The Toyota FDF/FGF 15/35 Series Forklift Truck represents a robust and reliable solution in industrial material handling. Renowned for Toyota's commitment to engineering excellence, these forklifts are designed for durability and optimal performance across a wide range of demanding applications. Built upon a legacy of innovation, the FDF/FGF series embodies the quality and dependability that have made Toyota a global leader in material handling equipment, ensuring efficient operation and a long service life. This comprehensive Service Repair Workshop Manual provides in-depth technical information essential for the maintenance, troubleshooting, and repair of the Toyota FDF/FGF 15/35 Series Forklift Truck. It covers critical systems including the engine, powertrain, chassis, hydraulics, and electrical systems, alongside detailed procedures for preventive maintenance, diagnostics, and component repair. This manual is an indispensable resource for technicians, mechanics, and fleet managers seeking to maintain the peak operational efficiency and longevity of their Toyota forklifts. 🏷️ Basic Information Identification Make: Toyota Model: FDF/FGF 15/35 Series Forklift Truck Product Type: Service Repair Workshop Manual Product Format: Downloadable PDF 👋 Introduction Market Position Industry Segment: Industrial Material Handling Equipment (Forklift Trucks) Competitive Analysis Brand Reputation: Toyota is a globally recognized leader in material handling, known for reliability, durability, and innovation in forklift technology. Key Features Value Proposition: Provides comprehensive factory-level technical information essential for maintaining, troubleshooting, and repairing Toyota FDF/FGF series forklifts, ensuring optimal performance and longevity. Target Audience: Forklift technicians, maintenance departments, fleet managers, service workshops, and knowledgeable owner-operators. 📋 Manual Details Coverage Areas Systems Covered: Engine, Powertrain, Chassis, Hydraulics, Electrical System, Operator Compartment, Safety Features, Maintenance, Troubleshooting, Diagnostics, Repair Procedures, Component Identification, Specifications, Diagrams, Illustrations Page Count Estimated Page Count: Extensive (typically 1000+ pages for full factory manuals) Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English (assumed, standard for factory service manuals) Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Service: Complete engine overhaul, component testing, carburetor/fuel injection, ignition system, cooling system, lubrication system, exhaust system Powertrain Service: Transmission repair (torque converter, clutch, gearbox), drive axle, differential, drive shaft, wheel bearings Hydraulic System: Hydraulic pump, control valves, cylinders, hoses, fluid specifications, troubleshooting, repair of lift, tilt, and steering functions Electrical System: Wiring diagrams, battery, starter, alternator, lighting, instrumentation, fuses, relays, troubleshooting electrical faults, component testing Chassis And Frame: Frame inspection, steering system, brake system (hydraulic, parking brake), suspension components, tire/wheel specifications Operator Compartment: Seat adjustment, controls identification, safety interlocks, dashboard layout, cabin components Procedures Included Preventive Maintenance: Scheduled inspections, lubrication points, fluid change intervals, filter replacement, general upkeep Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, fault codes interpretation, symptom-based troubleshooting guides Repair Procedures: Step-by-step instructions for component removal, installation, and overhaul, including torque specifications and special tool requirements Adjustments And Calibration: Engine idle speed adjustment, brake system bleeding, hydraulic control adjustments, linkage alignment Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, electrical schematics, hydraulic circuit diagrams, component resistance/voltage checks Rebuild Information: Complete engine rebuild specifications, transmission overhaul procedures, hydraulic cylinder seal replacement, full disassembly and reassembly guides Special Tools: Identification and usage of specialized tools required for specific repairs and diagnostics 📊 Manual Specifications File Format File Quality: High-resolution, searchable text, printable pages Print Quality Print Recommendation: Printable on standard office printers for on-site use Binding Type Binding Type: N/A (Digital Download - PDF) Paper Type Paper Type: N/A (Digital Download - PDF) ⚙️ Engine Specifications Primary Engine Engine Family: Toyota Industrial Engines (specific model varies by forklift variant and region - e.g., 4Y, 1DZ-II, 1HD-FT, 1FZ-FE, LPG, Diesel, Electric) Performance Power Output: Varies significantly based on engine type (Gasoline, Diesel, LPG) and displacement. Detailed specifications available within the manual. Torque Output: Varies by engine type and displacement. Detailed specifications available within the manual. Fuel System Fuel Type: Gasoline, Diesel, LPG (Liquid Propane Gas) - dependent on specific forklift model configuration. Fuel Delivery: Carbureted or Electronic Fuel Injection (EFI) for gasoline/LPG; Direct Injection or Indirect Injection for diesel. 🔧 Transmission Standard Transmission Type: Automatic (Torque Converter with powershift transmission is common) Optional Transmission Options: Manual transmissions are rare in this class of forklift. Features Transmission Control: Hydraulic actuation, electronic control modules for shifting logic. 📐 Dimensions Exterior Lift Height: Variable, typically ranging from 3 meters to 7 meters or more, depending on mast configuration. Fork Length: Standard fork lengths (e.g., 1070mm, 1220mm) are typical, with variations available. Weights Operating Weight: Varies significantly based on capacity and configuration, typically from 2500 kg to 5000 kg or more. Load Capacity: Designated by series (e.g., 15 = 1.5 Tonne, 35 = 3.5 Tonne). Specific capacities are model-dependent. 🛡️ Safety Features Ratings Design Standards: Meets relevant ANSI/ASME B56.1, ISO 3691, and other international safety standards for industrial trucks. Active Features Operator Presence System: Often equipped with sensors that prevent hydraulic operation and travel if the operator is not seated. Parking Brake Interlock: Automatic parking brake engagement...