Toyota LPG Forklift Truck: 7FG35, 7FG40, 7FG45, 7FGK40, 7FGA50 Workshop Service Manual

SECTION INDEX NAME SECTION GENERAL 0 ENGINE 1 CLUTCH 2 TORQUE CONVERTER & TRANSMISSION 3 MANUAL 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 SAS 17 APPENDIX 18 7FD/FG 35-50 < Tillbaka till Index BT Svenska AB

FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 7FG/7FD35 ~ 45 series. Please use this manual for providing quick, correct servicing of the corresponding forklift models. This manual deals with the above models as of January 1999. Please under- stand 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 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 G4(GM6-262)ENGINE REPAIR MANUAL (No.C4630) TOYOTA 11Z,12Z,13Z,14Z ENGINE REPAIR MANUAL (No.C4615)

0-1 0 GENERAL Page EXTERIOR VIEWS ......................................................... 0-2 VEHICLE MODEL .......................................................... 0-3 FRAME NUMBER ........................................................... 0-4 HOW TO USE THIS MANUAL .................................... 0-5 EXPLANATION METHOD ................................................. 0-5 TERMINOLOGY ................................................................ 0-6 ABBREVIATIONS ............................................................. 0-6 OPERATIONAL TIPS .................................................... 0-7 HOISTING THE VEHICLE ............................................ 0-7 CIRCUIT TESTER .................................................. 0-8 STANDARD BOLT & NUT TIGHTENING TORQUE ....................................................................... 0-10 BOLT STRENGTH TYPE IDENTIFICATION METHOD ...... 0-10 TIGHTENING TORQUE TABLE ........................................ 0-11 PRECOAT BOLTS ......................................................... 0-12 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE ............................................ 0-12 WIRE ROPE SUSPENSION ANGLE LIST ............... 0-13 SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE ............................................... 0-13 COMPONENTS WEIGHT ............................................. 0-14 RECOMMENDED LUBRICANT QUANTITY & TYPES ................................................. 0-15 LUBRICATION CHART ................................................. 0-16 PERIODIC MAINTENANCE .......................................... 0-18 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS ............................................................... 0-24 0

0-2 EXTERIOR VIEWS

0-3 VEHICLE MODEL 7FG35 02-7FG35 7FD35 02-7FD35 7FGK40 02-7FGK40 7FDK40 02-7FDK40 7FG40 02-7FG40 7FD40 02-7FD40 7FG45 02-7FG45 7FD45 02-7FD45 02-7FGA50 02-7FDA50 3.5 ton model K4.0 ton model 4.0 ton model 4.5 ton model 5.0 ton model 3.5 ton series 4.0 ton series 4.5 ton series 5.0 ton series M/T T/C M/T T/C M/T T/C M/T T/C M/T T/C M/T T/C M/T T/C M/T T/C T/C T/C Transmission Type Vehicle Model Engine Model Series Classification Note: The G4 engine is the same as the GM6-262 engine except for the nomenclature. G4 (GM6-262) G4 (GM6-262) G4 (GM6-262) G4 (GM6-262) 13Z G4 (GM6-262) 13Z 13Z 13Z 13Z Gasoline Gasoline Gasoline Gasoline Diesel Gasoline Diesel Diesel Diesel Diesel

0-4 FRAME NUMBER Frame No. Punching Position Series Engine G4(GM6-262) 13Z G4(GM6-262) 13Z Vehicle model 7FG35 02-7FG35 7FGK40 02-7FGK40 7FD35 02-7FD35 7FDK40 02-7FDK40 7FG40 02-7FG40 7FG45 02-7FG45 02-7FGA50 7FD40 02-7FD40 7FD45 02-7FD45 02-7FDA50 Punching format EEC spec. models 7FGK40 10011 Other models 7FGK40-10011 EEC spec. models 7FDK40 10011 Other models 7FDK40-10011 EEC spec. models 7FGA50 10011 Other mod ls 7FGA50-10011 EEC spec. models 7FDA50 10011 Other models 7FDA50-10011 Punching position Punching format 3.5 • K4.0 ton model 4.0 ~ 5.0 ton model

0-5 HOW TO USE 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 illustration. Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, fol- lowed by explanation of cautions and notes summarized as point operations. Example of description in pattern B DISASSEMBLY·INSPECTION·REASSEMBLY Tightening torque unit T = N·m (kgf-cm) [ft-lbf] Disassembly Procedure 1 Remove the cover. [Point 1] 2 Remove the bushing [Point 2]  Operation explained later 3 Remove the gear. Point Operations Explanation of key point for operation with an illustration [Point 1] Disassembly: Put a match mark when removing the pump cover. [Point 2] Inspection: Measure the bush inside diameter. Limit: 19.12 mm (0.7528 in) • Step Nos. are partially sometimes omitted in illustrations. • When a part requiring tightening torque instruction is not indicated in the illustration, the part name is described in the illustration frame.  T = 46.1 ~ 48.1 (470 ~ 490) [34.0 ~ 35.5]

0-6 Abbreviation (code) ASSY LH LLC M/T OPT O/S PS RH SAE 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 components figure indicates the Fig. number in the 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: Important 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 requiring special attention. Standard: Values showing allowable range in inspection and adjustment. Limit: Maximum or minimum allowable value in inspection or adjustment. ABBREVIATIONS Meaning System of active stability Special service tool Standard Tightening torque Torque converter & transmission Number of teeth ( ) Undersize With Less Meaning Assembly Left hand Long life coolant Manual transmission Option Oversize Power steering Right hand Society of Automotive Engineers (USA) Abbreviation (code) SAS SST STD T = T/C T U/S W/ L/ - FIG number in parts catalog 3201

0-7 OPERATIONAL TIPS 1. Safe operation (1) After jacking up, always support with wooden blocks or rigid stands. (2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load capacity. (3) Always disconnect the battery terminal before the inspection or servicing of electrical parts. 2. Tactful operation (1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure gauge, etc.) and SSTs before starting operation. (2) Before disconnecting wiring, always check the cable color and wiring state. (3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts neatly to prevent confusion. (4) When disassembling and inspecting such a precision part as the control valve, use clean tools and operate in a clean location. (5) Follow the described procedures for disassembly, inspection and reassembly. (6) Replace, gaskets, packings and O-rings with new ones each time they are disassembled. (7) Use genuine Toyota parts for replacement. (8) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly. Tighten to the center of the specified tightening torque range. 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. 4. Disposal of waste fluid, etc. When draining waste fluid from the vehicle, receive it in a container. If any oil, fuel, coolant, oil filter, battery or other harmful substance is directly discharged or scrapped without permission, it will either adversely affect human health or destroy the environment. Always sort waste fluids, etc. and treat them properly by requesting disposal by specialized companies. 5. Jack up points Front side: Jack up at the bottom surface of the frame. Rear side: Jack up at the under the counterweight. HOISTING THE VEHICLE When hoisting the vehicle, sling with wire rope(s) at the mast hook holes and the counterweight hook holes.

0-8 CIRCUIT TESTER Circuit testers are available in both the analog and digital types. They should be used selectively according to the purpose of measurement. Analog type: This type is convenient for observing movement during operation, but the measured value should only be used for reference or rough judgement. Digital type: Fairly accurate reading is possible, but it is difficult to observe the variation or movement. 1. Difference in measurement results with the digital type and analog type * The result may be different between measurements with the analog type and digital type. Always use a circuit tester according to its operation manual. Cautions when the polarities are different between the analog type and digital type are described below. (1) Analog circuit tester (2) Digital circuit tester Measurement result example Tester range: kΩ range Analog type Continuity exists 11 kΩ No continuity Forward Reverse Measurement result example Tester range: MΩ range Digital type No continuity 1 Continuity exists 2 MΩ Forward Reverse ∞ Forward direction Forward direction Reverse direction Reverse direction

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Toyota LPG Forklift Truck: 7FG35, 7FG40, 7FG45, 7FGK40, 7FGA50 Workshop Service Manual

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