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Toyota 7FG 7FD 7FGK 7FDK Forklift Trucks Repair Manual PDF.pdf

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LisandroMarotta

Manual Forklift, toyota autoelevador . manual de repuestos de equipo toyota.

Engineering
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CG-, CG-, 1 1b b https://www.forkliftpdfmanuals.com/
FOREWORD FOREWORD Th This is ma manu nual al co cove vers rs th the e se serv rvic ice e pr proc oced edur ures es of of th the TOY e TOYOT OTA A FO FORK RKLI LIFT FT 7FG 7FG/7F /7FD10 D10 - - 30 s 30 seri eries. es. Ple Please use th ase use this is man manual for prov ual for providi iding ng qui quick, corre ck, correct ct servi servicing cing of of the the corre correspond sponding ing fork forklift lift mode models. ls. Th This is ma manu nual al de deal als s wi with th th the e ab abov ove e mo mode dels ls as of Se as of Sept ptem embe ber r 20 2000 00. . Pl Plea ease se und unders erstan tand d tha that t dis disagr agreem eement ent can can tak take e pla place ce bet betwee ween n the desc the descrip riptio tions ns in in the the man manual ual and act and actual vehic ual vehicles les due t due to cha o change nge in in des design ign and sp and speci ecific ficati ations ons. . Any Any ch chan ange ge or mod or modif ific icat atio ions ns th ther erea eaft fter er wi will ll be inf be infor orme med d by To by Toyo yota ta In Indu dust stri rial al Equ Equipm ipment ent Par Parts & Serv ts & Service ice New News. s. For t For the serv he service ice pro proced cedure ures s of t of the moun he mounted ted eng engine ine, , rea read the d the rep repair air man manual uals s lis listed below ted below as ref as refere erence nce tog togeth ether er wit with this h this man manual ual. . (Reference) (Reference) Rep Repair air man manual uals s rel relate ated d to thi to this s man manual ual are as foll are as follows ows: : TOYO TOYOTA TA INDU INDUSTRIA STRIAL L EQUI EQUIPMENT PMENT 7FG 7FG1 1 0-3 0-30, 0, 7FD 7FD1 1 0-3 0-30, 0, 7FG 7FGK20 K20-30 -30, , 7FG 7FGJ35 J35, , 7FD 7FDK20 K20-30 -30, , 7FO 7FOJ35 J35 REPAI REPAIR R MANU MANUAL AL (No. C (No. CE024 E024) ) TOYO TOYOTA TA INDU INDUSTRIA STRIAL L EQUI EQUIPMEN PMENT T 5K 5K ENGIN ENGINE E REPAI REPAIR R MANU MANUAL AL (No. C (No. CE617) E617) TOYO TOYOTA TA INDU INDUSTRIA STRIAL L EQUIP EQUIPMENT MENT 4Y E 4Y ENGIN NGINE E REPAI REPAIR R MANU MANUAL AL (No. C (No. CE602- E602-1) 1) TOYOT TOYOTA A INDU INDUSTRIA STRIAL L EQUIP EQUIPMENT MENT 1D2-1 1D2-11 1ENGI ENGINE NE REPAI REPAIR R MANU MANUAL AL (No. (No. CE618 CE618-1) -1) TOYO TOYOTA TA INDU INDUSTRIA STRIAL L EQUI EQUIPMENT PMENT 22 EN 22 ENGINE GINE REPAI REPAIR R MANU MANUAL AL (No. C (No. CE625- E625-1) 1) TOYO TOYOTA TA INDU INDUSTRIA STRIAL L EQUI EQUIPMENT PMENT 4Y 4Y ENGIN ENGINE E Suppl Supplement ement 4Y-EC 4Y-ECS S REPAI REPAIR R MANU MANUAL AL (No. C (No. CU642 U642) ) TO TOYO YOTA TA MO MOTO TOR R CO CORP RPOR ORATIO ATION N https://www.forkliftpdfmanuals.com/
SE SECT CTIO ION N IN INDE DEX X II ~ ~E E II GENERAL GENERAL F FE EA AT T E ES S II MAN MANUAL UAL TRA TRANSM NSMISS ISSION ION II DIFFERENTIAL DIFFERENTIAL II APPENDIX APPENDIX https://www.forkliftpdfmanuals.com/
GENERAL GENERAL Page Page EX EXTE TERI RIOR OR VI VI EW EWS S 0-2 0-2 VE VEH IC H ICLE LE MO MODE L DE L Q Q-3 -3 F FR RAM AM E N E N U UM M BE BER R 0-5 0-5 H HO OW W T TO O U US SE E T TH HI IS S M MAN ANU UAL AL 0-7 0-7 E EX XP PL LA AN NA AT TI IO ON N M ME ET TH HO OD D 0 0- -7 7 TERMINOLOGy TERMINOLOGy o o- -a a A AB BB BRE REV VIA IATI TIO ONS NS o o- -a a OP OPE RAT E RATIO IO NAL NAL TI TI PS PS 0-9 0-9 H HOI OIST STIN ING G TH TH E E VE VEHI HIC CLE LE 0-10 0-10 C C I R I R C CUlT UlT TE TEST STER ER 0-11 0-11 ST STAND ANDARD ARD BOL BOLT T & & NUT NUT TIGHT TIGHTENIN ENING G T TO O RQU RQUE E 0-13 0-13 BOLT BOLT ST STRE RENGT NGTH H TY TYPE PE I IDE DENT NTI IFI FICATI CATION ON MET METHOD HOD 0- 0-13 13 T TI IG GH HT TE EN NI IN NG G T TO OR RQ QU UE E T TA AB BL LE E 0 0- -1 14 4 P PR RE EC CO OAT AT BO BO LT LTS S 0-15 0-15 HI HIGH GH PR PRES ESSU SURE RE HO HOSE SE FI FITT TTIN ING G TI TIGH GHTE TENI NING NG TO TORQ RQUE UE 0-15 0-15 W WIR IRE E R ROP OPE E SU SUSP SPEN ENSI SION ON ANG ANGLE LE LIS LIST T 0-16 0-16 S SAF AFE E LO LOAD AD F FO OR R E EAC ACH H W WI IR RE E R RO OP PE E SU SUSP SPEN ENSI SION ON ANG ANG LE LE 0-16 0-16 CO COMP MPON ON EN ENTS TS WE WEIG IGHT HT 0-17 0-17 RE RECO COMM MMEN ENDE DED D LUBRI LUBRICANT CANT QUANTITY QUANTITY & & TYPES TYPES 0-18 0-18 LUBR LUBRIC ICATI ATION ON CH CHART ART 0-20 0-20 PER PERIOD IODIC IC MAINT MAINTENANC ENANCE E 0-22 0-22 PE PER RIO IOD DIC IC RE REPL PLACE ACEM MEN ENT T OF P OF PAR ARTS TS AND AND LU LU BRIC BRICANTS ANTS 0-28 0-28 0-1 0-1 https://www.forkliftpdfmanuals.com/
0-2 0-2 EXTE EXTERIO RIOR R VIE VIEWS WS https://www.forkliftpdfmanuals.com/
0-3 0-3 MODEL MODEL VEHICLE VEHICLE Classification Classification Tran Transmiss smission ion Type Type Engine Engine Vehi Vehicle cle Mode Model l I I Series Series Model Model 7FG10 7FG10 Mff Mff 5K 5K Gasoline Gasoline 02-7FG10 02-7FG10 T I C T I C 1.0 ton model 1.0 ton model 7FD10 7FD10 Mff Mff 10Z-11 10Z-11 Diesel Diesel 02-7FD10 02-7FD10 T I C T I C 7FG15 7FG15 Mff Mff 5K 5K Gasoline Gasoline 02-7FG15 02-7FG15 T I C T I C 1 1 ton ser ton series ies 40-7FG15 40-7FG15 Mff Mff 4Y 4Y Gasoline Gasoline 1.5 ton model 1.5 ton model 42-7FG15 42-7FG15 T I C T I C 7FD15 7FD15 Mff Mff 10Z-11 10Z-11 Diesel Diesel 02-7FD15 02-7FD15 T I C T I C T I C T I C 4Y 4Y Gasoline Gasoline 42-7FG18 42-7FG18 1.75 ton 1.75 ton mode model l T I C T I C 10Z-11 10Z-11 Diesel Diesel 02-7FD18 02-7FD18 7FG20 7FG20 Mff Mff 5K 5K Gasoline Gasoline 02-7FG20 02-7FG20 T I C T I C 4O-7FG20 4O-7FG20 Mff Mff 4Y 4Y Gasoline Gasoline 42-7FG20 42-7FG20 T I C T I C 2.0 ton model 2.0 ton model 6O-7FD20 6O-7FD20 Mff Mff 10Z-11 10Z-11 Diesel Diesel 62-7FD20 62-7FD20 T I C T I C 7F020 7F020 Mff Mff 2Z 2Z Diesel Diesel 02-7F020 02-7F020 T I C T I C 2 ton 2 ton serie series s 7FG25 7FG25 Mff Mff 5 5K K G Ga as so ol li in ne e 02-7FG25 02-7FG25 T I C T I C 4O-7FG25 4O-7FG25 Mff Mff 4 4Y Y G Ga as so ol li in ne e 42-7FG25 42-7FG25 T I C T I C 2.5 ton model 2.5 ton model 6O-7F025 6O-7F025 Mff Mff 1 10 0Z Z- -1 11 1 D Di ie es se el l 62-7F025 62-7F025 T I C T I C 7F025 7F025 Mff Mff 2Z 2Z Diesel Diesel I I T I C T I C II 02-7F025 02-7F025 https://www.forkliftpdfmanuals.com/
04 04 - - - - Classification Classification Vehicle Model Vehicle Model T Tr ra an ns sm miis ss siio on n T Ty yp pe e E En ng giin ne e Series Series Model Model 7FG30 7FG30 MI MIT T 4Y 4Y Gasoline Gasoline 02-7FG30 02-7FG30 T I C T I C 6O-7FD30 6O-7FD30 MI MIT T 1 1D DZ Z- -I II I D Diie es se ell 3 ton series 3 ton series 3.0 3.0 ton ton model model 62-7FD30 62-7FD30 T I C T I C 7FD30 7FD30 MI MIT T 2 2Z Z Diesel Diesel 02-7FD30 02-7FD30 T I C T I C 7FGK20 7FGK20 MI MIT T 5K 5K Gasoline Gasoline 02-7FGK20 02-7FGK20 T I C T I C 4 40 0- -7 7F FG GK K2 20 0 M MI IT T 4 4Y Y G Ga as so olliin ne e K2.0 ton model K2.0 ton model 42-7FGK20 42-7FGK20 T I C T I C 7 7F FD DK K2 20 0 M MI IT T 1DZ-II 1DZ-II Diesel Diesel 02-7FDK20 02-7FDK20 T I C T I C K2 ton series K2 ton series 7 7F FG GK K2 25 5 M MI IT T 5K 5K Gasoline Gasoline - - 02-7FGK25 02-7FGK25 T I C T I C 4 40 0- -7 7F FG GK K2 25 5 M MI IT T 4Y 4Y Gasoline Gasoline K2.5 ton model K2.5 ton model 42-7FGK25 42-7FGK25 T I C T I C 7 7F FD DK K2 25 5 M MI IT T 1 1D DZ Z- -I II I D Diie es se ell 02-7FDK25 02-7FDK25 T I C T I C 7FGK30 7FGK30 MI MIT T 4Y 4Y Gasoline Gasoline 02-7FGK30 02-7FGK30 T I C T I C K3 ton series K3 ton series K3.0 K3.0 ton mod ton model el 7FDK30 7FDK30 MI MIT T 1 1D DZ Z- -I II I D Diie es se ell 02-7FDK30 02-7FDK30 T I C T I C 7 7F FG GJ J3 35 5 M MI IT T 4Y 4Y Gasoline Gasoline 02-7FGJ35 02-7FGJ35 T I C T I C J3.5ton J3.5ton J3.5 ton model J3.5 ton model 7FDJ35 7FDJ35 MI MIT T Diesel Diesel series series 2 2Z Z 02-7FDJ35 02-7FDJ35 T I C T I C - - https://www.forkliftpdfmanuals.com/
FRAME NUMBER FRAME NUMBER F Fra rame me No No. Punchin . Punching g Po Position sition Punching position Punching position 0-5 0-5 Series Series Engine Engine Vehic Vehicle mode le model l Punching Punching format format 7FG10 7FG10 02-7FG10 02-7FG10 5K 5K 7FG18-10011 7FG18-10011 7FG15 7FG15 02-7FG15 02-7FG15 4O-7FG15 4O-7FG15 4Y 4Y 42-7FG15 42-7FG15 407FG 407FG 18-100 18-10011 11 1 1 ton series ton series 42-7FG18 42-7FG18 7FD10 7FD10 02-7FD10 02-7FD10 10Z-11 10Z-11 7FD15 7FD15 7F018-10011 7F018-10011 02-7FD15 02-7FD15 02-7FD18 02-7FD18 7FG20 7FG20 02-7FG20 02-7FG20 5 5K K 7 7F FG G2 25 5- -1 1 0 00 01 11 1 7FG25 7FG25 02-7FG25 02-7FG25 4O-7FG20 4O-7FG20 42-7FG20 42-7FG20 4Y 4Y 407FG25-1oo11 407FG25-1oo11 4O-7FG25 4O-7FG25 42-7FG25 42-7FG25 2 2 ton ton seri series es 7FD20 7FD20 02-7FD20 02-7FD20 2Z 2Z 7FD25 7FD25-1 -1 0011 0011 7FD25 7FD25 02-7FD25 02-7FD25 6O-7FD20 6O-7FD20 62-7FD20 62-7FD20 1 10 0Z Z- -1 11 1 6 60 07 7F FD D2 25 5- -1 10 00 01 11 1 6O-7FD25 6O-7FD25 62-7FD25 62-7FD25 https://www.forkliftpdfmanuals.com/
0-6 0-6 Engine Engine Vehic Vehicle le model model Punching Punching format format 7FG30 7FG30 02-7FG30 02-7FG30 4Y 4Y 7FGJ35-1 7FGJ35-1 0011 0011 7FGJ35 7FGJ35 02-7FGJ35 02-7FGJ35 3 ton, J3.5 3 ton, J3.5 7FD30 7FD30 ton series ton series 02-7FD30 02-7FD30 2 2Z Z 7FDJ35-1oo11 7FDJ35-1oo11 7FDJ35 7FDJ35 02-7FDJ35 02-7FDJ35 6O-7FD30 6O-7FD30 1DZ-II 1DZ-II 607FD3Q-10011 607FD3Q-10011 62-7FD30 62-7FD30 7FGK20 7FGK20 02-7FGK20 02-7FGK20 5K 5K 7FGK25-10011 7FGK25-10011 7FGK25 7FGK25 02-7FGK25 02-7FGK25 4Q-7FGK20 4Q-7FGK20 K2ton K2ton 42-7FGK20 42-7FGK20 series series 4Y 4Y 7FGK3Q-1OO11 7FGK3Q-1OO11 4Q-7FGK25 4Q-7FGK25 42-7FGK25 42-7FGK25 6O-7FDK20 6O-7FDK20 62-7FDK20 62-7FDK20 1DZ-II 1DZ-II 7FDK3Q-10011 7FDK3Q-10011 6O-7FDK25 6O-7FDK25 62-7FDK25 62-7FDK25 7FGK30 7FGK30 4Y 4Y 7FGK30-10011 7FGK30-10011 K3 ton K3 ton 02-7FGK30 02-7FGK30 series series 7FDK30 7FDK30 1DZ-II 1DZ-II 7FDK3Q-10011 7FDK3Q-10011 02-7FDK30 02-7FDK30 https://www.forkliftpdfmanuals.com/
0-7 0-7 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL EXPLANATION METHOD EXPLANATION METHOD 1. 1. Op Oper erat atio ion n pr proc oced edur ure e (1) (1) The oper The operati ation on pro proced cedure ure is is des descri cribed bed in in eit either patt her pattern ern A o A or p r patt attern ern B B bel below. ow. Pat Patter tern n A: A: Exp Explan lanati ation on of of eac each h ope operat ration ion ste step with ill p with illust ustrat ration ion. . Pat Patter tern n B: B: Exp Explan lanati ation on of of ope operat ration ion pro proced cedure ure by i by indi ndicat cating ing ste step p num number bers s in in one ill one illust ustrat ration ion, , fol fol- - low lowed ed by ex by expla planat nation ion of cau of cautio tions ns and notes and notes sum summar marize ized d as poin as point t ope operat ration ions. s. Exa Exampl mple e of d of desc escrip riptio tion n in in pat patter tern n B B DISASSEMBlY·INSPECTION·REASSEMBlY DISASSEMBlY·INSPECTION·REASSEMBlY Tight Tightening ening torqu torque e unitT unitT = = N'm N'm (kgf- (kgf-cm) cm) [ft-I [ft-Ibf] bf] • • St Step ep No Nos. s. ar are e pa part rtia iall lly y so some meti time mes s omitt omitted ed in in illus illustratio trations. ns. • • Wh When en a a pa part rt re requ quir irin ing g ti tigh ghte teni ning ng tor torque que ins instru tructi ction on is n is not ind ot indica icated ted in in the the ill illust ustrat ration ion, , the part name is de the part name is de- - scr scribe ibed d in in the the ill illust ustrat ration ion fra frame. me. 8 8 4 4 T T = = 4 46. 6.1 1 - - 48 48.1 .1 (4 (470 70 - - 49 490) 0) [3 [34.0 4.0 - - 35 35.5] .5] Disassembly Procedure Disassembly Procedure 1 1 R Re em mo ov ve th e the e c co ov ve er r. . [P [Point oint 1 1] ] 2 2 R Re emo mov ve t e the he bu bush shi ing ng [Point 2] [Point 2] + - + - Op Opera eratio tion n exp explai lained ned lat later er 3 3 R Re em mo ov ve t e th he e g ge ea ar r. . Poi Poi nt nt Operations Operations Expla Explanatio nation n of key of key point for o point for operat peration ion with an with an illus illustrati tration on i i t t [P [Point oint 1 1] ] Dis Disass assemb embly: ly: Put Put a mat a match ch mar mark when k when rem removi oving ng the pum the pump p cov cover. er. [P [Point oint 2] 2] Inspe Inspection ction: : Meas Measure ure the bus the bush h insid inside diamet e diameter. er. Limit: Limit: 19 19.1 .12 2 mm (0. mm (0.75 7528 in) 28 in) https://www.forkliftpdfmanuals.com/
0-8 0-8 2. 2. Ho How t w to o re read ad co comp mpon onen ents ts fi figu gure res s (1) (1) The co The compo mponen nents ts fig figure uses th ure uses the ill e illust ustrat ration ion in th in the e pa part rts s ca cata talo log g fo for r th the e ve vehi hicl cle e mo mode del. l. Ple Please ase ref refer to th er to the e cat catalo alog g for chec for checkin king g the the part name. part name. Th The e nu numb mber er at t at the he ri righ ght t sh shou ould lder er of ea of each ch com compon ponent ents s fig figure ure ind indica icates tes the Fig. nu the Fig. num- m- ber in the parts catalog. ber in the parts catalog. (Example) (Example) FIG numbe FIG number r in part in parts s cat catalo alog g 3. 3. Ma Matt tter ers omi s omitt tted in ed in th this m is man anua ual l (1) (1) Thi This s man manual omits desc ual omits descrip riptio tion n of of the f the foll ollowi owing ng job jobs, s, but p but perf erform orm the them m in in act actual opera ual operatio tion: n: C D C D Cle Cleani aning ng and and was washin hing g of re of remov moved ed par parts as ts as req requir uired ed ® ® Visua Visual inspec l inspection tion (part (partially descr ially described) ibed) TERMINOLOGY TERMINOLOGY Caution: Caution: I Importa mportant nt mat matte ters rs of wh of which ich ne negli gligen gence ce may ca may cause use ac accide cidents. nts. Be Be sure t sure to obser o observe ve the them. m. Note: Note: Importa Important nt ite items of which ms of which negli negligence gence may ca may cause accide use accidents, nts, or mat or matter ters s in in opera operation tion procedure procedure requi requiring ring specia speciall at attent tention. ion. Sta Standa ndard: rd: Val Values show ues showing ing all allowa owable ble ran range ge in in ins inspec pectio tion n and adj and adjust ustmen ment. t. Lim Limit: it: Max Maximu imum m or min or minimu imum m all allowa owable ble val value ue in in ins inspec pectio tion n or ad or adjus justme tment. nt. A AB BB BR RE EV VIA IA T TIO ION NS S Abbreviation (code) Abbreviation (code) Meaning Meaning Abbrevia Abbreviation tion (code) (code) Meaning Meaning ASSY ASSY Assembly Assembly SA SAS S System System of of active active stabil stability ity LH LH Left Left hand hand SS SST T Special Special service service tool tool LLC LLC Long Long life life coolant coolant S STD TD Standard Standard MfT MfT Manual Manual transmiss transmission ion T= T= Tightening Tightening torque torque OP OPT T Option Option TIC TIC Torque Torque converte converter r & & transmission transmission O/S O/S Oversize Oversize OO OOT T Numb Number er of of te teet eth h (0 (0 0) 0) PS PS Power Power steeri steering ng U/S U/S Undersize Undersize R R H H Right Right hand hand W/ W/ With With SA SAE E Society Society of of Automotiv Automotive e U U Less Less Engineers (USA) Engineers (USA) https://www.forkliftpdfmanuals.com/
0-9 0-9 OPE OPERATION RATIONAL AL TIP TIPS S 1. 1. Sa Safe fe op oper erat atio ion n (1) (1) Aft After jac er jackin king g up, up, alw always ays sup suppor port t wit with woo h wooden den blo blocks or cks or rig rigid sta id stands nds. . (2) (2) Whe When n hoi hoisti sting ng the v the vehi ehicle cle or it or its h s heav eavy com y compon ponent ent, , use use wir wire e rop rope(s e(s) ) wit with a s h a suff uffici icient ent res reserv erve e in in loa load d capacity. capacity. (3) (3) Alw Always ays dis discon connec nect t the ba the batte ttery ry ter termin minal al bef before ore the the ins inspec pectio tion n or s or serv ervici icing ng of el of elect ectric rical al par parts. ts. 2. 2. Ta Tact ctfu ful l op oper erat atio ion n (1) (1) Pre Prepar pare e the me the mecha chanic nic too tools, ls, nec necess essary ary mea measur suring ing ins instru trumen ments ts (ci (circu rcuit te it teste ster, r, meg megger ger, , oil oil pre pressu ssure re gaug gauge, e, etc.) and SSTs befo etc.) and SSTs before re start starting ing opera operation. tion. (2) (2) Bef Before dis ore discon connec nectin ting g wir wiring ing, , alw always che ays check the cabl ck the cable col e color and w or and wiri iring state ng state. . (3) (3) Whe When n ove overha rhauli uling ng fun functi ctiona onal l par parts, c ts, comp omplic licate ated d por portio tions or re ns or relat lated mech ed mechani anisms sms, , arr arrang ange the part e the parts s neat neatly to ly to preve prevent nt confu confusion sion. . (4) (4) Whe When n dis disass assemb emblin ling g and in and inspe specti cting ng suc such a pre h a precjs cjsion ion par part as t as the c the cont ontrol val rol valve, ve, use use cle clean too an tools ls and and opera operate te in a in a clea clean n loca location. tion. (5) (5) Fol Follow t low the des he descri cribed bed pro proced cedure ures s for di for disas sassem sembly bly, , ins inspec pectio tion n and r and reas eassem sembly bly. . (6) (6) Rep Replac lace, e, gas gasket kets, s, pac packin kings gs and O- and O-rin rings gs wit with h new new one ones each time the s each time they y are dis are disass assemb embled led. . (7) (7) Use Use gen genuin uine e Toy Toyota parts f ota parts for rep or replac laceme ement. nt. (8 (8) ) Us Use spe e speci cifi fied ed bo bolt lts s an and d nu nuts ts. . Ob Obse serv rve e th the e sp spec ecif ifie ied d ti tigh ghte teni ning ng to torq rque ue at at th the e ti time me of rea of reass ssem embl bly. y. Tig Tighte hten n to th to the e cen center ter of t of the spec he specifi ified ed tig tighte htenin ning g tor torque que ran range. ge. If If no no tight tightenin ening g torqu torque e is is spec specified ified, , tight tighten en the bolt or the bolt or nut a nut accord ccording ing to to the stan the standard dard tight tightening ening torqu torque e table. table. 3. 3. Gr Gras aspi ping t ng the he tr trou oubl ble st e stat ate e Whe When n a a tro troubl uble e occ occurs urs, , do not a do not atte ttempt mpt imm immedi ediate ate dis disass assemb embly ly or re or repla placem cement ent but f but firs irst chec t check k if if the the tro troubl uble e req requir uires es dis disass assemb embly ly or repl or replace acemen ment t for reme for remedyi dying. ng. 4. 4. Di Disp spos osal of al of wa wast ste e fl flui uid, e d, etc tc. . Whe When n dra draini ining ng was waste te flu fluid id fro from m the vehi the vehicle cle, , rec receiv eive e it it in a c in a cont ontain ainer. er. If a If any oil ny oil, fue , fuel, l, coo coolan lant, t, oil oil fil filter ter, , bat batter tery y or ot or other her har harmfu mful l sub substa stance nce is is dir direct ectly ly dis discha charge rged d or scr or scrapp apped ed wit withou hout t per permis missio sion, n, it it wil will eith l either er adv advers ersely ely aff affect ect hum human an hea health lth or des or destro troy y the the env enviro ironme nment. nt. Alw Always ays sor sort wast t waste e flu fluids ids, , etc etc. and trea . and treat t the them m pro proper perly ly by r by requ equest esting ing dis dispos posal al by s by spec pecial ialize ized d com compan panies ies. . I I I I I I I I I I I I = = m - m - - - For scr For screw jack ew jack 5. 5. Jack up Jack up point points s Jac Jack k up p up poin oints are ts are pro provid vided ed in in the fron the front t and re and rear porti ar portions ons of th of the e veh vehicl icle. e. Alw Always ays app apply jack ly jacks s at t at the jack he jack up po up point ints. s. Front Front side side: : A A circular circular groove groove to to accept accept a a screw screw jack jack is is provided provided un- un- der the front der the front sid side e of th of the e fra frame. me. Wh When en a g a gar arag age e ja jack ck is us is used ed, , ja jack ck up a up at the bot t the botto tom m su sur- r- fac face e of the fram of the frame. e. Rear Rear side side: : A A circular circular groove groove to to accept accept a a screw screw or or garage garage jack jack is is provi provided ded at at the bottom the bottom surfa surface ce of the count of the counterwei erweight. ght. https://www.forkliftpdfmanuals.com/
I: I: : : i i For screw jack ~ For screw jack ~ For gara For garage jack ge jack~ ~ 0-10 0-10 HOI HOISTI STING NG THE VEHI THE VEHICLE CLE When When hoist hoisting ing the vehi the vehicle, sling with wir cle, sling with wire rope(s) e rope(s) at at the the mast mast hook holes and the rear side of the head guard. hook holes and the rear side of the head guard. Sli Slinging nging at t at the he head guard head guard is is done done in in two ways. two ways. Method A: Method A: Sling after removing the head guard seat. Sling after removing the head guard seat. Method B: Method B: Caref Carefull ully y sli sling so as not t ng so as not to damage o damage rear co rear combinat mbination ion lamps. lamps. https://www.forkliftpdfmanuals.com/
0-11 0-11 CIR CIRCUI CUIT T TEST TESTER ER Cir Circui cuit t tes tester ters s are av are avail ailabl able e in in bot both the h the ana analog and log and dig digita ital l typ types. es. The They y sho should uld be u be used sele sed selecti ctivel vely y acc accord ording ing to th to the e purpo purpose se of measu of measuremen rement. t. Analog Analog type: type: This This type type is is convenient convenient for for observing observing movement movement during during operation, operation, but but the the measured measured value value sho should uld onl only y be use be used d for for ref refere erence nce or roug or rough h jud judgem gement ent. . Dig Digita ital typ l type: e: Fai Fairly a rly accu ccurat rate e rea readin ding g is is pos possib sible, le, but i but it t is is dif diffic ficult ult to to obs observ erve e the the var variat iation ion or mo or movem vement ent. . 1. 1. Di Diff ffer eren ence ce in in me meas asur urem emen ent t re resu sult lts s wi with t th the d he dig igit ital typ al type e an and an d anal alog og ty type pe * * The resul The result t may be may be dif differ ferent ent bet betwee ween n mea measur sureme ements nts wit with the a h the anal nalog og typ type and digi e and digital tal typ type. e. Always Always use use a a circuit circuit tester tester according according to to its its operation operation manual. manual. Cau Cautio tions ns whe when n the pola the polarit rities ies are dif are differ ferent ent bet betwee ween n the ana the analog log typ type e and d and digi igital tal typ type e are de are descr scribe ibed d below. below. (1 (1) ) An Anal alog og ci circ rcui uit tes t teste ter r Forward direction Forward direction Reverse Reverse direction direction Meas Measureme urement result nt result exam example ple Tes Tester ter ran range: ge: kQ ran kQ range ge Analog Analog type type Forward Forward Conti Continuity nuity exist exists s 11 kQ 11 kQ Reverse Reverse No continuity No continuity 00 00 (2 (2) ) Di Digi gita tal cir l circu cuit te it test ster er Forward direction Forward direction Reverse Reverse direction direction Measu Measuremen rement t resul result exa t example mple Tes Tester range ter range: : MQ ra MQ range nge Digit Digital al type type Forward Forward No continuity No continuity 1 1 Reverse Reverse Conti Continuity nuity exist exists s 2M 2MQ Q https://www.forkliftpdfmanuals.com/
0-12 0-12 2. 2. Di Diff ffer eren ence ce in in re resu sult of m lt of mea easu sure reme ment nt wi with c th cir ircu cuit te it test ster er The The cir circui cuit t tes tester ter pow power er sup supply ply vol voltag tage e dep depend ends s on t on the test he tester er typ type. e. 1.5 1.5 V, V, 3.0 V or 6.0 V is us 3.0 V or 6.0 V is used. ed. The The res resist istanc ance e of a s of a semi emicon conduc ductor tor suc such h as a d as a diod iode e var varies ies wit with the h the cir circui cuit t tes tester ter pow power er sup supply ply vol voltag tage. e. The The dio diode de cha charac racter terist istics ics are sh are shown own in in the fi the figur gure e bel below. ow. ( (r rn nA A) ) 6 6 5 5 o o .1 .1 II I I I I I I ~ ~ Germanium Germanium II diode diode JJ II ~ lJ ~ lJ I I il il Silicondio~1 Silicondio~1 I - I - - I - - - I - - / / It It / / IJ IJ ....• ....• / / .... ..•• ...... . . / / 0 0. .1 1 0 0. .2 2 0 0. .3 3 0 0. .4 4 0 0. .5 5 0 0. .6 6 0 0. .7 7 0 0. .8 8 F Fo or rw wa ar rd d v vo ol lt ta ag ge e ( (V V) ) Th The e re resi sist stan ance ce va valu lues es of t of the he sa same me se semi mico cond nduc ucto tor r me mea- a- sured with t sured with two type wo types s of ci of circuit test rcuit testers ers havin having g diffe different rent powe power r supp supply ly volta voltages ges are diffe are different. rent. Thi This s man manual desc ual describ ribes es the res the result ults s of mea of measur sureme ement nt wit with a h a cir circui cuit t tes tester ter who whose se pow power er sup supply ply vol voltag tage e is is 3.0 V. 3.0 V. 3. 3. Di Diff ffer eren ence ce in in me meas asur urem emen ent t re resu sult by m lt by mea easu sure reme ment nt ra rang nge (ana e (analo log typ g type) e) In In the anal the analog og typ type e cir circui cuit t tes tester ter, , cha changi nging ng the meas the measure uremen ment t ran range ge swi switch tches es ove over r the inte the interna rnal l cir circui cuit t to to var vary y the cir the circui cuit t res resist istanc ance. e. Eve Even when the same n when the same dio diode de is m is meas easure ured, d, the meas the measure uremen ment t res result vari ult varies es wit with h the meas the measure uremen ment t ran range. ge. ~ ~ OQ OQ ~ ~ V Va ar ri ia ab bl le e r re es si is st to or r Always Always use use the the range range described described in in the the repair repair manual manual for for measurement. measurement. Meter Meter Range: Range: x x 10 10 Resistor Resistor Range: Range: x x 1 1 I I ~ ~ Power source: Power source: 1. 1.5 5 V V $ $0 0 Red Red (SW1) (SW1) (SW2) (SW2) e e o o Black Black https://www.forkliftpdfmanuals.com/
0-13 0-13 S ST TAN AND DAR ARD D BO BOLT LT & NU & NUT TI T TIG GH HT TE EN NI IN NG G T TO OR RQ QU UE E Stand Standard ard bolt a bolt and tig nd tighteni htening ng torqu torques es are not in are not indicat dicated. ed. Jud Judge ge the st the stand andard ard tig tighte htenin ning g tor torque que as s as show hown n bel below. ow. 1. 1. Fin Find ou d out the ty t the type of th pe of the bolt f e bolt from the list b rom the list belo elow and the w and then n fin find the bo d the bolt t lt tigh ighten tening ing tor torque que fro from m the t the tabl able. e. 2. 2. Th The e nu nut t t tig ight hten enin ing g to torq rque ue ca can be n be ju judg dged ed fr from th om the e ma mati ting ng bo bolt lt ty type pe. . BOLT BOLT ST STREN RENGT GTH H TY TYPE PE ID IDENT ENTIF IFIC ICATI ATION ON MET METHOD HOD 1. 1. Ident Identific ification ation by by bolt bolt shape shape 2. 2. Ident Identific ification ation by by part part No. No. Sha Shape pe and and cla class ss Class Class Hexago Hexagonhead nhead bolt bolt 4=4T 4=4T @ @ - - 5=5T 5=5T Bol Bolt t hea head No. d No. 6=6T 6=6T Parts Parts No. No. 7=7T 7=7T 91611- 91611-4 4r r25 25 Hexagon Hexagon 8=8T 8=8T L LLen Length gth (mm (mm) ) head headbolt bolt D D Dia Diamet meter (m er (mm) m) 0 0 No mark No mark 4T 4T Class Class Hexagon Hexagon 0 0) ) No No mark mark 4T 4T flang flange e bolt bolt Diameter Diameter Hexagon Hexagon C C D D Two Two protruding protruding 5 5T T Length Length head headbolt bolt lines lines Hexagon Hexagon ( (C C) ) Two Two protruding protruding 6 6T T flan flange ge bolt bolt lines lines Stud bolt Stud bolt Hexagon Hexagon @ @ Three Three protruding protruding 7 7T T head headbolt bolt lines lines Part No. Part No. Hexagon Hexagon ~ ~ Four protruding Four protruding 92132 92132 -406.14 -406.14 8 8T T ~ ~L L Len Length gth (mm (mm) ) head headbolt bolt lines lines Dia Diamet meter er (mm (mm) ) ~ ~ Class Class Welded bolt Welded bolt 4T 4T Diameter Diameter No mark No mark 4 4T T Stud bolt Stud bolt Length Length https://www.forkliftpdfmanuals.com/
" " Grooved Grooved 6 6T T 0-14 0-14 TI TIGHTE GHTENI NING NG TOR TORQUE QUE TABLE TABLE Specified torque Specified torque Class Class Diameter Diameter Pitch Pitch Hexagon Hexagon B B - - Hexagon Hexagon ~ ~ mm mm mm mm head head bolt bolt flang flange e bolt bolt N·m N·m I I kgf-cm kgf-cm I I ft-Ibf ft-Ibf N·m N·m II kgf-cm kgf-cm I I ft-Ibf ft-Ibf .. 6 6 1.0 1.0 5.4 5.4 I I 55 55 I I 48 in-Ibf 48 in-Ibf 5.9 5.9 I I 60 60 I I 52 in-Ibf 52 in-Ibf 8 8 1.25 1.25 13 13 II 130 130 II 9 9 14 14 II 145 145 I I 10 10 II II II II 4T 4T 10 10 1.25 1.25 25 25 II 260 260 I I 19 19 28 28 II 290 290 II 21 21 12 12 1.25 1.25 47 47 II 480 480 II 35 35 53 53 II 540 540 II 39 39 14 14 1.5 1.5 75 75 II 760 760 II 55 55 83 83 II 850 850 II 61 61 16 16 1.5 1.5 113 113 I I 1150 1150 II 83 83 - - II - - II - - 6 6 1.0 1.0 6.4 6.4 II 65 65 II 56 56 in-Ib in-Ibf f 7.5 7.5 II 75 75 I I 65 i 65 in-Ib n-Ibf f 8 8 1.25 1.25 16 16 II 160 160 II 12 12 18 18 II 175 175 I I 13 13 II II II II 5T 5T 10 10 1.25 1.25 32 32 II 330 330 II 24 24 36 36 II 360 360 II 26 26 12 12 1.25 1.25 59 59 II 600 600 II 43 43 65 65 I I 670 670 I I 48 48 14 14 1.5 1.5 91 91 II 930 930 II 67 67 100 100 II 1050 1050 I I 76 76 16 16 1.5 1.5 137 137 I I 1400 1400 II 101 101 157 157 I I 1600 1600 I I 116 116 6 6 1.0 1.0 7.8 7.8 I I 80 80 II 69 i 69 in-Ib n-Ibf f 8.8 8.8 II 90 90 I I 78 78 in-Ib in-Ibf f 8 8 1.25 1.25 19 19 II 195 195 II 14 14 21 21 I I 215 215 I I 16 16 10 10 1.25 1.25 38 38 II 400 400 II 29 29 43 43 I I 440 440 I I 32 32 6 6T T I I II I I I I 12 12 1.25 1.25 72 72 II 730 730 II 53 53 79 79 II 810 810 I I 59 59 14 14 1.5 1.5 110 110 I I 1100 1100 II 80 80 123 123 II 1250 1250 I I 90 90 16 16 1.5 1.5 170 170 II 1750 1750 II 127 127 191 191 I I 1950 1950 I I 141 141 6 6 1.0 1.0 11 11 II 110 110 II 8 8 12 12 II 120 120 I I 9 9 8 8 1.25 1.25 25 25 II 260 260 II 19 19 28 28 I I 290 290 I I 21 21 10 10 1.25 1.25 52 52 II 530 530 II 38 38 58 58 II 590 590 I I 43 43 IT IT I I I I I I I I 12 12 1.25 1.25 95 95 II 970 970 I I 70 70 103 103 I I 1050 1050 I I 76 76 14 14 1.5 1.5 147 147 II 1500 1500 II 108 108 167 167 II 1700 1700 I I 123 123 16 16 1.5 1.5 226 226 II 2300 2300 II 166 166 - - I I - - I I - - 6 6 1.0 1.0 12 12 II 125 125 II 9 9 14 14 II 145 145 II 9 9 8 8 1.25 1.25 29 29 II 300 300 I I 22 22 32 32 II 330 330 II 24 24 10 10 1.25 1.25 61 61 II 620 620 II 45 45 68 68 II 690 690 I I 50 50 a aT T II II II I I 12 12 1.25 1.25 108 108 1100 1100 80 80 123 123 1250 1250 90 90 II II 127 127 II I I 145 145 14 14 1.5 1.5 172 172 II 1750 1750 196 196 II 2000 2000 II II 16 16 1.5 1.5 265 265 I I 2700 2700 II 195 195 299 299 II 3050 3050 I I 221 221 https://www.forkliftpdfmanuals.com/
Sea Seal l lock agent lock agent 0-15 0-15 PR PREC ECOAT OAT BOLTS BOLTS (Bo (Bolts lts wit with seal h seal loc lock k age agent nt coa coatin ting g on th on threa reads) ds) 1. 1. Do Do no not us t use the pre e the preco coat at bo bolt a lt as s it it is i is in n ei eith ther er of of th the e fo foll llow ow- - ing cases: ing cases: (a (a) ) Af Afte ter r it it is is re remo move ved. d. (b (b) ) Wh When en th the e pr prec ecoa oat t bo bolt is m lt is mov oved ed (l (loo oose sene ned d or t or tig ight ht- - ene ened) d) by by tig tightn htness ess che check, ck, etc etc. . Note: Note: F For to or torqu rque e che check, ck, use t use the he low lowe er r lim limit it of the allo of the allow- w- a able t ble tigh ighte tenin ning g tor torque que ra range nge. . I If the bol f the bolt t mov move es, s, re re- - tig tighte hten n it a it acco ccordi rding ng to the ste to the steps ps be below low. . 2. 2. Me Meth thod f od for r or reu euse of se of pr prec ecoa oat t bo bolt lts s (1 (1) ) Wa Wash the bol sh the bolt and t and th thre read aded ed ho hole le. . (T (The he th thre read aded ed ho hole le mus must t be be was washed hed eve even for n for rep replac laceme ement nt of t of the he bol bolt.) t.) (2 (2) ) Pe Perf rfec ectl tly y dr dry the wa y the wash shed ed pa part rts s by a by air bl ir blow owin ing. g. (3) (3) Coa Coat th t the sp e speci ecifie fied d sea seal lock ag l lock agent to ent to the the thr thread eaded ed por por- - tion of the tion of the bolt. bolt. HI HIGH GH PR PRES ESSU SURE RE HO HOSE SE FIT FITTI TING NG TI TIGH GHTE TENI NING NG TO TORQ RQUE UE 1. 1. Whe When n con connec nectin ting g a a hig high pre h pressu ssure re hos hose, w e, wipe t ipe the h he hose ose fit fittin ting g and and mat mating nip ing nipple cont ple contact surfa act surfaces ces wit with h cl clea ean n cl clot oth h to to re remo move ve fo fore reig ign n ma matt tter ers s an and d di dirt rt. . Al Also so ch chec eck k no de no dent or oth nt or other er da dama mage ge on th on the e co cont ntac act t surfa surfaces ces befor before e insta installati llation. on. 2. 2. Whe When n con connec nectin ting g a hi a high pre gh pressu ssure re hos hose, hold e, hold the hos the hose t e to al o align the f ign the fitt itting wit ing with the nipp h the nipple and le and tig tighte hten n the the fitting. fitting. 3. 3. Th The e ma maxi ximu mum m ti tigh ghte teni ning ng to torq rque ue mu must not e st not exc xcee eed twi d twice th ce the stan e standa dard rd ti tigh ghte teni ning ng to torq rque ue. . Nominal diameter Nominal diameter Stan Standard dard tight tightening ening torq torque ue N·m N·m (kgf (kgf-cm) -cm) [ft- [ft-Ibf] Ibf] Hose inside Hose inside of screw of screw Standard Standard Tight Tightening ening rang range e dia diamet meter er mm mm (in (in) ) 7/16-20UNF 7/16-20UNF 25 25 ( ( 25 250) 0)[ [ 18 18.1 .1] ] 24 24 - - 2 26 6 ( 2 ( 24 40 0- - 2 27 70 0) ) [ [1 17 7. .4 4- - 1 19 9. .5 5] ] 6 6 (0.2 (0.24) 4) 9/16-18UNF 9/16-18UNF 49 49 ( ( 50 500) 0) [ [ 36 36.2 .2] ] 47 47 - - 52 52 ( 48 ( 480 0- - 5 530 30) [ ) [34 34.7 .7- - 3 38 8. .3 3] ] 9 9 ( (0 0. .3 35 5) ) 3/4-16UNF 3/4-16UNF 59 59 ( ( 60 600) 0) [ [ 43 43.4 .4] ] 5 56 6- - 6 62 2 ( ( 5 57 70 0- - 630 630) [41 ) [41.2 .2 - - 45.6] 45.6] 12 12 (0.47) (0.47) 7/8-14UNF 7/8-14UNF 59 59 ( ( 60 600) 0) [ [ 43 43.4 .4] ] 56 56 - - 62 62 ( 57 ( 570- 0- 6 630 30) [ ) [41 41. .2- 2- 4 45 5. .6 6] ] 1 12 2 ( (0 0. .4 47 7) ), , 1 15 5 ( (0 0. .5 59 9) ) 1·1/16 1·1/16 12UNF 12UNF 118 118 (12 (1200) 00) [ 86 [ 86.8] .8] 11 112 2 - 12 - 123 3 (1 (114 140 0 - 12 - 1250 50) ) [8 [82. 2.5 5 - - 90 90.4 .4] ] 19(0.75) 19(0.75) 1·5/16-12UNF 1·5/16-12UNF 137 137 (140 (1400) 0) [101 [101.3] .3] 1 13 30 0 - - 1 14 44 4 ( (1 13 33 30 0 - - 1 14 47 70 0) ) [ [9 96 6. .2 2 - - 1 10 06 6. .4 4] ] 2 25 5 ( (0 0. .9 98 8) ) PF1/4 PF1/4 25 25 ( ( 25 250) 0)[ 18 [ 18.1 .1] ] 2 24 4 - - 2 26 6 ( ( 2 24 40 0 - - 2 27 70 0) ) [ [1 17 7. .4 4 - - 1 19 9. .5 5] ] 6 6 ( (0 0. .2 24 4) ) PF3/8 PF3/8 49 49 ( ( 50 500) 0) [ [ 36 36.2 .2] ] 4 47 7 - - 5 52 2 ( ( 4 48 80 0 - - 5 53 30 0) ) [ [3 34 4. .7 7 - - 3 38 8. .3 3] ] 9 9 ( (0 0. .3 35 5) ) https://www.forkliftpdfmanuals.com/
PF1/2 PF1/2 59 59 ( ( 60 600) 0) [ [ 43 43.4 .4] ] 5 56 6 - - 6 62 2 ( ( 5 57 70 0 - - 6 63 30 0) ) [ [4 41 1. .2 2 - - 4 45 5. .6 6] ] 12 12 (0.47) (0.47) PF3/4 PF3/4 118 118 (12 (1200) 00) [ [ 86. 86.8] 8] 1 11 12 2 - -1 12 23 ( 3 (1 11 14 40 0 - -1 12 25 50 0) ) [ [8 82 2. .5 5 - 90 - 90. .4 4] ] 1 19 9 ( (0 0. .7 75 5) ) PF1 PF1 137 137 (140 (1400) 0) [101 [101.3] .3] 1 13 30 0 - -1 14 44 ( 4 (1 13 33 30 0 - - 1 14 47 70 0) ) [ [9 96 6. .2 2 - -1 10 06 6. .4 4] ] 2 25 5 ( (0 0. .9 98 8) ) 0-16 0-16 WI WIRE RE RO ROPE PE SU SUSP SPEN ENSI SION ON ANG ANGLE LE LIS LIST T Lifting angle Lifting angle 3 3 0 0 0 0 Tension Tension 1.00time 1.00time 1.04time 1.04time 1.16 time 1.16 time Compres- Compres- sion sion o o time time 0.27 time 0.27 time 0.S8time 0.S8time Suspension Suspension method method 2t 2t Lifting angle Lifting angle Tension Tension 1.41 time 1.41 time 2.00 time 2.00 time Compres- Compres- sion sion 1.00 time 1.00 time 1.73 time 1.73 time Suspension Suspension method method 2t 2t SAF SAFE E LOAD LOAD FO FOR R EACH W EACH WIR IRE E RO ROPE SUS PE SUSPE PENS NSIO ION N ANG ANGLE LE Uni Unit: t: N N (tf (tf) ) [Ib [Ibf] f] R Ro op pe e C Cu ut tt ti in ng g Single-rope Single-rope Two-r Two-rope ope suspe suspension nsion Four Four-rope -rope suspe suspension nsion suspension suspension d di ia am me et te er r l lo oa ad d 0 0 0 0 0 0 0 0 30 30 0 0 60 60 0 0 90 90 0 0 0 0 0 0 30 30 0 0 60 60 0 0 90 90 0 0 6mm 6mm 21380 21380 3040 3040 6080 6080 5880 5880 5200 5200 4 43 31 10 0 1 12 21 16 60 0 11770 11770 10400 10400 8630 8630 (0. (0.24 24 in) in) (2.18) (2.18) (0.31 (0.31 ) ) (0.62) (0.62) (0.6) (0.6) (0.53) (0.53) (0.44) (0.44) (1.24) (1.24) (1.2) (1.2) (1.06) (1.06) (0.88) (0.88) [4807] [4807] [683.6] [683.6] [1367] [1367] [1323] [1323] [1169] [1169] [970] [970] [2734] [2734] [2646] [2646] [2337] [2337] [1940] [1940] 8 8 mm mm 31480 31480 4 44 41 10 0 8 88 83 30 0 8530 8530 7650 7650 6280 6280 17650 17650 17060 17060 15300 15300 12550 12550 (0. (0.32 32 in) in) (3.21 ) (3.21 ) (0.45) (0.45) (0.9) (0.9) (0.87) (0.87) (0.78) (0.78) (0.64) (0.64) (1.8) (1.8) (1.74) (1.74) (1.56] (1.56] (1.28) (1.28) [7078] [7078] [992.3] [992.3] [1985] [1985] [1918] [1918] [1720] [1720] [1411] [1411] [3969] [3969] [3937] [3937] [3440] [3440] [2322] [2322] 10 mm 10 mm 49230 49230 6960 6960 14020 14020 13440 13440 1 11 17 77 70 0 9 98 81 10 0 27460 27460 26480 26480 23540 23540 19610 19610 (0. (0.4 4 in) in) (5.02) (5.02) (0.71 (0.71 ) ) (1.43) (1.43) (1.37) (1.37) (1.2) (1.2) (1.0) (1.0) (2.8) (2.8) (2.7) (2.7) (2.4) (2.4) (2.0) (2.0) [11.69] [11.69] [1565.6] [1565.6] [3153] [3153] [3021] [3021] [2646] [2646] [2205] [2205] [6174] [6174] [5954] [5954] [5292] [5292] [4410] [4410] 76880 76880 10980 10980 21570 21570 21280 21280 18630 18630 14710 14710 43150 43150 41190 41190 37270 37270 29420 29420 https://www.forkliftpdfmanuals.com/
12 12.5 .5 mm mm (0. (0.5 5 in) in) (7.84) (7.84) (1.12) (1.12) (2.2) (2.2) (2. (2.1 1 ) ) (1.9) (1.9) (1.5) (1.5) (4.4) (4.4) (4.2) (4.2) (3.8) (3.8) (3.0) (3.0) [17387] [17387] [2469.5] [2469.5] [4851] [4851] [4631] [4631] [4190] [4190] [3308] [3308] [9702] [9702] [9261] [9261] [8379] [8379] [6615] [6615] 14 mm 14 mm 96400 96400 13730 13730 27460 27460 26480 26480 23540 23540 18630 18630 54920 54920 52960 52960 47070 47070 37270 37270 (0. (0.56 56 in) in) (9.83) (9.83) (1.4) (1.4) (2.8) (2.8) (2.7) (2.7) (2.4) (2.4) (1.9) (1.9) (5.6) (5.6) (5.4) (5.4) (4.8) (4.8) (3.8) (3.8) [21675] [21675] [3087] [3087] [6174] [6174] [ [5 59 95 54 4] ] [ [5 52 29 92 2] ] [4190] [4190] [12348] [12348] [11907] [11907] [10584] [10584] [8379] [8379] CO COMP MPON ONEN ENTS TS WE WEIGH IGHT T 0-17 0-17 Component Component W We ei ig gh ht t k kg g ( (I Ib b) ) 5K 5K 97 97 ( ( 21 214) 4) Engine Engine 4Y 4Y 134 134 ( ( 295 295) ) 1DZ-II 1DZ-II 176 176 ( ( 388 388) ) 2Z 2Z 24 240 0 ( ( 52 529) 9) Mf Mf f f 75 75 ( ( 16 165 5) ) Transmission Transmission TIC TIC (1 speed) (1 speed) 12 124 4 ( ( 27 273) 3) TIC TIC (2 speeds) (2 speeds) 15 153 3 ( ( 33 337) 7) 1.0 to 1.0 ton n mode model l Ap Appr prox ox. . 40 400 0 ( ( 88 880) 0) 1.5 to 1.5 ton n mode model l Ap Appro prox. x. 745 745 (16 (1640) 40) 1.75 to 1.75 ton n mode model l Ap Appro prox. x. 880 880 (19 (1940) 40) 2.0 ton model 2.0 ton model Appr Approx. ox. 1150 1150 (2535 (2535) ) Coun Counter ter weigh weight t 2.5 ton model 2.5 ton model Appr Approx. ox. 1500 1500 (330 (3300) 0) 3.0 ton model 3.0 ton model Appr Approx. ox. 1800 1800 (400 (4000) 0) K2.0 ton K2.0 ton mode model l Appr Approx. ox. 1140 1140 (2510 (2510) ) K2.5 ton K2.5 ton mode model l Appr Approx. ox. 1550 1550 (3410 (3410) ) K3.0 ton model K3.0 ton model Appr Approx. ox. 1925 1925 (4240 (4240) ) J3.5 ton model J3.5 ton model Appr Approx. ox. 2135 2135 (470 (4700) 0) 1 1 t to on n s se er ri ie es s A Ap pp pr ro ox x. . 41 410 ( 900 0 ( 900) ) V ma V mast ASSY st ASSY Uba Ubackr ckrest est and and for fork k 2 ton 2 ton serie series s App Approx rox. . 505 505 (11 (1110) 10) (with lift cy (with lift cylinde linder, r, max. max. liftin lifting g heigh height: t: 3 3 t to on n, , K K3 3 t to on n s se er ri ie es s A Ap pp pr ro ox x. . 570 ( 570 (1260) 1260) 300 3000 0 mm mm (11 (118 in 8 in» » K K2 2 t to on n s se er ri ie es s A Ap pp pr ro ox x. . 465 ( 465 (1030) 1030) J J3 3. .5 5 t to on n s se er ri ie es s A Ap pp pr ro ox x. . 680 680 (1500 (1500) ) https://www.forkliftpdfmanuals.com/
0-18 0-18 RE RECO COMM MMEN ENDE DED D LUBRIC LUBRICANT ANT QU QUANT ANTIT ITY Y & & TYPES TYPES Description Description Application Application Quantity Quantity f f ( (U US S g ga al l) ) C Cl la as ss si if fi ic ca at ti io on n T Ty yp pe e Motor oil Motor oil 5K 5K 4.0 4.0 (1.06) (1.06) SAE30 SAE30 Gasoline Gasoline AP API I (SAE20 (SAE20 in in cold cold area) area) SH, SJ SH, SJ SAE20W-40 SAE20W-40 4Y 4Y 4.0 4.0 (1.06) (1.06) (SAE1 (SAE10W-30 0W-30 in in cold cold Engine Engine area) area) 1DZ-II 1DZ-II 7.9 7.9 (2.09) (2.09) Diesel Diesel engine engine oil oil AP API I SAE30 SAE30 (SAE2 (SAE20 0 in in Diesel Diesel CE,CF CE,CF cold cold area) area) 2Z 2Z 9.0 9.0 (2.38) (2.38) SAE10W-30 SAE10W-30 Mf Mff f 3.8 3.8 (1.0) (1.0) AP API I Hypoid Hypoid gear gear oil oil GL-4, GL-5 GL-4, GL-5 SAE85W-90 SAE85W-90 Transmission Transmission TIC TIC (1 speed) (1 speed) 9.0 9.0 (2.38) (2.38) AT ATF F GM GM Dexron® Dexron® II II TIC TIC (2 speeds) (2 speeds) 10.5 10.5 (2.77) (2.77) 1 ton series 1 ton series 6.3 6.3 (1.66) (1.66) 2 ton series, 2 ton series, Differential Differential K2 K2 ton ton series, series, 7.1 7.1 (1.87) (1.87) AP API I Hypoid Hypoid gear gear oil oil K3 ton series K3 ton series GL-4,GL-5 GL-4,GL-5 SAE85W-90 SAE85W-90 3 ton series, 3 ton series, 7.7 (2.03) 7.7 (2.03) J3.5 ton series J3.5 ton series Hydrauli Hydraulic c oil oil Attache Attached d Table Table 1 1 ISO ISO Hydraulic oil Hydraulic oil Hydrauli Hydraulic c oil volu oil volume me VG32 VG32 1 ton series 1 ton series 45(11.9) 45(11.9) Fuel tank Fuel tank K2 K2 ton ton series series 55 55 (14.5) (14.5) - - Other series Other series 65 65 (17.2) (17.2) Proper Proper quanti quantity ty SAEJ-1703 SAEJ-1703 Brake and clutch line Brake and clutch line All All models models Reservoir Reservoir Tank Tank - - OOT-3 OOT-3 0.2 (0.05) 0.2 (0.05) • • MPgre MPgrease ase Chassis parts Chassis parts All All models models Proper Proper quanti quantity ty - - • • Molyb Molybdenu denum m disulfide grease disulfide grease • • LLC LLC 30- 30-50% 50% mixt mixture ure https://www.forkliftpdfmanuals.com/
(for wint (for winter er or all- or all- Coolant (excluding Coolant (excluding season) season) reservoir tank) reservoir tank) Attache Attached d Table Table 2 2 Coolant Coolant volume volume LLC LLC • • Cool Coolant ant wit with h rust rust- - inhibitor (for spring, inhibitor (for spring, summer and summer and autumn) autumn) Coolant (Reservoir Tank) Coolant (Reservoir Tank) All All models models 0.6 0.6 (0.16) (0.16) f f f f (at Full level) (at Full level) 0-19 0-19 36 (9.5) 36 (9.5) Unit: Unit: l l (US gal) (US gal) J3.5 ton series J3.5 ton series Attached Attached Table Table 1 1 Hyd Hydrau raulic lic oil oil vol volume ume [V ma [V mast, max. lift st, max. lifting ing hei height 3000 ght 3000 mm mm (11 (118 i 8 in)] n)] Model Model 1 1 ton ton seri series es 2 2 ton ton seri series es 3 3 t to on n s se er ri ie es s K K2 2· ·K K3 3 t to on n s se er ri ie es s 5K eng 5K engine ine mode models ls 27 27 (7.1 (7.1) ) 34 34 (9.0 (9.0) ) 30 30 (7.9 (7.9) ) 4Y eng 4Y engine ine mode models ls 27 27 (7.1 (7.1) ) 34 34 (9.0 (9.0) ) 36 36 (9.5) (9.5) 30 30 (7.9 (7.9) ) 1DZ-II engine models 1DZ-II engine models 27 27 (7.1 (7.1) ) 34 34 (9.0 (9.0) ) 36 36 (9.5) (9.5) 2Z engi 2Z engine ne mode models ls 39 39 (10.3 (10.3) ) 41 41 (10. (10.8) 8) Note: Note: Si Since the hydr nce the hydrau aulic lic oil vol oil volume ume va varie ries s with the mas with the mast t spe specific cifica ation, tion, be be sure to c sure to che heck ck fina finally lly with the with the leve level l gauge gauge. . Attached Attached Table Table 2 2 Coolant Coolant volume volume Unit: Unit: l l (US gal) (US gal) Engine Engine Transmission Transmission 1 1 t to on n s se er ri ie es s K K2 2· ·K K3 3 t to on n s se er ri ie es s 2·3·J3.5 2·3·J3.5 ton ton series series M Mf fT T 6 6. .0 0 ( (1 1. .5 58 8) ) 6.0 6.0 (1.5 (1.58) 8) 6.1 6.1 (1.6 (1.61) 1) 5K 5K T I C T I C 6 6. .5 5 ( (1 1. .7 72 2) ) 6 6. .5 5 ( (1 1. .7 72 2) ) 7.6 7.6 (2.0 (2.01) 1) M Mf fT T 7 7. .0 0 ( (1 1. .8 85 5) ) 8 8. .2 2 ( (2 2. .1 16 6) ) 8.4 8.4 (2.2 (2.22) 2) 4Y 4Y T I C T I C 8.5 8.5 (2.24) (2.24) 8 8. .5 5 ( (2 2. .2 24 4) ) 9 9. .6 6 ( (2 2. .5 53 3) ) MfT MfT 6.7 6.7 (1.7 (1.77) 7) 6 6. .9 9 ( (1 1. .8 82 2) ) 7 7. .1 1 ( (1 1. .8 87 7) ) 1DZ-II 1DZ-II T I C T I C 7.2 7.2 (1.90 (1.90) ) 7 7. .2 2 ( (1 1. .9 90 0) ) 8 8. .3 3 ( (2 2. .1 19 9) ) MfT MfT ------------- ------------- ------------- ------------- 8.1 8.1 (2.1 (2.14) 4) 2Z 2Z ------------- ------------- ---------- ---------- T I C T I C 9.3 9.3 (2.4 (2.46) 6) https://www.forkliftpdfmanuals.com/
0-20 0-20 LUBRIC LUBRICATIO ATION N CH CHART ART Ma Manua nual l Tr Trans ansmissi mission on Mode Model l 1 4 1 4 2 2 1 3 1 3 1 4 1 4 4 4 1 3 1 3 3 3 3 3 5 5 1 2 1 2 1 6 1 6 1 5 1 5 1 0 1 0 2 0 2 0 1 7 1 7 8 8 7 7 9 9 6 6 7 7 1 8 1 8 6 6 1 9 1 9 1 8 1 8 1 1 1 1 1 1 9 9 ill ill N N v v o o Inspection Inspection • • R Re ep pl la ac ce em me en nt t C D C D MPgrease MPgrease ® ® Engineoil Engineoil ® ® Hypo Hypoid id gear gear oil oil @ @ Hydr Hydraulic aulic oil oil ® ® Hypo Hypoid id gear gear oil oil ® ® Brake Brake fluid fluid ( (j j) ) Molybdenum Molybdenum disulfide disulfide grease grease L L In Insp spec ect t ev ever ery y 8 8 ho hour urs s (d (dai aily ly) ) II II. . In Insp spec ect t ev ever ery y 40 40 ho hour urs (w s (wee eekl kly) y) IlL IlL Ins Inspec pect t eve every 1 ry 170 70 hou hours ( rs (mon monthl thly) y) IV. IV. Ins Inspec pect t eve every 1 ry 100 000 h 0 hour ours (6 m s (6 mont onthly hly) ) V. V. Ins Inspec pect t eve every ry 20 2000 00 hou hours rs (an (annua nual) l) https://www.forkliftpdfmanuals.com/
1 1 C Ch ha ai in n 2 2 Di Diff ffer eren enti tial al 3 3 Fr Fron ont t wh whee eel l be bear arin ing g 4 4 Bra Brake ke and and clu clutch tch mas master ter cyl cylind inder er 5 5 Tr Tran ansm smis issi sion on ca case se 6 6 Re Rear ar wh whee eel b l bea eari ring ng 7 7 Ste Steeri ering ng knu knuckl ckle e kin king g pin pin 8 8 O Oi ilt lta an nk k 9 9 En Engi gine ne cr cran ank k ca case se 10 10 Re Rear ar ax axle le be beam am fr fron ont p t pin in 11 11 Re Rear ar ax axle le be beam am re rear ar pi pin n 12 12 Tilt Tilt ste steeri ering ngloc lockin king g me mecha chanis nism m 13 13 Ma Mast st su supp ppor ort t bu bush shin ing g 14 14 Ti Tilt lt cyl cylin inde der r fr fron ont p t pin in 15 15 Pr Prop opel elle ler r sh shaf aft t 16 16 Ge Gear ar sh shif ift t li link nk 17 17 Sw Swin ing g lo lock ck cy cylin linde der lo r lowe wer p r pin in 18 18 Ti Tie e ro rod d en end d p pin in 19 19 Re Rear ar ax axle le cy cylin linde der r en end d pi pin n 20 20 Ge Gear ar sh shif ift t le leve ver r 0-21 0-21 To Torque Conv rque Conver erte ter r & & Tr Tran ansmiss smission ion Mo Mode del l 1 1 1 1 1 4 1 4 2 2 1 3 1 3 1 4 1 4 3 3 1 3 1 3 3 3 4 4 1 2 1 2 5 5 1 5 1 5 1 0 1 0 8 8 1 6 1 6 9 9 7 7 7 7 6 6 6 6 1 7 1 7 1 7 1 7 1 8 1 8 1 8 1 8 1 1 1 1 ill ill N N v v o o Inspection Inspection • • R Re ep pl la ac ce em me en nt t G ) G ) MPgrease MPgrease @ @ Engineoil Engineoil ® ® Hypo Hypoid id gea gear r oil oil @ @ Hydr Hydraulic aulic oil oil ® ® Automatic Automatic transmission transmission fluid fluid ® ® Brake Brake fluid fluid l l Inspe Inspect ct ever every 8 ho y 8 hours urs (dail (daily) y) It It In Insp spec ect t ev ever ery y 40 40 ho hour urs s (w (wee eekl kly) y) I I l l Inspe Inspect ev ct every 170 ho ery 170 hours (mon urs (monthly) thly) IV. IV. Ins Inspec pect e t ever very 1000 y 1000 hou hours (6 rs (6 mo month nthly) ly) V. V. Ins Inspec pect t eve every ry 200 2000 0 hou hours rs (an (annu nual) al) https://www.forkliftpdfmanuals.com/
( ( j j) ) Molybdenum Molybdenum disulfide disulfide grease grease 1 1 C Ch ha ai in n 2 2 Di Diff ffer eren enti tial al 3 3 Fr Fron ont t wh whee eel l be bear arin ing g 4 4 Br Brak ake e ma mast ster er cy cyli lind nder er 5 5 To Torq rque ue co conv nver erte ter r ca case se 6 6 Re Rear ar wh whee eel l be bear arin ing g 7 7 Ste Steeri ering ng knu knuckl ckle e kin king g pin pin 8 8 O Oi ilt lta an nk k 9 9 En Engi gine ne cr cran ank k ca case se 10 10 Re Rear ar ax axle le be beamfron amfront t pi pin n 11 11 Re Rear ar ax axle le be beam am re rear ar pi pin n 12 12 Tilt Tilt ste steeri ering ng loc lockin king g me mecha chanis nism m 13 13 Ma Mast st su supp ppor ort t bu bush shin ing g 14 14 Ti Tilt c lt cyl ylin inde der r fr fron ont t pi pin n 15 15 Pr Prop opel elle ler r sh shaf aft t 16 16 Sw Swin ing lo g lock c ck cyl ylin inde der l r low ower p er pin in 1 17 7 Ti Tie e ro rod d e en nd d p pin in 18 18 Rea Rear r axl axle e cyl cylind inder er end end pin pin 0-22 0-22 PERI PERIODI ODIC C MAINTE MAINTENANCE NANCE IN INSPECTI SPECTION ON METHOD METHOD I I : : Insp Inspecti ection. on. Rep Repair air or or rep replace lacemen ment t if if req requir uired. ed. M : M : Mea Measur sureme ement. nt. Rep Repair air or or adj adjust ustmen ment t if if req requir uired. ed. T T : : Re Reti tigh ghte teni ning ng C C : : Cl Clea eanin ning g L L : : Lu Lubr brica icati tion on * * : : Fo For r ne new w ve vehi hicl cle e *1 *1: : F Fla law w d det etec ecto tor r Inspection Period Inspection Period Every Every Every Every Every Every Every Every 1 month 1 month 3 3 months months 6 6 months months 12 12 months months Every Every Every Every Every Every Every Every Item Item 170 170 hours hours 500 500 hours hours 1000 1000 hours hours 2000 2000 hours hours ENGINE ENGINE Proper starting and abnormal noise Proper starting and abnormal noise I I + + - - + + - - + + - - Rotat Rotating ing condi condition tion at idli at idling ng M M + + - - + + - - + + - - Rotating condition Rotating condition during accelerati during acceleration on M M + + - - + + - - + + - - Exhaust Exhaust gas condit gas condition ion I I + + - - + + - - + + - - Main body Main body Air Air clean cleaner er elemen element t C C + + - - + + - - + + - - Valve clearance Valve clearance M* M* M M Compression Compression M M Cylinder head bolt loosening Cylinder head bolt loosening T T Muffler rubber mount Muffler rubber mount I I PCV PCV syste system m Clogging Clogging and and damage damage in in PCV PCV valve and valve and piping piping I I + + - - + + - - + + - - Governor Governor No-l No-load oad maximum maximum rpm rpm M M + + - - + + - - + + - - Oil leak Oil leak I I + + - - + + - - + + - - Lubrication Lubrication Oil level Oil level I I + + - - + + - - + + - - system system Clogging Clogging and dirt of oil and dirt of oil filt filter er I I + + - - + + - - + + - - Fuel leak Fuel leak I I + + - - + + - - + + - - Operation Operation of of carburetor carburetor link link mechanism mechanism I I + + - - + + - - + + - - Dirt and clogging of fuel filter and element Dirt and clogging of fuel filter and element I I + + - - + + - - + + - - Fu Fuel el sy syst stem em In Inje ject ctiion on ti timi ming ng M M + + - - https://www.forkliftpdfmanuals.com/
Inje Injecti ction on nozzl nozzle inject e injection ion press pressure ure and and M M spray spray statu status s Draining of sedimenter Draining of sedimenter I I + + - - Coolan Coolant t leve level in radi l in radiator ator and leak and leak I I + + - - + + - - + + - - Rubber hose degradation Rubber hose degradation I I + + - - + + - - + + - - Cooling Cooling Radiator cap condition Radiator cap condition I I + + - - + + - - + + - - system system Fan belt Fan belt tensi tension, on, loos looseness eness and damage and damage I I + + - - + + - - + + - - Radiator rubber mount Radiator rubber mount I I 0-23 0-23 Insp Inspectio ection n Peri Period od E Ev ve er ry y E Ev ve er ry y E Ev ve er ry y E Ev ve er ry y 1 month 1 month 3 3 months months 6 6 m mon onth ths s 12 12 mo mont nths hs E Ev ve er ry y E Ev ve er ry y E Ev ve er ry y E Ev ve er ry y Item Item 170 170 hours hours 50 500 0 ho hour urs s 10 1000 00 ho hour urs s 2000 2000 hour hours s POW POWER ER TRA TRANSM NSMISS ISSION ION SYS SYSTEM TEM Clutc Clutch h peda pedal l play play M M - - - - - - Abnormal Abnormal sound sound and and functioning functioning I I - - - - - - (connection) (connection) Clutch Clutch Clutc Clutch h mast master er cylin cylinder der funct function ion and and leak leak I I - - - - - - Fluid level Fluid level I I - - - - - - Oil cl Oil clutc utch h mec mechan hanism ism fun functi ction on and lea and leak k I I (OPT) (OPT) - - Leak Leak I I - - - - - - Fluid level Fluid level I I - - - - - - Manual Manual Gear functi Gear function on and abno and abnormal rmal noise noise I I - - - - - - transmission transmission Dama Damage ge of shift leve of shift lever cable r cable boot boot I I D Da am ma ag ge e o of f c ca ab bl le e o ou ut te er r I I Leak Leak I I - - - - - - D Di if ff fe er re en nt ti ia al l O Oi il l l le ev ve el l I I - - - - - - B Bo ol lt t l lo oo os se en ni in ng g T T L Le ea ak k I I - - - - - - Fluid level Fluid level I I - - - - - - Torque Torque Oper Operating ating mech mechanism anism func function tion and and I I - - - - - - converter converter & & looseness looseness transmission transmission Contr Control ol valve and valve and clutc clutch h funct functions ions I I - - - - - - I In nc ch hi in ng g v va al lv ve e f fu un nc ct ti io on n I I - - - - - - Stall and hydrau Stall and hydraulic lic pres pressure sure meas measurem urement ent M M - - Loose joint Loose joint T T - - - - Prop Propeller eller shaft shaft Loos Loosenes eness s at at splin spline conne e connection ctions s I I and axle shaft and axle shaft Loos Loosenes eness s of u of univer niversal sal joint joint I I Twis Twisting ting and crack and cracks s of axle s of axle shaft haft I I https://www.forkliftpdfmanuals.com/
DRIVE DRIVE SYSTE SYSTEM M Tire inflation pressure Tire inflation pressure M M - - - - - - Tire cuts, damag Tire cuts, damage e and une and uneven wearing ven wearing I I - - - - - - Loo Loose se rim and hu rim and hub b nut nuts s T T - - - - - - Wheels Wheels Tire groove depth Tire groove depth M M - - - - - - Meta Metal l chip chips, s, pebb pebbles les and other fore and other foreign ign I I - - - - - - matt matter er trap trapped ped in tir in tire grooves e grooves 0-24 0-24 Inspection Period Inspection Period Every Every Every Every Every Every Every Every 1 month 1 month 3 3 months months 6 6 months months 12 12 months months E Ev ve er ry y E Ev ve er ry y E Ev ve er ry y Every Every Item Item 170 170 hours hours 500 500 hours hours 100 1000 0 hou hours rs 200 2000 0 hou hours rs Rim, side bearing and disc wheel damage Rim, side bearing and disc wheel damage I I - - - - - - Abnor Abnormal mal sound and loosen sound and looseness ess of of fro front nt I I Wheels Wheels wheel wheel bearing bearing - - - - - - Abnor Abnormal mal sound and loos sound and looseness eness of r of rear ear I I wheel bearing wheel bearing - - - - - - Front axle Front axle Cracks Cracks, , damage damage and and defor deformatio mation n of of housi housing ng I I Cracks Cracks, , damage damage and d and defor eformatio mation n of of beam beam I I Rear axle Rear axle Loosen Looseness ess of ax of axle beam le beam in in vehi vehicle cle longitudi longitudinal nal directi direction on M* M* M M STEE STEERING RING SYST SYSTEM EM Play and looseness Play and looseness I I - - - - - - Steering wheel Steering wheel Function Function I I - - - - - - Oil leak Oil leak I I - - - - - - Steering valve Steering valve Looseness of mounting Looseness of mounting T T - - - - - - Oil leak Oil leak I I - - - - - - Power Steering Power Steering Mounti Mounting ng and l and linka inkage ge loos looseness eness I I - - - - - - Damage of power steering hose Damage of power steering hose I I King pin looseness King pin looseness I I - - - - - - Knuckle Knuckle Cranks and deformation Cranks and deformation I I BRAKING SYSTEM BRAKING SYSTEM Play and reserve Play and reserve M M - - - - - - Brake pedal Brake pedal Braking effect Braking effect I I - - - - - - Operating force Operating force I I - - - - - - https://www.forkliftpdfmanuals.com/
Parking brake Parking brake Braking Braking effect effect I I - - - - - - Rod and cab Rod and cable loosene le looseness ss and damage and damage I I - - - - - - Brake pipe Brake pipe Leak, Leak, damage damage and and mounti mounting condi ng conditio tion n I I - - - - - - Reservoir tank Reservoir tank Leak Leak and and fluid fluid level level I I - - - - - - Master Master Functi Function, on, wear, da wear, damage, mage, leak and mounti leak and mounting ng cyli cylinder nder and and I I wheel cylinder wheel cylinder looseness looseness 0-25 0-25 Insp Inspectio ection n Perio Period d Every Every E Ev ve er ry y E Ev ve er ry y Every Every 1 1 mo month nth 3 3 months months 6 6 m mon onth ths s 1 12 2 m mon onth ths s Every Every Every Every E Ev ve er ry y E Ev ve er ry y Item Item 170 170 hours hours 500 500 hour hours s 1000 1000 hours hours 2000 2000 hour hours s Clear Clearance ance betwe between drum and lining en drum and lining M M . - . - . - . - . - . - Wea Wear r of sh of shoe slidi oe sliding ng por portio tion n and lin and lining ing I I Brake drum Brake drum Drum Drum wear wear and and dama damage ge I I and brake and brake Shoe Shoe oper operating ating cond condition ition I I shoe shoe Anchor Anchor pin pin rusting rusting I I Return spring fatigue Return spring fatigue M M Automatic Automatic adjuster adjuster function function I I Defor Deformati mation, on, crack cracks s and da and damage mage I I Backi Backing ng plate plate Loose mounting Loose mounting T T MATER MATERIAL IAL HANDL HANDLING ING SYSTEM SYSTEM Abnormality Abnormality of of fork fork and and stopper stopper pin pin I I . - . - . . - - . . - - Forks Forks Misa Misalignm lignment be ent between tween left left and and right right fork fork I I . - . - . . - - . . - - fingers fingers Cra Cracks cks at for at fork k roo root t and weld and welded ed par part t 1 * 1 1 * 1 Defo Deformati rmation on and dama and damage ge of eac of each part an h part and d I I . - . - . - . - . - . - cra crack ck at at wel welded ded par part t Mast and Mast and lift b lift bracke racket t loose looseness ness I I . - . - . . - - . . - - Mas Mast t and lift and lift Wear and Wear and dama damage of ge of mast mast suppo support bushin rt bushing g I I bracket bracket Wear Wear, , dama damage ge and ro and rotatin tating g cond condition of ition of rollers rollers I I . - . - . . - - . . - - Wea Wear r and da and damag mage e of ro of rolle ller r pin pins s I I Wea Wear r and da and dama mage ge of m of mast trip ast trip I I . - . - . . - - . . - - Tens Tension, deform ion, deformation ation and dama and damage ge of of chain chain I I . - . - . - . - . - . - Chain lubrication Chain lubrication I I . - . - . . - - . . - - Chain and Chain and chainwheel chainwheel Abnor Abnormalit mality y of of chain chain anch anchor bo or bolt lt I I . - . - . - . - . - . - Wear Wear, , dama damage ge and rot and rotating conditio ating condition n of of https://www.forkliftpdfmanuals.com/
I I . . . . . . chainwheel chainwheel Various Various Abnor Abnormalit mality and y and moun mounting ting condi condition tion of of each each I I . - . - . - . - . - . - attachments attachments part part HYDRA HYDRAULIC ULIC SYSTEM SYSTEM Loos Loosening ening and and dama damage ge of c of cylind ylinder er moun mounting ting T T . - . - . . - - . . - - Defo Deformat rmation ion and da and damage mage of rod, r of rod, rod scr od screw ew I I . - . - . . - - . . - - and rod end and rod end Cylinder Cylinder Cylinder operation Cylinder operation I I . - . - . - . - . - . - Natur Natural al drop and natura drop and natural l forwa forward rd tilt tilt M M . - . - . - . - . - . - (hydraulic drift) (hydraulic drift) 0-26 0-26 I In ns sp pe ec ct tiio on n P Pe er riio od d E Ev ve er ry y E Ev ve er ry y Every Every Every Every 1 month 1 month 3 3 months months 6 6 months months 12 12 months months E Ev ve er ry y E Ev ve er ry y Every Every Every Every Item Item 17 170 0 ho hour urs s 50 500 0 ho hour urs s 1000 1000 hours hours 2000 2000 hours hours Oil l Oil leak eak and damage and damage I I - - - - - - Wear Wear and damage and damage of p of pin and in and cyli cylinder nder I I bearing bearing - - - - - - Cytinder Cytinder Lifting speed Lifting speed M M - - - - - - Uneven movement Uneven movement I I - - - - - - Oil pump Oil pump Oil Oil leak leak and and abnor abnormal mal sound sound I I - - - - - - Oil level and contamination Oil level and contamination I I - - - - - - Hydrau Hydraulic lic oil oil Tank and oil strainer Tank and oil strainer C C - - tank tank Oil leak Oil leak I I - - - - - - Loose linkage Loose linkage I I - - - - - - Control lever Control lever Operation Operation I I - - - - - - Oil leak Oil leak I I - - - - - - Oil control Oil control Relief pressure measurement Relief pressure measurement M M valve valve Relief valve and tilt lock valve functions Relief valve and tilt lock valve functions I I - - - - - - Oil leak Oil leak I I - - - - - - Hydraulic Hydraulic Defor Deformatio mation n and damage and damage I I - - - - - - piping piping Loose joint Loose joint T T - - - - - - ELECTRICAL SYSTEM ELECTRICAL SYSTEM Cracks Cracks on di on distri stributor butor cap cap I I - - - - - - Spark plug burning and gap Spark plug burning and gap I I - - - - - - Distributor side terminal burning Distributor side terminal burning I I - - - - - - Ignition timing Ignition timing Distr Distribut ibutor or cap cent cap center er piec piece wear and e wear and damage damage I I - - - - - - Plug cord internal discontinuity Plug cord internal discontinuity I I Ignition timing Ignition timing M M - - https://www.forkliftpdfmanuals.com/
Starting motor Starting motor Pini Pinion gea on gear mesh r meshing status ing status I I - - - - - - Charger Charger Charging Charging function function I I - - - - - - Battery fluid level Battery fluid level I I - - - - - - Battery Battery Battery fluid specif Battery fluid specific ic gravity gravity M M - - Electrical Electrical Damage Damage of of wiri wiring ng harn harness ess I I - - - - - - wiring wiring Fuses Fuses I I - - - - - - 0-27 0-27 Inspe Inspection ction Per Period iod Every Every Every Every Every Every Every Every 1 month 1 month 3 3 months months 6 6 months months 12 12 months months Every Every E Ev ve er ry y E Ev ve er ry y Every Every Item Item 170 170 hours hours 500 500 hour hours s 1000 1000 hours hours 2000 2000 hours hours Open Open-circ -circuit uit in in glow plug glow plug I I + + - - Preheater Preheater Open Open-circ -circuit uit in in inta intake ke heat heater er I I + + - - Engi Engine ne stop stop- - Diese Diesel l engin engine e key st key stop device op device func function tion I I ping ping syste system m + + - - + + - - + + - - Filter Filter I I + + - - DPFMafier DPFMafier Inlin Inline filt e filter er (for ba (for back ck pres pressure sure sens sensor) or) I I + + - - + + - - SAF SAFETY ETY DEVI DEVICES CES, , ETC. ETC. Crac Cracks ks at at weld welded ed port portion ion I I + + - - + + - - + + - - Head guard Head guard Defor Deformatio mation n and damag and damage e I I + + - - + + - - + + - - Loose Loosening ning of mount of mounting ing T T + + - - + + - - + + - - Back-rest Back-rest Defor Deformatio mation, n, crac crack k and dam and damage age I I + + - - + + - - + + - - Lighting Lighting Func Function tion and moun and mounting ting cond condition ition I I - - + + - - + + - - system system Hom Hom Func Function tion and and moun mounting ting cond condition ition I I + + - - + + - - + + - - Direction Direction Func Function tion and moun and mounting ting cond condition ition I I indicator indicator + + - - + + - - + + - - Instruments Instruments Functions Functions I I + + - - + + - - + + - - Back Backup up buzze buzzer r Func Function and moun tion and mounting ting cond condition ition I I + + - - + + - - + + - - Rear-view Rear-view Dirt, Dirt, damage damage I I + + - - + + - - + + - - mirror mirror Rear refl Rear reflectio ection n statu status s I I 4 4 - - 4 4 - - + + - - Loos Loosenin ening g and damag and damage e of mo of mountin unting g I I 4 4 - - + + - - + + - - Seat Seat Seat Seatbelt belt dama damage ge and fun and function ction I I + + - - 4 4 - - + + - - Dam Damage age and cra and cracks cks of fr of frame ame, , cro cross ss I I Body Body memb members, ers, etc. etc. Bolt looseness Bolt looseness T T https://www.forkliftpdfmanuals.com/
Functions Functions I I + + - - + + - - + + - - Loos Loosening ening and dam and damage age at at senso sensor r moun mounting ting I I 4 4 - - + + - - + + - - portion portion Dama Damage, ge, defo deformat rmation, ion, oil oil leaka leakage ge and and I I 4 4 - - + + - - + + - - SAS SAS loose loosening ning of th of the mountin e mounting g of fu of functio nctional nal part parts s Loos Loosenin ening g and damag and damage e of of wire wire harn harnesses esses I I 4 4 - - 4 4 - - + + - - Lock cylin Lock cylinder der accum accumulato ulator r perf performa ormance nce I I R Ru us st ti in ng g a an nd d c co or rr ro os si io on n o of f l lo oa ad d s se en ns so or r I I Others Others Grea Grease se up up L L 4 4 - - 4 4 - - + + - - 0-28 0-28 PE PERIO RIODI DIC C RE REPLACEM PLACEMEN ENT T OF PART OF PARTS S AND L AND LUBRI UBRICANTS CANTS • • : : Rep Replac laceme ement nt Interval Interval Every Every Every Every Every Every Every Every 1 month 1 month 3 3 mo mont nths hs 6 6 mo mont nths hs 12 12 months months Every Every E Ev ve er ry y E Ev ve er ry y E Ev ve er ry y Item Item 170 170 hours hours 500 500 hours hours 1000 1000 hours hours 2000 2000 hours hours Engine oil Engine oil • • + + - - + + - - + + - - Engine oil filter Engine oil filter •• **11 • • + + - - + + - - Engin Engine e cool coolant ant (ever (every 2 years for LLC) y 2 years for LLC) • • + + - - + + - - Fuel filter Fuel filter • • + + - - Torque converter oil Torque converter oil • • + + - - Torque converter Torque converter oil oil filter filter • • + + - - Manual Manual tran transmissi smission on oil oil • • Differenti Differential al oil oil • • Hydraul Hydraulic ic oil oil • • + + - - Hydraulic Hydraulic oil oil filt filter er ..**11 • • + + - - Wheel bearing grease Wheel bearing grease • • Spark plugs Spark plugs • • + + - - Air clea Air cleaner ner element element • • Cups and seals for brake master and wheel cylinders Cups and seals for brake master and wheel cylinders • • Brake fluid Brake fluid • • + + - - Power stee Power steerin ring g hoses hoses ..**22 Power steer Power steering ing rubbe rubbers rs part parts s ..**22 Hydrau Hydraulic lic hoses hoses ..**22 Brake fluid reservoir tank hose Brake fluid reservoir tank hose ..**22 Fuel hoses Fuel hoses ..**22 Torque conv Torque converte erter r rubbe rubber r hoses hoses ..**22 https://www.forkliftpdfmanuals.com/
Chains Chains ..**33 DPF Mafler filter (OPT) DPF Mafler filter (OPT) ..**33 DPF M DPF Mafl afler er back pressure back pressure sensor inlin sensor inline fil e filter (OPT) ter (OPT) • • + + - - DPF Air cl DPF Air cleaner eaner (OPT) (OPT) ..**22 SAS Swing SAS Swing lock cyli lock cylinder nder ..**55 *1 *1 : : for new vehicle for new vehicle *2 *2 : : Every 2 years Every 2 years * *3: 3: Every Every 3 yea 3 years rs *5 *5 : : Eve Every ry 100 10000 00 hou hours rs Rep Replac laceme ement nt sha shall ll be ma be made upon arriv de upon arrival al of th of the operat e operation ion hou hours rs or mo or month nths, s, whi whiche chever ver is is ear earlie lier. r. FEATURES FEATURES Page Page C C L LUTC H... UTC H...... ...... .... . 1-2 1-2 MANUAL MANUAL TRANS TRANSMI MISS SSI ION ON 1-5 1-5 FRONT FRONT AXL AXL E-DI E-DIFFERENTI FFERENTIAL AL 1-9 1-9 WH WH E EE LS . E LS . 1-13 1-13 1-1 1-1 CHAN CHANGE GE LEV LEVER ER . . . . . . • . . . . . . . . • . . . . . . . . . . . . . • . . . . . . . . • . . . . . . . . . • . . . • . . . . . . • . . . • • • . . • . . . . . • . . . • . . . . . . • . . . • • • . . • . . . . . . • • • . . . . . . . . • • • . . . . . 1-16 1-16 STEE RING STEE RING 1-17 1-17 FRAM E-WEI FRAM E-WEIG G HT HT 1-18 1-18 V V M MA AST ST............ ......................... .......................... .......................... .......................... .......................... ............. 1-19 1-19 T TI I LT C LT CYLI ND YLI ND ER ER 1-19 1-19 LIFT CYLIN DER LIFT CYLIN DER 1-20 1-20 FS FSV· V·FV FV FRON FRONT T CYLI CYLINDE NDER R • • • . . . . . . . . . . • . . . • . . . . . • • • . . . . . . . . . . • . . . • . . . . . • • • • . • . . . . . . . . . . . • • • • . • . . . . . . . . . . . 1-21 1-21 S SA AS S 1-22 1-22 https://www.forkliftpdfmanuals.com/
Ref Refer to er to th the lat e latest data in est data in th the Toy e Toyot ota a In Indus dustr tria ial l Equ Equip ipment ment Pro Produc duct t In Info forma rmati tion on and and Toy Toyot ota a I. I.E. Sp E. Speci ecifi ficat catio ion n Man Manual ual fo for the main vehi r the main vehicl cle e spe speci cifi ficat catio ions. ns. 1-2 1-2 CLUTCH CLUTCH GENERAL GENERAL The The cl clut utch ch re rele lease ase hub li hub link nk mech mechani anism sm has bee has been n modi modifi fied. ed. On conv On convent entio ional nal veh vehic icle les, s, th the e ped pedal al dep depre ressi ssion on fo forc rce e was was trans transmitted mitted from the cl from the clutch utch relea release se cyli cylinder to th nder to the clutch cover e clutch cover thr through ough the relea the release fork se fork shaf shaft, t, rel release ease for fork k and rel and release ease hub. hub. The same The same is is transmi transmitted tted from the from the releas release e cyli cylinder to t nder to the clutch he clutch cover through the release fork and release hub after the modi- cover through the release fork and release hub after the modi- fi ficati cation on made made thi this time. s time. The clutc The clutch h syst system, em, the theref refore ore, , has been simpli has been simplifi fied. ed. Vehi Vehicle cles s wit with the 4Y-ECS h the 4Y-ECS engi engine ne consi consisti sting ng of of the 4Y eng the 4Y engine ine and ECS are newly added. and ECS are newly added. CLUTCH CLUTCH SPECIFI SPECIFICATIONS CATIONS 5K 5K 4Y·10Z-11 4Y·10Z-11 2Z 2Z - - Type Type Dry, Dry, single-plate, single-plate, 4 4 - - 4 4 - - Clutch Clutch spri spring ng type type Operating method Operating method Hydraulic Hydraulic 4 4 - - 4 4 - - Size Size m mm m 27 278 8 4 4 - - 4 4 - - Clutch cover Clutch cover Installati Installation on load load N N (kg) (kg) 2,354 2,354 (240) (240) 3,236 3,236 (330) (330) 3,923 3,923 (400) (400) 0.0. 0.0. x x 1.0. 1.0. x x thickness thickness (mm) (mm) 27 275 5 x x 17 175 5 x x 3 3.5 .5 4 4 - - 4 4 - - Front f Front frictional rictional area area (cm (cm 2 2 ) ) 300.5 300.5 x x 2 2 4 4 - - 4 4 - - Clutch disc Clutch disc Material Material Special Special woven woven 4 4 - - 4 4 - - https://www.forkliftpdfmanuals.com/
Type Type Conventional Conventional 4 4 - - 4 4 - - Master cylinder Master cylinder Inside diameter Inside diameter m mm m 15.87 15.87 4 4 - - 4 4 - - Type Type Adjust Adjust-fre -free e type type 4 4 - - 4 4 - - Release cylinder Release cylinder Inside diameter Inside diameter m mm m 20.64 20.64 4 4 - - 4 4 - - Appli Applicable cable oil oil Brake Brake fluid fluid 2500H 2500H 4 4 - - 4 4 - - N Note ote: : P Powe ower- r-a assi ssist st typ type e clu clutch tch is a is adop dopte ted d on v on ve ehic hicle les s ins insta talle lled d wit with h the op the optio tiona nal l oil cl oil clutc utch. h. T The he powe power- r-a assist ssist type clut type clutch, ch, howe howeve ver, r, is n is not prov ot provide ided d as as an an indiv individua idual l optio option. n. CLU CLUTC TCH H ME MECH CHANI ANISM SM SE SECT CTI ION ONAL AL VI VIEW EW Tra Transmi nsmissio ssion n side side Eng Engine ine side side 1-3 1-3 https://www.forkliftpdfmanuals.com/
Clu Clutch tch rel releas ease e fo fork rk 1-4 1-4 OI OIL CLUTCH L CLUTCH (OP (OPTI TION) ON) The oil c The oil clut lutch ch veh vehicl icles es rem remain ain unc unchan hanged ged fro from m the old mode the old models. ls. The 4Y The 4Y-EC -ECS S eng engine ine veh vehicl icles es are ne are newly add wly added. ed. CLUTCH SPECIFICATIONS CLUTCH SPECIFICATIONS - - 5K·4Y·1OZ-1I 5K·4Y·1OZ-1I - - - - - - - - 'lZ. 'lZ. Type Type Wet, Wet, singl single-pl e-plate, ate, coil coil spri spring ng type type - - Clutch Clutch Operat Operating ing method method Hydraulic Hydraulic - - Size Size mm mm 27 278 8 - - Clutch cover Clutch cover Installati Installation on load load N N (kg) (kg) 5,070 5,070 (517) (517) 6865 6865 (700) (700) 0.0. 0.0. x x 1.0. 1.0. mm mm 27 275 5 x x 17 175 5 - - Clutc Clutch h disc disc Front Front fricti frictional onal area area cm cm2 2 300.5 300.5 x x 2 2 - - Material Material Speci Special al cork cork - - Type Type Port Portless less with with hydra hydrauli ulic c boost booster er - - Master cylinder Master cylinder Inside diameter Inside diameter mm mm 25.4 25.4 - - Type Type Adjus Adjustabl table e type type - - Release cylinder Release cylinder Inside diameter Inside diameter mm mm 20.64 20.64 - - Appli Applicabl cable e oil oil Hydrau Hydrauli lic c oil oil ISO ISO VG32 VG32 - - https://www.forkliftpdfmanuals.com/
1-5 1-5 MANUAL TRANSMISSION MANUAL TRANSMISSION GENERAL GENERAL The tran The transmi smissi ssion on cas case e has bee has been n cha change nged d fro from m con conven ventio tional nal cas cast t iro iron to alu n to alumin minum um die die-ca -casti sting. ng. In p In pla lace ce of th of the e cl clut utch ch ho hous usin ing g an and d tr tran ansm smis issi sion on ca case se in inde depe pend nden ent t fr from om ea each ch ot othe her r on con on conve vent ntio iona nal l ve ve- - hic hicles les, , the tran the transmi smissi ssion on cas case e is is div divide ided d int into the f o the fron ront t and and rea rear r cas cases. es. In In the case of dry clut the case of dry clutch ch veh vehicl icles, es, the the fro front nt cas case e is in is integ tegrat rated ed wit with h the clu the clutch tch hou housin sing. g. I I I I MANUA MANUA L L TRANSMIS TRANSMISSI SION ON SPECI SPECIFI FICATIONS CATIONS Tran Transmiss smission ion type type Synchromesh Synchromesh Oper Operating ating meth method od Floor Floor shift shift link link Tran Transmiss smission ion case oil case oil capa capacity city l l (US gal) (US gal) 3.8 3.8 (1.0) (1.0) Applicable Applicable oil oil Hypoi Hypoid d gear gear oil oil SAE SAE85W 85W -90 -90 Cha Change nge Ge Gear ar Ra Ratio tio Chan Change ge gear ratio gear ratio Vehi Vehicle cle mode model l Engine Engine Forward Forward Reverse Reverse 1 1s st t s sp pe ee ed d 2 2n nd d s sp pe ee ed d 1 1s st t s sp pe ee ed d 2 2n nd d s sp pe ee ed d 5K 5K 3 3. .7 71 15 5 2 2. .1 12 27 7 3 3. .7 72 22 2 2.132 2.132 1 to 1 ton n serie series s * *4 4Y Y· ·1 1D DZ Z- -1 1I I 3 3. .5 54 41 1 1 1. .5 56 64 4 3 3. .5 54 48 8 1 1. .5 56 67 7 5K 5K 3 3. .7 71 15 5 2 2. .1 12 27 7 3 3. .7 72 22 2 2 2. .1 13 32 2 K2 ton K2 ton serie series s *4Y'1DZ-1I *4Y'1DZ-1I 3.541 3.541 1 1. .5 56 64 4 3 3. .5 54 48 8 1 1. .5 56 67 7 5 5K K 3 3. .7 71 15 5 2 2. .1 12 27 7 3 3. .7 72 22 2 2.132 2.132 2 ton series 2 ton series *4Y·1DZ-1I *4Y·1DZ-1I 3 3. .5 54 41 1 1 1. .5 56 64 4 3 3. .5 54 48 8 1.567 1.567 https://www.forkliftpdfmanuals.com/
2 2Z Z 3 3. .3 37 79 9 1 1. .3 35 55 5 3 3. .3 38 85 5 1 1. .3 35 58 8 K3 ton K3 ton serie series s *4Y·1DZ-1I *4Y·1DZ-1I 3 3. .5 54 41 1 1 1. .5 56 64 4 3 3. .5 54 48 8 1.567 1.567 4Y 4Y f f f f f f f f 3 ton series 3 ton series 2 2Z Z 3 3. .3 37 79 9 1 1. .3 35 55 5 3 3. .3 38 85 5 1 1. .3 35 58 8 4 4Y Y 3 3. .5 54 41 1 1 1. .5 56 64 4 3 3. .5 54 48 8 1 1. .5 56 67 7 J3.5 ton series J3.5 ton series 2 2Z Z 3 3. .3 37 79 9 1 1. .3 35 55 5 3 3. .3 38 85 5 1 1. .3 35 58 8 *Th *The e gea gear r rat ratios of the 4 ios of the 4Y-EC Y-ECS S eng engine ine veh vehicl icles es are th are the same e same as as tho those se of the 4-Y eng of the 4-Y engine ine veh vehicl icles. es. 1-6 1-6 MANUAL MANUAL TRANSM TRANSMI ISSI SSION ON SEC SECTI TIONAL ONAL VI VIEW EW Cou Counte ntersh rshaft aft gea gear, 1st r, 1st Sp Speed eed ge gear ar sha shaft ft For Forwar ward d ge gear ar Forw Forward- ard-reve reverse rse sync synchrom hromesh esh Countershaft Countershaft https://www.forkliftpdfmanuals.com/
Fo Forwa rward rd idl idle e gea gear r Outp Output ut gea gear r POWER POWER TRANSMIS TRANSMISSION SION CHARTS CHARTS For Forwar ward d 1s 1st spe t speed ed Forw Forward ard 2nd speed 2nd speed 1-7 1-7 https://www.forkliftpdfmanuals.com/
Rev Revers erse e 1st sp 1st speed eed Reve Reverse rse 2nd speed 2nd speed 1-8 1-8 MANUAL TRANSMI MANUAL TRANSMISSI SSION ON SECT SECTIO IONAL NAL VI VIEW (Oil EW (Oil CLUTC CLUTCH VEHI H VEHICLE) CLE) Countershaft gear, 2nd Countershaft gear, 2nd Speed gear shaft Speed gear shaft Forward-reverse synchromesh Forward-reverse synchromesh Countershaft Countershaft https://www.forkliftpdfmanuals.com/
Forward idle gear Forward idle gear 1-9 1-9 FRONT AXLE-DIFFERENTIAL FRONT AXLE-DIFFERENTIAL MAJOR MAJOR MODI MODIFI FICATIO CATIONS NS FRO FRONT NT AXLE AXLE HOU HOUSI SING NG The The num number ber of f of fron ront t axl axle e hou housin sing g bol bolts ts has be has been en cha change nged d fro from m 16 16 to to 12 12 pcs pcs./v ./vehi ehicle cle. . Old Old New New F F RO RONT NT AX AXLE LE BRA BRACK CKET ET The The num number ber of fr of front ont axl axle e bra bracke cket t set bolts has been set bolts has been cha change nged d fro from m 8 t 8 to 6 pc o 6 pcs./ s./veh vehicl icle. e. Old Old https://www.forkliftpdfmanuals.com/
A ADO DOPT PTIO ION N OF OF SE SERR RRA ATI TION ON FO FOR R HU HUB B B BOL OLTS TS (1 (1· ·2-TON VEHI 2-TON VEHICLE CLE WI WITH TH SI SINGLE NGLE TI TIRES RES) ) The The hub bo hub bolts wer lts were e fas fasten tened ed by loc by lock k nut nuts on the s on the inn inner er sid side of th e of the e bra brake ke dru drum m on on the the con conven ventio tional nal veh vehicl icles. es. Ser Serrat ration ion is is ado adopte pted d for fi for fixin xing g hub bol hub bolts ts on th on the e bra brake ke dru drum this tim m this time. e. Old Old New New 1-10 1-10 FR FRONT ONT AXLE AXLE BRACKET BRACKET RE REACTI ACTION ON FO FORCE BOLT RCE BOLT The reac The reactio tion n for force ce bol bolt used for fix t used for fixing the front axle brac ing the front axle bracket ket on t on the diffe he differen rentia tial l hou housin sing g has bee has been n cha change nged d to to a s a stan tandar dard d bol bolt. t. (Ex (Exclu cludin ding g 3.0 3.0-to -ton n and J3. and J3.5-t 5-ton on veh vehicl icles) es) Old Old Tigh Tighteni tening ng torq torque ue T=265 T=265-34 -343 3 N'm N'm (27 (2700 00-35 -3500 00 kgf kgf-cm -cm) ) [195 [195.3-2 .3-253.2 53.2 ft-Ib ft-Ibf] f] Rea Reacti ction on for force ce bo bolt lt New New Tigh Tighteni tening ng torq torque ue T=294 T=294-34 -343 3 N'm N'm (300 (3000-35 0-3500 00 kgf- kgf-cm) cm) [217 [217.1-2 .1-253.2 53.2 ft-I ft-Ibf} bf} * * 0883 08833-00 3-00070 070 appl applicat ication ion Stan Standard dard bolt bolt https://www.forkliftpdfmanuals.com/
1-11 1-11 DIFFERENTIAL DIFFERENTIAL The diff The differe erenti ntial al red reduct uction ion gea gear porti r portion on has b has been mod een modifi ified ed in in the dif the differ ferent ential ial sec sectio tion. n. The The ret retain ainer er use used d in in the dri the drive pini ve pinion on and redu and reducti ction on gea gear r mou mounti nting ng por portio tion n has b has been disc een discont ontinu inued ed and the and the dif differ ferent ential ial car carrie rier r sha shape pe has b has been cha een change nged. d. The spac The spacer er und under the neck of th er the neck of the driv e drive e pin pinion ion has a has also bee lso been n discontinued. discontinued. Old Old New New https://www.forkliftpdfmanuals.com/
1 1 to to 1.8 to 1.8 ton n ser series ies 2- 2- 3 3 to ton n ser series ies, , J3. J3.5 5 ton ton ser series ies 1-12 1-12 DIF DIFFERENT FERENTIAL IAL REDUCTI REDUCTION ON GEAR RA GEAR RA TI TIO O SPECI SPECIFI FICATIONS CATIONS ~ ~ Tonnage Tonnage 1 1. .0 0 t to on n, , 1 1. .3 35 5 t to on n 1 1. .5 5 t to on n, , 1 1. .7 75 5 t to on n Engine Engine 5K 5K 10Z-11 10Z-11 5K 5K 4Y'10Z-11 4Y'10Z-11 MfTvehicle MfTvehicle 1.741 1.741 1.741 1.741 1.586 1.586 1.586 1.586 6.50-10 6.50-10 1-speed 1-speed TIC TIC vehicle vehicle 2.363 2.363 2.363 2.363 2-speed 2-speed TIC TIC vehicle vehicle Not Not provided provided 21 21 x x 8-9 8-9 MfTVehicle MfTVehicle 1.642 1.642 4 4. .5 50 0- -1 12 2 1 1- -s sp pe ee ed d TIC TIC vehicle vehicle 2 2. .3 36 63 3 1 1. .5 58 86 6 2 2. .2 21 17 7 1 1. .5 58 86 6 6.00-9 6.00-9 2-speed 2-speed TIC TIC vehicle vehicle - - - - - - - - ~ ~ Tonnage Tonnage K2 K2 ton ton serie series s K3 K3 ton ton serie series s E En ng gi in ne e 5 5K K 4 4Y Y II 1 10 0Z Z- -1 11 1 4 4Y Y II 10Z-11 10Z-11 MfTvehicle MfTvehicle 1.642 1.642 1.586 1.586 With With STO ti STO tires res 1-speed 1-speed TIC TIC vehicle vehicle 2.217 2.217 2-speed 2-speed TIC TIC vehicle vehicle Not Not provided provided ~ ~ Tonnage Tonnage 2 2 ton ton serie series s Engine Engine 5K 5K 4Y·10Z-11 4Y·10Z-11 II 2 Z . 2 Z . MfTvehicle MfTvehicle 2.00 2.00 1.846 1.846 2.75 2.75 https://www.forkliftpdfmanuals.com/
With With STO t STO tires ires 1 speed 1 speed TIC TIC vehicle vehicle 2-speed 2-speed TIC TIC vehicle vehicle Not Not provided provided 2.75 2.75 II 2.363 2.363 Tonnage Tonnage 3.0 3.0 ton ton serie series s J3.5 J3.5 ton ton serie series s Engine Engine 4Y·10Z-11 4Y·10Z-11 2 Z 2 Z.. 4Y·10Z-11 4Y·10Z-11 2 Z 2 Z.. MfTvehicie MfTvehicie 2.00 2.00 2.083 2.083 With With STO tir STO tires es 1-speed 1-speed TIC TIC vehicle vehicle 2-speed 2-speed TIC TIC vehicle vehicle 2.75 2.75 2.363 2.363 2.75 2.75 2.217 2.217 WHEELS WHEELS TIRE TABLE TIRE TABLE • • : : In Indi dica cate tes s ST STD tir D tire for mod e for model el 0: 0: In Indi dica cate tes s ST STD tir D tire for ea e for each ty ch type pe 1 1.0 .0 Ton Vehicle Ton Vehicle 6. : Ind 6. : Indica icates tes OPT tir OPT tire e - - : : Not Not app applic licabl able e 1-13 1-13 Component Component Pneu Pneumati matic c Tir Tire e Pne Pneuma umati tic c Typ Type e Sol Solid id Ti Tire re Rim Rim J-Lug J-Lug Soft Soft White White Green Green Type Type Tir Tire e Siz Size e J- J-Lu Lug g Ti Tire re Si Size ze Non- Non- N No on n- - N No on n- - N No on n- - Puncture Puncture Punc Punctu ture re Pun Punct cture ure Puncture Puncture Divi Divided ded *' *' • • ~ ~ Standard Standard 6.00-9-10 6.00-9-10 6.00-9 6.00-9 Single Single Sid Side e ri ring ng *' *' Front Front Divided*' Divided*' ~ ~ Tires Tires Oversize Oversize 6.50-10-10 6.50-10-10 6.50-10 6.50-10 - - Sta Standar ndard d Doub Double le 4.50-12-8 4.50-12-8 0 0 4.50-12 4.50-12 ~ ~ Sid Side e ri ring *' ng *' Spec Special ial Doub Double le 6.00-9-10 6.00-9-10 ~ ~ 6.00-9 6.00-9 Divid Divided ed *2 *2 • • ~ ~ Rear Tires Rear Tires 5 5. .0 00 0- -8 8- -8 8 5 5. .0 00 0- -8 8 Sid Side e ri ring *2 ng *2 I I ~ ~ - - 1 1.5 .5 Ton & Ton & 1. 1.75 Ton Vehicle 75 Ton Vehicle Component Component Pneu Pneumati matic c Tir Tire e Pneu Pneumati matic c Type Type Sol Solid id Tir Tire e Rim Rim J J- -L Lu ug g S So of ft t W Wh hi it te e G Gr re ee en n Type Type Ti Tir re e Si Siz ze e J J- -L Lug ug T Ti ir re e S Si iz ze e N No on n- - N No on n- - N No on n- - Non- Non- https://www.forkliftpdfmanuals.com/
Puncture Puncture Pun Punct ctur ure e Pun Punct ctur ure e Puncture Puncture Divi Divided ded *1 *1 6.50-10-10 6.50-10-10 • • 6.50-10 6.50-10 ~ ~ Standard Standard Single Single 6.00-9-10*3 6.00-9-10*3 ~ ~ 6. 6.00- 00-9 9 *3 *3 Front Front Tires Tires 21 21 x8-9-10 x8-9-10 ~ ~ 21x8-9 21x8-9 Sid Side e ri ring *1 ng *1 - - Stan Standard dard Doub Double le 4.50-12-8 4.50-12-8 0 0 4.50-12 4.50-12 ~ ~ Spec Special ial Doubl Double e 6.00-9-10 6.00-9-10 ~ ~ 6.00-9 6.00-9 Divi Divided ded *2 *2 • • ~ ~ Rear Tires Rear Tires 5.00-8-8 5.00-8-8 5.00-8 5.00-8 Sid Side e ri ring *2 ng *2 ~ ~ - - *1 *1 • • Div Divide ided d rim rims and s and sid side e rin ring g rim rims are a set wi s are a set with the th their ir res respec pectiv tive e exc exclus lusive ive hub hubs. s. • • Tir Tires es are inte are interch rchang angeab eable le bet betwee ween n div divide ided d rim rims, or be s, or betwe tween en sid side ring rims, e ring rims, but but are not inte are not interch rchang ange- e- abl able e bet betwe ween en div divide ided d rim rims and sid s and side e rin ring g rim rims. s. *2 *2 • • Div Divide ided d rim rims s and sid and side e rin ring g rim rims are a set wi s are a set with the th their ir res respec pectiv tive e exc exclus lusive ive hob hobs. s. • • Di Divid vided ed rim rims and s and sid side e rin ring g rim rims are not s are not int interc erchan hangea geable ble. . *3 *3 • • 6.0 6.00-9 0-9 is o is only set as STD for the nly set as STD for the 1.5 1.5 ton seri ton series es wit with h 5K. 5K. 1-14 1-14 K2. K2.0 0 Ton Ton & & K2.5 K2.5 Ton Ton Veh Vehicl icle e Pneumatic Tire Pneumatic Tire Pneumat Pneumatic ic Type Type Soli Solid d Tir Tire e Component Component R Rim im J-Lug J-Lug Soft Soft White White Green Green Tire Size Tire Size J- J-Lug Lug Ti Tire re Si Size ze Non- Non- Non- Non- Non- Non- Non- Non- Puncture Puncture Puncture Puncture Puncture Puncture Puncture Puncture Divided *1 Divided *1 21 21 x8-9-14 x8-9-14 • • Front Tires Front Tires 21 21 x8-9 x8-9 ~ ~ Side ring *1 Side ring *1 21 21 x8-9-14 x8-9-14 ~ ~ ~ ~ Divided *2 Divided *2 18x7-8-10 18x7-8-10 • • Rear Tires Rear Tires 18x7-8 18x7-8 Side ring *2 Side ring *2 18x7-8-16 18x7-8-16 ~ ~ *1 *1 • • Divi Divided ded rims and side ring rims are not intercha rims and side ring rims are not interchangeab ngeable. le. *2 *2 • • Div Divide ided d rim rims s and sid and side e rin ring rims are g rims are a s a set wi et with the th their ir res respec pectiv tive e exc exclus lusive ive hub hubs. s. • • Div Divide ided d rim rims s and side ring rims are and side ring rims are not int not interc erchan hangea geable ble. . 2.0 Ton 2.0 Ton & & 2.5 Ton 2.5 Ton Veh Vehicl icle e Component Component Pneumatic Pneumatic Tire Tire Pneumat Pneumatic ic Type Type Soli Solid d Tir Tire e Ri Rim m .J-Lug .J-Lug Soft Soft White White Green Green Type Type Tire Tire Size Size J-Lug J-Lug Tire Tire Size Size Non- Non- Non- Non- Non- Non- Non- Non- Puncture Puncture Puncture Puncture Puncture Puncture Puncture Puncture Divided *1 Divided *1 • • ~ ~ 7.00-12-12 7.00-12-12 Side ring *1 Side ring *1 ~ ~ Single Single 7.00-12 7.00-12 Front Front Center Center disc disc - - - - Tires Tires typesiderin9*2 typesiderin9*2 https://www.forkliftpdfmanuals.com/
Stand Standard ard Double Double 5.50-15-8 5.50-15-8 0 0 5.50-15 5.50-15 ~ ~ Side ring *1 Side ring *1 Speci Special al Doubl Double e 7.00-12-12 7.00-12-12 ~ ~ 7.00-12 7.00-12 Divided Divided • • ~ ~ Rear Tires Rear Tires 6.00-9-10 6.00-9-10 6.00-9 6.00-9 Side ring *3 Side ring *3 - - ~ ~ Oversize Oversize Divided Divided *4 *4 6.50-10-10'4 6.50-10-10'4 6.50-10 6.50-10 *4 *4 ~ ~ *1 *1 • • Div Divide ided d rim rims s and sid and side e rin ring g rim rims s are a s are a set wi et with thei th their r res respec pectiv tive e exc exclus lusive ive hub hubs. s. • • Tir Tires es are int are interc erchan hangea geable ble bet betwee ween n div divide ided d rim rims, or be s, or betwe tween en sid side e rin ring rims, but a g rims, but are not int re not interc erchan hange- ge- abl able e bet betwe ween en div divide ided d rim rims and s and sid side e rin ring g rim rims. s. * * 2 2 . . Cen Center ter dis disc type side ring rims are int c type side ring rims are interc erchan hangea geable ble wit with h div divide ided d rim rims. s. * * 3 3 . . Sid Side e rin ring g rim rims are a s s are a set wi et with their exclu th their exclusiv sive e rea rear hubs r hubs. There . There is n is no int o interc erchan hangea geabil bility ity wit with h div divide ided d rim rims. s. * * 4 4 . . Opt Option for ion for 2.5 2.5 ton v ton vehi ehicle cle onl only. y. K3. K3.0 0 Ton Ton Veh Vehicl icle e 1-15 1-15 Pneu Pneumatic matic Tire Tire Pneu Pneumatic matic Type Type Soli Solid d Tire Tire Component Component Rim Rim J-Lug J-Lug S So of ft t W Wh hi it te e G Gr re ee en n Tire Size Tire Size J-Lug J-Lug T Ti ir re e S Si iz ze e N No on n- - Non- Non- N No on n- - N No on n- - Puncture Puncture Puncture Puncture Pun Punctu cture re Pun Punctu cture re Front Tires Front Tires Side Side ring ring 23x9-1 23x9-1 0-16 0-16 23x9-1 23x9-1 0 0 • • l::. l::. Rear Tires Rear Tires Side Side ring ring 18x7-8-16 18x7-8-16 18x7-8 18x7-8 3.0 Ton 3.0 Ton Veh Vehicl icle e Component Component Pneu Pneumati matic c Tire Tire Pneu Pneumati matic c Type Type Soli Solid d Tire Tire Rim Rim J-Lug J-Lug Soft Soft Wh Whi it te e G Gr re ee en n Type Type T Tir ire e Si Siz ze e J J-L -Lug ug Tire Tire Size Size Non- Non- N No on n- - N No on n- - Non- Non- Puncture Puncture Pu Punctur ncture e Punc Puncture ture Puncture Puncture Single Single 28x9-15-12 28x9-15-12 • • 28x9-15 28x9-15 l::. l::. Front Front 0 0 Tire Tire Standard Standard Double Double Side Side ring ring 6.00-15-10 6.00-15-10 6.00-15 6.00-15 - - Spec Special ial Doubl Double e 28x8-15-12 28x8-15-12 6 6 7.00-15 7.00-15 6 6 . . Divided Divided • • 6.50-10-10 6.50-10-10 6.50-10 6.50-10 l::. l::. Rear Tires Rear Tires Side Side ring· ring·1 1 6 6 Di Divi vid ded ed 6 6.5 .50- 0-10 10- -12 12 - - - - - - *1 *1 • • Divi Divided ded rims are inter rims are interchang changeabl eable. e. https://www.forkliftpdfmanuals.com/
J3. J3.5 5 Ton Ton Veh Vehicl icle e Component Component Pneu Pneumatic matic Tire Tire Pneu Pneumatic matic Type Type Soli Solid d Tire Tire Rim Rim J J- -L Lu ug g S So of ft t W Wh hi it te e G Gr re ee en n Type Type Tire Tire Size Size J J- -L Lu ug g T Ti ir re e S Si iz ze e N No on n- - Non- Non- N No on n- - N No on n- - Punc Puncture ture Punc Puncture ture Punc Punctur ture e Pun Punctu cture re Single Single 250-15-16 250-15-16 • • 250-15 250-15 6 6 . . Front Front 0 0 Tire Tire Standard Standard Double Double 6.00-15-10 6.00-15-10 6.00-15 6.00-15 Side ring Side ring l::. l::. - - Spec Special ial Doub Double le 28x8-15-12 28x8-15-12 6 6 7.00-15 7.00-15 Rear Tires Rear Tires 6.50-10-12 6.50-10-12 • • 6.50-10 6.50-10 l::. l::. 1-16 1-16 CH CHANGE ANGE LEVE LEVER R GENERAL GENERAL Th The e sh shif ift t me mech chan anis ism m on manu on manual al tr tran ansm smis issi sion on ve vehi hicl cles es is is ch chan ange ged d fr from the om the co conv nven enti tion onal al li link ty nk type to the pe to the cable type. cable type. Adoption Adoption of of the the cable cable type type has has reduced reduced lever lever vibration vibration and and stroke, stroke, resulting resulting in in easier easier operation. operation. The The bra brace ce rod used rod used in in the the lin link type k type is is als also o eli elimin minate ated. d. https://www.forkliftpdfmanuals.com/
STEERING STEERING TI TILT STEE LT STEERI RING NG LOCK LOCK MECHANI MECHANISM SM The The str struct ucture ure of t of the til he tilt steer t steering ing loc lock k mec mechan hanism ism has been cha has been change nged d as sh as shown own bel below. ow. 1-17 1-17 Old Old https://www.forkliftpdfmanuals.com/
1-18 1-18 FRAME-WEIGHT FRAME-WEIGHT HEAD GUARD HEAD GUARD For eas For easier ier mate materia riall hand handli ling ng in in an el an eleva evated ted loc locati ation, on, a roo a roof hole is f hole is pro provid vided ed in in the head guard the head guard roo roof. f. A A roo roof f cap is al cap is also provided so provided for oper for operation ation under under rainy weat rainy weather. her. WEIGHT WEIGHT The weigh The weight t mass has been chan mass has been changed. ged. https://www.forkliftpdfmanuals.com/
Vehi Vehicle cle mode model l Tonnage Tonnage Weigh Weight t (kg) (kg) 1.0 1.0 400 400 1.35 1.35 610 610 1 to 1 ton n serie series s 1.5 1.5 745 745 1.75 1.75 880 880 2.0 2.0 1,140 1,140 Comp Compact act 2·3 2·3 ton ton 2.5 2.5 1,550 1,550 3.0 3.0 1,925 1,925 2.0 2.0 1,150 1,150 Stan Standard dard 2 2 ton series ton series 2.25 2.25 1,360 1,360 2.5 2.5 1,500 1,500 2.75 2.75 1,650 1,650 3 ton 3 ton serie series s 3.0 3.0 1,800 1,800 3.5 3.5 2,135 2,135 V V M MAST AST LIFT BRACKET LIFT BRACKET The V mast The V mast lif lift brac t bracket ket for the 1 for the 1.35 .35 and and 1.5 1.5 ton ve ton vehic hicles les has be has been chan en changed ged as as sho shown wn bel below. ow. 1-19 1-19 Old Old o o o o 6 6 Uft Uft roll rollers/ ers/vehi vehicle cle Ne New w o o o o 4 4 lift lift roll rollers/ ers/vehi vehicle cle https://www.forkliftpdfmanuals.com/
TILT CYLINDER TILT CYLINDER The til The tilt cyl t cylind inder er rod rod gui guide de and cy and cylin linder der bot bottom tom end st end struc ructur tures es hav have been chan e been changed ged as as sho shown wn bel below. ow. Bush Bush Collar Collar rt-.l.-T'! rt-.l.-T'! I , I , . . • • • ' • ' I ' I '. . a-ring a-ring Grea Grease se groo groove ve Oil Oil groove groove 1-20 1-20 LIFT CYLINDER LIFT CYLINDER LIFT CYUNDER LIFT CYUNDER The The pis piston ton rod gu rod guide ide str struct ucture ure in in the the lif lift cyl t cylind inder er ASSY ASSY has bee has been n cha change nged d par partia tially lly. . Old Old RH RH LH LH I I I I 'I 'I https://www.forkliftpdfmanuals.com/
. . . . I I I I Ne New w RH RH II II L L H H The stru The structu ctural ral cha change nge is is the sam the same e als also for th o for the e LH. LH. FSV FSV· ·FV FV FRO FRONT NT CYLIND CYLINDER ER FRONT CYUNDER FRONT CYUNDER The fron The front t cy cylin linder der str struct ucture ure has bee has been n cha change nged d par partia tially lly. . Old Old 1-21 1-21 https://www.forkliftpdfmanuals.com/
New New 1-22 1-22 S SA AS S LIFTI LIFTING NG HEI HEIGHT GHT SWITC SWITCH H 1. 1. Sw Switch itch Le Leve ver r The switch The switch lev lever er rol roller str ler structu ucture re has been changed has been changed in in the lif the lifti ting ng hei height ght swi switch for durabi tch for durabili lity ty impr improvement ovement. . Old Old https://www.forkliftpdfmanuals.com/
Ne New w 2. 2. Switch Switch Ca Case se The The lif liftin ting g hei height ght swi switch tch cas case e set bol set bolt has been t has been cha change nged d fro from m an ord an ordina inary ry to a t to a tapp apping ing bol bolt. t. 1-23 1-23 https://www.forkliftpdfmanuals.com/
Ordi Ordinary nary bolt bolt T=9.8 T=9.8-15 -15.7 .7 N·m N·m (10 (100-1 0-160 60 kg kgf-c f-cm) m) (7.2 (7.23-11 3-11.57 .57 ft-Ib ft-Ibf] f] Tap Tapping ping bolt bolt T=22-25N'm T=22-25N'm (224 (224-225 -225 kgf- kgf-cm) cm) [16. [16.21-1 21-18.45 8.45 ft-Ib ft-Ibf] f] [Caution] [Caution] Whe When n the t the tapp apping ing bol bolt t is lo is loos osene ened d or re or remov moved ed, , remo remove remaini ve remaining ng alum aluminum inum part particle icles. s. MAN MANUAL UAL TRA TRANSM NSMISSI ISSION ON Page Page G EN ERAL G EN ERAL 2-2 2-2 SPE SPECI CIFIC FICATIO ATION NS S 2-3 2-3 CO COM M PO PON NEN ENTS TS 2-4- 2-4- MAN MANUAL UAL TRA TRANSM NSMISS ISSION ION ASS ASSY Y 2-6 2-6 ~E:~c ~E:~c:>"~· :>"~·I~!)1r I~!)1r~~1rI ~~1rIc:>~ c:>~ ...... ......•.... •........... ............. ............ ............ ............. ........... .... 2-6 2-6 DISA!) DISA!)!)E:~B !)E:~BLy·I~S Ly·I~SPE:C"O PE:C"O~·RE:A ~·RE:A!)SE:~ !)SE:~BLY BLY ...... ............ .........••. ...••.. . 2-10 2-10 SPEED SHAFT ASSY SPEED SHAFT ASSY 2-14 2-14 DI!)A! DI!)A!)!)E:~ )!)E:~BLY BLY ·1~!)P ·1~!)PE:C11C E:C11C:>~· :>~· ~ ~E E: :A A! !) )S SE E: :~ ~B BL LY Y 2 2- -1 14 4 COU COUNTE NTERSH RSHAFT AFT ASS ASSY Y 2-17 2-17 D DI I! !) )A A! !) )! !) )E E: :~ ~B BL LY Y· ·I I~ ~S SP PE E: :C C" "C C: :> >~ ~·~E ·~E: :A A! !) )S SE E: :~ ~B BL LY Y 2 2- -1 17 7 2-1 2-1 https://www.forkliftpdfmanuals.com/
SH SHIFT LINK IFT LINK BR BRAC ACKET KET AS ASSY SY 2-22 2-22 DI!)A! DI!)A!)!)E:~ )!)E:~BLY·I~ BLY·I~SPE:C" SPE:C"c:>~ ·~ c:>~ ·~EA!)SE: EA!)SE:~BLY ~BLY ...... ........•... ..•......... ...... 2-22 2-22 SHI SHIFT FT LEV LEVER- ER-WIR WIRE E CAB CABLE LE 2-23 2-23 ~E~C: ~E~C:>"~ ·1~S >"~ ·1~S1r~~T 1r~~Tlc:>~ lc:>~ ...... ............ .........•.. ...•........ ............ ............. ............. .......... .... 2-23 2-23 2-2 2-2 GENERAL GENERAL https://www.forkliftpdfmanuals.com/
SPECIFICATIONS SPECIFICATIONS 2-3 2-3 Tran Transmiss smission ion type type Full Full sync synchrom hromesh esh type type Oper Operating ating meth method od Floo Floor r shift shift link link meth method od Tran Transmiss smission ion case o case oil il capa capacity city l l (US gal) (US gal) 3.8 3.8 (1.0 (1.0) ) Tran Transmiss smission ion oil oil Hypoi Hypoid d gear gear oil oil Ge Gear ar ratio ratio Gear ratio Gear ratio Vehi Vehicle cle mode model l Engine Engine Forward Forward Reverse Reverse 1st speed 1st speed 2nd 2nd speed speed 1 1st st sp spe eed ed 2 2nd nd s spe peed ed 5K 5K 3.715 3.715 2.127 2.127 3.722 3.722 2.132 2.132 1 ton 1 ton serie series s 4Y-1DZ-1I 4Y-1DZ-1I 3.541 3.541 1.564 1.564 3_548 3_548 1.567 1.567 5K 5K 3.715 3.715 2.127 2.127 3.722 3.722 2.132 2.132 K2 ton K2 ton serie series s 4Y-1DZ-1I 4Y-1DZ-1I 3.541 3.541 1.564 1.564 3.548 3.548 1.567 1.567 5K 5K 3.715 3.715 2.127 2.127 3.722 3.722 2.132 2.132 https://www.forkliftpdfmanuals.com/
2 ton 2 ton serie series s 4Y-1DZ-1I 4Y-1DZ-1I 3.541 3.541 1.564 1.564 3.548 3.548 1.567 1.567 2Z 2Z 3.379 3.379 1.355 1.355 3.385 3.385 1.358 1.358 K3 ton K3 ton serie series s 4Y-1DZ-1I 4Y-1DZ-1I 3 3. .5 54 41 1 1 1. .5 56 64 4 3_548 3_548 1.567 1.567 4Y-1DZ-1I 4Y-1DZ-1I f f f f f f f f 3 ton series 3 ton series 2Z 2Z 3.379 3.379 1.355 1.355 3 3. .3 38 85 5 1 1. .3 35 58 8 4Y 4Y 3 3. .5 54 41 1 1 1. .5 56 64 4 3.548 3.548 1.567 1.567 J3.5 ton J3.5 ton serie series s 2Z 2Z 3 3. .3 37 79 9 1 1. .3 35 55 5 3 3. .3 38 85 5 1 1. .3 35 58 8 2-4 2-4 COMPONENTS COMPONENTS 3301 3301 https://www.forkliftpdfmanuals.com/
54 54 3301-064A 3301-064A https://www.forkliftpdfmanuals.com/
2-6 2-6 MANU MANUAL AL TR TRANSM ANSMISS ISSIO ION N ASSY ASSY REMOVAL-INSTALLATION REMOVAL-INSTALLATION T T = = N·m (kgf-c N·m (kgf-cm) m) [ft-I [ft-Ibf] bf] https://www.forkliftpdfmanuals.com/
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Toyota 7FG 7FD 7FGK 7FDK Forklift Trucks Repair Manual PDF.pdf
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Toyota 7FG 7FD 7FGK 7FDK Forklift Trucks Repair Manual PDF.pdf
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Toyota 7FG 7FD 7FGK 7FDK Forklift Trucks Repair Manual PDF.pdf
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Toyota 7FG 7FD 7FGK 7FDK Forklift Trucks Repair Manual PDF.pdf

  • 3. FOREWORD FOREWORD Th This is ma manu nual al co cove vers rs th the e se serv rvic ice e pr proc oced edur ures es of of th the TOY e TOYOT OTA A FO FORK RKLI LIFT FT 7FG 7FG/7F /7FD10 D10 - - 30 s 30 seri eries. es. Ple Please use th ase use this is man manual for prov ual for providi iding ng qui quick, corre ck, correct ct servi servicing cing of of the the corre correspond sponding ing fork forklift lift mode models. ls. Th This is ma manu nual al de deal als s wi with th th the e ab abov ove e mo mode dels ls as of Se as of Sept ptem embe ber r 20 2000 00. . Pl Plea ease se und unders erstan tand d tha that t dis disagr agreem eement ent can can tak take e pla place ce bet betwee ween n the desc the descrip riptio tions ns in in the the man manual ual and act and actual vehic ual vehicles les due t due to cha o change nge in in des design ign and sp and speci ecific ficati ations ons. . Any Any ch chan ange ge or mod or modif ific icat atio ions ns th ther erea eaft fter er wi will ll be inf be infor orme med d by To by Toyo yota ta In Indu dust stri rial al Equ Equipm ipment ent Par Parts & Serv ts & Service ice New News. s. For t For the serv he service ice pro proced cedure ures s of t of the moun he mounted ted eng engine ine, , rea read the d the rep repair air man manual uals s lis listed below ted below as ref as refere erence nce tog togeth ether er wit with this h this man manual ual. . (Reference) (Reference) Rep Repair air man manual uals s rel relate ated d to thi to this s man manual ual are as foll are as follows ows: : TOYO TOYOTA TA INDU INDUSTRIA STRIAL L EQUI EQUIPMENT PMENT 7FG 7FG1 1 0-3 0-30, 0, 7FD 7FD1 1 0-3 0-30, 0, 7FG 7FGK20 K20-30 -30, , 7FG 7FGJ35 J35, , 7FD 7FDK20 K20-30 -30, , 7FO 7FOJ35 J35 REPAI REPAIR R MANU MANUAL AL (No. C (No. CE024 E024) ) TOYO TOYOTA TA INDU INDUSTRIA STRIAL L EQUI EQUIPMEN PMENT T 5K 5K ENGIN ENGINE E REPAI REPAIR R MANU MANUAL AL (No. C (No. CE617) E617) TOYO TOYOTA TA INDU INDUSTRIA STRIAL L EQUIP EQUIPMENT MENT 4Y E 4Y ENGIN NGINE E REPAI REPAIR R MANU MANUAL AL (No. C (No. CE602- E602-1) 1) TOYOT TOYOTA A INDU INDUSTRIA STRIAL L EQUIP EQUIPMENT MENT 1D2-1 1D2-11 1ENGI ENGINE NE REPAI REPAIR R MANU MANUAL AL (No. (No. CE618 CE618-1) -1) TOYO TOYOTA TA INDU INDUSTRIA STRIAL L EQUI EQUIPMENT PMENT 22 EN 22 ENGINE GINE REPAI REPAIR R MANU MANUAL AL (No. C (No. CE625- E625-1) 1) TOYO TOYOTA TA INDU INDUSTRIA STRIAL L EQUI EQUIPMENT PMENT 4Y 4Y ENGIN ENGINE E Suppl Supplement ement 4Y-EC 4Y-ECS S REPAI REPAIR R MANU MANUAL AL (No. C (No. CU642 U642) ) TO TOYO YOTA TA MO MOTO TOR R CO CORP RPOR ORATIO ATION N https://www.forkliftpdfmanuals.com/
  • 4. SE SECT CTIO ION N IN INDE DEX X II ~ ~E E II GENERAL GENERAL F FE EA AT T E ES S II MAN MANUAL UAL TRA TRANSM NSMISS ISSION ION II DIFFERENTIAL DIFFERENTIAL II APPENDIX APPENDIX https://www.forkliftpdfmanuals.com/
  • 5. GENERAL GENERAL Page Page EX EXTE TERI RIOR OR VI VI EW EWS S 0-2 0-2 VE VEH IC H ICLE LE MO MODE L DE L Q Q-3 -3 F FR RAM AM E N E N U UM M BE BER R 0-5 0-5 H HO OW W T TO O U US SE E T TH HI IS S M MAN ANU UAL AL 0-7 0-7 E EX XP PL LA AN NA AT TI IO ON N M ME ET TH HO OD D 0 0- -7 7 TERMINOLOGy TERMINOLOGy o o- -a a A AB BB BRE REV VIA IATI TIO ONS NS o o- -a a OP OPE RAT E RATIO IO NAL NAL TI TI PS PS 0-9 0-9 H HOI OIST STIN ING G TH TH E E VE VEHI HIC CLE LE 0-10 0-10 C C I R I R C CUlT UlT TE TEST STER ER 0-11 0-11 ST STAND ANDARD ARD BOL BOLT T & & NUT NUT TIGHT TIGHTENIN ENING G T TO O RQU RQUE E 0-13 0-13 BOLT BOLT ST STRE RENGT NGTH H TY TYPE PE I IDE DENT NTI IFI FICATI CATION ON MET METHOD HOD 0- 0-13 13 T TI IG GH HT TE EN NI IN NG G T TO OR RQ QU UE E T TA AB BL LE E 0 0- -1 14 4 P PR RE EC CO OAT AT BO BO LT LTS S 0-15 0-15 HI HIGH GH PR PRES ESSU SURE RE HO HOSE SE FI FITT TTIN ING G TI TIGH GHTE TENI NING NG TO TORQ RQUE UE 0-15 0-15 W WIR IRE E R ROP OPE E SU SUSP SPEN ENSI SION ON ANG ANGLE LE LIS LIST T 0-16 0-16 S SAF AFE E LO LOAD AD F FO OR R E EAC ACH H W WI IR RE E R RO OP PE E SU SUSP SPEN ENSI SION ON ANG ANG LE LE 0-16 0-16 CO COMP MPON ON EN ENTS TS WE WEIG IGHT HT 0-17 0-17 RE RECO COMM MMEN ENDE DED D LUBRI LUBRICANT CANT QUANTITY QUANTITY & & TYPES TYPES 0-18 0-18 LUBR LUBRIC ICATI ATION ON CH CHART ART 0-20 0-20 PER PERIOD IODIC IC MAINT MAINTENANC ENANCE E 0-22 0-22 PE PER RIO IOD DIC IC RE REPL PLACE ACEM MEN ENT T OF P OF PAR ARTS TS AND AND LU LU BRIC BRICANTS ANTS 0-28 0-28 0-1 0-1 https://www.forkliftpdfmanuals.com/
  • 7. 0-3 0-3 MODEL MODEL VEHICLE VEHICLE Classification Classification Tran Transmiss smission ion Type Type Engine Engine Vehi Vehicle cle Mode Model l I I Series Series Model Model 7FG10 7FG10 Mff Mff 5K 5K Gasoline Gasoline 02-7FG10 02-7FG10 T I C T I C 1.0 ton model 1.0 ton model 7FD10 7FD10 Mff Mff 10Z-11 10Z-11 Diesel Diesel 02-7FD10 02-7FD10 T I C T I C 7FG15 7FG15 Mff Mff 5K 5K Gasoline Gasoline 02-7FG15 02-7FG15 T I C T I C 1 1 ton ser ton series ies 40-7FG15 40-7FG15 Mff Mff 4Y 4Y Gasoline Gasoline 1.5 ton model 1.5 ton model 42-7FG15 42-7FG15 T I C T I C 7FD15 7FD15 Mff Mff 10Z-11 10Z-11 Diesel Diesel 02-7FD15 02-7FD15 T I C T I C T I C T I C 4Y 4Y Gasoline Gasoline 42-7FG18 42-7FG18 1.75 ton 1.75 ton mode model l T I C T I C 10Z-11 10Z-11 Diesel Diesel 02-7FD18 02-7FD18 7FG20 7FG20 Mff Mff 5K 5K Gasoline Gasoline 02-7FG20 02-7FG20 T I C T I C 4O-7FG20 4O-7FG20 Mff Mff 4Y 4Y Gasoline Gasoline 42-7FG20 42-7FG20 T I C T I C 2.0 ton model 2.0 ton model 6O-7FD20 6O-7FD20 Mff Mff 10Z-11 10Z-11 Diesel Diesel 62-7FD20 62-7FD20 T I C T I C 7F020 7F020 Mff Mff 2Z 2Z Diesel Diesel 02-7F020 02-7F020 T I C T I C 2 ton 2 ton serie series s 7FG25 7FG25 Mff Mff 5 5K K G Ga as so ol li in ne e 02-7FG25 02-7FG25 T I C T I C 4O-7FG25 4O-7FG25 Mff Mff 4 4Y Y G Ga as so ol li in ne e 42-7FG25 42-7FG25 T I C T I C 2.5 ton model 2.5 ton model 6O-7F025 6O-7F025 Mff Mff 1 10 0Z Z- -1 11 1 D Di ie es se el l 62-7F025 62-7F025 T I C T I C 7F025 7F025 Mff Mff 2Z 2Z Diesel Diesel I I T I C T I C II 02-7F025 02-7F025 https://www.forkliftpdfmanuals.com/
  • 8. 04 04 - - - - Classification Classification Vehicle Model Vehicle Model T Tr ra an ns sm miis ss siio on n T Ty yp pe e E En ng giin ne e Series Series Model Model 7FG30 7FG30 MI MIT T 4Y 4Y Gasoline Gasoline 02-7FG30 02-7FG30 T I C T I C 6O-7FD30 6O-7FD30 MI MIT T 1 1D DZ Z- -I II I D Diie es se ell 3 ton series 3 ton series 3.0 3.0 ton ton model model 62-7FD30 62-7FD30 T I C T I C 7FD30 7FD30 MI MIT T 2 2Z Z Diesel Diesel 02-7FD30 02-7FD30 T I C T I C 7FGK20 7FGK20 MI MIT T 5K 5K Gasoline Gasoline 02-7FGK20 02-7FGK20 T I C T I C 4 40 0- -7 7F FG GK K2 20 0 M MI IT T 4 4Y Y G Ga as so olliin ne e K2.0 ton model K2.0 ton model 42-7FGK20 42-7FGK20 T I C T I C 7 7F FD DK K2 20 0 M MI IT T 1DZ-II 1DZ-II Diesel Diesel 02-7FDK20 02-7FDK20 T I C T I C K2 ton series K2 ton series 7 7F FG GK K2 25 5 M MI IT T 5K 5K Gasoline Gasoline - - 02-7FGK25 02-7FGK25 T I C T I C 4 40 0- -7 7F FG GK K2 25 5 M MI IT T 4Y 4Y Gasoline Gasoline K2.5 ton model K2.5 ton model 42-7FGK25 42-7FGK25 T I C T I C 7 7F FD DK K2 25 5 M MI IT T 1 1D DZ Z- -I II I D Diie es se ell 02-7FDK25 02-7FDK25 T I C T I C 7FGK30 7FGK30 MI MIT T 4Y 4Y Gasoline Gasoline 02-7FGK30 02-7FGK30 T I C T I C K3 ton series K3 ton series K3.0 K3.0 ton mod ton model el 7FDK30 7FDK30 MI MIT T 1 1D DZ Z- -I II I D Diie es se ell 02-7FDK30 02-7FDK30 T I C T I C 7 7F FG GJ J3 35 5 M MI IT T 4Y 4Y Gasoline Gasoline 02-7FGJ35 02-7FGJ35 T I C T I C J3.5ton J3.5ton J3.5 ton model J3.5 ton model 7FDJ35 7FDJ35 MI MIT T Diesel Diesel series series 2 2Z Z 02-7FDJ35 02-7FDJ35 T I C T I C - - https://www.forkliftpdfmanuals.com/
  • 9. FRAME NUMBER FRAME NUMBER F Fra rame me No No. Punchin . Punching g Po Position sition Punching position Punching position 0-5 0-5 Series Series Engine Engine Vehic Vehicle mode le model l Punching Punching format format 7FG10 7FG10 02-7FG10 02-7FG10 5K 5K 7FG18-10011 7FG18-10011 7FG15 7FG15 02-7FG15 02-7FG15 4O-7FG15 4O-7FG15 4Y 4Y 42-7FG15 42-7FG15 407FG 407FG 18-100 18-10011 11 1 1 ton series ton series 42-7FG18 42-7FG18 7FD10 7FD10 02-7FD10 02-7FD10 10Z-11 10Z-11 7FD15 7FD15 7F018-10011 7F018-10011 02-7FD15 02-7FD15 02-7FD18 02-7FD18 7FG20 7FG20 02-7FG20 02-7FG20 5 5K K 7 7F FG G2 25 5- -1 1 0 00 01 11 1 7FG25 7FG25 02-7FG25 02-7FG25 4O-7FG20 4O-7FG20 42-7FG20 42-7FG20 4Y 4Y 407FG25-1oo11 407FG25-1oo11 4O-7FG25 4O-7FG25 42-7FG25 42-7FG25 2 2 ton ton seri series es 7FD20 7FD20 02-7FD20 02-7FD20 2Z 2Z 7FD25 7FD25-1 -1 0011 0011 7FD25 7FD25 02-7FD25 02-7FD25 6O-7FD20 6O-7FD20 62-7FD20 62-7FD20 1 10 0Z Z- -1 11 1 6 60 07 7F FD D2 25 5- -1 10 00 01 11 1 6O-7FD25 6O-7FD25 62-7FD25 62-7FD25 https://www.forkliftpdfmanuals.com/
  • 10. 0-6 0-6 Engine Engine Vehic Vehicle le model model Punching Punching format format 7FG30 7FG30 02-7FG30 02-7FG30 4Y 4Y 7FGJ35-1 7FGJ35-1 0011 0011 7FGJ35 7FGJ35 02-7FGJ35 02-7FGJ35 3 ton, J3.5 3 ton, J3.5 7FD30 7FD30 ton series ton series 02-7FD30 02-7FD30 2 2Z Z 7FDJ35-1oo11 7FDJ35-1oo11 7FDJ35 7FDJ35 02-7FDJ35 02-7FDJ35 6O-7FD30 6O-7FD30 1DZ-II 1DZ-II 607FD3Q-10011 607FD3Q-10011 62-7FD30 62-7FD30 7FGK20 7FGK20 02-7FGK20 02-7FGK20 5K 5K 7FGK25-10011 7FGK25-10011 7FGK25 7FGK25 02-7FGK25 02-7FGK25 4Q-7FGK20 4Q-7FGK20 K2ton K2ton 42-7FGK20 42-7FGK20 series series 4Y 4Y 7FGK3Q-1OO11 7FGK3Q-1OO11 4Q-7FGK25 4Q-7FGK25 42-7FGK25 42-7FGK25 6O-7FDK20 6O-7FDK20 62-7FDK20 62-7FDK20 1DZ-II 1DZ-II 7FDK3Q-10011 7FDK3Q-10011 6O-7FDK25 6O-7FDK25 62-7FDK25 62-7FDK25 7FGK30 7FGK30 4Y 4Y 7FGK30-10011 7FGK30-10011 K3 ton K3 ton 02-7FGK30 02-7FGK30 series series 7FDK30 7FDK30 1DZ-II 1DZ-II 7FDK3Q-10011 7FDK3Q-10011 02-7FDK30 02-7FDK30 https://www.forkliftpdfmanuals.com/
  • 11. 0-7 0-7 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL EXPLANATION METHOD EXPLANATION METHOD 1. 1. Op Oper erat atio ion n pr proc oced edur ure e (1) (1) The oper The operati ation on pro proced cedure ure is is des descri cribed bed in in eit either patt her pattern ern A o A or p r patt attern ern B B bel below. ow. Pat Patter tern n A: A: Exp Explan lanati ation on of of eac each h ope operat ration ion ste step with ill p with illust ustrat ration ion. . Pat Patter tern n B: B: Exp Explan lanati ation on of of ope operat ration ion pro proced cedure ure by i by indi ndicat cating ing ste step p num number bers s in in one ill one illust ustrat ration ion, , fol fol- - low lowed ed by ex by expla planat nation ion of cau of cautio tions ns and notes and notes sum summar marize ized d as poin as point t ope operat ration ions. s. Exa Exampl mple e of d of desc escrip riptio tion n in in pat patter tern n B B DISASSEMBlY·INSPECTION·REASSEMBlY DISASSEMBlY·INSPECTION·REASSEMBlY Tight Tightening ening torqu torque e unitT unitT = = N'm N'm (kgf- (kgf-cm) cm) [ft-I [ft-Ibf] bf] • • St Step ep No Nos. s. ar are e pa part rtia iall lly y so some meti time mes s omitt omitted ed in in illus illustratio trations. ns. • • Wh When en a a pa part rt re requ quir irin ing g ti tigh ghte teni ning ng tor torque que ins instru tructi ction on is n is not ind ot indica icated ted in in the the ill illust ustrat ration ion, , the part name is de the part name is de- - scr scribe ibed d in in the the ill illust ustrat ration ion fra frame. me. 8 8 4 4 T T = = 4 46. 6.1 1 - - 48 48.1 .1 (4 (470 70 - - 49 490) 0) [3 [34.0 4.0 - - 35 35.5] .5] Disassembly Procedure Disassembly Procedure 1 1 R Re em mo ov ve th e the e c co ov ve er r. . [P [Point oint 1 1] ] 2 2 R Re emo mov ve t e the he bu bush shi ing ng [Point 2] [Point 2] + - + - Op Opera eratio tion n exp explai lained ned lat later er 3 3 R Re em mo ov ve t e th he e g ge ea ar r. . Poi Poi nt nt Operations Operations Expla Explanatio nation n of key of key point for o point for operat peration ion with an with an illus illustrati tration on i i t t [P [Point oint 1 1] ] Dis Disass assemb embly: ly: Put Put a mat a match ch mar mark when k when rem removi oving ng the pum the pump p cov cover. er. [P [Point oint 2] 2] Inspe Inspection ction: : Meas Measure ure the bus the bush h insid inside diamet e diameter. er. Limit: Limit: 19 19.1 .12 2 mm (0. mm (0.75 7528 in) 28 in) https://www.forkliftpdfmanuals.com/
  • 12. 0-8 0-8 2. 2. Ho How t w to o re read ad co comp mpon onen ents ts fi figu gure res s (1) (1) The co The compo mponen nents ts fig figure uses th ure uses the ill e illust ustrat ration ion in th in the e pa part rts s ca cata talo log g fo for r th the e ve vehi hicl cle e mo mode del. l. Ple Please ase ref refer to th er to the e cat catalo alog g for chec for checkin king g the the part name. part name. Th The e nu numb mber er at t at the he ri righ ght t sh shou ould lder er of ea of each ch com compon ponent ents s fig figure ure ind indica icates tes the Fig. nu the Fig. num- m- ber in the parts catalog. ber in the parts catalog. (Example) (Example) FIG numbe FIG number r in part in parts s cat catalo alog g 3. 3. Ma Matt tter ers omi s omitt tted in ed in th this m is man anua ual l (1) (1) Thi This s man manual omits desc ual omits descrip riptio tion n of of the f the foll ollowi owing ng job jobs, s, but p but perf erform orm the them m in in act actual opera ual operatio tion: n: C D C D Cle Cleani aning ng and and was washin hing g of re of remov moved ed par parts as ts as req requir uired ed ® ® Visua Visual inspec l inspection tion (part (partially descr ially described) ibed) TERMINOLOGY TERMINOLOGY Caution: Caution: I Importa mportant nt mat matte ters rs of wh of which ich ne negli gligen gence ce may ca may cause use ac accide cidents. nts. Be Be sure t sure to obser o observe ve the them. m. Note: Note: Importa Important nt ite items of which ms of which negli negligence gence may ca may cause accide use accidents, nts, or mat or matter ters s in in opera operation tion procedure procedure requi requiring ring specia speciall at attent tention. ion. Sta Standa ndard: rd: Val Values show ues showing ing all allowa owable ble ran range ge in in ins inspec pectio tion n and adj and adjust ustmen ment. t. Lim Limit: it: Max Maximu imum m or min or minimu imum m all allowa owable ble val value ue in in ins inspec pectio tion n or ad or adjus justme tment. nt. A AB BB BR RE EV VIA IA T TIO ION NS S Abbreviation (code) Abbreviation (code) Meaning Meaning Abbrevia Abbreviation tion (code) (code) Meaning Meaning ASSY ASSY Assembly Assembly SA SAS S System System of of active active stabil stability ity LH LH Left Left hand hand SS SST T Special Special service service tool tool LLC LLC Long Long life life coolant coolant S STD TD Standard Standard MfT MfT Manual Manual transmiss transmission ion T= T= Tightening Tightening torque torque OP OPT T Option Option TIC TIC Torque Torque converte converter r & & transmission transmission O/S O/S Oversize Oversize OO OOT T Numb Number er of of te teet eth h (0 (0 0) 0) PS PS Power Power steeri steering ng U/S U/S Undersize Undersize R R H H Right Right hand hand W/ W/ With With SA SAE E Society Society of of Automotiv Automotive e U U Less Less Engineers (USA) Engineers (USA) https://www.forkliftpdfmanuals.com/
  • 13. 0-9 0-9 OPE OPERATION RATIONAL AL TIP TIPS S 1. 1. Sa Safe fe op oper erat atio ion n (1) (1) Aft After jac er jackin king g up, up, alw always ays sup suppor port t wit with woo h wooden den blo blocks or cks or rig rigid sta id stands nds. . (2) (2) Whe When n hoi hoisti sting ng the v the vehi ehicle cle or it or its h s heav eavy com y compon ponent ent, , use use wir wire e rop rope(s e(s) ) wit with a s h a suff uffici icient ent res reserv erve e in in loa load d capacity. capacity. (3) (3) Alw Always ays dis discon connec nect t the ba the batte ttery ry ter termin minal al bef before ore the the ins inspec pectio tion n or s or serv ervici icing ng of el of elect ectric rical al par parts. ts. 2. 2. Ta Tact ctfu ful l op oper erat atio ion n (1) (1) Pre Prepar pare e the me the mecha chanic nic too tools, ls, nec necess essary ary mea measur suring ing ins instru trumen ments ts (ci (circu rcuit te it teste ster, r, meg megger ger, , oil oil pre pressu ssure re gaug gauge, e, etc.) and SSTs befo etc.) and SSTs before re start starting ing opera operation. tion. (2) (2) Bef Before dis ore discon connec nectin ting g wir wiring ing, , alw always che ays check the cabl ck the cable col e color and w or and wiri iring state ng state. . (3) (3) Whe When n ove overha rhauli uling ng fun functi ctiona onal l par parts, c ts, comp omplic licate ated d por portio tions or re ns or relat lated mech ed mechani anisms sms, , arr arrang ange the part e the parts s neat neatly to ly to preve prevent nt confu confusion sion. . (4) (4) Whe When n dis disass assemb emblin ling g and in and inspe specti cting ng suc such a pre h a precjs cjsion ion par part as t as the c the cont ontrol val rol valve, ve, use use cle clean too an tools ls and and opera operate te in a in a clea clean n loca location. tion. (5) (5) Fol Follow t low the des he descri cribed bed pro proced cedure ures s for di for disas sassem sembly bly, , ins inspec pectio tion n and r and reas eassem sembly bly. . (6) (6) Rep Replac lace, e, gas gasket kets, s, pac packin kings gs and O- and O-rin rings gs wit with h new new one ones each time the s each time they y are dis are disass assemb embled led. . (7) (7) Use Use gen genuin uine e Toy Toyota parts f ota parts for rep or replac laceme ement. nt. (8 (8) ) Us Use spe e speci cifi fied ed bo bolt lts s an and d nu nuts ts. . Ob Obse serv rve e th the e sp spec ecif ifie ied d ti tigh ghte teni ning ng to torq rque ue at at th the e ti time me of rea of reass ssem embl bly. y. Tig Tighte hten n to th to the e cen center ter of t of the spec he specifi ified ed tig tighte htenin ning g tor torque que ran range. ge. If If no no tight tightenin ening g torqu torque e is is spec specified ified, , tight tighten en the bolt or the bolt or nut a nut accord ccording ing to to the stan the standard dard tight tightening ening torqu torque e table. table. 3. 3. Gr Gras aspi ping t ng the he tr trou oubl ble st e stat ate e Whe When n a a tro troubl uble e occ occurs urs, , do not a do not atte ttempt mpt imm immedi ediate ate dis disass assemb embly ly or re or repla placem cement ent but f but firs irst chec t check k if if the the tro troubl uble e req requir uires es dis disass assemb embly ly or repl or replace acemen ment t for reme for remedyi dying. ng. 4. 4. Di Disp spos osal of al of wa wast ste e fl flui uid, e d, etc tc. . Whe When n dra draini ining ng was waste te flu fluid id fro from m the vehi the vehicle cle, , rec receiv eive e it it in a c in a cont ontain ainer. er. If a If any oil ny oil, fue , fuel, l, coo coolan lant, t, oil oil fil filter ter, , bat batter tery y or ot or other her har harmfu mful l sub substa stance nce is is dir direct ectly ly dis discha charge rged d or scr or scrapp apped ed wit withou hout t per permis missio sion, n, it it wil will eith l either er adv advers ersely ely aff affect ect hum human an hea health lth or des or destro troy y the the env enviro ironme nment. nt. Alw Always ays sor sort wast t waste e flu fluids ids, , etc etc. and trea . and treat t the them m pro proper perly ly by r by requ equest esting ing dis dispos posal al by s by spec pecial ialize ized d com compan panies ies. . I I I I I I I I I I I I = = m - m - - - For scr For screw jack ew jack 5. 5. Jack up Jack up point points s Jac Jack k up p up poin oints are ts are pro provid vided ed in in the fron the front t and re and rear porti ar portions ons of th of the e veh vehicl icle. e. Alw Always ays app apply jack ly jacks s at t at the jack he jack up po up point ints. s. Front Front side side: : A A circular circular groove groove to to accept accept a a screw screw jack jack is is provided provided un- un- der the front der the front sid side e of th of the e fra frame. me. Wh When en a g a gar arag age e ja jack ck is us is used ed, , ja jack ck up a up at the bot t the botto tom m su sur- r- fac face e of the fram of the frame. e. Rear Rear side side: : A A circular circular groove groove to to accept accept a a screw screw or or garage garage jack jack is is provi provided ded at at the bottom the bottom surfa surface ce of the count of the counterwei erweight. ght. https://www.forkliftpdfmanuals.com/
  • 14. I: I: : : i i For screw jack ~ For screw jack ~ For gara For garage jack ge jack~ ~ 0-10 0-10 HOI HOISTI STING NG THE VEHI THE VEHICLE CLE When When hoist hoisting ing the vehi the vehicle, sling with wir cle, sling with wire rope(s) e rope(s) at at the the mast mast hook holes and the rear side of the head guard. hook holes and the rear side of the head guard. Sli Slinging nging at t at the he head guard head guard is is done done in in two ways. two ways. Method A: Method A: Sling after removing the head guard seat. Sling after removing the head guard seat. Method B: Method B: Caref Carefull ully y sli sling so as not t ng so as not to damage o damage rear co rear combinat mbination ion lamps. lamps. https://www.forkliftpdfmanuals.com/
  • 15. 0-11 0-11 CIR CIRCUI CUIT T TEST TESTER ER Cir Circui cuit t tes tester ters s are av are avail ailabl able e in in bot both the h the ana analog and log and dig digita ital l typ types. es. The They y sho should uld be u be used sele sed selecti ctivel vely y acc accord ording ing to th to the e purpo purpose se of measu of measuremen rement. t. Analog Analog type: type: This This type type is is convenient convenient for for observing observing movement movement during during operation, operation, but but the the measured measured value value sho should uld onl only y be use be used d for for ref refere erence nce or roug or rough h jud judgem gement ent. . Dig Digita ital typ l type: e: Fai Fairly a rly accu ccurat rate e rea readin ding g is is pos possib sible, le, but i but it t is is dif diffic ficult ult to to obs observ erve e the the var variat iation ion or mo or movem vement ent. . 1. 1. Di Diff ffer eren ence ce in in me meas asur urem emen ent t re resu sult lts s wi with t th the d he dig igit ital typ al type e an and an d anal alog og ty type pe * * The resul The result t may be may be dif differ ferent ent bet betwee ween n mea measur sureme ements nts wit with the a h the anal nalog og typ type and digi e and digital tal typ type. e. Always Always use use a a circuit circuit tester tester according according to to its its operation operation manual. manual. Cau Cautio tions ns whe when n the pola the polarit rities ies are dif are differ ferent ent bet betwee ween n the ana the analog log typ type e and d and digi igital tal typ type e are de are descr scribe ibed d below. below. (1 (1) ) An Anal alog og ci circ rcui uit tes t teste ter r Forward direction Forward direction Reverse Reverse direction direction Meas Measureme urement result nt result exam example ple Tes Tester ter ran range: ge: kQ ran kQ range ge Analog Analog type type Forward Forward Conti Continuity nuity exist exists s 11 kQ 11 kQ Reverse Reverse No continuity No continuity 00 00 (2 (2) ) Di Digi gita tal cir l circu cuit te it test ster er Forward direction Forward direction Reverse Reverse direction direction Measu Measuremen rement t resul result exa t example mple Tes Tester range ter range: : MQ ra MQ range nge Digit Digital al type type Forward Forward No continuity No continuity 1 1 Reverse Reverse Conti Continuity nuity exist exists s 2M 2MQ Q https://www.forkliftpdfmanuals.com/
  • 16. 0-12 0-12 2. 2. Di Diff ffer eren ence ce in in re resu sult of m lt of mea easu sure reme ment nt wi with c th cir ircu cuit te it test ster er The The cir circui cuit t tes tester ter pow power er sup supply ply vol voltag tage e dep depend ends s on t on the test he tester er typ type. e. 1.5 1.5 V, V, 3.0 V or 6.0 V is us 3.0 V or 6.0 V is used. ed. The The res resist istanc ance e of a s of a semi emicon conduc ductor tor suc such h as a d as a diod iode e var varies ies wit with the h the cir circui cuit t tes tester ter pow power er sup supply ply vol voltag tage. e. The The dio diode de cha charac racter terist istics ics are sh are shown own in in the fi the figur gure e bel below. ow. ( (r rn nA A) ) 6 6 5 5 o o .1 .1 II I I I I I I ~ ~ Germanium Germanium II diode diode JJ II ~ lJ ~ lJ I I il il Silicondio~1 Silicondio~1 I - I - - I - - - I - - / / It It / / IJ IJ ....• ....• / / .... ..•• ...... . . / / 0 0. .1 1 0 0. .2 2 0 0. .3 3 0 0. .4 4 0 0. .5 5 0 0. .6 6 0 0. .7 7 0 0. .8 8 F Fo or rw wa ar rd d v vo ol lt ta ag ge e ( (V V) ) Th The e re resi sist stan ance ce va valu lues es of t of the he sa same me se semi mico cond nduc ucto tor r me mea- a- sured with t sured with two type wo types s of ci of circuit test rcuit testers ers havin having g diffe different rent powe power r supp supply ly volta voltages ges are diffe are different. rent. Thi This s man manual desc ual describ ribes es the res the result ults s of mea of measur sureme ement nt wit with a h a cir circui cuit t tes tester ter who whose se pow power er sup supply ply vol voltag tage e is is 3.0 V. 3.0 V. 3. 3. Di Diff ffer eren ence ce in in me meas asur urem emen ent t re resu sult by m lt by mea easu sure reme ment nt ra rang nge (ana e (analo log typ g type) e) In In the anal the analog og typ type e cir circui cuit t tes tester ter, , cha changi nging ng the meas the measure uremen ment t ran range ge swi switch tches es ove over r the inte the interna rnal l cir circui cuit t to to var vary y the cir the circui cuit t res resist istanc ance. e. Eve Even when the same n when the same dio diode de is m is meas easure ured, d, the meas the measure uremen ment t res result vari ult varies es wit with h the meas the measure uremen ment t ran range. ge. ~ ~ OQ OQ ~ ~ V Va ar ri ia ab bl le e r re es si is st to or r Always Always use use the the range range described described in in the the repair repair manual manual for for measurement. measurement. Meter Meter Range: Range: x x 10 10 Resistor Resistor Range: Range: x x 1 1 I I ~ ~ Power source: Power source: 1. 1.5 5 V V $ $0 0 Red Red (SW1) (SW1) (SW2) (SW2) e e o o Black Black https://www.forkliftpdfmanuals.com/
  • 17. 0-13 0-13 S ST TAN AND DAR ARD D BO BOLT LT & NU & NUT TI T TIG GH HT TE EN NI IN NG G T TO OR RQ QU UE E Stand Standard ard bolt a bolt and tig nd tighteni htening ng torqu torques es are not in are not indicat dicated. ed. Jud Judge ge the st the stand andard ard tig tighte htenin ning g tor torque que as s as show hown n bel below. ow. 1. 1. Fin Find ou d out the ty t the type of th pe of the bolt f e bolt from the list b rom the list belo elow and the w and then n fin find the bo d the bolt t lt tigh ighten tening ing tor torque que fro from m the t the tabl able. e. 2. 2. Th The e nu nut t t tig ight hten enin ing g to torq rque ue ca can be n be ju judg dged ed fr from th om the e ma mati ting ng bo bolt lt ty type pe. . BOLT BOLT ST STREN RENGT GTH H TY TYPE PE ID IDENT ENTIF IFIC ICATI ATION ON MET METHOD HOD 1. 1. Ident Identific ification ation by by bolt bolt shape shape 2. 2. Ident Identific ification ation by by part part No. No. Sha Shape pe and and cla class ss Class Class Hexago Hexagonhead nhead bolt bolt 4=4T 4=4T @ @ - - 5=5T 5=5T Bol Bolt t hea head No. d No. 6=6T 6=6T Parts Parts No. No. 7=7T 7=7T 91611- 91611-4 4r r25 25 Hexagon Hexagon 8=8T 8=8T L LLen Length gth (mm (mm) ) head headbolt bolt D D Dia Diamet meter (m er (mm) m) 0 0 No mark No mark 4T 4T Class Class Hexagon Hexagon 0 0) ) No No mark mark 4T 4T flang flange e bolt bolt Diameter Diameter Hexagon Hexagon C C D D Two Two protruding protruding 5 5T T Length Length head headbolt bolt lines lines Hexagon Hexagon ( (C C) ) Two Two protruding protruding 6 6T T flan flange ge bolt bolt lines lines Stud bolt Stud bolt Hexagon Hexagon @ @ Three Three protruding protruding 7 7T T head headbolt bolt lines lines Part No. Part No. Hexagon Hexagon ~ ~ Four protruding Four protruding 92132 92132 -406.14 -406.14 8 8T T ~ ~L L Len Length gth (mm (mm) ) head headbolt bolt lines lines Dia Diamet meter er (mm (mm) ) ~ ~ Class Class Welded bolt Welded bolt 4T 4T Diameter Diameter No mark No mark 4 4T T Stud bolt Stud bolt Length Length https://www.forkliftpdfmanuals.com/
  • 18. " " Grooved Grooved 6 6T T 0-14 0-14 TI TIGHTE GHTENI NING NG TOR TORQUE QUE TABLE TABLE Specified torque Specified torque Class Class Diameter Diameter Pitch Pitch Hexagon Hexagon B B - - Hexagon Hexagon ~ ~ mm mm mm mm head head bolt bolt flang flange e bolt bolt N·m N·m I I kgf-cm kgf-cm I I ft-Ibf ft-Ibf N·m N·m II kgf-cm kgf-cm I I ft-Ibf ft-Ibf .. 6 6 1.0 1.0 5.4 5.4 I I 55 55 I I 48 in-Ibf 48 in-Ibf 5.9 5.9 I I 60 60 I I 52 in-Ibf 52 in-Ibf 8 8 1.25 1.25 13 13 II 130 130 II 9 9 14 14 II 145 145 I I 10 10 II II II II 4T 4T 10 10 1.25 1.25 25 25 II 260 260 I I 19 19 28 28 II 290 290 II 21 21 12 12 1.25 1.25 47 47 II 480 480 II 35 35 53 53 II 540 540 II 39 39 14 14 1.5 1.5 75 75 II 760 760 II 55 55 83 83 II 850 850 II 61 61 16 16 1.5 1.5 113 113 I I 1150 1150 II 83 83 - - II - - II - - 6 6 1.0 1.0 6.4 6.4 II 65 65 II 56 56 in-Ib in-Ibf f 7.5 7.5 II 75 75 I I 65 i 65 in-Ib n-Ibf f 8 8 1.25 1.25 16 16 II 160 160 II 12 12 18 18 II 175 175 I I 13 13 II II II II 5T 5T 10 10 1.25 1.25 32 32 II 330 330 II 24 24 36 36 II 360 360 II 26 26 12 12 1.25 1.25 59 59 II 600 600 II 43 43 65 65 I I 670 670 I I 48 48 14 14 1.5 1.5 91 91 II 930 930 II 67 67 100 100 II 1050 1050 I I 76 76 16 16 1.5 1.5 137 137 I I 1400 1400 II 101 101 157 157 I I 1600 1600 I I 116 116 6 6 1.0 1.0 7.8 7.8 I I 80 80 II 69 i 69 in-Ib n-Ibf f 8.8 8.8 II 90 90 I I 78 78 in-Ib in-Ibf f 8 8 1.25 1.25 19 19 II 195 195 II 14 14 21 21 I I 215 215 I I 16 16 10 10 1.25 1.25 38 38 II 400 400 II 29 29 43 43 I I 440 440 I I 32 32 6 6T T I I II I I I I 12 12 1.25 1.25 72 72 II 730 730 II 53 53 79 79 II 810 810 I I 59 59 14 14 1.5 1.5 110 110 I I 1100 1100 II 80 80 123 123 II 1250 1250 I I 90 90 16 16 1.5 1.5 170 170 II 1750 1750 II 127 127 191 191 I I 1950 1950 I I 141 141 6 6 1.0 1.0 11 11 II 110 110 II 8 8 12 12 II 120 120 I I 9 9 8 8 1.25 1.25 25 25 II 260 260 II 19 19 28 28 I I 290 290 I I 21 21 10 10 1.25 1.25 52 52 II 530 530 II 38 38 58 58 II 590 590 I I 43 43 IT IT I I I I I I I I 12 12 1.25 1.25 95 95 II 970 970 I I 70 70 103 103 I I 1050 1050 I I 76 76 14 14 1.5 1.5 147 147 II 1500 1500 II 108 108 167 167 II 1700 1700 I I 123 123 16 16 1.5 1.5 226 226 II 2300 2300 II 166 166 - - I I - - I I - - 6 6 1.0 1.0 12 12 II 125 125 II 9 9 14 14 II 145 145 II 9 9 8 8 1.25 1.25 29 29 II 300 300 I I 22 22 32 32 II 330 330 II 24 24 10 10 1.25 1.25 61 61 II 620 620 II 45 45 68 68 II 690 690 I I 50 50 a aT T II II II I I 12 12 1.25 1.25 108 108 1100 1100 80 80 123 123 1250 1250 90 90 II II 127 127 II I I 145 145 14 14 1.5 1.5 172 172 II 1750 1750 196 196 II 2000 2000 II II 16 16 1.5 1.5 265 265 I I 2700 2700 II 195 195 299 299 II 3050 3050 I I 221 221 https://www.forkliftpdfmanuals.com/
  • 19. Sea Seal l lock agent lock agent 0-15 0-15 PR PREC ECOAT OAT BOLTS BOLTS (Bo (Bolts lts wit with seal h seal loc lock k age agent nt coa coatin ting g on th on threa reads) ds) 1. 1. Do Do no not us t use the pre e the preco coat at bo bolt a lt as s it it is i is in n ei eith ther er of of th the e fo foll llow ow- - ing cases: ing cases: (a (a) ) Af Afte ter r it it is is re remo move ved. d. (b (b) ) Wh When en th the e pr prec ecoa oat t bo bolt is m lt is mov oved ed (l (loo oose sene ned d or t or tig ight ht- - ene ened) d) by by tig tightn htness ess che check, ck, etc etc. . Note: Note: F For to or torqu rque e che check, ck, use t use the he low lowe er r lim limit it of the allo of the allow- w- a able t ble tigh ighte tenin ning g tor torque que ra range nge. . I If the bol f the bolt t mov move es, s, re re- - tig tighte hten n it a it acco ccordi rding ng to the ste to the steps ps be below low. . 2. 2. Me Meth thod f od for r or reu euse of se of pr prec ecoa oat t bo bolt lts s (1 (1) ) Wa Wash the bol sh the bolt and t and th thre read aded ed ho hole le. . (T (The he th thre read aded ed ho hole le mus must t be be was washed hed eve even for n for rep replac laceme ement nt of t of the he bol bolt.) t.) (2 (2) ) Pe Perf rfec ectl tly y dr dry the wa y the wash shed ed pa part rts s by a by air bl ir blow owin ing. g. (3) (3) Coa Coat th t the sp e speci ecifie fied d sea seal lock ag l lock agent to ent to the the thr thread eaded ed por por- - tion of the tion of the bolt. bolt. HI HIGH GH PR PRES ESSU SURE RE HO HOSE SE FIT FITTI TING NG TI TIGH GHTE TENI NING NG TO TORQ RQUE UE 1. 1. Whe When n con connec nectin ting g a a hig high pre h pressu ssure re hos hose, w e, wipe t ipe the h he hose ose fit fittin ting g and and mat mating nip ing nipple cont ple contact surfa act surfaces ces wit with h cl clea ean n cl clot oth h to to re remo move ve fo fore reig ign n ma matt tter ers s an and d di dirt rt. . Al Also so ch chec eck k no de no dent or oth nt or other er da dama mage ge on th on the e co cont ntac act t surfa surfaces ces befor before e insta installati llation. on. 2. 2. Whe When n con connec nectin ting g a hi a high pre gh pressu ssure re hos hose, hold e, hold the hos the hose t e to al o align the f ign the fitt itting wit ing with the nipp h the nipple and le and tig tighte hten n the the fitting. fitting. 3. 3. Th The e ma maxi ximu mum m ti tigh ghte teni ning ng to torq rque ue mu must not e st not exc xcee eed twi d twice th ce the stan e standa dard rd ti tigh ghte teni ning ng to torq rque ue. . Nominal diameter Nominal diameter Stan Standard dard tight tightening ening torq torque ue N·m N·m (kgf (kgf-cm) -cm) [ft- [ft-Ibf] Ibf] Hose inside Hose inside of screw of screw Standard Standard Tight Tightening ening rang range e dia diamet meter er mm mm (in (in) ) 7/16-20UNF 7/16-20UNF 25 25 ( ( 25 250) 0)[ [ 18 18.1 .1] ] 24 24 - - 2 26 6 ( 2 ( 24 40 0- - 2 27 70 0) ) [ [1 17 7. .4 4- - 1 19 9. .5 5] ] 6 6 (0.2 (0.24) 4) 9/16-18UNF 9/16-18UNF 49 49 ( ( 50 500) 0) [ [ 36 36.2 .2] ] 47 47 - - 52 52 ( 48 ( 480 0- - 5 530 30) [ ) [34 34.7 .7- - 3 38 8. .3 3] ] 9 9 ( (0 0. .3 35 5) ) 3/4-16UNF 3/4-16UNF 59 59 ( ( 60 600) 0) [ [ 43 43.4 .4] ] 5 56 6- - 6 62 2 ( ( 5 57 70 0- - 630 630) [41 ) [41.2 .2 - - 45.6] 45.6] 12 12 (0.47) (0.47) 7/8-14UNF 7/8-14UNF 59 59 ( ( 60 600) 0) [ [ 43 43.4 .4] ] 56 56 - - 62 62 ( 57 ( 570- 0- 6 630 30) [ ) [41 41. .2- 2- 4 45 5. .6 6] ] 1 12 2 ( (0 0. .4 47 7) ), , 1 15 5 ( (0 0. .5 59 9) ) 1·1/16 1·1/16 12UNF 12UNF 118 118 (12 (1200) 00) [ 86 [ 86.8] .8] 11 112 2 - 12 - 123 3 (1 (114 140 0 - 12 - 1250 50) ) [8 [82. 2.5 5 - - 90 90.4 .4] ] 19(0.75) 19(0.75) 1·5/16-12UNF 1·5/16-12UNF 137 137 (140 (1400) 0) [101 [101.3] .3] 1 13 30 0 - - 1 14 44 4 ( (1 13 33 30 0 - - 1 14 47 70 0) ) [ [9 96 6. .2 2 - - 1 10 06 6. .4 4] ] 2 25 5 ( (0 0. .9 98 8) ) PF1/4 PF1/4 25 25 ( ( 25 250) 0)[ 18 [ 18.1 .1] ] 2 24 4 - - 2 26 6 ( ( 2 24 40 0 - - 2 27 70 0) ) [ [1 17 7. .4 4 - - 1 19 9. .5 5] ] 6 6 ( (0 0. .2 24 4) ) PF3/8 PF3/8 49 49 ( ( 50 500) 0) [ [ 36 36.2 .2] ] 4 47 7 - - 5 52 2 ( ( 4 48 80 0 - - 5 53 30 0) ) [ [3 34 4. .7 7 - - 3 38 8. .3 3] ] 9 9 ( (0 0. .3 35 5) ) https://www.forkliftpdfmanuals.com/
  • 20. PF1/2 PF1/2 59 59 ( ( 60 600) 0) [ [ 43 43.4 .4] ] 5 56 6 - - 6 62 2 ( ( 5 57 70 0 - - 6 63 30 0) ) [ [4 41 1. .2 2 - - 4 45 5. .6 6] ] 12 12 (0.47) (0.47) PF3/4 PF3/4 118 118 (12 (1200) 00) [ [ 86. 86.8] 8] 1 11 12 2 - -1 12 23 ( 3 (1 11 14 40 0 - -1 12 25 50 0) ) [ [8 82 2. .5 5 - 90 - 90. .4 4] ] 1 19 9 ( (0 0. .7 75 5) ) PF1 PF1 137 137 (140 (1400) 0) [101 [101.3] .3] 1 13 30 0 - -1 14 44 ( 4 (1 13 33 30 0 - - 1 14 47 70 0) ) [ [9 96 6. .2 2 - -1 10 06 6. .4 4] ] 2 25 5 ( (0 0. .9 98 8) ) 0-16 0-16 WI WIRE RE RO ROPE PE SU SUSP SPEN ENSI SION ON ANG ANGLE LE LIS LIST T Lifting angle Lifting angle 3 3 0 0 0 0 Tension Tension 1.00time 1.00time 1.04time 1.04time 1.16 time 1.16 time Compres- Compres- sion sion o o time time 0.27 time 0.27 time 0.S8time 0.S8time Suspension Suspension method method 2t 2t Lifting angle Lifting angle Tension Tension 1.41 time 1.41 time 2.00 time 2.00 time Compres- Compres- sion sion 1.00 time 1.00 time 1.73 time 1.73 time Suspension Suspension method method 2t 2t SAF SAFE E LOAD LOAD FO FOR R EACH W EACH WIR IRE E RO ROPE SUS PE SUSPE PENS NSIO ION N ANG ANGLE LE Uni Unit: t: N N (tf (tf) ) [Ib [Ibf] f] R Ro op pe e C Cu ut tt ti in ng g Single-rope Single-rope Two-r Two-rope ope suspe suspension nsion Four Four-rope -rope suspe suspension nsion suspension suspension d di ia am me et te er r l lo oa ad d 0 0 0 0 0 0 0 0 30 30 0 0 60 60 0 0 90 90 0 0 0 0 0 0 30 30 0 0 60 60 0 0 90 90 0 0 6mm 6mm 21380 21380 3040 3040 6080 6080 5880 5880 5200 5200 4 43 31 10 0 1 12 21 16 60 0 11770 11770 10400 10400 8630 8630 (0. (0.24 24 in) in) (2.18) (2.18) (0.31 (0.31 ) ) (0.62) (0.62) (0.6) (0.6) (0.53) (0.53) (0.44) (0.44) (1.24) (1.24) (1.2) (1.2) (1.06) (1.06) (0.88) (0.88) [4807] [4807] [683.6] [683.6] [1367] [1367] [1323] [1323] [1169] [1169] [970] [970] [2734] [2734] [2646] [2646] [2337] [2337] [1940] [1940] 8 8 mm mm 31480 31480 4 44 41 10 0 8 88 83 30 0 8530 8530 7650 7650 6280 6280 17650 17650 17060 17060 15300 15300 12550 12550 (0. (0.32 32 in) in) (3.21 ) (3.21 ) (0.45) (0.45) (0.9) (0.9) (0.87) (0.87) (0.78) (0.78) (0.64) (0.64) (1.8) (1.8) (1.74) (1.74) (1.56] (1.56] (1.28) (1.28) [7078] [7078] [992.3] [992.3] [1985] [1985] [1918] [1918] [1720] [1720] [1411] [1411] [3969] [3969] [3937] [3937] [3440] [3440] [2322] [2322] 10 mm 10 mm 49230 49230 6960 6960 14020 14020 13440 13440 1 11 17 77 70 0 9 98 81 10 0 27460 27460 26480 26480 23540 23540 19610 19610 (0. (0.4 4 in) in) (5.02) (5.02) (0.71 (0.71 ) ) (1.43) (1.43) (1.37) (1.37) (1.2) (1.2) (1.0) (1.0) (2.8) (2.8) (2.7) (2.7) (2.4) (2.4) (2.0) (2.0) [11.69] [11.69] [1565.6] [1565.6] [3153] [3153] [3021] [3021] [2646] [2646] [2205] [2205] [6174] [6174] [5954] [5954] [5292] [5292] [4410] [4410] 76880 76880 10980 10980 21570 21570 21280 21280 18630 18630 14710 14710 43150 43150 41190 41190 37270 37270 29420 29420 https://www.forkliftpdfmanuals.com/
  • 21. 12 12.5 .5 mm mm (0. (0.5 5 in) in) (7.84) (7.84) (1.12) (1.12) (2.2) (2.2) (2. (2.1 1 ) ) (1.9) (1.9) (1.5) (1.5) (4.4) (4.4) (4.2) (4.2) (3.8) (3.8) (3.0) (3.0) [17387] [17387] [2469.5] [2469.5] [4851] [4851] [4631] [4631] [4190] [4190] [3308] [3308] [9702] [9702] [9261] [9261] [8379] [8379] [6615] [6615] 14 mm 14 mm 96400 96400 13730 13730 27460 27460 26480 26480 23540 23540 18630 18630 54920 54920 52960 52960 47070 47070 37270 37270 (0. (0.56 56 in) in) (9.83) (9.83) (1.4) (1.4) (2.8) (2.8) (2.7) (2.7) (2.4) (2.4) (1.9) (1.9) (5.6) (5.6) (5.4) (5.4) (4.8) (4.8) (3.8) (3.8) [21675] [21675] [3087] [3087] [6174] [6174] [ [5 59 95 54 4] ] [ [5 52 29 92 2] ] [4190] [4190] [12348] [12348] [11907] [11907] [10584] [10584] [8379] [8379] CO COMP MPON ONEN ENTS TS WE WEIGH IGHT T 0-17 0-17 Component Component W We ei ig gh ht t k kg g ( (I Ib b) ) 5K 5K 97 97 ( ( 21 214) 4) Engine Engine 4Y 4Y 134 134 ( ( 295 295) ) 1DZ-II 1DZ-II 176 176 ( ( 388 388) ) 2Z 2Z 24 240 0 ( ( 52 529) 9) Mf Mf f f 75 75 ( ( 16 165 5) ) Transmission Transmission TIC TIC (1 speed) (1 speed) 12 124 4 ( ( 27 273) 3) TIC TIC (2 speeds) (2 speeds) 15 153 3 ( ( 33 337) 7) 1.0 to 1.0 ton n mode model l Ap Appr prox ox. . 40 400 0 ( ( 88 880) 0) 1.5 to 1.5 ton n mode model l Ap Appro prox. x. 745 745 (16 (1640) 40) 1.75 to 1.75 ton n mode model l Ap Appro prox. x. 880 880 (19 (1940) 40) 2.0 ton model 2.0 ton model Appr Approx. ox. 1150 1150 (2535 (2535) ) Coun Counter ter weigh weight t 2.5 ton model 2.5 ton model Appr Approx. ox. 1500 1500 (330 (3300) 0) 3.0 ton model 3.0 ton model Appr Approx. ox. 1800 1800 (400 (4000) 0) K2.0 ton K2.0 ton mode model l Appr Approx. ox. 1140 1140 (2510 (2510) ) K2.5 ton K2.5 ton mode model l Appr Approx. ox. 1550 1550 (3410 (3410) ) K3.0 ton model K3.0 ton model Appr Approx. ox. 1925 1925 (4240 (4240) ) J3.5 ton model J3.5 ton model Appr Approx. ox. 2135 2135 (470 (4700) 0) 1 1 t to on n s se er ri ie es s A Ap pp pr ro ox x. . 41 410 ( 900 0 ( 900) ) V ma V mast ASSY st ASSY Uba Ubackr ckrest est and and for fork k 2 ton 2 ton serie series s App Approx rox. . 505 505 (11 (1110) 10) (with lift cy (with lift cylinde linder, r, max. max. liftin lifting g heigh height: t: 3 3 t to on n, , K K3 3 t to on n s se er ri ie es s A Ap pp pr ro ox x. . 570 ( 570 (1260) 1260) 300 3000 0 mm mm (11 (118 in 8 in» » K K2 2 t to on n s se er ri ie es s A Ap pp pr ro ox x. . 465 ( 465 (1030) 1030) J J3 3. .5 5 t to on n s se er ri ie es s A Ap pp pr ro ox x. . 680 680 (1500 (1500) ) https://www.forkliftpdfmanuals.com/
  • 22. 0-18 0-18 RE RECO COMM MMEN ENDE DED D LUBRIC LUBRICANT ANT QU QUANT ANTIT ITY Y & & TYPES TYPES Description Description Application Application Quantity Quantity f f ( (U US S g ga al l) ) C Cl la as ss si if fi ic ca at ti io on n T Ty yp pe e Motor oil Motor oil 5K 5K 4.0 4.0 (1.06) (1.06) SAE30 SAE30 Gasoline Gasoline AP API I (SAE20 (SAE20 in in cold cold area) area) SH, SJ SH, SJ SAE20W-40 SAE20W-40 4Y 4Y 4.0 4.0 (1.06) (1.06) (SAE1 (SAE10W-30 0W-30 in in cold cold Engine Engine area) area) 1DZ-II 1DZ-II 7.9 7.9 (2.09) (2.09) Diesel Diesel engine engine oil oil AP API I SAE30 SAE30 (SAE2 (SAE20 0 in in Diesel Diesel CE,CF CE,CF cold cold area) area) 2Z 2Z 9.0 9.0 (2.38) (2.38) SAE10W-30 SAE10W-30 Mf Mff f 3.8 3.8 (1.0) (1.0) AP API I Hypoid Hypoid gear gear oil oil GL-4, GL-5 GL-4, GL-5 SAE85W-90 SAE85W-90 Transmission Transmission TIC TIC (1 speed) (1 speed) 9.0 9.0 (2.38) (2.38) AT ATF F GM GM Dexron® Dexron® II II TIC TIC (2 speeds) (2 speeds) 10.5 10.5 (2.77) (2.77) 1 ton series 1 ton series 6.3 6.3 (1.66) (1.66) 2 ton series, 2 ton series, Differential Differential K2 K2 ton ton series, series, 7.1 7.1 (1.87) (1.87) AP API I Hypoid Hypoid gear gear oil oil K3 ton series K3 ton series GL-4,GL-5 GL-4,GL-5 SAE85W-90 SAE85W-90 3 ton series, 3 ton series, 7.7 (2.03) 7.7 (2.03) J3.5 ton series J3.5 ton series Hydrauli Hydraulic c oil oil Attache Attached d Table Table 1 1 ISO ISO Hydraulic oil Hydraulic oil Hydrauli Hydraulic c oil volu oil volume me VG32 VG32 1 ton series 1 ton series 45(11.9) 45(11.9) Fuel tank Fuel tank K2 K2 ton ton series series 55 55 (14.5) (14.5) - - Other series Other series 65 65 (17.2) (17.2) Proper Proper quanti quantity ty SAEJ-1703 SAEJ-1703 Brake and clutch line Brake and clutch line All All models models Reservoir Reservoir Tank Tank - - OOT-3 OOT-3 0.2 (0.05) 0.2 (0.05) • • MPgre MPgrease ase Chassis parts Chassis parts All All models models Proper Proper quanti quantity ty - - • • Molyb Molybdenu denum m disulfide grease disulfide grease • • LLC LLC 30- 30-50% 50% mixt mixture ure https://www.forkliftpdfmanuals.com/
  • 23. (for wint (for winter er or all- or all- Coolant (excluding Coolant (excluding season) season) reservoir tank) reservoir tank) Attache Attached d Table Table 2 2 Coolant Coolant volume volume LLC LLC • • Cool Coolant ant wit with h rust rust- - inhibitor (for spring, inhibitor (for spring, summer and summer and autumn) autumn) Coolant (Reservoir Tank) Coolant (Reservoir Tank) All All models models 0.6 0.6 (0.16) (0.16) f f f f (at Full level) (at Full level) 0-19 0-19 36 (9.5) 36 (9.5) Unit: Unit: l l (US gal) (US gal) J3.5 ton series J3.5 ton series Attached Attached Table Table 1 1 Hyd Hydrau raulic lic oil oil vol volume ume [V ma [V mast, max. lift st, max. lifting ing hei height 3000 ght 3000 mm mm (11 (118 i 8 in)] n)] Model Model 1 1 ton ton seri series es 2 2 ton ton seri series es 3 3 t to on n s se er ri ie es s K K2 2· ·K K3 3 t to on n s se er ri ie es s 5K eng 5K engine ine mode models ls 27 27 (7.1 (7.1) ) 34 34 (9.0 (9.0) ) 30 30 (7.9 (7.9) ) 4Y eng 4Y engine ine mode models ls 27 27 (7.1 (7.1) ) 34 34 (9.0 (9.0) ) 36 36 (9.5) (9.5) 30 30 (7.9 (7.9) ) 1DZ-II engine models 1DZ-II engine models 27 27 (7.1 (7.1) ) 34 34 (9.0 (9.0) ) 36 36 (9.5) (9.5) 2Z engi 2Z engine ne mode models ls 39 39 (10.3 (10.3) ) 41 41 (10. (10.8) 8) Note: Note: Si Since the hydr nce the hydrau aulic lic oil vol oil volume ume va varie ries s with the mas with the mast t spe specific cifica ation, tion, be be sure to c sure to che heck ck fina finally lly with the with the leve level l gauge gauge. . Attached Attached Table Table 2 2 Coolant Coolant volume volume Unit: Unit: l l (US gal) (US gal) Engine Engine Transmission Transmission 1 1 t to on n s se er ri ie es s K K2 2· ·K K3 3 t to on n s se er ri ie es s 2·3·J3.5 2·3·J3.5 ton ton series series M Mf fT T 6 6. .0 0 ( (1 1. .5 58 8) ) 6.0 6.0 (1.5 (1.58) 8) 6.1 6.1 (1.6 (1.61) 1) 5K 5K T I C T I C 6 6. .5 5 ( (1 1. .7 72 2) ) 6 6. .5 5 ( (1 1. .7 72 2) ) 7.6 7.6 (2.0 (2.01) 1) M Mf fT T 7 7. .0 0 ( (1 1. .8 85 5) ) 8 8. .2 2 ( (2 2. .1 16 6) ) 8.4 8.4 (2.2 (2.22) 2) 4Y 4Y T I C T I C 8.5 8.5 (2.24) (2.24) 8 8. .5 5 ( (2 2. .2 24 4) ) 9 9. .6 6 ( (2 2. .5 53 3) ) MfT MfT 6.7 6.7 (1.7 (1.77) 7) 6 6. .9 9 ( (1 1. .8 82 2) ) 7 7. .1 1 ( (1 1. .8 87 7) ) 1DZ-II 1DZ-II T I C T I C 7.2 7.2 (1.90 (1.90) ) 7 7. .2 2 ( (1 1. .9 90 0) ) 8 8. .3 3 ( (2 2. .1 19 9) ) MfT MfT ------------- ------------- ------------- ------------- 8.1 8.1 (2.1 (2.14) 4) 2Z 2Z ------------- ------------- ---------- ---------- T I C T I C 9.3 9.3 (2.4 (2.46) 6) https://www.forkliftpdfmanuals.com/
  • 24. 0-20 0-20 LUBRIC LUBRICATIO ATION N CH CHART ART Ma Manua nual l Tr Trans ansmissi mission on Mode Model l 1 4 1 4 2 2 1 3 1 3 1 4 1 4 4 4 1 3 1 3 3 3 3 3 5 5 1 2 1 2 1 6 1 6 1 5 1 5 1 0 1 0 2 0 2 0 1 7 1 7 8 8 7 7 9 9 6 6 7 7 1 8 1 8 6 6 1 9 1 9 1 8 1 8 1 1 1 1 1 1 9 9 ill ill N N v v o o Inspection Inspection • • R Re ep pl la ac ce em me en nt t C D C D MPgrease MPgrease ® ® Engineoil Engineoil ® ® Hypo Hypoid id gear gear oil oil @ @ Hydr Hydraulic aulic oil oil ® ® Hypo Hypoid id gear gear oil oil ® ® Brake Brake fluid fluid ( (j j) ) Molybdenum Molybdenum disulfide disulfide grease grease L L In Insp spec ect t ev ever ery y 8 8 ho hour urs s (d (dai aily ly) ) II II. . In Insp spec ect t ev ever ery y 40 40 ho hour urs (w s (wee eekl kly) y) IlL IlL Ins Inspec pect t eve every 1 ry 170 70 hou hours ( rs (mon monthl thly) y) IV. IV. Ins Inspec pect t eve every 1 ry 100 000 h 0 hour ours (6 m s (6 mont onthly hly) ) V. V. Ins Inspec pect t eve every ry 20 2000 00 hou hours rs (an (annua nual) l) https://www.forkliftpdfmanuals.com/
  • 25. 1 1 C Ch ha ai in n 2 2 Di Diff ffer eren enti tial al 3 3 Fr Fron ont t wh whee eel l be bear arin ing g 4 4 Bra Brake ke and and clu clutch tch mas master ter cyl cylind inder er 5 5 Tr Tran ansm smis issi sion on ca case se 6 6 Re Rear ar wh whee eel b l bea eari ring ng 7 7 Ste Steeri ering ng knu knuckl ckle e kin king g pin pin 8 8 O Oi ilt lta an nk k 9 9 En Engi gine ne cr cran ank k ca case se 10 10 Re Rear ar ax axle le be beam am fr fron ont p t pin in 11 11 Re Rear ar ax axle le be beam am re rear ar pi pin n 12 12 Tilt Tilt ste steeri ering ngloc lockin king g me mecha chanis nism m 13 13 Ma Mast st su supp ppor ort t bu bush shin ing g 14 14 Ti Tilt lt cyl cylin inde der r fr fron ont p t pin in 15 15 Pr Prop opel elle ler r sh shaf aft t 16 16 Ge Gear ar sh shif ift t li link nk 17 17 Sw Swin ing g lo lock ck cy cylin linde der lo r lowe wer p r pin in 18 18 Ti Tie e ro rod d en end d p pin in 19 19 Re Rear ar ax axle le cy cylin linde der r en end d pi pin n 20 20 Ge Gear ar sh shif ift t le leve ver r 0-21 0-21 To Torque Conv rque Conver erte ter r & & Tr Tran ansmiss smission ion Mo Mode del l 1 1 1 1 1 4 1 4 2 2 1 3 1 3 1 4 1 4 3 3 1 3 1 3 3 3 4 4 1 2 1 2 5 5 1 5 1 5 1 0 1 0 8 8 1 6 1 6 9 9 7 7 7 7 6 6 6 6 1 7 1 7 1 7 1 7 1 8 1 8 1 8 1 8 1 1 1 1 ill ill N N v v o o Inspection Inspection • • R Re ep pl la ac ce em me en nt t G ) G ) MPgrease MPgrease @ @ Engineoil Engineoil ® ® Hypo Hypoid id gea gear r oil oil @ @ Hydr Hydraulic aulic oil oil ® ® Automatic Automatic transmission transmission fluid fluid ® ® Brake Brake fluid fluid l l Inspe Inspect ct ever every 8 ho y 8 hours urs (dail (daily) y) It It In Insp spec ect t ev ever ery y 40 40 ho hour urs s (w (wee eekl kly) y) I I l l Inspe Inspect ev ct every 170 ho ery 170 hours (mon urs (monthly) thly) IV. IV. Ins Inspec pect e t ever very 1000 y 1000 hou hours (6 rs (6 mo month nthly) ly) V. V. Ins Inspec pect t eve every ry 200 2000 0 hou hours rs (an (annu nual) al) https://www.forkliftpdfmanuals.com/
  • 26. ( ( j j) ) Molybdenum Molybdenum disulfide disulfide grease grease 1 1 C Ch ha ai in n 2 2 Di Diff ffer eren enti tial al 3 3 Fr Fron ont t wh whee eel l be bear arin ing g 4 4 Br Brak ake e ma mast ster er cy cyli lind nder er 5 5 To Torq rque ue co conv nver erte ter r ca case se 6 6 Re Rear ar wh whee eel l be bear arin ing g 7 7 Ste Steeri ering ng knu knuckl ckle e kin king g pin pin 8 8 O Oi ilt lta an nk k 9 9 En Engi gine ne cr cran ank k ca case se 10 10 Re Rear ar ax axle le be beamfron amfront t pi pin n 11 11 Re Rear ar ax axle le be beam am re rear ar pi pin n 12 12 Tilt Tilt ste steeri ering ng loc lockin king g me mecha chanis nism m 13 13 Ma Mast st su supp ppor ort t bu bush shin ing g 14 14 Ti Tilt c lt cyl ylin inde der r fr fron ont t pi pin n 15 15 Pr Prop opel elle ler r sh shaf aft t 16 16 Sw Swin ing lo g lock c ck cyl ylin inde der l r low ower p er pin in 1 17 7 Ti Tie e ro rod d e en nd d p pin in 18 18 Rea Rear r axl axle e cyl cylind inder er end end pin pin 0-22 0-22 PERI PERIODI ODIC C MAINTE MAINTENANCE NANCE IN INSPECTI SPECTION ON METHOD METHOD I I : : Insp Inspecti ection. on. Rep Repair air or or rep replace lacemen ment t if if req requir uired. ed. M : M : Mea Measur sureme ement. nt. Rep Repair air or or adj adjust ustmen ment t if if req requir uired. ed. T T : : Re Reti tigh ghte teni ning ng C C : : Cl Clea eanin ning g L L : : Lu Lubr brica icati tion on * * : : Fo For r ne new w ve vehi hicl cle e *1 *1: : F Fla law w d det etec ecto tor r Inspection Period Inspection Period Every Every Every Every Every Every Every Every 1 month 1 month 3 3 months months 6 6 months months 12 12 months months Every Every Every Every Every Every Every Every Item Item 170 170 hours hours 500 500 hours hours 1000 1000 hours hours 2000 2000 hours hours ENGINE ENGINE Proper starting and abnormal noise Proper starting and abnormal noise I I + + - - + + - - + + - - Rotat Rotating ing condi condition tion at idli at idling ng M M + + - - + + - - + + - - Rotating condition Rotating condition during accelerati during acceleration on M M + + - - + + - - + + - - Exhaust Exhaust gas condit gas condition ion I I + + - - + + - - + + - - Main body Main body Air Air clean cleaner er elemen element t C C + + - - + + - - + + - - Valve clearance Valve clearance M* M* M M Compression Compression M M Cylinder head bolt loosening Cylinder head bolt loosening T T Muffler rubber mount Muffler rubber mount I I PCV PCV syste system m Clogging Clogging and and damage damage in in PCV PCV valve and valve and piping piping I I + + - - + + - - + + - - Governor Governor No-l No-load oad maximum maximum rpm rpm M M + + - - + + - - + + - - Oil leak Oil leak I I + + - - + + - - + + - - Lubrication Lubrication Oil level Oil level I I + + - - + + - - + + - - system system Clogging Clogging and dirt of oil and dirt of oil filt filter er I I + + - - + + - - + + - - Fuel leak Fuel leak I I + + - - + + - - + + - - Operation Operation of of carburetor carburetor link link mechanism mechanism I I + + - - + + - - + + - - Dirt and clogging of fuel filter and element Dirt and clogging of fuel filter and element I I + + - - + + - - + + - - Fu Fuel el sy syst stem em In Inje ject ctiion on ti timi ming ng M M + + - - https://www.forkliftpdfmanuals.com/
  • 27. Inje Injecti ction on nozzl nozzle inject e injection ion press pressure ure and and M M spray spray statu status s Draining of sedimenter Draining of sedimenter I I + + - - Coolan Coolant t leve level in radi l in radiator ator and leak and leak I I + + - - + + - - + + - - Rubber hose degradation Rubber hose degradation I I + + - - + + - - + + - - Cooling Cooling Radiator cap condition Radiator cap condition I I + + - - + + - - + + - - system system Fan belt Fan belt tensi tension, on, loos looseness eness and damage and damage I I + + - - + + - - + + - - Radiator rubber mount Radiator rubber mount I I 0-23 0-23 Insp Inspectio ection n Peri Period od E Ev ve er ry y E Ev ve er ry y E Ev ve er ry y E Ev ve er ry y 1 month 1 month 3 3 months months 6 6 m mon onth ths s 12 12 mo mont nths hs E Ev ve er ry y E Ev ve er ry y E Ev ve er ry y E Ev ve er ry y Item Item 170 170 hours hours 50 500 0 ho hour urs s 10 1000 00 ho hour urs s 2000 2000 hour hours s POW POWER ER TRA TRANSM NSMISS ISSION ION SYS SYSTEM TEM Clutc Clutch h peda pedal l play play M M - - - - - - Abnormal Abnormal sound sound and and functioning functioning I I - - - - - - (connection) (connection) Clutch Clutch Clutc Clutch h mast master er cylin cylinder der funct function ion and and leak leak I I - - - - - - Fluid level Fluid level I I - - - - - - Oil cl Oil clutc utch h mec mechan hanism ism fun functi ction on and lea and leak k I I (OPT) (OPT) - - Leak Leak I I - - - - - - Fluid level Fluid level I I - - - - - - Manual Manual Gear functi Gear function on and abno and abnormal rmal noise noise I I - - - - - - transmission transmission Dama Damage ge of shift leve of shift lever cable r cable boot boot I I D Da am ma ag ge e o of f c ca ab bl le e o ou ut te er r I I Leak Leak I I - - - - - - D Di if ff fe er re en nt ti ia al l O Oi il l l le ev ve el l I I - - - - - - B Bo ol lt t l lo oo os se en ni in ng g T T L Le ea ak k I I - - - - - - Fluid level Fluid level I I - - - - - - Torque Torque Oper Operating ating mech mechanism anism func function tion and and I I - - - - - - converter converter & & looseness looseness transmission transmission Contr Control ol valve and valve and clutc clutch h funct functions ions I I - - - - - - I In nc ch hi in ng g v va al lv ve e f fu un nc ct ti io on n I I - - - - - - Stall and hydrau Stall and hydraulic lic pres pressure sure meas measurem urement ent M M - - Loose joint Loose joint T T - - - - Prop Propeller eller shaft shaft Loos Loosenes eness s at at splin spline conne e connection ctions s I I and axle shaft and axle shaft Loos Loosenes eness s of u of univer niversal sal joint joint I I Twis Twisting ting and crack and cracks s of axle s of axle shaft haft I I https://www.forkliftpdfmanuals.com/
  • 28. DRIVE DRIVE SYSTE SYSTEM M Tire inflation pressure Tire inflation pressure M M - - - - - - Tire cuts, damag Tire cuts, damage e and une and uneven wearing ven wearing I I - - - - - - Loo Loose se rim and hu rim and hub b nut nuts s T T - - - - - - Wheels Wheels Tire groove depth Tire groove depth M M - - - - - - Meta Metal l chip chips, s, pebb pebbles les and other fore and other foreign ign I I - - - - - - matt matter er trap trapped ped in tir in tire grooves e grooves 0-24 0-24 Inspection Period Inspection Period Every Every Every Every Every Every Every Every 1 month 1 month 3 3 months months 6 6 months months 12 12 months months E Ev ve er ry y E Ev ve er ry y E Ev ve er ry y Every Every Item Item 170 170 hours hours 500 500 hours hours 100 1000 0 hou hours rs 200 2000 0 hou hours rs Rim, side bearing and disc wheel damage Rim, side bearing and disc wheel damage I I - - - - - - Abnor Abnormal mal sound and loosen sound and looseness ess of of fro front nt I I Wheels Wheels wheel wheel bearing bearing - - - - - - Abnor Abnormal mal sound and loos sound and looseness eness of r of rear ear I I wheel bearing wheel bearing - - - - - - Front axle Front axle Cracks Cracks, , damage damage and and defor deformatio mation n of of housi housing ng I I Cracks Cracks, , damage damage and d and defor eformatio mation n of of beam beam I I Rear axle Rear axle Loosen Looseness ess of ax of axle beam le beam in in vehi vehicle cle longitudi longitudinal nal directi direction on M* M* M M STEE STEERING RING SYST SYSTEM EM Play and looseness Play and looseness I I - - - - - - Steering wheel Steering wheel Function Function I I - - - - - - Oil leak Oil leak I I - - - - - - Steering valve Steering valve Looseness of mounting Looseness of mounting T T - - - - - - Oil leak Oil leak I I - - - - - - Power Steering Power Steering Mounti Mounting ng and l and linka inkage ge loos looseness eness I I - - - - - - Damage of power steering hose Damage of power steering hose I I King pin looseness King pin looseness I I - - - - - - Knuckle Knuckle Cranks and deformation Cranks and deformation I I BRAKING SYSTEM BRAKING SYSTEM Play and reserve Play and reserve M M - - - - - - Brake pedal Brake pedal Braking effect Braking effect I I - - - - - - Operating force Operating force I I - - - - - - https://www.forkliftpdfmanuals.com/
  • 29. Parking brake Parking brake Braking Braking effect effect I I - - - - - - Rod and cab Rod and cable loosene le looseness ss and damage and damage I I - - - - - - Brake pipe Brake pipe Leak, Leak, damage damage and and mounti mounting condi ng conditio tion n I I - - - - - - Reservoir tank Reservoir tank Leak Leak and and fluid fluid level level I I - - - - - - Master Master Functi Function, on, wear, da wear, damage, mage, leak and mounti leak and mounting ng cyli cylinder nder and and I I wheel cylinder wheel cylinder looseness looseness 0-25 0-25 Insp Inspectio ection n Perio Period d Every Every E Ev ve er ry y E Ev ve er ry y Every Every 1 1 mo month nth 3 3 months months 6 6 m mon onth ths s 1 12 2 m mon onth ths s Every Every Every Every E Ev ve er ry y E Ev ve er ry y Item Item 170 170 hours hours 500 500 hour hours s 1000 1000 hours hours 2000 2000 hour hours s Clear Clearance ance betwe between drum and lining en drum and lining M M . - . - . - . - . - . - Wea Wear r of sh of shoe slidi oe sliding ng por portio tion n and lin and lining ing I I Brake drum Brake drum Drum Drum wear wear and and dama damage ge I I and brake and brake Shoe Shoe oper operating ating cond condition ition I I shoe shoe Anchor Anchor pin pin rusting rusting I I Return spring fatigue Return spring fatigue M M Automatic Automatic adjuster adjuster function function I I Defor Deformati mation, on, crack cracks s and da and damage mage I I Backi Backing ng plate plate Loose mounting Loose mounting T T MATER MATERIAL IAL HANDL HANDLING ING SYSTEM SYSTEM Abnormality Abnormality of of fork fork and and stopper stopper pin pin I I . - . - . . - - . . - - Forks Forks Misa Misalignm lignment be ent between tween left left and and right right fork fork I I . - . - . . - - . . - - fingers fingers Cra Cracks cks at for at fork k roo root t and weld and welded ed par part t 1 * 1 1 * 1 Defo Deformati rmation on and dama and damage ge of eac of each part an h part and d I I . - . - . - . - . - . - cra crack ck at at wel welded ded par part t Mast and Mast and lift b lift bracke racket t loose looseness ness I I . - . - . . - - . . - - Mas Mast t and lift and lift Wear and Wear and dama damage of ge of mast mast suppo support bushin rt bushing g I I bracket bracket Wear Wear, , dama damage ge and ro and rotatin tating g cond condition of ition of rollers rollers I I . - . - . . - - . . - - Wea Wear r and da and damag mage e of ro of rolle ller r pin pins s I I Wea Wear r and da and dama mage ge of m of mast trip ast trip I I . - . - . . - - . . - - Tens Tension, deform ion, deformation ation and dama and damage ge of of chain chain I I . - . - . - . - . - . - Chain lubrication Chain lubrication I I . - . - . . - - . . - - Chain and Chain and chainwheel chainwheel Abnor Abnormalit mality y of of chain chain anch anchor bo or bolt lt I I . - . - . - . - . - . - Wear Wear, , dama damage ge and rot and rotating conditio ating condition n of of https://www.forkliftpdfmanuals.com/
  • 30. I I . . . . . . chainwheel chainwheel Various Various Abnor Abnormalit mality and y and moun mounting ting condi condition tion of of each each I I . - . - . - . - . - . - attachments attachments part part HYDRA HYDRAULIC ULIC SYSTEM SYSTEM Loos Loosening ening and and dama damage ge of c of cylind ylinder er moun mounting ting T T . - . - . . - - . . - - Defo Deformat rmation ion and da and damage mage of rod, r of rod, rod scr od screw ew I I . - . - . . - - . . - - and rod end and rod end Cylinder Cylinder Cylinder operation Cylinder operation I I . - . - . - . - . - . - Natur Natural al drop and natura drop and natural l forwa forward rd tilt tilt M M . - . - . - . - . - . - (hydraulic drift) (hydraulic drift) 0-26 0-26 I In ns sp pe ec ct tiio on n P Pe er riio od d E Ev ve er ry y E Ev ve er ry y Every Every Every Every 1 month 1 month 3 3 months months 6 6 months months 12 12 months months E Ev ve er ry y E Ev ve er ry y Every Every Every Every Item Item 17 170 0 ho hour urs s 50 500 0 ho hour urs s 1000 1000 hours hours 2000 2000 hours hours Oil l Oil leak eak and damage and damage I I - - - - - - Wear Wear and damage and damage of p of pin and in and cyli cylinder nder I I bearing bearing - - - - - - Cytinder Cytinder Lifting speed Lifting speed M M - - - - - - Uneven movement Uneven movement I I - - - - - - Oil pump Oil pump Oil Oil leak leak and and abnor abnormal mal sound sound I I - - - - - - Oil level and contamination Oil level and contamination I I - - - - - - Hydrau Hydraulic lic oil oil Tank and oil strainer Tank and oil strainer C C - - tank tank Oil leak Oil leak I I - - - - - - Loose linkage Loose linkage I I - - - - - - Control lever Control lever Operation Operation I I - - - - - - Oil leak Oil leak I I - - - - - - Oil control Oil control Relief pressure measurement Relief pressure measurement M M valve valve Relief valve and tilt lock valve functions Relief valve and tilt lock valve functions I I - - - - - - Oil leak Oil leak I I - - - - - - Hydraulic Hydraulic Defor Deformatio mation n and damage and damage I I - - - - - - piping piping Loose joint Loose joint T T - - - - - - ELECTRICAL SYSTEM ELECTRICAL SYSTEM Cracks Cracks on di on distri stributor butor cap cap I I - - - - - - Spark plug burning and gap Spark plug burning and gap I I - - - - - - Distributor side terminal burning Distributor side terminal burning I I - - - - - - Ignition timing Ignition timing Distr Distribut ibutor or cap cent cap center er piec piece wear and e wear and damage damage I I - - - - - - Plug cord internal discontinuity Plug cord internal discontinuity I I Ignition timing Ignition timing M M - - https://www.forkliftpdfmanuals.com/
  • 31. Starting motor Starting motor Pini Pinion gea on gear mesh r meshing status ing status I I - - - - - - Charger Charger Charging Charging function function I I - - - - - - Battery fluid level Battery fluid level I I - - - - - - Battery Battery Battery fluid specif Battery fluid specific ic gravity gravity M M - - Electrical Electrical Damage Damage of of wiri wiring ng harn harness ess I I - - - - - - wiring wiring Fuses Fuses I I - - - - - - 0-27 0-27 Inspe Inspection ction Per Period iod Every Every Every Every Every Every Every Every 1 month 1 month 3 3 months months 6 6 months months 12 12 months months Every Every E Ev ve er ry y E Ev ve er ry y Every Every Item Item 170 170 hours hours 500 500 hour hours s 1000 1000 hours hours 2000 2000 hours hours Open Open-circ -circuit uit in in glow plug glow plug I I + + - - Preheater Preheater Open Open-circ -circuit uit in in inta intake ke heat heater er I I + + - - Engi Engine ne stop stop- - Diese Diesel l engin engine e key st key stop device op device func function tion I I ping ping syste system m + + - - + + - - + + - - Filter Filter I I + + - - DPFMafier DPFMafier Inlin Inline filt e filter er (for ba (for back ck pres pressure sure sens sensor) or) I I + + - - + + - - SAF SAFETY ETY DEVI DEVICES CES, , ETC. ETC. Crac Cracks ks at at weld welded ed port portion ion I I + + - - + + - - + + - - Head guard Head guard Defor Deformatio mation n and damag and damage e I I + + - - + + - - + + - - Loose Loosening ning of mount of mounting ing T T + + - - + + - - + + - - Back-rest Back-rest Defor Deformatio mation, n, crac crack k and dam and damage age I I + + - - + + - - + + - - Lighting Lighting Func Function tion and moun and mounting ting cond condition ition I I - - + + - - + + - - system system Hom Hom Func Function tion and and moun mounting ting cond condition ition I I + + - - + + - - + + - - Direction Direction Func Function tion and moun and mounting ting cond condition ition I I indicator indicator + + - - + + - - + + - - Instruments Instruments Functions Functions I I + + - - + + - - + + - - Back Backup up buzze buzzer r Func Function and moun tion and mounting ting cond condition ition I I + + - - + + - - + + - - Rear-view Rear-view Dirt, Dirt, damage damage I I + + - - + + - - + + - - mirror mirror Rear refl Rear reflectio ection n statu status s I I 4 4 - - 4 4 - - + + - - Loos Loosenin ening g and damag and damage e of mo of mountin unting g I I 4 4 - - + + - - + + - - Seat Seat Seat Seatbelt belt dama damage ge and fun and function ction I I + + - - 4 4 - - + + - - Dam Damage age and cra and cracks cks of fr of frame ame, , cro cross ss I I Body Body memb members, ers, etc. etc. Bolt looseness Bolt looseness T T https://www.forkliftpdfmanuals.com/
  • 32. Functions Functions I I + + - - + + - - + + - - Loos Loosening ening and dam and damage age at at senso sensor r moun mounting ting I I 4 4 - - + + - - + + - - portion portion Dama Damage, ge, defo deformat rmation, ion, oil oil leaka leakage ge and and I I 4 4 - - + + - - + + - - SAS SAS loose loosening ning of th of the mountin e mounting g of fu of functio nctional nal part parts s Loos Loosenin ening g and damag and damage e of of wire wire harn harnesses esses I I 4 4 - - 4 4 - - + + - - Lock cylin Lock cylinder der accum accumulato ulator r perf performa ormance nce I I R Ru us st ti in ng g a an nd d c co or rr ro os si io on n o of f l lo oa ad d s se en ns so or r I I Others Others Grea Grease se up up L L 4 4 - - 4 4 - - + + - - 0-28 0-28 PE PERIO RIODI DIC C RE REPLACEM PLACEMEN ENT T OF PART OF PARTS S AND L AND LUBRI UBRICANTS CANTS • • : : Rep Replac laceme ement nt Interval Interval Every Every Every Every Every Every Every Every 1 month 1 month 3 3 mo mont nths hs 6 6 mo mont nths hs 12 12 months months Every Every E Ev ve er ry y E Ev ve er ry y E Ev ve er ry y Item Item 170 170 hours hours 500 500 hours hours 1000 1000 hours hours 2000 2000 hours hours Engine oil Engine oil • • + + - - + + - - + + - - Engine oil filter Engine oil filter •• **11 • • + + - - + + - - Engin Engine e cool coolant ant (ever (every 2 years for LLC) y 2 years for LLC) • • + + - - + + - - Fuel filter Fuel filter • • + + - - Torque converter oil Torque converter oil • • + + - - Torque converter Torque converter oil oil filter filter • • + + - - Manual Manual tran transmissi smission on oil oil • • Differenti Differential al oil oil • • Hydraul Hydraulic ic oil oil • • + + - - Hydraulic Hydraulic oil oil filt filter er ..**11 • • + + - - Wheel bearing grease Wheel bearing grease • • Spark plugs Spark plugs • • + + - - Air clea Air cleaner ner element element • • Cups and seals for brake master and wheel cylinders Cups and seals for brake master and wheel cylinders • • Brake fluid Brake fluid • • + + - - Power stee Power steerin ring g hoses hoses ..**22 Power steer Power steering ing rubbe rubbers rs part parts s ..**22 Hydrau Hydraulic lic hoses hoses ..**22 Brake fluid reservoir tank hose Brake fluid reservoir tank hose ..**22 Fuel hoses Fuel hoses ..**22 Torque conv Torque converte erter r rubbe rubber r hoses hoses ..**22 https://www.forkliftpdfmanuals.com/
  • 33. Chains Chains ..**33 DPF Mafler filter (OPT) DPF Mafler filter (OPT) ..**33 DPF M DPF Mafl afler er back pressure back pressure sensor inlin sensor inline fil e filter (OPT) ter (OPT) • • + + - - DPF Air cl DPF Air cleaner eaner (OPT) (OPT) ..**22 SAS Swing SAS Swing lock cyli lock cylinder nder ..**55 *1 *1 : : for new vehicle for new vehicle *2 *2 : : Every 2 years Every 2 years * *3: 3: Every Every 3 yea 3 years rs *5 *5 : : Eve Every ry 100 10000 00 hou hours rs Rep Replac laceme ement nt sha shall ll be ma be made upon arriv de upon arrival al of th of the operat e operation ion hou hours rs or mo or month nths, s, whi whiche chever ver is is ear earlie lier. r. FEATURES FEATURES Page Page C C L LUTC H... UTC H...... ...... .... . 1-2 1-2 MANUAL MANUAL TRANS TRANSMI MISS SSI ION ON 1-5 1-5 FRONT FRONT AXL AXL E-DI E-DIFFERENTI FFERENTIAL AL 1-9 1-9 WH WH E EE LS . E LS . 1-13 1-13 1-1 1-1 CHAN CHANGE GE LEV LEVER ER . . . . . . • . . . . . . . . • . . . . . . . . . . . . . • . . . . . . . . • . . . . . . . . . • . . . • . . . . . . • . . . • • • . . • . . . . . • . . . • . . . . . . • . . . • • • . . • . . . . . . • • • . . . . . . . . • • • . . . . . 1-16 1-16 STEE RING STEE RING 1-17 1-17 FRAM E-WEI FRAM E-WEIG G HT HT 1-18 1-18 V V M MA AST ST............ ......................... .......................... .......................... .......................... .......................... ............. 1-19 1-19 T TI I LT C LT CYLI ND YLI ND ER ER 1-19 1-19 LIFT CYLIN DER LIFT CYLIN DER 1-20 1-20 FS FSV· V·FV FV FRON FRONT T CYLI CYLINDE NDER R • • • . . . . . . . . . . • . . . • . . . . . • • • . . . . . . . . . . • . . . • . . . . . • • • • . • . . . . . . . . . . . • • • • . • . . . . . . . . . . . 1-21 1-21 S SA AS S 1-22 1-22 https://www.forkliftpdfmanuals.com/
  • 34. Ref Refer to er to th the lat e latest data in est data in th the Toy e Toyot ota a In Indus dustr tria ial l Equ Equip ipment ment Pro Produc duct t In Info forma rmati tion on and and Toy Toyot ota a I. I.E. Sp E. Speci ecifi ficat catio ion n Man Manual ual fo for the main vehi r the main vehicl cle e spe speci cifi ficat catio ions. ns. 1-2 1-2 CLUTCH CLUTCH GENERAL GENERAL The The cl clut utch ch re rele lease ase hub li hub link nk mech mechani anism sm has bee has been n modi modifi fied. ed. On conv On convent entio ional nal veh vehic icle les, s, th the e ped pedal al dep depre ressi ssion on fo forc rce e was was trans transmitted mitted from the cl from the clutch utch relea release se cyli cylinder to th nder to the clutch cover e clutch cover thr through ough the relea the release fork se fork shaf shaft, t, rel release ease for fork k and rel and release ease hub. hub. The same The same is is transmi transmitted tted from the from the releas release e cyli cylinder to t nder to the clutch he clutch cover through the release fork and release hub after the modi- cover through the release fork and release hub after the modi- fi ficati cation on made made thi this time. s time. The clutc The clutch h syst system, em, the theref refore ore, , has been simpli has been simplifi fied. ed. Vehi Vehicle cles s wit with the 4Y-ECS h the 4Y-ECS engi engine ne consi consisti sting ng of of the 4Y eng the 4Y engine ine and ECS are newly added. and ECS are newly added. CLUTCH CLUTCH SPECIFI SPECIFICATIONS CATIONS 5K 5K 4Y·10Z-11 4Y·10Z-11 2Z 2Z - - Type Type Dry, Dry, single-plate, single-plate, 4 4 - - 4 4 - - Clutch Clutch spri spring ng type type Operating method Operating method Hydraulic Hydraulic 4 4 - - 4 4 - - Size Size m mm m 27 278 8 4 4 - - 4 4 - - Clutch cover Clutch cover Installati Installation on load load N N (kg) (kg) 2,354 2,354 (240) (240) 3,236 3,236 (330) (330) 3,923 3,923 (400) (400) 0.0. 0.0. x x 1.0. 1.0. x x thickness thickness (mm) (mm) 27 275 5 x x 17 175 5 x x 3 3.5 .5 4 4 - - 4 4 - - Front f Front frictional rictional area area (cm (cm 2 2 ) ) 300.5 300.5 x x 2 2 4 4 - - 4 4 - - Clutch disc Clutch disc Material Material Special Special woven woven 4 4 - - 4 4 - - https://www.forkliftpdfmanuals.com/
  • 35. Type Type Conventional Conventional 4 4 - - 4 4 - - Master cylinder Master cylinder Inside diameter Inside diameter m mm m 15.87 15.87 4 4 - - 4 4 - - Type Type Adjust Adjust-fre -free e type type 4 4 - - 4 4 - - Release cylinder Release cylinder Inside diameter Inside diameter m mm m 20.64 20.64 4 4 - - 4 4 - - Appli Applicable cable oil oil Brake Brake fluid fluid 2500H 2500H 4 4 - - 4 4 - - N Note ote: : P Powe ower- r-a assi ssist st typ type e clu clutch tch is a is adop dopte ted d on v on ve ehic hicle les s ins insta talle lled d wit with h the op the optio tiona nal l oil cl oil clutc utch. h. T The he powe power- r-a assist ssist type clut type clutch, ch, howe howeve ver, r, is n is not prov ot provide ided d as as an an indiv individua idual l optio option. n. CLU CLUTC TCH H ME MECH CHANI ANISM SM SE SECT CTI ION ONAL AL VI VIEW EW Tra Transmi nsmissio ssion n side side Eng Engine ine side side 1-3 1-3 https://www.forkliftpdfmanuals.com/
  • 36. Clu Clutch tch rel releas ease e fo fork rk 1-4 1-4 OI OIL CLUTCH L CLUTCH (OP (OPTI TION) ON) The oil c The oil clut lutch ch veh vehicl icles es rem remain ain unc unchan hanged ged fro from m the old mode the old models. ls. The 4Y The 4Y-EC -ECS S eng engine ine veh vehicl icles es are ne are newly add wly added. ed. CLUTCH SPECIFICATIONS CLUTCH SPECIFICATIONS - - 5K·4Y·1OZ-1I 5K·4Y·1OZ-1I - - - - - - - - 'lZ. 'lZ. Type Type Wet, Wet, singl single-pl e-plate, ate, coil coil spri spring ng type type - - Clutch Clutch Operat Operating ing method method Hydraulic Hydraulic - - Size Size mm mm 27 278 8 - - Clutch cover Clutch cover Installati Installation on load load N N (kg) (kg) 5,070 5,070 (517) (517) 6865 6865 (700) (700) 0.0. 0.0. x x 1.0. 1.0. mm mm 27 275 5 x x 17 175 5 - - Clutc Clutch h disc disc Front Front fricti frictional onal area area cm cm2 2 300.5 300.5 x x 2 2 - - Material Material Speci Special al cork cork - - Type Type Port Portless less with with hydra hydrauli ulic c boost booster er - - Master cylinder Master cylinder Inside diameter Inside diameter mm mm 25.4 25.4 - - Type Type Adjus Adjustabl table e type type - - Release cylinder Release cylinder Inside diameter Inside diameter mm mm 20.64 20.64 - - Appli Applicabl cable e oil oil Hydrau Hydrauli lic c oil oil ISO ISO VG32 VG32 - - https://www.forkliftpdfmanuals.com/
  • 37. 1-5 1-5 MANUAL TRANSMISSION MANUAL TRANSMISSION GENERAL GENERAL The tran The transmi smissi ssion on cas case e has bee has been n cha change nged d fro from m con conven ventio tional nal cas cast t iro iron to alu n to alumin minum um die die-ca -casti sting. ng. In p In pla lace ce of th of the e cl clut utch ch ho hous usin ing g an and d tr tran ansm smis issi sion on ca case se in inde depe pend nden ent t fr from om ea each ch ot othe her r on con on conve vent ntio iona nal l ve ve- - hic hicles les, , the tran the transmi smissi ssion on cas case e is is div divide ided d int into the f o the fron ront t and and rea rear r cas cases. es. In In the case of dry clut the case of dry clutch ch veh vehicl icles, es, the the fro front nt cas case e is in is integ tegrat rated ed wit with h the clu the clutch tch hou housin sing. g. I I I I MANUA MANUA L L TRANSMIS TRANSMISSI SION ON SPECI SPECIFI FICATIONS CATIONS Tran Transmiss smission ion type type Synchromesh Synchromesh Oper Operating ating meth method od Floor Floor shift shift link link Tran Transmiss smission ion case oil case oil capa capacity city l l (US gal) (US gal) 3.8 3.8 (1.0) (1.0) Applicable Applicable oil oil Hypoi Hypoid d gear gear oil oil SAE SAE85W 85W -90 -90 Cha Change nge Ge Gear ar Ra Ratio tio Chan Change ge gear ratio gear ratio Vehi Vehicle cle mode model l Engine Engine Forward Forward Reverse Reverse 1 1s st t s sp pe ee ed d 2 2n nd d s sp pe ee ed d 1 1s st t s sp pe ee ed d 2 2n nd d s sp pe ee ed d 5K 5K 3 3. .7 71 15 5 2 2. .1 12 27 7 3 3. .7 72 22 2 2.132 2.132 1 to 1 ton n serie series s * *4 4Y Y· ·1 1D DZ Z- -1 1I I 3 3. .5 54 41 1 1 1. .5 56 64 4 3 3. .5 54 48 8 1 1. .5 56 67 7 5K 5K 3 3. .7 71 15 5 2 2. .1 12 27 7 3 3. .7 72 22 2 2 2. .1 13 32 2 K2 ton K2 ton serie series s *4Y'1DZ-1I *4Y'1DZ-1I 3.541 3.541 1 1. .5 56 64 4 3 3. .5 54 48 8 1 1. .5 56 67 7 5 5K K 3 3. .7 71 15 5 2 2. .1 12 27 7 3 3. .7 72 22 2 2.132 2.132 2 ton series 2 ton series *4Y·1DZ-1I *4Y·1DZ-1I 3 3. .5 54 41 1 1 1. .5 56 64 4 3 3. .5 54 48 8 1.567 1.567 https://www.forkliftpdfmanuals.com/
  • 38. 2 2Z Z 3 3. .3 37 79 9 1 1. .3 35 55 5 3 3. .3 38 85 5 1 1. .3 35 58 8 K3 ton K3 ton serie series s *4Y·1DZ-1I *4Y·1DZ-1I 3 3. .5 54 41 1 1 1. .5 56 64 4 3 3. .5 54 48 8 1.567 1.567 4Y 4Y f f f f f f f f 3 ton series 3 ton series 2 2Z Z 3 3. .3 37 79 9 1 1. .3 35 55 5 3 3. .3 38 85 5 1 1. .3 35 58 8 4 4Y Y 3 3. .5 54 41 1 1 1. .5 56 64 4 3 3. .5 54 48 8 1 1. .5 56 67 7 J3.5 ton series J3.5 ton series 2 2Z Z 3 3. .3 37 79 9 1 1. .3 35 55 5 3 3. .3 38 85 5 1 1. .3 35 58 8 *Th *The e gea gear r rat ratios of the 4 ios of the 4Y-EC Y-ECS S eng engine ine veh vehicl icles es are th are the same e same as as tho those se of the 4-Y eng of the 4-Y engine ine veh vehicl icles. es. 1-6 1-6 MANUAL MANUAL TRANSM TRANSMI ISSI SSION ON SEC SECTI TIONAL ONAL VI VIEW EW Cou Counte ntersh rshaft aft gea gear, 1st r, 1st Sp Speed eed ge gear ar sha shaft ft For Forwar ward d ge gear ar Forw Forward- ard-reve reverse rse sync synchrom hromesh esh Countershaft Countershaft https://www.forkliftpdfmanuals.com/
  • 39. Fo Forwa rward rd idl idle e gea gear r Outp Output ut gea gear r POWER POWER TRANSMIS TRANSMISSION SION CHARTS CHARTS For Forwar ward d 1s 1st spe t speed ed Forw Forward ard 2nd speed 2nd speed 1-7 1-7 https://www.forkliftpdfmanuals.com/
  • 40. Rev Revers erse e 1st sp 1st speed eed Reve Reverse rse 2nd speed 2nd speed 1-8 1-8 MANUAL TRANSMI MANUAL TRANSMISSI SSION ON SECT SECTIO IONAL NAL VI VIEW (Oil EW (Oil CLUTC CLUTCH VEHI H VEHICLE) CLE) Countershaft gear, 2nd Countershaft gear, 2nd Speed gear shaft Speed gear shaft Forward-reverse synchromesh Forward-reverse synchromesh Countershaft Countershaft https://www.forkliftpdfmanuals.com/
  • 41. Forward idle gear Forward idle gear 1-9 1-9 FRONT AXLE-DIFFERENTIAL FRONT AXLE-DIFFERENTIAL MAJOR MAJOR MODI MODIFI FICATIO CATIONS NS FRO FRONT NT AXLE AXLE HOU HOUSI SING NG The The num number ber of f of fron ront t axl axle e hou housin sing g bol bolts ts has be has been en cha change nged d fro from m 16 16 to to 12 12 pcs pcs./v ./vehi ehicle cle. . Old Old New New F F RO RONT NT AX AXLE LE BRA BRACK CKET ET The The num number ber of fr of front ont axl axle e bra bracke cket t set bolts has been set bolts has been cha change nged d fro from m 8 t 8 to 6 pc o 6 pcs./ s./veh vehicl icle. e. Old Old https://www.forkliftpdfmanuals.com/
  • 42. A ADO DOPT PTIO ION N OF OF SE SERR RRA ATI TION ON FO FOR R HU HUB B B BOL OLTS TS (1 (1· ·2-TON VEHI 2-TON VEHICLE CLE WI WITH TH SI SINGLE NGLE TI TIRES RES) ) The The hub bo hub bolts wer lts were e fas fasten tened ed by loc by lock k nut nuts on the s on the inn inner er sid side of th e of the e bra brake ke dru drum m on on the the con conven ventio tional nal veh vehicl icles. es. Ser Serrat ration ion is is ado adopte pted d for fi for fixin xing g hub bol hub bolts ts on th on the e bra brake ke dru drum this tim m this time. e. Old Old New New 1-10 1-10 FR FRONT ONT AXLE AXLE BRACKET BRACKET RE REACTI ACTION ON FO FORCE BOLT RCE BOLT The reac The reactio tion n for force ce bol bolt used for fix t used for fixing the front axle brac ing the front axle bracket ket on t on the diffe he differen rentia tial l hou housin sing g has bee has been n cha change nged d to to a s a stan tandar dard d bol bolt. t. (Ex (Exclu cludin ding g 3.0 3.0-to -ton n and J3. and J3.5-t 5-ton on veh vehicl icles) es) Old Old Tigh Tighteni tening ng torq torque ue T=265 T=265-34 -343 3 N'm N'm (27 (2700 00-35 -3500 00 kgf kgf-cm -cm) ) [195 [195.3-2 .3-253.2 53.2 ft-Ib ft-Ibf] f] Rea Reacti ction on for force ce bo bolt lt New New Tigh Tighteni tening ng torq torque ue T=294 T=294-34 -343 3 N'm N'm (300 (3000-35 0-3500 00 kgf- kgf-cm) cm) [217 [217.1-2 .1-253.2 53.2 ft-I ft-Ibf} bf} * * 0883 08833-00 3-00070 070 appl applicat ication ion Stan Standard dard bolt bolt https://www.forkliftpdfmanuals.com/
  • 43. 1-11 1-11 DIFFERENTIAL DIFFERENTIAL The diff The differe erenti ntial al red reduct uction ion gea gear porti r portion on has b has been mod een modifi ified ed in in the dif the differ ferent ential ial sec sectio tion. n. The The ret retain ainer er use used d in in the dri the drive pini ve pinion on and redu and reducti ction on gea gear r mou mounti nting ng por portio tion n has b has been disc een discont ontinu inued ed and the and the dif differ ferent ential ial car carrie rier r sha shape pe has b has been cha een change nged. d. The spac The spacer er und under the neck of th er the neck of the driv e drive e pin pinion ion has a has also bee lso been n discontinued. discontinued. Old Old New New https://www.forkliftpdfmanuals.com/
  • 44. 1 1 to to 1.8 to 1.8 ton n ser series ies 2- 2- 3 3 to ton n ser series ies, , J3. J3.5 5 ton ton ser series ies 1-12 1-12 DIF DIFFERENT FERENTIAL IAL REDUCTI REDUCTION ON GEAR RA GEAR RA TI TIO O SPECI SPECIFI FICATIONS CATIONS ~ ~ Tonnage Tonnage 1 1. .0 0 t to on n, , 1 1. .3 35 5 t to on n 1 1. .5 5 t to on n, , 1 1. .7 75 5 t to on n Engine Engine 5K 5K 10Z-11 10Z-11 5K 5K 4Y'10Z-11 4Y'10Z-11 MfTvehicle MfTvehicle 1.741 1.741 1.741 1.741 1.586 1.586 1.586 1.586 6.50-10 6.50-10 1-speed 1-speed TIC TIC vehicle vehicle 2.363 2.363 2.363 2.363 2-speed 2-speed TIC TIC vehicle vehicle Not Not provided provided 21 21 x x 8-9 8-9 MfTVehicle MfTVehicle 1.642 1.642 4 4. .5 50 0- -1 12 2 1 1- -s sp pe ee ed d TIC TIC vehicle vehicle 2 2. .3 36 63 3 1 1. .5 58 86 6 2 2. .2 21 17 7 1 1. .5 58 86 6 6.00-9 6.00-9 2-speed 2-speed TIC TIC vehicle vehicle - - - - - - - - ~ ~ Tonnage Tonnage K2 K2 ton ton serie series s K3 K3 ton ton serie series s E En ng gi in ne e 5 5K K 4 4Y Y II 1 10 0Z Z- -1 11 1 4 4Y Y II 10Z-11 10Z-11 MfTvehicle MfTvehicle 1.642 1.642 1.586 1.586 With With STO ti STO tires res 1-speed 1-speed TIC TIC vehicle vehicle 2.217 2.217 2-speed 2-speed TIC TIC vehicle vehicle Not Not provided provided ~ ~ Tonnage Tonnage 2 2 ton ton serie series s Engine Engine 5K 5K 4Y·10Z-11 4Y·10Z-11 II 2 Z . 2 Z . MfTvehicle MfTvehicle 2.00 2.00 1.846 1.846 2.75 2.75 https://www.forkliftpdfmanuals.com/
  • 45. With With STO t STO tires ires 1 speed 1 speed TIC TIC vehicle vehicle 2-speed 2-speed TIC TIC vehicle vehicle Not Not provided provided 2.75 2.75 II 2.363 2.363 Tonnage Tonnage 3.0 3.0 ton ton serie series s J3.5 J3.5 ton ton serie series s Engine Engine 4Y·10Z-11 4Y·10Z-11 2 Z 2 Z.. 4Y·10Z-11 4Y·10Z-11 2 Z 2 Z.. MfTvehicie MfTvehicie 2.00 2.00 2.083 2.083 With With STO tir STO tires es 1-speed 1-speed TIC TIC vehicle vehicle 2-speed 2-speed TIC TIC vehicle vehicle 2.75 2.75 2.363 2.363 2.75 2.75 2.217 2.217 WHEELS WHEELS TIRE TABLE TIRE TABLE • • : : In Indi dica cate tes s ST STD tir D tire for mod e for model el 0: 0: In Indi dica cate tes s ST STD tir D tire for ea e for each ty ch type pe 1 1.0 .0 Ton Vehicle Ton Vehicle 6. : Ind 6. : Indica icates tes OPT tir OPT tire e - - : : Not Not app applic licabl able e 1-13 1-13 Component Component Pneu Pneumati matic c Tir Tire e Pne Pneuma umati tic c Typ Type e Sol Solid id Ti Tire re Rim Rim J-Lug J-Lug Soft Soft White White Green Green Type Type Tir Tire e Siz Size e J- J-Lu Lug g Ti Tire re Si Size ze Non- Non- N No on n- - N No on n- - N No on n- - Puncture Puncture Punc Punctu ture re Pun Punct cture ure Puncture Puncture Divi Divided ded *' *' • • ~ ~ Standard Standard 6.00-9-10 6.00-9-10 6.00-9 6.00-9 Single Single Sid Side e ri ring ng *' *' Front Front Divided*' Divided*' ~ ~ Tires Tires Oversize Oversize 6.50-10-10 6.50-10-10 6.50-10 6.50-10 - - Sta Standar ndard d Doub Double le 4.50-12-8 4.50-12-8 0 0 4.50-12 4.50-12 ~ ~ Sid Side e ri ring *' ng *' Spec Special ial Doub Double le 6.00-9-10 6.00-9-10 ~ ~ 6.00-9 6.00-9 Divid Divided ed *2 *2 • • ~ ~ Rear Tires Rear Tires 5 5. .0 00 0- -8 8- -8 8 5 5. .0 00 0- -8 8 Sid Side e ri ring *2 ng *2 I I ~ ~ - - 1 1.5 .5 Ton & Ton & 1. 1.75 Ton Vehicle 75 Ton Vehicle Component Component Pneu Pneumati matic c Tir Tire e Pneu Pneumati matic c Type Type Sol Solid id Tir Tire e Rim Rim J J- -L Lu ug g S So of ft t W Wh hi it te e G Gr re ee en n Type Type Ti Tir re e Si Siz ze e J J- -L Lug ug T Ti ir re e S Si iz ze e N No on n- - N No on n- - N No on n- - Non- Non- https://www.forkliftpdfmanuals.com/
  • 46. Puncture Puncture Pun Punct ctur ure e Pun Punct ctur ure e Puncture Puncture Divi Divided ded *1 *1 6.50-10-10 6.50-10-10 • • 6.50-10 6.50-10 ~ ~ Standard Standard Single Single 6.00-9-10*3 6.00-9-10*3 ~ ~ 6. 6.00- 00-9 9 *3 *3 Front Front Tires Tires 21 21 x8-9-10 x8-9-10 ~ ~ 21x8-9 21x8-9 Sid Side e ri ring *1 ng *1 - - Stan Standard dard Doub Double le 4.50-12-8 4.50-12-8 0 0 4.50-12 4.50-12 ~ ~ Spec Special ial Doubl Double e 6.00-9-10 6.00-9-10 ~ ~ 6.00-9 6.00-9 Divi Divided ded *2 *2 • • ~ ~ Rear Tires Rear Tires 5.00-8-8 5.00-8-8 5.00-8 5.00-8 Sid Side e ri ring *2 ng *2 ~ ~ - - *1 *1 • • Div Divide ided d rim rims and s and sid side e rin ring g rim rims are a set wi s are a set with the th their ir res respec pectiv tive e exc exclus lusive ive hub hubs. s. • • Tir Tires es are inte are interch rchang angeab eable le bet betwee ween n div divide ided d rim rims, or be s, or betwe tween en sid side ring rims, e ring rims, but but are not inte are not interch rchang ange- e- abl able e bet betwe ween en div divide ided d rim rims and sid s and side e rin ring g rim rims. s. *2 *2 • • Div Divide ided d rim rims s and sid and side e rin ring g rim rims are a set wi s are a set with the th their ir res respec pectiv tive e exc exclus lusive ive hob hobs. s. • • Di Divid vided ed rim rims and s and sid side e rin ring g rim rims are not s are not int interc erchan hangea geable ble. . *3 *3 • • 6.0 6.00-9 0-9 is o is only set as STD for the nly set as STD for the 1.5 1.5 ton seri ton series es wit with h 5K. 5K. 1-14 1-14 K2. K2.0 0 Ton Ton & & K2.5 K2.5 Ton Ton Veh Vehicl icle e Pneumatic Tire Pneumatic Tire Pneumat Pneumatic ic Type Type Soli Solid d Tir Tire e Component Component R Rim im J-Lug J-Lug Soft Soft White White Green Green Tire Size Tire Size J- J-Lug Lug Ti Tire re Si Size ze Non- Non- Non- Non- Non- Non- Non- Non- Puncture Puncture Puncture Puncture Puncture Puncture Puncture Puncture Divided *1 Divided *1 21 21 x8-9-14 x8-9-14 • • Front Tires Front Tires 21 21 x8-9 x8-9 ~ ~ Side ring *1 Side ring *1 21 21 x8-9-14 x8-9-14 ~ ~ ~ ~ Divided *2 Divided *2 18x7-8-10 18x7-8-10 • • Rear Tires Rear Tires 18x7-8 18x7-8 Side ring *2 Side ring *2 18x7-8-16 18x7-8-16 ~ ~ *1 *1 • • Divi Divided ded rims and side ring rims are not intercha rims and side ring rims are not interchangeab ngeable. le. *2 *2 • • Div Divide ided d rim rims s and sid and side e rin ring rims are g rims are a s a set wi et with the th their ir res respec pectiv tive e exc exclus lusive ive hub hubs. s. • • Div Divide ided d rim rims s and side ring rims are and side ring rims are not int not interc erchan hangea geable ble. . 2.0 Ton 2.0 Ton & & 2.5 Ton 2.5 Ton Veh Vehicl icle e Component Component Pneumatic Pneumatic Tire Tire Pneumat Pneumatic ic Type Type Soli Solid d Tir Tire e Ri Rim m .J-Lug .J-Lug Soft Soft White White Green Green Type Type Tire Tire Size Size J-Lug J-Lug Tire Tire Size Size Non- Non- Non- Non- Non- Non- Non- Non- Puncture Puncture Puncture Puncture Puncture Puncture Puncture Puncture Divided *1 Divided *1 • • ~ ~ 7.00-12-12 7.00-12-12 Side ring *1 Side ring *1 ~ ~ Single Single 7.00-12 7.00-12 Front Front Center Center disc disc - - - - Tires Tires typesiderin9*2 typesiderin9*2 https://www.forkliftpdfmanuals.com/
  • 47. Stand Standard ard Double Double 5.50-15-8 5.50-15-8 0 0 5.50-15 5.50-15 ~ ~ Side ring *1 Side ring *1 Speci Special al Doubl Double e 7.00-12-12 7.00-12-12 ~ ~ 7.00-12 7.00-12 Divided Divided • • ~ ~ Rear Tires Rear Tires 6.00-9-10 6.00-9-10 6.00-9 6.00-9 Side ring *3 Side ring *3 - - ~ ~ Oversize Oversize Divided Divided *4 *4 6.50-10-10'4 6.50-10-10'4 6.50-10 6.50-10 *4 *4 ~ ~ *1 *1 • • Div Divide ided d rim rims s and sid and side e rin ring g rim rims s are a s are a set wi et with thei th their r res respec pectiv tive e exc exclus lusive ive hub hubs. s. • • Tir Tires es are int are interc erchan hangea geable ble bet betwee ween n div divide ided d rim rims, or be s, or betwe tween en sid side e rin ring rims, but a g rims, but are not int re not interc erchan hange- ge- abl able e bet betwe ween en div divide ided d rim rims and s and sid side e rin ring g rim rims. s. * * 2 2 . . Cen Center ter dis disc type side ring rims are int c type side ring rims are interc erchan hangea geable ble wit with h div divide ided d rim rims. s. * * 3 3 . . Sid Side e rin ring g rim rims are a s s are a set wi et with their exclu th their exclusiv sive e rea rear hubs r hubs. There . There is n is no int o interc erchan hangea geabil bility ity wit with h div divide ided d rim rims. s. * * 4 4 . . Opt Option for ion for 2.5 2.5 ton v ton vehi ehicle cle onl only. y. K3. K3.0 0 Ton Ton Veh Vehicl icle e 1-15 1-15 Pneu Pneumatic matic Tire Tire Pneu Pneumatic matic Type Type Soli Solid d Tire Tire Component Component Rim Rim J-Lug J-Lug S So of ft t W Wh hi it te e G Gr re ee en n Tire Size Tire Size J-Lug J-Lug T Ti ir re e S Si iz ze e N No on n- - Non- Non- N No on n- - N No on n- - Puncture Puncture Puncture Puncture Pun Punctu cture re Pun Punctu cture re Front Tires Front Tires Side Side ring ring 23x9-1 23x9-1 0-16 0-16 23x9-1 23x9-1 0 0 • • l::. l::. Rear Tires Rear Tires Side Side ring ring 18x7-8-16 18x7-8-16 18x7-8 18x7-8 3.0 Ton 3.0 Ton Veh Vehicl icle e Component Component Pneu Pneumati matic c Tire Tire Pneu Pneumati matic c Type Type Soli Solid d Tire Tire Rim Rim J-Lug J-Lug Soft Soft Wh Whi it te e G Gr re ee en n Type Type T Tir ire e Si Siz ze e J J-L -Lug ug Tire Tire Size Size Non- Non- N No on n- - N No on n- - Non- Non- Puncture Puncture Pu Punctur ncture e Punc Puncture ture Puncture Puncture Single Single 28x9-15-12 28x9-15-12 • • 28x9-15 28x9-15 l::. l::. Front Front 0 0 Tire Tire Standard Standard Double Double Side Side ring ring 6.00-15-10 6.00-15-10 6.00-15 6.00-15 - - Spec Special ial Doubl Double e 28x8-15-12 28x8-15-12 6 6 7.00-15 7.00-15 6 6 . . Divided Divided • • 6.50-10-10 6.50-10-10 6.50-10 6.50-10 l::. l::. Rear Tires Rear Tires Side Side ring· ring·1 1 6 6 Di Divi vid ded ed 6 6.5 .50- 0-10 10- -12 12 - - - - - - *1 *1 • • Divi Divided ded rims are inter rims are interchang changeabl eable. e. https://www.forkliftpdfmanuals.com/
  • 48. J3. J3.5 5 Ton Ton Veh Vehicl icle e Component Component Pneu Pneumatic matic Tire Tire Pneu Pneumatic matic Type Type Soli Solid d Tire Tire Rim Rim J J- -L Lu ug g S So of ft t W Wh hi it te e G Gr re ee en n Type Type Tire Tire Size Size J J- -L Lu ug g T Ti ir re e S Si iz ze e N No on n- - Non- Non- N No on n- - N No on n- - Punc Puncture ture Punc Puncture ture Punc Punctur ture e Pun Punctu cture re Single Single 250-15-16 250-15-16 • • 250-15 250-15 6 6 . . Front Front 0 0 Tire Tire Standard Standard Double Double 6.00-15-10 6.00-15-10 6.00-15 6.00-15 Side ring Side ring l::. l::. - - Spec Special ial Doub Double le 28x8-15-12 28x8-15-12 6 6 7.00-15 7.00-15 Rear Tires Rear Tires 6.50-10-12 6.50-10-12 • • 6.50-10 6.50-10 l::. l::. 1-16 1-16 CH CHANGE ANGE LEVE LEVER R GENERAL GENERAL Th The e sh shif ift t me mech chan anis ism m on manu on manual al tr tran ansm smis issi sion on ve vehi hicl cles es is is ch chan ange ged d fr from the om the co conv nven enti tion onal al li link ty nk type to the pe to the cable type. cable type. Adoption Adoption of of the the cable cable type type has has reduced reduced lever lever vibration vibration and and stroke, stroke, resulting resulting in in easier easier operation. operation. The The bra brace ce rod used rod used in in the the lin link type k type is is als also o eli elimin minate ated. d. https://www.forkliftpdfmanuals.com/
  • 49. STEERING STEERING TI TILT STEE LT STEERI RING NG LOCK LOCK MECHANI MECHANISM SM The The str struct ucture ure of t of the til he tilt steer t steering ing loc lock k mec mechan hanism ism has been cha has been change nged d as sh as shown own bel below. ow. 1-17 1-17 Old Old https://www.forkliftpdfmanuals.com/
  • 50. 1-18 1-18 FRAME-WEIGHT FRAME-WEIGHT HEAD GUARD HEAD GUARD For eas For easier ier mate materia riall hand handli ling ng in in an el an eleva evated ted loc locati ation, on, a roo a roof hole is f hole is pro provid vided ed in in the head guard the head guard roo roof. f. A A roo roof f cap is al cap is also provided so provided for oper for operation ation under under rainy weat rainy weather. her. WEIGHT WEIGHT The weigh The weight t mass has been chan mass has been changed. ged. https://www.forkliftpdfmanuals.com/
  • 51. Vehi Vehicle cle mode model l Tonnage Tonnage Weigh Weight t (kg) (kg) 1.0 1.0 400 400 1.35 1.35 610 610 1 to 1 ton n serie series s 1.5 1.5 745 745 1.75 1.75 880 880 2.0 2.0 1,140 1,140 Comp Compact act 2·3 2·3 ton ton 2.5 2.5 1,550 1,550 3.0 3.0 1,925 1,925 2.0 2.0 1,150 1,150 Stan Standard dard 2 2 ton series ton series 2.25 2.25 1,360 1,360 2.5 2.5 1,500 1,500 2.75 2.75 1,650 1,650 3 ton 3 ton serie series s 3.0 3.0 1,800 1,800 3.5 3.5 2,135 2,135 V V M MAST AST LIFT BRACKET LIFT BRACKET The V mast The V mast lif lift brac t bracket ket for the 1 for the 1.35 .35 and and 1.5 1.5 ton ve ton vehic hicles les has be has been chan en changed ged as as sho shown wn bel below. ow. 1-19 1-19 Old Old o o o o 6 6 Uft Uft roll rollers/ ers/vehi vehicle cle Ne New w o o o o 4 4 lift lift roll rollers/ ers/vehi vehicle cle https://www.forkliftpdfmanuals.com/
  • 52. TILT CYLINDER TILT CYLINDER The til The tilt cyl t cylind inder er rod rod gui guide de and cy and cylin linder der bot bottom tom end st end struc ructur tures es hav have been chan e been changed ged as as sho shown wn bel below. ow. Bush Bush Collar Collar rt-.l.-T'! rt-.l.-T'! I , I , . . • • • ' • ' I ' I '. . a-ring a-ring Grea Grease se groo groove ve Oil Oil groove groove 1-20 1-20 LIFT CYLINDER LIFT CYLINDER LIFT CYUNDER LIFT CYUNDER The The pis piston ton rod gu rod guide ide str struct ucture ure in in the the lif lift cyl t cylind inder er ASSY ASSY has bee has been n cha change nged d par partia tially lly. . Old Old RH RH LH LH I I I I 'I 'I https://www.forkliftpdfmanuals.com/
  • 53. . . . . I I I I Ne New w RH RH II II L L H H The stru The structu ctural ral cha change nge is is the sam the same e als also for th o for the e LH. LH. FSV FSV· ·FV FV FRO FRONT NT CYLIND CYLINDER ER FRONT CYUNDER FRONT CYUNDER The fron The front t cy cylin linder der str struct ucture ure has bee has been n cha change nged d par partia tially lly. . Old Old 1-21 1-21 https://www.forkliftpdfmanuals.com/
  • 54. New New 1-22 1-22 S SA AS S LIFTI LIFTING NG HEI HEIGHT GHT SWITC SWITCH H 1. 1. Sw Switch itch Le Leve ver r The switch The switch lev lever er rol roller str ler structu ucture re has been changed has been changed in in the lif the lifti ting ng hei height ght swi switch for durabi tch for durabili lity ty impr improvement ovement. . Old Old https://www.forkliftpdfmanuals.com/
  • 55. Ne New w 2. 2. Switch Switch Ca Case se The The lif liftin ting g hei height ght swi switch tch cas case e set bol set bolt has been t has been cha change nged d fro from m an ord an ordina inary ry to a t to a tapp apping ing bol bolt. t. 1-23 1-23 https://www.forkliftpdfmanuals.com/
  • 56. Ordi Ordinary nary bolt bolt T=9.8 T=9.8-15 -15.7 .7 N·m N·m (10 (100-1 0-160 60 kg kgf-c f-cm) m) (7.2 (7.23-11 3-11.57 .57 ft-Ib ft-Ibf] f] Tap Tapping ping bolt bolt T=22-25N'm T=22-25N'm (224 (224-225 -225 kgf- kgf-cm) cm) [16. [16.21-1 21-18.45 8.45 ft-Ib ft-Ibf] f] [Caution] [Caution] Whe When n the t the tapp apping ing bol bolt t is lo is loos osene ened d or re or remov moved ed, , remo remove remaini ve remaining ng alum aluminum inum part particle icles. s. MAN MANUAL UAL TRA TRANSM NSMISSI ISSION ON Page Page G EN ERAL G EN ERAL 2-2 2-2 SPE SPECI CIFIC FICATIO ATION NS S 2-3 2-3 CO COM M PO PON NEN ENTS TS 2-4- 2-4- MAN MANUAL UAL TRA TRANSM NSMISS ISSION ION ASS ASSY Y 2-6 2-6 ~E:~c ~E:~c:>"~· :>"~·I~!)1r I~!)1r~~1rI ~~1rIc:>~ c:>~ ...... ......•.... •........... ............. ............ ............ ............. ........... .... 2-6 2-6 DISA!) DISA!)!)E:~B !)E:~BLy·I~S Ly·I~SPE:C"O PE:C"O~·RE:A ~·RE:A!)SE:~ !)SE:~BLY BLY ...... ............ .........••. ...••.. . 2-10 2-10 SPEED SHAFT ASSY SPEED SHAFT ASSY 2-14 2-14 DI!)A! DI!)A!)!)E:~ )!)E:~BLY BLY ·1~!)P ·1~!)PE:C11C E:C11C:>~· :>~· ~ ~E E: :A A! !) )S SE E: :~ ~B BL LY Y 2 2- -1 14 4 COU COUNTE NTERSH RSHAFT AFT ASS ASSY Y 2-17 2-17 D DI I! !) )A A! !) )! !) )E E: :~ ~B BL LY Y· ·I I~ ~S SP PE E: :C C" "C C: :> >~ ~·~E ·~E: :A A! !) )S SE E: :~ ~B BL LY Y 2 2- -1 17 7 2-1 2-1 https://www.forkliftpdfmanuals.com/
  • 57. SH SHIFT LINK IFT LINK BR BRAC ACKET KET AS ASSY SY 2-22 2-22 DI!)A! DI!)A!)!)E:~ )!)E:~BLY·I~ BLY·I~SPE:C" SPE:C"c:>~ ·~ c:>~ ·~EA!)SE: EA!)SE:~BLY ~BLY ...... ........•... ..•......... ...... 2-22 2-22 SHI SHIFT FT LEV LEVER- ER-WIR WIRE E CAB CABLE LE 2-23 2-23 ~E~C: ~E~C:>"~ ·1~S >"~ ·1~S1r~~T 1r~~Tlc:>~ lc:>~ ...... ............ .........•.. ...•........ ............ ............. ............. .......... .... 2-23 2-23 2-2 2-2 GENERAL GENERAL https://www.forkliftpdfmanuals.com/
  • 58. SPECIFICATIONS SPECIFICATIONS 2-3 2-3 Tran Transmiss smission ion type type Full Full sync synchrom hromesh esh type type Oper Operating ating meth method od Floo Floor r shift shift link link meth method od Tran Transmiss smission ion case o case oil il capa capacity city l l (US gal) (US gal) 3.8 3.8 (1.0 (1.0) ) Tran Transmiss smission ion oil oil Hypoi Hypoid d gear gear oil oil Ge Gear ar ratio ratio Gear ratio Gear ratio Vehi Vehicle cle mode model l Engine Engine Forward Forward Reverse Reverse 1st speed 1st speed 2nd 2nd speed speed 1 1st st sp spe eed ed 2 2nd nd s spe peed ed 5K 5K 3.715 3.715 2.127 2.127 3.722 3.722 2.132 2.132 1 ton 1 ton serie series s 4Y-1DZ-1I 4Y-1DZ-1I 3.541 3.541 1.564 1.564 3_548 3_548 1.567 1.567 5K 5K 3.715 3.715 2.127 2.127 3.722 3.722 2.132 2.132 K2 ton K2 ton serie series s 4Y-1DZ-1I 4Y-1DZ-1I 3.541 3.541 1.564 1.564 3.548 3.548 1.567 1.567 5K 5K 3.715 3.715 2.127 2.127 3.722 3.722 2.132 2.132 https://www.forkliftpdfmanuals.com/
  • 59. 2 ton 2 ton serie series s 4Y-1DZ-1I 4Y-1DZ-1I 3.541 3.541 1.564 1.564 3.548 3.548 1.567 1.567 2Z 2Z 3.379 3.379 1.355 1.355 3.385 3.385 1.358 1.358 K3 ton K3 ton serie series s 4Y-1DZ-1I 4Y-1DZ-1I 3 3. .5 54 41 1 1 1. .5 56 64 4 3_548 3_548 1.567 1.567 4Y-1DZ-1I 4Y-1DZ-1I f f f f f f f f 3 ton series 3 ton series 2Z 2Z 3.379 3.379 1.355 1.355 3 3. .3 38 85 5 1 1. .3 35 58 8 4Y 4Y 3 3. .5 54 41 1 1 1. .5 56 64 4 3.548 3.548 1.567 1.567 J3.5 ton J3.5 ton serie series s 2Z 2Z 3 3. .3 37 79 9 1 1. .3 35 55 5 3 3. .3 38 85 5 1 1. .3 35 58 8 2-4 2-4 COMPONENTS COMPONENTS 3301 3301 https://www.forkliftpdfmanuals.com/
  • 61. 2-6 2-6 MANU MANUAL AL TR TRANSM ANSMISS ISSIO ION N ASSY ASSY REMOVAL-INSTALLATION REMOVAL-INSTALLATION T T = = N·m (kgf-c N·m (kgf-cm) m) [ft-I [ft-Ibf] bf] https://www.forkliftpdfmanuals.com/