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INFORMATION
SUBJECT :
REF NO. :
MODEL
02-7FG35.40.45, 02-7FGA50
42-7FD35.40.45, 42-7FDA50
General countries
APPLICATION
STD / OPT
PRODUCTION
EFFECTIVE
DATE :
See below
European countries
See below
U.S.A. &
Exporting countries of TIEM products
STD
Now in effect
OPT
See below
See below
The new 15Z engine (a 14Z-II engine with IDI) is now available for complying with European EEC
Directive 97/68/EC, Stage IIIA for Non-road Mobile Machinery (NMM). And the powerful and
proven 1FZ-E engine with its electrically controlled fuel injection system has also been introduced.
The combustion systems of these engines are optimized to realize both high performance and
clean gas emission.
The parts used for 8 Series have been incorporated into this series with the aim of improving
productivity and operator friendliness.
An upgrade of the Operator Presence Sensing (OPS) system makes this series even safer. Other
quality improvements have been taken to enhance product reliability.
You are kindly requested to use this information for internal use only. Models and/or equipment introduced
in this information may not be available in certain countries due to technical or other reasons.
The data shown here was determined based on our standard testing conditions. Operating performance may
vary depending on the actual specifications and usage conditions of the vehicle as well as the conditions for
the area where it is operated.
Please keep in mind that specifications may be changed without notice.
Model Availability
Current
New
Model
Engine
Model
Engine
02-7FG35
TOYOTA 1FZ
02-7FG35
TOYOTA 1FZ-E
42-7FD35
TOYOTA 14Z
42-7FD35
TOYOTA 15Z
02-7FG40
TOYOTA 1FZ
02-7FG40
TOYOTA 1FZ-E
42-7FD40
TOYOTA 14Z
42-7FD40
TOYOTA 15Z
02-7FG45
TOYOTA 1FZ
02-7FG45
TOYOTA 1FZ-E
42-7FD45
TOYOTA 14Z
42-7FD45
TOYOTA 15Z
02-7FGA50
TOYOTA 1FZ
02-7FGA50
TOYOTA 1FZ-E
42-7FDA50
TOYOTA 14Z
42-7FDA50
TOYOTA 15Z
Frame Numbering
Model
02-7FG35
Engine
Frame Number
TOYOTA 1FZ-E
A7FGK40
50011
TOYOTA 1FZ-E
A7FGA50
50011
TOYOTA 15Z
40A7FDK40
30011
TOYOTA 15Z
40A7FDA50
30011
02-7FG40
02-7FG45
02-7FGA50
42-7FD35
42-7FD40
42-7FD45
42-7FDA50
15Z Engine
Overview
The 15Z engine has been newly developed for use in Europe. It is a 5.2 liter vortex chamber diesel engine
that is a based on the previous 14Z engine with a different combustion system. The optimization of the
combustion system provides both high performance and clean operation.
Engine Specifications
Main Engine Specifications
Engine Type
15Z
Inline 6/Longitudinal
Vortex chamber
1 per cylinder
Valve Operation
5.204
98.0 x 115.0
Compression Ratio
21.5
Open
16o BTDC
Close
30o ABDC
Open
52o BBDC
Close
14o ATDC
Firing Order
1-4-2-6-3-5
2981 (304)
Fuel
Diesel
Engine Performance
Model
42-7FD35.40.45
42-7FDA50
NMR
[rpm]
Maximum Fuel
Consumption Ratio
(Full Load)
[g/kW-h {PS-h}] (rpm)
2300
55 {75} (2100)
60
Engine Horsepower
(kW)
Engine Torque
(N-m)
50
40
30
20
10
Fuel Consumption
(g/kW-h)
320
300
280
260
240
220
200
10
15
20
25
30 x 10
555 mm
760 mm
875 mm
Engine Hanger
Head (Chamber)
Intake Manifold
Injection Pump
Injection Pipe
Oil filter
Oil Cooler
Heat Insulator
Exhaust Manifold
Water Pump
Alternator
Crankshaft Pulley
Oil Pan
Changed part
Change
Compliant with
exhaust gas
regulations
Engine assembly
Head (Chamber)
Head gasket
Piston rings
Piston
Intake manifold
Others
Improved reliability
Injection pump
ACSD discontinued
10
Injection nozzle
11
Injection pipe
12
Linkage pipe
13
Glow plug
14
15
Intake heater
16
Connecting rod
Friendlier to environment
17
Camshaft bearing
Pb free
Friendlier to environment
18
Crankshaft bearing
Pb free
Friendlier to environment
19
Heat insulator
Newly available
Improves serviceability
Insulates from exhaust manifold heat.
20
Exhaust manifold
Improves serviceability
(Compatible with insulator change)
21
Exhaust manifold
gasket
Changed to metal
Improved reliability
22
Exhaust manifold
mounting stud bolt
Increased strength
Improved reliability
23
Rocker arm
Resists wear
24
Oil pan
Improves serviceability
Compatible with equipped new models.
25
Crankshaft damper
Newly available
26
27
Crankshaft pulley
Improved reliability
28
Engine hanger
Newly available
29
1FZ-E Engine
Overview
The field-proven 1FZ engine has been fully enhanced to meet growing market demands for lower exhaust gas
emissions, higher power and better fuel efficiency. Various mechanical control systems, such as those for fuel,
ignition and the throttle, have been replaced with electronic control as standard equipment.
New
Fuel control
Gasoline
LPG
Ignition control
Current
Carburetor (Mixer)
Governor
Mechanical advance
Air governor
Throttle
3-way catalytic converter [C11D]
Wire system
OPT
OPT
Engine Specifications
Main Engine Specifications
Engine Type
1FZ-E
Inline 6/Longitudinal
2 per cylinder
Valve Operation
4476
100.0 x 95.0
Compression Ratio
8.5
Open
5o BTDC
Close
40o ABDC
Open
40o BBDC
Close
5o ATDC
Firing Order
1-5-3-6-2-4
2364 (241)
Gasoline
Fuel
LPG
Engine Performance
NMR
[rpm]
Maximum Fuel
Consumption Ratio
(Full Load)
[g/kW-h {PS-h}] (rpm)
2350
63 {86} (2350)
LPG
Convertible LPG
2350
63 {86} (2350)
2350
63 {86} (2350)
LPG Exclusive
2350
63 {86} (2350)
Model
7FG35.40.45
7FGK40
02-7FG35.45.50
02-7FGK40
02-7FGA50
Fuel
Gasoline
Gasoline
Note: Idling speed is 750 rpm for all models and specifications.
Gasoline
LPG
280
270
260
100
63 kW (86ps)/2350 rpm
80
60
Gasoline
LPG
40
20
0
Gasoline
LPG
400
300
200
10
15
20
25
30 x 10
863 mm
793 mm
584 mm
250
Electronic Throttle
Pressure Regulator
LPG Injector
Gasoline Filter
Delivery Pipe
Distributor
(Equipped Cam Angle Sensor,
Built-in crankshaft angle)
Alternator
Oxigen Sensor
10
LPG filter
LPG
LPG
regulator
Balance hose
Main solenoid
valve
FCM
Temperature
manifold pressure
sensor
Gasoline
filter
LPG adopter
LPG injector
Pressure regulator
Air
cleaner
Air
Electronic
throttle
Delivery pipe
Gasoline
Distributor
Fuel pump
Ignition coil
Water
temperature
sensor
Engine ECU
Exhaust manifold
Exhaust gas
Oxygen sensor
This drawing shows the convertible type. Note that fuel system for gasoline will not exist on LPG exclusive models and the LPG fuel system will not exist on gasoline-only models.
NOx
100
HC
Theoretic
ratio
50
CO
Scope of
control
0
rich
Air-fuel ratio
lean
11
Alternator
As with the current model, an alternator with an IC regulator is used.
The standard alternator is a high-output type with a rated output of 70 amperes.
Alternator Specifications
Rated Output [V-A]
Effective Pulley Diameter [mm]
Regulator Adjustment Voltage [V]
New
Current
12-70
12-70
70
74
13.2 14.0
13.0 13.7
Cooling System
1. Fan
Differences with the Current Model
Puller Type Fan
Forward-blade fan
15Z
1FZ-E
440
Current
15Z
410
410
New
400
12
2. Radiator
Differences with the Current Model
The plastic tank adopted on the current model continues to be used, ensuring reliability. (An O-ring seals is
used for the joint between the core plates and the tank, which achieves better resistance to water leakage
than a soldered joint.)
The aluminum core adopted on the current model continues to be used, ensuring reliability. (Brazed joints are
used between the core plates and the tubes, which achieves better resistance to water leakage than soldered
joints.)
The 15Z uses a special large radiator to improve reliability.
Radiator uses
Engine
Powershift
transmission model
Model
Core size
15Z
Corrugate
56x527.6x550
1FZ-E
Cross-flow
48x449x525
Aluminum 10 step
Aluminum 10 step
Radiator Applications
Torque converter oil cooler built into radiator
As with the current models, all powershift transmission models have torque converter oil coolers included
as standard equipment.
Radiator screen
As with the current models, all models have a 6.5 inch mesh screen mounted as standard equipment. This
screen can be removed or attached without tools
13
Controller Overviews
Design of the controller
The controllers for the SAS, OPS, Mini-Levers which had been independent units on current series, have been
integrated. In addition, the number of signal wires between the controller and instruments has been reduced by
using the controller that was newly introduced to the 8 Series for complying with exhaust gas emission
regulations.
Establishing communication among the controllers enables them to share information. It also enables the
combination meter to display the error code and unifies the specifications of the plug-in analyzer and makes
multifunction display [L26A/B] optionally available.
While the standard model does not include SAS, the design of the controllers is the same and a SAS/OPS
controller without the SAS functions is installed. Note that the Multifunction Display is not available for models
without SAS specifications.
Figure of controller and meter arrangement
Current Model
Mini Lever
STD
OPT
Meter
Controller and
meter
Special service
tool
SAS
Plug-in Analyzer
OPS
Signal wires
Communication
wires
SAS/OPS
Multifunction
Display
Plug-in Analyzer
1FZ-E ECS
ECS: Electronic control system
Model without
Multifunction Display
SAS/OPS
Multifunction
Display
Plug-in Analyzer
Model without
Multifunction Display
14
Plug-in Analyzer
An off-truck plug-in analyzer has been made available as a Special Service
Tool (SST) for servicing the SAS/OPS controller.
The plug-in analyzer is able to read information about the states of the
sensors, actuators, and other such components used by the controller, as
well as reading information on errors detected by the controllers. These can
help shorten the time of service such as checking the status of function
working.
This plug-in analyzer can be used for servicing the engine controller
(electronic control system, or ECS) for the 1FZ-E engine.
Note, however, that vehicles equipped with Multifunction display [L26A/B]
have a built-in analyzer that provides similar functionality, and so the plug-in
analyzer is not required and this analyzer is same as that of 8 series.
Functions
No.
Item
Availability for
standard vehicle
Description
Yes
Control-monitor display
No
Operation test
No
Initialization (matching)
Yes
Relay
ECU Box
An glow relay and glow timer have been newly added to the 15Z engine and the engine ECU for the 1FZ-E
engine has been arranged in the inside of the ECU box, enhancing water resistance.
ECU box
15
Seat
The Deluxe Seat [G40H] is available as an option.
This seat is made by Grammer and incorporates the operator restraint system (ORS).
Main features
1) Seat slide amount: 150 mm (15 mm increments x 10 increments)
2) Suspension stroke: 60 mm
3) Side wing
Helps hold the operator in an emergency.
4) Reclining function
5) Built-in seat belt
ELR type (Retractor locks during an emergency)
16
Combination Meters
Differences with the Current Model
1. A digital fuel meter has been adopted (except on LPG Exclusive vehicles).
2. A digital water-temperature indicator has been adopted.
3. A brake warning light, remaining coolant-water warning light, and clogged air-cleaner warning indicator are
available as an optional OK monitor [L09A].
Design of the combination meters
1
3
12
11
2
10
17
9. Diagnostic light
(Equipped on Vehicles with System of Active Stability [A41A])
This warns operator in the event of a problem with any of the following:
SAS, OPS, 1FZ-E engine, Mini Lever, Joystick, and/ or Multifunction
Display.
18
Weight
Counterweight weight
Weight
Model
1FZ-E
15Z
kg
kg
3.5 ton
2230
2260
2625
4.0 ton
2585
2630
4.5 ton
2875
2925
5.0 ton
3125
3138
19
26
35
8
6
34
25
27
29
30
31
32
9
10
33
28 -1
28 -2
42
21
12
20
3
22
Center of
steering wheel
23
16
17
19
18
F2
43
F1
N
R
R
Powershift
transmission model
2-Speed Powershift
transmission model
Manual
transmission model
41
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
16
17
18
40
39
38
Name
Dual-action Parking Brake
Electric Horn
Direction Selection Lever *1 *2
Full Hydraulic Power Steering
Seat
Lift Lever
Tilt Lever
Operating Lever for Attachment
Operating Lever for Attachment
Operating Lever for Attachment
Inching Pedal
Brake Pedal
Acceleration Pedal
Lift Lever *3
Tilt Lever *3
Operating Lever for Attachment
37
12
36
No.
19
20
21
22
23
24
25
26
27
28-1
28-2
29
30
31
32
33
Name
Operating Lever for Attachment
Turn Signal Switch *1
Integrated Light Switch *1
Hood Lock Release Lever
Tilt Steering Adjusting Lever
Engine Water Temperature Indicator
Fuel Meter
Hour Meter
Sedimenter Warning Light (Diesel Models)
Preheat Indicator Light (Diesel Models)
Engine Control Light (Gasoline Models)
Engine Oil Pressure Warning Light
Charge Warning Light
OPS Light
Diagnostic Light
Clogged Air Cleaner Warning Light
Note:
*1 Optional Right Hand Shift Lever [E11B] is set symmetrically to the right and
left of the center of the steering wheel.
*2 If No. 42 is mounted when either the Mini Lever [E45A] or Joystick [E45B] is
selected, No. 3 cannot be mounted.
*3 When Mini Lever [E45A] or Joystick [E45B] is mounted.
No.
34
35
36
37
38
39
40
41
42
43
Name
Engine Coolant Level Warning Light
(OK Monitor [L09A])
Brake Warning Light (OK Monitor [L09A])
Rear Working Light Switch
(Rear Working Light [J26A])
Heater Switch (Heater [H11A])
Rear Wiper Switch
Front Wiper Switch
LPG Remaining Fuel Warning Device Switch
(LPG Remaining Fuel Warning Device [C28A])
Gas/LPG Selection Switch
Direction Selection Lever *2
Ignition Key Switch
20
1FZ-E engine
CEN
83
82
DIN
81
80
15Z engine
1FZ-E engine
108
106
The noise level at the operators ear becomes approximately 1--2 dB(A) high when the optional 3-way catalytic
muffler, upswept exhaust muffler and front glass are equipped.
21
Multifunction Display
[L26A]
Digital speedometer
Load meter
Odometer
Trip meter
Over-speed alarm
Menu-lock setting
Feature
Status display
Cumulative meters
Warnings
Level settings