Toyota Forklift 5FD (G) 10-30 Series Repair Manual CE001-1

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 re-
lated 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
HOW TO READ THIS MANUAL ............................... 0-6
PERIODIC MAINTENANCE ....................................... 0-8
PERIODIC REPLACEMENT LUBRICANTS AND

PARTS .............................................................. 0 -9
0-2
EXTERIOR VIEWS
Front View
Rear View
VEHICLE LISTING
2.0 ton
5FD20 Clutch
1z
02-5FD20 Torque converter
2 ton series
60-5FD20 Clutch
1 DL
5FG23 Clutch
5K
02-5FG23 Torque converter
2.25 ton
40-5FG23 Clutch
4Y
Series Load capacity Model Engine model Drive system
5FD23 Clutch
1z
2.25 ton
60-5FD23 Clutch
1 DZ
5FG25 Clutch
5K
2 ton series
40-5FG25 Clutch
4Y
2 . 5 ton
5FD25 Clutch
1z
60-5FD25 Clutch
1 DZ
5FG28 Clutch
4Y
5FD28 Clutch
2.75 ton 1Z
60-5FD28 Clutch
1 DZ
3 ton series
5FG30 Clutch
4Y
5FD30 Clutch
3.0 ton 1Z
60-5FD30 Clutch
1 DZ
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
Vehicle model
5FG15 40-5FG15 5FD15
02-5FG 1 5 42-5FG15 02-5FD15
5FG18 40-5FG1 8 5FD18
02-5FG18 42-5FG18 02-5FD18
Punching format A5FG18-60011 405FG18-60011 A5FD18-60011
2 ton series
Engine model 5K 4Y 1Z 1 DZ
5FG20 40-5FG20 5FD20 60-5FD20
02-5FG20 42-5FG20 02-5FD20 62-5FD20
5FG23 40-5FG23 5FD23 60-5FD23
Vehicle model
02-5FG23 42-5FG23 02-5FD23 62-5FD23
5FG25 40-5FG25 5FD25 60-5FD25
02-5FG25 42-5FG25 02-5FD25 62-5FD25
Punch~ngformat 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
Vehicle model
5FG30 5FD30 60-5FD30
02-5FG30 02-5FD30 62-5FD30
Punching format 5FG30-6001 1 5FD30-60011 A605FD30-60011
--- - -
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
If a place or part cannot be indicat-

ed 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 explained on a laterpage
3 . Remove the gear.
POINT OPERATIONS Explanation of key point for operation with an illustration

[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.)
r----v
2. How to read components figures (Example)
( 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.
FIG number in parts catalog
The number at the right shoulder of each
components figure indicates the Fig. num-
ber in the 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 requir-
ing 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

Society of Automotive
ABCV Air Bleed Control Valve SAE
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.
T : Retightening C : Cleaning L : Lubrication
: For new vehicle 1 : Soapy water "2: Detector '3 : Flaw detector
Inspection Period Months 1 3 6 12

Item Hours 170 500 1000 2000
ENGINE
Three-way ex- 1. Exhaust gas (carbon monoxide) con-
M 0 0 0 0
haust emission centration measurement
system 2. Exhaust system piping joint loosening
T 0
and damage
3. System function check I 0 0 0 0
4. Vacuum p ~ p i n gdamage I 0 0 0 0
5. Vacuum switch damage (gasoline
I 0
model)
6. Idle switch damage (gasoline model) I 0
7 . Water temperature sensor damage
I 0
(gasoline model)
8. ABCV damage (gasoline model) I 0 0 0 0
9. Injector cleanlng and damage

C.1 0
(LPG model)
10. Register damage (LPG model) I 0
0
11. Three-way catalytic muffler function I
(2000H)
PERIODIC REPLACEMENT LUBRICANTS AND PARTS
: Replacement
Interval 1 month 3 months 6 months 12 months

Item 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 hoses • "2
Power steering rubbers parts • *?
Hydraulic hoses a'2

Reservoir tank tube •*2
Fuel hoses • "2
Torque converter rubber hoses @*2
Chains • "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 ........................................................ 1-2
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 ...........................................
AIR CLEANER
GENERAL
/ >
L
(OPT: Double element)
Air Cleaner Sectional View
SPECIFICATIONS
Type Combined type (dry + cyclone)

Size 6 in.
Air ~ n t a k esystem Outside air intake
STD: Single 14200
Filtering area cm2 OPT: Double Outer: 1 8 5 0 0
Inner: 535
Vacuum sensor operating pressure mmHg - 44.1
Other With evacuator valve
COMPONENTS
Air Cleaner Components

AIR CLEANER MAINTENANCE
1. Element cleaning
( 1) For cleaning in ordinary status, blow com-
pressed 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
Cleaning the Element (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 ele-
ment when cleaning the double cyclone
Washing the Element 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 evacu-
ator 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 Remove the three-way catalytic muffler
2 Remove the idle switch.
3 Remove the water temperature sensor.
4 Remove the vacuum switch.
5 Remove the ABCV.
6 Remove the 0 sensor.
7 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

-
CO concentration at NG Idle switch inspec- NG Idle switch
-
idling tion and adjustment replacement
OK
1
CO concentration at CO concentration
NG -TO inspectiAn 2 NG 40inspection 2
full acceleration measurement
0K
-Normal
lnspection 2: Muffler inspection

-
Has the muffler been used for more
-TO inspection 3
than 2000 hours
YES
Muffler replacement - CO concentration

NG -To inspection 3
measurement
OK
Normal
lnspection 3: Water temperature sensor inspection
lnspection of wiring
between water tem-
perature sensor and
NG - 1 Wiring repair
CO concentration
measurement
ATO
inspection 4
EC U
0K 0K
-Normal
- Inspection of water
temperature sensor alone
NG
___)
Water temperature
sensor replacement
0K
To inspection 4
CO concentration
NG -To inspection 4
measurement
OK
-Normal
lnspection 4: Vacuum
lnspection of wiring
CO concentration
between vacuum Wiring repair - NG -TO inspection 5
measurement
s w ~ t c hand ECU !
--F- OK N o r m a l
Inspection of vacu- Vacuum switch

u m switch alone replacement
t
To inspection 5 Normal
CO concentration
To inspection 5
measurement
1 - Inspection 5 : ABCV inspection b

I l n s ~ e c t i o nof sianal I
~ o l ~ a g( A
tween ABCV and E
eBCV)'~~
terminals of ECU at
NG lnspect~onof wiring be-
tween ECU and ABCV
- NG 4 Wiring repair I
1
i
full acceleration
0K
I OK
CO concentration
To inspection 6
measurement
To inspection 6 - X I
Inspection of ABCV alone lOK L N o r m a l
Replace ABCV To inspection 6

measurement
1 - Inspection 6 : 0, sensor inspection b

Inspection of signal voltage
between RIL and E terminals
of ECU at full acceleration
Inspection of wiring be-
NG tween RIL of ECU and
check connector
x d Wiring repair 1
0K OK CO concentration check
I
- -
ECU r e p l a c e m e n t 1 -CO concentration
check
1
Normal - OK
0, sensor replacement
NG _I ECU replacement
Always check no gas leak from exhaust piping and
no vacuum hose disconnection before starting in-
spection jobs.
lnsoection 1 : CO concentration check
Caution
The idling speed and maximum no-load speed
shall be adjusted normally.
1. Warm up the engine sufficiently.
I - -
' ~ e s t connector (black wiring)l Standard:
Engine cooling water temperature:
Setting the Engine Tachometer
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:
Measuring the CO Concentration (at Idling) (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
Inspecting the ldle Switch 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 ad-
justment by turning the idle switch adjusting
bolt.
ldle switch adjusting bolt
Adjusting the ldle Switch

4. Measure the CO concentration at full acceler-
ation (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 im-
merse 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 approprl-
ate 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
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.
the 0, sensor.
Standard:
(4) Return to the idling speed.
ABCV Check Connector
( 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:
Between @B (0) and FCM1: 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)
Inspecting the ABCV Alone (2)
Inspection 6: 0, sensor inspection

1 . Check the 0, sensor funct~on.
( 1 ) Check that the vacuum piping and electri-
cal wiring are not disconnected.
(2)Disconnect the ECU check connector.
( 3 ) Keep the engine running at the maximum
the 0, sensor.
Standard:
(4) Keep the maximum no-load speed.
ECU Check Connector
(5)lnspect the s~gnalvoltage from the 0, sen-
sor 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.)
Checking the O2 Sensor Function

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
-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 Remove the three-way catalytic muffler
2 Remove the register.
3 Remove the injector. [Point 11
4 Remove the 0 sensor.
5 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 pip-

ing, 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

Power screw than 30%, the carburetor should be re-adjusted in
following manner:
( 1 ) Loosen the power screw bolt lock nut.

(2) Turn the power screw open rate limiter to
Power screw clockwise to contact to stopper. (Power
screw bolt turns with the limiter. See the
illustration below.)
LPG Carburetor
(3) Tighten the power screw bolt lock nut.
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
Power screw
Adjustment ( A t 30%)
for less than
Adjustment Method
-34-
TROUBLESHOOTING
High CO concentration in exhaust gas.
Perform engine tune-up without fail before starting inspection for troubleshooting.
CO concentration at
idling
lnspect~onand adjust-
ment of carburetor
and LPG regulator
ko inspection 2
CO concentration at
full acceleration
1
1- lnspect~on2: Muffler inspection t-

Has the muffler been used for 2 0 0 0
To inspection 3
hours or more
1 YES
Muffler CO concentration
To inspect~on3
replacement measurement
i OK
Normal
OK
Normal
I
1-
acceleration
i0K
lnspection 3:
Inspection of signal vol-

tage (VF) between VF and
E terminals of ECU at full
To Inspection 5
lnspection of w i r ~ n g
between ECU and
injector
i
To inspection 4
--
- 1
ECU signal voltage iVFl inspection
7-1
Wiring repair
CO concentration
measurement
TO inspection 4
1 - Inspection 4: Register Inspection I
1 lnspect~onofOK
reglster alone
1 -1
NG Reg~ster
replacement
CO c o n c y ,on
measurement
1 OK
NG Normal
To ~nspectlon5 To rnspect~on5
Injection 5: Injector inspection

I
l Injectorn cleaningp n o f
injector atone ,$:
To inspection 6 To inspection 6
Injector replacement
Normal-
OK iCO concentration
measurement
NG To inspection 6
lnspection of signal vol-

lnspect~onof wiring be-
tage between OXM of E
Wiring repair
terminal of ECU at full ac-
check connector
celeration
CO concentrat'/on check
B
ECU rep lac ern en^ ECU replacement
replacement
I
CO concentration check
t
Normal
Always check no gas leak from the exhaust piping
and no disconnection of the vacuum hose, etc. be-
fore starting inspection jobs.
lnsaection 1 . CO concentratton check
Caution
The idling speed and maximum no-load speed
shall b e adjusted normally.
1. Warm up the engine sufficiently.

C J ~ e s tconnector (black wiring)
Standard:
I -- I
Engine cooling water temperature:
Setting the Engine Tachometer
65OC (14g°F) or above
Hydraulic oil temperature:
50°C ( 1 22OF) or above
2 hAt>il~L~ r ~ CO ~;c.ricent~dt:on
rloc: 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:
3 7 0 ° C (698OF) or above.
(31 t?etr,ln ro ti;c. ~cd~ir~(j
speed
Measuring the CO concentration (at Idling) ( 4 ) Measure CO concentration.
3 . Inspect and adjust the carburetor and LPG
regulator.
If idling speed adjustment is difficult, discon-
nect the injector connector.
( 1 ) Adjust the LPG regulator idle adjusting
screw and carburetor air adjusting screw.
Adjusting Position
Measure the CO concentration at full acceler-

ation (at the maximum no-load speed).
( 1) Fully depress the accelerator pedal (to the
maximum no-load speed).
(2) Measure the CO concentration.
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
lnspection 3: ECU signal voltage (VF) inspection

1 . lnspect the ECU signal voltage (VF).
( 1) Check that vacuum hose and electrical wir-
ing are not disconnected.
( 2 ) Disconnect the ECU check connector.
the 0, sensor.
Standard:
I
. . I
( 4 ) Keep the maximum no-load speed.
lnspecting the VF Signal Voltage
(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 ex-
2 mm tract a 41.2 mm (0.047 in) wire to and
(0.079 in) from the nozzle about 10 times.
Caution
The wire insertion depth shall be within 2.0
Cleaning the lnjector
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.
Inspecting the lnjector
Inspection 6: 0, sensor inspection

1. Inspect the 0, sensor function.
(1) Check that the vacuum piping and electri-
cal 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:
( 4 ) Keep the maximum no-load speed.
ECU Check Connector
( 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.)
Checking the 0, Sensor Function
3 9
TORQUE CONVERTER
Page
GENERAL .......................................................... 2-2
HYDRAULIC CIRCUIT DIAGRAM .............................. 2 -4
SPECIFICATIONS ................................................... 2-5
COMPONENTS ...................................................... 2-7
TROUBLESHOOTING .............................................. 2-8
TORQUE CONVERTER ASSY ................................... 2-9
REMOVAL ............................................................. 2-9
DISASSEMBLY ...................................................... 2-9
MEASUREMENT TEST .......................................... 2-10

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 l t o n vehicle I - t o n vehicle I - t o n vehicle
Item
(High speed) ( L o w speed) (High speed) (Low speed)
Manufacturer Aisin Seiki t t t
3-speed, single
Torque converter type t t t
stage, 2-phase
Torque converter designation AlSlN t t c
Stall torque ratio 2.94 t 2.65
4Y : 2 0 5 0
Stall speed rPm 1900 t t
1DZ : 2 1 0 0
4Y : 2 6 0 0
Maximum no-load speed rpm 3050 t t
1 DZ : 2 6 0 0
Forward 1 st 1.366 1.628 1.033 1.366

2nd - - - -
Gear ratio
Reserve 1.359 1.61 9 1.028 1.359
Speed selection system Hydraulic t t t
Modulating control pressure -

39 392
(0.4- 4.0) t t t
kPa (kg/cm2) [psi] -
15.7 571
Clutch actuating pressure 9 81
(main pressure) t t t
kPa (kglcmz) [psi] O.O) [ I 421

(I
Torque converter pressure 392
(outlet pressure) t t t
kPa (kglcm2) [psi] (4.0) [571
011capacity !(Usgal) 14(3.7) t t t
Castle
011type t t t
Auto Fluld DII
Gasoline 5K 5K 4Y 4Y
Connected
engine Diesel - -
1 DZ 1 DZ
Item
2-ton vehicle 2 - 3 ton vehicle 2-ton vehicle 2 - 3 ton vehicle
(High speed) (Low speed) (High speed) (2nd TIC)
Manufacturer Aisin Seiki c t t
3-speed, single
Torque converter type c t c
stage, 2-phase
Torque converter designation AlSlN c t t
Stall torque ratio 2.94 2.65 c
4Y : 2050 4Y : 2050
Stall speed rPm 1900 1DZ : 2100 1DZ : 2100 t
1z : 2200 1z : 2200
4Y : 2600 4Y : 2600
Maximum no-load speed rpm 3050 1 DZ : 2600 1 DZ : 2600 t
1Z : 2600 1Z : 2600
Forward 1st 1.628 1.220 1.154 1.474
Gear ratio 2nd - - - 1.040
Reserve 1.619 1.214 1.148 1.214
Speed selection system Hydraulic t t c
Modulating control pressure -

3 9 392
(0.4- 4.0) t t e
kPa (kglcmz) [psi1 -
r5.7 571
Clutch actuating pressure 981
(main pressure) e e t
kPa (kglcmz) [psi] O.O) [ I 421

(I
Torque converter pressure 392
(outlet pressure) e t t
kPa (kglcm2) [psi] (4.0) [571
Oil capacity !(Usgal) 14(3.7) t c t
Castle
Oil type t t t
Auto Fluid DII
Connected Gasoline 5K 4Y 4Y 4Y
engine Diesel - 1 DZ.1Z 1 DZ.1 Z 1Z
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 - 3 0 Repair
Manual (No. CEO01- 1 ) .
Symptom
I Inspection method
I Judgement and
corrective action I
1 Lack of gradeab~lltyand Stall speed a Too low stall speed
tractlve abillty (rnsufflc~ent Standard ( 3 0 0 rpm or more below the
power) 4Y 2 0 5 0 rpm standard)
Due to torque converter not 5K 1 9 0 0 rpm 0 The one-way clutch of the
generating torque 1DZ 2 1 0 0 rpm stator 1s slipplng
1Z 2 2 0 0 rpn) -+ Replace the torque con-
The stall speed may be deviat- verter ASSY
ed by about 1 0 0 rpm from the
standard value above because b. Too high stall speed
of slight dispersions in engine O T h e clutch is slipping exces-
and torque converter perfor- sively.
mances and their subtle match. -t Disassemble, inspect and
ing. Use the values above, replace the clutch.

therefore, only as reference.
2. Overheat 2 . 1 Torque converter inspection a. Torque converter defect

0 Stator sticking
-+ Replace the torque con-
verter ASSY.
0 Impeller contact
+ Judge from the oil filter.
Replace the torque con-

verter ASSY if defective.
0 Reduced circulating flow rate
-P Clogging of stator shaft
orifice, etc.
+ Disassemble, inspect and
replace.
TORQUE CONVERTER ASSY
REMOVAL
1 Remove the englne wltorque converter ASSY

SST 09010-201 11-71
Removing the Engine w1Torque Converter ASSY
2. D~sconnectthe drive plate

( 1) Set bolt
Caution
Apply a ring spanner on the engine crank-
shaft set bolt and rotate the crankshaft clock-
wise 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 dis-
assembled.
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)
8 7
Measuring the Oil Level 2. Oil pressure measurement

I 1
( 1 ) After warnrng up the engine, measure the
ter rdlrng speed and maximum no-load speed
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 Vehicletype I Idling speed I Maximum no-load speed I

t I -ton veh~cle
2-ton vehicle
I -ton vehicle
650 +?rpm
7 5 0 +?,O r ~ m
700 +Frpm
3050 + 5 0 rpm
3050 +50 r ~ r n
2 6 0 0 t 5 0 rpm
213-ton veh~cle 7 5 0 '+: rpm 2600 + 5 0 rpm
I -ton vehrcle 7 5 0 + 2 5 rpm 2 6 0 0 1 5 0 rpm
1 DZ
2-ton vehicle 700 + i0 rpm 2600 + 5 0 rpm
I 1Z I 213-ton vehicle I 750 + 2 5 rpm I 2 6 0 0 + 5 0 rpm 1
13) Jack up the front axle untll tlres (both

wheels) leave the ground
( 4 ) Remove the toe board and set the o ~pres-
l
sure gauge
( 5 ) Place the control lever In the neutral posl-
tron and start the englne Measure the
maln pressure and torque converter pres-
sure In thrs state
( 6 ) Shrft the control lever to each of the for-
ward 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 490 834- -

932 1373
kPa (kgicm2) [psi] (5.0- 8.5) [71 1211- ( 9 . 5 - 1 4 . 0 )[135-1991
Torque converter pressure -

196 588
t
kPa (kgIcm2) [psll ( 2 . 0 - 6 . 0 ) [28-851
Clutch pressure -
441 834 -
883 1373
kPa (kgicm2) Ipsil ( 4 . 5 - 8 . 5 ) L64.0- 1211 ( 9 . 0 - 14.0) [ 1 2 8 - 1991
3. 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 im-
movable 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-
mum loaded engine speed.
[Method]
After adjusting the maximum no-load
Checking the Maximum Loaded Speed speed, operate the tilt lever to the forward
or backward tilting position and measure
the maximum speed at full acceleration in
Checking the Maximum Loaded Speed relief state. (Maximum loaded speed meas-
Maximum loaded speed urement)
Gasoline engine vehicle 1 5 0 -
300 rpm [Judgement]
d o w n from the maximum no-load speed If the engine speed drops excessively, per-
-
Diesel engine vehicle 100 200 rpm d o w n form engine time-up because the adjust-
from the maximum no-load speed ment 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)
Itern 1 Z englne
Stall speed
Max~rnurnno-load
I
All veh~cles
1 9 0 0 rprn
All veh~cles
I
All veh~cles
2 0 5 0 rpm
All veh~cles
I
I
All veh~cles
2 1 0 0 rprn
All veh~cles
I
All vehlcles
2 2 0 0 rprn
All veh~cles
6 0 0 1 5 0 rprn
Stall Test
OTHER MODIFICATIONS
Page
CLUTCH ............................................................... 3-2
CLUTCH PEDAL ................................................. 3-2
CYLINDERS ( 1-TON VEHICLE) ................................. 3-3
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 ...................................................
MATERIAL HANDLING SPEED ( 1-TON VEHICLE) ....
OIL CONTROL VALVE ............................................
GENERAL ..........................................................
SPECIFICATIONS ................................................
COMPONENTS ...................................................
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
Cylinder type Single actlng type t t
Cylinder bore mm (in) 45.0 (1.772) c t
Piston rod o u t s ~ d ediameter

35.0 (1.378) t 32.0 (1.260)
m m (in)
Piston seal type U-pack~ng t Wear ring
Rod seal type U-pack~ng t t
With flow regulator valve (RH)

Others + t
With safety down valve (LH)
INSPECTION
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)
I I
lnspecting the Cylinder Bore
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)
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 FSV mast FV mast
Cylinder type 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 +
Others With safety down valve t
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)
lnspecting the Lift Cylinder Bore
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 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

21 .O (1.282) 22.9 (1.397) t
cclrev (in'lrev)
Discharge rate dmin (USgallmin)

30.2 (7.97) 32.8 (8.66) t
(pump at 1500 rpm)
Drive type PTO gear type + t

3-9
COMPONENTS
Oil Pump Components
-61 -
MATERIAL HANDLING SPEED (1-TON VEHICLE)
V-SV Mast
Lifting speed Lowering speed

Engine Oil pump rnrnlsec (f.p.rn.) rnrnlsec (f.p.m.)
model model
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
L~ftingspeed Lowering speed

Eng~ne Oil pump rnmlsec (f.p.m.) rnrnlsec (f.p.rn.)
model model
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
Lifting speed Lowering speed

Engine 011pump rnrnlsec (f.p.rn.) rnmlsec (f.p.rn.)
model model
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
Item I-ton vehicle
Oil control valve type Add-on type
Lift 171 60 ( 175) [24901

Relief pressure kPa (kglcm*) [psi]
Tilt 11770 (120) [I7101
9.5 (2.51) [4Y: 13.0 ( 3 . 4 3 ) l

Flow d ~ v ~ d e
flow
r rate 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

.............................
LPG ENGINE EXHAUST

4-3
E
EMISSION CONTROL SYSTEM ............................. 4-12
GENERAL
As exhaust gas causes a c ~ dram, photo chemlcal smog, destruction of the ozonosphere and other environ-
mental 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%
NOx (nitrogen oxides) - 95%
Note: For LPG englne vehicles, the three-way catalytic muffler is adjusted to the fuel consisting of 25% pro-
pane 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
System Standard settlng Object~ve-function

Three-way catalytic muffler - Reduction of CO, HC and
NOx (Monolithic platinum-
rhodium type catalyst)
Air-fuel ratio controller Controlling the air-fuel ratio
Carburetor at around the theoretical
ABCV Main: 5.0Plmin level
(Air Bleed Control Valve) Slow: 3.2Plrnin
Idle switch 1 2 0 0 rpm.
Engine cooling water temperature 65°C
switch 1 0 0 rnrnHg
H ~ g hload detecting vacuum
switch
O2 sensor
ECU
(Erniss~onControl Unit)
Crankcase emission control system - Purge of HC and recirculation
(in standard vehicle) of blowby gas
GASOLINE ENGINE EXHAUST EMISSION CONTROL SYSTEM DIAGRAM
11I I1
Air
garburetor
Idling switch
O2 sensor
z' Vacuum switch
Intake manifold
Water temperature switch

Three-way catalytic muffler
Engine
Gasoline Engine Exhaust Emission Control System
6 7 -
4- 4
WORKING PRINCIPLE AND PERFORMANCE OF GASOLINE ENGINE EXHAUST

Working Principle
The ECU judges whether the air-fuel mixture is richer or leaner than the theoretical ratio according to the sig-
nal 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 ex-
haust gas is purged effectively by the three-way catalyst.
Equation
CO 2CO + 0, -t 2C02
m m Ox~dation
HC CnHm + ( n +-) 0, + nCO, + (-) H20
4 2
NOx 2 N 0 + 2C0 + N, + 2C0 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
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
High 1 Thts catalyst is suitable for simultaneous purge of
T Conforming
range of
the CO, HC and NOx contents in the exhaust gas.
As shown at left, the air-fuel ratlo should be main-
Purge air-fuel ratio
tained near the theoretical level to obtain h ~ g hpurge
% ratio
ratios for the CO, HC and NOx contents.
1
Low
The air-fuel ratlo controller, therefore, controls the
air-fuel ratio around the theoretical level.
,qich -Air-fuel, Lean
ratio
- 69
4- 6
AIR-FUEL RATIO CONTROL ECU
Input-Output Connection Diagram
ECU
ABCV
FCMl
O1 Sensor FCM2
70 (1 Air blead control
/phase valve (ABCV)
FCM3
FCM4.
Eng~necool~ngwater r-,"E- i-q-w -- Hlqn
RiL
R~chileanslgnal for check
-
temperature switch
A ABCV slgnal for check

ACBV
+B 4,
Vacuum switch r*F;;-)-pwR
i
IG s w ~ t c h
4
- lDL -
ldllng swrtch r-;r23 r Fuse
I
E
I
Battery 11 2 V )
(1) Hugh load (2)- W ~ d ethrottle openlng
Connector Pin Arrangement
OX FCM4 FCM2 7 1 ABCV PWR IDL

E1 FCM3 FCM 1 E +B WTR R /L
[Fi
Air-Fuel Ratio Control Conditions
1. The air-fuel ratio control is not performed when
the cooling water temperature is below 60°C
No air-fuel ratio control (during automatic choke operation).
(Priority is given to engine warm-up in this
state.)
Normal control
2. When the negat~vepressure in the intake
[ o*:e I Idling control

manifold IS -100 mmHg or less (in absolute
value), the air-fuel ratio is not controlled(to en-
sure the output in the power operation range).
z r 3. When the cooling water temperature IS at or
.-w0 0
.-
C Open Close
above 6 0 ° C and the negative pressure in the
2 2 intake manifold is -100 mmHg or above, nor-
m Engine cooling water
.-
9
-
C
5
0
temperature switch mal air-fuel ratio control is performed if the
m idling switch is closed and idling air-fuel ratio
>
m control IS performed if the idling switch is open.
.-
4-
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
1 v
O2 sensor I
I
0 v
Rich
Lean
comparator output
TFR
Richllean signal
I , T~~
I
Air-fuel I (TI!)
ABCV operation ratio
Rich
vR : 0,sensor comparator output

Tl(Tll) : ABCV step count d r ~ v espeed constant
KPL-KPR : Skip constants
TFR.TFL : 0,sensor lnverslon delay constant
TDO.TDC : 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
Item
Alr horn diameter 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 l ~ n e Main jet diameter (rnrn) (1.22) (1.07)
Primary main air bleed diameter (rnrn) (0.55) (0.60)
Slow llne 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
Power line Type Negative pressure Negative pressure
operation type operation type
Power jet diameter (rnm) (0.4) (0.4)
Acceleration Pump diaphragm diameter (rnm) 20 20
line 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
Float Oil level height (from top to body) (mm) 20.0 20.0
system Float adjusting Lip clearance (mrn) 1.20 1.20
dimensions Tare dimension (mrn) 5.50 5.50
Throttle Fully closed angle (deg.) 7 7
valve Fully opened angle (deg.) 90 90
Choke TYpe Wax type auto Wax type auto

system choke choke
Valve fully closed angle (deg.) 15 15
(ABCV) Maln air bleed flow rate (dmin) (5.0) (5.0)

Slow air bleed flow rate (Urnin) (3.2) (3.2)
( ) : 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 nee-
dle linear motion via the w o r m to control the air
bleed flow rate.
ABCV Sectional View
A
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
Idling switch
1 200 rpm.
adjusting bolt
Adjusting the Idling Switch Installation

COOLING WATER TEMPERATURE SWITCH
Water Temperature Switch Exterior View
Water Temperature Switch Exterior View
Operation
65+3OC Close
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.
Open (ON) The operation characteristic of the water tempera-
(OFF) 58OC MIN ture 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
v
M18x 1.5
I'
0 2
High
Little
Rich signal
I
Width across flats 22
Reference voltage
I
0
-0.6
--
0, Sensor Exterior View
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 theo-
ret~calratio, the air requ~redfor fuel combust~onis
suffic~entand much oxygen is contained in the ex-
haust gas.
When the air-fuel mixture is r~cherthan the theo-
retical ratlo on the contrary, almost no oxygen is
contained in the exhaust gas. Threfore, it is possi-
ble 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 in-
creases as the air-fuel mixture becomes sensor and
decreases at ~t becomes leaner.
Much
1 Low Rich-Air-fuel - Lean I
Note: The 0, sensor starts t o operate at about
370°C or above.
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

Three-way catalyt~cmuffler - Decrease of CO, HC and
NOx contents
(Monol~thicplatinum-rhodium
alloy catalyst)
Air-fuel ratio controller 14Ylmin Control of air-fuel ratio at
Carburetor around theoretical ratio
Regulator set
Injector
O2 sensor
ECU
Crankcase em~ssioncontrol system - Purge of HC by recombustion
(standard veh~cle) 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 slg-
nal from the 0, sensor Installed In the exhaust man~fold,and sends the correspond~ngslgnal to [he LPG In-
jector
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 three-
way catalyst
Equation
C0
HC
2CO + 0,
m
CnHm + ( n +-I
4 0,
-t
+
2C0,
m
nCO, + (--i H 2 0
2
1 Oxdnt~on
NOx 2 N 0 + 2C0 + N2 + 2 C 0 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
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. The exhaust gas flow from the LPG engine is straightened by the straightening vanes and enters into
the monolithic catalyst chamber.
2. 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
This catalyst is suitable for simultaneous purge of
t
Purge
/ range of
a~r-fuelratio the CO, HC and NOx contents in the exhaust gas.
As shown at left, the air-fuel ratio should be rnain-
% ratio tained near the theoretical level to obtain high purge
i
Low
ratios for the CO, HC and NOx contents.
The air-fuel ratio controller, therefore, controls the
air-fuel ratio around the theoretical level.
Rich t Air-fuel t Lean
ratio
Three-way Catalytic Muffler Performance Curves
-78-
AIR-FUEL RATIO CONTROL ECU
Input-Output Connection and Block Diagram
.--.-.-.-------------,OX RIL monitor

I---:
Connector Pin Arrangement
E01 OXM VSW2

0, sensor VR
RichILean signal (VR/L) Lean

I
I
-I
Rich
--
/ I
I Rich
1 Lean
OIL signal (VOP)
-
Corresponds
VF monitor (VF)
Corresponds
to TI. P to To.
Detail (Enlar ement

of timeaxis?
I I
@ symbol In the f ~ g u r eabove shows that inltlal set To (initial set lnjectlon time) is selected as the VF wave-
form 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 ) .
VR : 0,sensor reference voltage
F : Oscillation frequency
Tmax : Maximum injection tlme
Tp : Resistor short-clrcu~ttime
To : Initial injection tlme setting
KR : lnjectlon time integration constant
KL : Injection time Integration constant
P : Skip
TI : 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.
Only the carburetor for the 4 Y engine has the pow-

er screw opening l ~ m ~ t e
(made
r of r e s ~ n )
Carburetor body T h ~ sIS provided to change the power screw open-
Ing 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.)
Power screw
Power Screw Opening Limiter (4Y Engine)

- - -
REGULATOR SET
Regulator Set Exterior View and Regulator Sectional View
Main solenoid High performance filter Union for -PG injector

Union L.PG iniector / / /
Carburetor
Fuel hose
main line
injector
v
Hot water hose
S I O ~fuel hose t
LPG
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 stan-
dard veh~cle
Fuel E n ~ o nEjector Diameter Unit: m m
Eng~ne
Standard vehicle
Air-fuel ratio control 2.5 3.0
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 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 theo-
retical ratio, the air required for fuel combustion is
Rich signal
Reference voltage sufficient and much oxygen is contained in the ex-
I I haust gas.
When the air-fuel mixture is richer than the theo-
retical ratio on the contrary, almost no oxygen is
contained in the exhaust gas. Threfore, it is possi-
ble 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 in-
creases as the air-fuel mixture becomes sensor and
decreases at it becomes leaner.
Note: The 0, sensor starts t o operate at about
I 370°C or above.
I I Rich-Air-fuel- Lean
0, Sensor Output Characteristic
- 84
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 3 4
Part No
1
lllustrat~on
i'" 09010-201 11-71

Englne unlt
hanger
0
SERVICE STANDARDS
ENGINE
Item
I.O-ton -3.0-ton
vehicles
Gasoline exhaust emission control system (three-way catalyst)
CO concentration (at idling) Standard 0 . 2 % or less
No conduction
In pressed state Standard
Idle switch 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
ldle switch conduction
1 2 0 0 f 5 0 rpm or more Standard Conduction
CO concentration (at maximum no-load speed) Standard 0 . 5 % or less
Three-way catalytic muffler Limit 2 0 0 0 hours
No conduction
58' C or below Standard
Water temperature sensor ( 1 M Q or more)
conduction Conduction
6 5 " C or less Standard
( 0 . 5 Q or less)
- 1 0 0 f 2 0 mmHg or No conduction
Standard
below ( 1 MQ or more)
Vacuum switch conduction
- 7 0 f 2 0 rnmHg or Conduction
Standard
above ( 0 . 7 Q or less)
Between ABCV and Good if the pointer deflects
ABCV signal voltage Standard
E terminals (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
ABCV signal voltage
Between @B(@) and FCM2 Lim~t 70f5 Q
Between @ B ( @ ) and FCM4 Standard 70f5 Q
No conduction
Between body and F C M l Standard
( 1 0 M Q or rnore)
No conduction
Between body and FCM2 Standard
Conduction between ABCV ( 1 0 M Q or more)
body and motor coils No conduction
( 10 M Q or rnore)
No conduction
( 10 M Q or rnore)
10 tlmes or morel10 sec
0, sensor signal voltage Between RIL and E terminals Standard
(Voltage at the 0 - 1 2 V,
LPG exhaust emission control system (three-way catalyst)
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
Good ~f the pointer deflects
531ECU signal voltage Between VF and E terminals Standard
(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 10 times or morel10 sec
0, sensor signal voltage Standard
E terminals -
(Voltage at the time: 0 12 V)
5- 4
TORQUE CONVERTER
Item
I.O-ton -3.0-ton
vehicles
Torque converter
5K engine Standard 1900
4Y engine Standard 2050
Stall speed rPm -
1 DZ engine Standard 2100
1Z engine Standard 2200
5 K engine Standard 3050 + 50
Max~mumno-load speed rpm
4Y engine Standard 2600 + 50
1 DZ engine Standard 2600 + 50
1Z engine Standard 2600 k 5 0
at idling Standard
-
490 834
Main pressure -
( 5 . 0 - 8 . 5 ) [71 121 I
kPa(kglcm2) [psi]
at 2000 rpm Standard
-
932 1373
( 9 . 5 - 14.0) [135- 1991
at idling Standard
-
44 1 834
Clutch pressure ( 4 . 5 - 8 . 5 ) L64.0- 1211
kPa(kglcm2) [psi]
at 2000 rpm Lim~t
-
883 1373
( 9 . 0 -14.0) [ I 2 8 - 1991
at idling Standard
-
196 588
Torque converter 011pressure (2.0-6.0) 128-851
kPa (kglcmz) [psi] 196- 588
at 2000 rpm Standard
(2.0- 6.0) [28 851-
Torque converter oil capacity [(Usgal) Standard 14 (3.7)
MATERIAL HANDLING SYSTEM
Item
I .O-ton -
3.0-ton
vehicles
Rear lift cylinder ( 1-ton vehicle)
Standard 45.0 (1.772)
Cylinder bore m m (in)
Limit 45.20 (1.780)
V.SV:35.0 (1.378)
Standard
FV:32.0 (1.260)
Piston rod outside diameter mm (in)
V.SV:34.92 (1.3748)
Limit
FV:31.92 (1.2567)
Piston rod bend m m (in) Limit 2.0 (0.079)
Front lift cylinder (1-ton vehicle)
Standard 85.0 (3.346)
Cylinder bore m m (in)
Limit 85.4 (3.362)
Standard 70.0 (2.756)
Piston rod outside diameter mm (in)
Limit 69.91 (2.7524)
Piston rod bend m m (in) Limit 2 . 0 (0.079)
Oil control valve ( 1-ton vehicle)
171 60
Lift Standard
( 175) [24901
Rel~efset pressure
kPa (kglcmz) [psi] 11 770
Tilt Standard
(120) [I7101
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
(FROM 1/21 @
1
~ -
0
- - - --_ ---
A6 _- -
7
- - - -&- - - - - -
I I
a o
I IDLE I
I
0 2 1 Sw IGB IGB I
VACUUM ( I (' A B C V I
SW. ' I
FCMl FCM2 FCM3 FCMA
I @
] I m J 0 II--
CARBURETOR
J
8 1 2 5 4
3 Y ' P , P , T J J .
2 I 1 1 4 12 5 9
PWR IDL FCMl FCM2 FCM3 FCM4 IGB
B
@ E M I S S I O N CONTROL U N I T
P A ABCV WTR El OX EOI
7 3 8 13 6 10
7 7 8 ,
5
- - -
- $ 8 m7
l - :112:
2 1
BLOCK CILINDEIl
51( *ATE. PUMP BLOC*
FRAME
@EMISSION
CONTROL U N I T
@CARBURETOR QWATER TEMPLKAIURF

SW I i C t i
-1
O V A C U U M SWITCH EARTH FOR 0,SENSOK
CHECK CONNECTOR
3- 4
SHORT PIN (BR)
Gasoline vehicle connector drawings
-92-
LPG VEHICLE
LPG vehicle connector drawings

Toyota Forklift 5FD (G) 10-30 Series Repair Manual CE001-1

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Toyota Forklift 5FD (G) 10-30 Series Repair Manual CE001-1

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FOREWORD

Repair manuals related to this manual are as follows:

TO YO TA 5FG/5FD 10-30 SERIES REPAIR

TOYOTA MOTOR CORPORATION

VEHICLE LISTING .................................................. 0 -3

FRAME NUMBER ................................................... 0-5

HOW TO READ THIS MANUAL ............................... 0-6

PERIODIC MAINTENANCE ....................................... 0-8

PERIODIC REPLACEMENT LUBRICANTS AND

HOW TO READ THIS MANUAL

Example of description in pattern B

DISASSEMBLY . INSPECTION . REASSEMBLY Tightening torque unit :T = N.m (kg-cm) [ft-lbl

If a place or part cannot be indicat-

Oil Pump Disassembly Procedure

POINT OPERATIONS Explanation of key point for operation with an illustration

3 . Matters omitted in this manual

Standard: Values showing allowable range in ~nspectionand adjustment.

Abbreviation (code) Mean~ng Abbreviation (code) Meaning

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

Inspection Period Months 1 3 6 12

9. Injector cleanlng and damage

Interval 1 month 3 months 6 months 12 months

Torque converter oil • •

Power steering rubbers parts • *?

Hydraulic hoses a'2

Torque converter rubber hoses @*2

Air Cleaner Sectional View

Type Combined type (dry + cyclone)

Air Cleaner Components

After wash~ng,dry In the air or with cold air

Evacuator valve (dust discharge valve) cleaning.

ater temperature switch

Gasoline Exhaust Emission Control System

Baffle plate lnterram mat Straightening vane

Three-way Catalytic Muffler Sectional View

Three-way Catalytic Gasoline Exhaust Emission Control System Components

lnspection 1 : CO concentration check

lnspection 2: Muffler inspection

Muffler replacement - CO concentration

lnspection 3: Water temperature sensor inspection

Inspection of vacu- Vacuum switch

1 - Inspection 5 : ABCV inspection b

Replace ABCV To inspection 6

1 - Inspection 6 : 0, sensor inspection b

1. Warm up the engine sufficiently.

2. Measure the CO concentration at the idling

3. If the CO concentration at idling does not satisfy

ldle switch adjusting bolt

Adjusting the ldle Switch

Measuring the Co Concentration (at Full Acceleration)

lnspection 2: Muffler inspection

Three-way Catalytic Muffler

Inspection 3: Water temperature sensor inspection

lnspection 4: Vacuum switch inspection

Connecting the Mity Vac

Measuring the Switch Conduction

lnspection 5: ABCV inspection

lnspecting the ABCV Signal Voltage

2. lnspection of ABCV alone