Toyota 5FDC Series, Manual

Page 1: ...iptions in the manual and actual vehicles due to change in design and specifications Any change or modifications thereafter will be informed by Toyota Industrial Vehicles Parts Service News For the se...

Page 2: ...SECTION INDEX GENERAL TORQUE CONVERTER PROPELLER SHAFT DIFFERENTIAL FRONT AXLE REAR AXLE I STEERING BRAKE BODY y 0 MAST CYLINDER OIL PUMP OIL CONTROL VALVE APPENDIX...

Page 3: ...UT TIGHTENING TORQUE PRECOAT BOLTS HIGH PRESSURE HOSE FllTlNG TIGHTENING TORQUE FRAME NUMBER SAFE LOAD BY WIRE ROPE SUSPENSION ANGLE WIRE ROPE SUSPENSION ANGLE LIST CAPACITY AND TYPES OF SPECIFIED LUB...

Page 4: ...VEHICLE EXTERIOR VIEWS Vehicle Front View LAPI 8 8 Vehicle Rear View LAPI 8 4...

Page 5: ...1 2 0 ton 42 g i n e i Torque converter Mounted I englne 1 Eng netype 5FGC25 42 E iine Torque converter 1 1 5FDC25 I t I I I Power transmlsslon I i 2 2 5 t o n I 5FGC23 4 Y I I Remarks 3 ton serles I...

Page 6: ...s and underlines 1 Keep the working place neat and orderly to make operation easler 2 Hydraulic equipment should be disassembled with clean tools in clean places 4 Genulne Toyota parts Always use genu...

Page 7: ...by part number 1 Shape and description I Strength code 4 4T 1 Number in relief or 5 5T Hexagon I hallmark on head 6 6T bolt I I I 7 7T Standard I I Hexagon bolt I Part number example 3 4 0 6 0 L Nomi...

Page 8: ...TIGHTENING TORQUE TABLE Standard Collar 1 head head Standard t ghten ng torque kg cm ft lb...

Page 9: ...pressure hose wipe the high pressure hose fitting and mating n pple contact surfaces with clean cloth to remove foreign matters and dirt Check that there IS no dent or other surface defect on the cont...

Page 10: ...1 2 1 0 2 8 2 7 2 4 2 0 1 0 4 in 1 1 1069 1 565 6 3153 30211 2646 2205 11 6174 5954 5292 4410 2J 5FDC30 5FDC30 10001 5FDC30E10001 Un filar Breakdown load 2 18 4807 12 5 mrn 0 5 n 14 mrn SusPen sion 0...

Page 11: ...on method Suspen s on Ten I C O P S angle On I strength method 1 I I I I 1 1 I I I I I I I 1 I 30 I 027 1 t o e tme I times 1 times I I I 1 1 6 1 0 5 8 60 tmes tme 1 I I i I Suspen angle slon ston str...

Page 12: ...r oil SAE85W 90 Hydraulic oil 90 Torque converter Differential Hydraulic oil Fuel tank All models All models 4Y 2J Chassis parts Coolant 45P 12 US gal Proper quantity 9 OP 2 38 US gal 9 51 2 51 US gal...

Page 13: ...sal jolnt Tllt steerlng locking mechanism Mast support bushing T lt cylinder front pin Propeller shaft Inspect every 8 hours dally lnspect every 40 hours weekly inspect every 170 hours monthly lnspect...

Page 14: ...tion during acceleration Exhaust gas Air cleaner element Valve clearance Compression Cylinder head bolt loosening Clogging and damage of PCV valve and piping No load maximum engine speed Oil leakage O...

Page 15: ...converter and transmis sion Propeller shaft and axle shaft 6 1000 t Oil leakage Oil level Loose bolts Oil leakage Oil level Operating mechanism function and looseness Control valve and clutch function...

Page 16: ...el bearing abnormal sound and looseness Rear wheel bearing abnormal sound and looseness Housing crack damage and deforma tion Beam crack damage and deformation Looseness of axle beam in vehicle longit...

Page 17: ...Braking effect Looseness and damage of rod and cable Looseness and damage of level link Leakage damage and installation status Function wear damage oil leakage and loosening of installation Clearance...

Page 18: ...amage and rotation status Roller pin wear and damage Mast strip wear and damage Chain tension deformation and damage Chain lubrication Abnormality of chain anchor bolt Chain wheel wear damage and rota...

Page 19: ...ressure measurement Relief valve and tilt lock valve func Deformation and damage Looseness of joints Hose tension and torsion Distributor side terminal burning Wear and damage of distributor cap cente...

Page 20: ...Deformation crack and damage...

Page 21: ...r parts Master and wheel cylinder cups and seals Power steering hose Power steering rubber parts Hydraulic hose Reservoir tank tube Fuel hose Torque converter rubber hose Chain Every month Every six E...

Page 22: ...PERFORMANCE ENGINE PERFORMANCE CURVES ENGINE ASSY W TORQUE CONVERTER TRANSMISSION ENGINE ASSY ENGINE SPEED ADJUSTMENT AIR CLEANER RADIATOR MUFFLER EXHAUST PIPE BATTERY STARTING MOTOR ALTERNATOR ACCEL...

Page 23: ...GENERAL 2J Engine Front View 4 7 2J Engine Rear View 26...

Page 24: ...4Y Engine Front Righthand View 4Y Eng ne Rear Lefthand View...

Page 25: ...spiace i I 1 Engne statlc maxlmum Rated output Max mum torque ton seres i I 23 2481 I ment speed 1 PS rpm kg v rpm I 1 I I 1 4Y 2237 2700 54 2400 16 5 1800 2600 3 ton series I I 1 2J 2481 2600 1 50 25...

Page 26: ...ENGINE PERFORMANCE CURVES I I I I I 6 10 14 18 22 26 XI 02 Engine speed rpm 2J Engine Performance Curves 29 KAHM 19...

Page 27: ...u I I 1 I I 6 I 10 14 18 22 27 x 102 Engine speed rpm...

Page 28: ...attery negative terminal first 2 Remove the battery stopper 3 Remove the battery ASSY 4 Battery case removal 1 Remove the set bolts 2 pcs and remove the battery 5 Electr cal wiring and fuel hose disco...

Page 29: ...or reservoir tank removal I Dlsconnect the reservoir tank hose from the radiator 2 Remove the reservoir tank Removing the Radiator Cover 2 2 8 10 Rad ator ASSY removal I Loosen the radiator drain plug...

Page 30: ...pipe Disconnecting the Exhaust Pipe 1 3 1 1 1 2 Accelerator flex ble wire disconnect on 1 Disconnect the wire clevis from the injection pump 2 Disconnect the accelerator cable bracket from the manifol...

Page 31: ...necting the Torque Convener Link Portion 3 r g z o 16 Propeller shaft ASSY disconnection 1 Remove the set bolts 2 pcs and remove the propeller shaft cover 2 Remove the propeller shaft set bolts 4 pcs...

Page 32: ...n mounting set bolts 19 Check fany electr cal wiring cable or link IS left connected Removing the Set Bolts 3 2 2 20 Englne ASSY W torque converter trans mlsslon removal I Use the SST and remove the e...

Page 33: ...removal 1 j Remove the set bolts 3 pcs and remove the battery case 5 Electr cal wirlng and fuel hose drsconnec tion 1 Disconnect the starting motor bond strap 2 Disconnect the connector of each elect...

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