Toyota Forklift 6FG - 6FD10-30 Service Repair Manual

FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT

6FGl6FD10- 30. Please use this manual for providing quick, correct ser-
vicing of the corresponding forklift models.
This manual deals with the above models as of January 1994. Please
understand that disagreement can take place between the descriptions
in the manual and actual vehicles due to change in design and specifica-
tions. Any change or mod,ifications thereafter will be informed by
Toyota Industrial Equipment Parts & Service News.
For the service procedures of the mounted engine, read the repair manu-
als listed below as reference together with this manual.
(Reference)
Repair manuals related to this manual are as follows:
TOYOTA INDUSTRIAL EQUIPMENT 5K ENGINE

REPAIR MANUAL (No.CE617)
TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINE
TOYOTA INDUSTRIAL EQUIPMENT 1DZ ENGINE
TOYOTA INDUSTRIAL EQUIPMENT 22 ENGINE
TOYOTA MOTOR CORPORATION

SECTION INDEX
I NAME I SECTION
GENERAL
ENGINE
-
CLUTCH
TORQUE CONVERTER
TRANSMISSION
PROPELLER SHAFT
DIFFERENTIAL
FRONT AXLE
REAR AXLE
STEERING
@@
BODY
MATERIAL HANDLING SYSTEM
CYLINDER
OIL PUMP
OIL CONTROL VALVE
GENERAL
Page
EXTERIOR VIEWS ............................................... 0-2
VEHICLE MODEL ............................................... 0-3
FRAME NUMBER ................................................0-6
HOW TO READ THIS MANUAL ......................... 0-9
EXPLANATION METHOD ...................................... 0-9
TERMINOLOGY ................................................. 0-10
ABBREVIATIONS ................................................. 0-10
OPERATIONAL TIPS ........................................... 0-11
STANDARD BOLT & NUT TIGHTENING
TORQUE ...........................................................'0-1
2
BOLT STRENGTH TYPE IDENTIFICATION
METHOD ........................................................ 0-12
TIGHTENING TORQUE TABLE ............................... 0-13
PRECOAT BOLTS ...............................................0-14
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE ..................................... 0-14
WIRE ROPE SUSPENSION ANGLE LIST ............. 0-15
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE ....................................... 0-15
COMPONENTS WEIGHT ..................................... 0-16
RECOMMENDED LUBRICANT
QUANTITY & TYPES ....................................... 0-17
LUBRICATION CHART ........................................0-19
PERIODIC MAINTENANCE .................................. 0-21
PERIODIC REPLACEMENT OF PARTS
AND LUBRICANTS ........................................... 0-27
EXTERIOR VIEWS
VEHICLE MODEL
Series Load capacity Model Engine model Engine type Drive system
6FG 1 0 Gasoline Clutch

5K
02-6FG 1 0 t Torque converter
40-6FG 1 0 t Clutch
1.0 ton 4Y
6FD 1 0 Diesel Clutch

1DZ
02-6FD 1 0 t Torque converter

5K
40-6FG 1 4 t Clutch
1.35 ton 4Y

1DZ
1 ton series
5K
40-6FG 1 5 t Clutch
1.5 ton 4Y

1DZ

5K
40-6FG 18 t Clutch
1.75 ton 4Y

1DZ
02-6FD 18 t Torque converter
6FG20 Gasoline Clutch

5K
02-6FG20 t Torque converter
40-6FG 2 0 t Clutch
2 ton series 2.0 ton 4Y
60-6FD20 Diesel Clutch

1DZ
62-6FD20 t Torque converter
6FD20 Diesel Clutch

2.0 ton 22

5K
40-6FG 23 Gasoline Clutch

4Y
42-6FG 23 t Torque converter
2.25 ton
1 DZ
6FD23 t Clutch
2 ton series 22

5K
40-6FG25 t Clutch
4Y
42-6FG 25 t Torque converter
2.5 ton
1DZ
6FD25 't Clutch

22
6FG 28 Gasoline Clutch

4Y

2.75 ton 1DZ
6FD28 t Clutch
22
3 ton series
4Y

3.0 ton 1DZ
6FD 3 0 t Clutch
22
South Africa
Torque
02-6FGA15 5K Gasoline
1.5 ton converter
1 ton series 02-6FDA 1 5 7 DZ Diesel t

02-6FGA18 5K Gasoline t
1.75 t o n
02-6FDA18 1 DZ Diesel t
42-6FGA20 4Y Gasoline t
2 . 0 ton 02-6FDA20 2Z Diesel t
62-6FDA20 1 DZ t t
2 ton series
42-6FGA25 4Y Gasoline t
2 . 5 ton 02-6FDA25 22 Diesel t
62-6FDA25 1 DZ t t
02-6FGA30
pp
3 t o n series 3.0 t o n 02-6FDA30 22 Diesel t

62-6FDA30 1 DZ t t
Indonesia
6FDN20 2Z Diesel Clutch
2 . 0 ton
60-6FDN20 1 DZ ? t
2 ton series
6FDN25 2Z t t
2.5 ton
60-6FDN25 1 DZ t ?
6FDN30 22 t t
3 t o n series 3 . 0 ton
60-6FDN30 1 DZ t t
FRAME NUMBER
Frame No. Punching Position
of frame
Engine Model Punching format

6FG 1 0
02-6FG 1 0
6FG 1 4
02-6FG 1 4
5K
6FG 1 5
02-6FG 1 5
6FG 1 8
02-6FG 1 8
40-6FG 1 0
42-6FG 1 0
1 ton series 40-6FG 1 4
42-6FG 1 4
4Y
40-6FG 1 5
42-6FG 1 5
40-6FG 1 8
42-6FG 1 8
6FD 1 0
02-6FD 1 0
1 DZ 6FD 1 4 6FD18-10001
02-6FD 1 4
6FD 1 5
Eng~ne Model Punching format
02-6FD 1 5
1 ton series 1DZ 6FD 1 8 6FD18-10001
02-6FD 1 8
6FG 2 0
02-6FG20
6FG 2 3
5K
02-6FG23
6FG 2 5
02-6FG25
40-6FG20
42-6FG 2 0
40-6FG23
4Y
42-6FG 2 3
40-6FG 2 5
42-6FG25
2 ton series
6FD20
02-6FD20
6FD23
22
02-6FD23
6FD25
02-6FD25
60-6FD20
62-6FD20
60-6FD23
1DZ
62-6FD23
60-6FD25
62-6FD25
6FG 2 8
02-6FG28
4Y 6FG 30- 1 0001
6FG 3 0
02-6FG30
60-6FD28
62-6FD28
3 ton series 1DZ 606FD30- 10001
60-6FD30
62-6FD30
6FD28
02-6FD 2 8
22 6FD 30- 1 0001
6FD30
02-6FD30
South Africa
02-6FGA15
5K 6FGA18-10001
02-6FGA 18
1 ton series
02-6FDA 1 5
1DZ 6FDA 1 8- 1 0 0 0 1
02-6FDA 18
42-6FGA20
4Y 406FGA25- 10001
42-6FGA25
02-6FDA20
2 ton series 22 6FDA25-10001
02-6FDA25
62-6FDA20
1DZ 606FDA25-10001
62-6FDA25
4Y 02-6FGA30 6FGA30-1000 1
3 ton series 22 02-6FDA30 6FDA30- 1000 1
1DZ 62-6FDA30 606FDA30-10001
Indonesia
6FDN20
2Z 6FDN25-I 0001
6FDN25
2 ton series
60-6FDN20
1DZ 606FDN25- 10001
60-6FDN25
2Z 6FDN30 6FDN30-10001
3 ton series
1DZ 60-6FDN30 606FDN30-10001
HOW TO READ THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with a photo or illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration,
followed by explanation of cautions and notes summarized as point operations.
Example of description in pattern B
DISASSEMBLY -INSPECTION-REASSEMBLY Tightening torque unit T = N - m (kg-cm)
If a place or part cannot be indicated

directly, the part name is described on
the either side of the illustration.
Example: 1 Piping
Disassembly Procedure
1 Remove the cover. [Point 11
2 Remove the bush [Point 21 cl Operation explained later
3 Remove the gear.
Point operations Explanation of key point for operation with an illustration
[Point 1I I
Disassembly: Put a match mark when removing the pump cover
[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.1 2 m m (0.7528 in)
2. H o w t o read components figures (Example)
(1 The components figure uses the illustra-
I
tion in the parts catalog for the vehicle
model. Please refer t o the catalog for
checking the part name.
The number at the right shoulder of each FIG number in parts catalog
components figure indicates the Fig. num-
ber in the parts catalog.
3. Matters omitted in this manual

( 1 ) This manual omits description of the following jobs, but perform them in actual operation:
TERMINOLOGY
8 Cleaning and washing of removed parts as required
2 Visual inspection (partially described)
Caution:
Important matters of which negligence may cause accidents. Be sure to abserve them.
Note:
important items of which negligence may cause accidents, or matters in operation procedure re-
quiring special attention.
Standard: Values showing allowable range in inspection and adjustment.

Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONS
Abbreviation (code) Meaning Abbreviation (code) Meaning
ASSY Assembly SST Special service tool
LH Left hand STD Standard
LLC Long life coolant T = Tightening torque
OPT Option O O T Number of teeth (0 0)
01s Oversize U IS Undersize
PS Power steering W/ With
RH Right hand L/ Less
Society of Automotive
SAE
Engineers (USA)
OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire repe(s) with a sufficient reserve in
load capacity.
(3) Always disconnect the battery plugs before the inspection or servicing of electrical parts.
2. Tactful operation
(1 ) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pres-
sure gauge, etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the parts
neatly t o prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools
and operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
( 6 ) Replace, gaskets, packings and O-rings w i t h new ones each time they are disassembled.
(7) Use genuine Toyota parts for replacement.
(8)Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
If no tightening torque is specified, tighten the bolt or nut according t o the standard tightening
torque table.
3. Grasping the trouble state

When a trouble occurs, do not attempt immediate disassembly or replacement but first check if
the trouble requires disassembly or replacement for remedying.
4. Method for battery connection upon occurrence of run-down batteries on 24-V specification ve-
hicle with 22 engine (with 1 2 / 2 4 V voltage switching system)
( 1 ) Connect a 12-V aiding battery t o the one on the rear

side of the t w o mounted batteries.
Mounted side
( 2 ) If starting falls with one aiding battery, connect an-

other aiding battery to the front side one of the
mounted batteries.
Caution:
As batteries are shorted when the negative (-1 termi-
nal of the aiding battery on the front side of the vehicle
is connected t o the body ground, connect the booster
cables t o the vehicle side t o each corresponding termi-
nal.
Never connect between aiding batteries.
(3) When the batteries are required t o charge by the

charger, remove the battery from the vehicle t o charge
the battery.
0-1 2
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.
BOLT STRENGTH TYPE IDENTIFICATION METHOD

1. Identification by bolt shape 2. Identification by part No.
Shape and class Class Hexagon head bolt
4 = 4T
Hexagon
@ Bolt head No.
5 = 5T
6 = 6T
7 = 7T
Parts No.
9161 1-40625
head bolt L L e n g t h (mml
0 No mark 4T Diameter (mm)
Hexagon iameter
No mark 4T
flange bolt
Hexagon
head bolt
8 Two protruding
lines
5T
Hexagon Two protruding

6T Stud bolt
flange bolt lines
Hexagon
head bolt
0 Three protruding
lines
7T Part No.
92 132-406 1 4
Length (mm)
Diameter (mm)
Welded bolt 4T
Stud bolt
k No mark 4T iameter
$- Grooved 6T
0-13
TIGHTENING TORQUE TABLE

I PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the fol-

lowing cases:
(a) After it is removed.
(b) When the precoat bolt is moved (loosened or tight-
ened) by tightness check, etc.
1 Note:
For torque check, use the lower limit of the allowable tight-
ening 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 threaded hole
must be washed even for replacement of the bolt.)
(2) Parfectly dry the washed parts by air blowing.
(3) Coat the specified seal lock agent to the threaded
portion of the bolt.
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.
Standard tightening torque N.m (kg-cm) [ft-lbl Hose inside

Nominal diameter
diameter
of screw Standard Tightening range mm (in)
7116 - 20UNF 25 (250) [I8.11 24 - - 270) [ 1 7.4 - 19.51
26 (240 6 (0.24)
9/16 - 18UNF 49 (500) [36.2] 47 - 52 (480 - 530) 134.7 - 38.31 9 (0.35)
314 - 16UNF 59 (600) t43.41 56 - 62 (570 - 630) 141.2 - 45.61 12 (0.47)
718 - 14UNF 59 (600) 143.41 56 - 62 (570 - 630) 141.2 - 45.61 12 (0.47)
718 - 14UNF 78 (800) 157.91 74 - 82 (760 - 840) 155.0 - 60.81 15 (0.59)
1.1/16 - 12UNF 118 (1200) 186.81 112 - 123 (1140 - 1250) f82.5 - 90.41 19 (0.75)
1.5116 - 12UNF 137 (1400) [101.3] 130 - 144 (1330 - 1470) t96.2 - 106.41 25 (0.98)
PFI I 4 25 (250) t18.11 24 - 26 (240 - 270) 117.4 - 19.51 6 (0.24)
PF318 49 (500) I36.21 47 - 52 (480 - 530) 134.7 - 38.31 9 (0.35)
PF112 59 (600) 143.41 56 - 62 (570 - 630) 141.2 - 45.61 12 (0.47)
PF314 11 8 (1200) 186.81 11 2 - 123 ( 1140 - 1250) 182.5 - 90.41 19 (0.75)
PF 1 137 (1400) [101.3] 130 - 144 (1330 - 1470) L96.2 - 106.41 25 (0.98)
WlRE ROPE SUSPENSION ANGLE LIST
Lifting Compres- Suspension Lifting Compres- Suspension
~e'nsion Tension
angle sion method angle sion method
0O 1.OO time 0 time
-1
y
90 O 1.41 time 1.OO time
b2<
2' A
30O 1.04 time 0.27 time
B
h
do 1 20° 2.00 time 1.73 time
k0
2%
60O 1.16time 0.58time
h'
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE Unit: N (ton) [lbl
Single-rope
Rope Cutting Two-rope suspension Four-rope suspension
suspension
diameter load
O0 0O 30O 60O 90° 0O 30° 60O 90O
21380 3040 6080 5880 5200 4310 12160 11770 10400 8630
6 mm
(2.18) (0.31) (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
(0'24 [I1691 127341 [2646] 123371 [ I 9401
148071 1683.61 113671 113231 19701
31480 4410 8830 8530 7650 6280 17650 17060 15300 12550
8 mm
(3.21 ) (0.45) (0.9) (0.87) (0.78) (0.64) (1.8) (1.74) (1.56) (1.28)
(0'32 in)
170781 1992.31 119851 [I91 81 117201 11 41 11 139691 [39371 134401 123221
49230 6960 14020 13440 11770 9810 27460 26480 23540 '19610
1 0 mm
(5.02) (0.71) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4) (2.0)
(0'4 in'
[ I 10691 [I 565.61 I31531 13021I [2646] [2205] [61741 159541 [52921 144101
76880 10980 21570 21280 18630 14710 43150 / 41 190 / 37270 29420
12.5 mm
(7.84) (1.12) (2.2) (2.1) (1.9) (1.5) (4.4) (4.2) (3.8) (3.0)
(0.5 in)
1173871 [2469.5] [4851I [46311 [41901 [33081 197021 19261 I I83791 [6615]
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
1 4 mm
(9.83) (1.4) (2.8) (2.7) (2.4) (1.9) (5.6) (5.4) (4.8) (3.8)
(0'56 in) 152921 141901 11 23481 [ I 19071 1105841
1216751 [3087] 161741 159541 183791
COMPONENTS WEIGHT Unit: kg (Ib)
Component Weight (mass)
5K 97 (214)
4Y 134 (295)
Engine
1DZ 176 (388)
22 240 (529)
Transmission 78 (172)
For 1 speed 152 (335)

Torque converter
For 2 speeds 163 (359)
1.0 ton model Approx. 460 (101 4)
1.35 ton model Approx. 7 10 (1566)
1.5 ton model Approx. 845 (1863)
Balance weight 2.0 ton model Approx. 1220 (2690)
2.25 ton model Approx. 141 5 (3120)
1 .O- 1.75
Approx. 410 (904)
ton model
2.0 ton model Approx. 460 (101 4)

V mast ASSY Wllift bracket
(with lift cylinder, without fork, max. 2.25.2.5
lifting height: 3000 mrn (118 in)) Approx. 500 (1103)
ton model
2.75-3.0 Approx. 570 (1257)

ton model
1.0 - 1.75 Approx. 340 (750)

ton model

V mast ASSY Lllift bracket and fork
(with lift cylinder max. lifting height: 2.25.2.5
3000 mm (118 in)) Approx. 400 (882)
ton model
2.75.3.0 Approx. 445 (981

ton model
RECOMMENDED LUBRICANT QUANTITY & TYPES
Description Classification TYpe Application Quantity
Motor oil
SAE30 5K 4.0 1 (1.06 US gal)
(SAE20 in cold area)
API
Gasoline
SD, SE
SAE20W-40
(SAE1OW-30 in cold 4Y 4.0 1 (1.06 US gal)
Engine area)
Diesel engine oil

1DZ 7.9 1 (2.09 US gal)
API SAE30 (SAE20 in
Diesel CC, CD cold area)
or better
22 9.0 1 (2.38 US gal)
SAE1OW-30
API
Hypoid gear oil
Transmission GL-4 Clutch models 4.0 1 (1.06 US gal)
SAE85W-90
GL-5
Torque
Torque converter ATF GM Dexronm I1 converter 14.0 1 (3.70 US gal)
models
API 1 ton series 5.4 1 (1.43 US gal)

Hypoid gear oil
Differential GL-4 2 ton series 6.4 1 (1.69 US gal)
SAE85W-90
GL-5 3 ton series 9.0 1 (2.38 US gal)
Hydraulic oil
IS0 Attached Table 2
[Max. fork height = Hydraulic oil
VG32 Hydraulic oil volume
3000 mm ( 11 8 in)]
1 ton series 4 5 1 ( 11.9 US gal)

Fuel tank 2 ton series 6 5 1 (17.2 US gal)
3 ton series 6 5 1 ( 17.2 US gal)
Proper quantity
SAE J-1703
Brake and clutch line All models Reservoir Tank
DOT-3
0.2 1 (0.05 US gal)
Chassis parts MP grease All models Proper quantity
LLC 30-50% mixture

(for winter or
Coolant
all-season) Attached Table 1
(excluding reservoir LLC
Coolant with rust- Coolant volume
tank)
inhibitor (for spring,
summer and autumn)
Coolant 1.1 1 (0.29 US gal)

(Reservoir Tank)
t t All models
(at Full level)
Attached Table I Coolant volume Unit: 1 (US gal)
Engine Drive method 1 ton series 2 t o n series 3 t o n series
Clutch models 7.1 (1.87) 7.2 (1.90)

5K Torque converter
7.6 (2.01) 7.3 (1.93)
models
Clutch models 9.1 (2.40) 9.2 (2.43) 10.0 (2.64)

4Y
Torque converter
9.6 (2.53) 9.3 (2.46) 9.6 (2.53)
models
Clutch models 7.8 (2.06) 8.6 (2.27) 8.7 (2.30)

1DZ
Torque converter
8.1 (2.14) 8.3 (2.19) 8.3 (2.19)
models
Clutch models 8.9 (2.35) 9.3 (2.46)

22
Torque converter
9.0 (2.38) 8.9 (2.35)
models
Attached Table 2 Hydraulic oil volume Unit: 1 (US gal)
Model 1 ton series 2 t o n series 3 t o n series
5K engine models 27 (7.1) 34 (9.0)
4Y engine models 27 (7.1) 34 (9.0) 37 (9.8)
1DZ engine models 27 (7.1) 34 (9.0) 37 (9.8)
22 engine models 39 (10.3) 42 (11.1)

LUBRICATION CHART
Clutch Model
0 Inspection
Replacement
@ MP grease
a Engine oil I. lnspect every 8 hours (daily)
0 Hypoid gear oil 11. lnspect every 4 0 hours (weekly)
@ Hydraulic oil 111. lnspect every 170 hours (monthly)
@ Hypoid gear oil IV. lnspect every 1000 hours (6 monthly)
@ Brake fluid V. lnspect every 2000 hours (annually)
1 Chain Engine crank case

2 Differential Rear axle beam front
3 Front wheel bearing Rear axle beam rear
4 Brake and clutch master cylinder Tilt steering universal joint
5 Transmission case Tilt steering locking mechanism
6 Rear wheel bearing Mast support bushing
7 Steering knuckle king pin Tilt cylinder front pin
8 Bell crank pin Propeller shaft
9 Oil tank Gear shift link
Torque Converter Model
3 lnspectlon
Replacement
L
P
MP grease
Engine oil I. lnspect every 8 hours (daily)
3 Hypold gear 011 11. lnspect every 4 0 hours (weekly)
4 Hydraulic oil 111. lnspect every 1 7 0 hours (monthly)
'5 Automatic transmission fluid IV. lnspect every 1 0 0 0 hours (6 monthly)
5 Brake fluld V. lnspect every 2 0 0 0 hours (annually)
Chain Engine crank case

Differential Rear axle beam front
Front wheel bearlng Rear axle beam rear
Brake master cylinder Tilt steering universal joint
Torque converter case Tilt steering locking mechanism
Rear wheel bearing Mast support bushing
Steering knuckle king pin Tilt cylinder front pin
Bell crank pin Propeller shaft
011tank
PERIODIC MAINTENANCE
INSPECTION METHOD
I : Inspection. Repair or replacement if required.
M : Measurement. Repair or adjustment if required.
T : Retightening C ; Cleaning L : Lubrication
* : For n e w vehicle " 1 : Flaw detector
Inspection Period Every Every Every Every

1 month 3 months 6 months 12 months
Every Every Every Every
Item 1 7 0 hours 500 hours 1000 hours 2000 hours
ENGINE
Proper starting and abnormal noise I + + +
Rotating condition at idling M c c +
Rotating condition during

M t t t
acceleration
Exhaust gas condition I +- +- t
Main body Air cleaner element C t t +
Valve clearance M
Compression M
Cylinder head bolt loosening T
Muffler rubber mount I
Clogging and damage in PCV valve
PCV system I + + +-
and piping
Governor No-load maximum rpm M @ t +-
Oil leak I c t t
Lubrication
Oil level I t + c
system
Clogging and dirt of oil filter I t + +
Fuel leak I t + +
Operation of carburetor link

I C t C
mechanism
Dirt and clogging of fuel filter and
I t e t
Fuel system element
Injection timing M t
Injection nozzle injection pressure

M
and spray status
Draining of sedimenter I +
Coolant level in radiator and leak I t + +-
Rubber hose degradation I c +- +
Cooling Radiator cap condition I +- t 4-
system
Fan belt tension, looseness and
I 4- e t
damage
Radiator rubber mount I
1 month 3 months 6 months 1 2 months
Item 1 7 0 hours 5 0 0 hours 1 0 0 0 hours 2 0 0 0 hours
POWER TRANSMISSION SYSTEM
Clutch pedal play M t + c
Abnormal sound and functioning

I t t e
(connection)
Clutch master cylinder function and
Clutch I t t e
leak
Fluid level I t t c
Oil clutch mechanism function and

I t
leak
Leak I + + t
Transmission Fluid level I t t t
Gear function and abnormal noise I + + +
Leak I t +- +-
Differential Oil level

Bolt loosening
I t t
I +
T
Leak I t + +-
Fluid level I t + +-
Torque Operating mechanism function and

I t t 4-
converter looseness
and Control valve and clutch functions I t t t
transmission
Inching valve function I t t +-
Stall and hydraulic pressure

M t
measurement
Loose joint T t e
Propeller Looseness at spline connections I

shaft and
axle Looseness of universal joint I
Twisting and cracks of axle shaft I
DRIVE SYSTEM
Tire inflation pressure M +- +- t
Tire cuts, damage and uneven

I t t t
wearing
Loose rim and hub nuts T t t t
Tire groove depth M t t t
Wheels
Metal chips, pebbles and other for-
I C t t
eign matter trapped .in tire grooves
Rim, side ring and disc wheel
I t t t
damage
Abnormal sound and looseness of
I t t t
front wheel bearing
Abnormal sound and looseness of
Wheel I t e t
rear wheel bearing
Cracks, damage and deformation of
Front axle I
housing
Cracks, damage and deformation of
I
beam
Rear axle
Looseness of axle beam in vehlcle
M
longitudinal direction
STEERING SYSTEM
Steering Play and looseness I C t t
wheel Funct~on I t + +
Oil leak I + +- t
Gear box Looseness of mounting T t e +
Clogging of relief valve filter C e
Looseness and damage I e t +

Rods, links
and arm Linkage wear and mounting condi-
I
tion
-
011leak I e + t
Power
Mounting and linkage looseness I + + t
Steering
Damage of power steering hose I
King pin looseness I + +- i--
Knuckle
Cracks and deformation I
Steering Wheel alignment M

shaft Left and right turning angle M
BRAKING SYSTEM
Play and reserve M t c t
Brake pedal
Braking effect I t + t
Operating force I +- t t
Parking Braking effect I t t t
brake
Rod and cable looseness and
I t C C
damage
Leak, damage and mounting
Brake pipe I t t +
condition
Reservoir
Leak and fluid level I c t +
tank
Master cylinder and Function, wear, damage,
I
wheel cylinder leak and mounting looseness
Item 170 hours 500 hours 1000 hours 2 0 0 0 hours
Clearance between drum and lining M t t t
Wear of shoe sliding portion and

I
lining
Brake drum Drum wear and damage I
and brake
Shoe operating condition I
shoe
Anchor pin rusting I
Return spring fatigue M
Automatic adjuster function I
Backing Deformation, cracks and damage I

plate Loose mounting T
MATERIAL HANDLING SYSTEM
Abnormality of fork and stopper pin I t +- +
Misalignment between left and right

Forks I t +- +-
fork fingers
Cracks at fork root and welded part I *'
Deformation and damage of each
I t t t
part and crack at welded part
Mast and lift bracket looseness I +- t t
Wear and damage of mast support

Mast and lift I
bush
bracket
Wear, damage and rotating condi-
I t t t
tion of rollers
Wear and damage of roller pins 1
Wear and damage of mast strip I t +- t
Tension, deformation and damage

I t t t
of chain
chain and Chain lubrication I +- t +
chain wheel Abnormality of chain anchor bolt I t t t
Wear, damage and rotating condi-

I t t. t
tion of chain wheel
Various Abnormality and mounting condition
I t 4- t
attachments of each part
HYDRAULIC SYSTEM
Loosening and damage of cylinder
I t t 4-
mounting
Deformation and damage of rod, rod
I t t 4-
Cylinder screw and rod end

Cylinder operation I 4- +- +
Natural drop and natural forward tilt

M t t t
(hydraulic drift)
Oil leak and damage I t +- +-
Wear and damage of pin and I t t t
Cylinder cylinder bearing

Lifting speed M t +- +-
Uneven movement I t t t
Oil pump Oil leak and abnormal sound I t t t
Oil level and contamination I t t t
Hydraulic C +
Tank and oil strainer
oil tank
Oil leak I t 4- C
Control Loose linkage I + + +-
lever Operation I +- + t
Oil leak I t t t
Oil control Relief pressure measurement M

valve
Relief valve and tilt lock valve
I t t t
functions
Oil leak I +- t +-
Hydraulic Deformation and damage I + t t

piping
Loose joint T t +- t
ELECTRICAL SYSTEM
Cracks on distributor cap I t t t
Spark plug burning and gap I t t t
Distributor side terminal burning I +- t +-
lgnition
timing Distributor cap center piece wear
I t t +-
and damage
Plug cord internal discontinuity I
Ignition timing M +
Starting I
Pinion gear meshing status t t t
motor
Charger Charging function I 4- t t
Battery fluid level I +- +- t
Battery
Battery fluid specific gravity M c
Electrical Damage of wiring harness I t e t
wiring Fuses I t t t
Open-circuit in glow plug I t
Preheater
Open-circuit in intake heater I t
Engine stop- Diesel engine key stop device func-

I t t t
ping system tion
SAFETY DEVICES, ETC.
Cracks at welded portion I t 4- t
Head guard
Deformation and damage I +- t t
Loosening of mounting T t t t
Back-rest
Deformation, crack and damage I +- t +
Lighting
Function and mounting condition I t +- +-
system
Horn Function and mounting condition I t t +
Direction
Function and mounting condition I t t t
indicator
Instruments Functions I t +- +-
Backup
Function and mounting conditon I t- t +
buzzer
Rearqview Dirt, damage I t t t
mirror Rear reflection status I t t t
Seat Loosening and damage of mounting I t t t
Damage and cracks of frame, cross

I
Body members, etc.
Bolt looseness T
Others Grease u p L t + t
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
a:Replacement
Engine oil • t +- +
Engine oil filter • +- t
Engine coolant (every 2 years for LLC) • c t
Fuel filter • +
Torque converter oil • t
Torque converter oil filter • t
Transmission oil •
Differential oil •
Hydraulic oil • t
Hydraulic oil return filter 0'' • +-
Wheel bearing grease

-
•
.
Spark plugs • t
Air cleaner element @

Cups and seals for brake master and wheel cylin-
ders
Brake fluid • t
Power steering hoses

Power steering rubbers parts
Hydraulic hoses .
*
2
Brake fluid reservoir tank hose 0e2

Fuel hoses 2'.
Torque converter rubber hoses .

*
2
Chains
'1: for new vehicle "2: Every 2 years '3: Every 3 years
Replacement shall be made upon arrival of the operation hours or months, whichever is earlier.
ENGINE
Page
ENGINE SECTIONAL VIEWS .............................. 1-2
MAJOR SPECIFICATIONS ................................. 1-4
ENGINE PERFORMANCE CURVES ..................... 1-5
ENGINE ASSY .................................................... 1-7
ENGINE WITRANSMISSION
REMOVAL.INSTALLATION ................................ 1-7
ENGINE REMOVAL.INSTALLATI0N ....................... 1-11
ENGINE WITORQUE CONVERTER
REMOVAL-INSTALLATION ................................ 1.12
ENGINE REMOVAL.INSTALLATION ....................... 1-15
ENGINE SPEED ADJUSTMENT .......................... 1-17
AIR CLEANER ..................................................... 1-21
RADIATOR ....................................................... 1-25
MUFFLER & EXHAUST PIPE .............................. 1-27
BATTERY ........................................................... 1-31
STARTING MOTOR ........................................ 1-33
ALTERNATOR .................................................... 1-34
ACCELERATOR PEDAL ...................................... 1-36
ENGINE SECTIONAL VIEWS
5K Engine
4 Y Engine
1 DZ Engine
22 Engine
MAJOR SPECIFICATIONS
Gasoline Engines
5K 4Y (1.2 ton series) 4Y (3 ton series)
Engine type Gasoline 4-cycle c c
Number of cylinders and lnline 4 cylinders 4- e

arrangement -longitudinal
Combustion chamber type Wedge type c c
Valve mechanism 0HV.chain-driven + c
80.5 x 73.0 91.0 x 86.0

Bore x stroke mm (in)
(3.169 x 2.874)
4-
(3.583 x 3.386)
Total displacement cc (cu-in) 1486 (90.68) 2237 (136.51) c
Compression ratio 9.3 8.8 +
Maximum power PSlrpm 3812800 5412400 5812600

Maximum torque kg-mlrpm 11.512000 16.511 800 c
Minimum specific fuel c

2 10 (2800) 200 (2300)
consumption SIPS-h (rpm)
Service weight N (kg) [Ibl 951 (97) [2141 1314 (134) [2951 4-
No-load maximum rpm rPm 3050 2600 2800
Diesel Engines
Engine 1DZ (1 ton series) I D 2 (2.3 ton series) 22
Engine type Diesel.4-cycle c +
Number of cylinders and lnline 4 cylinders + 4-

arrangement .longitudinal
Combustion chamber type Whirl chamber type c Direct injection type
Valve mechanism OHVmgear-driven +- 4-
Bore x stroke mm ("I

86.0 x 107.0 C
- 98.0x 11 5.0
(3.386 x 4.21 3) (3.858 x 4.528)
Total displacement cc (cu-in) 2486 (151.71 + 3469 (211.69)
Compression ratio 21.5 4- 18.6
Maximum power PSIrpm 5512400 6012600 6612200
Maximum torque kg-mlrpm 17.011 600 c 22.011 6 0 0
Minimum specific fuel c 1 54 ( 1 600)

185 (1400)
consumption SIPS-h (rpm)
Service weight N (kg) [Ibl 1726 (176) 13881 + 2345 (240) 15291
No-load maximum rpm rPm 2600 2800 2400

1DZ Engine
1 ton series 17.011600 2.3 ton series -17.011600
X I 0'
Engine speed (rpm) Engine speed (rprn) x 10'
22 Engine
22.011600
-
m
Y
c
V)
6612200
0
a
C
0
C1
a
1C
m
r
V)
1 5411600 -
.
-m
.K
VI
P
-w0
I
110 Id
I
18 22 26 LL
X 1 0'
Engrne speed (rprn)
ENGINE ASSY
ENGINE WITRANSMISSION REMOVAL-INSTALLATION
1 Radiator cover
3 Toe board
8 Under cover and tire cover
9 Coolant
1 2 Fuel hose
13 Accelerator wire
1 9 Electrical wiring
1 Remove the radiator cover.
2 Remove the engine hood.
3 Remove the toe board.
4 Remove the battery and battery case.
5 Disconnect the electrical parts wiring, and remove the bracket Wlelectrical parts.
(Keep the fuse box free by removing the set bolts.)
6 Remove the radiator reservoir tank.
7 Remove the air cleaner: [Point 11
8 Remove the undercover and tire cover RH.

(Only 22 engine models)
9 Drain the coolant.
1 0 Remove the radiator.
1 1 Disconnect the exhaust pipe.
12 Disconnect the fuel hose. [Point 21
13 Disconnect the accelerator wire. (Disconnect on the carburetor side on gasoline engine models, or
on the injection pump side on diesel engine models.)
1 4 Remove the frame side covers RH (rear and front).
15 Remove the oil pump Wlpump hose.
16 Remove the horn.
17 Disconnect the clutch release cylinder from the clutch housing and keep it free.
18 Disconnect the gear shift lever link rod. [Point 31
19 Disconnect electrical wiring.
2 0 Remove the propeller shaft cover and propeller shaft.
21 Remove the transmission mounting set bolts.
2 2 Remove the engine mounting set nuts.
23 Remove the engine Wltransmission. [Point 41
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Bleed air from the fuel system after engine installation. (In diesel engine models only)
Bleeding Air from Fuel System (Diesel Engine Models)
1 DZ.2Z engine
1. Operate the fuel filter hand pump until the pump oper-
ation becomes heavy to indicate the end of air bleed-
ing.
Point Operations
[Point 1I
Removal.lnstallation: Remove the air cleaner inlet side

connector as follows.
1. Disconnect the connector on the air cleaner case side.

(1) Hold the connector elbow portion with a hand, and.
pull downward until the connector side protrusion
comes off from the groove on the case side.
2. Disconnect the head guard pillar side connector.

(1) Rotate the connector upward as illustrated and dis-
connect at the position where the pillar side notch
aligns with the connector flange protruded portion.
3. Reverse the removal procedure for installation.
[Point 21
Installation: Do not mistake the fuel hose connecting po-

sition. (Gasoline engine models)
[Point 31
Removal: Wrap each of the disconnected rod and the

freed shift lever with tape for holding in place.
[Point 41
Removal.lnstallation: SST 09010-201 1 1 -7 1

In the case of the 5K engine, use
the SST above and a sling device
(SST 09090-04010) for more effi-
cient operation.
Removal: Remove after checking thorough disconnection

of wiring, hose and cables.
Thank you very much
for your reading.
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FOREWORD

This manual covers the service procedures of the TOYOTA FORKLIFT

TOYOTA INDUSTRIAL EQUIPMENT 5K ENGINE

TOYOTA MOTOR CORPORATION

6FG 1 0 Gasoline Clutch

6FD 1 0 Diesel Clutch

6FG 1 4 Gasoline Clutch

6FD 1 4 Diesel Clutch

6FD 1 5 Diesel Clutch

6FG 1 8 Gasoline Clutch

6FD 1 8 Diesel Clutch

6FG20 Gasoline Clutch

60-6FD20 Diesel Clutch

6FD20 Diesel Clutch

6FG23 Gasoline Clutch

40-6FG 23 Gasoline Clutch

6FG25 Gasoline Clutch

6FD25 't Clutch

6FG 28 Gasoline Clutch

60-6FD28 Diesel Clutch

60-6FD30 Diesel Clutch

1 ton series 02-6FDA 1 5 7 DZ Diesel t

3 t o n series 3.0 t o n 02-6FDA30 22 Diesel t

Engine Model Punching format

Engine Model Punching format

3 ton series 22 02-6FDA30 6FDA30- 1000 1

1DZ 62-6FDA30 606FDA30-10001

Engine Model Punching format

Example of description in pattern B

DISASSEMBLY -INSPECTION-REASSEMBLY Tightening torque unit T = N - m (kg-cm)

If a place or part cannot be indicated

1 Remove the cover. [Point 11

2 Remove the bush [Point 21 cl Operation explained later

3 Remove the gear.

Point operations Explanation of key point for operation with an illustration

3. Matters omitted in this manual

Standard: Values showing allowable range in inspection and adjustment.

Abbreviation (code) Meaning Abbreviation (code) Meaning

ASSY Assembly SST Special service tool

LH Left hand STD Standard

LLC Long life coolant T = Tightening torque

OPT Option O O T Number of teeth (0 0)

01s Oversize U IS Undersize

PS Power steering W/ With

RH Right hand L/ Less

3. Grasping the trouble state

( 1 ) Connect a 12-V aiding battery t o the one on the rear

( 2 ) If starting falls with one aiding battery, connect an-

(3) When the batteries are required t o charge by the

STANDARD BOLT & NUT TIGHTENING TORQUE

BOLT STRENGTH TYPE IDENTIFICATION METHOD

Shape and class Class Hexagon head bolt

0 No mark 4T Diameter (mm)

Hexagon Two protruding

TIGHTENING TORQUE TABLE

1. Do not use the precoat bolt as it is in either of the fol-

2. Method for reuse of precoat bolts