FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT

5FD50 - 80, 5FG50 - 60, Series. Please use this manual for providing quick,
correct servicing of the corresponding forklift models.

This manual deals with the above models as of December 1990. Please un-
derstand that disagreement can take place between the descriptions in the manu-
al and actual vehicles due to change in design and specifications. Any change
or modifications thereafter will be informed by Toyota Industrial Vehicles' Parts
& Service News.

For the service procedures of the mounted engine, read the repair manuals listed
below as reference together with this manual.

(Reference)

Repair manuals related to this manual are as follows:

0TOYOTA INDUSTRIAL VEHICLE 122 ENGINE (NO. CE6 15- 1)
REPAIR MANUAL
070YOTA INDUSTRIAL VEHICLE W06E ENGINE (No. CE6221
REPAIR MANUAL
070YOTA INDUSTRIAL VEHICLE 3F ENGINE (No. CE614)
REPAIR MANUAL

TOYOTA MOTOR CORPORATION

 SECTION INDEX
NAME

GENERAL
X I
TORQUE CONVERTER
1 1
DlFFERENTlALu A

FRONT AXLE

* REAR AXLE

BRAKE
a

MATERIAL HANDLING SYSTEM

MAST
CYLINDER

OIL CONTROL VALVE

HYDRAULIC PIPING
p
 GENERAL

Page
EXTERIOR VIEWS .................................................. 0-2

VEHICLE LISTING ..................................................

FRAME NUMBER ...................................................
HOW TO READ THIS MANUAL ...............................
EXPLANATION METHOD .....................................
TERMINOLOGY ..................................................
ABBREVIATIONS ................................................

OPERATIONAL TIPS ...............................................

STANDARD BOLT & NUT TIGHTENING TORQUE ......
BOLT STRENGTH TYPE IDENTIFICATION
METHOD ...........................................................
TIGHTENING TORQUE TABLE ..............................
PRECOAT BOLTS ...................................................
HIGH PRESSURE HOSE FITTING TIGHTENING
TORQUE ............................................................

WIRE ROPE SUSPENSION ANGLE LIST .....................

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION
ANGLE ..............................................................

COMPONENTS WEIGHT .........................................

RECOMMENDED LUBRICANT QUANTITY & TYPES ...
LUBRICATION CHARTS ..........................................
PERIODIC MAINTENANCE .......................................
PERIODIC REPLACEMENT LUBRICANTS & PARTS .....
-5-
0- 2

EXTERIOR VIEWS

Front View

Rear View

-6-
 0-3

VEHICLE LISTING

FRAME NUMBER
Engine Model Punching format Punching position

5FG50 Top on rear right frame

3F 5FG60-10001
5FG60

5FD50

122 5FD60 5FD70-10001

5FD70

W06E 5FD80 5FD80-10001

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 = kg-cml

If a place or part cannot be indicat-

ed directly, the part name is
described on the either side of the
illustration.

Example: 1 Piping

T = 470 - 490

Oil Pump Disassembly Procedure

DISSASEMBLY
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 1 I
1
Disassembly: Put a match mark when removing the pump cover.
[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.12 mm (0.7528 in.)
 How to read components figures (Example)
( 1) The components figure use the illustration
in the parts catalog for the vehicle model.

l-----7
please refer to the catalog for checking the
part name.
The number at the right shoulder of each FIG number in parts catalog
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:
Important 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 inspection and adjustment.

Limit: Maximum or minimum allowable value in inspection or adjustment.

ABBREVIATIONS

Abbreviation (code) Meaning Abbreviation (code) Meaning

ASSY Assembly SST Special service Tool

LH Lifthand STD Standard

OPT Option T= Tightening torque

01s Oversize OOT Number of teeth (00)

PS Power steering UIS Undersize

RH Right hand WI With

SAE Society of Automotive

Engineers (USA)
OPERATIONAL TIPS
1. Safe operation
( 1 ) After jacking up, always support with rigid stands.
( 2 ) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load
capacity.
( 3 ) Always disconnect the battery plugs before the inspection or servicing of electrical parts.

2. Tactful operation
( 1 ) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure
gauge, etc.) and SSTs before starting operation.
( 2 ) Before disconnecting wiring, always check the cable color and wiring state.
( 3 ) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts
neatly to prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools and
operate in a clean location.
( 5 ) Follow the described procedures for disassembly, inspection and reassembly.
( 6 ) Replace, gaskets, packings and O-rings with new ones each time of disassembly.
( 7 ) Use genuine Toyota parts for replacement.
( 8 ) Use specified bolt and nuts. Observe the specified tightening torque at the time of reassembly. If
no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque
table.

3. Grasping the troule state

When a trouble occurs, do not attempt immediate disaaaembly or replacement but first check if the trou-
ble requires dissassembly or replacement for remedying.
 0-7

STANDARD BOLT & NUT TIGHTENING TORQUE

Standard bolt and tightening torques are not indicated.
Judge the standard tightening torque as shown below.

1. Find out the type of the bolt from the list below and then find the bolt tigttening toghtening torrue from
the table.
2. The nut tightening torque can judged from the mating bolt type.

BOLT STRENGTH TYPE IDENTIFICATION METHOD

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

Hexagon head bolt

91611- 40625

D ~ a m e t e r( m m 1

D ~ a m e t e r( m m 1
TIGHTENING TORQUE TABLE

S p e c ~ f l e dtorque
Class Dtameter Pltch Hexagon Hexagon
head bolt flange bolt
rnm rnm kg-crn ; ft-lb N-rn kg-cm ;
f t -l b N-m
6 1 .o 55 1 48 m.lbl 5. 4 60 52 ~n-lb 5. 9
8 1.25 130 I 13 145 I 10 I 14

4T
10 1.25 260 19
1
25 290 21 , 28
12 1.25 480 1 35 1 47 540 1 39 1 53
I4 1.5 760 I 55 I 75 850 I 61 I 83
16 I .5 1150 1 83 1 113 - I - I -
6 1 .O 65 1 561nl b ; 6.4 I I
8 1.25 160 I 12 I 16 I I

5 T
10 1.25 330 1 24 1 32 I
I
- I
I
-
12 1.25 600 59
14 1.5 930 1 91 I I

16 I .5 1400 101 1 137

I
I
I
I
6 1 .O 80 1 6 9 1n-lbl 7.8 90 1 78 ~ n - l b1 8.8
8 1.25 195 I4 I 19 215 1 16 21
6 T 10 1.25 400 29 j 39 440 32 1 43
12 1.25 730 53 72 810 59 79
14 1.5 - I - I - 1250 1 90 1 123
6
8
1 .O
1-25
110
260
I 8
19
I I 1
25
120
290
9 1
21
1 2
28
10 1-25 530 1 38 1 52 590 1 43 1 58
7T
12 1-25 970 I 70 1 95 1050 1 76 1 103
14 1.5 1500 I 108 I 147 1700 1 123 I 167
16 1.5 2300 1 166 1 226 - 1 - 1 -
PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)

1. Do not use the precoat bolt as it is in either of

the following cases:
(a) After it is removed.
(b) When the precoat bolt is moved (loosened
or tightened) by tightness check, etc.

Note:
For torque checkruse the lower limit of the
allowable tightening torque range. If the bolt
moves, retighten it according t o 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 blowing.
threaded hole must be washed even for (3) Coat the specified seal lock agent to the thread-
replacement of the bolt.) ed portion of the bolt.

HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE

1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact with clean cloth
to remove foreign matters and dirt. Also check no dent or other damage on the contact surfaces before
installation.

2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten the
fitting.

3. The maximum tightening torque must not exceed twice the standard tightening torque

Nominal diameter Standard tightening torque kg-cm (ft-lb) Hose inside diameter
of screw (mm)
Standard Tightening range

7116 - 20 UNF 2.5 ( 18.1) 2.4- 2.6 (17.4- 18.8) 6

9116 - 18 UNF 5.0 ( 36.2) 4.8- 5.3 (34.7- 38.3) 9
314 - 16 UNF 6.0 ( 43.4) 5.7- 6.3 (41.2- 45.5) 12
718 - 14 UNF 6.0 ( 43.4) 5.7- 6.3 (41.2- 45.5) 12
1 . 1116 - 12 UNF 12.0 ( 86.6) 11.4- 12.6 (82.4- 91.1) 19
1 . 5116 - 12 UNF 14.0 (101.2) 13.3- 14.7 (96.2- 106.3) 25

PFI14 5.0 ( 36.2) 4.8- 5.3 (34.7- 38.3) 9

PF318 5.0 ( 36.2) 4.8- 5.3 (34.7- 38.3) 9
PFI12 6.0 ( 43.4) 5.7- 6.3 (41.2- 45.5) 12
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
WlRE ROPE SUSPENSION ANGLE LIST
[Lifting Compres- Suspension Lifting Compres- Suspension
Tension Tension
angle sion method angle sion method

0"
1.oo
time
0
time

-lA
7
90O
1.41
time
.
time
\-
dk
2 t

30"
1.04
time
0.27
time fi.
.0" *
l*oO
2.00
time time

1.16
60"
time time
\.
2 1

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE

unit: ton (Ib)
S~ngle-rope
Two-rope suspension Four-rope suspension
Rope Cutting SusDenslon
d~arneter load
0" 30° 60' 90'

6 rnrn 1.24 1.2 1.06 0.88

(0.24 in.) (2734) (2646) (2337) (1940)

8 mm 1.8 1.74 1.56 1.28

(0.32 in.) (3969) (3937) (3440) (2822)

10 rnm 2.8 2.7 2.4 2.0

(0.4 in.) (6174) (5954) (5292) (4410)

12.5 rnrn 4.4 4.2 3.8 3.0

(0.5 in.) (9702) (9261) (8379) (6615)

14 rnrn 5.6 5.4 4.8 3.8

(0.56 in.) (12348) (11907) (10584) (8379)
COMPONENTS WEIGHT
Unit: kg (Ib.) [NI

Component Applicable vehicle Weight

122 335 (739) [32851

Engine W06E 490 (1080) 148051

3F 250 (551 [54001

Two speeds 360 (794) [35301

Torque convertor
Three speeds 390 (860) 184341

5-ton Approx. 2450 (5400) [240261

6-ton Approx. 3000 (6615) [294201

7-ton Approx. 3700 (8159) [362801

Balance weight
8-ton Approx. 4210 (9283) [412901

6-ton (M60) Approx. 2810 (6196) [275571

7-ton (M70) Approx. 3560 (7850) [349101

5 - 6-ton Approx. 370 (816) [36301

Mast LlLift Bracket 7-ton Approx. 430 (948) [42201

8-ton Approx. 660 ( 1460) [64721

RECOMMENDED LUBRICANT QUANTITY & TYPES
Description Classification TYpe Application Quantity

API Motor oil 3F

SD, SE, SF SAE30
(SAE20 in cold area)
Gasoline 9.31 (2.46 US.gal)
SAE20W-40
(SAEIOW-30 in cold
Engine area)

API Diesel engine oil

122 12.51 (3.30 US.gal)
CC, CD SAE30
Diesel
(SAE20 in cold area)
W06E 13.OP (3.43 US.gal)
SAEl OW-30
API Hypoid gear oil 5FGID50-70 1.5F (0.40 US.gal)
Planetary gear oil SAE85W-90
GL-4
(left and right)
G L-5 5FD80 2.0P (0.53 US.gal)

API Hypoid gear oil All models

Differential G L-4 SAE85W-90 6.51 (1.72 US.gal)
GL-5

AT F GM All models
Torque converter 33.01 (8.72 US.gal)
Dexronm I1

Maximum
fork height
IS0 Hydraulic oil IS0 901 (23.8 US.gal)
Hydraulic oil below
VG32 VG32 6.0 m (236 in)

8.0 m (315 in) 1001(26.4 US.gal)

Fuel tank All models 1401 (37 US.gal)

Chassis parts MP Grease All models Proper quantity

LLC LLC 30-50% mix-

3F 13.01 ( 3 . 4 US.gal)
ture (for winter or
Coolant all-season)
(Excluding reserve Coolant with rust- 122 13.01 (3.4 US.gal)
tank) inhibitor (for
spring, summer
W06E 15.OP (4.0 US.gal)
and autumn)

Coolant (Reservoir All models 1 .I1(0.29 US.gal)

tank)
t T
(at Full level)

"L.L.C. = Long Life Coolant

(Appropriately diluted with fresh water)
LUBRICATION CHARTS

4
5

10

12

15
16

17

1. Fork shaft (8ton models)

2. Chain
3. Tilt cylinder front pin
4. Planetary gear
[Inspect every 8 hours (daily)]
5. Mast support cap
[Inspect every 4 0 hours (weekly)]
6. Differential case
[Inspect every 170 hours (monthly)]
7. Tilt steering universal joint
[Inspect every 1000 hours (6 monthly)]
8. Tilt steering locking mechanism
[Inspect every 2000 hours (annually)]
9. Universal joint
10. Tilt cylinder rear pin
Check and replenish
11. Torque convertor and transmis-
Replace
sion case
Multi-purpose grease
12. Oil tank
Hypoid gear oil SAE 9 0
13. Engine crankshaft case
Engine oil
14. Rear axle beam front pin
Hydraulic oil
15. Steering knuckle king pin
Automatic transmission fluid
16. Tie rod end
17. Rear wheel bearing
18. Rear axle beam rear pin

Lubrication Chart
 - - -

PERIODIC MAINTENANCE
INSPECTION METHOD

I : Inspection. Repair or replacement 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
I ENGINE I
Proper starting and abnormal noise I 0 0 0 0
Rotating condition at idling M 0 0 0 0
Rotating condition during acceleration M 0 0 0 0
!
i Exhaust gas condition I 0 0 0 0
Main body Air cleaner element C 0 0 0 0
Valve clearance M 0" 0
Compression M 0
Cylinder head bolt loosening T 0" 0
Muffler rubber mount I 0
Clogging and damage in PCV valve and
PCV system I 0 0 0 0
piping
Governor No-load maximum rpm M 0 0 0 0
Oil leak I 0 0 0 0
Lubrication
system
Oil level I 0 0 0 0
Clogging and dirt of oil filter I 0 0 0 0
Fuel leak I 0 0 0 0
Operation of carburetor link mechanism I 0 0 0 0
Dirt and clogging of fuel filter and element I 0 0 0 0
Fuel system Injection timing M 0 0
Injection nozzle injection pressure and
spray status
M 0
Draining of sedirnenter I 0 0
Coolant level in radiator ana leak I 0 0 0 0
Rubber hose degradtion I 0 0 0 0
Cooling
system
Radiator cap condition I 0 0 0 0
Fan belt tension, looseness and damage I 0 0 0 0
Radiator rubber mount I 0
Radiator screen C 0 0 0 0
 Inspection Period Months 1 3 6 12
Item Hours 170 500 1000 2000
POWER TRANSMISSION SYSTEM
Leak I 0 0 0 0
Differential Oil level I 0 0 0 0
Bolt loosening T 0
Oil leak I 0 0 0 0
Planetary gear Oil level I 0 0 0 0
Bolt loosening T 0
Leak I 0 0 0 0
Fluid level I 0 0 0 0
Operating mechanism function and I 0 0 0 0
Torque looseness
converter and
transmission Control valve and clutch functions I 0 0 0 0
Inching valve function I 0 0 0 0
Stall and hydraulic pressure M 0 0
measurement
Loose joint T 0 0 0
Propeller Looseness at spline connections I 0
shaft and
axle shaft Looseness of universal joint I 0
Twisting and cracks of axle shaft I 0
DRIVE SYSTEM
Tire inflation pressure M 0 0 0 0
Tire cuts, damage and uneven wearing I 0 0 0 0
Loose rim and hub nuts T 0 0 0 0 .
Tire groove depth M 0 0 0 0
Wheels
Metal chips, pebbles and other
I 0 0 0 0
foreign matter trapped in tire grooves
Rim, side bearing and disc wheel damage I 0 0 0 0
Abnormal sound and looseness of
I 0 0 0 0
fornt wheel bearing
Abnormal sound and looseness of
Wheel I 0 0 0 0
rear wheel bearing
Cracks, damage and deformation of
Front axle I 0
housing
Cracks, damage and deformation of beam I 0
Rear Axle Looseness of axle beam in vehicle
M 0' 0
longitudinal direction
 Inspection Period Months 1 3 6 12

Item Hours 170 500 1000 2000

STEERING SYSTEM

Steering Play and looseness I 0 0 0 0

wheel Function I 0 0 0 0
Oil leak I 0 0 0 0
Gear box Looseness of mounting T 0 0 0 0
Clogging of relief valve filter C 0 0
Rods, links Looseness and damage I 0 0 0 0
and arm Linkage wear and mounting condition I 0
Oil leak I 0 0 0 0
Power
Mounting and linkage looseness I 0 0 0 0
steering
Damage of power steering hose I 0
King pin looseness I 0 0 0 0
Knuckle
Cracks and deformation I 0
Steering Wheel alignment M 0
shaft Left and right turning angle M 0
BRAKING SYSTEM
Play and reserve M 0 0 0 0
Brake pedal
Braking effect I 0 0 0 0
Operating force I 0 0 0 0
Parking brake Braking effect I 0 0 0 0
-- -~
Rod and cable looseness and damage I 0 0 0 0
Brake pipe Leak, damage and mounting condition I 0 0 0 0
Brake valve . Function, wear, damage, leak and
I 0
Acurnrnulator mounting looseness
and wheel
cylinder
Clealance between drum and lining M 0 0 0 0
Wear of shoe sliding portion and lining I 0
Brake Drum wear and damage I 0
and brake Shoe operating condition I 0
shoe Anchor pin rusting I 0
Return spring fatique M 0
Automatic adjuster function I 0
Deformation, cracks and damage 1 0
Backing plate
Loose mounting T 0
 Inspection Period Months 1 3 6 12
Item Hours 170 500 1000 2000
MATERIAL HANDLING SYSTEM
Abnormality of fork and stopper pin I 0 0 0 0
Misalignment between left and right
Forks I 0 0 0 0
fork fingers
Cracks at fork root and welded part Ir3 0
Deformation and damage of each part
I 0 0 0 0
and crack at welded part
Mast and lift bracket looseness I 0 0 0 0
Mast and Wear and damage of mast support bush I 0
fork bracket Wear, damage and rotating condition
I 0 0 0 0
of rollers
Wear and damage of roller pins I 0
Wear and damage of mast strip I 0 0 0 0
Tension, deformation and damage of
I 0 0 0 0
chain

Chain and Chain lubrication I 0 0 0 0

chain wheel Abnormality of chain anchor bolt I 0 0 0 0
Wear, damage and rotating condition
I 0 0 0 0
of chain wheel
Various Abnormality and mounting condition of
I 0 0 0 0
attachments each part
HYDRAULIC SYSTEM
Loosening and damage of cylinder
T 0 0 0 0
mounting
Deformation and damage or rod, rod
I 0 0 0 0
Cylinder screw and rod end
Cylinder operation I 0 0 0 0
Natural drop and natural forward tilt
M 0 0 0 0
(hydraulic drift)
Oil leak and damage I 0 0 0 0
Wear and damage of pin and cylinder
I 0 0 0 0
Cylinder bearing
Lifting speed M 0 0 0 0
Uneven movement I 0 0 0 0
Oil pump Oil leak and abnormal sound I 0 0 0 0
Oil level and contamination I 0 0 0 0
Hydaulic
Tank and oil strainer C 0 0
oil tank
Oil leak I 0 0 0 0
 Inspection Period Months 1 3 6 12
Item Hours 170 500 1000 2000

Control Loose linkage I 0 0 0 0

level Operation I 0 0 0 0
Oil leak I 0 0 0 0
Oil control
Relief pressure measurement M 0
valve
Relief valve and tilt lock valve functions I 0 0 0 0
Oil leak I 0 0 0 0
Hydraulic
Deformation and damage I 0 0 0 0
piping
Loose joint T 0 0 0 0
ELECTRICAL SYSTEM
Cracks on distributor cap I 0 0 0 0
Spark plug burning and gap I 0 0 0 0
Distributor side terminal burning I 0 0 0 0
Ignition Distributor cap center piece wear and
I 0 0 0 0
timing damage
Distributor points gap M 0 0 0 0
Plug cord internal discontinuity I 0
Ignition timing M 0 0
Starting
Pinion gear meshing status I 0 0 0 0
motor
Charger Charging function I 0 0 0 0
Battery fluid level I 0 0 0 0
Battery
Battery fluid specific gravity M 0 0
Electrical Damage of wiring harness I 0 0 0 0
wirning Fuses I 0 0 0 0
Engine stop-
ping system
Diesel engine key stop device function I 0 0 0 0
SAFETY DEVICE, ETC.
Cracks at welded portion I 0 0 0 0
Head guard
Deformation and damage I 0 0 0 0
Loosening of mounting T 0 0 0 0
Back-rest
Deformation, crack and damage I 0 0 0 0
Lighting
Function and mounting condition I 0 0 0 0
system
 Inspection Period Months 1 3 6 12
Item Hours 170 500 1000 2000
Horn Function and mounting condition I 0 0 0 0
Direction
indicator
Function and mounting condition I 0 0 0 0
Instruments Functions I 0 0 0 0
Backup buzzer Function and mounting condition I 0 0 0 0
Rear-view Dirt, damage I 0 0 0 0
mirror Rear reflection status I 0 0 0 0
Seat Loosening and damage of mounting 1 0 0 0 0
Damage and cracks of frame, cross
I 0
members, etc.
Body
Bolt looseness T 0
Others Grease up L 0
-
0
-
0 0
PERIODIC REPLACEMENT LUBRICANTS AND PARTS
0 : Reolacement
Interval 1 3 month 1 6 month 1 12 month
Item 1 500 hours 1 1000 hours 1 2000 hours
Engine
Engine oil filter
Engine coolant (every 2 years for LLC)
Fuel filter
Torque convertor oil
Torque convertor oil filter
Planetary gear oil
Differential oil
Hydraulic oil
Hydraulic oil filter
Wheel bearing grease
Spark plug
Distributor points
I Cyclone air cleaner element
I Brake valve & accumulator rubber parts
I Cups and seals for wheel cylinders
I Power steering hoses
Power steering rubber parts
Hydralic hoses
Fuel hoses
Torque converter rubber hoses
Chains

* ' : 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
EXTERIOR VIEWS .................................................. 1-2

ENGINE SECTIONAL VIEWS .................................... 1-4

ENGINE PERFORMANCE CURVES ............................ 1-7

ENGINE ASSY .......................................................

REMOVAL . INSTALLATION .................................
ENGINE SPEED ADJUSTMENT .............................
AIR CLEANER .......................................................
RADIATOR ............................................................
MUFFLER . EXHAUST PIPE .....................................

BATTERY ..............................................................

STARTING MOTOR ................................................

ALTERNATOR .......................................................
ACCELERATOR PEDAL ...........................................
EXTERIOR VIEWS

L 122 Engine Exterior View

W06E Engine Exterior View

3F Engine Exterior View
ENGINE SECTIONAL VIEWS

122 Engine Sectional View

-28-
W 0 6 E Engine Sectional View

-29-
3F Engine Sectional V i e w

-30-
 1- 7

ENGINE PERFORMANCE CURVES

122 Engine Performance Curves

-31 -
 Engine speed (rpm) x loZ

W 0 6 E Engine Performance Curves

-32-
 26.011200

24.511400
-26 !J'
'D.
-25 2
S
,,
<
.... n

/
, ,, . ... -24 $

-
23 (kg-m)

\ - 22
\

80 -
7512300 \
\
- 21
6712300

70 -
z
L

%
L

60 - \
*-
C
m
r
V)

50 -

(PSI
Gasoline

- - - - - - - LP gas
40 -
(combined with gasoline)

-
/
/

30
71
C

210 ;
----__
-----__ 200
z.
:
20012000

(glpsh)
I I I I I
10 14 18 22 26

Engine speed (rpm) Gasoline x lo2

3F Engine Performance Curves

-33-
ENGINE ASSY
REMOVAL . INSTALLATION

Disconnect the wires

and pipes.
Temporarily suspend
the engine ASSY
L I
Engine ASSY Removal and Installation

Removal Procedure
1 Remove the body ASSY. [Point 11
2 Drain coolant.
3 Disconnect the wlres and fuel pipes from around the injection pump.
(Vehicle with 122 or W06E engine)
Disconnect the wires and fuel pipes from the carburetor and air governor.
(Vehicle with 3F engine)
4 Disconnect the electrical wiring (including bond cable).
5 Remove the set bolts (or nuts) from the exhaust pipe flange (on the engine side)
6 Remove the radiator ASSY Wlfan shroud. [Point 21
7 Remove the torque converter drive plate set bolts. [Point 31
8 Remove the engine mounting set nuts.
9 Remove the mater~alhandling oil return filter set bolt
10 Temporarily suspend the engine ASSY. [Point 41
11 Remove the engine ASSY and torque converter housing set bolts. [Point 51
12 Remove the engine ASSY. [Point 61
Installation Procedure

The installation procedure is the reverse of the removal procedure

Note:
Operate as follows after installing the engine ASSY.
Air bleeding from fuel circuit (Vehicle w i t h 122 or W06E engine)
Inspection and adjustment of engine speed

Point Operations
[Point 1I
Removal . Installation:
See the removal section for the body ASSY.

Removing the Body ASSY

Removing the Fan

[Point 31
Removal . Installation:
When rotating the torque converter drive plate, ro-
tate the engine crank pulley for easy operation.

Rotating the Crank Pulley

-35-
1- 12

Installation:
Carefully operate so as not to drop set bolts into the
housing.

Removing the Set Bolts

[Point 41
Removal:
Temporarily suspend the engine ASSY by using the
SST.
SST 09090-04010

Temporarily Suspending the Engine

[Point 51
Removal . Installation:
Support the torque converter with a panta graph
jack.
Alternately raise the engine side with a hoist and the
torque converter side with the jack little by little un-
til the engine ASSY is raised by approximately 1 0
cm (3.94 in) at the engine mount.

Supporting with a Jack

[Point 61
Removal . Installation:
Remove the engine ASSY after checking no wiring,
hose or cable is left unconnected while paying at-
tention to the surrounding area.

Removing the Engine ASSY

-
ENGINE SPEED ADJUSTMENT
(122 ENGINE)
Idling Speed lnspection and
Adjustment
1. Warm up the engine.
Coolant temperature:
75 - 85' (167 -
185OF)
2. Install the engine tachometer.
3. lnspect the idling speed.
Standard idling speed: 750 25 rpm
4. Adjust the idling speed.
( 1) Loosen the lock nut, and turn the adjust- Setting the Engine Tachometer
ing screw for adjustment.

No-load Static Maximum Speed

lnspection and Adjustment
1. Warm up the engine.
Coolant temperature:
75 - 85 (167 - 185OF)
2. Install the engine tachometer.
3. lnspect the no-load static maximum speed.
( 1) Fully depress the accelerator pedal, and in-
spect the no-load static maximum speed.
No-load static maximum speed:
- -
2400 ? 50 rpm
Adjusting the Idling Speed

4 Adjust the no-load stattc maximum speed

(1) Remove the seal
( 2 ) Adjust the no-load stat~cmaxlmum speed
by turnlng the maxlmum speed adjust~ng
screw
( 3 ) Operate the material handl~nglever when
the englne IS runnrng at the maxlmum
speed, and measure the engine speed In
the full relief sta:e Conftrm that the speed
decrease (relief down) IS w ~ t h ~then l~mrt
shown below
Engine speed d o w n at full rel~ef:
Adjusttng the Max~mumSpeed
W ~ t h i n250 rpm
(4) Seal the adjusting screw after the ad
justment.

Measuring the Relief Down

ENGINE SPEED ADJUSTMENT
(W06E ENGINE)
Idling Speed lnspection and
Adjustment
1. Warm up the engine
Coolant temperature:
75 - 85' (167 - 185OF)
2. Install the engine tachometer.
3. lnspect the idling speed.
Standard idling speed: 7 5 0 5 2 5 rpm
4. Adjust the idling speed.
( 1) Loosen the lock nut, and turn the adjust- Setting the Engine Tachometer
Ing screw for adjustment

No-load Static Maximum Speed

lnspection and Adjustment
1. Warm up the engine.
Coolant temperature:
75 - 85O (167 - 185OF)
2. Install the engine tachometer.
3. lnspect the no-load static maximum speed.
(1 ) Fully depress the accelerator pedal, and in-
spect the no-load static maximum speed.
No-load static m a x i m ~ r nspeed:
2400 k 50 rpm
1 - --
Adjusting the Idling Speed

4. Adjust the no-load static maximum speed.

( 1) Remove the seal.
( 2 ) Adjust the no-load static maximum speed
by turning the maximum speed adjusting
screw.
( 3 ) Operate the material handling lever when
the engine is running at the maximum
speed, and measure the engine speed in
the full relief state. Confirm that the speed
decrease (relief down) is within the limit
shown below.
Engine speed d o w n at full relief:
Adjusting the Maximum Speed
Within 250 rpm
(4) Seal the adjusting screw after the ad-
justment.

Measuring the Relief Down

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