Toyota 8FBCU20 8FBCU25 8FBCHU25 8FBCU28 8FBCU30 8FBCU32 Electric Forklift Workshop Service Repair Manual PDF - MTOIN8FBCU346CU347.zip
Full factory service and repair documentation, complete with Electrical Wiring Diagrams, covering Toyota Forklift Truck models 8FBCU20, 8FBCU25, 8FBCHU25, 8FBCU28, 8FBCU30, and 8FBCU32 — containing every technical detail needed to service, troubleshoot, fix, and overhaul these trucks the way professional technicians do.
The workshop service repair manual for Toyota Forklift Trucks 8FBCU and 8FBCHU 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