6.13
INSPECTION AND ADJUSTMENT
6.13.1
OIL PRESSURE MEASUREMENT
(1)
Check transmission oil level.
(a)
Check oil level using a level gauge.
(b)
Run the engine at idling speed, then stop the engine.
(c)
Wait for 1 minute or more after the engine stops, and check the oil level.
(d)
The oil level checking must be completed within 3 minutes after the engine stopped.
(2)
Engine warm-up
(a)
Warm up the engine, and raise the temperature of the transmission oil between the range of 35 to 45°C (95 to 113°F).
(3)
Engine speed measurement
(a)
After the engine is warmed up, measure the idling speed and maximum no-load speed according to the engine service manual. Make the necessary adjustments if either or both of the speeds do not meet the specifications.
(4)
Preparation for oil pressure measurement
(a)
Stop the engine after checking and adjusting the engine speeds.
(b)
Raise the front wheels off the ground either by jacking up the front axle housing or tilting the mast forward after placing wood blocks under the outer mast.
(c)
Block the rear wheels.
NOTE:
The front wheels spin during the clutch pressure measurement. Stay away from the front wheels and be careful not to get caught in the spinning wheels.
(d)
Connect oil pressure gauges to each of the oil pressure taps shown in the illustration on the right.
a.
Main pressure (M)
b.
Clutch pressure (D) Directional clutch pressure (F1) Forward 1st gear clutch pressure (F2) Forward 2nd gear clutch pressure (R) Reverse clutch pressure
c.
Torque converter inlet pressure
d.
Lubrication oil pressure
NOTE:
When loosening the plugs a through d, tap the plugs on the head once or twice to loosen them.
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(e)
Use the following tools for oil pressure measurement.
Oil pressure measurement tools
Special tool/part number
Remark
a: Main pressure
b: Clutch pressure
c: Torque converter inlet pressure
d: Lubrication oil pressure
Connector 65628-00400
G1/8, Rc 1/8
?
?
-
-
Connector (plug) 91K67-00500
Rc 1/8, M16×1.5
-
-
?
-
Connector (eye bolt) 91868-01600
Rc 1/8, M16×1.5
-
-
-
?
*Gauge 64309-17714 or 64309-17713
0.6 MPa 2 MPa
-
-
?
?
*Gauge 64309-17713
2 MPa
?
?
-
-
*Connector 64309-17733
R(PT)1/8 thread
?
?
?
?
*Hose 64309-17722
?
?
?
?
*Connector 64309-17731
For gauge connection
?
?
?
?
NOTE:
The tool marked by * is included in the 64309-17701 gauge kit.
(5)
Oil Pressure Measurement
(a)
Start the engine and place the direction lever into the neutral position, and then measure the main oil pressure, the torque converter inlet oil pressure, and the lubrication oil pressure.
(b)
Place the direction lever into the forward position, and measure the clutch oil pressure. Repeat the procedure with the lever shifted in reverse position.
NOTE:
Oil temperature measurement should be within the range of 35 to 45°C (95 to 113°F).
Unit: MPa (kgf/cm2) [psi]
Pressure for measurement1600 ± 25 min-1(rpm) Forward 1st gear 1.15 ± 0.05 (11.73 ± 0.51) [166.81 ± 7.25] Forward
Engine speed
Oil pressure
a
Main pressure
700 ± 25 min-1(rpm)
Neutral
1.08 ± 0.03 (11.01 ± 0.30) [156.66 ± 4.35]
1600 ± 25 min-1(rpm)
1.14 ± 0.02 (11.62 ± 0.20) [165.36 ± 2.90]
2450 ± 25 min-1(rpm)
1.18 ± 0.02 (12.03 ± 0.20) [171.16 ± 2.90]
b
Clutch pressure
700 ± 25 min-1(rpm)
Forward 1st gear
1.05 ± 0.05 (10.71 ± 0.51) [152.30 ± 7.25]
Forward 2nd gear
1.05 ± 0.05 (10.71 ± 0.51) [152.30 ± 7.25]
Reverse
1.05 ± 0.05 (10.71 ± 0.51) [152.30 ± 7.25]
1600 ± 25 min-1(rpm)
Forward 1st gear
1.15 ± 0.05 (11.73 ± 0.51) [166.81 ± 7.25]
Forward 2nd gear
1.15 ± 0.05 (11.73 ± 0.51) [166.81 ± 7.25]
Reverse
1.15 ± 0.05 (11.73 ± 0.51) [166.81 ± 7.25]
2450 ± 25 min-1(rpm)
Forward 1st gear
1.23 ± 0.05 (12.54 ± 0.51) [178.41 ± 7.25]
Forward 2nd gear
1.23 ± 0.05 (12.54 ± 0.51) [178.41 ± 7.25]
Reverse
1.23 ± 0.05 (12.54 ± 0.51) [178.41 ± 7.25]
c
Torque converter inlet pressure
600 ± 50 min-1(rpm)
Neutral
0.12 ± 0.02 (1.22 ± 0.20) [17.41 ± 2.90]
1600 ± 100 min-1(rpm)
0.40 ± 0.02 (4.08 ± 0.20) [58.02 ± 2.90]
2450 ± 25 min-1(rpm)
0.54 ± 0.02 (5.51 ± 0.20) [78.33 ± 2.90]
d
Lubrication oil pressure
600 ± 50 min-1(rpm)
Neutral
0.02 ± 0.01 (0.20 ± 0.10) [2.90 ± 1.45]
1600 ± 100 min-1(rpm)
0.03 ± 0.01 (0.30 ± 0.10) [4.35 ± 1.45]
2450 ± 25 min-1(rpm)
0.04 ± 0.01 (0.41 ± 0.10) [5.80 ± 1.45]
6.13.2
BRAKE INCHING PEDAL ADJUSTMENT
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1
BRAKE PEDAL
2
INCHING PEDAL
3
INCHING PEDAL STOPPER
4
STOP LAMP SWITCH
5
INCHING STOPPER BOLT
6
INCHING CABLE
7
BRAKE STOPPER
The clutch (inching) mechanism is linked to the brake pedal. Pressing the inching pedal cuts the pressure acting on the transmission before the brakes take effect, bringing the transmission to a neutral condition.
A faulty inching pedal adjustment may create such problems as failure in clutch disengagement and partial clutch engagement. This in turn may cause an abnormal increase in the transmission oil temperature, as well as braking malfunctions and clutch plate seizures. Be sure to make all the following adjustments carefully so that these problems can be avoided.
(1)
Brake pedal adjustment
(a)
Measure height A between the floor plate top surface and the brake pedal top surface, and adjust the height to the following standard value by turning the stopper bolt 1 and then lock it with the lock nut.
Unit: mm (in.)
Brake pedal height A
187.6 to 191.6 (7.386 to 7.543)
(b)
Adjust the clearance to 1.0 mm (0.04 in.), between the push rod and piston of the brake valve 2. To do this, turn the push rod clockwise until it contacts the piston, then turn it back counterclockwise for approx. 0.8 turns, and finally secure the clevis with nut. After this adjustment, check the brake pedal play.
Unit: mm (in.)
Brake pedal free play
Approx. 5 (0.2)
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(2)
Inching pedal adjustment
(a)
Measure height A between the floor plate top surface and the inching pedal top surface, and adjust the height to the following standard value by turning the stopper bolt 3 and then lock it with the locknut.
Unit: mm (in.)
Inching pedal height A
187.6 to 191.6 (7.386 to 7.543)