Toyota 40 8 fd45n forklift service repair manual

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Table of Contents
0 GENERAL ................................................................................................ 2
1 ENGINE .................................................................................................. 27
2 TORQUE CONVERTER & TRANSMISSION....................................... 152
3 PROPELLER SHAFT........................................................................... 221
4 DIFFERENTIAL.................................................................................... 228
5 FRONT AXLE....................................................................................... 247
6 REAR AXLE ......................................................................................... 264
7 STEERING............................................................................................ 296
8 BRAKE ................................................................................................. 330
9 BODY.................................................................................................... 355
10 MATERIAL HANDLING SYSTEM........................................................ 373
11 MAST.................................................................................................... 387
12 CYLINDER............................................................................................ 435
13 OIL PUMP............................................................................................. 473
14 OIL CONTOROL VALVE ..................................................................... 484
15 MINI LEVER / JOYSTICK .................................................................... 558
16 SAS/OPS.............................................................................................. 568
17 SST LIST AND SERVICE STANDARDS LIST .................................... 593

0-2 0 GENERAL
0 GENERAL
0.1 EXTERIOR VIEWS .................................................................................... 3
0.2 VEHICLE MODEL ...................................................................................... 4
0.3 FRAME NUMBER ...................................................................................... 4
0.4 HOW TO USE THIS MANUAL................................................................... 5
0.5 OPERATIONAL TIPS................................................................................. 7
0.6 HOUR METER START .............................................................................. 8
0.7 1KD TIMING BELT..................................................................................... 8
0.8 PERIODIC MAINTENANCE....................................................................... 9
0.9 FRAME BOLTS........................................................................................ 15
0.10 CIRCUIT TESTER.................................................................................... 15
0.11 STANDARD BOLT & NUT TIGHTENING TORQUE................................ 17
0.12 PRECOAT BOLTS ................................................................................... 20
0.13 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE.................. 20
0.14 HOISTING THE VEHICLE ....................................................................... 21
0.15 WIRE ROPE SUSPENSION ANGLE LIST .............................................. 21
0.16 SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE .............. 22
0.17 COMPONENTS WEIGHT ........................................................................ 22
0.18 RECOMMENDED LUBRICANT QUANTITY & TYPES............................ 23
0.19 LUBRICATION CHART............................................................................ 24
0.20 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS................. 26

0-30 GENERAL
0.1 EXTERIOR VIEWS
0

0-4 0 GENERAL
0.2 VEHICLE MODEL
Classification Model Engine Capacity
(L.C. 500 mm)
kgf
3.5 ton model 8FG35N 1FS Gasoline 4000
40-8FD35N 1KD Diesel
6.0 ton model 40-8FD60N 1KD Diesel 6000
(L.C. 600 mm)
(L.C. 600 mm)
(L.C. 600 mm)
0.3 FRAME NUMBER
Frame number
Classification Engine Vehicle model Frame No. Stamping
3.5 / 4.0 ton model 1FS 8FG35N 8FG40N*10011
8FG40N
1KD 40-8FD35N 40-8FD40N*10011
40-8FD40N
4.5 / 5.0 ton model 1FS 8FG45N 8FG50N*10011
8FG50N
1KD 40-8FD45N 40-8FD50N*10011
40-8FD50N
6.0 to 8.0 ton model 1KD 40-8FD60N 40-8FD80N*10011
40-8FD70N
40-8FD80N
Detail of *

0-50 GENERAL
0.4 HOW TO USE THIS MANUAL
0.4.1 EXPLANATION METHOD
Operation procedure
The operation procedure is described to explain each operation step with illustration which indicates the step
number.
How to read components figures
The components figure uses the illustration in the parts catalog for the vehicle model. Please refer to the cat-
alog for checking the part name.
The number in the illustration of each component figure indicates the Fig. number in the parts catalog.
(Example)
3701-118
CN
CN
DU
CR
40A
40
CU
AZ
01
BZ
This manual omits description of the following jobs, but perform them in actual operation:
▪ Cleaning and washing of removed parts as required
▪ Visual inspection (partially described)
0.4.2 TERMINOLOGY
"CAUTION": Indicates a hazardous situation that, if not avoided, could result in minor or moderate
injury, or property damage.
"NOTICE": Indicates information to be considered important, to do your job right and easier, and to
keep your truck running well.
"Standard": Values showing allowable range in inspection and adjustment.
"Limit": Maximum or minimum allowable value in inspection or adjustment.
0

0-6 0 GENERAL
0.4.3 ABBREVIATIONS
Abbrevia-
tion
(code)
Meaning
Abbrevia-
tion
(code)
Meaning
ASSY Assembly SAE Society of Automotive Engineers (USA)
LH Left hand RH Right hand
LLC Long life coolant SST Special service tool
STD Standard OPT Option
O/S Oversize T= Tightening torque
T/C Torque converter & transmission U/S Undersize
SAS System of active stability OPS Operator presence sensing
PS Power steering **T Number of teeth (** )
NMR No-load maximum revolution W/ With
L/ Less

0-70 GENERAL
0.5 OPERATIONAL TIPS
1. Safe operation
a) After jacking up, always support with wooden blocks or rigid stands.
b) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load
capacity.
c) Always disconnect the battery terminal before the inspection or servicing of electrical parts.
d) Do not touch the high pressure hoses by bare hands when inspecting them.
2. Tactful operation
a) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pressure
gauge, etc.) and SSTs before starting operation.
b) Before disconnecting wiring, always check the cable color and wiring state.
c) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts
neatly to prevent confusion.
d) When disassembling and inspecting such a precision part as the control valve, use clean tools and
operate in a clean location.
e) Follow the described procedures for disassembly, inspection and reassembly.
f) Replace gaskets, packings and O-rings with new ones each time they are disassembled.
g) Use genuine Toyota parts for replacement.
h) Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
Tighten to the center of the specified tightening torque range. If no tightening torque is specified,
tighten the bolt or nut according to the standard tightening torque table.
3. Grasping the trouble state
a) When a trouble occurs, do not attempt immediate disassembly or replacement but first check if the
trouble requires disassembly or replacement for remedying.
4. Disposal of waste fluid, etc.
a) When draining waste fluid from the vehicle, receive it in a container.
If any oil, fuel, coolant, oil filter, battery or other harmful substance is directly discharged or scrapped
without permission, it will either adversely affect human health or destroy the environment.
Always sort waste fluids, etc. and treat them properly by requesting disposal by specialized compa-
nies.
5. Jack up points
Front side: Jack up the bottom edge of the front plate under the frame.
Rear side: Jack up the under the counterweight.
0

0-8 0 GENERAL
0.6 HOUR METER START
FR
UPPER
RH
Hour meter connectors
It is necessary to start the hour meter by con-
necting the connector which is located under
the left of toe-board.
0.7 1KD TIMING BELT
1. When a SAS/OPS controller is replaced or swapped from another forklift, replace the timing belt, then do
reset procedure.
NOTICE! If the analyzer is reset without replacing the timing belt, warning function doe not work
even if operating time exceeds 4000 hours.
2. When a meter is replaced or swapped from another forklift, replace the timing belt, then do reset proce-
dure.
NOTICE! If the analyzer is reset without replacing the timing belt, warning function doe not work
even if operating time exceeds 4000 hours.
3. Hour meter
If the timing belt is replaced after 58500 hours passing, the meter should be replaced because maximum
cumulated value of the hour meter is 62500 hours.
4. Hour meter start
If the procedure of hour meter start is not done by a dealer, this warning function does not work.
5. Maintenance interval
The warning of maintenance interval will appear 1 hour faster at a maximum than 4000 hours.
6. Refer to 1KD engin repair manual for removal, inspection and installation.

0-90 GENERAL
0.8 PERIODIC MAINTENANCE
INSPECTION METHOD
I : Inspection. Repair or replacement if required.
M : Measurement. Repair or adjustment if required.
T : Retightening
C : Cleaning
L : Lubrication
*: Same as the left column
*1 : For new vehicle
*2 : Flaw detector
Item Inspection Period
Every
6 weeks
Every
3 months
Every
6 months
Every
12 months
Every
250 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
ENGINE
Main body Proper starting and abnor-
mal noise
I *1 I * *
Rotating condition at idling M *1 M * *
Rotating condition during
acceleration
M *1 M * *
Exhaust gas condition I *1 I * *
Air cleaner element C *1 C * *
Valve clearance M *1 M
Muffler rubber mount I
Engine Ancillary drive belt
tension, looseness and
damage
I * * *
PCV system Clogging and damage in
PCV valve and piping
I *1 I * *
Lubrication
system
Oil leak I *1 I * *
Oil level I *1 I * *
Clogging and dirt of oil fil-
ter
I * *
Fuel system Fuel leak I *1 I * *
Dirt and clogging of fuel
filter and element
I * *
Draining of sedimenter I *
Cooling sys-
tem
Coolant level in radiator
and leak
I *1 I * *
Rubber hose degradation I *1 I * *
Radiator cap condition I *1 I * *
Fan belt tension, loose-
ness and damage
I *1 I * *
Radiator rubber mount I
Exhaust emis-
sion control
system
(OPT : 3-way
Catalytic Con-
verter)
Exhaust system piping
joint loosening and dam-
age
T
Hose and piping damage I * * *
Sensor damage I
Injection cleaning and
damage of 1FS
I
Resistor damage of 1FS I
0

0-10 0 GENERAL
Every
6 weeks
Every
3 months
Every
6 months
Every
12 months
Every
250 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
POWER TRANSMISSION SYSTEM
Differential Leak I * *
Oil level I * *
Bolt loosening T
Planetary gear Leak I * * *
Oil level I * * *
Bolt loosening T
Torque con-
verter & trans-
mission
Leak I * *
Fluid level I * *
Operating mechanism
function and looseness
I * *
Control valve and clutch
functions
I * *
Inching valve function I * *
Stall and hydraulic pres-
sure measurement
M *
Propeller shaft
and axle shaft
Loose joint I * *
Looseness at spline con-
nections
I
Looseness of universal
joint
I
Twisting and cracks of
axle shaft
I
DRIVE SYSTEM
Wheels Tire inflation pressure M * *
Tire cuts, damage and un-
even wearing
I * *
Loose rim and hub nuts T * *
Tire groove depth M *1 M * *
Metal chips, pebbles and
other foreign matter trap-
ped in tire grooves
I *1 I * *
Rim, side bearing and
disc wheel damage
I *1 I * *
Abnormal sound and
looseness of front wheel
bearing
I *1 I * *
Abnormal sound and
looseness of rear wheel
bearing
I *1 I * *
Front axle Cracks, damage and de-
formation of housing
I
Rear axle Cracks, damage and de-
formation of beam
I
Looseness of axle beam
in vehicle longitudinal di-
rection
M *1 M
STEERING SYSTEM
Steering wheel Play and looseness I *1 I * *

0-110 GENERAL
Every
6 weeks
Every
3 months
Every
6 months
Every
12 months
Every
250 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
Function I *1 I * *
Steering valve Oil leak I *1 I * *
Looseness of mounting T *1 T * *
Power Steer-
ing
Oil leak I * *
Mounting and linkage
looseness
I * *
Damage of power steering
hose
I
Knuckle King pin looseness I * *
Cracks and deformation I
BRAKING SYSTEM
Brake pedal Play and reserve M * *
Braking effect I * *
Parking brake Operating force I * *
Braking effect I * *
Rod and cable looseness
and damage
I *1 I * *
Brake pipe Leak, damage and mount-
ing condition
I * *
Brake booster
and wheel cyl-
inder
Function, wear, damage,
leak and mounting loose-
ness
I
Brake drum
and brake
shoe
Clearance between drum
and lining
M * *
Wear of shoe sliding por-
tion and lining
I
Drum wear and damage I
Shoe operating condition I
Anchor pin rusting I
Return spring fatigue M
Automatic adjuster func-
tion
I
Backing plate Deformation, cracks and
damage
I
Loose mounting T
MATERIAL HANDLING SYSTEM
Forks Abnormality of fork and
stopper pin
I * *
Misalignment between left
and right fork fingers
I * *
Cracks at fork root and
welded part
I *2
Mast and lift
bracket
Deformation and damage
of each part and crack at
welded part
I * *
Mast and lift bracket
looseness
I * *
Wear and damage of
mast support bushing
I
0

0-12 0 GENERAL
Every
6 weeks
Every
3 months
Every
6 months
Every
12 months
Every
250 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
Wear, damage and rotat-
ing condition of rollers
I * *
Wear and damage of roll-
er pins
I
Wear and damage of
mast trip
I * *
Chain and
chain wheel
Tension, deformation and
damage of chain
I *1 I * *
Chain lubrication I *1 I * *
Elongation of chain I
Abnormality of chain an-
chor bolt
I * *
Wear, damage and rotat-
ing condition of chain
wheel
I * *
Various attach-
ments
Abnormality and mounting
condition of each part
I * *
HYDRAULIC SYSTEM
Cylinder Loosening and damage of
cylinder mounting
T * *
Deformation and damage
of rod, rod screw and rod
end
I * *
Cylinder operation I * *
Natural drop and natural
forward tilt (hydraulic drift)
M * *
Oil leak and damage I * *
Wear and damage of pin
and pin support
I * *
Lifting speed M * *
Uneven movement I * *
Oil pump Oil leak and abnormal
sound
I * *
Hydraulic oil
tank
Oil level and contamina-
tion
I * *
Tank and oil strainer C *
Oil leak I * *
Control lever Loose linkage I * *
Operation I * *
Oil control
valve
Oil leak I * *
Relief pressure measure-
ment
M
Relief valve and tilt lock
valve functions
I * *
Hydraulic pip-
ing
Oil leak I * *
Deformation and damage I * *
Loose joint T * *
ELECTRICAL SYSTEM

0-130 GENERAL
Every
6 weeks
Every
3 months
Every
6 months
Every
12 months
Every
250 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
Ignition timing State of spark plug (car-
bon, soot)
I * * *
Starting motor Pinion gear meshing sta-
tus
I * *
Battery Battery fluid level I * *
Battery fluid specific gravi-
ty
M *
Electrical wir-
ing
Damage of wiring harness I * *
Fuses I * *
Preheater Open-circuit of glow plug I *
LPG DEVICE
LPG Device Gas leak from fuel lines
and fittings
I * * *
Damage of fuel lines and
fittings
I * * *
Tar removal from regula-
tor
C * * *
Regulator adjustment sta-
tus
I * * *
Regulator function I * *
Mixer I * *
Filter clogging C * *
Service valve function I * *
Leaks, damage, and
cracks of the tank
I * * *
Loose or damaged tank
bracket
I * * *
Damage to electrical wir-
ing, loose terminals
I * * *
Rotation of liquid drain
valve
I * * *
Gas leak from the regula-
tor body
I * * *
SAFETY DEVICES AND OTHERS
Head guard Cracks at welded portion I * *
Deformation and damage I * *
Back-rest Loosening of mounting T * *
Deformation, crack and
damage
I * *
Lighting sys-
tem
Function and mounting
condition
I * *
Horn Function and mounting
condition
I * *
Direction indi-
cator
Function and mounting
condition
I * *
Instruments Functions I * *
Backup buzzer Function and mounting
condition
I * *
0

0-14 0 GENERAL
Every
6 weeks
Every
3 months
Every
6 months
Every
12 months
Every
250 hours
Every
500 hours
Every
1000 hours
Every
2000 hours
Rear-view mir-
ror
Dirt, damage I * *
Rear reflection status I * *
Seat Loosening and damage of
mounting
I * *
Seatbelt damage and
function
I * *
Seat belt Mounting looseness I * *
Webbing damage (cut,
frayed straps, loose stitch-
ing)
I * *
Plate damage I * *
Buckle and retractor dam-
age
I * *
Function (retract and
locks)
I * *
Body Damage and cracks of
frame, cross members,
etc.
I
Bolt looseness T
Frame bolt (See the cau-
tion on FRAME BOLTS
[P 15] section)
I
SAS Functions I * *
Loosening and damage at
sensor mounting portion
I * *
Damage, deformation, oil
leakage and loosening of
the mounting of functional
parts
I * *
Loosening and damage of
wire harnesses
I * *
Lock cylinder accumulator
performance
I
Rusting and corrosion of
load sensor
I
OPS Functions I *1 I * *
Others Grease up L * *

0-150 GENERAL
0.9 FRAME BOLTS
CAUTION
Do not loosen the frame bolts
The frame structure is bolts tightening method. These bolts are strictly prohibited to loosen. Heavy mainte-
nance such as engine/torque converter disassembling/reassembling can be possible without loosening these
bolts.
Match mark is painted on the rear frame bolt for each, then check them if they are not out of alignment on
annual inspection maintenance.
If this match mark is faded, paint again.
a (6 bplts) : T = 610 to 830 N m (6220 to 8464 kgf-cm) [455.0 to 612.4 ft-lbf]
b (4 bplts) : T = 170 to 250 N m (1734 to 2549 kgf-cm) [125.5 to 184.4 ft-lbf]
0.10 CIRCUIT TESTER
Circuit testers are available in both the analog and digital types. They should be used selectively according
to the purpose of measurement.
▪ Analog type:
This type is convenient for observing movement during operation, but the measured value should only be
used for reference or rough judgement.
▪ Digital type:
Fairly accurate reading is possible, but it is difficult to observe the variation or movement.
1. Difference in measurement results with the digital type and analog type
The result may be different between measurements with the analog type and digital type. Always use a cir-
cuit tester according to its operation manual.
Cautions when the polarities are different between the analog type and digital type are described below.
0

0-16 0 GENERAL
Analog circuit tester
a Forward direction b Reverse direction
Measurent result example
Analog type
(Tester range: kΩ range)
Forward Continuity exists
11 kΩ
Reverse No continuity
∞
Digital circuit tester
a Forward direction b Reverse direction
Measurement result example
Digital type
(Tester range: MΩ range)
Forward Continuity exists
1

0-170 GENERAL
Reverse Continuity exists
2 MΩ
2. Difference in result of measurement with circuit tester
The circuit tester power supply voltage depends
on the tester type. 1.5 V, 3.0 V or 6.0 V is used.
The resistance of a semiconductor such as a di-
ode varies with the circuit tester power supply volt-
age.
The diode characteristics are shown in the figure.
The resistance values of the same semiconductor
measured with two types of circuit testers having
different power supply voltages are different.
This manual describes the results of measure-
ment with a circuit tester whose power supply volt-
age is 3.0 V.
3. Difference in measurement result by measurement range (analog type)
In the analog type circuit tester, changing the
measurement range switches over the internal cir-
cuit to vary the circuit resistance.
Even when the same diode is measured, the
measurement result varies with the measurement
range.
0.11 STANDARD BOLT & NUT TIGHTENING TORQUE
Standard bolt and tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. Find out the type of the 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.
0

0-18 0 GENERAL
0.11.1 BOLT STRENGTH TYPE IDENTIFICATION METHOD
IDENTIFICATION BY BOLT SHAPE
Shape Class
Hexagon head bolt Bolt head No. 4 = 4T
5 = 5T
6 = 6T
7 = 7T
8 = 8T
No mark 4T
Hexagon flange bolt No mark 4T
Hexagon head bolt Two protruding lines 5T
Hexagon flange bolt Two protruding lines 6T
Hexagon head bolt Three protruding lines 7T
Hexagon head bolt Four protruding lines 8T
Welded bolt 4T
Stud bolt No mark 4T
Grooved 6T
IDENTIFICATION BY PART NO.
Hexagon head bolt Stud bolt

0-190 GENERAL
0.11.2 TIGHTENING TORQUE TABLE
Class
Diameter
mm
Pitch
mm
Specified torque Specified torque
Hexagon head bolt Hexagon flange bolt
N m kgf-cm ft-lbf N m kgf-cm ft-lbf
4T 6 1.0 5.4 55 48 in-lbf 5.9 60 52 in-lbf
8 1.25 13 130 9 14 145 10
10 1.25 25 260 19 28 290 21
12 1.25 47 480 35 53 540 39
14 1.5 75 760 55 83 850 61
16 1.5 113 1150 83 - - -
5T 6 1.0 6.4 65 56 in-lbf 7.5 75 65 in-lbf
8 1.25 16 160 12 18 175 13
10 1.25 32 330 24 36 360 26
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1050 76
16 1.5 137 1400 101 157 1600 116
6T 6 1.0 7.8 80 69 in-lbf 8.8 90 78 in-lbf
8 1.25 19 195 14 21 215 16
10 1.25 38 400 29 43 440 32
12 1.25 72 730 53 79 810 59
14 1.5 110 1100 80 123 1250 90
16 1.5 170 1750 127 191 1950 141
7T 6 1.0 11 110 8 12 120 9
8 1.25 25 260 19 28 290 21
10 1.25 52 530 38 58 590 43
12 1.25 95 970 70 103 1050 76
14 1.5 147 1500 108 167 1700 123
16 1.5 226 2300 166 - - -
8T 6 1.0 12 125 9 14 145 9
8 1.25 29 300 22 32 330 24
10 1.25 61 620 45 68 690 50
12 1.25 108 1100 80 123 1250 90
14 1.5 172 1750 127 196 2000 145
16 1.5 265 2700 195 299 3050 221
0

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0-20 0 GENERAL
0.12 PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the following cases:
▪ After it is removed.
▪ When the precoat bolt is moved (loosened or tightened) by tightness check, etc.
NOTICE
For torque check, use the lower limit of the allowable tightening torque range. If the bolt moves, re-
tighten it according to the steps below.
2. Method for reuse of precoat bolts
▪ Wash the bolt and threaded hole. (The threaded hole must
be washed even for replacement of the bolt.)
▪ Perfectly dry the washed parts by air blowing.
▪ Coat the specified seal lock agent to the threaded portion
of the bolt.
0.13 HIGH PRESSURE HOSE FITTING TIGHTENING
TORQUE
1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces 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.
Nominal diameter of
screw
Standard tightening torque
N m [ft-lbf]
Hose nominal size
mm (in)
Standard Tightening range
7/16 - 20UNF 25 [18.4] 24 to 26 [17.7 to 19.2] 6 (0.24)
9/16 - 18UNF 34 [25.1] 32 to 36 [23.6 to 26.6] 9 (0.35)
3/4 - 16UNF
7/8 - 14UNF
59 [43.5] 56 to 62 [41.3 to 45.7] 12 (0.47)
7/8 - 14UNF 78 [57.5] 74 to 82 [54.6 to 60.5] 15 (0.59)
1・1/16 - 12UNF 118 [87.1] 112 to 123 [82.6 to 90.7] 19 (0.75)
1・5/16 - 12UNF 137 [101.1] 130 to 144 [95.9 to 106.2] 25 (0.98)
PF1/4 25 [18.4] 24 to 26 [17.7 to 19.2] 6 (0.24)
PF3/8 34 [25.1] 32 to 36[23.6 to 26.6] 9 (0.35)
PF1/2 59 [43.5] 56 to 62 [41.3 to 45.7] 12 (0.47)
PF3/4 118 [87.1] 112 to 123 [82.6 to 90.7] 19 (0.75)
PF1 137 [101.1] 130 to 144 [95.9 to 106.2] 25 (0.98)

0-210 GENERAL
0.14 HOISTING THE VEHICLE
When hoisting the vehicle, sling with wire rope(s) at the mast
hook holes and the counterweight hook holes.
CAUTION
Use wire ropes having sufficient strength.
0.15 WIRE ROPE SUSPENSION ANGLE LIST
Lifting angle Tension Compression Suspension method
0° 1.00 time 0 time
30° 1.04 time 0.27 time
60° 1.16 time 0.58 time
90° 1.41 time 1.00 time
120° 2.00 time 1.73 time
0

0-22 0 GENERAL
0.16 SAFE LOAD FOR EACH WIRE ROPE SUSPENSION
ANGLE
Unit: N (tf) [lbf]
Rope di-
ameter
Cutting
load
Single-
rope
suspen-
sion
Two-rope suspension Four-rope suspension
0° 0° 30° 60° 90° 0° 30° 60° 90°
6mm
(0.24 in)
21380
(2.18)
[4807]
3040
(0.31)
[683.6]
6080
(0.62)
[1367]
5880
(0.6)
[1323]
5200
(0.53)
[1169]
4310
(0.44)
[970]
12160
(1.24)
[2734]
11770
(1.2)
[2646]
10400
(1.06)
[2337]
8630
(0.88)
[1940]
8 mm
(0.32 in)
31480
(3.21)
[7078]
4410
(0.45)
[992.3]
8830
(0.9)
[1985]
8530
(0.87)
[1918]
7650
(0.78)
[1720]
6280
(0.64)
[1411]
17650
(1.8)
[3969]
17060
(1.74)
[3937]
15300
(1.56)
[3440]
12550
(1.28)
[2322]
10 mm
(0.4 in)
49230
(5.02)
[11.69]
6960
(0.71)
[1565.6]
14020
(1.43)
[3153]
13440
(1.37)
[3021]
11770
(1.2)
[2646]
9810
(1.0)
[2205]
27460
(2.8)
[6174]
26480
(2.7)
[5954]
23540
(2.4)
[5292]
19610
(2.0)
[4410]
12.5 mm
(0.5 in)
76880
(7.84)
[17387]
10980
(1.12)
[2469.5]
21570
(2.2)
[4851]
21280
(2.1)
[4631]
18630
(1.9)
[4190]
14710
(1.5)
[3308]
43150
(4.4)
[9702]
41190
(4.2)
[9261]
37270
(3.8)
[8379]
29420
(3.0)
[6615]
14 mm
(0.56 in)
96400
(9.83)
[21675]
13730
(1.4)
[3087]
27460
(2.8)
[6174]
26480
(2.7)
[5954]
23540
(2.4)
[5292]
18630
(1.9)
[4190]
54920
(5.6)
[12348]
52960
(5.4)
[11907]
47070
(4.8)
[10584]
37270
(3.8)
[8379]
0.17 COMPONENTS WEIGHT
Component Weight kg (lb)
Engine 1FS 198 (437)
1KD 225 (496)
Torque converter & transmission 3.5 to 5.0 ton
model
209 (461)
6.0 to 8.0 ton
model
218 (480)
Counter weight 3.5 ton model Approx.1675 (3695)
4.0 ton model Approx. 2025 (4465)
V mast ASSY L/backrest and fork
(with lift cylinder, max. lifting height: 3000 mm
(118 in))
3.5 / 4.0 ton mod-
el
Approx. 850 (1870)
6.0 / 7.0 ton mod-
el
Approx. 1360 (3000)

Toyota 40 8 fd45n forklift service repair manual

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Toyota 40 8 fd45n forklift service repair manual