Toyota 02 7 fgjf35 forklift service repair manual

Toyota 02 7 fgjf35 forklift service repair manual

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  SERVICE MANUAL TOYOTA 7FDF/FGF15-35 BT Svenska AB Per Wärmlund Per Wärmlund Per Wärmlund Per Wärmlund Per Wärmlund NAME SECTION GENERAL ENGINE TRANSMISSION 0 1 2 PROPELLER SHAFT DIFFERENTIAL FRONT AXLE REAR AXLE STEERING BRAKE BODY MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL CONTROL VALVE SAS APPENDIX 3 4 5 6 7 8 9 10 11 12 13 14 15 16 INDEX < Tillbaka till Index
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  0-1 0 GENERAL Page EXTERIOR VIEWS......................................................... 0-2 VEHICLEMODEL .......................................................... 0-3 FRAME NUMBER........................................................... 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 CIRCUIT TESTER.................................................. 0-9 STANDARD BOLT & NUT TIGHTENING TORQUE ....................................................................... 0-11 BOLT STRENGTH TYPE IDENTIFICATION METHOD ...... 0-11 TIGHTENING TORQUE TABLE ........................................ 0-12 PRECOAT BOLTS ......................................................... 0-13 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE ............................................ 0-13 WIRE ROPE SUSPENSION ANGLE LIST ............... 0-14 SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE............................................... 0-14 COMPONENTS WEIGHT............................................. 0-15 RECOMMENDED LUBRICANT QUANTITY & TYPES ................................................. 0-16 SMÖRJSCHEMA ........................................................... 0-18 PERIODISKT UNDERHÅLL ........................................ 0-19 UTBYTE AV SMÖRJMEDEL OCH DELAR ................................................................. 0-25
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  0-2 EXTERIOR VIEWS
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  0-3 VEHICLE MODEL 42-7FGF15 02-7FDF15 42-7FGF18 02-7FDF18 42-7FGF20 62-7FDF20 02-7FDF20 42-7FGF25 62-7FDF25 02-7FDF25 02-7FGF30 62-7FDF30 02-7FDF30 02-7FGJF35 02-7FDJF35 1.5 tonmodel 1.75 ton model 2.0 ton model 2.5 ton model 3.0 ton model J3.5 ton model 1 ton series 2 ton series 3 ton series J3.5 ton series T/C T/C T/C T/C T/C T/C T/C T/C T/C T/C T/C T/C T/C T/C T/C 4Y 1DZ-II 4Y 1DZ-II 4Y 1DZ-II 2Z 4Y 1DZ-II 2Z 4Y 1DZ-II 2Z 4Y 2Z Gasoline Diesel Gasoline Diesel Gasoline Diesel Gasoline Diesel Gasoline Diesel Gasoline Diesel Transmission Type Vehicle Model Engine Model Series Classification
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  0-4 FRAME NUMBER Frame No.Punching Position Punching position Series 1 ton series 2 ton series 3 ton, J3.5 ton series Engine 4Y 1DZ-II 4Y 2Z 1DZ-II 4Y 2Z 1DZ-II Vehicle model 42-7FGF15 42-7FGF18 02-7FDF15 02-7FDF18 42-7FGF20 42-7FGF25 02-7FDF20 02-7FDF25 62-7FDF20 62-7FDF25 02-7FGF30 02-7FGJF35 02-7FDF30 02-7FDJF35 62-7FDF30 Punching format 407FGF18 10011 7FDF18 10011 407FGF25 10011 7FDF25 10011 607FDF25 10011 7FGJF35 10011 7FDJF35 10011 607FDF30 10011
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  0-5 HOW TO USETHIS MANUAL EXPLANATIONMETHOD 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 illustration. 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 description in pattern B DISASSEMBLY·INSPECTION·REASSEMBLY Tightening torque unit T = N·m (kgf-cm) [ft-lbf] DisassemblyProcedure 1 Remove the cover. [Point 1] 2 Remove the bushing [Point 2] Operation explained later 3 Remove the gear. Point Operations Explanation of key point for operation with an illustration [Point 1] Disassembly: Put a match mark when removing the pump cover. [Point 2] Inspection: Measure the bush inside diameter. Limit: 19.12 mm (0.7528 in) • Step Nos. are partially sometimes omitted in illustrations. • When a part requiring tightening torque instruction is not indicated in the illustration, the part name is de- scribed in the illustration frame. T = 46.1 ~ 48.1 (470 ~ 490) [34.0 ~ 35.5]
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  0-6 Abbreviation (code) ASSY LH LLC M/T NMR OPT O/S PS RH SAE 2. Howto 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 components figure indicates the Fig. num- ber in the 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: Important matters of which negligence may cause accidents. Be sure to observe them. Note: Important items of which negligence may cause accidents, or matters in operation procedure requiring special attention. Standard: Values showing allowable range in inspection and adjustment. Limit: Maximum or minimum allowable value in inspection or adjustment. ABBREVIATIONS Meaning System of active stability Special service tool Standard Tightening torque Torque converter transmission Number of teeth ( ) Undersize With Less Meaning Assembly Left hand Long life coolant Manual transmission No-load maximum speed Option Oversize Power steering Right hand Society of Automotive Engineers (USA) Abbreviation (code) SAS SST STD T = T/C T U/S W/ L/ - FIG number in parts catalog 3201
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  1-8 REMOVAL• • • • •INSTALLATION T =N• • • • •m (kgf-cm) [ft-lbf] ENGINE ASSY Engine mounting nut End plate set bolt Drive plate set bolt (for connecting engine crankshaft) Drive plate set bolt (for connecting torque converter) Torque converter housing set bolt T = 53.9 ~ 99.0 (550 ~ 1010) [39.8 ~ 73.1] T = 49.0 ~ 78.5 (500 ~ 800) [36.2 ~ 57.9] 4Y: T = 56.9 ~ 64.7 (580 ~ 660) [42.0 ~ 47.7] 1DZ-II•2Z: T = 76.5 ~ 93.2 (780 ~ 950) [56.4 ~ 68.7] T = 14.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9] T = 29.4 ~ 44.1 (300 ~ 450) [21.7 ~ 32.6]
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  1-9 Removal Procedure 1 Removethe engine hood. (See p. 9-5.) 2 Remove the toe board. 3 Drain coolant. 4 Remove the battery and battery tray. 5 Remove the relay block and electrical parts plate set bolts to free them. 6 Disconnect the accelerator wire and fuel hose. [Point 1] 7 Diesel Vehicle: Remove the sedimenter bracket set bolt to free the bracket. 8 Disconnect connectors and wiring harness clamps around the engine. 9 Disconnect the torque converter cooler hose. [Point 2] 10 Remove the radiator. 11 Disconnect the air cleaner hose. 12 Remove the oil pump set bolts to free the pump. 13 Disconnect the exhaust pipe. 14 Disconnect the wiring from the starting motor. 15 Remove the under cover. 16 Remove the cover plate. 17 Remove 6 drive plate set bolts. 18 Remove the engine ASSY mounting nuts. 19 Slightly hoist the engine. [Point 3] 20 Support the torque converter housing with wooden blocks. 21 Separate the torque converter housing and engine. [Point 4] 22 Remove the engine ASSY with drive plate and torque converter end plate. 23 Remove the drive plate. 24 Remove the torque converter end plate. 25 Remove the starting motor. Installation Procedure The installation procedure is the reverse of the removal procedure. Note: • • • • • Apply sealant (08833-00080) before tightening the drive plate set bolt (for connecting engine crankshaft). • • • • • Bleed air from the fuel system after installation of the engine ASSY. (For diesel vehicle) (See p. 1-11.)
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  1-10 Point Operations [Point 1] Removal: Puta match marks on the fuel hose and the coupler. [Point 2] Removal: Put a match mark on the radiator and torque converter cooler hose. [Point 3] Removal•Installation: SST 09010-20111-71 --- 09010-23320-71 --- Removal: Tentatively hoist up until the mounting bolt completely comes out from the hole in the frame. [Point 4] 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. SST SST
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  1-11 AIR BLEEDING FROMFUEL SYSTEM (DIESEL VEHICLE) 1. Operate the hand pump of the fuel filter until the pump operating force 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 (176° ° ° ° °F) or more, engine oil: 70° ° ° ° °C (158° ° ° ° °F) or more, operating oil tem- perature: 50° ° ° ° °C (122° ° ° ° °F) or more, auto choke in release state (4Y engine) 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 ± 30 rpm 3. If the measured value is out of the specified range, ad- just by turning adjusting screw B. 4. Connect the idle up actuator. 5. Check the idling speed. Standard: 750 rpm 6. If the measured value 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 using the following procedure: A B Actuator hose + 50 -0
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  1-12 (1) If theauto choke cam is contacting although the cool- ant temperature is as specified above, replace the auto choke. (2) If the idle up actuator rod and adjusting screw B are in contact with each other, turn adjusting screw B coun- terclockwise. LPG/Gasoline or LPG 1. Install the engine speedometer. 2. Disconnect the idle up actuator and inspect the idle up speed. Standard: LPG/Gasoline: 1000 ± 30 rpm Actuator hose B B B Actuator hose LPG/Gasoline Actuator hose LPG LPG: 1400 ± 30 rpm LPG (France spec.): 1400 ± 30 rpm 3. If the measured value is out of the specified range, adjust by turning adjusting screw B. Loosen the lock nut before adjustment in case of the LPG engine vehicle (France spec.). 4. Connect the idle up actuator. Lock nut B 5. Check the idling speed. Standard: LPG/Gasoline: 750 rpm LPG: 800 rpm LPG (France spec.) : 750 rpm + 50 - 0 + 50 - 0 + 50 - 0 LPG (France spec.)
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  1-13 A Regulator LPG carburetor B C 6. Ifthe measured value is out of the specified range, make adjustment according to the following procedure: (1) Make adjustment by turning adjusting screw B (LPG vehicle) or C (LPG/gasoline vehicle). (If less than the standard, turn adjusting screw A coun- terclockwise beforehand.) (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) until the value obtained in step (2) satisfies the standard. (4) Slowly turn adjusting screw A clockwise until the CO concentration becomes 2 to 3%, and then turn it 45 degrees counterclockwise from the position where the speed begins to drop. E D LPG (France spec.) (1) Make adjustment by turning adjusting screw D (LPG vehicle). (If less than the standard, turn adjusting screw E clock- wise beforehand.) (2) Determine the position of adjusting screw D by re- peating step (1) until the value obtained in step (1) sat- isfies the standard. (3) Slowly turn adjusting screw E counter-clockwise until the CO concentration becomes 2 to 3%, and then turn it 45 degrees counterclockwise from the position where the speed begins to drop. No-load Maximum Speed Inspection• • • • • Adjustment Gasoline, LPG or LPG/Gasoline Vehicle 1. Install the engine speedometer. 2. Inspect and adjust the no-load static maximum speed. (1) Measure the speed when the accelerator pedal is fully depressed. Standard: 4Y engine: 1•2 ton series: ...................... 2600 ± 50 rpm 3• J3.5 ton series: ................. 2800 ± 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 depress the accelerator pedal. Turn the bushing for adjustment, while holding the adjusting screw of the air governor immovable with a straight-edge screwdriver. Lock bolt Fix. Adjusting screw Bushing
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  1-14 3. Check andadjust 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 300 rpm Tilt lever (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. Return the screw by 1/10 of a turn to eliminate twist- ing of the spring in the air governor. Adjust the no-load maximum speed. Repeat steps , and until the measured value 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 1/2 of a turn or more. Return the screw counterclockwise by 1/4 of a turn. Finally, turn it by 1/10 of a turn to eliminate twisting of the spring in the air governor. Adjust the no-load maximum speed. Repeat steps through until hunting occurs no more. 5. Repeat adjustments in steps 2 to 4 until respective stan- dards are satisfied. 6. Seal the lock bolt.
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  1-15 1DZ-II• • • • •2Z ENGINE Idle SpeedInspection• • • • •Adjustment 1. Install the engine speedometer. 2. Check the idle speed. Standard: 750 ± 25 rpm 3. If the measured value is out of the standard, loosen the lock nut and make adjustment by turning adjusting screw A. No-load Maximum Speed Inspection• • • • •Adjustment 1. Install the engine speedometer. 2. Inspect and adjust the no-load maximum speed. (1) Measure the speed when the accelerator pedal is fully depressed. Standard: 1DZ-II engine: 1 ton series: .................... 2600 ± 50 rpm Vehicle speed control system spec.: .............. 2600 ± 50 rpm 2• 3 ton series: ................. 2800 ± 50 rpm 2Z engine: ........................... 2400 ± 50 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. A B Tilt lever
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  1-16 AIR CLEANER SPECIFICATIONS Type Size Intake type Filteringarea cm2 (in2 ) Others Single (STD) Cyclone type 7-inch Fresh air introduction type 14600 (2263) With evacuator valve Double (OPT) ← ← ← Outer: 18600 (2883) Inner: 510 (79.1) ← COMPONENTS 1703
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  1-17 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 ordinary cleaning, blow with compressed air [690 kPa (7kgf/cm2 ) [100 psi] or less] vertically along the pleats from the inside of the element. If heavily contaminated, washing is possible. (2) Element washing method Dissolve neutral detergent in tepid water (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 kgf/cm2 ) [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). (1) Hold the 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 electric bulb in the element to inspect any damage in the element. If any pinhole, tear or damage is found, replace it with a new ele- ment. 6. Element replacement Replace the element after it is washed six times or gen- erally at intervals of 12 months. Vehicle without vehicle speed control system 7. Install the element. (1) Install the evacuator valve in the illustrated direction. Vehicle with vehicle speed control system 60° 25°
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  1-18 CLOGGING WARNING SYSTEMINSPECTION 1. Warning lamp inspection (1) See that the air cleaner warning lamp comes on when the ignition switch is turned ON and goes out when the engine starts. 2. Individual inspection (1) Use a mity vac to apply a negative pressure to the vacuum switch, and inspect conduction. Standard Gasoline models: 2942 ± 294 Pa (300 ± 30 mm H2O) (22.1 ± 2.2 mmHg) [11.81 ± 1.18 in H2O] [0.870 ± 0.087 in Hg]: Conduction Diesel models: 7473 ± 569 Pa (762 ± 58 mm H2O) (56.0 ± 4.3 mmHg) [30.00 ± 2.28 in H2O] [2.205 ± 0.169 in Hg]: Conduction RADIATOR COMPONENTS 1603
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  1-19 Total amount of coolant 7.4 (1.95) 5.9(1.56) 9.3 (2.46) 8.3 (2.19) 9.0 (2.37) 9.5 (2.51) 8.2 (2.16) 8.8 (2.32) 9.5 (2.51) 8.8 (2.32) SPECIFICATIONS Type Crossflow Fin type Corrugated fin Coolant capacity (in radiator) See the table below Cap opening pressure kPa (kgf/cm2 ) [psi] 88 ± 14.7 (0.9 ± 0.15) [13 ± 2.1] Others Built in torque converter cooler (torque converter model) COOLANT CAPACITY AND ANTIFREEZE TABLE Unit: (US gal) Radiator capacity 2.5 (0.66) 2.5 (0.66) 3.7 (0.98) 3.7 (0.98) 3.7 (0.98) 3.7 (0.98) 3.7 (0.98) 3.7 (0.98) 3.7 (0.98) 3.7 (0.98) LLC mixing ratio at 30% (to - 15°C (5°F)) 2.2 (0.58) 1.8 (0.48) 2.8 (0.74) 2.5 (0.66) 2.7 (0.71) 2.9 (0.77) 2.5 (0.66) 2.6 (0.69) 2.9 (0.77) 2.6 (0.69) LLC mixing ratio at 50% (to - 35°C (- 31°F)) 3.7 (0.98) 3.0 (0.79) 4.7 (1.24) 4.2 (1.11) 4.5 (1.19) 4.8 (1.27) 4.1 (1.08) 4.4 (1.16) 4.8 (1.27) 4.4 (1.16) Antirust mixing at 5% 0.4 (0.11) 0.3 (0.08) 0.5 (0.13) 0.4 (0.11) 0.5 (0.13) 0.5 (0.13) 0.4 (0.11) 0.4 (0.11) 0.5 (0.13) 0.4 (0.11) 4Y 1DZ-II 4Y 1DZ-II 2Z 4Y 1DZ-II 2Z 4Y 2Z 1 ton series 2 ton series 3 ton series J3.5 ton series Note: • • • • • The total amount of coolant does not include the capacity of the reservoir tank. • • • • • Reservoir tank capacity: 0.6 (0.16 US gal) (at FULL mark position)
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  1-20 MUFFLER EXHAUSTPIPE COMPONENTS 1702 Gasoline model Diesel model
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  1-21 REMOVAL• • • • •INSTALLATION Note: The muffler canbe removed by either of the two methods shown below. Remove the muffler after removing the counterweight. Remove the muffler after removing the radiator W/counterweight. Here, method is explained. Removal Procedure 1 Remove the counterweight. (See p. 9-6.) 2 Disconnect the exhaust pipe. 3 Remove the muffler W/tail pipe. 4 Disconnect the tail pipe from the muffler. Installation Procedure The installation procedure 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. 3 2