Toyota 8FG/8FD10~30 Series Diesel Forklift Truck Service & Repair Manual

FOREWORD This manual covers the service procedures of the TOYOTA FORKLIFT 8FG/ 8FD10~30 series. Please use this manual for providing quick, correct servicing of the corresponding forklift models. This manual deals with the above models as of August 2006. Please understand 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 the repair manuals listed below as reference together with this manual. (Reference) Repair manuals related to this manual are as follows: TOYOTA INDUSTRIAL EQUIPMENT 8FG/8FD10~30 VOL.2 REPAIR MANUAL (No. CE049) TOYOTA INDUSTRIAL EQUIPMENT 4Y ENGINE REPAIR MANUAL (No. CE663) TOYOTA INDUSTRIAL EQUIPMENT 1DZ-II ENGINE REPAIR MANUAL (No. CE664) TOYOTA INDUSTRIAL EQUIPMENT 2Z ENGINE REPAIR MANUAL (No. CE665)

NAME SECTION SECTION INDEX GENERAL 0 ENGINE 1 CLUTCH 2 TORQUE CONVERTER & TRANSMISSION 3 MANUAL TRANSMISSION 4 PROPELLER SHAFT 5 DIFFERENTIAL 6 FRONT AXLE 7 REAR AXLE 8 STEERING 9 BRAKE 10 BODY 11 MATERIAL HANDLING SYSTEM 12 MAST 13 CYLINDER 14 OIL PUMP 15 OIL CONTROL VALVE 16 MINI LEVER·JOYSTICK 17 SAS/OPS 18 SST LIST·SERVICE STANDARDS LIST 19 MULTIFUNCTION DISPLAY (OPT) 20 ELECTRICAL SYSTEM TROUBLESHOOTING 21 WIRING DIAGRAM E

0-1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E GENERAL Page Page EXTERIOR VIEWS .................. 0-2 VEHICLE MODEL .................... 0-3 FRAME NUMBER .................... 0-5 HOW TO USE THIS MANUAL ....................... 0-7 EXPLANATION METHOD........... 0-7 TERMINOLOGY ........................ 0-8 ABBREVIATIONS...................... 0-8 OPERATIONAL TIPS .............. 0-9 HOISTING THE VEHICLE ..... 0-10 CIRCUIT TESTER.................. 0-11 STANDARD BOLT & NUT TIGHTENING TORQUE ....... 0-13 BOLT STRENGTH CLASS IDENTIFICATION METHOD .... 0-13 PRECOAT BOLTS ................. 0-16 HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE ....... 0-16 WIRE ROPE SUSPENSION ANGLE LIST ........................ 0-17 SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE ........ 0-17 COMPONENTS WEIGHT ...... 0-18 RECOMMENDED LUBRICANT QUANTITY & TYPES .......... 0-19 LUBRICATION CHART ......... 0-21 PERIODIC MAINTENANCE................... 0-23 INSPECTION METHOD ........... 0-23 PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS ...................... 0-28

0-2 0-2 EXTERIOR VIEWS

0-3 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E VEHICLE MODEL Classification Vehicle Model Transmission Type Engine Series Model 1 ton series 1.0 ton model 30-8FG10 M/T 4Y Gasoline 32-8FG10 T/C 60-8FD10 M/T 1DZ-II Diesel 62-8FD10 T/C 1.5 ton model 30-8FG15 M/T 4Y Gasoline 32-8FG15 T/C 60-8FD15 M/T 1DZ-II Diesel 62-8FD15 T/C 1.75 ton model 32-8FG18 T/C 4Y Gasoline 62-8FD18 T/C 1DZ-II Diesel 2 ton series 2.0 ton model 30-8FG20 M/T 4Y Gasoline 32-8FG20 T/C 60-8FD20 M/T 1DZ-II Diesel 62-8FD20 T/C 70-8FD20 M/T 2Z Diesel 72-8FD20 T/C 2.5 ton model 30-8FG25 M/T 4Y Gasoline 32-8FG25 T/C 60-8FD25 M/T 1DZ-II Diesel 62-8FD25 T/C 70-8FD25 M/T 2Z Diesel 72-8FD25 T/C

0-4 0-4 Note: Control specification of 4Y engine is as follows. STD: 4Y-M (carburetor specification) OPT: 4Y-E (electronically controlled specification) Classification Vehicle Model Transmission Type Engine Series Model 3 ton series 3.0 ton model 30-8FG30 M/T 4Y Gasoline 32-8FG30 T/C 60-8FD30 M/T 1DZ-II Diesel 62-8FD30 T/C 70-8FD30 M/T 2Z Diesel 72-8FD30 T/C K2 ton series K2.0 ton model 32-8FGK20 T/C 4Y Gasoline 62-8FDK20 T/C 1DZ-II Diesel K2.5 ton model 32-8FGK25 T/C 4Y Gasoline 62-8FDK25 T/C 1DZ-II Diesel K3 ton series K3.0 ton model 32-8FGK30 T/C 4Y Gasoline 62-8FDK30 T/C 1DZ-II Diesel J3.5 ton series J3.5 ton model 30-8FGJ35 M/T 4Y Gasoline 32-8FGJ35 T/C 70-8FDJ35 M/T 2Z Diesel 72-8FDJ35 T/C

0-5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E FRAME NUMBER Frame No. Punching Position Series Engine Vehicle model Punching format Series Engine Vehicle model Punching format 1 ton series 4Y 30-8FG10 308FG18-10011 2 ton series 4Y 30-8FG20 308FG25-10011 32-8FG10 32-8FG20 30-8FG15 30-8FG25 32-8FG15 32-8FG25 32-8FG18 1DZ-II 60-8FD20 608FD25-10011 1DZ-II 60-8FD10 608FD18-10011 62-8FD20 62-8FD10 60-8FD25 60-8FD15 62-8FD25 62-8FD15 2Z 70-8FD20 708FD25-10011 62-8FD18 72-8FD20 70-8FD25 72-8FD25 Punching position

0-6 0-6 Series Engine Vehicle model Punching format 3 ton, J3.5 ton series 4Y 30-8FG30 308FGJ35-10011 32-8FG30 30-8FGJ35 32-8FGJ35 1DZ-II 60-8FD30 608FD30-10011 62-8FD30 2Z 70-8FD30 708FDJ35-10011 72-8FD30 70-8FDJ35 72-8FDJ35 K2·K3 ton series 4Y 32-8FGK20 308FGK30-10011 32-8FGK25 32-8FGK30 1DZ-II 62-8FDK20 608FDK30-10011 62-8FDK25 62-8FDK30

0-7 HOW TO USE THIS MANUAL EXPLANATION METHOD 1. Operation procedure (1) The operation procedure is described in either pattern A or pattern B below. Pattern A: Explanation of each operation step with illustration. Pattern B: Explanation of operation procedure by indicating step numbers in one illustration, followed by explanation of cautions and notes summarized as point operations. Example of description in pattern B DISASSEMBLY·INSPECTION·REASSEMBLY Tightening torque unit T = N·m (kgf·cm) [ft·lbf] Disassembly Procedure 1 Remove the cover. [Point 1] 2 Remove the bushing. [Point 2] 3 Remove the gear. Point Operations [Point 1] Disassembly: Put a match mark when removing the pump cover. [Point 2] Inspection: Measure the bush inside diameter. Limit: 19.12 mm (0.7528 in) • Step Nos. are partially sometimes omitted in illustrations. • When a part requiring tightening torque instruction is not indicated in the illustration, the part name is described in the illustration frame. T = 46.1 ~ 48.1 (470 ~ 490) [34.0 ~ 35.5] Operation explained later Explanation of key point for operation with an illustration

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Toyota 8FG/8FD10~30 Series Diesel Forklift Truck Service & Repair Manual

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