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1. FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT
6FGCU15- 30. Please use this manual for providing quick, correct ser-
vicing of the corresponding forklift models.
This manual deals with the above models as of July 1995. Please
understand that disagreement can take place between the descriptions
in the manual and actual vehicles due to change in design and specifica-
tions. Any change or modifications thereafter will be informed by
Toyota Industrial Equipment Parts & Service News.
For the service procedures of the mounted engine, read the repair
manuals listed below as reference together with this manual.
(Reference)
Repair manuals related to this manual are as follows:
TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINE
REPAIR MANUAL (No. CE602)
TOYOTA INDUSTRIAL EQUIPMENT GM4-181 ENGINE
REPAIR MANUAL (No. CU629)
TOYOTA MOTOR CORPORATION

2. SECTION INDEX
GENERAL
ENGINE
NAME
TORQUE CONVERTER
DIFFERENTIAL
FRONT AXLE
REAR AXLE
STEERING
BRAKE
BODY
MATERIAL HANDLING SYSTEM
MAST
CYLINDER
OIL PUMP
OIL CONTROL VALVE
APPENDIX
SECTION

3. GENERAL
Page
EXTERIOR VIEWS ...............................................0-2
VEHICLE MODEL ................................................0-3
FRAME NUMBER ..............................................0-4
..........................HOW TO READ THIS MANUAL 0-5
EXPLANATION METHOD .......................................0-5
TERMINOLOGY ...................................................0-6
ABBREVIATIONS ..................................................0-6
OPERATIONAL TIPS ............................................0-7
STANDARD BOLT & NUT TIGHTENING
TORQUE ...........................................................0-8
BOLT STRENGTH TYPE IDENTIFICATION
..........................................................METHOD 0-8
................................TIGHTENING TORQUE TABLE 0-9
PRECOAT BOLTS ..............................................0-10
HIGH PRESSURE HOSE FITTING
.....................................TIGHTENING TORQUE 0-10
WIRE ROPE SUSPENSION ANGLE LIST .............0-11
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE .......................................0-11
COMPONENTS WEIGHT .....................................0-12
RECOMMENDED LUBRICANT
........................................QUANTITY & TYPES 0-13
........................................LUBRICATION CHART 0-14
..................................PERIODIC MAINTENANCE 0-15
PERIODIC REPLACEMENT OF PARTS
AND LUBRICANTS ...........................................0-21

4. EXTERIOR VIEWS
1 ton series
2-3 ton series

5. VEHICLE MODEL
Series
+1 ton series
2 ton series
L3 ton series
1.5 ton
1.75 ton
Engine typeEngine modelLoad capacity
2.0 ton
Drive systemModel
42-6FGCU15
42-6FGCU18
2.5 ton
3.0 ton
42-6FGCU20
52-6FGCU20
4Y
4Y
42-6FGCU25
52-6FGCU25
42-6FGCU30
52-6FGCU30
4Y
GM
Gasoline
t
4Y
GM
4Y
GM
Torque converter
'I
t
t
t
t
t
t
t
t
t
t
T
t

6. FRAME NUMBER
Frame No. Punching Position
Punching position
1 ton series
2 ton series I I
Punching formatEngine
3 ton series I I
Model
*: EEC Spec.

7. HOW TO READ THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with a photo or illustration.
Pattern B: ~xplanationof operation procedure by indic-sting step numbers in one illustration,
followed by explanation of cautions and notes summarized as point operations.
Example of description in pattern B
/ DISASSEMBLY.INSPECTION.REASSEMBLY Tightening torque unit T = N m (kgf-cm) [fb-lbfl
If a place or part cannot be indicated
directly, the part name is described on
the either side of the illustration.
Example: 1 Piping
Disassembly Procedure
1 Remove the cover. [Point 11
2 Remove the bush [Point 21 4- Operation explained later
3 Remove the gear.
1 Point operations Explanation of key point for operation with an illustration
[Point 1I &
Disassembly: Put a match mark when removing the pump cover.
6
[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.12 mm (0.7528 in)

8. 2. How to read components figures (Example)
(1) The components figure uses the illustration
in the parts catalog for the vehicle model.
Please refer to the catalog for checking the
part name.
The number at the right shoulder of each FIG number in parts catalog
components figure indicates the Fig. num-
ber inthe parts catalog.
3. Matters omitted in this manual
(1) This manual omits description of the following jobs, but perform them in actual operation:
@ Cleaning and washing of removed parts as required
@ Visual inspection (partially described)
TERMINOLOGY
Caution:
lmportant matters of which negligence may cause accidents. Be sure to abserve them.
Note:
Important items of which negligence may cause accidents, or matters in operation procedure re-
quiring special attention.
Standard: Values showing allowable range in inspection and adjustment.
Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONS
I LH 1 Left hand I STD I Standard
Abbreviation (code)
ASSY
I LLC I Long life coolant I T = I Tightening torque
I 0PT 1 Option I OOT I Number of teeth (00)
Meaning
Assembly
I RH 1 Right hand 1 L/ I Less
Abbreviation (code)
SST
01s
PS
SAE
Meaning
Special service tool
Society of Automotive
Engineers (USA)
Oversize
Power steering
U/S
W/
Undersize
With

9. OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire repe(s)with a sufficient reserve in
load capacity.
(3) Always disconnect the battery plugs before the inspection or servicing of electrical parts.
2. Tactful operation
Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pres-
sure gauge, etc.) and SSTs before starting operation.
Before disconnecting wiring, always check the cable color and wiring state.
When overhauling functional parts, complicated portions or related mechanisms, arrange the parts
neatly to prevent confusion.
When disassembling and inspecting such a precision part as the control valve, use clean tools
and operate in a clean location.
Follow the described procedures for disassembly, inspection and reassembly.
Replace, gaskets, packings and O-rings with new ones each time they are disassembled.
Use genuine Toyota parts for replacement.
Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
If no tightening torque is specified, tighten the bolt or nut according to the standard tightening
torque table.
3. Grasping the trouble state
When a trouble occurs, do not attempt immediate disassembly or replacement but first check if
the trouble requires disassembly or replacement for remedying.

10. STANDARD BOLT & NUT TIGHTENING TORQUE
Standard bolt and tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. Find out the type of the bolt from the list below and then find the bolt tightening torque from the table.
2. The nut tightening torque can be judged from the mating bolt type.
BOLT STRENGTH TYPE IDENTIFICATION METHOD
1. lndentification by bolt shape 2. Identification by part No.
Hexagon head boltShape and class Class
@- Bolt head No.
Parts No.
9161 1-40625
1T-LLength (rnm)
Hexagon
head bolt
0 No mark
No mark
iarneter
Hexagon
flange bolt
Length
HTwo protruding
lines
Hexagon
head bolt
Two protruding
lines
Hexagon
flange bolt
Stud bolt /
Three protruding
lines
Hexagon
head bolt
Part No.
92132-40614
Length (rnm)
Diameter (mm)
Four protruding
@ lines
Hexagon
head bolt
Welded bolt
iarneter
$- No mark
Stud bolt
Grooved

11. TIGHTENING TORQUE TABLE
Diameter
Class
I Specified torque
Pitch
rnm
1.O
1.25
1.25
1.25
1.5
1.5
1.O
1.25
N-m 1 kgf-cm 1 ft-lbf
I I
5.4 1 55 1 48 in.-lbf
I
13 / 130 1 9
25 260 j 19
47 11 480 i 35
75 1 760 j 55
113 1 1150 1 83
I I
I I
6.4 1 65 1 56 in.-lbf
I 1
16 ! 160 ] 12
N.rn / kgf-crn ft-lbf
I I
5.9 1 60 1 52 in.-lbf
14 / 145 / 10
I I
28 1 290 1 21
53 i 540 / 39
83 1 850 1 61
- I1 I -I I
I I
I I
I I
I I
I I
I I

12. PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the
following cases:
(a) After it is removed.
(b) When the precoat bolt is moved (loosened or tight-
ened) by tightness check, etc.
Note:
For torque check, use the lower limit of the allowable tight-
ening torque range. If the bolt moves, retighten it according
to the steps below.
2. Method for reuse of precoat bolts
(1) Wash the bolt and threaded hole. (The threaded hole
must be washed even for replacement of the bolt.)
(2) Parfectly dry the washed parts by air blowing.
(3) Coat the specified seal lock agent to the threaded por-
tion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces
with clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the
contact surfaces before installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten
the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
11.1116 - 12 UNF 1 118 (1200) [ 86.81 1 112 - 123 (1140 - 1250) 182.5 - 90.41 1 19 (0.75) 1
Nominal diameter
of screw
Hose inside
diameter
mm (in)
Standard tightening torque N.m (kgf-cm) [ft-lbfl
Standard Tightening range

13. WlRE ROPE SUSPENSION ANGLE LIST
Compres-
sion
SuspensionLifting
angle
Tension
Suspension
method
Cornpres-
sion
Lifting
angel method
Tension
1.OO time
1.04 time
1.16 time
0 time
0.27 time
0.58 time
I.OO time
2.00 time 1.73 time
SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE unit: N (ton) [Ibfl
6 mm
21380
(2.18)
(0.24 in)
[48071
Rope
31480
8 mm
(0.32 in)
(3.21
r70781
(0.4 in)
(5.02)
[ I1.691
diameter load .
0 O O0 1 30° 1 60° 1 90° O0 1
12.5 mm
76880
(0.5 in)
(7.84)
[ I73871
' Single-rope
14 mm
96400
(0.56 in)
(9.83)
1216751
Two-rope suspensionCutting Four-rope suspension
suspension

14. COMPONENTS WEIGHT Unit: kg (Ib)
'I Component I Weight (mass) i
Engine
Balance weight
Torque converter Wldifferential
1 2.5 ton model I Approx. 1520 (3352)
1 ton series
2.3 ton series
1.5 ton model
1.75 ton model
2.0 ton model
163 (359)
189 (416)
Approx. 925 (2040)
Approx. 1175 (2591)
Approx. 1115 (2459)
V mast ASSY Wllift bracket
(with lift cylinder, without fork, max.
lifting height: 3000 mm (118 in))
1 ton series
3.0 ton model
1 ton series
2 ton series
3 ton series
Approx. 340 (750)
(with lift cylinder max. lifting height:
3000 mm (118 in))
Approx. 1910 (4212)
Approx. 410 (904)
Approx. 475 (1047)
Approx. 590 (1301)
IV mast ASSY Lllift bracket and fork 1 12 ton series
3 ton series
Approx. 380 (838)
Approx. 465 (1025)

15. RECOMMENDED LUBRICANT QUANTITY & TYPES
Description Classification Application Quantity
Motor oil
SAE30
(SAE20 in cold area)
SAE20W-40
(SAEIOW-30 in cold
area)
Engine
4.0 l (1.06 US gal)
Gasoline
API
SD, SE
3.8 1 (I.OO US gal)
1 ton series
2.3 ton series
Torque converter ATF
14.0 1 (3.70 US gal)
1 ton series 5.4 1 (1.43 US gal)
API
GL-4
GL-5
Hypoid gear oil
SAE85W-90
2 ton series
3 ton series
6.4 1 (1.69 US gal )
6.4 l (1.69 US gal)
Differential
1 ton series 27 1 (7.1 US gal)
Hydraulic oil
[Max. for height =
3000 mm (118 in)]
2 ton -series 34 1 (9.0 US gal)Hydraulic oil
3 ton series
1 ton series
37 1 (9.8 US gal)
45 l (11.9 US gal)
2 ton series 65 l (17.2 US gal)Fuel tank
3 ton series 65 1 (17.2 US gal)
Proper quantity
Reservoir Tank
0.2 1 (0.05 US gal)
SAE J-1703
DOT-3
Brake line All models
Chassis parts See page 0-14. All models Proper quantity
LLC 30-50% mixture
(for winter or
all-season)
Cooland with rust-
inhibitor (for spring,
summer and autumn)
Coolant
(exclulding reservoir
tank)
Attached Table 1
Coolant volume
LLC
Coolant
(Reservoir Tank)
Attached Table 1 Coolant volume
All models
Unit: f2 (US gal)
1.1 1 (0.29 US gal)
(at Full level)
Engine 1 ton series 2 ton series 3 ton series

16. LUBRICATION CHART
0 Inspection
Replacement
@ MP grease
@ Engine oil
@ Hypoid gear oil
@ Hydraulic oil
@ Automatic transmission fluid
@ Brake flluid
@ Molykote G-n paste
Chain
Differential gear
Front wheel bearing
Brake master cylinder
Torque converter case
Rear wheel bearing
Steering knuckle king pin
Power steering cylinder pin
Oil tank
I. lnspect every 8 hours (daily)
II. lnspect every 40 hours (weekly)
Ill. lnspect every 170 hours (monthly)
IV. lnspect every 1000 hours (6 monthly)
V. lnspect every 2000 hours (annually)
10 Engine crankshaft
11 Tilt steering locking mechanism
12 Mast support bushing
13 Tilt cylinder front pin
1 4 Oil pump spline shaft
(GM engine model)

17. PERIODIC MAINTENANCE
INSPECTION METHOD
I : Inspection. Repair or replacement if required.
M : Measurement. Repair or adjustment if required.
T : Retightening C : Cleaning L : Lubrication
* : For new vehicle *1 : Flaw detector
ENGINE
Every
Inspection Period
1 month
Every
Item
170 hours
Main body
PCV system
Governor
Every
3 months
Every
500 hours
Lubrication
system
Fuel system
Every
6 months
Every
1000 hours
Cooling
system
Every
12 months
Every
2000 hours
Proper starting and abnormal noise
Rotating condition at idling
Rotating condition during
acceleration
Exhaust gas condition
Air cleaner element
Valve clearance
Compression
Cylinder head bolt loosening
Muffler rubber mount
Clogging and damage in PCV valve
and piping
No-load maximum rpm
Oil leak
Oil level
Clogging and dirt of oil filter
Fuel leak
Operation of carburetor link
mechanism
Dirt and clogging of fuel filter and
element
Coolant level in radiator and leak
Rubber hose degradation
Radiator cap condition
Fan belt tension, looseness and
damage
Radiator rubber mount

18. POWER TRANSMISSION SYSTEM
Every
Inspection Period
1 month
Every
Item
170 hours
Differential
Torque
converter
and
transmission
Every
3 months
Every
500 hours
Axle shaft
DRIVE SYSTEM
Every
6 months
Every
1000 hours
Wheels
Every
12 months
Every
2000 hours
Front axle
Rear axle
Leak
Oil level
Bolt loosening
Leak
Fluid level
Operating mechanism function and
looseness
Control valve and clutch functions
Inching valve function
Stall and hydraulic pressure
measurement
Tire cuts, damage and uneven
wearing
Loose rim and hub nuts
Tire groove depth
Metal chips, pebbles and other for-
eign matter trapped in tire grooves
Rim, side ring and disc wheel
damage
Abnormal sound and looseness of
front wheel bearing
Abnormal sound and looseness of
rear wheel bearing
Twisting and cracks of axle shaft I
Crack, damage and deformation of
housing
Cracks, damage and deformation of
beem
I
I

19. STEERING SYSTEM
Inspection Period
Item
Steering
wheel
Play and looseness
Function
Every
1 month
Every
170 hours
Steering
valve
Oil leak
Looseness of mounting
Every
3 months
Every
500 hours
I Oil leak I
Power
Steering
Mounting and linkage looseness
I
Every
6 months
Every
1000 hours
I I Damage of power steering hose I
Every
12 months
Every
2000 hours
Play and reserve
Brake pedal
Operating force
Knuckle
IParking 1 Braking effect
King pin looseness
Cracks and deformation
Ibrake
BRAKING SYSTEM
1 Rod and cable looseness and
damage
I I
Leak, damage and mounting con-
Brake pipe
dition
Reservoir
Itank
Clearance between drum and lining I
Leak and fluid level
Master cylinder and
wheel cylinder
Wear of shoe sliding portion and
lining
Drum wear and damage
Shoe operating condition
Anchor pin rusting
Function, wear, damage,
leak and mounting looseness
Brake drum
and brake
shoe
Return spring fatigue
I I Automatic adjuster function I
Backing
plate
Forks
Deformation, cracks and damage
Loose mounting
Misalignment between left and right
fork fingers
MATERIAL HANDLING SYSTEM
c
I Cracks at fork root and welded Dart I
tcAbnormality of fork and stopper pin I

20. Every
Inspection Period
1 month
Every
3 months
Every
6 months
Every
12 months
Every
170 hours
I
Every
500 hours
Every
1000 hours
Every
2000 hours
Deformation and damage of each
part and crack at welded part
Mast and lift bracket looseness
Wear and damage of mast support
bush
Wear, damage and rotating condi-
tion of rollers
Wear and damage of roller pins
Wear and damage of mast strip
Mast and lift
bracket
Tension, deformation and damage o
chain
Chain lubrication
Abnormality of chain anchor bolt
Wear, damage and rotating condi-
tion of chain wheel
Chain and
chain wheel
Various Abnormality and mounting condition
of each partattachments
HYDRAULIC SYSTEM
Loosening and damage of cylinder
mounting
Deformation and damage of rod, rod
screw and rod end
Cylinder operation
Natural drop and natural forward tilt
(hydraulic drift)Cylinder
Oil leak and damage
Wear and damage of pin and
cylinder bearing
Lifting speed
Uneven movement
Oil pump Oil leak and abnormal sound
Oil level and contamination
Tank and oil strainer
Oil leak
Hydraulic
oil tank
Control
lever
Loose linkage
Operation

21. Every
3 months
Every
500 hours
C
Inspection Period
Item
Every EveryEvery
1 month
Every
170 hours
Oil leak
I Oil control I Relief pressure measurement
valve
IRelief valve and tilt lock valve
functions
Oil leak
Deformation and damage
Hydraulic
piping
Loose joint I T
'STEM
lgnition
timing
Starting
motor
Cracks on distributor cap
Spark plug burning and gap
Distributor side terminal burning
Distributor cap center piece wear
and damage
Plug cord internal discontinuity
Ignition timing
Pinion gear meshing status
I Charger I Charging function
Battery
Battery fluid level
Battery fluid specific gravity
Damage of wiring harness
Fuses
Electrical
wiring
Head guard
Lighting
system
Function and mounting condition
I I
Back-rest
Cracks at welded portion
Deformation and damage
Loosening of mounting
Deformation, crack and damage
Horn
I
I
T
I
Function and mounting condition
c
c
c
+-
I
c
c
c
c
c
+-
c
c
c
c c

22. Every
Inspection Period
1 month
Every
170 hours
Direction
Function and mounting condition
indicator I I
Instruments Functions I
Backup
Function and mounting condition
buzzer
mirror ( Rear reflection status I I
Seat Loosening and damage of mounting
Mounting looseness
Webbing damage
Seat belt
Plate damage
I Buckle damage I
Body
Damage and cracks of frame, cross
members, etc.
Bolt looseness
Others 1 Grease up 1 L
Every Every
3 months 6 months
Every Every
500 hours 1000 hours
Every
12 months
Every
2000 hours

23. 0-21
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
a:Replacement
Engine oil I a I C 1 4 - I +
Every
Interval
1 month
Every
Item
170 hours
Every
3 months
Every
500 hours
Engine oil filter
Engine coolant (every 2 years for LLC)
Differential oil I 1 I 1
Fuel filter
Torque converter oil
Torque converter oil filter
Every
6 months
Every
1000 hours
a*?
Wheel bearing grease I I I I
Every
12 months
Every
2000 hours
Hydraulic oil
Hydraulic oil return filter
- -
+
c
4-
axl
Spark plugs
Air cleaner element
Power steering rubbers parts I I 1 1 ax2
4-
c
Cups and seals for brake master and wheel
cylinders
Brake fluid
Power steering hoses
Hydraulic hoses I 1
t
t
Brake fluid reservoir tank hose I 1 I 1 ax2
c
t
+
4-
ax2
Fuel hoses
Torque converter rubber hoses
Replacement shall be made upon arrival of the operation hours or months, whichever is earlier.
ax2
a*2
Chains a*3
*I: for new vehicle **: Every 2 years *3: Every 3 years

25. ENGINE
Page
ENGINE EXTERIOR VIEWS .................................. 1-2
MAJOR SPECIFICATIONS ...................................1-4
ENGINE PERFORMANCE CURVES ......................1-5
ENGINE ASSY .....................................................1-6
ENGINE REMOVAL.INSTALLATION ........................1-6
ENGINE SPEED ADJUSTMENT ...........................1-9
......................................................AIR CLEANER I-I I
...........................................................RADIATOR 1 5-I
MUFFLER & EXHAUST PIPE ...............................1-17
BATTERY .............................................................1-21
STARTING MOTOR .............................................1-23
.....................................................ALTERNATOR 1-24
.......................................ACCELERATOR PEDAL 1-26

26. ENGINE EXTERIOR VIEWS
4Y Engine

27. GM Engine

28. MAJOR SPECIFICATIONS
Engine type 1 Gasoline 4-cycle I +- I c
GM (2.3 ton series)
Engine
Valve mechanism I 0HV.chain drive ( c
Number of cylinders and
arrangement
Combustion chamber type
OHV gear drive
4Y (1 ton series)
Bore x stroke
4Y (2.3 ton series)
Inline 4-cylinder
.longitudinal
Wedge type
Total displacement cc (cu-in) ( 2237 (136.511 1 t
4-
c
Maximum torque kgf-mlrpm 1 16.511800 1 t
C
c
Compression ratio
Maximum power PSIrpm
Maximum specific fuel
consumption g/PS-h (rpm)
1 200 (19001 1 200 123001 1 230 (16001
Service weight kg (Ibl 1 134 (295) 1 t
8.8
4512100
No-load maximum rpm rPm 1
c
5412400
8.2
6012400

29. ENGINE P E R F O R M A N C E C U R V E S
4Y Engine
G a s o l i n e 16 Y l r n
---Exclusive Type
16.OIlBW
------Convenble~ y p e
15.011600
i
L ib ih I; 22 26x10'
Engine Speed (rpm)
1 ton series
G a s o l i n e 15.011600
---Exclusive Type
/-
I
6C 10 14 18 22 26X 10'
EngineSpeed (rpm)
2.3 ton series
GM Engine
G a s o l i n e 18.0/1200
--- LPG Only
------Gasolineand LPG
Engine Speed (rpm)

30. ENGINE ASSY
ENGINE REMOVAL-INSTALLATION
Radiator cover
Toe board
Coolant
Fuel hose
Acceleration wire
Electrical wiring
Engine
Housing set bolt

31. Removal Procedure
Remove the radiator cover.
Remove the engine hood.
Remove the toe board.
Remove the battery and battery case.
Remove the radiator reservoir tank and bracket.
Remove the air cleaner.
Drain the coolant.
Remove the radiator and fan shroud.
Disconnect the exhaust pipe.
Disconnect the fuel hose. [Point 11
Disconnect the accelerator wire (on the carburetor side).
Remove the oil pump Wlpump hose. (4Y)
Remove the pump universal joint. (GM)
Disconnect the electorical wiring.
Remove the cover plate.
Remove the drive plate set bolts. (6 pieces) [Point 21
Slightly hoist the engine.
Support the
Remove the
Remove the
Remove the
Remove the
Remove the
Remove the
Remove the
bottom of the torque converter case with wooden blocks.
housing set bolt.
engine mounting set nut.
engine mounting bracket.
engine ASSY. [Point 31
flywheel.
starting motor.
torque converter end plate.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Drive plate set bolts (flywheel set bolts)
/ 14.71 - 21.57 (150 - 220) f10.85 - 15.921
1(for connecting to toraue converter)
Note:
Carry out the following job after engine installation.
Tighten the flywheel set bolts after applying thread tightener (08833-00070).
The tightening torque for each part is as follows:
Unit: N-m (kgf-cm) [ft-lbfl
Torque converter end plate set bolts
Drive plate set bolts (for connecting to the
engine crankshaft)
49.03 - 78.45 1500 - 800) i36.18 - 57.881
4Y: 56.88 - 64.72 (580 - 660) [41.96 - 47.751
GMmIDZ: 76.49 - 93.16 (780 - 950) 156.43 - 68.731
-
Torque converter housing set bolts
Engine mounting set nut
29.42 - 44.13 (300 - 450) [21.71 - 32.561
53.9 - 99.0 (550 - 1010) f39.8 - 73.11

32. SST
Point Operations
[Point 1I
Removal: Always close the fuel cock piping.
Installation: Do not mistake the fuel hose connecting po-
sition.
[Point 21
Removal.Installation: Rotate the flywheel by using a crank-
shaft pulley set bolt.
[Point 31
Removal.Installation: SST 09010-20111-71
Removal: Remove after checking through disconnection
of the wiring, hoses and cables.

33. connector
hose
ENGINE SPEED ADJUSTMENT
4Y-GM Engine
Idle up and Idling Speed Inspection and Adjustment
1. Warm up the engine.
Coolant temperature: 80°C (176OF) or above
Engine oil: 70°C (158OF) or above
Hydraulic oil temperature: 50°C (122OF) or above
Auto choke cancellation
2. Install the engine tachometer.
3. lnspect and adjust the idle up speed.
Disconnect the idle up actuator hose and inspect the
idle up speed.
4Y: 1250 & 25 rpm
GM: 1050 ~t50 rpm
Turn the adjusting screw (A) to adjust the idle up
speed.
Increasing the speed: Clockwise turn
Decreasing the speed: Counterclockwise turn
Connect the idle up actuator hose.
4. lnspect and adjust the idling speed.
(1) lnspect the idling speed.
Idling speed + 50
4Y-GM: 750 rpm
(2) Turn the idle adjusting screw (B) to adjust the idling
speed.
(3) If the speed cannot be decreased by turning the ad-
justing screw (B), make adjustment as follows:
@ Raise the coolant temperature when the auto choke
cam is in contact with the throttle lever roller.
@ When the idle up actuator rod is in contact with
the adjusting screw (A), turn the adjusting screw
counterclockwise.

34. @ To decrease the speed
@ To increase the speed
Maximum speed adjustment
No-load Maximum Speed Inspection and Adjustment
1. Warm up the engine.
Coolant temperature: 80°C (176OF) or above
Engine oil temperature: 70°C (158OF) or above
Hydraulic oil temperature: 50°C (122OF) or above
2. Install the engine tachometer
3. lnspect the no-load maximum speed.
No-load maximum speed
4Y (1 ton series): 2450 * 50 rprn
4Y (2.3 ton series): 2650 & 50 rprn
GM: 2600 * 50 rprn
4. Adjust the no-load maximum speed.
(1) Remove the sealing wire.
(2) Fully depress the accelerator pedal, and make ad-
justment by means of the air governor adjusting nut
and screw.
Relief speed adjustment
5. lnspect the relief speed.
Operate the material handling lever when the engine is
running at the maximum speed and measure the engine
speed in the full relief state. Confirm that the speed
decrease (relief down) satisfies the following value.
Engine speed down at full relief
4Y: 250 rprn or less
GM: 250 rprn or less
6. Seal the engine with wire after adjustment.
Note:
Turn the adjusting nut clockwise to increase the engine speed.
Turn the screw clockwise to increase the engine speed.
If the engine speed decrease in relief state is excessive, turn the adjusting nut clockwise and the screw
counterclockwise. In the process of this adjustment, the engine is about to start hunting. Stop adjust-
ment immediately before hunting starts.
If the engine running at the maximum speed is not stabilized (hunting), turn the adjusting nut counter-
clockwise and the screw clockwise. Excessive turning may increase the relief down the cause hunting.
If the relief down is about 200 rprn in the new vehicle state or is 300 rprn or above, make adjustment
by means of the engine, carburetor and air governor.

35. AIR CLEANER
GENERAL
SPECIFICATIONS
TYpe
Size
IFiltering area
crn2 (in2) I
Intake type
Cyclone type
6-inch
+
t
Fresh air introduction type
14000 (2170.0)
c
Outer: 14000 (2170.0)
Inner: 570 (88.4)
Others With dust discharge valve c

36. COMPONENTS

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