Toyota 5fd23 forklift service repair manual

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1. FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 5FGIO- 30/5FD70-30 Series. Please use this manual for providing quick, correct servicing of…
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  • 1. FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 5FGIO- 30/5FD70-30 Series. Please use this manual for providing quick, correct servicing of the corresponding forklift models. These models on the market since August 7986 are subject to minor changes in September 7986. This manual deals with the models produced in the period between A ugust 7988 and August 7989 as well as the models as of September 7989 (after m~norchanges}. Any change or modifications thereafter will be informed by Toyota Industrial Vehicles' 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 manuals related to this manual are as follows: TOY0TA INDUSTRIAL VEHICLE 4P ENGINE REPAIR MANUAL (No. CE604) TOYOTA INDUSTRIAL VEHICLE 4Y ENGINE REPAIR MANUAL (No. CE602) TOYOTA INDUSTRIAL VEHICLE 2J ENGINE REPAIR MANUAL (No. CE603) TOYOTA INDUSTRIAL VEHICLE 7ZENGINE REPAIR MANUAL (No. CE60 7) TOYOTA INDUSTRIAL VEHICLE 5K ENGINE REPAIR MANUAL (No. CE67 7) TOYOTA INDUSTRIAL VEHICLE 7DZ ENGINE REPAIR MANUAL (No. CE6 18) (Note: 2-3 ton models mounted with 2J, IDZ diesel engine are only available in designated areas.) TOYOTA MOTOR CORPORATION
  • 2. GENERAL Page ..............................EXTERIOR VIEWS 0-2 VEHICLE LISTING .............................. 0-3 ABBREVIATIONS................................ 0-7 .............................OPERATIONAL TIPS 0-7 STANDARD BOLT & NUT TIGHTENING TORQUE ..................................... 0-8 HIGH PRESSURE HOSE FITTING ........................TIGHTENING TORQUE 0-10 FRAME NUMBER ............................... 0-11 WIRE ROPE SUSPENSION ANGLE LIST ............ 0-14 SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE .......................... 0-14 COMPONENT WEIGHT ........................... 0-15 RECOMMENDED LUBRICANT QUANTITY & TYPE ...................................... 0-17 LUBRICATION CHARTS .......................... 0-21 .......................PERIODIC MAINTENANCE 0-22 PERIODIC REPLACEMENT LUBRICANTS ..................................AND PARTS 0-29
  • 3. EXTERIOR VIEWS Front View (5FG15) LATI4-16 Rear View (5FG15) LAT14-18
  • 4. VEHICLE LISTING (1986.8-1989.8) Se- ries %.-L % C 0 + - V) Q, .-L % 0 + CU Payload 1.0 ton 1.35 ton 1.5 ton 1.75 ton 2.0ton Model 5FG10 02- 5FG10 40- 5FG10 42- 5FG10 5FD10 02 - 5FD10 5FG14 02- 5FG14 40- 5FG14 42- 5FG14 5FD14 02- 5FD14 5FG15 02- 5FG15 40- 5FG15 42- 5FG15 5FD15 02- 5FD15 5FG18 02- 5FG18 40- 5FG18 42- 5FG18 5FD18 02- 5FD18 5FG20 02- 5FG20 40- 5FG20 42- 5FG20 5FD20 02- 5FD20 60 - 5FD20 62 - 5FD20 Engine model 4 P ? 4 Y f 2 J f 4 P f 4 Y f 2 J t 4 P f 4 Y f 2 J t 4 P f 4 Y t 2 J f 4 P t 4 Y t 1 Z f 2 J f Engine tYPe Gasoline f f f D~esel T Gasoline f 7' t Diesel .f Gasoline t f t Diesel t Gasoline ? f f Diesel t Gasoline t t t Diesel t f f Drive system 11" clutch Torque converter 11" clutch Torque converter 11 " clutch Torque converter I1" clutch Torque converter 11 " clutch Torque converter 1 1" clutch Torque converter I 1" clutch Torque converter I 1" clutch Torque converter I I"clutch Torque converter 11" clutch Torque converter 1I" clutch Torque converter 11" clutch Torque converter 1 1" clutch Torque converter 11" clutch Torque converter 11" clutch Torque converter 11" clutch Torque converter Remarks P/S installed as standard f f t f t f f 7. f f t f t t f f f f f t t f f t I. t 7- f f t f
  • 5. VEHICLE LISTING (1989.9 - Ser~es 1 ton serles 2 ton series Engine model 5K 4Y 1DZ 5K 4Y 1DZ 5K 4Y 1DZ 5K 4Y 1DZ 5K 4Y 1z 1 DZ 5K 4Y Dr~vesystem Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Load capac~ty 1.0 ton 1.35 ton 1.5 ton 1.75 ton 2.0 ton 2.25 ton Model 5FG10 02-5FG10 40-5FG10 42-5FG10 5FD10 02-5FD10 5FG14 02-5FG14 40-5FG14 42-5FG14 5FD14 02-5FD14 5FG15 02-5FG15 40-5FG15 42-5FG15 5FD15 02-5FD15 5FG18 02-5FG18 40-5FG18 42-5FG18 5FD18 02-5FD18 5FG20 02-5FG20 40-5FG20 42-5FG20 5FD20 02-5FD20 60-5FD20 62-5FD20 5FG23 02-5FG23 40-5FG23 42-5FG23
  • 6. Series 2 ton series Load capacity 2.25 ton 2.5 ton Model 5FD23 02-5FD23 60-5FD23 62-5FD23 5FG25 02-5FG25 40-5FG25 42-5FG25 5FD25 02-5FD25 60-5FD25 62-5FD25 Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter 4Y 3 ton series Engine model 1z 1DZ 5K 4Y 1z 1DZ Drive system Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter 2.75 ton 3.0 ton 5FD28 02-5FD28 60-5FD28 62-5FD28 5FG30 02-5FG30 5FD30 02-5FD30 60-5FD30 62-5FD30 1Z 1DZ 4Y 1Z 1DZ
  • 7. ABBREVIATIONS Abbreviations used in this manual are as follows: OPERATIONAL TIPS 1. Safe operation ( 1 ) Make sure that correct size wire is used for hoisting a heavy material (2)After jacking up, always support with rigid racks or stands. Meaning Power Steering Right Hand Society of Automotive Engineers (USA) Special Service Tool Standard Sub-assembly Tightening Torque Number of Teeth (00) Undersize With Abbreviation (Code) ABDC ASSY ATDC ATM BBDC LH LLC MTM OHV 0PT 0/S PS 2. Preparation of SSTs and measuring tools ( 1 ) Prepare SSTs and measuring tools before starting operation. 3. Clearing and arrangement ( 1) Always keep the workshop neat and orderly for easy operation. (2)Disassembly of hydraulic equipment shall always be done in a clean place using clean tools. Meaning After Bottom Dead Center Assembly After Top Dead Center Automatic Transmission Before Bottom Dead Center Left Hand Long Life Coolant Manual Transmission Overhead valve Option Oversi~e Horsepower 4. Genuine Toyota parts Genuine Toyota parts should be used even in the replacement of packings, gaskets and O-rings. Abbreviation (Code) P/S RH SAE SST STD SUB-ASSY T = OOT U/S w/ 5. Repairs on electrical system Before doing any repairs on the electrical system, disconnect the cables from the battery terminals. Be sure to disconnect the negative @ cable first. 6. Tightening torque for irlstallation Be sure to observe the tightening torque given in this manual. If not specified, tighten to the torque ' listed in standard bolt & nut tightening torque. 7. Defect status grasp Do not start disassernbly and replacement as soon as a defect is found, but first grasp whether the defect requires disassembly and replacement. In the case of torque converter for example, do not attempt torque converter disassembly upon a failure in starting the vehicle, but first check such factors as the oil, pressure and rotation status causing the failure.
  • 8. STANDARD BOLT AND NUT TIGHTENING TORQUES 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 tighting torque of a standard unit. The nut tightening torque can be judged from the bolt type. (See the item above.) LIST OF BOLT TYPES AND STRENGTH 1 . Judging by part 1 Shape and class Hexagon head bolt @Bolt head No* Hexagon flange bolt No mark Hexagon head bolt Hexagon Three protruding head bolt Two protruding lines Hexagon flange bolt Welded bolt @ l;')protruding Class 2. Judging by part No. Hexagon head bolt Parts No, I91611-do625 Length (rnrn) Diameter ( m m ) Diameter Parts No. ~ e n ~ t h( r n m ) Diameter ( m m ) Diameter
  • 9. STANDARD BOLT TIGHTENING TORQUES
  • 10. PRECOAT BOLTS (Bolts with seal lock agent coating on threads) 1. Do not use the precoat bolt as itisineither of the following cases: (a) After it is removed. (b) When the precoat bolt is moved Cloos- ened or tightened) by tightness check, etc. Note: . For torque check, use the lower limit of the Precoat ~~l~~ allowable tightening torque range. If the bolt moves, retighten it accordicg to the steps below. 2. Method for reuse of precoat bolts (I)Wash ,the bolt and threaded hole. (The (2) Perfectly dry the washed parts by air threaded hole must be washed even for blowing. replacement of the bolt.) (3) Coat the specified seal lock agent to the threaded portion of the bolt. HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE 1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces with clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before installation. 2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting. 3. The maximum tightening torque must not exceed twice.the standard tightening torque. Nominal diameter of screw 7116 - 20'UNF 9/16 - 18UNF 314 - 16UNF 7/8 - 14UNF 11/16 - 12UNF 15/16 - 12UNF PF1/4 PF3/8 PF112 P F3/4 PF1 Hose inside diarneter (mrn) 6 9 12 12 19 25 9 9 12 19 25 Standard tightening torque kg-m (ft-lb) Standard 2.5 ( 18.1) 5.0 ( 36.2) 6.0 ( 43.4) 6.0 ( 43.4) 12.0 ( 86.8) 14.0 (101.2) 5.0 ( 36.2) 5.0 ( 36.2) 6.0 ( 43.4) 12.0 ( 86.8) 14.0 (101.2) Tightening range 2.4 - 2.6 (17.4 - 18.8) 4.8 - 5.3 (34.7 - 38.3) 5.7 - 6.3 (41.2- 45.5) 5.7 - 6.3 (41.2 - 45.5) 11.4- 12.6 (82.4- 91.1) 13.3 -14.7 (96.2 -- 106.3) 4.8 - 5.3 (34.7 -- 38.3) 4.8 - 5.3 (34.7 - 38.3) 5.7 -- 6.3 (41.2 - 45.5) 11.4-12.6 (82.4- 91.1) 13.3 -- 14.7 (96.2 -106.3)
  • 11. FRAME NUMBER (1986.8-- 1989.8) Punching position Vehicle series Engine model Vehicle model Punching format Vehicle series Eng~nemodel Vehicle model Punching format Top on rear right frame - 1 ton series 1 Z - - - - - - - - - - 4 P 5FG10 02- 5FG10 5FG14 02- 5FG14 5FG15 02- 5FG15 5FG18 02- 5FG18 5FG18 - 10001 4 Y 40- 5FG10 42- 5FG10 40- 5FG14 42- 5FG14 40- 5FG15 42- 5FG15 40- 5FG18 42- 5FG18 405FG18 - 10001 2 ton series 2 J 5FD10 02- 5FD10 5FD14 02 - 5FD14 5FD15 02 - 5FD15 5FD18 02- 5FD18 5FD18 - 10001 4 P 5FG20 02- 5FG20 5FG23 02 - 5FG23 5FG25 02 - 5FG25 5FG25 - I0001 1 Z 5FD20 02 - 5FD20 5FD23 02 - 5FD23 5FD25 02- 5FD25 5FD25 - 10001 4 Y 40- 5FG20 42- 5FG20 40- 5FG23 42- 5FG23 40- 5FG25 42- 5FG25 405FG25 - 10001 2 J 60 - 5FD20 62 - 5FD20 60 - 5FD23 62 - 5FD23 60 - 5FD25 62 - 5FD25 605FD25 - 10001
  • 12. Vehicle series Engine model Vehicle model Punching format 3.0 ton series 4 P - - - - - - 2 J 60- 5FD28 62- 5FD28 60- 5FD30 62- 5FD30 605FD30 - 10001 4 Y 5FG28 02- 5FG28 5FG30 02- 5FG30 5FG30 - 10001 1 Z 5FD28 02- 5FD28 5FD30 02- 5FD30 5FD30 - 10001
  • 13. FRAME NUMBER (1989.9- 1 5FG14 40-5FG14 5FD14 02-5FG14 42-5FG14 02-5FD14 Vehicle model 5FG15 40-5FG15 02-5FG15 42-5FG15 02-5FD1 5 5FG18 40-5FG18 02-5FG18 42-5FG18 02-5FD18 Punching format A5FG18-40011 405FG18-40011 A5FD18-40011 2 ton series 1DZ 60-5FD20 62-5FD20 60-5FD23 62-5FD23 60-5FD25 62-5FD25 A605FD25-40011 1Z 5FD20 02-5FD20 5FD23 02-5FD23 5FD25 02-5FD25 5FD25-40011 Engine model Vehicle model Punching format 3 ton series 5K 5FG20 02-5FG20 5FG23 02-5FG23 5FG25 02-5FG25 A5FG25-40011 4Y 40-5FG20 42-5FG20 40-5FG23 42-5FG23 40-5FG25 42-5FG25 405FG25-40011 1DZ 60-5FD28 62-5FD28 60-5FD30 62-5FD30 A605FD30-40011 A Engine model Vehicle model Punching format 4Y 5FG28 02-5FG28 5FG30 02-5FG30 5FG30-40011 1Z 5FD28 02-5FD28 5FD30 02-5FD30 5FD30-40011
  • 14. WlRE ROPE SUSPENSION ANGLE LIST SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE Unit: ton (lb) Lifting angle 0" 30" 60" Rope diameter 6 mm (0.24 in.) 8 mm (0.32 in.) 10 mm (0.4 in.) 12.5 mm (0.5 in.) 14 mm (0.56in.) Cutting load Tension 1.OO time 1.04 time 1.16 time Single-rope suspension Two-rope suspension Compres- 0 time 0.27 time 0.58 time Four-rope suspension Suspension method Lifting angle 90" 120" wF 2t * I. Tension 1.41 time 2.00 time 2t 2t Compres- sion 1.OO time 1.73 time Suspension method 2t 2t b
  • 15. COMPONENTS WEIGHT (1986.8-- 1989.8) unit: kg (Ib) Engine 4P 4Y 2J 1Z Transmission ASSY Torque Converter ASSY Differential & Front Axle (w/ Brake Counter Weight Mast 128 (282) 134 (295) 214 (471) 237 (523) 78 (172) AlSlN One speed 152 (335) AlSlN Twospeed 163 (359) 1 ton series 210 (463) 2 ton series 260 (573) 3 ton series 318 (701) 1.0 ton Approx. 430 (950) 1.35 ton Approx. 645 (1420) 1.5 ton Approx. 785 (1730) 1.75 ton Approx. 915 (2020) 2.0 ton Approx. 1110 (2670) 2.25 ton Approx.1225 (2700) 2.5 ton Approx. 1430 (31 50) 2.75 ton Approx.1670 (3680) 3.0 ton Approx. 1860 (4100) 1.O ton Approx. 400 (880) 2.0 ton Approx. 500 (1100) 3.0 ton Approx. 600 (1320)
  • 16. COMPONENTS WEIGHT (1989.9- unit: kg (Ib) 93 (205) 134 (295) 190 (419) 237 (523) 78 (172) 152 (335) 163 (359) 210 (463) 260 (573) 318 (701) Approx. 430 (950) Approx. 645 (1420) Approx. 785 (1730) Approx. 915 (2020) Approx. 1110 (2670) Approx. 1225 (2700) Approx. 1430 (3150) Approx. 1670 (3680) Approx. 1864 (4100) Approx. 400 (880) Approx. 500 (1100) Approx. 600 (1320) . . Engine 5K 4Y 1DZ 1Z Transmission ASSY Torque Converter ASSY Differential & Front Axle (w/ Brake) Balance Weight Mast AlSlN One speed Two speed 1 ton series 2 ton series 3 ton series 1.0 ton 1.35 ton 1.5 ton 1.75 ton 2.0 ton 2.25 ton 2.5 ton 2.75 ton 3.0 ton 1.0 ton 2.0 ton 3.0 ton
  • 17. RECOMMENDED LUBRICANT QUANTITY & TYPES (1986.8 -1989.8) Application 4 P 4 Y 2 J 1 Z MTM models AlSlN make 1 ton series 2 ton series 3 ton series 1 ton series 2 ton series 3 ton series 1 ton series All models Attached Table Description Classification API SD,SE,SF API CC,CD API GL-4 GL-5 ATF API GL-4 GL-5 ISO VG32 - LLC ?- Quantity 4.32 (1.14 USgal) 4.0 Q (1.06 US gal) 6.9 2 (1.82 US gal) 9.0 P (2.38 US gal) 4.0 2 (1.06 US gal) 14 11 (3.70 US gal) 5.8 Q (1.53 US gal) 6.8 Q (1.80 US gal) 9.0 Q (2.38 US gal) 27 2 (7.1 US gal) 34 2 (9.0 US gal) 37 11 (9.8 US gal) Proper quantity Reservoir Tank 0.2 Q (0.05 US gal) Proper quantity 1 Engine Type Motor oil SAE30 (SAE20 in cold area) SA E20W-40 (SAE 1OW-30 in cold area) Diesel engine oil SAE30 (SAE20 in cold area) SAE 1OW-30 Hypoid gear oil SAE85W-90 GM Dexrono II Hypoid gear oil SAE85W-90 Hydraulic oil #90 SAE J-1703 DOT-3 MP Grease "LLC 30-50% mix- ture (for winter or alI-season) a Coolant with rust- inhibitor (for spring, summer and autumn) ? Gasoline Diesel Transmission Torque converter Differential Hydraulic oil Brake (1.O-1.75 ton models) Chassis parts Coolant Coolant (Reservoir Tank) Coolant volume All models 1.1 Q (0.3 US gal) (at Full level)
  • 18. Attached Table 1 Coolant volume unit: f (US gal) Engine 4 P 4 Y 1 z 2 J Drive method MTM ATM MTM ATM MTM ATM MTM ATM 1.O - 1.75 ton vehicles 9.7 (2.56) 11.5 (3.03) 9.7 (2.56) 11.5 (3.03) - - 12.7 (3.35) 14.5 (3.70) 2.0 - 2.5 ton vehicles 9.9 (2.61) 11.2 (2.95) 9.9 (2.61) 11.2 (2.95) 9.3 (2.46) 8.6 (1-01 14.9 (3.93) 14.2 (3.75) 2.75,3.0 ton vehicles - - 12.2 (3.22) 11.8 (2.92) 9.6 (2.53) 9.2 (2.43) 15.2 (4.01) 14.8 (3.72)
  • 19. RECOMMENDED LUBRICANT QUANTITY & TYPES (1989.9 - 1 Quantity 4.0 Q (1.06US gal) 4.0 11 (1.06 US gal) 6.511 (1.7US gal) 9.0 Q (2.38 US gal) 4.0 Q (1.06 US gal) 14.0Q (3.70 US gal) 5.8 Q (1.53 US gal) 6.8 Q (1.80 US gal) 9.0 Q (2.38US gal) 27.0 Q (7.1 US gal) 34.0 Q (9.0 US gal) 37.0 R (9.8US gal) 45.0 Q (11.9 US gal) 65.0Q(17.2USgal) 70.0 Q (18.5 US gal) 45.0 Q (11.9 US gal) 65.0 Q (17.2 US gal) 70.0 R (18.5 US gal) Proper quantity Reservoir Tank 0.2 R (0.05US gal) Proper quantity 1 Application 5K 4Y 1DZ 1z MTM r~odels AlSlN make 1 ton series 2 ton series 3 ton series 1 ton series 2 ton series 3 ton series 1 ton series Description Coolant (ReservoirTank) Classification API SD,SE,SF API CC, CD API GL-4 GL-5 ATF API GL-4 GL-5 IS0 ' VG32 Engine 2tonseries 3 ton series Fuel tank 1 ton series 2 ton series 3 ton series Brake 1 ton series (1.O-1.75 ton models) TYpe Motor oil SAE30 (SAE20 in cold area) SAE20W-40 (SAE1OW-30 in cold area) Diesel engine oil SAE30 (SAE20in cold area) SAE1OW-30 Hypoid gear oil SAE85W-90 GM Dexron@I1 Hypoid gear oil SAE85W-90 Hydraulic oil #90 Gasoline , Diesel Chassis parts Coolant t Transmission Torque converter Differential Hydraulic oil LLC (for winter or alI-season) Coolant with rust- inhibitor (for spring, summer and autumn) t MP grease 0" LLC 30-50% mixture Coolant volume All models Attached Table All models 1.1 Q (0.3 US gal) (at Full level)
  • 20. Attached Table 1 Coolant volume unit: 2 (US gal) Engine 5K 4Y 2.0 - 2.5 ton vehicles 1z 1DZ Drive method / MTM ATM MTM ATM 2.75, 3.0 ton vehicles 1.0 - 1.75 ton vehicles 5.5 (1.45) 7.3 (1.93) 7.5 (1.98) 9.3 (2.46) MTM ATM MTM ATM 5.7 (1.50) 7.0 (1.85) 7.7 (2.03) 9.0 (2.38) 10.0 (2.64) 9.6 (2.53) 9.7 (2.56) 9.3 (2.46) 8.3 (2.19) 7.9 (2.09) 9.4 (2.48) 8.7 (2.30) 5.8 (1.53) 7.6 (2.01) 8.0 (2.19) 7.3 (1.93)
  • 21. LUBRICATION CHARTS 2 1 Chain 2 Differential 3 Front wheel bearing 4 Brake master cylinder (1.O-1.75 ton models) I 5 Transmission case 3 6 Rear wheel bearing 7 Steering knuckle kingpin 8 Bell crank pin 16 9 Oil tank 15 10 Engine crank case 11 Rear axle beam front 4 12 Rearaxlebeam rear 13 Tilt steeringuniversal joint 13 14 Tilt steeringliocking meachanism 15 Mast support bushing 5 16 Tilt cylinder front pin 11 17 Propeller shaft I lnspectevery8hours(daily) 7 I1 Inspect every 40 hours (weekly) I11 Inspect every 170 hours (monthly) 6 IV lnspect every 1000 hours (6 month1y) V lnspectevery2000hours(annually) o lnspect and service Replace 1 MP grease 2 Engine oil 3 Hypoid gear oil 4 Hydraulic oil 5 Gear oil 6 Brake fluid (1.O-1.75 ton models) Clutch Model Lubrication Chart LAOM136 Chain Differential Front wheel bearing Brake master cylinder (1.O-1.75 ton models) Torque converter case Rear wheel bearing Steering knuckle king pin Bell crank pin Oil tank Engine crank case Rear axle beam front Rear axle beam rear Tilt steering universal joint Tilt steering liocking meachanism Mast support bushing Tilt cylinder front pin Propeller shaft lnspect every 8 hours (daily1 lnspect every 40 hours (weekly) lnspect every 170 hours (monthly) lnspect every 1000 hours (6 monthly) lnspect every 2000 hours (annually) Inspect and service Replace MP grease Engine oil Hypoid gear oil Hydraulic oil Automatic transmission fluid Brake fluid (1.O-1.75 ton models) Torque Converter Model Lubrication Chart
  • 22. PERIODIC MAINTENANCE INSPECTION METHOD I : Inspection. Repair or replacement if required. M : Measurement. Repair or adjustment if required. T : Retightening C : Cleaning L : Lubrication * : For new vehicle "1 : Soapy water " 2 : Detector "3: Flaw detector Inspection Period ltem Months Hours 1 170 ENGINE Main body PCV system Governor Lubrication system Fuel system Cooling system Proper starting and abnormal noise Rotating condition at id1ing Rotating condition during acceleration Exhaust gas condition Air cleaner element Valve clearance Compression Cylinder head bolt loosening Muffler rubber mount Clogging and damage in PCV valve and piping No-load maximum rpm Oil leak Oil level Clogging and dirt of oil filter Fuel leak Operation of carburetor link mechanism Dirt and clogging of fuel filter and element Injection timing lnjection nozzle injection pressure and spray status Draining of sedimenter Coolant level in radiator and leak Rubber hose degradation Radiator cap condition Fan belt tension, looseness and damage Radiator rubber mount 3 500 I M M I C M M T I I M I I I I I I M M I I I I I I 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0" 0" 6 1000 12 2000 0 0 0 0 0 0 0 0 0 0
  • 23. - Inspection Period ltem Months Hours POWER Clutch Transmis
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