🏷️ Basic Information

Make:

Toyota

Model:

LPG Forklift Truck

Chassis Codes:

5FG33, 5FG35, 5FGE35, 5FG40, 5FG45

Engine Codes Implied:

Toyota LPG Engine (specific code not provided in product info)

👋 Introduction

Target Audience:

Owners, operators, and maintenance technicians of Toyota 5FG/5FD series LPG forklift trucks.

Manual Value:

Original factory documentation providing in-depth technical guidance for efficient operation, routine maintenance, and complex repairs, crucial for minimizing downtime and ensuring safety.

📋 Manual Details

Covered Models:

Toyota LPG Forklift Truck: 5FG33, 5FG35, 5FGE35, 5FG40, 5FG45

Covered Vehicle Types:

IC-Engined Forklift Truck

Additional Covered Models:

Toyota (BT) Forclift Trucks, Type 5FD (implied through description)

Total Pages:

559

Type:

Workshop Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Major Systems:

Engine, Clutch, Torque Converter, Transmission & Differential, Front Axle, Rear Axle, Steering, Brake, Body, Material Handling System (Hydraulics, Mast, Cylinders, Oil Pump, Oil Control Valve)

Electrical System:

Implied coverage through circuit diagrams (though not explicitly listed in TOC, typically present in factory service manuals of this caliber).

Hydraulics Control:

Oil Pump, Oil Control Valve, Lift Cylinder, Tilt Cylinder, Flow Regulator Valve, and associated hydraulic circuits.

Repair And Maintenance:

General Inspection, Periodic Maintenance, Component Removal/Installation, Disassembly, Inspection, Assembly, Adjustment, Troubleshooting, Hydraulic Circuit Diagrams, Wiring Diagrams (implied by circuit diagrams)

Troubleshooting Guidance:

Specific troubleshooting sections are present for key systems like the Torque Converter and Brake Booster.

Mast Adjustment Procedures:

Detailed procedures for various mast adjustments including lift bracket rollers, mast rollers, mast strips, and lift cylinder rod shimming.

Depth:

Comprehensive, covering detailed repair procedures, specifications, and diagnostic information for all major systems, suitable for professional technicians and advanced DIY users.

Diagnostic Capability:

High, with detailed specifications, component analysis, and step-by-step repair procedures enabling advanced diagnostics and component-level repairs.

📊 Manual Specifications

Format Details:

Searchable Text, Navigation Bookmarks, Printable Pages

Image Quality:

High Quality Images

Binding:

N/A (PDF Download)

Paper Type:

N/A (PDF Download)

⚙️ Engine Specifications

Type:

Internal Combustion (IC) - LPG (Liquefied Petroleum Gas) powered, with potential reference to Diesel Engine Models for specific sections (e.g., fuel system bleeding).

Engine Adjustment:

Procedures for engine speed adjustment for both Gasoline and Diesel engine models are detailed.

Lpg System Details:

Implied coverage of LPG fuel system components and maintenance procedures, though specific details are not itemized in the TOC provided.

Diesel Engine Specifics:

While the primary focus is LPG, the manual includes procedures specific to Diesel Engine Models such as fuel system bleeding and water draining from the sedimenter.

Radiator And Fan:

Includes Radiator components, specifications, coolant capacity, and fan drive system (removal, inspection, assembly, installation, belt tension adjustment).

Spark Plugs And Ignition:

Implied coverage for LPG engines; specific details not itemized in the TOC.

Air Cleaner And Hot Air Intake:

Details on air cleaner components, specifications, inspection, and hot air intake for gasoline engines.

Accelerator Pedal:

Includes procedures for accelerator pedal removal and adjustment.

Battery Specifications And Inspection:

Covers Battery components, specifications, and inspection methods.

🔧 Transmission

Type:

Clutch Model and Torque Converter Model variants are covered.

Torque Converter Details:

Extensive coverage of the Torque Converter, including hydraulic circuit diagrams, troubleshooting, components, removal, disassembly, inspection, assembly, installation, and integration with the transmission and differential.

Clutch Features:

Detailed procedures for clutch removal, disassembly, inspection, assembly, and installation, including oil clutch and clutch booster components and adjustments.

Clutch Booster And Release Cylinder:

Detailed procedures for clutch booster and clutch release cylinder removal, disassembly, inspection, assembly, installation, and bleeding.

Transmission And Differential Assembly:

Comprehensive section covering the Transmission & Differential assembly, including removal, disassembly, inspection, assembly, and installation. Also covers output gear and differential procedures.

Torque Converter Stator Shaft Oil Pump:

Details the removal, disassembly, inspection, assembly, and installation of the torque converter, stator shaft, and oil pump assembly.

📐 Dimensions

Exterior Views:

Manual includes exterior views for model identification and general reference.

Component Weights:

The manual lists component weights, essential for rigging and safe handling during maintenance.

Safe Load Capacities:

Provides safe load capacities for wire rope suspension angles.

🛡️ Safety Features

Industry Standards:

Adherence to industry standards for safe operation and maintenance is implied through the detailed procedures and specifications.

Brake System Safety:

Detailed coverage of brake system adjustments, automatic adjuster operation tests, and braking force inspections to ensure operator safety.

Structural Integrity:

Implied by detailed component repair and assembly instructions which contribute to the overall structural integrity and safe operation of the forklift.

Safety Tips:

Includes operational tips and safe load data for rigging, contributing to safe handling and operation.

💡 Technology Features

Instrumentation:

Covers the Combination Meter, including its removal, disassembly, assembly, and installation.

Steering And Brake Enhancements:

Details power steering system components, adjustments, and brake booster functionality, which enhance operational ease and safety.

Advanced Hydraulic Control:

Includes detailed hydraulic circuit diagrams for clutch and torque converter vehicles, as well as procedures for lift and tilt cylinders, and oil control valves, demonstrating sophisticated hydraulic control.

🔧 Maintenance

Periodic Maintenance Schedule:

The manual details Periodic Maintenance, including inspection methods and recommended replacement lubricants and parts at specified intervals.

Lubricant Recommendations:

Provides Recommended Lubricant Quantity & Types and detailed Lubrication Charts for all major components.

Coolant Capacity:

Specifies coolant capacity for the radiator.

Common Troubleshooting Areas:

The manual includes troubleshooting sections for key components like the Torque Converter and Brake Booster, addressing potential common issues.

Lift Cylinder Uneven Lifting:

Specific troubleshooting for preventing uneven lifting through lift cylinder rod shim adjustment.

Tightening Torques:

Extensive tables for Standard Bolt & Nut Tightening Torque, identification of bolt strength types, and specific torque values for various fittings (e.g., High Pressure Hose Fitting).

Lubrication Charts:

Comprehensive lubrication charts detailing all lubrication points and recommended intervals.

📚 Vehicle History

Toyota Industrial Equipment:

Toyota has a long-standing reputation for manufacturing reliable and durable industrial equipment, including forklifts, known for their engineering quality and innovation.

5Fg Series Evolution:

The 5FG series represents a lineage of Toyota's robust IC-engine forklifts, known for their versatility and application in various industrial settings. This manual pertains to a specific generation within this series.

🏆 Awards & Recognition

Toyota Industrial Equipment Reputation:

Toyota's industrial equipment is consistently recognized for reliability, durability, and operator comfort, often exceeding industry benchmarks.

📄 Front Axle

Front Axle Assembly:

Covers the entire Front Axle Assembly, including removal, disassembly, inspection, assembly, and installation.

📄 Rear Axle

Rear Axle Assembly:

Covers the Rear Axle Assembly, including removal, disassembly, inspection, assembly, and installation. Also details rear axle hub and steering knuckle procedures.

Wheel Alignment Angles:

Includes specifications and procedures for Rear Wheel Alignment, Toe-in, Turning Radius, Camber, Caster, and King-Pin angles.

📄 Steering

Steering Systems:

Covers Steering Gear Box Assembly, Mast Jacket Assembly, and Power Cylinder, with detailed procedures for removal, disassembly, inspection, assembly, adjustment, and installation.

Steering Oil Pressure Test:

Includes procedures for steering oil pressure testing.

📄 Brake

Brake Systems:

Detailed coverage of Front Brake, Brake Booster, and Parking Brake components, including removal, inspection, assembly, adjustment, and troubleshooting.

Brake Bleeding And Adjustment:

Procedures for air bleeding from the brake system, brake adjustment, and braking force inspection.

📄 Body

Body And Meter Assembly:

Covers body components and the Combination Meter assembly.

📄 Material Handling System

Hydraulic Circuits And Testing:

Detailed Hydraulic Pressure Piping, Hydraulic Circuit diagrams for clutch and torque converter vehicles, and hydraulic system testing procedures (Natural Drop Test, Forward Test, Oil Leak Test).

Mast And Cylinder Overhaul:

Extensive coverage of V Mast Assembly, FV SV FSV Mast Assembly, Lift Cylinder, Tilt Cylinder, and associated components (lift bracket, chain wheel, chains, forks). Includes detailed removal, disassembly, inspection, assembly, installation, and critical adjustments like mast roller and lift bracket roller adjustments, and lift cylinder rod shim adjustment.