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 I (Sections 0 to 15) and Repair Manual (Supplement)
Pub. No. CE014. as Part11 (Sections
0 to 4).
Part
I 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
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
-
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
O . CE615-1)
TOYOTA MOTOR CORPORATION

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

GENERAL
Page
EXTERIOR VIEWS
................................ 0 - 2
VEHICLE LISTING
................................ 0 - 3
ABBREVIATIONS
................................ 0 - 4
OPERATIONAL TIPS
............................. 0 - 4
STANDARD BOLT
& NUTTIGHTENING
......................................... TORQUE 0-5
BOLT STRENGTH TYPE IDENTIFICATION
METHOD
...................................... 0 - 5
TIGHTENINGTORQUE TABLE .................. 0-6
PRECOAT BOLTS .............................. 0 - 7
HIGHPRESSURE HOSE FITTING
TIGHTENING TORQUE
........................... 0 - 7
FRAME NUMBER ................................ 0 - 8
WIRE ROPE SUSPENSION ANGLE LIST ...........
0 - 9
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE
............................ 0 - 10
COMPONENTS WEIGHT ......................... 0 - 10
RECOMMENDEDLUBRICANT QUANTITY
&TYPES
......................................... 0-11
..........................
LUBRICATION CHARTS 0 - 12
PERIODIC MAINTENANCE
....................... 0 - 14
.........................
INSPECTION METHOD 0 - 14
PERIODIC REPLACEMENT LUBRICANTS
ANDPARTS
..................................... 0 - 20

EXTERIOR VIEWS
Front View (5FD35) ~~0.72-1
Rear View (5FD35)
- 6 -

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
3F
t
11Z
t
3F
t
11Z
t
3F
t
11Z
t
3F
t
11Z
t
3F
t
11Z
t
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
t
Diesel
t
Gasoline
t
Diesel
t
Gasoline
t
Diesel
t
Gasoline
t
Diesel
t
Gasoline
t
Diesel
t
Remarks
Wheelbase
1800 mm
(71 in)
Wheelbase
2000
mm
(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.
4
Meaning
Horsepower
Power steering
Right hand
Society of automotive engineers
(USA)
Special service tool
Standard
Sub-assembly
Tightening torque
Number of teeth (00)
U ndersize
With
Abbreviation
(Code)
ABDC
ASSY
ATDC
ATM
BTDC
L/
LH
LLC
MTM
OHV
0 PT
0 /s
2.
Preparation of SSTs and measuringtools
(1) Prepare SSTs and measuring tools before starting operation.
3. 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
4. Genuine Toyota parts
Genuine Toyota partsshould be used even in the replacement of packings, gaskets and O
- rings.
Abbreviation
(Code)
PS
P/S
RH
SAE
SST
STD
SUB
- ASSY
T =
OOT
U /S
W/
5. 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.
6. Tightening torque for installation
Be sure to observe the tightening torque given in this manual. If not specified, tighten
to thetorque
listed in standard bolt
& nut tightening torque.
7. 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.
1.
Find out the straight type of bolt from the list below and then find the bolt tightening torque from
the table.
2.
The nut tightening torque can be judged from the mating bolt type.
BOLT STRENGTH TYPE IDENTIFICATION METHOD
1. Identification by bolt shape 2. Identification by part No.
Standard
hexagon
bolt
Hexagon bolt I
Part NO. example
9 I1 11 - 40610
-1
T~engthunder head
(mm)
Nominal diamter
(mm)
two rel~efl~neson
Standard bolt with
-
Strength
type
4 = 4T
5
= 5T
6
= 6T
7 = 7T
4T
Shape and identification method
-
Strength type
0
@
I
Nominal
diameter
Length under head
Stud bolt
Part
No. example
92132-4-061 4
1
T~ength(mm)
Nominal diameter
(mm)
Number in relief or
hallmark on the head
No mark
-
Strength type
Nominal
diameter
Length

TIGHTENING TORQUE TABLE

PR 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
is removed.
(b) When the precoat bolt is 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
it 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
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 the standard tightening torque.
Hose inside
diameter (mm)
6
9
12
12
19
25
9
9
12
19
25
Nominal diameter
of screw
5 - 20 UNF
% - 18 UNF
- 16 UNF
5 - 14 UNF
- 12 UNF
I& - 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 (1 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.)
" 5 1993.10-(EEC spec.)
Engine
3F
11Z
3F
11Z
LAQS 1 29
Punching,position
Frame No.punching position
a
Model
5FG 33
02
- 5FG 33
5FG 35
02
- 5FG 35
5FD 33
02
- 5FD 33
5FD 35
02
- 5FD 35
5FGE35
02-5FGE35
5FG 40
02
- 5FG 40
5FG 45
02
- 5FG 45
5FDE35
02-5FDE35
5FD 40
02
- 5FD 40
5FD 45
02
- 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

- -
WIRE ROPE SUSPENSION ANGLE LIST
Lifting
angle
o
O
30°
60°
Compres -
sion
0
time
0.27
time
0.58
time
Tension
1 .oo
time
1.04
time
1 .I 6
time
Suspension
method
:LI
fiO
A.
@
\'
Lifting
angle
90°
120°
Tension
1.41
time
2.00
time
Compres -
sion
time
loo
Suspension
method
ko
,"
time

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE
Unit: ton (Ib)
I Rope
diameter
8 mm
(0.32in.)
10
mm
(0.4in.)
14 mm
(0.56in)
Cutting
load
Two
- rope suspension Four
- rope suspension
COMPONENTS WEIGHT
Unit: kg (lb.)
Engine
Transmission with differential
Torque converter with differential
Balance weight
Mast
L/ Lift Bracket
(Max.Fork Height:
3000 mm (1 18 in.)
11Z: 330 (728)
3F
: 250 (551)
Approx. 200 (441 )
Approx. 360 (794)
3.25
ton Approx. 1920 (4234)
3.5
ton Approx. 2220 (4895)
E3.5
ton Approx. 2 1 30 (44 1 0)
4.0
ton Approx. 2520 (5557)
4.5
ton Approx. 2830 (6240)
3.25
- 4.0 ton Approx. 650 (1 433)
4.5 ton Approx. 850 (1 874)

RECOMMENDED LUBRICANT QUANTITY & TYPES
Application
3F
11Z
MTM models
All models
ATM models
Description Quantity
Up to '88 Nov.
8.0
Q (2.1US gal)
From '88 Dec.
9.3 Q (2.5US gal)
12.5
Q (3.3US gal)
6.0
Q (1.6US gal)
9.5
Q (2.5US gal)
15
Q (4.0US gal)
Classification
API
SD, SE, SF
API
CC,
CD
API
GL
- 4
GL
- 5
API
GL
- 4
GL
- 5
ATF
Engine
Hydraulic oil
Fuel tank
Chasis parts
Coolant
(Excludingreserve
tank)
Coolant (Reservoir
tank)
Drive shaft pulley
(Oil pump spline
shaft)
TYpe
Motor Oil
SAE30
(SAE20in cold area)
SAE20W-40
(SAE1OW - 30 in cold
area)
Diesel engine oil
SAE30
(SAE20 in cold area)
SAE1OW - 30
Hypoid gear oil
SAE85W-90
Hypoid gear oil
SAE85W-90
GM
Gasoline
Diesel
Torque converter
Transmission
Differential
DexronB I1
IS0
VG32
LLC
T
Hydraulic oil IS0
VG32
MP Grease
@LLC30 - 50% mix-
ture (for winter or
all season)
*Coolant with rust-
inhibitor (for
spring, summer
and autumn)
T
Molybdenum disulfide
grease
Fork height
3000 mm
(1 18 in.)
Gasoline
models
5FD33,35
Diesel models
5FDE35,
5FD40,45
All models
3F
All models
All models
60
Q (16 US gal)
95 Q (25US gal)
95
Q (25 US gal)
120
Q (32US gal)
Proper quantity
13.0
Q (3.4US gal)
13.0
Q (3.4US gal)
1.1
Q (0.3US gal)
(at Full level)
Proper quantity

LUBRICATION CHARTS
Chain
Differential gear
Front wheel bearing
Power cylinder joint
Transmission case
Rear wheel bearing
Steering knuckle king pin
Bell crank pin
Oil tank
Engine crankshaft
Rear axle beam front
Rear axle beam rear
Tilt steering universal joint
Tilt steering locking mechanism
Mast support bushing
Tilt cylinder front pin
Propeller shaft (Oilpump drive shaft)
Tie
- rod end
Drive shaft pulley (Oil pump spline shaft)
lnspect every
8 hours(daily)
lnspect every
40 hours (weekly)
lnspect every 1 70hours (monthly)
lnspect every 1000 hours (6monthly)
lnspect every 2000 hours (annually)
lnspect and service
Replace
MP grease
Engine oil
Hypoidgear oil
Hydraulic oil
Hypoidgear oil
Molybdenumdisulfide grease
Clutch Model Lubrication Chart
- 16 -

13
2 14
1 1
16 16
3 3
15 15
10 5
17 9
11 4
8 4
6
6
7 7
12 18
18 19
1.
Chain I . Inspect every 8 hours (daily)
2. Differential gear n. Inspect every 40 hours(weekly)
3. Front wheel bearing 111. Inspect every 170 hours (monthly)
4. Power cylinder joint IV. Inspect every 1000 hours (6monthly)
5. Transmission case V. Inspect every 2000 hours (annually)
6. Rear wheelbearing
7. Steering knuckle king pin
0 lnspect and service
8. Bell crank pin Replace
9. Oil tank @ MP grease
10. Engine crankshaft
@ Engine oil
11. Rear axle beam front @ Hypoidgear oil
12. Rear axle beam rear @ Hydraulic oil
13. Tilt steering universal joint @ Automatic transmission fluid
14. Tilt steering locking mechanism
@ Molybdenumdisulfidegrease
15. Mast support bushing
16. Tilt cylinder front pin
17.
Propeller shaft(Oil pump drive shaft)
18. Tie - rod end
19.
Drive shaft pulley (Oil pump spline shaft)
i
Torque Converter Model Lubrication Chart

PERIODIC MAINTENANCE
INSPECTION METHOD
I : Inspeciton. Repairorreplacementif required.
M
: Measurement. Repair or adjustment if required.
T : Retightening C : Cleaning L : Lubrication
* : For new vehicle * 1 : Soapy water "2 : Detector "3 : Flaw detector
12
2000
Months
Hours
3
500
1
170
h
Inspection Period
Item --------___
6
1000
Every
Every
ENGINE
Main body
PCV system
Governor
Lubrication
system
Fuel system
Cooling
system
I
Proper starting and abnormal noise
Rotating condition at idling
Rotating condition during acceleration
Exhaust gas condition
Air cleaner element
Valve clearance
Compression
Cylinder head bolt loosening
Muffler rubber mount
Clogging and damage in
PCV valve and
piping
No
- load maximum rpm
Oil leak
Oil level
Clogging and dirt of oil filter
Fuel leak
Operation of carburetor link mechanism
Dirt and clogging of fuel filter and element
Injection timing
lnjection nozzle injection pressure and
spray status
Draining of sedimenter
Coolant level in radiator and leak
Rubber hose degradation
Radiator cap condition
Fan belt tension, looseness and damage
Radiator rubber mount
Radiator screen
lCtt
Mttt
M++~
lCtt
cCtt
lCtt
~ttt
I+++
lCtt
it+-+
lCtt
I+++
lttC
lttC
lttt
ICtt
+++
cttC
M
M
T
I
Mt
M
It
I

Inspection Period
Item
-
3
500
Every
Every
6
1000
1
170
POWER
Clutch
Transmission
Differntial
Torque
converter and
transmission
DRIVE SYSTEM
I
TRANSMISSION SYSTEM
Clutch pedal play
Abnormal sound and functioning
(connection)
Clutch booster function and leak
Oil clutch mechanism and leak
Leak
Fluid level
Gear function and abnormal noise
Leak
Oil level
Bolt loosening
Leak
Fluid level
Operating mechanism function and
looseness
Control valve and clutch functions
Inching valve function
Stall and hydraulic pressure measurement
12
2000
Months
Hours
M-++
ICtC
lCCe
I
I++-+
I+-+
lCtt
I+++
ttt
it++
I+-++
I++-
I+++
I++-
M
Mt++
I+++
Tttc
M+++
I+++-
I+++
I+++
Wheels
+
T
+
Tire inflation pressure
Tire cuts, damage and uneven wearing
Loose rim and hub nuts
Tire groove depth
Metal chips, pebbles and other foreign
matter trapped in tire grooves
Rim, side bearing and disc wheel damage
Abnormal sound and looseness of front
wheel bearing

-
-
Inspection Period
-
Item --------
Every
Every
1
170
Wheel
Front axle
Rear axle
lttt
Abnormal sound and looseness of rear wheel
bearing
Cracks, damage and deformation of
housing
Cracks, damage and deformation of beam
Looseness of axle beam in vehicle
longitudinal direction
3
500
I
I
M
STEERING SYSTEM
Steering
wheel
Gear box
Rods, links
and arm
Power
steering
Knuckle
Steering
shaft
6
1000
Play and looseness
Function
Oil leak
Looseness of mounting
Clogging of relief valve filter
Looseness and damage
Linkage and wear and mounting condition
Oil leak
Mounting and linkage looseness
Damage of power steering hose
King pin looseness
Cracks and deformation
Wheel alignment
Left and right turning angle
12
2000
BRAKING SYSTEM
Months
Hours
ttt
lee+-
lttt
T++-+-
I'--'-
I+++
lCCt
I+++
Brake pedal
Parking brake
Brake pipe
Brake booster
and wheel
cylinder
C+
I
I
I
M
M
Play and reserve
Braking effect
Operating force
Braking effect
Rod and cable looseness and damage
Leak, damage and mouting condition
Function, wear, damage, leak and
mounting looseness
M++~
I+++
lCtC
I+++
Ieet
I+++-
I

Inspection Period
Item
1
170
Every
Every
3
500
Brake drum
and brake
shoe
Backing plate
MATERIAL
Forks
Mast and
fork
bracket
Chain and
chain wheel
Various
attachment
HYDRAULIC
Clearance between drum and lining
Wear of shoe sliding portion and lining
Drum wear and damage
Shoe operat~ngcondition
Anchor pin rusting
Return spring fatique
Automatic adjuster function
Deformation, cracks and damage
Loose mounting
lCtt
I++~
CCC
l-'-;I I++-+
I-++
ICCC
lttt
it++
ICCC
I+--
6
1000
M+-++
1 *3
I
HANDLING SYSTEM
Abnormality of fork and stopper pin
Misalignment between left and right fork
fingers
Cracks at fork root and welded part
Deformation and damage of each part and
crack at welded part
Mast and lift bracket looseness
Wear and damage of mast support bush
Wear, damage and rotating consdition of
rollers
Wear and damage of roller pins
Wear and damage of mast strip
Tension, deformation and damage of
chain
Chain lubrication
Abnormality of chain anchor bolt
Wear, damage and rotating condition of
chain wheel
Abnormality and mounting condition of
each part
SYSTEM
I
Tttt
ICCC
I+++
MCC
Cylinder
12
2000
I
I
I
I
M
I
I
T
Loosening and damage of cylinder
mounting
Deformation and damage of rod, rod
screw and rod end
Cylinder operation
Natural drop and natural forward tilt
(hydraulic drift)
Months
Hours

C
Inspection Period
-
Item
Every
Every
1
170
Cylinder
Oil pump
Hydraul~c
oil tank
Control
lever
Oil control
valve
Hydraulic
piping
ELECTRICAL
1
Oil leak and damage
Wear and damage of pin and cylinder
bearing
Lifting speed
Uneven movement
Oil leak and abnormal sound
Oil level and contamination
Tank and oil strainer
Oil leak
Loose linkage
Operation
Oil leak
Relief pressure measurement
Relief valve and tilt lock valve functions
011 leak
Deformation and damage
Loose joint
SYSTEM
3
500
Ignition
timing
Starting
motor
Charger
Battery
Electrical
wiring
I-++
It+'-
M+++
I++-+
I++-
I--'-
I--+
I'-'-'-
I-++
I+-++
I++-+
tCC
I+++
T---
C+
M
6
1000
Cracks on distributor cap
Spark plug and burning and gap
(- 1997.12)
Distributor side terminal burning
Distributor cap center piece wear and
damage
Distributor points gap
Plug cord internal discontinuity
Ignition timing
12
2000
+
I
Months
Hours
Pinion gear meshing status
/I
Charging function
Battery fluid level
Battery fluid specific gravity
Damage of wiring harness
Fuses
-++
I+-++
+++
IttC
M++-
+
I-+--
I++-
I'-+'-
let+
I
Mt
+
Mt