Toyota FORKLIFT 5FGIO Series User manual

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
inSeptember 7986. This manual deals withthe models produced intheperiod
between August
7 988 andAugust 7 989as wellas the models as of September
7 989(after m~norchanges}.
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
listedbelow as reference together withthis manual.
(Reference)
Repair manuals relatedto this manual are as follows:
TOY0TA INDUSTRIAL VEHICLE 4P ENGINE
REPAIRMANUAL(No. CE604)
TOYOTA INDUSTRIAL VEHICLE 4 Y ENGINE
REPAIRMANUAL(No. CE602)
TOYOTA INDUSTRIAL VEHICLE 2 J ENGINE
REPAIRMANUAL(No. CE603)
TOYOTA INDUSTRIAL VEHICLE 7ZENGINE
REPAIRMANUAL(No. CE607)
TOYOTA INDUSTRIAL VEHICLE 5K ENGINE
REPAIRMANUAL (No. CE67
7)
TOYOTA INDUSTRIAL VEHICLE 7 DZ ENGINE
REPAIRMANUAL (No. CE6
18)
(Note: 2 - 3 ton models mounted with 2J, IDZ diesel engine are only available
in designated areas.)
TOYOTA MOTOR CORPORATION

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

EXTERIOR VIEWS
Front View (5FG15) LATI 4 - 16
Rear View (5FG15) LAT14-18

VEHICLE LISTING (1986.8 - 1989.8)
Se-
ries
%
. -
L
%
C
0
+
-
V)
Q,
.-
L
%
0
+
CU
Pay load
1.0 ton
1.35 ton
1.5 ton
1.75 ton
2.0ton
Model
5FG10
02 - 5FG10
40 - 5FG10
42 - 5FG10
5FD10
02 - 5FD10
5FG14
02 - 5FG14
40 - 5FG14
42 - 5FG14
5FD14
02 - 5FD14
5FG15
02
- 5FG15
40 - 5FG15
42 - 5FG15
5FD15
02 - 5FD15
5FG18
02 - 5FG18
40 - 5FG18
42 - 5FG18
5FD18
02 - 5FD18
5FG20
02 - 5FG20
40 - 5FG20
42 - 5FG20
5FD20
02 - 5FD20
60 - 5FD20
62 - 5FD20
Engine
model
4 P
?
4 Y
f
2 J
f
4 P
f
4 Y
f
2 J
t
4 P
f
4 Y
f
2J
t
4 P
f
4 Y
t
2 J
f
4 P
t
4 Y
t
1 Z
f
2 J
f
Engine
tY Pe
Gasoline
f
f
f
D~esel
T
Gasoline
f
7'
t
Diesel
.f
Gasoline
t
f
t
Diesel
t
Gasol i ne
?
f
f
Diesel
t
Gasoline
t
t
t
Diesel
t
f
f
Drive system
11 " clutch
Torque converter
11 " clutch
Torque converter
1 1 " clutch
Torque converter
I 1 " clutch
Torque converter
1 1 " clutch
Torque converter
1 1" clutch
Torque converter
I1 " clutch
Torque converter
I 1" clutch
Torque converter
I I" clutch
Torque converter
11 " clutch
Torque converter
1 I " clutch
Torque converter
11 " clutch
Torque converter
1 1 " clutch
Torque converter
11" clutch
Torque converter
11" clutch
Torque converter
11 " clutch
Torque converter
Remarks
P/S installed
as standard
f
f
t
f
t
f
f
7.
f
f
t
f
t
t
f
f
f
f
f
t
t
f
f
t
I.
t
7-
f
f
t
f

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

Series
2 ton series
Load capacity
2.25 ton
2.5 ton
Model
5FD23
02-5FD23
60-5FD23
62-5FD23
5FG25
02-5FG25
40-5FG25
42-5FG25
5FD25
02-5FD25
60-5FD25
62-5FD25
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
4Y
3 ton series
Engine model
1 z
1 DZ
5K
4Y
1 z
1 DZ
Drive system
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
2.75 ton
3.0 ton
5FD28
02-5FD28
60-5FD28
62-5FD28
5FG30
02-5FG30
5FD30
02-5FD30
60-5FD30
62-5FD30
1 Z
1 DZ
4Y
1 Z
1 DZ

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
Power Steering
Right Hand
Society of Automotive Engineers
(USA)
Special Service Tool
Standard
Sub
- assembly
Tightening Torque
N umber of Teeth (00)
U ndersize
With
Abbreviation
(Code)
ABDC
ASSY
ATDC
ATM
BBDC
LH
L
LC
MTM
OHV
0 PT
0 /S
PS
2. Preparation of SSTs and measuring tools
( 1 ) Prepare SSTs and measuring tools before starting operation.
3. Clearingand arrangement
(1 ) Always keep the workshop neat and orderly for easy operation.
(2) Disassembly of hydraulic equipment shall always be done in a clean place using clean tools.
Meaning
After Bottom Dead Center
Assembly
After Top Dead Center
Automatic Transmission
Before Bottom Dead Center
Left Hand
Long Life Coolant
Manual Transmission
Overhead valve
Option
Oversi~e
Horsepower
4. Genuine Toyota parts
Genuine Toyota parts should be used even in the replacement of packings, gaskets and O
- rings.
Abbreviation
(Code)
P/S
RH
SA
E
SST
STD
SUB
- ASSY
T
=
OOT
U/S
w/
5. Repairs on electrical system
Before doing any repairs on the electrical system, disconnect the cables from the battery terminals.
Be sure to disconnect the negative
@ cable first.
6. Tightening torque for irlstallation
Be sure to observe the tightening torque given in this manual. If not specified, tighten to the torque '
listed in standard bolt & nut tightening torque.
7. Defect status grasp
Do not start disassernbly 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 upon a failure in starting the vehicle, but first check such
factors as the oil, pressure and rotation status causing the failure.

STANDARD BOLT AND NUT TIGHTENING TORQUES
How to judge tightening torque of a standard bolt or nut.
1.
How to judge tightening torque of a standard bolt.
Find out the type of the bolt from the list below.
Then, find the bolt tightening torque from the table.
2.
How to judge tighting torque of a standard unit.
The nut tightening torque
can be judged from the bolt type. (See the item above.)
LIST OF BOLT TYPES AND STRENGTH
1. Judging by part
\ 1 Shape and class
Hexagon
head bolt
@ Bolt head No*
Hexagon
flange bolt
No mark
Hexagon
head bolt
Hexagon Three protruding
head bolt
Two protruding
lines
Hexagon
flange bolt
Welded
bolt
@ l;') protruding
Class
2. Judging by part No.
Hexagon head bolt
Parts No,
I
91611 - do625
Length (rnrn)
Diameter ( mm )
Diameter
Parts No.
~en~th (rnm)
Diameter ( mm )
Diameter

STANDARD BOLT TIGHTENING TORQUES

PRECOAT BOLTS
(Boltswith seal lock agent coating on threads)
1. Do not use the precoat bolt as itisineither
of the following cases:
(a) After it is removed.
(b) When the precoat bolt is moved Cloos-
ened or tightened) by tightness check,
etc.
Note
:
.
For torque check, use the lower limit of the
Precoat ~~l~~
allowable tightening torque range. If the
bolt moves, retighten
it accordicg to the
steps below.
2.
Method for reuse of precoat bolts
(I)
Wash ,the bolt and threaded hole. (The
(2) Perfectly dry the washed parts by air
threaded hole must be washed even for blowing.
replacement of the bolt.)
(3) Coat the specified seal lock agent to the
threaded portion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
1.
When connecting a high pressure hose, wipe the hose fittingand mating nipple contact surfaces with
clean cloth to remove foreign matters and dirt. Also check no dent or other damage on the contact
surfaces before installation.
2.
When connecting a 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.thestandard tightening torque.
Nominal diameter
of screw
7116 - 20'UNF
9/16 - 18UNF
314 - 16UNF
7/8 - 14UNF
11/16 - 12UNF
15/16 - 12UNF
PF1/4
P F3/8
PF112
P F3/4
PF1
Hose inside
diarneter
(mrn)
6
9
12
12
19
25
9
9
12
19
25
Standard tightening torque kg
- m (ft-l b)
Standard
2.5 ( 18.1)
5.0
( 36.2)
6.0
( 43.4)
6.0
( 43.4)
12.0
( 86.8)
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 (17.4 - 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 (1986.8 -- 1989.8)
Punching
position
Vehicle series
Engine model
Vehicle model
Punching format
Vehicle series
Eng~nemodel
Vehicle model
Punching format
Top on rear right frame
-
1 ton series
1 Z
-
-
-
-
-
-
-
-
-
-
4 P
5FG10
02 - 5FG10
5FG14
02 - 5FG14
5FG15
02 - 5FG15
5FG18
02 - 5FG18
5FG18 -
10001
4
Y
40 - 5FG10
42 - 5FG10
40 - 5FG14
42 - 5FG14
40 - 5FG15
42 - 5FG15
40 - 5FG18
42 - 5FG18
405FG18 -
10001
2 ton series
2 J
5FD10
02 - 5FD10
5FD14
02 - 5FD14
5FD15
02 - 5FD15
5FD18
02 - 5FD18
5FD18 -
10001
4
P
5FG20
02 - 5FG20
5FG23
02 - 5FG23
5FG25
02 - 5FG25
5FG25 -
I0001
1 Z
5FD20
02 - 5FD20
5FD23
02
- 5FD23
5FD25
02 - 5FD25
5FD25 -
10001
4
Y
40 - 5FG20
42 - 5FG20
40 - 5FG23
42 - 5FG23
40 - 5FG25
42 - 5FG25
405FG25 -
10001
2 J
60 - 5FD20
62 - 5FD20
60
- 5FD23
62 - 5FD23
60
- 5FD25
62
- 5FD25
605FD25 -
10001

Vehicle series
Engine model
Vehicle
model
Punching
format
3.0 ton series
4 P
-
-
-
-
-
-
2J
60 - 5FD28
62 - 5FD28
60 - 5FD30
62- 5FD30
605FD30 -
10001
4 Y
5FG28
02 - 5FG28
5FG30
02 - 5FG30
5FG30 -
10001
1 Z
5FD28
02 - 5FD28
5FD30
02 - 5FD30
5FD30 -
1000 1

FRAME NUMBER (1 989.9 -
1
5FG14 40-5FG14 5FD14
02-5FG14 42
- 5FG14 02 - 5FD14
Vehicle model
5FG15 40-5FG15
02-5FG15 42 - 5FG15 02 - 5FD 1 5
5FG18 40 - 5FG18
02-5FG18 42-5FG18 02 - 5FD18
Punching
format
A5FG18 - 40011 405FG
1 8 - 40011 A5FD18
- 40011
2 ton series
1DZ
60-5FD20
62-5FD20
60-5FD23
62-5FD23
60-5FD25
62-5FD25
A605FD25-40011
1 Z
5FD20
02-5FD20
5FD23
02-5FD23
5FD25
02-5FD25
5FD25-40011
Enginemodel
Vehicle model
Punching
format
3 ton series
5K
5FG20
02-5FG20
5FG23
02-5FG23
5FG25
02-5FG25
A5FG25-40011
4Y
40-5FG20
42-5FG20
40-5FG23
42-5FG23
40-5FG25
42-5FG25
405FG25-40011
1DZ
60-5FD28
62-5FD28
60-5FD30
62-5FD30
A605FD30-40011
A
Enginemodel
Vehicle model
Punching
format
4Y
5FG28
02-5FG28
5FG30
02-5FG30
5FG30-40011
1 Z
5FD28
02-5FD28
5FD30
02-5FD30
5FD30-40011

WlRE ROPE SUSPENSION ANGLE LIST
SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE
Unit: ton (lb)
Lifting
angle
0"
30"
60"
Rope
diameter
6 mm
(0.24
in.)
8 mm
(0.32
in.)
10 mm
(0.4 in.)
12.5 mm
(0.5
in.)
14 mm
(0.56
in.)
Cutting
load
Tension
1 .OO
time
1.04
time
1.16
time
Single - rope
suspension Two
- rope suspension
Compres -
0
time
0.27
time
0.58
time
Four - rope suspension
Suspension
method Lifting
angle
90 "
120"
w F
2 t
* I.
Tension
1.41
time
2.00
time
2t
2t
Compres -
s
i
o
n
1 .OO
time
1.73
time
Suspension
method
2t
2t
b

COMPONENTS WEIGHT
(1986.8 -- 1989.8)
unit: kg (Ib)
Engine 4P
4Y
2J
1 Z
Transmission ASSY
Torque Converter ASSY
Differential
& Front
Axle (w/ Brake
Counter Weight
Mast
128 (282)
134 (295)
214 (471)
237 (523)
78 (172)
AlSl N One speed 152 (335)
AlSlN Twospeed 163 (359)
1 tonseries 210 (463) 2 tonseries 260 (573)
3 ton series 31
8 (701 )
1.0 ton Approx. 430 (950) 1.35 ton Approx. 645 (1 420)
1.5ton Approx. 785 (1730) 1.75 ton Approx. 915 (2020)
2.0 ton Approx. 1
1 10 (2670) 2.25 ton Approx.1225 (2700)
2.5 ton Approx. 1430 (3
1 50) 2.75 ton Approx.1670 (3680)
3.0 ton Approx. 1860 (4100)
1 .O ton Approx. 400 (880) 2.0 ton Approx. 500 (1 100)
3.0 ton Approx. 600 (1320)

COMPONENTS WEIGHT (1 989.9 -
unit: kg (Ib)
93 (205)
134 (295)
190 (41
9)
237 (523)
78 (1
72)
152 (335)
163 (359)
210(463)
260(573)
318 (701)
Approx. 430(950)
Approx. 645 (1420)
Approx. 785 (1730)
Approx. 915 (2020)
Approx. 1110 (2670)
Approx. 1225 (2700)
Approx. 1430(3150)
Approx. 1670(3680)
Approx. 1864(4100)
Approx. 400 (880)
Approx. 500
(1 100)
Approx. 600
( 1320)
. .
Engine
5K
4Y
1
DZ
1 Z
Transmission ASSY
Torque Converter ASSY
Differential & Front Axle
(w/ Brake)
Balance Weight
Mast
AlSlN One speed
Two speed
1 ton series
2 ton series
3 ton series
1.0ton
1.35 ton
1.5 ton
1.75 ton
2.0ton
2.25 ton
2.5ton
2.75ton
3.0ton
1.0ton
2.0ton
3.0ton

RECOMMENDED LUBRICANT QUANTITY & TYPES
(1986.8 - 1989.8)
Application
4
P
4 Y
2 J
1 Z
MTM
models
AlSlN
make
1 ton series
2 ton series
3 ton series
1 ton series
2 ton series
3 ton series
1 ton series
All models
Attached Table
Description Classification
API
SD,SE,SF
AP I
CC,CD
AP I
GL - 4
G L - 5
ATF
API
GL
- 4
G
L - 5
ISO
VG32
-
LLC
?-
Quantity
4.32 (1.14 USgal)
4.0 Q (1.06 US gal)
6.9
2 (1.82 US gal)
9.0
P (2.38US gal)
4.0 2 (1.06US gal)
14
11 (3.70 US gal)
5.8
Q (1.53US gal)
6.8
Q (1.80 US gal)
9.0
Q (2.38 US gal)
27
2 (7.1 US gal)
34
2 (9.0US gal)
37
11 (9.8US gal)
Proper quantity
Reservoir Tank
0.2
Q (0.05 US gal)
Proper quantity
1
Engine
Type
Motor oil
SAE30
(SAE20in cold area)
SA E20W-40
(SAE 1OW - 30 incold
area)
Diesel engine oil
SAE30
(SAE20incold area)
SAE 1OW - 30
Hypoid gear oil
SAE85W-90
GM
Dexrono II
Hypoidgear oil
SAE85W-90
Hydraulic oil
#90
SAE J - 1703
D OT - 3
MP Grease
" LLC 30 - 50%mix -
ture (forwinter or
alI - season)
a Coolant with rust-
inhibitor (forspring,
summer and autumn)
?
Gasoline
Diesel
Transmission
Torque converter
Differential
Hydraulic oil
Brake
(1 .O - 1.75 ton models)
Chassis parts
Coolant
Coolant
( Reservoir
Tank)
Coolant volume
All models
1.1 Q (0.3US gal)
(at Full level)

Attached Table 1 Coolant volume unit: f (US gal)
Engine
4 P
4 Y
1 z
2 J
Drive method
MTM
ATM
MTM
ATM
MTM
ATM
MTM
ATM
1 .O - 1.75 ton
vehicles
9.7 (2.56)
11.5
(3.03)
9.7 (2.56)
11.5 (3.03)
-
-
12.7 (3.35)
14.5 (3.70)
2.0 - 2.5 ton
vehicles
9.9 (2.61)
11.2 (2.95)
9.9 (2.61)
11.2 (2.95)
9.3 (2.46)
8.6 (1-01
14.9 (3.93)
14.2 (3.75)
2.75,3.0 ton
vehicles
-
-
12.2 (3.22)
1 1.8 (2.92)
9.6 (2.53)
9.2 (2.43)
15.2 (4.01)
14.8 (3.72)