1997 Toyota 52-6FGU33/35/40/45, 02-6FDU33/35/40/45, 52-6FGAU50 & 02-6FDAU50 Forklift Service Manual

Toyota Motor Corporation's March 1997 service manual covers the listed 6FGU/6FDU33-45 and 6FGAU/6FDAU50 forklifts with GM6-262 gasoline, gasoline/LPG or LPG engines and the 13Z diesel.

Search, navigation, and wiring detail: The main PDF has OCR text and chapter bookmarks, but some tables, illustrations, and wiring labels are not searchable. The three separate wiring PDFs have no text search or bookmarks. Small schematic labels require zooming, and some supplement pages need rotation.

• Engine and governor: Engine removal and installation, speed adjustment, electronic governor fault codes, sensor tests, and throttle-switch adjustment.

• Torque converter and transmission: MT15 converter repair, F1/R and F2 clutch overhaul, control-valve service, hydraulic pressure checks, and stall testing.

• Axles, steering, and brakes: Planetary front-axle service, rear-axle and steering-valve overhaul, brake shoe replacement, booster repair, and brake bleeding.

• Masts and cylinders: V, FV, and FSV mast adjustments, lift-cylinder repacking, tilt-cylinder overhaul, chain inspection, and uneven-lifting correction.

• Hydraulic system: Tandem gear-pump overhaul, lift and tilt drift testing, flow regulator and safety down valve service, and relief-pressure adjustment.

• Electrical references: Configuration-specific wiring diagrams, governor diagnostic flowcharts, component circuit tests, and electrical service standards.

This manual is suited to forklift mechanics familiar with hydraulic testing and component overhaul, with access to the measuring equipment and special service tools specified in the procedures.

Engine Service and Governor Diagnostics

Gasoline and dual-fuel GM6-262 models use an electronic governor; LPG-only models use an air governor. CHECK-lamp flash codes link to tests for the accelerator sensor, throttle switches, stepping motor, ignition relay, and alternator. These flowcharts help separate wiring and sensor faults from controller faults before a repair decision.

Engine repair scope: Coverage includes 13Z fuel-line bleeding, air-cleaner inspection, radiator specifications, fan-drive service, and starter/alternator removal and installation. For detailed engine repair, the foreword refers readers to the GM6-262 manual No. C4630 and the 11Z/12Z/13Z/14Z manual No. C4615; neither is included in this set.

Drivetrain, Steering, and Brake Repair

Coverage extends through the transmission cover and control valve assembly, stator shaft and oil pump, clutch-pack clearances, and differential backlash, bearing preload, and gear-contact adjustment. Final-drive ratios and brake-booster specifications distinguish the 3.25/3.5-ton and 4.0-5.0-ton groups.

The Danfoss OSPC-160-ON steering valve has dedicated troubleshooting, seal-installation, and relief-pressure sections. Brake coverage includes a foot-brake system diagram, automatic shoe adjusters, parking-brake linkage, and brake/inching-pedal adjustment.

Mast Adjustment and Hydraulic Fault Isolation

Separate V, FV, and FSV instructions distinguish roller selection and lift-bracket adjustment by capacity group. Lift-cylinder rod-shim adjustment addresses uneven lifting after mast or cylinder replacement. The SST list identifies the inner mast stopper 09610-22000-71 and chain wear scale 09631-22000-71.

Natural-drop, forward-tilt, and oil-leak tests help distinguish control-valve leakage from cylinder-packing or tilt-lock faults. Hydraulic coverage includes the SDY (SGP2 + YP15) tandem gear pump and its engine-dependent output, with hydraulic circuit diagrams and lift-cylinder section views.

The manual warns that careless relief-valve adjustment can damage the oil pump and other hydraulic components. Its governor testing notes also address damage risks to the accelerator sensor's gold-plated terminals.

Follow the factory safety precautions for suspended masts, high-pressure hydraulic lines, and electrical servicing.

Wiring Variants and Workshop Reference Data

GM6-262 wiring is separated into gasoline, gasoline/LPG, and LPG diagrams; 13Z diagrams distinguish 12 V and 24 V systems. The governor System Circuit and torque-converter Hydraulic Circuit Diagram support the corresponding troubleshooting sections.

The additional 6FGCU33-45 and 6FG10-30/6FD10-30 files provide wiring coverage only; they do not extend the main workshop manual's repair coverage to those models.

The general section provides component weights, lubrication charts, and periodic maintenance schedules. Exploded component views and service tables cover wear limits, fluid capacities, and torque specifications for flexible-plate bolts, engine mounts, and high-pressure hose fittings.

PDF Set and Wiring Supplements

The ZIP contains 327 pages across four printable PDFs: the 303-page workshop manual, an 8-page wiring extract for the covered models, a 6-page 6FGCU33-45 wiring file, and a 10-page 6FG10-30/6FD10-30 wiring file. The main manual's count includes the foreword, section index, one blank page, and eight wiring pages; the separate 8-page extract repeats those wiring pages, and the 10-page file includes its own wiring index.