FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT 5FGIO30/5FD 7 0 -3 0 Series. Please use this manual for providing quick, correct servicing of the corresponding forklift models. These models on the market since August 7986 are subject to minor changes i n September 7986. This manual deals with the models produced i n the period between A ugust 7 988 and August 7 9 8 9 as well as the models as of September
7 989 (after m ~ n o changes}. r 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: TOY0TA INDUSTRIAL VEHICLE 4P ENGINE REPAIR MANUAL (No. CE604) TOYOTA INDUSTRIAL VEHICLE 4 Y ENGINE REPAIR MANUAL (No. CE602) TOYOTA INDUSTRIAL VEHICLE 2J ENGINE REPAIR MANUAL (No. CE603) TOYOTA INDUSTRIAL VEHICLE 7Z ENGINE REPAIR MANUAL (No. CE60 7) TOYOTA INDUSTRIAL VEHICLE 5K ENGINE REPAIR MANUAL (No. CE67 7) TOYOTA INDUSTRIAL VEHICLE 7DZ ENGINE REPAIR MANUAL (No. CE6 18) (Note: 2 - 3 ton models mounted with 2J, IDZ diesel engine are only available
in designated areas.)
TOYOTA MOTOR CORPORATION
GENERAL
Page EXTERIOR VIEWS
..............................
0-2
VEHICLE LISTING
..............................
0-3
ABBREVIATIONS ................................
0-7
OPERATIONAL TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0-7
STANDARD BOLT & NUT TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0-8
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . 0-10 FRAME NUMBER
...............................
0-11
WIRE ROPE SUSPENSION ANGLE LIST . . . . . . . . . . . . 0-14 SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . 0-14 COMPONENT WEIGHT
...........................
0-15
RECOMMENDED LUBRICANT QUANTITY & TYPE ...................................... 0-17 LUBRICATION CHARTS .......................... 0-21 PERIODIC MAINTENANCE
.......................
0-22
PERIODIC REPLACEMENT LUBRICANTS AND PARTS .................................. 0-29
EXTERIOR VIEWS
Front View (5FG15)
LATI 4-16
Rear View (5FG15)
LAT14-18
VEHICLE LISTING (1986.8 Series
Pay load
Model
5FG10
1.0 ton
4 0 - 5FG10
4Y
4 2 - 5FG10
f
5FG14
2J
f 4P
Engine tY Pe Gasoline
f f f D~esel
T Gasoline
Drive system
11" clutch
Remarks
P/S instal led as standard
11 clutch
f f
Torque converter
t
1 1 " clutch
f
Torque converter
t
I1 " clutch
f
Torque converter "
0 2 - 5FG14
f
f
Torque converter
f
4 0 - 5FG14
4Y
7'
1 1 " clutch
7.
4 2 - 5FG14
f
t
Torque converter
f
1 1" clutch
f
Torque converter
t
I 1 " clutch
f
5FD14 0 2 - 5FD14
%
4P
?
02 - 5FD10
% .L -
Engine model
0 2 - 5FG10
5FD10
1.35 ton
- 1989.8)
2J
t
Diesel
.f
C
-
0 +
5FG 15
1.5 ton
f
t
Torque converter
4 0 - 5FG15
4Y
f
I 1" clutch
t t
4 2 - 5FG15
f
t
Torque converter
f
I I"clutch Torque converter
f f
11" clutch
f
0 2 - 5FD15 5FG18
0
+ CU
2.0ton
4P
t Gasol i ne
?
Torque converter
f
4 0 - 5FG18
4Y
f
1 I" clutch
4 2 - 5FG18
t
f
Torque converter
t t
11" clutch
f
Torque converter
f
1 1 clutch
t
Torque converter
I.
11" clutch
t
Torque converter
11" clutch
7f
5FG20
%
t
Diesel
f
0 2 - 5FD18
Q, .L
2J
0 2 - 5FG18
5FD18
V)
Gasoline
0 2 - 5FG15
5FD15
1.75 ton
4P
2J
f 4P
0 2 - 5FG20
t
4 0 - 5FG20
4Y
4 2 - 5FG20
t
5F D20
1Z
Diesel
t Gasoline
t t t Diesel
"
02- 5FD20
f
t
Torque converter
f
60 - 5FD20
2J
11 clutch
t
62 - 5FD20
f
f f
Torque converter
f
"
VEHICLE LISTING (1989.9 Ser~es
Load capac~ty
Model
5FG10 02-5FG10
1.0 ton
40-5FG10 42-5FG10 5FD10 02-5FD 10 5FG14 02-5FG14
1.35 t o n
40-5FG14 42-5FG14 5FD14 02-5FD14
1 ton serles
5FG15 02-5FG15 1.5 ton
40-5FG15 42-5FG15 5FD15 02-5FD15 5FG18 02-5FG18
1.75 t o n
40-5FG18 42-5FG18 5FD18 02-5FD 18 5FG20 02-5FG20 40-5FG20
2.0 ton
42-5FG20 5FD20 02-5FD20
2 ton series
60-5FD20 62-5FD20 5FG23
2.25 ton
02-5FG23 40-5FG23 42-5FG23
Engine model
5K
4Y
1 DZ
5K
4Y
D r ~ v esystem Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter
1DZ
5K
4Y
1DZ
5K
4Y
Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter
1DZ
5K
4Y 1z 1 DZ
5K
4Y
Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter
Series
Load capacity
Model
5FD23
2.25 t o n
02-5FD23 60-5FD23 62-5FD23 5FG25 02-5FG25
2 ton series
40-5FG25
2.5 ton
42-5FG25 5FD25 02-5FD25 60-5FD25 62-5FD25
Engine model
1z
1 DZ
Drive system Clutch Torque converter Clutch Torque converter
5K
Clutch Torque converter
4Y
Clutch Torque converter
1z
1 DZ
Clutch Torque converter Clutch Torque converter
4Y
Clutch Torque converter
2.75 t o n
5FD28 02-5FD28 60-5FD28 62-5FD28
3 ton series
5FG30 02-5FG30
3.0 ton
5FD30 02-5FD30 60-5FD30 62-5FD30
1Z
Clutch Torque converter
1 DZ
Clutch Torque converter
4Y
Clutch Torque converter
1Z
Clutch Torque converter
1 DZ
Clutch Torque converter
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ABBREVIATIONS Abbreviations used in this manual are as follows: Abbreviation (Code)
Meaning
Abbreviation (Code)
Meaning
ABDC ASSY
After Bottom Dead Center Assem bl y
P/S RH
Power Steering Right Hand
ATDC ATM
After Top Dead Center Automatic Transmission
SA E
BBDC
Before Bottom Dead Center Left Hand Long Life Coolant Manual Transmission
Society of Automotive Engineers (USA) Special Service Tool
LH L LC MTM OHV 0PT
0 /S PS
SST STD SU B-ASSY T=
Standard Sub-assem bly
Overhead valve
OOT
Opt ion Oversi~e
U/S
Tightening Torque N um ber of Teeth (00) U ndersize
w/
With
Horsepower
OPERATIONAL TIPS 1.
Safe operation ( 1 ) Make sure that correct size wire is used for hoisting a heavy material (2)After jacking up, always support with rigid racks or stands.
2.
Preparation of SSTs and measuring tools ( 1 ) Prepare SSTs and measuring tools before starting operat ion.
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.
4.
Genuine Toyota parts Genuine Toyota parts should be used even in the replacement of packings, gaskets and O-rings.
5.
Repairs on electrical system Before doing any repairs on the electrical system, disconnect the cables from the battery terminals. Be sure to disconnect the negative @ cable first.
6.
Tightening torque for irlstallation 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 disassernbly 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 upon a failure in starting the vehicle, but first check such factors as the oil, pressure and rotation status causing the failure.
'
STANDARD BOLT AND NUT TIGHTEN ING TORQUES How to judge tightening torque of a standard bolt or nut. 1 . How to judge tightening torque of a standard bolt. Find out the type of the bolt from the list below. Then, find the bolt tightening torque from the table. 2. How to judge tighting torque of a standard unit. The nut tightening torque can be judged from the bolt type. (See the item above.)
LIST OF BOLT TYPES AND STRENGTH 1.
2. Judging by part No.
Judging by part
\1 Hexagon head bolt
Shape and class
@
Class
Hexagon head bolt
Bolt head No*
I
Parts No,
91611- do625 L e n g t h (rnrn) Diameter ( m m ) Hexagon flange bolt
No mark
Hexagon head bolt
Two protruding lines
Hexagon flange bolt Hexagon head bolt Welded bolt
@
Diameter
l;') protruding Three protruding Parts No.
~ e n ~ (tr nhm ) Diameter ( m m )
Diameter
STANDARD BOLT TIGHTENING TORQUES
PRECOAT BOLTS (Bolts with seal lock agent coating on threads)
1.
.
2.
Do not use the precoat bolt as i t i s i n e i t h e r of the following cases: (a) After i t is removed. (b) When the precoat bolt is moved Cloosened or tightened) by tightness check, etc. Note : For torque check, use the lower limit of the allowable tightening torque range. If the bolt moves, retighten it accordicg t o the steps below.
Precoat ~~l~~
Method for reuse of precoat bolts (I)Wash ,the bolt and threaded hole. (The threaded hole must be washed even for replacement of the bolt.)
(2) Perfectly dry the washed parts by air blowing. (3) Coat the specified seal lock agent to the threaded 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 surfaces 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 of screw
Standard tightening torque Standard
2.5 ( 18.1)
2.4
9/16 - 18UNF
5.0 ( 36.2)
4.8 5.7
314 - 16UNF
6.0 ( 43.4) 6.0 ( 43.4)
11/16 - 12UNF 15/16 - 12UNF
12.0 ( 86.8) 14.0 (101.2)
PF1/4
Hose inside d iarneter (mrn)
Tightening range
7116 - 20'UNF
7/8 - 14UNF
kg-m (ft-lb)
-
-
2.6 (17.4
-
18.8)
6
5.3 (34.7 38.3) 6.3 (41.2- 45.5)
9
-
12
6.3 (41.2 45.5) 11.4- 12.6 (82.4- 91.1)
12
14.7 (96.2 -- 106.3)
25
5.3 (34.7 -- 38.3)
9
5.7
13.3
-
5.0 ( 36.2)
4.8
P F3/8
5.0 ( 36.2)
4.8
PF112
6.0 ( 43.4)
5.7 -- 6.3 (41.2
P F3/4
12.0 ( 86.8)
11.4-12.6
PF1
14.0 (101.2)
13.3 -- 14.7 (96.2
5.3 (34.7
-
38.3) 45.5)
(82.4- 91.1) 106.3)
19
9 12 19 25
FRAME NUMBER (1986.8 -- 1989.8) Top on rear right frame
Punching posit ion
1 ton series
Vehicle series Engine model
Vehicle model
Punching format
4P
4Y 40- 5FG10
5FD10
-
02- 5FG10
42- 5FG10
02- 5FD10
-
5FG14
40- 5FG14
5FD14
-
02- 5FG14
42- 5FG14
02 - 5FD14
-
5FG15
40- 5FG15
5FD15
-
02- 5FG15
42- 5FG15
02 - 5FD15
-
5FG18
40- 5FG18
5FD18
-
02- 5FG18
42- 5FG18
02- 5FD18
-
5FG18 -
405FG18 -
5FD18 -
-
Punching format
10001
10001
-
2 ton series
Vehicle series
Vehicle model
1Z
5FG10
10001
Eng~nemodel
2J
4P
4Y
1Z
2J
5FG20
40- 5FG20
5FD20
60 - 5FD20
02- 5FG20
42- 5FG20
02 - 5FD20
62 - 5F D20
5FG23
40- 5FG23
5F D23
60 - 5FD23
02 - 5FG23
42- 5FG23
02 - 5FD23
62 - 5F D23
5FG25
40- 5FG25
5FD25
60 - 5F D25
02 - 5FG25
42- 5FG25
02- 5FD25
62 - 5FD25
5FG25 -
405FG25 -
5FD25 -
605FD25 -
I0001
10001
10001
10001