Toyota 6FG, 6FD10-30 Repair Manual
FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT
6FGl6FD 10- 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
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
&
Service News.
(No.CE617)
-
-
-
TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINE
REPAIR MANUAL
TOYOTA INDUSTRIAL EQUIPMENT 1DZ ENGINE
REPAIR MANUAL
TOYOTA INDUSTRIAL EQUIPMENT 22 ENGINE
REPAIR MANUAL
(No.CE602)
(No.CE618)
(No.CE625)
TOYOTA MOTOR CORPORATION
SECTION INDEX
I
NAME
GENERAL
ENGINE
CLUTCH
-
TORQUE CONVERTER
TRANSMISSION
PROPELLER SHAFT
DIFFERENTIAL
FRONT AXLE
I
SECTION
REAR AXLE
STEERING
@
BODY
MATERIAL HANDLING SYSTEM
CYLINDER
OIL PUMP
OIL CONTROL VALVE
@
GENERAL
Page
EXTERIOR VIEWS
VEHICLE MODEL
FRAME NUMBER
HOW TO READ THIS MANUAL
EXPLANATION METHOD
TERMINOLOGY
ABBREVIATIONS
OPERATIONAL TIPS
STANDARD BOLT
TORQUE
BOLT STRENGTH TYPE IDENTIFICATION
METHOD
TIGHTENING TORQUE TABLE
PRECOAT BOLTS
...........................................................
........................................................
...............................................
...............................................
................................................
.........................
......................................
.................................................
.................................................
...........................................
&
NUT TIGHTENING
...............................
...............................................
0-2
0-3
0-6
0-9
0-9
0-10
0-10
0-11
'0-1 2
0-12
0-13
0-14
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE
WIRE ROPE SUSPENSION ANGLE LIST
SAFE LOAD FOR EACH WlRE ROPE
SUSPENSION ANGLE
COMPONENTS WEIGHT
RECOMMENDED LUBRICANT
QUANTITY
LUBRICATION CHART
PERIODIC MAINTENANCE
PERIODIC REPLACEMENT OF PARTS
AND LUBRICANTS
&
TYPES
.....................................
.......................................
.....................................
.......................................
........................................
..................................
...........................................
.............
0-14
0-15
0-15
0-16
0-17
0-19
0-21
0-27
EXTERIOR VIEWS
VEHICLE
MODEL
Series
1 ton series
Load capacity
1.0 ton
1.35 ton
Model
6FG 10
-
6FG 10
02
-
6FG 10
40
-
6FG 10
42
6FD 10
-
6FD 10
02
6FG 14
02
-
6FG 14
-
6FG 14
40
40
-
6FG 1 4
-
6FD 14
02
02
-
6FG 1 5
6FD 14
6FG 1 5
Engine model
5K
4Y
1DZ
5K
4Y
1 DZ
5K
Engine type
Gasoline
t
t
t
Diesel
t
Gasoline
t
t
t
Diesel
t
Gasoline
t
Drive system
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
2 ton series
1.5 ton
1.75 ton
2.0 ton
-
6FG 1 5
40
-
6FG 1 5
42
6FD 1 5
02
-
6FD 1 5
6FG 18
-
6FG 1 8
02
-
6FG 18
40
-
6FG 18
42
6FD 18
-
6FD 18
02
6FG20
02-6FG20
40-6FG 20
42-6FG20
4Y
1 DZ
5K
4Y
1 DZ
5K
4Y
t
t
Diesel
t
Gasoline
t
t
t
Diesel
t
Gasoline
t
t
t
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
60-6FD20
62-6FD20
1 DZ
Diesel
t
Clutch
Torque converter
Series
Load capacity
Model
Engine model
Engine type
Drive system
2 ton series
2.0 ton
2.25 ton
2.5 ton
6FD20
02-6FD20
6FG23
02-6FG23
40-6FG 23
-
6FG 23
42
60-6FD23
62-6FD23
6FD23
02-6FD23
6FG25
02-6FG25
40-6FG25
42-6FG 25
60-6FD25
62-6FD25
5K
4Y
1
5K
4Y
1
22
DZ
22
DZ
Diesel
t
Gasoline
t
Gasoline
t
Diesel
t
t
t
Gasoline
t
t
t
Diesel
t
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
3 ton series
2.75 ton
3.0 ton
6FD25
02-6FD25
6FG 28
02-6FG28
60-6FD28
62-6FD28
6FD28
02-6FD28
6FG 30
02-6FG30
60-6FD30
62-6FD30
6FD 30
02-6FD30
4Y
1
22
4Y
1
22
22
DZ
DZ
't
t
Gasoline
t
Diesel
t
t
t
Gasoline
t
Diesel
t
t
t
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
Clutch
Torque converter
South Africa
Series
1 ton series
2 ton series
3 ton series
Load capacity
1.5 ton
1.75
ton
2.0 ton
2.5 ton
3.0 ton
Model
02-6FGA15
02-6FDA 15
02-6FGA18
02-6FDA18
42-6FGA20
02-6FDA20
62-6FDA20
42-6FGA25
02-6FDA25
62-6FDA25
02-6FGA30
pp
02-6FDA30
Engine model
5K
7
DZ
5K
1
DZ
4Y
Z
2
1 DZ
4Y
22
1 DZ
22
Engine type
Gasoline
Diesel
Gasoline
Diesel
Gasoline
Diesel
t
Gasoline
Diesel
t
Diesel
Drive system
Torque
converter
t
t
t
t
t
t
t
t
t
t
Indonesia
Series
2 ton series
3 ton series
Load capacity
2.0 ton
2.5 ton
3.0 ton
62-6FDA30
Model
6FDN20
60-6FDN20
6FDN25
60-6FDN25
6FDN30
60-6FDN30
1 DZ
Engine model
2 Z
1 DZ
2 Z
1 DZ
22
1 DZ
t
Engine type
Diesel
?
t
t
t
t
t
Drive system
Clutch
t
t
?
t
t
FRAME NUMBER
Frame
No. Punching Position
of
frame
1
ton series
Engine
5K
4Y
1 DZ
Model
-
6FG 10
02
02
-
6FG 14
-
6FG 1 5
02
6FG 1 8
02
-
6FG 1 8
40
-
6FG 10
-
6FG 10
42
40
-
6FG 14
42
-
6FG 14
-
6FG 15
40
-
6FG 1 5
42
40
-
6FG 18
-
6FG 1 8
42
6FD 10
-
6FD 10
02
6FD 14
02
-
6FD 14
6FD 1
Punching format
6FG 10
6FG 14
6FG 1 5
6FD18-10001
5
1
ton series
2
ton series
3
ton series
Eng~ne
1
DZ
5K
4Y
22
1 DZ
4Y
1
DZ
22
Model
02-6FD 1 5
6FD 18
-
6FD 18
02
6FG 20
02-6FG20
6FG 23
02-6FG23
6FG 2 5
02-6FG25
40-6FG20
42-6FG 20
40-6FG23
42-6FG 23
40
-
6FG 2
5
42-6FG25
6FD20
02-6FD20
6FD23
02-6FD23
6FD25
02-6FD25
60-6FD20
62-6FD20
60-6FD23
62-6FD23
60-6FD25
62-6FD25
6FG 28
02-6FG28
6FG 30
02-6FG30
60-6FD28
62-6FD28
60-6FD30
62-6FD30
6FD28
02-6FD 28
6FD30
02-6FD30
Punching format
6FD18-10001
6FG 30- 1
606FD30- 1 000
6FD 30- 1
000
000
1
1
1
South
Africa
1
ton series
2
ton series
3
ton series
Engine
5K
1 DZ
4Y
22
1 DZ
4Y
22
1 DZ
Model
02-6FGA15
02-6FGA 18
-
02
6FDA 1
5
02-6FDA 18
42-6FGA20
42-6FGA25
02-6FDA20
02-6FDA25
62-6FDA20
62-6FDA25
02-6FGA30
02-6FDA30
62-6FDA30
Punching format
6FGA18-10001
6FDA 1 8- 1 000 1
406FGA25- 10001
6FDA25-10001
606FDA25-10001
6FGA30- 1000 1
6FDA30- 1000 1
606FDA30-10001
Indonesia
2
ton series
3
ton series
Engine
2
Z
1 DZ
2 Z
1 DZ
Model
6FDN20
6FDN25
60-6FDN20
60-6FDN25
6FDN30
60-6FDN30
Punching format
6FDN25-I 0001
606FDN25- 10001
6FDN30-10001
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:
Pattern B:
followed by explanation of cautions and notes summarized as point operations.
Explanation of each operation step with a photo or illustration.
Explanation of operation procedure by indicating step numbers in one illustration,
Example of description
DISASSEMBLY -INSPECTION-REASSEMBLY
If a place or part cannot be indicated
directly, the part name is described on
the either side of the illustration.
1
Example:
Piping
in
pattern B
Tightening torque unit T = N-m (kg-cm)
Disassembly Procedure
Remove the cover.
1
2
Remove the bush
3
Remove the gear.
Point operations
[Point
Disassembly: Put a match mark when removing the pump cover
[Point
Inspection:
1
21
I
Explanation of key point for operation with an illustration
Measure the bush inside diameter.
Bush inside diameter limit:
[Point
[Point
21
I
11
cl
Operation explained later
2
19.1
mm
(0.7528
in)
2.
How to read components figures (Example)
The components figure uses the illustra
(1
tion in the parts catalog for the vehicle
model. Please refer to the catalog for
checking the part name.
The number at the right shoulder of each
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:
Cleaning and washing of removed parts as required
2
Visual inspection (partially described)
8
-
FIG number in parts catalog
-
I
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 requiring special attention.
Standard: Values showing allowable range in inspection and adjustment.
Limit:
Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONS
Abbreviation (code)
ASSY
H
L
LLC
OPT
01s
PS
RH
SAE
Meaning
Assembly
Left hand
Long life coolant
Option
Oversize
Power steering
Right hand
Society of Automotive
Engineers (USA)
Abbreviation (code)
SST
STD
=
T
OOT
U
IS
W/
L/
Meaning
Special service tool
Standard
Tightening torque
Number of teeth
Undersize
With
Less
(0
0)
OPERATIONAL
1. Safe operation
(1) After jacking up, always support with rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire
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 to 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 with 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 to 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.
TIPS
repe(s) with a sufficient reserve in
-
4.
Method for battery connection upon occurrence of run-down batteries on 24-V specification ve
hicle with
22
engine (with
12/24 V
Mounted
side
voltage switching system)
(1)
Connect a 12-V aiding battery to the one on the rear
side of the two mounted batteries.
(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
nal of the aiding battery on the front side of the vehicle
is connected to the body ground, connect the booster
cables to the vehicle side to each corresponding termi
nal.
Never connect between aiding batteries.
(-1
termi
-
-
-
-
(3)
When the batteries are required to charge by the
charger, remove the battery from the vehicle to charge
the battery.
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