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
i n the manual and actual vehicles d u e t o change i n 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

 SECTION INDEX
I NAME 1 SECTION
I

I GENERAL
ENGINE
TORQUE CONVERTER
FRONT AXLE
rn
REAR AXLE
STEERlNG
BRAKE

MATERIAL HANDLING SYSTEM 00

MAST
CYLINDER o

OIL CONTROL VALVE

APPENDIX
 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
0-2

EXTERIOR VIEWS
VEHICLE MODEL * FRAME NUMBER
Load capacity *
Model Engine Drive system Punching format

02-6FDU33 3.25 (7000)

TOYOTA 132
02-6FDU35 3.5 (8000)

Torque converter I 506FGU45-60011

-- - --

02-6FDU40 4.0 (9000)

TOYOTA 132

02-6FDAU 50 5.0 (11000) TOYOTA 132

*: When the load center is 600 m m (24 in)

Frame No. punching position

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]

'T = 46.09 - 48.05

(470 - 4901
134.00 -- 35 451

Disassembly Procedure

2
3
Remove the cover. [Point 11

Remove the bush [Point 21

Remove the gear.

- Operation explained later

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)
2. H o w t o read components figures (Example)
( 1 1 T h e components figure uses the illustra-
t i o n in the parts catalog for the vehicle
model. Please refer to the catalog for
checking t h e part name.
T h e number a t the right shoulder of each FIG number in parts catalog
components figure indicates the Fig. num-
ber in the parts catalog.

3. M a t t e r s o m i t t e d in this manual
( 1 ) This manual o m i t s descript~ono f the following jobs, but perform them in actual operation:

8 Cleaning and washing of removed parts as required

2 Visual inspection (partially described)

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 i n inspection and adjustment.

L i m i t : M a x i m u m or minimum allowable value in inspection or adjustment.

ABBREVIATIONS

Abbreviation (code) Meaning Abbreviation (code) Meaning

ASSY Assembly RH Righthand

Full hydraulic Society of Automotive

FHPS SAE
power steering Engineers (USA)

L/ Less SST Special service tool

LH Lefthand STD Standard

LLC Long life coolant T = Tightening torque

0PT Option O T Number of teeth (0 0)

01s Oversize U/S Undersize

PS Power steering W/ With

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) w i t h 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 t o 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 t o 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.
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.

Shape and class Class Hexagon head bolt

4 = 4T
Part No.

@
5 = 5T
9161 1-40625

1T-L
Bolt head No. 6 = 6T
7 = 7T
Hexagon 8 = 8T Length (mm)
head bolt I D i a m e t e r (mm)
L Class
No mark 4T

iameter
Hexagon
No mark 4T
flange bolt
I Length I
Hexagon Two protruding
5T
head bolt lines

Hexagon
flange bolt

Hexagon
head bolt
Two protruding
lines

Three protruding
lines
6T

7T
r Stud bolt

Part No.
92 132-406 14

[TL Length (mm)

Hexagon Four protruding

8T
I Diameter lmml
head bolt lines LClass

Welded bolt 4T
I
TIGHTENING TORQUE TABLE

5.4 I 55 I 48 in-lbf

83 j 850 61
16 1.5 113 / 1150 83 - I
I
_ I
I
_
I I I I
6 1 .O 6.4 1
I
65 1 56 in-lbf 1
I
I
I
8 1.25 1
I
160 1 12 I
I
I
I
10 1.25 32 I 330 I 24 I I
5T I I - I - I -
12 1.25 59 1 600 I 43 I I
I I I I
14 1.5 91 1 930 1 67 I I
I I
16 1.5 137 11400 1101 I I
I
I I I

6 1 .O 7.8 1 80 1 69 in-lbf 8.8 1 90 1 78 in-lbf

8 1.25
l9
I
I
195 14
21
I
I
215
1 16
6T 10 1.25 1 400 129 43 440 3 2
39 1 I
12 1.25 72 1 730 1 53 1 810 1 59
I I 79 1 I
14 1.5 - I I - 123 I 1250 I 90
I I I I
I I I I
6 1 .o 11 1 1 1 0 1 8 12 1 120 1 9
8 1.25 25 1 260 1 19 28
I
1 290
I
1 21

7T
10 1.25 52 1 530 1 38 58 1 590 1 43
12 1.25 95 1 970 1 70 103 / 1050 1 7 6
14 1.5 147 1500 1108 167 1 1700 1 123
16 1.5 226 1
I
2300 1 166 - I
I
- I
I
-
I I I I
8 1.25 29 I 300 I 22 33 I 330 I 24
1 I I I
8T 10 1.25 61 1 620 I 45 68 I 690 I 50
I I I I
12 1.25 110 11100 180 120 1 1250 1 90
 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
t o 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
w i t h 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 t o align the fitting with the nipple and tighten
the fitting.

3. The maximum tightening torque must not exceed twice the standard tightening torque.

Standard tightening torque N.m (kgf-cm) [ft-lbfl Hose inside

Nominal diameter diameter
of screw Standard Tightening range mm (in)
711 6 - 20UNF 2 5 ( 2 5 0 ) [ 18.11 24- 26(240- 270)[17.4- 19.51 6 (0.24)
9/16 - 18UNF 4 9 ( 500) [ 36.21 47 - 52 ( 480 - 530) [34.7 - 38.31 9 (0.35)
314 - 16UNF 59 ( 600) [ 43.41 56 - 62 ( 570 - 630) [41.2 - 45.61 12 (0.47)
718 - 14UNF 59 ( 600) [ 43.41 56 - 62 ( 5?0 - 630) l41.2 - 45.61 12 (0.47)
718 - 14UNF 78 ( 800) [ 57.91 74 - 82 ( 760 - 840) [55.0 - 60.81 15 (0.59)
1.1116 - 12 UNF 118 (1200) [ 86.81 112 - 123 (1140 - 1250) 182.5 - 90.41 19 (0.75)
1,5116 - 12UNF 137 (1400) [101.3] 130 - 144 (1330 - 1470) (96.2 - 106.41 25 (0.98)
PF 1 I 4 25 ( 250) [ 18.11 24 - 26 ( 240 - 270) I17.4 - 19.51 6 (0.24)
PF318 4 9 ( 500) [ 36.21 47 - 52 ( 480 - 530) 134.7 - 38.31 9 (0.35)
PF 112 59 ( 600) [ 43.41 56 - 62 ( 570 - 630) [41.2 - 45.61 12 (0.47)
PF314 1 1 8 ( 1 2 0 0 ) [ 86.81 1 1 2 - 123(1140- 1250)[82.5- 90.41 19 (0.75)
PF 1 137 (1400) [101.3] 130 - 144 (1330 - 1470) f96.2 - 106.41 25 (0.98)
WlRE ROPE SUSPENSION ANGLE LIST
Suspension Compres- Suspens~on Suspension Compres- Suspens~on
Tens~on Tension
angle I sion method angle sion method

I
0O 1 .OO time 0 time 90 O 1.41 time 1.OO time

1 ij
2
b'

30 O 1.04 time 0.27 time ?

b

ha 2 t
1 20° 2.00 time 1.73 time

60O 1.16 time 0.58 time

SAFE LOAD FOR EACH WlRE ROPE SUSPENSION ANGLE unit: N (ton) [lbfl
Single-rope
Rope Cutting Two-rope suspension Four-rope suspension
suspension
diameter load -
OD 0O 30° 60 O 90O 0O 30O 60° 90 O
21380 3040 6080 5880 5200 4310 12160 11 770 10400 8630
6 mm
(2.18) (0.311 (0.62) (0.6) (0.53) (0.44) (1.24) (1.2) (1.06) (0.88)
(0.24 in)

8 mm
[4807]
31480 1 [683.6]
4410
[ 13671
8830
[ 13231
8530
I11691
7650
[9701
6280
I27341
17650
[2646]
17060
[23371
15300
119401
12550

(0.32 in)
-
(3.21)
[70781
49230
.I (0.45)
1992.31
6960
(0.9)
[I9851
14020
(0.87)
I 191 81
13440
(0.78)
I17201
11 770
(0.64)
[ I 4 1 11
98iO
(1.8)
139691
27460
(1.74)
[39371
26480
(1.56)
134401
23540
(1.28)
[2322]
19610
10 mm
(0.4 in)
15.021 1 (0.71) (1.43) (1.37) (1.2) (1.0) (2.8) (2.7) (2.4) (2.0)
[I10691 11565.61 [31531 [30211 [2646] 122051 [6174] [59541 [52921 [4410]
76880 10980 21570 21280 18630 14710 43150 41 190 37270 29420
12.5 mm
(0.5 in)
(7.84) (1.12) (2.21 (2.1) (1.9) (1.5) (4.4) 14.21 (3.8) (3.0) 1
.
[ 173871 [2469.51 I4851I 146311 141901 133081 [97021 [9261I [83791 166151
96400 13730 27460 26480 23540 18630 54920 52960 47070 37270
14 rnrn
(9.83) (1.4) (2.7) (2.4) (1.91 (5.6) (5.4) (4.8) (3.8)
(0.56 tn)
[216751 [30871 [59541 I52921 141901 [I23481 [ 119071 [I
05841 [8379]
COMPONENTS WEIGHT
Unit: kg (Ib)

Component Weight (mass)

GM6-262 185 (408)

Engine
1 32 325 (717)

Transmission W I differential Approx. 200 (441)

Torque converter W/ differential Approx. 360 (794)

3.25 ton model Approx. 1920 (4230)

3.5 ton model Approx. 2210 (4870)

Counterweight 4.0 ton model Approx. 2520 (5560)

4.5 ton model Approx. 2840 (6260)

5.0 ton model Approx. 2840 (6260)

3.25 - 4.0 ton model Approx. 890 (1960)

V mast ASSY Llbackrest and fork
(with lift cylinder max. lifting 4.5 ton model Approx. 1 140 (2510)
height: 3000 mm (118in))
5.0 ton model Approx. 1270 (2800)
0-1 2

RECOMMENDED LUBRICANT QUANTITY & TYPES

Description Classification Type Application Quantity

Motor oil
SAE30
(SAE2O in cold area)
API
Gasoline GM6-262 4.2 Q (1.11 US gal)
SD, SE, SF
SAE20W-40
(SAE1 OW-30 in cold
Engine area)

Diesel engine oil

API SAE3O (SAE20 in
Diesel CC, CD cold area) 132 12.5 Q (3.30 US gal)
or better
SAE 1 OW-30

Torque converter ATF G M Dexron"l1 All models 15 Q (4.0 US gal)

API
Hypoid gear oil
Differential GL-4 All models 9.5 Q (2.51 US gal)
SAE85W-90
GL-5

Hydraulic oil
IS0
[Max. fork height =
VG32
Hydraulic oil I S 0 V G 3 2 All models 68 Q ( 18.0 US gal)
3000 m m (11 8 in)]
-
3'25 3'5
ton model
9 5 Q (25.1 US gal)
Fuel tank
4.0 - 5.0
ton model
120 Q (31.7 US gal)

Chassis parts All models Proper quantity

Propeller shaft and Molybdenum disulfide

pump spline shaft
All models t

LLC 3 0 -5 0 % mixure
(for winter or all- GM6-262 13.0 Q (3.43 US gal)
Coolant season)
(excluding reservoir LLC Coolant w i t h
tank) rust inhibitor (for
spring, summer and 132 13.0 Q (3.43 US gal)
autumn)

Coolant 1.1 Q (0.29 US gal)

(Reservoir Tank) ? ? All models
(at Full levell
LUBRICATION CHART

() lnspect~on
Replacement
(v M P grease
Eng~ne011 I. lnspect every 8 hours (da~ly)
H y p o ~ dgear 011 11. lnspect every 4 0 hours (weekly)
@ Hydraul~c011 Ill. lnspect every 1 7 0 hours (monthly)
a Automat~ctransmlsslon f l u ~ d IV. lnspect every 1000 hours (6 monthlyl
a Molybdenum disulfide grease V. lnspect every 2000 hours (annually)

1 Cham Rear axle beam front

2 D i f f e r e n t ~ agear
l Rear axle beam rear
3 Front wheel bear~ng Tilt steerlng un~versallotnt
4 Torque converter case T ~ l steerlng
t lock~ngmechan~sm
5 Rear wheel bear~ng Mast support bush~ng
6 Steer~ngknuckle k ~ n gptn T ~ l cyltnder
t front ptn
7 Power steering cylinder pin and tie-rod Propeller shaft
8 011tank Oil pump spline shaft
9 E n g ~ n ecrankshaft Tilt cylinder rear pin
PERIODIC MAINTENANCE
INSPECTION METHOD
I : Inspection. Repair or replacement if required.
M : Measurement. Repair or adjustment if required.
T : Retightening C : Cleaning L : Lubrication
: For n e w vehicle " 1 : Flaw detector

Inspection period Every Every Every Every

month 3 months 6 months 1 2 months
Every Every Every Every
Item 170 hours 500 hours 1000 hours 2 0 0 0 hours
ENGINE
Proper starting and abnormal noise I + +- +

Rotating condition at idling M +- +- +

Rotating condition during

M C C 4-
acceleration
Exhaust gas condition I e t c
Basic
components Air cleaner element C +- + +

Valve clearance M
Compression M
Cylinder head bolt loosening T
Muffler rubber mount I
Clogging and damage in PCV valve
'yStem I C C C
and piping
Governor No-load maximum rpm M +- +- +-

Oil leakage I +- +- C

Lubrication
Oil level I + +- C
system
Clogging and dirt of oil filter I +- +- +-

Fuel leakage I c + C

Operation of carburetor link

I C t t
mechanism
Dirt and clogging of fuel filter and
I 4- t 4-

Fuel system element

Injection timing M C

Injection nozzle injection pressure

M
and spray status
Draining of sedimenter I +

Coolant level in radiator and leak I + +- +-

Rubber hose degradation I c c +-

Cooling Radiator cap condition I 4- + +

system
Fan belt tension, looseness and
I C C C
damage
Radiator rubber mount I
 Inspection period Every Every Every Every
month 3 months 6 months 1 2 months
Every Every Every Every
Item 1 7 0 hours 5 0 0 hours 1 0 0 0 hours 2 0 0 0 hours

POWER TRANSMISSION SYSTEM

Oil leakage I + t t

Differential Oil level I +- +- t

Bolt loosening T
Leakage I + t +-

Fluid level I t t 4-

Torque Operating mechanism function and

I + t t

converter looseness
and Control valve and clutch functions I t + +-
transmission
Inching valve function I t t t

Stall and hydraulic pressure

M t
measurement
Loose joint T t t

Propeller Looseness at spline connections I

shaft and
axle Looseness of universal joint I
Twisting and cracks of axle shaft I
DRIVE SYSTEM
Tire inflation pressure M t t +

Tire cuts, damage and uneven

I t t t
wear
Loose rim and hub nuts T t + +

Tire groove depth M t t +

Wheels Metal chips, pebbles and other for-

I t t +-
eign matter trapped in tire grooves
Rim, side bearing and disc wheel
I t t t
damage
Abnormal noise and looseness of I t t t
front wheel bearing
Abnormal noise and looseness of I t t t
rear wheel bearing
Crack, damage and deformation of I
Front axle
housing
Crack, damage and deformation of I
beam
Rear axle
Looseness of axle beam in vehicle M
longitudinal direction
 Inspection period Every Every Every Every
month 3 months 6 months 12 months
Every Every Every Every
Item 1 7 0 hours 5 0 0 hours 1000 hours 2000 hours

STEERING SYSTEM

Steering Play and looseness I t C t

wheel Function I +- c t

Steering Oil leakage I 4- t t

valve Looseness of mounting T + + +-

Oil leakage I + + C

Power c +-
Mounting and linkage looseness 1 c
Steering
Damage of power steering hose I
King pin looseness I + t +
Knuckle
Crack and deformation I
BRAKING SYSTEM
Play and reserve M C +- t
Brake pedal
Braking effect I + + +-

Operating force I +- + 4-

Parking Braking effect I e + c

brake
Rod and cable looseness and
I t t t
damage
Leak, damage and mounting
Brake pipe I + t +-
condition
Brake booster and Function, wear, damage,
I
wheel cylinder leak and mounting looseness
Clearance between drum and lining M + t +

Wear of shoe sliding portion and

I
lining
Brake drum Drum wear and damage I
and brake
Shoe operating condition I
shoe
Anchor pin rusting I
Return spring fatigue M
Automatic adjuster function I
Backing Deformation, crack and damage I
plate Loose mounting T
MATERIAL HANDLING SYSTEM
Abnormality of fork and stopper pin I + +- +-

Misalignment between left and right

Forks I C e t
fork fingers
Crack at fork root and welded part I*'
 Inspection period Every Every Every Every
month 3 months 6 months 12 months
-
Every Every Every Every
Item 1 7 0 hours 5 0 0 hours 1000 hours 2000 hours
Deformation and damage of each
I t C t
part and crack at welded part
Mast and lift bracket looseness I + e +

Wear and damage of mast support

Mast and I
bust,
lift bracket
Wear, damage and rotating condi-
I C C e
tion of rollers
Wear and damage of roller pins I
Wear and damage of mast trip I + + +

Tension, deformation and damage

I 4- C 4-
of chain

Chain and Chain lubrication I c c t

chain Abnormality of chain anchor bolt I t c +

Wear, damage and rotating condi-

I t C C
tion of chain wheel1
Various Abnormality and mounting condition
I C C t
attachments of each part
HYDRAULIC SYSTEM
Loosening and damage of cylinder
I C e C
mounting
Deformation and damage of rod, rod
I C 4- C
screw and rod end
Cylinder operation I + c c

Natural drop and natural forward tilt

Cylinder M C C C
(hydraulic drift)
Oil leakage and damage I t c t

Wear and damage of pin and

I C e 4-
cylinder bearing
Lifting speed M +- + +

Uneven movement I + + +

Oil pump Oil leakage and abnormal sound I t c +

Oil level and contamination I + e +-

Hydraulic
Tank and oil strainer C t
oil tank
Oil leakage I +- +- +

Control Loose linkage I t t C

lever Operation I t +- C
 Inspection period Every Every Every Every
month 3 months 6 months 1 2 months
Every Every Every Every
Item 1 7 0 hours 500 hours 1000 hours 2000 hours

Oil leakage I e 4- +-

Oil control Relief pressure measurement M

valve
Relief valve and tilt lock valve
I 4- C 4-
functions
Oil leakage I t 4- e
Hydraulic + c +
Deformation and damage I
piping
Loose joint T t 4- +

ELECTRICAL SYSTEM
Crack at distributor cap I + + +

Spark plug burning and gap I t d- t

Distributor side terminal burning I C t t

lgnition
timing Distributor cap center piece wear
I t +- t
and damage
Plug cord internal discontinuity I
Ignition timing M +

Starting
Pinion gear meshing status I t + t
motor
Charger Charging function I t + +-

Battery fluid level I 4- 4- +

Battery
Battery fluid specific gravity M +-

Electrical Damage of wiring harness I C t C

wiring Fuses I c t c

Open-circuit in glow plug I +

Preheater
Open-circuit in intake heater I +

Engine
Diesel engine key stop device
stopping I + +- t
function
system
SAVETY DEVICES, ETC.
Crack at welded portion I +- C +-
Head guard
Deformation and damage I c t +

Loosening of mounting T c C +
Back-rest
Deformation, crack and damage I + + e

Lighting
Function and mounting condition I + C +
system
Horn Function and mounting condition I t C +
 Inspection period Every Every Every Every
month 3 months 6 months 12 months
Every Every Every Every
Item 1 7 0 hours 500 hours 1000 hours 2000 hours
Direction +
Function and mounting condition I 4- +
indicator
Instruments Functions I C + +

Backup +-
Function and mounting condition I t t
buzzer
Rear-view Dirt, damage I C 4- +

mirror Rear reflection status I 4- e c

Seat Loosening and damage of mounting I C +- +-

Damage and crack of frame, cross

I
Body members, etc.
Bolt looseness T
Others Grease up L 4- +- +
-
PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
0 : Replacement
Every Every Every Every
Interval
month 3 months 6 months 12 months
Every Every Every Every
Item
1 70 hours 500 hours 1000 hours 2000 hours
Engine oil • t t +

Engine oil filter • t t

Engine coolant (every 2 years for LLC) • C t

Fuel filter 1 1 a t
Torque converter oil I 1 / I C
Torque converter oil filter • t

Differential oil •
Hydraulic oil I 1 I a I C
Hydraulic oil return filter I a*' I I t
Wheel bearing grease
--
I I 1 1 l
Spark plugs • t

Air cleaner element •

Cups and seals for brake booster and wheel
cylinders

-
Power steering hoses I 1 I I er2
Power steering rubber parts O*
Hydraulic hoses a*2
Fuel hoses
Torque converter rubber hoses 1 I 1 1 a*z
j Chains a"3
*I: for n e w vehicle *2: Every 2 years *3: Every 3 year

Replacement shall be made upon arrival o f the specified operation hours or months, whichever is earlier.
 ENGINE
Page
ENGINE EXTERIOR VIEWS ................................. 1-2
MAJOR SPECIFICATIONS .................................. 1-3
ENGINE PERFORMANCE CURVES ..................... 1- 4
ENGINE ASSY ..................................................... 1-5
REMOVAL .INSTALLATION................................... 1-5
ENGINE SPEED ADJUSTMENT ( G M 6 - 2 6 2 ) ....... 1-8
ELECTRONIC GOVERNOR ..................................... 1-11
ENGINE SPEED ADJUSTMENT (132) ................ 1- 32
AIR CLEANER ..................................................... 1- 33
GENERAL ............................................................ 1 - 3 3
SPECIFICATIONS ................................................. 1 - 3 3
COMPONENTS .................................................... 1 - 3 4
.
AIR CLEANER CLEANING INSPECTION .................. 1 - 3 4
CLOGGING WARNING SYSTEM INSPECTION .......... 1-35
RADIATOR ......................................................... 1-36
COMPONENTS .................................................... 1-36
SPECIFICATIONS ................................................. 1-36
FAN DRIVE ......................................................... 1- 37
REMOVAL .INSTALLATION ................................... 1-37
DISASSEMBLY .INSPECTION .REASSEMBLY ............ 1 - 3 9
MUFFLER & EXHAUST PIPE .............................. 1- 42
COMPONENTS .................................................... 1- 42
REMOVAL .INSTALLATION ................................... 1- 43
BATTERY SPARK PLUG ( G M 6 - 2 6 2 )
rn .................. 1-44
COMPONENTS .................................................... 1 - 4 4
SPECIFICATIONS ................................................. 1- 44
STARTING MOTOR ............................................ 1-47
REMOVAL .INSTALLATION ................................... 1-47
ALTERNATOR .................................................... 1- 48
REMOVAL . INSTALLATION ................................... 1-48
ACCELERATOR PEDAL ....................................... 1-50
COMPONENTS .................................................... 1- 50
ACCELERATOR PEDAL ADJUSTMENT ................... 1 - 5 1
ENGINE EXTERIOR VIEWS
GM6-262 Engine

132 Engine
MAJOR SPECIFICATIONS
GM6-262 Engine
Gasoline GasolineILPG LPG
Engine type 4 - cycle t t

Number of cylinders and arrangement

I V-type 6 cylinders
longitudinal
Combustion chamber type Wedge type t t

Number of valves per cylinder

I Intake valve x 1
Exhaust valvex 1 I t

Valve mechanism OHV chain-driven t t

101.60 x 88.39
Bore x stroke mm (in) t t
(4.0 x 3.480)
Total displacement cm3(in 3) 4300 (262.4) t t

Compression ratio 9.2 t t

( Maximum power kW (PS)/rpm 1 67 (91)I2350 1 61 (83112350 1 61 (83)/2150 1

I Maximum torque N*m (kgf-m)/rpm 1 294 (30)/1200 1 284 (29)/1200 1 284 (29)/1200 1
Minimum specific fuel
g/kW-h (g1PS-h)/rpm 258 (190)/1800 249 (183)/1400 250 (184)/1400
consumption
I Governor system I Electronic governor I t I Air governor I
I Service weight kg (Ib) I 185 (408) 1 t I t I
No-load maximum rpm rPm 2350 t 2400

132 Engine

Engine type Diesel .4-cycle

Number of cylinders and arrangement Inline 6 cylinders.vertical
Combustion chamber type Direct injection
Intake valve x 1
Number of valves per cylinder
Exhaust valve x 1
Valve mechanism 0HV.chain-driven
Bore x stroke mm (in) 98.0 x 102.0 (3.858 x 4.016)
Total displacement cm3 (in 3 ) 4616 (281)
Compression ratio 18.5
Maximum power kW (PS)/rpm 6 2 (85112200
Maximum torque N. m (kgf-m)/rpm 284 (29111600
Minimum specific fuel g,kW-h (g/PS-h)/rpm 224 (165111200
consumption
Service weight kg (Ib) 325 (717)
No-load maximum rpm rPm 2400
ENGINE PERFORMANCE CURVES
GM6-262 Engine
I I
294 (30111200
Gasoline
LPG 284 (29111200
GasolinelLPG

260
kW

24

60

30

2 50
249 (183)11400
1 I I I 1 , I I
10 12 14 16 18 20 22 24

Engine speed (rpm) x lo2

132 Engine
284 N.m (29.0 kgf-m)/1600 rpm

I 1

10 14 18 22 x lo2
Engine speed (rpm)
ENGINE ASSY
REMOVAL. INSTALLATION
Removal Procedure
1 Remove the radiator cover.
2 Remove the engine hood. (See page 7-61
3 Remove the toe board.
4 Remove the battery, battery case and bracket.
5 Remove the air cleaner case ASSY
6 Disconnect the electrical wiring.
7 Remove the undercover.
8 Disconnect the oil pump drive shaft. [Point 11
9 Remove the exhaust pipe.
1 0 Disconnect t w o radiator hoses. (GM6-262 Engine)
11 Remove the radiator and fan shroud. ( 132 Engine)
12 Disconnect the fuel hose.
13 Slightly hoist the engine. [Point 21
14 Support the torque converter lower side with wooden blocks.
1 5 Remove the flexible plate set bolts. [Point 31
1 6 Disconnect the torque converter end plate from transmission case.
17 Remove t w o engine mount brackets.
18 Remove the engine. [Point 41
19 Remove the flywheel and torque converter end plate.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
Tighten the flexible plate set bolts after applying locking agent (08833-00070).
The tightening torque for each part is as follows:
Unit: N - m (kgf-cm) [ft-lbfl
Engine mount bracket set bolt : 48.05 - 8 9 . 2 4 ( 4 9 0 - 910)[35.45 - 65.841
Torque converter end plate set bolt : 29.42 - 44.13 (300 - 450) [21.71 - 32.561
Flexible plate set bolt : 14.71 - 24.52 (150 - 250) i10.85 - 18.091
Flywheel set bolt : 98.1 - 156.9 (1000 - 1600) E72.4- 115.81

Bleeding Air from Fuel Line (13 2 Engine)

I
1. Operate the fuel pump hand pump until it becomes
heavy. Air bleeding is completed when the handle is felt
heavy.
 Point Operations
[Point 1 I

Removal: Disconnect after tying with a string so as not to

cause disconnection at the spline.

[Point 21

Removal .Installation: SST 09010-201 1 1-71

\ SST Removal.Installation: Use a sufficiently strong wire. Set
length A at approx. 250 mm (9.84
in) to obtain a sufficient hoisting
stroke.

A I [Point 31

Removal Installation: Remove nine (9)set bolts while rotat-

ing the torque converter.

[Point 41

Removal: Remove after checking perfect disconnection of

the wiring, hose and cables.
 ENGINE SPEED ADJUSTMENT (GM6-262)
ldle Speed Inspection .Adjustment
<Gasoline engine or gasolinelLPG engine model >

Note:
The idling speed is electronically controlled.

1. Warm up the engine.

Cooling water temperature: 80°C (176OF) or more

Hydraulic oil temperature: 60°C ( 140°F) or more

Install a tachometer and vacuum gage.

( 1) Disconnect the inspection connector and connect the
tachometer measurement cord t o the male side.
(2) Disconnect the vacuum hose and install the vacuum
gage.

ldle speed inspection and adjustment

(1 Measure the idle speed.
I ' I
Standard: 750;:' rpm
I I

Adjust the mixture adjusting screw so that the nega-

tive pressure then is stabilized at the highest level.

Note:
When the idling speed is high, check if the idle adjust-
ing screw is pushing the lever. If so, loosen the screw.

(2) Check and adjust the clearance between the idle

adjusting screw and lever.

Standard: 0 m m (0 in)

< LPG Engine Model >

1. Warm up the engine in the same way as for the gaso-
line or gasoline1LPG engine and connect a tachometer.

2. ldle speed inspection and adjustment.

(1 Adjust the idle speed with the throttle adjust screw.

Standard: 800 t 25 rpm

(2) Turn the idle adjusting screw gradually clockwise or

-
counterclockwise t o the position where the engine rpm
Throttle adjust screw
is the highest.
(3) Adjust the standard value by turning the throttle ad-
justing screw.

Note:
Repeat steps (2)and (3) until the state after step (2)
satisfies the standard.

(4) Turn the idle adjusting screw counterclockwise until

the rpm starts t o drop, and then turn it clockwise by
45O.
 Idle Up Inspection. Adjustment
<LPG Engine Model >

1. Warm up the engine.

Cooling water temperature: 80°C (176OF) or more

Hydraulic oil temperature: 60°C (140°F1 or more

2. Install a tachometer.

Check the idle-up speed.

(1) Start the engine. Disconnect the vacuum hose from
Plug the idle-up actuator and measure the speed after plug-

1
ging the hose.

Standard: 1 2 5 0 k 5 0 rpm

(2) If the standard is not satisfied, make adjustment by

turning the adjusting screw.

Note:
Turn the adjusting screw clockwise t o increase speed.

(3) After adjustment, connect the vacuum hose.

No-Load Maximum Speed Inspection-Adjustment

<Gasoline or GasolinelLPG Engine Model >

Note:
The maximum speed is controlled electronically.

1. Warm up the engine.

Cooling water temperature: 80°C (176OF) or more

~ ~ d r a i loil
i ctemperature: 60°C (140° F) or more

2. Install a tachometer.

3. lnspect the no-load maximum speed when the acceler-

ator pedal is fully depressed.

Standard: 2350 + 3 0 rpm

c LPG Engine Model >
1
' 1. Warm up the engine

Cooling water temperature: 80°C (176OF1 or more

Hydraulic oil temperature: 60°C (140°F1 or more

2. Install a tachometer.

3. lnspect and adjust the no-load maximum speed.

( 1 1 Measure the speed when the accelerator pedal is ful-
ly depressed.

Standard: 2 4 0 0 ? 5 0 rpm
 (2) If the standard is not satisfied, adjust the speed.
(3) Remove the air governor bush lock bolt.
Turn the air governor bush while fixing the adjusting
screw t o adjust the speed.

Note:
Less than the standard: Turn the bushing clock-
wise.
More than the standard: Turn the bushing counter-
clockwise.

(4) Install the air governor bush lock bolt.

Loaded Maximum Speed Measurement

Note:
In the gasoline or gasolineILPG engine model, the maximum
speed is controlled electronically.

c LPG Engine Model >

1. While the engine is running at the maximum speed, oper-
ate the material handling lever and measure the engine
speed at full relief. Check that the decrease in the speed
is within the following range.
Adjusting screw
Standard: 2150 rpm or more

2. If the standard is n o t satisfied, turn the adjusting screw

for adjustment.
ELECTRONIC GOVERNOR
Repair operation
1. Carefully protect electrical parts from direct water pressure (100 kPa (1 kgf/cm 2) [ I 4 psi]) application
during vehicle washing.
2. After any repair, always conduct the final inspection according t o the specified procedure.
3. Never attempt at electrical wiring modification. (Never install any electrical parts other than OPT.)

Parts handling
1. Handle each part with care. Especially avoid any impact on controller sensor parts as it will bring
about adverse influence.
2. Sensor adjustment is necessary after repairing a part related to each sensor.
3. When installing the throttle switch, avoid incorrect connection of the max. (full) side and min. (idle)
side. (The shorter wiring is for the min. side.)
4. Three types of controllers are used selectively according to the vehicle model.

Items to be provided
Prepare the following tools:

Name Part No. Purpose

Sensor and switch inspection
Toyota electrical tester 09082-00050
SSTImeasuring and measurement
instrument Sensor and switch inspection
Thickness gauge
and measurement
Bond, etc. Thread tightener 08833-00070 Upon sensor adjustment

Outline of Repair Procedure

Procedure Job description Reference page
1. Prepare necessary tools. Page 1-1 1 (Items to
Preparation
be prepared)
Troubleshooting 1. Inspect basic characteristics before Page 1-1 2
1. Basic inspection starting troubleshooting. (basic inspection)
2. Functional 2. Perform functional inspection (function Page 1-1 2
inspection check of each part) to clarify the defect (final inspection)
status.
3. Diagnostic 1. Inspect according to the self-diagnosis Page 1-1 3
inspection code. (inspection by
4. Other inspection 2. For a defect for which no self-diagnosis diagnosis)
Repair
code is displayed, determine the Page 1-31
operation
inspection method according t o the (inspection of defect no
phenomenon. indicated by diagnosis)
Removal, installation 1. Perform removal, installation, inspection
or replacement and replacement.
1. Sensor adjustment is necessary if any Page 1-19
part related t o the system is repaired (sensor and switch
(removed, installed or replaced). Parts adjustment)
Adjustment
requiring adjustment are as follows:
Acceleration sensor, idle switch and
throttle switch
Stopped state 1. After the end of repair job, inspect Page 1-1 2
Final according to the final inspection (final inspection)
inspection procedure.
Traveling state
1. Summarize the defects and repair details.
End
(Keep them for reference in the later.)
Basic lnspection
lnspect basic items shown below before starting troubleshooting:

Item Content Remarks

1. lnspect the battery voltage and
specific gravity of electrolyte.
Electrical system
2. Inspect any blown fuse and
inspection
grounding state.
3. Inspect the wiring and harness
connector conditions.
1. lnspect the carburetor function.
(1) Carburetor link operation state
lnspection around
(2) Stepping motor operation state
carburetor
Specific gravity: 1.280
Voltage: 10 to 14 V
Erroneous diagnosis will result if the
battery voltage is low.
Defective grounding will cause
erroneous diagnosis.
Defective contact of the wiring or
harness connector will cause erroneous
diagnosis.
There shall be no looseness in the
carburetor link.
Manually rotate the throttle lever and
stepping motor.
Shall be rotated smoothly.

Final lnspection
After the end of repair, perform inspection according to the following procedure:

Inspection order Inspection method Inspection standard Check

1. lnspect each connector Shall not be disconnected,
1. Inspection with for the connection state. loosened or wetted.
engine switch 2. Mechanical operation of Shall move smoothly.
OFF acceleration sensor and
idle switch
Vehicle
stopping state 2. lnspection before 1. Depress the accelerator The movement shall follow
engine starting pedal and check the the accelerator pedal
with engine throttle movement. depression state.
switch ON
3. lnspection after 1. lnspect the CHECK lamp Shall normally be off.
engine starting for lighting state.
1. lnspect the CHECK lamp The CHECK lamp shall be
during traveling. kept off.
Vehicle 4. Self-diagnostic 2. Disconnect the diagnosis No self-diagnostic code
traveling state inspection connector for self- shall be displayed.
diagnostic code display,
and check if any code is
displayed.
Self-diagnosis
The self-diagnostic function inform the driver of trouble occurrence and trouble position by flashing the
CHECK lamp in the combination meter if any trouble occurs in electronic governor control.
The trouble position is indicated by the CHECK lamp flashing count.
Display of diagnostic code 5

1.2 S

- - - - - - - - ON
- - - - - - OFF
Display of diagnostic codes 5 and 7

0.3 S

Repetition of above cycle operation

Note:
The CHECK lamp may come o n when t h e engine switch i s turned t o ON or may flash during
traveling (during operation).
If it flashes during operation, immediately stop the vehicle and check the flashing count with the
engine switch at t h e ON position (engine n o t running). The flashing count becomes the self-
diagnostic code.
The diagnosis is repeated when t h e engine switch is set t o OFF once and t o ON again. If any
abnormality exists, the CHECK lamp flashes.
After the end of repair according t o the diagnosis, disconnect the memory clear terminal, connect
the male side of the disconnected terminal t o the body ground, and turn the engine switch t o ON
t o reset the ECU memory. (See the illustration below.)

Rechecking the diagnostic result displayed before

To check the diagnostic result displayed i n the past (after
ECU memory resetting), disconnect the diagnosis connector
(checker) for re-display.
Once the ECU memory is reset, preceding results are not
displayed.
1-14

Diagnostic Code List

0:
Normal traveling A:Low-speed traveling X : Traveling failure
Backup
Code Diagnostic
Diagnosed state Controller action upon defect
No item Engine
detection.

The engine is stopped by setting

1 Overrun Abnormal engine speed rise X
engine ignition to off.

Accelerator When the signal from the sensor

2 opening signal is abnormal or the line is shorted A Idle traveling possible.
line or opened.

Acceleration1 ON signal though the Ordinary traveling possible

3 idle signal line potentiometer opening signal is 0 thoughthemaximumspeed
(short circuit) 112 or more (short circuit) may decrease.

Throttle full The signal is OFF though the Normal traveling possible
close switch stepping motor is rotated toward though the maximum speed
signal the throttle closing side by a O may decrease because the
(open circuit) specified angle or more. throttle opening is limited.

Throttlefull
The signal is OFF though the
Open switch t
signal
throttle is opened beyond the 0
specified opening.
(short circuit)

Throttlefull
The signal is ON though the
Close switch
t
signal
throttle opening is beyond the 0
specified level.
(short circuit)

Throttlefull
The signal is ON when the throttle
open switch
signal
opening is below the specified 0 7.
level.
(short circuit)

The engine speed does not drop

* Stepping
motor
though the controller issues the
throttle closing instruction.
The engine is stopped by setting
the engine ignition to OFF.

9 Engine pulse No engine ignition signal A Idle traveling possible.

10 Alternator The alternator signal is OFF A 'r

Components
1-16

System Circuit

Altern

Governor ECU

Functional Parts Inspection

Acceleration Sensor

Note
Carefully handle pins VTA a n d E2 since they are gold-
plated.
Do not pinch a terminal directly with an alligator clip.

Vc V TA IDL E2 1. Measure the resistance between Vc and E2 (between 4

and 1).

Standard: 4.0 + 1.2 kf2 (at 25 +. 10°C)

E2 Vc
n n
2. Turn the potentiometer and measure the resistance
between VTA and Ez.
? 7,
1 \
IDL VTA
Standard: t h e resistance shall increase in proportion
t o the degree of opening.

3. Turn the potentiometer and measure the continuity

between IDL and E2 (between 2 and 1).

Standard: Shall be turned from O N t o OFF by about

r
(V) 15" when turned from the free state.
-m 5 - . - - - - ...
C
[n
r
.-
4-

0
-X
1
-

OFF Close Open + Pedal depression

Potentiometer turning angle
(accelerator pedal opening)
 Throttle Switch

1. lnspect the throttle switch.

(1) Disconnect the connector and inspect continuity of
full open (between 3 and 4) and full close (between 1
and 2) switches for ON and OFF.

Standard:
ON Continuity
OFF No continuity

2. lnspect the vehicle side harness.

(1) Disconnect t h e connector and inspect the wire
harness side connector.

Standard:
-
1 Body ground
-
2 Body ground
-
4.5 5.25 V
Continuity
Harness
side
-
3 Body ground
-
4 Body ground
-
4.5 5.25 V
Continuity

Stepping Motor

1. lnspect the signal voltage on the vehicle.

(1) Measure the stepping motor operating voltage with
the engine switch in the ON position.

Standard:
Between 3 and ground: Battery voltage

2. lnspect continuity individually.

( 1 ) Manually rotate the stepping motor shaft and check
that it is rotated smoothly.
(2) Measure the resistance between 1 and 3, 2 and 3, 4
and 3, and 5 and 3.

Standard: 2.97 to 3.63 R (at 25°C)

(3) Measure the i n s u l a t i o n resistance between the

stepping motor and each of terminals 1, 2, 3, 4 and 5.

Standard: 100 MR or more (with a 500 V DC

megger)
 (4) After installing the stepping motor, manually turn the
throttle lever in the full opening direction (full open,
112 open and 114 open) and release it. Check to see
that the lever shall be returned smoothly by the
spring force.

Ignition Relay

1. lnspect continuity of the relay coil.

Standard: 55 - 82 R

. lnspect the ignition relay for proper functioning.

(1) Connect the battery to the ignition relay and inspect
the switch continuity.

Standard: Continuity

(2) Disconnect the battery from the relay, and inspect

switch continuity.

Standard: No continuity

Fuse

1. Remove the fuse from the fuse box, and inspect it.
(1) Check continuity between both terminals of the fuse.

Standard:
Between fuse terminals: 0 R (continuity)
Fuse capacity: 7.5 A for ECU
Sensor and Switch Adjustment
Acceleration Sensor

Note:
The acceleration sensor requires adjustment after the following jobs:
Acceleration sensor part replacement (removal/installation)
Accelerator pedal height adjustment

Accelerator Pedal Height Adjustment

Accelerator link stopper bolt

Accelerator link roller

Pedal stopper bolt

Accelerator link

1. Return side pedal height adjustment

Make adjustment by turning the accelerator link stopper
bolt to make the height (A) from top of the accelerator
link roller to the link bracket mounting surface satisfy
the following standard:

Standard
Accelerator link roller height:
A = 83 2 2 m m (3.35 2 0.08 in)

[::!A 1
top of floor to top of roller: C = 89.5 mrn 13.524 in)

2. Depression side pedal height adjustment

Make adjustment to make the pedal stopper bolt height
(6)satisfy the following standard:

Standard
Pedal stopper bolt height:
B = 50-E mm (1.97-:,,, in)
 Acceleration Sensor Adjustment

1. See that the accelerator pedal heights (on the return

and depression sides) are normal. (See the accelerator
pedal height section.)

2. Remove the accelerator link bracket Wlsensor.

(1) Accelerator link bracket set bolts
(2) Acceleration sensor wiring disconnection
(3) Accelerator link bracket Wlsensor

3. Adjust the acceleration sensor mounting position.

(Adjustment of ON-OFF transition point of IDL switch in
sensor)
(1) Loosen the sensor set screw.
(2) Use a c i r c u i t t e s t e r a n d check ON-OFF of the
acceleration sensor switch.
Between connector terminals 1 and 2 (E2and IDL)

Note:
Carefully operate so as not t o damage the sensor
terminals.

(3) lnsert a 0.8 mm (0.031 in) thickness gauge between

the accelerator link stopper bolt and accelerator link.
Insert a thickness gauge here.

Accelerator link

(4) I n the state of (31, manually turn the acceleration

sensor gradually. Tighten the acceleration sensor set
Accelerator link bracket screw for fixing at the position where the signal is set
from ON to OFF.

Acceleration sensor position adjusting standard

Thickness gage IDL switch

0.8 m m (0.031 in) : ON-OFF transition point

4. Check the IDL ONIOFF state after fixing the acceleration

sensor (between terminals 1 and 2 in the same way as
in step 3).
(1) lnsert each of the following thickness gauges between
the accelerator link stopper bolt and accelerator link
for confirmation:

Acceleration sensor position adjustment standard

(for confirmation)

Thickness gauge IDL switch

0.8 m m (0.031 in) : ON
1.0 mm (0.039 in) : OFF
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