Positioning:
Essential technical resource for owners and technicians of Toyota 5FD series diesel forklift trucks, aimed at ensuring optimal performance, longevity, and safety.
Target Audience:
Forklift technicians, maintenance personnel, service departments, and experienced owner-operators requiring in-depth technical information.
Value Proposition:
Provides original factory-level detail, surpassing generic repair guides by offering specific Toyota engineering data, torque specifications, and troubleshooting insights.
Manual Features:
Comprehensive coverage across a wide range of models, detailed diagrams, and systematic troubleshooting guides.
Original Documentation:
Emphasizes the authenticity of the manual as an 'Original Illustrated Factory Workshop Service Manual'.
Engine Systems:
Air Cleaner, Engine Assembly Removal/Installation, Engine Tune-Up, Radiator, Muffler and Exhaust Pipe, Battery, Starting Motor, Alternator, Accelerator Pedal
Powertrain Systems:
Clutch (Cover, Release Cylinder, Master Cylinder, Booster, Adjustment, Oil Clutch System), Torque Converter (Assembly, Oil Pump, Transmission Assy), Transmission Assembly, Propeller Shaft, Differential, Front Axle, Rear Axle
Chassis Systems:
Steering (Gear Box, Power Cylinder, Link Adjustment), Brake (Front Brake, Parking Brake, Brake Pedal, Master Cylinder, Brake Booster), Wheels and Tires
Material Handling Systems:
Material Handling System (Hydraulic Piping, Return Filter, Suction Strainer, Natural Drop Test, Natural Forward Tilt Test, Oil Leak Test), Mast (V, FV, FSV, SV types), Cylinders (Lift, Tilt, Front Lift), Oil Pump (Single and Tandem types), Oil Control Valve (Removal, Disassembly, Inspection, Assembly, Installation, Adjustment, Link)
Body And Electrical:
Body Frame, Combination Meter, Wiring Diagram
Hydraulic Systems:
Material Handling System, Hydraulic Piping, Oil Pump, Oil Control Valve, Lift Cylinders, Tilt Cylinders, Torque Converter Hydraulic Circuit.
Steering And Brake Systems:
Comprehensive coverage including steering gear box, power cylinders, brake systems (front, parking), master cylinders, and brake boosters.
Mast And Lift Systems:
Detailed sections on various mast types (V, FV, FSV, SV) and associated lift and tilt cylinders, along with oil pump and control valve systems.
Maintenance Procedures:
Periodic Maintenance, Lubricant and Parts Replacement Schedules
Repair Procedures:
Engine Assembly Removal/Disassembly/Installation, Component Removal/Disassembly/Inspection/Assembly, System Troubleshooting
Diagnostic Procedures:
Troubleshooting sections for major components (e.g., Torque Converter, Engine, Transmission, Steering, Brakes)
Troubleshooting Procedures:
Dedicated troubleshooting sections for major systems like the Engine, Torque Converter, Transmission, Steering, and Brakes, aiding in diagnosing and resolving issues.
Installation Procedures:
Detailed procedures for removal, disassembly, inspection, assembly, and installation of major forklift components.
Hydraulic System Tests:
Includes specific tests for the hydraulic system such as Natural Drop Test, Natural Forward Tilt Test, and Oil Leak Test.
Depth:
Comprehensive Workshop Level. Covers detailed disassembly, inspection, measurement, adjustment, and reassembly procedures for all major systems.
Diagnostic Capabilities:
Advanced diagnostic procedures for engine tune-up, hydraulic systems, and drivetrain components are covered.
Specification Detail:
Provides specific data such as 'STANDARD BOLT & NUT TIGHTENING TORQUE' and 'HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE', critical for accurate assembly.
Engine Types Mentioned:
4P, 2J, 1Z, 4Y, 5K, 1DZ (Specific engine designations depend on the exact forklift model and manufacturing year range within the 5FD series. The manual covers multiple engine options used across these models.)
Engine Performance Data:
Engine performance specifications are detailed for each covered engine type, likely including power output, torque curves, and operating parameters relevant to forklift applications.
Fuel Type:
Diesel (as indicated by model prefix '5FD'). The supplement mentions Gasoline and LPG exhaust emission control systems, suggesting potential variations or options within the broader 5FD platform or related models, though the primary focus is diesel.
Emission Control Systems:
Details on Gasoline Exhaust Emission Control Systems and LPG Exhaust Emission Control Systems (Three-Way Catalyst) are present in the supplement, indicating the manual's broad applicability or historical context.
Engine References In Manual:
The manual refers to multiple engine types (4P, 2J, 1Z, 4Y, 5K, 1DZ) and associates them with specific vehicle model year ranges, indicating comprehensive engine documentation within the 5FD series.
Engine Tune Up Procedures:
Detailed tune-up procedures are provided for specific engine families covered by the manual.
Transmission Types:
Torque Converter Type, Clutch Type
Optional Features:
Oil Clutch System (as an option)
Torque Converter Details:
Includes hydraulic circuit diagrams, specifications, troubleshooting, and detailed removal/disassembly/measurement tests of the torque converter assembly.
Transmission Systems Covered:
Detailed sections on torque converter, clutch systems, transmission assembly, propeller shaft, differential, front axle, and rear axle.
Drivetrain Components:
Extensive coverage of the entire drivetrain, from the engine connection through to the drive axles.
Scheduled Maintenance:
Detailed 'PERIODIC MAINTENANCE' section outlines recommended service intervals and tasks. 'PERIODIC REPLACEMENT LUBRICANTS AND PARTS' provides guidance on what items need regular replacement.
Parts Replacement Schedule:
Highlights parts and lubricants recommended for periodic replacement to maintain optimal condition.
Lubricant Recommendations:
Includes 'RECOMMENDED LUBRICANT QUANTITY & TYPE' and 'LUBRICATION CHARTS' for various components, ensuring correct fluid usage.
Fluid Capacities Availability:
Recommended lubricant quantities for various systems are provided, essential for correct fluid service.
Common Wear Items:
While specific 'common issues' aren't listed as such, the detailed troubleshooting sections and component wear inspection procedures implicitly guide technicians to identify and address potential failure points.
Tune Up Details:
Specific 'ENGINE TUNE-UP' procedures are provided for different engine types, covering adjustments and settings essential for optimal performance.
Brake System Maintenance:
Detailed procedures for brake system maintenance, including air bleeding, component removal/inspection/assembly for different tonnage series, and master cylinder/booster servicing.
Lubrication Guidelines:
Includes detailed lubrication charts and schedules for comprehensive preventative maintenance.
