16-2 SST LIST Illustration Part No. Part Name Section : Newly adopted SST 1 2 4 5 6 7 8 11 12 13 14 15 09082-76002-71 (09082-00050) TOYOTA electrical tester 09090-76002-71 (09090-04020) Engine sling device 09214-76004-71 (09214-76011) Crankshaft pulley replacer 09216-76002-71 (09216-00021) Belt tension gage 09222-76001-71 (09222-30010) Connecting rod bushing remover & replacer 09228-76004-71 (09228-07501) Oil filter wrench 09316-76002-71 (09316-60011) Transmisson & transfer bearing replacer 09509-76003-71 (09509-55030) Rear wheel bearing nut wrench 09608-76003-71 (09608-04031) Front hub inner bearing cone replacer 09623-76001-71 (09623-30011) Steering worm bearing & oil seal replacer
16-3 Illustration Part No. Part Name Section 1 2 4 5 6 7 8 11 12 13 14 15 09717-76001-71 (09717-20010) Brake shoe return spring remover 09718-76001-71 (09718-20010) Brake shoe return spring replacer 09950-76014-71 (09950-40011) Puller B set 09950-76003-71 (09950-50012) Puller C set 09950-76018-71 (09950-60010) Replacer set 09950-76019-71 (09950-60020) Replacer set No. 2 09950-76020-71 (09950-70010) Handle set 09010-20111-71 Engine unit hanger 09010-23320-71 Engine with transmission hanger 09120-23600-71 Puller 16
16-4 Illustration Part No. Part Name. Section 1 2 4 5 6 7 8 11 12 13 14 15 09190-30510-71 Spark plug wrench 09220-33901-71 Torque converter clutch drum spring remover & replacer 09240-23321-71 Plug-in analyzer 09310-23321-71 Reamer bolt remover 09320-23000-71 Bearing remover 09370-20270-71 Drive pinion bearing replacer 09410-23320-71 Differential carrier stand 09420-23000-71 Bearing remover 09450-23320-71 Adapter 09510-31960-71 Brake hold down spring remover and replacer
16-5 Illustration Part No. Part Name Section 1 2 4 5 6 7 8 11 12 13 14 15 09610-10160-71 Oil control valve spring remover and replacer 09620-10100-71 Cylinder cap remover and replacer 09630-10110-71 Tilt cylinder cap remover and replacer 09630-31720-71 Deep socket C 09630-33900-71 Deep socket B 09630-33910-71 Deep socket D 09631-22000-71 Wear scale chain 09810-20172-71 Joint pin remover 09820-31040-71 Joint bolt 16
16-6 SERVICE STANDARDS LIST ENGINE Engine (G4 (GM6-262)) Engine speeds rpm Engine (13Z) Idling speed rpm No-load static maximum speed Pn35 ~ 50 model rpm Pn60 ~ 80 model Full relief engine speed down Pn35 ~ 50 model rpm Pn60 ~ 80 model Air cleaner Vacuum switch continuity test G4 (GM6-262) (Continuity shall exist.) Pa (mmh2o, mmhg) [inh2o, inhg] 13Z Fan drive Fan belt flexure (when pushed with 29 N (3 kgf) [6.6 lbf]) Battery Spark Plug Specific gravity of electrolyte (at 20 C [68 F]) Spark plug gap Alternator Alternator drive V-belt tension G4 (GM6-262) (when pushed with 98 N (10 kgf) [22 lbf]) 13Z Alternator drive V-belt tension G4 (GM6-262) (when measured with a tension gauge (SST)) N (kgf) [lbf] 13Z Accelerator pedal Pedal roller height (from G4 Electronic governor accelerator bracket to top of (GM6-262) Air governor roller) 13Z Accelerator pedal (EEC spec.) Pedal roller height (from G4 Electronic governor accelerator bracket to top of (GM6-262) Air governor roller) 13Z Tightening torque Unit: N m (kgf-cm) [ft-lbf] Engine mounting nut Flywheel set bolt G4 (GM6-262) 13Z Torque converter end plate set bolt Flexible plate set bolt (for flyweel connection) See page 1-9 750 ± 25 2400 ± 50 2600 ± 50 250 or less 350 or less 7473 ± 569 (762 ± 58, 56.0 ± 4.3) [30.00 ± 2.28, 2.25 ± 0.169] 6 ~ 8 (0.24 ~ 0.31) 1.280 1.4 (0.055)/in initial state 1.6 (0.063) 8 ~ 16 (0.31 ~ 0.63) 8 ~ 13 (0.31 ~ 0.51) 294 ~ 392 (30 ~ 40) [66 ~ 88] 196 ~ 392 (20 ~ 40) [44 ~ 88] 99 ± 1 (3.90 ± 0.04) +2 +0.08 80 (3.15 ) 0 +2 +0.08 80 (3.15 ) 0 108 ± 1 (4.25 ± 0.04) +2 +0.08 80 (3.15 ) 0 +2 +0.08 80 (3.15 ) 0 53.9 ~ 99.0 (550 ~ 1010) [39.8 ~ 73.1] 98.07 ~ 156.9 (1000 ~ 1600) [72.35 ~ 115.8] 49.0 ~ 78.0 (500 ~ 800) [36.2 ~ 57.9] 14.7 ~ 21.6 (150 ~ 220) [10.9 ~ 15.9] 0 0 0 0
16-7 TORQUE CONVERTER & TRANSMISSION ASSY Transmission cover & control valve Inner Regulator valve spring free length Outer Inner Accumulator spring free length Outer Inching regulator spring free length Inching return spring free length Torque converter Pump boss outside diameter Stator (No.2) roller outside diameter Stator (No.2) hub to cam clearance Stator shaft No.2 & oil pump Stator shaft outside diameter (at portion in sliding contact with oil pump gear) Driven gear to pump body clearance Pump drive gear bush to stator shaft clearance Pump body surface to drive/driven gear clearance 153.5 (6.043) 135.5 (5.315) 148.0 (5.827) 131.0 (5.157) 150.0 (5.906) 135.0 (5.315) 153.5 (6.043) 138.5 (5.453) 27 (1.06) 24 (0.94) 63.3 (2.49) 58 (2.28) 70.00 (2.7559) 69.85 (2.7450) 8.30 (0.3268) 8.17 (0.3217) 0.03 ~ 0.07 (0.0012 ~ 0.0028) 0.15 (0.0059) 55.0 (2.165) 54.9 (2.161) 0.12 ~ 0.20 (0.0047 ~ 0.0078) 0.3 (0.012) 0.03 ~ 0.079 (0.0012 ~ 0.00311) 0.15 (0.0059) 0.05 ~ 0.10 (0.0020 ~ 0.0039) 0.13 (0.0051)
16-8 Transmission Main shaft piston seal ring side clearance Main shaft servo seal ring side clearance Clutch disc plate thickness Clutch plate thickness Clutch camber plate warp Clutch return spring free length Clutch piston ring side clearance Measurement Test Stall speed rpm G4 (GM6-262) 13Z Main pressure kpa (kgf/cm 2 ) [psi] At idling At 1500 rpm Clutch operating pressure kpa (kgf/cm 2 ) [psi] Torque converter outlet pressure kpa (kgf/cm 2 ) [psi] At idling At 1500 rpm At 1500 rpm Tightening torque Unit: N m (kgf-cm) [ft-lbf] Solenoid valve set bolt Pump boss set bolt Drive cover set bolt Pilot boss set bolt Flexible plate set bolt Stator shaft No.2 & oil pump set bolt Oil filter Torque converter & transmission case set bolt Inching valve ASSY set bolt Suction filter set bolt Output coupling set bolt 0.30 (0.012) 0.29 (0.011) 2.6 (0.102) 2.3 (0.091) 2.3 (0.091) 2.1 (0.083) 3.4 (0.134) 3.1 (0.122) 56 (2.20) 50 (1.97) 0.15 (0.0059) 1950 1950 588 (6) [85] or more 981 ~ 1373 (10 ~ 14) [142 ~ 199] 588 (6) [85] or more 981 ~ 1373 (10 ~ 14) [142 ~ 199] 167 ~ 441 (1.7 ~ 4.5) [24 ~ 64] 4.9 ~ 7.8 (50 ~ 80) [3.6 ~ 5.8] 18.6 ~ 24.5 (190 ~ 250) [13.7 ~ 18.1] 18.6 ~ 24.5 (190 ~ 250) [13.7 ~ 18.1] 18.6 ~ 24.5 (190 ~ 250) [13.7 ~ 18.1] 18.6 ~ 24.5 (190 ~ 250) [13.7 ~ 18.1] 18.6 ~ 24.5 (190 ~ 250) [13.7 ~ 18.1] 14.7 ~ 19.6 (150 ~ 200) [10.9 ~ 14.5] 35.2 ~ 44.1 (360 ~ 450) [26.0 ~ 32.6] 18.6 ~ 24.5 (190 ~ 250) [13.7 ~ 18.1] 18.6 ~ 24.5 (190 ~ 250) [13.7 ~ 18.1] 107.9 ~ 127.5 (1100 ~ 1300) [79.59 ~ 94.06]
16-9 DIFFERENTIAL Differential Ring gear backlash Differential pinion bore Spider outside diameter Side gear thrust washer thickness Pinion gear thrust washer thickness Drive pinion bearing starting torque N m (kgf-cm) [ft-lbf] Tightening torque Unit: N m (kgf-cm) [ft-lbf] Drive pinion lock nut Drive pinion rear cover set bolt Differential carrier cover set bolt Ring gear set bolt Differential upper case set bolt Differential case bearing cap set bolt Differential carrier set bolt 0.2 ~ 0.3 (0.008 ~ 0.012) 22.12 (0.8709) 22.22 (0.8748) 22.00 (0.8661) 21.75 (0.8563) 1.6 (0.063) 1.3 (0.051) 1.6 (0.063) 1.0 (0.039) 8.82 ~ 13.23 (90 ~ 135) [6.51 ~ 9.77] 343.2 ~ 392.3 (3500 ~ 4000) [253.2 ~ 289.4] 15.7 ~ 19.6 (160 ~ 200) [11.6 ~ 14.5] 39.2 ~ 53.9 (400 ~ 550) [28.9 ~ 39.8] 127.4 ~ 176.5 (1300 ~ 1800) [94.06 ~ 130.2] 43.1 ~ 53.9 (440 ~ 550) [31.8 ~ 39.8] 117.7 ~ 137.3 (1200 ~ 1400) [86.82 ~ 101.3] 49.1 ~ 78.5 (500 ~ 800) [36.2 ~ 57.9]
16-10 FRONT AXLE Pn35 ~ 50 Model Front axle ASSY Planet gear bush inside diameter Planet gear shaft outside diameter Front axle shaft starting force (Measured at axle housing set bolt) Tightening torque Brake ASSY set nut Hub bolt lock nut Axle shaft lock nut Front axle housing set bolt N (kgf) [lbf] Unit: N m (kgf-cm) [ft-lbf] Front axle bracket set bolt (for fixing on frame) Front axle bracket set bolt Front wheel hub nut (Single tire, double tire (inside), double tire (outside)) 22.0 (0.866) 22.18 (0.860) 22.0 (0.866) 21.85 (0.873) 68.6 ~ 127.5 (7 ~ 13) [15 ~ 29] M12: 88.3 ~ 117.7 (900 ~ 1200) [65.1 ~ 86.8] M14: 117.7 ~ 137.3 (1200 ~ 1400) [86.82 ~ 101.3] 264.8 ~ 294.2 (2700 ~ 3000) [195.3 ~ 217.1] 294.2 ~ 343.2 (3000 ~ 3500) [217.1 ~ 253.2] 180.4 ~ 323.6 (1840 ~ 3300) [133.1 ~ 238.8] 235.4 ~ 294.2 (2400 ~ 3000) [173.6 ~ 217.1] 294.2 ~ 392.3 (3000 ~ 4000) [217.1 ~ 289.4] 294.2 ~ 588.4 (3000 ~ 6000) [217.1 ~ 434.1] Pn60 ~ 80 Model Front axle ASSY Planet gear bush inside diameter Planet gear shaft outside diameter Front axle hub starting force (Measured at hub bolt) N (kgf) [lbf] Tightening torque Unit: N m (kgf-cm) [ft-lbf] Brake ASSY set bolt Hub bolt lock nut Front axle housing set bolt Front axle bracket set bolt (for fixing on frame) Front wheel hub nut (inside, outside) Brake drum set bolt Planet gear carrier cover set bolt Planet gear carrier set bolt 26.0 (1.024) 25.85 (1.018) 26.0 (1.024) 26.18 (1.031) 88.2 ~ 156 (9 ~ 16) [20 ~ 35] 300.0 ~ 400.0 (3060 ~ 4080) [221.4 ~ 295.2] 294.2 ~ 588.4 (3000 ~ 6000) [217.1 ~ 434.1] 180 ~ 323 (1840 ~ 3290) [133.1 ~ 238.0] 343 ~ 441 (3500 ~ 4500) [253.2 ~ 325.6] 294.2 ~ 588.4 (3000 ~ 6000) [217.1 ~ 434.1] 137.3 ~ 205.9 (1400 ~ 2100) [101.3 ~ 151.9] 20.4 ~ 30.6 (208 ~ 312) [15.0 ~ 22.6] 98.1 ~ 127.5 (1000 ~ 1300) [72.4 ~ 94.1]
16-11 Cu35 45 Model Front axle ASSY Planet gear bush inside diameter Planet gear shaft outside diameter Front axle hub starting force (Measured at hub bolt) N (kgf) [lbf] Tightening torque Unit: N m (kgf-cm) [ft-lbf] Brake ASSY set bolt Hub bolt lock nut Front axle bracket set bolt (for fixing on frame) Front wheel hub nut Brake drum set bolt Planet gear carrier cover set bolt Planet gear carrier set bolt Cu55 ~ 70 Model Front axle ASSY Planet gear bush inside diameter Planet gear shaft outside diameter Front axle hub starting force (Measured at hub bolt) N (kgf) [lbf] Tightening torque Unit: N m (kgf-cm) [ft-lbf] Brake ASSY set bolt Hub bolt lock nut Front axle bracket set bolt (for fixing on frame) Front wheel hub nut Planet gear carrier cover set bolt Planet gear carrier set bolt 26.0 (1.024) 25.85 (1.018) 26.0 (1.024) 26.18 (1.031) 49 ~ 118 (5 ~ 12) [11 ~ 26] 88.3 ~ 117.7 (900 ~ 1200) [65.1 ~ 86.8] 264.8 ~ 294.2 (2700 ~ 3000) [195.3 ~ 217.1] 245 ~ 324 (2500 ~ 3300) [180.9 ~ 238.8] 294.2 ~ 323.6 (3000 ~ 3300) [217.1 ~ 238.8] 88.3 ~ 137.3 (900 ~ 1400) [65.1 ~ 101.3] 20.4 ~ 30.6 (208 ~ 312) [15.0 ~ 22.6] 98.1 ~ 127.5 (1000 ~ 1300) [72.4 ~ 94.1] 26.0 (1.024) 25.85 (1.018) 26.0 (1.024) 26.18 (1.031) 88.2 ~ 156 (9 ~ 16) [20 ~ 35] 300.0 ~ 400.0 (3060 ~ 4080) [221.4 ~ 295.2] 264.8 ~ 294.2 (2700 ~ 3000) [195.3 ~ 217.1] 343 ~ 441 (3500 ~ 4500) [253.2 ~ 325.6] 294.2 ~ 323.6 (3000 ~ 3300) [217.1 ~ 238.8] 20.4 ~ 30.6 (208 ~ 312) [15.0 ~ 22.6] 98.1 ~ 127.5 (1000 ~ 1300) [72.4 ~ 94.1]
16-12 REAR AXLE Pn35 ~ 80 Model Rear axle ASSY Rear axle ASSY front to rear clearance Rear axle center pin bushing inside diameter Rear axle hub and steering knuckle Rear axle hub starting force (at hub bolt) N (kgf) [lbf] King pin outside diameter Steering knuckle starting force (at front end of knuckle) Rear axle cylinder Rear axle cylinder piston rod outside diameter N (kgf) [lbf] Rear axle cylinder piston rod bend Rear axle cylinder inside diameter Tightening torque Axle bracket cap set bolt King pin lock bolt and lock nut Divided rim bolt set nut (Pn35 ~ 45 model only) Rear axle cylinder rod guide set nut Rear axle cylinder set bolt Hub nut Pn35 ~ 50 model Pn60 ~ 80 model Pn35 ~ 50 model Pn60 ~ 80 model Pn35 ~ 50 model Pn60 ~ 80 model Pn35 ~ 50 model Pn60 ~ 80 model Pn35 ~ 50 model Pn60 ~ 80 model Unit: N m (kgf-cm) [ft-lbf] Pn35 ~ 50 model Pn60 ~ 80 model Pn35 ~ 50 model Pn60 ~ 80 model 1.0 (0.039) or less 67.0 (2.638) Front: 82.0 (3.228) Rear: 67.0 (2.638) 43 ~ 72 (4.4 ~ 7.3) [9.7 ~ 16.1] 78 ~ 157 (8.0 ~ 16.0) [17.6 ~ 35.3] 34.8 (1.370) 39.8 (1.567) 19.3 (2.0) [4.4] or less 54.91 (2.1618) 69.91 (2.7524) 0.5 (0.017) 95.40 (3.7559) 105.40 (4.1496) 128 ~ 175 (1310 ~ 1780) [94.78 ~ 128.8] 44.1 ~ 53.9 (450 ~ 550) [32.6 ~ 39.8] 63.7 ~ 73.5 (650 ~ 750) [47.0 ~ 54.3] 117.6 ~ 176.4 (1200 ~ 1800) [86.82 ~ 130.2] 117.7 ~ 137.3 (1200 ~ 1400) [86.82 ~ 101.3] 421.7 ~ 470.7 (4300 ~ 4800) [311.1 ~ 347.3] 176.5 ~ 196.1 (1800 ~ 2000) [130.2 ~ 144.7] 294.1 ~ 588.4 (3000 ~ 6000) [217.1 ~ 434.1]
16-13 Cu35 ~ 70 Model Rear axle ASSY Rear axle ASSY front to rear clearance Rear axle center pin bushing inside diameter Rear axle hub and steering knuckle Rear axle hub starting force (at tire periphery) N (kgf) [lbf] King pin outside diameter Steering knuckle starting force (at front end of knuckle) Rear axle cylinder N (kgf) [lbf] Rear axle cylinder piston rod outside diameter Rear axle cylinder piston rod bend Rear axle cylinder inside diameter Tightening torque Axle bracket cap set bolt King pin lock bolt and lock nut Rear axle cylinder rod guide set nut Rear axle cylinder set bolt Cu35 45 model Cu55 ~ 70 model Cu35 45 model Cu55 ~ 70 model Unit: N m (kgf-cm) [ft-lbf] 1.0 (0.039) or less Front: 82.0 (3.228) Rear: 67.0 (2.638) 29 ~ 44 (3.0 ~ 4.5) [6.6 ~ 9.9] 78 ~ 157 (8.0 ~ 16.0) [17.6 ~ 35.3] 39.8 (1.567) 19.3 (2.0) [4.4] or less 54.91 (2.1618) 0.5 (0.017) 87.40 (3.4409) 90.40 (3.5591) 128 ~ 175 (1310 ~ 1780) [94.78 ~ 128.8] 63.7 ~ 73.5 (650 ~ 750) [47.0 ~ 54.3] 117.7 ~ 137.3 (1200 ~ 1400) [86.82 ~ 101.3] 421.7 ~ 470.7 (4300 ~ 4800) [311.1 ~ 347.3]
16-14 STEERING Hydrostatic steering valve ASSY Pn35 ~ 45 model Relief pressure Pn50 ~ 80, Cu70 model kpa (kgf/cm 2 ) [psi] Cu35 ~ 60 model Tightening torque Mast jacket set nut Steering wheel set nut Steering valve ASSY set bolt Steering valve end cap set screw 9610 +4 0 90 (98 +5 0) [1390 +7 0 0 ] 11100 +4 0 90 (113 +5 0) [1610 +7 0 0 ] 9120 +4 0 90 (93 +5 0) [1320 +7 0 0 ] Unit: N m (kgf-cm) [ft-lbf] 34.3 ~ 53.9 (350 ~ 550) [25.3 ~ 39.8] 24.5 ~ 58.8 (250 ~ 600) [18.1 ~ 43.4] 29.4 ~ 39.2 (300 ~ 400) [21.7 ~ 28.9] 24 ~ 36 (245 ~ 367) [19.7 ~ 26.6] BRAKE Front brake Brake drum bore Brake lining thickness Brake lining livet sinking Brake booster Master cylinder piston side clearance Power piston side clearance Parking brake Lever operating force Brake pedal N (kgf) [lbf] Pedal height (from toe board to top center of pedal) Pedal play Push rod play Pedal height in fully depressed state Inching pedal stroke until interlocking with brake Inching pedal play (until start of inching valve spool movement) Pn35 ~ 50, Cu35 45 model Pn60 ~ 80, Cu55 ~ 70 model Pn60 ~ 80, Cu55 ~ 70 model Pn35 ~45, Pn60 70, Cu35 ~ 70 model Pn50, Pn80 model With pad 317.5 (12.50) 319.5 (12.58) 9.3 (0.36) 4.3 (0.17) 10.0 (0.39) 1.0 (0.039) 0.032 (0.0013) 0.032 (0.0013) 196 ~ 245 (20 ~ 25) [44 ~ 55] 245 ~ 294 (25 ~ 30) [55 ~ 66] 150 ~ 155 (5.91 ~ 6.10) 3 ~ 7 (0.12 ~ 0.28) 1 (0.04) 90 (3.54 ) or more 26 ~ 32 (1.02 ~ 1.26) 1 ~ 3 (0.04 ~ 0.12)
16-15 Tightening torque Parking brake actuator lever set bolt Wheel cylinder set bolt Unit: N. m (kgf-cm) [ft-lbf] Pn35 ~ 50, Cu35 45 model Pn35 40 model Pn45 model Pn50 model Upper Lower Upper Lower Pn60 ~ 80, Cu55 ~ 70 model 13.7 ~ 22.6 (140 ~ 230) [10.1 ~ 16.6] 69.6 ~ 94.1 (710 ~ 960) [51.4 ~ 69.5] 125.5 ~ 170.6 (1280 ~ 1740) [92.6 ~ 125.9] 186.3 ~ 255.0 (1900 ~ 2600) [137.5 ~ 188.1] 122.6 ~ 166.7 (1250 ~ 1700) [90.4 ~ 123.0] 186.3 ~ 255.0 (1900 ~ 2600) [137.5 ~ 188.1] 17.7 ~ 26.5 (180 ~ 270) [13.0 ~ 19.5] MATERIAL HANDLING SYSTEM Natural drop test Natural drop Natural forward tilt test Natural forward tilt Oil leak test Lift cylinder oil leak amount (at lift port) cm 3 (in 3 ) Tilt cylinder oil leak amount (total for lift and tilt) cm 3 (in 3 ) MAST Fork 45 (1.77) 25 (0.98) 8 (0.49) 16 (0.98) Front end misalignment 10 (0.39) Mast adjustment (V mast) Mast lift roller Inner mast roller clearance Outer mast roller clearance 0 ~ 0.8 (0 ~ 0.031) 0 ~ 0.8 (0 ~ 0.031) Lift bracket roller Pn35 40, Cu35 45 model Pn45 ~ 80, Cu55 ~ 70 model Lower lift roller clearance Upper side roller clearance Lower side roller clearance Side roller clearance 0 ~ 0.5 (0 ~ 0.020) 0 ~ 0.5 (0 ~ 0.020) 0.5 ~ 1.0 (0.020 ~ 0.039) 0 ~ 0.8 (0 ~ 0.031) Mast strip to inner mast clearance 0 ~ 0.8 (0 ~ 0.031)
16-16 CYLINDER Lift cylinder (V) Piston rod outside Pn35 ~ 50, Cu35 45 49.92 (1.9654) diameter Pn60 ~ 80, Cu55 54.91 (2.1618) Pn35 40, Cu35 65.35 (2.5728) Cylinder bore Pn45 50, Cu45 Cu55 70.35 (2.7697) 75.35 (2.9665) Pn60 ~ 80 80.35 (3.1594) Piston rod bend 2.0 (0.079) Rear lift cylinder (FV FSV) Piston rod outside diameter Pn35 ~ 45, Cu35 45 Pn35 ~ 50, Cu35 45 Pn60, Cu55 ~ 70 FV FSV FSV 44.92 (1.7685) 49.92 (1.9654) 54.91 (2.1618) Pn35 ~ 50, Cu35 45 FV 65.35 (2.5728) Cylinder bore Pn35 ~ 50, Cu35 ~ 55 Cu55 FSV FSV 70.35 (2.7697) 75.35 (2.9665) Pn60 ~ 70, Cu60 FSV 80.35 (3.1594) Front lift cylinder (FV FSV) Piston rod outside diameter FV FSV 69.91 (2.7524) Pn35 40, Cu35 FV FSV 95.40 (3.5779) Cylinder bore Pn45 50, Cu45 Cu55 FV FSV FSV 105.40 (4.1496) 110.40 (4.3465) FSV 120.40 (4.7402) Piston rod bend 2.0 (0.079) Tilt cylinder Cylinder bore Pn35 ~ 50, Cu35 45 90.40 (3.5591) Cu55 ~ 70, Pn60 ~ 80 100.40 (3.937) Piston rod outside Pn35 ~ 50, Cu35 45 39.92 (1.5717) diameter Cu55 ~ 70, Pn60 ~ 80 44.92 (1.7685) Piston rod bend 1.0 (0.039)
16-17 Tightening torque Lift cylinder cover FV rear cylinder cover FSV rear cylinder Flow regulator valve Safety down valve Front lift cylinder cover Tilt cylinder piston castle nut Tilt cylinder cover Unit: N m (kgf-cm) [ft-lbf] V: Pn35 ~ 80, Cu35 ~ 70 Pn35 ~ 45 RH cyl. Cu35 45 Lift cylinder cover Lift cylinder rod guide FV FSV FSV LH cyl. Pn35 ~ 50 Cu35 45 RH, LH Pn60 70 Cu55 ~ 70 RH, LH Pn35 40, Cu35 Pn45, Cu45 Pn50 ~ 70 Cu55 ~ 70 343.2 ~ 441.3 (3500 ~ 4500) [253.2 ~ 325.6] 343.2 ~ 441.3 (3500 ~ 4500) [253.2 ~ 325.6] 284 ~ 421 (2900 ~ 4300) [209.8 ~ 311.1] 284 ~ 421 (2900 ~ 4300) [209.8 ~ 311.1] 343 ~ 441 (3500 ~ 4500) [253.2 ~ 325.6] 88.3 ~ 98.1 (900 ~ 1000) [65.12 ~ 72.35] 58.8 ~ 68.6 (600 ~ 700) [43.4 ~ 50.6] 343.2 ~ 441.3 (3500 ~ 4500) [253.2 ~ 325.6] 392.3 ~ 490.3 (4000 ~ 5000) [289.4 ~ 361.8] 245.2 ~ 343.2 (2500 ~ 3500) [180.9 ~ 253.2] 343.2 ~ 441.3 (3500 ~ 4500) [253.2 ~ 325.6]
16-18 OIL PUMP Oil pump Body inner face flaw depth Front or middle side Rear side 0.05 (0.002) 0.1 (0.004) Bushing inside diameter Front or middle side Rear side 24.1 (0.949) 17.1 (0.673) Plate thickness Front or middle side Rear side 2.65 (0.1043) 4.85 (0.1909) Gear shaft outside diameter Front or middle side Rear side 46.27 (1.8217) 33.05 (1.3012) Tightening torque Unit: N m (kgf-cm) [ft-lbf] Oil pump body set bolt 98.1 (1000) [72.4] OIL CONTROL VALVE Oil control valve Relief set pressure (common to lift and tilt) kpa (kgf/cm 2 ) [psi] Relief set pressure (common to lift and tilt (backward)) kpa (kgf/cm 2 ) [psi] Relief set pressure (tilt (forward)) kpa (kgf/cm 2 ) [psi] Tightening torque Outlet housing set bolt Unit: N m (kgf-cm) [ft-lbf] Pn35 ~ 50, Cu35 ~ 55 model Pn60 ~ 80, Cu60 70 model Pn60 ~ 80, Cu60 70 model + 490 +5 +70 18140 0 (185 0) [2630 0 ] + 490 +5 +70 20590 0 (210 0) [2990 0 ] + 490 +5 +70 13240 0 (135 0) [1920 0 ] 34.3 ~ 44.1 (350 ~ 450) [25.3 ~ 32.6] SAS Tightening torque Unit: N m (kgf-cm) [ft-lbf] SAS controller set bolt Swing lock cylinder Pn35 ~ 50, Cu35 45 model upper pin set bolt Cu55 ~ 70 model Swing lock cylinder Pn35 ~ 50, Cu35 45 model lower pin set bolt Cu55 ~ 70 model Tilt angle sensor set bolt Load sensor Speed sensor set bolt Fork height switch ASSY set bolt 10 ~ 15 (102 ~ 153) [7.3 ~ 11.1] 10.5 ~ 24.5 (107 ~ 250) [7.74 ~ 18.1] 21.6 ~ 50.4 (220 ~ 514) [15.9 ~ 37.2] 16.2 ~ 37.8 (165 ~ 385) [11.9 ~ 27.9] 21.6 ~ 50.4 (220 ~ 514) [15.9 ~ 37.2] 6.9 ~ 15.8 (69 ~ 161) [5.0 ~ 11.6] 35.3 ~ 43.1 (360 ~ 440) [26.0 ~ 31.8] 3.0 ~ 7.0 (31 ~ 71) [2.2 ~ 5.1] 14.4 ~ 33.6 (147 ~ 343) [10.6 ~ 24.8]
16-19 WIRING DIAGRAM NAME G D LP G/LP LPS Page BATTERY, RELAY BOX 16-20 ELECTRIC SHIFT T/C STARTING BACK UP LAMP 16-21 BACK BUZZER SMART ALARM ELECTRIC SHIFT T/C (EZ PEDAL) STARTING BACK UP LAMP 16-22 BACK BUZZER SMART ALARM CHARGING 16-23 SAS ECU 16-24 FUEL SYSTEM (GASOLINE) IGNITION SYSTEM 16-25 FUEL SYSTEM (LPG EXCLUSIVE) IGNITION SYSTEM *1 16-26 3 WAY CATALYTIC SYSTEM FUEL SYSTEM (LPG EXCLUSIVE) ELECTRONIC GOVERNOR CONTROL SYSTEM *2 IGNITION SYSTEM 16-27 3 WAY CATALYTIC SYSTEM FUEL SYSTEM (LPG EXCLUSIVE) *1 IGNITION SYSTEM 16-28 FUEL SYSTEM (LPG EXCLUSIVE) ELECTRONIC GOVERNOR CONTROL SYSTEM *2 16-29 IGNITION SYSTEM FUEL SYSTEM (LPG CONVERTIBLE) IGNITION SYSTEM 16-30 FUEL SYSTEM (DIESEL) IGNITION SYSTEM 16-31 HEAD LAMP 16-32 T/C OIL TEMPERATURE INDICATOR INDICATOR 16-33 STROBE LIGHT COMBINATION METER 16-34 COMBINATION METER (EZ PEDAL) 16-35 STOP LAMP 16-36 TAIL LAMP CLEARANCE LAMP 16-37 TURN SIGNAL LAMP 16-38 COMPARTMENT LIGHT REAR WORKING LAMP 16-39 ENGINE SHUT DOWN DEVICE 16-40 LPG WARNING INDICATOR 16-41 INTAKE HEATER 16-42 PARKING BRAKE LAMP SAFETY START SW *3 *3 *3 16-43 MOTION ALARM *1: 7FGU35 ~ 45, 7FGCU35 ~ 60 *2: 7FGAU50, 7FGU60 ~ 80, 7FGCU70 *3: 7FGCU35 45
16-20 BATTERY, RELAY BOX
ELECTRIC SHIFT T/C, STARTING, BACK UP LAMP, BACK BUZZER, SMART ALARM 16-21
16-22 ELECTRIC SHIFT T/C (EZ PEDAL), STARTING, BACK UP LAMP, BACK BUZZER, SMART ALARM
CHARGING 16-23
16-24 SAS ECU
FUEL SYSTEM (GASOLINE), IGNITION SYSTEM 16-25
16-26 FUEL SYSTEM (LPG EXCLUSIVE), IGNITION SYSTEM, 3 WAY CATALYTIC SYSTEM
16-27 FUEL SYSTEM (LPG EXCLUSIVE), ELECTRONIC GOVERNOR CONTROL SYSTEM, IGNITION SYSTEM, 3 WAY CATALYTIC SYSTEM
16-28 FUEL SYSTEM (LPG EXCLUSIVE), IGNITION SYSTEM
16-29 FUEL SYSTEM (LPG EXCLUSIVE), ELECTRONIC GOVERNOR CONTROL SYSTEM, IGNITION SYSTEM
16-30 FUEL SYSTEM (LPG CONVERTIBLE), IGNITION SYSTEM
FUEL SYSTEM (DIESEL), IGNITION SYSTEM 16-31
16-32 HEAD LAMP
T/C OIL TEMPERATURE INDICATOR, INDICATOR, STROBE LIGHT 16-33
16-34 COMBINATION METER
COMBINATION METER (EZ PEDAL) 16-35
16-36 STOP LAMP
TAIL LAMP, CLEARANCE LAMP 16-37
16-38 TURN SIGNAL LAMP
COMPARTMENT LIGHT, REAR WORKING LAMP 16-39
16-40 ENGINE SHUT DOWN DEVICE
LPG WARNING INDICATOR 16-41
16-42 INTAKE HEATER
PARKING BRAKE LAMP, SAFETY START SW, MOTION ALARM 16-43
16-44