B & L EQUIPMENT INC, 7318 NORTHERN BOULEVARO EAST SYRACUSE, NEW YORK 12057 PHONE (i) 450-00 a veneer errPrepared by TOYOTA MOTOR CORPORATION No, 23-22 Izumi 1-chome, Higashi-ku Nagoya, Japan ‘Ist Printing: April 1980 6th Printing: June 1984 No. 9650-1 Printed in JapanFOREWORD This repair manual applies to the Toyota Forklift 4FG10, 4FG15, 3FG20, and 3FD30 series, and covers the procedures essential for performing the inspec- tion, adjustment, and repair on the engine, chassis, and material handling system with special attention directed to overhaul. It is emphasized that this manual be fully utilized to preserve the high standard of performance and durability originally built into the Toyota forklifts, and to maintain top operating condition through appropriate maintenance. The vehicles 2s of March 1980 have been used as the standard in the prepa- ration of this manual. All subsequent modifications shall be notified to you through the Toyota Parts and Service News. The following repair manuals should be as reference in connection with this manual. TOYOTA 4P ENGINE REPAIR MANUAL No. 95649 TOYOTA 5R ENGINE REPAIR MANUAL No. 95648 TOYOTA 5P ENGINE REPAIR MANUAL No. 95647 TOYOTA 2J ENGINE REPAIR MNAUAL No. 95646 TOYOTA MOTOR CORPORATIONSECTION INDEX NAME GENERAL CLUTCH | MATERIAL HANC ILING SY SYSTEM _ ae | APPENDIXGENERAL VEHICLE EXTERIOR VIEWS VEHICLE LISTING... FRAME NUMBERING SYSTEM LOADING CURVE ... VEHICLE DIMENSIONS TIGHTENING TORQUE FOR GENERAL STANDARD BOLTS ABBREVIATIONS AND OPERATIONAL TIPS... RECOMMENDED LUBRICANT QUANTITY & KIND PERIODIC MAINTENANCE LUBRICATION CHARTSVEHICLE E o-2 VEHICLE EXTERIOR VIEWS Fig. 0-1 Front ViewVEHICLE LISTING Payload Model Engine Type Drive System Remarks 4FG10 11" Clutch “02-4FG10 ap Torque Converter, 40-4FG10 11” Clutch 42.4FG10 Torque Converter 3FD10 11” Cluteh 023FD10 Toraue Converter, ee) 4FG14 11" Cluteh o2arer4 Torque Converter 40-4FG14 11" Clutch 42-4F G14 Torque Converter 3FD14 11 Cluteh oar D14 “Torque Converter 4Fain 11 Clutch 024FG15 Torque Converter 40-4F C15 11" Clutch 42-4FG15 ‘Torque Converter FDIS 11" Clutch 02.3FD15 Torque Converter Fo18 11” Clutch o2-FGI8 FG18 Torque Converter 11" Clutch 42F618 Torque Converter FDI8 11" Cluteh O2FDI8 Torque Converter GOPPOO|GCOOS OB|OSCPOOe) 3FG20 1 Clutch 02.9620 Torque Converter 3 : 40:3F620 11" Clutch 42:3FG20 Torque Converter 60.3F 620 11" Clutch 623620 Torque Converter 3FD20 023FD20 11” Clutch Torque Convertero-4 Payload | Model Engine Type Drive Syatem | Remarks Fa28 Larewen © 68 | o2-Faas ce [Torque converter | (5) 40FG28 1 lutch © © 42-FG23 ce Torque Converter 22ston | eo-rG28 1 Give © e2F62 Fi “Toraue Converter @ F028 7 1 clutch o2F023 Toraue Converter @ oF 625 . 11" Guten @ o2.0F 625 Torque convener | @)_€8 403° 625 17" Guten 6 4237625 = Torque Converter__| €S) 28Ton epara7s 17" Glan © 6 © 62.3625 i Toraue Converter | 3) @ 3F O25 TV cluten @_@ © wearo | Torque Converter @ F628 = 17" luten © @ © aye ton | O2FS8 Torque Converter © F028 11" cluteh @ © © [ oaroze a Torque Converter @ 2F620 = 1" cluten @ 02.2630 Torque Co ® aoton : a 3FD20 1 cluten © 029FD30 z Torque Converter © : Power Sterna tondard Equipment Power Brake Standard Equipment (@8 : Power Clutch tandord EquipmentBST ME NUMBERING SYSTEM Fig. 03 Frame Saal Number Location <1 BL ee ap apegial Oe wr Fig. 0-4 Frame Serial Numbur = NUMBERING SYSTEM Payload 1.01.78 Ton 2.0~25 Ton 2.78830 Ton Enoine Type 4? Engine Fq18.20011 3F.625-20011 - BR Engine 40 FG18-20011 40 3625-20011 - 5P Engine - 60 3F625-20011 2FG30-20011 2) Engine FD18-20011 3F025.20011 '3FD30-20011