Toyota 8FGU15, 8FGU18, 8FGU20, 8FGU25, 8FGU30, 8FGU32 LPG Forklift Truck Workshop Service Manual

Original Illustrated Factory Workshop Service Manual for Toyota LPG Forklift Models 8FGU15, 8FGU18, 8FGU20, 8FGU25, 8FGU30, 8FGU32

Original factory manuals for Toyota Forklift 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