Toyota 5FBCU15

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This manual covers the service procedures for the modified portions of

TOYOTA BATTERY FORKLIFT 5FBCU15 - 30 series. Please use this


manual for quick accurate servicing of these vehicles and as the tool for
sales and service activities.

As this manual is edited as a supplement to Repair Manual for the


5FBCU15 - 30 series, please refer to Repair Manual (Pub. No.CU305) for
the matters not covered herein.

This manual deals with the above models as of October 1999. Please under-
stand 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 Equipment
Parts & Service News.

For your reference, we herewith indicate the titles of relevant manuals


TOYOTA INDUSTRIAL EQUIPMENT REPAIR MANUAL
5FBCU15 - 30 (No.CU305)

TOYOTA MOTOR CORPORATION


SECTION INDEX
NAME I SECTION

GENERAL
DRIVE UNIT (2.3 TON SERIES)
-
FRONT AXLE (2.3 TON S E R I E S )
REAR AXLE (2.3 TON SERIES)
MAST (2.3TON SERIES)
CYLINDER (2.3 TON SERIES)
OIL CONTROL VALVE
APPENDIX
GENERAL

EXTERIOR VIEWS .......................................................0-2


VEHICLE MODEL .....................................................0-3
LUBRICATION CHART (2.3TON SERIES) ............. 0-4
PERIODIC MAINTENANCE ..........................................0-5
INFORMATION ON REFERENCE MANUAL ........... 0-6
MEANING OF LATEST MODIFICATION ON
SFBCU 2 TON AND 3 TON SERIES ...................... 0-7
EXTERIOR VIEWS
VEHICLE MODEL
Load Capacity Model
Types on Spec. Load center Load center
= 500mm = 24in
(kg) (Ibs) 36Vl48V

1-ton 1500 3000 5FBCU15


series

1750 3500 5FBCU18


STD capacity battery
compartment 2-ton 2000 4000 5FBCU20
series
STD spec. models
2500 5000 5FBCU25

3-ton 3000 6000 5FBCU30


series

High capacity 2000 4000 5FBCHU20


2-ton
* series 2500 5000 5FBCHU25

1-ton 1500 3000 30-5FBCU15


series

1750 3500 30-5FBCU18


STD capacity battery
compartment 2-ton 2000 4000 30-5FBCU20
Dust proof models series
2500 5000 30-5FBCU25

3-ton 3000 6000 30-5FBCU30


series

2000 4000 30-5FBCHU20


High capacity 2-ton
* series 2500 5000 30-5FBCHU25

*: These high capacity (battery compartment) models are not established in EEC specification.

Note: Way and the position of the model and frame No. indications have been unchanged.
LUBRICATION CHART (2.3TON SERIES)

I*
2*
3*
4*
5
6
7
8
9
lo*
11*
12*
13*

Chain lnspect every 8 hours (daily)


Mast support bushing lnspect every 40 hours (weekly)
Tilt cylinder front pin lnspect every 170 hours (monthly)
Front wheel bearing lnspect every 1000 hours (6 monthly)
Differential & transmission lnspect every 2000 hours (annually)
Brake fluid reservoir tank lnspect and service
Tilt steering locking mechanism Replace
Tilt steering universal joint
Oil tank MP grease
Rear wheel bealing Engine oil
Steering knuckle king pin Hypoid gear oil
Tie rod end pin Hydraulic oil
Rear axle cylinder end pin Brake fluid
Rear axle beam front pin Molybdenum disulfide grease
Rear axle beam rear pin
Located on right and left sides
PERIODIC MAINTENANCE
INSPECTION METHOD
I: Inspection. Repair or replacement if required.
M: Measurement. Repair or adjustment if required.
T Retightening C: Cleaning L: Lubrication
* : For new vehicle *1: Flaw detector

Note: This manual covers only the portions different from conventional models. Refer to the
Repair Manual (No.CU305) for the maintenance of other portions.

Inspection Period Months 1 3 6 12

Item Hours 170 500 1000 2000

TRAVELING EQUIPMENT

Rear axle Cracks, damage and I 0


deformation of beam

Looseness of axle beam in M* 0


vehicle longitudinal direction
(2.3ton series: from October
1999)
-

INFORMATION ON REFERENCE MANUAL


3n and after October 1999 products of 5FBCU series, choose the reference publication for proper servic-
ng in accordance with the following instructions:
0: Applicable reference
-
5FBCU15 30 Repair manual
Remarks
Section Pub. No. CU305 This book

GENERAL 0 0

BAlTERY 0
CONTROLCIRCUIT 0
MULTIDISPLAYFUNCTIONS 0
ELECTRICAL SYSTEM TROUBLESHOOTING 0
MOTOR 0 Refer to Parts & Service
News GE-8031 of Dec.
1998.

1 ton series 0
DRIVE UNIT
2.3 ton series 0
1 ton series 0
FRONT AXLE
2.3 ton series 0
1 ton series 0
REAR AXLE
2.3 ton series 0
STEERING 0
BRAKE 0
BODY & FRAME 0
MATERIAL HANDLING SYSTEM 0
1 ton series 0
MAST
2.3 ton series 0
Lift 1 ton series 0
CYLINDER 2.3 ton series 0
Tilt cylinder 0
OIL PUMP 0 Refer to Parts & Service
News GE-8024 of Oct.
1998

OIL CONTROLVALVE 0
APPENDIX 0 0
MEANING OF LATEST MODIFICATION ON 5FBCU
2 TON AND 3 TON SERIES
Accompanied by the model change - Development to 7FGCU 2 ton & 3 ton series from GFGCU 2 ton & 3
ton series -, several new design features of 7FGC 2 ton & 3 ton series have also been adapted for 5FBCU
2 ton & 3 ton series. As the effect that, several components have been standardized for the developments
as well as for service efficiencies and conveniences.
The major components involved are tabulated as follows:
Standardization between model series
Meaning of Marks Used for List item
0 Standardized between 5FBCU series and 7FGCU series, or interchangeable.
Partly standardized between 5FBCU series and 7FGCU series, or Partly Interchangeable.
x Exclusively for 5FBCU series

1
Components 2 ton series 3 ton series

Mast Assembly V.FV.FSV.QFV x x

Front axle Differential housing x

Axle housing 0 0
Axle bracket 0 0
Axle shaft 0 0
Wheel bearing 0 0
Wheel & hub drum 0 0
Differentialcase 0
Rear axle Rear axle beam 0 0
Rear axle cylinder 0
Tie rod 0
Steering knuckle 0
Wheel bearing 0
Mount rubber or bushing 0 0
Tire size Front tire x

Rear tire 0
Forks 0 0
Seat belt 0
DRIVE UNIT
(2.3TON SERIES)

GENERAL ........................................................................ page


1-2 m
SPECIFICATIONS .......................................................... 1-3
COMPONENTS .............................................................. 1-4
DRIVE UNIT ASSY ......................................................... 1-5
REMOVAL*INSTALLATION............................................... 1-5
................... 1-8
DISASSEMBLY*INSPECTION*REASSEMBLY
DIFFERENTIAL CASE ASSY ....................................... 1-14
DISASSEMBLY-INSPECTION-REASSEMBLY.................. 1-14
GENERAL
SPECIFICATIONS
Vehicle Series 2 ton Series 3 ton Series

Item STD Dustproof STD Dustproof

Ring gear teeth 35 +

Drive pinion teeth 6 C

Gear ratio (Differential) 5.833 +

Number of gears 4 +-

Pinion gear
Teeth 10 C

Number of gears 2 +

Side gear
Teeth 14 +

Drive gear teeth 22 17 22 17

Output gear teeth 60 65 60 65

Gear ratio (Transmission) 2.727 3.824 2.727 3.824

Drive unit oil capacity J? ( (US gal) 7.5 (1.98) C


COMPONENTS
DRIVE UNIT ASSY
REMOVAL-INSTALLATION
T = N-m (kgf-cm) [ft-lbfl
Removal Procedure
1 Remove the mast. (See page 4-7)

2 Remove the battery hood Wldriver seat.

3 Remove the battery ASSY.

4 Jack up the vehicle and remove the front wheels.

5 Drain differential oil. [Point 11

6 Disconnect the drive motor wiring.

7 Disconnect the speed sensor sub-harness connector.

8 Disconnect the brake pipe (from the wheel cylinder).

9 Remove the front toe-board.

10 Disconnect the parking brake wires.

11 Remove the drive motor set bolts.

12 Support the front axle & drive motor ASSY with a hoist and garage jack. [Point 21

13 Remove the front axle bracket set bolts. [Point 31

14 Remove the front axle & drive motor ASSY.

15 Disconnect the drive unit and drive motor

16 Remove the front axle shaft. [Point 41

17 Remove the front axle housing Wlbrake.

18 Remove the speed sensor cover and the sensor.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Bleed air from the brake system after installation.

Point Operations
[Point 11
Installation:
After reassembly, fill hypoid gear oil to the specified level.
A = 15 mm (0.59 in) or less
[Point 21
Removal.lnstallation:
Install hub nuts on hub bolts on the left and right side, and
sling wire at the tapered portion.

[Point 31
Removal:
Remove the reamer bolts. (2 pcs. each at top and bottom
on one side)
SST 09310-23320-71

[Point 41
Removal.Installation:
Operate carefully so as not to bring the axle shaft into con-
tact with the oil seal lip to damage it.
N.m (kgf-cm) [ft-lbfl

Disassembly Procedure
1 Remove the differential cover. [Point 11

2 Measure the ring gear backlash. [Point 21

3 Remove the bearing cap and adjusting nut. [Point 31

4 Remove the differential case ASSY. (See page 1-1 4 for the disassembly, inspection and reassembly
procedure.)

5 Remove the drive pinion ASSY. [Point 41

6 Remove the output gear. [Point 51

7 Remove the drive pinion, bearing, spacer and shim from the retainer. [Point 61

8 Remove the pilot bearing. [Point 71

9 Remove the drive pinion bearing inner race. [Point 81

10 Remove the drive gear

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
[Point 11
Reassembly:
Apply sealing agent (Three Bond's No.1217C or the equiva-
lent) on the mating surfaces of the differential cover and
housing before reassembly.

[Point 21
Inspection:
Measure the ring gear backlash.

- -
Standard: 0.2 0.3 mm (0.008 0.012 in)

[Point 31
Disassembly:
Put match marks on the bearing cap and differential hous-
ing.

Reassembly:
Install the adjusting nuts and bearing cap.
1, Install the adjusting nuts.
2. Install the bearing cap by aligning the match marks and
temporarily tighten the set bolt.
T = 19.6 N-m(200 kgf-cm) [I4.5 ft-lbf]
3. Set the dial gauge in the thrust direction of the differential
case.
4. Use the SST and tighten until the thrust clearance is elimi-
nated.
SST 09630-10110-71
5. Tighten adjusting nuts on both sides by one notch each.
6. Set the dial gauge vertical to the ring gear tooth surface,
and measure the backlash.

Standard: 0.2 - 0.3 mm (0.008 - 0.012 in)


If the standard is not satisfied, adjust by turning the adjust-
ing nut to move the differential case ASSY in the thrust di-
rection.
(1) When the backlash is excessive:
Loosen the adjusting nut on the ring gear teeth side
and tighten the adjusting nut on the rear side as much
to bring the ring gear closer to the drive pinion.
(2) When the backlash is insufficient:
Loosen the adjusting nut of the rear side of the ring
gear and tighten the adjusting nut on the teeth side as
much to bring the ring gear away from the drive pin-
ion.
7. Side bearing starting torque (Reference only):
Measure the torque by turning the output gear lock nut
with a torque wrench.
Standard:
- -
6.37 15.20 N-m(65 155 kgf-cm)
-
[4.70 11.21 ft-lbf]
8. Tighten the adjusting nut on the rear side of the ring gear
further by 1.5 to 2 notches.
9. Install the adjusting nut lock plate.
10.Finallytighten the bearing cap set bolts.
- -
T = 117.7 137.3 N-m(1200 1400 kgf-cm)
-
[86.82 101.3 ft-lbfl
11. Check the tooth contact.
(1) Uniformly coat red lead thinly on both faces of 7 to 8
gear teeth, and turn the ring gear forward and back-
ward several times after installing a box wrench on
the output gear lock nut. Judge the gear teeth contact
by observing the pattern formed on the gear teeth. If
the tooth contact is not correct, make adjustment ac-
cording to the "Drive Pinion Protrusion Adjustment"
and "Ring Gear Backlash and Differential Case Bear-
ing Starting Torque Adjustment" procedures.

(2) Correct teeth contact


Heeal The pattern should be slightly leaning to the inside circle
contact of the ring gear with respect to the center of the tooth
length, as shown.
(3) Heeal contact
Move the drive pinion croser to the ring gear by de-
creasing the drive pinion adjusting shim thickness.
Then move the ring gear away from the pinion to ad-
just the backlash.

(4) Toe contact


Move the pinion away from the ring gear by increasing
the drive pinion adjusting shim thickness. Then move
the ring gear closer to the pinion to adjust the back-
lash.
(5) Flank contact (low shallow contact)
Flank Move the pinion awayfrom the ring gear by increasing
contact
the drive pinion adjusting shim thickness. Then move
the ring gear closer to the pinion to adjust the back-
lash.

(6) Face contact (high shallow contact)


Face
contact
Move the pinion closer to the ring gear by decreasing
the drive pinion adjusting shim thickness. Then move
the ring gear away from the pinion to adjust the back-
lash.

[Point 41
Reassembiy:
Adjust the drive pinion protrusion by means of the drive pin-
ion bearing retainer shims. Select the shim by teeth con-
tact inspection. (See Point 3.)

Shim thickness:
0.10.0.15.0.35 and 0.45 mm
(0.0039~0.0059~0.0138 and 0.0177 in)

[Point 51
Reassembly:
After the drive pinion bearing starting torque adjustment,
caulk the output gear lock nut.
0 Good examples 0
Point contact

[Point 61
Reassembly:
SST 09370-20270-71
Reassembly:
Adjust the drive pinion bearing starting torque.

1. Install the output gear and tighten the lock nut to the speci-
fied torque.
2. Set a torque wrench on the lock nut, and measure the start-
ing torque.

Starting torque:
-
10.79 13.24 N-m
-
(110 135 kg-cm)
-
[7.96 9.77 ft-lb]

3. If the starting torque does not satisfy the standard make


adjustment by changing the shim thickness.

Shim thickness:
0.03.0.1 0.0.15.0.35 and 0.45 mm
(0.0012~0.0039~0.0059~0.0138 and 0.0177 in)

[Point 71
Disassembly:
SST 09950-40011
SST

Reassembly:
Use the SST and install the pilot bearing.
SST 09608-04031
Check the installed direction.

[Point 81
Disassembly:
SST 09420-23000-71
Reassembly:
SST 09316-60011
DIFFERENTIAL CASE ASSY
DISASSEMBLYINSPECTION-REASSEMBLY T = N-m (kgf-cm) [ft-lbfl

Disassembly Procedure
1 Remove the differential case bearings. [Point I ]

2 Remove the differential upper case. [Point 21

3 Remove the side gear and pinion gear. [Point 31

4 Remove the ring gear. [Point 41

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
SST a [Point I]
Disassembly:
SST 09950-40011 --- @
09950-60010 --- @

Reassembly:

, SST @
Install the side bearing.
1. Use the SST and drive in the side bearing to the end
surface.
SST 09950-60020 --- O
09950-70010 --- @
2. Use a striking driver and fully drive in the bearing.

[Point 21
Disassembly-Reassembly:
Check the match marks.

Reassembly:
Apply locking agent (08833-00070) on the set bolt threaded
Match marks portion before reassembly.

[Point 31
Inspection:
Measure the inside diameter of the differential pinion.
Standard: 22.12 mm(0.8709 in)
Limit: 22.22 mm(0.8748 in)

Inspection:
Measure the spider outside diameter
Standard: 22.00 mm(0.8661 in)
Limit: 21.75 mm(0.8563 in)
Inspection:
Measure the side gear thrust washer thickness.

Standard: 1.6 mm (0.063 in)


Limit: 1.3 mm (0.051 in)

Inspection:
Measure the pinion gear thrust washer thickness.

Standard: 1.6 mm (0.063 in)


Limit: 1.0 mm (0.039 in)

Reassembly:
Install the side gear thrust washer with its oil groove facing
the gear.

Reassembly:
Apply chassis grease (molybdenum disulfide grease) on
both sides of the spider pinion thrust washer before reas-
sembly.

[Point 41
Reassembly:
Apply locking agent (08833-00070) on the set bolt threaded
portion before reassembly. Tighten the set bolts gradually
in the diagonal order, and finally tighten in the circular order
to the specified torque.
FRONT AXLE
(2.3TON SERIES)
Page
GENERAL ........................................................................ 2-2
SPECIFICATIONS .......................................................... 2 9
COMPONENTS .............................................................. 2 4
FRONT AXLE SHAFTmAXLE HUB ............................. 2-5
REMOVAL*INSTALLATION...............................................2-5
FRONT AXLE BRACKETmAXLE HOUSING ............ 2-9
REMOVAL*INSTALLATION............................................... 2-9
2-2

GENERAL
2 ton series

3 ton series
SPECIFICATIONS
Vehicle model
2 ton series 3 ton series
Item

Front axle type Full-floating +


+

Suspension type Fixed to frame +

Axle shaft diameter mm (in) 40 (1.57) +

Axle shaft diameter (spline portion) mm (in) 40 (1.57) e


COMPONENTS
2 ton series

3 ton series
FRONT AXLE SHAFTeAXLE HUB
REMOVAL- INSTALLATION T = N.m (kgf-cm) [I?-lbfl
Removal Procedure
1 Drain differential oil. [Point I]

2 Jack up the vehicle and remove front wheel

3 Remove the front axle shaft. [Point 21

4 Remove the axle shaft oil seal. [Point 31

5 Remove the bearing lock nut and plate. [Point 41

6 Remove the outer bearing roller and front axle hub. [Point 51

7 Remove the oil seal and inner bearing roller. [Point 61

8 Remove the bearing outer race. [Point 71

9 Remove the hub bolt.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Apply thread tightener (08833-00070)on the hub bolt set nut before tightening.

Point Operations
[Point I ]
Installation:
Fill Hypoid gear oil to the specified level after installation.
A = 15 mm (0.59 in) or less

[Point 21
Removal.lnstallation:
Carefully operate so as not to damage the oil seal by con-
tact with the axle shaft.
[Point 31
Removal:
SST 09320-23000-71

Installation:
SST 09950-60010 --- O
09950-70010 --- @

[Point 41
Removal.Installation:
SST 09509-55020

Installation:
Adjust the front axle hub starting force.
1. Install the plate.
2. Fully tighten the bearing lock nut, and rotate the hub by 4
to 5 turns to run in the bearing.
3. Return the bearing lock nut by 1/12 to 116 turn (30 to
60°), and rotate the hub by 4 to 5 turns again.
4. Set a spring scale on a hub bolt, and measure the start-
ing force.

Standard:
25.5 - 72.6 N (2.6 - 7.4 kg9 [5.7 - 16.3 Ibf]
5. If the standard is not satisfied, adjust the degree of bear-
ing lock nut tightening for adjustment.
6. Install the nut lock bolt.
Coat thread tightener (08833-00070) on the nut lock bolt
before tightening.
[Point 51
Installation:
Fill MP grease in the hub before installing the front axle hub.

Installation:
SST 09370-10410-7 1

[Point 61
Removal:
Use a screwdriver or the like to remove the oil seal.

Installation:
SST 09950-60020 --- @I
09950-70010 --- @

[Point 71
Removal:
Use a brass bar to remove the bearing outer race.

Installation:
SST 09950-60020 --- @I
09950-70010 --- @
FRONT AXLE BRACKET*AXLEHOUSING
REMOVAL.INSTALLATION T = N.m (kgf-cm) [ft-lbfl

T = 265 - 343 (2700 - 3500) [195.3 - 253.21

- -
T = 107.9 137.3 (1100 1400) 179.59 - 101.3]

T = 118 - 137 (1200 - 1400) [86.8 - 101.31

Removal Procedure
1 Remove the front axle & drive motor ASSY. (See page 1-5)

2 Remove the front axle shaft and axle hub. (See page 2-5)

3 Remove the brake ASSY. [Point 11

4 Remove the front axle bracket and O-ring.

5 Remove the axle hosing and O-ring.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Apply grease on the O-ring before installation.
Point Operations
[Point I ]
Installation:
Apply sealing agent (08826-00080) on the mating surfaces
of the brake backing plate and front axle bracket before in-
stallation.

Installation:
Apply locking agent (08833-00070) on the set bolts before
tightening.
REAR AXLE
(2.3TON SERIES)
Page
GENERAL ........................................................................3-2
SPECIFICATIONS .........................................................3-3
COMPONENTS ..............................................................3 9
REAR AXLE ASSY ....................................................... 3-5
...............................................3-5
REMOVAL*INSTALLATION
STEERING KNUCKLE .................................................. 3-7
REMOVALINSTALLATION............................................... 3-7
REAR AXLE CYLINDER ...............................................3-11
REMOVAL*INSTALLATION............................................... 3-11
DISASSEMBLVINSPECTION~REASSEMBLY .................. 3-13
REAR WHEEL ALIGNMENT ....................................... 3-15
GENERAL
Rear Axle Cylinder

SPECIFICATIONS
Rear axle type Elliot type

Rear axle suspension type Center-supported right-left rocking type

Toe-in mm (in) 0 (0)


Camber degree 1.5"
Wheel alignment
Caster degree 0"

King pin angle 0"

5FBCU18,30 - 5FBCU18 1740 (68.5)

5FBCU20,30 - 5FBCU20 1765 (69.5)

5FBCU25,30 - 5FBCU25 1790 (70.5)


Minimum turning radius (outermost) mm (in)
5FBCU30,30 - 5FBCU30 1960 (66.0)

5FBCHU20,30- 5FBCHU20 1920 (75.5)

5FBCHU25,30 - 5FBCHU25 1940 (76.0)

Cylinder type Double acting

Piston rod outside


Rear axle cylinder 50.0 (1.969)
diameter mm (in)

Cylinder bore mm (in) 76.0 (2.992)


COMPONENTS

4302

L... a
.

4302-024
REAR AXLE ASSY
REMOVAL- INSTALLATION T = N-m (kgf-cm) [ft-lbfl

Removal Procedure
1 Remove the counter weight.
2 Apply the parking brake and chock the front wheels.
3 Jack up the frame and support it with the wooden block.
4 Remove the rear wheels (See removal procedure steps 2 to 4 in steering knuckle removal section on
page 3-7).
5 Disconnect the rear axle cylinder hose.
6 Support the rear axle ASSY with a garage jack.
7 Remove the rear axle ASSY. [Point I]
8 Remove the center pin bushing. [Point 21

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
After installation, add grease through each grease fitting. Add genuine molybdenum disulfide grease
at the rear axle beam center pins (two places). Use MP grease to other grease fittings.
Point Operations
[Point I ]
Inspection:
Measure the rear axle front to rear clearance.
1. Before removing the rear axle ASSY, measure the front
to rear clearance on the rear side.

Standard clearance: 0.7 mm (0.028 in) or less

2. If the measured value does not satisfy the standard, re-


move the rear axle ASSY and make adjustment by se-
lecting the spacer.

Spacer thickness:
L I 1.2.2.3.3.0.3.5.4.0.4.5 and 5.0 mm
j First and 0.1 97 in)
(0.047~0.091~0.118~0.138~0.157~0.177
I
I : I Second
3, Install the spacer at the rear side center pin.
The first spacer shall be installed with its chamfered at
the inside diameter in contact with the center pin boss.
t ;
I

[Point 21
Inspection:
Inspect the inside diameter of the rear axle center pin bush-
ing.

Limit: 52.0 mm (2.047 in)

Installation:
Apply molybdenum disulfide grease on the bushing and in-
stall the bushing by aligning the grease groove in the bush-
ing with the grease fitting position.
-rI I I

Grease fitting
STEERING KNUCKLE
REMOVAL-INSTALLATION T = N-m (kgf-cm) [ft-lbfl

Removal Procedure
1 Jack up the vehicle.
2 Remove the hub cap. [Point 11
3 Remove the castle nut and claw washer. [Point 21
4 Remove the outer bearing and rear wheel. [Point 31
5 Remove the bearing outer race from the rear wheel. [Point 41
6 Remove the inner bearing roller and oil seal. [Point 51
7 Disconnect the tie rod (on the knuckle side).
8 Remove the king pin cover.
9 Remove the king pin lock bolt and king pin. [Point 61
10 Remove the thrust bearing, spacer and steering knuckle.
11 Remove the king pin oil seal and needle roller bearing. [Point 71

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
After installation, add MP grease through grease fittings.
Point Operations
[Point 11
Installation:
Fill MP grease in the hub cap, and install by tapping the
flange portion.

[Point 21
Installation:
Adjust the rear wheel starting force.
1. Install the claw washer in the correct direction.
2. Install the castle nut and temporarily tighten it to a torque
of 15 to 32 N-rn(150 to 330 kgf-cm) [I 0.9 to 23.9 ft-lbfl.
3. Rotate the hub by 3 to 5 turns to run in the bearing.

4. Set a spring scale at the outer periphery of the wheel,


and measure the starting force.

Standards: 9.8 - 29 N (1.0 - 3.0 kg9 [2.2 - 6.6 Ibf]


5. If the standard is not satisfied, adjust the degree of castle
nut tightening for adjustment.
6. Install a new cotter pin.

[Point 31
Installation:
Fill MP grease in the hub and knuckle spindle.

Installation:
Install the rear wheel and outer bearing.
SST 09370-20270-71
[Point 41
Removal:
Use a brass bar and remove the bearing outer race

Installation:
SST 09950-60020 --- @
09950-7001 0 --- @

SST
[Point 51
Removal:
SST 09950-40011

Installation:
Install the oil seal and inner bearing roller.
1. Use the SST and install the oil seal.
SST 09370-10410-71

2. Use the SST and install the inner bearing roller.


SST 09370-20270-71

[Point 61
Inspection:
Measure the king pin outside diameter

Limit: 27.8 mm (1.094 in)


Installation:
Measure the steering knuckle starting force.
1. Temporarily install the king pin and king pin lock bolt.
Select the spacer so as to minimize vertical looseness
of the knuckle, and install it on top of the thrust bearing.

2. Set a spring scale at the tip end of the knuckle spindle,


and measure the starting force.

Standard: 19.3 N (2.0 kgf) [4.4 Ibf] or less

3. If the standard is exceeded, check the king pin for bend,


the needle bearing for damage and axle beam for defor-
mation.

Spacer thickness:3.0,3.5,4.0 and 4.5 mm


(0.118,0.138,0.157 and 0.177 in)

4. Tighten the lock nut for the king pin lock bolt.

[Point 71
Removal:
Remove the king pin oil seal and needle roller bearing.
1. Use a straight-edge screwdriver to remove the dust seal
and oil seal.
2. Use the SST and remove the needle roller bearing.
SST 09950-60010 --- @
09950-70010 --- @

Installation:
Install the needle roller bearing and king pin oil seal.
1. Use the SST and install the needle bearing.
Check the needle roller bearing press-fitting surface,
pressing direction and installation depth.
SST 09950-60010 --- @
0 rnrn
09950-70010 --- @
(0 in) 2. Install the dust seal.
3. Use the SST and install the oil seal.
SST 09950-60010 --- O
09950-70010 --- @

4 rnrn
(0.16 in)

Press-fitting direction
3-11

REAR AXLE CYLINDER


REMOVAL0lNSTALLATlON T = N-m (kgf-cm) [ft-Ibfl

Removal Procedure
1 Jack up the vehicle.

2 Disconnect the tie rod (on the piston rod side). [Point 11

3 Disconnect the rear axle cylinder hose and remove the fitting. [Point 21

4 Remove the rear axle cylinder.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Point Operations
[Point 11
Removal:
Mark the punch mark position on each of cylinder end pins
LH and RH.

Installation:
Install each cylinder end pin by aligning the punch mark
with the mark.

[Point 21
Installation:
Install the fitting in the illustrated direction.
DISASSEMBLY*lNSPECTIONgREASSEMBLY T = N-m (kgf-cm) [ft-Ibfl

Disassembly Procedure
1 Remove the through bolt.

2 Remove the piston rod guide.

3 Remove the piston rod. [Point I ]

4 Inspect the cylinder. [Point 21

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Coat hydraulic oil before reassembly.
Point Operations
[Point I ]
Inspection:
Measure the piston rod outside diameter.
Limit: 49.92 mm (1.9654 in)

Inspection:
Measure the bend of the piston rod.
Limit: 0.5 mm (0.020 in)

Reassembly:
Warm the seal ring to a little below 80°C (176°F) in hot oil
or water before installation.
Do not stretch it excessively.

Caution:
Operate carefully to avoid scalding.

[Point 21
Inspection:
Measure the rear axle cylinder bore.

Limit: 76.35 mm (3.0059 in)


REAR WHEEL ALIGNMENT
Toe-in Inspection
1. Check to see that dimensions Ar and A! of the rear axle cylinder are equal.

2. Measure the toe-in (Bf - Br).


Standard: 0 + 4 mm (0 + 0.16 in)

Toe-in Adjustment
1. Check to see that Ar and A! of the rear axle cylinder are
equal.
Punch mark on plate side 2. Align the punch mark on the cylinder end pin (eccentric pin)
with the punch mark on the plate on the front side for both
the LH and RH sides.
3. Measure and adjust the toe-in (Bf - Br).
Standard: 0 + 4 mm (0 + 0.16 in)
If the standard is not satisfied, make adjustment by the cyl-
inder end pin in the range where the difference between Rt
and Rr is within 0 t 3 mm (0.12 in).
Punch mark on cylinder end pin side ( I ) When measued value > 4 mm (0.16 in):
Measure Rt and Rr, and adjust the cylinder end pin on
the smaller side toward IN.
(2) When measured value < 4 mm (0.16 in):
Measure Rt and Rr, and adjust the cylinder end pin on
the greater side toward OUT.
Note:
If Rt equals to Rr, adjust the same amount on the LH
and RH sides.
If the standard is not attained by adjustment on one
side, make adjustment also on the other side.
4. Install the plate. The plate can be installed with either face
UP.
5. After adjustment, fully steer the tires and check to see that
they do not come into contact with the vehicle body.
MAST
(2.3TON SERIES)
Page
V MAST ASSY................................................................. 4-2
COMPONENTS ............................................................... 4-2
REMOVAL*INSTALLATION ............................................... 4-5
REMOVAL-INSTALLATION (WJLIFTBRACKET) .............. 4-7
MAST DISASSEMBLY*INSPECTION*REASSEMBLY........ 4-9
LlFTBRACKET DISASSEMBLY-INSPECTION-
REASSEMBLY ............................................................. 4-11
MAST ADJUSTMENT (V MAST) ....................................... 4-13
MAST ROLLER REMOVAL-INSTALLATION ..................... 4-18
CHAIN .............................................................................4-19
INSPECTION .................................................................... 4-19
REASSEMBLY O/.FV*FSV)............................................... 4-19
REASSEMBLY (Q FV) ....................................................... 4-20
ADJUSTMENT ................................................................ 4-21
FORK................................................................................. 4-21
REMOVAL ........................................................................4-21
INSTALLATION ................................................................. 4-21
INSPECTION .................................................................... 4-21
FV*FSV MAST ASSY .................................................... 4-22
COMPONENTS ................................................................ 4-22
FSV) ....................................... 4-25
MAST ADJUSTMENT (FV-
QFV MAST ASSY .......................................................... 4-29
COMPONENTS ................................................................ 4-29
MAST ADJUSTMENT (an/)............................................. 4-31
LlFT CYLINDER ROD SHIM ADJUSTMENT
(PREVENTION OF UNEVEN LIFTING) ................. 4-33
V MAST ASSY
COMPONENTS

2 ton series 6301


V FV -

40

FSV QFV

02

40
6301-467A
3 ton series 6301
V FV

02

6301-465
3 ton series 6302

6302-298
- - - - -

REMOVAL*INSTALLATION T = N-m (kgf-cm) [ft-lbfl

Removal Procedure
1 Set the mast vertical and fully lower the fork.

2 Disconnect the chain. [Point 11

3 Remove the chain wheel. [Point 21

4 Remove the lift bracket. (For lift bracket removal, raise the inner mast until it comes off from the lift
bracket, and slowly run the vehicle backward to depart from the lift bracket.)

5 Remove the toe board.

6 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the
inner mast, operate the lift lever several times to release the residual pressure in the lift cylinder.)

7 Slightly hoist the mast.

8 Remove the mast support cap.

9 Remove the tilt cylinder front pin. [Point 31

10 Remove the mast ASSY.


Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior
surfaces. Apply MP grease to the tilt cylinder front pin.
Adjust lift cylinder uneven movement when the mast ASSY, outer mast, inner mast or either lift
cylinder is replaced. (See page 4-34.)
Adjust the chain tension after installation.

Point Operations
[Point I ]
Removal-Installation:
SST 09630-23600-71

[Point 21
Removal:
If the fitting is hard, use the SST for removal.
SST 09950-40011

[Point 31
Removal:
SST 09810-20172-71
REMOVAL. INSTALLATION (WILI FT BRACKET) T = N-m (kgf-cm) [ft-lbfj

Removal Procedure
1 Set the mast vertical.

2 Remove the forks.

3 Remove the toe board.

4 Disconnect the overflow hose and high pressure hose. (Before hose disconnection, fully lower the
inner mast and operate the lift lever several times to release the residual pressure from the lift cylin-
der.)

5 Slightly hoist the mast.

6 Remove the mast support cap.

7 Remove the tilt cylinder front pin. [Point I]

8 Remove the mast ASSY W/lift bracket.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Apply molybdenum disulfide grease on the mast support bushing and mast support cap interior
surfaces. Apply MP grease to the tilt cylinder front pin.
Correct lift cylinder uneven lifting, if any, when the mast ASSY, outer mast, inner mast or either
lift cylinder is replaced. (See page 4-33.)

Point Operation
[Point I ]
Removal:
SST 09810-20172-71
MAST DISASSEMBLY-INSPECTION-REASSEMBLY

Disassembly Procedure
1 Remove the hose cover.

2 Disconnect the high pressure hose.

3 Remove each cylinder rod end set bolt, and take each rod end off. [Point 11

4 Remove each cylinder support. [Point 21

5 Remove each cylinder bottom set bolt, and remove each lift cylinder.

6 Slide the inner mast in the lowering direction, and remove the lift rollers.

7 Remove the mast strip. [Point 31

8 Remove the outer mast.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.
Point Operations
Shim
[Point I ]
Disassembly:
Shim adjustment is made at the lift cylinder rod end for pre-
venting uneven lifting by lift cylinders LH and RH.
Take a note on the cylinder where the adjustment is made
and the number of shims in use.

[Point 21
Disassmbly:
Take a note on the number of cylinder support shims in use.

Reassembly:
Make cylinder support shim adjustment if the mast or either
cylinder is replaced.
With the cylinder rod end inserted to the inner mast, insert
shim(s) between the cylinder support and outer mast to elimi-
nate the clearance. The shim thickness should be slightly
greater than the clearance.

[Point 31
Inspection:
Measure the mast strip thickness.

Thickness limit: A = 2.7 mm (0.106 in)


B = 1.3 mm (0.051 in)
LIFTBRACKET DISASSEMBLY*INSPECTION*REASSEMBLY T = N-m (kgf-cm) [ft-lbfl

Disassembly Procedure
1 Remove lift rollers. [Point 11

2 Remove side rollers. [Point 21

3 Remove the back rest.

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Point Operations
[Point I ]
Disassembly:
SST 09950-4001 1
[Point 21
Reassembly:
Install the side roller in the correct direction.
The side chamfered with a greater radius of the roller shall
be on the front side of the vehicle.
MAST ADJUSTMENT (V MAST)
Lift Roller Adjustment at Mast

1. Clearance between inner mast roller and outer mast

;::rJ
Inner mast

into

These ;oilers

Adjust the mast overlap to approx. 450 mm (17.72 in).


Shift the inner mast to one side to bring the roller into
contact with the outer mast, and inspect the clearance
between the roller side face and mast where they are the
closest.

Standard: A = 0 - 0.8 mm (0 - 0.031 in)


If the standard is not satisfied, make adjustment by chang-
ing the inner mast roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)


I (3) Distribute shims equally to the rollers on the left and right
Shim side.
(4) After the adjustment, see that the inner mast moves
smoothly in the outer mast.
2. Clearance between outer mast roller and inner mast

These rollers

Outer
mast inner
mast

Adjust the mast overlap to approx. 450 mm (17.72 in).


Shift the inner mast to one side to bring the roller into
contact with the outer mast, and inspect the clearance
between the roller side face and mast where they are the
closest.

Standard: B = 0 - 0.5 mm (0 - 0.020 in)


If the standard is not satisfied, make adjustment by chang-
ing the outer mast roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) Distribute shims equally to the rollers on the left and right
side.
(4) After the adjustment, see that the inner mast moves
smoothly in the outer mast.
4-15

Roller Adjustment at Lift Bracket

1. Middle/lower lift roller and side roller clearance adjustment

:$tif
lnner
mast
bracket
11
100 rnrn (3.94 in)

100 rnrn (3.94 in)

lnner
mast bracket

(1) Bring the center of the side roller in the upper part of the
lift bracket to approx. 100 mm (3.94 in) from the top of
the inner mast.
(2) Remove side rollers.
(3) Shift the lift bracket to one side to bring the roller into
contact with the inner mast, and inspect on the opposite
side the clearance between the roller side face and the
mast where they are the closest. (No adjustment is nec-
essary for the upper lift rollers since they are fastened
by snap rings.)

Standard
- -
C = 0 0.5 mm (0 0.020 in)

If the standard is not satisfied, make adjustment by chang-


ing the lift roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)


(4) Distribute shims equally to the left and right side.
(5) Install side rollers.

(6) After adjusting the middle and lower lift rollers, bring the
side roller on one side into contact with the outer mast
and measure on the opposite side the clearance between
the side roller and inner mast surface.

Standard
- -
D = 0 0.5 mm (0 0.020 in)

If the standard is not satisfied, make adjustment by


changing the side roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

7) Distribute shims equally to the left and right side. (See


Lift Bracket Disassembly-Inspection-Reassembly sec-
tion for the side roller installation method. Shim replace-
ment is possible on the vehicle.)
(8) After the adjustment, see that the lift bracket moves
smoothly over the entire length of the mast.
Mast Strip Adjustment

1. Mast strip clearance adjustment


-

- Roller

Bring into contact

Outward

Note: The strip is of tapered shape, thicker side of the


width must be placed outward.

(1) Lower the inner mast fully.


(2) With the inner mast in contact with the outer mast roller,
measure the clearance between the mast strip and in-
ner mast.

Standard: E = 0.5 - 1.0 mm (0.020 - 0.039 in)


If the standard is not satisfied, make adjustment by
changing the mast strip shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) After the adjustment, check the mast for smooth move-
ment.
MAST ROLLER REMOVAL-INSTALLATION
1. Remove the lift bracket. (See steps 1 to 4 of the mast
ASSY removal procedure on page 4-5.)
2. Jack up the vehicle, and support tires with wooden blocks.
Also lock the front and rear tires from rotation.
3. Remove the lift cylinders. (See page 5-11.)

4. Remove mast rollers.


I (1) Remove wooden blocks under the inner mast, and
Shim lower the hoisted inner mast slowly until mast rollers
appear.
(2) Support the bottom of the inner mast with wooden
blocks.
(3) Remove the inner mast rollers and shims.

(4) Remove the outer mast rollers and shims.


5. The installation procedure is the reverse of the removal
procedure.
CHAIN
INSPECTION
1. lnspect the chain elongation according to the following
procedure:
SST 09631-22000-71
(1) Since the SST measurement line varies with the chain type,
set the corresponding line on the chain as illustrated.
(2) Check the number of the chain to be inspected, and
check the pin center position.
If the pin center is at the arrow mark on the chain gauge,
it is the limit.
Chain Link Pitch Standard (V.FV.FSV.QFV)
Vehicle model Pitch mm (in) Type Chain No.
2 ton series
QFV inner and 19.05 (0.7500) BL634 60
middle chain
3 ton series 25.4 (1 .O) BL823 80
QFV outer chain 25.4 (1 .O) BL834 80

Note:
Perform measurement without removing the chain
from the vehicle.
lnspect elongation over the entire chain length since
it may be localized.

REASSEMBLY O/.FV0FSV)
1. Installing direction
-

mast FV: Lift bracket


V: Lift bracket FSV: Inner mast
and portion FSV: Lift bracket
Outside of 0 ' Rear of 0
vehicle vehicle

Split pin Split pin


Sketch

Install with the split pin on the Install with the split pin on the Install with the split pin on the
vehicle center side. vehicle outside. vehicle rear side.

2. Chain adjusting nut tightening order


(1) Tighten nuts @ andI0. T = 49.0 - 78.0 N-m (500 - 800 kgf-cm) [36.2 57.9 ft-lbfl -
(2) Tighten nut 0.
V: Outer mast
Applicable mast and FV: Front cylinder (3 ton series) FSV: Outer mast
FV: Front cylinder (2 ton series)
portion FSV: Front cylinder (3 ton series)
FSV: ~~~~tcylinder (2 ton series)

Clamp

Sketch
0 0 0
0 0 0
REASSEMBLY (QFV)
1. Installing direction
As shown in the table below.
2. Chain adjusting nut tightening order
(I) Tighten nuts @ and 0. T = 49.0- 78.0N.m (500 - 800 kgf-cm) [36.2- 57.9fi-lbfl
(2) Tighten nut @.

$
Outer chain Middle chain Inner chain

Clamp ZZ clamp 5s @ yw5 $&


:r

y7
T = 98.0-
[72.35
147.0 N m (1000
- 108.5 ft-lbfl
- 1500 kgf-cm)

Upper middle

&
Split pin

lnner mast

T = 98.0 - 147.0 N.m (1000 - 1500 kgf-cm) Installation side of split pin is at center Installation side of split pin is outward of
[72.35 - 108.5 ft-lbfl side of the truck. the truck center.

Chain connection
ADJUSTMENT
1. Park the vehicle on a flat ground and set the mast vertical.

2. Lower the fork to the ground, and make adjustment to eliminate any chain sag by turning the adjusting
nut.

3. Check to see that the chain tension is equal on the left and right side.
4. Check to see no chain twist.

5. See that the fork height is the standard.

6. With the fork raised fully, check to see that the lift bracket freeing prevention stopper at the inner mast
is not in contact with the lift bracket.

FORK
REMOVAL
1. Set the fork at approx. 20 cm (7.9 in) above the ground.
2. Place a wooden block under the knotched portion of the
fork rail.
3. Unlock the fork by lifting the fork stopper pin, and shift
the fork blades, one at a time, to the center.
4. Slowly lower the fork for removal.

INSTALLATION
The installation procedure is the reverse of the removal pro-
cedure.

INSPECTION
1. Inspect misalignment of the fork tip ends.

Limit: 10 mm (0.39 in)

If the limit is exceeded, inspect individual fork bend, loose-


ness of fork installation and lift bracket finger bar distor-
tion.
FV*FSV MAST ASSY
COMPONENTS

FSV 31
61O I

43A
6101-491A
FV 2 ton series 6302

21K

FV 3 ton series

6302-297
FSV 6302
2 ton series

FSV
3 ton series

6302-296
MAST ADJUSTMENT (FV-FSV)
Lift Roller Adjustment at Mast

1. Clearance between:
lnner mast roller and outer mast (FV).
lnner mast lower roller and middle mast (FSV).
Middle mast lower roller and outer mast (FSV).

Position where the


roller is the closest

FSV mast
FV mast
lnner mast

Outer mast

@These rollers

(1) Adjust the mast overlap to approx. 450 mm (17.72 in).


These rollers

(2) Shift the inner mast to one side to bring the roller into contact with the outer mast, and inspect the
clearance between the roller side face and mast where they are the closest.

Standard: A = 0 - 0.8 mm (0 - 0.031 in)


If the standard is not satisfied, make adjustment by changing the inner mast roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) Distribute shims equally to the rollers on the left and right sides.
(4) After the adjustment, see that mutual mast movement is smooth.
2. Clearance between:
Outer mast roller and inner mast (FV).
Middle mast upper roller and inner mast (FSV).
Outer mast upper roller and middle mast (FSV)

N mast FSV mast These rollers


These rollers

Outer mast
Outer mast

Middle mast

Inner
mast

(1) Adjust the mast overlap to approx. 450 mm (17.72 in).


(2) Shift the inner mast to one side to bring the roller into contact with the inner mast, and measure on
the opposite side the clearance between the roller side face and mast where they are the closest.

Standard: B = 0 - 0.5 mm (0 - 0.020 in)


If the standard is not satisfied, make adjustment by changing the outer mast roller shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) Distribute shims equally to the rollers on the left and right sides.
(4) After the adjustment, see that mutual mast movement is smooth.
LiftISide Roller Adjustment at Lift Bracket

FV-FSV mast

Lower lift roller

100 mm (3.94 in)

Lift bracket

FSV Mast N Mast

(1) Raise the lift bracket to the uppermost position for the FSV mast, and bring the center of the upper
lift roller to approx. 100 mm (3.94 in) from the top of the inner mast for FV mast.

(2) Shift the lift bracket to one side to bring the lower lift roller, and measure on the opposite side the
clearance between the roller side face and the mast where they are the closest.

Standard: C = 0 - 0.5 mm (0 - 0.020 in)


If the standard is not satisfied, make adjustment by changing the shim thickness. (Distribute shims
equally to the rollers on the left and right sides.)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) After the inspection and adjustment in step (3) above, inspect and adjust the side rollers.
Bring the side roller on one side into contact with mast side surface, measure on the opposite side
the clearance between the side roller and the inner mast side surface where they are the closest.
Standard: D = 0 - 0.5 mm (0 - 0.020 in)
If the standard is not satisfied, make adjustment by changing the shim thickness. (Distribute shims
equally to the rollers on the left and right sides.)
Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(4) After the adjustment, check to see that the lift bracket moves smoothly over the entire length of the
mast.
Mast Strip Adjustment

Mast strip clearance adjustment

FV mast

Bring into contact

FSV mast

Bring into contact

w
-
(1) Lower the inner (or middle) mast fully.
(2) With the inner (or middle) mast in contact with the outer mast roller (or middle mast upper roller),
measure the clearance between the mast strip and mast.

Standard: E = 0.5 - 1.0 mm (0.020 - 0.039 in)


If the standard is not satisfied, make adjustment by changing the mast strip shim thickness.

Shim thickness: 0.5 and 1.0 mm (0.020 and 0.039 in)

(3) After the adjustment, check the mast for smooth movement.
4-29

QFV MAST ASSY


COMPONENTS
MAST ADJUSTMENT (QFV)
Lift Roller Adjustment
The lift roller adjustments, for most part, are same with FSV mast. Where to be adjusted are as shown:

Channel seen from the top Channel seen from the bottom

--
0 0.5 mm
(0 0.02 in)

-
0 0.5 mm
<
-
(0 0.02 in)

-
0 0.8 mm
-
(0 0.03 in) 450 mm
(17.7 in)

450 mm
(17.7 in)

450 mm
(17.7 in)

Note:
The mast strip & shim adjustment between the mast channels can also be performed in the same
sequence with those of V.FV.FSV.
Lift Roller Position on Each Upright:

Inner

Upper Middle

Lower Middle

B f

Outer
LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN
LIFTING)

Note:
For double lift cylinders, inspection and adjustment are required t o prevent uneven lifting on
the left and right sides due to tolerances of parts, etc.
The inspection and adjustment must be made whenever any of the following parts is replaced:
Lift cylinder ASSY, lift cylinder rod SUB-ASSY, lift cylinder SUB-ASSY, mast ASSY, outer mast
SUB-ASSY, and inner mast SUB-ASSY

1. Inspection method
Slowly raise the inner mast, and observe the stopping
states of the left and right cylinder rods at the moment
when the inner mast reaches the maximum height.
(1) Normal case
Both the left and right rods stop almost simultaneously
with almost no shaking of the inner mast.
(2) Abnormal case
The rods stop with slight difference and the top of the
inner mast shakes at the time of stopping. To correct
this, add shims to the cylinder that stops first.

2. Adjustment method
(1) Raise the inner mast, set the SST to the outer mast
tie beam, and lower the inner mast until it reaches the
SST.
SST 09610-22000-71
(2) Remove the set bolt of the cylinder rod end on the
side requiring shim adjustment.
(3) Slowly lower the lift cylinder rod and disconnect the
cylinder rod end.
(4) Place shims on the cylinder rod end. Slowly raise the
cylinder rod end into the inner mast.
(5) Fix the set bolt of the cylinder rod end.
(6) Raise the inner mast for reinspection.
(7) Repeat the inspection and adjustment until the num-
ber of shims is determined.

Shim thickness:
0.5 and 1.0 mm (0.020 and 0.039 in)
CYLINDER
(2.3TON SERIES)
Page
LlFT CYLINDER (V)
REAR LIFT CYLINDER (FV-FSV*QFV)................. 5-2
GENERAL ........................................................................5-2
SPECIFICATIONS ............................................................ 5-5
COMPONENTS ................................................................ 5-7

FLOW REGULATOR VALVE (V*FV*FSV-QFV)..... 5-22


GENERAL .................................................................... 5-22
SPECIFICATIONS .............................................................5-22
SAFETY DOWN VALVE (V-FV-FSVoQFV).............. 5-23
GENERAL .....................................................................5-23
FRONT LIFT CYLINDER (W-FSV-QFV) ................. 5-24
GENERA1 ........................................................................5-24
SPECIFICATIONS .............................................................5-25
COMPONENTS ............................................................... 5-26
REMOVAL~INSTALLATION ..............................................5-27
DISASSEMBLY.INSPECTI0N.REASSEMBLY.................. 5-28
TILT CYLINDER .............................................................*

* The tilt cylinder has been unchanged.


Please refer to the Repair Manual 5FBCU15. 18.20.25. 30 Pub. No. CU305.
LlFT CYLINDER (V) REAR LlFT CYLINDER (FV*FSV*QFV)
GENERAL
Lift Cylinder 0//2Ton Series)

Lift Cylinder (V13 Ton Series)


Rear Lift Cylinder (FV)
Rear Lift Cylinder (FSV12 Ton Series)

Rear Lift Cylinder (FSVl3 Ton Series)


Rear Lift Cylinder (QFV)

SPECIFICATIONS
Lift Cylinder O/)

Vehicle model
2 ton series 3 ton series
Itern
Cylinder type Single-acting Single-acting
Cylinder bore mrn (in) 50.0 (1.97) 55.0 (2.17)
Piston rod outside diameter rnm (in) 42.0 (1.65) 45.0 (1.77)
Piston seal type U packing U packing
Rod seal type U packing U packing
Others Built-in safety down valve (RH, LH)
Rear Lift Cylinder (FV)

Vehicle model
2 ton series 3 ton series
ltem
Cylinder type Single acting Single acting
Cylinder bore mm (in) 50.0 (1.97) 55.0 (2.17)
Piston rod outside diameter mm (in) 34.9 (1.37) 40.0 (1 57)
Rod seal type U packing U packing
Others Built-in safety down valve (LH)

Rear Lift Cylinder (FSV)

Vehicle model
2 ton series 3 ton series
ltem
Cylinder type Single acting Single acting
Cylinder bore mm (in) 50.2 (1.98) 55.0 (2.17)
Piston rod outside diameter mm (in) 42.0 (1.65) 45.0 (1.77)
Piston seal type U packing U packing
Rod seal type U packing U packing
Others Built-in safety down valve (RH)

Rear Lift Cylinder (QFV)

Vehicle model
2 ton series
ltem
Cylinder type Single acting type
Cylinder bore mm (in) 63.5 (2.50)
Piston rod outside diameter mm (in) 50.8 (2.00)
Rod seal type U packing
Others Built-in safety down valve (LH)
5-7

COMPONENTS
Lift Cylinder for V Mast (2 Ton Series)

Lift Cylinder for V Mast (3 Ton Series)


Rear Lift Cylinder for N Mast on 2 Ton & 3 Ton Series
6503

AN

AM
OP[LH] 01[RH]
...,
22

21 1 , 20

I
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6503-113A

Rear Lift Cylinder for FSV Mast on 2 Ton Series


Rear Lift Cylinder for FSV Mast on 3 Ton Series

6503
94125-4120-
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91611-41014d 6503-1 12A


Rear Lift Cylinder for QFV Mast

6503

AW
02 [LH] 01 [RH]

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Llll 11111 Llll 11111

6503-0938
REMOVAL-INSTALLATION

Removal Procedure
1 Set the mast vertical and lower the fork fully.

2 Remove the lift cylinder rod end set bolt.

3 Hoist the inner mast by slinging with a wire and disconnect the lift cylinder rod end. [Point I ]

4 Hoist the inner mast further so that the lift cylinder ASSY can be removed from the front space.

5 Support the bottom of the inner mast with wooden blocks and fix the blocks by taping onto the outer
mast.

6 Remove the hose cover.

7 Disconnect the hose.

8 Remove the lift cylinder bottom end set bolt.

9 Remove the lift cylinder support. [Point 21

10 Remove the lift cylinder ASSY.


Installation Procedure
. The installation procedure is the reverse of the removal procedure.

Note:
After installing the lift cylinder, follow the steps below.
1. Repeat full-stroke raising and lowering of the cylinder to bleed air and check normal function-
ing.
2. Check the hydraulic oil level and add if insufficient.
3. Inspect lift cylinders for uneven lifting, and make necessary adjustment.

Point Operations
[Point I ]
Removal:
Shim adjustment is made at the lift cylinder rod end to pre-
vent uneven lifting by lift cylinders LH and RH. Take notes
on the cylinder where adjustment is made and the number
of shims used.

[Point 21
Installation:
Temporarily fasten the cylinder support here, and eliminate
any clearance between the cylinder support and outer mast
by shim insertion after connecting the rod end. (Use shim(s)
slightly thicker than the clearance.)
DISASSEMBLY-INSPECTION-REASSEMBLY
Lift Cylinder for V Mast T = N-m (kgf-cm) [ft-lbfl

2 2

4 4

* Cylinder cover
2 ton series: 3 ton series:
- -
T = 230 265 (2345 2703) [I 70 - 1951 - -
T = 264 305 (2695 31 10) [I 75 - 2251

Disassembly Procedure
1 Remove the safety down valve.

2 Remove the cylinder cover. [Point 11

3 Remove the seals from the cylinder cover

4 Remove the piston rod. [Point 21

5 Remove the seals on the piston rod

6 Remove the check valve from the piston rod. [Point 31

7 Remove the cylinder. [Point 41

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.
Point Operations
[Point I]

Disassem bly-Reassembly:
SST 09620-10100-71

[Point 21

Inspection:
Measure the piston rod outside diameter.

2 ton series
Standard: 42.0 mm(1.654 in)
Limit: 41.92 mm(1.6504 in)

3 ton series
Standard: 45.0 mm(1.772 in)
Limit: 44.92 mm(1.7685 in)

Inspection:
Measure the piston rod bend.

Limit: 2.0 mm(0.079 in)

[Point 31

Reassembly:
Install the check valve arrow pointing to the lower side of
the cylinder.

Inspection:
Measure the cylinder bore.

2 ton series
Standard: 50.0 mm(1.969 in)
Limit: 50.20 mm(1.9764 in)

3 ton series
Standard: 55.0 mm(2.165 in)
Limit: 55.35 mm(2.1791 in)
- - - - - - --

Rear Lift Cylinder for FV Mast T = N-m (kgf-cm) [ft-lbfl

*-I Cylinder cover *-2 Air bleed screw:


2 ton series: -
T = 4.5 5.0 (46 - 51) [3.33 - 3.691
- - -
T = 203 271 (2073 2764) [ I 50 2001
3 ton series:
T = 2 3 7 - 305 (2419 -3110) [I75 -2251
Disassembly Procedure
(1) LH Rear Lift Cylinder.
1 Remove the safety down valve.
2 Remove the cylinder cover. [Point 11
3 Remove the seals from the cylinder cover.
4 Remove the piston rod. [Point 21
5 Remove the wear ring.
6 Remove the bleed screw.
7 Remove the cylinder. [Point 41
(2) RH Lift Cylinder.
1 Loosen the cylinder cover. [Point 11
2 Remove the piston rod. [Point 21
3 Remove the piston. [Point 31
4 Remove the piston seals.
5 Remove the cover and the seals.
6 Remove the bleed screw.
7 Remove the cylinder. [Point 41

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
Apply sealant (08833-00080)on the threaded portion of the cylinder cover before tightening.
Upon completing the installation of the FV rear lift cylinder, perform air bleeding in the following
sequence:
(1) Extend the N rear lift cylinder.
(2) Stop the engine.
(3) Loosen the bleed screw by the time oil will come out and tighten the bleed screw again.

Point Operations
[Point 1]

Disassembly.Reassernbly:
SST 09620-10100-71
[Point 21

Inspection:
Measure the piston rod outside diameter.

2 ton series
Standard: 34.9 mm (1.374 in)
Limit: 34.82 mm (1.3709 in)

3 ton series
Standard: 40.0 mm (1.575 in)
Limit: 39.92 mm (1.5717 in)

Inspection:
Measure the piston rod bend.

Limit: 2.0 mm (0.079 in)

[Point 31

Disassembly~Reaseembly:
Follow the procedure view.
1. Fix the boss portion at the tip end of the piston rod in a
vise.

2. Use a screwdriver and rotate the piston to remove the


wire.

3. The installation is the reverse.

[Point 41

Inspection:
Measure the lift cylinder bore.

2 ton series
Standard: 50.0 mm (1.969 in)
Limit: 50.20 mm (1.9764 in)

3 ton series
Standard: 55.0 mm (2.165 in)
Limit: 55.35 mm (2.1791 in)
Rear Lift Cylinder for FSV Mast

T = N-m (kgf-cm) [ft-lbfl

LH RH

2 ton series and 3 ton series

*Cylinder cover:
2 ton series - - -
T = 230 265 (2345 2702) [I70 1951
3 ton series - - -
T = 237 305 (2419 31 10) [I75 2251

Disassembly Procedure
1 Remove the safety down valve.

2 Remove the cylinder cover. [Point I]

3 Remove the seals from the cylinder cover.

4 Remove the piston rod. [Point 21

5 Remove the piston seals, and the check valve. [Point 31

6 Remove the cylinder. [Point 41

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.
Point Operations
[Point 1]

Disassembly-Reassembly:
SST 09620-10100-71

[Point 21

Inspection:
Measure the piston rod outside diameter.

2 ton series
Standard: 42.0 mm(1.654 in)
Limit: 41.92 mm(1.6504 in)

3 ton series
Standard: 45.0 mm(1.772in)
Limit: 44.92 mm(1.7685 in)

Inspection:
Measure the piston rod bend.

Limit: 2.0 mm(0.079 in)

[Point 31

Reassembly:
Install the check valve so that the arrow directs to down-
ward of the lift cylinder.

[Point 41

Inspection:
Measure the lift cylinder bore.

2 ton series
Standard: 50.2 mm(1.976 in)
Limit: 50.40 mm(1.9843 in)

3 ton series
Standard: 55.0 mm(2.165 in)
Limit: 55.20 mm(2.1732 in)
Rear Lift Cylinder for QFV Mast

Disassembly Procedure
1 Remove the safety down valve.

2 Remove the plug.

3 Remove the cylinder cover.

4 Remove the seals from the cylinder cover.

5 Remove the piston rod. [Point 11

6 Remove the piston seals.

7 Remove the cylinder. [Point 21

Reassembly Procedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.
Point Operations
[Point I ]

Inspection:
Measure the piston rod outside diameter.

Standard: 50.8 mm (2.00 in)


Limit: 50.72 mm (1.9969 in)

Inspection:
Measure the piston rod bend.

Limit: 2.0 mm (0.079 in)

[Point 21

Inspection:
Measure the lift cylinder bore.

Standard: 63.5 mm (2.50 in)


Limit: 63.85 mm (2.5138 in)
FLOW REGULATOR VALVE (V-FV-FSV-QFV)
GENERAL T = N-m (kgf-cm) [ft-lbfl

Piston

-
T = 58.8 68.6
-
(600 700)
-
[43.4 50.61

SPECIFICATIONS
Fork Lowering Speed Unit: mmtsec (fpm)

V FV FSV QFV

No-load 500 (98) 420 (83) 450 (89) 400 (79)


2 ton series
Loaded 500 (98) 480 (94) 480 (94) 510 (100)
No-load 500 (98) 390 (77) 420 (83)
3 ton series
Loaded 500 (98) 460 (91) 460 (91)

Note:
The flow regulator valve is installed in the hydraulic piping system, respectively for each model.
SAFETY DOWN VALVE (V*FV*FSV-QFV)
GENERAL

I
I

I'
I I

Cartridge type L---.


Ex. FSV Rear Cyl.
on 2.3 ton series Internaltype
FRONT LIFT CYLINDER (FV-FSVQFV)
GENERAL

FV: 2 ton series


FSV: 2 ton series
QFV: 2 ton series O

FV: 3 ton series r


FSV: 3 ton series
0
w

4 I

0
5-25

SPECIFICATIONS
Front Lift Cylinder (FV)

Vehicle model
2 ton series 3 ton series
ltem
Cylinder type Single acting Single acting
Cylinder bore mm (in) 75.0 (2.95) 85.0 (3.35)
Piston rod outside diameter mm (in) 50.8 (2.00) 50.8 (2.00)
Rod seal type U packing U packing
Piston seal type U packing U packing
Others Built in safety down valve

Front Lift Cylinder (FSV-QFV)

Vehicle model
2 ton series 3 ton series 2 ton series QFV
ltem
Cylinder type Single acting Single acting Single acting
Cylinder bore mm (in) 75.0 (2.95) 85.0 (3.35) 75.0 (2.95)
Piston rod outside diameter mm (in) 50.8 (2.00) 50.8 (2.00) 50.8 (2.00)
Piston seal type U packing U packing U packing
Rod seal type U packing U packing U packing
Others Built-in safety down valve
COMPONENTS
Front Lift Cylinder for N Mast

Front Lift Cylinder for FSV and QFV Mast


REMOVAL-INSTALLATION
Removal Procedure
1 Remove the lift bracket Wlfork.

2 Disconnect the piping.

3 Remove the front lift cylinder

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
After installing the lift cylinder, follow the steps below.
(1) Repeat full-stroke raising and lowering without load to bleed air and check normal function-
ing.
(2) Check the hydraulic oil level, and add if insufficient.
(3) Adjust the lift chain tension equally on the left and right sides.
Front Lift Cylinder for FV-FSV-QFV

T = N-m (kgf-cm) [ft-lbfl


FV FSVQFV

4 4

* Cylinder cover
FVIFSVIQFV on 2 ton series - - -
T = 339 407 (3455 4147) [250 3001
FVIFSV on 3 ton series - - -
T = 420 454 (4283 4630) [310 3351

Disassembly Procedure
1 Remove the safety down valve.

2 Remove the cylinder cover. [Point I ]

3 Remove the cover seals.

4 Remove the piston rod. [Point 21

5 Remove the piston seals.

6 Remove the check valve. [Point 31

7 Remove the cylinder. [Point 41

ReassemblyProcedure
The reassembly procedure is the reverse of the disassembly procedure.

Note:
Apply MP grease or hydraulic oil on the packing, O-ring, and dust seal lip portion.
Apply sealant (08833-00080) on the threaded portion of the cylinder cover before tightening.
Fill the amount of hydraulic oil specified below into the cylinder from its top before installing the
cylinder cover.

Filling amount cm3 (in3): FVIFSV 2 ton series 100 (6.10)


-
FVIFSV 3 ton series 75 80 (4.57 - 4.88)
Point Operations
[Point I]

Disassembly.Reassembly:
SST 09620-10100-71

[Point 21

Inspection:
Measure the piston rod outside diameter.

2 ton series and 3 ton series:


Standard: 50.8 mm (2.0 in)
Limit: 50.72 mm (1.9969 in)

Inspection:
Measure the piston rod bend.

Limit: 2.0 mm (0.079 in)

[Point 31

Assembly:
Install the check valve so that the arrow will direct down-
ward of the front lift cylinder.

[Point 41

Inspection:
Measure the lift cylinder bore.

2 ton series
Standard: 75.0 mm (2.953 in)
Limit: 75.35 mm (2.9665 in)

3 ton series
Standard: 85.0 mm (3.346 in)
Limit: 85.40 mm (3.3622 in)
OIL CONTROL VALVE
Page
GENERAL .....................................................................6-2
SPECIFICATIONS .....................................................6-4
COMPONENTS .........................................................6-4
OIL CONTROL VALVE ASSY ..................................6-5
REMOVAL.INSTALLATION........................................... 6-5
DISASSEMBLY.INSPECTI0N.REASSEMBLY ................ 6-6
RELIEF PRESSURE ADJUSTMENT ......................6-8
GENERAL
Oil Control Valve

Relief Valve

Lift relief valve Tilt relief valve


Tilt Lock Valve

Hydraulic Circuit

TI T2 P

..- ---........-- -.
..........-....-. .......-.
..

P: Pump port
T: Tank port
TI: To tank
T2: From power steering
SPECIFICATIONS
Spec. item Type & values

Oil control valve type Add on type of 3 spools (Monoblock for each spool section)

Lift relief valve set pressure


17160 (175) [2490]
kPa (kgf/cm2) [psi]

Tilt relief valve set pressure


15690 (160) [2280]
kPa (kgf/cm2) [psi]

COMPONENTS
OIL CONTROL VALVE ASSY
REMOVAL-INSTALLATION
Note:
Before disconnecting the control lever link, release the residual pressure in the material han-
dling system piping by operating the control lever, set the mast in the neutral state and lowering
the fork to the bottom position.

Removal Procedure
1 Remove the toe board.

2 Disconnect the control valve lever link

3 Disconnect the piping.

4 Remove the oil control valve set bolt.

5 Remove the oil control valve ASSY.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Note:
Apply grease to the oil control valve lever link parts.
Check the hydraulic oil level, and add if insufficient.
DISASSEMBLY-INSPECTION-REASSEMBLY
Note:
Operate in a clean place.
As each part is finished with high precision, carefully disassemble them to prevent any damage.

Disassembly Procedure
1 Remove the through bolt.

2 Separate each housing.

3 Remove the O-ring, spring and check valve.

4 Remove the seal holder.

5 Remove the spring holder.

6 Remove the spool Wlspring.

7 Remove the spring. [Point I ]

8 Remove the tilt lock valve.

9 Remove the relief valve. [Point 21


Point Operations
[Point 11
Disassembly.Reassembly:
SST 09610-10161-71

[Point 21
Reassembly:
When the relief valve is disassembled, always loosen the
adjust screw fully.
RELIEF PRESSURE ADJUSTMENT
Note:
Always make adjustment according to the procedure described below. Careless adjustment may
generate a high pressure to cause damage to the oil pump or other hydraulic devices.

1. Install an oil pressure gage.


(1) Remove the oil pressure detection plug (9116-1 8UNF-
2B) installed on top of the oil control valve, and install
the oil pressure gage.

2. Check loosening of the adjust screw.


(1) Remove the cap nuts and packings on top of the relief
valves. Loosen the adjust screw to a degree not to
come off from the body.

3. Turn the key switch on.

4. Adjust the lift side relief pressure.


(1) Set the control lever to the lift position and gradually
tighten the adjust screw on the lift relief valve until the
fork starts to rise.
(2) Lift the forks to the maximum height, and read the pres-
sure gage. Adjust the oil pressure then to the speci-
fied level by turning the adjust screw.

5. Adjust the tilt side relief pressure.


(1) Set the control lever at the backward tilt position, and
gradually tighten the adjust screw on the tilt relief valve
until the mast starts to be tilted backward.
Relief Set Pressure (2) Tilt the mast fully backward, and read the oil pressure
Unit: kPa (kgf/cm2) [psi] gage. Adjust the oil pressure then to the specified level
All models I by turning the adjust screw.
Lift 17160:~(175::)[2490:~] 6. After the adjustment, insert the packing and tighten the
cap nut. Inspect the relief pressure again.
Tilt 15690::,9: (1601~)[2280:~~]
7. Remove the oil pressure gage, and tighten the plug.
APPENDIX
Page
SST LlST......................................................................7-2
SERVICE STANDARDS LlST ...................................... 7 4
SST LIST
Sectlon
lllustrat~on Part No Part Name
1 2 3 4 5 6

Transmlsson &
09316-60011 transfer bearlng 0
replacer

Rear wheel bearlng nut


09509-55020
wrench
O

Front hub inner bearlng


09608-04031
cone replacer
0

09950-40011 Puller B set 0 0

09950-60010 Replacer set 0 0 0

000~
09950-60020 Replacer set No 2 0 0 0

Front axle bearlng


Drlve pinlon bearing

011
control valve sprlng

09610-22000-71 Inner mast stopper 0

@ 09620-10100-71
Cylinder cap remover
and replacer
O

4 09630-1
Tilt cylinder cap
remover and replacer
0

0 09630-23600-71 Deep socket A 0 0

-g
-c 09631-22000-71 Wear scale chain 0

e 09810-20172-71 Jolnt pln remover 0


SERVICE STANDARDS LIST
DRIVE UNIT
Differential

Ring gear backlash mm (in) Standard 0.2 - 0.3 (0.008 - 0.012)


Standard 22.12 (0.8709)
Differential pinion bore mm (in)
Limit 22.22 (0.8748)

Standard 22.00 (0.8661)


Spider outside diameter mm (in)
Limit 21.75 (0.8563)

Standard 1.6 (0.063)


Side gear thrust washer thickness mm (in)
Limit 1.3 (0.051)

Standard 1.6 (0.063)


Pinion gear thrust washer thickness mm (in)
Limit 1 .O (0.039)

Drive pinion bearing starting torque


N.m (kgf-cm) [ft-lbfl
Standard 10.79 - 13.24 (110 - 135) [7.96 - 9.771
Tightening torque Unit: N-m(kgf-cm) [ft-lbf]

Drive pinion lock nut Standard 343 - 392 (3500 - 4000) [253.2 - 289.31
Drive pinion bearing retainer set bolt Standard 88.3 - 117.7 (900 - 1200) [65.1 - 86.821

Ring gear set bolt Standard 127.4 - 176.5 (1300 - 1800) [94.0 - 130.21

Differential upper case set bolt Standard 43.1 - 53.9 (440 - 550) [31.8 - 39.81

Differential case bearing cap set bolt Standard 117.7 - 137.3 (1200 - 1400) [86.82 - 101.31

Differential cover set bolt Standard 29.4 - 44.1 (300 - 450) [21.7 - 32.61
FRONT AXLE
-
Front axle shaft hub

Front axle bearing starting force


N (kgf) [Ibfl
Standard 25.5 - 72.6 (2.6 - 7.4) [5.7 - 16.31
Tightening torque Unit: N.m (kgf-cm) [ft-lbf]

Hub bolt set nut Standard 166.7 - 205.9 (1700 - 2100) [ I23.0 - 151.91
Bearing lock nut stopper bolt Standard 14.7 - 21.6 (150 - 220) [ I0.9 - 15.91
Axle shaft set bolt Standard 98.07 - 127.5 (1000 - 1300) [72.35 - 94.061

Front wheel hub nut Standard - - -


294.2 588.4 (3000 6000) [217.1 434.11

Front axle housing set bolts Standard 107.9 - 137.3 (1100 - 1400) [79.59 - 101.31

REAR AXLE
Rear axle ASSY

Rear axle ASSY front to rear clearance mm (in) Standard 0.7 (0.028) or less

Rear axle center pin bushing


Limit 52.0 (2.047)
inside diameter mm (in)

Rear axle hub and steering knuckle

Rear axle wheel starting force


(at outer periphery of the wheel) N (kgf) [Ibfl
Standard 9.8 - 29 (1.O - 3.0) [2.2 - 6.61
King pin outside diameter mm (in) Limit 27.8 (1.094)

Steering knuckle starting force


Standard 19.3 (2.0) [4.4] or less
(at front end of knuckle) N (kgf) [Ibfl
Rear axle cylinder

Rear axle cylinder piston rod outside diameter


Limit 49.92 (1.9654)
mm (in)

Rear axle cylinder piston rod bend mm (in) Limit 0.5 (0.017)

Rear axle cylinder inside diameter mm (in) Limit 76.35 (3.0059)

Rear wheel alignment

Toe-in mm (in) Standard 0 k 4 (0 k0.16)

Tightening torque Unit: N-m (kgf-cm) [ft-lbf]

Axle bracket cap set bolt Standard 117.7- 166.7 (1200 - 1700) [86.82 - 123.01
King pin lock bolt and lock nut Standard 44.1 - 53.9 (450 - 550) [32.6 - 39.81

Rear axle cylinder rod guide set nut Standard 88 - 118 (900 - 1200) [65.1 - 86.81

Rear axle cylinder set bolt Standard 166.7-215.8(1700-2200)[123.0-159.11


Mast adjustment (V mast)

Mast Inner mast roller clearance mm (in) Standard 0 - 0.8 (0 - 0.031)


0 - 0.5 (0 - 0.020)
'Oilers Outer mast roller clearance Standard
mm (in)

Middle and lower lift roller clearance


Lift
mm (in)
Standard 0 - 0.5 (0 - 0.020)
bracket
'Oilers Side roller clearance mm (in) Standard 0 - 0.5 (0 - 0.020)
Mast strip to inner mast clearance mm (in) Limit 0.5 - 1 .O (0.020 - 0.039)
Fork

Fork front end misalignment mm (in)

Tightening torque Unit: N.m (kgf-cm) [ft-lb]

Mast support cap set bolt Standard 68.6 - 107.9 (700 - 1100) [50.6 - 79.571
Back rest set bolt Standard 99.54 - 184.9 (1015 - 1885) [73.42 - 136.31

Chain adjusting nut Standard 49.0 - 78.0 (500 - 800) [36.2 - 57.91
CYLINDER
Lift cylinder 01)

Piston rod outside 2 ton series Limit 41.92 (1.6504)


diameter mm (in) 3 ton series Limit 44.92 (1.7685)

2 ton series Limit 50.20 (1.9764)


Cylinder bore mm (in)
3 ton series Limit 55.35 (2.1791)

Piston rod bend mm (in) Limit 2.0 (0.079)

Rear lift cylinder (FV-FSV-QFV)

FV Limit 34.82 (1.3709)


2 ton series
FSV Limit 41.92 (1.6504)
Piston rod outside
FV Limit 39.92 (1.5717)
diameter mm On) 3 ton series
FSV Limit 44.92 (1.7685)

2 ton series QFV Limit 50.72 (1.9969)

FV Limit 50.20 (1.9764)


2 ton series
FSV Limit 50.40 (1.9843)

Cylinder bore mm (in) FV Limit 55.35 (2.1791)


3 ton series
FSV Limit 55.20 (2.1732)

2 ton series QFV Limit 63.85 (2.5138)

Piston rod bend mm (in) Limit 2.0 (0.079)


Front lift cylinder (FV.FSV.QFV)

FV Limit 50.72 (1.9969)


2 ton series
FSV Limit t
Piston rod outside
diameter mm On) 3 ton series
FV Limit t
FSV Limit 7
2 ton series QFV Limit ?
FV Limit 75.35 (2.9665)
2 ton series
FSV Limit t
Cylinder bore mm (in) FV Limit 85.40 (3.3622)
3 ton series
FSV Limit t
2 ton series QFV Limit 75.35 (2.9665)

Piston rod bend mm (in) Limit 2.0 (0.079)


Tightening torque Unit: N-m (kgf-cm) [ft-lbf]
Flow regulator valve Standard 58.8 - 68.7 (600 - 700) [43.4 - 50.61
OIL CONTROL VALVE
Oil control valve

Lift Standard 17160 'igO(l75 'i) [2490'?]


Relief set pressure
kPa (kgf/cm2) [psi] Tilt Standard 15690 ~ ~ ~ ~'3,) ( [2280'j:]
1 6 0

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