Toyota FORKLIFT 5FGIO Series Manual
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Toyota FORKLIFT 5FGIO Series Manual

Toyota FORKLIFT 5FGIO Series Manual

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This manual covers the service procedures of the TOYOTA FORKLIFT 5FGIO-
servicing of the corresponding forklift models.
These models on the market since August 7986 are subject to minor changes
i n September 7986. This manual deals with the models produced i n the period
between A ugust 7 988 and August 7 9 8 9 as well as the models as of September
7 989 (after m ~ n o r 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:
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
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.)
FOREWORD
TOYOTA MOTOR CORPORATION

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  • Page 1 FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 5FGIO- servicing of the corresponding forklift models. These models on the market since August 7986 are subject to minor changes i n September 7986. This manual deals with the models produced i n the period between A ugust 7 988 and August 7 9 8 9 as well as the models as of September 7 989 (after m ~ n o r changes}.

  • Page 3: Table Of Contents

    GENERAL Page ......EXTERIOR VIEWS VEHICLE LISTING ABBREVIATIONS ......OPERATIONAL TIPS STANDARD BOLT &...

  • Page 4: Exterior Views

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

  • Page 5: Vehicle Listing

    VEHICLE LISTING (1986.8 Engine Engine Pay load Model Drive system Remarks ries model Gasoline clutch as standard 0 2 - 5FG10 Torque converter 1.0 ton 4 0 - 5FG10 clutch 4 2 - 5FG10 Torque converter clutch Torque converter Gasoline clutch 0 2 - 5FG14 Torque converter...
  • Page 7 VEHICLE LISTING (1989.9 Load capac~ty Model Engine model Clutch Torque converter Clutch Torque converter Clutch 02-5FD 10 Torque converter Clutch Torque converter 1.35 t o n Torque converter Clutch 1 DZ Torque converter 1 ton serles Clutch Torque converter Clutch 1.5 ton Torque converter Clutch...
  • Page 8 Series Load capacity Model Engine model Drive system Clutch Torque converter 2.25 t o n 1 DZ Torque converter Clutch Torque converter 2 ton series Torque converter Clutch Torque converter Clutch Torque converter Clutch Torque converter Clutch 2.75 t o n Torque converter 1 DZ Torque converter...

  • Page 9: Abbreviations

    Disassembly of hydraulic equipment shall always be done in a clean place using clean tools. Genuine Toyota parts Genuine Toyota parts should be used even in the replacement of packings, gaskets and O-rings. Repairs on electrical system Before doing any repairs on the electrical system, disconnect the cables from the battery terminals.
  • Page 10 STANDARD BOLT AND NUT TIGHTEN ING TORQUES How to judge tightening torque of a standard bolt or nut. 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. How to judge tighting torque of a standard unit.
  • Page 11 STANDARD BOLT TIGHTENING TORQUES...
  • Page 12 PRECOAT BOLTS (Bolts with seal lock agent coating on threads) Do not use the precoat bolt as i t i s i n e i t h e r of the following cases: (a) After i t is removed. ened or tightened) by tightness check, etc.

  • Page 13: Frame Number

    FRAME NUMBER (1986.8 1989.8) Top on rear right frame Punching posit ion series Vehicle series Engine model 40- 5FG10 02- 5FG10 42- 5FG10 02- 5FD10 40- 5FG14 02- 5FG14 42- 5FG14 Vehicle model 40- 5FG15 02- 5FG15 42- 5FG15 40- 5FG18 42- 5FG18 02- 5FD18 02- 5FG18...
  • Page 14 Vehicle series ton series Engine model 60- 5FD28 02- 5FG28 02- 5FD28 62- 5FD28 Vehicle model 60- 5FD30 02- 5FG30 02- 5FD30 Punching format 10001 1000 1 10001...
  • Page 15 FRAME NUMBER (1 989.9 42-5FG 14 02-5FD 14 Vehicle model 42-5FG 1 5 02-5FD 1 5 40-5FG 18 02-5FD 18 Punching format ton series 1 DZ Engine model Vehicle model Punching format ton series Engine model 1 DZ Vehicle model Punching format...

  • Page 16: Safe Load For Each Wlre Rope Suspension Angle

    Lifting Com pres- Suspension Lifting Compres- Suspension Tension Tension met hod angle angle method s i o 1 .OO 1.41 1 .OO 90" time time time time 1.04 0.27 2.00 1.73 time time time time 1.16 0.58 time time SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE Unit: ton (lb) Single-rope Two-rope suspension...
  • Page 17 COMPONENTS WEIGHT (1986.8 1989.8) unit: k g (Ib) Engine 128 (282) 134 (295) 214 (471) 237 (523) Transmission ASSY 78 (172) Torque Converter ASSY Differential & Front 1 ton series 21 0 (463) 260 (573) Axle Brake 3 ton series 31 8 (701 Counter Weight 1.0 ton Approx.

  • Page 18: Component Weight

    COMPONENTS WEIGHT (1 989.9 unit: kg (Ib) 93 (205) 134 (295) Engine 1 DZ 190 (41 9) 237 (523) Transmission ASSY 78 (1 72) 152 (335) One speed Torque Converter ASSY Two speed 1 63 (359) 1 ton series 2 10 (463) Differential &...
  • Page 19 RECOMMENDED LUBRICANT QUANTITY & TYPES (1 986.8 1989.8) Classification Application Quantity Description AP I Motor oil 4.32 (1.14 USgal) (1.06 US gal) Gasoline SA E20W-40 (SAE 1 OW-30 in cold area) Engine AP I (1.82 US gal) Diesel engine oil (2.38 US gal) Diesel SAE 1 OW-30...
  • Page 20 Attached Table 1 Coolant volume unit: (US gal) 1 . O 1.75 t o n - 2.5 Engine Drive method vehicles vehicles vehicles 9.7 (2.56) 9.9 (2.61) 11.5 (3.03) 11.2 (2.95) 9.7 (2.56) 9.9 (2.61) 12.2 (3.22) 11.2 (2.95) 1.8 (2.92) 9.3 (2.46) 9.6 (2.53) 8.6 (1 -01...
  • Page 21 RECOMMENDED LUBRICANT QUANTITY & TYPES (1 989.9 Classification Application Quantity Description Motor oil (1.06 US gal) Gasoline 4.0 1 1 (1.06 US gal) area) Engine Diesel engine oil 6.511 (1.7 US gal) 1 DZ CC, CD Diesel area) (2.38 US gal) SAE 1 OW-30 Transmission 4.0 Q (1.06 US gal)
  • Page 22 Attached Table 1 Coolant volume unit: (US gal) 2.0 - 2.5 ton 1.75 ton 2.75, 3.0 ton Engine Drive method vehicles vehicles vehicles 5.5 (1.45) 5.7 (1.50) 7.3 (1.93) 7.0 (1.85) 7.7 (2.03) 10.0 (2.64) 7.5 (1.98) 9.3 (2.46) 9.6 (2.53) 9.0 (2.38) 9.4 (2.48) 9.7 (2.56)

  • Page 23: Lubrication Charts

    LUBRICATION CHARTS Chain Differential Front wheel bearing Brake master cylinder (1 .O-1.75 ton models) Transmission case Rear wheel bearing Steering knuckle kingpin Bell crank pin Oil tank Engine crank case Rear axle beam front Rearaxlebeam rear Tilt steering universal joint Tilt steering liocking meachanism Mast support bushing Tilt cylinder front pin...

  • Page 24: Periodic Maintenance

    PERIODIC MAINTENANCE INSPECTION METHOD I : Inspection. Repair or replacement if required. Measurement. Repair or adjustment if required. Retightening C : Cleaning Lubrication : For new vehicle : Detector : Flaw detector Inspection Period Months 1000 2000 Hours ENGINE Proper starting and abnormal noise Rotating condition at id1 ing Rotating condition during acceleration Exhaust gas condition...
  • Page 25 Inspection Period Months 2000 1000 Hours POWER TRANSMISSION SYSTEM Clutch pedal play Abnormal sound and functioning (connect ion) Clutch booster function and leak Clutch Fluid level Oil clutch mechanism function and leak Leak Transmission Fluid level Gear function and abnormal noise Leak Differential Oil level...
  • Page 26 Period Months Hours 1000 2000 Abnormal sound and looseness of rear Wheel wheel bearing Cracks, damage and deformation of Front axle housing Cracks, damage and deformation of beam Rear axle Looseness of axle beam in vehicle longitudinal direction STEERING SYSTEM Play and looseness Steering wheel...
  • Page 27 Inspection Period Months Hours 1000 2000 Clearance between drum and lining Wear of shoe sliding portion and lining Drum wear and damage Brake drum and brake Shoe operating condition shoe Anchor pin rusting Return spring fatigue Automatic adjuster function Deformation, cracks and damage Backing plate Loose mounting...
  • Page 28 Inspection Period Months Hours 1000 2000 Oil leak and damage Wear and damage of pin and cylinder Cylinder bearing Lifting speed Uneven rnovemen t Oil purrip Oil leak and abnormal sound Oil level and contamination Hydraulic Tank and oil strainer oil tank Oil leak Loose l in kage...
  • Page 29 Months 1000 2000 Hours Open-circuit in glow plug Preheater Open-circuit in intake heater Engine stop- Diesel engine key stop device function poing system SAFETY DEVICES, ETC. Cracks at welded portion Head guard Deformation and damage Loosening of mounting Back-rest Deformation, crack and damage Lighting Function and mounting condition system...

  • Page 30: Periodic Replacement Lubricants And Parts

    PERIODIC REPLACEMENT LUBRICANTS AND PARTS a : Replacement 1 month 3 months 6 months months 1000 170 hours 500 hours hours 2000 hours Engine Engine oil filter years for LLC) Engine coolant (every Fuel filter Torque converter oil Transmission oil Differential oil Hydraulic oil Hydraulic oil filter...
  • Page 31 ENGINE Page ........... GENERAL ......ENGINE PERFORMANCES ENGINE ASSY REMOVAL 4P ENGINE VEHICLE (1 986.8 1989.8) ......I Z ENGINE VEHICLE 4Y ENGINE VEHICLE 5K ENGINE VEHICLE (1 989.9 1 DZ ENGINE VEHICLE (1 989.9 ENGINE ASSY DISCONNECTION ..... TORQUE CONVERTER TYPE VEHICLE ......
  • Page 32 GENERAL 4P Engine Front View (1 986.8 -- 1989.8) 4P Engine Rear View 1989.8)
  • Page 33 4Y Engine Front View KAJ 14-2 4Y Engine Front View...
  • Page 34 2J Engine Front View (1 986.8 1989.8) 1989.8) K A H I - 1 5...
  • Page 35 1 Z Engine Front View...
  • Page 36 5K Engine Front View (1 989.9 5K Engine Front View (1 989.9 KAPI-5...
  • Page 37 1 DZ Engine Front View (1 989.9 1 DZ Engine Front View (1 989.9...
  • Page 38 ENGINE PERFORMANCES (1 986.8 Tota No-load Rated Maximum Engine displacement maximum governed horsepower torque model speed rpm 1493 3050 1.75 ton 2237 2450 16.511 800 4412700 248 1 2300 14.512000 3050 3512800 10.511 800 1493 2237 2600 5412400 2.5 ton 2953 2600 6012400...
  • Page 39 ENGINE PERFORMANCES (1989.9 Total No-load maximum Rated Maximum displacement governed horsepower torque model speed rpm 1486 3050 1 1.5/2000 1.75 ton 2237 2600 1 DZ 2486 2600 1486 3050 1 1.5/2000 2237 2600 2.5 ton 2953 2600 2486 2600 1 7.0/ 1 6 0 0 2237 2600 1.75...
  • Page 40 1- 10 PERFORMANCE CURVES Engine speed (rpm) 4P Engine Performance Curve (1 986.8 1989.8)
  • Page 41 (kg-m Engine speed (rpm) (1 . O 1.75 ton vehicle) -300 ,280 -260 -240 -220 Engine speed (rpm) (2.0 vehicle) KAOM 19,20 2J Engine Performance Curve (1 986.8 1989.8) - 4 3 -...
  • Page 42 (kg-m Engine Performance Curve...
  • Page 43 Engine speed (rpm) 1.75 ton vehicle) (kg-m 4Y Engine Performance Curve (1 986.8 1989.8)
  • Page 44 Engine horsepower Shaft torque Fuel consumption...
  • Page 45 Engine speed (rpm) 5K Engine Performance Curve (1 989.9...
  • Page 46 Engine speed (rpm) 1 DZ Engine Performance Curve (1 989.9...
  • Page 47 ENGINE ASSY REMOVAL 4P ENGINE VEHICLE (1 986.8 1989.8) Engine hood removal ( 1 ) Disconnect the engine hood damper from the frame bracket. ( 2 ) Disconnect the engine hood stay from the frame bracket. Remove engine hood hinge set screws ( 2 pcs.
  • Page 48 Radiator reserve tank removal ( 1 ) Disconnect the reserve tank hose from the radiator. ( 2 ) Remove the reserve tank. Removing the Reserve Tank Fan removal Remove fan set bolts pcs.) and re- move the fan. Coolant draining Loosen the radiator drain plug to drain the coolant.
  • Page 49 Oil pump disconnection Remove oil pump set bolts pcs.) ( 2 ) Disconnect the oil pump from engine. Horn removal Disconnect the horn wiring connector. ( 2 ) Remove set bolts pcs.), and remove the horn. Removing the Oil Pump ASSY LA054-32 Torque converter shift...
  • Page 50 Shift lever removal (in clutch vehicle) transmission side. Remove the shift lever set plate, and remove the shift levers (forward & reverse, and speed). Remove the plate washer and spring. D i s c o n n e c t i n g t h e S h i f t Lever R o d LA055-1 Shift lever shaft removal (in clutch vehicle) Remove set bolts (4 pcs.), and remove...
  • Page 51 nting set bolt removal Remove the engine mounting set bolts left and right. Remove the torque converter trans- mission mounting set bolts (in torque converter vehicle). Remove the transmission mounting set bolts (in clutch vehicle). Removing the Mounting Set Bolts 24.
  • Page 52 2J ENGINE VEHICLE (1 986.8 1989.8) Engine hood removal Disconnect the engine hood damper from the frame bracket. (2) Disconnect the engine hood stay from the frame bracket. Remove the engine hood hinge set screws (2 pcs. on one side), and remove the engine hood.
  • Page 53 :leaner removal Remove the hydraulic tank breather. Loosen the hose clamp for the air cleaner hose. Remove air cleaner case set bolts (4 pcs.), and remove the air cleaner. L A 0 1 -1 Removing the A i r Cleaner ASSY Radiator cover removal radiator cover.
  • Page 54 Exhaust pipe disconnection ( 1 ) Remove flange set nuts connect the exhaust pipe. Disconnecting the Exhaust Pipe Accelerator cable disconnection the cable clevis on the injection pump side. Remove the accelerator cable bracket from the manifold. Disconnecting t h e Accelerator Cable L A 0 1 -14 Oil pump removal pcs.).
  • Page 55 Torque converter shlft rod and inching cable disconnection (in torque converter vehicle) ( 1 ) Remove the set nut, and disconnect the shift rod. Disconnect the clevis, loosen the cable set nut, and disconnect the inching cable. Disconnecting the Torque Converter L i n k Components Clutch release cylinder removal (in clutch vehicle)
  • Page 56 19. Shift lever shaft rer~loval (in and remove the shift lever shaft. Removing the S h i f t Lever Shaft Propeller shaft disconnection ( 1 ) Remove set bolts pcs.), and remove the propeller shaft cover. Remove propeller shaft set bolts ( 4 pcs. on one side), and disconnect the propel- ler shaft.
  • Page 57 Remove the torque converter trans- mission mounting set bolts (in torque converter vehicle). Removing th e M o u n t i n g Set Bolts (1 Remove the transmission mounting set bolts (in clutch vehicle). LAO 126-34 Removing the M o u n t i n g Set Bolts Measure the stabilizer installed dimen- tions.
  • Page 58 Engine ASSY with transmission removal ( 1 ) Use the SST and remove the engine ASSY with transmission. ASSY Weight of engine with transmission With torque converter transmission: (726 I b) With transmission : (770 Ib) Caution: Try safe operation by fully considering the Removing t h e Engine ASSY w i t h Transmission Center of gravity in setting wire ropes for hoisting.
  • Page 59 ENGINE VEHICLE Engine hood removal Disconnect the engine hood damper from the frame bracket. Disconnect the engine hood stay form the frame bracket. ( 3 ) Remove engine hood hinge set screws pcs. on one side), and remove the engine hood. Radiator cover and toe board removal Removing the Engine Hood LA088-1...
  • Page 60 Disconnect the inlet and outlet hoses from the engine. ( 4 ) Disconnect the fan shroud from the radiator. Disconnecting t h e Fan Shroud Remove set bolts ( 2 pcs.), and remove the radiator. Removing the Radiator LA096-15 A i r cleaner removal ( 2 ) Loosen the hose clamp for the air cleaner hose.
  • Page 61 Torque converter shift rod and inching cable disconnection (in torque converter vehicle) Remove the set nut and disconnect the shift rod. ( 2 ) Disconnect the inching cable. Disconnecting the Shift Rod L A 0 9 6 -2 1 Shift lever removal (in clutch vehicle) ( 1 ) Disconnect the shift lever rod on the transmission side.
  • Page 62 Oil pump ASSY disconnection ( A l l models excluding ton clutch models) pcs.). Disconnect the oil pump from the engine. D i s c o n n e c t i n g t h e O i l Pump Clutch release cylinder removal (in clutch vehicle) Diconnect the clevis.
  • Page 63 Parking brake cable clamp removal Remove the clamp set bolt at the lower part of the transmission case, and dis- connect the cable from the transmission case. Disconnecting the Parking Brake Cable Mounting set bolts removal ( 1 ) Remove the engine mounting set bolts left and right.
  • Page 64 Loosen the stabilizer bar lock nut. Remove the set nuts at both ends, remove the cushion rubber, plate, bi I izer stopper and stabilizer bar. Removing the Stabilizer (Upper L e f t ) L A 0 1 13-24 . Radiator reserve tank bracket removal Remove set bolts (2 pcs.) and remc the reserve tank bracket.
  • Page 65 ENGINE VEHICLE Engine hood removal Disconnect the engine hood damper from the frame bracket. ( 2 ) Disconnect the engine hood stay from the frame bracket. Remove the engine hood hinge set screws ( 2 pcs. on one side), and remove the engine hood.
  • Page 66 A i r cleaner removal ( 2 ) Loosen the hose clamp for the air cleaner hose. Remove air cleaner case set bolts (4 pcs.), and remove the air cleaner. Removing the Air Cleaner ASSY LA057-5,6 Loosen the hose clamps at both ends of pipe, and disconnect both ends.
  • Page 67 Coolant draining Loosen the radiator drain plug to drain the coolant. Loosen the engine drain plug to drain the coolant. Draining the Coolant 14. Radiator removal Loosen the inlet and outlet hose clamps. Rernove the radiator set bolts, and remove the radiator. Removing the Radiator ASSY L A 0 5 8 - 3 15.
  • Page 68 Clutch release cylinder removal Disconnect the clevis. Disconnect the piping. Remove set bolts pcs.), and remove the clutch release cylinder. Removing the Clu tc h Release Cylinder Shift lever removal ( 1 ) Clisconnect the shift lever rod on the transmission side.
  • Page 69 Stabilizer removal Measure the stabilizer instal led dimen- sions. Measure and record for both stabilizer stopper and stabilizer bar. mm (in.) A? , Dimension Vehicle model Demension A ---- 1.0 - 2.5 ton series (7.8 0.04) 205.5 2.75 3.0 ton series 0.04) Measuring the Stabilizer Installed Dimension Loosen the stabilizer bar lock nut,...
  • Page 70 5 K ENGINE VEHICLE (1 989.9 Engine hood removal ( 1 ) Disconnect the engine hood damper from the frame bracket. (2) Disconnect the engine hood stay from the frame bracket. Remove engine hood hinge set screws (2 pcs. on each side), and remove the engine hood.
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