Page 1

FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 5FGi5FD33

- 45 series. Please use this manual for providing quick, correct

servicing of the corresponding forklift models. This manual has been edited by combining Repair Manual Pub. No. CEO05 as Part I (Sections 0 t o 15) and Repair Manual ( S u p p l e m e n t ) Pub. No. CE014. as Part 11(Sections 0 to 4). Part I explains the service procedures for the models produced since August, 1988 while Part IIcovers those for the models subject to the minor change in September, 1994. For servicing the vehicles after the minor change, please refer to both Part I and PartII. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be informed by Toyota Industrial Equipment 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:

TOYOTA INDUSTRIAL EQUIPMENT 3F ENGINE REPAIR MANUAL (No. CE614) TOYOTA INDUSTRIAL EQUIPMENT 1FZ ENGINE REPAIR MANUAL (No. CE627) TOYOTA INDUSTRIAL EQUIPMENT 1 IZ, 122 ENGINE REPAIR MANUAL (NO. CE615-1)

TOYOTA MOTOR CORPORATION


PART I : 1988. 8SECTION INDEX (CE005)

GENERAL

ENGINE0 CLUTCH

C

R

TRANSMISSION & DIFFERENTIAL FRONT AXLE REAR AXLE

BRAKE a

BODY MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL CONTROL VALVE APPENDIX


GENERAL Page

................................ 0-2 VEHICLE LISTING ................................ 0-3 ABBREVIATIONS ................................ 0 -4 OPERATIONAL TIPS ............................. 0 -4 EXTERIOR VIEWS

STANDARD BOLT & NUT TIGHTENING TORQUE ......................................... BOLT STRENGTH TYPE IDENTIFICATION METHOD ...................................... TIGHTENING TORQUE TABLE .................. PRECOAT BOLTS ..............................

0-5

0-5 0-6 0-7

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE ........................... 0-7

................................ 0 -8 WIRE ROPE SUSPENSION ANGLE LIST ........... 0 -9

FRAME NUMBER

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE ............................ 0-10 COMPONENTS WEIGHT

......................... 0-10

RECOMMENDED LUBRICANT QUANTITY &TYPES ......................................... 0-11

.......................... 0-12 PERIODIC MAINTENANCE ....................... 0 -1 4 INSPECTION METHOD ......................... 0-14 LUBRICATION CHARTS

PERIODIC REPLACEMENT LUBRICANTS AND PARTS ..................................... 0 -2 0


EXTERIOR VIEWS

Front View (5FD35)

Rear View (5FD35)

- 6 -

~~0.72-1


VEHICLE LISTING Load capaclty

Model 5FG33 02-5FG33

Engine model

Engine tY Pe

3F

Gasoline

t

t

11Z

Diesel

t

t

3F

Gasoline

t

t

11Z

Diesel

t

t

3F

Gasoline

t

t

11Z

Diesel

t

t

3F

Gasoline

t

t

11Z

Diesel

t

t

3F

Gasoline

t

t

11Z

Diesel

t

t

Drive system

Remarks

Clutch Torgue converter

3.25 ton 5FD33 02-5FD33 5FG35 02-5FG35 5FD35 02-5FD35

Clutch Torque converter Clutch

Wheel base 1800 mm ( 7 1 in)

Torque converter Clutch Torque converter

3.5 ton 5FGE35 02-5FGE35 5FDE35 02-5FDE35 5FG40 02-5FG40

Clutch Torque converter Clutch Torque converter Clutch Torque converter

4.0 ton 5FD40 02-5FD40 5FG45 02-5FG45

Clutch Torque converter Clutch Torque converter

4.5 ton 5FD45 02-5FD45

Clutch Torque converter

Wheel base 2000 mm (78.5 in)


ABBREVIATIONS Abbreviations used in this manual are as follows: 4

Abbreviation (Code) ABDC ASSY ATDC ATM BTDC L/ LH LLC MTM OHV 0PT

0 /s

Meaning After button dead center Assembly After top dead center Automatic transmission Before top dead center Less Left hand Long life coolant Manual transmission Overhead valve Option Oversize

Abbreviation (Code) PS P/S RH SAE SST STD SUB-ASSY T= OOT U /S W/

Meaning Horsepower Power steering Right hand Society of automotive engineers (USA) Special service tool Standard Su b-assembly Tightening torque Number of teeth (00) Undersize With

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.

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 o f hydraulic equipment shall always be done in a clean place using clean tools.

4.

Genuine Toyota parts Genuine Toyota parts should be used even in the replacement of packings, gaskets and O-rings.

5. Repairs on electrical system Before doing any repairs on the electical system, disconnect the cables from the battery terminals. cable first. Be sure to disconnect the negative

6.

Tightening torque for installation Be sure t o observe the tightening torque given in this manual. I f not specified, tighten t o the torque listed in standard bolt & nut tightening torque.

7.

Defect status grasp Do not start disassembly 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 dpon a failure in starting the vehicle, but first check such factors as the oil, pressure and rotation status causing the failure.


STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and nut tightening torques are not indicated. Judge the standard tightening torque as shown below.

1. 2.

Find out the straight type of bolt from the list below and then find the bolt tightening torque from the table. The nut tightening torque can be judged from the mating bolt type.

BOLT STRENGTH TYPE IDENTIFICATION METHOD 1.

Identification by bolt shape Shape and identification method

Standard hexagon bolt

0

Number in relief or hallmark on the head

@

No mark

2. Strength type

4 = 4T 5 = 5T 6 = 6T 7 = 7T

Identification by part No.

I

Hexagon bolt Part

NO.

example

9 I 1 1 1-

4 0 61 0

-1

T ~ e n g t under h head (mm) Nominal diamter (mm)

4T

-

- Strength type

I

Nominal diameter

Length under head

Stud bolt two rel~efl~neson

Part No. example

9 2 1 32-4-061 Standard bolt with

1

4

T ~ e n g t (mm) h

Nominal diameter (mm)

-

Strength type

Nominal diameter Length


TIGHTENING TORQUE TABLE


PR ECOAT BOLTS (Bolts with seal lock agent coating on threads) 1.

Do not use the precoat bolt as it is in either of the following cases: (a) After it is removed. (b) When the precoat bolt is moved (loosened or tightened) by tightness check, etc. Note: For torque check, use the lower limit of the allowable tightening torque range. I f the bolt moves, retighten it according to the steps below.

2.

Bolts

Method for reuse of precoat bolts (1) Wash the bolt and threaded hole. (The threaded hole must be washed even for replacement of the bolt.)

(2) Perfectly dry the washed parts by air blowing. (3) Coat the specified seal lock agent to the threaded portion of the bolt.

HIGH PRESSURE HOSE FllTlNG TIGHTENING TORQUE 1.

When connecting a high pressure hose, wipe the hose fitting and mating nipple contact sufaces 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

5 %

5

kg-cm (ft-lb)

Tightening range

Standard

-

18 UNF

5.0 ( 36.2)

-

16 UNF

6.0 ( 43.4)

2.4 -- 2.6 ( 17.4 -- 18.8) 4.8 -- 5.3 (34.7 -- 38.3) 5.7 6.3 (41.2 -- 45.5)

6.0 ( 43.4)

5.7-

20 UNF

-

-

14 UNF

2.5 ( 18.1)

-

6.3 (41.2

-

45.5)

Hose inside diameter (mm) 6 9 12 12

14.7 (96.2 -- 106.3)

19 25

5.0 ( 36.2)

4.8 -- 5.3 (34.7 -- 38.3)

9

PF3/8

5.0 ( 36.2)

4.8

PF1/2

6.0 ( 43.4)

I&

Standard tightening torque

-

12 UNF 12 UNF

PF1/4

PF314 PFI

12.0 ( 86.6) 14.0 (101.2)

11.4- 12.6 (82.4- 91.1) 13.3

-

-

--

38.3)

9

45.5)

12.0 ( 86.8)

11.4-12.6(82.4-

91.1)

12 19

14.0 (101.2)

13.3 -- 14.7 (96.2 -- 106.3)

25

5.7

5.3 (34.7 6.3 (41.2


FRAME NUMBER Engine

Model

Punching format

Punching ,position

5FG 3 3 02-5FG 33 3F 5FG 3 5

"1 "2 "3 "4 "5

5FG35-10011 5FG35E10011 5FG35-20011 5FG35E20011 5FG35O20011

"1 "2 "3 "4 *5

5FD35-10011 5FD35E10011 5FD35-20011 5FD35E20011 5FD35020011

"1 "2 "3 "4 "5

5FG45- 1001 1 5FG45E10011 5FG45-20011 5FG45E20011 5FG45Q20011

02-5FG 3 5 5FD 33 02-5FD 33

11Z

5FD 3 5

Frame No. punching position

02-5FD 3 5 5FGE35 02-5FGE35 5FG 4 0 3F 02-5FG 4 0 5FG 4 5

a

02-5FG 4 5 5FDE35 02-5FDE35 5FD 4 0

11Z 02-5FD 4 0

"1 "2 "3 "4 "5

5FD45- 1001 1 5FD45E10011 5FD45-20011 5FD45E20011 5FD45~20011

5FD 4 5 02-5FD 4 5 "1 "2 "3 "4 "5

1988.6- 1993.3 1992.11 - 1993.3 (EEC spec.) 1993.41993.4- 1993.9 (EEC spec.) 1993.10-(EEC spec.)

LAQS 1 29


-

WIRE ROPE SUSPENSION ANGLE LIST Lifting angle

o

O

30째

60째

Tension

Compressi o n

1 .oo

0

time

time

1.04

0.27

time

time

1 .I6

0.58

time

ti me

Suspension method

Lifting angle

:LI fiO

90째

120째

A.

@ \'

Tension

Compression

1.41 time

time loo

2.00 time

time

Suspension method

ko

,"


SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE U n i t : t o n (Ib)

I

Rope diameter

Cutting load

Four-rope suspension

Two-rope suspension

8 mm (0.32 in.) 10 mm ( 0 . 4 in.)

14 mm (0.56 in)

COMPONENTS WEIGHT Unit: kg (lb.)

1 1 Z : 3 3 0 (728) 3F : 250 (551)

Engine Transmission with differential

Approx. 200 (441 )

Torque converter with differential

Approx. 3 6 0 ( 7 9 4 )

3.25 ton Approx. 1920 (4234) Balance weight

3 . 5 ton Approx. 2220 ( 4 8 9 5 ) E3.5 ton Approx. 2 1 3 0 ( 4 41 0 ) 4.0 ton Approx. 2520 ( 5 5 5 7 ) 4.5 ton Approx. 2830 ( 6 2 4 0 )

Mast L/ Lift Bracket (Max. Fork Height: 3 0 0 0 mm ( 1 18 in.)

3.25

- 4.0 ton Approx. 6 5 0 ( 1 433) 4.5 ton Approx. 8 5 0 ( 1 874)


RECOMMENDED LUBRICANT QUANTITY & TYPES Description

Classification

TYpe

API

Motor Oil

SD, SE, SF

SAE30 (SAE20 in cold area)

Gasoline

Application 3F

Diesel

API

Diesel engine oil

CC, CD

SAE30 (SAE20 in cold area)

Up to '88 Nov. 8 . 0 Q ( 2 . 1 US gal) From ' 8 8 Dec. 9 . 3 Q ( 2 . 5 US gal)

SAE20W-40 (SAE1OW-30 in cold area)

Engine

Quantity

11Z

12.5

Q ( 3 . 3 US gal)

SAE1 OW-30

Transmission

API

Hypoid gear oil

GL-4

SAE85W-90

MTM models

6 . 0 Q ( 1 . 6 US gal)

All models

9 . 5 Q ( 2 . 5 US gal)

ATM models

15

Q ( 4 . 0 US gal)

Fork height 3000 m m ( 1 18 in.)

60

Q ( 16 US gal)

95

Q ( 2 5 US gal)

GL-5

Differential

API

Hypoid gear oil

GL-4

SAE85W-90

GL-5 Torque converter

GM

ATF

DexronB I1 IS0

Hydraulic oil

VG32

Hydraulic oil IS0 VG32

Gasoline models Fuel tank

5FD33,35 Diesel models 5FDE35, 5FD40,45

Chasis parts

MP Grease @LLC30-50% mixture (for winter or all season)

LLC Coolant (Excluding reserve tank)

Coolant (Reservoir tank) Drive shaft pulley (Oil pump spline shaft)

All models 3F

*Coolant with rustinhibitor (for spring, summer and autumn)

T

T Molybdenum disulfide grease

9 5 Q (25US gal) 120 Q ( 3 2 US gal) Proper quantity 1 3 . 0 Q ( 3 . 4 US gal)

1 3 . 0 Q ( 3 . 4 US gal)

All models

1.1 Q ( 0 . 3 US gal) (at Full level)

All models

Proper quantity


LUBRICATION CHARTS

Chain Differential gear Front wheel bearing Power cylinder joint Transmission case Rear wheel bearing Steering knuckle king pin Bell crank pin Oil tank Engine crankshaft Rear axle beam front Rear axle beam rear Tilt steering universal joint Tilt steering locking mechanism Mast support bushing Tilt cylinder front pin Propeller shaft (Oil pump drive shaft) Tie-rod end Drive shaft pulley (Oil pump spline shaft)

lnspect lnspect lnspect lnspect lnspect

lnspect and service Replace MP grease Engine oil Hypoid gear oil Hydraulic oil Hypoid gear oil Molybdenum disulfide grease

Clutch Model Lubrication Chart -

16 -

every 8 hours (daily) every 40 hours (weekly) every 1 7 0 hours (monthly) every 1000 hours (6 monthly) every 2000 hours (annually)


13 2

14

1

1

16

16

3

3

15

15

10

5

17

9

11

4

8

4

6

6

7

7

12

18

18

19

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Chain Differential gear Front wheel bearing Power cylinder joint Transmission case Rear wheel bearing Steering knuckle king pin Bell crank pin Oil tank Engine crankshaft Rear axle beam front Rear axle beam rear Tilt steering universal joint Tilt steering locking mechanism Mast support bushing Tilt cylinder front pin Propeller shaft (Oil pump drive shaft) Tie-rod end

I.

n. 111. IV. V.

Inspect every 8 hours (daily) Inspect every 40 hours (weekly) Inspect every 170 hours (monthly) Inspect every 1000 hours (6 monthly) Inspect every 2000 hours (annually)

0

lnspect and service Replace

@ @ @ @ @

MP grease Engine oil Hypoid gear oil Hydraulic oil Automatic transmission fluid Molybdenum disulfide grease

@

Drive shaft pulley (Oil pump spline shaft)

i

Torque Converter Model Lubrication Chart


PERIODIC MAINTENANCE INSPECTION METHOD I : Inspeciton. Repairorreplacement if required. M : Measurement. Repair o r adjustment i f required. T : Retightening C : Cleaning L : Lubrication * : For new vehicle * 1 : Soapy water " 2 : Detector

" 3 : Flaw detector

h

Inspection Period

Every

3

1

12

6

Months

--------___

Every 170 500 1000 2000 Hours

Item ENGINE

Proper starting and abnormal noise

Main body

Rotating condition at idling

M

Rotating condition during acceleration

M

Exhaust gas condition

l

Air cleaner element

c

t

t

t

t

t

+ C

+

t

t

C

t

t

Compression

M

Cylinder head bolt loosening

T

Muffler rubber mount

I

Governor

No-load maximum rpm

l

C

t

~

t t

t

Oil leak

I

+

+

Oil level

l

C

t

t

Clogging and dirt of oil filter

i

-

+

Fuel leak

l

C

t

t

Operation of carburetor link mechanism

I

+

+

Dirt and clogging of fuel filter and element

l

t

t

+

+

+

t

C M

Injection timing

t

lnjection nozzle injection pressure and spray status

M I

Draining of sedimenter

Cooling system

~

M

Clogging and damage in PCV valve and piping

Fuel system

C

Valve clearance

PCV system

Lubrication system

l

t

t

Coolant level in radiator and leak

l

t

C

Rubber hose degradation

l

t

Radiator cap condition

I

C

t

t

Fan belt tension, looseness and damage

I

+

+

+

t

t

I

Radiator rubber mount Radiator screen

c

t

t

C

t


Inspection Period Item

Every -

1

12

6

3

Every 170 500 1000 2000 Hours

POWER TRANSMISSION SYSTEM Clutch pedal play

Clutch

M

Abnormal sound and functioning (connection)

I

Clutch booster function and leak

l

-

+

+

C

t

C

Differntial

C

C

e I

Oil clutch mechanism and leak

Transmission

+

+

+

Leak

I

-

Fluid level

I

+

-

+

Gear function and abnormal noise

l

C

t

t

Leak

I

Oil level

I

+

+

+

t

+

t

t

T

Bolt loosening

Torque converter and transmission

Leak

i

t

Fluid level

I

+

Operating mechanism function and looseness

I

+

+

-

Control valve and clutch functions

I

+

+

+

Inching valve function

I

+

+

-

+

-

+

+

+

M

Stall and hydraulic pressure measurement

+

DRIVE SYSTEM M

t

Tire cuts, damage and uneven wearing

I

+

Loose rim and hub nuts

T

t

Tire groove depth

M

+

Tire inflation pressure

Wheels

Months

+

+

+

+

t +

c +

Metal chips, pebbles and other foreign matter trapped in tire grooves

I

Rim, side bearing and disc wheel damage

I

+

+

+

Abnormal sound and looseness of front wheel bearing

I

+

+

+

+

+

+

-


-

-

-

Item

Inspection Period --------

Every

1

3

12

6

Every 170 500 1000 2000 Hours

Wheel

Abnormal sound and looseness of rear wheel bearing

Front axle

Cracks, damage and deformation of housing

I

Cracks, damage and deformation of beam

I

Looseness of axle beam in vehicle longitudinal direction

M

Rear axle

Months

l

t

t

t

STEERING SYSTEM Steering wheel

Gear box

Play and looseness

t

Function

l

Oil leak

l

Looseness of mounting

T + + - + -

t

e

e

t

+

t

t

Power steering

Looseness and damage

t

C

Clogging of relief valve filter Rods, links and arm

-

+

I ' - - ' I

Linkage and wear and mounting condition Oil leak

I

+

+

+

Mounting and linkage looseness

l

C

C

t

I

Damage of power steering hose

Knuckle

Steering shaft

King pin looseness

I

+

+

+ I

Cracks and deformation Wheel alignment

M

Left and right turning angle

M

BRAKING SYSTEM

Brake pedal

Play and reserve

M

+

+

Braking effect

I

+

+

Operating force

l

C

t

Braking effect

I

+

+

Rod and cable looseness and damage

I

Brake pipe

Leak, damage and mouting condition

I

Brake booster and wheel cylinder

Function, wear, damage, leak and mounting looseness

Parking brake

e +

~

+ C

+ e

+

+

t -

I


Inspection Period Item

Backing plate

1

12

6

3

Months

Every 170 500 1000 2000 Hours Clearance between drum and lining

Brake drum and brake shoe

Every

M

+

-

+

+

Wear of shoe sliding portion and lining

I

Drum wear and damage

I

Shoe operat~ngcondition

I

Anchor pin rusting

I

Return spring fatique

M

Automatic adjuster function

I

Deformation, cracks and damage

I

Loose mounting

T

MATERIAL HANDLING SYSTEM

Forks

Abnormality of fork and stopper pin

l

Misalignment between left and right fork fingers

I

C

t

t

+

+

1 *3

Cracks at fork root and welded part Deformation and damage of each part and crack at welded part

~

I

C

C

C

Mast and lift bracket looseness Mast and fork bracket

Wear and damage of mast support bush Wear, damage and rotating consdition of rollers

Il - + ' -+ ; - I + I

Wear and damage of roller pins

Chain and chain wheel

Various attachment

Wear and damage of mast strip

I

Tension, deformation and damage of chain

I

Chain lubrication

l

t

t

t

t

+

+

Abnormality of chain anchor bolt

i

Wear, damage and rotating condition of chain wheel

I

Abnormality and mounting condition of each part

I

-

+ C

C

C

+

+ C

C

-

C

-

HYDRAULIC SYSTEM

Cylinder

Loosening and damage of cylinder mounting

T

t

t

t

Deformation and damage of rod, rod screw and rod end

I

C

C

C

Cylinder operation

I

Natural drop and natural forward tilt (hydraulic drift)

M

+

+ C

+ C


C

-

Inspection Period

Oil pump

Hydraul~c oil tank

Control lever

Oil control valve

Hydraulic piping

12

6

3

Oil leak and damage

I

Wear and damage of pin and cylinder bearing

I

Lifting speed

M

Uneven movement

I

Oil leak and abnormal sound

I

Oil level and contamination

I

-

+

t

+

+

'

+

-

+

+

+

+

-

+

+

+

-

-

-

'

C

Tank and oil strainer

-

-

+

Oil leak

I

+

Loose linkage

I ' - ' - ' -

Operation

I

-

Oil leak

I

+

-

+

+

Relief valve and tilt lock valve functions

I

+

+

-

+

011leak

1

Deformation and damage

I

+

+

Loose joint

T

-

-

+

+

M

Relief pressure measurement

t

C

C

+

-

ELECTRICAL SYSTEM

Ignition timing

-

Cracks on distributor cap

I

Spark plug and burning and gap ( - 1997.12)

I

Distributor side terminal burning

+

Distributor cap center piece wear and damage

I

t

M

+

Distributor points gap

+

+

-

+

+

+

+

+

t

+

C

I

Plug cord internal discontinuity M

Ignition timing Starting motor

Pinion gear meshing status

Charger

Charging function

I

Battery fluid level

I

/

I

+

+

+

Damage of wiring harness

I ' - + ' -

Fuses

l

e

+

-

M

Battery fluid specific gravity

t

+

+

Battery

Electrical wiring

Months

Every 170 500 1000 2000 Hours

Item

Cylinder

1

Every

t

t

+


-

Item

Inspection Period

Every

-------___Every

Preheater

Open-circuit in intake heater

Engine stopping system

Diesel engine key stop device function

1

6

3

12

Months

170 500 10002000 Hours I I

t

t t

t

SAFETY DEVICE, ETC. Cracks at welded portion

I

+

+

+

Deformation and damage

l

C

t

C

Loosening of mounting

T

Deformation, crack and damage

l

t

t

I Function and mounting condition

i

t

+

+

Horn

Function and mounting condition

I

+

+

+

Direction indicator

Function and mounting condition

I

Instruments

Functions

I

Backup buzzer

Function and mounting condition

I

Rear-view mirror

Dirt, damage

I

Rear reflection status

l

t

C

t

Seat

Loosening and damage of mounting

l

t

t

t

Damage and cracks of frame, cross members, etc

I

Body

Bolt looseness

T

Head guard

Back-rest Lighting system

Other

Grease up

L

t t

-

+

+

+

+

+

+

+ -

t

+

t

+ t

-

+

t

+

~


PERIODIC REPLACEMENT LUBRICANTS AND PARTS l: Replacement Every 1 month

Every 3 months

Every 6 months

Every 12 months

Item

Every 1 7 0 hours

Every 5 0 0 hours

Every 1000 hours

Every 2000 hours

Engine

t

+

+

+

C

t-

+

Interval

• •

Engine oil filter Engine coolant (every 2 years for LLC)

• • • • • • •

Fu,el filter Torque converter oil Torque converter oil filter Transmission oil Differential oil Hydraulic oil

a*'

Hydraulic oil return filter

C

t

+ C

+ t

+

Wheel bearing grease

l (-1997.12)

Spark plug

Distributor points

• • +

Cups and seals for wheel cylinders

• • •

Power steering hoses

e*2

Air cleaner element Brake booster rubber parts

•* •* •

Power steering rubber parts Hydraulic hoses Fuel hoses Torque converter rubber hoses

Chains

*I:

for n e w vehicle

"2:

Every 2 years

*3:

Every 3 years

Replacement shall be made u p o n arrival of the operation hours or months, w h ~ c h e v e ris'earlier.


GENERAL

1 1 Z Engine Exterior View

KAI-28-26,35-1li


3F Engine Exterior View


112 Engine Sectional V i e w

3F Engine Sectional View

- 28 -

LAQM61.62


Engine Performance Curves 29.0/1600 29 28 - 27 Engine torque 26 (kg'm) 25

-

90

85/2200

80 70 Shaft horsepower (PSI 6050 40 -

]

-

Fuelconsumption ratio. (g/ps.h)

I

I

10 14 18 22 Engine speed (rpm) x 1O2

Engine Performance Curve (1 12)

Gasoline model LPG model only - - - - - -. Gasoline LPG model

KALMl

26.0/1200 25.0/1200

j24

Engine torque

Shaft horsepower

200/2000

1 185/1800 ,"

200 Fuel consumption

180

-

10

14

18

22

Engine speed (rpm) x 1O2 Engine Performance Curve (3F)

- 29

-

KALM 47


SPECIFICATIONS

-

Piston displacement

cc (cu-in.)

Number of cylinders Valve mechanism mm (in.)

Bore x stroke Compression ratio

Maximum torque

pslrpm (SAE NET: ~ p h kg-mlrpm (SAE NET : ft-lblrpm)

Fuel consumption ratio

3F (Gasoline)

4429 (270)

3955 (241 )

6

6

OHV gear driven

t

96.0 x 102.0 (3.78 x 4.02)

94.0 x 95.0 (3.70 x 3.74)

18.6

8.1

Direct injection

Combustion chamber type Rated output

11 Z (Diesel)

glps-hlrpm

Injection pump type

~

85/2200 (8112200) ~ )

72/21 00 (6912100)

2911600 (202/1600)

26/1200 (182/1200)

1 6511 200

20011800

Bosch (VE)

l njection timing (BTDC) Injectio n order

1- 4- 2- 6- 3- 5

lgnition timing (BTDC) Ignition order Service weight

1- 5- 3- 6- 2- 4 kg (Ib.1

330 (728)

250 (551)


ENGINE ASSY REMOVAL (CLUTCH MODEL) 1.

Remove the toe board. (1) Toe board (2) Floor set bolts (3) Floor

Removing the Toe Board

2.

Remove the engine hood. (1 ) Disconnect the engine hood damper on the frame side. (2) Disconnect the engine hood stay on the frame bracket side. (3) Hood hinge set screws (4) Engine hood

Removing the Engine Hood

3.

4.

~ ~ 2 8 - 1 7

~ ~ 2 9 - 9

Remove the radiator cover

Removing the Radiator Cover

~ ~ 2 9 - 1 1

Removing the Air Cleaner ASSY

~ ~ 2 9 - 1 9

Remove the air cleaner ASSY. (1) Disconnect the vacuum switch harness. (2) Disconnect the air cleaner hose. (3) Hydraulic oil tank breather set bolt. (4) Air cleaner set bolt (5) Air cleaner ASSY (with hose)


5.

Remove the battery. (1) Disconnect the battery cables. Caution: Always disconnect the negative (-) terminal first.

(2) Disconnect the wiring t o the battery. (3) Disconnect the wirings to the distributor and ignition coil. (3F) (4) Battery stopper (5) Battery (6) Battery case 6.

Removing the Batery

LAQ29-22

Remove the sedimenter. (11 Z) (1 ) Disconnect the fuel hose. (2) Disconnect the wirings. (3) Set bolt (4) Sedimenter (with bracket)

Removing the Sedimenter

Disconnecting Wiring (1)

w 9 - 2 7

LAQ29-28.34

(4) Starting motor wiring (5) Engine oil pressure switch wiring

Disconnecting Wirings (2)

LAQ~o-s,~~-~s


(6) Fuel cut solenoid wiring (11 Z) (7) Intake heater wiring (11Z ) (8) Carburetor wiring (3F)

8.

Disconnecting Wirings (3)

LAQ30-1.29-32

Disconnecting the Fuel Piping (1 lZ/3F)

u Q 3 0 - 8 - 19-•

Disconnect piping and wires. (1) Fuel piping

(2) Accelerator wire

Disconnecting the Accelerator Wire (1 12)

Disconnecting the Accelerator Wire (3F)

LAQ~O-9

~ ~ 1 9 - 1 8


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