Toyota LPG Forklift 8-Series: 8FGU15, 8FGU18, 8FGU20, 8FGU25, 8FGU30, 8FGU32 Service Manual

Toyota LPG Forklift 8-Series: 8FGU15, 8FGU18, 8FGU20, 8FGU25, 8FGU30, 8FGU32 Service Manual

Original Illustrated Factory Workshop Service Manual for Toyota LPG Forklift 8-Series.

Original factory manuals for Toyota (BT) Forclift Trucks, contains high quality images, circuit diagrams and instructions to help you to operate, maintenance and repair your truck. All Manuals Printable, contains Searchable Text and Navigation Bookmarks

Covered models:
8FGU15
8FGU18
8FGU20
8FGU25
8FGU30
8FGU32

Format: ZIP, Contains set of PDF files with sections of manual:
Sections 0-1.3, PDF, 620 pages
Sections 2-3, PDF, 190 pages
Sections 4-9, PDF, 224 pages
Sections 10-15, PDF, 176 pages
Sections 16-19-E, PDF, 690 pages
Reapair manual Supplement, PDF, 227 Pages (April 2010)

Language: English

Contents:

GENERAL 0
    EXTERIOR VIEWS 
    VEHICLE MODEL
    FRAME NUMBER
    HOW TO USE THIS MANUAL
    EXPLANATION METHOD
    TERMINOLOGY
    ABBREVIATIONS
    OPERATIONAL TIPS 
    HOISTING THE VEHICLE 
    HOW TO START THE HOUR METER 
    ATTENTIVE POINTS ON SAS
    CIRCUIT TESTER
    STANDARD BOLT & NUT TIGHTENING TORQUE
    BOLT STRENGTH CLASS IDENTIFICATION METHOD
    PRECOAT BOLTS
    HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
    WIRE ROPE SUSPENSION ANGLE LIST
    SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE
    COMPONENTS WEIGHT
    RECOMMENDED LUBRICANT QUANTITY & TYPES 
    LUBRICATION CHART 
    PERIODIC MAINTENANCE 
    INSPECTION METHOD
    PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS
ENGINE - CHASSIS 1
    ENGINE EXTERIOR VIEW
    ENGINE MAIN PARAMETERS
    ENGINE PERFORMANCE CURVES
    ENGINE ASSY
    REMOVAL·INSTALLATION
    AIR BLEEDING OF THE FUEL SYSTEM 
    ENGINE INSPECTION·ADJUSTMENT
    4Y ENGINE
    1DZ-II ENGINE VEHICLE
    AIR CLEANER
    SPECIFICATIONS
    COMPONENTS
    AIR CLEANER 
    CLEANING·INSPECTION
    CLOGGING WARNING SYSTEM INSPECTION (OPT)
    RADIATOR
    COMPONENTS
    SPECIFICATIONS
    COOLANT CAPACITY AND ANTIFREEZE TABLE
    COOLANT INSPECTION
    MUFFLER & EXHAUST PIPE
    COMPONENTS
    REMOVAL·INSTALLATION
    BATTERY 
    COMPONENTS
    SPECIFICATIONS
    INSPECTION
    V-BELT TENSION ADJUSTMENT
    ACCELERATOR PEDAL
    COMPONENTS
    INSPECTION·ADJUSTMENT
    EZ PEDAL (OPT) 
    COMPONENTS
    DISASSEMBLY·INSPECTION·
    REASSEMBLY
    ADJUSTMENT
    TRAVEL AND LOAD HANDLING CONTROL DEVICE (OPT) 
    COMPONENTS
    REMOVAL·INSTALLATION
    THROTTLE OPENING 
    DEGREE ADJUSTMENT
    TROUBLESHOOTING.
4Y-E REPAIR 1.1
    GENERAL
    TROUBLESHOOTING 
    ENGINE OVERHAUL (4Y-M) 
    ENGINE OVERHAUL (4Y-E) 
    FUEL SYSTEM (4Y-M) 
    FUEL SYSTEM (4Y-E) 
    PCV DEVICE 
    COOLING S
    LUBRICATION SYSTEM 
    IGNITION SYSTEM (4Y-M) 
    IGNITION SYSTEM (4Y-E) 
    STARTING SYSTEM 
    CHARGING SYSTEM 
    APPENDIX 
1DZ-II REPAIR 1.2
    GENERAL 
    TROUBLESHOOTING
    ENGINE OVERHAUL 
    FUEL SYSTEM 
    COOLING SYSTEM 
    LUBRICATION SYSTEM 
    STARTING SYSTEM 
    APPENDIX 
4Y-E LPG DEVICE REPAIR 1.3
    GENERAL
    OPERATION DESCRIPTION
    LPG REGULATOR OVERHAUL
    ELECTRICAL TROUBLESHOOTING
    APPENDIX
TRANSMISSION (Pn1•2•3 / Cu2•3) 2
    1 SPEED TORQUE 
        CONVERTER (STD) 
        GENERAL
        HYDRAULIC CIRCUIT DIAGRAM
        SPECIFICATIONS
        COMPONENTS
        TROUBLESHOOTING
        TRANSMISSION COVER & CONTROL VALVE ASSY
        TORQUE CONVERTER·OIL PUMP
        TORQUE CONVERTER & TRANSMISSION ASSY
        TRANSMISSION ASSY
        CLUTCH DRUM ASSY
    2 STATORS TORQUE CONVERTER (OPT)
        GENERAL
        HYDRAULIC CIRCUIT DIAGRAM
        SPECIFICATIONS
        COMPONENTS
        TROUBLESHOOTING
        TORQUE CONVERTER
        TORQUE CONVERTER & TRANSMISSION ASSY
        TRANSMISSION ASSY
        STATOR SHAFT NO.2 & OIL PUMP ASSY
        CLUTCH DRUM ASSY
        DIRECTION SWITCH ASSY 
        REMOVAL·INSTALLATION
        OIL PRESSURE MEASUREMENT AND STALL TEST (1 SPEED TORQUE CONVERTER (STD))
        OIL PRESSURE MEASUREMENT AND STALL TEST (2 STATORS TORQUE CONVERTER (OPT))
TRANSMISSION (Cu1 Ton Series) 2.1
    GENERAL
    HYDRAULIC CIRCUIT DIAGRAM 
    SPECIFICATIONS 
    COMPONENTS 
    TROUBLESHOOTING
    CONTROL VALVE ASSY 
    REMOVAL·INSTALLATION
    DISASSEMBLY·INSPECTION·REASSEMBLY
    TORQUE CONVERTER·OIL PUMP
    REMOVAL·INSTALLATION
    TORQUE CONVERTER & TRANSMISSION ASSY 
    REMOVAL·INSTALLATION
    TRANSMISSION ASSY
    DISASSEMBLY·INSPECTION·REASSEMBLY
    CLUTCH DRUM ASSY
    DISASSEMBLY·INSPECTION·REASSEMBLY
    DIRECTION SWITCH ASSY 
    REMOVAL·INSTALLATION
    OIL PRESSURE MEASUREMENT AND STALL TEST
PROPELLER SHAFT 3
    GENERAL
    SPECIFICATIONS 
    COMPONENTS 
    PROPELLER SHAFT 
    REMOVAL·INSTALLATION (DRY BRAKE MODEL (STD))
    REMOVAL·INSTALLATION (WET BRAKE MODEL (OPT))
    DISASSEMBLY·INSPECTION·REASSEMBLY.
DIFFERENTIAL 4
    GENERAL
    SPECIFICATIONS 
    COMPONENTS 
    DIFFERENTIAL ASSY 
    REMOVAL·INSTALLATION  (DRY BRAKE MODEL (STD))
    REMOVAL·INSTALLATION (WET BRAKE MODEL (OPT))
    REMOVAL·INSTALLATION (Cu 1 TON SERIES)
    DISASSEMBLY·INSPECTION·REASSEMBLY (Pn1·2 TON SERIES AND Cu2·3 TON SERIES)
    DISASSEMBLY·INSPECTION·REASSEMBLY (Pn3 TON SERIES)
    DIFFERENTIAL CASE ASSY 
    DISASSEMBLY·INSPECTION·REASSEMBLY (Pn1·2 TON SERIES AND Cu2·3 TON SERIES)
    DISASSEMBLY·INSPECTION·REASSEMBLY (Pn3 TON SERIES)
    DISASSEMBLY·INSPECTION·REASSEMBLY (Cu1 TON SERIES).
FRONT AXLE 5
    DRY BRAKE MODEL (STD) 
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    TIRES·WHEELS (PNEUMATIC TIRE)
    FRONT AXLE SHAFT·AXLE HUB
    FRONT AXLE BRACKET·AXLE HOUSING
    WET BRAKE MODEL (OPT)
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    TIRES·WHEELS (PNEUMATIC TIRE)
    FRONT AXLE SHAFT·AXLE HUB
    FRONT AXLE BRACKET·AXLE HOUSING.
REAR AXLE 6
    GENERAL
    SPECIFICATIONS 
    COMPONENTS 
    TIRES·WHEELS (PNEUMATIC TIRE) 
    REAR AXLE ASSY (Pn1·2·3 TON SERIES) 
    REMOVAL·INSTALLATION
    REAR AXLE ASSY (Cu2·3 TON SERIES)
    REMOVAL·INSTALLATION
    REAR AXLE HUB·STEERING KNUCKLE (Pn1·2·3 TON SERIES)
    REMOVAL·INSTALLATION
    STEERING KNUCKLE (Cu2·3 TON SERIES) 
    REMOVAL·INSTALLATION
    REAR AXLE CYLINDER 
    REMOVAL·INSTALLATION
    DISASSEMBLY·INSPECTION·REASSEMBLY
STEERING 7
    GENERAL
    SPECIFICATIONS 
    COMPONENTS 
    STEERING WHEEL·MAST JACKET 
    REMOVAL·INSTALLATION
    DISASSEMBLY·INSPECTION·REASSEMBLY
    HYDROSTATIC STEERING VALVE ASSY 
    TROUBLESHOOTING
    REMOVAL·INSTALLATION
    DISASSEMBLY·INSPECTION·REASSEMBLY
    RELIEF PRESSURE INSPECTION·ADJUSTMENT.
BRAKE 8
    GENERAL
    SPECIFICATIONS 
    COMPONENTS
    FRONT BRAKE 
    DISASSEMBLY·INSPECTION·REASSEMBLY (Pn1, Cu2·3 TON SERIES)
    DISASSEMBLY·INSPECTION·REASSEMBLY (Pn2·3 TON SERIES)
    BRAKE AIR BLEEDING
    BRAKING FORCE INSPECTION·ADJUSTMENT
    BRAKE MASTERCYLINDER
    REMOVAL·INSTALLATION
    DISASSEMBLY·INSPECTION·REASSEMBLY
    PARKING BRAKE INSPECTION·ADJUSTMENT
    RELEASE LEVER CABLE ADJUSTMENT
    BRAKE PEDAL INSPECTION
    ADJUSTMENT
    INCHING PEDAL INSPECTION·ADJUSTMENT
    SINGLE BRAKE (INCHING) 
    PEDAL INSPECTION·ADJUSTMENT (1-PEDAL: OPT) 
    WET BRAKE
    GENERAL
    SPECIFICATIONS
    HYDRAULIC CIRCUIT DIAGRAM
    COMPONENTS
    FRONT BRAKE ASSY
    DEPRESSURIZING THE ACCUMULATOR
    PURGING THE AIR FROM THE BRAKE
    BRAKING POWER INSPECTION
    POINTS FOR LOCKING 
    THE BRAKE DISK 
    - PLATE NO. 1 
    - PLATE NO. 2
    ADJUSTING THE BRAKE 
    DISK GAP
    BRAKE VALVE
    BRAKE VALVE OPERATION 
    INSPECTION
    ACCUMULATOR ASSY
    ACCUMULATOR INSPECTION
    PARKING BRAKE ASSY
    PARKING BRAKE FUNCTION INSPECTION
    ADJUSTING THE PARKING LEVER SWITCH
    PARKING BRAKE INSPECTION AND ADJUSTMENT
    ADJUSTING THE RELEASE LEVER CABLE
    BRAKE COOLING OIL TANK
    PROCEDURE FOR POURING IN BRAKE COOLING OIL
    BRAKE COOLING OIL COOLER
    BRAKE PEDAL INSPECTION AND ADJUSTMENT
    INCHING PEDAL INSPECTION AND ADJUSTMENT
    INSPECTION AND ADJUSTMENT OF THE SINGLE BRAKE (INCHING) PEDAL
    GREASING TO PARKING BRAKE PEDAL RELEASE PIN .
BODY 9
    COMPONENTS 
    ENGINE HOOD ASSY REMOVAL·INSTALLATION
    COUNTERWEIGHT REMOVAL·INSTALLATION
    DRIVER’S SEAT REMOVAL·INSTALLATION
    SEATBELT REMOVAL·INSTALLATION
    SEATBELT RETRACTOR INSPECTION
    HEADLAMPS REMOVAL·INSTALLATION
    COMBINATION METER REMOVAL·INSTALLATION
    COMBINATION SWITCH INSPECTION
    FUEL SENDER GAUGE INSPECTION
MATERIAL HANDLING SYSTEM 10
    HYDRAULIC CIRCUIT DIAGRAM 
    COMPONENTS 
    RETURN FILTER
    REMOVAL·INSTALLATION
    SUCTION FILTER
    REMOVAL·INSTALLATION
    NATURAL DROP TEST 
    NATURAL FORWARD TILT TEST 
    OIL LEAK TEST 
    LIFT CYLINDER
    TILT CYLINDER.
MAST 11
    V MAST ASSY
    COMPONENTS
    REMOVAL·INSTALLATION (Pn model)
    REMOVAL·INSTALLATION (Cu model)
    REMOVAL·INSTALLATION (W/LIFT BRACKET) (Pn model)
    REMOVAL·INSTALLATION (W/LIFT BRACKET) (Cu model)
    MAST DISASSEMBLY·INSPECTION·REASSEMBLY
    LIFT BRACKET DISASSEMBLY·REASSEMBLY
    MAST ADJUSTMENT (V MAST)
    MAST ROLLER REMOVAL·INSTALLATION
    CHAIN 
    INSPECTION
    REASSEMBLY (V·FV·FSV)
    REASSEMBLY (QFV)
    ADJUSTMENT
    FORK. 
    REMOVAL. 
    INSTALLATION. 
    INSPECTION. 
    FV·FSV MAST ASSY . 
    COMPONENTS. 
    MAST ADJUSTMENT (FV·FSV). 
    QFV MAST ASSY. 
    COMPONENTS. 
    MAST ADJUSTMENT (QFV). 
    STANDARD FOR SELECTING AN OVERSIZE ROLLER . 
    LIFT CYLINDER ROD SHIM ADJUSTMENT (PREVENTION OF UNEVEN LIFTING) . 
    V·FSV·QFV MAST. 
    FV MAST. 
CYLINDER 12
    LIFT CYLINDER (V)·REAR LIFT CYLINDER (FV·FSV·QFV) 
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    REMOVAL·INSTALLATION
    DISASSEMBLY·INSPECTION·REASSEMBLY
    SAFETY DOWN VALVE 
    REMOVAL·INSTALLATION
    FRONT LIFT CYLINDER (FV·FSV·QFV) 
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    REMOVAL·INSTALLATION
    DISASSEMBLY·INSPECTION·REASSEMBLY
    TILT CYLINDER 
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    REMOVAL·INSTALLATION
    DISASSEMBLY·INSPECTION·REASSEMBLY
    MAST FORWARD BACKWARD TILT ANGLE ADJUSTMENT (ADJUSTMENT OF UNEVEN TILTING)
OIL PUMP 13
    GENERAL
    SPECIFICATIONS 
    COMPONENTS 
    OIL PUMP ASSY 
    REMOVAL·INSTALLATION (STD, Steel Cabin Spec.)
    REMOVAL·INSTALLATION (Wet Brake Spec.)
    DISASSEMBLY·INSPECTION·REASSEMBLY (4Y (STD), 1DZ-II)
    DISASSEMBLY·INSPECTION·REASSEMBLY (4Y (Steel Cabin Spec.))
    DISASSEMBLY·INSPECTION·REASSEMBLY (Wet Brake Spec.)
    PERFORMANCE TEST
OIL CONTROL VALVE 14
    OIL CONTROL VALVE ASSY 
    GENERAL
    SPECIFICATIONS
    COMPONENTS 
    TROUBLESHOOTING
    REMOVAL·INSTALLATION
    DISASSEMBLY·INSPECTION·REASSEMBLY
    OIL CONTROL VALVE ASSY 
    (MINI LEVER·JOYSTICK SPECIFICATION)
    GENERAL
    SPECIFICATIONS
    COMPONENTS
    TROUBLESHOOTING
    REMOVAL·INSTALLATION
    DISASSEMBLY·INSPECTION·REASSEMBLY
    CONTROL VALVE LEVER ASSY 
    REMOVAL·INSTALLATION
    RELIEF PRESSURE ADJUSTMENT 
    MANUAL DOWN VALVE.
MINI LEVER - JOYSTICK 15
    GENERAL
    JOYSTICK
    COMPONENTS 
    MINI LEVER·JOYSTICK
    REMOVAL·INSTALLATION
    DISASSEMBLY·INSPECTION·REASSEMBLY.
SAS / OPS 16
    GENERAL
    SAS FUNCTION 
    COMPONENTS
    PRECAUTIONS FOR REPAIR
    SAS/OPS CONTROLLER REMOVAL·INSTALLATION
    YAW RATE SENSOR REMOVAL·INSTALLATION
    TIRE ANGLE SENSOR (OPT) REMOVAL·INSTALLATION
    SWING LOCK CYLINDER REMOVAL·INSTALLATION
    STEERING KNOB POSITION CORRECTING VALVE (OPT) 
    REMOVAL·INSTALLATION
    TILT ANGLE SENSOR REMOVAL·INSTALLATION
    LOAD SENSOR REMOVAL·INSTALLATION
    SPEED SENSOR REMOVAL·INSTALLATION
    FORK HEIGHT SWITCH REMOVAL·INSTALLATION
    FUNCTIONAL PARTS
    OPS FUNCTIONS 
    GENERAL
    CONTROL SPECIFICATION
    MATCHING
    GENERAL
    BEFORE STARTING MATCHING
    OPTION SET 
    DIAGNOSIS MEMORY
    REAR WHEEL SWING CONTROL CHECK
    SAS/OPS PLUG-IN ANALYZER.
SSTLIST - SERVICE STANDARDS LIST 17
    SST LIST 
    SERVICE STANDARDS LIST 
MULTIFUNCTION DISPLAY DX (OPTIONAL) 18
    GENERAL
    GENERAL FUNCTIONS
    GENERAL
    DISPLAY SCREEN AND OPERATION 
    PROCEDURE
    ADMINISTRATOR FUNCTIONS
    MASK FUNCTIONS
    GENERAL
    PASSWORD
    ANALYZER
    TUNING
    OPTION SET
    MATCHING
    WHEEL RADIUS SET
    ENGINE IDLE SPEED ADJUSTMENT 
    (4Y ENGINE VEHICLE)
    LCD CONTRAST ADJUSTMENT
    METER START
    MULTIFUNCTION DISPLAY ASSY
    DISASSEMBLY·REASSEMBLY.
ELECTRICAL SYSTEM TROUBLESHOOTING [except Cu1] 19
    GENERAL
    GENERAL FUNCTIONS
    GENERAL
    DISPLAY SCREEN AND OPERATION 
    PROCEDURE
    ADMINISTRATOR FUNCTIONS
    MASK FUNCTIONS
    GENERAL
    PASSWORD
    ANALYZER
    TUNING
    OPTION SET
    MATCHING
    WHEEL RADIUS SET
    ENGINE IDLE SPEED ADJUSTMENT (4Y ENGINE VEHICLE)
    LCD CONTRAST ADJUSTMENT
    METER START
    MULTIFUNCTION DISPLAY ASSY
    DISASSEMBLY·REASSEMBLY.
ELECTRICAL SYSTEM TROUBLESHOOTING [Cu1 ton series] 19.1
    BEFORE TROUBLESHOOTING
    CONNECTOR HANDLING
    WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE
    TROUBLESHOOTING
    BEFORE BEGINNING TROUBLESHOOTING FOR THE 4Y-E ENGINE
    DIAGNOSIS (SELF DIAGNOSIS FUNCTION)
    DIAGNOSIS DISPLAY METHOD
    LIST OF DIAGNOSIS CODES
    WARNING LIST
    ERROR CONFIRMATION DRIVE MODE
    TROUBLESHOOTING BY ERROR CODE
    TROUBLESHOOTING WHEN THERE IS NO ERROR CODE
WIRING DIAGRAM E
    8FG(D)U15-32, 8FGCU20-32
        CHAPER 1 INTRODUCTION
        CHAPTER 2 ELECTRICAL WIRING ROUTING AND RELAY LOCATION
        CHAPTER 3 SYSTEM CIRCUITS
        CHAPTER 4 GROUND POINTS
        CHAPTER 5 FUSES FOR POWER SUPPLY
        CHAPTER 6 CONNECTOR LIST
    8FGCU15, 18, SU20
        CHAPTER 7 ELECTRICAL WIRING ROUTING AND RELAY LOCATION
        CHAPTER 8 SYSTEM CIRCUITS
        CHAPTER 9 GROUND POINTS
        CHAPTER 10 FUSES FOR POWER SUPPLY
        CHAPTER 11 CONNECTOR LIST
SERVICE INFORMATION BULLETINS SIB
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