The Toyota FD/FG 35-50 Forklift Truck series represents a robust line of medium-duty internal combustion engine forklifts, engineered for demanding applications in warehousing, manufacturing, and logistics. Renowned for Toyota's commitment to reliability and durability, these models offer dependable performance and high resale value. The FD (cushion tire) and FG (pneumatic tire) variants are designed to handle loads ranging from 3500 to 5000 lbs, featuring efficient powertrains, precise hydraulic systems, and ergonomic operator controls. Their construction prioritizes operational efficiency, safety, and operator comfort, making them a cornerstone in material handling operations worldwide. This comprehensive factory service repair workshop manual provides essential information for the maintenance and repair of Toyota FD35, FD40, FD45, FD50, FG35, FG40, FG45, and FG50 forklift trucks. It covers all major systems, including the engine, transmission, hydraulic system, electrical system, chassis, and mast. Detailed procedures for routine maintenance, diagnostic troubleshooting, component repair and rebuild, adjustments, and torque specifications are included. This manual is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance, longevity, and safety of their Toyota forklift equipment. 🏷️ Basic Information Identification Make: Toyota Model: FD/FG 35-50 Forklift Truck Product Type: Service Repair Workshop Manual Codes Product Identifier: Toyota FD FG 35 50 Forklift Truck Service Repair Workshop Manual Download PDF 👋 Introduction Market Position Vehicle Segment: Medium-duty internal combustion engine (ICE) forklifts, crucial in warehousing, manufacturing, and logistics. Competitive Analysis Competitors: Competes with forklift models from brands like Hyster, Yale, Caterpillar, Mitsubishi, Komatsu, Nissan. Key Features Manufacturer Reputation: Toyota is renowned for reliability, durability, and high resale value in the material handling industry. Manual Value Proposition: Provides comprehensive factory-level repair and maintenance information, essential for maximizing uptime and minimizing operational costs. 📋 Manual Details Coverage Areas Applicable Models: Toyota FD35, FD40, FD45, FD50, FG35, FG40, FG45, FG50 Forklift Trucks Coverage Scope: Comprehensive factory service, repair, and workshop procedures. Page Count Estimated Pages: Detailed page count not specified in product description, but typically exceeds 1000 pages for comprehensive forklift service manuals. Manual Type Manual Classification: Factory Service Repair Workshop Manual Language Primary Language: English (Standard for Toyota Service Manuals) Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (gasoline/LPG/diesel), transmission (torque converter, hydrostatic, manual), drive axle, differential. Chassis And Frame: Frame construction, steering system, suspension (if applicable to forklift design), wheels, tires. Hydraulic System: Lift/tilt hydraulics, power steering hydraulics, pump, valves, cylinders, hoses, fluid specifications. Electrical System: Battery, starter, alternator, ignition system, lighting, instrumentation, wiring diagrams, fuse/relay information, troubleshooting. Operator Compartment: Operator controls, seat, overhead guard, safety features. Mast And Attachments: Mast construction, rollers, chains, carriage, forks, attachment mounting and operation (e.g., side shifters, fork positioners). Procedures Included Routine Maintenance: Fluid level checks, lubrication points and schedule, filter replacements, battery maintenance, tire pressure checks. Diagnostic Procedures: Troubleshooting guides for common and uncommon issues, symptom-based diagnostics, fault code interpretation (if applicable). Repair And Rebuild: Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation. Adjustment And Calibration: Brake adjustments, parking brake settings, shift lever adjustments, hydraulic pressure adjustments, lift/tilt speed settings. Torque Specifications: Critical torque values for fasteners on all major components. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Technical Depth Diagnostic Capability: Advanced diagnostic procedures for engine, transmission, and hydraulic systems. Repair Complexity: Covers everything from routine maintenance to complete engine and transmission overhauls, hydraulic system rebuilds, and electrical system diagnostics. Level Of Detail: Detailed exploded views, diagrams, schematics, and step-by-step instructions suitable for trained technicians and knowledgeable DIY mechanics. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable, enabling quick access to specific information. Print Quality Print Readability: Designed for clear printing with legible text and diagrams. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper: N/A (Digital Download) Licensing Usage Rights: Instant download, no expiry dates, suggesting perpetual access. ⚙️ Engine Specifications Primary Engine Engine Types: Typically powered by robust Toyota industrial engines. Common options include gasoline, LPG (Liquid Propane Gas), and diesel variants depending on the specific model and market. Examples might include Toyota's 1DZ-II (diesel), 5K (gasoline/LPG), or 4Y (gasoline/LPG) industrial engines. Performance Power Output: Horsepower and torque figures vary significantly by specific engine and forklift model, but are optimized for material handling tasks. Expect ranges suitable for lifting capacities of 3500-5000 lbs (1.5 to 2.5 tons). Fuel System Fuel Delivery: Carbureted or Fuel Injection (EFI) depending on engine generation. LPG models feature specialized regulators and mixers. Cooling System Cooling Type: Liquid-cooled, typically with a radiator, fan, water pump, and thermostat. Emission Control Emission Systems: May include catalytic converters (for LPG/gasoline) and emission control systems to meet regulatory standards. 🔧 Transmission Standard Transmission Type: Most commonly a Toyota Hydrostatic Transmission (HST) or a Torque Converter Automatic Transmission, designed for smooth power delivery and precise control during lifting and travel. Optional...