s 0.
Example: Pinion mounting distance
146.00 mm + No indication of dimension C.
146.25 mm + 25 is indicated as dimension C.
Dimension C Indicated Position LAQ~Z-21
(4) Calculate the shim thickness by the fol- Transmission model
lowing equation: Shim part No. Thickness mm (in.)
@ Transmission model
33436-32880-7 1 0.10 (0.0039)
t = ( A - 29) + B/100 + C/100
t = shim thickness (mm) 33437-32880-7 1 0.1 5 (0.0059)
@ Torque converter model 33438-32880-7 1 0.35 (0.0138)
t = ( A - 24) + B/100+ C/100
33439-32880-7 1 0.45 (0.0177)
t = shim thickness (mm)

Example: Torque converter model Torque converter model


Dimension A (Actually measured value) :
Shim part No. Thickness mm (in.)
24.14
Dimension B (Value punched on case): 32345-31940-7 1 0. I0 (0.0039)
08 32346-31940-7 1 0.1 5 (0.0059)
Dimension C (Value written on pinion):
32343-31940-7 1 0.20 (0.0079)
00
t = (24.14 - 24) + 08/100 + 00/100 32344-3 1940-7 1 0.40 (0.0160)
= 0.22
Use two 0.10 mm thick shims, or use a
0.1 m m shim and a 0.15 mm shim.

Install the output gear & drive pinion ASSY.


(1) Shims (selected in the above step)
(2) Output gear & drive pinion ASSY
(3) Set bolt
Tightening torque:
Transmission model :
T = 9 -- 12 kg-m (65 -- 87 ft-lb)
Torque converter model:
T = 7 -- 8 kg-m (51 -- 58 ft-lb)

Note:
0 The bolt and hole shall be cleaned and
Installing the Drive Pinion ASSY ~~043-2.42-23
degreased.
0 Coat thread tightener (Locktite #242 or
equivalent) on the bolt theads, and
tighten the bolt to the specified torque.
0 Since a bolt with a hole i s used on the
torque converter model, lock the bolt
with a lock wire.

Tightening the Set Bolt

- 229 -
11. lnstall the bearing to the differential case
ASSY.
(1) Bearing inner race
SST 09608-35014
(2) Bearing outer race
(3) Bearing inner race
SST 09608-35014
(4) Bearing outer race

Installing the Bearing Inner Race ~042-2.6

12. Install the differential case ASSY.

Note:
When installing the differential case ASSY,
make the ring gear contact the drive pinion.

Installing the Differential Case ASSY 1~~42-26

13. Install the bearing cap.


(1) Adjusting nut

Installing the Adjusting Nut ~~042-27

(2) Bearing cap

Note:
Align the match marks a t the time of install-
ation.

(3) Temporary tighten the set bolt.


T = 2 kg-rn (14 ft-lb)

Temporarily Tightening the Set Bolt LAQ~~-29


Adjust the ring gear back lash.
(1) Apply the dial gauge vertically to the
rear surface of the ring gear.
(2) Alternately tighten the adjusting nuts
on the left and right sides.
SST 09330-3001 0
(3) Measure the thrust clearance and tighten
the adjusting nuts until the thrust clear-
ance becomes 0.
(4) Tighten the adjusting nuts on both sides
by one notch each.
(5) Apply the dial gauge vertically to the
Tightening the Adjusting Nuts ~ ~ 4 2 - 3 1
tooth surface of the ring gear.

Measuring the Backlash LAQ~~-32

I f the measured backlash is outside the


above standard range, adjust the backlash ac-
cording to the following procedure:
(1) If the measured backlash is greater than
the standard:
After loosening the adjusting nut on the
ring gear tooth surface side, tighten the
adjusting nut on the ring gear rear sur-
face side to bring the ring gear closer to
the drive pinion.
(2) If the measured backlash is smaller than
the standard:
Adjusting the Backlash (1 ) 1.~042-33
After loosening the adjusting nut on the
ring gear rear surface side, tighten the
adjusting nut on the ring gear tooth sur-
face side to move the ring gear away
from the drive pinion.

Note:
To adjust the backlash, loosen the adjusting
nut on one side by one notch and tighten
the adjusting nut on the other side by one
notch to gradually shift the differential case
while watching the dial gauge reading.

Adjusting the Backlash (2)

- 231 -
16. Measure the differential case bearing starting
torque.
(1) Wind a cord around the output gear and
measure the starting torque with a
spring scale.
Starting torque:
Starting torque specified in 7(2) + 2 kg
(4.4 Ib)

Note:
The value indicated by the spring scale also
includes the pinion bearing starting torque.
Measuring the Differential Case LAQ~S-IS
Bearing starting Torque
If the measured value is outside the
above standard range, adjust the starting
torque by turning the adjusting nuts as
follows:
@ To increase the starting torque:
Tighten the adjusting nuts on the
left and right sides by the same
amount.
@ To decrease the starting torque:
Loosen the adjusting nuts on the
left and right sides by the same
amount.
Adjusting the Bearing Starting Torque LAQ~~-36

Note:
After adjusting the starting torque, measure
the backlash again to confirm that it is
written the standard range.

17. Tighten the bearing cap set bolts to the spec-


if ied torque.
T = 1 2 - 14kg-m (87- 101 ft-lb)

Tightening the Cap Set Bolts ~~042-29

Check the tooth contact.


(1) Uniformly coat red lead thinly on both
faces of 7 t o 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. I f the tooth
contact is not correct, make adjustment
according to the "Drive Pinion Protru-
sion Adjustment" and "Ring Gear Back-
lash and Differential Case Bearing Start-
Turning the Ring Gear LAQ~~-4
ing Torque Adjustment" procedures.
(2) Correct teeth contact
The pattern is nearly at the center of
each tooth surface and its width is ap-
propriate.

Correct Teeth Contact

(3) Heel contact


Move the drive pinion closer to the ring
gear by decreasing the drive pinion ad-
justing shim thickness. Then move the
ring gear away from the pinion t o adjust
the backlash.

Heel Contact

(4) Toe contact


Move the pinion away from the ring
gear by increasing the drive pinion ad-
justing shim thickness. Then move the
ring gear closer to the pinion to adjust
the backlash.

Toe Contact L A C S ~ ~

(5) Flank contact (low shallow contact)


Move the pinion away from the ring
gear by increasing the drive pinion ad-
justing shim thickness. Then move the
ring gear closer t o the pinion t o adjust
the backlash.

Flank Contact

- 233 -
(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.

Face Contact L A C S ~ ~

19. Lock the bearing adjusting nut.


( 1 ) Adjusting lock

Caution:
When meatching the adjusting lock position,
turn the adjusting nuts in the tightening
direction.

( 2 ) Wire lock
(MTM: Discontinued since Nov. 1995)
(ATM: Discontinued since Jan. 1994)

Wire Lock ~0.43-7

20. Install the ring gear thrust screw and cap.


( I ) Thrust screw and cap

Caution:
Coat liquid seal on the thrust screw before
installing it.

(2) Thrust screw to cap clearance adjust-


ment
Clearance:
0.2 -- 0.3 mm (0.0079 -- 0.1 18 in.)
Adjusting the Thrust Screw (1 ) LAQ~~-5
Note:
Fully tighten the thrust screw and loosen it
by 118 turn.

(3) Thrust screw lock nut


T = 10.5 -- 13 kg-m (76 -- 94 ft-lb)

Adjusting the Thrust Screw (2)

- 234 -
Installing the Seal Cap LAQ~~-6

Transmission Gear

22. l nstall the counter shaft bearings.


(1) Install bearing No. 1 (front side) to the
transmission case.
SST 09608-2001 2

Installing Bearing No. 1 ~~0.43-10

Installing Bearing No. 2 ~~039-5

23. Install the synchronizer ring ASSY and


clutch gear.

Caution:
0 lnstall each synchronizer ring part in i t s
original position before disassembly.
0 When installing synchromesh key springs,
offset their joint positions. (See the illust-
ration.)
0 Do not mistake the relative positions of
the gear and bush.
Key Spring Joint Positions LAOS346
Clutch Gear Set 1.~038-29.30

Installing the Clutch Gear Sets 1.~043-9

25. Tighten the counter shaft nut.


(1) Counter shaft nut
-
T = 17 -22 kg-m (123 159 ft-lb)

Tightening the Nut ~ ~ 4 3 - 1 3

(2) Caulk the nut at two places.

Caulking the Nut LAQ43-15


26. Assemble the input shaft components.
(1) Install the needle bearing to the reverse
idle gear.

Installing the Needle Bearing LAQ~~-14

(2) Thrust washer (rear side)

Note:
Fit the protrusing of the thrust washer into
the groove notched on the reverse idle gear.

(3) Reverse idlegearwl bearing


(4) Thrust washer (front side)

Installing the Reverse Idle Gear ~ ~ 0 . 3 7 - 128


5.

(5) Speed shaft bearing


SST 09370-20270-7 1
(6) Snap ring

Installing the Speed Shaft Bearing ~ ~ 3 7 - 3 0

(7) lnstall the stop ring (front side) to the


input shaft.
(8) Insert the input shaft into the speed
shaft.

Installing the Input Shaft (1) ~~0.37-33.34


Installing the Input Shaft (2) mQ37-35.36

Installing the Input Shaft ASSY LAQ~~-16

Installing the Bearing LAQ~~-17

Transmission Case Rear Cover

29. l nstal l the rear cover.


(1) Oil seal
SST 09608-35014
(2) O-ring

Installing the Oil Seal and O-ring LAQ38-7.4


30. Install the rear cover to the transmission
case.
(1) Rear cover
(2) Set bolts (precoat bolts)
T = I .5 -- 2.2 kg-m (10.8 " 15.9 ft-lb)

Installing the Rear Cover LAQ~~-33

Shift Forks

31. Install the shift forks


(1) Forward & reverse shift fork
(2) First & second shift fork

Installing the Shift Forks LAQ~~-23

(3) Fork shaft (for forward & reverse)


(4) Spacer
(5) Spring pin

Note:
Use a new spring pin.

Installing the Fork Shaft ~~043-25.26

(6) Lock ball


(7) Compression spring

Installing the Lock Ball and Spring LAQ~~-27


(8) Fork shaft (for first & second)
(9) Spacer
(10) Lock washer
(11 )Taper bolt
T = 4.1 -- 5.1 kg-m (29.6 -- 36.9 ft-lb)
(12) Lock the taper bolt by folding the lock
washer at two places.

Installing the Fork Shaft ~ ~ 4 3 - 2 9

(13) Lock ball


(14) Compressing spring

INstalling the Lock Ball and Spring ~043-31

The shift shaft shorter in the overall length is Ins*a11inathe Shift Lever ~~036-18

Installing the Lock Pin ~ ~ 3 6 - 2 3


33. Install the turn lever.
(1) O-ring

Note:
Coat grease on the O-ring.

(2) Thrust washer


(3) Needle bearing
(4) Turn lever
(5) Thrust washer
(6) Turn lever shaft
(7) Lock bolt
Installing the Turn Lever LAQS122
T = 5 -- 8 kg-m (36 -- 58 ft-l b)
(8) Lock nut

34. Install the cover plate.


(1) Gasket
(2) Cover plate
(3) Set bolts

Installing the Cover Plate ~~36-27

Install the transmission case cover.


(1) Gasket
(2) Transmission case cover

Note:
Insert the tip ends of the shift levers and
turn lever into the holes in the upper part of
the fork.

(3) Set bolts

Installing the Case Cover LAQ~~-34

36. Temporarily install the gear shift levers, and


check if gear shifting can be done smoothly.

37. Place the transmission case in horizontal


state and pour oil through the level gauge
mounting port.
Use the level gauge to check the oil level.
Fill differential oil on the vehicle.

Filling Oil

-
Install the differential housing.
(1) Install the O-ring to the differential car-
rier.

Note:
Coat grease on the O-ring.

(2) Differential housing


(3) Set bolts

Caution:
Tighten from the front cover mounting por-
tion. installing the Differential ~ousing 1~~44-6.7

Use a copper washer for each set bolt.

(4) Front cover packing


(5) Front cover
(6) Set bolts

Installing the Front Cover ~~044-8

39. Install the back lamp switch cover.


(1) Packing
(2) Switch cover
(3) Set bolt

Installing the Switch Cover UQ44-9

INSTALLATION

The installation procedure is the reverse of the removal procedure.

Caution:
0 Refer to the cautions in the Front Axle Installation section.
0 Refer to the cautions in the Mast Installation section.
0 Check the differential oil level, transmission oil level and hydraulic oil level.
0 Check no oil i s leaking from each joint.
FRONT AXLE

Page
GENERAL ....................................... 5-2

COMPONENTS .................................. 5-4


FRONT AXLE ASSY .............................. 5-5
REMOVAL ..................................... 5-5
DISASSEMBLY ................................ 5 - 8
INSPECTION .................................. 5-12
ASSEMBLY .................................... 5-13
INSTALLATION ................................ 5-18
GENERAL

Front Axle Sectional View

- 244 -
SPECIFICATIONS
Front axle type Half-floating
Front axle suspension Fixed to frame
Reduction gear type Planetary gear reduction
Reduction ratio 3.00
Planet gear tooth number 15,3 pcs (one side)
Internal gear tooth number 62
Sun gear tooth number 31

Wheels

3.25,3.5 ton models E3.5 ton model 4.0,4.5 ton models


Tire size 250-15-1 6PR (I) 8.25- 1 5-1 4P R (I) 300-15-18PR (I)
STD Rimsize 7.00T-151R 6.50T-151R 8.00V-15 1 R
(Single) Tire air pressure
8.5 (121) 8.0 (114) t
kg/cm2 (psi)
Tire size 28x1 2.5-1 5-18PR (I) - 32x1 2.1-1 5-20PR(I)
OPT Rim size 9.75-1 5 1 R - 9.75-1 5 1 R
(Single) Tire air pressure
7.5 (107) - 8.5 (121)
kg/cm2 (psi)
Tire size 28x8-15-12PR(I) 8.25-15-12PR (I) t

OPT Rim size 6.00s-15 l R 6.50T-15 1 R t

(Dual) Tire air pressure


7.0 (100) t t
kg/cm2 (psi)
COMPONENTS

- 1
I
I
I
I
I

-.-.
I
I
I
I
...-
%
I
I
I
I . -. I
I
.. I
I
I . .. - I
I
I
I
I
.- - I
I
1
'-J
I
I
I
I
I
I
@ --,
I

I
I- -_
48A

J
741 H

40 Shaft, front axle 47A Bushing (for planet gear)


40C Seal, oil (for front axle shaft) 48 Carrier, planet gear
40E Seal, oil (for front axle shaft) 48A Bearing (for planet gear cariier)
41 B Bearing, No. 1 (for front axle hub) 49 Plate, lock nut
41 D Nut, bearing lock 53 Housing, front axle
41 E Bolt, hub 54 Gear, internal
41G Nut, hub 54A Ring, 0 (for internal gear)
41 H Bolt, double wheel stop 55 Shaft, front axle inner
42 Drum, brake AL Ring, shaft snap
46 Shaft, planet gear AM Shim
47 Gear, planet AN Washer, thrust

Front Axle Components

- 246 -
FRONT AXLE ASSY
REMOVAL

Note:
The front axle shaft cannot be removed on
the vehicle because of i t s structure.

1. Remove the mast.

Note:
See MAST REMOVAL for the removing me-
Removing the Mast ~047-20
thod.

Loosen the front wheel hub nut.

Jack up the vehcile body.

Note:
To facilitate the operation, place about 15
cm (6 in.) furring under the tires and then
support the frame with a stand at the front
on both sides so as to keep the vehicle hori-
zontal.

Jacking up the Vehicle ~032-30

4. Remove the front wheels.


(1) Hub nut
(2) Front wheel

Removing the Front Wheels ~ ~ 3 2 - 3 1

5. Drain the differential oil.

Draining the Differential Oil

- 247 -
Disconnecting the Brake Piping ~~033-3

7. Disconnect the parking cable.

Disconnecting the Parking Brake Cable LAQ~~-4

Removing the Set Bolts LAQ33-6

Removing the Wooden Block LAQ~~-8


10. Remove the front axle housing set bolt.
(1) Lightly suspend the front axle hous-
ing assy.

Caution:
Wind the cloth to the tilt cylinder rod. Be-
cause, it i s to be get damaged to the tilt
cylinder rod by the wire rope.

(2) Common bolts (center bolt and three


bolts on either side)
Removing the Bolts ~~033-9

(3) Reamer bolts (on upper one and lower


one on either side).
SST 09310-22000-7 1

Removing the Reamer Bolts ~ ~ 3 3 - 1 3

11. Remove the front axle housing ASSY to-


gether with the brake.

Removing the Axle Housing ~ ~ 3 3 - 1 6

12. Remove the inner front axle shaft.

Removing the Inner Front Axle Shah ~~033-18

249 -
DISASSEMBLY

1. Remove the parking cable bracket.


(1) Set bolt (two pieces)
(2) Parking cable bracket

Removing the Parking Cable Bracket ~ ~ 2 4 - 2 3

2. Remove the front axle bracket.


(1) Punch match marks

Caution:
Punch the match marks so that you
easily distinguish between right and left,
between the face and reverse side.

Removing the Match Marks ~ ~ 2 4 - 1 4

(2) Set bolts (two pieces)


(3) Front axle bracket

Removing the Front Axle Bracket ~ ~ 2 4 - 1 s

3. Remove the brake drum.

Removing the Brake Drum ~ ~ 2 4 - 1 7


4. Remove the axle shaft lock nut.
(1) Loosen the caulked lock nut
(2) Lock nut
(3) Lock nut plate

Removing the Lock Nut ~ ~ 2 4 - 2 1

5. Remove the planet gear carrier ASSY


( I ) Planet gear carrier ASSY
(2) Shim

Removing the Planet Gear Carrier ~~024-23.24

6. Disassemble the planet gear carrier ASSY.


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

Removing the Planet Gear 1~023-6.8

Removing the Bearing ~Ao23-23


(7) Remove bushing from the planet gear
SST 09222-3001 0

Caution:
Only when the bushing show any defect, dis-
assemble it. Also, if the gear is found to be
defective, replace this bushing with a new
one as well.

Removing the Planet Gear Bushing LAG 104-8

7. Remove the internal gear


(1) Punch match marks.

Caution:
Punch the match marks on the front axle
housing and internal gear so that you can
easily distinguish between right and left, and
between the direction of aligning surface.

Punching the Match Marks LAQ~~-28

(2) Reamer bolt


(3) l nternal gear
(4) O-ring

Removing the lnernal Gear ~~24-29.30

8. Separate the front axle housing from the


outer front axle shaft.

Separating the Axle Shaft ~~024-31


9. Remove the brake ASSY.
( 1) Backing plate set nut
(2) Brake ASSY
(3) Front axle housing

Removing the Brake ASSY ~~24-34

Remove the bearing from the outer front


axle shaft.
SST 09420-23000-7 1

Caution:
0 Only when the bearing or axle shaft show
any defect, disassemble it.
0 Use a bearing remover (SST) and press to-
gether for disassembly (same procedure as
for removing the bearing from the planet
gear carrier).

Removing the Bearing 1~025-10

11. Disassemble the front axle housing.


(1) Oil seal (outside)

Removing the Oil Seal ~~24-36

(2) Bearing outer race


(3) Oil seal (inside)

Removing the Oil Seal, Outer Race ~ ~ 2 5 -5 4 ,

- 253 -
I NSPECTION

1. Outer front axle shaft inspection


(1) Cracks, wear and damage on the spline
part
(2) Bending
(3) Damage, catching and rotation of the
bearing
(4) Damage to the hub bolt, loose nut
(5) Damage to the threaded part

Inspecting the Outer Front Axle Shaft 1.~026-a

Inner front axle shaft inspection


( I ) Cracks, wear and damage on the spline
part
(2) Bending
(3) Damage, defects and wear on the tooth
surfaces
(4) Wear on the shaft end (wheel side)

Planet gears inspection


(1) Defects, damage and wear on the planet
gear tooth surfaces
(2)
. , Wear and damaae " of the thrust washer
nspectin
(3) Wear on the planet gear bushing, wear I g the Inner Front Axle Shaft LAQ26-21

on the end caused by bushing lateral


movement r a
Bushing inner diameter standard:
22 mm (0.866 in.)
Bushing inner diameter limit:
0 0
22.18 mm (0.873 in.)
(4) Wear and damage on the planet gear
shaft
Shaft outer diameter standard:
22 mm (0.866 in.)
Shaft outer diameter limit:
21.85 mm (0.860 in.)
( 5 ) Clogging of the planet gear shaft oil Inspecting the Planetary Gear LAGIW-11.23.34
gallery

4. Planet gear carrier inspection


( 1) Cracks and damage
(2) Wear on the planet gear shaft inserted
part
(3) Cracks, wear and damage on the spline
part
(4) Damage, catching and rotation of the
bearing
(5) Wear of the lock nut plate

lnspecting the Planet Gear


Carrier, Washer
lnternal gear inspection
(1) Cracks and damage
(2) Defects, damage and wear on the tooth
surfaces

Inspecting the Internal Gear ~~2s-1s

6. Front axle housing inspection


( 1 ) Cracks and damage
(2) Damage and wear on the mast support,
and on the frame support section
(3) Damage and wear on the bearing outer
race

Inspecting the Front Axle Housing LAQZS-7

7. Front axle bracket inspection


(1) Cracks and damage

Inspecting the Front Axle Bracket ~~026.20

Assembling the Planet Gear Bushing 1.~~104-7


(2) Assemble the bearing onto the planet
gear carrier.

Note:
o Use a steel pipe for pressing it in.
0 Bearing inner diameter: 80 mm (3.15 in.)

Assembling the Bearing

(3) Assemble the planet gear and shaft.


@ Thrust washer
@ Planet gear
@ Planet gear shaft

Caution:
Apply a light and uniform coating of molyb-
denum disulphide grease over the planet gear
bushing inner surface and shaft outer cir-
cumference, nefore assembling.

@ Snap ring Assembling the Planet Gear, Shaft LAGI 1-8

Assemble the oil seal and bearing outer race


onto the front axle housing.
(I)Bearing outer race (inside)

Assembling the Bearing Outer Race ~026-8

(2) Oil seal (inside)


Oil seal assembly dimension:
A = 12 mm (0.47 in.)
(3) Bearing outer race (outside)
(4) Oil seal (outside)

Note:
0 Coat MP grease over the oil seal lip part.
0 Fill MP grease in the B portion in the
illustration.
Grease amount:
68 -- 170 g (0.15 -- 0.37 Ib)
Assembling the Oil Seal
3. Assemble the internal gear.
(1) O-ring
(2) lnternal gear
(3) Reamer bolt

Note:
0 Coat the O-ring with grease before aseem-
bling.
0 Align the internal gear match marks.

Assembling the Internal Gear LAWS-27

4. Assemble the brake ASSY.


(1) Brake ASSY
(2) Lock nut
-
T = 9 -- 12 kg-m (65 87 ft-lb)

Assemblimg the Brake ASSY LAQ~S-28

Assemble the beraing and hub bolt onto the


outer front axle shaft.
(1) Bearing
(inner diameter: 70 mm (2.76 in.))
(2) Hub bolt
(3) Hub bolt lock nut
T = 27 -- 30 kg-m (195 -- 2 12 ft-lb)
(4) Apply thread tightener to the nut.
(Locktite # 271)

Assembling the Bearing, Hub Bolt LAWS -13

Assemble the outer front axle shaft and


front axle housing.
(1) Coat the outer front axle shaft bearing
with a generous amount of MP grease.
(2) Apply MP grease to the oil seal lip.
(3) Put the housing on the axle shaft, and
assemble it carefully.

Assembling the Outer Front Axle Shaft 1.~025-30

- 257 -
Assembling the Carrier ASSY LAQ~S-31

-
(4) Lock nut (always use a new one).
T = 30 35 kg-m (212 -- 253 ft-lb)

Caution:
0 After tightening the lock nut, rotate the
axle housing several times to work the
bearing to a good smooth fit.
0 Leave the lock nut uncaulked here.

Tightening the Lock Nut 1.~025-33

Measure the preload of the front axle shaft.


(1) Measure the preload at the front axle
housing set bolt.
Preload: 7 - 13 kg (15- 29 Ib)

Note:
0 Hook a spring balance onto the set bolt,
slowly draw it tangentially and measure
the value when the housing starts to ro-
tate.
0 Pay attention to protecting the housing
from dirt. Measuring the Preload ~ ~ 2 6 - 3 5

Adjusting the Shims LAQ25-32


Note:
I f the preload is less than the specified value, Shim Table
reduce the number of shims, and if it is more Thickness
than the specified value, increase the number Shim part number
I I
mm (in.)
of shims.
No. 1 42555-31960-71 1 1 .O (0.04)
(3) As three kinds of shims are provided, No. 2 42556-31960-71 0.4 (0.02)
use the most suitable ones. No. 3 42557-31960-71 0.1 (0.004)

9. Caulk the lock nut for the front axle shaft.

Caution:
Stake the lock to ensure that A part comes
into a contact as shown. Staking may cause
cracking on B part.

Caulking the Clock Nut

Assemble the brake drum.

Note:
Turn the brake adjuster, and assemble the
brake drum when the outer diameter of the
brake shoe i s reduced t o the minimum.
For assembly, tap the brake drum with a
plastic hammer, or set the hub nuts at two
or four symmetrical positions, before tight-
ening.

Insert the front axle housing set bolt into


Assembling the Brake Drum ~~026.4
the housing after washing and degreasing it.

Assembling the Front Axle Bracket . LAQZB-6


13. Assemble the parking cable bracket.
(1) Parking cable bracket
(2) Set bolt

Assembling the Parking Cable Bracket LAQ~~-6

INSTALLATION

Reverse the removal procedure for installing the components back onto the vehicle.

Caution:
0 Apply locking compound to the set bolts for the front axle housing and differential housing, and
then tighten to the standard torque.
T = 22.5 -- 33 kg-m (162 -- 238 ft-lb)
0 Tighten the bolt of the front axle bracket which had been temporarily tightened.
- -
T = 25 33 kg-m (181 238 ft-lb)
0 After assembling the front axle housing onto the differential housing, make sure that the brake
drum part can smoothly rotate.
0 Tighten the hub nut to the standard torque.
Single tire T = 30 -- 33 kg-m (212 -- 238 ft-lb)
Double tire (inside) T = 30 -- 35 kg-m (212 -- 253 ft-lb)
Double tire (outside) T = 35 -- 40 kg-m (253 -- 289 ft-lb)
0 After re-filling the differential oil, no oil should leak from the connecting part.
o Carry out air bleeding from the brake system and brake adjustment.
[Refer to the brake section (pages 8-16 and 8-18.)]
REAR AXLE

Page
GENERAL ....................................... 6-2
SPECIFICATIONS ............................... 6-2
COMPONENTS .................................. 6 -3
REAR AXLEASSY ............................... 6-4
REMOVAL .................................... 6 -4
DISASSEMBLY ................................ 6-6
INSPECTION .................................. 6-10
ASSEMBLY ................................... 6-13
INSTALLATION ................................ 6-18
REAR AXLE HUB ................................ 6-20
REMOVAL AND DISASSEMBLY ............... 6-20
INSPECTION .................................. 6-21
ASSEMBLY AND ADJUSTMENT ............... 6-22
STEERING KNUCKLE AND KING PIN ............. 6-24
REMOVAL AND DISASSEMBLY ............... 6-24
INSPECTION .................................. 6-25
ASSEMBLY AND ADJUSTMENT ............... 6-26
REAR WHEEL ALIGNMENT ...................... 6-28
TOE-IN ....................................... 6-28
TURNING RADIUS ............................ 6-28
CAMBER. CASTER AND
KING-PIN ANGLES ............................ 6-29
TIE ROD END BOOTS FITTING PROCEDURE ........... 6-30
GENERAL

I I

Rear Axle Sectional View LAQLI

SPECIFICATIONS
r

TYpe Eliot type


Rear axle suspension Center support swing type
Rear wheel alignment Toe-in mm (in.) 0 (0)
Rear wheel alignment Camber angle 1O
Rear wheel alignment Caster angle 0"
Rear wheel alignment King-pin angle 6"
Inside 7 5"
Steering angle
Outside 54O
Tire size 7.00-12-12PR (I)
Rime size 5.00s-12TB
Wheel Tread mm (in.) 1090 (42.9)

Tire pressure
kglcrn2
(psi)
3.25 - 4.0 ton model 7.0 (99.54)
4.5 ton model 8.5 (110.87)
COMPONENTS

01 ~ Z O A

"'1
:

:b. ...d

Cc440
01 Axle ASSY, RR 42E Seal, oil, No. 2
10 End ASSY, Tie-rod, No. 1 42K Seal, kit, king pin
11 End ASSY, Tie-rod, No. 2 43 Pin, king pin lock
13K Tie-rod kit 44 Hub, rear axle
20 Beam SUB-ASSY, rear axle 44A Bearing, inner
20A Bushing, rear axle beam 44B Bearing, outer
20B Shim, rear axle beam 44C Bolt, hub
23 Bellcrank SUB-ASSY, steering 44D Nut, hub
23A Bearing (For steering bellcrank) 44F Seal, oil (For rear axle hub)
238 Seal, oil (For steering bellcrank) 44H Washer, claw (For rear axle hub)
23K Seal kit, bellcrank pin 45 Cap, rear axle hub
40 Knuckle, steering, RH 47 Tie-rod
41 Knuckle, steering, LH 48 Pin, bellcrank
42 Pin, steering knuckle king 58 Boot, Tie-rod end
42A Bearing, steering knuckle thrust AE Shim
428 Seal, oil, No. 1 AF Plate, stopper
42C Bearing, needle BL Washer, thrust
42D Shim, steering knuckle

Rear Axle Components LAQM103

- 263 -
REAR AXLE ASSY
REMOVAL

Caution:
0 Always support the weight with stands on the left and right sides.
0 To facilitate removal, set the distance between the ground and counterweight bottom to 300 -
400 mm ( 11.8 -- 15.7 in.).
0 Always use the parking brake and use wheel blocks.

I. Remove the rear wheels.


(1) Loosen the hub nuts.
(2) Jack the frame up.
(3) Hub nuts
(4) Rear wheels

Caution:
Support the weight underside with blocks
and make sure that they do not slip off.

Removing Rear Wheels ~066-3

2. Remove the power cylinder guard.


(1) Bolts
(2) Power cylinder guard

Removing the Cylinder Guard ~068-2

Disconnecting the Cylinder End LAQS~-36


4. Disconnect the drag ink end.
( 1) Cotter pin
( 2 ) Castle nut
( 3 ) Drag link end

Disconnecting the Drag Link End LAQS8-8

5. Punch match marks.


(1) Front bracket
( 2 ) Rear bracket

Caution:
Punch different match marks for the front
and rear to prevent confusion.

Punching Match Marks ~~058-9

6. Measure the rear axle beam front and rear


play
(1) Force the rear axle fully toward the
front.
(2) Measure the front and rear play on the
rear side.
Specified play:
0.02 -- 0.50 mm (0.0008 -- 0.020 in.)

Measuring the Front and Rear Play LAQS~-11

7. Remove the rear axle bracket.


(1) Jack up the rear axle at the center.
(2) Bracket bolts
( 3 ) Rear axle bracket

Removing the Bracket ~~0.58-14


8. Remove the rear axle ASSY.
(1) Gradually lower the jack.
(2) Draw out the rear axle in left and right
directions.

DISASSEMBLY
Removing the Rear Axle ASSY LAQSS-16
Caution:
Explanation here describes disassembly of
the rear axle ASSY after it i s removed from
the vehicle. Since disassembly, repair and ad-
justment of the rear axle hub and steering
knuckle are possible without removal from
the vehicle, see repesctive parts of this
manual for removal and installation proce-
dure.

Remove the hub cap.


(1) Fix the rear axle on a work bench.
(2) Remove the hub cap with a screwdriver. Removing the Hub Cap ~ ~ 6 4 - 3 5

Remove the rear axle hub.


(1) Cotter pin
(2) Castle nut
(3) Calw washer
(4) Rear axle hub
SST 09950-20017

Removing the Rear Axle Hub LAo65-4

3. Remove the inner bearing.


SST 09950-20017

4. Remove the oil retainer

Removing the Inner Bearing LAG~S-6


5. Remove the bearing outer races from the
hub.
(1) Outer bearing outer race
SST 09950-20017
(2) Inner bearing outer race
SST 09608-35014

Caution:
Remove the bearing only when abnormal
wear, noise or other fault is found.

Removing the Bearing Outer Races ~ ~-28.31


6 1

6. Disconnect the tie-rod end.


(1) Cotter pin
(2) Castle nut
(3) Tie-rod end
SST 09610-20012

Disconnecting the Tie-rod End ~ ~ 6 5 - 8

Removing the Lock Pin LAG65-11

8. Remove the king pin.


(1) Grease fitting
(2) King pin

Removing the King Pin LAG^^-13


Remove the steering knuckle.
( 1 ) Thrust bearing
(2) Shim
(3) Steering knuckle

Caution:
Keep removed shims in order, check the
quantity and thickness so as not to lose
them.

Removing the Steering Knuckle LAG~S-17

Remove the oil seal.

Caution:
Remove the oil seal only when the oil seal
and needle bearing are damaged.

Removing the Oil Seal LAG~S-18

Remove the needle bearing.


SST 09608-20012

Caution:
Remove the needle bearing only when it is
damaged.

Remcjving the Needle Bearing LAG~S-23.25

12. Remove the support pin bushing and shims.


(1) Bushing
(2) Shims

Removing the Bushing and Shims l.AG65-28


13. Remove the bellcrank pin.
(1) Bolt
(2) Stopper plate
(3) Bell crank pin

Removing the Bellcrank Pin LAG65-33.34

14. Remove the bellcrank with tie rod.

Caution:
Be careful not to lose the adjusting shim.

Removing the Bellcrank UG67-26

15. Remove the tie rod.


(1) Cotter pin
(2) Castle nut
(3) Tie rod
SST 09610-20012

Removing the Tie Rod LAG^^-20

16. Remove the oil seal and needle bearing.

Caution:
Remove the oil seal and needle bearing only
when they are damaged or worn.

Removing the Oil Seal ~ ~ 6 6 - 9


INSPECTION

Caution:
0 After cleaning and washing the components, inspect the following components and repalce i f de-
fective.
0 Visually inspect each bearing and rotate them to check the rotation status, abnormal noise, loose-
ness or damage.

Inspecting the Steering Knuckle LAQST-12

King pin and lock pin inspection


(1) Wear and damage of the king pin
Specified outside diameter:
35.0 mm (1.38 in.)
Outside diameter wear limit:
34.8 mm (1.37 in.)
(2) Bending of the king pin

Caution:
If the wear limit i s exceeded, replace the
king pin together with the knuckle bearing.
lnspecting the King Pin
(3) Bending and damage of the lock pin

Bearing inspection
(1) Wear, damage and rotation status of the
needle bearing for the king pin
(2) Damage of the oil seal for the king pin
(3) Wear, damage and rotation status of the
thrust bearing for the king pin
(4) Wear, damage and rotation status of the
needle bearing for the bell crank pin
(5) Damage of the oil seal for the bell crank
pin

Inspecting the King Pin Bearings LAG63-9

- 270 -
4. Support pin bushing inspection
( 1) Wear of bushing bore
Wear limit: 67.0 mm (2.64 in.)

Note:
Be sure t o replace the bushing when the oil
retaining force is lost.
(2) Clogging of oil groove in the bushing

Inspecting the Bushing 1~066-13

5. Bell crank inspection


( 1) Cracks and damage of the bellcrank

Inspecting the Bellcrank ~~067-13

6. Bellcrank pin inspection


( 1 ) Wear and damage of the bell crank pin
Specified outside diameter:
28.0 mm (1.10 in.)
Outside diameter wear limit:
27.8 mm (1.09 in.)
(2) Bending of the bell crank pin

Inspecting the Bellcrank Pin LAG66-16

Rear axle hub inspection


(1) Damage and crack of the rear axle hub
(2) Damage and bending of the rear axle
hub bolt
(3) Damage of the wheel bearing race sur-
f ace
(4) Rotation, noise and wear of the wheel
bearing, and damage to the roller and
holder
(5) Damage of the steering knuckle oil re-
tainer

Inspecting the Rear Axle Hub L A G ~ -34


I
Inspecting the Rear Axle Beam LAG66-27

9. Tie rod inspection


( 1 ) Bending of the tie rod
( 2 ) Damage of the tie-rod end threaded por-
tion
Note:
See page 6-30 with reference to the fitting
procedure of the tie rod end boots.

Inspecting the Tie Rod ~~066-1s

10. Rear axle beam bracket inspection


(1) Crack and damage

Inspecting the Rear Axle Beam Bracket ~~066-23


ASSEMBLY

Caution:
0 After the inspection, clean each compo-
nent again before assembling. Be sure to
grease the bellcrank and king pin needle
bearing.
0 Rubber parts such as the oil seal must al-
ways be rep1aced after disassembly.

Assembling the Needle Bearing


and Oil Seal (1 )

1. Assemble t h e needle bearing and oil seal t o


t h e rear axle beam.
(1) Needle bearing
SST 09608-20012
(2) Oil seal
SST 09608-20012

Caution:
Mount the oil seal with the lip facing out-
side.

Assembling the Needle Bearing


and Oil Seal (2)

2. Assemble t h e needle bearing and o i l seal t o


t h e bell crank.
(1) Needle bearing
SST 09620-300-10

Assembling the Needle Bearing


and Oil Seal (1)

(2) Oil seal


SST 09620-30010

Caution:
Install the oil seal with the lip facing outside.

Assembling the Needle Bearing


and Oil Seal (2)
3. Assemble the tie-rod to the bellcrank.
(1) Tie rod
(2) Castle nut
T = 7 -- 8 kg-m (51 -- 57 ft-lb)
(3) Cotter pin

4. Assemble the bellcrank with tie-rod to the


rear axle beam.
(1 ) Assemble the bellcrank with tie-rod into
the rear axle beam.
(2) Adjust the bellcrank clearance with
shims.
@ Place a 3.0 mm (0.12 in.) shim Assembling theTie Rod LAG67-5

Assembling the Bellcrank l.AG67-26

Shim Adjustment Shim Adjustment (2) 1.~067-28

(3) Assemble the bellcrank pin.


@ Bellcrank pin
@ Stopper plate
@ Bolts
T = 1.9 -- 3.1 kg-m
-
( 1 3.7 22.4 ft-lb)

Assembling the Bellcrank Pin LAG67-31.34


Assemble the steering knuckle.
(1) Steering knuckle
(2) Thrust bearing

Caution:
Assemble the thrust bearing above the steer-
ing knuckle

(3) Adjust the steering knuckle rotation


with shims placed under the steering
knuckle.
Specified clearance:
Assembling the Steering Knuckle LAG67-36
0.02 -- 0.15 mm

Steering knuckle pre-load: Measuring the Pre-load


-
~~068-3
3 -- 5 kg (6.6 11.0 Ib)
@ When the pre-load is insufficient,
readjust and measure again.
( 6 ) Install the steering knuckle.
@ After pre-load adjustment, align the
king pin with the lock pin hole
position.
@ Drive in the lock pin.
@ Lock nut
-
T = 3 -- 4.5 kg-m (22 32 ft-lb)

Installing the Steering Knuckle LAG68-6

6. Assemble the oil retainer.

Assembling the Oil Retainer

- 275 -
Assembling the Inner Bearing LAG68-10

8. Assemble the bearing outer race to the rear


axle hub.
SST 09608-35014

Assembling the Bearing Outer Race ~ ~ 6 2 - 4 . 3

(1) Attach a Spring scale to the hub bolt Assembling the Rear Axle ~ " b LAG68-11

and measure the rear axle hub revolving


pre-load.

-
Rear axle hub pre-load:
1.4 -- 4.3 kg (3.1 9.5 Ib)

Note:
For pre-load adjustment, first tighten the
nuts firmly and back off about 114 turn. Tap
the hub for loose turning. Retighten the nuts
and measure the pre-load.

(2) Cotter pin


Measuring the Pre-load 1.~068-13
11. Assemble the hub cap.
(1) Change grease in the hub cap.
(2) Hub cap

Assembling the Hub Cap LAG68-16

12. Assemble the tie rod to the steering knuckle.


(1) Tie rod
( 2 ) Castle nut
T = 7 -- 8 kg-m (51 -- 57 ft-lb)
(3) Cotter pin

13. Assemble the grease nipple t o the steering


knuckle king pin.

Assembling the Tie Rod LAGBB-18

14. Adjust the toe-in.


(1) Align the rear axle beam and bell crank
holes. l nsert a proper round rod to pro-
vide straight ahead position.
(2) Fit tires to rear axle hubs, and measure
the distance between tread centers
(front and rear).
Toe-in: 0 mm (0 in.)

Measuring the Toe-in ~ ~ 6 8 - 2 6

(3) If the center-to-center distances are dif-


ferent between the front and rear, make
adjustment by the tie-rods.
T = 12 -- 15 kg-m (87 -- 105 ft-lb)

Note:
Tie rod adjustment must be made equally on
the right and left sides.

(4) Remove tires after adjustment.

Toe-in Adjustment LAG68-28


. , U

Installing the Rear Axle (1) LAQSE-15


to the match marks.

Installing the Rear (2) LAQ38-14


with the rear axle fully pushed toward
the front side.
0 Use shims from the thickness one for
adjustment.
0 If the clearance exceeds the specified
value, remove the axle assembly and re-
place the shim with a proper one.

Tighten the rear axle bracket.


( 1 ) Rear axle bracket
(2) Set bolts

Measuring the Rear Axle Clearance LAQSS-11

4. l nstall the drag link rod (tie-rod).


(1) Drag link rod
(2) Castle nut
T = 7 -- 8 kg-m (51 -- 57 ft-lb)
(3) Cotter pin

Installing the Tie-rod

- 278 -
Installing the Power Cylinder Rod lAQ68-19

Putting on the Rear Wheels ~ ~ 6 8 - 2 2


REAR AXLE HUB
Caution:
The section describes removal, disassembly and adjustment of necessary components without re-
moving the rear axle ASSY from the vehicles.

care that no slip will occur.


Removing the Rear Wheel

Removing the Hub Cap ~~056-7

3. Remove t h e rear axle hub.


( I ) Cotter p i n
(2) Castle n u t
(3) Claw washer
(4) Rear axle hub
SST 09950-20017

Removing the Rear Axle Hub LAQ56-12


4. Remove the inner bearing.
SST 09950-20017

Caution:
Remove the bearing only when abnormal
sound, excessive wear or other defect is ob-
served.

Removing the lnner Bearing LA056-14

5. Remove the oil retainer.

Removing the Oil Retainer ~~056-15

6. Remove the bearing outer races from the


rear axle hub.
(1 ) lnner bearing outer race
SST 09950-20017
(2) Outer bearing outer race
SST 09608-35014

Caution:
Remove only when bearing abnormality is
found.

Removing the Bearing Outer Race LAG61-28.30

INSPECTION

1. Rear axle hub inspection


(1) Damage and cracks of the rear axle hub.
(2) Damage, breakage and bending of the
rear axle hub bolts
(3) Damage on the wheel bearing race sur-
face
(4) Poor rotation, noise and excessive wear
of the wheel bearing: damage of the
roller and holder
(5) Damage of the steering knuckle oil re- Inspecting the Rear Axle Hub LAG61-34
tainer
ASSEMBLY AND ADJUSTMENT

1. Assembling the oil retainer.

Assembling the Oil Retainer U~66-1s

2. Assemble the inner bearing.


SST 09370-20270-71

Caution:
Take care not to drive in a t an angle.
Otherwise, the knuckle spindle section may
be damaged.

Assembling the Inner Bearing lAQ57-23

3. Assemble the bearing outer race to the rear


axle hub.
SST 09608-35014

Assembling the Bearing Outer Race ~A062-4.3

4. Assemble the rear axle hub.


(1) Charge grease in the hub.
(2) Coat grease on the inner and outer bear-
ings.
(3) Install the rear axle hub and dri,ve in the
outer bearing.
SST 09370-20270-71
(4) Claw washer
(5) Castle nut

Assembling the Rear Axle Hub ~057-26

282 -
5. Measure the rear axle hub pre-load.
(1) Attach a spring scale to the hub bolt,
and measure the rear axle hub rotating
pre-load if the rear axle hub.
Rear axle hub pre-load:
1.4 -- 4.3 kg (3.1 -- 9.5 I b)

Note:
For pre-load adjustment, first tighten the
nuts fully and back off about 114 turn. Tap
the hub for loose turning, retighten the nuts
and then measure the pre-load.
Measuring the Rear Axle Hub Pre-load ~~057-28

(2) Cotter pin

6. Assemble the hub cap.


(1) Charge grease in hub cap.
(2) Hub cap

Assembling the Hub Caps ~~057-30

7. Install the rear wheel, remove the stands and


tighten the hub nuts with the specified tor-
que.
T = 18 -- 20 kg-m (130 -- 144 ft-lb)

Installing the Rear Wheel ~~058-22


STEERING KNUCKLE AND
KING PIN
Caution:
Since removal and installation of the steering
knuckle and king pin must be done with the
rear axle hub removed, see the rear axle hub
section for the removal and installation pro-
cedures.

REMOVAL AND DISASSEMBLY


Disconnecting the Tie-rod End
1. Disconnect the tie-rod end.

Removingthe Lock Pin LAQ66-23


of lock pin, always use a service nut (that
can be damaged).

3. Remove the king pin.


(1) Grease fitting
(2) King pin

Removing the King Pin LAQS~-27

4. Remove the steering knuckle.


(1) Thrust bearing
(2) Shims
(3) Steering knuckle

Caution:
Keep the shims in arranged state to prevent
missing, and record the number and thick-
ness.

Removing the Steering Knuckle ~ ~ 5 6 - 2 9


5. Remove to the oil seal.

Caution:
Remove the oil seal only when damage or
wear of the needle bearing and oil seal i s
found.

Removing the Oil Seal mQ56-34

6. Remove the needle bearing.


SST 09608-200 1 2

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

Removing the Needle Bearing ~~056-35.36

Steering knuckle inspection


(1) Cracks and wear at the spindle mount-
ing portion and threaded portion of the
steering knuckle.

Caution:
Use of a flow detector or flaw detecting
agent is recommended for inspection.

Inspecting the Steering Knuckle LAQ57-12

King pin inspection


( 1 ) Wear and damage of the king pin
Specified outside diameter:
35.0 mm (1.38 in.)
Outside diameter wear limit:
34.8 mm (1.37 in.)
(2) Bending of the king pin

Caution:
I f the wear limit is exceeded, replace the
king pin with the steering knuckle.

(3) Bending and damage of the lock pin lnspecting the King Pin LAQ57-16
3. Bearing inspection
( 1 ) Wear, damage and poor rotation of the
needle bearing for the king pin
(2) Damage of the oil seal for the king pin
(3) Wear, damage and poor revolution of
the thrust bearing for the king pin
(4) Wear, damage and poor revolution of
the needle bearing for the bell crank pin
(5) Damage of the oil seal for the bell crank
pin

Driving in the Needle Bearing and LAGS67


Oil Seal (1)

ASSEMBLY AND ADJUSTMENT

1. Drive in the needle bearing and oil seal to


the king pin sleeve.
(1) Needle bearing
SST 09608-2001 2
(2) Oil seal
SST 09608-2001 2

Caution:
The oil seal must be installed with the lip
side facing outside. Driving in the Needle Bearing and
Oil Seal (2)

2. Assemble the steering knuckle.


(1) Steering knuckle
(2) Thrust bearing

Caution:
The thrust bearing must be installed above
the steering knuckle.

Assembling the Steering Knuckle 1.~066-29

Adjust the steering knuckle rotation


with shims placed under the steering
knuckle.

--
Specified clearance:
0.02 0.15 mm
(0.0008 0.0059 in.)
Shim thickness:
0.1 5 mm (0.0059 in.)
0.25 mm (0.0098 in.)
0.35 mm (0.0138 in.)

King pin
Mounting the King Pin ~~056-27
(5) Adjust the steering knuckle pre-load.
@ After shim adjustment, attach a
spring scale to the knuckle spindle
end and measure the pre-load.
Specified steering knuckle pre-load:
-
3 -- 5 kg (6.6 11.0 Ib)
@ If the specified pre-load i s not at-
tained, readjust with shims.

Measuring the Pre-load LAQS~-17

(6) Assemble the steering knuckle.


@ After pre-load adjustment, align the
king pin with the lock pin hole
position.
@ Drive in the lock pin.
@ Lock nut
T = 3 -- 4.5 kg-m (22 -- 32 ft-lb)

Tightening the Lock Nut ~~057-19

3. Assemble the tie-road to the steering knuck-


le.
(1) Tie-rod
(2) Castle nut
T = 7 -- 8 kg-m (51 -- 57 ft-lb)
(3) Cotter pin

4. Assemble the grease nipple.

Assembling the Tie-rod LAQS~-20


REAR WHEEL ALIGNMENT
TOE-IN

Caution:
The rear axle ASSY must be remove before
toe-in measurement and adjustment.

1. Mark at the center of the left and right


wheels.

Measuring the Toe-in 1.~068-26

Adjusting the Toe-in 1.~068-28

Adjusting the Turning Angle


TURNING RADIUS

Adjust the turning angle of the rear wheels


by adjusting the knuckle stopper bolt (in
or out).

After turning angle adjustment, measure


the minimum turning radius for confirma-
tion.
5FG (D) 33 series mode12600 mm (102 in.)
5FG (D) 35 series model 2650 mm (104 in.)
5FG (D)E 35 series model 2740 mm (108 in.)
5FG (D) 40series model 2800 mm (110 in.)
5FG (D) 45 series model 2850 mm (1 12 in.) Measuring the Minimum Turning Radius 1.~063-8

- 288 -
CAMBER, CASTER AND KING-PIN
ANGLES

Use an alignment tester for measurement of the


camber , caster and ki ng-pin angles.
However, adjustment is impossible.
Camber angle: lo
Caster angle: 0"
King-pin angle: 6O
TIE ROD END BOOTS FITTING
PROCEDURE
1. Smear MP grease on boot upper surface lip por-
tion (Circumference of @ in drawing) and
shaft side lip portion (Circumference of @) be-
fore installing boot.
2. The escape valve on boot should be directed
to the tie rod end thread side, as shown in
drawing.

Smear grease on lip

3. Install the boot to the body and fix it with set


ring by using screw driver.
Note:
Take care not t o damage the boot.
Never tangle the ring.
Never bite the boot.

Install Set ring

4. Wipe off the grease on the ball stud.


5. Tighten the ball stud portion of the tie rod.
T = 1 5 - 2 0 kg-m
( 108.53- 144.70 ft-lb)
6. Supply grease.
Specified grease: MP grease
Note:
Don't supply too much grease t o such an ex-
tent that the grease will leak out of the es-
cape valve.
Never allow boot t o release grease out of
Clean Shaft surface
body and fixed portion.
STEERING

Page
GENERAL....................................... 7-2
COMPONENTS................................... 7-3

STEERING GEAR BOX ASSY ..................... 7-8


REMOVAL .................................... 7-8
DISASSEMBLY ................................ 7-11
INSPECTION .................................. 7-14
BEARING AND OIL SEAL REPLACEMENT ...... 7-16
ASSEMBLY AND ADJUSTMENT ............... 7-18
INSTALLATION ................................ 7-22
MAST JACKET ASSY ............................
REMOVAL ....................................
DISASSEMBLY ................................
INSPECTION ..................................
ASSEMBLY ....................................
INSTALLATION ................................
POWER CYLINDER ..............................
REMOVAL ....................................
DISASSEMBLY ................................
INSPECTION ..................................
ASSEMBLY AND ADJUSTMENT ...............
INSTALLATION ................................
OIL PRESSURE TEST ..........................
DRAG LINK ..................................... 7 -3 4
ADJUSTMENT ................................ 7-34
GENERAL

Steering Gear Box Sectional View LAOLI 1

- 292 -
COMPONENTS

10
r"' "'7
:
1- I

%
\
-'---ll

@@

b..-
12
...
a

10 Gear ASSY, steering 45A Ring, 0 (For top cover)


1 OK Gear O/H kit, steering 46 Cover, end
11 Ball screw set 46C Ring, 0 (For end cover)
11 A Bearing, No. 1 (For ball screw set) AL Plug, oil
11B Bearing,No.2(Forballscrewset) AM Bolt, adjusting
11C Bearing, thrust (For ball screw set) AN Plate, adjusting
12 Body ASSY, valve AS Seal, oil
21 Box SUB-ASSY, steering gear AV Packing
21 B Bearing, No. 1 (For sector shaft) AW Nut
21 C Seal, oil (For sector shafat) AX Nut
30 Cover SUB-ASSY, side AY Nut, lock
30A Bushing, sector shaft, No. 2 BA Ring, snap
30C Ring, 0 (For side cover) BB Seat
31 Valve set, relief BC Spring
33A Ring, 0 (For valve body set) BD Stopper, balance piston
40 Shaft, sector BE Ring, 0
44 Piston, balance BG Spring, balance piston
45 Cover, top

Steering Gear Box Components

- 293 -
20 Jacket SUB-ASSY, mast EC Ring
23 Bracket SUB-ASSY, tilt steering ED Ring
24 Stopper SUB-ASSY, steering shaft ES Spring, compressison
25 Stopper SUB-ASSY, steering ET Spring, tension
26 Shaft SUB-ASSY, tilt steering EU Spring, tension
49 Grommet, steering column (Insulator) EV Pipe
69 Wire, tilt steering EW Collar, tilt lock
AF Clamp EX Hose
AG Clamp, steering column, lower EY Lever SUB-ASSY, tilt lock
BN Bushing EZ Bolt, tilt lock
BR Boot, mast jacket FA Nut, adjusting, RH
BT Jacket FB Nut, adjusting, LH
BW Bolt

Tilt Steering System Components

- 294 -
01 Cylinder ASSY, power Ring, snap
01 K Packing kit, power cylinder Seal, dust
20 Cylinder SUB-ASSY, power Ring, 0
40 Rod, piston Collar, rear cover
40A Nut, self lock (For piston) Seat
41 Piston Ring, snap
42 Ring, piston Packing, U
43 Guide, rod Ring, back up
AA Bushing Ring, back up

Power Cylinder Components

- 295 -
0A

10

10 End ASSY, drag link 44 End, power cylinder


10A Nut, castle (For drag link end) 53 Hose, high pressure
11 End ASSY, power cylinder AA Clamp, end
1 1A Nut, castle (For power cylinder end) AB Clamp, end
30 Pipe SUB-ASSY, No. 1 (Steering to cylinder) AL Boot
31 Pipe SUB-ASSY, No. 2 (Steering to cylinder) AV Pipe
38 Pipe SUB-ASSY (Valve to steering) BB Clamp
40 Rod, drag link, No. 1 BJ Clamp
41 Arm, pitman BP Rubber, cushion
42 Hose, power cylinder, No. 1 DZ Pipe
43 Hose, power cylinder, No. 2 JO Rubber, cushion

Steering Link Components

- 296 -
Wheel ASSY, steering
Knob ASSY, steering wheel
Knob SUB-ASSY, steering wheel
Button, horn
Plate, horn contact
Seat, horn contact
Spring, horn
Plate, lead
Washer
Cap, steering wheel
Bolt, steering wheel knob set
Ring, horn contact No. 1

Steering Wheel Components LAQMI 08

SPECIFICATIONS
1
Steering wheel diameter mm (in.) 380 (15.0)
Gear type Recirculating ball screw
Gear ratio 1 : 18.5
Steering gear
Lock to lock 3.9
Ball twisting direction Counterclockwise

TYpe Semi-integral
Booster 2
Relief valve set pressure kg/cm (psi) 120 ( 1706)

TYpe Double action type


Cylinder bore mm (in.) 55 (2.17)
Power cylinder
Piston rod outside diameter mm (in.) 25 (0.98)
Piston stroke mm (in.) 290 (11.4)
i
(2) Remove set bolts (4 pcs.) and discon-
nect the electrical wiring connector.
(3) Remove the combination meter ASSY.

Removing the Combination Meter ASSY LAQ~O-35

3. Remove the turn signal switch ASSY.


( 1 ) Loosen the set bolt and remove the turn
signal switch ASSY.

4. Remove the boot.

Removing the Turn Signal Switch ASSY 1.~061-3

5. Remove the return spring.


( 1 ) Spring small (for steering stopper)
(2) Spring large (for steering post)

Caution:
Carefully operate because the spring force is
strong.

Removing the Springs LAQ61-5

6. Remove the tilt lock device.


(1 ) Remove the set bolt to remove the tilt
lock lever.
(2) Alternately turn the adjusting nuts and
remove the tilt lock bolt.

Caution:
The adjusting nuts use right hand thread on
the left side and left hand thread on the
right side.

Removing the Tilt Lock Device LAQGI-10


7. Remove the mast jacket with tilt steering
shaft.
( 1 ) Remove the set nut and set bolt, and re-
move the mast jacket with tilt steering
shaft.

8. Remove the toe board.

Removing the Mast Jacket ASSY ~ ~ 0-163 1

9. Disconnect the hydraulic piping.

Caution :
Prepare waste cloth around the hydraulic
piping because some oil will flow out from
the disconnected piping.

(1) Disconnect the inlet and outlet pipes.

Disconnecting the Hydraulic Piping (1) LA061-18

(2) Disconnect the pipe for power cylinder.

Disconnecting the Hydraulic Piping (2) 1.~061 -19

10. Disconnect the drag link.


( I ) Remove the cotter pin and castle nut.
(2) Use the SST and disconnect the drag
link.
SST 09611-2001 5

Disconnecting the Drag Link 1.~061-23


Removing the Gear Box set Nut ~ ~ 0-25
6 1

Removing the Steering Gear Box ASSY LAQGI-27

DISASSEMBLY

1. Remove the mast jacket lower.


( 1 ) Loosen the clamp set bolt.
(2) Remove the mast jacket lower.

Removing the Mast Jacket Lower LAOIZO-IS

Remove the pitman arm.


(1) Use a socket wrench whose width across
flats is 32 mm (1.26 in.) and remove the
pitman arm set nut.
(2) Use the SST to remove the pitman arm.
SST 09420-10410-71

Caution:
Check the match mark on the sector shaft
and pitman arm at the time of disassembly.

Removing the Pitman Arm

- 301 -
3. Remove the end cover.
(1) Remove the set bolts ( 4 pcs.) to remove
the end cover.

Caution:
After removing the end cover, temporarily
tighten the control valve body by using two
end cover set bolts.

Removing the End Cover LAOI 20-26

4. Remove the lock nut.


( I ) Unlock the lock nut.
(2) Remove the lock nut.

Removing the Lock Nut LAOI 20-29

5. Remove the needle bearing.

6. Remove the control valve body ASSY.


(1) Remove temporary set bolts.
(2) Remove the control valve body ASSY.

Removing the Control Valve Body ASSY ~~0120-as

7. Removethesidecoverwithsectorshaft.
(1) Remove the set bolts ( 4 pcs.).
(2) Loosen the adjusted bolt lock nut, and
screw in the adjusting nut.

Removing the Side Cover

-
(3) Remove the side cover with sector shaft.

Caution:
Place the ball screw nut at the lock-to-lock
center position, and draw out the sector
shaft carefully to prevent oil shaft damage.

Removing the Side Cover with Sector Shaft ~~0121-2

8. Separate of the side cover and sector shaft.


(1) Tighten the adjusting nut until the ad-
justing bolt leaves the side cover.

Separating the Side Cover and Sector Shaft ~~0121.3

9. Remove the top cover.


(1) Remove the set bolts to remove the top
cover.

Removing the Top Cover ~ ~ 0 1-72 1

10. Remove the ball screw set.


(1) Remove the ball screw set from the gear
box.

Removing the Ball Screw Set ~ ~ 0 1-92 1


1 1. Disassemble the control valve body ASSY.
(1) Remove the valve spool, reaction piston
and reaction spring from the valve body.

Disassembling the Control Valve


Body ASSY

Disassemble the relief valve.


(1) Remove the piston stopper, and remove
the piston, spring and relief valve set in
this order.

Note:
If relief valve set removal i s difficult, reverse
the valve body and strike it lightly against a
wooden block.

Disassembling the Relief Valve 1.~0122-14. 16

INSPECTION

Caution:
Disassembled parts shall be washed with
washing fluid and shall be checked for the
following points.

1. Ball screw set inspection


(1) Damage and cracks at shaft
(2) Damage of threaded portion
(3) Damage at ball nut tooth surface
(4) Rotating condition of ball screw Ball Screw Set Inspection LAO 122-8

2. Sector shaft inspection


(1) Damage at sector shaft serration and
gear
(2) Damage at adjusting bolt threaded por-
tion

Sector Shaft Inspection 1~0122-1


(3) Select the adjusting plate to make the
clearance between the sector shaft and
adjusting plate satisfy the limit shown
be1ow.
Clearance limit: 0.1 mm (0.0039 in.)

Thickness: 2.00 mm
(0.0787 in.)

(0.0768 in.)

Adjusting Plate Clearance Inspection ~~0122-2

Steering gear box inspection


(1) Damage and wear of gear box
(2) Wear and damage of oil seal lip
(3) Damage and rotating status of needle
bearing

Caution :
Inspect the oil seal and needle bearing as
they are installed t o the gear box. Replace
the oil seal or needle bearing only when it
i s found defective.
Gear Box Inspection ~~0121-10

Control valve inspection


(1) Damage and cracks of valve body
(2) Distortion and damage of valve spool
(3) Bending and fatigue of reaction cham-
ber spring
(4) Damage of needle bearing
(5) Sliding contact between body and spool

Caution:
0 Blow compressed air for sufficient clean-
ing before inspection.
o Replace the valve body as an ASSY when
Control Valve Inspection 1.~0122-12
any defect is found.

Relief valve inspection


(1) Sliding contact between balance piston
and valve body, and damage.
(2) Fatigue and bearing of balance spring
(3) Trapping of foreign matters

Caution:
Disassemble the relief valve only when the
relief pressure measured in installed state is
abnormal.

Relief Valve ASSY lnspection

- 305 -
(4) Disassemble the relief valve set, and in-
spect fatigue of relief valve spring and
damage on steel ball surface.
(5) Existence of foreign matters at filter

Caution:
Replace the relief valve set when any defect
i s found.

Relief Valve Set Inspection ~~0122-17

BEARING AND OIL SEAL


REPLACEMENT

Caution:
When an abnormality of the bearing, etc. is
found, carry out replacement according to
the following procedure:

1. Gear box
(1) Use the SST and remove the bearing on
the end cover side.
SST 09608-20012 Replacing the Gear Box Bearing 1.~0121-11
(2) Use the SST and drive the bearing into
the gear box.
SST 09608-20012

Note:
The driven-in bearing surface must be flush
with the gear box outer end surface.

(3) Remove the snap ring.


(4) Use another SST and remove the bear-
ing and oil seal on the sector shaft side.
SST 09480-10170-71
(5) Use the SST and drive in the bearing
Removing the Gear Box Bearing ~ ~ 0 ~ 3 2 8
and oil seal.
SST 09608-20012

Note:
The driven-in bearing surface must be flush
with the gear box outer end surface.

(6) Install the snap ring.

Driving the Bearing into Gear Box ~~0121-13


2. Side cover
(1) Remove the side cover bearing by using
the SST.
SST 09320-23000-71
-
To SST

Removing the Side Cover Bearing ~ ~ 0 ~ 3 2 9

. . , . ~ ..,,~: ...: :..-..


(2) Use the SST and drive in the bearing to
the side cover.
SST 09420-20150-71

~ r i v i the
n ~ Bearing into Side Cover 1.~0121-19

3. Top cover
(1) Use a screwdriver and remove the bear-
ing and oil seal.

Removing the Top Cover Bearing LAO121-22

(2) Use the SST and drive in the bearing


and oil seal to the top cover.
SST 09620-30010

Driving the Top Cover Bearing LA0121-21


ASSEMBLY AND ADJUSTMENT

Caution:
Clean each part with compressed air before
starting assembly

1. Ball screw set installation

Installing the Ball Screw Set 1~0122-21

Top cover instal lation


(1) Coat hydraulic oil on the O-ring.
(2) Install the top cover to the gear box.

Caution:
Place the protrusion a t the same position as
before disassem'bly.

(3) Tighten the set bolts to the specified


torque.
T = 4.5 -- 5.5 kg-m (32.5 -- 39.7 ft-lb)
Installing the Top Cover l ~ o22-23
1

Installing the Needle Begring, etc. LAO 122-24

(2) Install the control valve body ASSY.

Caution:
Coat hydraulic fluid on the O-ring.

Installing the Control Body ASSY 1~0122-27


Installing the Needle Bearing LAOI 22-30

Measure the Ball Screw Set Preload LAOI 22-31

Punching the Lock Nut 1~0122-33

5. End cover installation


(1) Coat hydraulic oil on the O-ring.
(2) Install the end cover to the gear box,
and tighten the set bolts to the specified
torque.
T = 4.0 -- 5.0 kg-m (29.2-- 36.5 ft-lb)

Installing the End Cover

- 309 -
Assembling the Sector Shaft 1.~0122-3s

Installing the Sector Shaft with Side Cover ~~0122-36

(3) l nstall the side cover set bolts and tight-


en them t o the specified torque.
T = 4.5 -- 5.5 kg-m (32.5-- 39.7 ft-lb)

Installing the Side Cover ~ ~ 0 ~ 3 3 1

Installing the Pitman Arm LAO 120-24


Backlash adjustment
(1 ) Place the pitman arm at the lock-to-lock
center position, and set a dial gauge.
(2) Screw in the adjusting bolt until the
backlash at the tip end of the pitman
arm becomes 0 mm.

Measuring the Backlash LAOIZO-17

Measuring the Preload ~~0126-7

(4) If the overall preload does not satisfy


the standard, position the pitman arm
again at the lock-to-lock center and ad-
just the overall preload by turning the
adjusting bolt.

(5) Measure the backlash with the pitman


arm at the lock-to-lock center or at the
extreme leftlright position.
Backlash at lock-to-lock center: 0 mm
Backlash at extreme leftlright:
0.1 -- 0.3 mm (0.0039 -- 0.01 18 in.)
Adjusting the Backlash LAOI 26-4
(6) After the backlash adjustment, tighten
the adjusting bolt lock nut.
Lock nut:
T = 3.0 -- 4.5 kg-m (21.7 -- 32.5 ft-lb)

-
Cap nut:
T = 3.0 4.5 kg-m (21.7 -- 32.5 ft-lb)

Tightening the Lock Nut LAOI 25-6


9. Mast jacket lower installation
(1) Install the mast jacket lower to the gear
box.
(2) Tighten the clamp set bolt.

Installing the Mast Jacket Lower ~~0120-14

10. After the end of assembly, inspect the following points:


(1) Rotate the shaft of the ball screw set 3 to 4 turns, to check if i t turns smoothly without uneven-
ness or excessive resistance.
(2) Turn the shaft of the ball screw set to the lock position, and check if i t returns smoothly by the
reaction spring action.

Installing the Steering Gear Box LA020-1

2. Hydraulic piping installation


(1) Install the inlet and outlet pipings.
(2) Install the power cylinder piping.

Installing the Hydraulic Piping LAQ~I-18.19


Installing the Drag Link LAQG1-2 1

Mast jacket ASSY installation


(1) Fit the universal joint to the steering
gear box shaft by matching the spline.
(2) Install the mast jacket ASSY to the
bracket by using the set bolts ( 2 pcs.).

Caution:
0 Install the mast jacket by placing the
spring hook on the front side.
0 Do not forget to use the nylon bush when
installing the mast jacket set bolt.
Installing the Mast Jacket ASSY LAQ~I-27

6. Installation of parts released t o tilt adjusting


bolt .
( 1 ) Install the tilt adjusting bolt.
(2) Coat MP grease on the lock portion.

Caution:
lnstall the lever so that it is positioned B-C
when it is locked.
Section A-A
(3) After installing the adjust lever, move
the lever and check if it is locked at the
desired position.
Installing the Tilt Adjusting Bolt

7. Return spring installation

Installing the Spring LAQGI-5


Installing the Combination Meter ASSY LAQ~O-35

Steering wheel installation


(1) Install the steering wheel by aligning the
match marks punched at the time of re-
moval.
(2) Install the horn contact parts.
(3) Tighten the steering wheel set nuts to

-
the specified torque.
-
T = 2.0 3.9 kg-m (14.4 21.7 ft-lb)
(4) Install the horn button.

Installing the Steering Wheel LAOI 8-4

Rel ief pressure measurement


(1) Remove the pressure measuring port
plug, and install an oil pressure gauge.
Place wooden blocks between rear
wheels and the rear axle beam.
Start the engine. Turn the steering
wheel and measure the relief pressure.
Standard re1ief pressure:
115- 125 kg/cm2 (1635- 1778 psi)

Add grease to the universal joint.

Measuring the Relief Pressure ~ ~ 6 1 - 3 1


MAST JACKET ASSY
REMOVAL

Caution:
Refer to the items 1 -- 7 of the "STEERING
, GEAR BOX ASSY REMOVAL".

Removing the Mast Jacket ASSY LAQ61-13

DISASSEMBLY

1. Tilt steering shaft with shaft stopper re-


moval.
(1) Remove the set bolt, and remove the tilt
steering shaft with shaft stopper.

Removing the Tilt Steering Shaft LAOI 23-6

2. Universal joint removal


(1) Remove the set bolt, and remove the
universal joint.

Removing the Universal Joint 1.~0123-9

Steering shaft stopper removal


(1) Use snap ring pliers and a screw-driver
to remove the snap ring.
(2) Use the SST and a soft hammer to re-
move the shaft stopper from the steer-
ing shaft.
SST 0941 1 -41800-71
T(J Screw-driver

Removing the Shaft Stopper ~~0123-16


18,
INSPECTION

1. Mast jacket SUB-ASSY inspection


(1) Deformation and damage on the mast
jacket cylinder.
(2) Spring hook deformation, and cracks at
welded portion.
(3) Degradation and damage of grommet

Mast Jacket SUB-ASSY Inspection LAO^ 23-27

Tilt Shaft Inspection LAO^ 23-20

Universal joint inspection


(1) Looseness and sticking at spider portion
(2) Damage at serration
(3) Damage and rusting of spline portion

Universal Joint Inspection LAO 123-23

Shaft Stopper lnspection LAO^ 23-22


ASSEMBLY

1. Shaft stopper installation


(1) Use the SST and install the shaft stop-
per to the tilt shaft.
SST 09700-30200-7 1
(2) Install the snap ring by using SST.
SST 09905-0001 2

Installing the Shaft Stopper LAOI 23-28, 31

Uni versa1 joint installation


( 1 Install the universal joint where i t s bolt
hole matches the bolt set groove on the
steering shaft.
Tighten the set bolt to the specified tor-
que.
T = 1.8-2.5 kg-m (13- 18 ft-lb)

Installing the Universal Joint LAOI 23-9

3. Steering shaft with universal joint installa-


tion
(1) Align the shaft stopper set bolt hole and
the mast jacket set bolt hole at the time
of installation.
(2) Firmly tighten the set bolt.

Installing the Universal Joint LAOI 23-4

INSTALLATION

Follow the steps for removal in the reverse order


POWER CYLINDER

Power Cylinder Sectional View LAQMI 8

REMOVAL

1. Remove the power cylinder guard.


( 1 ) Set bolts
( 2 ) Power cylinder guard

Removing the power Cylinder Guard ~ ~ ~ 6 0 . 1 2

2. Disconnect the power cylinder piping.

Note:
0 Turn the steering wheel until the power
cylinder end protrudes from the rear axle.
0 Receive the oil leaking from the piping
with an oil receiving tray.

Disconnecting the Piping LAQBO-13


Disconnecting the Power Cylinder Rear End LAQS;~-36

Disconnecting the Power Cylinder End LAQ~O-15

Removing the Power Cylinder LAQ~O-16


DISASSEMBLY

Caution:
0 Inspect oil leakage and piston rod damage before starting disassembly.
0 Measure the dimension between both ends of the cylinder in retracted state for reference at the
time of reassembly.

1. Remove the power cylinder ends.


(1) Clamp
(2) Front and rear ends

Remove the power cylinder rear cover.


(1) Loosen caulking.
(2) Power cylinder rear cover
SST 09620-10100-71

Caution:
0 When fixing the power cylinder with a
vice, carefully operate so as not to dam-
age the cylinder.
o For 3.25 -- 4.0 ton models, merely loosen
the rear cover and extract it together with
the piston rod. Remove the piston and
Removing the Rear Cover ~ ~ ~ 5 2 . 3 5
then the rear cover.

Extracting the Piston Rod LAQS2-36

4. Remove the piston from the piston rod.


( 1 ) Self-lock nut.
Caution:
0 When fixing the piston rod with a vice,
carefully operate so as not to damage the
rod surface.
0 Use a spanner at the other end of the pis-
ton rod to prevent rotation.

Removing the Self-lock Nut

- 320 -
(2) Piston (outer)
(3) Piston ring
(4) Piston (inner)

Removing the Piston w/ Piston Ring LAQSI 55

5. Disassemble the rear cover.


(1) Snap ring and collar
(2) U-packing and backup ring
(3) Bushing
(4) Snap ring and dust seal

Caution:
Disassemble only when oil leak the rear
cover i s found.

Disassembling Rear Cover ~~053-14

INSPECTION

1. Damage and wear inside the power cylinder


inspection

Note:
When using above gauge, measure the wear
and departure from roundness a t a place
about 200 mm (8 in.) from the cylinder
edge.
Cylinder bore standard: 55 mm (2.165 in.)
Cylinder bore limit: 55.35 mm (2.179 in.)
Inspecting the Cylinder ~~053-16

Piston rod inspection


( 1 ) Wear and damage
Diameter standard: 25 mm (0.984 in.)
Wear limit: 24.92 mm (0.981 in.)
(2) Bending
Bending limit: 1 mm (0.039 in.)

lnspecting the Piston Rod

- 321 -
3. Piston and piston ring inspection
(1) Wear and damage of the piston
(2) Wear and damage of the piston ring

Inspecting the Piston and Ring LAQSB-21

Rear cover inspection


(1) Wear and damage of the U-packing
(2) Wear and damage of the dust seal

Caution:
Remove and replace the dust seal only when
a defect is found.

Inspecting the Rear Cover Parts uQ63-22

ASSEMBLY AND ADJUSTMENT

1. Assemble the seal and other parts to the


cylinder rear cover.
(1) Dust seal and snap ring
(2) Bushing
(3) Backup ring and U-packing
(4) Collar and snap ring

Caution:
Use a hand press to drive in the dust seal
only when it is replaced.
Assembling the Rear Cover ~ ~ 6 3 - 1 4
2. Assemble the piston rings to the piston.
3. Assemble the piston to piston rod.
(1 ) Piston w/ piston ring
(2) Self-lock nut
T = 1 6 - 2 3 kg-m (108- 166ft-lb)
Caution :
Use a new self-lock nut.
- 1995. 3 :
T = 15-
1995. 3 -
2 3 kg-m ( 1 0 8 - 166ft-lb)
:
T = 1 2 -- 1 6 kg-m ( 8 7 - 1 1 6 ft-lb)

Assembling the Piston

- 322 -
4. Insert the piston into the cylinder.

Inserting the Piston ~ ~ 6 2 - 3 6

. . . . . . ..
5. Assemble the rear cover to the power cylin-
der.
SST 09620-10100-71
(1) Rear cover
(2) Staking

Note:
Coat liquid seal on the threaded portion of
the power cylinder rear cover.

Staking the Rear Cover LAQSZ-34

6. Install the power steering rear end and power steering end.
See the illustration below for the installed dimensions.

Power Cylinder Assembly Dimension

- 323 -
INSTALLATION

Follow the steps for removal in the reverse order.

OIL PRESSURE TEST

Measure the power steerint re1ief pressure.

1. Lift the fork.

2. Remove the relief valve plug (PT 114) and


set the oil pressure gauge.
Measuring the Relief Pressure LAQII-31

3. Start the engine. Turn the steering wheel


fully clockwise and counterclockwise to
operate the relief valve, and measure the oil
pressure for each steering wheel position.
PS relief pressure:
Standard:
1 15 -- 125 kg/cm2 ( 1635 -- 1778 psi)

DRAG LINK
ADJUSTMENT

1. Adjust the drag link end screwed-in depths to satisfy the dimensions specified below.

C
L (Actual length)
I-

Vehicle model Actual length ( L ) mm (in.) Reference (B) mm (in.)


3.25,3.5 ton 1660 + 2 (65.35 + 0.079) 60 (2.36)
E3.5,4.0, 4.5 ton 1861 k 2 (73.27 i. 0.079) 63 (2.48)

Drag Link End ~ s s e m b'~imension


l~ LAQM 157

- 324 -
BRAKE

Page
GENERAL ........................................ 8-2
SPECIFICATIONS ................................ 8-4
FRONT BRAKE ................................... 8-5
COMPONENTS ................................ 8 - 6
REMOVAL ..................................... 8 -7
INSPECTION ................................... 8-11
ASSEMBLY .................................... 8 - 1 3
AIR BLEEDING ................................. 8-16
AUTOMATIC ADJUSTER OPERATION TEST ..... 8 - 1 7
BRAKE ADJUSTMENT AND BRAKING FORCE
INSPECTION ................................... 8-18
BRAKE BOOSTER ................................ 8-19
TROUBLESHOOTING ........................... 8-19
COMPONENTS ................................ 8-20
REMOVAL ..................................... 8-22
DISASSEMBLY ................................. 8-23
INSPECTION ................................... 8-26
ASSEMBLY 8 -2 8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a .

INSTALLATION ................................. 8-31


PARKING BRAKE ................................ 8-32
COMPONENTS ................................ 8-32
TIPS ON SERVICE OPERATION ................. 8-33
ADJUSTMENT ................................. 8-34
BRAKE PEDAL ................................... 8-35
COMPONENTS ................................ 8-35
ADJUSTMENT ................................. 8-36
GENERAL

Foot Brake System Diagram (Clutch Model) LAOM33

&J Brake wheel cylinder

Foot Brake System Diagram (Torque Converter Model)

- 326 -
Parking Brake System Diagram
SPECIFICATIONS
L

ltem Model 3.25,3.5 ton models E3.5,4.0,4.5 ton models

Internal expanding hydraulic brake


Foot brake
TYpe for two front wheels
Parking brake Internal expanding mechanical toggle type brake
Foot brake type Duo servo brake
Brake drum diameter mm (in.) 317.5 (12.5)
Material Resin mold
Dimensions mm (in.) 343.6 x 60 x 9.3 343.6 x 75 x 9.1
Brake lining (length x width x thickness) (13.53 x 2.36 x 0.37) (13.53 x 2.95 x 0.36)
-

206 (31.9) x 2 sheets 258 (40.0) x 2 sheets


Area cm2 (in 2 )
x 2 wheels x 2 wheels
Wheel cylinder diameter mm (in.) 31.75 (1.25)
Wlaster Diameter mm (in.) 25.4 (1.OO)
cylinder
piston Full stroke mm (in.) 28 (1.10)
Power piston
mm (in.) 25.4 (1.OO)
diameter
Brake
booster Reaction Diameter mm (in.) 16 (0.63)
piston Full stroke mm (in.) 29.5 (1.I6)
Servo ratio 3.5 4.5
Maximum oil pressure for servo
(power re1ief pressure) 110 (1564) 130 (1849)
kg/cm2 (psi)
Oil to be used Hydraulic oil IS0 VG32
1
FRONT BRAKE

Front Brake LAQL~O

Wheel Cylinder Sectional View

- 329 -
COMPONENTS (Brake Components)

01 (RH)
01 (LH)
I
r-- --I
10 1 OK=(INCL.@) I

I --.,
I

I
A
.- I

r
II
--

%3
%.;

'@
/

(RH)
L -- AY (LH)
- -- J

01 Brake ASSY, RH 51 Spring, anchor to shoe


02 Brake ASSY, LH 53 Ring, parking lever retaining
10 Cylinder ASSY, wheel AB Cover, hole
1 OK Cylinder O/H kit, wheel AF Lever SUB-ASSY, parking
11 Screw ASSY, adjusting, RH AL Screw, breather
12 Screw ASSY, adjusting, LH AR Link
20 Shoe SUB-ASSY AT Lever, actuator
21 Shoe SUB-ASSY AX Spring, lever return, RH
32 Piston SUB-ASSY, wheel cylinder AY Spring, lever return, LH
33 Cable & fitting SUB-ASSY AZ Bolt, shoe return spring
40 Boot, wheel cylinder BB Ring, 0
41 Cup, wheel cylinder piston BC Bolt, parking lever
41A Ring, back up (For cylinder piston cup) BD Sheave, parking brake cable
42 Lever, automatic adjustment, RH BE Retainer, parking brake cable
43 Lever, automatic adjustment, LH B Ring, retaining
45 Spring, shoe hold down BJ Link, automatic adjuster, upper
46 Cup, shoe hold down BK Lever, automatic adjuster
47 Spring, adjuster BL Lever, parking
48 Pin, shoe hold down

Brake Components

- 330 -
8-7

REMOVAL

Caution:
0 There are 2 kinds of brake removal method, the method t o remove the brake ASSY and the
method to disassemble the brake sequentially on the vehicle. For example, the latter is used to
replace the brake shoe, etc. with a new one, and the former is used to replace the backing plate,
etc. with a new one. Select either of these two methods according t o the repair operation.
0 The method to disassemble the brake on the vehicle will be described below.

0 See the Front axle removal and disassem-


bly section for the brake ASSY removal.
Refer to this section for the sub-sequent
disassembly, because it is almost the same
as this disassembly procedure.

Removing the Brake ASSY ~026-28

1. Loosen the front wheel hub nut.

2. Jack up the vehicle front.

3. Remove the front wheels.

4. Remove the brake drum.

Note:
Remove the brake drum by using 2 service
bolts ( M I 4 X 1.5 pitch).

~emovin
Brake
~ Drum ~ ~ 2 2 - 1 6

5. Remove the shoe return spring.


( 1) Anchor t o secondary spring
( 2 ) Anchor to primary spring

Note:
0 Hook a wire t o the spring and remove it
forcibly with a screwdriver.
0 (Reference) when removing the brake
ASSY, the following SST can be used:
SST 0971 7-20010

Removing the Return Spring LAQ~~-20.25-23


(3) Adjuster spring

Note:
Hook a wire to the spring and remove it with
a screwdriver forcedly.

Removing the Adjuster Spring LAQ~~-22

Remove the shoe hold spring.


(I) Shoe hold water.
SST 09510-31960-7 1

Note:
Three shoe hold springs (the small, large and
middle springs from top to bottom) are
mounted on the shoe on one side. To re-
move the large and middle (the upper and
lower springs), pay special attention because
it is difficult to set the SST to them stably.

Removing the Shoe Hold Spring 1.~022-23


(2) Shoe hold spring
(3) Shoe hold pin

7. Remove the adjuster.

Removing the Adjuster ~~022-27

8. Remove the brake shoe.


(1) Brake shoe (secondary)
(2) Brake shoe (primary)

Removing the Brake Shoe ~~022-28


9. Disassemble the brake shoe (secondary).
(1) Cotter pin and washer
(2) Adjuster lever link
(3) Adjuster lower link
(4) Automatic adjuster lever
(5) Lever return spring
(6) Adjuster upper link
(7) Brake shoe

Disassembling the Brake Shoe 1~~23-3

10. Remove the wheel cylinder ASSY.


(1) Disconnect the brake piping.
(2) Set bolt
(3) Wheel cylinder ASSY.

Removing the Wheel Cylinder 1~~22-32

11. Disassemble the wheel cylinder ASSY.


(1) Boots
(2) Piston
(3) U-packing
(4) Backup ring
(5) O-ring
(6) Snap ring
(7) Baffle plate

Disassembling the Wheel Cylinder LAG~O-27

12. Disconnect the parking brake cable.

Disconnecting the Parking Cable LAG~E-22

- 333 -
13. Remove actuator lever.
(1) Loosen the lock nut.
(2) Snap ring
(3) Actuator lever

Remwing the Actuator Lever ~ ~ 5 8 - 2 4

Removing the Snap Ring uG58-25

(2) Parking brake lever ASSY.

Removing the Parking Lever ASSY 1.~068-28

15. Disassemble the parking brake lever ASSY.


(1) Parking cable lever
(2) Snap ring
(3) Parking cable
(4) Cable sheave
(5) Cable retainer
(6) Pin

Disassembling the Parking Lever ASSY ~ ~ 5 8 - 3 5


INSPECTION

I . Wheel cylinder inspection


(1) Damage, wear and rust of the cylinder
inside
(2) Clogging of the oil hole
(3) Damage of the breather plug
(4) Damage and deterioration of the boots
(5) Damage of the baffle plate and clogging
of orifice
(6) Wear and damage of the piston
(7) Damage and fatigue of the U-packing Inspecting the Wheel Cylinder LAG~O-26
and O-ring
(8) Damage of the backup ring

Note:
On overhaul, replace the old seals with new
ones.

Inspecting the Wheel Cylinder Piston LAG~O-20

Brake drum inspection


(1) Uneven wear, tapering and streaks on
the brake drum inside
Inside diameter:
317.5 mm (12.50 in.)
Correction limit:
319.5 mm (12.58 in.)

Brake shoe inspection


(1) Wear, damage, peeling and attached oil
of the brake shoe lining
Lining thickness standard:
Inspecting the Brake Drum LAQ~~-10
3.25 ton and 3.5 ton models:
9.3 mm (0.37 in.)
E3.5 ton, 4.0 ton and 4.5 ton models:
9.1 mm (0.36 in.)
Lining service limit:
3.25 ton and 3.5 ton models:
4.3 mm (0.17 in.)
€3.5 ton, 4.0 ton and 4.5 ton models:
4.3 mm (0.17 in.)
(The thickness dimension does not in-
clude the rim thickness.)
(2) Bend, wear and damage of the brake
shoe
inspecting the Brake Lining

- 335 -
Spring link and lever inspection
(1) Deformation and fatigue of the shoe re-
turn spring
(2) Deformation and fatigue of the adjuster
spring
(3) Deformation and fatigue of the shoe
hold spring
@ Upper (small):
Free length: 25.4 mm (1.0 in.)
@ Middle (targel:
Free length: 43.7 mm (1.72 in.)
@ Lower (middle): inspecting the Spring ~ ~ 2 3 - 6
Free length: 27.8 mm (1.09 in.)
@ Damage and deformation of the
hold washer link
Deformation and fatigue of the adjuster
lower link
Fatigue of the lever return spring
Damage and wear of the adjuster lever
link
Deformation and damage of the adjuster
upper link
Damage of the automatic adjuster lever
and wear of the adjuster meshing part

Inspecting the Link and the Lever LAQZ~-4

5. Adjuster inspection
(1) Wear, damage and deformation of the
teeth
(2) Wear and rotational conditions of the
threaded part

Inspecting the Adjuster ~~023-7

Parking brake inspection


(1) Bend, deformation and crack of the
cable lever
(2) Deterioration and elongation of the
cable
(3) Wear and damage of the cable sheave
(4) Deformation and damage of the cable
retainer
(5) Damage of the pin and wear of the
spline
(6) Damage and bend of the actuator lever
and wear and damage of the spline
Inspecting the Parking Brake (1 ) ~ ~ 5 8 - 3 6
4. Connect the parking brake cable.
( 1 ) Pin
(2) Washer
(3) Cotter pin

5. Assemblethewheelcylinder.
(1) Baffle plate
(2) Snap ring
(3) Assemble the O-ring, backup ring and U-
packing to the piston. lnsert the result- Connecting the Parking Cable LAGSS-9
ing assembly in the cylinder.

Note:
Before assembly apply hydraulic oil to these
parts sufficiently.

(4) Boots

Install the wheel cylinder ASSY.


(1) Wheel cylinder ASSY.
(2) Set bolts
3.25 ton and 3.5 ton models:
T = 7.1 -- 9.6 kg-m (51.3 -- 69.4 ft-lb)
Assembling the Wheel Cylinder LAG~O
17-
(Upper 2 positions)

Installing the Wheel Cylinder ~ ~ 2 2 - 3 2

(3) Connect the brake piping.

Assemble the brake shoe (secondary).

Note:
Before assembly, apply non-melt lub to the
rotational shaft (shown by the arrow) of the
adjuster lever link.

Assembling the Brake Shoe

- 338 -
8. lnstall the brake shoe and adjuster.
(1) Apply non-melt lub to the part (shown
by the arrow).
@ 3 positions on secondary shoe
@ 3 positions on primary shoe
@ 6 positions on backing plate

Note:
Apply non-melt lub to the brake shoe rim
and the backing plate sliding part.

Applying Grease ~~023-12

@ Threaded part and washer of the


adjuster screw

(2) Brake shoes (primary and secondary)


and ajuster
@ Brake shoe
@ Hold pin
@ Hold washer
@ Hold spring
@ Hold washer
SST 09510-31960-7 1
@ Adjuster
Applying Grease 1.~020-6

Note:
Tighten the threaded part of the adjuster
fully to decrease i t s full length to the mini-
mum. Install the adjuster together with the
brake shoe and engage the notch of the ad-
juster lever to the gear.

Installing the Brake Shoe ~~023-13

9. Install the shoe return spring.


(1) Adjuster spring

Note:
0 Hook a wire to the spring and guide the
spring to the spring hook hole with a
screwdriver to install it.
0 Follow the assembly order correctly.

Installing the Adjuster Spring ~~023-14


(2) Anchor t o primary spring
(3) Anchor to secondary spring
SST 097 18-20010

Installing the Return Spring LAO.23-16

Installing the Brake Drum LAOZZ-17

30 -- 33 kg-m
Single tire
(212 -- 238 ft-l b)

l nside
30
(212
- 35 kg-m.
253 ft-lb)
Double tire
35 -- 40 kg-m
Outside
-
(253 289 ft-l b)
Tightening the Hub Nuts
13. Release brake air and adjust the brakes.
AIR BLEEDING

1. Bleed the air from the wheel cylinder.

Note:
0 Two operators are required for air release
operations.
0 Start the engine and loosen the breather
plug with the brake pedal depressed.
When the bubbles are not observed any
longer in hydraulic oil flowing out,
tighten the breather plug.
Bleeding Wheel Cylinder Air LAQ27.26
AUTOMATIC ADJUSTER OPERATION TEST

Automatic Adjuster Operation Sequence LAQS132

Note:
Operate the parking brake lever with the brake drum removed to check the adjuster operation.

1. Push and pull the parking brake lever.


(1) When pulling the parking brake lever, the adjuster lever must be engaged with the next tooth of
the adjuster screw.
(2) When setting the parking brake lever to the original position, the adjuster lever feeds the screw by
one tooth and returns to the original position.

2. When the operation is abnormal, check the


following points:
(1) The adjuster lever must be positioned
with respect to the adjuster screw as
shown in the right figure.

Note:
When the meshing part of the screw of the
adjuster lever wears or i s deformed, the pro-
per engagement is impossible and the adjust-
ment screw cannot be adjusted.

After test, decrease the adjustment screw


length to the minimum.

LAQ25-24, LAQSI 33
Lever and Screw
BRAKE ADJUSTMENT AND BRAKING FORCE INSPECTION

Brake Adjustment

Note:
When disassembling repairing and replacing the brakes, be sure to adjust the brakes.

1. Advance and back the vehicle repeatedly to adjust the clearance between the brake drum and the
brake shoes.

Note:
0 Forward and backward the vehicle repeatedly in a short distance and apply the foot brake to stop
it.
0 Repeat the forward motion and the backward motion as often as possible.
0 The auto adjuster operates automatically by repetition of braking operation. Finally the clearance
between the brake shoe and brake drum is adjusted to the following value:
3.25, 3.5 ton model: 0.25 -- 0.35 mm (0.0098 -- 0.01 38 in.)
(Clearance on one side)
E3.5, 4.0, 4.5 ton model: 0.3 -- 0.5 mm (0.012 -- 0.020 in.)
(Clearance on one side)
0 When the brake operation is uneven or the braking force is insufficient, remove the brake drum to
check improper adjuster operation, insufficient lining contact, foreign matter adhered to the lining
brake oil (hydraulic oil) leakage, etc.

Braking Force Inspection

2. Check the braking force with a brake tester or the running test.

Braking distance (under no-load condition)

3.25 -- 4.5 ton model


Brake initial speed
19 (11.8)
kmlh (mph)

Stop distance 5.0 (197)


m(in.)
i
BRAKE BOOSTER

Master cylinder piston

Power piston Control valve Reaction piston

Brake Booster Section

TROUBLESHOOTING
Phenomenon Possible cause Corrective action
Oil leak from hydraulic piping or insufficient oil Repair or oil
level in tank supply
l nsufficient or Damaged reaction piston O-ring Replacement
delayed braking Foreign matter trapping by piston Cleaning or repair
Increased play caused by loosened clevis lock nut Clevis adjustment
Air entrance in wheel cylinder circuit Air bleeding
Spool holding due t o loosened clevis lock nut Adjustment
Brake dragging Foreign matter trapping by spool Cleaning and
correction
i

Caution:
When any of the above phenomena occurs, do not disassemble the brake booster immediately but
check the oil pressure between the brake booster and wheel cylinder. I f the oil pressure i s insufficient,
check the brake booster reaction piston stroke and pump pressure rise. Disassemble and inspect the
brake booster only when it is found to be the cause.
COMPONENTS

01 K Booster O/H kit, brake AM Cup, cylinder DV Spring


26 Piston SUB-ASSY, power AS Bolt DZ Spool, flow divider
27 Valve SUB-ASSY, control AT Gasket EA Piston, reaction
28 Seat SUB-ASSY, control valve AV Gasket EB Spring, relief valve
29 Piston SUB-ASSY, master cylinder AW Ring, 0 EC Piston, reaction
30 Guide SUB-ASSY, reaction piston BA Ring, 0 ED Spring, valve return
31 Rod SUB-ASSY, push BB Ring, snap EF Guide, reaction piston
40 Spring, compression BI Union EG Cup, cylinder
61 Boot CI Ball, steel EH Clevis, push rod
AA Pin CZ Plug El Rod, push
AB Ring, snap DA Spring EJ Ring, snap
AC Gasket DB Plug EK Ring, snap
AD Spring DC Pin EL Ring, snap
AG Ring, snap DD Ring,O EM Ball
AH Washer DE Ring,O EN Valve, outlet check
AJ Gasket DF Ring, 0 EO Bolt, union
AL Nut DU Plug EP Filter

Brake Booster Components

- 344 -
-

22 Pipe SUB-ASSY, Brake, RH No. 1


23 Pipe SUB-ASSY, Brake, LH No. 1
24 Pipe SUB-ASSY, brake, RH No. 2
25 Pipe SUB-ASSY, brake, LH No. 2
31 Pipe SUB-ASSY, valve to steering
32 Pipe SUB-ASSY, return, No. 1 (Valve to tank)
33 33 Pipe SUB-ASSY, return, No. 2 (Valve to tank)
BG Hose
CT Hose

Brake Pipe Components (Clutch Model) LA OM^^

22 Pipe SUB-ASSY, Brake, RH No. 1


23 Pipe SUB-ASSY, Brake, LH No. 1
24 Pipe SUB-ASSY, brake, RH No. 2
25 Pipe SUB-ASSY, brake, LH No. 2
31 Pipe SUB-ASSY, valve to steering
32 Pipe SUB-ASSY, return, No. 1 (Valve to tank)
33 Pipe SUB-ASSY, return, No. 2 (Valve to tank)
BJ Cover, brake pipe, LH
CT Hose

Brake Pipe Components (Torque Converter Model)

- 345 -
REMOVAL

1. Remove the toe board.

2. Disconnect the brake booster piping.

Disconnecting the Brake Booster Piping 1.~028-26

3. Remove the brake booster.


(1) Brake booster set bolt
(2) Remove the bolt for connection with
the clutch booster (in clutch model
only).

Removing the Set bolt u~28-29

(3) Brake booster

Removing the Brake Booster ~Ao28-31

4. Remove the push rod.


(1) Brake link set bolt

Removing the Link Set Bolt 1~~29-2


( 2 ) Brake link with push rod
(3) Brake link bush
(4) Spacer

Removing the Brake Link ~~029-4

(5) Disconnect the booster push rod from


the brake link.
@ Cotter pin
@ Washer
@ Pin
@ Push rod

Removing the Push Rod ~~064-28

DISASSEMBLY

1. Remove the boot.

Removing the Boot ~~042-5

2. Remove the reaction piston & power piston.


(1) Snap ring

Removing the Snap Ring ~~042-7


Removing the Piston ~~042-8

3. Remove the reaction piston.


(1) Snap ring
(2) Reaction piston
(3) Plate washer
(4) Reaction piston guide

Removing the Piston Guide 1.~042-9.10

(5) Snap ring


(6) Reaction piston

Caution:
Disassemble only when the reaction piston
or cylinder cup i s found defective.

Removing the Reaction Piston ~~042-11

Remove the master cylinder piston.


(1) Bolt and gasket
(2) Apply a cloth to the tip end of a plain
screwdriver and push the master cylin-
der piston while holding it.
( 3 ) Rotate the master cylinder by half turn,
and extract the piston after the pin fix-
ing the piston falls down.

Removing the Piston

- 348 -
5. Remove the flow divider spool.
(1) Snap ring
(2) Plug
(3) Spring
(4) Flow divider spool

Removing the Divider Spool ~~042-13

6. Remove the outlet check valve.


(1) Plug
(2) Gasket
(3) Outlet check valve
(4) Spring

Removing the Check Valve ~~042-14

7. Remove the check ball.


( 1 Plug
(2) Set bolt
(3) Check ball

Removing the Check Ball ~~042-'17

8. Remove the power piston.


(1) Use a wire to remove the pin connecting
the reaction piston.
Push the control valve seat with a round
bar during this operation.
(2) Reaction piston
(3) Control valve seat
(4) Valve return spring
(5) Relief valve spring

Removing Reaction Piston LA041-16


9. Remove the control valve.
(1) Snap ring
(2) Piston plug
(3) Spring
(4) Control valve

Removing the Control Valve ~ ~ 0-14


4 1

INSPECTION

Caution:
Wash each part with new hydraylic oil, and
inspect the following points. Replace any
defective part.
I f the cylinder body, piston or valve is defec-
tive, replace as SUB-ASSY.

1. Booster body inspection


(1) Extreme damage, uneven wear and rust-
ing on spool sliding surface.
(2) Cracks, damage and deformation of ~~042-20
body

Master cyl inder piston SU B-ASSY inspection


(1) Wear, damage and deformation of pis-
ton sliding surface
Wear limit: 0.032 mm (0.0013 in.)
(Diametrical clearance)
(2) Damage and wear or cylinder cup

Caution:
When replacement is necessary, always re-
place the piston SUB-ASSY.
Piston SUB-ASSY Inspection 1.~042-2s

Power piston and valve SUB-ASSY inspec-


tion
(1) Scuffing and damage of sliding part
Wear limit: 0.032 mm (0.0013 in.)
(Diametrical clearance)
(2) Damage and wear of seal and O-ring
(3) Deformation and fatigue of spring

Caution:
Always replace the piston SUB-ASSY or
valve SUB-ASSY.

Piston and Valve SUB-ASSY Inspection ~~042-24

- 350 -
Reaction piston related parts inspection
(1) Scuffing and damage of piston sliding
surf ace
(2) Damage and wear of seal and valve seat
(3) Damage and deformation of control
valve seat

Caution:
Always replace the valve & valve SUB-ASSY
when the seal or O-ring of the control valve
seat is defective.

Reaction Piston Related Parts lnspection


(4) Deformation and fatigue of spring
(5) Damage and wear of cylinder cup

5. Outlet check valve inspection


( 1 ) Damage and deformation of check valve
(2) Deformation and fatigue of spring

Check Valve Inspection ~~042-18

6. Flow divider spool inspection


( 1 ) Scuffing and damage of sl iding surface
(2) Deformation and fatigue of spring
(3) Clogging of orifice
(4) Damage and wear of hole plug and 0-
ring

Flow Divider,Spool Inspection 1.~042-19

Check Ball Inspection ~~042.17


reaches the seat surface.
Installing the Check Ball (1 )
( 2 ) lnstall the bolt and gasket, and check

-
if the ball moves.
T = 0.8 1.2 kg-m (5.78-- 8.66 ft-lb)

- -
( 3 ) lnstall the plug and gasket.
T = 2.7 3.5 kg-m (1 9.5 25.3 ft-lb)

Installing the Check Ball (2) ~~042-31

2. Assemble the outlet check valve.


(1) Check there is no clearance at the check
valve slit.
lnstall the spring to the valve and insert
them into the plug.
( 2 ) l nstall the gasket to the plug, and install
them to the body.
T = 5.3 -- 8.4 kg-m (38.3-- 60.7 ft-lb)

Assembling the Check Valve LA042-32

lnstall the flow divider spool.


( 1 ) Insert the spool into the body.
( 2 ) Make sure that it is smoothly inserted
by hand and moves lightly, and push i t
with the spring.
(3) lnstall tt?eO-ring to the hole plug, insert
them into the body against the spring
force, and install the snap ring.

Installing the Flow Divider Spool 1.~042-19

- 352 -
Install the master cylinder pinston SUB-
ASSY.
(1) Fix the body in a vise with the pin hole
on the rear side facing upward.

Caution:
For the clutch model, do not damage the oil
path to the clutch booster when fixing in the
vise.

(2) lnsert the return spring in the cylinder,


and align the piston slit groove with the
Installing the Piston (1 ) ~ ~ 0-24
4 1
vertical axis of the body (rear pin hole
center line).
Slowly insert the piston SUB-ASSY into
the cylinder.
Peep through the body pin hole and fur-
ther push the piston into the body until
the slip groove appears.
Insert the pin surely through the piston
slit groove into the body pin insertion
hole.
l nstall the bolt and gasket.
T = 0.8 -- 1.2 kg-m (5.78 -- 8.66 ft-lb)

Installing the Piston (2) LA041-7

5. Install the control valve.


( 1) lnsert the control valve with the spring
into the power piston.

Installing the Control Valve (1) LA041 -13

(2) Install the O-ring to the piston plug, in-


sert them into the power piston, and fix
them by the snap ring.

Installing the Control Valve (2) L A O ~ -1


I 4
6. Install the reaction piston.
(1) Install the O-ring to the reaction piston.
(2) lnsert the control valve seat into the re-
action piston.

Installing the Control Valve L A O ~ -1


I 5

(3) lnsert the relief valve spring into the re-


action piston.
(4) Install the valve return spring to the re-
action piston. Match the direction of
the pin holes on the reaction piston
valve seat, and push the piston slowly
into the valve.
(5) Peep through the piston pin hole and
further push the reaction piston in until
the valve seat pin hole appears.
(6) lnsert the pin without protustion from
the piston outer surface.
Installing the Reaction Piston ~ ~ 0-147 1

lnstall the power piston.


(1) lnsert the valve return spring.
(2) lnsert the reaction piston into the
power piston.
(3) Put the plate washer in from the side
and fix by using the snap ring.

Installing the Power Piston ~ ~ 0 4 4 - 3

lnstall the reaction piston guide.


(1) Coat silicone grease on two types of
cylinder cups, and install them to the
piston guide in correct directions.
(2) lnsert the piston guide into the reaction
piston, and install the snap ring.

lnstalling the Piston Guide

- 354 -
9. Install the power piston & reaction piston.
(1) Insert the power piston & reaction pis-
ton into the cylinder.
(2) Piston guide
(3) Snap ring
(4) Push the reaction piston with a hand to
check its smooth stroke.

Installing the Pistons LAOM-9

10. Install the boot.

Installing the Boot ~~042-5

INSTALLATION

The installation procedure is the reverse of the removal procedure.

Caution:
o Carefully prevent the O-ring at the brake booster and clutch booster joint from being caught.
Connection bolt tightening torque:
T = 3.5 -- 4.5 kg-m (25.3 -- 32.5 ft-lb)
0 Bleed air from the brake system. (See page 8-1 6.)
0 Adjust the brake pedal. (See page 8-36.)
PARKING BRAKE
COMPONENTS

10A Spring, compression


10B Knob SUB-ASSY, parking brake AF Pin, w/ hole
24 Cable SUB-ASSY, parking brake, No. 1 AL Pin, w/ hole
25 Cable SUB-ASSY, parking brake, No. 2 BL Plate, parking brake
27 Clevis SUB-ASSY EB Clamp, brake cable
28 Lever SUB-ASSY, parking brake EX Knob
32 Link SUB-ASSY, parking brake, No. 1 EY Ball
36 Rod SUB-ASSY, parking brake FC Hook
37 Knob SUB-ASSY, parking brake release rod FD Rubber, parking brake
55 Bracket SUB-ASSY, parking brake FS Stopper

Parking Brake components

- 356 -
TIPS O N SERVICE OPERATION

Parking Brake Lever Service Points LAQM58

1. The removal and disassembly procedures for the parking brake lever ASSY are the same as those for
the 5FG20 series.

2. Parking brake knob (A) removal and installation


(1 ) Remove the lever.
(2) Immerse the knob in hot water (70 -- 8 0 " ~ for
) 10 -- 20 seconds. (Never use hot water exceeding
1OO"C.)
(3) Extract the knob downward in the figure.
(4) The installation procedure is the reverse of the removal procedure.

3. Coat grease on the moving surface ( 6 ) .

4. Fill MP grease in the compression spring mounting portion (C).

5. Coat seal lock agent (Locktite #271 or equivalent) on the threaded portion (D).

6. After fully tightening the knob (E), loosen i t by a half turn. Then tighten knob (F) to the specified
torque.
Knob (F) tightening torque:
T = I .O -- 1.6 kg-m (7.23 -- 11.6 ft-lb)
ADJUSTMENT Clearance

or more
1. Parking brake cable adjustment
( 1 ) Be sure that the parking cables are
correctly installed to the clamps.

Matching marks

Adjusting the Parking Cable (Brake Side) LAQSI 3 4

( 2 ) Adjust distance ( R ) between the lever


side cable adjuster fulcrum (A) to link
pin ( B ) to the following value.
R = 70 -- 75 mm (2.76 -- 2.95 in.)

Adjusting the Parking Cable (Lever Side) LAQS159

Measuring the Lever Operating Force LAQ~S-2

Adjusting the Lever Operating Force ~ ~ 0 4 5 - 4

- 358 -
8-35

BRAKE PEDAL
COMPONENTS

20 Pedal SUB-ASSY, brake


20A Bushing (For brake pedal)
21 Link Sub-ASSY, brake, No. 2
23 Link SUB-ASSY, brake No. 2
23A Bushing (For brake link)

43 Spring, torsion (For pedal return)


AA Spacer
43 AE Spacer
AK Pin, w/ hole
20
AQ Bolt

Brake Pedal components (Clutch Model) L A Q M ~ ~

12 w i r e ASSY, inching
20 Pedal SUB-ASSY, brake
20A Bushing (For brake pedal)
21 Link SUB-ASSY, brake, No. 1
23 Link SUB-ASSY, brake, No. 2
23A Bushing (For brake link)
28 Link SUB-ASSY, inching
34 Pedal SUB-ASSY, inching brake
34A Bushing (For inching brake pedal)
40 Pad, pedal
43 Spring, torsion (For pedal return)
57 Spring, torsion (For pedal return)
AA Spacer
AE Spacer
Al Pin, w/ hole
AK Pin, w/ hole
AQ Bolt
ET Spacer

Brake Pedal components (Torque Converter Model)


ADJUSTMENT

1. Brake pedal height and play adjustment


(1) Adjust the brake pedal height from the
toe board top surface to the following
value by turning the pedal stopper bolt.
Pedal height (without pad):
134 mm (5.28 in.)
Pedal height (with pad):
140 mm (5.5 1 in.)

140mm (55 in.)

" Pedal play


Up to ' 8 8 Sep. 1 0 -
1 5 mm ( 0 . 3 9 -
0 . 5 9 in.)
From ' 8 8 Oct. 5 -
8 mm ( 0 . 2 0 -
0 . 3 1 in.)

Brake Pedal Adjustment

(2) Adjust the brake booster push rod


length to make the brake pedal play
satisfy the value shown below. Also ad-
just the push rod play to the value
shown below.
Pedal play:

-
Up to '88 Sep.
-
10 15 mm (0.39 0.59 in.)
From '88 Oct.
5 -- 8 mm (0.20 -- 0.31 in.)
Push rod play:
1 - 2 mm (0.04 -- 0.08 in.)
Push Rod Play

I
(3) After the above adjustment, depress the
brake pedal fully and check the depress-
ed brake pedal height. \
\
Depressed brake pedal height: \
\
\
90 mm (3.54 in.) or more \
\

Floor clearance

Depressed Brake Pedal Height LAOS 160


2. lnching pedal height and play adjustment
(1) Adjust the inching pedal height from
the toe board top surface to the follow-
ing value by turning the pedal stopper
bolt:
Pedal height: 134 mm (5.28 in.)
Pedal height (with pad):
140 mm (5.51 in.)

(2) Adjust the inching vable adjusting nut


to make the torque converter inching
lever stroke satisfy the following value
at the point (C) where the inching pedal 134 mm (5.28 in.)
and brake pedal interlocked movement
starts.
lnching lever stroke: 8 mm (0.31 in.)
The pedal stroke ( A to C) at the time
becomes as follows:
Pedal stroke (reference): Adjusting nut
50 mm (1.97 in.)

(3) Check the pedal play (A t o 6 ) .


Pedal play (reference):
3 -- 6 mm (0.12 -- 0.24 in.)
Use the play between the inching lever
clevis and wire as the guideline for the Inching Pedal
pedal play.
Wire play (reference): I

0.5 mm (0.02 in.) lnching cable

F~
0.5
(Pedal
mmplay)
(0.02 in.)

Play between Clevis and Wire


BODY

Page
COMPONENTS .................................... 9-2
COMBINATION METER ............................ 9 -4
REMOVAL ...................................... 9-5
DISASSEMBLY ................................. 9-5
ASSEMBLY AND INSTALLATION ................ 9-6
BALANCE WEIGHT ................................ 9 - 7
REMOVAL ...................................... 9 - 7
COMPONENTS

28 Boot Cover
30 Toe-board SUB-ASSY, No. 1 Cover
AG Safety walk Spacer
AH Cover Rubber
AP Plug, hole Cover
BZ Grommet Floor SUB-ASSY, No. 1
CU Rubber Box SUB-ASSY, instrument panel
CW Rubber Packing
CY Rubber Silencer
DA Rubber Clip

Instrument Panel & Floor Components

- 364 -
COMBINATION METER

Hour meter
Air cleaner cleaning warning lamp
Engine oil pressure warning lamp
Charge warning lamp
Preheating indicator lamp
(diesel models: Standard in designated area)
Water temperature gauge
Sedimenter warning lamp (diesel models)
Fuel gauge
Fuel warning lamp (OK monitor: OPT)
Engine coolant level warning lamp
(OK monitor: OPT)
Battery electrolyte level warning lamp
(OK monitor: OPT)
Brake warning lamp (OK monitor: OPT)
Torque converter oil temperature gauge (OPT)

Combination Meter

- 366 -
REMOVAL

1. Removethecover.
( 1 ) Set screws
(2) Cover

Removing the Cover LAO 17-36

2. Remove the combination meter.


( 1 ) Set bolts (4 pcs.)
(2) Disconnect electrical wiring.
(3) Combination meter

Removing the Combination Meter ~~053-25

DISASSEMBLY

1. Remove the warning lamp.


(1) Turn the bulb w/ socket counterclock-
wise for removal.
(2) Remove the bulb from the socket.

Removing the Bulb w/ Socket ~~053-18

2. Remove the cover.


(1) Screws
(2) Cover

Removing the Cover

-
3. Remove the instrument panel box.
(1) Screws
(2) lnstrument panel box

Removing the Instrument Panel Box ~~053-20

4. Disassemble the combination meter ASSY.


(1) Set screws
(2) Hood
(3) Glass
(4) Case

Disassembling the Combination Meter ASSY 1.~053-23

(5) Set nuts


(6) Gauge ASSY
(7) Meter ASSY

Removing the Meter LAOI 24-4.5

(8) Set screws


(9) Plate

ASSEMBLE AND INSTALLATION

Reverse the disassembly and removal procedures.

Removing the Plate

- 368 -
BALANCE WEIGHT
REMOVAL

1. Remove the radiator cover.


( 1 ) Loosen the set screws.
(2) Radiator cover

Removing the Radiator Cover ~~0.29-12

2. Remove the balance weight.


(1) Weight set bolt
(Width across flats: 46 mm)
(2) Cap

~ e m o v i the
n ~ Set ~ o tand
t Cap LAQ~~-2.3

Weight (approx.)
Vehicle model
kg (Ib)
3.25 ton model 1920 (4234)
3.5 ton model 2220 (4895)
E3.5 ton model 2130 (4410)
4.0 ton model 2520 (5557)
4.5 ton model 2830 (6240) Removing the Balance Weight LAQ66-6
MATERIAL HANDLING SYSTEM

Page
HYDRAULIC PRESSURE PIPING ............... 10-2
HYDRAULIC CIRCUIT ......................... 10-3
CLUTCH VEHICLE HYDRAULIC
CIRCUIT (STD) ..............................
TORQUE CONVERTER VEHICLE
HYDRAULIC CIRCUIT (STD) .................
NATURAL DROP TEST .........................
NATURAL FORWARD TEST ....................
OIL LEAK TEST ................................
LIFT CYLINDER .............................
TILT CYLINDER .............................
HYDRAULIC PRESSURE PIPING (V mast)

Oil tank

Return filter

Hydraulic Pressure Piping Diagram


HYDRAULIC CIRCUIT
r

Clutch master

Clutch Vehicle Hydraulic Circuit (STD)

- 373 -
Brake wheel cylinder

Torque Converter Vehicle Hydraulic Circuit (STD)


NATURAL DROP TEST
1. Erect the mast vertically under the standard

- -
load conditions. Raise the forks by about 1
1.5 m (40 60 in.) and stop the engine.

Standard Load Conditions LAQMII~

2. Draw the standard line on the inner and the


outer masts. Measure the natural drop for 15
minutes.

Natural Drop Test ~0.70-26

NATURAL FORWARD TEST


1. Erect the mast vertically under the standard
load conditions. Raise the forks by about 50
cm (20 in.) and stop the engine.

Standard Load Conditions LAQMII~

Natural Forward Tilt Test LAQ~O-28


OIL LEAK TEST
LIFT CYLINDER

1. Erect the mast vertically under the standard

-
load conditions. Raise the forks by about 1
-
1.5 m (40 60 in.)

Tile the mast to the foremost position slow-


ly and stop the engine. After 5 minutes, dis-
connect the joint of the control valve to oil
tank hose. Apply a measuring cylinder to the
Standard Load Conditions UQMI 15
elbow to measure the oil leak amount for 1
minute.

-
Oil leak amount standard (at lift port) :
-
6 16 cc (0.37 0.98 cu.in.)

Note:
When the natural drop is great even through
the oil leakage amount is within the standard
value, the lift cylinder packing is defective.

Oil Leak Test (Lift) ~ ~ 4 6 - 4

TILT CYLINDER

1. Erect the mast vertically under the standard


load conditions. Raise the forks by about 50
cm (20 in.)

2. Stop the engine. After 5 minutes, disconnect


the joint of the oil control valve to oil tank
hose. Apply a measuring cylinder to the
elbow to measure the oil leakage amount for
1 minute.
Oil leakage amount standard (total lift and
tilt amount) : 14 -34 cc (0.85 - 2.08 cc.in.). Standard Load Conditions LAQMI 14

3 . Obtain the tilt port leakage value by subtract-


ing the lift port leakage value from the above
total leakage value.

Oil Leak Test ~ ~ 4 6 - 4


Bracket SUB-ASSY
Fork SUB-ASSY
Bracket SUB-ASSY, lift
Roller, lift (Upper, lower)
Ring, shaft snap (Upper, lower)
Roller, lift (Center)
Ring, shaft snap (Center)
Roller, side
Pin, fork stopper
Knob, fork stopper pin
Spring, fork stopper pin
Pin, spring (For fork stopper pin)
Pin, side roller
Shim (For side roller pin)
Cover, lift bracket roller
Plate, side
Bolt
Ring, snap
Collar

Lift Bracket Components (3.25-4.0 ton models)


20 Chain SUB-ASSY
20A Nut, chain adjust
20L Bolt kit, chain anchor, No. 2
20N Link kit, chain joint
34 Support
40 Wheel, chain
40A Ring, shaft snap (For chain wheel)
AC Clamp, chain anchor bolt
AH Cover, chain wheel
AN Nut, hexagon
AR Nut, lock
BW Bolt
CD Support
CE Clamp

Chain Components (V)

- 381 -
REMOVAL

Caution:
0 Check the operation of the mast and the related parts and the clearance between the rollers t o
check any defect correctly before removing the mast.
0 When removing the mast ASSY after removing the tilt bracket, it can be comparatively easily re-
moved.

Disconnecting the Chain ~~063-25.26

Disconnecting the Chain ~~063-35.36

Removing the Chain Wheel LAQ63-31.30


Remove the lift bracket.
(1) Erect the mast vertically. Raise the
inner mast until it comes off the lift
bracket.

Caution:
When raising the inner mast, pay attention
so that the slackened chain does not tangle
around the inner mast.

Remove the Lift Bracket 1.~063-33

4. Disconnectthehose.
(1) Lower the inner mast fully.
(2) Overflow hose
(3) High pressure hose

Disconnecting the Hose 1~047-5.7

Hook a wire to the mast hook and lift the


mast slightly .

Lifting the Mast LAQ~~-19

Stamp the match mark on the mast support


cap.

Stamping the Match Mark LAQ47-8


7. Remove the mast support cap.
(1) Set bolts
(2) Mast support cap

Removing the Mast Support 1.~047-11

"
ASSY with a new one, it is not necessary Matching Marks ~ ~ 6 3 - 1 1

Removing the Front Pin ~~063-12.15

9. Remove the mast ASSY.

Removing the Mast ASSY ~~0.47-20


Lay down the mast.
( 1 ) Lay the mast flat on wooden stands
with the mast tie beam side up so that
the inner mast can slide.

Caution:
0 Never lean the removed mast against the
wall, etc. Lay down it at the height as low
as possible.
0 Place the removed mast in a wide margin
in the up and down directions and the
mast sliding direction (about one mast
Laying-down the Mast ~047-34
length) to disassembly it freely.

DISASSEMBLY
- -
. - -
. . - -

1. Disconnect the hose.


(1) High pressure hose

Disconnecting the Hose LAQ47-36

2. Disconnect the cylinder rod end.


( 1 ) Set bolts

Removing the Set Bolts ~0.48-11

Disconnecting the Cylinder-Rod End ~~0.48-12.13


Removing the Set Bolts ~ 0 . 4 814
-

(2) Plate
(3) Shim
(4) Lift cylinder support

Removing the Lift Cylinder Support ~0.48-15.16

.Removing the Lift Cylinder 1.~048-18

5. Remove the lift roller.


( 1 ) Outer mast lift roller
(2) Shim

Note:
When the lift roller is firmly fit, use SST
09950-20017.

Removing the Lift Roller ~0.48-20


(3) Inner mast lift roller
(4) Shim

Note:
When the lift roller is firmly fit, use SST
09950-20017.

Removing the Lift Roller

6. Remove the mast strip.


(1) Mast strip
(2) Shims

Note:
Replace the mast strip when no oil is re-
tained.

Removing the Mast Strip 1.~048-2s

Removing the Outer Mast LAQ48-27


Inspecting the Mast LAQ~~-30

2. Lift roller inspection


(1) Wear, damage, play and rotational con-
ditions

Inspecting Lift Roller LAQ~B-31

3.25 -- 4.0 ton models

Application Item Dimension


Outside diameter Standard value 124.5 (4.90 )
Inner mast, lower section (2 pieces) mm (in) Limit value 123.5 (4.86 )
Outer mast, upper section (2 pieces) Insidediameter Standard value 45.0 (1.77 )
mm (in) Limit value 45.02 (1.772)
Outside diameter Standard value 124.5 (4.90 )
Lift blacket, upper central section mm (in) Limit value 123.5 (4.86 )
(4 pieces) Inside diameter Standard value 45.0 (1.77 )
mm (in) Limit value -
- 45.02 - (1.772)
124.5 (4.90 )
Lift bracket, lower section Limit value 123.5 (4.86 )
(2 pieces) Inside diameter Standard value 45.0 (1.77 )
Limit value 45.02 (1.772)
Outside diameter Standard value 93.3 (3.67 )
mm (in) Limit value 92.3 (3.63 )
Lift bracket, side roller (4 pieces) -
Inside diameter Standard value 35.0 (1.377)
mm (in) Limit valve 35.02 (1.378)
4.5ton model
Application Item Dimension
Outside diameter Standard value 164.5 (6.48 )
lnner mast, lower section (2 pieces)
mm (in) Limit value 163.5 (6.43 )
l nside diameter Standard value 45.0 (1.77 )
Outer mast, upper section (2 pieces)
mm (in) Limit value 45.02 (1.772)

Table of lift ro Iler O/S


3.25 -- 4.0 ton models
Application Item Dimension
lnner mast, lower section (2 pieces)
- Outside diameter
Lift bracket, upper section (2 pieces) Standard value 125.2 (4.93)
mm (in)
Lift bracket, lower section (2 pieces)

3. Mast strip inspection


(1) Damage, biting and deformation
(2) Wear

Caution:
Replace when oil pockets are won out.

Inspecting the Mast Strip ~0.48-32


11-14

ASSEMBLY

Caution:
0 Assemble each roller of the mast sequently while adjusting the shim according to the mast adjust-
ment standard.
0 Apply MP grease to the inner mast sliding face of the mast strip.

Select the lift roller shims.

Note:
0 Add the shims to stop the gap caused
after the mast clearance measurement.
0 Shim thickness: 0.5 and 1.0 mm (0.02
and 0.04 in.)

Insert the outer mast through the inner mast


lower part.

Note:
Selecting the Shims (Inner Mast Roller) 1.~048-24
Place a block under the outer mast side so
that the inner mast can slide as before disas-
sembly.

Install the mast strip.

Install the lift roller.


SST 09370-20270-71

Reverse the disassembly procedure for the


subsequent operations.

Selecting the Shims (Outer Mast Roller) 1~048.21

INSTALLATION

Reverse the removal procedure for installation.

Caution:
o Before assembly, apply MP grease to the mast support bushing and the tilt cylinder front pin.
0 When installing the mast support cap and the tilt cylinder front pin, confirm that the match marks.
0 When replacing the old mast ASSY outer mast, inner mast or lift cylinder with a new one, check
the uneven motion of the lift cylinder and adjust it, if necessary. See lift cylinder rod shim adjust-
ment section for the inspection and adjustment methods.
LIFT BRACKET
REMOVAL

Note:
0 When replacing the old lift bracket roller
with a new one or when adjusting the
shims, be sure to remove the bracket.
0 See Mast ASSY removal, paragraph 1
through 3 for the lift bracket removal
procedure.
Removing the Lift Bracket ~ ~ 6 3 - 3 3
1. Remove the lift bracket.

DISASSEMBLY

1. Remove the lift roller.

3.25 -- 4.0 ton models


(1) Snap ring
(2) Lift roller
SST 09950-20017
(3) Snap ring
(4) Upper lift roller
SST 09950-20017
Lift Roller (Upper, Central Section) ~~49-34.36
(5) Lift roller
t

Bottom recessed lift roller

Lift Roller (Lower Section) L A Q S ~ ~

4.5 ton model


(6) Snap ring
(7) Upper lift roller
SST 09950-20017
(8) Snap ring
(9) Lower lift roller
SST 09950-20017

Lift Roller (Upper Lower Section) LAQ~~-8.10

-391 -
2. Remove the side rollers.

3.25 -- 4.0 t o n models


(1 ) Set bolt
(2) Side roller ASSY

Removing the Side Roller LAO~O-4.5

4.5 t o n model
( 1 ) Set bolts
(2) Holder
(3) Shim
(4) Spacer
(5) Side roller shaft
(6) Side roller

Removing the Side Roller ~064-11.13

INSPECTION

1. Lift roller inspection


(1) Wear, damage, play and rotational con-
dition.

lnspecting the Side Roller


(3.25-4.0 ton models)

2. Side roller inspection


(1) Wear, damage, play and rotational con-
dition.
(2) Wear and damage of the side roller pin
or shaft.
(3) Damage of the holder (4.5 ton model)

ASSEMBLY AND INSTALLATION

Follow the procedure for Disassembly and Re-


moval in the reverse order.
lnspecting the Side Roller
(4.5 ton model)
CHAIN WHEEL AND CHAIN
REMOVAL

Note:
0 See Mast ASSY removal section, para-
graph 1 and 2 for the chain wheel remov-
al procedure.
0 See the Mast ASSY removal section, para-
graph 1 through 3 for the removal pro-
cedure up to the lift bracket removal of
the chain. See the paragraph 2 given be- ~emovin
the
~ Chain Wheel LAQ65-31
low for the subsequent operation.

I. Remove the chain wheel.


(1) Snap ring
(2) Chain wheel

2. Remove the chain (on the bracket side).


(1) Cotter pin (4.5 ton model)
(2) Adjust nut and lock nut
(3) Chain

Removing the Chain LAQ~O-28

INSPECTION

1. Chains inspection
(1) Expansion
SST 09631 -22000-7 1

Caution:
Check the chain expansion before removing
the chain from the vehicle.

Inspecting the Chain (1) LAQ~~-18

(2) Cracks, damage, or bending


(3) Defective link movement

2. Chain wheel inspection


(1) Cracks or damage
(2) Defective rotation, play, or noise in the
chain wheel bearings.

Inspecting the Chain (2) LAQSI-1


r
INSTALLATION

Follow the procedure for Removal in the reverse


order:

Caution:
0 Refer to the section under "Chain Adjust-
ing" to install the parts correctly.
0 Tighten the adjust nut in accordance with
the procedure for Tightening. The chain Chain anchor bolt
must be tightened correctly in parallel to
the chain wheel without torsion. Chain Installation

ADJUST NUT TIGHTENING PROCEDURE

3.25 -- 4.0 ton models

-----
7

H2000-H3700 H4000--
Lift bracket side Outer mast side

Adjust Nut Tightening Procedure (3.25-4.0 ton models) LAOS136

Lift bracket side Lift cylinder side

1. Tighten the lock nut at @ first at the posi- -


HZ000 3700
tion as shown at the correct dimension. 1. Tighten at @ and @ first.
T = 10- 15 kg-m (72- 108 ft-lb) T = 10- 15 kg-m (72- 108 ft-lb)

2. Then, tighten at @ . 2. Then, tighten at @ .

H4000 -
1. Same as steps 1 and 2 for the lift bracket
side.
4.5 ton model

7-------
3
i 0

@+
0 0

Lift bracket side Lift cylinder side

Adjust Nut Tightening Procedure (4.5 ton model) LAQSI 37

Lift bracket side Lift cylinder side

1. Tighten the anchor bolt at 0 and @ first 1. Tighten at @ and @ first.


at the position as shown at the correct T = 1 7 - 2 3 kg-m (122- 165 ft-lb)
dimension.
-
T = 17 23 kg-m (122 165 ft-lb)- 2. Then, tighten at @ .

2. l nstall the cotter pin. 3. Install the cotter pin.

3.25 - 4.0 ton models

Adjust Nut Tightening Procedure (3.25-4.0 ton models)

1. Fully fasten 0 to @ .

2. Fully fasten @ to @ .

Tighten 0 and 0 .
3.
-
T = 10 15 kg-m (72 - 108 ft-lb)
ADJUSTMENT

1. Place the vehicle on a flat ground, and put


the mast in upright position.

2. Operate the fork up and down several times


without load, and check that the tension in
the both chains is equal.

3. Adjust the chain with the adjust nut (at the


lift cylinder side) so the bottom of the fork
barely touches the ground without slack in Checking the Chain Tension ~~059-21
the chain.

Note:

QZ,)
Tire
0 Measure the distance between the fork
Inner mast
bottom and ground (dimension h) as
Lift bracket roller
shown in figure on the right. Fork
0 When the fork is at the position of the di-
mension h, the bottom of the l i f t bracket r-.

roller must not exceed the dimension A.


I ', '
A ,
0 When the fork i s a t the highest position, I

the distance between the chain wheel and /////////////////+//I/////////////////////////


h
the lift bracket side chain anchor must
not be less than the dimension B (refer-
ence value). Chain Adjusting with the Fork at
the Low Position

4. Check that the tension in the both chains is


equal.

5. Check that the specified lift height is obtain-


ed.

h A B
mm (in.) mm (in.) mm (in.)
3.25-4.0 0-5 40 110
ton models (0-0.2) (1.6) (4.3)
4.5 ton 0-5 59 75 Chain Adjusting with the Fork at the Highest ~~Qs139
model (0-0.2) (2.3) (3.0) Position (3.25-4.0ton models)

Note:
0 Dimension A is taken when h = 0.
0 Dimension B is a reference value.

Chain Adjusting with the Fork at the


Highest Position (4.0ton model)
- 396 -
4. Lower the forks to remove them. Removing the Forks

INSTALLATION

Follow the removal procedure in the reverse


order.

INSPECTION

1. Forks inspection
(1 ) Bend, crack and unaligned tips.
Fork bend limit: 15 mm (0.16 in.)
Fork tip alignment error limit: 10 mm
(0.4 in.)
Inspecting the Forks ~~0.59-28

Caution:
When the unaligned tip exceeds the limit,
check the bend of the single fork, play of
the fork installed part and the distortion of
the lift bracket finger bar.
the mast titled forward. Lift Bracket Raised Position
(3) Attach a wire to the backrest when ad-
justing the upper roller and to the finger
bar underside when adjusting the lower
roller, then raise up. -
(0.02 0.08 in.)

Important:
Stop raising just before the lift bracket
upper rollers comes out from the inner mast.

2. Adjustment in fore-and-aft direction.


(1) Insert the thickness gauge in the roller
and inner mast running surface and mea-
sure the clearance.
Specified Clearance
Specified clearance:

Adjusting in Fore-and-Aft Direction ~~61-34.38

(2) If incorrect, change t o an over sized roller. See " Lift bracket" heading for the replacement pro-
cedure.

Caution:
0 When changing to an over size, the clearance should be no smaller than 0.5 mm (0.0197 in.)
0 When changing to an over size, prior to installation, confirm whether it is slidable or not by moving
the lower portion of the mast with the over size roller, if not, the lower portion of the mast needs
to be adjusted with a grinder to make it slidable.
Adjustment in lateral direciton
(1) Mount a dial gauge on the inner mast.
(2) From the opposite side, press the lift
bracket against the inner mast with a
screw driver, align the dial gauge in con-
tact with the lift bracket side and set
the indicator t o "0".
(3) Insert a screw driver between the dial
gauge lift bracket side and the inner
mast, press the lift bracket lower rollers
against the inner mast.
(4) Measure the amount of shift in lateral
Adjusting in Lateral Direction (Lower Roller) wQ62-1
direction at the lower roller.

-
Specified shift:
0 0.5 mm (0-- 0.020 in.)
(5) If defective, take the following actions:
@ Screw in bolt @ fully to the lower
roller pin of the lift bracket.
@ Install lower lift roller @ .
@ Fix lower lift roller @ to bolt @ @ Bottom recessed lift roller
by snap ring @ .
@ Adjust the lower lift roller. Lift bracket
@ Lock bolt @ by nut @ .
@ Nut
4.5 ton model

Note:
Lift rollers among lift bracket rollers require
no adjustment because they are fixed by
snap rings.

Adjusting in Lower Roller LAQS~S

Bring into
contact

Outer
Measure with this rolling
surface in close contact

Bring into contact

0-0.5mm(0-0.020in.)

the roller is the


nearest)

Adjusting the Lift Bracket Rollers LAQS 143

- 399 -
LIFT BRACKET SIDE ROLLER
ADJUSTMENT

1. Preparation for adjustment


(1) Prepare the screwdriver, dial gauge and
wire.
(2) Widen the forks to the maximum and
tilt the mast forward slightly.
(3) To adjust the upper roller, apply a wire
to the backrest to lift it.
To adjust the lower roller, apply a wire
to the finger bar underside to lift it. Lift Bracket Raised Position lA~61-33

Note:
Do not project the lift bracket upper roller
beyond the inner mast.

Side roller measurement


(1) Set the dial gauge to the inner mast.
(2) Press the lift bracket side roller against
the inner mast with a screwdriver from
the side opposite to the side where the
dial gauge is set. Apply the dial gauge to
the lift bracket side face and adjust the
pointer to the "0" position.
Adjusting the Side Roller in the Right and LAQ~I-36
(3) Insert the screwdriver between the lift Left Directions
bracket on the side where the dial gauge
is set and the inner mast to press the lift
bracket side roller against the inner
mast.
(4) Measure the moving distance in the right
and left directions.
Moving distance:
-
0 0.5 mm (0-- 0.020 in.)

3. Shim adjustment

4.5 ton model


(1) When the side roller is defective, follow Adjusting the Side Roller in the Right and ~ ~ 6 2 - 1
Left Directions
the procedure given below.
Adjust the shims of the upper and lower
side rollers to distributing them t o the
right and left equally.
Shim thickness:
0.5 and 1.0 mm (0.02 and 0.04 in.)

Adjusting the Shims (4.5 ton model) ~ ~ 6 4 - 115


3 ,

- 400 -
Apply a wire to the inner mast lower tie Masts Raised Position
beam and lift it by a hoist, etc. for safety
operation.

lnner mast roller measurement


(1) Set the dial gauge to the outer rnast
inside.
(2) Press the inner mast roller against the
outer mast with a screwdriver from the
side opposite to the side where the dial
gauge to the inner mast inside and ad-
just the pointer to the "0" point.

Adjusting the Inner Mast Roller in ~ ~ 6 2 - 7


the Right and Left Directions
(3) Insert the screwdriver between teh inner mast on the side where the dial gauge is set and the
outer mast to press the inner mast roller against the outer mast.
(4) Measure the moving distance of the inner mast roller in the right and left directions.
Moving distance standard: 0 -- 0.8 mm (0 -- 0.03 in.)
(5) When the inner mast roller is defective, adjust the inner mast roller shims.

V, SV mast

Measure with this rolling


surface in close contact

\
Bring into conLact This roller

(0-0.03in.)

roller is the nearest)

LAQS1 44
Clearance between the Outer Mast and the lnner Mast Roller
Outer mast roller measurement
(1) Set the dial gauge to the outer mast.
(2) Press the inner mast against the outer
mast roller with a screwdriver from the
side opposite to the side where the dial
gauge is set to apply t o the dial gauge t o
the inner mast inside and adjust the
pointer t o the "0" position.
(3) Insert the screwdriver between the inner
mast on the side where the dial gauge is
set and the outer mast to press the inner
mast against the outer mast roller.
Adjusting the Outer Mast Roller ~ ~ 6 2 - 8
(4) Measure the moving distance of the inner
mast in the right and left directions.
Moving distance standard: 0 -- 0.8 mm (0-- 0.03 in.)
(5) When the outer mast roller is defective, adjust the outer mast roller shims.

V, SV mast
This roller

Measure with this rolling


surface in close contact

(0-0.03 in.)
(Position where the
roller is the nearest)

Clearance between the Inner Mast and the Outer Mast Roller LAQSI~~

Roller and shim adjustment

Note:
0 When the roller and the shims are judged
defective by the measurement, replace
them with new ones.
0 Adjust the roller and the shims with the
lift bracket removed. See Mast ASSY re-
moval paragraph 1 through 3 for the re-
moval procedure.

(1) Remove the lift bracket.


~ e r n o v i nthe
i Lift Bracket ~ ~ 6 3 - 3 3
(2) Raise the inner mast. Set SST to the
outer master tie-beam, and lower the
inner mast until it reaches SST.
SST 09610-22000-71

Disconnecting the Lift Bracket Rollers 1.~062-10

(3) Use a hoist and remove the lift cylinder


ASSY.

Caution:
0 When hoisting the lift cylinder ASSY try
safe operation.
0 Remove the lift cylinder not to damage
the elbow at the cylinder bottom fittings.
0 Lay the removed cylinder down securely
on blocks.

Removing the Lift Cylinder ASSY IAQIZ-11

(4) Lower the lifted inner mast.

Note:
Tilt the mast backward.

Lowered Inner Mast ~ ~ 6 2 - 1 4

( 5 ) Remove the inner mast roller.


SST 09950-20017

Removing the Inner Mast Roller ~ ~ 615 2 -


(6) Select the adequate inner mast roller
shims'and distribute them equally to the
right and left.
Shim kind:
T = 0.5 and 1.0 mm (0.02 and 0.04 in.)

Adjusting the Shims ~062-16

Removing the Outer Mast Roller LAQ~Z-20

(8) Remove the outer mast roller.


SST 09950-2001 7

Adjusting the Shims

(9) After mast roller adjustment, check that


the inner mast smoothly goes up and
down along the outer mast.
MAST STRIP ADJUSTMENT

1. Preparation for adjustment


(1) Prepare the thickness gauge.
(2) Lower the inner mast fully and tilt i t for
forward fully.

Adjustment of the clearance between the


mast strip (on the outer mast side) and the
inner mast.
( 1 ) Measrue the clearance between the mast
strip and the inner mast with the thick- Adjusting the Mast strip ~ ~ 6 3 - 1
ness gauge.
Gap standard:
0.5 -- 1.0 mm (0.02 -- 0.04 in.)

Note:
Confirm that the inner mast is in contact
with the outer mast roller.

Clearance between the Mast Stripped LAOS 146


the Inner Mast
3. Mast strip adjustment

Note:
0 Carry out adjustment when the measured
clearance is judged defective.
0 Use shims for adjustment.
0 Refer to steps (1) to (4) in the preceding
roller and shim adjustment section (from
lift bracket removal to inner mast lower-
ing) for the mast strip removal procedure.

(1) Remove the mast strip and make adjust-


ment by selecting proper shims. Adjusting the Shims
Shim kind:
T = 0.5 and 1.0 mm (0.02 and 0.04 in.)
(2) After mast strip adjustment, check that
the inner mast smoothly goes up and
down along the outer mast.
LIFT CYLINDER ROD SHIM ADJUSTMENT
(PREVENTION OF UNEVEN LIFTING)
Caution:
0 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.
0 The inspection and adjustment must be made whenever any one of the following parts is replaced:
(1) Lift cylinder ASSY (4) Mast ASSY
(2) Lift cylinder rod ASSY (5) Outer mast SUB-ASSY
(3) Lift cylinder SUB-ASSY (6) Inner mast SUB-ASSY

Inspection method
Slowly raise the inner mast, and observe the
stopping of the right and left cylinder rods
the moment the inner mast reaches the
maximum height.
(1) Normal case
Both the right and left 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 the mo- 1~063-3
Inspecting Uneven Movement of Lift Cylinder
ment the later rod stops. To correct,
add shims to the cylinder that stops
first.

2. Adjustment method
(1) Raise the inner mast. Set SST to the
outer master tie-beam, and lower the
inner mast until i t reaches SST.
(2) Remove the set bolt of the cylinder rod
end on the side for shim adjustment.
(3) Slowly lower the lift cylinder rod t o dis-
connect the rod end.
(4) Place the shims on the cylinder rod end.
Slowly raise the lift cilinder rod into SSTSet
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 decided.
Shim thickness:
0.5 and 1.0 mm' (0.02 and 0.04 in.)

Shim Adjustment

- 406 -
20 Mast SUB-ASSY, outer
20B Bushing, mast support
21 Mast SUB-ASSY, inner
30 Strip SUB-ASSY, outer mast
30A Shim, outer mast strip
40 Roller, lift (For outer mast)
40A Shim, lift roller (For outer mast)
41 Roller, lift (For inner mast)
41A Shim, lift roller (For,inner mast)
53 Cushion, mast (For inner mast)
AC Stoper, inner mast U

AD Fitting, grease
AJ Shim, stopper
BH Cap, mast support

Mast Components (SV)

- 408 -
Mast SUB-ASSY, outer Shim, lift roller (For middle mast upper)
Bushing, mast support Roller, lift (For middle mast lower)
Mast SUB-ASSY, inner Shim, lift roller (For middle mast lower)
Mast SUB-ASSY, middle Roller, side (For inner mast)
Strip SUB-ASSY, outer mast Ring, shaft snap (For inner mast side roller)
Shim, outer mast strip Shaft, side roller (For inner mast)
Strip SUB-ASSY, middle mast Holder, side roller shaft (For inner mast)
Shim, middle mast strip Shim (For inner mast shaft holder)
Roller, lift (For outer mast) Fitting, grease
Shim, lift roller (For outer mast) Cover, roller
Roller, lift (For inner mast) Cap, mast support
Shim, lift roller (For inner mast) Guard, pipe
Roller, lift (For middle mast upper)

Mast Components (FSV)

- 409 -
Backet SUB-ASSY
Fork SUB-ASSY
Bracket SUB-ASSY, lift
Roller, lift (Upper, lower)
Ring, shaft snap (Upper, lower)
Roller, lift (Center)
Ring, shaft snap (Center)
Roller, side
Pin, fork stopper
Knob, fork stopper pin
Spring, fork stopper pin
Pin, spring (For fork stopper pin)
Pin, side roller
Shim (For side roller pin)
Cover, lift bracket roller
Plate, side
Bolt
Ring, snap
Collar

Lift Bracket Components (3.25-4.0 ton models)

- 410-
m;)
[LBACKREST]

~ - - A A
,
21 .
( W GERMANY)

20 Bracket SUB-ASSY
B
21 Fork SUB-ASSY
22 Bracket SUB-ASSY, lift
40 Roller, lift (Upper, lower)
40A Ring, shaft snap (Upper, lower)
42 Roller, side
42B Spacer (For side roller)
43 Shaft, side roller
44 Holder, side roller shaft
44A Shim (For shaft holder)
46 Pin, fork stopper
47 Knob, fork stopper pin
48 Spring, fork stopper pin
49 Pin, spring (For fork stopper pin)
AA Cover, lift bracket roller
AB Plate, side

Lift Bracket Components (4.5 ton model)

- 411 -
20 Chain SUB ASSY
20A Nut, chain adjust
20M Bolt kit, chain eye
20N Link kit, chain joint
30 Beam SUB-ASSY, chain
30A Bushing
31 Pin SUB-ASSY, chain wheel
40 Wheel, chain
AC Clamp, chain anchor bolt
AE Washer, chain special
AN Nut, hexagon
A0 Pin, spring
AP Collar, chain wheel
BW Bolt

Chain Components (SV)

- 413-
Chain SUB ASSY (Front) Ring, shaft snap (For chain wheel)
Nut, chain adjust (Front) Support, chain wheel
Bolt kit, chain anchor, No. 1 (Front) Clamp, chain anchor bolt
Bolt kit, chain anchor, No. 2 (Front) Washer, chain special
Chain SUB-ASSY (Rear) Cover, chain wheel
Nut, chain adjust (Rear) Cover, chain wheel
Bolt kit, chain eye Nut, hexagon
Link kit, chain joint Nut, lock
Wheel, chain (Front) Stopper, chain
Ring, shaft snap (For front chain wheel) Bolt
Wheel, chain (Rear)

Chain Components (FSV)

- 414-
-

MAST ADJUSTMENT (FV-SVaFSV)


LIFT ROLLER AND SIDE ROLLER ADJUSTMENT AT LIFT BRACKET

3.25 - 4.0 ton models, all masts

FV mast

Lower lift roller

asure with this roll


face in close conta

the roller is the


nearest)

Adjusting the Clearance between Lift Bracket Rollers and Inner Mast LAOSI47

1. Make adjustment with the upper lift roller of the lift bracket placed at 100 mm (4.0 in.) from the top
end of the inner mast.
2. No clearance adjustment is rewuired for the upper and center lift rollers because they are fixed by
snap rings.

- -
3. For the lower lift roller, shift the lift bracket to one side to bring the roller into contact with the mast
and adjust the clearance to 0 0.5 mm (0 0.020 in.) at the roller side surface nearest to the mast
on the opposite side.
4. Start the upper side roller adjustment after the lower lift roller (in step 3 above). Bring the side roller

- -
on one side into contact with the mast, and adjust the clearance between the side roller and mast on
the opposite side to 0 0.5 mm (0 0.020 in.)
5. Start the lower side roller adjustment after adjusting the lower lift roller and upper side roller (in step
3 and 4 above). Shift the lift bracket to one side to bring the upper side roller and lower lift roller
into contact with the mast, and adjust the clearance between the mast inside surface and lower side
roller t o 0.5 -- 1 mm (0.020 -- 0.039 in.). Make the same adjustment on the opposite side.
6. After making moves smoothly along the overall mast length and that the lower side roller is not ro-
tated by contact with the mast. If the side roller is rotated, repeat adjustment in step 5 to increase the
clearance between the roller and mast slightly and check that the lower side roller is not rotated
throughout the overall mast length.
* The lower side roller is a bottom-recessed roller. The installation method is shown below.

* lnstallation method @ Bottom recessed lift roller


(1) Screw in bolt @ fully t o the roller pin
in the lower part of hte lift bracket. Lift bracket
(2) Install bottom-recessed lift roller @ .
(3) Use snap ring @ to fix lift roller @ to
@ Nut
bolt @ .
(4) Make roller adjustment.
(5) Lockbolt @ b y n u t @ .

Bottom-recessed Roller Installation Method ~AQs89

7 . See the table below for the roller selection method.


(1) Use only No. 1 as the center roller.
(2) As a rule, select No. 2 and No. 4 (both oversize) as the upper and lower rollers, respectively.
Select No. 1 and No. 3 as the upper and lower rollers, respectively, only when the inside width
(rolling contact surfaces) of the mast is narrow. The roller sizes may be different between the left
and right sides or between the top and bottom sides.

Lift bracket roller list (FV-SV-FSV)


Vehicle model No. Outside diameter mm (in.) Place used Remarks
No. 1 124.5 (4.90) (upper), center
All masts for No. 2 125.2 (4.93) (upper) Oversize
3.25 -- 4.0 ton
models No. 3 124.5 (4.90) (lower) Bottom-recessed
(excluding 4.5 ton Bottom-recessed,
No. 4 125.2 (4.93) (Iower)
model) oversize
No. 5 93.3 (3.67) Side

All masts for 4.5 ton model

1. Of the lift bracket rollers for all masts for 4.5 ton model, lift rollers requires no adjustment because
they are fixed by snap rings. For side rollers, bring the side roller on one side into contact with the
mast, and adjust the clearance between the side roller and mast inside surface on the opposite side to

2.
- -
0 0.8 mm (0 0.032 in.).
For adjustment, place the center of the upper lift roller of the lift bracket at 100 mm (3.9 in.) from
the top end of the inner mast.
3. After adjustment, check that the lift bracket moves smoothly along the overall mast length.
LIFT ROLLER ADJUSTMENT AT MAST

All Masts

FV mast

Measure with this

This roller
FSV mast
Bring into conta

Outer

This roller

Lift Roller Adjustment at mast (FV.SV.FSV) LAQS 149

1. Outer mast and inner mast rollers (FVsSV)


Outer mast and middle mast lower rollers (FSV)
Middle mast and inner mast rollers (FSV, 3.25 -- 4.0 ton models)
(1) Carry out measurement when the mast overlap is near 500 mm ( 19.7 in.).
(2) Shift the inner mast to one side to bring the roller into contact with the mast, and adjust the
clearance between the roller and mast at the closest position on the opposite side to 0 -- 0.8 mm
(0-- 0.032 in.).
(3) See the table below for the roller selection method.
On 3.25 -- 4.0 ton models, select No. 2 (oversize) as a rule, and No. 1 only when the mast inside
width (between rolling contact surface) is narrow.
The roller size may be different between the left and right sides.
lnner mast and middle mast roller list (FV-SV.FSV)

Outside diameter Outer mast inside


Vehicle model No. Remarks
mm (in.) depth mm (in.)
3.25-4.0 ton models No 1 124.5 (4.90) -
(FV.SV.FSV) 125.0 (4.92)
No. 2 125.2 (4.93) Oversize
4.5 ton model -
No. 1 164.5 (6.48) 165.0 (6.5)
(FV.FSV)

(4) After the adjustments, check that the inner mast moves smoothly in the outer and middle masts
and the middle mast moves smoothly in the outer mast.
2. Middle mast and inner mast rollers (FSV, 4.5 ton model)
(1) Since inner mast rollers are cross rollers, the lift rollers are fixed by snap rings. For side rollers,
bring the side roller on one side into contact with the mast side surface and adjust the clearance
between the side roller and mast side surface on the opposite side to 0 -- 0.8 mm (0 - 0.03 in.).
(2) Afterthe adjustment, check the mast moves smoothly in the middle mast.
(3) Carry out measurement when the mast overlap is near 500 mm (19.7 in.).

Mast Lift Roller Adjustment

FV mast
This roller

Measure with this rolling


surface in close contact

FSV mast 2 roller

Outer'
roller is the nearest)
Middle

Lift Roller Adjustment at mast (FV6V.FSV) LAQSl5O

Outer mast rollers and inner mast (FVaSV)


Outer mast rollers and middle mast (FSV)
Middle mast upper rollers and inner mast (FSV)
(1 ) Carry out measurement when the mast overlap is near 500 mm ( 19.7 in.).
(2) Shift the inner or middle mast to one side to bring the roller into contact with the inner mast or
middle mast, and adjust the clearance between the roller side surface and mast at the closest posi-
tion on the opposite side to 0 -- 0.8 mm (0 "0.03 in.).
(3) Select the rollers according to the table below.

Outer mast rollers and middle mast rollers (FVaSV-FSV)


I - -
Vehicle model Outside diameter mm (in.)
3.25 -- 4.0 ton models (FV.SV.FSV) 124.5 (4.90)
4.5 ton model (FV.FSV) 164.5 (6.48)

(4) After the adjustment, check that the mutual mast movements are smooth.

- 418 -
CYLINDER

Page

FLOWREGULATORVALVE .................... 12-15


SPEClFlCATlON .............................. 12-15
REMOVAL ................................... 12-16
lNSPECTlON ................................. 12-1 6
INSTALLATION .............................. 12-16
SAFETY DOWN VALVE ........................ 12-1 7
SPECIFICATIONS ............................ 12-1'7
REMOVAL ................................... 12-1'7
DISASSEMBLY .............................. 12-18
lNSPECTlON ................................. 12-1 8
IlNSTALLATlON .............................. 12-18
TILT CYLINDER ................................ 12-19
GENERAL ................................... 12-19
SPECIFICATIONS ............................ 12-1 9
COMPONENTS .............................. 12-20
REMOVAL .................................. 12-21
DISASSEMBLY .............................. 12-22
INSPECTION ................................. 12-24
ASSEMBLY .................................. 12-25
INSTALLATION .............................. 12-25
MAST FORWARD/BACKWARD ANGLE
ADJUSTMENT ................................ 12-26
LIFT CYLINDER
GENERAL

Lift Cylinder (V-SV)

Lift cylinder Sectional View (3.25-4.0 ton Models)

Lift Cylinder (V)


-I

Safety down valve

I
!2
Lift Cylinder Sectional View (4.5 ton Model)

- 420 -
Rear Lift Cylinder (FSV)

Rear Lift Cylinder Sectional View (3.25-4.0 ton Models)

Rear Lift Cylinder (FSV)

LH Safety down valve

n
'rr'
- - - - -- - -
*---*---

Qn
L

Rear Lift Cylinder Sectional View (4.5 ton Model)

- 422 -
SPECIFICATIONS
Lift Cylinder (VmSV)
1
3.25 -- 4.0 ton models 4.5 ton model
l tem V, SV V
Cyl inder type Single-acting hydraulic system t

Cylinder number 2 t

Cylinder outside diameter mm (in.) $73 (2.87) $82 (3.23)


Cylinderinsidediameter mm(in.) $65 (2.56) $70 (2.76)
Piston rod outside diameter mm (in.) $50 (1.97) t

Cyl inder stroke mm (in.) 1500 (59) Lifting height: 3000 (118)
Piston seal type U-Packing t

' Piston rod seal type U-Packing t

Others With flow regulator valve (RH)


With safety down valve (LH)

Front Lift Cylinder (FV, FSV)


Vehicle model 3.25 - 4.0 ton models 4.5 ton model
FV FSV FV FSV

Cylinder type Single-acting hydraulic system

Cylinder number 1 t t t

Cylinder outside diameter mm (in.) $128 (5.04) t $140 (5.51) t

Cylinder inside diameter mm (in.) $1 10 (4.33) t 0120 (4.72) t

Piston rod outside diameter mm (in.) $95 (3.74) t $105 (4.13) c

Cylinder stroke mm (in.) 7 4 0ift( tin^


3 ~
( 1heightj
18)
~ ~ 630(Liftin
3700 g(146) height:) 6753700(146)
height:) 7503000(118)
(~ifting height:) ifti tin^
Piston rod seal type U-Packing t t t

Others With safety down valve

Rear Lift Cylinder (FV, FSV)


3.25 - 4.0 ton models 4.5 ton model
FV I FSV FV I FSV

Cylinder type Single-acting hydraulic system

Cylinder number 2 t t t

Cylinder outside diameter mm (in.) $73 (2.87) t $82 (3.23) t

Cylinder inside diameter mm (in.) $65 (2.56) 4- $70 (2.76) t

Piston rod outside diameter mm (in.) $45 (1.77) $50 (1.97) t t

1500 Lifting 1220 Lifting 1500 Lifting 1175 Lifting


Cylinder stroke mm (in.)
(heg
iht:) (height:) (height:app)) (heg
i ht:a:;j

Piston seal type - U-Packing - U-Pack ing

Piston rod seal type U-Pack ing t t t

With flow regulator valve (RH)


Others With safety down valve (LH)
COMPONENTS (V)

Lift Cylinder

01 Cylinder ASSY, lift, RH AC Ring, back up


01 K Cylinder O/H kit, lift, RH AE Packing, U
02 Cylinder ASSY, lift, LH AF Ring, 0
02K Cyinder O/H kit, lift, LH AG Seal, dust
10 Valve ASSY, flow regulator Al Shim
11 Valve ASSY, safety down AM Spacer
20 Cylinder SUB-ASSY, lift, RH AN Shim
21 Cylinder SUB-ASSY, lift, LH A0 Support, lift cylinder
22 RodSUB-ASSY,liftcylinder,RH AZ Rubber
23 Rod SUB-ASSY, lift cylinder, LH BB Spacer, lift cylinder
30 Guide SUB-ASSY, lift cylinder rod, RH BI Piston
31 Guide SUB-ASSY, lift cylinder rod, LH BJ Body
41 Cover, lift cylinder BK Spring
42 Sleeve, lift cylinder rod guide BQ Plate
AA Ring,wear BR Rubber
AB Packing, U

Lift Cylinder Components (3.25 - 4.0 ton Models)


- 424 -
Lift Cylinder

r.-- I
02K
11
-.-q
7
1 AI--43
- 9
I
II.-
& ..-J Bpf2!,,.,,$. AK

02(LH)
/1&~ BP

O~(RH)
...q
:

-01K

I :
L.. .-.J b--. 0-0 J

01 Cylinder ASSY, lift, RH AB Packing, U


01 K Cylinder O/H kit, lift, RH AC Ring, back up
02 Cylinder ASSY, lift, LH AE Packing, U
02K Cyinder O/H kit, lift, LH AF Ring,O
10 Valve ASSY, flow regulator AG Seal, dust
11 Valve ASSY, safety down Al Shim
2Q Cylinder SUB-ASSY, lift, RH AK Bracket SUB-ASSY, lift cylinder
21 Cylinder SUB-ASSY, lift, LH AN Shim
22 Rod SUB-ASSY, lift cylinder, RH BB Spacer, lift cylinder
23 Rod SUB-ASSY, lift cylinder, LH BI Piston
30 Guide SUB-ASSY, lift cylinder rod, RH BJ Body
31 GuideSUB-ASSY,liftcylinderrod,LH BK Spring
41 Cover, lift cylinder BO Pipe
42 Sleeve, lift cylinder rod guide BP Insulator
AA Ring, wear
1

Lift Cylinder Components (4.5 ton Model)

- 425 -
REMOVAL (V)

(3.25 - 4.0 ton model)

1. Disconnect the chain.


(1) Lower the lift bracket fully and tilt it
forward slightly to slacken the chain.
(2) Chain adjustment nut and lock nut
(upper side).
(3) Chain adjustment nut and lock nut
(lower side).
Disconnecting the Chain ~~63-25.26

(4.5 ton model)

1. Disconnect the chain.


(1) Lower the lift bracket fully and tilt i t
forward slightly t o slacken the chain.
(2) Cotter pin
(3) Chain adjustment nut and lock nut

Disconnecting the Chain LAQ63-35.36

2. Remove the chain wheel.


(1) Snap ring
(2) Chain wheel

Note:
When the chain wheel is firmly fit, use SST
09950-2001 7.

Removing the Chain Wheel 1.~063-31.30

3. Remove the tilt bracket.


(I)Erect the mast vertically. Raise the
inner mast until i t comes off the lift
bracket.

Caution:
When raising the inner mast, pay attention
so that the slackened chain does not tangle
around the inner mast.

Removing the Lift Bracket ~~063-33


4. Disconnect the hose.
(1) Lower the inner mast fully.
(2) Overflow hose
(3) High pressure hose

Disconnecting the Hose ~~0.58-28.29

5. Disconnect the lift cylinder rod end.


(1) Set bolt

Removing the Set Bolt ~~058-27

(2) Hoist the inner mast and set the SST


SST 09610-22000-7 1
(3) Shim

Caution:
To prevent the uneven movement of the
right and left lift cylinders, the shims at: the
lift cylinder rod end are adjusted. RemenI ber
which cylinder i s used for adjustment and
the number of shims.

Disconnecting the Cylinder Rod End LAQ~E-30

6. Remove the lift cylinder ASSY.


(1) Lift cylinder support set bolts
(2) Plate
(3) Shims
(4) Cylinder support

Removing the Support Set Bolts LAQ~E-32.34


(5) Take out the lift cylinder ASSY from
the vehicle front.

Caution:
0 When raising the lift cylinder, pay atten-
tion for the safety operation.
0 When taking out the lift cylinder ASSY,
do not damage the bottom elbow.

Removing the Lift Cylinder ASSY ~058-36

DISASSEMBLY (V)

1. Remove the overflow hose.


( 1 ) Hose clamp
(2) Overflow hose

Removing the Overflow Hose 1.~048-34.36

2. Remove the cylinder top cover.


SST 09620-10100-71

Removing the Top Cover ~ ~ 4 8 - 3 6

Pull out the lift cylinder rod.

Caution:
Pull out the lift cylinder rod in parallel with
the cylinder without scratching it.

Pulling Out the Cylinder Rod ~ ~ 4 9 - 1


Removing the Rod Guide 1~049-5

5. Disassemble the piston.


(1) Wear ring
(2) Backup ring
(3) U-packing

Caution:
The piston and the piston rod cannot be
disassembled.

Disassembling the Piston 1.~049-10

Remove the flow regulator valve or safety


down valve.

Caution:
0 The flow regulator valve is installed in the
lift cylinder RH.
0 The safety down valve is installed in the
lift cylinder LH.

Removing the Valve LAQ~~-11


INSPECTION (V)

Caution:
0 Oil leaks when the rod guide U-packing or dust seal i s defective.
0 Hydraulic drift occurs when the piston U-packing i s defective.
0 Wash each part and replace any defective or damaged part.

Lift cylinder inspection


(1) Damage and wear of the sliding part on
the cylinder inside face.
Cylinder inside diameter service limit:
-
3.25 4.0 ton model
63.35 mm (2.573 in.)
4.5 ton model
70.35 mm (2.770 in.)
(2) Deformation, damage and rust of the
cylinder
(3) Dint on the cylinder outside face
Inspecting the Lift Cylinder LAQ~~-14

Piston rod inspection


(1) Damage and wear of the sliding part of
the piston rod
Rod service limit:
3.25 -- 4.0 ton model
49.92 mm (1.965 in.)
4.5 ton model
49.92 mm (1.965 in.)
(2) Peeling, damage and rust of the plated
face
(3) Bend of the piston rod
Piston rod bend limit: 2.0 mm (0.8 in.)
the Piston Rod

3. Rod guide inspection


( 1) Wear and damage of the guide sleeve
(2) Wear, damage and denaturation of the
U-packing
(3) Damage and denaturation of the O-ring

Inspecting the Rod Guide 1.~049-16


4. Piston inspection
( 1 ) Wear and damage of the piston
(2) Wear and damage of the wear ring
(3) Wear, damage and denaturation of the
U-packing
(4) Damage of the backup ring

Inspecting the Piston 1~049-17

5. Lift cylinder top cover inspection


(1) Damage of the threaded part
(2) Crack of the top cover
(3) Wear and damage of the dust seal

Inspecting the Top Cover LAQ~~-18

6. Lift cylinder support bracket inspection


(1) Damage of the bracket
(2) Damage of the bushing
(3) Damage of the spacer

Inspecting the Bracket ~ ~ 4 9 - 2 0

7. Valve inspection
(1) Flow regulator valve
(2) Safety down valve

lnspecting the Valve

- 431 -
ASSEMBLY (V)

Reverse the disassembly procedure for assembly.

Caution:
0 Do not assemble the dry parts. Apply hydraulic oil to the parts before assembly.
0 When assembling the parts after disassembly, be sure to use the new O-rings, U-packing and dust
seals.

INSTALLATION (V)

Reverse the removal procedure for instal lation.

Caution:
0 Adjust the tension of the right and left lift chains equally.
0 Raise and lower the forks through the entire stroke repeatedly under no load conditions t o release
air and to confirm that the operation in normal.
0 After confirming the operation, check the hydraulic oil amount with the oil level gauge. When it is
insufficient, replenish hydraulic oil No. 90.
0 Confirm that the lifting height is normal.
0 When replacing the old lift cylinder ASSY, lift cylinder SUB-ASSY or lift cylinder rod SUB-ASSY
with a new one, check the uneven motion of the lift cylinder and adjust the operation. See Lift
cylinder rod shim adjustment section for the inspection and adjustment method.
REMOVAL

Caution:
o The flow regulator valve can be removed on the vehicle.
0 Before removal, measure the lowering speed for quality judgement.
0 The flow regulator valve i s set to the lift cylinder RH.

SST Set ~~018-30

2. Remove the flow regulator valve.


(1) Flow regulator valve
(Width across flats: 41 mm (1.6 in.))

INSPECTION
Removing the Flow Regulator Valve ~ ~ 6 9 - 5
1. Check the top cover for slippage or damage.

2. Check the check ball movement and clogging


of the check hole.

3. Check the piston movement.

4. Check the return spring for breakage.

5. Check the O-ring for wear or damage.

INSTALLATION

The installation procedure is the reverse of the Inspecting the Flow Regu1at0rVa1ve LAQ49-22

removal procedure.

Caution:
Flow regulator valve tightening torque:
T = 9.0 -- 10.0 kg-m (65.0 -- 72.2 ft-lb)
SAFETY DOWN VALVE

Safety Down Valve Sectional View LAOS174

SPEC1FICATIONS

Flow rate at piston seat Rlmin. (USgal) 135 (35.6)


Flow rate after piston seat Rlmin. (Usgal) 15 ( 4.0)

REMOVAL
Caution:
0 The safety down valve can be removed on the vehicle.
o The safety down valve is set to the lift cylinder LH.

1. Hoist the inner mast and set the SST.


2. Remove the safety dwon valve.
(1) Safety down valve
(Width across flats: 32 mm (1.3 in.))

Removing the Safety Down Valve LAQSS-3

DISASSEMBLY

1. Remove the snap-ring.


(1) Snap-ring

Removing the Snap-Ring ~ ~ ~ 4 9 . 2 4

2. Remove the valve and spring.

INSPECTION

1. Check the valve for orifice clogging or


damage inspection.

2. Check the spring for fatigue, Or damage ins- Removing the valve and spring ~ ~ 4 9 - 2 6

pection.

3. Check the screw for damage inspection.

INSTALLATION

The installation procedure is the reverse of the


removal procedure.

Caution:

-
Safety down valve tightening torque
T = 6.0 7.0 kg-m (43.3-- 50.5 ft-1b)
Safety Down Valve Inspection LAQ49-27
TILT CYLINDER
GENERAL

Tilt Cylinder Sectional View

SPECIFICATIONS
Cylinder type Double acting
No. of cylinder 2
Cylinder outside diameter mm (in.) $1 02 (4.02)
Cylinder inside diameter mm (in.) $90 (3.54)
Piston rod outside diameter mm (in.) $40 (1.57)
Piston stroke mm (in.) 184 (7.24)
Piston seal type U-packing
Rod seal type U-packing
REMOVAL

Caution:
The U-packing of the tilt cylinder can be re-
placed on the vehicle without removing the
cylinder ASSY. The method to disassemble
the cylinder ASSY after removing it will be
described below.

1. Lower the forks fully and tilt the mast for-


ward fully.
Stamping the Match Marks 1~063-11
Caution:

theaded hole or stamp the match marks. Removing the Stopper Plate ~ ~ 6 3 - 1 2

Removing the Front Pin LAQ63-15

3. Disconnect the piping.


(1) High pressure hose on the reasr side
(2) High pressure hose on the front side

Disconnecting the Piping ~ ~ 6 3 - 1 6


4. Remove the tilt cylinder rear pin.
(1) Set bolt
(2) Rear pin

Removing the Rear Pin ~~063-17

5. Remove the tilt cylinder ASSY.

Removing the Tilt Cylinder ~~059-17

DISASSEMBLY

1. Remove the tilt cylinder cover.


SST 09620-10160-71

Removing the Tilt Cylinder Cover 1~053-27

2. Pull out the piston rod.

Caution:
Pull out the piston rod in parallel with the
cy tinder.

Pulling Out the Piston Rod LAQS~-28


3. Remove the piston.
(1) Cotter pin
(2) Castle nut
(Width across flats: 46 mm (1.8 in.))

Removing the Castle Nut ~~53-30.32

(3) Piston

Removing the Piston LAQ~~-34

4. Remove the rod guide.

Removing the Rod Guide ~~063-35

5. Disassemble the piston.


(1) Sleeve
(2) U-packing

Caution:
0 Inspect the U-packing while it is installed
t o the piston. Remove it when any defect
is found.
0 Wind the vinyl tape, etc. around a spatula
so as not to damage the piston.

Disassembling the Piston ~~053-36


6. Disassemble the piston rod guide.
(1) Snap ring
(2) Stopper plate
(3) U-packing
(4) Backup ring
(5) O-ring
(6) Backup ring
(7) Snap ring
(8) Dust seal

Caution:
Only when the damage of the sleeve i s ob-
Disassembling the Rod Guide ~054-5
served remove it with a press.

INSPECTION

Caution:
0 When the U-packing of the rod guide and1
or the dust seal is defective, oil leaks.
0 When the U-packing of the piston is de-
fective. the natural forward tilt occurs.
0 Wash each part. Replace any defective or
damaged part with a new one.

1. Tilt cylinder inspection


(1) Damage and wear of the sliding part on lns~ectngtheTilt Cylinder ~~0.54-8

the cylinder inside surface


Cylinder inside diameter service limit:
90.40 mm (3.559 in.)
(2) Deformation, damage and rust of the
cy linder
(3) Local dint on the cylinder outside sur-
f ace

Piston rod inspection


(1) Damage and wear of the sliding part of
the piston rod
Rod service limit: 39.92 mm (1.572 in.)
(2) Peeling, damage and rust of the plated Inspecting the Piston Rod
su rface
(3) Bend of the piston rod
Piston rod bend limit: 1.0 mm (0.04 in.)

Piston inspection
(1) Wear and damage of the piston
(2) Wear and damage .and denaturation of
the U-packing
(3) Wear, damage and crack of the sleeve

lnspecting the Piston

- 442 -
4. Rod guide inspection
(1) Wear and damage of the guide sleeve
(2) Wear, damage and denaturation of the
U-packing
(3) Wear, damage and denaturation ring of
the dust seal, O-ring and backup ring
(4) Damage of the rod guide

Inspecting the Rod Guide ~~054-13

5. Cylinder inspection
(1) Damage of the threaded part
(2) Crack of the cylinder cover

Inspecting the Cylinder Cover LAQ~~-14

ASSEMBLY

Reverse the disassembly procedure for assembly.

Caution:
0 Do not assemble the dry parts. Apply hydraulic oil to them.
0 Be sure to use the new U-packing and O-ring, etc. except that they are not damaged or used for a
short time.

INSTALLATION

Reverse the removal procedure for installation.

Caution:
0 Apply chassis grease special (MP grease) to the front pin insertion part and the rear pin insertion
part.
0 Confirm the match mark on the front pin. When replacing the old tilt-cylinder with a new one, as-

0 Tilt the mast forward and backward 2 -


semble it according to the mast forwardlbackward tilt angle adjustment.
3 times slowly to confirm the operation.
0 Check hydraulic oil amount with a level gauge. When it i s insufficient, replenish it.
MAST FORWARD/BACKWARD ANGLE ADJUSTMENT
The tilt cylinder front pin is eccentric from the hexagonal flange by 5 mm (0.2 in.). The stopper plate can
be locked at 2 positions, so the rod length can be finely adjusted by +I .3mm (50.05in.) and also can be
roughly adjusted by *5 mm (k0.2 in.).
Mast forward angle: 6"
Mast backward angle: 12"
Tilt cylinder uneven motion: Within 1 mm (0.04 in.)

Front Pin and Stopper Plate Relationship Diagram

1. Direct the front pin downward with the


mast set at the neutral position.
However, in the case of the single tires (300- Front pin
15) and the STD double tire (7.50-16) of the
4.5 ton model, turn the front pin by 180'
Eccentricity
and direct the front pin upward.
r
2. When the forward/backward tilt angle and I
the tilt uneven motion with the front pin set
at the position described in the paragraph 1 Lower side Upper side
are not within the specified value, turn the
front pin for adjustment. The adjustable
range is k5 mm (0.2in.).
Front Pin

3. To make the fine adjustment, turn the stopper plate.


The minimum adjustable angle of the front pin 51 5' or the multiple of 15'.
(2) When adjusting the stopper plate by 930°, the rod length can be adjusted by k2.5 mm (0.1 in.).

2.5 mm' ' '2.5 mm

Adjustment (2) LAGS74

(3) When adjusting the stopper plate by *45O, the rod length can be adjusted by k3.5 mm (0.14 in.).

A Reverse the plate

Adjustment (3)

- 445 -
(4) When adjusting the front pin by *60°, the rod length can be adjusted by f4.3 mm (0.17 in.).

Adjustment (4) LAGS72

(5) Follow the procedures (1) through (4) by combining them according to the necessity to satisfy
the standards.
OIL PUMP

Page
OIL PUMP ...................................... 13-2
GENERAL .................................... 13-2
SPECIFICATIONS ............................ 13-2
COMPONENTS .............................. 13-3
REMOVAL ................................... 13-4
DISASSEMBLY .............................. 13-6
INSPECTION ................................. 13-10
ASSEMBLY .................................. 13-12
INSTALLATION .............................. 13-1 4
TEST METHOD ............................... 13-15
OIL PUMP DRIVE SHAFT ....................... 13-1 6
GENERAL .................................... 13-16
COMPONENTS .............................. 13-17
REMOVAL ................................... 13-1 8
DISASSEMBLY .............................. 13-1 8
INSPECTION ................................. 13-1 9
ASSEMBLY .................................. 13-19
INSTALLATION .............................. 13-19
OIL PUMP
GENERAL

Oil Pump Sectional View (Common for 112 and 3F Engines)

SPECIFICATIONS

1 1 Z engine model 3F engine model

Oil pump type Tandem gear pump c

Manufacturer's model SDY (SGP2 + YP15) t

Main pump
(Front side) 52.7 (3.21 ) 44.6 (2.72)
Theoretical discharge amount
cclrev (cu-in.) Sub pump
(Rear side) 7.1 (0.43) t

Main pump
Discharge (Front side) 76 (20.1) 64 ( 16.9)
Qlmin (US gallmin)
Sub pump
(at Pump speed of 1500 rpm) (Rear side) 10 (2.6) t

Drive system Direct driving by engine via universal point

Rotational ratio to engine 1 : l 4


Pump ASSY, oil AP Gasket
Pump O/H kit, oil BB Ring, back up
Gear set BG Plate, side, A
Gear set BH Plate, side, B
Body (Front) CK Gasket
Flange, mounting CL Gasket
Body (Rear) DK Plate, adaptor
Seal, oil DY Insulator
Ring, snap DZ Plate
Gasket

Oil Pump Components (Common 1 1Z, 3F Engine Models) LAQM96


REMOVAL

1. Drain hydraulic oil through the hydraulic oil


tan k drai n.

2. Remove the engine hood.

Removing the Engine Hood ~ ~ 2 9 - 9

3. Remove the radiator cover.

Removing the Radiator Cover ~029-12

Disconnect the Hose LAQ~O-12,


18

(4) Set bolts


(5) Radiator
(6) Fan shroud

Removing the Radiator ASSY LAQ~O-19,


20
5. Remove the oil pump drive shaft
(1) Set bolts (Engine)
(2) Set bolts (oil pump)
(3) Oil pump drive shaft

Caution:
Tie the oil pump drive shaft with a wire to
prevent separation.

Removing the Drive Shaft LAQ~O-20

6. Remove the fan belt.


(1) Loosen the set nut
(2) Lower the plate.
(3) Fan belt

Removing the Fan Belt LAQZO-13

7. Remove the balance weight


(I)Set bolts (Width across flats: 46 mm
(I.8 in.))
(2) Weight ASSY

Removing the Balance Weight ~ ~ 6 6 - 6

8. Remove the muffle.


(1) Loosen the clamp set bolts
(2) Set bolts
(3) Muffle

Removing the Muffle UQ66-8


9. Disconnect the oil pump piping.
(1 ) Outlet hose
(2) Inlet hose

Disconnecting the Piping LAQ66-10.14

10. Remove the oil pump.


(1 ) Set bolts
(2) Oil pump

Removing the Oil Pump ~ ~ 6 6 - 1 7

11. Remove the housing w/ pulley.


( 1 ) Set bolts
(2) Housing w/pu lley

Removing the Housing w/ Pulley LAQ66-19,20

DISASSEMBLY

Caution:
0 Perform the operation in a clean place.
0 Wash the parts in new hydraulic oil.

1. Stamp the match marks on the pump body


and the cover.

Stamping the Match Marks 1.~064-16


2. Remove the rear oil pump body.
(1 ) Set the oi I pump t o a vice.
( 2 ) Set bolts
(3) Rear cover

Removing the Rear Body ~~064-18.19

3. Remove the seals.


(1) Gasket
(2) Side plate B

Removing the Seals LAOH-20.21

Putting the Match Marks LAQ54-22

(2) Driven gear


(3) Drivegear

Removing the Gear Set ~0.54-24-25


5. Remove t h e seals.
( 1 ) Side plate B
( 2 ) Gasket
(3) Gasket

Removing the Seals 1.~054-26.29

6. Remove t h e adaptor plate.

Removing the Adaptor Plate ~~054-30

7. Remove t h e seals.
(1 ) Back up ring
(2) Gasket

Removing the Seals 1.~054-32-33

(3) Gasket
( 4 ) Side plate A

Removing the Seals

- 454 -
Putting the Match Marks ~ ~ 5 4 - 3 6

(2) Driven gear


(3) Drive gear
@ Snap ring
@ Drive gear

Removing the Gear Set LAQ~S-1.3

9. Remove the seals.


( 1 ) Side plate A

Removing the Seals 1.~056-4

10. Remove the front oil pump body

Removing the Front Body

- 455 -
1 1. Remove the sea Is.
(1 ) Back up ring
(2) Gasket
(3) Gasket

Removing the Seals LAQ55-7.9

Caution:
After disassembly, confirm the dirt and dis-
coloration of the parts and wash them for
inspection.

Body, plate inspection


( 1 ) Gear contact mark on the body inside
surface on the suction side.
(Normal = Contact mark of about 113
on the body inside circumference)
Inspecting the Pump Body LAQ~S-11.13
(2) Scratch on the body inside circumfer-
ence.
Body inside surface scratch depth limit:
Front : 0.05 mm (0.0020 in.)
Rear : 0.1 mm (0.0039 in.)
(3) Damage of the joint of the body, cover
and flange.
(4) Damage of the mounting parts and each
screw.

Inspecting the Plate 1.~065-12

(5) Contact of the inside diameter sliding


surface.
(Normal: When about a half of the
sliding surface on the suction side is
glossy.)
(6) Scratch on the inside diameter sliding
surface.
Bushing inside diameter limit
Front : 24.1 mm (0.949 in.)
Rear : 17.1 mm (0.673 in.)

Inspecting the Plate ~ ~ 0 . 5 5 - 220


2,
Side plate A.B inspection
(1 ) Contact of the side surface.
(Normal: When the contact on the
suction side is somewhat stronger and
only slight contact is observed on the
discharge side.)
(2) Scratch on the side surface.
Plate axial length limit
A: 2.65 mm (0.1043 in.)
B: 4.85mm (0.1909in.)

Inspecting the Side Plate A, B ~ ~ 5 5 - 2234 ,

Front, rear gears inspection


(1) Crack of the root of the tooth and
scratch on the side surface.
(2) Scratch and denaturation of the tooth
surface.
(3) Gear shaft scratch
Gear shaft limit
Front: 46,270 mm (1.8217 in.)
Rear: 33.050 mm (1.3012 in.)

Caution:
Be sure to replace a set of the wears
- at a time.
Inspecting the Gears ~ ~ 0 5 5 - 115
4.

4. Seals inspection
(1) Tear and cutting of the gasket
(2) Damage of the spacer

Inspecting the Seals ~~55-25

(3) Damage and deformation of the front


cover oil seal.

Inspecting the Oil Seals L~Qs135


ASSEMBLY

Caution:
Clean every component part sufficiently,
blow them with compressed air, apply them
hydraulic oil, and then assemble them.

1. Arrangement of component parts of oil


PUmp.

Arranging the Oil Pump Components LAQ~~-30

Assembling the Oil Seal ~~055-32

3. Assemble the seals.


(1 ) Apply grease to seals.
(2) Gasket
(3) Gasket
(4) Back up ring

Assembling the Seals 1.~055-8

4. Assemble the front oil pump body.


(1 ) Front body

Assembling the Front Body LAQ55-6


5. Assemble the seal.
( 1 ) Side plate A

Assembling the Seal LAQ~~-5

Assemble the set gear.


(1) Drive gear, snap ring
(2) Driven gear

Caution:
Assemble the drive and driven gears sccord-
ing to the match marks so that the tooth sur-
faces in mesh are engaged with each other
again.

Assembling the Set Gear ~055-33

7. Assemble the seals.


(I) Apply grease to seals
(2) Side plate A
(3) Gasket
(4) Gasket
(5) Back up ring

Assembling the Seals ~054-35.32

8. Assemble the adaptor plate.

Assembling the Adaptor Plate

- 459 -
9. Assemble the seals.
(1 ) Apply grease to seals.
(2) Gasket
(3) Gasket
(4) Side plate B

Assembling the Seals LAQ54-28.26

10. Assemble the set gear.


(1) Drive gear
(2) Driven gear

Caution:
Assemble the drive and driven gears sccord-
ing to the match marks so that the tooth sur-
faces in mesh are engaged with each other
again.

Assembling the Set Gear ~055-34

11. Assemble the sea Is.


(1 ) Apply grease to seals.
(2) Side plate B
(3) Gasket

Assembling the Seals ~~0.54-21.20

12. Assemble the rear oil pump body.


(1 ) Rear body
(2) Set bolts
T = 10 kg-m (72 ft-l b)

INSTALLATION

Reverse the removal procedure for installation.

Assembling the Set Bolts LAQ~~-36


Apply Molykoto G-n Paste to the drive
pulley spline inside and the oil pump spline
shaft.
Note: Drive shaft pulle
A grease gum equipped with an extension
or tube nozzle should be used for 3.2 ton
and 3.5 ton model due t o narrow space.

Apply Molykoto G-n Paste

Apply Molykote G-n Paste

Tightening direction of the oil pump set


bolts is as follows.
Left-hand side : Install the reamer bolt.
Right-hand side : Install the normal bolt.

Reamer bolt

Assembling the Pump Set Bolts

TEST METHOD
Caution:
I t is necessary to conduct the bench test t o test the oil pump strictly. However, it is impossible to
conduct such test in the actual field service. The oil pump discharge amount i s checked by the rise of
the lift cylinder after mounting it on the vehicle.
1. Set the oil pressure gauge (200 k g /cm 2 ) to the oil control valve and the tachometer to the engine.
2.
3.
Start the engine.
Operate the engine at the rotational frequency of 500
control valve lever set at the neutral position.
- 1,000 rpm for 10 minutes with the oil

4. When the oil pump is normal, operate the oil pump by rotating the engine at 1,500- 2,000 rpm for
10 minutes.
Caution:
When any abnormality is observed in the test described in the paragraph 3 and 4, stop the engine
immediately and disassemble the oil pump again.
5. Confirm that the relief set pressure of the oil control valve is as specified.
See Oil control valve adjustment section for details.
6. Confirm that the engine rotational frequency is as specified.
See Engine rotational frequency adjustment section for details.
7. Check the lift cylinder raising speed.

Raising speed mmlsec (fpm)


M ode l Engine Oil pump
No load Load
3.25-4.0 ton model 3F SDY (SGP2+YP15) 420 ( 83) 400 (79)
3.25-4.0 ton model 11 Z t 530 (105) 480 (95)
4.5 ton model 3F .f 360 ( 71 ) 340 (67)
4.5 ton model 11Z t 470 ( 93) 420 (83)
OIL PUMP DRIVE SHAFT
GENERAL

Oil Pump Drive Shaft Sectional View (1 l Z , 3F Engine Model) LAQM~~


COMPONENTS

01 Drive ASSY, oil pump


31 Spider kit, universal joint
40 Yoke, universal joint flange
42 Yoke, coupling
44 Plate, joint yoke set

Oil Pump Drive Shaft Components (1 l Z , 3F Engine Model)

- 463 -
REMOVAL

Caution:
For removing sequence of the oil pump drive
shaft, refer to Items 2 to 5 of the "OIL
PUMP REMOVAL".

Removing the Drive Shaft LAQ~O-20

DISASSEMBLY

1. Stamp the match marks on the universal


joint flange yoke and the coupl~ngyoke

Stamping the Match Marks ~~065-3

2. Remove the snap ring.

Removing the Snap Ring 1.~065-4

Remove the needle roller bearing cup.


(1 ) Pull out the needle roller bearing cup
with the press and the box wrench.
(2) Hold the needle roller bearing cup with
the press and remove the yoke by tap-
ing.

Remove other needle roller bearing cups by


the same procedure.

Removing the Bearing Cup

- 464 -
INSPECTION

Caution:
0 Wash each part. Repair or replace any defective part.
0 Although some part can be disassembled, the service parts are not available. In this case, it is
necessary to replace one ASSY with a new one.
0 Do not disconnect the coupling yoke.
Spider inspection.
(1 ) Deformation, crack, damage and wear

Yoke inspection
(1) Deformation, crack, damage and wear

Neelde roller bearing cup inspection


(1) Damage and fatigue of the oil seal lip
(2) Deformation and rotational condition
of the roller.
(3) Damage and crack of the cup

Inspecting the Pump Drive Shaft 1.~065-14

ASSEMBLY

Reverse the disassembly procedure for assembly.

Caution :
0 Apply MP grease sufficiently in the needle roller bearing cup.
0 Confirm the match marks. Assemble the spider, yoke and piece.
0 Do not disconnect the coupling yoke.
0 I f the coupling yoke is disconnected, either replace with a new ASSY or connect the
coupling yoke according to the steps below.
( 1) Uncaulk the seal cover and remove the seal w/cover.
(2) Fit the seal w/cover to the yoke shaft.
(3) Connect the coupling yoke.
(4) Caulk the seal cover.

INSTALLATION

Reverse the removal procedure for installation.


OIL CONTROL VALVE

Page
GENERAL ...................................... 14-2
HYDRAULIC PRESSURE CIRCUIT
DIAGRAM ...................................... 14-4
SPECIFICATIONS ............................... 14-4
COMPONENTS ................................. 14-5
OIL CONTROL VALVE ASSY ..................... 14-7
REMOVAL .................................... 14-7
DISASSEMBLY ............................... 14-8
INSPECTION ................................. 14-1 1
ASSEMBLY ................................... 14-13
INSTALLATION ............................... 14-15
ADJUSTMENT ............................... 14-16
GENERAL
Oil Control Valve

Oil Control Valve Sectional View (When in Neutral Point) L A Q M ~ ~

Relief Valve

Orifice

Relief valve spring Main plunger

Relief Valve Sectional View (For Lifting & Tilting)

- 468 -
Check Valve

\
Check valve

Check Valve Sectional View LA~s98

Tilt Lock Valve

P C3 Tilt lock plunger Spring


I I / m /

Tilt spool

I
Tilt Lock Valve Sectional View (When i n Neutral Point) LAOSI 82
I
Flow Divider

Orifice Center bypass circuit (handling circuit)

Flow Divider Sectional View LAQMBO

HYDRAULIC PRESSURE CIRCUIT DIAGRAM

--c2
c3

T1 T2 P PS

-
Hydraulic Pressure Circuit Diagram LAOS102

SPECIFICATIONS
h

ltem
- Model 3.25 - 4.5 ton models

Type of oil control valve Add-on type


Lift 185 (2630)
Relief pressure kg/cm2 (psi)
Tilt 185 (2630)
Flow of flow divider Rlmin. (USgal/min.) 17 (4.5)
COMPONENTS

20 Valve set, pilot relief, No. 1 BC Spring, compression


40 Cover, spring BD Plunger, check
41 Spring, compression (For spool return) BG Washer
AH Spring, compression BH Plug
AJ Stopper BJ Seat, valve
AK Holder, spring BL Seat, insert
A0 Plug BZ Plug
AQ Ring, back up CL Bolt
AR Holder, seal FG Pin
AT Stopper FZ End, spool
AU Stopper GA Housing, outlet
AW Spring, compression GX Holder, spring
BA Spring, compression JT Wire

Oil Control Valve Components

- 471 -
20 Lever SUB-ASSY, control valve, No. 1
21 Lever SUB-ASSY, control valve, No. 2
30 Rod SUB-ASSY, control valve lever, No. 1
30A Pin (For control valve lever rod)
40 Knob, oil control valve lever
49 Boot, control valve link, NO. 2
66 Bolt (For valve lever)
66A Bushing
AA Bracket SUB-ASSY

Oil Control Lever Components

- 472 -
Removing the Toe-Board LAQS~-32,
35

2. Disconnect the control lever.


(1) Peel up the boots.
(2) Cotter pin
(3) Clevis pin

Disconnecting the Control Lever LAQ~O-1

Disconnecting the Piping ~Aa60-3

4. Remove the oil control valve.


. ( 1) Set bolts
(2) Oil control valve

Removing the Control Valve 1.~060-5


DISASSEMBLY

Caution:
0 Perform the operation in a clean place.
0 Since each part is finished with high
accuracy, do not scratch it.

1. Remove the fitting.


(1) Fitting

Removing the Fitting LAQSI-6

2. Remove the seal holder.


( 1 ) Set screws
(2) Seal holder

Removing the Seal Holder LAQ~I-4

3. Remove the spring cover.


( 1) Set screws
(2) Spring cover

Removing the Spring Cover LAQ~I-16.15

4. Remove the lift spool and the tilt spool.


(1) Lift spool
(2) Tilt spool

Removing the Spools LAQ~I-17.18


5. Disassembletheliftand tiltspools.
(1)' Set SST 09610-10160-71
(2) Set bolt
(3) Spool end
(4) Spring holder
(5) Compression spring
(6) Spring holder
(7) Seal holder
(8) Back up ring
(9) 0 ring

Disassembling the Spools LAQSI-22

6. Remove the re1ief valve


(1) Relief valve
(2) Spring
(3) Main plunger

Removing the Relief Valve LAO51-30

(4) Stopper
(5) Valve seat

Removing the Stopper ~ ~ 5 2 - 1

7. Remove the flow divider valve.


( 1 ) Stopper (Upper side)
(2) Stopper ( Lower side)
(3) Spring
(4) Valve

Removing the Flow Divider Valve ~~052-3.5


8. Remove the check valve by using a hollow
wrench.
(1) Plug
(2) Spring
(3) Check plunger

Removing the Check Valve ~ 0 5 2 - 9 15


,

9. Remove the outlet housing.


( 1) Set b.olts
(2) Outlet housing

Removing the Outlet Housing LAQ~~-20

10. Remove the tilt lock valve from the tilt


spool.
( 1) Secure the spool tip with a vice.
(2) Tilt lock stopper

Removing the Tilt Lock Stopper LAQSI-26

(3) Spring
(4) Tilt lock plunger

Disassembling the Tilt Lock Valve

-
INSPECTION

Caution:
0 Wash each part carefully. Repair or re-
place any defective part.
0 Although some part can be disassembled,
the service part is not available. It is
necessary t o replace one ASSY at a time.

1. Body and outlet housing inspection


(1) Sliding scratch of each spool
(2) Stepped wear and crack of the check
Inspecting the Body 1.~052-22
valve seat
(3) Damage of each el bow and cap

2. Spool inspection
( 1) Damage of the lift spool
(2) Damage of the tilt spool

Note:
Conduct the oil leak test t o check the wear
o f the spool.

Inspecting the Spool 1.~052-23

3. Relief valve inspection


(1) Stepped wear of the needle valve
(2) Defect and da.mage of the valve seat
( 3 ) Fatigue of the spring

Inspecting the Relief Valve ~~052-24

Tilt lock valve inspection


(1) Sliding conditions of the tilt lock
plunger
(2) Break and fatigue of the spring

lnspecting the Tilt Lock Valve

- 477 -
Flow divider valve inspect ion
(1) Sliding conditions of the piston
(2) Damage o f the ctieck valve
(3) Break and fatigue of the spring

Inspecting the Flow Divider Valve ~052-26

6. Check valve inspection


( 1) Stepped wear of the check plunger
( 2 ) Break and fatigue o f the spring

Inspecting the Check Valve ~ ~ 6 2 - 2 9

7. Seal holder and spring cover inspection


( 1 ) Break and fatigue of the spring
(2) Damage of the seal holder and spring
cover
(3) Wear and damage of the seal holder oil
seal.

lnspecting the Seal Holder and


Spring Cover
ASSEMBLY

1. Wash each part and blow it with compressed


air.

2. Assemblethefitting

Assembling the Nipple !as140

Assemble the outlet housing.


(1) Outlet housing
( 2 ) Set bolts
T = 3.5 -- 4.5 kg-m (25.3-- 32.5 ft-lb)

Assembling the Outlet Housing LAQS~-32

Assemble the tilt lock valve on the tilt spool.


(1) Spring
(2) Tilt lock plunger
( 3 ) After applying lock tight (locking com-
pound) to the tilt lock stopper, tighten
it.

Assembling the Tilt Lock Valve -27


LAQS ~

5. Assemble the check valve.


(1) Check plunger
(2) Spring
(3) Plug

Assembling the Check Valve LAQ!~~-12


6. Assemble the flow divider valve.
( 1 ) Valve
(2) Spring
(3) Stopper ( Lower side)
(4) Stopper (Upper side)

Assembling the Flow Divider Valve ~~052-6

7. Assemble the relief valve. Assemble the as-


sembled relief valve on the control valve
body.

Note:
When disassembling the relief valve, be sure
to loosen the adjusting screw fully.

(1) Relief valve


(2) Spring
(3) Main plunger
(4) Stopper
Assembling the Relief Valve LAQBI-34
(5) Valve seat

8. Assemble the lift spool and the tilt spool on


the control valve.
(1) Oring
(2) Back up ring
(3) Seal holder
(4) Spring holder
(5) Compression spring
(6) Spring holder
(7) Spool end
(8) Set bolt
SST 0961 0- 10160-71 '

Assembling the Spool LAQSI -24.23

Caution:
Assemble the seal holder in the correct direc-
tion.

Assembling the Spool Spring

480 -
Assembling the Spool 1.~061-17

9. Assemble the spring cover.


( 1 ) Spring cover
(2) Set screw

Assembling the Spring Cover LAO61-16

10. Assemble the seal holder


(1) Seal holder
(2) Set screws

Caution:
Assemble the seal holder in the correct
direction.

Assembling the Seal Holder LAQS~-14

INSTALLATION

Reverse the removeal procedure for installation.

Note:
0 Install the toe board after making the adjustment.
0 Apply chassis grease special (molybdenum disulfide grease) to the links of the oil control valve
lever.
Caution:
Be sure to make the adjustment according t o
the procedure given below. I f not so, the
hydraulic devices such as the oil pump may
be damaged by improperly adjusted hydrau-
lic pressure.

Remove the plug (9116-18UNF-2B) on the


oil control valve top and mount the oil pres-
sure gauge.
Oil Pressure Gauge Mounting Position LAQ~O-7

Remove the cap nut of the relief valve on


the oil control valve top to confirm that the
re1ief valve adjusting screw is loosened fully.
If not so, loosen it.

Start the engine to check oil leakage, abnor-


mal sound, etc.

Set the cotrol lever to lift position, and


tighten the adjusting screw slowly until the
forks start to rise. When the forks reach the
uppermost position, read the oil pressure
gauge indication. Adjust the set screw so Measuring the Hydraulic Oil Pressure LAQ~O-8

that the oil pressure becomes normal.

Relief set pressure: 185 kg/cm2 (2,630 psi)

Note:
0 Confirm that the no-load static maximum
rotational frequency is as specified. See
Engine adjustment section for details.
0 When the hydraulic oil pressure exceeds
the specified value, set the control lever
to the neutral position immediately.

Adjusting Hydraulic Oil Pressure

5. After adjusting the hydraulic oil pressure, tighten the lock nut and the cap nut.

6. Remove the oil pressure gauge and mount the toe board.
APPENDIX

Page
SSTLlST ....................................... 1 5 -2
SERVICE STANDARDS ......................... 15-7
WIRING DIAGRAM ............................. 15-21
SST LIST

Hanger, engine unit

09220-22000-71
Remover & replacer,
torque converter
clutch drum spring

Remover & replacer,


connecting rod

09228-4401 1
Wrench, oil filter
0

09230-201 50-7 1
Remover, torque
converter drive cover 0

09310-22000-71
Remover, reamer

09320-23000-71
Remover, bearing
Illustration Parts Number 1 2 3 4 5 6 7 811127314
and Name

@
09330-30010
Tool, universal
joint flange holding 0

09330-32880-7 1

rB Wrench, counter
shaft nut

09370-20270-7 1
0

Replacer, drive
pinion bearing 0 0 0

094 1 1 -41 800-7 1


Replacer, 2nd drive
shaft dust seal

09420- 1 041 0-7 1


Puller, pitman arm

09420-201 50-7 1
Remover & replacer,
king pin needle 0
bearing

09420-23000-7 1
Remover, bearing
0
Illustration Parts Number 1 2 3 4 5 6 7 8 1 1 121314
and Name

09470- 101 70-7 1


Pre-load tool,
main shaft 0

09480- 101 70-7 1


Remover & replacer
steering gear box 0
bushing

09 510-3 1 960-7 1
Remover & replacer,
brake hold down 0
spring

09608-2001 2
Tool set. front hub
GB e
d 0 0
S @CB

09608-300 1 2

@ Tool set, front hub


& drive pinion 0 0
e g bearing

09608-3501 4

e$g!j:
m
Ir.R
-Qab@
TOOI set, axle hub
& drive pinion
bearing
0 0 0 0

09609-2001 1
Puller, steering
wheel 0
Remover & replacer,
oil control valve

096 10-2001 2
Puller, pitman arm

096 1 1-20015
Puller, tie-rod end
0

09620-101 00-71
Remover & replacer,
cylinder cap 0 0

09620-10160-71
Remover & replacer,
cylinder cap 0

09620-30010
Q
fa Replacer, steering
gear box 0 0 0 0 0 0
Q
Q
Illustration Parts Number 1 2 3 4 5 6 7 811121314
and Name

09631 -22000-71
f.-MRY+
r*.'*yyy.' ~~~~:])
:-.?i
Chain wear scale

.--- .
0
-roroG
"
FOR.+
' . -
-zz=cizz
,$

09700-30200-71
Remover, spring
pin tool 0

0971 7-20010
Remover, brake shoe
return spring 0

09718-20010
Replacer, brake shoe
return spring 0

09810-201 72-71
Remover, joint pin
0 0 0

09905-00012
Expander, snap ring
0 0

09950-20017
Puller, universal
0 0 0 0 0 0 0
SERVICE STANDARDS
ENGINE

Item 3.25-4.5 ton models


1 1Z engine Standard 750 1 25
Idling speed rPm
3F engine Standard
750 +
25
(Vacuum: 400 mmHg or morel

Engine No-load static maximum 1 1Z engine Standard 2350 + AoO


speed 'pm 3F engine Standard 2350 + 50
Relief down at full relief 1 1Z engine Standard Below 200
'prn 3F engine Standard Below 250
With pad Standard 136 (5.31)
Accelerator Pedal height mm (in.)
Without pad Standard 125 (4.92)
pedal
Pedal stopper bolt height mm (in.) Standard 50 (1 -96)

Vacuum switch conduc- 11Z: - 700- - 900


Switch-on Standard
tion test (negative 3F: - 6 1 0 - - 7 9 0
Air 'leaner
pressure base) 11Z: - 660- - 890
(1989.9- 1 mmAq Switch-off Standard
3F: - 570 -- - 780
Fan belt flexure ( 1 988.6 -- 1990.7)
Standard 4 -- 8 (0.16 -- 0.31)
F~~ drive (when pushed with 1.2 kg (2.6 Ib))mm (in.)
unit Fan belt flexure (1990.7 -- )
Standard 6 -- 8 (0.24 -- 0.31 1
(when pushed with 3 kg (7 Ib)) mm (in.)
Battery Electrolyte specific gravity (at 20°C) Standard 1.280

CLUTCH

Item 3.25 - 4.5 ton models


Number of springs Standard 16
Free length of spring mm (in.) Standard 7 1.9 (2.83)
Squareness of spring mm (in.) Limit 3.7 (0.15)
Effective wear margin of facing
Standard 1.3 (0.051 )
(one side) mm (in.)
Pressure plate set height
Standard 5.6 (0.22)
Clutch (at four service bolts) mm (in.)
Release bearing plate set height
Standard 66.8 (2.63)
(at adjusting nut) mm (in.)
Release bearing plate parallelism
(inclination) mm (in.)
Standard 0.5 (0.01 9)

Allowable clearance between release


lever and bearing plate
(Release lever end deviation limit) Standard 0.1 5 (0.006) maximum
mm (in.)
Master cylinder to piston diameter
Limit 0.032 (0.001 3)
Clutch clearance mm (in.)
booster Power piston to valve diameter clearance
Limit 0.032 ( 0 . 0 01 3 )
mm (in.)
----- - - -- - - - -
CLUTCH (Cont'd)
ltem 3.25- 4.5 ton models
clutch pedal Height (from toe board) Without pad Standard 144- 143 (5.7 - 5.9)
(5FG 1 5FD mm (in.) With pad Standard 150 - 155 (5.9 - 6.1)
33 - 45 Pedal play mm (in.) Standard 3 - 7 (0.12 - 0.28)
series) Push rod play mm (in.) Standard 0.5 - 1.5 (0.02 - 0.06)
Clutch pedal
Without pad Standard
144 -149 (5.7 - 5.9) (-1998.2)
(6FG / 6FD Height (from toe board) 149 -154 (5.9 -- 6.1) (1998.2%)
33 - 45 mm (in.) 150 -155 (5.9 - 6.1) (-1998.2)
With pad Standard
series) 155 .- 160 (6.1- 6.3) (1998.2-)
Pedal play mm (in.) Standard 1 - 3 (0.02 - 0.06)
Push rod play mm (in.) Standard 0.2 - 0.3 (0.008 -- 0.012)
Release Release bearing to clutch release lever
Standard 1 -2 (0.04- 0.08)
cylinder clearance mm (in.)
Tightenign Torque
Strap seat set bolt kg-m (ft-lb) 1.8 - 3.0 (13.0 - 21.7)
Adjusting nut lock plate kg-m (ft-lb) 0.2 - 0.5 (1.44 - 3.61)
Flywheel set bolt kg-m (ft-lb) 6 - 9 (43.3 - 65.0)
Check ball set bolt kg-m (ft-lb) 0.8 - 1.2 (5.78 - 8.66)
Check ball set plug kg-m (ft-lb) 2.7 -- 3.5 (19.5 - 25.27)
Master cylinder piston SUB-ASSY set bolt kg-m (ft-lb) 0.8 - 1.2 (5.78 - 8.66)
Clutch booster to brake booster connecting bolt kg-m (ft-lb) 3.5 - 4.5 (25.3 - 32.5)
Bleeder plug kg-m (ft-lb) 9 - 13 (64.98- 93.86)

TORQUE CONVERTER
Item 1 3.25 - 4.5 ton models
I Inner
I Standard I 1 53.5 ( 6 . 0 4 3 )
Regulator valve spring free
length mm (in.)
Outer
Limit 1 3 5 . 0 (5.31 5)
Transmis-
slon cover Standard 153.5 (6.043)
Accumulator spring free length mm (in.)
& cotrol Limit 138.5 (5.453)
valve
Standard 128 (5.04)
Inching valve spring free length mm (in.)
Limit 115.5 (4.574)
Standard 6 4 (2.52)
Selector valve spring free length mm (in.)
Limit 58 (2.28)
Standard 7 0 . 0 (2.756)
Pump boss outside diameter mm (in.)
Limit 69.85 ( 2 . 7 5 0 )
Standard 8.3 (0.327)
Torque Stator roller outs~ded~ameter mm (in.)
converter Limit 8.17 (0.322)
0.08 - 0.1 19
Stator hub to cam clearance mm (in.)
Standard
( 0 0 0 31 - 0.0047)
Limit 0.1 5 (0.0059)
- 490 -
Item 3.25 - 4.5 ton models
Stator shaft outside diameter Standard 55 (2.17)
(sliding contact portion with oil pump gear)
mm (in) Limit 54.9 ( 2 . 16 1 )

Standard
0.12 - 0.20
Driven gear to pump body clearance (0.0047 - 0.0079)
mm (in.)
Limit 0 . 3 ( 0 . 01 2)
Stator Driven gear to crescent clearance Limit 0.4 (0.016)
shaft & oil mm (in.)
Pump Drive gear to crescent clearance rnm (in.) Limit 0 . 2 5 (0.010 )

Standard
0.03 - 0.079
Pump drive gear bush to stator shaft (0.001 2 - 0.003 1 )
clearance mm (in.)
Limit 0.1 5 (0.0059)
-
0 . 0 5 0.10
Pump body surface to drive/driven gear
clearance mm (in.)
Standard
-
(0.002 0.0039)
Limit 0.1 3 (0.0051 )
Main shaft piston seal ring side
Limit 0.3 (0.012)
clearance mm (in.)
F2 clutch drum piston seal ring side
Limit 0.3 (0.012)
clearance mm (in.)
Main shaft servo seal ring side clearance
Limit 0.29 (0.011 )
mm (in.)
F2 clutch shaft servo seal ring side
Limit 0.29 ( 0 . 01 1 )
clearance mm (in.)
Standard 4.5 (0.177)
Clutch pressure plate thickness mm (in.)
Limit 4.3 (0.169)
Transmis- Standard 2.0 (0.0079)
sion Clutch plate thickness mm (in.)
Limit 1.8 (0.071 )
Standard 2.6 (0.102)
Clutch disc plate thickness mm (in.)
Limit 2 . 4 (0.094)
Standard 3 . 4 (0.134)
C1utc.h camber plate warp mm (in.)
Limit 3.1 (0.122)
Standard 6 2 (2.44)
Clutch return spring free length mm (in.)
Limit 56 (2.20)
clutch piston ring side clearance mm (in.) Standard 0 . I5 (0.0059)
. Clutch camber plate to snap ring
clearance mm (in.)
Standard 1 .O - 2.5 (0.039- 0.098)
1 1 Z engine Standard 1950
Stall speed rpm
Measure- 3F engine Standard 2010
ment and -- - -

kg/cm2 at idling Standard Minimum 4 (57)


test Main pressure
(psi) at 1500rpm Standard 8 - 12 ( 1 1 4 - 171)
TORQUE CONVERTER (Cont'd.)

Item 3.25 - 4.5 ton models


Clutch operating pressure at idling Standard Minimum 4 (57)
Measure- kg'cm2 (psi) at 1500rpm Standard 8 - 12 (11 4 - 171)
ment and
test Torque converter outlet
pressure kg/cm* (psi)
at 1500rpm Standard 0.8 - 4 (11 - 57)
Tightening torque
Control valve sub-plate set bolt kg-m (ft-lb) 0.8 - 1.2 (5.8 - 7.9)
Cover & control valve ASSY set bolt kg-m (ft-lb) 1.9 -- 2.5 (13.7 - 18.1)
Pump boss set bolt kg-m (ft-lb) 1.9 -- 2.5 (13.7 -- 18.1)
Drive cover set bolt kg-m (ft-lb) 1.9 - 2.5 ( 1 3.7 -- 18.1)
Pilot boss set bolt kg-m (ft-lb) 1.9 - 2.5 (13.7 - 18.1)
Flexible plate set bolt .kg-m (ft-lb) 1.9 - 2.5 (13.7 -- 18.1 )
Oil pump ASSY set bolt kg-m (ft-lb) 1.9 -- 2.5 (13.7 -- 18.1)
Stator shaft & oil pump set bolt kg-m (ft-lb) 1.9 - 2.5 (13.7 -- 18.1)
Servo case set bolt kg-m(ft-lb) 1.9-2.5(13.7-18.1)
Oil filter kg-m (ft-lb) 1.5 - 2.0 ( 1 0.8 -- 14.4)
TRANSMISSION & DIFFERENTIAL

Item 3.25 - 4.5 ton models


Standard 22.0 (0.866)
Shift shaft outside diameter mm (in.)
Limit 2 1.7 (0.854)
Transmis- Shift lever tip end outside diameter Standard 13.0 (0.512)
sion case mm (in.)
cover Limit 12.5 (0.492)

Turn lever tip end outside diameter Standard 17 (0.67)


mm (in.) Limit 16.5 (0.650)

Shift lever inserting hole inside diameter Standard


. 13.0 (0.512)
mm (in.) Limit 13.6 (0.535)
Standard 9.8 (0.386)
Shift Fork tip end thickness mm (in.)
Limit 9.2 (0.362)
Shift fork to clutch hub sleeve clearance
mm (in.) Standard 1 .O (0.039)

Standard
-
0.05 0.1 5
Backlash (0.0020 -- 0.0059)
~ ~ ~ between
~ gears ~ mm~ (in.) i ~ -
sion gears Limit 0.26 (0.010 2 )
Input shaft bend mm (in.) Limit 0.1 (0.0039)
- -- -p

TRANSMISSION & Dl FFERENTIAL (Cont'd)

Item 3.25- 4.5ton models


Standard 3.65 (0.1437)
Rear side
Reverse idle gear thrust Limit 3.35 (0.131 9)
washer thickness mm (in.) Standard 310 (0.118)
Front side
Limit 2.6 (0.102)
Forward gear/reverse gear bushing Standard 44.0 (1.732)
outs~dediameter mm (in.) ~ i r n i t 43.7 ( 1.720)
Forward gear/reverse gear bushing Standard 45.0 (1.772)
length mm (in.) ~ i ~ i t 44.7 (1.760)

First gear bushing outside diameter Standard 44.0 (1.732)


Transmis- mm (in.) ~irnit 43.7 (1.720)
-
sion gears
Standard 40.5 (1.594)
First gear bushing length mm (in.)
Limit 40.2 (1.583)

Second gear bushing outside diameter Standard 44.0 (1.732)


mm (in.) ~imit 43.7 (1.720)
Standard 32.5 (1.280)
Second gear bushing length mm (in.)
Limit 32.2 (1.268)

Synchronizer ring to gear thrust


clearance (for forward(reverse) mm (in.)
Standard -
1.10- 2.30
(0.0433 0.091 )
Limit 0 . 3 (0.012)

Synchronizer ring to gear thrust 1.10- 1.90


clearance (for first/second speed)
Standard
-
(0.0433 0.0748)
mm (in.) Limit 0.3 (0.012)
Ring gear face runout on rear side
mm (in.) Limit 0.1 (0.0039)

Ring gear backlash mm (in.) Standard 0.2 - 0.3 (0.008 - 0.0 12)
Differential pinion inside diameter Standard 22.12 (0.871 )
mm (in.) Limit 22.22 (0.875)
Standard 22.00 (0.866)
Spider outside diameter mm (in.)
Output Limit 2 1.75 (0.856)
gear & dif-
ferential Thrust washer thickness Standard I .6 (0.063)
(differential pinion side) (in.) ~imit 1 .O (0.039)

Thrust washer thickness Standard 1.6 (0.063)


(side gear side) mm (in.) Limit 1.3 (0.051 )
Standard 13.0 (0.512)
Thrust screw cap length mm (in.)
Limit 12.2 (0.480)
Drive pinion bearing starting
force (measured at output gear
MTM Standard 13.9 - 17.0 (30.6 - 37.5)
outer circumference) k g (Ib) ATM Standard 15.7 - 19.2 (34.6 - 42.3)
TRANSMISSION & DIFFERENTIAL (Cont'd)

Item 3.25 -- 4.5 ton models


Differential case bearing starting
Drive pinion bearing starting
Output
force (measured at output gear
outer circumference) kg (Ib)
Standard
+
force 2 (4.4)
gear & dif-
ferential - -
0.2 0.3 ( 0 . 0 0 8 0 . 01 2)
(After fully tightening
Thrust screw cap clearance mm (in.) Standard the thrust ,screw, loosen
it by 1 / 8 turn)
Tightening torque
Ring gear set bolt kg-m (ft-lb) 13 - 18 (93.9 - 130)
Differential upper case set bolt kg-m (ft-lb) 4.4 - 5.5 (31.8 -- 39.7)
Output gear lock nut kg-m (ft-lb) 3 5 - 4 5 (253 - 289)
MTM 9 - 12 ( 6 5 - 8 7 )
Output gear &drive pinion ASSY set bolt kg-m (ft-lb)
ATM 7 - 8 (51 - 58)
Bearing cap set bolt kg-m (ft-lb) 12- 1 4 ( 8 7 - - 101)
Thrust screw lock nut kg-m (ft-lb) 10.5 - 13 ( 7 6 - 94)
Counter shaft nut kg-m (ft-lb) 17-22(123-159)
Transmission case rear cover set bolt kg-m (ft-lb) 1.5 - 2.2 (10.8 - 15.9)
Fork shaft taper bolt kg-m (ft-lb) 4.1 - 5.1 (29.6 - 36.9)
Shift lever lock pin set nut kg-m (ft-lb) 3.0 - 4.5 (21.7 - 32.5)
Turn lever lock bolt kg-m (ft-lb) 5 - 8( 3 6 - 58)

FRONT AXLE

Item 3 . 2 5 - 4 . 5ton models


Planet gear bushing inside diameter Standard 22 (0.866)
mm (in.) Limit 22.18 (0.873)
Front Planet gear shaft outside diameter Standard 22 (0.866)
axle ASSY mm (in.) Limit 2 1.85 (0.860)
Front axle shaft starting force (measured
Standard 7 - 13 ( 1 5 - 2 9 )
at axle housing set bolt) kg (Ib)
3.25. 3.5 E3.5 4.0, 4.5
Tire inflating pressure
ton models ton model ton models
250-1 5-1 6PR (I) (STD) kg/cm2 (psi) Standard 8.5 ( 1 21) - -

28x8-12.5-15-18PR (1) (OPT) -


Standard 7.5 ( 1 0 7 ) -
kg/cm2 (psi)
Wheels 2 8 x 8 - 1 5- 1 2PR (I) (OPT: Double) - -
Standard 7.0 (100)
kg/cm2 (psi)
8.25- 1 5-1 4PR (I) (STD) kg/cm2 (psi) Standard
'
- 8.0(114) -

8.25- 1 5-1 2PR (I) (OPT: Double) - -


Standard 7.0 (100)
kg/cm2 (psi)
300- 1 5- 18PR (I) (STD) kg/cm2 (psi) Standard - - 8.0 ( 1 14)
3 2 x 1 2.1-1 5-20PR (I) (OPT) kg/cm2 (psi) Standard - - 8.5 ( 1 21)
FRONT AXLE (Cont'd)

Item 3.25 - 4.5 ton models


Tightening Torque
Brake ASSY set lock nut kg-m (ft-lb) 9-12(65-87)
Hub bolt lock nut kg-m (ft-lb) 27 - 3 0 (19 5 -- 21 2)
Axle shaft lock nut kg-m (ft-lb) 3 0 - 3 5 ( 21 2 - 253)
Front axle housing set bolt kg-m (ft-lb) 22.5 - 3 3 ( 1 6 2 - 238)
Front axle bracket set bolt kg-m (ft-lb) 2 5 - 3 3 (181 - 2 3 8 )
Single tire kg-m (ft-lb) 30 - 3 3 ( 21 2 - 238)
Front wheel hub nut Double tire (inside) kg-m(ft-lb) 30-35(212-253)
Double tire (outside) kg-m (ft-lb) 35 - 4 0 (253 - 289)
REAR AXLE

- 4.5 ton models


?

Item 3.25
0.02 - 0 . 5 0
Front to back play mm (in.) Standard (0.0008 - 0.020)
utside
O
Standard 3 5 . 0 (1.38)
diamter
King pln mm (in.) Outside
diameter Limit 34.8 (1.37)
wear
Bush inside diamter wear mm (in.) Limit 67.0 (2.64)
utside
O
Standard 28.0 (1.10)
diameter
Rear axle Bell-crank pin mrn (in.)
ASSY Outside
diameter Limit 27.8 (1.09)
wear
King pin angle degree Standard 6"
-
0.02 0 . 5 0
Bell-crank clearance mm (in.) Standard
-
(0.0008 0.020)
0.02 - 0.1 5
Steering knuckle clearance mm (in.) Standard (0.0008 - 0.0059)
Steering knuckle starting force kg (Ib) Standard 3 - 5 (6.6 -- 1 1 .O)
Rear axle hub starting force kg (lb) Standard 1.4 - 4.3 (3.1 - 9.5)
- -

REAR AXLE (Cont'd)

Item 3.25 - 4.5 ton models


Toe-in mm (in.) Standard 0 + 4 ( O f 0.16)
5FG
Standard 2600 ( 102)
33 series
5FG
Standard 2 6 5 0 (10 4 )
3 5 seried
Rear wheel
alignment Minimum turning radius 5FG
Standard 2740 (1 08)
mm (in.) 3 5 series
5FG 2 8 0 0 ( 1 10)
Standard
4 0 series
5FG (D) Standard 2 8 5 0 (1 12)
4 5 series
Inflating pressure
7.00 - 12 - 12 PR (I) 3.25 4.0 - Standard 7.0 (99.54)
ton models
kg/cm 2 (psi)
Wheels
Inflating pressuree
7.00 - 12 - 12 PR (I) 4.5 8.5 ( 1 10.87)
Standard
kg/cm2 (psi) ton model

Tightening Torque
Tie rod castle nut kg-m (ft-lb) 7 - 8(51 - 5 7 )
Bell-crank pin set nut kg-m (ft-lb) 1.9 - 3.1 (13.7 - 22.4)
Steering knuckle lock nut kg-m (ft-lb) 3 - 4 . 5 (22 - 32)
Tie rod lock nut kg-m (ft-lb) 12- 15(87-105)
Drag link rod castle nut kg-m (ft-lb) 7 - 8 (51 - 5 7 )
Power cylinder rod castle nut kg-m (ft-lb) 12-15(87-105)
Rear wheel hub nut kg-m (ft-lb) 18-20(130- 144)

STEERING

Item 3.25 - 4.5 ton models


No. 1
Limit 2.00 (0.0787)
Adjust plate clearance thickness
mm (in.) No, 2
Steering thickness Limit 1.95 (0.0768)
gear box
ASSY Ball screw set lock nut starting force
kg (Ib)
Standard 0.3 - 0.7 (0.66 - 1.54)
Ball screw set overall starting force
Standard 0.7 -- 1.5 ( 1 . 5 4 - 3.3 1 )
kg (Ib)
STEERING (Cont'd)

Item 3.25 - 4.5 ton models


Lock-to-lock center
Standard 0 (0)
Steering Backlash p osition
gear box mm (in.) After full clokwise 0.1 - 0.3
ASSY (or counterclockwise) turn (0.0039 - 0.0 1 1 8)
Relief pressure kg/cm2 (psi) Standard 1 15 - 125 ( 1 635 - 1778)
Mast jacket Tilt shaft bend mm (in.) Limit 1.5 (0.059)
ASSY
Standard 55 (2.165)
Cylinder bore mm (in.) - -- - -- - -

Limit 55.35 (2.175)


Power utside
cylinder O
Standard 25 (0.984)
diameter
Piston rod mm (in.)
wear Limit 2 4 . 9 2 (0.981 )
Bend Limit 1 (0.039)
Tightening Torque
Top cover set bolt kg-m (ft-lb) 4.5 - 5.5 (32.5 - 39.7)
End cover set bolt kg-m (ft-lb) 4 . 0 -- 5.0 (29.2 - 36.5)
Side cover set bolt kg-m (ft-lb) 4.5 - 5.5 (32.5 - 39.7)
Pitman arm set nut kg-m (ft-lb) 16 - 19 ( 1 1 1.5 - 137.2)
Adjust bolt lock nut kg-m (ft-lb) 3.0 - 4.5 ( 21.7 - 32.5)
Adjust bolt cap nut kg-m (ft-lb) 3.0 - 4.5 (2 1.7 - 32.5)
Steering gear box set nut kg-m (ft-lb) 5 - 8 (36.5 - 58.4)
Steering wheel set nut kg-m (ft-lb) 2.0 - 3 . 0 (14 . 4 - 2 1.7)
Universal joint set bolt kg-m (ft-lb) 1.8-2.5(13- 18)
- 1995.3: 15-23(108--166)
Power cylinder piston lock nut kg-m (ft-lb)
1 9 9 5 . 3 ~12-16(87--116)
:

BRAKE

3.25, 3.5 E3.5, 4.0 4.5


lte m
ton models ton models ton model
3175
Standard C

( 1 2.50)
Brake drum ~ n s ~ dd~ameter
e mm (in.)
31 9.5
Limit C

Front ( 1 2.581
brake 9.3 9.1
Standard (0.36)
10.371
Brake shoe lining thickness mm (in.)
4.3
Limit (0.169)
C
BRAKE (Cont'd)

3.25, 3 . 5 E3.5. 4.0 4.5


Item ton model
ton models ton models

Upper
(small)
Standard
h504 -
Shoe hold spring free
clearance mm (in.)
Center
(large)
Standard
43.7
,72,
-
Front
brake Lower
(medium)
Standard (,
27.8
,09)
-
0.25-0.35
0.3 - 0.5
Brake drum to lining clearance mm (in.) Standard (0.0098-
0.01 38)
(O.O1 - 0.020)
Master cylinder to piston diameter 0.032
Limit t

Brake clearance mm (in.) (0.0013)


Power piston to valve diameter 0.032
Limit t

clearance mm (in) (0.001


3)

Parking 2 0 -- 25 25-30
brake Lever operating force kg (Ib) Standard
-
(44.1 55.1) (55.1-66.1)

Pedal height mm (in.) without pad Standard 134 (5.28)


(from toe board to pedal
top surface at center)
with pad Standard 140 (5.51)
Brake
p eda l
-
up to '88 Sep. 10 - 15 (0.39 - 0.59)
Pedal play mm (in.) Standard From '88 Oct. 5 - 8 (0.20 - 0.31)
Push rod play mm (in.) Standard 1 - 2 (0.04- 0.08)
Depressed pedal height mm (in.) Standard 90 or more (3.54)

Pedal height mm (in.) without pad Standard 1 3 4 (5.28)


(from toe board to pedal
topsurface at center)
with pad Standard 140 (5.51)
$ pedal
Inching lever stroke mm (in.) Standard 8 (0.31 )
Pedal play (reference value) mm (in.) Standard 3 - 6 (0.12 - 0.24)
Tightening torque
Parking brake actuator lever set nut kg-m (ft-lb) 1 . 4 - 2 . 3(10.1 - 16.1)
7.1-9.6 19- 26
Upper (51.3-69.4) ( 1 37 - 188)
Wheel cylinder set bolt kg-m (ft-lb)
12.8-17.4 12.5- 17
(90.4- 1 23)
Lower
(925-126)
Check ball set bolt kg-m (ft-lb) 0.8 - 1.2 (5.78 -- 8.66)
Check ball set plug kg-m (ft-lb) 2.7 - 3.5 ( 1 9.5 - 25.3)
Outlet check valve set plug kg-m (ft-lb) 5.3 - 8.4 (38.3 - 60.7)
Master cylinder piston SUB-ASSY set bolt kg-m (ft-lb) 0.8 - 1.2 (5.78- 8.66)
Brake booster to clutch booster connecting bolt kg-m (ft-lb) 3.5 - 4.5 (25.3 - 32.5)
Parking brake release rod knob kg-m (ft-lb) 1 .O - 1.6 (7.23 - 1 1.6)
MATERIAL HANDLING SYSTEM

Item 3.25 - 4.5 ton models


-
3'25 3'5
Standard 4 0 -- 120 (1.6 -- 4.7)
ton models
Natural
drop test
Natural drop mm (in.) E3.5, 4.0
ton models
Standard 60 - 1 5 0 (2.4 - 5.9)
4.5
ton model
Standard 4 0 -- 1 2 0 (1.6 - 4.7)
Natural
forward tilt Natural forward tilt mm (in.) Standard 18 - 6 0 (0.7 - 2.3)
teest

Oil leak
Lift cylinder oil leak amount
(at lift port) cc (CU. in.)
Standard 6 - 16 (0.37 - 0.98)
test
1 4 - 3 4 (0.85 - 2.08)
Tilt cylinder oil leak amount
Standard
(total of lift and tilt) cc ( CU . in.)

MAST

Item 3.25 - 4.5 ton models


Inner mast Iift roller lower Outside Standard 1 24.5 (4.90)
( 2 PCS.) diameter ~irnit 123.5 (4.86)
Outer mast lift roller upper
( 2 pcs.1 Inside Standard 45.0 (1.77)
mm (in.) diameter ~irnit 45.02 (1.772)

Outside Standard 124.5 (4.90)


Lift bracket roller upper, diameter ~imit 123.5 (4.86)
middle ( 4 pcs.)
mm (in.) Inside Standard 4 5 . 0 (1.77)
V mast diameter
ASSY ~ i ~ i t 45.02 (1.772)
-
(3.25 4 . 0 Outside Standard 124.5 (4.90)
ton models)
Lift bracket roller lower diameter ~irnit 123.5 (4.86)
( 2 PCS.)
mm (in.) Inside Standard 4 5 . 0 (1.77)
diameter ~ i ~ i t 45.02 (1.772)

Outside Standard 93.3 (3.67)


Lift bracket side roller diameter ~imit 92.3 (3.63)
( 4 PCS.)
mm (in) Inside Standard 35.0 (1.377)
diameter ~irnit 35.02 (1.378)

Inner mast Iift roller lower Outside Standard 1 64.5 (6.48)


V mast diameter
ASSY ( 2 PCS.) Limit 1 63.5 (6.43)
Outer mast lift roller upper
(4.5 ton Standard 4 5 . 0 (1.77)
model) ( 2 PCS.) Inside
mm (in.) diameter ~ i ~ i 45.02
~ (1.772)
MAST (Cont'd)

Item 3.25 - 4.5 ton models


lnner mast lift roller O/S
V mast lower ( 2 pcs.)
ASSY mm (in.) utside
O
Standard
-
(3.25 4.0 Lift bracket roller O/S diameter
ton models) upper, lower ( 2 pcs.)
mm (in.)
Individual bend mm (in.) Limit 15 (0.6)
Fork
Front end misalignment mm (in.) Limit 1 0 (0.4)

~ i froller
t at lift
Roller rolling face to
inner mast clearance
Standard 0.5- 2 . 0 (0.02 - 0.08)
bracket mm (in.)
0 - 0.5 ( 0 - 0.020)
Each lower roller
lateral movement Standad

V mast
Side roller at lift
bracket mm (in.)
Side roller lateral
movement
Standard - 0.5 (O - 0,020)
adjustment
0 - 0.8 ( 0 -- 0.03)
Inner mast roller
atera l Standard
Lift roller at mast l
mm (in.) Outer mast roller
Standard 0 - 0 . 8 ( 0 - 0.03)
lateral movement
Mast strip Mast strip inner
Standard 0.5 - 1.0 (0.02 - 0.04)
mm (in.) mast clearance
Nol Standard 1 24.5 (4.90)
middle
Lift bracket Upper No. 2 Standard 125.2 (4.93)
FV, SV, roller outside
FSV mast diameter Lower No. 3 Standard 124.5 (4.90)
adjustment mm (in)
-
(3.25 4.0
~ower No. 4 Standard 125.2 (4.93)
ton models) Side No. 5 Standard 93.3 (3.67)
Inner mast/middle mast No. 1 Standard 124.5 (4.90)
roller outside diameter
mm (in,) N O. 2 Standard 125.2 (4.93)
FV, FSV
mast Inner mast/middle mast
adjustment roller outside diameter No. 1 Standard 1 64.5 (6.48)
(4.5 ton mm (in.)
model)
FV, SV,
FSV mast
adjustment Outer mast roller. middle Outside
Standard 124.5 (4.90)
-
(3,25 4,0 mast upper roller mm (in.) diameter
ton models)
FV, FSV,
mast Outer mast roller, middle
adjustment Outside
mast upper roller mm (in.) diameter Standard 164.5 (6.48)
(4.5 ton
ton model)
15 - 19

MAST (Cont'd)

Item 3.25 - 4.5 ton models


Tightening torque
Chain adjust nut on lift bracket side
-
(3.25 4.0 ton models) kg-m (ft-lb)
10- 15(72--108)

Chain adjust nut on lift cylinder side


10-15(72- 108)
(3.25 -- 4.0 ton models) kg-m (ft-lb)
Chain adjust nut on lift bracket side (4.5 ton model) kg-m (ft-lb) 1 7 - 2 3 ( 1 2 2 - 166)
Chain adjust nut on lift cylinder side (4.5 ton model) kg-m (ft-lb) 17-23(122-166)

CYLINDERS

Item 3.25 -- 4 . 5 ton models


-
3.25 4.0
Limit 65.35 (2.573)
Cylinder bore wear ton models
mm (in.) 4.5
Limit 70.35 (2.770)
ton model
Lift
cylinder
-
3 . 2 5 4.0
Limit 49.92 (1.965)
Piston rod outside ton models
diameter wear mm (in.) 4.5
Limit 49.92 (1.965)
ton model
Piston rod bend mm (in.) Limit 2.0 (0.8)
Cylinder bore wear mm (in.) Limit 90.40 (3.559)
Tilt Piston rod outside diameter wear Limit 39.92 (1.572)
cylinder mm (in.)
Piston rod bend mm (in.) Limit 1 .O (0.04)
Forward
Standard 6"
Mast tilt
forward/ Mast angle
backward Backward 12"
Standard
tilt
angle
Tilt cylinder uneven motion mm (in.) Standard within 1 (0.039)
Tightening torque
Flow regulator valve kg-m (ft-lb) 9.0- 10.0 ( 6 5 . 0- 72.2)
Safety down valve kg-m (ft-lb) 6.0 - 7.0 (43.3 - 50.5)
OIL PUMP

Item 3.25 - 4.5 ton models


Depth of flaw on body Front side Limit 0.05 (0.0020)
inside surface mm (in.) Rear side Limit 0 . 1 (0.0039)

Bush inside diameter Front side Limit 24.1 (0.949)


mm (in.) Rear side Limit 17.1 (0.673)
-
Oil pump
A Limit 2.65 (0.1043)
Plate thickness mm (in.)
B Limit 4.85 (0.1909)

Gear shaft outside diameter Front side Limit 46.270 (1.821 7)


mm (in.) Rear side Limit 33.050 (1.3012)
~ i ~ h t e n i torque
ng
Rear oil pump body set bolt kg-m (ft-lb.) 1 0 (72)

OIL CONTROL VALVE

Item 3.25 - 4.5 ton models


Oil control Relief set pressure (for lift and tilt)
Standard 185 (2630)
valve kg/cm2 (psi)
tightening torque
Outlet housing set bolt kg-m (ft-lb) 3.5 - 4.5 (25.3 - 32.5)
WIRING DIAGRAM

Wiring Diagram (Diesel models: 112)

- 504 -
1- : Optional parts.
Wiring Diagram (Gasoline model: 3F)
- 506 -
1-: Optional parts.
PART II: 1994.9- (Minor change)
SECTION INDEX (CE014)

GENERAL
ENGINE
STEERING

APPENDIX

Supplement

Pub. No. CEO14


GENERAL
Page
EXTERIOR VIEWS .............................................. 0-2
VEHICLE MODEL ................................................ 0-3
FRAME NUMBER .............................................. 0-4
HOW TO READ THIS MANUAL ......................... 0-5
EXPLANATION METHOD .................................... 0-5
TERMINOLOGY .................................................. 0-6
COMPONENTS WEIGHT .................................... 0-7
RECOMMENDED LUBRICANT
QUANTITY & TYPES ....................................... 0-8
LUBRICATION CHART ....................................... 0-9
PERIODIC REPLACEMENT OF PARTS
AND LUBRICANTS .......................................... 0-1I
EXTERIOR VIEWS
VEHICLE MODEL

capacity
Load I Model

5FG33
Engine model Drive system Remarks

Gasoline
02-5FG33
3.25 ton
5FD33
Diesel
02-5FD33 Torque converter Wheelbase:
1800 mm
5FG35 (71 in)
IFZ Gasoline
02-5FG35 Torque converter

Diesel
Torque converter
3 . 5 ton
5FGE35
IFZ Gasoline
02-5FGE35 Torque converter

Diesel
Torque converter
-- - - - - - - - - - - - - - -

5FG40 Clutch
1 FZ Gasoline
02-5FG40 Torque converter Wheelbase:
4 . 0 ton 2000 m m
5FD40 Clutch (78.5 in)
11Z Diesel
02-5FD40 Torque converter

5FG45
1 FZ Gasoline
02-5FG45 Torque converter
4 . 5 ton
5FD45 I Clutch 1
02-5FD45
11z Diesel
Wheelbase:
5.0 ton 5FDA50 Torque converter 2200 mm
(86.5 in)
0- 4

FRAME NUMBER
Frame No. Punching Position

Frame No. Punching Format

Engine Model Punching format I Engine 1 Model 1 Punching format I


5FG33

02-5FG33 A5FG35-3000 1
1 FZ
5FG35 *A5FG35@30001
02-5FG35

5FD33

02-5FD33 5FD35-30001
11z
5FD35

02-5FD35
*5~D35@30001
lli 1 5FDA501
5FDA50-30001

* 5FDA50@30001
5FGE35
*: EEC spec.
02-5FGE35

5FG40 A5FG45-30001
1 FZ
02-5FG4O *A5FG45@30001

5FG45

02-5FG45
HOW TO READ THIS MANUAL
EXPLANATION METHOD
1. Operation procedure

( 1 ) The operation procedure is described in either pattern A or pattern B below.


Pattern A: Explanation of each operation step with a photo or illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration,
followed by explanation of cautions and notes summarized as point operations.

Example of description in pattern B

DISASSEMBLY.INSPECTION.REASSEMBLY Tightening torque unit T = N.m (kgf-cm) [ft-lbfl

If a place or part cannot be indicated


directly, the part name is described
on the either side of the illustration.

Example: 1 Piping
1

T = 46.09 - 48.05
(470 - 490)
[34.00 - 35.451

Disassembly Procedure
1 Remove the cover. [Point I ]

2 Remove the bush. [Point 21-Operation explained later

3 Remove the gear.

Point operations Explanation of key point for operation with an illustration

[Point 11 I
Disassembly: Put a match mark when removing the pump cover.

[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.12 mm (0.7528 in)
How to read components figures
(Example)

I
(1) The components figure uses the illustra-
tion in the parts catalog for the vehicle
model. Please refer to the catalog for
checking the part name. FIG number in parts catalog
The number at the right shoulder of each
components figure indicates the Fig. num-
ber in the parts catalog.

3. Matters omitted in this manual

(1) This manual omits description of the following jobs, but perform them in actual operation:

@ Cleaning and washing of removed parts as required


@ Visual inspection (partially described)
TERMINOLOGY
Caution:
lmportant matters of which negligence may cause accidents. Be sure to abserve them.

Note:
lmportant items of which negligence may cause accidents, or matters in operation procedure re-
quiring special attention.

Standard: Values showing allowable range in inspection and adjustment.


Limit: Maximum or minimum allowable value in inspection or adjustment.
COMPONENTS WEIGHT
unit: kg (Ib)

Component Weight (mass)

11Z 330 (728)


Engine
1FZ 250 (551

Transmission Wldifferential Approx. 200 ( 4 41 )

Torque converter Wldifferential Approx. 360 (794)

3.25 ton Approx. 1920 (4234)

3.5 ton Approx. 2220 (4895)

E3.5 ton Approx. 21 3 0 (4410)


Balance weight
4.0 ton Approx. 2520 (5557)

4.5 ton Approx. 2830 (6240)

5.0 ton Approx. 2830 (6240)

3.25 - Approx. 650 ( 1 433)


V mast ASSY Lllift bracket 4.0 ton
(with lift cylinder)
4.5 ton Approx. 850 ( 1 874)
(Lifting height: 3000 mm (118 in))
5.0 ton Approx. 950 (2095)
RECOMMENDED LUBRICANT QUANTITY & TYPES
Description Classification TYpe Application Quantity

API Motor Oil 1FZ 9.51 (2.5 US gal)


SD, SE, SF SAE30
Gasoline (SAE2O in cold area)
SAE20W-40
(SAE1OW-30 in cold
Engine area)

API Diesel engine oil 11Z 12.51 (3.3 US gal)


Diesel CC, CD SAE30
(SAE20 in cold area)
SAE 1 OW-30

API Hypoid gear oil M T M models 6.01 (1.6 US gal)


Transmission G L-4 SAE85W-90
GL-5

API Hypoid gear oil All models 9.51 (2.5 US gal)


Differential GL-4 SAE85W-90
GL-5

Torque converter ATF GM ATM models 151 (4.0 US gal)


DexronB I1

ISO Hydraulic oil I S 0 Fork height 681 ( 18 . 0 US gal)


Hydraulic oil VG32 VG32 3000 mm
(I1 8 in.)

Gasoline 951 ( 2 5 US gal)


models

Diesel models
951 ( 2 5 US gal)
Fuel tank 5FD33, 3 5

Diesel models
5FDE35, 1201 ( 3 2 US gal)
5FD40, 4 5
5FDA50

Chassis parts MP Grease All models Proper quantity

LLC .LLC 30-50% 1 FZ 13.01 ( 3 . 4 US gal)


mixture (for winter
Coolant or all season)
(Excluding reserve .Coolant with 11Z 13.OP (3.4 US gal)
tank) rustinhibitor (for
spring, summer
and autumn)

Coolant (Reservoir All models 1. 1P (0.3 US gal)


tank) t t (at Full level)

Propeller shaft Molybdenum disulfide All models Proper quantity


and oil pump grease
spline shaft
LUBRICATION CHART
Clutch Model

0 Inspection
Replacement
@ MP grease
@) Engine oil I. Inspect every 8 hours (daily)
a
@
Hypoid gear oil
Hydraulic oil
11.
111.
Inspect
Inspect
every
every
4 0 hours (weekly)
170 hours (monthly)
@ Hypoid gear oil IV. Inspect every 1000 hours ( 6 monthly)
@ Molybdenum disulfide grease V. Inspect every 2000 hours (annually)

1. Chain 11. Rear axle beam front


2. Differential gear 12. Rear axle beam rear
3. Front wheel bearing 13. Tilt steering universal joint
4. Power cylinder joint 14. Tilt steering locking mechanism
5. Transmission case 15. Mast support bushing
6. Rear wheel bearing 16. Tilt cylinder front pin
7. Steering knuckle king pin 1 7. Propeller shaft
8. Bell crank pin 18. Tie-rod
9. Oil tank 19. Oil pump spline shaft
10. Engine crankshaft 20. Tilt cylinder rear pin
Torque Converter Model

0 Inspection
Replacement
@ MP grease
@ Engine oil lnspect every 8 hours (daily)
@ Hypoid gear oil lnspect every 4 0 hours (weekly)
@ Hydraulic oil lnspect every 1 7 0 hours (monthly)
@ Automatic transmission fluid lnspect every 1000 hours (6 monthly)
@ Molybdenum disulfide grease lnspect every 2 0 0 0 hours (annually)

Chain Rear axle beam front


Differential gear Rear axle beam rear
Front wheel bearing Tilt steering universal joint
Power cylinder joint Tilt steering locking mechanism
Torque converter case Mast support bushing
Rear wheel bearing Tilt cylinder front pin
Steering knuckle king pin Propeller shaft
Bell crank pin Tie-rod
Oil tank Oil pump spline shaft
Engine crankshaft Tilt cylinder rear pin
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
l : Replacement

Interval Every Every Every Every


1 month 3 months 6 months 1 2 months

Every Every Every Every


1 7 0 hours 5 0 0 hours 1 0 0 0 hours 2 0 0 0 hours

Engine l e 4- t

Engine oil filter l t t

Engine coolant (every 2 years for LLC) l + c

Fuel filter l t

Torque converter oil l c

Torque converter oil filter l t

Transmission oil l

Differential oil l

Hydraulic oil l +

Hydraulic oil return filter l *' l t

Wheel bearing grease l

Spark plug (-1 997.2)


Air cleaner element l

Brake booster rubber parts l

Cups and seals for wheel cylinders l

Power steering hoses l *2

Power steering rubber parts l *2

Hydraulic hoses OS2

Fuel hoses OS2

Torque converter rubber hoses OU2

Chains l *3

* ' : for n e w vehicle *2: Every 2 years *3: Every 3 years

Replacement shall be made upon arrival of the operation hours or months, whichever is earlier
ENGINE
Page
ENGINE SECTIONAL VIEWS .............................. 1-2
MAJOR SPECIFICATIONS ................................. 1-3
ENGINE PERFORMANCE CURVES ..................... 1-3
I FZ ENGINE ASSY ............................................. 1-4
ENGINE REMOVAL-INSTALLATION ....................... 1-4
ENGINE SPEED ADJUSTMENT (1 FZ) ..................... 1-6
AIR CLEANER ..................................................... I -I O
RADIATOR ......................................................... 1-I 4
BATTERY ........................................................... 1-14
STARTING MOTOR ............................................ 1-15
ALTERNATOR .................................................. 1-I6
ACCELERATOR PEDAL ...................................... 1-18
ENGINE SECTIONAL VIEWS
1 FZ Engine
MAJOR SPECIFICATIONS

Engine type Gasoline, 4-cycle

Number of cylinders and arrangement


I
In-line 6 cylinders, vertical
I
u
Combustion chamber type Pent roof type

Valve mechanism DOHC chain drive and gear drive

Bore x stroke mm (in) 1 0 0 . 0 95.0


~ (3.937 x 3.740)

I Total displacement cm3 (in3) / 4476 (273) 1


I Compression ratio I 9.0 I
l ~ a x i m u mpower kWlrpm(JIS PSlrpm)[SAE HPlrpml 1 621210 0 (8512100) [8112 100 Netl I
I Maximum torque N-mlrpm(JISkgf-mlrpm)[SAEft-lbflrpm] 1 29411 200 (3011200) [20911200 Netl I
I Minimum specific fuel consumption glPS-h (rpml ( 1 9011 400 I
FrvFe weight (miss) kg (Ib) I 250 (551) I
No-load maximum rpm rPm 2350

ENGINE PERFORMANCE CURVES


1FZ Engine

Gasoline spec.
- - - - - -LPG spec.,30.0'1200

I I I I
10 14 18 22x lo2
Engine Speed (rpm)
IF2 ENGINE ASSY
ENGINE REMOVAL.INSTALLATI0N

1 Toe board
3 Radiator cover
9 Cooling water
13 Accelerator wire
14 Electrical wiring
17 Temporary hoisting of engine
24 Starting motor, flywheel, torque converter end plate
(torque converter vehicle)
Removal Prpcedure
Remove the toe board.
Remove the engine hood.
Remove the radiator cover.
Remove the air cleaner.
Remove the radiator reservoir tank and tank bracket.
Remove the battery and battery case Wlignitor.
Remove the fuel pipe and hose Wlfuel filter.
Remove the harness bracket.
Drain cooling water.
Remove the radiator and fan shroud.
Remove the exhaust pipe.
Remove the oil pump drive shaft ASSY.
Disconnect the accelerator wire.
Disconnect electrical wiring.
Remove the clutch housing cover, and remove the clutch cover, clutch disc and flywheel. (Clutch
vehicle)
(Refer t o " Clutch Removal" in Section 2 of published repair manual No. CE005.)
Remove the torque converter case cover, and remove the flexible plate set bolts. (Torque con-
verter vehicle) [Point 1 I
Slightly hoist the engine. [Point 21
Remove the engine mounting set nuts.
Remove the engine mounting brackets (RH and LH).
Support the lower side of the clutch housing (clutch vehicle) or torque converter case (torque con-
verter vehicle) w i t h a wooden block.
Disconnect the clutch housing and engine. (Clutch vehicle)
Disconnect the torque converter case and engine. (Torque converter vehicle)
Remove the engine. [Point 31
Remove the starting motor, flywheel, and torque converter end plate. (Torque converter vehicle)

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

Note:
Tighten the flywheel set bolt after applying a thread tightener (08833-00070). (Clutch vehicle and
torque converter vehicle)
The tightening torque of each bolt is as follows:
Unit: N.m (kgf-crn)[ft-lbfl
Torque converter end plate set bolt 49.03- 78.45 (500-800)[36.18 - 57.881
Clutch vehicle: 98.06- 156.91 (1000- 1600)[72.35- 115.761
(or 19.61 (200)[14.471+additional turn of 90")
Flywheel set bolt -
Torque converter vehicle: 98.06- 156.91 (1000- 1600)[72.35 1 15.761
(or 19.61 (200)[14.471+additional turn of 9 0 " )
Point Operations
[Point 1 1

Removal.installation: Rotate the torque converter for turn-


ing the flywheel.
Set bolts: 9 pcs.

[Point 21

Removal.installation: SST 0901 0-201 1 1-71

Removal.installation: Use sufficiently strong wires and


shackle for hoisting with the short-
est length possible to provide
enough hoisting stroke.

[Point 31

Removal.wiring: Remove after checking no omission of


hose or cable disconnection.

fast 0

Before warming up
(initial state)
idle cT 0

After full warming up


ENGINE SPEED ADJUSTMENT (1FZ)
Note:
When warming the engine up, depress the accelerator
pedal fully before starting the engine (to return the fast idle
cam to the initial position).

Idle Speed Inspection Adjustment

1. Warm up the engine.

Cooling water temperature: 80°C (176OF) or


above

Hydraulic oil temperature: 60°C (140°F) or above

2. Tachometer and vacuum gage installation.

(1) Disconnect the speed inspection connector and con-


nect the tachometer harness to the male side of the
inspection connector.
Vacuum gage connecting position (2) Disconnect the plug from the intake manifold and
connect the vacuum gage.

3. Idle speed inspection and adjustment.

( 1) Inspect the idle speed.

Standards

Speed: 7 5 0 & 5 0 rpm

Negative pressure: 6 0 0 0 0 Pa (612 3 mmH20)


( 4 5 0 mmHg) [241.06 inH201 [ I 7.72 inHg1.

(2) If the standard is not specified, turn the idle speed


screw @ and idle mixture adjusting
::::ti% for adjustment t o the specified speed
while the negative pressure is stabilized and maxi-
mized.

Note:
If the idle speed does not drop because of the idle up ad-
justing screw in contact with the lower side the idle up ac-
tuator rod, loosen the adjusting screw.

Fast idle Speed Inspection Adjustment

1. Install a tachometer.

2. Disconnect the vacuum hose from each of the fast idle


cam breaker and choke breaker, and plug each discon-
nected hose.

3. Start the engine and race it lightly until the fast idle le-
ver is engaged with the 4th stage of the cam.

4. Measure the fast idle speed in the state in step 3


above.

Standard: 1 5 0 0 rpm

5. When the standard is not satisfied, turn the fast idle


adjusting screw for adjustment.

6. After racing the engine slightly, repeat steps 3 to 5


again.

7. Reconnect the disconnected hoses.


ldle up lnspection Adjustment

1. Warm up the engine.

Cooling water temperature: 80°C (176O F) or


above

Hydralic oil temperature : 60°C (140°F) or above

2. Install a tachometer.

3. ldle up speed inspection.

(1) Start the engine and measure the speed with the
vacuum hose disconnected from the idle up actuator
and its end plugged.

Standard: 1200 * 2 5 rpm

(2) If the standard is not satisfied, make adjustment by


turning the adjusting screw.

Note:
The speed increases when the adjusting screw is tuned
clockwise.

(3) Connect the vacuum hose after the end of adjust-


ment.

ldle up adjusting screw

No-load Stabilized Maximum Speed Inspection and Adjust-


ment

1. Warm up the engine.

Cooling water temperature: 80°C ( 176OF) or above

Hydraulic oil temperature: 60°C (140° F) or above

2. Install a tachometer.

3. Inspect and adjust the no-load stabilized maximum


speed.

(1) Loosen the air governor bushing lock bolt.

(2) Measure the speed when the accelerator pedal is


fully depressed.

Standard: 2350 & 5 0 rpm

(3) If the standard is not satisfied, rotate the air gover-


nor bushing to adjust the speed while fixing the ad-
justing screw.
Note:
Below the standard speed: Turn the bushing clockwise.
Above the standard speed: Turn the bushing counter-
clockwise.

4. Inspect the relief speed.

( I ) Operate the tilt lever fully backward with the engine


running at the maximum speed and measure the en-
gine speed in the full relief state. Check to see that
the decrease in speed (relief down) is within the fol-
lowing range.

Standard relief down: Within 200 rpm

(2) If the standard is not satisfied, make adjustment by


turning the adjusting screw. The relief down de-
creases when the screw is turned counterclockwise.

5. Adjust hunting.

(1) If hunting occurs, make adjustment by turning the


bushing and adjusting screw.

Adjusting screw: Hunting adjustment

Bushing: Maximum speed adjustment

Note:
If hunting disappears in several times, it should be treated
as no hunting.

6. Repeat steps 3 to 5 to set the maximum speed to the


standard level.
AIR CLEANER
GENERAL

Evacuator valve

SPECIFICATIONS

Single (STD) Double (OPT)

TYpe Cyclone type t

Size 7-inch c

Intake type Fresh air introduction type c

Outer: 1 8 6 0 0 (2883)
Filtering area cm 2 (in 2 ) 1 4 6 0 0 (2263)
Inner: 51 0 (79.1 )

Others With evacuator valve t


COMPONENTS
AIR CLEANER CLEANING-INSPECTION
I. Open the engine hood.

2. Remove the element.


(I)Element

Note:
In case of the double element type (OPT), do not remove
the inner element for other than replacement.

3. Clean the element.


(1) For ordinary cleaning, blow with compressed air
[ 6 9 0 kPa (7kgf/cm 2 ) [ I 0 0 psi] or less1 vertically
along the pleats from the inside of the element.
If heavily contaminated, washing is possible.
(2) Element washing method
Dissolve neutral detergent in tepid water (approx.
40°C (104OF)) and immerse the element in it for
about 3 0 minutes. Then, rinse the element well with
clear water. [Water pressure: 275 kPa (2.8
kgf/cm 2 ) [ 4 0 psi] or less1
After washing, naturally dry the element or dry the
element with a dryer (cold air).

Note:
Do not damage the element during washing.
Never use compressed air or hot air for drying.

4. Clean the evacuator valve (dust discharge valve).


(1) Hold the tip end of the evacuator valve and dis-
charge dust and dirt from the inside of the valve.

5. Inspect the element.


(1) After cleaning, place an electric balve in the element
t o inspect any damage in the element. If any pin-
hole, tear or damage is found, replace it with a new
element.

6. Element replacement

Replace the element after it is washed six times or


generally at intervals of 1 2 months.

CLOGGING WARNING SYSTEM INSPECTION


1. Warning lamp inspection
(1) See that the air cleaner warning lamp comes on
when the ignition switch is turned ON and goes out
when the engine starts.
2. Individual inspection
(11 Use a mity vac t o apply a negative pressure to the
vacuum switch, and inspect conduction.

Standard
Gasoline model ( 1FZI-Diesel model ( 1 121:
7473 *
5 6 9 Pa ( 7 6 2 5 8 mmH20)
(56.0 & 4.3 mmHg)[30 & 2.28 inH20]
*
[2.205 0 . 1 6 9 inHg1: Conduction
1-14

RADIATOR
RADIATOR SPECIFICATIONS
- - - - - - - -

1 1Z engine vehicles 1FZ engine vehicles

Torque converter
Clutch Torque converter Clutch
3.25.3.5 ton E3.5 - 4.5 ton
Heat radiation capacity kcallh 30400 35300 30400 35300 37500

Core ( T x W x H) mm (in) 65 x 500 x 430 C t t


65 x 500 x 490
( 2 . 6 ~9.7x 16.9) ( 2 . 6 19.7X
~ 19.31

Fin pitch 5.012 4.012 5.012 4.012


mm (in) (0.2012) (0.1612) (0.2012) 10.16/2)
t

P r 88
~ (0.9)~112.81~ ~
c e c c

Tank cap valve


opening pressure
kPa (kgflcm'll~sil +-
44.9(0.051 10.71 +- +- t

valve

Cooling water capacity 3.2 (0.84) 3.8 (1 .OO)


(in radiator) P (US gal) 3.9 (1.03) 3.2 (0.84) 3.9 (1.03)

Reservoir tank capacity 1.1 (0.29) e c c c


P (US gal)

COOLING WATER CAPACITY AND LONG LIFE COOLANT LIST


Total coolant With 25% LLC With 30% LLC With 40% LLC Antirust mixing
capacity (to -12OC (10.4OF)) (to -1 5OC (5OF)) (to -24°C(-11.20F)) ratio 5%

Diesel vehicle (11 Z) 13.0 (3.43) 3.3 (0.87) 3.9 (1.03) 5.2 (1.37) 0.7 (0.18)

Gasoline vehicle (1FZ) 13.0 (3.43) 3.3 (0.87) 3.9 (1.03) 5.2 (1.37) 0.7 (0.18)

FAN SPECIFICATIONS

11Z 1 FZ

Fan diameter m m (in) 4 1 0 (16.14) t

Pulley ratio 1.2 1.45

BATTERY
SPECIFICATIONS

11z 11z
1FZ
( 1 2V Specifications) (24V Specifications)

TYpe 95D31R 55B24R C

Voltage x quantity V 12x 1 12 x 2 12 x 1

5-hour ratio capacity Ah 64 36 t

Electrolyte specific gravity c


1.280 t
(at 20°C (68OF))
STARTING MOTOR

Note:
The starting motor installing position is on either the right or the left side depending on the engine
model. The explanation here is for the case of the right side (1FZ engine). Remove the sedimenter first
for the case of the left side (112 engine).

1 Battery negative terminal


2 Toe board

Removal Procedure
1 Disconnect the battery negative terminal.

2 Remove the toe board.

3 Disconnect the starting motor wiring.

4 Remove the starting motor ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
1-16

ALTERNATOR
REMOVALmINSTALLATION

1 Battery negative terminal


2 Air cleaner
3 V belt

Removal Procedure
1 Disconnect the battery negative terminal.

2 Remove the air cleaner. ( IFZ engine model)

3 Loosen the V belt tension.

4 Disconnect the alternator wiring.

5 Remove the alternator ASSY.

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

Note:
Adjust the V belt tension.
V belt (alternator drive) tension adjustment

1. Check the V belt tension.

Standard (flexure when pushed with 9 8 N (10 kgf)[22


Ibl)
1FZ: 1 5 - 2 0 m m (0.59 -
0.79 in)
112: 8 - 1 3 m m (0.31 -
0.51 in)

Standard (when tension gage (SST) is used)

SST 0921 6-00021

1FZ: 147 - 3 4 3 N ( 1 5 - 3 5 kgf) [33 - 7 7 lbfl


112: 196 - 3 9 2 N (20 - 4 0 k g f ) [ 4 4 - 8 8 I b f l

2. Adjust the V belt tension.

1FZ
(1) Make adjustment by turning the adjusting bolt. Keep
pivot bolt A and lock bolt C, and adjust the tension
by turning adjusting bolt B.

11z
(1) Use a lever and move the alternator for adjustment.
ACCELERATOR PEDAL
ADJUSTMENT
1. Adjust the accelerator pedal height.
(1) Adjust accelerator link stopper bolt @ t o make
pedal height A satisfy the following dimension:

Accelerator pedal roller height


I F Z : A = 56.5 *2 mm (2.224 + 0.08 in)
112: A = 66.5 =t 2 mm (2.618 & 0.08 in)
(from accelerator bracket to top of roller)
1 FZ: B = 1 4 rnrn (0.55 in) (reference value)
1 1 Z: B = 1 3 m m (0.5 1 in) (reference value)

2. Adjust the height of accelerator pedal stopper bolt @.


1 FZ. 1 1 Z: C = 3 4 m m (1.34 in) (reference value)

1FZ engine models


(1) Depress the accelerator pedal gradually, and adjust
the height of stopper bolt @ so that the carburetor
throttle lever stops immediately before the full open-
ing position.

1 1 Z engine models
(1) Adjust the height of stopper bolt @ so that the
clearance between the injection pump lever and
maximum speed adjusting screw satisfies the fol-
lowing range when the accelerator pedal is in con-
tact with stopper bolt @.

D = 0 - 0.5 mm (0 - 0.020 in)


0 m m (0in) clearance here means that the accelera-
tor pedal comes into contact with the stopper bolt at
the same time with establishment of the contact be-
tween the lever and adjusting screw.
STEERING
Page
GENERAL ........................................................... 2-2
SPECIFICATIONS ........................................ 2-3
COMPONENTS ................................................... 2-3
STEERING WHEEL MAST JACKET ....................
m
2-5
................................... 2-5
REMOVAL-INSTALLATION
STEERING GEAR BOX ASSY ............................. 2-7
REMOVAL.INSTALLATI0N ................................... 2-7
DRAG LINK ......................................................... 2-9
ADJUSTMENT .................................................... 2-9
GENERAL

Tilt adjusting lever

/ - -
SPECIFICATIONS
Steering wheel diameter mm (in) 360 (14.17)

Steering wheel play mm (in) 25 - 50 (0.98 - 1.97)


Gear type Recirculating ball screw type

Gear ratio 1:18.5


Steering gear
Lock to lock 3.9

I Ball twist direction I Counterclockwise I


TYpe Semi-integral
Booster Relief valve set pressure
1710 (120) [I7061
kPa (kgf/cm2) [psi]

TYpe Double-acting

Cylinder bore mm (in) 55 (2.17)


Power cylinder
Piston rod outside diameter mm (in) 25 (0.98)

Piston stroke 290 (11.4)

COMPONENTS
450 1

01
---7

93510-1M10 -4
L... ...J

4m~0
STEERING WHEELuMAST JACKET
REMOVAL.INSTALLATION

5 Universal joint set bolt


8 Combination meter ASSY set bolt
9 Combination meter wiring

Removal Procedure
1 Remove the steering wheel. [Point 11

2 Remove the turn signal switch cover.

3 Remove the combination meter cover.

4 Remove the turn signal switch.

5 Remove the steering universal joint set bolts. [Point 21

6 Extract the tilt steering shaft upward.

7 Remove the steering universal joint.

8 Remove the combination meter ASSY set bolts.

9 Disconnect the combination meter wiring.

10 Remove the combination meter ASSY.

1 1 Remove the tilt lock device. [Point 31

12 Remove the mast jacket.


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

Note:
Coat MP grease on the tilt lock device and each sliding contact portion.
Add MP grease through the grease fitting of the steering universal joint.
The tightening torque for each portion is as follows:

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

Steering universal joint set bolt 17.65 - 24.52 (180 - 250) [13.02 - 18.091

Mast jacket set nut 34.32 - 53.94 (350 - 550) [25.32 - 39.791
Steering wheel set nut 19.61 - 29.42 (200 - 300) [14.47 - 21.711

Point Operations
SST
[Point 1I

Removal: SST 09609-2001 1

[Point 21

Removal: The main shaft and joint are fixed by through


bolts at the mainshaft shouldered portion as il-
lustrated.
Therefore, the bolts must be loosened and re-
moved.

[Point 31

Installation: Check the functioning of the tilt lock device.

Left screw
STEERING GEAR BOX ASSY
REMOVAL-INSTALLATION

5 6 4

1 Pitman arm position


2 Toe board

Removal Procedure
1 Operate the steering wheel t o bring the pitman arm and drag link connecting position t o the front
side.
2 Remove the toe board.
3 Remove the steering universal joint. (See mast jacket removal procedure steps 1 t o 7 on page
2-5.)
4 Disconnect the piping.
5 Disconnect the drag link. [Point I ]
6 Remove the steering gear box ASSY.

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

Note:
The tightening torque o f each part is as follows:

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

I Steering gear box set nut 1 49.03 - 78.45(500 - 800)[36.18- 57.881 1


Steering universal joint set bolt 17.65 - 24.52(1 80 - 250)[I 3.02- 18.091
Steering wheel set nut 19.61 - 29.42(200 - 300)i14.47- 21.711
Point Operations
[Point 1 I

Removal: SST 096 1 1-2001 5


DRAG LINK
ADJUSTMENT
1. Adjust the length to the following dimension by adjusting the screwed-in amount of the drag link
end.

C
L (Actual length)
C

-
-

View A

L (Actual length) mm (in) B (Actual length)


(Reference value) mm (in)
3.25.3.5 ton vehicle 1660*2 (65.35h0.08) 6 0 (2.36)

E3.5.4.0.4.5 ton vehicle 1861 &2 (73.27 *0.08) 63 (2.48)


5.0 ton vehicle 2060*2 (81.10&0.08) 63 (2.48)
OTHER MODIFICATIONS
Page
CLUTCH ............................................................. 3-2
TORQUE CONVERTER ....................................... 3-3
TRANSMISSION & DIFFERENTIAL .................... 3-5
FRONT AXLE .................................................... 3-5
REAR AXLE ....................................................... 3-6
BRAKE ............................................................. 3-6
BODY ............................................................ 3-7
MATERIAL HANDLING SYSTEM ....................... 3-9
MAST ................................................................. 3-9
CYLINDER .......................................................... 3-9
OIL PUMP ........................................................ 3-10
OIL CONTROL VALVE ........................................ 3-1O
CLUTCH
GENERAL
1. The specifications of the 1 FZ engine vehicles are the same as those of old 3F engine vehicles.
2. The specifications of the 1 12 engine vehicles remain unchanged.
3. Refer t o t h e a l r e a d y Part I, Section 2 i n t h i s m a n u a l f o r service jobs.
TORQUE CONVERTER
GENERAL
1. The torque converter for the 1FZ engine vehicles is the same as that for the 1 1 Z engine vehicles
for standardization. The specifications of the torque converter for 1 FZ engine are, therefore, the
same as those for the 11Z engine.

2. The torque converter for the 5.0 ton model is the same as that for the 4.5 ton model.

3. Perform service jobs according t o Part I, Section 3 i n t h i s manual w i t h 1. and 2. above i n


mind. Only th e m o d i f i e d points are described below.

Engine speed
- - 11Z 1FZ
--
Idling speed rPm 750*25 750* 50

No-load stabilized maximum speed 2350


+ 100

Stall speed
-
11Z 1FZ
-

Stall speed rPm 1950 1950

Flywheel sectional view (for 1 FZ engine)


3-4

Selector lever connecting rod installed dimension

R
I
I

E3.5 ton vehicle


4.0 ton vehicle
3.25 ton vehicle 4.5 ton vehicle
3.5 ton vehicle 5.0 ton vehicle

Control valve modification


The shape of the orifice installed on the control valve is modified.

New models
Old models (Common t o 1 FZ and 1 1Z engine vehicles)
TRANSMISSION & DIFFERENTIAL
GENERAL
1. The transmission remains unchanged.

2. No manual transmission is provided for the 5.0 t o n vehicle.

3. The d i f f e r e n t i a l f o r t h e 5.0 t o n vehicle i s t h e same as t h a t f o r t h e 4.5 t o n vehicle. Refer t o


Part I, Section 4 i n t h i s m a n u a l f o r service j o b s a n d a p p l y t h e service s t a n d a r d values f o r
t h e 4.5 t o n vehicle.

FRONT AXLE
GENERAL
1. The front axle remains unchanged.

2. The front axle for the 5.0 t o n vehicle is the same as that for the 4.5 ton vehicle.

Tire inflating pressure

Tire size Tire inflating pressure kPa (kgf/cm2) [psi]

% 250-15-16PR(I) 834 (8.5) [I211

3.25-3.5 t o n vehicle 28 x 12.5-15-1 8PR(I) 735 (7.5) [ 1071

28x8-15-12PR(I) 686 (7.0) [I001

% 8.25-15-14PR(I) 785 (8.0) [ 1 141

E3.5 t o n vehicle 7.50- 1 6- 1 2PR(I) 686 (7.0) [I001

8.25-1 5-1 2PR(I) t


% 300- 1 5- 1 8PR(I) 785 (8.0) [ I 141

32 x 12.1-1 5-20PR(I) 834 (8.5) [I211


4.0 - 5.0 t o n vehicle
7.50- 16-1 2PR(I) 686 (7.0) [loo]

8.25-1 5-1 2PR(I) T

% : STD
REAR AXLE
GENERAL
The structure of the rear axle remains unchanged.

Tire inflating pressure

Tire size Tire inflating pressure kPa (kgf/cm2) [psi]

3.25.3.5 ton vehicle


E3.5 ton vehicle 7.00-1 2-1 2PR ( I ) 686 (7.0) [I001
4.0 ton vehicle

4.5.5.0 ton vehicle T 834 (8.5) [ I 211

Minimum turning radius (outermost) Unit: mm (in)

3.25 ton vehicle 2600 (102)

3.5 ton vehicle 2650 (104)

E3.5 ton vehicle 2740 (108)

4.0 ton vehicle 2800 (110)

4.5 ton vehicle 2850 (112)

5.0 ton vehicle 3070 (121)

GENERAL
1. The brake structures (front brake, brake booster, parking brake and brake pedal) remain un-
changed.

2. The brake specifications f o r t h e 5.0 ton vehicle are the same as those for the 4.5 t o n
vehicle. Refer t o Part I, Section 6 i n this manual for service jobs and apply the service
standard values for the 4.5 t o n vehicle.
BODY
COMBINATION METER REMOVAL.INSTALLATION

1 Tilt steering
5 Combination meter wiring

Removal Procedure
1 Tilt the tilt steering post backward.
2 Remove the turn signal switch cover.
3 Remove the combination meter cover.
4 Remove the combination meter set bolts.
5 Disconnect the combination meter wiring.
6 Remove the combination meter ASSY.

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

BALANCE WEIGHT
The weight of the balance weight is described on page 0-7.
MATERIAL HANDLING SYSTEM
GENERAL
1. The hydraulic circuit remains unchanged.

2. Refer t o Part I,Section 10 in this manual for the natural drop test and natural forward tilt test
procedures. The service standards are as shown below.
The oil leak test remains unchanged.

Natural drop test Natural forward tilt test

-
4 0 120mm 18- 60mm
3.25.3.5 t o n vehicle
( 1- 6 - 4.7in)
3.25.3.5 t o n vehicle
-
(0.7 2.3in)

E3.5.4.0 t o n vehicle
-
6 0 150mm E3.5.4.0 t o n vehicle t
( 2 . 4- 5.9in)
4 . 5 t o n vehicle t
4 0 - 1 20mm
4.5 t o n vehicle 5 . 0 t o n vehicle t
(1.6-4.7in)

5.0 t o n vehicle T

GENERAL
1. The mast structure remains unchanged.

2. The m a s t f o r t h e 5.0 t o n vehicle p a r t i a l l y uses special p a r t s (back rest, l i f t bracket, chain,


etc.) b u t t h e s t r u c t u r e is t h e s a m e as t h a t f o r t h e 4.5 t o n vehicle. See Part I,Section 11 i n
t h i s m a n u a l f o r s e r v i c e j o b s a n d a p p l y t h e s e r v i c e s t a n d a r d v a l u e s f o r t h e 4.5 t o n
vehicle.
For m a s t a d j u s t m e n t o f t h e 5.0 t o n vehicle, a p p l y t h e values f o r t h e 4.5 t o n vehicle as
t h e r o l l e r s are t h e s a m e as t h o s e f o r t h e 4.5 t o n vehicle.

GENERAL
1. The structures of the lift and tilt cylinders remain unchanged.

2. T h o u g h t h e l i f t c y l i n d e r f o r t h e 5.0 t o n vehicle is a specialized one, t h e s t r u c t u r e is t h e


same as t h a t f o r t h e 4.5 t o n vehicle. Refer t o Part I, Section 12 i n t h i s m a n u a l f o r service
jobs, a n d a p p l y service s t a n d a r d values f o r t h e 4.5 t o n vehicle.
The specifications o f t h e f l o w r e g u l a t o r v a l v e f o r t h e 5.0 t o n vehicle are also t h e s a m e as
t h o s e f o r t h e 4.5 t o n vehicle.

3. The tilt cylinder is common t o all vehicles (3.25 t o 5.0 t o n vehicles).


OIL PUMP
GENERAL
1. The oil pump is not changed in structure but the delivery is changed.

2. Refer t o Part I,Section 13 i n this manual for service jobs.

OIL PUMP SPECIF1,CATIONS


- - 1 1 Z engine vehicle 1 FZ engine vehicle

Oil pump name Tandem gear pump t

Manufacturer's model SDY (SGP2+YPl5) t

Theoretical delivery Main Pump lfront 55.8 (3.405) 48.7 (2.972)


cm3/rev (in3/rev) Sub pump (rear side) 7.00 (0.427) t

Delivery Main pump (front side) 77.0 (20.33) 67.2 (17.74)


Umin (USgalImin)
(pump at 1500 rpm) Sub pump (rear side) 9.66 (2.550) t

Drive method Direct drive by engine using universal joint


Rotational ratio to engine I : ? t

Lifting speed list (V mast)

Lifting speed mmlsec (f pm)


Vehicle model Engine oil pump
No load Loaded

3.25 - 4.0 ton vehicle 1FZ SDY (SGP2 + Y P l 5 ) 4 9 0 (97) 4 7 0 (93)

t 11Z t 550 (109) 510 (101)

4.5 ton vehicle 1 FZ t 4 1 0 (81) 3 9 0 (77)

t 11Z t 4 8 0 (95) 4 4 0 (87)

5.0 ton vehicle t t t t

OIL CONTROL VALVE


GENERAL
1. The oil control valve remains unchanged.

2. Refer to Part I, Section 1 4 in this manual for service jobs.


APPENDIX
Page
SST LIST .... .,....................................................... 4-2
SERVICE STANDARDS ...................................... 4-3
WIRING DIAGRAM ............................................. 4-5
SST LIST
Section
Illustration Part No. Part name
1 2 3

4 y;- 0921 6-0002 1 Belt tension gage 0

09609-2001 1 Steering wheel puiler 0

e 0961 1-2001 5 Tie rod end puller 0

09010-201 11-71 Engine unit hanger 0


- -
-

SERVICE STANDARDS
ENGINE
Engine
1FZ Standard 750* 50
Idling speed rPm
11Z Standard 750 * 25
1FZ Standard 2350& 50
No load stabilized maximum speed rPm
1 12 Standard 2350+Aoo

1FZ Standard Within 200


Engine speed down at full relief rPm
11Z Standard t
Air cleaner

Vacuum switch continuity test (conduction)


1FZ Standard 7473 * 569 (762 * 58) [30* 2.281
Pa ImmH20) [in H201
' , 1z Standard t
Alternator
Alternator driving V belt tension 1FZ Standard 15- 20 (0.59- 0.79)
(when pushed with 99 N (10 kgf) 122 Ibl)
mm (in) 11Z Standard 8 - 13 (0.31 -0.51)

Alternator driving V belt tension 1FZ Standard 147- 343 (15- 35)133-771
(when tension gage EST) is used)
N (kgf) [Ibfl 112 Standard 1 96 - 392 (20- 40) I44- 881
Accelerator pedal
Pedal rolier height 1FZ Standard 56.5&2 (2.224 & 0.08)
(from accelerator bracket to top of roller)
mm (in) 11Z Standard 66.5&2 (2.618 & 0.08)

Tightening torque Unit: N-m (kgf-cm) [ft-lbfl


1FZ Standard 49.03- 78.45 (500 - 800) 136.18 - 57.881
Torque converter end plate set bolt
1l Z Standard t

Clutch Standard
98.06 -172.35
156.91 (1000 - 1600)
- 11 5.761
Flywheel set bolt
Torque Standard t