This manual covers the Toyota Forklift Truck 5FG/5FD Series, specifically models 5FG/FD10 through 5FG/FD30. Toyota is a globally recognized leader in material handling equipment, renowned for its reliability and durability. The 5FG/5FD series represents a significant generation of Toyota's internal combustion engine forklift trucks, designed for demanding industrial environments and known for their robust construction and longevity. This series offers a range of capacities and configurations, built upon Toyota's long-standing reputation for producing high-quality, dependable material handling solutions. This comprehensive workshop service manual provides detailed information for the operation, maintenance, and repair of the Toyota Forklift Truck 5FG/5FD Series. It includes extensive coverage of powertrain, chassis, material handling, and electrical systems, along with specific procedures for engine tune-ups, component removal and installation, disassembly and assembly, and troubleshooting. With 823 pages of factory-original content, this manual is an essential resource for owners, mechanics, and technicians, offering accurate and complete guidance to ensure the optimal performance and longevity of these industrial forklifts. 🏷️ Basic Information Identification Make: Toyota Model: Forklift Truck 5FG/5FD Series Product Type: Workshop Service Manual Generation Covered Series: 5FG/FD10, 5FG/FD14, 5FG/FD15, 5FG/FD18, 5FG/FD20, 5FG/FD23, 5FG/FD25, 5FG/FD28, 5FG/FD30 Codes Product Name: Toyota Forklift Truck 5FG/5FD 10-30 series. Workshop Manual 👋 Introduction Market Position Product Category: Industrial Forklift Trucks Brand Strength: Toyota is a globally recognized leader in material handling equipment known for reliability and durability. Competitive Analysis Competitors: Competes with manufacturers like Hyster, Yale, Komatsu, Caterpillar, Crown Equipment. Key Features 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. 📋 Manual Details Coverage Areas Primary Coverage: Operation, Maintenance, Repair Supplementary Coverage: Troubleshooting, Component Removal/Installation, Disassembly/Assembly, Specifications, Circuit Diagrams Page Count Service Manual Pages: 734 Supplement Manual Pages: 89 Total Pages: 823 Manual Type Type: Factory Original Workshop Manual Language Language: English Format File Format: ZIP (PDF) 📖 Manual Coverage Systems Covered 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) Procedures Included 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) Technical Depth 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 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printability: Printable Searchability: Searchable Text Navigation: Navigation Bookmarks Visuals: High-Quality Images, Circuit Diagrams Binding Type Binding: Not Specified (Digital Format) Paper Type Paper: Not Specified (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Types Covered: Various Toyota industrial engines including 4P, 2J, 1Z, 4Y, 5K, 1DZ (Gasoline and LPG variants) Performance Engine Tune Up: Detailed procedures for engine tune-up covering ignition timing, valve clearance, and fuel system adjustments. Fuel System Fuel Types: Gasoline and LPG (Liquid Propane Gas) Components 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 Standard Transmission Types: Torque Converter Transmission, Clutch Transmission Optional Oil Clutch System: Coverage for optional Oil Clutch System. Features 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. 📐 Dimensions Exterior Model Range: 10 to 30 Series forklifts Weights 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 Features Ratings Safety Standards: Manual likely references relevant industrial safety standards for operation and maintenance. Active Features 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. Passive Features Body Frame: Information on the body frame structure. 💡 Technology Features Infotainment Infotainment System: N/A (Industrial Equipment) Driver Assistance Driver Assistance Features: N/A (Industrial Equipment Focus) Connectivity Connectivity Options: N/A (Industrial Equipment Focus) Electrical Systems Wiring Diagrams: Comprehensive wiring...