Model:
Forklift Truck 5FG/5FD Series
Product Type:
Workshop Service Manual
Covered Series:
5FG/FD10, 5FG/FD14, 5FG/FD15, 5FG/FD18, 5FG/FD20, 5FG/FD23, 5FG/FD25, 5FG/FD28, 5FG/FD30
Product Name:
Toyota Forklift Truck 5FG/5FD 10-30 series. Workshop Manual
Product Category:
Industrial Forklift Trucks
Brand Strength:
Toyota is a globally recognized leader in material handling equipment known for reliability and durability.
Competitors:
Competes with manufacturers like Hyster, Yale, Komatsu, Caterpillar, Crown Equipment.
Manual Value:
Original factory manual ensures accurate and comprehensive information for optimal service.
Content Highlight:
Covers a wide range of models and engine variants, offering detailed repair procedures.
Primary Coverage:
Operation, Maintenance, Repair
Supplementary Coverage:
Troubleshooting, Component Removal/Installation, Disassembly/Assembly, Specifications, Circuit Diagrams
Service Manual Pages:
734
Supplement Manual Pages:
89
Type:
Factory Original Workshop Manual
Powertrain:
Engine, Torque Converter, Clutch, Transmission, Differential, Drive Axles
Chassis:
Front Axle, Rear Axle, Steering System, Brake System, Wheels, Tires
Material Handling:
Mast System (V, FV, FSV, SV types), Lift Cylinders, Tilt Cylinders, Hydraulic Pump, Oil Control Valve
Electrical:
Wiring Diagrams, Starting Motor, Alternator, Battery, Combination Meter
Emissions:
Gasoline Exhaust Emission Control (Three-Way Catalyst), LPG Exhaust Emission Control (Three-Way Catalyst)
Maintenance:
Periodic Maintenance, Lubrication Charts, Periodic Lubricant and Parts Replacement
Repair:
Engine Assembly Removal/Installation/Disconnection/Tune-up, Component Repair and Overhaul (e.g., Differential, Axles, Mast Cylinders), Brake Bleeding, Clutch Adjustment
Troubleshooting:
System-specific troubleshooting guides for Engine, Torque Converter, Clutch, Transmission, Brakes, Hydraulics
Installation:
Component Installation procedures (e.g., Engine Assy, Steering Gear Box, Axles)
Depth Level:
Comprehensive Workshop Level
Diagnostic Capabilities:
Includes troubleshooting sections and component testing procedures
Rebuild Procedures:
Detailed disassembly, measurement, testing, assembly, and adjustment procedures for major components
Engine Types Covered:
Various Toyota industrial engines including 4P, 2J, 1Z, 4Y, 5K, 1DZ (Gasoline and LPG variants)
Engine Tune Up:
Detailed procedures for engine tune-up covering ignition timing, valve clearance, and fuel system adjustments.
Fuel Types:
Gasoline and LPG (Liquid Propane Gas)
Air Cleaner Maintenance:
Includes inspection, cleaning, and replacement procedures for the air cleaner system.
Radiator Maintenance:
Procedures for radiator inspection and maintenance.
Exhaust System:
Maintenance and troubleshooting for the muffler and exhaust pipe, including emission control systems.
Transmission Types:
Torque Converter Transmission, Clutch Transmission
Oil Clutch System:
Coverage for optional Oil Clutch System.
Torque Converter Section:
Includes hydraulic circuit diagrams, specifications, troubleshooting, removal, disassembly, measurement, and testing of the torque converter.
Clutch Section:
Covers clutch pedal, cylinders, release cylinder, master cylinder, booster, and adjustment procedures. Also includes the clutch cover.
Transmission Assy Coverage:
Detailed specifications and procedures for the transmission assembly, shift lever, and shaft.
Propeller Shaft:
Specifications and component details for the propeller shaft.
Model Range:
10 to 30 Series forklifts
Component Weights:
Listed in the manual for accurate weight distribution and handling calculations.
Safe Load Capacities:
Implied by model series (e.g., 10 is 10,000 lbs capacity), with detailed load charts potentially included or referenced.
Safety Standards:
Manual likely references relevant industrial safety standards for operation and maintenance.
Brake System:
Detailed coverage of front and rear brake systems, including master cylinder and booster procedures.
Parking Brake:
Procedures for parking brake operation and adjustment.
Body Frame:
Information on the body frame structure.
Infotainment System:
N/A (Industrial Equipment)
Driver Assistance Features:
N/A (Industrial Equipment Focus)
Connectivity Options:
N/A (Industrial Equipment Focus)
Wiring Diagrams:
Comprehensive wiring diagrams are included for electrical system diagnostics and repair.
Combination Meter:
Details on the combination meter functions and diagnostics.
Periodic Maintenance:
Comprehensive schedules for regular maintenance tasks.
Recommended Lubricants:
Detailed list of recommended lubricant types and quantities for various components (engine, transmission, hydraulics, etc.).
Hydraulic Fluid:
Specific hydraulic fluid requirements are detailed.
Common Wear Items:
While not explicitly listed as 'known issues,' detailed component wear specifications and replacement intervals are provided, allowing for proactive identification of potential problems.
Troubleshooting Guides:
Extensive troubleshooting sections for all major systems help diagnose and resolve common and uncommon operational problems.
Periodic Replacement Parts:
Guidance on parts that require periodic replacement as part of scheduled maintenance.
Toyota Material Handling:
Toyota has a long-standing reputation for producing robust and reliable material handling equipment.
5Fg 5Fd Series:
Represents a significant generation of Toyota's internal combustion engine forklift trucks, covering a range of capacities and configurations.
Engine Production Dates:
Specific engine models are associated with production date ranges (e.g., 1986.8 - 1989.8 for 4P/2J engines).
Brand Awards:
Toyota's material handling division consistently receives awards for reliability, productivity, and safety.
Product Quality:
Toyota forklifts are highly rated for their durability and longevity in demanding industrial environments.
Certification Implications:
Factory manuals ensure adherence to manufacturer specifications, which in turn support any relevant operational certifications.
