Page 1

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


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


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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


3.0 ton series

Vehicle series Engine model

Vehicle model

Punching format

4Y

1Z

-

5FG28

5FD28

60- 5FD28

-

02- 5FG28

02- 5FD28

62- 5FD28

-

5FG30

5FD30

60- 5FD30

-

02- 5FG30

02- 5FD30

6 2 - 5FD30

-

5FG30 -

5FD30 -

605FD30 -

4P

-

10001

1000 1

2J

10001

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