Toyota Forklift Service Manual (EN)

FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT - 45 series. Please use this manual for providing quick, correct 5FGi5FD33 servicing of the corresponding forklift models. This manual has been edited by combining Repair Manual Pub. No. CEO05 as Part I (Sections 0 to 15) and Repair Manual (Supplement) Pub. No. CE014. as Part 11 (Sections 0 to 4). Part I explains the service procedures for the models produced since August, 1988 while Part IIcovers those for the models subject to the minor change in September, 1994. For servicing the vehicles after the minor change, please refer to both Part I and Part II.

Please understand that disagreement can take place between the de - scriptions in the manual and actual vehicles due to change in design and specifications. Any change or modifications thereafter will be in - formed by Toyota Industrial Equipment Parts & Service News. For the service procedures of the mounted engine, read the repair man - uals listed below as reference together with this manual. (Reference) Repair manuals related to this manual are as follows: TOYOTA INDUSTRIAL EQUIPMENT 3F ENGINE REPAIR MANUAL (No. CE614) TOYOTA INDUSTRIAL EQUIPMENT 1FZ ENGINE REPAIR MANUAL (No. CE627) TOYOTA INDUSTRIAL EQUIPMENT 1 122 ENGINE REPAIR MANUAL (N O . IZ, CE615-1) TOYOTA MOTOR CORPORATION

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Part I: Section Index (CE005)

PART I : 1988. 8- SECTION INDEX (CE005) GENERAL ENGINE0 C R TRANSMISSION & DIFFERENTIAL FRONT AXLE REAR AXLE CLUTCH BRAKE a BODY MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL CONTROL VALVE APPENDIX a

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General

GENERAL Page EXTERIOR VIEWS ................................ 0 - 2 VEHICLE LISTING ................................ 0 - 3 ABBREVIATIONS ................................ 0 - 4 ............................. 0 - 4 OPERATIONAL TIPS STANDARD BOLT & NUT TIGHTENING ......................................... TORQUE 0-5 BOLT STRENGTH TYPE IDENTIFICATION METHOD ...................................... 0 - 5 TIGHTENING TORQUE TABLE 0-6 PRECOAT BOLTS .................. .............................. 0 - 7 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE ........................... 0 - 7 FRAME NUMBER ................................ 0 - 8 WIRE ROPE SUSPENSION ANGLE LIST ...........

0 - 9 WlRE ROPE SUSPENSION ANGLE SAFE LOAD FOR EACH ............................ 0 - 10 COMPONENTS WEIGHT ......................... 0 - 10 RECOMMENDED LUBRICANT QUANTITY &TYPES 0-11 .......................... LUBRICATION CHARTS 0 - 12 ......................................... PERIODIC MAINTENANCE ....................... 0 - 14 ......................... INSPECTION METHOD 0 - 14 PERIODIC REPLACEMENT LUBRICANTS AND PARTS ..................................... 0 - 20

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General

VEHICLE LISTING Load capaclty Model Engine model Engine tY Pe Drive system Remarks 3.25 ton 5FG33 3F Gasoline Clutch Wheel base 1800 mm (71 in) 02-5FG33 t t Torgue converter 5FD33 1 1 Z Diesel Clutch 02-5FD33 t t Torque converter 3.5 ton 5FG35 3F Gasoline Clutch 02-5FG35 t t Torque converter 5FD35 1 1 Z Diesel Clutch 02-5FD35 t t Torque converter 5FGE35 3F Gasoline Clutch Wheel base 2000 mm (78.5 in) 02-5FGE35 t t Torque converter 5FDE35 1 1 Z Diesel Clutch 02-5FDE35 t t Torque converter 4.0 ton 5FG40 3F Gasoline Clutch 02-5FG40 t t Torque converter 5FD40 11Z Diesel Clutch 02-5FD40 t t Torque converter 4.5 ton 5FG45 3F Gasoline Clutch 02-5FG45 t t Torque converter 5FD45 1 1 Z Diesel Clutch 02-5FD45 t t Torque converter

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