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 de-

scriptions in the manual and actual vehicles due to change in design

and specifications. Any change or modifications thereafter will be in-

formed by Toyota Industrial Equipment Parts & Service News.

For the service procedures of the mounted engine, read the repair man-

uals 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. 8-
SECTION 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
EXTERIOR VIEWS ................................ 0-2
VEHICLE LISTING ................................ 0-3
ABBREVIATIONS ................................ 0 -4
OPERATIONAL TIPS ............................. 0 -4
STANDARD BOLT & NUT TIGHTENING
TORQUE ......................................... 0-5
BOLT STRENGTH TYPE IDENTIFICATION
METHOD ...................................... 0-5
TIGHTENING TORQUE TABLE .................. 0-6
PRECOAT BOLTS .............................. 0-7
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE ........................... 0-7
FRAME NUMBER ................................ 0 -8
WIRE ROPE SUSPENSION ANGLE LIST ........... 0 -9
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE ............................ 0-10
COMPONENTS WEIGHT ......................... 0-10
RECOMMENDED LUBRICANT QUANTITY
&TYPES ......................................... 0-11
LUBRICATION CHARTS .......................... 0-12
PERIODIC MAINTENANCE ....................... 0 -1 4
INSPECTION METHOD ......................... 0-14
PERIODIC REPLACEMENT LUBRICANTS
AND PARTS ..................................... 0 -2 0
EXTERIOR VIEWS

Front View (5FD35) ~~0.72-1

Rear View (5FD35)

- 6 -
VEHICLE LISTING

Load Engine Engine Drive system Remarks

Model model
capaclty tY Pe

5FG33 3F Gasoline Clutch

02-5FG33 t t Torgue converter

3.25 ton
5FD33 11Z Diesel Clutch

02-5FD33 t t Torque converter Wheel base

1800 mm
( 7 1 in)
5FG35 3F Gasoline Clutch

02-5FG35 t t Torque converter

5FD35 11Z Diesel Clutch

02-5FD35 t t Torque converter

3.5 ton
5FGE35 3F Gasoline Clutch

02-5FGE35 t t Torque converter

5FDE35 11Z Diesel Clutch

02-5FDE35 t t Torque converter

5FG40 3F Gasoline Clutch

02-5FG40 t t Torque converter Wheel base

4.0 ton 2000 mm
(78.5 in)
5FD40 11Z Diesel Clutch

02-5FD40 t t Torque converter

5FG45 3F Gasoline Clutch

02-5FG45 t t Torque converter

4.5 ton
5FD45 11Z Diesel Clutch

02-5FD45 t t Torque converter

ABBREVIATIONS
Abbreviations used in this manual are as follows:
4

Abbreviation Abbreviation
Meaning Meaning
(Code) (Code)

ABDC After button dead center PS Horsepower

ASSY Assembly P/S Power steering
ATDC After top dead center RH Right hand
ATM Automatic transmission SAE Society of automotive engineers
BTDC Before top dead center (USA)
L/ Less SST Special service tool
LH Left hand STD Standard
LLC Long life coolant SUB-ASSY Su b-assembly
MTM Manual transmission T= Tightening torque
OHV Overhead valve OOT Number of teeth (00)
0PT Option U /S Undersize
0 /s Oversize W/ 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.
Be sure to disconnect the negative cable first.

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

BOLT STRENGTH TYPE IDENTIFICATION METHOD

1. Identification by bolt shape 2. Identification by part No.

Shape and identification method

Strength Hexagon bolt I
type Part NO. example
4 = 4T

Standard
hexagon
0 Number in relief or
hallmark on the head
5 = 5T
6 = 6T
7 = 7T
9 I 1 1 1- 4 0 61 0

-1 T ~ e n g t under
h

Nominal diamter
head
(mm)
bolt
(mm)

@ No mark 4T
- Strength type
-

I Nominal
diameter

Length under head

Stud bolt

two rel~efl~neson Part No. example

9 2 1 32-4-061 4
Standard bolt with
1 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 (loos-
ened or tightened) by tightness check,
etc.

Note:
For torque check, use the lower limit of the Bolts
allowable tightening torque range. I f the
bolt moves, retighten it according to the
steps below.

2. Method for reuse of precoat bolts

(1) Wash the bolt and threaded hole. (The (2) Perfectly dry the washed parts by air
threaded hole must be washed even for blowing.
replacement of the bolt.) (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.

Standard tightening torque kg-cm (ft-lb)

Nominal diameter Hose inside
of screw diameter (mm)
Standard Tightening range

5 - 20 UNF 2.5 ( 18.1) 2.4 -- 2.6 ( 17.4 -- 18.8) 6

% 18 UNF 5.0 ( 36.2) 4.8 -- 5.3 (34.7 -- 38.3) 9
-

16 UNF 6.0 ( 43.4) 5.7 -6.3 (41.2 -- 45.5) 12

-
-

5 - 14 UNF 6.0 ( 43.4) 5.7- 6.3 (41.2 45.5) 12

- 12 UNF 12.0 ( 86.6) 11.4- 12.6 (82.4- 91.1) 19
I& - 12 UNF 14.0 (101.2) 13.3 - 14.7 (96.2 -- 106.3) 25

4.8 -- 5.3 (34.7 -- 38.3) 9

PF1/4
PF3/8
5.0 ( 36.2)
5.0 ( 36.2) 4.8
5.7
-
-
5.3 (34.7
6.3 (41.2
-- 38.3)
45.5)
9
12
PF1/2 6.0 ( 43.4)
PF314 12.0 ( 86.8) 11.4-12.6(82.4- 91.1) 19
PFI 14.0 (101.2) 13.3 -- 14.7 (96.2 -- 106.3) 25
FRAME NUMBER
Engine Model Punching format Punching ,position

5FG 3 3
"1 5FG35-10011
02-5FG 33 "2 5FG35E10011
3F "3 5FG35-20011
5FG 3 5 "4 5FG35E20011
"5 5FG35O20011
02-5FG 3 5

5FD 33
"1 5FD35-10011
02-5FD 33 "2 5FD35E10011
11Z "3 5FD35-20011
5FD 3 5 "4 5FD35E20011
*5 5FD35020011 Frame No. punching position
02-5FD 3 5

5FGE35

02-5FGE35
"1 5FG45- 1001 1
5FG 4 0 "2 5FG45E10011
3F "3 5FG45-20011
02-5FG 4 0 "4 5FG45E20011
"5 5FG45Q20011
5FG 4 5 a

02-5FG 4 5

5FDE35

02-5FDE35
"1 5FD45- 1001 1
5FD 4 0 "2 5FD45E10011
11Z "3 5FD45-20011
02-5FD 4 0 "4 5FD45E20011
"5 5FD45~20011
5FD 4 5

02-5FD 4 5

"1 1988.6- 1993.3 LAQS 1 29

"2 1992.11 - 1993.3 (EEC spec.)
"3 1993.4-
"4 1993.4- 1993.9 (EEC spec.)
"5 1993.10-(EEC spec.)
 --

WIRE ROPE SUSPENSION ANGLE LIST

Lifting Compres- Suspension Lifting Compres- Suspension
Tension Tension
angle si o n method angle sion method

o O 1 .oo
time
0
time

:LI 90°
1.41
time loo
time
,"
ko
30°
1.04
time

1 .I6
0.27
time

0.58
fiO
A.
120°
2.00
time time

60°
time ti me
@
\'
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE
U n i t : t o n (Ib)

Two-rope suspension Four-rope suspension

I Rope Cutting
diameter load

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)
Engine
3F : 250 (551)

Transmission with differential Approx. 200 (441 )

Torque converter with differential Approx. 3 6 0 ( 7 9 4 )

3.25 ton Approx. 1920 (4234)

3 . 5 ton Approx. 2220 ( 4 8 9 5 )
Balance weight 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 3.25 - 4.0 ton Approx. 6 5 0 ( 1 433)

(Max. Fork Height: 3 0 0 0 mm ( 1 18 in.) 4.5 ton Approx. 8 5 0 ( 1 874)
RECOMMENDED LUBRICANT QUANTITY & TYPES

Description Classification TYpe Application Quantity

API Motor Oil 3F Up to '88 Nov.

SD, SE, SF SAE30 8 . 0 Q ( 2 . 1 US gal)
(SAE20 in cold area) From ' 8 8 Dec.
Gasoline
SAE20W-40 9 . 3 Q ( 2 . 5 US gal)
(SAE1OW-30 in cold
Engine area)

API Diesel engine oil 11Z 12.5 Q ( 3 . 3 US gal)

CC, CD SAE30
Diesel
(SAE20 in cold area)
SAE1 OW-30

API Hypoid gear oil MTM models 6 . 0 Q ( 1 . 6 US gal)

Transmission GL-4 SAE85W-90
GL-5

API Hypoid gear oil All models 9 . 5 Q ( 2 . 5 US gal)

Differential GL-4 SAE85W-90
GL-5

ATF GM ATM models 15 Q ( 4 . 0 US gal)

Torque converter
DexronB I1

IS0 Hydraulic oil IS0 Fork height 60 Q ( 16 US gal)

Hydraulic oil VG32 VG32 3000 m m
( 1 18 in.)

Gasoline
models
95 Q ( 2 5 US gal)

Fuel tank 9 5 Q (25US gal)

5FD33,35
Diesel models
5FDE35, 120 Q ( 3 2 US gal)
5FD40,45
Chasis parts MP Grease All models Proper quantity

LLC @LLC30-50% mix- 3F 1 3 . 0 Q ( 3 . 4 US gal)

ture (for winter or
Coolant all season)
(Excluding reserve *Coolant with rust- 1 3 . 0 Q ( 3 . 4 US gal)
tank) inhibitor (for
spring, summer
and autumn)

Coolant (Reservoir All models 1.1 Q ( 0 . 3 US gal)

tank) T T (at Full level)

Drive shaft pulley Molybdenum disulfide All models Proper quantity

(Oil pump spline grease
shaft)
LUBRICATION CHARTS

Chain lnspect every 8 hours (daily)

Differential gear lnspect every 40 hours (weekly)
Front wheel bearing lnspect every 1 7 0 hours (monthly)
Power cylinder joint lnspect every 1000 hours (6 monthly)
Transmission case lnspect every 2000 hours (annually)
Rear wheel bearing
Steering knuckle king pin lnspect and service
Bell crank pin Replace
Oil tank
MP grease
Engine crankshaft
Engine oil
Rear axle beam front
Hypoid gear oil
Rear axle beam rear
Hydraulic oil
Tilt steering universal joint
Hypoid gear oil
Tilt steering locking mechanism
Molybdenum disulfide grease
Mast support bushing
Tilt cylinder front pin
Propeller shaft (Oil pump drive shaft)
Tie-rod end
Drive shaft pulley (Oil pump spline shaft)

Clutch Model Lubrication Chart

- 16 -
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. Chain I. Inspect every 8 hours (daily)

2. Differential gear n. Inspect every 40 hours (weekly)
3. Front wheel bearing 111. Inspect every 170 hours (monthly)
4. Power cylinder joint IV. Inspect every 1000 hours (6 monthly)
5. Transmission case V. Inspect every 2000 hours (annually)
6. Rear wheel bearing
7. Steering knuckle king pin 0 lnspect and service
8. Bell crank pin Replace
9. Oil tank
@ MP grease
10. Engine crankshaft
@ Engine oil
11. Rear axle beam front
@ Hypoid gear oil
12. Rear axle beam rear
@ Hydraulic oil
13. Tilt steering universal joint
@ Automatic transmission fluid
14. Tilt steering locking mechanism
@ Molybdenum disulfide grease
15. Mast support bushing
16. Tilt cylinder front pin
17. Propeller shaft (Oil pump drive shaft)
18. Tie-rod end
19. Drive shaft pulley (Oil pump spline shaft)

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 1 3 6 12 Months

Item --------___ Every 170 500 1000 2000 Hours

ENGINE

Proper starting and abnormal noise l C t t

Rotating condition at idling M t t t

Rotating condition during acceleration M + + ~

Exhaust gas condition l C t t

Main body Air cleaner element c C t t

Valve clearance M
Compression M
Cylinder head bolt loosening T
Muffler rubber mount I

Clogging and damage in PCV valve and

PCV system l C t t
piping

Governor No-load maximum rpm ~ t t t

Oil leak I + + +
Lubrication l C t t
Oil level
system
Clogging and dirt of oil filter i t + - +

Fuel leak l C t t

Operation of carburetor link mechanism I + + +

Dirt and clogging of fuel filter and element l t t C

Fuel system Injection timing M t
lnjection nozzle injection pressure and
M
spray status
Draining of sedimenter I t

Coolant level in radiator and leak l t t C

Rubber hose degradation l t t t

Radiator cap condition I C t t

Cooling
system Fan belt tension, looseness and damage I + + +

Radiator rubber mount I

Radiator screen c t t C
 Inspection Period Every 1 3 6 12 Months
Item Every 170 500 1000 2000 Hours
-

POWER TRANSMISSION SYSTEM

Clutch pedal play M - + +

Abnormal sound and functioning I C t C

Clutch (connection)
Clutch booster function and leak l C C e

Oil clutch mechanism and leak I +

Leak I + + - +

Transmission Fluid level I + - +

Gear function and abnormal noise l C t t

Leak I + + +

Differntial Oil level I t t t

Bolt loosening T

Leak i t + +

Fluid level I + - + +

Torque Operating mechanism function and I + + -

converter and looseness
transmission Control valve and clutch functions I + + +

Inching valve function I + + -

Stall and hydraulic pressure measurement M +

DRIVE SYSTEM

Tire inflation pressure M t + +

Tire cuts, damage and uneven wearing I + + +

Loose rim and hub nuts T t t c

Tire groove depth M + + +

Wheels Metal chips, pebbles and other foreign I + + + -
matter trapped in tire grooves
Rim, side bearing and disc wheel damage I + + +
Abnormal sound and looseness of front I + + +
wheel bearing
- - - Inspection Period Every 1 3 6 12 Months
Item -------- Every 170 500 1000 2000 Hours

Abnormal sound and looseness of rear wheel

Wheel l t t t
bearing

Cracks, damage and deformation of

Front axle I
housing

Cracks, damage and deformation of beam I

Rear axle Looseness of axle beam in vehicle
M
longitudinal direction

STEERING SYSTEM

Steering Play and looseness t t t

wheel Function l e e + -

Oil leak l t t t

Gear box Looseness of mounting T + + - + -

Clogging of relief valve filter C +

Rods, links Looseness and damage I ' - - ' -

and arm Linkage and wear and mounting condition I

Oil leak I + + +
Power l C C t
Mounting and linkage looseness
steering
Damage of power steering hose I

King pin looseness I + + +

Knuckle
Cracks and deformation I

Steering Wheel alignment M

shaft Left and right turning angle M

BRAKING SYSTEM

Play and reserve M + + ~

Brake pedal
Braking effect I + + +

Operating force l C t C

Parking brake Braking effect I + + +

Rod and cable looseness and damage I e e t

Brake pipe Leak, damage and mouting condition I + + + -

Brake booster
Function, wear, damage, leak and
and wheel I
mounting looseness
cylinder
 Inspection Period Every 1 3 6 12 Months
Item Every 170 500 1000 2000 Hours

Clearance between drum and lining M + - + +

Wear of shoe sliding portion and lining I
Brake drum Drum wear and damage I
and brake Shoe operat~ngcondition I
shoe Anchor pin rusting I
Return spring fatique M
Automatic adjuster function I

Deformation, cracks and damage I

Backing plate
Loose mounting T

MATERIAL HANDLING SYSTEM

Abnormality of fork and stopper pin l C t t

Misalignment between left and right fork I + + ~
Forks
fingers
Cracks at fork root and welded part 1 *3

Deformation and damage of each part and

I C C C

crack at welded part

Mast and lift bracket looseness
Mast and
Wear and damage of mast support bush
fork
bracket Wear, damage and rotating consdition of Il - + ' -+ ; - I +
rollers
Wear and damage of roller pins I
Wear and damage of mast strip I - + +

Tension, deformation and damage of I C C C

chain
Chain and Chain lubrication l t t t
chain wheel Abnormality of chain anchor bolt i t + +
Wear, damage and rotating condition of I C C C
chain wheel

Various Abnormality and mounting condition of I + - -

attachment each part

HYDRAULIC SYSTEM

Loosening and damage of cylinder T t t t

mounting
Deformation and damage of rod, rod I C C C
Cylinder screw and rod end
Cylinder operation I + + +
Natural drop and natural forward tilt M C C
(hydraulic drift)
C

- Inspection Period Every 1 3 6 12 Months

Item Every 170 500 1000 2000 Hours

Oil leak and damage I - + +

Wear and damage of pin and cylinder I t + ' -

Cylinder bearing
Lifting speed M + + +

Uneven movement I + + - +

Oil pump Oil leak and abnormal sound I + + -

Oil level and contamination I - - ' -

Hydraul~c
Tank and oil strainer C +
oil tank
Oil leak I - - +

Control Loose linkage I ' - ' - ' -

lever Operation I - + +

Oil leak I + - + +
Oil control
Relief pressure measurement M
valve
Relief valve and tilt lock valve functions I + + - +

011leak 1 t C C

Hydraulic I + + +
Deformation and damage
piping
Loose joint T - - -

ELECTRICAL SYSTEM

Cracks on distributor cap I - + +

Spark plug and burning and gap ( - 1997.12) I + - + +

Distributor side terminal burning + + +

Ignition Distributor cap center piece wear and I t t C

timing damage
Distributor points gap M + + -

Plug cord internal discontinuity I

Ignition timing M t

Starting
Pinion gear meshing status / I + + +

motor

Charger Charging function I - + - -

Battery fluid level I + + -

Battery
Battery fluid specific gravity M t

Electrical Damage of wiring harness I ' - + ' -

wiring Fuses l e t +
 Item
- Inspection Period
-------___Every
Every 1 3
170 500 10002000 Hours
6 12 Months

Preheater Open-circuit in intake heater I t

Engine stop- I t t t
Diesel engine key stop device function
ping system

SAFETY DEVICE, ETC.

Cracks at welded portion I + + +

Head guard
Deformation and damage l C t C

Loosening of mounting T t t ~
Back-rest
Deformation, crack and damage l t t t

Lighting i t + +
I Function and mounting condition
system

Horn Function and mounting condition I + + +

Direction - + +
Function and mounting condition I
indicator

Instruments Functions I + + +

Backup buzzer Function and mounting condition I + + - +

Rear-view Dirt, damage I t t t

mirror Rear reflection status l t C t

Seat Loosening and damage of mounting l t t t

Damage and cracks of frame, cross

I
Body members, etc
Bolt looseness T

Other Grease up L + - + +
PERIODIC REPLACEMENT LUBRICANTS AND PARTS
l: Replacement
Interval Every Every Every Every
1 month 3 months 6 months 12 months
Every Every Every Every
Item 1 7 0 hours 5 0 0 hours 1000 hours 2000 hours

Engine • t + +

Engine oil filter • + C

Engine coolant (every 2 years for LLC) • t- +

Fu,el filter • C

Torque converter oil • t

Torque converter oil filter • +

Transmission oil • C

Differential oil • +

Hydraulic oil • t

Hydraulic oil return filter a*' • +

Wheel bearing grease •

Spark plug l(-1997.12) •
Distributor points • +

Air cleaner element •

Brake booster rubber parts •
Cups and seals for wheel cylinders •
Power steering hoses e*2
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 LAQM61.62

3F Engine Sectional View

- 28 -
Engine Performance Curves

29.0/1600
- 29
- 28
- 27 Engine torque

26 (kg'm)
25
90 85/2200

80 -

70 -
Shaft horsepower
(PSI 60-

50 -

40 -

-
] Fuelconsumption
ratio. (g/ps.h)

I I

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

Engine Performance Curve (1 12) KALMl

Gasoline model
LPG model only 26.0/1200
- - - - - -. Gasoline LPG model
25.0/1200

j24 Engine torque

Shaft horsepower

200/2000

1 200 Fuel consumption

185/1800 ," 180

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

Engine Performance Curve (3F) KALM 47

- 29 -
SPECIFICATIONS
-
11 Z (Diesel) 3F (Gasoline)

Piston displacement cc (cu-in.) 4429 (270) 3955 (241 )

Number of cylinders 6 6

Valve mechanism OHV gear driven t

96.0 x 102.0 94.0 x 95.0

Bore x stroke mm (in.)
(3.78 x 4.02) (3.70 x 3.74)

Compression ratio 18.6 8.1

Combustion chamber type Direct injection

pslrpm
Rated output (SAE NET: ~ p h ~ 85/2200
~ ) (8112200) 72/21 00 (6912100)
kg-mlrpm
Maximum torque 2911600 (202/1600) 26/1200 (182/1200)
(SAE NET : ft-lblrpm)

Fuel consumption ratio glps-hlrpm 1 6511 200 20011800

Injection pump type Bosch (VE)

l njection timing (BTDC)

Injectio n order 1- 4- 2- 6- 3- 5

lgnition timing (BTDC)

Ignition order 1- 5- 3- 6- 2- 4

Service weight 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 8 - 1 7

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 ~ ~ 2 9 - 9

3. Remove the radiator cover

Removing the Radiator Cover ~ ~ 2 9 - 1 1

4. 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)

Removing the Air Cleaner ASSY ~ ~ 2 9 - 1 9

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 distribu-
tor and ignition coil. (3F)
(4) Battery stopper
(5) Battery Removing the Batery
LAQ29-22
(6) Battery case

6. Remove the sedimenter. (11 Z)

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

Removing the Sedimenter w 9 - 2 7

Disconnecting Wiring (1) 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)

Disconnecting Wirings (3) LAQ30-1.29-32

8. Disconnect piping and wires.

(1) Fuel piping

Disconnecting the Fuel Piping (1 lZ/3F) u Q 3 0 - 8 - 19-•

(2) Accelerator wire

Disconnecting the Accelerator Wire (1 12) LAQ~O-9

Disconnecting the Accelerator Wire (3F) ~ ~ 1 9 - 1 8

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