Toyota 6FG 6FD 10-30 Forklift Trucks Service Repair Manual PDF

FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT

6FGl6FD 1 0 - 30. Pl
Plea
ease
se use this manual for providing quick, correct
cor rect 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 th e manual
manual and actual vehicles due
due t o change in design and
and specifica -
tions. Any change or mod,ifications thereafter will be informed by
Toyota Industrial Equipment
Equipment Parts Service News.
For the service procedures

procedures of t he mounted engine,
engine, read the repair
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 2 2 ENGINE
TOYOTA MOTOR CORPORATION
https://www.forkliftpdfmanuals.com/

SECTIO
SEC TION
N IN DEX
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
0-2
VEHICLE MODEL 0 3
-
FRAME NUMBER 0 6
-
HOW TO READ THIS MANUAL ......................... 0 9

-
EXPLANATION
EXPLANATION METHOD 09
-
TERMINOLOGY 0 10
-10

ABBREVIATIONS 0 10
-10

OPERATIONAL TIPS 0-11

0-11
STA
STANDA
NDARD
TORQUERD BOLT NUT TIGHT
TIGHTENING
ENING 0-1
BOLT STRENGTH TYPE IDENTIFICATION

METHOD 0 12
-
TIGHTENING TORQUE TABLE ............................... 0 13

-
PRECOAT BOLTS 0 14
-
HIGH PRESSURE HOSE FITTING

TIGHTENING TORQUE ..................................... 0 14 -
IRE ROPE SU
SUSPEN
SPENSION
SION ANGLE LIST ............. 0 15 -
SAFE LOAD
LOAD F
FO
OR EAC
EACHH WlRE ROPE
SUSPENSION ANGLE 0-15
0-15
COMPONENTS WEIGHT ..................................... 0 16

-
RECOMMENDED LUBRICANT
QUANTITY TYPES 0-17
0-17
LUBRICATION CHART 0-19

0-19
PERIODIC MAINTENANCE 0-21
PERIODIC REPLACEMENT
REPLACEMENT OF PARTS
AND LUBRICANTS ........................................... 0 27 -

EXTERIOR VIEWS

VEHICLE MODEL
Series Load capacity Model Engine model Engine type Drive system
6FG
6FG 10 Gasoline Clutch
5K
02 -6FG 10 Torque converter
40 -6FG10 Clutch
1.0 ton 4Y
42 - 6FG
6FG 10 Torque converter
6FD
6FD 10 Diesel Clutch
1DZ
02 - 6FD10 Torque converter
6FG
6FG 1 4 Gasoline Clutch
5K
02 -6FG 14 Torque converter
40 -6FG
6FG 14 Clutch
1.35 ton 4Y
40 -6FG 1 4 Torque converter
6FD
6FD 1 4 Diesel Clutch
1DZ
02 - 6FD 14 Torque converter
1 ton series
5K
40 -6FG 1 5 Clutch
1.5 ton 4Y
6FD 1 5 Diesel Clutch

1DZ
02 - 6FD 1 5 Torque converter
6FG
5K
40- 6FG 18 Clutch

1.75 ton 4Y
42 -6FG
6FG 18 Torque converter
6FD
6FD 18 Diesel Clutch
1DZ
02 - 6FD 18 Torque converter
6FG20 Gasoline Clutch

5K
02 6FG20 Torque converter
40 -6FG 20 Clutch
2 to n seri
series
es 2.0 ton 4Y
60 6FD20 Diesel Clutch

1DZ
62 6FD20 Torque converter

Series Load capacity Model Engine model Engine type Drive system
6FD20 Diesel Clutch

2.0 ton 22
02 6FD20 t Torque converter

5K
40-6FG 23 Gasoline Clutch

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

5K
40 6FG25 t Clutch
4Y
42-6FG 25 t Torque converter
2.5 ton
1DZ
6FD25 t Clutch
22
6FG
4Y

2.75 ton 1DZ
6FD28 t Clutch
22
3 to n serie
series
s
6FG
4Y
02 6FG30 t Torque converter

3.0 ton 1DZ
62 6FD30 Torque converter
6FD
6FD 30 Clutch
22

South Africa
Series Load capacity Model Engine model Engine

Engine type Drive system
Torque
02 6FGA15 5K Gasoline
1.5 ton converter
1 ton series 02 - 6FDA 15 7 DZ Diesel t
02 6FGA18 5K Gasoline t
1.75 ton
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
3 to n series
series 3.0 ton 02 6FDA30 2 Diesel
62 6FDA30 1 DZ t t
Indonesia
Series Load capacity Model Engine

Engine model Engine type Drive system
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
3 t on ser
series
ies 3.0 ton
60 6FDN30 1 DZ t t

FRAME NUMBER
Frame No.. Punching
No Punching Position
Position
of frame
Engine Model Punching

Punching format
6F
6FG
G 10
02-
02 - 6FG
6FG 10
6FG
6FG 1 4
02-
02 - 6 FG
FG 1 4
5K
6FG 1 5
02-
02 - 6FG 1 5
6FG 1 8
02 - 6FG 1 8
40-
40 - 6FG
6FG 1 0
42-
42 - 6F
6FG
G 10
1 to n serie
series
s 40-
40 - 6 FG
FG 1 4
42-
42 - 6F
6FG
G 14
4Y
40-
40 - 6FG 15
42-
42 - 6FG 1 5
40-
40 - 6FG 18
42-
42 - 6FG 1 8
6FD
6FD 1 0
02-
02 - 6FD
6FD 10
1D Z 6FD
6FD 1 4 6FD18 10001
02-
02 - 6 FD
FD 1 4
6FD 1 5

ng~ne Model Punching format
02 - 6FD 1 5
1 ton series 1DZ 6FD

6FD 18 6FD18 10001
02 - 6FD18
6FG
6FG 20
02 6FG20
6F
6FG
G 23
5K 02 6FG23
6FG 2 5
02 6FG25
40 6FG20
42-6FG 20
40 6FG23
4Y
42-6FG 23
40 -6FG 2
42 6FG25
2 to n series
6FD20
02 6FD20
6FD23
22
02 6FD23
6FD25
02 6FD25
60 6FD20
62 6FD20
60 6FD23
1DZ
62 6FD23
60 6FD25
62 6FD25
6F
6FG
G 28
02 6FG28
4Y 6FG 30 - 1 0001
6FG
6FG 3 0
02 6FG30
60 6FD28
62 6FD28
3 to n series 1DZ 6 0 6 F D 3 0 10001
60 6FD30
62 6FD30
6FD28
02 - 6FD 28
22 6FD 30 - 1 0001
6FD30
02 6FD30

South Africa
Engine Model Punching format
02 6FGA15
5K 6FGA18 10001
02 - 6FGA 18
1 ton series
02 - 6FDA 1 5
1 DZ 6FDA 1 8 - 1 0 0 01
01
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 1 0 0 01
01
3 ton series 22 02 6FDA30 6FDA30 1 0 0 01

01
1DZ 62 6FDA30 606FDA30 10001
Indonesia
Engine Model Punching format
6FDN20
2Z 6FDN25 I 0 0 0 1
6FDN25
2 to n series
series
60 6FDN20
1 DZ 606FDN25 10001
60 6FDN25
2Z 6FDN30 6FDN30 10001

3 to n series
series
1 DZ 60 6FDN30 606FDN30 10001

HOW TO READ THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
(1) The operatio
operation
n procedure
procedure is described
described in either
either pattern A or pattern B below.
Pattern A: Expla
Explanatio
nation
n of each
each operation
operation step wi th a ph oto or illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration,
foll owed b y explanation of cautions and notes summarized
summarized as point operations.
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,
direct ly, the part name is described on
on
the either side of the illustration.
Example: 1 Piping
Disassembly Procedure
1 Remove the cover. [Point

Remove 11
2 Remove the bush [Point 21 l Operation explained later
3 Remove the gear.

gear.
Point operations Explanation of key point for operation with an illustration
[Point I
Disassemb
Disassembly:
ly: Put a match mark when removing t he pump cover
[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.1 2 m m (0.7528 in)

2. Ho w t o read components figures (Exam
(Example
ple))
1 The components figure uses the illustra -
tion in the parts catalog for the vehicle
model. Please refer to the catalog for
checking th e part name.
name.
The number
number at t he right shoulder of each FIG number in parts catalog
components figure indicates the Fig.
Fig. num-
be
berr in th e parts catalog
catalog..
3.
1 Matters omittedomits
) This manual i n this manual
manual of the fol lowing jo
description jobs
bs,, but per form them i n actual operation
operation::
8
Cleaning and washing of removed parts as required
2 Visual inspection (partially described)
TERMINOLOGY
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 sho win g allowable range

range in inspecti on and adjustment .
Limit: Maxim um or mini mum allowable value
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 00)
01s Oversize U S Undersize
W
PS Power steering With
RH Right hand L Less
Society of Automotive
SAE
Engineers (USA)

OPERATIONAL T P S
1. Safe operation
(1 ) After jacki
jacking
ng up
up,, always supp
support
ort wi th rig
rigid
id st
stands
ands..
(2 ) When hoist
hoisting
ing the veh
vehicle
icle or its he
heavy
avy compone
component,
nt, us e wire repe s) wit h a sufficient reser
use reserve
ve in
load capacity.
3 ) Always disconnect the battery plugs before the inspection or servicing of electrical parts.
2. Tactful operation
(1 Prepare
sure gauge,the mechanic tools, before
etc.) and SSTs necessary measuring
starting instruments (circuit tester, megger, oil pres -
operation.
(2 ) Before disconnecting wiring, always check the c cabl
ablee co
color
lor and wiring state.
3 ) When overhauling functional partparts,
s, complicated portions or rela
related
ted mechan
mechanisms,
isms, arr
arrang
ange e the parts
neatly
nea tly t o prevent confusion.
(4) Whe n disassemb
disassembling
ling and inspecting such a precision part as the cont rol valve, use clean tools
and operate in a clean location.
(5) Follow the described procedures for disassem
disassembly,
bly, inspection and reassembl
reassembly.y.
6 ) Rep
Replac
lace,
e, gaskets, pa ckin gs and O-rings with new ones each time they are disassembled.
7) Use genuine Toyota parts for replacement.
8)Use specified
specified bolt s and nuts. Obser
Observe
ve the specified tightening torque at th e time o f reassem
reassembly.
bly.
If no tightening torque is specifie
specified,
d, tighten th e bolt or n ut according to the stan
standard
dard tig
tightening
htening
torq ue table.
3. Grasping the trouble state

Grasping
When a trouble occurs,
occurs, do not attem pt immediate disa
disassem
ssembly
bly or replacement but firs t check if
the trouble requires disassembly or replacement for remedying.
4. Method for battery connection upon occu occurrenc e of ru n - down batteries on 2 4 - V specification ve-
rrence
hicle with 2 2 engine (with 1 2 / 2 4 V voltage switching system)
1 ) Connect a 1 2 - V aiding battery to the one on the rear

side
side of the t w o mounted batte
batteries
ries..
Mounted sid e
( 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 t he aidi
aiding
ng battery on t he fron t side of the vehicle
is connected to t he body grouground,
nd, conne ct the booster
cables
cabl es t o th e vehicl
vehicle
e side t o each correspondi
correspondingng termi-
nal.
Neverr c onnect betwe en aidin
Neve aidingg batteries.
(3) When the batteries are required to charge by the

charger,
charger, remove th e battery from t he vehicl
vehicle
e t o char
charge
ge
the battery.

0 -1 2
STANDARD
STAND ARD BO
BOLT
LT NU
NUTT TIGHTENING TORQ
TORQUE
UE
Standard bolt and tightening torques are not indicated.
Judge the standard tightening torque as shown below.
1. Find out the type

Find ty pe of the bolt from
f rom the list below and then
then find the bolt tightening torque from
fr om the
th e table.
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
6
7
=
=
5T
6T
7T
Parts No.
9161 1 -40625
head bolt L L e n g t h (mml
No mark 4T Diameter (mm)
Hexagon iameter
No mark 4T
flange bolt
Hexagon Two protruding
8
5T
head bolt lines
Hexagon Two protr

protruding
uding
6T Stud bolt
flange bolt lines
Hexagon Three protruding

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

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 mode

modell 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)
2.5 ton model Approx. 1555 (3429)
1 O - 1.75 Approx. 410 904)

ton mode
modell
2.0 ton model Approx. 460 101 4)

V mast ASSY Wllift bracket
(w it h lif t c
cylind
ylinder,
er, w itho ut fork, max. 2.25.2.5
lifting height: 3000 mrn 118 in)) ton mode
modell Approx. 500 1 103)
2.75-3.0 Approx. 570 (1257)

(1257)
ton mode
modell
1.0 - 1.75 Approx. 340 750)

ton model
2.0 ton model Approx. 370 (816)

V mast ASSY Lllift bracket and fork
(w it h lif t cylinder
cylinder max. lifting heigh
height:
t: 2.25.2.5
3000 mm 118 in))
Approx. 400 (882)
ton model
2.75.3.0 Approx. 445 (981

ton model
model

RECOMMENDED LUBRICANT QUANTITY & TYPES
Description Classification TY
TYpe
pe Application Quantity
Motor oil
SAE30 5K 4.0 1 (1.0 6 US gal)
SAE20 in cold area)
API
Gasoline
SD, SE
SAE20W-40
SAE1OW -30 in cold 4Y 4.0 1 (1. 06 US gal

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)
SAE1 OW- 30
API
Hypoid gear oil
Transmission GL - 4 Clutch models 4.0 (1.0 6 US gal)
gal)
SAE85W-90
GL- 5
Torque
Torque converter ATF GM Dexronm I converter 14.0 1 (3. 70 US
US gal)
models
API 1 t on series
series 5.4 (1.4 3 US gal)
Hypoid gear oil
Differential GL - 4 2 t on series 6. 4 (1.6 9 US gal)
gal)
SAE85W-90
GL -5 3 t on ser
series
ies 9.0 (2.3 8 US gal)
gal)
Hydraulic oil
I S0 Attached Table 2
[Max. f ork heigh
heightt = Hydraulic oil
VG32 Hydraulic oil volume
3000 mm 11 8 in)]
1 ton series 4 5 1 11.9 US gal)

Fuel tan k 2 to n series 65 (17.2 US gal)
gal)
3 t on ser
series
ies 6 5 1 17.2 US gal)
Proper quantity
SAE J - 1703
Brake and clutch line All models Reservoir Tank
DOT
DO T-3 0.2 (0.0 5 US gal)
gal)
Chassis
Chassis parts MP grease All models Proper quantity
LLC 30 - 50% mixture

mixture
(for winter or
Coolant
all-season) Attache d Table
Table 1
(exclud ing reservoir LLC
Coolant with rust- Coolant volume
tank)
inhibitor (for spring,
summer and autumn)
Coolant 1.1 (0. 29 US gal

gal))
All models
(Reservoir Tank) (at Full level)

Attached Table I Coolant
Coolant volume
volume Unit::
Unit 1 (US gal)
Engine Drive method 1 to n series

series 2 to n series
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:

Uni t: 1 (US gal)
Model 1 to n series
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) 3 4 9.0) 37 9.8)
22 engine models 39 10.3) 42 (11.1)
LUBRICATION CHART
Clutch Model
Inspection
Replacement
MP grease
Engine oil I. lnspect every 8 hours (daily)
ypoid gear oil 11 lnspect every
every 4 0 hours (weekly)
Hydraulic oil 111 lnspect
lnspect every 1 70 hours (monthly)
ypoid gear oil IV lnspect every 1000 hours (6 monthly)
Brake
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
Brak e and clutc h master cylinder Tilt steering universal joint
5 Transmission case Tilt steering locking mechanism
6 Rearr wh eel bearing
Rea Mast support bushing
7 Steering knuckle king pin Tilt cylinder front pin
8 Bell crank pin Propeller shaft
9 Oil tank Gearr shi ft link
Gea
Torque Converter Model
3 ln sp e ctlo n
Replacement
MP grease
Engine oil I. lnspect every 8 hours (daily)
H y p o l d gear 11 11 lnspect
lnspect every 4 0 hours
hours (weekly)
4 Hydraulic oil 111 lnspect every 170 hours (monthly)
5 utomatic transmission fluid IV. lnspect every 1000 hours (6 monthly)
Brake flu ld V. lnspect every 2000 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
11 tank
PERIODIC MAINTENANCE
INSPECTION METHOD
I :
Inspectio n. Repai
Repairr or replacemen t if required.
M : Measurement. Rep air or adjustm ent if required.
Repair
T : Retightening C Cleaning L : Lubrication
* : For new vehicle 1 : Flaw detector
Inspection
Inspec tion Period 1 Every
month 3 Every
months 6 Every
months 12Every
months
Every Every Every Every
tem 1 70 hour
hours
s 50 0 hours 100 0 hours 200 0 hours
ENGINE
Proper starting and abnormal noise I
Rotating condition at idling M c c
Rotating condition during

M t
acceleration
Exhaust gas condition I - - t
Main body Air cleaner element C t
Valve clearance M
Compression M
Cylinder head bolt loosen
loosening
ing T
Muffle r rubbe
rubberr 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 c
system
Clogging and dirt of oil filter I t
I t
Fuel leak
Operation of carburetor link
I t
mechanism
Dirt and clogging of fuel filter and
I t e
Fuel system l m nt
Injection timing M t
Injection nozzle injection pressur

pressure
e
M
and spray status
Draining of sedimenter I
Coolant level in radiator and leak I t -
Rubber hose degradation I -
Cooling Radiator cap condition I

- t 4
system
Fan belt tension, looseness and
I 4 e t
damage
Radiator rubber mount I
Inspection Period
Period Every Every Every Every
1 month 3 months 6 months 12 months
Item 17 0 hours
hours 50 0 hours
hours 10 00 hou
hours
rs 20 00 hours
hours
POWER TRANSMISSION SYSTEM
Clutch pedal play M t
Abnormal sound and functioning

I t t e
(connection)
Clutc h master cylin
cylinder
der function and
Clutch I t t e
leak
Fluid level I t
Oil clutch mechanism funct ion and

I t
leak
Leak I t
Transmission Fluid level I t t
Gear function and abnormal noise I
Leak I t - -
Differential Oil level I t t
Bolt loosening
Leak I
I T
-
Fluid level I t -
Torque Operating mechanism

mechanism function and
I 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 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
Tire groove depth M t t t
Wheels
Metal chips, pebbles and other for
I C t t
eign matt er trapped ..in

in tire groo ves
Rim, side ring and disc wheel
I t t t
damage
Abnormal sound and looseness of
I t t t
front wheel bearing
Inspection Period Every Every Every Every
1 month 3 months 6 months 12 m ont hs
Item 17 0 hours
hours 50 0 hours 10 00 hours
hours 20 00 hour
hour s
Abnormal sound and looseness
looseness of
Wheel I t t
rear wheel bearing

Cracks, damage and deformation of
Front axle I
housing
Cracks, damage and deformation of
Cracks,
I
beam
Rear axle
Looseness of axle beam in vehlcle
M
longitudinal direction
STEERING SYSTEM
Steering Play and looseness I t t
wheel Funct~on I t
Oil leak I - t
Gear box Looseness of mounting T t
Clogging of relief valve filter C

Looseness and damage I t
Rods, links
and arm Linkage wear and mounting condi
I
tion
leak
11 I t
Power
Mount ing and linkage looseness
looseness I t
Steering
Damage of power steering hose I
King pin looseness I - i
Knuckle
Cracks
Cracks and de formation 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
brake
Rod and cable looseness and
I t
damage
Leak, damage and mountin g
Leak,
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
leak and moun ting looseness
looseness
Inspection
Inspecti on Period Every Every Every Every
Item 17 0 hours 500 hou
hours
rs 1 hours 20 00 hours
Clearance
Clearance between dru
drumm and lining M t t t
Wear of shoe sliding portion and

I
lining
Brake drum Drum wear and damage I

and br ke
Shoe operating condition I
shoe
Anchor pin rusting I
Return spring fatigue M

Automatic adjuster function I
Backing Deformation,
Deformati on, cracks and damage I
plate Loose mounting T

MATERIAL HANDLING SYSTEM
Abnormality of fork and stopper pin I t -
Misalignmentt between left and right

Misalignmen
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 co
condi
ndi--
I t t t
tion of rollers
Wear and damage of roller pins

Wear and damage of mast strip I t - t
Tension, deformation
Tension, deformati on and dama
damage
ge
I t t t
of chain
chain an
and
d 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
(hydraulic drift )
Inspe ction Period Every Every Every Every
1 month 3 months 6 months 1 2 months
tem 17 0 ho
hours
urs 50 0 hours 10 00 hours
hours 200 0 hours
hours
Oil leak and damage I t - -
Wear and damage of pin and I t t t
Cylinder cylinder bearing

t - -
Lifting speed
speed M
Uneven movement I 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
Loose linkage I -
Control
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 -
ydraulic Deformation and damage I t t
piping
Loose joint T t + - t
ELECTRICAL SYSTEM
Cracks on distributor cap I t t t
Spark
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
gear meshing stat us t t t
motor
Charger Charging function I 4 t t
Battery fluid level I - - t
Battery
Battery fluid specific gravity M c
Damage of wiring harness I t t

Electrical
wiring Fuses I t t t
Inspection Period Every Every Every Every
1 month 3 months 6 months 12 m onths
onths
Item 17 0 hour
hours
s 50 0 hours
hours 1 0 0 0 hours 20 00 hour
hourss
Open - circ
circuit
uit i n 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
Loosening of moun ting T t t t
Back- rest
Deformation, crack and damag
damage
e 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 Re
Rear
ar reflection sta tus I t t t
Seat Loosening and damage of mounting I t t t
Damage and cracks

cracks of frame,
frame, cross
I
Body members, etc.
Bolt looseness T
Others Grease up L t t
PERIOD
PERIODIC
IC REPLACEME
REPLACEMENT
NT OF PARTS A N D LUBRIC ANTS
a : Replacement

Item 17 0 ho
hour
urs
s 50 0 hour
hours
s 1 hours 20 00 hou
hours
rs
• -
Engine oil
Engine oil filter •
-
Engine coolant (every 2 years for LLC •
Fuel filter •
Torque converter oil •
Torque converter oil filter •
Transmission oil •
Differential oil •
Hydraulic oil •
Hydraulic oil return filter 0 •

-
Wheel bearing greas

grease
e •
Spark plugs •
Air cleaner element

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

Power steering rubbers parts
Hydraulic hoses .
Brake fluid reservoir tank hose 0 e 2
Fuel hoses .
Torque converter rubber hoses .
Chains
1: for n ew vehicl
vehicle
e 2: Every 2 years 3: Every 3 years
Replacemen
Replacementt sha
shallll be made upon arrival
arrival of t he operation hours or months, whichever is earlier.
earlier.

ENGINE
Page
ENGINE SECTIONAL
SECTIONAL VIEWS 1 2
1 4
MAJOR SPECIFICATIONS -
ENGINE PERFORMANCE CURVES ..................... 15
-
ENGINE ASSY 17
-
ENGINE W I T R A N S M I S S I O N
EMOVAL.INSTALLATION ................................ 17
-
ENGINE R E M O V A L . I N S T A L L A T I 0 N 1 11
-
ENGINE W I T O R Q U E CONVERTER
REMOVAL INSTALLATION
- 1 12
.
ENGINE REMOVAL.INSTALLATION ....................... 1 15
-
ENGINE
ENGINE SPEE
SPEED
D ADJUST
ADJ USTMEN
MEN T 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 Z Engine
22 Engine

1DZ Engine
1 ton series 17.011600

17.011600 2.3 ton series 17.011
17.011600
XI 0'
Engine speed (rpm) Engine speed (rprn) x 10
Engine
22.011600
m
Y
c
V
6612200
a
1C
V
1 5411 600
.K
P
. C
w
I I
11 d 8 22 26 LL
X1 0'
Engrne speed (rprn)
ENGINE ASSY
ENGINE W I T R N S M I S S I O N REMOVAL INSTALLATION

-
1 Radiator cover
3 Toe board
8 Under cover and tire cover
9 Coolant
12 Fuel hose
13 Accelerator wire
19 Electrical
Electrical wiring
1 Remo
Remove
ve the radiator cover.
2 Remove the
th e engine hood.
3 Remove
Remove the toe board.
board.
4 Remove
Remove the battery
batter y and battery case.
case.
5 Disconnect the electrical parts wiring, and remove the bracket Wlelectrical parts.
ep the fuse box free by removing the set bolts.)
(Keep
(Ke
6 Remove
Remove the
th e radiator reservoir
reservoir tank.
7 Remove the air cleaner: [Point 11
8 Remove the undercover and tire cover RH.

(Only 2 2 engine models)
9 Drain the coolant.
1 0 Remov
Remove
e the radiator.
radiator.
1 1 Disconnect the exhaust pipe.
[Point 21
1 2 Disconnect the fuel hose. [Point
1 3 Disconnect the accelera

accelerator
tor wire. (Disconnect on the carburetor side
side on gasoline engine models, or
or
on the
t he injection
in jection pump side on diesel
diesel engine
engine models.)
models.)
1 4 Remove
Remove the frame side
side covers RH (rear and front).
fron t).
Remove the oil pump Wlpump hose.

15 Remove
1 6 Remove
Remove the horn.
1 7 Disconnect the clutch release

release cylinder from the clutc
clutch housing and keep it free.
h housing
1 8 Disconnect the gear ever link rod. [Point 31

gear shift llever
1 9 Disconnect electrical wiring.
2 0 Remove
Remove the propelle
propellerr shaft cover and
and propeller
propeller shaft.
21 Remove
Remove the transmission mounting set bolts.
2 2 Remove
Remove the engin
engine
e mounting set nuts.
2 3 Remove engine Wltransmission [Point

Remove the engine 41
Installation Proc
Procedu
edure
re
The installation procedure is the reverse of the removal procedure.
Note:
Bleed air fro m the fuel
fu el system after engine installation.
installation. (In diesel engine
engine models only)
Bleeding Air from Fuel System (Diesel Engi
Engine
ne Mo
Models)
dels)
1D Z 2Z engine
1. Operat
Operatee the fuel filter hand pump unti l the pump oper
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

air cleaner
cleaner case
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) Rotat
Rotate
e the connector
connector upward as illustrate d and dis-
dis -
connect at the position where the pillar side notch
aligns
aligns wit h the connector
connector flange protrude d portion.
3. Reverse the removal procedure for installation.
[Point 21
Installation: Do not mistake the fuel hose connecting po -

sition. (Gasoline
(Gasoline engine models)
[Point 31
Removal:
Removal: Wrap each of the disconnected rod and th e
freed
freed shift lever wi th tape for holding i n place.
[Point 41
Removal.lnstallation: SST 0901

090100-201 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.

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This manual covers the service procedures of the TOYOTA FORKLIFT

vicing of the corresponding forklift models.

For the service procedures

TOYOTA INDUSTRIAL EQUIPMENT 5K ENGINE

REPAIR MANUAL (No.CE625)

TOYOTA MOTOR CORPORATION

OIL CONTROL VALVE

HOW TO READ THIS MANUAL ......................... 0 9

OPERATIONAL TIPS 0-11

BOLT STRENGTH TYPE IDENTIFICATION

TIGHTENING TORQUE TABLE ............................... 0 13

HIGH PRESSURE HOSE FITTING

COMPONENTS WEIGHT ..................................... 0 16

LUBRICATION CHART 0-19

PERIODIC MAINTENANCE 0-21

6FD 1 5 Diesel Clutch

40- 6FG 18 Clutch

6FG20 Gasoline Clutch

60 6FD20 Diesel Clutch

6FD20 Diesel Clutch

6FG23 Gasoline Clutch

40-6FG 23 Gasoline Clutch

6FG25 Gasoline Clutch

60 6FD28 Diesel Clutch

60 6FD30 Diesel Clutch

Series Load capacity Model Engine model Engine

1 ton series 02 - 6FDA 15 7 DZ Diesel t

2.0 ton 02 6FDA20 2Z Diesel t

2.5 ton 02 6FDA25 22 Diesel t

Series Load capacity Model Engine

6FDN20 2Z Diesel Clutch

Engine Model Punching

1 ton series 1DZ 6FD

Engine Model Punching format

3 ton series 22 02 6FDA30 6FDA30 1 0 0 01

Engine Model Punching format

2Z 6FDN30 6FDN30 10001

Example of description in pattern B

DISASSEMBLY INSPECTION REASSEMBLY

If a place or part cannot be indicated

1 Remove the cover. [Point

2 Remove the bush [Point 21 l Operation explained later

3 Remove the gear.

Point operations Explanation of key point for operation with an illustration

Standard: Values sho win g allowable range

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 00)

01s Oversize U S Undersize

3. Grasping the trouble state

1 ) Connect a 1 2 - V aiding battery to the one on the rear

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

(3) When the batteries are required to charge by the

1. Find out the type

BOLT STRENGTH TYPE IDENTIFICATION METHOD

1. Identification by bolt shape 2. Identification by part No.