Toyota LPG Forklift Truck 30-5FGC10, 30-5FGC13, 30-5FGC15, 5FGC10, 5FGC13, 5FGC15 Workshop Service Manual

FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 5FGIO- 30/5FD 7 0 - 30 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 in September 7986. This manual deals with the models produced in the period between A ugust 7 988 and August 7 989 as well as the models as of September 7 989 (after m~nor changes}. 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: TOY0 TA INDUSTRIAL VEHICLE 4P ENGINE REPAIR MANUAL (No. CE604) TOYOTA INDUSTRIAL VEHICLE 4 Y ENGINE REPAIR MANUAL (No. CE602) TOYOTA INDUSTRIAL VEHICLE 2 J 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 7 DZ 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

SECTION INDEX SECTION GENERAL 0 ENGINE 1 CLUTCH 2 TORQUE CONVERTER 3 TRANSMISSION 4 PROPELLER SHAFT 5 DIFFERENTIAL 6 FRONT AXLE 7 REAR AXLE 8 STEERING 9 BRAKE 10 BODY 11 MATERIAL HANDLING SYSTEM 12 MAST 13 CYLINDER 14 OIL PUMP 15 OIL CONTROL VALVE 16 APPENDIX 17 -3-

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 - 1989.8) Se- ries % . - L % C 0 + - V) Q, .- L % 0 + CU Pay load 1.0 ton 1.35 ton 1.5 ton 1.75 ton 2.0ton Model 5FG10 02 - 5FG10 40 - 5FG10 42 - 5FG10 5FD10 02 - 5FD10 5FG14 02 - 5FG14 40 - 5FG14 42 - 5FG14 5FD14 02 - 5FD14 5FG 15 02 - 5FG15 40 - 5FG15 42 - 5FG15 5FD15 02 - 5FD15 5FG18 02 - 5FG18 40 - 5FG18 42 - 5FG18 5FD18 02 - 5FD18 5FG20 02 - 5FG20 40 - 5FG20 42 - 5FG20 5F D20 02 - 5FD20 60 - 5FD20 62 - 5FD20 Engine model 4 P ? 4 Y f 2 J f 4 P f 4 Y f 2 J t 4 P f 4 Y f 2J t 4 P f 4 Y t 2 J f 4 P t 4 Y t 1 Z f 2 J f Engine tY Pe Gasoline f f f D~esel T Gasoline f 7' t Diesel .f Gasoline t f t Diesel t Gasol i ne ? f f Diesel t Gasoline t t t Diesel t f f Drive system 1 1 " clutch Torque converter 11 " clutch Torque converter 1 1 " clutch Torque converter I 1 " clutch Torque converter 1 1 " clutch Torque converter 1 1" clutch Torque converter I1 " clutch Torque converter I 1" clutch Torque converter I I" clutch Torque converter 11" clutch Torque converter 1 I " clutch Torque converter 11" clutch Torque converter 1 1 " clutch Torque converter 11" clutch Torque converter 11" clutch Torque converter 11 " clutch Torque converter Remarks P/S instal led as standard f f t f t f f 7. f f t f t t f f f f f t t f f t I. t 7- f f t f

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Toyota LPG Forklift Truck 30-5FGC10, 30-5FGC13, 30-5FGC15, 5FGC10, 5FGC13, 5FGC15 Workshop Service Manual

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