1986 Toyota 5FGC18-30 & 5FDC20-30 Forklift Service Manual

This Toyota service manual covers the 1986 5FGC18-30 and 5FDC20-30 forklift series with 4Y gasoline and 2J diesel engines. It documents chassis, electrical, drivetrain, and hydraulic control systems.

• Engine and cooling: Engine removal and installation, engine-speed adjustments, cyclone air cleaner checks, radiator service, and starter motor and alternator removal.

• Torque converter and transmission: Stall testing, hydraulic pressure diagnosis, control valve service, clutch disassembly, and transmission reassembly.

• Axles and differential: Propeller shaft service, differential carrier and reduction gear overhaul, front axle hub repairs, and rear axle beam inspection.

• Steering and brakes: Hydrostatic steering valve overhaul, relief-pressure adjustment, duo-servo foot brake service, brake bleeding, and automatic adjuster function tests.

• Mast and hydraulics: V, FV, and FSV mast procedures, lift and tilt cylinder overhaul, single-type oil pump service, and oil control valve repairs.

• Electrical documentation: Separate 4Y and 2J wiring diagrams, combination meter connector references, warning lamp replacement, and battery checks.

This manual is suited to forklift mechanics equipped for hydraulic pressure testing, precision measurement, and hoisting complete engine and mast assemblies.

Engine Service and Repair Scope

Engine procedures cover removal with the torque converter transmission and separation of the assemblies. Periodic maintenance and lubrication tables, engine performance curves, radiator cap testing, and muffler sectional views support the service work.

Engine repair scope: Internal 4Y and 2J engine procedures require the separate CE602 and CE603 repair manuals, respectively. Starter motor and alternator coverage is limited to removal and installation. Neither engine manual is included.

Torque Converter, Differential, and Axles

Pressure and stall tests are backed by torque converter sectional views and hydraulic circuit diagrams. Troubleshooting tables connect checks of engine output, main pressure, and clutch pressure to loss of drive, slipping, overheating, and inching faults, helping narrow the cause before transmission teardown.

Differential procedures cover ring gear backlash, tooth contact, bearing preload, and pinion shim calculations. Transmission work includes clutch-pack clearance and output-shaft shim selection, with tools such as clutch spring compressor SST 09220-22000-71.

Careless converter handling can break the pump impeller extension claw, a specific caution in the removal and bearing installation procedures.

Hydrostatic Steering and Brake Service

Steering coverage follows the rotary valve, gyrotor, power cylinder, and relief valve, with sectional views and adjustment procedures. Brake chapters add booster disassembly, flow-divider spool inspection, and parking-brake linkage work.

Wheel-cylinder service specifies mineral hydraulic oil and matching piston cups. These brakes do not use conventional brake fluid.

Mast, Cylinder, and Hydraulic Repairs

V, FV, and FSV sections distinguish roller layouts, shim adjustments, and lift-cylinder arrangements. FV disassembly is illustrated with A4 piping; FSV procedures include the middle mast.

Mast support bushing installation, chain tension, and lift-cylinder rod shimming accompany natural-drop, forward-tilt, and oil-leak tests. Cylinder coverage includes flow regulator and safety down valves; oil control valve procedures address tilt lock and lift/tilt relief valves.

Incorrect oil control valve adjustment can damage the pump and other hydraulic components.

Before maintenance, secure the lift truck on level ground, engage the parking brake, support raised components, and relieve hydraulic system pressure.

Electrical Wiring and Combination Meter

The diesel wiring diagram includes glow-plug, glow-relay, and glow-timer circuits. The combination-meter diagram maps connector pins to gauges and warning lamps, while the body chapter covers meter, switch, and bulb replacement.

A Sample of Fluid Capacities and Clutch Wear Limits

These are a few examples of the capacity and inspection data included in the manual.

The lubrication table lists an engine oil capacity of 4.0 liters for the 4Y engine. Hydraulic oil capacity is 27 liters for the 2-ton series and 28 liters for the 3-ton series.

For the torque converter transmission clutch, the inspection section lists a standard clutch disc thickness of 2.6 mm and a wear limit of 2.3 mm.

Text Search, Chapter Bookmarks, and PDF Contents

Search and diagram detail: OCR text search is available through much of the manual, but some tables and wiring pages have little or no searchable text. Embedded bookmarks open the main sections. Small wiring labels and wire-color codes require zooming for comfortable reading.

Supplied as one printable, 461-page English PDF: two pages of front matter, 435 pages of service content, and a 24-page appendix covering special service tools and service standards. All of these pages are included in the total.