Toyota 2SDK7 Skid Steer Loader Workshop Service Manual

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 2SGK6,2SDK6,2SDK7and 2SDK8. You are 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 to perform the proper servicing to maintain them in tip-top running condition. This repair manual contains the latest information available as of March, 1986. For any changes thereafter, you are asked to consult the Parts & Service News. Toyota reserves 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. TOYOTA 4P ENGINE REPAIR MANUAL (No. 95721) TOYOTA2J,2J-TENGINEREPAIRMANUAL (N0.95727) TOYOTA 3T84H ENGINE REPAIR MANUAL (No. 95731) TOYOTA MOTOR CORPORATION

SECTION INDEX I GENERAL ENGINE ' HYDROSTATIC TRANSMISSION FINAL REDUCTION GEAR 1 A AXLE I BRAKES L -- I BODY FRAME 1 LIFT ARMS & BUCKET BRACKET m 0 0 CYLINDERS I OIL PUMP I OIL CONTROL VALVE 1 1-

GENERAL Page ..................... VEHICLE EXTERIOR VIEWS 0-2 .............................. VEHICLE MODELS 0-3 ................................. ABBREVIATION 0-3 TIPS ON OPERATION ........................... 04 RIGHT ORDER OF OPERATION .................. 04 STANDARD BOLT & NUT TIGHTENING TORQUE . . 0-5 STANDARD HIGH-PRESSURE HOSE FITTING ........................ TIGHTENING TORQUE 0-7 ........................ FRAME SERIAL NUMBER 0-7 VEHICLE DIMENSIONS .......................... 0-8 ...................... GENERAL SPEC1 FlCATlONS 0-12 RECOMMENDED LUBRICANTS & CAPACITIES ...... 0-14 ....................... PERIODIC MAINTENANCE 0-15 .................................. LUBRICATION 0-20

VEHICLE EXTERIOR VIEWS Front View SAE45-4 Rear View -6-

VEHICLE MODELS I Model I Engine 1 Operating Load 1 Bucket Capacity I Machine Weight I 2SGK6 / TOYOTA 4P 1 460 kg (1000 bs) 1 0.28 m3 (10.0 it3) 1 2100 kg (4630 bs) I I 2SDK6 1 YANMAR 3T84H / 460 kg (1000 bs) 1 0.28 m3 (10.0 it3) 2100 kg (4630 lbs) I I 2SDK7 / TOYOTA 2J 1 520 kg (1150 bs) 1 031 m3 (1 1.0 ft3) / 2200 kg (4850 lbs) I 2SDK8 TOYOTA 2J 600 kg (1320 lbs) 0.34 m3 (1 2.0 ft3) 2490 kg (5490 Ibs)

TIPS ON OPERATION Safe operations (1) Carry out inspections and servicing with the lift arm lowered and the bucket on the ground. If such work must be performed with the lift arm in the air, support it with the lift arm lock pin, or use the safety block or safety pillar to prevent the arm from lowering. (2) Always use rigid racks or stands when jecking up the vehicle. (3) When lifting with a wire rope, make sure the rope is suffic~ently strong. SST & measuring tools Have the mechanic tools, SST and measuring tools on hand Order & arrangement (1 ) Always arrange things in an orderly manner for easy operations. (2) Disassembly of the hydraulics should be done with clean tools in a clean area Troubleshooting Do not immediately disassemble when trouble occurs; first determine whether or not dlsassembly is necessary. For example, wlth the HST, the pump should not be immediately turn down srmply because there is trouble with the travel system. Troubleshoot the cause in the steerlng levers, the final reduction gear, the change oil pressure, the hydraulic oil and so on. RIGHT ORDER OF OPERATION Disassembly Mark or punch matlng marks in a feasible location so as to facilitate dlsassembly of a complex unit. Also, if you are reparing electricals, be sure to disconnect the cables from the battery terminals. Always start with (-) terminal without fail when disconnecting cables from the battery term~nals. Inspections during disassembly In removing each and eavry part, check for the installed condition, deformation, breakage, roughness or damage. Assembly and installation (1) Always adhere to the tightening torques listed. If none are given, follow the "Standard Tighten- ing Torques." (2) When reassembling after disassembly, use Toyota Genuine Parts to replace packlngs, gaskets and O-rings. (3) Apply a seal pack~ng in terms of the gasket position, and coat the sliding surfaces at the specified locations with the recommended oil; apply the recommended grease and also coat oil seal lips with MP grease, when assembling.

STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and nut tightening torques are not indicated; therefore tightening torque must be judged as below. 1. Find out the type of the bolt from the list below. Then, find the bolt tightening torque frorn the table 2. The nut tightening torque can be judged from the bolt type. (See the table.) List of Bolt Types and Strength 1. Judging by part I 2. Judg~ng by part No. k - - , - BAHS2 Shape and description lexagon bolt 1 Sample number @, ; re : ber in relief or hallmark on the I 91 111-40610 Length (mm): A Hexagon bolt Standard bottom surface Hexagon bolt (Collared bottom) No mark No mark Hexagon bolt (Standard bottom surface) Hexagon bolt (Collared bottom) I I Two re1ief lines on I the head Stud bolt I Sample number 92132-,4O614 Length (mm): A Diameter (mm): B Type 0 ; ; ; ; l i e f 1 ines on I Hexagon bolt Welded bolt I No mark I Welding bolt Stud bolt Approximately 2 mm ' (0.08") hollow on I either or both ends

Standard Bolt Tightening Torque Standard t~ghtening torque kg-cm (it-lb) Diameter rnm Pitch mm Seat with flange

Toyota 2SDK7 Skid Steer Loader Workshop Service Manual

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