Toyota 8FGCU15, 8FGCU18, 8FGCU20, 8FGCU25, 8FGCU30, 8FGCU32, 8FGCSU20 Forklift Repair Manual

TOYOTA 8FGCU15, 8FGCU18, 8FGCU20, 8FGCU25, 8FGCU30, 8FGCU32, 8FGCSU20 Forklift Repair Manual – 1389 Pages & 1867 Pages
Supplement Manual (above models as of April 2010) – 227 Pages
Parts Catalog – 166 Pages
4Y model Engine Manual – 250 Pages
4Y-E Engine Manual – 104 Pages
1DZ-II Engine Manual – 196 Pages

This manual covers the service procedures of the TOYOTA FORKLIFT 8FGCU15 – 32 series and 8FGCSU 20 Series. Please use this manual for providing quick, correct servicing of the corresponding forklift model;.

This manual deals with the models release for this forklift even those after April 2010. Please under-stand that disagreement can take place between the descriptions in the manual and actual vehicles due to change in 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 repair manuals listed below as reference together with this manual.

Table of content of the Repair Service Manual

GENERAL
ENGINE – CHASSIS
4Y-E REPAIR
1DZ-II REPAIR
4Y-E LPG DEVICE REPAIR
TRANSMISSION (Pn1•2•3 / Cu2•3)
TRANSMISSION (Cu1 Ton Series)
PROPELLER SHAFT
DIFFERENTIAL
FRONT AXLE
REAR AXLE
STEERING
BRAKE
BODY
MATERIAL HANDLING SYSTEM
MAST
CYLINDER
OIL PUMP
OIL CONTROL VALVE
MINI LEVER – JOYSTICK
SAS / OPS
SSTLIST – SERVICE STANDARDS LIST
MULTIFUNCTION DISPLAY DX (OPTIONAL)
ELECTRICAL SYSTEM TROUBLESHOOTING [except Cu1]ELECTRICAL SYSTEM TROUBLESHOOTING [Cu1 ton series]WIRING DIAGRAM
SERVICE INFORMATION BULLETINS
ATTENTIVE POINTS ON SAS
1. Reference should be made to separate manual “New Model Feature 8FGU/8FDU15-32 Pub. No.PU023” for the explanations of SAS functions and operations.
2. Read Section 16 SAS/OPS “Precautions for Repair” on Page 16-11 in this repair manual in advance.
3. Whenever the repair or replacement is performed to the place where relative to SAS function, matching procedure by which the SAS regain proper function must be performed. (See Page 16-26)
4. The warning on the SAS caution label must be confirmed when the modification or change is such as to change the original specification. If improper, change the label. (See Page 16-32)

5. Care should always be exercised for safety operation whenever you operate the truck. Make distinction between the SAS featured trucks and those of none, because the control features are different.

6. The SAS oil control valves comprise many precision valves. Since dirty or contaminated hydraulic oil will adversely affect the functions of these valves, always wash the parts clean at the time of installation after disassembly or for replacement of hydraulic parts (valves, piping, etc.). Periodic replacement of the hydraulic oil is very important.

7. Since this vehicle uses high-precision electronic devices, modification of electrical parts may cause faults. Always use genuine Toyota parts when replacing or installing electrical parts (auxiliary equipment, optional parts, etc.).