Toyota FGC33/35/40/45 FDC33/35/40/45 Forklift Workshop Service & Repair Manual PDF - MTOINFDCFGC95687.zip
Toyota Forklift FGC33/35/40/45, FDC33/35/40/45 Repair Service Manual
This all-inclusive repair and service guide, complete with Electrical Wiring Diagrams, covers Toyota Forklift Models FGC33, FGC35, FGC40, FGC45, FDC33, FDC35, FDC40, and FDC45. Packed with the technical detail needed to service, troubleshoot, and overhaul your equipment the way a professional technician would.
Toyota Forklift FGC33-35-40-45, FDC33-35-40-45 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
This manual covers the inspection, adjustment and repair procedures mainly for the overhaul of the engine, chassis and material handling system of the Toyota Forklift FDC33, 35, 40, 45
Series, FGC33, 35, 40, 45 Series. The titles of the related repair manuals are as follows:
TOYOTA 2H ENGINE REPAIR MANUAL
TOYOTA 2F ENGINE REPAIR MANUAL
PRODUCT DETAILS:
Total Pages: 326 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
95687 - Toyota Forklift FGC33-35-40-45, FDC33-35-40-45 Series Service Repair Manual .pdf
MAIN SECTIONS
GENERAL
ENGINE
TORQUE CONVERTER
DIFFERENTIAL
FRONT AXLE
REAR AXLE
STEERING
BRAKE
BODY
MATERIAL HANDLING SYSTEM
APPENDIX
TABLE OF CONTENTS
95687R0.pdf.......2
PREFACE.......2
GENERAL.......3
VEHICLE EXTERIOR VIEWS .......3
VEHICLE MODELS .......4
FRAME NUMBER .......5
LOAD CAPACITY CHART .......6
VEHICLE DIMENSIONS .......7
STANDARD BOLT & NUT TIGHTENING TORQUE JUDGING PROCESS .......8
STANDARD BOLT TIGHTENING TORQUE .......9
ABBREVIATION AND OPERATIONAL TIPS .......10
RECOMMENDED LUBRICANTS .......11
PERIODIC MAINTENANCE .......12
PERIODIC REPLACEMENT PARTS AND LUBRICANTS .......21
LUBRICATION .......22
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95687R1.pdf.......23
ENGINE.......23
GENERAL.......23
ENGINE PERFORMANCE CURVE .......24
SPECIFICATIONS .......25
REMOVAL .......26
INSTALLATION .......31
ENGINE ADJUSTMENT (DIESEL MODEL) .......32
ENGINE ADJUSTMENT (GASOLINE MODEL) .......33
ACCELERATOR PEDAL .......34
AIR CLEANER .......35
RADIATOR .......36
MUFFLER .......38
BATTERY .......39
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95687R2.pdf.......40
TORQUE CONVERTER.......40
GENERAL .......40
HYDRAULIC CIRCUIT DIAGRAM .......42
SPECIFICATIONS .......43
TROUBLE SHOOTING .......44
COMPONENT PARTS .......51
TORQUE CONVERTER CASE .......51
TORQUE CONVERTER .......52
MAIN CLUTCH .......53
FORWARD 2-SPEED CLUTCH .......54
COUNTER GEAR AND OUTPUT GEAR .......55
CONTROL VALVE .......56
TORQUE CONVERTER OIL COOLER .......57
SERVICE STANDARDS .......58
UPPER COVER AND CONTROL VALVE ASSY .......60
REMOVAL.......60
DISASSEMBLY .......62
INSPECTION .......65
ASSEMBLY .......67
INSTALLATION.......69
ADJUSTMENT .......70
SELECTOR LEVER ADJUSTMENT .......70
CONTROL LEVER ADJUSTMENT .......70
INCHING LEVER ADJUSTMENT.......70
TORQUE CONVERTER .......72
REMOVAL .......72
DISASSEMBLY .......74
INSPECTION .......76
ASSEMBLY .......78
INSTALLATION .......81
STATOR SHAFT AND OIL PUMP .......82
REMOVAL .......82
DISASSEMBLY.......82
INSPECTION .......84
ASSEMBLY .......86
INSTALLATION.......87
REMOVING THE TORQUE CONVERTER AND TRANSMISSION ASSEMBLY WITH DIFFERENTIAL .......88
REMOVAL .......88
TRANSMISSION .......93
DISASSEMBLY.......93
INSTALLATION.......120
MEASUREMENT AND TEST.......121
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95687R3.pdf.......124
DIFFERENTIAL.......124
GENERAL .......124
SPECIFICATIONS.......124
COMPONENT PARTS .......125
SERVICE STANDARDS .......126
REMOVAL.......126
DISASSEMBLY .......127
INSPECTION .......133
ASSEMBLY AND ADJUSTMENT .......135
DRIVE PINION PROTRUSION ADJUSTMENT .......140
RING GEAR BACKLASH AND SIDE BEARING PRELOAD ADJUSTMENT .......142
TOOTH MESHING CHECK .......144
ASSEMBLY.......146
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95687R4.pdf.......147
FRONT AXLE.......147
SPECIFICATIONS .......147
SERVICE STANDARDS .......147
GENERAL .......148
COMPONENT PARTS .......149
DISASSEMBLY .......150
INSPECTION .......153
ASSEMBLY .......155
FRONT AXLE & DIFFERENTIAL HOUSING .......158
REMOVAL .......158
INSPECTION .......161
ASSEMBLY .......162
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95687R5.pdf.......163
REAR AXLE.......163
GENERAL .......163
COMPONENT PARTS .......164
SPECIFICATION .......166
REMOVAL .......167
DISASSEMBLY .......169
INSPECTION .......173
DISASSEMBLING THE REAR AXLE CYLINDER .......175
INSPECTING THE REAR AXLE CYLINDER .......176
ASSEMBLING THE REAR AXLE CYLINDER .......177
ASSEMBLY .......178
INSTALLATION .......182
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95687R6.pdf.......184
STEERING.......184
GENERAL .......184
HYDRAULIC CONTROL VALVE.......185
STRUCTURE.......185
HYDRAULIC CONTROL VALVE INTERNAL STRUCTURE .......186
OPERATION.......187
RELIEF VALVE .......191
HYDRAULIC POWER STEERING COMPONENT PARTS .......192
SPECIFICATION AND SERVICE STANDARD.......193
HYDROSTATIC POWER STEERING CONTROL VALVE .......193
REMOVAL.......193
DISASSEMBLY.......196
INSPECTION.......198
ASSEMBLY.......199
INSTALLATION.......201
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95687R7.pdf.......202
BRAKE.......202
GENERAL .......202
SPECIFICATIONS .......203
SERVICE STANDARDS.......203
FOOT BRAKE .......204
COMPONENT PARTS .......205
DISASSEMBLY .......206
INSPECTION .......209
ASSEMBLY .......211
AUTO ADJUSTER TEST .......215
BRAKE ADJUSTMENT .......216
BRAKE VALVE .......217
COMPONENT PARTS .......217
TROUBLESHOOTING .......218
REMOVAL .......220
DISASSEMBLY .......221
INSPECTION .......223
ASSEMBLY .......225
INSTALLATION.......226
ACCUMULATOR .......227
COMPONENT PARTS .......227
REMOVAL .......228
DISASSEMBLY.......228
INSPECTION .......229
ACCUMULATOR OPERATION INSPECTION .......229
INSTALLATION.......229
CHARGE PUMP .......230
SPECIFICATIONS.......230
COMPONENT PARTS .......231
REMOVAL .......232
DISASSEMBLY .......232
INSPECTION .......234
ASSEMBLY .......235
INSTALLATION.......235
PARKING BRAKE .......236
COMPONENT PARTS .......236
REMOVAL .......237
INSPECTION .......239
INSTALLATION.......239
ADJUSTMENT .......239
BRAKE PEDAL .......240
COMPONENT PARTS .......240
ADJUSTMENT.......240
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95687R8.pdf.......241
BODY.......241
COMPONENT PARTS .......241
ENGINE HOOD REMOVAL .......242
TOE BOARD.......242
BALANCE WEIGHT .......243
WIRING DIAGRAM (DIESEL MODEL) .......244
WIRING DIAGRAM (GASOLINE MODEL) .......245
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95687R9.pdf.......246
MATERIAL HANDLING SYSTEM.......246
GENERAL .......246
HYDRAULIC PIPING .......247
NATURAL DROP TEST .......248
NATURAL FORWARD TILT TEST .......248
OIL LEAK TEST .......249
MAST .......250
CYLINDER .......273
OIL PUMP .......296
OIL CONTROL VALVE .......309
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95687R10.pdf.......324
APPENDIX.......324
SST LIST .......324
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