Product Type:
Workshop Service Manual
Product Format:
PDF Download
Vehicle Model Codes:
6FG10, 6FG14, 6FG15, 6FG18, 6FG20, 6FG23, 6FG25, 6FG28, 6FG30, 02-6FG10, 02-6FG14, 02-6FG15, 02-6FG18, 02-6FG20, 02-6FG23, 02-6FG25, 02-6FG28, 02-6FG30, 40-6FG10, 40-6FG14, 40-6FG15, 40-6FG18, 40-6FG20, 40-6FG23, 40-6FG25, 42-6FG10, 42-6FG14, 42-6FG15, 42-6FG18, 42-6FG20, 42-6FG23, 42-6FG25
Positioning:
Essential resource for owners, operators, and technicians maintaining Toyota LPG forklift trucks
Target Audience:
Forklift service technicians, mechanics, fleet managers, and maintenance personnel.
Value Proposition:
Provides original factory-level documentation, ensuring accuracy and completeness for effective maintenance and repair, superior to generic third-party guides.
Key Features:
Original factory content, high-resolution illustrations, comprehensive system coverage, detailed electrical schematics, and user-friendly digital format.
Engine:
Detailed diagnostics, repair, and overhaul procedures for the LPG engine
Transmission:
Coverage of torque converter, transmission system, and propeller shaft
Drivetrain:
Includes front axle, rear axle, differential, and steering systems
Material Handling:
Comprehensive coverage of the material handling system, mast, cylinder, oil pump, and oil control valve
Body:
General body repairs and maintenance
Electrical System:
Includes battery, starting, charging, ignition, fuel system, emission control (Gasoline & LPG), lighting (headlamp, tail lamp, stop lamp, working lamp, turn signal, back up lamp), horn, combination meter, speed meter, rotary light, heater, wiper & washer, speed alarm, and T/C heat gauge
Clutch:
While it's an automatic transmission, 'Clutch' in the context of a forklift manual may refer to components within the torque converter or other power transmission elements. Detailed coverage provided.
General Maintenance:
Routine service, inspections, and preventative maintenance procedures
Troubleshooting:
Diagnostic procedures and fault finding for various systems
Repair:
Step-by-step repair instructions for all major components and systems
Overhaul:
Detailed instructions for complete engine and transmission overhauls
Wiring Diagram Analysis:
Interpretation and use of complex circuit diagrams for electrical troubleshooting
Cylinder Service:
Detailed procedures for the lift cylinders, tilt cylinders, and power steering cylinders.
Oil Pump Service:
Maintenance and repair of the hydraulic oil pump.
Oil Control Valve Service:
Service and troubleshooting for the hydraulic oil control valve.
Depth:
Comprehensive, from basic operation and maintenance to advanced diagnostics and complete component rebuilds
Diagrams:
Includes detailed circuit diagrams and high-quality illustrative images for clarity.
Appendix Content:
The Appendix likely contains valuable reference data such as specifications, torque values, and potential troubleshooting charts not covered in the main sections.
Packaging:
Delivered as a ZIP archive containing multiple PDF files
Printability:
All manuals are printable
Image Quality:
Contains high-quality images
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Searchability:
Contains searchable text
Navigation:
Includes navigation bookmarks for easy access to sections
Organization:
Well-organized into logical sections with clear headings for efficient use.
Engine Type:
LPG (Liquid Petroleum Gas) powered internal combustion engine
Engine Designation:
Likely utilizes robust Toyota industrial engines such as the 1DZ or 2Z series, designed for reliability and longevity in demanding applications.
Typical Power Range:
Varies by specific model, generally in the 40-70 HP range for this class of forklift
Typical Torque Range:
Varies by specific model, optimized for lifting applications
System Components:
LPG regulator, vaporizer, fuel injectors/carburetor specific to the engine model (e.g., 2Z or 1DZ variations)
Emission Systems:
Includes specific sections for Gasoline and LPG emission control systems, likely involving catalytic converters and air/fuel ratio management.
Type:
Automatic transmission, likely a hydrostatic or torque converter type commonly used in forklifts for smooth power delivery and maneuverability.
Optional Types:
N/A (typically single transmission type per model series for forklifts)
Features:
Smooth acceleration, precise control for load handling, potentially features like inching control.
Key Components:
Torque converter, transmission oil pump, transmission assembly, propeller shaft.
Operating Weight:
Varies by model capacity (e.g., 1000kg to 3000kg lift capacity), typically ranging from 2,000 kg to 4,000 kg.
Lift Capacity:
1.0 to 3.0 tons (1000kg to 3000kg) depending on the specific model designation (e.g., 6FG10 up to 6FG30).
Mast Type:
Various mast types covered, including duplex and triplex masts, with associated lift heights and lowered heights.
Infotainment System:
N/A (Industrial equipment focused; infotainment features are not applicable).
Driver Assistance Features:
Limited to operational aids like parking brakes, potentially speed alarms or interlocks. Covered in specific system sections.
Connectivity Features:
N/A (Industrial equipment focused; connectivity features are not applicable).
Instrumentation:
Includes coverage of the speed meter, fuel gauge, engine hour meter, and warning lights via the Combination Meter section.
Engine Oil Change:
Typically every 250-500 operating hours, or 6-12 months, depending on operating conditions. Specific interval in manual.
Transmission Fluid Change:
Typically every 1000-2000 operating hours. Specific interval in manual.
Filter Replacement:
Regular replacement of oil filters, fuel filters, and hydraulic filters as per manual recommendations (e.g., every 500-1000 hours).
Engine Oil Type:
API SG or higher, SAE 10W-30 or 15W-40 are common for industrial engines. Specific grade and API classification in manual.
Transmission Fluid Type:
Typically an automatic transmission fluid (ATF) such as Dexron III or equivalent. Specific type and capacity in manual.
Hydraulic Fluid Type:
ISO VG 32 or 46 hydraulic oil is common. Specific type and capacity in manual.
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water. Specific type in manual.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid is typically specified for hydraulic braking systems. Specific type in manual.
Common Issues:
Potential issues may include wear on the mast channels, hydraulic system leaks, ignition system problems (spark plugs, coils), and LPG system component wear. The manual provides diagnostic procedures for these.
Brand Heritage:
Toyota Industrial Equipment is a global leader in material handling, known for reliability and innovation in forklifts for decades.
Model Series Evolution:
The 'FG' series in Toyota forklifts typically denotes LPG-powered models, representing a long-standing line of efficient and versatile industrial trucks. The inclusion of '02-' and '40-/42-' prefixes likely indicates variations in configuration, emissions standards, or specific market versions.
Typical Production Era:
While specific years aren't stated, this manual likely covers models produced from the late 1990s through the 2000s and possibly early 2010s, a common period for the 2Z and 1DZ engine platforms.
