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Toyota Diesel Forklift 8FDU15, 8FDU18, 8FDU20, 8FDU25, 8FDU30, 8FDU32 Workshop Service Manual and Supplement
Original factory manuals for Toyota (BT) 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:
8FDU15
8FDU18
8FDU20
8FDU25
8FDU30
8FDU32
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 (Pn123 / Cu23) 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
DRIVERS 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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