Model:
Diesel Forklift Truck
Product Type:
Workshop Service Manual
Covered Models:
6FDA15, 6FDA18, 6FDA20, 6FDA25, 6FDA30, 6FDN20, 6FDN25, 6FDN30, 62-6FDA20, 62-6FDA25, 62-6FDA30
Model Variant Codes:
02- prefix for some models, 60- and 62- prefixes for others, indicating potential series or regional variations.
Industry Segment:
Industrial Material Handling Equipment
Target User:
Forklift fleet managers, maintenance supervisors, qualified forklift technicians, and repair shops specializing in material handling equipment.
Brand Strength:
Toyota is a globally recognized leader in material handling, known for reliability and durability. This manual reflects that commitment to quality support.
Manual Advantage:
Original factory documentation ensures accuracy and completeness, providing a significant advantage over generic or third-party repair guides.
Information Type:
Original, illustrated factory content
Visual Aid Quality:
Contains high quality images
Schematics:
Includes circuit diagrams
Navigability:
Searchable text and navigation bookmarks for efficient information retrieval.
Geographic Coverage:
South Africa, Indonesia (as indicated in product description)
Main Service Manual Pages:
462
Manual Classification:
Factory Workshop Service Manual
Download Format:
ZIP, containing multiple PDF files
PDF Quality:
High quality, with high-resolution images and clear text.
Printability:
Printable PDF files
Digital Binding:
Searchable Text and Navigation Bookmarks within PDFs
Digital Paper Type:
N/A (Digital Format)
Powertrain:
Engine (diesel, including specific mention of 2Z and 1DZ variants), Clutch, Torque Converter, Transmission, Propeller Shaft, Differential, Front Axle, Rear Axle
Chassis And Steering:
Steering System, Body
Material Handling:
Material Handling System, Mast, Cylinder, Oil Pump, Oil Control Valve
Electrical System:
Battery, Starting System, Charging System, Ignition System, Fuel System (likely related to diesel injection), Intake Heater (2Z), Glow System (1DZ), Emission Control (mention of Gasoline and LPG implies potential overlap or related systems in design, but focus is Diesel), Working Lamp, Headlamp, Tail Lamp, Illumination, Stop Lamp, Horn, Turn Signal Lamp, Back Up Lamp, T/C Heat Gage, Speed Meter, Rotary Light, Heater, Wiper & Washer, Speed Alarm, Combination Meter
Maintenance:
Routine checks, fluid changes, lubrication, filter replacements, component inspections.
Repair And Overhaul:
Detailed disassembly, assembly, and repair procedures for all major components and systems.
Diagnostics And Troubleshooting:
Guidance on identifying and rectifying common faults and issues across all systems, likely including troubleshooting charts.
Component Adjustment And Calibration:
Procedures for setting clearances, torques, and calibrations for various parts.
Electrical Troubleshooting:
Specific fault-finding procedures for the electrical system, aided by wiring diagrams.
Depth Of Information:
Comprehensive factory-level technical data, suitable for trained technicians.
Diagnostic Capabilities:
Includes troubleshooting guides, likely with symptom-based diagnostic trees and component testing procedures.
Component Rebuilds:
Detailed instructions for the complete overhaul of major sub-assemblies like engines, transmissions, and hydraulic systems.
Engine Variants Mentioned:
2Z, 1DZ (with specific mentions for intake heater and glow system, respectively)
Horsepower:
Not specified in product data, but typical for this class of forklift would range from 30-60 HP depending on model and engine variant.
Torque:
Not specified in product data, essential for heavy lifting operations.
Injection Type:
Likely direct injection or common rail, common for modern diesel forklifts.
Emissions Control:
Manual covers emission control, though specifically lists Gasoline/LPG; diesel systems would include fuel injection timing and potentially exhaust after-treatment systems depending on model year and region.
Transmission Type:
Automatic (Torque Converter transmission is explicitly mentioned, indicating an automatic transmission system common in forklifts for ease of operation and precise control).
Optional Transmissions:
Not specified, but typically a single automatic transmission type is standard for this class.
Torque Converter Details:
Manual covers the torque converter, implying detailed diagnostics and repair for this component.
Lifting Capacities:
Ranges from 1500 kg (6FDA15) to 3000 kg (6FDA30, 6FDN30), indicative of overall size and power.
Mast Height:
Not specified in product data, but mast height is a critical variable for forklift application and is a key section in the manual.
Operating Weight:
Not specified, but varies by model and configuration, crucial for load capacity calculations.
Safety Standards:
Manual will align with relevant industrial safety standards for forklift operation and maintenance, likely ISO or regional equivalents.
Braking System:
The manual covers the brake system, implying detailed procedures for maintenance and repair of both service and parking brakes.
Operator Protection:
Body and Mast sections imply information on structural integrity and operator protective features.
Instrument Cluster:
The manual details the combination meter (Speed Meter, T/C Heat Gage, Speed Alarm), providing information on instrument functions and troubleshooting.
Lighting Systems:
Covers Headlamp, Tail Lamp, Stop Lamp, Turn Signal Lamp, Back Up Lamp, Working Lamp, and illumination for safe operation.
Diagnostic Ports:
While not explicitly mentioned, factory manuals typically cover access and functionality of any onboard diagnostic ports for electronic systems.
Intake Heating:
Specific section on Intake Heater (2Z) indicates technology for cold-weather starting.
Glow Plugs:
Specific section on Glow System (1DZ) confirms pre-heating technology for diesel combustion.
Recommended Intervals:
The manual will contain detailed recommended service intervals for engine oil, hydraulic fluid, transmission fluid, filters, and component checks. Specific hours/months will be detailed within the document.
Engine Oil:
Specific SAE viscosity grades and API service classifications for diesel engine oil will be provided, crucial for engine longevity. Likely 15W-40 or 10W-30 depending on climate.
Hydraulic Fluid:
Recommendations for hydraulic fluid type and viscosity grade will be present, vital for the lift and tilt systems. Likely ISO VG 32 or VG 46.
Transmission Fluid:
Specific ATF or transmission fluid type and capacity for the torque converter transmission will be detailed. Likely a proprietary Toyota fluid or equivalent.
Coolant:
Specifications for engine coolant mixture and type (e.g., ethylene glycol-based) will be provided.
Common Wear Items:
The manual will guide on inspection and replacement of typical wear items such as brake pads, lift chains, mast rollers, hydraulic seals, and engine filters.
Troubleshooting Common Faults:
The troubleshooting section will address common issues like starting problems, hydraulic leaks, transmission slippage, and steering play, providing step-by-step solutions.
Manufacturer:
Toyota Industries Corporation is a pioneer and global leader in material handling equipment, with a long history of innovation and reliability dating back to 1946.
Product Line:
The 6F series represents Toyota's advanced range of diesel forklifts, designed for durability and performance in demanding industrial environments.
Manufacturing Focus:
While the product description mentions South Africa and Indonesia, Toyota has manufacturing facilities globally, indicating widespread availability and support for these models.
