1. This manual covers service procedures for Toyota forklifts including engine, transmission, steering, and brake systems.
2. It provides illustrations and descriptions to guide technicians through removal, inspection, and reinstallation of components.
3. The manual includes specifications, torque values, and periodic maintenance schedules to ensure correct servicing.
Hyundai r170 w 3 wheel excavator service repair manualdueikdkmem
1. The document provides instructions for removing and installing a pilot valve assembly, as well as disassembling and assembling the valve.
2. To remove the assembly, the work equipment must be lowered, pressure released from lines, and hoses disconnected before removing the pilot valve assembly. Installation is the reverse of removal.
3. Disassembly involves cleaning parts, removing springs, seals, and housing pieces. Assembly requires reinstalling these parts in reverse order and torquing fasteners to specified values.
Hyundai r140 w 9 wheel excavator service repair manualdueikdkmem
This document provides instructions for removing and assembling front and rear axles. It describes:
1) Removing various components of the front axle like the mounting bolts, propeller shaft nut, and oscillating cylinder bolts.
2) Removing components of the rear axle like the mounting bolts, propeller shaft nut, and hoses.
3) General safety instructions for working on axles including using proper tools and PPE, cleaning procedures, and marking work areas.
4) Detailed steps for disassembling and assembling the planetary reduction and axle shaft, including removing the carrier cover, hub, gears, and bearings.
Hyundai r140 lc 7 crawler excavator service repair manualdueikdkmem
The document describes the structure of various components. It lists over 100 different components, each labeled with a name. The names seem to indicate parts of a machine or device, though it is not entirely clear from the document alone what the overall system or device is. The components are organized into two sections that provide information on their structure and assembly.
Hyundai r130 lc 3 crawler excavator service repair manualdueikdkmem
The document provides instructions for removing and installing a hydraulic pump. It describes:
1. Removing the pump by loosening fittings, draining oil, disconnecting hoses and bolts, and lifting out the pump assembly.
2. Installing the pump by reversing the removal steps, cleaning and replacing filters, bleeding air from the system, and checking for leaks.
3. The main pump structure including its components and connections.
4. Tools and torque specifications for working on the pump.
Hyundai r110 7 a crawler excavator service repair manualdueikdkmem
This document provides instructions for removing, disassembling, and assembling a swing motor and reduction gear.
The removal process involves disconnecting hoses and pilot lines, loosening bolts, and removing the swing motor assembly. Disassembly involves removing snap rings, seals, bearings, pistons, plates, and other internal components. Assembly is the reverse of disassembly, applying loctite and ensuring proper alignment of parts. Reduction gear removal requires removing mounting bolts and the assembly, while disassembly involves separating carriers, gears, pins, and seals.
Daewoo doosan solar 225 lc v excavator operator and maintenance manualdueikdkmem
1. The document is an operation and maintenance manual for a Daewoo excavator that contains safety information and instructions.
2. It warns of serious injury or death risks from unsafe excavator operation and maintenance, and emphasizes the importance of understanding all safety procedures before working on the machine.
3. The manual identifies the locations of various safety labels on the excavator that provide warnings for hazards like high voltage, rotating parts, hot surfaces, and proper lifting procedures.
Daewoo doosan solar 210 w v wheel excavator operator and maintenance manualdueikdkmem
1. The document provides safety information and instructions for operating and maintaining a Daewoo excavator.
2. It identifies the location of safety labels on the excavator and summarizes precautions that must be followed when lifting loads in digging mode.
3. Operators and maintenance personnel are warned to read the manual thoroughly before operating or servicing the machine to avoid risk of serious injury or death from unsafe practices.
Daewoo doosan solar 170 w v wheel excavator operator and maintenance manualdueikdkmem
This document provides safety information and operating instructions for a Daewoo excavator. It includes sections on general safety, safety labels, lifting precautions, worksite precautions, operation, equipment, maintenance, transportation, specifications and troubleshooting. Operators must read and understand the manual before use to safely operate the excavator.
Hyundai r170 w 3 wheel excavator service repair manualdueikdkmem
1. The document provides instructions for removing and installing a pilot valve assembly, as well as disassembling and assembling the valve.
2. To remove the assembly, the work equipment must be lowered, pressure released from lines, and hoses disconnected before removing the pilot valve assembly. Installation is the reverse of removal.
3. Disassembly involves cleaning parts, removing springs, seals, and housing pieces. Assembly requires reinstalling these parts in reverse order and torquing fasteners to specified values.
Hyundai r140 w 9 wheel excavator service repair manualdueikdkmem
This document provides instructions for removing and assembling front and rear axles. It describes:
1) Removing various components of the front axle like the mounting bolts, propeller shaft nut, and oscillating cylinder bolts.
2) Removing components of the rear axle like the mounting bolts, propeller shaft nut, and hoses.
3) General safety instructions for working on axles including using proper tools and PPE, cleaning procedures, and marking work areas.
4) Detailed steps for disassembling and assembling the planetary reduction and axle shaft, including removing the carrier cover, hub, gears, and bearings.
Hyundai r140 lc 7 crawler excavator service repair manualdueikdkmem
The document describes the structure of various components. It lists over 100 different components, each labeled with a name. The names seem to indicate parts of a machine or device, though it is not entirely clear from the document alone what the overall system or device is. The components are organized into two sections that provide information on their structure and assembly.
Hyundai r130 lc 3 crawler excavator service repair manualdueikdkmem
The document provides instructions for removing and installing a hydraulic pump. It describes:
1. Removing the pump by loosening fittings, draining oil, disconnecting hoses and bolts, and lifting out the pump assembly.
2. Installing the pump by reversing the removal steps, cleaning and replacing filters, bleeding air from the system, and checking for leaks.
3. The main pump structure including its components and connections.
4. Tools and torque specifications for working on the pump.
Hyundai r110 7 a crawler excavator service repair manualdueikdkmem
This document provides instructions for removing, disassembling, and assembling a swing motor and reduction gear.
The removal process involves disconnecting hoses and pilot lines, loosening bolts, and removing the swing motor assembly. Disassembly involves removing snap rings, seals, bearings, pistons, plates, and other internal components. Assembly is the reverse of disassembly, applying loctite and ensuring proper alignment of parts. Reduction gear removal requires removing mounting bolts and the assembly, while disassembly involves separating carriers, gears, pins, and seals.
Daewoo doosan solar 225 lc v excavator operator and maintenance manualdueikdkmem
1. The document is an operation and maintenance manual for a Daewoo excavator that contains safety information and instructions.
2. It warns of serious injury or death risks from unsafe excavator operation and maintenance, and emphasizes the importance of understanding all safety procedures before working on the machine.
3. The manual identifies the locations of various safety labels on the excavator that provide warnings for hazards like high voltage, rotating parts, hot surfaces, and proper lifting procedures.
Daewoo doosan solar 210 w v wheel excavator operator and maintenance manualdueikdkmem
1. The document provides safety information and instructions for operating and maintaining a Daewoo excavator.
2. It identifies the location of safety labels on the excavator and summarizes precautions that must be followed when lifting loads in digging mode.
3. Operators and maintenance personnel are warned to read the manual thoroughly before operating or servicing the machine to avoid risk of serious injury or death from unsafe practices.
Daewoo doosan solar 170 w v wheel excavator operator and maintenance manualdueikdkmem
This document provides safety information and operating instructions for a Daewoo excavator. It includes sections on general safety, safety labels, lifting precautions, worksite precautions, operation, equipment, maintenance, transportation, specifications and troubleshooting. Operators must read and understand the manual before use to safely operate the excavator.
Daewoo doosan solar 170 lc v excavator operator and maintenance manualdueikdkmem
This document is an operation and maintenance manual for a Daewoo Solar 170LC-V excavator. It contains sections on safety, operating controls, operation, inspection, maintenance, transportation, troubleshooting, specifications, and an index. The safety section provides warnings and cautions regarding safe operation, maintenance, lifting capacity, and work-site precautions.
Daewoo doosan solar 160 w v wheel excavator operator and maintenance manualdueikdkmem
The document provides safety information and instructions for operating and maintaining a Daewoo excavator. It includes locations of safety labels on the machine, precautions for lifting loads, unauthorized modifications, hazards, starting and operating the machine, maintenance, batteries, towing, shipping and lift capacity tables. Operators and maintenance personnel must read the manual thoroughly before use to safely handle, operate and service the excavator.
The document provides instructions for removing and installing various engine components, including:
- Valve guides are removed from the cylinder head using a valve guide driver tool. New guides are installed using driver tools until the proper height is reached.
- Valve seat inserts are removed from the cylinder head using extractors. New inserts are installed using a driver tool after being cooled.
- The engine oil filter base, oil filter, and oil cooler are removed. Hoses are disconnected and bolts removed to access these components.
1. The document provides instructions for disassembling and assembling the piston pump of a 336D2 excavator.
2. The disassembly process involves removing 27 individual parts in a specific order, taking care with spring-loaded components.
3. Reassembly requires installing the parts in the reverse order, with various tools used to set clearances and retain components. Proper cleaning of parts is emphasized.
The document provides instructions for disassembling and assembling the piston pump (hydraulic fan) of an excavator model 336D2. The disassembly procedure involves removing 22 parts from the pump housing, including springs, seals, pistons, and bearings. The assembly procedure lists 30 steps to reinstall the parts in reverse order and adjust clearances using various tools. Precautions are provided to prevent injury from spring forces.
This document provides instructions for installing a final drive and travel motor on an excavator. It outlines 11 steps, including positioning the travel motor and final drive with lifting devices, installing O-rings and seals, connecting hoses and fittings, and tightening bolts to specified torques. Safety notices are provided to handle fluids properly and keep components clean from contaminants. Required tools include vacuum caps, link brackets, and anti-seize compound.
This document provides instructions for removing and installing a unit injector hydraulic pump on Caterpillar C9 engines. The removal procedure involves disconnecting tubes, hoses and harnesses from the pump before removing mounting bolts and the pump. For installation, the process is reversed - mounting bolts are installed and all connections reattached. Proper cleaning and use of new O-rings is emphasized to prevent contamination.
This document provides instructions for disassembling and assembling the travel motor on 336D2 and 336D2 L excavators. The disassembly process involves using various tools to remove components like retaining rings, seals, pistons, springs, and bearings. The assembly process describes installing these components in reverse order and notes that cleanliness is important, components should be lubricated, and parts must be installed in their proper positions and orientations.
The document provides step-by-step instructions to disassemble a travel motor from an excavator model 336D2. It lists 27 steps to remove components from the travel motor including removing the motor head assembly, piston assemblies, barrel assembly, springs, seals and other internal parts. Detailed illustrations accompany each step to show how to remove, disassemble and safely release spring forces from parts like pistons during the process. Protective equipment is recommended to safely complete the disassembly.
This document provides instructions for removing and installing a unit injector and unit injector sleeve on a Caterpillar C9 engine. It outlines the required tools and safety procedures. The key steps include cleaning parts, installing new seals, using tools to remove and install components, and refilling fluids after installation. Proper installation is important to prevent leaks and engine issues.
Caterpillar cat 336 d l excavator (prefix ptb) service repair manual (ptb0000...dueikdkmem
This document provides assembly instructions for a 336D L excavator transmission in 3 sentences:
It lists the required tools and parts, gives step-by-step instructions for assembling the transmission components which include gears, carriers, shafts, seals, and housing, and notes that cleanliness is important during assembly and O-rings and seals should always be replaced.
Caterpillar cat 336 d l excavator (prefix mds) service repair manual (mds0000...dueikdkmem
The document provides instructions for disassembling and assembling a piston pump (hydraulic fan) on an excavator. It outlines 30 steps to disassemble the pump, removing components like the head, port plate, bearings, pistons, and swashplate. It then lists 27 steps to reassemble the pump, replacing components in the reverse order and taking precautions around spring-loaded parts. The instructions specify using the proper tools and cleaning parts thoroughly during assembly.
Caterpillar cat 336 d l excavator (prefix m4t) service repair manual (m4t0000...dueikdkmem
The document provides instructions for removing and installing a final drive and travel motor on a 336D L excavator. It details 13 steps for removal, including disconnecting hoses, removing bolts and covers, and lifting out the final drive assembly. For installation, 11 steps are specified, such as positioning seals and components, installing bolts, reconnecting hoses, and filling fluids. Safety notices are provided regarding containing fluids and preventing contamination. Required tools are listed for each procedure.
Caterpillar cat 336 d l excavator (prefix j2f) service repair manual (j2f0000...dueikdkmem
The document provides instructions for removing and installing the final drive and travel motor on a 336D L excavator. It describes 13 steps for removal, including draining fluids, disconnecting hoses, and removing mounting bolts. 11 steps are listed for installation, covering tasks like replacing seals, positioning components, and reconnecting hoses. Tools and safety precautions are also outlined.
Caterpillar cat 330 f ln excavator (prefix wba) service repair manual (wba000...dueikdkmem
The document provides instructions for disassembling a 330F L excavator travel motor. It lists 28 steps to completely disassemble the travel motor, removing components like the head, springs, pistons, bearings, and housing. Various tools are required including an adapter, bolts, nuts, retaining ring pliers, and a bearing puller group. Safety precautions are provided throughout to warn of spring forces, pressurized air, and being struck by parts.
Caterpillar cat 330 f ln excavator (prefix kfa) service repair manual (kfa000...dueikdkmem
The document provides instructions for removing and installing a vibration damper and pulley assembly on a Caterpillar C7.1 engine. To remove it, a tool is used to prevent the crankshaft from rotating while the pulley assembly screws are removed with a torque socket. The assembly is then lifted off. To install it, the components are assembled in reverse order and tightened using guide studs and torque specifications. The process involves up to 21 steps and ensures proper alignment of parts to prevent damage and wear.
Caterpillar cat 330 f ln excavator (prefix jhf) service repair manual (jhf000...dueikdkmem
This document provides instructions for disassembling and assembling the final drive of an excavator model 330F. It begins with disassembly steps including removing the final drive assembly and various gears, shafts, and housings. It then describes assembling the final drive by cleaning parts, pressing in bearings, installing seals, adjusting bearing preload with shims, and reinstalling gears and housings. The summary provides an overview of the key steps and goals of the document.
Caterpillar cat 312 d l excavator (prefix kes) service repair manual (kes0000...dueikdkmem
The document provides instructions for removing and installing a flywheel housing on a Caterpillar C4.2 engine. It describes:
1) Removing the electric starting motor, flywheel, and ring gear before removing the flywheel housing.
2) Using lifting tools to remove the flywheel housing bolts and separate the housing from the cylinder block.
3) Installing a new gasket and oil seal before reinstalling the housing and torquing the bolts.
4) Reinstalling the flywheel and electric starting motor after installing the flywheel housing.
Caterpillar cat 312 d l excavator (prefix jbc) service repair manual (jbc0000...dueikdkmem
This document provides disassembly instructions for the final drive, travel motor, and various other components of excavator models 312D and 312D L. It lists required tools and outlines multi-step procedures for removing parts like sprockets, valves, gears, seals, and other components. Safety precautions are provided throughout regarding hazards such as heavy lifting, pressurized fluids, and released spring forces. Detailed illustrations accompany each step for clarity.
Caterpillar cat 312 d l excavator (prefix hcw) service repair manual (hcw0000...dueikdkmem
1) The document provides instructions for installing the crankshaft on a C4.2 engine. Steps include installing thrust washers, bearings, seals, and caps.
2) Crankshaft end play is checked after installation using a dial indicator. Connecting rods and pistons are then installed.
3) The procedure describes checking crankshaft rotation and installing remaining components like the oil supply tube to complete the crankshaft installation.
Daewoo doosan solar 170 lc v excavator operator and maintenance manualdueikdkmem
This document is an operation and maintenance manual for a Daewoo Solar 170LC-V excavator. It contains sections on safety, operating controls, operation, inspection, maintenance, transportation, troubleshooting, specifications, and an index. The safety section provides warnings and cautions regarding safe operation, maintenance, lifting capacity, and work-site precautions.
Daewoo doosan solar 160 w v wheel excavator operator and maintenance manualdueikdkmem
The document provides safety information and instructions for operating and maintaining a Daewoo excavator. It includes locations of safety labels on the machine, precautions for lifting loads, unauthorized modifications, hazards, starting and operating the machine, maintenance, batteries, towing, shipping and lift capacity tables. Operators and maintenance personnel must read the manual thoroughly before use to safely handle, operate and service the excavator.
The document provides instructions for removing and installing various engine components, including:
- Valve guides are removed from the cylinder head using a valve guide driver tool. New guides are installed using driver tools until the proper height is reached.
- Valve seat inserts are removed from the cylinder head using extractors. New inserts are installed using a driver tool after being cooled.
- The engine oil filter base, oil filter, and oil cooler are removed. Hoses are disconnected and bolts removed to access these components.
1. The document provides instructions for disassembling and assembling the piston pump of a 336D2 excavator.
2. The disassembly process involves removing 27 individual parts in a specific order, taking care with spring-loaded components.
3. Reassembly requires installing the parts in the reverse order, with various tools used to set clearances and retain components. Proper cleaning of parts is emphasized.
The document provides instructions for disassembling and assembling the piston pump (hydraulic fan) of an excavator model 336D2. The disassembly procedure involves removing 22 parts from the pump housing, including springs, seals, pistons, and bearings. The assembly procedure lists 30 steps to reinstall the parts in reverse order and adjust clearances using various tools. Precautions are provided to prevent injury from spring forces.
This document provides instructions for installing a final drive and travel motor on an excavator. It outlines 11 steps, including positioning the travel motor and final drive with lifting devices, installing O-rings and seals, connecting hoses and fittings, and tightening bolts to specified torques. Safety notices are provided to handle fluids properly and keep components clean from contaminants. Required tools include vacuum caps, link brackets, and anti-seize compound.
This document provides instructions for removing and installing a unit injector hydraulic pump on Caterpillar C9 engines. The removal procedure involves disconnecting tubes, hoses and harnesses from the pump before removing mounting bolts and the pump. For installation, the process is reversed - mounting bolts are installed and all connections reattached. Proper cleaning and use of new O-rings is emphasized to prevent contamination.
This document provides instructions for disassembling and assembling the travel motor on 336D2 and 336D2 L excavators. The disassembly process involves using various tools to remove components like retaining rings, seals, pistons, springs, and bearings. The assembly process describes installing these components in reverse order and notes that cleanliness is important, components should be lubricated, and parts must be installed in their proper positions and orientations.
The document provides step-by-step instructions to disassemble a travel motor from an excavator model 336D2. It lists 27 steps to remove components from the travel motor including removing the motor head assembly, piston assemblies, barrel assembly, springs, seals and other internal parts. Detailed illustrations accompany each step to show how to remove, disassemble and safely release spring forces from parts like pistons during the process. Protective equipment is recommended to safely complete the disassembly.
This document provides instructions for removing and installing a unit injector and unit injector sleeve on a Caterpillar C9 engine. It outlines the required tools and safety procedures. The key steps include cleaning parts, installing new seals, using tools to remove and install components, and refilling fluids after installation. Proper installation is important to prevent leaks and engine issues.
Caterpillar cat 336 d l excavator (prefix ptb) service repair manual (ptb0000...dueikdkmem
This document provides assembly instructions for a 336D L excavator transmission in 3 sentences:
It lists the required tools and parts, gives step-by-step instructions for assembling the transmission components which include gears, carriers, shafts, seals, and housing, and notes that cleanliness is important during assembly and O-rings and seals should always be replaced.
Caterpillar cat 336 d l excavator (prefix mds) service repair manual (mds0000...dueikdkmem
The document provides instructions for disassembling and assembling a piston pump (hydraulic fan) on an excavator. It outlines 30 steps to disassemble the pump, removing components like the head, port plate, bearings, pistons, and swashplate. It then lists 27 steps to reassemble the pump, replacing components in the reverse order and taking precautions around spring-loaded parts. The instructions specify using the proper tools and cleaning parts thoroughly during assembly.
Caterpillar cat 336 d l excavator (prefix m4t) service repair manual (m4t0000...dueikdkmem
The document provides instructions for removing and installing a final drive and travel motor on a 336D L excavator. It details 13 steps for removal, including disconnecting hoses, removing bolts and covers, and lifting out the final drive assembly. For installation, 11 steps are specified, such as positioning seals and components, installing bolts, reconnecting hoses, and filling fluids. Safety notices are provided regarding containing fluids and preventing contamination. Required tools are listed for each procedure.
Caterpillar cat 336 d l excavator (prefix j2f) service repair manual (j2f0000...dueikdkmem
The document provides instructions for removing and installing the final drive and travel motor on a 336D L excavator. It describes 13 steps for removal, including draining fluids, disconnecting hoses, and removing mounting bolts. 11 steps are listed for installation, covering tasks like replacing seals, positioning components, and reconnecting hoses. Tools and safety precautions are also outlined.
Caterpillar cat 330 f ln excavator (prefix wba) service repair manual (wba000...dueikdkmem
The document provides instructions for disassembling a 330F L excavator travel motor. It lists 28 steps to completely disassemble the travel motor, removing components like the head, springs, pistons, bearings, and housing. Various tools are required including an adapter, bolts, nuts, retaining ring pliers, and a bearing puller group. Safety precautions are provided throughout to warn of spring forces, pressurized air, and being struck by parts.
Caterpillar cat 330 f ln excavator (prefix kfa) service repair manual (kfa000...dueikdkmem
The document provides instructions for removing and installing a vibration damper and pulley assembly on a Caterpillar C7.1 engine. To remove it, a tool is used to prevent the crankshaft from rotating while the pulley assembly screws are removed with a torque socket. The assembly is then lifted off. To install it, the components are assembled in reverse order and tightened using guide studs and torque specifications. The process involves up to 21 steps and ensures proper alignment of parts to prevent damage and wear.
Caterpillar cat 330 f ln excavator (prefix jhf) service repair manual (jhf000...dueikdkmem
This document provides instructions for disassembling and assembling the final drive of an excavator model 330F. It begins with disassembly steps including removing the final drive assembly and various gears, shafts, and housings. It then describes assembling the final drive by cleaning parts, pressing in bearings, installing seals, adjusting bearing preload with shims, and reinstalling gears and housings. The summary provides an overview of the key steps and goals of the document.
Caterpillar cat 312 d l excavator (prefix kes) service repair manual (kes0000...dueikdkmem
The document provides instructions for removing and installing a flywheel housing on a Caterpillar C4.2 engine. It describes:
1) Removing the electric starting motor, flywheel, and ring gear before removing the flywheel housing.
2) Using lifting tools to remove the flywheel housing bolts and separate the housing from the cylinder block.
3) Installing a new gasket and oil seal before reinstalling the housing and torquing the bolts.
4) Reinstalling the flywheel and electric starting motor after installing the flywheel housing.
Caterpillar cat 312 d l excavator (prefix jbc) service repair manual (jbc0000...dueikdkmem
This document provides disassembly instructions for the final drive, travel motor, and various other components of excavator models 312D and 312D L. It lists required tools and outlines multi-step procedures for removing parts like sprockets, valves, gears, seals, and other components. Safety precautions are provided throughout regarding hazards such as heavy lifting, pressurized fluids, and released spring forces. Detailed illustrations accompany each step for clarity.
Caterpillar cat 312 d l excavator (prefix hcw) service repair manual (hcw0000...dueikdkmem
1) The document provides instructions for installing the crankshaft on a C4.2 engine. Steps include installing thrust washers, bearings, seals, and caps.
2) Crankshaft end play is checked after installation using a dial indicator. Connecting rods and pistons are then installed.
3) The procedure describes checking crankshaft rotation and installing remaining components like the oil supply tube to complete the crankshaft installation.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
Fleet management these days is next to impossible without connected vehicle solutions. Why? Well, fleet trackers and accompanying connected vehicle management solutions tend to offer quite a few hard-to-ignore benefits to fleet managers and businesses alike. Let’s check them out!
Welcome to ASP Cranes, your trusted partner for crane solutions in Raipur, Chhattisgarh! With years of experience and a commitment to excellence, we offer a comprehensive range of crane services tailored to meet your lifting and material handling needs.
At ASP Cranes, we understand the importance of reliable and efficient crane operations in various industries, from construction and manufacturing to logistics and infrastructure development. That's why we strive to deliver top-notch solutions that enhance productivity, safety, and cost-effectiveness for our clients.
Our services include:
Crane Rental: Whether you need a crawler crane for heavy lifting or a hydraulic crane for versatile operations, we have a diverse fleet of well-maintained cranes available for rent. Our rental options are flexible and can be customized to suit your project requirements.
Crane Sales: Looking to invest in a crane for your business? We offer a wide selection of new and used cranes from leading manufacturers, ensuring you find the perfect equipment to match your needs and budget.
Crane Maintenance and Repair: To ensure optimal performance and safety, regular maintenance and timely repairs are essential for cranes. Our team of skilled technicians provides comprehensive maintenance and repair services to keep your equipment running smoothly and minimize downtime.
Crane Operator Training: Proper training is crucial for safe and efficient crane operation. We offer specialized training programs conducted by certified instructors to equip operators with the skills and knowledge they need to handle cranes effectively.
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At ASP Cranes, customer satisfaction is our top priority. We are dedicated to delivering reliable, cost-effective, and innovative crane solutions that exceed expectations. Contact us today to learn more about our services and how we can support your project in Raipur, Chhattisgarh, and beyond. Let ASP Cranes be your trusted partner for all your crane needs!
Implementing ELDs or Electronic Logging Devices is slowly but surely becoming the norm in fleet management. Why? Well, integrating ELDs and associated connected vehicle solutions like fleet tracking devices lets businesses and their in-house fleet managers reap several benefits. Check out the post below to learn more.
What Could Be Behind Your Mercedes Sprinter's Power Loss on Uphill RoadsSprinter Gurus
Unlock the secrets behind your Mercedes Sprinter's uphill power loss with our comprehensive presentation. From fuel filter blockages to turbocharger troubles, we uncover the culprits and empower you to reclaim your vehicle's peak performance. Conquer every ascent with confidence and ensure a thrilling journey every time.
1. This manual covers the service procedures of the TOYOTA FORKLIFT
7FGU/7FDU15-32seriesand 7FGCU20-32series.Pleaseusethismanual
for providing quick, correct servicingof the correspondingforklift mode;&.
Thismanualdeals withthe above modelsas of October 1999.Pleaseunder-
standthat disagreementcantakeplacebetweenthedescriptionsinthemanual
and actual vehicles due to change in designand specifications. Any change
or modifications thereafter will be informed by Toyota Industrial Equipment
Parts & Service News.
For the service proceduresof the mounted engine, read the repair manuals
listedbelow as referencetogether with this manual.
(Reference)
Repair manuals relatedto this manual are as follows:
TOYOTAINDUSTRIAL EQUlPMENT4YENGINE
REPAIRMANUAL (NO. CE602-1)
TOYOTAINDUSTRIALEQUIPMENT1DZ-I1ENGINE
REPAIRMANUAL (NO. CE618-1)
TOYOTA Material Handling Company
A Division of TOYOTA INWSRIESCORPORATION
2. SECTIONINDEX
I W E 1 SECTIONI
GENERAL
ENGINE
TORQUE CONVERTER&
TRANSMISSION
PROPELLER SHAFT
DIFFERENTIAL
FRONT AXLE
REAR AXLE
STEERING
BRAKE
BODY
yI
MAST
CYLINDER
OIL PUMP
OIL CONTROL VALVE
$3
3. GENERAL
Page
EXTERIOR VIEWS ........................................................ 0-2
VEHICLEMODEL .........................................................0-3
FRAMENUMBER ...........................................................0-4
HOW TO USE THIS MANUAL ....................................0-5
EXPLANATIONMETHOD ................................................0-5
TERMINOLOGY..............................................................0-6
ABBREVIATIONS ............................................................0-6
OPERATIONAL TIPS ....................................................0-7
HOISTING THE VEHICLE...........................................0-8
ATTENTIVE POINTS ON SAS .................................... 0-8
CIRCUIT TESTER ............................................ 0-9
STANDARD BOLT & NUT TIGHTENING
TORQUE ............................................................ 0-11
BOLTSTRENGTHTYPEIDENTIFICATIONMETHOD ......0-11
TIGHTENINGTORQUETABLE ........................................0-12
PRECOAT BOLTS ........................................................0-13
HIGHPRESSURE HOSE FITTING
TIGHTENING TORQUE ............................................0-13
WIRE ROPE SUSPENSION ANGLE LIST ...............0-14
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSIONANGLE............................................... 0-14
COMPONENTS WEIGHT.............................................0-15
RECOMMENDEDLUBRICANT
QUANTITY & TYPES ................................................. 0-16
LUBRICATIONCHART .................................................0-18
..........................................PERIODIC MAINTENANCE 0-19
PERIODIC REPLACEMENT OF PARTS AND
LUBRICANTS...............................................................0-25
5. 0-3
VEHICLEMODEL
Pneumatic Tire Models (Pn)
Cushion Tire Models (Cu)
Classificatron
*: USA and CANADA Only
Load Capaclty
3000 Ibs
3500 Ibs
4000 Ibs
5000 Ibs
6000 Ibs
6500 Ibs
Series
Pnl ton series
Pn2ton series
Pn3 ton series
Model
Pn15
Pn18
Pn20
-
Pn25
Pn30
Pn32
Classification
VehicleModel
7FGU15
7FDU15
7FGU18
7FDU18
7FGU20
7FDU20
7FGU25
7FDU25
7FGU30
7FDU30
*7FGU32
*7FDU32
Load Capacity
4000 Ibs
5000 Ibs
6000 Ibs
Series
Cu2ton series
Cu3ton series
Model
Cu20
Cu25
Cu30
TransmissionType
TC
TIC
T/C
TIC
TIC
TK;
TK;
TK;
TIC
T/C
T/C
T/C
Cu32 1 6500 lbs / *7FGCU32 TIC
VehicleModel
7FGCU20
7FGCU25
7FGCU30
I
4Y
Engine
TransmissionType
TIC
TIC
TIC
Gasoline
Engine
4Y
1DZ-ll
4Y
1DZ-ll
4Y
1DZ-ll
4Y
1DZ-11
4Y
1DZ-ll
4Y
1DZ-ll
4Y
4Y
4Y
Gasoline
Diesel
Gasoline
Diesel
Gasoline
Diesel
Gasoline
Diesel
Gasoline
Diesel
Gasoline
Diesel
Gasoline
Gasoline
Gasoline
6. FRAMENUMBER
Frame No. Punching Position
Pneumatictire
Cushiontire
Series
1 ton series
Engine
2 ton series
3 ton series
4Y
1DZ-ll
4Y
Vehiclemodel
7FGU15
4Y
*: EEC spec.
Punchingformat
.
7FGU18
7FDU20
7FDU25
7FGU30
2 ton series
3 ton series
7FGU18-60011
7FGU25
7FDU25-60011
7FGU32-60011
7FGU25-60011
1DZ-ll
4Y
4Y
7FDU30
7FDU32
7FGCU20
7FGCU25
7FGCU30
I
7FDU32-60011
7FGCU25-60011
I 7FGCU25@60011
7FGCU32-60011
7. HOW TO USE THIS MANUAL
EXPLANATIONMETHOD
1. Operationprocedure
(1) The operationprocedure is describedin either patternA or patternB below.
PatternA: Explanationof eachoperation stepwithillustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, fol-
lowed by explanation of cautions and notes summarized as point operations.
Example of descriptionin pattern B
Step Nos. are partially sometimes
omitted in illustrations.
When a part requiring tightening
torque instructionis not indicatedin
the illustration,the part name is de-
scribed in the illustrationframe.
T= 46.1 -48.1
(470 -490)
r34.0-35.5)
8
DISASSEMBLY-INSPECTION-REASSEMBLY Tghteningtorqueunit T= N.m(kgf-cm)[ft-lbfl
DisassemblyProcedure
1 Remove the cover. [Point 11
2 Remove the bushing[Point 21 C Operation explained later
3 Remove the gear.
Point Operations Explanationof key point for operationwith an illustration
[Point 11
LL
Disassembly: Put a match mark when removing the pump cover.
[Point 21
Inspection: Measurethe bush inside diameter.
Limit: 19.12 mm(0.7528 in)
8. 2. How to read components figures (Example)
(1) Thecomponentsfigureusestheillustration
in the parts catalog for the vehicle model.
Please refer to the catalog for checkingthe
part name.
The number at the right shoulder of each
components figure indicates the Fig. num-
ber in the parts catalog.
FIGnumber inpartscatalog
3. Matters omitted inthis manual
(1) This manual omits description of the following jobs, but perform them in actual operation:
@ Cleaning and washing of removedparts as required
@ Visualinspection(partially described)
TERMINOLOGY
Caution:
lmportantmattersnegligenceof whichmaycausephysicaldamage. Be sure to observethem.
Note:
lmportant items negligence of which may cause breakage or breakdown. And operation pro-
cedure requiring special attention.
Standard: Values showing allowable range in inspection and adjustment.
Limit: Maximum or minimum allowable value in inspection or adjustment.
Abbreviation(code)
ASSY
Meaning Abbreviation(code) Meaning
Assembly
Cu Cushiontiremodels
--
LH Lefthand
SAE
SAS
SST
5-m
T =
TK;
O O T
U/S
W/
U
U C
M/T
Societyof Automotive
Engineers (USA)
System of active stability
Specialservicetool
Standard
Tighteningtorque
Torqueconverter &
transmission
Number of teeth (00)
Undersize
With
Less
Longlifecoolant
--
Manualtransmission
--
No-loadmaximum
speed
OPT
01s
Pn
PS
QFV
Option
Oversize
Pneumatic tiremodels
Power steering
4-stagemast
(Quadruple)
11. 1-3
MAJOR SPECIFICATIONS
Gasoline Engines
Diesel Engines
4Y (Pn3 ton series)
t
t
t
t
t
t
c
Gasoline :43 (58)/2600
GasolinelLPG :38 (52)/2600
LPG :40 (54)/2600
t
t
t
I 2800
Item
Engine type
Numberofcylindersanda@gpr~tent- -
. -
Combustionchambertype
Valvemechanism
Bore x stroke mm(in)
Totaldisplacement cm3(in3
)
Compressionratio
Maximumpower kW(PS)lrpm
Maximumtorque N.m (kgf-m)lrpm
Minimum specific fuel
consumption g/kW-h(g/PS-h)/rpm
Serviceweight kg(Ib)
No-load maximum rpm Tm
Note:
For 2.3 ton series 1DZ-I1 models equipped with vehicle speed control system (OPT), the spec.
figures and performance curve are same with those of 1 ton series 1DZ-II models.
Pnl.2 ton series
Cu2-3ton series
Gasolinek y c l e
lnline4 cylinders
longitudinal
Wedgetype
OHV-chaindriven
91.0 x 86.0
(3.583 x 3.386)
2237(136.51)
8.8
Gasoline :40 (54)/2400
GasolinelLPG :35 (48)/2400
LPG :37 (50)/2400
Gasoline :I62 (16.5)11800
GasolinelLPG :I47 (15.0)11600
LPG :I57 (16.0)11800
Gasoline :272 (200)/2300
GasolinelLPG :258 (190)/2400
LPG :252 (185)/2400
134 (295)
2600
Enginetype
Numberofcylindersandarrangement
Combustionchamber type
Valvemechanism
Bore x stroke mm(in)
Totaldisplacement cm3(in3
)
Compressionratio
Maximumpower kW (PS)lrpm
Maximumtorque N.m (kgf-m)lrpm
Minimum specificfuel
consumption glkW-h(g/PS-h)/rpm
Serviceweight kg (Ib)
No-loadmaximum rpm rpm
1DZ-11(Pnl ton series)
Diesel4-cycle
lnline 4cylinderslongitudinal
Whirlchamber type
OHV-geardriven
86.0 x 107.0
(3.386 x 4.213)
2486 (151.71)
21.5
40 (55)/2400
167 (17.0)/1600
252(185)/1400
162(357)
2600
1DZ-I1(Pn2-3tonseries)
t
t
t
t
C
t
t
44 (60)/2600
t
t
t
2800
12. Point Operations
[Point 11
Removal:
Put a match marks on the fuel hose and the coupler.
[Point 21
Removal:
Put a match mark on the radiator and torque converter
cooler hose.
[Point 31
Removal-Installation:
SST 09010-20111-71 -- GI
09010-23320-71 -4
Removal:
Tentatively hoist up until the mounting bolt completely
comes out from the hole in the frame.
[Point 41
Removal:
Use a straight-edge screwdriver for separation. If the fit-
ting is too tight, change the SST hook position and adjust
the engine angle for easier separation.
13. AIR BLEEDING FROM FUEL SYSTEM
(DIESEL VEHICLE)
1. Operate the hand pump of the fuel filter until the pump
operatingforce becomes heavy.
ENGINE SPEED INSPECTION AND ADJUSTMENT
Note:
Warm up the engine, set the vehicle to the following conditions, and conduct inspection and ad-
justment.
Coolant temperature: 80°C (176OF)or more, engine oil: 70°C (158'F) or more, operating oil tem-
perature: 50°C (122OF)or more, auto choke in release state (4Y engine)
B
tor
4YENGINE
Idling speed and idle up speed inspection and adjust-
ment
<Gasoline Vehicle>
1. Install the engine speedometer.
2. Disconnect the idle up actuator and inspect the idle up
speed.
Standard: 1000 a 30rpm
3. If the measured value is out of the specifiedrange, ad-
just by turning adjusting screw B.
4. Connect the idleup actuator.
5. Check the idling speed.
Standard: 800+ 5rpm
6. If the measuredvalue is out of the specified range, ad-
just by adjusting screw A.
7. If the speed is still higher after adjustment in 3 above,
adjust usingthe followingprocedure:
14. A
Regulator
(1) If the autochoke cam is contactingalthoughthe cool-
ant temperature is as specified above, replace the
auto choke.
(2) If the idle up actuator rod and adjusting screw B are
incontactwitheachother, turnadjustingscrew 6coun-
terclockwise.
<LPG/Gasolineor LPG>
1. Install the engine speedometer.
2. Disconnect the idle up actuator and inspect the idle up
speed.
Standard:
LPGIGasoline: 1000 2 30 rpm
3. Check theidlingspeed.
Standard:
LPGIGasoline: 800 :,sarpm
LPG: 800 :,50 rpm
4. If themeasuredvalueis out of the specifiedrange, make
adjustment according to the followingprocedure:
(1) Make adjustment by turning adjusting screw B (LPG
vehicle) or C (LPGIgasolinevehicle).
(Iflessthanthe standard, turnadjustingscrewAcoun-
terclockwisebeforehand.)
(2) Slowly turn adjusting screw A clockwise or counter-
clockwise until the maximum speed is obtained.
(3) Determine the positions of adjusting screws B and C
by repeating steps (1)and (2)untilthe value obtained
in step (2) satisfies the standard.
(4) Slowly turn adjusting screw A clockwiseuntil the CO
concentrationbecomes 2 to 3%, and then turn it 45
degreescounterclockwisefrom thepositionwherethe
speed begins to drop.
15. No-load Maximum Speed Inspection-Adjustment
<Gasoline, LPG or LPGlGasolineVehicle>
1. Install the engine speedometer.
2. Inspect and adjust the no-load static maximum speed.
(1) Measure thespeedwhen the acceleratorpedalis fully
depressed.
Standard:
4Y engine:
Pnl-2 ton series: ..........2600 f 50 rpm
Cu2-3ton series: ..........2600 f 50 rpm
Pn3 ton series: ............. 2800 f 50 rpm
(2) If the measured value does not satisfy the
standard,make adjustment as follows:
Remove the seal and loosen the lock bolt.
@ Fully depressthe accelerator pedal.
@ Turn the bushing for adjustment, while holding the
adjustingscrew of the air governorimmovablewith
a straight-edgescrewdriver.
3. Check and adjust relief down.
(1) Operate the tilt lever fully backward with the engine
runningat the maximum speed, and measure the de-
crease in speed (relief down) upon full relief.
Standard: Within 300 rpm
(2) If the measured value is out of the standard range,
make adjustment according to the following proce-
dure:
@ Turn the adjusting screw counterclockwise to de-
crease relief down.
@ Returnthe screwby 1110 of a turnto eliminatetwist-
ing of the spring in the air governor.
@ Adjust the no-loadmaximum speed.
@ Repeatsteps @, @and @untilthemeasuredvalue
satisfies the standard.
4. Check and adjust hunting.
(1) Check for hunting upon tilt relief at the no-load maxi-
mum speed.
(2) If hunting occurs a few times or more, make adjust-
ment according to the following procedure:
@ Turn the adjusting screw clockwise by 112 of a turn
or more.
@ Returnthe screwcounterclockwiseby 114 of a turn.
@ Finally,.tumit by 1110 of a turnto eliminatetwisting
of the spring in the air governor.
@ Adjust the no-loadmaximum speed.
@ Repeat steps @through@until hunting occurs no
more.
5. Repeat adjustmentsin steps 2 to4 until respectivestan-
dards are satisfied.
6. Seal the lock bolt.
16. 1DZ-llENGINE
Idle Speed Inspection.Adjustrnent
1. Install the engine speedometer.
2. Check the idle speed.
Standard: 750 f 25 rpm
3. If the measuredvalueis out of the standard,loosen the
locknut andmake adjustmentby turningadjustingscrew
A.
No-load Maximum Speed Inspection.Adjustment
1. Install the engine speedometer.
2. Inspect and adjust the no-load maximum speed.
(1) Measurethe speedwhen the acceleratorpedalis fully
depressed.
Standard:
1DZ-ll engine:
....................1 ton series: 2600 f 50 rpm
Vehicle speed control
..............system spec.: 2600 f 50 rpm
2.3 ton series: .................2800 f50 rpm
(2) If the measured value does not satisfy the standard,
make adjustment as follows:
@ Remove the seal and loosen the lock nut.
@ Make adjustment by turning adjusting screw B.
3. Check and adjust relief down.
(1) Operate the tilt lever fully backward with the engine
running at the maximum speed and measure the de-
crease in speed (relief down) upon full relief.
Standard: Within 200 rpm
4. Seal the adjusting screws after the end of adjustment.
18. Vehicle without
AIR CLEANER CLEANING-INSPECTION
1. Open the engine hood.
2. Remove the element.
Note: -
In case of the double element type (OPT), do not remove
the inner element for other than replacement.
3. Clean the element.
(1) For ordinarycleaning,blow with compressedair [690
kPa (7kgflcm2) [I00 psi] or less] vertically along the
pleats from the inside of the element.
If heavily contaminated, washing is possible.
(2) Element washing method
Dissolveneutraldetergentintepidwater (approx. 40°C
(104°F)) and immerse the element in it for about 30
minutes. Then, rinse the element well with clear wa-
ter. [Water pressure:275 kPa(2.8 kgflcm2
)[40 psi] or
less]
After washing, naturally dry the element or dry the
element with a dryer (cold air).
Note:
Do not damage the element during washing.
Never use compressed air or hot air for drying.
4. Clean the evacuator valve (dust discharge valve).
(7) Holdthe tip end of the evacuator valve and discharge
dust and dirt from the inside of the valve.
5. Inspect the element.
(1) After cleaning,place an electricbulbin theelement to
inspect any damage in the element. If any pinhole,
tear or damage is found, replace it witti a new ele-
ment.
6. Element replacement
Replace the elementafter it is washed six times or gen-
erally at intervals of 12 months.
7. Installthe element.
(1) Install the evacuator valve in the illustrated direction.
19. CLOGGING WARNING SYSTEM INSPECTION
1. Warning lamp inspection
(1) See thattheair cleanerwarninglampcomeson when
the ignition switch is turned ON and goes out when
the,enginestarts.
2. Individualinspection
(1) Use a mity vac to apply a negative pressure to the
vacuum switch, and inspect conduction.
Standard
Gasoline models:
2942 2 294 Pa (300 2 30 mm H20)
(22.1 f 2.2 mmHg) [11.81 f 1.18 in H,O]
[0.870 2 0.087 in Hg]: Conduction
Diesel models:
7473 f 569 Pa (762 2 58 mm H,O)
(56.0 2 4.3 mmHg) r30.00 +2.28 in H20]
[2.205 f 0.169 in Hg]: Conduction
RADIATOR
COMPONENTS
20. SPECIFICATIONS
COOLANT CAPACIN AND ANTIFREEZE TABLE Unit: e(US gal)
Type
Fin type
Coolantcapacity(inradiator)
Capopeningpressure kPa(kgflcm2
)[psi]
Others
Crossflow
Cormgatedfin
See thetablebelow
88 i 14.7 (0.9 i0.15) [13 f 2.11
Builtintorqueconvertercooler
Note:
The total amount of coolant does not include the capacity of the reservoir tank.
Reservoir tank capacity: 0.6t (0.16 US gal) (at FULL mark position)
Radiator
capacity
Total
amountof
coolant
8.5 (2.24)
8.5 (2.24)
9.6 (2.53)
9.6(2.53)
8.5 (2.24)
Pnl ton series
Pn2.3 ton series
Cu2.3 ton series
LLC mixing
ratio at 30%
(to-15OC
(5OF))
2.6 (0.69)
2.6 (0.69)
2.9 (0.77)
2.9 (0.77)
2.6 (0.69)
4Y
lDZ-Il
4Y
1DZ-II
4Y
2.7 (0.71)
2.7 (0.71)
3.7 (0.98)
3.7 (0.98)
2.7 (0.71)
LLC mixing
ratio at 50%
(to-35OC
(-31°F))
4.3 (1.14)
4.3 (1.14)
4.8 (1.27)
4.8 (1.27)
4.3 (1.14)
Antirust
mixing at
5%
0.4 (0.11)
0.4 (0.11)
0.5 (0.13)
0.5 (0.13)
0.4 (0.11)
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22. MUFFLER & EXHAUST PIPE
COMPONENTS
Gasoline model 1702
1702-362A
Diesel model
(UL-DS)
1702-361A
23. Note:
The muffler can be removed by either of the two methods shown below.
@ Remove the muffler after removing the counterweight.
@ Remove the muffler after removing the radiator Wlcounterweight.
Here, method @is explained.
RemovalProcedure
1 Remove the counterweight. (See p. 9-7.)
2 Disconnect the exhaust pipe.
3 Remove the muffler Witail pipe.
4 Disconnect the tail pipe from the muffler.
Installation Procedure
The installationprocedure is the reverse of the removal procedure.
CATALYTIC MUFFLER MAINTENANCE
Replace the muffler ASSY every year (2000 hours) on either the gasoline or diesel engine vehicle.
24. BATTERY
COMPONENTS
SPECIFICATIONS
Battery type list (The battery is selected according to the equipped engine.)
1DZ-ll
STD
GR35 GR24R
(JIS55D23L) (JIS80D26L)
GR24R
(JIS80D26L)
c
55
c
19.0 (41.9)
GR35
(JIS 55D23L)
Voltage V
5-hour rate capacity Ah
Specific gravity of battery
fluidinuse (at 20°C (68°F))
Battery weight kg (Ib)
12
48
1.280
16.2 (35.7)