Toyota 6FGCU15/6FGCU18/6FGCU20/6FGCU25/6FGCU30 LPG Forklift Service & Repair Manual

FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 6FGCU 15 - 30. Please use this manual for providing quick, correct servicing of the corresponding forklift models. This manual deals with the above models as of July 1995. Please understand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in design and specifica- tions. Any change or modifications thereafter will be informed by Toyota Industrial Equipment 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: TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINE REPAIR MANUAL (No. CE602) TOYOTA INDUSTRIAL EQUIPMENT GM4 - 181 ENGINE REPAIR MANUAL (No. CU629) TOYOTA MOTOR CORPORATION

SECTION INDEX GENERAL ENGINE NAME TORQUE CONVERTER DIFFERENTIAL FRONT AXLE REAR AXLE STEERING BRAKE BODY MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL CONTROL VALVE APPENDIX SECTION

GENERAL Page EXTERIOR VIEWS ............................................... 0-2 VEHICLE MODEL ................................................ 0-3 FRAME NUMBER .............................................. 0-4 .......................... HOW TO READ THIS MANUAL 0-5 EXPLANATION METHOD ....................................... 0-5 TERMINOLOGY ................................................... 0-6 ABBREVIATIONS .................................................. 0-6 OPERATIONAL TIPS ............................................ 0-7 STANDARD BOLT & NUT TIGHTENING TORQUE ........................................................... 0-8 BOLT STRENGTH TYPE IDENTIFICATION .......................................................... METHOD 0-8 ................................ TIGHTENING TORQUE TABLE 0-9 PRECOAT BOLTS .............................................. 0-10 HIGH PRESSURE HOSE FITTING ..................................... TIGHTENING TORQUE 0-10 WIRE ROPE SUSPENSION ANGLE LIST ............. 0-11 SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE ....................................... 0-11 COMPONENTS WEIGHT ..................................... 0-12 RECOMMENDED LUBRICANT ........................................ QUANTITY & TYPES 0-13 ........................................ LUBRICATION CHART 0-14 .................................. PERIODIC MAINTENANCE 0-15 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS ........................................... 0-21

EXTERIOR VIEWS 1 ton series 2- 3 ton series

VEHICLE MODEL Series + 1 ton series 2 ton series L 3 ton series 1.5 ton 1.75 ton Engine type Engine model Load capacity 2.0 ton Drive system Model 42- 6FGCU 1 5 42- 6FGCU1 8 2.5 ton 3.0 ton 42-6FGCU20 52-6FGCU20 4Y 4Y 42-6FGCU25 52-6FGCU25 42-6FGCU30 52-6FGCU30 4Y GM Gasoline t 4Y GM 4Y GM Torque converter 'I t t t t t t t t t t T t

FRAME NUMBER Frame No. Punching Position Punching position 1 ton series 2 ton series I I Punching format Engine 3 ton series I I Model *: EEC Spec.

HOW TO READ THIS MANUAL EXPLANATION METHOD 1. Operation procedure (1) The operation procedure is described in either pattern A or pattern B below. Pattern A: Explanation of each operation step with a photo or illustration. Pattern B: ~xplanation of operation procedure by indic-sting step numbers in one illustration, followed by explanation of cautions and notes summarized as point operations. Example of description in pattern B / DISASSEMBLY. INSPECTION. REASSEMBLY Tightening torque unit T = Nm (kgf-cm) [fb-lbfl If a place or part cannot be indicated directly, the part name is described on the either side of the illustration. Example: 1 Piping Disassembly Procedure 1 Remove the cover. [Point 11 2 Remove the bush [Point 21 4- Operation explained later 3 Remove the gear. 1 Point operations Explanation of key point for operation with an illustration [Point 1 I & Disassembly: Put a match mark when removing the pump cover. 6 [Point 21 Inspection: Measure the bush inside diameter. Bush inside diameter limit: 19.1 2 mm (0.7528 in)

2. How to read components figures (Example) (1 ) The components figure uses the illustration in the parts catalog for the vehicle model. Please refer to the catalog for checking the part name. The number at the right shoulder of each FIG number in parts catalog components figure indicates the Fig. number inthe parts catalog. 3. Matters omitted in this manual (1) This manual omits description of the following jobs, but perform them in actual operation: @ Cleaning and washing of removed parts as required @ Visual inspection (partially described) TERMINOLOGY Caution: lmportant matters of which negligence may cause accidents. Be sure to abserve them. Note: Important items of which negligence may cause accidents, or matters in operation procedure re- quiring special attention. Standard: Values showing allowable range in inspection and adjustment. Limit: Maximum or minimum allowable value in inspection or adjustment. ABBREVIATIONS I LH 1 Left hand I STD I Standard Abbreviation (code) ASSY I LLC I Long life coolant I T = I Tightening torque I 0 PT 1 Option I OOT I Number of teeth (0 0) Meaning Assembly I RH 1 Right hand 1 L/ I Less Abbreviation (code) SST 01s PS SAE Meaning Special service tool Society of Automotive Engineers (USA) Oversize Power steering U/S W/ Undersize With

OPERATIONAL TIPS 1. Safe operation (1) After jacking up, always support with rigid stands. (2) When hoisting the vehicle or its heavy component, use wire repe(s) with a sufficient reserve in load capacity. (3) Always disconnect the battery plugs before the inspection or servicing of electrical parts. 2. Tactful operation Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge, etc.) and SSTs before starting operation. Before disconnecting wiring, always check the cable color and wiring state. When overhauling functional parts, complicated portions or related mechanisms, arrange the parts neatly to prevent confusion. When disassembling and inspecting such a precision part as the control valve, use clean tools and operate in a clean location. Follow the described procedures for disassembly, inspection and reassembly. Replace, gaskets, packings and O-rings with new ones each time they are disassembled. Use genuine Toyota parts for replacement. Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly. If no tightening torque is specified, tighten the bolt or nut according to the standard tightening torque table. 3. Grasping the trouble state When a trouble occurs, do not attempt immediate disassembly or replacement but first check if the trouble requires disassembly or replacement for remedying.

STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and tightening torques are not indicated. Judge the standard tightening torque as shown below. 1. Find out the type of the 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. lndentification by bolt shape 2. Identification by part No. Hexagon head bolt Shape and class Class @ - Bolt head No. Parts No. 9161 1-40625 1T-L Length (rnm) Hexagon head bolt 0 No mark No mark iarneter Hexagon flange bolt Length H Two protruding lines Hexagon head bolt Two protruding lines Hexagon flange bolt Stud bolt / Three protruding lines Hexagon head bolt Part No. 921 32-40614 Length (rnm) Diameter (mm) Four protruding @ lines Hexagon head bolt Welded bolt iarneter $- No mark Stud bolt Grooved

Toyota 6FGCU15/6FGCU18/6FGCU20/6FGCU25/6FGCU30 LPG Forklift Service & Repair Manual

You're Reading a Preview

Recently Viewed