🏷️ Basic Information

Make:

Toyota

Model:

Forklift Truck

Product Name:

Toyota IC-Engined Forklift Truck Type 5FD50 5FD60 5FD70 5FD80 5FG50 5FG60 Workshop Service Repair Manual

Covered Model Codes:

5FD50, 5FD60, 5FD70, 5FD80, 5FG50, 5FG60

Product Type:

Workshop Service Repair Manual

👋 Introduction

Product Focus:

Essential technical documentation for owners, operators, and maintenance personnel of Toyota IC-Engined Forklift Trucks (5FG/5FD series) requiring detailed service and repair information.

Manual Value Proposition:

Provides original factory-level insights into the operation, maintenance, and repair of specific Toyota forklift models, ensuring accurate and efficient servicing through detailed illustrations, diagrams, and procedures.

Manual Utility:

Essential resource for maintaining the performance and longevity of Toyota forklifts, crucial for industries relying on efficient material handling.

📋 Manual Details

Covered Systems:

General Information, Engine, Torque Converter, Transmission, Differential, Front Axle, Rear Axle, Brake System, Material Handling System, Mast Systems (V Mast, FSV Mast), Cylinders (Lift, Tilt), Oil Control Valve, Hydraulic Piping

Supplementary Information:

Supplement Manual covers General Explanation, Engine, Torque Converter, Brake, Other Modifications, and Appendix.

Total Pages:

471

Type:

Original Illustrated Factory Workshop Service Manual

Language:

English

Delivery Format:

ZIP Archive

File Types:

PDF files for Service Manual and Supplement Manual

📖 Manual Coverage

Engine Details:

Exterior Views, Sectional Views, Performance Curves, Engine Assembly (Removal/Installation), Engine Speed Adjustment, Air Cleaner, Radiator, Muffler/Exhaust Pipe, Battery, Starting Motor, Alternator, Accelerator Pedal

Drivetrain Details:

Torque Converter (General, Hydraulic Circuit, Specifications, Troubleshooting, Components, Control Valve Assy, Disassembly/Reassembly for 2-speed/3-speed types), Transmission (Removal, Disassembly, Inspection, Reassembly, Installation), Control Lever (General, Change Rod Adjustment, Inching Adjustment), Differential (General, Specifications, Components, Removal, Disassembly, Inspection, Reassembly, Installation), Front Axle (General, Components, Front Axle Shaft Hub, Differential Housing), Rear Axle (General, Specifications, Components, Rear Axle Assy, Rear Axle Hub, Steering Knuckle/King Pin, Rear Axle Cylinder)

Braking System Details:

General, Specifications, Front Brake (Disassembly/Inspection/Reassembly for 5-7 Ton and 8 Ton), Brake Air-Bleeding Operation, Adjustment, Brake Valve (General, Removal, Operation Inspection, Disassembly/Inspection/Reassembly, Installation), Accumulator (Removal/Installation, Disassembly/Inspection/Reassembly), Electrical Accumulator Pump (for 5FD70/80), Parking Brake (General, Removal, Disassembly, Inspection, Adjustment, Reassembly, Installation), Brake Pedal Adjustment

Hydraulics And Material Handling Details:

Material Handling System (General, Hydraulic Circuit, Return Filter, Suction Filter, Natural Drop Test, Natural Forward Tilt Test, Oil Leak Test), Lift Cylinder, Tilt Cylinder, Mast (V Mast Assy Components, Removal/Installation, Disassembly/Inspection/Reassembly, Lift Bracket, Chain, Fork, Mast Adjustments), FSV Mast Assy Components and Adjustments, Cylinder (Lift Cylinder Assy, Tilt Cylinder Assy Specifications and Procedures), Oil Control Valve (Specifications, Components, Assy Procedures), Hydraulic Piping (Flow Divider Valve, Flow Regulator Valve, Safety Down Valve)

General Information Coverage:

Covers Exterior Views, Vehicle Listing, Frame Number, How to Read This Manual, Explanation Method, Terminology, Abbreviations, Operational Tips, and general tightening torque specifications.

Mast Systems Detail:

Detailed coverage for V Mast and FSV Mast assemblies, including components, removal/installation, disassembly/inspection/reassembly, and specific mast adjustments.

Electrical System Components:

Covers Battery, Starting Motor, and Alternator within the engine section.

Repair And Overhaul:

Complete disassembly, inspection, repair, and reassembly procedures for all major vehicle components and systems, including engine, torque converter, transmission, axles, brakes, and hydraulic systems.

Maintenance And Adjustment:

Periodic maintenance schedules, lubrication charts, fluid type and quantity recommendations, component adjustments (e.g., engine speed, brake pedal, inching, mast adjustments), torque specifications for fasteners, and wire rope suspension angle calculations.

Troubleshooting And Diagnostics:

Diagnostic procedures and troubleshooting guides for common issues across various systems, including torque converter and hydraulic system faults, brake system problems, and general vehicle performance issues.

Assembly Disassembly:

Detailed step-by-step procedures for the disassembly, inspection, and reassembly of all major mechanical and hydraulic components.

Component Replacement:

Procedures for removal and installation of individual components like the radiator, muffler, brake valve, and mast assemblies.

Adjustment Procedures:

Includes adjustments for change rods, inching, parking brake, and various mast components.

Hydraulic Component Service:

Detailed service procedures for hydraulic components such as lift cylinders, tilt cylinders, oil control valves, and various piping valves.

Depth Of Coverage:

Comprehensive factory-level technical detail covering all aspects of operation, maintenance, and repair, suitable for experienced technicians and mechanics. Includes detailed diagrams, specifications, and step-by-step instructions.

Specifications Detail:

Includes specific technical specifications for various components, such as brake system specifications, differential specifications, and lift/tilt cylinder specifications.

Circuit Diagrams:

Includes circuit diagrams for hydraulic and electrical systems.

Diagnostic Charts:

Includes troubleshooting sections which often contain diagnostic charts or symptom-cause tables.

📊 Manual Specifications

Format:

PDF (Printable)

Image Quality:

High quality images and illustrations

Text Search:

Searchable Text

Bookmarks:

Navigation Bookmarks

⚙️ Engine Specifications

Engine Type:

Internal Combustion (IC-Engined)

Engine Performance Curves:

Included (as per manual index)

Engine Speed Adjustment:

Procedure for adjusting engine speed is covered.

Engine Components Covered:

Air Cleaner, Radiator, Muffler, Exhaust Pipe, Battery, Starting Motor, Alternator, Accelerator Pedal

Engine Assy Procedures:

Engine Assembly Removal and Installation procedures are detailed.

🔧 Transmission

Torque Converter Type:

Two-speed and Three-speed variants

Transmission Procedures:

Removal, disassembly, inspection, reassembly, and installation of the transmission are covered.

Control System:

Control Valve Assembly, Control Lever with Change Rod and Inching Adjustments

Torque Converter Disassembly:

Detailed disassembly, inspection, and reassembly instructions for torque converters (2-speed and 3-speed types).

📐 Dimensions

Component Weights:

List of component weights provided

Safe Load Calculation:

Safe load calculations for wire rope suspension angles are detailed

Vehicle Listing:

Includes a vehicle listing for identification purposes.

🛡️ Safety Features

Safety Down Valve:

Detailed coverage of the Safety Down Valve Assy, including its operation and maintenance.

💡 Technology Features

Hydraulic Controls:

Detailed coverage of hydraulic control systems, including valves, cylinders, and mast operations, reflecting the technological integration in material handling.

Braking System Technology:

Includes details on air-bleeding operations, accumulator systems, and parking brake mechanisms.

🔧 Maintenance

Periodic Maintenance:

Detailed Periodic Maintenance schedule included

Periodic Parts Replacement:

Guidance on when to replace lubricants and parts at regular intervals.

Recommended Lubricants:

Recommended Lubricant Quantity & Types provided

Lubrication Charts:

Comprehensive Lubrication Charts included

Fluid Capacities:

Recommended lubricant quantities are specified, implying fluid capacity information.

Troubleshooting Focus:

Manual includes troubleshooting sections for key components like the torque converter and hydraulic systems, suggesting areas where common issues might arise.

Periodic Replacement:

Periodic Replacement of Lubricants & Parts detailed

Bolt Tightening Torque:

Standard Bolt & Nut Tightening Torque, Bolt Strength Type Identification, and Tightening Torque Table are provided.

Hose Fitting Torque:

High Pressure Hose Fitting Tightening Torque specifications are included.

Bolt Strength Identification:

Explanation of bolt strength type identification methods is included.

Wire Rope Suspension:

Wire Rope Suspension Angle List and Safe Load calculations provided.

📚 Vehicle History

Manufacturer:

Toyota Industries Corporation (Toyota Material Handling)

Model Series:

5FG/5FD series represents a line of IC-engined forklifts, indicating established engineering and design principles.

Documentation Origin:

Original Factory Documentation

Frame Number Importance:

Guidance on how to read frame numbers is provided.