Toyota Forklift Service Manual (EN)

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) TO YO TA INDUS TRIAL VEHICLE 2 J ENGINE REPAIR MANUAL (No. CE603) TO YO TA INDUSTRIAL VEHICLE 7Z ENGINE REPAIR MANUAL (No. CE60 7) TO YO TA 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

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General

GENERAL Page .............................. EXTERIOR VIEWS 0 - 2 .............................. 0 - 3 VEHICLE LISTING 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

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General

- VEHICLE LISTING (1986.8 1989.8) Se- ries Pay load Model Engine model Engine tY Pe Drive system Remarks %- . L % - +0C 1.0 ton 5FG10 02- 5FG10 40- 5FG10 42- 5FG10 5FD10 02 - 5FD10 4 P ? 4 Y f 2 J f Gasoline f f f D~esel T 11 " clutch Torque converter 11 " clutch Torque converter 11 " clutch Torque converter P/S instal led as standard f f t f t 1.35 ton 5FG14 02- 5FG14 40- 5FG14 42- 5FG14 5FD14 02- 5FD14 4 P f 4 Y f 2 J t Gasoline f 7' t Diesel .f I 1 " clutch Torque converter 11 " clutch Torque converter 1 1" clutch Torque converter f f 7.

f f t 1.5 ton 5FG 15 02 - 5FG15 40- 5FG15 42- 5FG15 5FD15 02- 5FD15 4 P f 4 Y f 2 J t Gasoline t f t Diesel t I 1 " clutch Torque converter I 1" clutch Torque converter I" I clutch Torque converter f t t f f f 1.75 ton 5FG18 02- 5FG18 40- 5FG18 42- 5FG18 5FD18 02- 5FD18 4 P f 4 Y t 2 J f Gasol i ne ? f f Diesel t 11" clutch Torque converter I" 1 clutch Torque converter 11" clutch Torque converter f f t t f f .V Q-) , L % +0 CU 2.0ton 5FG20 02- 5FG20 40- 5FG20 42- 5FG20 5F D20 02- 5FD20 60 - 5FD20 62 - 5FD20 4 P t 4 Y t 1 Z f 2 J f Gasoline t t t Diesel t f f 1 1 " clutch Torque converter 11" clutch Torque converter 11" clutch Torque converter 11 " clutch Torque converter t I. t 7- f f t f

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General

- VEHICLE LISTING (1989.9 Ser~es Load capac~ty Model Engine model Dr~vesy stem 1 ton serles 1.0 ton 5FG10 5K Clutch 02-5FG10 Torque converter 40-5FG10 4Y Clutch 42-5FG10 Torque converter 5FD10 1 DZ Clutch 02-5FD 10 Torque converter 1.35 ton 5FG14 5K Clutch 02-5FG14 Torque converter 40-5FG14 4Y Clutch 42-5FG14 Torque converter 5FD14 1D Z Clutch 02-5FD14 Torque converter 1.5 ton 5FG15 5K Clutch 02-5FG15 Torque converter 40-5FG15 4Y Clutch 42-5FG15 Torque converter 5FD15 1D Z Clutch 02-5FD15 Torque converter 1.75 ton 5FG18 5K Clutch 02-5FG18 Torque converter 40-5FG18 4 Y Clutch 42-5FG18 Torque converter 5FD18 1D Z Clutch 02-5FD 18 Torque converter 2 ton series 2.0 ton 5FG20 5K Clutch 02-5FG20 Torque converter 40-5FG20 4Y Clutch 42-5FG20 Torque converter 5FD20 1z Clutch 02-5FD20 Torque converter 60-5FD20 1 DZ Clutch 62-5FD20 Torque converter 2.25 ton 5FG23 5K Clutch 02-5FG23 Torque converter 40-5FG23 4 Y Clutch 42-5FG23 Torque converter

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