Toyota Forklift Trucks Model 8FBCU, 8FBCHU Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Toyota Forklift Trucks Series 8FBCU20, 8FBCU25, 8FBCHU25, 8FBCU28, 8FBCU30, 8FBCU32, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Toyota Forklift Trucks Model 8FBCU, 8FBCHU workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 653 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CU346 - TOYOTA ELECTRIC POWERED FORKLIFT 8FBCU, 8FBCHU series Service Manual - Vol. 1 Maintenance, Specifications & Repair for Chassis, Body & Load Handling System.pdf
CU347 - TOYOTA ELECTRIC POWERED FORKLIFT 8FBCU, 8FBCHU series Service Manual - Vol. 2 ELECTRICAL SYSTEM & TROUBLESHOOTING.pdf
MAIN SECTIONS
CU346 - TOYOTA ELECTRIC POWERED FORKLIFT 8FBCU, 8FBCHU series Service Manual - Vol. 1 Maintenance, Specifications & Repair for Chassis, Body & Load Handling System.......1
8fbc(h)u cover vol 1 cu346.pdf.......1
Cover 1.......1
Cover 2.......2
8fbc(h)u section index vol 1 cu346.......3
8fbc(h)u section 0 vol 1 cu346.......5
GENERAL.......5
EXTERIOR VIEWS.......6
VEHICLE MODEL.......7
FRAME NUMBER.......8
HOW TO USE THIS MANUAL.......9
EXPLANATION METHOD.......9
TERMINOLOGY.......10
ABBREVIATIONS.......10
SI UNITS.......11
OPERATIONAL TIPS.......12
JACK-UP POINT.......14
HOISTING THE VEHICLE.......15
CAUTION FOR TOWING.......15
ATTENTIVE POINTS ON SAS.......16
CIRCUIT TESTER.......17
STANDARD BOLT & NUTTIGHTENING TORQUE.......19
BOLT STRENGTH CLASSIDENTIFICATION METHOD.......19
PRECOAT BOLTS.......22
HIGH PRESSURE HOSE FITTINGTIGHTENING TORQUE.......22
WIRE ROPE SUSPENSIONANGLE LIST.......23
SAFE LOAD FOR EACHWIRE ROPE SUSPENSIONANGLE.......23
COMPONENTS WEIGHT.......24
RECOMMENDED LUBRICANTQUANTITY & TYPES.......24
LUBRICATION CHART.......25
PERIODIC MAINTENANCE.......26
PERIODIC REPLACEMENT OFPARTS AND LUBRICANTS.......31
8fbc(h)u section 1 vol 1 cu346.......33
BATTERY.......33
BATTERY COMPARTMENT ANDREQUIRED WEIGHT.......34
SERVICE STANDARD.......35
DISPLAY.......35
TROUBLESHOOTING.......36
BATTERY ASSY.......37
REMOVAL·INSTALLATION.......37
INSPECTION.......38
BATTERY STOPPER.......40
8fbc(h)u section 5 vol 1 cu346.......41
MOTOR.......41
DRIVE MOTOR.......42
GENERAL.......42
SPECIFICATIONS.......42
COMPONENTS.......43
REMOVAL·INSTALLATION.......44
DISASSEMBLY·INSPECTION·REASSEMBLY.......46
PUMP MOTOR.......49
GENERAL.......49
SPECIFICATIONS.......50
COMPONENTS.......51
REMOVAL·INSTALLATION.......52
DISASSEMBLY·INSPECTION·REASSEMBLY.......53
8fbc(h)u section 6 vol 1 cu346.......55
DRIVE UNIT.......55
GENERAL.......56
SPECIFICATIONS.......57
COMPONENTS.......57
DRIVE UNIT ASSY.......59
REMOVAL·INSTALLATION.......59
DISASSEMBLY·INSPECTION·REASSEMBLY.......62
DIFFERENTIAL CASE ASSY.......65
DISASSEMBLY·INSPECTION·REASSEMBLY.......65
8fbc(h)u section 8 vol 1 cu346.......79
REAR AXLE.......79
GENERAL.......80
SPECIFICATIONS.......82
COMPONENTS.......83
REAR AXLE ASSY.......85
REMOVAL·INSTALLATION.......85
STEERING KNUCKLE.......88
REMOVAL·INSTALLATION.......88
REAR AXLE CYLINDER.......93
REMOVAL·INSTALLATION.......93
DISASSEMBLY·INSPECTION·REASSEMBLY.......95
8fbc(h)u section 9 vol 1 cu346.......97
STEERING.......97
GENERAL.......98
SPECIFICATIONS.......100
COMPONENTS.......100
STEERING WHEEL·MAST JACKET.......103
REMOVAL·INSTALLATION.......103
DISASSEMBLY·INSPECTION·REASSEMBLY.......105
HYDROSTATIC STEERING VALVE ASSY.......106
TROUBLESHOOTING.......106
REMOVAL·INSTALLATION.......107
DISASSEMBLY·INSPECTION·REASSEMBLY.......108
RELIEF PRESSUREINSPECTION·ADJUSTMENT.......112
8fbc(h)u section 10 vol 1 cu346.......113
BRAKE.......113
GENERAL.......114
SPECIFICATIONS.......116
COMPONENTS.......117
FRONT BRAKE.......120
DISASSEMBLY·INSPECTION·REASSEMBLY.......120
BRAKE AIR BLEEDING.......125
BRAKING FORCE INSPECTION·ADJUSTMENT.......125
BRAKE MASTER CYLINDER.......126
REMOVAL·INSTALLATION.......126
DISASSEMBLY·INSPECTION·REASSEMBLY.......127
PARKING BRAKE.......129
REMOVAL·INSTALLATION.......129
PARKING BRAKE INSPECTION·ADJUSTMENT.......130
RELEASE LEVER CABLE ADJUSTMENT.......130
BRAKE PEDAL INSPECTION·ADJUSTMENT.......131
8fbc(h)u section 11 vol 1 cu346.......133
BODY.......133
COMPONENTS.......134
BATTERY HOOD ASSY.......138
REMOVAL·INSTALLATION.......138
COUNTERWEIGHT.......139
REMOVAL·INSTALLATION.......139
DRIVER’S SEAT.......140
REMOVAL·INSTALLATION.......140
FUSE.......141
FUSE MOUNTING POSITION.......141
NAMES (APPLICABLE PORTIONS) AND CAPACITIES.......141
8fbc(h)u section 12 vol 1 cu346.......143
MATERIAL HANDLING SYSTEM.......143
HYDRAULIC SYSTEM DIAGRAM.......144
COMPONENTS.......145
RETURN FILTER·SUCTION FILTER.......149
REMOVAL·INSTALLATION.......149
NATURAL DROP TEST.......150
NATURAL FORWARD TILT TEST.......150
OIL LEAK TEST.......151
LIFT CYLINDER.......151
TILT CYLINDER.......151
8fbc(h)u section 13 vol 1 cu346.......153
MAST.......153
V MAST ASSY.......154
COMPONENTS.......154
REMOVAL·INSTALLATION.......156
REMOVAL·INSTALLATION (W/LIFT BRACKET).......159
MAST DISASSEMBLY·INSPECTION REASSEMBLY.......161
LIFT BRACKET DISASSEMBLY·INSPECTION·REASSEMBLY.......163
MAST ADJUSTMENT (V MAST).......165
MAST ROLLER REMOVAL·INSTALLATION.......170
CHAIN.......171
INSPECTION.......171
REASSEMBLY (V·FV·FSV).......171
REASSEMBLY (QFV).......172
ADJUSTMENT.......173
FV·FSV MAST ASSY.......174
COMPONENTS.......174
MAST ADJUSTMENT (FV·FSV).......178
QFV MAST ASSY.......182
COMPONENTS.......182
MAST ADJUSTMENT (QFV).......183
STANDARD FOR SELECTING AN OVERSIZE ROLLER.......185
LIFT CYLINDER ROD SHIM ADJUSTMENT(PREVENTION OF UNEVEN LIFTING).......186
V·FSV·QFV MAST.......186
FV MAST.......187
8fbc(h)u section 14 vol 1 cu346.......189
CYLINDER.......189
LIFT CYLINDER (V)·REAR LIFT CYLINDER(FV·FSV·QFV).......190
GENERAL.......190
SPECIFICATIONS.......192
COMPONENTS.......193
REMOVAL·INSTALLATION.......198
DISASSEMBLY·INSPECTION·REASSEMBLY.......200
SAFETY DOWN VALVE.......202
FRONT LIFT CYLINDER (FV·FSV·QFV).......203
GENERAL.......203
SPECIFICATIONS.......203
COMPONENTS.......204
REMOVAL·INSTALLATION.......205
DISASSEMBLY·INSPECTION·REASSEMBLY.......206
TILT CYLINDER.......208
GENERAL.......208
SPECIFICATIONS.......208
COMPONENTS.......209
REMOVAL·INSTALLATION.......210
DISASSEMBLY·INSPECTION·REASSEMBLY.......212
MAST FORWARD BACKWARD TILTING ANGLE ADJUSTMENT(PREVENTION OF UNEVEN TILTING).......214
8fbc(h)u section 15 vol 1 cu346.......215
OIL PUMP.......215
GENERAL.......216
SPECIFICATIONS.......216
COMPONENTS.......217
OIL PUMP ASSY.......218
REMOVAL·INSTALLATION.......218
DISASSEMBLY·INSPECTION·REASSEMBLY.......219
TEST METHOD.......222
8fbc(h)u section 16 vol 1 cu346.......225
OIL CONTROL VALVE.......225
GENERAL.......226
SPECIFICATIONS.......231
COMPONENT.......232
OIL CONTROL VALVE ASSY.......234
REMOVAL·INSTALLATION.......234
RELIEF PRESSURE ADJUSTMENT.......236
MANUAL DOWN VALVE.......238
CONTROL VALVE LEVER ASSY.......239
REMOVAL·INSTALLATION.......239
8fbc(h)u section 17 vol 1 cu346.......241
SAS FUNCTIONS.......241
GENERAL.......242
SAS (System of Active Stability) systemconfiguration.......242
COMPONENTS.......244
BEFORE STARTING REPAIR WORK.......249
YAW RATE SENSOR.......251
REMOVAL·INSTALLATION.......251
SWING LOCK CYLINDER.......252
REMOVAL·INSTALLATION.......252
TILT ANGLE SENSOR.......254
REMOVAL·INSTALLATION.......254
LOAD SENSOR.......255
REMOVAL·INSTALLATION.......255
SPEED SENSOR.......256
REMOVAL·INSTALLATION.......256
MAST LIFTING HEIGHT SWITCH.......257
REMOVAL·INSTALLATION.......257
MATCHING.......258
STANDARD STATE OF VEHICLE.......260
CAUTIONS ON MODIFYING VEHICLES.......261
RENEWAL OF SAS CAUTION LABEL.......262
8fbc(h)u section 18 vol 1 cu346.......263
APPENDIX.......263
SST LIST.......264
SERVICE STANDARDS LIST.......267
WIRING DIAGRAM (Conventional Lever).......274
WIRING DIAGRAM (Mini Lever / Joystick Lever).......275
8fbc(h)u section 7 vol 1 cu346.pdf.......0
FRONT AXLE.......69
GENERAL.......70
SPECIFICATIONS.......72
COMPONENTS.......72
FRONT AXLE SHAFT·AXLE HUB.......74
REMOVAL·INSTALLATION.......74
FRONT AXLE BRACKET·AXLE HOUSING.......77
REMOVAL·INSTALLATION.......77
CU347 - TOYOTA ELECTRIC POWERED FORKLIFT 8FBCU, 8FBCHU series Service Manual - Vol. 2 ELECTRICAL SYSTEM & TROUBLESHOOTING.......276
8fbc(h)u cover vol 2 cu347.pdf.......276
8fbc(h)u forward vol 2 cu347.......278
8fbc(h)u section index vol 2 cu347.......280
8fbc(h)u section 0 vol 2 cu347.......282
GENERAL.......282
EXTERIOR VIEWS.......283
VEHICLE MODEL.......284
FRAME NUMBER.......284
OPERATIONAL TIPS.......285
ATTENTIVE POINTS ON SAS.......286
CIRCUIT TESTER.......287
8fbc(h)u section 2 vol 2 cu347.......290
CONTROL SYSTEM.......290
GENERAL.......291
SPECIFICATIONS.......292
COMPONENTS.......293
BEFORE REPAIR.......296
INSPECTION.......296
CONNECTOR INSPECTION.......297
TO USE SST.......297
INSPECTION.......297
CONTROLLER.......317
REMOVAL·INSTALLATION.......317
CONTACTOR PANEL ASSY.......319
REMOVAL·INSTALLATION.......319
INSPECTION.......320
OCL MEASUREMENT.......321
REASSEMBLY.......324
DISPLAY.......325
LAMP SWITCH.......326
REMOVAL·INSTALLATION.......326
DISASSEMBLY·INSPECTION·REASSEMBLY.......328
ACCELERATOR SENSOR(POTENTIOMETER).......329
MINI LEVER.......331
JOYSTICK.......333
COMPONENTS.......335
REMOVAL·INSTALLATION.......337
DISASSEMBLY·INSPECTION·REASSEMBLY.......338
DISASSEMBLY·INSPECTION·REASSEMBLY.......340
8fbc(h)u section 3 vol 2 cu347.......342
MULTI-FUNCTION DISPLAY.......342
GENERAL.......343
GENERAL FUNCTIONS.......344
GENERAL.......344
ADMINISTRATOR FUNCTIONS.......347
MASK FUNCTIONS.......361
GENERAL.......361
PASSWORD.......362
ANALYZER.......364
TUNING.......389
OPTION SET.......399
MATCHING.......403
OTHERS MENU.......412
MULTI-FUNCTION DISPLAY ASSY.......424
COMPONENTS.......424
REMOVAL·INSTALLATION.......425
DISASSEMBLY·INSPECTION·REASSEMBLY.......426
8fbc(h)u section 4 vol 2 cu347.......428
TROUBLESHOOTING.......428
BEFORE TROUBLESHOOTING.......429
CONNECTOR HANDLING.......429
WIRE HARNESS AND CONNECTOR INSPECTIONPROCEDURE.......429
TROUBLESHOOTING METHOD.......431
TO USE SST.......432
DIAGNOSIS CODE LIST.......433
WHEN ERROR CODE IS DISPLAYED.......450
A0-1.......450
A0-2.......453
A1-1.......456
A1-2.......457
A2-1.......458
A2-2.......459
A2-3.......462
A3-1.......465
A5-1.......467
A6-3.......469
A8-1.......471
A8-2.......471
A9-2.......475
AA-1.......477
AA-2.......478
AA-4.......479
AB-1.......480
AC-1.......483
AD-1.......485
AD-2.......485
AD-5.......485
AD-6.......485
AF-1.......488
AF-2.......488
AF-3.......488
AF-4.......488
AF-5.......488
AF-6.......488
AF-7.......488
AF-8.......488
C0-2.......489
C1-1.......491
C1-2.......492
C2-1.......494
C2-2.......495
C3-1.......497
C4-1.......498
C4-2.......498
C4-3.......498
C4-4.......498
C4-5.......498
C4-6.......498
C8-1.......501
C8-2.......504
CB-1.......507
CB-2.......507
CB-3.......507
CB-4.......507
CB-5.......507
CB-6.......512
CB-7.......514
CC-1.......516
CC-2.......516
CC-3.......516
CC-4.......516
CC-5.......516
CC-6.......516
CC-7.......516
CC-8.......516
E0-2.......517
E1-1.......519
E1-2.......520
E2-1.......522
E2-2.......523
E3-1.......525
E8-1.......526
E8-2.......528
EC-1.......530
EC-2.......530
EC-3.......530
EC-4.......530
EC-5.......530
EC-6.......530
EC-7.......530
EC-8.......530
EE-1.......531
EE-2.......531
F1-1.......532
F1-2.......532
F4-1.......533
F4-2.......533
F4-3.......533
F4-4.......533
F4-5.......533
F4-6.......533
F4-7.......533
F4-8.......533
FF-1.......534
FF-2.......534
32-1.......536
32-3.......537
52-1.......538
52-2.......538
52-3.......538
54-1.......540
54-2.......540
54-3.......540
54-4.......540
61-1.......543
61-2.......543
62-1.......545
62-2.......545
63-1.......547
63-2.......547
63-3.......547
64-1.......548
64-2.......548
64-3.......548
64-4.......548
65-1.......551
65-2.......551
65-3.......551
65-4.......551
66-1.......554
67-1.......555
68-1.......558
68-2.......558
68-3.......558
71-1.......561
71-2.......561
71-3.......561
72-1.......563
72-2.......563
72-3.......563
72-4.......563
73-1.......569
73-2.......569
73-3.......569
73-4.......569
74-1.......572
H1-1 (Conventional lever).......573
H1-2 (Conventional lever).......573
H1-3 (Conventional lever).......573
H1-4 (Conventional lever).......573
H1-5 (Conventional lever).......573
H1-1 (Mini lever).......576
H1-2 (Mini lever).......576
H1-3 (Mini lever).......576
H1-4 (Mini lever).......576
H1-5 (Mini lever).......576
H2-1.......578
H2-2.......578
H2-3.......578
H2-4.......578
H2-5.......578
H3-1.......580
H3-2.......580
H3-3.......580
H3-4.......580
H3-5.......580
H4-1.......580
H4-2.......582
H4-3.......582
H4-4.......582
H4-5.......582
H5-1.......584
H5-2.......584
H5-3.......584
H5-4.......584
H5-5.......584
H5-6.......584
H6-1.......587
H6-2.......587
H6-3.......587
H6-4.......587
H6-5.......587
H6-6.......587
H7-1.......590
H7-2.......590
H7-3.......590
H7-4.......590
H7-5.......590
H7-6.......590
H8-1.......593
H8-2.......593
H8-3.......593
H8-4.......593
H8-5.......593
H8-6.......593
HB-1.......596
HB-2.......596
HB-3.......596
HC-1.......600
HC-2.......600
HC-3.......600
HC-4.......600
G5-1.......603
G5-2.......603
G5-3.......603
G5-4.......603
G5-5.......603
G5-6.......603
WHEN NO ERROR CODE IS DISPLAYED.......606
8fbc(h)u section 18 vol 2 cu347.......631
APPENDIX.......631
SST LIST.......632
SERVICE STANDARDS LIST.......634
CONNECTOR DRAWING.......635
CONNECTING DIAGRAM (Conventional Lever).......651
CONNECTING DIAGRAM (Mini Lever / Joystick Lever).......652
WIRING DIAGRAM (Conventional Lever).......653
WIRING DIAGRAM (Mini Lever / Joystick Lever).......654
Toyota Forklift Trucks Model 8FBCU, 8FBCHU Repair Service Manual
