FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT Please use this manual for providing quick, correct servicing of the correspondin corresponding g forkli f orklift ft models. This manual deals with the above models as of March
1997.
Please
understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industria Indus triall Equipment Parts Parts
Service News.
For the service procedures of the mounted engine, read the repair manuals listed below as reference together with this manual. (Reference) Repair Repair manuals manuals related to this t his manual are are as as follows: fol lows:
TOYOTA TOYOTA INDUSTRIAL INDUSTRI AL EQUIPMENT EQUIPMENT GM6 G M6-262 ENGINE REPAIR MANUAL (No.
TOYOTA MOTOR CORPORATION
SECTI SECTION ON IND EX NAME
SECTION
ENGINE TORQUE CONVERTER FRONT AXLE A
STEERING
MATERIAL HANDLING SYSTEM MAST CYLINDER
APPENDIX
GENERAL Page EXTERIOR VIEWS VEHICLE MODEL FRAME NUMBER m
HOW TO READ
................... 0 3 -
MANUAL
04 -
EXPLANATION METHOD
04
TERMINOLOGY
05
ABBREVIATIONS
05
-
-
-
OPERATIONAL STANDARD BOLT TORQUE
06 -
NUT TIGHTENING TIGHTENING 07 -
BOLT STRENGTH TYPE IDENTIFICATION METHOD
07
TIGHTENING TORQUE TABLE
08
-
-
PRECOAT BOLTS
09 -
PRESSURE HOSE FITTING TIGHTENING TORQUE ROPE SUSPENSION ANGLE SAFE LOAD LO AD FOR FOR EACH EACH SUSPENSION
09 -
.............
ROPE
COMPONENTS WEIGHT RECOMMENDED LUBRICANT QUANTITY TYPES PERIODIC MAINTENANCE
..................................0 14
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
-
0 -2
EXTERIOR VIEWS
VEHICLE MODEL FRAME NUMBER -
Model
Load capacity * ton
Engine
Drive system
Torque converter
W h e n t h e load center is 600 mm (24 in). Frame
No. punching position
Punching position (Upper surface of frame
Punching format form at
HOW TO READ
MANUAL
EXPLANATION METHOD
1.
Operation procedure ( 1 The operation procedure is described in either pattern A or pattern B below. Pattern A: Explanation of each operation step with an illustration. operation procedure by indicating indicating ste p numbers in one Pattern B: Explanation of operation followed by explanation of cautions and notes summarized as point operations.
Example of description in pattern B Tightening torque unit T
DISASSEMBLY
=
disassembly Procedure Remove the cover. [Point 2
Remove th e bush [Point 2)
3
Remove the gear.
Point operations
Operation explained later
Explanation of key point for operation with an illustration
[Point Disassembly: Disassembly: Pu t a mat ch mark when remov removing ing the pump cove cover. r. [Point 21 Inspection:
Measure the bush inside diameter. Bush inside diameter limit: 19.12 m m (0.7528 in)
[fb
2.
3 .
H o w t o r ead com p ponents onents figur figur es The com po nents figu figurr e uses uses the in the par ts catalog for the vehicle model. Please refer to the catalog for checking the par t nam e. Th e num ber a t the r ight should shoulder er of each comp onen ts figure indicates the Fig. number in the par ts catalog.
( Exam Exam ple) ple)
FIG number
in
parts catalog
M a t t e r s o m i t t e d in this m anu anual al This m anual om its descr iption of the f ollowi ng jobs jobs,, but per p er for m the m in actual Cleaning Cleaning and was hing of r em ove d p par ar ts as r equir equired ed Visual inspection (partially described)
8
TERMINOLOGY Caution: Important matters of which negligence may cause accidents. Be sure to abserve them. Note: lmportant lmport ant items of which negligence neglige nce may cause cau se accidents, or or ma matters tters in operation operation procedure re special attention. Standar d: Values showin g allowable r ange in inspection and adjustment. lo w a bl bl e v a l u e in inspection or adjustment. L i m i t : M a x i m u m o r m i n i m u m a l lo ABBREVIATIONS
I
Abbreviation (code)
Meaning
Abbreviation (code)
Meaning
ASSY
Assembly
RH
Righthand
SAE
Society of Automotive Engineers (USA)
FHPS
I
Full hydraulic power steering steering Less
LH LLC PT
PS
Long life coolant Option
I I
sST STD T
=
Special service -
-
Standard
Tightening torque Number of teeth
Oversize
Undersize
Power steering
With
-
OPERATIONAL TIPS 1.
Safe operation operation After jacking jacking up, always support w it h rigid stands. stands. ( 2 ) When hoisting the vehicle or its heavy component, component, use wire wi th a sufficient reserve reserve in load capacity. Alw ays disconnect disconnect the battery plugs before the inspection inspection or servicing of electrica electricall parts.
2.
Tactful operation Prepa Prepare re the mechanic tools, necessary measuring instruments (circu it tester, megger, oil pres sure gauge, etc.) and before starting operation. operation. Before disconnecting wiring, always check the cable color and wiring state. When overhauling functional parts, complicated portions or related mechanisms, arrange the disassembled parts neatly to prevent confusion. When disassembling disassembling and inspecting such a precision part as the contr ol valve, valve, use clean too ls and operate in a clean location. Follow th e described procedures procedures for disassembly, disassembly, inspection and reassembly. reassembly. Replace gaskets, packings and O - rings with new ones each time they are disassembled. Use genuine Toyota parts for replacement. Use specifie specified d bolt s and nuts. Observe the specified tightening to rqu e at the time of r eassembly. If no tightening torque is speci specifie fied, d, tighten the bolt or nut according according t o the standard standard tightening torque table.
3.
Grasping the trouble state When a trouble occurs, do not attempt immediate disassembly or replacement but first check if the trouble requires disassembly disassembly or replacement fo r correction.
STANDARD BOLT BOLT
NUT TIGHTENING TIGHTE NING TORQUE TORQUE
How to judge tightening torque of a standard bolt or nut
1.
How to judge tightening torque of a standard bolt: Find out the type of the bolt from the list below. Then, find the bolt tightening torque from the table.
2.
How to judge tightening torque of a standard nut: The nut tightening torque can be judged from the bolt type. (See the item above.)
BOLT STRENGTH TYPE IDENTIFICATION METHOD
1.
2.
ldentification by bolt shape Shape and class
Class 4 5
Bolt head No. Hexagon head bolt
6 7
8
=
=
=
=
=
ldentification by part No.
Hexagon head bolt
4T 5T 6T 7T 8T
Part No.
Length Diameter
No mark
4T
iarneter
Hexagon flange bolt Length
Hexagon head bolt
Tw o protrud protruding ing lines
Hexagon flange bolt
Tw o protrud protruding ing
Hexagon head bolt
Three protruding lines
Hexagon head bolt
Four protruding lines
Stud bolt
Part
No.
Diameter Class
Welded bolt
No mark Stud bolt Grooved
Length
TIGHTENING TORQUE TABLE Specified torque Class
Diameter mm
Pitch mm
Hexagon flange bolt
Hexagon head bolt kg f - cm
kg f - cm
ft - lbf 5.9 14 28 53
ft - lbf
60
52
in -lbf
90
78
in-lbf
I I I I I
I I
6.4
I
65
56
59
600
43
91
930
67
1400
137 I
7.8 19
101 I
80
69
195
14
730
11
I
8.8
215
I
123
I
12
1050
167
1700
70
147
11500
29 61
I I
300 620
I
166 I I
I
22 45
9
103
970
2300
I
43
95
I I
120
590
38
226
90
I
58
530
52
I
59
I
21
28
260
I
16 2
290
19
25
1250 I
8
3 I
810
I
110
440
53 I
I I
in -lbf
43
400 72
in -lbf
I
33 68 120
I I
I
330 690 1250
123
I I I I
I
24 50 90
PRECOAT BOLTS (Bolts with seal lock agent coating on threads) 1.
Do not use the precoat bolt as it is in either of the following cases: (a) After it is removed. When the precoat bolt is moved (loosened or tight ened) by tightness check, etc.
Note: For For torque check, use the lower limit of the allowable tight ening torque range. If the bolt moves, retighten it according according to the steps below. -
2.
Method for reuse of precoat bolts (1) Wash the bolt and threaded hole. (T he threaded hole must be washed even for replacement of the bolt.) (2) Perfectly dry the washed parts by air blowing. (3) Appl y the specified seal lock agent on t he threaded portion of the bolt.
PRESSURE HOSE FITTING TIGHTENING TORQUE Whe n connecting a high pressur pressure e hose, hose, wi pe the hose fit ting and matin g nipple contact surfaces surfaces wi th clean clean cloth t o remove foreign foreign matters and and dirt. A lso check check no dent or other dam damage age on the contact surfaces before installation.
2.
When connecting a high pressure pressure hose hose,, hold the hose hose t o align align the fi tting wi th t he nipple and and tighten the fitting.
3.
The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter of screw
Standard tightening torque Standard
Tightening range
Hose inside diameter (in)
ROPE SUSPENSION ANGLE Compres-
Tension
sion
1.OO time
0. 27 time
1.16 time
time
SAFE LOAD FOR EACH Cutting
diameter
load
6 mm (0.24 in)
Single-rope suspension 0 3040 1683.61 4410 (0.45) 1992.31
10 mm (0.4 in) 12.5 ( 0 . 5i n) 14 (0.56
method
angle
6960 565.61 10980 (1.12) 13730
Tension
time
time
1.04 time
Rope
Suspension
2.00 time
Compres-
Suspension
sion
method
.OO
time
1.73 time
ROPE SUSPENSION ANGLE Two Tw o - rope suspension suspension
unit:
N
(ton)
Four-rope suspension
COMPONENTS WEIGHT Nnit: Weight (mass)
Component GM6-262
Engine Transmission Torque converter
185 (408) Approx. 200 (441)
differential
Approx. 360 (794)
differential
Approx. 2000 (4410) 2450
3.25 ton model I
Counterweight
3.5 ton model model
V mast ASSY ASSY and fork (wit h lift cylinder cylinder max. lifting height: 3000 3000 mm (118 (118 in)) in )) Compact specification model
3.
ton model 4.5 ton model
BCS) (OPT)
Approx. 2340 (5160) (5160) Approx. 3180 3180 Approx. 890 (1960) Approx. 1140 1140 (2510)
kg
RECOMMENDED LUBRICANT QUAN QUANTI TITY TY
TYPES TYPES Application
Quantity
Motor oil SAE 30 (SAE 20 in in cold cold area) Engine
SE, SF
All models
4.2
(1.11 (1.11 US US gal)
All models
15
(4.0 US gal) ga l)
All models
9.5 9.5
All models
One side: 0.5 0.5 (0.13 US gal) ga l)
All models
68
(18.0 US gal) ga l)
3.25 3.5 ton model
95
(25.1 US gal) gal )
4.5 ton model
120
(31.7 US gal:
OW-30 in cold area)
I
Torque converter
ATF
Differential
API GL-4 GL-5
gear gear oil
Planetary gear Hydraulic oil [Max. fork height 3000 3000 mm (118
Hydraulic oil VG32
Propeller shaft and
I Coolant
(excluding reservoir reservoir tank)
Coolant (Reservoir Tank) Tank)
LLC
MP grease
All models
Molybdenum disulfide grease
All models
LLC 30-50% mixure (for (fo r winter or season) Coolant with rust inhibitor (for spring, spring, summer and autumn)
(2.51 US gal) ga l)
Proper quantity
All models
13.0 13.0
(3.43 US gal) gal)
All models
1.1 (0.29 US gal) gal ) (at Full level)
Torque Converter Model
FHPS)
Replacement MP grease Engine gear
lnspect every 8 hours lnspect every 4 0 hours hours lnspect every every 17 0 hours hours (monthly)
Automatic Molybdenum disulfide grease
Cham gear Planetary gear Torque converter case Rear wheel knuckle Power steering cylinder pin and tie - rod tank Engine crankshaft
lnspect every every 100 0 hours monthly) lnspect every 2000 hours (annually)
Rear axle beam front Rear axle beam rear steering Mast support front Propeller shaft pump shaft cylrnder rear
PERIODIC PERIODIC MAINTENANCE INSPECTION METHOD I
:
M: T :
*
:
Inspection. Repair or replacement replacement if required. Measur ement . Repair Repair or adjustment if requ required ired.. Retightening C : Cleaning L : Lubrication F o r n e w v e h ic ic l e * 1 : Flaw detecto detect orr Inspection period
Every month Every 1 70 hours hours
ENGINE Proper starting and abnormal noise Rotating condition at idling Rotating condition during acceleration Basic components
Exhaust gas condition Air cleaner element Valve clearance clearance Compression Cylinder head bolt loosening Muffler rubber mount
PCV system
Clogging and damage in PCV valve and piping
Governor
No -load maximum Oil leakage
Lubrication system
Oil level Clogging and dirt of oil filter Fuel leakage
Fuel system
Operation of carburetor link mechanism Dirt and cloggin clogging g of fuel filter and element Coolant level in radiator and leak leak Rubber hose degradation
Cooling system
Radiator cap condition Fan belt tension, looseness and damage Radiator rubber mount
Every 3 months Every hours
500
Every 6 months
Every 12 months
Every 10 00 hours hours
Every 20 00 hours hours
Inspection period
Every month Every 1 7 0 hou hours rs
POWER POWER TRANSMISSION SYSTEM Oil leakage Differential
Oil level Bolt loosening Leakage Fluid level
Torque converter and transmission
Operating mechanism function and looseness Control valve and clutch functions valve valve function Stall and hydraulic pressure measurement Loose joint
Propeller shaft and axle shaft
Looseness at spline connections Looseness of universal joint Twisting and cracks of axle shaft
DRIVE SYSTEM Tire cuts, damage and uneven wear Loose rim and hub nuts Tire groove depth Metal chips, pebbles and other for eign matter trapped in tire grooves Wheels
Rim, side bearing and disc wheel damage Abnormal noise and looseness of front wheel bearing bearing Abnormal noise and looseness of rear wheel bearing
Front axle
Rear axle
Crack, damage and deformation of housing Crack, damage and deformation of beam Looseness of axle beam in vehicle longitudinal direction
.
3
Every months
Every 50 0 hours
6
Every months
Every 10 00 hou hours rs
12
Every months
Every 20 00 hou hours rs
Inspection period
Every month
3
Every months
Every 6 months
Every 12 months months
Every 100 0 hours
Every 20 00 hour hours s
Every 1 7 0 hou hours rs
Every 50 0 hours hours
Play and looseness
I
t
t
Function
I
t
t
Oil leakage
I
Looseness of mounting
T
Oil leakage
I
Mounting and linkage looseness
I
STEERING SYSTEM Steering wheel Steering valve Power Steering
t
t
t
Damage of power steering hose Knuckle
,
King p in looseness
I I
Crack Crack and deformatio n
I
BRAKING SYSTEM Brake pedal
Play and reserve Braking Braking effect Operating force
Parking brake
Brake pipe
Braking Braking effect
I
t
Rod and cable looseness and damage
I
t
Leak, damage and mounting condition
Brake booster and wheel cylinder
Function, wear, damage, leak and mounting looseness
Clearance between drum and lining
M
Wear of shoe sliding portion and lining Brake drum and brake shoe
Drum wear and damage Shoe operating condition Anchor pin rusting Return spring fatigue Automatic adjuster function
Backing plate
Deformation, crack and damage Loose mounting
MATERIAL HANDLING SYSTEM
Forks
Abnormality of fork and stopper pin
I
Misalignment between left and right fork fingers
I
Crack at fork root and welded part
Every month Every 17 0 hours Deformation and damage of each part and crack at welded part Mast and lift bracket looseness blast and bracket
Wear and damage of mast support bush Wear, damage and rotating condicondi tion of rollers Wear and damage of roller pins Wear and damage of mast trip Tension, deformation and damage of chain
Chain and chain wheel
Chain lubrication Abnormality of chain anchor bolt Wear, damage and rotating condicondi tion of chain
Various attachments
Abnormality and mounting conditior of each part
HYDRAULIC SYSTEM Loosening and damage of cylinder mounting Deformation and damage of rod, roc screw and rod end Cylinder operation Cylinder
Natural drop and natural forward (hydraulic drift) Oil leakage and damage Wear and damage of pin and cylinder bearing Lifting speed Uneven movement Oil leakage and abnormal sound Oil level and contamination
Hydraulic oil tank
Tank and oil strainer Oil leakage
Control lever
Loose linkage Operation
tilt
3
Every months
Every 50 0 hours
Every 6 months
Every 12 months months
Every 1000 hours
Every 20 00 hour hours s
Every 12 months
Inspection period Every
Every
17 0 hours hours Oil leakage Oil control valve
Relief pressure measurement Relief valve and functions
tilt
lock valve
Oil leakage Hydraulic piping
Deformatio n and damage damage Loose joint
ELECTRICAL SYSTEM Crack at distributor cap Spark plug burning and gap lgnition timing
Distributor side terminal burning Distributor cap center piece wear and damage Plug cord internal discontinuity Ignition timing
Starting motor
Pinion gear meshing status
Charger
Charging function
Battery Electrical wiring
Battery fluid level Battery fluid specific gravity Damage of wiring harness Fuses
SAVETY DEVICES, ETC. Crack at welded portion
I
Deformatio n and damage damage
I
Loosening of mounting
T
Deformation, crack and damage
I
Lighting system
Function and mounting condition
I
Horn
Function and mounting condition
I
Head guard
Back-rest
t
Every 2000 hours
Every month Every 17 0 hours hours
I
Direction indicator
Function and mounting condition
Instruments
Functions
Backup buzzer
Function and mounting condition
Rear-view mirror
Dirt, damage Rear reflection status Loosening and damage of mounting Damage and crack of frame, cross members, etc. Bolt looseness Grease up
Every
Every
Every 12 months Every 20 00 hours hours
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS Replacement Interval
month Every 1 7 0 hours hours
3
months
6
Every 50 0 hours hours
months
12 months
Every hours hours
20 00 hours hours
Engine oil Engine oil filter Engine coolant (every 2 years for Fuel filter Torque converter oil Torque converter oil filter Differential oil --
Planetary gear oil Hydraulic oil Hydraulic oil return filter Wheel bearing grease grease Spark plugs Air cleaner element Cups and seals for brake booster and wheel cylinders Power steering hoses Power steering rubber rubber part s Hydraulic hoses Fuel hoses Torque converter rubber hoses Chains I
for n ew vehicle vehicle
Every
2
years
Every 3 years
Replacement shall be made upon arrival of the specified operation hours or months, whichever is earlier.
ENGINE Page
ENGINE EXTERIOR VIEWS MAJOR SPECIFICATIONS ENGINE PERFORMANCE CURVES ENGINE ASSY
14 -
14 -
ENGINE SPEED ADJUSTMENT ELECTRONIC GOVERNOR
AIR CLEANER GENERAL SPECIFICATIONS COMPONENTS AIR CLEANE CLEANER R CLEANING .INSPECTIO .INSP ECTION N CLOGGING WARNING SYSTEM INSPECTION
RADIATOR
16 -
19 -
1 30 -
1 30 -
1 30 -
1 31 -
1 31 -
1 32 -
1 33 -
COMPONENTS ....................................................1 33 SPECIFICATIONS 1 33 -
-
FAN DRIVE
1 34 -
REMOVAL INSTALLATION DISASSEMBLY . INSPECTION REASSEMBLY
MUFFLER
EXHAUST
COMPONENTS .................................................. REMOVAL . INSTALLATION
BATTERY . SPARK PLUG
1 34 -
1 36 -
1 39 -
1 39 -
1 40 -
1 41 -
COMPONENTS ....................................................1 41 SPECIFICATIONS 1 41 -
-
STARTING MOTOR REMOVAL . INSTALLATION
ALTERNATOR REMOVAL INSTALLATION
ACCELERATOR PEDAL (VEHICLE ONLY ENGINE)
1 44 -
1 44 -
1 45 -
1 45 -
1 47 -
COMPONENTS .................................................... 1 47 ACCELERATOR PEDAL ADJUSTMENT 1 47 -
-
ENGINE EXTERIOR VIEWS
MAJOR SPECIFICATIONS Engine
Gasoline
Engine Engine type
LPG
cycle
4 -
I
Number of valves per cylinder I
Valve mechanis m x
Intake valve Exhaust
x
I
I
1
OHV OHV chain-driven 101.60 x 88.39 (4.0 x 3.480)
stroke
Total displacement
I
Wedge type
Combustio n chamber chamber type
Bore
I
cm (in ) 3
3
4300
Comp ress ion ratio
9.2 9.2
Maximum powe powerr
67 (91
61
Maximum torque torque
294
284
Min imu m specifi specific c fuel consumption
258
Electronic governor
Governor system Service weig ht No - load maximum rpm
800
kg
249
284 250
400
Air governor
185 2350
2400
ENGINE PERFORMANCE CURVES Gasoline LPG ,
Engine speed
ENGINE ASSY REMO VAL. INSTALLATIO INSTALLATION N
Removal Procedure Remove Remove the radiator cover. Remove the engin e hood. (See (See page Remove the counter w eight . (See page Remove th e muffler. (See page 1-40) Remove the radi ator and fan su pport ASSY ASSY.. (See page page 1 1--34) Remove the toe board. Remove the battery, battery case and bracket. Remove the air cleaner case ASSY. Disconnect the electrical wiring. Remove the undercover. Disconnect the oil pump drive shaft. [Point 11 Remove the exhaust pipe. Disconnect the fuel hose. Slightly hoist the engine. [Point 21 Support the torque converter lower side with wooden blocks. Remove the flexible plate set bolts. [Point 31 Disconnect the torque converter end plate from transmission case. Remove the 2 engine mount brackets. Remove the engine. [Point 41 Remove the flywheel and torque converter end plate.
Installation Procedure The installation procedure is the reverse of the removal procedure.
Note: Tighten th e flexible plate set bolts bolt s after applying lock locking ing agent (088 (08833 33--00070). The The tightenin tight ening g torque for each part is as as follows: 89.24 (490 44.13 (300 (150
Engine mount bracket set bolt Torque converter end plate set bolt Flexible plate set bolt
- 910) - 450) - 250)
Point Operations [Point 1I Removal:
Disconne Disconnect ct after tying wi th a string so so as not t o cause disconnection at the spline.
[Point 21 Removal . Installation:
SST
Remo val. Installat Installation: ion:
Use a sufficiently strong wire. Set length A at app rox. 250 m m (9.84 (9.84 in) to obtain a sufficient hoisting stroke.
[Point
31
Removal . Installation:
[Point
11-71
Remove 9 set bolts while rotating the tor que converter. converter.
41
Removal:
Remove after checking perfect disconnection of o f th e wiri ng, hose and cables cables..
ENGINE SPEED ADJUSTMENT
Speed Inspection
engine model
Note: The idl ing speed is electronically electronically controlled. 1.
Warm up the engine. Cooling water temperature: temperature: Hydraulic oil temperature:
2.
3.
80°C (176 (1 76 or more 60°C 60°C (140° (1 40°F) F)or or more
Install a tachometer and and vacuum gage. Disconnect Disconnect the inspection connector and connect th e tachometer measurement to th e male side. Disconnect the vacuum hose and install the vacuum speed inspectio n and adjustmen t Measure the idle speed. speed. Standard:
750
A d j u s t t h e m i x t u r e a d j u s t i n g s c re re w s o t h a t t h e negative pressure then is stabilized at the highest level. Note: When the idling speed is hig high, h, check check if t he idle adjust ing screw i s pushing t he lever. lever. If so, loosen th e screw. screw. Check Chec k and adjust the clearance clearance be tween th e idl e adjustin g screw and lever. lever. Standa Standard: rd:
mm
in)
Engine Model> 1.
W a r m u p t h e e n g i n e i n t h e s a m e w a y as as f o r t h e gasoline or engine and connect a tachometer.
2.
idle speed inspection and adjustment. Adjust the idle speed speed with the throttl e adjust screw. screw. Standard: 800
25 rpm
(2) Turn the idle adjusting screw gradually clockwise or counterclockwise to the position where the engine rpm is the highest. highest. (3) Adjust the standar standard d value by turning the throttle adjustin g screw. screw.
Throttle adjust screw
Note:
Repeat steps steps (2) and (3) until the state after step (2) satisfies satisfies the standard.
Turn the idle adjusting screw counterclockwise until the rpm starts starts to drop, and then tu rn it clockwise clockwise by 45 . "
Up Inspection Inspection Adjustment -
Warm up the engine. Cooling Cooling water temperature: Hydraulic oil temperature:
80°C or more 60°C 60°C (14 ( 140° 0°F) F) or more
2.
Install a tachomet er
3.
Check the idl e- up speed. Check Start the engine. Disconnect the vacuum hose from the idle - up actuator and measure the speed after plugging th e hose. Standard: 1250
50
rpm
(2) If the standard is not satisfied, satisfied, make adjustmen t by turning the adjusting screw. Note Note::
Turn th e adjusting screw clockwise to increase speed.
(3) After adjustment, connect the vacuum hose.
No-load Maximum Speed Inspection Adjustment -
Gasoline or
Engine Model>
Note : The maxi mum speed is controlled electron electronicall ically. y. 1.
Warm up the engine
(176°F)or (176°F)or more 60° 60°C (140°F)or F)or more
Cooling water temperature: temperature: Hydraulic Hydr aulic oi l temper tem per ature: atu re: 2.
Install a tachometer.
3.
lnspe ct th e no - l o a d m a x i m u m s p e ed ed w h e n t h e accelerato acceleratorr pedal is f ull y depressed. depressed. Standard:
2350 2350
30 rp m
1.
Warm up the engine. Cooli ng wa ter te r tempe rature: ratu re: Hydraulic Hydr aulic oi l temp eratu re:
80° 80°C (176° (176°F)or F)or more 60° 60°C (140° (140°F)or mo re
2.
Install a tachometer.
3.
lnspect and adjust the no- load ma ximu m speed. speed. Measure the speed when the accelerator pedal is ful ly depressed. depressed. Standard:
2400 2400
50 r pm
(2) If the stand ard is not satisfied, satisfied, adjust the speed. (3) Remove the air governor bush lock lock bolt. Turn Turn the air governor bush while fix ing the adjusting screw t o adju st the speed. speed.
Note: Less Less tha n t he standard standard:: Mor e th an th e standard standard::
Turn th e bushing clockclock wise. Turn the bushing counter clockwise.
(4) Install the air governor bush lock bolt.
Loaded Maximum Speed Measurement Note: Note: In t he gasoline or engine model, the max imu m speed is c ontrolled electronica electronically. lly.
While the engine is running at the maximum speed, operate the material handling lever and measure the engine speed at full relief. Check that the decrease in the speed speed is with in the fo llow ing range: range: Standard Standard::
2.
2150 2150 rp m or more
If the standard is not satisfied, turn the adjusting screw for adjustment.
ELECTRONIC GOVERNOR Repair operation Carefully protec t electrica electricall parts f rom direct water pressure (100 kgf/cm ) [14 psi]) application 1. duri ng vehicle washing. washing. After any repair repair,, always conduct th e final inspection according to the specified procedure. 2. parts other than OPT. OPT.)) 3. Never a ttempt at electrical wirin g modifi cation. (Never install any electrical parts 2
Parts handling Handle each part with care. Especially avoid any impact on controller sensor parts as it will bring 1. about adverse adverse influence. Sensor adjust ment is necess necessary ary after repairing a part related t o each senso sensor. r. 2. When installing the throttle switch, avoid incorre incorrect ct connection of the (ful l) side and min. (idle) 3. side. (The shorter wir ing is f or the mi n. side.) side.) used selectively according to the vehicle model. 4. Three types of controller s are used
Items to be provided Prepar Prepare e the foll owing tools: Name
Part No.
Toyota electrical tester instrument Bond, etc.
Thickness gauge Thread tigh tene tenerr
08833 088 33-0007 00070 0
Purpose Sensor and switch inspection and measurement Sensor and switch inspection and measurement Upon sensor sensor adjustmen t
Outline of Repair Procedure Procedure Preparation Troubleshooting 1. Basic inspection 2. Functional inspection
Repair operation
Job description 1. Prepare necessary tools.
basic basic characteristics before troubleshooting. 2. Perform functional inspection ( function check check of each each part) t o clarif y the defect status. 1. Inspect Inspect according according t o the self-diagnosis 3. Diagnostic inspection code. 2. For a defect defect for wh ich n o self-diagnosis 4.Other inspection code is displayed displayed,, determine th e inspection method according according t o the phenomenon. Removal, installation 1. Perform removal, installation, inspection or replacement and replacement. 1.
Sensor 1. Sensor
Adjustment
Stopped state Final inspection
ad justment i s necessary necessary if any part related to the system is repaired (removed, instal led or replaced). replaced). Parts Parts requiring adjustment are as follows: Acceleration senso sensor, r, idle switch and throttle switch 1. After the end of repair job, inspect according according to the final inspection procedure.
Traveling state End
1.
Summariz e the defects and repair details, (Keep th em f or reference later. later.))
Reference Page 1-9 (Items (Items to be prepared) Page 1-10 (basic inspect ion) Page 1-10 (final inspection) Page 1 - 1 I (inspection by diagnosis) Page 1-29 (inspection of defect no indicated by diagnosis)
Page 1 - 1 7 (sensor and switch adjustment)
Page 1-10 (final inspection)
I
Basic lnspection lnspect basic basic ite ms shown below before before starting troubleshooting: Remarks
Content 1. lnspect lnspect the battery vo ltage and specific gravity of electrolyte.
Inspect Inspect the carburetor function. (1) carburetor link operation state (2) Stepping m oto r operation state state
lnspection around carburetor I
I
Specific gra vity: 1.28 1.280 0 Voltage: 10 to 14 V Erroneous diagn diagnosis osis wi ll result if the battery voltage is low. Defective Defective groundin g wi ll caus cause e erroneous diagnosis. Defective Defective contact contact of the w iring or harness connector connector w ill cause cause erroneous diagnosis. There shall be no looseness looseness in t he carburetor link. Manually rotate the throttle lever and stepping motor. Shall be rotated smoothly.
Final lnspection After t he end of repa repair ir,, perform inspection according according to t he follo wing procedur procedure: e: order 1.
Inspection meth od with
OFF Vehicle stopping state
Vehicle traveling state
2. lnspection before engine starting with engine engine switch ON 3. lnspection after engine starting
4. Self-diagnostic inspection
standard
1. lnspect each connector for the connection state. state. 2. Mechanical of acceleration sensor and idle switch
Shall not be disconnected, loosened or wetted.
Depress the th e accelerator 1. Depress
The movement shall shall foll ow the accelerator accelerator pedal depression state.
pedal and check check the throttle movement. 1. lnspect the CHECK lamp for lighting state.
Shall normally be off.
1. lnspect the CHECK lamp during traveling. Disconnect the diagnosis 2. Disconnect connector for diagnostic code display, and check check if any code is
The CHECK lamp shall be kept off. No self self-diagnostic code shall be displayed.
Check
Self-diagnosis The self -diagnostic function i nfor m the driver of tr ouble occurren occurrence ce and trouble position by flashing the CHECK in the combination meter meter if any trouble occurs in electronic electronic governor control. The trou ble posi tion is indicated by the CHECK l amp flashing count. Display of diagnostic code 5
ON
- - - - - - OFF Display of diagnostic codes 5 and 7
Repetition of above cycle operation Note: The CHECK lamp may come on when the engine engine switch is turned t o ON or may flash flash during traveling (dur ing operation operation). ). If it flashes flashes durin g operat operation ion,, immediately stop t he vehicl vehicle e and check check the flashing count w it h the engine sw itc h a t the ON position (engine no t running). The The flashing count becomes becomes the diagnosti c code. The diagnosis i s repeated when the engine s wit ch is set t o OFF OFF once and to ON again again.. If any abnormality exists, the CHECK lam p flashes. Aft er th e end o f repair according according to the diagnosis diagnosis,, disconnect th e memory clear term termina inal, l, connect the male side of the disconnected disconnected terminal terminal to the body ground ground,, and turn the engine engine swi tch t o ON to reset the ECU memory. (See (See the illustrat ion below.) Checker
connector
Recheckin Rechecking g th e diagnostic resu lt displayed before To check the diagnostic result displayed in the past (after ECU memory resetting), disconnect the diagnosis connector (checker) for re-display. Once the ECU memory is reset, preceding results are not displayed.
1 - 12
Diagnostic Code List Normal traveling
Low -speed traveling
:
Traveling Traveling fail ure
Backup Code No
Diagnostic item
Diagnosed state
Engine
Controller action upon defect detection.
The engine is stopped by sett ing engine engine ignition to off.
1
Overrun
Abnormal en gine speed rise
2
Accelerator opening signal line
When the signal fro m t he sensor sensor is abnormal or the line is shorted or opened.
Acceleration1 idle signal line (short circuit)
ON signal signal thoug h the potentiometer opening signal is or more (short circuit)
Ordinary traveling possible though the max imum speed may decrease. decrease.
Throttle full close switch signal (open circuit)
The signal is OF OFF thou gh t he stepping stepping motor i s rotated toward the throttle closing side by a specified specified angle or m ore.
Normal traveling possible possible though the max imum speed speed may decrease because the throttle opening is limited.
Throttle full open switch signal (short circuit)
The signal is OF OFF tho ugh th e throttle is opened beyond the specified specified opening.
Throttle full close switch signal (short circuit) circuit)
The signa signall is ON th ough t he throttle opening is beyond the specified level.
Throttle full open switch signal (short circuit)
The signal signal is ON when the thr ottle opening is belo w the specified level.
Stepping motor
The engine engine speed does does not dro p though the controller issues issues the throttle closing instruction.
Engine pulse
No engine engine ignit ion signal
Alternator
The alternator signal is OFF
travelin g possible.
The engine is stopped by set ting the eng ine ig niti on to OFF.
travelin g possible.
Components
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