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Toyota sdk10 skid steer loader service repair manual
- 1. FOREWORD This repair manual covers the inspection, adjustment and repair procedures for the overhaul of the engine, chassis and materials handling system of the TOYOTA SKID STEER LOADER SDKI0. Youare encouraged to become thoroughly familiar with this manual so as to make the most of the outstanding performance and durability features of these loaders and toperform theproper servicing to maintain them in tip-toprunning condition. This repair manual contains the latest information available as of March, 1989. For any changes thereafter, you are asked to consult the Parts & Service News. Toyotareserves the right to make changes in specifications without incurring any obligation and without previous notice. For your reference, we herewith indicate the titles of relevant manuals. TOY0TA 1Z ENGINE REPAIR MANUAL (No. CE6O1) TOYOTA MOTOR CORPORATION
- 2. SECTION INDEX GENERAL ENGINE HYDROSTATICTRANSMISSION FINAL REDUCTION GEAR STEERING AXLE BRAKES BODY FRAME LIFTARMS & BUCKET BRACKET CYLINDERS OIL PUMP OIL CONTROL VALVE HYDRAULIC SYSTEM APPENDIX
- 3. GENERAL Page VEHICLE EXTERIOR VIEWS ....................... 0-2 VEHICLE MODELS ................................ 0-3 ABBREVIATION .................................. 0-3 OPERATIONAL TIPS .............................. 0-4 STANDARD BOLT & NUT TIGHTENING TORQUE ... 0-5 PRECOATED BOLTS .............................. 0-7 HIGH-PRESSURE HOSE FllTlNG TIGHTENING TORQUE .......................... 0-7 WIRE ROPE SUSPENSION ANGLE LIST ............ 0-8 SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE ........................... 0-8 COMPONENTS WEIGHT .......................... 0-9 FRAME SERIAL NUMBER ......................... 0-9 .... RECOMMENDED LUBRICANTS & CAPACITIES 0-10 LUBRICATION .................................... 0-11 PERIODIC REPLACEMENT PARTS AND LUBRICANTS ............................. 0-12 PERIODIC MAINTENANCE ........................ 0-13
- 4. VEHICLE EXTERIOR VIEWS Front View SAG5-32 Rear View -6-
- 5. VEHICLE MODELS ABBREVIATION Model SDKIO Abbreviation (Code) 1 Measuring ABDC Engine TOYOTA 1Z 1 After bottom dead center ASSY I Assembly Operating Load 820 kg (1,808 Ib) ATDC I After top dead center Bucket Capacity 0 35 m3 (1 2.5 ft3) CCA I Cold cranking amperes Mach~ne Weight 3,030 kg (6,681 Ib) BBDC BTDC HST Before bottom dead center Before top dead center Hydrostatic transmission LH 1 Left hand OHV I Over head valve PR 1 Ply rating 0PT OR Opt~on Off road SST I Special service tool RH SAE Right hand Society of Automotive Engineers (USA) T = 1 Tightening torque STD SUB-ASSY OOT 1 Number of teeth (00) Standard Sub-assembly
- 6. OPERATIONAL TIPS Safe operations (1) Carry out inspections and serv~cing wlth the rear arm lowered and the bucket on the ground. If the inspections and servicing must be performed with the rear arm In the air, use the safety block or safety pillar to prevent the arm from lowering. (2) Always use rigld racks or stands when jacking up the vehicle. (3) When lifting wlth a wire rope, make sure the rope is sufficiently strong. Preparation of SSTs and measuring tools ( 1 ) Prepare SSTs and measuring tools before starting operatlon Clearlng and arrangement (1) Always keep the workshop neat and orderly for easy operatlon (2) Dlsassembly of hydraulic equipment shall always be done In a clean place using clean tools Genulne Toyota parts Genulne Toyota parts should be used even in the replacement of packlngs, gaskets and 0-rlngs Repairs on electrical system Before dolng any repalrs on the electrical system, disconnect the cables from the battery terminals. Be sure to disconnect the negatlve - cable flrst Tightening torque for installation Be sure to observe the tightening torque given in this manual. If not speclfled, tighten to the torque hsted in Standard bolt & nut tightening torque. Defect status grasp Do not start dlsassembly and replacement as soon as a defect IS found, but flrst grasp whether the defect requlres dlsassembly and replacement For example, wlth the HST, the pump should not be lmmedlately turn down simply because there IS trouble wlth the travel system Troubleshoot the cause In the steering levers, the flnal reduction gear, the change 011 pressure, the hydraulic 011 and so on
- 7. STANDARD BOLT & NUT TIGHTENING TORQUE Tlghten~ng torques for standard bolts and nuts are not expl~cltly ~ n d ~ c a t e d In t h ~ s manual They are pre-determined. To get the tighting torque, follow thls procedure: 1. F ~ n d out the type of the bolt from the hst below. Then, flnd the bolt tlghtenlng torque from the table. 2. The nut t~ghtenlng torque can be judged from the bolt type. (See the table.) LIST OF BOLT TYPES AND STRENGTH 1. Judging by part 2 Judglng by part No. I Shape and descr~pt~on 7 Hexagon bolt I Sample number 91 11 1 - 4 0 6 2 0 Number on the head Hexagon bolt TTT 0I 1I I Length (mm) Diameter (mm) Standard (bottom surface No mark bolt No mark INominal diameter Two protrudlng lines on the heac Length to bottom surface of head Collared bottom I I Stud bolt / Two protrud~ng lhnes on the heac Sample number Hexagon Three protrudlnc lhnes on the heac 1~ a r n e t e r (mm) No mark Approx. 2 mm (0.08in.) hollow either or both en Nominal diameter C-------i Length
- 8. STANDARD BOLTTIGHTENING TORQUE Pitch mm Standard tightening torque kg-cm (ft-lb) Standard seat W Seat with flange
- 9. PRECOATED BOLTS 1 (BOLTS WITH SEAL LOCI< AGENT COATING ON THREADS) 1. Do not use the precoated bolt in either of the f o l l o w ~ n gcases w ~ t h o u tany spec~al treatment described below: (a) After it is removed. (b) When the precoated bolt is moved (loosened or tightened) for tightness check, etc Precoated Bolts KAKS25 Note: For torque check, use the lower limit of the allowable tightening torque range. If the bolt moves, retighten it according to the steps below. 2. Method for reuse of precoated bolts (2) Perfectly dry the washed parts by a ~ r (1) Wash the bolt and threaded hole. blow~ng. (The threaded hole must be washed (3) Apply the spec~fiedseal lock agent even for replacement of the bolt.) to the threaded portion of the bolt. HIGH-PRESSURE HOSE FllTlNG TIGHTENING TORQUE 1 . When connecting a high-pressure hose, wipe the hose fitt~ngand mating n~pple contact surfaces wlth a clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before installat~on. 2. When connecting a h~gh-pressure hose, hold the hose to align the fitt~ng with the nipple and t~ghten the f~tting. 3. The maximum t~ghten~ng torque must not exce'ed twlce the standard tightening torque Nominal dlameter of screw -& -20UNF ' -18UNF $ 1 6 U N F % -14UNF 'ik - 12UNF 1 6 - 12UNF Standard tightening torque kg-m (ft-lb) Standard 1 Torgue range Hose inside d~ameter (mm)
- 10. WlRE ROPE SUSPENSION ANGLE LIST L ~ f t ~ n g angle Suspension method L ~ f t ~ n g angle 90° Suspension method 1.41 time 1.oo time 1 04 tlme 2.00 tlme 1 73 tlme 1 1 6 time 0.58 tlme SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE U n ~ tton (Ib) Rope d~ameter 6 mm (0 24 ~n) 8mm (0 32 In ) 1 0mm (0 4 In ) 1 2 5 m m (0 5 In ) I 4mm (0 56 ~n) S~ngle-rope suspenslon Two-rope suspension Four-ro~e suspenslon Cutt~ng load
- 11. COMPONENTS WEIGHT 1 Item I Welght kg (Ib) I I Bucket 1 Approx. 160 kg (352.9) I HST Pump HST Motor Drive Unrt 1 011 Control Valve I Approx. (2-Way) 10 kg ( 22.1) I Approx. 56 kg ( 123.5) Approx. 1 2 kg ( 26.5) Approx. 60 kg (1 32.3) FRAME SERIAL NUMBER Frame Serial Number Location r Frame Numbering System Frame Serial Number Location SAGS36 Vehlcle SDKIO Serial Number SDKIO- 1001 1
- 12. ENGINE ASSY REMOVAL 1 Remove the englne hood ( I ) Set bolts ( 4 pcs ) (2) Engine hood Removingthe Engine Hood SAG8-3 2. Disconnect the battery earth cable. (1) Open the rear grille. (2) Dlsconnect the battery earth cable. 3 Drain the coolant ( 1 ) Prepare a coolant receiving con- tainer (2) Loosen the radlator drain cock Disconnectingthe Battery Earth Cable SAG8-4 4 Remove the radiator ( 1 ) Dlsconnect the inlet hose (on the engine side) (2) Dlsconnect the outlet hose (on the engine slde) (3) Dlsconnect the reservoir tank hose on the tank slde (4) Set bolts ( 4 pcs ) Removingthe Radiator SAG8-8, 12 5. Remove the fan shroud. (1) Set bolts (2 pcs.) (2) Fan shroud Removing the Fan Shroud SAG8-13, 14
- 13. 6. Remove the air cleaner. ( 1 ) Disconnect the alr cleaner hose (on the engine side). (2) Disconnect the wiring to the vacuum sensor. (3) Set bolts (2 pcs.) (4) Air cleaner with hose Removing the Air Cleaner SAG8-19 7 Remove the muffler and exhaust pipe (1) Exhaust pipe set nuts (3 pcs ) (2) Muffler clamp set bolt (2 pcs ) (3) Spacer and cushlon (4) Muffler and exhaust plpe with muf- fler clamp Removingthe Muffler & Exhaust Pipe SAG8-22 8. Disconnect the head tank to fuel tank hose (onthe fuel tank srde). 9. Disconnect the wirlngs. ( 1) Wiring to starting motor (2) Wiring to englne oil pressure switch (3) Wiring to alternator (4) Wiring to thermostat plug Disconnectingthe Wiring (Alternator) SAG8-23 10 Disconnect the accelerator wire. (1) Cotter pin and plate washer (2) Pin (3) Remove the accelerator wire from the clamp. Disconnectingthe Accelerator Wire SAG8-26
- 14. 11. D r a ~ n the hydraul~c 011. (1) Prepare a hydraulic 011 recelvlng con- tainer (2) Dra~n plug Draining the Hydraulic Oil SAG8-27 12. Disconnect the oil pump plplng (1) Low-pressure hose O HST outlet hose side O HST Inlet hose side @ Hydraul~c 011 tank s ~ d e (2) Oil pump piping O Set bolts ( 4 pcs.) Caution: Fit nylon cap or other covers to the hose, pipe and oil pump ports to prevent entr- ance of foreign matters. Disconnectingthe Oil Pump Piping SAG8-30 13. Remove the engine 011dra~nfrom the frame. (1) Set bolts (2 pcs.) (2) Eng~ne oil d r a ~ n 14. Remove the operator guard (1) Ducts LH and RH O Set screws (6 pcs.) O Ducts LH and RH Removingthe Ducts LH and RH SAG9-6 (2) D~sconnect the wlrlngs O M a ~ n harness O W ~ r ~ n g to horn @ W ~ r ~ n g to pedal lock solenold @ Earth cable (3) Set bolts (4pcs ) (4) Operator guard Removingthe Operator Guard SAG9-13
- 15. 15. Remove the dr~ver's seat. (1) Set bolts (6 pcs.) (2) Disconnect the w~ring (3) Driver's seat Removingthe Drivers Seat SAGS-17 16. Remove the backup lamp sw~tch. ( 1) Backup lamp switch LH O Disconnect the wir~ng. (2 pcs.). @ Backup lamp switch LH (2) Backup lamp switch RH Disconnect the wiring. (2 pcs.). @ Backup lamp switch RH 17. Remove the steering l~nk (1) Steering l~nk LH O Set nuts (2 pcs.) @ Steer~ng link LH (2) Steering link RH O Set nuts (2 pcs.) @ Steering link RH 18. Disconnect the HST frlter plplng Caution: Fit nylon caps or other covers to hoses and elbows to prevent entrance of foreign matters. (1) H~gh-pressure hose (3 pcs.) Removing the Backup Lamp Switch SAG9-18, 19 Removing the Steering Link SAG9-20,21 Disconnectingthe HST Filter Piping SAG9-32 28 -
- 16. 19. D~sconnect the HST plplng. Caution: Fit nylon caps or other covers to hoses and elbows to prevent entrance of foreign matters. (1) High-pressure hose (4 pcs.) Disconnectingthe High-pressure Hose SAG9-23.25 (2) Low-pressure hose (2 pcs.) 20. Disconnect the body earth cable 21. Remove the lift cylinder plplng ( 1) Lift cylinder piping Disconnecting the Low-Pressure Hose SAG9-33 Disconnectingthe Body Earth Cable SAG9-26 Removing the Lift Cylinder Piping SAG9-34.37
- 17. - -- - - 22 Drsconnect the fuel hose (on the engine srde) Disconnectingthe Fuel Hose SAG9-30 23. Disconnect the brake wrre bracket LH. (1) Brake wire Cotter pin @ Plate and pin (2) Brake wire bracket O Set bolts (2 pcs.) @ Brake wlre bracket Disconnectingthe Brake Wire Braket LH SAG9-31, 32 24. Drsconnect the battery earth cable. (1 ) Disconnect the battery earth cable Disconnecting the Battery Earth Cable SAG9-28 25 Drsconnect the fusrble lrnk connector - 30 Disconnectingthe Fusible Link Connector SAG9-29 -
- 18. 26 Remove the engine with HST pump. (1) Mounting set nuts (4 pcs.) (2) Remove the englne with HST pump accord~ng to the procedure describ- ed below. Prepare two 1.5 m (59 in.)wires and connect them to the front of the HST pump: The one wire to the front of the HST pump and set the other wire as shown so that the wire length can be adjusted. (See the figure at right.) Move the part A (in the figure above) upward to length- en the wire and downward to shorten it. O Set the chain hook on one side of the englne sling device (SST 09090-04000) to the rear side engine hanger. Set the other chain hook to the c h a ~ n fitted to the engine hanger. Removing the Mounting Set Nuts SAG9-39 Setting the Wires and Engine SAGM33 Sling Device (SST) O Adjust the wlre and chain lengths so that the hoist hook comes right above the frame member [Wire length adjustment] Move the part A (In the figure above) upward to lengthen the wire and downward to shorten it [Chain length adjustment] Turn the engine sl~ng devlce lever for length adjustment Hoisting the Engine SAG10-21
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- 20. Move the englne w ~ t h HST pump to the rear, and stop the move- ment where the wlre comes into contact w ~ t h the frame member Set the free c h a ~ nhook of the englne sling dev~ce (SST09090- 04000) to the front side engine hanger Operate the engine sling dev~ce (SST) lever to bung the HST pump up and loosen the wire tension Disconnect the wire at the hoist s ~ d eshackle, and suspend the engine wrth HST pump only with the engine sling device (SST). Operate the lever on the engine sl~ngdevice (SST) to bring up the HST pump side and loosen the wire tension. Remove the engine with HST Pump. Setting the Chain Hook to SAG10-24 Frnnt Fnnina Hannnr Operating the Engine Sling Device Lever SAG10-23 27. Remove the oil pump Removing the Oil Pump SAG10-25 28. Remove the englne with HST pump Removing the Engine with HST Pump SAG10-18
- 21. 29. Place the engine w ~ t hHST pump In stable state. 30. Separate the HST pump from the englne. (1) Slightly suspend the HST pump with a wire rope. (2) HST pump set bolts (4 pcs.) (3) HST pump Separatingthe HST Pump from the Engine SAG10-4 3 1. Remove the HST pump support (1) Set bolts (6 pcs ) (2) HST pump support 32. Remove the starter. (1) Set bolts (2 pcs.) (2) Starter 33. Remove the damper. (1) Set bolts (6 pcs.) (2) Damper Removingthe HST Pump Support SAG10-7.9 Removingthe Starter SAG10-12 Removingthe Damper SAG10-14, 15
- 22. 34. Remove the flywheel. ( 1) Set bolts (6 pcs.) (2) Flywheel Removingthe Flywheel SAG10-I6 INSTALLATION The installation procedure 1 s the reverse of the removal procedure Cautions: 0Apply molybdenum-disulfide grease to the spline portions of the HST pump and damper before installing the HST pump to the engine. 0 Connect the battery earth cable after checking correctness of all electrical wiring connections. Bleed air from the fuel system. See "Air Bleeding from Fuel System" on the next page for the air bleeding procedure. 0Always inspect the hydraulic oil, coolant, and engine oil before starting the engine, and add to the specified level if insufficient. 0When starting the engine, set the steering control lever at the neutral position and warm up the engine and HST pump at the idling speed. 0 Start the engine (at a low speed) and check if steering control lever neutral adjustment is proper. If not, adjust the spring holder according to the procedure in the "STEERING-Steering Neutral Adjustment" section (on page 4-9). 0 Bleed air from the hydraulic circuit according to the procedure in the "HYDRAULIC SYSTEM-BleedingAir from Hydraulic Circuit" section (on page 12-4).