Toyota 5 fge35 forklift service repair manual

Toyota 5 fge35 forklift service repair manual

• 1.
  FOREWORD This manual coversthe 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 (Supplement) Pub. No. CE014. as Part 11(Sections 0to 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 1FZENGINE REPAIR MANUAL (No. CE627) TOYOTA INDUSTRIAL EQUIPMENT 1IZ, 122ENGINE REPAIR MANUAL (NO. CE615-1) TOYOTA MOTOR CORPORATION
• 2.
  PART I :1988. 8- SECTION INDEX (CE005) GENERAL ENGINE0 CLUTCH C R TRANSMISSION & DIFFERENTIAL FRONT AXLE REAR AXLE BRAKEaa BODY MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL CONTROL VALVE APPENDIX
• 3.
  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 ....................... 0-14 .........................INSPECTION METHOD 0-14 PERIODIC REPLACEMENT LUBRICANTS AND PARTS ..................................... 0-20
• 4.
  EXTERIOR VIEWS Front View(5FD35) ~ ~ 0 . 7 2 - 1 Rear View (5FD35) - 6 -
• 5.
  VEHICLE LISTING Load capaclty 3.25 ton 3.5ton 4.0 ton 4.5 ton Model 5FG33 02-5FG33 5FD33 02-5FD33 5FG35 02-5FG35 5FD35 02-5FD35 5FGE35 02-5FGE35 5FDE35 02-5FDE35 5FG40 02-5FG40 5FD40 02-5FD40 5FG45 02-5FG45 5FD45 02-5FD45 Engine model 3F t 1 1 Z t 3F t 1 1 Z t 3F t 1 1 Z t 3F t 11Z t 3F t 1 1 Z t Drive system Clutch Torgue converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Engine tYPe Gasoline t Diesel t Gasoline t Diesel t Gasoline t Diesel t Gasoline t Diesel t Gasoline t Diesel t Remarks Wheelbase 1800 mm (71 in) Wheelbase 2000 mm (78.5 in)
• 6.
  ABBREVIATIONS Abbreviations used inthis manual are as follows: 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. 4 Meaning Horsepower Power steering Right hand Society of automotive engineers (USA) Special service tool Standard Sub-assembly Tightening torque Number of teeth (00) Undersize With Abbreviation (Code) ABDC ASSY ATDC ATM BTDC L/ LH LLC MTM OHV 0PT 0/s 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 of hydraulic equipment shall always be done in a clean place using clean tools. Meaning After button dead center Assembly After top dead center Automatic transmission Before top dead center Less Left hand Long life coolant Manual transmission Overhead valve Option Oversize 4. Genuine Toyota parts Genuine Toyota parts should be used even in the replacement of packings, gaskets and O-rings. Abbreviation (Code) PS P/S RH SAE SST STD SUB-ASSY T = OOT U/S W/ 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 to observe the tightening torque given in this manual. If not specified, tighten to 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.
• 7.
  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. Standard hexagon bolt Hexagon bolt I Part NO. example 9 I 1 1 1 - 4 0 61 0 -1T ~ e n g t hunder head (mm) Nominal diamter (mm) two rel~efl~neson Standard bolt with - Strength type 4 = 4T 5 = 5T 6 = 6T 7 = 7T 4T Shape and identification method - Strength type 0 @ INominal diameter Length under head Stud bolt Part No. example 9 2 1 3 2 - 4 - 0 6 1 4 1T ~ e n g t h(mm) Nominal diameter (mm) Number in relief or hallmark on the head No mark - Strength type Nominal diameter Length
• 8.
  TIGHTENING TORQUE TABLE
• 9.
  PRECOAT BOLTS (Bolts withseal 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. If 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. Hose inside diameter (mm) 6 9 12 12 19 25 9 9 12 19 25 Nominal diameter of screw 5- 20 UNF % - 18 UNF - 16 UNF 5- 14 UNF - 12 UNF I & - 12 UNF PF1/4 PF3/8 PF1/2 PF314 PFI Standard tightening torque kg-cm (ft-lb) Standard 2.5 ( 18.1) 5.0 ( 36.2) 6.0 ( 43.4) 6.0 ( 43.4) 12.0 ( 86.6) 14.0 (101.2) 5.0 ( 36.2) 5.0 ( 36.2) 6.0 ( 43.4) 12.0 ( 86.8) 14.0 (101.2) Tightening range 2.4 -- 2.6 (17.4 -- 18.8) 4.8 -- 5.3 (34.7 -- 38.3) 5.7 - 6.3 (41.2 -- 45.5) 5.7- 6.3 (41.2 - 45.5) 11.4- 12.6 (82.4- 91.1) 13.3 -14.7 (96.2 -- 106.3) 4.8 -- 5.3 (34.7 -- 38.3) 4.8 - 5.3 (34.7 - 38.3) 5.7 - 6.3 (41.2 - 45.5) 11.4-12.6(82.4- 91.1) 13.3 -- 14.7 (96.2-- 106.3)
• 10.
  FRAME NUMBER "1 1988.6-1993.3 " 2 1992.11- 1993.3 (EEC spec.) " 3 1993.4- " 4 1993.4-1993.9 (EEC spec.) " 5 1993.10-(EEC spec.) Engine 3F 11Z 3F 11Z LAQS129 Punching ,position Frame No. punching position a Model 5FG 33 02-5FG 33 5FG 35 02-5FG 35 5FD 33 02-5FD 33 5FD 35 02-5FD 35 5FGE35 02-5FGE35 5FG 40 02-5FG 4 0 5FG 45 02-5FG 45 5FDE35 02-5FDE35 5FD 4 0 02-5FD 40 5FD 45 02-5FD 45 Punching format "1 5FG35-10011 " 2 5FG35E10011 "3 5FG35-20011 " 4 5FG35E20011 " 5 5FG35O20011 "1 5FD35-10011 " 2 5FD35E10011 " 3 5FD35-20011 " 4 5FD35E20011 * 5 5FD35020011 "1 5FG45- 10011 " 2 5FG45E10011 " 3 5FG45-20011 " 4 5FG45E20011 "5 5FG45Q20011 "1 5FD45- 10011 " 2 5FD45E10011 " 3 5FD45-20011 " 4 5FD45E20011 "5 5FD45~20011
• 11.
  -- WIRE ROPE SUSPENSIONANGLE LIST Lifting angle oO 30° 60° Compres- sion 0 time 0.27 time 0.58 time Tension 1 .oo time 1.04 time 1 . I 6 time Suspension method :LI fiOA. @ ' Lifting angle 90° 120° Tension 1.41 time 2.00 time Compres- sion timel o o Suspension method ko," time
• 12.
  SAFE LOAD FOREACH WIRE ROPE SUSPENSION ANGLE Unit: ton (Ib) I Rope diameter 8 mm (0.32 in.) 10 mm (0.4in.) 14 mm (0.56 in) Cutting load Two-rope suspension Four-rope suspension COMPONENTS WEIGHT Unit: kg (lb.) Engine Transmission with differential Torque converter with differential Balance weight Mast L/ Lift Bracket (Max. Fork Height: 3000 mm ( 118 in.) 11Z: 330 (728) 3F : 250 (551) Approx. 200 (441) Approx. 360 (794) 3.25 ton Approx. 1920 (4234) 3.5 ton Approx. 2220 (4895) E3.5 ton Approx. 21 30 (4410) 4.0 ton Approx. 2520 (5557) 4.5 ton Approx. 2830 (6240) 3.25-4.0 ton Approx. 650 ( 1433) 4.5 ton Approx. 850 ( 1874)
• 13.
  RECOMMENDED LUBRICANT QUANTITY& TYPES Application 3F 11Z MTM models All models ATM models Description Quantity Up to '88 Nov. 8.0 Q (2.1 US gal) From '88 Dec. 9.3 Q (2.5 US gal) 12.5 Q (3.3 US gal) 6.0 Q (1.6 US gal) 9.5 Q (2.5 US gal) 15 Q (4.0 US gal) Classification API SD, SE, SF API CC, CD API GL-4 GL-5 API GL-4 GL-5 ATF Engine Hydraulic oil Fuel tank Chasis parts Coolant (Excluding reserve tank) Coolant (Reservoir tank) Drive shaft pulley (Oil pump spline shaft) TYpe Motor Oil SAE30 (SAE20 in cold area) SAE20W-40 (SAE1OW-30 in cold area) Diesel engine oil SAE30 (SAE20 in cold area) SAE1OW-30 Hypoid gear oil SAE85W-90 Hypoid gear oil SAE85W-90 GM Gasoline Diesel Torque converter Transmission Differential DexronB I1 IS0 VG32 LLC T Hydraulic oil IS0 VG32 MP Grease @LLC30-50% mix- ture (for winter or all season) *Coolant with rust- inhibitor (for spring, summer and autumn) T Molybdenum disulfide grease Fork height 3000 mm (118 in.) Gasoline models 5FD33,35 Diesel models 5FDE35, 5FD40,45 All models 3F All models All models 60 Q (16 US gal) 95 Q (25 US gal) 95 Q (25US gal) 120 Q (32 US gal) Proper quantity 13.0 Q (3.4 US gal) 13.0 Q (3.4 US gal) 1.1 Q (0.3 US gal) (at Full level) Proper quantity
• 14.
  LUBRICATION CHARTS Chain Differential gear Frontwheel bearing Power cylinder joint Transmission case Rear wheel bearing Steering knuckle king pin Bell crank pin Oil tank Engine crankshaft Rear axle beam front Rear axle beam rear Tilt steering universal joint Tilt steering locking mechanism Mast support bushing Tilt cylinder front pin Propeller shaft (Oil pump drive shaft) Tie-rod end Drive shaft pulley (Oil pump spline shaft) lnspect every 8 hours (daily) lnspect every 40 hours (weekly) lnspect every 170 hours (monthly) lnspect every 1000 hours (6 monthly) lnspect every 2000 hours (annually) lnspect and service Replace MP grease Engine oil Hypoid gear oil Hydraulic oil Hypoid gear oil Molybdenumdisulfide grease Clutch Model Lubrication Chart - 16 -
• 15.
  13 2 14 1 1 1616 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 disulfidegrease 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) i Torque Converter Model Lubrication Chart
• 16.
  PERIODIC MAINTENANCE INSPECTION METHOD I: Inspeciton. Repairorreplacement 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 12 2000 Months Hours 3 500 1 170 h Inspection Period Item --------___ 6 1000 Every Every ENGINE Main body PCV system Governor Lubrication system Fuel system Cooling system I Proper starting and abnormal noise Rotating condition at idling Rotating condition during acceleration Exhaust gas condition Air cleaner element Valve clearance Compression Cylinder head bolt loosening Muffler rubber mount Clogging and damage in PCV valve and piping No-load maximum rpm Oil leak Oil level Clogging and dirt of oil filter Fuel leak Operation of carburetor link mechanism Dirt and clogging of fuel filter and element Injection timing lnjection nozzle injection pressure and spray status Draining of sedimenter Coolant level in radiator and leak Rubber hose degradation Radiator cap condition Fan belt tension, looseness and damage Radiator rubber mount Radiator screen l C t t M t t t M + + ~ l C t t c C t t l C t t ~ t t t I + + + l C t t i t + - + l C t t I + + + l t t C l t t C l t t t I C t t + + + c t t C M M T I M t M I t I
• 17.
  Inspection Period Item - 3 500 Every Every 6 1000 1 170 POWER Clutch Transmission Differntial Torque converterand transmission DRIVE SYSTEM I TRANSMISSION SYSTEM Clutch pedal play Abnormal sound and functioning (connection) Clutch booster function and leak Oil clutch mechanism and leak Leak Fluid level Gear function and abnormal noise Leak Oil level Bolt loosening Leak Fluid level Operating mechanism function and looseness Control valve and clutch functions Inching valve function Stall and hydraulic pressure measurement 12 2000 Months Hours M - + + I C t C l C C e I I + + - + I + - + l C t t I + + + t t t i t + + I + - + + I + + - I + + + I + + - M M t + + I + + + T t t c M + + + I + + + - I + + + I + + + Wheels + T + Tire inflation pressure Tire cuts, damage and uneven wearing Loose rim and hub nuts Tire groove depth Metal chips, pebbles and other foreign matter trapped in tire grooves Rim, side bearing and disc wheel damage Abnormal sound and looseness of front wheel bearing
• 18.
  - - InspectionPeriod -Item -------- Every Every 1 170 Wheel Front axle Rear axle l t t t Abnormal sound and looseness of rear wheel bearing Cracks, damage and deformation of housing Cracks, damage and deformation of beam Looseness of axle beam in vehicle longitudinal direction 3 500 I I M STEERING SYSTEM Steering wheel Gear box Rods, links and arm Power steering Knuckle Steering shaft 6 1000 Play and looseness Function Oil leak Looseness of mounting Clogging of relief valve filter Looseness and damage Linkage and wear and mounting condition Oil leak Mounting and linkage looseness Damage of power steering hose King pin looseness Cracks and deformation Wheel alignment Left and right turning angle 12 2000 BRAKING SYSTEM Months Hours t t t l e e + - l t t t T + + - + - I ' - - ' - I + + + l C C t I + + + Brake pedal Parking brake Brake pipe Brake booster and wheel cylinder C + I I I M M Play and reserve Braking effect Operating force Braking effect Rod and cable looseness and damage Leak, damage and mouting condition Function, wear, damage, leak and mounting looseness M + + ~ I + + + l C t C I + + + I e e t I + + + - I
• 19.
  Inspection Period Item 1 170 Every Every 3 500 Brake drum andbrake shoe Backing plate MATERIAL Forks Mast and fork bracket Chain and chain wheel Various attachment HYDRAULIC Clearance between drum and lining Wear of shoe sliding portion and lining Drum wear and damage Shoe operat~ngcondition Anchor pin rusting Return spring fatique Automatic adjuster function Deformation, cracks and damage Loose mounting l C t t I + + ~ C C C l - ' - ; II + + - + I - + + I C C C l t t t i t + + I C C C I + - - 6 1000 M + - + + 1 *3 I HANDLING SYSTEM Abnormality of fork and stopper pin Misalignment between left and right fork fingers Cracks at fork root and welded part Deformation and damage of each part and crack at welded part Mast and lift bracket looseness Wear and damage of mast support bush Wear, damage and rotating consdition of rollers Wear and damage of roller pins Wear and damage of mast strip Tension, deformation and damage of chain Chain lubrication Abnormality of chain anchor bolt Wear, damage and rotating condition of chain wheel Abnormality and mounting condition of each part SYSTEM I T t t t I C C C I + + + M C C Cylinder 12 2000 I I I I M I I T Loosening and damage of cylinder mounting Deformation and damage of rod, rod screw and rod end Cylinder operation Natural drop and natural forward tilt (hydraulic drift) Months Hours
• 20.
  C Inspection Period- Item Every Every 1 170 Cylinder Oil pump Hydraul~c oiltank Control lever Oil control valve Hydraulic piping ELECTRICAL 1 Oil leak and damage Wear and damage of pin and cylinder bearing Lifting speed Uneven movement Oil leak and abnormal sound Oil level and contamination Tank and oil strainer Oil leak Loose linkage Operation Oil leak Relief pressure measurement Relief valve and tilt lock valve functions 011leak Deformation and damage Loose joint SYSTEM 3 500 Ignition timing Starting motor Charger Battery Electrical wiring I - + + I t + ' - M + + + I + + - + I + + - I - - ' - I - - + I ' - ' - ' - I - + + I + - + + I + + - + t C C I + + + T - - - C + M 6 1000 Cracks on distributor cap Spark plug and burning and gap (- 1997.12) Distributor side terminal burning Distributor cap center piece wear and damage Distributor points gap Plug cord internal discontinuity Ignition timing 12 2000 + I Months Hours Pinion gear meshing status / I Charging function Battery fluid level Battery fluid specific gravity Damage of wiring harness Fuses - + + I + - + + + + + I t t C M + + - + I - + - - I + + - I ' - + ' - l e t + I M t + M t
• 21.
  Inspection Period Item - -------___ Every Every Preheater Enginestop- ping system I t t t 1 170 Open-circuit in intake heater Diesel engine key stop device function I t 63 500 SAFETY DEVICE, Head guard Back-rest Lighting system Horn Direction indicator Instruments Backup buzzer Rear-view mirror Seat Body Other 12 10002000 I ETC. Cracks at welded portion Deformation and damage Loosening of mounting Deformation, crack and damage I Function and mounting condition Function and mounting condition Function and mounting condition Functions Function and mounting condition Dirt, damage Rear reflection status Loosening and damage of mounting Damage and cracks of frame, cross members, etc Bolt looseness Grease up Months Hours I + + + l C t C T t t ~ l t t t i t + + I + + + - + + I + + + I + + - + I t t t l t C t l t t t L + - + + I T
• 22.
  PERIODIC REPLACEMENT LUBRICANTSAND PARTS l: Replacement * I : for new vehicle "2: Every 2 years *3: Every 3 years Replacement shall be made upon arrival of the operation hours or months, wh~cheveris'earlier. Every 6 months Every 1000hours + + t- • • • • • • • l(-1997.12) • Every 3 months Every 500 hours t • • Interval Every 1 month Every Every 12 months Every 2000 hours + C + C t + C + t + • • + • • • e*2 •* •* • • Item Engine Engine oil filter Engine coolant (every 2 years for LLC) Fu,el filter Torque converter oil Torque converter oil filter Transmission oil Differential oil Hydraulic oil Hydraulic oil return filter Wheel bearing grease Spark plug Distributor points Air cleaner element Brake booster rubber parts Cups and seals for wheel cylinders Power steering hoses Power steering rubber parts Hydraulic hoses Fuel hoses Torque converter rubber hoses Chains 170 hours • a*'
• 24.
  GENERAL 11Z Engine ExteriorView KAI-28-26,35-1li
• 25.
  3F Engine ExteriorView
• 26.
  112 Engine SectionalView LAQM61.62 3F Engine Sectional View - 28 -
• 27.
  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 (112) KALMl Gasoline model LPG model only - -- ---.Gasoline LPG model 26.0/1200 25.0/1200 j24 Engine torque Shaft horsepower 200/2000 1200 Fuel consumption 185/1800 ," 180 -- 10 14 18 22 Engine speed (rpm)x 1O2 Engine Performance Curve (3F) - 29 - KALM47
• 28.
  SPECIFICATIONS - Piston displacement cc(cu-in.) Number of cylinders Valve mechanism mm (in.)Bore x stroke Compression ratio Combustion chamber type pslrpm Rated output (SAE NET: ~ p h ~ ~ ) kg-mlrpm Maximum torque (SAE NET : ft-lblrpm) Fuel consumption ratio glps-hlrpm Injection pump type Bosch (VE) l njection timing (BTDC) Injection 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) 11Z (Diesel) 4429 (270) 6 OHV gear driven 96.0 x 102.0 (3.78 x 4.02) 18.6 3F (Gasoline) 3955 (241) 6 t 94.0 x 95.0 (3.70 x 3.74) 8.1 Direct injection 85/2200 (8112200) 2911600 (202/1600) 16511200 72/21 00 (6912100) 26/1200 (182/1200) 20011800
• 29.
  ENGINE ASSY REMOVAL (CLUTCHMODEL) 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 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 Radiator Cover ~ ~ 2 9 - 1 1 Removing the Air Cleaner ASSY ~ ~ 2 9 - 1 9
• 30.
  5. Remove thebattery. (1) Disconnect the battery cables. Caution: Always disconnect the negative (-) terminal first. (2) Disconnect the wiring to 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. (11Z) (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) L A Q ~ o - s , ~ ~ - ~ s
• 31.
  (6) Fuel cutsolenoid wiring (11 Z) (7) Intake heater wiring (11Z) (8) Carburetor wiring (3F) 8. Disconnect piping and wires. (1) Fuel piping (2) Accelerator wire Disconnecting Wirings (3) LAQ30-1.29-32 Disconnecting the Fuel Piping (1lZ/3F) uQ30-8- 19-• Disconnecting the Accelerator Wire (112) LAQ~O-9 Disconnecting the Accelerator Wire (3F) ~ ~ 1 9 - 1 8
• 32.
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