Toyota 5FGC Series User manual

FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT
5FGC/5FDC18-30 Series. Please use this manual for providing quick, correct
servicing of the corresponding forklift models.
This manual deals with the above models as of August
1986.
Please understand
that disagreement can take place between the descriptions in the manual and
actual vehicles due to change in design and specifications. Any change or
modifications thereafter will be informed by Toyota Industrial Vehicles' Parts
&
Service News.
For the service procedures of themounted engine, read the repair manuals listed
below as referencetogether withthis manual.
(Reference)
Repair manuals related to this manual are as follows:
TOYOTA INDUSTRIAL VEHICLE
4
Y
ENGINE
REPAIR MANUAL (No. CE602)
TOY0TA INDUSTRIAL VEHICLE 2JENGINE
REPAIR MANUAL (No. CE603)
TOYOTA MOTOR CORPORATION

GENERAL
..........................
VEHICLE EXTERIOR VIEWS
VEHICLE MODELS
...................................
ABBREVIATIONS
&
TIPS ONOPERATION
..........
STANDARD BOLT
&
NUT TIGHTENINGTORQUE
...
PRECOATBOLTS
.....................................
HIGH PRESSURE HOSE FllTlNG
TIGHTENINGTORQUE
.............................
....................................
FRAME NUMBER
SAFE LOAD BY WIRE ROPE
.............................
SUSPENSION ANGLE
WIRE ROPE SUSPENSIONANGLE LIST
.............
CAPACITY ANDTYPES OF
SPECIFIED LUBRICANTS
..........................
........................................
LUBRICATION
PERIODIC MAINTENANCETABLE
...................
PERIODICREPLACEMENTPARTS
&
......................................
LUBRICANTS
Page
0
-
2

VEHICLE EXTERIOR VIEWS
Vehicle Front View
LAPI
8-8
Vehicle Rear View
LAPI
8-4

VEHICLE
MODELS
I
I
I I I
I
I
I
2ton
I175ion 5FGC18
I
I
4Y
Gasollne
1
Torque converter
as
standard
serles
,
I
I
PS
equ'pped
1
Model
I
Ser~es Payload
I
1
2.0 ton
42:
g:::;ine
i
Torque converter
Mounted
I
englne
1
Eng~netype
5FGC25
42:
E:::iine
Torque converter
1
1
5FDC25
It
I
I
I
Power
transmlsslon
I
i
225ton
I
5FGC23
4Y
I I
Remarks
3 ton
serles
I
Gasollne
I
Torque converter
I
1
2 75 ton
3
0
ton 5FGC30
1
5FDC30
4Y
'
GasOilne
Torque converter
1
2J
Diesel
i
I
5FGC28
1
4Y
Gasolne Torque converter
I

ABBREVIATIONS
The abbrev~at~onsused In thls manual are as follows:
I
Abbreviat~on
I
Meaning
/
Abbrev~ation
1
Meaning
I
1
1
I
ABDC
1
After bottom dead center
1
P/S
1
Power steering
I
ASSY Assembly
,
RH
/
Righthand
I
ATDC
BBDC
LH
LLC
OHV
I
OPT
1
After drop dead center
1
SAE
Before bottom dead center
1
Lefthand
1
SST
1
~ongl~iecoolant
Overhead valve
Option
Oversize
Horsepower
I
Soc~etyof Automot~ve
Engineers
Special service tool
1
STD
1
Standard
SUB-ASSY
I
Subassembly
T= T~ghten~ngtorque
OOT
I
I
Number of teeth
(00)
1
Undersire
TIPS ON OPERATION
1.
Safe operation
(1)
Make sure that correct size wire rope is used when
lifting
a heavy
material.
(2)
After jacking up, always support with a rigid rack or stand.
2.
Preparation of SSTs and measuring Instruments
(1)
Prepare necessary SSTs and measuring instruments before startlng repair
operation.
3.
Neatness and
underlines
(1
)
Keep the working place neat and orderly to make operation easler.
(2)
Hydraulic equipment should be disassembled with clean tools in clean places.
4.
Genulne Toyota parts
Always use genuine Toyota parts even for packlngs, gaskets and o
-
rings which are
-
replaced after each disassembly work.
5.
Repairs on electrrcal system
Before doing any repair on the electrical system,
disconnect
the cables from battery
terminals.
Always disconnect the negative
(
-
)
terminal first.
6.
Tightening torque at the time of installatron
Be sure to observe the tightening torque given In thls mannual. If not specified,
tlghten to the torque listed in
"
Standard Bolt
&
Nut t~ghteningTorques.
"
7.
Grasplng the defect status
When a defect is found, do not immediately start disassembly and replacement. First
check if the defect needs disassembly and replacement for repair. For example, do
not disassemble the torque converter for a defect of vehicle starting failure but check
such factors as the oil status, hydraulic pressure and rotation which directly cause the
defect.

STANDARD BOLT
&
NUTTIGHTENING TORQUE
Standard bolt and nut ttghtening torques are not ~ndicated
Therefore, judge the tightening torque as descr~bedbelow
1
Find out the type of bolt from the list below Then, judge the bolt tightenrng torque from the
tightening torque table
2
The nut tightening torque can be judged in the same way according to the type of the mating
bolt
DlSRlMlNATlONOF BOLT STRENGTH
1
Discriminat~onby actual bolt
2
Discrimination by part number
1
Shape and
description
I
Strength
code
4=4T
1
Number in relief or 5=5T
Hexagon
I
hallmark on head 6=6T
bolt
I
I
I
7=7T
Standard
;
I
I
Hexagon bolt
/
I
Part number example
3
-
4 06 0
L-
Nominal size
(mm)
l~om~naldlameter
Length
to
bottom surface of head
Stud bolt1
Part number example
92132
-
4 06 14
under head
imm)
L
;;;nai siz;
Strength code
Nomlnal d~ameter
Length
BAHS2
head
I
No mark
I
1
Hexagon
bolt
head
I
I
I
Hexagon
1
I
1
I
Bolt with two relief
Standard
I
llnes on head
6T
bolt
Hexagon
bolt
Collar
head
I
I
Hexagon
1
1
Boit w~ththree relief
7T
bolt llnes on head
!
I
I
BAHS28
I
I
I
I
Bolt with two relief
I
neson head
I

-
-
TIGHTENING
TORQUE
TABLE
Standard Collar
1
head head
~
Standard t~ghten~ngtorque kg
-
cm
(ft-lb)

- -
-
---
PRECOAT BOLTS
I
I
1
(Bolts coated wrth seal lock agent on threads)
I
1
Do not use the precoat bolt as it
IS
In
any of the follow~ngcases
I
(1
)
When the precoat bolt
IS
removed
I
(2)
When the precoat bolt 1s moved
(loosened or tightened) rn tighten-
rng check etc
I
Reference
:
I
I
The tightening torque must be checked
Precoat
601ts
84460
with the lower limit of the allowable
tightening toque range. If the bolt moves,
retighten it according to the following
procedure:
2.
Reusing the precoat bolt
(1)
Clean the bolt and threaded hole.
(2)
Dry the precoat bolt sufficiently by
(Clean the threaded hole even alr blowing, etc
when the precoat bolt
IS
to be
(3)
Coat the specifred seal lock agent
replaced.
j
on the theaded hole for the bolt.
HIGH PRESSURE HOSE FllTlNGTIGHTENING TORQUE
1.
Before connecting a h~ghpressure hose, wipe the high pressure hose fitting and mating n~pple
contact surfaces with clean cloth to remove foreign matters and dirt. Check that there
IS
no
dent or other surface defect on the contact surface.
2.
Al~gnthe high pressure hose f~ttingand nrpple and hold the hose In that the state during
tightening.
3.
The maximum t~ghten~ngtorque must not exceed twice the standard t~ghteningtorque.
Hose ~ns~de
diameter
mm
N~~~~~~
of screw
7/16 -20UNF 251 181)
9/16 -18UNF
1
50( 362)
3/4 -16UNF
I
60
(
43 3)
Standard t~ghtenrngtorque kg
-
cm (ft-l
b)
24
-
261173 188) 6
48
-
531347
-
383) 9
57
-
63141 2
-
455) 12
Standard Tighten~ngrange
7/8 -14UNF
11/16-12UNF
15/16-12UNF
PFI/4
60( 433)
1
57
-
63141 2- 455) 12
120( 866) 11 4-1261823- 91 0) 19
150(lOl1)
1
133-,471960-1061)
I
25
501 362) 48
-
531347- 383)
PF3/8
'
50( 362) 48
-
533347- 383) 9
9
PF1/2
PF3/4
PF
1
57
-
63141 2
-
455)
,
12
120( 866) 11 4-126(823- 91 0) 19
I
140(101
1)
1
133
-
1471960
-
1061) 25

FRAME NUMBER
1
top
of
rear
pan
of
I
Model serles
1
2.0ton serles
I
3.0 ton series
.
EEC
spec.
(1
992.
11
-
)
SAFE LOAD
BY
WIRE ROPE SUSPENSION ANGLE
Un~t.ton (Ib)
Eng~netype
,
4Y
Model
I
5FGC18
1
5FGC20
5FGC23
I
5FGC25
Rope
d~ameter
2J
5FDC20
5FDC25
-
-
5FDC25- 10001
"5FDC25E10001
Frame ser~alnumber format
6 rnm
(0.24in)
5FGC25-10001
'5FGC25E10001
4Y
5FGC28
5FGC30
-
-
5FGC30- 10001
'5FGC30E10001
Omm 502 071 143137 12
1
0 2827 2420
1
(04 in)
1
(1
1069)
(1
565 6) (3153) (3021
1
(2646) (2205)
11
6174)
(
5954)
(
5292) (4410)
2J
5FDC30
-
-
-
5FDC30- 10001
'5FDC30E10001
'
Un~filar
Breakdown
load
2.18
(
4807)
12.5mrn
(0.5 ~n)
14 mrn
SusPen-
sion
0"
0.31
(
683.6)
B~f~larsuspension Cross sling~ng
90
"
0.44
(
970)
0.64
(141
1)
0"
1.24
(
2734)
1.8
(
3969)(
0
"
0.62
(1
367)
3.2
1
0.9
(1985)
7.84 1.12
(
2.2
(1
7287)
.
9.83
(0.56
In)
1
(21675)
30
"
1.2
(
2646)
1.74
3837)(
30
"
0.6
(1
323)
0.87
(1918)
60
"
0.53
(1
169)
0.78
(1720)
4.4
(
9702)
5.6
(2469.5)l(4851)
(30870) 1.92.7
60"
1.06
(
2337)
1.56
3440)
(1
2348)
1.4 (6174) (4190)
2.4
(5954)
90
"
0.88
(1
940)
1.28
(2822)
4.2
(
9261)
5.4
2.8 (5292)
(1
1907)
3.8
(
8379)
4.8
3.0
(6615)
3.8
(1
0584) (8379)

-
-
WIRE ROPE SUSPENSION ANGLE LIST
Suspen-
slon
,
method
Suspen
-
s~on Ten-
I
CO~P~~S
angle
,
"On
I
strength method
1
I
I
I
I
1
1
I
I
I
I
I
I
I
1
I
30
"
I
027
1
toe tme
I
times
1
times
I
I
I
1161
058
/
60
"
'
tmes
,
tme
1
I
I
i
I
Suspen
angle
slon
,
ston strength
Suspei
I
~ompres-
SIO~
sion
slon

CAPACITY AND TYPES
OF
SPECIFIED LUBRICANTS
Description Classification
API
SD, SE, SF
API
CC, CD
AT
F
API
GL
-
4
GL
-
5
IS0
VG32
Engine
Gasoline
Deisel
TYpe
Motor oil
SAE30
(SAE20 in cold area)
SAE20W-40
(SAE10W-30in cold
area)
Diesel engine oil
SAE30 (SAE20in
cold area)
SAElOW
-
30
GM Dexron@
I1
Hypoid gear oil
SAE85W-90
Hydraulic oil #90
Torque converter
Differential
Hydraulic oil
Fuel tank All models
All models
4Y
2J
Chassis parts
Coolant
45P
(1
2 US gal)
Proper quantity
9.OP (2.38 US gal)
9.51(2.51 US gal)
Application
4Y
2
J
All models
All models
2 ton series
3
ton series
Quantity
4.01(1.06 US gal)
6.91(1.82
US
gal)
14.OP
(3.70
US gal)
6.81(1.80 US gal)
27P (7.1 US gal)
281(7.4US gal)
LLC
MP grease No.2
LLC 30
-
50% mixture
(for winter or
all
-
season)
Coolant with rust~nhi-
bitor (for spring,
summer and autumn)

LUBRICATION
Cha~n
Differential
Front wheel bearlng
Torque converter case
Rear wheel bear~ng
Steering knuckle king pln
Oil tank
Engine crank case
Rear axle beam front
Rear axle beam rear
Tilt
steerlng universal jolnt
Tllt steerlng locking mechanism
Mast support bushing
T~ltcylinder front pin
Propeller shaft
Inspect every
8
hours (dally)
lnspect every 40 hours (weekly)
inspect every 170 hours (monthly)
lnspect every 1000hours
(6
monthly)
V
lnspect every 2000 hours (annually)
0
lnspect
and
service
Replace
1
MP
grease
2
Eng~neoil
3
Hypoid gear 011
4
Hydraul~coil
5
Automat~c
transmission
fu~d
Lubr~cationChart
UPM~

PERIODIC MAINTENANCE TABLE
INSPECTION METHOD
I
.
Inspect and Correct or replace as required.
M
:
Measure and correct or adjust as requ~red
T
.
T~ghten
C
.
Clean
L
:
Lubricate
*
.
For new vehicle
*'
.
Soapy water
'2
Detector
"3
.
Flaw detector
Place Inspection item Every
ENGINE
Engine
proper
Positive
crankcase
ventilation
(PCV)
Governor
Lubrication
system
Fuel
system
Cooling
system
1
170
6
1000
3
500
t
C
C
+
+
M
M
T
+
C
+
+
C
+
+
C
+
M
+
C
t
t
I
Starting status and abnormal noise
Revolution in idling state
Revolution during acceleration
Exhaust gas
Air cleaner element
Valve clearance
Compression
Cylinder head bolt loosening
Clogging and damage of PCV valve
and piping
No
-
load maximum engine speed
Oil leakage
Oil level
Clogging and fouling of oil filter
Fuel leakage
Carburetor link mechanism operation
Fouling and damage of oil filter
element
Injection timing
Injection nozzle injection pressure
and spray status
Radiator cooling water level and
leakage
Rubber hose deterioration
Radiator cap status
Fan belt tension, looseness and
damage
Damage and hardening of radiator
rubber mount
C
+
t
t
+
t
t
+
+
+
C
t
t
C
+
+
+
I
M
M
I
C
M*
T"
I
M
I
I
I
I
I
I
I
I
I
I
t
+
C
t
+
C
+
+
t
t
C
+
t
M
C
+
+
C
12
2000
Months
Hours

Place
LPG fuel
system
1
170
1*1
1'2
C
I
Every
Gas leakage from piping and joints
Damage of pipng and joints
Vaporizer tar discharge
Looseness and damage of gas
cylinder mounting
POWER TRANSMISSION SYSTEM
3
500
t
,
t
+
--
Differential
Torque
converter
and
transmis-
sion
Propeller
shaft and
axle
shaft
6
1000
+
t
+-
+
Oil leakage
Oil level
Loose bolts
Oil leakage
Oil level
Operating mechanism function and
looseness
Control valve and clutch functions
Inching valve function
Stall test and oil pressure measure-
ment
Loose joint
~oosenessat spline connection
Looseness at flexible joint
Axle shaft torsion and crack
12
2000
+
C
+
C
I
I
I
I
I
I
I
Months
Hours
C
+
C
+
+
+-
C
I
+
+
C
+
t
+
t
M
C
+
+
T
+
-
+
t
+
-
t
1
I
I

Months
Hours
Place Every
1
170
TRAVELING EQUIPMENT
3
500
Wheels
Front axle
Rear axle
6
1000
I
T
M
I
I
I
I
M*
Tire cuts, damage and uneven wear
Loose rim and hub nuts
Tread depth
Metal fragments, stones or other
foreign matters on tires
Rim, side bearing and disc wheel
damage
Front wheel bearing abnormal sound
and looseness
Rear wheel bearing abnormal sound
and looseness
Housing crack, damage and deforma-
tion
Beam crack, damage and deformation
Looseness of axle beam in vehicle
longitudinal direction
12
2000
STEERING SYSTEM
+
+
+
-
+
t
-
Steering
wheel
Gear box
Power
steering
t
+
C
t
+
+
+
C
C
+
+
+
C
t
t
t
t
+
t
+
-
I
I
M
+
t
t
+
+
C
I
Play and looseness
Operating status
Oil leakage
Looseness of installation
Oil leakage
Looseness of mounting and linkage
Power steering hose damage
I
I
I
T
I
I
t
+
+
+
t
+-

Place
Knuckle
Steering
axle
1
170
I
Inspection item Every
King pin looseness
Crack and deformation
Wheel alignment
Left and right turning angles
BRAKING
Brake pedal
Parking
brake
Brake piping
Master
cylinder or
brake valve
and wheel
cylinder
Brake drum
and brake
shoe
Backing
plate
3
500
+
SYSTEM
Play and reserve
Braking effect
Pull margin
Braking effect
Looseness and damage of rod and
cable
Looseness and damage of level link
Leakage, damage and installation
status
Function, wear, damage, oil leakage
and loosening of installation
Clearance between drum and lining
Wear at shoe sliding contact portion
and lining
Drum wear and damage
Shoe operating state
Anchor pin rusting
Fatigue of return spring1
Automatic adjusting mechanism func-
tion
Deformation, crack and damage
Looseness of mounting
12
2000
+
I
M
M
6
1000
C
Months
Hours
M
I
I
I
I
I
M
+
+-
+
t-
+
+
e-
+
+-
-
+
t
C
+-
-
C
t
+
t
I
t
I
t
I
I
I
I
M
I
I
T

Place Every
12
2000
Months
Hours
1
170
3
500
I
I
I
I
+--
I
I
I
I
I
I
t
t
+
+
C
+
+
t
+
+
t
MATERIAL
Fork
Mast and
fork bracket
Chain and
chain wheel
Attachments
HYDRAULIC
6
1000
HANDLING SYSTEM
Abnormality of fork and stopper pin
Left and right fork blade misalignment
Crack at fork base and welded portion
Deformation and damage of each
part, crack at welded portion
Looseness of mast and lift bracket
Mast support bush wear and damage
Roller wear, damage and rotation
status
Roller pin wear and damage
Mast strip wear and damage
Chain tension, deformation and
damage
Chain lubrication
Abnormality of chain anchor bolt
Chain wheel wear, damage and
rotation status
Abnormality and installation status of
each attachment
SYSTEM
+
+
+
+
+
+
C
+
+
+.-
-
Cylinder
Oil pump
t
+-
lX3
C
t
I
I
+
+
t
t
+
t
T
I
I
M
I
I
M
I
I
Looseness and damage of cylinder
mounting
Deformation and damage of rod, rod
screw and rod end
Cylinder operation
Natural drop and natural forward tilt
Oil leakage and damage
Wear and damage of pin and cylinder
bearing
Lifting speed
Uneven movement
Oil leakage and abnormal sound
+
+
+
+
+
+
+
+
+--
+
+
C
+
t
+
t
+
+
t
+
t
t
t
t
+-
t
t

Tank and oil strainer
Relief pressure measurement
Relief valve and tilt lock valve func-
Deformation and damage
Looseness of joints
Hose tension and torsion
Distributor side terminal burning
Wear and damage of distributor cap
center terminal
Pinion gear meshing

Deformation, crack and damage
This manual suits for next models
8
Table of contents
Other Toyota Forklift manuals

Toyota
Toyota 8FGU15 Operating instructions

Toyota
Toyota 7FG 10 Operating instructions

Toyota
Toyota 8FBE18T User manual

Toyota
Toyota LOP10CW User manual

Toyota
Toyota 8FGU15 User manual

Toyota
Toyota 8FG35N User manual

Toyota
Toyota 30 Series User manual

Toyota
Toyota 7FBCU 15-55 User manual

Toyota
Toyota 8FGU 15 Operating instructions

Toyota
Toyota 7FBCU20 User manual