Toyota Forklift 5FGC/5FDC18-30 Series OEM 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: TOYOTA INDUSTRIAL VEHICLE 4 Y ENGINE REPAIR MANUAL (No. CE602) TOY0 TA INDUSTRIAL VEHICLE 2 J ENGINE REPAIR MANUAL (No. CE603) TOYOTA MOTOR CORPORATION

SECTION INDEX GENERAL - - - TORQUE CONVERTER PROPELLER SHAFT DIFFERENTIAL FRONT AXLE REAR AXLE I STEERING BRAKE BODY y 0 ' MAST CYLINDER OIL PUMP OIL CONTROL VALVE APPENDIX

GENERAL .......................... VEHICLE EXTERIOR VIEWS 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 Page 0-2

VEHICLE EXTERIOR VIEWS Vehicle Front View LAPI 8-8 Vehicle Rear View LAPI 8-4

VEHICLE MODELS I I I I I I I I 2ton I175ion 5FGC18 I I 4Y Gasollne 1 Torque converter as standard serles , I I PS equ'pped 1 Model I Ser~es Payload I 1 2.0 ton 42 : g : : : ; i ne i Torque converter Mounted I englne 1 Eng~ne type 5FGC25 42: E : i i ne Torque converter 1 1 5FDC25 I t I I I Power transmlsslon I i 225ton I 5FGC23 4Y I I Remarks 3 ton serles I Gasollne I Torque converter I 1 2 75 ton 3 0 ton 5FGC30 1 5FDC30 4Y ' GasOilne Torque converter 1 2J Diesel i I 5FGC28 1 4Y Gasolne Torque converter I

ABBREVIATIONS The abbrev~at~ons used In thls manual are as follows: I Abbreviat~on I Meaning / Abbrev~ation 1 Meaning I 1 1 I ABDC 1 After bottom dead center 1 P/S 1 Power steering I ASSY Assembly , RH / Righthand I ATDC BBDC LH LLC OHV I OPT 1 After drop dead center 1 SAE Before bottom dead center 1 Lefthand 1 SST 1 ~ong l~ie coolant Overhead valve Option Oversize Horsepower I Soc~ety of Automot~ve Engineers Special service tool 1 STD 1 Standard SUB-ASSY I Subassembly T= T~ghten~ng torque OOT I I Number of teeth (00) 1 Undersire TIPS ON OPERATION 1. 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. 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~ghtening Torques." 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.

STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and nut ttghtening torques are not ~ndicated Therefore, judge the tightening torque as descr~bed below 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 Discriminat~on by actual bolt 2 Discrimination by part number 1 Shape and description I Strength code 4=4T 1 Number in relief or 5=5T Hexagon I hallmark on head 6=6T bolt I I I 7=7T Standard ; I I Hexagon bolt / I Part number example 3 - 4 06 0 L- Nominal size (mm) l~om~nal dlameter Length to bottom surface of head Stud bolt1 Part number example 92132 - 4 06 14 under head imm) L ; ; ; na i siz; Strength code Nomlnal d~ameter Length BAHS2 head I No mark I 1 Hexagon bolt head I I I Hexagon 1 I 1 I Bolt with two relief Standard I llnes on head 6T bolt Hexagon bolt Collar head I I Hexagon 1 1 Boit w~th three relief 7T bolt llnes on head ! I I BAHS28 I I I I Bolt with two relief I nes on head I

- - TIGHTENING TORQUE TABLE Standard Collar 1 head head ~ Standard t~ghten~ng torque kg- cm (ft-lb)

- - - --- PRECOAT BOLTS I I 1 (Bolts coated wrth seal lock agent on threads) I 1 Do not use the precoat bolt as it IS In any of the follow~ng cases I (1 ) When the precoat bolt IS removed I (2) When the precoat bolt 1s moved (loosened or tightened) rn tightenrng check etc I Reference : I I The tightening torque must be checked Precoat 601ts 84460 with the lower limit of the allowable tightening toque range. If the bolt moves, retighten it according to the following procedure: 2. Reusing the precoat bolt (1) Clean the bolt and threaded hole. (2) Dry the precoat bolt sufficiently by (Clean the threaded hole even alr blowing, etc when the precoat bolt IS to be (3) Coat the specifred seal lock agent replaced. j on the theaded hole for the bolt. HIGH PRESSURE HOSE FllTlNG TIGHTENING TORQUE 1. Before connecting a h~gh pressure hose, wipe the high pressure hose fitting and mating n~pple 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. 2. Al~gn the high pressure hose f~tting and nrpple and hold the hose In that the state during tightening. 3. The maximum t~ghten~ng torque must not exceed twice the standard t~ghtening torque. Hose ~ns~de diameter mm N~~~~~~ of screw 7/16 -20UNF 251 181) 9/16 -18UNF 1 50( 362) 3/4 -16UNF I 6 0 ( 43 3) Standard t~ghtenrng torque kg-cm (ft-l b) 24 - 261173 188) 6 48 - 531347 - 383) 9 57 - 63141 2 - 455) 12 Standard Tighten~ng range 7/8 -14UNF 11/16-12UNF 15/16-12UNF PFI /4 6 0 ( 433) 1 57 - 63141 2- 455) 12 120( 866) 11 4-1261823- 91 0) 19 150(lOl 1) 1 133-,471960-1061) I 25 501 362) 48 - 531347- 383) PF3/8 ' 50( 362) 48 - 533347- 383) 9 9 PF1/2 PF3/4 PF 1 57 - 63141 2 - 455) , 12 120( 866) 11 4-126(823- 91 0) 19 I 140(101 1) 1 133 - 1471960 - 1061) 2 5

FRAME NUMBER 1 top of rear pan of I Model serles 1 2.0 ton serles I 3.0 ton series . EEC spec. (1 992. 11 - ) SAFE LOAD BY WIRE ROPE SUSPENSION ANGLE Un~t. ton (Ib) Eng~ne type , 4Y Model I 5FGC 18 1 5FGC20 5FGC23 I 5FGC25 Rope d~ameter 2J 5FDC20 5FDC25 - - 5FDC25- 10001 "5FDC25E10001 Frame ser~al number format 6 rnm (0.24 in) 5FGC25-10001 '5FGC25E10001 4Y 5FGC28 5FGC30 - - 5FGC30- 10001 '5FGC30E10001 O m m 502 0 7 1 1 4 3 137 12 1 0 2 8 2 7 2 4 2 0 1 (0 4 in) 1 (1 1069) (1 565 6) (31 53) (3021 1 (2646) (2205) 11 61 74) ( 5954) ( 5292) (4410) 2J 5FDC30 - - - 5FDC30- 10001 '5FDC30E10001 ' Un~filar Breakdown load 2.18 ( 4807) 12.5 mrn (0.5 ~n) 14 mrn SusPen- sion 0" 0.31 ( 683.6) B~f~lar suspension Cross sling~ng 90" 0.44 ( 970) 0.64 (141 1) 0" 1.24 ( 2734) 1.8 ( 3969)( 0" 0.62 (1 367) 3.2 1 0.9 (1985) 7.84 1.12 ( 2.2 (1 7287) . 9.83 (0.56 In) 1 (21 675) 30" 1.2 ( 2646) 1.74 3837)( 30 " 0.6 (1 323) 0.87 (1918) 60" 0.53 (1 169) 0.78 (1720) 4.4 ( 9702) 5.6 (2469.5)l (4851) (30870) 1.9 2.7 60" 1.06 ( 2337) 1.56 3440) (1 2348) 1.4 (61 74) (41 90) 2.4 (5954) 90" 0.88 (1 940) 1.28 (2822) 4.2 ( 9261) 5.4 2.8 (5292) (1 1907) 3.8 ( 8379) 4.8 3.0 (6615) 3.8 (1 0584) (8379)

Toyota Forklift 5FGC/5FDC18-30 Series OEM Service & Repair Manual

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