Table of Contents
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This manual covers the service procedures of the TOYOTA FORKLIFT
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 t o 15) and Repair Manual ( S u p p l e m e n t )
Pub. No. CE014. as Part 1 1 (Sections
I
Part
explains the service procedures for the models produced since
August, 1988 while Part IIcovers those for the models subject to the minor
change in September, 1994. For servicing the vehicles after the minor
change, please refer to both Part
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-
formed by 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 INDUSTRIAL EQUIPMENT 3F ENGINE
REPAIR MANUAL (No. CE614)
TOYOTA INDUSTRIAL EQUIPMENT 1FZ ENGINE
REPAIR MANUAL (No. CE627)
TOYOTA INDUSTRIAL EQUIPMENT 1 IZ, 122 ENGINE
REPAIR MANUAL (N
FOREWORD
to 4).
I
and Part I I .
. CE615-1)
O
TOYOTA MOTOR CORPORATION
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Table of Contents
Related Manuals for Toyota FORKLIFT 5FD45
Summarization of Contents
Operational Tips and Safety
General Operational Safety
Key safety practices for operation, including material handling, workplace organization, and tool preparation.
Maintenance and Repair Best Practices
Guidelines on using genuine parts, electrical system precautions, and proper tightening torque adherence.
Diagnostic Approach to Defects
Emphasizes thorough defect assessment before starting disassembly or replacement procedures.
Bolt and Nut Tightening Torque
Bolt Strength Identification
Methods for identifying bolt strength types based on shape, markings, and part numbers.
Standard Tightening Torque Table
Reference table for standard and flanged tightening torques for various bolt sizes and strength types.
Lubrication Charts
Lubrication Points and Intervals
Diagrams indicating lubrication points for various components and their inspection/service intervals.
Lubricant Types Reference
Key mapping lubricant types (MP grease, engine oil, etc.) to their corresponding codes used in the charts.
Periodic Maintenance Schedule
Inspection Methods Key
Explanation of symbols (I, M, T, C, L) used to denote inspection, measurement, retightening, cleaning, and lubrication.
Engine Maintenance Items
Periodic inspection and maintenance tasks for the engine, including main body, PCV, governor, lubrication, fuel, and cooling systems.
Periodic Replacement Schedule
Lubricant and Part Replacement Intervals
Table outlining replacement intervals for lubricants (engine oil, coolant, etc.) and parts (filters, hoses, spark plugs) based on time or hours.
Special Replacement Notes
Notes indicating specific conditions for replacement, such as 'for new vehicle', 'Every 2 years', or 'Every 3 years'.
Engine Sectional Views
11Z Engine Sectional View
Diagrams illustrating the internal cross-section of the 11Z engine.
3F Engine Sectional View
Diagrams illustrating the internal cross-section of the 3F engine.
Engine Performance Curves
11Z Engine Performance
Graphs detailing shaft horsepower, engine torque, and fuel consumption ratio for the 11Z engine.
3F Engine Performance
Graphs detailing shaft horsepower, engine torque, and fuel consumption ratio for the 3F engine (Gasoline and LPG models).
Engine Specifications
11Z Engine Specifications
Technical data for the 11Z diesel engine, including displacement, cylinders, bore/stroke, compression, and rated output.
3F Engine Specifications
Technical data for the 3F gasoline engine, including displacement, cylinders, bore/stroke, compression, and rated output.
Engine Assembly Removal Steps (Clutch Model)
Removing the Toe Board
Procedure for removing the toe board as the first step in engine assembly removal.
Removing the Engine Hood
Steps to disconnect the engine hood damper and stay before removing the hood itself.
Removing the Radiator Cover
Instruction for removing the radiator cover as part of the engine disassembly process.
Removing the Air Cleaner ASSY
Steps to disconnect electrical and hose connections before removing the air cleaner assembly.
Engine Assembly Component Removal (Clutch Model)
Removing the Battery
Disconnecting battery cables and wiring, cautioning to disconnect the negative terminal first.
Removing the Sedimenter
Steps for disconnecting fuel hoses and wirings to remove the sedimenter.
Disconnecting Engine Wiring
Disconnecting various electrical wirings, including alternator, sensors, starting motor, and oil pressure switch.
Engine Assembly Piping and Wire Disconnection
Disconnecting Fuel Piping and Accelerator Wire
Steps for disconnecting fuel piping and accelerator wire connections.
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