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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