Toyota 5FGC30 Forklift Service Repair Manual

FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT 5FGC/5FDC18-30 Series. Please use this manual for providing quick, correct servicing of the corresponding forklift models.

This manual deals with the above models as of August 1986. Please understand that disagreement can take place between the descriptions in the manual 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: TO YO TA INDUSTRIAL VEHICLE 4 Y ENGINE REPAIR MANUAL (No. CE602) TOY0TA INDUSTRIAL VEHICLE 2 J ENGINE REPAIR MANUAL (No. CE603)

TOYOTA MOTOR CORPORATION

SECTION INDEX GENERAL - - -

I

TORQUE CONVERTER PROPELLER SHAFT DIFFERENTIAL FRONT AXLE REAR AXLE STEERING BRAKE BODY

y 0

' MAST

CYLINDER OIL PUMP OIL CONTROL VALVE APPENDIX

GENERAL

Page VEHICLE EXTERIOR VIEWS

.......................... 0-2

VEHICLE MODELS ...................................

ABBREVIATIONS & TIPS ON OPERATION

..........

STANDARD BOLT & NUT TIGHTENING TORQUE ...

PRECOAT BOLTS

.....................................

HIGH PRESSURE HOSE FllTlNG TIGHTENING TORQUE .............................

FRAME NUMBER ....................................

SAFE LOAD BY WIRE ROPE SUSPENSION ANGLE .............................

WIRE ROPE SUSPENSION ANGLE LIST

.............

CAPACITY AND TYPES OF SPECIFIED LUBRICANTS ..........................

LUBRICATION

........................................

PERIODIC MAINTENANCE TABLE ...................

PERIODIC REPLACEMENT PARTS & LUBRICANTS ......................................

VEHICLE EXTERIOR VIEWS

Vehicle Front View

LAPI 8-8

Vehicle Rear View

LAPI 8-4

VEHICLE MODELS

I

Ser~es

Payload I

1

I1

I

I

I

I

,I 1 7 5 i o n

5FGC18 I

I I

I

1 i

I

225ton

I I

1

Gasollne

I

5FGC25 5FDC25

I

1 Torque converter

as standard PS equ'pped

I

nei;:g: Gasollne

4Y

5FGC23

I

1

4Y

42:

2 . 0 ton

I

Remarks

I

I

2ton serles

Power transmlsslon

Mounted englne E n g ~ n etype

Model

42:

nieE::

4Y

Gasolne

i Torque converter

I

I Torque converter

1

I

Torque converter I I

I

3 ton serles

2 7 5 ton

5FGC28

3 0 ton

5FGC30 5FDC30

1

I

1

1

4Y 2J

'

GasOilne

Diesel

Torque converter Torque converter

i

t

ABBREVIATIONS The abbrev~at~ons used In thls manual are as follows:

I Abbreviat~on I

Meaning

1

I

ABDC ASSY ATDC BBDC LH

LLC

I

1

1

11

After bottom dead center Assembly After drop dead center Before bottom dead center Lefthand ~ o n gl ~ i ecoolant

OHV

Overhead valve

OPT

Option Oversize

/ 1

,1

1

11

Abbrev~ation

P/S RH

1

Meaning

I

1

/

Power steering Righthand

I

SAE

Soc~etyof Automot~ve Engineers Special service tool

SST 1

STD

SUB-ASSY T= OOT

Horsepower

Standard

I

I

I

1

Subassembly T ~ g h t e n ~ ntorque g Number of teeth (00) Undersire

TIPS ON OPERATION Safe operation ( 1 ) Make sure that correct size wire rope is used when lifting a heavy material.

(2) After jacking up, always support with a rigid rack or stand.

2. Preparation of SSTs and measuring Instruments ( 1 ) Prepare necessary SSTs and measuring instruments before startlng repair operation.

1.

3.

Neatness and underlines ( 1 ) Keep the working place neat and orderly to make operation easler.

(2) Hydraulic equipment should be disassembled with clean tools in clean places.

4.

Genulne Toyota parts Always use genuine Toyota parts even for packlngs, gaskets and o-rings which are -replaced after each disassembly work.

5.

Repairs on electrrcal system Before doing any repair on the electrical system, disconnect the cables from battery terminals.

Always disconnect the negative (-) terminal first.

6. Tightening torque at the time of installatron Be sure to observe the tightening torque given In thls mannual. If not specified, tlghten to the torque listed in "Standard Bolt & Nut t~ghteningTorques."

7.

Grasplng the defect status When a defect is found, do not immediately start disassembly and replacement. First check if the defect needs disassembly and replacement for repair. For example, do not disassemble the torque converter for a defect of vehicle starting failure but check such factors as the oil status, hydraulic pressure and rotation which directly cause the defect.

I

I

STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and nut ttghtening torques are not ~ndicated Therefore, judge the tightening torque as descr~bedbelow 1

Find out the type of bolt from the list below Then, judge the bolt tightenrng torque from the tightening torque table

2

The nut tightening torque can be judged in the same way according to the type of the mating bolt

DlSRlMlNATlON OF BOLT STRENGTH 1

2 Discrimination by part number

Discriminat~onby actual bolt

1 Shape and description

Strength code

I

1

Hexagon bolt Standard head

I

I

;

Number in relief or hallmark on head I

I

I

Part number example

3

-

4

06

I

No mark

1

L-

Hexagon bolt head Hexagon

I

I

1

I I I

I

Standard bolt Hexagon bolt Collar head Hexagon bolt

1

l ~ o m ~ ndlameter a l

Length to bottom surface of head

Stud b o l t 1

I

I

Bolt with two relief n e s on head

6T Part number example

I

1

I 1 I

I

Nominal size (mm)

Bolt with two relief llnes on head

I I I

0

I

I

I

4=4T 5=5T 6=6T 7=7T

/

Hexagon bolt

Boit w ~ t hthree relief llnes on head

I

9 2 1 3 2 - 4

06

14

7T

!

under head imm)

Lnai;;;

siz;

Strength code

Nomlnal d~ameter Length

BAHS28

BAHS2

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--

TIGHTENING TORQUE TABLE

~

Standard t ~ g h t e n ~ ntorque g kg-cm (ft-lb)

1

Standard head

Collar head

-

-

-

- - -

PRECOAT BOLTS

I

I1

(Bolts coated wrth seal lock agent on threads) 1

Do not use the precoat bolt as it I S In any of the follow~ngcases (1) When the precoat bolt I S removed (2) When the precoat bolt 1s moved (loosened or tightened) rn tightenrng check etc Reference : The tightening torque must be checked with the lower limit of the allowable tightening toque range. If the bolt moves, retighten it according to the following procedure:

2.

I

I I

I I I

Precoat 601ts

Reusing the precoat bolt ( 1 ) Clean the bolt and threaded hole.

(Clean the threaded hole even when the precoat bolt IS to be replaced. j

(2) (3)

84460

Dry the precoat bolt sufficiently by alr blowing, etc Coat the specifred seal lock agent on the theaded hole for the bolt.

HIGH PRESSURE HOSE FllTlNG TIGHTENING TORQUE 1.

2.

3.

Before connecting a h ~ g hpressure hose, wipe the high pressure hose fitting and mating n ~ p p l e contact surfaces with clean cloth to remove foreign matters and dirt. Check that there IS no dent or other surface defect on the contact surface.

A l ~ g nthe high pressure hose f~ttingand nrpple and hold the hose In that the state during tightening.

The maximum t ~ g h t e n ~ ntorque g must not exceed twice the standard t~ghteningtorque.

Standard t~ghtenrngtorque

N~~~~~~ of screw

7/16 -20UNF 9/16 -18UNF 3 / 4 -16UNF 7/8 -14UNF 11/16-12UNF 15/16-12UNF PFI / 4 PF3/8 PF1/2 PF3/4 PF 1

1

I

' I

Standard

Tighten~ngrange

2 5 1 181) 5 0 ( 362) 6 0 ( 43 3) 6 0 ( 433) 1 2 0 ( 866) 1 5 0 ( l O l 1)

1

2 4 - 2 6 1 1 7 3 188) 4 8 - 531347- 383) 5 7 - 63141 2 - 4 5 5 ) 5 7 - 63141 2 - 4 5 5 ) 11 4 - 1 2 6 1 8 2 3 91 0) 133-,471960-1061)

1

4 8 - 5313474 8 - 5333475 7 - 63141 2 11 4 - 1 2 6 ( 8 2 3 133- 1471960-

1

5 0 1 362) 5 0 ( 362) 1 2 0 ( 866) 140(101 1)

Hose ~ n s ~ d e diameter mm

kg-cm (ft-lb)

383) 383) 455) 91 0 ) 1061)

I

,

6 9 12 12 19 25 9 9 12 19 25

FRAME NUMBER

1 top of rear pan of

I

I

Model serles

1

Eng~netype

,

2.0 ton serles

1 I

Model

I

4Y

2J

4Y

2J

5FGC 18 5FGC20 5FGC23 5FGC25

5FDC20 5FDC25

5FGC28 5FGC30

5FDC30

-

-

-

-

-

-

5FGC25-10001 5FDC25- 10001 5FGC30- 10001 5FDC30- 10001 '5FGC25E10001 "5FDC25E10001 '5FGC30E10001 '5FDC30E10001

Frame ser~alnumber format

. EEC spec. (1992. 1 1

3.0 ton series

-)

SAFE LOAD BY WIRE ROPE SUSPENSION ANGLE

'

Un~filar Rope Breakdown SusPension load d~ameter 0"

Un~t. ton (Ib)

Cross sling~ng

B ~ f ~ l suspension ar 0"

30"

90"

60"

0"

30"

60"

90"

1.24 1.2 0.62 0.53 0.44 1.06 0.88 2.18 0.31 0.6 ( 4807) ( 683.6) ( 1 367) ( 1323) ( 1 169) ( 970) ( 2734) ( 2646) ( 2337) ( 1 940)

6 rnm (0.24 in)

1.74 1.28 0.9 0.78 1.8 1.56 0.64 0.87 (1985) (1918) (1720) (1411 ) ( 3 9 6 9 ) ( 3837)( 3440) (2822)

3.2 1

1

O m m 502 0 7 1 1 4 3 1 3 7 12 0 2 8 2 7 2 4 2 0 ( 0 4 in) 1 ( 1 1069) ( 1 565 6) (3153) (30211 (2646) (2205) 11 61 74) ( 5954) ( 5292) (4410)

(

7.84 1.12 2.2 12.5 mrn ( 0 . 5 ~ n ) ( 1 7287) (2469.5)l(4851)

4.4

4.2

3.8

3.0

( 9702) ( 9261) ( 8379) (6615)

5.4 1.4 2.7 2.4 1.9 2.8 5.6 14 mrn .

9.83 4.8 3.8 ( 0 . 5 6 In) (21675) ( 3 0 8 7 0 ) (6174) (5954) (5292) (4190) ( 1 2348) ( 1 1907) ( 1 0584) (8379)

1

1

--

WIRE ROPE SUSPENSION ANGLE LIST Suspens~on angle

,

,

C O ~ P ~ ~ S

Ten-

slon I strength

"On

Suspen ston method

I

Suspei SIO~

sion

slon

angle

strength

1

I

I

I

I

I 1 1

I

I

I

I

1

I

30"

1

t o e

I 027 I tme

times

1

I

I

I

60"

'

1 1 6 1 058 tmes

,

tme

/

1

, I

I

I

~ompres-

I

i

I I

times

Suspenslon method

CAPACITY AND TYPES OF SPECIFIED LUBRICANTS Description

Classification API SD, SE, SF

TYpe

Application

Quantity

Motor oil SAE30 (SAE20 in cold area)

Gasoline

4Y

4.01 (1.06 US gal)

2J

6.91 (1.82 US gal)

SAE20W-40 (SAE10W-30 in cold area)

Engine API CC, CD Deisel

Diesel engine oil SAE30 (SAE20 in cold area) SAEl OW-30

Torque converter

AT F

GM Dexron@I1

All models

14.OP (3.70 US gal)

Differential

API GL-4 GL-5

Hypoid gear oil SAE85W-90

All models

6.81 (1.80 US gal)

IS0 VG32

Hydraulic oil # 9 0

Hydraulic oil

Fuel tank Chassis parts Coolant

MP grease No.2 LLC

LLC 30-50% mixture (for winter or all-season) Coolant with rust~nhibitor (for spring, summer and autumn)

2 ton series 3 ton series

27P (7.1 US gal) 281 (7.4 US gal)

All models

45P ( 1 2 US gal)

All models

Proper quantity

4Y 2J

9.OP (2.38 US gal) 9.51 (2.51 US gal)