17 SST LIST AND SERVICE STANDARDS LIST

Transcription

1 SST LIST AND SERVICE STANDARDS LIST 17.1 SST LIST Illustration Part No. Part Name Section Belt tension gage Connecting rod bushing remover & replacer Oil filter wrench Transmisson & transfer bearing replacer Spring pin remover Rear wheel bearing nut wrench Steering worm bearing & oil seal replacer Brake shoe return spring remover Brake shoe return spring replacer Puller B set Puller C set Replacer set Replacer set No. 2 Revised September 30, 2014

2 Illustration Part No. Part Name Section Handle set Engine unit hanger Engine with transmission hanger Puller Spark plug wrench Torque converter clutch drum spring remover & replacer Bearing remover Drive pinion bearing replacer Bearing remover Adapter Brake hold down spring remover and replacer Oil control valve spring remover and replacer Cylinder cap remover and replacer

3 Illustration Part No. Part Name Section Tilt cylinder cap remover and replacer Deep socket C Deep socket B Deep socket D Wear scale chain Joint pin remover Joint bolt 17

4 SERVICE STANDARDS LIST ENGINE 1FS Engine Idling speed Standard 750 ± 30 rpm No-load static maximum speed 3.5 to 5.0 ton model Standard 2350 ± 35 rpm 5.5 to 8.0 ton model Standard 2550 ± 35 1KD Engine Idling speed Standard 750 ± 30 rpm No-load static maximum speed 3.5 to 5.0 ton model Standard 2350 ± 35 rpm 5.5 to 8.0 ton model Standard 2600 ± 35 Air cleaner Vacuum switch continuity test (Continuity 1FS Standard 7.5 ± 1.1 [1.09 ± 0.16] shall exist.) 1KD kpa [psi] Fan drive Fan belt flexure (when pushed with 29 N [6.6 lbf]) Standard 6 to 8 (0.24 to 0.31) Battery and Spark Plug Specific gravity of electrolyte (at 20 C [68 F]) Standard Spark plug gap Standard 1.4 (0.055) / in initial state Limit 1.6 (0.063) Alternator Alternator drive V-belt tension (when pushed with 98 N [22 lbf]) 1FS/1KD Standard New belts: 7 to 9 (0.28 to 0.36) Standard Belts in use: 8 to 13 (0.32 to 0.51) Alternator drive V-belt tension N [lbf] 1FS/1KD Standard New belts: Standard Belts in use: 520 to 760 [117 to 172] 320 to 560 [73 to 126]

5 Accelerator pedal Pedal angle (at the accelerator OFF) 1FS Standard 45 1KD Standard 45 Engine mounting nut Standard 53.2 to 98.0 [39.3 to 72.2] Flywheel set bolt 1FS Standard 80 to 120 [59 to 88.5] 1KD to [123.5 to 150.9] Torque converter end plate set bolt Standard 49.0 to 78.0 [36.2 to 57.9] Flexible plate set bolt (for flyweel connection) Standard 18.6 to 24.5 [13.7 to 18.1] TORQUE CONVERTER & TRANSMISSION ASSY Transmission cover & control valve Regulator valve spring free length Accumulator spring free length Inching valve spring free length Standard 97.0 (3.819) Limit 86.0 (3.386) Inner Standard (5.906) Limit (5.315) Outer Standard (6.043) Limit (5.453) Inner Standard 28.0 (1.10) Limit 25.0 (0.98) Outer Standard 64.0 (2.52) Limit 58.0 (2.28) 17 Measurement and Test Stall speed Main pressure Clutch operating pressure 1FS Standard 1700 rpm 1KD At idling Standard 500 [73] or more kpa [psi] At 2000 rpm 900 to 1300 [131 to 189] At idling Standard 500 [73] or more kpa [psi] At 2000 rpm 900 to 1300 [131 to 189] Solenoid valve set bolt 4.9 to 7.8 [3.6 to 5.8] Pump boss set bolt 18.6 to 24.5 [13.7 to 18.1] Drive cover set bolt 18.6 to 24.5 [13.7 to 18.1] Pilot boss set bolt 18.6 to 24.5 [13.7 to 18.1] Flexible plate set bolt 18.6 to 24.5 [13.7 to 18.1] Stator shaft No.2 & oil pump set bolt 18.6 to 24.5 [13.7 to 18.1] Oil filter 14.7 to 19.6 [10.9 to 14.5] Torque converter & transmission case set bolt 39.2 to 49.1 [28.9 to 36.2] Inching valve ASSY set bolt 18.6 to 24.5 [13.7 to 18.1]

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7 Tightening torque Unit: N m [ft-lbf] Brake ASSY set bolt to [221.4 to 295.2] Hub bolt lock nut to [217.1 to 434.1] Front axle housing set bolt 180 to 323 [133.1 to 238.0] Front axle bracket set bolt (for fixing on frame) 326 to 420 [240.5 to 309.9] Front wheel hub nut 294 to 588 [216.9 to 433.8] Brake drum set bolt 137 to 206 [101.1 to 1512] Planet gear carrier cover set bolt 20.4 to 30.6 [15.0 to 22.6] Planet gear carrier set bolt 107 to 140 [78.9 to 103.3] Cu35 and 45 Model Front axle ASSY Front axle shaft starting force (Measured at axle housing set bolt) N [lbf] Standard 49 to 118 [11.0 to 26.5] Tightening torque Unit: N m [ft-lbf] Brake ASSY set nut 88 to 118 [64.9 to 87.1] Hub bolt lock nut 265 to 294 [195.5 to 216.9] Front axle bracket set bolt (for fixing on frame) 219 to 285 [161.7 to 210.0] Front wheel hub nut 265 to 294 [195.7 to 216.9] Brake drum set bolt 88 to 137 [64.9 to 101.1] Planet gear carrier cover set bolt 20.4 to 30.6 [15.0 to 22.6] Planet gear carrier set bolt 107 to 140 [78.9 to 103.3] 17 Cu55 to 70 Model Front axle shaft starting force (Measured at axle housing set bolt) N [lbf] Standard 88.2 to 156 [20 to 35] Tightening torque Unit: N m [ft-lbf] Brake ASSY set bolt to [221.4 to 295.2] Hub bolt lock nut 265 to 294 [195.5 to 216.9] Front axle bracket set bolt (for fixing on frame) 268 to 336 [197.7 to 247.9] Front wheel hub nut to [217.1 to 238.8] Planet gear carrier cover set bolt 20.4 to 30.6 [15.0 to 22.6] Planet gear carrier set bolt 107 to 140 [78.9 to 103.3]

8 REAR AXLE Pn 35 to 80 Model Rear axle ASSY Rear axle ASSY front to rear clearance Standard 1.0 (0.039) or less Rear axle center pin bushing inside Pn 35 to 50 model Limit 67.0 (2.638) diameter Pn 60 to 80 model Limit Front: 82.0 (3.228) Rear: 67.0 (2.638) Rear axle hub and steering knuckle Rear axle hub starting force (at Pn 35 to 50 model Standard 43 to 72 [9.7 to 16.1] hub bolt) Pn 60 to 80 model Standard 78 to 157 [17.6 to 35.3] N [lbf] King pin outside diameter Pn 35 to 50 model Limit 34.8 (1.370) Pn 60 to 80 model Limit 39.8 (1.567) Steering knuckle starting force (at front end of knuckle) N [lbf] Standard 19.3 [4.4] or less Rear axle cylinder Rear axle cylinder piston rod outside Pn 35 to 50 model Limit (2.1618) diameter Pn 60 to 80 model Limit (2.7524) Rear axle cylinder piston rod bend Rear axle cylinder inside diameter Limit 0.5 (0.017) Pn 35 to 45 model Limit 90.0 (3.54) Pn 50 model Limit (3.7559) Pn 60 to 80 model Limit (4.1496) King pin lock bolt and lock nut Pn 35 to 50 model Standard 44.1 to 53.9 [32.6 to 39.8] Pn 60 to 80 model Standard 63.7 to 73.5 [47.0 to 54.3] King pin lock nut Standard 35.0 to 52.0 [25.8 to 38.4] Divided rim bolt set nut (Pn 35 to 45 model only) Standard to [87 to 130] Rear axle cylinder rod guide set nut Standard to [86.82 to 101.3] Rear axle cylinder set bolt Standard 422 to 548 [311 to 404] Rear axle bracket set bolt Standard 233 to 350 [172 to 258] Hub nut Pn 35 to 50 model Standard 177 to 392 [130.6 to 289.2] Pn 60 to 80 model Standard 294 to 588 [217.0 to 433.8]

9 Cu 35 to 70 Model Rear axle ASSY Rear axle ASSY front to rear clearance Rear axle center pin bushing inside diameter Standard 1.0 (0.039) or less Limit Front: 82.0 (3.228) Rear: 67.0 (2.638) Rear axle hub and steering knuckle Rear axle hub starting force (at tire Cu 35 and 45 model Standard 29 to 44 [6.6 to 9.9] periphery) Cu 55 to 70 model Standard 78 to 157 [17.6 to 35.3] N [lbf] King pin outside diameter Steering knuckle starting force (at front end of knuckle) N [lbf] Limit 39.8 (1.567) Standard 19.3 [4.4] or less Rear axle cylinder Rear axle cylinder piston rod outside diameter Limit (2.1618) Rear axle cylinder piston rod bend Limit 0.5 (0.017) Rear axle cylinder inside diameter Cu 35 and 45 model Limit (3.4409) Cu 55 to 70 model Limit (3.5591) 17 King pin lock bolt and lock nut Standard 63.7 to 73.5 [47.0 to 54.23] Rear axle cylinder rod guide set nut Standard 422 to 548 [311.3 to 404.2] Rear axle cylinder set bolt Standard 422 to 548 [311.3 to 404.2] Rear axle bracket set bolt Standard 233 to 350 [172 to 258] STEERING Hydrostatic steering valve ASSY Relief pressure Pn35 to 45 model Standard 11.8 to 12.3 [1711 to 1784] MPa [psi] Pn50 to 80, Cu70 model Standard 11.3 to 11.8 [1639 to 1711] Cu35 to 60 model Standard 9.3 to 9.8 [1348 to 1421] Mast jacket set nut Standard 44 [33] Steering wheel set nut Standard 35 [26] Steering valve ASSY set bolt Standard 34.3 [25.3] Tilt lock bolt Standard 12.0 [8.85]

10 Steering valve end cover set screw Standard 24 to 36 [19.7 to 26.6] BRAKE Front brake Brake drum bore Brake lining thickness Brake lining livet sinking Pn35 to 50, Cu 35 and 45 model Pn60 to 80, Cu55 to 70 model Pn35 to 50, Cu 35 and 45 model Pn60 to 80, Cu55 to 70 model Standard (12.50) Limit (12.58) Standard 9.3 (0.36) Standard 10.0 (0.39) Limit 1.0 (0.039) Limit 1.0 (0.039) Brake booster Master cylinder piston side clearance Power piston side clearance Limit (0.0013) Limit (0.0013) Parking brake Lever operating force (At 27.5mm) Pn35 to 45,60 and 70, Cu 35 to 70 model Standard 197 to 231 [44.3 to 51.9] N [lbf] Pn50 and 80 model Standard 239 to 274 [53.7 to 61.6] Brake pedal Pedal height (from toe board to top center of pedal) Pedal play Push rod play Inching pedal stroke until interlocking with brake With pad Standard 155 to 160 (6.102 to 6.299) Inching pedal play (until start of inching valve spool movement) Standard 3 to 7 (0.12 to 0.28) Standard 1 (0.04) Standard 27 to 33 (1.06 to 1.30) Standard 0 to 2 (0 to 0.08) Parking brake actuator lever set bolt Cu35 and 45 model to [10.13 to 16.64] Wheel cylinder set bolt Pn35 to 80, Cu55 to 70 model Standard to [13.02 to 19.54]

11 MATERIAL HANDLING SYSTEM Natural drop test Natural drop Limit 45 (1.77) Natural forward tilt test Natural forward tilt Limit 25 (0.98) Oil leak test Lift cylinder oil leak amount (at lift port) Tilt cylinder oil leak amount (total for lift and tilt) cm 3 (in 3 ) cm 3 (in 3 ) Limit 8 (0.49) Limit 16 (0.98) MAST Fork Front end misalignment Limit 10 (0.39) 17 Mast adjustment (V mast) Mast lift roller Wheel cylinder set bolt Inner mast roller clearance Outer mast roller clearance Pn35 and Lower lift roller 40, Cu35 clearance and 45 model Upper side roller clearance Pn45 to 80, Cu55 to 70 model Mast strip to inner mast clearance Lower side roller clearance Side roller clearance Standard 0 to 0.8 (0 to 0.031) Standard 0 to 0.8 (0 to 0.031) Standard 0 to 0.5 (0 to 0.020) Standard 0 to 0.5 (0 to 0.020) Standard 0.5 to 1.0 (0.020 to 0.039) Standard 0 to 0.8 (0 to 0.031) Standard 0 to 0.8 (0 to 0.031) CYLINDER Lift cylinder (V) Piston rod outside diameter Pn35 to 50, Cu 35 and 45 Limit (1.9654)

12 Cylinder bore Piston rod bend Pn60 to 80, Cu55 Limit (2.1618) Pn35 and 40, Cu35 Limit (2.5728) Pn45 and 50, Cu45 Limit (2.7697) Cu55 Limit (2.9665) Pn60 to 80 Limit (3.1594) Limit 2.0 (0.079) Rear lift cylinder (FV and FSV) Piston rod outside diameter Cylinder bore Pn35 to 45, Cu35 and 45 Pn35 to 50, Cu35 and 45 Pn60, Cu55 to 70 Pn35 to 50, Cu35 and 45 Pn35 to 50, Cu35 to 55 FV Limit (1.7685) FSV Limit (1.9654) FSV Limit (2.1618) FV Limit (2.5728) FSV Limit (2.7697) Cu55 FSV Limit (2.9665) Pn60 to 70, Cu60 FSV Limit (3.1594) Tilt cylinder Cylinder bore Pn35 to 50, Cu 35 and Limit (3.5591) 45 Pn60 to 80, Cu55 to 70 Limit (3.937) Piston rod outside diameter Pn35 and 50, Cu35 and Limit (1.5717) 45 Pn60 and 80, Cu55 to 70 Limit (1.7685) Piston rod bend Limit 1.0 (0.039) Lift cylinder cover FV rear cylinder cover FSV rear cylinder V: Pn35 to 80, Cu35 to 70 Standard to [253.2 to 325.6] Pn35 to 45, Cu35 and 45 Lift cylinder cover Lift cylinder rod guide RH cyl. Standard to [253.2 to 325.6] LH cyl. Standard 284 to 421 [209.8 to 311.1] Pn35 to 50, Cu35 and 45 RH, LH Pn60 and 70 Cu55 to 70 RH, LH Standard 284 to 421 [209.8 to 311.1] Standard 343 to 441 [253.2 to 325.6] Flow regulator valve Standard 88.3 to 98.1 [65.12 to 72.35] Safety down valve Standard 58.8 to 68.6 [43.4 to 50.6] Front lift cylinder cover FV, FSV Pn35 and 40, Cu35 Standard to [253.2 to 325.6]

13 FSV Pn45, Cu45 Standard to [289.4 to 361.8] Pn50 to 70, Cu55 to 70 Standard to [289.4 to 361.8] Tilt cylinder piston castle nut Standard to [180.9 to 253.2] Tilt cylinder cover Standard to [253.2 to 325.6] OIL PUMP Oil pump Piston rod outside diameter Cylinder bore Plate thickness Gear shaft outside diameter Front or middle side Limit 0.05 (0.002) Rear side Limit 0.1 (0.004) Front or middle side Limit 24.1 (0.949) Rear side Limit 17.1 (0.673) Front or middle side Limit 2.65 (0.1043) Rear side Limit 4.85 (0.1909) Front or middle side Limit (1.8217) Rear side Limit (1.3012) Oil pump body set bolt Limit 98.1 [72.4] OIL CONTROL VALVE Oil control valve Relief set pressure (Lift) Relief set pressure (Tilt) MPa [psi] Pn35 to 80, Cu35 to 70 model Limit [ ] Pn35 to 50, Cu35 and 55 Limit [ ] MPa [psi] model Pn60/70, Cu60/70 model [ ] Tightening torque Outlet housing set nut Unit: N m [ft-lbf] 35.3 to 43.1 [26.0 to 31.8] SAS/OPS SAS/OPS controller set bolt Standard 3.3 to 7.7 [72.4 to 5.7] Swing lock cylinder pin set bolt Standard 29 [21.4] Yaw rate sensor cover Standard 3.3 to 7.7 [2.4 to 5.7] Tilt angle sensor cover set bolt Standard 0.7 to 1.3 [0.52 to 0.96] Tilt angle sensor set bolt Standard 10 to 16 [7.38 to 11.8] Mast lifting height switch set bolt Standard 16.2 to 37.8 [11.9 to 27.9]

14 Mast lifting height switch connector cover set bolt Standard 7.8 to 18.2 [5.8 to 13.5]

15 Published by 1st Printing: Oct Pub. No. CE104 Printed in USA

16 PRINTED IN USA Pub. No. CE104

17 SERVICE INFORMATION BULLETIN Front Axle FA October 31, 2016 Correction of Front Wheel Hub Nut Torque 8FG35-50U, 8FD35-50U Subject: Correction of Front Wheel Hub Nut Torque Page 1 of 1 MODEL APPLICATION: 8FG35U, 8FG40U, 8FG45U, 8FG50U, 8FD35U, 8FD40U, 8FD45U and 8FD50U GENERAL INFORMATION: The tightening specification for the front wheel hub nut has been corrected. REPAIR INFORMATION: Replace the original repair manual pages with the new pages with updated specification that have been attached to this bulletin. Repair Manual CE104: Page: to Page: to Contents Incorrect Correct Tightening Torque of Front Wheel Hub Nut N m N m kgf cm kgf cm ft lb ft lb

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19 5-278 Match marks Step 1 Remove the front axle shaft (outer). Step 2 Remove the lock nut. Removal/Installation use SST Step 3 Remove the brake drum. Step 4 Remove the bearing. Step 5 Remove the oil seal and bearing. Step 6 Disassemble the front axle housing. Step 7 Remove the front axle bracket. Step 8 Remove the brake ASSY. Step 9 Remove the internal gear. Punch match mark and remove the reamer bolts. Step 10 Step 11 Step 12 Remove the front axle shaft (inner). Remove the snap ring. Disassemble the planet carrier ASSY. Measure the planet gear shaft outside diameter. Standard: 22.0 mm (0.866 in) Limit: mm (0.860 in) Measure the planet gear bushing inside diameter. Standard: 22.0 mm (0.866 in)) Limit: mm (0.873 in) a: SST b: SST b a Revised September 30, 2014

20 Accelerator pedal Pedal angle (at the accelerator OFF) 1FS Standard 45 1KD Standard 45 Engine mounting nut Standard 53.2 to 98.0 [39.3 to 72.2] Flywheel set bolt 1FS Standard 80 to 120 [59 to 88.5] 1KD to [123.5 to 150.9] Torque converter end plate set bolt Standard 49.0 to 78.0 [36.2 to 57.9] Flexible plate set bolt (for flyweel connection) Standard 18.6 to 24.5 [13.7 to 18.1] TORQUE CONVERTER & TRANSMISSION ASSY Transmission cover & control valve Regulator valve spring free length Accumulator spring free length Inching valve spring free length Standard 97.0 (3.819) Limit 86.0 (3.386) Inner Standard (5.906) Limit (5.315) Outer Standard (6.043) Limit (5.453) Inner Standard 28.0 (1.10) Limit 25.0 (0.98) Outer Standard 64.0 (2.52) Limit 58.0 (2.28) 17 Measurement and Test Stall speed Main pressure Clutch operating pressure 1FS Standard 1700 rpm 1KD At idling Standard 500 [73] or more kpa [psi] At 2000 rpm 900 to 1300 [131 to 189] At idling Standard 500 [73] or more kpa [psi] At 2000 rpm 900 to 1300 [131 to 189] Solenoid valve set bolt 4.9 to 7.8 [3.6 to 5.8] Pump boss set bolt 18.6 to 24.5 [13.7 to 18.1] Drive cover set bolt 18.6 to 24.5 [13.7 to 18.1] Pilot boss set bolt 18.6 to 24.5 [13.7 to 18.1] Flexible plate set bolt 18.6 to 24.5 [13.7 to 18.1] Stator shaft No.2 & oil pump set bolt 18.6 to 24.5 [13.7 to 18.1] Oil filter 14.7 to 19.6 [10.9 to 14.5] Torque converter & transmission case set bolt 39.2 to 49.1 [28.9 to 36.2] Inching valve ASSY set bolt 18.6 to 24.5 [13.7 to 18.1]

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