This is the Highly Detailed factory service repair manual for theTOYOTA 52-6FGU33 FORKLIFT, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.TOYOTA 52-6FGU33 FORKLIFT Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: Foreword Section Index General Engine Torque Converter Front Axle Rear Axle Steering Brake Body Material Handling System Mast Cylinder Oil Pump Oil Control Valve Appendix Wire Diagrams File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveTOYOTA 52-6FGU33 FORKLIFT Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: https://www.aservicemanualpdf.com/ Thanks for visiting!

1. FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT
6FGU16FDU33-45, 6FGAU16FDAU50. Please use this manual for
providing quick, correct servicing of the corresponding forklift models.
This manual deals with the above models as of March 1997. Please
understand that disagreement can take place between the descriptions
in the manual and actual vehicles due t o change in design and
specifications. Any change or modifications thereafter will be informed
by Toyota Industrial Equipment Parts & Service News.
For the service procedures of the mounted engine, read the repair
manuals listed below as reference together with this manual.
(Reference)
Repair manuals related to this manual are as follows:
TOYOTA INDUSTRIAL EQUIPMENT GM6-262 ENGINE
REPAIR MANUAL (No. C4630)
TOYOTA INDUSTRIAL EQUIPMENT 11Z,12Z,13Z,14Z ENGINE
REPAIR MANUAL (No. C4615)
TOYOTA MOTOR CORPORATION

2. SECTION INDEX
I NAME 1SECTIONI
IGENERAL
ENGINE
TORQUE CONVERTER
FRONT AXLE
REAR AXLE
STEERlNG
rn
BRAKE
MATERIAL HANDLING SYSTEM 00
MAST
CYLINDER o
OIL CONTROL VALVE
APPENDIX

3. GENERAL
Page
...............................................EXTERIOR VIEWS 0-2
...................VEHICLE MODEL-FRAME NUMBER 0-3
HOW TO READ THIS MANUAL .........................0-4
EXPLANATION METHOD ...................................... 0-4
...................................................TERMINOLOGY 0-5
ABBREVIATIONS .................................................0-5
OPERATIONAL TIPS ...........................................0-6
STANDARD BOLT AND NUT TIGHTENING
...........................................................TORQUE 0-7
BOLT STRENGTH TYPE IDENTIFICATION
METHOD ........................................................0-7
TIGHTENING TORQUE TABLE ............................... 0-8
PRECOAT BOLTS ...............................................0-9
HIGH PRESSURE HOSE FITTING
TIGHTENING TORQUE ..................................... 0-9
WIRE ROPE SUSPENSION ANGLE LIST ............. 0-10
SAFE LOAD FOR EACH WlRE ROPE
.......................................SUSPENSION ANGLE 0-10
COMPONENTS WEIGHT ..................................... 0-11
RECOMMENDED LUBRICANT
.......................................QUANTITY & TYPES 0-12
........................................LUBRICATION CHART 0-13
..................................PERIODIC MAINTENANCE 0-14
PERIODIC REPLACEMENT OF PARTS
...........................................AND LUBRICANTS 0-20

4. 0-2
EXTERIOR VIEWS

5. VEHICLE MODEL * FRAME NUMBER
Model
Load capacity *
Engine
02-6FDU33 3.25 (7000)
TOYOTA 132
02-6FDU35 3.5 (8000)
*: When the load center is 600 m m (24 in)
TOYOTA 132
-- -
02-6FDU40
02-6FDAU50
Drive system Punching format
--
4.0 (9000)
Torque converter I 506FGU45-60011
5.0 (11000)
Frame No. punching position
TOYOTA 132

6. HOW TO READ THIS MANUAL
EXPLANATION METHOD
1. Operation procedure
(1) The operation procedure is described in either pattern A or pattern B below.
Pattern A: Explanation of each operation step with an illustration.
Pattern B: Explanation of operation procedure by indicating step numbers in one illustration,
followed by explanation of cautions and notes summarized as point operations.
Example of description in pattern I3
DISASSEMBLY .INSPECTION.REASSEMBLY Tightening torque unit T = N.m (kgf-cm) [fb-lbf]
1
'T = 46.09 - 48.05
(470 - 4901
134.00 -- 35 451
8
Disassembly Procedure
1 Remove the cover. [Point 11
2 Remove the bush [Point 21-Operation explained later
3 Remove the gear.
Point operations Explanation of key point for operation with an illustration
[Point 11 1
Disassembly: Put a match mark when removing the pump cover.
[Point 21
Inspection: Measure the bush inside diameter.
Bush inside diameter limit: 19.12 m m (0.7528 in)

7. 2. H o w to read components figures (Example)
( 1 1 The components figure uses the illustra-
tion in the parts catalog for the vehicle
model. Please refer to the catalog for
checking the part name.
The number at the right shoulder of each FIG number in parts catalog
components figure indicates the Fig. num-
ber in the parts catalog.
3. Matters omitted in this manual
( 1 ) This manual omits descript~onof the following jobs, but perform them in actual operation:
Cleaning and washing of removed parts as required
2 Visual inspection (partially described)8
TERMINOLOGY
Caution:
Important matters of which negligence may cause accidents. Be sure to abserve them.
Note:
Important items of which negligence may cause accidents, or matters in operation procedure re-
quiring special attention.
Standard: Values showing allowable range in inspection and adjustment.
Limit: Maximum or minimum allowable value in inspection or adjustment.
ABBREVIATIONS
Abbreviation (code)
ASSY
FHPS
L/
LH
LLC
0PT
01s
PS
Meaning
Assembly
Full hydraulic
power steering
Less
Lefthand
Long life coolant
Option
Oversize
Power steering
Abbreviation (code)
RH
SAE
SST
STD
T =
O T
U/S
W/
Meaning
Righthand
Society of Automotive
Engineers (USA)
Special service tool
Standard
Tightening torque
Number of teeth ( 0 0 )
Undersize
With

8. OPERATIONAL TIPS
1. Safe operation
(1) After jacking up, always support with rigid stands.
(2) When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in
load capacity.
(3) Always disconnect the battery plugs before the inspection or servicing of electrical parts.
2. Tactful operation
(1) Prepare the mechanic tools, necessary measuring instruments (circuit tester, megger, oil pres-
sure gauge, etc.) and SSTs before starting operation.
(2) Before disconnecting wiring, always check the cable color and wiring state.
(3) When overhauling functional parts, complicated portions or related mechanisms, arrange the dis-
assembled parts neatly to prevent confusion.
(4) When disassembling and inspecting such a precision part as the control valve, use clean tools
and operate in a clean location.
(5) Follow the described procedures for disassembly, inspection and reassembly.
(6) Replace gaskets, packings and O-rings with new ones each time they are disassembled.
( 7 ) Use genuine Toyota parts for replacement.
(8)Use specified bolts and nuts. Observe the specified tightening torque at the time of reassembly.
If no tightening torque is specified, tighten the bolt or nut according to the standard tightening
torque table.
3. Grasping the trouble state
When a trouble occurs, do not attempt immediate disassembly or replacement but first check if
the trouble requires disassembly or replacement for correction.

9. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
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click on the link above,
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10. STANDARD BOLT AND NUT TIGHTENING TORQUE
How to judge tightening torque of a standard bolt or nut
1. How to judge tightening torque of a standard bolt:
Find out the type of the bolt from the list below.
Then, find the bolt tightening torque from the table.
2. How to judge tightening torque of a standard nut:
The nut tightening torque can be judged from the bolt type. (See the item above.)
BOLT STRENGTH TYPE IDENTIFICATION METHOD
1. Identification by bolt shape 2. Identification by part No.
Hexagon Two protruding
head bolt lines
5T
Class
4 = 4T
5 = 5T
6 = 6T
7 = 7T
8 = 8T
4T
Shape and class
Hexagon
flange bolt
Hexagon Two protruding
flange bolt lines
6T
Hexagon
head bolt
Hexagon Three protruding
head bolt lines
7T
@Bolt head No.
No mark
No mark
Hexagon Four protruding
head bolt lines
8T
4T
Welded bolt 4T
I
Hexagon head bolt
Part No.
91611-40625
1T-LLength (mm)
I D i a m e t e r (mm)
LClass
iameter
I Length I
Stud bolt
rPart No.
92132-406 14
[TLLength (mm)
I Diameter lmml
LClass

11. TIGHTENING TORQUE TABLE
5.4 I 55 I 48 in-lbf
5T
6T
7T
8T
16
6
8
10
12
14
16
6
8
10
12
14
6
8
10
12
14
16
8
10
12
1.5
1.O
1.25
1.25
1.25
1.5
1.5
1.O
1.25
1.25
1.25
1.5
1.o
1.25
1.25
1.25
1.5
1.5
1.25
1.25
1.25
113 / 1150 83
I I
6.4 1 65 1 56 in-lbf
I
1 160 1 12
I
32 I 330 I 24
I I
59 1 600 I 43
I I
91 1 930 1 67
137 1 1 4 0 0 1101
I I
7.8 1 80 1 69 in-lbf
I 195 14
l9 I
1 400 1 2 9
39 1
72 1 730 1 53
I
-
I
I I -
I I
11
I I
1 1 1 0 1 8
25 1 260 1 19
52 1 530 1 38
95 1 970 1 70
147 1500 1108
226 1 2300 1 166
I
I I
29 I 300 I 22
1 I
61 1 620 I 45
110
I I
1 1 1 0 0 1 8 0
83 j 850 61
- I _ I _
I I
I I
1 I
I I
I I
I I
I I
- I - I -
I I
I
I I
I
I I
I I
I
I
8.8 1 90 1 78 in-lbf
I 215
1 1621 I
43 440 3 2
I
1 810 1 59
79 1 I
123 I 1250 I 90
I I
I I
12 1 120 1 9
I I
28 1 290 1 21
58 1 590 1 43
103 / 1050 1 7 6
167 1 1700 1 123
- I - I -
I I
I I
33 I 330 I 24
I I
68 I 690 I 50
I I
120 1 1250 1 90

12. PRECOAT BOLTS
(Bolts with seal lock agent coating on threads)
1. Do not use the precoat bolt as it is in either of the
following cases:
(a) After it is removed.
(b) When the precoat bolt is moved (loosened or tight-
ened) by tightness check, etc.
Note:
For torque check, use the lower limit of the allowable tight-
ening torque range. If the bolt moves, retighten it according
to the steps below.
2. Method for reuse of precoat bolts
(1) Wash the bolt and threaded hole. (The threaded hole
must be washed even for replacement of the bolt.)
(2) Perfectly dry the washed parts by air blowing.
(3) Apply the specified seal lock agent on the threaded
portion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
1. When connecting a high pressure hose, wipe the hose fitting and mating nipple contact surfaces
with clean cloth t o remove foreign matters and dirt. Also check no dent or other damage on the
contact surfaces before installation.
2. When connecting a high pressure hose, hold the hose to align the fitting with the nipple and tighten
the fitting.
3. The maximum tightening torque must not exceed twice the standard tightening torque.
Nominal diameter
of screw
7116 - 20UNF
9/16 - 18UNF
314 - 16UNF
718 - 14UNF
718 - 14UNF
1.1116 - 12 UNF
1,5116 - 12UNF
PF1I 4
PF318
PF 112
PF314
PF1
Hose inside
diameter
mm (in)
6 (0.24)
9 (0.35)
12 (0.47)
12 (0.47)
15 (0.59)
19 (0.75)
25 (0.98)
6 (0.24)
9 (0.35)
12 (0.47)
19 (0.75)
25 (0.98)
Standard tightening torque N.m (kgf-cm)[ft-lbfl
Standard
2 5 ( 2 5 0 ) [ 18.11
49 ( 500) [ 36.21
59 ( 600) [ 43.41
59 ( 600) [ 43.41
78 ( 800) [ 57.91
118 (1200) [ 86.81
137 (1400) [101.3]
25 ( 250) [ 18.11
49 ( 500) [ 36.21
59 ( 600) [ 43.41
1 1 8 ( 1 2 0 0 ) [ 86.81
137 (1400) [101.3]
Tightening range
2 4 - 2 6 ( 2 4 0 - 2 7 0 ) [ 1 7 . 4 - 19.51
47 - 52 ( 480 - 530) [34.7 - 38.31
56 - 62 ( 570 - 630) [41.2 - 45.61
56 - 62 ( 5?0 - 630) l41.2 - 45.61
74 - 82 ( 760 - 840) [55.0 - 60.81
112 - 123 (1140 - 1250) 182.5 - 90.41
130 - 144 (1330 - 1470) (96.2 - 106.41
24 - 26 ( 240 - 270) I17.4 - 19.51
47 - 52 ( 480 - 530) 134.7 - 38.31
56 - 62 ( 570 - 630) [41.2 - 45.61
1 1 2 - 1 2 3 ( 1 1 4 0 - 1250)[82.5- 90.41
130 - 144 (1330 - 1470) f96.2 - 106.41

13. WlRE ROPE SUSPENSION ANGLE LIST
SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE unit: N (ton) [lbfl
Suspens~on
method
2
b'
ij
Compres-
sion
1.OO time
1
1.73 time
Rope
diameter
6 mm
(0.24 in)
8 mm
(0.32 in)
-
10 mm
(0.4 in)
12.5 mm
(0.5 in)
.
14 rnrn
(0.56 tn)
Suspension
angle
90 O
120°
Suspension
Four-rope suspension
Tension
1.41 time
2.00 time
Compres-
sion
Tens~on
Cutting
load
21380
(2.18)
[4807]
Suspens~on
method
90 O
8630
(0.88)
119401
12550
(1.28)
[2322]
19610
(2.0)
[4410]
29420
(3.0) 1
166151
37270
(3.8)
[8379]
0 O
12160
(1.24)
I27341
17650
(1.8)
139691
27460
(2.8)
[6174]
43150
(4.4)
[97021
54920
(5.6)
[I23481
0 time
I
0.27 time b?
2 t
ha
0.58 time
angle I
0 O
30O
60O
Single-rope
suspension-
OD
3040
(0.311
[683.6]
1.OO time
1.04 time
1.16 time
30O
11770
(1.2)
[2646]
17060
(1.74)
[39371
26480
(2.7)
[59541
41 190
14.21
[9261I
52960
(5.4)
[ 119071
Two-rope suspension
60°
10400
(1.06)
[23371
15300
(1.56)
134401
23540
(2.4)
[52921
37270
(3.8)
[83791
47070
(4.8)
[I05841
(3.21) (0.45)
31480 1 4410
1992.31[70781 .I696049230
15.021 1 (0.71)
0 O
6080
(0.62)
[13671
8830
(0.9)
[I9851
14020
(1.43)
[31531
21570
(2.21
I4851I
27460
[I10691
76880
(7.84)
[173871
96400
(9.83)
[216751
11565.61
10980
(1.12)
[2469.51
13730
(1.4)
[30871
30°
5880
(0.6)
[13231
8530
(0.87)
I19181
13440
(1.37)
[30211
21280
(2.1)
146311
26480
(2.7)
[59541
60O
5200
(0.53)
I11691
7650
(0.78)
I17201
11770
(1.2)
[2646]
18630
(1.9)
141901
23540
90O
4310
(0.44)
[9701
6280
(0.64)
[ I 4 111
98iO
(1.0)
122051
14710
(1.5)
133081
18630
(2.4)
I52921
(1.91
141901