Toyota 7fg 10 Operating instructions

https://www.besttruckmanuals.com/



CG-,CG-,  11bb

https://www.besttruckmanuals.com/



FOREWORDFOREWORD

ThThis is mamanunual al cocovevers rs ththe e seservrvicice e prprococededurures es of of ththe TOYe TOYOTOTA A FOFORKRKLILIFTFT

7FG7FG/7F/7FD10 D10 - - 30 s30 serieries. es. PlePlease use thase use this is manmanual for provual for providiiding ng quiquick, correck, correctct

serviservicing cing of of the the correcorrespondsponding ing forkforklift lift modemodels.ls.

ThThis is mamanunual al dedealals s wiwith th ththe e ababovove e momodedels ls as of Seas of Septptemembeber r 20200000. . PlPleaeasese

undunderserstantand d thathat t disdisagragreemeement ent can can taktake e plaplace ce betbetweeween n the descthe descripriptiotions ns in in thethe

manmanual ual and actand actual vehicual vehicles les due tdue to chao change nge in in desdesign ign and spand speciecificficatiationsons. . AnyAny

chchanange ge or modor modifificicatatioions ns ththerereaeaftfter er wiwill ll be infbe inforormemed d by Toby Toyoyota ta InInduduststririalal

EquEquipmipment ent ParParts & Servts & Service ice NewNews.s.

For tFor the servhe service ice proprocedcedureures s of tof the mounhe mounted ted engengineine, , rearead the d the reprepair air manmanualualss

lislisted below ted below as refas refereerence nce togtogethether er witwith this h this manmanualual..

(Reference)(Reference)

RepRepair air manmanualuals s relrelateated d to thito this s manmanual ual are as follare as followsows::

TOYOTOYOTA TA INDUINDUSTRIASTRIAL L EQUIEQUIPMENTPMENT

7FG7FG1 1 0-30-30, 0, 7FD7FD11 0-30-30, 0, 7FG7FGK20K20-30-30, , 7FG7FGJ35J35,,

7FD7FDK20K20-30-30, , 7FO7FOJ35J35

REPAIREPAIR R MANUMANUAL AL (No. C(No. CE024E024))

TOYOTOYOTA TA INDUINDUSTRIASTRIAL L EQUIEQUIPMENPMENT T 5K 5K ENGINENGINEE

REPAIREPAIR R MANUMANUAL AL (No. C(No. CE617)E617)

TOYOTOYOTA TA INDUINDUSTRIASTRIAL L EQUIPEQUIPMENT MENT 4Y E4Y ENGINNGINEE

REPAIREPAIR R MANUMANUAL AL (No. C(No. CE602-E602-1)1)

TOYOTTOYOTA A INDUINDUSTRIASTRIAL L EQUIPEQUIPMENT MENT 1D2-11D2-111ENGIENGINENE

REPAIREPAIR R MANUMANUAL AL (No. (No. CE618CE618-1)-1)

TOYOTOYOTA TA INDUINDUSTRIASTRIAL L EQUIEQUIPMENT PMENT 22 EN22 ENGINEGINE

REPAIREPAIR R MANUMANUAL AL (No. C(No. CE625-E625-1)1)

TOYOTOYOTA TA INDUINDUSTRIASTRIAL L EQUIEQUIPMENT PMENT 4Y 4Y ENGINENGINEE

SupplSupplement ement 4Y-EC4Y-ECSS

REPAIREPAIR R MANUMANUAL AL (No. C(No. CU642U642))

TOTOYOYOTA TA MOMOTOTOR R COCORPRPORORATIOATIONN

https://www.besttruckmanuals.com/



SESECTCTIOION N ININDEDEXX

II  ~~ EE

II  GENERAL GENERAL

FFEEAAT T EESS

II  MANMANUAL UAL TRATRANSMNSMISSISSIONION

II  DIFFERENTIAL DIFFERENTIAL

II  APPENDIX APPENDIX

https://www.besttruckmanuals.com/



GENERALGENERAL

PagePage

EXEXTETERIRIOR OR VIVI EWEWSS  0-20-2

VEVEH ICH ICLE LE MOMODE LDE L  QQ-3-3

FFRRAM AM E NE N UUMM BEBERR  0-50-5

HHOOW W TTO O UUSSE E TTHHIIS S MMANANUUALAL  0-70-7

EEXXPPLLAANNAATTIIOON N MMEETTHHOOD D 00--77

TERMINOLOGyTERMINOLOGy  oo --aa

AABBBBRERE VVIAIA TITIOONSNS  oo --aa

OPOPE RATE RATIO IO NAL NAL TITI PSPS  0-90-9

HHOIOISTSTINING G THTH EE VEVEHIHICCLELE  0-10 0-10

C C I RI R C CUlT UlT TETESTSTERER  0-11 0-11

STSTANDANDARD ARD BOLBOLTT  &&  NUT  NUT TIGHTTIGHTENINENINGG

TTOO RQURQUEE  0-13 0-13

BOLT BOLT STSTRERENGTNGTH H TYTYPE PE IIDEDENTNTIIFIFICATICATION ON METMETHOD HOD 0-0-1313

TTIIGGHHTTEENNIINNG G TTOORRQQUUE E TTAABBLLE E 00--1144

PPRREECCOOAT AT BOBO LTLTSS  0-15 0-15

HIHIGH GH PRPRESESSUSURE RE HOHOSE SE FIFITTTTININGG

TITIGHGHTETENINING NG TOTORQRQUEUE  0-15 0-15

WWIRIRE E RROPOPE E SUSUSPSPENENSISION ON ANGANGLE LE LISLISTT  0-16 0-16

SSAFAFE E LOLOAD AD FFOOR R EEACACH H WWIIRRE E RROOPPEE

SUSUSPSPENENSISION ON ANG ANG LELE  0-16 0-16

COCOMPMPON ON ENENTS TS WEWEIGIGHTHT  0-17 0-17

RERECOCOMMMMENENDEDED D LUBRILUBRICANTCANT

QUANTITYQUANTITY  &&  TYPES TYPES  0-18 0-18

LUBRLUBRICICATIATION ON CHCHARTART  0-20 0-20

PERPERIODIODIC IC MAINTMAINTENANCENANCEE  0-22 0-22

PEPERRIOIODDIC IC REREPLPLACEACEMMENENT T OF POF PARARTS TS ANDAND

LULU BRICBRICANTSANTS  0-28 0-28

0-10-1

https://www.besttruckmanuals.com/



0-20-2

EXTEEXTERIORIOR R VIEVIEWSWS

https://www.besttruckmanuals.com/



0-30-3

MODELMODEL

VEHICLEVEHICLE

ClassificationClassification

TranTransmisssmission ion TypeType  Engine Engine

VehiVehicle cle ModeModell

SeriesSeries  Model Model

7FG107FG10  MffMff

5K5K  Gasoline Gasoline

02-7FG1002-7FG10  T I CT I C

1.0 ton model1.0 ton model

7FD107FD10  MffMff

10Z-1110Z-11  Diesel Diesel

02-7FD1002-7FD10  T I CT I C

7FG157FG15  MffMff

5K5K  Gasoline Gasoline

02-7FG1502-7FG15  T I CT I C

11 ton serton seriesies

40-7FG1540-7FG15  MffMff

4Y4Y  Gasoline Gasoline

1.5 ton model1.5 ton model

42-7FG1542-7FG15  T I CT I C

7FD157FD15  MffMff

10Z-1110Z-11  Diesel Diesel

02-7FD1502-7FD15  T I CT I C

T I CT I C  4Y4Y  Gasoline Gasoline

42-7FG1842-7FG18

1.75 ton 1.75 ton modemodell

T I CT I C  10Z-11 10Z-11  Diesel Diesel

02-7FD1802-7FD18

7FG207FG20  MffMff

5K5K  Gasoline Gasoline

02-7FG2002-7FG20  T I CT I C

4O-7FG204O-7FG20  MffMff

4Y4Y  Gasoline Gasoline

42-7FG2042-7FG20  T I CT I C

2.0 ton model2.0 ton model

6O-7FD206O-7FD20  MffMff

10Z-1110Z-11  Diesel Diesel

62-7FD2062-7FD20  T I CT I C

7F0207F020  MffMff 2Z2Z  Diesel Diesel

02-7F02002-7F020  T I CT I C

2 ton 2 ton serieseriess

7FG257FG25  MffMff

55K K GGaassoolliinnee

02-7FG2502-7FG25  T I CT I C

4O-7FG254O-7FG25  MffMff

44Y Y GGaassoolliinnee

42-7FG2542-7FG25  T I CT I C

2.5 ton model2.5 ton model

6O-7F0256O-7F025  MffMff

1100ZZ--111 1 DDiieesseell

62-7F02562-7F025  T I CT I C

7F0257F025  MffMff 2Z2Z  Diesel Diesel II

T I CT I C

II  02-7F025 02-7F025

https://www.besttruckmanuals.com/



0404

ClassificationClassification

Vehicle ModelVehicle Model  TTrraannssmmiissssiioon n TTyyppe e EEnnggiinnee

SeriesSeries  Model Model

7FG307FG30  MIMITT

4Y4Y  Gasoline Gasoline

02-7FG3002-7FG30  T I CT I C

6O-7FD306O-7FD30  MIMITT

11DDZZ--III I DDiieesseell3 ton series3 ton series  3.0 3.0 ton ton modelmodel 62-7FD3062-7FD30  T I CT I C

7FD307FD30  MIMITT

22ZZ  Diesel Diesel

02-7FD3002-7FD30  T I CT I C

7FGK207FGK20  MIMITT

5K5K  Gasoline Gasoline

02-7FGK2002-7FGK20  T I CT I C

4400--77FFGGKK220 0 MMIITT

44Y Y GGaassoolliinnee

K2.0 ton modelK2.0 ton model

42-7FGK2042-7FGK20  T I CT I C

77FFDDKK220 0 MMIITT

1DZ-II1DZ-II  Diesel Diesel

02-7FDK2002-7FDK20  T I CT I C

K2 ton seriesK2 ton series

77FFGGKK225 5 MMIITT

5K5K  Gasoline Gasoline

02-7FGK2502-7FGK25  T I CT I C

4400--77FFGGKK225 5 MMIITT

4Y4Y  Gasoline Gasoline

K2.5 ton modelK2.5 ton model

42-7FGK2542-7FGK25  T I CT I C

77FFDDKK225 5 MMIITT

11DDZZ--III I DDiieesseell

02-7FDK2502-7FDK25  T I CT I C

7FGK307FGK30  MIMITT

4Y4Y  Gasoline Gasoline

02-7FGK3002-7FGK30  T I CT I C

K3 ton seriesK3 ton series  K3.0 K3.0 ton modton modelel

7FDK307FDK30  MIMITT

11DDZZ--III I DDiieesseell

02-7FDK3002-7FDK30  T I CT I C

77FFGGJJ335 5 MMIITT

4Y4Y  Gasoline Gasoline

02-7FGJ3502-7FGJ35  T I CT I C

J3.5tonJ3.5ton J3.5 ton modelJ3.5 ton model

7FDJ357FDJ35  MIMITT

DieselDiesel

seriesseries

22ZZ

02-7FDJ3502-7FDJ35  T I CT I C --

https://www.besttruckmanuals.com/



FRAME NUMBERFRAME NUMBER

FFrarame me NoNo. Punchin. Punching g PoPositionsition

Punching positionPunching position

0-50-5

SeriesSeries  Engine Engine  VehicVehicle modele modell  Punching Punching formatformat

7FG107FG10

02-7FG1002-7FG10

5K5K  7FG18-10011 7FG18-10011

7FG157FG15

02-7FG1502-7FG15

4O-7FG154O-7FG15

4Y4Y  42-7FG15 42-7FG15  407FG 407FG 18-10018-1001111

11ton serieston series

42-7FG1842-7FG18

7FD107FD10

02-7FD1002-7FD10

10Z-1110Z-11  7FD15 7FD15  7F018-10011 7F018-10011

02-7FD1502-7FD15

02-7FD1802-7FD18

7FG207FG20

02-7FG2002-7FG20

55K K 77FFGG2255--1 1 00001111

7FG257FG25

02-7FG2502-7FG25

4O-7FG204O-7FG20

42-7FG2042-7FG20

4Y4Y  407FG25-1oo11 407FG25-1oo11

4O-7FG254O-7FG25

42-7FG2542-7FG25

22  ton ton seriserieses

7FD207FD20

02-7FD2002-7FD20

2Z2Z  7FD257FD25-1 -1 00110011

7FD257FD25

02-7FD2502-7FD25

6O-7FD206O-7FD20

62-7FD2062-7FD20

1100ZZ--111 1 660077FFDD2255--1100001111

6O-7FD256O-7FD25

62-7FD2562-7FD25

https://www.besttruckmanuals.com/



0-60-6

EngineEngine  VehicVehicle le modelmodel  Punching Punching formatformat

7FG307FG30

02-7FG3002-7FG30

4Y4Y  7FGJ35-1 7FGJ35-1 00110011

7FGJ357FGJ35

02-7FGJ3502-7FGJ35

3 ton, J3.53 ton, J3.5  7FD30 7FD30

ton serieston series 02-7FD3002-7FD30

22 ZZ  7FDJ35-1oo11 7FDJ35-1oo11

7FDJ357FDJ35

02-7FDJ3502-7FDJ35

6O-7FD306O-7FD30

1DZ-II1DZ-II  607FD3Q-10011 607FD3Q-10011

62-7FD3062-7FD30

7FGK207FGK20

02-7FGK2002-7FGK20

5K5K  7FGK25-10011 7FGK25-10011

7FGK257FGK25

02-7FGK2502-7FGK25

4Q-7FGK204Q-7FGK20

K2tonK2ton  42-7FGK20 42-7FGK20

seriesseries  4Y4Y  7FGK3Q-1OO11 7FGK3Q-1OO11

4Q-7FGK254Q-7FGK25

42-7FGK2542-7FGK25

6O-7FDK206O-7FDK20

62-7FDK2062-7FDK20

1DZ-II1DZ-II  7FDK3Q-10011 7FDK3Q-10011

6O-7FDK256O-7FDK25

62-7FDK2562-7FDK25

7FGK307FGK30

4Y4Y  7FGK30-10011 7FGK30-10011

K3 tonK3 ton  02-7FGK30 02-7FGK30

seriesseries 7FDK307FDK30

1DZ-II1DZ-II  7FDK3Q-10011 7FDK3Q-10011

02-7FDK3002-7FDK30

https://www.besttruckmanuals.com/



0-70-7

HOW TO USE THIS MANUALHOW TO USE THIS MANUAL

EXPLANATION METHODEXPLANATION METHOD

1. 1. OpOpereratatioion n prprococededururee

(1) (1) The operThe operatiation on proprocedcedure ure is is desdescricribed bed in in eiteither patther pattern ern A oA or pr pattattern ern B B belbelow.ow.

PatPattertern n A: A: ExpExplanlanatiation on of of eaceach h opeoperatration ion stestep with illp with illustustratrationion..

PatPattertern n B: B: ExpExplanlanatiation on of of opeoperatration ion proprocedcedure ure by iby indindicatcating ing stestep p numnumberbers s in in one illone illustustratrationion, , folfol--

lowlowed ed by exby explaplanatnation ion of cauof cautiotions ns and notes and notes sumsummarmarizeized d as poinas point t opeoperatrationions.s.

ExaExamplmple e of dof descescripriptiotion n in in patpattertern n BB

DISASSEMBlY·INSPECTION·REASSEMBlYDISASSEMBlY·INSPECTION·REASSEMBlY  TightTightening ening torqutorque e unitTunitT  ==  N'm  N'm (kgf-(kgf-cm) cm) [ft-I[ft-Ibf]bf]

• • StStep ep NoNos. s. arare e papartrtiaialllly y sosomemetitimemess

omittomitted ed in in illusillustratiotrations.ns.

• • WhWhen en a a papart rt rereququiririning g titighghteteniningng

tortorque que insinstrutructiction on is nis not indot indicaicated ted inin

the the illillustustratrationion, , the part name is dethe part name is de--

scrscribeibed d in in the the illillustustratration ion fraframe.me.

TT  ==  4 46.6.1 1 - - 4848.1.1

(4(470 70 - - 49490)0)

[3[34.0 4.0 - - 3535.5].5]

Disassembly ProcedureDisassembly Procedure

1 1 RReemmoovve the the e ccoovveerr..  [P [Point oint 11]]

2 2 RReemomovve te the he bubushshiingng  [Point 2] [Point 2]  + -+ -  Op Operaeratiotion n expexplailained ned latlaterer

3 3 RReemmoovve te thhe e ggeeaarr..

Poi Poi nt nt OperationsOperations  ExplaExplanationation n of key of key point for opoint for operatperation ion with an with an illusillustratitrationon

iitt

[P[Point oint 11]]

DisDisassassembembly: ly: Put Put a mata match ch marmark when k when remremovioving ng the pumthe pump p covcover.er.

[P[Point oint 2]2]

InspeInspectionction: : MeasMeasure ure the busthe bush h insidinside diamete diameter.er.

Limit: Limit: 1919.1.12 2 mm (0.mm (0.757528 in)28 in)

https://www.besttruckmanuals.com/



0-80-8

2. 2. HoHow tw to o reread ad cocompmpononenents ts fifigugureress

(1) (1) The coThe compomponennents ts figfigure uses thure uses the ille illustustratrationion

in thin the e papartrts s cacatatalolog g fofor r ththe e vevehihiclcle e momodedel.l.

PlePlease ase refrefer to ther to the e catcataloalog g for checfor checkinking g thethe

part name.part name.

ThThe e nunumbmber er at tat the he ririghght t shshououldlder er of eaof eachch

comcomponponentents s figfigure ure indindicaicates tes the Fig. nuthe Fig. num-m-

ber in the parts catalog.ber in the parts catalog.

(Example)(Example)

FIG numbeFIG number r in partin parts s catcataloalogg

3. 3. MaMatttterers omis omitttted in ed in ththis mis mananuauall

(1) (1) ThiThis s manmanual omits descual omits descripriptiotion n of of the fthe follollowiowing ng jobjobs, s, but pbut perferform orm thethem m in in actactual operaual operatiotion:n:

C DC D  CleCleanianing ng and and waswashinhing g of reof removmoved ed parparts as ts as reqrequiruireded

®®  VisuaVisual inspecl inspection tion (part(partially descrially described)ibed)

TERMINOLOGYTERMINOLOGY

Caution:Caution:

IImportamportant nt matmatteter s rs of w hof which i ch nen eg lig l igengence ce may camay cause use acaccidecidents. nts. Be Be sure tsure to ob s e ro observe ve thethem.m .

Note:Note:

ImportaImportant nt iteitems of which ms of which neglinegligence gence may camay cause accideuse accidents, nts, or mator matterters s in in operaoperation tion procedureprocedure

requirequiring ring speciaspecial l atattenttention.ion.

StaStandandard: rd: ValValues showues showing ing allallowaowable ble ranrange ge in in insinspecpectiotion n and adjand adjustustmenment.t.

LimLimit: it: MaxMaximuimum m or minor minimuimum m allallowaowable ble valvalue ue in in insinspecpectiotion n or ador adjusjustmetment.nt.

AABBBBRREEVVIAIA TTIOIONNSS

Abbreviation (code)Abbreviation (code)  Meaning Meaning  AbbreviaAbbreviation tion (code)(code)  Meaning Meaning

ASSYASSY  Assembly Assembly  SASASS  System System of of active active stabilstabilityity

LHLH  Left Left handhand  SSSSTT  Special Special service service tooltool

LLCLLC  Long Long life life coolantcoolant  SS TDTD  Standard Standard

MfTMfT  Manual Manual transmisstransmissionion  T=T=  Tightening Tightening torquetorque

OPOPTT  Option Option  TICTIC  Torque Torque converteconverter r &&

transmissiontransmission

O/SO/S  Oversize Oversize  OOOOTT  NumbNumber er of of teteeteth h (0 (0 0)0)

PSPS  Power Power steeristeeringng  U/SU/S  Undersize Undersize

RR HH  Right Right handhand  W/W/  With With

SASAEE  Society Society of of AutomotivAutomotivee UU  Less Less

Engineers (USA)Engineers (USA)

https://www.besttruckmanuals.com/



0-90-9

OPEOPERATIONRATIONAL AL TIPTIPSS

1. 1. SaSafe fe opopereratatioionn

(1) (1) AftAfter jacer jackinking g up, up, alwalways ays supsupporport t witwith wooh wooden den bloblocks or cks or rigrigid staid standsnds..

(2) (2) WheWhen n hoihoististing ng the vthe vehiehicle cle or itor its hs heaveavy comy componponentent, , use use wirwire e roprope(se(s) ) witwith a sh a suffufficiicient ent resreserverve e in in loaloadd

capacity.capacity.

(3) (3) AlwAlways ays disdisconconnecnect t the bathe battettery ry terterminminal al befbefore ore the the insinspecpectiotion n or sor serverviciicing ng of elof electectricrical al parparts.ts.

2. 2. TaTactctfuful l opopereratatioionn

(1) (1) PrePreparpare e the methe mechachanic nic tootools, ls, necnecessessary ary meameasursuring ing insinstrutrumenments ts (ci(circurcuit teit testester, r, megmeggerger, , oil oil prepressussurere

gauggauge, e, etc.) and SSTs befoetc.) and SSTs before re startstarting ing operaoperation.tion.

(2) (2) BefBefore disore disconconnecnectinting g wirwiringing, , alwalways cheays check the cablck the cable cole color and wor and wiriiring stateng state..

(3) (3) WheWhen n oveoverharhauliuling ng funfunctictionaonal l parparts, cts, compompliclicateated d porportiotions or rens or relatlated meched mechanianismssms, , arrarrangange the parte the partss

neatneatly to ly to preveprevent nt confuconfusionsion..

(4) (4) WheWhen n disdisassassembemblinling g and inand inspespecticting ng sucsuch a preh a precjscjsion ion parpart as t as the cthe contontrol valrol valve, ve, use use cleclean tooan tools ls andand

operaoperate te in a in a cleaclean n localocation.tion.

(5) (5) FolFollow tlow the deshe descricribed bed proprocedcedureures s for difor disassassemsemblybly, , insinspecpectiotion n and rand reaseassemsemblybly..

(6) (6) RepReplaclace, e, gasgasketkets, s, pacpackinkings gs and O-and O-rinrings gs witwith h new new oneones each time thes each time they y are disare disassassembembledled..

(7) (7) Use Use gengenuinuine e ToyToyota parts fota parts for repor replaclacemeement.nt.

(8(8) ) UsUse spee specicifified ed boboltlts s anand d nunutsts. . ObObseservrve e ththe e spspececififieied d titighghtetenining ng totorqrque ue at at ththe e titime me of reaof reassssememblbly.y.

TigTightehten n to thto the e cencenter ter of tof the speche specifiified ed tigtightehteninning g tortorque que ranrange.ge.

If If no no tighttighteninening g torqutorque e is is specspecifiedified, , tighttighten en the bolt or the bolt or nut anut accordccording ing to to the stanthe standard dard tighttightening ening torqutorquee

table.table.

3. 3. GrGrasaspiping tng the he trtrououblble ste statatee

WheWhen n a a trotroubluble e occoccursurs, , do not ado not attettempt mpt immimmediediate ate disdisassassembembly ly or reor replaplacemcement ent but fbut firsirst chect check k if if thethe

trotroubluble e reqrequiruires es disdisassassembembly ly or replor replaceacemenment t for remefor remedyidying.ng.

4. 4. DiDispspososal of al of wawastste e flfluiuid, ed, etctc..

WheWhen n dradrainiining ng waswaste te flufluid id frofrom m the vehithe vehiclecle, , recreceiveive e it it in a cin a contontainainer.er.

If aIf any oilny oil, fue, fuel, l, coocoolanlant, t, oil oil filfilterter, , batbattertery y or otor other her harharmfumful l subsubstastance nce is is dirdirectectly ly disdischachargerged d or scror scrappappeded

witwithouhout t perpermismissiosion, n, it it wilwill eithl either er advadversersely ely affaffect ect humhuman an heahealth lth or desor destrotroy y the the envenviroironmenment. nt. AlwAlwaysays

sorsort wastt waste e flufluidsids, , etcetc. and trea. and treat t thethem m proproperperly ly by rby requequestesting ing disdisposposal al by sby specpecialializeized d comcompanpaniesies..

I I II

I I I II I I I

= = m -m - --  For scrFor screw jackew jack

5.5.  Jack up Jack up pointpointss

JacJack k up pup poinoints are ts are proprovidvided ed inin the fronthe front t and reand rear portiar portionsons

of thof the e vehvehiclicle. e. AlwAlways ays appapply jackly jacks s at tat the jack he jack up poup pointints.s.

Front Front sideside::

A A circular circular groove groove to to accept accept a a screw screw jack jack is is provided provided un-un-

der the front der the front sidside e of thof the e fraframe.me.

WhWhen en a ga gararagage e jajack ck is usis useded, , jajack ck up aup at the bott the bottotom m susur-r-

facface e of the framof the frame.e.

Rear Rear sideside::

A A circular circular groove groove to to accept accept a a screw screw or or garage garage jack jack isis

proviprovided ded at at the bottom the bottom surfasurface ce of the countof the counterweierweight.ght.

https://www.besttruckmanuals.com/

I:I:::  ii

For screw jack ~For screw jack ~

For garaFor garage jackge jack ~~



0-100-10

HOIHOISTISTING NG THE VEHITHE VEHICLECLE

When When hoisthoisting ing the vehithe vehicle, sling with wircle, sling with wire rope(s) e rope(s) at at the the mastmast

hook holes and the rear side of the head guard.hook holes and the rear side of the head guard.

SliSlinging nging at tat the he head guard head guard is is done done in in two ways.two ways.

Method A:Method A:

Sling after removing the head guard seat.Sling after removing the head guard seat.

Method B:Method B:

CarefCarefullully y slisling so as not tng so as not to damage o damage rear corear combinatmbination ion lamps.lamps.

https://www.besttruckmanuals.com/



0-110-11

CIRCIRCUICUIT T TESTTESTERER

CirCircuicuit t testesterters s are avare availailablable e in in botboth the h the anaanalog and log and digdigitaital l typtypes. es. TheThey y shoshould uld be ube used selesed selectictivelvely y accaccordordinging

to thto the e purpopurpose se of measuof measuremenrement.t.

Analog Analog type: type: This This type type is is convenient convenient for for observing observing movement movement during during operation, operation, but but the the measured measured valuevalue

shoshould uld onlonly y be usebe used d for for refrefereerence nce or rougor rough h judjudgemgementent..

DigDigitaital typl type: e: FaiFairly arly accuccuratrate e reareadinding g is is pospossibsible, le, but ibut it t is is difdifficficult ult to to obsobserverve e the the varvariatiation ion or moor movemvementent..

1. 1. DiDiffffererenence ce in in memeasasururememenent t reresusultlts s wiwith tth the dhe digigitital typal type e anand and analalog og tytypepe

**  The resulThe result t may be may be difdifferferent ent betbetweeween n meameasursuremeements nts witwith the ah the analnalog og typtype and digie and digital tal typtype.e.

Always Always use use a a circuit circuit tester tester according according to to its its operation operation manual.manual.

CauCautiotions ns whewhen n the polathe polaritrities ies are difare differferent ent betbetweeween n the anathe analog log typtype e and dand digiigital tal typtype e are deare descrscribeibedd

below.below.

(1(1) ) AnAnalalog og cicircrcuiuit test testeterr

Forward directionForward direction  Reverse Reverse directiondirection  MeasMeasuremeurement result nt result examexampleple

TesTester ter ranrange: ge: kQ rankQ rangege

Analog Analog typetype

ForwardForward ContiContinuity nuity existexistss

11 kQ11 kQ

ReverseReverse No continuityNo continuity

0000

(2(2) ) DiDigigitatal cirl circucuit teit teststerer

Forward directionForward direction  Reverse Reverse directiondirection

MeasuMeasuremenrement t resulresult exat examplemple

TesTester rangeter range: : MQ raMQ rangenge

DigitDigital al typetype

ForwardForward No continuityNo continuity

ReverseReverse ContiContinuity nuity existexistss

2M2MQQ

https://www.besttruckmanuals.com/



0-120-12

2. 2. DiDiffffererenence ce in in reresusult of mlt of meaeasusureremement nt wiwith cth cirircucuit teit teststerer

The The circircuicuit t testester ter powpower er supsupply ply volvoltagtage e depdependends s on ton the testhe tester er typtype. e. 1.5 1.5 V, V, 3.0 V or 6.0 V is us3.0 V or 6.0 V is used.ed.

The The resresististancance e of a sof a semiemiconconducductor tor sucsuch h as a das a diodiode e varvaries ies witwith the h the circircuicuit t testester ter powpower er supsupply ply volvoltagtage.e.

The The diodiode de chacharacracterterististics ics are share shown own in in the fithe figurgure e belbelow.ow.

((rrnnAA) ) 66

.1.1

II  II

~~  Germanium Germanium  II

diodediode  JJ  II

~ lJ~ lJ  II

ilil  Silicondio~1 Silicondio~1  I-I-- I--- I--

//  ItIt

IJIJ

. . . . •. . . . •  //  . . . . . . • • . . . . ..  ..//

00..1 1 00..2 2 00..3 3 00..4 4 00..5 5 00..6 6 00..7 7 00..88

FFoorrwwaarrd d vvoollttaagge e ((VV))

ThThe e reresisiststanance ce vavalulues es of tof the he sasame me sesemimicocondnducuctotor r memea-a-

sured with tsured with two typewo types s of ciof circuit testrcuit testers ers havinhaving g diffedifferent rent powepowerr

suppsupply ly voltavoltages ges are diffeare different.rent.

ThiThis s manmanual descual describribes es the resthe resultults s of meaof measursuremeement nt witwith ah a

circircuicuit t testester ter whowhose se powpower er supsupply ply volvoltagtage e is is 3.0 V.3.0 V.

3. 3. DiDiffffererenence ce in in memeasasururememenent t reresusult by mlt by meaeasusureremement nt rarangnge (anae (analolog typg type)e)

In In the analthe analog og typtype e circircuicuit t testesterter, , chachanginging ng the measthe measureuremenment t ranrange ge swiswitchtches es oveover r the intethe internarnal l circircuicuit t toto

varvary y the cirthe circuicuit t resresististancance. e. EveEven when the same n when the same diodiode de is mis measeasureured, d, the measthe measureuremenment t resresult variult varieses

witwith h the measthe measureuremenment t ranrange.ge.

~ ~ OQOQ

~ ~ VVaarriiaabblle e rreessiissttoor r 

Always Always use use the the range range described described in in the the repair repair manual manual forfor

measurement.measurement.

MeterMeter

Range:Range:  xx  1010

ResistorResistor

Range:Range: xx  11

II~~

Power source:Power source:  1.1.55VV

$$00

RedRed

(SW1)(SW1)

(SW2)(SW2)

BlackBlack

https://www.besttruckmanuals.com/



0-130-13

SSTTANANDDARARD D BOBOLT LT & NU& NUT TIT TIGGHHTTEENNIINNG G TTOORRQQUUEE

StandStandard ard bolt abolt and tignd tightenihtening ng torqutorques es are not inare not indicatdicated.ed.

JudJudge ge the stthe standandard ard tigtightehteninning g tortorque que as sas showhown n belbelow.ow.

1. 1. FinFind oud out the tyt the type of thpe of the bolt fe bolt from the list brom the list beloelow and thew and then n finfind the bod the bolt tlt tighightentening ing tortorque que frofrom m the tthe tablable.e.

2. 2. ThThe e nunut tt tigighthtenenining g totorqrque ue cacan be n be jujudgdged ed frfrom thom the e mamatiting ng bobolt lt tytypepe..

BO LT BO LT STSTRENRENGTGTH H TYTYPE PE IDIDE NTENTIFIFICICAT IATION ON METMETHODHO D

1.1.  IdentIdentificification ation by by bolt bolt shapeshape  2.2.  IdentIdentificification ation by by part part No.No.

ShaShapepe andand claclassss  Class Class  Hexago Hexagonheadnhead boltbolt

4=4T4=4T

@@--  5=5T 5=5T

BolBoltt heahead No.d No.  6=6T 6=6T  Parts Parts No.No.

7=7T7=7T 91611-91611-44rr2525

HexagonHexagon 8=8T8=8T LLLenLength gth (mm(mm))

headheadboltbolt DD

 DiaDiametmeter (mer (mm)m)

00 No markNo mark  4T4T ClassClass

HexagonHexagon 00))  No No markmark  4T4T

flangflangee boltbolt DiameterDiameter

HexagonHexagon C C DD  Two Two protrudingprotruding 55TT  Length Length

headheadboltbolt  lines lines

HexagonHexagon ((C C ))  Two Two protrudingprotruding 66TT

flanflangege boltbolt  lines lines

Stud boltStud bolt

HexagonHexagon @@  Three Three protrudingprotruding 77TT

headheadboltbolt  lines lines

Part No.Part No.

HexagonHexagon

Four protrudingFour protruding  92132 92132  -406.14 -406.14

88TT ~~LL  LenLength gth (mm(mm))

headheadboltbolt  lines lines

DiaDiametmeter er (mm(mm))

ClassClass

Welded boltWelded bolt  4T4T

DiameterDiameter

No markNo mark  44TT

Stud boltStud bolt  Length Length

https://www.besttruckmanuals.com/

GroovedGrooved  66TT



0-140-14

TITIGHTEGHTENINING NG TORTORQUE QUE TABLETABLE

Specified torqueSpecified torque

ClassClass  Diameter Diameter  Pitch Pitch  Hexagon Hexagon BB-- HexagonHexagon

mmmm  mmmm  head head boltbolt  flangflange e boltbolt

N·mN·m  II  kgf-cm kgf-cm  II  ft-Ibf ft-Ibf  N·mN·m  II  kgf-cm kgf-cm  II  ft-Ibf ft-Ibf

66  1.01.0  5.45.4

 II

5555

 II

48 in-Ibf48 in-Ibf  5.95.9

 II

6060

 II

52 in-Ibf52 in-Ibf

88  1.25 1.25  1313  II 130130  II 99  1414  II 145145  II 1010

II  II  II  II

4T4T  1010  1.25 1.25  2525 II  260260 II  1919  2828 II  290290 II  2121

1212  1.25 1.25  4747 II  480480 II  3535  5353 II  540540 II  3939

1414  1.51.5  7575  II  760760  II  5555  8383  II  850850  II  6161

1616  1.51.5  113113  II  1150 1150  II  8383  --  II  --  II  --

66  1.01.0  6.46.4  II  6565  II  56 56 in-Ibin-Ibff  7.57.5  II  7575  II  65 i65 in-Ibn-Ibff

88  1.25 1.25  1616  II 160160  II 1212  1818  II 175175  II 1313

II  II  II  II

5T5T  1010  1.25 1.25  3232 II  330330 II  2424  3636 II  360360 II  2626

1212  1.25 1.25  5959 II  600600 II  4343  6565 II  670670 II  4848

1414  1.51.5  9191 II  930930 II  6767  100100 II  1050 1050 II  7676

1616

 1.51.5  137137  II  1400 1400  II  101101  157157  II  1600 1600  II  116116

66  1.01.0  7.87.8  II  8080  II  69 i69 in-Ibn-Ibff  8.88.8  II  9090  II  78 78 in-Ibin-Ibff

88  1.25 1.25  1919  II  195195  II  1414  2121  II  215215  II  1616

1010  1.25 1.25  3838  II 400400  II 2929  4343  II 440440  II 3232

66 TT  II  II  II  II

1212  1.25 1.25  7272 II  730730 II  5353  7979 II  810810 II  5959

1414  1.51.5  110110 II  1100 1100 II  8080  123123 II  1250 1250 II  9090

1616  1.51.5  170170  II  1750 1750  II  127127  191191  II  1950 1950  II  141141

66  1.01.0  1111  II  110110  II  88  1212  II  120120  II  99

88  1.25 1.25  2525  II  260260  II  1919  2828  II  290290  II  2121

1010  1.25 1.25  5252  II 530530  II 3838  5858  II 590590  II 4343

ITIT  II  II  II  II

1212  1.25 1.25  9595 II  970970 II  7070  103103 II  1050 1050 II  7676

1414  1.51.5  147147 II  1500 1500  II  108108  167167 II  1700 1700  II  123123

1616  1.51.5  226226 II  2300 2300  II  166166  -- II  -- II  --

66  1.01.0  1212  II  125125  II  99  1414  II  145145  II  99

88  1.25 1.25  2929  II  300300  II  2222  3232  II  330330  II  2424

1010  1.25 1.25  6161  II  620620  II  4545  6868  II  690690  II  5050

aa TT II  II  II  II

1212  1.25 1.25  108108  1100 1100  8080  123123  1250 1250  9090

II II  127127  II II  145145

1414  1.51.5  172172 II  1750 1750  196196 II  2000 2000

II  II

1616  1.51.5  265265 II  2700 2700  II  195195  299299 II  3050 3050  II  221221

https://www.besttruckmanuals.com/



SeaSeal l lock agentlock agent

0-150-15

PRPRECECOAT OAT BOLTSBOLTS

(Bo(Bolts lts witwith seal h seal loclock k ageagent nt coacoatinting g on thon threareads)ds)

1. 1. Do Do nonot ust use the pree the precocoat at bobolt alt as s it it is iis in n eieithther er of of ththe e fofollllowow--

ing cases:ing cases:

(a(a) ) AfAfteter r it it is is reremomoveved.d.

(b(b) ) WhWhen en ththe e prprececoaoat t bobolt is mlt is movoved ed (l(loooosesenened d or tor tigightht--

eneened) d) by by tigtightnhtness ess checheck, ck, etcetc..

Note:Note:

FFor toor torqurque e checheck, ck, use tuse the he lowloweer r limlimit it of the alloof the allow-w-

aable tble tighighteteninning g tortorque que rarangenge. . IIf the bolf the bolt t movmovees, s, rere--

tigtightehten n it ait accoccordirding ng to the steto the steps ps bebelowlow..

2. 2. MeMeththod fod for ror reueuse of se of prprececoaoat t boboltltss

(1(1) ) WaWash the bolsh the bolt and t and ththrereadaded ed hoholele. . (T(The he ththrereadaded ed hoholele

musmust t be be waswashed hed eveeven for n for repreplaclacemeement nt of tof the he bolbolt.)t.)

(2(2) ) PePerfrfecectltly y drdry the way the washshed ed papartrts s by aby air blir blowowining.g.

(3) (3) CoaCoat tht the spe speciecifiefied d seaseal lock agl lock agent to ent to the the thrthreadeaded ed porpor--

tion of the tion of the bolt.bolt.

HIHIGH GH PRPRESESSUSURE RE HOHOSE SE FITFITTITING NG TITIGHGHTETENINING NG TOTORQRQUEUE

1. 1. WheWhen n conconnecnectinting g a a highigh preh pressussure re hoshose, we, wipe tipe the hhe hose ose fitfittinting g and and matmating niping nipple contple contact surfaact surfaces ces witwithh

clcleaean n clclototh h to to reremomove ve foforereigign n mamatttterers s anand d didirtrt. . AlAlso so chchececk k no deno dent or othnt or other er dadamamage ge on thon the e cocontntacactt

surfasurfaces ces beforbefore e instainstallatillation.on.

2. 2. WheWhen n conconnecnectinting g a hia high pregh pressussure re hoshose, hold e, hold the hosthe hose te to alo align the fign the fittitting witing with the nipph the nipple and le and tigtightehten n thethe

fitting.fitting.

3. 3. ThThe e mamaxiximumum m titighghtetenining ng totorqrque ue mumust not est not excxceeeed twid twice thce the stane standadard rd titighghtetenining ng totorqrqueue..

Nominal diameterNominal diameter  StanStandard dard tighttightening ening torqtorque ue N·m N·m (kgf(kgf-cm) -cm) [ft-[ft-Ibf]Ibf] Hose insideHose inside

of screwof screw StandardStandard  TightTightening ening rangrangee  diadiametmeter er mm mm (in(in))

7/16-20UNF7/16-20UNF  25 25 ( ( 25250)0)[ [ 1818.1.1]]  24 24 --  226 6 ( 2( 24400- - 227700) ) [[1177..44- - 1199..55]]  6 6 (0.2(0.24)4)

9/16-18UNF9/16-18UNF  49 49 ( ( 50500) 0) [ [ 3636.2.2]]  47 47 --  52 52 ( 48( 4800- - 553030) [) [3434.7.7--  3388..33] ] 9 9 ((00..3355))

3/4-16UNF3/4-16UNF  59 59 ( ( 60600) 0) [ [ 4343.4.4]]  5566- - 662 2 ( ( 557700--  630630) [41) [41.2 .2 --  45.6] 45.6]  12 12 (0.47)(0.47)

7/8-14UNF7/8-14UNF  59 59 ( ( 60600) 0) [ [ 4343.4.4]]  56 56 --  62 62 ( 57( 570- 0- 663030) [) [4141..2-2-  4455..66] ] 112 2 ((00..4477)), , 115 5 ((00..5599))

1·1/161·1/16  12UNF 12UNF  118 118 (12(1200) 00) [ 86[ 86.8].8]  11112 2 - 12- 123 3 (1(114140 0 - 12- 125050) ) [8[82.2.5 5 - - 9090.4.4]]  19(0.75) 19(0.75)

1·5/16-12UNF1·5/16-12UNF  137 137 (140(1400) 0) [101[101.3].3]  11330 0 - - 11444 4 ((1133330 0 - - 11447700) ) [[9966..2 2 - - 110066..44] ] 225 5 ((00..9988))

PF1/4PF1/4  25 25 ( ( 25250)0)[ 18[ 18.1.1]]  224 4 - - 226 6 ( ( 22440 0 - - 227700) ) [[1177..4 4 - - 1199..55] ] 6 6 ((00..2244))

PF3/8PF3/8  49 49 ( ( 50500) 0) [ [ 3636.2.2]]  447 7 - - 552 2 ( ( 44880 0 - - 553300) ) [[3344..7 7 - - 3388..33] ] 9 9 ((00..3355))

https://www.besttruckmanuals.com/

PF1/2PF1/2  59 59 ( ( 60600) 0) [ [ 4343.4.4]]  556 6 - - 662 2 ( ( 55770 0 - - 663300) ) [[4411..2 2 - - 4455..66]]  12 12 (0.47)(0.47)

PF3/4PF3/4  118 118 (12(1200) 00) [ [ 86.86.8]8]  11112 2 --11223 (3 (1111440 0 --11225500) ) [[8822..5 5 - 90- 9 0..44] ] 119 9 ((00..7755))

PF1PF1  137 137 (140(1400) 0) [101[101.3].3]  11330 0 --11444 (4 (1133330 0 - - 11447700) ) [[9966..2 2 --110066..44] ] 225 5 ((00..9988))



0-160-16

WIWIRE RE ROROPE PE SUSUSPSPENENSISION ON ANGANGLE LE LISLISTT

Lifting angleLifting angle

33 00 00

TensionTension

1.00time1.00time

1.04time1.04time

1.16 time1.16 time

Compres-Compres-

sionsion

oo  time time

0.27 time0.27 time

0.S8time0.S8time

SuspensionSuspension

methodmethod

2t2t

Lifting angleLifting angle  Tension Tension

1.41 time1.41 time

2.00 time2.00 time

Compres-Compres-

sionsion

1.00 time1.00 time

1.73 time1.73 time

SuspensionSuspension

methodmethod

2t2t

SAFSAFE E LOAD LOAD FOFOR R EACH WEACH WIRIRE E ROROPE SUSPE SUSPEPENSNSIOION N ANGANGLELE  UniUnit: t: N N (tf(tf) ) [Ib[Ibf]f]

RRooppe e CCuuttttiinngg Single-ropeSingle-rope Two-rTwo-rope ope suspesuspensionnsion  FourFour-rope -rope suspesuspensionnsion

suspensionsuspension

ddiiaammeetteer r llooaadd

0000 0000 303000 606000 909000 0000 303000 606000 909000

6mm6mm 2138021380  3040 3040  6080 6080  5880 5880  5200 5200  4 433110 0 1122116600  11770 11770  10400 10400  8630 8630

(0.(0.24 24 in)in) (2.18)(2.18)  (0.31 (0.31 ))  (0.62) (0.62)  (0.6) (0.6)  (0.53) (0.53)  (0.44) (0.44)  (1.24) (1.24)  (1.2) (1.2)  (1.06) (1.06)  (0.88) (0.88)

[4807][4807]  [683.6] [683.6]  [1367] [1367]  [1323] [1323]  [1169] [1169]  [970] [970]  [2734] [2734]  [2646] [2646]  [2337] [2337]  [1940] [1940]

8 8 mmmm 3148031480  4 444110 0 88883300  8530 8530  7650 7650  6280 6280  17650 17650  17060 17060  15300 15300  12550 12550

(0.(0.32 32 in)in) (3.21 )(3.21 )  (0.45) (0.45)  (0.9) (0.9)  (0.87) (0.87)  (0.78) (0.78)  (0.64) (0.64)  (1.8) (1.8)  (1.74) (1.74)  (1.56] (1.56]  (1.28) (1.28)

[7078][7078]  [992.3] [992.3]  [1985] [1985]  [1918] [1918]  [1720] [1720]  [1411] [1411]  [3969] [3969]  [3937] [3937]  [3440] [3440]  [2322] [2322]

10 mm10 mm 4923049230  6960 6960  14020 14020  13440 13440  1 11177770 0 99881100  27460 27460  26480 26480  23540 23540  19610 19610

(0.(0.4 4 in)in) (5.02)(5.02)  (0.71 (0.71 ))  (1.43) (1.43)  (1.37) (1.37)  (1.2) (1.2)  (1.0) (1.0)  (2.8) (2.8)  (2.7) (2.7)  (2.4) (2.4)  (2.0) (2.0)

[11.69][11.69]  [1565.6] [1565.6]  [3153] [3153]  [3021] [3021]  [2646] [2646]  [2205] [2205]  [6174] [6174]  [5954] [5954]  [5292] [5292]  [4410] [4410]