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Toyota FORKLIFT 5FD33, Manual

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Toyota FORKLIFT 5FD33 Manual Download Page 22

PERIODIC REPLACEMENT LUBRICANTS AND PARTS 

l 

: 

Replacement 

for n e w  vehicle 

Every 

2 

years 

Every 

3 

years 

Replacement  shall be made u p o n  arrival of the operation hours or months, 

Every 
6 months 

Every 

hours 

• 

• 
• 

• 
• 
• 
• 

l 

(-1997.12) 

• 

Every 
3 months 

Every 
5 0 0  hours 

• 
• 

Interval 

Every 
1 month 

Every 

Every 
12 months 

Every 
2000 hours 

• 
• 

• 
• 
• 

• 

* 

• 

* 

• 

• 

Engine 

Engine oil filter 

Engine  coolant  (every 

2 

years for 

filter 

Torque  converter  oil 

Torque  converter  oil filter 

Transmission oil 

Differential  oil 

Hydraulic  oil 

Hydraulic oil return filter 

Wheel  bearing grease 

Spark  plug 

Distributor  points 

Air cleaner element 

Brake  booster  rubber  parts 

Cups and seals  for wheel cylinders 

Power  steering hoses 

Power  steering rubber  parts 

Hydraulic hoses 

Fuel  hoses 

Torque  converter  rubber  hoses 

Chains 

1 7 0  hours 

• 

Summary of Contents for FORKLIFT 5FD33

Page 1: ... 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 repa...

Page 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 ...

Page 3: ...HTENING 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 ...

Page 4: ...EXTERIOR VIEWS Front View 5FD35 0 7 2 1 Rear View 5FD35 6 ...

Page 5: ...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 Diese...

Page 6: ... 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 f...

Page 7: ...NGTH 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 ...

Page 8: ...TIGHTENING TORQUE TABLE ...

Page 9: ...ose 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 insid...

Page 10: ...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 2001...

Page 11: ...IST 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 ...

Page 12: ...T 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 ...

Page 13: ... 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 ...

Page 14: ...ing locking mechanism Mast support bushing Tilt cylinder front pin Propeller shaft Oil pump drive shaft Tie rod end Drive shaft pulley Oil pump spline shaft lnspect every 8 hours daily lnspect every 40 hours weekly lnspect every 170 hours monthly lnspect every 1000 hours 6 monthly lnspect every 2000 hours annually lnspect and service Replace MP grease Engine oil Hypoid gear oil Hydraulic oil Hypoi...

Page 15: ...ar wheel bearing 7 Steering knuckle king pin 0 lnspect and service 8 Bell crank pin Replace 9 Oil tank MP grease 10 Engine crankshaft Engine oil 11 Rear axle beam front Hypoid gear oil 12 Rear axle beam rear Hydraulic oil 13 Tilt steering universal joint Automatic transmission fluid 14 Tilt steering locking mechanism Molybdenum disulfidegrease 15 Mast support bushing 16 Tilt cylinder front pin 17 ...

Page 16: ...t gas condition Air cleaner element Valve clearance Compression Cylinder head bolt loosening Muffler rubber mount Clogging and damage in PCV valve and piping No load maximum rpm Oil leak Oil level Clogging and dirt of oil filter Fuel leak Operation of carburetor link mechanism Dirt and clogging of fuel filter and element Injection timing lnjection nozzle injection pressure and spray status Drainin...

Page 17: ...evel Bolt loosening Leak Fluid level Operating mechanism function and looseness Control valve and clutch functions Inching valve function Stall and hydraulic pressure measurement 12 2000 Months Hours M I C t C l C C e I I I l C t t I t t t i t I I I I M M t I T t t c M I I I Wheels T Tire inflation pressure Tire cuts damage and uneven wearing Loose rim and hub nuts Tire groove depth Metal chips pe...

Page 18: ...ss of mounting Clogging of relief valve filter Looseness and damage Linkage and wear and mounting condition Oil leak Mounting and linkage looseness Damage of power steering hose King pin looseness Cracks and deformation Wheel alignment Left and right turning angle 12 2000 BRAKING SYSTEM Months Hours t t t l e e l t t t T I I l C C t I Brake pedal Parking brake Brake pipe Brake booster and wheel cy...

Page 19: ...between left and right fork fingers Cracks at fork root and welded part Deformation and damage of each part and crack at welded part Mast and lift bracket looseness Wear and damage of mast support bush Wear damage and rotating consdition of rollers Wear and damage of roller pins Wear and damage of mast strip Tension deformation and damage of chain Chain lubrication Abnormality of chain anchor bolt...

Page 20: ...and tilt lock valve functions 011 leak Deformation and damage Loose joint SYSTEM 3 500 Ignition timing Starting motor Charger Battery Electrical wiring I I t M I I I I I I I I t C C I T C M 6 1000 Cracks on distributor cap Spark plug and burning and gap 1997 12 Distributor side terminal burning Distributor cap center piece wear and damage Distributor points gap Plug cord internal discontinuity Ign...

Page 21: ... Seat Body Other 12 10002000 I ETC Cracks at welded portion Deformation and damage Loosening of mounting Deformation crack and damage I Function and mounting condition Function and mounting condition Function and mounting condition Functions Function and mounting condition Dirt damage Rear reflection status Loosening and damage of mounting Damage and cracks of frame cross members etc Bolt loosenes...

Page 22: ...ery 12 months Every 2000 hours C C t C t e 2 Item Engine Engine oil filter Engine coolant every 2 years for LLC Fu el filter Torque converter oil Torque converter oil filter Transmission oil Differential oil Hydraulic oil Hydraulic oil return filter Wheel bearing grease Spark plug Distributor points Air cleaner element Brake booster rubber parts Cups and seals for wheel cylinders Power steering ho...

Page 23: ......

Page 24: ...GENERAL 11Z Engine Exterior View KAI 28 26 35 1li ...

Page 25: ...3F Engine Exterior View ...

Page 26: ...112 Engine Sectional View LAQM61 62 3F Engine Sectional View 28 ...

Page 27: ...elconsumption ratio g ps h I I 10 14 18 22 Engine speed rpm x 1O2 Engine Performance Curve 112 KALMl Gasoline model LPG model only Gasoline LPG model 26 0 1200 25 0 1200 j24 Engine torque Shaft horsepower 200 2000 1200 Fuel consumption 185 1800 180 10 14 18 22 Engine speed rpm x 1O2 Engine Performance Curve 3F 29 KALM47 ...

Page 28: ...l consumption ratio glps hlrpm Injection pump type Bosch VE l njection timing BTDC Injection order 1 4 2 6 3 5 lgnition timing BTDC Ignition order 1 5 3 6 2 4 Service weight kg Ib 1 330 728 250 551 11Z Diesel 4429 270 6 OHV gear driven 96 0 x 102 0 3 78 x 4 02 18 6 3F Gasoline 3955 241 6 t 94 0 x 95 0 3 70 x 3 74 8 1 Direct injection 85 2200 8112200 2911600 202 1600 16511200 72 21 00 6912100 26 12...

Page 29: ...ect the engine hood stay on the frame bracket side 3 Hood hinge set screws 4 Engine hood Removing the Engine Hood 2 9 9 3 Remove the radiator cover 4 Remove the air cleaner ASSY 1 Disconnect the vacuum switch harness 2 Disconnect the air cleaner hose 3 Hydraulic oil tank breather set bolt 4 Air cleaner set bolt 5 Air cleaner ASSY with hose Removing the Radiator Cover 2 9 1 1 Removing the Air Clean...

Page 30: ...tribu tor and ignition coil 3F 4 Battery stopper 5 Battery Removing the Batery LAQ29 22 6 Battery case 6 Remove the sedimenter 11Z 1 Disconnect the fuel hose 2 Disconnect the wirings 3 Set bolt 4 Sedimenter with bracket Removing the Sedimenter w 9 2 7 Disconnecting Wiring 1 LAQ29 28 34 4 Starting motor wiring 5 Engine oil pressure switch wiring Disconnecting Wirings 2 L A Q o s s ...

Page 31: ... Carburetor wiring 3F 8 Disconnect piping and wires 1 Fuel piping 2 Accelerator wire Disconnecting Wirings 3 LAQ30 1 29 32 Disconnecting the Fuel Piping 1lZ 3F uQ30 8 19 Disconnecting the Accelerator Wire 112 LAQ O 9 Disconnecting the Accelerator Wire 3F 1 9 1 8 ...

Page 32: ...Thank you very much for your reading Please Click Here Then Get More Information ...

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