Toyota FORKLIFT 5FD 7 0-30 Series Manual Download

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FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT

7 0 -3 0 Series. Please use this manual for providing quick, correct

servicing of the corresponding forklift models.

These models on the market since August 7986 are subject to minor changes

i n September 7986. This manual deals with the models produced i n the period

between A

988

and August

7 9 8 9 as well as the models as of September

7 989 (after

changes}.

Any change or modifications thereafter will be informed by Toyota

Vehicles' Parts

Service News.

For the service procedures of the mounted engine, read the repair manuals

listed below as reference together with this manual.

(Reference)

Repair manuals related to this manual are as follows:

TA INDUSTRIAL VEHICLE 4P ENGINE

REPAIR MANUAL (No.

TOYOTA INDUSTRIAL VEHICLE 4

ENGINE

REPAIR MANUAL (No.

TO YO TA INDUS TRIAL VEHICLE

ENGINE

REPAIR MANUAL (No.

TO YO TA INDUSTRIAL VEHICLE

ENGINE

REPAIR MANUAL (No. CE60

TO YO TA INDUSTRIAL VEHICLE

ENGINE

REPAIR MANUAL (No. CE67

TOYOTA INDUSTRIAL VEHICLE DZ ENGINE

REPAIR MANUAL (No. CE6

(Note: 2 - 3 ton models mounted with

diesel engine are only available

designated areas.)

TOYOTA MOTOR CORPORATION

Summary of Contents for FORKLIFT 5FD 7 0-30 Series

Page 1: ...oyota Industrial Vehicles Parts Service News For the service procedures of the mounted engine read the repair manuals listed below as reference together with this manual Reference Repair manuals related to this manual are as follows TOY0TA INDUSTRIAL VEHICLE 4P ENGINE REPAIR MANUAL No CE604 TOYOTA INDUSTRIAL VEHICLE 4Y ENGINE REPAIR MANUAL No CE602 TOYOTA INDUSTRIAL VEHICLE 2J ENGINE REPAIR MANUAL...

Page 2: ......

Page 3: ...RQUE 0 8 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 0 10 FRAME NUMBER 0 11 WIRE ROPE SUSPENSION ANGLE LIST 0 14 SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE 0 14 COMPONENT WEIGHT 0 15 RECOMMENDED LUBRICANT QUANTITY TYPE 0 17 LUBRICATION CHARTS 0 21 PERIODIC MAINTENANCE 0 22 PERIODIC REPLACEMENT LUBRICANTS AND PARTS 0 29 ...

Page 4: ...EXTERIOR VIEWS Front View 5FG15 LATI4 16 Rear View 5FG15 LAT14 18 ...

Page 5: ...ngine tYPe Gasoline f f f D esel T Gasoline f 7 t Diesel f Gasoline t f t Diesel t Gasoline f f Diesel t Gasoline t t t Diesel t f f Drive system 11 clutch Torque converter 11 clutch Torque converter 11 clutch Torque converter I1 clutch Torque converter 11 clutch Torque converter 1 1 clutch Torque converter I 1 clutch Torque converter I 1 clutch Torque converter I I clutch Torque converter 11 clut...

Page 6: ......

Page 7: ...rque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Load capac ty 1 0 ton 1 35 ton 1 5 ton 1 75 ton 2 0 ton 2 25 ton Model 5FG10 02 5FG10 40 5FG10 42 5FG10 5FD10 02 5FD10 5FG14 02 5FG14 40 5FG14 42 5FG14 5FD14 02 5FD14 5FG15 02 5FG15 40 5FG15 42...

Page 8: ...h Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter 4Y 3 ton series Engine model 1z 1DZ 5K 4Y 1z 1DZ Drive system Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter 2 75 ton 3 0 ton 5FD28 02 5FD28 60 5FD28 62 5FD28 5FG30 02 5FG30 5FD30 02 5FD30 60 5FD30 62 5FD30 1Z 1D...

Page 9: ...ion Before Bottom Dead Center Left Hand Long Life Coolant Manual Transmission Overhead valve Option Oversi e Horsepower 4 Genuine Toyota parts Genuine Toyota parts should be used even in the replacement of packings gaskets and O rings Abbreviation Code P S RH SAE SST STD SUB ASSY T OOT U S w 5 Repairs on electrical system Before doing any repairs on the electrical system disconnect the cables from...

Page 10: ... a standard unit The nut tightening torque can be judged from the bolt type See the item above LIST OF BOLT TYPES AND STRENGTH 1 Judging by part 1 Shape and class Hexagon head bolt Bolt head No Hexagon flange bolt No mark Hexagon head bolt Hexagon Three protruding head bolt Two protruding lines Hexagon flange bolt Welded bolt l protruding Class 2 Judging by part No Hexagon head bolt Parts No I 916...

Page 11: ...STANDARD BOLT TIGHTENING TORQUES ...

Page 12: ...e hose fitting and mating nipple contact surfaces with clean cloth to remove foreign matters and dirt Also check no dent or other damage on the contact surfaces before installation 2 When connecting a high pressure hose hold the hose to align the fitting with the nipple and tighten the fitting 3 The maximum tightening torque must not exceed twice the standard tightening torque Nominal diameter of ...

Page 13: ...5FG18 5FG18 10001 4 Y 40 5FG10 42 5FG10 40 5FG14 42 5FG14 40 5FG15 42 5FG15 40 5FG18 42 5FG18 405FG18 10001 2 ton series 2 J 5FD10 02 5FD10 5FD14 02 5FD14 5FD15 02 5FD15 5FD18 02 5FD18 5FD18 10001 4 P 5FG20 02 5FG20 5FG23 02 5FG23 5FG25 02 5FG25 5FG25 I0001 1 Z 5FD20 02 5FD20 5FD23 02 5FD23 5FD25 02 5FD25 5FD25 10001 4 Y 40 5FG20 42 5FG20 40 5FG23 42 5FG23 40 5FG25 42 5FG25 405FG25 10001 2 J 60 5F...

Page 14: ...ries Engine model Vehicle model Punching format 3 0 ton series 4 P 2 J 60 5FD28 62 5FD28 60 5FD30 62 5FD30 605FD30 10001 4 Y 5FG28 02 5FG28 5FG30 02 5FG30 5FG30 10001 1 Z 5FD28 02 5FD28 5FD30 02 5FD30 5FD30 10001 ...

Page 15: ...FD23 60 5FD25 62 5FD25 A605FD25 40011 1Z 5FD20 02 5FD20 5FD23 02 5FD23 5FD25 02 5FD25 5FD25 40011 Engine model Vehicle model Punching format 3 ton series 5K 5FG20 02 5FG20 5FG23 02 5FG23 5FG25 02 5FG25 A5FG25 40011 4Y 40 5FG20 42 5FG20 40 5FG23 42 5FG23 40 5FG25 42 5FG25 405FG25 40011 1DZ 60 5FD28 62 5FD28 60 5FD30 62 5FD30 A605FD30 40011 A Engine model Vehicle model Punching format 4Y 5FG28 02 5F...

Page 16: ...mm 0 32 in 10 mm 0 4 in 12 5 mm 0 5 in 14 mm 0 56in Cutting load Tension 1 OO time 1 04 time 1 16 time Single rope suspension Two rope suspension Compres 0 time 0 27 time 0 58 time Four rope suspension Suspension method Lifting angle 90 120 w F 2t I Tension 1 41 time 2 00 time 2t 2t Compres sion 1 OO time 1 73 time Suspension method 2 t 2t b ...

Page 17: ... One speed 152 335 AlSlN Twospeed 163 359 1 ton series 210 463 2 ton series 260 573 3 ton series 318 701 1 0 ton Approx 430 950 1 35 ton Approx 645 1420 1 5 ton Approx 785 1730 1 75 ton Approx 915 2020 2 0 ton Approx 1110 2670 2 25 ton Approx 1225 2700 2 5 ton Approx 1430 31 50 2 75 ton Approx 1670 3680 3 0 ton Approx 1860 4100 1 O ton Approx 400 880 2 0 ton Approx 500 1100 3 0 ton Approx 600 1320...

Page 18: ...0 Approx 1225 2700 Approx 1430 3150 Approx 1670 3680 Approx 1864 4100 Approx 400 880 Approx 500 1100 Approx 600 1320 Engine 5K 4Y 1DZ 1Z Transmission ASSY Torque Converter ASSY Differential Front Axle w Brake Balance Weight Mast AlSlN One speed Two speed 1 ton series 2 ton series 3 ton series 1 0 ton 1 35 ton 1 5 ton 1 75 ton 2 0 ton 2 25 ton 2 5 ton 2 75 ton 3 0 ton 1 0 ton 2 0 ton 3 0 ton ...

Page 19: ...8 US gal 27 2 7 1 US gal 34 2 9 0 US gal 37 11 9 8 US gal Proper quantity Reservoir Tank 0 2 Q 0 05 US gal Proper quantity 1 Engine Type Motor oil SAE30 SAE20 in cold area SA E20W 40 SAE 1OW 30 in cold area Diesel engine oil SAE30 SAE20 in cold area SAE 1OW 30 Hypoid gear oil SAE85W 90 GM Dexrono II Hypoid gear oil SAE85W 90 Hydraulic oil 90 SAE J 1703 DOT 3 MP Grease LLC 30 50 mix ture for winter...

Page 20: ...M ATM MTM ATM MTM ATM MTM ATM 1 O 1 75 ton vehicles 9 7 2 56 11 5 3 03 9 7 2 56 11 5 3 03 12 7 3 35 14 5 3 70 2 0 2 5 ton vehicles 9 9 2 61 11 2 2 95 9 9 2 61 11 2 2 95 9 3 2 46 8 6 1 01 14 9 3 93 14 2 3 75 2 75 3 0 ton vehicles 12 2 3 22 11 8 2 92 9 6 2 53 9 2 2 43 15 2 4 01 14 8 3 72 ...

Page 21: ... ton series 1 ton series Description Coolant ReservoirTank Classification API SD SE SF API CC CD API GL 4 GL 5 ATF API GL 4 GL 5 IS0 VG32 Engine 2tonseries 3 ton series Fuel tank 1 ton series 2 ton series 3 ton series Brake 1 ton series 1 O 1 75 ton models TYpe Motor oil SAE30 SAE20 in cold area SAE20W 40 SAE1OW 30 in cold area Diesel engine oil SAE30 SAE20in cold area SAE1OW 30 Hypoid gear oil SA...

Page 22: ...es 1z 1DZ Drive method MTM ATM MTM ATM 2 75 3 0 ton vehicles 1 0 1 75 ton vehicles 5 5 1 45 7 3 1 93 7 5 1 98 9 3 2 46 MTM ATM MTM ATM 5 7 1 50 7 0 1 85 7 7 2 03 9 0 2 38 10 0 2 64 9 6 2 53 9 7 2 56 9 3 2 46 8 3 2 19 7 9 2 09 9 4 2 48 8 7 2 30 5 8 1 53 7 6 2 01 8 0 2 19 7 3 1 93 ...

Page 23: ...P grease 2 Engine oil 3 Hypoid gear oil 4 Hydraulic oil 5 Gear oil 6 Brake fluid 1 O 1 75 ton models Clutch Model Lubrication Chart LAOM136 Chain Differential Front wheel bearing Brake master cylinder 1 O 1 75 ton models Torque converter case Rear wheel bearing Steering knuckle king pin Bell crank pin Oil tank Engine crank case Rear axle beam front Rear axle beam rear Tilt steering universal joint...

Page 24: ...on Cylinder head bolt loosening Muffler rubber mount Clogging and damage in PCV valve and piping No load maximum rpm Oil leak Oil level Clogging and dirt of oil filter Fuel leak Operation of carburetor link mechanism Dirt and clogging of fuel filter and element Injection timing lnjection nozzle injection pressure and spray status Draining of sedimenter Coolant level in radiator and leak Rubber hos...

Page 25: ...ns Inching valve function Stall and hydrau lic pressure measurement Loose joint Looseness at spline connections Looseness of universal joint Twisting and cracks of axle shaft 12 2000 0 0 0 M I I I I I I I I I T I I I I I M T I I I Wheels 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Tire inflation pressure Tire cuts damage and uneven wearing Lo...

Page 26: ...age Linkage wear and mounting condition Oil leak Mounting and linkage looseness Damage of power steering hose King pin looseness Cracks and deformation Wheel alignment Left and right turning angle SYSTEM 12 2000 0 0 0 Brake pedal Parking brake Brake pipe Reservoir tank I I I T C I I I I I I I M M Play and reserve Braking effect Operating force Braking effect Rod and cable looseness and damage Leak...

Page 27: ...h part and crack at welded part Mast and lift bracket looseness Wear and damage of mast support bush Wear damage and rotating condition of rollers Wear and damage of roller pins Wear and damage of mast strip Tension deformation and damage of chain Chain lubrication Abnormality of chain anchor bolt Wear damage and rotating condition of chain wheel Abnormality and mounting condition of each part SYS...

Page 28: ...eformation and damage Loose joint SYSTEM Ignition timing Starting rnotor Charger Battery Electrical wiring 1 170 0 Cracks on distributor cap Spark plug burning and gap Distributor side terminal burning Distributor cap center piece wear and darnage Plug cord internal discontinuity Ignition timing Pinion gear meshing status Charging function Battery fluid level Battery fluid specific gravity Darnage...

Page 29: ...ew mirror Seat Body Others 6 1000 0 0 Engine stop poing system 1 Diesel engine key stop device function I I T I I I I I I I I I I T L DEVICES ETC Cracks at welded portion Deformation and damage Loosening of mounting Deformation crack and damage Function and mounting condition Function and mounting condition Function and mounting condition Functions Function and mounting condition Dirt damage Rear ...

Page 30: ...ter oil filter Transmission oil Differential oil Hydraulic oil Hydraulic oil filter Wheel bearing grease Spark plugs Cyclone air cleaner element Brake vaIve rubber parts Cups and seals for master and wheel cylinders Brake fluid Power steering hoses Power steering rubbers parts Hydraulic hoses Reservoir tank tube Fuel hoses Torque converter rubber hoses Chains 1 month 170 hours a 1 a 3 months 500 h...

Page 31: ...Y DISCONNECTION TORQUE CONVERTER TYPE VEHICLE CLUTCH TYPE VEHICLE ENGINE ASSY INSTALLATION 4P ENGINE VEHICLE 1986 8 1989 8 2J ENGINE VEHICLE 1986 8 1989 8 1Z ENGINE VEHICLE 4Y ENGINE VEHICLE 5K ENGINE VEHICLE 1989 9 1DZ ENGINE VEHICLE 1989 9 ENGINE TUNE UP 4P 4Y 5K ENGINE VEHICLE 2J 1 Z l DZ ENGINE VEHICLE AIR CLEANER RADIATOR MUFFLER AND EXHAUST PIPE BAlTERY STARTING MOTOR ALTERNATOR ACCELERATOR ...

Page 32: ...GENERAL 1 I 4P Engine Front View 1986 8 1989 8 KAF1 1 I 1 4P Engine Rear View 1986 8 1989 8 KAF25 32 ...

Page 33: ...4Y Engine Front View KAJ14 2 1 4Y Engine Front View KAJl4 16 ...

Page 34: ...2J Engine Front View 1986 8 1989 8 KAH2 2 i 2J Engine Rear View 1986 8 1989 8 KAHI 15 ...

Page 35: ...12 Engine Front View KAG1 14 1Z Engine Front View ...

Page 36: ...1 5K Engine Front View 1989 9 1 KAPI 4 5K Engine Front View 1989 9 1 KAPI 5 ...

Page 37: ...1DZ Engine Front View 1989 9 1 1DZ Engine Front View 1989 9 1 ...

Page 38: ...237 2953 2481 2 75 3 0 ton No load maximum governed speed rpm 3050 2450 2300 3050 2600 2J 4Y 1Z 2J 2600 2600 2600 2600 2600 Rated horsepower PS rpm 35 2800 4512100 4412700 3512800 5412400 Maximum torque kg m rpm 10 5 1800 16 511800 14 512000 10 511800 16 5 1800 6012400 5012500 54 2400 60 2400 5012500 18 5 1600 14 512200 16 5 1800 18 511600 14 512260 ...

Page 39: ... 1486 2237 2953 2486 2237 2953 2486 No load maximum governed speed rpm 3050 2600 2600 3050 2600 2600 2600 2600 2600 2600 Rated horsepower PS rpm 38 2800 54 2400 55 2400 38 2800 54 2400 60 2400 55 2400 54 2400 60 2400 55 2400 Maximum torque kg m rpm 1 1 5 2000 16 5 1800 17 0 1600 1 1 5 2000 16 5 1800 18 5 1600 17 0 1600 16 5 1800 18 5 1600 17 0 1600 ...

Page 40: ...1 10 PERFORMANCE CURVES Engine speed rpm 4P Engine Performance Curve 1986 8 1989 8 LAOM18 ...

Page 41: ...4 18 22 26 XI 02 Engine speed rpm 1 O 1 75 ton vehicle 2J Engine PerformanceCurve 1986 8 1989 8 43 1 19511000 KAOM19 20 300 5 280 E 260 2 240 220 5 200 LL 180 glpsh I 6 10 14 18 22 26 Engine speed rpm x102 2 0 3 0 ton vehicle ...

Page 42: ...I kg m 12 Engine Performance Curve 44 ...

Page 43: ...Engine speed rpm 1 O 1 75 ton vehicle kg m 4Y Engine Performance Curve 1986 8 1989 8 LAOM11 12 ...

Page 44: ...3 u Fuel consumption v Engine horsepower CI r y Shaft torque 3 ...

Page 45: ... 1 0 2 Engine speed rpm 5K Engine PerformanceCurve 1989 9 1 ...

Page 46: ...1 I I I 10 14 18 22 1 26 102 Engine speed rpm 1DZ Engine PerformanceCurve 1989 9 1 48 ...

Page 47: ...ion Always disconnect the negative terminal first 2 Remove the battery cap 3 Remove the battery Removing the Battery LA054 6 Battery case removal 1 Remove set bolts 3 pcs and remove the battery case Electrical wiring and fuel hose disconnec tion 1 Disconnect the starting motor bond strap 2 Disconnect each electrical wiring con nector 3 Disconnect the fuel hose Removing the Battery Case LA054 9 Air...

Page 48: ...ain plug to drain the coolant Removing the Fan LA054 27 Radiator removal 1 Loosen the inlet and outlet hose clamps 2 Disconnect the torque converter cooler hose in torque converter vehicle Caution Identify the hose installed positions 3 Remove radiator set bolts and remove the radiator Removing the Radiator LA054 29 Exhaust pipe disconnection 1 Remove flange set nuts 2 pcs and re move the exhaust ...

Page 49: ...nd disconnect the shift rod 2 Disconnect the Inching Cable Disconnecting the Rod and Cable LA059 26 28 Clutch release cylinder removal in clutch vehicle 1 Disconnect the clevis 2 Remove set bolts 2 pcs the clutch release cylinder Accelerator peda l with pedal removal and remove toe board Removing the Clutch Release Cylinder LA054 15 Oil control valve return hose removal in clutch vehicle 1 Loosen ...

Page 50: ...ever shaft Removing the Shift Lever Shaft LA055 10 Propeller shaft disconnection I Remove set bolts 2 p a and remove the propeller shaft cover 2 Remove propeller shaft set bolts 4 pcs on one side and disconnect the propel ler shaft Note It may be disconnected on either of the differential or the transmission side Disconnecting the Propeller Shaft ASSY LA055 7 Parking brake cable clamp removal in t...

Page 51: ... in i Measuring the Stabilizer Installed Dimensions LAOM166 2 Loosen the stabilizer bar lock nut 3 Remove the set nuts at both ends and remove the cushion rubber plate sta bilizer stopper and stabilizer bar 25 Check that all electrical wiring cables and links are disconnected 26 Engine ASSY with transmission removal 1 Use the SST and remove the engine Removing the Stabilizer LA052 4 ASSY with tran...

Page 52: ... negative terminal first 2 Remove the battery cap 3 Remove the battery Removing the Battery LAO1 10 4 Battery case removal 1 Remove set bolts 3 pcs and remove the battery 5 Electrical wiring and fuel hose disconnec tion 1 Disconnect the starting motor bond strap 2 Disconnect electrical wiring such as the injection pump solenoid cut wiring 3 Disconnect the fuel hose Disconnecting the Solenoid Cut W...

Page 53: ...or reserve tank removal I Disconnect the reserve tank hose from the radiator 2 Remove the reserve tnak Removing the Radiator Cover L A O1 28 Radiator removal 1 Loosen the radiator drain plug to drain the coolant 2 Loosen the engine drain plug to drain the coolant 3 Disconnect the torque converter cooler hose in torque converter model Caution Identify the hose installed positions 4 Remove the radia...

Page 54: ...able from the manifold on the bracket 13 Oil pump removal 1 Remove oil pump set bolts 2 pcs 2 Disconnect the oil pump from the engine Disconnecting the Exhaust Pipe LA02 7 Disconnecting the Accelerator Cable L A 0 1 14 Removing the Oil Pump LA03 3 Accelerator pedal with pedal toe board removal 1 Remove toe board set bolts and remove accelerator pedal with pedal toe board Removing the Pedal Toe Boa...

Page 55: ...sh rod and remove the clutch release cylinder Removing the Clutch Booster ASSY LA07 21 17 Oil control valve return hose removal in cluich vehicle 1 Loosen the hose clamps a t both ends of the hose and disconnect both ends 2 Remove the hose bracket set bolt and remove the return hose Removing the Valve Return Hose LA07 7 18 Shiaft lever removal in clutch vehicle 1 Dlsconnnect the shift lever rod fr...

Page 56: ...on one side and disconnect the propel ler shaft Note It may be disconnected on either the differ ential or the transmission side Disconnecting the Propeller Shaft LA03 16 Parking brake cable calmp removal I Remove the parking brake clamp set bolt and disconnect the cable from the transmission calbe Disconnect ng the Parking Brake Cable LA0126 31 22 Mounting set bolt removal 1 Remove the engine mou...

Page 57: ...m m in 2 Loosen the stabil zerbar lock nut 3 Remove set nuts a t both ends and remove the cushion rubber plate sta b i l i e r stopper and stabilizer bar Check that all electrical wiring cables and links are disconnected Dimension B 1 9 8 1 7 8 0 04 205 52 1 8 1 0 041 Vehicle model 1 O 2 5ton series 2 75 3 0 tor series Removing the Mounting Set Bolts 1 LA03 22 Dimension A 83 3 27 2 0 04 90 5 _ 1 3...

Page 58: ...n SST09010 20111 71 Weight of engine ASSY with transmission With torque converter transmission 330 kg 726 I b With transmission 350 kg 770 Ib Caution Try safe operation by fully considering the Center of gravity in setting wire ropes for Removing the Engine ASSY with Transmission LA04 9 hoisting ...

Page 59: ...ttery 2pcs Removing the Battery LA088 5 Battery case removal 1 Remove set bolts 3 pcs and remove the battery case Electrical wiring and fuel hose disconnection 1 Disconnect the starting motor bond strap 2 Disconnect each wiring connector 3 Disconnect the fuel hose Removing the Battery Case LA096 4 Coolant dra ning 1 Loosen the radiator drain plug to drain the coolant 2 Loosen the engine drain plug...

Page 60: ...cleaner removal 1 Remove the hydraulic tank breather 2 Loosen the hose clamp for the air cleaner hose 3 Remove air cleaner case set bolts 4 pcs and remove the air cleaner Removing the Air Cleaner LA096 18 Exhaust pipe disconnection 1 Remove flange set nuts 3 pcs and dis connect the exhaust pipe Accelerator cable disconnection 1 Disconnect the accelerator cable from the injection pump Disconnecting...

Page 61: ...transmission side 2 Remove the shift lever rod set nut and remove the plate and shift levers for ward reverse and speed 3 Remove the plate washer and spring Removing the Shift Lever LAO113 10 Disconnect the oil pump tandem pump 2 3 ton clutch model 1 Disconnect the oil pump return hose from the hydraulic tank Disconnecting theReturn Hose L A 0 113 11 2 Remove oil pump set bolts 2 pcs 3 Disconnect ...

Page 62: ...ng the Release Cylinder L A O113 22 16 Oil control valve return hose removal in 2 0 3 0 ton clutch vehicle 1 Loosen hose clamps at both ends of the hose 2 Remove the return hose Removing the Return Hose L A 0 1 13 13 14 Propeller shaft disconnection 1 Remove set bolts 2 pcs and remove the propeller shaft cover 2 Remove propeller shaft set bolts 4 pcs on each side and disconnect the pro peller shaf...

Page 63: ...set bolts in torque converter vehicle 3 Remove the transmission mounting set bolts in clutch vehicle Removing the Transmission LA096 29 113 20 Mounting Bolts Measuring the Stabilizer l nstalled Dimension LAOM166 65 20 Stabilizer removal in clutch vehicle 1 Measure the stabilizer installed dimen sions Measure and record for both the stabilizer at the upper left and stabilizer at lower right mm in I...

Page 64: ...n removal 1 Remove set bolts 4 pcs and remove the fan Check that all electrical wiring cables and lin ksare disconnected 24 Engine ASSY with transmission removal Removing the Fan L A O1 13 36 1 Use the SST and remove the engine with transmission SST 09010 201 11 71 Weight of engine ASSY with transmission With torque converter transmission approx 350 kg 770 lb With transmission approx 380 kg 836 Ib...

Page 65: ... battery cap 3 Remove the battery Removing the Battery LA064 2 1 Battery case reomoval 1 Remove set bolts 3 pcs and remove the battery case Electrical wiring and fuel hose disconnection 1 Disconnect the starting motor bond strap 2 Disconnect the electrical wiring con nector 3 Disconnect the fuel hose Removing the Battery Case LA054 9 Horn removal 1 Disconnec the wiring connector 2 Remove set bolts...

Page 66: ...th ends of pipe and disconnect both ends Remove the bracket set bolt and re move the return pipe Removing the Return Pipe LA057 3 Accelerator cable disconnectio 1 Disconnect the accelerato carburetor side Exhaust pipe disconnection 1 Remove flange set nuts remove the exhaust pipe n r cable on the 2 pcs and Disconnecting the Exhaust Pipe LA057 11 Radiator reserve tank removal 1 Disconnect the reser...

Page 67: ...radiator Removing the Radiator ASSY LA058 3 15 Oil pump disconnection tandem pump in 2 0 3 0 ton clutch model 1 Disconnect the oil pump return hose from the hydraulic tank 2 Remove oil pump set bolts 2 pcs 3 Disconnect the oil pump from the engine Removing the Oil Pump Tandem Pump LA062 2 16 Oil pump disconnection All models excluding 2 0 3 0 ton clutch models 1 Remove oil pump set bolts 2 pcs 2 D...

Page 68: ...ve the plate washer and spring Removing the Shift Lever LA057 17 Propeller shaft disconnection 1 Remove set bolts 2 pcs and remove the propeller shaft cover 2 Remove the propeller shaft set bolts 13 mm 4 pcs on each side and discon nect the propeller shaft Note It may be disconnected on either the dif ferential or the transmission side Removing the Propeller Shaft LA058 10 20 Mounting set bolts re...

Page 69: ... t 0 04 L Vehicle model 1 0 2 5 ton series 2 75 3 0 ton series 23 Engine ASSY with transmission removal 1 Use the SST and remove the engine ASSY with transmission With torque converter transmission approx 250 kg 550 Ib With transmission approx 270 kg 594Ib SST 09010 20111 71 Demension A 83 t 1 13 27 0 04 9 0 5 5 1 3 56 0 041 Caution Try safe operation by fully considering the center of gravity in ...

Page 70: ...ery removal 1 Disconnect the battery terminals Caution Always disconnect the negative terminal first 2 Remove the battery cap 3 Remove the battery Removing the Battery lAT4 1 3 Battery case removal 1 Remove set bolts 3 pcs and remove the battery case Removing the Battery Case LAT4 2 Air 1 2 cleaner ASSY removal Remove the hydraulic tank breather Loosen the hose clamp for the air clean er hose Remo...

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