Toyota 02 5 fd33 forklift service repair manual
- 1. 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 t o 15) and Repair Manual (Supplement) Pub. No. CE014. as Part 1 1(Sections 0to 4). Part I 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 I and PartI I . 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 1FZENGINE REPAIR MANUAL (No. CE627) TOYOTA INDUSTRIAL EQUIPMENT 1IZ, 122ENGINE REPAIR MANUAL (NO. CE615-1) TOYOTA MOTOR CORPORATION
- 2. PART I : 1988. 8- SECTION INDEX (CE005) GENERAL ENGINE0 CLUTCH C R TRANSMISSION & DIFFERENTIAL FRONT AXLE REAR AXLE B R A K E a a BODY MATERIAL HANDLING SYSTEM MAST CYLINDER OIL PUMP OIL CONTROL VALVE APPENDIX
- 3. GENERAL Page EXTERIOR VIEWS ................................ 0-2 VEHICLE LISTING ................................ 0-3 ABBREVIATIONS ................................ 0-4 OPERATIONAL TIPS ............................. 0-4 STANDARD BOLT & NUT TIGHTENING ......................................... TORQUE 0-5 BOLT STRENGTH TYPE IDENTIFICATION METHOD ...................................... 0-5 TIGHTENING TORQUE TABLE .................. 0-6 PRECOAT BOLTS .............................. 0-7 HIGH PRESSURE 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 RECOMMENDED LUBRICANT QUANTITY &TYPES ......................................... 0-11 .......................... LUBRICATION CHARTS 0-12 PERIODIC MAINTENANCE ....................... 0-14 ......................... INSPECTION METHOD 0-14 PERIODIC REPLACEMENT LUBRICANTS AND PARTS ..................................... 0-20
- 4. EXTERIOR VIEWS Front View (5FD35) ~ ~ 0 . 7 2 - 1 Rear View (5FD35) - 6 -
- 5. VEHICLE LISTING Load capaclty 3.25 ton 3.5 ton 4.0 ton 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 1 1 Z t 3F t 1 1 Z t 3F t 1 1 Z t 3F t 11Z t 3F t 1 1 Z 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 tYPe 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 (78.5 in)
- 6. 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) Undersize With Abbreviation (Code) ABDC ASSY ATDC ATM BTDC L/ LH LLC MTM OHV 0PT 0/s 2. Preparation of SSTs and measuring tools (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 of hydraulic equipment shall always be done in a clean place using clean tools. Meaning After button dead center Assembly After top dead center Automatic transmission Before top dead center Less Left hand Long life coolant Manual transmission Overhead valve Option Oversize 4. Genuine Toyota parts Genuine Toyota parts should 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. Repairs on 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 the torque 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.
- 7. STANDARD BOLT & NUT TIGHTENING TORQUE Standard bolt and nut tightening torques are not indicated. Judge the standard 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 I 1 1 1 - 4 0 6 1 0 -1T ~ e n g t h under head (mm) Nominal diamter (mm) two rel~ef l~nes on Standard bolt with - Strength type 4 = 4T 5 = 5T 6 = 6T 7 = 7T 4T Shape and identification method - Strength type 0 @ INominal diameter Length under head Stud bolt Part No. example 9 2 1 3 2 - 4 - 0 6 1 4 1T ~ e n g t h (mm) Nominal diameter (mm) Number in relief or hallmark on the head No mark - Strength type Nominal diameter Length
- 9. PRECOAT BOLTS (Bolts with seal lock agent coating on threads) 1. Do not use the precoat bolt a s 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. replacement of the bolt.) (3) Coat the specified seal lock agent to the threaded portion of the bolt. HIGH PRESSURE HOSE FllTlNG TIGHTENING 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 before installation. 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 Standard tightening 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 (17.4 -- 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)
- 10. 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 LAQS129 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 4 0 5FG 45 02-5FG 45 5FDE35 02-5FDE35 5FD 4 0 02-5FD 40 5FD 45 02-5FD 45 Punching format "1 5FG35-10011 " 2 5FG35E10011 "3 5FG35-20011 " 4 5FG35E20011 " 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
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- 12. - - WIRE ROPE SUSPENSION ANGLE LIST Lifting angle oO 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 l o o Suspension method ko , " time
- 13. SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE Unit: ton (Ib) I Rope diameter 8 mm (0.32 in.) 10 mm (0.4in.) 14 mm (0.56 in) 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 ( 118 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. 21 30 (4410) 4.0 ton Approx. 2520 (5557) 4.5 ton Approx. 2830 (6240) 3.25-4.0 ton Approx. 650 ( 1433) 4.5 ton Approx. 850 ( 1874)
- 14. RECOMMENDED LUBRICANT QUANTITY & TYPES Application 3F 11Z MTM models All models ATM models Description Quantity Up to '88 Nov. 8.0 Q (2.1 US gal) From '88 Dec. 9.3 Q (2.5 US gal) 12.5 Q (3.3 US gal) 6.0 Q (1.6 US gal) 9.5 Q (2.5 US gal) 15 Q (4.0 US 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 (Excluding reserve tank) Coolant (Reservoir tank) Drive shaft pulley (Oil pump spline shaft) TYpe Motor Oil SAE30 (SAE20 in 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 (118 in.) Gasoline models 5FD33,35 Diesel models 5FDE35, 5FD40,45 All models 3F All models All models 60 Q (16 US gal) 95 Q (25 US gal) 95 Q (25US gal) 120 Q (32 US gal) Proper quantity 13.0 Q (3.4 US gal) 13.0 Q (3.4 US gal) 1.1 Q (0.3 US gal) (at Full level) Proper quantity