Product Category:
Industrial Equipment - Forklift Trucks
Target User:
Maintenance technicians, service engineers, fleet managers, and owners of Toyota LPG Forklift Trucks.
Value Proposition:
Provides original factory-level technical information, enabling accurate diagnosis, repair, and maintenance, crucial for operational efficiency and longevity of the forklift.
Manual Features:
Original factory content, detailed illustrations, searchable PDF format with bookmarks, comprehensive coverage of multiple models within the 5FG series.
General:
Exterior Views, Vehicle Listing, Frame Number, How to Read This Manual, Periodic Maintenance, Periodic Replacement Lubricants and Parts
Engine:
Air Cleaner, General Specifications, Components, Air Cleaner Maintenance, Gasoline Exhaust Emission Control System (Three-Way Catalyst), LPG Exhaust Emission Control System (Three-Way Catalyst), Removal/Installation, Troubleshooting
Powertrain:
Torque Converter, Clutch, Transmission, Propeller Shaft, Differential
Chassis:
Front Axle, Rear Axle, Steering, Brake
Body And Structure:
Body Frame, Combination Meter
Material Handling:
Material Handling System, Hydraulic Piping, Return Filter and Suction Strainer, Mast, Cylinders (Lift, Tilt), Oil Pump, Oil Control Valve
Service Manual Pages:
734
Type:
Workshop Service Manual
Content Origin:
Original Illustrated Factory Workshop Manual
File Format:
ZIP (containing PDF files)
Engine Systems:
Engine Assembly Removal/Installation, Engine Tune-Up (4P/4Y/5K, 2J/1Z/1DZ engines), Air Cleaner, Radiator, Muffler and Exhaust Pipe, Battery, Starting Motor, Alternator, Accelerator Pedal, Emission Control Systems (Gasoline & LPG Three-Way Catalyst)
Transmission Systems:
Torque Converter, Clutch (Cover, Release Cylinder, Master Cylinder, Booster, Adjustment, Oil Clutch System), Transmission Assembly, Propeller Shaft, Differential
Axle And Steering:
Front Axle (Shaft Hub, Differential Housing), Rear Axle, Steering (Gear Box, Mast Jacket, Telescopic Jacket, Power Cylinder, Link Adjustment)
Brake System:
Front Brake, Master Cylinder, Brake Booster, Parking Brake, Brake Pedal, Air Bleeding
Hydraulic Systems:
Material Handling System, Hydraulic Piping, Oil Pump (Single/Tandem Type), Oil Control Valve, Lift Cylinders, Tilt Cylinders, Return Filter and Suction Strainer
Maintenance:
Periodic Maintenance, Periodic Replacement Lubricants and Parts, Engine Tune-Up, Lubrication Charts, Fluid Specification and Quantities
Repair And Rebuild:
Component Removal and Installation, Disassembly and Assembly of Engine, Transmission, Torque Converter, Axles, Steering, Brakes, Mast, Cylinders, Pumps, Valves
Troubleshooting:
Engine Troubleshooting, Torque Converter Troubleshooting, General Troubleshooting sections within various systems
Adjustments:
Clutch Adjustment, Steering Link Adjustment, Brake Adjustments (where applicable), Valve Adjustments (engine tune-up)
Testing:
Oil Pump Test Procedures, Natural Drop Test (Mast/Hydraulics), Natural Forward Tilt Test (Mast/Hydraulics), Oil Leak Test
Depth:
Comprehensive Workshop Service Manual covering detailed repair, overhaul, and maintenance procedures for all major vehicle systems.
Diagnostic Capability:
Includes troubleshooting guides for common issues across engine, powertrain, hydraulic, and chassis systems.
Specifications:
Detailed specifications for components, torque settings, fluid types and capacities, and engine performance parameters.
Fuel Type:
LPG (Liquid Propane Gas)
Engine Variants:
Manual covers multiple engine types used in the 5FG series, including mentions of 4P, 2J, 1Z, 4Y, 5K, and 1DZ engines, with specific tune-up procedures for different engine families and production date ranges (e.g., 1986.8 - 1989.8, 1989.9 -).
General Note:
Specific horsepower and torque figures are not provided in the product description but are detailed within the manual for each engine type.
Lpg Components:
Covers LPG specific systems including the LPG exhaust emission control system (Three-Way Catalyst).
Type:
Torque Converter Transmission (mentioned throughout)
Clutch System:
Oil Clutch System (Option) is covered, indicating potential variations.
Components Covered:
Torque Converter, Transmission Assembly, Shift Lever and Shaft, Clutch components (Cover, Cylinders, Booster), Inching Brake Pedal.
Type:
N/A (Industrial Equipment)
Type:
N/A (Industrial Equipment)
Type:
N/A (Industrial Equipment)
Manual Role:
The manual acts as the primary diagnostic and repair tool for technicians.
System Details:
Detailed coverage of Gasoline and LPG Exhaust Emission Control Systems, specifically 'Three-Way Catalyst' systems, including components, removal/installation, and troubleshooting.
General:
The manual provides a 'Periodic Maintenance' section detailing recommended service intervals and tasks.
Lubrication:
Includes 'Periodic Replacement Lubricants and Parts' and detailed 'Lubrication Charts'.
Engine Oil:
Specific engine oil types and capacities are detailed within the manual for various engine models.
Hydraulic Fluid:
Recommended hydraulic fluid type and capacity are covered, crucial for the material handling system.
Transmission Fluid:
Transmission fluid type and refill quantities are specified for torque converter transmissions.
General Note:
While specific common issues are not listed in the product description, the troubleshooting sections within the manual address typical problems encountered with forklift operation and components.
Areas Covered:
Common repairs would likely involve wear items in the brake system, hydraulic components (cylinders, pumps, valves), powertrain (clutch, torque converter), and engine tune-ups.
