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Table of Contents
This manual covers the service procedures of the TOYOTA FORKLIFT
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 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:
TO YO TA INDUSTRIAL VEHICLE 4 Y ENGINE
REPAIR MANUAL (No. CE602)
REPAIR MANUAL (No. CE603)
FOREWORD
TOYOTA MOTOR CORPORATION
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Table of Contents
Related Manuals for Toyota 5FGC25
Summarization of Contents
GENERAL
VEHICLE EXTERIOR VIEWS
Visual representations of the forklift's exterior from front and rear views.
VEHICLE MODELS
Table detailing forklift models, payload, engine, and transmission types.
ABBREVIATIONS & TIPS ON OPERATION
Glossary of abbreviations and operational guidance for safe and effective use.
STANDARD BOLT & NUT TIGHTENING TORQUE
Guidelines for determining correct bolt and nut tightening torques based on strength and size.
PRECOAT BOLTS
Information on using precoat bolts, including precautions and reuse procedures.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
Specifications for tightening high-pressure hose fittings to ensure proper sealing and safety.
FRAME NUMBER
Details on identifying forklift frame serial numbers and their formats.
SAFE LOAD BY WIRE ROPE SUSPENSION ANGLE
Table showing safe load capacities based on wire rope diameter and suspension angles.
CAPACITY AND TYPES OF SPECIFIED LUBRICANTS
Comprehensive list of lubricants, capacities, and types for various forklift components.
LUBRICATION
Visual chart indicating lubrication points, types, and inspection frequencies.
PERIODIC MAINTENANCE TABLE
ENGINE
Maintenance checks for the engine, including starting, idling, exhaust, and components.
Positive crankcase ventilation (PCV)
Inspection of the PCV valve and piping for clogging or damage.
Lubrication system
Checks for oil leakage, oil level, and clogging of the oil filter.
POWER TRANSMISSION SYSTEM
Maintenance schedule for differential, torque converter, and propeller shaft systems.
TRAVELING EQUIPMENT
Maintenance for wheels, front axle, and rear axle, including tire condition and alignment.
STEERING SYSTEM
Checks for steering wheel play, gearbox oil leakage, and power steering system condition.
BRAKING SYSTEM
Maintenance procedures for brake pedal, parking brake, brake piping, and drum/shoe clearance.
MATERIAL HANDLING SYSTEM
Inspection of forks, mast, chain, and attachments for wear, damage, and alignment.
HYDRAULIC SYSTEM
Maintenance for cylinders and oil pumps, focusing on leaks, damage, and operation.
ELECTRICAL SYSTEM
Checks for ignition system, starting motor, charger, battery, and electrical wiring integrity.
SAFETY DEVICES, ETC.
Maintenance for head guard, back rest, lighting, horn, instruments, and body components.
ENGINE
GENERAL
Overview of engine section, including general information and component details.
ENGINE PERFORMANCE
Data on engine performance metrics like output and torque for different models.
ENGINE PERFORMANCE CURVES
Graphical representation of engine performance characteristics against speed.
ENGINE ASSY W/TORQUE CONVERTER TRANSMISSION
REMOVAL
Step-by-step instructions for removing the engine and transmission assembly.
[2J ENGINE MODELS]
Specific removal procedures applicable to 2J engine models.
[4Y ENGINE MODEL]
Specific removal procedures tailored for 4Y engine models.
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