Toyota 5fdc30 forklift service repair manual

FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT 5FGC/5FDC18-30 Series. Please use this manual for providing quick, correct servicing of the corresponding forklift models.

This manual deals with the above models as of August 1986. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Vehicles' Parts & Service News.

For the service procedures of the mounted engine, read the repair manuals listed below as reference together with this manual.

(Reference) Repair manuals related to this manual are as follows: TO YO TA INDUSTRIAL VEHICLE 4 Y ENGINE REPAIR MANUAL (No. CE602) TOY0TA INDUSTRIAL VEHICLE 2 J ENGINE REPAIR MANUAL (No. CE603)

TOYOTA MOTOR CORPORATION

SECTION INDEX GENERAL - - -

I

TORQUE CONVERTER PROPELLER SHAFT DIFFERENTIAL FRONT AXLE REAR AXLE STEERING BRAKE BODY

y 0

' MAST

CYLINDER OIL PUMP OIL CONTROL VALVE APPENDIX

GENERAL

Page VEHICLE EXTERIOR VIEWS

.......................... 0-2

VEHICLE MODELS ...................................

ABBREVIATIONS & TIPS ON OPERATION

..........

STANDARD BOLT & NUT TIGHTENING TORQUE ...

PRECOAT BOLTS

.....................................

HIGH PRESSURE HOSE FllTlNG TIGHTENING TORQUE .............................

FRAME NUMBER ....................................

SAFE LOAD BY WIRE ROPE SUSPENSION ANGLE .............................

WIRE ROPE SUSPENSION ANGLE LIST

.............

CAPACITY AND TYPES OF SPECIFIED LUBRICANTS ..........................

LUBRICATION

........................................

PERIODIC MAINTENANCE TABLE ...................

PERIODIC REPLACEMENT PARTS & LUBRICANTS ......................................

VEHICLE EXTERIOR VIEWS

Vehicle Front View

LAPI 8-8

Vehicle Rear View

LAPI 8-4

VEHICLE MODELS

I

Ser~es

Payload I

1

I1

I

I

I

I

,I 1 7 5 i o n

5FGC18 I

I I

I

1 i

I

225ton

I I

1

Gasollne

I

5FGC25 5FDC25

I

1 Torque converter

as standard PS equ'pped

I

nei;:g: Gasollne

4Y

5FGC23

I

1

4Y

42:

2 . 0 ton

I

Remarks

I

I

2ton serles

Power transmlsslon

Mounted englne E n g ~ n etype

Model

42:

nieE::

4Y

Gasolne

i Torque converter

I

I Torque converter

1

I

Torque converter I I

I

3 ton serles

2 7 5 ton

5FGC28

3 0 ton

5FGC30 5FDC30

1

I

1

1

4Y 2J

'

GasOilne

Diesel

Torque converter Torque converter

i

t

ABBREVIATIONS The abbrev~at~ons used In thls manual are as follows:

I Abbreviat~on I

Meaning

1

I

ABDC ASSY ATDC BBDC LH

LLC

I

1

1

11

After bottom dead center Assembly After drop dead center Before bottom dead center Lefthand ~ o n gl ~ i ecoolant

OHV

Overhead valve

OPT

Option Oversize

/ 1

,1

1

11

Abbrev~ation

P/S RH

1

Meaning

I

1

/

Power steering Righthand

I

SAE

Soc~etyof Automot~ve Engineers Special service tool

SST 1

STD

SUB-ASSY T= OOT

Horsepower

Standard

I

I

I

1

Subassembly T ~ g h t e n ~ ntorque g Number of teeth (00) Undersire

TIPS ON OPERATION Safe operation ( 1 ) Make sure that correct size wire rope is used when lifting a heavy material.

(2) After jacking up, always support with a rigid rack or stand.

2. Preparation of SSTs and measuring Instruments ( 1 ) Prepare necessary SSTs and measuring instruments before startlng repair operation.

1.

3.

Neatness and underlines ( 1 ) Keep the working place neat and orderly to make operation easler.

(2) Hydraulic equipment should be disassembled with clean tools in clean places.

4.

Genulne Toyota parts Always use genuine Toyota parts even for packlngs, gaskets and o-rings which are -replaced after each disassembly work.

5.

Repairs on electrrcal system Before doing any repair on the electrical system, disconnect the cables from battery terminals.

Always disconnect the negative (-) terminal first.

6. Tightening torque at the time of installatron Be sure to observe the tightening torque given In thls mannual. If not specified, tlghten to the torque listed in "Standard Bolt & Nut t~ghteningTorques."

7.

Grasplng the defect status When a defect is found, do not immediately start disassembly and replacement. First check if the defect needs disassembly and replacement for repair. For example, do not disassemble the torque converter for a defect of vehicle starting failure but check such factors as the oil status, hydraulic pressure and rotation which directly cause the defect.

I

I

STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and nut ttghtening torques are not ~ndicated Therefore, judge the tightening torque as descr~bedbelow 1

Find out the type of bolt from the list below Then, judge the bolt tightenrng torque from the tightening torque table

2

The nut tightening torque can be judged in the same way according to the type of the mating bolt

DlSRlMlNATlON OF BOLT STRENGTH 1

2 Discrimination by part number

Discriminat~onby actual bolt

1 Shape and description

Strength code

I

1

Hexagon bolt Standard head

I

I

;

Number in relief or hallmark on head I

I

I

Part number example

3

-

4

06

I

No mark

1

L-

Hexagon bolt head Hexagon

I

I

1

I I I

I

Standard bolt Hexagon bolt Collar head Hexagon bolt

1

l ~ o m ~ ndlameter a l

Length to bottom surface of head

Stud b o l t 1

I

I

Bolt with two relief n e s on head

6T Part number example

I

1

I 1 I

I

Nominal size (mm)

Bolt with two relief llnes on head

I I I

0

I

I

I

4=4T 5=5T 6=6T 7=7T

/

Hexagon bolt

Boit w ~ t hthree relief llnes on head

I

9 2 1 3 2 - 4

06

14

7T

!

under head imm)

Lnai;;;

siz;

Strength code

Nomlnal d~ameter Length

BAHS28

BAHS2

--

TIGHTENING TORQUE TABLE

~

Standard t ~ g h t e n ~ ntorque g kg-cm (ft-lb)

1

Standard head

Collar head

-

-

-

- - -

PRECOAT BOLTS

I

I1

(Bolts coated wrth seal lock agent on threads) 1

Do not use the precoat bolt as it I S In any of the follow~ngcases (1) When the precoat bolt I S removed (2) When the precoat bolt 1s moved (loosened or tightened) rn tightenrng check etc Reference : The tightening torque must be checked with the lower limit of the allowable tightening toque range. If the bolt moves, retighten it according to the following procedure:

2.

I

I I

I I I

Precoat 601ts

Reusing the precoat bolt ( 1 ) Clean the bolt and threaded hole.

(Clean the threaded hole even when the precoat bolt IS to be replaced. j

(2) (3)

84460

Dry the precoat bolt sufficiently by alr blowing, etc Coat the specifred seal lock agent on the theaded hole for the bolt.

HIGH PRESSURE HOSE FllTlNG TIGHTENING TORQUE 1.

2.

3.

Before connecting a h ~ g hpressure hose, wipe the high pressure hose fitting and mating n ~ p p l e contact surfaces with clean cloth to remove foreign matters and dirt. Check that there IS no dent or other surface defect on the contact surface.

A l ~ g nthe high pressure hose f~ttingand nrpple and hold the hose In that the state during tightening.

The maximum t ~ g h t e n ~ ntorque g must not exceed twice the standard t~ghteningtorque.

Standard t~ghtenrngtorque

N~~~~~~ of screw

7/16 -20UNF 9/16 -18UNF 3 / 4 -16UNF 7/8 -14UNF 11/16-12UNF 15/16-12UNF PFI / 4 PF3/8 PF1/2 PF3/4 PF 1

1

I

' I

Standard

Tighten~ngrange

2 5 1 181) 5 0 ( 362) 6 0 ( 43 3) 6 0 ( 433) 1 2 0 ( 866) 1 5 0 ( l O l 1)

1

2 4 - 2 6 1 1 7 3 188) 4 8 - 531347- 383) 5 7 - 63141 2 - 4 5 5 ) 5 7 - 63141 2 - 4 5 5 ) 11 4 - 1 2 6 1 8 2 3 91 0) 133-,471960-1061)

1

4 8 - 5313474 8 - 5333475 7 - 63141 2 11 4 - 1 2 6 ( 8 2 3 133- 1471960-

1

5 0 1 362) 5 0 ( 362) 1 2 0 ( 866) 140(101 1)

Hose ~ n s ~ d e diameter mm

kg-cm (ft-lb)

383) 383) 455) 91 0 ) 1061)

I

,

6 9 12 12 19 25 9 9 12 19 25

FRAME NUMBER

1 top of rear pan of

I

I

Model serles

1

Eng~netype

,

2.0 ton serles

1 I

Model

I

4Y

2J

4Y

2J

5FGC 18 5FGC20 5FGC23 5FGC25

5FDC20 5FDC25

5FGC28 5FGC30

5FDC30

-

-

-

-

-

-

5FGC25-10001 5FDC25- 10001 5FGC30- 10001 5FDC30- 10001 '5FGC25E10001 "5FDC25E10001 '5FGC30E10001 '5FDC30E10001

Frame ser~alnumber format

. EEC spec. (1992. 1 1

3.0 ton series

-)

SAFE LOAD BY WIRE ROPE SUSPENSION ANGLE

'

Un~filar Rope Breakdown SusPension load d~ameter 0"

Un~t. ton (Ib)

Cross sling~ng

B ~ f ~ l suspension ar 0"

30"

90"

60"

0"

30"

60"

90"

1.24 1.2 0.62 0.53 0.44 1.06 0.88 2.18 0.31 0.6 ( 4807) ( 683.6) ( 1 367) ( 1323) ( 1 169) ( 970) ( 2734) ( 2646) ( 2337) ( 1 940)

6 rnm (0.24 in)

1.74 1.28 0.9 0.78 1.8 1.56 0.64 0.87 (1985) (1918) (1720) (1411 ) ( 3 9 6 9 ) ( 3837)( 3440) (2822)

3.2 1

1

O m m 502 0 7 1 1 4 3 1 3 7 12 0 2 8 2 7 2 4 2 0 ( 0 4 in) 1 ( 1 1069) ( 1 565 6) (3153) (30211 (2646) (2205) 11 61 74) ( 5954) ( 5292) (4410)

(

7.84 1.12 2.2 12.5 mrn ( 0 . 5 ~ n ) ( 1 7287) (2469.5)l(4851)

4.4

4.2

3.8

3.0

( 9702) ( 9261) ( 8379) (6615)

5.4 1.4 2.7 2.4 1.9 2.8 5.6 14 mrn .

9.83 4.8 3.8 ( 0 . 5 6 In) (21675) ( 3 0 8 7 0 ) (6174) (5954) (5292) (4190) ( 1 2348) ( 1 1907) ( 1 0584) (8379)

1

1

--

WIRE ROPE SUSPENSION ANGLE LIST Suspens~on angle

,

,

C O ~ P ~ ~ S

Ten-

slon I strength

"On

Suspen ston method

I

Suspei SIO~

sion

slon

angle

strength

1

I

I

I

I

I 1 1

I

I

I

I

1

I

30"

1

t o e

I 027 I tme

times

1

I

I

I

60"

'

1 1 6 1 058 tmes

,

tme

/

1

, I

I

I

~ompres-

I

i

I I

times

Suspenslon method

CAPACITY AND TYPES OF SPECIFIED LUBRICANTS Description

Classification API SD, SE, SF

TYpe

Application

Quantity

Motor oil SAE30 (SAE20 in cold area)

Gasoline

4Y

4.01 (1.06 US gal)

2J

6.91 (1.82 US gal)

SAE20W-40 (SAE10W-30 in cold area)

Engine API CC, CD Deisel

Diesel engine oil SAE30 (SAE20 in cold area) SAEl OW-30

Torque converter

AT F

GM Dexron@I1

All models

14.OP (3.70 US gal)

Differential

API GL-4 GL-5

Hypoid gear oil SAE85W-90

All models

6.81 (1.80 US gal)

IS0 VG32

Hydraulic oil # 9 0

Hydraulic oil

Fuel tank Chassis parts Coolant

MP grease No.2 LLC

LLC 30-50% mixture (for winter or all-season) Coolant with rust~nhibitor (for spring, summer and autumn)

2 ton series 3 ton series

27P (7.1 US gal) 281 (7.4 US gal)

All models

45P ( 1 2 US gal)

All models

Proper quantity

4Y 2J

9.OP (2.38 US gal) 9.51 (2.51 US gal)

LUBRICATION

Cha~n

Differential Front wheel bearlng Torque converter case Rear wheel bear~ng Steering knuckle king pln Oil tank Engine crank case Rear axle beam front Rear axle beam rear Tilt steerlng universal jolnt Tllt steerlng locking mechanism Mast support bushing T ~ lcylinder t front pin Propeller shaft

V

0 1 2

3 4

5

Inspect every 8 hours (dally) lnspect every 4 0 hours (weekly) inspect every 1 7 0 hours (monthly) lnspect every 1 0 0 0 hours (6monthly) lnspect every 2 0 0 0 hours (annually) lnspect and service Replace MP grease E n g ~ n eoil Hypoid gear 011 Hydraul~coil Automat~ctransmission f u ~ d

Lubr~cationChart

UPM~

PERIODIC MAINTENANCE TABLE INSPECTION METHOD I . Inspect and Correct or replace as required. M : Measure and correct or adjust as requ~red . T~ghten C . Clean L : Lubricate * . For new vehicle * ' . Soapy water '2 Detector "3 . Flaw detector

T

1

3

6

12

170

500

1000

2000

I

C

t

t

Revolution in idling state

M

+

+

C

Revolution during acceleration

t

C

C

Exhaust gas

M I

t

t

+

Air cleaner element

C

+

+

+

Valve clearance

M*

M

Cylinder head bolt loosening

T"

M T

Positive crankcase ventilation (PCV)

Clogging and damage of PCV valve and piping

I

t

C

+

Governor

No-load maximum engine speed

M

t

+

C

Lubrication system

Oil leakage

I

+

+

+

Oil level

I

+

t

+

Clogging and fouling of oil filter

I

+

t

C

Fuel leakage Carburetor link mechanism operation

I

C

C

+

I

t

+

+

Fouling and damage of oil filter element

I

t

t

C

M

+

Place Inspection item

Every

ENGINE Engine proper

Starting status and abnormal noise

Compression

Fuel system

Injection timing

M

Injection nozzle injection pressure and spray status Cooling system

Radiator cooling water level and leakage

I

Rubber hose deterioration

I I I

Radiator cap status Fan belt tension, looseness and damage Damage and hardening of radiator rubber mount

C

C

+

+

+

C

+

+

t

+

C

t

I

Months Hours

Place LPG fuel system

Every

1

3

6

12

170

500

1000

2000

t

+

+

,

t

C

t

+-

+

+--

+

C

Gas leakage from piping and joints

1*1

Damage of pipng and joints

1'2

Vaporizer tar discharge

C

Looseness and damage of gas cylinder mounting

I

POWER TRANSMISSION SYSTEM Differential

Oil leakage

I

C

+

+

Oil level

I

+

+

+

T

Loose bolts Torque converter and transmission

Oil leakage

I

C

C

Oil level

I

+

+

Operating mechanism function and looseness

I

+

t

+

Control valve and clutch functions

I

+-

+

t

Inching valve function

I

C

t

M

-

C

t

Stall test and oil pressure measurement Propeller shaft and axle shaft

Loose joint

I

-

+

+

1

~oosenessat spline connection Looseness at flexible joint

I

Axle shaft torsion and crack

I

Months Hours

1

3

6

12

170

500

1000

2000

I T M I

+

t

t

+

+

t

+

-

C

t

t

t

Rim, side bearing and disc wheel damage

I

+

+

+

Front wheel bearing abnormal sound and looseness Rear wheel bearing abnormal sound and looseness

I

t

+

t

+

+-

Place

Every

TRAVELING EQUIPMENT Wheels

Tire cuts, damage and uneven wear Loose rim and hub nuts Tread depth Metal fragments, stones or other foreign matters on tires

I

-

Front axle

Housing crack, damage and deformation

I

Rear axle

Beam crack, damage and deformation

I M

Looseness of axle beam in vehicle longitudinal direction

M*

STEERING SYSTEM Steering wheel Gear box

Power steering

t

C

+

Operating status

I I

+

C

t

Oil leakage

I

+

+

t

Looseness of installation

T

+

+

+

Oil leakage Looseness of mounting and linkage

I

t

+

+

I

+-

C

C

Play and looseness

Power steering hose damage

I

Months Hours

Place Inspection item Knuckle

Every

King pin looseness

1

3

6

12

170

500

1000

2000

I

+

C

+

I

Crack and deformation Steering axle

M M

Wheel alignment Left and right turning angles

BRAKING SYSTEM Brake pedal

Parking brake

+

+

Braking effect

I

+-

+-

Pull margin

I

+

Braking effect

I

t-

+

+

Looseness and damage of rod and cable

I

+

t

t

-

Brake piping

Leakage, damage and installation status

Master cylinder or brake valve and wheel cylinder

Function, wear, damage, oil leakage and loosening of installation

Brake drum and brake shoe

Clearance between drum and lining

C

t

I

Looseness and damage of level link I

+

C

t

I

M

e-

+-

t

Wear at shoe sliding contact portion and lining

I

Drum wear and damage

I

Shoe operating state

I

Anchor pin rusting Fatigue of return spring1

Backing plate

-

M

Play and reserve

I M

Automatic adjusting mechanism function

I

Deformation, crack and damage

I

Looseness of mounting

T

Months Hours

1

3

6

170

500

1000

Abnormality of fork and stopper pin

I

t

+

t

Left and right fork blade misalignment

I

t

+

+-

Place

Every

12

2000 Hours

MATERIAL HANDLING SYSTEM Fork

lX3

Crack at fork base and welded portion Mast and fork bracket

Deformation and damage of each part, crack at welded portion

I

+

+

C

Looseness of mast and lift bracket

I

+

+

t

I

Mast support bush wear and damage Roller wear, damage and rotation status

+--

C

+

Mast strip wear and damage

I

+

+

+

Chain tension, deformation and damage Chain lubrication

I

+

C

+

I

t

+

t

Abnormality of chain anchor bolt

I

+

+

t

Chain wheel wear, damage and rotation status

I

+

+.-

+

Abnormality and installation status of each attachment

I

t

Looseness and damage of cylinder mounting

T

+

+

t

Deformation and damage of rod, rod screw and rod end

I

+

+

+

Cylinder operation

I

+

C

t

Natural drop and natural forward tilt

M

+

+

t

Oil leakage and damage

I

+

t

t

Wear and damage of pin and cylinder bearing

I

+

+

t

Lifting speed

M

+

t

+-

Uneven movement

I

+

+

t

Oil leakage and abnormal sound

I

+--

+

t

I

Roller pin wear and damage

Chain and chain wheel

Attachments

-

t

HYDRAULIC SYSTEM Cylinder

Oil pump

Months

Tank and oil strainer

Relief pressure measurement Relief valve and tilt lock valve func-

Deformation and damage Looseness of joints Hose tension and torsion

Distributor side terminal burning Wear and damage of distributor cap center terminal

Pinion gear meshing

Deformation, crack and damage

PERIODIC REPLACEMENT PARTS & LUBRICANTS

1

E n g ~ n eoil E n g ~ n e011filters

Every month

months

Every 1 7 0 hours

Every 5 0 0 hours

Replacement Every 12 months

Every six months I Every 1,000 hours

1

Every 2,000 hours

a a ( V e w vehicle)

Cooiihg water (except for LLC, every two years for LLC) Fuei filter Torque converter oil Torque converter oil f ~ l t e r D ~ f f e r e n t ~oil al Hydraulic oil Hydraul~coil filter Wheel bearing grease Spark plug Cyclone air cleaner element Brake valve rubber parts Master and wheel cylinder cups and seals Power steering hose Power steering rubber parts Hydraulic hose Reservoir tank tube Fuel hose Torque converter rubber hose Chain Carry out accord~ngto operating hours or months, whichever comes earlier

a a (Every t w o years) a (Every t w o years) a (Every t w o years) a (Every t w o years)

(Every i w o years)

a (Every t w o years)

a (Every three years)

ENGINE

Page GENERAL

.......................................

ENGINE PERFORMANCE

........................

ENGINE PERFORMANCE CURVES

...............

ENGINE ASSY W/TORQUE CONVERTER . ........

TRANSMISSION ................... .

ENGINE ASSY

...................................

ENGINE SPEED ADJUSTMENT AIR CLEANER RADIATOR

...................................

......................................

MUFFLER & EXHAUST PIPE BATTERY

..................

......................

........................................

STARTING MOTOR ALTERNATOR

..............................

...................................

ACCELERATOR PEDAL

....................... ...

1-2

GENERAL

2J Engine Front View

2J Engine Rear View

- 26 -

~ ~ 4 . 7

4 Y Engine Front Righthand View

4Y Eng~neRear Lefthand View

ENGINE PERFORMANCE

i 1 Engne 1I Dspiacement

I

No-load statlc maxlmum speed

I

1

Rated output PS/rpm

1

I

?-ton seres

i I

1

!

23

2481

2600

50/2500 I

2237

4Y

3-ton series ,

1

Max~mumtorque kg-v/rpm

2J

I

2481

2700

,

2600

54/2400

1

50/2500

1 4 5/2200 I I

1

16.5/1800 14.5/2200

ENGINE PERFORMANCE CURVES

I

I

I

I

I

6

10

14

18

22

26 XI02

Engine speed (rpm)

2J Engine Performance Curves

- 29 -

KAHM 19

u

I

I

1

I

6

10

14

18

I

22

I

27 x 102

Engine speed (rpm)

ENGINE ASSY W/TORQUE CONVERTER TRANSMISSION REMOVAL [2J ENGINE MODELS] 1.

Eng~nehood removal ( 1 ) Disconnect the engine hood damper from the frame bracket. ( 2 ) D~sconnectthe engine hood stay from the frame bracket. ( 3 ) Remove the engine hood hinge set screws (two on each side), and remove the englne hood.

2

Toe board removal

3.

Battery ASSY removal ( 1 ) D~sconnectthe battery term~nals

Removing the Engine Hood

LAPZ-'I

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

(2) Remove the battery stopper (3) Remove the battery ASSY.

Removing the Battery

~ ~ ~ 2 . 1 1

Disconnecting the Solenoid Cut Wiring

~ ~ ~ 2 . 1 3

4. Battery case removal ( 1 ) Remove the set bolts ( 2 pcs). and remove the battery.

5

Electr~calwiring and fuel hose disconnection (I)Disconnect the starting motor bond strap (2) .D~sconnectelectrical wlrings such as the ~njectionpump solenold cut wirin9 (3) Disconnect the fuel hose

6. Fuel fllter ASSY removal (I) Disconnect the fuel piping. ( 2 ) Remove the set bolts ( 2 pcs.), and remove the fuel filter ASSY.

Removing the Fuel Filter

-

-

7

Air cleaner ASSY removal ( I ) Remove the hydraulic tank breather ( 2 ) Loosen the hose clamp for the alr cleaner hose (3) Remove the set bolts ( 4 pcs ) of the alr cleaner case, and remove the alr cleaner ASSY

Removing the Air Cleaner

8. Rad~atorcover removal ( 1 ) Remove the set knob, and remove the fadlator cover.

9. Radiator reservoir tank removal ( I ) Dlsconnect the reservoir tank hose from the radiator.

(2) Remove the

reservoir

tank.

Removing the Radiator Cover

~ ~ ~ 2 . 2 8

10. Rad~atorASSY removal ( I ) Loosen the radiator drain plug to drain the cooling water.

(2) Loosen the engine draln plug to drain the cooling water.

Cooling Water Drain Plugs

1~~2.33.31

(3) D~sconnectthe torque converter cooler hose.

Caution: Identify the hose connecting positions.

(4) Remove the fan shroud set bolts. and remove the fan shroud ASSY.

Removing the Fan Shroud

~ ~ 3 . 7

(5) Remove the rad~ator set bolts, and remove the radiator ASSY.

Removing the Radiator

~ ~ ~ 3 . 1 0

Disconnecting the Exhaust Pipe

1~~3.11

1 1. Exhaust pipe disconnection (1 ) Remove the flange set nuts (3 pcs.). and disconnect the exhaust pipe.

1 2. Accelerator flex~blewire disconnect~on (1) Disconnect the wire clevis from the injection pump. ( 2 ) Disconnect, the accelerator cable bracket from the manifold.

Disconnecting the Accelerator Wire

13. Oil pump ASSY removal (1) Remove the oil pump set bolts (2 pcs.).

(2) Disconnect the oil pump ASSY from the engine.

Removing the Oil Pump

33 -

LAP^-13.14

1 4. Accelerator pedal W/accelerator bracket removal ( 1 ) Remove the toe board set bolts, and removal the accelerator pedal W/accelerator bracket.

Removing the Accelerator Bracket

~~~3.17

15. Torque converter shift rod and inchrng wire d~sconnect~on. ( 1 ) Remove the set nut. and disconnect the shift rod.

(2) Drsconnect the clevis, loosen the wire set nut, and disconnect the inching wire.

Disconnecting the Torque Convener Link Portion

~~~3-rg.zo

16. Propeller shaft ASSY disconnection ( 1 ) Remove the set bolts ( 2 pcs.), and remove the propeller shaft cover.

(2) Remove the propeller shaft set bolts ( 4 pcs. on each side), and disconnect the propeller shaft.

Note: The propeller shaft may be disconnected on either the differential side or the transmission side.

Disconnecting the Propeller Shaft

1-4~1-4.8

Disconnecting the Parking Brake Cable

up3-21

1 7 . Parkrng brake cable clamp removal ( I ) Remove the parkrng brake cable clamp set bolt. and disconnect the cable from the transmissron case.

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18. Mount~ngset bolt removal ( 1 ) Remove the engine mountlng set bolts from the left and right sides.

Removing the Set Bolts

LAP3-23

Removing the Set Bolts

~ ~ ~ 3 . 2 2

Remov~ngthe Engine

~ ~ ~ 3 . 2 4

(2) Remove the torque converter transmission mounting set bolts.

19.Check ~fany electr~calwiring, cable or link IS

left connected.

20. Englne ASSY W/torque converter transmlsslon removal ( I ) Use the SST and remove the engine ASSY W/transmission.

SST090t0-20111-71 Caution: Carry out slinging in due consideration of the center-of-gravity position for safe operation.

[4Y ENGINE MODEL] 1

Eng~nehood removal ( I )Dlsconnect the engine hood damper from the frame bracket ( 2 ) Dlsconnect the engine hood stay from the frame bracket (3) Remove the englne hood hlnge set bolts ( 2 pcs on each side), and remove the engine hood

2

Radlator cover and toe board removal

3.

Battery ASSY removal (I) Disconnect the battery terminals.

Removing the Engine Hood

LAPIZ-9.10

Caution: Always disconnect the battery negative (-) terminal first. ( 2 ) Remove the battery stopper ( 3 ) Remove the battery ASSY. 4.

5

Battery case removal ( 1 j Remove the set bolts ( 3 pcs.), and remove the battery case.

Removing the Battery

~ ~ ~ 1 2 . 1 7

Removing the Battery Case

~ ~ ~ 1 2 . 1 9

Electr~calwirlng and fuel hose drsconnection ( 1 ) Disconnect the starting motor bond strap (2) Disconnect the connector of each electrical wirlng (3) Drsconnect the fuel hose

6. Horn ASSY removal f l ) Disconnect the wiring at the connector.

(2) Remove the set bolts ( 2 pcs.) and remove the horn ASSY.

7 . Air cleaner ASSY removal ( 1 ) Remove the hydraulic tank breather.

(2) Loosen the hose ciamp for the air cleaner hose. ( 3 ) Remove the air cleaner case set bolts ( 4 pcs ), and remove the air cleaner ASSY.

Removing the Air Cleaner

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