Toyota FORKLIFT 5FG33 User manual

FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT

5FGi5FD33

45 series. Please use this manual for providing quick, correct

servicing of the corresponding forklift models.

This manual has been edited by combining Repair Manual Pub. No. CEO05

as Part

(Sections 0 to 15) and Repair Manual (Supplement)

Pub. No. CE014. as Part11 (Sections

to 4).

Part

explains the service procedures for the models produced since

August, 1988 while Part IIcoversthose for the models subject to the minor

change in September, 1994. For servicing the vehicles after the minor

change, please refer to both Part

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

formedby 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 INDUSTRIALEQUIPMENT 3F ENGINE

REPAIR MANUAL (No.CE614)

TOYOTA INDUSTRIALEQUIPMENT 1FZENGINE

REPAIR MANUAL (No.CE627)

TOYOTA INDUSTRIALEQUIPMENT 1IZ, 122ENGINE

REPAIR MANUAL (N

. CE615-1)

TOYOTA MOTOR CORPORATION

PART

1988.

SECTION INDEX (CE005)

GENERAL

ENGINE0

CLUTCH

TRANSMISSION

DIFFERENTIAL

FRONT AXLE

REAR AXLE

BRAKE

BODY

MATERIAL HANDLING SYSTEM

MAST

CYLINDER

OIL PUMP

OIL CONTROL VALVE

APPENDIX

GENERAL

Page

EXTERIOR VIEWS

................................

VEHICLE LISTING

................................

ABBREVIATIONS

................................

OPERATIONAL TIPS

.............................

STANDARD BOLT

NUTTIGHTENING

.........................................

TORQUE 0-5

BOLT STRENGTH TYPE IDENTIFICATION

METHOD

......................................

TIGHTENINGTORQUE TABLE

..................

0-6

PRECOAT BOLTS

..............................

HIGHPRESSURE HOSE FITTING

TIGHTENING TORQUE

...........................

FRAME NUMBER

................................

WIRE ROPE SUSPENSION ANGLE LIST

...........

SAFE LOAD FOR EACH WlRE ROPE

SUSPENSION ANGLE

............................

COMPONENTS WEIGHT

.........................

RECOMMENDEDLUBRICANT QUANTITY

&TYPES

.........................................

0-11

..........................

LUBRICATION CHARTS 0

PERIODIC MAINTENANCE

.......................

.........................

INSPECTION METHOD 0

PERIODIC REPLACEMENT LUBRICANTS

ANDPARTS

.....................................

EXTERIOR

VIEWS

Front

View

(5FD35)

~~0.72-1

Rear

View

(5FD35)

VEHICLE LISTING

Load

capaclty

3.25ton

3.5 ton

4.0ton

4.5 ton

Model

5FG33

02-5FG33

5FD33

02-5FD33

5FG35

02-5FG35

5FD35

02-5FD35

5FGE35

02-5FGE35

5FDE35

02-5FDE35

5FG40

02-5FG40

5FD40

02-5FD40

5FG45

02-5FG45

5FD45

02-5FD45

Engine

model

11Z

Drive system

Clutch

Torgue converter

Clutch

Torque converter

Clutch

Torque converter

Clutch

Torque converter

Clutch

Torque converter

Clutch

Torque converter

Clutch

Torque converter

Clutch

Torque converter

Clutch

Torque converter

Clutch

Torque converter

Engine

tY Pe

Gasoline

Diesel

Gasoline

Diesel

Gasoline

Diesel

Gasoline

Diesel

Gasoline

Diesel

Remarks

Wheelbase

1800 mm

(71

in)

Wheelbase

2000

(78.5in)

ABBREVIATIONS

Abbreviations used in this manual are as follows:

OPERATIONAL TIPS

1. Safe operation

(1) Make sure that correct size wire is used for hoisting a heavy material.

(2)

After jacking up, always support with rigid racks or stands.

Meaning

Horsepower

Power steering

Right hand

Society of automotive engineers

(USA)

Special service tool

Standard

Sub-assembly

Tightening torque

Number of teeth (00)

ndersize

With

Abbreviation

(Code)

ABDC

ASSY

ATDC

ATM

BTDC

LLC

MTM

OHV

Preparation of SSTs and measuringtools

(1)

Prepare SSTs and measuring tools before starting operation.

Clearing and arrangement

(1) Always keep the workshop neat and orderly for easy operation.

(2)

Disassembly ofhydraulic equipment shall always be done in a clean place using clean tools.

Meaning

After buttondead center

Assembly

After top dead center

Automatic transmission

Before top dead center

Less

Left hand

Long lifecoolant

Manual transmission

Overhead valve

Option

Oversize

Genuine Toyota parts

Genuine Toyota partsshould be used even in the replacement of packings, gaskets and O

rings.

Abbreviation

(Code)

P/S

SAE

SST

STD

SUB

ASSY

OOT

Repairson electrical system

Before doing any repairs on the electical system, disconnect the cables from the battery terminals.

Be sure to disconnect the negative cable first.

Tightening torque for installation

Be sure to observe the tightening torque given in this manual. If not specified, tighten

thetorque

listed in standard bolt

nut tightening torque.

Defect status grasp

Do not start disassembly and replacement as soon as a defect is found, but first grasp whether the

defect requires disassembly and replacement. In the case of torque converter for example, do not

attempt torque converter disassembly dpon a failure in starting the vehicle, but first check such

factors as the oil, pressure and rotation status causing the failure.

STANDARD BOLT

NUT TIGHTENING TORQUE

Standard bolt and nut tightening torques are not indicated.

Judge thestandard tightening torque as shown below.

Find out the straight type of bolt from the list below and then find the bolt tightening torque from

the table.

The nut tightening torque can be judged from the mating bolt type.

BOLT STRENGTH TYPE IDENTIFICATION METHOD

Identification by bolt shape

Identification by part

No.

Standard

hexagon

bolt

Hexagon bolt

Part

NO.

example

40610

-1

T~engthunder head

(mm)

Nominal diamter

(mm)

two rel~efl~neson

Standard bolt with

Strength

type

Shape and identification method

Strength type

Nominal

diameter

Length under head

Stud bolt

Part

No.

example

92132-4-061 4

T~ength(mm)

Nominal diameter

(mm)

Number in relief or

hallmark on the head

No mark

Strength type

Nominal

diameter

Length

TIGHTENING

TORQUE

TABLE

ECOAT BOLTS

(Boltswith seal lock agent coating on threads)

1. Do not use the precoat bolt as it is in either

of the following cases:

(a) After it

removed.

(b)

When the precoat bolt

moved (loos

ened or tightened) by tightness check,

etc.

Note

For torque check, use the lower limit of the

Bolts

allowable tightening torque range. If the

bolt moves, retighten

according to the

steps below.

2. Method for reuse of precoat bolts

(1) Wash the bolt and threaded hole. (The (2) Perfectly dry the washed parts by air

threaded hole must be washed even for blowing.

replacementof the bolt.) (3) Coat the specified seal lock agent to the

threadedportion of the bolt.

HIGH PRESSURE HOSE FllTlNGTIGHTENING TORQUE

1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact sufaces with

clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the contact

surfaces beforeinstallation.

2. When connecting

high pressure hose, hold the hose to align the fitting with the nipple and tighten

the fitting.

3. The maximum tightening torque must not exceed twice the standard tightening torque.

Hose inside

diameter (mm)

Nominal diameter

of screw

UNF

12 UNF

PF1/4

PF3/8

PF1/2

PF314

PFI

Standardtightening torque kg

cm (ft-lb)

Standard

2.5

(

18.1)

5.0

(

36.2)

6.0

(

43.4)

6.0

(

43.4)

12.0

(

86.6)

14.0 (101.2)

5.0

(

36.2)

5.0

(

36.2)

6.0

(

43.4)

12.0

(

86.8)

14.0 (101.2)

Tightening range

2.4

2.6

7.4

18.8)

4.8

5.3 (34.7

38.3)

5.7

6.3 (41.2

45.5)

5.7- 6.3 (41.2

45.5)

11.4- 12.6 (82.4

91.1)

13.3

14.7 (96.2

106.3)

4.8

5.3 (34.7

38.3)

4.8

5.3 (34.7

38.3)

5.7

6.3 (41.2

45.5)

11.4-12.6(82.4- 91.1)

13.3

14.7 (96.2

106.3)

FRAME

NUMBER

"1 1988.6

1993.3

2 1992.11

1993.3 (EEC

spec.)

3 1993.4-

"4 1993.4

1993.9 (EEC

spec.)

1993.10-(EEC

spec.)

Engine

11Z

LAQS

Punching,position

Frame

No.punching position

Model

5FG 33

5FG 35

5FD 33

5FD 35

5FGE35

02-5FGE35

5FG 40

5FG 45

5FDE35

02-5FDE35

5FD 40

5FD 45

Punching

format

"1 5FG35-10011

2 5FG35E10011

3 5FG35-20011

"45FG35E20011

5 5FG35O20011

"1 5FD35-10011

2 5FD35E10011

3 5FD35-20011

4 5FD35E20011

5 5FD35020011

1 5FG45- 10011

2 5FG45E10011

3 5FG45-20011

4 5FG45E20011

5 5FG45Q20011

1 5FD45- 10011

2 5FD45E10011

3 5FD45-20011

4 5FD45E20011

"5 5FD45~20011

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