FOREWORD
This manual covers the inspection, adjustment and repair procedures of the engine, chassis and hydraulic equipment of the TO YOTA FORKLIFT 5FG/5FD 10-30 series. Since this manual describes alterations made in the vehicles being produced in September 199 1, it is supplement to the existing repair manuals for the 5FG/5FD 10-30 series, and it should be read and used together with the related repair manuals listed below. Any alterations after September 199 1 will be announced in the Toyota Parts
& Service News. Repair manuals related to this manual are as follows:
TO YO TA 5FG/5FD 10-30 SERIES REPAIR MANUAL
NO. CEO01- 1
TO YOTA 4Y ENGINE REPAIR MANUAL
NO. CE602
TOYOTA 5K ENGINE REPAIR MANUAL
NO. CE61 7
TO YO TA 1Z ENGINE REPAIR MANUAL
NO. CE60 1
TO YO TA 1DZ ENGINE REPAIR MANUAL
NO. CE6 18
TOYOTA MOTOR CORPORATION
SECTION INDEX
GENERAL
Page EXTERIOR VIEWS ..................................................
0-2
VEHICLE LISTING
..................................................
0 -3
FRAME NUMBER
...................................................
0-5
...............................
0-6
PERIODIC MAINTENANCE .......................................
0-8
PERIODIC REPLACEMENT LUBRICANTS AND PARTS ..............................................................
0 -9
HOW TO READ THIS MANUAL
0-2
EXTERIOR VIEWS
Front View
Rear View
VEHICLE LISTING
2.0 ton
5FD20
z
Clutch
1
02-5FD20 2 ton series
60-5FD20
1 DL
Clutch
5K Torque converter
02-5FG23 2.25 ton
40-5FG23 42-5FG23
Clutch Torque converter
62-5FD20 5FG23
Torque converter
Clutch 4Y Torque converter
Series
Load capacity
Model
5FD23 02-5FD23 2.25 ton
60-5FD23
Engine model
1z
1 DZ
62-5FD23 5FG25 02-5FG25 2 ton series
40-5FG25
5FD25 02-5FD25 60-5FD25
5K
4Y
5FD28 02-5FD28 60-5FD28
1z
1 DZ
5FG30
4Y
5FD30
1Z
62-5FD30
Clutch Torque converter Clutch
Clutch
Clutch Torque converter
1 DZ
Clutch Torque converter
4Y
Clutch Torque converter
1Z
02-5FD30 60-5FD30
Clutch
Torque converter
02-5FG30 3.0 ton
Clutch
Torque converter
62-5FD28 3 ton series
Clutch
Torque converter
02-5FG28 2.75 ton
Torque converter
Torque converter
62-5FD25 5FG28
Clutch
Torque converter
42-5FG25 2 . 5 ton
Drive system
Clutch Torque converter
1 DZ
Clutch Torque converter
FRAME NUMBER
Punch~ng position
1 ton series Eng~nemodel
5K
4Y
1 DZ
5FG10
40-5FG 1 0
5FD10
02-5FG10
42-5FG10
02-5FD10
5FG 14
40-5FG1 4
5FD14
02-5FG14
42-5FG14
02-5FD14
5FG15
40-5FG15
5FD15
02-5FG 1 5
42-5FG15
02-5FD15
5FG18
40-5FG1 8
5FD18
02-5FG18
42-5FG18
02-5FD18
A5FG18-60011
405FG18-60011
A5FD18-60011
Vehicle model
Punching format
2 ton series Engine model
Vehicle model
Punch~ngformat
5K
4Y
1Z
5FG20
40-5FG20
5FD20
60-5FD20
02-5FG20
42-5FG20
02-5FD20
62-5FD20
5FG23
40-5FG23
5FD23
60-5FD23
02-5FG23
42-5FG23
02-5FD23
62-5FD23
5FG25
40-5FG25
5FD25
60-5FD25
02-5FG25
42-5FG25
02-5FD25
62-5FD25
A5FG25-60011
405FG25-60011
5FD25-60011
A605FD25-60011
3 ton series Engine model
4Y
1Z
1 DZ
5FG28
5FD28
60-5FD28
02-5FG28
02-5FD28
62-5FD28
5FG30
5FD30
60-5FD30
02-5FG30
02-5FD30
62-5FD30
5FG30-6001 1
5FD30-60011
A605FD30-60011
Vehicle model
Punching format
1 DZ
---
-
-
HOW TO READ THIS MANUAL EXPLANATION METHOD 1.
Operation procedure ( 1 ) The operation procedure is described in either pattern A or pattern B below. Pattern A: Explanation of each operation step with a photo or illustration. Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, followed by explanation of cautions and notes summarized as point operations.
Example of description in pattern B DISASSEMBLY . INSPECTION . REASSEMBLY
Tightening torque unit :T = N.m (kg-cm) [ft-lbl
I If a place or part cannot be indicated directly, t h e part name is described on the either side of the illustration.
Example: 1
Piping
Oil Pump Disassembly Procedure
DISASSEMBLY 1 . Remove the cover. [Point 1 I 2. Remove the bush [Point 21 -Operation 3 . Remove the gear.
explained on a laterpage
Explanation of key point for operation with an illustration POINT OPERATIONS [Point 11 Disassembly: Put a match mark when removing the pump cover. [Point 21 Inspection: Measure the bush inside diameter. Bush inside diameter limit: 19.12 m m (0.7528 in.)
/
2.
How to read components figures ( 1 ) The components figure use the illustration in the parts catalog for the vehicle model, please refer to the catalog for checking the part name. The number at the right shoulder of each components figure indicates the Fig. number in the parts catalog.
r----v (Example)
FIG number in parts catalog
3 . Matters omitted in this manual ( 1 ) This manual omits description of the following jobs, but perform them in actual operation:
@ Cleaning and washing of removed parts as required @ Visual inspection (Partially described)
TERMINOLOGY Caution: lmportant matters of which negligence may cause accidents. Be sure t o observe them. Note: lmportant items of which negligence may cause accidents or matters in operation procedure requiring special attention. Standard: Values showing allowable range in ~nspectionand adjustment. Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATION Abbreviation (code)
Mean~ng
Abbreviation (code)
Meaning
ABCV
Air Bleed Control Valve
SAE
Society of Automotive Engineers (USA)
ASSY
Assembly
SST
Special Service Tool
EC U
Em~ssionControl Unit
STD
Standard
LH
Left Hand
T =
Tightening Torque
OPT
Option
OOT
Number of Teeth (00)
01s
Oversize
UIS
Undersize
PS
Power Steering
W1
With
RH
Right Hand
PERIODIC MAINTENANCE INSPECTION METHOD I : Inspection. Repair or replacement if required. M : Measurement. Repair or adjustment if required. L : Lubrication T : Retightening C : Cleaning : For new vehicle 1 : Soapy water "2: Detector Inspection Period Item
'3 : Flaw detector Months
1
3
6
12
Hours
170
500
1000
2000
0
0
0
0
ENGINE Three-way exhaust emission
1. Exhaust gas (carbon monoxide) concentration measurement
M
system
2. Exhaust system piping joint loosening and damage
T
3. System function check
I
4. Vacuum p ~ p i n gdamage
I
5. Vacuum switch damage (gasoline
0 0 0
0
0
0 0
0 0
I
0
6. Idle switch damage (gasoline model)
I
0
7 . Water temperature sensor damage (gasoline model)
I
0
8. ABCV damage (gasoline model)
I
9. Injector cleanlng and damage (LPG model)
C.1
10. Register damage (LPG model)
I
model)
11. Three-way catalytic muffler function
I
0
0
0
0 0 0 0 (2000H)
PERIODIC REPLACEMENT LUBRICANTS AND PARTS : Replacement
Interval Item
1 month
3 months
6 months
12 months
170 hours
500 hours
1000 hours
2000 hours
• • •
• • • •
Engine Engine oil filter Engine coolant (every 2 years for LLC) Fuel filter
• • • • • • • • •
Three-way catalytic muffler Injector (LPG model)
"2
•
Torque converter oil Torque converter oil filter Transmission oil Differential oil
• •
Hydraulic oil Hydraulic oil filter
@*I
• • • • • •
Wheel bearing grease
•
Spark plugs Cyclone air cleaner element Brake valve rubber parts Cups and seals for master and wheel cylinders
•
Brake fluid
Power steering rubbers parts
• •
Hydraulic hoses
a'2
Power steering hoses
"2 *?
Fuel hoses
•*2 •
Torque converter rubber hoses
@*2
Chains
•
Reservoir tank tube
"2
"3
"1
: for new vehicle
"2 :
Every 2 years
"3 :
Every 3 years
Replacement shall be made upon arrival of the operation hours or months, whichever is earlier.
ENGINE
Page AIR CLEANER ........................................................ GENERAL .......................................................... SPECIFICATIONS ................................................ COMPONENTS ................................................... AIR CLEANER MAINTENANCE
.............................
GASOLINE EXHAUST EMISSION CONTROL SYSTEM (THREE-WAY CATALYST) ................................... GENERAL .......................................................... COMPONENTS ................................................... REMOVAL
. INSTALLATION ................................
TROUBLESHOOTING ........................................... LPG EXHAUST EMISSION CONTROL SYSTEM (THREE-WAY CATALYST) ................................... GENERAL .......................................................... COMPONENTS ................................................... REMOVAL INSTALLATION ................................. TROUBLESHOOTING ...........................................
1-2
AIR CLEANER GENERAL
>
/
L
(OPT: Double element)
Air Cleaner Sectional View
SPECIFICATIONS Combined type (dry
Type
6 in.
Size
Outside air intake
Air ~ n t a k esystem Filtering area Vacuum sensor operating pressure Other
+ cyclone)
cm2 mmHg
STD: Single OPT: Double
14200 Outer: 1 8 5 0 0 Inner: 535
- 44.1 With evacuator valve
COMPONENTS
Air Cleaner Components
AIR CLEANER MAINTENANCE 1.
Cleaning the Element
Washing the Element
Element cleaning ( 1) For cleaning in ordinary status, blow compressed air (686 kPa ( 7 kglcm2) [ I 0 0 0 psil or less) from the inside of the element along the pleats. If the element is heavily contaminated, washing is allowable. ( 2 ) Element Washing Method Dissolve a neutral detergent in tepid water (about 40°C (104°F)). Immerse the element for about 30 minutes in the washing liquid, then rinse it thoroughly with clear water. (The water pressure must be 275 kPa (2.8 kglcm2)[40 psil or less.) Caution 0 Carefully protect the filtering paper from damage during washing. 0 Never use compressed or hot air for drying. 0 It is unnecessary t o clean the inside element when cleaning the double cyclone air cleaner. Only clean the outside element. It is essential t o replace both outside and inside element in time of replacement. After wash~ng,dry In the air or with cold air blow. Evacuator valve (dust discharge valve) cleaning. Hold the tip end of the evacuator valve between fingers and pull it lightly to the left and to the right to discharge the dust and dirt in the evacuator valve.
Cleaning the Evacuator (Dust Discharge) Valve
Evacuator valve cleaning timing: Clean at the same time with the element.
GASOLINE EXHAUST EMISSION CONTROL SYSTEM (THREE-WAY CATALYST) GENERAL
lr connector
Intake manifold
ater temperature switch catalytic muffler Engine
Gasoline Exhaust Emission Control System
Baffle plate
lnterram mat
Straightening vane
Inlet Exhaust gas
Monolithic Catalyst
Outlet
Three-way Catalytic Muffler Sectional View
1 9 -
COMPONENTS
Three-way Catalytic Gasoline Exhaust Emission Control System Components
20-
Three-way Catalytic Gasoline Exhaust Emission Control System Components (2)
-21
-
Three-way Catalytic Gasoline Exhaust Emission Control System Components (3)
-22-
1-9
REMOVAL
INSTALLATION
Three-way Catalytic Gasoline Exhaust Emission Control System Removal & Installation
Removal Procedure 1 2 3 4 5 6 7
Remove the three-way catalytic muffler Remove the idle switch. Remove the water temperature sensor. Remove the vacuum switch. Remove the ABCV. Remove the 0 sensor. Remove the ECU.
Installation Procedure The installation procedure is the reverse of the removal procedure.
Caution Always perform engine tune-up after the end of operation and measure the CO concentration. If it does not satisfy the standard, carry out inspection according t o the troubleshooting procedure. (See page 1-10.)
TROUBLESHOOTING High CO concentration in exhaust gas. Perform engine tune-up without before starting inspection for troubleshooting. lnspection 1 :
CO concentration check
idling
Idle switch replacement
NG
Idle switch inspection and adjustment
NG
- CO concentration at
1
OK CO concentration at full acceleration
NG -TO
CO concentration measurement
inspectiAn 2
NG 40 inspection 2
0K -Normal
lnspection 2:
Muffler inspection
Has the muffler been used for more than 2000 hours
-TO
inspection 3
YES Muffler replacement
-
CO concentration measurement
NG -To
inspection 3
OK Normal
lnspection 3:
lnspection of wiring between water temperature sensor and EC U
NG -
1
Water temperature sensor inspection
Wiring repair
CO concentration measurement
0K -Normal
0K
-
ATO inspection 4
Inspection of water temperature sensor alone
NG ___)
Water temperature sensor replacement
0K To inspection 4
CO concentration measurement
NG -To
OK -Normal
inspection 4
lnspection 4:
lnspection of wiring between vacuum s w ~ t c hand ECU
Vacuum
CO concentration measurement
Wiring repair
- NG -TO
!
--F-
OK N Inspection of vacuu m switch alone
t
To inspection 5
1 I l n s ~ e c t i o nof sianal ~ o l ~ a g( A eBCV)'~~ tween ABCV and E terminals of ECU at full acceleration
r
m
CO concentration measurement
lnspect~onof wiring between ECU and ABCV
4
NG
Wiring repair
CO concentration measurement
X
I
Inspection 6 :
Inspection of signal voltage between RIL and E terminals of ECU at full acceleration
0K - ECU r e p l a c e m e n t 1
Normal
To inspection 6
lOK L N o r m a l
Inspection of ABCV alone
Replace ABCV
I
1
0K
I OK
1 -
l
b
i
-
a
To inspection 5
ABCV inspection
I NG
o
Vacuum switch replacement
Normal
Inspection 5 :
To inspection 6
inspection 5
To inspection 6
measurement
b
0, sensor inspection
Inspection of wiring be-
NG tween RIL of ECU and check connector
x d
Wiring repair
I
OK
CO concentration check
-CO concentration check
OK
1 0, sensor replacement
1
NG
_I
ECU replacement
Always check no gas leak from exhaust piping and no vacuum hose disconnection before starting inspection jobs. lnsoection 1 : CO concentration check Caution The idling speed and maximum no-load speed shall be adjusted normally.
I
1.
Warm up the engine sufficiently. Standard: Engine cooling water temperature: 65OC (1 4g°F) or above Hydraulic oil temperature: 50°C (122OF) or above
2.
Measure the CO concentration at the idling speed. ( 1 ) Set the engine tachometer. (2) Keep the engine running at the maximum no-load speed for 2 minutes to warm up the 0, sensor. Standard: Exhaust gas temperature: 370°C (698OF) or above (3) Return to the idling speed. (4) Measure the CO concentration. Standard: CO concentration: 0.2 % or less
3.
If the CO concentration at idling does not satisfy the standard, inspect and adjust the idle switch. ( 1 ) Measure the idle switch resistance. In pressed state: No conduction ( 1 0 MQ or more) In released state: Conduction ( 3 0 0 Q or less) (2)Inspect conduction of the idle switch at an engine speed of 1200 rpm. Standard: Engine speed at less than 1 2 0 0 + 5 0 rpm: No conduction Engine speed at 1 2 0 0 -t 50 rpm or more: Conduction If the standard above is not satisfied, make adjustment by turning the idle switch adjusting bolt.
' ~ e s t connector (black wiring)l -
-
Setting the Engine Tachometer
Measuring the CO Concentration (at Idling)
Inspecting the ldle Switch
ldle switch adjusting bolt Adjusting the ldle Switch
4.
Measure the CO concentration at full acceleration (at the maximum no-load speed). ( 1 ) Fully depress the accelerator pedal (to the maximum no-load speed). ( 2 ) Measure the CO concentration. Standard: CO concentration: 0.5 % or less
Measuring the Co Concentration (at Full Acceleration) lnspection 2: Muffler inspection The durable hours of the muffler catalyst is 2000 hours as a rule. 1 . Check the muffler operation hours. 2 0 0 0 hours or more: Muffler replacement Less than 2 0 0 0 hours: To inspection 3
Monolithic catalyst
Three-way Catalytic Muffler Inspection 3: Water temperature sensor inspection 1 . lnspect the water temperature sensor alone. ( 1 ) Pour water in a proper container and immerse the water temperature and sensor resistance when the sensor is turned on (becomes conductive). Standard: No conduction (1 M Q or more at 5 8 OC ( 136OF) or less) Conduction (0.5 Q or less) at 65OC ( 1 4 9 OF) or above Inspecting the Water Temperature Sensor Alone lnspection 4: Vacuum switch inspection 1. lnspect the vacuum switch alone. ( 1 ) Connect the rnity vac (using an approprlate vinyl hose) to the vacuum switch.
Connecting the Mity Vac
(2) Apply a negative pressure and measure conduction. Standard: Conduction (0.7 Q or less) at - 7 0 2 0 mmHg ( 9 5 0 2 7 0 mmAq) or above No conduction (1 M Q or more) at - 1 0 0 2 0 mmHg (13 6 0 +_ 2 7 0 mmAq) or below
+
+
+
Measuring the Switch Conduction
ABCV Check Connector
lnspection 5: ABCV inspection 1 . lnspect the ABCV function. ( 1 ) Check that vacuum piping and electrical wiring are not disconnected. (2) Disconnect the ECU check connector. (3) Keep the engine running at the maximum no-load speed for 2 minutes to warm up the 0, sensor. Standard: Exhaust gas temperature: 370°C (698OF) or above (4) Return to the idling speed. ( 5 ) lnspect the signal voltage from the ABCV at the check connector (female side). Standard: Between ABCV and E terminals: Good if the pointer deflects (The voltage at the time shall be 0 t o 12 V.)
lnspecting the ABCV Signal Voltage
2.
lnspection of ABCV alone ( 1 ) Measure the resistance between the @B terminals and motor coils. Standard: and FCM1: 7 0 5 Q Between @B (0) Between @B (0) and FCM3: 7 0 5 Q Between @B (0) and FCM2: 7 0 5 Q Between @B (0) and FCM4: 7 0 +_ 5 Q
+ + +
lnspecting the ABCV Alone ( 1 )
(2) lnspect conduction between the ABCV body and motor coils. Standard: Between body and FCM1: 1 0 M Q or more (no conduction) Between body and FCM2: 1 0 M Q or more (no conduction) Between body and FCM3: 1 0 M Q or more (no conduction) Between body and FCM4: 1 0 M Q or more (no conduction) Inspecting the ABCV Alone (2)
ECU Check Connector
Checking the O2 Sensor Function
Inspection 6: 0, sensor inspection 1 . Check the 0, sensor funct~on. ( 1 ) Check that the vacuum piping and electrical wiring are not disconnected. (2)Disconnect the ECU check connector. ( 3 ) Keep the engine running at the maximum no-load speed for 2 minutes to warm up the 0, sensor. Standard: Exhaust gas temperature: 370°C (698OF) or above (4) Keep the maximum no-load speed. (5)lnspect the s~gnalvoltage from the 0, sensor at the check connector (female side). Standard: Between RIL and E terminals: 1 0 times or morel10 sec. (The voltage at the time shall be 0 t o 1 2 V.)
LPG EXHAUST EMISSION CONTROL SYSTEM (THREE-WAY CATALYST) GENERAL Var~edmlxture ratio have been chosen among the nations with reference to Propane and Butane content ratio in LPG. TOYOTA industrial vehicles on delivery have been adjusted to 95% of CO . HC . NOx emission purification rate by carburetor setting on assumption that LPG contains over 60% of propane. Where the ratio of propane is very low less than 30%, therefore, the carburetor re-adjustment is required. (See page 1-20 for re-adjustment).
Intake manifold
Catalytic muffler
f
/
Engine
LPG Exhaust Emission Control System
Baffle plate
lnterram mat
Straightening vane
Inlet Exhaust gas
Monolithic Catalyst
Outlet Three-way Catalytic Muffler Sectional View -30-
COMPONENTS
LPG Exhaust Emission Control System Components
- 31
-
LPG Exhaust Emission Control System Components (2)
REMOVAL
. INSTALLATION
Three-way Catalytic LPG Exhaust Emission Control System Removal & Installation
Removal Procedure 1 2 3 4 5
Remove the three-way catalytic muffler Remove the register. Remove the injector. [Point 11 Remove the 0 sensor. Remove the ECU.
Installation Procedure The ~nstallationprocedure is the reverse of the removal procedure Caution Always perform engine time-up after the end of operation and measure the CO concentration. If the standard is not satisfied, carry out inspection according t o the troubleshooting procedure. (See page 1-21.)
Point Operations [Point 1I Installation: When connecting the injector fuel piping, keep the union fixed. Tightening torque: 29.4 N.m ( 3 0 0 kg-cm) [21.71 in.lb1
Connecting the Fuel Piping
ADJUSTMENT METHOD In countries where the propane content ratio is less than 30%, the carburetor should be re-adjusted in following manner:
Power screw
( 1 ) Loosen the power screw bolt lock nut. (2) Turn the power screw open rate limiter to clockwise to contact to stopper. (Power screw bolt turns with the limiter. See the illustration below.) (3) Tighten the power screw bolt lock nut.
Power screw
LPG Carburetor
T = 11.77- 14.71 N.m ( 1 2 0 1 5 0 kg-cm) [8.68- 10.85 ft-lbl
-
Adjust point for over 60% propane content Adjustment ( A t 30%)
for less than
Adjustment Method
-34-
Power screw
TROUBLESHOOTING High CO concentration in exhaust gas. Perform engine tune-up without fail before starting inspection for troubleshooting.
lnspect~onand adjustment of carburetor and LPG regulator
CO concentration at idling
inspection 2
1
CO concentration at full acceleration
1-
ko
lnspect~on2:
t-
Muffler inspection
Has the muffler been used for 2 0 0 0 hours or more
To inspection 3
1 YES Muffler replacement
i
OK Normal
1-
lnspection 3:
Inspection of signal voltage (VF) between VF and E terminals of ECU at full acceleration
i
0K To Inspection 5
CO concentration measurement
I
OK Normal
To inspect~on3
-- 1
ECU signal voltage iVFl inspection
lnspection of w i r ~ n g between ECU and injector
i
To inspection 4
Wiring repair
CO concentration measurement
7-1 TO inspection 4
1 -
Inspection 4:
1
lnspect~onofOK reglster alone
1 -1 NG
I
Register Inspection
CO c o n c y ,on measurement
Reg~ster replacement
NG To ~nspectlon5
1
OK
Normal
To rnspect~on5
Injection 5:
l Injectorn cleaningp
n
To inspection 6
Injector inspection
o f injector atone
To inspection 6
Injector replacement
NormalOK
lnspection of signal voltage between OXM of E terminal of ECU at full acceleration
,$:
I
i
CO concentration measurement
NG
To inspection 6
lnspect~onof wiring beWiring repair check connector CO concentrat'/on check
B
ECU rep lac ern en^
replacement
I
CO concentration check
t
Normal
ECU replacement
Always check no gas leak from the exhaust piping and no disconnection of the vacuum hose, etc. before starting inspection jobs. lnsaection 1 . CO concentratton check Caution The idling speed and maximum no-load speed shall b e adjusted normally.
C I
J ~ e s tconnector (black wiring)
-Setting the Engine Tachometer
1.
I
2
Measuring the CO concentration (at Idling)
Warm up the engine sufficiently. Standard: Engine cooling water temperature: 65OC (14g°F) or above Hydraulic oil temperature: 50°C ( 1 22OF) or above hAt>il~L~ rloc: r ~ CO ~;c.ricent~dt:on i j l tile C C ~ ~ I I I ~ ~ speecr t o \/i;lrrrl i.p me O2 sensor 1 1 ) Set {tie ~?n:j.nc:I:~c:hor~~t:ler (21 <t?ep tile en(jlnc !trnr,,ri(]at tna n!,~x::r~rirri no ,o;d sl)c~:tlfor 2 nr!nrr:es lo v \ . l ! r r l i ~ p thc o2 Si'n'Or Standard: Exhaust gas temperature: 3 7 0 ° C (698OF) or above. (31 t?etr,ln ro ti;c. ~cd~ir~(j speed ( 4 ) Measure CO concentration.
Standard: CO concentration: 0.2 % or less 3 . Inspect and adjust the carburetor and LPG regulator. If idling speed adjustment is difficult, disconnect the injector connector. ( 1 ) Adjust the LPG regulator idle adjusting screw and carburetor air adjusting screw.
Adjusting Position Measure the CO concentration at full acceleration (at the maximum no-load speed). ( 1) Fully depress the accelerator pedal (to the maximum no-load speed). (2) Measure the CO concentration. Standard: CO concentration: 0.1 % or less
Measuring the Co Concentration (at Full Acceleration)
lnspection 2: Muffler lnspection The durable hours of muffler catalyst function is 2000 hours in principle. 1. Check the muffler operation hours. 2000 hours or more: muffler replacement Less than 2000 hours: To inspection 3
Three-way Catalytic Muffler
.
I
lnspecting the VF Signal Voltage
.
I
lnspection 3: ECU signal voltage (VF) inspection 1 . lnspect the ECU signal voltage (VF). ( 1) Check that vacuum hose and electrical wiring are not disconnected. ( 2 ) Disconnect the ECU check connector. (3) Keep the engine running at the maximum no-load speed for 2 minutes to warm up the 0, sensor. Standard: Exhaust gas temperature: 370°C (698OF) or above ( 4 ) Keep the maximum no-load speed. (5) lnspect the VF signal voltage at the check connector (female s~de). Standard: Between VF and E terminals: Good if the pointer deflects. (The voltage at the time shall be 0 to 12 V.)
VF Check Connector
lnspection 4: Register inspection 1. lnspect the register individually. ( 1 ) Measure the resistance between register connector terminals. Standard: 6 k 0 . 3 Q
lnspecting the Register
Inspection 5: Injector inspection 1. Clean the ejector. ( 1 ) Wipe carbon near the nozzle thoroughly off with cloth. (2) Apply an air pressure of 343 490 kPa (3.5 5 . 0 kglcmz) [ 5 0 71 psi] through the fuel supply port, insert and extract a 41.2 mm (0.047 in) wire to and from the nozzle about 10 times.
-
-
2 mm (0.079 in)
Caution The wire insertion depth shall be within 2.0 m m (0.079 in) from the end face of the nozzle. ( 3 ) Measure the resistance between injector connector terminals. Standard: 3.5 4.5 Q (4) Apply the battery voltage (12 V) to both injector connector terminals and confirm that clicking sound is heard.
Cleaning the lnjector
-
Inspecting the lnjector
Inspection 6: 0, sensor inspection 1. Inspect the 0, sensor function. (1) Check that the vacuum piping and electrical wiring are not disconnected. (2) Disconnect the ECU check connector. ( 3 ) Keep the engine running at the maximum no-load speed for 2 mlnutes to warm up the 0, sensor. Standard: Exhaust gas temperature: 370°C (698OF) or above ( 4 ) Keep the maximum no-load speed. ( 5 ) Inspect the signal voltage from the 0, sensor at the check connector (female side). Standard: Between OXM and E terminals: 1 0 times or morel10 sec (The voltage at the time shall be 0 t o 1 2 V.)
ECU Check Connector
Checking the 0, Sensor Function
3
9
TORQUE CONVERTER
Page
GENERAL ..........................................................
2-2
HYDRAULIC CIRCUIT DIAGRAM ..............................
2 -4
SPECIFICATIONS ...................................................
2-5
......................................................
2-7
..............................................
2-8
TORQUE CONVERTER ASSY ...................................
2-9
REMOVAL .............................................................
2-9
......................................................
2-9
..........................................
2-10
COMPONENTS
TROUBLESHOOTING
DISASSEMBLY
MEASUREMENT TEST
GENERAL One-speed Torque Converter
Torque Converter Sectional View (One-Speed)
-42-
Two-Speed Torque Converter (Option)
Torque Converter Sectional View (Two-Speed) Option
--43-
2- 4
HYDRAULIC CIRCUIT DIAGRAM One-Speed Torque Converter
9 Clutch pressure
Hydraulic Circuit Diagram (One-Speed)
Two-Speed Torque Converter (Option) Clutch pressure
Q
Hydraulic Circuit Diagram (Two-Speed) Option
2- 5
SPECIFICATIONS I-ton vehicle (High speed)
l t o n vehicle ( L o w speed)
I - t o n vehicle (High speed)
I - t o n vehicle (Low speed)
Aisin Seiki
t
t
t
3-speed, single stage, 2-phase
t
t
t
Torque converter designation
AlSlN
t
t
c
Stall torque ratio
2.94
t
2.65
rPm
1900
t
4Y : 2 0 5 0 1DZ : 2 1 0 0
t
Maximum no-load speed rpm
3050
t
4Y : 2 6 0 0 1 DZ : 2 6 0 0
t
Forward 1 st 2nd
1.366
1.628
1.033
1.366
-
-
-
-
Reserve
1.359
1.61 9
1.028
1.359
Speed selection system
Hydraulic
t
t
t
Modulating control pressure kPa (kg/cm2) [psi]
39 392 (0.4- 4.0) 15.7 571
-
t
t
t
Clutch actuating pressure (main pressure) kPa (kglcmz) [psi] Torque converter pressure (outlet pressure) kPa (kglcm2) [psi]
9 81 (I O.O) [ I 421
t
t
t
392 (4.0) [571
t
t
t
14(3.7)
t
t
t
Castle Auto Fluld DII
t
t
t
Gasoline
5K
5K
4Y
4Y
Diesel
-
-
1 DZ
1 DZ
Item Manufacturer Torque converter type
Stall speed
Gear ratio
011capacity
!(Usgal)
011type Connected engine
2-ton vehicle (High speed)
2
- 3 ton vehicle (Low speed)
2-ton vehicle (High speed)
2 - 3 ton vehicle (2nd TIC)
Aisin Seiki
c
t
t
3-speed, single stage, 2-phase
c
t
c
Torque converter designation
AlSlN
c
t
t
Stall torque ratio
2.94
2.65
c
4Y : 2050 1DZ : 2100 1 z : 2200 4Y : 2600 1 DZ : 2600 1Z : 2600
4Y : 2050 1DZ : 2100 1 z : 2200 4Y : 2600 1 DZ : 2600 1Z : 2600
Item Manufacturer Torque converter type
rPm
1900
Maximum no-load speed rpm
3050
Forward 1st 2nd
1.628
1.220
1.154
-
-
-
Reserve
1.619
1.214
1.148
1.214
Speed selection system
Hydraulic
t
t
c
Modulating control pressure kPa (kglcmz) [psi1
3 9 392 (0.4- 4.0) r5.7 571
-
t
t
e
Clutch actuating pressure (main pressure) kPa (kglcmz) [psi] Torque converter pressure (outlet pressure) kPa (kglcm2) [psi]
981 (I O.O) [ I 421
e
e
t
392 (4.0) [571
e
t
t
14(3.7)
t
c
t
Castle Auto Fluid DII
t
t
t
Gasoline
5K
4Y
4Y
4Y
Diesel
-
1 DZ.1Z
1 DZ.1 Z
1Z
Stall speed
Gear ratio
Oil capacity
!(Usgal)
Oil type Connected engine
t
t
1.474 1.040
COMPONENTS
Torque Converter Components
Only the items related to the torque converter is covered here. For other items (related to transmission and control valve), refer to the exlsting 5FGI5FD 1 0 Manual (No. CEO01- 1 ) . Symptom 1 Lack of gradeab~lltyand tractlve abillty (rnsufflc~ent power) Due to torque converter not generating torque
2. Overheat
I
Inspection method
I
- 3 0 Repair
Judgement and corrective action
Stall speed Standard 4Y 2 0 5 0 rpm 5K 1 9 0 0 rpm 1DZ 2 1 0 0 rpm 1Z 2 2 0 0 rpn) The stall speed may be deviated by about 1 0 0 rpm from the standard value above because of slight dispersions in engine and torque converter performances and their subtle match. ing. Use the values above, therefore, only as reference.
a Too low stall speed ( 3 0 0 rpm or more below the standard) 0 The one-way clutch of the stator 1s slipplng Replace the torque converter ASSY
2 . 1 Torque converter inspection
a. Torque converter defect 0 Stator sticking Replace the torque converter ASSY. 0 Impeller contact + Judge from the oil filter. Replace the torque converter ASSY if defective. 0 Reduced circulating flow rate -P Clogging of stator shaft orifice, etc. + Disassemble, inspect and replace.
-+
b. Too high stall speed O T h e clutch is slipping excessively. -t Disassemble, inspect and replace the clutch.
-+
I
TORQUE CONVERTER ASSY REMOVAL 1
Remove the englne wltorque converter ASSY SST 09010-201 11-71
2.
D~sconnectthe drive plate ( 1) Set bolt
Removing the Engine w1Torque Converter ASSY
Caution Apply a ring spanner on the engine crankshaft set bolt and rotate the crankshaft clockwise t o rotate the converter.
Disconnecting the Drive Plate
DISASSEMBLY 1.
Remove the torque converter ASSY ( 1 1 Torque converter Assy
Caution 0 Carefully operate not to damage the pump impeller extension pawl when the torque converter ASSY comes off from the stator shaft. 0 Be careful as t h e removed torque converter ASSY contains oil. 0 The torque converter ASSY cannot be disassembled.
Removing the Torque Converter ASSY
MEASUREMENT. TEST 1.
011Ievt?. rrlo;js~rrelncr,l t 1 r Keep me vcn1c.c: In level state, and place the control levsr In rne neutral ~ o s ~ t ~roo r ; ~er-!p the enylne runnlrlg a t tnt: rillnq spec:d
121 After walri I,(] L I ~ kcep , rne t?nginc ~dlrig stale ;nfl nleasure rhu 011levt:, w.th tne lev(:I gauyt: Tne o I levei s aopropr~ate~f bctwt:cn tne tlooer l ~ r nt IFI and lower . ~ n i (~L t) Oil pressure measurement ( 1 ) After warnrng up the engine, measure the rdlrng speed and maximum no-load speed 8
Measuring the Oil Level
2.
I
1
ter
7
Caut~on If the speeds do n o t satisfy the standards, carry out engine tune up. ( 2 ) Stop the englne after adjusting the speeds
ector (black wlrlng) Setting the Engcne Tachometer
I
Engine
1
t
1 DZ
I
1Z
I
Vehicletype
I
Idling speed
I Maximum no-load speed I + 5 0 rpm 3050 +50 r ~ r n
+?rpm
I -ton veh~cle
650
2-ton vehicle
7 5 0 +?,O r ~ m
I -ton vehicle
700
2 6 0 0 t 5 0 rpm
213-ton veh~cle
+Frpm 7 5 0 '+: rpm
2600
I -ton vehrcle
7 5 0 + 2 5 rpm
2 6 0 0 1 5 0 rpm
2-ton vehicle
700
i0 rpm
+ 5 0 rpm 2 6 0 0 + 5 0 rpm
213-ton vehicle
I
750
+
+ 2 5 rpm
3050
+ 5 0 rpm
2600
I
1
13) Jack up the front axle untll tlres (both wheels) leave the ground ( 4 ) Remove the toe board and set the o ~presl sure gauge ( 5 ) Place the control lever In the neutral posltron and start the englne Measure the maln pressure and torque converter pressure In thrs state ( 6 ) Shrft the control lever to each of the forward and reverse posrtions, and measure the clutch actuatrng pressure Oil Pressure Gauge Installing Position
-50-
-
-
Caution 0 Use an oil pressure gauge for about 20 kgIcm2. 0 When measuring the oil pressure, do not operate the ~nchingand brake pedals. (Only on a vehicle provided w i t h the power assisted brake.)
-
Main pressure kPa (kgicm2) [psi]
-
490 834 (5.0- 8.5) [71 1211
932 1373 ( 9 . 5 - 1 4 . 0 )[135-1991
-
t
-
Torque converter pressure kPa (kgIcm2) [psll
196 588 ( 2 . 0 - 6 . 0 ) [28-851
Clutch pressure kPa (kgicm2) Ipsil
441 834 ( 4 . 5 - 8 . 5 ) L64.0- 1211
-
3.
-
883 1373 ( 9 . 0 - 14.0) [ 1 2 8 - 1991
Stall test ( 1) Check the front and real wheels perfectly, load a cargo near the allowable load, and apply the parking brake suffic~ently. Caution Keep the vehicle perfectly in the stationary state. Stretch wires t o keep the vehicle immovable for safety.
( 2 ) Warm up the englne and measure the idling speed and maximum no-load speed.
( 3 ) Measure the engine output by the maxi-
Checking the Maximum Loaded Speed
Checking the Maximum Loaded Speed Maximum loaded speed Gasoline engine vehicle 1 5 0 300 rpm d o w n from the maximum no-load speed Diesel engine vehicle 100 200 rpm d o w n from the maximum no-load speed
-
-
mum loaded engine speed. [Method] After adjusting the maximum no-load speed, operate the tilt lever to the forward or backward tilting position and measure the maximum speed at full acceleration in relief state. (Maximum loaded speed measurement) [Judgement] If the engine speed drops excessively, perform engine time-up because the adjustment is improper.
141 Starl the englne S h ~ f tthe control lever to the forward or reverse posltlon Depress the accelerator fully and measure the speed when the englne speed 1s stablllzed (stall speed)
1 Z englne
Itern Stall speed I
Max~rnurnno-load
Stall Test
All veh~cles 1 9 0 0 rprn All veh~cles
All veh~cles 2 0 5 0 rpm I
I I
All veh~cles
All vehlcles 2 2 0 0 rprn
All veh~cles 2 1 0 0 rprn I
All veh~cles
All veh~cles 6 0 0 1 5 0 rprn
OTHER MODIFICATIONS
Page CLUTCH ............................................................... CLUTCH PEDAL
................................................. 3-2
CYLINDERS ( 1-TON VEHICLE) .................................
.
LlFT CYLINDERS (V-SV) REAR LIFT CYLINDERS (FSV-FV) .......................... GENERAL .......................................................... SPECIFICATIONS ................................................ INSPECTION
......................................................
FRONT LIFT CYLINDERS (FSV-FV) ........................ GENERAL .......................................................... SPECIFICATIONS ................................................ INSPECTION
......................................................
OIL PUMP (1-TON VEHICLE) ................................... GENERAL .......................................................... SPECIFICATIONS ................................................ COMPONENTS
3-2
...................................................
MATERIAL HANDLING SPEED ( 1-TON VEHICLE) .... OIL CONTROL VALVE ............................................ GENERAL .......................................................... SPECIFICATIONS ................................................ COMPONENTS ...................................................
3-3
CLUTCH CLUTCH PEDAL
Turnover spring
Clutch Pedal Mechanism
A turnover mechanism is added to the clutch pedal for the I -ton series 4 Y engine vehicles and 1 DZ engine vehicles to reduce the pedal depressing force. The pedal height, pedal play and other adjustment values remain unchanged.
CYLINDERS (1-TON VEHICLE) LlFT CYLINDERS (V-SV). REAR LlFT CYLINDERS (FSV-FV) GENERAL
Lift Cylinder Sectional View (V.SV Mast)
Rear Lift Cylinder Sectional View (FSV Mast)
5 5 -
Rear Lift Cylinder Sectional View (FV Mast)
SPECIFICATIONS
.
Lift Cylinders (V-SV) Rear Lift Cylinders (FSV-FV) Item
V.SV mast
FSV mast
FV mast
Single actlng type
t
t
mm (in)
45.0 (1.772)
c
t
Piston rod o u t s ~ d ediameter m m (in)
35.0 (1.378)
t
32.0 (1.260)
Piston seal type
U-pack~ng
t
Wear ring
Rod seal type
U-pack~ng
t
t
With flow regulator valve (RH) With safety down valve (LH)
+
t
Cylinder type Cylinder bore
Others
INSPECTION
I
1.
Inspect the lift cylinder ( 1 ) Wear of cylinder bore Standard cylinder bore: 4 5 . 0 m m (1.772 in) Cylinder bore wear limit: 45.20 m m ( 1 . 7 8 0 in)
2.
Inspect the piston rod. ( 1 ) Wear of piston rod outside diameter Standard piston rod outside diameter V.SV.FSV: 35.0 m m (1.378 in) FV: 32.0 m m (1.260 in) Piston rod outside diameter wear limit V.SV.FSV: 34.92 m m (1.3748 in) FV: 31.92 m m (1.2567 in) (2) P~stonrod bend Piston rod bend limit: 2.0 m m (0.079 in)
I
lnspecting the Cylinder Bore
lnspecting the Piston Rod
FRONT LIFT CYLINDERS (FSV-FV) GENERAL
Front Lift Cylinder Sectional View (FSV Mast)
Front Lift Cylinder Sectional View (FV Mast)
-58-
3-7
SPECIFICATIONS Front Lift Cylinders (FSV-FV) Item Cylinder type
FSV mast
FV mast
Single acting type
+
Cylinder bore
m m (in)
85.0 (3.346)
+
Piston rod outs~dediameter
mm ( ~ n )
70.0 (2.756)
t
Piston seal type
Wear ring
t
Rod seal type
U-packing
+
With safety down valve
t
Others
INSPECTION 1.
Inspect the lift cylinder. ( 1 ) Wear of cylinder bore Standard cylinder bore: 85.0 m m (3.346 in) Cylinder bore wear limit: 85.40 m m (3.362 in)
2.
Inspect the piston rod. ( 1 ) Wear of p~stonrod outside diameter Standard piston rod outside diameter: 70.0 m m (2.7524 in) Piston rod outside diameter wear limit: 69.91 m m (2.752 in) ( 2 ) Piston rod bend Piston rod bend limit: 2 . 0 mrn (0.079 in)
lnspecting the Lift Cylinder Bore
lnspecting the Piston Rod
OIL PUMP (1-TON VEHICLE) GENERAL
Oil Pump Sectional View
SPECIFICATIONS 5K
4Y
1 DZ
Kind of oil pump
Single pump
t
t
Manufacturer's model
KZP4-21 C
KZP4-23C
t
Oil pump type
Gear pump
t
t
Theoretical discharge rate cclrev (in'lrev)
21 .O (1.282)
22.9 (1.397)
t
30.2 (7.97)
32.8 (8.66)
t
PTO gear type
+
t
Discharge rate
Drive type
dmin (USgallmin) (pump at 1500 rpm)
3-9 COMPONENTS
Oil Pump Components
-61 -
MATERIAL HANDLING SPEED (1-TON VEHICLE) V-SV Mast Engine model
Oil pump model
Lowering speed rnrnlsec (f.p.m.)
Lifting speed rnrnlsec (f.p.rn.) No load
Loaded
No load
Loaded
5K
KZP4-21 C
600 ( 118)
570 (112)
550 (108)
500 (98)
4Y
KZP4-23C
630 (124)
580 (114)
?
t
1 DZ
KZP4-23C
670 (132)
640 ( 128)
t
T
FSV Mast Eng~ne model
Oil pump model
L~ftingspeed rnmlsec (f.p.m.)
Lowering speed rnrnlsec (f.p.rn.)
No load
Loaded
No load
Loaded
5K
KZP4-21C
580 (114)
550 (108)
400 (79)
480 (94)
4Y
KZP4-23C
610 (120)
550 (108)
T
t
1 DZ
KZP4-23C
640 (126)
610 (120)
T
T
FV Mast Engine model
011pump model
Lifting speed rnrnlsec (f.p.rn.)
Lowering speed rnmlsec (f.p.rn.)
No load
Loaded
No load
Loaded
5K
KZP4-21 C
570 ( 112)
540 (106)
400 (79)
480 (94)
4Y
KZP4-23C
600 ( 118)
540 (106)
T
t
1 DZ
KZP4-23C
640 (126)
600 (118)
t
T
OIL CONTROL VALVE GENERAL --
-
-
Oil Control Valve Sectional View
SPECIFICATIONS I-ton vehicle
Item Oil control valve type
Relief pressure
Add-on type Lift
171 60 ( 175) [24901
Tilt
11770 (120) [I7101
kPa (kglcm*) [psi]
9.5 (2.51) [4Y: 13.0 ( 3 . 4 3 ) l flow r rate Flow d ~ v ~ d e
Plmin (USgalIm~n) 13.0 (3.43) (OPT: CHPS vehicle)
Spool outside diameter
mm (in)
16.0 (0.630)
Stroke
mm ( ~ n )
7.0 (0.276)
Others
With built-in flow divider and tilt lock valve
COMPONENTS
Oil Control Valve Components
-64-
[EXPLANATION] THREE-WAY CATALYTIC EXHAUST EMISSION CONTROL SYSTEM
Page GENERAL ..............................................................
4-2
GASOLINE ENGINE EXHAUST EMISSION CONTROL SYSTEM .............................
4-3
LPG ENGINE EXHAUST EMISSION CONTROL SYSTEM .............................
4-12
E
GENERAL As exhaust gas causes a c ~ dram, photo chemlcal smog, destruction of the ozonosphere and other environmental problems, decrease of harmful CO, HC and NOx in the exhaust gas has become a global problem. To cope with such social requirement and environmental problems, a three-way catalytic exhaust emission control system, featuring higher purge performance than the conventional two-way catalytic emission control system, has been developed both for gasoline engines and LPG fueled engines. Purge Performance (reduction ratio of each pollutant after catalyt~cmuffler to that before the muffler)
-
__
Two-way catalyt~cmuffler
Theree-way catalytic muffler
CO (carbon monoxide)
90%
95%
T.HC (total hydro carbon)
80%
95%
-
95%
NOx (nitrogen oxides)
\
Note: For LPG englne vehicles, the three-way catalytic muffler is adjusted to the fuel consisting of 25% propane and 7 5 % butane. The purge performance is slightly lowered when the propane-butane ratio In the fuel is varied.
GASOLINE ENGINE EXHAUST EMISSION CONTROL SYSTEM LIST OF GASOLINE ENGINE EXHAUST EMISSION CONTROL SYSTEMS Object~ve-function
Standard settlng
System
Reduction of CO, HC and NOx (Monolithic platinumrhodium type catalyst)
-
Three-way catalytic muffler
Air-fuel ratio controller Carburetor ABCV (Air Bleed Control Valve) Idle switch Engine cooling water temperature switch H ~ g hload detecting vacuum switch O2 sensor ECU (Erniss~onControl Unit)
Controlling the air-fuel ratio at around the theoretical level
Main: 5.0Plmin Slow: 3.2Plrnin 1 2 0 0 rpm. 65°C 1 0 0 rnrnHg
Purge of HC and recirculation of blowby gas
-
Crankcase emission control system (in standard vehicle)
GASOLINE ENGINE EXHAUST EMISSION CONTROL SYSTEM DIAGRAM
Air
O2 sensor
z'
garburetor Idling switch Vacuum switch
Intake manifold Water temperature switch Three-way catalytic muffler Engine
Gasoline Engine Exhaust Emission Control System
6 7 -
11I I1
4- 4
WORKING PRINCIPLE AND PERFORMANCE OF GASOLINE ENGINE EXHAUST EMISSION CONTROL SYSTEM Working Principle The ECU judges whether the air-fuel mixture is richer or leaner than the theoretical ratio according to the signal from the 0, sensor Installed In the exhaust man~fold,and sends the corresponding signal to the ABCV. The ABCV controls the intake air flow to the slow and main air bleeds to control the fuel-air mixture taken into the combustion chamber at around the theoret~calratio. Thus the CO, HC and NOx centents in the exhaust gas is purged effectively by the three-way catalyst.
Equation CO HC NOx
2CO + 0, m CnHm + ( n +-) 4 2 N 0 + 2C0
2C02 m nCO, + (-) 2 + N, + 2C0 -t
0,
+
H20
Ox~dation Reduct~on
Exhaust Emission Control Performance Purge ratlo: 95% or more for each of CO, HC and NOx contents
Power operation range . .
ngine performance curve
Toraue '
I
range
\
Idling range I
Engine speed (rpm)
>
Exhaust Emission Control Performance Chart
Note: The air-fuel ratio control range is other than the hatched portion (power operation range). The air-fuel ratio is not controlled in the power operation range t o ensure the output.
4- 5
THREE-WAY CATALYTIC MUFFLER Structure Baffle board
Inter-ram mat
Straightening vanes
Outlet Three-way Catalytic Muffler Sectional View The main body is made of stainless steel excellent In heat reststance and anticorrosion. Monolith~cplatinum-rhodium type three-way catalyst is packed Inside to decrease the CO, HC and NOx contents
Operation 1.
The exhaust gas flow from the gasoltne englne is stra~ghtenedby the straighten~ngvanes and enters the monolithic catalyst chamber. 2. The CO and HC contents in the exhaust gas are decreased by ox~dationw h ~ l ethe NOx content is decreased by reduct~onupon contact with the catalyst at the surface of monol~thichoneycomb, resulting in harmful gas purge.
Maintenance Replace the three-way catalyttc muffler every 2000 hours Three-way Catalyst
1
High
T
Thts catalyst is suitable for simultaneous purge of the CO, HC and NOx contents in the exhaust gas. As shown at left, the air-fuel ratlo should be maintained near the theoretical level to obtain h ~ g hpurge ratios for the CO, HC and NOx contents. The air-fuel ratlo controller, therefore, controls the
Conforming range of air-fuel ratio
Purge % ratio
1
Low ,qich Air-fuel, ratio
air-fuel ratio around the theoretical level. Lean
Three-way Catalytic Muffler Sectional View
69
-
4- 6
AIR-FUEL RATIO CONTROL ECU Input-Output Connection Diagram ECU ABCV FCMl O1 Sensor
FCM2
70 (1 /phase
FCM3
Air blead control valve (ABCV)
FCM4.
- i-q-w r-,"E --
Eng~necool~ngwater temperature switch
Hlqn
R~chileanslgnal for check
RiL
-
Vacuum switch
r*F;;-)-pwR
ldllng swrtch
r-;r23
4
ABCV slgnal for check
A
ACBV +B
-
4,
i
IG s w ~ t c h
r Fuse
lDL E
I
I
Battery 11 2 V ) (1)
Hugh load (2)-
W ~ d ethrottle openlng
Input-Output Connection Diagram
Connector Pin Arrangement OX
E1
[Fi
FCM4 FCM3
FCM2 FCM 1
7
1 E
ABCV
PWR
IDL
+B
WTR
R /L
Air-Fuel Ratio Control Conditions
z
.-w0
2
m
.C
9
1. No air-fuel ratio control
Normal control
[ o*:e
r 0
C .-
2
5
0
m >
m
.4-
Open
I
2.
Idling control
Close
Engine cooling water temperature switch
3.
The air-fuel ratio control is not performed when the cooling water temperature is below 60°C (during automatic choke operation). (Priority is given to engine warm-up in this state.) When the negat~vepressure in the intake manifold IS -100 mmHg or less (in absolute value), the air-fuel ratio is not controlled(to ensure the output in the power operation range). When the cooling water temperature IS at or above 6 0 ° C and the negative pressure in the intake manifold is -100 mmHg or above, normal air-fuel ratio control is performed if the idling switch is closed and idling air-fuel ratio control IS performed if the idling switch is open. In the idling air-fuel ratio control, the control is slower than in the normal air-fuel ratio control to prevent hunting.
Operation Timing Diagram and Air-Fuel Ratio Control Constants 1v
O2 sensor
I I
0v Rich
Lean
comparator output
TFR Richllean signal
ABCV operation
I , T~~
Air-fuel ratio
I
I
(TI!)
I
Rich
Operation Timing Diagram and Air-Fuel Ratio Control Constants
vR
: 0,sensor comparator output
Tl(Tll) KPL-KPR TFR.TFL TDO.TDC
: ABCV step count d r ~ v espeed constant : Skip constants : 0,sensor lnverslon delay constant : ABCV step lnverslon delay constant
Note: In the idling air-fuel control, TI, applies in place of TI and K,
and K,
are not set.
4- 8
CARBURETOR Carburetor Specifications \
Engine
\
5K
4Y
Inside diameter (rnm)
44.5
44.5
Outside diameter (rnrn)
50.0
50.5
Large ventury
Inside diameter ( m m )
23
23
Small ventury
Inside diameter (mrn)
11.8
11.8
Outside diameter (rnrn)
16
16
Main jet diameter (rnrn)
(1.22)
(1.07)
Primary main air bleed diameter (rnrn)
(0.55)
(0.60)
Slow jet diameter (mm)
0.49
0.47
Slow air bleed diameter No.2 (body) (rnrn)
0.55
0.55
Slow alr bleed diameter No.1 (air horn) (rnrn)
(1.10)
(1.00)
Slow economizer diameter (rnm)
1.10
1. I 0
Idle port dlameter ( m m )
1.2
1.4
Negative pressure operation type
Negative pressure operation type
Power jet diameter (rnm)
(0.4)
(0.4)
Pump diaphragm diameter (rnm)
20
20
Pump jet diameter ( m m )
0.45
0.45
Pump stroke ( m m )
2.15
2.15
Delivery (at throttle opening of 6 0 deg) (cclsl)
0.39
0.39
Oil level height (from top to body) (mm)
20.0
20.0
Float adjusting dimensions
Lip clearance (mrn)
1.20
1.20
Tare dimension (mrn)
5.50
5.50
Fully closed angle (deg.)
7
7
Fully opened angle (deg.)
90
90
Wax type auto choke
Wax type auto choke
Valve fully closed angle (deg.)
15
15
Maln air bleed flow rate (dmin)
(5.0)
(5.0)
Slow air bleed flow rate (Urnin)
(3.2)
(3.2)
Item Alr horn diameter
Main l ~ n e
Slow llne
Power line
Acceleration line
Float system
Throttle valve Choke system
(ABCV)
(
Type
TYpe
) : Dimension different from standard vehlcle
Carburetor Exterior Views
Carburetor Exterior Views
ABCV The ABCV installed on the carburetor is driven in a range between 0 step and 100 steps according t o the signal from the ECU to vary the air bleed flow rates in the slow and maln lines for air-fuel ratio control A motor IS prov~dedin the ABCV, and the rotating direction and angle are controlled by the signals from the ECU. The motor rotat~onis changed to the needle linear motion via the w o r m to control the air bleed flow rate.
ABCV Sectional View
A
\
Idling switch adjusting bolt Adjusting the Idling Switch Installation
Idling Switch The idling switch mounted on the carburetor is opened and closed by the Idling switch adjust~ngbolt at the throttle to send a signal to the ECU for idling detection. Set the switch at the position so that it IS closed when the engine speed IS at or above 1 2 0 0 rpm, and is opened when the engine speed is less than 1 200 rpm.
COOLING WATER TEMPERATURE SWITCH Water Temperature Switch Exterior View
Water Temperature Switch Exterior View
Operation 65+3OC
Open (OFF)
Close
(ON)
58OC MIN
When the cooling water temperature rlses to approx. 60°C, the water temperature switch is turned o n the send a signal to the ECU for fuel-a~rratio control. The operation characteristic of the water temperature switch is as shown in the figure at left.
HIGH LOAD DETECTING VACUUM SWITCH
Open air close
O N
1 7
0 mmHg
- 100 mmHG
open (OFF)
Operation Vacuum Switch Section
The Vacuum switch detects the negative pressure in the intake manifold and send a signal t o the ECU to stop air-fuel ratio control (ABCV: 0 step) when the load is high (at -100 m m H g or less).
O2 SENSOR O2 Sensor Exterior View 0 -0.6
Width across flats 22
M18x 1.5
--
0, Sensor Exterior View
v Rich signal
I'
Reference voltage
I
I
High Little
0 2
Much
1 Low
Rich-Air-fuel
-
Lean
Operation
The 0,sensor Installed in the exhaust pipe detects the oxygen (0,) concentration In the exhaust gas. When the air-fuel mixture is leaner than the theoret~calratio, the air requ~redfor fuel combust~onis suffic~entand much oxygen is contained in the exhaust gas. When the air-fuel mixture is r~cherthan the theoretical ratlo on the contrary, almost no oxygen is contained in the exhaust gas. Threfore, it is possible to judge whether the air-fuel m ~ x t u r eis richer or leaner than the theoretical ratlo. When the fresh air with high oxygen concentration
is led inside the 0,sensor and the exhaust gas w ~ t h l o w oxygen concentration IS led outs~deof the 0, sensor, the electromotive force of the 0, sensor increases as the air-fuel mixture becomes sensor and decreases at ~t becomes leaner. Note: The 0, sensor starts t o operate at about 370°C or above.
I
0, Sensor Output Characteristic
7 5
LPG ENGINE EXHAUST EMISSION CONTROL SYSTEM LIST OF LPG ENGINE EXHAUST EMISSION CONTROL SYSTEM System
Standard setting
Objective-function
-
Decrease of CO, HC and NOx contents (Monol~thicplatinum-rhodium alloy catalyst)
Three-way catalyt~cmuffler
Control of air-fuel ratio at around theoretical ratio
14Ylmin
Air-fuel ratio controller Carburetor Regulator set Injector O2 sensor ECU
-
Crankcase em~ssioncontrol system (standard veh~cle)
Purge of HC by recombustion of crankcase emission gas
LPG ENGINE EXHAUST EMISSION CONTROL SYSTEM
Air
pacer for injector
ntake manifold
Engine
LPG Engine Exhaust Emission Control System
WORKING PRINCIPLE AND PERFORMANCE OF LPG ENGINE EXHAUST EMISSION CONTROL SYSTEM Working Principle The ECU judges whether the alr fuel mlxture IS r~cheror leaner than the theoret~calratlo accord~ngto the slgnal from the 0, sensor Installed In the exhaust man~fold,and sends the correspond~ngslgnal to [he LPG Injector The LPG ~njectorcontrols the LPG fuel flow to the Intake manlfold for controll~ngthe alr-fuel m ~ x t u r enear the theoretlcal ratlo Thus, the CO, HC and NOx contents In t h exhaust ~ gas are purged e f f ~ c ~ e n tby l y the threeway catalyst
Equation
C0 HC NOx
2CO + 0, m CnHm + ( n +-I 4 2 N 0 + 2C0
2C0, m nCO, + (--i H 2 0 2 + N2 + 2 C 0
-t
0,
+
1
Oxdnt~on
Reduction
Exhaust Emission Control Performance Purge ratlo: 95% or more for each of CO, HC and NOx contents
Power operation range Englne performance curve
Torque range Idling range
Engine speed (rpm)
Exhaust Emission Control Performance Chart
Note: The air-fuel ratio control range is other than t h e hatched portion (power operation range). T h e air-fuel ratio is n o t controlled i n t h e p o w e r operation range t o ensure t h e output. The air-fuel ratio is n o t controlled i n t h e idling range t o prevent hunting o f t h e idling engine.
4-14
THREE-WAY CATALYTIC MUFFLER Structure
Three-way Catalytic Muffler Sectional View
The main body is made of stainless steel excellent in heat resistance and anticorrosion. Monolithic platinum-rhodium type three-way catalyst is packed inside to decrease the CO, HC and NOx contents.
Operation 1. 2.
The exhaust gas flow from the LPG engine is straightened by the straightening vanes and enters into the monolithic catalyst chamber. The CO and HC contents in the exhaust gas are decreased by oxidation while the NOx content is decreased by reduction upon contact with the catalyst at the surface of monolithic honeycomb, resulting in harmful gas purge.
Maintenance Replace the three-way catalytic muffler every 2000 hours
Three-way Catalyst High
Conforming
t
This catalyst is suitable for simultaneous purge of the CO, HC and NOx contents in the exhaust gas. As shown at left, the air-fuel ratio should be rnaintained near the theoretical level to obtain high purge ratios for the CO, HC and NOx contents. The air-fuel ratio controller, therefore, controls the air-fuel ratio around the theoretical level.
/ range of a~r-fuelratio
Purge % ratio
i
Low
Rich t Air-fuel t ratio
Lean
Three-way Catalytic Muffler Performance Curves
-78-
AIR-FUEL RATIO CONTROL ECU Input-Output Connection and Block Diagram
.--.-.-.-------------,OX
RIL monitor
I :
Input-Output Connection Diagram
Connector Pin Arrangement
E01
OXM
VSW2
Operation Timing Diagram and Air-Fuel Ratio Control Constants
0, sensor
VR I
RichILean signal (VR/L) OIL signal (VOP)
Lean
I -I
Rich
--
/
I
I
1 Lean
Rich
-
Corresponds
VF monitor (VF) to TI.
Corresponds P to To.
Detail (Enlar ement of time
axis?
I
I
Operation Timing Diagram and Air-Fuel Ratio Control Constants
@ symbol In the f ~ g u r eabove shows that inltlal set To (initial set lnjectlon time) is selected as the VF waveform when the alr-fuel ratlo is not controlled (Vop), and integration waveform (KR-KL-P) IS selected as the VF waveform when the alr-fuel ratlo is controlled ( V o p = O ) . : 0,sensor reference voltage VR F : Oscillation frequency : Maximum injection tlme Tmax : Resistor short-clrcu~ttime Tp : Initial injection tlme setting To : lnjectlon time integration constant KR KL P TI
: Injection time Integration constant
: Skip : Invalid lnlectlon time
CARBURETOR The LPG carburetor for a~r-fuelratio control 1s different in the flow rate characterist~cfrom the one for the standard vehicle. S ~ n c ethey cannot be dlstingu~shedby appearance, check the part No.
Carburetor body
Power screw
Power Screw Opening Limiter (4Y Engine)
Only the carburetor for the 4 Y engine has the power screw opening l ~ m ~ t e (made r of r e s ~ n ) T h ~ sIS provided to change the power screw openIng according to the difference in composition of LPG in Japan and abroad. (The power screw opening limiter is not provided for the 5K engine carburetor.)
-
-
-
REGULATOR SET Regulator Set Exterior View and Regulator Sectional View Main solenoid
/
Union L.PG iniector
High performance filter
/
Union for -PG injector
/ Carburetor main line
Fuel hose injector
v
t
S I O ~fuel hose
LPG
Hot water hose Regulator Set and Regulator Sectional View
Structure A fuel unlon for the Injector 1s ~nstalledon top of the regulator for alr fuel ratlo control The fuel unlon for the Injector 1s connected to the prlmary chamber In the regulator The fuel unlon ejector d~ameterof the regulator for alr fuel ratlo control IS d~fferentfrom the one on the standard veh~cle Fuel E n ~ o nEjector Diameter
Unit: m m
Eng~ne Standard vehicle
Air-fuel ratio control
3.0
2.5
diameter
Fuel Union
4- 19
LPG INJECTOR LPG lnjector Sectional View
I
I
LPG Injector Sectional View
Operation The LPG injector is installed o n the LPG injector spacer between the governor and intake manifold. The LPG injector injects the fuel Into the intake manifold according to the duration of the signal from the ECU to control the air-fuel mixture at around the stoichiometric air-fuel ratio.
4-20
O2 SENSOR O2 Sensor Exterior View 0 Widthe across flats 22-0,6
M18x 1.5
0,Sensor Exterior View
v Rich signal
I
I
I
Reference voltage
I
Rich-Air-fuel- Lean
I
0, Sensor Output Characteristic - 84
Operation The 0,sensor installed in the exhaust pipe detects the oxygen (0,) concentration in the exhaust gas. When the air-fuel mixture is leaner than the theoretical ratio, the air required for fuel combustion is sufficient and much oxygen is contained in the exhaust gas. When the air-fuel mixture is richer than the theoretical ratio on the contrary, almost no oxygen is contained in the exhaust gas. Threfore, it is possible to judge whether the air-fuel mixture is richer or leaner than the theoretical ratio. When the fresh air with high oxygen concentration is led inside the 0,sensor and the exhaust gas with low oxygen concentration is led outside of the 0, sensor, the electromotive force of the 0,sensor increases as the air-fuel mixture becomes sensor and decreases at it becomes leaner. Note: The 0, sensor starts t o operate at about 370°C or above.
APPENDIX
Page
SST LIST ..............................................................
5-2
SERVICE STANDARDS ...........................................
5-3
ENGINE .............................................................
5-4
TORQUE CONVERTER ......................................... 5-5 MATERIAL HANDLING SYSTEM ........................... 5-6 ELECTRIC WIRING DIAGRAM .................................. 5-7 THREE-WAY CATALYTIC EXHAUST EMISSION CONTROL SYSTEM WIRING DIAGRAM ................. 5-13 CONNECTOR DRAWINGS .................................... 5-9
SST LIST Sect~on Part name
1
2
Part No 1
lllustrat~on
i'"
09010-201 11-71
Englne unlt hanger
0
3
4
SERVICE STANDARDS ENGINE
-
I.O-ton 3.0-ton vehicles
Item Gasoline exhaust emission control system (three-way catalyst) Standard
0 . 2 % or less
In pressed state
Standard
No conduction ( 10 MQ or more)
In released state
Standard
Conduction ( 3 0 0 Q or less)
Less than 1 2 0 0 f 5 0 rpm
Standard
No conduction
CO concentration (at idling) Idle switch conduction
ldle switch conduction
1 2 0 0 f 5 0 rpm or more
CO concentration (at maximum no-load speed) Three-way catalytic muffler Water temperature sensor conduction
Vacuum switch conduction
ABCV signal voltage
Standard
Conduction
Standard
0 . 5 % or less
Limit
2 0 0 0 hours
58' C or below
Standard
No conduction ( 1 M Q or more)
6 5 " C or less
Standard
Conduction ( 0 . 5 Q or less)
- 1 0 0 f 2 0 mmHg or below
Standard
No conduction ( 1 MQ or more)
- 7 0 f 2 0 rnmHg or above
Standard
Conduction ( 0 . 7 Q or less)
Between ABCV and E terminals
Standard
Good if the pointer deflects (voltage at the time: 0 - 12 Vl
Between @ B ( @ ) and F C M l
Standard
70f5 Q
Between @ B ( @ ) and FCM3
Standard
70+5 Q
Between @B(@) and FCM2
Lim~t
70f5 Q
Between @ B ( @ ) and FCM4
Standard
70f5 Q
Between body and F C M l
Standard
No conduction ( 1 0 M Q or rnore)
Between body and FCM2
Standard
No conduction ( 1 0 M Q or more)
Between body and FCM3
Standard
No conduction ( 10 M Q or rnore)
Between body and FCM4
Standard
No conduction ( 10 M Q or rnore)
Between RIL and E terminals
Standard
10 tlmes or morel10 sec (Voltage at the 0 - 1 2 V,
CO concentration (at i d l ~ n g )
Standard
0 . 2 % or less
CO concentration (at maximum no-load speed)
Standard
0 . 1 % or less
ABCV signal voltage
Conduction between ABCV body and motor coils
0, sensor signal voltage
LPG exhaust emission control system (three-way catalyst)
531ECU signal voltage
Between VF and E terminals
Standard
Good ~f the pointer deflects (Voltage at the time: to 12 V )
Register conduction
Between connector terminals
Standard
650.3 Q
Injector conduction
Between connector terminals
Standard
3.5- 4.5 0
Between OXM and E terminals
Standard
10 times or morel10 sec (Voltage at the time: 0 12 V)
0, sensor signal voltage
-
5- 4
TORQUE CONVERTER
-
I.O-ton 3.0-ton vehicles
Item Torque converter
rPm -
Stall speed
Max~mumno-load speed
rpm
Main pressure kPa(kglcm2) [psi]
Clutch pressure kPa(kglcm2) [psi]
Torque converter 011pressure kPa (kglcmz) [psi] Torque converter oil capacity
5K engine
Standard
1900
4Y engine
Standard
2050
1 DZ engine
Standard
2100
1Z engine
Standard
2200
5 K engine
Standard
3050
4Y engine
Standard
2600
1 DZ engine
Standard
+ 50 + 50 2600 + 50
1Z engine
Standard
2600 k 5 0
at idling
Standard
490 834 ( 5 . 0 - 8 . 5 ) [71 121 I
at 2000 rpm
Standard
932 1373 ( 9 . 5 - 14.0) [135- 1991
at idling
Standard
44 1 834 ( 4 . 5 - 8 . 5 ) L64.0- 1211
at 2000 rpm
Lim~t
883 1373 ( 9 . 0 -14.0) [ I 2 8 - 1991
at idling
Standard
196 588 (2.0-6.0) 128-851
at 2000 rpm
Standard
196- 588 (2.0- 6.0) [28 851
Standard
14 (3.7)
[(Usgal)
-
-
-
-
-
-
-
MATERIAL HANDLING SYSTEM I .O-ton - 3.0-ton
Item
vehicles
Rear lift cylinder ( 1-ton vehicle) m m (in)
Cylinder bore
Piston rod outside diameter
Piston rod bend
Standard
45.0 (1.772)
Limit
45.20 (1.780)
Standard
V.SV:35.0 (1.378) FV:32.0 (1.260)
Limit
V.SV:34.92 (1.3748) FV:31.92 (1.2567)
Limit
2.0 (0.079)
Standard
85.0 (3.346)
mm (in)
m m (in)
Front lift cylinder (1-ton vehicle) m m (in)
Cylinder bore
Limit
85.4 (3.362)
Standard
70.0 (2.756)
Limit
69.91 (2.7524)
Limit
2 . 0 (0.079)
Lift
Standard
171 60 ( 175) [24901
Tilt
Standard
11 770 (120) [I7101
Piston rod outside diameter
mm (in)
Piston rod bend
m m (in)
Oil control valve ( 1-ton vehicle)
Rel~efset pressure kPa (kglcmz) [psi]
ELECTRIC WIRING DIAGRAM THREE-WAY CATALYTIC EXHAUST EMISSION CONTROL SYSTEM WIRING DIAGRAM
Fuse arrangement
mp, 081 pressure swllch. Charge lamp. Air cleaner clogglng warning lamp Air cleaner vacuum switch.
Three-way catalytic exhaust emission control system wiring diagram
-90-
CONNECTOR DRAWINGS GASOLINE VEHICLE @
1/21
(FROM
1
~
-
0 - -
I I
0
VACUUM
SW.
A6
&7
a
o
- --_ --- - -_ ------- --IDLE Sw
1 ( I (' ' ] I m 2
I
IGB A B C V
IGB FCMl
I
I I
FCM2
I I
FCM3
J
I
FCMA
@
II--
0
CARBURETOR
J
8
3
1
Y
'
2
I
PWR
IDL
B
2
P
,
P FCM2
4
T
4
1 1 FCMl
5
,
J
J 5
12 FCM3
.
9 IGB
FCM4
@ E M I S S I O N CONTROL U N I T P A
ABCV
WTR
7
3
8
-
5
$ 2
OX
13
6
- - -
7 7 8 ,
8
1
BLOCK 51( *ATE.
El
PUMP
EOI
10
m7 l - :112:
CILINDEIl BLOC*
FRAME
@EMISSION CONTROL U N I T
@CARBURETOR
QWATER
TEMPLKAIURF SW I i C t i
-1
EARTH FOR 0,SENSOK
O V A C U U M SWITCH
CHECK CONNECTOR
3- 4 SHORT PIN (BR) Gasoline vehicle connector drawings
-92-
LPG VEHICLE
LPG vehicle connector drawings