Toyota 42-6FGU15, 02-6FDU15, 42-6FGU18, 02-6FDU18, 42-6FGU20, 52-6FGU20, 62-6FDU20, 42-6FGU25, 52-6FGU25, 62-6FDU25, 02-6FGU30, 52-6FGU30, 62-6FDU30 Forklift Service Manual (P/N 6FGU/6FDU15-30)

• Exact coverage as of July 1995: Torque-converter trucks 42-6FGU15/18/20/25 and 02-6FGU30 with the 4Y gasoline engine; 52-6FGU20/25/30 with the GM gasoline engine; and 02-6FDU15/18 plus 62-6FDU20/25/30 with the 1DZ diesel.
• Powertrain procedures: Documents engine-with-torque-converter removal, engine separation, 1DZ fuel-system bleeding, engine-speed setup, and standard one-speed or optional two-speed Aisin transmission repair. Coverage includes control-valve and oil-pump service, clutch-shaft overhaul, shift and inching adjustment, pressure checks, and stall testing.
• Axles, steering, and brakes: Details differential removal and overhaul, backlash and tooth-contact setup, drive-pinion and bearing adjustment, front and rear hub work, rear axle cylinder repair, hydrostatic steering valve disassembly and relief testing, brake overhaul and bleeding, plus braking-force, parking-brake, and pedal adjustments.
• Mast and hydraulic work: Covers V, FV, and FSV mast removal and roller/strip adjustment; lift-bracket, chain, and fork inspection; lift and tilt cylinder repair; safety-down and flow-regulator valves; lift-cylinder rod shimming; and natural-drop, forward-tilt, oil-leak, pump-delivery, and relief-pressure tests.
• Troubleshooting and diagrams: Includes symptom-to-cause charts for no or slow travel, poor tractive effort, delayed engagement, inching shock, overheating, noise, and leaks. Named drawings include the one- and two-speed torque-converter hydraulic circuits, brake and material-handling hydraulic diagrams, brake and wheel-cylinder section views, safety-down-valve section views, and 1DZ glow/combination-meter wiring.
• 374 PDF pages in four files: 350-page core repair manual; 10-page 6FG/6FD10-30 wiring file; 6-page 6FGCU33-45 wiring file; and 8-page 6FGU/6FDU33-45 plus 6FGAU/6FDAU50 wiring file. The last two diagram files cover larger trucks and do not expand the core 15-30 repair scope.

Model and Frame Identification

Toyota's vehicle table spans the 1.5- through 3.0-ton load classes and ties each covered truck to its engine, fuel type, load class, and torque-converter drive. The frame-number page shows the stamping location on the stiffener below the front protector and groups the trucks under the 406FGU18, 6FDU18, 406FGU25, 506FGU25, 606FDU25, 6FGU30, 506FGU30, and 606FDU30 punching formats, illustrated with the -60011 sequence. Because the procedures assume hoists, pressure gauges, a tachometer, dial indicators, a press, and Toyota SSTs, this publication is suited to trained forklift technicians and experienced repairers working in a properly equipped shop.

Component and System Technical Data

The general and appendix sections bring together standard bolt-and-nut and high-pressure hose-fitting torque tables, component-specific tightening data, lubricant types and capacities, component weights, wire-rope suspension and safe-load tables, a lubrication chart, and periodic maintenance and replacement schedules. Consolidated service standards cover inspection limits, running clearances, bearing starting forces, spring lengths, axle and brake measurements, pressure tests, hydraulic drift and leak limits, cylinder dimensions, and mast adjustment data.

The SST list identifies the tools behind the procedures, including engine unit hanger 09010-20111-71, torque-converter clutch-drum spring tool 09220-22000-71, axle-hub and drive-pinion bearing tool set 09608-35014, inner-mast stopper 09610-22000-71, cylinder-cap tool 09620-10100-71, and chain wear scale 09631-22000-71. Component drawings carry parts-catalog figure references, but this is not a parts catalog; the manual directs the reader to the matching catalog for part names. Routine cleaning and washing, along with some visual inspection steps, are intentionally omitted from the written procedures.

Engine, Drivetrain, and Electrical Scope

The engine chapter contains exterior views, major specifications, displacement data, and performance curves, engine-with-torque-converter removal and engine separation procedures, plus service information for the air cleaner, radiator, standard or optional catalytic muffler, battery, starting motor, alternator, and accelerator pedal. It does not include internal engine overhaul procedures. Toyota instead calls for separate engine repair manuals CE602-1 for the 4Y, CU629 for the GM4-181, and CE618 for the 1DZ; those three publications are not part of this set. Although the transmission and clutch components are serviceable, the manual states that the torque-converter assembly itself cannot be disassembled.

The core appendix includes lighting, combination-meter, and 1DZ glow-system wiring. The separate 6FG/6FD10-30 diagram adds battery, starting, charging, ignition, fuel, gasoline/LPG emission-control, lighting, horn, gauge, and accessory circuits. Since the standalone diagram files are labeled for model families that do not exactly match every U-suffix truck in the core manual, confirm the diagram model designation before electrical repair.

Repair Cautions

The oil-control-valve section warns that careless relief adjustment can create excessive pressure and damage the oil pump or other hydraulic components. Hydraulic-pump overhaul also depends on preserving match-marked orientation while avoiding damage to the bushings and gears. Forklift service involves suspended assemblies, divided rims, brakes, and pressurized hydraulics; use rated lifting support, fully release tire pressure before divided-rim disassembly, and relieve residual material-handling pressure before oil-control-valve removal.